Clarke CA30 20B and 17E

Clarke CA30 20B and 17E
Service Manual
Model numbers:
CA30 20B - CLARKE510B
CA30 17E - CLARKE430C
English
12/15 Revised 2/16 Form No. 56043171
Service Manual – Clarke CA30 20B and 17E

Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parts And Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Property Damage Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
120 VAC Power Cord Requirements (Corded Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lifting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CA30 20B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CA30 17E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control System (Corded Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Solution Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brush Motor and Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Scrub Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Whole Machine Not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Covers (Control Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Relays and Brush Motor Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control System (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Solution Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Vacuum, Solution, and Brush Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Battery Meter LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Service Manual – Clarke CA30 20B and 17E

Whole Machine Not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Machine Enable Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power, Vacuum, Solution, and Brush Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear Covers (Control Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Brush Motor relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Setting AGM/Wet Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Battery Type Dip-Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Vacuum Motor (17E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Vacuum Motor (20B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Weak Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacement Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Vacuum Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brush Motor (17E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
No Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Low Speed, lack of Power, or Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Start Relay Troubleshooting Voltage Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Scrub System (17E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brush Motor (20B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Replacement Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Brush Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor Carbon Brushes (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Solution Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Solution Solenoid (17E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Solution Solenoid (20B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Solution Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Service Manual – Clarke CA30 20B and 17E

Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Floor Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Squeegee Blade Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Squeegee Trim Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Service Manual – Clarke CA30 20B and 17E
General Information
General Information
General Machine Description
The CA30 is a walk-behind commercial floor scrubbing machine designed to wash and dry commercial floors.
The machine is powered by either on-board batteries (Battery version) or with electric mains via power cord
(corded version). 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 Application
This Service Manual a technical resource intended to aid service personnel in maintaining and repairing
the CA30 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 and Information Sources
Document Name
Document
Number
Document Type
CA30 17E, Instructions for Use
56091131
User Manual/Parts List
CA30 20B, Instructions for Use
56091130
User Manual/Parts List
Parts And Service
Service and repairs must be performed only by authorized personnel or Nilfisk Service Centers. The
authorized personnel is trained directly at the manufacturer’s premises and has original spare parts and
accessories.
Contact Nilfisk Retailer indicated below for service or to order spare parts and accessories, specifying the
machine model and serial number.
Name Plate
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 ________________________________
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Service Manual – Clarke CA30 20B and 17E
General Information
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.
Note: 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.
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Service Manual – Clarke CA30 20B and 17E
General Information
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.
120 VAC Power Cord Requirements (Corded Machine)
This machine is equipped with a grounding power cord, and must be connected to a grounded facility
receptacle that is installed in accordance with all applicable codes and ordinances. The ground wire provides
a low resistance path for fault current, in the event of an equipment malfunction.
Warning: To reduce the chance of electrocution or serious injury, follow all instructions and warnings
below.
The machine comes equipped with a short power cord, and must be used with an additional extension power
cord. This extension cord must be of the appropriate type, size, and length as described below.
• The cord must be a 3-wire (including ground) flexible cord with a minimum length of 15 feet.
• The cord type letter designations must have (S) or (SJ) as the first digits, but cannot have (SV) or (SP)
as the first digits. Additional letter designations with (W) or (OW) are preferred but not required. For
example, a cord designated (SJOW) is Extreme-Service, Junior-Grade (300V), with Oil and Weather
resistance.
• The minimum size of the power cord’s conductors will vary according to the length of the cord. This is to
minimize the effects of voltage-drop at the machine, which can reduce machine performance.
Extension Cord Ratings
Cord Length
Size (AWG)
<25 Ft.
25-50 Ft.
50-100 Ft.
>100 Ft.
Size (mm2)
14
2.0
12
2.5
10
3.5
Not recommended
• Minimum rating: 300V 140/167°F (60/75°C)
Improper connection of the equipment-grounding conductor can result in a risk of electric shock. Check with
a qualified electrician or service person if you are in doubt as to whether the outlet is properly grounded. Do
not modify the plug provided with the machine. If it will not fit the outlet, have a proper outlet installed by a
qualified electrician.
Replace the plug if the grounding pin is damaged or broken. The Green (or Green/Yellow) wire in the cord is
the grounding wire. When replacing a plug, this wire must be attached to the grounding pin only.
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Service Manual – Clarke CA30 20B and 17E
General Information
Lifting The Machine
Caution! Never work under a machine without safety stands or blocks to support the machine.
Transporting The Machine
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
Technical Specifications
Model
CA30 20B
CA30 17E
Machine Height
980mm (39 in.)
980mm (39 in.)
Solution tank capacity
40 liter (10.5 gal.)
50 liter (15.2 gal.)
Recovery tank capacity
40 liter (10.5 gal.)
50 liter (15.2 gal.)
Diameter of transport wheel
200mm (8 in.)
200mm (8 in.)
Diameter of guide wheel
63.5mm (2.5 in.)
63.5mm (2.5 in.)
Power of vacuum system motor
350w
400w
Maximum gradient when working
2% (Max)
2% (Max)
Sound pressure level at workstation
70dB(A) ±3dB(A)
72dB(A) ±3dB(A)
Standard batteries
(2×12V) 24V 105Ah AGM
N/A
Power Cord Length
N/A
20m
Battery compartment size (W x L x H)
340 x 330 x 260mm
N/A
Vacuum system circuit capacity
1200 mm H2O
1200 mm H2O
Cleaning width
510mm (20 in.)
430mm (17 in.)
Squeegee width
790mm (31 in.)
730mm (28.7 in.)
Machine length
1100mm (43 in.)
1060mm (42 in.)
Machine width without squeegee
540mm (21 in.)
480mm (19 in.)
Brush diameter
510mm (20 in.)
430mm (17 in.)
Dry Weight
128kg (282 lb) with batteries
70kg (154 lb)
Gross weight of the machine ready for use
168kg (370 lb)
120kg (265 lb)
Brush motor power
560W
750W
Brush speed
150rpm
150rpm
Brush /pad-holder Maximum pressure
35kg (77 lb)
32kg (70 lb)
Packing size (Lx W x H)
1200 x 610 x 1170mm
1200 x 610 x 1170mm
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Service Manual – Clarke CA30 20B and 17E
General Information
Maintenance Schedule
Procedure
Daily,
after use
Charge Battery
X
Clean squeegee blades
X
Inspect pad/brush
X
Clean solution and recovery tanks
X
Inspect power cord (corded model)
X
Weekly/
Monthly
Inspect squeegee blades for damage
X
Clean the solution filter
X
Inspect for loose fasteners and electrical connections
Every 6
Months
Annually
X1
Inspect/replace scrub motor brushes (battery model)
X
Inspect/replace vacuum motor brushes
X
1
Also perform this inspection after the initial 10 hours of new machine usage.
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Service Manual – Clarke CA30 20B and 17E
General Information
Know Your Machine
CA30 20B
1.
Brush Switches
10. Squeegee Lift Handle
19 Solution Tank Fill
28 Vacuum Tube
2.
Handle
11. Recovery Tank Drain
20 Scrub Deck
29 On-Board Charger
3.
Control Panel
12. Squeegee Pivot
21 Brush/Pad Holder
30 Battery Low LED
4.
Serial Number Plate
13. Squeegee Adjust
22 Solution Sight Tube
31 Battery Level LEDs
5.
Control Cover
14. Squeegee Thumbscrews 23 Shut-Off Float
32 Power Switch
6.
Charging Indicator
15. Squeegee Clip
24 Vacuum Motor
33 Vacuum Switch
7.
Circuit Breakers
16. Squeegee Blade
25 Brush Motor
34 Solution Switch
8.
Battery Disconnect
17 Recovery Tank Lid
26 Wheels
35 Hour Meter (optional)
9.
Lower Cover
18 Recovery Tank
27 Batteries
10
Service Manual – Clarke CA30 20B and 17E
General Information
CA30 17E
1.
Brush Switches
10. Squeegee Lift Handle
19 Solution Tank Fill
28 Vacuum Tube
2.
Handle
11. Recovery Tank Drain
20 Scrub Deck
29 Electrical Box
3.
Control Panel
12. Squeegee Pivot
21 Brush/Pad Holder
30 N/A
4.
Serial Number Plate
13. Squeegee Adjust
22 Solution Sight Tube
31 N/A
5.
Control Cover
14. Squeegee Thumbscrews 23 Shut-Off Float
32 Power Switch
6.
N/A
15. Squeegee Clip
24 Vacuum Motor
33 Vacuum Switch
7.
Circuit Breakers
16. Squeegee Blade
25 Brush Motor
34 Solution Switch
8.
