User manual | Clarke Fusion 201 Operator`s manual

Operator's

Manual

Fusion 27

Battery

Burnisher

Patent Pending

READ THIS BOOK

This book has important information for the use and safe operation of this machine. Failure to read this book prior to operating or attempting any service or maintenance procedure to your Clarke machine could result in injury to you or to other personnel; damage to the machine or to other property could occur as well. You must have training in the operation of this machine before using it. If your operator(s) cannot read English, have this manual explained fully before attempting to operate this machine.

Si Ud. o sus operadores no pueden leer el Inglés, se hagan explicar este manual completamente antes de tratar el manejo o servicio de esta máquina.

All directions given in this book are as seen from the operator’s position at the rear of the machine.

For new books write to: Clarke ® , 2100 Highway 265, Springdale, Arkansas 72764.

Form No. 70788B 10/04 Clarke ®

Printed in the U.S.A.

Table of Contents

Operator Safety Instructions ............................................................................................................................. 3

Introduction & Machine Specifications ............................................................................................................. 5

Procedures For Transporting ........................................................................................................................... 6

Symbols Used On Fusion 27 Machine ............................................................................................................ 7

Machine Control Panel ..................................................................................................................................... 8

How To Prepare The Machine For Operation .................................................................................................. 10

How To Install The Batteries ............................................................................................................. 10

Battery Maintenance ........................................................................................................................... 10

How To Charge The Batteries ........................................................................................................... 11

How To Install The Brushes Or Pad Drivers ..................................................................................... 12

How To Remove The Brushes Or Pad Drivers ................................................................................. 12

How To Operate The Machine ......................................................................................................................... 12

Pad Pressure Operation .................................................................................................................... 12

Pad Pressure Adjustment ................................................................................................................. 13

Operating the Machine ....................................................................................................................... 13

Maintenance ..................................................................................................................................................... 14

Section II Parts and Service Manual

How To Correct Problems In The Machine ...................................................................................................... 16

Maintenance, Adjusting Pad Head Limit Switches .......................................................................................... 17

Final Assembly Drawing .................................................................................................................................. 18

Parts List ............................................................................................................................................ 19

Dust Tank Assembly Drawing and Parts List .................................................................................................. 20

Head/MainFrame Asssembly Drawing and Parts List .................................................................................... 21

Main Frame Assembly Drawing ....................................................................................................................... 22

Parts List ............................................................................................................................................ 23

Pad Head Assembly Drawing .......................................................................................................................... 24

Parts List ............................................................................................................................................ 25

Pad Motor .......................................................................................................................................................... 26

Transaxle .......................................................................................................................................................... 27

Control Panel Assembly Drawing .................................................................................................................... 28

Parts List ............................................................................................................................................ 29

Rear Cover Assembly Drawing ........................................................................................................................ 30

Parts List ............................................................................................................................................ 31

Electrical Schematic ......................................................................................................................................... 32

Connection Diagram ........................................................................................................................................ 33

Page -2 Clarke ®

Operator's Manual -Fusion 27 Battery Burnisher

WARNING

OPERATOR SAFETY INSTRUCTIONS

AVERTISSEMENT ADVERTENCIA

DANGER: Failure to read and observe all DANGER statements could result in severe bodily injury or death. Read and observe all DANGER statements found in your Owner's Manual and on your machine.

WARNING: Failure to read and observe all WARNING statements could result in injury to you or to other personnel; property damage could occur as well. Read and observe all WARNING statements found in your Owner's Manual and on your machine.

CAUTION: Failure to read and observe all CAUTION statements could result in damage to the machine or to other property. Read and observe all

CAUTION statements found in your Owner's Manual and on your machine.

DANGER:

DANGER:

DANGER:

DANGER:

DANGER:

DANGER:

Failure to read the Owner's Manual prior to operating or attempting any service or maintenance procedure to your Clarke machine could result in injury to you or to other personnel; damage to the machine or to other property could occur as well.

You must have training in the operation of this machine before using it. If your operator(s) cannot read English, have this manual explained fully before attempting to operate this machine.

Operating a machine that is not completely or fully assembled could result in injury or property damage. Do not operate this machine until it is completely assembled.

Inspect the machine carefully before operation.

Machines can cause an explosion when operated near flammable materials and vapors. Do not use this machine with or near fuels, grain dust, solvents, thinners, or other flammable materials. This machine is not suitable for picking up hazardous dust.

Lead acid batteries generate gases which can cause an explosion. Keep sparks and flames away from batteries. Do not smoke around the machine. Charge the batteries only in an area with good ventilation. Unplug the AC charger from the wall outlet before operating the machine.

Working with batteries can be dangerous! Always wear eye protection and protective clothing when working near batteries. Remove all jewelry. Do not put tools or other metal objects across the battery terminals, or the tops of the batteries.

Using a charger with a damaged power cord could result in an electrocution. Do not use the charger if the power cord is damaged.

WARNING: Operating this machine from anywhere other than the back of the machine could result in injury or damage. Operate this machine only from the rear.

WARNING: This machine is heavy. Get assistance before attempting to transport or move it. Use two able persons to move the machine on a ramp or incline. Always move slowly. Do not turn the machine on a ramp. If operating machine on a gradient over 2%, do not stop, turn or park. Read the "Procedures For Transporting" in this manual before transporting.

WARNING: Machines can topple over if guided over the edges of stairs or loading docks and cause injury or damage. Stop and leave this machine only on a level surface. When you stop the machine, turn the key "OFF".

