106 - FORM NO. 56043093 / Captor
™
4300, 4800, 5400
TABLE OF CONTENTS
GENERAL INFORMATION ................................................................................................................................................1-2
SAFETY INSTRUCTIONS .................................................................................................................................................... 3
SPECIFICATIONS .............................................................................................................................................................4-5
MAINTENANCE ................................................................................................................................................................. 6-8
PM CHECKLIST ..............................................................................................................................................................9-10
KNOW YOUR MACHINE ............................................................................................................................................... 12-25
CONTROL ERROR CODES ........................................................................................................................................ 15-17
GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ............................................................... 18
OPERATOR’S COMPARTMENT ......................................................................................................................................19
GENERAL TROUBLESHOOTING FLOW CHARTS .................................................................................................... 20-25
WHEEL DRIVE SYSTEM .................................................................................................................................................... 26
TROUBLESHOOTING CHECK LIST ................................................................................................................................ 26
STEERING SYSTEM .......................................................................................................................................................... 27
STEERING SYSTEM TROUBLESHOOTING OVERVIEW .............................................................................................. 27
TROUBLESHOOTING GUIDE..........................................................................................................................................27
SWEEPING SYSTEM .................................................................................................................................................... 28-35
MAIN BROOM .............................................................................................................................................................28-29
SIDE BROOMS ............................................................................................................................................................30-31
SIDE BROOM LIFT ACTUATOR ......................................................................................................................................32
DUST CONTROL IMPELLER ......................................................................................................................................33-34
SHAKER MOTOR ............................................................................................................................................................. 35
HOPPER SYSTEM ........................................................................................................................................................36-42
LIFT CYLINDER ..........................................................................................................................................................36-39
DUMP DOOR CYLINDER............................................................................................................................................40-42
SCRUB SYSTEM ...........................................................................................................................................................43-52
DECK LIFT ACTUATOR ..............................................................................................................................................43-50
SCRUB MOTORS ........................................................................................................................................................ 51-52
SOLUTION SYSTEM .......................................................................................................................................................... 53
SOLUTION SOLENOID VALVE ........................................................................................................................................ 53
RECOVERY SYSTEM ...................................................................................................................................................54-58
VACUUM MOTOR .......................................................................................................................................................54-56
SQUEEGEE LIFT ACTUATOR ....................................................................................................................................57-58
ENGINE SYSTEM .........................................................................................................................................................59-62
ENGINE SPECIFICATIONS.............................................................................................................................................. 59
ENGINE MAINTENANCE ................................................................................................................................................. 59
CHECK ENGINE LIGHT TROUBLESHOOTING NON-CERTIFIED & TIER I ..................................................................60
1.6L DTC CODES FOR TIER I .........................................................................................................................................61
MISCELLANEOUS ENGINE SYSTEM INFORMATION ................................................................................................... 62
1.6L DTC CODES FOR TIER II ........................................................................................................................................63
MISCELLANEOUS ENGINE SYSTEM INFORMATION ................................................................................................... 64
ENGINE FUEL SYSTEM FOR GASOLINE MODELS .................................................................................................64-66
HYDRAULIC SYSTEM ..................................................................................................................................................67-74
HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................67
GENERAL HYDRAULIC SPECIFICATIONS TABLE ........................................................................................................68
SETTING RELIEF VALVES .........................................................................................................................................69-71
HYDRAULIC DIAGRAM ...................................................................................................................................................72
HYDRAULIC SCHEMATIC ............................................................................................................................................... 73
HYDRAULIC COMPONENT LOCATION .......................................................................................................................... 74
ELECTRICAL SYSTEM .................................................................................................................................................75-73
ELECTRICAL COMPONENT LOCATION......................................................................................................................... 75
WIRING DIAGRAM FOR TIER I ....................................................................................................................................... 76
WIRING SCHEMATIC FOR TIER I ................................................................................................................................... 77
WIRING DIAGRAM FOR TIER II ...................................................................................................................................... 78
WIRING SCHEMATIC FOR TIER II .................................................................................................................................. 79
WIRING DIAGRAM FOR DIESEL ..................................................................................................................................... 80
ENGINE HARNESS GASOLINE/PETROL LPG TIER I ....................................................................................................81
ENGINE HARNESS ECM DETAIL FOR TIER I ................................................................................................................ 82
ENGINE HARNESS GASOLINE/PETROL TIER II ........................................................................................................... 83
ENGINE HARNESS LPG TIER II......................................................................................................................................84
ENGINE WIRING HARNESS DETAIL FOR TIER II..........................................................................................................85
PROGRAMMABLE CONTROL OPTIONS .....................................................................................................................87-95
INPUT/OUTPUT TABLES .............................................................................................................................................. 96-98
AXP/EDS SYSTEM ......................................................................................................................................................99-104
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
revised 12/08
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