Nilfisk-Advance Captor 4300, Captor 4800, CR 1400, Captor 5400CR 1100, CR 1200 Quick Start Manual

10/03 Form Number 56043093

QUICK STQUICK ST

QUICK ST

ART TROUBLESHOOTING MANUALART TROUBLESHOOTING MANUAL

ART TROUBLESHOOTING MANUAL

Advance MODELS 56304000(4300 P), 56304001(4300 G), 56304003(4800 P), 56304004(4800 G), 56304006(5400 P), 56304007(5400 G) Nilfisk MODELS 56304009(1100 P), 56304010(1100 G), 56304012(1200 P), 56304013(1200 G), 56304015(1400 P), 56304016(1400 G)

CaptorCaptor

Captor

™™

™

4300, 4800, 5400 4300, 4800, 5400

4300, 4800, 5400

CR 1100, 1200, 1400CR 1100, 1200, 1400

CR 1100, 1200, 1400

76 76

76 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

GENERAL INFORMATION ................................................................................................................................................. 1-2

SAFETY INSTRUCTIONS ...................................................................................................................................................... 3

SPECIFICATIONS ................................................................................................................................................................ 4-5

MAINTENANCE .................................................................................................................................................................. 6-7

PM CHECKLIST ...................................................................................................................................................................8-9

KNOW YOUR MACHINE ................................................................................................................................................ 10-19

CONTROL ERROR CODES ............................................................................................................................................ 13-15

GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ............................................................. 16

OPERATOR’S COMPARTMENT ....................................................................................................................................... 17

GENERAL TROUBLESHOOTING FLOW CHARTS .....................................................................................................18-23

WHEEL DRIVE SYSTEM ...................................................................................................................................................... 24

TROUBLESHOOTING CHECK LIST .................................................................................................................................. 24

STEERING SYSTEM ............................................................................................................................................................ 25

STEERING SYSTEM TROUBLESHOOTING OVERVIEW ............................................................................................... 25

TROUBLESHOOTING GUIDE ............................................................................................................................................ 25

SWEEPING SYSTEM ...................................................................................................................................................... 26-33

MAIN BROOM ............................................................................................................................................................... 26-27

SIDE BROOMS .............................................................................................................................................................. 28-29

SIDE BROOM LIFT ACTUATOR ....................................................................................................................................... 30

DUST CONTROL IMPELLER ........................................................................................................................................ 31-32

SHAKER MOTOR ................................................................................................................................................................ 33

HOPPER SYSTEM ...........................................................................................................................................................34-40

LIFT CYLINDER ..............................................................................................................................................................34-37

DUMP DOOR CYLINDER ..............................................................................................................................................38-40

SCRUB SYSTEM ............................................................................................................................................................. 41-50

DECK LIFT ACTUATOR .................................................................................................................................................41-48

SCRUB MOTORS .......................................................................................................................................................... 49-50

SOLUTION SYSTEM ............................................................................................................................................................ 51

SOLUTION SOLENOID VALVE ......................................................................................................................................... 51

RECOVERY SYSTEM ....................................................................................................................................................... 52-56

VACUUM MOTOR .........................................................................................................................................................52-54

SQUEEGEE LIFT ACTUATOR .......................................................................................................................................55-56

ENGINE SYSTEM ............................................................................................................................................................ 57-60

ENGINE SPECIFICATIONS ............................................................................................................................................... 57

ENGINE MAINTENANCE .................................................................................................................................................. 57

CHECK ENGINGE LIGHT TROUBLESHOOTING ............................................................................................................. 57

SYSTEM FAULT CODES ...............................................................................................................................................58-59

HYDRAULIC SYSTEM .....................................................................................................................................................61-68

HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................. 61

GENERAL HYDRAULIC SPECIFICATIONS TABLE ........................................................................................................ 62

HYDRUALIC DIAGRAM ..................................................................................................................................................... 66

HYDRUALIC SCHEMATIC ................................................................................................................................................. 67

HYDRUALIC COMPONENT LOCATION .......................................................................................................................... 68

ELECTRICAL SYSTEM ....................................................................................................................................................69-73

ELECTRICAL COMPONENT LOCATION ......................................................................................................................... 69

WIRING DIAGRAM ............................................................................................................................................................ 70

WIRING SCHEMATIC........................................................................................................................................................ 71

ENGINE HARNESS ............................................................................................................................................................ 72

ENGINE WIRING HARNESS DETAIL .............................................................................................................................. 73

Note: Note:

Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.

TT

T

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

11

1

KK

INTRODUCTIONINTRODUCTION

INTRODUCTION

This manual will help you get the most from your Nilfisk-Advance rider Scrubber-Sweeper. Read it thoroughly before servicing the machine. Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (

Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (

Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (

BB

B

).).

).

This product is intended for commercial use only.

PP

P

ARTS AND SERVICEARTS AND SERVICE

ARTS AND SERVICE

Repairs, when required, should be performed by your Authorized Nilfisk-Advance Service Center, who employs factory trained service personnel, and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.

Call the NILFISK-ADVANCE DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing your machine.

(Dealer, affix service sticker here.)

NAME PLANAME PLA

NAME PLA

TETE

TE

The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. 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.

MODEL NUMBER

SERIAL NUMBER

HOPPER SAFETY SUPPORTHOPPER SAFETY SUPPORT

HOPPER SAFETY SUPPORT

WW

W

ARNING!ARNING!

ARNING!

Make sure the Hopper Safety Support

(KK)(KK)

(KK) is in place whenever attempting to do any maintenance work under or near the raised hopper. The Hopper Safety Support

(KK)(KK)

(KK) holds the hopper in the raised position to allow work to be performed under the hopper. NEVER rely on the machine’s hydraulic components to safely support the hopper.

JACKING THE MACHINEJACKING THE MACHINE

JACKING THE MACHINE

CAUTION!CAUTION!

CAUTION!

Never work under a machine without safety stands or blocks to support the machine.

• When jacking the machine, do so at designated locations (Do Not jack on the hopper) – see jacking locations

((

(

4444

44

))

).

GENERAL INFORMAGENERAL INFORMA

GENERAL INFORMA

TIONTION

TION

2 2

2 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

TRANSPORTING THE MACHINETRANSPORTING THE MACHINE

TRANSPORTING THE MACHINE

CAUTION!CAUTION!

CAUTION!

Before transporting the machine on an open truck or trailer, make sure that . . .

••

• All access doors are latched securely.

••

• The machine is tied down securely - see tie-down locations

((

(

66

6

))

).

••

• The machine parking brake is set.

TOWING OR PUSHING A DISABLED MACHINETOWING OR PUSHING A DISABLED MACHINE

TOWING OR PUSHING A DISABLED MACHINE

CAUTION!CAUTION!

CAUTION!

The machine’s drive propelling pump is manufactured with a selectable tow valve. This valve prevents damage to the hydraulic system when the machine is being towed/pushed short distances without use of the engine.

To access the valve, open the Engine Compartment Door

((

(

2222

22

))

) and lift off the Right Engine Compartment Access Panel

((

(

3737

37

))

). Locate the valve as shown on the underside of the hydrostatic pump by reaching under the radiator. Turn the valve 90 degrees, this disengages the hydrostatic lock between the motor and pump.

The hydrostatic pump can be damaged if the machine is towed with the valve in the normal working position

(A)(A)

(A). Reference the

illustration below for the normal working setting

(A)(A)

(A) and the free wheeling towing setting

(B)(B)

(B). Note: If the tow valve is left in free

wheeling

(B)(B)

(B ) position the hydrostatic pump can’t drive the machine FWD or REV. No damage will result, just re-set valve to the normal

working setting

(A)(A)

(A). Tow or push machine no faster than a normal walking pace (2-3 miles per hour) and for short distances only.

If the machine is to be moved long distances the drive wheel needs to be raised off the floor and placed on a suitable transport dolly.

OTHER MANUALS AOTHER MANUALS A

OTHER MANUALS A

VV

V

AILABLEAILABLE

AILABLE

The following manuals are available from the Nilfisk-Advance Literature Service Department, for your Rider Scrubber/Sweeper:

••

• Parts List - Form Numbers 56042440 (all systems except hydraulic)

56042445 (hydraulic system)

••

• Operation Manual - Form Numbers 56041546 (Danish, Norwegian, Swedish, Finnish)

56041547 (English, German, French, Netherlands) 56041548 (Spanish, Portuguese, Italian, Greek)

• Mechanical Repair Service Manual 56043094

BOTTOM VIEW OF HYDROSTBOTTOM VIEW OF HYDROST

BOTTOM VIEW OF HYDROST

AA

A

TIC PUMPTIC PUMP

TIC PUMP

GENERAL INFORMAGENERAL INFORMA

GENERAL INFORMA

TIONTION

TION

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

33

3

CAUTIONS AND WARNINGSCAUTIONS AND WARNINGS

CAUTIONS AND WARNINGS SYMBOLSSYMBOLS

SYMBOLSSYMBOLS

SYMBOLS

Nilfisk-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.

DANGER!DANGER!

DANGER!

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

WARNING!WARNING!

WARNING!

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

CAUTION!CAUTION!

CAUTION!

Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.

GENERAL SAFETY INSTRUCTIONSGENERAL SAFETY INSTRUCTIONS

GENERAL SAFETY INSTRUCTIONS

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

WARNING!WARNING!

WARNING!

••

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

••

• While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills.

••

• Keep sparks, flame and smoking materials away from the battery and fuel system.

••

• Remove all jewelry when working near electrical components.

••

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

••

• Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.

••

• 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.

••

• This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide adequate ventilation when operating this machine.

• Keep the LP tank Service Valve closed when the tank is not in use.

CAUTION!CAUTION!

CAUTION!

••

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

••

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

••

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

••

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

••

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

••

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

••

• 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 battery must be removed from the machine before the machine is scrapped. The disposal of the battery should be safely done in accordance with your local environmental regulations.

SASA

SA

VE THESE INSTRUCTIONSVE THESE INSTRUCTIONS

VE THESE INSTRUCTIONS

4 4

4 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SPECIFICASPECIFICA

SPECIFICA

TIONSTIONS

TIONS

General Specifications common to General Specifications common to

General Specifications common to

All ModelsAll Models

All Models

English (Metric)English (Metric)

English (Metric)

DimensionsDimensions

Dimensions

Gas & PropaneGas & Propane

Gas & Propane Length 105 inches (267cm) Height 58 inches (147cm) Height w/overhead guard 79 inches (200cm) Ground clearance 3 inches (7.6cm) Minimum ceiling height dumping clearance 92 inches (233.6cm)

WeightsWeights

Weights

Net weight* 4040 lbs. (1832kg) Gross weight** 4720 lbs. (2141kg)

Speed and GradeabilitySpeed and Gradeability

Speed and Gradeability

Maximum travel speed 6 mph (9.6km/h) Maximum reverse speed 4 mph (6.4km/h) Maximum grade angle scrubbing 6 deg. Maximum grade angle non-scrubbing 8 deg.

Sound LevelSound Level

Sound Level

At operators ear 85.1 dBA

Sweep SystemSweep System

Sweep System

Sweeping path w/out side broom(s) 40 inches (102cm) Main broom length 40 inches (102cm) Main broom diameter 14 inches (35.5cm) Side broom diameter 20 inches (50.8cm) Side broom bristle length 7 inches (17.7cm)

Hopper SystemHopper System

Hopper System

Capacity 9.2 Cu. Ft. (261l) Lifting capacity 550 lbs. (250kg) Dump height (variable) Max. 60 inches (152cm) Dump height with door open 56-1/2 inches (143.5cm)

Dust Control SystemDust Control System

Dust Control System

Filter type: Pleated paper panel Filter dimension 3-3/16" x 20" x 27" (8cm x 50.8cm x 68.5cm) Filter media area 78 ft2 (7.25m2)

Steering SystemSteering System

Steering System

Type: Power steering unit with rack and pinion Turns lock to lock right: 4-3/8 Turns lock to lock left: 3-3/8 Minimum aisle turn width 118 in. (300cm) left and right

Hydraulic SystemHydraulic System

Hydraulic System

Oil type: SAE 10W-30 System fill capacity 11 gal. (41.6l)

Engine SystemEngine System

Engine System

Engine coolant fill capacity 10-11 qts. (9.5-10.4l)

Recovery SystemRecovery System

Recovery System

Vacuum water lift (sealed) minimum 22 inches Vacuum water lift (open hole adapter 1") minimum 20 inches

*Net Weight: *Net Weight:

*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and full tank of fuel. **Gross Weight:**Gross Weight:

**Gross Weight:**Gross Weight:

**Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and full tank of fuel.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

55

5

SPECIFICASPECIFICA

SPECIFICA

TIONSTIONS

TIONS

Height

Length

Widt h

FRONT VIEW

SIDE VIEW

Specifications common to Specifications common to

Specifications common to

Deck SizeDeck Size

Deck Size

English (Metric)English (Metric)

English (Metric)

Model designation: (43") Model designation: (43")

Model designation: (43") = Captor 4300 / CR 1100

(48") (48")

(48") = Captor 4800 / CR 1200

(54") (54")

(54") = Captor 5400 / CR 1400

43"43"

43"

48"48"

48"

54"54"

54"

Width w/out squeegee & deck 50 inches (127cm) 50 inches (127cm) NA Solution Tank Capacity NA 80 gal. (303l) 80 gal. (303l) Recovery Tank Capacity NA 80 gal. (303l) 80 gal. (303l) Cleaning Rate per hour (theory) NA 84,500 ft2 (7,850m2)NA Sweeping path w/side brooms (2) X 62 in. (158cm) 62 in. (158cm) Sweeping path w/side broom (1) NA X X Sweeping rate per hour NA 163,700 ft2 (15,210m2) 163,700 ft2 (15,210m2) Scrub Brush quantity 3 3 4 Scrub Brush diameter 15 inches (38cm) 17 inches (43cm) 14 inches (36cm) Squeegee Tool Width NA 57 in. (145cm) NA

NANA

NA = Not Available at time of printing.

6 6

6 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

MAINTENANCE SCHEDULEMAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE

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

MAINTENANCE ITEMMAINTENANCE ITEM

MAINTENANCE ITEM

PERFORM DAILYPERFORM DAILY

PERFORM DAILY

Perform the “After Use” maintenance steps X

Check parking brake X

Check engine oil X

*Clean main and side brooms X

Check filter indicator and lights (hyd & air) X

Check engine coolant level X

Check hydraulic oil level X

MAINTENANCE ITEMMAINTENANCE ITEM

MAINTENANCE ITEM

15 hrs.15 hrs.

15 hrs.

30 hrs.30 hrs.

30 hrs.

150 hrs.150 hrs.

150 hrs.

300 hrs.300 hrs.

300 hrs.

500 hrs.500 hrs.

500 hrs.

1000 hrs.1000 hrs.

1000 hrs.

*Rotate main broom X

Clean solution filter X

*Inspect/adjust brooms X

*Clean hopper filter X X X

*Inspect broom housing skirts X

*Inspect hopper seals X

Clean radiator and oil cooler X

Perform engine maintenance X

*Inspect and grease steering rack X

Change the hydraulic “charge” oil filter X

Change reservoir hydraulic oil and filter X

Flush the radiator X

Engine fuel filter(s) gas or propane X

*See the Mechanical Repair Service Manual and Operator Manual for detailed maintenance information of systems listed.

• Sweeping

• Hopper

• Steering

• Dust control

• Squeegee

WARNING!WARNING!

WARNING!

Turn the key switch off, set the parking brake and disconnect the battery before servicing the machine.

AFTER USEAFTER USE

AFTER USE

11

1 Raise the squeegee, the scrub brushes, and the brooms. 22

22

2 Shake the dust control filter and empty the hopper. 33

33

3 Drain and flush the recovery tank. 44

44

4 Flush the vacuum hose and squeegee by opening the recovery tank lid and running water down the pickup tube on the right side

of the tank.

SERVICE NOTE:SERVICE NOTE:

SERVICE NOTE: Tip the recovery tank out and check the squeegee hose elbow below the tank to make sure it has

flushed out completely.

55

5 Remove and clean the squeegee tool (adjust as needed*). 66

66

6 Remove and clean the scrub brushes. Rotate the scrub brushes. 77

77

7 Wipe the machine with a damp cloth. 88

88

8 Perform all required maintenance before storage. 99

99

9 Move the machine to a clean, dry storage area. 1010

1010

10 Store the machine with the brooms, the squeegee and the scrub brushes in the UP position, and the tank covers open so that

the tanks can air out.

LUBRICALUBRICA

LUBRICA

TING THE MACHINETING THE MACHINE

TING THE MACHINE

Steering RackSteering Rack

Steering Rack Once every 150 hours pump a small amount of grease onto the steering rack and pinion components.

Also every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door hinges etc. Broom, squeegee and hopper pivots use composite bearings lubrication is not required.

MAINTENANCEMAINTENANCE

MAINTENANCE

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

77

7

ENGINE COOLANTENGINE COOLANT

ENGINE COOLANT

CAUTION!CAUTION!

CAUTION!

Do not remove the radiator cap when the engine is hot.

To check the engine coolant level, lift the Engine Compartment Door

((

(

2222

22

))

) and observe the coolant level on the Coolant Recovery

Tank

((

(

2323

23

))

). If the level is low add a mixture of half water and automotive type anti-freeze. Clean the radiator and oil cooler exteriors

by washing with low-pressure water or using compressed air every 30 hours. Service Note: The oil cooler tips out for easy cleaning.

ENGINE OILENGINE OIL

ENGINE OIL

Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the first 35 hours of operation and every 150 hours after that. Use 3.5 quarts (3.3 liters) with filter, of any SF or SG rated oil meeting API specifications and suited to seasonal temperatures. Refer to the Engine System for additional information. Replace the oil filter with every oil change.

TEMPERATURE RANGETEMPERATURE RANGE

TEMPERATURE RANGE

OIL WEIGHTOIL WEIGHT

OIL WEIGHT Above 60° F (15° C) SAE 10W-30 Below 60° F (15° C) SAE 5W-30

ENGINE AIR FILENGINE AIR FIL

ENGINE AIR FIL

TERTER

TER

The engine Air Filter

((

(

88

8

))

) is located in the engine compartment. Check the air mechanical vacuum filter Service Indicator

((

(

4646

46

))

) before

each use of the machine. Do not service the air filter unless the indicator is lit (red).

CAUTION!CAUTION!

CAUTION!

When servicing the engine air filter elements, use extreme caution to prevent dust and dirt from entering the engine.

The engine air filter contains a primary (outer) and a safety (inner) filter element. The primary element may be cleaned twice before being replaced. Replace the safety element every third time that the primary element is serviced. Never try to clean the safety element. To clean the primary filter element, remove the cover from the dust cup end of the canister and pull out the primary element. Clean the element with compressed air (maximum pressure 100 PSI) or wash it with water (maximum pressure 40 PSI). Do not put the element back into the canister until it is completely dry.

