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1. MISTING VALVE 1 VACUUM RESTORE VALVE 2 10 W004 FLASHING LIGHT ad X13 JL RED X18 u GRY BLK 18 W003 5 tol 1 gt N 5 gt CONN 5 ns umnd pe Sasu ost ox Te 2 D m K2 L mx x BRUSH 5 ar Tm RED 12 4174 1 n 525 S RED 12 W172 v 0 0 9 Ag J kr Ze X25 m E a c l 2 2 0 c amp 4 D v m m Lr m gt 4 l I m m WHT RED 18 W010 X61 CA CRED 4 031 c Lo RED 1 0734 BRN 18 4157 2 8 8158 E perc TET KEY SW BRN 18 W165 n d E 2 SEAT SW GRN YEL 16 W171 0 133 m JS Li 122 GRN YEL 16 W069 0 X32 N 5 m S GRN YEL 14 W070 0 Mm MO m x x CHASSIS GROUND 7OAMP E WHT BRN 18 W163 Q dl BRN BLK 10 030 e9 2 x e X21 X22 ON BOARD BATTERY CHARGER gt OPTIONAL 0 o Lg 55 H1 M INTERLOCK Z TOAMP re x HORN 0 2 x x S BRN Y
2. 158 Maintenance and Adjustments 154 Removal and Installation 155 Steering Column shroud removal 155 Wheel System Non Traction 157 Functional 157 Component Locations 235 xo ox 3o x 9o wok X wk X e wo OX 08x 903 9 eae 157 Removal and Installation 158 Replacing the Rear Wheels 158 Service Manual ES4000 Contents 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 n soss oc eae 3s 79 3 3X S3 wn Q Be eee ee oe 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 ee 171 Drive Pedal Replacement 171 Potentiometer
3. 1 188 BLK WHT 18 W068 CRN EL LB NORV BLK 18 W034 40 E 179 10 4033 c34 amp 8 SPEED LIMIT POT 18 ORN 18 160 4s BLK 10 W033 E m BLU ORN 18 W160 REVERSE 17 GRY BLK 18 W029 344 m HORN 16 157 e 45 BDI 15 144 ORN 18 056 BLU BLK 16 W065 PROGRAMMER RED WHT 18 058 5 13 V0 18 WOB4 POT LOW 13 YEL BLK 10 1072 8 gt 12 ORN BLU 18 W067 BRN YEL 18 W164 46 B 11 11 42 GRN BLK 18 W156 49 314 B 10 10 9 610 STATUS ORN RED 18 W155 MODE M1 2 RED GRN 10 w071 88 _ NE VIO BLK 18 W047 X46 GRY BLK 18 4003 412 BRAKE 6 7 aH lt 13 5 WHT RED 18 W010 POT WIPER 4 Jy 54 CRY BLK 18 W026 BRN 19 W169 POT HIGH 3 T El 4 n BRN BLK 10 W030 E A B 2 GRI 18 052 p X B 1 3 YEL 18 W060 29 BLk 18 403s N 16 2 93 BLK WHT 18 W068 44 10 18 085 5 4 a EG YEL 18 NOS1 5 2 o one LZ 44 sen 18 165 gt 54 BLK 18 037 1e is 5 H BI VIO 0RN 18 W167 PE YEL VI0 18 042 410 911 GRN YEL 16 W069 tj
4. HTH Pup muni E FUMER a h 12 16 2010 Service Manual ES4000 Options and Accessories 87 Accessories 1 Warning Beacon kit 2 Battery Watering Kit aa ET aN 74 k Service Manual ES4000 Options and Accessories 88 3 Chemical Bottle Assembly 4 Battery Hill indicator Service Manual ES4000 Options and Accessories 89 5 AquaWand Carpet Scrub Wand 13 and Accessory hose assembly Nilfisk Advance 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 hose 15 connected to each shoe to direct water to the Recovery Tank hose that 15 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 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 th
5. 7 D uc Remove Adjuster Cover Rotate Nylon Nut to Adjust A Note Use a 1 2 18mm socket to turn the adjuster 8 After each adjustment hold the spring housing assembly run the actuator IN amp 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 AN WARNINGI Disconnect the battery pack by activating the emergency stop switch and using the battery disconnect before Figure D 12 servicing Remove the scrub brush drive belt using a belt installation removal tool Figure D 14 A 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 amp Neg brush motor terminal studs and note the correct wiring connections for reinstallation Figure D 15 Then remove the 3 Screws Y and lift th
6. for positive and 4 4 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 54000 is equipped with a low voltage cutout feature to prevent over discharging of the batteries When machine s battery pack voltage falls below specifically defined thresholds voltage settings the cleaning system 1s 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 unles
7. 1 6 x LL O vv B B B B OIO OjO J2 10 K2 Brush Contactor oe 4 Brush Lift Actuator M7 Brush Motor M8 Brush Motor Calibrated Ground Wires 132 Service Manual ES4000 Component Locations The Scrub System main components are Figure D 1 Scrub brushes A Brush motors and drive belts Debris hopper tray D Restoration Nozzle E Maintenance Nozzle F Scrub deck lift actuator G i uo OX Me mo Wes TIP Ul 64 2 7 DE 44449 e Ssg ROTATION Figure D 1 Scrub System Service Manual ES4000 Scrub System 133 Maintenance 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 iP Rinse clean built up debris from the debris hopper drain holes daily Remove any string wrapped around the scrub brush drive hub and idler hub daily Clean spray nozzles attached to the front and top of the scrub deck weekly See Solution section of this manual Clean built up dirt from the inside of the scrub brush housing weekly Remove both the scrub brushes and rotate turn the front brush end for end weekly See Scrub Brush Removal and Installation section Inspect the scrub brush bristles for wear monthly The brushes should be replaced when the bristle length of the f
8. Lift and tilt the Control Panel Assembly to access the board underneath f ng 4 54 A lt lt 2 ie S NET 1 lt 2 AN 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 AN Caution The ribbon cable s and membrane switch grounding film are fragile Do not scratch or crease during disassembly or re assembly or f 2 Fi damage may 2 a Lo 2010 occur VIN AN 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 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 1t with the new one Install the new board assembly in the reverse order Be extra careful when plugging in the connectors on the board A Note After replacing the Main Controller no special programming of operational values is required if th
9. POT LOW J 2 5 H PIN 3 POT HIGH NE POT 5 0K OHM m B J 1 8 BLK B J2 7 HORN GRN LK 13 9 HORN E BLK optiona M2 B J2 2 BLK EM RED YEL Jl1 CHEMICAL PUMP 4 J 1 3 CHEMICAL NOTES Bs PUMP lt 1 DISCONNECT RED WIRE ON 2 AND Electrical System BLK BLK gt RED GRN 2 Q YELBLK l c lt REPLACE WITH GREEN WIRE FROM CHARGER WHEN ON BOARD CHARGER IS USED 81 Service Manual ES4000 Electrical System 82 Wiring Ladder Diagram 56344090 Rev C 2 of 2 B B 1 T A CONTROL BOARD SHOE J 1 9 BLK YEL M3 SHOE ACT J 1 10 WHT GRN 5 ACTUACTOR BRUSH J 1 5 ORN BLK M4 BRUSH ACT J 1 4 BLU MOTOR BRUSH LIFT ACTUACTOR REAR BRUSH MOTOR SENSE J 1 6 VOI RED FRONT BRUSH MOTOR SENSE J 2 10 VACUUM MOTOR SENSE J 2 9 BRN RED RED 4 3 WHT 1 2 M6 CONTACTOR VACUUM MOTOR VAC M5 MOTOR VAC K2 M7 RED 4 3 RED RED M BLK BLK CONTACTOR BRUSH MOTOR BRUSH FRONT M8 MOTOR BRUSH REAR Service Manual ES4000 Electrical System 83 Wiring Harness Diagram 56344091 Rev C 1 of 2 J3 J4 E
10. 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 AY Nilfisk Advance Service Manual ES4000 27 Control System Functional Description The Control System consists of the Main Controller Speed Controller and Operators 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 Operators Control Panel is where the driver controls all the machine cleaning functions Main Controller located inside Control Panel 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 saf
11. 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 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 3 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 O ER Scrub Deck Lift Excessive current draw was sensed Code sets at approximately Actuator Circuit Over 3 amps or more Current Check for shorted actuator mechanical binding of actuator linkage shorted wiring 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 O1 Shoe Lift Actuator Excess
12. 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 RE lt fn TA Fastener knob Access cover Brush Left M otor FRONT I Right M otor o d o o L T eee 1 uc CCW Rotation 2 from shaft end la T P 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 Scrub path 28 in 71 1 cm Scrub Motor s Service Manual ES4000 Scrub System 152 Special Tools Actuator Power Cord Adaptor Part 56407502 SW Nilfisk Advance Service Manual ES4000 Steering System 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 QUA 2 Lower Column Shroud Steering System 153 Servic
13. 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 1n 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 Charge Batteries s CheckClean Vacuum Shoes s ws NENNEN _ Inspect and clean solution filter Check foot parking brake for wear adjustment if applicable Lubricaton greasefitings ws C
14. U Up or D Down SP Solution Pump blank OFF or CP Chemical Pump blank OFF or X ON Note In Figure E 28a 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 Figure E 23a SERVICE TEST MODE instructions end here Service Manual ES4000 Backup Alarm Volume Control System 42 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 18 variable using the hidden menu Set the volume to one of the avallable 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 16 adjustable to various levels using the hidden menu Set the Horn volume to one of the avallable 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 EE Display Service Manual ES4000 Control System 43 Extra Info on LCD This scr
15. CHASSIS GROUND X6 RED GRN 10 W071 J1 a RED YEL 18 W050 341 2 u u VIO ORN 18 W167 42 BLU GRY 18 W051 45 X58 YEL BLK 10 W072 ORN BLK 18 055 45 RED WHT 18 1058 x55 VIO ORN 18 W177 45 e RED WHT 18 W057 RED WHT 18 4077 9 amp X49X51 iem a gt BLK 18 N038 46 ORN 18 4056 lt B2 0RN 18 4078 9 TON gt X50 X52 X56 2 WHT GRN 18 N053 3410 GRN YEL 16 W171 0 132 7 5515 GROUND YEL 18 W061 _ n z 1 A lt N as YEL 18 8060 6 YEL 18 N059 4 E Mt gt GRY 18 W062 98 Z 8 SPL a 2 gt m VIO 18 W064 VIO 18 N063 4c o amp Y 8 TE m x V10 18 W065 o 7 xg i m 1 om oss in CONN n m lt 136 D 5 E i Y m a 0 N N SHOE LIFT ACTUATOR x x BRUSH BACK 2 CONN x5 Service Manual ES4000 Electrical System 84 Wiring Harness Diagram 56344091 Rev C 2 of 2
16. EE G M Main Controller ES 1 ES E T F I ic kisa Ej h n EET zT af i A Battery Charger with AC power charging cord met eii 2t sit ail S Service Manual ES4000 Control System 33 Operator s Control Panel 15 2010 Speed Controller Located under Electrical compartment 2 4682010 Service Manual ES4000 Control System 34 Maintenance 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 B LCD Display 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 amp Detergent OFF LED 5 Release both switches The display will now show Program Options 6 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 r
