Nilfisk-Advance CR 1200 Quick start guide

Nilfisk-Advance
Brand
Nilfisk-Advance
Model
CR 1200
Category
Scrubber
Type
Quick start guide
10/03 Form Number 56043093
QUICK STQUICK ST
QUICK STQUICK ST
QUICK ST
ART TROUBLESHOOTING MANUALART TROUBLESHOOTING MANUAL
ART TROUBLESHOOTING MANUALART TROUBLESHOOTING MANUAL
ART TROUBLESHOOTING MANUAL
Advance MODELS 56304000(4300 P), 56304001(4300 G), 56304003(4800 P),
56304004(4800 G), 56304006(5400 P), 56304007(5400 G)
Nilfisk MODELS 56304009(1100 P), 56304010(1100 G), 56304012(1200 P),
56304013(1200 G), 56304015(1400 P), 56304016(1400 G)
CaptorCaptor
CaptorCaptor
Captor™™
™™
™ 4300, 4800, 5400 4300, 4800, 5400
4300, 4800, 5400 4300, 4800, 5400
4300, 4800, 5400
CR 1100, 1200, 1400CR 1100, 1200, 1400
CR 1100, 1200, 1400CR 1100, 1200, 1400
CR 1100, 1200, 1400
76 76
76 76
76 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
GENERAL INFORMATION ................................................................................................................................................. 1-2
SAFETY INSTRUCTIONS ...................................................................................................................................................... 3
SPECIFICATIONS ................................................................................................................................................................ 4-5
MAINTENANCE .................................................................................................................................................................. 6-7
PM CHECKLIST ................................................................................................................................................................... 8-9
KNOW YOUR MACHINE ................................................................................................................................................ 10-19
CONTROL ERROR CODES ............................................................................................................................................ 13-15
GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ............................................................. 16
OPERATOR’S COMPARTMENT ....................................................................................................................................... 17
GENERAL TROUBLESHOOTING FLOW CHARTS ..................................................................................................... 18-23
WHEEL DRIVE SYSTEM ...................................................................................................................................................... 24
TROUBLESHOOTING CHECK LIST .................................................................................................................................. 24
STEERING SYSTEM ............................................................................................................................................................ 25
STEERING SYSTEM TROUBLESHOOTING OVERVIEW ............................................................................................... 25
TROUBLESHOOTING GUIDE ............................................................................................................................................ 25
SWEEPING SYSTEM ...................................................................................................................................................... 26-33
MAIN BROOM ............................................................................................................................................................... 26-27
SIDE BROOMS .............................................................................................................................................................. 28-29
SIDE BROOM LIFT ACTUATOR ....................................................................................................................................... 30
DUST CONTROL IMPELLER ........................................................................................................................................ 31-32
SHAKER MOTOR ................................................................................................................................................................ 33
HOPPER SYSTEM ........................................................................................................................................................... 34-40
LIFT CYLINDER .............................................................................................................................................................. 34-37
DUMP DOOR CYLINDER .............................................................................................................................................. 38-40
SCRUB SYSTEM ............................................................................................................................................................. 41-50
DECK LIFT ACTUATOR ................................................................................................................................................. 41-48
SCRUB MOTORS .......................................................................................................................................................... 49-50
SOLUTION SYSTEM ............................................................................................................................................................ 51
SOLUTION SOLENOID VALVE ......................................................................................................................................... 51
RECOVERY SYSTEM ....................................................................................................................................................... 52-56
VACUUM MOTOR ......................................................................................................................................................... 52-54
SQUEEGEE LIFT ACTUATOR ....................................................................................................................................... 55-56
ENGINE SYSTEM ............................................................................................................................................................ 57-60
ENGINE SPECIFICATIONS ............................................................................................................................................... 57
ENGINE MAINTENANCE .................................................................................................................................................. 57
CHECK ENGINGE LIGHT TROUBLESHOOTING ............................................................................................................. 57
SYSTEM FAULT CODES ............................................................................................................................................... 58-59
HYDRAULIC SYSTEM ..................................................................................................................................................... 61-68
HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................. 61
GENERAL HYDRAULIC SPECIFICATIONS TABLE ........................................................................................................ 62
HYDRUALIC DIAGRAM ..................................................................................................................................................... 66
HYDRUALIC SCHEMATIC ................................................................................................................................................. 67
HYDRUALIC COMPONENT LOCATION .......................................................................................................................... 68
ELECTRICAL SYSTEM .................................................................................................................................................... 69-73
ELECTRICAL COMPONENT LOCATION ......................................................................................................................... 69
WIRING DIAGRAM ............................................................................................................................................................ 70
WIRING SCHEMATIC........................................................................................................................................................ 71
ENGINE HARNESS ............................................................................................................................................................ 72
ENGINE WIRING HARNESS DETAIL .............................................................................................................................. 73
Note: Note:
Note: Note:
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
TT
TT
TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTS
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 11
11
1
KK
INTRODUCTIONINTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
This manual will help you get the most from your Nilfisk-Advance rider Scrubber-Sweeper. Read it thoroughly before servicing the
machine.
Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (
Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (
Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 9-10 i.e. (BB
BB
B).).
).).
).
This product is intended for commercial use only.
PP
PP
PARTS AND SERVICEARTS AND SERVICE
ARTS AND SERVICEARTS AND SERVICE
ARTS AND SERVICE
Repairs, when required, should be performed by your Authorized Nilfisk-Advance Service Center, who employs factory trained
service personnel, and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.
Call the NILFISK-ADVANCE DEALER named below for repair parts or service. Please specify the Model and Serial Number when
discussing your machine.
(Dealer, affix service sticker here.)
NAME PLANAME PLA
NAME PLANAME PLA
NAME PLATETE
TETE
TE
The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed
when ordering repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine
for future reference.
MODEL NUMBER
SERIAL NUMBER
HOPPER SAFETY SUPPORTHOPPER SAFETY SUPPORT
HOPPER SAFETY SUPPORTHOPPER SAFETY SUPPORT
HOPPER SAFETY SUPPORT
WW
WW
WARNING!ARNING!
ARNING!ARNING!
ARNING!
Make sure the Hopper Safety Support (KK)(KK)
(KK)(KK)
(KK) is
in place whenever attempting to do any
maintenance work under or near the raised
hopper. The Hopper Safety Support (KK)(KK)
(KK)(KK)
(KK)
holds the hopper in the raised position to
allow work to be performed under the hop-
per. NEVER rely on the machine’s hydraulic
components to safely support the hopper.
JACKING THE MACHINEJACKING THE MACHINE
JACKING THE MACHINEJACKING THE MACHINE
JACKING THE MACHINE
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
Never work under a machine without safety stands or blocks to support the machine.
• When jacking the machine, do so at designated locations (Do Not jack on the hopper) – see jacking locations ((
((
(4444
4444
44))
))
).
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMATIONTION
TIONTION
TION
2 2
2 2
2 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
TRANSPORTING THE MACHINETRANSPORTING THE MACHINE
TRANSPORTING THE MACHINETRANSPORTING THE MACHINE
TRANSPORTING THE MACHINE
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that . . .
••
••
• All access doors are latched securely.
••
••
• The machine is tied down securely - see tie-down locations ((
((
(66
66
6))
))
).
••
••
• The machine parking brake is set.
TOWING OR PUSHING A DISABLED MACHINETOWING OR PUSHING A DISABLED MACHINE
TOWING OR PUSHING A DISABLED MACHINETOWING OR PUSHING A DISABLED MACHINE
TOWING OR PUSHING A DISABLED MACHINE
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
The machine’s drive propelling pump is manufactured with a selectable tow valve. This valve prevents damage to the hydraulic
system when the machine is being towed/pushed short distances without use of the engine.
To access the valve, open the Engine Compartment Door ((
((
(2222
2222
22))
))
) and lift off the Right Engine Compartment Access Panel ((
((
(3737
3737
37))
))
). Locate
the valve as shown on the underside of the hydrostatic pump by reaching under the radiator. Turn the valve 90 degrees, this
disengages the hydrostatic lock between the motor and pump.
The hydrostatic pump can be damaged if the machine is towed with the valve in the normal working position (A)(A)
(A)(A)
(A). Reference the
illustration below for the normal working setting (A)(A)
(A)(A)
(A) and the free wheeling towing setting (B)(B)
(B)(B)
(B). Note: If the tow valve is left in free
wheeling (B)(B)
(B)(B)
(B) position the hydrostatic pump can’t drive the machine FWD or REV. No damage will result, just re-set valve to the normal
working setting (A)(A)
(A)(A)
(A). Tow or push machine no faster than a normal walking pace (2-3 miles per hour) and for short distances only.
