Advance acoustic 56303000 Mechanical Repair Service Manual Download

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- FORM NO. 56043096 - Captor

™

4300B, 4800B

ELECTRICAL SYSTEM

F11

CURTIS 1244 SPEED CONTROLLER

M16

M10

K11

M15

Item Description

CONTROL BOX ASSEMBLY

SWITCH/DISPLAY PANEL ASSEMBLY

CURTIS 1244 SPEED CONTROLLER

BT1 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)

F10

FUSE, 400 AMP (MAIN)

F11

FUSE, 250 AMP (BRUSH MOTORS)

BACKUP ALARM (OPTIONAL)

H2 HORN

HEADLIGHT, RIGHT

HEADLIGHT, LEFT

LAMP, TAIL

LAMP, FLASHING (OPTIONAL)

LAMP, CURB (OPTIONAL)

LAMP, TROUBLE (OPTIONAL)

H10 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

K10

CONTACTOR, AUXILIARY

K11

CONTACTOR, HYDRAULIC PUMP MOTOR

VALVE, SOLUTION

VALVE, DUMP DOOR OPEN

VALVE, DUMP DOOR CLOSE

VALVE, HOPPER RAISE

L6A

VALVE, HOPPER LOWER

MOTOR, BROOM 2.0 HP

MOTOR, LEFT BRUSH

MOTOR, CENTER BRUSH

MOTOR, RIGHT BRUSH

MOTOR, DUST CONTROL

MOTOR, VACUUM

MOTOR, RIGHT SIDE BROOM

MOTOR, LEFT SIDE BROOM

M10 MOTOR, ASSEMBLY, HYDRAULIC PUMP

M11 MOTOR, BRUSH ACTUATOR

M12 MOTOR, SQUEEGEE ACTUATOR

M13 MOTOR, SIDE BROOM ACTUATOR

M14 MOTOR, SHAKER

M15 MOTOR, WHEEL DRIVE

M16 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

S10 SWITCH, HOPPER FIRE (OPTIONAL)

S11

SWITCH, KEY

S12 SWITCH, WAND (OPTIONAL)

S13 SWITCH, BATTERY INTERLOCK

WIRING DIAGRAM (before SN 1767238)

Summary of Contents for 56303000

Page 1: ...Captor 4300B 4800B 10 04 revised 6 12 FORM NO 56043096 MECHANICAL REPAIR SERVICE MANUAL Advance MODELS 56303000 4800 battery 56303001 4300 battery...

Page 2: ...DRIVE BELT INSTALLATION AND TENSIONING ADJUSTMENT 21 MAIN BROOM MOTOR BELT REMOVAL 22 MAIN BROOM MOTOR BELT INSTALLATION AND TENSIONING ADJUSTMENT 22 SIDE BROOM MAINTENANCE 22 SIDE BROOM MOTOR REMOVAL...

Page 3: ...s product is intended for commercial use only PARTS AND SERVICE Repairs when required should be performed by your Authorized Advance Service Center who employs factory trained service personnel and ma...

Page 4: ...locks 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...

Page 5: ...s 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 unde...

Page 6: ...8 Main Broom Left Access Door belt motor access 9 Hopper Cover Prop Rod 10 Front Wheel 11 Jacking Location 12 Left Side Broom 13 Hopper Cover Latch 14 Headlights 15 Right Side Broom 16 Hopper Cover 17...

Page 7: ...ut Grip 27 Hydraulic Power Unit Reservoir Filter 28 Right Battery Compartment Access Panel 29 Main Broom Right Access Door broom removal 30 Access Door Latch 31 Skirt Assembly 32 Inline Solution Filte...

Page 8: ...Tank Full Indicator N Vacuum System Switch Vacuum System ON Indicator O Scrub System OFF Switch Scrub System Indicator P Side Broom ON Side Broom ON Indicator Q Main Broom ON Indicator R Light Sensor...

Page 9: ...ever GG Main Broom Adjust Knob height pattern HH Hopper Safety Support Lever II Control Panel JJ Main Broom Overload Indicator Light KK Emergency Battery Disconnect LL Steering Wheel Tilt Lever MM Dri...

Page 10: ...e Figure 1 2 when pulling the wheel POWER STEERING UNIT REMOVAL 1 Disconnect the battery by using the Emergency Disconnect Knob KK 2 Remove the 4 screws that fasten the steering unit cover to the chas...

