ES4000™

Service Manual
Advance Model 56344200

English

06/11 Revised 11/13 Form No. 56043152

Service Manual – ES4000 Contents ii

Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Manuals Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions and Warnings Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional Description for Battery Condition Displays . . . . . . . . . . . . . . . . . . 10
Functional Description of Additional Status Displays . . . . . . . . . . . . . . . . . . 10
Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Functional Description of Control Switches . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vacuum Shoe Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Spray Nozzle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lubricating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning the Vacuum Motor Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Scrub Brush Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery Compartment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Aisle Turn Around Radius (turning left) . . . . . . . . . . . . . . . . . . 24
Minimum Door Pass-Thru Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Functional Description—Main Components . . . . . . . . . . . . . . . . . . . . . . . . 25

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control System Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Functional Description of Main Controller . . . . . . . . . . . . . . . . . . . . . . . . . 30
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hidden Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Program Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Extra Info on LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replace the Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Shop Measurements – Main Controller . . . . . . . . . . . . . . . . . . . . . . . . 55
Service Manual – ES4000 Contents iii

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Battery Charger (on-board and portable) . . . . . . . . . . . . . . . . . . . . . . . 62
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
When Servicing Batteries: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Battery Low Voltage Cutout Feature - Description . . . . . . . . . . . . . . . . . . 66
Battery Condition Indicator - Description . . . . . . . . . . . . . . . . . . . . . . . 66
Battery LOCK Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Charging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
To Charge the Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Machine and Chassis Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Machine and Chassis Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INPUT/OUTPUT TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Shop Measurements – Main Controller . . . . . . . . . . . . . . . . . . . . . . . . 78
Wiring (Ladder) Diagram 56344090 Rev. C (1 of 2) . . . . . . . . . . . . . . . . . . . . 81
Wiring (Ladder) Diagram 56344090 Rev. C (2 of 2) . . . . . . . . . . . . . . . . . . 82
Wiring Harness Diagram 56344091 Rev. C (1 of 2) . . . . . . . . . . . . . . . . . . . . 83
Wiring Harness Diagram 56344091 Rev. C (2 of 2) . . . . . . . . . . . . . . . . . . 84

Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Recovery System—Vacuum General . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Recovery System Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . 91
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Recovery System Service Maintenance Checklist . . . . . . . . . . . . . . . . . . . 94
Vacuum Filter and Float Cage Maintenance . . . . . . . . . . . . . . . . . . . . . 94
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Vacuum Motor(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Recovery Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Vacuum Shoes Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Recovery System Wet and Dry Pickups—Accessory Port . . . . . . . . . . . . . . 102
Pickup Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Dry Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Accessory Port—Using Attachments . . . . . . . . . . . . . . . . . . . . . . . 105
Recovery Shoe Lift Actuator Removal and Adjustment . . . . . . . . . . . . . . . 106
Actuator Drive Screw Tube Adjustment . . . . . . . . . . . . . . . . . . . . . . . 108
General Instructions for All Actuator Motors . . . . . . . . . . . . . . . . . . 108
Lift Actuator Drive Screw Tube Adjustment . . . . . . . . . . . . . . . . . . 109
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Actuator Power Cord Adaptor (part # 56407502) . . . . . . . . . . . . . . . . . . . 111
Service Manual – ES4000 Contents iv

Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Solution System Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . 113
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Mechanical / Electrical / Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Purge Chemical Pump Weekly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
To Reset the Detergent Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Detergent Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Nozzle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Chemical Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Solution Solenoid Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Solenoid Valve Disassembly and Cleaning . . . . . . . . . . . . . . . . . . . . . . 128
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Scrub System Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Scrub System Brush Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Scrub Deck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Scrub Deck Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Actuator Drive Nut Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
General Instructions for All Actuator Motors . . . . . . . . . . . . . . . . . . 144
Scrub Deck Lift Actuator Drive Nut Adjustment . . . . . . . . . . . . . . . . . . 145
Brush Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Scrub Brush Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Scrub Brush Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 150
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Actuator Power Cord Adaptor—Part # 56407502 . . . . . . . . . . . . . . . . . . 152

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Steering Column shroud removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Wheel System, Non-Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Service Manual – ES4000 Contents v

Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wheel System, Traction Circuit Description . . . . . . . . . . . . . . . . . . . . . 160
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Curtis Speed Controller Installation Checkout Procedure . . . . . . . . . . . . . . 165
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Speed Controller Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Speed Controller Status Light /Display Functions . . . . . . . . . . . . . . . . . 168
Wheel Drive Circuit Error Codes / Speed controller Error Flash Codes . . . . . . . 169
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Drive Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Potentiometer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Testing the Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Replacing the Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 173
Replacing the Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Inspecting/Replacing the Drive Wheel Assembly Carbon Brushes . . . . . . . . . 177
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Service Manual – ES4000 6

General Information

General Machine Description

The ES4000 is a commercial rider extractor. The ES4000 has two solution flow options and on board
chemical to allow for varying extraction needs. The ES4000 also has the ability to be a sweeper by
vacuumizing the deck and recovering soil in the recovery tank.

Service Manual Purpose and Application

This Service Manual is a technical resource designed to aid service personnel in maintaining and repairing
the ES4000 Sweeper/Extractor to ensure optimum performance and long service life. Please read it
thoroughly before servicing your machine.

Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on
pages 12-14 i.e. (B).

Document Revision History

• 05/12

–– Expanded Table of Contents

–– Turned some pages to landscape orientation for easier viewing on a computer screen

–– Added engineering identification information to wiring (ladder)diagrams and wiring harness

diagrams.
Service Manual – ES4000 General Information 7

• 11/13

–– General Information: Added missing vibration specification values

–– Electrical System: Corrected minimum voltage reset value following low voltage cut out from 24.6v to
25.08v

Nameplate

The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. The
nameplate is mounted on the steering column facing the driver. 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.

Nameplate

Transporting the Machine

CAUTION! Before transporting the machine on an open truck or trailer, make sure that .
The machine is tied down securely - see Figure G-1. All access doors and covers are
secured (tape and strap as necessary).

Figure G-1 Front Tie-Down

Service Manual – ES4000 General Information 8

Towing

CAUTION! If the machine must be towed or pushed, make sure the Key Switch (Main Power)
(J) is in the OFF position and do not move the machine faster than a normal walking
pace (2-3 mph, 3-5 kph) and for short distances only. Disengage the electromagnetic
brake by wedging an angle bar or flat head screwdriver between the brake lever and
motor as shown in the photo below.

Brake disengaged

Other Manuals Available

The following manuals are available from the Advance Literature Service Department, for your Rider
Extractor:

Parts List - Form Number 56042573

Operation Manual - Form Number 56091013

Cautions and Warnings Symbols

Advance uses the symbols below to signal potentially dangerous conditions. Always read this information
carefully and take the necessary steps to protect personnel and property. (Triangle Symbol may or may not
be used).

DANGER! Is used to warn of immediate hazards that will cause severe personal injury or death.

WARNING! Is used to call attention to a situation that could cause severe personal injury.

CAUTION! Is used to call attention to a situation that could cause minor personal injury or damage
to the machine or other property.
Service Manual – ES4000 General Information 9

General Safety Instructions

Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily
harm.

WARNING! This machine shall be used only by properly trained and authorized persons.

Other Warnings:

• While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed
down hills. Clean only while ascending (driving up) the ramp.

• Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during
normal operation.

• Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated
areas, away from open flame. Do not smoke while charging the batteries.

• Remove all jewelry when working near electrical components.

• Turn the key switch off (O) and disconnect the 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.

• Do not clean this machine with a pressure washer.

CAUTION! This machine is not approved for use on public paths or roads.

Other Cautions:

• This machine is not suitable for picking up hazardous dust.

• When operating this machine, ensure that third parties, particularly children, are not endangered.

• Before performing any service function carefully read all instructions pertaining to that function.

• Do not leave the machine unattended without first turning the key switch off (O), removing the key and
applying the parking brake.

• Turn the key switch off (O) before changing the brushes, and before opening any access panels.

• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.

• Use caution when moving this machine in below freezing temperature conditions. Any water in the
solution or recovery tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush
with windshield washer fluid.

• The batteries must be removed from the machine before the machine is scrapped. The disposal of the
batteries should be safely done in accordance with your local environmental regulations.
Service Manual – ES4000 General Information 10

Functional Description for Battery Condition Displays

The battery condition indicator (K) consists of three lights; a green (K3), a yellow (K2) and a red (K1).
A fully charged battery pack will measure above 24 volts with no load applied. The ES4000 is equipped
with a low voltage cutout feature that will turn the scrub system off when the batteries are discharged to
their minimum level. There are two different cutout levels to accommodate different battery types. See the
Electrical System “Main Control Board Special Program Options” for details. The voltage levels for the
various indications are as follows (the voltages shown represent the voltage under load):

Standard Alternate
Green 22.00+ 22.50+
Green & Yellow 21.00-21.99 22.00-22.49
Yellow 20.00-20.99 21.50-21.99
Yellow & Red 19.50-19.99 21.00-21.49
Red 19.00-19.49 21.50-21.99
Flashing Red/Cutoff <19.00 <21.50

NOTE: When the low voltage cutout level has been reached (flashing red indicator) the batteries
must be FULLY recharged (25.08V) to reset the battery condition indicator. The scrub system
will not function until the indicator has been reset.

Functional Description of Additional Status Displays

The character display on the control panel is used as a display for all functional codes. This display is also
used to display the following information depending upon which mode the control is in:

• Error codes*

• Display of control system default parameters*

• Recovery tank FULL indicator*

• If any of the systems on the machine are on or if the throttle is not in neutral, the display will be blank.

* NOTE: Reference (in the Electrical System manual section) the Main Control Board
Troubleshooting Guide and the Control Board Special Program Options sections. These
sections will explain the machine error code descriptions and cleaning system controller
default parameter changes.
Service Manual – ES4000 General Information 11
Service Manual – ES4000 General Information 12

Know Your Machine

21. Steering Wheel Tilt Adjust Knob 34. Machine Battery Connector
22. Control Panel 35. Solution Filter
23. Solution Tank Fill Cover 36. Solution Shutoff Valve
24. Recovery Tank Cover 37. Steering Wheel
25. Vacuum Motor Filter Housing 38. Wet Mode Port
26. Strainer Basket
27. Recovery Tank Shutoff Float
28. Recovery Tank Drain Hose
29. Recovery Hose
30. Dry Mode Port
31. Accessory Port
32. Seat Prop Rod
33. Rear Brush End Cap

38
Service Manual – ES4000 General Information 13

Control Panel
A. Key Switch / Main Power F. Wet Mode Switch
B. Solution ON/OFF Switch G. Interim Mode Switch
C. Detergent ON/OFF Switch H. Restorative Mode Switch
D. Dry Mode Switch I. PreTreat Mode Switch
E. LCD Display J. Horn Switch
E1. Hour Meter K. Vacuum ON/OFF Switch
E2. Fault Codes
E3. Solution Tank Level Indicator
E4. Transport Mode Indicator
E5. Detergent Indicator
E6. Detergent Ratio Indicator
E7. Battery Indicator
E8. Prespray mode Indicator
E9. Maintenance Mode Indicator
E10. Restore Mode indicator

E11. Sweep Mode Indicator

E12. Recovery Tank Full Indicator

E13. Low Voltage Cutout Indicator

Service Manual – ES4000 General Information 14

Component Descriptions
Reference machine drawings on the previous pages of this section.

• Emergency Stop / Battery Disconnect (3) – Push in on lever to disconnect batteries.

• Control Circuit Circuit Breaker (4) – Provides overload protection, 10 Amp. If it trips, it will pop out.
To reset, wait one minute and press the button back in.

• Wheel Drive Circuit Breaker (5) – Provides overload protection to machine’s wheel drive motor, 45
Amp. If it trips, it will pop out. To reset, wait one minute and press the button back in.

• Detergent Cartridge Access Cover (6)—Insert the detergent cartridge in this area. Replace when
empty.

• Battery Charger (7)—Charges batteries when plugged into an AC outlet.

• Battery Charger Access Door (8)—Access the charger through this cover.

• Drive and Steer Wheel (9) – Wheel drive motor attached to this wheel to propel machine either forward
or reverse. Also attached to Steering Wheel for steering left or right.

• Drive Pedal, Directional / Speed (10) – The operator can make the machine go forward by pushing
forward on it, or reverse by pulling backward on it. The speed is variable depending on how far forward or
backward the pedal is moved.

• Front Roller Bumper (11)—Keeps machine safe distance from walls and other obstacles.

• Brush Idler Removal Knob (12)—Removes idler for brush assembly.

• Brush deck (13)—Contains brush drive motor(s), brush(es) and solution spray jets.

• Debris Tray (14)—Collects debris that has been swept up by the machine. Empty and clean daily.

• Vacuum Shoes (15)—Removes excess solution from carpet after Extraction.

• Solution Tank Drain Hose (16)—Used to empty the solution tank.

• Rear Wheel (17)—These two wheels along with the drive wheel, support the machine. Power and
steering are supplied through the front drive wheel.

• Detergent Cartridge (18)—Contains carpet treatment/detergent.

• Battery Compartment (19)—Batteries stored here, flip seat panel up to access.

• Solution Spray Jets (20)—Based upon which extraction mode is selected (interim or restorative) the
solution will be sprayed out one of the two different jets.
Service Manual – ES4000 General Information 15

• Steering Wheel Tilt Adjust Knob (21)—Push down on this knob to adjust the Steering Wheel up or
down.

• Control Panel (22)—Operator Controls found here, see “FUNCTIONAL DESCRIPTION OF CONTROL
SWITCHES”.

• Solution Tank Fill Cover (23)—Open to fill the solution tank. Total capacity is 40 gallons (151 Liters).

• Recovery Tank Cover (24) – Open to access Recovery Tank for cleaning.

• Vacuum Motors’ Filter Housing (25) – Location of Vacuum Motors air intake filters.

• Strainer Basket (26)—Catches large to mid-size debris in Recovery Tank.

• Recovery Tank Shutoff Float (27)—Shuts off fluid flow from Recovery System when tank is full.

• Recovery Tank Drain Hose (28)—Used to empty the recovery tank.

• Recovery Hose (29)—Hose used to recover solution from carpet and deposit into Recovery Tank.

• Dry Mode Port (30)—Attach Recovery Hose (29) when using the Dry Sweep Mode.

• Accessory Port (31)—Solution attachment for additional accessories.

• Seat Prop Rod (32)—Props the seat upright for access to batteries and battery connector.

• Rear Brush End Cap (33)—Access to rear brush.

• Machine Battery Connector (34)—Batteries plug into this connector, disconnect to charge batteries.

• Solution Filter (35)—Filters solution prior to entering pump and being sprayed on the floor.

• Solution Shutoff Valve (36)—This valve should be fully open whenever operating ES4000. Only close
this valve before removing the solution filter to prevent loss of solution.

• Steering Wheel (37)—Steers the machine just like an automobile. Directs the Wheel Drive System.

• Wet Mode Port (38)—Attach Recovery Hose (29) when using any wet mode.
Service Manual – ES4000 General Information 16

Functional Description of Control Switches

™
The controls on the ES4000 were designed with one touch operation in mind. For single pass extracting the
user can simply depress one switch and all systems on the machine will be ready to go. For most single-pass
extracting operations, the operator should only need to use one of the switches on the control panel. Two
of these are the Interim Mode and Restorative Mode switches. In the Interim Mode the solution spray is
directed at the scrub brush and the flow rate is reduced. The travel speed is limited to a medium speed. In
the Restorative Mode the solution spray is directed at the carpet ahead of the scrub brush and the flow is at
maximum. The travel speed is limited to a slow speed.

See drawing on previous pages in this section.

Dry Mode Switch (D)—Pressing this switch when the deck system is active will cause the following to
occur:

• The brush(es) will turn off and the deck will raise to the up position

• The solution flow will be stopped

• The vacuum will shut off after a 10 second delay

• The travel speed limit will return to the transport speed setting

Interim Mode Switch (G)—If the scrub system is off, pressing this switch will cause the following to occur:

• The system will be enabled with the system configured for Interim Mode and the deck will be lowered

• The vacuum system will be enabled

• The solution system will be enabled for Interim Mode

• The travel speed will be limited to the Interim Mode speed setting

• As soon as the throttle is moved from the neutral position the scrub brush(es) will start turning and the
vacuum will turn on. If the direction is forward the solution flow will start. If the direction is reverse the
solution flow will be stopped. It is possible to program the control to automatically raise the scrub deck in
reverse. Refer to the Electrical System “Main Control Board Special Program Options” for details.

Note: If the Restorative Mode is selected, pressing this switch will select the Interim Mode. If the
Interim Mode is already selected, pressing this switch will have no effect.
Service Manual – ES4000 General Information 17

Restorative Mode Switch (H)—If the scrub system is off, pressing this switch will cause the following to
occur:

• The scrub system will be enabled with the system configured for Restorative Mode and the scrub deck will
be lowered

• The vacuum system will be enabled

• The solution system will be enabled for Restorative Mode

• The travel speed will be limited to the Restorative Mode speed setting

• As soon as the throttle is moved from the neutral position the scrub brush(s) will start turning and the
vacuum will turn on. If the direction is forward the solution flow will start. If the direction is reverse the
solution flow will be stopped. It is possible to program the control to automatically raise the scrub deck in
reverse. Refer to the Electrical System “Main Control Board Special Program Options” for details.

Note: If the Interim Mode is selected, pressing this switch will select the Restorative Mode. If the
Restorative Mode is already selected, pressing this switch will have no effect.

Key Switch / Main Power (A)—Main Power Switch. See the Electrical System “Main Control Board
Special Program Options” for details.

The Interim Mode, and Restorative Mode speed limits can be programmed using a Curtis handheld
programmer. Refer to the Electrical System “Main Control Board Special Program Options” for details.

Horn Switch (J)—This switch will sound the horn as long as the switch is held. The horn also functions as
an automatic back-up alarm when the throttle is moved to the reverse position. The volume of the back-
up alarm is programmable. It can also be programmed to provide an annunciation feature that will sound
whenever the throttle is in the forward position. See the Electrical System “Main Control Board Special
Program Options” for details.

Vacuum ON/OFF Switch (K)—This switch is used to turn the vacuum system on or off. Pressing this
switch will alternate between on and off. The vacuum will only turn on when the throttle is moved from the
neutral position. It will remain on for 10 seconds after the throttle returns to neutral.

The vacuum also has an automatic shutoff feature that will turn the vacuum and scrub systems off if the
recovery bladder becomes full. If this occurs, the status display will show the word “FULL”. This feature
can be disabled if desired. The shutoff threshold can also be adjusted if necessary. See the Electrical System
“Main Control Board Special Program Options” for details.

Solution ON/OFF Switch (B)—This switch is used to turn the solution system on or off. Pressing this
switch when the scrub system has been activated will alternate between on and off. The solution flow will
only turn on when the throttle is moved from the neutral position in the forward direction. The solution flow
will turn off if the throttle returns to neutral or is moved to reverse.

Detergent ON/OFF Switch (C)—Activates or deactivates the Detergent dispensing system. When the
system is ON the pump is activated at a specofic rate while the solution pump is running. The Detergent
pump turns OFF whenever the solution pump is not running or when the detergent system is OFF. See
Electrical Section for more details.

LCD Display (E)—Displays functions of the Control Panel and activity indicators.

Wet Mode Switch (F)—Activates and de-activates the extraction functions of the Recovery System. There
are four states for this switch; ON, OFF, Standby/Transport and Flashing. See Electrical section for more
details.

PreTreat Mode Switch (I)—PreTreat is activated from this switch. It is only active when the machine is
in either Extract Standby or Extract ON modes. The switch is inactive whenever the machine is in the Dry
Sweep Mode. See Electrical section for more details.
Service Manual – ES4000 General Information 18

Maintenance

Maintenance Schedule
Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service
more often.

MAINTENANCE ITEM Daily Weekly Monthly Yearly

Charge Batteries x
Check/Clean Tanks & Hoses x
Check/Clean/ Power Brush(s) x
Check/Clean Vacuum Shoes x
Check/Clean Vacuum Shut-Off Float x
Check/Clean the vacuum motor foam filter(s) x
Empty debris hopper x
Clean spray nozzles x
Check each battery cell(s) water level x
Inspect brush deck x
Inspect and clean solution filter x
Check foot/parking brake for wear and x
adjustment (if applicable)
Lubrication - grease fittings x
Check carbon brushes* x

Note: See the individual machine system sections for maintenance information.

* Check vacuum motor carbon brushes (Qty 2) once a year or after 300 operating hours. Check
brush motor carbon brushes (Qty 4) once a year or after 500 operating hours. Note if the
vacuum or brush motor brushes are 9.5mm (3/8 inches) or shorter, replace them. Check
wheel drive motor carbon brushes every 500 operating hours. The original length of each
brush is 20mm (25/32 inches). Replace when shorter than 9.5 mm (3/8 inches) to obtain the
same motor efficiency as a new brush.

WARNING! Turn the key switch off and disconnect the battery before servicing the machine.
Service Manual – ES4000 General Information 19

Vacuum Shoe Maintenance

Check the vacuum shoes daily, they can be removed to aid in cleaning, see “Removing the Vacuum Shoes”
in the operators manual. Remove any built-up string, hair or carpet fibers. See the RECOVERY SYSTEM
section of this manual for additional information.

Spray Nozzle Maintenance

Remove the spray nozzles once a week. Soak the nozzles overnight in a vinegar solution to remove chemical
deposits. See SOLUTION SYSTEM section of this manual for additional information.