17. Electrical System Functional Description The Electrical System is integrated throughout the machine functions The main functional interface 1s the Operators Interface Panel Assembly See CONTROL SYSTEM Control Panel operator s functions are initiated and controlled from this panel The machine is Battery powered and rechargeable The drive system 15 variable speed controlled via the foot pedal and selection of various operational functions at the Control Panel An optional on board Battery Charger 15 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 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 150 Amp fuse 24 VDC Contactor 24 V 100 AMP Contactor Speed Controller Service Manual ES4000 Batteries battery with Recovery Tank removed and Operators Seat up Battery connector shown disconnected Fuses and E stop locations Electrical System 59 Service Manual ES4000 On board Battery Charger Operators main interface panel CONTROL PANEL Speed Controller Electrical System 60 Service Manual ES4000 Electrical System 61 f Mann Ele
18. J3 10 J3 11 4 8v After energized for a few seconds To hold contactor Service Manual ES4000 Electrical System 80 Wire Description Measured Comments Color Value J3 13 wht red Brush Motor When first energized To pull in contactor Contactor output After energized for few seconds hold contactor J3 14 Key Switch input l With vacuum motors running input B voltage when key is turned on Service Manual ES4000 Wiring Ladder Diagram 56344090 Rev C 1 of 2 RED 1 2 FUSE 1504 BATTERY 24 Vdc Kuu CIRCUIT BREAKER 70A ON BOARD BATTERY CHARGER RED p OPTIONAL I B LK LP1 MENE WHT BRN 1 62 2 BLK lt i LAMP FLASHING OPTIONAL S1 94 lt gt 52 RED 2 1 BRN EL 1 2 BRN WHT BRN 220 GRA BLK CIBCUIPEREAKER SW SPST KEY EMERGENCY STOP SWITCH SEAT n cc BRN YEL I SEAT 31 SWITCH 3 4 GRAIBLK ORN J3 8B BRN a 3 14 KEY SWITCH a BRN GRA BLK 3 12 VACUUM I BRAKE sss CONTACTOR A2 NTACTOR VACUUM CURTIS 1228 SPEED CONTROL BOARD 2 13 13 BRUSH NA CONNACTOR 4 4 ac x m FORWARD REVERSE 3 6 EDWHT PIN 6 BRAKE J 3 11 MISTING SOLUTION SOLENOID STATUS J 3 PIN9 STATUS B REVERSE J 3 5 BLU BLK PIN 16 REV ALARM RER PT BLKAVHT PIN 18 SPEED LIMITO 3 3 MAINTENANCE PIN 13 POT LOW MI POT HIGH J 2 6 11 2 SOLUTION PUMP M2
19. enters the Recovery Tank Hose Connected to DRY Connector Service Manual ES4000 Recovery System 104 1 misting nozzle is installed into the side of the Misting chamber adaptor The nozzle assembly can be removed to access the misting nozzle itself x TER T Misting nozzle for DRY sweeping 2 Turn and pull the misting nozzle assembly from the misting chamber adaptor Misting nozzle assembly amm removed 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 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 the master key switch and press the VACUUM ON Switch Vacuum motor will run continuously until the switch 1s pressed again to turn 1t OFF IG gt 4 EC ON L 27 Accessory Port Recovery System lower panel bottom rear of machine Service Manual ES4000 Recovery S
20. scroll through the menu use the Interim mode 4 button to scroll up and the Restorative mode x button to scroll down See Control Panel Image for button locations 2 To enter sub menu press the PreTreat button If no Service Manual ES4000 Control System further sub menus exist then this button has no effect 3 To go back one level in the menus press the Detergent button There is one additional feature that is available only when you enter into the 2 level of menus This feature automatically turns on and off when you enter or leave 244 level menu B LCD Display Upon entering 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 1st level function has 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 wil
21. 2 Shortin motor or in motor wiring 2 Short in motor or in motor wiring 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 1 71 Removal and Installation Drive Pedal Replacement AN 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 AN 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 1 72 Potentiometer Testing The Potentiometer is part of the drive pedal assembly It is not serviced separately and does not require adjustment The potentiometer 1s 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
22. 3 0 00v 1 55v Switch open J3 5 blu blk Reverse Direction Reverse input from Speed Controller input GND when moving in reverse Fwd Reverse input from Speed Controller input GND when moving in forward or reverse Speed Controller 1 19v With no speed control faults Status input input pulses between B and GND to indicate error status from Speed Controller brn yel Battery lead 24 5v With vacuum motors running grn bik Horn output 13 3v off Connects to battery negative to sound horn 24 1v Neutral or Forward J3 6 red wht 0 24v Reverse or Neutral 24 1v Neutral J3 7 org blu 24v With speed control faults The voltage jumps lower as the code signal is communicated J3 8 J3 9 0 01v on org red Horn output 15 0v Constant power supply vio blk Misting solenoid 0 19v When energized output gra blk Vacuum Contactor 0 26v When first energized To pull in contactor output J3 10 43 11 9 12 4 8 After energized for few seconds To hold contactor Service Manual ES4000 Control System 57 Wire Description Measured Comments Color Value 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 Key Switch input 24 1v With vacuum motors running input B voltage when key is turned on Nilfisk Advance Service Manual ES4000 58
23. 62A Current or more Check for shorted solenoid winding shorted wiring 4 Service Manual ES4000 LCD Code Definition Display Code Rear Brush Motor Over Current Maintenance Solenoid Circuit Open Front Brush Motor Circuit Open Scrub Deck Lift Actuator Circuit Open Vacuum Motor Circuit Open Shoe Lift Actuator open Brush Contactor Coil Circuit Open Vacuum Contactor Coil Circuit Open Detergent Pump Circuit Open Rear Brush motor Circuit Open Solution Pump Open Control System 48 Explanation Code Setting Conditions Flash Indicator Disables Check Thresholds Excessive current draw was sensed Code sets at approx 19 8A or more Check for shorted motor current sense wire connections ground connections The Main Machine Controller has turned the solution solenoid circuit on but it is not sensing any current flow Senses lt 20mAmps for 10 seconds Check for open solenoid winding open wiring The Main Machine Controller has energized the Brush Contactor but it is not sensing any current flow through the brush motor ground circuit for at least 5 seconds Senses lt 2 Amps for 10 seconds Check Motor Contactor contacts Wiring The Main Machine Controller is trying to move the actuator but it is not sensing any current flow Senses lt 67 m Amps for 10 seconds Check Actuator wiring The Main Machine Controller has energized the Vacuum Contactor but it i
24. ASA ANA 9S 9 y at 18 y f 121600 b gt FEL EL LLL LL Figure S 6 Service Manual ES4000 Solution System 128 Solenoid Valve Disassembly and Cleaning A Note See Figure S 7 for valve disassembly amp cleaning A 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 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 5 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 Solution Flow Rates 1 Maintenance mode 29 gal min TR 10155 AO 2 Restore Mode 8gallmn TR 10155 ee 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 Flow Rate GPM Working Pressu
25. 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 ACT CURR EXTRA INFO ON LCD 13 SHOE ACT CURR EXTRA INFO ON LCD 14 CHEM PUMP CURR EXTRA INFO ON LCD 15 SOLN PUMP CURR EXTRA INFO ON LCD 16 ALT AVG BR CURR EXTRA INFO ON LCD 17 ALT INST BR CURR EXTRA INFO ON LCD 18 FR INST BR CURR EXTRA INFO ON LCD 19 RR INST BR CURR EXTRA INFO ON LCD 20 BRUSH HOURS 12 Brush actuator current amps 13 Shoe actuator current amps 14 Chemical pump current amps 15 Solution pump current amps 16 Alternate every 5 seconds between front and rear average brush current amps 17 Alternate every 5 seconds between front and rear instantaneous brush current amps 18 Front instantaneous brush current amps 19 Rear instantaneous brush curren
26. ES4000 Control System 52 Disable System Flash Indicator Fault Description Display Code 2 le ag 5 E EI A m 2 i 5 AIN Q 53 Vacuum Contactor Coil Open Chemical Pump Open Rear Brush Motor Open Solution Pump Open Restore Solenoid Open Misting Solenoid Open Front Brush motor Stuck Closed Vacuum Motor Stuck Closed Maintenance Solenoid Stuck Closed Brush Contactor Coil Stuck Closed Vacuum Contactor Coil Stuck Closed O O TS Restore Solenoid Stuck Closed Misting Solenoid Stuck Closed Rear Brush motor Stuck Closed gt lt Chemical dsl gt dme gt gt lt gt lt gt lt Sweep recovery _ _ ww ___ fx le N o amp 21 s gt Figure 33 Disabled Systems for each fault code Note Flash indicator at 1 hz rate Service Manual ES4000 Control System 53 Removal Installation Replace the Main Control Board Caution You must 7 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
27. Gauge 2 Batt Gauge 2 Bar Bar Batt Gauge 2 Batt Gauge 1 Bar Bar 13 22 35 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 17 21 75 Batt Gauge 1 Bar 19 21 45 Batt Gauge 0 LVI Bar 21 21 15 Batt Gauge 0 LVI Bar 23 20 85 Batt Gauge 0 LVI Bar 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 hfe 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 instruc
28. Main Controller 78 Wiring Ladder Diagram 56344090 Rev lof 2 81 Wiring Ladder Diagram 56344090 Rev 2 of 2 82 Wiring Harness Diagram 56344091 Rev 1062 83 Wiring Harness Diagram 56344091 Rev C 2of2 84 Options and Accessories 85 85 PCCCSGOVICS E RC E EOM E E T RO 87 Recovery System 90 Functional Description 90 Recovery System Vacuum General 90 Recovery System Circuit Description 91 Component Locations ss ss ss 9 43 9 3 0 ROW od 3 xod 92 Maintenance and Adjustments 94 Recovery System Service Maintenance Checklist 94 Vacuum Filter and Float Cage Maintenance 94 Troubleshooting s nao we wx X sC Z wow x 9 o w X OS dh SUS ea S W 96 Removal and Installation s 97 Vacuum Motor s Removal 97 Recovery Tank Removal 98 Vacuum Shoes Removal 100 Recovery System Wet and Dry Pickups Accessory Port 102 PIOEHD Gal 00 55 4 x z Z RUE ate w Q RU ms S X Q s 102 Wet 1
