Nilfisk-Advance Captor 4300 User manual

4/04 revised 1/06 Form Number 56043094
Captor™4300, 4800, 5400
CR 1100, 1200, 1400
MECHANICAL REPAIR SERVICE MANUAL
Advance MODELS 56304000, 56304001, 56304002, 56304003, 56304004,
56304005, 56304006, 56304007, 56304008
Nilfisk MODELS 56304009, 56304010, 56304011, 56304012, 56304013,
56304014, 56304015, 56304016, 56304017
This manual applies to Diesel, Gasoline/Petrol and LPG models.

52 -FORMNO.56043094/Captor™4300,4800,5400/CR1100,1200,1400
GENERALINFORMATION ...........................................................................................................................2-3
SAFETYINSTRUCTIONS...............................................................................................................................4
KNOWYOURMACHINE...............................................................................................................................5-6
OPERATOR’SCOMPARTMENT ..................................................................................................................7-8
STEERINGSYSTEM ..................................................................................................................................9-11
STEERINGWHEELREMOVAL......................................................................................................................9
HYDRAULICSTEERINGUNITREMOVAL....................................................................................................9
HYDRAULIC STEERINGCYLINDERREMOVAL ........................................................................................10
WEARADJUSTMENTFORCYLINDERRACK ........................................................................................... 10
STEERINGSPINDLEASSEMBLYREMOVAL .............................................................................................10
BEARINGREPLACEMENTANDSPINDLEINSTALLATION.......................................................................10
WHEELDRIVESYSTEM ..........................................................................................................................12-13
DRIVETIREREMOVAL...............................................................................................................................12
WHEELDRIVEMOTORREMOVAL............................................................................................................. 12
HYDROBACKDRIVEPEDAL NEUTRALADJUSTMENT............................................................................ 13
HYDROBACKCABLEASSEMBLYREMOVAL ............................................................................................13
FRONTWHEELSYSTEM.........................................................................................................................14-15
FRONTWHEELREMOVALANDBRAKEINSPECTION ............................................................................. 14
FRONTBRAKESHOEADJUSTMENT........................................................................................................ 14
BRAKECABLEREPLACEMENT................................................................................................................. 14
HYDRAULICSYSTEM..............................................................................................................................16-23
REMOVALOFHYDRAULICOILCOOLER..................................................................................................16
REMOVALOFENGINECOOLANTRADIATOR ..........................................................................................16
REMOVALOFHYDRAULICENGINEFANMOTOR.................................................................................... 16
ACCESSORYPUMPASSEMBLYREMOVAL .............................................................................................. 18
PROPULSIONPUMPREMOVAL................................................................................................................. 18
HYDRAULICHOSE ROUTING...............................................................................................................20-21
HYDRAULICSCHEMATIC43"MODELS .................................................................................................... 22
HYDRAULICSCHEMATIC48"MODELS .................................................................................................... 23
HYDRAULICSCHEMATIC54"MODELS .................................................................................................... 24
SWEEPINGSYSTEM................................................................................................................................26-34
MAINBROOMMAINTENANCE................................................................................................................... 26
BROOMLEVERSWITCHS16REPLACEMENTANDADJUSTMENT......................................................... 27
MAINSWEEPINGBROOMMOTORREMOVAL .......................................................................................... 27
SIDEBROOMMAINTENANCE.................................................................................................................... 28
SIDEBROOMMOTORREMOVAL ..............................................................................................................29
SIDEBROOMLIFT ACTUATORMOTORREPLACEMENT........................................................................ 30
SIDEBROOM LIFT ACTUATORMOTORADJUSTMENT ..........................................................................31
SKIRTIDENTIFICATION AND REPLACEMENT.........................................................................................32
SWEEPINGPERFORMANCECHECKLIST ................................................................................................ 32
IMPELLERMOTORREMOVAL ...................................................................................................................33
MAINBROOM LIFTCABLE REPLACEMENT ........................................................................................33-34
HOPPERSYSTEM ...................................................................................................................................35-37
SEALSANDSKIRTS IDENTIFICATION AND REPLACEMENT .................................................................. 35
DUMPDOORCYLINDERREMOVAL..........................................................................................................36
HOPPERLIFTCYLINDERREMOVAL ........................................................................................................37
TABLE OF CONTENTS
revised 1/06

