Clarke SA40 56104487 (20D) Service Manual

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Page 1

SA40

Service Manual

Clarke SA40 Models: 56104487 (20D)

English

03/2016, Form No. 56043173

Page 2

Contents

General Informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Machine Conguraons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Manual Purpose and Applicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Other Reference Manuals and Informaon Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Diagnosc and Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Convenons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Modicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cauons and Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General Safety Instrucons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Moving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Transporng the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Specicaons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fastener Torque Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General Maintenance Informaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lubricaon Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Major Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Key Switch, Emergency Stop and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Speed and Direcon Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Scrub Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Soluon Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Vacuum Power Adjustment Switch and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Informaon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Baery Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Major Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Plaorm Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

System Disabled by Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

To Access the Service Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Service Test Mode Funcons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Programming Opons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Main Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Submenu Funcons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Deck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Low Baery Voltage Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Baery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Burst Of Power Operaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Detergent (EcoFlex™) Opon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chemical Rate Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Open Fault Detect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Display Rev Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Lock Out Brush Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Lock Out Soluon Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Backup Alarm Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Forward Alarm Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Horn Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Restore Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fault Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Service Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Extra Informaon on the Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Frozen Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Save Scrub Sengs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

A1 Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

E1 Curs 1210 Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

A1 Control Board Shop Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

On-board Baery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Interlock Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Delta-Q Charging Proles and Charging Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Delta-Q Baery Charging Prole Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Wiring (Ladder) Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Wiring Harness Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Electrical Connector Pin-out Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

To Locate and Idenfy a Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Connector Pin-out Assignment Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Circuit Descripons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Vacuum Motor O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Vacuum Motor On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

General Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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Bench-tesng the Flyback Diode (bridge recer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Vacuum Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Scrub Deck and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

20D Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Brush Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Deck Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Circuit Descripons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Scrub Brush Motor O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Scrub Brush Motor On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Deck Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Scrub Deck Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Scrub Deck in Vacuum-only Posion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Scrub Deck at Normal Scrub Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Scrub Deck at Extra Scrub Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Scrub Deck Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Scrub Deck Actuator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Soluon System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Soluon Tank, Water Filter and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Soluon Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Circuit Descripons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Soluon Solenoid Valve O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Soluon Solenoid Valve On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Cleaning the Water Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Component Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Nominal Soluon Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Wheel System - Tracon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Wheel Drive Motor Circuit Descripons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Power to the E1 Curs 1210 Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Speed Control Drive Funcons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Speed Control Communicaon with the A1 Control Board . . . . . . . . . . . . . . . . . . . . . . . 110

Component Locaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Speed Control Programming Opons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

General Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

E1 Curs Speed Controller Diagnoscs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Diagnoscs Method A - Graphic Display and Direcon Indicator . . . . . . . . . . . . . . . . . . . .115

Diagnoscs Method B - Curs Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Diagnosc History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Status LED Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Drive Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Steering Spindle Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Drive Wheel Motor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Replacing the Motor Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

E1 Curs 1210 Speed Controller – Low Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

E1 Curs 1210 Speed Controller – Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

General Specicaons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

vService Manual – SA40

Page 6

General Information

Machine Congurations

The SA40 machine is a battery-powered commercial oor scrubbing machine suitable for use in hotels, schools, hospitals, factories, shops, ofces, rental businesses and similar applications. The SA40-20D has a 20” brush deck to accommodate a variety of disc brushes, and can also be used with several grades of pads by using the optional pad holder.

The machine is powered by either four 6-volt batteries or two 12-volt batteries, connected in series, to provide 24 VDC to the motors and controls.

Service Manual Purpose and Application

This Service Manual is a technical resource designed to aid service personnel in maintaining and repairing the Advance SA40 Scrubbers to ensure optimum performance and long service life. Please read it thoroughly before servicing your machine.

Revision History

6Service Manual – SA40

Date Revisions

3/16 Initial publication

Other Reference Manuals and Information Sources

Model Name Model Number

Clarke SA40 56104487 (20D) 56042653 56091196 - English, Español, Français

These manuals can be found on the following Nilsk-Advance’s electronic supported databases:

• Nilsk-Advance Dealer Customer Zone

• Advance website: www.advance-us.com

• Nilsk website: www.nilsk.com

• Clarke website: www.clarkeus.com

• EzParts service/parts CD-ROM

Parts List

Form Number

Instructions for Use

Form Number

Page 7

General Information 7Service Manual – SA40

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 oor cleaning equipment.

• Digital voltmeter (DVM) with DC current clamp

• Hydrometer

• Battery load tester for checking batteries

• Set of torque wrenches

These tools are also available from Nilsk-Advance, Inc.:

• Curtis 1311 hand held programmer, p/n 56409441,

• Vacuum water lift gauge, p/n 56205281.

Conventions

All references to right, left, front and rear in this manual are as seen from the Operator’s position.

Parts and Service

Repairs should be performed by an Authorized Advance Service Center that employs factory-trained service personnel and maintains an inventory of Advance original replacement parts and accessories.

Call the Advance Dealer named below for repair parts or service. Please specify the Model Number (same as the Part Number) and Serial Number when discussing your machine.

Modications

Modications and additions to the cleaning machine which affect capacity and safe operation shall not be performed by the customer or user without prior written approval from Nilsk-Advance Inc. Unapproved modications will void the machine warranty and make the customer liable for any resulting accidents.

Nameplate

The Model Number (Part No.) and Serial Number of the

machine are shown on the Nameplate located on the inside of the battery compartment.

This information is needed when ordering repair parts for the machine.

Page 8

General Information 8Service Manual – SA40

Cautions and Warning Symbols

Nilsk-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.

Caution! Is used to call attention to a situation that could cause minor personal injury or

damage to the machine or other property.

Read all instructions before using.

General Safety Instructions

Specic Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm. This machine is for commercial use, for example in hotels, schools, hospitals, factories, shops and ofces other than normal residential housekeeping purposes.

Warning! Be sure to follow these safety precautions to avoid situations that could cause

severe personal injury.

• This machine should only be used by properly-trained and authorized personnel.

• This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge.

• Avoid sudden stops when on ramps or inclines. Avoid abrupt sharp turns. Use low speed down ramps.

• Observe the Gross Vehicle Weight, GVW, of the machine when loading, driving, lifting or supporting the machine.

• Keep sparks, ame and smoking materials away from batteries. Explosive gases are vented during normal operation.

• Charging the batteries produces highly-explosive hydrogen gas. Charge the batteries only in well-ventilated areas away from open ame. Do not smoke while charging the batteries.

• Remove all jewelry when working near electrical components.

• Turn the Key Switch off (O) and disconnect the batteries before servicing electrical components.

• Never work underneath a machine without safety blocks or stands to support the machine.

• Do not dispense ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ammable liquids exist.

• Only use the brushes provided with the machine or those specied in the Instructions for Use. The use of other brushes may impair safety.

• Do not clean this machine with a pressure washer.

Page 9

General Information 9Service Manual – SA40

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.

• This machine is not suitable for picking up hazardous dust.

• Do not use scarier discs and grinding stones. Advance will not be held responsible for any damage to oor surfaces caused by scariers or grinding stones (can also cause damage to the brush drive system).

• When operating this machine, ensure that individuals in close proximity, particularly children, are not endangered.

• Before performing any service function, carefully read all instructions pertaining to that function.

• Do not leave the machine unattended without rst turning the Key Switch off (O), removing the key and applying the parking brake.

• Turn the Key Switch off (O) and remove the key before changing the brushes, and before opening any access panels.

• Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving parts.

• Use caution when moving this machine in below-freezing temperature conditions. Any water in the solution, recovery or detergent tanks, or in the hose lines could freeze, causing damage to valves and ttings. Flush with windshield washer uid.

• The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be safely done in accordance with your local environmental regulations.

• Do not use on surfaces having a gradient exceeding that marked on the machine.

• All doors and covers are to be positioned as indicated in the Instructions for Use before using the machine.

• This machine should only be used and stored indoors.

Caution! Do not clean this machine with a pressure washer.

Page 10

Prop Rod

To prevent the Control Panel Housing / Recovery

Tank Cover from dropping unexpectedly and

causing injury, always engage the Prop Rod as shown before working under the Panel Housing

/ Recovery Tank Cover.

Moving the Machine

General Information 10Service Manual – SA40

Control Panel

Housing/

Recovery

Tank Cover

Prop Rod

(engaged)

The drive wheel motor has a built-in electromagnetic brake that engages whenever the Key Switch is Off or the Go Pedal is released. You can manually override this brake if necessary by reaching up around the back of the front drive wheel and rotating the Brake Arm up as shown. This should only be done if you need to push or pull the machine. Remember to reengage the

Brake Arm once you nish moving the machine.

Note: Turn the drive wheel 45° to the

right for easier access to the Brake

Arm.

Brake

Arm

Brake

Arm

Page 11

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.

• The machine’s electromagnetic brake is engaged (not manually overridden).

General Information 11Service Manual – SA40

Left

Tie-down

Front

Tie-down

Specications

General Specications

Model SA40-X20D

Model No. 56104487

Battery Voltage 24V

Battery Capacity 260 Ah

Protection Grade IPX3

Sound Pressure Level IEC 60335-2-72: 2002 Amend. 1:2005, ISO 11201 dB(A)

Gross Vehicle Weight / Transport Weight 897 lbs / 407 kg

Empty Weight 620 lbs / 281 kg

Maximum Wheel-Floor Load, Front 160 psi / 1.10 N/mm

Maximum Wheel-Floor Load, Right-Rear 139 psi / 0.96 N/mm

Maximum Wheel-Floor Load, Left-Rear 135 psi / 0.93 N/mm

Scrub Deck Width 20 in / 50.8 cm

Squeegee Width 26.5 in / 67.3 cm

Tank Capacities

Sound Pressure Level IEC 60335-2-72: 2002 Amend. 1:2005, ISO 11201

Vibrations at the Hand Controls (ISO 5349-1) 0.17 m/s

Vibrations for the Whole Body (ISO 2631-1) 0.01 m/s

Gradeability

63 dB LpA, ±3 dB KpA

Solution Tank: 11.7 gal / 44.28 L

Recovery Tank: 13.5 gal / 46.67 L

63 dB LpA, ±3 dB KpA

Transport: 14% / 7.1˚

Cleaning: 8.3% / 4.75˚

Right

Tie-down

Page 12

Overall Dimensions

1.13

[28,7]

General Information 12Service Manual – SA40

[1232]

48.5

Fastener Torque Specications

Size Plated Steel Stainless Steel

#10 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” 17 ft.-lb. [23.05 N-m] 11 ft.-lb. [14.91 N-m]

3/8” 31 ft.-lb. [42.03 N-m] 20 ft.-lb. [27.12 N-m]

Standard Torque

Specications (unless otherwise specied)

1/2” 75 ft.-lb. [101.69 N-m] 50 ft.-lb. [67.79 N-m]

3/4” 270 ft.-lb. [366.07 N-m] 180 ft.-lb. [244.05 N-m]

M5 61 in.-lb. [6.89 N-m] 36 in.-lb. [4.07 N-m]

M6 9 ft.-lb. [12.2 N-m] 62 in.-lb. [7.0 N-m]

M8 22 ft.-lb. [29.83 N-m] 13 ft.-lb. [17.63 N-m]

M10 44 ft.-lb. [59.66 N-m] 25 ft.-lb. [33.9 N-m]

M12 70 ft.-lb. [94.91 N-m] 40 ft.-lb. [54.23 N-m]

52.5

[1332]

24.5

27.9

[623]

[710]

Page 13

General Information 13Service Manual – SA40

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

Maintenance Item Daily Weekly Monthly Yearly

Charge Batteries X

Check/Clean Tanks & Hoses X

Check/Clean the Brushes/Pads X

Check/Clean the Squeegee X

Check/Clean Vacuum Shutoff Float X

Empty/Clean Debris Catch Tray in Recovery Tank X

Check Each Battery Cell(s) Water Level X

Inspect Scrub Housing Skirt X

Inspect and Clean Solution Filter X

Lubricate Machine X

* Check Carbon Brushes X

* Have an Authorized Advance Service Center check the vacuum motor carbon motor brushes once a year or

after 300 operating hours. The brush and drive motor carbon brushes should be checked every 500 hours or once a year.

Page 14

General Information 14Service Manual – SA40

Lubrication Locations

• Once a month apply Lubriplate® 730-2 or equivalent grease to, or grease the tting on, the following components. Avoid using too much grease.

• Hex Shaft/Steering Tube Assembly

• Drive Wheel Chain

• Drive Chain Idler Sprocket (grease tting)

• Steering Chain

• Once a month apply light machine oil to the Upper and Lower Steering Shaft Universal Joints.

Upper

Steering

Shaft

U-Joint

Hex

Shaft

Steering

Tube

Assembly

Lower Steering

Steering

Chain

Shaft U-Joint

Drive Chain

Idler

Sprocket

(grease

tting)

Drive

Wheel

Chain

Page 15

Major Machine Components

Control System

General Information 15Service Manual – SA40

Electrical

System

Solution

System

Recovery

System

Chassis

System

Squeegee Assembly

Scrub

System - 20D

Scrub

System - REV

Page 16

Machine Controls

Key Switch, Emergency Stop and Horn Switch

• Key Switch – controls the battery power to the machine. Note that you must turn the Key Switch to the on (I) position before stepping onto the machine platform.

General Information 16Service Manual – SA40

Key

Switch

• Emergency Stop – shuts off all battery power to the machine when pressed. To reset the Emergency Stop, rotate the red knob clockwise.

• Horn Switch – sounds the horn when pressed.

Emergency

Stop

Horn

Switch

Page 17

General Information 17Service Manual – SA40

Circuit Breakers

The Circuit Breakers are mounted on the top of the control panel. To reset a Circuit Breaker, press the corresponding reset button

• 50-amp Circuit Breaker – labeled CB1 in the Ladder Diagram; controls the positive voltage to the E1 Curtis 1210 Speed Controller.

• 5-amp Circuit Breaker – labeled CB2 in the Ladder Diagram; controls the positive voltage to the key switch and to the battery positive inputs J3-1 and J3-8 on the A1 Control Board.

• 20-amp Circuit Breaker – labeled CB3 in the Ladder Diagram; controls the positive voltage to the contacts on solid state relay K1. Relay K1 controls the positive voltage to the vacuum motor, M4.

• 25-amp Circuit Breaker – labeled CB4 in the Ladder Diagram; controls the positive voltage to the contacts on relay K2. Relay K2 controls the positive voltage to the brush motor, M5/M6.

