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Advance acoustic HydroCat 5015B Service Manual

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GENERAL INFORMATION AND SAFETY
SERVICE
TM
HydroCat
5015B
Models 459020, 459025
8/93 Form Number 043020
Hydro Cat 5015B Service Manual

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Summary of Contents for Advance acoustic HydroCat 5015B

  • Page 1 GENERAL INFORMATION AND SAFETY SERVICE HydroCat 5015B Models 459020, 459025 8/93 Form Number 043020 Hydro Cat 5015B Service Manual...
  • Page 2 GENERAL INFORMATION AND SAFETY TABLE OF CONTENTS _________________________________________________________________________________________________________________________________________________________________________________________________________________________ Battery......................10 Brake Adjustment ...................89 General Information & Safety................1 Hydro-Max Recovery Tank Removal .............92 Hydro-Max Solution Pump Removal ..............92 Hydro-Max Solution Tank Removal ..............17 Hydro-Max System Recycling Information .............90 Hydro-Max System Troubleshooting ..............94 Scrub Brush Belt &...
  • Page 3 GENERAL INFORMATION AND SAFETY TABLE OF CONTENTS ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Specifications & Scheduled Maintenance ............5 Squeegee Blade Replacement & Adjustment ..........46 Squeegee Lift Actuator Replacement & Adjustment ........49 Steering Chain Adjustment ................85 Steering System Spindle & Wheel Removal ..........86 Sweeping Broom Bearing Replacement ............76 Sweeping Broom Belt Adjustment &...

  • Page 4: Transporting The Machine

    GENERAL INFORMATION AND SAFETY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ OTHER MANUALS AVAILABLE FOR THE HYDRO-CAT 5015B The following manuals are available from the Advance Literature Service Department: • Hydro-Cat 5015B Parts List - Advance Form Number 042265 • Hydro-Cat 5015B Operation Manual - Advance Form Number 041252 ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TRANSPORTING THE MACHINE CAUTION!
  • Page 5 GENERAL INFORMATION AND SAFETY FIGURE 1 2 Tie-Downs, 1 under 2 Tie-Downs under each roller bumper front edge of machine ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TOWING If the machine must be towed or pushed, do not move the machine faster than walking speed. Hydro Cat 5015B Service Manual...

  • Page 6: General Safety Instructions

    GENERAL INFORMATION AND SAFETY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SYMBOLS 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.
  • Page 7 GENERAL INFORMATION AND SAFETY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL SAFETY INSTRUCTIONS (continued...) CAUTION! Before performing any service function, carefully read all instructions pertaining to that service function. Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts. Keep the Battery Compartment Cover OPEN while charging the battery. Charging produces highly explosive hydrogen gas.

  • Page 8: Specifications

    SPECIFICATIONS AND MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________ SPECIFICATIONS Dimensions English (Metric) Scrub Brush Diameter 13.5 inches (34 cm) Scrub Brush Path 50 inches (127 cm) Scrub Brush Pressure 285 lbs (129 kg) Scrub Brush Speed 120 rpm (120 rpm) Machine Length 81 inches (206 cm) Machine Width 54 inches (137 cm) Machine Height...
  • Page 9 SPECIFICATIONS AND MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BASIC SERVICE INSPECTION CHECKLIST The items below are essential to proper machine operation. They should be checked each time a machine is serviced, for whatever reason. For Further Information Item To Be Inspected See Page... Check Scrub Brushes - Min. Bristle Length/1/2 inch (13 mm) Check Sweeping Broom - Min.
  • Page 10 SPECIFICATIONS AND MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SCHEDULED MAINTENANCE Maintenance intervals given on this page are for average operating conditions. Machines used in a severe environment may require service more often. For Further Information Daily See Page... Flush Out Recovery Tank Empty and Clean Debris Tray Remove and Rinse Scrub Brushes Remove and Clean The Squeegee Tool Charge Battery...
  • Page 11 SPECIFICATIONS AND MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ LUBRICATION Grease fittings are provided at lube points where regular maintenance is required. The location of each fitting is detailed below. Using a grease gun, pump Multi-Purpose Lithium Grease into each fitting until grease can be seen seeping out. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEERING SYSTEM LUBRICATION •...
  • Page 12 SPECIFICATIONS AND MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE LIFT ACTUATOR LUBRICATION • Lower the squeegee and remove the recovery tank. • Apply a light coating of grease to the actuator shaft. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL OIL Remove the dipstick under the operator’s seat to check the differential oil level. Add 90W gear lube if neces- sary, to bring the oil level up to the indentation on the dipstick.