Clarke ®

Operator's Manual - Fusion 27 Battery Burnisher - 3 -

WARNING: Maintenance and repairs performed by unauthorized personnel could result in damage or injury. Maintenance and repairs must be performed by authorized Clarke personnel only.

WARNING: Any alterations or modifications of this machine could result in damage to the machine or injury to the operator or other bystanders. Alterations or modifications not authorized by the manufacturer voids any and all warranties and liabilities.

WARNING: Electrical components of this machine can "short-out" if exposed to water or moisture.

Keep the electrical components of the machine dry. Wipe the machine down after each use. For storage, keep the machine in a dry building.

WARNING: Operating a machine without observing all labels and instructional information could result in injury or damage. Read all machine labels before attempting to operate. Make sure all of the labels and instructional information are attached or fastened to the machine. Get replacement labels and plates from your Clarke distributor.

CAUTION: Use of this machine to move other objects or to climb on could result in injury or damage.

Do not use this machine as a step or furniture. Do not ride on this machine.

CAUTION: Your machine warranty will be voided if anything other than genuine Clarke parts are used on your machine. Always use Clarke parts for replacement.



Introduction & Machine Specifications

Introduction & Machine Specifications

Clarke’s newly designed Fusion 27 battery burnisher is an efficient and superior floor burnishing machine . The machine uses a pad to burnish a path 27 inches wide. The powder created by burnishing is collected by a dust system.

The machine comes complete with six - 6 volt batteries, one on board battery charger, a pad driver and one operator’s manual.

SPECIFICATIONS:

Model Fusion 27 (01264A)

Motor, Pad

Power Supply

Dust Tank

Motor Traction

Pad Speed

Pad Pressure

Speed, Forward

Speed, Reverse

3 hp

36V 370 Ah

1/2 gallon

1/2 hp

1500 rpm

50 lbs.

192 ft./min.

167 ft./min.

Charger

Length

Width - Machine

Height

Buffing Rate

36V 23A

74"

30"

45"

26,000 Sq. ft /hr.

Buffing Swath 27"

Weight w/Batteries (370Ah) 1,150 lbs.

Shipping Weight w/batteries (370Ah) 1,300 lbs.

Clarke ®


PROCEDURES FOR TRANSPORTING

How To Put The Machine In A Van Or Truck

WARNING: The machine is heavy. Make sure you use two able persons to assist the machine in climbing the ramp.

1. Make sure the loading ramp is at least eight (8) feet long, and strong enough to support the machine.

2. Make sure the ramp is clean and dry.

3. Put the ramp in position.

4. Turn key switch "ON".

5. Align the machine on a level surface ten (10) feet in front of the ramp.

6. Put the traverse speed in the "HI" position.

7. Push the control handles toward the machine all the way.

8. Push the machine to the top of the ramp.

9. Turn the key switch "OFF".

10. Fasten the machine to the vehicle.

How To Remove The Machine From A Van Or Truck

1. Make sure there are no obstructions in the area.

2. Make sure the unloading ramp is at least eight (8) feet long and strong enough to support the machine.

3. Make sure the ramp is clean and dry.

4. Put the ramp in position.

5. Unfasten the machine.

WARNING: The machine is heavy. Make sure you use two able persons to assist in moving the machine down the ramp.

6. Turn the key switch "ON".

7. Carefully and slowly, pull the machine to the top of the ramp.

8. Put the traverse speed in the "HI" position.

9. As the machine begins to travel down the ramp, push the control handles toward the machine to maintain a slow downward speed.



SYMBOLS USED ON FUSION 27

Warning

Power

Traverse Speed Control

Pad Up/Down

Charge/Battery Meter

Pad Pressure

Hour Meter

Warning Label

Clarke ®


MACHINE CONTROLS

NOTE: Reference figures #1, 2 and 3 on page 9.

Key Switch (See Figure #1, Item "A")

The key switch turns "ON" the power to the control panel. "0" is "OFF" and "1" is "on".

Traverse Speed (See Figure #1, Item "B")

The speed control varies from low to high speed. To increase the speed, turn the knob to the right. To decrease the speed, turn the knob to the left.

Head Position Switch (See Figure #1, Item "C")

The head switch has three positions: "Up" positions the pad driver up; "Down" positions the pad driver on the floor. The middle position stops the actuator. The head motor operates only when the head is down and the machine is traversing.

Pad Pressure Meter (See Figure #1, Item "D")

The pad pressure meter indicates the relative pressure of the pad on the floor. Do not continue to run the machine when the meter is in "red" area. This will trip the pad motor circuit breaker.

Control Handle (See Figure #1, Item "E")

The control handle is located at the rear of the machine. It controls the direction of the machine. Push forward to go forward. (See Figure #2, page 9). Pull back to move in reverse. (See Figure #3, page 9).

Circuit Breakers (See Figure #1, Item "F"-"H")

The circuit breaker reset buttons are located on the rear cover, below the control handle. The breakers are located as follows:

Item F - Pad Motor (90A)

Item G - Traverse Motor (30A)

Item H - Actuator Motor, Brush Head (5A)

If a circuit breaker trips, determine which motor is not operating and turn the key switch "OFF". Wait five minutes and push the reset button back in. Turn the key switch "ON", and try again. An authorized service person should be contacted if the breaker trips again.

Hour Meter (See Figure #1, Item I)

The hour meter indicates the number of hours the machine has operated. It runs only when the machine is moving forward or reverse.