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 1
TABLE OF CONTENTS
SOLUTIONSYSTEM ................................................................................................................................38-39
SOLUTIONTANKREMOVAL ...................................................................................................................... 38
SOLUTIONVALVECONTROLCABLEREPLACEMENT ............................................................................ 38
TROUBLESHOOTINGGUIDE ..................................................................................................................... 38
SOLUTIONSYSTEMMAINTENANCE ........................................................................................................ 38
SCRUBBINGSYSTEM .............................................................................................................................40-41
SCRUBDECKASSEMBLYREMOVAL........................................................................................................ 40
SCRUBDECKASSEMBLYINSTALLATION................................................................................................ 40
SCRUBDECKCYLINDER REMOVAL ........................................................................................................ 40
SCRUBBRUSHMOTORREMOVAL........................................................................................................... 40
RECOVERYSYSTEM...............................................................................................................................42-43
TROUBLESHOOTINGGUIDE ..................................................................................................................... 42
VACUUM/RECOVERYSYSTEMSERVICEMAINTENANCECHECKLIST ................................................. 42
RECOVERYTANKREMOVAL..................................................................................................................... 42
VACUUMFAN MOTOR REPLACEMENT....................................................................................................43
SQUEEGEESYSTEM...............................................................................................................................44-47
SQUEEGEEMAINTENANCE ......................................................................................................................44
REMOVALOFSQUEEGEEMOUNTASSEMBLY........................................................................................ 46
SQUEEGEELIFTCYLINDERREMOVAL....................................................................................................46
ELECTRICALSYSTEM ............................................................................................................................48-49
A1MAINCONTROLBOARDREMOVAL.....................................................................................................48
ENGINEDISABLEDECMREMOVAL .....................................................................................................48-49
ENGINESYSTEM.............................................................................................................................................*
Note: Allreferencestoright,left,front,orrearinthismanualareasseenfromtheoperator’sstand-point.
*SeeOTHERMANUALSAVAILABLEforlistofavailableengineinformation.
revised 1/06

2-FORMNO.56043094/Captor™4300,4800,5400/CR1100,1200,1400
INTRODUCTION
ThismanualwillhelpyougetthemostfromyourNilfisk-Advanceriderscrubbersweeper. Readitthoroughlybeforeservicingthemachine.
Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 5-6 i.e. (B).
Thisproductisintendedforcommercialuseonly.
PARTSANDSERVICE
Repairs,whenrequired,shouldbeperformedbyyourAuthorizedNilfisk-AdvanceServiceCenter,whoemploysfactorytrainedservicepersonnel,
andmaintainsaninventoryofNilfisk-Advanceoriginalreplacementpartsandaccessories.
CalltheNILFISK-ADVANCEDEALERnamedbelowforrepairpartsorservice. PleasespecifytheModelandSerialNumberwhendiscussing
yourmachine.
(Dealer,affixservicestickerhere.)
NAME PLATE
TheModelNumberandSerialNumberofyourmachineareshownontheNameplateonthemachine. Thisinformationisneededwhenordering
repairpartsforthemachine. UsethespacebelowtonotetheModelNumberandSerialNumberofyourmachineforfuturereference.
MODELNUMBER
SERIALNUMBER
HOPPER SAFETY SUPPORT
WARNING!
Make sure the Hopper Safety Support (KK) is in place whenever attempting to do any maintenance work under or near the
raised hopper. The Hopper Safety Support (KK) holds the hopper in the raised position to 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.
• Whenjackingthemachine,dosoatdesignatedlocations(DoNotjackonthehopper)–seejackinglocations(44).
TRANSPORTING THE MACHINE
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that…
•Themachineistieddownsecurely-seetie-downlocations(6).
•Allaccessdoorsandcoversaresecured(tapeandstrapasnecessary).
•Themachineparkingbrakeisset.
GENERAL INFORMATION

