Nilfisk-Advance Captor 5400, Captor 4800, Captor 4300 Quick Start Troubleshooting Manual

Page 1

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 certied engine.

10/03 revised 6/12 Form Number 56043093

Quick Start Troubleshooting Manual

Captor™ 4300, 4800, 5400

Page 2

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

Page 3

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, afx 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

Page 4

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 certied)

• Operation Manual - Form Numbers 56041580 (English, Spanish)

• Mechanical Repair Service Manual 56043094

• EngineManuals(TierI)

1.6L Industrial Engine Operator Manual (excerpt from 16LECSS) 56041564

1.6L Industrial Engine Service Manual 36100009*

1.6L Emission Certied Industrial Engine Emission Control System Service Manual 16LECSS*

• EngineManuals(TierII)

1.6L Industrial Engine Operator Manual (excerpt from 16LECSS) 56041564

1.6L Industrial Engine Service Manual 36100009*

PSI Tier 2 1.6L PFI Certied 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.

Page 5

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

Specic 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

Page 6

4 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SPECIFICATIONS

GeneralSpecicationscommontoAll 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.

Page 7

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 5

SPECIFICATIONS

SpecicationscommontoDeck 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

Page 8

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

oillter,Hydraulicsystemoil,Hydraulicsystemoillters).

MAINTENANCE

revised 4/04

Page 9

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

oillter,Hydraulicsystemoil,Hydraulicsystemoillters).

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 specications and suited to seasonal temperatures. Refer to the Engine System section for oil capacities and additional engine specications. 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 specications 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 specications. 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

O O

TBN ≥ 10

CF-4

O X

CG-4

O X

O : Recommendable X : Not recommendable

MAINTENANCE

revised 7/08

Page 10

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 signicant this can affect the function of the fuel control system. Note: Reference the Tier 2 PSI 1.6l PFI certied 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

Page 11

9 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

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

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

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

Page 12

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 10

Ref

VISUAL INSPECTION ITEMS (continued)

Comments

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

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

Page 13

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 11

THIS PAGE IS INTENTIONALLY BLANK

Page 14

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

Page 15

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

Page 16

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 briey 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

Page 17

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

Page 18

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 (-).

Page 19

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

Page 20

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.

Page 21

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

100

1/2

Page 22

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

At the K4 relay do you have

12 volts at the BLU/PNK?

Yes

Engine will still not crank?

Yes

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.

change setting press the speed switch, To exit turn key off.

Does the light go off?

Replace the A1 control board.

Does the engine crank?

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.

Page 23

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.

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

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

Page 24

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

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

Repair or replace defective

parts.

Do the A2 panel lights now

function?

Yes

Replace the A1 Controller

Yes

Page 25

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 specications (relief valves, pumps, motors etc.).

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

Page 26

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?

Yes Yes

Replace the A1 Control Board

Replace pedal sensor or wiring (switch is open).

Yes

Replace

A1 board

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?

Page 27

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

Is the green indicator light

for the malfunctioning

motor OFF at A1 control

board?

Replace the

A1 control board.

Yes

Page 28

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 specication manual section, tables that list all the individual system component values (pressures, ows, rpms etc).

Hydraulic Wheel Drive System

Troubleshooting Check List

Page 29

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

25 PSI

.58

P2 P3 T2

Page 30

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

Replace the A1 Main Con-

troller. Does broom run?

Yes

Clean, Adjust or

replace the magnetic

broom switch (S16)

Does broom run?

No No

Page 31

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 29

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Main broom will not turn.

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.

Replace defective spool

valve L6.

Does motor operate?

Replace motor

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?

Page 32

30 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side brooms will not turn

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

On the A1 board is the S10

side brooms motor relay

indicator light on?

Replace A1 control

board

Do the side broom

motors operate?

Yes

Page 33

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 31

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side brooms will not turn

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.

See hydraulic load

trouble shooting, No

accessories work.

Yes

Page 34

32 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side broom lift actuator motor will not raise or lower

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

Press the side broom ON

(Lower) button and check on

the A1 control board to see if

its red relay indicator light

comes on.

Yes

Replace the M4 side broom lift

actuator motor.

Page 35

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 33

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Dust control impeller will not run

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

On the A1 board is the S9

impeller motor relay light

on?

Replace A1 control

board.

Does impeller motor

operate?

Yes

Page 36

34 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Dust control impeller will not run

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.

Du st 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

Page 37

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 35

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Shaker motor will not run

Electrical Circuit

Note1: Before testing rst conrm that the 10Amp F7 circuit breaker is good. Note2: Do all testing with the key switch turned ON.

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

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?

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

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

Replace the M2 shaker motor

Page 38

36 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not raise

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

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?

Yes

Page 39

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 37

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not raise

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?

Repair or replace

damaged parts.

Does the hopper raise?

See hydraulic load trouble-

shooting, No accessories

work

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

Yes

Page 40

38 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not lower

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

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?

Yes

Page 41

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 39

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not lower

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?

Inspect for possible

mechanical binding of:

•Hopper linkage

•Hopper cylinder

Hopper will not lower

Replace hydraulic

hopper cylinder

Yes

Page 42

40 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper dump door will not open in dump mode.

Part A:

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

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

Yes

Replace the

A1 Control board

Yes

Repair or replace L11 coil

wiring

Yes

Substitute a new A2 Display

panel. Does dump door

operate?

Repair or replace (S12)

switch wiring.

Does door open?

Yes

Dump Door will n ot 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

Page 43

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 41

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper dump door will not close in dump mode.

Part A:

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

Dump Door w ill 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 coi

Does the door operate?

Yes

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

Check (S12) switch wiring

for a short.

Yes

Replace the A1 Control

board.

Does the door operate?

Yes

Repair or replace L12 coil

wiring.

Does the door operate?

Repair or replace (S12)

switch

Yes

Substitute a new A2 Display

panel. Does dump door

operate?

Repair or replace (S12)

switch wiring.

Yes

Page 44

42 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

Part B:

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

Dump Door

will not oper ate

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).

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”.

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?

Repair or replace

door cylinder

Page 45

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 43

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not lower

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

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?

Yes

Page 46

44 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

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

Yes

Scrub deck will not lower

or lowers partially in (1)

Page 47

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 45

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

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.

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 positio

n 2.

Yes

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?

Yes

Page 48

46 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

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

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?

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

(3) 385 lbs.

Replace cylinder

Does the deck function

in pressure setting (1)?

Scrub deck will not func-

tion in pressure setting (2)

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 No

Page 49

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 47

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

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

Yes

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?

Yes

Page 50

48 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

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

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

Install a pressure gauge to

the bottom of the scrub

deck lift cylinder.

Does the pressure

read 0 PSI?

Check deck pressure with a

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

(3) 385 lbs.

Replace cylinder

Does the deck function in

pressure setting (1 & 2)

Scrub deck will not func-

tion in pressure setting (3)

Yes

See section B pressure

settings (1 & 2)

Replace defective spool

valve L15.

Are you able to get 160

PSI?

Yes

Page 51

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 49

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not raise

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

Does the squeegee raise?

See squeegee will not raise or lower troubleshooting section.

Yes

Page 52

50 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not raise

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.

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?

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).

Adjust, clean or replace

#8 relief valve. Does

scrub deck function?

Yes

Does the squeegee raise?

Yes

See squeegee will not raise or

lower section.

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

Yes

Page 53

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 51

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck motors will not operate

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.

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

Press scrub decrease switch

(-) on the display.

Is its green indicator light on?

Sub. a new A2 display panel.

Do the motors operate?

Yes

See Part B hydraulic scrub

deck motors will not operate

troubleshooting section.

Yes

Check for coil resistance

L7 at (9 ohm)

Replace A1 control board.

Do the motors operate?

Page 54

52 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck motor(s) will not operate

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).

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

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?

Check for debris wrapped

around the motor shafts.

Repair or replace

individual defective

motor.

Do the motors run?

Remove and disassemble L7

scrub motor spool valve

(cartridges). Inspect, clean

and reinstall.

Do the motors turn?

Replace defective

spool valve L7

Scrub deck motor(s) will

not operate

Yes

Repair or replace

individual defective motor.

Adjust, clean or replace

1B relief valve.

Do the motors run?

Yes

Remove debris.

Do the motors run?

Page 55

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 53

SOLUTION SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Solution solenoid valve does not operate

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

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?

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

Page 56

54 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

RECOVERY SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Vacuum motor will not operate

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.

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

Replace the recovery

tank full switch.

Does vacuum operate?

Yes

Replace A1 control

board does the vacuum

motor operate?

Continued on next page

Yes

Sub. a new A2 display panel

Does vacuum operate?

Page 57

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 55

RECOVERY SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Vacuum motor will not operate

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.

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

Check for coil resistance

at L8 valve (9 ohm)

Replace defective coil.

Does vacuum motor operate?

Yes

Page 58

56 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

RECOVERY SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Vacuum motor will not operate

Part B: Hydraulic

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

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

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?

See hydraulic load trou-

bleshooting section title,

No accessories work.

Yes

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.

Page 59

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 57

RECOVERY SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Squeegee will not raise or lower.

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.

Squeegee will not raise

or lower

Press the squeegee switch. Is

its green indicator light on?

Substitute 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 oper-

ate?

Check for coil resistance at

L1 and L2 (9 ohm)

Replace defective coil.

Does squeegee operate?

See Hydraulic squeegee

troubleshooting section

Part B

Yes

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 oper-

ate?

Yes

Page 60

58 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

RECOVERY SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Squeegee will not raise or lower.

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.

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

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.

Adjust, clean or replace

#8 relief valve

Does squeegee function?

Yes

Repair or replace damaged parts.

Does squeegee function?

Yes

Page 61

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 59

ENGINE SYSTEM

1.6literGMEngineSpecication

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 (ywheel 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 MAINTENANCE

• Keep the fuel tank lled. 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 lter clean.

• Observe the engine coolant temperature gauge frequently.

• Observe the engine oil pressure gauge frequently.

• Check the voltmeter and charging system.

revised 4/04

Page 62

60 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

ENGINE SYSTEM

CHECK ENGINE LIGHT TROUBLESHOOTING FOR 1.6L GM ENGINE NON-CERTIFIED & TIER I CERTIFIED

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

1 On the A2 display panel the engine check light (MIL) comes on steady will not shut off. 2 Locate the 4-way ECM communication test port, which is a part of the engine wiring harness (location in area of engine starter). 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).

4 Turn the engine key switch to the on position and observe the indicator lights special error code ashing sequence. See PSI’s 1.6L

Emission Certied Industrial Engine Emission Control System Service Manual for a description of the fault indications.

Code examples: 123 code = engine checks OK on non-certied engine (Pre 2004). 166 code = engine checks OK on certied engine (after machine S.N. 1734015).

