Obsolete Advance MODELS 56304000, 56304001, 56304002, 56304003, 56304004,
56304005, 56304006, 56304007, 56304008
Active Advance MODELS 56306050, 56306051, 56306052, 56306053, 56306054,
56306055, 56306056, 56306057, 56306058, 56307251
56306182, 56306183, 56306184, 56306185, 56306186, 56306187, 56306188,
56306189, 56306190
All model numbers starting with “56306” and “56307” are manufactured with the
2007 certied engine.
10/03 revised 6/12 Form Number 56043093
Quick Start Troubleshooting Manual
Captor™ 4300, 4800, 5400
106 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
TABLE OF CONTENTS
GENERAL INFORMATION ................................................................................................................................................ 1-2
SAFETY INSTRUCTIONS .................................................................................................................................................... 3
SPECIFICATIONS .............................................................................................................................................................4-5
MAINTENANCE .................................................................................................................................................................6-8
PM CHECKLIST ..............................................................................................................................................................9-10
KNOW YOUR MACHINE ...............................................................................................................................................12-25
CONTROL ERROR CODES ........................................................................................................................................15-17
GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ............................................................... 18
OPERATOR’S COMPARTMENT ...................................................................................................................................... 19
GENERAL TROUBLESHOOTING FLOW CHARTS ....................................................................................................20-25
WHEEL DRIVE SYSTEM ....................................................................................................................................................26
TROUBLESHOOTING CHECK LIST ................................................................................................................................ 26
STEERING SYSTEM .......................................................................................................................................................... 27
STEERING SYSTEM TROUBLESHOOTING OVERVIEW ..............................................................................................27
TROUBLESHOOTING GUIDE..........................................................................................................................................27
SWEEPING SYSTEM ....................................................................................................................................................28-35
MAIN BROOM .............................................................................................................................................................28-29
SIDE BROOMS ............................................................................................................................................................30-31
SIDE BROOM LIFT ACTUATOR ......................................................................................................................................32
DUST CONTROL IMPELLER ......................................................................................................................................33-34
SHAKER MOTOR ............................................................................................................................................................. 35
HOPPER SYSTEM ........................................................................................................................................................36-42
LIFT CYLINDER ..........................................................................................................................................................36-39
DUMP DOOR CYLINDER............................................................................................................................................40-42
SCRUB SYSTEM ...........................................................................................................................................................43-52
DECK LIFT ACTUATOR ..............................................................................................................................................43-50
SCRUB MOTORS ........................................................................................................................................................51-52
SOLUTION SYSTEM .......................................................................................................................................................... 53
SOLUTION SOLENOID VALVE ........................................................................................................................................ 53
RECOVERY SYSTEM ...................................................................................................................................................54-58
VACUUM MOTOR .......................................................................................................................................................54-56
SQUEEGEE LIFT ACTUATOR ....................................................................................................................................57-58
ENGINE SYSTEM .........................................................................................................................................................59-62
ENGINE SPECIFICATIONS..............................................................................................................................................59
ENGINE MAINTENANCE ................................................................................................................................................. 59
CHECK ENGINE LIGHT TROUBLESHOOTING NON-CERTIFIED & TIER I ..................................................................60
1.6L DTC CODES FOR TIER I .........................................................................................................................................61
MISCELLANEOUS ENGINE SYSTEM INFORMATION ...................................................................................................62
1.6L DTC CODES FOR TIER II ........................................................................................................................................63
