Clarke Fusion 20 Bedienungsanleitung

Troubleshooting Guide

Current Revision: June 2009

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

Tru-Charge ------------------------------------------------------------------------------15-17

Battery Gauge-------------------------------------------------------------------------------18

Fusion 20B Electrical schematic ---------------------------------------------------------19

Fusion 20T Electrical schematic ---------------------------------------------------------20

Pad assist adjustment ------------------------------------------------------------------21-23

Fusion Burnisher Pad Motor Assembly Removal ---------------------------------24-29

NOTE PAGE--------------------------------------------------------------------------------30

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. Two manufactures are Syn-Tech-

NS-50040-GC and NYE- Nyogel 760G

•

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” and turn everything “OFF”. Is the

5Amp Fuse in series with the Key Switch good, otherwise check the Key Switch and wiring?

YES, Go to Step2.

2. Is there a minimum of 36.0Vdc across the Load terminals of the Pad Solenoid with the

Forward or Reverse Traverse not selected?

NO, check the Main Solenoid, Pad Motor, Pad Motor C.B. and wiring.

IDrive Controller:

Note:

All voltage measurements should be in reference to the (B-) connection on the IDrive

Controller.

1. Is there a minimum of 36Vdc at the (B+) and (B-) connections on the IDrive?

NO, check the Traverse C.B. and / or wiring.

YES, Go to Step 2.

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.

There should be 36Vdc across the input of the IDrive Key Relay with the Key Switch turned

“ON”. If not, check the Key Switch and / or wiring.

YES, Go to Step 4.

Note:

All measurements below should be taken with the “Key Switch” turned “ON”.

4. Is there 5.0Vdc between Pin 2 and Pin 8?

NO, defective IDrive.

YES, Go to Step 5.

5. Is there 0Vdc to 5.0Vdc between Pin 8 and Pin 1 with either “Forward” engaged?

NO, check the Forward Switches, Potentiometer and / or wiring.

YES, Go to Step 6.

6. Is there 0Vdc at Pin 6 of the 14 Pin connector of the IDrive with the Burnisher on the floor and

2.5Vdc with the Burnisher tilted back on the “Stops”?

NO, if there is 2.5Vdc there all the time the Tilt Switch is defective and / or wiring. If there is

0Vdc there all the time, then disconnect the Tilt Switch to see if the voltage goes to 2.5Vdc, if

the voltage does not return to 2.5Vdc the IDrive is defective.

YES, Go to Step 7.

7. Is there 2.5Vdc on Pin 12 of the 14 Pin connector of the IDrive with the “Reverse” Button not

depressed? If not, defective IDrive. This voltage should go to 0Vdc when the “Reverse” Button

is depressed.

NO, defective Reverse Button and / or wiring.

YES, Go to Step 8.

8. Is there 10.5Vdc on Pin 10 of the 14 Pin connector of the IDrive, which is the input to the

Battery Meter on the Control Panel?

NO, defective IDrive.

YES, Go to Step 9.

9. Is there 36.0Vdc at Pin 2 of the 2 Pin connector of the IDrive with the “Pad Switch” turned

“ON” and with the traverse not engaged? If not, check the Pad Solenoid, Pad Switch and / or

wiring. This voltage should go to 0Vdc when the Forward traverse is selected.

NO, defective IDrive.

YES, Go to Step 10.

10. Is there 0Vdc to 36Vdc at the Motor Output on the IDrive when the Forward Traverse is

engaged? Is there 0Vdc to 24Vdc at the Motor Output on the IDrive when the Reverse Traverse

is engaged?

NO, defective IDrive.

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” and turn everything “OFF”. Is the

5Amp Fuse in series with the Key Switch good, otherwise check the Key Switch and wiring?

YES, Go to Step2.

2. With the “Key Switch” turned “ON”. Is there a minimum of 36.0Vdc across the Load

terminals of the Pad Solenoid with the Pad Switch Buttons not depressed?

NO, check the Main Solenoid, Pad Motor, Pad Motor C.B. and wiring.

41035A Battery/Low Voltage/Delay Module:

Note:

All voltage measurements should be in reference to Pin 10 of the 41035A Battery/Low

Voltage/Delay Module:

41035A Battery/Low Voltage/Delay

Module

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” and turn everything “OFF”. Is the

5Amp Fuse in series with the Key Switch good, otherwise check the wiring?

YES, Go to Step2.

2. Is there a minimum of 36Vdc between Pin 7 and Pin 10 with the “Key Switch” turned “ON”?

NO, check the Key Switch and wiring.