FIGURE 1

revised 7/08

Page 63

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 61

ENGINE SYSTEM

Code Description Page Code Description Page

DTC 111 IAT High Voltage 1C4-16 DTC 413 Injector Driver 2 Open 1C4-102 DTC 112 IAT Low Voltage 1C4-20 DTC 414 Injector Driver 2 Shorted 1C4-106 DTC 113 IAT Higher Than Expected 1 1C4-24 DTC 511 COP Failure 1C4-110 DTC 114 IAT Higher Than Expected 2 1C4-26 DTC 512 Invalid Interrupt 1C4-112 DTC 115 Oil Pressure Low 1C4-28 DTC 513 A/D Loss 1C4-114 DTC 121 ECT High Voltage 1C4-32 DTC 514 RTI 1 Loss 1C4-116 DTC 122 ECT Low Voltage 1C4-36 DTC 515 Flash Checksum Invalid 1C4-118 DTC 123 ECT Higher Than Expected 1 1C4-40 DTC 516 RAM Failure 1C4-120 DTC 124 ECT Higher Than Expected 2 1C4-42 DTC 531 5V Ref Lower Than Expected 1C4-122 DTC 131 MAP High Pressure 1C4-44 DTC 532 5V Ref Higher Than Expected 1C4-126 DTC 132 MAP Low Voltage 1C4-48 DTC 555 RTI 2 Loss 1C4-128 DTC 134 BP High Pressure 1C4-52 DTC 556 RTI 3 Loss 1C4-130 DTC 135 BP Low Pressure 1C4-54 DTC 611 FPP High Voltage 1C4-132 DTC 142 Crank Sync Noise 1C4-58 DTC 612 FPP Low Voltage 1C4-136 DTC 143 Never Crank Sync at Start 1C4-62 DTC 613 FPP Higher Than IVS Limit 1C4-140 DTC 211 C.L. Multiplier High (LPG) 1C4-64 DTC 614 FPP Lower Than IVS Limit 1C4-142 DTC 212 HO2S Open/Inactive 1C4-68 DTC 631 TPS 1 Signal Voltage High 1C4-144 DTC 221 C.L. Multiplier High (Gasoline) 1C4-72 DTC 632 TPS 1 Signal Voltage Low 1C4-148 DTC 222 C.L. Multiplier Low (Gasoline) 1C4-74 DTC 633 TPS2 Signal Voltage High 1C4-152 DTC 224 C.L. Multiplier Low (LPG) 1C4-76 DTC 634 TPS 2 Signal Voltage Low 1C4-156 DTC 241 Adaptive Lean Fault (Gasoline) 1C4-78 DTC 635 TPS1 Higher Than TPS 2 1C4-160 DTC 242 Adaptive Rich Fault (Gasoline) 1C4-82 DTC 636 TPS1 Lower Than TPS2 1C4-164 DTC 243 Adaptive Learn High (LPG) 1C4-84 DTC 637 Throttle Unable To Open 1C4-168 DTC 244 Adaptive Learn Low (LPG) 1C4-88 DTC 638 Throttle Unable To Close 1C4-172 DTC 261 System Voltage Low 1C4-90 DTC 651 Max Govern Speed Override 1C4-176 DTC 262 System Voltage High 1C4-92 DTC 652 Fuel Rev Limit 1C4-178 DTC 411 Injector Driver 1 Open 1C4-94 DTC 653 Spark Rev Limit 1C4-180 DTC 412 Injector Driver 1 Shorted 1C4-98

1.6L DTC Codes and Descriptions

ForallTIERICertiedEngines

revised 7/08

Page 64

62 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

ENGINE SYSTEM

ENGINE SYSTEM CHECK ENGINE LIGHT TROUBLESHOOTING FOR 1.6L GM ENGINE (TIER II CERTIFIED)

The engine ECM will light (turn on) the dash panel (C) check engine light if there is a problem associated with the computerized engine control

system.

Note: Tier II Engine type identication, the LP engine uses an EPR (electronic pressure regulator) for the main component in its fuel delivery system. The gasoline engine uses a special fuel sensor manifold (mounted on the fuel tank). The manifold records the temperature of the fuel

and controls the fuel pressure sent to the fuel rail. This fuel system is different in that it doesn’t use a fuel pressure regulator and has a small

amount of fuel returned to the tank.

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

1 On the operator display panel the engine check light (MIL ) comes on steady will not shut off. 2 Locate the 8 way ECM communication test port, which is a part of the engine wiring harness. 3 Next remove the test port protective cap. See Figure 1.5. Insert a suitable jumper wire across pin “1” (black/green wire) & pin “4” (orange

wire).

Blink Code Function Although the DST (Diagnostic Service Tool software) is considered a required tool to access the DTC codes, codes may be retrieved without a

laptop computer using the blink code function. To enable this function follow the steps below:

4 Turn the ignition key to the on position. 5 The system will now enter the self diagnostic blink code mode. Be ready with pen and paper to write down any codes that may be

stored.

6 The ECM will ash the MIL indicator with a pause between represented numbers that represent DTC codes. The sequence starts with

code 1654. Code 1654 conrms the system has entered the blink code mode. The ECM will ash code 1654 (3) times before displaying

the actual DTC code that may be set.

Example:

One short blink (pause) six short blinks (pause) veshortblinks (pause) four short blinks.

• If no DTC codes are found, the ECM will continue to ash 1654 only. This means no stored DTC codes were found.

FIGURE 1.5

revised 7/08

Page 65

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 63

ENGINE SYSTEM

DTC

Code

Description SPN Code

FMI

Code

DTC

Code

Description SPN Code

FMI

Code

16 Crank Never Synced at Start 636 8 604 RAM Failure 630 12

91 Fuel Pump Low Voltage 94 4 606 COP Failure 629 31

92 Fuel Pump High Voltage 94 3 642 External 5V Reference Low 1079 4

107 MAP Low Voltage 106 4 643 External 5V Reference High 1079 3

108 MAP High Pressure 106 16 685 Power Relay Open 1485 5

111 IAT Higher Than Expected 1 105 15 686 Power Relay Shorted 1485 4

112 IAT Low Voltage 105 4 687 Power Relay Short to Power 1485 3

113 IAT High Voltage 105 3 1111 Fuel Rev Limit 515 16

116 ECT Higher Than Expected 1 110 15 1112 Spark Rev Limit 515 0

117 ECT Low Voltage 110 4 1151 Closed Loop Multiplier High LPG 520206 0

118 ECT High Voltage 110 3 1152 Closed Loop Multiplier Low LPG 520206 1

121 TPS 1 Lower Than TPS 2 51 1 1155 Closed Loop Multiplier High Gasoline 520204 0

122 TPS 1 Signal Voltage Low 51 4 1156 Closed Loop Multiplier Low Gasoline 520204 1

123 TPS 1 Signal Voltage High 51 3 1161 Adaptive Learn High LPG 520202 0

127 IAT Higher Than Expected 2 105 0 1162 Adaptive Learn Low LPG 520202 1

129 BP Low Pressure 108 1 1165 LPG Cat Monitor

520213 10

134 EGO 1 Open/Inactive 724 10 1171 LPG Pressure Higher Than Expected 520260 0

154 EGO 2 Open/Inactive 520208 10 1172 LPG Pressure Lower Than Expected 520260 1

171 Adaptive Learn High Gasoline 520200 0 1173 EPR Comm Lost 520260 31

172 Adaptive Learn Low Gasoline 520200 1 1174 EPR Voltage Supply High 520260 3

182 Fuel Temp Gasoline Low Voltage 174 4 1175 EPR Voltage Supply Low 520260 4

183 Fuel Temp Gasoline High Voltage 174 3 1176 EPR Internal Actuator Fault 520260 12

187 Fuel Temp LPG Low Voltage 520240 4 1177 EPR Internal Circuitry Fault 520260 12

188 Fuel Temp LPG High Voltage 520240 3 1178 EPR Internal Comm Fault 520260 12

217 ECT Higher Than Expected 2 110 0 1612 RTI 1 Loss 629 31

219 Max Govern Speed Override 515 15 1613 RTI 2 Loss 629 31

221 TPS 2 Signal Voltage Low 51 0 1614 RTI 3 Loss 629 31

222 TPS 2 Signal Low Voltage 520251 4 1615 A/D Loss 629 31

223 TPS 2 Signal High Voltage 520251 3 1616 Invalid Interupt 629 31

336 Crank Sync Noise 636 2 1626 CAN Tx Failure 639 12

337 Crank Loss 636 4 1627 CAN Rx Failure 639 12

420 Gasoline Cat Monitor 520211 10 1628 CAN Address Conflict Failure 639 13

524 Oil Pressure Low 100 1

2111 Unable to Reach Lower TPS 51 7

562 System Voltage Low 168 17 2112 Unable to Reach Higher TPS 51 7

563 System Voltage High 168 15 2229 BP Pressure High 108 0

601 Flash Checksum Invalid 628 13

1.6L DTC Code to SPN:FMI Code Cross Reference

ForallTIERIICertiedEngines

revised 7/08

Page 66

64 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

ENGINE SYSTEM

revised 7/08

MISCELLANEOUS ENGINE SYSTEM INFORMATION

Additional Engine Troubleshooting Symptom

Engine Overheating

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

• Check coolant level in overow 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: The GM 1.6L engine will set a diagnostic test code (DTC 116) after 5 sec. at temperatures over 215 °F and a power derate level one will be enforced. This engine fault will limit the maximum throttle position to 50%. With further overheating the engine will set a code (DTC 217) after 10-15 sec. at temperatures over 225 °F and the engine will then shut down.

Loss of Oil Pressure Protection: Engine shutdown if oil pressure is only 3-7 PSI.

Engine Speed Settings

Fast Engine Speed 2400 RPM Idle Engine Speed 1200 RPM

GASOLINE FUEL SYSTEM FOR MODELS (NON-CERTIFIED & TIER I CERTIFIED)

WARNING!

To prevent injury or re 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 tting (Schrader valve).

GM 1.6L GASOLINE FUEL SYSTEM DESCRIPTION (TIER II CERTIFIED)

This engine is equipped with a fuel injector rail that does not have a pressure regulator. Fuel pressure for this engine is regulated by the engine’s ECM controlling the fuel pump via pulse width modulation. The ECM receives fuel pressure and temperature feedback from the gasoline fuel

sensor manifold and uses this information to control the ground side of the fuel pump. Fuel pressure is regulated by the ECM pulse width

modulating (PWM) the fuel pump. The fuel pressure and temperature sensor manifold has a return or “bleed” circuit that is comprised of a .020” orice and a 6 psi check valve that connects back to the equipment fuel tank. This circuit is used to bleed off any vapor that develops in the line and returns a small amount of fuel to the tank. The fuel comes from the fuel tank and passes through the inline fuel pump. Fuel exits the fuel pump, passes through the lter and then enters the fuel pressure and temperature manifold assembly. Fuel ows through the feed circuit and is delivered to the fuel injector rail. Fuel that enters the bleed circuits through the by-pass valve in the manifold is returned to the fuel tank.

Page 67

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 65

ENGINE SYSTEM

A - F1 5 Amp Fuse for:

• LP fuel lock-off coil

• starter relay coil

• fuel pump relay coil

B - F3 15 A mp Fuse for

• input power to the alternator

C - F4 15 A mp Fuse for

• Fuel Pump

D - F2 20 A mp Fuse for:

• ECM input

• alternator power relay coil

E - Relay Fuel Pump F - Engine Starter Relay G - Power Relay Alternator

FRONT

Engine Fuse Box

FIGURE 3

FIGURE 2

Non-Certied

& TIER I

All 1.6L Models

revised 7/08

Page 68

66 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

ENGINE SYSTEM

FIGURE 4

TIER II

revised 7/08

Page 69

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 67

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM TROUBLESHOOTING

Accurate measurements are the key to troubleshooting a hydraulic system. Once measurements are obtained, they can be compared with specications to

analyze a problem.

To troubleshoot the hydraulic system it is possible to use tachometers, ow 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 ow 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 ow. 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 gures 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)

• 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 2

FIGURE 1

Page 70

68 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HYDRUALIC SYSTEM

Pump Circuit DISPL GPM

RPM

(in)

RPM (out) PSI Relief PSI

Pump 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

Pump Circuit (2) Engine @ 2400rpms No Load (XT2) .58cu.in. 6 2400 *1200 2400

Pump Circuit (2A) 1.75 Steering Sy stem 4.5cu.in. 1.75 **1850 Dump Door (open/close time 2 - 3 sec.) 1.75 **1850 Hopper Lift (Ex tend 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 c u.in. 4.3 106 1250 2400

Pump Circuit (3) Engine @ 2400rpms No Load (XT3) .50 cu.in 5.2 2400 *300 2400

Scrub (1) Std. 180 grit brush on s ealed c oncrete 4.5 cu.in 5.2 270 650 2400 Scrub (2) Std. 180 grit brush on s ealed c oncrete 4.5 cu.in 5.2 265 1000 2400 Scrub (3) Std. 180 grit brush on s ealed c oncrete 4.5 cu.in 5.2 255 1350 2400 Scrub (1) Black pad on sealed concrete 4.5 c u.in 5.2 270 800 2400 Scrub (2) Black pad on sealed concrete 4.5 cu.in 5.2 265 1200 2400 Scrub (3) Black pad on sealed concrete 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. ** Total steering relief pressure at pump. (Sum of 1450 plus line pressure = 1850)

*** Adjustable pressure ow valve. Factory setting 160psi.

GENERAL HYDRAULIC SPECIFICATIONS TABLE

Page 71

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 69

HYDRAULIC SYSTEM

FIGURE 3

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.

FRONT

Re lief Valve 2700 PSI vacuum fan & main broom

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

elie f Valve 2400 PSI scrub brushes, squeegee lift & scrub lift

Divider Cartridge

Pressure Switch main broom/vac fan

Main Broo m Valve

Sc rub Brush Valve

S6 Coil

Adjustment Screw

Lock-nut

Top Hose Locat ion

FRONT

Main Broom Mot or

Main Relief and Broom/Scrub Motors Valve Block

Page 72

70 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HYDRUALIC SYSTEM

FIGURE 4

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 2B

Open the hopper lter door and remove the lter and metal cover under the lter. 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 will 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.