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 3
TOWING OR PUSHINGADISABLED MACHINE
Themachine’sdrivepropellingpumpismanufacturedwithatowvalve. Thisvalvepreventsdamagetothehydraulicsystemwhenthemachine
isbeingtowed/pushedshortdistanceswithoutuseoftheengine.
Toaccessthevalve,opentheEngineCompartmentDoor(22)andliftofftheRightEngineCompartmentAccessPanel(37). Locatethevalve
asshownontheundersideofthehydrostaticpumpbyreachingundertheradiator. Turnthevalve90degrees,thisdisengagesthehydrostatic
lockbetweenthemotorandpump.
CAUTION!
The hydraulic propelling pump can be damaged if the machine is towed with the valve in the normal working position (A).
Referencetheillustrationsbelowforthenormalworkingsetting(A)(vertical)andthefreewheelingtowingsetting(B)(horizontal). Note: Ifthetow
valveisleftinfreewheeling(B)(horizontal)positionthepropellingpumpcan’tdrivethemachineFWDorREV. Nodamagewillresult,justre-set
valvetothenormalworkingsetting(A)(vertical). NOTE:Toworpushmachinenofasterthananormalwalkingpace(2-3mph-3-5km/h)and
forshortdistancesonly. Ifthemachineistobemovedlongdistancesthedrivewheelneedstoberaisedoffthefloorandplacedonasuitabletransport
dolly.
OTHER MANUALS AVAILABLE
ThefollowingmanualsareavailablefromtheNilfisk-AdvanceLiteratureServiceDepartment,foryourRiderScrubber/Sweeper:
•PartsList-FormNumbers 56042440(allsystemsexcepthydraulic)
56042445(hydraulicsystem)
•OperationManual-FormNumbers 56041546(Danish,Norwegian,Swedish,Finnish)
56041547(German,French,Dutch,Russian)
56041548(Spanish,Portuguese,Italian,Greek)
56041578(Estonian,Latvian,Lithuanian,Slovenian)
56041579(Slovakian,Czech,Polish,Hungarian)
56041580(English)
•QuickStartServiceManual 56043093
•EngineManuals
1.6LIndustrialEngineOperatorManual(excerptfrom16LECSS) 56041564
1.6LIndustrialEngineServiceManual 36100009*
1.6LEmissionCertifiedIndustrialEngineEmissionControlSystemServiceManual 16LECSS*
*Availableinelectronicformatonly
BOTTOM VIEW OF HYDROSTATIC PUMP
GENERAL INFORMATION

4-FORMNO.56043094/Captor™4300,4800,5400/CR1100,1200,1400
CAUTIONS AND WARNINGS
SYMBOLS
Nilfisk-Advanceuses thesymbols belowto signalpotentially dangerousconditions. Always readthis informationcarefullyand
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.
DANGER!
• This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide adequate
ventilation when operating this machine.
WARNING!
• This machine shall be used only by properly trained and authorized persons.
• Whileonrampsorinclines,avoidsudden stopswhenloaded. Avoidabruptsharpturns. Use lowspeeddownhills. Clean
only while ascending (driving up) the ramp.
• Keep sparks, flame and smoking materials away from the battery and fuel system.
• Remove all jewelry when working near electrical components.
• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
• Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.
• Never work under a machine without safety blocks or stands to support the machine.
• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where
flammable liquids exist.
• Do not clean this machine with a pressure washer.
• Keep the LP tank Service Valve closed when the tank is not in use.
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.
• Donotleavethemachineunattendedwithoutfirstturningthekeyswitchoff(O),removingthekeyandapplyingtheparking
brake.
• Turn the key switch off (O) before changing the 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. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 5
1 Operator’s Seat
2 Strobe Light (optional)
3 Solution Tank Fill
4 Gasoline Tank Cap
5 Fuel Tank
6 Tie Down Locations
7 Recovery Tank Drain Hose
8 Engine Air Filter
9 Left Engine Compartment Access Panel
10 Main Broom Left Access Door
11 Battery
12 Hopper Lid Prop Rod
13 Front Wheel
14 Left Side Broom
15 Hopper Lid Latch
16 Headlights
17 Right Side Broom
18 Hopper Cover
19 Dust Control Filter
20 Dust Control Shaker Assembly
KNOW YOUR MACHINE
1
2
3
4
5
6
7
98
10
6
13
14
15
16
17
18
19
20
21
12
22
23
24
44
46
47
45
48
49

6-FORMNO.56043094/Captor™4300,4800,5400/CR1100,1200,1400
21 Shaker Assembly Latch
22 Engine Compartment Door
23 Coolant Recovery Tank
24 Steering Wheel
25 Squeegee Handle
26 Squeegee Tool Assembly
27 Tail Light
28 Exhaust Tail Pipe
29 Fuel Tank Compartment Door
30 Recovery Tank Lid
31 RecoveryTank“Tip-Out”Grip
32 Engine Air Filter Hood
33 Radiator Cap
34 Oil Cooler “Tip-Out” Latches
35 Hydraulic “Charge” Oil Filter
36 Hydraulic Reservoir / In Tank Return Oil Filter
37 Right Engine Compartment Access Panel
38 Main Broom Right Access Door
39 Access Door Latch
40 SkirtAssembly
41 Inline Solution Filter
42 Solution Tank Drain Hose
43 Rear Roller Bumper
44 Jacking Location
45 Engine Oil Dipstick
46 Air Filter Service Indicator
47 Fuel Filter (Gas Models)
48 Recovery Tank Latch
49 HydraulicReservoir AccessPanel
50 Water Level Gauge
51 Operator Seat Adjustment Lever
KNOW YOUR MACHINE
26 25
27
28
29
30
31 32
33 34 35
36
6
37
38
39
40
41
42
6
43
44
11
50
51