If the machine is to be moved long distances the drive wheel needs to be raised off the floor and placed on a suitable transport dolly.
OTHER MANUALS AOTHER MANUALS A
OTHER MANUALS AOTHER MANUALS A
OTHER MANUALS AVV
VV
VAILABLEAILABLE
AILABLEAILABLE
AILABLE
The following manuals are available from the Nilfisk-Advance Literature Service Department, for your Rider Scrubber/Sweeper:
••
••
• Parts List - Form Numbers 56042440 (all systems except hydraulic)
56042445 (hydraulic system)
••
••
• Operation Manual - Form Numbers 56041546 (Danish, Norwegian, Swedish, Finnish)
56041547 (English, German, French, Netherlands)
56041548 (Spanish, Portuguese, Italian, Greek)
• Mechanical Repair Service Manual 56043094
BOTTOM VIEW OF HYDROSTBOTTOM VIEW OF HYDROST
BOTTOM VIEW OF HYDROSTBOTTOM VIEW OF HYDROST
BOTTOM VIEW OF HYDROSTAA
AA
ATIC PUMPTIC PUMP
TIC PUMPTIC PUMP
TIC PUMP
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMATIONTION
TIONTION
TION
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 33
33
3
CAUTIONS AND WARNINGSCAUTIONS AND WARNINGS
CAUTIONS AND WARNINGSCAUTIONS AND WARNINGS
CAUTIONS AND WARNINGS
SYMBOLSSYMBOLS
SYMBOLSSYMBOLS
SYMBOLS
Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this information
carefully and take the necessary steps to protect personnel and property.
DANGER!DANGER!
DANGER!DANGER!
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!WARNING!
WARNING!WARNING!
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
GENERAL SAFETY INSTRUCTIONSGENERAL SAFETY INSTRUCTIONS
GENERAL SAFETY INSTRUCTIONSGENERAL SAFETY INSTRUCTIONS
GENERAL SAFETY INSTRUCTIONS
Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
WARNING!WARNING!
WARNING!WARNING!
WARNING!
••
••
• This machine shall be used only by properly trained and authorized persons.
••
••
• While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills.
••
••
• Keep sparks, flame and smoking materials away from the battery and fuel system.
••
••
• Remove all jewelry when working near electrical components.
••
••
• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
••
••
• Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.
••
••
• Never work under a machine without safety blocks or stands to support the machine.
••
••
• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where
flammable liquids exist.
••
••
• Do not clean this machine with a pressure washer.
••
••
• This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide
adequate ventilation when operating this machine.
• Keep the LP tank Service Valve closed when the tank is not in use.
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
••
••
• This machine is not approved for use on public paths or roads.
••
••
• This machine is not suitable for picking up hazardous dust.
••
••
• When operating this machine, ensure that third parties, particularly children, are not endangered.
••
••
• Before performing any service function carefully read all instructions pertaining to that function.
••
••
• Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the
parking brake.
••
••
• Turn the key switch off (O) before changing the brooms and brushes, and before opening any access panels.
••
••
• Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or
recovery tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer
fluid.
••
••
• The battery must be removed from the machine before the machine is scrapped. The disposal of the battery should
be safely done in accordance with your local environmental regulations.
SASA
SASA
SAVE THESE INSTRUCTIONSVE THESE INSTRUCTIONS
VE THESE INSTRUCTIONSVE THESE INSTRUCTIONS
VE THESE INSTRUCTIONS
4 4
4 4
4 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
SPECIFICASPECIFICA
SPECIFICASPECIFICA
SPECIFICATIONSTIONS
TIONSTIONS
TIONS
General Specifications common to General Specifications common to
General Specifications common to General Specifications common to
General Specifications common to All ModelsAll Models
All ModelsAll Models
All Models English (Metric)English (Metric)
English (Metric)English (Metric)
English (Metric)
DimensionsDimensions
DimensionsDimensions
Dimensions Gas & PropaneGas & Propane
Gas & PropaneGas & Propane
Gas & Propane
Length 105 inches (267cm)
Height 58 inches (147cm)
Height w/overhead guard 79 inches (200cm)
Ground clearance 3 inches (7.6cm)
Minimum ceiling height dumping clearance 92 inches (233.6cm)
WeightsWeights
WeightsWeights
Weights
Net weight* 4040 lbs. (1832kg)
Gross weight** 4720 lbs. (2141kg)
Speed and GradeabilitySpeed and Gradeability
Speed and GradeabilitySpeed and Gradeability
Speed and Gradeability
Maximum travel speed 6 mph (9.6km/h)
Maximum reverse speed 4 mph (6.4km/h)
Maximum grade angle scrubbing 6 deg.
Maximum grade angle non-scrubbing 8 deg.
Sound LevelSound Level
Sound LevelSound Level
Sound Level
At operators ear 85.1 dBA
Sweep SystemSweep System
Sweep SystemSweep System
Sweep System
Sweeping path w/out side broom(s) 40 inches (102cm)
Main broom length 40 inches (102cm)
Main broom diameter 14 inches (35.5cm)
Side broom diameter 20 inches (50.8cm)
Side broom bristle length 7 inches (17.7cm)
Hopper SystemHopper System
Hopper SystemHopper System
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 SystemDust Control System
Dust Control SystemDust Control System
Dust Control System
Filter type: Pleated paper panel
Filter dimension 3-3/16" x 20" x 27" (8cm x 50.8cm x 68.5cm)
Filter media area 78 ft2 (7.25m2)
Steering SystemSteering System
Steering SystemSteering System
Steering System
Type: Power steering unit with rack and pinion
Turns lock to lock right: 4-3/8
Turns lock to lock left: 3-3/8
Minimum aisle turn width 118 in. (300cm) left and right
Hydraulic SystemHydraulic System
Hydraulic SystemHydraulic System
Hydraulic System
Oil type: SAE 10W-30
System fill capacity 11 gal. (41.6
l
)
Engine SystemEngine System
Engine SystemEngine System
Engine System
Engine coolant fill capacity 10-11 qts. (9.5-10.4
l
)
Recovery SystemRecovery System
Recovery SystemRecovery System
Recovery System
Vacuum water lift (sealed) minimum 22 inches
Vacuum water lift (open hole adapter 1") minimum 20 inches
*Net Weight: *Net Weight:
*Net Weight: *Net Weight:
*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and full tank
of fuel.
**Gross Weight:**Gross Weight:
**Gross Weight:**Gross Weight:
**Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and
full tank of fuel.
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 55
55
5
SPECIFICASPECIFICA
SPECIFICASPECIFICA
SPECIFICATIONSTIONS
TIONSTIONS
TIONS
Height
Length
Width
FRONT VIEW
SIDE VIEW
Specifications common to Specifications common to
Specifications common to Specifications common to
Specifications common to Deck SizeDeck Size
Deck SizeDeck Size
Deck Size English (Metric)English (Metric)
English (Metric)English (Metric)
English (Metric)
Model designation: (43") Model designation: (43")
Model designation: (43") Model designation: (43")
Model designation: (43") = Captor 4300 / CR 1100 (48") (48")
(48") (48")
(48") = Captor 4800 / CR 1200 (54") (54")
(54") (54")
(54") = Captor 5400 / CR 1400
43"43"
43"43"
43" 48"48"
48"48"
48" 54"54"
54"54"
54"
Width w/out squeegee & deck 50 inches (127cm) 50 inches (127cm) NA
Solution Tank Capacity NA 80 gal. (303
l
) 80 gal. (303
l
)
Recovery Tank Capacity NA 80 gal. (303
l
) 80 gal. (303
l
)
Cleaning Rate per hour (theory) NA 84,500 ft2 (7,850m2)NA
Sweeping path w/side brooms (2) X 62 in. (158cm) 62 in. (158cm)
Sweeping path w/side broom (1) NA X X
Sweeping rate per hour NA 163,700 ft2 (15,210m2) 163,700 ft2 (15,210m2)
Scrub Brush quantity 3 3 4
Scrub Brush diameter 15 inches (38cm) 17 inches (43cm) 14 inches (36cm)
Squeegee Tool Width NA 57 in. (145cm) NA
NANA
NANA
NA = Not Available at time of printing.