FRONT

Dump Door Open Valve

L11

L12

Dump Door Close Valve

Side Broom Valve

L10

L13

Hopper Ra ise Valve

L14

Hopper Lower Valve

FRONT

Outside Hose Loc ation

Right Side Broo m Motor

Hopper and Side Broom Function Valve Block

Page 73

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 71

HYDRAULIC SYSTEM

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.

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.

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 ow valve see Figure 5.

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

increase.

FRONT

Relief Valve 800 PSI squeegee lift

L15

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 Cylind er Valve Block

FIGURE 5

Page 74

72 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

HYDRUALIC SYSTEM

Page 75

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 73

HYDRAULIC SYSTEM

Page 76

74 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

HYDRAULIC SYSTEM

HYDRAULIC COMPONENT LOCATION

Item Qty 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

Page 77

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 75

ELECTRICAL SYSTEM

ELECTRICAL COMPONENT LOCATION

Item 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) F8 Circuit Breaker, 10 Amp (AXP/EDS) 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) K6 Relay, SPDT (AXP/EDS) L16 Solution Valve M2 Shaker Motor M3 Fuel Pump (Gas only) M4 Actuator, Side Broom M6 Pump Assy, (AXP/EDS) P6 Gauge, Combination R2 Drive Pedal Sensor R4 Flow Position Sensor (AXP/EDS) 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 S1 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

FRONT

S12

L16

Fuses

S16

H16

Relays

L16

Page 78

76 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

A1 Control Box Assembly

H15 Back-Up Alarm (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

Item Description

WIRING DIAGRAM / SCHEMATIC FOR (Gasoline/Petrol and LPG) Captor/CR 1100 series (56304xxx Models) TIER I

Item Description

L15 Scrub Down Valve, S15 L16 Solution Valve M2 Shaker Motor M3 Fuel Pump (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) S3 Switch, Low LP Pressure S4 Switch, Broom Pressure S5 Switch, Dust Control Filter (optional) S6 Switch, Hydraulic Filter S7 Switch, Hopper Fire (optional) S8 Switch, Recovery Full S9 Switch, Solution Empty S12 Switch, Hopper Interlock S16 Switch, Main Broom

Item Description

Page 79

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 77

ELECTRICAL SYSTEM

SCHEMATIC FOR Captor/CR 1100 series (56304xxx Models) TIER I

Revised 11/04

Page 80

78 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

A1 Control Box Assembly

H16 Horn K1 Relay, Horn K2 Relay, Lights K3 Relay, Shaker K4 Relay, Neutral (closed in neutral) K6 Relay, SPDT (AXP/EDS) 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

Item Description

WIRING DIAGRAM / SCHEMATIC FOR (Gasoline and LPG) Captor/CR 1100 series (56306xxx & 56307xxx Models) TIER II

Item Description

M2 Shaker Motor M3 Fuel Pump (Gas only) M4 Actuator, Side Broom M5 Fuel Pump (Gasoline/Petrol) M6 Pump Assembly (AXP/EDS) P6 Gauge, Combination R1 Sender, Oil Pressure R2 Drive Pedal Sensor R3 Sender, Fuel R4 Flow Position Sensor (AXP/EDS) S1 Switch, Ignition S2 Switch, Wand (optional) S3 Switch, Low LP Pressure S4 Switch, Broom Pressure S5 Switch, Dust Control Filter (optional) S6 Switch, Hydraulic Filter S7 Switch, Hopper Fire (optional) S8 Switch, Recovery Full S9 Switch, Solution Empty S12 Switch, Hopper Interlock S16 Switch, Main Broom

Item Description

FROMLIGHTING CIRCUIT

NOTE: R3IS NOTUSED ON L.P.MODEL

(CLOSEDIN NEUTRAL)

TOCONTROL BOX ASSEMBLY

(OPTION)

CHECKENGINE LIGHT OUTPUTTO CONTROL BOXASSEMBLY

CONNECTTO CONTROLBOX ASSEMBLY

COOLANTTEMPERATURE OUTPUT

(REFERENCE: E-CONTROLS,INC. DRAWINGNO. E1737100 ANDE1737200)

GM ENGINE SYSTEM

STARTERCOMMAND

STARTERB+

IGN.SW INPUT

MILOUTPUT (SWITCHED GROUND)

THROTTLEINPUT (12VFOR HIGH)

FUELPUMP OUTPUT

GROUND

ALT.EXCITE

SOLUTIONJ2-9 LEVEL

J1-4SOLUTION

UMP

B- J1-1

CHEMICAL J2-2 PUMP1+

CHEMICAL J2-4 PUMP1-

CHEMICAL J2-6 PUMP1+

CHEMICAL J2-8 PUMP1-

J2-10SOLUTION

FLOWRATE

J2-14SENSE

INPUT

J2-13 +5V

J2-12B-

CHEMICALSENSING BOARD

J1-4

J1-1

J1-2

AXPSYSTEM

J2-11SIGNAL INPUT

(SOLENOID)

J1-2B+

SEESHEET 2

RED

ORN/GRN

BLK

WHT/GRNWHT/GRN

WHT/GRN

ORN

GRN/BLK

YEL/BLK

GRA/BLK

VIO

BLK

WHT/BLK

VIO

PINK

BLK

RED

VIO/BLU

RED

RED/GRN

BLU/PINK

VIO BLK

YEL/BRNVIO BLK

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

PINK PURPLE

BLK/REDBLK/RED

PINK

GRA/BLU

BLU/BLKGRN/YEL

GRA/BLU

PINK

TAN

PINK/YEL PINK/YEL

BLU/PINK

BLK

GRN

YEL

VIO

BLU

GRA/BRN

GRA/BRN BLK/GRA

GRA/BRN BLK

BLU/ORN

RED VIO/GRA

VIO

BLK

RED

YEL/BLK

ORN

PINK

GRA/BLU

BLU/BLK

CIRCUITBREAKER, 60AMP

FUELPUMP

SENDER,OIL PRESSURE

1 2

CIRCUITBREAKER, 10A.

1 2

F4 CIRCUITBREAKER, 15AMP

RELAY,AXP

30 87

87a

X13

SENSOR,GASOLINE

INS11076957

1 2

LIGHT,BEACON

1 2

M19

PUMP2, CHEMICAL

X12

A A

M18

PUMP1, CHEMICAL

SWITCH,IGN.

ACC

BAT

IGN

CIRCUITBREAKER, 10AMP

1 2

GAUGE,COMBINATION

12345

X4 A

F1 CIRCUITBREAKER, 25AMP

FLOWPOSITION SENSOR

123

SENDER,FUEL

1 2

LAMP,BROOM PRESSURE

1 2

CIRCUITBREAKER, 15AMP

1 2

B B

12VDC

+ -

RELAY,NEUTRAL

30 87

87a

PUMP,SOLUTION

K K

F F

56306080 REV C Sheet 1 of 2

FROMLIGHTING CIRCUIT

NOTE: R3IS NOT USED ONL.P. MODEL

(CLOSEDIN NEUTRAL)

TOCONTROL BOX ASSEMBLY

(OPTION)

CHECKENGINE LIGHT OUTPUTTO CONTROL BOXASSEMBLY

CONNECTTO CONTROLBOX ASSEMBLY

COOLANTTEMPERAT URE OUTPUT

(REFERENCE: E-CONTROLS,INC. DRAWING NO.E1737100 ANDE1737200)

GM ENGINE

SYSTEM

STARTERCOMMAND

STARTERB+

IGN.SW INPUT

MILOUTPUT (SWITCHED GROUND)

THROTTLEINP UT (12VFOR HIGH)

FUELPUMP OUTPUT

GROUND

ALT.EXCITE

SOLUTIONJ2-9 LEVEL

J1-4SOLUTION

UMP

B- J1-1

CHEMICAL J2-2 PUMP1+

CHEMICAL J2-4 PUMP1-

CHEMICAL J2-6 PUMP1+

CHEMICAL J2-8 PUMP1-

J2-10SOLUTION

FLOWRAT E

J2-14SENSE

INPUT

J2-13 +5V

J2-12B-

CHEMICALSENSING BOARD

J1-4

J1-1

J1-2

AXPSYSTEM

J2-11SIGNAL INPUT

(SOLENOID)

J1-2B+

SEESHEET 2

RED

ORN/GRN

BLK

WHT/GRNWHT/GRN

WHT/GRN

ORN

GRN/BLK

YEL/BLK

GRA/BLK

VIO

BLK

WHT/BLK

VIO

PINK

BLK

RED

VIO/BLU

RED

RED/GRN

BLU/PINK

VIO BLK

YEL/BRNVIO BLK

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

PINK PURPLE

BLK/REDBLK/RED

PINK

GRA/BLU

BLU/BLKGRN/YEL

GRA/BLU

PINK

TAN

PINK/YEL PINK/YEL

BLU/PINK

BLK

GRN

YEL

VIO

BLU

GRA/BRN

GRA/BRN BLK/GRA

GRA/BRN BLK

BLU/ORN

RED VIO/GRA

VIO

BLK

RED

YEL/BLK

ORN

PINK

GRA/BLU

BLU/BLK

CIRCUITBREAKER, 60 AMP

FUELPUMP

SENDER,OIL PRESSURE

1 2

CIRCUITBREAKER, 10 A.

1 2

CIRCUITBREAKER, 15 AMP

RELAY,AXP

30 87

87a

X13

SENSOR,GASOLINE

INS11076957

1 2

LIGHT,BEACON

1 2

M19

PUMP2, CHEMICAL

X12

A A

M18

PUMP1, CHEMICAL

SWITCH, IGN.

ACC

BAT

IGN

CIRCUITBREAKER, 10 AMP

1 2

GAUGE,COMBINATION

12345

X4 A

CIRCUITBREAKER, 25 AMP

FLOW POSITIONSENSOR

123

SENDER,FUEL

1 2

LAMP,BROOM PRESSURE

1 2

CIRCUITBREAKER, 15 AMP

1 2

B B

12VDC

+ -

RELAY,NEUTRAL

30 87

87a

PUMP,SOLUTION

K K

F F

56306080 REV C Shee t 1 of 2

Note: AXP/EDS system introduced in 5/08 is backward compatible for all machines

Page 81

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 79

ELECTRICAL SYSTEM

BLK 4-1

ORN 18-4

YEL/BLK 16-7

ORN 18-1

BLK 14-2

ORN 18-7

BLK/WHT 18-2

ORN 18-2

YEL/RED 18-2

BLK 18-8

YEL/BLK 16-8

BRN/BLK 18-2

BRN/YEL 18-2

BRN/GRN 18-2

ORN 18-1

ORN 18-2

ORN 18-6

ORN 18-3

BLK 16-2

RED/GRA 18-2

BLK 16-3

ORN 18-5

RED/BLK 18-2

BLK 18-2

BLU/GRN 18-2

WHT 18-1

BLK 18-1

ORN 18-6

ORN 16-22

ORN 18-3

ORN 18-5

ORN 18-7

ORN 18-4

GRN/YEL 16-2

BLU/BRN 16-2

RED 1-1

BLK 1-1

YEL/BLK 16-6

YEL/BLK 16-8

YEL/BLK 16-7

GRA/VIO 16-2

BLU/BRN 16-2

GRN/YEL 16-2

BLK 14-2

BRN/BLK 18-2

BLK/WHT 18-2

RED/BLK 18-2

RED/GRA 18-2

YEL/BLK 16-6

BRN/GRN 18-2

BRN/YEL 18-2

ORN 16-22

YEL/RED 18-2

GRA/VIO 16-2

BLK 18-26

BLK 18-30

GRN 18-2

BLK 18-11

YEL/VIO 18-2

BLK 18-9

WHT/GRA 18-2

BLK 16-3 BLK 18-8

RED.