  • Page 13: Battery Installation

    BATTERY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BATTERY INSTALLATION • Lay a piece of plywood, cardboard or non-conductive material on top of the battery to keep the lift chains from touching the cell connectors or battery terminals. • See Figure 1. Use an overhead hoist or a fork lift to lift the battery up and into the machine. The battery connector should face the right side of the machine.
  • Page 14 BATTERY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BATTERY REMOVAL • Apply the parking brake and block the wheels. • Remove the negative battery cable. • Remove the battery connector from the machine connector. • Lay a piece of plywood, cardboard or non-conductive material on top of the battery to keep the lift chains from touching the cell connectors or battery terminals.

  • Page 15: Battery Maintenance

    BATTERY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BATTERY MAINTENANCE WARNING! Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact skin or eyes. Explosive hydrogen gas is vented from inside the battery caps. This gas can be ignited by any electrical arc, spark, or flame.

  • Page 16: Battery Testing

    BATTERY ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BATTERY TESTING A battery problem is usually recognized by the machine operator, as a decrease in the machine’s running time. This condition is usually caused by one (or more) “dead cells” in the battery system- that is, one (or more) cell that is putting out less voltage than the other cells.

  • Page 17: Solution System

    SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The solution tank (see Figure 1) is located in the area just to the left of the operator’s compartment. A filter screen in the bottom of the tank keeps dirt out of the solution valves. The solution tank can be drained by removing the plug from the solution drain hose, located behind the lower-left door panel.

  • Page 18: Solution System Maintenance

    SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION SYSTEM MAINTENANCE The solution system should be flushed every 15 hours of operation to prevent a build-up of soap residue in the solution valves. To flush the system... Park the machine outdoors or near a floor drain and open the solution tank drain valve. When the tank is empty, close the drain valve and put about 6 inches (15 cm) of clean, warm water in the tank.
  • Page 19 SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN SOLUTION VALVE REMOVAL The main solution valve is located at the front of the machine, just below the horn. Replace the valve if water leaks from the center of the brush holders with the solution lever in the OFF posi- tion.
  • Page 20 SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION TANK REMOVAL MACHINES WITHOUT HYDRO-MAX II OPTION - Open door “C” (see Figure 3), drain the solution tank, remove the drain hose and valve from the bottom of the tank. MACHINES WITH HYDRO-MAX II OPTION - Open door “D” drain the solution tank and remove the drain hose from the back of the tank.
  • Page 21 SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION TANK REMOVAL (continued...) See Figure 4. Remove the cover panel from FIGURE 4 electrical box “ K “. Remove screw “M”. Loosen the ( 6 ) “L” screws and tip the electrical box forward, away from the tank. See Figure 3.
  • Page 22 SOLUTION SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING Follow the instructions under the “Problem” that best describes the condition of the machine being serviced. Also see the Hydro-Max II chapter for additional solution system troubleshooting information. Before Troubleshooting, make sure that there is at least 6 inches of water in the solution tank and the solution lever is pushed all the way forward, to the maximum ON position.

