Captor™ 4300b, 4800b Cr 1100b, 1200b

Transcript

Captor™ 4300B, 4800B CR 1100B, 1200B QUICK START TROUBLESHOOTING SERVICE MANUAL Advance MODELS 56303000 (4800 battery), 56303001 (4300 battery) Nilfisk MODELS 56303004 (CR 1200 battery), 56303005 (CR 1100 battery) 10/04 revised 1/05 FORM NO. 56043095 TABLE OF CONTENTS GENERAL INFORMATION ................................................................................................................................................1-2 SAFETY INSTRUCTIONS .................................................................................................................................................... 3 SPECIFICATIONS .............................................................................................................................................................4-5 MAINTENANCE .................................................................................................................................................................6-7 PM CHECKLIST ................................................................................................................................................................8-9 KNOW YOUR MACHINE ...............................................................................................................................................10-21 MAIN CONTROLLER SELF-DIAGNOSTIC TEST MODE ................................................................................................ 18 MAIN CONTROLLER ERROR CODES.......................................................................................................................19-21 GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ................................................................. 22 WHEEL DRIVE SYSTEM...............................................................................................................................................23-28 FLOWCHART ................................................................................................................................................................... 23 TROUBLESHOOTING GUIDE ......................................................................................................................................... 25 DRIVE AND ACCESSORY FUNCTIONS ....................................................................................................................27-28 STEERING SYSTEM .......................................................................................................................................................... 29 POWER STEERING ......................................................................................................................................................... 29 SWEEPING SYSTEM ....................................................................................................................................................30-35 MAIN BROOM .............................................................................................................................................................30-31 SIDE BROOMS............................................................................................................................................................32-33 SIDE BROOM LIFT ACTUATOR .................................................................................................................................34-35 HYDRAULIC SYSTEM ..................................................................................................................................................36-37 HYDRAULIC PUMP MOTOR.......................................................................................................................................36-37 HOPPER SYSTEM ........................................................................................................................................................38-45 HOPPER DUMP DOOR ..............................................................................................................................................38-40 HOPPER ......................................................................................................................................................................42-45 SQUEEGEE SYSTEM ........................................................................................................................................................ 46 SQUEEGEE ...................................................................................................................................................................... 46 VACUUM SYSTEM ........................................................................................................................................................47-48 VACUUM MOTOR .......................................................................................................................................................47-48 DUST CONTROL SYSTEM ...........................................................................................................................................49-51 IMPELLER MOTOR .....................................................................................................................................................49-50 SHAKER MOTOR ............................................................................................................................................................. 51 SCRUB SYSTEM...........................................................................................................................................................52-56 SCRUB DECK LIFT .....................................................................................................................................................52-54 SCRUB MOTORS ........................................................................................................................................................55-56 SOLUTION SYSTEM .......................................................................................................................................................... 57 SOLUTION SOLENOID VALVE ........................................................................................................................................ 57 PROGRAMMABLE CONTROL OPTIONS.....................................................................................................................58-66 ELECTRICAL SYSTEM .................................................................................................................................................67-81 CURTIS CONTROLLER DIAGNOSTICS ......................................................................................................................... 67 STATUS LED FAULT CODES (TABLE 1) ....................................................................................................................... 68 INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER .................................................................... 69 PROGRAMMER OPERATION ..................................................................................................................................70-72 OPERATING MODES ................................................................................................................................................72-76 ELECTRICAL COMPONENT LOCATION ........................................................................................................................ 77 WIRING LADDER DIAGRAM (BEFORE SN 1767238) .................................................................................................... 78 WIRING SCHEMATIC (BEFORE SN 1767238) ............................................................................................................... 78 WIRING LADDER DIAGRAM (AFTER SN 1767237) ....................................................................................................... 80 WIRING SCHEMATIC (AFTER SN 1767237 BUT BEFORE SN 1808249)...................................................................... 81 WIRING SCHEMATIC (AFTER SN 1808248) .................................................................................................................. 82 HYDRAULIC SYSTEM ....................................................................................................................................................... 83 HYDRAULIC COMPONENT LOCATION .......................................................................................................................... 83 HYDRAULIC SCHEMATIC ............................................................................................................................................... 83 Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point. revised 1/05 2 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B 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 10-13 i.e. (B). This product is intended for commercial use only. PARTS 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 PLATE The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed when ordering repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference. MODEL NUMBER SERIAL NUMBER FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 1 GENERAL INFORMATION HOPPER SAFETY SUPPORT WARNING! Make sure the Hopper Safety Support (A) is in place whenever attempting to do any maintenance work under or near the raised hopper. The Hopper Safety Support (A) holds the hopper in the raised position to allow work to be performed under the hopper. NEVER rely on the machine’s hydraulic components to safely support the hopper. JACKING THE MACHINE CAUTION! Never work under a machine without safety stands or blocks to support the machine. • When jacking the machine, do so at designated locations (Do Not jack on the hopper) – see jacking locations (11). TRANSPORTING THE MACHINE CAUTION! Before transporting the machine on an open truck or trailer, make sure that . . . • • • All access doors are latched securely. The machine is tied down securely - see tie-down locations (4). The machine parking brake is set. A OTHER MANUALS AVAILABLE The following manuals are available from the Nilfisk-Advance Literature Service Department, for your Rider Scrubber/Sweeper: • Parts List - Form Numbers 56042441 • Operation Manual - Form Numbers 56041565 (Danish, Norwegian, Swedish, Finnish) 56041566 (German, French, Dutch, Russian) 56041567 (Spanish, Portuguese, Italian, Greek) 56041575 (Estonian, Latvian, Lithuanian, Slovenian) 56041576 (Slovakian, Czech, Polish, Hungarian) 56041577 (English) • Mechanical Repair Service Manual 56043096 2 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B 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. WARNING! Is used to call attention to a situation that could cause severe personal injury. CAUTION! Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property. GENERAL SAFETY INSTRUCTIONS Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm. • • • • • • • • • • • • • • • • • • 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. Clean only while ascending (driving up) the ramp. Keep sparks, flame and smoking materials away from the battery. Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open flame. Do not smoke while charging the batteries. 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. 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. SAVE THESE INSTRUCTIONS FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 3 SPECIFICATIONS General Specifications common to All Models English (Metric) Dimensions Length 105 inches (267cm) Height 59 inches (150cm) Height w/overhead guard 79 inches (200cm) Ground clearance 3 inches (7.6cm) Minimum ceiling height dumping clearance 92 inches (233.6cm) Weights 43” 48” Net weight* 3197 lbs. (1450kg) 3200 lbs. (1451kg) Gross weight** 5535 lbs. (2510kg) 5702 lbs. (2586kg) Speed and Gradeability Maximum travel speed / Maximum reverse speed 6 mph (9.6km/h) / 4 mph (6.4km/h) Maximum grade angle scrubbing 7.5 deg. Maximum grade angle non-scrubbing 12 deg. Sound Level At operators ear 77.2 dBA Sweep System Sweeping path w/out side broom(s) 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) Main broom speed 380 RPM Side broom speed 100 RPM Hopper System Capacity 9.2 Cu. Ft. (261l) Lifting capacity 550 lbs. (250kg) Dump height (variable) Max. 60 inches (152cm) Dump height with door open 56-1/2 inches (143.5cm) Dust Control System Filter type: Pleated paper panel Filter dimension 3-3/16” x 20” x 27” (8cm x 50.8cm x 68.5cm) Filter media area 78 ft2 (7.25m2) Steering System Type: Power assisted chain drive Turns lock to lock right: 2-1/2 Turns lock to lock left: 2-1/2 Minimum aisle turn width 118 in. (300cm) left and right Hydraulic System Oil type: SAE 10W-30 System fill capacity 1.7 qts. (1.6l) Recovery System Vacuum water lift (sealed) minimum 72 inches Vacuum water lift (open hole adapter 1”) minimum 6.3 inches Electrical System Battery compartment size Width 18.25” (46.35cm) Height 23.75” (60.32cm) Length 38.75” (98.42cm) Battery Weight and Dimensions Maximum weight: 770 Amp/Hr @ 6 hrs 1875 lbs. (850.5kg) / 38.69” (98.3cm) L x 18” (45.7cm) W x 22.81” (57.9cm) H Minimum weight: 510 Amp/Hr @ 6 hrs 1480 lbs. (635kg) / 38.05” (96.6cm) L x 15.54” (39.5cm) W x 22.81” (57.9cm) H *Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and battery removed. **Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and maximum sized battery (770AH). 4 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B SPECIFICATIONS Specifications common to Deck Size Model designation: (43”) = Captor 4300 / CR 1100 Width w/out squeegee & deck Solution Tank Capacity Recovery Tank Capacity Scrubbing Rate per hour Sweeping path w/side brooms (2) Sweeping path w/side broom (1) Sweeping rate per hour Scrub Brush quantity Scrub Brush diameter Scrub Brush Motor Speed Squeegee Tool Width English (Metric) (48”) = Captor 4800 / CR 1200 43” 50 inches (127cm) 60 gal. (227l) 60 gal. (227l) 75,700 ft2 (7,630m2) X 51” (130cm) 134, 600 ft2 (12,500m2) 3 15” (38cm) 225 RPM 51.25” (130cm) 48” 50 inches (127cm) 80 gal. (303l) 80 gal. (303l) 84,500 ft2 (7,850m2) 62 in. (158cm) X 163,700 ft2 (15,210m2) 3 17” (43cm) 225 RPM 57” (145cm) Height FRONT VIEW Width SIDE VIEW Length FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 5 MAINTENANCE AFTER USE 1 2 3 4 Raise the squeegee, the scrub brushes, and the brooms. Shake the dust control filter and empty the hopper. Drain and flush the recovery tank. Tip the recovery tank out and check the squeegee hose elbow below the tank for debris. DO NOT run water down the recovery tank vacuum tubes, this may cause damage to the vacuum motors. 5 Remove and clean the squeegee tool. 6 Remove and clean the scrub brushes. Rotate the scrub brushes. 7 Wipe the machine with a damp cloth. 8 Perform all required maintenance before storage. 9 Move the machine to a clean, dry storage area. 10 Store the machine with the brooms, the squeegee and the scrub brushes in the UP position, and the tank covers open so that the tanks can air out. REPORT ANY DEFECT OR MALFUNCTION NOTED DURING OPERATION TO AUTHORIZED SERVICE OR MAINTENANCE PERSONNEL. MAINTENANCE SCHEDULE Keep the machine in top condition by following the maintenance schedule closely. Maintenance intervals given are for average operating conditions. Machines used in severe environments may require service more often. MAINTENANCE ITEM Charge Battery Drain / Check / Clean Tanks & Hoses Check / Clean / Rotate Scrub Brushes & Pads Check / Clean / Adjust Squeegee *Check / Clean Vacuum Motor Inlet Screen Cap Clean Solution Filter (32) Check Battery Cell Water Level(s) Check Foot/ Parking Brake For Wear & Adjustment Inspect Broom Housing Skirts Check Hydraulic Fluid Level Check / Clean Hopper Dust Control Filter Using Method “A” Inspect Scrub Deck Skirts Main Broom Maintenance Side Broom Maintenance Lubrication Inspect Main Broom Upper & Lower Belts Check / Clean Hopper Dust Control Filter Using Method “B” Check / Clean Hopper Dust Control Filter Using Method “C” Replace Hydraulic Oil & Filter ** Check Carbon Brushes Have Nilfisk-Advance service center inspect the wheel drive gearbox Daily X X X X X X 25 Hours 150 Hours 300 Hours Yearly (1,000hrs) X X X X X X X X X X X X X X X X * DO NOT run water down the vacuum tube in the recovery tank this will damage the vacuum motors. Vacuum tube is on left side of tank with screen cap. ** Have your Nilfisk-Advance Dealer check the vacuum motors carbon motor brushes once a year or after 300 operating hours, all other motors yearly or 1000 hours. DRIVE WHEEL GEAR CASE OIL Change the gear lube in the drive wheel gear case after the first 350 hours of operation (break in period). Required oil specification: API GL4, SAE 80/90 weight gear oil. Gear case oil fill capacity is 2.8 quarts (2.7 liters). NOTE: Refer to Mechanical Repair Service Manual (56043096) for drain and fill instructions. LUBRICATING THE MACHINE 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 materials and there lubrication is not required. Grease Fitting locations: * 1 on each steering sprocket, 6 total * 2 on drive wheel gear case spindle * 1 on each squeegee caster, 2 total Lube Oil locations: * steering chain 6 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B MAINTENANCE WARNING For the protection of the environment; when servicing any of the machine’s lubrication fluids they must be disposed of safely in accordance with your local environmental regulations (recycling). Examples of machine lubrication products: (Hydraulic system oil, Hydraulic system oil filter). HOPPER DUST CONTROL FILTER The hopper dust control filter must be cleaned regularly to maintain the efficiency of the vacuum system. Follow the recommended filter service intervals for the longest filter life. CAUTION! Wear safety glasses when cleaning the filter. Do not puncture the paper filter. Clean the filter in a well-ventilated area. FIGURE 1 To remove the hopper dust control filter... 1 2 3 4 5 6 Lift the Hopper Cover (16) on top of the hopper. Make sure that the Hopper Cover Prop Rod (9) is in place. Inspect the top of the Hopper Dust Control Filter (17) for damage. A large amount of dust on top of the filter is usually caused by a hole in the filter or a damaged filter gasket. Turn the two hold-downs to the side (one on each side at the front of the frame) to release the shaker frame, then swing the Dust Filter Shaker Assembly (18) up and latch in place with the Shaker Assembly Latch (19). Lift the Hopper Dust Control Filter (17) out of the machine. Clean the filter using one of the methods below: Method “A” Vacuum loose dust from the filter. Then gently tap the filter against a flat surface (with the dirty side down) to remove loose dust and dirt. NOTE: Take care not to damage the metal lip which extends past the gasket. Method “B” Vacuum loose dust from the filter. Then blow compressed air (maximum pressure 100 psi) into the clean side of the filter (in the opposite direction of the airflow). Method “C” Vacuum loose dust from the filter. Then soak the filter in warm water for 15 minutes, and then rinse it under a gentle stream of water (maximum pressure 40 psi). Let the filter dry completely before putting it back into the machine. Follow the instructions in reverse order to install the filter. If the gasket on the filter is torn or missing, it must be replaced. HYDRAULIC OIL Raise and prop (HH) the hopper. See Figure 1. The oil level should be approximately 1 inch (2.54cm) below the bottom of the Elbow (A) on the front of the reservoir when the hopper is up (when the hopper is fully down the oil level should be up to the bottom of the elbow). If it is below this level, add 10W30 motor oil. Change the oil if major contamination from a mechanical failure occurs. SERVICE NOTE: The Cap (B) on Elbow (A) on the side of the reservoir is for adding oil. SERVICE NOTE: Remove Vent Plug (D) to allow oil to be filled. IMPORTANT! This machine is equipped with an Indicator Light (F) which lights if the Hydraulic Oil Filter (C / Figure 1) requires changing. The Hydraulic Filter (C / Figure 1) is found on the side of the Hydraulic Power Unit (27) as shown. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 7 Advance Captor 4300/4800 B Nilfisk CR 1100/1200 B PM Checklist Customer A B C D L M W Address City St Model Zip Serial Hours OPERATIONAL INSPECTION ITEMS Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 OK 34 Comments Side Broom Height (min bristle wear 3 inches) Side Broom Motor(s) Hopper Cover Gasket Hopper Dust Filter & Gasket Impeller Motor (remove cover to access motor & fan) Hopper Dump Door Cylinder Hopper Skirting & Seals (raise hopper to inspect) Hopper Dump Door & Seal (raise hopper to inspect) Brake Cable, Brake Shoes & Drum Wear Hopper Lift Cylinder & Hopper Magnetic Switch Main Broom Pattern Adjustment (min bristle wear 2-1/2" 6.4cm length) & Magnetic on/off broom switch Main Broom Motor (open left side access door to inspect belts) Copyright 2004 Nilfisk-Advance. B A A Does Not Work C A rough low power A C Noisy sluggish A B W A A A A A B B B B B C C <-----> <-----> A B C L W C L <-----> <-----> <-----> A VISUAL INSPECTION ITEMS 23 24 25 26 27 28 29 30 31 32 33 Defect Codes (circle) A Check Neutral Sense Switch Operation. To test, sit on seat and depress the drive pedal then turn the key switch on. The machine should not move, it should set a drive system code. Drive pedal operation, check for FWD & REV drive and any neutral return creep Seat safety switch (machine will not drive without an operator on seat) Drive System Performance (Reference SVR manual for Curtis drive programmer speed changes). Battery compartment interlock safety switch (machine will not run with bar removed) Steering Brakes (check both service & parking) Hopper Up/Down (also check operation of the safety hopper support) Hopper Dump Door Open/Close Main Broom Raise /Lower Side Broom Raise /Lower Main Broom On/Off and sweeping performance Side Broom On/Off and sweeping performance Scrub System (Raise/Lower and auto scrubbing functions and performance) Squeegee System (Raise/Lower, Auto Lift in Reverse and water pickup performance) Vacuum Performance (Sealed water lift 72" and 1- inch open hole adapter 6-7 inches) Solution Control (On/Off and Flow Volume Min/Max) Perform the machine self-diagnostic test. (see manual PN 56043095) Headlights, Gauges and (optional) accessories rotating beacon, backup alarm Dust control filter shaker & impeller Battery charger (auto turn On & Off) Battery emergency disconnect knob, tilt steering mechanism and seat adjustment lever Ref Defect Codes needs adjustment binding dirty or contaminated damaged, bent or torn leaks missing worn out OK B Defect Codes (circle) A B D Does Not Work W B D C W D C B 2-3" (5-7.5cm) wide pattern Page 1 of 2 8 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B W W L D M W B A A D B B W W L A A B D B W W 6/11/2004 VISUAL INSPECTION ITEMS (continued) Ref Comments OK D 35 36 37 38 39 Broom Housing & Door Skirts Battery (Load Test) Circuit Breaker panel (inspect electrical connections) Hydraulic System Hoses & fittings Hydraulic Oil Reservoir Level (10W-30 engine oil only) Hydraulic Oil Filter (change yearly or 1,000 hrs.) 40 41 42 43 44 Steer Spindle & Drive Wheel motor (remove recovery tank)* Rear Tire (check lug nut torque 100 FT LB, 135Nm) Drive Wheel gear case (see service manual)* Front & Rear Tires Steering chain & sprockets Clean & Water M C C W W D L L Add Oil Fill level (bottom of elbow with hopper closed) 45 Steering chain tension 46 Gear case/spindle grease fittings 47 Scrub Brushes, check for wear and rotate 48 Scrub Deck Skirts 49 Solution Solenoid Valve 50 Solution Flow Control Valve and Linkage 51 Solution Tank, Delivery Hoses & Filter 52 Vacuum Motor Gasket & Metal Elbow Gasket 53 Vacuum Stand Pipe Deflector 54 Recovery Tank Cover Gasket 55 Recovery Tank Drain Hose & Cap 56 Squeegee Pick-Up Hose & Metal Elbow 57 Squeegee Tool & Blades 58 Squeegee Casters (lubricate) *See service manual 56043096. Does Not Work Defect Codes (circle) D L W Gear oil level Tread wear Oil chain / grease sprockets Adjust* Grease L W D D A Clean filter screen Clean Back flush Clean & Rotate C C L C C A A M M C B C W W D L D D M D D D D W L M W L L W W *NOTE: For additional service information see service manuals form numbers 56043095 & 56043096 and operators manual form number 56041577 (English). Defect Codes A B needs adjustment binding WORK COMPLETED BY: Service Technician Signature Copyright 2004 Nilfisk-Advance. C D L dirty or contaminated damaged, bent or torn leaks M missing W worn out ACKNOWLEDGED BY: Date Customer Signature Page 2 of 2 Date 6/11/2004 FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 9 KNOW YOUR MACHINE 1 2 3 4 5 6 7 8 9 10 11 Operator’s Seat Strobe Light (optional / standard on Nilfisk Models) Solution Tank Fill Tie Down Locations Recovery Tank Drain Hose Recovery Tank Latch Left Battery Compartment Access Panel Main Broom Left Access Door (belt/motor access) Hopper Cover Prop Rod Front Wheel Jacking Location 12 13 14 15 16 17 18 19 20 21 22 Left Side Broom Hopper Cover Latch Headlights Right Side Broom Hopper Cover Dust Control Filter Dust Control Shaker Assembly Shaker Assembly Latch Battery Battery Compartment Door Steering Wheel 2 1 3 22 21 20 19 4 18 17 5 16 6 7 9 14 15 4 13 11 10 12 10 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B 8 KNOW YOUR MACHINE 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Electrical Compartment Door Water Level Gauge Recovery Tank Lid Recovery Tank “Tip-Out” Grip Hydraulic Power Unit (Reservoir & Filter) Right Battery Compartment Access Panel Main Broom Right Access Door (broom removal) Access Door Latch Skirt Assembly Inline Solution Filter Solution Tank Drain Hose Rear Roller Bumper Squeegee Tool Handle Squeegee Tool Assembly Tail Light 27 26 25 24 28 23 30 37 32 36 35 34 4 33 4 11 29 31 FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 11 CONTROL PANEL A B * C D * E F G * H * I * J K * L M N * O * Low Battery Indicator Horn Horn ON Indicator Parking Brake Indicator (not used) Headlights Headlight ON Indicator Speed Controller Fault Code Status Light Hydraulic Filter Plugged Indicator Speed Switch Speed Switch Indicator Scrub Pressure Decrease Switch Scrub Pressure Decrease Indicator Scrub Pressure Increase Switch Scrub Pressure Increase Indicator Scrub Pressure Display Solution Switch Solution ON Indicator Solution Tank Empty Indicator Recovery Tank Full Indicator Vacuum System Switch Vacuum System ON Indicator Scrub System OFF Switch Scrub System Indicator P * Q R S * * T * U * V * W X Y * Z * AA * BB CC DD A DD C B Side Broom ON Side Broom ON Indicator Main Broom ON Indicator Light Sensor Shaker Switch Shaker ON Indicator (left) Dust Filter Plugged Indicator (right / optional) Dust Control Switch Dust Control ON Indicator Side Broom UP/OFF Switch Side Broom OFF Indicator Open Dump Door Switch Open Dump Door Indicator Hopper Open Indicator Hopper Over-temp Indicator Close Dump Door Switch Close Dump Door Indicator Lower Hopper Switch Lower Hopper Indicator Raise Hopper Switch Raise Hopper Indicator Hour Meter Display Main Power Switch Battery Condition Indicator E D F G H CC I J K L M BB O P N Q R U S T V W AA X Z 12 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Y OPERATOR’S COMPARTMENT EE FF GG HH II JJ KK LL MM NN OO PP Solution Flow Control Lever Main Broom Raise/Lower (ON/OFF) Lever Main Broom Adjust Knob (height pattern) Hopper Safety Support Lever Control Panel Main Broom Overload Indicator Light Emergency Battery Disconnect Steering Wheel Tilt Lever Drive Pedal Brake Pedal Parking Brake Latch Operator Seat Adjustment Lever GG II HH FF KK EE LL JJ MM PP NN OO FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 13 KNOW YOUR MACHINE DESCRIPTIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Operator’s Seat – Operator sits here. Seat is adjustable forward and back. Strobe Light (optional / standard on Nilfisk models) – This light starts flashing when the ignition switch is turned ON. Solution Tank Fill – Open to fill the solution tank, use non-foaming chemicals only. 75 gallon (284 liter) maximum capacity. Tie down Locations – Safe point to tie down machine while transporting. Recovery Tank Drain Hose – Used to empty the recovery tank (hold the end of the hose above the water level in the tank to avoid sudden, uncontrolled flow of waste water). Recovery Tank Latch – Push down on latch lever to release recovery tank for “Tip-Out” feature. Left Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the battery compartment from the left side of the machine. SERVICE NOTE: Battery can only be removed from this side. Main Broom Left Access Door – Open to access main broom for servicing. Hopper Cover Prop Rod – Used to support the hopper cover while raised. Front Wheel – Machine front wheel. Jacking Location – Safe points for jacking machine up. DO NOT jack the machine on the hopper. Left Side Broom – Used for sweeping along walls or curbs. Hopper Cover Latch – Holds Hopper Cover (16) in place. Headlights – Use when sweeping in hard to see areas. Right Side Broom – Used for sweeping along walls or curbs. Hopper Cover – Open to access the hopper dust control filter. Dust Control Filter – Filters dust from the air. Dust Control Shaker Assembly – Vibrates the Dust Control Filter (17) to shake dust out of it. Shaker Assembly Latch – Used to hold the Shaker Assembly (18) UP while servicing the filter. Battery – Provides electrical power for operating the machine. Battery Compartment Door – Unlatch and open to access battery compartment. Steering Wheel – Used to steer machine left or right. Electrical Compartment Door – Open this door to access the main controller and solenoids. DO NOT open this door unless the Emergency Battery Disconnect (KK) has been pushed IN. Water Level Gauge – When filling the solution tank do not exceed the maximum level. Recovery Tank Lid – Open to rinse and clean inside of recovery tank. Recovery Tank “Tip-Out” Grip – Grab and pull here after unlatching to tip the recovery tank out to the side for cleaning. Hydraulic Power Unit (Reservoir / Filter) – Holds the hydraulic system oil, 1.7 quart (1.6 liter) capacity. SERVICE NOTE: Open and prop the hopper to add oil. Hydraulic return oil filter on side of the unit filters oil after flowing through system and prior to returning to reservoir. Right Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the battery compartment from the Right side of the machine. Main Broom Right Access Door – Open to access main broom for servicing. Access Door Latch – Push UP on lever to unlatch (Recovery Tank utilizes same latch for “Tip-Out” feature). Skirt Assembly – Scrub system has left and right skirt assemblies to channel solution on floor into the path of the squeegee assembly. Inline Solution Filter – Filters solution prior to dispensing on floor. Solution Tank Drain Hose – Used to empty the solution tank. Rear Roller Bumper – Protects both machine and other objects in the event the machine brushes up against anything. Squeegee Handle – Loosen these two handles to remove the squeegee assembly from the machine. Squeegee Assembly – Picks up solution after scrubbing. Tail Light – Turns ON with headlights. 14 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B CONTROL PANEL DESCRIPTIONS A B * C D * E F G * Low Battery Indicator – This indicator will flash when the battery requires charging. Horn Switch – This switch will sound the horn as long as the switch is held. Horn Indicator: Lights up when the horn switch is pressed. Parking Brake Indicator – This indicator is currently not used. Headlight Switch – Turns the headlights and taillights ON or OFF. Headlight ON Indicator: Lights up when the lights are ON. It is OFF when the lights are OFF. Speed Controller Fault Code Status Light – This light will flash on and off identifying a speed controller fault. Note: Refer to troubleshooting chart in this manual for explanation. Hydraulic Filter Plugged Indicator – Indicates when the hydraulic oil filter should be serviced. Have your Nilfisk-Advance Service Center check the machine. SERVICE NOTE: This light may give a FALSE indication when the hydraulic oil is cold. Speed Select Switch – This switch will allow the operator to select the transport speed limit while the scrub system is enabled thereby allowing scrubbing at a higher rate of speed. This option can be disabled if desired. See the programming section for details. The transport and scrub speed limits can be programmed using a Curtis handheld programmer. Refer to the electrical section in this manual for details. Speed Select Switch Indicator: This indicator will be green if a scrub mode has been selected and the faster scrub speed has been selected. This indicator will be off if the Speed Select Switch has been turned OFF. SCRUB SYSTEM H • • • • * I • • • • * J K * L M N * O • • • • * Scrub Pressure Decrease Switch – If the scrub system is off, pressing this switch will cause the following to occur: The scrub system will be enabled with the scrub pressure set to the lightest setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled As soon as the drive pedal is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on. If the direction is forward the solution flow will start. If the direction is reverse, the squeegee will raise and the solution flow will be stopped. The scrub brushes will turn off after an adjustable delay once the drive pedal returns to neutral. See the programming section for details. If the scrub system is already enabled when this switch is pressed and the scrub pressure is at 2 or 3, the scrub pressure will decrease. If the switch is held, the pressure will decrement until the minimum setting of 1 is reached. Scrub Pressure Decrease Indicator: The scrub pressure decrease indicator will be lit if the scrub system is enabled and the pressure is set at 1 or 2. The indicator will be off if the scrub system is off or if the scrub pressure is set to 3. Scrub Pressure Increase Switch – If the scrub system is off, pressing this switch will cause the following to occur: The scrub system will be enabled with the scrub pressure set to the lightest setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on. If the direction is forward the solution flow will start. If the direction is reverse, the squeegee will raise and the solution flow will be stopped. The scrub brushes will turn off after an adjustable delay once the drive pedal returns to neutral. See the programming section for details. If the scrub system is already enabled when this switch is pressed and the scrub pressure is at 1 or 2, the scrub pressure will increase. If the switch is held, the pressure will increment until the maximum setting of 3 is reached. Scrub Pressure Increase Indicator: The scrub pressure increase indicator will be lit if the scrub system is on and the pressure is set at 2 or 3. The indicator will be off if the scrub system is off or if the scrub pressure is set to 1. Scrub Pressure Display: The single character display on the control panel is used as a display for the scrub pressure. If the scrub system is ON, the display will indicate the relative pressure setting of 1, 2 or 3 otherwise it is blank. Note: This display is also used to show error codes see the main controller A1 self diagnostic test mode found in this manual for a complete explanation. Solution Switch - This switch is used to turn the solution system on or off. Pressing this switch when the scrub system has been activated will alternate between on and off. The solution flow will only turn on when the drive pedal is moved from the neutral position in the forward direction. The solution flow will turn off if the drive pedal returns to neutral or is moved to reverse. Pressing this switch when the scrub system is off will momentarily turn the solution flow on to allow pre-wetting of the scrub brushes. Solution System Indicator: The solution indicator will be lit if the solution is enabled. If the solution is off, this indicator will be OFF. Solution Tank Empty Indicator – This indicator will illuminate when the solution tank is low. Recovery Tank FULL Indicator – This indicator will flash when the recovery tank is FULL. The vacuum system is shut OFF at this point. Draining the recovery tank will reset this indicator. Vacuum System Switch – This switch is used to turn the vacuum system on or off. When the vacuum is on the squeegee will lower (unless the machine is in reverse) and when the vacuum is off the squeegee will rise. Pressing this switch will alternate between on and off. The vacuum will only turn on when the drive pedal is moved from the neutral position. It will remain on for 10 seconds after the drive pedal returns to neutral. The vacuum also has an automatic shutoff feature that will turn the vacuum and scrub systems off if the recovery tank becomes full. If this occurs, the recovery tank full indicator (M) will flash. The vacuum shutoff delay is adjustable. See the programming section for details. Vacuum System Indicator: The vacuum indicator will be lit if the vacuum is enabled. It will flash if the vacuum is in the delayed-off condition. If the vacuum is off, this indicator will be off. Scrub System OFF Switch - Pressing this switch when the unit is in a scrub mode will cause the following to occur: The scrub brushes will turn off The scrub deck will raise to the UP position The solution flow will be stopped The first time that this button is pressed, the vacuum/squeegee system will NOT be turned off. This is so that any remaining water may be picked up without having to turn the vacuum back on. If this button is pressed a second time (pressed after the scrub mode has been turned off) the squeegee will raise and the vacuum will shut off after a 10 second delay. Scrub System OFF Indicator: This indicator will be lit if the scrub system is OFF. This indicator will be OFF if the scrub system is enabled or running. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 15 CONTROL PANEL DESCRIPTIONS SWEEP SYSTEM P Side Broom DOWN/ON Switch – This switch is used to lower and/or turn the side broom(s) on. The side broom(s) will lower whenever this switch is pressed until the bottom limit is reached. The side broom(s) will turn on when the drive pedal is moved from the neutral position. They will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for details. * Side Broom ON Indicator: • This indicator will be lit if the side broom(s) are turned ON. Q Main Broom ON Indicator: This indicator will be lit if the main broom is down, otherwise it is OFF. R Light Sensor – Not currently used. S Shaker Switch – This switch controls the hopper dust control filter shaker. Pressing this button will cause the dust control to turn off and the shaker to turn on. The shaker will run for approximately 20 seconds. This period is adjustable. See the service manual for details. Pressing the switch while the shaker is operating will cancel the timer and turn the shaker off. If the dust control was previously on, it will turn back on. * Shaker Indicator (left): This indicator will be lit if the shaker is turned ON, otherwise it is OFF. * Dust Filter Plugged Indicator (right / optional): This indicator will be lit if the dust filter requires cleaning, otherwise it is OFF. NOTE: Requires optional Hopper Filter Switch Kit. T Dust Control Switch – This switch controls the hopper dust control. Pressing this switch alternates between on and off. The dust control will run when the drive pedal is moved from the neutral position. The dust control will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for details. * Dust Control Indicator: This indicator will be green if the dust control system is ON, otherwise it is OFF. U Side Broom UP/OFF Switch – This switch is used to raise and/or turn the side broom(s) off. The side broom(s) will rise whenever this switch is pressed until the upper limit is reached. When the upper limit is reached, the side broom(s) will turn off. * Side Broom OFF Indicator: This indicator will be lit if the side broom(s) are turned OFF. HOPPER SYSTEM V Open Dump Door Switch – This switch is used to open the hopper dump door. This switch will only function when the main broom is down or when the hopper is raised. NOTE: The dump door will automatically open when the hopper is fully down and the main broom is lowered. * Open Dump Door Indicator: This indicator will be lit while the dump door is in the process of opening, otherwise it is OFF. W Hopper Open Indicator: This indicator flashes if the hopper is open, otherwise it is OFF. X Hopper Overtemp Indicator – This indicator will flash when the hopper temperature exceeds 140 degrees Fahrenheit. NOTE: the hopper temperature switch is optional. Y Close Dump Door Switch – This switch is used to close the hopper dump door. This switch will only function when the main broom is up or when the hopper is raised. NOTE: The dump door will automatically close when the main broom is raised or when the hopper is raised. * Close Dump Door Indicator: This indicator will be lit while the dump door is in the process of closing, otherwise it is OFF. Z Lower Hopper Switch – This switch is used to lower the hopper. The hopper will drop as long as this switch is held. Once the hopper is in the full-down position, the Hopper Open Indicator (W) will turn off. If any of the sweep or scrub functions were on when the hopper was raised, they will be reactivated. The dump door will automatically open or close depending on whether the main broom is down or up. The switch indicator will be lit as long as the switch is held. * Lower Hopper Indicator: This indicator will be lit while the hopper is in the process of lowering, otherwise it is OFF. AA Raise Hopper Switch – This switch is used to raise the hopper. Pressing this switch will cause the following to occur: • The switch indicator will illuminate • If the dump door is open (main broom down) the door will close • The main broom, side brooms, scrub system, solution, and vacuum will all turn off • If the dust control was on, it will remain on unless programmed otherwise • Once the dump door is closed, the hopper will begin to raise • The hopper will continue to raise as long as this switch is held Once the hopper is no longer in the full-down position, the Hopper Open Indicator (W) will flash. The dump door open and close switches will now be functional * Raise Hopper Indicator: This indicator will be lit while the hopper is in the process of raising, otherwise it is OFF. BB Hour meter / Error Code Display – Upon power up or if the machine has been idle for at least ten seconds with all systems turned off, the hour meter will display the hours for each major electric motor system for 3 seconds and continue to cycle through each system as long as the drive pedal is in neutral and all systems are OFF. Once the drive pedal is pressed or any system activated it will indicate the drive system hours (default). If an overload fault occurs, the display will indicate the associated error code immediately. 16 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B CONTROL PANEL DESCRIPTIONS CC Main Power / Key Switch – Main Power Switch. DD Battery Condition Indicator - The battery condition indicator consists of three lights, a green (G), a yellow (Y), and a red (R). The voltage indication will change based on the cutoff level (standard or alternate) selected in the control unit. The battery voltage ranges for the various indications are listed below: Standard Green 34.00 Green & Yellow 33.00-33.99 Yellow 32.00-32.99 Yellow & Red 31.50-31.99 Red 31.00-31.49 Flashing Red/Cutoff <31.00 NOTE: Refer to service manual for selection of alternate cut-off level. Once the low voltage cutout level has been reached (flashing red indicator) the battery must be FULLY recharged to reset the battery condition indicator. The scrub system will not function until the indicator has been reset. COCKPIT EE Solution Flow Control Lever – Move this lever FORWARD to increase solution flow to the floor. Move BACKWARD to decrease the amount of solution flow to the floor. When the Drive Pedal (OO) is released from either forward or reverse travel, the solution flow will stop automatically, and resume when the drive is engaged. Solution flows in forward only, stops in reverse. FF Main Broom Raise/Lower (ON/OFF) Lever – This lever primarily controls the main broom. It can also control the side brooms and dust control if desired. Lowering this lever will cause the following to occur: • The main broom indicator will illuminate • The main broom will be lowered to the operating position • The side brooms will be lowered to the operating position • The dust control will be enabled • The hopper dump door will open As soon as the drive pedal is moved from the neutral position the main broom and side brooms will start turning and the dust control will turn on. The brooms and dust control will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for details. Raising the main broom lever will cause the following to occur: • The main broom indicator will turn off • The main broom will be raised to the off position • The side brooms will be raised and will turn off • The dust control will turn off • The hopper dump door will close The side brooms and dust control can be programmed not to automatically come on with the main broom. See the service manual for details GG Main Broom Adjust Knob – Used to compensate for main broom wear in order to maintain a 3 inch (7.62cm) wide broom pattern. HH Hopper Safety Support Lever – NEVER work under a raised hopper without the safety support engaged. To engage; raise the hopper all the way UP, pull back on lever and then lower hopper until it seats. II Control Panel – See items A through DD. JJ Main Broom Overload Indicator Light – This indicator will be lit if the main broom pressure is too high. The main broom will shut off if overloaded for an extended period of time. KK Emergency Battery Disconnect – Push in on knob to disconnect battery. LL Steering Wheel Tilt Lever – Pull lever out to release steering column for adjusting up or down. MM Drive Pedal – Controls the machine’s travel speed and direction: Push down on the Back of the pedal to move the machine Backward. Push down on the Front of the pedal to move the machine Forward. The SPEED of the machine will increase as the pedal is pushed closer to the floor. Maximum forward speed is faster than maximum reverse speed. NN Brake Pedal – Operates the mechanical brakes on the front wheels. OO Parking Brake Latch – Used to “lock” the brake pedal in place after engaging the brakes. NEVER leave machine unattended without setting Parking Brake. Press on this latch with your foot instead of the brake pedal to activate. PP Operator Seat Adjustment Lever - Use this lever to slide the operator’s seat forward or backward. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 17 KNOW YOUR MACHINE IMPORTANT SERVICE TIP Before any troubleshooting is done perform this troubleshooting special control system procedure. MAIN CONTROLLER (A1) SELF-DIAGNOSTIC TEST MODE If problems with the main 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 Scrub Pressure Display (J) see Figure 2. 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! Make sure that all persons are away from these parts of the machine to prevent injury. 2 Turn the main power key switch to the off position. 3 Press and hold the side broom down/on switch. 4 While holding the side broom down/on switch, turn the main power key switch to the on position. 5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off (approximately two seconds). 6 Release the side broom down/on switch. 7 The control will now activate each output in sequence and perform the tests mentioned above. 8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10. 9 If abnormal output conditions were detected, the display will now show the error code(s), see “Main Control Error Code Display Descriptions Table”. An example of how two codes, 6 and 18, would be displayed is as follows: • The display will show “E” followed by a brief blank period • The display will show “0” followed by a brief blank period • The display will show “6” followed by a slightly longer blank period • The display will show “E” followed by a brief blank period • The display will show “1” followed by a brief blank period • The display will show “8” followed by a long blank period • The above sequence will repeat 10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult the general machine troubleshooting section of this manual which will show machine system flow charts. 11 The hopper limit, main broom, recovery tank full, and solution tank empty switches may also be tested in this mode. The corresponding indicators will indicate the state of each of the inputs. 12 To exit this mode, turn the main power key switch to the off position. NOTE: If the machine is not equipped with an optional back-up alarm, an error code 59 will be indicated. FIGURE 2 J 18 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Control Error Codes for Battery Powered Captor Display Code Error Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Troubleshooting Actions Side broom actuator overload Output bank 1 overload (horn & shaker) Output bank 2 overload (contactors) Light circuit overload Scrub deck actuator overload Squeegee actuator overload Scrub motor overload Main broom overload Check for binding or frozen side broom linkage & actuator motor. Check for short circuit in lift motor or wiring. Run self-diagnostic for specific cause Run self-diagnostic for specific cause Check for short circuit in bulb and wiring. Run self-diagnostic for specific cause Run self-diagnostic for specific cause See scrub motor troubleshooting part B. See main broom motor troubleshooting part B. Check for wiring problems at the K10 coil. Accessory contactor coil circuit short Check K10 coil resistance if below 116 ohms Replace. Accessory contactor coil circuit current too high Same as Error 9 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K10 coil wire colors Accessory contactor coil circuit open YEL/BRN (+), BLU/ORN (-). Horn circuit short Check for wiring or horn shorted. Horn circuit current too high Same as Error 12 Replace Wiring or horn. Check for open in wiring. Check for 36V at the Horn wire Horn circuit open colors VIO (+), VIO/BRN (-). Replace or repair. Check for wiring problems at the K1 coil. Left scrub motor M2 contactor coil circuit short Check K1 coil resistance if below 116 ohms Replace. Left scrub motor M2 contactor coil current too high Same as Error 15 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K1 coil wire colors Left scrub motor M2 contactor coil circuit open VIO (+), YEL/BLU (-). Shaker circuit short See shaker will not run troubleshooting flow chart. Shaker circuit current too high See shaker will not run troubleshooting flow chart. Shaker circuit open See shaker will not run troubleshooting flow chart. Check for wiring problems at the K4 coil. Main broom contactor coil circuit short Check K4 coil resistance if below 194 ohms Replace. Main broom contactor coil current too high Same as Error 21 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K4 coil wire colors Main broom contactor coil circuit open VIO (+), GRN/GRA (-). Center scrub motor M3 contactor coil circuit Check for wiring problems at the K2 coil. short Check K2 coil resistance if below 116 ohms Replace. Center scrub motor M3 contactor coil current too high Same as Error 24 Replace coil. (Shorted Coil) Check for open in coil & wiring. Center scrub motor M3 contactor coil circuit Check for 36V at the K2 coil wire colors open VIO (+), WHT/VIO (-). Check for wiring problems at the L4 coil. Door open solenoid coil circuit short Check L4 coil resistance if below 66 ohms Replace. Door open solenoid coil current too high Same as Error 27 Replace coil. (Shorted Coil) FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 19 Display Code Error Description 48 Troubleshooting Actions Check for open in coil & wiring. Check for 36V at the L4 coil wire colors Door open solenoid coil circuit open VIO (+), BRN/GRN (-). Check for wiring problems at the K3 coil. Right scrub motor M4 contactor coil circuit short. Check K3 coil resistance if below 116 ohms Replace. Right scrub motor M4 contactor coil current too high Same as Error 24 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K3 coil wire colors Right scrub motor M4 contactor coil circuit open VIO (+), GRA/RED (-). Check for wiring problems at the K6 coil. Dust control contactor coil circuit short Check K6 coil resistance if below 116 ohms Replace. Dust control contactor coil current too high Same as Error 33 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K6 coil wire colors Dust control contactor coil circuit open VIO (+), BRN/YEL (-). Check for wiring problems at the K7 coil. Vacuum contactor coil circuit short Check K7 coil resistance if below 116 ohms Replace. Vacuum contactor coil circuit current too high Same as Error 36 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K7 coil wire colors Vacuum contactor coil circuit open VIO(+), BLU (-). Check for wiring problems at the L5 coil. Door close solenoid coil circuit short Check L5 coil resistance if below 66 ohms Replace. Door close solenoid coil current too high Same as Error 39 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L5 coil wire colors Door close solenoid coil circuit open VIO (+), BLU/RED (-). Check for wiring problems at the K8 coil. Side broom contactor coil circuit short Check K8 coil resistance if below 116 ohms Replace. Side broom contactor coil current too high Same as Error 42 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K8 coil wire colors Side broom contactor coil circuit open VIO(+), BRN/BLK (-). Check for wiring problems at the L6A coil. Hopper down solenoid coil circuit short Check L6A coil resistance if below 66 ohms Replace. Hopper down solenoid coil circuit current too high Same as Error 45 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L6A coil wire colors Hopper down solenoid coil circuit open VIO (+), YEL/RED (-). Check for wiring problems at the L6 coil. Hopper up solenoid coil circuit short Check L6 coil resistance if below 66 ohms, replace. 49 Hopper up solenoid coil circuit current too high 50 Hopper up solenoid coil circuit open 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Same as Error 48 replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L6 coil wire colors VIO (+), RED/GRA (-). 20 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Display Code Error Description Troubleshooting Actions Check for wiring problems at the L1 and L2 coils. Check L1 and L2 coils resistance if below 70 ohms, replace. 51 52 Solution solenoid coil circuit short Solution solenoid coil current too high 53 Solution solenoid coil circuit open 54 55 Hydraulic pump contactor coil circuit short Hydraulic pump contactor coil current too high 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Hydraulic pump contactor coil circuit open Back-up alarm circuit short Back-up alarm current too high Back-up alarm circuit open Side broom actuator circuit short Side broom actuator circuit current too high Side broom actuator circuit open Scrub deck actuator circuit short Scrub deck actuator circuit current too high Scrub deck actuator circuit open Squeegee actuator circuit short Squeegee actuator circuit current too high Squeegee actuator circuit open Same as Error 51 Replace coil. (Shorted Coil) Check for open in coil(s) & wiring. Check for 36V at the L1 and L2 solution valve coil wire colors VIO(+), YEL/GRN (-). Check for wiring problems at the K11 coil. Check K11 coil resistance if below 149 ohms Replace. Same as Error 54 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K11 coil wire colors VIO (+), BLU/WHT (-). Check alarm and wiring Check alarm and wiring Check alarm and wiring Check for short in wires or motor. Check for binding of linkage. See service manual section flowcharts. Check for short in wires or motor. Check for binding of linkage. See service manual section flowcharts. Check for short in wires or motor. Check for binding of linkage. See service manual section flowcharts. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 21 GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTS No Wheel Drive ................................................................................................................................................................... 23 No Wheel Drive and no machine accessory functions........................................................................................................ 27 Forward/Reverse auto accessory functions do not work .................................................................................................... 28 No power assist steering..................................................................................................................................................... 29 Main broom will not turn .................................................................................................................................................30-31 Side brooms will not turn................................................................................................................................................32-33 Side broom lift actuator will not lower ................................................................................................................................. 34 Side broom lift actuator will not raise .................................................................................................................................. 35 Hydraulic pump will not operate .....................................................................................................................................36-37 Hopper dump door will not open in the dump mode ..................................................................................................... 38, 40 Hopper dump door will not close in the dump mode ......................................................................................................39-40 Hopper will not raise ......................................................................................................................................................42-43 Hopper will not lower......................................................................................................................................................44-45 Squeegee will not raise or lower ......................................................................................................................................... 46 Vacuum motor will not activate ......................................................................................................................................47-48 Dust control impeller will not run ....................................................................................................................................49-50 Shaker motor does not operate .......................................................................................................................................... 51 Scrub deck will not raise ..................................................................................................................................................... 52 Scrub deck will not lower ...............................................................................................................................................53-54 Scrub deck motors will not operate ................................................................................................................................55-56 Solution solenoid valve(s) do not operate ........................................................................................................................... 57 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. ACC SCRUB 3 MAIN BROOM DOOR OPEN DUST CONTROL DOOR CLOSE HOPPER DOWN FW D/ RE V ST AT US HO PP RE ER TR HO ACT PP DU ER ST TE M R FIL P NO ECO TER T VE FU R LL Y SOLUTION HORN SHAKER SIDE BROOM LIFT SCRUB DECK LIFT SCRUB 2 SCRUB 1 VACUUM SIDE BROOM   SQUEEGEE LIFT HOPPER UP KEY SW ACC LIGHTS HYDRAULIC RE VE S RS MA EAT E IN S W BR I T OO CH M OF F HY EXT WA DR EN ND A D SO ULI LIM L U C F IT TI ILT ON E EM R PT Y BACK-UP ALARM 22 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B A1 Control Board Indicator Lights WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 No Wheel Drive Note 1: Do all testing with key switch on, seat switch closed and battery hold down interlock switch closed. Do the A2 display panel lights come on? See “No drive & no machine accessory functions” in this manual no yes Is the Speed Controller Fault Code Status Light (E) on at the A2 display board flashing when attempting to drive the machine? yes See “Table 1” Curtis troubleshooting Status LED Fault Codes no Individually check for (+) 36V at the A3 speed control pin 1 (ORN) and pin 9 (ORN) no Repair or replace the ORN wire(s). yes Check for (+) 36V at A3 speed control pin 2 (GRN) no Check for (+) 36V through the seat switch and battery interlock switch yes yes no Repair or replace wiring or switches. Motor still does not operate yes Check the drive motor carbon brushes for wear if worn replace. Motor still does not run yes Replace drive motor Does the motor run? no Replace A3 speed controller FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 23 WHEEL DRIVE SYSTEM Low Current controller A3 Pin Key Detail Pin # 1 Wire Color ORN 2 GRN 3 BLU/BLK 4 Not Used 5 ORN/RED 6 7 8 9 10 11 12 13 14 15 16 Not Used Not Used Not Used ORN Not Used Not Used Not Used VIO/BLK WHT/BLK BRN/RED Not Used 17 BLK/YEL 18 19 Not Used RED/WHT 20 GRA 21 22 23 24 Not Used Not Used Not Used Not Used Controller Pin Description & Function Key switch input (KSI): Battery (+) 36V powers up controller logic circuits. Interlock: Seat switch (S9) and Battery interlock Switch (S13) input battery (+) 36V to pin 2 to allow an output to the Pin 17 (-) 36V BLK/YEL wire to K5 contactor coil. Mode 1: Drive motor scrub speed battery (+) input from main controller (A1). When pin 3 sees (+)36V the machine will drive in the slow scrub speed Fault 1 output: Speed controller (A3) fault code output to the operator display panel Speed Controller Fault Code Status Light (Wrench). Battery Pos (+) Coil Return input: connects internal suppression diode to K5 coil. Throttle input : Wire pot high Throttle input : Wire pot Low Throttle input : Wire pot wiper Main Contactor Driver: Battery (-) 36V output to main contactor K5 Coil. Activated by Key switch input from Pin 1. Reverse signal driver output: Signals the A1 Main Control Board when machine is in reverse. Electromagnetic brake drive: Battery (-) output to main controller (A1) to turn on (activate) all auto functions. Detail of A3 24-pin connector: 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Used 24 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Not Used WHEEL DRIVE SYSTEM WHEEL DRIVE TROUBLESHOOTING GUIDE Problem Possible Cause • Wheel drive motor will not run in forward and reverse • Batteries need charging (low battery voltage, recharge batteries) • Control Circuit, (F2) Circuit Breaker tripped (reset circuit breaker) • Parking Brake (OO) set (release parking brake) • Emergency Stop Switch (KK) tripped (plug in battery connector) • Seat switch (S9) and Battery Interlock switch (S13) not closed. Repair or Replace defective switch. • Defective Wheel Drive Motor (replace motor) * • Defective or miss adjusted throttle pot. (R1) (replace or adjust throttle pot) * • Defective Main Contactor (K5) (replace main contactor) * • Wheel drive in one direction only, loss of either forward and reverse • Test the Fwd & Rev (R1) Throttle Pot. Throttle’s wiring inputs at the speed control for an open. Forward 2.5-4.5V(pins 13 & 14) Reverse .5-2.5V(pins 15 & 14) Repair wiring or replace the throttle pot (R1). • Controller can’t change electrical polarity to wheel motor replace the (A3) speed control. * • Speed Controller Fault Code Status Light (E) flashes a fault code. • Speed controller has sensed an operation error code fault. (see the Status LED Fault Codes (Table 1) in the Electrical System) * = See Curtis Speed Control Troubleshooting Section. GENERAL FUNCTIONAL OVERVIEW A 4 HP separately excited (field & armature) 36V DC motor/gear/wheel unit (M15) is used to propel the machine. A Curtis model 1244 PMC solid state speed controller (A3) regulates (outputs) the variable speed Fwd/Rev wheel drive motor functions. The controller unit is located in the left rear electrical access panel. The (R1) throttle pot mounted to the operator foot pedal inputs to the (A3) controller. The (A3) Controller operator’s specific speed and direction demands. DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW To make the A3 speed controller’s internal circuits operational (power it up) the main power Key Switch S11 must be closed. Next the seat switch S9 and battery interlock S13 must be closed for the main contactor K5 to be energized. Depressing the foot pedal in either Fwd or Rev will move the throttle pot R1 out of its neutral position and provide the needed directional and throttle inputs for controller outputs. Depressing the foot pedal in either Fwd or Rev will move the 5K Ohm (R1) potentiometer shaft off its centered balanced (neutral) setting of approximately 2500 Ohms. With this pot shaft movement the pot’s resistance value changes which generates a variable voltage signal (0-5 volts). These control board voltage input signals are what energizes the Fwd & Rev internal directional relays, which selects the motor polarity and what also manages switches the battery voltage On and Off (*PWM) that varies the motor speed. MOTOR OPERATION The motor has (4) terminal connections, (2) armature A1, A2 and (2) field F1, F2. The separate motor armature circuit receives from the controller a chopped on time off time *PWM voltage output that varies the motor speed. The separate field circuit sees the current direction polarity change that effects the rotation of the motor CW for FWD and CCW for REV. DRIVE WHEEL SYSTEM SPEEDS The speed controller is programmed for two maximum speed setting modes, M1-max and M2-max. The M1-max is the transport speed mode and is set at 100% of the total system’s speed potential. The M2-max is the scrubbing speed mode and is set at 80% of the total system’s speed potential. Note: Both of the speed settings (M1 & M2) can be changed (increased or decreased) from the original factory specifications only by using the hand held programmer PN 56409441. See in the electrical system section of this manual, instructions for using the programmer for speed setting changes and troubleshooting diagnostics. *PWM; pulse width modulation, also called “chopping” is a technique that switches the battery voltage ON and OFF to the motor very quickly, thereby controlling the speed of the motor. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 25 B- GRN BLU/BLK ORN/RED GRA RED/WHT ORN B+ WHEEL DRIVE SYSTEM A3 CURTIS 1244 SPEED CONTROLLER ORN K5 BRN/RED BLK/YEL BLK/YEL RED/WHT GRA B R1 C Pot. 5k Ohm VIO/BLK 24 23 22 21 20 19 18 17 16 15 14 13 Contactor, Wheel Drive A WHT/BLK ORN/RED ORN ORN 12 11 10 9 8 7 6 5 4 3 2 1 X51 BLU/BLK GRN F1 F2 1 K5 2 RED 1-2 Contact N.O. 26 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B M A2 F2 WHT/YEL A1 Motor, Wheel Drive F1 M15 BLK RED 1-A2 BLK 1-A1 RED/BLU RED 1-1 B+ M- B- WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 No drive and no machine accessory functions Note 1: Do all testing with key switch on seat switch closed and battery hold down interlock switch closed. Check for open in: F10 (400 A) Fuse F2 (5A) Circuit Breaker yes At the A1 board is the red key switch light on? no no no yes Reset C.B. Replace Fuse. Does the machine function? 