MISCELLANEOUS ENGINE SYSTEM INFORMATION ...................................................................................................64
ENGINE FUEL SYSTEM FOR GASOLINE MODELS .................................................................................................64-66
HYDRAULIC SYSTEM ..................................................................................................................................................67-74
HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................67
GENERAL HYDRAULIC SPECIFICATIONS TABLE ........................................................................................................68
SETTING RELIEF VALVES .........................................................................................................................................69-71
HYDRAULIC DIAGRAM ...................................................................................................................................................72
HYDRAULIC SCHEMATIC ...............................................................................................................................................73
HYDRAULIC COMPONENT LOCATION ..........................................................................................................................74
ELECTRICAL SYSTEM .................................................................................................................................................75-73
ELECTRICAL COMPONENT LOCATION......................................................................................................................... 75
WIRING DIAGRAM FOR TIER I ....................................................................................................................................... 76
WIRING SCHEMATIC FOR TIER I ...................................................................................................................................77
WIRING DIAGRAM FOR TIER II ...................................................................................................................................... 78
WIRING SCHEMATIC FOR TIER II ..................................................................................................................................79
WIRING DIAGRAM FOR DIESEL ..................................................................................................................................... 80
ENGINE HARNESS GASOLINE/PETROL LPG TIER I ....................................................................................................81
ENGINE HARNESS ECM DETAIL FOR TIER I ................................................................................................................ 82
ENGINE HARNESS GASOLINE/PETROL TIER II ...........................................................................................................83
ENGINE HARNESS LPG TIER II......................................................................................................................................84
ENGINE WIRING HARNESS DETAIL FOR TIER II.......................................................................................................... 85
PROGRAMMABLE CONTROL OPTIONS .....................................................................................................................87-95
INPUT/OUTPUT TABLES ..............................................................................................................................................96-98
AXP/EDS SYSTEM ......................................................................................................................................................99-104
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
revised 12/08
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 1
INTRODUCTION
This manual will help you get the most from your 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. (B).
This product is intended for commercial use only.
PARTS AND SERVICE
Repairs, when required, should be performed by your Authorized Advance Service Center, who employs factory trained service personnel, and
maintains an inventory of Advance original replacement parts and accessories.
Call the ADVANCE DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing your
machine.
(Dealer, afx service sticker here.)
NAME PLATE
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 SUPPORT
WARNING!
Make sure the Hopper Safety Support (KK)
is in place whenever attempting to do any
maintenance work under or near the raised
hopper. The Hopper Safety Support (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 MACHINE
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 (44).
GENERAL INFORMATION
2 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
TRANSPORTING THE MACHINE
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 (6).
• The machine parking brake is set.
TOWING OR PUSHING A DISABLED MACHINE
CAUTION!
OTHER MANUALS AVAILABLE
The following manuals are available for your Rider Scrubber/Sweeper:
• Parts List - Form Numbers 56042440 (main parts list)
56042445 (Hydraulic Systems)
56042449 (Options/Accessories)
56042478 (Engine Systems 2007 certied)
• Operation Manual - Form Numbers 56041580 (English, Spanish)
• Mechanical Repair Service Manual 56043094
• EngineManuals(TierI)
1.6L Industrial Engine Operator Manual (excerpt from 16LECSS) 56041564
1.6L Industrial Engine Service Manual 36100009*
1.6L Emission Certied Industrial Engine Emission Control System Service Manual 16LECSS*
• EngineManuals(TierII)
1.6L Industrial Engine Operator Manual (excerpt from 16LECSS) 56041564
1.6L Industrial Engine Service Manual 36100009*
PSI Tier 2 1.6L PFI Certied Engine Service Manual G/LP PSI1P6LPFI-A*
V1505 Kubota Diesel Engine Service Manual (WSM English) 97897-02432
V1505 Kubota Diesel Engine Service Manual (WSM English, French, German) 97897-01640
V1505 Kubota Diesel Engine Operator Manual (English, French, German, Italian, Spanish) 16622-8916-3
*Available in electronic format only
BOTTOM VIEW OF HYDROSTATIC PUMP
GENERAL INFORMATION
revised 7/08
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 (22) and lift off
the Right Engine Compartment Access Panel (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). Reference the illustration
below for the normal working setting (A) and the free wheeling towing
setting (B). Note: If the tow valve is left in free wheeling (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). 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 oor and placed on a suitable
transport dolly.
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 3
CAUTIONS AND WARNINGS
SYMBOLS
Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the
necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
GENERAL SAFETY INSTRUCTIONS
Specic Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
DANGER!
• This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide adequate
ventilation when operating this machine.