  • Page 23: Scrub Brush System

    SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The 4 disc-type scrub brushes on the front of the machine are driven by a single scrub brush motor (see item “A” on Figure 1). The motor is located on top of the left scrub brush gear case. A poly-v belt (“B”) connects the motor to the input shaft on the left gear case.
  • Page 24 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SCRUB BRUSH BELT TENSION ADJUSTMENT Adjust the belt tension if the belt squeals when the brushes are lowered, or if the belt moves out of position on its pulleys. To adjust the belt tension... Turn the key switch ON and put the brush switch in the ON (I) position. When the brushes are all the way down, turn the key switch OFF and disconnect the battery (connector behind the right-rear door).
  • Page 25 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SCRUB BRUSH BELT or GEAR BOX COUPLER REPLACEMENT Turn the key switch ON and put the brush switch in the OFF (O) position. When the brushes are all the way up, turn the key switch OFF. Open the access panel on the front of the machine (held closed by 3 screws).
  • Page 26 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SCRUB BRUSH MOTOR - CARBON BRUSH INSPECTION The carbon brushes in the scrub brush motor should be inspected once a year. To inspect the carbon brushes... Turn the key switch OFF and disconnect the battery (connector behind the right-rear door). Open the access panel on the front of the machine (held closed by 3 screws).

  • Page 27: Scrub Brush Motor Removal

    SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SCRUB BRUSH MOTOR REMOVAL Turn the key switch ON and put the brush switch in the OFF (O) position. When the brushes are all the way up, turn the key switch OFF. Open the access panel on the front of the machine (held closed by 3 screws). See Figure 3.
  • Page 28 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH DRIVE GEAR CASE - OIL CHECK Check the oil level in the brush drive gear cases once each year or when there is evidence of oil leakage. To check the oil level... Turn the key switch ON and put the brush switch in the ON (O) position. When the brushes are all the way down, turn the key switch OFF.
  • Page 29 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH SHAFT REPLACEMENT Follow the instructions below if one or the brush drive shafts is bent or broken. Turn the key switch ON and put the brush switch in the OFF (O) position. When the brushes are all the way up, turn the key switch OFF and disconnect the battery (connector behind the right-rear door).
  • Page 30 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH SHAFT REPLACEMENT (continued...) See Figure 6. Remove the (4) “G” screws and, using a soft hammer, tap downward on coupler “F” to remove the shaft assembly from the gear case. Look through the shaft opening in the bottom of the gear case and make sure that the horizontal worm shaft is not damaged.
  • Page 31 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ WORM SHAFT REPLACEMENT Follow the instructions below to replace a worm shaft that is broken at the flexible coupling between the 2 gear cases. Remove the lower-front corner panel from the side of the machine with the damaged gear case. Remove both brush drive shafts from the damaged gear case (follow instructions in Brush Shaft Replace- ment section).
  • Page 32 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ LEFT GEAR CASE REMOVAL Put the scrub brushes on the machine, turn the key switch ON and put the brush switch in the ON (I) position. When the brushes are all the way down, turn the key switch OFF and disconnect the battery (connector behind the right-rear door).
  • Page 33 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ LEFT GEAR CASE REMOVAL (continued...) 10 See Figure 9. Remove the (4) “X” bolts and remove the skirt assembly from the left gear box. 11 Remove the (4) “U” lock nuts and the (4) “V” bolts. Be careful not to lose the bushings and washers. 12 Remove bolt “W”...
  • Page 34 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ RIGHT GEAR CASE REMOVAL Put the scrub brushes on the machine, turn the key switch ON and put the brush switch in the ON (I) position. When the brushes are all the way down, turn the key switch OFF and disconnect the battery (connector behind the right-rear door).
  • Page 35 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ FRONT SKIRT ADJUSTMENT AND REPLACEMENT Adjust or replace the skirts if they leave water in front of the drive wheels or if they allow water to splash outside the path of the squeegee. To adjust or replace the front skirts... Put the scrub brushes on the machine, turn the key switch ON and put the brush switch in the ON (I) position.
  • Page 36 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH LIFT LIMIT SWITCHES The UP and DOWN limit switches for the brush lift system are mounted on the brush lift actuator (see Figure 12). When a malfunction occurs in the brush lift system, the solution tank should be removed from the machine to allow a thorough troubleshooting inspection.
  • Page 37 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH LIFT LIMIT SWITCHES (continued...) Check the condition of the switch operating rod. Replace if bent - do not straighten. Check for built-up dirt or corrosion on the switch operating rod, remove and clean if necessary. The rod must move easily through the nylon bushing in the switch bracket (see Figure 12).
  • Page 38 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH LIFT ACTUATOR REPLACEMENT Turn the key switch ON and put the brush switch in the ON (I) position. When the brushes are all the way down, turn the key switch OFF and disconnect the battery (connector behind the right-rear door). If the actuator is stuck in the up position, jack up the front of the machine, place blocks under the brush holders and lower the jack just enough to take the weight of the brush drive assembly off the actuator.
  • Page 39 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH LIFT ACTUATOR REPLACEMENT (continued...) Install the new actuator, pin “S” and pin “P”. 10 Connect the wiring to the actuator and the limit switches. Violet/Black wire to the COM terminal on the top switch. Brown/Red wire to the NC terminal on the top switch. Yellow/Red wire to the COM terminal on the bottom switch.
  • Page 40 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING Follow the instructions under the “Problem” that best describes the condition of the machine being serviced. WARNING! USE EXTREME CAUTION WHEN TESTING LIVE ELECTRICAL CIRCUITS. REMOVE JEWELRY FROM HANDS AND WRISTS BEFORE TROUBLESHOOTING. WARNING! NEVER ALLOW A TOOL OR TEST PROBE TO TOUCH MORE THAN ONE ELECTRICAL TERMINAL AT A TIME.
  • Page 41 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) See Figure 15. Remove the Violet/ FIGURE 15 Black wire from the brush ON/OFF switch. Connect the positive voltmeter lead to the terminal on the switch, Violet/Black where the Violet/Black wire used to be. Leave the negative voltmeter lead connected to the Black wires on the (R3) brush lift solenoid.
  • Page 42 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Scrub Brushes Will Not Go Down Before troubleshooting, open the electrical access panel on the front of the machine and check the 10 amp brush lift circuit breaker (see Figure 17). Push the reset button if necessary. Note: Make all tests with the key switch ON and the brush lift switch in the ON (I) position.
  • Page 43 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) See Figure 19. Connect the negative FIGURE 19 voltmeter lead to the Orange/White wire on the (R3) brush lift solenoid. Connect the positive voltmeter lead to the Green/Black wire on the (R4) brush lower solenoid. 0 volts - replace the (R3) brush lift and the (R4) brush lower solenoids.
  • Page 44 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Scrub Brush Motor Will Not Run Before troubleshooting, open the electrical access panel on front of the machine and check the 70 amp scrub brush circuit breaker (see Figure 20), reset if necessary. WARNING! DISCONNECT THE ORANGE/BLUE WIRE FROM THE SPEED POTENTIOMETER BEFORE PERFORMING THE FOLLOWING TESTS.
  • Page 45 SCRUB BRUSH SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) FIGURE 21 See Figure 21. Move the positive voltmeter lead to wire #8 on the (R5) scrub brush solenoid. Leave the negative meter lead on the negative terminal. Turn the key switch ON, push down on the operator’s seat and push the drive pedal.

