Kirby Sentria G10D Service Manual
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Kirby Sentria G10D Service Manual

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TM
Sentria
Service Manual
MODEL Gl0D
120V
50-60 Hz.
7A
Primed in USA • © 2006 The Kirby Company • PIN 246506 RE\'. A 6/06

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  • Page 1 Sentria Service Manual MODEL Gl0D 120V 50-60 Hz. Primed in USA • © 2006 The Kirby Company • PIN 246506 RE\'. A 6/06...
  • Page 2 TABLE OF CONTENTS FORWARD SECTION 1 The Kirby Warranty SECTION 4 Troubleshooting Use of This Section Warnings, Cautions, and Notes 4.1.2 Arrangement of the Troubleshooting Section Kirby Troubleshooting Guide Troubleshooting Matrix Assembly of Unit and Section References Micron Magic HEPA Filtration System...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 5 Service Details and Instructions Use of This Section 5.1. l Warnings, Cautions, and Notes 5. l.2 Arrangement of Illustrated Patts List and Exploded Views 5.1.3 Relationship of Text to Theory Illustrations and Exploded Views Power Unit Checkout Power Unit Disassembly General 5.3.1...
  • Page 4 TABLE OF CONTENTS SECTION 6 Slide Bracket Service Instructions Slide Bracket Assembly Service 6.1.1 Slide Bracket Assembly Component Replacement 6.1.2 Handle Pivot Spring Assembly 6.1.3 Final Assembly of Unit SECTION 7 Outer Bag Service Instructions 7. I Outer Bag Assembly Service 7.1.
  • Page 5 NOTES...
  • Page 6 SECTION 2 - 120 V THE SERVICE CENTER/DEPARTMENT OPERATION TOOLS AND METERS Tools required include: Screwdrivers - Flat and Phillips Assorted Sizes Pliers - Assorted Impact Screwdriver Bench Vise File Round Rattail 8" long File -¼" pillar 6" long Tap Wrench Threading Taps 6 x 32, 8 x 32, 10 x 24, and IO x 32 In addition, certain special tools and supplies available from the factory are: Tools:...
  • Page 7 NOTES...
  • Page 8 SECTION 4 - 120 V TROUBLESHOOTING USE OF THIS SECTION 4.1.1 Warnings, Cautions, and Notes Observe all Warnings, Cautions, and Notes in this section as well as those sections to which you will be referred. 4.1.2 Arrangement of the Troubleshooting Section The troubleshooting section is arranged in two parts;...
  • Page 9 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING GUIDE When the problem appears electrical in nature, and the information contained 4.2.1 TroubleShooting Matrix in the following table does not correct the problem, proceed to Section 4.4 The following matrix guides the user to the probable cause and a solution to for information on conducting an electrical resistance check.
  • Page 10 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION Armature/carbon Motor binds Replace motor ( 5.6. l ) or failed brushes spark motor component ( 5.6.2 5.6.7) Carbon brush stuck in holder 2. Replace carbon brush assembly ( 5.6.3) Armature or field coil failure Replace armature ( 5.6.5 ) or...
  • Page 11 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION Base pan dirty inside Motor seal pinched/leaking Reset or replace motor seal ( 5.6.8 A) Horn gasket torn Replace horn gasket ( 5.3.3 ) Headlight bulb Bulb failure Replace circuit board ( 8.3 ) does not work Loose wiring or incorrect connection...
  • Page 12 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION 17. Drive system assembly Primary drive belt tight Adjust primary drive belt rattles on wind down ( 5.4.4 F I and F 2 ) Primary drive sprocket gear loose Remove clip and sprocket gear on drive system shaft and replace 18.
  • Page 13 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAU SOLUTIO 22. Brush roll belt breaks Brush roll binds Remo,e brush roll end!, to clean, or replace bru h roll ( 8. I E ) Motor runs backwards 2. Motor brush leads rever!-.ed. Correct brush lead routing ( Fi g .
  • Page 14 TROUBLESHOOTING 4.3.1 Basic Electrical Design 4.2.2 Assembly of Unit Section References The Kirby unit is powered by a two speed Once the problem has been serviced, universal motor. Basic circuit elements assemble the unit. Repair assembly include a motor field, armature, main power references are given below.
  • Page 15 SECTION 4 - 120 V TROUBLESHOOTING Sentria CIRCUIT SHOvVN SLOW SPEED OPERATION LED CIRCUIT BOARD L swn CH l"I T ERLOCKS ARE "O"I" SWlfCH ARMATURE LEFT BRUSH figure I Schematic Diagram SWITCH ARMATURE FIELD SWITCH Figure 2 Block Diagram...
  • Page 16 Mini Emtor bag assembly. This service manual is available through the Kirby Distributor Service Center or the Unplug the cord. The cleaner should be in International Warehouse in your location. the on condition and ready for the Open Circuit lsolation Check.
  • Page 17 SECTION 4 - 120 V TROUBLESHOOTING Chart 4.4.1 Open Circuit Isolation Sequence (120 Volt) Procedure Continuity Comments (Yes/No) Step 1: Unit functions properly. Problem is Attach one of the multi-meter probes to in supply voltage, power cord, or an point I (upper switch prong) and the other intermittent open circuit.
  • Page 18 SECTION 4 -120 V TROUBLESHOOTING 4.4.2 Failure in the Motor Field The ohm readings are pe1formed by measuring the resistance of the commutator bars 180 degrees apart. The ohm value for the 11 bar A high resolution ohm-meter can be used to to bar readings, transverse l 80 degrees help find a motor field problem.
  • Page 19 SECTION 4 - 120 V TROUBLESHOOTING 4.4.5 Failure in the Switch Speed Selection Contacts On Check To check the speed blade contact, use the If it is suspected that the See Figure 4. following sequence: switch has a failure, a resistance check with a regular ohm-meter can be used to help find I .
  • Page 21 NOTES...