Page 11: ...proper operation STEERING CHAIN REMOVAL 1 Follow the Solution Tank Removal instructions in this manual 2 Turn the Key Switch to the OFF position set the Parking Brake and disconnect the batteries 3 Se...

Page 12: ...Follow steps in reverse order to install new wheel Torque spec 100 ft lbs 135 N m WHEEL DRIVE MOTOR REMOVAL 1 Follow the Solution Tank Removal Instructions in this manual 2 Turn the Key Switch to the...

Page 13: ...re on the floor and tilt the top of the motor away from the wheel and roll out the opposite side NOTE The motor is heavy block or strap motor to assist when removing Installation 1 NOTE Refer to the G...

Page 14: ...tance of the rotary sensor at the plug wires WHT BLK pin14 and VIO BLK pin 13 4 Divide the measured resistance in half to find the neutral setting dead band 5 Move one meter lead to wire BRN RED pin 1...

Page 15: ...he pot shaft and disturb move its neutral setting To Replace Pedal or Spring 4 Position the torsion spring ends V W as shown This is with the bushing and screw not installed 5 Place the bushing inside...

Page 16: ...tain the proper Brake Pedal free play approximately one inch 25mm NOTE Fewer threads will equal a tighter Brake Pedal BRAKE CABLE REPLACEMENT 1 See Front Wheel Removal and Brake Inspection instruction...

Page 17: ...FORM NO 56043096 Captor 4300B 4800B 15 FRONT WHEEL SYSTEM FIGURE 3 1...

Page 18: ...otor Frame F off the motor armature 7 Remove the Armature G from the pump coupler input noting not to lose the Coupling H HYDRAULIC PUMP MOTOR INSTALLATION 1 Separate the new motor armature from the m...

Page 19: ...ve for reinstallation on the new pump assembly 7 Remove the 4 hydraulic hoses at the pump assemble Note mark cap and plug hoses 8 Remove the 2 Screws I that fasten the pump assemble to the chassis and...

Page 20: ...18 FORM NO 56043096 Captor 4300B 4800B HYDRAULIC SYSTEM FIGURE 4 3...

Page 21: ...ce 8 Close and latch the Main Broom Right Access Door 38 To Adjust the Main Broom Height 1 Drive the machine to an area with a level floor and set the parking brake GG 2 Pull the Main Broom Raise Lowe...

Page 22: ...and then remove the screw and nut that fasten it to the chassis 4 Install new switch but leave the mounting screws loose Insert a continuity tester or Ohm meter in the switch wiring then adjust switc...

Page 23: ...ectrical terminal studs 8 Follow the above steps and re install the motor in reverse order See the broom motor and broom belt installation and tensioning instructions in this manual section to re tens...

Page 24: ...k Nut W 3 Reinstall the Rear Belt Guard T 4 Follow the instructions in this manual section to reinstall and tension the main broom Belt Z Then test the main broom system for its proper operation SIDE...

Page 25: ...rew AE Washer and AF Nut that fasten the 2 broom bracket weldments AG together 4 Remove AH Hairpin that fastens the 2 broom bracket weldment AG together 5 Twist and pull the side broom motor assembly...

Page 26: ...anel held in place by 11 Philips head screws 3 Disconnect the lift actuator motor wiring harness connector 4 See Figure 5 6 Next remove the Hairpin AL from its mount pin 5 Remove both the front Retain...

Page 27: ...lift cable Hanger Weldment AU Then remove the cable ball joint end from the broom hanger mount 8 Raise the hopper and set SAFETY SUPPORT HH See Figure 5 8 Remove the 3 AV Screws that fasten the access...

Page 28: ...NT To access Hopper should be empty Raise and support the hopper open the dump door WARNING Do not have engine running when working under hopper Qty Description A 1 Blade B 1 Hopper Boot C 1 Dust Shie...

Page 29: ...ctions when reassembling CAUTION There may be oil in hoses and cylinder be prepared to plug hoses and cap cylinder connections 2 Remove lower and upper cotter pins and Cylinder Pins L 3 Remove cylinde...

Page 30: ...the hopper and pull the safety prop rod into position then lower hopper until the rod is secure 2 Disconnect the battery 3 Remove the two hydraulic hopper cylinder hoses at the cylinder be prepared to...

Page 31: ...CEMENT 1 Open and latch the hopper filter cover to gain access to the S3 hopper interlock switch located on the left side of the hopper 2 Disconnect the switch wiring connector then remove the switch...

