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Clarke CR 28 Boost, Service Manual

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ENGLISH

Service Manual - CR 28 

BOOST

®

 

TABLE OF CONTENTS

GENERAL INFORMATION ............................................................................................................................. 3

CONVENTIONS............................................................................................................................................................................... 3

MACHINE.LIFTING......................................................................................................................................................................... .3

MACHINE.TRANSPORTATION....................................................................................................................................................... .3

OTHER.AVAILABLE.MANUALS...................................................................................................................................................... .3

SAFETY........................................................................................................................................................................................... .4

SYMBOLS....................................................................................................................................................................................... .4

GENERAL.INSTRUCTIONS............................................................................................................................................................ .4

SYMBOLS.SHOWN.ON.THE.MACHINE.......................................................................................................................................... 5

TECHNICAL.DATA........................................................................................................................................................................... .6

MAINTENANCE  ............................................................................................................................................  7

SCHEDULED.MAINTENANCE....................................................................................................................................................... .7

SCHEDULED.MAINTENANCE.TABLE........................................................................................................................................... .7

MACHINE.NOMENCLATURE......................................................................................................................................................... .8

DETERGENT SUPPLY SYSTEM.................................................................................................................  2

SOLUTION.SYSTEM.AND.TANK.CLEANING............................................................................................................................... .12

SOLUTION.FILTER.CLEANING.................................................................................................................................................... .12

SOLUTION.SYSTEM.SOLENOID.VALVE/TAP/FILTER.DISASSEMBLY/ASSEMBLY.................................................................. .13

TROUBLESHOOTING................................................................................................................................................................... .15

BRUSHING SYSTEM  ..................................................................................................................................  6

BRUSH.CLEANING....................................................................................................................................................................... .16

SIDE.SKIRT.CHECK.AND.REPLACEMENT................................................................................................................................. .16

BRUSH.DECK.LIFTING/LOWERING.ACTUATOR.DISASSEMBLY/ASSEMBLY......................................................................... .17

TROUBLESHOOTING................................................................................................................................................................... .19

RECOVERY WATER SYSTEM  ...................................................................................................................  20

RECOVERY.WATER.TANK.AND.VACUUM.Screen.AUTOMATIC.SHUT-OFF.FLOAT.CLEANING............................................. .20

VACUUM.SYSTEM.MOTOR.FILTER.CLEANING......................................................................................................................... .21

VACUUM.SYSTEM.MOTOR.ELECTRICAL.INPUT.CHECK......................................................................................................... .21

VACUUM.SYSTEM.MOTOR.CARBON.BRUSH.CHECK.AND.REPLACEMENT......................................................................... .22

VACUUM.SYSTEM.MOTOR.DISASSEMBLY/ASSEMBLY........................................................................................................... .23

SQUEEGEE.CLEANING/CHECK.AND.BLADE.REPLACEMENT................................................................................................ .24

SQUEEGEE.LIFTING.CABLE.SLIDING.SHOE.LUBRICATION................................................................................................... .25

SQUEEGEE.LIFTING.ACTUATOR.DISASSEMBLY/ASSEMBLY................................................................................................. .26

SQUEEGEE.LIFTING.CABLE.DISASSEMBLY/ASSEMBLY......................................................................................................... .27

TROUBLESHOOTING................................................................................................................................................................... .28

PARKING BRAKE SYSTEM  .......................................................................................................................  29

PUSHING/TOWING.THE.MACHINE.............................................................................................................................................. 29

PARKING.BRAKE.CHECK............................................................................................................................................................ .29

ELECTROMAGNETIC.BRAKE.AND.DISC.WITH.BRAKING.MASSES.DISASSEMBLY/ASSEMBLY.......................................... .30

TROUBLESHOOTING................................................................................................................................................................... .32

DRIVE SYSTEM  ..........................................................................................................................................  33

DRIVING.WHEEL.COVER.DISASSEMBLY/ASSEMBLY.............................................................................................................. .33

DRIVE.SYSTEM.MOTOR.ELECTRICAL.INPUT.CHECK............................................................................................................. .33