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, ame 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 ammable cleaning agents, operate the machine on or near these agents, or operate in areas where
ammable liquids exist.
• Do not clean this machine with a pressure washer.
• Keep the LP tank Service Valve closed when the tank is not in use.
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 rst 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 ttings. Flush with windshield washer uid.
• 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.
SAVE THESE INSTRUCTIONS
revised 4/04
4 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
SPECIFICATIONS
GeneralSpecicationscommontoAll Models English (Metric)
Dimensions 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)
Weights
Net weight* 4040 lbs. (1832kg)
Gross weight** 4720 lbs. (2141kg)
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 Level
At operators ear 85.1 dBA
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 System
Capacity 9.2 Cu. Ft. (261 L)
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 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 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 System
Oil type: SAE 10W-30
System ll capacity 11 gal. (41.6 L)
Engine System
Engine coolant ll capacity 10-11 qts. (9.5-10.4L)
Recovery System
Vacuum water lift (sealed) minimum 22 inches
Vacuum water lift (open hole adapter 1”) minimum 20 inches
*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and full tank of fuel.
**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 - 5
SPECIFICATIONS
SpecicationscommontoDeck Size English (Metric)
Model designation: Captor 4300 Captor 4800 Captor 5400
Width w/out squeegee & deck 50 in. (127cm) 50 in. (127cm) 50 in. (127cm)
Solution Tank Capacity 60 gal. (227L) 80 gal. (303L) 80 gal. (303L)
Recovery Tank Capacity 60 gal. (227L) 80 gal. (303L) 80 gal. (303L)
Cleaning Rate per hour (theory) 75,700 ft2 (7030m2) 84,500 ft2 (7,850m2) 95,000 ft2 (8,825m2)
Sweeping path w/side brooms (2) NA 62 in. (158cm) 62 in. (158cm)
Sweeping path w/side broom (1) 51 in. (130cm) NA NA
Sweeping rate per hour 134,600 ft2 (12,500m2) 163,700 ft2 (15,210m2) 163,700 ft2 (15,210m2)
Scrub Brush quantity 3 3 4
Scrub Brush diameter 15 in. (38cm) 17 in. (43cm) 14 in. (36cm)
Squeegee Tool Width 51.5 in. (131cm) 57 in. (145cm) 63-5/8 in. (161cm)
NA = Not Applicable
revised 7/08
6 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
MAINTENANCE SCHEDULE
Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often.
MAINTENANCE ITEM PERFORM DAILY
Perform the “After Use” maintenance steps X
Check parking brake X
Check engine oil X
*Clean main and side brooms X
Check lter indicator and lights (hyd & air) X
Check engine coolant level X
Check hydraulic oil level X
MAINTENANCE ITEM 15 hrs. 30 hrs. 150 hrs. 300 hrs. 500 hrs. 1000 hrs.
*Rotate main broom X
Clean solution lter X
*Inspect/adjust brooms X
*Clean hopper lter 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 lter X
Change reservoir hydraulic oil and lter X
Flush the radiator X
Engine fuel lter(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!
Turn the key switch off, set the parking brake and disconnect the battery before servicing the machine.
AFTER USE
1 Raise the squeegee, the scrub brushes, and the brooms.
2 Shake the dust control lter and empty the hopper.
3 Drain and ush the recovery tank.
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: Tip the recovery tank out and check the squeegee hose elbow below the tank to make sure it has ushed out
completely.
5 Remove and clean the squeegee tool (adjust as needed*).
6 Remove and clean the scrub brushes. Rotate the scrub brushes.
7 Wipe the machine with a damp cloth.
8 Perform all required maintenance before storage.
9 Move the machine to a clean, dry storage area.
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.
LUBRICATING THE MACHINE
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.
WARNING
For the protection of the environment; when servicing any of the machine’s lubrication uids they must be disposed of safely in accordance
with your local environmental regulations (recycling). Examples of machine lubrication products: (Engine crankcase oil, Engine crankcase
oillter,Hydraulicsystemoil,Hydraulicsystemoillters).
MAINTENANCE
revised 4/04
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 7
ENGINE COOLANT
CAUTION!