29. 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 1 77 Inspecting Replacing the Drive Wheel Assembly Carbon Brushes A 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 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
30. Service Manual ES4000 Solution System 120 Figure S 2d Solution hose for drainage 5 2 Service Manual ES4000 Solution System 1 21 Troubleshooting Mechanical Electrical Plumbing 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 all models the solution system s electrical solution solenoids L1 L2 amp L3 misting restoration amp maintenance modes are monitored by the main controller Al 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 AN Note Reference the Main Control Board Troubleshooting Guide in the electrical system of this manual for specific fault descriptions and seruice repair actions Maintenance and Adjustments Solution Tank Weekly empty the solution tank remove the solution Drain Hose from 1ts storage area located underneath the left side of chassis See figure 5 2 Direct the hose to a designated Disposal Site and flush the tank with clean water e Solution Filter Remove and clean the inline Solution Filter See Figure 5 24 To access the filter housing for removal work underneath the middle front
31. 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 PDECIHOADIGHS 2 E chon 6 5 179 MULTI eh es 179 Service Manual ES4000 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 1118 General Information Added
32. 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 5v POT High B POT Low 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 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 wo
33. at the steering sprocket to allow the chain to release some Figure W 1 Service Manual ES4000 Wheel System Traction 174 4 Using 8 8 magnetic socket remove the four bolts holding the charger in place and remove the charger and bottom plate Figure W 2 5 See Figure W 3 Using 1 7 16 socket remove the hex nut at the top of the Spindle Weldment 6 See Figure W 4 Turn the Drive Wheel to the right and remove the motor wiring cover 7 Using a 13mm and 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 1 75 11 Reassemble the drive wheel in reverse order attaching the motor wires as shown in Figure W 5 AN Caution Use a Torque Wrench set at 20 ft Ib to retighten the 1 7 16 hex nut at the top of the steering spindle A 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 RED GRN going to each post To A ET VU r Figure W 5 Service Manual ES4000 Wheel System Traction 176
34. by pressing the TEST key Scroll down to observe the status of the forward reverse and brake switch Cycle each switch 1n 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 Ifthe 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 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 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 Defect
35. 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 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 Control System 31 Service Manual ES4000 Control System 32 s s TRUR TPT YE dew nem Ve gi h r aa EE 4 T s rr i id 951
36. 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 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 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 FIGURE Service Manual ES4000 Wheel System Traction 173 Replacing the Drive Wheel Assembly AN 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
37. page 3 See Figure W 7 and photos Remove the four metric socket head cap screws A securing the electric motor to the casting i i 4 Use a hard piece of wood or a brass drift punch to tap the motor mounting flange 3 notched locations B to loosen A 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 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 Service Manual ES4000 Wheel System Traction 179 Specifications Wheel Diameter 9 84 in 25 cm Width 3 15 in 80 cm Type Material Blue Urethane 1 05HP 780 watts Fwd 3 91 mph 6 30 kph M
38. 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 enter press PreTreat mode 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 USsing 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 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 betwe
39. the speed controller for the speed limit pots terminal of battery Service Manual ES4000 Electrical System 75 Designation Wire Description Signal Nominal Reference Range Comments ID Characteristic Value To Color input J2 yel Front Brush Analog voltage voltage is present only if brush 10 vio Motor Current motor is ON voltage range Sense input corresponds to motor load voltage on range 3to 21 this wire wrt GND represents the motor current no J2 connection 12 power J3 1 brn Battery DC voltage 24 V 20 5 terminal of battery yel lead 25 5 V i Org input J3 5 blu DC voltage 0V bik 0 100 V Voltage nominal 0 V when solenoid is energized and 24 V otherwise Maintenance solenoid output Voltage nominal 0V when drive motor is operating in Reverse Direction input from Speed reverse voltage nominal Controller 24V all other times input GND when moving in reverse Service Manual ES4000 Electrical System Designation Wire Description Signal Nominal Reference Range Comments ID Characteristic Value To Color voltage nominal 0V when there is no speed controller fault voltage pulses between OV and 24V when there is a Speed Controller Status input input pulses DC voltage blu between B fault with the speed controller and GND PULSED SIGNAL EQUAL TO to
40. 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 N CAUTION This machine is not approved for use on public paths or roads Other Cautions This machine 1s 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 1s scrapped The disposal
41. 00 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 IDeck lowered fec CU 2 Pull off the vacuum hose from 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 4 Pull Vacuum shoe from deck mounting 3 Remove the sweep debris Hopper Figure D4 from the scrub deck Figure D 4 IDebris Hopper Ap N 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 hen remove the link pin Fs gt b gt T y uM aum ES Figure D 6 Service Manual ES4000 Scrub System 139 7 Remove the tubing for the solution nozzles Figure D 7 Figure D 7 8 Remove the two Hitch Pins Figure Dla amp D 8 that attach the scrub deck to the machine chassis linkage arm weldment Figure
42. 03 Diy Connection Fe are eee RU 5 103 Accessory Port Using 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 5 110 Special Tools 25 40 bore Be ee Xo 3o 9 Go RR Re end ke dee e sur e s 111 Actuator Power Cord Adaptor part 56407502 111 Service Manual ES4000 Contents iv Solution System GRE sesso s s s s s s s s s s s s s sz s s s s s e e o 405 112 Functional Description 112 Solution System Circuit 113 Component Locations 114 Tro bleshooting s s ea EN EE 121 Mechanical Electrical Plumbing 121 Maintenance and Adjustments 121 Purge Chemical Pump Weekly 122 Reset the Detergent Counter 122 Detergent Ratio 122 Nozzle Maintenance gt 125 Chemical Pump Removal 126 Solution Solenoid Valve Removal 127 Solenoid Valve Disassembly and 128 SPT 129 Se
43. D 8 9 Carefully maneuver the deck from under the machine to complete its removal Figure D 9 AN 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 S 2 i removed Figure D 9 Service Manual ES4000 Scrub System 140 Scrub Deck Actuator Removal 1 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 m 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 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 r
44. EL 18 022 175 B5 z a DAN TEL 19 7 x m X54 X53 m Dm x x Y BLK 18 W035 R n BLK 18 W034 5 BLK 18 W036 n BLK 18 W037 Y in m 5 BLK 18 W038 VIO ORN 18 177 gt is YEL V10 18 042 BLK 12 W175 1 1 BRN RED 18 1046 amp a BLK 10 W045 BLK 10 W044 SPL 4 BLK 12 W176 BLK 12 W039 M zi SpL 3 I 29 930 n s Me GROUND Y a BLK 8 1043 X27 PU L BLK 10 W033 4 gt o 2 5 NI m Briss lt x 7 BLU GRY 18 W051 y B p 05 77 CONN m gt Xm d CHEMICAL PUMP Y hi 1 Y x Gp o ine VACUUM T M m m BRUSH FRONT 1 33 6 CONN VACUUM Nilfisk f Advance Service Manual ES4000 Options and Accessories Options 1 Battery 6V 312 AH AGM 6v420 AH 2 Shelf Charger Portable 24V auto 20 AMP qia NER 120 VAC 60HZ acce MN 24V auto 25 AMP Le aa mo i 120 VAC 60HZ x 24V auto 36 AMP FU oe 120 VAC 60HZ 24 VOLT BATTERY CHARGER r PART NO 372947 pote 86 Options and Accessories Service Manual ES4000 Board Charger Assembly On COMER MTT LAL xa ta Tz DU
45. ET 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 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 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 Def
46. Electronic Service Manuals This electronic document is provided as service to our customers We do not create the contents of the information contained in this docu ment Should you have detailed questions pertaining to the information contained in this document you may contact Michco or the manufac turer which provided the original information in this electronic deliver able s only part in this electronic deliverable was the electronic assembly process By providing this manual on line we are not guaran teeing parts availability You may contact Michco through the following methods Phone 517 484 9312 or 800 331 3339 2011 N High St Lansing Michigan 48906 Fax 517 484 9836 Email CustServe Michco com Web site www Michco Com Parts Web site www FloorMachineParts Com Order Parts on Line at www FloorMachineParts Com Directly to Parts amp Service By Email ShopQMichco com By Fax 517 702 2041 By Voice Use numbers above Serving the Cleaning Industry Since 1922 Notice All copyrighted material remains property of original owners all trademarks are property of respective owners Manuals are subject to Manufacturer s reproduction limitations Originals or reproductions were provided by manufacturers through a request We make no warranty as to the correctness of information provided in this document and you assume all risk By placing these manuals on line we are not declaring our corporat