DRIVE.SYSTEM.MOTOR.CARBON.BRUSH.CHECK.AND.REPLACEMENT.............................................................................. .36

DRIVE.SYSTEM.MOTOR.SLIDING.CONTACT.CHECK.AND.REPLACEMENT.......................................................................... .37

DRIVE.SYSTEM.MOTOR,.BEARING.AND.GASKET.DISASSEMBLY/ASSEMBLY..................................................................... .39

FORWARD.GEAR.PEDAL.DISASSEMBLY/ASSEMBLY.............................................................................................................. .42

FORWARD.GEAR.PEDAL.POTENTIOMETER.CHECK.AND.ADJUSTMENT.............................................................................. .43

SPEED.REDUCTION.SENSOR.CHECK/ADJUSTMENT............................................................................................................. .44

SPEED.REDUCTION.SENSOR.REPLACEMENT........................................................................................................................ .45

DRIVER’S.SEAT.SAFETY.MICROSWITCH.OPERATION.CHECK.............................................................................................. .47

DRIVER’S.SEAT.SAFETY.MICROSWITCH.REPLACEMENT...................................................................................................... .47

TROUBLESHOOTING................................................................................................................................................................... .48

Summary of Contents for CR 28 Boost

Page 1: ...Operator s Manual Libro de Instrucciones Manuel d utilisation READ THIS BOOK LEA ESTE MANUAL LISEZ CE MANUEL EN ES FR English 1 24 Espa ol Fran ais Form No 9097862000 05 2008 SERVICE MANUAL...

Page 2: ......

Page 3: ...STEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT 22 VACUUM SYSTEM MOTOR DISASSEMBLY ASSEMBLY 23 SQUEEGEE CLEANING CHECK AND BLADE REPLACEMENT 24 SQUEEGEE LIFTING CABLE SLIDING SHOE LUBRICATION 25 SQUEEGE...

Page 4: ...PROCEDURE 53 BATTERY MAINTENANCE AND RECHARGING 53 BATTERY DISASSEMBLY ASSEMBLY 53 BATTERY INSTALLATION AND BATTERY TYPE SETTING WET OR GEL 54 FUSE CHECK REPLACEMENT 55 DRIVE SYSTEM ELECTRONIC BOARD R...

Page 5: ...ll doors and cases are closed The ignition key is removed The machine is securely fastened to the means of transport OTHER AVAILABLE MANUALS The following manuals are available at Clarke Literature Se...

Page 6: ...produces highly explosive hydrogen gas Keep the tank assembly open during battery charging and perform this procedure in well ventilated areas and away from bare flames WARNING Carefully read all the...

Page 7: ...e electromagnetic brake After moving the machine by hand the electromagnetic brake must be engaged Do not use the machine when the electromagnetic brake is disengaged Do not remove or modify the ident...

Page 8: ...s2 Battery compartment size 24 V battery box 23 6 x 15 3 x 11 8 in 600 x 390 x 300 mm Four 6 V batteries Wet and maintenance free available Vacuum system capacity 70 9 in 1 800 mmH2 O Machine height...

Page 9: ...edures see the following paragraphs SCHEDULED MAINTENANCE TABLE Procedure Daily after machine use Weekly Every six months Yearly Squeegee cleaning Brush cleaning Cleaning of Tank and Vacuum screen and...

Page 10: ...itch Ignition key Steering wheel inclination control lever Steering wheel Drive pedal BOOST deck BOOST deck motor Side skirts Battery charger cable housing Battery charger cable Solution filter Recove...

Page 11: ...BOOST GENERAL INFORMATION MACHINE NOMENCLATURE continues 33 34 35 13 14 42 32 15 19 20 25 18 16 21 25 29 30 26 27 31 24 26 27 25 37 38 40 39 41 17 16 18 36 15 22 23 28 15 3 2 4 5 36 7 7c 7b 7a 8 11 1...

Page 12: ...ENGLISH 10 Service Manual CR 28 BOOST GENERAL INFORMATION MACHINE NOMENCLATURE continues S311219A S311220A...

Page 13: ...ENGLISH Service Manual CR 28 BOOST 11 GENERAL INFORMATION MACHINE NOMENCLATURE Continues S301319A...

