Nilfisk-Advance Captor 4300 Mechanical Repair Service Manual

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Page 1 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. 4/04 revised 1/06 Form Number 56043094...
Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION ........................... 2-3 SAFETY INSTRUCTIONS ..........................4 KNOW YOUR MACHINE ..........................5-6 OPERATOR’S COMPARTMENT ........................7-8 STEERING SYSTEM ..........................9-11 STEERING WHEEL REMOVAL ........................9 HYDRAULIC STEERING UNIT REMOVAL ....................9 HYDRAULIC STEERING CYLINDER REMOVAL ..................10 WEAR ADJUSTMENT FOR CYLINDER RACK ...................
Page 3 TABLE OF CONTENTS SOLUTION SYSTEM ..........................38-39 SOLUTION TANK REMOVAL ........................38 SOLUTION VALVE CONTROL CABLE REPLACEMENT ................38 TROUBLESHOOTING GUIDE ........................38 SOLUTION SYSTEM MAINTENANCE ......................38 SCRUBBING SYSTEM ..........................40-41 SCRUB DECK ASSEMBLY REMOVAL ......................40 SCRUB DECK ASSEMBLY INSTALLATION ....................40 SCRUB DECK CYLINDER REMOVAL ......................
Page 4: General Information
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 5-6 i.e. (B).
Page 5 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. BOTTOM VIEW OF HYDROSTATIC PUMP OTHER MANUALS AVAILABLE 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) •...
Page 6: Safety Instructions
CAUTIONS AND WARNINGS 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! Is used to warn of immediate hazards that will cause severe personal injury or death.
Page 7: Know Your Machine
KNOW YOUR MACHINE Operator’s Seat 11 Battery Strobe Light (optional) 12 Hopper Lid Prop Rod Solution Tank Fill 13 Front Wheel Gasoline Tank Cap 14 Left Side Broom Fuel Tank 15 Hopper Lid Latch Tie Down Locations 16 Headlights Recovery Tank Drain Hose 17 Right Side Broom Engine Air Filter 18 Hopper Cover...
Page 8: Know Your Machine
KNOW YOUR MACHINE 21 Shaker Assembly Latch 36 Hydraulic Reservoir / In Tank Return Oil Filter 22 Engine Compartment Door 37 Right Engine Compartment Access Panel 23 Coolant Recovery Tank 38 Main Broom Right Access Door 24 Steering Wheel 39 Access Door Latch 25 Squeegee Handle 40 Skirt Assembly 26 Squeegee Tool Assembly...
Page 9: Operator's Compartment
OPERATOR'S COMPARTMENT Low Fuel Indicator (LP) Scrub Pressure Increase Switch Horn Switch Scrub Pressure Increase Indicator Horn ON Indicator Scrub Pressure Display Engine Service Indicator (triggered by ECU) Solution Switch Headlight Switch Solution System Indicator Headlight ON Indicator Solution Tank Empty Indicator Glow Plug Indicator (Diesel / Release key after indicator turns OFF) Recovery Tank Full Indicator Hydraulic Filter Plugged Indicator...
Page 10 OPERATOR'S COMPARTMENT Light Sensor AA Scrub System OFF Switch Shaker Switch Scrub System OFF Indicator Shaker Indicator (left) BB Coolant Temperature Gauge Dust Filter Plugged Indicator (right) CC Oil Pressure Gauge Open Dump Door Switch DD Fuel Gauge (Gas / Diesel) Open Dump Door Indicator EE Voltmeter Hopper Open Indicator...
Page 11: Steering System
STEERING SYSTEM FIGURE 1 STEERING WHEEL REMOVAL See Figure 1. Pry up steering wheel Cap (A). Remove center hex Nut (B). Note: This is a metric nut, you will need a 24mm socket. Use a steering wheel puller to remove steering wheel from splined FRONT shaft.
Page 12: Hydraulic Steering Cylinder Removal
STEERING SYSTEM HYDRAULIC STEERING CYLINDER REMOVAL Remove the recovery tank assembly from the machine. Follow steps in the Solution Tank Removal section. Remove the (2) screws that secure the electrical relay mount assembly and pull it out from the control box compartment. See Figure 3.
Page 13 STEERING SYSTEM FIGURE 3 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 11 ™...
