Clarke FUSION 20 Troubleshooting Manual
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Clarke FUSION 20 Troubleshooting Manual

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Troubleshooting Guide

Current Revision: June 2009

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Summary of Contents for Clarke FUSION 20

  • Page 1: Troubleshooting Guide

    Troubleshooting Guide Current Revision: June 2009...

  • Page 2: Table Of Contents

    Table of Contents PAGE IMPORTANT NOTES ------------------------------------------------------------------- 3 20T Main Electrical System -------------------------------------------------------------- 4 I Drive Traverse Controller --------------------------------------------------------------4-5 20B Main Electrical System --------------------------------------------------------------- 6 40135A Battery / Low Voltage / Delay Module --------------------------------------6-7 Battery Charger 41036A Manual --------------------------------------------------------- 8 Battery Charger 41036A programming -------------------------------------------------- 9 Battery Charger 41036A Troubleshooting Guide ---------------------------------10-13 Battery Charger 41036A Flow Chart ----------------------------------------------------14...

  • Page 3: Important Notes

    IMPORTANT NOTES • ANY time any of the electronic connectors are unplugged or serviced, electronic grease Clarke P/N 94822A (or equivalent) must be applied to the connector pins prior to re-connecting the plugs. Failure to add the grease could cause random signal lose between connectors. This grease is silica thicken, medium viscosity, synthetic hydrocarbon grease for lubrication and protection of tin-lead electrical connectors.

  • Page 4: Main Electrical System

    20T Main Electrical System: Note: All voltage measurements should be in reference to the (B-) connection on the Pad Solenoid. 1. Is there a minimum of 36.0Vdc across the input terminals of the “Main Solenoid” and the “IDrive Key Relay” with the “Key Switch” turned “ON”? NO, is the battery charger plugged into the wall outlet? When the Charger is plugged into the wall outlet the Charger Internal Inhibit Switch will “Open”...
  • Page 5 2. Is there a minimum of 36Vdc at Pin 7 of the 14 Pin connector of the IDrive? NO, defective controller. YES, Go to Step 3. 3. Is there a minimum of 36Vdc at Pin 5 of the 14 Pin connector of the IDrive with the Key Switch turned “ON”? NO, If not, check for voltage at the input of the IDrive Key Relay and / or the Key Switch.

  • Page 6: Main Electrical System

    20B Main Electrical System: Note: All voltage measurements should be in reference to the (B-) connection on the Pad Solenoid. 1. Is there a minimum of 36.0Vdc across the input terminals of the “Main Solenoid” and the “IDrive Key Relay” with the “Key Switch” turned “ON”? NO, is the battery charger plugged into the wall outlet? When the Charger is plugged into the wall outlet the Charger Internal Inhibit Switch will “Open”...
  • Page 7 1. Is there a minimum of 36Vdc between Pin 1 and Pin 10 at all times, unless the battery charger is plugged into the wall outlet? NO, is the battery charger plugged into the wall outlet? When the Charger is plugged into the wall outlet the Charger Internal Inhibit Switch will “Open”...

  • Page 8: Battery Charger 41036A Manual

    Product Manual for: 41036A Charger IF THIS IS A REPLACEMENT CHARGER; IT IS SET TO CHARGE 871334 BATTERIES INFORMATIONS IMPORTANTES SAVE THESE IMPORTANT SAFETY INSTRUCTIONS DE SÉCURITÉ This manual contains important safety, operating, and Conserver ces instructions. Ce manuel contient des instructions installation instructions –...

  • Page 9: Battery Charger 41036A Programming

    Information de Sécurité Électrique Danger: Risque de chocs électriques. Ne pas toucher les parties non isolées du connecteur de sortie ou les bornes non isolées de la batterie. Toujours connecter le chargeur à une prise de courant mise à la terre. Ne pas ouvrir ni desassembler le chargeur –...
  • Page 11 4. Optional Charger Single-LED Display (internal or external) LED indications following “Power-On Self Test”: Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge. Long: >80% Charge. When battery is not connected: Algorithm Number display. Flashing: Charger error. Reset charger power and refer to Troubleshooting below.

  • Page 19: Fusion 20B Electrical Schematic

    FUSION 20B ELECTRICAL SCHEMATIC...

  • Page 20: Fusion 20T Electrical Schematic

    FUSION 20T ELECTRICAL SCHEMATIC...

  • Page 21: Pad Assist Adjustment

    Fusion / Advolution 20B Pad Assist Adjustment Issue: Machine does not pull itself, Operator effort too high Root Cause Analysis: Pad bracket orientation is too flat resulting in insufficient pad assist. Containment: Adjust pad bracket orientation as shown in Fig’s 1-4. Permanent Corrective: Add pad orientation adjustment instruction to Operators Manual Action Fig 1- Tip burnisher back as shown to...
  • Page 22 Fig 3- Pull down on the dust skirt to gain access to the adjustment hardware. Pivot bracket Pivot bolt Pivot bolt rear front Loosen pivot bracket adjustment hardware and rotate bracket counterclockwise to increase pad assist. Pivot bracket has slots to allow adjustment.
  • Page 23 Fig 4- Adjust pivot bracket so pad is tipped down towards the RH side RH side of the machine to increase the pad assist. Then retighten the adjustment hardware. View from rear CAUTION! Pad assist will vary depending on the aggressive of pad and the floor finish.

  • Page 24: Fusion Burnisher Pad Motor Assembly Removal

    Fusion Burnisher Pad Motor Assembly Removal This would be the machine (Fusion 20B or 20T) that you would remove the Pad Motor Assy. from. The pictures shown in this instruction are using a Fusion 20T. The Pad Motor Assy. removal and reinstallation is the same for both burnishers.
  • Page 25 Remove the Positive and Negative Battery Cables for the batteries. Step 3. Remove the wires that go to the Pad Motor. One wire is on the C.B. and the other wire is on the Pad Motor Solenoid. Step 4.
  • Page 26 This shows the Pad Motor wires removed Step 5.. Tilt the Burnisher back on the “Stops” and allow the Pad Motor Assy. to hang down. Then install a ¼ inch bolt or ¼ inch diameter rod in each side of the Pad Motor Assy.
  • Page 27 Better view of bolts in the Pad Motor Lift Assy. Step 7. . There is a Nylon Washer on each side of the Pad Motor Assy. as shown above. This washer is needed to reduce vibration and noise and must be left in place as shown when reinstalling the Pad Motor Assy.
  • Page 28 NOTE: If you do not remove this spring at this time you will damage the spring and it will have to be replaced with a new spring. This spring is located at the rear of the Pad Motor Assy. and must be removed at this time and reinstalled at the same time during reinstallation.
  • Page 29 Step 10. Tilt the Burnisher back on the “Stops”. You will be able to slide the Pad Motor Assy. out from under the frame, where you can work on the assembly. Step 11. REINSTALLATION: To reinstall the Pad Motor Assy., repeat all steps in the reverse order from Step 11 to Step1.

  • Page 30: Note Page

    NOTE PAGE...

This manual is also suitable for:

Fusion 20t

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