Nilfisk-Advance CR 1200 Quick start guide

10/03 Form Number 56043093

QUICK STQUICK ST

QUICK ST

ART TROUBLESHOOTING MANUALART TROUBLESHOOTING MANUAL

ART TROUBLESHOOTING MANUAL

Advance MODELS 56304000(4300 P), 56304001(4300 G), 56304003(4800 P),

56304004(4800 G), 56304006(5400 P), 56304007(5400 G)

Nilfisk MODELS 56304009(1100 P), 56304010(1100 G), 56304012(1200 P),

56304013(1200 G), 56304015(1400 P), 56304016(1400 G)

CaptorCaptor

Captor™™

™™

™ 4300, 4800, 5400 4300, 4800, 5400

4300, 4800, 5400 4300, 4800, 5400

4300, 4800, 5400

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

CR 1100, 1200, 1400

76 76

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Note: Note:

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

TT

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

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. (BB

BB

B).).

).).

).

This product is intended for commercial use only.

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 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 SUPPORT

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 MACHINE

CAUTION!CAUTION!

CAUTION!

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

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

((

(4444

4444

44))

))

).

GENERAL INFORMAGENERAL INFORMA

GENERAL INFORMATIONTION

TIONTION

TION

2 2

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

TRANSPORTING THE MACHINETRANSPORTING THE MACHINE

TRANSPORTING THE MACHINE

CAUTION!CAUTION!

CAUTION!

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

••

• All access doors are latched securely.

••

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

((

(66

66

6))

))

).

••

• The machine parking brake is set.

TOWING OR PUSHING A DISABLED MACHINETOWING OR PUSHING A DISABLED MACHINE

TOWING OR PUSHING A DISABLED MACHINE

CAUTION!CAUTION!

CAUTION!

The machine’s drive propelling pump is manufactured with a selectable tow valve. This valve prevents damage to the hydraulic

system when the machine is being towed/pushed short distances without use of the engine.

To access the valve, open the Engine Compartment Door ((

((

(2222

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 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 HYDROSTAA

AA

ATIC PUMPTIC PUMP

TIC PUMPTIC PUMP

TIC PUMP

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 WARNINGS

SYMBOLSSYMBOLS

SYMBOLS

Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this information

carefully and take the necessary steps to protect personnel and property.

DANGER!DANGER!

DANGER!

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

WARNING!WARNING!

WARNING!

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

CAUTION!CAUTION!

CAUTION!

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

GENERAL SAFETY INSTRUCTIONSGENERAL SAFETY INSTRUCTIONS

GENERAL SAFETY INSTRUCTIONS

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

WARNING!WARNING!

WARNING!

••

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

••

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

••

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

••

• Remove all jewelry when working near electrical components.

••

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

••

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

••

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

••

• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where

flammable liquids exist.

••

• Do not clean this machine with a pressure washer.

••

• This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide

adequate ventilation when operating this machine.

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

CAUTION!CAUTION!

CAUTION!

••

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

••

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

••

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

••

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

••

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

parking brake.

••

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

••

• Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or

recovery tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer

fluid.

••

• The battery must be removed from the machine before the machine is scrapped. The disposal of the battery should

be safely done in accordance with your local environmental regulations.

SASA

SAVE THESE INSTRUCTIONSVE THESE INSTRUCTIONS

VE THESE INSTRUCTIONSVE THESE INSTRUCTIONS

VE THESE INSTRUCTIONS

4 4

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

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

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

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

Weights

Net weight* 4040 lbs. (1832kg)

Gross weight** 4720 lbs. (2141kg)

Speed and GradeabilitySpeed and Gradeability

Speed and Gradeability

Maximum travel speed 6 mph (9.6km/h)

Maximum reverse speed 4 mph (6.4km/h)

Maximum grade angle scrubbing 6 deg.

Maximum grade angle non-scrubbing 8 deg.