50-amp

Circuit

Breaker CB1

20-amp

Circuit

Breaker CB3

Breaker CB2

Breaker CB4

5-amp

Circuit

25-amp

Circuit

Page 18

General Information 18Service Manual – SA40

Speed and Direction Controls and Indicators

• The Speed Adjustment Knob – labeled R1 in the Ladder Diagram; 100K potentiometer that controls the machine speed in both forward and reverse.

• The Forward and Reverse Drive Switches select the direction the machine will move when the Go Pedal is pressed. The corresponding Drive Indicator will light when a Drive Switch is selected.

• Forward Drive Switch – selects the forward direction.

• Forward Drive Indicator – lights to indicate that the

Forward Drive Switch has been selected. Note that this

Forward Drive

indicator is lighted in the adjacent drawing.

• Reverse Drive Switch – selects the reverse direction.

• Reverse Drive Indicator – lights to indicate that the

Reverse Drive Switch has been selected.

Speed

Adjustment

Knob R1

Indicator

Forward

Drive Switch

Reverse

Drive Switch

• Operator Presence Pedal – ensures that the Operator is standing on the Platform before the Go Pedal will drive the machine forward or reverse.

• Go Pedal – drives the machine in

the direction selected with the

Forward Drive or Reverse Drive Switches.

Reverse Drive

Indicator

Pedal

Operator

Presence

Pedal

Platform

Page 19

General Information 19Service Manual – SA40

Scrub Controls and Indicators

Note: Thescrubpressure,recoveryvacuumpower,solutionow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.

• IfSAVE SCRUB SETTINGS/YES is selected, the machine will use the scrub settings that were in use when the key switch was switched off.

• IfSAVE SCRUB SETTINGS/NO is selected, the machine will use the default settings.

(Refer to the Save Scrub Settings subsection in the Control System section.)

• One-touch

™

Scrub On/Off Switch – lowers the scrub deck and

squeegee to the oor and enables the scrub, vacuum, solution and detergent systems. The scrub motor, solution system, detergent pump and vacuum motor will start when you press the Go Pedal.

• Scrub On/Off Indicator – lights to indicate that the scrub system is active.

• Extra Pressure Switch – toggles the scrub pressure between standard pressure (bottom box lled as shown) and extra pressure (both top and bottom boxes lled).

• Extra Pressure Indicator – lights to indicate that the scrub system is active.

• Scrub Brush Pressure Bar Graph – displays the scrub pressure on the graphic display as follows:

• Bottom box lled – standard scrub pressure (as

shown).

• Top and bottom boxes lled – extra scrub

pressure.

Scrub On/Off

Indicator

One-touch™

Scrub On/Off

Switch

Scrub

Pressure

Bar Graph

Extra Pressure Indicator

Extra

Pressure

Switch

Page 20

General Information 20Service Manual – SA40

Solution Controls and Indicators

• Solution Flow Adjustment Switch – functions as follows:

• When the scrub system is enabled, pressing the Solution

Flow Adjustment Switch will cycle the solution ow rates

from low (bottom box lled as shown), to medium (bottom two boxes lled), to high (all three boxes lled), then to off (no boxes lled).

• When the scrub system is not enabled (machine in transport mode), pressing and holding the Solution Flow

Adjustment Switch will dispense solution at the high ow

rate to pre-wet the oor. The solution will continue to dispense as long as the Solution Flow Adjustment Switch is pressed.

• Solution On/Off Indicator – lights to indicate that the solution system is active.

• Solution Flow Rate Bar Graph – displays the solution ow rate on the graphic display as follows:

• Bottom box lled – low solution ow rate (as shown).

• Bottom two boxes lled – medium solution ow rate.

• All three boxes lled – high solution ow rate.

• All three boxes empty – solution system off.

Solution

Flow Rate

Bar Graph

Solution On/Off

Indicator

Solution

Flow Adjustment

Switch

Vacuum Power Adjustment Switch and Indicators

• Vacuum Power Adjustment Switch – functions as follows:

• Pressing the Vacuum Power Adjustment

Switch while in the scrub mode will cycle

Quiet

Vacuum

Mode

Indicator

the vacuum mode from low/quiet (bottom box lled as shown), to high/standard (both top and bottom boxes lled), then to off (no boxes lled). Note that the vacuum motor will switch on when the machine is driven forward. When the machine is driven in reverse or stops, or if the Vacuum Power

Adjustment Switch is pressed while the

vacuum motor is running, the vacuum motor will continue to run for 10 seconds, then switch off.

Pressing the Vacuum Power Adjustment Switch during this 10-second delay period will shut off the vacuum motor immediately.

• When the scrub system is not enabled (machine in transport mode), the Vacuum Power Adjustment

Switch functions as follows:

◦ Pressing the Vacuum Power Adjustment Switch once will enable the wet vacuuming mode. The

vacuum power will default to the low/quiet mode and the deck actuator will drive the deck to the “vacuum only” position.

◦ Pressing the Vacuum Power Adjustment Switch a second time will switch the vacuum motor to high/

standard mode.

◦ Pressing the Vacuum Power Adjustment Switch a third time will disable the wet vacuuming mode.

The actuator will immediately raise the deck, and the vacuum motor will turn off after a 10-second delay.

Vacuum

Level Bar

Graph

Standard Vacuum

Mode Indicator

Vacuum Power

Adjustment

Switch

Page 21

General Information 21Service Manual – SA40

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.

• Quiet Vacuum Mode Indicator – indicates that the vacuum motor is in the low/quiet mode.

• Standard Vacuum Mode Indicator – indicates that the vacuum motor is in the high/standard mode.

• Vacuum Level Bar Graph – displays the vacuum motor power mode as follows:

• Bottom box lled – low/quiet mode (as shown).

• Top and bottom boxes lled – high/standard mode.

• Both boxes empty – vacuum motor off.

Information Switch

• Information Switch – displays the Information Screen on the graphic display. The Information Screen will also be displayed if a signicant error occurs that results in the shutdown of some machine system. The graphic display will

Hour

Meter

Fault

Codes

then display the Information screen until next key switch cycle.

The Information Screen shows the Hour Meter, Fault Codes and the Battery Charge Level Indicator.

• Hour Meter – displays the total number of run hours on the machine.

• Fault Codes – displays the wrench icon and any active two-digit fault code. If more than one error exists, the display will sequence through the error codes at one-second intervals.

Battery

Charge Level

Indicator

Information

Switch

(Refer to the Fault Codes subsection in the Control System section.)

• Battery Charge Level Indicator – indicates the charge level of the batteries according to the number of lled “bars” in the battery icon.

• Five solid bars indicates a full battery charge.

• No solid bars (empty battery icon) indicates that the batteries are discharged.

Page 22

General Information 22Service Manual – SA40

Battery Status Screens

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

Note that:

• When the voltage in AGM or Gel batteries drops to 21.75 volts, the A1 Control Board switches off the

scrub motor, solution system and detergent pump, and raises the scrub deck. The vacuum motor can still remain on.

• When the voltage in AGM or Gel batteries drops to 21.6 volts, the A1 Control Board switches off the

vacuum motor.

• When the voltage in Wet batteries drops to 20.55 volts, the A1 Control Board switches off the scrub

motor, solution system and detergent pump, and raises the scrub deck. The vacuum motor can still remain on.

• When the voltage in Wet batteries drops to 20.4 volts, the A1 Control Board switches off the vacuum

motor.

Battery Low Voltage Screen

Page 23

Chassis System

Major Chassis Components

The Chassis System provides the framework on which the machine components are mounted.

The Battery Tray contains the batteries and connectors and is

mounted to the top of

the Chassis Weldment.

The Platform Assembly

provides a place for the Operator to stand and houses the Operator Presence Pedal and Go Pedal.

The Battery Charger

is mounted to the bottom of the Chassis

Weldment.

The non-traction

Wheels are held by at

washers and M8 x 20

screws that thread into

the axle in the Chassis

Weldment.

The Drive Wheel

Assembly is fastened

to the Spindle Mount

Weldment which

bolts to the Chassis

Weldment.

Battery

Tray

Chassis

Weldment

Spindle

Mount

Weldment

Battery

Charger

Link Bar

Platform

Assembly

Wheel (2)

Linkage

Bar (2)

23Service Manual – SA40 23

The Link Bar and the two Linkage Bars are

bolted to vertical plates on the bottom of

the Chassis Weldment

and support the Scrub Deck.

Drive

Wheel

Assembly

Page 24

Chassis System 24Service Manual – SA40

Platform Switches

The Operator Presence Pedal and Go Pedal are mounted on the top of the Platform.

• When the Operator stands on the Platform, he/she presses the Operator Presence Pedal which actuates the

Operator Presence Switch (called the “Deadman Switch S2” in the Wiring Diagram). The Operator Presence Switch must be actuated before the Go Pedal will drive the machine forward or reverse.

• When the Operator presses the Go Pedal it actuates the Go Switch to drive the machine in the direction selected with the Forward Drive or Reverse Drive Switches.

Go Switch

Go Pedal

Operator

Presence

Switch

Platform

Operator Presence

Pedal

Page 25

Control System 25Service Manual – SA40 25

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. The A1 Control Board can store and display a variety of fault codes to inform the Operator of any machine fault conditions. The A1 Control Board also supports special modes of operation called the “Programming Mode” and the “Service Test Mode”. The Programming Mode is used primarily for “telling” the A1 Control Board how the machine is equipped so that it can operate accordingly. The Service Test Mode allows you to operate various machine components regardless of current inputs.

The E1 Curtis 1210 Speed Controller controls the drive motor that propels the machine based on Operator requests. (Refer to the Wheel System, Traction section for more information.)

Page 26

Component Locations

The following components are included in this section:

• A1 Control Board

• E1 Curtis 1210 Speed Controller

The A1 Control Board is mounted to the rear of the Interface Panel Assembly.

The E1 Curtis 1210 Speed Controller is

mounted inside of the Control Panel.

Interface

Panel

Assembly

A1 Control

Board

Control System 26Service Manual – SA40

E1 Curtis

1210 Speed

Controller

Control

Panel

Troubleshooting

Fault Codes

The graphic display will show any error codes detected by the A1 Control Board on the Information Screen as they occur. The display will show the wrench icon and the two-digit fault code number. The example shown here, 03, is a speed control fault.

If more than one fault exists, the display will sequence through the fault codes at one-second intervals. If the error is signicant and results in a machine system shutdown, the graphic display will show the Information Screen until next key switch cycle. Otherwise the Information Screen will be active only when the Information Switch is pressed.

Page 27

Fault Code Table

Control System 27Service Manual – SA40

Display

Code

03 Speed Control fault

04 Scrub Deck Actuator overload The Scrub Deck Actuator has drawn more than 4.5 amps.

08 Solution Solenoid overload

10 Brush Contactor (K2) coil overload

11 Detergent Pump overload

21 Detergent Pump driver fault

24 Deck Actuator driver fault

30 Solution Solenoid open

32 Scrub Deck Actuator open

35 Brush Contactor (K2) coil open

37 Detergent Pump open

52 Scrub Deck Actuator position fault

62 Solution Solenoid driver on

65 Detergent Pump driver stuck on

70 On-board Battery charger fault

Fault Description Conditions Needed to Set the Fault Code

The E1 Curtis Speed Controller is communicating a problem to the A1 Control Board.

The Solution Solenoid Valve has drawn more than approximately 1 amp.

Vacuum Contactor (SSR1) coil overload

Vacuum Contactor (SSR1) coil open

Brush Contactor (K2) driver stuck onThe measured current was above the minimum value while the

Vacuum Contactor (SSR1) driver stuck on

The Vacuum Contactor has drawn more than approximately 1 amp.

The Brush Contactor has drawn more than approximately 1 amp.

The Detergent Pump has drawn more than approximately 1 amp.

The driver IC for the Detergent Pump is reporting a fault; current limiting or shutdown is in effect due to either a detected over-current or over-temperature condition.

The driver IC for the Deck Actuator is reporting a fault; current limiting or shutdown is in effect due to either a detected overcurrent or over-temperature condition

The measured current was below the minimum value while the Solution Solenoid should have been on.

The measured current never exceeded the minimum threshold while moving from one deck position to another (only valid when the target position and the starting position switch states should be different).

The measured current was below the minimum value while the Brush Contactor should have been on.

The measured current was below the minimum value while the Vacuum Contactor should have been on.

The measured current was below the minimum value while the Detergent Pump should have been on.

The measured current was greater than or equal to the minimum threshold value while the deck was moving, but the software timed out looking for the new position (never saw the actuator switch states read the target values).

The measured current was above the minimum value while the Solution Solenoid driver should have been off.

Brush Contactor driver should have been off.

The measured current was above the minimum value while the Vacuum Contactor driver should have been off.

The measured current was above the minimum value while the Detergent Pump driver should have been off.

An error has been generated via the serial communications between the charger and the A1 Control Board due to an

incorrect charging prole code being repeatedly sent by the

charger, or the bit timing being severely out of spec.

Page 28

System Disabled by Fault Codes

Control System 28Service Manual – SA40

Disable System Flash Indicator

Motor

Display Code

Fault Description

03 Speed Control fault x

04 Scrub Deck Actuator overload x x x x x

08 Solution Solenoid overload x x x

09 Vacuum Contactor (SSR1) coil

overload

10 Brush Contactor (K2) coil

overload

11 Detergent Pump overload x x

21 Detergent Pump driver fault x x

24 Deck Actuator driver fault x x x x

30 Solution Solenoid open x x x

32 Scrub Deck Actuator open x x x x

35 Brush Contactor (K2) coil open x x x x x

36 Vacuum Contactor (SSR1) coil

open

37 Detergent Pump open x x

52 Scrub Deck Actuator position

fault

62 Solution Solenoid stuck closed x

63 Brush Contactor (K2) coil stuck

closed

64 Vacuum Contactor (SSR1) coil

stuck closed

65 Detergent Pump stuck closed x

70 On-board Battery charger fault

Disable Detergent

x x x x x x

x x x x x

x x x x x x

x x x x

x x x x x

Disable Brush

Disable Solution

Disable Recovery

Scrub Deck

Vacuum Motor

Actuator Disable

Detergent Indicator

Solution Indicator

Indicator

Brush Motor

Vacuum Indicator

Page 29

Control System 29Service Manual – SA40

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” on page 31.

Note: Service Test Mode is not available if the machine is being charged.

To Access the Service Test Mode

1. With the machine off, press and hold the solution switch and brush pressure

switch while turning the machine on, and continue to hold the switches.

