Alto ENCORE R Programming manual

AMERICAN-LINCOLN
TECHNOLOGY
ELECTRICAL
TROUBLESHOOTING
GUIDE
ENCORE R
SCRUBBER
Beginning with Serial No. 178575
Part No. 2-86-00207 2001 Printed in the U.S.AAmerican-Lincoln Technology®

American-Lincoln Technology 1-1
ENCORE R Troubleshooting Guide
GENERAL STATEMENT ......................................................................................................................... 1-2
DRIVE MOTOR FORWARD .................................................................................................................... 1-3
DRIVE MOTOR REVERSE ..................................................................................................................... 1-4
SQUEEGEE CIRCUIT ............................................................................................................................. 1-5
VACUUM CIRCUIT .................................................................................................................................. 1-6
HORN, HOUR, AND CONDITION METER CIRCUITS .............................................................................. 1-7
LOW BATTERY SHUT DOWN CIRCUIT .................................................................................................. 1-8
SCRUB BRUSHES CIRCUIT ................................................................................................................... 1-9
BRUSHES AND SOLUTION OFF IN NEUTRAL CIRCUIT ......................................................................... 1-10
INDEX ..................................................................................................................................................... 1-11
TABLE OF CONTENTS

1-2 American-Lincoln Technology
ENCORE R Troubleshooting Guide
ELECTRICAL SERVICE GUIDE
ENCORE R (2)
CAUTION STATEMENT
As with all electrical equipment, caution is essential when doing electrical service. Remove all watches, rings
and jewelry before proceeding. Take care when doing power checks. Take time needed to place meter leads
correctly so as not to short to nearby terminals and/or electrical connections. Do not forget to disconnect
power at the battery when doing continuity checks or damage to your test meter may result. All Electrical
service should be done by a qualified technician experienced in DC voltage and DC testing equipment.
GENERAL STATEMENT
The following guide will present each electrical circuit separately, not including options, unless they are
in electrical series with the standard machine.
1. "Power Off" means key switch is turned off.
2. "Power Disconnect" means battery unplugged from the machine.
3. All voltages are taken with the battery plugged in and the key switch on unless noted otherwise.
4. All voltage readings are taken with the meter (-) lead connected to the battery (-) or the (-) side of the
condition meter unless otherwise specified.
5. All continuity readings are taken with the key switch off and the battery disconnected.
GENERAL STATEMENT

American-Lincoln Technology 1-3
ENCORE R Troubleshooting Guide
DRIVE MOTOR FORWARD
DRIVE MOTOR FORWARD
Conditions necessary for circuit to work
1. Battery voltage 36VDC
2. Key switch on
3. CB-4&5, FU1 closed
4. Solenoids 1A & 6 closed
5. Seat switch closed
36 V BATTERY BANK
CB-5
CB-4
70 AMP
FWD. MTR. SOL.
REV. MTR. SOL.
THE SEAT SWITCH JUMPS FROM
THE REV. SOL. TO 1A AND THEN
TO THE FWD. SOL.
FU-1
10 AMP
10 AMP
10A 10
11
11
7K
7K
11
11A
7,7C,7H,
77,77C,77D
2
3
12
12
25A
25V
25W
25W
25Y
25Y 25Y
25V
1T
1
1,1A,1B
AB
AM
3
25F
25G
25A
BATT.
IGN.
ACC
FIELD
S2
6A
5B
NEW MODULE
12
11 16
1A
1A
SEAT
SW.
B+
25X
25
25
25
25X
25X
19
C
C
D
C
M
ET-103
10A
10
W/BRN.
GRN.
ORG.
BLK.
BLK./WHT
WHT
FWD.
REV.
6
5
19
39
38
18
17
17
8
16 9
1
S1
A1
A2
A1
2+ HP
DRIVE MTR.
ARM
16 PIN
1207-1141
M- B- B+ A2
T0200/0002
T200

