Clarke ENCORE MAX Installation and operation manual

CLARKE 1-1
ENCOREMAX
All directions given in this book are as seen from the operator's position at the rear of the machine.
For new books, write to: Clarke 2100 Highway 265, Springdale, Arkansas 72764
READ THIS BOOK
This book has important information for the use and safe operation of this machine. Failure
to read this book prior to operating or attempting any service or maintenance procedure to
your machine could result in injury to you or to other personnel; damage to the machine or to
other property could occur as well. you must have training in the operation of this machine
before using it. If you or your operator(s) cannot read English, have this manual explained
fully before attempting to operate this machine.
Part No. 2-86-00318 2003 Clarke Printed in the USA
OPERATOR’S
MANUAL &
PARTS LIST
ENCORE MAX
SCRUBBER
Beginning with Serial Number 180001
UL
®
ISO 9001
FILE A2287
#
®
Clarke
Division of

1-2 CLARKE
ENCOREMAX
NOTES

CLARKE 1-3
ENCOREMAX
INDEX
C
CONTROLS 21
D
DECIMAL-METRICCONVERSIONTABLE 5
DISCLAIMER 4
E
ELECTRICALSCHEMATIC 53
H
HARDWAREABBREVIATIONS 6
HYDRAULICTORQUEREQUIRENMENTS 8
I
INDEX 3
M
MACHINEPREPARATION 17
MAINTENANCE 39
O
OPERATINGINSTRUCTIONS 30
ORDERINGPARTS 10
S
SAFETYPRECAUTIONS 11
SPECIFICATIONS 14
STANDARD HARDWARE &TORQUEVALUES 7
SYMBOLS 9
T
TROUBLESHOOTING 50
W
WIREHARNESSCONNECTIONS 54
WIREHARNESS CONNECTIONS-SPRAYWAND 58
WIREHARNESSROUTING &CONNECTIONS 56

1-4 CLARKE
ENCOREMAX
DISCLAIMER
DISCLAIMER
Theinformationcontainedinthismanualisbelievedcorrectatthetimeofpublication.
AmericanLincolnassumesnoresponsibilityorliabilityfor unauthorized changes made
tothismanualorpagesremoved,causingindirectorconsequentialdamagesresulting
fromtheuseoftheinformation appearing herein.
WARNING!
Intheeventthatmachineryor controls described herein are modified in any way,orin
theeventthat such machinery or controlsarenotmaintainedinapropermanner,the
instructionalmaterialcontained herein may be renderedinaccurate.Theinformation
containedhereinistobeused only by persons knowledgeable in the operation of
machinerysuchasthatdescribedherein,orotherpersonsbeingdirectlysupervisedby
suchknowledgeablepersons.
Noportionofthis manual may be reproducedwithouttheexpresswrittenconsentof:
CLARKE
ProductEngineering
1100 Haskins Road
BowlingGreen,OH43402
Telephone:[phone] Fax: [phone]
Copyright2003Clarke.Allrightsreserved.
PrintedinUSA March 2003

CLARKE 1-5
ENCOREMAX
FRACTION FRACTION
DECIMAL DECIMAL
MILLIMETER MILLIMETER
C-2001/9907
DECIMAL-METRIC CONVERSIONTABLE

1-6 CLARKE
ENCOREMAX
HARDWARE ABBREVIATIONS
ABBREVIATIONS - SCREWS
ADJ = Adjusting Screw
ADJ.SP = Adjusting Plunger Screw
BHM = Binding Head Machine Screw
BHS = Button Head Socket Screw
CAPT.SL = Captivated Slotted Screw
CAPT.WG = Captivated Wing Screw
FHM = Flat Head Machine Screw
FIL.HM = Filister Head Machine Screw
HHC = Hexagon Head Cap Screw
HHM = Hexagon Head Machine Screw
HIHD = 1/2 High Head Screw
HSHC = Hexagonal Socket Head Cap Screw
HSFHC = Hexagonal 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 Screw
SHC = Shiny Crown Cap Screw
SHTB = Shoulder Thumb Screw
SQ = Square Head Screw
TB = Thumb Screw
THM = Truss Head Machine Screw
WELD = Weld Stud
WG = Wing Screw
ABBREVIATIONS - SETSCREWS
HS = Hexagonal Socket Setscrew
S= Slotted Setscrew
SH = Square Head Setscrew
-KCP = Knurled Cup Point Setscrew
-CP = Cup Point Setscrew
-OP = Oval Point Setscrew
-FDP = Full Dog Point Setscrew
-HDP = Half Dog Point Setscrew
-FP = Flat Point Setscrew
-COP = Cone Point Setscrew
C-2004