ENGINE MAINTENANCE (150 HOURS)ENGINE MAINTENANCE (150 HOURS)

ENGINE MAINTENANCE (150 HOURS)

At 150 hour intervals it is recommended that the following service be performed: Change oil and filter, clean and inspect spark plugs, check all engine belts condition and adjustment, check battery charge and level, check cooling system hoses and clamps and check general condition and performance of engine. Note: Note:

Note: Note:

Note: Reference the separately supplied PSI GM Power Train Products Operation and Maintenance manual for more detailed service data. PSI manual number is 3610000.

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

WW

W

ARNING!ARNING!

ARNING!

MAINTENANCEMAINTENANCE

MAINTENANCE

To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection when working with or near hydraulic system.

Check the Hydraulic Oil Level.Check the Hydraulic Oil Level.

Check the Hydraulic Oil Level. Remove the Right Engine Access Panel

((

(

3737

37

))

) and look at the gauge on the side of the reservoir. If the oil level is below the minimum level, add 10W30 motor oil until the gauge is 3/4 full. Do not fill above maximum. Change the oil if major contamination from a mechanical failure occurs.

SERVICE NOTE:SERVICE NOTE:

SERVICE NOTE: Remove the small access panel

((

(

4949

49

))

) directly above the reservoir to add oil. This panel is held on by (2) wing nuts on the underside of the panel. Only filtered oil should be added.

IMPORTIMPORT

IMPORT

ANT!ANT!

ANT!

This machine is equipped with an indicator light which lights if the “In Tank” oil filter requires changing. Remove filter element from the filter cup and replace with new filter. Hydraulic filter is found on top of the Hydraulic Reservoir

((

(

3636

36

))

).

Change the Hydraulic “Charge” Oil Filter

((

(

3535

35

))

).

Note: Oil should be warm, cold oil is thicker and may cause the light to come on intermittently until it warms up.

FIGURE 1FIGURE 1

FIGURE 1

8 8

8 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

Page 1 of 2

10/14/2003

Advance Captor 4300/4800/5400 G/P/D

Nilfisk CR 1100/1200/1400 G/P/D

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

Ref

OPERATIONAL INSPECTION ITEMS

OK

Defect Codes

(circle)

Does

Not

Work

1 Check Neutral Safety Switch Operation (To test depress drive pedal and start the

engine, it should not start.)

A B C

2 Engine Starting with pedal in neutral (if it will not start check neutral safety switch) A

3 Engine Idle 1200rpms A rough

4 Engine High Speed (high switch setting) 2400 RPM A low power

5 Drive Pedal Linkage (check for FWD/REV drive and any neutral creep) A B

6 Drive System Performance Noisy sluggish

7 Brakes (check both service & parking)

A B W

8 Steering excessive play

9 Hopper Up/Down (also check operation of the safety hopper support) A B

10 Hopper Dump Door Open/Close A B

11 Main Broom Raise /Lower A B

12 Side Broom Raise /Lower

A B C

13 Main Broom On/Off (will drift)

A B C

14 Side Broom On/Off <----->

15 Scrub System (Raise/Lower and auto scrubbing functions) <----->

16 Scrub Brush (pressure settings 1,2 &3) A B

17 Squeegee System (Raise/Lower and Auto Lift in Reverse) A B

18 Vacuum Performance (Sealed water lift 22" and 1- inch open hole adapter 20 inches)

C L W

19 Solution Control (On/Off and Flow Volume Min/Max) C L

20 Perform the machine self-diagnostic test. (see manual PN 56043093) <----->

21 Headlights, Gauges and (optional) accessories Rotating Beacon, Backup Alarm <----->

22 Dust Control Filter Shaker & Impeller <----->

23 Tilt Steering Mechanism and Seat Adjustment lever A B

Ref

VISUAL INSPECTION ITEMS

Comments

OK

Defect Codes

(circle)

Does

Not

Work

24 Side Broom Height (min bristle wear 3 inches) A B D W

25 Side Broom Motor B L

26 Hopper Cover Gasket D W

27 Hopper Dust Filter & Gasket D W

28 Impeller Motor (remove cover to access motor, fan & valve)

C L W

29 Hopper Dump Door Cylinder

A B L

30 Hopper Skirting & Seals (raise hopper to inspect)

D M W

31 Hopper Dump Door & Seal A B D W

32 Brake Cable, Brake Shoes & Drum Wear

A B W

33 Hopper Lift Cylinder & Magnetic Switch

A B L

34 Main Broom Pattern Adjustment (min bristle wear 2-1/2"

6.4cm length) & Magnetic on/off broom switch

2" (5 cm) wide pattern A B D W

35 Main Broom Motor (open left side access door to inspect) B L

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

99

9

Page 2 of 2

10/14/2003

Ref

VISUAL INSPECTION ITEMS (continued)

Comments

OK

Defect Codes

(circle)

Does

Not

Work

36 Broom Housing & Door Skirts

D M W

37 Battery Clean & Water C W

38 Engine Air Cleaner Element (inner & outer) Check SVR Indicator C W

39 Circuit Breaker/Relay panel (inspect electrical connections) C D

40 Hydrostatic Dump Valve (Tow Valve) B

41 Propulsion drive & Accessory Pumps L

42 Hydraulic System Hoses & fittings L

43 Propulsion Pump Hydro Back Cable & Clevis Connections

B M W

44 Propulsion Pump Hydraulic Filters Change with reservoir

filter

L

45 Engine, Oil Level, Hoses & Belts Add or Change L W

46 Engine Coolant Level Fill at reservoir L Add Coolant

47 Radiator & Oil Cooler Core Blockage L Needs Cleaning

48 Hydraulic Oil Reservoir Level (10W-30 engine oil only) Middle of sight glass L Add Oil

49 Steer Spindle & Drive Wheel motor (remove recovery tank) Grease pinion & rack D L

50 Rear Tire (check lug nut torque 100 FT LB, 135Nm)

L M W

51 Gasoline/Diesel Fuel Tank , Filter & Lines C L

52 LP Tank, Hoses & Fittings L

53 LP Fuel Filter SVR Life 1500 Hrs L Replace

54 LP Fuel Regulator, Lock Off Valve & Hoses L

55 Diesel Glow Plug Indicator Light Hard Starting Replace

56 Diesel Fuel Filter Yearly L Replace

57 Scrub Brushes, check for wear and rotate

D M W

58 Scrub Deck Skirts

D M W

59 Solution Solenoid Valve

D L W

60 Solution Flow Control Valve and Linkage A B D W

61 Solution Tank, Delivery Hoses & Filter Clean filter screen C L

62 Vacuum Motor Gasket & Metal Elbow Gasket

C D L

63 Vacuum Stand Pipe Screen Clean Screen

C D M

64 Recovery Tank Cover Gasket

L M W

65 Recovery Tank Drain Hose & Cap

C D L

66 Squeegee Pick-Up Hose & Metal Elbow Back flush

C D L

67 Squeegee Tool & Blades Clean & Rotate

A D W

68 Squeegee Casters (lubricate)

A D W

69 Squeegee Hydraulic Lift Cylinder

B D L

70 Rear Drive Wheel Motor L

71 Front & Rear Tires tread wear W

NOTE: For additional service information see service manual form number 56043093 and operators manual form number 56041547.

Defect Codes A needs adjustment C dirty or contaminated M missing B binding D damaged, bent or torn W worn out L leaks

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

10 10

10 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

1

2

3

4

5

6

7

9

8

10

6

13

14

15

16

17

18

19

20

21

12

22

23

24

44

46

47

45

48

49

11

1

Operator’s SeatOperator’s Seat

Operator’s Seat

22

2

Strobe Light (optional)Strobe Light (optional)

Strobe Light (optional)

33

3

Solution Tank FillSolution Tank Fill

Solution Tank Fill

44

4

Gasoline Tank CapGasoline Tank Cap

Gasoline Tank Cap

55

5

Fuel TankFuel Tank

Fuel Tank

66

6

Tie Down LocationsTie Down Locations

Tie Down Locations

77

7

Recovery Tank Drain HoseRecovery Tank Drain Hose

Recovery Tank Drain Hose

88

8

Engine Air FilterEngine Air Filter

Engine Air Filter

99

9

Left Engine Compartment Access PanelLeft Engine Compartment Access Panel

Left Engine Compartment Access Panel

1010

10

Main Broom Left Access DoorMain Broom Left Access Door

Main Broom Left Access Door

1111

11

BatteryBattery

Battery

1212

12

Hopper Lid Prop RodHopper Lid Prop Rod

Hopper Lid Prop Rod

1313

13

Front WheelFront Wheel

Front Wheel

1414

14

Left Side BroomLeft Side Broom

Left Side Broom

1515

15

Hopper Lid LatchHopper Lid Latch

Hopper Lid Latch

1616

16

HeadlightsHeadlights

Headlights

1717

17

Right Side BroomRight Side Broom

Right Side Broom

1818

18

Hopper CoverHopper Cover

Hopper Cover

1919

19

Dust Control FilterDust Control Filter

Dust Control Filter

2020

20

Dust Control Shaker AssemblyDust Control Shaker Assembly

Dust Control Shaker Assembly

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

1111

11

26

25

27

28

29

30

31

32

33

34

35

36

6

37

38

39

40

41

42

6

43

44

11

50

44

2121

21

Shaker Assembly LatchShaker Assembly Latch

Shaker Assembly Latch

2222

22

Engine Compartment DoorEngine Compartment Door

Engine Compartment Door

2323

23

Coolant Recovery TankCoolant Recovery Tank

Coolant Recovery Tank

2424

24

Steering WheelSteering Wheel

Steering Wheel

2525

25

Squeegee HandleSqueegee Handle

Squeegee Handle

2626

26

Squeegee Tool AssemblySqueegee Tool Assembly

Squeegee Tool Assembly

2727

27

Tail LightTail Light

Tail Light

2828

28

Exhaust Tail PipeExhaust Tail Pipe

Exhaust Tail Pipe

2929

29

Fuel Tank Compartment DoorFuel Tank Compartment Door

Fuel Tank Compartment Door

3030

30

Recovery Tank LidRecovery Tank Lid

Recovery Tank Lid

3131

31

Recovery Tank “Tip-Out” GripRecovery Tank “Tip-Out” Grip

Recovery Tank “Tip-Out” Grip

3232

32

Engine Air Filter HoodEngine Air Filter Hood

Engine Air Filter Hood

3333

33

Radiator CapRadiator Cap

Radiator Cap

3434

34

Oil Cooler “Tip-Out” LatchesOil Cooler “Tip-Out” Latches

Oil Cooler “Tip-Out” Latches

3535

35

Hydraulic “Charge” Oil FilterHydraulic “Charge” Oil Filter

Hydraulic “Charge” Oil Filter

3636

36

Hydraulic Reservoir / In Tank Return Oil FilterHydraulic Reservoir / In Tank Return Oil Filter

Hydraulic Reservoir / In Tank Return Oil Filter

3737

37

Right Engine Compartment Access PanelRight Engine Compartment Access Panel

Right Engine Compartment Access Panel

3838

38

Main Broom Right Access DoorMain Broom Right Access Door

Main Broom Right Access Door

3939

39

Access Door LatchAccess Door Latch

Access Door Latch

4040

40

Skirt AssemblySkirt Assembly

Skirt Assembly

4141

41

Inline Solution FilterInline Solution Filter

Inline Solution Filter

4242

42

Solution Tank Drain HoseSolution Tank Drain Hose

Solution Tank Drain Hose

4343

43

Rear Roller BumperRear Roller Bumper

Rear Roller Bumper

4444

44

Jacking LocationJacking Location

Jacking Location

4545

45

Engine Oil DipstickEngine Oil Dipstick

Engine Oil Dipstick

4646

46

Air Filter Service IndicatorAir Filter Service Indicator

Air Filter Service Indicator

4747

47

Fuel Filter (Gas Models)Fuel Filter (Gas Models)

Fuel Filter (Gas Models)

4848

48

Recovery Tank LatchRecovery Tank Latch

Recovery Tank Latch

4949

49

Hydraulic Reservoir Access PanelHydraulic Reservoir Access Panel

Hydraulic Reservoir Access Panel

5050

50

Water Level GaugeWater Level Gauge

Water Level Gauge

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

12 12

12 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

IMPORTIMPORT

IMPORT

ANT SERVICE TIPANT SERVICE TIP

ANT SERVICE TIP

Before any troubleshooting is done perform this troubleshooting special control system procedure.Before any troubleshooting is done perform this troubleshooting special control system procedure.

Before any troubleshooting is done perform this troubleshooting special control system procedure.

CONTROL SYSTEM SELF-DIAGNOSTIC TEST MODECONTROL SYSTEM SELF-DIAGNOSTIC TEST MODE

CONTROL SYSTEM SELF-DIAGNOSTIC TEST MODE

If problems with the electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is activated, the control unit will activate each one of the outputs in sequence and test for short circuits, open circuits, or overload conditions. This mode will also provide an easy test for the touch panel switches and indicators. If an abnormal condition is encountered with one of the outputs, an error code will be displayed on the Display

((

(

JJ

J

))

) see Figure 2.

11

1 During this test, the horn will sound briefly and the scrub deck and squeegee will move if they are in the up position. If the hopper

is not in the down position it will also move slightly.

CAUTION!CAUTION!

CAUTION!

Make sure that all persons are away from these parts of the machine to prevent injury.

22

2 Turn the

main power key switchmain power key switch

main power key switch to the

offoff

off position.

33

3 Press and hold the

side broom down/on switchside broom down/on switch

side broom down/on switch.

44

4 While holding the side broom down/on switch, turn the

main power key switchmain power key switch

main power key switch to the

onon

on position.

55

5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off

(approximately two seconds).

66

6 Release the side broom down/on switch. 77

77

7 The control will now activate each output in sequence and perform the tests mentioned above. 88

88

8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10. 99

99

9 If abnormal output conditions were detected, the display will now show the error code(s), see “Main Control Error Code Display

Descriptions Table”. An example of how two codes, 6 and 18, would be displayed is as follows:

• The display will show “E” followed by a brief blank period

• The display will show “0” followed by a brief blank period

• The display will show “6” followed by a slightly longer blank period

• The display will show “E” followed by a brief blank period

• The display will show “1” followed by a brief blank period

• The display will show “8” followed by a long blank period

• The above sequence will repeat

1010

10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult

the service manual general machine troubleshooting section which will show machine system flow charts.

1111

11 The hopper limit, main broom, recovery tank full, and solution tank empty switches may also be tested in this mode. The

corresponding indicators will indicate the state of each of the inputs.

1212

12 To exit this mode, turn the

main power key switchmain power key switch

main power key switch to the

offoff

off position.

NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.

NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.

J

FIGURE 2FIGURE 2

FIGURE 2

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

1313

13

Display

Code Error Description Troubleshooting Actions

Additional troubleshooting see general machine troubleshooting flow charts

01 Side broom actuator overload Check for binding or frozen side broom linkage &

actuator motor.

Check for short circuit in lift motor or wiring. 02 Contactor bank 1 overload 03 Contactor bank 2 overload 04 Contactor bank 3 overload 05 Contactor bank 4 overload 06 Contactor bank 5 overload 07 Engine speed actuator overload (diesel) Check for binding or frozen throttle linkage.

Check for short circuit in actuator motor or wiring. 08 Not used 09 Light relay coil circuit short Check for wiring problems at the K2 relay.

Check K2 coil resistance if below 315 ohms, replace 10 Light relay coil circuit current too high Same as Error 9 Replace relay. (Shorted Relay) 11 Light relay coil circuit open Check for open in relay wiring.

Check for 12V at the K2 relay coil wire colors ORG (+),

YEL (-). 12 Neutral-start relay coil circuit short Check for wiring problems at the K4 relay.

Check K4 coil resistance if below 315 ohms, replace 13 Neutral-start relay coil circuit current too high Same as Error 12 Replace relay. (Shorted Relay) 14 Neutral-start relay coil circuit open Check for open in relay wiring.

Check for 12V at the K4 relay coil wire colors PINK (+),

GRA/WHT (-). 15 Shaker relay coil circuit short See shaker will not run troubleshooting flow chart. 16 Shaker relay coil circuit current too high See shaker will not run troubleshooting flow chart. 17 Shaker relay coil circuit open See shaker will not run troubleshooting flow chart. 18 Back-up alarm circuit short Check alarm and wiring 19 Back-up alarm circuit current too high Check alarm and wiring 20 Back-up alarm circuit open Check alarm and wiring 21 Horn relay coil circuit short Check for wiring problems at the K1 relay.

Check K4 coil resistance if below 315 ohms, replace 22 Horn relay coil circuit current too high Same as Error 21 Replace relay. (Shorted Relay) 23 Horn relay coil circuit open Check for open in relay wiring.

Check for 12V at the K1 relay coil wire colors ORG (+),

VIO/BRN (-). 24 S15 (scrub deck pressure) circuit short Check for wiring problems at the L15 coil.

Check L15 coil resistance if below 7 ohms, replace 25 S15 (scrub deck pressure) circuit current too high Same as Error 24 Replace coil. (Shorted Coil) 26 S15 (scrub deck pressure) circuit open Check for open in coil & wiring.

Check for 12V at the L15 coil wire colors ORG (+),

GRN/VIO (-). 27 Solution solenoid circuit short Check for wiring problems at the L16 coil.

Check L16 coil resistance if below 7 ohms, replace. 28 Solution solenoid circuit current too high Same as Error 27 Replace coil. (Shorted Coil) 29 Solution solenoid circuit open Check for open in coil & wiring.

Check for 12V at the L16 solution valve coil wire colors

ORG (+), YEL/GRN (-). 30 S13 (hopper up) circuit short Check for wiring problems at the L13 coil.

Check L13 coil resistance if below 7 ohms, replace. 31 S13 (hopper up) circuit current too high Same as Error 30 Replace coil. (Shorted Coil) 32 S13 (hopper up) circuit open Check for open in coil & wiring.

Check for 12V at the L13 coil wire colors ORG (+),

RED/GRA (-).

A1 Main Control Error Codes

Run self-diagnostic for specific cause

14 14

14 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

Display

Code Error Description Troubleshooting Actions

33 S14 (hopper down) circuit short Check for wiring problems at the L14 coil.

Check L14 coil resistance if below 7 ohms Replace. 34 S14 (hopper down) circuit current too high Same as Error 33 Replace coil. (Shorted Coil) 35 S14 (hopper down) circuit open Check for open in coil & wiring.

Check for 12V at the L14 coil wire colors ORG (+),

YEL/RED (-). 36 S10 (side broom) circuit short Check for wiring problems at the L10 coil.

Check L10 coil resistance if below 7 ohms Replace. 37 S10 (side broom) circuit current too high Same as Error 36 Replace coil. (Shorted Coil) 38 S10 (side broom) circuit open Check for open in coil & wiring.