Do not remove the radiator cap when the engine is hot.
To check the engine coolant level, lift the Engine Compartment Door (22) and observe the coolant level on the Coolant Recovery Tank (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.
WARNING
For the protection of the environment; when servicing any of the machine’s lubrication uids they must be disposed of safely in accordance
with your local environmental regulations (recycling). Examples of machine lubrication products: (Engine crankcase oil, Engine crankcase
oillter,Hydraulicsystemoil,Hydraulicsystemoillters).
ENGINE OIL – GASOLINE (PETROL) & LPG
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 rst 35 hours
of operation and every 150 hours after that. Use any SF or SG rated oil meeting API specications and suited to seasonal temperatures. Refer
to the Engine System section for oil capacities and additional engine specications. Replace the oil lter with every oil change.
TEMPERATURE RANGE OIL WEIGHT
Above 60° F (15° C) SAE 10W-30
Below 60° F (15° C) SAE 5W-30
ENGINE OIL - DIESEL
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 rst 35
hours of operation and every 150 hours after that. Use CF, CF-4 or CG-4 oil meeting API specications and suited temperatures (*important
reference the oil/fuel type note below for further diesel oil recommendations). Refer to the Engine System section for oil capacities and
additional engine specications. Replace the oil lter with every oil change.
TEMPERATURE RANGE OIL WEIGHT
Above 77 °F (25 °C) SAE 30 or 10W-30
32 °F to 77 °F (0 °C to 25 °C) SAE 20 or 10W-30
Below 32 °F (0 °C) SAE 10W or 10W-30
* Diesel Lubricating Oil Note:
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-sulfur fuel on-road vehicle
engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high
total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Lubricating
Oil class
Low sulfur
(0.5 % ≥)
High sulfur Remarks
CF
O O
TBN ≥ 10
CF-4
O X
CG-4
O X
O : Recommendable X : Not recommendable
MAINTENANCE
revised 7/08
8 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
ENGINE AIR FILTER
The engine Air Filter (8) is located in the engine compartment. Check the air mechanical vacuum lter Service Indicator (46) before each use
of the machine. Do not service the air lter unless the indicator is lit (red).
CAUTION!
When servicing the engine air lter elements, use extreme caution to prevent dust and dirt from entering the engine.
The engine air lter contains a primary (outer) and a safety (inner) lter 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 lter 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.
Special Service Note: Inspect the complete air intake system for proper routing (kinks & restrictions) and sound tight connections. The
mechanic should run their hand around the air intake hoses to check for any cracks and holes that will allow non-ltered air to enter the
engine that will severely shorten the engine’s useful life.
ENGINE MAINTENANCE (150 HOURS)
At 150 hour intervals it is recommended that the following service be performed: Change oil and lter, 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: Reference the separately supplied PSI GM Power Train Products Operation and Maintenance manual for more detailed service data.
PSI manual number is 3610000.
SPECIAL LIQUID PROPANE FUEL SYSTEM MAINTENANCE ON THE GM 1.6L ENGINE
Every 150 hours inspect and drain any oil build up from the LP fuel system electronic pressure regulator (EPR). During the course of normal
operation oils or “heavy ends” may build inside the chambers of the propane regulator. These oils and heavy ends may be a result of poor fuel
quality, contamination of the fuel supply chain, or regional variation in the make up of the fuel. If the build up of the oil is signicant this can
affect the function of the fuel control system. Note: Reference the Tier 2 PSI 1.6l PFI certied engine service manual form # PSI1P6LPFI-A, and
follow the procedure to drain the EPR regulator.
HYDRAULIC OIL
WARNING!
FIGURE 1
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. Remove the Right Engine Access Panel (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 ll above maximum. Change the oil if major contamination from a mechanical
failure occurs. SERVICE NOTE: Remove the small access panel (49) directly above the reservoir to
add oil. This panel is held on by (2) wing nuts on the underside of the panel. Only ltered oil should
be added.
IMPORTANT!