YES, Go to Step3.

3. Is there a minimum of 36Vdc between Pin 4 and Pin 10 with the “Key Switch” turned “ON”

and with the Burnisher setting on the floor in the operating position and with either one of the

Pad Switches depressed?

NO, check the Tilt Switch, Pad Switches and wiring.

Note: When the Burnisher is tilted back on the “Stops” this voltage should be 0Vdc because

“Tilt Switch” is “Open”.

YES, Go to Step4.

4. Is there a minimum of 36Vdc between Pin 9 and Pin 10 with the “Key Switch” turned “ON”

and with the Burnisher setting on the floor in the operating position and with either one of the

Pad Switches not depressed?

NO, check the Pad Solenoid and wiring.

YES, Go to Step5.

5. Is there 0Vdc between Pin 9 and Pin 10 with the “Key Switch” turned “ON” and with the

Burnisher setting on the floor in the operating position and with either one of the Pad Switches

depressed?

NO, defective 41035A Module.

Product Manual for: 41036A Charger

IF THIS IS A REPLACEMENT CHARGER; IT IS SET TO CHARGE 871334 BATTERIES

SAVE THESE IMPORTANT SAFETY

INFORMATIONS IMPORTANTES

INSTRUCTIONS

This manual contains important safety, operating, and

installation instructions – read before using charger.

Battery Safety Information

Warning:

Use charger only on battery systems with an

algorithm selected that is appropriate to the specific battery type.

Other usage may cause personal injury and damage. Lead acid

batteries may generate explosive hydrogen gas during normal

operation. Keep sparks, flames, and smoking materials away from

batteries. Provide adequate ventilation during charging. Never

charge a frozen battery. Study all battery manufacturers’ specific

precautions such as recommended rates of charge and removing

or not removing cell caps while charging.

Electrical Safety Information

Danger:

Risk of electric shock. Connect charger power cord to

an outlet that has been properly installed and grounded in

accordance with all local codes and ordinances. A grounded outlet

is required to reduce risk of electric shock – do not use ground

adapters or modify plug. Do not touch uninsulated portion of output

connector or uninsulated battery terminal. Disconnect the AC

supply before making or breaking the connections to the battery

while charging. Do not open or disassemble charger. Do not operate

charger if the AC supply cord is damaged or if the charger has

received a sharp blow, been dropped, or otherwise damaged in any

way – refer all repair work to qualified personnel. Not for use by

children.

1 Always connect the charger to a

GROUNDED

outlet. When using an extension cord, avoid

excessive voltage drops by using a grounded, 3-wire, 12-AWG cord no longer than 30m (100’).

2 AVOID connecting a QuiQ charger and another device to a single 15A/20A circuit or the

circuit may become overloaded.

3 Charger 10-LED Display

LED indications following “Power-On Self Test”

DE SÉCURITÉ

Conserver ces instructions. Ce manuel contient des instructions

importantes concernant la sécurité et le fonctionnement.

Information de Sécurité de la Batterie

Attention:

Utiliser seulement sur les systèmes batteries avec

un algorithme approprié au type spécifique de batterie. D´autres

types de batteries pourraient éclater et causer des blessures ou

dommages. Les batteries peuvent produire des gaz explosives en

service normal. Ne jamais fumer près de la batterie et éviter toute

étincelle ou flame nue à proximité de ces derniers. Fournisser la

bonne ventilation lors du chargement. Ne jamais charger une

batterie gelée. Prendre connaissance des mesures de précaution

spécifiées par le fabricant de la batterie, p. ex., vérifier s´il faut

enlever les bouchons des cellules lors du chargement de la

batterie, et les taux de chargement recommandés.

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 – referer toute reparations aux personnes qualifiés. Pas à

l´usage des enfants.

Ammeter (Amber)

Solid: Displays approximate scale of current output during bulk stage

Flashing: High internal charger temperature. Current output reduced.

Also displays algorithm #1

-6 for 11 seconds if no battery is connected

80% Charge (Amber)

Solid: Bulk charge phase complete, 80% charged. In absorption phase

Flashing: With no battery connected, indicates algorithm# by number of

flashes

100% Ammeter (Green)

Solid: Charging complete. Charger in maintenance Mode

Flashing: Absorption phase complete. In finish stage

AC ON (Amber)

Solid: AC Power Good

Flashing: Low AC Voltage, check voltage and extension cord (Maximum

100 ft, 12AWG)

FAULT (Red)

Flashing: Charger error. Reset charger power and refer to

Troubleshooting below

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