Lubricating the Machine

Once a month, pump a small amount of grease into each grease fitting on the machine until grease seeps out
around the bearings.

Grease fitting locations are:

• Steering Wheel Shaft Universal joint

Once a month, apply light machine oil to lubricate the:

• Steering Chain

• General Pivot Points For the Brush Deck Linkage

• Cleaning Deck Adjustment Knobs (4)

Cleaning the Vacuum Motor Filters

Clean the vacuum motor filters daily with compressed air. For extremely dirty filters, wash with warm,
soapy water and rinse thoroughly with clean water. Allow the filters to dry completely before re-installing in
the machine. MAINTENANCE NOTE: Keep a second set of filters on hand to use while first set is drying.

Scrub Brush Maintenance

Check the brush(s) daily. Remove any built-up string, hair or carpet fibers.
Service Manual – ES4000 General Information 20

Advance ES4000
PM Checklist
Defect Codes

Customer A needs adjustment

B binding
Address C dirty or contaminated
D damaged, bent or torn
City
St Zip L leaks
M missing
Model Serial Hours W worn out

Does
Defect
OPERATIONAL INSPECTION ITEMS Not
Codes
Work
Ref OK
(circle)
A
1 Steering
B
A B
2 Drive Pedal Operation (check for Fwd/Rev Drive & any neutral creep)
D
A
3 Seat Safety Switch
D
A B
4 Brakes (Service & Parking)
W
Drive System Performance (reference SVR Manual for Curtis drive noisy
5
programmer speed changes) sluggish
Deck System (Raise/Lower and test auto scrubbing functions A
6
Maintenance & Restoration) B
A
7 Vac Shoe Recovery System (Raise/Lower)
B
Vacuum Performance (sealed water lift 64” and 1- inch open hole C L
8
adapter 20 inches) W
Solution Control (On/Off and flow volume Maintenance & C L
9
Restoration) W
10 Emergency Battery Disconnect Switch D
A B
11 Tilt Steering Mechanism and Seat
D
12 Optional Accessories (headlight, safety beacon, etc.) D
Main Control Board Special Program Options (check all applicable Program
13 program settings, reference SVR Manual 56043089); Example, Fault as
Recall Mode, Etc. needed
14 Battery Charger Operation D
Service Manual – ES4000 General Information 21

Does
Defect
Ref VISUAL INSPECTION ITEMS Comments OK Not
Codes
Work

(circle)
A B
15 Scrub Brushes, check for wear and rotate Cylindrical D
W
B L
16 Scrub Brush Motors Carbon Brushes
W
D
17 Scrub Brush Drive Belt, wear and tension
W
A B
18 Scrub Brush Deck Actuator Motor D
W
D
19 Brush Deck Idler Assembly Bearings
M
A B
20 Scrub Deck Rear Deflector
W
Solution Solenoid Valves (Maintenance & C
21
Restoration) L
A B
22 Solution Flow Control Valve D
W
Clean Filter C
23 Solution Tank, Delivery Hoses & Filter
Screen L
24 Vacuum Motor Carbon Brushes Wear Limit 3/8” W
L
25 Vacuum Motor Gaskets and Filters
W
C
26 Vacuum Float Ball & Cage Assembly Clean Float
M
C D
27 Recovery Tank Cover Gasket
L
C
28 Recovery Tank Drain Hose & Cap Flush
L
C
29 Vacuum Pick-Up Tool & Hoses Back flush
L
Service Manual – ES4000 General Information 22

Does
Defect
Ref VISUAL INSPECTION ITEMS (continued) Comments OK Not
Codes
Work

(circle)
C
30 Battery Pack Condition (clean & water) Load Test
W
C
31 Front Drive Wheel Motor Carbon Brushes
W
32 Front Drive Tire (rim fastener torque) Tread Wear W
A
33 Drive Pedal Linkage (neutral return)
B
A B
34 Steering Chain (lubricate & tension) 1/4” Deflection
C
Steering Column (knob & plunger spring) also A
35 Grease
Universal Joint D
36 Rear Wheels W
37 Sweep Debris Tray C

NOTE: For additional information see operator manual form number 56091013.

Defect Codes

A needs adjustment C dirty or contaminated M missing

B binding D damaged, bent or torn W worn out

L leaks

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date
Service Manual – ES4000 General Information 23

Specifications

General
Machine Voltage 24 VDC

Length: 61 in (155 cm)

Dimensions Width (body): 27.5 in (70 cm)

(without Squeegee
and Scrub Deck) Without Overhead Guard 51.7 in (131.3 cm)
Height
(Recovery tank:
With Overhead Guard NA in (NA cm)

Solution Tank: 28.8 gal (109 L)

Tank Capacities
Recovery Tank: dynamic: 24.7 gal ( 93 L); static: 28.6 gal ( 108 L)

Gross Weight (standard machine w/o options; w/full solution tank,

1447 lbs ( 656 kg)
empty recovery tank and heaviest batteries installed)

Net Weight (standard machine w/o options, batteries or removable

587 lbs ( 266 kg)
brushes; w/empty solution and recovery tanks)

R Rear: 463 lbs (210 kg)

Static Wheel Loading Front: 587 lbs ( 266 kg)
L Rear: 401 lbs. (182 kg)

R Rear: 150.81 psi (10.6 kg/cm2)

Static Wheel Pressure Front: 178.64 psi ( 12.56 kg/cm2)
L Rear: 130.61 psi (9.18 kg/ cm2)

Ingress Protection Code IPX3

Sound Pressure Level

65 dB(A) (3.0 dB(A) uncertainty) Sound and Vibration Report
(IEC 60704-1) (AXP)

Vibrations at the Hand Controls (ISO 5349-1) .22m/s2 (.044 m/s2 uncertainty)

Vibrations at the Seat (EN 1032) .02m/s2 (.004 m/s2 uncertainty)

Transport: 16 percent 9 degrees

Gradeability
Cleaning: 9 percent 5 degrees
Service Manual – ES4000 General Information 24

Battery Compartment Dimensions

Maximum Battery Compartment

with box: 25” L X 15.5” W X 21” H

without the box: 26.25” X 16” X 21”

Minimum Aisle Turn Around Radius (turning left)

28” deck 62.5 inches (1.59 m)

Minimum Door Pass-Thru Width

28” deck (AXP & ST) 31.5 inches (.80 m) ENG 1825
Service Manual – ES4000 25

Chassis System

Functional Description—Main Components

The chassis system consists of :

• Main machine frame

• Deck Lift Actuator assembly (See Scrub System)

• Shoe Lift Actuator assembly (See Recovery Ssytem)

• Drive Wheel assembly and Rear Wheel assembly (See Wheel System, Traction and Non-Traction)

• Lower WET/DRY/ACCESSORY attachment (See Recovery System)

• Vacuum Shoes (See Recovery System)

Deck Lift Actuator settings

Shoe Lift Actuator Settings

Main Frame
(Chassis)

Rear Wheel assembly

Vacuum Shoes

Drive Wheel
Service Manual – ES4000 Chassis System 26

Lift actuator assembly

Lower Attachment unit for

Recovery System

Lift actuator assemblies

Underside of Chassis System

Reference these sections of this manual for more details about the various parts of the Chassis System:

• Electrical Section—all other electrical functions for entire machine.

• Recovery System for lower attachment unit, Vacuum Shoe functions, and Shoe Lift Actuator

• Wheel System, Traction and Non-Traction for Drive Wheel assembly and Rear Wheel assembly
functions and maintenance

• Scrub System for Deck Lift Actuator functions and maintenance

Service Manual – ES4000 27

Control System

Functional Description
The Control System consists of the Main Controller, Speed Controller and Operator’s Control Panel.

The Main Controller operates the floor cleaning functions of the machine based on inputs from the operator
and other programmed inputs.

The Speed controller controls the speed of the machine as the operator presses the drive pedal.

The Operator’s Control Panel is where the driver controls all the machine cleaning functions.

Control Panel

Main Controller (located

inside Control Panel

Speed Controller
Service Manual – ES4000 Control System 28

Control System Circuit Descriptions

The main controller is directly wired to battery negative with five wires. Positive battery voltage is supplied
directly to terminals J3-1 and J3-8. When the key is turned on, power is supplied to J3-14 to “wake up” the
main controller. Power is also supplied through the emergency stop switch and the seat switch to let the
main controller know that it is safe to operate the machine.

Some machines are equipped with an optional onboard battery charger. The battery charger has an internal
“interlock” relay that prevents the operator from driving the machine away and pulling on the power cord
when it is plugged into the electrical receptacle. When the AC power cord is NOT plugged in, battery voltage
is allowed to pass through the normally closed contacts of the relay to the #2 Circuit breaker. This allows
the machine to power up and work normally. When the AC power cord IS plugged in, the interlock relay
energizes and opens the contacts, removing power from the #2 circuit breaker. This prevents the machine
from powering up and moving.

F1 150 A fuse
24v Battery

87a 87 86

AC Power
30 85 Cord
On Board
Battery Charger

CB 2 S1 Key S4 Emergency S2 Seat

Switch Stop Switch Switch

J3-4
J3-14

J3-1
J1-8

J2-8
J2-7
J3-8
J2-1
J2-2

A1 Main Controller

Main Controller Power Supply With Charger Unit

Service Manual – ES4000 Control System 29

F1 150 A fuse
24v Battery

CB 2 S1 Key S4 Emergency S2 Seat

Switch Stop Switch Switch

J3-4
J3-14

J3-1
J1-8

J2-8
J2-7
J3-8
J2-1
J2-2

A1 Main Controller

Main Controller Power Supply Without Charger Unit

Service Manual – ES4000 Control System 30

Functional Description of Main Controller

There are two controllers on the machine, a Main Controller and a Speed Controller (see WHEEL SYSTEM,
TRACTION).

The Main Controller operates the floor cleaning functions of scrub, solution and vacuum based on operator
requests and other inputs. It is located directly underneath the operator control panel. It is capable of storing
and displaying many fault codes. In addition to fault codes, it supports special modes of operation called
“Hidden Menus” that includes “Service Test Mode”. The service test mode is a powerful and convenient
diagnostic feature that allows a technician to request specific outputs to operate regardless of current inputs.
Most of the other Hidden Menus contain information that tells the controller how the machine is equipped
so it can operate accordingly. To access any of the Hidden Menus, refer to the section “To Change Program
Option Settings” found later in this chapter.

The Drive Motor Controller (Speed Controller) operates the drive motor that propels the machine based on
operator requests. (See the section “Wheel System, Traction” for more information)
Service Manual – ES4000 Control System 31

Component Locations
• Operator’s Control Panel

• Main Control Board

• Speed Controller (See WHEEL SYSTEM, TRACTION)

• Battery Charger

Operator’s seat

Operator’s Control Panel -location

Main Control Board inside

Batteries located under drivers

(operator’s) seat.

Electrical Compartment houses

SPEED CONTROLLER

Battery Charger compartment-lid closed

Service Manual – ES4000 Control System 32

Main Controller

Battery Charger with AC

power charging cord
Service Manual – ES4000 Control System 33

Operator’s Control Panel

Speed Controller -
Located under Electrical
compartment
Service Manual – ES4000 Control System 34

Maintenance and Adjustments

Hidden Menus

Program Option Settings

To change all or any one setting, perform the following steps: Use Control Panel shown for button locations.

1. Turn the main power key switch (A) to the off

position.

2. Press and hold the Solution switch (B) and

Vacuum switch (K) together.

3. While holding both switches, turn the main

power key switch (A) to the ON position. All
indicator LEDs on the Control Panel turn on.

4. Continue to hold both switches for 2 seconds

until only the following indicators are still on:
Interim mode LED (G), Restorative mode LED
(H), PreTreat mode LED (I) & Detergent ON/
OFF LED (C).

5. Release both switches. The display will now

show “Program Options.”

6. To scroll through the menu use the Interim

mode (G) button to scroll up (from menu 1 to
2, 2 to 3, etc) and the Restorative mode button
(H) to scroll down (from menu 19 to 18, 18 to
17, etc). When you hit the top or bottom of the
list, you can continue to press these buttons
to roll the menus over from the last (19) to the
first (1) or visa-versa.

7. To enter a sub menu press PreTreat mode (I)

button

8. To change the selection within a sub menu,

use the Interim mode (G) button to scroll up
and the Restorative mode (H) button to scroll
down through the choices.

9. To save the current choice and go back to the

main menu press the Detergent ON/OFF (C)
button.

10. See Figure E-10 (next page) for a list of all available categories for the top level menu.
Service Manual – ES4000 Control System 35

1. LOW VOLTAGE CUTOUT

2. MAX MAINT SPEED
3. MAX RESTORE SPEED
4. MAX PRESPRAY SPD
5. MAX SWEEP SPEED
6. RECOVERY TANK FULL
7. CHEMICAL RATE BIAS
8. DECK DOWN TIME
9. RESTORE DEFAULTS
10. DISPLAY REV LEVEL
11. FAULT RECALL
12. FAULT DETECTION
13. SERVICE TEST MODE See 13. Service Test Mode
instructions. All applicable
14. BACKUP ALARM VOL options are identified
specifically as part of the
15. FWD ALARM VOL Service Test Mode.
16. HORN VOL
17. EXTRA INFO ON LCD
18. FROZEN PARAMETERS
19. PANEL TEST
Figure E-10 Top Level Main Options

Low Voltage Cutout

The Low Voltage Cutout Selection is a MANDATORY setting when the Main Control Board is
replaced and the machine uses AGM or GEL Batteries. Default is WET BATTERY 80%.

The purpose of the special low battery voltage cutout function is to help prolong battery life. The cleaning
deck will be raised and the brush motors and all solution solenoid valves and pumps will turn OFF
automatically and cease to function when the batteries discharge to the selected cutout level. The cutout
level is adjustable between two settings. The standard setting (wet cell/lead acid) is 20.55 volts and alternate
setting (gel/maintenance free) is 21.75 volts. Figure E-11 shows the display.

LOW VOLT CUTOUT

WET BATTERY 80%

LOW VOLT CUTOUT

MAIN FREE BATTERY 70%
Figure E-11 Low voltage Cutout Selection Submenu Options
Service Manual – ES4000 Control System 36

Maximum Maintenance Speed

Program to limit the maximum speed while in maintenance extraction mode to a value less than that
allowed for driving when not extracting (0-99% of transport speed in increments of 1%). Default is 22% OF
TRANSPORT, see Figure E-12.

Max MAINT Speed

95% OF TRANSPORT

Figure E-12: Maximum Maintenance Speed Submenu Options (example value shown)

Maximum Restore Speed

Program to limit the maximum speed while in restore extraction mode to a value less than that allowed for
driving when not extracting (0-99% of transport speed in increments of 1%). Default is 1% OF TRANSPORT,
see Figure E-13.

Max RESTORE Speed

95% OF TRANSPORT

Figure E-13: Maximum Restore Speed Submenu Options (example value shown)

Maximum Prespray Speed

Program to limit the maximum speed while in prespray extraction mode to a value less than that allowed
for driving when not extracting (0-99% of transport speed in increments of 1%). Default is 58% OF
TRANSPORT, see Figure E-14.

Max PRESPRAY Spd

95% OF TRANSPORT

Figure E-14: Maximum Prespray Speed Submenu Options (example value shown)

Maximum Sweep Speed

Program to limit the maximum speed while in dry sweep mode to a value less than that allowed for driving
when not sweeping (0-100% of transport speed in increments of 1%). Default 65% OF TRANSPORT, see
Figure E-15.

MAX SWEEP SPEED

100% OF TRANSPORT

Figure E-15: Maximum Sweep Speed Submenu Options (example value shown)

Recovery Tank Full Enable/Disable

Enable or disable Recovery Tank Full automatic shutoff feature. Enable means that the automatic shutoff
feature is turned on; disable means that the automatic shutoff feature is turned off. Default is 1.ENABLED,
see Figure E-16.

RECOVERY TANK FULL

1. ENABLED
Service Manual – ES4000 Control System 37

RECOVERY TANK FULL

2.DISABLED
Figure E-16: Recovery Tank Full Enable/Disable Submenu Options

Chemical Ratio Bias:

The main controller can be programmed to increase or decrease the chemical mix rate by 10% to achieve
a more or less concentrated mix than that determined by the user programmed ratio. Selection of a value
other than “none” will adjust the delay time between voltage pulses sent to the chemical pump to accomplish
a richer or leaner mixture. Default is 1. NONE, see Figure E-17.

CHEMICAL BIAS
1. NONE
CHEMICAL BIAS
2. +10% MORE CHEMICAL
CHEMICAL BIAS
3. -10% LESS CHEMICAL

Figure E-17: Chemical Ratio Bias Submenu Options

Deck Down Time Period Adjustment:

When either the extraction or sweep button is pressed, the control unit will automatically lower the brush
deck for a specified period prior to the deck being automatically adjusted to maintain a specific pressure
on the brushes. The time that the deck is lowered is adjustable from 1 second to 5 seconds in 0.1 second
increments. However, it is highly recommended that the default value of 2.5 be used to avoid over-current
errors on the brush motors. Default is DECK DOWN TIME - 2.5 SECONDS, see Figure E-18.

Deck Down Time

2.5 Seconds

Figure E-18: Deck Down Time Submenu (example value shown)

Restore (Factory) Defaults

This submenu should reset all parameters stored in the EEPROM except Brush On Time. Default is 1. NO,
see Figure E-19.

RESTORE FACTORY DEFAULTS

1. NO
RESTORE FACTORY DEFAULTS
2. YEs

Figure E-19: Restore Factory Defaults Submenu Options

Service Manual – ES4000 Control System 38

Display Revision Level

The LCD display will show the revision level of the software in the control board. Default is REV. C but
may change with new software updates, see Figure E-20.

REVISION LEVEL
REV. C

Figure E-20: Restore Factory Defaults Submenu Options (example value shown)

Fault Recall

Whenever the control unit detects an electrical system fault, one or more error codes are displayed and
stored in the EEPROM. If it is desired, the error codes (if any) from the previous operation for the machine
can be recalled for troubleshooting purposes.

• If no fault code is present, the display should show a “-“

• If the Restorative button is pressed in the Fault Recall submenu the fault history shall be erased and
after a few seconds the display will show “-“ to confirm the erase.
In addition to clearing the logged fault codes, all saved data in the “Frozen Parameters” section will be erased. See
section 8.19 for more information. See Figure E-21 for an example of a Fault Recall submenu.

FAULT RECALL
3 10 32

Figure E-21: Fault Recall Submenu with faults 3, 10, and 32

Fault Detection

Normally, the main control unit will perform checks of the electrical system during operation. If a
fault occurs in a particular system, that system (and possibly others) will be shut down. This can make
troubleshooting the system difficult. This option will allow service personnel to disable some of the fault
detection checks to facilitate troubleshooting. This will not disable the over-current protection on any of
the systems. The default value as shipped from the factory is “DISABLED”, see Figure E-22.

FAULT DETECTION
1. ENABLED
FAULT DETECTION
2. DISABLED

Figure E-22: Fault Detection Submenu Options

Service Manual – ES4000 Control System 39

Service Test Mode

The Service Test Mode is one of the top level Hidden Menus. Due to the value of these options, and to you
the technician, the instructions are elevated to a separate level of importance. Each option is identified as
part of the Service Test Mode when relevent.

To assist in the troubleshooting and servicing of the electrical system and related components on the
ES4000 extractors, a special test mode allows
independent control of the various outputs
and monitoring of various inputs. Some
outputs (like the scrub brush motors) are only
turned on when other conditions are met,
such as when the machine is moving. It can be
difficult to check for voltage to the scrub brush
motors while the machine is moving. Also, if
voltage is not present, the question is what
other conditions may not have been met yet.
The Service Test Mode solves these problems
for the technician. In Service Test Mode the
technician can request that the Main Machine
Controller ignore all other conditions and
directly turn on the scrub brush motors as
well as other outputs. Service Test mode can
also be used to verify that certain inputs are
seen by the controller.

Use Control Panel image for button locations.

To enter the service test mode perform the

following steps: (steps 1-5 are the same for
entering the Hidden Menus but repeated here
for your convenience. Steps 6-8 are specific to
Service Test Mode).

1. Turn the main power key switch (A) to

the off position.

2. Press and hold the Solution switch (B)

and Vacuum switch (K) together.

3. While holding both switches, turn the

main power key switch (A) to the ON
position. All LED indicators on the Control Panel turn on.

4. Continue to hold both switches for 2 seconds until only the following indicators are still on: Interim
Mode LED (G), Restorative mode LED (H), PreTreat mode LED (I) & Detergent ON/OFF LED (C).

5. Release both switches. The display will now show “Programming Options ”

6. Scroll through the menu using the Interim Mode (G) button to scroll up (from menu 1 to 2, 2 to 3, etc)
or the Restorative Mode button (H) to scroll down (from menu 19 to 18, 18 to 17, etc) until you see “13.
Service Test Mode.”

7. To enter, press PreTreat mode (I) button

8. After you enter “Service Test Mode” the only way to exit from it is to turn OFF the Key Switch.
Service Manual – ES4000 Control System 40

How to Read the Battery Voltage—Using the Battery Display

The status display will show the battery voltage in the upper left corner of the panel display. This display
is accurate to within +/- 0.15 volts. Therefore, the voltage displayed may not correlate precisely to a high-
accuracy, calibrated voltmeter.