Charge / Battery Meter (See Figure #1, Item J)

The charge/battery meter indicates the battery is being charged when the charger is plugged into a live outlet and it indicates the amount of charge left in the batteries while they are being discharged. It will shut the pad motor off when the battery voltage gets too low.



MACHINE CONTROLS

E

J

A

C D B

I

H

G

Figure #1

F

Figure #2 Figure #3

Clarke ®


HOW TO PREPARE THE MACHINE FOR OPERATION

How To Install The Batteries

The Fusion 27 machines uses six 6-volt batteries. The batteries are located in the battery compartment under the battery cover.

To Install the batteries, follow this procedure:

1. Turn key switch off.

2. Remove the battery cover.

3. Place the batteries in the body as shown in figure 4.

WARNING: Lifting batteries without help could result in an injury. Get help to lift the batteries. The batteries are heavy.

WARNING: Working with batteries can be dangerous. Always wear eye protection and protective clothing when working near batteries.

NO SMOKING!

4. Connect the battery cables between batteries as indicated. See figure 4.

NOTE: Charge the batteries before using the machine.

Battery Maintenance

The electrical power to operate the machine comes from the storage batteries. Storage batteries need preventive maintenance.

WARNING: Working with batteries can be dangerous. Always wear eye protection and protective clothing when working near batteries. NO SMOKING!

To maintain the batteries in good condition, follow these instructions:

1. Remove each cap to all of the cells of the batteries.

2.

Check the electrolyte level in the batteries. The minimum level is just above the tops of the plates.

See figure 5 A.

NOTE: Check the level of electrolyte prior to charging the batteries.

Page -10-

Figure #4

Figure #5

B

A

(Maximum level)

Correct Range

(Minimum level)

Plates

Battery

Clarke ®



CAUTION: Irreversible damage will occur to the batteries if the electrolyte level does not cover the plates. Keep the electrolyte at the correct level.

3. Reinstall the caps.

4. After charging, top off the batteries. NOTE: USE

DISTILLED WATER ONLY. THIS SHOULD BE

DONE AFTER CHARGING. The maximum level is within 1/4 inch of the bottom of the tube in each cell.

See figure 5 B. For instructions on how to charge the batteries, see "How To Charge The Batteries" below.

CAUTION: Machine damage and discharge across the tops of the batteries can occur if the batteries are filled above the bottom of the tube in each cell. Do not fill the batteries up to the bottom of the tube in each cell. Wipe any acid from the machine or the tops of the batteries. Never add acid to a battery

after installation.

CAUTION: Tap water may contain contaminants that will damage batteries.

Batteries must be re-filled with distilled water only.

5. Keep the tops of the batteries clean and dry.

Keep the terminals and connectors clean. To clean the top of the batteries, use a damp cloth with a weak solution of ammonia or bicarbonate of soda solution.

To clean the terminals and connectors, use a terminal and connector cleaning tool. Do not allow ammonia or bicarbonate of soda to get into batteries.

6.

Keep the batteries charged.

How To Charge The Batteries

WARNING: Charging the batteries in an area without adequate ventilation could result in an explosion. To prevent an explosion, charge the batteries only in an area with good ventilation.

WARNING: Lead acid batteries generate gases which could explode. Keep sparks and flames away from batteries. NO SMOKING!

To charge the batteries, follow this procedure:

1. Make sure the key switch is in the “OFF” position.

2.

Connect the charger to a properly grounded single phase (3-wire) wall receptacle having the voltage, frequency, and ampere capacity specified on the nameplate of the charger.

Clarke ®



How To Install The Pad

To install the pad on the machine, follow this procedure:

1. Position the pad centered on the pad driver.

See figure 6

2. Install and tighten the pad retainer.

How To Remove The Pad

To remove the pad on the machine, follow this procedure:

1. Loosen and remove the pad retainer.

2. Pull the pad from the pad driver. See figure 7.

HOW TO OPERATE THE MACHINE

Pad Pressure Operation

In order to maintain the amount of "pad pressure" being applied to the floor, this machine comes with:

1.

Pad Presssure Meter - "10 Bar" LED, (2)

Yellow, (6) Green and (2) Red. This is located on the upper right side of the control panel. See figure 8.

2.

90 amp circuit breaker

3.

Pad Pressure adjustment nut

The color bands on the pad pressure meter indicate whether the pad pressure is too low (Yellow); within recommended pad motor specifications (Green); or too high (Red). If the machine is operating in the Red band for more than 5 - 10 seconds, the circuit breaker will

"pop", indicating that the pressure on the floor has exceeded the pad motor specifications. Excessive

"popping" (or blowing) of the circuit breaker will cause the breaker to stop functioning and will need to be replaced.

This machine operates on a "Pivot-Control" system. This allows for the machine to "float" along the floor consistently and continues to burnish the floor as the pad wears. When the pad pressure meter starts to operate in the Yellow band, it is recommended that the pad be checked for excessive wear and possible replacement.

If the machine operates in the (Red) band for more than 2-

3 seconds, it is recommended that you reduce the amount of pad pressure being applied to the floor. Refer to the "Pad Pressure Adjustment" instructions.

Figure #6

Figure #7

Yellow

Green

Red

Figure #8

Retainer

Retainer

Pad Pressure

Meter

Factory

Setting

Recommended

Setting



HOW OPERATE THE MACHINE

Pad Pressure Operation (Contiuned)

While operating the machine, you may notice that the pad pressure meter moves from Yellow to Green to Red to Green etc. This is due to the condition of the floor being burnished. The more consistent the floor, the more stable the reading on the meter.

