Clarke CA60 20B User manual

CA60 20B/CA60 24B CA60 20D/CA60 20TD
SERVICE MANUAL
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 this manual, have it explained fully before
attempting to operate this machine.
All directions given in this book are as seen from the operator’s position at the rear of the machine.

Service Manual-CA60 Table of Contents
Table of Contents
SERVICE MANUAL.......................................................................................................................................................1
Table of Contents........................................................................................................................................................2
03 General Information..............................................................................................................................................2
Machine General Description.................................................................................................................................2
Service Manual Purpose and Field of Application..................................................................................................2
Other Reference Manuals ......................................................................................................................................2
Conventions............................................................................................................................................................2
Service and Spare Parts ..........................................................................................................................................3
Serial Number Label ...............................................................................................................................................3
Safety......................................................................................................................................................................4
General Safety Instructions ....................................................................................................................................4
Machine Lifting.......................................................................................................................................................5
Transporting The Machine .....................................................................................................................................5
Technical Data ........................................................................................................................................................6
Maintenance Schedule...........................................................................................................................................8
Machine Nomenclature (machine structure).........................................................................................................9
Machine Nomenclature (control panel).............................................................................................................. 10
Service and Diagnostic Equipment ...................................................................................................................... 11
Dimensions (Continues) ...................................................................................................................................... 12
04 Control System ................................................................................................................................................... 15
Functional Description......................................................................................................................................... 15
Component LocationsFunction electronic board (E1) (CA60 20B/24B) .............................................................. 16
Troubleshooting .................................................................................................................................................. 18
Control Panel Removal and Installation.............................................................................................................. 19
Handlebar and drive switches disassembly/assembly (ES3)............................................................................... 20
10 Chassis System.................................................................................................................................................... 21
Chassis(main parts).............................................................................................................................................. 21
14 Wheel System, Traction...................................................................................................................................... 22
Functional Description......................................................................................................................................... 22
Component Locations.......................................................................................................................................... 24
Troubleshooting .................................................................................................................................................. 26

Service Manual-CA60 Table of Contents
Removal and Installation..................................................................................................................................... 27
Specifications....................................................................................................................................................... 32
24 Electrical System................................................................................................................................................. 33
Functional Description......................................................................................................................................... 33
Component LocationsBattery Charger (CH1) ...................................................................................................... 35
Removal and Installation..................................................................................................................................... 39
30 Solution System .................................................................................................................................................. 43
Functional Description......................................................................................................................................... 43
Component Locations.......................................................................................................................................... 45
Maintenance and Adjustment............................................................................................................................. 46
Troubleshooting .................................................................................................................................................. 47
Removal and Installation..................................................................................................................................... 48
Specifications....................................................................................................................................................... 49
34 Scrub System, Disc (CA60 20D/20TD)................................................................................................................. 50
Functional Description......................................................................................................................................... 50
Component Locations.......................................................................................................................................... 51
Troubleshooting .................................................................................................................................................. 53
Removal and Installation..................................................................................................................................... 54
Specifications....................................................................................................................................................... 59
34 Scrub System, REV(CA60 20B/24B) .................................................................................................................... 60
Functional Description......................................................................................................................................... 60
Component Locations.......................................................................................................................................... 62
Troubleshooting .................................................................................................................................................. 64
Actuator Disassembly/Assembly ......................................................................................................................... 65
Maintenance and Adjustment............................................................................................................................. 66
Troubleshooting .................................................................................................................................................. 67
Orbital deck Disassembly/Assembly.................................................................................................................... 68
Checking/Replacing REV Motor Carbon Brushes ................................................................................................ 71
Specifications....................................................................................................................................................... 72
38 Squeegee System................................................................................................................................................ 73
Functional Description......................................................................................................................................... 73
Component Locations.......................................................................................................................................... 74
Troubleshooting .................................................................................................................................................. 75