25.16 37 BAC:
SPD: N MSL: X SAC:
BRU: X RSL: SP:
VAC: MST: CP: X
If over-current faults are present, the status display will indicate the error codes in the upper center of the
display. If more than one error is present, the display will cycle through them every second.

Control Panel Switch Functions

See Control Panel image for button locations. The control panel switches are used in the Service Test Mode
to control various output functions of the main control unit. Below is a list of each switch and the function it
controls. Pressing a button more than once will toggle through the available states. A detailed description of
each function follows.

• Wet Mode switch (F): Controls shoe lift

actuator (toggle between OFF, Down and Up).

• Interim mode switch (G): Controls maintenance

solenoid (ON/OFF).

• Restorative mode switch (H): Controls the

restore solenoid (ON/OFF).

• Vacuum ON/OFF switch (K): Controls vacuum

motor contactor (ON/OFF).

• Solution ON/OFF switch (B): Controls solution

pump (ON/OFF).

• Horn switch (J): Controls brush motors

contactor (ON/OFF).

• Detergent ON/OFF switch (C): Controls the

chemical detergent pump (ON/OFF).

• PreTreat mode ON/OFF switch (I): Controls

misting solenoid (ON/OFF).

• Dry Mode (D) switch: Controls brush deck lift

actuator (toggle between Down and Up)
Service Manual – ES4000 Control System 41

Control Panel LCD Information in Service Test Mode

The Control Panel LCD shows various information. Each item has an Acronym or display code to describe
the state of the Service Test Mode. See Figure E-23 and E-23a for position of data on LCD.

• 25.31: Display actual battery voltage

• SPD (Speed Controller): N (Neutral), F

(Forward), R (Reverse)

• BRU (Brush Contactor): blank (OFF) or X

(ON)

• VAC (Vacuum Contactor): blank (OFF) or

X (ON)

• 37: Error code or “00” if there are no faults

(37 is an example for demonstration)

• MSL (Maintenance solenoid): blank (OFF)

or X (ON)

• RSL (Restore solenoid): blank (OFF) or X

(ON)

• MST (Mist solenoid): blank (OFF) or X Figure E-23

(ON)

• BAC (Brush Actuator): blank (OFF), U (Up), or D (Down)

• SAC (Shoe Actuator): blank (OFF), U (Up), or D (Down)

• SP (Solution Pump): blank (OFF) or “X” (ON)

• CP (Chemical Pump): blank (OFF) or “X” (ON)

Note: In Figure E-23a below, an example screen shows the speed control in Neutral, Brush
Contactor on, Maintenance Solenoid on, and Chemical Pump on. One error code is also
present, CODE 37.

25.31 37 BAC:
SPD: N MSL: X SAC:
BRU: X RSL: SP:
VAC: MST: CP: X
Figure E-23a

SERVICE TEST MODE instructions end here.

Service Manual – ES4000 Control System 42

Backup Alarm Volume

The backup alarm is variable. Set the back up alarm volume in the hidden menu to: Off, Low, Medium and
High. Figure E-24.

BACKUP ALARM VOL

1. OFF
BACKUP ALARM VOL
2. LOW
BACKUP ALARM VOL
3. MEDIUM
BACKUP ALARM VOL
4. HIGH

Figure E-24: Backup Alarm Volume Display

Forward Alarm Volume

The forward annunciation volume is variable using

the hidden menu. Set the volume to one of the
available levels: Off, Low, Medium and High. Figure
E-25.

FWD ALARM VOL

1. OFF
FWD ALARM VOL
2. LOW
FWD ALARM VOL
3. MEDIUM
FWD ALARM VOL
4. HIGH

Figure E-25: Forward Alarm Volume Display

Horn Volume

The horn is adjustable to various levels using the

hidden menu. Set the Horn volume to one of the
available levels: Off, Low, Medium and High. Figure
E-26.

HORN VOLUME
1. OFF
HORN VOLUME
2. LOW
HORN VOLUME
3. MEDIUM
HORN VOLUME
4. HIGH

Figure E-26: Horn Volume Display

Service Manual – ES4000 Control System 43

Extra Info on LCD

This screen selects the extra information that can be displayed real-time on the LCD. This aids in
troubleshooting the machine in normal operation. The default is to display no extra info. If extra
information is selected for display, a 2-letter or 3-letter code is displayed to identify the information,
while underneath the code is a number. The number indicates a value in amps, volts, or is without a unit
designation depending upon what is selected. Only one piece of extra information can be displayed at any
time, but the selected information can be changed at will via the hidden menu. Press DETERGENT button
to back out of the menu and save the selection. Cycle the Key Switch to return to normal operations mode. A
summary of the identification codes shown on the LCD display is as follows:

• BV = Battery Voltage

• LOK = Battery Lock Level

• FBR, RBR = Front/Rear Brush Motor Current (Instantaneous or Average)

• VAC = Vacuum Motor Current (the sum of two vac motors)

• MSO, RSO = Maintenance Solenoid Current & Restore Solenoid Current

• MST = Misting Solenoid Current

• BCO, VCO = Brush Contactor Current, Vacuum Contactor Current

• BAC, SAC = Brush Actuator Current & Shoe Actuator Current

• CP, SP = Chemical Pump Current & Solution Pump Current

• HRS = Brush On-Time Hourmeter

See Figure E-27 for a list of all available info that can be selected for display.

EXTRA INFO ON LCD

1. NONE
EXTRA INFO ON LCD
2. BATT VOLTS 2. Battery Voltage (volts)
EXTRA INFO ON LCD
3. BATT LOCK VALUE 3. Battery Lock Value (no units)
EXTRA INFO ON LCD
4. FR AVG BRUSH CURR 4. Front average brush current (amps)
EXTRA INFO ON LCD
5. RR AVG BRUSH CURR 5. Rear average brush current (amps)
EXTRA INFO ON LCD
6. VAC MOTOR CURR 6. Vacuum motor current (total of both motors)
EXTRA INFO ON LCD (amps)
7. MAINT SOL CURR 7 Maintenance solenoid current (amps)
EXTRA INFO ON LCD
8. REST SOL CURR 8. Restore solenoid current (amps)
EXTRA INFO ON LCD
9. MIST SOL CURR 9. Misting solenoid current (amps)
EXTRA INFO ON LCD
10. BRUSH CONT CURR 10. Brush contactor current (amps)
EXTRA INFO ON LCD
11. VAC CONT CURR 11. Vacuum contactor current (amps)
Service Manual – ES4000 Control System 44

EXTRA INFO ON LCD 12. Brush actuator current (amps)

12. BRUSH ACT CURR
EXTRA INFO ON LCD 13. Shoe actuator current (amps)
13. SHOE ACT CURR
EXTRA INFO ON LCD 14. Chemical pump current (amps)
14. CHEM PUMP CURR
EXTRA INFO ON LCD 15. Solution pump current (amps)
15. SOLN PUMP CURR
EXTRA INFO ON LCD 16. Alternate every 5 seconds between front
16. ALT AVG BR CURR and rear average brush current (amps)
EXTRA INFO ON LCD 17. Alternate every 5 seconds between front
17. ALT INST BR CURR and rear instantaneous brush current (amps)
EXTRA INFO ON LCD 18. Front instantaneous brush current (amps) The instantaneous
views are preferred
18. FR INST BR CURR over the alternating
EXTRA INFO ON LCD 19. Rear instantaneous brush current (amps) views since they
show what the
19. RR INST BR CURR brushes are doing in
EXTRA INFO ON LCD 20. Brush hour meter (hours) real time.
20. BRUSH HOURS

Figure E-27: Diagnostic Mode Selection Display

Frozen Parameters

This screen is used to view all of the internal parameters

that were saved or “frozen” when the 1st error code was
detected. Nine different parameters are logged, and all but
two are saved at 100 msec intervals for 6.4 seconds leading
up to the error code. The first viewable parameter is the
error code that actually initiated the freezing of parameter
values. The second viewable parameter is the hour meter
value at the time of the frozen error code. If no error code
occurred, then the stored data will all be blank (all zeroes).
Examples of the main menu and sub-menus are shown in
figures E-29 and E-30. In the Sub-menus, data point #1 is
the newest value and #64 is the oldest value (that occurred
6.3 seconds earlier).

There are 2 levels of sub-menus for this top-level menu. In

the first sub-menu you select the category of parameter to
view by choosing 1 of the 9 categories listed in Figure E-28.
For most categories there is a second sub-menu in which
you select the specific value in history to view (data point
1 through 64). See figures E-29 and E-30 for examples of
submenus. Keypad navigation is the same for each level, so
the following set of 3 rules applies to each level:

1. To scroll through the menu use the Interim mode

button (G) to scroll up and the Restorative mode (H)
button to scroll down. See Control Panel Image for
button locations.

2. To enter a sub-menu press the PreTreat button (I). If no

Service Manual – ES4000 Control System 45

further sub-menus exist then this button has no effect.

3. To go back one level in the menus press the Detergent

button (C).

There is one additional feature that is available only

when you enter into the 2nd level of menus. This feature
automatically turns on and off when you enter or leave a 2nd-
level menu:

Upon entering any 1st-level menu, the LED on the Vacuum

ON/OFF (K) button will turn on to indicate that this button
can be used. Pressing this button in any 1st-level function
has no effect, but after entering the 2nd level menu a press
of this button will toggle between fast and slow increment
modes when you are scrolling through the 64 available data
points for each logged parameter.

In slow mode the increment/decrement value is 1, so that

pressing the Interim mode (G) button will cycle you from
data record 1 to 2, 2 to 3, etc, and pressing the Restorative
button will cycle you from data record 64 to 63, 63 to 62, etc.

In fast mode the increment/decrement value is 10, so that

pressing the Interim button will cycle you from data record
10 to 20, 20 to 30, etc, and pressing the Restorative button
will cycle you from data record 60 to 50, 50 to 40, etc. The
purpose of this feature is to reduce the number of button
presses required to cycle through all 64 data records should
you choose to do so. Use of this feature will automatically end
when you press the Detergent button (C) to leave a 2nd-level
menu, and the Vacuum button LED will turn off when you
press the Detergent button (C) again to leave the 1st-level
menu.

Note: Error codes will remain even after an error occurance has been corrected. Clear error codes
using the Fault Recall menu.
1. Error code

FROZEN PARAMETERS
2. Hour meter
1.ERROR CODE
FROZEN PARAMETERS
3. Battery Voltage
2.HOUR METER
FROZEN PARAMETERS
4. Front brush current
3.BATT VOLTAGE
FROZEN PARAMETERS
5.Vacuum motor current
4.F BRUSH CURR
FROZEN PARAMETERS
6. Rear brush current
5.VAC MTR CURR
FROZEN PARAMETERS
7. Shoe actuator current
6.R BRUSH CURR
FROZEN PARAMETERS
8.Brush actuator current
7.SHOE ACT CURR
FROZEN PARAMETERS
9.Machine mode of operation (Transport, Figure E-28: Frozen
8.BRUSH ACT CURR
Extract, Sweep) Parameters Display
Service Manual – ES4000 Control System 46

FROZEN PARAMETERS
9.MODE

FROZEN PARAMETERS
1.ERROR CODE
37
Figure E-29: Error Code Sub-Menu Example

FROZEN PARAMETERS
3.BATT VOLTAGE
64: 24.56

Figure E-30: Battery Voltage Sub-Menu Example—Data Record #64 for

the Battery Voltage reads 24.56 Volts

Panel Test

This Hidden Menu screen is used for identifying intermittent

membrane buttons and LEDs and to verify that they all function
properly.

• In this mode the button that has been pressed will be

displayed on the line below “PANEL TEST.”

• The corresponding green LED for the button is also turned

on. All buttons except the Horn button (J) have an associated
green LED. When the Horn button is pressed, both the yellow “Sweep” LED (D) and the yellow “Extract”
LED (F) will turn on. In this way it is possible to test all 10 LEDs and all 9 membrane buttons from this
menu.

• Identification of the button and the corresponding LED will occur as soon as the button is pressed down.
The display and LED will stay in that state until a different button is pressed.

• Each button will have its own button counter. When you press a button, the corresponding counter will
be displayed on the bottom line of the LCD. Each button press will increment the counter until it hits
255, after which the counter will roll over to 0. The purpose of the counter is to allow you to compare the
number of detected button presses to the number of times you actually pressed the button. This may help
you to determine if the button is working correctly or if it is intermittent.

• After this menu is entered, the only way to exit is by cycling the key switch.

• See Figure E-31 for an example of an LCD screen that shows the Detergent button (C) pressed with 14
counts so far.

PANEL TEST
CHEMICAL
14

Figure E-31: Button Test Sub-Menu Example

Service Manual – ES4000 Control System 47

Troubleshooting

Fault Codes
Any error codes detected by the main control board will be displayed on the LCD as they occur. If more than
one error exists the display will sequence through the error codes at one-second intervals. The error will
display as a mechanical wrench symbol followed by a two-digit code. EX:03 would be a speed control fault.
Error codes 30 – 41 (open circuit detection for various loads) are enabled and disabled via the Hidden Menu
setting for “Fault Detection”. Only this set of 12 error codes can be disabled.

LCD Code Definition Explanation / Code Setting Conditions / Flash Indicator

Display Code Disables / Check / Thresholds
03 Speed Control Fault The Drive Controller is communicating that it has a fault code
stored. Count the number of flashes of the Detergent button LED
to identify the specific fault code, and then check the specific
code in the Drive System Controller.
04 Scrub Deck Lift Excessive current draw was sensed. Code sets at approximately
Actuator Circuit Over 3.7 amps or more.
Current Check for shorted actuator, mechanical binding of actuator
linkage, shorted wiring.
05 Front Brush Motor Excessive current draw was sensed. Code sets at approximately
Circuit Over Current 19.8 amps or more.
Check for shorted motor, mechanical binding of motor shaft,
current sense wire connections, ground connections.
06 Shoe Lift Actuator Excessive current draw was sensed. Code sets at approximately
Over Current 3.7 amps or more.
Check for shorted actuator, mechanical binding of actuator
linkage, shorted wiring.
07 Vacuum Motor Circuit Excessive current draw was sensed. Code sets at approximately
Over Current 68 amps or more. Check for shorted motor, current sense wire
connections, ground connections, on either or both motors.
08 Maintenance Solenoid Excessive current draw was sensed. Code sets at approximately
Circuit Over Current 0.62 amps or more. Check for shorted solenoid winding, shorted
wiring
09 Vacuum Contactor Coil Excessive current draw was sensed. Code sets at approximately
Circuit Over Current 0.89 amps or more. Check for shorted contactor winding,
shorted wiring.
10 Brush Contactor Coil Excessive current draw was sensed. Code sets at approximately
Circuit Over Current 0.89 amps or more. Check for shorted contactor winding,
shorted wiring
11 Detergent Pump Excessive current draw was sensed. Code sets at approx. 2.9A
Circuit Over Current or more. Check for shorted pump winding, shorted wiring
12 Solution Pump Over Excessive current draw was sensed. Code sets at approx. 4.3A
Current or more. Check for shorted pump winding, shorted wiring
13 Restore Solenoid Over Excessive current draw was sensed. Code sets at approx. 4.3A
Current or more.Check for shorted solenoid winding, shorted wiring.
14 Misting Solenoid Over Excessive current draw was sensed. Code sets at approx. 0.62A
Current or more. Check for shorted solenoid winding, shorted wiring
Service Manual – ES4000 Control System 48

LCD Code Definition Explanation / Code Setting Conditions / Flash Indicator

Display Code Disables / Check / Thresholds

15 Rear Brush Motor Excessive current draw was sensed. Code sets at approx.
Over Current 19.8A or more. Check for shorted motor, current sense wire
connections, ground connections.
30 Maintenance Solenoid The Main Machine Controller has turned the solution solenoid
Circuit Open circuit on but it is not sensing any current flow. (Senses <=
20mAmps for 10 seconds).
Check for open solenoid winding, open wiring.
31 Front Brush Motor The Main Machine Controller has energized the Brush Contactor
Circuit Open but it is not sensing any current flow through the brush motor
ground circuit for at least 5 seconds. (Senses <= 2 Amps for 10
seconds)
Check Motor, Contactor contacts, Wiring.
32 Scrub Deck Lift The Main Machine Controller is trying to move the actuator but
Actuator Circuit Open it is not sensing any current flow. (Senses <= 67 m Amps for 10
seconds)
Check Actuator, wiring.
33 Vacuum Motor Circuit The Main Machine Controller has energized the Vacuum
Open Contactor but it is not sensing any current flow through the
vacuum motor ground circuit for at least 5 seconds. (Senses<= 2
Amps for 5 seconds)
Check motor, wiring, contactor
34 Shoe Lift Actuator The Main Machine Controller is trying to move the actuator
open but it is not sensing any current flow. (Senses <=67mA for 10
seconds)
Check Actuator, wiring
35 Brush Contactor Coil The Main Machine Controller has attempted to energize the
Circuit Open Brush Contactor but it is not seeing any current flow. (Senses <=
40 m Amps for 10 seconds).
Check for open Contactor winding, wiring
36 Vacuum Contactor Coil The Main Machine Controller has attempted to energize the
Circuit Open Vacuum Contactor but it is not seeing any current flow. if
(Senses <= 40 m Amps for 5 seconds)
Check for open Contactor winding, wiring.
37 Detergent Pump The Main Machine Controller has energized the detergent pump
Circuit Open but it is not sensing any current flow. (Senses <= 100 m Amps
for 5 seconds).
Check for open pump winding, wiring.
38 Rear Brush motor The Main Machine Controller has energized the Brush Contactor
Circuit Open but it is not sensing any current flow through the brush motor
ground circuit for at least 5 seconds. (Senses <= 2 Amps for 10
seconds)
Check Motor, Contactor contacts, Wiring.
39 Solution Pump Open The Main Machine Controller has energized the solution pump
but it is not sensing any current flow.
(Senses<= 150 mA for 10 seconds)
Check for open pump winding, wiring.
Service Manual – ES4000 Control System 49

LCD Code Definition Explanation / Code Setting Conditions / Flash Indicator

Display Code Disables / Check / Thresholds

40 Restore Solenoid The Main Machine Controller has turned the solution solenoid
Open circuit on but it is not sensing any current flow (<=20mA for 10
seconds)
Check for open solenoid winding, open wiring.
41 Misting Solenoid Open The Main Machine Controller has turned the solution solenoid
circuit on but it is not sensing any current flow (<=20 mA for 10
seconds)
Check for open solenoid winding, open wiring.
60 Front Brush Motor The Main Machine Controller is sensing current flow through the
Stuck Closed Front Brush Motor ground circuit when it has not energized the
Brush Motor Contactor (Senses >= 2 Amps for 10 seconds)
Check for a short in the harness wiring to the motor.
61 Vacuum Motor Stuck The Main Machine Controller is sensing current flow through
Closed the Vacuum Motor ground circuit when it has not energized the
Vacuum Motor Contactor (Senses >= 2 Amps for 5 seconds)
Check for a short in the wiring harness to the motor
62 Maintenance Solenoid The Main Machine controller is sensing current flow through its
Circuit Stuck On internal switch for the maintenance solenoid circuit when it has
(closed) not requested that the switch be turned on. (Senses >= 20 m
Amps for 10 seconds).
63 Brush Contactor The Main Machine controller is sensing current flow through its
Coil Circuit Stuck On internal switch for the Brush Contactor Coil circuit when it has
(closed) not requested that the switch be turned on. (Senses >= 40 m
Amps for 10 seconds).
64 Vacuum Contactor The Main Machine controller is sensing current flow through its
Coil Circuit Stuck On internal switch for the Vacuum Contactor Coil circuit when it has
(closed) not requested that the switch be turned on. (Senses >= 40 m
Amps for 5 seconds).
65 Restore Solenoid The Main Machine controller is sensing current flow through its
Stuck Closed internal switch for the restore solenoid circuit when it has not
requested that the switch be turned on. (Senses >= 20 m Amps
for 10 seconds).
66 Misting Solenoid Stuck The Main Machine controller is sensing current flow through its
Closed internal switch for the misting solenoid circuit when it has not
requested that the switch be turned on. (Senses >= 20 m Amps
for 10 seconds).
67 Rear Brush Motor The Main Machine Controller is sensing current flow through the
Stuck closed Rear Brush Motor ground circuit when it has not energized the
Brush Motor Contactor (Senses >= 2A for 10 seconds).
Check for a short in the harness wiring to the motor.

Figure E-32: Fault Code Descriptions

Service Manual – ES4000 Control System 50

Specific actions will happen for each electrical system fault detected. See figure E-33 for systems to be
disabled for each fault code. Once any system is disabled it cannot be turned on again until key switch is
cycled. Details of how each system are disabled is as follows:

1. Chemical System: Detergent LED (C) turns off (unless it is flashing due to a chem. pump fault) and
chemical off icon is displayed on LCD. Chemical pump turns off.

2. Solution System: Solution LED turns off (unless it is flashing due to a solution pump fault). Solution
pump turns off.

3. Extract System: Extract LED, Restore LED, Maintenance LED, and Prespray LED turn off (extract
LED will flash if the fault is due to a maintenance or restore solenoid fault). Maintenance and Restore
solenoids turn off. Shoe deck returns to raised position. Extract button is locked out. Hose change
screens appear on LCD until user acknowledges and switches to Sweep Mode.

4. Sweep System: Sweep LED turns off. Sweep button is locked out. Hose change screens appear on LCD
until user acknowledges and switches to Extract Mode.