Depending on the type of pad and the finish being used, the pad pressure may need to be adjusted in order to keep the pressure within specifications. Refer to the

"Pad Pressure Adjustments" instructions.

Pad Pressure Adjustments

1.

Locate the pad pressure adjustment nut located underneath the machine between the rear casters. See figure 9.

2.

Using a 3/4" wrench (1/2 turn increments only), tighten the nut to reduce the pad pressure or loosen the nut to increase the pad pressure.

3.

Run the machine for a few seconds in order to get a reading from the pad pressure meter.

4.

If adjustment is still needed, follow steps 2-3 until the pad pressure meter stays within the "Green" band.

Operating the Machine

NOTE: Put the machine in the slow traverse speed (less than 1/2 speed). Use the machine in an area that has no furniture and objects until you can do the following:

1.

Move the machine in a straight direction, forward and backward.

2.

Stop the machine safely.

3.

Move the machine in a straight direction after you turn the machine.

To move the machine, follow this procedure:

1.

Turn the key switch “ON” position.

2.

Press and hold the top of the head position switch until you hear the actuator rachet.

3.

To go forward, push the control handles toward the machine. See figure #10.

4.

To stop the machine, put the handles in the center position.

5.

To go backward, pull the handles away from the machine. See figure #11.

6.

To turn the machine, push the rear of the machine to the side.

7.

When you stop the machine, turn the key switch

"OFF".

Clarke ®

Operator's Manual - Fusion 27 Battery Burnisher

Pad

Pressure

Adjustment Nut

REAR OF MACHINE

Figure # 9

Figure #10

'

Figure #11

- 13 -

MAINTENANCE

WARNING: Maintenance and repairs must be done by authorized personnel only.

WARNING: Keep all fasteners tight.

These Maintenance Procedures Must Be Done Every

Day

Keep the machine clean, it will need fewer repairs and have longer life.

Do These Procedures When You Begin Your Work

Period

1. Turn off key switch.

2. Disconnect the plug on the charger from the wall. See figure #12.

3. Make sure pad skirt is in position on the head.

8. Make sure pad is in position and installed correctly

These Maintenance Procedures Must Be Done Every

Week:

WARNING: Maintenance and repairs must be done by authorized personnel only.

Keep all fasteners tight.

WARNING: Always wear eye protection and protective clothing when working near batteries. Do not put tools or other metal objects across the battery terminals or the tops of the batteries.

CAUTION: To prevent damage to the machine, and discharge across the tops of the batteries, do not fill the batteries above the bottom of the tube in each cell. Wipe any acid from the machine or the tops of the batteries. Do not add acid to battery after installation.

NOTE: Always turn off key switch before servicing the machine.

WARNING: Always wear eye protection and protective clothing when working near batteries. NO SMOKING!

1. To inspect the batteries, tilt the battery cover. See

Figure #13.

2. Use a cloth and a solution of ammonia or bicarbonate of soda to wipe the top of the batteries. Clean the battery terminals. Reconnect the batteries.

3. Check the hoses for leaks, obstructions and other damages.

4. Use a grease gun to lubricate the casters. See figure

#14.

5. The main tires are foam filled. They do not require air.

Page -14-

Figure #12

Figure #13

Figure #14

Clarke ®


Fusion 27

Battery

Burnisher

Section II

Parts and Service Manual

(70788A)

Clarke ®

Operator's Manual - Fusion 27 Battery Burnisher

Patent Pending

- 15 -

PROBLEM

The batteries do not give the normal running time.

CAUSE

The battery terminals are dirty or damaged.

The electrolyte level is too low.

The batteries are not fully charged.

The charger is damaged.

The battery is defective.

The batteries are disconnected.

ACTION

Clean the terminals and connectors. Replace the damaged cables. Charge the batteries.

Add distilled water to each cell and charge the batteries.

Charge the batteries for a full 16 hour charge.

Have an authorized service person repair the charger.

Check voltage of each cell while discharging.

Connect the batteries.

The burnishing is not even.

The pad is worn.

There is damage to the pad assembly.

The pad motor is not running

Replace the pad.

Have an authorized service person make the needed repairs.

Check for tripped breaker, reset. Check for loose connections.

NOTE: If the motor continues to stop consult an authorized service person.

The machine does not run.

Pad motor circuit breaker trips.

The machine loses power.

Pad pressure is too high

Reset the circuit breaker.

Check wire connection to traverse motor.

Replace the fuse.

Check the battey connections.

NOTE: If the motor continues to stop, consult an authorized service person.

Tighten the adjustment nut between the rear casters.

Pad pressure meter readings are too low.

Pad pressure is too low.

Loosen the adjustment nut between the rear casters.

Machine vibrates

Machine pulls right.

Machine pulls left.

HOW TO CORRECT PROBLEMS IN THE MACHINE

Unbalanced pad.

Pad pressure too high on right.

Pad pressure too high on left.

Recenter pad on driver.

Install new pad.

Tighten right front lift plate nut.

Tighten left front lift plate nut.



.

MAINTENANCE

Adjusting Pad Head Limit Switch: (See figure 13)

1.Turn "ON" the key switch.

2. Press and hold the top of the head position switch to raise the head.

3. Press and hold the bottom of the head position switch to lower the head.

4. Traverse the machine to verify the pad motor comes on. If not, the lever on the touch down switch must be bent to contact the main frame sooner.