Power Cord
17 Recovery Tank Lid
26 Wheels
9.
Lower Cover
18 Recovery Tank
27 N/A
11
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Control System (Corded Model)
Functional Description
The CA30 17E utilizes switch and relay logic for machine control. It receives operator inputs through
switches, and activates various solenoids and relays to control components. Most of the components operate
at line voltage, except for the scrub switches and scrub control relay, which operate at 24 volts, DC.
Control Panel
The control panel contains the operator controls, including the scrub switches located in the handle of the
machine.
Solution Switch
Vacuum Switch
Power Switch
Scrub Switches
12
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Schematic
The following shows the electrical controls schematic. Each of the functions are further described in the
subsequent sections.
CONTROL PANEL
POWER
SWITCH
VACUUM
SWITCH
Brush Switches
24V DC
Power Supply
SOLUTION
SWITCH
+
~
~
24V
DC
-
Scrub Control
Relay
Coil
8
7
SOLUTION
SOLENOID
BRUSH
MOTOR
4
1
START
RUN
5
2
MOTOR START
RELAY
Main Power
The main machine power comes from 120-volt AC mains power. This first passes through a resettable circuit
breaker for circuit overload protection. All power to the remainder of the machine passes through the main
power switch in the control panel, which switches both line and neutral conductors to the rest of the system.
All downstream functions are in series with this circuit breaker and switch.
Vacuum Motor
The vacuum motor receives its power from the main power switch. It too switches both line and neutral
conductors. From here, the line-side passes through a resettable circuit breaker to protect the motor, and
then directly to the motor. The vacuum motor is a “universal motor”, which means it uses internal carbon
brushes for mechanical commutation of the winding polarity.
13
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Solution Solenoid
The solution solenoid is a 120-volt magnetically controlled valve that permits fluid to gravity-flow to the
scrub deck. Power to the solenoid first passes through the main power switch, then the solution switch.
The neutral conductor passes straight to the solenoid, but the line-side conductor passes through the scrub
control relay before going to the solenoid. (See Scrub Control Relay described on page 15 for a description
of the scrub function.) This series connection causes the solution solenoid to be active only if the scrub
system is active. No solution will flow unless the brush is also active.
Brush Motor and Starter
The brush motor is a single-phase induction motor with a separate start winding to get the motor up to
operating speed. An analogy for this type of motor is the pedals on a bicycle, where the pedals are positioned
straight up-and-down, and can’t be started until the pedals are moved slightly past-center. The start
winding is used to “pull the pedals (motor winding) past center” so normal magnetism can cause complete
rotation.
The power through this start winding needs to be slightly delayed (electrically) from the main AC power,
which is accomplished with capacitors. When the motor is already running at-speed, the “Run Capacitor”
provides sufficient delayed-power to the start winding to keep the motor spinning past this “straight upand-down” position. However, when the motor is just getting started, it needs a little extra power (extra
kick) in the start winding to get moving. This is provided by an additional, larger capacitor, called a “Start
Capacitor”. During start-up, the Run capacitor and Start capacitor combine to give this extra amperage to
the start winding to begin to turn. However, this extra current
BRUSH
LINE 1
in the start winding would be too much current when running at
MOTOR
normal speed, so the Start capacitor must be disconnected from
START
the motor once it begins to turn near operating speed. This is the
WINDING
function of the “Motor Start Relay”.
Motor Start Relay
The motor start relay controls when the start capacitor is
connected to the brush motor. The start capacitor needs to be
connected during startup, but to prevent too much current in
the winding, it must be disconnected once the motor is up to
speed. The start relay is a voltage-controlled relay that turns off
(normally closed contacts open) once a prescribed voltage has been
reached at its coil. This relay senses when the voltage of the Start
Winding has reached its operating voltage, and then disconnects
the start capacitor.
NEUTRAL
RUN
START
V
MOTOR
START RELAY
The most common failure-mode of a capacitor-start, capacitor-run motor is failure to achieve operating
speed. Refer to the Troubleshooting described on page 16, but this is most commonly caused by a failure of
the start capacitor.
14
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Scrub Control Relay
The scrub control relay permits low-voltage control from the operator’s scrub switches to control both the
solution solenoid and the brush motor, while still permitting the operator to control whether the solution
system is active or not active when the brush is active.
The scrub control relay is acting as the primary motor contactor for the brush motor, but a second set of
contacts also functions to “enable” the solution solenoid circuit. This prevents the solution solenoid from
being active when the brush motor is not also active.
POWER
SWITCH
Brush Switches
24V DC
Power Supply
SOLENOID
SWITCH
+
~
~
24V
DC
-
Scrub Control
Relay
8
7
SOLUTION
SOLENOID
BRUSH
MOTOR
4
1
START
RUN
5
2
MOTOR START
RELAY
15
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Troubleshooting
Warning! Risk of electrical shock. Some of the procedures below require examining parts of the
machine while electrical power is present. Use care when examining or troubleshooting the
machine when power is present. Always disconnect power from the machine before and
after these examinations are performed.
Whole Machine Not Functioning
If the whole machine is not functioning, it is an indication of a power failure up to and including the main
power switch in the control panel. Make the following inspections:
• Verify that facility power is available. If the
electrical circuit is protected by a Ground Fault
Circuit protection device (GFC/GFCI), make sure
the device, such as receptacle or GFCI breaker,
has not tripped.
• Inspect the power cord or extension cord for
damage and loose, bent, broken prongs.
Neutral
L1
• Check the machine on-board circuit breaker for
trip by pressing in on the button.
• With the power cord removed, remove the control
panel and inspect for loose wires at the main
power switch, as well as the remaining switches.
• After verifying that no wires are exposed or
shorted, carefully plug the machine back in to
power and check for full line voltage between
L1 and Neutral at both sides of the main power
switch when the switch is turned on.
Switched
Incoming
Power
Switch
• If voltage is present at the incoming side but not at the switched side when the switch is in the onposition, replace the switch.
• If no voltage was present at either pair of switch contacts, inspect the main circuit breaker.
16
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Removal and Installation
Rear Covers (Control Cover)
The rear covers provide access to the motor capacitors and
the system relays. Even though the upper and lower covers
are separable, it is best to treat them as a single cover during
removal and replacement.
F
1. Unplug the machine from power.
G
2. (Optional) You may wish to remove the squeegee
assembly (E). When the upper cover is removed, the
squeegee will no longer be lifted by the lift cable (F).
3. (Optional) If you need to separate the cover from the
machine entirely, you will need to remove the squeegee
lift cable (F). Remove the bolt (G) and remove the cable.
4. Free the recovery drain hose from its clip and lay it to the
side.
E
5. Remove the 6 screws (C) that secure the
upper (A) and lower (B) covers to the
machine.
• The 2 screws (D) at the top of the lower
cover do not need to be removed at this
time, but may be removed later if you
wish to separate the upper and lower
covers.
A
6. Free the covers from the vacuum and
recovery hoses, and remove the covers.
B
C
D
7. To separate the cover from the machine, remove the
following wire connectors:
• Main power (H) from main circuit breaker to
control panel
J
• Main neutral (I) from power cord to control panel
• Ground wire (J) from terminal lug
• Vacuum motor circuit breaker wires (K)
I
H
K
17
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Control Panel
The control panel contains the machine control switches
and the DC power supply for the scrub relay. The
machine’s relays are located below the control panel.
B
A
1. Make sure the machine is unplugged from power.
2. Remove the 4 screws (B) that secure the control
panel (A).
3. Carefully lift the control panel up to expose the
wiring below.
4. Remove the 2 AC input wires from the power
supply board.
• The polarity of the wires is not critical to the
function of the power supply.
5. Unplug the DC output connector from the power
supply.
6. Using tape or similar label, make note of which
wiring bundles are connected to each of the 3
switches, and remove the 4 wires from each
switch.
• During replacement, take care not to mix
the line and neutral wires on each side of
the switch. One side of the switch switches
the line-side and the other side switches the
neutral-side.
• Important: Reversing these wires will result
in a direct short circuit of the 120-volt power.
AC
Input
24 VDC
Output
Neutral
Line
18
Service Manual – Clarke CA30 20B and 17E
Control System (Corded Model)
Relays and Brush Motor Capacitors
The relays and brush motor capacitors are
located below the control panel, but to access
them, they must be removed from below.
1. Remove the Control Panel described on page
18, and disconnect all of the associated
wiring.
2. Disconnect the scrub switches from the
scrub relay coil.
D
C
3. Remove the Rear Covers (Control Cover)
described on page 17.
4. Remove the 2 screws (A) that secure the
capacitor holder (B) to the machine, and
carefully lower the assembly and wires out
of the machine.