  • Page 22: Service Details And Instructions

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS USE OF THIS SECTION 5.1.1 Warnings, Cautions, and Notes Observe all Warnings, Cautions, and Notes. 5.1.2 Arrangement of Illustrated Parts Lists and Exploded Views The parts list and related exploded views are provided in Section 9. Item numbers on the exploded views relate to the parts list contained in Tables 1 through 12.

  • Page 24: Cover Assembly Removal

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 5.3.2 Fan Case Assembly and Wheel 5.3.1 Cover Assembly Removal Shaft Main Assembly Removal A. Remove rug nozzle, Mini Emtor, handle with bag f om power unit. ! NOTE Removal of the fan case is necessary only if B.
  • Page 25 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 5. If the fan blade requires 2. Remove two screws from top of replacement, refer to Section fan case. 5.6.2. 6. Prior to the reassembly of fan case, 3. Remove two remaining screws from clean old sealant from joining lower end of the fan case.

  • Page 26: Base Pan

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS C. Wheel Shaft and Ratchet Lock 6. While ratchet lock and spring are Service: compressed, install wheel shaft to I. Inspect wheel shaft components for fan case by inserting teeth of ratchet breaks or cracks and center shaft for pedal onto teeth of ratchet lock.

  • Page 27: Drive System Assembly

    The drive system assembly is a sealed unit is provided in Section 5.4.2. and should only be serviced at Kirby. However, wheel covers and wheels may be A. See Figure 14. Using a thin flat blade...

  • Page 28: Neutral/Drive Pedal Assembly Service

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS DRIVE B. Carefully lift power switch foot pedal REMOVE SYSTEM up and out of power unit until sufficient DRIVE BELT ASSEMBLY clearance is available to slide power switch actuating rod out of foot pedal. �...

  • Page 34: Motor Unit Assembly Service

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS ! NOTE om the C. Remove static wire assembly f All work conducted on the motor should be left rear motor hold-down screw. done with the switch actuating rod removed. D. See Figure 23. Remove exhaust duct 5.6.2 Fan Replacement screw.

  • Page 36: Power Switch Replacement

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 5.6.5 Armature Assembly and Front MOTOR UNIT Bearing Replacement A. See Figure 26. Using Tl snap ring expander pliers No. 0200, remove motor drive clip at rear of armature shaft. B. Remove motor sprocket gear from rear of armature shaft.