Figure #13

Clarke ®


Clarke ®

Fusion 27

Final Assembly Drawing 9/04

Drawing # (01264A)

12

16 17

15

30

31

18

29

28

27

26

22

21

20

23

24

25

32

37

19

13

14

6

8

9

10

11

7

2

1

5

3

4



Clarke ®

Fusion 27

Final Assembly Parts List 9/04

11

12

13

14

7

8

9

10

Ref # Part No. Description

1 pg 28,29 Control Panel Asm.

2

3 pg 30,31 Rear Cover Asm.

38722B Spacer*, Battery 3/4 x 2 x 18

4

5

6

38720B

40704A pg 21

Spacer**, Battery 1¼ x 2 x 15

Battery

Head/Mainframe Asm.

pg 22,23 Mainframe Asm.

30424A

87000A

980638

962244

81105A

980645

Hose

Washer, Flat 3/8

Washer, Lock 3/8

Screw, 3/8-16 x 3/4 pg 24,25 Pad Head Asm.

30480B Front Cover

Nut, Lock 3/8-16

Washer, Flat 3/8

19

20

21

22

15

16

17

18

39713A Washer, Rubber

87032A Washer, Flat 1/4

85524A Screw, 1/4-14 x 3/4

61569A Weldment, Dust Container

85614A Screw, #8-32 X 3/4

30587A Diaphragm

920065 Nut, Lock #8-32

87054A Washer, 3/8

27

28

29

30

23

24

25

26

69548A

87622A

80043A

85703A

962957

193951

53396A

61578A

Recovery Tank Support

Washer, Nylon

Screw, Shoulder 5/16

Screw, 3/8-16 X 1 1/2

Screw, #10-16 X 1/2

Snakeskin

Filter, Dust

Screen

31 30543A Top Cover

32 pg 20 Dust Tank Asm.

33 842406 Cable, Series (NI)

34 40612A Cable, Red (NI)

35 40613A Cable, Black (NI)

36 77092A Label, Gases (NI)

1

1

3

1

1

2

1

1

4

2

4

1

1

1

1

1 ref.

1

2

2

4

4

1

4

Qty ref.

ref.

2

2

6 ref.

ref.

1 ref.

5

1

1

1

NOTE: indicates a change has been made since the last publication of this manual.

*Front and Back Spacers

** Left and Right Spacers

Clarke ®


1

2

Clarke ®

Fusion 27

Dust Tank Assembly Drawing and Parts List 9/04

Drawing #10691A

9

3

4

5

6

8

7

10

20

11

15

14

12

13

19

17

18

16

7

8

9

10

3

4

5

6

Ref # Part No. Description Qty

1

2

30454A

64900A

Tube, Vinyl

Handle, Stationary

2

1

980205

980652

85815A

69879A

Washer, Flat 5/16

Washer, Lock 5/16

Screw, 5/16-18x1-1/2 Hex

Bracket, Support

4

1

4

4

170892 Washer, Lock 1/4 SS 2

170915 Screw, 1/4-20 x 3/4 SS Hex 2

30586A Adaptor, Dust Hose

30481A Tank

1

1


11

12

920797

61493A

Locknut

Spacer, Latch

1

2

13

14

15

16

61494A

55723A

85614A

59614A

Plate, Cover Support

Latch

Screw, #8-32x3/4 Pn.

Valve, Battery Drain

4

1

2

2

17 35196A Hose

18 50248A Clamp, Hose

19 53427A Plug, 1-1/2

20 70849A Label, Battery Install

1

1

1

1




13

15

Clarke ®

Fusion 27

 Head/MainFrame Assembly Drawing and Parts List 9/04

Drawing # (01594A)

2

3

4

1

5

14

6

9

7

8

9

10

12 11

14


1 82501A Clevis Pin, 3/8 x 2 1/4 1

2

3

Pg 22,23 Mainframe Asm. ref

38708A Spacer, Nylon - Black

4 766780 Hairpin

5 50208A Actuator

2

1

1

6

7

81104A

920278

Nut, Nylock 1/4 SS

Nut, Hex Jam 1/2-20

8

9

10

11

980626 Washer, Lock 1/2

38723A Spacer, Nylon - White

67705B

85838A

Bearing, Sleeve

Bolt, Hex 1/2-20 x 1 1/2

2

2

12 85602A Screw, Hex Cap 1/4-20 x 3 1

13 Pg 24,25 Pad Head Asm. Ref.

14 70779B Label

15 70673A Label

1

1

2

4

1

4


Clarke ®


Clarke ®

Fusion 27

Mainframe Assembly Drawing 7/04

Drawing # (10597A)

17

18

1

2

3

6

5

4

7

11

9

12

10

9

12

8

16

15

13

14

15



Clarke ®

Fusion 27

Mainframe Assembly Parts List 10/04

12

13

14

15

8

9

10

11

4

5

6

7


1 61488B Main Frame

2

3

30499A

85700A

Spring, Urethane-Blue

Screw, 1/4-20 x 1

81104A

980614

Nut, Nylock 1/4 SS

Washer, Star Lock 1/4

Qty

1

2

1

1

3

980205 Washer, Flat - .312 x 1.06 x .075

2

69639A Strap, Static 1

16

17

18

61571A

980648

30588A

30577A

920365

59116A

899769

81105A

65963A

81221A

59955A

Frame, Pivot

Washer, Flat, ½" SAE

Washer, Rubber 1.38 x .50

Spring, Urethane, Red

Nut, Nylock - 1/2-13

Transaxle

Caster, Asm.