This machine is equipped with an indicator light which lights if the “In Tank” oil lter requires
changing. Remove lter element from the lter cup and replace with new lter. Hydraulic lter is
found on top of the Hydraulic Reservoir (36).
Change the Hydraulic “Charge” Oil Filter (35).
Note: Oil should be warm, cold oil is thicker and may cause the light to come on intermittently until it
warms up.
revised 7/08
MAINTENANCE
9 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
Copyright 2003 Nilfisk-Advance. 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 - 10
Copyright 2003 Nilfisk-Advance. 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
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 11
THIS PAGE IS INTENTIONALLY BLANK
12 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
1 Operator’s Seat
2 Strobe Light (optional)
3 Solution Tank Fill
4 Gasoline Tank Cap
5 Fuel Tank
6 Tie Down Locations
7 Recovery Tank Drain Hose
8 Engine Air Filter
9 Left Engine Compartment Access Panel
10 Main Broom Left Access Door
11 Battery
12 Hopper Lid Prop Rod
13 Front Wheel
14 Left Side Broom
15 Hopper Lid Latch
16 Headlights
17 Right Side Broom
18 Hopper Cover
19 Dust Control Filter
20 Dust Control Shaker Assembly
KNOW YOUR MACHINE
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
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 13
21 Shaker Assembly Latch
22 Engine Compartment Door
23 Coolant Recovery Tank
24 Steering Wheel
25 Squeegee Handle
26 Squeegee Tool Assembly
27 Tail Light
28 Exhaust Tail Pipe
29 Fuel Tank Compartment Door
30 Recovery Tank Lid
31 Recovery Tank “Tip-Out” Grip
32 Engine Air Filter Hood
33 Radiator Cap
34 Oil Cooler “Tip-Out” Latches
35 Hydraulic “Charge” Oil Filter
36 Hydraulic Reservoir / In Tank Return Oil Filter
37 Right Engine Compartment Access Panel
38 Main Broom Right Access Door
39 Access Door Latch
40 Skirt Assembly
41 Inline Solution Filter
42 Solution Tank Drain Hose
43 Rear Roller Bumper
44 Jacking Location
45 Engine Oil Dipstick
46 Air Filter Service Indicator
47 Fuel Filter (Gas Models)
48 Recovery Tank Latch
49 Hydraulic Reservoir Access Panel
50 Water Level Gauge
KNOW YOUR MACHINE
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
14 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
KNOW YOUR MACHINE
IMPORTANT SERVICE TIP
Before any troubleshooting is done perform this troubleshooting special control system procedure.
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 (J) see Figure 2.
1 During this test, the horn will sound briey 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!
Make sure that all persons are away from these parts of the machine to prevent injury.
2 Turn the main power key switch to the off position.
3 Press and hold the side broom down/on switch.
4 While holding the side broom down/on switch, turn the main power key switch to the on position.
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).
6 Release the side broom down/on switch.
7 The control will now activate each output in sequence and perform the tests mentioned above.
8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10.
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
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 ow charts.
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.
12 To exit this mode, turn the main power key switch to the off position.
NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.
FIGURE 2
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 15
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/W HT (-).
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
16 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
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/W HT (-).
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 - 17
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/W HT (-).
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
18 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE 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: 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 Board
Indicator Lights
Note: Remove left side
operator's compartment panel
to access A1 Board.
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 19
OPERATOR’S COMPARTMENT
A Low Fuel Indicator (LP)
B Horn Switch
* Horn ON Indicator
C Engine Service Indicator (triggered by
ECU)
D Headlight Switch
* Headlight ON Indicator
E Glow Plug Indicator (Diesel / Release key
after indicator turns OFF)
F Hydraulic Filter Plugged Indicator
G Engine Speed Switch
* Engine Speed Switch Indicator
H Scrub Pressure Decrease Switch
* Scrub Pressure Decrease Indicator
I Scrub Pressure Increase Switch
* Scrub Pressure Increase Indicator
J Scrub Pressure & Error Code Display
K Solution Switch
* Solution System Indicator
L Low Solution Indicator (8-10 gal.)