CLARKE 1-7
ENCOREMAX
SAE - Grade 5 SAE - Grade 8
Screw
Size
Grade
5
Plated
Grade
8
Plated
410H
Stainless
Brass Type
F&T
&BT
Type
B, AB
*6
*8
*10
*1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
14
27
39
86
15
28
44
68
98
135
239
387
579
15
28
43
108
17
31
49
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
CCC
FFF F
C = Coarse Thread
F = Fine Thread
* = Torque values for #6 through 1/4 are lb./in. All others are lb./ft.
NOTE
Decrease the torque by 20% when using thread lubricant
The torque tolerance is ± on torque values.
C2000/9905
STANDARD HARDWARE & TORQUE VALUES

1-8 CLARKE
ENCOREMAX
HYDRAULIC TORQUE REQUIREMENTS
Refer to the following chart for torque values on all hydraulic hoses and fittings.
Nominal O-Ring Face Seal End SAE O-Ring Boss End
SAE Thread Swivel Thread Str. Fitting
Dash Size Nut Size or Locknut
Size Inch Torque Inch Torque
LB-FT 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 3/16-12 65-70 1 3/16-12 160-180
-16 1 7-16-12 92-100 1 5/16-12 200-220
-20 1 11/16-12 125-140 1 5/8-12 210-280
-24 2-12 150-165 1 7/8-12 270-360
* O-Ring face seal type end not defined for this tube size.
NOTE
Parts must be lightly oiled with hydraulic fluid.
C-2002
HYDRAULIC TORQUE REQUIRENMENTS

CLARKE 1-9
ENCOREMAX
Scrub Brush Down Heavy Pressure
Squeegee Down & Vacuum On
Squeegee Up & Vacuum On
Solution Tank Low
Solution Flow Control
Throttle
Read Machine Manual
No gas or combustibles in tank
Keep Away From Flames/
Wear Eye Protection
Electrical Hazard
Stay Clear
Moving Fan Blade
Pinch Point/Crush 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
Horn
Main Broom & Side Broom Up
Main Broom & Side Broom Down
No Step
Off
On
Power
Recovery Tank High
Scrub Brush Down & On
Scrub Brush Up and Off
THESE SYMBOLS IDENTIFY CONTROLS, DISPLAYS/FEATURES, AND SAFETY SYMBOLS ON THE MACHINE.
Before Operating or Servicing
NO Smoking
Engage Support
Before Leaving Seat
SYMBOLS