Check for 12V at the L10 coil wire colors ORG (+),

BRN/BLK (-). 39 S12 (door close) circuit short Check for wiring problems at the L12 coil.

Check L12 coil resistance if below 7 ohms Replace. 40 S12 (door close) circuit current too high Same as Error 39 Replace coil. (Shorted Coil) 41 S12 (door close) circuit open Check for open in coil & wiring.

Check for 12V at the L12 coil wire colors ORG (+),

BRN/GRN (-). 42 S8 (vacuum) circuit short Check for wiring problems at the L8 coil.

Check L8 coil resistance if below 7 ohms Replace. 43 S8 (vacuum) circuit current too high Same as Error 42 Replace coil. (Shorted Coil) 44 S8 (vacuum) circuit open Check for open in coil & wiring.

Check for 12V at the L8 coil wire colors ORG (+),

BLU (-). 45 S9 (dust control) circuit short Check for wiring problems at the L9 coil.

Check L9 coil resistance if below 7 ohms Replace. 46 S9 (dust control) circuit current too high Same as Error 45 Replace coil. (Shorted Coil) 47 S9 (dust control) circuit open Check for open in coil & wiring.

Check for 12V at the L9 coil wire colors ORG (+),

BRN/YEL (-). 48 S7 (scrub motors) circuit short Check for wiring problems at the L7 coil.

Check L7 coil resistance if below 7 ohms Replace. 49 S7 (scrub motors) circuit current too high Same as Error 48 Replace coil. (Shorted Coil) 50 S7 (scrub motors) circuit open Check for open in coil & wiring.

Check for 12V at the L7 coil wire colors ORG (+),

ORG/BLU (-). 51 S11 (door open) circuit short Check for wiring problems at the L11 coil.

Check L11 coil resistance if below 7 ohms Replace. 52 S11 (door open) circuit current too high Same as Error 51 Replace coil. (Shorted Coil) 53 S11 (door open) circuit open Check for open in coil & wiring.

Check for 12V at the L11 coil wire colors ORG (+),

BLK/WHT (-). 54 S5 (deck pressure) circuit short Check for wiring problems at the L5 coil.

Check L5 coil resistance if below 7 ohms Replace. 55 S5 (deck pressure) circuit current too high Same as Error 54 Replace coil. (Shorted Coil) 56 S5 (deck pressure) circuit open Check for open in coil & wiring.

Check for 12V at the L5 coil wire colors ORG (+),

WHT/VIO (-). 57 S6 (main broom) circuit short Check for wiring problems at the L6 coil.

Check L6 coil resistance if below 7 ohms Replace. 58 S6 (main broom) circuit current too high Same as Error 57 Replace coil. (Shorted Coil) 59 S6 (main broom) circuit open Check for open in coil & wiring.

Check for 12V at the L6 coil wire colors ORG (+),

GRN/GRA (-). 60 S3 (deck direction) circuit short Check for wiring problems at the L3 coil.

Check L3 coil resistance if below 7 ohms Replace. 61 S3 (deck direction) circuit current too high Same as Error 60 Replace coil. (Shorted Coil) 62 S3 (deck direction) circuit open Check for open in coil & wiring.

Check for 12V at the L3 coil wire colors ORG (+),

BRN (-).

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

1515

15

Display

Code Error Description Troubleshooting Actions

63 S4 (deck direction) circuit short Check for wiring problems at the L4 coil.

Check L4 coil resistance if below 7 ohms Replace. 64 S4 (deck direction) circuit current too high Same as Error 63 Replace coil. (Shorted Coil) 65 S4 (deck direction) circuit open Check for open in coil & wiring.

Check for 12V at the L4 coil wire colors ORG (+),

YEL/BLU (-). 66 S1 (deck & squeegee lift) circuit short Check for wiring problems at the L1 coil.

Check L1 coil resistance if below 7 ohms Replace. 67 S1 (deck & squeegee lift) circuit current too high Same as Error 66 Replace coil. (Shorted Coil) 68 S1 (deck & squeegee lift) circuit open Check for open in coil & wiring.

Check for 12V at the L1 coil wire colors ORG (+),

BLU/WHT (-). 69 S2 (squeegee direction) circuit short Check for wiring problems at the L2 coil.

Check L2 coil resistance if below 7 ohms Replace. 70 S2 (squeegee direction) circuit current too high Same as Error 69 Replace coil. (Shorted Coil) 71 S2 (squeegee direction) circuit open Check for open in coil & wiring.

Check for 12V at the L2 coil wire colors ORG (+),

ORG/RED (-). 72 Side broom actuator circuit short Check for short in wires or motor. 73 Side broom actuator circuit current too high Check for binding of linkage. 74 Side broom actuator circuit open See service manual section flowcharts. 75 Engine speed actuator circuit short (diesel) Check for short at motor and wires. 76

Engine speed actuator circuit current too high

(diesel) Check for binding of linkage. 77 Engine speed actuator circuit open (diesel) Check for open in wires or motor. 78 79 80

16 16

16 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

WAND

(S4) DECK

(S2) SQUEEGEE

(S6) MAIN BROOM

(S11)

DOOR OPEN

(S9) DUST CONTROL

(S12) DOOR CLOSE

(S14) HOPPER DOWN

SOLUTION

LOW

FUEL

UP

HOPPE R

GLOW

PLUG

DUST

FILTER

TEMP

HOPPE R

RECOVE RY

FULL

FILTER

HYDRA ULIC

MAIN

BROOM

ENGIN E

SERVI CE

EMPTY

SOLUT ION

(S1)

SQ. & DECK

(S3)

DECK

(S5)

DECK

(S7)

SCRUB MOTORS

(S8)

VACUUM

(S10)

SIDE BROOM

(S13)

HOPPER UP

(S15)

DECK

BACKUP

LIGHTS

SHAKER

HORN

NEUTRAL

IGN.

ACC.

ENGINE

SPEED

SIDE BROOM ACTUATOR

J2

J1

GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TGENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE T

GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE T

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

ENGINE WILL NOT CRANK ................................................................................................................................................ 18

ENGINE WILL CRANK BUT NOT START .......................................................................................................................... 19

ALL THE MACHINE ACCESSORY FUNCTIONS DO NOT WORK ............................................................................. 20-21

FORWARD/REVERSE AUTO ACCESSORY FUNCTION DO NOT WORK ...................................................................... 22

HYDRAULIC MOTOR(S) WILL NOT STOP RUNNING ..................................................................................................... 23

WHEEL DRIVE SYSTEM (TROUBLESHOOTING CHECK LIST) ...................................................................................... 24

STEERING SYSTEM (TROUBLESHOOTING GUIDE) ....................................................................................................... 25

SWEEP SYSTEM ............................................................................................................................................................. 26-33

MAIN BROOM WILL NOT TURN ................................................................................................................26-27

SIDE BROOMS WILL NOT TURN ............................................................................................................... 28-29

SIDE BROOMS WILL NOT RAISE/LOWER ..................................................................................................... 30

DUST CONTROL IMPELLER WILL NOT RUN ............................................................................................31-32

SHAKER MOTOR WILL NOT RUN ................................................................................................................... 33

HOPPER SYSTEM ...........................................................................................................................................................34-40

HOPPER WILL NOT RAISE .......................................................................................................................... 34-35

HOPPER WILL NOT LOWER ........................................................................................................................36-37

HOPPER DUMP DOOR WILL NOT OPEN ....................................................................................................... 38

HOPPER DUMP DOOR WILL NOT CLOSE ...................................................................................................... 39

HOPPER DUMP DOOR WILL NOT OPEN OR CLOSE .................................................................................... 40

SCRUB SYSTEM ............................................................................................................................................................. 41-50

SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 1) ..............................................................41-42

SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 2) ..............................................................43-44

SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 3) ..............................................................45-46

SCRUB DECK WILL NOT RAISE ................................................................................................................. 47-48

SCRUB BRUSH MOTORS WILL NOT OPERATE ...................................................................................... 49-50

SOLUTION SYSTEM ............................................................................................................................................................ 51

SOLUTION SOLENOID WILL NOT OPERATE ................................................................................................. 51

RECOVERY SYSTEM ....................................................................................................................................................... 52-56

VACUUM MOTOR WILL NOT OPERATE ................................................................................................... 52-54

SQUEEGEE WILL NOT RAISE/LOWER ....................................................................................................... 55-56

Note:Note:

Note: To aid in machine system troubleshooting; see the electrical and hydraulic manual sections for additional drawing of part

component locations and diagrams to support wiring and hydraulic circuits.

A1 Control BoardA1 Control Board

A1 Control Board

Indicator LightsIndicator Lights

Indicator Lights

Note: Remove left side

operator's compartment panel

to access A1 Board.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

1717

17

TEMP

F/C

VOLTSFUEL

OIL

PSI/BAR

HOURS 1/10

250

175

120

50

75

100

50

0

1

3

8

F

E

1/2

18

13

10

+

-

A

B

C

D

E

F

G

BB

CC

DD

EE

I

J

H

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Z

AA

FF

OPERAOPERA

OPERA

TOR’S COMPTOR’S COMP

TOR’S COMP

ARTMENTARTMENT

ARTMENT

AA

A

Low Fuel Indicator (LP)Low Fuel Indicator (LP)

Low Fuel Indicator (LP)

BB

B

Horn SwitchHorn Switch

Horn Switch

**

*

Horn ON IndicatorHorn ON Indicator

Horn ON Indicator

CC

C

Engine Service Indicator (triggered byEngine Service Indicator (triggered by

Engine Service Indicator (triggered by ECU)ECU)

ECU)ECU)

ECU)

DD

D

Headlight SwitchHeadlight Switch

Headlight Switch

**

*

Headlight ON IndicatorHeadlight ON Indicator

Headlight ON Indicator

EE

E

Glow Plug Indicator (Diesel / ReleaseGlow Plug Indicator (Diesel / Release

Glow Plug Indicator (Diesel / Release key after indicator turns OFF)key after indicator turns OFF)

key after indicator turns OFF)key after indicator turns OFF)

key after indicator turns OFF)

FF

F

Hydraulic Filter Plugged IndicatorHydraulic Filter Plugged Indicator

Hydraulic Filter Plugged Indicator

GG

G

Engine Speed SwitchEngine Speed Switch

Engine Speed Switch

**

*

Engine Speed Switch IndicatorEngine Speed Switch Indicator

Engine Speed Switch Indicator

HH

H

Scrub Pressure Decrease SwitchScrub Pressure Decrease Switch

Scrub Pressure Decrease Switch

**

*

Scrub Pressure Decrease IndicatorScrub Pressure Decrease Indicator

Scrub Pressure Decrease Indicator

II

I

Scrub Pressure Increase SwitchScrub Pressure Increase Switch

Scrub Pressure Increase Switch

**

*

Scrub Pressure Increase IndicatorScrub Pressure Increase Indicator

Scrub Pressure Increase Indicator

JJ

J

Scrub Pressure & Error Code DisplayScrub Pressure & Error Code Display

Scrub Pressure & Error Code Display

KK

K

Solution SwitchSolution Switch

Solution Switch

**

*

Solution System IndicatorSolution System Indicator

Solution System Indicator

LL

L

Low Solution Indicator (8-10 gal.)Low Solution Indicator (8-10 gal.)

Low Solution Indicator (8-10 gal.)

MM

M

Recovery Tank Full IndicatorRecovery Tank Full Indicator

Recovery Tank Full Indicator

NN

N

Side Broom DOWN/ON SwitchSide Broom DOWN/ON Switch

Side Broom DOWN/ON Switch

**

*

Side Broom ON IndicatorSide Broom ON Indicator

Side Broom ON Indicator

OO

O

Main Broom ON IndicatorMain Broom ON Indicator

Main Broom ON Indicator

PP

P

Light SensorLight Sensor

Light Sensor

QQ

Q

Shaker SwitchShaker Switch

Shaker Switch

**

*

Shaker Indicator (left)Shaker Indicator (left)

Shaker Indicator (left)

**

*

Dust Filter Plugged Indicator (right)Dust Filter Plugged Indicator (right)

Dust Filter Plugged Indicator (right)

RR

R

Open Dump Door SwitchOpen Dump Door Switch

Open Dump Door Switch

**

*

Open Dump Door IndicatorOpen Dump Door Indicator

Open Dump Door Indicator

SS

S

Hopper Open IndicatorHopper Open Indicator

Hopper Open Indicator

TT

T

Hopper Overtemp IndicatorHopper Overtemp Indicator

Hopper Overtemp Indicator

UU

U

Close Dump Door SwitchClose Dump Door Switch

Close Dump Door Switch

**

*

Close Dump Door IndicatorClose Dump Door Indicator

Close Dump Door Indicator

VV

V

Lower Hopper SwitchLower Hopper Switch

Lower Hopper Switch

**

*

Lower Hopper IndicatorLower Hopper Indicator

Lower Hopper Indicator

WW

W

Raise Hopper SwitchRaise Hopper Switch

Raise Hopper Switch

**

*

Raise Hopper IndicatorRaise Hopper Indicator

Raise Hopper Indicator

XX

X

Dust Control SwitchDust Control Switch

Dust Control Switch

**

*

Dust Control ON IndicatorDust Control ON Indicator

Dust Control ON Indicator

YY

Y

Side Broom UP/OFF SwitchSide Broom UP/OFF Switch

Side Broom UP/OFF Switch

**

*

Side Broom OFF IndicatorSide Broom OFF Indicator

Side Broom OFF Indicator

ZZ

Z

Vacuum System SwitchVacuum System Switch

Vacuum System Switch

**

*

Vacuum System IndicatorVacuum System Indicator

Vacuum System Indicator

AAAA

AA

Scrub System OFF SwitchScrub System OFF Switch

Scrub System OFF Switch

**

*

Scrub System OFF IndicatorScrub System OFF Indicator

Scrub System OFF Indicator

BBBB

BB

Coolant Temperature GaugeCoolant Temperature Gauge

Coolant Temperature Gauge

CCCC

CC

Oil Pressure GaugeOil Pressure Gauge

Oil Pressure Gauge

DDDD

DD

Fuel Gauge (Gas / Diesel)Fuel Gauge (Gas / Diesel)

Fuel Gauge (Gas / Diesel)

EEEE

EE

VoltmeterVoltmeter

Voltmeter

FFFF

FF

Hour meterHour meter

Hour meter

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

A2 Control PanelA2 Control Panel

A2 Control Panel

AssemblyAssembly

Assembly

18 18

18 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

Repair or replace relay or

wiring. Is there 12 volts at

the BLU/PNK?

Replace engine fuse box start relay.

Location of fuse box on top of engine

No

At the K4 relay do you have

12 volts at the BLU/PNK?

Yes

No

Engine will still not crank?

No

Yes

No

Engine will not crank

Is the neutral indicator

light off at the A1 board?

The pedal is not returning to its neutral state. Repair any mechanical problems

to the foot pedal linkage or

hydroback.

Does the light go off?

Replace the drive pedal

sensor. Does the light go

off? (See note 4)

Reset drive pedal sensor dead band setting. Sensor

has a range of 1-9 factory setting is 2-5.

Turn key switch off, press and hold the engine speed

switch then turn the key on. Setting should be at 2-5.

To change setting press the speed switch, To exit

turn key off. Does the light go off?

No

Replace the A1 control

board. Does the engine

crank?

Yes

Check for 12 volts at WHT

wire located on starter solenoid with the key in the start

position. If yes repair or

replace starter.

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Engine will not crank

Electrical Control CircuitElectrical Control Circuit

Electrical Control Circuit

Note 1: To test the key switch must be in the START position and foot pedal in neutral. Note 2: Before troubleshooting check the F4 (15 amp) circuit breaker location under steering column. Note 3: Check for 12V at the F4 machine circuit breaker. If no input voltage at the GRN/BLK wire, repair or replace wiring or key switch. Service Adjustment Note:Service Adjustment Note:

Service Adjustment Note:Service Adjustment Note:

Service Adjustment Note: A drive pedal sensor setting that is set too low will not target (match) the drive pedal neutral return position (dead-band too narrow) and the engine will not start. Too high of a setting will increase the neutral range (dead-band too wide) and delay the activation of turning on the auto sweep and scrub functions when the drive pedal is moved out of an excessively wide programmed neutral range.

Note 4: A new pedal sensor must be programmed for its neutral position and dead-band setting, follow instructions shown on this page.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

1919

19

Check the 5 Amp fuse (F1)

see engine system Figure 2

fuse box.

Engine will crank but

not start

Replace the F3 (10 Amp)

circuit breaker

Check for 12V (+) at the X9 harness

connector (location by engine

starter) pin “A” wire color pink.

Repair or replace wiring

back to the F3 circuit

breaker

Check the continuity of

the F3 circuit breaker

Replace the F1

5 Amp fuse.

Select fuel typeGasoline

LP

Check for 12V at

fuel pump

Check fuel pump F4 fuse (15 Amp)

Replace F4 fuse

(15 Amp)

-Check fuel filter (pickup)

-Check fuel pump output. Repair or

replace

• Engine still will not start

-Replace the fuel pump relay.

• Engine still will not start

Check for 12V at

the fuel lock-off

Repair wiring to

fuel lock-off.

-Replace fuel lock-off

• Engine still will not start

See engine fuel system manual

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Engine will crank but not start

Electrical Control CircuitElectrical Control Circuit

Electrical Control Circuit

Note 1: Check for 12V at the F3 machine circuit breaker. If no input voltage at the ORG/GRN wire repair or replace wiring or key switch. Note 2: Check the fuel supply (empty tank).

20 20

20 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 All the machine accessory system’s functions (operations) do not work. Example: no brush, broom, vacuum and hopper

functions etc.

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with Key Switch ON.

All the machine accessory

system’s functions

(operations) do not work

When key is first turned

on do all the A2 display

panel lights momentarily

turn on?

Test for the 12V output from

A1 wires WHT/BRN & BLK

Check the power & commu-

nication inputs to A2

•Test circuit continuity of

wires BRN/BLU & GRN/BLU

•Test for 12V power input wires WHT/BRN & BLK

Sub a new A2 Display Panel

Machine system fixed all

functions now operational

See Hydraulic Load Circuit

Part B

Repair or replace

defective wiring

Replace A1 Main

Controller

No

Test for the 12V power

input to A1, wires VIO &

BLK

•Check for a defective F2 circuit breaker (15A)

•An open in either the circuit

battery (pos.) VIO wire or BLK

battery (neg.) wire

No

Repair or replace defective

parts.

Do the A2 panel lights now

function?

No

Yes

Replace the A1 Controller

No

Yes

No

Yes

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

2121

21

No

Yes

Have you lost both of

the machine hydraulic

systems,

Drive and Accessory

Does wheel drive motor

move the machine

See wheel drive system

troubleshooting

Defective drive coupler

between engine and

propulsion pump.

