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Electrical System

19

Service Manual – CA90 32T

Electrical Circuit Diagram (ladder style)

Key

Switch

Trigger

Switch

Solution Switch

Solution Solenoid

Brush Switch

Hour Meter

Brush

Solenoid

Left Brush Motor

Right Brush Motor

35A

35A

Ammeter

Actuator Motor

Actuator Switch

Driving Motor

Speed Controller

Direction Switch

Vacuum Switch

Vacuum Solenoid

Vacuum Motor

35A

PCB

Battery Capacity Lights

12

A

Main Solenoid

Drive Motor

36V Battery

Summary of Contents for CA90 32T

Page 1: ...Clarke CA90 32T 11 2015 Form No 56043170 Service Manual Model Numbers Clarke 810T English...

Page 2: ...nt Locations 11 Control System 12 Functional Description 12 Component Locations 12 Maintenance and Adjustment 15 Electrical System 16 Functional Description 16 Wiring Harness Diagram 18 Electrical Cir...

Page 3: ...44 Functional Description 44 Circuit Description 44 Circuit Diagram 44 Component Locations 45 Maintenance and Adjustment 47 Solution Filter Cleaning 47 Resetting the Solution Flow Adjustment Knob 47...

Page 4: ...ual is a resource for professional service technicians It provides information for understanding how the machine operates where components are located basic troubleshooting maintenance and mechanical...

Page 5: ...ing machine which affect capacity and safe operation shall not be performed by the customer or user without prior written approval Nilfisk Inc Unapproved modifications will void the machine warranty a...

Page 6: ...parks flame and smoking materials away from batteries Explosive gases are vented during normal operation Charging the batteries produces highly explosive hydrogen gas Charge the batteries only in well...

Page 7: ...Variable Forward Reverse Variable Forward Reverse Cleaning Productivity 34 560 Sq ft hr 3211 Sq m hr Drive System 5 H P Transaxle Drive 37 kW Transaxle Drive Wheels Non marking Gray 2 12 Inch Foam Fi...

Page 8: ...Meter Solution Switch Brush Pressure Meter Brush UP DOWN Switch Drain Hose Squeegee Assembly Circuit Breakers Rear Casters Solution Sight Tube Squeegee Lift Handle Solution Fill Hose Recovery Tank Li...

Page 9: ...General Information 9 Service Manual CA90 32T Operating Triggers Reverse Switch Key switch Solution fill Pail Console Adjustment Levers Speed Control Knob Solution Flow control knob...

Page 10: ...n with a damp cloth X Remove the float shut off and rinse thoroughly X Clean off the machine with a damp towel X Check fluid levels in battery cells X Check batteries for loose or corroded connections...

Page 11: ...ssis to support the machine Bolted to the chassis are the solution tank transaxle casters squeegee bracket and brush deck supports Also the main wiring harness travels through one of the channels of t...

Page 12: ...everse switch and the Speed Control Potentiometer When all of the inputs to the Curtis Speed Control Board are within the proper range the machine will move All of the controls are located on or in th...

Page 13: ...Control System 13 Service Manual Machine Name Vacuum Motor Switch Solution Switch Actuator Up Down Switch Brush Switch Trigger Switch looking up through lower housing panel Forward Reverse Switch...

Page 14: ...Control System 14 Service Manual CA90 32T Speed control knob Solution control knob MAIN Solenoid Brush Solenoid Vacuum Solenoid Circuit Breakers Located on lower control housing panel...

Page 15: ...Control System 15 Service Manual CA90 32T Maintenance and Adjustment No maintenance or adjustment is required for the control system...

Page 16: ...an output of 25 amps maximum The electrical system is powered by 6 6 volt batteries for a total of 36 volts Heavy cables connect the batteries in series A large gray main battery pack connector is use...

Page 17: ...Electrical System 17 Service Manual Machine Name The machine wiring is color coded and the wires are marked with yellow numbered bands corresponding to their location on the Wiring Harness Diagram...

Page 18: ...LU 14AWG RED ACTUATOR 0 16AWG BLU 0 16AWG BLU 16 14AWG BLK 15 14AWG RED 01 14AWG BLK 13 14AWG RED 10 10 12 20 0 3 MAIN SOLENOID SOLUTION SOLENOID ACTUATOR MOTOR LEFT BRUSH MOTOR RIGHT BRUSH MOTOR VACU...