BLK

VIO 18-1

ORN 18-19

YEL/GRN 18-1

YEL/BLK 16-2

ORN 18-12

YEL/GRN 18-3

YEL/GRN 18-2

PINK 16-1

ORN/BLU 18-1

BLK 14-1

ORN 18-9

ORN 16-1

RED 10-1

BLK 18-19

GRA/YEL 18-1

BLU/WHT 18-1

ORN 18-24

BRN/WHT 18-1

WHT/GRN 12-1

ORN 18-10

ORN/BRN 18-1

WHT/YEL 18-1

BRN/BLU 18-1

VIO/BRN 18-1

BLK/WHT 18-1

ORN 18-16

YEL/BLK 16-2

WHT/BRN 18-1

GRN/BLU 18-1

WHT/GRA 18-1

GRA/YEL 18-1

ORN 18-16

RED/GRA 18-1

ORN 18-11

BRN/BLU 18-1

YEL/BLK 16-3

WHT/GRA 18-1

ORN 18-20

GRA 18-1

VIO/YEL 18-1

BLK 18-23

ORN/GRN 16-1

VIO 16-3

PINK/YEL 16-1

BLK 16-7

ORN 18-25

ORN/BLK 18-1

ORN/BLU 18-1

BRN 18-1

YEL/WHT 18-1

GRA/RED 14-1

YEL/GRN 18-2

YEL/BLK 16-4

BRN/YEL 18-1

BRN/GRN 18-1

BLK 18-16

ORN/GRA 18-1

WHT/VIO 18-1

GRN/GRA 18-1

BLK 18-20

GRN/BLK 14-1

BLU/GRN 18-1

GRN 18-1

YEL/GRA 18-1

ORN 18-25

ORN 14-1

YEL/BLK 16-3

YEL 18-1

ORN 16-2

BLU/GRN 18-1

BRN 18-1

GRN 18-1

ORN 18-11

ORN 18-8

ORN 14-1

ORN 18-15

GRA/BLK 18-1

RED/YEL 18-1

BLK 18-18

ORN 18-10

GRA/RED 14-1

YEL/BLK 16-5

BLU/BRN 16-1

BRN/GRN 18-1

VIO 16-4

BRN/BLK 18-1

YEL/RED 18-1

VIO 16-1

WHT/GRN 12-2

VIO/YEL 18-1

BLU/BRN 16-1

BLK 16-1

ORN 18-12

ORN/GRN 16-1

RED/BRN 18-1

YEL/GRN 18-1

ORN 18-19

YEL/BLK 16-4

BLK 18-13

BLK 18-21

ORN 18-20

BLK 18-17

GRN/VIO 18-1

BLK 18-29

ORN 18-8

ORN 18-21

GRN/YEL 16-1

ORN 16-2

ORN 18-22

ORN/RED 18-1

ORN/GRA 18-1

GRA/BLK 18-1

BLK 16-7

BRN/YEL 18-1

ORN 18-14

RED/YEL 18-1

VIO 16-2

WHT/BRN 18-1

ORN 12-1

PINK 16-4

BLK 18-19

BLK 18-25

VIO 16-1

VIO/BRN 18-1

YEL/BLU 18-1

GRA/WHT 18-1

WHT/GRN 12-2

GRN/YEL 16-1

BLK 16-8

YEL/VIO 18-1

WHT/YEL 18-1

PINK 16-5

GRN/GRA 18-1

YEL/RED 18-1

WHT/BLK 18-1

BLU 18-1

RED/BRN 18-1

WHT/VIO 18-1

ORN 18-14

BLK 16-6

BRN/BLK 18-1

BLU 18-1

ORN 18-22

YEL/BLK 16-1

BLK 18-23

ORN 18-18

BLK 18-13

YEL/GRN 18-3

RED/BLK 18-1

BLK/WHT 18-1

BLK 18-28

BLK 16-5

BLK 16-8

PINK 16-2

BLU/YEL 18-1

ORN 18-9

ORN 18-18

BLU/BLK 18-1

BLK 14-1

BLK 16-4

BLK 18-17

ORN 12-1

BLK 18-14

RED/GRN 16-1

GRN/BRN 18-1

ORN 18-17

BLK 16-6

YEL/BLU 18-1

BLK 18-20

YEL/BLK 16-9

GRA 18-1

YEL/GRA 18-1

GRN/BRN 18-1

GRA/VIO 16-1

ORN 16-1

ORN/BRN 18-1

ORN 18-13

WHT/GRN 12-1

BLK 18-25

GRN/VIO 18-1

GRN/BLU 18-1

BRN/WHT 18-1

YEL/BLK 16-1

BLK 16-4

RED/GRA 18-1

BLK 16-5

BLU/YEL 18-1

RED 10-1

ORN/RED 18-1

YEL/VIO 18-1

YEL 18-1

RED/BLK 18-1

BLK 18-16

GRA/VIO 16-1

BLK 18-21

BLU/WHT 18-1

ORN 18-24

ORN 18-15

ORN 18-17

ORN 18-21

BLK 18-18

BLK 18-14

GRA/BLU 18-1

RED 8-1

RED 14-3

RED 14-2

RED 14-1

RED 14-3

RED 14-1

VIO 16-4

PINK 16-3

PINK 16-2

GRA/WHT 18-1

RED/GRN 16-1

BLU/PINK 16-1

VIO 16-3

PINK 16-1

PINK 16-6

GRA/RED 18-2

YEL/BLK 16-5

YEL/BLK 16-9

YEL/BLK 16-10

BLK 18-32

GRA/RED 18-2

BLK 18-31

YEL/BLK 16-10

BLK 18-32

YEL/WHT 18-1

BLK 18-33

BLK/YEL 18-1

BLK 18-33

BLK 18-26

ORN/BLK 18-1

VIO 16-5

YEL/BRN 18-1

VIO 16-5

BLK 18-31

BLK 18-29

BLK 18-34 BLK 18-28

YEL/BRN 18-1

BLK 18-34

WHT/BLK 18-1

RED 1-1

RED 8-1

BLK 4-1

BLK 1-1

GRA/BLU 18-1

VIO/BLU 18-1

BLK/RED 16-1

PINK/YEL 16-1

BLU/BLK 18-1

BLU/PINK 16-1

PINK 16-6

PINK 16-7

WHT/GRN 18-1

GRN/RED 18-1

GRN/WHT 18-1

BLK/GRN 18-1

GRN/WHT 18-1

GRN/RED 18-1

WHT/GRN 18-1

RED 14-4

VIO/GRA 18-1

RED 14-4

PINK 16-3

PINK 16-4 PINK 16-5

ORN 18-26

BLK 18-37

VIO/GRA 18-1

GRA/BRN 18-1

GRA/BRN 18-2

ORN 18-26

VIO/YEL 18-2

GRA/BRN 18-2

BLK 18-35

YEL/GRN 18-4

BLU/ORN 18-1

BLK/GRA 18-1

VIO/YEL 18-2

BLK 18-36

BLK 18-37

BLK 18-35

GRA/BRN 18-3

BLU/ORN 18-1

BLK 18-36

BLK/GRA 18-1

GRA/BRN 18-4

GRA/BRN 18-3

GRA/BRN 18-1

YEL/GRN 18-1

YEL/GRN 18-4

VIO/YEL 18-1

(CLOSED WHEN HOPPER IS DOWN)

140 DEG. F

(OPTIONAL)

NOTE: RED IS POSITIVE TO LOWER SIDE BROOM

SWITCH/DISPLAY PANEL ASSEMBLY

CIRCUIT BREAKERS F1 -- ACCESSORY 1 F2 -- ACCESSORY 2 F3 -- IGNITION F4 -- START F5 -- HORN F6 -- LIGHTS F7 -- SHAKER F8 -- NONE

CONTROL BOX ASSEMBLY

DATE

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

CHECKED

U/MQTY. CODE

DESCRIPTION

PART NUMBER

DRAWN

ITEM

BILL OF MATERIAL

NILFISK-ADVANCE, INC.

WGL

(OPTION)

(OPTIONAL)

NOTE: R3 IS NOT USED ON L.P. MODEL

F9 -- MAIN

(NO CONNECTION)

(CLOSED WHEN BROOM IS DOWN)

COOLANT TEMPERATURE

OUTPUT

THROTTLE INPUT

(12V FOR HIGH SPEED)

GM ENGINE SYSTEM

(REFERENCE: E-CONTROLS, INC. DRAWING NO. E1737100 AND E1737200)

GASOLINE SENSOR

IGN. SWITCH INPUT

FUEL PUMP (+)

MIL OUTPUT

ALT. EXCITE

START COMMAND

CAN (+)

CAN (-)

FUEL PUMP (-)

10-19-06

A-03130 10-19-06 WGL

10-19-06

(AXP SYSTEM)

NOTE: FOR AXP SYSTEM, YEL/GRN 18-4 WIRE IS SPLICED TO YEL/GRN 18-1 WIRE FROM J1

NOTE: FOR AXP SYSTEM, VIO/YEL 18-2 WIRE IS SPLICED TO VIO/YEL 18-1 WIRE FROM J2

AXP SYSTEM

(AXP OPTION)

GROUND

X80 GROUND

X80

SENDER, OIL PRESSURE

1 2

X48X48

X81X81

X22X22

X7X7

GROUND X70

123

X79X79

123

SP15SP15

2 2

X41X41

SWITCH, SOLUTION EMPTY

1 2

SP10SP10

2 2

DEMAND VALVE S3

1 2

15 AMPF715 AMP

1 2

SP17SP17

X25X25

15 AMPF415 AMP

1 2

SP3SP3

H15

BACK UP ALARM

H15

BACK UP ALARM

X52X52

S12

SWITCH, HOPPER INTERLOCK

S12

SWITCH, HOPPER INTERLOCK

1 2

X18X18

L10

SIDE BROOM VALVE S10

L10

SIDE BROOM VALVE S10

1 2

X86X86

SWITCH, DUST CONTROL FILTER

1 2

X87X87

A B

RELAY, NEUTRAL

86 85

87a 87

X167X167

X5X5

J3J3

RELAY, LIGHTSK2RELAY, LIGHTS

86 85

87a 87

X37X37

X28X28

A B C

X49X49

X15X15

X27X27

A B C

X35X35

60 AMPF960 AMP

1 2

SWITCH, WAND

(OPTIONAL)

SWITCH, WAND

(OPTIONAL)

X62X62

X57X57

X65X65

X73X73

X63X63

SENDER, FUELR3SENDER, FUEL

1 2

SWITCH, BROOM PRESSURE

1 2

L11

DUMP DOOR OPEN VALVE S11

L11

DUMP DOOR OPEN VALVE S11

1 2

X36X36

X55X55

RELAY, SHAKERK3RELAY, SHAKER

86 85

87a 87

SP18SP18

1 1

X39X39

L12

DUMP DOOR CLOSE VALVE S12

L12

DUMP DOOR CLOSE VALVE S12

1 2

X44X44

SCRUB DOWN VALVE S5

1 2

X83X83

RELAY, HORNK1RELAY, HORN

86 85

87a 87

X34X34

GAUGE, COMBINATION

12345

123

SENSOR, GASOLINE

123

SENSOR, GASOLINE

X11X11

X2X2

NPR

L15

SCRUB DOWN VALVE S15

L15

SCRUB DOWN VALVE S15

1 2

FLOW POSITION SENSOR

DRIVE PEDAL SENSOR 5K OHM

123

X168X168

SP4SP4

SP11SP11

X17X17

SP6SP6

221

X1X1

NPR

X91X91

LIGHT, BEACONH5LIGHT, BEACON

1 2

X33X33

SP16SP16

SW, SPDT TEMP.S7SW, SPDT TEMP.

2 3

MAIN BROOM VALVE S6

1 2

LAMP, TROUBLEH7LAMP, TROUBLE

1 2

ENGINE GROUND

X3 ENGINE GROUND

2 3

PUMP, AXP SOLUTION

HEAD LIGHT, LEFT

1 2

SP9SP9

X72X72

CHASSIS GROUND

X4 CHASSIS GROUND

123

X51X51

X90X90

X64X64

A B C D E F

LAMP, TAILH4LAMP, TAIL

SP7SP7

X76X76

SQUEEGEE VALVE S2

1 2

SP12SP12

X74X74

15 AMPF215 AMP

1 2

X78X78

X56X56

X68X68

GROUND

X85

GROUND

X85

1 2

X20X20

X23X23

A B C

X45X45

X16X16

DEMAND VALVE S1

1 2

X53X53

X13X13

X38X38

X31X31

HEAD LIGHT, RIGHT

1 2

X47X47

LAMP, CURBH6LAMP, CURB

1 2

ACTUATOR, SIDE BROOM

BLK

RED

WHT

X40X40

X46X46

LAMP, BROOM PRESSURE

+ -

SWITCH, RECOVERY FULL

1 2

X8X8

SCRUB BRUSH VALVE S7

1 2

X43X43

GROUND X82

123

CHASSIS GROUND

X169

CHASSIS GROUND

X169

X24X24

A B C

J1 BLACKJ1BLACK

1234567891011121314151617

1920212223242526272829303132333435

S16

SWITCH, MAIN BROOM

S16

SWITCH, MAIN BROOM

1 2

SWITCH, IGN.S1SWITCH, IGN.