2. Continue to hold the switches until the display shows “Programming Options”.

3. Press the Forward or Reverse switches to scroll through the menu

options until “16. Service Test Mode” is visible.

4. Press the scrub on/off switch to enter service test mode. The display will

show the Service Test Mode submenu.

PROGRAM OPTIONS

16. SERVICE TEST MODE

SPD: N 26.5 BRU: OFF REV: OFF VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

5. Refer to “Service Test Mode Functions” below for a description of the

available functions.

6. To exit service test mode, turn off the key switch.

Service Test Mode Functions

The control panel switches are used to control various A1 Control Board output functions. The table below lists the control panel switches, and their corresponding Service Test Mode functions and displays:

Control Panel Switch Service Test Mode Function Graphic Display Descriptions

Forward Drive Switch

The Forward Drive Switch enables the machine to drive forward. The blue LED indicator will be lit when the Switch is active. For the machine

SPD: F 26.5 BRU: OFF

REV: OFF VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

to move forward, the Emergency Stop must be reset, the Operator Presence Pedal must be pressed and the Go Pedal must be pressed. Note that the Inhibit (INH) output must be off (via the Information Switch – see below).

• SPD: – indicates the drive controller state. In this case it would display F for forward.

• The three digits display the battery voltage (26.5 volts in this example).

Reverse Drive Switch

The Reverse Drive Switch enables the machine to drive in reverse. The blue LED indicator will be lit when the Switch is active. For the machine

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF

INH: ON E00 SOL: OFF DEK: UP CP: OFF

to move backward, the Emergency Stop must be reset, the Operator Presence Pedal must be pressed and the Go Pedal must be pressed. Note that the Inhibit (INH) output must be off (via the Information Switch – see below).

• SPD: – indicates the drive controller state. In this case it would display R for reverse.

• The three digits display the battery voltage (26.5 volts in this example).

• REV: – indicates that the reverse output is ON.

Page 30

Control System 30Service Manual – SA40

Control Panel Switch Service Test Mode Function Graphic Display Descriptions

Information Switch

Pressing the Information Switch toggles the Inhibit output (INH) from the A1 Control Board to the E1 Curtis Speed Controller ON and OFF. Note

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF

INH: ON E00 SOL: OFF

DEK: UP CP: OFF

that INH must be OFF in order to test the forward and reverse drive in the Service Test Mode. • INH: – indicates the state of

the inhibit signal. In this case the inhibit signal is ON.

• E(NN) – displays any active fault codes.

Extra Pressure and Horn Switches

Pressing the Extra Pressure Switch scrolls the DEK: eld through the four available deck positions:

• UP – raised (transport) position

• VAC – vacuum-only (wet vacuuming) position

• LOW – standard scrub pressure position

• HI – extra scrub pressure position

Pressing the Horn Switch will move the deck

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF INH: ON E00 SOL: OFF

DEK: UP CP: OFF

DEK: – indicates the scrub deck

position. In this case the deck would be in the UP (transport)

position. to the selected position. Note that the Extra Pressure Switch is locked out while the deck is moving. The DEK: line will be highlighted and inverted.

Scrub On/Off Switch

Pressing the Scrub On/Off Switch toggles the brush motor contactor and scrub deck motor ON and OFF.

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

Vacuum Power Adjustment Switch

Solution Flow Adjustment Switch

Pressing the Vacuum Power Adjustment Switch scrolls the Solid State Relay (K1) and Vacuum Motor among the three states: OFF (0V), LOW (16.8V) and HI (battery voltage).

Pressing the Solution Flow Adjustment Switch toggles the solution solenoid ON and OFF. When the solenoid is ON it will operate at 50% duty cycle (1 cycle = 3 seconds ON, 3 seconds OFF).

BRU: – indicates the state of the

brush motor. In this case the

motor would be OFF.

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

VAC: – indicates the state of the

vacuum motor. In this case the

motor would be OFF.

SPD: R 26.5 BRU: OFF REV: ON VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

SOL: – indicates the state of the

solution solenoid. In this case

the solenoid would be OFF.

Page 31

Control System 31Service Manual – SA40

Programming Options

The SA40 graphic display has two “layers” of hidden menus that allow you to view and change the various programmable machine congurations, system settings and parameters. The top “layer” is the main menu from which you can navigate to the 20 submenus. The second “layer” is the submenus that display the programmable options. These submenus are the screens on which you can change the congurations and settings.

Note: The hidden menu is not available if the machine is being charged.

Main Menu Access

1. With the machine off, press and hold the solution switch and brush pressure switch while turning the machine on, and continue to hold the switches.

2. Continue to hold the switches until the display shows “Programming Options”.

PROGRAM OPTIONS

1. DECK TYPE

3. Press the Forward or Reverse switches to scroll through the menu options.

4. Press the scrub on/off switch to either enter or exit (with save) a submenu.

5. Within a submenu, press the forward/reverse switches to scroll through the options.

6. The main menu contains the following links to the corresponding programming option submenus:

1. DECK TYPE

2. LOW VOLTAGE CUTOUT

3. BATTERY CHARGER

4. BURST OF POWER

Service Note:

Not all menu entries listed will be functional,

dependingonthemachineconguration.

Service Note:

The A1 Control Board will automatically display the main menu upon machine power-up if no scrub deck has been selected and saved in the DECK TYPE submenu. This will occur when a new Control Board is installed into a machine, or the RESTORE

DEFAULTS has been performed. The purpose of this

is to prompt the Operator to select the appropriate deck type before using the Control Board in the machine. Once the deck type has been selected, the controller will no longer automatically display the main menu at machine power-up.

5. DETERGENT OPTION

6. DETERGENT RATE BIAS

7. OPEN FAULT DETECT

8. DISPLAY REV LEVEL

9. LOCKOUT BRUSH

10. LOCKOUT SOLUTION

11. BACKUP ALARM VOL

12. FWD ALARM VOL

13. HORN VOL

14. RESTORE DEFAULTS

15. FAULT RECALL

16. SERVICE TEST MODE

17. XTRA INFO ON DISPLAY

18. FROZEN PARAMETERS

19. PANEL TEST

20. SAVE SCRUB SETTINGS

Page 32

Submenu Functions

Deck Type

Control System 32Service Manual – SA40

The SA40 supports only 1 deck type. So this function should not be changed. This submenus allow you to specify the type of deck installed in your machine. Note that the type of deck selected congures the solution ow rate settings corresponding to the deck type.

Low Battery Voltage Cutout

The purpose of the low battery voltage cutout is to help prolong battery life. The A1 Control Board will raise the deck, and switch off the brush and vacuum motors, and solution solenoid valve automatically when the batteries discharge to the selected cutout level. The 2. LOW VOLT CUTOUT submenus allow you to select the voltage cutout level for the type of battery installed in your machine:

• The standard cutout setting for wet cell/lead acid batteries is 20.55

volts (80% discharged or 20% charge remaining).

• The alternate cutout setting for gel/maintenance free batteries is 21.75

volts (70% discharged or 30% charge remaining).

The default setting is WET BATTERY 80% / LVC=20.55V.

PROGRAM OPTIONS

1. DECK TYPE

PROGRAM OPTIONS DECK TYPE 20 INCH / 51 CM DISC

PROGRAM OPTIONS DECK TYPE 20 INCH / 51 CM REV

PROGRAM OPTIONS

2. LOW VOLT CUTOUT

PROGRAM OPTIONS LOW VOLT CUTOUT WET BATTERY 80% LVC=20.55V

PROGRAM OPTIONS LOW VOLT CUTOUT MAIN FREE BATTERY 70% LVC=21.75V

Page 33

Battery Charger

Control System 33Service Manual – SA40

The current series of battery chargers don’t communicate with the A1 control board. So this menu entry has no current function. If there was communication, this menu entry would permit the A1 control board to notify the charger which type of battery was being charged so the onboard charger would use the charging algorithm that is compatible with the battery type.

PROGRAM OPTIONS

3. BATTERY CHARGER

PROGRAM OPTIONS BATTERY CHARGER NONE

PROGRAM OPTIONS BATTERY CHARGER WET 25A

PROGRAM OPTIONS BATTERY CHARGER AGM DISCOVER 25A

PROGRAM OPTIONS BATTERY CHARGER GEL EXIDE 25A

PROGRAM OPTIONS BATTERY CHARGER GEL-AGM 25A

PROGRAM OPTIONS BATTERY CHARGER WET 15A

Burst Of Power Operation

The SA40 machine does not support Burst of Power. So this menu item is not functional at this time.

PROGRAM OPTIONS BATTERY CHARGER AGM FULLRIVER 25A

PROGRAM OPTIONS

4. BURST OF POWER

PROGRAM OPTIONS BURST OF POWER NO

PROGRAM OPTIONS BURST OF POWER YES

Page 34

Detergent (EcoFlex™) Option

Control System 34Service Manual – SA40

The SA40 does not utilize a separate detergent system. So this menu item is not applicable at this time. The menu choice must be set to “No”.

Chemical Rate Bias

The SA40 does not utilize a separate detergent system. So this menu item is not applicable at this time.

PROGRAM OPTIONS

5. ECOFLEX INSTALLED

PROGRAM OPTIONS ECOFLEX INSTALLED NO

PROGRAM OPTIONS ECOFLEX INSTALLED YES

PROGRAM OPTIONS

6. CHEMICAL RATE BIAS

PROGRAM OPTIONS CHEMICAL RATE BIAS NONE

PROGRAM OPTIONS CHEMICAL RATE BIAS

-10% LESS CHEMICAL

Open Fault Detect

Normally, the A1 Control Board will perform checks of the electrical system during operation. If a fault occurs in a particular system, that system (and possibly others) will be shut down. This can make troubleshooting the system difcult. The 7. OPEN FAULT DETECT submenus allow service personnel to disable all of the open circuit faults to facilitate troubleshooting. Note that selecting OPEN FAULT DETECT /

OFF will not disable the over-current protection on any of the systems.

The default setting is OFF.

Display Rev Level

The 8. DISPLAY REV LEVEL submenu displays the revision level of the

software in the A1 Control Board. This revision level is a parameter hardcoded in the software.

PROGRAM OPTIONS CHEMICAL RATE BIAS +10% MORE CHEMICAL

PROGRAM OPTIONS

7. OPEN FAULT DETECT

PROGRAM OPTIONS OPEN FAULT DETECT OFF

PROGRAM OPTIONS OPEN FAULT DETECT ON

PROGRAM OPTIONS

8. DISPLAY REV LEVEL

PROGRAM OPTIONS DISPLAY REV LEVEL REV A

Page 35

Lock Out Brush Pressure

Control System 35Service Manual – SA40

The 9. LOCKOUT BRUSH submenus allow you to lock out the low or high scrub pressure settings. The Operator will not be able to select a scrub pressure setting that is locked out.

The default setting is NONE.

Lock Out Solution Flow Rate

PROGRAM OPTIONS

9. LOCKOUT BRUSH

PROGRAM OPTIONS LOCKOUT BRUSH NONE

PROGRAM OPTIONS LOCKOUT BRUSH LOW

PROGRAM OPTIONS LOCKOUT BRUSH HIGH

The 10. LOCKOUT SOLUTION submenus allow you to lock out single or multiple solution ow rate settings. The Operator will not be able to select ow rate(s) that are locked out during normal operation.

The default setting is NONE.

PROGRAM OPTIONS

10. LOCKOUT SOLUTION

PROGRAM OPTIONS LOCKOUT SOLUTION NONE

PROGRAM OPTIONS LOCKOUT SOLUTION LOW

PROGRAM OPTIONS LOCKOUT SOLUTION MEDIUM

PROGRAM OPTIONS LOCKOUT SOLUTION HIGH

PROGRAM OPTIONS LOCKOUT SOLUTION LOW & MEDIUM

PROGRAM OPTIONS LOCKOUT SOLUTION LOW & HIGH

PROGRAM OPTIONS LOCKOUT SOLUTION MEDIUM & HIGH

Page 36

Backup Alarm Volume

Control System 36Service Manual – SA40

The 11. BACKUP ALARM VOL (volume) submenus allow you to set the

backup alarm volume.

The default setting is MEDIUM.

Forward Alarm Volume

The 12. FWD (forward) ALARM VOL (volume) submenus allow you to set the forward alarm volume.

The default setting is OFF.

PROGRAM OPTIONS

11. BACKUP ALARM VOL

PROGRAM OPTIONS BACKUP ALARM VOL OFF

PROGRAM OPTIONS BACKUP ALARM VOL LOW

PROGRAM OPTIONS BACKUP ALARM VOL MEDIUM

PROGRAM OPTIONS BACKUP ALARM VOL HIGH

PROGRAM OPTIONS

12. FWD ALARM VOL

Horn Volume

The HORN VOLUME submenus allow you to set the horn volume.

The default setting is HIGH.

PROGRAM OPTIONS FWD ALARM VOL OFF

PROGRAM OPTIONS FWD ALARM VOL LOW

PROGRAM OPTIONS FWD ALARM VOL MEDIUM

PROGRAM OPTIONS FWD ALARM VOL

PROGRAM OPTIONS HIGH

13. HORN VOLUME

PROGRAM OPTIONS HORN VOLUME OFF

PROGRAM OPTIONS HORN VOLUME LOW

PROGRAM OPTIONS HORN VOLUME MEDIUM

PROGRAM OPTIONS HORN VOLUME HIGH

Page 37

Restore Defaults

Control System 37Service Manual – SA40

The 14. RESTORE DEFAULTS submenus allow you to reset the programmed

options/parameters stored in the A1 Control Board EEPROM to their factory default values. Note that selecting RESTORE DEFAULTS / YES will not reset the hour meter.

The default setting is NO.

Note: IfyouselectYES to restore the defaults, it will be like

installinganew“outofthebox”controller.Therst

time you turn on the key switch, the graphic display will automatically bring you to the programming options menu. Also any “user preferences” like brush pressure lock

outorsolutionowratelockoutwillbelost.

Fault Recall

Whenever the A1 Control Board detects an electrical system fault, one or more error codes are displayed and stored in the Board EEPROM. The

15. FAULT RECALL submenu allows you to recall any error code(s) that

had been logged from previous machine operation. This can be useful for troubleshooting the machine.

• Any logged fault codes will be shown on the display. (Fault codes 3, 32

and 52 are shown here in this example.)

• If no fault code is present, the display will show a “-“

Pressing the Information Switch with the FAULT RECALL submenu displayed will erase the fault history and the entire Frozen Parameters memory. (Refer to “Frozen Parameters” on page 39.)