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 7
TEMP
F/C
VOLTSFUEL
OIL
PSI/BAR
HOURS 1/10
250
175
120
50
75
100
100 50
0
1
3
8
F
E1/2
18
13 10
+
-
AB
C
D
E
FG
BB
CC
DD
EE
I
J
H
K
L
M
N
O
P
Q
R
S
T
V
W
X
Y
Z
AA
PP
A Low Fuel Indicator (LP)
B Horn Switch
* Horn ON Indicator
C Engine Service Indicator (triggered by ECU)
D Headlight Switch
* Headlight ON Indicator
E Glow Plug Indicator (Diesel / Release key after indicator turns OFF)
F Hydraulic Filter Plugged Indicator
G Engine Speed Switch
* Engine Speed Switch Indicator
H Scrub Pressure Decrease Switch
* Scrub Pressure Decrease Indicator
I Scrub Pressure Increase Switch
* Scrub Pressure Increase Indicator
J Scrub Pressure Display
K Solution Switch
* Solution System Indicator
L Solution Tank Empty Indicator
M Recovery Tank Full Indicator
N Side Broom DOWN/ON Switch
* Side Broom ON Indicator
O Main Broom ON Indicator
OPERATOR'S COMPARTMENT

8-FORMNO.56043094/Captor™4300,4800,5400/CR1100,1200,1400
OO
FF
HH
II
JJ
KK LL
MM
NN
GG
QQ
P Light Sensor
Q Shaker Switch
* Shaker Indicator (left)
* Dust Filter Plugged Indicator (right)
R Open Dump Door Switch
* Open Dump Door Indicator
S Hopper Open Indicator
T Hopper Overtemp Indicator
U Close Dump Door Switch
* Close Dump Door Indicator
V Lower Hopper Switch
* Lower Hopper Indicator
W Raise Hopper Switch
* Raise Hopper Indicator
X Dust Control Switch
* Dust Control ON Indicator
Y Side Broom UP/OFF Switch
* Side Broom OFF Indicator
Z Vacuum System Switch
* Vacuum System Indicator
AA Scrub System OFF Switch
* Scrub System OFF Indicator
BB Coolant Temperature Gauge
CC OilPressureGauge
DD Fuel Gauge (Gas / Diesel)
EE Voltmeter
FF Brake Pedal
GG Parking Brake Latch
HH Solution Flow Control Lever
II Main Broom Raise/Lower (ON/OFF) Lever
JJ Main Broom Adjust Knob
KK Hopper Safety Support Lever
LL Control Panel
MM Ignition Switch
NN Tilt Wheel Lever
OO DrivePedal
PP Hour meter
QQ Main Broom Overload Indicator Light
OPERATOR'S COMPARTMENT

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 9
STEERING SYSTEM
Splined
Bushing
FIGURE 1
FIGURE 2
STEERING WHEEL REMOVAL
1SeeFigure 1. Pry up steering wheel Cap (A).
2RemovecenterhexNut(B). Note:Thisisametricnut,youwillneed
a24mmsocket.
3Useasteeringwheelpullertoremovesteeringwheelfromsplined
shaft.NOTE:Itmaybenecessarytoenlargeholesinsteeringwheel,
alsobesuretosupportthemetalsplinedbushinginthecenterofthe
steeringwheel(seeFigure2)whenpullingthewheel.
HYDRAULIC STEERING UNIT REMOVAL
1Followsteps1-3intheSteeringWheelRemovalsection.
2Removethe(5)screwsthatsecurethebottomconsolepanel(location
operator’scompartmentbelowsteeringwheel).
3SeeFigure1. Removethe(4)item(C)Screwsandpullofftherubber
SteeringBoot(D).
4Removethe(4)hexscrews(10mm)thatsecurethehydraulicsteering
unittoitsMountingBracket(E).
5Adjustthetiltsteeringtohelpinremovingthesteerunitandseparate
thecolumn. Note:Gripsteeringcolumnandpulldownonsteerunit
toeasilyseparate.
6Removethe(5)hydraulichosestocompleteremovalofsteeringunit.
CAUTION!
Therewillbeoilinthemotorandhoses,bepreparedtoplugand
cap system connections.
FRON T
C
B
A
D
E
Steering Column
Hydraulic Steering Unit

