Clarke CA60 20B, Service Manual

Page 1: ...ce 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 m...

Page 2: ...e 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 Contro...

Page 3: ...8 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...

Page 4: ...intenance 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 Remova...

Page 5: ...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...

Page 6: ...ontact 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 S...

Page 7: ...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 dangero...

Page 8: ...e 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 b...

Page 9: ...m 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 minut...

Page 10: ...andle Vibration Level Max m S 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 Inche...

Page 11: ...queegee 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 e...

Page 12: ...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 g...

Page 13: ...ent 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...

Page 14: ...m 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...

Page 15: ...Service Manual CA60 03 General Information 12 Dimensions Continues CA60 20D CA60 20TD Figure 4...

Page 16: ...Service Manual CA60 03 General Information 13 Dimensions Continues CA60 20B Figure 5...

Page 17: ...Service Manual CA60 03 General Information 14 Dimensions Continues CA60 24B Figure 6...

Page 18: ...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...

Page 19: ...cuit 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...

Page 20: ...ntinues 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...

Page 21: ...ies faulty Check the battery no load voltage Battery charger faulty Replace The fuses F1 F2 F3 are open Replace The wiring harness is cut or pressed or short circuited Repair Control electronic board...

Page 22: ...rn the recovery tank sideways then disconnect the battery connector 5 Unscrew the screws A and carefully move the control panel B 6 Disconnect the electrical connections C from the control electronic...

Page 23: ...ch then remove the handlebar G from its seat 9 If necessary proceed as follows to remove the drive switches H Unscrew the screws I and detach the switch assembly Unscrew the inner screws J and remove...

Page 24: ...ual CA60 10 Chassis System 21 10 Chassis System Chassis main parts The chassis installed in the solution tank The chassis is not the same for orbital machine Figure 1 and disc machine Figure 2 Figure...

Page 25: ...a variable voltage input which is dependent on the speed pot position and serves as an input request for the drive wheel controller to propel the machine A higher voltage input is a request for more...

Page 26: ...tive J1 5 J1 4 J1 10 J1 1 1 2 3 4 5 6 7 Traction System Wiring Diagram Only For CA60 20B 24B E1 Main Control Board Power Supply B Power Supply J1 18 J1 13 J1 3 J1 4 J1 17 J1 5 F3 Circuit Breaker 12A B...

Page 27: ...R2 Handle switches Reverse switch Traction motor controller curtis 1210 E2 Traction Relay K3 Traction circuit breaker F3 Handle switches Reverse switch Speed potentiometer VR2 Figure 3 Figure 4 Tracti...

Page 28: ...Service Manual CA60 14 Wheel System 25 Component Locations Continues Traction motor M3 Rear pivoting wheel Driving wheel Driving wheels Traction motor M3 Rear pivoting wheel Figure 5...

Page 29: ...ace The machine has been started using the ignition key keeping one of the switches pressed Turn the ignition key to 0 then restart the machine without pressing the switches Drive is weak or non exist...

Page 30: ...that the motor power draw is around 15 A at 24 V Repeat the test driving at least two different directions across the floor to compensate for any unevenness Stop the machine Turn the ignition key to...

Page 31: ...Drain the recovery tank 2 Drain the clean water tank 3 Remove the brush 4 Remove the squeegee 5 Remove the machine s batteries 6 Remove the rear panel see the procedure in the relevant paragraph 7 Dis...

Page 32: ...turn the machine over sideways and rest its right hand side on the box positioned on the floor 9 Remove the wheels assembly with drive motor D fastening screws C 10 Move the wheels assembly with drive...

Page 33: ...the same size as the machine s side With the assistance of a second person turn the machine over sideways and rest its right hand side on the box positioned on the floor 7 Unscrew the screws A inside...

Page 34: ...e the procedure in the relevant paragraph 2 Unscrew the screws A inside the two wheels 3 Remove the outer cover B of the wheels 4 Unscrew the screws C and remove the wheels D 5 Remove the drive motor...