  • Page 38: Assembly Of Motor

    SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 0. Install Fan. MOTOR HOUSING l . Make sure top suli'ace of bearing plate is clean. Apply thin, visible layer of Tl 59S grease to bearing plate eyelet. 2. See Figure 25. Install spacer/seal assembly with flat side of seal toward spacer shoulder and tapered side of seal coward bearing plate.
  • Page 39 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS E. Now install the right brush cartridge 2. Install motor mount screws. a. Install rear motor mount assembly. Tilt brush cartridge and insert screws first. Be sure that static cartridge tab into slot in motor housing. discharge wire is connected to Seat cartridge securely in channel.
  • Page 40 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 2. Insert two screws into rear legs of slide bracket ca ting to base pan in ont of rear wheel wells. Tighten screws to 16-20 in-lbs. 3. Refer to Section 5.5.F. Install tie wrap around top right lide bracket casting leg to secure headlight lead wires against tube insulation.
  • Page 42 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS Slide Bracket Assembly Service E. Refer Figures 31 and 32 as needed to assemble. Assembly is as follows: 6.1.1. Slide Bracket Assembly Component I. If new roller bearing assemblies are Replacement to be installed, bend along score line so that flat surface of cage will be Service is limited to disassembly and...
  • Page 44 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS B. See Figure 35. Remove two screws from bracket tab. Remove handle pivot assembly. spring assembly with "FACE UP TO SET HANDLE PIVOT" facing up. SCREWS ! NOTE HANDLE Do not put pressure on drive system PIVOT 'J"'l';:,:i;:;;:::c:�, linkage arm when installing handle SPRING...
  • Page 45 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS 3. Apply inward pressure on trim strips at rear of cover shell while tightening rear crews. Tighten screws to 12-16 in-lbs. 4. Fasten cover lo fan case with two nat head screws. Tighten screws to 28-30 in-lbs.
  • Page 46 SECTION 7 - 120 V OUTER BAG SERVICE INSTRUCTIONS 7.1.2 Removal/Installation of Bag Outer Bag Assembly Service to Mini Emtor 7.1.1 Bag Top Assembly Service A. To remove outer bag as embly from Mini Emtor, cut through all bars of the A.
  • Page 47 SECTION 7 - 120 V OUTER BAG SERVICE INSTRUCTIONS OUTER BAG -.__; BAG CLAMP STRAP RUBBER SEAL . J;;:_ 1 _ �--� � :::'::: :::::::: = :..: MINI EMTOR Figure 3 7. Bag Clamp Strap Position G. Lock the strap and ensure that all the teeth on the end opposite the cross bar lock are secured by the ribs of the lock.
  • Page 48 SECTION 8 - 120 V BELT LIFTER, ATTACHMENT HOSE AND HEADLIGHT SERVICE Belt Lifter Replacement Hook should point toward top of nozzle when belt lifter is turned coumer-clockwise to its fullest Remove rug nozzle assembly from extent. power unit. Re-install bru h roll and belt. Remove rug plate, brush roll and belt from nozzle.
  • Page 49 SECTION 8 - 120 V BELT LIFTER, ATTACHMENT HOSE AND HEADLIGHT SERVICE Attachment Hose Swivel Tube Or 8.3 Headlight Lens And LED Service Suction Blower Connector Materials Needed: Replacement • EL-164306 - Headlight LED circuit board Static Mat with ground wire, Wri ·t Strap !NOTE with cable (P/ 166906 ESD Kit) Repair method described in Section A and...
  • Page 50 SECTION 8 - 120 V HEADLIGHT SERVICE Procedure: 7. U ing the release latch on the harness connector, remove the Board from 1he I. Place the Sentria Power Unit on the wire harnes . Static Mat. 8. Gently bend one of the snap latches on 2.
  • Page 51 NOTES...
  • Page 52 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 39 Base Pan Assembly and Cord Set Table I Base Pan Assembly and Cord Set Figure Motor Assembly Table 2 Motor Assembly Figure 4 I Fan Case Assembly Table 3 Fan Case Assembly Figure 42...
  • Page 53 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 39. Base Pan Assembly and Cord Set...
  • Page 54 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 1. Base Pan Assembly and Cord Set Base Pan Assembly 604306S 0 - Ring - Horn Adaoter (5 oack) 60 l996S Rivet - llorn Adaoter (l0 oack) I00689A 106393 Exhaust Duce l04106S...
  • Page 55 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Fi g ure 40. Motor Assembly...
  • Page 56 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 2. Motor Assembly Motor Housing wffolerance Ring I00I96S Ring Retainer - Front Bearing (IO pack) I0I076A I04689A Screw - Motor Field (IO pack) Bearing Plate Assembly w/Motor Seal 105793S Brush Holder w/Brush (IO pack) I07I89A...