Service Manual-CA60 Table of Contents
Maintenance and Adjustment............................................................................................................................. 76
Removal and Installation..................................................................................................................................... 80
Specifications....................................................................................................................................................... 81
40 Recovery System................................................................................................................................................. 82
Functional Description......................................................................................................................................... 82
Component Locations.......................................................................................................................................... 83
Maintenance and Adjustment............................................................................................................................. 84
Troubleshooting .................................................................................................................................................. 85
Removal and Installation..................................................................................................................................... 86
Specifications....................................................................................................................................................... 88

Service Manual-CA60 03 General Information 2
03 General Information
Machine General Description
The CA60 is a walk-behind commercial floor scrubbing machine designed to wash and dry commercial floors. The machine is
powered by on-board batteries. The machine is equipped with a single-disc scrubbing pad, a controlled solution flow dosing
system, and a rear squeegee with vacuum suction. The machine also has an on-board solution tank and wastewater recovery
tank. This machine is not to be used outdoors, on carpets, or on coarse floors.
Service Manual Purpose and Field of Application
This Service Manual is a technical resource intended to aid service personnel in maintaining and repairing the CA60 to
ensure optimum performance and long service life. Please read this manual carefully before performing any
maintenance and repair procedure on the machine.
Other Reference Manuals
Document name
Document number Document type
CA60 20B/ CA60 24B/ CA60 20D/ CA60 20TD, Instructions for Use
VS13039
Instructions for Use
These manuals are available at:
–Local Clarke Retailer
–https://www.clarkeus.com/
Conventions
Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in driving
position.

Service Manual-CA60 03 General Information 3
Service and Spare Parts
Service and repairs must be performed only by authorized personnel or Service Centers. The authorized
personnel is trained directly at the manufacturer’s premises and has original spare parts and accessories.
Contact Retailer indicated below for service or to order spare parts and accessories, specifying the ma-chine
model and serial number.
(Apply Retailer label here)
Serial Number Label
The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This
information is needed when ordering repair parts for the machine. Use the space below to note the Model
Number and Serial Number of your machine for future reference.
MODEL NUMBER
SERIAL NUMBER
Figure 1

Service Manual-CA60 03 General Information 4
Safety
Symbols
It is important for you to read and understand this manual. The information it contains relates to protecting
your safety and preventing problems. The symbols below are used to help you recognize this information.
Warning: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury
Caution: Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury.
Caution: When used without the Safety Alert Symbol, indicates a potential situation which,
if not avoided, could result in property or machine damage.
Nota: Indicates an important informational message.
General Safety Instructions
These safety instructions are included to warn you of potential bodily injury or property damage.
Caution! Read and understand all safety warnings and instructions. Failure to follow the
warnings and instructions may result in electric shock, fire, and/or serious injury.
–To avoid personal injury, this machine should be used only by properly trained
and authorized persons.
–Do not operate the machine near toxic, dangerous, flammable and/or explosive
materials. This machine is not suitable for collecting dangerous or hazardous
materials.
–In case of fire, use a powder fire extinguisher, not a water-based extinguisher.
–Do not use on surfaces having a gradient exceeding that marked on the machine.
While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp
turns.
–Disconnect the power source and/or batteries before servicing electrical
components
–Never work under a machine without safety blocks or stands to support the
machine.
–Do not dispense flammable cleaning agents, operate the machine on or near
these agents, or operate in areas where flammable liquids exist.
–When using floor cleaning detergents, follow all safety and handling instructions
of the respective manufacturer.
–Battery charging may produce highly explosive hydrogen gas. Charge the
batteries only in well-ventilated areas and away from ignition sources or open
flames.
–When operating this machine, ensure that third parties, particularly children, are
not endangered.
–Take precautions to prevent hair, jewelry, or loose clothing from becoming caught
in moving parts.

Service Manual-CA60 03 General Information 5
Caution!
Before transporting the machine on an open truck or trailer, make sure that . . .
–
–
–
–
All covers are closed
The recovery tank and detergent tank are empty
Batteries (if so equipped) are disconnected
The machine is securely fastened in place on the transport.
Property Damage Messages
–Storage and operation temperature must be above 0°C and a humidity between
30% and 95%, non-condensing.
–Before use, all doors and hoods should be properly latched.
–This machine is not approved for use on public paths or roads.
–This machine is only approved for hard surface use.
–Use brushes and pads supplied with the machine or those specified in the User
Manual. Using other brushes or pads could reduce safety.
–Do not wash the machine with direct or pressurised water jets, or with corrosive
substances.
–Do not allow the brush/pad to operate while the machine is stationary to avoid
damaging the floor.
–Use only factory authorized parts and accessories.
–This machine must be properly disposed of in accordance with local laws and
regulations.
Machine Lifting
Caution! Never work under a machine without safety stands or blocks to support the
machine.
Transporting The Machine

Service Manual-CA60 03 General Information 6
Technical Data
MODEL
Units
CA60 24B
CA60 20B
CA60 20D
CA60 20TD
Packing
dimensions (Lx W
x H)
mm/Inches
(1370x700x1300m
m)/(54x28x52
Inches)
（1370x600x1300mm)/
(54x24x52 Inches)
Machine height
mm/Inches
1080mm/42.5 Inches
Machine length
mm/Inches
1260mm/50 Inches
Machine width
(without
squeegee)
mm/Inches
650mm/26 Inches
550mm/22 Inches
Machine weight
with empty tanks
(without batteries)
Kg/Lbs.
124 Kg/273Lbs.
122 Kg/268Lbs.
91 Kg/200Lbs.
97 Kg/213Lbs.
Gross vehicle
weight (GVW)
Kg/Lbs.
243 Kg/535Lbs.
241 Kg/530Lbs.
208 Kg/458Lbs.
214 Kg/471Lbs.
Shipping weight
Kg/Lbs.
170 Kg/374Lbs.
154 Kg/339Lbs.
121 Kg/266Lbs.
127 Kg/280Lbs.
Solution tank
capacity
L / Gal
61 L / 16 Gal.
Recovery tank
capacity
L / Gal
61 L / 16 Gal.
Vacuum motor
power
Watt / HP
350 W / 0.47 HP
Vacuum capacity
mm/In of H2O
1200 mm / 47.2 Inches H2O
Climbing capacity
(Max)
% grade
2%
Front wheel
diameter
mm/Inches
200 mm / 8 Inches
Rear wheel
diameter
mm/Inches
76 mm / 3 Inches
Sound level
dB (A)
69 +/- 3 dB (A)
Solution/
Flow(Max)
L / Gal per minute
(0.4/0.8/1.4/2.2) Liters
(0.11/0.21/0.37/0.6) Gallons
(0.7/1.2/1.7/2.2) Liters
(0.2/0.3/0.45/0.6) Gallons
Working width
mm/Inches
610mm/24 Inches
510 mm / 20
Inches
530mm/21 Inches
Squeegee width
mm/Inches
760mm/30 Inches
Brush/pad
diameter
mm/Inches
(610x360mm)
(24x14 Inches)
(510x360mm)
(20x14 Inches)
(530mm/21Inches)/(508mm/20Inche
s)
Brush motor
power
Watt / HP
750 Watt / 1.0 HP
450 Watt / 0.6 HP
Brush speed
Rpm
2200
150
Brush/pad
pressure(Max)
Kg/Lbs.
40 - 50 Kg / 88 - 110 Lbs.
27 Kg /60 Lbs.
23 Kg /51 Lbs.
Drive motor
power
Watt / HP
250 W / 0.33 HP
/
150 W / 0.2 HP
Working speed
Km / Miles per
hour
0-3.2 Km / 0 - 2 Miles per hour
/
0 - 4.0 Km / 0 - 2.5
Miles per hour
Forward speed
Km / Miles per
hour
0 - 4.0 Km / 0 - 2.5 Miles per hour
/
0 - 4.0 Km / 0 - 2.5
Miles per hour
Reverse speed
Km / Miles per
hour
0 - 2.0 Km / 0 - 1.25 miles per hour
/
0 - 2.0 Km / 0 -
1.25 miles per
hour

