Clarke SA40 56104487 (20D) User manual

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

iiService Manual – SA40 ii
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

6Service Manual – SA40
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
Date Revisions
3/16 Initial publication
Other Reference Manuals and Information Sources
Model Name Model Number Parts List
Form Number
Instructions for Use
Form 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

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.

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.

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.

General Information 10Service Manual – SA40
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
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.
Control Panel
Housing/
Recovery
Tank Cover
Prop Rod
(engaged)
Brake
Arm
Brake
Arm

General Information 11Service Manual – SA40
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).
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) 63 dB LpA, ±3 dB KpA
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 Solution Tank: 11.7 gal / 44.28 L
Recovery Tank: 13.5 gal / 46.67 L
Sound Pressure Level
IEC 60335-2-72: 2002 Amend. 1:2005, ISO 11201 63 dB LpA, ±3 dB KpA
Vibrations at the Hand Controls (ISO 5349-1) 0.17 m/s2
Vibrations for the Whole Body (ISO 2631-1) 0.01 m/s2
Gradeability Transport: 14% / 7.1˚
Cleaning: 8.3% / 4.75˚
Front
Tie-down
Left
Tie-down
Right
Tie-down

General Information 12Service Manual – SA40
Overall Dimensions
24.5 [623]
27.9 [710]
52.5
[1332]
48.5 [1232]
1.13 [28,7]
Fastener Torque Specications
Standard Torque
Specications (unless
otherwise specied)
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]
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]

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.

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
Steering
Tube
Assembly
Hex
Shaft
Lower Steering
Shaft U-Joint
Drive
Wheel
Chain
Drive Chain
Idler
Sprocket
(grease
tting)
Steering
Chain

General Information 15Service Manual – SA40
Major Machine Components
Electrical
System
Recovery
System
Solution
System
Chassis
System
Squeegee
Assembly
Scrub
System - 20D
Scrub
System - REV
Control
System

General Information 16Service Manual – SA40
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.
• 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.
Key
Switch
Emergency
Stop
Horn
Switch

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
5-amp
Circuit
Breaker CB2
20-amp
Circuit
Breaker CB3
25-amp
Circuit
Breaker CB4

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
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.
• 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.
Speed
Adjustment
Knob R1
Forward
Drive Switch
Forward Drive
Indicator
Reverse
Drive Switch
Reverse Drive
Indicator
Operator
Presence
Pedal
Platform
Go
Pedal

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

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.
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
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.
Solution
Flow Adjustment
Switch
Solution On/Off
Indicator
Solution
Flow Rate
Bar Graph
Vacuum
Level Bar
Graph
Vacuum Power
Adjustment
Switch
Standard Vacuum
Mode Indicator
Quiet
Vacuum
Mode
Indicator