6 6
6 6
6 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
MAINTENANCE SCHEDULEMAINTENANCE SCHEDULE
MAINTENANCE SCHEDULEMAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require
service more often.
MAINTENANCE ITEMMAINTENANCE ITEM
MAINTENANCE ITEMMAINTENANCE ITEM
MAINTENANCE ITEM PERFORM DAILYPERFORM DAILY
PERFORM DAILYPERFORM DAILY
PERFORM DAILY
Perform the “After Use” maintenance steps X
Check parking brake X
Check engine oil X
*Clean main and side brooms X
Check filter indicator and lights (hyd & air) X
Check engine coolant level X
Check hydraulic oil level X
MAINTENANCE ITEMMAINTENANCE ITEM
MAINTENANCE ITEMMAINTENANCE ITEM
MAINTENANCE ITEM 15 hrs.15 hrs.
15 hrs.15 hrs.
15 hrs. 30 hrs.30 hrs.
30 hrs.30 hrs.
30 hrs. 150 hrs.150 hrs.
150 hrs.150 hrs.
150 hrs. 300 hrs.300 hrs.
300 hrs.300 hrs.
300 hrs. 500 hrs.500 hrs.
500 hrs.500 hrs.
500 hrs. 1000 hrs.1000 hrs.
1000 hrs.1000 hrs.
1000 hrs.
*Rotate main broom X
Clean solution filter X
*Inspect/adjust brooms X
*Clean hopper filter X X X
*Inspect broom housing skirts X
*Inspect hopper seals X
Clean radiator and oil cooler X
Perform engine maintenance X
*Inspect and grease steering rack X
Change the hydraulic “charge” oil filter X
Change reservoir hydraulic oil and filter X
Flush the radiator X
Engine fuel filter(s) gas or propane X
*See the Mechanical Repair Service Manual and Operator Manual for detailed maintenance information of systems listed.
• Sweeping
• Hopper
• Steering
• Dust control
• Squeegee
WARNING!WARNING!
WARNING!WARNING!
WARNING!
Turn the key switch off, set the parking brake and disconnect the battery before servicing the machine.
AFTER USEAFTER USE
AFTER USEAFTER USE
AFTER USE
11
11
1 Raise the squeegee, the scrub brushes, and the brooms.
22
22
2 Shake the dust control filter and empty the hopper.
33
33
3 Drain and flush the recovery tank.
44
44
4 Flush the vacuum hose and squeegee by opening the recovery tank lid and running water down the pickup tube on the right side
of the tank. SERVICE NOTE:SERVICE NOTE:
SERVICE NOTE:SERVICE NOTE:
SERVICE NOTE: Tip the recovery tank out and check the squeegee hose elbow below the tank to make sure it has
flushed out completely.
55
55
5 Remove and clean the squeegee tool (adjust as needed*).
66
66
6 Remove and clean the scrub brushes. Rotate the scrub brushes.
77
77
7 Wipe the machine with a damp cloth.
88
88
8 Perform all required maintenance before storage.
99
99
9 Move the machine to a clean, dry storage area.
1010
1010
10 Store the machine with the brooms, the squeegee and the scrub brushes in the UP position, and the tank covers open so that
the tanks can air out.
LUBRICALUBRICA
LUBRICALUBRICA
LUBRICATING THE MACHINETING THE MACHINE
TING THE MACHINETING THE MACHINE
TING THE MACHINE
Steering RackSteering Rack
Steering RackSteering Rack
Steering Rack
Once every 150 hours pump a small amount of grease onto the steering rack and pinion components.
Also every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door
hinges etc. Broom, squeegee and hopper pivots use composite bearings lubrication is not required.
MAINTENANCEMAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 77
77
7
ENGINE COOLANTENGINE COOLANT
ENGINE COOLANTENGINE COOLANT
ENGINE COOLANT
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
Do not remove the radiator cap when the engine is hot.
To check the engine coolant level, lift the Engine Compartment Door ((
((
(2222
2222
22))
))
) and observe the coolant level on the Coolant Recovery
Tank ((
((
(2323
2323
23))
))
). If the level is low add a mixture of half water and automotive type anti-freeze. Clean the radiator and oil cooler exteriors
by washing with low-pressure water or using compressed air every 30 hours. Service Note: The oil cooler tips out for easy cleaning.
ENGINE OILENGINE OIL
ENGINE OILENGINE OIL
ENGINE OIL
Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the
first 35 hours of operation and every 150 hours after that. Use 3.5 quarts (3.3 liters) with filter, of any SF or SG rated oil meeting API
specifications and suited to seasonal temperatures. Refer to the Engine System for additional information. Replace the oil filter with
every oil change.
TEMPERATURE RANGETEMPERATURE RANGE
TEMPERATURE RANGETEMPERATURE RANGE
TEMPERATURE RANGE OIL WEIGHTOIL WEIGHT
OIL WEIGHTOIL WEIGHT
OIL WEIGHT
Above 60° F (15° C) SAE 10W-30
Below 60° F (15° C) SAE 5W-30
ENGINE AIR FILENGINE AIR FIL
ENGINE AIR FILENGINE AIR FIL
ENGINE AIR FILTERTER
TERTER
TER
The engine Air Filter ((
((
(88
88
8))
))
) is located in the engine compartment. Check the air mechanical vacuum filter Service Indicator ((
((
(4646
4646
46))
))
) before
each use of the machine. Do not service the air filter unless the indicator is lit (red).
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
When servicing the engine air filter elements, use extreme caution to prevent dust and dirt from entering the engine.
The engine air filter contains a primary (outer) and a safety (inner) filter element. The primary element may be cleaned twice before
being replaced. Replace the safety element every third time that the primary element is serviced. Never try to clean the safety
element. To clean the primary filter element, remove the cover from the dust cup end of the canister and pull out the primary element.
Clean the element with compressed air (maximum pressure 100 PSI) or wash it with water (maximum pressure 40 PSI). Do not put
the element back into the canister until it is completely dry.
ENGINE MAINTENANCE (150 HOURS)ENGINE MAINTENANCE (150 HOURS)
ENGINE MAINTENANCE (150 HOURS)ENGINE MAINTENANCE (150 HOURS)
ENGINE MAINTENANCE (150 HOURS)
At 150 hour intervals it is recommended that the following service be performed: Change oil and filter, clean and inspect spark plugs,
check all engine belts condition and adjustment, check battery charge and level, check cooling system hoses and clamps and check
general condition and performance of engine.
Note: Note:
Note: Note:
Note: Reference the separately supplied PSI GM Power Train Products Operation and Maintenance manual for more detailed
service data. PSI manual number is 3610000.
HYDRAULIC OILHYDRAULIC OIL
HYDRAULIC OILHYDRAULIC OIL
HYDRAULIC OIL
WW
WW
WARNING!ARNING!
ARNING!ARNING!
ARNING!
MAINTENANCEMAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye
protection when working with or near hydraulic system.
Check the Hydraulic Oil Level.Check the Hydraulic Oil Level.
Check the Hydraulic Oil Level.Check the Hydraulic Oil Level.
Check the Hydraulic Oil Level. Remove the Right Engine Access Panel ((
((
(3737
3737
37))
))
) and look at the
gauge on the side of the reservoir. If the oil level is below the minimum level, add 10W30 motor
oil until the gauge is 3/4 full. Do not fill above maximum. Change the oil if major contamination
from a mechanical failure occurs. SERVICE NOTE:SERVICE NOTE:
SERVICE NOTE:SERVICE NOTE:
SERVICE NOTE: Remove the small access panel ((
((
(4949
4949
49))
))
)
directly above the reservoir to add oil. This panel is held on by (2) wing nuts on the underside
of the panel. Only filtered oil should be added.
IMPORTIMPORT
IMPORTIMPORT
IMPORTANT!ANT!
ANT!ANT!
ANT!
This machine is equipped with an indicator light which lights if the “In Tank” oil filter requires changing. Remove filter
element from the filter cup and replace with new filter. Hydraulic filter is found on top of the Hydraulic Reservoir ((
((
(3636
3636
36))
))
).
Change the Hydraulic “Charge” Oil Filter ((
((
(3535
3535
35))
))
).
Note: Oil should be warm, cold oil is thicker and may cause the light to come on intermittently until it warms up.