Service Manual-CA60 03 General Information 7
Handle Vibration
Level(Max)
m/S²
2.5
2.5
Voltage
Volts
24 Volts
Battery(Optional)
Amp/hour
105/130 WET, 105/140 AGM C20
Battery charger
Volts/Amps
24 Volt/13 Amp
Battery
compartment size
(L x W x H)
mm/Inches
(350 x 350 x 300) mm / 13.8 x 13.8 x 11.8) Inches

Service Manual-CA60 03 General Information 8
Maintenance Schedule
Procedure
Daily, after use
Weekly/ Monthly
Every 6 Months
Annually
Charge Battery
X
Clean squeegee blades
X
Inspect pad/brush
X
Clean solution and recovery tanks
X
Inspect recovery tank seal
X
Inspect squeegee blades for damage
X
Clean the solution filter
X
Inspect for loose fasteners and electrical connections
X1
Inspect/replace scrub motor brushes (battery model)
X
1 Also perform this inspection after the initial 10 hours of new machine usage.

Service Manual-CA60 03 General Information 9
24
23
22
21
20
Machine Nomenclature (machine structure)
1.
Recovery tank lid
20. Brush/pad-holder
2.
Can holder
21. Brush/pad-holder deck
3.
Handlebar
22. Recovery water drain hose
4.
Control panel
23. Solution tank
5.
Squeegee lifting/lowering lever
24. Hinge
6.
Garden coupling
25. Recovery tank
7.
Power supply cable holder
26. Filter support
8.
Power cable
27. Filler hose holder
9.
Solution drain and level check hose
28. Filter cover
10.
Deck lifting/lowering pedal(only for disc machine)
29. Baseboard cleaner(*)
a) Pedal position when deck is lifted
30. Tank cover gasket
b) Pedal position when deck is lowered
31. Debris collection box
11.
Squeegee knobs
32. Splash guard 510mm
12.
Serial number plate/technical data
33. Float ball filter
13.
Squeegee vacuum hose
34. Mop and trash kit (*)
14.
Squeegee
35. Solenoid valve
15.
Squeegee balance adjusting knob
16.
Solution/clean water tap
(*): Optional
17.
Rear steering wheels
(A): Only for disc machine without traction
18.
Solution filter
(B): Only for disc machine with traction
19.
Front wheels on fixed axle (A).
Driving wheels (B)
1 2 3
30
31
28
25 5
6 27
7 26
8
9 33
10
10b
34
10a
19
35
18 17 16 15 11 14 13
12 11
29 32
Figure 2
4

Service Manual-CA60 03 General Information 10
45
Machine Nomenclature (control panel)
36. Machine backward switch (B)
37. Tank safety cable
38. Battery connector (red).
39. Detergent tank filler plug (**)
40. Detergent tank (**)
41. Reference table for detergent proportioning (**)
42. Detergent pump (**)
43. Detergent tank - pump connecting hose (**)
44. Detergent feed hose (**)
45. Batteries
46. Battery caps
47. Flow increase switch
48. Flow decrease switch
49. Solution flow indicator
50. Safe switch
51. Discharged battery warning light (red)
52. Semi-discharged battery warning light (yellow)
53. Charged battery warning light (green)
54. Ignition key (0 - I)
55. Detergent flow control knob (**)
36
56. Speed adjuster (B)
57. Hour meter
58. • Brush/pad-holder release switch(only for disc
machine)
•Extra pressure active(only for orbital machine)
59. Vacuum system switch
60. • Brush/pad-holder and vacuum system
switch(only for disc machine)
• Pad deck moving up/down and Brush/pad-
holder and vacuum system switch(only for orbital
machine)
61. Charging red LED
62. Charging yellow LED
63. Charging green LED
64. Security cover of charging jack
65. Overload protector of brush/pad
66. Overload protector of traction (B)
67. Overload protector of vacuum
(*): Optional
(**): Only for machines with Chemical Mixing
System (optional)
(A): Only for machine without traction
(B): Only for machine with traction
50 51 52 53 50
37
38
49
48
39
47
40
41
42
43
44 46
54
55
56
60 59 58 57
61 62 63
VACUUM TRACTION BRUSH
67 66 65 64
Figure 3

Service Manual-CA60 03 General Information 11
Service and Diagnostic Equipment
Besides a complete set of standard meters, the following instruments are necessary to perform fast checks and
repairs on machines:
Laptop computer charged with the current version of EzParts, Adobe Reader and (if possible) Internet con-
nection
• Digital Volt Meter (DVM)
• Amp clamp with possibility of making DC measurements
• Battery charge tester to check 12 V batteries
• Dynamometric wrench set
• A copy of the User Manual and Spare Parts List of the machine to be serviced.