1-10 CLARKE
ENCOREMAX
®
®
MODEL NO. SERIAL NO.
Manufactured By
AMERICAN LINCOLN
TECHNOLOGY
BOWLING GREEN, OHIO
Parts may be ordered from Clarke authorized distributors. Record the
information from the serial number plate to avoid delays in filling your order.
Parts may be ordered from Clarke authorized distributors. Record the
information from the serial number plate to avoid delays in filling your order.
Parts and supplies listed in this manual can be ordered from the following address
:Parts and supplies listed in this manual can be ordered from the following address:
Clarke Clarke Distributor
Clarke Distributor
2100 Highway 265
Springdale, AR 72764
1-800-253-0367
2100 Highway 265
Springdale, AR 72764
1-800-253-0367
505-947
505-948
ENCORE MAX 34” (330 AH) w/POLYPROPYLENE SCRUB BRUSHES
ENCORE MAX 34” (330 AH) w/LITE GRIT SCRUB BRUSHES
505-949 ENCORE MAX 34” (330 AH) w/PAD DRIVER ASSEMBLY
505-950 ENCORE MAX 34” (370 AH) w/POLYPROPYLENE SCRUB BRUSHES
505-951 ENCORE MAX 34” (370 AH) w/LITE GRIT SCRUB BRUSHES
505-952 ENCORE MAX 34” (370 AH) w/PAD DRIVER ASSEMBLY
505-953 ENCORE MAX 38” (330 AH) w/POLYPROPYLENE SCRUB BRUSHES
505-954 ENCORE MAX 38” (330 AH) w/LITE GRIT SCRUB 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 AH) w/PAD DRIVER ASSEMBLY
505-947
505-948
ENCORE MAX 34” (330 AH) w/POLYPROPYLENE SCRUB BRUSHES
ENCORE MAX 34” (330 AH) w/LITE GRIT SCRUB BRUSHES
505-949 ENCORE MAX 34” (330 AH) w/PAD DRIVER ASSEMBLY
505-950 ENCORE MAX 34” (370 AH) w/POLYPROPYLENE SCRUB BRUSHES
505-951 ENCORE MAX 34” (370 AH) w/LITE GRIT SCRUB BRUSHES
505-952 ENCORE MAX 34” (370 AH) w/PAD DRIVER ASSEMBLY
505-953 ENCORE MAX 38” (330 AH) w/POLYPROPYLENE SCRUB BRUSHES
505-954 ENCORE MAX 38” (330 AH) w/LITE GRIT SCRUB 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 AH) w/PAD DRIVER ASSEMBLY
MACHINE CATALOG NUMBERS
MACHINE CATALOG NUMBERS
1. Use the model number, catalog number, and serial number when ordering.
2. Give the part number, description, and quality of parts needed.
3. Give shipping instructions for either freight, UPS, or parcel post.
1. Use the model number, catalog number, and serial number when ordering.
2. Give the part number, description, and quality of parts needed.
3. Give shipping instructions for either freight, UPS, or parcel post.
ORDERING PARTS

CLARKE 1-11
ENCOREMAX
SAFETY PRECAUTIONS
ELECTRICAL HAZARD - Shocks can
cause serious personal injury
Disconnect battery 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 damaged
or illegible replace with identical label.
Scrub deck presents hazard
for crushing, entanglement,
friction and abrasion

1-12 CLARKE
ENCOREMAX
HAZARDSERIOUSNESSLEVEL
Signalwords (DANGER,WARNING and CAUTION)are used toidentify levelsof hazard seriousness.The
degreeofseverityis based on the likely consequences of human interaction with the hazard.
DANGER
To warnof immediate hazards whichwillresult in severe personalinjury or death.
WARNING
To warnof hazard or unsafepractices which could resultinsevere personal injury.
CAUTION
Towarn of hazards or unsafe practiceswhich could result in minor personal injury.
ATTENTION
Towarn of unsafepractices which could resultin extensive equipment damage.
NOTE
To giveimportantinformation or to warnof unsafe practices whichcould result in equipmentdamage.
Forthe safe operationof this machine,read and understandallWARNINGS, CAUTIONSANDNOTES.
PERSONALSAFETY
• Readthis manual carefully.The following information signalspotentially dangerous conditionstothe
operator or equipment. Know when these conditions can exist then take necessary steps to train
machineoperatingpersonnel.
• Dress appropriately; loose clothing, jewelry and other accessories may get caught in the machine and
cause physical injury.
• WearOSHA/NIOSH protective eye wear orprescriptionglasses to protect eyes.
• Wearappropriate gloveswhen fillingand/ordraining tanks.
• Beforeoperating machine, test brake mechanism, lightsand back up alarm (if applicable).
• Observemaintenance schedule guidelinesto assume optimalsafeoperation of themachine.
• Be aware of pinch pints that exist on the machine.
• Do not operate machine if you are tired, upset, ill on medication or intoxicated.
• Becompletely aware of yoursurroundings. STOP,LOOK,and LISTEN forotheremployees walking in or
aroundyour cleaningarea.
MACHINESAFETY
• Operatormust be properlytrained to operate machine.
• Readthis manualbefore operatingmachine
• Familiarizeyourself with all componentsandsafety features.
• Do not operate machine unless it is completely assembled.
• Do not use machine other than intended use.
• Reportdamages or maintenance problem immediately. Donotuse machine until ithasbeen repaired.
• Repairsshould bedoneby authorizedpersonnel.
• For storage, keep machine in a building.
• This machine is not at tow truck and should not be used for towing.
•Do not use this machine as a step or furniture.
•Donot operate machine onpublic highways, gravel, sand,grass and other unsafesurfaces.
SAFETY PRECAUTIONS