1.Check for 36V(+) at the A1 board ORN wire J2-11 to battery ground 2.Check 36V(-) at the Binputs BLK wires to bat pos. no Repair or replace key switch or wiring yes At the A1 board are the grn and red acc. lights on? no At the K10 Aux. coil is there 36V YEL/BRN(+) BLK/ORN(-) no yes Repair or replace wiring. Is there voltage at the coil? no Replace the A1 control board yes Check coil resistance at K10 120 ohms (+ or - 10%) no Replace K10 contactor. Are the red and grn acc lights on? yes no Check for 36V(+) at K10 load input RED wire to bat ground. no Repair or replace wiring. no Replace K10 contactor yes Check for 36V(+) at the K10 load output BLU/GRN wire to bat. ground. yes Check for 36V(+) at the A1 board J1/J23 GRN/BLK wires to bat. ground. no Repair or replace CB F3 20 amp or wiring. Does the machine function? no yes Check for 36V(+) at the F1 25 amp CB VIO wire to bat. ground. yes no Repair or replace CB F1 25 amp or wiring. Does the machine function? no Replace the A1 control board FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 27 WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Forward/ reverse auto accessory functions do not work, examples; main broom, side brooms, scrub motors, vacuum motor and dust control motor. Note: Do all testing with key switch on and drive pedal activated (forward/reverse) Machine drive auto accessory functions do not work Is the MIL light (E) flashing at the A2 display board? no With the seat switch closed, drive wheel jacked properly, place the pedal in forward or reverse position. At the A3 Curtis Speed control back probe pin 20 GRA wire check for 36V to battery positive yes yes See Curtis troubleshooting section Check for an open circuit from the A3 Curtis Speed controller pin 20 GRA wire to A1 main board J2-26 GRA wire. no Replace the A3 Curtis Controller no Replace the A1 Main Board no Replace the A3 Curtis Controller no Replace the A1 Main Board yes Repair or replace GRA wire Machine auto reverse function does not work Is the MIL light (E) flashing at the A2 display board? yes See Curtis troubleshooting section no With the seat switch closed, drive wheel jacked properly, place the pedal in reverse position. At the A3 Curtis Speed control back probe pin 19 RED/WHT wire check for 36V to battery positive yes Check for an open circuit from the A3 Curtis Speed controller pin 19 RED/WHT wire to A1 main board J2-25 RED/WHT wire. yes Repair or replace RED/WHT wire 28 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B STEERING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 No power assist steering Part A: Electrical Control Circuit Note: Do all testing with key switch on. Do any other accessory functions work? no See no accessory function no Check both wire(s) for continuity. Repair or replace defective wire(s). Does the power steering operate? yes Check for 36V at the K9 solenoid coil: wires: BLK(-) & VIO(+) no yes Check the K9 coil resistance 120 ohms (+ or - 10%) no Replace K9 solenoid. Does the power steering operate? no yes See Part B Load Circuit Part B: Load Circuit Note: Do all testing with key switch on. Is the F9 40 amp CB open? no At the K9 solenoid load wire BRN/GRA (battery input +) check for 36V to battery ground. no Repair or replace defective wire. Does the power steering operate? no yes yes Check for a short in the steering motor or load wires. Reset the F9 40 amp CB. Does the power steering operate? At the K9 solenoid load wire GRA/WHT (+ output to steering motor) check for 36V to battery ground. no no Replace K9 solenoid. Does the power steering operate? no yes Check for 36V at power steering motor wires GRN/WHT(+) & BLK(-) Does the power steering operate? no Repair or replace defective wire(s) or connectors. Does the power steering operate? no yes Replace Power Steering Unit FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 29 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Main Broom will not turn. Part A: Electrical Control Circuit Note 1: Do all testing with the key switch on, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or Reverse). Note 2: If the main broom overload indicator light is on see part B Main broom will not turn On the A1 board is the main broom indicator light on? Check the adjustment and operation of the S8 main broom switch. Is the switch open when main broom lever is lowered. no no yes yes Replace the A1 main controller. Does the broom run? Check for 36V at the K4 solenoid coil: wire colors: GRN/GRA(-) & VIO(+) no no Check both wire(s) for continuity. Repair or replace defective wire(s). Does the broom run? no no Replace K4 solenoid. Does the broom run? no yes Check the K4 coil resistance 120 ohms (+ or - 10%) yes See Part B 30 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Clean, adjust or replace the broom switch S8. Does the broom run? no SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Main Broom will not turn. Part B: Electrical Load Circuit Note 1: Do all testing with the key switch on, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or reverse). Main broom will not turn Inspect main broom for possible mechanical binding, damage broom lug inserts and debris wrapped around motor or broom. no At the K4 solenoid load wire RED 6-1 (battery input +) check for 36V to battery ground. no Repair or replace defective wire(s). Does the broom run? no yes yes Remove debris and make any repairs or replace damage parts. Does the broom run? no At the K4 solenoid load wire RED 6-2 (output to broom motor +) check for 36V to battery ground. no Replace K4 solenoid. Does the broom run? no yes Check for 36V at main broom motor. no Repair or replace defective wire(s) + or -. Does the broom run? no yes Repair or replace the M1 main broom motor FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 31 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Side Broom(s) will not turn. Part A: Electrical Control Circuit Note 1: Check the F5 20A side broom(s) Circuit breaker if tripped reset. If breaker continues to trip see part B. Note 2: Do all testing with the key switch on, side brooms lowered, main broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or Reverse). Side broom(s) will not turn At the A2 display panel is the side broom increase light on? no Substitute an A2 display panel. Does the side broom(s) run? no yes On the A1 board is the side broom grn indicator light on? no Replace the A1 main controller. Does the side broom(s) run? no yes Check for 36V at the K8 solenoid coil: wire colors: BRN/BLK(-) & VIO(+) no Check both wire(s) for continuity. Repair or replace defective wire(s). Does the side broom(s) run? no yes Check the K8 coil resistance 120 ohms (+ or - 10%) no Replace K8 solenoid. Does the side broom(s) run? no yes See Part B 32 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Side Broom(s) will not turn. Part B: Electrical Load Circuit Note 1: Do all testing with the key switch on, side brooms lowered, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or reverse). Side broom(s) will not turn Is the F5 20 amp CB open no yes Inspect side broom(s) for possible mechanical binding, (clean debris wrapped around motor or brooms). Reset or replace CB Do the side broom(s) run? no At the K8 solenoid load wire VIO/GRA (+ battery input) check for 36V to battery ground no Repair or replace defective wire. Do the side broom(s) run? no yes At the K8 solenoid load wire WHT/RED (+ output to side broom motor(s) ) check for 36V to battery ground. no Replace K8 solenoid. Do the side broom(s) run? no yes Check for 36V at side broom motor(s) wires WHT/RED(+) & BLK(-) no Repair or replace defective wire(s) or connectors. Note: there are 2 splices located in the hopper dust control compartment for the motor wires. Do the side broom(s) run? no yes Repair or replace the M8/M9 side broom motors FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 33 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Side broom lift actuator will not lower. Note: Do all testing with key switch on, main broom lever lowered (press the side broom lower button on the A2 display panel if side brooms are not programmed to lower automatically). Side broom(s) will not lower At the A2 display panel is the side broom increase light on? no Substitute an A2 display panel. Does the side broom(s) work? no yes On the A1 board does the green side broom lift indicator light stay on while motor is extending no Replace the A1 main controller. Does the side broom(s) run? no yes Check for a 36V at the motor harness plug. no Repair or replace wiring to motor. Does the motor operate? yes Replace lift motor 34 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no SWEEPING SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Side broom lift actuator will not raise. Note: Do all testing with key switch on, main broom lever raised (press the side broom raise button on the A2 display panel if side brooms are not programmed to raise automatically). Side broom(s) will not raise At the A2 display panel is the side broom decrease light on? no Substitute an A2 display panel. Does the side broom(s) raise? no yes On the A1 board does the side broom lift indicator red light stay on momentarily while the motor is retracting? no Replace the A1 control board yes Check for open circuit in lift motor wiring to the A1 board. J1-35 GRA/VIO J1-23 GRN/ORN no yes Repair the wiring to motor. Does the motor retract? no Check for an open in lift motor. yes Replace lift motor FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 35 HYDRAULIC SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hydraulic pump motor will run but all hydraulic functions do not operate. Note: Do all testing with the key switch on and hopper raise button pressed at A2 Display panel. Hydraulic pump will not operate Separate the motor from the pump is the coupler sheared? See pump removal in SM56043096 no Replace Pump Assembly yes Replace damaged coupler. TROUBLESHOOTING GUIDE Possible Symptom 1 Hydraulic pump motor will not operate. Part A: Coil Circuit Note: Do all testing with the key switch on and hopper raise button pressed at A2 Display panel. Hydraulic pump motor will not operate At the A1 board is the Hydraulic Pump green indicator light on? no Replace the A1 Board. Does the pump operate? no yes Check for 36V at the K11 coil wire colors VIO(+) & BLU/WHT(-) no Repair or replace K11 coil wiring. Does the pump operate? no yes Check for coil resistance at K11 (149 ohms + or - 10%) no Replace K11 Contactor Does the pump operate? no yes See Part B Load Circuit 36 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B HYDRAULIC SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hydraulic pump motor will not operate. Part B: Load Circuit Note: Do all testing with the key switch on and hopper raise button pressed at A2 Display panel. Hydraulic pump motor will not operate At the K11 solenoid load wire ORN/WHT (+ battery input) check for 36V to battery ground. no Repair or replace defective wire. Does the pump operate? no yes At the K11 solenoid load wire (+) output to pump motor check for 36V to battery ground. no Replace K11 solenoid. Does the pump operate? no yes Check for 36V at pump motor negative input from battery ground. no Repair or replace defective wire from battery ground. Does the pump operate? no yes Repair or replace pump motor FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 37 HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hopper dump door will not open in the dump mode. Part A: To test: Key switch must be on, hopper must be raised. Dump door will not open Check continuity and adjustment of hopper interlock switch(S3). Check if the hopper raise indicator light is flashing on A2 panel no yes Note: switch will check open when hopper is raised Repair or replace (S3) switch no yes On A2 Press and hold hopper door open switch, is its green indicator light on? no Substitute a new A2 display panel. Does dump door operate? no yes Press and hold dump door open button. At the A1 board is the door open green indicator light on? no Replace A1 control board. Does dump door operate? no yes At the A1 board is the Hydraulic Pump green indicator light on? no See Hydraulic pump will not operate no Repair or replace L4 coil wiring Does dump door operate? yes Check for 36V at L4 dump door coil. Wire color (+)VIO & (-)BRN/GRN no yes Check for coil resistance at L4 (66 ohm) no Replace L4 coil. Does dump door operate? yes See hydraulic dump door troubleshooting section part B 38 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hopper dump door will not close in the dump mode. Part A: To test: Key switch must be on, hopper must be raised. Dump door will not close Check continuity and adjustment of hopper interlock switch(S3). Check if the hopper raise indicator light is flashing on A2 panel no yes Note: switch will check open when hopper is raised Repair or replace (S3) switch no yes Press and hold hopper door close switch, is its green indicator light on? no Substitute a new A2 display panel. Does dump door operate? no yes Press and hold dump door close switch. At the A1 board is the door close green indicator light on? no Replace A1 control board. Does dump door operate? no yes At the A1 board is the Hydraulic Pump green indicator light on? no See Hydraulic pump will not operate yes Check for 36V at L5 dump door coil. Wire color (+)VIO & (-)BLU/RED no Repair or replace L5 coil wiring. Does dump door operate? no yes Check for coil resistance at L5 (66 ohm) no yes Replace L5 coil. Does dump door operate? no See hydraulic dump door troubleshooting section part B FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 39 HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Dump door will not open or close when in dump mode Part B: Door will not operate Do any hydraulic functions operate? no See pump motor runs but no hydraulic functions no Is broom door cylinder in relief? yes Inspect for possible mechanical binding of: •Dump door •Dump door linkage •Dump door cylinder yes Repair or replace damaged parts. Does dump door operate? no yes Plumb in a pressure gauge at the pump port (D) See Figure 1. Test the relief valve setting (1500psi) by activating the door close switch. Adjust, clean or replace relief valve. no Does dump door operate? yes Remove and disassemble •L4 door open •L5 door closed Spool valve (cartridge) inspect clean and reinstall Does the door operate? no Replace defective spool valve L4 door open L5 door closed Does the door operate no Replace defective dump door cylinder 40 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no HOPPER SYSTEM FIGURE 1 Gauge­ 3,000 PSI (207 bar) Hose­ 2' (61 cm) 6,000 PSI (414 bar) Fitting­ Parker Diagnostics PD222 D B FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 41 HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hopper will not raise. Part A: Note: Do all testing with the key switch on, hopper raise switch pressed on the display panel. Hopper will not raise Does the Hydraulic pump motor run? no See Hydraulic pump motor will not operate no Substitute a new A2 display panel. Does the hopper raise? yes Press and hold hopper raise switch, is its green indicator light on? no yes Press and hold Hopper up switch. At the A1 board is the hopper up green indicator light on? no Replace A1 control board. Does the hopper raise? no yes Check for 36V at L6 hopper up coil. Wire color (+)VIO no Repair or replace L6 coil wiring. Does the hopper raise? & (-)RED/GRA no yes Check for coil resistance at L6 (66 ohm) no Replace L6 coil. Does the hopper raise? yes See hydraulic hopper will not raise troubleshooting section part B 42 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hydraulic Hopper will not raise. Part B: Note: Key switch must be turned on Hopper will not raise Do any other hydraulic functions operate? no yes Does the pump motor run? no See Pump motor runs but no hydraulic function. yes Is the hopper over its weight 550 lbs. capacity? no yes Empty the hopper. Does the hopper raise? Inspect for possible mechanical binding of: no no Is hopper cylinder in relief? no yes •Hopper linkage •Hopper cylinder yes Plumb in a pressure gauge at the pump port (B) See Figure 1. Test the relief valve setting (1500psi) by activating the hopper up switch. no Adjust, clean or replace relief valve. no Does the hopper raise? yes Repair or replace damaged parts does the hopper raise? Remove and disassemble •L6 hopper raise spool valve (cartridge) inspect clean and reinstall. •Does the hopper raise? no Replace defective spool valve L6 hopper raise. Does the hopper raise? no Replace hydraulic hopper cylinder FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 43 HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hopper will not lower. Part A: Note: Do all testing with the key switch on, hopper lower switch pressed on the display panel. Hopper will not lower Press and hold hopper lower switch, is its green indicator light on? no Substitute a new A2 display panel. Does the hopper lower? no yes Press and hold Hopper lower switch. At the A1 board is the hopper down green indicator light on? no Replace A1 control board. Does the hopper lower? no yes Check for 36V at L6A hopper down coil. Wire colors (+)VIO & (-)YEL/RED no Repair or replace L6A coil wiring. Does the hopper lower? no yes Check for coil resistance at L6A (66 ohms) no Replace L6A coil. Does the hopper lower? no See hydraulic hopper Lower troubleshooting section part B 44 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B HOPPER SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Hopper will not lower. Part B: Note: To test key switch must be on and hopper lower switch pressed. WARNING! Do not stand underneath a hopper that is not supported with the use of a safety support. Hopper will not lower Inspect for possible mechanical binding of: no •Hopper linkage •Hopper cylinder yes Repair or replace damaged parts. Does the hopper lower? no Remove and disassemble •L6A hopper lower spool valve (cartridge) inspect clean and reinstall. Does the hopper lower? no Replace defective spool valve •L6A hopper lower FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 45 SQUEEGEE SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Squeegee will not raise or lower. Note: Do all testing with the key switch on, empty recovery tank and the hopper closed. Squeegee switch must be activated on the display panel. Press the squeegee switch, is its green indicator light on? no Substitute a new A2 display panel. Does squeegee operate? no yes While pressing the squeegee switch, does the squeegee lift light stay on at the A1 board for 5-10 sec? Down: RED Up: GREEN no Are the squeegee lift lights on momentarily while the squeegee switch is pressed? (1 sec or less) yes yes Replace motor Check for open circuit in wiring or motor yes Repair or replace wiring or motor 46 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no Replace A1 control board. Does squeegee motor operate? no VACUUM SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Vacuum motor will not activate Part A: Note: Do all testing with the key switch on, empty recovery tank, hopper closed, squeegee lowered, seat switch and the foot pedal activated. On the A2 board is the recovery tank full light on? no yes Locate the indicator switch plug and jump out the machine harness wires GRA/YEL and BLK. Does the light go off? yes Inspect, clean or replace tank indicator switch and wires. (Switch is closed when tank is empty) Press the squeegee switch, is its green indicator light on at the A2 display panel no Substitute a new A2 display panel. Does vacuum operate? no yes Lower the squeegee then activate the foot pedal. Note seat switch must be closed, is the green vacuum light on at the A1 main board? no Replace A1 control board. Does the vacuum motor operate? no yes Check for 36V input at the K7 coil wires colors (+)VIO & (-)BLU no Repair or replace wiring to coils. Does vacuum motor operate? no Replace defective contactor. Does squeegee operate? no yes Check for K7 coil resistance 120 ohms (+ or - 10%) no yes See Part B Load Circuit FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 47 VACUUM SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Vacuum motor will not activate Part B: Note: Do all testing with the key switch on, empty recovery tank, hopper closed, squeegee lowered, seat switch and the foot pedal activated. Vacuum motor(s) will not run Is the F8 40amp CB open no yes Inspect motor(s) for possible mechanical binding, (debris in and around motor). Reset or replace CB no At the K7 solenoid load wire GRN/RED (+ battery input) check for 36V to battery ground. no Repair or replace defective wire. Do the motor(s) run? no yes At the K7 solenoid load wire BLU/GRA (+) output to motor(s) check for 36V to battery ground. no Replace K7 solenoid. Do the motor(s) run? no yes Check for 36V at each motor wires BLU/GRA(+) & BLK(-) no Repair or replace defective wires or connectors at motor(s). Do the motor(s) run? no yes Repair or replace the M6/M7 vacuum motors 48 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B DUST CONTROL SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Dust control impeller motor will not run Part A: Note: Do all testing with the key switch on, hopper closed, dust control switch on, seat switch and foot pedal activated. Press the dust control switch, (located on the A2 display panel) is its green indicator light on? no Substitute a new A2 display panel. Does impeller operate? no yes On the A1 board is the dust control light on? no Replace A1 control board. Does the impeller motor operate? yes Check for 36V at K6 impeller motor coil. Wire colors (+)VIO & (-)BRN/YEL no no Repair or replace K6 coil wiring. Does impeller motor operate? no yes Check K6 coil resistance (120 ohms) + or - 10% yes no Repair or replace K6 contactor. Does impeller motor operate? no See Part B Load Circuit FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 49 DUST CONTROL SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Dust control impeller motor will not run Part B: Load Circuit Note: Do all testing with the key switch on, hopper closed, dust control switch on, seat switch and foot pedal activated. Dust control impeller motor will not run Is the F4 15 amp CB open? no yes Inspect motor for possible mechanical binding, (debris in and around motor). Reset or replace CB. no At the K6 solenoid load wire BRN/WHT (+ battery input) check for 36V to battery ground. no Repair or replace defective wire. Does the motor run? no yes At the K6 solenoid load wire ORN/GRN (+ output to motor) check for 36V to battery ground. no Replace K6 solenoid. Does the motor run? no yes Check for 36V at motor wires ORN/GRN(+) & BLK(-) yes Repair or replace the M5 dust impeller motor 50 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no Repair or replace defective wires or connectors at motor Does the motor run? no DUST CONTROL SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Shaker motor does not operate Note: Do all testing with the key switch on and shaker button pressed. Press and hold the shaker switch on the A2 display board. Does its green indicator light come on? no Substitute an A2 display panel. Does the shaker operate? no yes On the A1 board is the shaker green indicator light on? no Replace the A1 control board. Does the shaker operate? no yes Check for 36V at the shaker motor M14. Wire colors BLK/RED(-) & VIO(+) no Check wires for continuity. Repair or replace wires. Does the shaker operate? no yes Repair or replace motor. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 51 SCRUB SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Scrub deck will not raise Note: Do all testing with the key switch on, the hopper closed. Press the scrub off switch, is its green indicator light on? Substitute a new A2 display panel. no Does the scrub deck raise? no yes On the A1 Board is the retract limit yellow light on? Note: the yellow limit light is one of 14 grouped together. no At the lift motor separate the plug and check for continuity between the RED and ORN wires (retract limit switch) at the motor plug. Replace lift motor. no Repair or replace wiring or plug. Does the motor run? yes Check for continuity in the harness wires RED/ORN to pin J2-3 at the A1 board. BLK wire to battery ground. yes no yes See Motor Load section Motor Load section While Pressing the scrub off switch, does the scrub deck lift light turn on at the A1 board? Down: RED Up: GREEN no Replace A1 control board. yes Separate motor plug and then jump lift motor to battery (wires RED & YEL) Does the motor run? no Check for continuity in the lift motor, wire colors RED & YEL no Repair or replace wiring or plug. yes Check for continuity at the motor harness plug wires RED/GRN to pin J1-12 and YEL/GRA J1-11 at the A1 board. 52 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no Repair or replace wiring, plug or motor no SCRUB SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Scrub deck will not lower Part A: Note: Do all testing with the key switch on, recovery tank empty and the hopper closed. On the A2 board is the recovery tank full light on? yes Locate the indicator switch plug and jump out the machine harness wires GRA/YEL and BLK. Does the light go off? no no Open in harness wires repair or replace wires to A1 board yes Inspect, clean or replace tank indicator switch and wires. (Switch is closed when tank is empty) Press the scrub pressure increase/decrease switch, is its green indicator light on? no Substitute a new A2 display panel. Does the scrub deck raise? no yes On the A1 board is the extend limit yellow light on? Note: the yellow limit light is one of the 14 grouped together. no At the lift motor separate the plug and check for continuity between the RED and BLK wires (extend limit switch) at the motor plug. no Replace lift motor. no Repair or replace wiring or plug. Does the motor run? yes yes Check for continuity in the harness wires GRN/VIO to pin J2-15 at the A1 board and the BLK wire to battery ground. no yes See Motor Load section FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 53 SCRUB SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Scrub deck will not lower Part B: Load Note: Do all testing with the key switch on, recovery tank empty and the hopper closed. While pressing the scrub decrease or increase switch, does the scrub deck lift light turn on at the A1 board? Down: RED Up: GREEN no Replace A1 control board. yes Separate motor plug and then jump lift motor to battery (wires RED & YEL). Does the motor run? no Check for continuity in the lift motor, wire colors RED & YEL no yes Check for continuity at the motor harness plug wires RED/GRN to pin J1-12 and YEL/GRA J1-11 at the A1 board. no 54 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B Repair or replace wiring or plug. Repair or replace wiring, plug or motor SCRUB SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Scrub deck motors will not operate. Part A: Note: Do all testing with the key switch on, seat switch closed, scrub deck pressure set on (1) foot pedal activated and solution shut off. Scrub deck motors will not operate See machine drive auto function do not work section no Do other auto drive functions work? yes Press scrub decrease switch(-) On the display, is its green indicator light on? Substitute a new A2 display panel. Do the motors operate? no no yes Press the scrub increase switch along with moving the foot pedal. Are the numbers 1, 2 and 3 green scrub lights on at the A1 board? no Replace A1 control board. Do the motors operate? no yes no Do any of the brush motors run? See Brush motor load section yes Left brush does not run. Check for 36V at K1 brush motor coil. Wires (+)VIO & (-)YEL/BLU no yes Center brush does not run. Check for 36V at K2 brush motor coil. Wires (+)VIO & (-)WHT/VIO no Repair or replace coil wiring. Does the motor run? no yes yes Right brush does not run. Check for 36V at K3 brush motor coil. Wires (+)VIO & (-)GRA/RED yes no Check coil resistance (120 ohms) + or 10% no Repair or replace contactor. Does scrub motor operate? no yes See Part B Load Circuit FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 55 SCRUB SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Scrub deck motors will not operate. Part B: Load Circuit Note: Do all testing with the key switch on, seat switch closed, scrub deck pressure set on (1) foot pedal activated and solution shut off. All the scrub brush motors will not turn Inspect individual motor gearbox assy for possible mechanical problems. Repair motor gearbox. no yes Is the F11 250 amp Fuse open no no yes Inspect motor gearbox assy for possible mechanical problems, (debris in and around motors). Replace fuse. Left brush motor does not run. Check for 36V at K1 brush motor load wire RED/VIO (+ battery input) to battery ground. no yes Center brush does not run. Check for 36V at K2 brush motor load wire RED/VIO (+ battery input) to battery ground. Repair or replace defective wire. Does the motor run? no yes Right brush does not run. Check for 36V at K3 brush motor load wire RED/VIO (+ battery input) to battery ground. no yes At the solenoid load wires K1 WHT/ORN, K2 GRA/BLK, K3 BLU/YEL (+ output to motor) check for 36V to battery ground. Replace defective solenoid. Does the motor run? no no yes Check for 36V at brush motors wires M2, M3 & M4 yes Repair or replace defective motor. 56 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B no Repair or replace defective wire. Does the motor run? no SOLUTION SYSTEM TROUBLESHOOTING GUIDE Possible Symptom 1 Solution solenoid valve(s) do not operate. Note: Do all testing with the key switch on, solution switch pressed, seat switch closed, scrub deck lowered and drive pedal activated in forward. Is the solution green indicator light on at the A2 Display Panel? no Substitute a new A2 Display Panel. Do the solution valve(s) work? no yes On the A1 control board is the solution indicator light on? no Replace the A1 control board. Do the solution valve(s) work? no yes Check for 36V at the solution valve(s). no Repair or replace wiring to solution valve(s). Do the solution valve(s) work? no yes Check the resistance of the solution valve(s). 70 ohms. no Replace the solution valve(s) yes Clean and repair solution valve(s). Does the solution valve(s) work? no FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 57 PROGRAMMABLE CONTROL OPTIONS Scrub Motor Turn-Off Delay Adjustment: FACTORY DEFAULT: 1 (0.5 second) RANGE: 1 - 9 (0.5 – 4.5 seconds) The amount of time that the scrub brushes continue to run after the foot pedal returns to neutral is adjustable. To select the desired delay: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the scrub system off switch. While holding the scrub system off switch turn the main power key switch to the on position. Continue to hold the scrub system off switch until all indicators except the scrub off indicator turn off (approximately two seconds). Release the scrub off switch. The status display will now show a number from 1 to 9. Pressing and releasing the scrub off switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents 0.5 second with 1 equal to 0.5 second. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Vacuum Turn-Off Delay Adjustment: FACTORY DEFAULT: 1 (12 seconds) RANGE: 1 - 9 (12 – 20 seconds) The amount of time that the vacuum continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the vacuum/squeegee switch. While holding the vacuum/squeegee switch turn the main power key switch to the on position. Continue to hold the vacuum/squeegee switch until all indicators except the vacuum/squeegee indicator turn off (approximately two seconds). Release the vacuum/squeegee switch. The status display will now show a number from 1 to 9. Pressing and releasing the vacuum/squeegee switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to twelve seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Main and Side Broom Turn-Off Delay Adjustment: FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds) The amount of time that the main broom and side brooms continue to run after the foot pedal returns to neutral is adjustable. To select the desired delay: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the side broom up/off switch. While holding the side broom up/off switch turn the main power key switch to the on position. Continue to hold the side broom up/off switch until all indicators except the side broom up/off indicator turn off (approximately two seconds). Release the side broom up/off switch. The status display will now show a number from 1 to 9. Pressing and releasing the side broom up/off switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. 58 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B PROGRAMMABLE CONTROL OPTIONS Dust Control Turn-Off Delay Adjustment: FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds) The amount of time that the dust control continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the dust control switch. While holding the dust control switch turn the main power key switch to the on position. Continue to hold the dust control switch until all indicators except the dust control indicator turn off (approximately two seconds). Release the dust control switch. The status display will now show a number from 1 to 9. Pressing and releasing the dust control switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Shaker Duration Adjustment: FACTORY DEFAULT: 5 (20 seconds) RANGE: 1 - 9 (12 – 28 seconds) The amount of time that the shaker runs once it has been activated is adjustable. To select the desired duration: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the shaker switch. While holding the shaker switch turn the main power key switch to the on position. Continue to hold the shaker switch until all indicators except the shaker indicator turn off (approximately two seconds). Release the shaker switch. The status display will now show a number from 1 to 9. Pressing and releasing the shaker switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents two seconds with 1 equal to twelve seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Hopper Door Open/Close Duration Adjustment: FACTORY DEFAULT: 1 (2.0 seconds) RANGE: 1 - 9 (2.0 – 4.0 seconds) The amount of time the valves that open or close the hopper door remain on when automatically opening or closing the door is adjustable. To select the desired duration: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the hopper door open switch. While holding the hopper door open switch turn the main power key switch to the on position. Continue to hold the hopper door open switch until all indicators except the hopper door open indicator turn off (approximately two seconds). Release the hopper door open switch. The status display will now show a number from 1 to 9. Pressing and releasing the hopper door open switch will increase the displayed value until 9 is reached. The next press will return to 1. Each increment represents 0.25 second with 1 equal to two seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 59 PROGRAMMABLE CONTROL OPTIONS Scrub Pressure Default Adjustment: FACTORY DEFAULT: 1 (minimum pressure) RANGE: 0 - 3 The default scrub pressure that is selected each time the scrub system is activated can be adjusted. To select the desired default value: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the scrub pressure decrease switch. While holding the pressure decrease switch turn the main power key switch to the on position. Continue to hold the pressure decrease switch until all indicators except the scrub pressure decrease indicator turn off (approximately two seconds). The status display will now show a number from 0 to 3. Pressing and releasing the scrub pressure decrease switch will increase the displayed value until 3 is reached. The next press will return to 0. If 0 is selected, the scrub pressure will return to the last used setting when the scrub system is activated. If 1 is selected, the scrub pressure will default to the minimum setting when activated. If 2 is selected, the scrub pressure will default to the medium setting when activated. If 3 is selected, the scrub pressure will default to the maximum setting when activated. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Scrub Pressure Limit Adjustment: FACTORY DEFAULT: 3 (maximum pressure) RANGE: 1 - 3 The maximum scrub pressure that the operator can select can be adjusted. To select the desired limit value: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the scrub pressure increase switch. While holding the pressure increase switch turn the main power key switch to the on position. Continue to hold the pressure increase switch until all indicators except the scrub pressure increase indicator turn off (approximately two seconds). The status display will now show a number from 1 to 3. Pressing and releasing the scrub pressure increase switch will increase the displayed value until 3 is reached. The next press will return to 1. If 1 is selected, the only available scrub pressure will be the minimum setting. If 2 is selected, the minimum and medium scrub pressures will be available. If 3 is selected, all scrub pressures will be available. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Scrub Pressure Range Selection: FACTORY DEFAULT: 1 (FULL RANGE) The Captor / CR 1100 & 1200 has three scrub pressure settings. The default pressure settings range from the minimum pressure required for adequate cleaning to the maximum pressure that the scrub motors can safely handle with one setting halfway in between. It is possible to bias these settings either to a low range or a high range. If biased to the low range, the minimum setting will be the same as the default however, the middle and maximum pressures will be lower than the defaults. If the high range bias is selected, the minimum and middle pressures will be greater than the defaults but the maximum pressure will be the same. To select the pressure range: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the scrub system off and the scrub pressure decrease switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the scrub system off and scrub pressure decrease indicator turn off (approximately 2 seconds). Release both switches. The status display will now indicate a number from 1 to 3 depending on the current range. Pressing and releasing the scrub pressure decrease switch will now select the pressure range. 1 = full range, 2 = low bias, 3 = high bias. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. 60 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B PROGRAMMABLE CONTROL OPTIONS Back-up Alarm Mode Control: FACTORY DEFAULT: 1 (reverse only) RANGE: 0 - 4 The Captor / CR 1100 & 1200 may be equipped with an optional back-up alarm. This alarm can be programmed to operate at times other than backing up or it may be turned off. To select the operating mode: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the horn switch. While holding the horn switch turn the main power key switch to the on position. Continue to hold the horn switch until all indicators except the horn indicator turn off (approximately two seconds). Release the horn switch. The status display will now show a number from 0 to 4. Pressing and releasing the horn switch will increase the displayed value until 4 is reached. The next press will return to 0. If 0 is selected, the back-up alarm will be disabled and will not sound at any time. If 1 is selected, the alarm will sound only when backing up. If 2 is selected, the alarm will sound when driving forward or in reverse. It will be off in neutral. If 3 is selected, The alarm will sound when backing up or if the hopper is being raised or lowered. If 4 is selected, The alarm will sound when driving forward or in reverse or if the hopper is being raised or lowered. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Side Broom Mode Control: FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2 The side brooms on the Captor / CR 1100 & 1200 are programmed to always come on when the main broom is first activated. If this is not desired, the operating mode of the side booms can be changed. To select the operating mode: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the side broom up/off and the scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the side broom up/off and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 0 to 2. Pressing and releasing the side broom up/off switch will increase the displayed value until 2 is reached. The next press will return to 0. If 0 is selected, the side brooms will not come on with the main broom. They will be manual control only. If 1 is selected, the side brooms will always come on when the main broom is initially turned on. If 2 is selected, the side brooms will come on if they were used the last time the main broom was on otherwise they will not automatically come on. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Dust Control Mode Control: FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2 The dust control on the Captor / CR 1100 & 1200 is programmed to always come on when the main broom is first activated. If this is not desired, the operating mode of the dust control can be changed. To select the operating mode: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the dust control and the scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the dust control and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 0 to 2. Pressing and releasing the dust control switch will increase the displayed value until 2 is reached. The next press will return to 0. If 0 is selected, the dust control will not come on with the main broom. It will be manual control only. If 1 is selected, the dust control will always come on when the main broom is initially turned on. If 2 is selected, the dust control will come on if it was used the last time the main broom was on otherwise it will not automatically come on. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 61 PROGRAMMABLE CONTROL OPTIONS Dust Control Mode Control with Hopper Up: FACTORY DEFAULT: 2 (no change) RANGE: 0 - 2 The dust control on the Captor / CR 1100 & 1200 can be programmed to turn on or off or stay in its current state when the hopper is raised for dumping. To select the operating mode: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the dust control and the scrub pressure decrease switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the dust control and scrub pressure decrease indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 0 to 2. Pressing and releasing the dust control switch will increase the displayed value until 2 is reached. The next press will return to 0. If 0 is selected, the dust control will turn off when the hopper is raised. If 1 is selected, the dust control will turn on when the hopper is raised. If 2 is selected, the dust control will remain in the same state that it was in prior to raising the hopper (no change). To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Shaker Mode Control: FACTORY DEFAULT: 1 (timed – manual control) RANGE: 0 - 3 The dust control filter shaker on the Captor / CR 1100 & 1200 is programmed to run for an adjustable period of time when the operator depresses the shaker switch on the control panel. The shaker can be programmed to operate in a momentary fashion or automatically. To select the operating mode: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the shaker and scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the shaker and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 0 to 3. Pressing and releasing the shaker switch will increase the displayed value until 3 is reached. The next press will return to 0. If 0 is selected, the shaker will turn on only when the control panel switch is held (momentary). If 1 is selected, the shaker will run for an adjustable period of time (see above to adjust time period). If 2 is selected, the shaker will automatically run for an adjustable period of time when the main broom is turned off. If 3 is selected, the shaker will automatically run for an adjustable period of time when the hopper is lowered all the way down after being in the up position. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Control Assembly Revision Display: To display the revision of the control assembly, perform the following steps: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the hopper up switch. While holding the hopper up switch turn the main power key switch to the on position. Continue to hold the hopper up switch until all indicators except the hopper up indicator turn off (approximately two seconds). Release the hopper up switch. The status display will now show a letter representing the revision of the display assembly. To exit this mode, turn the main power key switch to the off position. 62 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B PROGRAMMABLE CONTROL OPTIONS Solution Flow in Reverse Enable/Disable: FACTORY DEFAULT: 0 (solution flow off in reverse) RANGE: 0 - 1 The solution flow is programmed to stop when backing up to prevent excessive cleaning solution from being dispensed. If it is desired to allow solution flow in reverse, perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the solution and the scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the solution and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a 0 or a 1. Pressing and releasing the solution switch will alternate between the two. If 0 is selected, solution flow will stop when backing up. If 1 is selected, solution flow will stay on when backing up. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. High Speed Scrub/Sweep (Fast/Slow Switch) Enable/Disable: FACTORY DEFAULT: 1 RANGE: 0 - 1 Normally, the maximum travel speed is reduced during scrubbing and/or sweeping operations. The fast/slow switch on the control panel allows the operator to override this speed reduction which allows scrubbing and/or sweeping at maximum speed. If this is not desirable, this feature can be disabled. This will prevent traveling at maximum speed while scrubbing and/or sweeping. Note: see programming of reduced speed mode to select speed reduction while scrubbing and/or sweeping. To enable or disable this feature, perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the fast/slow switch. While holding the fast/slow switch turn the main power key switch to the on position. Continue to hold the fast/slow switch until all indicators except the fast/slow indicator turn off (approximately two seconds). Release the fast/slow switch. The status display will now show a 0 or a 1. Pressing and releasing the fast/slow switch will alternate between the two. If 0 is selected, high speed scrubbing/sweeping will not be allowed. If 1 is selected, high speed scrubbing/sweeping will be allowed. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Reduced Speed Mode: FACTORY DEFAULT: 1 (reduced speed while scrubbing) RANGE: 1 - 3 The Captor / CR 1100 & 1200 can be programmed to automatically limit the maximum travel speed while scrubbing only, sweeping only, or either scrubbing or sweeping. To select which operation will cause the automatic speed reduction, perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the fast/slow and the scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the fast/slow and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 1 to 3. Pressing and releasing the fast/slow switch will increase the displayed value until 3 is reached. The next press will return to 1. If 1 is selected, the maximum travel speed will be reduced while scrubbing. If 2 is selected, the maximum travel speed will be reduced when scrubbing or sweeping. If 3 is selected, the maximum travel speed will be reduced when sweeping only. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 63 PROGRAMMABLE CONTROL OPTIONS Control System Self-Diagnostic Mode: If problems with the electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is 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. A listing of error codes is provided at the end of this section. 1 CAUTION! During this test, the horn will sound briefly and the various motors will turn on momentarily. Make sure that all persons are away from ALL moving parts of the machine to prevent injury. 2 Turn the main power key switch to the off position. 3 Press and hold the side broom down/on switch switch. 4 While holding the side broom down/on switch, turn the main power key switch to the on position. 5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off (approximately two seconds). 6 Release the side broom down/on switch. 7 The control will now activate each output in sequence and perform the tests mentioned above. 8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10. 9 If abnormal output conditions were detected, the display will now show the error code(s). An example of how two codes, 6 and 18, would be displayed is as follows: • The display will show “E” followed by a brief blank period • The display will show “0” followed by a brief blank period • The display will show “6” followed by a slightly longer blank period • The display will show “E” followed by a brief blank period • The display will show “1” followed by a brief blank period • The display will show “8” followed by a long blank period • The above sequence will repeat 10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult the service manual trouble-shooting section. 11 The hopper limit, main broom, recovery tank full, solution tank empty, hydraulic filter, hopper temperature, and dust control filter switches may also be tested in this mode. The corresponding indicators will indicate the state of each of the inputs. The speed controller fault code status light will indicate the state of the speed control fault output (a periodic flash is normal). The Battery status indicators will indicate the following: red indicator = state of seat switch, yellow indicator = state of forward/reverse signal from speed control, green indicator = state of reverse signal from speed control. The hourmeter display will indicate the battery voltage. 12 To exit this mode, turn the main power key switch to the off position. NOTE: If the machine is not equipped with an optional back-up alarm, an error code 59 will be indicated. Also, this test does not include the light circuit. 64 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B PROGRAMMABLE CONTROL OPTIONS Recall Of Stored Error Codes: Whenever an electrical system fault is detected by the main control unit, one or more error codes are displayed and stored by the control unit. If it is desired, the error code (if any) from the previous operation of the machine can be recalled for troubleshooting purposes. To recall the last stored error codes perform the following steps: 1 Turn the main power key switch to the off position. 2 Press and hold the solution switch. 3 While holding the solution switch, turn the main power key switch to the on position. 4 Continue to hold the solution switch until all indicators except the solution indicator turn off (approximately two seconds). 5 Release the solution switch. 6 If there were previously no error codes stored, the display will now show “-”. Go to step 10. 7 If error codes were stored, the display will now show the stored code(s). An example of how two codes, 6 and 18, would be displayed is as follows: • The display will show “E” followed by a brief blank period • The display will show “0” followed by a brief blank period • The display will show “6” followed by a slightly longer blank period • The display will show “E” followed by a brief blank period • The display will show “1” followed by a brief blank period • The display will show “8” followed by a long blank period • The above sequence will repeat 8 To clear the stored codes press and release the solution switch. The display will now show “-“. Go to step 10. 9 If it is desired to save the codes, go to step 10. 10 To exit the error code recall mode, turn the main power key switch to the off position. Reset of All Programmable Parameters to Factory Default Settings: To reset all of the above parameters to the factory defaults, perform the following steps: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the all three scrub system switches (scrub off, pressure increase, & pressure decrease). While holding all three switches turn the main power key switch to the on position. Continue to hold all three switches until all indicators turn off and the status display shows “d” (approximately two seconds). Release all switches. The programmable parameters are now restored to the default values. To exit this mode, turn the main power key switch to the off position. Reset of Hourmeters to Zero: To reset all hourmeters to zero: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the scrub pressure increase, scrub pressure decrease, and solution switches. While holding all three switches turn the main power key switch to the on position. Continue to hold all three switches until all indicators turn off and the status display shows “d” (approximately two seconds). Release all switches. The hourmeters are now reset to zero. To exit this mode, turn the main power key switch to the off position. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 65 PROGRAMMABLE CONTROL OPTIONS Low Voltage Cutout Level: FACTORY DEFAULT: 1 (1.75VPC cutoff; 2.15VPC reset, VPC = Volts Per Cell) RANGE: 1-3 The low voltage cutoff feature will disable scrub and sweep functions when the battery becomes discharged. The cutoff and reset thresholds are selectable from three options. These are Option 1 – 1.75VPC cutoff, 2.15VPC reset; Option 2 – 1.75VPC cutoff, 2.09VPC reset; Option 3 – 1.83VPC cutoff, 2.09VPC reset. To select the desired cutoff level perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the side broom down/on and the scrub system off switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the side broom down/on and scrub off indicators turn off (approximately two seconds). Release both switches. The status display will now show a number from 1 to 3. Pressing and releasing the side broom down/on switch will increase the displayed value until 3 is reached. The next press will return to 1. If 1 is selected, the cutoff level will be 1.75VPC & the reset level will be 2.15VPC. If 2 is selected, the cutoff level will be 1.75VPC & the reset level will be 2.09VPC. If 3 is selected, the cutoff level will be 1.83VPC & the reset level will be 2.09VPC. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Control Unit Sleep Delay Period: FACTORY DEFAULT: 1 (10 minutes) RANGE: 0 - 9 If the Captor / CR 1100 & 1200 is left in an idle state for a period determined by the sleep delay setting the control unit will automatically turn off any accessories. This is to conserve battery power. The sleep period is adjustable from 10 to 90 minutes in 10 minute increments. It can also be turned off. To change the sleep delay period perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the scrub system off and the hopper up switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the scrub system off and the hopper up indicators turn off (approximately 2 seconds). Release both switches. The status display will now indicate a number from 0 to 9 depending on the current sleep delay period. Pressing and releasing the hopper up switch will now select the delay period. The level will increment from 0 to 9. 0 = off (sleep disabled), 1 = 10 minutes, 2 = 20 minutes, ... up to 9 = 90 minutes. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. Squeegee Raise-In-Reverse Time Period Adjustment: FACTORY DEFAULT: 3 (2.5 seconds) RANGE: 1 - 9 When backing up with the recovery system active, the control unit will automatically raise the squeegee just enough to prevent dragging on the floor. The time that the squeegee is raised is adjustable from 2 to 4 seconds in .25 second increments. To adjust the distance the squeegee is raised in reverse, perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the scrub system off and the vacuum switches. While holding both switches turn the main power key switch to the on position. Continue to hold both switches until all indicators except the scrub system off and vacuum indicator turn off (approximately 2 seconds). Release both switches. The status display will now indicate a number from 1 to 9 depending on the current time period. Pressing and releasing the vacuum switch will now select the time period. The level will increment from 1 to 9. 1 = 2 second, 2 = 2.25 seconds, 3 = 2.5 seconds, ... up to 9 = 4.0 seconds. To save the new setting, turn the main power key switch to the off position. The new setting will be saved and will remain in effect until it is changed again. 66 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B ELECTRICAL SYSTEM CURTIS CONTROLLER (A3) DIAGNOSTICS Diagnostics Method A: Uses the machine’s control panel LED status display. FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY The Curtis 1244 speed control will output a fault code if there is a problem associated with the speed control and wheel drive system. See Figure 1. If a speed control or drive motor fault occurs, the Wrench Symbol (E) located in the top center on the (A2) operator panel will flash a special error code sequence until the fault is corrected. See “Table 1” for a description of the fault indications. Service Note: Instructions on how to read the error code status light. Example, OO O = two light flashes, a short pause, one flash, a long pause and the code will be repeated. FIGURE 1 E Diagnostics Method B: Uses the optional hand held programmer. PROGRAMMER DIAGNOSTICS With a programmer, diagnostics and troubleshooting is more direct than with the LED alone. The programmer presents complete diagnostic information in plain language, no codes to decipher. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu. The following 4-step process is generally used for diagnosing and troubleshooting an inoperative vehicle: (1) visually inspect the vehicle for obvious problems; (2) diagnose the problem, using the programmer; (3) test the circuitry with the programmer: and (4) correct the problem. Repeat the last three steps as necessary until the vehicle is operational. Example: A vehicle that does not operate in “forward” is brought in for repair. 1 Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose connections. 2 Connect the programmer, put it in diagnostic mode, and read the displayed fault information. In this example, the display shows “No Faults Present”, indicating that the controller has not detected anything out of the norm. 3 Put the programmer in test mode, and observe the status of inputs and outputs in the forward direction. In this example, the display shows that the forward input did not activate when “forward” was selected, which means the problem is either in the electronic throttle or the throttle wiring. 4 Check or replace the electronic throttle and wiring and repeat the test. If the programmer shows the forward switch closing and the vehicle now drives normally, the problem has been corrected. Refer to the Status Fault Codes (Table 1) for suggestions covering a wide range of possible faults. DIAGNOSTIC HISTORY The handheld programmer can be used to access the controller’s diagnostic history file. Connect the programmer, press the MORE INFO key, and then while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The programmer will read out all the faults that the controller has experienced since the last time the diagnostic history file was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator errors. Faults such as contactor faults may be the result of loose wires; contactor wiring should be carefully checked out. Faults such as HPD or over temperature may be caused by operator habits or by overloading. After a problem has been diagnosed and corrected, clearing the diagnostic history file is advisable. This allows the controller to accumulate a new file of faults. By checking the new diagnostic history file at a later date, you can readily determine whether the problem was indeed completely fixed. To clear the diagnostic history file, go to the Special Program Menu (by pressing and holding the MORE INFO key, and then pressing the PROGRAM key), scroll through the menu until “Clear Diagnostic History” is the top line in the display, and then press MORE INFO again. The programmer will prompt you to acknowledge or cancel. See the PROGRAMMER OPERATION section of this chapter for more detail on programmer operation. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 67 ELECTRICAL SYSTEM STATUS LED FAULT CODES (TABLE 1) LED CODE Off Solid On 0,1 1,2 1,3 2,1 2,2 STATUS LIGHT DISPLAY EXPLANATION – O O OO No power or defective controller Controller or microprocessor fault Controller operational; no faults Hardware failsafe error O OOO M-, current sensor, or motor fault OO O OO OO POSSIBLE CAUSE 1. Controller defective. 1. Controller defective. 2. Motor field wiring loose. 3. Motor field winding open. Throttle fault 1. Throttle input wire open. 2. Throttle input wire shorted to B+ or B-. 3. Throttle pot defective. 4. Wrong throttle type selected Static return to off (SRO) fault 1. Improper sequence of KSI*, interlock, and direction inputs. 2. Wrong HPD type selected. 3. Interlock or direction switch circuit open. 4. Sequencing delay too short. 1. Improper sequence of direction and throttle inputs. 2. Wrong HPD type selected. 3. Misadjusted throttle pot. 4. Sequencing delay too short. 2,3 OO OOO High Pedal Disable (HPD) fault 2,4 OO OOOO Emergency reverse circuit check fault 3,1 OOO O Contactor driver overcurrent 3,2 OOO OO Welded Main Contactor 3,3 OOO OOO Precharge fault 1. Controller defective. 2. External short, or leakage path to B- on external B+ connection. 3,4 OOO OOOO Missing contactor, or main cont. did not close 1. Any contactor coil open or not connected. 2. Main contactor missing or wire to coil open. 4,1 OOOO O Low battery voltage 1. Battery voltage overvoltage shutdown limit. 2. Vehicle operating with charger attached. 3. Battery disconnected during regen braking. 4,3 OOOO OOO Thermal cutback, due to over/undertemp 1. Temperature >85°C (185°F) or<-25°C (-13°F). 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. Operation in extreme environments. 4,4 OOOO OOOO Anti-tiedown fault 1. Mode switches shorted to B+ 2. Mode switches “tied down” to select Mode 2 or Mode 4 permanently. 1. Emergency reverse wire open. 2. Emergency reverse check wire open. 1. Contactor coil shorted. 1. Main contactor stuck closed. 2. Main contactor driver shorted. *NOTE: A KSI (key switch input) system problem is a specific HPD (high pedal disable) type operational fault, caused by the operator activating the Fwd/Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat. This can be cleared by returning the operator’s drive pedal to neutral and cycling the key switch OFF and ON. 68 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B ELECTRICAL SYSTEM INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER SAFETY! The 1244 controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated wrenches. After installing a controller and before operating the vehicle, carefully complete the following checkout procedure. If you find a problem during the checkout, refer to the DIAGNOSTICS section of this chapter for further information. The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer otherwise observe the Status LED for codes. The part number of the handheld programmer is 56409441. NOTE: The Captor / CR 1100 & 1200 has a newer revision controller if you have a programmer with a serial number before 2100 you will need to update your programmer. A free upgrade kit is available, order part number 56409822. Also a different quad 4 pin programmer cable (PN 56409823) is needed to link the programmer to the controller plug-in port. WARNING! Put the vehicle up on blocks to get the drive wheel off the ground before beginning these tests. Turn the key switch off and make sure that the seat switch is open, and the throttle is in neutral. Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests. 1 2 3 • • 4 5 6 Remove electrical panel to access controller then observe LED status light on controlller. If a programmer is available, connect it to the programmer connector. Turn the key switch on. The programmer should “power up” with an initial display, and the controller’s Status LED should begin steadily blinking a single flash (once every 5 seconds). If neither happens, check for continuity in the key switch circuit and controller ground. If you are using a programmer, put it into the diagnostic mode by pressing the DIAGNOSTICS key. The display should indicate “No Faults Found”. Note: Before pressing the diagnostics key, wait until model # screen appears, if the throttle is activated prior to this screen appearing the controller will shut down. Close the seat switch (sit in the seat). The LED should continue blinking a single flash (every 5 seconds) and the programmer should continue to indicate no faults. If there is a problem, the LED will flash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, look up the LED diagnostic code in the DIAGNOSTICS section of this chapter (Table 1). When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the fault code. While sitting on the seat, operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the main contactor, and the motor. The motor should run proportionally faster with increasing throttle. If not, refer to the DIAGNOSTICS section of this chapter (Table 1). If you are using a programmer, put it into the test mode by pressing the TEST key. Scroll down to observe the status of the forward, reverse and brake switch (brake switch is actually the seat switch on the Captor / CR 1100 & 1200). Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer. Take the vehicle off the blocks and drive it in an open area. It should have smooth acceleration and good top speed. PROGRAMMING VEHICLE SPEED CHANGES The maximum high-speed (transport) and maximum low speed (scrub) can be changed electronically, using the handheld programmer. To change a parameter using the programmer, press the PROGRAM key, and scroll down the Program Menu until the desired parameter is the top line of the display. Press the appropriate CHANGE VALUE key (“up” or “down”) until the desired number is reached. The parameter is now set at the desired value. All programming occurs in real time. In other words, the parameters can be changed while the vehicle is in operation. The upper and lower limits of parameters are set at the factory. Some parameters have dependencies on other parameters. When the programmer is being used to adjust a parameter and a limit is reached, the display will stop changing. To see why the display has stopped changing, press the MORE INFO key. If the limit is related to another parameter, that information will be displayed; changing the value of the related parameter may allow the original parameter to be adjusted further. Otherwise, the display simply says “Max Limit” or “Min Limit.” Use of the programmer is described more fully in the PROGRAMMER OPERATION section of this chapter. MAINTENANCE There are no user-serviceable parts inside the Curtis PMC 1244 controller. No attempt should be made to open the controller. Opening the controller may damage it and will void the warranty. However, it is recommended that the controller exterior be cleaned periodically, and if a handheld programmer is available, this periodic cleaning provides a good opportunity to check the controller’s diagnostic history file. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 69 ELECTRICAL SYSTEM PROGRAMMER OPERATION The optional universal Curtis PMC handheld programmer / PART NUMBER 56409441 (Figure 2) allows you to program, test, and diagnose Curtis PMC 1244 controllers. The programmer is powered by the host 1244 controller, via a modular connector located in the front of the controller. FIGURE 2 When the programmer is first plugged into the controller, wait until the programmer has acquired all the controller parameters. When this step has been completed, the programmer displays the controller’s model number, date of manufacture and software revision code. Following this initial display, the programmer displays a prompt for further instructions. 