47. Maintenance 19 Lubricating the Machine 19 Cleaning the Vacuum Motor Filters 19 Scrub Brush Maintenance 19 23 EEE NE EE 23 Battery Compartment Dimensions 24 Minimum Aisle Turn Around Radius turning left 24 Minimum Door Pass Thru 24 Chassis System 25 Functional Description Main Components 25 Control System lt s wow ho ROUX wow OK w Roo Q lt 27 Functional Description xke cox dec c OR ez eza a a a ee SEGRE ox wk 27 Control System Circuit 28 Functional Description of Main Controller 30 Component ol Maintenance and Adjustments 34 Hidden 34 Program Option Settings 4k weds Soo x Ex a E oae der i 34 Service Test 39 Extalnioon 43 TTOMDIESHOOIIO ss csc asumassa saida OW ch x 47 PD a ue ee _ _ _ 47 Removal and Installation 53 Replace
48. 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 56 06 RETRACTED NO LOAD Z2 01 06 EXTENDED NO LOAD O Drive Screw Tube SCALE 0 220 SHOE LIFT ACTUATOR SETTINGS General Instructions for All Actuator Motors 1 This shows the special actuator power cord adaptor part 56407502 that 1s needed to connect a battery pack and actuator motor for setting the drive nut limit settings 2 Ifthe 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 amp 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 16 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 hou
49. 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 5 2 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 15 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 AL DETERGENT ENABLED DETERGENT DISABLED Press and hold amp more than 2 seconds to Purge Detergent system is ON when indicator is ON Service Manual ES4000 Solution System 124 110 0 2 0 Ifthe 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 Toremove the Restore nozzle remove the fastener
50. Solution System Service Manual ES4000 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 1 1 Misting Solenoid 1 2 Restore Solenoid 1 8 Maintenance Solenoid Detergent Chemical cartridge Solution Tank geek 8 an 8 m Dr 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 Figure S 2a Service Manual ES4000 Solution System 117 Detergent Cartridge viewed from Battery compartment Figure S 2b 2 121 1 50 3 a 1 32 Detergent Mix Ratios label inside Cartridge housing Figure S 2c 118 Solution System Service Manual ES4000 3 c 6 0 o o o 6 6 o c O a lt z c 3 o Solution Solenoid Valves L2 and L3 7 gt 4 A O E s AEMELLLILIIIIL FA MM SKIENE 2 o c E 2 gt Service Manual ES4000 Solution System 119 Misting Spray Nozzle Maintenance and Restoration Spray nozzles
51. 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 1n order to drive the actuator It reverses the polarity to drive the motor in both directions 24v Battery 1 o S1 Key Switch A1 Main Controller nternal o Voltmeter Vacuum Contactor M M3 Vacuum Shoe Lift Actuator M5 Vacuum Motor Calibrated M6 Vacuum Motor Ground 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 AULA d Dry Port Vacuum Shoes Vacuum shoe lift actuator ARAUCA K1 vacuum contactor See Figure R 1 Recovery Tank recovery hose and and dump hose Vacuum shoe K1 vacuum contactor Strainer Basket Wet Port Vacuum shoe lift actuator 93 Recovery System Service Manual ES4000 Recovery Hose Recovery Tank and Lid BACK OF THE VAC MOTOR COVER THROUGH VAC MOTOR WIRES TO ROUTE OUT THE THE GROOVES MOLDED IN AND BETWEEN THE VAC PLATE Dump Strainer Basket Vacuum Motors Figure R 1 Service Manual ES4000 Recovery System 94 Maintenance Adjustments Recovery System Service Maintena
52. al 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 AN 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 h
53. al 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 F1 150 A fuse T ME NN 24v Battery CB 1 o o EM un dud aL zen o o CB 2 51 Key 54 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 1s a slightly simplified explanation as the motor 15 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 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 Low circuit inside the speed controller This provides a clean filtered ground third wire runs from the speed controller to the center terminal of the potentiometer This is called th
54. al Pump is activated at a specific rate The Solution pump brush motors Chemical Pump and the restore valve will turn OFF when the throttle 1s in reverse or neutral Service Manual ES4000 Solution System 113 Solution System Circuit Description 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 o o Key Switch Main Controller CY EBEN L1 Misting Sofenoid o 2 Restore Solenoid o o o Solution Pump M2 Detergent Chemical Pump 114
55. ault 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 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 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 adjusta
56. ax Transport Speed ph Rev 2 61 mph 4 20 kph Special Tools 1 Curtis Programmer unit 1311 The part number of the handheld programmer is 56409441 A NOTE If you have programmer with serial number before 2100 you will need to update your programmer A free upgrade kit is available order part number 56409822 Also 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 cable and plug unit Nilfisk Advance
57. ble from 1 second to 5 seconds in 0 1 second increments However it 15 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 6 f no fault code is present the display should show a Ifthe 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 addit
58. 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 1s 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 1s 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 1t 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 1s 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
59. charged of an electric vehicle battery at various specific gravity values corrected to 80 F 26 790 79 Service Manual ES4000 Electrical System 71 Machine and Chassis Wiring LOOP CABLE TIES THROUGH LINKS ON CHASSIS LOOP CABLE TIE THROUGH HOLE IN ACTUATOR BRACKET 00 CABLE THROUGH LINK 00 CABLE TIE THROUGH HOLE IN CHASSIS BRACKET TAB A ATION et RUE Ls pe UNS ARNESS RUNS UP LEFT REAR INSIDE OF TANK CONNECTIONS TO VAC MOTORS AND BEACON ABLE TIE MAIN HARNESS TO BOTTOM OF FRAME USING HOLES PROVIDED UNDER BATTERY CHARGER COMPARTMENT gt 3 SHOW ING MAIN HARNESS ROUTING aa IN ELECTRICAL ENCLOSURE 2 ENTER BRANCH OF HARNESS GOING TO PEDAL BETWEEN CABLE TIE HOLES Service Manual ES4000 Electrical System 72 and Chassis Wiring SECURE TRACTION HARNESS TO P CLIP E ON STEERING PLATE TIE WRAP TRACTION HARNESS e TO MAIN HARNESS END OF BLACK FLEX CONDUIT TO BE NO MORE THEN 17 BELOW TOP SURFACE OF TANK ALLOW APR0X 12 LOOP FOR WHEEL MOVEMENT ROUND ING WIRES SECURED FRAME AT THIS POINT HARNESS BRANCH TO RUN UNDER PLATE HOLD ING BATTERY CHARGER 4 1 TO LAY IN CHANNEL DOUBLE BACK THE SLACK IN THE TRACTION HARNESS AND TIE WRAP AGAIN TO MAIN HARNESS 7 55 TO RUN UP ALONG RIGHT SIDE OF STEERING PILLER Service Manual ES4000 Electrical System 73 Specificatio
60. ctrical Panel Detergent bottle Speed Controller Electrical components in electrical panel Service Manual ES4000 Electrical System 62 Battery Specifications Advance recommended battery pack capacity is a 310 or 420 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 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 A 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 When Servicing Batteries Remo
61. cuit Breaker 4 Provides overload protection 10 Amp Ifit 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 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 1s 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 s
62. d jump around when pump is output operated 1 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 DH 0 26v down J1 5 blu Brush Deck 23 7v up Measured when actuator was moving in both Actuator motor directions 0 15 down 41 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 41 10 wht grn Shoe Actuator 24 6v down Measured when actuator was moving in both motor output directions 0 12v up Battery input With vacuum motors running J22 Netued J233 Notused J2 4 blk wht Speed limit output Restore mode Interim mode Pretreat mode Signal from main 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 Battery input With vacuum motors running Battery input With vacuum motors running 78 Service Manual ES4000 Electrical System 79 Wire Desc
63. de Etc needed Service Manual ES4000 General Information 21 A B Scrub Brushes check for wear and rotate Cylindrical D W Solution Solenoid Valves Maintenance amp C 21 Restoration L 23 Solution Tank Delivery Hoses Filter ri Screen L C D 27 Recovery Tank Cover Gasket L Vacuum Pick Up Tool amp Hoses Back flush I ov Service Manual ES4000 General Information 22 Battery Pack Condition clean amp water Load Test Steering Chain lubricate amp tension 1 4 Deflection wp NOTE Hor additional information see operator manual form number 56091013 Defect Codes A needs adjustment C dirty or contaminated M missing 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 54000 General Information Specifications General Length 61 in 155 cm Dimensions without Squeegee and Scrub Deck Without Overhead Guard 51 7 in 131 3 cm Height Recovery tank Solution Tank 28 8 gal 109 L Tank Capacities Gross Weight standard machine w o options w lull solution tank recovery tank and heaviest batteries installed R Rear 463 Ibs 210 kg Static Wheel Loading Front 587 Ibs 266 kg L Rear 401 Ibs 182 kg Ingress Protection Code IPX3 Vibratio