ACC

BAT

IGN

X29X29

FUEL PUMP

- +

X32X32

X30X30

L13

HOPPER RAISE VALVE S13

L13

HOPPER RAISE VALVE S13

1 2

L14

HOPPER LOWER VALVE S14

L14

HOPPER LOWER VALVE S14

1 2

X19X19

A B

10 AMPF810 AMP

1 2

SP5SP5

121

STARTER

BAT

GND

X67X67

SCRUB DOWN VALVE S4

1 2

X71X71

MOTOR, SHAKER

SP8SP8

121

25 AMPF125 AMP

1 2

12 VDCBT12 VDC

+ -

X61X61

VAC FAN VALVE S8

1 2

J2 NATURALJ2NATURAL

1234567891011

1314151617181920212223

SP13SP13

1 1

SP2SP2

122

DUST CONTROL VALVE S9

1 2

SWITCH, LOW LP PRESSURE

1 2

X42X42

10 AMPF310 AMP

1 2

X50X50

15 AMPF615 AMP

1 2

X88X88

A B

X69X69

X59X59

RELAY, AXPK6RELAY, AXP

86 85

87a 87

10 AMPF510 AMP

1 2

H16

HORN

H16

HORN

X75X75

X60X60

L16

SOLUTION VALVE

L16

SOLUTION VALVE

1 2

X54X54

X14X14

X26X26

X66X66

LAMP, TAILH3LAMP, TAIL

X77X77

X10X10

SP14SP14

X21X21

A B

SWITCH, HYDRAULIC FILTER

1 2

X12X12

X58X58

ELECTRICAL SYSTEM

SCHEMATIC FOR Captor/CR 1100 series (56306xxx & 56307xxx Models) TIER II

Page 82

80 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

YEL/BLK

WHT/GRN

RED/GRN

VIO

YEL/BRN

GRA/BLK

VIO

ORN

VIO BLK

PINK

BLK

VIO

WHT/BLK

RED BLK

VIO/BLU

RED RED

RED

ORN/GRN BLK

WHT/GRN

RED

PINK

WHT

PINK

BLU/PINK

RED

PINK

GRN/BLK

WHT

BLK

BRN/GRA BRN/GRA

BLK

RED

BLK

RED

RED VIO/GRA

GRA/BRN

BLK/GRA

GRA/BRN

BLU/ORN

BLK

VIO

BLK

RED

YEL/BLK

ORN

BRN/GRA

PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-

DWG. NO.

THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,

DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT

REV

SHEET

APPDECO DATE

1 OF 2

CONFIDENTIAL

DFTM

AGREES TO RETURN IT UPON REQUEST.

REVISIONS

WGL WGL

56304764

RELEASED

(OPTION)

(CLOSED IN NEUTRAL)

FROM LIGHTING CIRCUIT

GLOW PLUGS

TO J2-1 ON CONTROL BOX

1/14/04

A-02214

WGL WGLA-02389

UPDATE: K1 WAS K7, K2 WAS K9, K3 WAS K8

3/1/04

WGL WGLA-03793 9-25-07

UPDATE: ADD AXP SYSTEM

AXP SYSTEM

TO SOLUTION EMPTY SWITCH SEE SHEET 2

TO SOLUTION VALVE SEE SHEET 2

FUEL PUMP

S1 SWITCH, IGN.S1SWITCH, IGN.

5030AC

K5 RELAY, SPDTK5RELAY, SPDT

8787a

SENDER, COOLANT REMP.

1 2

SENDER, FUELR3SENDER, FUEL

1 2

CIRCUIT BREAKER, 10 AMP

1 2

GAUGE, COMBINATION

12345

CIRCUIT BREAKER, 25 AMP

COIL, RELAYK5COIL, RELAY

SWITCH, BROOM PRESSURE

1 2

CIRCUIT BREAKER, 10 A.F8CIRCUIT BREAKER, 10 A.

1 2

X5X5

F9 CIRCUIT BREAKER, 60 AMP

RELAY, AXPK6RELAY, AXP

30 87

87a

LAMP, BROOM PRESSURE

1 2

SENDER, OIL PRESSURER1SENDER, OIL PRESSURE

1 2

LIGHT, BEACONH5LIGHT, BEACON

1 2

E4E4

1 2

E3E3

1 2

L17

SOLENOID, FUEL

L17

SOLENOID, FUEL

PUMP, AXP SOLUTION

FLOW POSITION SENSORR5FLOW POSITION SENSOR

123

12 VDCBT12 VDC

+ -

ALTERNATOR

B+

B-

E1E1

1 2

RELAY, NEUTRALK4RELAY, NEUTRAL

30 87

87a

M1 STARTERM1STARTER

3050

E2E2

1 2

CIRCUIT BREAKER, 15 AMP

1 2

CIRCUIT BREAKER, 15 AMP

1 2

RED/BRN WHT/YEL

YEL/BLK

BLKYEL/BLK

BLK

RED GRA/RED

YEL/BLK

BLKYEL/BLK

YEL/BLK

BLU/YEL BLU/GRN WHT BLK

RED

VIO

BLK

WHT/GRA

BLK

TAN/BRN

BLK

RED/BLK

YEL/WHT

ORN/BLK

BLK

GRA/YEL

BLU/BRN

GRA/VIO

GRN/YEL

YEL/GRA

ORN/GRA

BRN/WHT

BLKYEL/VIO

ORN/BRN

RED/YEL

GRN/BLU

WHT/BRN

BLK

BRN/BLU

BLK

YEL/BLK

BLK

BLK/YEL

BLK

BRN/GRA

BLK

GRA/BLU

GRN/BRNORN

YEL/GRNORN

ORN BRN/BLK

BLU/WHT

ORN ORN/RED

BRNORN

ORN YEL/BLU

WHT/VIOORN

ORN GRN/GRA

BLU

ORN ORN/BLU

BRN/YELORN

ORN

VIO/BRN

ORN

BLK/WHT

BRN/GRN

RED/GRA

YEL/RED

GRN/VIOORN

GRA/WHT

YELORN

GRNORN

VIO

ORN BLK

YEL/GRN

VIO/YEL

BLKRED ORN VIO

YEL/BLK

BRN/GRA

CONTROL BOX ASSEMBLY

TO GAUGES

U/M

1. ALL DIMENSIONS IN INCHES.

WGL

TITLE

SPECIFIED

DIAGRAM, DIESEL LADDER

DWG. NO.

NOTES UNLESS OTHERWISE

REV.

DIM. IN [ ] ARE MM. UNITS IN [ ] ARE ISO METRIC

CODE

APPROVED

SIZE

PROJ ENG

AS NOTED.

EDGES.

DRAWN

PART NUMBER

DESCRIPTION

4. REMOVE ALL BURRS AND SHARP

NILFISK-ADVANCE, INC.

BUT BEFORE PAINTING.

BILL OF MATERIAL

CHECKED

PLYMOUTH, MINNESOTA 55447-3408

PLATING AND HEAT TREATING,

ITEM CODE

APPROVED

3. ALL DIMENSIONS APPLY AFTER

QTY.

APPROVED

2. DO NOT SCALE DRAWING.

56304764

APPD

CONFIDENTIAL

DFTM

WGL

THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,

DATE

REV

DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT

PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-

AGREES TO RETURN IT UPON REQUEST.

REVISIONS

ECO

RELEASED

56340764

SHEET

2 OF 2

WGL

DWG. NO.

140 DEG. F

(OPTIONAL)

(CLOSED WHEN HOPPER IS DOWN)

(OPEN WHEN BROOM IS DOWN)

SIDE BROOM ACTUATOR WIRING: (-) WHITE & (+) RED = CW (EXTEND FOR DOWN) (+) WHITE & (-) BLACK = CCW (RETRACT FOR UP) WHITE = COMMON

J3-2 LIGHT SENSOR

J3-3 BUZZER

J3-6 SDA

J3-5 SCL

J3-7 (B+)

J3-8 (B-)

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

J2-6

J2-5

J2-15

J1-34

J1-1

J1-29

J1-30

J1-31

J1-32

J1-33

J1-26

J1-12

J1-35

J1-23

WGL

(CLOSES WITH HIGH HOPPER TEMPERATURE)

(OPENS WHEN TANK IS FULL)

(CLOSES WHEN TANK IS EMPTY)

CLOSES WHEN FILTER IS PLUGGED)

FUNCTION SCRUB ON SCRUB (1) SCRUB (2) SCRUB (3) SCRUB UP

SQUEEGEE UP MAIN BROOM SIDE BROOM DUST CONTROL HOPPER UP HOPPER DOWN DUMP DOOR OPEN DUMP DOOR CLOSE

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15

HYDRAULIC VALVE TRUTH TABLE

XXX

SQUEEGEE DOWN VAC FAN

XXX

X X

J2-16

J2-9DIESEL MODE

SELECT

J2-23

J2-1

FROM GLOW PLUGS

J1-25

9/22/03

1/14/04

THROTTLE ACTUATOR WIRING: (+) A & (-) B = (EXTEND FOR IDLE) (-) A & (+) B = (RETRACT FOR RUN)

A-02241

1/5/04

(OPTIONAL)

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

WGLBWGL

A-02389 3/1/04

SEE SHEET 1

WGLCWGL

A-03793 9-25-07

SEE SHEET 1

TO AXP SYSTEM SEE SHEET 1

CURB LAMPH6CURB LAMP

1 2

DUST CONTROL VALVE S9

1 2

RELAY, NEUTRALK6RELAY, NEUTRAL

H15

BACK UP ALARM

H15

BACK UP ALARM

1 2

ACTUATOR, SIDE BROOM

BLK

RED

WHT

L13

HOPPER RAISE VALVE S13

L13

HOPPER RAISE VALVE S13

1 2

RELAY, SHAKERK3RELAY, SHAKER

30 87

87a

DRIVE PEDAL SENSOR, 5K OHM

123

HEAD LIGHT, LEFTH2HEAD LIGHT, LEFT

1 2

L11

DUMP DOOR OPEN VALVE S11

L11

DUMP DOOR OPEN VALVE S11

1 2

CIRCUIT BREAKER, 10 AMP

1 2

CIRCUIT BREAKER, 15 AMP

1 2

L12

DUMP DOOR CLOSE VALVE S12

L12

DUMP DOOR CLOSE VALVE S12

1 2

H16

HORN

H16

HORN

1 2

SWITCH, DUST CONTROL FILTER

1 2

RELAY, HORNK1RELAY, HORN

30 87

87a

L10

SIDE BROOM VALVE S10

L10

SIDE BROOM VALVE S10

1 2

L14

HOPPER LOWER VALVE S14

L14

HOPPER LOWER VALVE S14

1 2

RELAY, AXPK6RELAY, AXP

L15

SCRUB DOWN VALVE S15

L15

SCRUB DOWN VALVE S15

1 2

SQUEEGEE VALVE S2

1 2

ACTUATOR, THROTTLE

S16

SWITCH, MAIN BROOM

S16

SWITCH, MAIN BROOM

1 2

SWITCH, HYDRAULIC FILTER

1 2

SWITCH, RECOVERY FULL

1 2

DEMAND VALVE S1

1 2

SWITCH, SOLUTION EMPTY

(OPTIONAL)

SWITCH, SOLUTION EMPTY

(OPTIONAL)

1 2

TROUBLE LAMPH7TROUBLE LAMP

1 2

RELAY, HORNK1RELAY, HORN

VAC FAN VALVE S8

1 2

LAMP, TAILH3LAMP, TAIL

1 2

RELAY, LIGHTSK2RELAY, LIGHTS

30 87

87a

SCRUB BRUSH VALVE S7

1 2

M2 MOTOR, SHAKER

1 2

LAMP, TAILH4LAMP, TAIL

1 2

SWITCH, WANDS2SWITCH, WAND

SCRUB DOWN VALVE S4

1 2

L16

SOLUTION VALVE

L16

SOLUTION VALVE

1 2

RELAY, LIGHTSK2RELAY, LIGHTS

MAIN BROOM VALVE S6

1 2

RELAY, SHAKERK3RELAY, SHAKER

SWITCH, HOPPER FIRE

2 3

CIRCUIT BREAKER, 15 AMP

1 2

S12

SWITCH, HOPPER INTERLOCK

S12

SWITCH, HOPPER INTERLOCK

1 2

HEAD LIGHT, RIGHT

1 2

SCRUB DOWN VALVE S5

1 2

DEMAND VALVE S3

1 2

A1 Control Box Assembly

A2 Membrane Switch BT Battery E1-E4 Glow Plugs 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) F8 Circuit Breaker, 10 Amp (AXP/EDS) F9 Circuit Breaker, 60 Amp (MAIN) G1 Alternator H1 Headlight, Right H2 Headlight, Left H3 Lamp, Tail H4 Lamp, Tail H5 Light, Beacon (optional) H6 Lamp, Curb (optional) H7 Lamp, Trouble (optional) H8 Lamp, Broom Pressure H15 Back-Up Alarm (optional)