5. Recovery System: Vacuum/Wand LED turns off (unless it is flashing due to a vacuum fault). Vacuum
turns off.

6. Brush Deck: Machine should remain in its current mode (sweep or extract). Brush deck actuator turns
off.

7. Brush Motors: Brushes turn off.

8. Misting Solenoid: Solenoid turns off.

NOTE: If both the extract and sweep systems are simultaneously disabled (see chart below) then
both the Extract & Sweep LEDs will flash and the LCD will revert to the normal sweep
mode screen.

Disable System Flash Indicator

Misting Solenoid

Detergent LED
Brush Motors

Solution LED

Vacuum LED
Extract LED
Brush Deck

Sweep LED
Chemical

Recovery
Solution

Extract

Sweep

Display Fault
Code Description
Speed Control
x x x x x x
3 Fault
Brush Deck
Lift Actuator x x x
4 Overload
Front Brush
Motor x x x x x x x x x
5 Overload
Shoe Lift
Actuator x x x x
6 Overload
Vacuum Motor
x x x x x x x x x
7 Overload
Service Manual – ES4000 Control System 51

Disable System Flash Indicator

Misting Solenoid

Detergent LED
Brush Motors

Solution LED

Vacuum LED
Extract LED
Brush Deck

Sweep LED
Chemical

Recovery
Solution

Extract

Sweep
Display Fault
Code Description
Maintenance
Solenoid x x x x
8 Overload
Vacuum
Contactor Coil x x x x x x x x x
9 Overload
Brush
Contactor Coil x x x x x x x x
10 Overload
Chemical
Pump x x
11 Overload
Solution Pump
x x x x x x
12 Overload
Restore
Solenoid x x x x
13 Overload
Misting
Solenoid x x
14 Overload
Rear Brush
Motor x x x x x x x x x
15 Overload
Maintenance
x x x x
30 Solenoid Open
Front Brush
x x x x x x x x
31 motor Open
Brush Deck
Lift Actuator x x x
32 Open
Vacuum Motor
x x x x x x x x x
33 Open

Shoe Lift x x x x
34 Actuator Open

Brush x x x x x x x x
Contactor Coil
35 Open
Service Manual – ES4000 Control System 52

Disable System Flash Indicator

Misting Solenoid

Detergent LED
Brush Motors

Solution LED

Vacuum LED
Extract LED
Brush Deck

Sweep LED
Chemical

Recovery
Solution

Extract

Sweep
Display Fault
Code Description
Vacuum
Contactor Coil x x x x x x x x x
36 Open
Chemical
x x
37 Pump Open
Rear Brush
x x x x x x x x
38 Motor Open
Solution Pump
x x x x x x
39 Open
Restore
x x x x
40 Solenoid Open
Misting
x x
41 Solenoid Open
Front Brush
motor Stuck
60 Closed
Vacuum Motor
61 Stuck Closed
Maintenance
Solenoid x x
62 Stuck Closed
Brush
Contactor Coil
63 Stuck Closed
Vacuum
Contactor Coil
64 Stuck Closed
Restore
Solenoid x x
65 Stuck Closed
Misting
Solenoid x
66 Stuck Closed
Rear Brush
motor Stuck
67 Closed

Figure E-33: Disabled Systems for each fault code (Note: Flash indicator at 1 hz rate)
Service Manual – ES4000 Control System 53

Removal and Installation

Replace the Main Control Board

Caution! You must

disconnect the
batteries from
the machine
at the battery
connector
before
accessing the
control board.

Flip the operator’s seat upward and

prop it in place.

Remove the 4 screws from the

Control Panel assembly.

Lift and tilt the Control Panel

Assembly to access the board
underneath.

Caution! To prevent
damage to the control panel assembly due to static electricity (ESD), wear a properly
grounded static control wrist strap before removing the new assembly from its
protective static shielding bag. Wear the strap throughout the entire installation
process until the four screws attaching the control panel to the machine have been
fastened.

Note all wiring and hose connections.

Disconnect the wiring and hose
connections.

Caution! The ribbon

cable(s) and
membrane
switch
grounding film
are fragile. Do
not scratch or
crease during
disassembly or
re-assembly or
damage may
occur.

Caution! DO NOT pull the clear tube off the control board or it WILL break the control board!
Instead, use a raor knife and carefully cut the tube off the control board.
Service Manual – ES4000 Control System 54

Remove the key switch from 1 of 5 screws

the control board panel
assembly.

Remove the 5 screws from

the board assembly. Save
the screws and key switch.
Discard the old board and
replace it with the new one.

Install the new board

assembly in the reverse
order. Be extra careful when
plugging in the connectors
on the board.

Key switch assy

Note: After replacing the Main Controller, no special programming of

operational values is required if the machine is equipped with WET
BATTERIES . However, if the ES4000 machine is equipped with
AGM or GEL batteries, it is MANDATORY to set the LOW VOLTAGE
CUTOUT function in the Hidden Menus. By default, the initial setting
is “Wet Battery 80%” but will need to be changed to “Main Free Battery
70%” if the machine has AGM or GEL batteries. Failure to do so may
cause premature battery failure.
Service Manual – ES4000 Control System 55

Specifications

Shop Measurements – Main Controller

The following tables contain some “real world” shop voltage measurements to help you recognize what “normal”
looks like. All voltage values were measured with the key switch on and the black (Negative) voltmeter lead con-
nected to the main battery negative terminal unless otherwise specified.

Pin Wire Description Measured Comments

ID Color Value
J1-1 red/yel Chemical Pump “+” 2v to 20v Voltage should jump around when pump is
output operated
J1-2 vio/org Solution Pump 0.15v When solution flows
output
J1-3 blu/gra Chemical Pump “-“ 2v to 20v Voltage should jump around when pump is
output operated
J1-4 org/blk Brush Deck 23.9v up Measured when actuator was moving in both
Actuator motor “+” directions
output
0.26v down
J1-5 blu Brush Deck 23.7v up Measured when actuator was moving in both
Actuator motor “-“ directions
output
0.15v down
J1-6 vio/red Rear Brush Motor 0.02v Brushes running without touching the floor
Current Sense
input
J1-7 blk/wht Restore solenoid 0.18v When energized
output
J1-8 blk/wht Battery “-“ input 0.05v While operating in extract mode with vacuum
motors on
J1-9 blk/yel Shoe Actuator 24.4v up Measured when actuator was moving in both
motor “-” output directions
0.13v down
J1-10 wht/grn Shoe Actuator 24.6v down Measured when actuator was moving in both
motor “+” output directions
0.12v up
J2-1 blk Battery “-“ input 0.02v With vacuum motors running
J2-2 Not used
J2-3 Not used
J2-4 blk/wht Speed limit output 0.53v Restore mode
1.29v Maintenance mode
2.5v Prespray mode
(Signal from main
4.5v Transport and Sweep modes
controller to speed
controller)
J2-5 vio Speed limit pot low 0.38v
ref
J2-6 yel Speed limit pot 4.58v
high ref
Service Manual – ES4000 Control System 56

Pin Wire Description Measured Comments

ID Color Value
J2-7 blk Battery “-“ input 0.02v With vacuum motors running
J2-8 blk Battery “-“ input 0.02v With vacuum motors running
J2-9 brn/red Vacuum Motor 0.192v Vacuum on with open hose
Current Sense
input
0.150v Vacuum on with hose blocked
J2-10 yel/vio Front Brush Motor 0.028v Brush running with deck up
Current Sense
input
0.111v Brush running with deck all the way down
J2-11 Not used
J2-12 Not used
J3-1 brn/yel Battery “+“ lead 24.2v With vacuum motors running
J3-2 blk Battery “-“ input 0.02v With vacuum motors running
J3-3 blu/org Maintenance 0,18v When energized
solenoid output
J3-4 gra/blk Seat Switch input 25.0v Switch closed

0.00v Switch open

J3-5 blu/blk Reverse Direction 1.55v Reverse
input from Speed
Controller (input =
24.1v Neutral or Forward
GND when moving
in reverse)
J3-6 red/wht Fwd/Reverse 0.24v Reverse or Neutral
input from Speed
Controller (input =
24.1v Neutral
GND when moving
in forward or
reverse)
J3-7 org/blu Speed Controller 1.19v With no speed control faults
Status input (input
pulses between
24v With speed control faults (The voltage jumps
B+ and GND to
lower as the code signal is communicated)
indicate error
status from Speed
Controller)
J3-8 brn/yel Battery “+“ lead 24.5v With vacuum motors running
J3-9 grn/blk Horn “-” output 13.3v off Connects to battery negative to sound horn

0.01v on
J3-10 org/red Horn “+” output 15.0v Constant power supply
J3-11 vio/blk Misting solenoid 0.19v When energized
output
J3-12 gra/blk Vacuum Contactor 0.26v When first energized (To pull in contactor)
output
4.8v After energized for a few seconds (To hold
contactor)
Service Manual – ES4000 Control System 57

Pin Wire Description Measured Comments

ID Color Value
J3-13 wht/red Brush Motor 0.28v When first energized (To pull in contactor)
Contactor output
4.8v After energized for a few seconds (To hold
contactor)
J3-14 brn Key Switch input 24.1v With vacuum motors running
(input = B+ voltage
when key is turned
on)
Service Manual – ES4000 58

Electrical System

Functional Description
The Electrical System is integrated throughout the machine functions. The main functional interface is the
Operator’s Interface Panel Assembly (See CONTROL SYSTEM, Control Panel). All operator’s functions
are initiated and controlled from this panel. The machine is Battery-powered and rechargeable. The drive
system is variable speed controlled via the foot pedal and selection of various operational functions at the
Control Panel.

An optional on-board Battery Charger is available for this machine. This manual shows the ES4000 with the
Optional Battery Charger installed.

Components Locations
• Batteries and connections

• Fuses, E-Stop button

• Battery charger

• Main operator’s interface panel (see CONTROL SYSTEM)

• Speed controller (see WHEEL SYSTEM, TRACTION)

70 amp circuit
breaker Battery Connect/
Disconnect

Operator’s
Control Unit
10 Amp
Circuit
Breaker
Emergency
Stop

150 Amp fuse

24 VDC
Contactor
24 V, 100 AMP
Contactor

Speed
Controller
Service Manual – ES4000 Electrical System 59

Batteries in battery tray with

Recovery Tank removed and
Operator’s Seat up.

Battery connector (shown

disconnected)

Fuses and E-stop locations

Service Manual – ES4000 Electrical System 60

On-board Battery Charger

Operator’s main interface

panel (CONTROL PANEL)

Speed Controller
Service Manual – ES4000 Electrical System 61

Detergent pump

Main Electrical Panel

Contactors

Detergent bottle
Speed Controller

Electrical components in
electrical panel

K1 Vacuum Contactor 24VDC K2 Brush Contactor 24V, 100 AMP

Service Manual – ES4000 Electrical System 62

Battery Specifications
Advance recommended battery pack capacity is a 310 or 420 AH @ 20 Hour Rate deep cycle battery system
(four 6V-batteries). Note: The battery pack must fit the battery compartment size listed in Specifications.

Battery Charger (on-board and portable)

–– Use a 24V DC output charger matching the DC battery pack voltage and the input AC line voltage
supply being used.

–– Always when selecting a battery charger follow the recommendation of the battery supplier to match
the proper charger DC output amperage to the amp/hour rating batteries being installed. This will
prevent the battery pack from being over or under charged.

◦◦ The recommended 310 AH battery should be matched to a 24V, 25 Amp charger. The recommended
420 AH battery should be matched to a 24V, 36 Amp charger.

Removal and Installation

On-Board Battery Charger and power cord

Service Manual – ES4000 Electrical System 63

Install Batteries

WARNING! Use extreme caution when working with batteries. Sulfuric acid in batteries can
cause severe injury if allowed to contact the skin or eyes. Explosive hydrogen gas is
vented from inside the batteries through openings in the battery caps. This gas can
be ignited by any electrical arc, spark or flame.

When Servicing Batteries:

• Remove all jewelry.

• Do not smoke.

• Wear chemical goggles, rubber gloves and a protective apron.

• Work in a well-ventilated area.

• Do not allow tools to touch more than one battery terminal at a time.

CAUTION! Electrical components in this machine can be severely damaged if the batteries are
not installed and connected properly.
Service Manual – ES4000 Electrical System 64

Turn the Master Key Switch

OFF and remove the key from
the Operator’s Control Panel.

To access the battery Seat Prop

compartment tip the operator’s Operator’s Control
seat forward and set the Panel

prop rod. Remove the battery

cables from inside the battery
compartment. (Figure E-1).

Battery Connector

Figure E-1

Remove the batteries from

their shipping crate and
carefully inspect them for
cracks or other damage. If
damage is evident, contact the
carrier that delivered them or
the battery manufacturer to
file a damage claim.

Your machine comes from the

factory with enough battery
cables to install four (6 volt),
420 Amp hour batteries. Using
two people and an appropriate
lifting strap, carefully lift the
batteries into the compartment
tray exactly as shown on Batteries with connectors and main
machine decal (Figure E-2). cable disconnected

Figure E-2
Service Manual – ES4000 Electrical System 65

The terminals on the

battery cables are marked
“+” for positive and “-“
for negative. Install the
battery cables as shown,
with the terminals marked
“+” on the positive battery
terminals and the terminals
marked “-“ on the negative
terminals. Position the
cables so the battery caps
can be easily removed for
battery service.

Carefully tighten the nut

in each battery terminal
until the terminal will not
turn on the battery post.
Then tighten the nut half
an additional turn. Do not
over-tighten the terminals,
or they will be very difficult
to remove for future service.

Coat the terminals and

posts with spray-on battery
terminal coating (available
at most auto parts stores).

Put one of the black rubber boots over each of the terminals and retain with supplied tie straps.

Connect the battery pack connector to the Machine Battery Connector and close the operator’s seat
platform.
Service Manual – ES4000 Electrical System 66

Battery Low Voltage Cutout Feature - Description

The ES4000 is equipped with a low voltage cutout feature to prevent over-discharging of the batteries. When
a machine’s battery pack voltage falls below specifically defined thresholds (voltage settings) the cleaning
system is automatically shut down. The cutout level is adjustable. The standard lead acid battery (wet
cell) setting is 1.72V per cell and alternate maintenance free battery (gel cell) setting is 1.81V per cell. The
standard setting is factory selected and should be used unless the battery manufacturer specifies the higher
cutout voltage. The Low Voltage Cutout is indicated by the Voltage Low indication shown on the display and
everything is disabled except the Horn.

Special Service Note: On all machines (24V) a minimum recharge voltage of 25.08 volts (2.09 volts
per cell) must be reached to allow the brush and solution system to (reset) function again
following a low voltage cutout.

Battery Condition Indicator - Description

The Battery Condition Indicator will give an indication of the state of charge of the BATTERY CONDITION

batteries. The battery condition indicator will retain the state-of-charge even if the
key has been turned off. The state-of-charge indication is reset to full charge when the
batteries have been recharged. It is also possible to choose between two different low
voltage thresholds depending on whether maintenance free or standard batteries are
being used.

The indicator is shown as an icon on the operator control panel’s display. This icon is
present 10 seconds after the Key Switch is turned ON. The icon is a battery with up to
5 vertical bars inside. The number of bars inside the icon represents the charge state of
the battery as follows:

1. Battery full = 5 bars

2. Battery at 80% = 4 bars

3. Battery at 60% = 3 bars

4. Battery at 40% = 2 bars

5. Bsttery at 20% = 1 bar

6. Battery depleted = no bars

*Important Note: See the Main Control Board Special Program Options manual section and follow
the instructions for changing the low voltage cutout threshold.
Service Manual – ES4000 Electrical System 67

Battery LOCK Value

The Battery LOCK Value is a term used by Nilfisk-Advance to reference the representation of the machine
battery voltage after it is converted to a digital number and ran through the battery voltage monitoring
algorithm. The LOCK value is used to determine the correct battery gauge level to be displayed on the LCD.
The LOCK value is also used to trigger a LVI (Low Voltage Inhibit) warning. The LOCK value is nonvolatile
and can only be reset as explained above for BATT_RESET.

Low voltage inhibit process

1. When Gel battery reaches LVI Lock value 17, turn off the brushes, pumps and solenoids and raise the
brush deck. Still active are the shoe actuator, vacuum and horn.

2. When Gel battery reaches LVI Lock value 18, disable and turn off everything except horn.

3. When Wet battery reaches LVI Lock value 25, turn off the brushes, pumps and solenoids and raise the
brush deck. Still active are the shoe actuator, vacuum and horn.

4. When Wet battery reaches LVI Lock value 26, disable and turn off everything except the horn

LOCK Battery Voltage LCD Display

Threshold Wet Battery Gel Battery
0 24.30 Batt Gauge = 5 Batt Gauge = 5
Bar Bar
1 24.15 Batt Gauge = 5 Batt Gauge = 5
Bar Bar
2 24.0 Batt Gauge = 5 Batt Gauge = 5
Bar Bar
3 23.85 Batt Gauge = 4 Batt Gauge = 4
Bar Bar
4 23.7 Batt Gauge = 4 Batt Gauge = 4
Bar Bar
5 23.55 Batt Gauge = 3 Batt Gauge = 3
Bar Bar
6 23.4 Batt Gauge = 3 Batt Gauge = 3
Bar Bar
7 23.25 Batt Gauge = 3 Batt Gauge = 2
Bar Bar
8 23.1 Batt Gauge = 2 Batt Gauge = 2
Bar Bar
9 22.95 Batt Gauge = 2 Batt Gauge = 2
Bar Bar
10 22.8 Batt Gauge = 2 Batt Gauge = 1
Bar Bar
11 22.65 Batt Gauge = 2 Batt Gauge = 1
Bar Bar
12 22.5 Batt Gauge = 2 Batt Gauge = 1
Bar Bar
13 22.35 Batt Gauge = 1 Batt Gauge = 0
Bar Bar
14 22.2 Batt Gauge = 1 Batt Gauge = 0
Bar Bar
Service Manual – ES4000 Electrical System 68

LOCK Battery Voltage LCD Display

Threshold Wet Battery Gel Battery
15 22.05 Batt Gauge = 1 Batt Gauge = 0
Bar Bar
16 21.9 Batt Gauge = 1 Batt Gauge = 0
Bar Bar
17 21.75 Batt Gauge = 1 LVI
Bar
18 21.6 Batt Gauge = 1 LVI
Bar
19 21.45 Batt Gauge = 0 LVI
Bar
20 21.3 Batt Gauge = 0 LVI
Bar
21 21.15 Batt Gauge = 0 LVI
Bar
22 21.0 Batt Gauge = 0 LVI
Bar
23 20.85 Batt Gauge = 0 LVI
Bar
24 20.7 Batt Gauge = 0 LVI
Bar
25 20.55 LVI LVI
26 20.4 LVI LVI
27 20.25 LVI LVI
28 20.1 LVI LVI
29 19.95 LVI LVI
30 19.8 LVI LVI

Battery Voltage Threshold and LCD Display for given LOCK values
Service Manual – ES4000 Electrical System 69

Maintenance and Adjustments

Battery Maintenance
Proper maintenance of electric vehicle batteries can greatly extend their life. Well-maintained batteries may
last up to 3 years, but failure after 1 year is common if maintenance has been poor. There are 3 simple rules
for good battery maintenance:

• Maintain Proper Electrolyte Level (Weekly) - Use distilled water in batteries whenever possible. If
batteries are discharged, add just enough water to cover the plates in each cell. If batteries are fully
charged, fill each cell to the bottom of the filler tube. Do not over-fill the batteries! Do not add acid to
batteries!

• Keep the Batteries Charged (Weekly) - Batteries should be charged each time that a machine is used for
more than 1 hour. Machine operators should open the battery compartment cover for charging, to avoid
a concentrated build-up of hydrogen gas. Operators should follow the instructions provided with their
specific battery charger, to determine how long the batteries should be charged. Even when a machine is
stored, the batteries should be charged once a month to prevent the batteries from “sulfating”. Almost all
battery caps are vented, so there’s no need to loosen or remove them for charging.

• Keep the Batteries Clean (Monthly) - Use a damp cloth to wipe dirt from the top of the batteries. Battery
terminals must be clean and tight. If the tops of the batteries are wet after charging, the batteries have
probably been over-filled or over-charged. Note: If there is acid on the batteries, wash the tops of the
batteries with a solution of baking soda and water (2) tablespoons of baking soda to 1 quart of water.

Charging the Batteries

Charge the machine’s battery pack each time the machine is used, or when the Battery Condition Indicator
show no vertical bars in the battery icon.

Note: The machine also uses a special low voltage cutout that inhibits the cleaning system see in
this manual section the Description of the Battery Low Voltage Cutout Feature.

To Charge the Batteries.

1. Disconnect the Battery Connector.

2. Lift the seat and prop it open with the prop rod to provide proper ventilation.

3. Push the connector from the charger into the Battery Connector.

4. Follow the instructions on the battery charger.

5. Check the fluid level in all battery cells after charging the batteries. Add distilled water, if necessary, to
bring the fluid level up to the bottom of the filler tubes.

WARNING! Do not fill the batteries before charging. Only charge batteries in a well-ventilated
area. Do not smoke while servicing the batteries.
Service Manual – ES4000 Electrical System 70

Battery Testing
A battery problem is usually recognized by the machine operator as a decrease in the machine’s running
time. This condition is usually caused by one or more “dead cells” in the battery system (one or more cells
that is producing less voltage than the other cells).