64. e 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 5 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 Ov 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 Neutral 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 Al main controller from the 9 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
65. e Manual ES4000 Steering System 154 Maintenance 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 attaches to the Column This is 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 4 Steering Wheel Shaft Universal Joint Service Manual ES4000 Steering System 1 55 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 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 the process Steering Wheel removed Service Manual ES4000 Steering System 156 5 Pull accordian Steering Boot from the upper steering column 6 Lift the battery charger cover Shroud lifted from battery y charger compartment Battery charger cover open 7 Prythe plastic Lower Column Shroud off the weldment by starting on the left side away from knob so shroud ca
66. e 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 12 10 2070 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 Block rear wheels to prevent machine from rolling then Jack up the front of the machine 3 4 inches AN CAUTION Support machine with proper blocking for safety Cut the necessary wiring harness tie straps used the Solenoid Valve Assembly then unplug each valve from the machine s wiring harness Loosen the two screws that secure the solenoid mount bracket to the chassis and slide the valve assembly off of the mounting screws Loosen the necessary hose clamps from the solenoid valve that needs service then pry the hoses off their fittings Remove the two screws that fasten the valve body to the mount bracket to complete removal Solution Valves A gt lt c Y gt 7 f gt F y b ig NUT P RAAN Gu ix m Tem S SEDENT n
67. e 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 Al 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 through the key switch energize the contactor the main controller completes a path to ground battery negative on the other side of the coll 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 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
68. e 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 norma 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 Wire Description Measured Comments Color Value 1 1 red yel Chemical Pump 2v to 20v Voltage should jump around when pump is output operated 1 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 Lo 0 26v down J1 5 blu Brush Deck 23 7v up Measured when actuator was moving in both Actuator motor directions 0 15v down J1 6 vio red Rear Brush Motor Brushes running without touching the floor Current Sense input 1 7 blk
69. e motor out from the scrub deck Reassemble in reverse order A Note Install motors with wires pointing to the rear towards the plastic motor wiring standoffs ire connections on motor PG er EL ean vn EE Figure D 15 Service Manual ES4000 Scrub System 149 Scrub Brush Belt Replacement A 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 AN Important Service Tip The left and right side drive belts are not E the same lengths and they 2 must be ordered individually Remove the belt using belt removal tool 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 A Note Rotation of shaft from shaft end is Counter Clockwise CCW for both motors A 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 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
70. e 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 H F1 150 A fuse 24v Battery AC Power Cord On Board Battery Charger o O E g 9 2 51 54 52 Seat Switch Stop Switch Switch A1 Main Controller Controller Power Supply With Charger Unit Service Manual ES4000 F1 150 A fuse CB 2 S1 Key Switch Control System 29 24v Battery O a S4 Emergency S2 Seat Stop Switch Switch A1 Main Controller 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
71. ed Vacuum Motor Stuck Closed Maintenance Solenoid Circuit Stuck On closed 63 Brush Contactor Coil Circuit Stuck On closed Vacuum Contactor Coil Circuit Stuck On closed Restore Solenoid Stuck Closed Misting Solenoid Stuck Closed Rear Brush Motor Stuck closed Figure E 32 Fault Code Descriptions Control System 49 Explanation Code Setting Conditions Flash Indicator Disables Check Thresholds The Main Machine Controller has turned the solution solenoid circuit on but it is not sensing any current flow lt 20mA for 10 seconds Check for open solenoid winding open wiring The Main Machine Controller has turned the solution solenoid circuit on but it is not sensing any current flow lt 20 mA for 10 seconds Check for open solenoid winding open wiring The Main Machine Controller is sensing current flow through the Front Brush Motor ground circuit when it has not energized the Brush Motor Contactor Senses gt 2 Amps for 10 seconds Check for a short in the harness wiring to the motor The Main Machine Controller is sensing current flow through the Vacuum Motor ground circuit when it has not energized the Vacuum Motor Contactor Senses gt 2 Amps for 5 seconds Check for a short in the wiring harness to the motor The Main Machine controller is sensing current flow through its internal switch for the maintenance solenoid circuit when it has not requested that the switch be turned on Sen
72. een selects the extra information that 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 16 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 15 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 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 Vacuum Motor Current the sum of two vac motors MSO RSO Maintenance Solenoid Current amp Restore Solenoid Current MST Misting Solenoid Current BCO VCO Brush Contactor Current Vacuum Contactor Current BAC SAC Brush Actuator Current amp Shoe Actuator Current CP SP Chemical Pump Current amp Solution Pump Current HRS Brush On Time Hourmeter See Figure 27 for a list of all available info that can be selected for display EXTRA INFO ON LCD EXTRA INFO ON LCD 2 BATT VOLTS 2 Battery Voltage volts EXTRA INFO ON LCD 3
73. eld 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
74. emoved F 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 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 10 Remove the remaining fastener bolt in the frame careful when the Actuator becomes E Peri loose Be ready to grasp it with your hand Remove the remaining fastener k bolt in the frame EE 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 Adjustmen
75. en OFF Down and Up Interim mode switch G Controls maintenance solenoid ON OFF B LCD Display Restorative mode switch H Controls the restore solenoid Vacuum ON OFF switch Controls vacuum motor contactor Solution ON OFF switch 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 28 for position of data LCD 25 31 Display actual battery voltage SPD Speed Controller N Neutral F Forward R Reverse BRU Brush Contactor blank OFF or X ON Vacuum Contactor blank OFF 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 ON Figure E 23 BAC Brush Actuator blank OFF U Up or D Down SAC Shoe Actuator blank OFF
76. ersal 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 A ame 7 8 A Drive System Performance reference SVR Manual for Curtis drive noisy programmer speed changes sluggish Vac Shoe Recovery System Raise Lower Solution Control On Off and flow volume Maintenance amp C L Restoration W 11 Tilt Steering Seat D Main Control Board Special Program Options check all applicable Program program settings reference SVR Manual 56043089 Example Fault as Recall Mo
77. ervice 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 Spindle Hex nut Drive wheel assembly Speed controller 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 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 N 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 c
78. essary to bring the fluid level up to the bottom of the filler tubes A WARNING Do not fill the batteries before charging Only charge batteries 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 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 AN Note Always charge batteries before testing There are 2 ways to find 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 Ifthe 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 newer battey mixed in with old batteries will end up being overcharged and cause 14 to fail prematurely The table below shows the approximate percent
79. 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 A 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 Manu
80. he 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 AN 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 that is secured to the recovery tank by six 6 Screws 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 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 A 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 Strainer basket F Figure R 5 Recovery System 98 Service Manual ES4000 Recovery Tank Removal Drain the recovery tank by using the drain hose See Figure R 6 Cover Lift here with both hands Vacuum Hose Drain Hose E ES mr Tae _ E Figure R 6 Serv
81. heck carbon brushes 1 1 1 x gt AN Note See the indiuidual machine system sections for maintenance information Check vacuum motor carbon brushes Qty 2 once a year or after 900 operating hours Check brush motor carbon brushes Qty 4 once year or after 500 operating hours Note if the vacuum or brush motor brushes are 9 5mm 8 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 82 inches Replace when shorter than 9 5 mm 8 8 inches to obtain the same motor efficiency as a new brush A 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 SYSTEM section of this manual for additional information Spray Nozzle Maintenance Remove the spray nozzles once a week Soak the nozzles overnight in 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 Univ