B
A
5. Remove the screw (E) that secures the motor starter (F).
6. Loosen the 2 screws and nuts (G) that secure the scrub
relay (H).
7. Simultaneously slide out both capacitors by pushing up
on them through the holes in the bottom of the capacitor
holder.
8. Before disconnecting any of the wires, make note of their
locations for later replacement.
H
F
G
• (J) Start Capacitor
• (K) Run Capacitor
M
L
• (L) Start Relay
• (M) Scrub Relay
J
K
E
19
Service Manual – Clarke CA30 20B and 17E
20
Control System (Battery Model)
Functional Description
The CA30 20B utilizes a main machine controller to turn on various machine functions. It receives operator
switch inputs, and activates various solenoids and components. Each of the machine components is described
below. Refer to the machine Schematic on page 22 for details.
Control Panel
The control panel (display) provides the main operator interface for the machine. It provides battery status
and contains the switches for operating the machine.
Battery Indicator
Battery Charge Level
Solution Switch
Vacuum Switch
Hour Meter
Main Power Switch
Main Power Switch
The main power switch controls power to the main control board and the hour meter. For the hour meter,
both the positive and negative power leads are switched. For the control board, only the negative power
lead is switched. Positive power is always present at the control board, but passes through a 30-amp circuit
breaker.
This arrangement reduces the total amperage flowing through the main power switch. The power consumed
by the brush motor and vacuum motor do not pass through this switch. Only their control signal power
passes through this switch. This reduces the likelihood of the switch contacts being damaged by high
amperage current flow.
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Battery Charger
The battery charger is semi-autonomous, and is always connected to the batteries unless the main battery
disconnect is unplugged. The charger is microprocessor-controlled to provide the optimal charge-curve to the
batteries depending on the battery type. The battery type, voltage, and max. current is determined by DIP
switches inside the charger. The charger also contains a small normally-closed relay that opens whenever
the charger is plugged in to building power. This relay serves to notify the machine’s control board that the
charger is plugged in and active, so that the control board can disable all machine functions while being
charged. When the charger is unplugged, the circuit is closed and the machine is enabled. When the charger
is plugged in, the circuit is open and the machine is disabled.
Vacuum Motor
The vacuum motor is controlled by a relay built in to the main control board. This relay switches the positive
power to the vacuum motor. This is fused through the same circuit breaker that provides power to the
control board. The negative power to the motor is unswitched and unfused from the battery.
Solution Solenoid
The solution solenoid is a 24-volt magnetically controlled valve that permits fluid to gravity-flow to the
scrub deck. Power to the solenoid comes from a relay on the machine control board. This relay switches the
negative power to the solenoid. The solution solenoid is active only when the solution switch is closed, and
at least one of the brush switches are closed. This causes the solution solenoid to be active only if the scrub
system is active. No solution will flow unless the brush is also active.
Brush Motor
The brush motor is controlled by a power relay adjacent to the control board. The positive power to the motor
passes through the second 30-amp circuit breaker. This circuit breaker serves only the brush motor. The
negative power to the motor is switched by the brush relay. Both positive and negative power to the relay
coil comes from the machine control board.
Vacuum, Solution, and Brush Switches
These switches are low-power control signals to the machine control board. They share a common positive
lead from the control board, and return that positive signal back to the control board when closed. The two
brush switches are in parallel, so that if either switch is closed, the circuit is completed.
Hour Meter
The hour meter is a simple clock that receives power from the main power switch, but is enabled only when
the scrub switches are closed.
Battery Meter LEDs
The battery meter LEDs are controlled by the main control board based on the voltage of the battery. Each
successive LED turns on at a higher voltage level, depending on the position of the Wet/Gel DIP switch.
The operating voltage range of a wet battery is lower than a gel battery, so the LEDs will turn on at lower
voltage for wet versus gel batteries. When the battery is fully depleted, the 2 red LEDs will flash, and the
machine will shut down.
21
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Schematic
The following shows the electrical controls schematic.
Battery Meter
CONTROL PANEL
7
POWER
SWITCH
Hour Meter
SOLUTION
SWITCH
VACUUM
SWITCH
Brush Switches
+Common
Scrub Active
Solution S4
Vacuum S3
Scrub Active S2
+Common
Switched Batt -
7
Batt +
30A
Machine Enable
+Common
CHARGER
C+
CS4
S3
S2
COM
C+ = Com = Common
C- = Machine Enable (Charger)
S4 = Solution SW
S3 = Vacuum SW
S2 = Scrub SW
COM = C+ = Common
Solution
Relay
MACHINE ENABLE
NORMALLY
CLOSED RELAY
SOLUTION
VCC
Batt (+)
Batt (-)
BRUSH
CIRCUIT
BREAKER
Batt +
Vac
Relay
Vac
Motor
GND
Switched Batt -
30A
BATTERY
DISCONNECT
BATTERY
BRUSH
MOTOR
BRUSH
RELAY
SOLUTION
SOLENOID
VACUUM
MOTOR
22
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Troubleshooting
The following sections present some common troubleshooting scenarios based on symptoms.
Whole Machine Not Functioning
The symptom of “whole machine not functioning” means that the vacuum motor does not run, brush
motor does not run, and solution solenoid does not engage. If the whole machine is not functioning, it is
an indication of a power failure, control board failure, or a battery charger failure. Make the following
inspections:
1. Make sure the battery charger is not plugged in to building power. The machine is disabled when
plugged in to power.
2. Turn on the main power switch and observe the lights on the control panel. During normal operation,
the following should take place:
• If present, the hour meter will illuminate immediately.
• The two red LEDs below the battery icon will illuminate for about 1 second.
• When the red LEDs turn off, the green battery level LEDs will turn on.
3. If the hour meter does not illuminate, then power is not reaching the main power switch. Check the
following:
• Make sure the battery disconnect plug is firmly connected.
• Make sure the circuit breaker labeled “Vacuum” is not tripped by pressing in on the button.
• Remove the Rear Covers (Control Cover) described on page 26 and begin checking voltages, starting
at the main power switch and working back toward the batteries.
4. Unplug the battery disconnect and measure the battery voltage to ensure the batteries are not fully
depleted. Reconnect the plug when done.
5. If the red LEDs below the battery icon do not illuminate for 1 second during startup (and the batteries
are not depleted), then it is likely that the control board is not getting power or the control board is
faulty.
• With the main power switch on, check the voltage between VCC and GND at the top of the control
board. If power is present, then the main control board is faulty and needs to be replaced.
Machine Enable Circuit
Battery
Charger
6. If the red LEDs illuminate but the green
LEDs do not illuminate (and the battery
voltage measured above is not depleted),
then it is likely that the controller believes
the machine is being charged.
• Inspect the 2 machine enable wires
between the control board (S2 and COM)
and the charger for breaks or an open
circuit. An open circuit on these wires
will disable the machine as though it was
being charged.
• Measure the voltage between these two
wires as you cycle the machine power
switch and cycle the battery charger
power, and compare the results to the
table data on page 24.
Machine
Enable
Voltage
Probes
23
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Voltage between Machine Enable and +Com
Normal
Open circuit at
Controller
Open circuit at
charger
Short Circuit †
Charger relay
resistance w/o
control board ‡
Charger = off
Power = off
0V
0V
0V
0V
0 Ω (short)
Charger = off
Power = on
0V
0V
24 V
0V
N/A
Charger = on
Power = off
0V
0V
0V
0V
∞ Ω (open)
Charger = on
Power = on
24 V
0V
24 V
0V
N/A
Charger and Power
Switch Status
† Column-4, Short Circuit isn’t specifically applicable to the scenario because the machine would be
functioning. However, the machine would also be fully functional when the charger was plugged in.
‡ Important: To avoid damaging your multimeter, make sure to disconnect the control board before
checking the resistance of the charger relay contacts. Leave the machine turned off.
• The Red entries in the table above are the measurements that are indicative of the associated failure
modes.
• If all of your measurements show 0 volts (columns 2 and 4 above), turn the machine power off,
disconnect the wires, and measure the resistance of the relay contacts in the charger with the charger
unplugged and then plugged in. Compare these to the results in the last column of the table above.
• Briefly jumper the two wires together and turn the machine on. If the machine functions normally,
then the battery charger is faulty and needs to be replaced.
24
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Power, Vacuum, Solution, and Brush Switches
Hour Meter
POWER
SWITCH
VACUUM
SWITCH
SOLUTION
SWITCH
Brush Switches
Scrub
GND Bat- Bat+ +Common
To C.B.
From C.B.