Note: Always charge batteries before testing. There are 2 ways to find a dead cell:

• Use a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell is
one that reads 50 points (or more) lower than the other cells.

• Use a volt meter to check the voltage of each battery with the cleaning and drive motors running. The
battery with the dead cell will read 1 or 2 volts lower than the other batteries in the system.

• If the batteries in the machine are more than 1 year old, it’s usually best to replace the whole set, rather
than replacing just one battery. As batteries age, their maintenance requirements change. As they age
they usually require longer charging times and a higher finish rate. A newer battey mixed in with old
batteries will end up being overcharged and cause it to fail prematurely.

The table below shows the approximate “percent charged” of an electric vehicle battery at various specific
gravity values, corrected to 80°F (26.7°C).

APPROXIMATE STATE OF CHARGE

Charged 1.265 Initial Full Charge
100% 1.265
75% 1.225
50% 1.190
25% 1.155
Discharged 1.120
Service Manual – ES4000 Electrical System 71

Machine and Chassis Wiring

Service Manual – ES4000 Electrical System 72

Machine and Chassis Wiring

Service Manual – ES4000 Electrical System 73

Specifications

INPUT/OUTPUT TABLES
Designation Pin Wire Description Signal Nominal Reference Range Comments
ID ID/ Characteristic Value To:
Color
output J1-1 red/ Chemical pulsed voltage +24V B- 20.5 to This signal alternates between
yel Pump “+” 25.5 V 0V and 24V when chemical
output pump is active
output J1-2 vio/ Solution Pump PWM voltage 0V B- 0 to voltage on this pin cycles
org output (sweep mode); 0.100 between 0 and 24V; pump is
DC voltage V energized when this voltage =
(extract mode) 0V; PWM period = 6 seconds;
duty cycle = 17% for sweep
mode & 100% for extract
mode
output J1-3 blu/ Chemical pulsed voltage +24V B- 20.5 to This signal alternates between
gra Pump “-“ 25.5 V 0V and 24V when chemical
output pump is active
output J1-4 org/ Brush Deck DC voltage +24V B- 20.5 to 24V when lowering deck; 0
blk Actuator motor 25.5 V volts when raising deck
“+” output
output J1-5 blu Brush Deck DC voltage +24V B- 20.5 to 24V when raising deck; 0 volts
Actuator motor 25.5 V when lowering deck
“-“ output
input J1-6 vio/ Rear Brush Analog voltage 0.036 V B- 0.011 voltage is present only if brush
red Motor Current to motor is ON; voltage range
Sense input 0.075 corresponds to motor load
(voltage on V range = 3 to 21A
this wire
wrt GND
represents the
motor current)
output J1-7 blk/ Restore DC voltage 0V B- 0 to Voltage = nominal 0 V when
wht solenoid 0.100 solenoid is energized and 24
output V V otherwise
ground J1-8 blk/ Battery “-“ DC voltage -24V B+ -20.5 “-” terminal of battery
wht input to
-25.5 V
Service Manual – ES4000 Electrical System 74

Designation Pin Wire Description Signal Nominal Reference Range Comments

ID ID/ Characteristic Value To:
Color
output J1-9 blk/ Shoe Actuator DC voltage +24V B- 20.5 to 24V when raising deck; 0 volts
yel motor “-” 25.5 V when lowering deck
output
output J1- wht/ Shoe Actuator DC voltage +24V B- 20.5 to 24V when lowering deck; 0
10 grn motor “+” 25.5 V volts when raising deck
output
ground J2-1 blk Battery “-“ DC voltage -24V B+ -20.5 “-” terminal of battery
input to
-25.5 V
ground J2-2
no J2-3
connection
output J2-4 blk/ speed limit pot Analog voltage +5V B- 0.0 to 0V corresponds to machine
wht wiper output 5.0 V stopped, 5V corrersponds to
max allowed speed
input J2-5 vio speed limit pot DC voltage 0V B- 0 to 0V supply provided by the
low ref 0.100 speed controller for the speed
V limit pots
input J2-6 yel speed limit pot DC voltage +5V B- 4.90 to power supply voltage provided
high ref 5.10 V by the speed controller for the
speed limit pots
ground J2-7 blk Battery “-“ DC voltage -24V B+ -20.5 “-” terminal of battery
input to
-25.5 V
ground J2-8 blk Battery “-“ DC voltage -24V B+ -20.5 “-” terminal of battery
input to
-25.5 V
input J2-9 brn/ Vacuum Motor Analog voltage 0.130 V B- 0.103 voltage is present only if
red Current Sense to vacuum is ON; voltage range
input (voltage 0.154 corresponds to current range
on this wire V = 30 to 45A
wrt GND
represents the
motor current)
Service Manual – ES4000 Electrical System 75

Designation Pin Wire Description Signal Nominal Reference Range Comments

ID ID/ Characteristic Value To:
Color
input J2- yel/ Front Brush Analog voltage 0.050 B- 0.011 voltage is present only if brush
10 vio Motor Current to motor is ON; voltage range
Sense input 0.075 corresponds to motor load
(voltage on V range = 3 to 21A
this wire
wrt GND
represents the
motor current)
no J2-11
connection
no J2-
connection 12
Designation Pin Wire Description Signal Nominal Reference Range Comments
ID ID/ Characteristic Value To:
Color
power J3-1 brn/ Battery “+” DC voltage ‘+ 24 V B- 20.5- “+” terminal of battery
yel lead 25.5 V
ground J3-2 blk Battery “-“ DC voltage -24V B+ -20.5 “-” terminal of battery
input to
-25.5 V
output J3-3 blu/ Maintenance DC voltage 0V B- 0 to Voltage = nominal 0 V when
org solenoid 0.100 solenoid is energized and 24
output V V otherwise
input J3-4 gra/ Seat Switch DC voltage +24V B- 20.5 to This signal is 24V when
blk input 25.5 V the seat switch is closed
(someone is sitting on the
seat) and 0V when seat
switch is open.
input J3-5 blu/ Reverse DC voltage 0V B- 0 to Voltage = nominal 0V when
blk Direction input 0.100 drive motor is operating in
from Speed V reverse; voltage = nominal
Controller 24V all other times
(input = GND
when moving
in reverse)
Service Manual – ES4000 Electrical System 76

Designation Pin Wire Description Signal Nominal Reference Range Comments

ID ID/ Characteristic Value To:
Color
input J3-6 red/ Fwd/Reverse DC voltage 0V B- 0 to Voltage = nominal 0V when
wht input from 0.100 drive motor is moving; voltage
Speed V = nominal 24V when in neutral
Controller
(input = GND
when moving
in forward or
reverse)
input J3-7 org/ Speed DC voltage 0V B- 0 to voltage = nominal 0V when
blu Controller 0.200 there is no speed controller
Status input V fault; voltage pulses between
(input pulses 0V and 24V when there is a
between B+ fault with the speed controller.
and GND PULSED SIGNAL EQUAL TO
to indicate THE FAULT CODE FLASHED
error status BY THE SPEED CONTROL
from Speed BUILT-IN STATUS LED
Controller)
power J3-8 brn/ Battery “+“ DC voltage +24V B- 20.5 to “+” terminal of battery
yel lead 25.5 V
output J3-9 grn/ horn “-” output PWM voltage 0V B- 0 to when horn button is pressed,
blk 0.200 this signal = 0V. When
V moving in reverse or when
switching machine modes
this signal pulses between 0
and 24V using a 50% duty
cycle with the on time further
modulated at 1 KHz.
output J3- org/ horn “+” output DC voltage +15V B- 14.7 to constant 15V as supplied by
10 red 15.3 V PCB
output J3-11 vio/ Misting DC voltage 0V B- 0 to Voltage = nominal 0 V when
blk solenoid 0.100 solenoid is energized and 24
output V V otherwise
Service Manual – ES4000 Electrical System 77

Designation Pin Wire Description Signal Nominal Reference Range Comments

ID ID/ Characteristic Value To:
Color
output J3- gra/ Vacuum PWM voltage 0V B- 0 to voltage on this pin cycles
12 blk Contactor 0.100 between 0 and 24V; contactor
output V is energized when this voltage
= 0V; PWM frequency =
5KHz; duty cycle = 100% for
startup and 80% steady state
when vacuum is ON
output J3- wht/ Brush Motor PWM voltage 0V B- 0 to voltage on this pin cycles
13 red Contactor 0.100 between 0 and 24V; contactor
output V is energized when this voltage
= 0V PWM frequency = 5KHz;
duty cycle = 100% for startup
and 80% steady state when
brush motor is ON
input J3- brn Key Switch DC voltage +24V B- 20.5 to voltage is = battery voltage
14 input (input = 25.5 V when the key switch is ON
B+ voltage -
key is on)
Service Manual – ES4000 Electrical System 78

Shop Measurements – Main Controller

The following tables contain some “real world” shop voltage measurements to help you recognize what “normal”
looks like. All voltage values were measured with the key switch on and the black (Negative) voltmeter lead con-
nected to the main battery negative terminal unless otherwise specified.

Pin Wire Description Measured Comments

ID Color Value
J1-1 red/yel Chemical Pump “+” 2v to 20v Voltage should jump around when pump is
output operated
J1-2 vio/org Solution Pump 0.15v When solution flows
output
J1-3 blu/gra Chemical Pump “-“ 2v to 20v Voltage should jump around when pump is
output operated
J1-4 org/blk Brush Deck 23.9v up Measured when actuator was moving in both
Actuator motor “+” directions
output
0.26v down
J1-5 blu Brush Deck 23.7v up Measured when actuator was moving in both
Actuator motor “-“ directions
output
0.15v down
J1-6 vio/red Rear Brush Motor 0.02v Brushes running without touching the floor
Current Sense
input
J1-7 blk/wht Restore solenoid 0.18v When energized
output
J1-8 blk/wht Battery “-“ input 0.05v While operating in extract mode with vacuum
motors on
J1-9 blk/yel Shoe Actuator 24.4v up Measured when actuator was moving in both
motor “-” output directions
0.13v down
J1-10 wht/grn Shoe Actuator 24.6v down Measured when actuator was moving in both
motor “+” output directions
0.12v up
J2-1 blk Battery “-“ input 0.02v With vacuum motors running
J2-2 Not used
J2-3 Not used
J2-4 blk/wht Speed limit output 0.53v Restore mode
1.29v Interim mode
2.5v Pretreat mode
(Signal from main
4.5v Transport and Sweep modes
controller to speed
controller)
J2-5 vio Speed limit pot low 0.38v
ref
J2-6 yel Speed limit pot 4.58v
high ref
J2-7 blk Battery “-“ input 0.02v With vacuum motors running
J2-8 blk Battery “-“ input 0.02v With vacuum motors running
Service Manual – ES4000 Electrical System 79

Pin Wire Description Measured Comments

ID Color Value
J2-9 brn/red Vacuum Motor 0.192v Vacuum on with open hose
Current Sense
input
0.150v Vacuum on with hose blocked
J2-10 yel/vio Front Brush Motor 0.028v Brush running with deck up
Current Sense
input
0.111v Brush running with deck all the way down
J2-11 Not used
J2-12 Not used
J3-1 brn/yel Battery “+“ lead 24.2v With vacuum motors running
J3-2 blk Battery “-“ input 0.02v With vacuum motors running
J3-3 blu/org Maintenance 0,18v When energized
solenoid output
J3-4 gra/blk Seat Switch input 25.0v Switch closed

0.00v Switch open

J3-5 blu/blk Reverse Direction 1.55v Reverse
input from Speed
Controller (input =
24.1v Neutral or Forward
GND when moving
in reverse)
J3-6 red/wht Fwd/Reverse 0.24v Reverse or Neutral
input from Speed
Controller (input =
24.1v Neutral
GND when moving
in forward or
reverse)
J3-7 org/blu Speed Controller 1.19v With no speed control faults
Status input (input
pulses between
24v With speed control faults (The voltage jumps
B+ and GND to
lower as the code signal is communicated)
indicate error
status from Speed
Controller)
J3-8 brn/yel Battery “+“ lead 24.5v With vacuum motors running
J3-9 grn/blk Horn “-” output 13.3v off Connects to battery negative to sound horn

0.01v on
J3-10 org/red Horn “+” output 15.0v Constant power supply
J3-11 vio/blk Misting solenoid 0.19v When energized
output
J3-12 gra/blk Vacuum Contactor 0.26v When first energized (To pull in contactor)
output
4.8v After energized for a few seconds (To hold
contactor)
Service Manual – ES4000 Electrical System 80

Pin Wire Description Measured Comments

ID Color Value
J3-13 wht/red Brush Motor 0.28v When first energized (To pull in contactor)
Contactor output
4.8v After energized for a few seconds (To hold
contactor)
J3-14 brn Key Switch input 24.1v With vacuum motors running
(input = B+ voltage
when key is turned
on)
Service Manual – ES4000 Electrical System 81

Wiring (Ladder) Diagram 56344090 Rev. C (1 of 2)

F1 BT1
RED 1 2 + - BLK
CB1 FUSE, 150A. BATTERY, 24 Vdc
RED 2 1
BRN/BLK
CIRCUIT BREAKER, 70A.
ON BOARD
BATTERY CHARGER
RED B+ (OPTIONAL) B- BLK
LP1
INTERLOCK
1 WHT/BRN 1 2 BLK

LAMP, FLASHING
OPTIONAL
CB2 S1 S4
S2
RED 2 1 BRN/YEL 1 2 BRN WHT/BRN 1 2 GRA/BLK
SW, SPST KEY EMERGENCY, STOP SWITCH, SEAT
CIRCUIT BREAKER, 10 AMP
RED

BRN/YEL SEAT
J3-1 B+ GRA/BLK ORN
J3-8 B+ SWITCH J3-4
BRN

2
K1 J3-14 KEY SWITCH
Y1
BRN GRA/BLK J3-12 VACUUM BRAKE
CONTACTOR A2
CONTACTOR, VACUUM A1
CURTIS 1228 SPEED

RED/WHT 1
CONTROL BOARD
K2 CONTROLLER
BRN WHT/RED J3-13 BRUSH

PIN 14 - BRAKE +

PIN 5 - KSI
CONNACTOR

B+
CONTACTOR, BRUSH
L1 FORWARD/
RED/WHT PIN 6 - BRAKE -
BRN 1 2 VIO/BLK REVERSE J3-6
J3-11 MISTING
ORN/BLU
VALVE, SOLENOID SOLUTION SOLENOID STATUS J3-7 PIN 9 - STATUS C
B- BLK
L2 BLU/BLK
REVERSE J3-5 PIN 16 - REV. ALARM
1 2 BLK/WHT J1-7 RESTORE
SPEED
VALVE, SOLENOID SOLUTION SOLENOID BLK/WHT PIN 18 - SPEED LIMIT
LIMIT J2-4 C

MOTOR, WHEEL DRIVE

L3
M1 RED/GRN
BRN 1 2 BLU/ORN J3-3 MAINTENANCE VIO PIN 13 - POT. LOW 2
VALVE, SOLENOID SOLUTION SOLENOID GRA PIN 4 - POT. WIPER
S5 M9 YEL M1 M
POT. HIGH J2-6
BRN 1 2 - M + VIO/ORN J1-2 SOLUTION
R1 B 1
PUMP M2 YEL/BLK
POT. LOW J2-5 VIO C A YEL PIN 3 -POT HIGH
SOLUTION PUMP
NOTE: SWITCH IS PART OF C
POT 5.0K OHM
PUMP ASSEMBLY
H1 BLK
B- J1-8
B- J2-8 BLK
- + ORN/RED J3-10 HORN +
B- J2-7 BLK
HORN GRN/BLK J3-9 HORN - BLK
B- J2-1
OPTIONAL M2 BLK
B- J2-2
- M + RED/YEL J1-1 CHEMICAL
PUMP(+)
B-
CHEMICAL PUMP
BLU/GRA
J1-3 CHEMICAL NOTES:
B+ PUMP(-)

1. DISCONNECT RED WIRE ON CB2 AND

REPLACE WITH GREEN WIRE FROM CHARGER
WHEN ON BOARD CHARGER IS USED
Service Manual – ES4000 Electrical System 82

Wiring (Ladder) Diagram 56344090 Rev. C (2 of 2)

B-
B+
A1
CONTROL BOARD
SHOE ACT(-) J1-9 BLK/YEL

M3

SHOE ACT(+) J1-10 WHT/GRN + M -

MOTOR,SHOE LIFT ACTUACTOR

BRUSH ACT(-) J1-5 ORN/BLK

M4

BRUSH ACT(+) J1-4 BLU + M -

MOTOR, BRUSH LIFT ACTUACTOR

REAR BRUSH MOTOR SENSE J1-6 VOI/RED

FRONT BRUSH MOTOR SENSE J2-10 YEL/VIO

VACUUM MOTOR SENSE J2-9 BRN/RED

C
K1
RED 4 3 WHT 1 2

CONTACTOR, VACUUM
M6

M
MOTOR, VAC

WHT 1 2 BLK

M5

M
MOTOR, VAC

C M7
K2
RED 4 3 RED RED - M + BLK BLK
CONTACTOR, BRUSH
MOTOR, BRUSH FRONT

M8
RED - M + BLK

MOTOR, BRUSH REAR

Service Manual – ES4000 Electrical System 83

Wiring Harness Diagram 56344091 Rev. C (1 of 2)

Service Manual – ES4000 Electrical System 84

Wiring Harness Diagram 56344091 Rev. C (2 of 2)

Service Manual – ES4000 85

Options and Accessories

Options
1. Battery

6V 312 AH AGM,

6v420 AH WET

2. Shelf Charger (Portable)

24V auto 20 AMP
120 VAC/60HZ

24V auto 25 AMP

120 VAC/60HZ

24V auto 36 AMP

120 VAC/60HZ
Service Manual – ES4000 Options and Accessories 86

3. On-Board Charger Assembly

Service Manual – ES4000 Options and Accessories 87

Accessories
1. Warning Beacon kit

2. Battery Watering Kit

Service Manual – ES4000 Options and Accessories 88

3. Chemical Bottle Assembly

4. Battery Fill indicator

Service Manual – ES4000 Options and Accessories 89

5. AquaWand Carpet Scrub Wand 13

and Accessory hose assembly
Service Manual – ES4000 90

Recovery System

Functional Description

Recovery System—Vacuum General

During extraction, dirty water is lifted out of the carpet pile by airflow created by two 3 stage 24V vacuum
motors. See Figure R-1. The dirty water and air enter at the two vacuum pick-up tools through their small
narrow shoe openings that contact the carpet surface. A hose is connected to each shoe to direct water to the
Recovery Tank hose that is connected to the Recovery Tank. Once inside the Recovery Tank, the heavier
water falls to the bottom of the tank while the air continues through the shutoff float, vacuum motors and is
exhausted out of the exhaust tube at the bottom of the vacuum motor housing.

The vacuum system uses a shutoff float that prevents the tank from being overfilled and also stops any
water from being sucked into the vacuum motors. This shut-off function works when the float ball reaches its
tank full level and the ball becomes seated in the float housing. The added restriction to the vacuum airflow
causes a large electrical current load change (lower Amps) to the vacuum motors. Sensing the lowering of
the vacuum circuit current load, the main controller A1 automatically shuts off the vacuum and cleaning
systems and displays “FULL” on the hourmeter/status display.
Service Manual – ES4000 Recovery System 91

Recovery System Circuit Description

The main controller turns on the vacuum motors by energizing the vacuum contactor. The vacuum contactor
is provided battery positive voltage on one side of the coil through the key switch. To energize the contactor,
the main controller completes a path to ground (battery negative) on the other side of the coil through an
internal switch. When the vacuum contactor is energized, the contacts close and supply battery positive
voltage to each of the vacuum motors. The vacuum motors are hard-wired to battery negative using a
specially calibrated ground wire that has a specific resistance along its length. The purpose of this special
calibrated ground wire is to allow the main controller to calculate the current flowing through the wire by
measuring the voltage difference between the two ends of the wire. Inside the main controller there is an
“internal voltmeter” which is connected across the ends of these wire. As the current increases, the voltage
measured increases. The main controller also drives the vacuum shoe lift actuator. It acts as a double throw,
double pole switch to provide battery positive and battery negative voltage across the actuator wires in order
to drive the actuator. It reverses the polarity to drive the motor in both directions.

24v Battery

S1 Key Switch
A1 Main Controller

Internal
Voltmeter
J3-12

B+ B- B- B+
J2-9

K1 Vacuum Contactor

M3 Vacuum Shoe
Lift Actuator

M5 Vacuum Motor

Calibrated
Ground
M6 Vacuum Motor
Wire
Service Manual – ES4000 Recovery System 92

Component Locations
• Recovery Tank and lid

• Recovery hose and dump hose

• Vacuum motor filter

• Strainer basket

• Tank Float shutoff

• Vacuum motor

• Wet Port

• Dry Port

• Vacuum Shoes

• Vacuum shoe lift actuator

• K1 vacuum contactor

See Figure R-1. Recovery Tank recovery hose and

and dump hose

Vacuum shoe Tank Float Shutoff

Vacuum motor filter

K1 vacuum contactor Strainer Basket

Dry Port Wet Port

Vacuum shoe lift actuator

Service Manual – ES4000 Recovery System 93

Recovery Tank and Lid

Vacuum Motor Filter

Strainer Basket

Recovery Hose
Recovery Tank Float
shutoff

Vacuum Motors

Dump hose

Figure R-1
Service Manual – ES4000 Recovery System 94

Maintenance and Adjustments

Recovery System Service Maintenance Checklist

Whenever there is a vacuum problem, check over the entire system. Use the checklist below as a guide to
thoroughly check the vacuum system.
−− Clean built-up dirt from the inside of both vacuum pick-up (shoes) tools.
−− Inspect the vacuum motors duct (plenum housing) cover gaskets, clean foam air inlet filters and
screens.
−− Inspect the hose between the pick-up tools and the recovery tank, rinse any built-up dirt from
the hoses. Replace the hose(s) if it is kinked or damaged.
−− Inspect and make sure the gaskets on the recovery tank covers are sealing and not damaged.
−− Inspect and clean the vacuum motor float cage, float ball and shut-off seat.
−− Make sure that the recovery tank drain hose cap seals airtight.