CLARKE 1-13
ENCOREMAX
•Becareful when operating the machineon a ramp or incline.Do not operate machine onincline greater
than 8° or longer than 100’. Always move slowly on a ramp. Do not turn this machine on a ramp.
•Do not stop and leave this machine on a ramp.Always stop the machine on a level surface, put the
power switch in the on position.
• To prevent injury, and damage to the machine, do not lift the machine or move it to an edge of a stair or
loadingdock.
•Turnoff machinewhen unattended, filling,fueling ordoingmaintenance onmachine (if applicable).
•Donot operate machine nearflammablematerials, fire or explosionmay occur.
•Solution or recovery tank should not be filled with fuel or chemicals.
•Read label on cleaning solutions to verify it is safe for machine.
•Usea cleaning concentraterecommended by the chemicalmanufacturer.
•Watersolutions or cleaning materialsused can leave wetareason floor surfaces causingdangerous
conditionsfor the operator orother persons.AlwaysputCAUTION signs near areayou are cleaning.
•Usecare whenreversing machine.
•Alwaysempty the solution tankandrecovery tank before doingmaintenance.
• Unplugthe battery first toprevent possible injury whenservicing a machine.
• Lead acid batteries generate gases, which can cause an explosion. Keep sparks and flames away
frombatteries. NO SMOKING.Charge batteries only inarea with good ventilation.
• Alwayswear eye protectionand protective clothingwhen working near batteries.Remove all jewelry.
Do not put tools or other metal objects across the battery terminals, or the tops of batteries.
•Keep electrical parts of the machine dry.
• Make sure that all labels, decals, warnings, cautions and instructions are fastened to the machine.
Getnew labels anddecalsfromAmerican-Lincoln.
SAFETY PRECAUTIONS

1-14 CLARKE
ENCOREMAX
POWER SUPPLY
EncoreMax (34”) 36 volt(6-6 volt batteries) 340AHor 370AH
EncoreMax (38”) 36 volt(6-6 volt batteries) 340AHor 370AH
EncoreMax(34” & 38”) For machinetooperate properly,voltage readingshould fall
withinthe 32-40Vrange
CHARGER
EncoreMax (34” & 38”) 36 Volt output, 115V/60Hzor 230V/50Hz Input
MOTORS,VACUUM 1 HP (.74 kw), 3 stage, tangential discharge
MOTORS,BRUSH 1.7hp(1.3kw)
MOTOR,DRIVE 1.5 hp(1.1kw)
WHEELS (1)Front 12.0” (31.8 cm) (2)rear 12.0” (31.8 cm)
BRUSHSIZE
EncoreMax (34”) 2-17” (43.2cm) DIA.
EncoreMax (38”) 2-19” (48.3cm) DIA.
CLEANINGPATH
EncoreMax (34 “) 34” (86.4 cm)
EncoreMax (38”) 38” (96.5cm)
BRUSHSPEED 300RPM
SOLUTIONTANK 45gallon (171liter)
RECOVERYTANK 45gallon(171liter)
SPEED,TRANSPORT 5 MPH
SPEED,SCRUBBING 2.5 MPH
TURNRADIUS 56”(142.2 cm)
U-TURNAISLE WIDTH 80” (203.2 cm)
CLEANINGRATE
EncoreMax (34”) 37,000 sq. ft/hr (3426 sq. m/hr)
EncoreMax (38”) 42,000 sq. ft/hr (3901 sq. m/hr)
GRADECLEANING 3°
GRADETRANSPORT 8°
LENGTH 71.5”(181.6 cm)
SPECIFICATIONS

CLARKE 1-15
ENCOREMAX
WIDTH
EncoreMax (34”) Machine 33.5” (85cm)
BrushHousings 38.0” (96.5 cm)
Squeegee 42.0”(106.7cm)
EncoreMax (38”) Machine 33.5” (85cm)
BrushHousings 41.0” (104.1cm)
Squeegee 42.0”(106.7 cm)
HEIGHT 51”(129.5 cm)
HEIGHTW/OHG 80” (203.2cm)
WEIGHT
EncoreMax (34”) 1800 lb.(817.2 kg)
EncoreMax (38”) 1820 lb.(826.3 kg)
WARRANTY
Machine 2 year/2,000hours
Polydur® tanks lifeof machine
ElectricaDrive LineComponents 3 years/3,000hours
Batteries 18months, prorated
SPECIFICATIONS

1-16 CLARKE
ENCOREMAX
SPECIFICATIONS

CLARKE 1-17
ENCOREMAX
Your Encore Max battery machine has been shipped complete, but do not attempt to operate without reading
thefollowing instructions:
UNPACKINGANDASSEMBLING MACHINE
The Encore Max is shipped 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 corner of machine from slot in machine frame.
4)Remove rearsqueegee andhose fromunder rearsqueegee location.
6) Position a 11° and 36” ramp on base of pallet.
MACHINE PREPARATION
11 DEGREE
36 INCHES
Fig. 2
Fig. 1

1-18 CLARKE
ENCOREMAX
METAL BAR
BRAKE RELEASE LEVER ELECTRICALLY ACTUATED
MECHANICAL PARKING BRAKE
MACHINE PREPARATION
Fig. 3
WARNING
Disconnect the traction harness before towing the machine.
6) The machine is shipped with a metal bar between the electrically actuated parking brake and the brake
releaseleverto keep the electrically actuated parking brake disengaged.
7) Push machine down the ramp onto a flat surface.
WARNING
8) Remove the metal bar to engage the electrically actuated mechanical parking brake.
9)Connect rear squeegee hoseand install squeegee bladeas shown in manual.
10)Remove battery chargerfrom under theseatin battery compartment(if applicable).
11) Installbatteries.
-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 place the batteries battery compartment.
-Install Battery wires as shown in manual.
-Plugthe polarized connector from thebatteryon into the 36 Voltplug provided.
-Install scrub brushes as shown in the manual.
-Lowerseat and coverassembly.
12)Charge batteries asshownin the manual.Readbattery manufacturer literaturefor battery care and
maintenance.
WARNING
Do not charge batteries on a concrete grounded surface. Hydrogen gas is formed during the charging
operation and is explosive. Only charge batteries in a well ventilated area with the lid open. Avoid
any smoking, open flame, or electrical sparks.
DISCONNECT TRACTION
HARNESS CABLE BEFORE
TOWING THE MACHINE
Fig. 4

CLARKE 1-19
ENCOREMAX
REMOVE BATTERY
FROM BOX
UNPACKINGBATTERY
The batteries are shipped separately in six boxes as shown in figure 5. Open the boxes on a clean work
surface and lift out the battery as shown in figure 6.
BATTERY COMPARTMENT
SAFETY LATCH
BATTERY CONECTOR
SIDE PANNEL
BATTERY SPACER
(
NARROW SIDE UP)
BATTERY SPACER
(NARROW SIDE UP
6VOLT
LEAD ACID
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 compartment. Lower batteries using a 1000 lb. (454 KG) lifting mechanism to lift
and install batteries into battery compartment placing battery spacers to stop from moving. Connect battery
connector wires in series to batteries as shown in figure 8.
WARNING
Do not leave charged batteries on concrete surface, they will discarge.
MACHINE PREPARATION
Fig. 6
Fig. 5
Fig. 7 Fig. 8

1-20 CLARKE
ENCOREMAX
CONNECT BATTERIES
MACHINE PREPARATION
Connect the battery connector assembly to battery 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 figure
10. Reinstall the side panel and then release the safety latch and lower the seat as shown in figure 11.