Nut, Lock 3/8-16

Mount, Transaxle

Nut, 1/2-20

Wheel Asm., Foam Filled

2

6

2

3

1

2

12

1

5

2

2

Clarke ®


Clarke ®

Fusion 27

Pad Head Assembly Parts List 9/04

1

2 3

8

4

5

6

7

9

29

28

26E

16

27

26D

26C

26B

25

26A

26

2A*

24

23

22

19

20

21

17

18

14

15

13

12

10

11



Clarke ®

Fusion 27

Pad Head Assembly Parts List 9/04

18

19

20

21

14

15

16

17

10

11

12

13

3

4

5

6


1 85813A Screw, 5/16-18 x 1

Qty

4

2 40660B Motor, 3.25 HP (includes #2A) 1

2A 915102 Key (included w/ #2) (1)

920056

47374A

962980

61379B

Nut, Lock #6-32

Switch, Lever

Screw, #6-32 x 1

Lift Plate

7 81105A Nut, Lock 3/8-16

8 30585A Spring, Urethane-Yellow

9 21076B Housing

2

1

2

1

3

3

1

1 30351A Driver, Pad - 27"

57370A Base, Pad Retainer

99953A Pad, Beige-27"

57369A Retainer, Pad

1

1

1

3 80242A Screw, #8-18 x 5/8

962285 Screw, 1/4-20 x 1

61384B Stud Plate

980651 Washer, Flat 5/16

6

1

4

1 61378A Mount, Motor


980638 Washer, Lock 3/8

962244 Screw, 3/8-16 x 3/4

4

4

4

1 22

23

61377A Hub

962714 Screw, 5/16-18 x 3/4

24 980205 Washer, Flat

25 962593 Screw, Set 1/4-20 x 3/8

26 10833A Skirt Asm (incl. 26A - 26E)

26A 30589A Sleeve

26B 832002 Clamp, Hose

26C 30478B Adaptor, Scoop

26D 53186A Tie, Cable - 14"

26E 30576A Skirt

1

1

1

1

(1)

(1)

(1)

(1)

27

28

920110

30570A

Nut, Nylock 5/16-18

Bumper

29 53555A Clamp, Hose 95"

30 77091A Label

(1)

4

1

1

2


Clarke ®


Clarke ®

Fusion 27

Pad Motor 40660B

1/04

10

7

8

9

10

11

3A

4

5

6

Ref # Part No.

Description

1 Field

2

3

Cover

Brush Board

7-76-00110 Spring

Bracket

Brush

Wave Washer

Screw

902550 Bearing

98660A

85517A

Armature Assembly

Bearing

Screw

4

1

4

1

Qty

1

1

1

1

1

2

1

8

11

Clarke ®

Fusion 27

Imperial Transaxle Parts 1/04

PN 59116A

Transaxle has black motor

All models after SN#YH

Page -28-

Clarke ®

Fusion 27

Control Panel Assembly Drawing 9/04

Drawing# 10599A

1

2

42

4

5

6

41

7

8

20

21

19

18

13B

12C

12D

16

15

14

13A

13

12

9

10

11

3

12B

12A

23

24

38

22

37

25

36

35

26

34

28

29

39

35

30A

30

31

27

30A

30B

32

33

Clarke ®


Clarke ®

Fusion 27

Control Panel Assembly Parts List 9/04

6

7

8

9

10

11

12

Ref # Part No.

Description

1

2

3

4

5

84237A

40168B

40668B

70770B

61380B

Screw, #10-32 x 1/2

Switch, Rocker

Harness, Traverse

Label, Control Panel

Weldment, Console Panel

30022A

50883A

30483A

40731A

38724B

920056

Gasket, Panel

Retainer, Potentiometer

Control Housing

Meter, Pad Pressure

Standoff, Nylon

Nut, Lock #6-32

Qty

8

1

1

1

1

1

1

1

1

2

2

40664A Circuit Breaker 90A (includes #12A-12D) 1

35

36

37

38

31

32

33

34

12A

12B

12C

12D

13

13A

13B

14

15

16

17

18

80208A Screw, M6-1 x 10 (included w/#12)

Washer, Belleville (included w/#12)

Nut, CB Mount (included w/#12)

Washer, Wave (included w/#12)

47380A Key Switch (includes 2 #13A, 1 #13B)

55413A

41448B

41423B

Key

Nut

Circuit Breaker 30A

Circuit Breaker 5A

19

20

21

23

24

66871A Retainer, Switch

40667B Harness, Meter (NI)

87052A Washer, Flat Nylon

912226

40898A

920722

85391A

87032A

Hour Meter

Meter, Charge/Battery

Nut, Lock #10-32

Screw, 1/4-20 x 5/8

Washer, Flat 1/4

25

26


80043A Screw, Shoulder

1

1

27

28

29**

30

30A

30B

60662A Bracket Asm., Centering

61651A Collar, Control Switch

962304

"

"

Screw, Set 5/16-18 x 1/2

40084A Switch, Toggle (includes #30A, 30B)

Nut, Toggle Switch (included w/#30)

1

1

4

1

(2)

Washer, Toggle Switch (included w/#30) (1)

1

1

2

2

2

1

1

1

(2)

(2)

(1)

(1)

1

(1)

(1)

1

1

39

40*

40A*

41

42

43

61266A

53038A

60042A

66548A

170892

85390A

24309B

66549A

170915

40665B

42909A

70778B

55502A

40667B

Bracket, Weldment, Control

Spring, Control Handle

Stud

Pin, Control Handle RH

Washer, Lock 1/4 S.S.