Vacuum Filter and Float Cage

Maintenance
To inspect and clean the vacuum
motor foam filter just lift open the Vacuum System Filter
tethered Vac Duct Cover. Remove
the filter by pulling it out from the
housing opening. Clean the filter by
vacuum or washing it out in warm
water.

Note: The filter must be

completely dry before
reinstalling.

To inspect the vacuum shut off float

just open the recovery tank cover to
access the float cage assembly (back
center in recovery tank). The cage Recovery System Tank
openings must be kept free of any Float
debris that can restrict maximum
airflow. To keep it clean, wipe off with
a rag regularly or remove and flush
with water. The cage is a two piece
design and can be snapped apart to
separate.
Service Manual – ES4000 Recovery System 95

The Recovery Tank Strainer Basket

requires frequent cleaning to avoid
clogging the system. Remove the
strainer by lifting it upward off the Recovery Tank Strainer Basket
mounting tab.

Completely rinse the basket with clean

water and remove any debris that may
still cling to the inside or outside.

Re-install the Basket by pushing

the mounting tab into position and
snapping it into place.

Recovery Tank Strainer Basket

Installation
Service Manual – ES4000 Recovery System 96

Troubleshooting
When extracting and experiencing little or no (below normal) waste recovery water entering the recovery
tank, the vacuum system is not working properly. When the vacuum system performs poorly, it is usually
because of one of the following problems:

Vacuum Leak(s) – Air flowing into the vacuum system past a bad gasket or leaky hose, damaged tank,
or a leaky drain hose cap. A vacuum leak below the water line will create turbulence in the recovery tank,
causing water to enter the vacuum motor.

Restriction(s) – Anything that blocks the flow of air through the system. Restrictions may also be caused
by built-up debris in the pick-up tools, vacuum hoses, float cage or wherever the airflow is forced to make a
sharp turn. Both leaks and restrictions decrease the quantity of air flowing through the pick-up tools. This
results in less pick-up power.

Vacuum Electrical Components – The vacuum motors and vacuum solenoid are monitored by the main
controller to detect any system function failures (error codes). Detected error codes are displayed on the hour
meter LED display as they occur.

Note: Reference the Main Control Board Troubleshooting Guide in the Electrical System of this
manual for specific fault descriptions and service repair actions.
Service Manual – ES4000 Recovery System 97

Removal and Installation

Vacuum Motor(s) Removal

1. See Figure R-5. Remove the vacuum motor Cover (A) that is secured to the recovery tank by six (6)
Screws (B).

2. Separate the wiring harness from the motor and lift motor out from it’s mounting cavity.

3. Inspect all the vacuum/recovery system Gaskets, (C, D) also clean the vacuum motor(s) Foam Filter (E),
Strainer basket (F) and Hoses.

4. Inspect the carbon motor brushes, if less than 3/8” (10mm) in length replace.

Service Note: The hinged Tank Cover can easily be separated from the vacuum Duct Cover by
removing the slotted Pin (use a flat blade screwdriver).

Foam Filter - E
Strainer basket - F

Gaskets - D

Vacuum Motors
Gaskets - C

Screws-B
Vacuum Motor Cover-A

Figure R-5
Service Manual – ES4000 Recovery System 98

Recovery Tank Removal

Drain the recovery tank by using the drain hose.

See Figure R-6.

Cover

Lift here with both hands

Recovery Tank with hoses and connections

Vacuum Hose
Drain Hose

Figure R-6
Service Manual – ES4000 Recovery System 99

Remove the Recovery hose from the bottom

connector bracket.

Swing open the operator seat platform (set

the prop rod) and pull apart the vacuum
motors’ harness connector (located left rear
of battery compartment).

Open the hinged recovery tank Cover and

grip the top inside edge of the tank and
pull straight up to complete the tank’s
separation from the machine’s solution
tank/chassis assembly. Next guide the
tank off the rear of the machine while
taking care to prevent crushing of the Lift here to remove the tank assembly
vacuum hose, then lay the Tank down onto
the floor.

Note: There is some weight to the

tank assembly. Be careful
when lifting it off. Ask for
an extra helper to assist.
Service Manual – ES4000 Recovery System 100

Vacuum Shoes Removal

1. With the Master Key Switch off, the vacuum shoes should be checked and cleaned daily.

2. See Figure R-7, Disconnect the vacuum recovery hose (AA) from the vacuum shoe (BB). Then pull up on
the gold chain (CC). and slide the shoe (BB) away from the Shoe Support Weldment (DD).

Note: The procedure is the same for both shoes, however, the RIGHT shoe must be removed before
removing the LEFT shoe.

3. Rinse the shoe housings with warm water to remove any build up of string, hair or carpet fibers. Then
reinstall shoes in reverse order of removal.

Figure R-7
Service Manual – ES4000 Recovery System 101

Extraction Shoe

Lift the chain to remove the

Shoe from the shoe support
weldment.

Shoe Removal Chain

Service Manual – ES4000 Recovery System 102

Recovery System Wet and Dry Pickups—Accessory Port

Pickup Connectors

The pickup connectors are located on the lower rear part of the machine. This area is best accessed by
removing the Recovery Tank but is also accessible by lowering the connector bracket as shown in the photo.
Both Wet and Dry connectors are part of the connector bracket.

Accessory Port Dry Connection Wet Connection

Lower Recovery System Connectors - Recovery tank removed

Wet connection to Recovery Hose

Service Manual – ES4000 Recovery System 103

Wet Connection

When extracting connect the Recovery hose to the WET connection. When the Extraction shoes pull
moisture from the carpet the liquid is transported through the hose to the Recovery Tank through the WET
Connection. See photo on previous page. SEE OPERATOR’S MANUAL section OPERATING MACHINE–
EXTRACT MODE.

Dry Connection

When operating in the Dry Sweep mode, connect the Recovery hose to the DRY connection. In Dry
Sweep mode the vacuum system pulls dust from the hopper area and lightly sprays a water mist into the
airstream to dampen dust as it sends it through the DRY Connection and hose to the Recovery Tank. SEE
OPERATOR’S MANUAL section “OPERATING THE MACHINE–SWEEP MODE.

Large debris is either thrown into the hopper on the back of the deck, or captured in the strainer basket as it
enters the Recovery Tank.

Hose Connected to DRY Connector

Service Manual – ES4000 Recovery System 104

1. A misting nozzle is installed into the

side of the Misting chamber adaptor.
The nozzle assembly can be removed to
access the misting nozzle itself.

Misting nozzle for DRY sweeping

2. Turn and pull the misting nozzle

assembly from the misting chamber
adaptor.

Misting nozzle assembly

removed from Misting
chamber adaptor

3. Again, turn and pull the nozzle from

the misting nozzle assembly. Clean or
replace the nozzle and re-install into
the assembly.

Install the misting nozzle assembly

into the Misting chamber adaptor.

Nozzle
Service Manual – ES4000 Recovery System 105

Accessory Port—Using Attachments

Optional attachments are available for detail or upholstery cleaning with an accessory hose.

1. Disconnect the recovery hose and connect the accessory hose to the Recovery Hose.

2. Attach the SOLUTION connection from the accessory hose to the accessory port located next to the DRY
pick-up connection.

3. While not seated in the operator’s seat Turn ON the master key switch and press the VACUUM ON/
OFF Switch. The Vacuum motor will run continuously until the switch is pressed again to turn it OFF.

Accessory Port

Accessory Port on Recovery System lower panel – bottom rear of machine

Service Manual – ES4000 Recovery System 106

Recovery Shoe Lift Actuator Removal and Adjustment

1. Remove Batteries and Battery tray leaving

the open chassis.

2. Access the actuator opening (s) in the

chassis.

Access to Shoe Lift Actuator Pin

3. Working from the rear of the machine,

Connect the actuator power cord adaptor
(part # 56407502) to the harness connector
for the Shoe Lift Actuator.

Attach the Positive and Negative leads to

the corresponding terminals on a Battery.

Run the Actuator to place the Recovery

Shoes to their lowest (on the floor) level.
Service Manual – ES4000 Recovery System 107

4. Remove the Retaining Clips from both

ends of the lift pin that connects the
actuator to the shoe lift cable.

Remove the connecting pin from the

Actuator and frame.

Release the cable holding clip.

5. Remove the motor mounting bracket

bolts.

6. Remove the Actuator from the frame.

7. Reverse the process to reinstall. See Note!

Note: When re-installing the

actuator be very careful not
to turn the actuator nut.
If the nut has remained in
it’s original position the
actuator can be reinserted
and fastened into place
without any other
adjustments.
Service Manual – ES4000 Recovery System 108

Actuator Drive Screw Tube Adjustment

The following instructions cover the procedure to adjust the drive nut (housing assembly) setting for the
machine’s vacuum shoe lift actuator motor. Reference the chart below.

Actuator Motor Drive Drive Screw Tube Drive Drive Screw Tube
IN OUT
Shoe Lift 0.56 inches (14 mm) 2.81 inches (71 mm)

The “Drive Screw Tube IN/OUT Position” dimensions must be measured and adjusted before installing the
actuator assembly on the machine.

Drive Screw Tube

General Instructions for All Actuator Motors

1. This shows the special actuator power cord

adaptor (part # 56407502) that is needed to
connect a battery pack and actuator motor
for setting the drive nut limit settings.

2. If the batteries are installed, open the

machine battery compartment and
disconnect the battery connector. The
battery pack is needed to power the lift
actuator motor to properly set the IN &
OUT limit switches.

3. Connect the actuator motor to be tested to

the power cord adapter end. Then connect
the alligator clips from the cord adapter (red
clip to the positive and black to negative) to
battery connector or battery posts. The rocker switch is used to change the motor rotation in setting
the correct drive nut dimension.
Service Manual – ES4000 Recovery System 109

Lift Actuator Drive Screw Tube Adjustment

1. With the drive screw tube removed from the threaded shaft, press the rocker switch on the power cord
to run the drive motor all the way in until the motor stops.

2. Install the drive screw tube on the drive screw until the clearance between the end of the tube and the
motor housing is approximately 0.56” (14 mm), which is the “In position”.

3. Hold the Drive Screw Tube then press the adapter cord rocker switch to run the drive motor to the OUT
position (wait until the motor stops).

4. Measure the distance between the end of the tube and the motor housing. It should be 2.81 inches (71
mm).

a. If the distance is not correct, remove the rubber adjuster cover from the end of the motor. Then
rotate the nylon nut found under the cover with a 1/2” (13 mm) SOCKET (Not a screwdriver!).
Turning the nut one click will change the distance approximately on tenth of an inch (2.5 mm).

Rotate Nylon Nut to

Remove Adjuster Cover
Adjust

Note: Use a 1/2” (13mm) socket to turn the adjuster.

5. After each adjustment, hold the spring housing assembly, run the actuator IN & OUT and recheck the
adjustments. Reinstall the adjuster cover.
Service Manual – ES4000 Recovery System 110

Specifications

Vacuum Motor(s) 2 of .75 HP (560-watt) three-stage

Sealed: 66.92 in of Water ( kPa)

Vacuum
Two Motors
performance 1” Open-hole Aperture: 23.09 in of Water ( kPa)
Max Airflow: 90.1 CFM / 42.52 L/s
Service Manual – ES4000 Recovery System 111

Special Tools

Actuator Power Cord Adaptor (part # 56407502)

Power Cord Adaptor in use

Service Manual –ES4000 112

Solution System

Functional Description
See Figure S-1. A molded plastic (polyethylene) tank stores the machine’s extraction solution. Total machine
solution capacity is 29 gallons (109 L). Plumbed into the solution shut off Valve outlet is a serviceable spin
off Filter Housing Assembly that keeps debris from entering the Solution Pump and solenoid valves (L1, L2
and L3). Also fitted is a short flexible Drain Hose to drain the tank for system maintenance. The electrical
circuit that energizes the solenoid coils is activated through the operator panel buttons and main controller
assembly A1.

Note: See the Know Your Machine section in this manual for a detailed explanation of the complete
solution operation modes.

The three electrical solenoid valves L3 maintenance, L2 restoration and L1 misting control flow to the
nozzles. The Maintenance nozzle directs the solution spray pattern onto the cleaning brush when in the
maintenance extraction mode. The Restoration nozzle directs the solution in front of the cleaning brush
when in the restoration mode (maximum flow). The misting nozzle directs solution to the misting chamber
adaptor during dry sweeping, helping to improve dust filtration during dry pickup.

Chemical Pump
The Chemical Pump is provided for automatically mixing detergent with water from the Solution Tank.
When prespray mode is selected at the control panel, the deck is lowered and the shoes are retracted
upward, if they are down. When the throttle is engaged forward, the solution pump, the brush motors, and
the restore valve will be activated, while the Chemical Pump is activated at a specific rate. The Solution
pump, brush motors, Chemical Pump, and the restore valve will turn OFF when the throttle is in reverse or
neutral.
Service Manual –ES4000 Solution System 113

Solution System Circuit Description

To get solution flowing, the main controller turns on the solution pump and energizes one of three solenoids
valves. The solution pump is supplied battery positive power on one side from the key switch. To turn the
pump on, the main controller closes a switch to battery negative to complete the circuit. There are three
solenoids that control the solution flow. Each of the solenoids is supplied battery positive power to the
key switch. To energize one of the solenoids and allow the solution to spray, the main machine controller
completes the path to battery negative through an internal switch.

The Main Controller also operates the detergent (Chemical) pump. The two wires for the pump are wired
directly to the Main Machine Controller. The Main Machine Controller supplies battery positive on one wire
and battery negative on the other for a short period of time to stroke the piston in one direction. It then
immediately reverses polarity and does it again to stroke the piston back in the other direction.

24v Battery

Key Switch
Main Controller

L1 Misting Solenoid

L2 Restore Solenoid

L3 Maintenance Solenoid

Solution Pump

B+ B- B- B+

M2 Detergent (Chemical) Pump

Service Manual –ES4000 Solution System 114

Component Locations
The main components of the Solution System are (See Figure S-1, S-2, S-2a –2e):

• Solution / Detergent Cartridge

• Solution Filter

• Chemical pump

• Solution Pump

• Spray nozzles

• Solution Tank

• L1 Misting Solenoid

• L2 Restore Solenoid

• L3 Maintenance Solenoid

Detergent (Chemical) cartridge

Filler Cap

Solution Tank

Solution filter

Figure S-1
Service Manual –ES4000 Solution System 115

Solution Filter and shut-off

Detergent (Chemical) Pump

Service Manual –ES4000 Solution System 116

Detergent Cartridge Access Cover

Figure S-2

Detergent Cartridge location

Figure S-2a
Service Manual –ES4000 Solution System 117

Detergent Cartridge viewed from

Battery compartment

Figure S-2b

Detergent Mix Ratios

label inside Cartridge
housing

Figure S-2c
Service Manual –ES4000 Solution System 118

Solution Tank with Detergent cartridge access panel

Solution Solenoid Valves L2 and L3 L2

L3

Solution Pump

Misting Solenoid L1
Service Manual –ES4000 Solution System 119

Misting Spray Nozzle

Maintenance and Restoration

Spray nozzles
Service Manual –ES4000 Solution System 120

Solution Filter location

Figure S-2d

Solution hose (for drainage)

Figure S-2e
Service Manual –ES4000 Solution System 121

Troubleshooting

Mechanical / Electrical / Plumbing

Problem Possible Cause

Inadequate or no solution flow No solution in the tank
Main solution flow shut off valve arm is in the closed position
Clogged solution filter, hoses and solenoid valves
Defective solution solenoid coils (L1, L2 or L3)
Solution system fault in the main controller A1*

*On all models the solution system’s electrical solution solenoids L1, L2 & L3 (misting, restoration &
maintenance modes) are monitored by the main controller A1 to detect any system function failures (error
codes). Detected error codes from the main controller are displayed on the operator panel display as they
occur.

Note: Reference the Main Control Board Troubleshooting Guide in the electrical system of this
manual for specific fault descriptions and service repair actions.

Maintenance and Adjustments

• Solution Tank: Weekly, empty the solution tank; remove the solution Drain Hose from its storage area
(located underneath the left side of chassis). See figure S-2e. Direct the hose to a designated “Disposal
Site” and flush the tank with clean water.

• Solution Filter: Remove and clean the inline Solution Filter. See Figure S-2d. To access the filter
housing for removal, work underneath the middle front of the solution tank see molded “FILTER ”
callout. No tools are needed to remove the filter (hand tighten only).

Service Tip: The manual solution shut off valve (located next to the solution filter) must be placed
in the full CLOSED position. This prevents loss of solution when servicing the filter strainer
while there is solution in the tank.
Service Manual –ES4000 Solution System 122

Purge Chemical Pump Weekly:

1. Disconnect and remove the detergent cartridge. Install and connect a Cartridge filled with clean water.

2. Turn the Key Switch (A) ON. Press and hold the Detergent ON / OFF Switch (C) and the Solution ON /
OFF Switch (B) for more than 2 seconds while the controller is in any mode except standby to initiate a
purge cycle.

Note: Once activated the purge process takes 10 seconds. See illustration on page 135 for Detergent
System indicators. Normally one purge cycle is adequate to purge the system.

To Reset the Detergent Counter

As the detergent cartridge is used a counter counts down to keep track of the amount of detergent
remaining. When the counter reaches it’s lowest level, the control panel indicates that the cartridge is
empty. When refilling or replacing the cartridge, the counter needs to be reset.

To reset the counter, turn the Key Switch (A) ON. Press and hold the Maintenance Mode Switch (G) and
the Restoration Mode Switch (H) for more than 2 seconds while the solution and detergent are ON. The
Detergent Reset Icon will display for 5 seconds. See illustration on page 135 for Detergent System indicators.

Detergent Ratio

The pre-programmed ratio of detergent to water can be adjusted. There is a decal on the inside of the
detergent cartridge access cover (see figures S-2 and S-2c) that will help to determine what ratio should be
used for a specific detergent.To set the ratio, with the detergent system OFF, press and
hold the Detergent ON/OFF Switch (C) for 2 seconds. The detergent indicator will fl ash
and each press of the switch will cycle through the available ratios (1:64, 1:75, 1:100,
1:125, 1:150, 1:175, 1:200, 1:250). Once the desired ratio is displayed on the screen, stop and ratio setting
will lock in after 5 seconds.
Service Manual –ES4000 Solution System 123

DETERGENT SYSTEM PREPARATION AND USE

DETERGENT ENABLED

DETERGENT DISABLED

FULL (RESET)

Press and hold (G) & (H) for more D F

than 2 seconds to Reset.

LOW DETERGENT C I

PURGE

Press and hold (B) & (C) for more A

than 2 seconds to Purge.

Detergent system is ON when indicator is ON.

Service Manual –ES4000 Solution System 124

If the Restoration nozzle

is removed for cleaning, it
must be readjusted after it
is installed.

Figure S-3 Restoration Nozzle Assy

Service Manual –ES4000 Solution System 125

Nozzle Maintenance
The nozzles are mounted on the Scrub Deck and shown in the Scrub System and the Chassis System. See
Figure S-3a.

To inspect and clean both nozzles.

1. To remove the Restore nozzle, remove the fastener nut that secures the nozzle and pull it from the brush
housing slot with the hose still connected.

Note: The entire Restore Nozzle assembly must be cleaned or the nozzle removed from the fittings
and readjusted after the nozzle has been re-installed. See figure S-3.

2. To remove the Maintenance nozzle tip, twist the nozzle a 1/4 turn to separate it from the nozzle body.

Note: Nozzles should be inspected and cleaned once per week.

3. Clean the nozzles by soaking overnight in a solution of full vinegar solution or properly diluted and
handled muriatic acid solution to remove build up of chemical deposits.

Note: Do not increase the size of the orifice by cleaning with a drill bit. This will adversely affect the
nozzle pressure and spray pattern.

Nozzles

Figure S-3a - Nozzles are shown attached to the Scrub Deck

Service Manual –ES4000 Solution System 126

Chemical Pump Removal

CAUTION! Disconnect the machine’s battery pack connector before servicing machine.

1. See Figure S-5. Drain the solution tank using the drain hose or put the flow shutoff valve into its closed
position to prevent the uncontrollable solution loss.

2. Remove the hose ends from the Chemical Pump inlet and outlet fittings.

3. Cut the pump wiring harness tie straps then disconnect the pump wiring connector.

4. Loosen the (2) screws that secure the pump assembly from underneath the pump and remove the pump
from the electrical panel.

Service Tip: Use a long thin shaft #2 Phillips screwdriver to access the two pump mounting screws.
When replacing the pump, install the mounting screws into the pump through the frame
holes provided and then slide the pump with screws installed, into place. Tighten the screws.

Mounting Screws
under here.