M Recovery Tank Full Indicator
N Side Broom DOWN/ON Switch
* Side Broom ON Indicator
O Main Broom ON Indicator
P Light Sensor
Q Shaker Switch
* Shaker Indicator (left)
* Dust Filter Plugged Indicator (right)
R Open Dump Door Switch
* Open Dump Door Indicator
S Hopper Open Indicator
T Hopper Overtemp Indicator
U Close Dump Door Switch
* Close Dump Door Indicator
V Lower Hopper Switch
* Lower Hopper Indicator
W Raise Hopper Switch
* Raise Hopper Indicator
X Dust Control Switch
* Dust Control ON Indicator
Y Side Broom UP/OFF Switch
* Side Broom OFF Indicator
Z Vacuum System Switch
* Vacuum System Indicator
AA Scrub System OFF Switch
* Scrub System OFF Indicator
BB Coolant Temperature Gauge
CC Oil Pressure Gauge
DD Fuel Gauge (Gas / Diesel)
EE Voltmeter
FF Hour meter
KNOW YOUR MACHINE
A2 Control Panel
Assembly
TEMP
F/C
VOLTSFUEL
OIL
PSI/BAR
HOURS 1/10
250
175
120
50
75
100
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
20 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
TROUBLESHOOTING GUIDE
Possible Symptom
1 Engine will not crank
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: A drive pedal sensor setting that is set too low will not target (match) the drive pedal neutral return position (deadband 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.
Repair or replace relay or wir-
ing. Is there 12 volts at t he
BLU/PNK?
Replace engine fuse b ox start relay. Loca-
tion of fuse box on top of engine
No
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 sen-
sor. 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
Yes
Yes
Check for 12 volts at WHT wire
located on starter soleno id with
the key in the start position. If
yes repair or replace starter.
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 21
TROUBLESHOOTING GUIDE
Possible Symptom
1 Engine will crank but not start
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).
Check the 5 Amp fuse (F1)
see engine system Figure 2
fuse box.
E
ngine 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
-Rep
lace 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
No
Yes
No
Yes
No
Yes
No
Yes
22 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
TROUBLESHOOTING GUIDE
Possible Symptom
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 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
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
Yes
No
No
Yes
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 23
TROUBLESHOOTING GUIDE
Possible Symptom
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 Circuit
Note: Do all testing with Key Switch ON.
*Note: See hydraulic manual section for system specications (relief valves, pumps, motors etc.).
No
No
Yes
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 belowfor
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 YesYes
No NoNo
No
24 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
TROUBLESHOOTING GUIDE
Possible Symptom
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 Circuit
Note: Do all testing with the key switch ON, hopper lowered and drive pedal activated (forward/reverse).
Service Adjustment Note: A drive pedal sensor setting that is set too low will not target (match) the drive pedal neutral return position (deadband 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 set-
ting. 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 - 25
TROUBLESHOOTING GUIDE
Possible Symptom
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.
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
26 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
WHEEL DRIVE SYSTEM
Symptom 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 uid (loose ttings).
• Propulsion pump inlet restriction (cavitation of hydraulic uid).
• 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 position.
• Check connection of foot pedal linkage (cable assembly) to
propulsion pump arm.
• Worn propulsion pump (*test output oil volume with a ow 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 specication manual section, tables that list all the individual system component values (pressures, ows,
rpms etc).
Hydraulic Wheel Drive System
Troubleshooting Check List
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 27
STEERING SYSTEM
Steering System Hydraulic Diagram
TROUBLESHOOTING GUIDE
Problem Possible cause
Slow steering, hard steering or loss of Priority ow 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 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 ows through
a priority divider built into the pressure relief block
assembly that divides the pump output and reduces the
oil ow 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 ow to the
unit. The relief valve for the steering system is located
in the steering unit and is set to open at 1450 PSI.
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
28 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400
SWEEPING SYSTEM
TROUBLESHOOTING GUIDE
Possible Symptom
1 Main broom will not turn.
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 wil l 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 hydrau
lic load circuit
Yes
Yes
Yes
No
No
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
No
No
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