1-4 American-Lincoln Technology
ENCORE R Troubleshooting Guide
DRIVE MOTOR REVERSE
DRIVE MOTOR REVERSE
Conditions necessary for circuit to work
1. Battery voltage 36VDC
2. Key switch on
3. CB-4&5, FU1 closed
4. 4 - Solenoids 1A & 5 closed
5 5. Seat switch closed
36 V BATTERY BANK
CB-5
CB-4
70 AMP
REV. MTR. SOL.
THE SEAT SWITCH JUMPS FROM
THE REV. SOL. TO 1A AND THEN
TO THE FWD. SOL.
FU-1
10 AMP
10 AMP
11 9A
9A
9B
9
11
7K
7K
11
11A
7,7C,7H,
77,77C,77D
2
3
12
12
25A
25V
25W
25W
25Y
25Y 25Y
25V
1T
1
1,1A,1B
AB
AM
3
25F
25G
25A
BATT.
IGN.
ACC
5B
NEW MODULE
12
11 16
1A
1A
SEAT
SW.
B+
25
25
25
19
C
C
C
C
D
M
ET-103
W/BRN.
GRN.
ORG.
BLK.
BLK./WHT
WHT
REV.
5
19
39
38
17
17
8
16 9
1
S1
5A
FIELD
S2
A1
A1
A2
A1
2+ HP
DRIVE MTR.
ARM
16 PIN
1207-1141
M- B- B+ A2
T0201/0002
T201

American-Lincoln Technology 1-5
ENCORE R Troubleshooting Guide
SQUEEGEE CIRCUIT
SQUEEGEE CIRCUIT
Conditions necessary for circuit to work.
1. Battery voltage
2. Key switch on
3. FU-3 closed
4. Rev. Switch closed
36V BANK
1,1A,1B
3
KEY SW.
8M
3A
RED
2 AMP SB
FU-3
SQUEEGEE
SWITCH
RAISE
VAC. OFF
VAC. ON
(C)
OPEN IN REVERSE
(NC)
D-100
VAC. ON
LOWER
23
23A 37
23
23A
22A
24
24
3C
7B
7P
7C,7P,7R
22,22A
22
21
20
7R
SQUEEGEE
ACTUATOR
T0202/0002
T202

1-6 American-Lincoln Technology
ENCORE R Troubleshooting Guide
VACUUM CIRCUIT
VACUUM CIRCUIT
Conditions necessary for vacuum circuit to operate
1. Battery voltage
2. Key switch on
3. Squeegee switch in middle or lower position
4. FU-3 & CB-1 closed
5. Solenoid 3A closed
KEY
SW.
CB-1
25 AMP.
CHANGE TO 50A
FOR 2ND MTR.
.
VACUUM
VACUUM SOLENOID
3A
3A
2ND VAC. OPTION
3
1,1A,1B
3C 22,22A
24
23
7B
H
FL77C
2AMPSB
FU-3
SQUEEGEE
SWITCH
RAISE
VAC. OFF
VAC. ON
D-100
VAC. ON
LOWER
T0204/0002
T204

American-Lincoln Technology 1-7
ENCORE R Troubleshooting Guide
HORN, HOUR AND CONDITION METER CIRCUITS
HORN, HOUR AND CONDITION METER CIRCUITS
Conditions necessary for circuits to work:
1. Battery voltage
2. Key switch on
3. CB-5&6 closed
4. Horn button depressed (for horn only)
5. Seat switch closed for hour meter to work
HORN
SW.
36V BANK
HORN
KEY SW.
ACC.
CB-6
10 AMP.
CB-5
10 AMP.
3A,3B,3C
1,1A1B
88
1D 1E
77D
7L
7L,7M
NEW MODULE
(B+)
12
12
3
456 7
8
9
10
11
17
13
15 14
16
11
11A
11A
12
1T
T0205/0002
CM
HM
T205

1-8 American-Lincoln Technology
ENCORE R Troubleshooting Guide
LOW BATTERY SHUT DOWN CIRCUIT
LOW BATTERY SHUT DOWN CIRCUIT
Conditions necessary for circuit to work
1. Battery voltage
2. Key switch on
3. CB-5 closed
4. Solenoid 2A opens with battery voltage 31.5(CCV) for more then 60 seconds. Water shut off solenoid off
with battery volt age 31.5(CCV) for more then 60 seconds.
5. Items 4 and 5 can be re -set by turning key off for about 3-5 seconds, then back on.
T0206/0002
NEW MODULE
(B+)
11
12
16 14
15
13
17
(B-)
CB-5
2A
SCRUB BRUSH SOL.
10 AMP
11
13
32A 32
7A,7B
7M,7N
14
77
77Z
7,7A
3
3
3A
12
1T
1,1A,1B
BATT.
IGN.
ACC
WATER
SHUT OFF SOL.
SOLUTION FLOW
MODULE
36 V BATTERY BANK
7,7C,7H,
77,77C,77D
1AB
REV. MTR. SOL.
FWD. MTR. SOL.
5
6
10,10A
11
11A
R
LOW VOLTAGE
(B+)
(B-) (M-)
(M+)
17
17
18
18
1207-1135
CONNECTOR
TO THROTTLE
CONTROL UNDER
FOOT PEDAL 10
10B
9B
9A
9A
9
8
16 9
1
T206