Chemical pump with hoses and mounted on frame

Figure S-5
Service Manual –ES4000 Solution System 127

Solution Solenoid Valve Removal

1. See Figure S-6. Put the solution flow shutoff Valve (C) into its closed position and the scrub deck in the
down position then disconnect the battery pack.

2. Block rear wheels to prevent machine from rolling then jack up the front of the machine 3-4 inches.

CAUTION! Support machine with proper blocking for safety.

3. Cut the necessary wiring harness tie straps used on the Solenoid Valve Assembly then unplug each
valve from the machine’s wiring harness.

4. Loosen the two screws that secure the solenoid mount bracket to the chassis, and slide the valve
assembly off of the mounting screws.

5. Loosen the necessary hose clamps from the solenoid valve that needs service then pry the hoses off their
fittings.

6. Remove the two screws that fasten the valve body to the mount bracket to complete removal.

L2

Solution Valves

L3

Figure S-6
Service Manual –ES4000 Solution System 128

Solenoid Valve Disassembly and Cleaning

Note: See Figure S-7 for valve disassembly & cleaning.

Service Tip: To just clean the valve assembly of any trapped debris it isn’t necessary to completely
remove it from the chassis mount bracket. Follow the short cut steps listed.

1. Use a flat bladed screwdriver to hold the slot on the end of the Valve Spool (N) and remove the Nut (O).
Next pull off the metal protective Cap (P), Coil (Q) and Washers (R). Use the screwdriver again and turn
out (remove) the valve spool and Piston (S) (be careful not to lose any internal parts).

2. Thoroughly wash out all debris from the Valve Body Seat (T) then reassemble and test the solenoid for
proper operation. Loosen the necessary hose clamps from the solenoid valve that needs service then pry
the hoses off their fittings.

Figure S-7
Service Manual –ES4000 Solution System 129

Specifications

Solution Control 1 Pump

Solution Flow Rates (1) Maintenance mode .29 gal/min TR 10155

(2) Restore Mode .8 gal/min TR 10155
Detergent Ratios 400:1 = .25% 200:1 = .5% 100:1 = 1% 32:1 = 3%
Available Using 300:1 = .3% 150:1 = .66% 64:1 = 1.5%
Ecoflex™ 256:1 = .4% 128:1 = .8% 50:1 = 2%
Recycle System No
Available

Nozzle and Pump Data

Components Flow Rate GPM/Working Pressure
Nozzle “Maintenance” .29 GPM
Spec. 033” orifice diameter
Brass
Nozzle tip I.D.1/8 K1
Nozzle “Restoration” GPM
SPec. .091” orifice diameter - Brass
Nozzle tip I.D.1/8 K 7.5
Pump Specifications Pressure relief switch opens at 100 PSI
Max. flow rate 1.6 GPM
Max. current 3.5A (average current 3.2A)
Service Manual –ES4000 130

Scrub System

Functional Description
Cylindrical Brush System Overview

The ES4000 uses two cylindrical brushes that counter rotate to sweep up light debris and scrub at the same
time. Each scrub brush is powered by 1/2 HP permanent magnet motors and driven by separate poly-V belt/
pulley drives. Debris is swept into the hopper on the back of the scrub deck.

The scrub deck platform is raised & lowered automatically by an electric lift actuator motor (M4). The
operation of the machine’s scrub functions are activated when the operator selects (presses) either the
Extract or Sweep panel buttons. The scrub brush pressure is electronically controlled to optimize scrub
performance on a wide range of carpeted surfaces.

The vacuum motors and brushes run during all system cleaning modes. In DRY SWEEP mode, debris is
swept into the hopper on the back of the scrub deck while dust and air are drawn toward the recovery tank.
As the dirty air makes it’s way to the recovery tank it passes thru the misting chamber adaptor where the
misting nozzle applies a mist that helps to contain the dust.
Service Manual –ES4000 Scrub System 131

Scrub System Circuit Description

The main controller turns on the brush motors by energizing the brush contactor. The brush contactor
winding is provided battery positive voltage on one side of the coil through the key switch. The main
controller completes a path to ground on the other side, through an internal switch, in order to energize
the contactor. When the brush contactor is energized, the contacts close and supply battery positive voltage
to the brush motors which, are connected in parallel. The motors are hard-wired to battery negative using
specially calibrated ground wires that have a specific resistance along their length. The purpose of these
special calibrated ground wires is to allow the main controller to calculate the current flowing through the
wire by measuring the voltage difference between the two ends of the wire. Inside the main controller there
are “internal voltmeters” which are connected across the ends of these wires. As the current increases, the
voltage measured increases. The main controller also drives the brush lift actuator. It acts as a double throw,
double pole switch to provide battery positive and battery negative voltage across the actuator wires in order
to drive the actuator. It reverses the polarity to drive the motor in both directions.

24v Battery

S1 Key Switch
A1 Main Controller

Internal
Voltmeters

J3-13

J1 - 6
B+ B- B- B+
J2-10

K2 Brush Contactor

M4 Brush Lift Actuator

M7 Brush Motor

M8 Brush Motor
Calibrated
Ground
Wires
Service Manual –ES4000 Scrub System 132

Component Locations
The Scrub System main components are (Figure D-1):

• Scrub brushes (A)

• Brush motors (B) and drive belts (C)

• Debris hopper (tray) (D)

• Restoration Nozzle (E)

• Maintenance Nozzle (F)

• Scrub deck lift actuator (G)

Figure D-1
Service Manual –ES4000 Scrub System 133

Maintenance and Adjustments

Scrub System Brush Maintenance

The scrub system must be serviced at regular
intervals to maintain good scrub performance. Follow
the maintenance steps listed below.

1. Rinse clean, built up debris from the debris

hopper drain holes (daily).

2. Remove any string wrapped around the scrub

brush, drive hub and idler hub (daily).

3. Clean spray nozzles attached to the front and top

of the scrub deck (weekly) (See Solution section
of this manual).

4. Clean built up dirt from the inside of the scrub

brush housing (weekly).

5. Remove both the scrub brushes and rotate, turn

the front brush end for end (weekly). See Scrub Brush Removal and Installation section.

6. Inspect the scrub brush bristles for wear monthly. The brushes should be replaced when the bristle
length of the front brush is 1 inch (26 mm) or less and when the bristle length of the rear brush is 3/4 of
an inch (19 mm) or less.
Service Manual –ES4000 Scrub System 134

Troubleshooting
The ES4000 deck brush system’s major electrical components are monitored by the main controller (A1) to
detect any system function failures (error codes). The system components covered are the brush motor(s) (M7
& M8), brush solenoid (K1) and brush lift actuator motor (M1). Detected error codes from the main controller
are displayed on the hour meter LED display (E) as they occur. See Functional Description section wiring
diagram.

Note: Reference the Main Control Board Troubleshooting Guide in the Electrical System of this
manual for specific fault descriptions and service repair actions.
Service Manual –ES4000 Scrub System 135

Removal and Installation

Scrub Deck Removal

1. See RECOVERY SYSTEM section of this manual to remove the vacuum hoses and shoes prior to deck
removal. Also refer to Figures D1 & D1a through D-10.

2. To REMOVE the Scrub Deck assembly use the instructions on the following pages.

3. To INSTALL the Scrub Deck assembly follow the removal steps in reverse order.

Vacuum Hose

Vacuum Shoe

Debris Hopper

Drive belt guard

Brush Brush access cover

Scrub Deck
 Service Manual –ES4000 Scrub System 136

Vacuum hose

Scrub Deck mounting hitch pin

Debris Hopper

FWD

Scrub Deck mounting hitch pin

FWD

Figure D-1a
Service Manual –ES4000 Scrub System 137

1. Lower the scrub deck with the

brush(es) installed (Figure D-2).
Attention: Don’t turn the key
switch off until after disconnecting
the battery pack with the Battery
Disconnect (34). This will prevent
the scrub deck from automatically
raising when the key is turned off.

Figure D-2 Deck lowered

2. Pull off the vacuum hose from

Lift chain to remove the vac shoes
the intake connector (Figure D1a).
Remove both vacuum pickup shoes
by lifting the removal chains then
lift up and pull out to separate them
from the shoe support weldment.
(Figure D-3).

Figure D-3 Pull Vacuum shoe from deck mounting

3. Remove the sweep debris Hopper

(Figure D4) from the scrub deck.

Figure D-4
Debris Hopper
Service Manual –ES4000 Scrub System 138

4. Unplug the brush motor wiring

harness (Figure D-5).

5. Remove the ground wire

on the deck.

Remove deck wiring harness

Figure D-5

6. Remove the Hitch Pin that

secures the brush deck lift
actuator to the scrub deck.
(Figure D-6).

Remove cotter key from actuator link pin,

then remove the link pin.

Figure D-6
Service Manual –ES4000 Scrub System 139

7. Remove the tubing for the

solution nozzles (Figure D-7).

Figure D-7

Remove solution hose from nozzle(s)

8. Remove the two Hitch Pins

(Figure D1a & D-8) that attach
the scrub deck to the machine
chassis linkage arm weldment.

Figure D-8
Deck mounting pin removed

9. Carefully maneuver the deck from

under the machine to complete its
removal (Figure D-9).

Service Note: It is important

that the
disconnected
deck actuator
motor is not run.
This precaution
will prevent the
actuator drive
nut from being
moved from its
set specification.
Deck removed

Figure D-9
Service Manual –ES4000 Scrub System 140

Scrub Deck Actuator Removal

1. To remove the Scrub Deck

Actuator begin by removing the
Recovery Tank. This will expose
the battery compartment and the
lower accessory, Wet and Dry hose
connections.

2. Remove the battery post

connectors and disconnect the
cable connectors at the rear of
the compartment. Use a hoist to
lift all of the batteries together or
individually remove them from the
battery tray.

3. Remove the battery tray. This

will expose the access holes for the
Actuators.

Access opening for Scrub

Deck Actuator.
Service Manual –ES4000 Scrub System 141

Remove two bracket screws

4 Working from the rear of the machine,
locate the actuator position and the
electrical harness for that particular
actuator. Disconnect the harness to the
actuator. The connection is usually near
the end of the actuator (see circle in photo).
Remove the 2 bracket screws over the Brush
Lift Actuator motor.

Remove bracket

5. Place a wooden block under both sides

of the deck. Tension will be released on the
actuator allowing it to be loosened and the
lift cable removed.

6. Attach the actuator power cord adaptor

to the harness connector for the Deck Lift
Actuator. Attach the Positive and Negative
leads from the adaptor to a battery on
the corresponding Positive and Negative
terminals. See section on Actuator Drive
Nut Adjustment.
Service Manual –ES4000 Scrub System 142

7. Make note of the actuator position in

case it rotates out of adjustment.

Run the actuator with the power adaptor

until the tension on the lift cable is
released.

Indicator runs inside this groove. Move

the indicator back just far enough to
release tension.

Lift Actuator mounted under

chassis near solution solenoids

Cotter key and mounting

8. Remove the cotter keys at both ends of the pin through end of Actuator
mounting pin that passes through the end of Housing
the Actuator housing. Remove the washers and
slide the brass bushings off the pin.
Service Manual –ES4000 Scrub System 143

9. Remove mounting pin from the housing.

Remove the Pin

10. Remove the remaining fastener bolt in the

frame. Be careful when the Actuator becomes
loose. Be ready to grasp it with your hand. Remove the remaining fastener
bolt in the frame.

11. Remove the Actuator Assembly

from the frame.

12. To install the Actuator assembly

after adjustments or replacement,
reverse the removal process. Be
careful to not spin the Spring
Housing out of adjustment.
Service Manual –ES4000 Scrub System 144

Actuator Drive Nut Adjustment

The following instructions cover the procedure to adjust the drive nut (housing assembly) setting for the
machine’s scrub deck actuator motor. Reference the chart below that shows the IN & OUT dimensional
specification for the actuator motor that is used on the ES4000.

Actuator Motor Drive Nut Housing Assy • Drive Nut Housing Assy
IN OUT
Brush Lift (ALL) See Adjustment 3.5 inches (89 mm)
Procedure

The “Drive Nut Housing Assy IN/OUT Position” dimensions are measured when completely assembled and
off the machine. Reference points are the edge of the plastic Spring Housing Assembly.

General Instructions for All Actuator Motors

1. This shows the special actuator power cord

adapter that is needed to connect a battery pack
and actuator motor for setting the drive nut limit
settings.

2. If the batteries are installed, open the machine

battery compartment and disconnect the battery
connector. The battery pack is needed to power
the lift actuator motor to properly set the IN &
OUT limit switches.

3. Connect the actuator motor to be tested to

the power cord adapter end. Then connect the
alligator clips from the cord adapter (red clip to
the positive and black to negative) to battery connector or battery posts. The rocker switch is used to
change the motor rotation in setting the correct drive nut dimension.
Service Manual –ES4000 Scrub System 145

Scrub Deck Lift Actuator Drive Nut Adjustment

1. Assemble spring housing

a. Install the 3 springs and drive nut into one half of the spring housing as shown. Then snap the two
spring housing halves together, retaining the springs and nuts inside the housing.

Drive Nut

Spring Housing Half

3 Springs

2. Screw the spring housing assembly onto the threaded drive screw a few turns.

3. Press the rocker switch on the power cord to run the drive motor all the way in until the motor stops.

4. Screw the spring housing onto the threaded drive screw until the end of the drive screw shaft just
contacts the end of the spring housing.

5. Rotate the housing, either direction (whichever is shortest) until the “flat” surface of the housing will
be“up” when the actuator assembly is installed on the machine.

Flat Surface Up

6. Hold the spring housing assembly then press the adapter cord rocker switch to run the drive motor to
the OUT position (wait until the motor stops).
Service Manual –ES4000 Scrub System 146

7. Measure the distance between the end of the spring housing and the motor housing. It should be 3.5
inches (89 mm)

a. If the distance is not correct, remove the rubber adjuster cover from the end of the motor. Then
rotate the nylon nut found under the cover with a 1/2” (13 mm) SOCKET (Not a screwdriver!).
Turning the nut one click will change the distance approximately on tenth of an inch (2.5 mm). After
changing the adjustment, run the motor in and out and recheck the “Out” position distance.

Rotate Nylon Nut to

Remove Adjuster Cover
Adjust

Note: Use a 1/2” (13mm) socket to turn the adjuster.

8. After each adjustment, hold the spring housing assembly, run the actuator IN & OUT and recheck the
adjustments. Reinstall the adjuster cover.
Service Manual –ES4000 Scrub System 147

Brush Motor Removal

It is recommended that you remove the Deck

assembly from the machine to remove the
brush motors.

See Figures D-12 through D-15. Remove

the Belt Guards (1 screw per side). With an
operator in the driver’s seat with the key
switch ON and the maintenance mode scrub
function selected press the drive pedal to
start the scrub brushes and observe which
brush motor needs to be removed.

WARNING! Disconnect the battery

pack by activating the
emergency stop switch
Belt guard
and using the battery
disconnect before Figure D-12
servicing.

Belt Guard removed

Figure D-13

Remove the scrub brush drive belt using a

belt installation/removal tool (Figure D-14).

Note: The installation/removal

tool shown may be
replaced by a flat blade
screwdriver. The photo
shows installation of the
belt but removal uses a
similar method.

Belt installation/removal tool

and method

Figure D-14
Service Manual –ES4000 Scrub System 148

Remove the wiring at both the

Pos. & Neg. brush motor terminal
studs and note the correct wiring
connections (for reinstallation)
(Figure D-15). Then remove the (3)
Screws (Y) and lift the motor out
from the scrub deck.

Reassemble in reverse order.

Note: Install motors with

wires pointing to
the rear towards
the plastic motor
wiring standoffs.

Wire connections on motor

Figure D-15
Service Manual –ES4000 Scrub System 149

Scrub Brush Belt Replacement

WARNING! Disconnect the battery pack by activating the emergency stop switch/battery
disconnect lever (13) before servicing.

Remove the belt guard(s) (1 screw each).

Important Service Tip: The left and

right side drive belts are not
the same lengths and they
must be ordered individually.

Remove the belt using a belt removal tool as

shown in the photo. Re-install the drive belt.
Re-install the belt guard, reconnect the battery
pack and test the scrub system for proper
operation.

Note: Rotation of shaft from shaft end

is Counter-Clockwise (CCW)
for both motors.

Note: The installation/removal

tool shown in the
accompanying photo can be
replaced with a standard
flat blade screwdriver.
Service Manual –ES4000 Scrub System 150

Scrub Brush Removal and Installation

Make sure the key switch is off and

disconnect the battery pack before
servicing.

See Figure D-16. Loosen the black

fastener knobs (one on each side)
that secure the removable access
covers. Pull the covers down and out
to remove. Grip the scrub brush and
slide it out from the housing end.

To install the brush slide it into

the housing, lift slightly, push and
turn until it seats into the drive end
assembly slots.

Re-install the access cover and

tighten the fastener knobs.

See Figure D-17 for shaft rotation

and orientation.

Figure D-16

Fastener knob Access cover Brush

Figure D-17
Service Manual –ES4000 Scrub System 151

Specifications

Scrub System

Cleaning Deck Type(s) Cylindrical

Cleaning Brush Size(s)

and Type(s) (2) 27 in (68.6 cm) Type: Cyl
Scrub path: 28 in. (71.1 cm)

373 watts/15.54
Right-hand Motor: .5 HP
Amps
Scrub Motor(s) 373 watts/15.54
Left-hand Motor: .5 HP
Amps

Right-hand Motor: 1800 Left-hand Motor: 1800

Scrub Head Speed(s)
RPM RPM
Service Manual –ES4000 Scrub System 152

Special Tools

Actuator Power Cord Adaptor—Part # 56407502

Service Manual – ES4000 Steering System 153

Steering System

Chain and drive sprocket

Functional Description
The Steering System is all mechanical consisting
of the steering wheel, shaft, gears
and the chain gear drive on the Drive Wheel.

Component Locations
The Steering System main components are:

• Steering Wheel

• Lower Column Shroud

• Lower Steering Column

• Steering Column Spindle

• Steering boot

• Steering knuckle

• Steering shaft, gears, chain gear on Drive Wheel

Steering Wheel

Steering Column Spindle

Steering Knuckle

Steering Boot

Lower Steering Column

Drive gear and chain Lower Column Shroud

Service Manual – ES4000 Steering System 154

Maintenance and Adjustments

The Steering System requires minimal maintannce and no adjustment. The most important maintenance
item is the Steering Knuckle (Steering Wheel Shaft Universal Joint) where the Spindle attaches to the
Column. This is a critical part of the steering mechanism and requires lubrication at least once per month.
An oil fitting is located where the knuckle pivots. Use light machine oil in this fitting.

Steering Wheel Shaft

Universal Joint
Service Manual – ES4000 Steering System 155

Removal and Installation

Steering Column shroud removal

1. Remove the 4 screws fastening the Lower Column

Shroud to the Lower Column Weldment. Figure ST-1.

Screws 2 of 4

Figure ST-1

2. Using a flat bladed screwdriver, pry off the steering

wheel plastic center cap.

3. Using a 3/4” socket, remove the hex nut from the

steering wheel center.

4. Pound the steering wheel off from behind using a

mallet, observing the Woodruff key as it may fall out in
the process.

Steering Wheel removed

Service Manual – ES4000 Steering System 156

5. Pull accordian Steering Boot from the upper

steering column.

Steering Boot

6. Lift the battery charger cover.

Shroud lifted from battery

charger compartment

Battery charger cover open

7. Pry the plastic Lower Column Shroud off the weldment by

starting on the left side (away from knob) so shroud can clear the
weldment linkage bump on the right side.
Shroud lifted
up and off
the Steering
Column

Reassemble in reverse order, applying a light coat of Silicone spray or

water to the inside of the Steering Boot. This will permit free travel
over the shaft and ease assembly.
Service Manual – ES4000 157

Wheel System, Non-Traction

Functional Description
The rear wheels are undriven and individually fastened to the machine via spindles and mounting bolts.

Component Locations
The Wheel System Non-Traction consists of the two rear (Left and Right) wheels, tires, mounting washers
and bolts and a wheel bearing. They are mounted to the rear spindles on the lower frame of the main
chassis.

Wheel bearing

Mounting washer and bolt

Spindle
Tire and wheel assy
Service Manual – ES4000 Wheel System, Non-Traction 158

Removal and Installation

Replacing the Rear Wheels

1. Block the front Drive Wheel

2. Raise the Rear Wheel (17) to be replaced

using a bottle jack on a secure frame
member of the machine.

3. To prevent injury, if the rear wheel

bearing has frozen, replace the bottle
jack with blocks or a jack stand.

4. See Figure WNT-1. Use a 17 mm socket

to remove bolt (A), washer (B) and wheel
(C).

5. If the bearing has seized, pound off the

wheel and use a bearing puller to remove
the inner race from the axle.

6. Apply anti-sieze to the inner bearing

surface of the new wheel. Install wheel
on axle.

7. Apply anti-sieze to the bolt threads

before tightening the bolt, washer and
wheel.

Figure WNT-1
Service Manual – ES4000 159

Wheel System, Traction

Functional Description
The drive wheel assembly is directly connected to the speed controller, which not only provides an
output signal of 24V to the drive wheel for forward and reverse movement, but also monitors current and
temperature, and controls the electromagnetic brake. The speed controller is programmable through, and
can be monitored via, the Curtis Handheld Programmer(part # 56409441) and Curtis Adapter Cable with
Quad Plug (part # 56409823), listed in the Special Tools section of this chapter. For information on how to
use the Curtis programmer, please refer to the Curtis Programmer Manual (doc. # 56043101).