Page 14: Wheel Drive System
WHEEL DRIVE SYSTEM DRIVE TIRE REMOVAL WARNING! Never work under a machine without safety block or stands to support machine. Disconnect battery before servicing. Turn steering wheel to the right full lock position and also remove the squeegee tool. Turn off engine, set parking brake and block front wheels. See Figure 1.
Page 15: Hydroback Drive Pedal Neutral Adjustment
WHEEL DRIVE SYSTEM HYDROBACK DRIVE PEDAL NEUTRAL ADJUSTMENT When servicing the hydrostatic drive system, always check for any machine creeping (movement) in the neutral position. The machine must not move in either Fwd or Rev after the drive pedal is released. If machine creeping is experienced the neutral position of the hydro back must be adjusted. WARNING! Use jack stands to support the machine when setting the neutral drive pedal adjustment.
Page 16: Front Wheel System
FRONT WHEEL SYSTEM FRONT WHEEL REMOVAL AND BRAKE INSPECTION Raise hopper and engage safety support. Open broom-housing door (LH or RT) and remove the top gasket seal (so not to damage). Place jack towards front of housing and jack on machine frame to where the front wheel clears the floor.
Page 17 FRONT WHEEL SYSTEM FIGURE 1 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 15 ™...
Page 18: Hydraulic System
HYDRAULIC SYSTEM REMOVAL OF HYDRAULIC OIL COOLER CAUTION! Disconnect the battery before servicing. Remove the right side engine panel. See Figure 1. Remove the (2) hydraulic hoses attached to the Pre-charge Filter Housing (A). Then remove the (2) inlet and outlet oil cooler hoses (plug and cap all hoses).
Page 19 HYDRAULIC SYSTEM FIGURE 1 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 17 ™...
Page 20: Accessory Pump Assembly Removal
HYDRAULIC SYSTEM ACCESSORY PUMP ASSEMBLY REMOVAL CAUTION! Disconnect the battery before servicing. Remove right side engine panel. See Figure 2. Disconnect the (3) accessory pump Outlet Hoses (M, N & O) (plug & cap). Remove the (3) tee fittings from the pump housing assembly and plug. Note: The fittings need to be removed to access the right housing mounting bolt.
Page 21 HYDRAULIC SYSTEM FIGURE 2 FRONT FIGURE 3 1/2" socket (3/8" drive) 9/16" box end wrench (12 point) weld 2-3/4" FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 19 ™...
Page 22: Hydraulic Hose Routing
HYDRAULIC SYSTEM HYDRAULIC HOSE ROUTING INSTRUCTIONS WHEEL DRIVE MOTOR The illustrations below show the proper routing for the hydraulic hoses which feed the wheel drive motor. 20 - FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 revised 1/06 ™...
Page 23: Hydraulic Hose Routing
HYDRAULIC SYSTEM HYDRAULIC HOSE ROUTING INSTRUCTIONS WHEEL DRIVE MOTOR (CONTINUED) revised 1/06 FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 21 ™...
Page 24: Hydraulic Schematic 43" Models
HYDRAULIC SYSTEM 22 - FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 ™...
Page 25: Hydraulic Schematic 48" Models
HYDRAULIC SYSTEM FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 23 ™...
Page 26: Hydraulic Schematic 54" Models
HYDRAULIC SYSTEM 24 - FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 ™...
Page 27 HYDRAULIC SYSTEM This Page is Intentionally Blank FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 25 ™...
Page 28: Sweeping System
SWEEPING SYSTEM MAIN BROOM MAINTENANCE Since the Main Broom Motor always turns in the same direction, the bristles on the broom eventually become curved, reducing sweeping performance. Sweeping performance can be improved by removing the broom and turning it around (end-for-end). This procedure, known as “rotating” the main broom, should be done once every 30 hours of operation.
Page 29: Broom Lever Switch S16 Replacement And Adjustment
SWEEPING SYSTEM BROOM LEVER SWITCH S16 REPLACEMENT AND ADJUSTMENT Drain, unlatch and swing open the recovery tank to locate the switch access panel. Remove the (4) screws from the access panel near the location of the broom lever. Remove the two wire connectors from the broom switch (S16) and then remove the screw and nut that fasten it to the chassis. Install new switch but leave the mounting screws loose.
Page 30: Side Broom Maintenance
SWEEPING SYSTEM SIDE BROOM MAINTENANCE The side broom(s) move dirt and debris away from walls or curbs and into the path of the main broom. Adjust the side broom so that the bristles are contacting the floor from the 10 O’clock (R) to the 3 O’clock (S) area shown in Figure 3 when the broom is down and running. To adjust the Side Broom...
Page 31: Side Broom Motor Removal
SWEEPING SYSTEM SIDE BROOM MOTOR REMOVAL Lower the side broom(s). Note: The main broom must be first lowered to allow the side brooms to be lowered. Raise hopper to a comfortable work position (eye level). Then remove the side broom and plastic broom guard. Mark and remove the hydraulic hoses to the motor that needs to be serviced (plug and cap).
Page 32: Side Broom Lift Actuator Motor Replacement
SWEEPING SYSTEM SIDE BROOM LIFT ACTUATOR MOTOR REPLACEMENT Removal Place the side brooms in the lowered position if possible or blocking underneath the brooms to remove weight from the lift linkage. Open hopper cover, set cover prop rod, remove hopper filter, and latch filter rack. Then remove the hopper access panel held in-place by (11) Philips head screws.
Page 33: Side Broom Lift Actuator Motor Adjustment
SWEEPING SYSTEM SIDE BROOM LIFT ACTUATOR MOTOR ADJUSTMENT See Figure 6. This shows the jumper wiring needed to connect the machine’s battery to the actuator motor’s three-wire connector. Note: Reference the bill of material for building the two jumper wires. Important Service Note: The P.N. 56407502 power cord adapter normally used on all other two-wire actuator motors should not be used.
Page 34: Skirt Identification And Replacement
SWEEPING SYSTEM SKIRT IDENTIFICATION AND REPLACEMENT FIGURE 7 Description Broom Housing Skirt Broom Door Skirt Rear Skirt Rear Skirt FRONT SWEEPING PERFORMANCE CHECK LIST Complaint Possible Cause Leaving debris behind Rear skirt damaged Main broom worn Main broom out of adjustment Hopper full Debris coming out sides Worn side skirts...
Page 35: Impeller Motor Removal
SWEEPING SYSTEM FIGURE 8 IMPELLER MOTOR REMOVAL WARNING! Remove key and disconnect battery before servicing impeller. Raise and support hopper cover. See Figure 8. Raise and support shaker assembly and remove Filter (AK). Remove 11 bolts from access cover and remove cover.
Page 36: Sweeping System
SWEEPING SYSTEM MAIN BROOM LIFT CABLE REPLACEMENT (CONTINUED) Start the engine and lower the scrub deck and then remove the rear engine panel to access the exhaust system. CAUTION! Allow a hot exhaust system to cool before disassembling. See Figure 10. Remove the (2) item (AW) Exhaust Flange Bolts and separate the exhaust pipe inlet tubing Connection (AX). Next remove the Muffler Clamp (AY) and separate the outlet exhaust Tube (AZ) from the muffler.
Page 37: Hopper System
HOPPER SYSTEM SEALS AND SKIRTS IDENTIFICATION 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. Description Blade Hopper Boot Dust Shield Blade Dump Door Wiper Seal Horizontal Hopper Door Blade...
Page 38: Dump Door Cylinder Removal
HOPPER SYSTEM FIGURE 2 FRONT DUMP DOOR CYLINDER REMOVAL To access: Raise Hopper Cover and engage hopper cover prop rod. See Figure 2. Raise and support Shaker Assembly (H). Remove filter assembly. Remove (11) Bolts (I) and remove Access Panel (J). To remove cylinder: Remove the two hoses from Door Cylinder (K).
Page 39: Hopper Lift Cylinder Removal
HOPPER SYSTEM HOPPER LIFT CYLINDER REMOVAL Note: To remove the cylinder it is necessary for the hopper to be in the raised position. If the cylinder will not raise under its own power it will be necessary to press and hold the hopper raise switch with the key switch on and raise the hopper with an overhead hoist or some other alternate method.
Page 40: Solution System
SOLUTION SYSTEM SOLUTION TANK REMOVAL Drain both the solution and recovery tanks using the tanks’ drain hoses, then start machine and lower the scrub deck. Remove the A1 control board Access Panel (A) and disconnect the solution float wire harness connector. Swing open the recovery tank, separate the support strap, and disconnect tank full indicator wiring harness and lift tank off its hinge plate.
Page 41 SOLUTION SYSTEM FIGURE 1 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 39 ™...
Page 42: Scrubbing System
SCRUB SYSTEM SCRUB DECK ASSEMBLY REMOVAL Remove both scrub deck side skirt assemblies. Then lower the scrub deck and leave the scrub brushes on so that the deck can slide easily to remove. See Figure 1. Loosen the Hose Clamp (A) and pry the solution feed hose off from the solution manifold barbed Fitting (B). Important General Service Note: When removing hydraulic hoses cap and plug all open hoses and fittings.
Page 43: Scrub System
SCRUB SYSTEM FIGURE 1 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 41 ™...
Page 44: Recovery System
RECOVERY SYSTEM TROUBLESHOOTING GUIDE If water flows around the ends of the squeegee tool, instead of being pulled into the tool, the vacuum system is not working properly. When a vacuum system performs poorly, it is usually because of one of the following problems: Vacuum Leak(s) –...
Page 45: Vacuum Fan Motor Replacement
RECOVERY SYSTEM VACUUM FAN MOTOR REPLACEMENT Remove recovery tank; following the steps in Recovery Tank Removal manual section. See Figure 2. Remove the Top Plate (A) held in place by (4) item (B) hex HD screws. Remove the Vacuum Fan (C) secured by the Hex Nut (D). Note: Do not lose the Fan Spacer (E) and the Keyway (F). Remove the three hydraulic hoses #18, #20 &...
Page 46: Squeegee System
SQUEEGEE SYSTEM SQUEEGEE MAINTENANCE After each use, clean the squeegee tool and check the blades for damage. If the squeegee leaves water in the middle of its path or at both ends of its path, it probably needs to be adjusted. Reverse or replace the blades if they are cut, torn, wavy or worn. To adjust the squeegee: Park the machine on a level floor, lower the squeegee and drive forward a short distance.
Page 47 SQUEEGEE SYSTEM FIGURE 1 revised 1/06 FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 45 ™...
Page 48: Removal Of Squeegee Mount Assembly
SQUEEGEE SYSTEM REMOVAL OF SQUEEGEE MOUNT ASSEMBLY Remove the squeegee tool assembly from the machine then start the engine and lower the squeegee mount. See Figure 3. Remove the (4) Parallel Arms (J) (two per side) from the squeegee mount Towers (K) as shown. This will allow movement of the Mount Assembly (L) and allow easy access to the lift cylinder rod Nut (M).
Page 49: Squeegee System
SQUEEGEE SYSTEM FIGURE 2 FRONT FORM NO. 56043094 / Captor 4300, 4800, 5400 / CR 1100, 1200, 1400 - 47 ™...
Page 50: Electrical System
ELECTRICAL SYSTEM A1 MAIN CONTROL BOARD REMOVAL WARNING! Disconnect the battery before servicing. Set the foot pedal activated parking brake (press it all the way forward). Remove the A1 board’s Access Panel (A) held in place by (4) screws. Remove the Relay Bracket Assembly (B) fastened by (2) screws from the control board compartment. Then lay the relay bracket to the side onto the floor plate.
Page 51 ELECTRICAL SYSTEM ENGINE DISABLED ECM REMOVAL (CONTINUED) If servicing a gasoline model skip the next two steps. LP Model Disconnect the wire connector at the LP fuel lock-off Valve (F). Then remove the LP Fuel Feed Hose (G) at the fuel lock-off valve. CAUTION! Wear gloves to protect hands from possible fuel frosting and vent trapped fuel in a well-ventilated area.
Page 52 Austria (Sales Sub) Holland (Sales Sub) Nilﬁ sk-Advance GmbH Phone: +43 Nilﬁ sk-Advance B.V. Phone: +31 Voralberger Allee 46 1616 58 30 22 Camerastraat 9 (2e verdieping) 36 546 07 00 A-1230 Wien Fax: +43 1322 BB Almere Fax: +31 info@nilﬁ...
Page 53 Sweden (Prod.) Hong Kong (Sales Sub) Nilﬁ sk-Advance A/S Phone: +46 Nilﬁ sk-Advance Ltd. Phone: +852 Åmål Branch 5321 7500 2001 HK Worsted Mills Ind’l Bldg., 2427 5951 Strömsbergsgatan Fax: +46 31-39 Wo Tong Tsui St. Fax: +852 Box 127 5321 7595 Kwai Chung, Hong Kong 2487 5828...

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Nilfisk-Advance Captor 4300 Mechanical Repair Service Manual

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