American-Lincoln Technology 1-9
ENCORE R Troubleshooting Guide
SCRUB BRUSHES CIRCUIT
SCRUB BRUSHES CIRCUIT
Conditions necessary for circuit to work
1. Battery voltage
2. Key switch on
3. CB-4&5 closed
4. Solenoid 5 closed in rev.
5. Solenoid 6 closed in forward.
6. Solenoid 2A closed when not in neutral andbrushes down with battery voltage above 31.5(CCV)
7. Seat switch closed
NEW MODULE
(B+)
11 1
2
3
45
67
8
9
10
13
12
15
16 (B-)
CB-5
CB-4
2A
SCRUB BRUSH SOL.
10 AMP
10 AMP 25F
7D,7E
27
26
26
33 34 35 28 27
11
13
7K
17
17
18
18
7G
7F,7G
7E,7F
7A,7B7A,7B
7,7A
29
30
31
28
2
3
3
3A
12
1T
25G,H,J
36
36
25
25F
25G
1,1A,1B
BRUSH
DECK
SWITCH
BATT.
IGN.
ACC
OFF
UP
DOWN
YEL
RED
LOADED
DOWN
OFF
RAISE
BRUSH DECK
ACTUATOR
1207-1135
CONNECTOR
TO THROTTLE
CONTROL UNDER
FOOT PEDAL
R
Y
G
36 V BATTERY BANK
7,7C,7H,
77,77C,77D
1AB
REV. MTR. SOL.
FWD. MTR. SOL.
5
6
10,10A 11
10
10B
9B
9A
9A
9
11A
SCRUB BRUSH
MOTORS
300 RPM
2A
E
77A
77B
K
J
E
G
CB-2
45 AMP.
45 AMP.
CB-3
8
16 9
1
T0207/0002
T207

1-10 American-Lincoln Technology
ENCORE R Troubleshooting Guide
BRUSHES AND SOLUTION OFF IN NEUTRAL CIRCUIT
BRUSHES AND SOLUTION OFF IN NEUTRAL CIRCUIT
Conditions necessary for circuit to work
1. Battery voltage
2. Key switch on
3. CB-5 closed
4. Solenoid 2A opens with foot pedal in neutral and no voltage on pin #9 (wire11)
5. Water shut off solenoid off with foot pedal in neutral and no voltage on pin #9 (wire11) or knob on solution
flow module is turned full clockwise.
NEW MODULE
(B+)
11
12
16 14
13 (B-)
CB-5
2A
SCRUB BRUSH SOL.
10 AMP
11
13
7A,7B
7,7A
3
3
3A
12
1T
1,1A,1B
BATT.
IGN.
ACC
36 V BATTERY BANK
7,7C,7H,
77,77C,77D
1AB
15
(B+)
(B-) (M-)
(M+)
32A 32
77
77Z
WATER
SHUT OFF SOL.
SOLUTION FLOW
MODULE
REV. MTR. SOL.
FWD. MTR. SOL.
5
6
10,10A
11
11A
17
17
18
18
1207-1135
CONNECTOR
TO THROTTLE
CONTROL UNDER
FOOT PEDAL
10
10B
9B
9A
9A
9
8
16 9
1
T0208/0002
T208

American-Lincoln Technology 1-11
ENCORE R Troubleshooting Guide
INDEX
BRUSHES AND SOLUTION OFF IN NEUTRAL CIRCUIT ......................................................................... 1-10
DRIVE MOTOR FORWARD .................................................................................................................... 1-3
DRIVE MOTOR REVERSE ..................................................................................................................... 1-4
GENERAL STATEMENT ......................................................................................................................... 1-2
HORN, HOUR, AND CONDITION METER CIRCUITS .............................................................................. 1-7
INDEX ..................................................................................................................................................... 1-11
LOW BATTERY SHUT DOWN CIRCUIT .................................................................................................. 1-8
SCRUB BRUSHES CIRCUIT ................................................................................................................... 1-9
SQUEEGEE CIRCUIT ............................................................................................................................. 1-5
VACUUM CIRCUIT .................................................................................................................................. 1-6

1-12 American-Lincoln Technology
ENCORE R Troubleshooting Guide
NOTES