Sound LevelSound Level

Sound Level

At operators ear 85.1 dBA

Sweep SystemSweep System

Sweep System

Sweeping path w/out side broom(s) 40 inches (102cm)

Main broom length 40 inches (102cm)

Main broom diameter 14 inches (35.5cm)

Side broom diameter 20 inches (50.8cm)

Side broom bristle length 7 inches (17.7cm)

Hopper SystemHopper System

Hopper System

Capacity 9.2 Cu. Ft. (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 System

Filter type: Pleated paper panel

Filter dimension 3-3/16" x 20" x 27" (8cm x 50.8cm x 68.5cm)

Filter media area 78 ft2 (7.25m2)

Steering SystemSteering System

Steering System

Type: Power steering unit with rack and pinion

Turns lock to lock right: 4-3/8

Turns lock to lock left: 3-3/8

Minimum aisle turn width 118 in. (300cm) left and right

Hydraulic SystemHydraulic System

Hydraulic System

Oil type: SAE 10W-30

System fill capacity 11 gal. (41.6

l

)

Engine SystemEngine System

Engine System

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

l

)

Recovery SystemRecovery System

Recovery System

Vacuum water lift (sealed) minimum 22 inches

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

*Net Weight: *Net Weight:

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

of fuel.

**Gross Weight:**Gross Weight:

**Gross Weight: 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

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

Height

Length

Width

FRONT VIEW

SIDE VIEW

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") = 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" 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

NA = Not Available at time of printing.

6 6

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

MAINTENANCE SCHEDULEMAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE

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

service more often.

MAINTENANCE ITEMMAINTENANCE ITEM

MAINTENANCE ITEM PERFORM DAILYPERFORM DAILY

PERFORM DAILYPERFORM DAILY

PERFORM DAILY

Perform the “After Use” maintenance steps X

Check parking brake X

Check engine oil X

*Clean main and side brooms X

Check filter indicator and lights (hyd & air) X

Check engine coolant level X

Check hydraulic oil level X

MAINTENANCE ITEMMAINTENANCE ITEM

MAINTENANCE ITEM 15 hrs.15 hrs.

15 hrs.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!

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

AFTER USEAFTER USE

AFTER USE

11

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

22

2 Shake the dust control filter and empty the hopper.

33

3 Drain and flush the recovery tank.

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

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

66

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

77

7 Wipe the machine with a damp cloth.

88

8 Perform all required maintenance before storage.

99

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

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

LUBRICATING THE MACHINETING THE MACHINE

TING THE MACHINETING THE MACHINE

TING THE MACHINE

Steering RackSteering Rack

Steering Rack

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

Also every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door

hinges etc. Broom, squeegee and hopper pivots use composite bearings lubrication is not required.

MAINTENANCEMAINTENANCE

MAINTENANCE

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 77

77

7

ENGINE COOLANTENGINE COOLANT

ENGINE COOLANT

CAUTION!CAUTION!

CAUTION!

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

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

((

(2222

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 OIL

Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the

first 35 hours of operation and every 150 hours after that. Use 3.5 quarts (3.3 liters) with filter, of any SF or SG rated oil meeting API

specifications and suited to seasonal temperatures. Refer to the Engine System for additional information. Replace the oil filter with

every oil change.

TEMPERATURE RANGETEMPERATURE RANGE

TEMPERATURE RANGE OIL WEIGHTOIL WEIGHT

OIL 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 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!

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

The engine air filter contains a primary (outer) and a safety (inner) filter element. The primary element may be cleaned twice before

being replaced. Replace the safety element every third time that the primary element is serviced. Never try to clean the safety

element. To clean the primary filter element, remove the cover from the dust cup end of the canister and pull out the primary element.

Clean the element with compressed air (maximum pressure 100 PSI) or wash it with water (maximum pressure 40 PSI). Do not put

the element back into the canister until it is completely dry.

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

ENGINE MAINTENANCE (150 HOURS)

At 150 hour intervals it is recommended that the following service be performed: Change oil and filter, clean and inspect spark plugs,

check all engine belts condition and adjustment, check battery charge and level, check cooling system hoses and clamps and check

general condition and performance of engine.

Note: Note:

Note: Reference the separately supplied PSI GM Power Train Products Operation and Maintenance manual for more detailed

service data. PSI manual number is 3610000.

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

WW

WARNING!ARNING!

ARNING!ARNING!

ARNING!

MAINTENANCEMAINTENANCE

MAINTENANCE

To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye

protection when working with or near hydraulic system.