Screw, 1/4-20 x 1 1/4

Handle, Control

Pin, Control Handle LH

Screw, 1/4-20 x 3/4 SS

Harness, Main (includes #40A)

Fuse AGC-5 (incuded w/#40) (NI)

Label

Knob

Harness, Charger/Battery Meter

4

2

1

1

1

2

1

1

2

1

(1)

1

1

1


* NI = Not illustrated

** #29 must use red loctite set screws.

Clarke ®


10

11

9

Clarke ®

Fusion 27

Rear Cover Assembly Drawing 9/04

Drawing # 10595A

1

14

13

15

16

17

19

18

12 6

5

4

3

2

23

20

21

24

22

7

8



Clarke ®

Fusion 27

Rear Cover Assembly Parts List 9/04


1 193951 Trim, 8" Bulk

11

12

13

14

15

16

17

18

19

20

21

22

23

24

7

8

9

10

2

3

4

5

6

6A

Qty

1

10686A Panel, Lower Electrical


170892

170915

Washer, Lock 1/4 S.S.

Screw, ¼-20 x 3 /

4

Hex

40666A Charger, Battery

912064 Terminal, Ring (Not illustrated)

80043A Screw, Shoulder 5/16


30477A Cover, Rear

85391A Screw, 1/4-20x5/8

87026A Washer, Flat 1/4 SS

85614A Screw, #8-32 x 3/4

81104A Nut, Nylock 1/4-20 SS

40662A Controller, Traverse

41802A Contactor, 36V (Main)

920722 Nut, Lock #10-32

912287 Bridge Rectifier

60552A Bracket, Solenoid Main

41801A Contactor, 36V (Pad)

70080A Plate, Warning

930093

--------

Rivet 3

Serial Number Plate (1)

70777B Label

30484A Retainer, Cord

1

1

1

1

1

1

1

1

6

1

2

8

1

2

2

2

1

2

4

4

1

4


Clarke ®


Clarke ®

Fusion 27

Electrical Schematic 6/04



Clarke ®

Fusion 27

Connection Diagrams 6/04

INSIDE CONTROL HOUSING

Clarke ®


NOTE S

PRODUCT SUPPORT BRANCHES

U. S. A. Locations European Locations

CORPORATE OFFICE

ALTO U.S. Inc., St. Louis, Missouri

16253 Swingley Ridge Road, Suite 200

Chesterfield, Missouri 63017-1725

PRODUCTION FACILITIES

Clarke ® , Springdale, Arkansas

2100 Highway 265

Springdale, Arkansas 72764

(479) 750-1000

Customer Service - 1-800-253-0367

Technical Service - 1-800-356-7274

American Lincoln ® , Bowling Green, Ohio 43402

1100 Haskins Road

PRODUCTION FACILITIES

ALTO Danmark A/S, Aalborg

Blytaekkervej 2

DK-9000 Aalborg

+45 72 18 21 00

ALTO Danmark A/S, Hadsund

Industrikvarteret

DK-9560 Hadsund

+45 72 18 21 00

SERVICE FACILITIES

Clarke ® , Elk Grove, Illinois 60007

2280 Elmhurst Road

(847) 956-7900

Clarke ® , Denver, Colorado 80204

1955 West 13th Ave.

(303) 623-4367

Clarke ® , Houston, Texas 77040

7215 North Gessner Road

713-937-7717

SERVICE AND SALES FACILITY

American Lincoln ® / Clarke ® , Madison Heights,

Michigan 48071-0158

29815 John R.

(810) 544-6300

American Lincoln ® / Clarke ® , Marietta, Georgia 30066

1455 Canton Road

(770) 973-5225

SALES AND DISTRIBUTION CENTER

Clarke ® , Secaucus, NJ 07094

74 Henry Street

(201) 864-5503

Clarke ®

Clarke American Sanders

A.L. Cook

Customer Service Headquarters and Factory

2100 Highway 265

Springdale, Arkansas 72764

(479) 750-1000

Technical Service

1-800-356-7274

SALES SUBSIDIARIES

Clarke ® Canada Ltd., Rexdale Ontario

24 Constellation Ct.

(416) 675-5830

ALTO Overseas Inc., Sydney (Australia)

1B/8 Resolution Drive

Caringbah NSW 2229

+61 2 9524 6122

ALTO Cleaning Systems Asia Pte Ltd., Singapore

No. 17 Link Road

Singapore 619034

+65 268 1006

ALTO Deutschland GmbH, Bellenberg (Germany)

Guido-Oberdorfer-Straße 2-8

89287 Bellenberg

+49 0180 5 37 37 37

ALTO Cleaning Systems (UK) Ltd., Penrith

Gilwilly Industrial Estate

Penrith

Cumbria CA11 9BN

+44 1768 868 995

ALTO France S.A. Strasbourg

B.P. 44, 4 Place d’Ostwald

F-67036 Strasbourg

Cedex 2

+33 3 8828 8400

ALTO Nederland B.V.

Postbus 65

3370 AB Hardinxveld-Giessendam

The Netherlands

+31 184 677 200

ALTO Sverige AB, Molndal (Sweden)

Aminogatan 18

Box 4029

S-431 04 Molndal

+46 31 706 73 00

ALTO Norge A/S, Oslo (Norway)

Bjornerudveien 24

N-1266

+47 2275 1770

Clarke

®

U.S. LIMITED WARRANTY

This Clarke Industrial/Commercial Product is warranted to be free from defects in materials and workmanship under normal use and service for a period of one year from the date of purchase, when operated and maintained in accordance with Clarke's Maintenance and Operations instructions.

The pad drive and traverse motors are warranted to be free from defects in materials and workmanship under normal use and service for one additional year, for a total of two years, from the date of purchase, provided the motors are inspected for carbon motor brush wear at six-month intervals by an authorized Clarke repair station. Failure to comply with the six-month inspection requirement or failure to replace worn motor brushes identified during the inspection will void the additional one-year warranty on the motors. Cost of the six-month inspection and replacement of carbon motor brushes is the responsibility of the purchaser. In the event of a warranty claim on the motors, proof of inspection and any required motor brush replacement must be provided.

This warranty is extended only to the original purchaser for use of the product. It does not cover normal wear parts such as electrical cable, rubber parts, hoses and motor brushes.

Clarke's liability under this warranty is limited to repair of the product and/or replacement of parts and is given to purchaser in lieu of all other remedies, including INCIDENTAL AND CONSEQUENTIAL DAMAGES.

THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE SPECIFIED HEREIN. THERE ARE NO WARRANTIES WHICH

EXTEND BEYOND THE DESCRIPTION OF THE FACE HEREOF. NO WARRANTIES, INCLUDING BUT NOT LIMITED TO WAR-

RANTY OF MERCHANTABILITY, SHALL BE IMPLIED. A warranty registration card is provided with your Clarke product.

Return the card to assist Clarke in providing the performance you expect from your new floor machine.

If a difficulty develops with the product, you should: a) Contact the nearest authorized Clarke repair location or contact the Clarke Service Operations Department, 2100 Highway 265, Springdale, Arkansas 72764, for the nearest authorized

Clarke repair location. Only these locations are authorized to make repairs to the product under this warranty. (b) Return the product to the nearest Clarke repair location. Transportation charges to and from the repair location must be prepaid by the purchaser. Clarke will repair the product and/or replace any defective parts with out charge within a reasonable time after reciept of the product.

Clarke ® , 2100 Highway 265, Springdale, Arkansas 72764.

BATTERY WARRANTY

In addition to the items above (except as to the one-year period), any original equipment Clarke Battery which becomes unserviceable under normal use within a period of ninety (90) days from date of sale to the original user will be repaired or replaced with one of equal specification at our option, F.O.B. any authorized Clarke Sales or Service Branch, with no charge to the user, except transportation costs. After expiration of the above ninety (90) day period, any battery which fails under normal use will be adjusted to the original user with a new battery of equal specification on an eighteen (18) months pro rate basis from the date of purchase. Adjustment will be determined using the then current list price, plus transportation costs.

Warranty is rendered null and void if battery is not kept filled to the proper level with DISTILLED WATER.

POLYDUR

®

DUST RECOVERY TANK AND BATTERY COVER

EIGHT-YEAR GUARANTEE

Your new Clarke burnisher has a polydur dust recovery tank and battery cover. Polydur is a rotationally molded, lowdensity linear polyethylene that won't crack or dent, and withstands most corrosives and temperature extremes. Clarke backs up your Polydur tanks with an eight-year guarantee. If a tank breaks or leaks under normal use within eight years of the date of purchase, it will be replaced free.

UNIBODY FRAME

FIVE-YEAR WARRANTY

Clarke warranties the frame for the new burnisher for a period of five years against defects in materials and workmanship under normal use and service.

Clarke reserves the right to make changes or improvements to its machine without notice.

Always use genuine Clarke Parts for repair.

2100 Highway 265

Springdale, Arkansas, 72764

User manual | Clarke Fusion 201 Operator`s manual

Operator's

Manual

Fusion 27

Battery

Burnisher

Patent Pending

READ THIS BOOK

Table of Contents

WARNING

OPERATOR SAFETY INSTRUCTIONS

AVERTISSEMENT ADVERTENCIA

Introduction & Machine Specifications

PROCEDURES FOR TRANSPORTING

How To Put The Machine In A Van Or Truck

How To Remove The Machine From A Van Or Truck

SYMBOLS USED ON FUSION 27

MACHINE CONTROLS

MACHINE CONTROLS

HOW TO PREPARE THE MACHINE FOR OPERATION

Battery Maintenance

HOW TO PREPARE THE MACHINE FOR OPERATION

How To Charge The Batteries

HOW TO PREPARE THE MACHINE FOR OPERATION

How To Install The Pad

How To Remove The Pad

HOW TO OPERATE THE MACHINE

Pad Pressure Operation

HOW OPERATE THE MACHINE

Pad Pressure Operation (Contiuned)

Pad Pressure Adjustments

Operating the Machine

MAINTENANCE

Fusion 27

Battery

Burnisher

Section II

Parts and Service Manual

Patent Pending

PROBLEM

CAUSE

ACTION

HOW TO CORRECT PROBLEMS IN THE MACHINE

MAINTENANCE

PRODUCT SUPPORT BRANCHES

U. S. A. Locations European Locations

Clarke

U.S. LIMITED WARRANTY

BATTERY WARRANTY

POLYDUR

DUST RECOVERY TANK AND BATTERY COVER

EIGHT-YEAR GUARANTEE

UNIBODY FRAME

FIVE-YEAR WARRANTY

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Clarke

Fusion 27 01264A

Clarke

Fusion 201

Clarke

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RYC300

Clarke

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Clarke

Fusion 20T

Table of contents