FIGURE 1FIGURE 1
FIGURE 1FIGURE 1
FIGURE 1
8 8
8 8
8 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
Copyright 2003 Nilfisk-Advance. Page 1 of 2 10/14/2003
Advance Captor 4300/4800/5400 G/P/D
Nilfisk CR 1100/1200/1400 G/P/D
PM Checklist
Defect Codes
Customer
A needs adjustment
B binding
Address
C dirty or contaminated
D damaged, bent or torn
City
St Zip L leaks
M missing
Model
Serial Hours W worn out
Ref
OPERATIONAL INSPECTION ITEMS
OK
Defect Codes
(circle)
Does
Not
Work
1 Check Neutral Safety Switch Operation (To test depress drive pedal and start the
engine, it should not start.)
A B C
2 Engine Starting with pedal in neutral (if it will not start check neutral safety switch) A
3 Engine Idle 1200rpms A rough
4 Engine High Speed (high switch setting) 2400 RPM A low power
5 Drive Pedal Linkage (check for FWD/REV drive and any neutral creep) A B
6 Drive System Performance Noisy sluggish
7 Brakes (check both service & parking) A B W
8 Steering excessive play
9 Hopper Up/Down (also check operation of the safety hopper support) A B
10 Hopper Dump Door Open/Close A B
11 Main Broom Raise /Lower A B
12 Side Broom Raise /Lower A B C
13 Main Broom On/Off (will drift) A B C
14 Side Broom On/Off <----->
15 Scrub System (Raise/Lower and auto scrubbing functions) <----->
16 Scrub Brush (pressure settings 1,2 &3) A B
17 Squeegee System (Raise/Lower and Auto Lift in Reverse) A B
18 Vacuum Performance (Sealed water lift 22" and 1- inch open hole adapter 20 inches) C L W
19 Solution Control (On/Off and Flow Volume Min/Max) C L
20 Perform the machine self-diagnostic test. (see manual PN 56043093) <----->
21 Headlights, Gauges and (optional) accessories Rotating Beacon, Backup Alarm <----->
22 Dust Control Filter Shaker & Impeller <----->
23 Tilt Steering Mechanism and Seat Adjustment lever A B
Ref
VISUAL INSPECTION ITEMS
Comments
OK
Defect Codes
(circle)
Does
Not
Work
24 Side Broom Height (min bristle wear 3 inches) A B D W
25 Side Broom Motor B L
26 Hopper Cover Gasket D W
27 Hopper Dust Filter & Gasket D W
28 Impeller Motor (remove cover to access motor, fan & valve) C L W
29 Hopper Dump Door Cylinder A B L
30 Hopper Skirting & Seals (raise hopper to inspect) D M W
31 Hopper Dump Door & Seal A B D W
32 Brake Cable, Brake Shoes & Drum Wear A B W
33 Hopper Lift Cylinder & Magnetic Switch A B L
34 Main Broom Pattern Adjustment (min bristle wear 2-1/2"
6.4cm length) & Magnetic on/off broom switch
2" (5 cm) wide pattern A B D W
35 Main Broom Motor (open left side access door to inspect) B L
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 99
99
9
Copyright 2003 Nilfisk-Advance.
Page 2 of 2
10/14/2003
Ref
VISUAL INSPECTION ITEMS (continued)
Comments
OK
Defect Codes
(circle)
Does
Not
Work
36 Broom Housing & Door Skirts D M W
37 Battery Clean & Water C W
38 Engine Air Cleaner Element (inner & outer) Check SVR Indicator C W
39 Circuit Breaker/Relay panel (inspect electrical connections) C D
40 Hydrostatic Dump Valve (Tow Valve) B
41 Propulsion drive & Accessory Pumps L
42 Hydraulic System Hoses & fittings L
43 Propulsion Pump Hydro Back Cable & Clevis Connections B M W
44 Propulsion Pump Hydraulic Filters Change with reservoir
filter
L
45 Engine, Oil Level, Hoses & Belts Add or Change L W
46 Engine Coolant Level Fill at reservoir L Add Coolant
47 Radiator & Oil Cooler Core Blockage L Needs Cleaning
48 Hydraulic Oil Reservoir Level (10W-30 engine oil only) Middle of sight glass L Add Oil
49 Steer Spindle & Drive Wheel motor (remove recovery tank) Grease pinion & rack D L
50 Rear Tire (check lug nut torque 100 FT LB, 135Nm) L M W
51 Gasoline/Diesel Fuel Tank , Filter & Lines C L
52 LP Tank, Hoses & Fittings L
53 LP Fuel Filter SVR Life 1500 Hrs L Replace
54 LP Fuel Regulator, Lock Off Valve & Hoses L
55 Diesel Glow Plug Indicator Light Hard Starting Replace
56 Diesel Fuel Filter Yearly L Replace
57 Scrub Brushes, check for wear and rotate D M W
58 Scrub Deck Skirts D M W
59 Solution Solenoid Valve D L W
60 Solution Flow Control Valve and Linkage A B D W
61 Solution Tank, Delivery Hoses & Filter Clean filter screen C L
62 Vacuum Motor Gasket & Metal Elbow Gasket C D L
63 Vacuum Stand Pipe Screen Clean Screen C D M
64 Recovery Tank Cover Gasket L M W
65 Recovery Tank Drain Hose & Cap C D L
66 Squeegee Pick-Up Hose & Metal Elbow Back flush C D L
67 Squeegee Tool & Blades Clean & Rotate A D W
68 Squeegee Casters (lubricate) A D W
69 Squeegee Hydraulic Lift Cylinder B D L
70 Rear Drive Wheel Motor L
71 Front & Rear Tires tread wear W
NOTE: For additional service information see service manual form number 56043093 and
operators manual form number 56041547.
Defect Codes A needs adjustment C dirty or contaminated M missing
B binding D damaged, bent or torn W worn out
L leaks
WORK COMPLETED BY: ACKNOWLEDGED BY:
Service Technician Signature Date Customer Signature Date
10 10
10 10
10 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
1
2
3
4
5
6
7
98
10
6
13
14
15
16
17
18
19
20
21
12
22
23
24
44
46
47
45
48
49
11
11
1Operator’s SeatOperator’s Seat
Operator’s SeatOperator’s Seat
Operator’s Seat
22
22
2Strobe Light (optional)Strobe Light (optional)
Strobe Light (optional)Strobe Light (optional)
Strobe Light (optional)
33
33
3Solution Tank FillSolution Tank Fill
Solution Tank FillSolution Tank Fill
Solution Tank Fill
44
44
4Gasoline Tank CapGasoline Tank Cap
Gasoline Tank CapGasoline Tank Cap
Gasoline Tank Cap
55
55
5Fuel TankFuel Tank
Fuel TankFuel Tank
Fuel Tank
66
66
6Tie Down LocationsTie Down Locations
Tie Down LocationsTie Down Locations
Tie Down Locations
77
77
7Recovery Tank Drain HoseRecovery Tank Drain Hose
Recovery Tank Drain HoseRecovery Tank Drain Hose
Recovery Tank Drain Hose
88
88
8Engine Air FilterEngine Air Filter
Engine Air FilterEngine Air Filter
Engine Air Filter
99
99
9Left Engine Compartment Access PanelLeft Engine Compartment Access Panel
Left Engine Compartment Access PanelLeft Engine Compartment Access Panel
Left Engine Compartment Access Panel
1010
1010
10 Main Broom Left Access DoorMain Broom Left Access Door
Main Broom Left Access DoorMain Broom Left Access Door
Main Broom Left Access Door
1111
1111
11 BatteryBattery
BatteryBattery
Battery
1212
1212
12 Hopper Lid Prop RodHopper Lid Prop Rod
Hopper Lid Prop RodHopper Lid Prop Rod
Hopper Lid Prop Rod
1313
1313
13 Front WheelFront Wheel
Front WheelFront Wheel
Front Wheel
1414
1414
14 Left Side BroomLeft Side Broom
Left Side BroomLeft Side Broom
Left Side Broom
1515
1515
15 Hopper Lid LatchHopper Lid Latch
Hopper Lid LatchHopper Lid Latch
Hopper Lid Latch
1616
1616
16 HeadlightsHeadlights
HeadlightsHeadlights
Headlights
1717
1717
17 Right Side BroomRight Side Broom
Right Side BroomRight Side Broom
Right Side Broom
1818
1818
18 Hopper CoverHopper Cover
Hopper CoverHopper Cover
Hopper Cover
1919
1919
19 Dust Control FilterDust Control Filter
Dust Control FilterDust Control Filter
Dust Control Filter
2020
2020
20 Dust Control Shaker AssemblyDust Control Shaker Assembly
Dust Control Shaker AssemblyDust Control Shaker Assembly
Dust Control Shaker Assembly
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINE
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 1111
1111
11
26 25
27
28
29
30
31 32
33 34 35
36
6
37
38
39
40
41
42
6
43
44
11
50
44
2121
2121
21 Shaker Assembly LatchShaker Assembly Latch
