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Clarke ENCORE MAX, Operator'S Manual & Parts List, Page: 3 / 61

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Clarke ENCORE MAX Operator'S Manual & Parts List Download Page 3

CLARKE

          1-3

ENCORE MAX

INDEX

C

CONTROLS  21

D

DECIMAL-METRIC CONVERSION TABLE  5
DISCLAIMER  4

E

ELECTRICAL SCHEMATIC  53

H

HARDWARE ABBREVIATIONS  6
HYDRAULIC TORQUE REQUIRENMENTS  8

I

INDEX  3

M

MACHINE PREPARATION  17
MAINTENANCE  39

O

OPERATING INSTRUCTIONS  30
ORDERING PARTS  10

S

SAFETY PRECAUTIONS  11
SPECIFICATIONS  14
STANDARD HARDWARE & TORQUE VALUES  7
SYMBOLS  9

T

TROUBLESHOOTING  50

W

WIRE HARNESS CONNECTIONS  54
WIRE HARNESS CONNECTIONS-SPRAY WAND  58
WIRE HARNESS ROUTING & CONNECTIONS  56

Summary of Contents for ENCORE MAX

Page 1: ...empting any service or maintenance procedure to your 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 i...

Page 2: ...1 2 CLARKE ENCORE MAX NOTES...

Page 3: ...6 HYDRAULIC TORQUE REQUIRENMENTS 8 I INDEX 3 M MACHINE PREPARATION 17 MAINTENANCE 39 O OPERATING INSTRUCTIONS 30 ORDERING PARTS 10 S SAFETY PRECAUTIONS 11 SPECIFICATIONS 14 STANDARD HARDWARE TORQUE VA...

Page 4: ...ny way or in the event that such machinery or controls are not maintained in a proper manner the instructional material contained herein may be rendered inaccurate The information contained herein is...

Page 5: ...CLARKE 1 5 ENCORE MAX FRACTION FRACTION DECIMAL DECIMAL MILLIMETER MILLIMETER C 2001 9907 DECIMAL METRIC CONVERSIONTABLE...

Page 6: ...exagonal Socket Flat Head Cap Screw KNH Knurled Head Screw MHHC Metric Hexagon Head Cap Screw PHM Pan Head Machine Screw RHD Round Head Drive Screw RHM Round Head Machine Screw RHW Round Head Wood Scr...

Page 7: ...9 76 110 153 267 130 22 40 63 95 138 191 338 545 818 151 24 44 70 108 155 216 378 18 33 47 114 19 34 55 85 20 35 54 132 22 39 62 95 5 9 13 32 6 10 16 20 37 49 120 23 41 64 156 21 34 49 120 C C C C F F...

Page 8: ...LB FT 3 3 8 24 8 10 4 9 16 18 10 12 7 16 20 14 16 5 1 2 20 18 20 6 11 16 16 18 20 9 16 18 24 25 8 13 16 16 32 35 3 4 16 50 60 10 1 14 46 50 7 8 14 72 80 12 1 3 16 12 65 70 1 1 16 12 125 135 14 1 3 16...

Page 9: ...Hazard Cover or Hopper Could Close Turn Key Off Lock Wheel WARNING ATTENTION Squeegee Up Vacuum Off Battery Charger Choke Fan On Filter Shaker On Forward Reverse Headlights Hopper Dump Hopper Return H...

Page 10: ...B BRUSHES 505 955 ENCORE MAX 38 330 AH w PAD DRIVER ASSEMBLY 505 956 ENCORE MAX 38 370 AH w POLYPROPYLENE SCRUB BRUSHES 505 957 ENCORE MAX 38 370 AH w LITE GRIT SCRUB BRUSHES 505 958 ENCORE MAX 38 370...

Page 11: ...before working in this area Repairs must be performed by authorized personnel only WARNING The following safety labels are mounted on the machine in the locations indicated If the labels become damag...

Page 12: ...es may get caught in the machine and cause physical injury Wear OSHA NIOSH protective eye wear or prescription glasses to protect eyes Wear appropriate gloves when filling and or draining tanks Before...

Page 13: ...ate recommended by the chemical manufacturer Water solutions or cleaning materials used can leave wet areas on floor surfaces causing dangerous conditions for the operator or other persons Always put...

Page 14: ...SH 1 7 hp 1 3kw MOTOR DRIVE 1 5 hp 1 1kw WHEELS 1 Front 12 0 31 8 cm 2 rear 12 0 31 8 cm BRUSH SIZE Encore Max 34 2 17 43 2 cm DIA Encore Max 38 2 19 48 3 cm DIA CLEANING PATH Encore Max 34 34 86 4 cm...

Page 15: ...5 85 cm Brush Housings 41 0 104 1 cm Squeegee 42 0 106 7 cm HEIGHT 51 129 5 cm HEIGHT W OHG 80 203 2 cm WEIGHT Encore Max 34 1800 lb 817 2 kg Encore Max 38 1820 lb 826 3 kg WARRANTY Machine 2 year 2...