10 -FORMNO.56043094/Captor™4300,4800,5400/CR1100, 1200, 1400
STEERING SYSTEM
HYDRAULIC STEERING CYLINDER REMOVAL
1Removetherecoverytankassemblyfromthemachine.
2FollowstepsintheSolutionTankRemovalsection.
3Removethe(2)screwsthatsecuretheelectricalrelaymountassemblyandpullitoutfromthecontrolboxcompartment.
4SeeFigure3. RemovetheHairpin(F)andthenslideoutthecylinderMountPin(G).
5Removethecylinderhoses,thenplugandcaptopreventoilloseandsystemcontamination.
6Markthesteeringrackandspurgearlocationwithacenterpunchtohelpwhenreassembling.
7Lifttherackandcylinderassemblystraightuptocompleteitsremovalfromthechassis.
8Withtherackandcylinderassemblyremovedinspectthenylonwearplates. Replacewhenmountingscrewsareexposedandstrikingthe
rack.
WEAR ADJUSTMENT FOR CYLINDER RACK
1SeeFigure3. Loosenthe(2)HexHDScrews(H).ThenusingalargeflatbladedscrewdriverprybetweentheAdjustmentBracket(I)and
thesteerspindle. Thiswillremoveanyexcessiveplayinthenylonwearplateandtherack,thentightenbracket-mountingscrewstosecure.
STEERING SPINDLE ASSEMBLY REMOVAL
1Removethesqueegeetoolassemblyfromthemachinethenremovetheignitionkey,settheparkingbrakeandblockthefrontwheels.
2Removethesolutiontankassembly(seeSolutionTankRemovalsectionforinstructions).
3SeeFigure3. Removethe(2)(H)HexScrewsthatfastentherackadjustmentBracket(I)thenrotatethebrackettoclearthespurgearand
remove.
4RemovefromthespindleshafttheCotterPin(J)andCastleNut(K). Nextremovethe(2)SetScrews(L)usinga4mmhexkeywrench.
5PullthespurgearfromitsshaftthenremovethesquareshaftKey(M)andGearSpacer(N). Note:Thegearspacerbevelfacesdownto
reassemble.
WARNING!
Never work under a machine without safety blocks and stands to support machine.
6Jackuptherearofthemachineapproximately24inches(60cm)andputthejackstandsinplaceunderrearcornersupports. Note:Guide
thespindleandwheelassemblyoutfromunderitsframehousingbeingcarefulnottodamageshaftthreadsandbearingsurfaces.
7ImportantServiceTip:Observethehydraulicwheelmotorhosestheirroutingandcorrectfittinglocationsthendisconnectthe(3)hoses,(2)
P-clamps(plugandcaphosesandfittings).
8ServiceTip:Wheninstallingorremovingthespindlewheelassembly,useapieceofcardboardunderneaththewheeltohelpinslidingthe
assemblyaround(positioning).
BEARING REPLACEMENT AND SPINDLE INSTALLATION
1Younowhaveaccesstotheupperandlowerbearingcones,cupsandseals(O,P&Q). Note:Ifreplacingorinspectingbearingsbesure
to(re)packbearingswithwhitelithiumgreasebeforeinstalling.
2Toreassemble,firstinstallthelowerbearingcup,coneandsealintotheSteeringCasting(R). Note:Itisimportantthattheshaftgoesthrough
thelowerbearingasstraightaspossible,itmaybeeasiertoinstallthespindlewiththetireremovedplacingthespindleweldmentontopof
amovableservicejack.
3Slowlylowertherearofthemachineguidingandrepositioningtheshaftthroughthecenterofthehousinguntilthedrivewheelsupportsthe
machine.
4Installtheupperbearingcup,cone,seal,spacerandspurgear.
5Installandtightenthecastlenut,torqueto40ft/lbs.(54Nm). Thenloosennuttoaligncotterpin.
6Followthespindleremovalsteps1-4inreverseorder. Checkthatthedrivewheelispositionedstraightahead,aligntherackandgear(marked
teeth).Nextfollowtheadjustmentinstructionsforthecylinderrackandspurgearclearance(fitup)toeliminateanysloppysteeringoperation.