H16 Horn K1 Relay, Horn K2 Relay, Lights K3 Relay, Shaker K4 Relay, Neutral (closed in neutral) K5 Relay, Accessory K6 Relay, SPDT (AXP/EDS) 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

Item Description

WIRING DIAGRAM / SCHEMATIC FOR Captor/CR 1100 series (Diesel Models)

Item Description

L17 Fuel Solenoid M1 Starter Motor M2 Shaker Motor M3 Fuel Pump M4 Actuator, Side Broom M5 Fuel Pump (Gasoline/Petrol) M6 Pump Assembly (AXP/EDS) P6 Gauge, Combination R1 Sender, Oil Pressure R2 Drive Pedal Sensor R3 Sender, Fuel R4 Sender, Coolant Temp R5 Flow Position Sensor (AXP/EDS) S1 Switch, Ignition S2 Switch, Wand (optional) S4 Switch, Broom Pressure S5 Switch, Dust Control Filter (optional) S6 Switch, Hydraulic Filter S7 Switch, Hopper Fire (optional) S8 Switch, Recovery Full S9 Switch, Solution Empty S12 Switch, Hopper Interlock S16 Switch, Main Broom

Item Description

Note: AXP/EDS

system introduced in 5/08 is backward compatible for all machines

Page 83

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 81

ELECTRICAL SYSTEM

ENGINE HARNESS for 1.6L Gasoline/Petrol and LPG Tier I

BROWN/BLUE16

ORANGE/BLUE16

BROWN/GREEN16 LTBLUE/WHITE 18 TAN/DKGREEN 18 LTGRN 18

DKBLUE 18 TAN18

YELLOW/GRAY18

PURPLE/YELLOW18 DKBLUE/YELLOW 18 BLACK16 BLACK16 BLACK/LTGREEN 18 LTGREEN/RED 18 PINK/TAN18 DKGREEN/ORANGE 18

PURPLE/WHITE18

WHITE/PURPLE18

RED/TAN16

GRAY/ORANGE18

WHITE/BLACK18

TAN/BLACK18

WHITE/LTBLUE 18

PURPLE/LTBLUE 18

LTBLUE/DK BLUE18 PINK/WHITE18

TAN/ORANGE18

LTGREEN/BLACK 18

YELLOW/LTGREEN 18

LTBLUE/BLACK 18

BLACK/WH

ITE18 PURPLE/DKBLUE 18 TAN/BROWN18 YELLOW/DKBLUE 18 GRAY/DKBLUE 18 WHITE/RED18

BLUE/PINK18 BLUE/WHITE18 DKGREEN 18 ORANGE18 YELLOW18 YELLOW/BLACK18

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

LTGREEN/RED 18

BLK/LTGREEN 18

LTGREEN/RED 18

DKGREEN 18

ORANGE18

RTN

TWR

COMM

TWISTWIRES 10 TURNS(360DEG)/INCH FULL LENGTH

INJ1

INJ+

INJ2

AUXOUT 2

AUXANA PD1

MAP FPP IAT ECT IVS

AUXANA PU1 POWERGROUND POWERGROUND

ANA_RTN 5VOLT REF

VSW EGO1

KNK-

KNK+

CRANK+ CRANK-

CAM+ CAM-

VBAT VBAT

STARTERLOCKOUT

FUELLOCKOFF

FUELPUMP

RELAYCONTROL

TPS1

TPS2 DBW+ DBW-

OILPRESSURE

TACH

MIL

AUXANA PD2

AUXOUT 1

AUXANA PU2

FUELSELECT

GOVSELECT

GASEOUSTRIM

CAN+

CAN-

RS232 TX RS232 RX

COIL1

COIL2

UNUSED UNUSED UNUSED

INJ7 UNUSED UNUSED

PSIECM

YELLOW18 YELLOW/BLACK18 BLACK16 PINK/DKGREEN 16

SHD

12162859

BLACK18

PURPLE/WHITE18

WHITE/PURPLE18

CRANK_PSI_1P6

TAN/ORANGE18

BOSCH THROTTLE

PINK/WHITE18

LTBLUE/DK BLUE18

PURPLE/LTBLUE 18

LTGREEN/RED 18

BLK/LTGREEN 18

RED14

RED/TAN14

WHITE/BLUE18

POWER_RELAY

PINK/DKGREEN 16

F3 15A

PINK/DKGREEN 16 PINK/DK GREEN 16

RED12 RED16

ALTERNATOR

RED16

ALTERNATOR

BATT+2

RED12

FUEL_PUMP_RELAY

F4 15A

PINK/YELLOW16

RED14

PINK/TAN18

TAN/BLACK18

BATT+ 1

F2 20A

RED/TAN14

RED14

RED12

STARTER_RELAY

STARTER SOLENOID

LTBLUE/PINK 16

PINK/BLACK16

87A

GRAY/ORANGE18

PINK/TAN18

WHITE16

RELAYFUSED POWER

GROUND

FUELPUMP

AUXIN PU1

AUXIN PU2

AUXIN PD2

TWR

PINK/DKGREEN 16

BLACK16

PINK/YELLOW16

DKBLUE/YELLOW 18

YELLOW/DKBLUE 18

BLACK/WHITE18

BLUE/PINK18

GRAY/DKBLUE 18

TAN/BROWN18

YELLOW/LTGREEN 18

TAN/DKGREEN 18

LTBLUE/WHITE 18

BLUE/WHITE18

PURPLE/DKBLUE 18

LTBLUE/BLK 18

LTGREEN/BLACK 18

BLACK/LTGREEN 18

PURPLE/YELLOW18

DKBLUE 18

PINK

LTGREEN/RED 18

ORANGE/YELLOW18

CAN+

GOVSELECT

FUELSELECT

TACH

AUXIN PD1

AUXOUT 2

CANAUXOUT 1

G H

TWR

G H J K

TWR

MIL

OILPRES

ANARTN

IVS

FPP1

VSW

VREF CHARGEVOLTS STARTIN (INTERUPTTYPE) STARTIN (AUTOCRANKING)

LTBLUE/PINK 16 PINK/BLACK16

GROUND

PINK18

PINK/TAN18

BLACK12

BLACK16

RED/TAN16

BLACK16

RED/TAN16

ECT

YELLOW/GRAY18

BLACK/LTGREEN 18AB

BOSCH_TMAP

LTGREEN 18 LTGREEN/RED 18 TAN18 BLACK/LTGREEN 18

4 3 2

MTRSHD6

MTRTWR4_EGO

PINK/TAN18

WHI

TE/RED18

WHITE/BLACK18

BROWN/GREEN16

BROWN/BLUE16

ORANGE/BLUE16

SHD

BLACK18

PINK/DKGREEN 16

DKGREEN/ORANGE 18

BLK/LTGREEN 18

TWR

OIL PRES

G H

RED/WHITE18

RING

Page 84

82 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

FUEL PUMP OUTPUT

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

G H

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

35 33 3

39 36 19

20 49

50 21 55 41 42 11

13 14 22 23 9 8 7 10 53 54

25 37 56

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

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

GROUND

FUEL PUMP

AUX IN PU1

AUX IN PU2

AUX IN PD2

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

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

G H

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

Wirin g

Harne ss Wirin g Ha rness Com ponen t D escrip tion

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 engine

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

TIER I ENGINE HARNESS ECM DETAIL

Page 85

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 83

ELECTRICAL SYSTEM

ENGINE HARNESS for 1.6L Gasoline/Petrol Tier II

GASOLINE SENSOR INTERFACE

BOSCH THROTTLE

INJECTOR #1

INJECTOR #2

INJECTOR #3

INJECTOR #4

FUEL PUMP RELAY

FUEL PUMP

BATT +

GROUND

ALTERNATOR

ALTERNATOR+

ALTERNATOR -

DIAGNOSTIC CONNECTOR

CONNECTOR 1

VEHICLE INTERFACE CONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURE SENSOR

IGNITION COIL

CRANK SENSOR

GROUND

POWERRELAY

IGNITION

STARTERREL AY

STARTER

SOLENOID

ECM

STARTER

VSW

GCP 90 WAY CONNECTOR

Page 86

84 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

POWERRELAY

EPR CONNECTOR

LPG TEMPERATURE

GCP 90 WAY CONNECTOR

BOSCH THROTTLE

BATT +

GROUND

ALTERNATOR

ALTERNATOR+

ALTERNATOR -

DIAGNOSTIC CONNECTOR

CONNECTOR 1

VEHICLE INTERFACE CONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURE SENSOR

IGNITION COIL

CRANK SENSOR

GROUND

EPR

IGNITION

STARTERREL AY

STARTER

SOLENOID

ECM

STARTER

VSW

LOCKOFF

ENGINE HARNESS for GM 1.6L LPG (Propane) Tier II

Page 87

FORM NO. 56043093 Captor™ 4300, 4800, 5400 - 85

ELECTRICAL SYSTEM

Tier II ENGINE HARNESS ECM Detail

LT GREEN/PURPLE 18

LT GREEN/BLACK 18

BLUE/WHITE 18

BLUE/PINK 18

LT GREEN/RED 18

BLACK/LT GREEN 18

DK BLUE/ORANGE 18

PURPLE/YELLOW 18

UNUSED

GREEN/YELLOW 18

LT BLUE/PINK 16

DK BLUE 18

PINK/YELLOW 16

BLACK/RED 16

PURPLE 16

PINK 18

S 5V EXT 2 (FPP2 ONLY) R 5V RTN 2 P CAN1 N CAN1 + M 5V EXT 1 L 5V RTN 1 K FPP1 J FPP2/IVS H FUELSELECT (AUX DIG 1) G MIL F START COMMAND E AUX PWM 1 D FUELPUMP + C FUELPUMP B ALT E XCITE A VSW

PINK/DK GREEN 16

TAN/DK GREEN 18

RED/BLACK 18 RED/WHITE 18 TAN/BLACK 18

TAN/RE

D 18 GRAY/DK BLUE 18 GRAY/ORANGE 18

DK BLUE/YELLOW 18 YELLOW/DK BLUE 18

TAN 18

BLACK 16

GRAY 18 BROWN/WHITE 16 WHITE/BROWN 16

S 12V RELAYED POWER R AUXANA PD1 P VS N VS + M AUX DIG 3 L AUX DIG 2 K GOV SELECT 1 J GOV SELECT 2 H AUXANA PU1 G AUX ANA PU2 F AUX PWM 2 E GROUND D TACH C AUX PWM 5 B AUX PWM 5 RECIRC A UNUSED

BLACK/LT GREEN 18 LT GREEN/WHITE 18

LT GREEN/RED 18

WHITE/LT GREEN 18

A B C D

ECM Detail

CONNECTOR 1

CONNECTOR 2

BLACK/LT GREEN 18

LT GREEN/RED 18

DK GREEN 18

ORANGE 18

BLUE/PINK 18

BLUE/WHITE 18

1 ANA RTN 2 5V REF 3 PC TX 4 PC RX 5 UNUSED 6 UNUSED 7 CAN1 + 8 CAN1 -

GASOLINE SENSOR INTERFACE

TAN/BRN 16-1 GRN/YEL 18-1 BLU/PINK 16-1

PINK/YEL 16-1 BLK/RED 16-1 PINK 16-7 PINK 16-4

S R

CAN1 (-) P

CAN1 (+) N

FUEL SELECT H

MIL OUTPUT G

START COMMAND F

FUEL PUMP (+) D

FUEL PUMP (-) C

ALT.EXCITE B

IGN. SWITCH INPUT A

GRA/BLU 18-1

TAN 18-1

S R P N M

THROTTLE INPUT K

(12V FOR HIGH SPEED)

H G

COOLANT TEMP. OUTPUT F

E D C B A

WHT/GRN 18-1 GRN/RED 18-1 GRN/WHT 18-1 BLK/GRN 18-1

D C B A

X78

(GASOLINE

MODELS ONLY)

DIAGNOSTIC CONNECTOR

Machine

Harness Connectors

ECM

Harness Connectors

Wiring

Harness Wiring Harness Component Description

Item

A ECM Wiring Connector (90 Pins) B Gasoline/Petrol Fuel Sensor Interface Connecto r (fuel pressure

regulation and temperature sensor manifold assembly)

