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Hydro Cat 5015B

Service Manual

HYDRO-MAX SYSTEM

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Problem: Chemical Does Not Inject

1

See Figure 5. Clogged metering barb.

2

Stuck check valve in chemical injector.

3

Air leak in chemical hose.

FIGURE 5

Front

Chemical
Injector

Metering Barb

95

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96
97
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Summary of Contents for HydroCat 459020

Page 1: ...Hydro Cat 5015B Service Manual GENERAL INFORMATION AND SAFETY HydroCat 5015B Models 459020 459025 8 93 Form Number 043020 SERVICE TM...

Page 2: ...stem Recycling Information 90 Hydro Max System Troubleshooting 94 Scrub Brush Belt Coupler Replacement 22 Scrub Brush Belt Tension Adjustment 21 Scrub Brush Drive Gear Case Oil Check 25 Scrub Brush Dr...

Page 3: ...al 80 Sweeping System Troubleshooting 83 Vacuum Motor Removal Carbon Brush Inspection 45 Vacuum System Information Maintenance 43 Vacuum System Troubleshooting 53 Wheel Drive Motor Differential Remova...

Page 4: ...____________________________________________________________________________________________________________________________________________________________________________________ TRANSPORTING THE MA...

Page 5: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Page 6: ...al injury or damage to the machine or other property ___________________________________________________________________________________________________________________________________________________...

Page 7: ...arging the battery Charging produces highly explosive hydrogen gas Charge only in well ventilated areas away from open flame Do not smoke while charging the battery Use caution when moving the machine...

Page 8: ...ard 79 inches 200 cm Drive Wheels 14 inch 36 cm solid traction tires Rear Wheel 10 inch 25 cm soft ride tire Solution Tank Capacity 60 gal 227 litre Recovery Tank Capacity 50 gal 189 litre Hopper Capa...

Page 9: ...m To Be Inspected See Page Check Scrub Brushes Min Bristle Length 1 2 inch 13 mm N A Check Sweeping Broom Min Bristle Length 1 3 4 inch 45 mm N A Check Sweeping Broom Pattern 1 1 2 inch 38 mm 73 Check...

Page 10: ...A Empty and Clean Debris Tray N A Remove and Rinse Scrub Brushes N A Remove and Clean The Squeegee Tool N A Charge Battery 12 50 Hours Inspect Sweeping Broom 73 Inspect All Skirts 32 81 82 Inspect All...

Page 11: ...l grease can be seen seeping out _______________________________________________________________________________________________________________________________________________________________________...

Page 12: ...______________________________________________________________________________________________________________________________________ DIFFERENTIAL OIL Remove the dipstick under the operator s seat to...

Page 13: ...oard 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 batte...

Page 14: ...__________ 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 no...

Page 15: ...Maintain Proper Electrolyte Level Use distilled water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell If batteries are fully charged f...

Page 16: ...th the brush and vac systems running The battery s with the dead cell will read 1 or 2 volts low If the battery s in the machine is more than 1 year old it s usually best to replace it them __________...

Page 17: ...d by removing the plug from the solution drain hose located behind the lower left door panel Three valves are used to control flow of solution to the scrub brushes The main valve is operated by a leve...

Page 18: ...ne outdoors or near a floor drain and open the solution tank drain valve 2 When the tank is empty close the drain valve and put about 6 inches 15 cm of clean warm water in the tank 3 Reach under the f...

Page 19: ...tion To replace the main solution valve 1 Turn the key switch ON and put the scrub brush switch in the down posi tion When the brushes are all the way down turn the key switch OFF 2 See Figure 2 Open...

Page 20: ...ON TANK REMOVAL 1 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 Op...

Page 21: ...so disconnect the 2 electrical connectors in front of the tank 13 Lift the solution tank off of the machine Follow steps in reverse order to reassemble Note On Hydro Max II machines the electrical con...

Page 22: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Page 23: ...nput shaft on the right gear case through a flexible coupler C Rubber skirts at both sides of the scrub brushes confine water to the area covered by the squeegee and wipe water from the floor in front...

Page 24: ...position When the brushes are all the way down turn the key switch OFF and disconnect the battery connector behind the right rear door 2 See Figure 2 Open the access panel on the front of the machine...

Page 25: ...2 Loosen the 2 G bolts and back them out 3 or 4 turns 4 Disconnect the top end of the spring L from the bracket on the machine frame 5 Turn the key switch ON and put the brush switch in the ON I posi...

Page 26: ...shes in the scrub brush motor should be inspected once a year To inspect the carbon brushes 1 Turn the key switch OFF and disconnect the battery connector behind the right rear door 2 Open the access...