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

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

((

(3737

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

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 1

8 8

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

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

Page 2 of 2

10/14/2003

Ref

VISUAL INSPECTION ITEMS (continued)

Comments

OK

Defect Codes

(circle)

Does

Not

Work

36 Broom Housing & Door Skirts D M W

37 Battery Clean & Water C W

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

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

40 Hydrostatic Dump Valve (Tow Valve) B

41 Propulsion drive & Accessory Pumps L

42 Hydraulic System Hoses & fittings L

43 Propulsion Pump Hydro Back Cable & Clevis Connections B M W

44 Propulsion Pump Hydraulic Filters Change with reservoir

filter

L

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

46 Engine Coolant Level Fill at reservoir L Add Coolant

47 Radiator & Oil Cooler Core Blockage L Needs Cleaning

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

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

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

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

52 LP Tank, Hoses & Fittings L

53 LP Fuel Filter SVR Life 1500 Hrs L Replace

54 LP Fuel Regulator, Lock Off Valve & Hoses L

55 Diesel Glow Plug Indicator Light Hard Starting Replace

56 Diesel Fuel Filter Yearly L Replace

57 Scrub Brushes, check for wear and rotate D M W

58 Scrub Deck Skirts D M W

59 Solution Solenoid Valve D L W

60 Solution Flow Control Valve and Linkage A B D W

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

62 Vacuum Motor Gasket & Metal Elbow Gasket C D L

63 Vacuum Stand Pipe Screen Clean Screen C D M

64 Recovery Tank Cover Gasket L M W

65 Recovery Tank Drain Hose & Cap C D L

66 Squeegee Pick-Up Hose & Metal Elbow Back flush C D L

67 Squeegee Tool & Blades Clean & Rotate A D W

68 Squeegee Casters (lubricate) A D W

69 Squeegee Hydraulic Lift Cylinder B D L

70 Rear Drive Wheel Motor L

71 Front & Rear Tires tread wear W

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

operators manual form number 56041547.

Defect Codes A needs adjustment C dirty or contaminated M missing

B binding D damaged, bent or torn W worn out

L leaks

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

10 10

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

1

2

3

4

5

6

7

98

10

6

13

14

15

16

17

18

19

20

21

12

22

23

24

44

46

47

45

48

49

11

1Operator’s SeatOperator’s Seat

Operator’s SeatOperator’s Seat

Operator’s Seat

22

2Strobe Light (optional)Strobe Light (optional)

Strobe Light (optional)Strobe Light (optional)

Strobe Light (optional)

33

3Solution Tank FillSolution Tank Fill

Solution Tank FillSolution Tank Fill

Solution Tank Fill

44

4Gasoline Tank CapGasoline Tank Cap

Gasoline Tank CapGasoline Tank Cap

Gasoline Tank Cap

55

5Fuel TankFuel Tank

Fuel TankFuel Tank

Fuel Tank

66

6Tie Down LocationsTie Down Locations

Tie Down LocationsTie Down Locations

Tie Down Locations

77

7Recovery Tank Drain HoseRecovery Tank Drain Hose

Recovery Tank Drain HoseRecovery Tank Drain Hose

Recovery Tank Drain Hose

88

8Engine Air FilterEngine Air Filter

Engine Air FilterEngine Air Filter

Engine Air Filter

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

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

11 BatteryBattery

BatteryBattery

Battery

1212

12 Hopper Lid Prop RodHopper Lid Prop Rod

Hopper Lid Prop RodHopper Lid Prop Rod

Hopper Lid Prop Rod

1313

13 Front WheelFront Wheel

Front WheelFront Wheel

Front Wheel

1414

14 Left Side BroomLeft Side Broom

Left Side BroomLeft Side Broom

Left Side Broom

1515

15 Hopper Lid LatchHopper Lid Latch

Hopper Lid LatchHopper Lid Latch

Hopper Lid Latch

1616

16 HeadlightsHeadlights

HeadlightsHeadlights

Headlights

1717

17 Right Side BroomRight Side Broom

Right Side BroomRight Side Broom

Right Side Broom

1818

18 Hopper CoverHopper Cover

Hopper CoverHopper Cover

Hopper Cover

1919

19 Dust Control FilterDust Control Filter

Dust Control FilterDust Control Filter

Dust Control Filter

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 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