C Engine Diagnostic Communication Port (8 Pin)

(MIL shorting location)

D Ignition Coil Pack Wiring Connector E Engine Oil Pressure Switch F Crankshaft Position Sensor Connector G Throttle Fly Actuator Motor Conne ctor (Bosch) H EGO #1 Sensor Wiring Connector

I Combined TMAP Engine Air Temperature and MAP Sensor Wiring

Connector

J Engine Coolant Temperature (ECT) Sensor Connector K Engine Starter Solenoid Wire Connector L EGO #2 Sensor Wiring Conn ector M LPG Fuel Lockoff Wiring Connector N LPG Temp Sensor Wiring Connector P EPR Conne ctor (LPG) Fuel Regulato r Q Gasoline Fuel Injectors

Definition of Terms for Computerized Engine Co ntrollers

• ANA-RTN:

• ECM: Engine Control Mod ule

• EGO: Exhaust Gas Oxygen Sensor (O2)

• EPR: Electronic Pressure Re gulator

• IAT: Intake Manifold Air Temperature

• MAP: Intake Manifold Absolute Pressure

• MIL: Malfunction Indicator Light

• VSW: Switched Battery Voltage

• VBAT: Battery Voltage

Page 88

86 - FORM NO. 56043093 Captor™ 4300, 4800, 5400

ELECTRICAL SYSTEM

THIS PAGE IS INTENTIONALLY BLANK

Page 89

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 87

PROGRAMMABLE CONTROL OPTIONS

Scrub Motor Turn-Off Delay Adjustment:

FACTORY DEFAULT: 1 (0.5 second) RANGE: 1 - 9 (0.5 – 4.5 seconds)

The amount of time that the scrub brushes continue to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub system off switch. 3 While holding the scrub system off switch turn the main power key switch to the on position. 4 Continue to hold the scrub system off switch until all indicators except the scrub off indicator turn off (approximately two seconds). 5 Release the scrub off switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the scrub off switch will increase the displayed value until

9 is reached. The next press will return to 1. Each increment represents 0.5 second with 1 equal to 0.5 second.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Vacuum Turn-Off Delay Adjustment:

FACTORY DEFAULT: 1 (12 seconds) RANGE: 1 - 9 (12 – 20 seconds)

The amount of time that the vacuum continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the vacuum/squeegee switch. 3 While holding the vacuum/squeegee switch turn the main power key switch to the on position. 4 Continue to hold the vacuum/squeegee switch until all indicators except the vacuum/squeegee indicator turn off (approximately two

seconds).

5 Release the vacuum/squeegee switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the vacuum/squeegee switch will increase the displayed

value until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to twelve seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Main and Side Broom Turn-Off Delay Adjustment:

FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds)

The amount of time that the main broom and side brooms continue to run after the foot pedal returns to neutral is adjustable. To select the

desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the side broom up/off switch. 3 While holding the side broom up/off switch turn the main power key switch to the on position. 4 Continue to hold the side broom up/off switch switch until all indicators except the side broom up/off indicator turn off (approximately two

seconds).

5 Release the side broom up/off switch switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the side broom up/off switch will increase the displayed

value until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Page 90

88 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

PROGRAMMABLE CONTROL OPTIONS

Dust Control Turn-Off Delay Adjustment:

FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds)

The amount of time that the dust control continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the dust control switch. 3 While holding the dust control switch turn the main power key switch to the on position. 4 Continue to hold the dust control switch until all indicators except the dust control indicator turn off (approximately two seconds). 5 Release the dust control switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the dust control switch will increase the displayed value

until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Shaker Duration Adjustment:

FACTORY DEFAULT: 5 (20 seconds) RANGE: 1 - 9 (12 – 28 seconds)

The amount of time that the shaker runs once it has been activated is adjustable. To select the desired duration:

1 Turn the main power key switch to the off position. 2 Press and hold the shaker switch. 3 While holding the shaker switch turn the main power key switch to the on position. 4 Continue to hold the shaker switch until all indicators except the shaker indicator turn off (approximately two seconds). 5 Release the shaker switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the shaker switch will increase the displayed value until

9 is reached. The next press will return to 1. Each increment represents two seconds with 1 equal to twelve seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

S1 Valve (Squeegee & Scrub Deck Lift) Duration Adjustment:

FACTORY DEFAULT: 4 (2.5 seconds) RANGE: 1 - 9 (1.0 – 5.0 seconds)

The amount of time that the S1 valve remains on when lifting the squeegee or scrub deck is adjustable. To select the desired duration:

1 Turn the main power key switch to the off position. 2 Press and hold the hopper down switch. 3 While holding the hopper down switch turn the main power key switch to the on position. 4 Continue to hold the hopper down switch until all indicators except the hopper down indicator turn off (approximately two seconds). 5 Release the hopper down switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the hopper down switch will increase the displayed value

until 9 is reached. The next press will return to 1. Each increment represents 0.5 second with 1 equal to one second.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

revised 4/04

Page 91

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 89

PROGRAMMABLE CONTROL OPTIONS

Hopper Door Open/Close Duration Adjustment:

FACTORY DEFAULT: 3 (2.5 seconds) RANGE: 1 - 9 (2.0 – 4.0 seconds)

The amount of time that the valves that open or close the hopper door remain on when automatically opening or closing the door is adjustable.

To select the desired duration:

1 Turn the main power key switch to the off position. 2 Press and hold the hopper door open switch. 3 While holding the hopper door open switch turn the main power key switch to the on position. 4 Continue to hold the hopper door open switch until all indicators except the hopper door open indicator turn off (approximately two

seconds).

5 Release the hopper door open switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the hopper door open switch will increase the displayed

value until 9 is reached. The next press will return to 1. Each increment represents 0.25 second with 1 equal to two seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Hopper Door, Squeegee & Scrub Deck Lift Position-Refresh Interval Adjustment:

FACTORY DEFAULT: 0 (refresh disabled) RANGE: 0 - 9 (5 - 45 minutes)

The hydraulic cylinders that control the hopper door, squeegee lift and scrub deck lift are not continuously pressurized by the hydraulic system. If any leakage occurs in the valves that control these cylinders, the cylinder position may drift over time. If this does occur, the control can be programmed to automatically “refresh” the pressure on the cylinders to make sure that they remain at the limit of their travel. This refresh interval is adjustable. To select the desired interval:

1 Turn the main power key switch to the off position. 2 Press and hold the hopper door close switch. 3 While holding the hopper door close switch turn the main power key switch to the on position. 4 Continue to hold the hopper door close switch until all indicators except the hopper door close indicator turn off (approximately two

seconds).

5 Release the hopper door close switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the hopper door close switch will increase the displayed

value until 9 is reached. The next press will return to 0. Each increment represents ve minutes with 1 equal to ve minutes. Selecting 0

disables the refresh action.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Scrub Pressure Default Adjustment:

FACTORY DEFAULT: 1 (minimum pressure) RANGE: 0 - 3

The default scrub pressure that is selected each time the scrub system is activated can be adjusted. To select the desired default value:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub pressure decrease switch. 3 While holding the pressure decrease switch turn the main power key switch to the on position. 4 Continue to hold the pressure decrease switch until all indicators except the scrub pressure decrease indicator turn off (approximately two

seconds).

5 The status display will now show a number from 0 to 3. Pressing and releasing the scrub pressure decrease switch will increase the

displayed value until 3 is reached. The next press will return to 0. If 0 is selected, the scrub pressure will return to the last used setting

when the scrub system is activated. If 1 is selected, the scrub pressure will default to the minimum setting when activated. If 2 is selected,

the scrub pressure will default to the medium setting when activated. If 3 is selected, the scrub pressure will default to the maximum setting

when activated.

6 To save the new setting, turn the main power key switch to the off position. 7 The new setting will be saved and will remain in effect until it is changed again.

revised 4/04

Page 92

90 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

PROGRAMMABLE CONTROL OPTIONS

Scrub Pressure Limit Adjustment:

FACTORY DEFAULT: 3 (maximum pressure) RANGE: 1 - 3

The maximum scrub pressure that the operator can select can be adjusted. To select the desired limit value:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub pressure increase switch. 3 While holding the pressure increase switch turn the main power key switch to the on position. 4 Continue to hold the pressure increase switch until all indicators except the scrub pressure increase indicator turn off (approximately two

seconds).

5 The status display will now show a number from 1 to 3. Pressing and releasing the scrub pressure increase switch will increase the

displayed value until 3 is reached. The next press will return to 1. If 1 is selected, the only available scrub pressure will be the minimum

setting. If 2 is selected, the minimum and medium scrub pressures will be available. If 3 is selected, all scrub pressures will be available.

6 To save the new setting, turn the main power key switch to the off position. 7 The new setting will be saved and will remain in effect until it is changed again.

Foot Pedal Neutral Position and Dead-band Adjustment:

FACTORY DEFAULT: 2 RANGE: 1 - 9

The various scrub and sweep functions on the Captor are activated when the foot pedal is moved from the neutral position. The engine neutralstart relay is also activated when the foot pedal is moved from the neutral position. These functions are triggered via a position sensor mounted

on the hydrostat. Whenever adjustments are made to the hydrostat unit, the neutral position will need to be programmed. Also, the neutral dead-band (sensitivity) can be adjusted if necessary. To set the neutral position and adjust the neutral dead-band perform the following steps:

1 Turn the main power key switch to the off position. 2 Depress the foot pedal to the full reverse position. 3 Allow the foot pedal to slowly return to the neutral position and do not move the pedal during the remainder of this procedure. 4 Press and hold the engine speed switch. 5 While holding the engine speed switch turn the main power key switch to the on position. 6 Continue to hold the engine speed switch until all indicators except the engine speed indicator turn off (approximately two seconds). 7 Release the engine speed switch. 8 The status display will now show a number from 1 to 9. Pressing and releasing the engine speed switch will increase the displayed value

until 9 is reached. The next press will return to 1. This number represents the dead-band value. A value of 1 results in the smallest deadband (most sensitive to pedal movement) and 9 results in the largest dead-band (least sensitive to pedal movement). The neutral position

is automatically detected at the beginning of this procedure. A dead-band value of 2 or 3 usually produces the best results.

9 To save the new setting, turn the main power key switch to the off position. 10 The new setting will be saved and will remain in effect until it is changed again.

revised 4/04

Page 93

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 91

PROGRAMMABLE CONTROL OPTIONS

Back-up Alarm Mode Control:

FACTORY DEFAULT: 1 (reverse only) RANGE: 0 - 4

The Captor may be equipped with an optional back-up alarm. This alarm can be programmed to operate at times other than backing up or it

may be turned off. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the horn switch. 3 While holding the horn switch turn the main power key switch to the on position. 4 Continue to hold the horn switch until all indicators except the horn indicator turn off (approximately two seconds). 5 Release the horn switch. 6 The status display will now show a number from 0 to 4. Pressing and releasing the horn switch will increase the displayed value until 4 is

reached. The next press will return to 0. If 0 is selected, the back-up alarm will be disabled and will not sound at any time. If 1 is selected, the alarm will sound only when backing up. If 2 is selected, the alarm will sound when driving forward or in reverse. It will be off in neutral. If 3 is selected, The alarm will sound when backing up or if the hopper is being raised or lowered. If 4 is selected, The alarm will sound when

driving forward or in reverse or if the hopper is being raised or lowered.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Side Broom Mode Control:

FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2

The side brooms on the Captor are programmed to always come on when the main broom is rst activated. If this is not desired, the operating

mode of the side booms can be changed. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the side broom up/off and the scrub system off switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the side broom up/off and scrub off indicators turn off (approximately two

seconds).