70 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B ELECTRICAL SYSTEM PROGRAMMER OPERATION (CONTINUED) The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the PROGRAM or the DIAGNOSTICS key, the MORE INFO key selects the Special Program mode or the Special Diagnostics mode. The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode. When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of programmer operation. For example, if the TEST key is pressed, the LED at the corner of the key indicates that the programmer is now in the Test mode, and the Test Menu is displayed. Four lines of a menu are displayed at a time. The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window. The selected item is always the top line. (In the Program mode, the selected item is highlighted by a flashing arrow). To modify a parameter or obtain more information about it, it must be scrolled to the top position in the display window. To scroll up and down within a menu, use the two SCROLL DISPLAY arrow keys. The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down. When a key is held down, the scrolling speed increases the longer the key is held. SCROLL DISPLAY A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This sample display is from the Program Menu (Figure 3). FIGURE 3 Scroll Bar PLUG C/L L/S PLUG C/L EMR REV C/L L/S EMR REV C/L 100 80 140 80 Selected Item FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 71 ELECTRICAL SYSTEM PROGRAMMER OPERATION (CONTINUED) The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item. Like the SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter. An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible. When the value of a parameter is being increased, the LED on the “up” CHANGE VALUE key is on until you reach the maximum value for that parameter. When the LED goes off, you cannot increase the value. The MORE INFO key has three functions: (1) to display more information about the selected item, (2) to access the Special Program and Special Diagnostics modes (when used together with the PROGRAM and DIAGNOSTICS keys), and (3) to initiate certain commands (such as the Self Test). CHANGE VALUE “More information” is available in all of the programmer operating modes. After using the MORE INFO key to display additional information about the selected item, press the MORE INFO key again to return to the original list. MORE INFO OPERATING MODES PROGRAM MODE In the Program mode, accessed by pressing the PROGRAM key, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item, the item at the top of the display, with the flashing arrow can be changed, using the two CHANGE VALUE keys. The LEDs on these keys indicate whether there is still room for change. That is, when the upper limit of a parameter’s range is reached, the LED on the “up” key no longer lights up indicating that the present value cannot be increased; when the lower limit is reached, the LED on the “down” key no longer lights up. PROGRAM 72 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B ELECTRICAL SYSTEM OPERATING MODES (CONTINUED) The MORE INFO key, when used in the Program mode, displays a bar graph along with the minimum and maximum values possible for the selected parameter. Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the additional information is being displayed. PROGRAM MENU M1MAX M2MAX High speed (transport), as percent of full throttle Low speed (scrubbing), as percent of full throttle TEST MODE In the Test mode, accessed by pressing the TEST key, real-time information is displayed about the status of the inputs, outputs, and controller temperature. For example, when the status of the forward switch is displayed, it should read “On/Off/On/Off/On/Off’ as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list; it only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, and also for troubleshooting should problems occur. The MORE INFO key, when used in the Test mode, causes additional information to be displayed about the selected item (top line in the window). TEST TEST MENU THROTTLE % FIELD CURRENT ARM CURRENT FIELD PWM ARM PWM BATT VOLTAGE HEATSINK TEMP FORWARD INPUT REVERSE INPUT MODE INPUT A MODE INPUT B INTERLOCK EMR REV INPUT MAIN CONT AUX DRIVER Throttle reading, as % of full throttle Motor field current, in amps Motor armature current, in amps Motor field applied duty cycle, as % Motor armature appl’d duty cycle, as % Battery voltage across the capacitors Heatsink temperature, in °C Forward switch: on/off Reverse switch: on/off Mode Select 1 switch: on/off Mode Select 2 switch: on/off Interlock switch: on/off Emergency reverse switch: on/off Main contactor: on/off Auxiliary driver: on/off Note: Some items may not be available on all 1244 models. FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 73 ELECTRICAL SYSTEM OPERATING MODES (CONTINUED) DIAGNOSTICS MODE In the Diagnostics mode, accessed by pressing the DIAGNOSTICS key, currently active faults detected by the controller are displayed. The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item. The following is not a menu as such, but a list of possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes. DIAGNOSTICS DIAGNOSTICS AND SPECIAL DIAGNOSTICS MENU ANTI-TIEDOWN CONT COIL/FLD SHORT CURRENT SHUNT FAULT EMR REV WIRING FIELD OPEN HPD HW FAILSAFE LOW BATTERY VOLTAGE M- SHORTED MAIN CONT WELDED MISSING CONTACTOR NO KNOWN FAULTS OVERVOLTAGE SRO THERMAL CUTBACK THROTTLE FAULT 1 THROTTLE FAULT 2 Mode Select 1 switch closed at startup Contactor driver overcurrent or field winding short Current sensor error Emerg. reverse wiring check failed Motor field winding open High-pedal disable (HPD) activated Hardware failsafe activated Battery voltage too low M- shorted to BWelded main contactor Missing contactor No known faults Battery voltage too high Static return to off (SRO) activated Cutback, due to over/under temp Throttle wiper input fault Throttle low input fault 74 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B ELECTRICAL SYSTEM SPECIAL PROGRAM MODE The Special Program mode allows you to perform a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the programmer memory, load the controller settings from the programmer into a controller, clear the controller’s diagnostic history, adjust the contrast of the programmer’s LCD display, select the language to be displayed by the programmer, and display basic information (model number, etc.) about the controller and the programmer. To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the programmer is in Program mode. To distinguish between the program and Special Program modes, look at the menu items in the display. MORE INFO PROGRAM The MORE INFO key is used initially to access the Special Program mode, and once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select “Contrast Adjustment” by scrolling until this item is at the top of the screen, and then press MORE INFO to find out how to make the adjustment. SPECIAL PROGRAM MENU RESET ALL SETTINGS CONT SETTINGS - PROG PROG SETTINGS - CONT CLEAR DIAG HISTORY CONTRAST ADJUSTMENT LANGUAGE SELECTION PROGRAMMER INFO CONTROLLER INFO Revert to original settings Save controller settings in programmer Load programmer settings in controller Clear diagnostic history memory Adjust display contrast Select displayed language Display programmer information Display controller information FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 75 ELECTRICAL SYSTEM OPERATING MODES (CONTINUED) SPECIAL DIAGNOSTICS MODE In the Special Diagnostics mode, the controller’s diagnostic history file is displayed. This file includes a list of all faults observed and recorded by the controller since the history was last cleared. (Note: The maximum and minimum temperatures recorded by the controller are included in the Test Menu). Each fault is listed in the diagnostic history file only once, regardless of the number of times it occurred. To access Special Diagnostics, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key will light, just as when the programmer is in Diagnostics mode. The seat switch must be open in order to access the diagnostic history file. The MORE INFO key, when used within the Special Diagnostics mode, causes additional MORE INFO PROGRAM information to be displayed about the selected item. To clear the diagnostic history file, put the programmer into the Special Program mode, select “Clear Diagnostic History”, and press the MORE INFO key for instructions. Clearing the diagnostic history file also resets the maximum/minimum temperatures in the Test Menu. DIAGNOSTICS AND SPECIAL DIAGNOSTICS MENU ANTI-TIEDOWN CONT COIL/FLD SHORT CURRENT SHUNT FAULT EMR REV WIRING FIELD OPEN HPD HW FAILSAFE LOW BATTERY VOLTAGE M- SHORTED MAIN CONT WELDED MISSING CONTACTOR NO KNOWN FAULTS OVERVOLTAGE SRO THERMAL CUTBACK THROTTLE FAULT 1 THROTTLE FAULT 2 Mode Select 1 switch closed at startup Contactor driver overcurrent or field winding short Current sensor error Emerg. Reverse wiring check failed Motor field winding open High-pedal disable (HPD) activated Hardware failsafe activated Battery voltage too low M- shorted to BWelded main contactor Missing contactor No known faults Battery voltage too high Static return to off (SRO) activated Cutback, due to over/under temp Throttle wiper input fault Throttle low input fault PEACE-OF-MIND PROGRAMMING Each time the programmer is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select “Revert to Previous Settings” by scrolling it to the top of the display window, press the MORE INFO key, and follow the instructions displayed. Any inadvertent changing of parameters can be “undone” using this procedure, even if you can’t remember what the previous settings were, as long as the programmer has not been unplugged and power has not been removed from the controller. PROGRAMMER SELF TEST You can test the programmer by displaying two special test screens. Press the MORE INFO key while the programmer is powering up. During the Self-Test, you can toggle between the two test screens by pressing the SCROLL DISPLAY keys (Figure 4). The first screen turns on every LCD element and the second screen displays all the characters used in the various menus. As part of the Self-Test, you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the Self-Test, unplug the programmer or turn off the controller, and then repower it without holding the MORE INFO key. 76 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B FIGURE 4 SCROLL DISPLAY !“#$%&‘ ( ) *+, - . / 012345 6789 : ; <=>? @A B C D E FG H I J K LMNO P QR ST U VWX Y Z x ½ º ELECTRICAL SYSTEM K6 K1 S8 F3 K8 F4 K4 K9 F5 K5 K10 K3 S11 F2 K7 K2 S5 F1 F7 F8 S4 COMPONENT LOCATION A2 H10 Item M6 M7 F9 M16 C1 Contactors Fuses A1 M15 A3 H5 M10 K11 M11 H6 F11 M3 H2 M4 M12 S13 S3 M2 M14 L1 M9 R1 L4 M5 L6 L6A M13 S7 L5 M1 H4 M8 H3 F10 A1 A2 A3 C1 F1 F2 F3 F4 F5 F7 F8 F9 F10 F11 H2 H3 H4 H5 H6 H10 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 L1 L4 L5 L6 L6A M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 R1 S3 S4 S5 S7 S8 S11 S13 Description Control Box Assembly Switch/Display Panel Assembly Curtis 1244 Speed Controller Capacitor, 180 MFD Circuit Breaker, 25 Amp (Auxiliary Circuit 1) Circuit Breaker, 5 Amp (Auxiliary Circuit 2) Circuit Breaker, 20 Amp (Auxiliary Circuit 3) Circuit Breaker, 15 Amp (Dust Control) Circuit Breaker, 20 Amp (Side Brooms) Circuit Breaker, 70 Amp (Hydraulic Pump) Circuit Breaker, 40 Amp (Vacuum Motors) Circuit Breaker, 40 Amp (Power Steering) Fuse, 400 Amp (Main) Fuse, 250 Amp (Brush Motors) Horn Headlight, Right Headlight, Left Lamp, Tail Lamp, Tail Lamp, Broom Overload Contactor, Left Brush Motor Contactor, Center Brush Motor Contactor, Right Brush Motor Contactor, Broom Motor Contactor, Drive Wheel Contactor, Dust Control Motor Contactor, Vacuum Motor Contactor, Side Broom Contactor, Steering Contactor, Auxiliary Contactor, Hydraulic Pump Motor Valve, Solution Valve, Dump Door Open Valve, Dump Door Close Valve, Hopper Raise Valve, Hopper Lower Motor, Broom 2.0 HP Motor, Left Brush Motor, Center Brush Motor, Right Brush Motor, Dust Control Motor, Vacuum Motor, Vacuum Motor, Right Side Broom Motor, Left Side Broom Motor, Assembly, Hydraulic Pump Motor, Brush Actuator Motor, Squeegee Actuator Motor, Side Broom Actuator Motor, Shaker Motor, Wheel Drive Motor, Steering Potentiometer, 5K Ohm Switch, Hopper Interlock Switch, Recovery Full Switch, Solution Empty Switch, Hydraulic Filter Switch, Main Broom Switch, Key Switch, Battery Interlock FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 77 To Speed Controller RED BLK/ORN Contactor, Aux. To Speed Controller ORN K10 1 2 Contactor, Aux. 1 2 Switch, Key S9 1 2 GRA/ORN Switch, Seat 1 VIO 1 1 VIO 1 VIO 1 1 L2 2 Valve, Dump Door Close BLU/RED 2 Valve, Solution YEL/GRN Contactor, Vacuum Motor Contactor, Side Broom K11 Contactor, Hyd. Pump Motor M14 M VIO A A 1 RED/GRN J1-11 YEL/GRA J1-18 A1 CONTROL BOX ASSEMBLY J2-15 J2-3 J1-13 J1-16 J1-24 J1-14 J1-35 J1-23 J2-2 YEL/BLU WHT/VIO GRA/RED GRN/GRA BRN/YEL J3-1 (+12V) J2-6 J1-8 J2-17 J1-7 J2-5 J1-19 J1-17 J2-16 ORN Contactor, Wheel Drive ORN/RED J1-6 J2-13 H3 H4 BRN/BLK BLU/WHT J1-5 J2-4 M WHT WHT WHT GRN/ORN RED/BLK J1-3 J4-14 BLK Motor, Shaker BLK/RED 2 Head Light, Right YEL/BLK YEL/BLK S2 GRN BLK Switch, Retract Limit M BLK M13 Motor, Squeegee Actuator (+ to RED to Extend) RED 1-1 M BLK S3 1 H6 2 BLK GRA/YEL 1 2 Horn 2 2 VIO/YEL 1 WHT/GRA 1 S5 2 Switch, Solution Empty S6 2 BLK RED F11 1 2 BLK 1 S7 2 1 ORN/BLK S8 2 1 RED/VIO S10 2 140 DEG. F o 3 t 1 Switch, Hopper Fire (optional) S12 GRA/WHT 2 1 Switch, Wand (optional) 2 K2 2 RED/VIO 1 F4 RED BLK 2 1 BRN/WHT K6 1 2 1 GRN/RED -12 VDC K7 1 + VIO 1 J2-8 J2-1 J2-26 J2-25 J2-21 J2-22 2 - 2 2 M - BLK ORN/GRN A1 M5 M A2 78 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B BLK Motor, Dust Control BLU/GRA 1 2 BLK 2 BLK M6 VIO/BRN J1-10 1 M7 M Motor, Vacuum RED 2 1 VIO/GRA 1 K8 2 Contact N.O. Circuit Breaker, 20 Amp WHT/RED + M8 M - BLK Motor, Right Side Broom M9 GRN/BRN 2 BLK/GRA J1-2 + M - BLK Motor, Left Side Broom F7 RED J2-20 1 2 Circuit Breaker, 70 Amp 2 1 K9 Contactor, Steering 1 ORN/WHT RED 1 2 Circuit Breaker, 40 Amp BLK M10 2 BLK Contact N.O. F9 BLK K11 BRN/GRA 1 K9 + M - M16 2 Contact N.O. GRN/WHT + M - Motor, Steering + B- BLK Motor Asm., Hyd. Pump C1 - Capacitor, 180 MFD B+ CURRENT SENSE Motor, Right Brush BLU/GRA Lamp, Flashing VIO + BLU/YEL BLU/BLK ORN/RED GRA RED/WHT BRN ORN/BLU H7 VIO M M F5 Backup Alarm (optional) Lamp, Broom Overload + Motor, Center Brush WHT/RED H10 M M4 H1 VIO + Contact N.O. Circuit Breaker, 40 Amp BLK M3 GRA/BLK Contact N.O. Circuit Breaker, 15 Amp - Motor, Left Brush Contact N.O. BLK - WHT/ORN BLK K3 M + M2 K1 Contact N.O. BLK CURRENT SENSE Motor, Broom Contact N.O. Fuse, 250 Amp BLK 1 RED/VIO Switch, Dust Control Filter (optional) YEL/WHT F2 RED 6-2 Contact N.O. Switch, Recovery Full A2 M1 K4 1 Switch, Hopper Interlock S4 M RED 1-2 RED 6-1 Lamp, Curb 1 2 BLK M15 A1 Motor, Wheel Drive F1 F8 MODE 1 FAULT 1 BRAKE DRIVER REVERSE SIGNAL BRUSH CURRENT SENSE BROOM CURRENT SENSE B Lamp, Tail H8 K5 B+ Contact N.O. Motor, Side Broom Actuator (+ to RED to Extend) 2 M- Motor, Vacuum B Lamp, Tail C Forward F2 B- RED 2 Head Light, Left H5 VIO/BLK BLU/BLK GRN J1-9 J2-34 J2-35 R1 Motor, Brush Actuator (+ to RED to Extend) BLK Switch, Extend Limit M12 1 YEL S1 BLK RED BLU/BRN YEL/VIO B A Pot. 5k Ohm F1 Switch, Hydraulic Filter BLU Reverse X51 M11 RED RED/ORN GRA/VIO WHT/BLK BLK/YEL RED/WHT GRA Switch/Display Panel Assembly J3-5 (SCL) J3-6 SDA J3-7 (B+) J3-8 (B-) GRN/VIO WHT/GRN BLK/YEL A2 J3-3 (PIEZO) J1-20 H2 VIO K5 Switch, Main Broom K8 1 J2-23 J1-12 2 Valve, Solution Contactor, Dust Control Motor 1 VIO L1 BRN/GRN K7 RED GRN/BLK 2 Valve, Dump Door Open K6 VIO VIO L5 Contactor, Broom Motor VIO J1-1 GRN/BLU BRN/BLU WHT/BRN BLK J1-15 Contactor, Right Brush Motor VIO ORN/BRN J2-7 J2-19 J2-10 J2-33 YEL/RED K4 VIO J2-9 2 Valve, Hopper Lower K3 VIO BLU/ORN J1-4 Contactor, Center Brush Motor VIO VIO L4 BRN/RED BLK BLK BLK BLK BLK BLK J1-34 J1-32 J1-30 J1-28 J1-26 J2-31 J2-1 RED/GRA K2 VIO J2-11 J2-24 2 Valve, Hopper Raise Contactor, Left Brush Motor VIO VIO L6 K1 VIO ORN GRN GRN/BLK L6A VIO B- INPUT S13 2 1 2 BLU/GRN Circuit Breaker, 25 A. 1 J1-21 ORN 1 2 Circuit Breaker, 20 A F1 BLK ORN F3 BLU/GRN VIO 2 Lamp, Trouble Switch, Battery Interlock GRN A3 CURTIS 1244 SPEED CONTROLLER BLK ORN/BLU 2 YEL/BRN 1 Circuit Breaker, 5 AMP H9 X1 X2 J1-22 S11 F2 RED - BRN YEL/BRN K10 1 + WHT/YEL YEL/BRN YEL/BRN - RED 1-A2 Fuse, 400 A. + ORN RED 2 BLK 1-A1 F10 ORN 1 24 23 22 21 20 19 18 17 16 15 14 13 RED B- 12 11 10 9 8 7 6 5 4 3 2 1 CONTROL BOX ASSEMBLY SWITCH/DISPLAY PANEL ASSEMBLY CURTIS 1244 SPEED CONTROLLER BATTERY 36VDC CAPACITOR, 180 MFD CIRCUIT BREAKER, 25 AMP (AUXILIARY CIRCUIT 1) CIRCUIT BREAKER, 5 AMP (AUXILIARY CIRCUIT 2) CIRCUIT BREAKER, 20 AMP (AUXILIARY CIRCUIT 3) CIRCUIT BREAKER, 15 AMP (DUST CONTROL) CIRCUIT BREAKER, 20 AMP (SIDE BROOMS) CIRCUIT BREAKER, 70 AMP (HYDRAULIC PUMP)) CIRCUIT BREAKER, 40 AMP (VACUUM MOTORS) CIRCUIT BREAKER, 40 AMP (POWER STEERING) FUSE, 400 AMP (MAIN) FUSE, 250 AMP (BRUSH MOTORS) BACKUP ALARM (OPTIONAL) HORN HEADLIGHT, RIGHT HEADLIGHT, LEFT LAMP, TAIL LAMP, TAIL LAMP, FLASHING (OPTIONAL) LAMP, CURB (OPTIONAL) LAMP, TROUBLE (OPTIONAL) LAMP, BROOM OVERLOAD CONTACTOR, LEFT BRUSH MOTOR CONTACTOR, CENTER BRUSH MOTOR CONTACTOR, RIGHT BRUSH MOTOR CONTACTOR, BROOM MOTOR CONTACTOR, DRIVE WHEEL CONTACTOR, DUST CONTROL MOTOR CONTACTOR, VACUUM MOTOR CONTACTOR, SIDE BROOM CONTACTOR, STEERING CONTACTOR, AUXILIARY CONTACTOR, HYDRAULIC PUMP MOTOR VALVE, SOLUTION VALVE, SOLUTION VALVE, DUMP DOOR OPEN VALVE, DUMP DOOR CLOSE VALVE, HOPPER RAISE VALVE, HOPPER LOWER MOTOR, BROOM 2.0 HP MOTOR, LEFT BRUSH MOTOR, CENTER BRUSH MOTOR, RIGHT BRUSH MOTOR, DUST CONTROL MOTOR, VACUUM MOTOR, VACUUM MOTOR, RIGHT SIDE BROOM MOTOR, LEFT SIDE BROOM MOTOR, ASSEMBLY, HYDRAULIC PUMP MOTOR, BRUSH ACTUATOR MOTOR, SQUEEGEE ACTUATOR MOTOR, SIDE BROOM ACTUATOR MOTOR, SHAKER MOTOR, WHEEL DRIVE MOTOR, STEERING POTENTIOMETER, 5K OHM SWITCH, EXTEND LIMIT SWITCH, HOPPER INTERLOCK SWITCH, RECOVERY FULL SWITCH, SOLUTION EMPTY SWITCH, DUST CONTROL FILTER (OPTIONAL) SWITCH, HYDRAULIC FILTER SWITCH, MAIN BROOM SWITCH, SEAT SWITCH, HOPPER FIRE (OPTIONAL) SWITCH, KEY SWITCH, WAND (OPTIONAL) SWITCH, BATTERY INTERLOCK B+ BT1 BLK + Battery, 36 Vdc RED/BLU A1 A2 A3 BT1 C1 F1 F2 F3 F4 F5 F7 F8 F9 F10 F11 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 L1 L2 L4 L5 L6 L6A M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 R1 S1 S2 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 RED GRA ORN/RED BLU/BLK Description ORN/BLU BRN RED/WHT Item GRN BLU/BLK ORN/RED GRA RED/WHT WIRING DIAGRAM (before SN 1767238) ELECTRICAL SYSTEM BLK WIRING SCHEMATIC (before SN 1767238) H7 BLK 18-12 LAMP, FLASHING FUSES F10: MAIN F11: BRUSH MOTORS S8 VIO 16-17 SWITCH, MAIN BROOM H10 LAMP, BROOM OVERLOAD X49 X50 SP24 SP5 S11 F10 ORN 18-1 X18 X70 SWITCH, KEY RED 3/0-1 X17 X71 X72 YEL/BRN 18-4 FUSE, 400 A. RED 6-1 RED 1-1 SP18 ELECTRICAL SYSTEM SP23 A2 F11 SWITCH/DISPLAY PANEL ASSEMBLY FUSE, 250 A. F2 F1 CIR. BREAKER, 25 A. BLK 18-1 WHT/BRN 18-1 BRN/BLU 18-1 GRN/BLU 18-1 F3 CIR. BREAKER, 20 A. CIR. BREAKER, 5 A. J3 BLU/ORN 18-1 H1 X54 X55 F4 GRN/BRN 18-1 ORN/BRN 18-1 F5 VIO 16-18 BACKUP ALARM (OPTIONAL) M12 X47 X48 SP20 SP11 BLU/BRN 18-1 SP21 GRN/BLK 16-1 GRN/BLK 16-2 GRN/BLK 12-1 SP6 X51 SP13 ORN 18-6 ORN 18-5 ORN 18-4 GRN 18-2 GRN 18-3 GRN 18-1 SP8 SP22 A H5 SP14 1 B LAMP, TAIL YEL/BLK 16-12 YEL/BLK 16-1 YEL/BLK 16-2 A H6 B LAMP, TAIL YEL/BLK 16-3 VIO 16-19 VIO 16-20 VIO 16-21 2 2 X57 X56 VIO/YEL 18-1 YEL RED MOTOR, BRUSH ACTUATOR YEL/BLK 16-4 WHT VIO 16-20 S2 ORN 18-2 GRA/ORN 18-1 GRN SW., RETRACT LIMIT YEL/BLK 16-5 RED VIO 16-21 SWITCH, SEAT S1 BLK SW., EXTEND LIMIT F2 RED 1-A2 BLK 1-A1 X58 X21 X69 X59 X22 SP10 F2 WHT/YEL 10-1 HORN X66 YEL/BLU 18-1 K6 DUST CONTROL VIO 16-7 VIO 16-6 K2 GRA/BLK 8-1 CENTER BRUSH RED/VIO 8-2 VIO 16-6 VIO 16-5 BLU/YEL 8-1 K7 RED/VIO 8-3 K8 SIDE BROOMS GRA/RED 18-1 VIO 16-5 VIO 16-3 K4 RED 6-2 RED 6-1 K9 STEERING ORN 18-3 ORN 18-4 RED 1-1 K10 AUXILIARY BLK/YEL 18-1 WHT/RED 12-4 VIO 12-5 VIO 12-3 VIO 16-1 BLK 18-10 BX61 YEL/GRN 18-4 YEL/GRN 18-2 YEL/GRN 18-3 GRA/VIO 18-2 ORN/GRN 14-1 VIO 14-4 VIO 14-6 RED/BLK 18-3 RED/BLK 18-2 WHT/RED 12-4 WHT/RED 12-3 BLK 12-5 BLK 12-3 BLK/RED 18-3 YEL/VIO 18-3 YEL/VIO 18-2 WHT/GRA 18-3 YEL/BLK 16-10 WHT/GRA 18-2 YEL/BLK 16-7 YEL/BLK 16-8 GRN/WHT 10-1 VIO 16-1 WHT/RED 12-1 SP2 S12 GRA/WHT 18-2 BLK 18-8 MOTOR, BROOM SP4 SP15 H4 X4 X2 HEAD LIGHT, RIGHT X6 X5 M8 RED BLK BLK 12-1 SP3 MOTOR, RIGHT SIDE BROOM S6 WHT/GRA 18-2 BLK 18-5 SWITCH, DUST CONTROL FILTER S10 YEL/VIO 18-2 VIO 18-3 SWITCH, HOPPER FIRE MOTOR, CENTER BRUSH BLK/RED 18-3 BLK 18-6 MOTOR, RIGHT BRUSH WHT/BLK 18-2 X35 BLU/GRN 10-1 REVERSE R1 BRN/RED 18-2 VIO/BLK 18-2 POT. 5K OHM L4 L5 VALVE, DUMP DOOR CLOSE X23 X34 X33 X31 X32 L2 VALVE, SOLUTION VALVE, DUMP DOOR OPEN X24 FORWARD YEL/BRN 18-2 YEL/BRN 18-5 VALVE, SOLUTION HEAD LIGHT, LEFT VIO 14-7 SP1 H3 X3 X1 VIO 14-8 BLK 12-4 BLK/RED 18-2 BLK MOTOR, LIFT SIDE BROOM YEL/BLK 16-9 YEL/BLK 16-8 YEL/BLK 16-7 SWITCH, WAND (OPTIONAL) M4 YEL/BLK 16-9 RED BLK 18-4 M3 L1 BX60 GRA/VIO 18-3 ORN/GRN 14-2 M1 SP12 BLK 12-2 X9 X10 M9 X7 X8 ORN/GRN 14-1 BLK BLK 18-5 BLK 18-6 RED 10-1 DRIVE SP17 WHT/RED 12-2 MOTOR, SIDE BROOM ACTUATOR MOTOR, LEFT BRUSH BLK/ORN 18-1 K5 RED 1-2 BRN 18-2 BLK 1-1 BLK 8-1 BLK 8-2 WHT/ORN 8-1 WHT S3 SWITCH, HOPPER INTERLOCK BLK 18-3 BLK 12-4 BLK 18-4 A2 M13 VIO 14-1 BRN/GRA 10-1 MAIN BROOM GRN/GRA 18-1 BLU/GRA 12-1 BLU/GRA 12-2 VIO 16-2 VIO 12-5 BRN/BLK 18-1 VIO/GRA 12-1 K3 RIGHT BRUSH M2 GRN/RED 8-1 VACUUM WHT/VIO 18-1 SP9 M5 X12 X11 BLK 18-3 GRN/ORN 18-2 BLK 12-6 VIO 16-3 VIO 16-2 BLU 18-1 M7 X14 X13 GRN/ORN 18-3 BRN/WHT 14-1 ORN/GRN 14-2 MOTOR, STEERING RED/BLK 18-2 MOTOR, DUST CONTROL MOTORS, VACUUM X67 BRN/YEL 18-1 LEFT BRUSH RED/VIO 8-1 M6 H2 A1 K1 WHT/ORN 8-1 A1 SWITCH, BATTERY INTERLOCK S13 BLK 10-1 X45 X46 SWITCH, RECOVERY FULL BLU/GRA 12-2 X68 M16 GRN/WHT 10-1 S4 BLK 18-24 X42 X39 BLK 12-9 C1 CAPACITOR, 180 MFD GRA/YEL 18-2 X41 X40 MOTOR, DRIVE VIO 16-7 X43 X44 BLK 16-2 BLK 12-8 B+ M- BRED/BLU 10-1 A2 F9 GRA/YEL 18-1 BT1 BATTERY, 36Vdc GRN/RED 8-1 RED 8-1 BLU/GRA 12-1 BLK 1-2 F1 SP16 BLK 18-11 BLK 16-2 RED 1-2 M15 CIR. BREAKER, 40 AMP CIR. BREAKERS BRN/GRA 10-1 F1: AUXILIARY CIRCUIT 1 RED 8-3 F2: AUXILIARY CIRCUIT 2 CIR. BREAKER, 40 AMP F3: AUXILIARY CIRCUIT 3 F4: DUST CONTROL MOTOR F5: SIDE BROOM MOTORS F6: NONE F7: HYDRAULIC PUMP F8: VACUUM MOTORS F9: POWER STEERING S9 BLK 16-1 F1 F8 SWITCH, SOLUTION EMPTY H9 LAMP, TROUBLE RED 3/0-1 BLK 18-18 M11 YEL/BLK 16-2 YEL/BLK 16-4 YEL/BLK 