Service Manual-CA60 03 General Information 12
Dimensions (Continues)
CA60 20D/CA60 20TD
Figure 4

Service Manual-CA60 03 General Information 13
Dimensions (Continues)
CA60 20B
Figure 5

Service Manual-CA60 03 General Information 14
Dimensions (Continues)
CA60 24B
Figure 6

Service Manual-CA60 04 Control System 15
04 Control System
Functional Description
The machine utilizes a main control board (E1) to turn on various machine functions and a speed controller (E2) to control
traction speed. The E1 Main control board receives operator press button inputs, and activates various components.
Brush motor (M1)
Vacuum motor (M2)
Release brush (Only for CA60 20D and CA6020TD)
Solution flow solenoid valve (EV1)
Deck actuator (Only for CA60 20B / 24B)
Detergent pump (Option M4)
Battery type setting
The main control board (E1) also shows the battery capacity by 3 LEDs, show the running time by LED digital display
.The main control E1 can display the error message”LO-18”,if the battery voltage falls below 18 volts, and will display
“Charg”when battery charger plug in , and so on. The system is completed by the on-board battery charger which also
uses a proprietary serial protocol to communicate with the Main Control Board (E1), In order to set the battery type.
Functional Block Diagram
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
D D
C C
B B
A A
CA60 Functional Block Diagram
M1
M2
E2 Curtis 1210(*1)
B+
B-
B+
B- M
M3
Traction Motor
+
-
Speed Mode(*2)
Battery
24V
Battery Charger
CH1 Power +
Data COM
Charger In Signal
E1 Main Control Board
Brush Motor M1
Vacuum Motor M2
Detergent Pump(Option) M4
Solution Valve EV1
Brush Actuator(*3) M5
Reverse
Inhibit Potentiometer(*1)
Pot High
Pot Low
Pot Wiper
NO
Brush Enable Button
Vacuum Enable Button
Solution EnableButton
(*5)Bush Release Button
(*6)Brush Actuator Position Selection
Brush Active Swtich
(*1) Only for CA60 20B/CA60 24B/CA60 20TD.
(*2) Only for CA60 20B/CA60 24B.
(*3) Only for CA60 20B/CA60 24B.
(*4) Only for CA60 20B/CA60 24B/CA60 20TD.
(*5) Only for CA60 20D/CA60 20TD.
(*6) Only for CA60 20B/CA60 24B.
(*4)Reverse Switch
Key Switch
(Option)Detergent Flow Control Knob
Battery Discharge Indicator(3 LEDs)
Hour Meter/Message Display
Figure 1

Service Manual-CA60 04 Control System 16
Component LocationsFunction electronic board (E1) (CA60 20B/24B)
• Signal circuit fuse 5A(F1) (CA60 20B/24B)
• Brush actuator fuse 5A(F3) (CA60 20B/24B)
• Battery capacity LEDs
• LED digital display
• Key switch
Battery Capacity LEDS
LED digital display
Key switch
Function electronic board(E1) (CA60 20B/24B)
Brush actuator fuse 5A(F3) (CA60
20B/24B)
Signal circuit fuse 5A(F1) (CA60
20B/24B)
Figure 2
Figure 3

Service Manual-CA60 04 Control System 17
Component Locations(Continues)
Function electronic board (E1) (CA60 20D/20TD)
Signal circuit fuse 5A(F1) (CA60 20D/20TD)
Brush release fuse 20A(F3) (CA60 20D/20TD)
Brush release fuse 20A(F3) (CA60 20D/20TD)
Function electronic board (E1) (CA60 20D/20TD)
Signal circuit fuse 5A(F1) (CA60 20D/20TD)
Figure 4