Page 35: ...B Driving wheel diameter 8 in 202mm Rear wheel diameter 3 in 76 2mm Electric wheel drive unit technical data Power 150W 250W Voltage 24V Transmission ratio 16 1 Protection class IP44 insulation class...

Page 36: ...trol panel can display the current charging status to the operator The battery charger and main control board communicate through a dedicated wire This communication connection allows the battery char...

Page 37: ...sing button A After the battery mode setting is completed turn off the power D and the new setting of battery mode can be saved automatically 3 The battery type setting is completed Note Regarding the...

Page 38: ...ection J1 Battery Connector C1 Brush Circuit Breaker F1 Vacuum Circuit Breaker F2 Traction Circuit Breaker F3 only for CA60 20B 24B 20TD Batteries BAT1 Battery Connector C1 Battery Charger CH1 4 way s...

Page 39: ...um Motor 5V YEL RED BLK RED RD BK RED YEL GRN BLK BU BK BN BK RED BRN OPTION WHI BU BK BU BK WHI WHI ORA GRN RED RED RED BLK BLK BLK BLK RD BK RED RED BLK BLK BLK RED RED BLK BLU WHI M M4 Detergent Pu...

Page 40: ...Active Charger IN COM K2 F2 Circuit Breaker 30A OPTION M M2 Vacuum Motor 5V YEL RED BLK RED RD BK RED YEL GRN BLK BU BK BN BK RED BRN OPTION WHI GN BK BU BK GN BK WHI WHI ORA GRN RED RED RED BLK BLK B...

Page 41: ...TION M M2 Vacuum Motor 5V YEL RED BLK RED RD BK RED YEL GRN BU BK BN BK RED BRN OPTION RED BLK BLK RD BK RED RED BLK BLK RED BLK BLU WHI M M4 Detergent Pump Detergent ADJ BRN BRN BLU BLU WHI WHI WHI C...

Page 42: ...nector 5 Lower the squeegee A with the lever B 6 Disconnect and lower the recovery water drain hose C 7 Unscrew and remove the caps D of the thermal fuses 8 Lift the cover E and unscrew the electrical...

Page 43: ...nel see the procedure in the relevant paragraph 2 Disconnect the electrical connections A on the drive system electronic board B then move the wiring out of the way 3 Unscrew the two screws C and remo...

Page 44: ...nect the battery connector C 7 Remove the rear panel see the procedure in the relevant paragraph 8 Unscrew the fastening screws D for the battery charger E then move it 9 Disconnect the battery charge...

Page 45: ...tection of the control electronic board D fuse F3 rated 20 A for protection of the brush motor 7 Perform steps 4 and 5 in reverse order A B A D C Fuses on control panel F2 F4 F5 1 Remove the rear pane...

Page 46: ...the brush deck The quantity of detergent is defined by the operator via the knob on the Main Control Board E1 Located centrally below the tank there is also a hole for draining any liquid in the batt...

Page 47: ...44 Wiring Diagram CA60 20D 20TD 3 4 5 6 olution System Wiring Diagram 20D 20TD E1 Main Control Board B B Power Supply J2 5 24V J2 1 J2 2 24V J2 6 OPTION M M4 Detergent Pump C11a C10a C11b C10b EV1 So...

Page 48: ...Service Manual CA60 30 Solution System 45 Component Locations Solution valve EV1 Detergent pump M4 EcoFlex detergent tank Detergent pump M4 EcoFlex detergent tank Solution valve EV1 Figure 3 Figure 4...

Page 49: ...d 3 Close the solution tap A Figure 5 under the machine behind the right rear wheel The tap A is closed when it is on the position B and it is open when it is on the position C 4 Remove the transparen...

Page 50: ...r electrical connection broken Replace the solenoid valve or repair the electrical connection There is dust debris in the tank or in the detergent hoses obstructing the solution flo Clean the tank hos...

Page 51: ...paragraph 2 Loosen the clamps A and disconnect the hoses B from the solenoid valve C 3 Unscrew the screws D and move the solenoid valve C 4 Cut the wiring retaining clamp E 5 Cut the heat shrink tubin...