Repair or replace the

coupler

Yes

No Hydraulic

Accessories Work

Do some accessory

functions work? If so

see chart below for

appropriate pump circuit

*Pump circuit 2 poor or no

performance of steering

system, dump door, hop-

per lift, engine fan, dust

control and side brooms

Failure of the propulsion coupler input to the front

accessory pump repair

or replace the faulty

pump

*Pump circuit 3 poor or

no performance of scrub

motors, scrub deck

up/down and squeegee

up/down

*Pump circuit 1 poor or

no performance of main

broom, vac fan and

hydraulic charge line

Adjust, clean or replace

#1A relief valve.

Does the system

function?

Adjust, clean or replace

#1 relief valve.

Does the system

function?

Adjust, clean or replace

#1B relief valve.

Does the system

function?

Repair or replace pump

Repair or replace pumpRepair or replace pump

Yes Yes Yes

No NoNo

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 All the machine accessory system’s functions (operations) do not work. Example: no brush, broom, vacuum, and hopper

functions etc.

Part B: Hydraulic Load CircuitPart B: Hydraulic Load Circuit

Part B: Hydraulic Load Circuit

Note: Do all testing with Key Switch ON.

*Note: See hydraulic manual section for system specifications (relief valves, pumps, motors etc.).

22 22

22 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Forward/Reverse auto accessory functions do not work or activate slowly (do not function properly). Examples: Main broom,

side brooms, scrub motors, vacuum motor and dust control motor.

Electrical Control CircuitElectrical Control Circuit

Electrical Control Circuit

Note: Do all testing with the key switch ON, hopper lowered and drive pedal activated (forward/reverse). Service Adjustment Note:Service Adjustment Note:

Service Adjustment Note:Service Adjustment Note:

Service Adjustment Note: A drive pedal sensor setting that is set too low will not target (match) the drive pedal neutral return position (dead-band too narrow) and the engine will not start. Too high of a setting will increase the neutral range (dead-band too wide) and delay the activation of turning on the auto sweep and scrub functions when the drive pedal is moved out of an excessively wide programmed neutral range.

Machine drive auto

function does not work

Place the pedal in forward or

reverse position. Check on the

A1 control board. Is the green

neutral indicator light on?

Is the hopper yellow indicator

light on at the A1 board?

Adjust or replace

magnetic switch

S12.

Does light come

on?

No

Yes Yes

Replace the A1 Control Board

Replace pedal

sensor or wiring

(switch is open).

No

Yes

No

Replace

A1 board

No

Reset drive pedal sensor dead band setting.

Sensor has a range of 1-9

factory setting is 2-5.

Turn key switch off, press and hold the

engine speed switch then turn the key on.

Setting should be at 2-5. To change setting

press the speed switch, To exit turn key

off. Does the light come on and

auto functions operate?

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

2323

23

Hydraulic motor(s) will

not stop running.

Is the indicator light OFF at

the A2 display panel for the

malfunctioning motor?

Replace the

A2 touch pad.

Locate the malfunctioning

motors hydraulic cartridge

valve, clean or replace.

See hydraulic system’s

troubleshooting section for

locations.

Yes

No

Is the green indicator light

for the malfunctioning

motor OFF at A1 control

board?

Replace the

A1 control board.

No

Yes

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hydraulic motor(s) will not stop running.

Note 1: Do all testing with the key switch ON and all machine functions OFF. Note 2: If optional “Vacuum Wand Kit” is installed and its switch is activated the vacuum motor will turn on when the engine is started.

24 24

24 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

WHEEL DRIVE SYSTEMWHEEL DRIVE SYSTEM

WHEEL DRIVE SYSTEM

SymptomSymptom

Symptom

Possible CausePossible Cause

Possible Cause

Wheel drive functions sluggish or slow • Engine not operating in high-speed setting or engine speed is

too slow (2400 RPM).

• Air in hydraulic fluid (loose fittings).

• Propulsion pump inlet restriction (cavitation of hydraulic fluid).

• Worn drive wheel motor (*test working pressure & wheel drive speed).

Wheel drive in one direction only • Inspect propulsion pump relief valves for:

A. Debris that allows valve seat to be held open, B. Damaged or weak valve spring, C. Valve unloading pressure setting to low for application.

No wheel drive in either direction • Check that pump bypass valve (tow valve) is in correct posi-

tion.

• Check connection of foot pedal linkage (cable assembly) to propulsion pump arm.

• Worn propulsion pump (*test output oil volume with a flow meter).

• Defective propulsion pump charge circuit. Test its relief valve pressure setting (75-150 psi).

• Worn or damaged wheel drive motor

No hydraulic system functions drive or accessory • Check for a damaged coupling connection from the engine to

the pump shaft input.

*Note: See in the hydraulic specification manual section, tables that list all the individual system component values (pressures, flows, rpms etc).

Propulsion Pump

Relief Valve 2500 PSI

Relief Valve

2500 PSI

Tow Valve

Up

Hydraulic Wheel Drive SystemHydraulic Wheel Drive System

Hydraulic Wheel Drive System

Troubleshooting Check List

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

2525

25

STEERING SYSTEMSTEERING SYSTEM

STEERING SYSTEM

1.75 GPM

6.0 GPM

RESERVOIR

COOLER

FILTER

2400 PSI

MANIFOLD

STEER CYLINDER 2 x 6

STEERING UNIT

ENGINE FAN

1450 PSI

4.5 .323

L

R

T

E

25 PSI

.58

C

D

P

P2 P3 T2

Steering System Hydraulic DiagramSteering System Hydraulic Diagram

Steering System Hydraulic Diagram

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

ProblemProblem

Problem

Possible causePossible cause

Possible cause

Slow steering, hard steering or loss of Priority flow divider not providing 1.75 GPM. Power assist.

1450 PSI relief valve open or malfunctioning.

Steering wandering. Rack and pinion worn or out of

adjustment.

Loose or leaking cylinder piston.

Steering control unit worn.

Steering wheel turns freely Problem with steering column without moving wheel. Shaft or spline.

Steering binding. Rack and pinion worn or out of

adjustment.

Steer cylinder loose.

STEERING SYSTEM TROUBLESHOOTING OVERVIEWSTEERING SYSTEM TROUBLESHOOTING OVERVIEW

STEERING SYSTEM TROUBLESHOOTING OVERVIEW

See Figure 1. A hydraulic steering unit, with the steering wheel mounted to it, controls the rack cylinder. The steering unit runs off the middle gear pump of the auxiliary pump assembly. The oil flows through a priority divider built into the pressure relief block assembly that divides the pump output and reduces the oil flow to 1.75 GPM for the steering system. There is a check valve built into the steering unit that allows for manual steering if there is no hydraulic oil flow to the unit. The relief valve for the steering system is located in the steering unit and is set to open at 1450 PSI.

26 26

26 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Main broom will not turn.

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with Key Switch ON, Broom Lever lowered, Hopper closed, Broom Door open and the Drive Pedal activated (placed in forward or reverse).

Main broom will not turn

On the A1 - Board, is the

S6 broom motor relay

indicator light on?

Check the adjustment &

operation of the S16 broom

switch. Switch continuity,

is open with broom lever

lowered.

Check for 12V at the L6 sole-

noid coil, wire colors

GRN/GRA (-) & ORG (+).

Check both wires for continuity. Repair or

replace defective wire(s)

Does broom run?

Check the L6 coil resistance

it should read 7-9 ohms.

Replace (L6) coil (checks

open or shorted). Does broom run?

See Part B main broom

motor hydraulic load circuit

Yes

No

Replace the A1 Main Con-

troller. Does broom run?

Yes

Clean, Adjust or

replace the magnetic

broom switch (S16)

Does broom run?

No No

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

2727

27

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Main broom will not turn.

Part B: Hydraulic Load CircuitPart B: Hydraulic Load Circuit

Part B: Hydraulic Load Circuit

Note: Do all testing with the Broom Lever lowered, Hopper closed, Broom Door open, the Drive Pedal forward/reverse, and engine running at (2400 RPM) high speed.

No

Replace defective spool

valve L6.

Does motor operate?

Replace motor

No No

No

Yes

Inspect the main broom for

possible mechanical bind-

ing, damaged broom lug

inserts and debris wrapped

around broom or broom

motor.

Remove debris and make

any repairs or replace

damaged parts.

Does the main broom

turn?

Yes

Main broom will not turn

See troubleshooting sec-

tion titled, No hydraulic

accessories work.

Remove and disassemble

L6 broom motor spool

valve (cartridge) inspect,

clean and reinstall.

Does the broom function?

Does the vacuum motor on pump circuit 1 work?

28 28

28 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Side brooms will not turn

Part A: ElectricalPart A: Electrical

Part A: Electrical

Note: Do all testing with the key switch ON, the hopper closed, main broom lowered. Side broom lower switch pressed on the display panel and the drive pedal activated.

Side brooms will not turn

Press the side broom lower

switch, (located on the

A2 display panel).

Is its green indicator light on?

Substitute a new A2

display panel

Do side brooms operate?

Check for 12 volts at L10 side

broom motors coil.

Wire colors

(+) ORG

(-) BRN/BLK

Repair or replace L10

coil wiring.

Do the side broom

motors operate?

Check L10 coil resistance

(9 ohm)

Repair or replace L10

coil.

Do the side broom

motors operate?

See Hydraulic side broom

troubleshooting section

Part B

Yes

No

On the A1 board is the S10

side brooms motor relay

indicator light on?

Replace A1 control

board

Do the side broom

motors operate?

No

Yes

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

2929

29

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Side brooms will not turn

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: Do all testing with the engine running (2400 rpm), the hopper closed, main broom lowered. Side broom lower switch pressed and the drive pedal activated.

Side brooms

will not turn

Clean and repair motors.

Do they turn?

Replace defective

spool valve L10.

Do the side broom motors run?

Repair or replace side

broom motors

Remove and disassemble L10

spool valve (cartridge). Inspect

clean and reinstall.

Do the side broom motors run?

Yes

Do some pump circuit 2

funtion work steering,

engine fan, dust control?

Inspect for possible debris

wrapped around motor shafts.

No

See hydraulic load

trouble shooting, No

accessories work.

No

Yes

No

Yes

30 30

30 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Side broom lift actuator motor will not raise or lower

Electrical CircuitElectrical Circuit

Electrical Circuit

Note: Do all testing with the key switch turned ON and main broom lever lowered.

Side brooms do not raise or

lower

Press one at a time the side

broom ON (lower) and OFF

(raise) buttons on the A2 panel.

Do both the green indicator

lights turn on.

Substitute a new A2 display

panel.

Do the brooms now raise or

lower?

Press the side broom OFF

(raise) button and check on

the A1 control board to see if

its green relay indicator light

comes on.

Replace the A1 control

board. Do brooms now raise

or lower?

Test for 12V at the M4

actuator motor.

To lower wire colors

(-) WHT & (+) RED.

To raise (-) BLK & (+) WHT

Repair or replace defective

connector and or wiring. Do

brooms raise or lower?

Yes

No

Press the side broom ON (Lower) button and check on the A1 control board to see if

its red relay indicator light

comes on.

No

Yes

No

Replace the M4 side broom lift

actuator motor.

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

3131

31

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Dust control impeller will not run

Part A: ElectricalPart A: Electrical

Part A: Electrical

Note: Do all testing with the key switch ON, and the hopper closed. Also dust control switch must be activated on the display panel and the drive pedal must be activated (placed in forward or reverse).

Dust control impeller

motor will not run

Press the dust control switch,

(located on the A2 display

panel).

Is its green indicator light on?

Substitute a new A2 display panel.

Does impeller operate?

Check for 12V at L9 impeller

motor coil.

Wire colors

(+) ORG

(-) BRN/YEL

Repair or replace L9 coil

wiring.

Does impeller motor

operate?

Check L9 coil resistance

(9 ohm)

Repair or replace L9

coil.

Does impeller motor

operate?

See Hydraulic impeller

motor troubleshooting

section Part B

Yes

No

On the A1 board is the S9 impeller motor relay light

on?

Replace A1 control

board.

Does impeller motor

operate?

No

Yes

32 32

32 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Dust control impeller will not run

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: Do all testing with the engine running (2400 rpm). Also dust control switch must be activated on the display panel and the drive pedal must be activated.

Dust control impeller

will not run

Remove and disassemble L9 spool valve (cartridge)

inspect, clean and reinstall

Does the impeller motor run?

Replace defective spool

valve L9 (located on

impeller motor).

Does it operate?

Repair or replace impeller

motor

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

3333

33

SWEEPING SYSTEMSWEEPING SYSTEM

SWEEPING SYSTEM

Shaker motor will not run

Press the shaker button on the

operator A2 panel. Is the upper

left green indicator light on?

Substitute a new A2 display

panel.

Does shaker motor operate?

Check for 12V at the K3 shaker

relay coil, wire colors (-) GRN

& (+) ORG

Repair or replace wiring to

coil.

Does shaker motor operate?

Check the K3 coil resistance

should measure

370 Ohms + or - 10%

Replace the defective

K3 relay.

Does shaker motor operate?

Yes

No

Press shaker switch button

and check on the A1 control

board to see if the shaker

relay green indicator light is

on.

Replace A1 control board.

Does shaker motor

operate?

No

Yes

Check for 12V at the shaker

motor, wire colors

BLU/GRN & BLK

Replace the defective K3

relay or wiring.

Does shaker motor operate?

Yes

No

Test for 12V (+) at the K3 relay

load terminals

•(output #87) BLU/GRN to battery ground

•(input #30) BLU/YEL to bat. GND

Repair or replace

motor wiring.

Does shaker motor operate?

Yes

No

Replace the M2 shaker motor

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Shaker motor will not run

Electrical CircuitElectrical Circuit

Electrical Circuit

Note1: Before testing first confirm that the 10Amp F7 circuit breaker is good. Note2: Do all testing with the key switch turned ON.

34 34

34 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper will not raise

Part A: ElectricalPart A: Electrical

Part A: Electrical

Note: Do all testing with the key switch turned ON, and the hopper raise switch pressed on the operator display panel.

Hopper will not raise

Press and hold hopper raise

switch. Is its green indicator

light on the A2 display panel

Substitute a new A2

display panel.

Does the hopper raise?

Check for 12 volts at

L13 hopper raise coil.

Wire colors

(+) ORG

(-) RED/GRY

Repair or replace L13

coil wiring.

Does the hopper raise?

Check for coil resistance

at L13 (9 ohm)

Repair or replace L13

coil.

Does the hopper raise?

See Hydraulic hopper lift

troubleshooting section

Part B

Yes

No

Press and hold hopper raise button. On the A1 board is the S13 relay green indicator light

on? Note relay S12 will be on

momentary

Replace A1 control

board.

Does the hopper raise?

No

Yes

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

3535

35

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper will not raise

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: To test engine must be running (2400 rpm).

Empty the hopper.

Does the hopper raise?

Inspect for possible

mechanical binding of:

•Hopper linkage

•Hopper cylinder

Do some pump circuit 2

function work steering,

engine fan, dust control?

No

Repair or replace

damaged parts.

Does the hopper raise?

See hydraulic load trouble-

shooting, No accessories

work

No

Remove and disassemble

•L13 hopper raise

Spool valve (cartridge)

inspect clean and reinstall

Does the hopper raise?

Yes

Replace defective spool

valve

•L13 hopper raise

Does the hopper rasie?

Is the hopper over

its weight capacity?

Hopper will not raise

Replace hydraulic

hopper cylinder

No

Yes

No

Yes

36 36

36 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper will not lower

Part A: ElectricalPart A: Electrical

Part A: Electrical

Note: Do all testing with the key switch turned ON, and the hopper lower switch pressed on the display panel.

Hopper will not lower

Press and hold hopper lower switch. Is its green indicator

light on?

Substitute a new A2

display panel.

Does the hopper lower?

Check for 12 volts at

L14 hopper lower coil.

Wire colors

(+) ORG

(-) YEL/RED

Repair or replace L14

coil wiring.

Does the hopper lower?

Check for coil resistance

at L14 (9 ohm)

Repair or replace L14

coil.

Does the hopper lower?

See Hydraulic hopper lower

troubleshooting

section Part B

Yes

No

Press and hold hopper lower

button is the green light on the

A1 board S14

Note relay S12 will be on

momentary

Replace A1 control

board.

Does the hopper lower?

No

Yes

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

3737

37

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper will not lower

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: To test engine must be running (2400 rpm).

Repair or replace damaged

parts

Does the hopper lower?

Remove and disassemble

•L14 hopper lower

Spool valve (cartridge)

inspect clean and reinstall

Does the hopper lower?

Replace defective spool

valve

•L14 hopper lower

Does the hopper lower?

No

Inspect for possible

mechanical binding of:

•Hopper linkage

•Hopper cylinder

Hopper will not lower

Replace hydraulic

hopper cylinder

No

Yes

38 38

38 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

Press and hold dump door

open switch. Is the green

light on the A1 board S11

relay.

Check for 12 volts at L11

Dump Door coil. Wire color

(+) ORN, (-) BLK/WHT

Check for coil resistance at

L11 (9 ohm)

See hydraulic dump door

troubleshooting section

Part B

Repair or replace L11 coil

No

Yes

No

Yes

Replace the

A1 Control board

No

Yes

Repair or replace L11 coil

wiring

No

Yes

Substitute a new A2 Display

panel. Does dump door

operate?

Repair or replace (S12)

switch wiring.

Does door open?

Yes

No

Dump Door will not open

Check if the hopper raise

indicator light is flashing

on A2 panel

Check continuity and

adjustment of hopper raise

switch (S12)

Note: Switch will check

open when hopper is

raised

Repair or replace (S12)

switch.

Press and hold dump door

open switch, is its green

indicator light on

Check (S12) switch wiring

for a short

Replace A2 control panel

display

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper dump door will not open in dump mode.

Part A:Part A:

Part A:

Note: Do all testing with Key Switch ON, hopper raised (engine must be run to raise hopper).

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

3939

39

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

Dump Door will not close

Check if the hopper raise

indicator light is flashing

on A2 panel.

Press and hold dump door

closed button and observe on

the A1 board to see if the S12

relay light is on.

Check for 12 volts at L12

Dump Door coil. Wire color

(+) ORN, (-) BLK/WHT

Check for coil resistance at

L12 (9 ohm)

See hydraulic dump door

troubleshooting section

Part B

Check continuity and

adjustment of hopper raise

magnetic switch (S12)

Note: Switch will check

open when hopper is

raised.

Repair or replace L12 coil.

Does the door operate?

No

Yes

Press and hold hopper door close switch. Is its green indicator light on?

Check (S12) switch wiring

for a short.

No

Yes

Replace the A1 Control

board.

Does the door operate?

No

Yes

No

Repair or replace L12 coil

wiring.

Does the door operate?