  • Page 57 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS � \ 1s ..,,, ,,, ', .._ ....../ � � Figure 41. Fan Case Assembly...
  • Page 58 SECTION 9 -120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 3. Fan Case Assembly I I 9797S Fan Case Assembly 125297A Nozzle Lock Lever Assembly (2 pack) 12IIS Screw Nozzle Lock (IO pack) 12I297S Spring- Nozzle Lock (10 pack) 121689S Nozzle Attachment Shaft (5 pack) 122097S...
  • Page 59 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS � 16 o<'.? � ii ! 1 12 l ! � -"""'-- 1� �i a---i Figure 42. Headlight Cap/Slide Bracket/Handle Pivot Spring Assembly...
  • Page 60 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 4. Headlight Cap/Slide Bracket/Handle Pivot Spring Assembly 102168A Screw - Plate to Pivot Casting/Axle Clamp (10 pack) 108506S Lens Headlight Cap (5 pack) 164306 LED Circuit Board 160006 Headlight Cap Casting 161389 Headlight Pivot Casting...
  • Page 61 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 43. Cover Shell Assembly...
  • Page 62 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 5. Cover Shell Assembly I35606A Cover Casting - Polished - Sentria 630906S Left Trim Strip Cover Shell (5 pack) 630806S Right Trim Strip - Cover Shell (5 pack) 111206 Scuff Plate...
  • Page 63 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 44. Power Dri\'e Assembly...
  • Page 64 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 6. Power Drive Assembly I02095G Rear Axle Assembly with Overload Gear Assembly 60I689A Clip - Rear Wheel & Motor Sprocket Gear ( l 0 pack) 110306S Foot Pedal (5 pack) 550505 Primary Gear 550889S...
  • Page 66 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 7. Floor Nozzle Assembly 140406 Nozzle Bumper I41381A Rivel - Latch Assembly (IO pack) 141606S Nozzle Assembly (Less Brush and Belt) 159206 Belt Lifter Body Assembly 144291 Hook - Belt Lifter 144681S Flat Washer - Belt Lifter (IO pack) l45481S...
  • Page 67 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS ----::::0 -- - - ---- ---- ---- --- - Figure 46. Handle Fork and Grip Assembly...
  • Page 68 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 8. Handle Fork and Grip Assembly Screw - Latch Plate (IO pack) 233797S Latch Plate - Handle Fork 672189 173806S Upper Cord Hook Swivel - (5 pack) I74167A Spring - Cord Hook Swivel (10 pack) Screw - Cord Hook Swivel (5 pack) 174006$...
  • Page 69 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 47. Cloth Bag and Mini Emtor Assembly...
  • Page 70 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 9. Cloth Bag and Mini Emtor Assembly I87906G Bag/Mini Emtor Assembly - Senlria 190006 Bag Assembly - (w/Latch Only) - Sentria Bag Top Cover 191806 Latch Cloth Bag (5 pack) l96406S 196506S Bag Clamp Strap (5 pack)
  • Page 71 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS 10-n -�20 � � �--� �� � 31 � Blllm tJJEiml D o � Figure 48. Attachments...
  • Page 72 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 10. Attachments Attachment Set - Service 207006S 213806 lnflator/Deflator 201306 Portable Handle Assembly Atlachmcnt Grip 22S106 214106 Massage Cup Intake Guard Assembly 224206 286906S A11achment Kaddy Assembly Spray Gun Assembly 250206S 256606S Venturi - Spray Gun (5 pack)
  • Page 73 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS __,,.,16 Figure 49. Carpet Shampoo System...
  • Page 74 SECTION 9 - 120 V .ILLUSTRATED PARTS L.IST AND EXPLODED VIEWS Table 11. Carpet Shampoo System Carpet Fluffer Shield 313506 159206 Belt Lifter Body Assembly 144291 Belt Lifter Hook Flat Washer Belt Lifter (10 pack) 14468LS 145481S Bearing - Belt Lifter ( l 0 pack) Belt (25 pack) 301291A 304406...
  • Page 75 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 50. Floor Care System With Miracle Waxer...
  • Page 76 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 12. Floor Care System With Miracle Waxer 313406 Warning Label - Floor Care System ozzle ( A for Sale) 1S9206 Belt Lifter Body As. embly 144291 Belt Lifter Hook 144681S Flat Washer - Belt Lifter (10 pack) 145481S...
  • Page 77 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS ---- _________ Figure 51. Handi-Butler Tool ™...
  • Page 78 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 13. Handi-Butler TooI Randi-Butler Body Assembly 409506 Rigid Shaft Coupling 407206 407306 Flexible Shaft Coupling 405906 Mou nti ng-Crad le 407106 Acee ory Kit 407406S Polishing Compound (IO pack) 255690 Sponge (not shown) 237306S...

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