Vacuum
Solution
Scrub
Checking the function of the switches in the operator’s control panel is typically required for other
troubleshooting procedures. The main power switch provides the negative power (GND) to the control
board. So nearly all troubleshooting procedures rely on verifying the function of the main power switch.
The remaining switches use a shared positive power (+Com) from the control board, which should also be
checked.
1. Verify incoming battery power at the main power switch (24V between terminals).
• Note that these switch terminals will provide convenient battery +/- reference test points for the
remaining examinations.
2. Verify outgoing power at main switch. Terminal-to-terminal should be 0 volts when the switch is off, and
24 volts when the switch is on.
3. Verify that the control board is providing +Com at the vacuum, solution, and brush switches.
• When main power switch is on, voltage between Bat- and +Com should be the same as battery voltage.
• When the main power switch is off, the voltage between Bat- and +Com should be 0 volts.
4. Verify the outgoing power from the vacuum, solution, and brush switches.
• When the switch is off, the voltage between Bat- and the wire leading to the control board should be 0
volts.
• When the switch is on, the voltage between Bat- and the wire leading to the control board should be 24
volts.
25
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Removal and Installation
Rear Covers (Control Cover)
The rear covers provide access to the control board, brush
relay, batteries, and battery charger. Even though the upper
and lower covers are separable, it is best to remove them as a
single cover.
F
1. Unplug the machine from power.
G
2. (Optional) You may wish to remove the squeegee
assembly (E). When the upper cover is removed, the
squeegee will no longer be lifted by the lift cable (F).
3. (Optional) If you need to separate the cover from the
machine entirely, you will need to remove the squeegee
lift cable (F). Remove the bolt (G) and remove the cable.
4. Free the recovery drain hose from its clip and lay it to the
side.
E
5. Remove the 6 screws (C) that secure the
upper (A) and lower (B) covers to the
machine.
• The 2 screws (D) at the top of the lower
cover do not need to be removed at this
time, but may be removed later if you
wish to separate the upper and lower
covers.
A
• During reassembly, you may find it
easier to install the covers separately.
Install the upper cover first.
6. Free the covers from the vacuum and
recovery hoses, and remove the covers.
B
C
D
J
7. To separate the cover(s) from the machine,
remove the following wire connectors and
tethers:
• Brush motor power (H)
I
H
• Vacuum motor power (I)
• Control board power wires (J)
• Machine enable wires (K) from battery
charger
• Main battery disconnect (L)
8. Remove the screw from each of the 3 support
cords (tethers).
L
K
26
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Control Panel
The control panel contains the machine control switches,
battery indicator LEDs, and the optional hour meter.
B
A
1. Disconnect the main battery connector.
2. Remove the 4 screws (B) that secure the control
panel (A).
3. Carefully lift the control panel up to expose the
wiring below.
4. Remove the battery meter connector from
the battery meter circuit board.
5. Using tape or other label, make note of
which wiring bundles are connected to each
of the 3 switches, and remove the wires
from each switch.
• During replacement, take care not to mix
the positive and negative wires on each
side of the main power switch.
6. Unplug the 3 wire terminal lugs from the
hour meter.
Vacuum
Switch
Solution
Switch
Hour
Meter
Battery
Meter
Main
Power
27
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Control Board
Brush Motor relay
The control board is located between the
recovery and drain hoses behind the upper rear
cover of the machine. The brush motor relay is
attached to the control board enclosure. The two
procedures are interrelated.
B
1. Remove the Rear Covers (Control Cover)
described on page 26.
• Make sure to unplug the main battery
disconnect during the procedure.
2. Remove the 4 screws (B) that secure the
control board enclosure to the machine.
C
A
B
3. Carefully move the control board away from the machine enough
to reach the electrical connections on the back side. Remove the
following connectors:
I
• Main power negative/ground (D)
• Main power positive (F)
• Vacuum motor positive (E)
H
• Solution solenoid (G)
C+
CS4
S3
S2
COM
• Operator switches (H)
• Brush motor relay coil (I)
J
C+ = Com = Common
C- = Scrub SW
S4 = Vacuum SW
S3 = Solution SW
S2 = Machine Enable (Charger)
COM = C+ = Common
Sol
Relay
• Battery level LED board (J)
Vac
Relay
SOLUTION
G
VCC
F
Vac
Motor
GND
E
D
28
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
4. Remove the 2 coil wires (K) from the brush relay
(M).
5. Remove the two power wires (L) from the brush
relay.
L
K
6. Remove the 4 screws (Q) that
secure the control board (P) to
the enclosure (A), and remove
the control board.
7. Remove the 2 screws (N) that
secure the brush relay (M) to the
enclosure, and remove the relay.
M
M
A
P
Q
N
29
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Batteries
Caution: Care must be taken to avoid shorting the battery terminals or battery wires. Never rest tools
on top of the batteries, as they can contact and short across the battery terminals.
1. Remove the Squeegee Assembly.
2. Remove the Rear Covers (Control Cover) described on page
26.
B
• For battery access, only the lower cover need be removed.
Remove the 2 screws marked (D) in the procedure.
• Remove the squeegee lift cable (F) in the procedure.
A
• Unplug the main battery disconnect in the procedure.
3. Route the vacuum hose (A) and recovery drain (B) through
the operator’s handle to keep them out of the way during the
procedure.
F
4. Remove the 2 screws (C) that secure the battery
retaining bracket (E), and remove the bracket.
C
C
E
5. Position a platform or lift (G) in back of
the machine that matches the height of the
battery compartment.
H
6. Simultaneously slide both batteries (H) out of
the machine and onto the lift.
• The batteries are not mechanically joined,
but they are connected by the rear battery
cable, and must be moved together.
G
30
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Make sure the replacement batteries
fit the machine. They may be either
wet-type, AGM-type, or Gel 12-volt
batteries, but AGM is preferred. The
original batteries are:
• L:307 x W:169 x H:211 mm
The machine maximum capacity is:
• L:330 x W:170 x H:260 mm
• L:13.0 x W:6.7 x H:10.25 in.
260 MAX
10.25 MAX
340 MAX
13.39 MAX
330 MAX
13.00 MAX
170 MAX
6.69 MAX
Caution: Care must be taken to correctly
connect the battery cables to
avoid damaging the machine
or the batteries.
7. Slide the protective boots (I) off of each terminal.
8. For easier access, you may temporarily
remove the carrying handles (J).
9. Remove the terminal bolts and transfer the
rear jumper (K) from the old batteries to
the new batteries. Make sure to connect this
from positive to negative between the two
batteries.
Black/Negative
• Torque the terminal bolts to:
7.1-8.0 ft-lbs, 85-95 in-lbs, or 9.6-10.7 N•m
10. Remove the terminal bolts and transfer the
battery cable (L) from the old batteries to
the new batteries. Make sure to connect this
from positive to negative between the two
batteries.
K
Red/Positive
J
I
Black/Negative
L
Red/Positive
• Torque the terminal bolts to:
7.1-8.0 ft-lbs, 85-95 in-lbs, or 9.6-10.7 N•m
11. To verify proper connection of the battery cables, check the voltage at the battery disconnect connector
(L). The voltage should be nominally 24 volts. If not, recheck the cable connections.
12. Slide the protective boots (I) back over the terminals.
13. Replace the carrying handles if they were removed.
31
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Because the machine is frequently tilted, it is
important that the batteries fit properly front-to-rear
to prevent them from moving during machine use.
For batteries that are less than the maximum size,
24 mm spacers are used to fill the space in front of
the battery.
N
• For batteries less than 310 mm (12.25 in) long, use
1-24mm spacer
• For batteries less than 285 mm (11.25 in) long, use
2-24mm spacers
14. As needed, place 0, 1, or 2 spacer bars (M)
against the forward wall of the battery bay (N).
M
15. Slide the batteries into the battery bay until
they are pressing against the forward wall (N) or
spacer (M).
16. Reinstall the battery retaining bracket (E).
17. If the battery type has not changed, finish the
reassembly. Otherwise complete the procedure
below to set the battery type.
Setting AGM/Wet Battery Type
The battery charger uses different charging curves, depending on the battery type. This is controlled by a
dip-switch setting in the charger. Additionally, the battery level LEDs on the control panel will function
differently for the different battery types. This is controlled by a dip-switch setting on the control board.
1. Complete the procedure to remove the Battery Charger described on page 33. The end of the procedure
contains the settings for the charger’s dip-switch settings.
• It is not necessary to disconnect any wires from the charger. Just free the charger from the rear cover
to access the dip-switches.
2. Remove the control board enclosure as described on page 28, but it is not necessary to unplug any
wires.
3. The dip-switches are located at the bottom-left corner of the control board. Move both switches to either
“Wet” or “GEL”, as necessary. (Use “GEL” for AGM batteries.)
32
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Battery Charger
The battery charger is located on the inside of
the rear cover, and is connected directly to the
batteries. The charger is microprocessor controlled
and uses different charging curves for optimal
performance for different battery types.
E
D
1. Remove the Rear Covers (Control Cover)
described on page 26.
2. Disconnect the cable connector (D) leading to
the batteries.
3. Disconnect the two wire terminals (E) leading
to the control board.
C
B
B
4. Remove the 4 screws (B) that secure the
mounting straps (C) to the cover, and remove
the charger (A).
A
Battery Type Dip-Switches
The charger’s functions are controlled by 4 dipswitches (2-pair) inside the back cover. The second
2 switches should never be touched unless the
charger has been replaced and their position
needs to be confirmed. They set the battery
voltage (24V) and maximum amperage (10A), and
should always be in the Off position.
SW1
ON
SW2
ON
Off
F
1
2
1
2
The first 2 switches are accessible through a
plastic plug without opening the charger. These
switches set the type of charge curve used for
each type of battery. The curve type signifies
the manner and magnitude in which current
and voltage are applied to the battery during its
distinct phases of the charge cycle.
1. Only if the charger is new and the 2nd pair of
DIP switches need to be confirmed, is it necessary to remove the
rear cover.
F
2. Remove the plastic plug covering the DIP switch access hole (F).
3. Set the first 2 DIP switches according to the table data below.
4. Replace the plastic plug.
Battery Type/Brand
Curve
Type
SW1
SW2
D1
D2
Lead-acid (Wet) batteries
IUIa-ACD
On
Off
Gel batteries, Exide-Sonnenschein
IUIa-GEL
Off
Off
HAZE Gel and Most AGM batteries (Default)
IUUO-GEL
Off
On
Discover AGM batteries
IUIUa-GEL
On
On
D1
D2
Off
Off
33
Service Manual – Clarke CA30 20B and 17E
Control System (Battery Model)
Specifications
Shop Measurements
Brush
The following table represents actual machine voltage
measurements. Because battery voltage will vary with
level of charge, those values within 0.1 volts of the current
battery voltage are listed simply as “B+”.
B+
Sw Return
B+
Taking a measurement between VCC and GND terminals
when the main power switch is on will establish your
current battery voltage (B+).
C+
CS4
C+ = Com = Common
S3
C- = Scrub SW
S2
COM S4 = Vacuum SW
S3 = Solution SW
S2 = Machine Enable (Charger)
COM = C+ = Common
Sol
Relay
Solution
Solenoid
SOLUTION
VCC
Vac
Relay
Vac
Motor
Bat Pos
GND
Bat Neg
Vac Relay
Reference
Point
Active
Inactive
Vac Relay
GND
B+
0V
Active-high
Solution Solenoid
Itself
B+
0V
Active-high, polarity not important
Com, C+
GND
B+
B+
Always active power to switches
S2, Machine Enable
GND
B+
0V
See page 23
S3, Solution Switch
GND
B+
0V
Active-high switch return
S4, Vacuum Switch
GND
B+
0V
Active-high switch return
C-, Scrub Switches
GND
B+
0V
Active-high switch return
Brush Relay
Itself
B+
0V
Active-high, polarity not important
Test Point
Comment
34
Service Manual – Clarke CA30 20B and 17E
35
Recovery System
Functional Description
The purpose of the recovery system is to
remove water from the floor. The vacuum
motor creates negative pressure in the
recovery tank by sucking air out of the tank
through the vacuum suction hose. To protect
the vacuum motor from ingesting water, a
ball float is located at the end of the vacuum
suction hose inside the recovery tank. When
the tank’s water level reaches the float ball,
the ball rises until it blocks the inlet of the
suction hose.
The negative pressure inside the recovery
tank (not shown) causes air/water to be drawn
in through the squeegee suction hose. The
recovery tank serves to isolate the air/water
stream in the squeegee suction hose from
the air-only stream in the vacuum suction
hose. The water and debris drawn in through
the squeegee suction hose falls out of the
stream into the bottom of the recovery tank. A
separate tank drain hose is used to drain this
water and debris from the tank.
The squeegee suction hose draws air/water
from the squeegee assembly. The squeegee
consists of two squeegee blades: a forward,
notched blade, and a rear scraping blade.
The notched blade permits water to pass into
the space between the two blades, where it is
drawn into the suction hose.
Squeegee
Suction
Float &
Filter
Tank Drain
Vacuum
Motor
Vacuum
Suction
Squeegee
Service Manual – Clarke CA30 20B and 17E
Recovery System
Troubleshooting
The following sections present some common troubleshooting scenarios based on symptom.
Warning! Risk of electrical shock. Some of the procedures below require examining parts of the
machine while electrical power is present. Use care when examining or troubleshooting the
machine when power is present. Always disconnect power from the machine before and
after these examinations are performed.
Vacuum Motor (17E)
The vacuum motor circuit gets it power from the main power switch, which then passes through a 5-amp
circuit breaker before reaching the motor. The vacuum motor has brushes, which may also be a cause of
motor failure.
• Check the vacuum 5-amp circuit breaker for trip by pressing in on the button.
• Remove the control panel and check for line voltage across both pair of terminals on the vacuum switch
when the switch is in the on-position. If not, replace the switch.
• Inspect the motor brushes and replace if necessary. (See Vacuum Motor Brushes described on page 39.)
Vacuum Motor (20B)
The vacuum motor circuit gets its positive-power from the control board, and negative-power direct from
the battery disconnect. Failure of the vacuum motor can generally be isolated to 1 of 3 areas: motor brushes,
control board failure, or switch failure. The brushes may be the most likely cause, but it is easiest to
eliminate other causes before disassembling the machine.
1. Verify that the vacuum switch is functioning by performing the procedure Power, Vacuum, Solution, and
Brush Switches described on page 25.
2. Check the voltage from the control board when the vacuum should normally be running. The voltage
between the “Vac Motor” terminal and “GND” terminal should be 24 volts. If 24 volts is not present,
replace the control board.
3. Remove the vacuum motor from the machine (a prerequisite to replacing the motor brushes), and check
the voltage at the motor. If 24 volts is present, then replace the brushes as described on page 39.
Weak Suction
The most common cause for weak suction is a vacuum leak, but it may also be caused by a blockage.
• A blockage can be identified as the cause if the vacuum pressure feels weak when air is flowing, but feels
strong when completely blocked (high static pressure). If a blockage is suspected:
• Inspect and clean the float/filter canister in the recovery tank.
• Inspect the suction lines for obstruction.
• A vacuum leak can be identified as the cause if the vacuum pressure is low when blocked or unblocked. If
a vacuum leak is suspected:
• Make sure the recovery tank cover is properly closed and seated.
• Make sure the recovery tank cover gasket is not damaged or torn.
• Make sure the recovery tank drain hose is not open.
• Inspect the squeegee suction hose for tears or holes.
• Inspect the squeegee blades for tears, and proper trim adjustment (page 58).
• Inspect the vacuum suction hose between the vacuum motor and recovery tank.
36
Service Manual – Clarke CA30 20B and 17E
Recovery System
Removal and Installation
Vacuum Motor
The vacuum motor is located above the scrub deck. The inlet to the vacuum motor comes from the recovery
tank via a flexible hose. The exhaust from the motor passes through a sound attenuator and out of the
machine above the scrub deck.
1. Make sure the solution and recovery tanks
are empty. Excess weight in the tanks can
throw off the balance of the machine when the
weight of the scrub deck is removed from the
machine.
H
G
2. Remove the Scrub Deck described on page
46.
• When disconnecting the motor connector
(F) and solution solenoid connectors (G) in
the procedure, also disconnect the vacuum
motor connector (H).
3. Prop the machine up so it does not tilt forward
while working under the recovery tank.
F
H
4. Remove the forward-most mounting screw (B)
from the vacuum plate (A).
B
5. Loosen, but do not remove, the two rearward
mounting screws (C) from the vacuum
plate (A). (The screws may be removed, but
reinstallation is easier when the screws
remain in position.)
6. Slide the vacuum plate out from the mounting
screw slots, and support the motor as you
remove the plate.
C
A
37
Service Manual – Clarke CA30 20B and 17E
Recovery System
7. Carefully cut the wire tie (E) that holds the motor
connector (H) to the vacuum hose.
8. Loosen the hose clamp (D) and remove the motor
from the vacuum hose.
E
I
H
D
Replacement Notes
• The rotational position of the vacuum hose elbow (I)
determines the rotational position of the blower’s
exhaust (J), which must line up with the hole in the
vacuum plate. To set this position, leave the hose
clamp (D) slightly loose, put the motor in position and
rotate the motor as needed. Then lower the motor to
tighten the hose clamp.
• The vacuum motor is supported by the lower
gasket (K) against the vacuum plate. You
may find it helpful to temporarily hold the
gasket to the motor with a piece of tape while
positioning the vacuum plate. Remove the tape
after the plate is installed.
J
B
• Reinstalling the vacuum plate and motor is
easiest if the rearward mounting screws (C)
are in position but left loose.
• Before installing the forward screw (A), make
sure the exhaust (J) and motor gasket (K) are
centered in their respective holes.
C
A
K
38
Service Manual – Clarke CA30 20B and 17E
Recovery System
Vacuum Motor Brushes
The vacuum motor brushes are a wear item that should periodically be inspected and replaced.
1. Make sure the solution and recovery tanks are
empty. Excess weight in the tanks can throw off
the balance of the machine when the weight of
the scrub deck is removed from the machine.
A
B
2. Remove the Scrub Deck described on page 46.
3. Remove the Vacuum Motor described on page
37.
4. Remove the two screws (B) that secure the brush
cover (A), and remove the cover.
B
5. Remove the two screws (C) that secure the brush
holder (D) to the motor.
C
6. Tilt the brush holder (D) out of its pocket, and
slide it away from the motor.
E
7. Examine the commutator bars (E). If any are
damaged or missing, replace the motor.
D
39
Service Manual – Clarke CA30 20B and 17E
Recovery System
8. Press in on the retaining tab (G) and slide the
brush wire (F) out of the brush holder.
9. Slide the brush (H) out the rear of the brush
holder (D).
10. Slide the new brush into the brush holder.
H
D
H
D
11. With the brush and its spring contact plate fully
inserted into the brush holder, replace the brush
wire (F) into the brush holder. The brush wire
also serves to retain the brush, so it needs to be
installed before the brush holder is replaced in the
motor.
G
F
12. Align the tip of the carbon brush (H) against the
commutator (E).
E
13. Slide the brush holder inward, compressing the
spring.
14. Lower the brush holder into the pocket in the
motor housing.
15. Reinstall the two retaining screws (C).
16. Repeat the process for the second brush.
17. Before replacing the brush cover, examine the
cooling fan impeller for damaged or bent blades.
18. Replace the brush cover (A).
19. Reinstall the vacuum motor in the machine as described on page 38.
D
40
Service Manual – Clarke CA30 20B and 17E
41
Scrub System
Functional Description
The scrub system consists of scrub brush or pad,
which is powered by a drive belt from the brush
motor. The drive belt and pulleys results in nearly a
10-to-1 speed reduction of the brush. This significant
speed reductions results in a proportional increase in
torque.
The scrub deck floats on a pair of pivot brackets. This
allows the scrub brush/pad to rest flat on a floor as
the machine moves. The left of these pivot brackets is
rigid in height position, but the other floats vertically.
This applies a slightly greater force on the left side of
the scrub pad, which in turn assists in propelling the
machine forward.
Brush
Motor
Pivot
Bracket
Scrub Deck
Brush/Pad
Service Manual – Clarke CA30 20B and 17E
Scrub System
Troubleshooting
Brush Motor (17E)
Caution! If the brush motor does not reach normal operating speed within a few seconds of receiving power,
immediately disconnect power to prevent further damage to the motor. Prolonged high-amperage
current through the windings can permanently damage the motor.
The brush motor is a capacitor-start/capacitor-run induction motor. The two primary failure-modes of this
type of motor are when it’s not receiving any power, or when the start circuit is not functioning properly.
During normal operation, you should hear 2 clicks as the motor starts and stops. The first click is the scrub
relay providing power to the motor, and the second click is the start relay disconnecting the start capacitor.
This is reversed when the motor shuts down. If the second click isn’t heard, it means the start circuit isn’t
functioning.
No Power
• If neither the solution solenoid nor brush
motor are functioning, proceed to the Scrub
System (17E) described on page 44 .
Unused
Contacts
• If the solution solenoid is functioning, then the
24-volt power supply and scrub control relay
coil can be eliminated as the cause. However,
a failed contact or loose wire could still be the
cause.
• The scrub control relay has 3-pair of
contacts, but only 2-pair are being used. To
verify that the brush motor contacts have
not failed, move the wires for the brush
motor to the unused contact pair. This
pair can be easily identified, because one
of them will connect to the adjacent brush
motor starter.
Wire to
Brush Starter
Scrub Switches
(Disconnected)
• If the brush motor functions after relocating the wires to the unused contacts, then the relay should be
replaced. The relay has severe internal damage and should not be used.
Low Speed, lack of Power, or Overheating
These symptoms and conditions are related to a failed start circuit. If not diagnosed quickly, many of these
conditions can cause permanent damage to the motor. While making observations, it is important to not run
the motor for more than a second or two, and to allow the motor windings to cool down between observations.
Caution! The motor start and run capacitors can hold a significant electrical charge long after power
has been disconnected. Take care when handling any wires leading to the capacitors.
• If the brush motor comes up to speed rapidly, but is very noisy, overheats without load, or trips the circuit
breaker, then it is most likely that the start relay is not disconnecting the start capacitor when it should.
Replace the start relay.
• This condition can rapidly damage the motor. Do not permit the machine to operate in this condition.
• The motor will sound very loud and unbalanced (not smooth).
• If the brush motor turns slowly, hums without turning, or is very slow to reach operating speed without
load, then the most likely cause is a failed start capacitor. Replace the start capacitor (see page 19)
• This condition can rapidly damage the motor. Do not permit the machine to operate in this condition.
• This is the most common failure mode of a capacitor-start motor.
• If the brush motor gets up to speed reasonably fast but lacks power or bogs down easily, it is likely that
the run capacitor has failed.
42
Service Manual – Clarke CA30 20B and 17E
Scrub System
Start Relay Troubleshooting Voltage Readings
Most brush motor troubleshooting can be completed by simple observations. The table below provides
further information if confirmation is required, or to isolate the cause of similar symptoms. As with other
troubleshooting observations, these measurements should be preformed for no more
than a couple seconds at a time, and time should be given to allow the motor windings
5
to cool between measurements.
4
Warning! Risk of electrocution. These measurements require measurement of
voltages with the system powered and active. Unplug the machine
while setting up the test probes, and stay clear of the probes and
system wiring when the machine is powered.
VO = Voltage Off,
VS = Voltage Startup,
2
1
VR = Voltage Running
Normal Operation
Terminals
VO
VS
VR
2-4
1.0
↑
239
2-5
0
↑
203
2-1
0
0
239
1-4
0
69
0
Building start capacitor voltage, then disconnected
1-5
0.7
15
1.3
Building start capacitor voltage, then disconnected
4-5
0
120
120
Normal line voltage
Scope
Comment
Shorted, then Jumps after relay opens
Failed Start Capacitor (Never Reaches Run Speed, Relay Never Opens)
Terminals
VO
VS
VR
2-4
0
105
---
2-5
0
21
---
2-1
0
0
---
Shorted by relay contacts, relay never opens
1-4
0
105
---
Same as 2-4
1-5
0
21
---
Same as 2-5
4-5
0
95
---
Voltage drop in power cord due to high amperage
Scope
Comment
Failed Run Capacitor (Relay Opens Normal)
Terminals
VO
VS
VR
2-4
0
↑
191
Slight stutter as relay opens
2-5
0
↑
140
Slight stutter as relay opens
2-1
0
→
191
Shorted, then Jumps after relay opens
1-4
0
120
0
1-5
0
↑
120
4-5
0
120
120
Scope
Comment
Same as 2-4 until relay opens
Same as normal operation
Failed Start Relay (Start Circuit Never Disengages)
Terminals
VO
VS
VR
2-4
0
↑
170
2-5
0
↑
220
Scope
Comment
The motor starts normally, but then enters an overpowered condition when the starter doesn’t disengage.
43
Service Manual – Clarke CA30 20B and 17E
Scrub System
Scrub System (17E)
The scrub system combines the functions of the solution solenoid and the brush motor for the purpose of
limiting the solution flow only when the brush motor is active. The scrub control relay allows simultaneous,
yet isolated, control of both the low-power solution circuit and the high-power brush motor circuit. The relay
uses a low-voltage coil (24VDC) so that high-voltage power is not required in the operator’s handle for the
brush switches.
The failure modes of the scrub system include loss
of the 24VDC power supply, failure of the scrub
control relay, and to a lesser degree, failure of both
brush switches in the handle. The reason why the
switches are less likely to be the cause of the failure is
because both independent switches would have to fail
simultaneously.
• Because the solution solenoid and brush motor
are otherwise isolated, if both are non-functional,
the likely cause is that the scrub relay has not
engaged.
• If 24 volts is present at the scrub relay coil when
the brush switch(es) are closed, then the relay is
the cause.
• Verify that the 24-VDC power supply is receiving
120-volt power.
• Verify that the output of the power supply is 24
volts when receiving 120-volt supply.
24VDC
Power Supply
120 V AC
24 V DC
44
Service Manual – Clarke CA30 20B and 17E
Scrub System
Brush Motor (20B)
The brush motor is a DC-powered, internally commutated (carbon brush) motor. The motor receives positive
battery power through its own dedicated 30-amp circuit breaker. Negative battery power comes from the
brush relay located adjacent to the control board. The brush relay coil receives both positive and negative
power directly from the control board. Failure of the brush motor can generally be isolated to the 30-amp
circuit breaker, the brush relay, the motor’s carbon brushes, the control board, or the brush switches in the
machine handle.
If the brush motor is non-functional, make the following inspections and observations. The sequence of the
following examinations is based on ease of access, and not necessarily by likelihood to occur.
1. Check the function of the brush circuit breaker.
2. Hold both brush switches closed. If the brush motor works with one switch but not the other, then the
switch or the wires at the switch are the cause.
3. Verify the function of the switches by performing the procedure Power, Vacuum, Solution, and Brush
Switches described on page 25.
4. Turn the solution switch on and hold both brush switches.
• If solution does not flow, then the most likely cause is the control board itself, or the brush switch
connection at the control board. If 24 volts is present between C- and GND on the control board, then
the control board has failed.
Relay
• If solution does flow, the control board is not likely the
Contacts
cause, but one more check (brush relay coil voltage) is
required to eliminate the control board as the cause.
5. Check the voltage across the brush motor relay coil.
• If 24 volts is not present (and the above examination
was complete), then the control board is faulty and must
be replaced.
• If 24 volts is present, then the function of the relay will
be identified or eliminated in the next step below.
6. Check the voltage between battery positive and the output Relay
lug of the brush relay that leads to the brush motor.
Coil
• If 24 volts is not present but the coil had 24 volts in the
previous step, then the relay has failed and must be
replaced.
Brush
Relay
45
Service Manual – Clarke CA30 20B and 17E
Scrub System
Removal and Installation
Scrub Deck
Removing the scrub deck is a prerequisite procedure for many other procedures that require access to the
components on or above the scrub deck. Among other items, this provides access to the brush motor, solution
solenoid, and vacuum motor.
1. Make sure the solution and recovery tanks
are empty. Excess weight in the tanks can
throw off the balance of the machine when the
weight of the scrub deck is removed from the
machine.
A
B
C
2. Remove the squeegee to permit the machine to
tilt back farther without obstruction.
3. Remove the brush or pad holder from the
machine, and rest the scrub deck on the floor
as shown.
4. Using a 10mm hex key, remove the 4 socket
head cap screws (A) and spacer sleeves (B)
that secure the scrub deck (C) to the machine.
5. Slowly tilt the machine back until it is stable
and resting on the rear idler wheel. The scrub
deck (C) should remain on the floor.
C
B
A
6. Disconnect the solution hose (D) from the solution filter (E).
7. Move the scrub deck forward, but not so far that you pull on the wires.
D
E
46
Service Manual – Clarke CA30 20B and 17E
Scrub System
8. Disconnect the motor connector (F) and
solution solenoid connectors (G). It is not
necessary to disconnect the vacuum motor
connector (H), unless you need to service the
vacuum motor.
H
G
F
Replacement Notes
The replacement procedure is the reverse of the disassembly. When installed in the machine, the scrub deck
floats on two pivot brackets to conform to the slope of the floor. The left bracket rotates about its bolt. The
right bracket both rotates and slides vertically.
If you have difficulty holding these brackets in
K
the vertical position while lowering the machine,
use the following tips to help align them during
reassembly.
L
1. Move the scrub deck into position below the
machine. Verify the position by temporarily
lowering the machine to ensure it clears the
top of the brush motor. Raise the machine
back up.
2. Route a piece of string or light rope (L)
through one of the mounting holes in the
machine body (K).
3. Route the string through the corresponding
hole (J) in the pivot bracket (I). Note that the
string is routed from outside to inside through
the bracket.
4. Repeat the same for the second pivot bracket.
5. While lowering the machine body down over
the scrub deck, pull the string tight to keep
both pivot brackets vertical.
6. Loosely install the first screws and sleeves
(left & right), but do not fully tighten them
yet.
• Because the right-hand bracket slides
vertically, you may need to push up slightly
from the bottom to align the hole.
7. Remove the string and install the remaining
two screws and sleeves.
8. After all 4 screws are loosely installed, tighten
them all down.
J
I
47
Service Manual – Clarke CA30 20B and 17E
Scrub System
Brush Drive Belt
The brush drive belt should be periodically inspected and replaced. The drive belt is ribbed for better
engagement with the motor shaft. Belt tension is controlled by a spring loaded idler pulley.
1. Although not required, it is much easier to
perform this procedure with the scrub deck
removed from the machine. Remove the scrub
deck as described on page 46.
2. Using a 19mm wrench, loosen the belt tension jam
nut (A).
3. Using a 12mm open-end wrench, fully loosen (but
do not remove) the belt tension screw (B).
A
B
4. Starting at the pad hub (C), lift the drive belt (F)
off the pulleys (C&E) and off the motor shaft (D).
Replacement
1. Before replacing the belt, inspect the idler and
brush hub bearings. The pulleys should turn
smooth and easily, but not so easy that they
freewheel-spin. Replace if necessary.
F
2. Wrap the ribbed side of the belt around the motor
shaft. Make sure the ribs are aligned and the top
rib on the drive belt is in the top groove on the
motor shaft.
3. Wrap the smooth side of the drive belt around the
idler pulley (E).
E
4. Finish wrapping the belt around the brush hub
(C).
5. Begin tightening the belt tension screw (B) and
make sure the tension spring (G) is correctly in
position.
6. Continue tightening the tension screw until
reasonable hand pressure against the belt at (H)
deflects the belt approximately 1/8" (3mm).
7. While holding the tension screw (A) from turning,
tighten the jam nut (B).
H
G
D
C
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Service Manual – Clarke CA30 20B and 17E
Scrub System
Motor Carbon Brushes (Battery Model)
The motor brushes provide an electrical connection to the spinning rotor. The motor contains 4 brushes. The
brushes will wear over time and must be replaced. The copper strips on the rotor that the brushes contact
are called the commutator bars, and these are connected to the individual windings on the rotor.
1. Remove the Scrub Deck described on page 46.
Caution: The position of the end bell (top cap) of the motor
is critical to the operation and clearances within the
motor. Do not remove the end bell. Do not loosen the
screws securing the end bell.
DO NOT
REMOVE
Caution: Take care to not drop any objects into the motor. The
motor contains permanent magnets, which may make
retrieving metal objects difficult.
2. Remove the two screws (B) that secure the brush
shield (A) to the motor, and remove the shield.
Take care when loosening the last screw, as the
shield is springy and may fling the last screw.
A
B
The components of the brush mechanism are shown.
There are 4 of these mechanisms spaced around the
motor. The coiled spring (D) presses against the top of the
carbon brush (C), pressing it against the commutator bars
of the rotor. The carbon brush has a flexible, embedded
wire that connects to the incoming power connections (E).
3. Remove the terminal nut (E).
D
• Take care not to bend the terminal. Hold the
terminal from twisting as you loosen the nut.
C
• Take care to not drop the nut (or anything else) into
the motor.
E
4. Remove the brush wire from the terminal.
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Service Manual – Clarke CA30 20B and 17E
Scrub System
5. Using a small hooked tool, such as a dental tool (F), lift
the spring (D) off the top of the brush. Take care to not
release the spring or uncoil it.
6. While holding the spring away from the brush, slide the
old brush (C) out of the brush holder, and slide in the
new brush.
• Make sure the embedded brush wire (G) is facing
toward the bottom of the motor (toward the output
shaft).
7. Release the spring and make sure it is position in the
depression (H) in the center of the brush.
8. Connect the wire (G) to the terminal (E) and tighten the
nut. Take care to not bend the terminal.
H
G
9. Repeat the steps for the other 3 brushes.
F
D
H
G
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Service Manual – Clarke CA30 20B and 17E
51
Solution System
Functional Description
The solution tank is molded into the main body of the
machine, and is located below the recovery tank. It is
comprised of the hollow interior of the main body of the
machine.
The solution exits the solution tank at the lower-right
corner through a flow-control and shutoff valve. The
solution then passes through a filter, before reaching
the solution solenoid. The solution valve can be
adjusted to control the amount of solution flow. The
solution solenoid is strictly on/off.
Solution
Fill
Solution
Tank
The exit of the solution solenoid is positioned above
the scrub brush/pad to put solution into the scrubbing
area. The solution solenoid can be active only when the
scrub motor is active.
Solution
Solenoid
Solution
Valve
Solution
Filter
Service Manual – Clarke CA30 20B and 17E
Solution System
Maintenance and Adjustment
Solution Filter Cleaning
The solution filter prevents large particles from
fouling the solution solenoid, and must be cleaned
periodically.
1. Turn off the solution valve (A) by rotating the
handle perpendicular to the flow.
A
• Note that there will still be some water in the
lines when you remove the filter.
2. Tilt the machine up to access the filter just behind
the scrub deck.
3. Unscrew the filter bowl from the filter body.
C
B
4. Rinse the filter bowl and screen (D). Do Not try to remove the
screen from the bowl.
D
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Service Manual – Clarke CA30 20B and 17E
Solution System
Troubleshooting
The following sections present some common troubleshooting scenarios based on symptom.
Warning! Risk of electrical shock. Some of the procedures below require examining parts of the
machine while electrical power is present. Use care when examining or troubleshooting the
machine when power is present. Always disconnect power from the machine before and
after these examinations are performed.
Solution Solenoid (17E)
If neither the solution solenoid nor brush motor are functioning, proceed to the Scrub System (17E) described
on page 44.
• If the brush motor is functioning, then the 24-volt power supply, scrub switches, and scrub control relay
can be eliminated as the cause.
• Remove the control panel and check for line voltage across both pair of terminals on the solution switch
when the switch is in the on-position. If not, replace the switch.
• Check for voltage at the solution solenoid. If line voltage is present, replace the solenoid.
Solution Solenoid (20B)
The solution solenoid will be active only when the brush motor is active. If the brush motor is not
functioning, troubleshoot the brush motor first. The solution solenoid receives both positive and negative
power directly from the control board. Failure of the solution solenoid can generally be isolated to 1 of 3 ares:
the solenoid itself, the control board, or the solution switch.
1. Verify that the solution switch is functioning by performing the procedure Power, Vacuum, Solution, and
Brush Switches described on page 25.
2. Check the voltage from the control board at the wire connectors just below the control board. If 24 volts
is not present between the two wires, replace the control board.
3. Lower the brush deck out of the machine (a prerequisite to replacing the solenoid), and check the voltage
at the solenoid. If 24 volts is present, then replace the solenoid as described on page 54.
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Service Manual – Clarke CA30 20B and 17E
Solution System
Removal and Installation
Solution Solenoid
The solution solenoid is located on the scrub deck.
The inlet to the solution solenoid comes from the
solution filter, and the outlet points downward
into the center of the scrub brush.
H
G
1. Make sure the solution and recovery tanks
are empty. Excess weight in the tanks can
throw off the balance of the machine when the
weight of the scrub deck is removed from the
machine.
F
2. The scrub deck needs to be lowered from the
machine, but it doesn’t need to be completely
removed. Remove (or partially remove) the
Scrub Deck described on page 46.
• When disconnecting the solution solenoid
connectors (G) in the procedure, it is not
necessary to disconnect the brush motor
connector (F) unless you wish to completely
remove the scrub deck.
A
3. Prop the machine up so it does not tilt forward
while working under the recovery tank.
B
4. Remove the two mounting screws (C) that
secure the mounting bracket (B) to the
scrub deck, and remove the solution solenoid
assembly (A).
5. Remove the two mounting screws (D) and transfer
the mounting bracket (B) from the old solenoid to
the new solenoid.
C
A
E
6. Loosen the hose clamp (E) and transfer the
solution hose from the old solenoid to the new
solenoid.
B
D
54
Service Manual – Clarke CA30 20B and 17E
55
Squeegee System
Functional Description
The squeegee suction hose draws air/water
from the squeegee assembly. The squeegee
consists of two squeegee blades: a forward,
notched blade, and a rear scraping blade.
The notched blade permits water to pass into
the space between the two blades, where it is
drawn into the suction hose.
Squeegee
Suction
Float &
Filter
Tank Drain
Vacuum
Suction
Vacuum
Motor
Squeegee
Troubleshooting
Floor Streaks
Generally, floor streaks are caused by a problem with the squeegee. However, they can also be caused by
weak suction (see Weak Suction described on page 36).
• During normal operation, debris can get trapped under the squeegee blades. Periodically raise the
squeegee blade to clear debris.
• Clean and inspect the squeegee blades.
• If the streaks consistently appear at the center
or outside edges of the squeegee, check the
Squeegee Trim Adjustment described on page
58.
• If streaks are consistently occurring at specific
locations on the squeegee blade, check to make
sure the blade is flat and without waves (N).
• If the waves (N) keep reappearing after being
corrected, it is an indication that the retaining
strap (I) is not tightened enough to hold the
squeegee blade from slipping.
I
N
Service Manual – Clarke CA30 20B and 17E
Squeegee System
Maintenance and Adjustment
Squeegee Blade Changing
The two squeegee blades periodically need to be changed as
they wear. The blades may be flipped or 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 the
floor.
C
B
1. Remove the squeegee suction hose (C) from the squeegee
assembly (A).
B
2. Loosen the two thumbscrews (B) and slide the squeegee
assembly out of the mounting slots, and remove the
squeegee.
A
3. Pull out on the latch (D) to release the tension
on the retaining strap.
4. Free the retaining hook (E) from the edge of
the squeegee frame, and out through the hole
in the squeegee blade (F).
5. Do the same for the retaining hook on the
other end of the blade.
F
6. Remove the retaining strap and 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 all 4 edges are worn,
replace the squeegee blade with a new one.
D
E
7. To replace the blade, it may be easier to stand
the squeegee frame upright.
H
8. Lay the squeegee blade (G) over the frame
(H), and make sure the tabs and slots (J) are
aligned.
9. Replace the strap (I) and make sure the hooks
(E) pass through the holes in the blade and
around the edge of the frame.
10. Before tightening the latch, make sure the
blade is straight without waves.
J
G
I
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Service Manual – Clarke CA30 20B and 17E
Squeegee System
11. Loosen both clamping thumbscrews (K) on the
rear strap (L), and remove the strap from the
frame.
12. Remove the rear squeegee blade.
L
• The squeegee can be rotated and/or flipped
3 times to expose a new edge (4 edges total)
to the lower front. If all 4 edges are worn,
replace the squeegee blade with a new one.
K
13. To replace the blade, it may be easier to stand
the squeegee frame upright.
14. Lay the squeegee blade (M) over the frame
(H), and make sure the tabs and slots (J) are
aligned.
M
L
J
15. Replace the strap (L) and retighten both
clamping thumbscrews equally until the strap
is tight against the frame.
16. Rest the squeegee assembly flat on the floor
and examine 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 downward
force on the squeegee blades.
I
N
• If there are waves, loosen the strap and
straighten the blade.
17. Examine both front and rear squeegee blades
to make sure they are the same height, and
that both blades rest flat on the floor when the
squeegee frame is sitting level.
• Because the squeegee is curved, it is important that the blades be level with the frame, and then the
frame will be adjusted level to the floor in the next procedure.
18. Reinstall the squeegee assembly to the machine.
19. Perform the Squeegee Trim Adjustment described on page 58
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Service Manual – Clarke CA30 20B and 17E
Squeegee System
Squeegee Trim Adjustment
The squeegee trim adjustment ensures that the squeegee frame is level with the floor when the squeegee is
in the lowered, operating position. If the trim is
out of adjustment, the squeegee can leave streaks
of water at either the center or the edges of the
squeegee.
1. If this procedure is not being performed as a
follow-up to replacing the squeegee blade(s),
then make the blade examinations described
on page 57 beginning with step 16.
A
2. With 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
floor.
B
• A small bubble level (B) may be used to set
the frame of the squeegee to be level with
the floor.
4. If the squeegee is tilted up, there will be a gap at
the center, and the level’s bubble will be toward
the rear of the machine.
• Turn the adjustment knob (A) counterclockwise.
Gap
5. If the squeegee is tilted down, there will be a gap
at the outsides of the squeegee, and the level’s
bubble will be toward the front of the machine.
• Turn the adjustment knob (A) clockwise.
Gap
58