Page 27: ...op end of the spring L from the bracket on the machine frame 5 Turn the key switch ON and put the brush switch in the ON I position When the brushes are all of the way down turn the key switch OFF 6 T...

Page 28: ...brush drive gear cases once each year or when there is evidence of oil leakage To check the oil level 1 Turn the key switch ON and put the brush switch in the ON O position When the brushes are all t...

Page 29: ...sh drive shafts is bent or broken 1 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 connect...

Page 30: ...or remove shims to decrease end play as required Note When properly shimmed you should feel little or no end play with your bare hands However you should be able to feel a small amount of backlash wh...

Page 31: ...er part of the broken shaft from the yoke and the pulley left gear case only between the gear cases Clean the yoke thoroughly so the new worm shaft will slide easily into the yoke 5 Remove the plastic...

Page 32: ...t the battery connector behind the right rear door 2 Remove the solution tank from the machine see Solution System chapter for instructions 3 Remove the lower front corner panel from the left side of...

Page 33: ...ings and washers 12 Remove bolt W and slide the gear case to the left out from under the machine X V U W V FIGURE 9 ____________________________________________________________________________________...

Page 34: ...he key switch OFF and disconnect the battery connector behind the right rear door 2 Remove the rear floor panel from the operator s compartment 3 Remove the lower front corner panel from the right sid...

Page 35: ...are all the way down turn the key switch OFF 2 Remove the lower front corner panels from both sides of the machine and inspect the skirts The skirts should be replaced if they are worn out torn or wav...

Page 36: ...chapter for instructions 2 Check the mechanical condition of the UP and DOWN limit switches Replace damaged switches as required 3 Check the electrical operation of the UP and DOWN limit switches usin...

Page 37: ...emove bolt K and apply grease to the bushing at the bottom of the switch operating rod 9 Position tab J so the end of the operating rod is flush with the top lock nut 10 Turn tab J so it makes firm co...

Page 38: ...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 2 Remove the solution tan...

Page 39: ...on the bottom switch 11 Adjust the limit switch mechanism See the Brush Lift Limit Switch section for instructions 12 Turn the key switch ON and run the brushes up and down to test the system for pro...

Page 40: ...RICAL TERMINAL AT A TIME _______________________________________________________________________________________________________________________________________________________________________________...

Page 41: ...e White Black Violet Black 3 See Figure 16 Connect the positive voltmeter lead to the Orange White wire on the R3 brush lift solenoid Connect the negative voltmeter lead to the Green Black wire on the...

Page 42: ...te Make all tests with the key switch ON and the brush lift switch in the ON I position 1 See Figure 17 Remove the cover from the left electrical box Con nect a DC voltmeter to the Yellow Red and Blac...

Page 43: ...sh lower solenoid 0 volts replace the R3 brush lift and the R4 brush lower solenoids 36 volts replace the brush lift actua tor _________________________________________________________________________...

Page 44: ...ISCONNECT THE ORANGE BLUE WIRE FROM THE SPEED POTENTIOMETER BEFORE PERFORMING THE FOLLOWING TESTS THIS WILL PREVENT THE MACHINE FROM MOVING WHEN THE DRIVE PEDAL IS DEPRESSED THE POTENTIOMETER IS LOCAT...

Page 45: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Page 46: ...because less air will flow through the squeegee A build up of dirt or restriction in the system will also decrease the amount of air flowing into the squeegee The most common place to find a restrict...

Page 47: ...lter 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 To s...

Page 48: ...Lift the operator s seat and put the prop rod in position to hold it up 3 See Figure 3 Remove the 4 C cap nuts 2 on each side of the motor and the 2 D brush covers FIGURE 3 HERE 4 Remove the brush re...

Page 49: ...__________________________________________________________________________________________________________________________________________________ SQUEEGEE ADJUSTMENTS Before adjusting the squeegee 1...

Page 50: ...____________________________________________________________________________________________________________________________________________________________________________________________________ SQU...

Page 51: ...es 4 Put the squeegee back on the machine The flat washers on the 4 squeegee mounting studs should be positioned between the top of the squeegee mount and the bottom of the tee nuts __________________...

Page 52: ...of the squeegee when the actuator is removed 2 This step is only for machines with the Hydro Max II option For standard machines skip this step and go to step 3 Remove the 1 1 2 inch 3 8 cm drain hose...

Page 53: ...stic Nut Adjuster Cover FIGURE 8 11 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 If the position of the p...