21 Shaker Assembly LatchShaker Assembly Latch

Shaker Assembly LatchShaker Assembly Latch

Shaker Assembly Latch

2222

22 Engine Compartment DoorEngine Compartment Door

Engine Compartment DoorEngine Compartment Door

Engine Compartment Door

2323

23 Coolant Recovery TankCoolant Recovery Tank

Coolant Recovery TankCoolant Recovery Tank

Coolant Recovery Tank

2424

24 Steering WheelSteering Wheel

Steering WheelSteering Wheel

Steering Wheel

2525

25 Squeegee HandleSqueegee Handle

Squeegee HandleSqueegee Handle

Squeegee Handle

2626

26 Squeegee Tool AssemblySqueegee Tool Assembly

Squeegee Tool AssemblySqueegee Tool Assembly

Squeegee Tool Assembly

2727

27 Tail LightTail Light

Tail LightTail Light

Tail Light

2828

28 Exhaust Tail PipeExhaust Tail Pipe

Exhaust Tail PipeExhaust Tail Pipe

Exhaust Tail Pipe

2929

29 Fuel Tank Compartment DoorFuel Tank Compartment Door

Fuel Tank Compartment DoorFuel Tank Compartment Door

Fuel Tank Compartment Door

3030

30 Recovery Tank LidRecovery Tank Lid

Recovery Tank LidRecovery Tank Lid

Recovery Tank Lid

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

32 Engine Air Filter HoodEngine Air Filter Hood

Engine Air Filter HoodEngine Air Filter Hood

Engine Air Filter Hood

3333

33 Radiator CapRadiator Cap

Radiator CapRadiator Cap

Radiator Cap

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

35 Hydraulic “Charge” Oil FilterHydraulic “Charge” Oil Filter

Hydraulic “Charge” Oil FilterHydraulic “Charge” Oil Filter

Hydraulic “Charge” Oil Filter

3636

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

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

Hydraulic Reservoir / In Tank Return Oil Filter

3737

37 Right Engine Compartment Access PanelRight Engine Compartment Access Panel

Right Engine Compartment Access PanelRight Engine Compartment Access Panel

Right Engine Compartment Access Panel

3838

38 Main Broom Right Access DoorMain Broom Right Access Door

Main Broom Right Access DoorMain Broom Right Access Door

Main Broom Right Access Door

3939

39 Access Door LatchAccess Door Latch

Access Door LatchAccess Door Latch

Access Door Latch

4040

40 Skirt AssemblySkirt Assembly

Skirt AssemblySkirt Assembly

Skirt Assembly

4141

41 Inline Solution FilterInline Solution Filter

Inline Solution FilterInline Solution Filter

Inline Solution Filter

4242

42 Solution Tank Drain HoseSolution Tank Drain Hose

Solution Tank Drain HoseSolution Tank Drain Hose

Solution Tank Drain Hose

4343

43 Rear Roller BumperRear Roller Bumper

Rear Roller BumperRear Roller Bumper

Rear Roller Bumper

4444

44 Jacking LocationJacking Location

Jacking LocationJacking Location

Jacking Location

4545

45 Engine Oil DipstickEngine Oil Dipstick

Engine Oil DipstickEngine Oil Dipstick

Engine Oil Dipstick

4646

46 Air Filter Service IndicatorAir Filter Service Indicator

Air Filter Service IndicatorAir Filter Service Indicator

Air Filter Service Indicator

4747

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

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

Fuel Filter (Gas Models)

4848

48 Recovery Tank LatchRecovery Tank Latch

Recovery Tank LatchRecovery Tank Latch

Recovery Tank Latch

4949

49 Hydraulic Reservoir Access PanelHydraulic Reservoir Access Panel

Hydraulic Reservoir Access PanelHydraulic Reservoir Access Panel

Hydraulic Reservoir Access Panel

5050

50 Water Level GaugeWater Level Gauge

Water Level GaugeWater Level Gauge

Water Level Gauge

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

12 12

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

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

IMPORTIMPORT

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.

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

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

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

CAUTION!CAUTION!

CAUTION!

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

22

2 Turn the main power key switchmain power key switch

main power key switchmain power key switch

main power key switch to the offoff

offoff

off position.

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

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

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

(approximately two seconds).

66

6 Release the side broom down/on switch.

77

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

88

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

99

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

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

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

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

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

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

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

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

• The above sequence will repeat

1010

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

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

1111

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

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

1212

12 To exit this mode, turn the main power key switchmain power key switch

main power key 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.

J

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 - 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 - 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.

ACC.

ENGINE

SPEED

SIDE BROOM

ACTUATOR

J2

J1

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

component locations and diagrams to support wiring and hydraulic circuits.

A1 Control BoardA1 Control Board

A1 Control Board

Indicator LightsIndicator Lights

Indicator Lights

Note: Remove left side

operator's compartment panel

to access A1 Board.

FORM NO. 56043093 / Captor™ 4300, 4800, 5400 / CR 1100, 1200, 1400 - 1717

1717

17

TEMP

F/C

VOLTSFUEL

OIL

PSI/BAR

HOURS 1/10

250

175

120

50

75

100

50

0

1

3

8

F

E

1/2

18

13

10

+

-

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

OPERATOR’S COMPTOR’S COMP

TOR’S COMPTOR’S COMP

TOR’S COMPARTMENTARTMENT

ARTMENTARTMENT

ARTMENT

AA

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

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

Low Fuel Indicator (LP)

BB

BHorn SwitchHorn Switch

Horn SwitchHorn Switch

Horn Switch

**

*Horn ON IndicatorHorn ON Indicator

Horn ON IndicatorHorn ON Indicator

Horn ON Indicator

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)

DD

DHeadlight SwitchHeadlight Switch

Headlight SwitchHeadlight Switch

Headlight Switch

**

*Headlight ON IndicatorHeadlight ON Indicator

Headlight ON IndicatorHeadlight ON Indicator

Headlight ON Indicator

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)

FF

FHydraulic Filter Plugged IndicatorHydraulic Filter Plugged Indicator

Hydraulic Filter Plugged IndicatorHydraulic Filter Plugged Indicator

Hydraulic Filter Plugged Indicator

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

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

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

JScrub Pressure & Error Code DisplayScrub Pressure & Error Code Display

Scrub Pressure & Error Code DisplayScrub Pressure & Error Code Display

Scrub Pressure & Error Code Display

KK

KSolution SwitchSolution Switch

Solution SwitchSolution Switch

Solution Switch

**

*Solution System IndicatorSolution System Indicator

Solution System IndicatorSolution System Indicator

Solution System Indicator

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

MRecovery Tank Full IndicatorRecovery Tank Full Indicator

Recovery Tank Full IndicatorRecovery Tank Full Indicator

Recovery Tank Full Indicator

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

OMain Broom ON IndicatorMain Broom ON Indicator

Main Broom ON IndicatorMain Broom ON Indicator

Main Broom ON Indicator

PP

PLight SensorLight Sensor

Light SensorLight Sensor

Light Sensor

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

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

SHopper Open IndicatorHopper Open Indicator

Hopper Open IndicatorHopper Open Indicator

Hopper Open Indicator

TT

THopper Overtemp IndicatorHopper Overtemp Indicator

Hopper Overtemp IndicatorHopper Overtemp Indicator

Hopper Overtemp Indicator

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

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

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

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

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

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

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

BB Coolant Temperature GaugeCoolant Temperature Gauge

Coolant Temperature GaugeCoolant Temperature Gauge

Coolant Temperature Gauge

CCCC

CC Oil Pressure GaugeOil Pressure Gauge

Oil Pressure GaugeOil Pressure Gauge

Oil Pressure Gauge

DDDD

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

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

Fuel Gauge (Gas / Diesel)

EEEE

EE VoltmeterVoltmeter

VoltmeterVoltmeter

Voltmeter

FFFF

FF Hour meterHour meter

Hour meterHour meter

Hour meter

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

A2 Control PanelA2 Control Panel

A2 Control Panel

AssemblyAssembly

Assembly

18 18

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

Repair or replace relay or

wiring. Is there 12 volts at

the BLU/PNK?

Replace engine fuse box start relay.

Location of fuse box on top of engine

No

At the K4 relay do you have

12 volts at the BLU/PNK?

Yes

No

Engine will still not crank?

No

Yes

No

Engine will not crank

Is the neutral indicator

light off at the A1 board?

The pedal is not returning

to its neutral state. Repair

any mechanical problems

to the foot pedal linkage or

hydroback.

Does the light go off?

Replace the drive pedal

sensor. Does the light go

off? (See note 4)

Reset drive pedal sensor dead band setting. Sensor

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

Turn key switch off, press and hold the engine speed

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

To change setting press the speed switch, To exit

turn key off. Does the light go off?

No

Replace the A1 control

board. Does the engine

crank?

Yes

Check for 12 volts at WHT

wire located on starter sole-

noid with the key in the start

position. If yes repair or

replace starter.

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

Possible SymptomPossible Symptom

Possible Symptom

11

1 Engine will not crank

Electrical Control CircuitElectrical Control Circuit

Electrical Control Circuit

Note 1: To test the key switch must be in the START position and foot pedal in neutral.

Note 2: Before troubleshooting check the F4 (15 amp) circuit breaker location under steering column.

Note 3: Check for 12V at the F4 machine circuit breaker. If no input voltage at the GRN/BLK wire, repair or replace wiring or key switch.

Service Adjustment Note:Service Adjustment Note:

Service Adjustment Note: 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

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