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 11
STEERING SYSTEM
L
F
J
H
MK
G
I
P
P
O
O
Q
Q
N
R
FRONT
FIGURE 3

12 -FORMNO.56043094/Captor™4300,4800,5400/CR1100, 1200, 1400
WHEEL DRIVE SYSTEM
D
C
A
B
G
E
F
H
Torque to 375 ft./lbs. (508 Nm) dry
or 475 ft./lbs. (644 Nm) lubed,
then tighten to align cotter pin.
Torque to
100 ft./lbs. (135 Nm).
FRONT
DRIVE TIRE REMOVAL
WARNING!
Never work under a machine without safety block or stands to support machine.
Disconnect battery before servicing.
1Turnsteeringwheeltotherightfulllockpositionandalsoremovethesqueegeetool.
2Turnoffengine,setparkingbrakeandblockfrontwheels.
3SeeFigure1. Removethe(6)WheelLugNuts(A)(usea21mmsocket). Installationtorqueis100ft/lbs.(135N/M).
4Ifremovingdrivemotor,removetheCotterPin(B)andloosenthemotorshaftCastleNut(C). Note:Youwillneeda1-7/16inchsocketfor
castlenut(seetorquenotesFigure1).
5Thread(2)1/2-13x2"threadedtoHDPusherBolts (D)intothe(E)TireHubsthreadedholes.
6Jackupmachineuntilwheelclearsthefloorandplacejackstandsundermachine.
7Turn(thread)inequallybothboltstoseparatethetireassemblyfromthewheelmotorDriveHub(F).
WHEEL DRIVE MOTOR REMOVAL
1Followsteps1-7inDriveTireRemovalsection.
2Removethedrivemotorshaftcastlenut.
3Markandremovethethreehydraulichosesatthemotor.
CAUTION!
There will be oil in the hoses and motor, be prepared to plug hoses and cap motor fittings.
4Removethe(4)HexScrews(G)andNuts(H)andremovethemotorfromthespindleweldment. Useapullertoremovethedrivehubassembly
fromthetaperedmotorshaftandreuse(salvage).
5Reassembleinreverseorder(seetorquenotesFigure1). Operatethemachineandcheckforleaksandproperperformance.
FIGURE 1

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 13
WHEEL DRIVE SYSTEM
HYDROBACK DRIVE PEDAL NEUTRALADJUSTMENT
Whenservicingthehydrostaticdrivesystem,alwayscheckforanymachinecreeping(movement)intheneutralposition. Themachinemustnot
moveineitherFwdorRevafterthedrivepedalisreleased.Ifmachinecreepingisexperiencedtheneutralpositionofthehydrobackmustbeadjusted.
WARNING!
Use jack stands to support the machine when setting the neutral drive pedal adjustment.
1Blockthefrontwheels. Jackupmachineuntilthereardrivewheelisoffthefloor. Placesupportsattherearcornersofthemachine.
2Removetherightsideenginecovertoaccessthehydrobackadjustmentbracket.
3SeeFigure2. LoosenthetwoLockScrews(I)thatsecurethemoveablecablemountBracket(J)tothechassis.
4Starttheengineandobservethedirectionofthedrivewheelrotation. NextturntheadjustmentScrew(K)clockwise(CW)orcounterclockwise
(CCW)tomovethecablemountingbracket(inorout)enoughtostopanywheelmovement. Thepumparmisnowinneutral,tightenthetwo
lockscrewstosecuretheneutralpumparmsetting.
5TesttheneutraladjustmentbyactivatingthedrivepedalinbothFWD&REVtoconfirmproperwheelmotorcontrol. Readjustagainifneutral
settingisnotrepeatable. Replacethehydrobackandoritslinkageifaneutraladjustmentcannotbeobtained.
6Turntheengineoffthenchecktoseethatitwillrestart. Ifenginewillnotstartthepedalsenseswitchisprobablyoutofitsneutral(deadband)
settingandneedstobereprogrammed. Seethesenseswitchreplacementmanualsectionforprogramminginstructions.
HYDROBACK CABLE ASSEMBLY REMOVAL
1Disconnectatbothcableends(footpedalandpumparm)theClevis(L) andRodEnd(M).
2Loosenbothcableanchorconnectornuts.
3Slidehydrobackassemblyfromitschassisandcableadjustmentmountingbrackets.
4Afterinstallinganewcable/hydrobackseethehydrobackpedalneutraladjustmentinstructions.
FIGURE 2
I
J
K
L
M
FRONT