The throttle potentiometer in the foot pedal controls drive speed and forward/reverse movement. The
throttle pot input to the main control board also determines whether or not the vacuum system will engage
and is therefore critical to machine performance When the vacuum system is enabled, the brushes are
energized and cleaning begins. If the control board senses a Neutral position of the foot pedal, it will not
engage these systems unless placed in Service Test Mode or one of the vacuuming modes.

The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral. When the Brake is released,
Forward/Reverse is enabled and the drive wheel is energized.
Service Manual – ES4000 Wheel System, Traction 160

Wheel System, Traction Circuit Description

The A2 speed controller has heavy current battery positive and battery negative wires that supply the
current it needs to drive the wheel motor. The controller wakes up when it receives power through the key
switch, emergency stop switch and the seat switch.

B-
F1 150 A fuse
24v Battery

B+
CB 1

CB 2 S1 Key S4 Emergency S2 Seat

Switch Stop Switch Switch A2 Speed
Controller

The controller switches power on to the drive wheel motor by providing a connection to battery positive on
one wire and to battery negative on the other wire. To reverse direction the controller reverses polarity.
Of course this is a slightly simplified explanation, as the motor is not merely switched full on or off. The
controller regulates the amount of voltage supplied to the motor to control the motor speed.

A2 Speed
Controller

B+ B- B- B+

Drive Wheel Motor

Service Manual – ES4000 Wheel System, Traction 161

The main input for the speed controller is the drive pedal potentiometer. The controller sends out a
regulated five volt supply to one side of the potentiometer. The other side of the potentiometer is connected
to battery negative through the POT Low circuit inside the speed controller. This provides a clean filtered
ground. A third wire runs from the speed controller to the center terminal of the potentiometer. This is
called the “signal” or “wiper” circuit. Inside the potentiometer, a “wiper” moves along a resistive strip. When
the drive pedal is in the center or “neutral position”, the wiper is exactly in the middle of the resistive strip
and the voltage output is 2.5v to the speed controller. As the drive pedal is moved forward, the wiper moves
toward the 5v supply so the voltage increases up to nearly 5v when the pedal is all the way forward. When
the drive pedal is moved backwards from the center position the wiper moves towards the ground supply so
the voltage drops from 2.5 V down to nearly 0v in full reverse. These voltage changes are “understood” by the
controller and are used to request forward and reverse direction as well as speed.

Forward
5v supply
Neutral Wiper (Input)
B-

Reverse
Drive Pedal Potentiometer
A2 Speed Controller

There is a second input, called “Speed Limit” that is used to regulate top speed. The POT high and POT low
circuits are also provided to the A1 main controller from the A2 speed controller. This is a 5 V supply source
which the main controller modifies and sends back on the speed limit circuit to the drive controller. To
request a high top speed, the main controller sends a higher voltage. To request a lower top speed, the main
controller reduces the voltage. The speed limit request is dependant on the machine operating mode.

The drive wheel has an electronic brake which is spring-loaded in the locked position. To release the brake,
an electric solenoid must be energized. The speed controller supplies battery positive to one side of the brake
solenoid winding and switches the other side to battery negative to release the brake. The brake is released
whenever the drive pedal is moved from the center “neutral” position in either the forward or reverse
direction.

Speed Limit
0-5v

5v (POT High)
5v
B- POT Low
B-

A1 Main Controller A2 Speed

Controller
Service Manual – ES4000 Wheel System, Traction 162

There are also three wires that run between the speed controller and the main controller to communicate
speed controller functions to the main controller. The FWD/REV circuit is used to let the main machine
controller know that the machine is moving in either direction. This allows the machine to turn the scrub
motors off when the machine is sitting still and turn them back on when the machine begins to move. Here
is how the circuit works. The main controller sends a 24 V power supply through an internal resistor to a
switch inside the speed controller. There is an “internal voltmeter” inside the main controller that monitors
the voltage between the resistor and the switch. When the switch is open the voltmeter sees 24 volts. When
the switch is closed the voltmeter sees 0 volts. The speed controller closes the switch whenever it is driving
the wheel in either the forward or the reverse direction. (This same switch is used to energize and release
the brake).

The REV circuit works just like the forward/reverse circuit except that the speed controller only closes the
switch when the machine is moving in the reverse direction. This means that in a neutral position and
forward position the voltage seen on the reverse wire would be 24 volts. When the machine is moving in the
reverse direction the voltage seen would be zero volts.

There is also a “status” circuit which is used to communicate whether or not there are any speed controller
faults to the main controller. It is used to let the main controller know that a speed controller fault has been
set (Error 03) and tell it which speed controller fault is set, so that the main controller can flash out the
appropriate speed controller fault on the vacuum switch LED. It works similar to the other circuits where
the main controller supplies 24 V through resistor to a switch inside the speed controller. As the switch
opens and closes its cycles of voltage on an offer from 24 V to 0 V.

Internal
Y1 Brake
Voltmeter

B-
FWD/REV Pin 6 - Brake
+24v B+
Status
+24v B-
REV
+24v

A1 Main Controller A2 Speed Controller

Service Manual – ES4000 Wheel System, Traction 163

F1 150 A fuse
24v Battery

CB 1

CB 2 S1 Key S4 Emergency S2 Seat

Switch Stop Switch Switch

Internal J3-4
Y1 Brake
Voltmeter

B-
FWD/REV Pin 6 - Brake
+24v B+
Status
+24v B- B+
REV
+24v
Speed Limit B-
0-5v
Internal
Voltmeter
B- POT Low

A2 Speed
5v (POT High) Controller
Signal

B+ B- B- B+
A1 Main Controller

Drive Wheel Motor

Speed Control System Functional Electrical Schematic

Service Manual – ES4000 Wheel System, Traction 164

Component Locations
• Lower Chassis

• Drive Spindle

• Drive Wheel assembly with Electromagnetic Brake

• Drive Pedal (forward/reverse) and Potentiometer (Also shown in CONTROL SYSTEM)

• Curtis Speed Controller

Drive pedal

Spindle Hex nut

Chassis

Potentometer

Drive wheel assembly

Speed controller Spindle

Wheel Drive System

Service Manual – ES4000 Wheel System, Traction 165

Maintenance and Adjustments

The Speed Controller is programmable. Programming is covered in the manufacturer’s literature. When the
Speed Controller is replaced (installed) a specific checkout procedure is required.

Curtis Speed Controller Installation Checkout Procedure

After installing a controller and before operating the vehicle, carefully complete the following checkout
procedure. If you find a problem during checkout, refer to the Curtis programmer manual for more
information.

The installation checkout can be conducted with or without the handheld programmer. The checkout
procedure is easier with a programmer otherwise observe the Status LED for codes (located on operator
panel wand indicator light).

WARNING! Put the vehicle up on blocks to get the drive wheel off the ground before beginning
these tests.Turn the key switch off and make sure that the seat switch is open, and
the throttle (pedal) is in neutral.
Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle
during the tests.

Remove the electrical cover panel to access the controller.

1. Observe the error status fault indicator (DETERGENT LED) on the operator control panel. If a
programmer is available, connect it to the programmer plug-in port

2. Sit on the seat and turn the key switch on. The programmer should “power up” with an initial display.
If neither happens, check for continuity in the key switch circuit and controller ground.

3. If you are using a programmer, put it into diagnostic mode by pressing the DIAGNOSTICS key.

◦◦ If there is no error detected, the display should indicate “No Faults Found”. Note: Before pressing
the diagnostics key, wait until model # screen appears, if the throttle is activated prior to this
screen appearing the controller will shut down.

◦◦ If there is a problem, the control panel will flash a diagnostic code and the programmer will
display a diagnostic message. If you are conducting the checkout without a programmer, refer to
the Status LED Fault Codes table in “Speed controller Error Flash Codes” to diagnose the cause.

4. When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the
fault code.

5. While sitting on the seat, operate the throttle. The motor should begin to turn in the selected direction.
If it does not, verify the wiring to the controller, and the motor. The motor should run proportionally
faster with increasing throttle. If not, refer to the Curtis manual.

6. Put the programmer into test mode by pressing the TEST key. Scroll down to observe the status of the
forward, reverse and brake switch. Cycle each switch in turn, observing the programmer. Each input
should show the correct state on the programmer.

7. Take the vehicle off the blocks and drive it in an open area. It should have smooth acceleration and
good top speed.
Service Manual – ES4000 Wheel System, Traction 166

Troubleshooting

General Troubleshooting
When troubleshooting various problems related to the WHEEL SYSTEM it is best to approach the issues
with some fundamental steps:

1. If the machine isn’t responding to the drive pedal inputs, forward or reverse, visually inspect that all
connections are intact, such as the potentiometer connection.

2. Check and test the batteries for proper charge.

3. Check for any Fault codes. If codes are present, repair malfunction if possible.

4. Be sure the key switch is correctly inserted and/or reset the machine by turning the key off and then ON
again.

If these basic checks do not reveal the nature of the problem then see simplified wiring diagram in electrical
section of this manual.

Problem Possible Cause

Machine will still not move forward or reverse 1. Wheel drive motor circuit breaker (CB1) tripped
(reset 70A circuit breaker).
2. Control board circuit breaker (CB2) tripped (reset
circuit breaker).
3. Emergency stop knob tripped (pull out and twist).
4. Safety switch (S2) in seat not closed (check seat
switch).
5. Defective wheel drive motor (replace motor).
6. Defective throttle potentiometer (replace).

The wheel drive motor will run only in forward or run 1. Test the Potentiometer wiring outputs pins 3, 4,
only in reverse. & 13) at the speed controller for an open. Repair
wiring or replace the Drive Pedal Assembly.
2. Controller can’t change electrical polarity to wheel
motor - replace the (A2) speed controller.

Pin Function Wire Color

3 5.02k Ohm Pot High YEL
4 5.02k Ohm pot Wiper GRA
5 Seat switch GRA/BLK
6 Brake - (minus) RED/WHT
8 Mode BLK/WHT
9 Error status ORN/BLU
13 5.02k Ohm Pot Low VIO
14 Brake + (plus) ORN
16 Reverse alarm BLU/BLK
18 Speed limit BLK/WHT

A2 Pin assignments
Service Manual – ES4000 Wheel System, Traction 167

A2 (J10) pin outs

Wheel Drive Motor Typical Current (AMPS) Wire colors

Transport, Full Throttle
M1 15-20 Red/Green and Yellow/Black
Service Manual – ES4000 Wheel System, Traction 168

Speed Controller Diagnostics

The Speed Controller diagnostics uses the machine’s control panel LCD display and DETERGENT switch
indicator. Another available method is to use the optional hand held Curtis programmer model 1311.

Speed Controller Status Light /Display Functions

If a speed controller fault occurs, the LCD
display will indicate “E03”. Additionally
the DETERGENT button LED flashes out
a specific speed control error code until the
fault is corrected. Speed control codes consist
of two digits. Count the flash sequence of
the DETERGENT LED to obtain the code.
Example: (OOO O )3 flashes and a short pause
followed by 1 flash and a long pause = 3,1 .
See ERROR CODES table for a description of the
fault indications.

Speed Controller

Error code displayed

Count Detergent LED

flashes for Speed Control
Fault Codes
Service Manual – ES4000 Wheel System, Traction 169

Wheel Drive Circuit Error Codes / Speed controller Error Flash Codes
These codes are displayed on the main control panel display and flash codes on the DETERGENT LED.

CODE DETERGENT EXPLANATION POSSIBLE CAUSE

BUTTON LED
DISPLAY
1,1 O O Speed controller fault-
over/under
- temperature cutback
1. Temperature >97°C (206°F) or <
-25°C (-13°F).
2. Excessive load on vehicle.
3. Operation in extreme environments.
4. Electromagnetic, foot or parking
brake not releasing properly.

1,2 O OO throttle fault 1. Throttle input wire open or shorted.

2. Throttle pot defective.
3. Wrong throttle type selected.

1,3 O OOO speed limit pot fault 1. Speed limit pot wire(s) broken or
shorted.
2. Broken speed limit pot.

1,4 O OOOO battery voltage too low 1. Battery voltage <17 volts.
2. Bad connection at battery or
controller.

1,5 O OOOOO battery voltage too high 1. Battery voltage >36 volts.
2. Vehicle operating with charger
attached.
3. Intermittent battery connection.

2,1 OO O main contactor driver Off 1. Main contactor driver failed open.
fault

2,3 OO OOO main contactor fault 1. Main contactor welded or stuck open.
2. Main contactor driver fault.
3. Brake coil resistance too high.

2,4 OO OOOO main contactor driver On 1. Main contactor driver failed closed.
fault

3,1 OOO O HPD fault present for 1. Misadjusted throttle.

>10 sec.
2. Broken throttle pot or throttle
mechanism.
Service Manual – ES4000 Wheel System, Traction 170

CODE DETERGENT EXPLANATION POSSIBLE CAUSE

BUTTON LED
DISPLAY

3,2 OOO OO brake On fault 1. Electromagnetic brake driver shorted.

2. Electromagnetic brake coil open.

3,3 OOO OOO precharge fault 1. Low battery voltage.

2. KS1 and Throttle turned ON at the
same time

3,4 OOO OOOO brake Off fault 1. Electromagnetic brake driver open.
2. Electromagnetic brake coil shorted.

3,5 OOO OOOOO HPD (High Pedal 1. Improper sequence of throttle and
Disable) fault KSI*, push, or inhibit inputs
2. Misadjusted throttle pot

4,1 OOOO O current sense fault 1. Short in motor or in motor wiring.

2. Controller failure.

4,2 OOOO OO motor voltage fault 1. Motor voltage does not correspond to
(hardware failsafe) throttle request.
2. Short in motor or in motor wiring
3. Controller failure.

4,3 OOOO OOO EEPROM fault 1. EEPROM failure or fault.

4,4 OOOO OOOO power section fault 1. EEPROM failure or fault.

2. Short in motor or in motor wiring.
3. Controller failure.

*NOTE: A KSI (key switch input) system problem is a specific HPD (high pedal disable) type operational
fault, caused by the operator activating the Fwd/Rev drive pedal before turning on the main key switch or
activating the throttle before sitting on the seat. This can be cleared by returning the operator’s drive pedal
to neutral and cycling the key switch.
Service Manual – ES4000 Wheel System, Traction 171

Removal and Installation

Drive Pedal Replacement

WARNING! Disconnect the machine’s battery pack connector (13) before servicing.

1. See Figure B. Remove the 5 Screws (BB) securing the Drive Pedal (CC) to the floor.

2. Disconnect the Potentiometer electrical connector and remove the Drive Pedal (CC) from the machine.

3. Install new pedal in reverse order.

NOTE: The Potentiometer does not require adjustment.

Drawing
depicts typical
assembly but
may not match
your machine
precisely.

See Photo

Figure B
Service Manual – ES4000 Wheel System, Traction 172

Potentiometer Testing
The Potentiometer is part of the drive pedal assembly. It is not serviced separately and does not require
adjustment. The potentiometer is pre-set at the factory and needs service only when replaced.

Testing the Potentiometer

Note: The pot doesn’t have to be removed from the drive pedal assembly to test.

1. Jack the front drive wheel off the floor and support the machine with jack stands and wheel chocks.

2. Do not remove the the throttle potentiometer.

3. Test the pedal signal with a volt meter with the harness connected and the pedal installed on the
machine.

4. See Figure A. Connect the meter leads to each of the outside connections on the potentiometer. The
meter should read approximately 4.6V to 5.02V.

5. Next move the test leads to the number two and number three terminals as shown in the lower
picture in Figure A to validate the signal voltage. (The range of readings for the signal voltage should
be 2.19 V to 2.4 V at neutral , .8 V to 5 V over the entire range of travel , .87 V to 2.19 V in reverse and
lastly 2.19 volts to 4.1 volts in forward.

Note: The drive pedal is shown without the machine wiring harness connector for clarity. Do not
disconnect the drive pedal harness connector.
Service Manual – ES4000 Wheel System, Traction 173

Replacing the Drive Wheel Assembly

WARNING! Park the machine on a dry flat surface, turn the main key switch (J) to the Off
position and disconnect the battery pack at the red connectors inside the battery
compartment.
Place bottle jack here

1. Block the rear wheels.

2. Jack up the front of the

machine using a bottle jack
on the frame member, or use
a hoist to lift up the front
end of the machine.

3. See Figure W-1. Using

a 17mm socket, loosen but
don’t remove the four bolts
(Shown in photo - 2 of 4) at
the steering sprocket to allow
the chain to release some.

Figure W-1
Service Manual – ES4000 Wheel System, Traction 174

4. Using a 3/8” magnetic socket, remove the

four bolts holding the charger in place, and
remove the charger and bottom plate. (Figure
W-2).

Charger
bottom plate
covering
spindle nut

Figure W-2

5. See Figure W-3. Using a 1 7/16” socket,

remove the hex nut at the top of the Spindle
Weldment.

Hex Nut

Figure W-3

6. See Figure W-4. Turn the Drive Wheel to the

right and remove the motor wiring cover (C).

7. Using a 13mm and a 7mm socket, remove

the nuts and wires from the drive motor.

8. Turn the motor towards the left. Using a

7/16” socket and wrench, remove the P-clamp.

9. Jack up the front end of the machine

enough to allow the wheel to slip free from the
machine.

10. See Figure W-1. Using a 17mm socket,

remove the four bolts (A) at the top to free the
motor from the Steering Plate.
Figure W-4
Service Manual – ES4000 Wheel System, Traction 175

11. Reassemble the drive wheel in reverse order, attaching the motor wires as shown in Figure W-5.

Caution! Use a Torque Wrench set at 20 ft-lb to retighten the 1 7/16” hex nut at the top of the
steering spindle.

Note: Orient the wires in such a way as to minimize bending at the crimps for optimum motor
performance. There are (2) each YEL/BLK and RED/GRN going to each post.

YELLOW/BLACK WHITE
BLACK RED/GREEN

RED/WHITE ORANGE

Figure W-5
Service Manual – ES4000 Wheel System, Traction 176

Replacing the Drive Tire

The Drive Tire is assembled as shown in Figure W-6:

1. To replace the tire, follow steps 1-3 of “Replacing the Drive Wheel Assembly.” Then follow Figure W-6 and
step through assembly from A through E as shown.

2. Remove the six metric socket head screws.

3. Use Tire Puller Kit (part # 56422174) to replace the tire.

Reassemble in reverse order.

Figure W-6

In addition to carbon brushes, parts available for replacement are:

See figure W-6.

• tire with hub (A)

• tire (B)

• motor (C)

• parking brake (D)

• motor cover (E).

Service Manual – ES4000 Wheel System, Traction 177

Inspecting/Replacing the Drive Wheel Assembly Carbon Brushes

Important! To remove/replace/inspect the Carbon Brushes, observe the following:

1. The motor must come off of the machine.
2. The motor assembly must be kept vertical while being disassembled to prevent loss of gear
oil.

WARNING! Park the machine on a dry flat surface, turn the main key switch to the Off position
and disconnect the battery pack at the red Anderson connectors inside the battery
compartment.

1. Follow the instructions in “Replacing the Drive Wheel Assembly”.

2. Place the motor assembly upright, motor side up, as shown.

Caution! To prevent gear oil from draining from the gearbox, disassemble the motor with the
Drive Wheel assembly in a vertical position. If some oil is lost, drain completely and
refill the oil as indicated at the bottom of the page.

3. See Figure W-7 and photos. Remove the four metric socket head cap screws (A) securing the electric
motor to the casting.

4. Use a hard piece of wood or a brass drift punch to tap the

motor mounting flange (3 notched locations (B)) to loosen.

5. Grip the motor/brake end bell and pull the motor (C) up and
out of its housing.

6. Inspect the 4 carbon brushes and springs. A new carbon brush

measures 3/4”. If less than 1/4”, replace.

7. Clean the foam filters, and blow out the motor.

8. If gear oil has been lost, drain and replace with 4.5856 oz (130
g) of Mobilgear 600 XP 150 or AGIP BLASIA 150 gear oil.

9. When placing the motor back into the housing, the brushes can
be spring-flexed aside for easy insertion. Release the spring
tension on the brushes after the motor is in place.

Changing the
Motor brushes
- 4 total

See photos next page Figure W-7

Service Manual – ES4000 Wheel System, Traction 178

1 2

1. Turn motor assembly over and

expose the brushes.

2. Locate brushes and retainer

springs (clips).

3. Using a screwdriver or other

similar tool, release the tension
on the springs to allow the
brushes to be removed.

4. Remove, inspect the brushes,

then clean or replace the
brushes.

4
Service Manual – ES4000 Wheel System, Traction 179

Specifications

Diameter: 9.84 in (25 cm) Width: 3.15 in (80 cm)

Drive Wheel
Type/Material: Blue Urethane
Drive Motor 1.05 HP (780 watts)
Fwd: 3.91 mph (6.30 kph)
Max. Transport Speed
Rev: 2.61 mph (4.20 kph)

Special Tools
1. Curtis Programmer unit 1311

The part number of the handheld programmer is 56409441.

NOTE: If you have a programmer with a serial number before 2100 you will need to update your
programmer. A free upgrade kit is available, order part number 56409822. Also a different
quad 4 pin programmer cable (PN 56409823) is needed to link the programmer to the
controller plug-in port.

2. Tire Puller Kit (part # 56422174)

Curtis programmer

Curtis programmer
cable and plug unit