Page 16: ...1 16 CLARKE ENCORE MAX SPECIFICATIONS...

Page 17: ...hipped on a pallet covered by a plastic bag and fastened with four hold down brackets 1 Remove plastic bag 2 Unbolt lag screws located on each corner of machine 3 Lift out bracket located on each corn...

Page 18: ...cable 11 Install batteries Turn the key to the O position Lift the hinged seat and cover then disconnect seat switch and remove seat plate Use a battery lifting device with a 150 LB 68KG capacity to p...

Page 19: ...BATTERY BATTERY CONNECTOR WIRE BATTERYINSTALLATION To install batteries lift the seat cover and secure safety latch in notch Pull up on the side panel and remove to gain access to the battery compart...

Page 20: ...as shown in figure 9 Fig 9 CONNECTOR ASSEMBLY TO BATTERY Fig 10 LOWER SEAT TO COVER BATTERIES Fig 11 Plug the battery connector assembly from the battery to the machine connector assembly as shown in...

Page 21: ...itch 3 Low Solution Light Left High Recovery Light Right 4 Scrub Pressure Switch 5 Squeegee Vacuum Switch 6 ESP 7 Light Switch Optional 8 LCD Display 9 Forward Reverse Switch 10 Key Switch 11 Secondar...

Page 22: ...monitor machine operation The LCD display button is located in the center of the console to the right under the display Pushing on the menu button enables the operator to view screen functions and mo...

Page 23: ...n in figure 17 The brushes will not rotate until the foot throttle is depressed Releasing the foot throttle will raise the scrub deck to the top position and the brushes will stop rotating SCRUB PRESS...

Page 24: ...he squeegee vacuum switch up raises and turns off the vacuum Pushing the squeegee vacuum switch down lowers the squeegee and turns on the vacuum When the vacuum is on it is displayed as shown in figur...

Page 25: ...posited Solution flow will stop when the brushes are off or the key is in the off position LOW SOLUTION INDICATOR LIGHT The low solution amber indicator light is located on the left side above the swi...

Page 26: ...urned to the right the I position will activate all machine systems as shown in fugure 23 KEY SWITCH FORWARD REVERSE SWITCH HORN BUTTON FOOT THROTTLE FOOT THROTTLE The foot throttle is located on the...

Page 27: ...ting A secondary mechanically actuated parking brake is available as an option as shown in figure 25 To set the secondary parking brake press down the brake and then press the lock on the upper portio...

Page 28: ...g the ESP option the solution tank could become overfilled during operation LIGHT SWITCH OPTION The light switch is located on the left side of the console to the left of the steering wheel as shown i...

Page 29: ...28 SEAT SWITCH The seat switch is a interlock safety switch located on the underside the seat and is activated by the operator s body weight while seated The machine will stop immediately if there is...

Page 30: ...with all other controls in the off position 2 Push the forward reverse switch to desired position up for forward and down for reverse 3 Push down on the foot throttle to obtain desired travel speed re...

Page 31: ...bbing and dirty water pick up The rate of solution feed and the speed of travel required will vary with floor condition This knowledge will come with operator experience SAFETY FEATURES SEAT SAFETY SW...

Page 32: ...water from the solution tank is fed to the solution line There it is fed to the floor where two disc scrubbing brushes work to dislodge soil After scrubbing the dirty solution is vacuumed from the flo...

Page 33: ...s filtered water from the solution tank is fed to the solution line and then to the floor where two disc scrubbing brushes work to dislodge soil After scrubbing the dirty solution is vacuumed from the...

Page 34: ...t turn steering wheel to sharply when machine is in motion The machine is very responsive to movement of the steering wheel so avoid sudden turns Try to follow as straight a path as possible Avoid bum...

Page 35: ...Protection Agency has established certain regulations regarding discharge of wastewater The local city and state regulations regarding wastewater discharge may be in effect in your area Understand and...

Page 36: ...figure 40 and 41 To order replacement brushes see scrub brush options in this manual RECOVERY TANK HOSE RECOVERY TANK SCREEN When the draining operation is completed flush the recovery drain hose as...

Page 37: ...d reinstall so the unworn edge is now the wiping edge This process can be repeated until all four edges are worn If the squeegee blade has become rippled it will need to be replaced Inspect the inner...

Page 38: ...ed when full as shown in figure 46 WARNING There is a potential risk of the bag tearing and causing premature failure to the dust control motor and the main and side broom motor Fig 46 PRE SWEEP OPTIO...

Page 39: ...for wear or damage 2 Clean recovery tank 3 Scrub brushes for wear or damage 4 Rear squeegee for wear or damage 5 Charge and check batteries 50 HOUR MAINTENANCE CHECKLIST 6 Check battery electrolyte le...