  • Page 46: Vacuum System

    VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The Vacuum System lifts water and dirt off of the floor and into the recovery tank. The main parts of the vacuum system are shown in FIGURE 1. Recovery Tank Cover FIGURE 1 HERE FIGURE 1 Recovery Tank Drain Hose Shut-off Float...
  • Page 47 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ VACUUM FILTER The Vacuum Filter prevents light debris and dust from entering the vacuum motor. The filter should be serviced by the machine operator each time that the machine is used. For access to the vacuum filter, open the right rear access door. The filter box is located just below the battery.

  • Page 48: Vacuum Motor Removal

    VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ VACUUM MOTOR - CARBON BRUSH INSPECTION, REPLACEMENT The Carbon Brushes in the vacuum motor should be checked once each year, or every 1000 hours of opera- tion. They should be replaced if they are worn to a length of 3/8 inch (10 mm) or less. To inspect the brushes .

  • Page 49: Squeegee Adjustments

    VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ RECOVERY TANK ADJUSTMENT Two adjustable bumpers are located under the front of the Recovery Tank. These bumpers should be ad- justed so the tank cover seals air-tight against the top of the recovery tank. When adjusting the bumpers, also check the spring-loaded tubes under the tank (not on Hydro-Max II). The tubes should move up and down freely and the gaskets on each tube should seal air-tight against the bottom of the recovery tank.