82. ice 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 vacuum hose then lay the Tank down onto the floor A Note There is some weight to the tank assembly Be careful when lifting it off Ask for an extra helper to assist 100 Recovery System Service Manual ES4000 Vacuum Shoes Removal With the Master Key Switch off the vacuum shoes should be checked and cleaned daily 1 See Figure 7 Disconnect the vacuum recovery hose AA from the vacuum shoe Then pullup on the gold chain and slide the shoe away from the Shoe Support Weldment 2 A Note The procedure is the same for both shoes however the RIGHT shoe must be removed before removing the LEFT shoe 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 Lift the cha
83. in 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 lt Accessory Port Dry Connection x CEN 2o Wet connection to Recovery Hose Service Manual ES4000 Recovery System 103 Wet Connection When extracting connect the Recovery hose to the 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 5 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
84. indicate THE FAULT CODE FLASHED error status BY THE SPEED CONTROL from Speed BUILT IN STATUS LED Controller horn when horn button is pressed this signal OV When 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 PWM voltage bik Misting solenoid output Voltage nominal 0 V when solenoid is energized and 24 V otherwise DC voltage output J3 11 vio bik Service Manual ES4000 Electrical System 77 Designation Wire Description Signal Nominal Reference Range Comments ID Characteristic Value To Color output J3 wht Brush Motor PWM voltage 0V 010 voltage on this cycles 13 red Contactor 0 100 between 0 and 24V contactor output V is energized when this voltage PWM frequency 5KHz duty cycle 100 for startup and 80 steady state when brush motor is ON Service Manual ES4000 Electrical System Shop Measurements Main Controller The following tables contain some real world shop voltage measurements to help you recognize what norma 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 Wire Description Measured Comments Color Value 1 1 red yel Chemical Pump 2v to 20v Voltage shoul
85. ion 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 1n 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 18 directed at the scrub brush and the flow rate is reduced The travel speed is limited to medium speed In the Restorative Mode the solution spray is directed at the carpet ahead of the scrub brush and the
86. ion to be an manufacturer authorized dealer or provider please check our web site for authorized manufacturers we represent ES4000 Service Manual Advance Model 56344200 Nilfisk Advance 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 x x3 Z x gt Z X w eee lt e S NON EUER EN RUE IE RE REN 4 7 Transporting the 7 TOWIBS e eere ri 295 59 44 93 s 8 Other Manuals 8 Cautions and Warnings Symbols 4 uoce doce x xo 9 X X o9 oko ow ox ow 8 General Safety Instructions 9 Functional Description for Battery Condition Displays 10 Functional Description of Additional Status Displays 10 Know Your Machine s s s es x w k we lt 12 Conrol 18 Component 14 Functional Description of Control Switches 16 2 2 2 eee Z s 18 Maintenance Schedule 18 Vacuum Shoe Maintenance 19 Spray Nozzle
87. ion 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 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 1n 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 16 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 15 identified as part of the Service Test Mode when relevent assist 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 monit
88. ive 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 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 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 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 2 Solution Pump Over Excessive current draw was sensed Code sets at approx 4 3A Current or more Check for shorted pump winding shorted wiring 3 Restore Solenoid Over Excessive current draw was sensed Code sets at approx 4 Current or more Check for shorted solenoid winding shorted wiring Misting Solenoid Over Excessive current draw was sensed Code sets at approx 0
89. ive 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 amp 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 V B plus O LU BLK Speed limit BLK WHT A2 Pin assignments RA R 5 02k Ohm Pot Low B Service Manual ES4000 Wheel System Traction 167 POT WIPER BRAKE MODE 1 2 LOW m Used 9 pins Not Used 9 pins SPEED LIMIT HORN POT A2 J10 pin outs Wheel Drive Motor Typical Current AMPS Wire colors Transport Full Throttle 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 DETERGENT switch Indicator Another available method is to use the optional hand held Curtis programmer model 1311 Speed Controller Status Light Display Functions If 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
90. l 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 k when you press the Detergent button to leave a 2nd level X menu 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 FROZEN PARAMETERS T FROZEN PARAMETERS 2 HOUR METER 3 Battery Voltage FROZEN PARAMETERS rare FROZEN PARAMETERS EV FROZEN PARAMETERS 5 VAC MTR CURR FROZEN PARAMETERS 6 R BRUSH CURR FROZEN PARAMETERS 7 5 ACT CURR FROZEN PARAMETERS 8 BRUSH ACT CURR 6 Rear brush current 7 Shoe actuator current 8 Brush actuator current 9 Machine mode of operation Transport Figure E 28 Frozen Extract Sweep Parameters Display 45 Service Manual ES4000 Control System 46 FROZEN PARAMETERS 9 MODE FROZEN PARAMETERS 1 ERROR CODE ME Lco 37 Display 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
91. 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 AN 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 Service Manual ES4000 General Information 8 Towing AN CAUTIONI 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 i Brake disengaged Arrius UA ME ET RENS a Mp FT kc Ue es v gt M EEUU gir Tae KE TN pr Un GT Tn En Other Manuals Available The following man
92. n clear the weldment linkage bump on the right side Shroud lifted up and off 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 Nilfisk Advance 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 heel bearing Mounting washer and bolt Tire and wheel ass 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 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 5 Ifthe 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 t
93. nce Checklist Whenever there is a vacuum problem check over the entire system Use the checklist below 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 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 A 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 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 sna
94. ns INPUT OUTPUT TABLES Designation Wire Description Signal Nominal Reference Range Comments ID Characteristic Value To Color Solution Pump output PWM voltage sweep mode DC voltage extract mode voltage on this pin cycles between 0 and 24V pump is energized when this voltage 0V PWM period 6 seconds duty cycle 17 for sweep mode amp 100 for extract mode Org Brush Deck Actuator motor output 24V when lowering deck 0 bik volts when raising deck Rear Brush Analog voltage voltage is present only if brush red Motor Current motor is ON voltage range Sense input corresponds to motor load voltage on range 3 to 21A this wire wrt GND represents the motor current Battery input terminal of battery wht un Service Manual ES4000 Electrical System 74 Designation Wire Description Signal Nominal Reference Range Comments ID Characteristic Value To Color output 1 wht Shoe Actuator 10 grn motor output DC voltage 24V 20 5 to 25 5 V 24V when lowering deck 0 volts when raising deck ground j22 O speed limit pot wiper output speed limit pot high ref Battery input Analog voltage DC voltage DC voltage OV corresponds to machine stopped 5V corrersponds to max allowed speed power supply voltage provided by
95. ns at the Hand Controls ISO 5349 1 22m s2 044 m s2 uncertainty Transport 16 percent 9 degrees Gradeability 23 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 ST 31 5 inches 80 m ENG 1825 Nilfisk Advance 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 150 06 RETRACTED NO LOAD 5 38 06 EXTENDED NO LOAD LI ur Deck Lift Actuator settings DECK LIFT ACTUATOR SETTINGS Shoe Lift Actuator Settings 564 06 RETRACTED LOAD EXTENDED LOAD Main Frame Chassis H e SCALE 0 250 SHOE LIFT ACTUATOR SETTINGS 0 Rear Wheel assembly Vacuum Shoes Service Manual ES4000 Chassis System 26 Lift actuator assembly Lower Attachment unit for Recovery System Lift actuator assemblies
96. ntrol Panel Solution Tank Fill Cover Recovery Tank Cover Vacuum Motor Filter Housing Strainer Basket Recovery Tank Shutoff Float Recovery Tank Drain Hose Recovery Hose Dry Mode Port Accessory Port Seat Prop Rod Rear Brush End Cap Machine Battery Connector Solution Filter Solution Shutoff Valve Steering Wheel Wet Mode Port General Information 12 Service Manual ES4000 Control Panel o O m gt Key Switch Main Power Solution ON OFF Switch Detergent ON OFF Switch Dry Mode Switch LCD Display 1 Fault Codes Solution Tank Level Indicator Transport Mode Indicator Detergent Indicator Detergent Ratio Indicator Battery Indicator Prespray mode Indicator Maintenance Mode Indicator Hour Meter 10 Restore Mode indicator 11 Sweep Mode Indicator E12 Recovery Tank Full Indicator E13 Low Voltage Cutout Indicator General Information 13 F Wet Mode Switch G Interim Mode Switch H Restorative Mode Switch I PreTreat Mode Switch J Horn Switch K Vacuum ON OFF Switch APPEARS FOR FIRST 10 SECONDS APPEARS AFTER 10 SECONDS E T umi 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 Cir
97. nut that secures the nozzle and pull it from the brush housing slot with the hose still connected A 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 A 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 N 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 Figure 5 Nozzles are shown attached to the Scrub Deck Service Manual ES4000 Solution System 126 Chemical Pump Removal AN CAUTION Disconnect the machine s battery pack connector before servicing machine 1 See Figure 5 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 AN Servic