5 Release both switches. 6 The status display will now show a number from 0 to 2. Pressing and releasing the side broom up/off switch will increase the displayed

value until 2 is reached. The next press will return to 0. If 0 is selected, the side brooms will not come on with the main broom. They will be

manual control only. If 1 is selected, the side brooms will always come on when the main broom is initially turned on. If 2 is selected, the side brooms will come on if they were used the last time the main broom was on otherwise they will not automatically come on.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Dust Control Mode Control:

FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2

revised 4/04

Page 94

92 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

PROGRAMMABLE CONTROL OPTIONS

The dust control on the Captor is programmed to always come on when the main broom is rst activated. If this is not desired, the operating

mode of the dust control can be changed. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the dust control and the scrub system off switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the dust control and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a number from 0 to 2. Pressing and releasing the dust control switch will increase the displayed value

until 2 is reached. The next press will return to 0. If 0 is selected, the dust control will not come on with the main broom. It will be manual

control only. If 1 is selected, the dust control will always come on when the main broom is initially turned on. If 2 is selected, the dust control will come on if it was used the last time the main broom was on otherwise it will not automatically come on.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

revised 4/04

Page 95

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 93

PROGRAMMABLE CONTROL OPTIONS

Shaker Mode Control:

FACTORY DEFAULT: 1 (timed – manual control) RANGE: 0 - 3

The dust control lter shaker on the Captor is programmed to run for an adjustable period of time when the operator depresses the shaker switch on the control panel. The shaker can be programmed to operate in a momentary fashion or automatically. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the shaker and scrub system off switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the shaker and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a number from 0 to 3. Pressing and releasing the shaker switch will increase the displayed value until 3

is reached. The next press will return to 0. If 0 is selected, the shaker will turn on only when the control panel switch is held (momentary). If 1 is selected, the shaker will run for an adjustable period of time (see above to adjust time period). If 2 is selected, the shaker will automatically run for an adjustable period of time when the main broom is turned off. If 3 is selected, the shaker will automatically run for an adjustable period of time when the hopper is lowered all the way down after being in the up position.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Dust Control Mode Control with Hopper Up:

FACTORY DEFAULT: 2 (no change) RANGE: 0 - 2

The dust control on the Captor can be programmed to turn on or off or stay in its current state when the hopper is raised for dumping. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the dust control and the scrub pressure decrease switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the dust control and scrub pressure decrease indicators turn off (approximately

two seconds).

5 Release both switches. 6 The status display will now show a number from 0 to 2. Pressing and releasing the dust control switch will increase the displayed value

until 2 is reached. The next press will return to 0. If 0 is selected, the dust control will turn off when the hopper is raised. If 1 is selected,

the dust control will turn on when the hopper is raised. If 2 is selected, the dust control will remain in the same state that it was in prior to

raising the hopper (no change).

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Control Assembly Revision Display:

To display the revision of the control assembly, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the hopper up switch. 3 While holding the hopper up switch turn the main power key switch to the on position. 4 Continue to hold the hopper up switch until all indicators except the hopper up indicator turn off (approximately two seconds). 5 Release the hopper up switch. 6 The status display will now show a letter representing the revision of the display assembly. 7 To exit this mode, turn the main power key switch to the off position.

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94 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

PROGRAMMABLE CONTROL OPTIONS

Solution Flow in Reverse Enable/Disable:

FACTORY DEFAULT: 0 (solution ow off in reverse) RANGE: 0 - 1

The solution ow is programmed to stop when backing up to prevent excessive cleaning solution from being dispensed. If it is desired to allow solution ow in reverse, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the solution and the scrub system off switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the solution and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a 0 or a 1. Pressing and releasing the solution switch will alternate between the two. If 0 is selected,

solution ow will stop when backing up. If 1 is selected, solution ow will stay on when backing up.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Automatic Engine Speed Control Enable/Disable:

FACTORY DEFAULT: 0 (automatic engine speed control disabled) RANGE: 0 - 1

The Captor can be programmed to automatically speed-up or slow-down the engine speed based on selected functions. If the automatic engine

speed control is enabled, the engine speed will switch to the run speed if any of the major systems are turned on and the foot pedal is moved form the neutral position. The engine speed will return to idle approximately 25 seconds after the foot pedal returns to the neutral position. To

turn the automatic control on or off, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the engine speed and the scrub system off switches. 3 While holding both switches turn the main power key switch to the on position. 4 Continue to hold both switches until all indicators except the engine speed and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a 0 or a 1. Pressing and releasing the engine speed switch will alternate between the two. If 0 is

selected, the automatic engine speed control is disabled (turned off). If 1 is selected, the automatic engine speed control is enabled (turned on).

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Recall Of Stored Error Codes:

Whenever an electrical system fault is detected by the main control unit, one or more error codes are displayed and stored by the control unit. If it is desired, the error code (if any) from the previous operation of the machine can be recalled for troubleshooting purposes. To recall the last

stored error codes perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the solution switch. 3 While holding the solution switch, turn the main power key switch to the on position. 4 Continue to hold the solution switch until all indicators except the solution indicator turn off (approximately two seconds). 5 Release the solution switch. 6 If there were previously no error codes stored, the display will now show “-”. Go to step 10. 7 If error codes were stored, the display will now show the stored code(s). 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

8 To clear the stored codes press and release the solution switch. The display will now show “-“. Go to step 10. 9 If it is desired to save the codes, go to step 10. 10 To exit the error code recall mode, turn the main power key switch to the off position.

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FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 95

PROGRAMMABLE CONTROL OPTIONS

Control System Self-Diagnostic Mode:

If problems with the electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is

1 During this test, the horn will sound briey 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. Make sure that all persons are away from these parts of the machine to prevent injury.

seconds).

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 trouble-shooting section.

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.

Reset of All Programmable Parameters to Factory Default Settings:

To reset all of the above parameters to the factory defaults, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the all three scrub system switches (scrub off, pressure increase, & pressure decrease). 3 While holding all three switches turn the main power key switch to the on position. 4 Continue to hold all three switches until all indicators turn off and the status display shows “d” (approximately two seconds). 5 Release all switches. 6 The programmable parameters are now restored to the default values. 7 It will now be necessary to reprogram the throttle neutral position. Refer to the proper section above. 8 To exit this mode, turn the main power key switch to the off position.

revised 4/04

Page 98

96 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

I/O Tables for current Production Machines w/56305288 Control Box Assembly

2/26/2007

B- = Battery -

B+ = Battery +

Designation Pin ID Wire

ID/Color

Description Signal

Characteristic

Nominal

Value

Reference

To:

Range Comments

Control Box Assembly

Input J1-1 PINK Ignition input DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

Output J1-2 YEL Lights relay (K2) DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

Lights on

Output J1-3 GRN/BRN Back-up alarm DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Moving in reverse

Output J1-4 GRN/VIO Scrub down valve (S15) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing at low or

medium pressure settings

Output J1-5 RED/GRA Hopper raise valve (S13) DC Voltage -14V B+ 13.5-14.5V w/engine running Raising hopper

Output J1-6 BRN/BLK Side broom valve (S10) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and sweeping with side

brooms down

Output J1-7 BLU Vacuum fan valve (S8) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and squeegee down

Output J1-8 ORN/BLU Scrub valve (S8) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing

Output J1-9 WHT/VIO Scrub down valve (S5) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing at medium or

high pressure settings

Output J1-10 BRN Demand valve (S3) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing and

squeegee raising and/or squeegee lowering

Output J1-11 BLU/WHT Demand valve (S1) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrub raising and/or

squeegee raising and/or squeegee lowering

Output J1-12 GRA/VIO Side broom actuator (M4)

common

DC Voltage 14V See

comments

13.5-14.5V w/engine running Measure between J1-23 and J1-12 when

raising side brooms

Measure between J1-35 and J1-12 when

lowering side brooms

Output J1-13 GRA/WHT Neutral relay (K4) DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

When drive pedal is pushed forward or

reverse

Output J1-14 VIO/BRN Horn relay (K1) DC Voltage

+14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

Sounding horn

Output J1-15 YEL/GRN Solution valve (L16) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing

Output J1-16 YEL/RED Hopper lower valve (S14) DC Voltage -14V B+ 13.5-14.5V w/engine running Lowering hopper

Output J1-17 BRN/GRN Dump door close valve DC Voltage -14V B+ 13.5-14.5V w/engine running Closing dump door

Output J1-18 BRN/YEL Dust control valve (S9) DC Voltage -14V B+ 13.5-14.5V w/engine running Dust control on

Output J1-19 BLK/WHT Dump door open valve (S11) DC Voltage -14V B+ 13.5-14.5V w/engine running Opening dump door

Output J1-20 GRN/GRA Main broom valve (S6) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and sweeping

Output J1-21 YEL/BLU Scrub down valve (S4) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and scrubbing at low or high

pressure settings

Output J1-22 ORN/RED Squeegee Valve (S2) DC Voltage -14V B+ 13.5-14.5V w/engine running Moving forward and squeegee down

Output J1-23 GRN/YEL Side broom actuator (M4)

raise

DC Voltage -14V B+ 13.5-14.5V w/engine running Measure between J1-23 and J1-12 when

raising side brooms

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FORM NO. 56043093 / Captor™ 4300, 4800, 5400 - 97

Designation Pin ID Wire

ID/Color

Description Signal

Characteristic

Nominal

Value

Reference

To:

Range Comments

Control Box Assembly

Output J1-24 GRN Shaker relay (K3) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Shaker on

J1-25 Empty

Output J1-26 GRA/BLU Throttle output DC Voltage +14V B- (Ground) 13.5-14.5V w/engine running On when high engine speed is selected

J1-27 Empty

J1-28 Empty

Input J1-29 BLK B- DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J1-30 BLK B- DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J1-31 BLK B- DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J1-32 BLK B- DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J1-33 BLK B- DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J1-34 VIO Accessory power DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

Output J1-35 BLU/BRN Side broom actuator (M4)

lower

DC Voltage +14V B- (Ground) 13.5-14.5V w/engine running Measure between J1-35 and J1-12 when

lowering side brooms

J2-1 Empty

Output J2-2 YEL/GRA Drive pedal sensor (R2) low

side

DC Voltage -5V J2-17

Input J2-3 GRA Low LPG pressure switch

(S3)

DC Voltage -12V B+ 12-12.6V w/o engine running On when LPG tank is empty or fuel line is

disconnected

Input J2-4 YEL/VIO Hopper fire switch (S7) DC Voltage -14V B+ 13.5-14.5V w/engine running On when internal temperature of hopper is

too high

Input J2-5 YEL/WHT Hydraulic filter switch (S6) DC Voltage -14V B+ 13.5-14.5V w/engine running On when filter is too dirty or plugged

Input J2-6 WHT/GRA Dust control filter switch (S5) DC Voltage -14V B+

13.5-14.5V w/engine running On when hopper filter is too dirty or plugged

Input J2-7 VIO/YEL Solution empty switch (S9) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

On when solution tank is empty

Input J2-8 GRA/YEL Recovery full switch (S8) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Off when recovery tank is full or

disconnected

J2-9 Empty

Input J2-10 ORN/GRA Drive pedal sensor (R2)

wiper

DC Voltage 0 to +5V J2-2 0-5V

Input/Output J2-11 BRN/BLU To switch/display panel (A4) Serial clock signal 0 to +5V B- (Ground) 0-5V

Input/Output J2-12 GRN/BLU To switch/display panel (A4) Serial data signal 0 to +5V B- (Ground) 0-5V

Input J2-13 BLU/BLK Check engine light DC Voltage -12V B+ 12-12.6V w/o engine running Key switch on and engine not running.

Input J2-14 RED/BLK Hopper interlock switch

(S12)

DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

On when hopper is down

Input J2-15 ORN/BLK Main broom switch (S16) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Off when main broom is down

Input J2-16 BLK/YEL Wand switch (S2) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

On with wand switch

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98 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400

Designation Pin ID Wire

ID/Color

Description Signal

Characteristic

Nominal

Value

Reference

To:

Range Comments

Control Box Assembly

Output J2-17 BRN/WHT Drive pedal sensor (R2) high

side

DC Voltage +5V J2-2

J2-18 ORN/BRN Not used

Input J2-19 RED/YEL Light sensor DC Voltage Between

0 and +5V

B- (Ground) 0-5V

Output J2-20 BLK To switch/display panel (A4) DC Voltage -14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Output J2-21 WHT/BRN To switch/display panel (A4) DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J2-22 PINK Ignition input DC Voltage +14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

J2-23 Empty

Switch/Display Panel Assembly

J3-1 Empty

Output J3-2 RED/YEL Light sensor DC Voltage Between

0 and +5V

B- (Ground) 0-5V

J3-3 ORN/BRN Not used

J3-4 Empty

Input/Output J3-5 BRN/BLU To control box assembly Serial clock signal 0 to +5V B- (Ground) 0-5V

Input/Output J3-6 GRN/BLU To control box assembly Serial data signal 0 to +5V B- (Ground) 0-5V

Input J3-7 WHT/BRN To control box assembly

(A1)

DC Voltage +14V B+ 12-12.6V w/o engine running

13.5-14.5V w/engine running

Input J3-8 BLK To control box assembly

(A1)

DC Voltage -14V B- (Ground) 12-12.6V w/o engine running

13.5-14.5V w/engine running

revised 7/08

Nilfisk-Advance Captor 5400, Captor 4800, Captor 4300 Quick Start Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual