Nilfisk-Advance Captor 4300 Mechanical Repair Service Manual Download Page 1

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4/04 revised 1/06 Form Number 56043094

Captor

™

4300, 4800, 5400

CR 1100, 1200, 1400

MECHANICAL REPAIR SERVICE MANUAL

Advance MODELS 56304000, 56304001, 56304002, 56304003, 56304004,
56304005, 56304006, 56304007, 56304008
Nilfisk MODELS 56304009, 56304010, 56304011, 56304012, 56304013,
56304014, 56304015, 56304016, 56304017

This manual applies to Diesel, Gasoline/Petrol and LPG models.

Summary of Contents for Captor 4300

Page 1: ...CHANICAL REPAIR SERVICE MANUAL Advance MODELS 56304000 56304001 56304002 56304003 56304004 56304005 56304006 56304007 56304008 Nilfisk MODELS 56304009 56304010 56304011 56304012 56304013 56304014 56304015 56304016 56304017 This manual applies to Diesel Gasoline Petrol and LPG models ...

Page 2: ... 23 REMOVAL OF HYDRAULIC OIL COOLER 16 REMOVAL OF ENGINE COOLANT RADIATOR 16 REMOVAL OF HYDRAULIC ENGINE FAN MOTOR 16 ACCESSORYPUMPASSEMBLYREMOVAL 18 PROPULSION PUMP REMOVAL 18 HYDRAULIC HOSE ROUTING 20 21 HYDRAULIC SCHEMATIC 43 MODELS 22 HYDRAULIC SCHEMATIC 48 MODELS 23 HYDRAULIC SCHEMATIC 54 MODELS 24 SWEEPINGSYSTEM 26 34 MAIN BROOM MAINTENANCE 26 BROOM LEVER SWITCH S16 REPLACEMENT AND ADJUSTMEN...

Page 3: ...TOR REMOVAL 40 RECOVERYSYSTEM 42 43 TROUBLESHOOTING GUIDE 42 VACUUM RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST 42 RECOVERY TANK REMOVAL 42 VACUUM FAN MOTOR REPLACEMENT 43 SQUEEGEESYSTEM 44 47 SQUEEGEE MAINTENANCE 44 REMOVAL OF SQUEEGEE MOUNT ASSEMBLY 46 SQUEEGEE LIFT CYLINDER REMOVAL 46 ELECTRICALSYSTEM 48 49 A1 MAIN CONTROL BOARD REMOVAL 48 ENGINE DISABLED ECM REMOVAL 48 49 ENGINESYSTEM Note A...

Page 4: ...hisinformationisneededwhenordering repairpartsforthemachine UsethespacebelowtonotetheModelNumberandSerialNumberofyourmachineforfuturereference MODELNUMBER SERIALNUMBER HOPPER SAFETY SUPPORT WARNING Make sure the Hopper Safety Support KK is in place whenever attempting to do any maintenance work under or near the raised hopper The Hopper Safety Support KK holds the hopper in the raised position to ...

Page 5: ...amagewillresult justre set valve to the normal working setting A vertical NOTE Tow or push machine no faster than a normal walking pace 2 3 mph 3 5 km h and forshortdistancesonly Ifthemachineistobemovedlongdistancesthedrivewheelneedstoberaisedoffthefloorandplacedonasuitabletransport dolly OTHER MANUALS AVAILABLE ThefollowingmanualsareavailablefromtheNilfisk AdvanceLiteratureServiceDepartment foryo...

Page 6: ...nt 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 ...

Page 7: ... Drain Hose 8 Engine Air Filter 9 Left Engine Compartment Access Panel 10 Main Broom Left Access Door 11 Battery 12 Hopper Lid Prop Rod 13 Front Wheel 14 Left Side Broom 15 Hopper Lid Latch 16 Headlights 17 Right Side Broom 18 Hopper Cover 19 Dust Control Filter 20 Dust Control Shaker Assembly KNOW YOUR MACHINE 1 2 3 4 5 6 7 9 8 10 6 13 14 15 16 17 18 19 20 21 12 22 23 24 44 46 47 45 48 49 ...

Page 8: ...Latches 35 Hydraulic Charge Oil Filter 36 Hydraulic Reservoir In Tank Return Oil Filter 37 Right Engine Compartment Access Panel 38 Main Broom Right Access Door 39 Access Door Latch 40 Skirt Assembly 41 Inline Solution Filter 42 Solution Tank Drain Hose 43 Rear Roller Bumper 44 Jacking Location 45 Engine Oil Dipstick 46 Air Filter Service Indicator 47 Fuel Filter Gas Models 48 Recovery Tank Latch ...

Page 9: ... Headlight ON Indicator E Glow Plug Indicator Diesel Release key after indicator turns OFF F Hydraulic Filter Plugged Indicator G Engine Speed Switch Engine Speed Switch Indicator H Scrub Pressure Decrease Switch Scrub Pressure Decrease Indicator I Scrub Pressure Increase Switch Scrub Pressure Increase Indicator J Scrub Pressure Display K Solution Switch Solution System Indicator L Solution Tank E...

Page 10: ...r Indicator X Dust Control Switch Dust Control ON Indicator Y Side Broom UP OFF Switch Side Broom OFF Indicator Z Vacuum System Switch Vacuum System Indicator AA Scrub System OFF Switch Scrub System OFF Indicator BB Coolant Temperature Gauge CC Oil Pressure Gauge DD Fuel Gauge Gas Diesel EE Voltmeter FF Brake Pedal GG Parking Brake Latch HH Solution Flow Control Lever II Main Broom Raise Lower ON ...

Page 11: ...ULIC STEERING UNIT REMOVAL 1 Followsteps1 3intheSteeringWheelRemovalsection 2 Removethe 5 screwsthatsecurethebottomconsolepanel location operator scompartmentbelowsteeringwheel 3 SeeFigure1 Removethe 4 item C Screwsandpullofftherubber SteeringBoot D 4 Removethe 4 hexscrews 10mm thatsecurethehydraulicsteering unittoitsMountingBracket E 5 Adjustthetiltsteeringtohelpinremovingthesteerunitandseparate ...

Page 12: ...the square shaft Key M and Gear Spacer N Note The gear spacer bevel faces down to reassemble WARNING Never work under a machine without safety blocks and stands to support machine 6 Jackuptherearofthemachineapproximately24inches 60cm andputthejackstandsinplaceunderrearcornersupports Note Guide thespindleandwheelassemblyoutfromunderitsframehousingbeingcarefulnottodamageshaftthreadsandbearingsurface...

Page 13: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 11 STEERING SYSTEM L F J H M K G I P P O O Q Q N R FRONT FIGURE 3 ...

Page 14: ...ut C Note Youwillneeda1 7 16inchsocketfor castlenut seetorquenotesFigure1 5 Thread 2 1 2 13 x 2 threaded to HD Pusher Bolts D into the E Tire Hubs threaded holes 6 Jackupmachineuntilwheelclearsthefloorandplacejackstandsundermachine 7 Turn thread in equally both bolts to separate the tire assembly from the wheel motor Drive Hub F WHEEL DRIVE MOTOR REMOVAL 1 Followsteps1 7in DriveTireRemovalsection ...

Page 15: ...eelrotation NextturntheadjustmentScrew K clockwise CW orcounterclockwise CCW tomovethecablemountingbracket inorout enoughtostopanywheelmovement Thepumparmisnowinneutral tightenthetwo lockscrewstosecuretheneutralpumparmsetting 5 TesttheneutraladjustmentbyactivatingthedrivepedalinbothFWD REVtoconfirmproperwheelmotorcontrol Readjustagainifneutral settingisnotrepeatable Replacethehydrobackandoritslink...

Page 16: ...tdrivemachineforproper operation FRONT BRAKE SHOE ADJUSTMENT 1 Raisehopperandengagesafetysupport 2 See Figure 1 Remove the 6 Philips Screws B then pull the broom Housing Skirt C to the side to access the brake cable clevis 3 SeeFigure1detailofclevisadjustment lengthorshortenitsthreadedendtoobtainthecorrectbrakepedalfreeplay Notebothbrakes LH RT need to be adjusted equally 4 Ifthebrakecableclevisad...

Page 17: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 15 FRONT WHEEL SYSTEM B A C B FRONT FIGURE 1 ...

Page 18: ...frontoperatorcompartmentAccessPanels D E locatedinfrontofoperator sfeetandbelowthesteeringwheelconsole 4 Removeboththeupperandlowerradiatorhoses Note Toremovethebottomhoseworkthroughtheoperatorcompartmentaccesspanel 5 Workthroughthetwopreviouslyremovedaccesspanelstoremovethe 2 HexScrews F and 2 HexNuts G thatfastentheleftsideradiator mount 6 Removethe 6 Screws H thatholdtheradiatortoitsmount Thenc...

Page 19: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 17 HYDRAULIC SYSTEM H K B L G F I J A C B D E FRONT FIGURE 1 ...

Page 20: ...hethreeseparatesetsofinstructionsinthis manualsection 2 SeeFigure2 RemovetheSenseSwitch R securedwiththeScrew S fromtheLeverWeldment T Note DonotlosethesmallBushing U and Washer V 3 Disconnect the Ball Joint cable rod end W from the Lever T 4 Removetheleverweldmentfromthepropulsionpumpshaftsecuredbyhardwareitems X Y 5 Disconnect the 4 Hoses Z AA AB AC as shown from the propulsion pump plug and cap...

Page 21: ... NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 19 HYDRAULIC SYSTEM M N O P Q R V S U T X Y W AD AD AE Z AA AB AC FRONT 1 2 socket 3 8 drive 9 16 box end wrench 12 point 2 3 4 AE weld FIGURE 2 FIGURE 3 ...

Page 22: ...3094 Captor 4300 4800 5400 CR 1100 1200 1400 HYDRAULIC SYSTEM revised 1 06 HYDRAULIC HOSE ROUTING INSTRUCTIONS WHEEL DRIVE MOTOR Theillustrationsbelowshowtheproperroutingforthehydraulichoseswhichfeedthewheeldrivemotor ...

Page 23: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 21 HYDRAULIC SYSTEM revised 1 06 HYDRAULIC HOSE ROUTING INSTRUCTIONS WHEEL DRIVE MOTOR CONTINUED ...

Page 24: ...22 FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 HYDRAULIC SYSTEM Hydraulic Schematic 43 models ...

Page 25: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 23 HYDRAULIC SYSTEM Hydraulic Schematic 48 models ...

Page 26: ...24 FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 HYDRAULIC SYSTEM Hydraulic Schematic 54 models ...

Page 27: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 25 HYDRAULIC SYSTEM This Page is Intentionally Blank ...

Page 28: ...reandre installtheT Boltthatholdstheidlerarminplace 8 CloseandlatchtheMainBroomRightAccessDoor 38 To Adjust the Main Broom Height 1 Drive the machine to an area with a level floor and set the parking brake GG 2 PulltheMainBroomRaise Lower ON OFF Lever II backandslidetotherightanduptolowerthemainbroom Pushlightlyonthefront oftheDrivePedal OO tostartthemainbroomrotating DONOTmovethemachine 3 Letthem...

Page 29: ...nthebroomleverisintheraised stored positionandnocontinuitywhenleverislowered insweeppositions Thebroom switchtypeismagneticandtheswitchcircuitisclosedwhenplacednexttothemetalbroomlever 5 Tightenscrews reconnectswitchwiringandtestforproperoperation MAIN SWEEPING BROOM MOTOR REMOVAL 1 Lowerthemainbroomthenremovethebroomfromitshousing 2 See Figure 2 Mark the broom motor hydraulic hoses for reassembly...

Page 30: ...OWN ONSwitch N ortheSideBroomUP OFFSwitch Y untilthedesiredamountofbristlesarecontactingthefloor NOTE ThemachineshouldbestoredwiththeSideBroom s intheraisedposition TheSideBroom s shouldbereplacedwhenthebristlesare worntoalengthof3inches 7 62cm ortheybecomeineffective ToreplacetheSideBroom 1 RaisetheSideBroom s 2 See Figure 4 Reach under the Side Broom and remove the large Thumb Nut T holding the ...

Page 31: ... Mark and remove the hydraulic hoses to the motor that needs to be serviced plug and cap 4 SeeFigure4 Pulloutmotorbracketto extend gainaccesstomotormountinghardware Thenremovethe 2 U Screwsand V Nuts thatfastensthemotortoitsmount Completetheremovalofthemotorbyliftingitthroughtheholeonthemotorbracket 5 Salvage the motor Drive Hub W Use a pin punch to drive out the Roll Pin X and pull the hub from t...

Page 32: ...untedpositionandthenrestitonthecornerofthemount thisneedstobedonetoaccesstherear actuatormotormount NextremovetheHairpin AA fromitsmountpin 6 RemoveboththefrontRetainerRing AB andtheMountPin AC thatattachestheactuatordrivetubetotheLiftingShaftWeldment AD Thenpullouttheliftmotortocompleteitsremovalfromthemachine Installation ServiceNote Newreplacementliftactuatormotorsdonotcomewithliftdrivetubepre ...

Page 33: ...drivenuttube AE andpresstheswitchtorunthedrivenuttowardsthemotorhousing it sINlimit 4 MeasurethepositionofthedrivenutontheactuatorshaftthencompareittotheretracteddimensionspecificationshowninFigure6 Manually turnthesteeldrivenuttubetomatchtheINpositionshown 5 See Figure 6 B Connect the jumper wiring to run the actuator motor in the extended OUT mode Next hold the drive nut tube AE and presstheswit...

Page 34: ...K LIST Complaint Possible Cause Leaving debris behind Rearskirtdamaged Main broom worn Mainbroomoutofadjustment Hopperfull Debriscomingoutsides Wornsideskirts Mainbroomnotlevel Hopperfull Not sweeping evenly Rear skirt worn Mainbroomnotlevel Main broom worn Sidebroomkickingoutdebris Sidebroomoutofadjustment Sidebroomanglenotcorrect Poorsweepingperformance Main broom worn Mainbroomoutofadjustment W...

Page 35: ... center Nut AO and washer from impellermotorshaftandremoveImpellerFan AP 7 Remove the four Nuts AQ from impeller bracketandremovemotorfrombracket 8 Reassembleinreverseorder Note Besure theimpellerassemblyismountedwiththecase drain smallhose onmotorfacingdown 1 Removebothsidebrushdeckskirtassemblies andalsothesqueegeetool 2 Draintherecoverytankthenremovethetank completelyfromthemachinebydisconnecti...

Page 36: ...fromthebroomhangermount 11 Loosenthecablecasinganchorjamnutsandpullthecablefromitsmountingbracket Note Alsoremovethejamnutsfromthecablecasing 12 RemovetheA1controlleraccesspanel 4screws locatedinthedriver scompartmentbelowthesolutionlever 13 RemovetheA1controlboxtohelproutethecablethroughthemachinechassis 14 Removeallthejamnutsfromthenewcablethenattachsecurelythenewcabletotheoldcableatthelowerbroo...

Page 37: ... AND REPLACEMENT To access Hopper should be empty Raise and support the hopper open the dump door WARNING Do not have engine running when working under hopper Qty Description A 1 Blade B 1 HopperBoot C 1 DustShieldBlade D 2 DumpDoorWiper E 1 SealHorizontal F 2 Hopper Door Blade G 1 HopperSkirt B C A G E F D D FRONT ...

Page 38: ...e Markhoselocationstoinsurecorrectconnectionswhenreassembling CAUTION There may be oil in hoses and cylinder be prepared to plug hoses and cap cylinder connections 2 Remove lower and upper cotter pins and Cylinder Pins L 3 Removecylinder Toreassemble 1 Mountcylinderendtouppermountingbracketusingpinandcotterpin 2 Pullcylinderrodoutuntilclevismeetswithdumpdoorarm 3 Mount cylinder rod end to dump doo...

Page 39: ...tthebattery 3 Separatetheengine sECUmodule wiringharnesslocatedonthefrontengineaccesspanel thenremovetheengineaccessdoorpanel 4 Remove the Retaining Ring M from the Rod Pin N and completely remove the pin 5 RemovetheScrew O thatfastensthelowerHingePinWeldment P tothechassisthenprypintotheside 6 Pullthehoppercylinderforwardandremovethetwohydraulichoppercylinderhosestocompletecylinderremovalfrommach...

Page 40: ...ontrolboxandrelaybracketassemblytoroutethecablethroughthemachinechassis 8 Fromunderneaththemachineatthesolutioncontrolvalvearmremoveitscableballjointend Nextloosenthecablecasinganchorhardware andpullthecablefreefromitsslottedmountingbracket 9 Removethe 2 cableP clamps E thatfastenthecablecasingtothemachineframe 10 Attach wireortapetogether anewsolutioncabletotheendofdefectivecableatthesolutionvalv...

Page 41: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 39 SOLUTION SYSTEM E D C A B C F G FRONT FIGURE 1 ...

Page 42: ...K ASSEMBLY INSTALLATION Installationnoteforthelowerscrubdeckliftcylindermountingbolt Positionthebottomendofthehydraulicliftcylinderdirectlyoveritsdeckmount attachmentpoint pocket Thenstartengine runathighspeed andlowerthecylinderbypressingeithertheoperatorincreaseordecreaseswitch WiththecylinderextendedinserttheMountingBolt G andtightentofinishthedeckinstallation SCRUB DECK CYLINDER REMOVAL 1 Remo...

Page 43: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 41 SCRUB SYSTEM G C F A L B J E K D 41 46 22 18 16 H 56 FRONT FIGURE 1 ...

Page 44: ...ctionsdecreasethequantityofairflowingthroughthesqueegeetool Theairthatdoesgothroughthesqueegeetoolmoves slower so it has less pick up power VACUUM RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST Wheneverthereisavacuumproblem it sbesttocheckovertheentiresystem Usethechecklistbelowasaguide tothoroughlycheckthevacuum system Cleanbuilt updirtfromtheinsideofthesqueegeetool Replace the squeegee blades if ...

Page 45: ... C secured by the Hex Nut D Note Do not lose the Fan Spacer E and the Keyway F 4 Removethethreehydraulichoses 18 20 21atthemotorfittings GeneralServiceNote Capandplugthemotorfittingsandhoses 5 Removethe 4 item G HexNutsthenseparatethemotorplateassemblyfromtheirmountingstudstoremoveassemblyfromthemachine Thenremovethe 4 ScrewsandNutsitem H I thatfastensthevacuumfanmotortoitsmountplate 6 Reassemblet...

Page 46: ...as 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large radius 4 Installtheblade followingthestepsinreverseorderandadjustthesqueegeetilt To reverse or replace the front squeegee blade 1 DisconnecttheSqueegeeHosefromthesqueegeetool 2 Loosenthe 2 SqueegeeLevers G andslidethesqueegeeassembly...

Page 47: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 45 SQUEEGEE SYSTEM FIGURE 1 revised 1 06 ...

Page 48: ...aiseittowherethecylinderrodendisinstalledthroughitsmountinghole Theninstallthewasher andnuttoretaintheliftcylindertothemount Note Tightencylindernutsothereisnoplaybetweenthecylinderandmount butdonotover tighten 3 Remount the squeegee tool and test squeegee for proper water pick up See in this manual Squeegee Maintenance for tool adjustment instructions SQUEEGEE LIFT CYLINDER REMOVAL 1 Removethesqu...

Page 49: ...FORM NO 56043094 Captor 4300 4800 5400 CR 1100 1200 1400 47 SQUEEGEE SYSTEM FRONT M L K J J K FIGURE 2 ...

Page 50: ...tcornerofthecompartmentopening Thiswillallowadditionalclearancetoremove theboard 6 CarefullymaneuverthetightfittingA1boardfromitschassiscompartment ENGINE DISABLED ECM REMOVAL 1 Turn the LP fuel tank service valve off if servicing an LP model 2 Open the top engine cover and remove the long console cover secured with 2 wing nuts 3 Positionaflashlightbetweenthehopper leftside andenginepaneltoviewthe...

Page 51: ...rapped fuel in a well ventilated area 9 Removethe 2 Screws H thatfastentheLPRegulatorAssembly I tothemachinechassis Nextusingasmalllockingplierspinchoffthe regulator swaterCoolantHose J closesttothefuellock offvalve Thenpulltheregulatorupenoughtoremovethecoolanthoseandclamp 10 Position hang thecompletefuelregulatorassemblyandmountontheoutsideoftheenginecompartment Thisstepisdonetocreatetheneeded w...

Page 52: ...Advance A E Tel 30 8 Thoukididou Str 210 963 3443 Argioupoli Fax 30 Gr 164 52 Athens 210 965 0975 Greece Holland Sales Sub Nilfisk Advance B V Phone 31 Camerastraat 9 2e verdieping 36 546 07 00 1322 BB Almere Fax 31 Postbus 60112 36 523 51 48 1320 AC Almere www nilfisk advance nl Ireland Sales Sub Nilfisk Advance Limited Phone 35 28 Sandyford Office Park 3 12 94 38 38 Sandyford Dublin 18 Fax 35 Ir...

Page 53: ...42 Fuitian Free Trade Zone Fax 86 755 518038 Shenzhen 8359 1063 P R China China Suzhou Nilfisk Advance Professional Phone 86 512 Cleaning Equipment Suzhou Co Ltd 8918 5656 306 Su Hong Zhong Road Build 2 Fax 86 512 Suzhou Industrial Park 8918 5666 215021 Suzhou P R China Hong Kong Sales Sub Nilfisk Advance Ltd Phone 852 2001 HK Worsted Mills Ind l Bldg 2427 5951 31 39 Wo Tong Tsui St Fax 852 Kwai C...

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