Page 40: ...must be done by authorized personnel only Always empty the solution tank and the recovery tank before doing any maintenance Keep all fasteners tight Keep adjustments according to the specifications as...

Page 41: ...rush deck When the red light comes on steady the batteries can be charged 1 Lift seat cover make sure safety latch is secure in notch 2 Insert charging plug into battery receptacle 3 Plug power cord i...

Page 42: ...eries Always remove jewelry wear protective clothing and face protection when working near batteries Lead acid batteries generate gases which cause explosions Keep sparks and flames away from batterie...

Page 43: ...assembly from the battery to the machine connector assembly 4 Disconnect the battery connector wires from the batteries 5 Remove battery spacers holding batteries in place 6 Use a 100 lb 454 KG lifti...

Page 44: ...h a new brush onto the scrub brush driver until it clicks in place 6 Lower Scrub Deck to the NORMAL position and check the brush for proper floor contact 7 Replace side squeegees REPLACING PADS ON A P...

Page 45: ...tment handles 6 Adjust the wheels to 3 16 476 cm above the floor 7 Tighten the wheel brackets with the adjustment handles SQUEEGEE KNOB Fig 58 MAINTENANCE FOR THE REAR SQUEEGEE To remove the squeegee...

Page 46: ...he plug Fig 61 SQUEEGEE CLAMP SQUEEGEE BLADE REPLACEMENT Replace if front or rear blades are worn or damaged 1 Set the parking brake 2 Turn the key to the on position 3 Put the Squeegee Blade Switch i...

Page 47: ...4 2 Loosen pulley and broom nut 3 Force pulley and broom forward 4 Retighten Fig 64 MAIL BROOM BELT LOOSEN NUT TO ADJUST BELT IDLER PULLEY TO TIGHTEN BELT PUSH DOWN Fig 62 Fig 63 PRE SWEEP OPTION Main...

Page 48: ...cover and tighten the internal hex screws FRONT COVER 10 AMP FUSES 2 AMP FUSES 70 AMP FUSE FOR BATTERY SHORT CIRCUIT PROTECTION INTERNAL HEX SCREW Fig 65 Fig 66 Fig 67 Fig 68 MAINTENANCE Figure 67 Fu...

Page 49: ...tch Fuse Fuse 7 10 Amp Light and Horn Fuse Fuse 8 10 Amp Option Pump Fuse WARNING Replace fuses with the same size fuse to avoid damage to electrical components FU1 FU2 FU3 FU4 FU5 FU6 FU6 FU7 FU8 Fig...

Page 50: ...lution strainer and clean feed hoses for obstructions Check valve control for proper operation 5 Check wiring connections Water splashes from sides of scrub deck 1 Scrub deck bumpers poor contact with...

Page 51: ...charge low 2 Brakes dragging 3 Loose connection at foot pedal 4 Overload of drive circuit 1 Change 2 Adjust 3 Repair 4 Remove obstruction put drive pedal in neutral 5 Adjust Machine does not move 1 Bl...

Page 52: ...urn 4 Check position of switches 1 Adjust 2 Adjust 1 Replace PROBLEM Machine moves slow or erratically Machine does not move Poor water pick up at squeegee Water spills from squeegee Squeegee leaves w...

Page 53: ...CLARKE 1 53 ENCORE MAX ELECTRICAL SCHEMATIC PG 53 REMOVE INSERT 11 X 17...

Page 54: ...1 54 CLARKE ENCORE MAX WIRE HARNESS CONNECTIONS PG 54 REMOVE INSERT 11 X 17...

Page 55: ...CLARKE 1 55 ENCORE MAX NOTES...

Page 56: ...1 56 CLARKE ENCORE MAX ITEM QTY PART NUMBER DESCRIPTION 1 1 0795 169 MACHINE HARNESS 2 1 0795 175 TRACTION MOTOR HARNESS 3 1 0795 176 BATTERY POWER PANEL HARNESS WIRE HARNESS ROUTING CONNECTIONS...

Page 57: ...CLARKE 1 57 ENCORE MAX WIRE HARNESS ROUTING PG 57 Ref 71716 3 REMOVE INSERT 11 X 17...

Page 58: ...1 58 CLARKE ENCORE MAX 11 x 17 WIRE HARNESS CONNECTIONS SPRAY WAND PG 58...

Page 59: ...or the LCD s 16 way connector Ref if used the wiring to front panel switches controls and the actual switches controls All 081x codes Throttle wiring Check wiring for short circuits or broken wires on...

Page 60: ...heel switch wiring to freewheel switch switch itself Check traction motor connection on Trio wiring from this connector down to electromagnectic brake on traction motor checking connections all the wa...

Page 61: ...ct programming incorrectly specified vac thermal trip motor vac motor developing fault debris in vac motor or airways blocked by debris Vacuum current overload Incorrect programming incorrectly specif...

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