Repair or replace (S12)

switch

No

Yes

Substitute a new A2 Display

panel. Does dump door

operate?

Repair or replace (S12)

switch wiring.

No

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper dump door will not close in dump mode.

Part A:Part A:

Part A:

Note: Do all testing with Key Switch ON, hopper raised (engine must be run to raise hopper).

40 40

40 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HOPPER SYSTEMHOPPER SYSTEM

HOPPER SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Hopper dump door will not open or close when in dump mode.

Part B:Part B:

Part B:

Note: To test engine must be running in high speed (2400 rpm).

Dump Door

will not operate

Inspect for possible

mechanical binding of:

•Dump door

•Dump door linkage

•Dump door cylinder

Do some pump circuit 2

functions work?

Steering, engine fan, dust

control and side broom

motor(s).

No

Yes

Repair or replace dump

door, dump door linkage,

dump door cylinder. Does

the door function?

See hydraulic load trou-

bleshooting, section

titled, “No Accessories

work”.

No

Remove and disassemble

•L11 door open

•L12 door closed

Spool valve (cartridge)

inspect clean and reinstall.

Does the door function?

Yes

Replace defective spool

valve.

•L11 door open

•L12 door closed

Does the door function?

No

Repair or replace

door cylinder

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

4141

41

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not lower

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with the key switch ON, scrub deck pressure set on (1) by depressing the scrub decrease switch on the A2 display panel.

Scrub deck will not lower (1)

Press and hold scrub

decrease switch (-).

Is its green indicator light on?

Substitute a new A2

display panel.

Does the deck lower?

Check for 12 volts at coil

• L4 (+) ORG (-) YEL/BLU.

Repair or replace

defective coil wiring.

Does the deck lower?

Check for coil resistance

at L4 (9 ohm)

Replace defective coil.

Does the deck lower?

See Hydraulic scrub deck

troubleshooting section Part B

position 1.

Yes

No

Press scrub off switch then scrub

decrease switch (may need to be

cycled to observe lights) observe the

green lights on the A1 board S3 & S4

are they on.

Replace A1 control

board.

Does the deck lower?

No

Yes

No

42 42

42 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not lower or lowers partially in (1)

Part B: Hydraulic Scrub Deck (Pressure Setting 1)Part B: Hydraulic Scrub Deck (Pressure Setting 1)

Part B: Hydraulic Scrub Deck (Pressure Setting 1)

Note: All tests should be done with the engine running in high speed (2400 rpm).

Repair or replace damaged

parts.

Does scrub deck lower?

Remove and disassemble

•L4 scrub deck spool valve (cartridge) inspect, clean

and reinstall.

Does scrub deck lower?

Replace defective spool

valve L4.

Does scrub deck

function?

No

Inspect for possible

mechanical binding of:

•Scrub deck mount linkage

•Scrub deck cylinder

Check deck pressure with a scale (1) 120 lbs. (2) 237 lbs.

(3) 385 lbs.

Replace cylinder

No

Yes

Scrub deck will not lower

or lowers partially in (1)

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

4343

43

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

Scrub deck will not function in

pressure setting (2)

Press and release scrub

increase switch (+) until 2 appears in

the display.

Is its green indicator light on?

Substitute a new A2

display panel.

Does the deck lower?

Check for 12 volts at coils

•L3 (+) ORG (-) BRN

•L5 (+) ORG (-) WHT/VIO

•L15 (+) ORG (-) GRN/VIO

Repair or replace

defective coil wiring.

Does the deck lower?

Check for coil resistance

at L3, L5 & L15 (9 ohm)

Replace defective coil(s).

Does the deck lower?

See Hydraulic scrub deck troubleshoot-

ing section Part B position 2.

Yes

No

Press the scrub off switch then scrub

increase switch (may need to be cycled to observe lights) observe the green lights on the A1 board S3, S5 &

S15 are they on?

Replace A1 control

board.

Does the deck lower?

No

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not operate in pressure setting (2)

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with the key switch ON, scrub deck pressure set on (2) by depressing the scrub increase switch on the A2 display panel.

44 44

44 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not operate in pressure setting (2)

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: All tests should be done with the engine running in high speed (2400 rpm).

Check deck pressure with a

scale (1) 120 lbs. (2) 237 lbs.

(3) 385 lbs.

Remove and disassemble L5,

L15 scrub deck spool valve

(cartridges) inspect, clean

and reinstall. Does scrub

deck function in setting (2)?

Install a pressure gauge to

the top of the scrub deck lift

cylinder XT4. Does the

pressure read 160 PSI +/-

5%? In 2 and 0 in 1

No

Yes

Install a pressure gauge to

the bottom of the scrub

deck lift cylinder.

Does the pressure read 160

PSI?

Replace defective spool

valve L15.

Does scrub deck function?

Replace pressure valve 2

(160 PSI) & reset

Does the deck function?

No

Check deck pressure with a scale (1) 120 lbs. (2) 237 lbs.

(3) 385 lbs.

Replace cylinder

No

Does the deck function

in pressure setting (1)?

Scrub deck will not function

in pressure setting (2)

No

Yes

See section B pressure

setting (1).

If pressure is 0 PSI in

setting 2 replace defec-

tive spool valve L5. If

pressure is greater or

less than 160 PSI +/- 5%

adjust pressure valve 2

on scrub block (see

valve block diagram for

location). Are you able to

get 160 PSI?

Yes

No

Yes

No No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

4545

45

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not operate in pressure setting (3)

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with the key switch ON, scrub deck pressure set on (3) by depressing the scrub increase switch on the A2 display panel.

Scrub deck will not function in

pressure setting (3)

Press and release scrub

increase switch (+) until 3 appears in

the display.

Is its green indicator light on?

Substitute a new A2

display panel.

Does the deck lower?

Check for 12 volts at coils:

•L3 (+) ORG (-) BRN

•L4 (+) ORG (-) YEL/BLU

•L5 (+) ORG (-) WHT/VIO

Repair or replace

defective coil wiring.

Does the deck lower?

Check for coil resistance

at L3, L4 & L5 (9 ohm)

Replace defective coil(s).

Does the deck lower?

See Hydraulic scrub deck troubleshooting section Part B position 3.

Yes

No

Press scrub off switch then scrub

increase switch (may need to be cycled to observe lights) observe the green lights on the A1 board S3, S4 &

S5 are they on?

Replace A1 control

board.

Does the deck lower?

No

Yes

No

46 46

46 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not operate in pressure setting (3)

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: All tests should be done with the engine running in high speed (2400 rpm).

Check deck pressure with a

scale (1) 120 lbs. (2) 237 lbs.

(3) 385 lbs.

Remove and disassemble L15

scrub deck spool valve

(cartridge) inspect, clean and

reinstall. Does scrub deck

function in setting (2)?

Install a pressure gauge to

the top of the scrub deck lift

cylinder XT4. Does the

pressure read 160 PSI +/-

5%? In 3 and 0 in 1

No

Install a pressure gauge to

the bottom of the scrub

deck lift cylinder.

Does the pressure

read 0 PSI?

No

Check deck pressure with a

scale (1) 120 lbs. (2) 237 lbs.

(3) 385 lbs.

Replace cylinder

No

Does the deck function in

pressure setting (1 & 2)

Scrub deck will not function

in pressure setting (3)

No

Yes

See section B pressure

settings (1 & 2)

Replace defective spool

valve L15.

Are you able to get 160

PSI?

Yes

No

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

4747

47

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not raise

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with the key switch on, the hopper closed.

Scrub deck will not raise

Press the scrub off switch. Is

its green A2 indicator light on?

Sub. a new A2 display panel.

Does the scrub deck raise?

Press the scrub deck off button. On the A1 board is the S3 green relay indicator light on?

Repair or replace BRN L3 coil

wire. Short to frame ground.

Does the scrub deck raise?

Replace A1 control board.

Does the scrub deck raise?

Check for 12 volts at (L3)

squeegee & deck coil. Wire

colors (+) ORG (-) BRN

See Hydraulic scrub deck

troubleshooting section Part B

Yes

No

Does the squeegee raise?

See squeegee will not raise or lower troubleshooting section.

No

Yes

No

48 48

48 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

Scrub deck will not raise

Press the scrub off switch. Is the

scrub deck cylinder in relief?

Repair or replace

damaged parts.

Does scrub deck function?

Remove and disassemble L3 & L4

scrub deck spool valve (cartridge)

inspect, clean and reinstall.

Does scrub deck function?

Replace defective

cartridge.

Does the scrub

deck raise?

No

Yes

Inspect for possible

mechanical binding of:

scrub deck mount linkage

scrub deck cylinder.

*Insert a pressure gauge

at the XT3 pressure fitting.

Test the (8) relief valve

found on squeegee brush

cylinder valve block

(800 psi).

No

Adjust, clean or replace

#8 relief valve. Does

scrub deck function?

No

Yes

No

Does the squeegee raise?

Yes

See squeegee will not raise or

lower section.

No

Scrub deck will not reach its

correct position?

Inspect for possible mechanical

binding of:

•Scrub deck mount linkage

•Scrub deck cylinder

Repair or replace damaged parts.

Does squeegee function?

Replace cylinder

No

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck will not raise

Part B: Hydraulic Load CircuitPart B: Hydraulic Load Circuit

Part B: Hydraulic Load Circuit

Note: All tests should be done with the engine running in high speed (2400 rpm).

*Note: See hydraulic system manual section for more troubleshooting information.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

4949

49

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

Scrub deck motors

will not operate

Do other auto drive

functions work?

See machine drive auto

function do not work section

Press the scrub decrease

switch along with moving the

foot pedal.

Check on the A1 board to see

if the green S7 motor relay

light is on.

Repair or replace defective

coil wiring.

Do the motors operate?

Check for 12 volts at coil

•L7 (+) ORG (-) ORG/BLU

Replace the defective

L7 coil.

Do the motors operate?

Yes

No

Press scrub decrease switch

(-) on the display.

Is its green indicator light on?

Sub. a new A2 display panel.

Do the motors operate?

No

Yes

See Part B hydraulic scrub

deck motors will not operate

troubleshooting section.

Yes

No

Check for coil resistance

L7 at (9 ohm)

No

Replace A1 control board.

Do the motors operate?

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck motors will not operate

Part A: Electrical Control CircuitPart A: Electrical Control Circuit

Part A: Electrical Control Circuit

Note: Do all testing with the key switch ON, scrub deck pressure set on (1), foot pedal activated and solution OFF.

50 50

50 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

SCRUB SYSTEMSCRUB SYSTEM

SCRUB SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Scrub deck motor(s) will not operate

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: All tests should be done with the scrub deck lowered, drive pedal activated and engine running in high speed (2400 rpm).

All the scrub brush motors

will not turn.

Are the scrub deck and

squeegee in their lowered

position?

*Insert a pressure gauge at

the XT3 pressure fitting.

Does the (1B) relief valve

found on main relief valve

block open at 2400 PSI?

No

Check for debris wrapped

around the motor shafts.

Repair or replace

individual defective

motor.

Do the motors run?

No

Remove and disassemble L7

scrub motor spool valve

(cartridges). Inspect, clean

and reinstall.

Do the motors turn?

Replace defective

spool valve L7

No

Scrub deck motor(s) will

not operate

No

Yes

Repair or replace

individual defective motor.

Adjust, clean or replace

1B relief valve.

Do the motors run?

Yes

No

Yes

Remove debris.

Do the motors run?

No

*Note: See hydrualic sysem manual section for more troubleshooting information.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

5151

51

SOLUTION SYSTEMSOLUTION SYSTEM

SOLUTION SYSTEM

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Solution solenoid valve does not operate

ElectricalElectrical

Electrical

Note: Do all testing with the key switch turned ON, solution switch button depressed, scrub system activated and the drive pedal moved into the FORWARD direction.

Solution solenoid valve does

not work

Press the solution button on the operator A2 panel. Is the green

indicator light on?

Substitute a new A2

display panel. Does the

solution solenoid operate?

Check for 12V at the L16 sole-

noid coil, wire colors (+) ORG

& (-) YEL/GRN

Repair or replace wiring to

the solenoid valve.

Does the solution solenoid

operate?

Check the L16 solenoid coil

resistance it should read

7-9 Ohms.

Replace the L16 coil as it tests

either open or shorted.

Yes

No

Press the solution button and check on the A1 control board to see if the green L16 solution

relay indicator light is on.

Replace the A1 control board.

Does solution solenoid

operate?

No

Yes

Disassemble and clean the

solution valve body and retest.

If it still does not operate replace with a new L16 solution solenoid valve assembly

No

52 52

52 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

RECOVERY SYSTEMRECOVERY SYSTEM

RECOVERY SYSTEM

Vacuum motor

will not operate

Press the squeegee switch, is

its green A2 indicator light on?

On the A2 board is the

recovery tank full light on?

Locate the indicator switch

plug and jump out the

machine harness wires

GRY/YEL and BLK.

Does the light go off?

Repair machine harness

wires to A1 board

(GRN/YEL & BLK)

Does the light go off?

Press the squeegee button along with moving the foot

pedal. On the A1 board, is the

(S8) vacuum relay light on?

Yes

No

Replace the recovery

tank full switch.

Does vacuum operate?

Yes

Replace A1 control

board does the vacuum

motor operate?

Continued on next page

Yes

No

Sub. a new A2 display panel

Does vacuum operate?

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Vacuum motor will not operate

Part A1: ElectricalPart A1: Electrical

Part A1: Electrical

Note: Do all testing with the key switch ON, recovery tank empty and the hopper closed. Squeegee switch must be activated on the display panel and the foot pedal moved into forward or reverse.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

5353

53

RECOVERY SYSTEMRECOVERY SYSTEM

RECOVERY SYSTEM

Continued from previous

page

Check for 12 volts at

the L8 coil, wire colors

(+) ORG, (-) BLU.

Repair or replace wiring

to coils.

Does vacuum motor operate?

See Hydraulic vacuum motor

troubleshooting section Part B.

Yes

No

Check for coil resistance

at L8 valve (9 ohm)

Replace defective coil.

Does vacuum motor operate?

No

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Vacuum motor will not operate

Part A2: ElectricalPart A2: Electrical

Part A2: Electrical

Note: Do all testing with the key switch ON, recovery tank empty and the hopper closed. Squeegee switch must be activated on the display panel and the foot pedal moved into forward or reverse.

54 54

54 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

RECOVERY SYSTEMRECOVERY SYSTEM

RECOVERY SYSTEM

Vacuum motor will not operate

Is machine pump circuit 1 in relief?

Repair or replace

damaged parts.

Does the vacuum motor

operate?

Remove and disassemble L8 vacuum

motor spool valve (cartridge) inspect,

clean and reinstall.

Does motor operate?

Replace defective

spool valve L8.

Does motor operate?

Replace motor

No

Yes

Inspect for possible

mechanical binding or

debris in the vacuum

motor impeller assembly.

Does the vacuum motor

operate?

Does the main broom on

pump circuit 1 work?

No

See hydraulic load troubleshooting section title,

No accessories work.

No

Yes

No

Poor pick-up performance

Inspect for possible mechanical

binding or debris in the vacuum

motor impeller assembly.

Should run at 7250 + or - (5%) RPM

Replace motor

Repair or replace damaged parts.

Check for vacuum air flow

restriction and leaks.

Water lift min. 22 inches.

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Vacuum motor will not operate

Part B: HydraulicPart B: Hydraulic

Part B: Hydraulic

Note: Do all testing with the engine running in high speed (2400 rpm).

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

5555

55

RECOVERY SYSTEMRECOVERY SYSTEM

RECOVERY SYSTEM

Squeegee will not raise

or lower

Press the squeegee switch. Is

its green indicator light on?

Sub. a new A2 display

panel

Does squeegee operate?

Check for 12 volts inputs at L1

and L2 coils, wire colors

(+)ORG L1 and L2

(-) L1 BLU/WHT (-) L2 ORG/RED

Repair or replace wiring

to coils

Does squeegee operate?

Check for coil resistance at

L1 and L2 (9 ohm)

Replace defective coil.

Does squeegee operate?

See Hydraulic squeegee

troubleshooting section

Part B

Yes

No

Press the squeegee button,

then observe the green lights

on the A1 relay board.

down: S1 (momentary) S2 on

up: S2 off S1 (momentary)

Replace A1 control

board.

Does squeegee operate?

No

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Squeegee will not raise or lower.

Part A:Part A:

Part A:

Note: Do all testing with the key switch ON, recovery tank empty and the hopper closed. Squeegee switch must be activated on the display panel.

56 56

56 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

RECOVERY SYSTEMRECOVERY SYSTEM

RECOVERY SYSTEM

Squeegee will not raise or lower

Is squeegee cylinder in relief

Repair or replace dam-

aged parts.

Does squeegee function?

Remove and disassemble

L1 and L2 squeegee spool

valve (cartridge) inspect,

clean and reinstall

Does squeegee function?

Squeegee will not reach its

correct position?

Inspect for possible

mechanical binding of:

•Squeegee mount linkage

•Squeegee cylinder

Replace defective spool valve

L1 and L12.

Does squeegee function?

Replace cylinder

No

Yes

Inspect for possible

mechanical binding of:

•Squeegee mount linkage

•Squeegee cylinder

*Insert a pressure gauge

at the XT3 pressure fitting.

Test the (800 PSI) relief

valve see Figure 5 hydrau-

lic system.

No

Adjust, clean or replace

#8 relief valve

Does squeegee function?

No

Yes

No

Repair or replace damaged parts.

Does squeegee function?

Yes

No

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Squeegee will not raise or lower.

Part B:Part B:

Part B:

Note: Do all testing with the engine running in high speed (2400 rpm).

*Note: See hydrualic sysem manual section for more troubleshooting information.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

5757

57

ENGINE SYSTEMENGINE SYSTEM

ENGINE SYSTEM

6"

Jumper Wire (AWG 16)

“A”

“D”

Protective Cap

Communication Port

1.6 liter GM Engine Specification1.6 liter GM Engine Specification

1.6 liter GM Engine Specification

Engine type Liquid Cooled, 4 Cylinder, Single Overhead cam

Distributor-less Displacement 98 Cubic inches (1600 cc) Fuel Gasoline 87 Octane Unleaded Gasoline with no more than

10% Ethanol by volume Fuel LP 33 Lbs. Tank Size (liquid withdrawal system) Spark Plugs AC DELCO PN 93206675, Gap .032 -.035 (.8 mm-.9 mm) Spark Plug wiring Match Numbered Coil Position to Spark Plug

Number (front to rear 1, 2, 3 & 4) Engine Firing Order 1-3-4-2 Ignition Timing Fixed (controlled by engine ECM) Engine Rotation CCW (flywheel end) Valve lifters Hydraulic Oil Capacity 3.7 qts. (3.5L) with Oil Filter Oil Pressure 21 PSI (minimum with engine hot at idle) Cooling System 3.5 qts. Engine Only

ROUTINE ENGINE MAINTENANCEROUTINE ENGINE MAINTENANCE

ROUTINE ENGINE MAINTENANCE

• Keep the fuel tank filled. This helps to reduce condensation and moisture entering the fuel system (gasoline).

• Make daily checks of the engine oil and coolant levels.

• Repair any oil or coolant leaks immediately.

• Check condition of battery (water level) and cables weekly.

• Keep the engine air filter clean.

• Observe the engine coolant temperature gauge frequently.

• Observe the engine oil pressure gauge frequently.

• Check the voltmeter and charging system.

CHECK ENGINE LIGHT TROUBLESHOOTINGCHECK ENGINE LIGHT TROUBLESHOOTING

CHECK ENGINE LIGHT TROUBLESHOOTING

The engine ECM will light (turn on) the dash panel

((

(

CC

C

))

) check engine light if there is a problem associated with the computerized engine

control system.

The following steps explain how to correctly access the engine controller’s fault code outputs.

11

1 On the A2 display panel the engine check light (MIL) comes on steady will not shut off. 22

22

2 Locate the 4-way ECM communication test port, which is a part of the engine wiring harness (location in area of engine starter). 33

33

3 Next remove the test port protective cap. See Figure 1. Insert a suitable jumper wire across pin “A” (orange wire) & pin “D”

(black/green wire).

44

4 Turn the engine key switch to the on position and observe the indicator lights special error code flashing sequence. See

PSI

Engine Fault Code Table

for a description of the fault indications.

FIGURE 1FIGURE 1

FIGURE 1

58 58

58 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

ENGINE SYSTEMENGINE SYSTEM

ENGINE SYSTEM

PSI ENGINE FAULT CODE TABLEPSI ENGINE FAULT CODE TABLE

PSI ENGINE FAULT CODE TABLE

FAULT CODESFAULT CODES

FAULT CODES

CORRECTIVE ACTIONCORRECTIVE ACTION

CORRECTIVE ACTION

SFC 111- IAT High Voltage * SFC 112- IAT Low voltage * SFC 113- IAT Higher Than Expected 1 * SFC 114- IAT Higher Than Expected 2 * SFC 115- Oil Pressure Low * SFC 121- CHT/ECT High Voltage * SFC 122- CHT/ECT Low Voltage * SFC 123- CHT Higher Than Expected 1 * SFC 124- CHT Higher Than Expected 2 * SFC 131- MAP High Pressure * SFC 132- MAP Low Voltage * SFC 134- BP High Pressure * SFC 135- BP Low Pressure * SFC 136- TIP Voltage High * SFC 137- TIP Voltage Low * SFC 142- Crank Sync Noise * SFC 143- Never Crank Synced At Start * SFC 211- Closed Loop Multiplier High (LPG) * SFC 212- HO2S Open/Inactive * SFC 221- Closed Loop Multiplier High (gasoline) * SFC 222- Closed Loop Multiplier Low (gasoline) * SFC 241- Adaptive Lean Fault (high limit- gasoline) * SFC 242- Adaptive Rich Fault (low limit- gasoline) * SFC 243- Adaptive Learn High (LPG) * SFC 244- Adaptive Learn Low (LPG) * SFC 261- System Voltage High * SFC 262- System Voltage Low * SFC 311- Coil Driver #1 Open * SFC 312- Coil Driver #1 Shorted * SFC 313- Coil Driver #2 Open * SFC 314- Coil Driver #2 Shorted * SFC 411- Injector Driver #1 Open * SFC 412- Injector Driver #1 Shorted * SFC 413- Injector Driver #2 Open * SFC 414- Injector Driver #2 Shorted * SFC 415- Injector Driver #3 Open * SFC 416- Injector Driver #3 Shorted * SFC 421- Injector Driver #4 Open * SFC 422- Injector Driver #4 Shorted * SFC 511- COP Failure * SFC 512- Invalid Interrupt * SFC 513- A/D Loss * SFC 514- RTI 1 Loss * SFC 515- Flash Checksum Invalid * SFC 516- RAM Failure * SFC 521- Shutdown Request * SFC 531- External 5v Reference Lower Than Expected * SFC 532- External 5v Reference Higher Than Expected * SFC 555- RTI 2 Loss * SFC 556- RTI 3 Loss * SFC 611- FPP High Voltage * SFC 612- FPP Low Voltage * SFC 613- FPP Higher Than IVS Limit * SFC 614- FPP Lower Than IVS Limit *

**

*Information not available at time of printing.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

5959

59

ENGINE SYSTEMENGINE SYSTEM

ENGINE SYSTEM

PSI ENGINE FAULT CODE TABLE (continued)PSI ENGINE FAULT CODE TABLE (continued)

PSI ENGINE FAULT CODE TABLE (continued)

FAULT CODESFAULT CODES

FAULT CODES

CORRECTIVE ACTIONCORRECTIVE ACTION

CORRECTIVE ACTION

SFC 631- TPS1 (signal voltage) High * SFC 632- TPS1 (signal voltage) Low * SFC 633- TPS2 (signal voltage) High * SFC 634- TPS2 (signal voltage) Low * SFC 635- TPS1 Higher Than TPS2 * SFC 636- TPS1 Lower Than TPS2 * SFC 637- Throttle Unable To Open * SFC 638- Throttle Unable To Close * SFC 651- Max Govern Speed Override * SFC 652- Fuel Rev Limit * SFC 653- Spark Rev Limit *

**

*Information not available at time of printing.

MISCELLANEOUS ENGINE SYSTEM INFORMAMISCELLANEOUS ENGINE SYSTEM INFORMA

MISCELLANEOUS ENGINE SYSTEM INFORMA

TIONTION

TION

Additional Engine Troubleshooting Symptom

Engine OverheatingEngine Overheating

Engine Overheating Use the checklist below as a guide, to thoroughly check the engine cooling system.

• Check coolant level in overflow tank and radiator.

• Inspect and clean radiator and hydraulic oil cooler.

• Check for proper operations of the hydraulic driven engine cooling fan (RPM’s).

• Check to see that the engine thermostat opens.

• Check for proper operation of water pump.

• Check engine crankcase oil level.

Over Temperature Protection: Engine shutdown occurs at X* degrees.

Loss of Oil Pressure Protection: Engine shutdown upon detecting loss of oil pressure.

Engine Speed SettingsEngine Speed Settings

Engine Speed Settings Fast Engine Speed 2400 RPM Idle Engine Speed 1200 RPM

**

*Information not available at time of printing.

ENGINE FUEL SYSTEM FOR GASOLINE MODELSENGINE FUEL SYSTEM FOR GASOLINE MODELS

ENGINE FUEL SYSTEM FOR GASOLINE MODELS

WARNING!WARNING!

WARNING!

To prevent injury or fire when servicing the engine fuel system its high fuel delivery pressure must be relieved. First relieve the built up (trapped) fuel pressure by safely discharging it at the engine fuel injector fuel rail bleeder fitting (Schrader valve).

60 60

60 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

ENGINE SYSTEMENGINE SYSTEM

ENGINE SYSTEM

1

FRONT

2

4

3

1

2

3

4

1-4

2-3

Coil Pack

Cylinders

Firing Order

1, 3, 4, 2

AA - F1 5 Amp Fuse for:

• LP fuel lock-off coil

• starter relay coil

• fuel pump relay coil

BB - F3 15 Amp Fuse for

• input power to the alternator

CC - F4 15 Amp Fuse for

• Fuel Pump

DD - F2 20 Amp Fuse for:

• ECM input

• alternator power relay coil

EE - Relay Fuel Pump FF - Engine Starter Relay GG - Power Relay Alternator

FRONT

B

C

G

F

A

D

Engine Fuse Box

E

FIGURE 3FIGURE 3

FIGURE 3

FIGURE 2FIGURE 2

FIGURE 2

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

6161

61

HYDRAULIC SYSTEMHYDRAULIC SYSTEM

HYDRAULIC SYSTEM

Gauge- 3,000 PSI (207 bar) Hose- 2‘ (61 cm) 6,000 PSI (414 bar) Fitting- Parker Diagnostics PD222

FRONT

Scrub Deck Cylinder

Triple-Gear Pump

XT1

XT2

XT3

XT4

ENGINE

HYDRAULIC SYSTEM TROUBLESHOOTINGHYDRAULIC SYSTEM TROUBLESHOOTING

HYDRAULIC SYSTEM TROUBLESHOOTING

Accurate measurements are the key to troubleshooting a hydraulic system. Once measurements are obtained, they can be compared with specifications to analyze a problem.

To troubleshoot the hydraulic system it is possible to use tachometers, flow gauges or pressure gauges. The pressure gauge should have a range of 0 – 3000 PSI (see Figure 2) and have a Parker Diagnostics connector number PD222. The most convenient way to check for oil flow is to check the motor RPM. Use the chart below to determine the motor RPM, if the motor speed is correct the pump is producing the correct amount of oil flow. However, this does not mean that, if a motor is running too slow the problem is in the pump.

The following information should be used to check for proper motor RPM, system pressure and relief valve settings. The readings are nominal figures and there will be variations due to manufacturer tolerances and system oil temperature. If any reading varies greater than 20% there will be a noticeable loss of performance and should be corrected.

TEST PORT NOMINAL PRESSURE READINGS (see Figure 1)TEST PORT NOMINAL PRESSURE READINGS (see Figure 1)

TEST PORT NOMINAL PRESSURE READINGS (see Figure 1)

••

• Insert pressure gauge (see Figure 1) into one of the three test ports.

••

• Run engine in high idle position. Allow oil to warm up.

••

• The bypass pressure is the pressure reading with no motor or cylinder operating.

••

• The operational pressure is the pressure range the motor or cylinders will operate in.

Note: 100 PSI = 6.9 bar

••

• A much lower than normal bypass pressure could indicate a gear pump problem.

••

• If the bypass pressure remains the same after turning the function on, there could be a problem in the control valve or circuit.

••

• If the operational pressure is within range but the motor speed is too slow the problem could be in the motor.

••

• If the broom motor Operational PSI reading is above the Bypass PSI but is below the Operational PSI check the broom adjustment and wear.

••

• Check individual system troubleshooting sections of this manual for additional information.

FIGURE 2FIGURE 2

FIGURE 2

FIGURE 1FIGURE 1

FIGURE 1

62 62

62 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HYDRUALIC SYSTEMHYDRUALIC SYSTEM

HYDRUALIC SYSTEM

Pump Circuit DISPL GPM

RPM

(in) RPM (out) PSI Relief PSI

Pum p Circuit (1)

Engine @ 2400rpms No Load

(XT1)

.58 cu.in. 6 2400 *675 2700

Main Broom @ sweep postion (Std Broom 2.5" pattern) 3.6cu. in. 6 370 - 390 1400 - 1800 2700 Vacuum Fan .16 cu.in. 6 6800-7100 1575 2700 Hydrostat Charge 150 Main Broom over pressure indicator switch (light) 2400

Pum p Circuit (2)

Engine @ 2400rpms No Load

(XT2)

.58cu.in. 6 2400 *1200 2400

Pum p Ci rcuit (2A)

1.75 Steering Sy stem 4.5c u.in. 1.75 **1850 Dump Door (open/close time 2 - 3 sec.) 1.75 **1850 Hopper Lift (E xtend time 15.4 sec. ) Empty 1.75 **1850

Pump Circuit (2B)

Engine @ 2400rpms No Load 6 *1200 2400 Engine Fan .32 cu. in. 4.3 2900-3000 1200 2400 Dust Control . 16 cu. in 4.3 4950 1550 2400 Side Brooms 8.9 cu.in. 4.3 106 1250 2400

Pum p Circuit (3)

Engine @ 2400rpms No Load

(XT3)

.50 c u.in 5.2 2400 *300 2400 Scrub (1) Std. 180 grit brush on sealed concrete 4.5 cu.in 5.2 270 650 2400 Scrub (2) Std. 180 grit brush on sealed concrete 4.5 cu.in 5.2 265 1000 2400 Scrub (3) Std. 180 grit brush on sealed concrete 4.5 cu.in 5.2 255 1350 2400 Scrub (1) Black pad on s ealed c oncrete 4.5 cu.in 5.2 270 800 2400 Scrub (2) Blac k pad on sealed conc rete 4.5 cu.in 5.2 265 1200 2400 Scrub (3) Blac k pad on sealed conc rete 4.5 cu.in 5.2 255 1650 2400 Scrub Deck Cylinder (Pressure Setting 1) piston end 0 0 Scrub Deck Cylinder (Pressure Setting 2) piston end ***160 Scrub Deck Cylinder (Pressure Setting 3) piston end ***160 Scrub up 800 800 Squeegee Up/Down 800 800

Propulsion Pump Circuit

Hydrostatic Pump 1.44 cu. in

.

14.9 2400 2500

Wheel Motor @ 6mph (level surface) 19.8 cu. in

.

10.8 Fwd 126 1000 Rev. 73

* The bypass pressure is the pressure reading with no motor or cylinder operating.* The bypass pressure is the pressure reading with no motor or cylinder operating.

* The bypass pressure is the pressure reading with no motor or cylinder operating. ** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850)** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850)

** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850)** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850)

** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850) *** Adjustable pressure flow valve. Factory setting 160psi.*** Adjustable pressure flow valve. Factory setting 160psi.

*** Adjustable pressure flow valve. Factory setting 160psi.*** Adjustable pressure flow valve. Factory setting 160psi.

*** Adjustable pressure flow valve. Factory setting 160psi.

GENERAL HYDRAULIC SPECIFICAGENERAL HYDRAULIC SPECIFICA

GENERAL HYDRAULIC SPECIFICA

TIONS TTIONS T

TIONS T

ABLEABLE

ABLE

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

6363

63

HYDRAULIC SYSTEMHYDRAULIC SYSTEM

HYDRAULIC SYSTEM

FRONT

Relief Valve 2700 PSI vacuum fan & main broom

1

1A

1B

Relief Valve 2400 PSI engine fan, steering, dump door, hopper lift, side brooms & dust control

Relief Valve 2400 PSI scrub brushes, squeegee lift & scrub lift

Divider Cartridge

L6

Pressure Switch main broom/vac fan

S4

Main Broom Valve

L7

Scrub Brush Valve

S6 Coil

Adjustment Screw

Lock-nut

Top Hose Location

FRONT

Main Broom Motor

Main Relief and Broom/Scrub Motors Valve Block

FIGURE 3FIGURE 3

FIGURE 3

Setting Relief valve pump circuit 1Setting Relief valve pump circuit 1

Setting Relief valve pump circuit 1

Cap and plug broom drive motor inlet hose # 56 (top hose from B port valve block).

Raise hopper and install a metal washer to the magnetic hopper switch (S12).

Open engine hopper door panel to access pump relief valve block assembly.

Connect adapter cord PN 56407502 to L6 Main Broom solenoid coil (wire colors ORG & GRN/GRY).

Insert hydraulic test gauge (3000psi) to the XT 1 test port.

To adjust the hydraulic oil must be warm and engine in high speed (2400rpm).

Energize L6 main broom solenoid using the adapter cord. The pump circuit 1 will be in overload use caution not to leave in this position for a long period, may cause damage.

Observe the pressure gauge and adjust accordingly. Relief should be at 2700psi. Loosen Lock-nut, turn Adjustment Screw CCW to decrease pressure CW to increase.

64 64

64 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HYDRUALIC SYSTEMHYDRUALIC SYSTEM

HYDRUALIC SYSTEM

FRONT

Dump Door Open Valve

L11

L12

Dump Door Close Valve

Side Broom Valve

L10

L13

Hopper Raise Valve

L14

Hopper Lower Valve

FRONT

Outside Hose Location

Right Side Broom Motor

Hopper and Side Broom Function Valve Block

FIGURE 4FIGURE 4

FIGURE 4

To test Relief valve setting pump circuit 2ATo test Relief valve setting pump circuit 2A

To test Relief valve setting pump circuit 2A

Insert hydraulic test gauge (3000psi) to the XT 2 test port.

To check, the hydraulic oil must be warm and engine in high speed (2400rpm).

Turn steering wheel to its stop and hold. The pressure reading should be 1850psi. Remove, clean and inspect. If still not correct replace steering control unit.

Setting Relief valve pump circuit 2BSetting Relief valve pump circuit 2B

Setting Relief valve pump circuit 2B

Open the hopper filter door and remove the filter and metal cover under the filter. Connect adapter cord PN 56407502 to L10 side Broom solenoid coil, (wire colors ORG & BRN/BLK) and carefully lower the door back in place do not latch. Raise the hopper part way and lower the side brooms. Cap the right side broom drive motor inlet hose # 37 (outside hose at motor). Finish raising the hopper and engage the safety latch. Carefully reopen the door.

Open engine hopper door panel to access pump relief valve block assembly.

Insert hydraulic test gauge (3000psi) to the XT 2 test port.

To adjust, the hydraulic oil must be warm and engine in high speed (2400rpm).

Energize L10 side broom solenoid using the adapter cord. The pump circuit 2B will be in overload and

the engine fan willthe engine fan will

the engine fan will

stop running use caution not to leave in overload for a long period. May cause engine damage.stop running use caution not to leave in overload for a long period. May cause engine damage.

stop running use caution not to leave in overload for a long period. May cause engine damage.

Observe the pressure gauge and adjust accordingly. Relief should be at 2400psi. CCW to decrease pressure CW to increase.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

6565

65

HYDRAULIC SYSTEMHYDRAULIC SYSTEM

HYDRAULIC SYSTEM

FRONT

Relief Valve 800 PSI squeegee lift

L15

L3

L4

L1

L2

L5

Port Check Cartridge

Pressure Reducer Cartridge 160 PSI

Scrub Down Valve

Squeegee Valve

Demand Valve

Right Side Scrub Brush Motor

Inside Hose Location

FRONT

Squeegee/Brush Cylinder Valve Block

FIGURE 5FIGURE 5

FIGURE 5

Setting main relief valve pump circuit 3Setting main relief valve pump circuit 3

Setting main relief valve pump circuit 3

Cap and plug the right side scrub brush drive motor inlet hose # 41 (inside hose).

Raise hopper and open engine hopper door panel to access pump relief valve block assembly.

Connect adapter cord PN 56407502 to L7 Main scrub brush motor solenoid coil (wire colors ORG & ORG/BLU).

Insert hydraulic test gauge (3000psi) to the XT 3 test port.

To adjust the hydraulic oil must be warm and engine in high speed (2400rpm).

Energize L7 scrub brush solenoid using the adapter cord. The pump circuit 3 will be in overload use caution not to leave in this position for a long period, may cause damage.

Observe the pressure gauge and adjust accordingly. Relief should be at 2400psi. CCW to decrease pressure CW to increase.

Setting relief valve scrub up and squeegee system cylinders.Setting relief valve scrub up and squeegee system cylinders.

Setting relief valve scrub up and squeegee system cylinders.

Locate the valve body assembly under the recovery tank. Connect the adapter cord to the L1 demand valve wire colors ORG and BLU/WHT.

Insert hydraulic test gauge (1000psi) to the XT 3 test port.

To adjust the hydraulic oil must be warm and engine in high speed (2400rpm).

Energize L1 demand valve solenoid using the adapter cord. The pump circuit 3 will be in overload use caution not to leave in this position for a long period, may cause damage.

Observe the pressure gauge and adjust accordingly. Relief should be at 800psi. CCW to decrease pressure CW to increase.

Setting the adjustable pressure flow valve scrub pressures 2 and 3.Setting the adjustable pressure flow valve scrub pressures 2 and 3.

Setting the adjustable pressure flow valve scrub pressures 2 and 3.

Insert hydraulic test gauge (1000psi) to the test port on the scrub deck cylinder.

Locate the valve body assembly under the recovery tank. Locate the adjustable pressure flow valve see Figure 5.

Observe the pressure gauge and adjust accordingly. Circuit flow pressure should be 160psi. CCW to decrease pressure CW to increase.

66 66

66 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HYDRUALIC SYSTEMHYDRUALIC SYSTEM

HYDRUALIC SYSTEM

STEERING

56304120

56305040

STEER

SLEEVE

56304790

SLEEVE

56305489

VALVE BLOCK

56304533

R L P T E

P T P1 C D T1 B A

56416121

DOOR

DUST FAN

56418973

26

25

57

27

28

36

33

ENGINE FAN

56305068

RIGHT SIDE

BROOM

56305204

LEFT SIDE

BROOM

56305204

38

40

37

A-PORT

B-PORT

31

56304477

HOPPER

30

MANIFOLD

56304791

COOLER

56304702

39

5

6

RESERVOIR

56304186

4

SLEEVE

56463427

WHEEL

56304114

11

9

12

PUMP HYDRO

56304351

PUMP

GEAR

56304111

7

8

14

15

52

47

13

21

35

34

46

FILTER

56304419

19

20

VAC FAN

56304261

1

2

3

A B E F G D C

T1 P1 P2 P3 T2

VALVE BLOCK

56304258

16

56

22

MAIN

BROOM

56304116

SCRUB

LEFT

56305070

SCRUB

MID

56304118

SCRUB

RIGHT

56305071

56

55

43

54

45

42

41

32

23

24

52

VALVE BLOCK

56304257

T P1 P T2 B A D C

50

56305244

SQUEEGEE

50

56305245

SCRUB

48

49

HOPPER

44

60

61

58

59

REV. FOR.

PS

17

18

B

FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

- 67- 67

- 67

HYDRAULIC SYSTEMHYDRAULIC SYSTEM

HYDRAULIC SYSTEM

6868

68

--

- FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

HYDRAULIC SYSTEMHYDRAULIC SYSTEM

HYDRAULIC SYSTEM

17

11

12

18

20

19

13

HYDRAULIC COMPONENT LOCAHYDRAULIC COMPONENT LOCA

HYDRAULIC COMPONENT LOCA

TIONTION

TION

ItemItem

Item

QtyQty

Qty

DescriptionDescription

Description

1 1 Squeegee Cylinder Assembly 2 1 Steering Cylinder Assembly 3 1 Scrub Cylinder Assembly 4 1 Hopper Lift Cylinder Assembly 5 1 Hopper Door Cylinder Assembly 6 1 Steering Unit Assembly 7 1 Oil Cooler Assembly 8 1 Oil Filter Assembly

9 1 Reservoir Assembly 10 3 Scrub Motor Assembly 11 1 Squeegee Fan Motor Assembly 12 1 Engine Fan Motor Assembly 13 1 Impeller Motor Assembly 14 1 Wheel Motor Assembly 15 1 Main Broom Motor Assembly 16 2 Side Broom Motor Assembly 17 1 Squeegee/Brush Cylinder Valve Block Assembly 18 1 Manifold Assembly 19 1 Main Relief and Broom/Scrub Motors Valve Block Assy. 20 1 Hopper and Side Broom Valve Block Assembly 21 1 Piston Pump Assembly 22 1 Triple Gear Pump Assembly

10

9

6

14

15

21

22

16

1

2

3

7

8

4

5

FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

- 69- 69

- 69

ELECTRICAL SYSTEMELECTRICAL SYSTEM

ELECTRICAL SYSTEM

F2

FRONT

M3

A3

S12

M2

M4

H1

BT

L16

Fuses

S16

S1

A2

S9

S3

S8

H16

H8

S6

R2

A1

F1

F3

F4

F9

F5

F6

F7

Relays

P6

H2

H3

H4

K1

K2

K3

K4

ELECTRICALELECTRICAL

ELECTRICAL COMPONENT LOCACOMPONENT LOCA

COMPONENT LOCACOMPONENT LOCA

COMPONENT LOCA

TIONTION

TION

ItemItem

Item

DescriptionDescription

Description

A1 Control Box Assembly A2 Membrane Switch A3 Engine System BT Battery

F1 Circuit Breaker, 25 Amp (ACC 1) F2 Circuit Breaker, 15 Amp (ACC 2) F3 Circuit Breaker, 10 Amp (IGN) F4 Circuit Breaker, 15 Amp (ST) F5 Circuit Breaker, 10 Amp (HORN) F6 Circuit Breaker, 15 Amp (HEADLIGHTS) F7 Circuit Breaker, 15 Amp (SHAKER)

F9 Circuit Breaker, 60 Amp (MAIN) H1 Headlight, Right H2 Headlight, Left H3 Lamp, Tail H4 Lamp, Tail H8 Broom Pressure Lamp

H16 Horn

K1 Relay, Horn K2 Relay, Lights K3 Relay, Shaker K4 Relay, Neutral (closed in neutral)

L16 Solution Valve

M2 Shaker Motor M3 Fuel Pump

(Gas only)(Gas only)

(Gas only)

M4 Actuator, Side Broom

P6 Gauge, Combination R2 Drive Pedal Sensor S1 Switch, Ignition S3 Switch, Low LP Pressure S6 Switch, Hydraulic Filter S8 Switch, Recovery Full S9 Switch, Solution Empty

S12 Switch, Hopper Interlock S16 Switch, Main Broom

Hydraulic Valve Truth Table

Function S 1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15

Scrub On X Scrub (1) X X X Scrub (2) X X X Scrub (3) X X X Scrub Up X Squeegee Down X X X Vacuum Fan X Squeegee Up X X Main Broom X Side Broom X Dust Control X Hopper Up X Hopper Down X Dump Door Open X Dump Door Close X

7070

70

--

- FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

ELECTRICAL SYSTEMELECTRICAL SYSTEM

ELECTRICAL SYSTEM

X8

R3

SENDER, FUEL

R1

SENDER, OIL PRESSURE

X8

H8

LAMP, BROOM PRESSURE

H5

LIGHT, BEACON

F1

CIRCUIT BREAKER, 25 AMP

P6

GAUGE, COMBINATION

1

2

3

4

5

6

7

X9

BT

12 VDC

F9

CIRCUIT BREAKER, 60 AMP

M3

FUEL PUMP

M

S1

SWITCH, IGN.

X9

F2

CIRCUIT BREAKER, 15 AMP

K4

RELAY, NEUTRAL

X7

S4

I4249050

X8

F4

CIRCUIT BREAKER, 15 AMP

F3

CIRCUIT BREAKER, 10 AMP

X9

VIO

BLK

RED

YEL/BLK

ORN

PINK

GRA/BLU

BLU/BLK

E

1

2

1

2

D

1

2

1

2

3

4

5

6

7

F

+

-

J

A

D

H

K

PINK/YEL

RED

ORN/GRN

BLK

WHT/GRN

ORN

GRN/BLK

YEL/BLK

GRA/BLK

BLK

VIO

BLK

WHT/BLK

VIO

PINK

BLK

RED

BLU/PINKBLU/PINK

PINK

VIO/BLU

RED

PINK/BLK

BLU/PINK

PINK

RED/GRN

GRA/BLU

BLU/BLKBLU/BLK

GRA/BLU

TAN/BRNTA N/BR N

VIO

BLK

YEL/BRN

VIO

BLK

A3

ENGINE

SYSTEM

FROM LIGHTING

CIRCUIT

NOTE:

R3 IS NOT USED ON L.P. MODEL

(CLOSED IN NEUTRAL)

STARTER SOLENOID INPUT

STARTER B+

IGN. SW INPUT

MIL OUTPUT

(SWITCHED

GROUND)

THROTTLE INPUT

(12V FOR HIGH)

FUEL PUMP OUTPUT

GROUND

(REFERENCE: E-CONTROLS, INC. DRAWING NO.

E1331)

FUEL SELECT INPUT

COOLANT TEMPERATURE

OUTPUT

STARTER SOLENOID INPUT

TO CONTROL BOX

ASSEMBLY

CHECK ENGINE LIGHT OUTPUT TO CONTROL BOX ASSEMBLY

CONNECT TO J3-9

ON CONTROL BOX ASSEMBLY

(OPTION)

NOTE: TAN/BRN WIRE IS CONNECTED (+12 V) FOR LP.

TAN/BRN WIRE IS CUT (OPEN) FOR GASOLINE.

2

1

2

1

-

+

2

1

2

1

87a

30

87

2

1

IGN

BAT

ST

ACC

2

1

2

1

A1 Control Box Assembly A2 Membrane Switch A3 Engine System BT Battery F1 Circuit Breaker, 25 Amp (ACC 1) F2 Circuit Breaker, 15 Amp (ACC 2) F3 Circuit Breaker, 10 Amp (IGN) F4 Circuit Breaker, 15 Amp (ST) F5 Circuit Breaker, 10 Amp (HORN) F6 Circuit Breaker, 15 Amp (HEADLIGHTS) F7 Circuit Breaker, 15 Amp (SHAKER) F9 Circuit Breaker, 60 Amp (MAIN) H1 Headlight, Right H2 Headlight, Left H3 Lamp, Tail H4 Lamp, Tail H5 Light, Beacon

(optional)(optional)

(optional)

H6 Lamp, Curb

(optional)(optional)

(optional)

H7 Lamp, Trouble

(optional)(optional)

(optional)

H8 Lamp, Broom Pressure

H15 Back-Up Alarm

(optional)(optional)

(optional)

H16 Horn

K1 Relay, Horn K2 Relay, Lights K3 Relay, Shaker K4 Relay, Neutral (closed in neutral)

L1 Demand Valve, S1 L2 Squeegee Valve, S2 L3 Demand Valve, S3 L4 Scrub Down Valve, S4 L5 Scrub Down Valve, S5 L6 Main Broom Valve, S6 L7 Scrub Brush Valve, S7 L8 Vac Fan Valve, S8

L9 Dust Control Valve, S9 L10 Side Broom Valve, S10 L11 Dump Door Open Valve, S11 L12 Dump Door Close Valve, S12 L13 Hopper Raise Valve, S13 L14 Hopper Lower Valve, S14 L15 Scrub Down Valve, S15 L16 Solution Valve M2 Shaker Motor

ItemItem

Item

DescriptionDescription

Description

WIRING DIAGRAM / SCHEMAWIRING DIAGRAM / SCHEMA

WIRING DIAGRAM / SCHEMA

TIC FORTIC FOR

TIC FOR

CaptorCaptor

Captor

™™

™

ItemItem

Item

DescriptionDescription

Description

M3 Fuel Pump

(Gas only)(Gas only)

(Gas only)

M4 Actuator, Side Broom

P6 Gauge, Combination R1 Sender, Oil Pressure R2 Drive Pedal Sensor R3 Sender, Fuel S1 Switch, Ignition S2 Switch, Wand

(optional)(optional)

(optional) S3 Switch, Low LP Pressure S4 Switch, Broom Pressure S5 Switch, Dust Control Filter

(optional)(optional)

(optional) S6 Switch, Hydraulic Filter S7 Switch, Hopper Fire

(optional)(optional)

(optional) S8 Switch, Recovery Full S9 Switch, Solution Empty

S12 Switch, Hopper Interlock S16 Switch, Main Broom

ItemItem

Item

DescriptionDescription

Description

H6

CURB LAMP

M4

ACTUATOR, SIDE BROOM

M

L16

SOLUTION VALVE

L2

SQUEEGEE VALVE S2

S7

SWITCH, HOPPER FIRE

K1

RELAY, HORN

K3

RELAY, SHAKER

F5

CIRCUIT BREAKER, 10 AMP

M2

MOTOR, SHAKER

M

K2

RELAY, LIGHTS

L5

SCRUB DOWN VALVE S5

S9

SWITCH, SOLUTION EMPTY

(OPTIONAL)

H7

TROUBLE LAMP

L1

DEMAND VALVE S1

R2

DRIVE PEDAL SENSOR, 5K OHM

L3

DEMAND VALVE S3

L15

SCRUB DOWN VALVE S15

H2

HEAD LIGHT, LEFT

H3

LAMP, TAIL

F6

CIRCUIT BREAKER, 15 AMP

L11

DUMP DOOR OPEN VALVE S11

L13

HOPPER RAISE VALVE S13

H1

HEAD LIGHT, RIGHT

S5

SWITCH, DUST CONTROL FILTER

L14

HOPPER LOWER VALVE S14

H16

HORN

L4

SCRUB DOWN VALVE S4

K3

RELAY, SHAKER

L7

SCRUB BRUSH VALVE S7

L6

MAIN BROOM VALVE S6

S6

SWITCH, HYDRAULIC FILTER

S12

SWITCH, HOPPER INTERLOCK

L12

DUMP DOOR CLOSE VALVE S12

K1

RELAY, HORN

S3

SWITCH, LOW LP PRESSURE

K4

RELAY, NEUTRAL

H15

BACK UP ALARM

L10

SIDE BROOM VALVE S10

S2

SWITCH, WAND

L9

DUST CONTROL VALVE S9

H4

LAMP, TAIL

K2

RELAY, LIGHTS

S8

SWITCH, RECOVERY FULL

S16

SWITCH, MAIN BROOM

L8

VAC FAN VALVE S8

F7

CIRCUIT BREAKER, 15 AMP

BLK

RED

ORN

VIO

BLU/BLK

GRA/BLU

PINK

YEL/BLK

12

1

2

1

2

1

2

12

1

2

123

1

2

1

2

12

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

12

1

2

ORN

RED/BRN

WHT/YEL

BLU

BRN/BLK

VIO/BRN

ORN/BLU

BLK/WHT

ORN

GRN/BRN

ORN

BRN/YEL

YEL

GRN

YEL/RED

GRN/GRA

RED/GRA

YEL/BLK

BLK

YEL/BLK

BLK

RED

GRA/RED

YEL/BLK

BLK

YEL/BLK

BLU/YEL

BLU/GRN

WHT

BLK

BRN/GRN

ORN

RED

ORN

BLU/WHT

BRN

ORN

YEL/BLU

ORN/RED

ORN

RED

ORN

WHT/VIO

ORN

VIO

ORN

GRN/VIO

ORN

BLK

WHT/GRA

BLK

GRA/BLU

BLK

RED/BLK

YEL/WHT

ORN/BLK

BLK

GRA/YEL

BLU/BRN

GRA/VIO

GRN/YEL

YEL/GRN

GRA/WHT

YEL/GRA

ORN/GRA

BRN/WHT

BLK

YEL/VIO

ORN/BRN

RED/YEL

GRN/BLU

WHT/BRN

BLK

BRN/BLU

PINK

BLK

VIO/YEL

BLK

GRA

BLK

YEL/BLK

BLK

BLK/YEL

(OPTIONAL)

A1

CONTROL BOX

ASSEMBLY

TO GAUGES

t

140 DEG. F

(OPTIONAL)

(CLOSED WHEN

HOPPER IS

DOWN)

(OPEN WHEN

BROOM IS DOWN)

CHECK ENGINE OUTPUT

FROM ENGINE SYSTEM

TROTTLE OUTPUT TO ENGINE SYSTEM (+ 12 V FOR HIGH SPEED)

ACTUATOR MOTOR WIRING:

(-) WHITE & (+) RED = CW (EXTEND)

(+) WHITE & (-) BLACK = CCW( RETRACT)

WHITE = COMMON

(IGN. INPUT)

(ACC INPUT)

(MIL INPUT)

(THROTTLE OUTPUT)

J3-2 LIGHT SENSOR

J3-3 BUZZER

J3-6 SDA

J3-5 SCL

J3-7 (B+)

J3-8 (B-)

A2

SWITCH/DISPLAY

PANEL

ASSEMBLY

J2-22

J2-19

J2-18

J2-11 J2-12

J2-21

J2-20

J2-17

J2-10

J2-2

J2-4

J2-14

J2-8

J2-7

J2-13

J2-6

J2-5

J2-3

J2-15

J1-34

J1-1

J1-11

J1-22

J1-10

J1-21

J1-9

J1-4

J1-20

J1-8

J1-7

J1-18

J1-6

J1-19

J1-17

J1-5

J1-16

J1-15

J1-3

J1-14

J1-2

J1-24

J1-13

J1-29

J1-30

J1-31

J1-32

J1-33

J1-26

J1-12

J1-35

J1-23

16 AWG

(IGN. INPUT)

FROM IGNITION

CIRCUIT

(CLOSES WITH

HIGH HOPPER

TEMPERATURE)

(OPENS WHEN

TANK IS FULL)

(CLOSES WHEN

TANK IS EMPTY)

CLOSES WHEN FILTER IS

PLUGGED)

CLOSES WHEN FILTER IS

PLUGGED)

(CLOSES WHEN TANK

IS EMPTY)

J2-16

2

1

87a

30

87

87a

30

87

21

3

1

2

1

2

12

30

87

87a

12

FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

- 71- 71

- 71

ELECTRICAL SYSTEMELECTRICAL SYSTEM

ELECTRICAL SYSTEM

SCHEMASCHEMA

SCHEMA

TIC FOR CaptorTIC FOR Captor

TIC FOR Captor

™™

™

7272

72

--

- FORM NO. 56043093 Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400

ELECTRICAL SYSTEMELECTRICAL SYSTEM

ELECTRICAL SYSTEM

ENGINE HARNESS for 1.6L Gasoline and PropaneENGINE HARNESS for 1.6L Gasoline and Propane