Shaker Assembly LatchShaker Assembly Latch
Shaker Assembly Latch
2222
2222
22 Engine Compartment DoorEngine Compartment Door
Engine Compartment DoorEngine Compartment Door
Engine Compartment Door
2323
2323
23 Coolant Recovery TankCoolant Recovery Tank
Coolant Recovery TankCoolant Recovery Tank
Coolant Recovery Tank
2424
2424
24 Steering WheelSteering Wheel
Steering WheelSteering Wheel
Steering Wheel
2525
2525
25 Squeegee HandleSqueegee Handle
Squeegee HandleSqueegee Handle
Squeegee Handle
2626
2626
26 Squeegee Tool AssemblySqueegee Tool Assembly
Squeegee Tool AssemblySqueegee Tool Assembly
Squeegee Tool Assembly
2727
2727
27 Tail LightTail Light
Tail LightTail Light
Tail Light
2828
2828
28 Exhaust Tail PipeExhaust Tail Pipe
Exhaust Tail PipeExhaust Tail Pipe
Exhaust Tail Pipe
2929
2929
29 Fuel Tank Compartment DoorFuel Tank Compartment Door
Fuel Tank Compartment DoorFuel Tank Compartment Door
Fuel Tank Compartment Door
3030
3030
30 Recovery Tank LidRecovery Tank Lid
Recovery Tank LidRecovery Tank Lid
Recovery Tank Lid
3131
3131
31 Recovery Tank “Tip-Out” GripRecovery Tank “Tip-Out” Grip
Recovery Tank “Tip-Out” GripRecovery Tank “Tip-Out” Grip
Recovery Tank “Tip-Out” Grip
3232
3232
32 Engine Air Filter HoodEngine Air Filter Hood
Engine Air Filter HoodEngine Air Filter Hood
Engine Air Filter Hood
3333
3333
33 Radiator CapRadiator Cap
Radiator CapRadiator Cap
Radiator Cap
3434
3434
34 Oil Cooler “Tip-Out” LatchesOil Cooler “Tip-Out” Latches
Oil Cooler “Tip-Out” LatchesOil Cooler “Tip-Out” Latches
Oil Cooler “Tip-Out” Latches
3535
3535
35 Hydraulic “Charge” Oil FilterHydraulic “Charge” Oil Filter
Hydraulic “Charge” Oil FilterHydraulic “Charge” Oil Filter
Hydraulic “Charge” Oil Filter
3636
3636
36 Hydraulic Reservoir / In Tank Return Oil FilterHydraulic Reservoir / In Tank Return Oil Filter
Hydraulic Reservoir / In Tank Return Oil FilterHydraulic Reservoir / In Tank Return Oil Filter
Hydraulic Reservoir / In Tank Return Oil Filter
3737
3737
37 Right Engine Compartment Access PanelRight Engine Compartment Access Panel
Right Engine Compartment Access PanelRight Engine Compartment Access Panel
Right Engine Compartment Access Panel
3838
3838
38 Main Broom Right Access DoorMain Broom Right Access Door
Main Broom Right Access DoorMain Broom Right Access Door
Main Broom Right Access Door
3939
3939
39 Access Door LatchAccess Door Latch
Access Door LatchAccess Door Latch
Access Door Latch
4040
4040
40 Skirt AssemblySkirt Assembly
Skirt AssemblySkirt Assembly
Skirt Assembly
4141
4141
41 Inline Solution FilterInline Solution Filter
Inline Solution FilterInline Solution Filter
Inline Solution Filter
4242
4242
42 Solution Tank Drain HoseSolution Tank Drain Hose
Solution Tank Drain HoseSolution Tank Drain Hose
Solution Tank Drain Hose
4343
4343
43 Rear Roller BumperRear Roller Bumper
Rear Roller BumperRear Roller Bumper
Rear Roller Bumper
4444
4444
44 Jacking LocationJacking Location
Jacking LocationJacking Location
Jacking Location
4545
4545
45 Engine Oil DipstickEngine Oil Dipstick
Engine Oil DipstickEngine Oil Dipstick
Engine Oil Dipstick
4646
4646
46 Air Filter Service IndicatorAir Filter Service Indicator
Air Filter Service IndicatorAir Filter Service Indicator
Air Filter Service Indicator
4747
4747
47 Fuel Filter (Gas Models)Fuel Filter (Gas Models)
Fuel Filter (Gas Models)Fuel Filter (Gas Models)
Fuel Filter (Gas Models)
4848
4848
48 Recovery Tank LatchRecovery Tank Latch
Recovery Tank LatchRecovery Tank Latch
Recovery Tank Latch
4949
4949
49 Hydraulic Reservoir Access PanelHydraulic Reservoir Access Panel
Hydraulic Reservoir Access PanelHydraulic Reservoir Access Panel
Hydraulic Reservoir Access Panel
5050
5050
50 Water Level GaugeWater Level Gauge
Water Level GaugeWater Level Gauge
Water Level Gauge
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINE
12 12
12 12
12 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINE
IMPORTIMPORT
IMPORTIMPORT
IMPORTANT SERVICE TIPANT SERVICE TIP
ANT SERVICE TIPANT SERVICE TIP
ANT SERVICE TIP
Before any troubleshooting is done perform this troubleshooting special control system procedure.Before any troubleshooting is done perform this troubleshooting special control system procedure.
Before any troubleshooting is done perform this troubleshooting special control system procedure.Before any troubleshooting is done perform this troubleshooting special control system procedure.
Before any troubleshooting is done perform this troubleshooting special control system procedure.
CONTROL SYSTEM SELF-DIAGNOSTIC TEST MODECONTROL SYSTEM SELF-DIAGNOSTIC TEST MODE
CONTROL SYSTEM SELF-DIAGNOSTIC TEST MODECONTROL SYSTEM SELF-DIAGNOSTIC TEST MODE
CONTROL SYSTEM SELF-DIAGNOSTIC TEST MODE
If problems with the electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this
mode is activated, the control unit will activate each one of the outputs in sequence and test for short circuits, open circuits, or
overload conditions. This mode will also provide an easy test for the touch panel switches and indicators.
If an abnormal condition is encountered with one of the outputs, an error code will be displayed on the Display ((
((
(JJ
JJ
J))
))
) see Figure 2.
11
11
1 During this test, the horn will sound briefly and the scrub deck and squeegee will move if they are in the up position. If the hopper
is not in the down position it will also move slightly.
CAUTION!CAUTION!
CAUTION!CAUTION!
CAUTION!
Make sure that all persons are away from these parts of the machine to prevent injury.
22
22
2 Turn the main power key switchmain power key switch
main power key switchmain power key switch
main power key switch to the offoff
offoff
off position.
33
33
3 Press and hold the side broom down/on switchside broom down/on switch
side broom down/on switchside broom down/on switch
side broom down/on switch.
44
44
4 While holding the side broom down/on switch, turn the main power key switchmain power key switch
main power key switchmain power key switch
main power key switch to the onon
onon
on position.
55
55
5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off
(approximately two seconds).
66
66
6 Release the side broom down/on switch.
77
77
7 The control will now activate each output in sequence and perform the tests mentioned above.
88
88
8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10.
99
99
9 If abnormal output conditions were detected, the display will now show the error code(s), see “Main Control Error Code Display
Descriptions Table”. An example of how two codes, 6 and 18, would be displayed is as follows:
• The display will show “E” followed by a brief blank period
• The display will show “0” followed by a brief blank period
• The display will show “6” followed by a slightly longer blank period
• The display will show “E” followed by a brief blank period
• The display will show “1” followed by a brief blank period
• The display will show “8” followed by a long blank period
• The above sequence will repeat
1010
1010
10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult
the service manual general machine troubleshooting section which will show machine system flow charts.
1111
1111
11 The hopper limit, main broom, recovery tank full, and solution tank empty switches may also be tested in this mode. The
corresponding indicators will indicate the state of each of the inputs.
