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