  • Page 50: Squeegee Blade Replacement

    VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE ADJUSTMENTS (continued...) Drive the machine forward to bend over the squeegee blades into their “operating position” and look at the squeegee caster wheels. If they do not touch the floor, increase the squeegee pressure by loosen- ing the thumb screw in collar “H”, pulling the collar toward the back of the machine and tightening the thumb screw.
  • Page 51 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE BLADE REPLACEMENT (continued...) FIGURE 6 Rear Strap Back-up Blade Wiping Blade Squeegee Weldment Front Blade Front Strap Front To replace the squeegee blades . . . Remove the squeegee from the machine, remove the front strap and the front blade from the squeegee. Remove the wing nuts at the ends of the rear straps, release the latch at the center of the straps and remove the wiping blade and the back-up blade.
  • Page 52 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE LIFT ACTUATOR REPLACEMENT Manually lift the squeegee and put blocks under it to hold the blades about 2 inches (5.14 cm) off of the floor. This will support the weight of the squeegee when the actuator is removed. This step is only for machines with the Hydro-Max II option.
  • Page 53 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE LIFT ACTUATOR REPLACEMENT (continued...) Remove one of the retaining rings from pin “P”, pull the pin out of the actuator and work the actuator out of the machine. Hold the new actuator in place, install pin “P” and its retaining ring. Do not install bracket “M” yet. Connect the new actuator cord to the machine wiring harness.
  • Page 54 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE LIFT ACTUATOR ADJUSTMENT Check the adjustment of the squeegee lift actuator if . . . • The squeegee blades are less than 1-1/4 inches (3.2 cm) off of the floor when the actuator stops in the “squeegee up”...
  • Page 55 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SQUEEGEE LIFT ACTUATOR ADJUSTMENT (continued...) FIGURE 7 Front Turn the key switch and the vacuum switch ON (I). When the actuator stops, the plastic nut should be located at the 9-1/4 inch (23.8 cm) position (See Figure 8). If the position of the plastic nut is between 9-1/8 and 9-3/8 inches (23.4 and 24 cm), no adjustment is required.
  • Page 56 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Machine will not pick up water Whenever the vacuum system does not perform properly, the entire system should be inspected, following the checklist below. Remove the squeegee from the machine and clean it thoroughly. Service the squeegee blades if they are damaged or worn (see SQUEEGEE BLADE REPLACEMENT section of this chapter for further information).
  • Page 57 VACUUM SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Squeegee Will Not Go Up or Down Squeegee switch defective. Up and down solenoids defective. Squeegee lift motor defective. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Squeegee Will Not Go Up With Drive Pedal In Reverse Squeegee back up switch defective. Hydro Cat 5015B Service Manual...