1212
1212
12 To exit this mode, turn the main power key switchmain power key switch
main power key switchmain power key switch
main power key switch to the offoff
offoff
off position.
NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.
NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.
NOTE: If the machine is not equipped with an optional back-up alarm, an error code 20 will be indicated.
J
FIGURE 2FIGURE 2
FIGURE 2FIGURE 2
FIGURE 2
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 1313
1313
13
Display
Code Error Description Troubleshooting Actions
Additional troubleshooting see general machine
troubleshooting flow charts
01 Side broom actuator overload Check for binding or frozen side broom linkage &
actuator motor.
Check for short circuit in lift motor or wiring.
02 Contactor bank 1 overload
03 Contactor bank 2 overload
04 Contactor bank 3 overload
05 Contactor bank 4 overload
06 Contactor bank 5 overload
07 Engine speed actuator overload (diesel) Check for binding or frozen throttle linkage.
Check for short circuit in actuator motor or wiring.
08 Not used
09 Light relay coil circuit short Check for wiring problems at the K2 relay.
Check K2 coil resistance if below 315 ohms, replace
10 Light relay coil circuit current too high Same as Error 9 Replace relay. (Shorted Relay)
11 Light relay coil circuit open Check for open in relay wiring.
Check for 12V at the K2 relay coil wire colors ORG (+),
YEL (-).
12 Neutral-start relay coil circuit short Check for wiring problems at the K4 relay.
Check K4 coil resistance if below 315 ohms, replace
13 Neutral-start relay coil circuit current too high Same as Error 12 Replace relay. (Shorted Relay)
14 Neutral-start relay coil circuit open Check for open in relay wiring.
Check for 12V at the K4 relay coil wire colors PINK (+),
GRA/WHT (-).
15 Shaker relay coil circuit short See shaker will not run troubleshooting flow chart.
16 Shaker relay coil circuit current too high See shaker will not run troubleshooting flow chart.
17 Shaker relay coil circuit open See shaker will not run troubleshooting flow chart.
18 Back-up alarm circuit short Check alarm and wiring
19 Back-up alarm circuit current too high Check alarm and wiring
20 Back-up alarm circuit open Check alarm and wiring
21 Horn relay coil circuit short Check for wiring problems at the K1 relay.
Check K4 coil resistance if below 315 ohms, replace
22 Horn relay coil circuit current too high Same as Error 21 Replace relay. (Shorted Relay)
23 Horn relay coil circuit open Check for open in relay wiring.
Check for 12V at the K1 relay coil wire colors ORG (+),
VIO/BRN (-).
24 S15 (scrub deck pressure) circuit short Check for wiring problems at the L15 coil.
Check L15 coil resistance if below 7 ohms, replace
25 S15 (scrub deck pressure) circuit current too high Same as Error 24 Replace coil. (Shorted Coil)
26 S15 (scrub deck pressure) circuit open Check for open in coil & wiring.
Check for 12V at the L15 coil wire colors ORG (+),
GRN/VIO (-).
27 Solution solenoid circuit short Check for wiring problems at the L16 coil.
Check L16 coil resistance if below 7 ohms, replace.
28 Solution solenoid circuit current too high Same as Error 27 Replace coil. (Shorted Coil)
29 Solution solenoid circuit open Check for open in coil & wiring.
Check for 12V at the L16 solution valve coil wire colors
ORG (+), YEL/GRN (-).
30 S13 (hopper up) circuit short Check for wiring problems at the L13 coil.
Check L13 coil resistance if below 7 ohms, replace.
31 S13 (hopper up) circuit current too high Same as Error 30 Replace coil. (Shorted Coil)
32 S13 (hopper up) circuit open Check for open in coil & wiring.
Check for 12V at the L13 coil wire colors ORG (+),
RED/GRA (-).
A1 Main Control Error Codes
Run self-diagnostic for specific cause
14 14
14 14
14 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
Display
Code Error Description Troubleshooting Actions
33 S14 (hopper down) circuit short Check for wiring problems at the L14 coil.
Check L14 coil resistance if below 7 ohms Replace.
34 S14 (hopper down) circuit current too high Same as Error 33 Replace coil. (Shorted Coil)
35 S14 (hopper down) circuit open Check for open in coil & wiring.
Check for 12V at the L14 coil wire colors ORG (+),
YEL/RED (-).
36 S10 (side broom) circuit short Check for wiring problems at the L10 coil.
Check L10 coil resistance if below 7 ohms Replace.
37 S10 (side broom) circuit current too high Same as Error 36 Replace coil. (Shorted Coil)
38 S10 (side broom) circuit open Check for open in coil & wiring.
Check for 12V at the L10 coil wire colors ORG (+),
BRN/BLK (-).
39 S12 (door close) circuit short Check for wiring problems at the L12 coil.
Check L12 coil resistance if below 7 ohms Replace.
40 S12 (door close) circuit current too high Same as Error 39 Replace coil. (Shorted Coil)
41 S12 (door close) circuit open Check for open in coil & wiring.
Check for 12V at the L12 coil wire colors ORG (+),
BRN/GRN (-).
42 S8 (vacuum) circuit short Check for wiring problems at the L8 coil.
Check L8 coil resistance if below 7 ohms Replace.
43 S8 (vacuum) circuit current too high Same as Error 42 Replace coil. (Shorted Coil)
44 S8 (vacuum) circuit open Check for open in coil & wiring.
Check for 12V at the L8 coil wire colors ORG (+),
BLU (-).
45 S9 (dust control) circuit short Check for wiring problems at the L9 coil.
Check L9 coil resistance if below 7 ohms Replace.
46 S9 (dust control) circuit current too high Same as Error 45 Replace coil. (Shorted Coil)
47 S9 (dust control) circuit open Check for open in coil & wiring.
Check for 12V at the L9 coil wire colors ORG (+),
BRN/YEL (-).
48 S7 (scrub motors) circuit short Check for wiring problems at the L7 coil.
Check L7 coil resistance if below 7 ohms Replace.
49 S7 (scrub motors) circuit current too high Same as Error 48 Replace coil. (Shorted Coil)
50 S7 (scrub motors) circuit open Check for open in coil & wiring.
Check for 12V at the L7 coil wire colors ORG (+),
ORG/BLU (-).
51 S11 (door open) circuit short Check for wiring problems at the L11 coil.
Check L11 coil resistance if below 7 ohms Replace.
52 S11 (door open) circuit current too high Same as Error 51 Replace coil. (Shorted Coil)
53 S11 (door open) circuit open Check for open in coil & wiring.
Check for 12V at the L11 coil wire colors ORG (+),
BLK/WHT (-).
54 S5 (deck pressure) circuit short Check for wiring problems at the L5 coil.
Check L5 coil resistance if below 7 ohms Replace.
55 S5 (deck pressure) circuit current too high Same as Error 54 Replace coil. (Shorted Coil)
56 S5 (deck pressure) circuit open Check for open in coil & wiring.
Check for 12V at the L5 coil wire colors ORG (+),
WHT/VIO (-).
57 S6 (main broom) circuit short Check for wiring problems at the L6 coil.
Check L6 coil resistance if below 7 ohms Replace.
58 S6 (main broom) circuit current too high Same as Error 57 Replace coil. (Shorted Coil)
59 S6 (main broom) circuit open Check for open in coil & wiring.
Check for 12V at the L6 coil wire colors ORG (+),
GRN/GRA (-).
60 S3 (deck direction) circuit short Check for wiring problems at the L3 coil.
Check L3 coil resistance if below 7 ohms Replace.
61 S3 (deck direction) circuit current too high Same as Error 60 Replace coil. (Shorted Coil)
62 S3 (deck direction) circuit open Check for open in coil & wiring.
Check for 12V at the L3 coil wire colors ORG (+),
BRN (-).
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 1515
1515
15
Display
Code Error Description Troubleshooting Actions
63 S4 (deck direction) circuit short Check for wiring problems at the L4 coil.
Check L4 coil resistance if below 7 ohms Replace.
64 S4 (deck direction) circuit current too high Same as Error 63 Replace coil. (Shorted Coil)
65 S4 (deck direction) circuit open Check for open in coil & wiring.
Check for 12V at the L4 coil wire colors ORG (+),
YEL/BLU (-).
66 S1 (deck & squeegee lift) circuit short Check for wiring problems at the L1 coil.
Check L1 coil resistance if below 7 ohms Replace.