PROGRAM OPTIONS

14. RESTORE DEFAULTS

PROGRAM OPTIONS RESTORE DEFAULTS NO

PROGRAM OPTIONS RESTORE DEFAULTS YES

PROGRAM OPTIONS

15. FAULT RECALL

PROGRAM OPTIONS FAULT RECALL 3 32 52

PROGRAM OPTIONS FAULT RECALL

Note that there may be a slight delay after pressing the Information Switch before the “-“ symbol appears to conrm that the memory has been cleared. This is normal and is due to the large amount of Frozen Parameter data that is being erased.

Service Test Mode

The 16. SERVICE TEST MODE allows you to switch the individual electrical

PROGRAM OPTIONS

16. SERVICE TEST MODE

system components on and off independent of the normal Operator inputs. This function is described in the Troubleshooting section on page

29.

SPD: N 26.5 BRU: OFF REV: OFF VAC: OFF INH: ON E00 SOL: OFF DEK: UP CP: OFF

Page 38

Extra Information on the Graphic Display

Control System 38Service Manual – SA40

The 17. EXTRA INFO ON LCD submenus allow you to display additional information on the graphic display. This additional information is displayed in real time on both the Scrubbing and Information screens and can aid in troubleshooting the machine in normal operation.

The extra information is displayed in a two-letter or three-letter code that identies the information. A number below the letter code indicates the unit value in amps or volts.

Only one type of extra information can be displayed at any time, but the selected information can be changed at will via the 17. EXTRA INFO ON

LCD submenus. Descriptions of the letter codes are as follows:

• BV = Battery Voltage

• LOK = Battery Lock Level

• ACT = Deck Actuator Current

• SOL = Solution Solenoid Current

• BRU = Brush Motor Contactor Current

• VAC = Vacuum Motor Contactor Current

• DET = Detergent/Chemical Pump Current

The default setting is NONE.

PROGRAM OPTIONS

17. EXTRA INFO ON LCD

PROGRAM OPTIONS EXTRA INFO ON LCD NONE

PROGRAM OPTIONS EXTRA INFO ON LCD BATT VOLTS

PROGRAM OPTIONS EXTRA INFO ON LCD BATT LOCK VALUE

PROGRAM OPTIONS EXTRA INFO ON LCD ACTUATOR CURR

PROGRAM OPTIONS EXTRA INFO ON LCD SOLUTION CURR

PROGRAM OPTIONS EXTRA INFO ON LCD BRUSH CONT CURR

PROGRAM OPTIONS EXTRA INFO ON LCD VAC CONT CURR

PROGRAM OPTIONS EXTRA INFO ON LCD CHEM PUMP CURR

Page 39

Frozen Parameters

Control System 39Service Manual – SA40

The 18. FROZEN PARAMETER rst and second-level submenus allow you

to view the machine parameters that were saved prior to when an error code was detected. This can be helpful when troubleshooting intermittent problems that are causing a code to set.

Note: Frozenparametersareonlysavedfortherstcodethatis

set, not for any subsequent codes.

Eleven different machine parameters are logged, and all but the error code number and hour meter time are saved at 0.1 second intervals for the 12.8 seconds leading up to the time of the error code. This results in a total of 128 data points (one every 0.1 seconds) for each parameter. These data points are displayed in a second-level of submenus.

The rst-level ERROR CODE submenu displays the error code number (32 in this example). The rst-level HOUR METER submenu displays the time on the hour meter when the error code occurred (12:15 in this example). The other nine rst-level submenus are links to the next (second) layer of submenus that display the 128 data points corresponding to the functions listed on the submenus.

Note that in the second-level submenus, data point #1 is the newest value and #128 is the oldest value (that occurred 12.7 seconds earlier).

Pressing the Forward (up) or Reverse (down) Drive Switches will scroll through the 18. FROZEN PARAMETER rst-level submenus shown here.

PROGRAM OPTIONS

18. FROZEN PARAMETER

PROGRAM OPTIONS FROZEN PARAMETER ERROR CODE 32

PROGRAM OPTIONS FROZEN PARAMETER HOUR METER 12:15

PROGRAM OPTIONS FROZEN PARAMETER

3. BATT VOLTAGE

PROGRAM OPTIONS FROZEN PARAMETER

4. ACTUATOR CURR

PROGRAM OPTIONS FROZEN PARAMETER

5. SOLUTION CURR

PROGRAM OPTIONS FROZEN PARAMETER

6. VAC CONT CURR

PROGRAM OPTIONS FROZEN PARAMETER

7. BRU CONT CURR

PROGRAM OPTIONS FROZEN PARAMETER

8. DET PUMP CURR

PROGRAM OPTIONS FROZEN PARAMETER

9. DIRECTION

PROGRAM OPTIONS FROZEN PARAMETER

10. ACT SW 1

PROGRAM OPTIONS FROZEN PARAMETER

11. ACT SW 2

Page 40

To display the parameter data points in a second-level submenu:

1. Press the Forward (up) or Reverse (down) Drive Switch to scroll through the available rst-level submenus. (The rst-level submenu 3. BATT

VOLTAGE is selected in this example.)

Control System 40Service Manual – SA40

PROGRAM OPTIONS FROZEN PARAMETER

3. BATT VOLTAGE

2. Press the Information Switch to display the second-level submenu. (The second-level submenu 3. BATT VOLTAGE / 1: 20.35 is shown in this example.) This submenu tells you that at data point 1 (0.1 seconds prior to the error code), the battery voltage was 20.35 volts.

FROZEN PARAMETER

3. BATT VOLTAGE 1: 20.35

• Note that if the selected rst-level submenu has no second-level submenu, the Information Switch will have no effect.

3. To go back one level from a second-level submenu to a rst-level submenu, press the Scrub On/Off Switch.

To scroll through the data points on a second-level submenu:

When you display a rst-level submenu, the Brush Pressure Indicator (LED) will turn on.

When you display a second-level submenu, pressing the Brush Pressure Switch will toggle the data point scrolling mode between the fast and slow scrolling modes. The two scrolling modes work as follows:

• In the slow scrolling mode the

increment/decrement value is 1 (0.1 seconds). Pressing the Forward Drive

FROZEN PARAMETER

3. BATT VOLTAGE 1: 20.35

FROZEN PARAMETER

3. BATT VOLTAGE 126: 20.45

Switch will step you from data record 1 to 2, 2 to 3, etc. Pressing the Reverse Drive Switch will step you from data record 128 to 127, 127 to 126, etc.

FROZEN PARAMETER

3. BATT VOLTAGE 2: 20.36

FROZEN PARAMETER

3. BATT VOLTAGE 127: 20.47

FROZEN PARAMETER

3. BATT VOLTAGE 3: 20.37

FROZEN PARAMETER

3. BATT VOLTAGE 128: 20.55

• In the fast scrolling mode the

increment/decrement value is 10 (one second). Pressing the Forward Drive Switch will step you from data record 10 to 20, 20 to 30 etc. Pressing the Reverse Drive Switch will step you

FROZEN PARAMETER

3. BATT VOLTAGE 10: 24.53

FROZEN PARAMETER

3. BATT VOLTAGE 100: 24.57

from data record 120 to 110, 110 to 100, etc.

The purpose of the fast-scrolling feature is to reduce the number of switch presses required to cycle through all 128 data

FROZEN PARAMETER

3. BATT VOLTAGE 20: 24.59

FROZEN PARAMETER

3. BATT VOLTAGE 110: 24.54

points if you choose to do so.

This fast-scrolling feature will automatically end when you press the Scrub On/Off Switch to leave a second-level submenu.

FROZEN PARAMETER

3. BATT VOLTAGE 30: 24.52

FROZEN PARAMETER

3. BATT VOLTAGE 120: 24.56

The Brush Pressure Indicator will turn off when you press the Scrub On/Off Switch again to leave the rstlevel submenu.

To capture the parameters prior to another fault condition, you’ll need to clear the current fault from the 15.

FAULT RECALL submenu. (Refer to “Fault Recall” on page 37.)

Page 41

Control System 41Service Manual – SA40

Panel Test

The 19. PANEL TEST submenus allow you to verify the function of the control

panel membrane switches and LEDs, This will help identify any intermittent

PROGRAM OPTIONS

19. PANEL TEST

or non-functioning switches or LEDs. When the submenu is rst entered, all LED will turn off

PROGRAM OPTIONS PANEL TEST

When you press a membrane switch, the display will show the name of the switch and how many times its press was recorded. The display shows

HORN 2

that the HORN Switch has been pressed twice in this example.

When a switch is pressed, its associated LED will illuminate. The LED will remain illuminated until a different switch is pressed or the menu is exited. Because the Horn and Information Switches do not have LED indicators, the vacuum mode indicators are used, as described in the table below.

Membrane Switch

LED Indicator That Will Light When the

Switch is Pressed

Horn Switch Quiet Vacuum Mode

Indicator on the Vacuum Power Adjustment Switch

Information Switch

Standard Vacuum Mode Indicator on the Vacuum Power Adjustment Switch

Vacuum Power Adjustment Switch

Both Quiet & Standard Vacuum Mode Indicators on the Vacuum Power Adjustment Switch

Scrub Switch Both the Scrub Switch

and Scrub Pressure LEDs will illuminate.

All Other Switches Their respective On/Off Indicator

Save Scrub Settings

The 20. SAVE SCRUB SETTINGS submenus allow you determine whether

the machine uses the scrub settings that were in use when the key switch was switched off, or the default settings.

PROGRAM OPTIONS

20. SAVE SCRUB SETTINGS

PROGRAM OPTIONS SAVE SCRUB SETTINGS YES

PROGRAM OPTIONS SAVE SCRUB SETTINGS NO

Page 42

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. Do not walk around with a Control Board in your hands.

Control System 42Service Manual – SA40

1. Disconnect the batteries.

2. Remove the four Phillips

Screws and Flat Washers

holding the Interface Panel

Assembly to the Control Panel.

Phillips Screw

and Flat

Washer (4)

Control

Panel

Interface

Panel

Assembly

3. Carefully lift the Interface

Panel Assembly out of the Control Panel.

Interface Panel

Assembly

Control

Panel

Page 43

4. Carefully disconnect the Electrical

Connectors from the A1 Control Board.

5. Remove the Phillips Screws and grounding strap, then remove the A1 Control Board from the Interface Panel Assembly.

Control System 43Service Manual – SA40

6. Reinstall the A1 Control Board by following the above steps in reverse order.

E1 Curtis 1210 Speed Controller

1. Disconnect the batteries.

2. Remove the four Phillips

Screws and Flat Washers

holding the Interface Panel

Assembly to the Control Panel.

Phillips Screw

and Flat

Washer (4)

Control

Board

Phillips

Screw

(typical

Control

Panel

Electrical

Connector

(typical)

Interface

Panel

Assembly

Interface

Panel

Assembly

Page 44

3. Carefully lift the Interface

Panel Assembly out of the Control Panel.

Control System 44Service Manual – SA40

4. Carefully disconnect the

Electrical Connectors from

the E1 Curtis 1210 Speed

Controller.

5. Remove the two Socket

Head Screws and remove

the E1 Curtis 1210 Speed

Controller from the Control Panel.

6. Reinstall the E1 Curtis

1210 Speed Controller by

following the above steps in reverse order.

Interface Panel

Assembly

Electrical

Connector

(typical)

Control

Panel

E1 Curtis

1210 Speed

Controller

Socket Head

Screw (2)

Control

Panel

Page 45

Control System 45Service Manual – SA40

A1 Control Board Shop Measurements

The following table lists measurements taken from one SA40 machine. While these are not “specications”, they can help you recognize abnormal vs. normal conditions.

Note that the black voltmeter lead is on B- unless otherwise indicated.

Pin Color Description Ref. Measurements

J1-1 RED/YEL Chemical Pump + B- 2.1v not on

J1-2 -

J1-3 BLU/GRY Chemical Pump B- 2.1v not on

J1-4 -

J1-5 -

J1-6 -

J1-7 RED/YEL Inhibit SPC B- 0.001v no direction selected

23.2v FWD or REV requested

J1-8 BLK B- 0.09v Vacuum on

J1-9 BLU Brush Act. - B- 2.1v or 3.8v at rest

0.2v extending

22.9v retracting

J1-10 ORN/BLK Brush Act. + B- 2.1v or 3.8v at rest

0.2v retracting

22.9v extending

J2-1 BLK B- B- 0.09v Vacuum On

J2-2 BLK B- B- 0.09v Vacuum On

J2-3 ORN Batt. Chg. Comm. B- 0.8v key off

Plug in Charger: 12v, then 3.9v, then 12 v

J2-4 -

J2-5 -

J2-6 -

J2-7 BLK B- B- 0.09v Vacuum On

J2-8 BLK B- B- 0.09v Vacuum On

J2-9 -

J2-10 -

J2-11 BLK/WHT Act. Position 2 B- 4.99v switch open

0.03v switch closed

J2-12 RED/VIO Act. Position 1 B- 4.99v switch open

0.03v switch closed

J3-1 BRN/VIO B+ B- 24.5v key off or on

J3-2 -

J3-3 RED/BRN Reverse B- 0v no direction request or forward request

23.1v reverse direction request

J3-4 BRN Dead Man Switch B- 24.4v when pressed (Key and Emergency Switch

also closed)

J3-5 BLU/BLK Rev. Alarm B- 23.4v forward or stationary

1.5v in reverse

J3-6 RED/WHT Motion B- 24v stationary

0.1v moving forward or reverse

Page 46

Pin Color Description Ref. Measurements

J3-7 ORN/BLU Status B- 1.77v when no code

Unstable when code – max 23.5v

J3-8 BRN B+ B- 24.4v key off or on

J3-9 GRN/BLK Horn - B- 14.9v horn off

0.004v horn on

J3-10 ORN/RED Horn + B- 14.9v horn off or on

J3-11 VIO/BLK Solution Solenoid B- 24.4v solenoid off

0.12v solenoid on

J3-12 GRA/BLK Vacuum Control B- 23.4v Vacuum off

6.9v Vacuum low

0.104 Vacuum high

J3-13 WHT/RED Brush Contacator B- 24.3v off

0.2v on

J3-14 BRN Key Switch B- 0v key off

24.2v key on

Control System 46Service Manual – SA40

Page 47

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.

The electrical system is powered by two 12-volt or four 6-volt batteries for a total of 24 volts. Heavy cables connect the batteries in series. On machines without an on-board battery charger, a large red main battery pack connector is used for connecting the batteries to a “shelf” battery charger unit.

The control system will turn off the scrub system and recovery systems if the battery voltage drops too low to prevent damage to the batteries due to excessive discharging.

The circuit breakers and a 150-amp fuse protect various circuits from excessive current.

47Service Manual – SA40

The machine wiring is color coded, and the wires are marked corresponding to their location on the “Wiring

Harness Diagram” on page 57. (Wire W010 to the Brush

Contactor K2 is shown in this example.)

Page 48

Electrical System 48Service Manual – SA40

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 Keyswitch Input (KSI) signal to the drive speed controller when the charger is plugged into an AC power outlet. This prevents the machine from being propelled while the batteries are charging.

Here is how the battery charger interlock circuit works. The interlock relay contacts inside the charger are normally closed, allowing positive control voltage to be present in the Keyswitch, E-Stop, and Deadman circuit. When all switches are closed, positive voltage is applied to the enabling inputs of the A1 Control Board and the Speed Controller. When the AC power cord is plugged in, the relay is energized and opens the relay contacts opening the circuit.

Delta-Q Charger

Charger Interlock Circuit, Not Plugged In

YEL/ORN

CB2

Circuit Breaker, 5 Amp

Not Used

Control Board

Main Machine

Controller

YEL/ORN

J2-3 Bat Charger On-board Communication

RED

A B

B+

Gnd

1 2

Dead Man

Switch J3-4

Fuse, 150 A.

1 2

B-

Internal Relay in Battery Charger

SPST Key

Switch

Emergency Stop S4

BRN

Battery 24 VDC

RED

BLK

Dead Man Switch

111

2222

Curtis 1210

Controller

BT1

Speed

KLBOIV/NRBDER

Pin 5 - KSI

Page 49

Electrical System 49Service Manual – SA40

Charter Interlock Circuit, Plugged In

YEL/ORN

CB2

Circuit Breaker, 5 Amp

Control Board

Main Machine

Controller

YEL/ORN

J2-3 Bat Charger On-board Communication

Not Used

RED

A B

B+

Gnd

1 2

Dead Man

Switch J3-4

Fuse, 150 A.

1 2

B-

Internal Relay in Battery Charger

SPST Key

Switch

Emergency Stop S4

BRN

RED

BLK

Dead Man Switch

111

2222

Curtis 1210

Controller

BT1

Battery 24 VDC

KLBOIV/NRBDER

Speed

Pin 5 - KSI

Page 50

Delta-Q Charging Proles 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 prole is in use. If you replace the batteries with a different type of battery or replace the battery charger, you must select the correct charging prole to be compatible with the batteries. There are a set of proles stored inside the charger. You can interface directly with the charger to select the prole to be used from that set. See the Delta-Q IC650 Product Manual (710-0138-Delta-Q.pdf) for complete instructions on selecting the prole. Use the Delta-Q Battery Charging Prole Table below to choose the prole to match the batteries that are in the machine.

Delta-Q Battery Charging Prole Table

Electrical System 50Service Manual – SA40

Battery Manufacturer Volts Battery Model # 20 Hour

Rating

DISCOVER 6 EV250A-AGM 260 40953A P-0-4-3

DISCOVER 6 EV305A-A 312 56112546 P-0-4-3

DISCOVER 6 EV305A-A 312 56315959 P-0-4-3

DISCOVER 6 EV305A-AGM 312 40964A P-0-4-3

DISCOVER 6 EVGT6A 255 56112545 P-0-4-3

DISCOVER 6 EVGT6A 255 56315772 P-0-4-3

DISCOVER 6 EVL 16A-A 390 56388582 P-0-4-3

DISCOVER 12 EV12A-A 140 56380239 P-0-4-2

DISCOVER 12 EV185A- A 234 56393912 P-0-4-3

DISCOVER 12 EV185A-A 234 41023A P-0-4-3

EAST PENN MFG. CO. 6 8GGC 2/T881 (GEL

CELL)

EAST PENN MFG. CO. 12 8G27MM/T876 86.4 56206988 P-0-2-6

FULL RIVER 6 DC 250-6 250 56112545 P-1-5-1

FULL RIVER 6 DC 335-6 335 56112546 P-1-4-1

TROJAN 6 J -305G 285 56391391 P-0-0-7

TROJAN 6 J-250-2992-41 250 56026200 P-0-0-3

TROJAN 6 L16-5592-41 395 56388582 NOT RECOMMENDED

TROJAN 6 T-125LPT 235 56206079 P-0-0-3

TROJAN 6 T-605LPT 195 56206117 P-0-0-3

TROJAN 12 J185-2292-42 195 56206078 P-0-0-3

US BATTERY 6 L16 375 40602A P-0-7-3

US BATTERY 6 L16 375 40704A P-0-7-3

US BATTERY 6 L16HC 415 56388582 P-0-7-3

US BATTERY 6 US-125 235 331318 P-0-1-1

US BATTERY 6 US-125 235 881317 P-0-1-1

180 56206987 P-0-2-6

N-A P/N Use Prole

Page 51

Electrical System 51Service Manual – SA40

Battery Manufacturer Volts Battery Model # 20 Hour

N-A P/N Use Prole

Rating

US BATTERY 6 US-125 235 56206079 P-0-1-1

US BATTERY 6 US-125 235 40136A P-0-1-1

US BATTERY 6 US-125 235 40136B P-0-1-1

US BATTERY 6 US-14 5XC 251 56317154 P-0-7-2

US BATTERY 6 US1800 201 56206117 P-0-1-1

US BATTERY 6 US250HC 275 56026200 P-0-1-1

US BATTERY 6 US-305 305 891384 P-0-7-2

US BATTERY 6 US-305 305 891385 P-0-7-2

US BATTERY 6 US-305 305 56391391 P-0-7-2

US BATTERY 12 UB27 86 40070A P-0-0-6

US BATTERY 12 US-185 195 871334 P-0-1-1

US BATTERY 12 US-185 195 871335 P-0-1-1

US BATTERY 12 US-185 195 56206078 P-0-1-1

US BATTERY 12 US-31TMX 130 40605A P-0-7-1

US BATTERY 12 US-31TMX 130 40606A P-0-7-1

Page 52

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

The Batteries sit in the

Battery Tray. To access

the Batteries, lift up the

Control Panel Housing / Recovery Tank Cover,

engage the Prop Rod,

then tilt the Recovery

Tank back.

Control Panel

Housing/

Recovery

Tank Cover

Batteries

Electrical System 52Service Manual – SA40

Recovery

Tank

Battery

Tray

The On-board Battery Charger is mounted on the underside of the machine above the scrub deck.

On-board

Battery

Charger

Page 53

The 25-amp Circuit Breaker

(CB4), 20-amp Circuit

Breaker (CB3), 5-amp Circuit Breaker (CB2) and 50-amp Circuit Breaker (CB1), 100k Speed Control Potentiometer

(R1), Emergency Disconnect and Key Switch (S1) are all

mounted on the back of the

Control Panel.

100k Speed

Control

Potentiometer

Control

Panel

25-amp

Circuit

Breaker

20-amp

Circuit

Breaker

5-amp

Circuit

Breaker

Electrical System 53Service Manual – SA40

50-amp

Circuit

Breaker

Emergency Disconnect

Key

Switch

The Solid State Relay (K1),

Brush Motor Contactor (K2), Fly-back Diode (D2) and 150-amp Fuse are located

inside the control panel

assembly.

Fly-back

Diode (D2)

Solid State

Relay (K1)

Brush Motor

Contactor (K2)

150-amp

Fuse

Page 54

Electrical System 54Service Manual – SA40

Troubleshooting

Note: Refer to the individual machine system sections for electrical troubleshooting procedures.

Problem Cause Correction

No power to the machine.

Insufcient machine

run time.

The battery charger does not charge.

Discharged batteries. Check the battery voltage and charge as necessary.

Poor battery connection(s). Check the battery cables, terminals and connections

and tighten/repair/replace as necessary.

Batteries need to be replaced. Perform a load test on the batteries and replace if

necessary.

Incorrect low-voltage cutout setting.

Batteries not fully charged. If there is any question whether the batteries are fully

One or more weak batteries. • Measure the voltage across each individual battery

Poor battery connection(s). Check the battery cables, terminals and connections

Battery charger not operating correctly.

There’s a problem with the charger wiring and/or connections.

One or more weak batteries Check and replace the batteries as necessary.

Make sure the low battery voltage cutout setting is correct for the battery type in the machine. (Refer to the Control System/Programming Options/Low Battery Voltage Cutout subsection.)

charged, they should be charged for at least 16 hours.

while operating the machine. Write down the values and compare them. A battery that has a dead cell will typically be 1 - 2 volts lower than the others.

• Use a battery load tester to test each battery.

• For wet batteries, a hydrometer can be used to

check the specic gravity of the electrolyte in each

cell. A dead cell is one that reads 50 points or more lower than the other cells.

and tighten/repair/replace as necessary.

1. Check the charger 120VAC power cord and power source to the charger and repair as necessary.

2. If the electrical connections are OK, replace the charger.

Check the charger connections to the machine and repair as necessary.

Page 55

Wiring Diagrams

Wiring (Ladder) Diagram

Drawing 56104446, Rev. C

CB1

RED

X001

WHEN CHARGER IS NOT INSTALLED THERE NEEDS TO BE A JUMPER BETWEEN PINS 1 AND 2 ON CONNECTOR X126 ON MAIN HARNESS

CIRCUIT BREAKER, 5 AMP

RED

CIRCUIT BREAKER, 50A .

123

YEL/ORN

CB2

BRN/VIO

BRN

SW, SPST KEY

BRN/VIO

RED

CHARGER OPTIONAL SEE PAGE 2

A B

2 3

X004

J3-1 B+ J3-8 B+

J3-14 KEY SWITCH

FUSE, 150A.

RED

BLK

EMERGENCY STOP

WHT/BRN BLK

X161C

DEAD MAN SWITCH J3-4

DEADMAN SW ITCH

X162C

BRN/WH T

BATTERY, 24 Vdc

+ -

X162E

X161E

BT1

1 2

ORN

Y1 BRAKE

X162D

BLK

X144A

X161D

BRN/BLK

X158A

Electrical System 55Service Manual – SA40

X002

BRN/ORNBLU

ORN

RED/YEL

ORN/BLU

BLU/BL K

RED/BRN

X144B

X158B

GRN/ORG

BLU

X162A

RED/WHT

YEL

VIO

X161A

BRN

VALVE, SOLENO ID

RED

BRN

YEL/ORN

B+

WHT/RED

CONTACTOR, B RUSH

VIO/BL K

ORN/RED

HORN

GRN/BLK

OPTION AL

DETERGENT PUMP

BLU/GRY

RED/YEL

A1 (CONTROL BOARD)

MAIN MACHINE CONTROLLER

X003

J3-13 BRUSH CONTACTO R

J3-11 SOLUTION SOL ENOID

J3-10 HORN +

J3-9 HORN -

J1-1 + DETERGENT

PUMP

J1-3 - DETERGENT

PUMP

MOTION J3-6

STATUS J3-7

REV. ALARM J3-5

DRIVE SWITCH J3-3

B- J2-8 B- J2-7 B- J2-1 B- J2-2

YEL

X161B

RED/W HT

BLK

X162B

X006

100K POT

GO SWI TCH

TRACKCLEAN CONNECTIONS

X001=B+(R ED) X002=B-(BLU) X003=SCRUB(W HT) X004=KEY SW(BRN) X005=VACUUM(GRA) X006=DRIVE(PNK ) X007=BYPASS(BRN) X008=MACHINE SUPPLY(ORN)

TRACKCLEAN BYPASS: CONNECT BROWN WIRE FROM THE MACHINE TO BROWN WIRE (X007).

USE ADAPTER HARNESS FOR RETROFIT MACHINES.

RED/W HT

GRA

BLK BLK BLK BLK

E1 CURTIS 1210 SPEED CONTROLLER

PIN 6 - BRAKE -

PIN 12 - INHIBITINHIBIT SPC J1-7

PIN 9 - STATUS

PIN 16 - REV. ALARM

PIN 17 - DRIVE SWITCH

PIN 3 - HIGH

PIN 18 - SPEED LIMIT

PIN 13 - POT. LOW

PIN 4 - GO SWITCH

B+

PIN 5 - KSI

YEL/BLK

RED/GRN

X143B

X143A

BLK

X157B

X157A

YEL/BLK

RED/GRN

MOTOR, WHEEL DRIVE

PIN 14 - BRAKE +

B-

KEY SWITCH DETAIL

KEY SW

BRN/VIO

004

BRN

TRACKCLEAN H ARNESS

X008

ORN

BRN-MACHINE

Page 56

Wiring (Ladder) Diagram, continued

Electrical System 56Service Manual – SA40

B+

RED

CIRCUIT BREAKER, 20 AMP

CB3

CIRCUIT BREAKER, 25 AMP

CB4

YEL/OR N

BLU/O RN

BRN/YEL

SOLID STATE "RELAY"

4 3

CONTACTOR, B RUSH

MOTOR, BRUS H LIFT A CTUACTOR

J2-3 BAT CHARGER ON BOARD COMMUNICATION

BRUSH ACT (-) J1-9

A1(CONTROL BOARD) MAIN MACHINE CONTROLLER

ACT POSITION1 J2-12

ACT POSITION2 J2-11

GRA/B LKBRN

WHT

J3-12 VACUUM MOTOR

POWER M ODULE

BRUSH ACT (+) J1-10

B- J1-8

X005

BLU

RED/VI O

BLK/W HT

ORN/BLK

YEL/BL K

POS 1

POS 2

2 1

TOP LIMIT

2 1

BOTTOM LIM IT

B-

BLK

MOTOR, VAC

~ ~

FLY-BACK DI ODE

RED BLK

MOTOR, BRUS H

GND

INLINE FUSE 3A

P/N 56383587

B+ B-

A B

B+ B -

GND

1 2 3

CHARGER DEL TA Q

1 2 3

CHARGER S. P.E.

Page 57

Wiring Harness Diagram

Drawing 56104447, Rev. B

Electrical System 57Service Manual – SA40

Page 58

Electrical System 58Service Manual – SA40

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 nd out which connector is on the L1 (solution) Solenoid Valve and what it looks like, refer to the Wiring Harness Diagram. The Wiring Harness Diagram shows that connector X7 is on the

L1 (solution) Solenoid Valve. Refer to the Wiring (Ladder) Diagram and the appropriate table below, X7 (Delphi

12015792) in this example, for the corresponding wire colors, and wire and connector pin assignments.

Section of Wiring Harness Diagram

X7 (Delphi 12015792)

Pin# Conductor Wire Color

A W284 BRN

B W283 VIO/BLK

Section of Wiring Diagram

Page 59

Connector Pin-out Assignment Tables

J1 (Molex Mini Fit Jr. 39012105)

Pin# Conductor Wire Color

1 W279 RED/YEL

2 – –

3 W280 BLU/GRA

4 – –

5 – –

7 W302 RED/YEL

8 W165

YEL/BLK

Electrical System 59Service Manual – SA40

9 W054 BLU

10 W055 ORN/BLK

J2 (Molex Mini Fit Jr. 39012125)

Pin# Conductor Wire Color

1 W162 BLK

2 W161 BLK

3 W174 YEL/ORN

4 – –

5 – –

6 – –

7 W163 BLK

8 W164 BLK

9 – –

10 – –

11 W218 BLK/WHT

12 W204 RED/VIO

Page 60

J3 (Molex Mini Fit Jr. 39012145)

Pin# Conductor Wire Color

1 W181 BRN/VIO

2 – –

3 W166 RED/BRN

4 W294 BRN

5 W066 BLU/BLK

6 W277 RED/WHT

7 W067 ORN/BLU

8 W182 BRN/VIO

9 W281 GRN/BLK

10 W282 ORN/RED

11 W283 VIO/BLK

12 W003 GRA/BLK

13 W010 WHT/RED

14 W183 BRN

Electrical System 60Service Manual – SA40

Page 61

J4 (39012185)

Pin# Conductor Wire Color

1 – –

2 – –

3 W060 YEL

4 W272 GRA

5 W293 BRN

6 W276 RED/WHT

7 – –

8 – –

9 W067 ORN/BLU

10 – –

11 – –

12 W302 RED/YEL

13 W064 VIO

14 W278 ORN

15 – –

16 W066 BLU/BLK

17 W166 RED/BRN

18 W217 GRN/ORN

Electrical System 61Service Manual – SA40

X2 (Ducon 12147067)

Pin# Conductor Wire Color

A W199 BLK

B W167 RED

Page 62

X6 (Delphi 12052613)

Pin# Conductor Wire Color

A W191 WHT

B W194 BLK

X7 (Delphi 12015792)

Electrical System 62Service Manual – SA40

Pin# Conductor Wire Color

A W284 BRN

B W283 VIO/BLK

X126 (AMP 282087-1)

Pin# Conductor Wire Color

1 W172 BRN

2 W173 RED-VIO

3 W174 YEL-ORN

Page 63

X127 (Delphi 15363990)

Pin# Conductor Wire Color

A W170 RED

B W171 BLK

X139 (Delphi 12020786)

Electrical System 63Service Manual – SA40

Pin# Conductor Wire Color

A W055 ORN/BLK

B W054 BLU

C W204 RED/VIO

D W165 YEL/BLK

E – –

F W218 BLK/WHT

X143 (Ducon 12147067)

Pin# Conductor Wire Color

A W273 RED/GRN

B W274 YEL/BLK

Page 64

X144 (Delphi 12015792)

Pin# Conductor Wire Color

A W278 ORN

B W275 RED/WHT

X161 (Delphi 12020926)

Electrical System 64Service Manual – SA40

Pin# Conductor Wire Color

A W272 GRA

B W271 YEL

C W289 WHT/BRN

D W293 BRN

E W294 BRN

Page 65

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 sufcient airow to lift the used cleaning solution from the squeegee and into the vacuum hose assembly, which then directs the water into the recovery tank.

The Operator can select from two vacuum power levels – standard and quiet vacuum.

The Recovery System includes the Vacuum

Hose Assembly, Debris Cage, Recovery Tank, Vacuum Motor, Solid State Relay, Float Cage Assembly and Drain Hose.

• The Vacuum Hose Assembly attaches to the squeegee assembly and directs the wastewater from the squeegee to the Debris

Cage and Recovery Tank.

• The Vacuum Motor creates a vacuum inside of the Recovery Tank to pull the wastewater from the squeegee into the Recovery Tank.

• The Float Cage Assembly contains two internal plastic oat balls that will rise to shut off the air intake to the Vacuum Motor if the wastewater level in the Recovery Tank gets too high. This is to prevent water from getting into the Vacuum Motor and possibly damaging the Vacuum Motor.

• The Debris Cage inside the Recovery Tank catches any large debris or particulates to keep these materials out of the Recovery

Tank. The debris tray cover can be removed

to clean out the Debris Cage.

• The Recovery Tank holds the wastewater picked up by the squeegee. Note that the

Recovery Tank is hinged at the rear and tips

back for access to the Vacuum Motor. The

Drain Hose is used to drain the wastewater

from the Recovery Tank.

Vacuum

Motor

Float Cage

Assembly

Recovery

Tank

Vacuum Hose

Assembly

Debris

Cage

Drain

Hose

65Service Manual – SA40

Page 66

Recovery System 66Service Manual – SA40

• The Solid State Relay (K1) controls the voltage to the Vacuum Motor. Note that the Solid State Relay has an LED that lights when the Relay is on.

Solid State

Relay (K1)

• The Flyback Diode (D2) reduces the highvoltage spike through the Solid State Relay that can occur when the Vacuum Motor is switched off. The inductive nature of the motor can cause a large, reverse polarity voltage spike across the solid state relay. The yback diode permits this energy to be dissipated through the motor windings without

Fly-back

Diode (D2)

the large voltage buildup at the relay. The yback diode uses a bridge rectier simply for its power handing capabilities.

Also refer to “Squeegee System” on page 101 for more information on the squeegee components and operation.

Circuit Descriptions

Vacuum Motor Off

Bat +

SPST Key

Switch

BRN/VIO

Circuit Breaker, 20 Amp

When the Vacuum Motor is off:

CB3

BLU/ORN WHT

Solid State Relay (K1)

Bat -

Control Board

Vacuum

GRA/BLKBRN

Fly-back

Diode

Contactor

J3-12

24v

Motion Input 24v

Vacuum Motor

Bat -

J3-6

RED/WHT

Pin 6

Curtis 1210

Speed

Controller

Brake -

Bat -

• The Brake - switch on Pin 6 in the E1 Curtis Speed Controller is open and is not sending the drive signal to the Motion Input line on pin J3-6 on the A1 Control Board.

• The Vacuum Contactor switch on pin J3-12 is open, the Solid State Relay (K1) is de-energized and open, and the M4 Vacuum Motor is off.

Page 67

Recovery System 67Service Manual – SA40

Vacuum Motor On

Bat + Bat -

SPST Key

Switch

BRN/VIO

Circuit Breaker, 20 Amp

CB3

BLU/ORN WHT

Solid State

Relay (K1)

GRA/BLKBRN

Fly-back

Diode

Control Board

Vacuum Contactor

J3-12

24v

Motion Input (0.1v)

Vacuum Motor

Bat -

J3-6

RED/WHT

Pin 6

Curtis 1210

Speed

Controller

Brake -

Bat -

The following conditions must be met before the Vacuum Motor can start:

• There can be no major faults active.

• The machine must not be in a low-voltage condition.

• The Scrub System or vacuum mode must be activated (the Vacuum Mode Indicator will be on or ashing).

• The A1 Control Board must have recently detected a motion signal from the E1 Curtis Speed Controller. (The

A1 Control Board will switch off the Vacuum Motor after a maximum 10 second delay once it loses the drive

signal from the E1 Curtis Speed Controller.)

When the Operator selects a drive direction and presses the go pedal:

• The Brake - switch on Pin 6 in the E1 Curtis Speed Controller closes to ground. This drops the voltage on the Motion Input line on pin J3-6 from 24v down to nearly 0 volts to signal the A1 Control Board that the machine is now in motion.

• The A1 Control Board switches the Vacuum Contactor line on pin J3-12 to battery ground to energize the

Solid State Relay (K1) and switch on the Vacuum Motor.

Note that the output from the Vacuum Contactor line on pin J3-12 drives the Solid State Relay at 100 Hz with either a 100% duty cycle for the high/standard vacuum mode, or a modulated (60%) duty cycle to provide an average of 16.8V to the Vacuum Motor in the low/quiet vacuum mode.

“Field” Voltage Measurements with Reference to Battery Negative

Pin Number Wire Color Description Voltage

J3-12 GRA/BLK Vacuum Contactor 23.4v - Vacuum Off

6.9v - Vacuum Low/Quiet

0.104v - Vacuum High/Standard

Page 68

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)

• Fly-back Diode (D2)

The Recovery Tank is located

underneath the control panel.

The Vacuum Motor is mounted below the Recovery Tank.

The Debris Cage lters any

debris out of the wastewater before it can enter the

Recovery Tank.

The Vacuum Hose Assembly

carries the wastewater from the squeegee to the Debris

Cage.

Float Cage

Assembly

Vacuum Hose

Assembly

(underneath

Debris Cage)

Recovery System 68Service Manual – SA40

Vacuum Motor

(underneath

oat support)

Debris

Cage

Recovery

Tank

Page 69

The Drain Hose allows you to drain the wastewater from the Recovery Tank.

Recovery System 69Service Manual – SA40

Drain Hose

The Solid State Relay

(K1) and Fly-back Diode (D2) (rectier bridge) are

located inside the control panel assembly

Solid State

Relay (K1)

Fly-back

Diode (D2)

Control

Panel

Page 70

Troubleshooting

General Troubleshooting

Problem Cause Correction

Vacuum motor not running - the LED on relay SSR1 is not on.

Vacuum motor not running - the LED on relay SSR1 is on.

Poor water pickup. Vacuum leak(s) due to:

No voltage from the Key Switch S1 to terminal 3+ on relay SSR1.

Terminal 4- on relay SSR1 is not getting ground from the Vacuum Contactor, pin J3-12, on the A1 Control Board.

Relay SSR1 is faulty. Replace relay SSR1.

No voltage to terminal 2+ on relay SSR1.

No voltage from terminal 1- on relay SSR1 to the Vacuum Motor M4.

The Vacuum Motor M4 is not connected to battery ground.

Relay SSR1 is faulty. Replace relay SSR1.

• Leaky vacuum hose.

• Bad recovery tank gasket.

• Drain plug not installed

correctly.

• Damaged tank.

Restrictions due to built-up debris in the squeegee tool or vacuum hose.

Squeegee blades worn or out of adjustment.

Check the wiring from the Key Switch S1 to terminal 3+ on relay SSR1 and repair as necessary.

Check the wiring from pin J3-12 on the A1 Control Board to terminal 4- on relay SSR1 and repair as necessary.

1. Check circuit breaker CB3 and reset if necessary.

2. Check the wiring from the Key Switch S1 to circuit breaker CB3 and repair as necessary.

Check the wiring from SSR1 to the Vacuum Motor M4 and repair as necessary.

Check the ground connection to the Vacuum Motor M4 and repair as necessary.

• Check the squeegee vacuum hose assembly and tighten/replace as necessary.

• Check the recovery tank gasket and replace as necessary.

• Make sure drain hose plug is installed correctly.

• Check the recovery tank for damage.

• Check the squeegee tool and vacuum hose

assembly for any accumulated dirt or debris and clean as necessary.

• Check the vacuum system airow pathway wherever the airow is forced to make a sharp turn for any

accumulated dirt or debris and clean as necessary.

• Check and replace the squeegee blades if necessary.

• Readjust the squeegee as necessary.

(Refer to the Squeegee Maintenance and Squeegee Adjustments sections in the Instructions For Use).

Recovery System 70Service Manual – SA40

Page 71

Recovery System 71Service Manual – SA40

Bench-testing the Flyback Diode (bridge rectier)

When functioning properly, the yback diode should conduct only when the voltage gets reversed by the vacuum motor. To test the bridge rectier, use a DC continuity tester or an ohm meter (on the R x 100 scale) as follows. If any of the internal diodes are shown to be defective in any of the following steps the rectier must be replaced. (Refer to steps 8 and 9 for the correct mounting position and wire connections.)

Note that the positive tab on the Flyback Diode is rotated 90 degrees from the other three tabs.

1. Disconnect the two wires from the Flyback Diode.

Reverse Bias Test

In the reverse bias direction, none of the internal diodes should conduct.

2. Connect the negative test lead to the negative terminal on the rectier.

3. One at a time, touch the positive test lead to the remaining 3 terminals.

• If the meter beeps or reads continuity for any of the 3, then the rectier is defective.

• If the meter does not beep, continue with the next step.

~ ~

Negative

Current

Positive

Forward Bias Test

In the forward bias direction, all of the diodes should conduct. Due to parallel paths, the positive and negative terminals have to be checked separately.

4. Connect the negative test lead to the positive terminal on the rectier.

5. One at a time, touch the positive test lead to the 2 AC terminals (1&2).

6. Connect the positive test lead to the negative terminal on the rectier.

7. One at a time, touch the negative test leads to the 2 AC terminals (3&4).

–

• If the meter does not beep or reads open circuit for any of the 4, then the rectier is defective.

• If the meter beeps for all 4, then the rectier is good.

Page 72

Recovery System 72Service Manual – SA40

8. If you replace the Fly-back

Diode, make sure the Positive Tab is in the upper left position

as shown, then fasten the

Fly-back Diode to the electrical

panel with the Screw and Nut.

9. Connect the White Wire to the

Positive Tab and the Black Wire

to the opposite tab as shown.

Nut

Positive Tab

Fly-back

Diode

White

Wire

Black

Wire

Screw

Fly-back

Diode (D2)

Solid State

Relay (K1)

Page 73

Removal and Installation

Recovery System 73Service Manual – SA40

Vacuum Motor

1. Drain the recovery tank.

2. Lift the recovery tank to access the Vacuum Cover.

3. Remove the three M6 Screws, Flat Washers and

Cover Plates and remove the Vacuum Cover to

access the vacuum motor.

Caution: Do not over torque the mounting

screws on reassembly. Torque the three screws to 3 NM (26 in lb)

4. Disconnect the Vacuum Motor Electrical Connector.

5. Remove the Vacuum Motor from the Recovery Tank.

M6 Screw, Flat

Washer and

Cover Plate (3)

Vacuum

Cover

6. Reinstall the Vacuum Motor by following the above steps in reverse order.

Note: Make sure you install the Acoustic

Insulation correctly around the Vacuum Motor when you reinstall the Vacuum Motor.

Note: Before you reinstall the Vacuum Cover,

make sure the top of the Vacuum Motor is centered in the matching cutout in the Recovery Tank as shown.

Recovery

Tank

Vacuum

Motor

Recovery

Tank

Vacuum

Motor

Acoustic

Insulation

Vacuum Motor

Electrical

Connector

Page 74

Specications

Component Specications

Vacuum Motor Current Draw

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

Recovery System 74Service Manual – SA40

Low Speed: 11 - 12 Amps

High Speed: 16 - 17 Amps

Vacuum water lift gauge, p/n 56205281

Page 75

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:

• The scrub deck is in the fully-retracted (up) position when the machine is in the transport mode (no

scrubbing or vacuuming).

• The vacuum-only position lowers the scrub deck so the attached squeegee contacts the oor, but the

brush/pad is raised slightly above the oor. This position is used for wet vacuuming of wastewater from the oor with no scrubbing.

• The “normal” scrub pressure position lowers the scrub deck so the brush/pad contacts the oor with

normal scrub pressure.

• The “extra” scrub pressure position lowers the scrub deck to its extension limit so the brush/pad contacts

the oor with greater than normal scrub pressure.

75Service Manual – SA40

The 20D Scrub Decks have a 20” brush plate assembly to accommodate a variety of disc brushes. The 20D models can also be used with several grades of pads by using the optional pad holder. The brush is driven by a Brush Motor connected to a 90-degree Gearbox.

20D Scrub Deck

Page 76

Scrub Deck and Motor

20D Scrub Deck

The 20D Scrub Decks use a horizontally-mounted Brush Motor with an integral gearbox to drive the

Brush Plate Assembly and attached Brush. The Brush Motor is fastened to

the Motor Spacer, which is bolted to the

Deck Lift Plate Weldment, Brush Housing

and Lower Deck Plate.

The Solution Solenoid Valve Assembly

controls the solution ow to the Brush.

Scrub System 76Service Manual – SA40

Brush Motor

Motor

Spacer

The squeegee assembly snaps onto the

Squeegee Link Weldment.

The Brush Skirt helps contain the

cleaning solution.

Deck

Lift Plate

Weldment

Brush

Housing

Lower

Deck Plate

Squeegee

Link

Weldment

Solution

Solenoid

Valve

Assembly

Brush

Skirt

Brush Plate

Assembly

Brush

(typical)

Page 77

Brush Motor Contactor

The Brush Motor Contactor (K2) controls the

power to the Brush/Pad Motor.

Scrub System 77Service Manual – SA40

Brush Motor

Contactor (K2)

Deck Actuator Assembly

The Deck Actuator Assembly uses an electric Motor to run a lead screw that extends and retracts the Tube and attached Plunger. The Plunger is connected to the Scrub Deck to raise and lower the Scrub Deck to any of four different positions:

• The fully-retracted (up) position is the Scrub Deck transport position

and is used when the Scrub and Recovery Systems are not active.

• Scrub Deck position 1 is the vacuum-only position. In this position the

Deck Actuator lowers the Scrub Deck just far enough for the squeegee to contact the oor to pick up wastewater with the Scrub, Solution and Detergent Systems off.

• Scrub Deck position 2 is the standard scrub pressure position.

• The fully-extended (down) position is the extra scrub pressure position.

Tube

Motor

Plunger

Deck Actuator Assembly

Page 78

Two internal Position Switches, actuated by rotating Cams, provide actuator position feedback to the A1 Control Board.

Two internal Limit Switches (top and bottom), also actuated by rotating Cams, switch off the actuator Motor at the fully-retracted and fully-extended positions.

Scrub System 78Service Manual – SA40

Cams (4)

Limit

Switch

Position

Switch

Page 79

Circuit Descriptions

Scrub Brush Motor

Scrub Brush Motor Off

Scrub System 79Service Manual – SA40

Bat +

BRN

SPST Key

Switch

BRN/VIO

Control Board

Brush

WHT/RED

Brush

Contactor

J3-13

Contactor

24v

Motion Input 24v

Brush Motor

RED

Bat -

J3-6

RED/WHT

BLK

Pin 6

Curtis 1210

Speed

Controller

Brake -

Bat -

When the machine is stationary:

• The Brake - switch on Pin 6 in the E1 Curtis Speed Controller is open and is not sending the drive signal to

the Motion Input line on pin J3-6 on the A1 Control Board.

• The Brush Contactor switch on pin J3-13 is open, the K2 Brush Contactor is de-energized and open, and the

M5 Brush Motor is off.

Page 80

Scrub Brush Motor On

Scrub System 80Service Manual – SA40

Bat + Bat -

WHT/RED

SPST Key

Switch

BRN

BRN/VIO

Brush

Contactor

Control Board

Brush Contactor

J3-13

Motion Input (0.1v)

RED

24v

Brush Motor

Bat -

J3-6

RED/WHT

BLK

Pin 6

Curtis 1210

Speed

Controller

Brake -

Bat -

The following conditions must be met before the Brush Motor can start:

• There can be no major faults active.

• The machine must not be in a low-voltage condition.

• The Scrub System must be enabled (the Solution On/Off Indicator is lighted).

• The S7 POS 1 limit switch on the scrub deck actuator must be closed to indicate that the scrub deck is

below the vacuum-only position.

• The A1 Control Board must receive a motion signal from the E1 Curtis Speed Controller.

When the Operator selects a drive direction and presses the go pedal:

• The Brake - switch on Pin 6 in the E1 Curtis Speed Controller closes to ground. This drops the voltage on

the Motion Input line on pin J3-6 from 24v down to nearly 0 volts to signal the A1 Control Board that the

machine is now in motion.

• The A1 Control Board switches the Brush Contactor line on pin J3-13 to battery ground to energize the coil

side of the K2 Brush Contactor to close the contacts and switch on the Brush Motor.

“Field” Voltage Measurements with Reference

to Battery Negative

Pin Number Wire Color Description Voltage

J3-13 WHT/RED Brush Contactor 24.3v - Brush Motor Off

0.2v Brush Motor On

Page 81

Deck Actuator Assembly

Scrub Deck Up

Scrub System 81Service Manual – SA40

When the Scrub System is switched from active to not active,

the Gang Switch in the A1 Control

Board switches on the power to the Brush Lift Actuator Motor M3.

Note: The Gang Switch position determines the polarity to run the Brush

Lift Actuator Motor in the

appropriate direction to raise or lower the scrub deck. The Gang Switch is, in reality, a “virtual” switch that is a type of transistor driver circuit in the A1 Control Board.

The Deck Actuator Assembly raises the scrub deck until the Cam opens the Upper Limit Switch. This shuts

off the power to the Brush Lift

Actuator Motor.

Control Board

B+

B-

Gang

Switch

B-

B+

+5V

Act. Position 1 (5v)

+5V

Act. Position 2 (5v)

Deck Actuator Assembly

Upper

Limit

Switch

Lower

Limit

Switch

B-

J1-8

J2-12

J2-11

D YEL/BLK

C RED/VIO

F BLK/WHT

Cam

S7 POS 1

S6 POS 2

Brush Lift Actuator Motor M3

Scrub Deck in Vacuum-only Position

When the Scrub System is not active and the Vacuum Power Adjustment

Switch is pressed to enable the wet vacuuming mode, the Gang Switch in the A1 Control Board switches on the power to the Brush Lift Actuator Motor

M3. The Deck Actuator Assembly lowers

the scrub deck to POS (position) 1.

When the deck reaches POS 1 the

Cam closes the S7 POS 1 switch, which

drops the voltage seen at the Act.

Position 1 input from 5v to 0v. The Gang Switch then switches polarity to

run the Brush Lift Actuator Motor in the opposite direction for a predetermined period of time to compensate for “overshoot” and position the deck at just the right height. The A1 Control

Board then shuts off the power to the Brush Lift Actuator Motor.

Control Board

B+

B-

Gang

Switch

B-

B+

+5V

Act. Position 1 (0v)

+5V

Act. Position 2

Deck Actuator Assembly

Upper

Limit

Switch

Lower

Limit

Switch

B-

J1-8

J2-12

J2-11

D YEL/BLK

C RED/VIO

S7 POS 1

F BLK/WHT

S6 POS 2

Brush Lift Actuator Motor M3

Cam

Page 82

Scrub Deck at Normal Scrub Pressure

Scrub System 82Service Manual – SA40

When the Scrub System is active, the

Gang Switch in the A1 Control Board

switches on the power to the Brush Lift

Actuator Motor M3. The Deck Actuator Assembly lowers the scrub deck to the

normal scrub pressure position, POS (position) 2.

When the deck reaches POS 2 the

Cam closes the S6 POS 2 switch, which

drops the voltage seen at the Act.

Position 2 input from 5v to 0v. The A1 Control Board then shuts off the power

to the Brush Lift Actuator Motor.

Control Board

B+

B-

Gang

Switch

B-

B+

+5V

Act. Position 1

+5V

Act. Position 2 (0v)

Deck Actuator Assembly

Upper

Limit

Switch

Lower

Limit

Switch

B-

J1-8

J2-12

J2-11

D YEL/BLK

C RED/VIO

S7 POS 1

F BLK/WHT

S6 POS 2

Brush Lift Actuator Motor M3

Cam

Scrub Deck at Extra Scrub Pressure

When the Scrub System is active and either the Extra Pressure Switch or Burst of Power switch is pressed, the

Gang Switch in the A1 Control Board

switches on the power to the Brush

Lift Actuator Motor. The Deck Actuator Assembly lowers the scrub deck to the

extra scrub pressure position.

When the deck reaches its lower travel limit, the Cam opens the Lower Limit

Switch. This shuts off the power to the Brush Lift Actuator Motor.

Control Board

B+

B-

Gang

Switch

B-

B+

+5V

Act. Position 1

+5V

Act. Position 2

Deck Actuator Assembly

Upper

Limit

Switch

Lower

Limit

Switch

B-

J1-8

J2-12

J2-11

D YEL/BLK

C RED/VIO

F BLK/WHT

Cam

S7 POS 1

S6 POS 2

Brush Lift Actuator Motor M3

Page 83

Component Locations

The following components are included in this section:

• Scrub Deck

• Scrub Deck Motor

• Brush Motor Contactor (K2)

• Scrub Deck Actuator Assembly

The Scrub Deck is suspended underneath the machine and pivots up and down on a mechanical mount.

Scrub

Deck

Scrub System 83Service Manual – SA40

The Scrub Deck Motor is mounted on the top of the Scrub Deck. Note that the 20D Scrub Deck and Brush Motor are shown here.

Scrub Deck

Motor

Scrub

Deck

Page 84

The Brush Motor Contactor (K2) controls

the power to the scrub deck motor and is located inside the control panel assembly.

Scrub System 84Service Manual – SA40

Brush Motor

Contactor (K2)

The Scrub Deck Actuator Assembly is attached to the Scrub Deck and

machine frame and lowers and raises the Scrub Deck.

Scrub Deck

Actuator

Assembly

Page 85

Troubleshooting

Problem Cause Correction

Brush Motor not running

Scrub Deck Actuator not running.

Scrub Deck not being lowered to the vacuum-only position

Scrub Deck not being lowered to the normal scrub position.

No voltage to the K2 Brush Contactor coil

No voltage through the contacts on the K2 Brush Contactor

No voltage to the Deck Actuator Motor

No signal from Position Switch 1, S7, to pin J2-12 on the A1 Control Board.

No signal from Position Switch 2, S6, to pin J2-11 on the A1 Control Board.

1. Check the voltage on pin J3-13 on the A1 Control Board. The signal, referenced to ground, should be 24.3v with the Brush Motor off, 0.2v with the Brush Motor on.

2. Check the wiring from the Key Switch to the K2 Brush Contactor coil and repair as necessary.

1. Check circuit breaker CB4 and reset if necessary.

2. Check the coil resistance on the K2 Brush Contactor. If the coil resistance is not 58.3 ohms ±10%, replace K2.

3. Check the continuity through the contacts on the K2 Brush Contactor with the coil energized. If the circuit is open, replace K2.

4. Check the wiring from battery positive to circuit breaker CB4, and from CB4 to the K2 Brush Contactor and repair as necessary.

5. Check the wiring from the K2 Brush Contactor to the Brush Motor and repair as necessary.

6. Check the Brush Motor ground connection and repair as necessary.

Check the voltage on pins J1-9 and J1-10 on the A1 Control Board. The signals, referenced to ground, should be as follows: Pin J1-9:

• 2.1v or 3.8v – actuator at rest

• 0.2v – actuator extending

• 22.9v – actuator retracting

Pin J1-10:

• 2.1v or 3.8v – actuator at rest

• 22.9v – actuator extending

• 0.2v – actuator retracting

Check the voltage on pin J2-12 on the A1 Control Board. The signals, referenced to ground, should be

4.99v with the switch open and 0.03v with the switch closed.

Check the voltage on pins J2-11 on the A1 Control Board. The signals, referenced to ground, should be

4.99v with the switch open and 0.03v with the switch closed.

Scrub System 85Service Manual – SA40

Page 86

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.

2. With the scrub deck down and the key switch on, disconnect the Actuator Electrical Connector. Note that you may need to cut a wire tie to do this.

3. Turn the key switch off.

Scrub System 86Service Manual – SA40

Actuator

Electrical

Connector

4. Make sure the Ball Valve from the solution tank to the

Filter is set to the off position.

5. Loosen the Clamp and remove the Solution

Hose from the Solution Solenoid Valve.

Note that a small amount of solution may leak out from the Solution Hose when you disconnect it from the Solution Solenoid

Valve.

6. Disconnect the Solenoid Electrical

Connector.

Ball

Filter

Valve

Solenoid

Electrical

Connector

Solution

Solenoid

Valve

Detergent

Hose

7. Disconnect the Detergent Hose from the

Scrub Deck.

Solution

Hose

Clamp

Scrub

Deck

Page 87

8. Remove the Vacuum Hose from the Scrub

Deck.

9. Press the rear of the Squeegee Mount

Bracket to disengage it from the pins on

the Squeegee Link Weldment and remove the Squeegee from the Scrub Deck.

Vacuum

Hose

Scrub System 87Service Manual – SA40

Scrub

Deck

Squeegee

Mount

Bracket

Squeegee

Mount

Bracket

10. Remove the four Shoulder Screws holding

the Lift Plate Weldment to the Link Bar and the two Linkage Bars. Note that you’ll need

to hold the M10 Nyloc® nuts with a 17mm wrench while you remove the Shoulder

Screws.

11. Remove the Shoulder Screw and nut that connect the scrub deck actuator to the Lift Plate Weldment on the scrub deck. Note that you’ll need to hold the M8 Nyloc® nut with a 13mm wrench while you remove the Shoulder Screw.

Link Bar

Shoulder Screw (4)

Linkage

Bar (2)

Lift Plate

Weldment

Shoulder

Screw

Lift Plate

Weldment

Page 88

Service Tip: Note of the rotational position of the screw

hole in the Plunger when you remove the

Shoulder Screw. Be careful not to rotate

the Tube and Plunger once the Scrub Deck

Actuator is disconnected from the scrub

deck. This can cause the Scrub Deck

Actuator to get out of adjustment.

Tube

Plunger

M8 Nyloc®

Nut

Scrub System 88Service Manual – SA40

Scrub Deck

Actuator

Shoulder

Screw

12. Lift up the link bar and rotate the scrub deck slightly (counterclockwise as viewed from the top) to get some slack in the Scrub Deck Ground Wire.

13. Disconnect the Scrub Deck Ground Wire from the scrub deck.

Scrub Deck

Ground Wire

Page 89

14. Disconnect the 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. When you remove a 20R REV™ scrub deck you’ll need to jack up and block the front of the machine slightly in order to get adequate clearance to remove the deck from the machine.

16. Reinstall the deck by following the above steps in reverse order.

Caution: Note that the scrub deck actuator will automatically raise the scrub deck when you

reconnect the Actuator Electrical Connector.

Scrub System 89Service Manual – SA40

Scrub Deck Motor

Electrical

Connector

Service Tip: When you reinstall the scrub deck, make sure you have all 16 Link Arm Bushings and all eight 12mm Flat Washers installed in the Link Bar and

Linkage Bars before reinstalling

the Shoulder Bolts and Nyloc

Nuts.

Link Bar

Linkage

Bar (2)

Nyloc

Nut (8)

Shoulder

Bolt (8)

12mm Flat Washer (8)

Link Arm

Bushing (16)

Page 90

Scrub System 90Service Manual – SA40

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. With the scrub deck down and the key switch on, disconnect the Actuator Electrical Connector. Note that you may need to cut a wire tie to do this.

3. Turn the key switch off.

4. Disconnect and remove the battery closest to the scrub deck actuator to get enough clearance to remove the actuator.

5. Remove the Shoulder Screw and nut that connect the scrub deck actuator to the Lift Plate Weldment on the scrub deck. Note that you’ll need to hold the M8 Nyloc® nut with a 13mm wrench while you remove the Shoulder Screw.

Actuator

Electrical

Connector

Shoulder

Screw

Lift Plate

Weldment

6. Remove the M10 Screw and actuator spacer holding the Scrub Deck Actuator to the Actuator

Bracket on the machine frame.

7. Carefully remove the Scrub Deck Actuator from the machine.

M10

Screw

Actuator

Bracket

Scrub

Deck

Actuator

Page 91

Service Tip: Ifyou’regoingtoreinstalltheScrub Deck

Actuator without readjusting the position

of the Tube, be careful not to rotate the

Tube and Plunger with the Scrub Deck

Actuator out of the machine. This can

cause the Scrub Deck Actuator to get out of adjustment.

8. Reinstall the scrub deck actuator by following the above steps in reverse order.

Note: Ifyou’reinstallingareplacementscrubdeck

actuator assembly, or if the scrub deck actuator assembly has gotten out of adjustment, you’ll need to set the tube position as described in the Scrub

Deck Actuator Adjustment subsection below.

Caution: Note that the scrub deck actuator will

automatically raise the scrub deck when you reconnect the Actuator Electrical Connector and battery.

Tube

Plunger

Scrub System 91Service Manual – SA40

Scrub Deck

Actuator

Scrub Deck Actuator Adjustment

The Scrub Deck Actuator adjustment consists of setting the Tube position with the retracted travel limit switch actuated. To set the Scrub Deck Actuator position:

1. Drive the actuator motor to the up (fully retracted) position using the Service Test Mode or a jumper to the batteries.

2. Wait until the motor stops running due to the travel limit switch opening.

Note: Do not allow the Tube to bottom

out against the Motor Housing.

3. Manually rotate the Tube toward the Motor

Housing until it bottoms out, then back the Tube out at least one-half turn, but no more

than one full turn, in order to align the mounting holes.

Service Tip: Be careful not to

rotate the Tube prior to installing the Scrub

Deck Actuator into the

machine. This can cause the Scrub Deck

Actuator to get out of

adjustment.

Motor

Housing

Scrub Deck Actuator

Tube

Page 92

Specications

Component Specications

Voltage – 24 VDC

RPM – 140

Scrub System 92Service Manual – SA40

20D Scrub Deck Brush Motor

K2 Brush Contactor Nominal Coil Resistance – 58.3 ohms ±10%

Scrub Deck Actuator

Current Draw

Output Power – 380 Watts / 1/2 HP

Voltage – 24 VDC

Output Power – 1/6 HP

Total Travel – 4.00” ±0.15”

Gearbox Ratio – 20.23:1

No load

No Load ≈ 6.2 Amps

Normal Operation ≈ 12-19 Amps depending on oor surface, solution ow

rate and scrub pressure

Performance Data

Thrust – 0 lbs.

Speed – 42.5 in/min

Current Draw – 1.8 ±1.0 Amps max.

Thrust – 600 lbs.

Full load

Starting Thrust – 700 lbs.

Speed – 34 in/min

Current Draw – 7.0 ±1.0 Amps

Page 93

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 ow 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 ow according to the ow rate selected with the solution ow adjustment switch.

The Solution System includes the Solution Tank, Water Filter, Solution Solenoid Valve Assembly and associated valves and hoses.

Solution Tank, Water Filter and Valves

The Solution Tank holds

approximately 12 gallons [45 liters] of water/solution.

The Ball Valve controls the solution ow to the Water Filter and downstream Solution Hose

that is plumbed to the Solution Solenoid Valve.

93Service Manual – SA40

The Water Filter can be

disassembled for cleaning.

Solution

Tank

Solution Hose

(to Solution

Solenoid Valve)

Water

Filter

Ball

Valve

Page 94

Solution Solenoid Valve

The L1 Solution Solenoid Valve controls the solution ow to the scrub deck. The solution from the solution tank enters the L1

Solution Solenoid Valve through the side port and exits through the

rear port to the scrub deck as shown.

The two wires in the Electrical Connector get power from the key switch and pin J3-11 - Solution Solenoid on the A1 Control Board.

The A1 Control Board sends a modulated signal through Pin J311 to switch the L1 Solution Solenoid Valve to ground and open the

L1 Solution Solenoid Valve for a period of time corresponding to the

selected solution ow rate. The period of time during which the solution solenoid is energized (open) is referred to as the “duty cycle” and is a percentage of the total six-second cycle.

For example, a 50-percent duty cycle would energize and open the L1 Solution Solenoid Valve for three seconds during every sixsecond cycle.

Solution System 94Service Manual – SA40

Electrical

Connector

Outlet to Scrub Deck

Inlet from Solution Tank

Note: 100percentdutycycleisfullsolutionowwiththe

L1 Solution Solenoid Valve continuously open.

L1 Solution

Solenoid

Valve

Page 95

Circuit Descriptions

Solution Solenoid Valve Off

Bat +

BRN/VIO

Solution Line from

Solenoid Valve

to Scrub Deck

SPST Key

Switch

Solution System 95Service Manual – SA40

Control Board

VIO/BLK

J3-11

Solution Solenoid

Bat -

E1 Curtis

1210 Speed

Controller

+24v

Motion Input 24v

J3-6

RED/WHT

Pin 6

Brake -

Bat -

L1 Solution

Solution Line from

Solution Tank

Solenoid Valve

(closed)

When the machine is stationary:

• The Brake - switch on Pin 6 in the E1 Curtis Speed Controller is open and is not sending the drive signal to

the Motion Input line on pin J3-6 on the A1 Control Board.

• The Solution Solenoid switch on pin J3-11 is open, and the L1 Solution Solenoid Valve is de-energized and

closed. This prevents solution ow from the solution tank to the scrub deck.

If the Solution System is disabled, the Solution Solenoid switch on pin J3-11 will remain open regardless of whether or not the A1 Control Board receives a drive signal from the E1 Curtis Speed Controller.

Page 96

Solution Solenoid Valve On

Bat +

BRN/VIO

Solution Line from

Solenoid Valve

to Scrub Deck

Solution Line from

Solution Tank

SPST Key

Switch

Solenoid Valve

L1 Solution

(open)

VIO/BLK

J3-11

Control Board

Solution Solenoid

+24v

Motion Input (0v)

Bat -

J3-6

RED/WHT

Pin 6

Solution System 96Service Manual – SA40

E1 Curtis

1210 Speed

Controller

Brake -

Bat -

The following conditions must be met before the L1 Solution Solenoid Valve can open:

• There can be no major faults active.

• The machine must not be in a low-voltage condition.

• The Scrub System must be enabled (the Solution On/Off Indicator is lighted).

• The S7 POS 1 limit switch on the scrub deck actuator must be closed to indicate that the scrub deck is

below the vacuum-only position.

• The A1 Control Board must receive a motion signal from the E1 Curtis Speed Controller.

When the Operator selects a drive direction and presses the go pedal:

• The Brake- switch on Pin 6 in the E1 Curtis Speed Controller closes to ground. This drops the voltage on

the Motion Input line on pin J3-6 from 24v down to nearly 0 volts to signal the A1 Control Board that the machine is now in motion.

• The Solution Solenoid switch on pin J3-11 switches to ground to energize and open the L1 Solution Solenoid

Valve. This allows solution ow from the solution tank to the scrub deck.

Note that the ground signal from the A1 Control Board to the L1 Solution Solenoid Valve is a pulse-width modulated (PWM) signal. The duty cycle of the PWM signal will vary according to the solution ow rate selected.

“Field” Voltage Measurements with Reference to Battery Negative

Pin Number Wire Color Description Voltage

J3-11 VIO/BLK Solution Solenoid 24.4v - Solenoid Off

0.12v - Solenoid On

Page 97

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

The Solution Tank holds approximately

12 gallons of solution.

Solution System 97Service Manual – SA40

The Solution Solenoid Valve is mounted on the Scrub Deck and controls the solution ow to the scrub brush/pad.

Solution

Tank

Solution

Solenoid Valve

Scrub

Deck

Page 98

The solution Ball Valve controls the solution ow from the solution tank to the Water Filter.

The Water Filter lters the solution upstream of the solution solenoid valve.

The 90° Ball Valve and Drain Hose allow you to drain the solution tank.

Solution System 98Service Manual – SA40

Ball

Valve

Water Filter

Drain Hose

90° Ball

Valve

Page 99

Maintenance

Solution System 99Service Manual – SA40

Cleaning the Water Filter

1. Close the solution Ball Valve to shut off the solution ow from the solution tank to the

Water Filter.

1. Unscrew the Filter Cap.

1. Remove and clean the internal lter screen.

1. Reinstall the lter screen and Filter Cap.

1. Open the Ball Valve and check for leaks.

Ball

Valve

Troubleshooting

Problem Cause Correction

No solution to the Scrub Deck (scrub system is working).

Plugged Water Filter. Clean or replace the Filter.

Plugged solution line or ball valve.

No voltage to the Solution Solenoid Valve.

Check the solution lines and ball valve and clear or replace as necessary.

1. Check the voltage on pin J3-11 on the A1 Control Board. The signal, referenced to ground, should be approximately 24.4v with the Solution Solenoid off, 0.12v with the Solution Solenoid on.

2. Check the wiring from pin J3-11 on the A1 Control Board to the Solution Solenoid Valve and repair as necessary

3. Check the wiring from the Key Switch to the Solution Solenoid Valve and repair as necessary.

The Solution Solenoid Valve is not operating correctly.

1. Check the Solution Solenoid Valve coil resistance. If the resistance is not 55.5 Ohms ±10%, replace the Valve.

2. If the Solution Solenoid Valve coil resistance is within spec, check for clogged ports, binding or a mechanical problem. Repair or replace the Valve as necessary.

Water Filter

Filter

Cap

Page 100

Specications

Component Specications

Nominal Voltage – 24 VDC, 11 Watt

Solution System 100Service Manual – SA40

Solution Solenoid Valve

Solution Tank Capacity – 12 gal. [45,4 l]

Duty – Continuous

Resistance – 55.5 Ohms ±10% @ 25° C

Nominal Solution Flow Rates

The nominal solution ow are listed in the following table. Note that these ow rates are based on a half-full solution tank.

Solution

Setting

Low 20” Disk 0.15 (gal./min.) / 0.57 l/min.

Medium 20” Disk 0.35 (gal./min.) / 1.32 l/min.

High 20” Disk 0.50 (gal./min.) / 1.89 l/min.

Deck Type Nominal Flow Rate

Clarke SA40 56104487 (20D) Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Service Manual Purpose and Application

Revision History

Other Reference Manuals and Information Sources

Diagnostic and Service Tools

Conventions

Parts and Service

Nameplate

Cautions and Warning Symbols

General Safety Instructions

Prop Rod

Moving the Machine

Transporting the Machine

Overall Dimensions

Maintenance

General Maintenance Information

Maintenance Schedule

Lubrication Locations

Major Machine Components

Machine Controls

Key Switch, Emergency Stop and Horn Switch

Circuit Breakers

Speed and Direction Controls and Indicators

Scrub Controls and Indicators

Solution Controls and Indicators

Vacuum Power Adjustment Switch and Indicators

Information Switch

Battery Status Screens

Chassis System

Major Chassis Components

Platform Switches

Control System

Functional Description

Component Locations

Troubleshooting

Fault Codes

Fault Code Table

System Disabled by Fault Codes

Service Test Mode

To Access the Service Test Mode

Service Test Mode Functions

Programming Options

Main Menu Access

Submenu Functions

Deck Type

Low Battery Voltage Cutout

Battery Charger

Burst Of Power Operation

Detergent (EcoFlex™) Option

Chemical Rate Bias

Open Fault Detect

Display Rev Level

Lock Out Brush Pressure

Lock Out Solution Flow Rate

Backup Alarm Volume

Forward Alarm Volume

Horn Volume

Restore Defaults

Fault Recall

Service Test Mode

Extra Information on the Graphic Display

Frozen Parameters

Panel Test

Save Scrub Settings

Removal and Installation

A1 Control Board

E1 Curtis 1210 Speed Controller

A1 Control Board Shop Measurements

Electrical System

Functional Description

Overview

On-board Battery Charger

Interlock Circuit

Component Locations

Troubleshooting

Wiring Diagrams