Page 14: ...er Manual and keep it running until the solution tank is completely empty Remove the support rod 57 and close the cover 56 Clean the solution filter see the following procedure SOLUTION FILTER CLEANIN...

Page 15: ...ve the screws F Move the support G forward by disengaging the fastener H from the screw I Disconnect the hoses J and K from their fittings L Disconnect the hose M from the pressure switch N by pulling...

Page 16: ...ENGLISH 14 Service Manual CR 28 BOOST DETERGENT SUPPLY SYSTEM SOLUTION SYSTEM SOLENOID VALVE TAP FILTER DISASSEMBLY ASSEMBLY Continues S301321...

Page 17: ...is broken or there is an open in the electrical connection replace the solenoid valve repair the electrical connection There is debris in the solution tank clogging the output hole clean the tank Ther...

Page 18: ...rn the ignition key 12 to 0 On both sides of the machine lift and remove the side skirt assembly A from the holders B Wash and clean the side skirts Check that the side skirt lower edge C Lays down on...

Page 19: ...12 to 0 Carefully lift the tank assembly 60 to reach the batteries Disconnect the battery connector 63 Remove the deck see the procedure in the relevant paragraph Remove the nuts A then carefully rem...

Page 20: ...ENGLISH 18 Service Manual CR 28 BOOST BRUSHING SYSTEM BRUSH DECK LIFTING LOWERING ACTUATOR DISASSEMBLY ASSEMBLY Continues S301334...

Page 21: ...ectronic board is damaged replace The motor deck is shorted replace The motor carbon deck are worn replace The motor is faulty repair or replace The wiring harness is damaged repair THE BRUSH DECK CAN...

Page 22: ...the hose 22 If necessary release the fasteners A and open the screen B recover the float C clean all components and then reinstall them Check the tank cover gasket D for integrity NOTE The gasket D cr...

Page 23: ...the solution tank 59 with the tap 36 Drive the machine on a level floor Turn the ignition key 12 to 0 Carefully lift the tank assembly 60 Apply the amperometric pliers A on one cable B of the vacuum...

Page 24: ...s Disconnect the battery connector 63 Remove the cover A from the vacuum system motor B Remove the screws C Disconnect the electrical connections D Remove the carbon brushes E Check the carbon brushes...

Page 25: ...63 Disconnect the connector D from the vacuum system motor Remove the screws A then remove the recovery water tank B with the vacuum hose C Remove the screws E and recover the washer Remove the vacuu...

Page 26: ...ing procedure Disengage the fastener G and loosen the wing nuts H to adjust the rear blade D then tighten the wing nuts and engage the fastener Loosen the wing nuts I to adjust the front blade C then...

Page 27: ...cedure shown in the User Manual Remove the batteries and the battery case see the procedure in the Electrical System chapter Clean and lubricate the sliding shoe A of the squeegee lifting cable B with...

Page 28: ...attery case see the procedure in the Electrical System chapter Remove the retaining rings A and the pin B thus disconnecting the terminal C of the squeegee lifting cable D Remove the screw E Disconnec...

Page 29: ...Remove the screw E and recover the washer F Remove the guide G Carefully lower the tank assembly 59 Remove the nut and the locknut H then remove the lifting cable I from the squeegee assembly J Assem...

Page 30: ...activated because the recovery water tank is full empty the recovery water tank The screen is dirty clean The tank cover is not correctly positioned adjust The tank cover gasket is not efficient repla...

Page 31: ...unscrewed the electromagnetic brake is deactivated Do not use the machine with the electromagnetic brake deactivated It is safer to screw the screws B only for the time necessary to handle the machin...

Page 32: ...connector B Remove the screws C then remove the case D by disengaging the wiring harness grommet E Remove the screws F then remove the electromagnetic brake G Remove the disc with braking masses H Ch...

Page 33: ...ENGLISH Service Manual CR 28 BOOST 31 PARKING BRAKE SYSTEM ELECTROMAGNETIC BRAKE AND DISC WITH BRAKING MASSES DISASSEMBLY ASSEMBLY Continues N N M O L F F F G H I H K J J S301642...

Page 34: ...rake Machines after January 2007 The electromagnetic brake air gap is not properly adjusted adjust THE BRAKE DOES NOT DEACTIVATE WHEN PRESSING THE FORWARD REVERSE GEAR PEDAL Possible causes There is a...

Page 35: ...out 1 18 in 3 cm from the floor Lift the tank assembly 60 and disconnect the battery connector 63 Remove the wiring harness fastening clamp A Cut the fastening clamps B of the connector C Disconnect t...

Page 36: ...ENGLISH 34 Service Manual CR 28 BOOST DRIVE SYSTEM DRIVING WHEEL COVER DISASSEMBLY ASSEMBLY continues S T R T I I J P O P O Q N O O M M L L K G G H S S301644...

Page 37: ...touch the wheel Seat on the machine driver s seat 37 Turn the ignition key 12 to I Drive the machine at the maximum forward speed by pressing the pedal 15 and check that the electrical input is 10 15...

Page 38: ...60 Disconnect the battery connector 63 Remove the drive system motor carbon brush covers A bayonet joint Remove the gasket B and check them for integrity and efficiency if necessary replace them Remov...

Page 39: ...the screws A then remove the sliding contact cover B Disconnect the sliding contact connections C Remove the sliding contact mounting screws D and nuts E Recover the washer E Remove both sliding cont...

Page 40: ...ENGLISH 38 Service Manual CR 28 BOOST DRIVE SYSTEM DRIVE SYSTEM MOTOR SLIDING CONTACT CHECK AND REPLACEMENT continues D G F E D E G D G E H H S301648...

Page 41: ...ont wheel AG completely to the left Apply proper wedges to right and left rear wheels 43 so that the machine cannot move when the front wheel AG is lifted With the help of an assistant slightly lift t...

Page 42: ...holder assembly V If necessary remove the bearing W With a puller K remove the brush side bracket X If necessary remove the screws Z and the fasteners AA then remove the bearing Y if necessary use a p...

Page 43: ...ENGLISH Service Manual CR 28 BOOST 41 DRIVE SYSTEM DRIVE SYSTEM MOTOR BEARING AND GASKET DISASSEMBLY ASSEMBLY Continues J P O P O Q N O O M M L K I I L AF X Y Z AA AC AB AE AD W V U U R T S S301650...

Page 44: ...ISASSEMBLY ASSEMBLY Disassembly Drive the machine on a level floor Engage the parking brake Remove the pedal mounting screws A Slightly lift the pedal B and disconnect the connector C Assembly Assembl...

Page 45: ...n B Apply a tester on the connector centre contact C and on the side contact D then check that the resistance is 0 100 Ohm when the pedal is released If necessary reset the resistance correct value by...

Page 46: ...ition If necessary adjust the speed reduction sensor according to the following procedure Adjustment Place the machine on a hoisting system if available Otherwise drive the machine on a level floor Tu...

Page 47: ...B of the foot board C Lift the foot board D and remove the sensor cable E through the passage F Remove the nuts G then remove the speed reduction sensor H with the cable Assembly Assemble the componen...

Page 48: ...ENGLISH 46 Service Manual CR 28 BOOST DRIVE SYSTEM SPEED REDUCTION SENSOR REPLACEMENT continues S301353...

Page 49: ...rding to the following procedure Check for driver s seat microswitch proper operation otherwise replace it according to the following procedure If necessary check the driver s seat microswitch wiring...

Page 50: ...entiometer is misadjusted or broken adjust or replace The speed adjuster is broken replace The drive system electronic board is faulty replace The wiring harness is damaged check all connections insid...

Page 51: ...function replace the electronic board 2 3 Faulty main contact replace the electronic board 2 4 Faulty main contact ON function replace the electronic board 3 1 Forward reverse gear pedal pressed when...

Page 52: ...ry water tank 58 with the hose 22 Empty the solution tank 59 with the tap 36 Drive the machine on a level floor Turn the ignition key 12 to 0 Carefully lift the tank assembly 60 Check Tightening of mo...

Page 53: ...the cover is press fitted Remove the steering wheel nut B and recover the washer C Remove the steering wheel D Remove the clamp E Remove the screws F and slightly lift the control panel G with care Di...

Page 54: ...ENGLISH 52 Service Manual CR 28 BOOST OTHER SYSTEMS FRONT FAIRING DISASSEMBLY ASSEMBLY continues S301356...

Page 55: ...se the switch C 5 times within 5 seconds The hour counter is reset B A C S301356C BATTERY MAINTENANCE AND RECHARGING See the User Manual BATTERY DISASSEMBLY ASSEMBLY Disassembly Drive the machine to t...

Page 56: ...set to GEL compatible with AGM If the red warning light 7c is flashing the machine is set to WET To change the settings proceed as follows Turn off the machine by turning the ignition key 12 to 0 Pres...

Page 57: ...e the following fuse Drive system electronic board protection fuse F2 60 A 96 Carefully move the electronic component panel 100 and check replace the following fuses Low power circuit protection fuse...

Page 58: ...the machine on a level floor Turn the ignition key 12 to 0 Carefully lift the tank assembly 60 Disconnect the battery connector 63 Remove the nuts 93 then remove the cover 92 Slightly move the electr...

Page 59: ...on a level floor Turn the ignition key 12 to 0 Carefully lift the tank assembly 60 Disconnect the battery connector 63 Remove the nuts 93 then remove the cover 92 Slightly move the electrical componen...

Page 60: ...e tap 36 Drive the machine on a level floor Turn the ignition key 12 to 0 Carefully lift the tank assembly 60 Disconnect the battery connector 63 Remove the mounting screws then slightly lift the cont...

Page 61: ...ON ELECTRONIC BOARD ERROR CODES On the function electronic board there are the following warning LEDs Red LED upper 101 Green LED 102 Red LED lower 103 Under normal conditions ignition key turned to I...

Page 62: ...ignition key 2 flashes Deck actuator CC1 lowering overcurrent Short circuit in deck actuator cable check or faulty deck actuator replace or faulty function electronic board replace Deck actuator By sw...

Page 63: ...ignition key 11 flashes Ignition key turned to 0 False contact from ignition key circuit check connections of dashboard function electronic board ignition switch emergency push button and battery char...

Page 64: ...on switch LED power supply Indef 0 V Out 8 Vacuum system on off switch LED power supply Indef 0 V Out 9 Battery GREEN LED power supply Indef 0 V Out 10 Battery YELLOW LED power supply Indef 0 V Out 11...

Page 65: ...In 7 Drive system inhibition output Indef 0 V Out 8 Horn output Indef 0 V Out J4 PIN Description Reference voltage Electronic board in out 1 Deck jack power supply Indef Out 2 Deck jack power supply I...

Page 66: ...valve F1 Function electronic board fuse F2 Drive system electronic board fuse F3 Low power circuit fuse F4 Pump fuse optional K1 Ignition switch LD1 Drive system electronic board diagnostic LED M1 Le...

Page 67: ...ENGLISH Service Manual CR 28 BOOST 65 ELECTRICAL SYSTEM COMPONENT LAYOUT continues SW0 K1 SW6 EB3 2 F4 EB3 RV2 M5 SW5 BE SW4 BRK S301651C...

Page 68: ...ENGLISH 66 Service Manual CR 28 BOOST ELECTRICAL SYSTEM COMPONENT LAYOUT continues S301362C...

Page 69: ...electronic board fuse F3 Low power circuit fuse F4 Pump fuse optional K1 Ignition switch LD1 Drive system electronic board diagnostic LED M1 Left brush motor M2 Right brush motor if equipped M3 Vacuu...

Page 70: ...ENGLISH 68 Service Manual CR 28 BOOST ELECTRICAL SYSTEM WIRING SYSTEM continues S311379A...

Page 71: ...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...

Page 72: ...lled to the proper level with DISTILLED WATER Clarke POLYDUR AUTOMATIC SCRUBBER SOLUTION AND RECOVERY TANK EIGHT YEAR U S GUARANTEE Your new Clarke machine has polydur Solution and Recovery Tanks Poly...

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