67 S1 (deck & squeegee lift) circuit current too high Same as Error 66 Replace coil. (Shorted Coil)
68 S1 (deck & squeegee lift) circuit open Check for open in coil & wiring.
Check for 12V at the L1 coil wire colors ORG (+),
BLU/WHT (-).
69 S2 (squeegee direction) circuit short Check for wiring problems at the L2 coil.
Check L2 coil resistance if below 7 ohms Replace.
70 S2 (squeegee direction) circuit current too high Same as Error 69 Replace coil. (Shorted Coil)
71 S2 (squeegee direction) circuit open Check for open in coil & wiring.
Check for 12V at the L2 coil wire colors ORG (+),
ORG/RED (-).
72 Side broom actuator circuit short Check for short in wires or motor.
73 Side broom actuator circuit current too high Check for binding of linkage.
74 Side broom actuator circuit open See service manual section flowcharts.
75 Engine speed actuator circuit short (diesel) Check for short at motor and wires.
76 Engine speed actuator circuit current too high
(diesel) Check for binding of linkage.
77 Engine speed actuator circuit open (diesel) Check for open in wires or motor.
78
79
80
16 16
16 16
16 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
WAND
(S4) DECK
(S2) SQUEEGEE
(S6)
MAIN BROOM
(S11)
DOOR OPEN
(S9) DUST
CONTROL
(S12)
DOOR CLOSE
(S14)
HOPPER DOWN
SOLUTION
LOW
FUEL
UP
HOPPER
GLOW
PLUG
DUST
FILTER
TEMP
HOPPER
RECOVERY
FULL
FILTER
HYDRAULIC
MAIN
BROOM
ENGINE
SERVICE
EMPTY
SOLUTION
(S1)
SQ. & DECK
(S3)
DECK
(S5)
DECK
(S7)
SCRUB MOTORS
(S8)
VACUUM
(S10)
SIDE BROOM
(S13)
HOPPER UP
(S15)
DECK
BACKUP
LIGHTS
SHAKER
HORN
NEUTRAL
IGN.
IGN.
ACC.
ENGINE
SPEED
SIDE BROOM
ACTUATOR
J2
J1
GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TGENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE T
GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TGENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE T
GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTS
ENGINE WILL NOT CRANK ................................................................................................................................................ 18
ENGINE WILL CRANK BUT NOT START .......................................................................................................................... 19
ALL THE MACHINE ACCESSORY FUNCTIONS DO NOT WORK ............................................................................. 20-21
FORWARD/REVERSE AUTO ACCESSORY FUNCTION DO NOT WORK ...................................................................... 22
HYDRAULIC MOTOR(S) WILL NOT STOP RUNNING ..................................................................................................... 23
WHEEL DRIVE SYSTEM (TROUBLESHOOTING CHECK LIST) ...................................................................................... 24
STEERING SYSTEM (TROUBLESHOOTING GUIDE) ....................................................................................................... 25
SWEEP SYSTEM ............................................................................................................................................................. 26-33
MAIN BROOM WILL NOT TURN ................................................................................................................ 26-27
SIDE BROOMS WILL NOT TURN ............................................................................................................... 28-29
SIDE BROOMS WILL NOT RAISE/LOWER ..................................................................................................... 30
DUST CONTROL IMPELLER WILL NOT RUN ............................................................................................ 31-32
SHAKER MOTOR WILL NOT RUN ................................................................................................................... 33
HOPPER SYSTEM ........................................................................................................................................................... 34-40
HOPPER WILL NOT RAISE .......................................................................................................................... 34-35
HOPPER WILL NOT LOWER ........................................................................................................................ 36-37
HOPPER DUMP DOOR WILL NOT OPEN ....................................................................................................... 38
HOPPER DUMP DOOR WILL NOT CLOSE ...................................................................................................... 39
HOPPER DUMP DOOR WILL NOT OPEN OR CLOSE .................................................................................... 40
SCRUB SYSTEM ............................................................................................................................................................. 41-50
SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 1) .............................................................. 41-42
SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 2) .............................................................. 43-44
SCRUB DECK WILL NOT LOWER IN (PRESSURE SETTING 3) .............................................................. 45-46
SCRUB DECK WILL NOT RAISE ................................................................................................................. 47-48
SCRUB BRUSH MOTORS WILL NOT OPERATE ...................................................................................... 49-50
SOLUTION SYSTEM ............................................................................................................................................................ 51
SOLUTION SOLENOID WILL NOT OPERATE ................................................................................................. 51
RECOVERY SYSTEM ....................................................................................................................................................... 52-56
VACUUM MOTOR WILL NOT OPERATE ................................................................................................... 52-54
SQUEEGEE WILL NOT RAISE/LOWER ....................................................................................................... 55-56
Note:Note:
Note:Note:
Note: To aid in machine system troubleshooting; see the electrical and hydraulic manual sections for additional drawing of part
component locations and diagrams to support wiring and hydraulic circuits.
A1 Control BoardA1 Control Board
A1 Control BoardA1 Control Board
A1 Control Board
Indicator LightsIndicator Lights
Indicator LightsIndicator Lights
Indicator Lights
Note: Remove left side
operator's compartment panel
to access A1 Board.
FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 1717
1717
17
TEMP
F/C
VOLTSFUEL
OIL
PSI/BAR
HOURS 1/10
250
175
120
50
75
100
100
50
0
1
3
8
F
E
1/2
18
13
10
+
-
AB
C
D
E
FG
BB
CC
DD
EE
I
J
H
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
AA
FF
OPERAOPERA
OPERAOPERA
OPERATOR’S COMPTOR’S COMP
TOR’S COMPTOR’S COMP
TOR’S COMPARTMENTARTMENT
ARTMENTARTMENT
ARTMENT
AA
AA
ALow Fuel Indicator (LP)Low Fuel Indicator (LP)
Low Fuel Indicator (LP)Low Fuel Indicator (LP)
Low Fuel Indicator (LP)
BB
BB
BHorn SwitchHorn Switch
Horn SwitchHorn Switch
Horn Switch
**
**
*Horn ON IndicatorHorn ON Indicator
Horn ON IndicatorHorn ON Indicator
Horn ON Indicator
CC
CC
CEngine Service Indicator (triggered byEngine Service Indicator (triggered by
Engine Service Indicator (triggered byEngine Service Indicator (triggered by
Engine Service Indicator (triggered by
ECU)ECU)
ECU)ECU)
ECU)
DD
DD
DHeadlight SwitchHeadlight Switch
Headlight SwitchHeadlight Switch
Headlight Switch
**
**
*Headlight ON IndicatorHeadlight ON Indicator
Headlight ON IndicatorHeadlight ON Indicator
Headlight ON Indicator
EE
EE
EGlow Plug Indicator (Diesel / ReleaseGlow Plug Indicator (Diesel / Release
Glow Plug Indicator (Diesel / ReleaseGlow Plug Indicator (Diesel / Release
Glow Plug Indicator (Diesel / Release
key after indicator turns OFF)key after indicator turns OFF)
key after indicator turns OFF)key after indicator turns OFF)
key after indicator turns OFF)
FF
FF
FHydraulic Filter Plugged IndicatorHydraulic Filter Plugged Indicator
Hydraulic Filter Plugged IndicatorHydraulic Filter Plugged Indicator
Hydraulic Filter Plugged Indicator
GG
GG
GEngine Speed SwitchEngine Speed Switch
Engine Speed SwitchEngine Speed Switch
Engine Speed Switch
**
**
*Engine Speed Switch IndicatorEngine Speed Switch Indicator
Engine Speed Switch IndicatorEngine Speed Switch Indicator
Engine Speed Switch Indicator
HH
HH
HScrub Pressure Decrease SwitchScrub Pressure Decrease Switch
Scrub Pressure Decrease SwitchScrub Pressure Decrease Switch
Scrub Pressure Decrease Switch
**
**
*Scrub Pressure Decrease IndicatorScrub Pressure Decrease Indicator
Scrub Pressure Decrease IndicatorScrub Pressure Decrease Indicator
Scrub Pressure Decrease Indicator
II
II
IScrub Pressure Increase SwitchScrub Pressure Increase Switch
Scrub Pressure Increase SwitchScrub Pressure Increase Switch
Scrub Pressure Increase Switch
**
**
*Scrub Pressure Increase IndicatorScrub Pressure Increase Indicator
Scrub Pressure Increase IndicatorScrub Pressure Increase Indicator
Scrub Pressure Increase Indicator
JJ
JJ
JScrub Pressure & Error Code DisplayScrub Pressure & Error Code Display
Scrub Pressure & Error Code DisplayScrub Pressure & Error Code Display
Scrub Pressure & Error Code Display
KK
KK
KSolution SwitchSolution Switch
Solution SwitchSolution Switch
Solution Switch
**
**
*Solution System IndicatorSolution System Indicator
Solution System IndicatorSolution System Indicator
Solution System Indicator
LL
LL
LLow Solution Indicator (8-10 gal.)Low Solution Indicator (8-10 gal.)