Page 19: ...tion Switch Solution Solenoid Brush Switch Hour Meter Brush Solenoid Left Brush Motor Right Brush Motor 35A 35A Ammeter Actuator Motor Actuator Switch Driving Motor Speed Controller Direction Switch V...

Page 20: ...position Insure the recovery tank is drained Open the recovery tank and set the prop rod to hold the tank in the UP position Plug approved charger into a grounded wall outlet before plugging the charg...

Page 21: ...position Reset Main breaker Re charge batteries Check and tighten battery connections Brush motor s does not run See Scrub System Little or no solution flow See Solution System Poor water pick up See...

Page 22: ...s designed so that when the recovery tank is full the ball will seal off the standpipe preventing dirty water from entering the vacuum motor The ball float is the only means of protection to keep wate...

Page 23: ...m 23 Service Manual CA90 32T Component Locations Vacuum Motor Vacuum Switch Vacuum Solenoid Vacuum Circuit Breaker Ball Float Assembly Pick up Tube Adapter Vacuum pick up Hose Drain Hose Vacuum Motor...

Page 24: ...Recovery System 24 Service Manual Machine Name Vacuum Solenoid Vacuum Circuit Breaker Ball Float Assembly...

Page 25: ...Recovery System 25 Service Manual CA90 32T Vacuum pick up Hose Pick up Tube Adapter Drain Hose Connection at Recovery Tank Other end of Drain Hose with Stopper...

Page 26: ...sembly Adjust pick up tube adapter bracket The pick up tube adapter hole must align with the hole in the recovery tank The angle of the pick up tube adapter can be adjusted Remove the pick up vacuum h...

Page 27: ...2 screws that attach the plastic cover Remove the 2 screws that attach each carbon brush CAREFULLY slide out the carbon brush assembly If the carbon brush is less than 1 4 inch 6mm as measured from th...

Page 28: ...Recovery System 28 Service Manual CA90 32T...

Page 29: ...ions above in maintenance section Drain hose has leaks Replace drain hose assembly Squeegee Issues Squeegee angle not correct Adjust squeegee angle Squeegee not mounted properly Confirm that the squee...

Page 30: ...or wire connector NOTE There may be protective heat shrink covering the connector If so carefully cut the heat shrink away Remove the 3 10mm nylock nuts that hold the vacuum motor to the mounting stud...

Page 31: ...age to the vacuum motor can occur Re connect the vacuum motor connector NOTE If you have replacement heat shrink use it to cover the connection Specifications Shop Measurements Water lift measured at...

Page 32: ...sure using an electric actuator The actuator can be operated up or down anytime the machine power is ON The brush pressure can be monitored by the operator using the ammeter brush pressure meter on th...

Page 33: ...t Diagram Figure 1 Brush Circuit Actuator Motor Actuator Switch Key Switch B B Figure 2 Actuator Circuit Key Switch Trigger Switch Brush Switch Hour meter Brush Solenoid Brush Pressure Meter Circuit B...

Page 34: ...ent Locations Linear Actuator Brush motors Brush Deck Drive Plate Access Panel Drive Plate Assembly Brush Pressure Gauge Brush Circuit Breakers Brush Solenoid Brush Deck Drive Plate Access Panel Left...

Page 35: ...Scrub System 35 Service Manual CA90 32T Drive Plate Assembly Left Brush Circuit Breaker Right Brush Circuit Breaker Brush Pressure Gauge Actuator Switch...

Page 36: ...r best performance While the machine is in full operation Brushes turning solution flowing and moving forward use the Linear Actuator switch to adjust the Brush Pressure Gauge just into the white line...

Page 37: ...ties and dis connect the brush motor connectors Remove the 2 motor bolts Wiggle the motor back and forth to release the motor from the gearbox Place the motor on the floor upside down and slide a stra...

Page 38: ...brush and spring Lift the spring tab to slide the brush out of the holder Remove the screw that attaches the wire tab to the contact Remove the carbon brush Install new brushes in the reverse order I...

Page 39: ...ush connectors back together Re install the front shroud Troubleshooting Problem Causes Solution Neither brush Motor will run Defective Brush Switch Replace Brush switch Defective Trigger Switch Repla...

Page 40: ...s full up position using the actuator switch Turn the key to the OFF position and disconnect the batteries Remove the 13mm bolt that holds the drive plate assembly onto the brush motor shaft Slide th...

Page 41: ...ies and turn the key to ON Insure the speed control is set to minimum turn on the brush switch and pull the trigger to turn on the brush motor Make sure the brush is rotating in the correct direction...

Page 42: ...hairpin from the lower mounting pin and remove the lower mounting pin Carefully remove the actuator NOTE It is important to measure the length of exposed threads on the actuator and to keep the brush...

Page 43: ...pin Reconnect the actuator wires RED to wire 17 Black to wire 18 Wire tie all of the connectors so they cannot contact the linear actuator Re install the front cover Component Specifications electrica...

Page 44: ...n continues to a hose T and the solution is split between the Right and Left hose barbs located above the brush drive plates The solution valve is mechanically adjustable and the amount of solution fl...

Page 45: ...ervice Manual CA90 32T Component Locations Solution Tank Solution Shut off Valve Solution Filter Solution Valve solenoid Solution Flow Adjustment Knob Solution Switch Solution Tank Solution Shut off V...

Page 46: ...Solution System 46 Service Manual Machine Name Solution Valve Solution Switch Solution Flow Adjustment Knob...

Page 47: ...full 360 degree turns of adjustment from OFF to Maximum The solution flow adjustment knob allows only about 1 full turn of adjustment The factory setting is at the mid range of the solution valve Some...

Page 48: ...the right brush head Re fill the solution tank Solution leaks while machine is idle Solution filter gasket is defective Replace Filter gasket Solution solenoid diaphram is not seating properly when OF...

Page 49: ...which tab on the valve 12 Rotate the adjustment shaft of the new valve so that it is approximately in the same setting as the old valve 13 Insure the Jam nut on the valve is not tightened 14 Install...

Page 50: ...Down pressure on the squeegee is obtained by using a spring between the squeegee mount bracket and the machine chassis The squeegee assembly itself does not have any adjustments The squeegee mounting...

Page 51: ...Squeegee System 51 Service Manual Machine Name Squeegee Lift Handle Squeegee Bracket Assembly Squeegee Lift Cable Squeegee Bracket Tension Spring Squeegee Angle Adjust Knob...

Page 52: ...forward direction This deflection places the edge of the squeegee blade in the proper position for wiping the floor nearly dry Proper deflection is between 1 4 and 1 2 inch To adjust the angle of the...

Page 53: ...rrectly Check the cover and adjust replace as necessary Check the tank for leaks Restrictions due to build up of debris In the recovery tank In the vacuum hose In the squeegee assembly Check the recov...

Page 54: ...e controller at terminals B1 and B2 When all of the inputs are in the proper range the Curtis controller will output voltage to the M1 and M2 terminals and the transaxle motor will drive the transaxle...

Page 55: ...Wheel System Traction 55 Service Manual CA90 32T Transaxle Transaxle Motor MAIN Solenoid...

Page 56: ...Wheel System Traction 56 Service Manual CA90 32T Trigger Switch looking up through lower housing panel Forward Reverse Switch...

Page 57: ...Wheel System Traction 57 Service Manual CA90 32T Speed Control Potentiometer With knob attached Speed Control Potentiometer Assembly Curtis Speed Controller Mounted in control housing...

Page 58: ...DVM Drives by itself Defective Trigger Switch Replace Trigger Switch Removal and Installation Transaxle 1 Remove all water from the solution and recovery tanks 2 Choose a workspace where you can tip...

Page 59: ...and M2 wires on the Curtis Speed Controller Speed Control Potentiometer 1 Disconnect the batteries 2 Remove the 4 screws from the upper control housing panel dash board and the 4 screws from the lower...

Page 60: ...best to hold the nylock nut on top of the switch Reach up with a 1 phillips screwdriver to unscrew the screw Repeat this for the other nut and screw NOTE The 3 mm screws strip easily so be careful 5...

Page 61: ...the transaxle motor If you hear 2 clicks the Curtis controller is fine and the problem is upstream So one if the inputs is not correct Trigger switch Speed Pot Direction switch or wiring If you hear n...

Page 62: ...C Curtis Controller Pin 13 Any 42 volts DC Curtis Controller Pin 5 Key On Trigger On 37 volts DC Curtis Controller Pin 4 Trigger On with Speed pot at minimum 4 6 volts DC Trigger On with Speed pot at...

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