14 -FORMNO.56043094/Captor™4300,4800,5400/CR1100, 1200, 1400
FRONT WHEEL SYSTEM
FRONT WHEEL REMOVAL AND BRAKE INSPECTION
1Raisehopperandengagesafetysupport.
2Openbroom-housingdoor(LHorRT)andremovethetopgasketseal(sonottodamage). Placejacktowardsfrontofhousingandjackon
machineframetowherethefrontwheelclearsthefloor.
3Placesafetyblockingunderthefrontframemembertosupport.
4RemovetheWheelScrew(A)thenworkthetireoffofwheelspindle. Note:theparkingbrakemustbereleasedtoallowwheeltoberemoved.
Alsotaponthebacksideofwheelwithwoodblockingtohelploosenastubbornstuckwheel.
5Inspectthespindle;wheelbearingsandbrakeshoeliningsforabnormalwearandreplaceallwornparts. Anewbrakeshoeliningthickness
willmeasure11/64(.172)inchesor4.4mm.
6Checkforapproximatelyoneinch(25mm)ofoperatorbrakepedalfree-play(seeinstructionsbelowtoadjust)andtestdrivemachineforproper
operation.
FRONT BRAKE SHOE ADJUSTMENT
1Raisehopperandengagesafetysupport.
2SeeFigure1.Removethe(6)PhilipsScrews(B)thenpullthebroomHousingSkirt(C)tothesidetoaccessthebrakecableclevis.
3SeeFigure1detailofclevisadjustment,lengthorshortenitsthreadedendtoobtainthecorrectbrakepedalfreeplay. Notebothbrakes(LH
&RT)needtobeadjustedequally.
4Ifthebrakecableclevisadjustmentdoesnoteliminateexcessivepedaltravel(poorbrakingperformance)checkforwornoutbrakeshoes
andastretchedbrakecable. Theendsofthebrakecableatthewheelshaveadjustablethreadedcableanchorfittings. Shortenthelength
ofcablewireextendingoutofthecablecasingbyadjustingthecableanchorfittingsatthewheelcastingpocket(inset).
BRAKE CABLE REPLACEMENT
1Followthescrubdeckremovalinstructioninthescrubsystemmanualsection. Theremovalofthedeckisnecessarytoaccessthebrakepedal
cableguidepulleyandcableanchorpoints(locationmiddleofmachineunderoperatorfloorplate).
2Seethebrakeshoeadjustmentinstructionsabovetoremovethebrakecableendsatthewheels.

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 15
FRONT WHEEL SYSTEM
B
A
C
B
FRONT
FIGURE 1

16 -FORMNO.56043094/Captor™4300,4800,5400/CR1100, 1200, 1400
HYDRAULIC SYSTEM
REMOVAL OF HYDRAULIC OIL COOLER
CAUTION!
Disconnect the battery before servicing.
1Removetherightsideenginepanel.
2SeeFigure1. Removethe(2)hydraulichosesattachedtothePre-chargeFilterHousing(A). Thenremovethe(2)inletandoutletoilcooler
hoses(plugandcapallhoses).
3Removethe(2)PivotBolts(B)thatfastentheoilcoolertotheradiatormount. Thenpullthecooleroutofthemachine.
REMOVAL OF ENGINE COOLANT RADIATOR
CAUTION!
Disconnect the battery before servicing.
1Removethehydraulicoilcoolerbyfollowingtheinstructionsinthismanualsection.
2SeeFigure1. Removetheradiatorcapandcoolantover-flowhosethendrainthecoolantfromtheradiatorusingtheDrainHose(C).
3RemovethetwofrontoperatorcompartmentAccessPanels(D&E)locatedinfrontofoperator’sfeetandbelowthesteeringwheelconsole.
4Removeboththeupperandlowerradiatorhoses. Note:Toremovethebottomhoseworkthroughtheoperatorcompartmentaccesspanel.
5Workthroughthetwopreviouslyremovedaccesspanelstoremovethe(2)HexScrews(F)and(2)HexNuts(G)thatfastentheleftsideradiator
mount.
6Removethe(6)Screws(H)thatholdtheradiatortoitsmount. Thencarefullyslidetheradiatoroutofthemachine. Notesomelossofcoolant
willoccurwhenremoving.
REMOVAL OF HYDRAULIC ENGINE FAN MOTOR
1Removethehydraulicoilcoolerandengineradiatorbyfollowingthetwoseparatesetsofinstructionsinthismanualsection.
2SeeFigure1. Removethe(4)fanmountingScrews(I)thenpulloffthefanfromtheFanSpacerHub(J).
3Loosenthe(2)spacerhubsetscrewsthenpullthehubfromthefanmotorshaft.
4Removethe(3)fanmotorhydraulichoses(plugandcap).
5Removethe(4)Nuts(K)and(4)Bolts(L)tocompletetheremovalofthemotorfromitsmountingbracket.