Page 32: ...to route the cable through the machine chassis 7 From underneath the machine at the solution control valve arm remove its cable ball joint end Next loosen the cable casing anchor hardware and pull the...

Page 33: ...FORM NO 56043096 Captor 4300B 4800B 31 SOLUTION SYSTEM FIGURE 7 1...

Page 34: ...n the scrub motors FIGURE 8 1 Important Service Note Use wire connections shown above but reverse the leads if the proper brush rotation is not achieved SCRUB DECK LIFT ACTUATOR MOTOR REMOVAL 1 Remove...

Page 35: ...FORM NO 56043096 Captor 4300B 4800B 33 SCRUB SYSTEM FIGURE 8 2 G M K to Center Brush to Left Brush to Right Brush C D E B A G F H FRONT L J I G...

Page 36: ...M RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST Whenever there is a vacuum problem it s best to check over the entire system Use the checklist below as a guide to thoroughly check the vacuum system Cl...

Page 37: ...ction 2 See Figure 9 2 Remove the 3 item A Hex Screws 3 Disconnect the vacuum motor plug 4 Remove the vacuum motor s B 5 Reassemble the vacuum motor s in reverse order following the steps above and ch...

Page 38: ...he Rear Squeegee Blade F from the machine 3 The squeegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are...

Page 39: ...FORM NO 56043096 Captor 4300B 4800B 37 SQUEEGEE SYSTEM FIGURE 10 1...

Page 40: ...and mounting hardware 2 Install the pin mounting hardware to retain the lift motor to the mount 3 Remount the squeegee tool and test squeegee for proper water pick up See in this manual Squeegee Maint...

Page 41: ...FORM NO 56043096 Captor 4300B 4800B 39 SQUEEGEE SYSTEM FIGURE 10 2...

Page 42: ...clip to the positive and black to negative to battery connector or battery posts The rocker switch is used to change the motor rotation in setting the correct drive nut dimension Instructions for Sque...

Page 43: ...actor Dust Control Motor K7 Contactor Vacuum Motor K8 Contactor Side Broom K9 Contactor Steering K10 Contactor Auxiliary K11 Contactor Hydraulic Pump Motor L1 Valve Solution L4 Valve Dump Door Open L5...

Page 44: ...MOTOR K2 CONTACTOR CENTER BRUSH MOTOR K3 CONTACTOR RIGHT BRUSH MOTOR K4 CONTACTOR BROOM MOTOR K5 CONTACTOR DRIVE WHEEL K6 CONTACTOR DUST CONTROL MOTOR K7 CONTACTOR VACUUM MOTOR K8 CONTACTOR SIDE BROO...

Page 45: ...FORM NO 56043096 Captor 4300B 4800B 43 WIRING SCHEMATIC before SN 1767238 ELECTRICAL SYSTEM...

Page 46: ...Limit H9 Lamp Trouble S9 Switch Seat H10 Lamp Broom Overload M14 Motor Shaker M S6 Switch Dust Control Filter optional H5 Lamp Tail K10 Contactor Aux F2 Circuit Breaker 5 AMP S12 Switch Wand optional...

Page 47: ...A UU O TOR 9 OWER TEERIN G K6 K1 K7 K2 K3 K8 K K4 K5 K10 L1 L2 M4 M3 M2 M1 S12 L5 L4 L6 L6A S7 M10 K11 H8 M14 M8 H4 H3 M S3 M16 C1 BT1 H A2 S11 F1 F2 F3 F4 F5 F7 F8 F S4 M5 M13 S6 S10 S13 M7 M6 S12 S...

Page 48: ...LUTION EMPTY 1 2 K9 CONTACTOR STEERING M M19 PUMP 2 CHEMICAL M M18 PUMP 1 CHEMICAL K1 CONTACTOR LEFT BRUSH MOTOR S3 SWITCH HOPPER INTERLOCK 1 2 F1 CIRCUIT BREAKER 25 A 1 2 S2 SWITCH RETRACT LIMIT WHT...

Page 49: ...WHT BLK BLK GRN WHT GRA ORN GRN WHT VIO GRA ORN GRA ORN WHT BLU ORN RED GRA ORN GRA ORN YEL GRN BLK B B GRA ORN K12 RELAY SAFETY A B S16 SWITCH RIGHT TRAVEL LIMIT 1 2 E1 STEERING WHEEL SENSOR A1 GRN A...

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