16-5 X16 X15 BLK 3/0-1 CIR. BREAKER, 70 A. S12 X64 X65 BLK 18-19 ORN/WHT 8-1 RED 8-2 X37 MOTOR, SQUEEGEE ACTUATOR YEL/BRN 18-3 F7 X38 WHT/GRN 18-1 ORN 18-7 CIR. BREAKER, 20 A. CIR. BREAKER, 15 A. X28 L6 VALVE, HOPPER LOWER X27 X53 X52 X30 BLK MOTOR, SHAKER SWITCH, HYD. FILTER M10 X25 X29 H8 LAMP, CURB MOTOR ASM., HYD PUMP K11 X26 VIO 16-10 M14 RED S7 VALVE, HOPPER RAISE L6A X19 X20 X63 X62 VIO 16-11 VIO 16-12 VIO 16-13 VIO 16-14 VIO 16-22 FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 79 K10 1 2 Contactor, Aux. S9 1 2 GRA/ORN Switch, Seat 1 GRN 1 2 BLU/GRN Circuit Breaker, 25 A. VIO 1 VIO 1 L6 L4 L5 1 VIO L1 1 2 Valve, Hopper Lower YEL/RED J1-15 2 Valve, Dump Door Open BRN/GRN J1-18 2 Valve, Dump Door Close BLU/RED YEL/GRN J1-7 BRN/YEL BLU BRN/BLK Contactor, Side Broom J1-35 K11 BLU/WHT Contactor, Hyd. Pump Motor VIO M RED H3 1 VIO 1 VIO A VIO A VIO 1 GRN/VIO ORN/RED WHT Motor, Brush Actuator (+ to RED to Extend) BLK Switch, Extend Limit S2 GRN BLK Switch, Retract Limit WHT M BLK BLU/BRN WHT M BLK GRN/ORN RED/BLK 1 S3 J2-17 J1-19 J2-5 J1-17 J2-16 GRA/YEL 1 S4 J1-6 J2-13 J1-5 J2-4 J1-3 J4-14 H4 BLK Motor, Shaker BLK/RED J1-9 2 Head Light, Right YEL/BLK YEL/BLK J2-34 J2-33 H5 Motor, Squeegee Actuator (+ to RED to Extend) Motor, Side Broom Actuator (+ to RED to Extend) RED 1-1 1 H6 2 2 RED 6-1 1 K4 2 + 1 H10 BLK VIO/YEL 1 WHT/GRA 1 S5 2 Switch, Solution Empty S6 BLK RED F11 1 2 2 1 RED/VIO YEL/WHT 1 S7 2 1 ORN/BLK S8 2 YEL/VIO S10 2 140 DEG. F o 3 t 1 Switch, Hopper Fire (optional) S12 GRA/WHT 2 1 Switch, Wand (optional) 2 1 RED/VIO BLK K2 2 K3 1 + F4 BLK RED 2 1 BRN/WHT K6 1 2 1 K7 1 - M4 2 + BLU/YEL 2 2 M CURRENT SENSE - BLK Motor, Right Brush ORN/GRN Contact N.O. GRN/RED M Motor, Center Brush Contact N.O. BLK + M3 GRA/BLK BLK RED/VIO M Motor, Left Brush Contact N.O. A1 M5 M A2 BLK Motor, Dust Control BLU/GRA 1 Contact N.O. 2 BLK 2 BLK M6 M BLU/BLK ORN/RED GRA RED/WHT BRN ORN/BLU Motor, Vacuum BLU/GRA 1 M7 M Motor, Vacuum 2 Horn VIO/BRN Backup Alarm (optional) GRN/BRN J1-10 F5 RED 2 1 K8 VIO/GRA 1 2 Contact N.O. Circuit Breaker, 20 Amp WHT/RED + M8 M - BLK Motor, Right Side Broom M9 WHT/RED J1-2 + M - BLK Motor, Left Side Broom 2 BLK/GRA J2-20 F7 RED 2 1 1 2 K9 1 ORN/WHT Circuit Breaker, 70 Amp K11 M10 2 BLK Contact N.O. + M - BLK Motor Asm., Hyd. Pump BLK F9 RED 1 2 Circuit Breaker, 40 Amp BLK Contactor, Steering 80 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - WHT/ORN BLK Switch, Dust Control Filter (optional) Lamp, Flashing B+ BLK M2 K1 Contact N.O. Fuse, 250 Amp H7 VIO - Switch, Recovery Full Lamp, Broom Overload VIO CURRENT SENSE Motor, Broom H1 VIO M + RED 6-2 Contact N.O. Circuit Breaker, 40 Amp H2 VIO F2 2 1 A2 M1 Lamp, Curb VIO M RED 1-2 BLK RED J2-8 J2-1 J2-26 J2-25 J2-21 J2-22 BLK M15 A1 Contact N.O. 2 -12 VDC MODE 1 FAULT 1 BRAKE DRIVER REVERSE SIGNAL BRUSH CURRENT SENSE BROOM CURRENT SENSE B Lamp, Tail H8 K5 B+ Motor, Wheel Drive F1 F8 B Lamp, Tail M- B- Circuit Breaker, 15 Amp 2 Head Light, Left C Forward F2 M13 GRA/VIO R1 Pot. 5k Ohm VIO/BLK F1 M12 WHT/GRN B A BLU/BLK GRN S1 BLK RED RED/ORN YEL Reverse X51 A2 Switch/Display Panel Assembly Switch, Hopper Interlock M14 VIO J2-3 M RED WHT/BLK BLK/YEL RED/WHT GRA Contactor, Wheel Drive Switch, Main Broom K8 VIO BLK/YEL Switch, Hydraulic Filter Contactor, Vacuum Motor VIO J2-15 J2-6 GRA/RED GRN/GRA K7 WHT/BRN J3-6 (B+) BLK J3-1 (B-) J1-20 J1-8 Contactor, Dust Control Motor VIO J1-14 WHT/VIO Contactor, Broom Motor K6 YEL/GRA J2-2 Contactor, Right Brush Motor VIO J1-11 J1-23 YEL/BLU K4 RED/GRN J1-13 J1-16 2 Valve, Solution K3 VIO A1 CONTROL BOX ASSEMBLY J1-12 J1-24 Contactor, Center Brush Motor VIO J2-35 J1-4 K2 WHT/BRN BLK BLU/ORN J3-2 (SCL-H) ORN/BRN J3-3 (SCL-L) GRN/BLU J3-4 (SDA-H) BRN/BLU J3-5 (SDA-L) K5 ORN M11 Contactor, Left Brush Motor VIO J2-10 J2-31 BRN/RED BLK BLK BLK BLK BLK J1-34 J1-32 J1-30 J1-28 J1-26 J2-7 BLU/ORN J2-18 ORN/BRN J2-8 GRN/BLU J2-19 BRN/BLU J1-1 RED/GRA K1 VIO J2-11 J2-24 2 Valve, Hopper Raise 2 Valve, Solution L2 1 GRN/BLK GRN/BLK L6A VIO GRN F3 1 2 Circuit Breaker, 20 A F1 1 ORN S13 2 Switch, Battery Interlock BLU/GRN VIO BLK/WHT BLK/WHT ORN/BLU To Speed Controller RED 3 B1 Switch, Key B- INPUT A3 CURTIS 1244 SPEED CONTROLLER BLK BRN 2 YEL/BRN 1 J1-21 ORN S11 Circuit Breaker, 5 AMP 2 Lamp, Trouble BLK 1-A1 RED BLK/ORN Contactor, Aux. To Speed Controller ORN F2 BLK J2-12 LAMP GROUND J2-23 K10 YEL/BRN 1 H9 X1 X2 WHT/YEL YEL/BRN - RED 1-A2 Fuse, 400 A. + ORN RED 2 B- 24 23 22 21 20 19 18 17 16 15 14 13 F10 B+ 12 11 10 9 8 7 6 5 4 3 2 1 1 - ORN RED + RED/BLU CONTROL BOX ASSEMBLY SWITCH/DISPLAY PANEL ASSEMBLY CURTIS 1244 SPEED CONTROLLER BATTERY 36VDC CAPACITOR, 180 MFD CIRCUIT BREAKER, 25 AMP (AUXILIARY CIRCUIT 1) CIRCUIT BREAKER, 5 AMP (AUXILIARY CIRCUIT 2) CIRCUIT BREAKER, 20 AMP (AUXILIARY CIRCUIT 3) CIRCUIT BREAKER, 15 AMP (DUST CONTROL) CIRCUIT BREAKER, 20 AMP (SIDE BROOMS) CIRCUIT BREAKER, 70 AMP (HYDRAULIC PUMP)) CIRCUIT BREAKER, 40 AMP (VACUUM MOTORS) CIRCUIT BREAKER, 40 AMP (POWER STEERING) FUSE, 400 AMP (MAIN) FUSE, 250 AMP (BRUSH MOTORS) BACKUP ALARM (OPTIONAL) HORN HEADLIGHT, RIGHT HEADLIGHT, LEFT LAMP, TAIL LAMP, TAIL LAMP, FLASHING (OPTIONAL) LAMP, CURB (OPTIONAL) LAMP, TROUBLE (OPTIONAL) LAMP, BROOM OVERLOAD CONTACTOR, LEFT BRUSH MOTOR CONTACTOR, CENTER BRUSH MOTOR CONTACTOR, RIGHT BRUSH MOTOR CONTACTOR, BROOM MOTOR CONTACTOR, DRIVE WHEEL CONTACTOR, DUST CONTROL MOTOR CONTACTOR, VACUUM MOTOR CONTACTOR, SIDE BROOM CONTACTOR, STEERING CONTACTOR, AUXILIARY CONTACTOR, HYDRAULIC PUMP MOTOR VALVE, SOLUTION VALVE, SOLUTION VALVE, DUMP DOOR OPEN VALVE, DUMP DOOR CLOSE VALVE, HOPPER RAISE VALVE, HOPPER LOWER MOTOR, BROOM 2.0 HP MOTOR, LEFT BRUSH MOTOR, CENTER BRUSH MOTOR, RIGHT BRUSH MOTOR, DUST CONTROL MOTOR, VACUUM MOTOR, VACUUM MOTOR, RIGHT SIDE BROOM MOTOR, LEFT SIDE BROOM MOTOR, ASSEMBLY, HYDRAULIC PUMP MOTOR, BRUSH ACTUATOR MOTOR, SQUEEGEE ACTUATOR MOTOR, SIDE BROOM ACTUATOR MOTOR, SHAKER MOTOR, WHEEL DRIVE MOTOR, STEERING POTENTIOMETER, 5K OHM SWITCH, EXTEND LIMIT SWITCH, HOPPER INTERLOCK SWITCH, RECOVERY FULL SWITCH, SOLUTION EMPTY SWITCH, DUST CONTROL FILTER (OPTIONAL) SWITCH, HYDRAULIC FILTER SWITCH, MAIN BROOM SWITCH, SEAT SWITCH, HOPPER FIRE (OPTIONAL) SWITCH, KEY SWITCH, WAND (OPTIONAL) SWITCH, BATTERY INTERLOCK BT1 BLK + Battery, 36 Vdc ORN A1 A2 A3 BT1 C1 F1 F2 F3 F4 F5 F7 F8 F9 F10 F11 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 L1 L2 L4 L5 L6 L6A M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 R1 S1 S2 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 RED GRA ORN/RED BLU/BLK Description ORN/BLU BRN RED/WHT Item GRN BLU/BLK ORN/RED GRA RED/WHT WIRING DIAGRAM (after SN 1767237) ELECTRICAL SYSTEM B- BRN/GRA 1 K9 M16 2 Contact N.O. GRN/WHT + M - Motor, Steering + C1 - Capacitor, 180 MFD BLK WIRING SCHEMATIC (after SN 1767237 but before SN 1808249) H7 SP23 S8 VIO 16-17 SWITCH, MAIN BROOM H10 LAMP, BROOM OVERLOAD X49 X50 GRN/BLU 18-1 BLU/ORN 18-1 GRA/YEL 18-1 WHT/GRA 18-1 YEL/VIO 18-1 RED/ORN 18-1 RED/BLK 18-1 ORN/RED 18-1 ORN/BRN 18-1 VIO/YEL 18-1 YEL/WHT 18-1 GRN/VIO 18-1 GRA/WHT 18-1 ORN/BLK 18-1 BLK/WHT 16-2 ORN 18-7 WHT/BRN 18-1 LAMP, FLASHING RED 3/0-1 ORN 18-1 X18 A2 F11 X70 F2 BLU/BLK 18-1 GRA 18-1 RED/WHT 18-1 GRN 18-2 BLK/WHT 16-1 ORN/BLU 18-1 BRN 18-1 BLK/GRA 18-1 BRN/BLU 18-1 CIR. BREAKER, 25 A. BLK 18-1 GRN/BLK 16-2 YEL/BLK 16-1 YEL/BLK 16-12 SWITCH/DISPLAY PANEL ASSEMBLY FUSE, 250 A. F1 F3 BLK 18-1 BLU/ORN 18-1 ORN/BRN 18-1 CIR. BREAKER, 20 A. CIR. BREAKER, 5 A. J3 WHT/BRN 18-1 BRN/BLU 18-1 GRN/BLU 18-1 H1 X54 X55 F4 GRN/BRN 18-1 F5 VIO 16-18 BACKUP ALARM (OPTIONAL) M12 X47 X48 SP20 SP11 BLU/BRN 18-1 SP21 GRN/BLK 16-1 GRN/BLK 16-2 GRN/BLK 12-1 SP6 X51 SP13 ORN 18-6 ORN 18-5 ORN 18-4 GRN 18-2 GRN 18-3 GRN 18-1 SP8 SP22 A H5 SP14 1 B LAMP, TAIL YEL/BLK 16-12 YEL/BLK 16-1 YEL/BLK 16-2 A H6 B LAMP, TAIL YEL/BLK 16-3 VIO 16-19 VIO 16-20 VIO 16-21 2 2 X57 X56 YEL/BLK 16-4 WHT VIO 16-20 S2 ORN 18-2 GRA/ORN 18-1 GRN SW., RETRACT LIMIT YEL/BLK 16-5 RED VIO 16-21 SWITCH, SEAT S1 BLK SW., EXTEND LIMIT F2 RED 1-A2 BLK 1-A1 X68 X58 X21 X69 X59 X22 S13 A1 WHT/YEL 10-1 HORN X66 BRN/YEL 18-1 K1 BRN/WHT 14-1 YEL/BLU 18-1 K6 DUST CONTROL VIO 16-7 VIO 16-6 K2 K7 VACUUM WHT/VIO 18-1 VIO 16-6 VIO 16-5 BLU/YEL 8-1 RIGHT BRUSH K8 SIDE BROOMS GRA/RED 18-1 VIO 16-5 VIO 16-3 K9 STEERING GRN/GRA 18-1 ORN 18-3 ORN 18-4 RED 1-1 K10 BX60 BLK 1-2 BLK 3/0-1 BLK 16-3 BLK 16-4 BLK 16-5 BLK 16-6 BLK 16-7 BLK/WHT 16-1 BLK/WHT 16-2 BLK 3/0-2 BX61 BLK 3/0-2 BLK 16-1 BLK 10-1 BLK 12-9 BLK 12-8 BLK 18-10 AUXILIARY VIO 14-6 RED/BLK 18-3 RED/BLK 18-2 WHT/RED 12-4 WHT/RED 12-3 BLK 12-5 BLK 12-3 BLK 12-6 BLK 12-4 YEL/BLK 16-8 SP12 BLK/RED 18-3 YEL/VIO 18-3 YEL/VIO 18-2 WHT/RED 12-1 WHT/GRA 18-3 WHT/GRA 18-2 BLK 12-1 YEL/BLK 16-10 YEL/BLK 16-7 SP1 SP2 GRA/WHT 18-2 BLK 18-8 MOTOR, BROOM SP4 SP15 SP3 H4 X4 X2 HEAD LIGHT, RIGHT X6 X5 M8 RED BLK MOTOR, RIGHT SIDE BROOM S6 WHT/GRA 18-2 S12 SWITCH, WAND (OPTIONAL) M3 M4 HEAD LIGHT, LEFT VIO 14-7 BLK/RED 18-2 M1 YEL/GRN 18-4 YEL/GRN 18-2 YEL/GRN 18-3 VIO 14-8 BLK 18-4 SWITCH, DUST CONTROL FILTER BLK 18-5 S10 YEL/VIO 18-2 VIO 18-3 SWITCH, HOPPER FIRE MOTOR, CENTER BRUSH BLK/RED 18-3 BLK 18-6 X19 X20 M14 BLK RED MOTOR, SHAKER MOTOR, RIGHT BRUSH VIO 16-1 X35 WHT/BLK 18-2 RED 10-1 DRIVE BLK/YEL 18-1 GRN/WHT 10-1 GRA/VIO 18-2 ORN/GRN 14-1 VIO 14-4 BLK 18-5 BLK 18-6 WHT/RED 12-4 VIO 12-5 VIO 12-3 VIO 16-1 SP17 GRA/VIO 18-3 BLK H3 X3 X1 YEL/BLK 16-9 YEL/BLK 16-8 YEL/BLK 16-7 MOTOR, LEFT BRUSH BLK/ORN 18-1 K5 RED 1-2 BRN 18-2 BLK 1-1 BLK 8-1 BLK 8-2 WHT/ORN 8-1 YEL/BLK 16-9 MOTOR, SIDE BROOM ACTUATOR ORN/GRN 14-2 RED MOTOR, LIFT SIDE BROOM X9 X10 BLK M9 X7 X8 BLK 12-2 GRN/ORN 18-2 VIO 14-1 BRN/GRA 10-1 MAIN BROOM RED 6-1 M2 BLK 18-10 K4 RED 6-2 BLU/GRA 12-1 BLU/GRA 12-2 VIO 16-2 VIO 12-5 BRN/BLK 18-1 VIO/GRA 12-1 K3 RED/VIO 8-3 SP9 VIO 16-3 VIO 16-2 BLU 18-1 GRN/RED 8-1 CENTER BRUSH RED/VIO 8-2 ORN/GRN 14-2 WHT/RED 12-2 ORN/GRN 14-1 M13 WHT X14 X13 GRN/ORN 18-3 MOTOR, DRIVE LEFT BRUSH M7 MOTORS, VACUUM A1 GRA/BLK 8-1 M6 H2 MOTOR, DUST CONTROL S3 SWITCH, HOPPER INTERLOCK BLK 18-3 BLK 12-4 BLK 18-4 A2 X12 X11 BLK 18-3 X45 X46 SWITCH, RECOVERY FULL X42 X39 X67 MOTOR, STEERING RED/BLK 18-2 M5 SWITCH, BATTERY INTERLOCK SP10 F2 RED/VIO 8-1 BLK 10-1 BLU/GRA 12-2 M15 WHT/ORN 8-1 M16 GRN/WHT 10-1 S4 BLK 18-24 X41 X40 BLK 12-9 C1 CAPACITOR, 180 MFD GRA/YEL 18-2 BLU/GRA 12-1 BLK 1-2 VIO 16-7 BLK 16-2 GRA/YEL 18-1 BT1 BATTERY, 36Vdc GRN/RED 8-1 RED 8-1 F9 X43 X44 BLK 12-8 B+ M- BRED/BLU 10-1 SP16 BLK 18-11 BLK 16-2 RED 1-2 A2 CIR. BREAKER, 40 AMP CIR. BREAKERS BRN/GRA 10-1 F1: AUXILIARY CIRCUIT 1 RED 8-3 F2: AUXILIARY CIRCUIT 2 CIR. BREAKER, 40 AMP F3: AUXILIARY CIRCUIT 3 F4: DUST CONTROL MOTOR F5: SIDE BROOM MOTORS F6: NONE F7: HYDRAULIC PUMP F8: VACUUM MOTORS F9: POWER STEERING S9 BLK 16-1 F1 F8 SWITCH, SOLUTION EMPTY YEL RED MOTOR, BRUSH ACTUATOR H9 LAMP, TROUBLE RED 3/0-1 BLK 18-18 M11 X16 X15 BLK 3/0-1 CIR. BREAKER, 70 A. S12 X64 X65 BLK 18-19 ORN/WHT 8-1 RED 8-2 VIO/YEL 18-1 YEL/BLK 16-2 YEL/BLK 16-4 YEL/BLK 16-5 YEL/BRN 18-3 F7 X38 X37 MOTOR, SQUEEGEE ACTUATOR ORN 18-7 CIR. BREAKER, 20 A. CIR. BREAKER, 15 A. WHT/GRN 18-1 F1 3 SWITCH, KEY FUSE, 400 A. X17 X71 GRAY S11 B1 YEL/BRN 18-4 F10 RED 6-1 RED 1-1 SP18 ELECTRICAL SYSTEM SP24 SP5 FUSES F10: MAIN F11: BRUSH MOTORS BLK 18-12 R1 BRN/RED 18-2 VIO/BLK 18-2 BLU/GRN 10-1 REVERSE POT. 5K OHM L4 L5 VALVE, DUMP DOOR CLOSE X24 FORWARD YEL/BRN 18-2 X23 X34 X33 X31 X32 L1 VALVE, SOLUTION L2 VALVE, SOLUTION VALVE, DUMP DOOR OPEN X28 L6 L6A VALVE, HOPPER LOWER X27 X53 X52 SWITCH, HYD. FILTER M10 X25 X29 H8 LAMP, CURB MOTOR ASM., HYD PUMP K11 X26 X30 VIO 16-10 S7 VALVE, HOPPER RAISE X63 X62 VIO 16-11 VIO 16-12 VIO 16-13 VIO 16-14 VIO 16-22 revised 1/05 FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 81 WIRING SCHEMATIC (after SN 1808248) ELECTRICAL SYSTEM H7 SWITCH, MAIN BROOM H10 LAMP, BROOM OVERLOAD X49 X50 S11 SWITCH, KEY FUSE, 400 A. RED 3/0-1 ORN 18-1 X18 X70 A2 F11 F2 BLU/BLK 18-1 CIR. BREAKER, 25 A. GRA 18-1 RED/WHT 18-1 GRN 18-2 BLK/WHT 16-1 ORN/BLU 18-1 BRN 18-1 BLK/GRA 18-1 BRN/BLU 18-1 BLK 18-1 GRN/BLK 16-2 YEL/BLK 16-1 YEL/BLK 16-12 SWITCH/DISPLAY PANEL ASSEMBLY FUSE, 250 A. F1 F3 BLK 18-1 BLU/ORN 18-1 ORN/BRN 18-1 CIR. BREAKER, 20 A. CIR. BREAKER, 5 A. J3 WHT/BRN 18-1 BRN/BLU 18-1 GRN/BLU 18-1 H1 X54 X55 F4 GRN/BRN 18-1 F5 VIO 16-18 BACKUP ALARM (OPTIONAL) M12 X47 X48 SP20 SP11 BLU/BRN 18-1 SP21 GRN/BLK 16-1 GRN/BLK 16-2 GRN/BLK 12-1 SP6 X51 SP13 ORN 18-6 ORN 18-5 ORN 18-4 GRN 18-2 GRN 18-3 GRN 18-1 SP8 SP22 A H5 SP14 1 A H6 RED MOTOR, BRUSH ACTUATOR WHT ORN 18-2 GRA/ORN 18-1 GRN SW., RETRACT LIMIT YEL/BLK 16-5 B S2 RED VIO 16-21 SWITCH, SEAT S1 BLK SW., EXTEND LIMIT F2 B+ M- BRED/BLU 10-1 RED 1-A2 BLK 1-A1 X58 X21 X59 X22 SP10 F2 WHT/YEL 10-1 X66 K1 YEL/BLU 18-1 K6 DUST CONTROL VIO 16-7 VIO 16-6 K2 GRA/BLK 8-1 CENTER BRUSH RED/VIO 8-2 VIO 16-6 VIO 16-5 BLU/YEL 8-1 K7 K8 SIDE BROOMS GRA/RED 18-1 VIO 16-5 VIO 16-3 K4 RED 6-1 K9 STEERING ORN 18-3 ORN 18-4 DRIVE RED 1-1 K10 WHT/RED 12-4 VIO 12-5 VIO 12-3 VIO 16-1 BLK 18-10 SP12 GRA/VIO 18-3 GRA/VIO 18-2 ORN/GRN 14-1 VIO 14-4 VIO 14-6 RED/BLK 18-3 RED/BLK 18-2 WHT/RED 12-4 WHT/RED 12-3 BLK 12-5 BLK 12-3 BLK/RED 18-3 YEL/VIO 18-3 YEL/VIO 18-2 WHT/GRA 18-3 YEL/BLK 16-10 WHT/GRA 18-2 YEL/BLK 16-7 YEL/BLK 16-9 YEL/BLK 16-8 YEL/BLK 16-7 YEL/BLK 16-8 WHT/RED 12-1 SP2 SWITCH, WAND (OPTIONAL) GRA/WHT 18-2 BLK 18-8 MOTOR, BROOM SP4 BLK 18-5 WHT/BLK 18-2 RED 10-1 BRN/RED 18-2 BLU/GRN 10-1 VIO/BLK 18-2 X35 REVERSE R1 POT. 5K OHM L4 L5 VALVE, DUMP DOOR CLOSE X34 X33 X31 X32 L2 VALVE, SOLUTION VALVE, DUMP DOOR OPEN X24 X23 X28 L6 M8 RED BLK VIO 18-3 BLK/RED 18-3 L6A VALVE, HOPPER LOWER X53 X52 VIO 16-11 VIO 16-12 VIO 16-13 VIO 16-22 M14 X30 BLK RED MOTOR, SHAKER SWITCH, HYD. FILTER M10 X25 X29 H8 LAMP, CURB MOTOR ASM., HYD PUMP K11 X26 VIO 16-10 X19 X20 S7 VALVE, HOPPER RAISE X27 VIO 16-14 revised 1/05 X6 X5 MOTOR, RIGHT SIDE BROOM S10 FORWARD YEL/BRN 18-2 BX60 HEAD LIGHT, RIGHT BLK 12-1 SP3 SWITCH, HOPPER FIRE MOTOR, CENTER BRUSH VALVE, SOLUTION H4 X4 X2 SWITCH, DUST CONTROL FILTER YEL/VIO 18-2 L1 SP15 S6 WHT/GRA 18-2 S12 MOTOR, RIGHT BRUSH VIO 16-1 HEAD LIGHT, LEFT VIO 14-7 SP1 H3 X3 X1 VIO 14-8 BLK 12-4 BLK/RED 18-2 BLK MOTOR, LIFT SIDE BROOM BLK 18-6 GRN/WHT 10-1 82 - FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B YEL/BLK 16-9 RED BLK 18-4 M3 M4 X9 X10 M9 X7 X8 BLK 12-2 MOTOR, SIDE BROOM ACTUATOR ORN/GRN 14-2 M1 YEL/GRN 18-4 YEL/GRN 18-2 YEL/GRN 18-3 WHT/RED 12-2 ORN/GRN 14-1 BLK BLK 18-5 BLK 18-6 BLK 1-2 BLK 3/0-1 BLK 16-3 BLK 16-4 BLK 16-5 BLK 16-6 BLK 16-7 BLK/WHT 16-1 BLK/WHT 16-2 BLK 3/0-2 BX61 BLK 3/0-2 BLK 16-1 BLK 10-1 BLK 12-9 BLK 12-8 BLK 18-10 AUXILIARY BLK/YEL 18-1 WHT MOTOR, LEFT BRUSH BLK/ORN 18-1 K5 RED 1-2 SP17 BLK 18-3 BLK 12-4 BLK 18-4 A2 M13 VIO 14-1 BRN/GRA 10-1 MAIN BROOM GRN/GRA 18-1 BRN 18-2 BLK 1-1 BLK 8-1 BLK 8-2 WHT/ORN 8-1 VIO/GRA 12-1 RIGHT BRUSH RED 6-2 BLU/GRA 12-1 BLU/GRA 12-2 VIO 16-2 VIO 12-5 BRN/BLK 18-1 K3 RED/VIO 8-3 M2 GRN/RED 8-1 VACUUM WHT/VIO 18-1 SP9 M5 GRN/ORN 18-2 BLK 12-6 VIO 16-3 VIO 16-2 BLU 18-1 M7 X14 X13 GRN/ORN 18-3 BRN/WHT 14-1 ORN/GRN 14-2 S3 SWITCH, HOPPER INTERLOCK MOTOR, DUST CONTROL MOTORS, VACUUM HORN BRN/YEL 18-1 LEFT BRUSH RED/VIO 8-1 M6 X67 X12 X11 SWITCH, RECOVERY FULL A1 H2 MOTOR, DRIVE WHT/ORN 8-1 MOTOR, STEERING RED/BLK 18-2 X42 X39 SWITCH, BATTERY INTERLOCK S13 BLK 10-1 BLK 18-3 X41 X40 BLK 12-9 X69 M16 GRN/WHT 10-1 S4 BLU/GRA 12-2 X68 C1 CAPACITOR, 180 MFD GRA/YEL 18-1 A1 VIO 16-7 BLK 16-2 BT1 BATTERY, 36Vdc GRN/RED 8-1 RED 8-1 F9 X43 X46 BLK 12-8 BLK 1-2 A2 CIR. BREAKER, 40 AMP BLU/GRA 12-1 RED 1-2 F1 SP16 BLK 18-11 BLK 16-2 H9 LAMP, TROUBLE RED 3/0-1 CIR. BREAKERS BRN/GRA 10-1 F1: AUXILIARY CIRCUIT 1 RED 8-3 F2: AUXILIARY CIRCUIT 2 CIR. BREAKER, 40 AMP F3: AUXILIARY CIRCUIT 3 F4: DUST CONTROL MOTOR F5: SIDE BROOM MOTORS F6: NONE F7: HYDRAULIC PUMP F8: VACUUM MOTORS F9: POWER STEERING S9 BLK 16-1 F1 F8 SWITCH, SOLUTION EMPTY YEL X16 X15 BLK 3/0-1 CIR. BREAKER, 70 A. S12 BLK 18-18 M11 YEL/BLK 16-2 YEL/BLK 16-4 YEL/BLK 16-5 VIO 16-20 LAMP, TAIL YEL/BLK 16-3 2 2 X57 X56 X64 X65 BLK 18-19 ORN/WHT 8-1 RED 8-2 VIO/YEL 18-1 YEL/BLK 16-4 B LAMP, TAIL YEL/BLK 16-12 YEL/BLK 16-1 YEL/BLK 16-2 VIO 16-19 VIO 16-20 VIO 16-21 YEL/BRN 18-3 F7 X38 X37 MOTOR, SQUEEGEE ACTUATOR ORN 18-7 CIR. BREAKER, 20 A. CIR. BREAKER, 15 A. WHT/GRN 18-1 M15 3 B1 YEL/BRN 18-4 X17 X71 /4); SP24 SP5 F10 RED 6-1 RED 1-1 SP18 SP23 FUSES F10: MAIN F11: BRUSH MOTORS S8 VIO 16-17 LAMP, FLASHING GRN/BLU 18-1 BLU/ORN 18-1 GRA/YEL 18-1 WHT/GRA 18-1 YEL/VIO 18-1 RED/ORN 18-1 RED/BLK 18-1 ORN/RED 18-1 ORN/BRN 18-1 VIO/YEL 18-1 YEL/WHT 18-1 GRN/VIO 18-1 GRA/WHT 18-1 ORN/BLK 18-1 BLK/WHT 16-2 ORN 18-7 WHT/BRN 18-1 BLK 18-12 X63 X62 HYDRAULIC SYSTEM Item 2 3 4 5 6 6A 7 8 9 COMPONENT LOCATION HYDRAULIC SCHEMATIC Description Replacement Hydraulic Filter Element Contactor (K11) Solenoid Valve Dump Door Open Solenoid Valve Dump Door Close Solenoid Valve Hopper Raise Solenoid Valve Hopper Lower Motor Assembly (M10) Cylinder, Hydraulic Cylinder, Hopper Lift Hopper Lift Dump Door 9 7 8 3 5 6 4 2 6A revised 1/05 FORM NO. 56043095 / Captor™ 4300B, 4800B / CR 1100B, 1200B - 83 Austria (Sales Sub) Nilfisk-Advance GmbH Voralberger Allee 46 A-1230 Wien [email protected] www.nilfisk-advance.at Belgium (Sales Sub) Nilfisk-Advance NV/SA Doornveld Sphere Business Park Industrie Asse 3, No. 11 B-1731 Zellik-Asse www.nilfisk-advance.be Czech Republic (Sales Sub) Nilfisk-Advance s.r.o. Lysinská 44/1863 143 00 Praha - Modrany Czech Republic Denmark Nilfisk-Advance A/S Sognevej 25 DK-2605 Brøndby [email protected] www.nilfisk-advance.com Denmark (Prod. Sub) Gerni A/S Myntevej 2 DK-8900 Randers www.gerni.com Denmark (Sales Sub) Nilfisk-Advance Nordic A/S Sognevej 25A Postbox 344 DK-2605 Brøndby [email protected] www.nilfisk-advance.dk France (Sales Sub) Nilfisk-Advance S.A. 27 avenue de la Baltique Villebon sur Yvette P.B. 246 F-91944 Courtaboeuf Cedex [email protected] www.nilfisk-advance.fr Germany (Sales Sub) Nilfisk-Advance AG Siemensstrasse 25-27 Postfach 1361 D-25462 Rellingen info@nilfisk-advancede www.nilfisk-advance.de Greece (Sales Sub) Nilfisk-Advance A.E. 8, Thoukididou Str. Argioupoli Gr - 164 52 Athens Greece Phone: +43 1616 58 30 22 Fax: +43 1616 58 30 40 Phone: +32 (0)2467 60 50 Fax: +32 (0)2463 44 16 Phone: +420 2 44 09 09 12 +420 2 44 09 09 21 4 Fax: +420 2 44 40 23 93 Phone: +45 43 23 81 00 Fax: +45 43 43 77 00 Phone: +45 89 12 22 00 Fax: +45 86 43 14 81 Phone: +45 43 23 40 50 Fax: +45 43 23 40 60 Phone: +33 1695 98 700 Fax: +33 1695 98 701 Phone: +49 4101 3990 Fax: +49 4101 39 91 91 Tel.: +30 210 963 3443 Fax: +30 210 965 0975 Holland (Sales Sub) Nilfisk-Advance B.V. Camerastraat 9 (2e verdieping) 1322 BB Almere Postbus 60112 1320 AC Almere www.nilfisk-advance.nl Ireland (Sales Sub) Nilfisk-Advance Limited 28 Sandyford Office Park Sandyford, Dublin 18 Ireland Italy (Prod & Sales Sub) CFM SpA Nilfisk-Advance Div. Guardamiglio Localita Novella III I-26862 Guardamiglio (Mi) Italy (Prod & Sales Sub) CFM S.p.A. Via Porrettana 1991 I-41059 Zocca (Modena) [email protected] Norway (Sales Sub) Nilfisk-Advance AS Ulvenveien 89C N-0581 Oslo Poland (Sales Sub) Nilfisk-Advance Sp.Z.O.O. 05-800 Pruszków ul. 3-go MAJA 8 Poland Portugal (Sales Sub) Nilfisk-Advance, Lda. Sintra Business Park Zona Industrial Da Abrunheira Edificio 1, 1o A P-2710-089 Sintra Russia (Sales Sub) Nilfisk-Advance LLC Vyatskaya str. 27, bld. 7 127015 Moscow Russia Spain (Sales Sub) Nilfisk-Advance S.A. Torre D’Ara Passeig del Rengle, 5 Pl.10 E-08302 Mataró (Barcelona) [email protected] Sweden (Sales Sub) Nilfisk -Advance A/S Sjöbjörnsvägen 5 Box 44045 S-100 73 Stockholm [email protected] www.nilfisk-advance.se Phone: +31 36 546 07 00 Fax: +31 36 523 51 48 Phone: +35 3 12 94 38 38 Fax: +35 3 12 94 38 45 Phone: +39 0377 /414021 /45 1124 Fax: +39 0377 51 443 Phone: +39 059 973 0000 Fax: +39 059 973 0099 Phone: +47 23 06 75 00 Fax: +47 23 06 75 01 Phone: +48 22 738 37 50 Fax: +48 22 738 37 51 Phone: +35 121 911 2670 Fax: +35 121 911 2679 Phone: 7 095 783 9602 Fax: +7 095 783 9603 Phone: +34 93 741 2400 Fax: +34 93 757 8020 Phone: +46 8555 94400 Fax: +46 8555 94430 Sweden (Prod.) Nilfisk-Advance A/S Åmål Branch Strömsbergsgatan Box 127 S-662 23 Åmål Switzerland (Sales Sub) Nilfisk-Advance AG Ringsstrasse 19 Kirchberg/Industrie Stelzl CH-9500 Wil www.nilfisk-advance.ch UK (Sales Sub) Nilfisk-Advance Limited Newmarket Road Bury St. Edmunds UK-Suffolk IP33 3SR USA (Prod.) Nilfisk-Advance Inc. 14600 21.st Avenue North Plymouth, MN 55447-3408 www.mn.nilfisk-advance.com USA (Sales Sub) Nilfisk-Advance America Inc. 300 Technology Drive Malvern, PA 19355 www.pa.nilfisk-advance.com Canada (Sales Sub) Nilfisk-Advance Canada Comp. 396 Watline Avenue Mississauga, Ontario L4Z 1X2 Australia (Sales Sub) Nilfisk-Advance Pty. Ltd. 48 Egerton Street Silverwater, NSW 2128 Postal addresse: PO Box 6046 Silverwater. NSW 1811 [email protected] www.nilfisk-advance.com.au China (Shenzhen) Nilfisk-Advance (Shenzhen) Ltd Blok 3, Unit 130, 1001 Honghua Road Int. Commercial & Trade Center Fuitian Free Trade Zone 518038 Shenzhen P.R. China China (Suzhou) Nilfisk-Advance Professional Cleaning Equipment (Suzhou) Co. Ltd. 306 Su Hong Zhong Road, Build. 2 Suzhou Industrial Park 215021 Suzhou P.R. China Phone: +46 5321 7500 Fax: +46 5321 7595 Phone: +41 71 92 38 444 Fax: +41 71 92 35 283 Phone: +44 1284 763163 Fax: +44 1284 750 562 Phone: +1 763 745 3500 Fax: +1 763 745 3718 Phone: +1 610 647 6420 Fax: +1 610 647 6427 Phone: + 1 905 712 3260 Fax: +1 905 712 3255 Phone: +61(0)2 9648 2700 Fax: +61(0)2 9648 2711 Phone: +86 755 8359 7937 el. 8359 7939-42 Fax: +86 755 8359 1063 Phone: +86 512 8918 5656 Fax: +86 512 8918 5666 Hong Kong (Sales Sub) Nilfisk-Advance Ltd. 2001 HK Worsted Mills Ind’l Bldg., 31-39 Wo Tong Tsui St. Kwai Chung, Hong Kong Japan (Sales Sub) Nilfisk-Advance Inc. 3-17-40-101 Chigasaki Higashi Tsuzuki-ku, Yokohama 224-0033 Japan Malaysia (Sales Sub) Nilfisk-Advance Sdn Bhd No. 21, Jalan SS 25/41 Mayang Industrial Park 47301 Petaling Jaya Selangor, Malaysia New Zealand (Sales Sub) Nilfisk-Advance Limited Danish House 6 Rockridge Avenue Penrose 92-829 Auckland1135 Postal addresse: Private Bag 92 825 Auckland New Zealand Singapore (Sales Sub) Nilfisk-Advance Pte. Ltd. 22,Woodlands Industrial Park E1 Singapore 757740 [email protected] Taiwan, ROC (Sales Sub) Nilfisk-Advance Ltd. Taiwan Branch (H.K.) 1F, No. 193, Sec.2 Xing Long Rd., Taipei Taiwan, R.O.C. Thailand (Sales Sub) Nilfisk-Advance Co. Ltd. 89 Soi Chokechai-Ruammitr Viphavadee-Rangsit Road Ladyao, Jatuchak, Bangkok 10900 Thailand Phone: +852 2427 5951 Fax: +852 2487 5828 Phone: +8145 942 7741 Fax: +8145 942 6545 Phone: +60 3 7956 8188 Fax: +60 3 7966 6828 Phone: +64(0)9 525 0092 Fax: +64(0)9 525 6440 Phone: + 65 6 7599100 Fax: +65 7599133 Phone: +886 2 2239 8812 Fax: +886 2 2239 8832 Phone: +66 2 275-5630 Fax: +66 2 691-4079 www.nilfisk-advance.com © 2005 Printed in USA