  • Page 58: Wheel Drive System

    WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The Hydro Cat is driven by a 4 horsepower permanent magnet motor, coupled to an automotive-type differen- tial. The speed of the motor is regulated by a solid-state speed control, located in the front electrical compart- ment.
  • Page 59 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION (continued...) The direction of travel is controlled by contactors mounted next to the speed control. Two switches, also operated by the drive pedal, control the contactors. An electronic interlock is used to prevent “plugging”. When the drive pedal is quickly moved from forward to reverse, the machine coasts almost to a complete stop and then gently goes into reverse.
  • Page 60 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL OIL LEVEL CHECK The dipstick for the differential oil is located under the operator’s seat. Add 90W gear lube if necessary, to bring the oil level up to the indentation in the dipstick (approximately 1 inch / 2.57 cm from the tip). ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ WHEEL MOTOR - CARBON BRUSH INSPECTION The carbon brushes in the wheel motor should be checked every 1000 hours of operation.
  • Page 61 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL REMOVAL Remove the solution tank (see Solution System chapter for instructions). Remove the wheel drive motor (see Wheel Motor Removal section for instructions). Loosen the lug nuts on both front wheels. Then jack up the front of the machine so the wheels are about 1-1/2 inches (38 mm) off the floor.
  • Page 62 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ FORWARD & REVERSE SWITCH CAUTION! SAFE OPERATION OF THE MACHINE MAY BE AFFECTED BY THE FORWARD AND REVERSE DRIVE SWITCHES. USE EXTREME CARE WHEN ADJUSTING OR REPLACING THE SWITCHES AND THEIR OPERATING LINKAGE. Before replacing or adjusting the forward or reverse switch... Gently move the front of the drive pedal up and down in neutral, to check the free travel in the pedal.
  • Page 63 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ FORWARD & REVERSE SWITCH (continued...) To replace the forward or reverse switch... See Figure 5. Open the front access panel and remove the (2) “J” screws. Pull switch bracket “K” out of the compartment as far as the attached linkage will allow and remove the switch needing replacement.
  • Page 64 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPEED POTENTIOMETER REPLACEMENT CAUTION! SAFE OPERATION OF THE MACHINE MAY BE AFFECTED BY THE SPEED POTENTIOMETER. USE EXTREME CARE WHEN ADJUSTING OR REPLACING THE POTENTIOMETER AND ITS OPERATING LINKAGE. Check the potentiometer for proper adjustment before replacing. See Speed Potentiometer Adjustment section.
  • Page 65 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPEED POTENTIOMETER ADJUSTMENT Before adjusting the potentiometer... Gently move the front of the drive pedal up and down in neutral, to check the free travel in the pedal. If there is more than 1/8 inch (3 mm) free travel at the front of the drive pedal, adjust bracket “G” (see Figure 6) up or down to eliminate the free travel.
  • Page 66 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPEED POTENTIOMETER ADJUSTMENT (continued...) Watch the ohmmeter while pressing down on the front of the drive pedal. The pedal should hit the forward stop bolt (under the front of the drive pedal) when the meter reads 4500 ohms. If the meter reads 4500 ohms before the pedal hits the stop bolt, release the pedal and adjust the bolt upward.
  • Page 67 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING Follow the instructions under the “Problem” that best describes the condition of the machine being serviced. DANGER! BEFORE TROUBLESHOOTING THE DRIVE SYSTEM, JACK UP THE MACHINE SO THE DRIVE WHEELS ARE OFF THE FLOOR AND PLACE JACK STANDS UNDER THE FRAME. THIS WILL PREVENT INJURY IF THE DRIVE MOTOR STARTS DURING TESTING.
  • Page 68 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) DANGER! DO NOT ATTEMPT TO PERFORM THE NEXT STEP WITH THE DRIVE WHEELS ON THE FLOOR. THE DRIVE MOTOR MAY RUN AT FULL SPEED WHEN THE DRIVE PEDAL IS PRESSED. Jack up the front of the machine, so both drive wheels are off the floor. Place jack stands under the frame.
  • Page 69 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) Turn the key switch OFF. See Figure 10. Disconnect the Orange/Blue and the Green/White wires from the speed control. Connect the wires to the leads from an ohmmeter. Green/White FIGURE 10 Orange/Blue Speed Control Press the front of the drive pedal and watch the ohmmeter.
  • Page 70 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) See Figure 11. Disconnect the Red/Brown and Black wires from the coil terminals on the main contactor. Connect a DC voltmeter to the wires (positive to Red/Brown). FIGURE 11 Black Red/Brown Main Contactor Turn the key switch ON and push down on the operator’s seat. If the meter reads 0 volts check the safety switch under the operator’s seat.
  • Page 71 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) Turn the key switch ON, push down on the operator’s seat and press the drive pedal. The forward contactor (see Figure 12) should engage when the pedal is pushed forward and the reverse contactor should engage when the pedal is pushed reverse.
  • Page 72 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: No Forward Drive (Reverse Only) DANGER! BEFORE TROUBLESHOOTING THE DRIVE SYSTEM, JACK UP THE MACHINE SO THE DRIVE WHEELS ARE OFF THE FLOOR AND PLACE JACK STANDS UNDER THE FRAME. THIS WILL PREVENT INJURY IF THE DRIVE MOTOR STARTS DURING TESTING. Note: All references to “right”...
  • Page 73 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) See Figure 14. Disconnect the diode from the Red/Green wire and connect a DC voltmeter as shown. If the meter reads 36 volts, replace the diode. If the meter reads 0 volts, check the forward and reverse switch mechanism (see Forward/Reverse Switch section).
  • Page 74 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: No Reverse Drive (Forward Only) DANGER! BEFORE TROUBLESHOOTING THE DRIVE SYSTEM, JACK UP THE MACHINE SO THE DRIVE WHEELS ARE OFF THE FLOOR AND PLACE JACK STANDS UNDER THE FRAME. THIS WILL PREVENT INJURY IF THE DRIVE MOTOR STARTS DURING TESTING. Note: All references to “right”...
  • Page 75 WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING (continued...) See Figure 16. Disconnect the diode from the Red/Green wire and connect a DC voltmeter as shown. If the meter reads 36 volts, replace the diode. If the meter reads o volts, check the forward and reverse switch mechanism (see Forward/Reverse Switch section).