FORM NO. 56043094 / Captor™4300, 4800, 5400 / CR 1100, 1200, 1400 - 17
HYDRAULIC SYSTEM
H
K
B
L
G
F
I
J
AC
B
D
E
FRONT
FIGURE 1

18 -FORMNO.56043094/Captor™4300,4800,5400/CR1100, 1200, 1400
HYDRAULIC SYSTEM
ACCESSORY PUMPASSEMBLY REMOVAL
CAUTION!
Disconnect the battery before servicing.
1Removerightsideenginepanel.
2SeeFigure2. Disconnectthe(3)accessorypumpOutletHoses(M,N&O)(plug&cap).
3Removethe(3)teefittingsfromthepumphousingassemblyandplug.Note:Thefittingsneedtoberemovedtoaccesstherighthousingmounting
bolt.
4Removethetwo-pumpflangeMountingBolts(P)andseparatetheaccessorypumpassemblyfromthepropulsionpump. Note:Beprepared
tocollectoillosswhenthepumpispulledapart.
5RaisethepumpassemblyabovetheheightoftheoilreservoirbeforedisconnectingthelargepumpassemblyinletFeedHose(Q)toprevent
excessiveoillossfromthereservoir(plug&cap). ServiceNote:Whenremovingtheaccessorypumpassemblytoremovethepropulsion
pump(createthenecessaryserviceworkingclearance). Leavethelargehydraulicfeedhoseontheaccessorypumpattached. Noneed
toplugandcapit,justtieitsafelytothechassisabovetheoilreservoir. Thiswillpreventtheunnecessaryneedtodisconnectthehoseand
eliminateanyleakageofhydraulicoil.
PROPULSION PUMP REMOVAL
CAUTION!
Disconnect the battery cables then remove the battery before servicing.
1Removethehydraulicoilcooler,engineradiatorandtheaccessorypumpassemblybyfollowingthethreeseparatesetsofinstructionsinthis
manualsection.
2SeeFigure2. RemovetheSenseSwitch(R)securedwiththeScrew(S)fromtheLeverWeldment(T). Note:DonotlosethesmallBushing
(U) andWasher(V).
3DisconnecttheBallJoint(cablerodend)(W)fromtheLever(T).
4Removetheleverweldmentfromthepropulsionpumpshaftsecuredbyhardwareitems(X&Y).
5Disconnectthe(4)Hoses(Z,AA,AB&AC)asshownfromthepropulsionpump(plugandcap).
6Removethe(2)HexHDScrews(AD)thatfastenthepumpassemblytotheenginebellhousing. TechnicalNote:ReferenceFigure3,this
illustratesaSpecialTool(AE)thatamechanicwillneedtofabricatetoremovethebottompumpretainingscrew.
7Tocompletetheremovalofthepumpfromthemachinepullstraightbacktoseparateitfromtheengineflywheelcoupler.
8Toreassemblefollowtheabovestepsinreverseorderandreadtheservicenotesshownbelowiftheenginewillnotstartormachinecreeps
whendrivepedalisinneutral.
ServiceNote1:IfenginewillnotstartseecaptorQuickStartServiceManual,enginestarterwillnotcranktroubleshootingflowchart. Thepedal
senseswitchisprobablyoutofitsneutraldeadbandsettingandneedstobereprogrammed. Followthefootpedalneutralanddeadbandadjustment
programminginstructionsshowninthismanual’ssenseswitchreplacementsection.
WARNING!
Jack up the rear drive tire before starting machine to check for possible drive wheel creep, linkage out of adjustment.
ServiceNote2:IfmachinecreepswithoutoperatorpedalinputseeHydrobackDrivePedalNeutralAdjustmentinthismanualtore-setneutral.