ENGINE HARNESS for 1.6L Gasoline and Propane

BROWN/BLUE 16

ORANGE/BLUE 16

BROWN/GREEN 16

LT BLUE/WHITE 18

TAN/DK GREEN 18

LT GRN 18 DK BLUE 18 TAN 18 YELLOW/GRAY 18 PURPLE/YELLOW 18 DK BLUE/YELLOW 18 BLACK 16 BLACK 16

BLACK/LT GREEN 18 LT GREEN/RED 18 PINK/TAN 18 DK GREEN/ORANGE 18

PURPLE/WHITE 18

WHITE/PURPLE 18

RED/TAN 16

RED/TAN 16 GRAY/ORANGE 18 WHITE/BLACK 18 TAN/BLACK 18 WHITE/LT BLUE 18 PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 PINK/WHITE 18 TAN/ORANGE 18 LT GREEN/BLACK 18 YELLOW/LT GREEN 18 LT BLUE/BLACK 18 BLACK/WHITE 18 PURPLE/DK BLUE 18 TAN/BROWN 18 YELLOW/DK BLUE 18 GRAY/DK BLUE 18 WHITE/RED 18 BLUE/PINK 18 BLUE/WHITE 18 DK GREEN 18 ORANGE 18 YELLOW 18 YELLOW/BLACK 18

18 16 17 30 35 33 38 32 31 39 36 19 20 49 50 21 55 41 42 11 12 13 14 22 23 9 8 7 10 53 54 24 25 37 56 26 47 29 40 48 34 15 43 44 51 52 27 28 1 4 3 2 5 6

LT GREEN/RED 18

BLK/LT GREEN 18

LT GREEN/RED 18

DK GREEN 18

ORANGE 18

A

B

C

D

RX

TX

5V

RTN

TWR

COMM

TWIST WIRES 10 TURNS(360 DEG)/INCH FULL LENGTH

INJ 1

INJ +

INJ 2

AUX OUT 2

AUX ANA PD1

MAP

FPP

IAT

ECT

IVS

AUX ANA PU1 POWER GROUND POWER GROUND

ANA_RTN 5 VOLT REF

VSW EGO 1

KNK -

KNK +

CRANK + CRANK -

CAM + CAM -

VBAT VBAT

STARTER LOCKOUT

FUEL LOCKOFF FUEL PUMP

RELAY CONTROL

TPS1

TPS2 DBW + DBW -

OIL PRESSURE

TACH

MIL

AUX ANA PD2

AUX OUT 1

AUX ANA PU2

FUEL SELECT

GOV SELECT

GASEOUS TRIM

CAN +

CAN -

RS 232 TX RS 232 RX

COIL 1

COIL 2 UNUSED UNUSED UNUSED

INJ 7 UNUSED UNUSED

PSIECM

YELLOW 18 YELLOW/BLACK 18 BLACK 16 PINK/DK GREEN 16

D

C

B

A

SHD

12162859

BLACK 18

PURPLE/WHITE 18

WHITE/PURPLE 18

CRANK_PSI_1P6

TAN/ORANGE 18

BOSCH THROTTLE

PINK/WHITE 18

LT BLUE/DK BLUE 18

PURPLE/LT BLUE 18

LT GREEN/RED 18

BLK/LT GREEN 18

1

4

5

6

3

2

RED 14

RED/TAN 14

WHITE/BLUE 18

POWER_RELAY

85

86

87

30

PINK/DK GREEN 16

F3 15A

PINK/DK GREEN 16 PINK/DK GREEN 16

RED 12 RED 16

ALTERNATOR

RED 16

ALTERNATOR

B

A

BATT+2

RED 12

FUEL_PUMP_RELAY

F4

15A

PINK/YELLOW 16

87

30

86

85

RED 14

PINK/TAN 18

TAN/BLACK 18

BATT+ 1

F2 20A

RED/TAN 14

RED 14

RED 12

STARTER_RELAY

STARTER SOLENOID

LT BLUE/PINK 16

PINK/BLACK 16

87A

87

30

86

85

GRAY/ORANGE 18

PINK/TAN 18

WHITE 16

RELAY FUSED POWER

GROUND

FUEL PUMP

AUX IN PU1

AUX IN PU2

AUX IN PD2

F

E

D

C

B

A

TWR

PINK/DK GREEN 16

BLACK 16

PINK/YELLOW 16

DK BLUE/YELLOW 18

YELLOW/DK BLUE 18

BLACK/WHITE 18

BLUE/PINK 18

GRAY/DK BLUE 18

TAN/BROWN 18

YELLOW/LT GREEN 18

TAN/DK GREEN 18

LT BLUE/WHITE 18

BLUE/WHITE 18 PURPLE/DK BLUE 18

LT BLUE/BLK 18

LT GREEN/BLACK 18

BLACK/LT GREEN 18

PURPLE/YELLOW 18

DK BLUE 18

PINK 18

LT GREEN/RED 18 ORANGE/YELLOW 18

CAN+

GOV SELECT

FUEL SELECT

TACH

AUX IN PD1

AUX OUT 2

CANAUX OUT 1

F

E

D

C

B

A

G H

TWR

F

E

D

C

B

A

G H J K

TWR

MIL

OIL PRES

ANA RTN

IVS

FPP1

VSW

VREF CHARGE VOLTS START IN (INTERUPT TYPE) START IN (AUTOCRANKING)

LT BLUE/PINK 16 PINK/BLACK 16

F1

5A

GROUND

PINK 18

PINK/TAN 18

BLACK 12

BLACK 16

RED/TAN 16

BLACK 16

RED/TAN 16

ECT

YELLOW/GRAY 18

BLACK/LT GREEN 18AB

BOSCH_TMAP

LT GREEN 18 LT GREEN/RED 18 TAN 18 BLACK/LT GREEN 18

4 3 2

1

MTRSHD6

MTRTWR4_EGO

PINK/TAN 18

WHITE/RED18

WHITE/BLACK 18

BROWN/GREEN 16

BROWN/BLUE 16

ORANGE/BLUE 16

F

E

D

C

B

A

SHD

BLACK 18

PINK/DK GREEN 16

DK GREEN/ORANGE 18

BLK/LT GREEN 18

D

C

B

A

TWR

OIL PRES

G H

RED/WHITE 18

X7

X8

X9

B

E

RING

C

A

D

G

F

K

J

I

H

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 -

7373

73

ELECTRICAL SYSTEMELECTRICAL SYSTEM

ELECTRICAL SYSTEM

FUEL PUMP OUTPUT

F

E

D

C

B

A

PINK/YEL 16-1

GRA/BLU 18-1

TAN/BRN 18-1

VIO/BLU 18-1

PINK 16-6

BLU/BLK 18-1

THROTTLE INPUT (12V for High Speed)

FUEL SELECT INPUT

COOLANT TEMPERATURE OUTPUT

F

E

D

C

B

A

G H

F

E

D

C

B

A

G

H J K

MIL OUTPUT (Switched Ground)

IGN. SWITCH INPUT

STARTER SOLENOID INPUT

BLU/PINK 16-3

BLU/PINK 16-4

BROWN/BLUE 16

ORANGE/BLUE 16

BROWN/GREEN 16

LT BLUE/WHITE 18

TAN/DK GREEN 18

LT GRN 18

DK BLUE 18

TAN 18

YELLOW/GRAY 18

PURPLE/YELLOW 18

DK BLUE/YELLOW 18

BLACK 16 BLACK 16

BLACK/LT GREEN 18 LT GREEN/RED 18

PINK/TAN 18

DK GREEN/ORANGE 18

PURPLE/WHITE 18

WHITE/PURPLE 18

RED/TAN 16

GRAY/ORANGE 18

WHITE/BLACK 18

TAN/BLACK 18

WHITE/LT BLUE 18

PURPLE/LT BLUE 18

LT BLUE/DK BLUE 18

PINK/WHITE 18 TAN/ORANGE 18

LT GREEN/BLACK 18

YELLOW/LT GREEN 18 LT BLUE/BLACK 18

BLACK/WHITE 18

PURPLE/DK BLUE 18

TAN/BROWN 18

YELLOW/DK BLUE 18

GRAY/DK BLUE 18

WHITE/RED 18 BLUE/PINK 18

BLUE/WHITE 18

DK GREEN 18

ORANGE 18 YELLOW 18

YELLOW/BLACK 18

18 16

17

30

35 33 38 32

31

39 36 19

20 49

50 21 55 41 42 11

12

13 14 22 23 9 8 7 10 53 54

24

25 37 56

26

47

29

40

48 34 15 43 44 51 52 27 28 1 4 3 2 5

6

INJ 1

INJ +

INJ 2

AUX OUT 2

AUX ANA PD1

MAP

FPP

IAT

ECT

IVS

AUX ANA PU1

POWER GROUND

ANA_RTN

5 VOLT REF

VSW

EGO 1

KNK -

KNK +

CRANK + CRANK -

CAM +

CAM -

VBAT

STARTER LOCKOUT

FUEL LOCKOFF

FUEL PUMP

RELAY CONTROL

TPS1 TPS2

DBW +

DBW -

OIL PRESSURE

TACH

MIL

AUX ANA PD2

AUX OUT 1

AUX ANA PU2

FUEL SELECT

GOV SELECT

GASEOUS TRIM

CAN +

CAN RS 232 TX RS 232 RX

COIL 1 COIL 2

UNUSED

INJ 7 UNUSED UNUSED

ECM Detail

RELAY FUSED POWER

X7

GROUND

FUEL PUMP

AUX IN PU1

AUX IN PU2

AUX IN PD2

F

E

D

C

B

A

PINK/DK GREEN 16

BLACK 16

PINK/YELLOW 16

DK BLUE/YELLOW 18

YELLOW/DK BLUE 18

BLACK/WHITE 18

X8

BLUE/PINK 18

GRAY/DK BLUE 18

TAN/BROWN 18

YELLOW/LT GREEN 18

TAN/DK GREEN 18

LT BLUE/WHITE 18

X9

BLUE/WHITE 18 PURPLE/DK BLUE 18

LT BLUE/BLK 18

BLACK/LT GREEN 18

PURPLE/YELLOW 18

DK BLUE 18

PINK 18

LT GREEN/RED 18

CAN+

GOV SELECT

FUEL SELECT

TACH

AUX IN PD1

AUX OUT 2

CAN-

AUX OUT 1

F

E

D

C

B

A

G H

F

E

D

C

B

A

G H J K

MIL

ANA RTN

IVS

FPP

VSW

VREF

START IN (INTERUPT TYPE)

START IN (AUTOCRANKING)

LT BLUE/PINK 16 PINK/BLACK 16

X7

X8

X9

Wiring

Harness Wiring Harness Component Description

Item

A ECM Wiring Connector B Fuel System Interface Connector; two separate wire

assemblies are connected and used to control either the

gasoline injectors or the LP (propane) fuel pressure solenoids. C Engine Diagnostic Communication Port (MIL shorting location) D Ignition Coil Pack Wiring Connector

E Engine Oil Pressure Switch

F Crankshaft Position Sensor Connector G Throttle Fly Actuator Motor Connector (Bosch) H EGO Sensor Wiring Connector (not used on pre 2004 engines)

I Combined Engine Air Temperature and MAP Sensor Wiring

Connector

J Engine Coolant Temperature (ECT) Sensor Connector K Engine Starter Solenoid Wire Connector

Definition of Terms for Computerized Engine Controllers

• ECM: Engine Control Module

• EGO: Exhaust Gas Oxygen Sensor (O2)

• MAP: Intake Manifold Absolute Pressure

• MIL: Malfunction Indicator Light

• IAT: Intake Manifold Air Temperature

• VSW: Switched Battery Voltage

• VBAT: Battery Voltage

• ANA-RTN:

RED/WHITE 18

Machine

Harness Connectors

ECM

Harness Connectors

DANMARKDANMARK

DANMARK

DANMARKDANMARK Nilfisk-Advance Nordic A/S Sognevej 25 - Box 344 DK-2605 Broendby ☎ 43 23 83 50 – Fax 43 42 15 95

NORGENORGE

NORGE

NORGENORGE Nilfisk-Advance AS Enebakkvn, 119, 0680 Oslo, Postboks 196, Manglerud, 0612 Oslo ☎ 22 08 63 50 – Fax 22 08 63 63 Distriktsrepresentanter over hele landet

SVERIGESVERIGE

SVERIGE

SVERIGESVERIGE Nilfisk-Advance AB Sjöbjörnsvägen 5, 117 67 Stockholm ☎ 085 55 944 00 – Fax 085 55 944 30

FINLAND/ SUOMIFINLAND/ SUOMI

FINLAND/ SUOMI

FINLAND/ SUOMIFINLAND/ SUOMI BERNER Ltd. Facotek Department Etäleranta 4B, 00130 Helsinki ☎ +358 9 1345 1382

AUSTRALIAAUSTRALIA

AUSTRALIA

AUSTRALIAAUSTRALIA Nilfisk-Advance Pty. Ltd. 48 Egerton Street Silverwater NSW 2128 ☎ (02) 8748 5905 – Fax (02) 9648 2711 Customer Responce Centre: ☎ 1 800 011 013

BELGIQUE / BELGIË/ LUXEMBOURGBELGIQUE / BELGIË/ LUXEMBOURG

BELGIQUE / BELGIË/ LUXEMBOURG

BELGIQUE / BELGIË/ LUXEMBOURGBELGIQUE / BELGIË/ LUXEMBOURG Nilfisk-Advance s.a./n.v. Doornveld/ Sphere Business Park Industrie Asse 3, nr 11 – bus 41 1731 Zellik-Asse ☎ (02) 467.60.50 Fax (02) 463.44.16

CANADACANADA

CANADA

CANADACANADA Nilfisk-Advance Ltd. 396 Watline Avenue Mississauga, Ontario L4Z 1X ☎ (905) 712-3260 – Fax (905) 712-3255

DEUTSCHLANDDEUTSCHLAND

DEUTSCHLAND

DEUTSCHLANDDEUTSCHLAND Nilfisk-Advance AG Siemensstraße 25-27 25462 Rellingen ☎ (041 01) 3990 – Fax ( 04101) 399191

Zentraler Kundenservice

☎ für die Industrie: 0180 535 67 97 ☎ Institutionen und Gebäudereiniger: 0180 500 11 70

FRANCEFRANCE

FRANCE

FRANCEFRANCE Nilfisk-Advance S.A. BP 246 91944 Courtaboeuf Cedex ☎ (01) 69.59.87.00 Télécopie (01) 69.59.87.01

HONG KONGHONG KONG

HONG KONG

HONG KONGHONG KONG Nilfisk-Advance Ltd. 2001, 20/F HK Worsted Mills Industrial Building 31-39 Wo Tong Tsui Street Kwai Chung, N.T. ☎ 2427 59 51 – Fax 2487 5828

IRELANDIRELAND

IRELAND

IRELANDIRELAND Nilfisk-Advance Ltd. 28 Sandyford Office Park Dublin 18 ☎ +353 1 2943838 – Fax +353 1 2943845

JAPANJAPAN

JAPAN

JAPANJAPAN Nilfisk-Advance Inc. 3-4-9 Chigasaki Minami Tsuzuki-Ku Yokohama 224 0037 ☎ 045-942-7741 – Fax 045-942-6545

MALAYSIAMALAYSIA

MALAYSIA

MALAYSIAMALAYSIA Nilfisk-Advance Sdn Bhd

st

Lot 2, 1

. Floor Lorong 19/1A 46300 Petaling Jaya Selangor Darul Ehsan ☎ 03-7568188 / 03-7568189 / 03-7568388 – Fax 03-7566828

NEDERLANDNEDERLAND

NEDERLAND

NEDERLANDNEDERLAND Nilfisk-Advance B.V. Flevolaan 7, Postbus 341 1380 AH Weesp ☎ 0294-462121 – Fax 0294-430053

NEW ZEALANDNEW ZEALAND

NEW ZEALAND

NEW ZEALANDNEW ZEALAND Nilfisk-Advance Limited 477 Great South Road, Penrose Auckland ☎ (09) 525 0092 – Fax (09) 525 6440

SCHWEIZ / SUISSESCHWEIZ / SUISSE

SCHWEIZ / SUISSE

SCHWEIZ / SUISSESCHWEIZ / SUISSE Nilfisk-Advance AG Ringstrasse 19, 9533 Kirchberg/Wil ☎ 719 23 52 83 – Fax 719 23 84 44

SINGAPORESINGAPORE

SINGAPORE

SINGAPORESINGAPORE Nilisk-Advance Pte. Ltd. 22, Woodlands Industrial Park E1 Singapore 757740 ☎ (65) 759 9100 – Fax (65) 759 9133

TAIWANTAIWAN

TAIWAN

TAIWANTAIWAN Nilfisk-Advance Ltd. 1 F, No.23, Lane 132, Sec. 2 Ta An Road, Taipei ☎ 700 22 68 – Fax 784 08 43

UNITED KINGDOMUNITED KINGDOM

UNITED KINGDOM

UNITED KINGDOMUNITED KINGDOM Nilfisk-Advance Limited Newmarket Road Bury St. Edmunds Suffolk IP 33 3SR ☎ (01284) 763163 – Fax (01284) 750562

USAUSA

USA

USAUSA Nilfisk-Advance Inc.

st

Avenue North

14600 21 Plymouth, MN 55447-3408 ☎ +1 800 989 2235 – Fax 1 800 989 6566

Nilfisk-Advance of America, Inc. 300 Technology Drive Malvern, PA 19355 ☎ (610) 647 647-6427

ÖSTERREICHÖSTERREICH

ÖSTERREICH

ÖSTERREICHÖSTERREICH Nilfisk-Advance GmbH Vorarlberg Allee 46 1230 Wien ☎ 1 616 58 30 – Fax 1 616 58 30 40

ESPAÑAESPAÑA

ESPAÑA

ESPAÑAESPAÑA Nilfisk-Advance, S.A. Torre D’Ara Passeig del Rengle, 5 PI.9-10 E-08302 – Mataró (Barcelona)

☎ Tel. 93 741 24 00 – Fax: 93 757 80 20

Central atención al cliente: 902 200 201

nilfisk@nilfisk-advance.es – www.nilfiskadvance.com

Distribuidores y Servicio Técnico en toda España y Andorra

ITALIAITALIA

ITALIA

ITALIAITALIA Nilfisk-Advance Italia Spa Località Novella Terza 26862 Guardamiglio (LO) Italy ☎ +39 0377 414067-54 – Fax +39 0377 414097

www.nilfisk-advance.com

PORTUGALPORTUGAL

PORTUGAL

PORTUGALPORTUGAL Nilfisk-Advance Lda. Rua Cândido de Figueiredo, 91-i, 1500-133 LISBOA ☎ 01/7784142 – Fax 01/7785613 Porto 02/526766 – Fax 02/520739 Açores 096/628092/3 – Fax 096/628129 Madeira 091/228965 – Fax 091/228796

GREECE

(PELRP6$

§ÂˆÊ. µÔ˘ÏÈ·ÁÌ¤ÓË˜ 60 ∞ÚÁ˘ÚÔ‡ÔÏË 164 52 ∞ı‹Ó· ☎9950613 - Fax 9951680

www.nilfisk-advance.com

Nilfisk-Advance Captor 4300, Captor 4800, CR 1400, Captor 5400CR 1100, CR 1200 Quick Start Manual

Specifications and Main Features

Frequently Asked Questions

User Manual