  • Page 76: Broom Height Adjustment

    SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION A cylindrical sweeping broom is used to keep small debris out of the squeegee tool, eliminating the need to sweep before scrubbing. The debris is lifted over the top of the broom and into a small hopper. The hopper is perforated so that water, swept up along with the debris, can drain back onto the floor and be picked up by the vacuum system.
  • Page 77 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM HEIGHT ADJUSTMENT (continued...) See Figure 1. If the strip is too narrow or too wide, open the lower access door on the left side of the machine. Loosen the locknut and adjust turnbuckle “A”. This turnbuckle controls the working height of the sweeping broom.
  • Page 78 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM LEVEL ADJUSTMENT (continued...) 3 After 1 minute, raise the broom, release the parking brake and move the machine out of the way, so that the polished strip is visible. 4 See Figure 2. If the strip is tapered, loosen the (2) “B” bolts. FIGURE 2 FIGURE 2 HERE Front...
  • Page 79 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM BEARING REPLACEMENT There are sealed ball bearings in the idler hub (on the right end of the broom) and in the drive hub (on the left end of the broom). Whenever the broom is removed for service, these bearings should be checked. Binding, noisy operation or excessive play indicate that the bearings should be replaced.
  • Page 80 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM BEARING REPLACEMENT (continued...) See Figure 4. Loosen locknut “H” and use a vicegrips or pliers to remove rod “I” from the hub. FIGURE 4 HERE FIGURE 4 To replace the bearings in either hub. . . Place the hub assembly in a vise as shown in Figure 4.
  • Page 81 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM MOTOR - CARBON BRUSH INSPECTION The carbon brushes in the sweeping broom motor should be inspected once a year. To inspect the brushes . . . Disconnect the battery cables and remove the battery and the battery tray from the machine. Remove the brush cover from the brush motor and remove the carbon brushes.
  • Page 82 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM MOTOR SWITCH The broom motor switch is located at the bottom of the sweeping broom lever. The switch automatically starts the broom motor when the lever is moved to either the “sweep” or the “full-float” position. Remove the access panel on the left side of the operator’s compartment for access to the switch.
  • Page 83 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM BELT ADJUSTMENT / REPLACEMENT (continued...) Remove the belt from the machine. Reassemble in reverse order and refer to the BROOM BELT ADJUSTMENT section for proper belt tensioning. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM HOUSING SKIRTS Rubber skirts are installed at the front and the sides of the broom housing to keep debris and water confined to the sweeping area of the machine.
  • Page 84 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BROOM HOUSING SKIRTS (continued...) The front skirt “R” (see figure 7) keeps litter from being thrown out of the broom housing. It also acts as a ramp to help guide the litter off of the floor and into the hopper. Small inner side skirts “S”...
  • Page 85 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ OUTER SIDE SKIRT ADJUSTMENT / REMOVAL Adjust the outer side skirts “T” (see figure 7) if the machine leaves water on the floor around turns. Inspect the skirts before adjusting, replace them if they are nicked, torn, or if the wiping edge is worn to a radius. To adjust the outer side skirts .
  • Page 86 SWEEP SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Broom Motor Will Not Run Circuit breaker tripped. Broom motor switch defective. Broom motor solenoid defective. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Broom Motor Runs But Sweeping Performance Is Poor Hopper full. Too much solution being dispensed. Broom needs adjustment. Front skirt damaged or missing.
  • Page 87 STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The Steer Wheel at the back of the machine is operated by a chain, which connects the steer wheel spindle to the steering column in the operator’s compartment. The steering system requires little service other than routine lubrication (refer to page 8) and inspection.

  • Page 88: Steering Chain Adjustment

    STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEERING CHAIN ADJUSTMENT To adjust the steering chain . . . Drain and remove the recovery tank. See Figure 2. Remove the cover over the steering spindle sprocket “A”. FIGURE 2 Front 3/8" (10 mm) deflection at midpoint Master Link Loosen the (2) “B”...
  • Page 89 STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEER WHEEL SPINDLE REMOVAL Turn the steering wheel so the rear wheel is straight. Drain and remove the recovery tank and the squeegee tool from the machine. See Figure 3. Disconnect the (2) “E” springs from the side skirt linkage on each side of the machine. FIGURE 3 Front Remove the hopper from the broom housing.
  • Page 90 STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEER WHEEL SPINDLE REMOVAL (continued...) Remove the cover over the steering spindle sprocket “G”. Using a scratch awl or a small center punch, mark the location of the chain on the sprocket and the location of the sprocket on the spindle for reassembly. Loosen the (2) “H”...
  • Page 91 STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEER WHEEL REMOVAL Drain the recovery and solution tanks and remove the squeegee tool. Jack up the rear of the machine high enough to allow access to the rear wheel. WARNING! NEVER WORK UNDER THE MACHINE WITHOUT JACK STANDS OR BLOCKS SUPPORTING THE FRAME.

  • Page 92: Brake Adjustment

    STEERING AND BRAKES ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRAKE ADJUSTMENT Cables are used to connect the brake pedal and the parking brake lever to the brake mechanism on the (2) front wheels. The brake pedal should have about 1 inch (25.4 mm) of down travel before the brakes are fully engaged.
  • Page 93 HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL INFORMATION The optional Hydro-Max system (see Figure 1) recycles the dirty water picked up from the floor, allowing the machine to scrub continuously, without stopping to empty the recovery tank and fill the solution tank. The dirty water passes through a 2 stage filtering system in the recovery tank to remove most of the dirt.
  • Page 94 HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ RECYCLING FILTER REMOVAL AND CLEANING See Figure 2. Open the recovery tank door, the recycling filter is located on the right side of the tank. Unscrew the filter cartridge and remove it from the machine. Use warm water to back flush the filter. FIGURE 2 Vacuum Hose Solution Pump Hose...

  • Page 95: Recovery Tank Removal

    HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ RECOVERY AND SOLUTION TANK CLEANING (continued...) Reinstall the screen panel. Drain and rinse the solution tank (see the SOLUTION SYSTEM chapter). Remove the chemical metering barb and rinse it in hot, soapy water. Use a pin to clean hardened chemical from the hole in the barb.
  • Page 96 HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOAP METERING BARB REMOVAL AND CLEANING Open the front access panel. The metering barb”A” is located on the front of the solution tank (see Figure 3). FIGURE 3 Front Remove the clear siphon hose “B” from the brass metering barb “A” and remove the barb. Wash the metering barb in hot water.
  • Page 97 HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING Follow the instructions under the “Problem” that best describes the condition of the machine being serviced. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Water Does Not Transfer From Recovery Tank To Solution Tank See Figure 4. Clogged recycling filter cartridge. FIGURE 4 Recovery tank float stuck.
  • Page 98 HYDRO-MAX SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem: Chemical Does Not Inject See Figure 5. Clogged metering barb. Stuck check valve in chemical injector. Air leak in chemical hose. FIGURE 5 Chemical Injector Metering Barb Front Hydro Cat 5015B Service Manual...
  • Page 99 Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 ©2000 Nilfisk-Advance, Inc., Plymouth, MN 55447-3408 Printed in the U.S.A.

This manual is also suitable for:

Hydrocat 459020Hydrocat 459025