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 2
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 3
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. 4
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. 5
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: 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: 6
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. 7
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 DE SÉCURITÉ This manual contains important safety, operating, and installation instructions read before using charger. Battery Safety Information Conserver ces instructions. Ce manuel contient des instructions importantes concernant la sécurité et le fonctionnement. Information de Sécurité de la Batterie 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. 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. 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 8
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 9
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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. Red Flashing: Charger error. Reset charger power and refer to Troubleshooting below. 1 For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the maintenance and safety instructions recommended by the battery manufacturer. 2 Make sure charger connections to battery terminals are tight and clean. 3 Do not expose charger to oil, dirt, mud or direct heavy water spray when cleaning vehicle. If a fault occurs, count the number of red flashes between pauses and refer to the table below: Red Flashes Cause Solution Battery High Voltage Check battery size and condition and reset charger (interrupt AC power for 15 seconds). Battery Low Voltage Check battery size and condition and reset charger (interrupt AC power for 15 seconds). Check connections. Operate charger at a lower ambient temperature. Charge Timeout caused by battery pack not reaching required voltage. Charger output was reduced due to high temperatures Check Battery: battery could not be trickle charged up to minimum voltage Over-Temperature: Charger shut down due to high internal temperature. Charger Internal Fault Check for shorted or damaged cells. Ensure sufficient cooling air flow and reset charger (interrupt AC power for 15 seconds). Reset charger (interrupt AC power for 15 seconds). Return to qualified service depot if fault persists. 11
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FUSION 20B ELECTRICAL SCHEMATIC 19
FUSION 20T ELECTRICAL SCHEMATIC 20
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 gain access to the pivot bracket. Dust bag Fig 2- Remove the dust bag 21
Fig 3- Pull down on the dust skirt to gain access to the adjustment hardware. Pivot bracket Pivot bolt rear Pivot bolt front Loosen pivot bracket adjustment hardware and rotate bracket counterclockwise to increase pad assist. Pivot bracket has slots to allow adjustment. 22
Fig 4- Adjust pivot bracket so pad is tipped down towards the RH side of the machine to increase the pad assist. Then retighten the adjustment hardware. RH side CAUTION! Pad assist will vary depending on the aggressive of pad and the floor finish. If the deck is angled too much it could result in the pad burning the floor on the RH side. View from rear 23
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. Step 1 Remove the top cover. Remove the electrical access cover using the screw at the top of the cover with an Allen wrench. Step 2. 24
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. 25
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. Step 6 26
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. Step 8. 27
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. Step 9. With the Burnisher lowered back down to the floor, use a 3/16 Allen wrench to remove the screw on each side of the Pad Motor Assembly 28
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. 29
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