Low Solution Indicator (8-10 gal.)Low Solution Indicator (8-10 gal.)
Low Solution Indicator (8-10 gal.)
MM
MM
MRecovery Tank Full IndicatorRecovery Tank Full Indicator
Recovery Tank Full IndicatorRecovery Tank Full Indicator
Recovery Tank Full Indicator
NN
NN
NSide Broom DOWN/ON SwitchSide Broom DOWN/ON Switch
Side Broom DOWN/ON SwitchSide Broom DOWN/ON Switch
Side Broom DOWN/ON Switch
**
**
*Side Broom ON IndicatorSide Broom ON Indicator
Side Broom ON IndicatorSide Broom ON Indicator
Side Broom ON Indicator
OO
OO
OMain Broom ON IndicatorMain Broom ON Indicator
Main Broom ON IndicatorMain Broom ON Indicator
Main Broom ON Indicator
PP
PP
PLight SensorLight Sensor
Light SensorLight Sensor
Light Sensor
QQ
QQ
QShaker SwitchShaker Switch
Shaker SwitchShaker Switch
Shaker Switch
**
**
*Shaker Indicator (left)Shaker Indicator (left)
Shaker Indicator (left)Shaker Indicator (left)
Shaker Indicator (left)
**
**
*Dust Filter Plugged Indicator (right)Dust Filter Plugged Indicator (right)
Dust Filter Plugged Indicator (right)Dust Filter Plugged Indicator (right)
Dust Filter Plugged Indicator (right)
RR
RR
ROpen Dump Door SwitchOpen Dump Door Switch
Open Dump Door SwitchOpen Dump Door Switch
Open Dump Door Switch
**
**
*Open Dump Door IndicatorOpen Dump Door Indicator
Open Dump Door IndicatorOpen Dump Door Indicator
Open Dump Door Indicator
SS
SS
SHopper Open IndicatorHopper Open Indicator
Hopper Open IndicatorHopper Open Indicator
Hopper Open Indicator
TT
TT
THopper Overtemp IndicatorHopper Overtemp Indicator
Hopper Overtemp IndicatorHopper Overtemp Indicator
Hopper Overtemp Indicator
UU
UU
UClose Dump Door SwitchClose Dump Door Switch
Close Dump Door SwitchClose Dump Door Switch
Close Dump Door Switch
**
**
*Close Dump Door IndicatorClose Dump Door Indicator
Close Dump Door IndicatorClose Dump Door Indicator
Close Dump Door Indicator
VV
VV
VLower Hopper SwitchLower Hopper Switch
Lower Hopper SwitchLower Hopper Switch
Lower Hopper Switch
**
**
*Lower Hopper IndicatorLower Hopper Indicator
Lower Hopper IndicatorLower Hopper Indicator
Lower Hopper Indicator
WW
WW
WRaise Hopper SwitchRaise Hopper Switch
Raise Hopper SwitchRaise Hopper Switch
Raise Hopper Switch
**
**
*Raise Hopper IndicatorRaise Hopper Indicator
Raise Hopper IndicatorRaise Hopper Indicator
Raise Hopper Indicator
XX
XX
XDust Control SwitchDust Control Switch
Dust Control SwitchDust Control Switch
Dust Control Switch
**
**
*Dust Control ON IndicatorDust Control ON Indicator
Dust Control ON IndicatorDust Control ON Indicator
Dust Control ON Indicator
YY
YY
YSide Broom UP/OFF SwitchSide Broom UP/OFF Switch
Side Broom UP/OFF SwitchSide Broom UP/OFF Switch
Side Broom UP/OFF Switch
**
**
*Side Broom OFF IndicatorSide Broom OFF Indicator
Side Broom OFF IndicatorSide Broom OFF Indicator
Side Broom OFF Indicator
ZZ
ZZ
ZVacuum System SwitchVacuum System Switch
Vacuum System SwitchVacuum System Switch
Vacuum System Switch
**
**
*Vacuum System IndicatorVacuum System Indicator
Vacuum System IndicatorVacuum System Indicator
Vacuum System Indicator
AAAA
AAAA
AA Scrub System OFF SwitchScrub System OFF Switch
Scrub System OFF SwitchScrub System OFF Switch
Scrub System OFF Switch
**
**
*Scrub System OFF IndicatorScrub System OFF Indicator
Scrub System OFF IndicatorScrub System OFF Indicator
Scrub System OFF Indicator
BBBB
BBBB
BB Coolant Temperature GaugeCoolant Temperature Gauge
Coolant Temperature GaugeCoolant Temperature Gauge
Coolant Temperature Gauge
CCCC
CCCC
CC Oil Pressure GaugeOil Pressure Gauge
Oil Pressure GaugeOil Pressure Gauge
Oil Pressure Gauge
DDDD
DDDD
DD Fuel Gauge (Gas / Diesel)Fuel Gauge (Gas / Diesel)
Fuel Gauge (Gas / Diesel)Fuel Gauge (Gas / Diesel)
Fuel Gauge (Gas / Diesel)
EEEE
EEEE
EE VoltmeterVoltmeter
VoltmeterVoltmeter
Voltmeter
FFFF
FFFF
FF Hour meterHour meter
Hour meterHour meter
Hour meter
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINEKNOW YOUR MACHINE
KNOW YOUR MACHINE
A2 Control PanelA2 Control Panel
A2 Control PanelA2 Control Panel
A2 Control Panel
AssemblyAssembly
AssemblyAssembly
Assembly
18 18
18 18
18 - FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400
Repair or replace relay or
wiring. Is there 12 volts at
the BLU/PNK?
Replace engine fuse box start relay.
Location of fuse box on top of engine
No
No
At the K4 relay do you have
12 volts at the BLU/PNK?
Yes
No
Engine will still not crank?
No
Yes
No
Engine will not crank
Is the neutral indicator
light off at the A1 board?
The pedal is not returning
to its neutral state. Repair
any mechanical problems
to the foot pedal linkage or
hydroback.
Does the light go off?
Replace the drive pedal
sensor. Does the light go
off? (See note 4)
Reset drive pedal sensor dead band setting. Sensor
has a range of 1-9 factory setting is 2-5.
Turn key switch off, press and hold the engine speed
switch then turn the key on. Setting should be at 2-5.
To change setting press the speed switch, To exit
turn key off. Does the light go off?
No
Replace the A1 control
board. Does the engine
crank?
Yes
Yes
Yes
Check for 12 volts at WHT
wire located on starter sole-
noid with the key in the start
position. If yes repair or
replace starter.
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Possible SymptomPossible Symptom
Possible SymptomPossible Symptom
Possible Symptom
11
11
1 Engine will not crank
Electrical Control CircuitElectrical Control Circuit
Electrical Control CircuitElectrical Control Circuit
Electrical Control Circuit
Note 1: To test the key switch must be in the START position and foot pedal in neutral.
Note 2: Before troubleshooting check the F4 (15 amp) circuit breaker location under steering column.
Note 3: Check for 12V at the F4 machine circuit breaker. If no input voltage at the GRN/BLK wire, repair or replace wiring or key switch.
Service Adjustment Note:Service Adjustment Note:
Service Adjustment Note:Service Adjustment Note:
Service Adjustment Note: A drive pedal sensor setting that is set too low will not target (match) the drive pedal neutral return
position (dead-band too narrow) and the engine will not start. Too high of a setting will increase the neutral range (dead-band too
wide) and delay the activation of turning on the auto sweep and scrub functions when the drive pedal is moved out of an excessively
wide programmed neutral range.
Note 4: A new pedal sensor must be programmed for its neutral position and dead-band setting, follow instructions shown on this
page.
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Nilfisk-Advance CR 1200 Quick start guide

Nilfisk-Advance
Brand
Nilfisk-Advance
Model
CR 1200
Category
Scrubber
Type
Quick start guide
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