Page 52: ...ions Description model CA60 20D CA60 20TD CA60 20B CA60 24B Solution tank capacity 61 L 61 L Solution flow values 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...

Page 53: ...ircuit breaker F1 turn the machine on To work properly the brush motor M1 needs the fol lowing Brush function on One of the two handle switches is pressed Battery level not in critical condition with...

Page 54: ...stem DISC CA60 20D 20TD 51 Component Locations Brush motor M1 Disc brush deck Brush Brush contractor Brush circuit breaker 30A F1 Brush motor M1 Disc brush deck Brush Brush circuit breaker 30A F1 Brus...

Page 55: ...Service Manual CA60 34 Scrub System DISC CA60 20D 20TD 52 Component Locations continues Brush release relay K1 Brush release fuse 20A F3 Brush release fuse 20A F3 Brush release relay K1 Figure 4...

Page 56: ...e brush does not turn The batteries are discharged Charge them The motor carbon brushes are worn Replace The motor is faulty Check the motor amperage replace the motor There are ropes or debris restra...

Page 57: ...hat the motor power draw is around 3 A at 24V Stop brush rotation Turn the ignition key to 0 Remove the amp clamp If the amperage is higher perform the following procedures to detect and correct the a...

Page 58: ...eegee 5 Remove the machine s batteries 6 Position a flattened cardboard box the same size as the machine s side With the assistance of a second person turn the machine over sideways and rest its right...

Page 59: ...t 15 Cut and remove the heat shrink tubing Q then disconnect the electrical connection below for the brush motor R Assembly 16 Assemble the components in the reverse order of disassembly and note the...

Page 60: ...ing D and remove the carbon brush E from its seat then detach the carbon brush by disengaging its electrical connection F 4 Check the condition of the four carbon brushes E Replace the carbon brushes...

Page 61: ...nscrew the screw A and remove the brush hub B along with the flange 3 Remove the brush motor D fastening screws C 4 Remove the brush motor D from the brush deck E Assembly 5 Assemble the components in...

Page 62: ...stem DISC CA60 20D 20TD 59 Specifications Description model CA60 20D CA60 20TD Cleaning width 21in 530mm Pressure 60lb 27KG 51lb 23KG motor power 450W Rotation speed 150RPM Insulation class F Brush Co...

Page 63: ...1 is driven by one of the handle switches Transmission of motion from the gear motor to the brush occurs via an eccentric system which provides the orbital movement The system once activated uses the...

Page 64: ...others words once the controller has learned the home position of the actuator it always knows exactly where it is positioned without the need of any additional inputs and the controller is able to st...

Page 65: ...e Manual CA60 34 Scrub System REV CA60 20B 24B 62 Component Locations REV motor M1 Brush deck REV Brush deck Actuator M5 REV pad REV motor M1 Brush deck REV REV PAD Brush deck actuator M5 Figure 1 Fig...

Page 66: ...Service Manual CA60 34 Scrub System REV CA60 20B 24B 63 Component locations continue Brush contactor Brush circuit breaker 30A F1 Brush contactor Brush circuit breaker 30A F1 Figure 3...

Page 67: ...ead can t move up or down The batteries BAT are discharged or its connections are not efficient Charge the batteries or clean repair the connections Batteries faulty Check the battery no load voltage...

Page 68: ...tion key A to I and press the button B Lowering the orbital head remove the ignition key A 2 Unscrew the screws C 3 Remove the key D and pin E 4 Disconnect the actuator electrical connection 5 Remove...

Page 69: ...djustment Adjusting the level of orbital deck only for orbital machine 1 Lower the brush pad holder deck by press the brush pad holder switch M Figure 9 2 Adjust the level of orbital deck by adjusting...

Page 70: ...ctions Batteries faulty Check the battery no load voltage Battery charger faulty Replace Control electronic board faulty Replace The wiring harness is cut or pressed or short circuited Repair The nois...

Page 71: ...the ignition key A to I and press the button B Lowering the orbital head remove the ignition key A 2 Unscrew the screws E 3 Loosen the clamp D and disconnect the water hose C from the deck 4 Disconne...

Page 72: ...eck Disassembly Assembly Continues 6 Unscrew the bumper roller H screws The weight block screws I The plate head deck screws G Remove it 7 Unscrew the screws K 8 Turn over the orbital deck Unscrew the...

Page 73: ...screws M Unscrew the screws N 10 Use three jaw catch the driver plate O and take out it 11 Remove the orbital motor fastening screws P Assembly 12 Assemble the components in the reverse order of disas...

Page 74: ...REV Motor Carbon Brushes 1 Place the motor on a workbench 2 Remove four screws A 3 Remove the cover of motor B 4 Replace the carbon brushes 5 Remove the screws D and replace the carbon brushes C 6 Ins...

Page 75: ...m First Stage Pressure 89lb 40KG Second Stage Pressure 110lb 50KG Brush distance from the floor when lifted 5 in 125 mm REV motor power 750W Rotation speed 2200RPM Insulation class F Actuator technica...

Page 76: ...els which fit in the slots of the squeegee support In case of fixed obstacles the quick fit system allows for squeegee immediate removal The squeegee can be raised and lowered by the operator manually...

Page 77: ...gee System 74 Component Locations Squeegee lifting lowering lever Mounting handwheels Impact deflection wheel Squeegee blades Squeegee blades Squeegee lifting lowering lever Mounting handwheels Impact...

Page 78: ...or there is no vacuuming The squeegee or the vacuum hose is clogged or damaged Clean or repair replace The squeegee leaves water marks on the floor There is debris under the blade Remove The squeegee...

Page 79: ...reversed to a fresh edge up to 3 times before replacement is required During replacement it is important for the blades to be installed flat without waves and then also adjusted to rest flat against t...

Page 80: ...tating or replacing the squeegee blade 7 Remove the squeegee blade from the squeegee frame The squeegee can be rotated and or flipped 3 times to expose a new edge 4 edges total to the lower front If a...

Page 81: ...xamine the edge of each blade front rear to make sure it is flat without any waves N Make this examination with the squeegee assembly still removed from the machine There should be no unnecessary down...

Page 82: ...h the machine parked on a level surface lower the squeegee to the floor 3 Examine the contact area between the squeegee blades and the floor The squeegee blades should be in even contact with the floo...

Page 83: ...box the same size as the machine s side With the assistance of a second person turn the machine over sideways and rest its right hand side on the box positioned on the floor 7 Remove the screw with th...

Page 84: ...Service Manual CA60 38 Squeegee System CA60 20B 24B 81 Specifications Description model CA60 20D CA60 20TD CA60 20B CA60 24B Squeegee width 29 9 in 760mm...

Page 85: ...automatic float in the vacuum grid stops vacuum system motor M2 from collecting any liquids The vacuum system is activated automatically with the One Touch button It can then be managed independently...

Page 86: ...nt Locations Vacuum motor M2 Squeegee vacuum hose Recovery water drain hose Vacuum relay K2 Vacuum Circuit Breaker 30A F2 Vacuum motor M2 Squeegee vacuum hose Recovery water drain hose Vacuum relay K2...

Page 87: ...e float ball D into the filter support frame E and then align the mark groove L of the bottom cap F of the float ball filter with the mark groove L of the float filter support frame E Screw the bottom...

Page 88: ...there is no vacuuming The recovery tank is full Drain the recovery tank The vacuum hose is disconnected from the squeegee Connect The vacuum grid is dirty or the float is blocked Clean the grid react...

Page 89: ...the motor power draw is around 16 A at 24V Stop the vacuum system Turn the ignition key to 0 Remove the amp clamp If the amperage is higher perform the following procedures to detect and correct the...

Page 90: ...the battery connector 5 Working from the bottom of the recovery tank unscrew the screws A and remove the vacuum motor retention plate B 6 Remove the vacuum motor C with the shock absorbing ring D and...

Page 91: ...88 Specifications Description model CA60 20D CA60 20TD CA60 20B CA60 24B Recovery tank capacity 61L 61L Vacuum motor technical data 0 47 hp 350W A VDC 24V Vacuum circuit capacity 47 2 in H2O 1200 mm H...