98. o the bolt threads before tightening the bolt washer and wheel Figure WNT 1 Nilfisk Advance Service Manual ES4000 159 Wheel System Traction Functional Description The drive wheel assembly is directly connected to the speed controller which not only provides 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 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 1t will not engage these systems unless placed in Service Test Mode or one of the vacuuming modes The Electromagnetic Brake 15 engaged whenever the foot pedal is in Neutral When the Brake is released Forward Reverse 16 enabled and the drive wheel 15 energized Service Manu
99. of the batteries should be safely done in accordance with your local environmental regulations General Information 9 Service Manual ES4000 General Information 10 Functional Description for Battery Condition Displays The battery condition indicator K consists of three lights a green 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 details The voltage levels for the various indications are as follows the voltages shown represent the voltage under load SY Sundad Item 0 Yellow amp Red 19 50 19 99 21 00 21 49 Red 1900 1949 21 50 21 99 Flashing Red Cutoff 19 00 21 50 A 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 contr
100. of the solution tank see molded FILTER callout No tools are needed to remove the filter hand tighten only AN Service 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 for more than 2 seconds while the controller is in any mode except standby to initiate a purge cycle A 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 18 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
101. ol 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 KNOW YOUR MACHINE As you read this manual you will occasionally run across bold number or letter in parentheses example 2 These numbers refer to an item shown on these pages unless otherwise noted Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text 1 Operator s Seat 11 Front Roller Bumper 2 Seat Adjustment Knob 12 Brush Idler Removal Knob 3 Emergency Stop 13 Brush Deck 4 Control Circuit Circuit Breaker 10 Amp 14 Debris Hopper 9 Drive Wheel Circuit Breaker 70 Amp 15 Vacuum Shoes 6 Detergent Cartridge Access Cover 16 Solution Tank Drain Hose 1 Battery Charger optional 11 Rear Wheel 8 Battery Charger Access Door 18 Detergent Cartridge 9 Drive Wheel 19 Battery Compartment under seat 10 Drive Pedal Directional Speed 20 Solution Spray Jets Service Manual ES4000 Know Your Machine Steering Wheel Tilt Adjust Knob Co
102. oll the menus over from the last 19 to the first 1 or visa versa 7 enter sub menu press PreTreat mode I button 8 To change the selection within a sub menu use the Interim mode button to scroll up Qh and the Restorative mode H button to scroll down through the choices k 9 the current choice and back to the main menu press the Detergent ON OFF button 10 See Figure 10 next page for a list of all available categories for the top level menu Service Manual ES4000 Control System 35 13 SERVICE TEST gt 13 Service Test Mode instructions All applicable options are identified Service Test Mode 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 1s 20 55 volts and alternate setting gel maintenance free is 21 75 volts Figure E 11 shows the display LOW VOLT CUTOUT W
103. olution 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 1 1 L2 and L3 Also fitted is a short flexible Drain Hose to drain the tank for system maintenance electrical circuit that energizes the solenoid coils is activated through the operator panel buttons and main controller assembly 1 N 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 15 lowered and the shoes are retracted upward if they are down When the throttle 1s engaged forward the solution pump the brush motors and the restore valve will be activated while the Chemic
104. olution 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 1s 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 Solut
105. oring of various inputs Some outputs 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 15 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 B LCD Display Use Control Panel image for button locations 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 Vacuum switch together KD 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 amp Detergent ON OFF LED 5 Release both
106. otor Overload Shoe Lift Actuator Overload Vacuum Motor Overload gt gt x i lee _ Sweep e dsl e _ Vacuum LED Service Manual ES4000 Control System Disable System Flash Indicator Fault Description Display 2 gla dal p 5 amp 9 58 2 D AIN EE Maintenance Solenoid Overload Vacuum Contactor Coil Overload Brush Contactor Coil Overload Chemical Pump Overload Solution Pump Overload Restore Solenoid Overload Misting Solenoid Overload Rear Brush Motor gt lt gt gt gt gt gt gt gt gt gt Chemical 1 N al amp e 3 gt g gt E 15 Overload Maintenance x 30 Solenoid Open Front Brush x 7 31 motor Open Brush Deck Lift Actuator 32 Open Vacuum Motor 7 x x 33 Open Shoe Lift Actuator Open gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt Solution gt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt Extract gt gt lt gt lt gt lt gt lt gt lt gt lt Sweep xf Ll Lb bel o Recovery CO IN EN Brush Contactor Coil Open CO o 2 Service Manual
107. over panel to access the controller 1 Observe the error status fault indicator DETERGENT LED on the operator control panel If a programmer 15 available connect 14 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 1n 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 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 1t 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 1t 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 Putthe programmer into test mode
108. pped 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 4 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 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 or wherever the airflow is forced to make 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 T
109. pring 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 Spring Housing Hal 2 Screw the spring housing assembly onto the threaded drive screw a few turns 9 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 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 89 mm a Ifthe 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 18 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
110. pub System Las Z dr 4 UP Wh ox ow 4 deo SESS 130 Functional Description aia x e x edEE 3o oG 4X 4 130 Scrub System Circuit Description 191 Component 132 Maintenance and Adjustments 133 Scrub System Brush Maintenance 133 TrouwDlesioH x x5 9 lt 48 lt Q amp 4 3 PE 4 Q 134 Removal and Installation 135 Scrub Deck Removal 185 Scrub Deck Actuator Removal 140 Actuator Drive Nut Adjustment 144 General Instructions for Actuator Motors 144 Scrub Deck Lift Actuator Drive Nut Adjustment 145 Brush Motor 1 147 Scrub Brush Belt Replacement 149 Scrub Brush Removal and Installation 150 Specifications a s ss as 30 151 ox um 493524 343 151 Bec Tools s e s mo w m G RUE ROW OWwOGBUR bow ded ow X ee Q Q jQ Q 3 152 Actuator Power Cord Adaptor Part 56407502 152 Steering System e ox 9o ox OE OX s s s sz s se s s s sz s s sz sz sz s s sz s se sos OUS eos 153 Functional
111. re Nozzle Maintenance 29 GPM Spec 033 orifice diameter Brass Nozzle tip 1 D 1 8 K1 Nozzle Restoration GPM SPec 091 orifice diameter Brass Nozzle tip 1 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 Nilfisk Advance Service Manual ES4000 130 Scrub System Functional Description Cylindrical Brush System Overview 54000 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 amp 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
112. ription Measured Comments 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 Front Brush Motor 0 028v Brush running with deck up Current Sense 0 111v Brush running with deck all the way down Notused Ntued 1 brn yel Battery lead With vacuum motors running Battery input With vacuum motors running blu org Maintenance 0 18v When energized solenoid output J2 10 J2 41 J J3 1 3 2 J3 3 43 4 gra blk Seat Switch input Switch closed Switch open J3 5 blu blk Reverse Direction Reverse input from Speed Controller input GND when moving Neutral or Forward reverse J3 6 red wht Fwd Reverse Reverse or Neutral input from Speed Controller input GND when moving in forward or reverse 43 7 org blu Speed Controller With no speed control faults Status input input pulses between B and GND to indicate error status from Speed Controller brn yel Battery lead With vacuum motors running grn bik Horn output 13 3v off Connects to battery negative to sound horn With speed control faults The voltage jumps lower as the code signal is communicated J3 8 J3 9 0 01v on org red Constant power supply H 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
113. rks 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 1 Brake Pin 6 Brake Status 1 Main Controller A2 Speed Controller Service Manual ES4000 Wheel System Traction 163 F1 150 A fuse 24v Battery CB 1 Eum cu we O CB 2 S1 Key S4 Emergency S2 Seat Switch Stop Switch Switch FWD REV Pin 6 Brake Speed Limit Internal Voltmeter B POT Low A2 Speed 5v POT High Controller Signal A1 Main Controller Drive Wheel Motor peed Control System Functional Electrical Schematic S
114. ront 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 amp 8 brush solenoid and brush lift actuator motor 1 Detected error codes from the main controller are displayed on the hour meter LED display as they occur See Functional Description section wiring diagram AN 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 amp Dla through D 10 2 To REMOVE the Scrub Deck assembly use the instructions on the following pages 3 INSTALL the Scrub Deck assembly follow the removal steps in reverse order Scrub Deck Service Manual ES4000 Scrub System 136 Scrub Deck mounting hitch pin 4 27 _ SS Y LYVCOQQQQOQOOOCCOA TOL c AG I Figure D 1a ROTATION Service Manual ES40
115. s 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 1 24 15 Batt Gauge 5 Batt Gauge 5 Bar Bar 3 23 85 Batt Gauge 4 Batt Gauge 4 Bar Bar 5 23 55 Batt Gauge 3 Batt Gauge 3 Bar Bar 7 23 25 Batt Gauge 3 Batt Gauge 2 Bar Bar 22 95 Batt
116. s not sensing any current flow through the vacuum motor ground circuit for at least 5 seconds Senses lt 2 Amps for 5 seconds Check motor wiring contactor The Main Machine Controller is trying to move the actuator but it is not sensing any current flow Senses lt 67mA for 10 seconds Check Actuator wiring The Main Machine Controller has attempted to energize the Brush Contactor but it is not seeing any current flow Senses lt 40 m Amps for 10 seconds Check for open Contactor winding wiring The Main Machine Controller has attempted to energize the Vacuum Contactor but it is not seeing any current flow if Senses lt 40 m Amps for 5 seconds Check for open Contactor winding wiring The Main Machine Controller has energized the detergent pump but it is not sensing any current flow Senses lt 100 m Amps for 5 seconds Check for open pump winding wiring The Main Machine Controller has energized the Brush Contactor but it is not sensing any current flow through the brush motor ground circuit for at least 5 seconds Senses lt 2 Amps for 10 seconds Check Motor Contactor contacts Wiring The Main Machine Controller has energized the solution pump but it is not sensing any current flow Senses lt 150 mA for 10 seconds Check for open pump winding wiring Service Manual ES4000 LCD Code Definition Display Code Restore Solenoid Open Misting Solenoid Open Front Brush Motor Stuck Clos
117. s 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 AN Special Service Note On all machines 24V 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 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 CBRE 4 Battery at 40 2 bars 5 Bsttery at 20 1 bar 6 Battery depleted no bars AN Important Note See the Main Control Board Special Program Option
118. ses gt 20 m Amps for 10 seconds The Main Machine controller is sensing current flow through its internal switch for the Brush Contactor Coil circuit when it has not requested that the switch be turned on Senses gt 40 m Amps for 10 seconds The Main Machine controller is sensing current flow through its internal switch for the Vacuum Contactor Coil circuit when it has not requested that the switch be turned on Senses gt 40 m Amps for 5 seconds The Main Machine controller is sensing current flow through its internal switch for the restore solenoid circuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 10 seconds The Main Machine controller is sensing current flow through its internal switch for the misting solenoid circuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 10 seconds The Main Machine Controller is sensing current flow through the Rear Brush Motor ground circuit when it has not energized the Brush Motor Contactor Senses gt 2A for 10 seconds Check for a short in the harness wiring to the motor Service Manual 54000 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 Sys
119. sing 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 Ifthe 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 18 mm SOCKET Not a screwdriver Turning the nut one click will change the distance approximately on tenth of an inch 2 5 mm Remove Adjuster Cover A Note Use a 1 2 18mm socket to turn the adjuster Rotate Nylon Nut to Adjust 5 After each adjustment hold the spring housing assembly run the actuator IN amp OUT and recheck the adjustments Reinstall the adjuster cover Service Manual ES4000 Recovery System 110 Specifications Vacuum Motor s 2 of 5 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 2010 Nilfisk Advance Service Manual ES4000 112 Solution System Functional Description See Figure 5 1 molded plastic polyethylene tank stores the machine s extraction s
120. t 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 amp OUT dimensional specification for the actuator motor that is used on the 54000 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 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 Ifthe 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 amp 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 s
121. t amps 20 Brush hour meter hours The instantaneous views are preferred over the alternating views since they show what the brushes are doing in real time 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 1 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 16 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 1s the newest value and 64 1s the oldest value that occurred 6 3 seconds earlier B LCD Display 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 through 64 See figures E 29 and E 30 for examples of submenus Keypad navigation 1s the same for each level so the following set of 3 rules applies to each level 1
122. tem Detergent LED 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 amp Sweep LEDs will flash and the LCD will revert to the normal sweep mode screen Disable System Flash Indicator Fault Description Speed Control Fault Brush Deck Lift Actuator Overload Front Brush Display Code Misting Solenoid M
123. the Main Control Board 53 PN arne ea eae OS 55 Shop Measurements Main Controller 55 Service Manual ES4000 Contents ili Electrical Systema v 93 xo Xox G e Q Q w Ox X XX 58 Functional Description e eaves Ew ee E OR a a eza OEE 58 Battery Specifications 62 Battery Charger on board and portable 62 Removal and Installation 62 Install Batteries gt gt s x wow x 9 NR 63 When Servicing Batteries 63 Battery Low Voltage Cutout Feature Description 66 Battery Condition Indicator Description 66 Battery LOCK Value verv eek xw s sz xo ore REOR s s e oa 67 Maintenance and Adjustments 69 Battery Maintenance 69 Charging the Batteries 69 To Charge the 69 Battery Testing oxk ox o o o X b o a 70 Machine and Chassis Wiring 71 Machine and Chassis T2 5 01263 UK 612 lt x x m We s ue S 73 INPUT OUTPUT TABLES to Shop Measurements
124. 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 1s 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 on o 4 51 Key Switch A1 Main Controller Internal Voltmeters TO J3 13
125. tions 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 N 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 Pushthe 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 1f nec
126. 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 lashes for Speed Control Fault Codes Ci 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 Temperature gt 97 C 206 or lt 25 13 9 Operation in extreme environments 1 Throttle pot defective _ 1 2 Broken speed limit pot battery voltage too low 1 Battery voltage lt 17 volts 2 Vehicle operating with charger attached ___ Main contactor driver fault 2 Broken throttle pot or throttle mechanism Service Manual ES4000 Wheel System Traction 1 70 DETERGENT EXPLANATION POSSIBLE CAUSE BUTTON LED DISPLAY OOO OO brake On fault 1 Electromagnetic brake driver shorted 2 KS1 and Throttle turned ON at the same time OOO OOOO brake Off fault 1 Electromagnetic brake driver open 2 Misadjusted throttle pot OOOO O current sense fault 1 Short in motor or in motor wiring ___ pp
127. uals 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 AN DANGERI Is used to warn of immediate hazards that will cause severe personal injury or death AN WARNING Is used to call attention to a situation that could cause severe personal injury AN CAUTION Is used to call attention to a situation that could cause minor personal 1 or damage to the machine or other property Service Manual ES4000 General Safety Instructions Specific Cautions and Warnings are included to warn you of potential danger of machine damage bodily harm A 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
128. ve 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 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 Operators Control Panel 4 Operator s Control Panel gt n Seat Prop im To access the battery compartment tip the operator s seat forward and set the prop rod Remove the battery A cables from inside the battery compartment Figure 1 y m 3 1 Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage If damage 15 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 2 i cable disconnected Figure E 2 Service Manual ES4000 Electrical System 65 The terminals on the battery cables are marked
129. 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 bik yel Shoe Actuator 24 4v up Measured when actuator was moving in both motor output directions 0 13v down 1 10 wht grn Shoe Actuator 24 6v down Measured when actuator was moving in both motor output directions 0 12v up Battery input With vacuum motors running J22 Netued oo J233 Notused J2 4 blk wht Speed limit output Restore mode Maintenance mode Prespray mode s roc nir 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 Wire Description Measured Comments Color Value Battery input 0 02v With vacuum motors running Battery input 0 02v With vacuum motors running Vacuum on with open hose J2 7 J2 8 J2 9 oO brn red oO 0 192 Motor Current Sense input 0 150v 0 028v Vacuum on with hose blocked J2 10 Front Brush Motor Brush running with deck up Current Sense input Brush running with deck all the way down S c S E bye 24 2v Battery input 0202 blu org Maintenance 0 18v When energized solenoid output J3 4 gra bik Seat Switch input 25 0v Switch closed yel vio 0 111v 42 11 42 12 43 1 J3 2 J3
130. ystem 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 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 AN 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

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