Page 54: ...moving forward Note When installing a new actuator follow the adjustment instructions in the SQUEEGEE LIFT ACTUATOR REPLACEMENT section To check or adjust the squeegee lift actuator 1 Remove the recov...

Page 55: ...n of the plastic nut is more than 9 3 8 inches 24 cm remove the adjuster cover and slowly turn the adjuster counter clockwise Then turn the vacuum switch off wait for the actuator to stop turn the vac...

Page 56: ...e hose between the left spring loaded tube and the squeegee Clean built up dirt from the inside of the hose Replace the hose if it is damaged There is no spring loaded tube on Hydro Max hose hooks dir...

Page 57: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Page 58: ..._____________________________________________________________________ GENERAL INFORMATION The Hydro Cat is driven by a 4 horsepower permanent magnet motor coupled to an automotive type differen tial T...

Page 59: ...the machine will not move without pressure on the seat The drive motor is protected by a 200 amp fuse located in the left electrical compartment as viewed facing the front of the machine The contactor...

Page 60: ...ecked every 1000 hours of operation To check the carbon brushes tip the operator s seat forward and carefully remove one of the brushes from the motor If the brush is worn to a length of 3 8 inch 10 m...

Page 61: ...NEVER WORK UNDER THE MACHINE WITHOUT JACK STANDS OR BLOCKS SUPPORTING THE FRAME 4 Place blocks or jack stands under each of the front roller bumpers to support the machine Then remove both front whee...

Page 62: ...inch 3 mm free travel at the front of the drive pedal adjust bracket G see Figure 5 up or down to eliminate the free travel FIGURE 5 Forward Switch Reverse Switch K J Squeegee Lift Switch H G 2 Gently...

Page 63: ...queegee lift switch clicks Then continue to move the bracket an additional 1 16 inch 1 5 mm toward the collar and tighten the J screws 4 Slide the REVERSE switch towards the switch collar H until it c...

Page 64: ...RATING LINKAGE Check the potentiometer for proper adjustment before replacing See Speed Potentiometer Adjustment section To replace the potentiometer 1 Disconnect the battery connector behind right re...

Page 65: ...the collar center the collar between the switch levers and tighten the set screws Make sure that the 2 set screws in collar H face directly toward the front of the machine The speed potentiometer lin...

Page 66: ...he bolt upward If meter reads less than 4500 ohms when the pedal hits the stop bolt adjust the stop bolt downward 9 Connect the wires to the potentiometer close the front panel and test the machine fo...

Page 67: ...LOOR AND PLACE JACK STANDS UNDER THE FRAME THIS WILL PREVENT INJURY IF THE DRIVE MOTOR STARTS DURING TESTING Note All references to right and left are as viewed from the operator s seat ______________...

Page 68: ...with the negative wire Reconnect the battery sit in the operator s seat to close the seat switch turn the key switch ON and press the drive pedal If the drive motor runs at full speed in both directi...

Page 69: ...scribed above see Speed Potentiometer Replacement and Adjustment sections 4 Turn the key switch ON and push down on the operator s seat while watching the main contactor see Figure 11 If the contacts...

Page 70: ...t If the meter reads 0 volts check the safety switch under the operator s seat If the meter reads 36 volts replace the main contactor Black Red Brown Main Contactor ___________________________________...

Page 71: ...7 Lift the operator s seat and disconnect wires 21 and 22 from the wheel drive motor Use jumper cables to connect a 12 volt battery directly to terminals on the motor If the motor runs check the cont...

Page 72: ...the front access panel and turn the key switch ON Push down on the operator s seat press the front of the drive pedal and watch the forward contactor see Figure 13 If the forward contactor engages whe...

Page 73: ...se switch mechanism see Forward Reverse Switch section If the switches work properly replace the electronic interlock FIGURE 14 Diode Red Green White Red ______________________________________________...

Page 74: ...eat 1 Open the front access panel and turn the key switch ON Push down on the operator s seat press the back of the drive pedal and watch the reverse contactor see Figure 15 If the reverse contactor e...

Page 75: ...rse switch mechanism see Forward Reverse Switch section If the switches work properly replace the electronic interlock FIGURE 16 Diode Red Green Violet ________________________________________________...

Page 76: ...aintenance steps should be completed every 50 hours of operation 1 Clean built up dirt from the inside of the broom housing 2 Remove any string wrapped around the broom broom drive hub or the idler hu...

Page 77: ...____________________________________________________________________________________________________________________ BROOM LEVEL ADJUSTMENT The sweeping broom has a level adjustment to control the hei...

Page 78: ...should be tight against the broom idler arm when the adjustment is completed 6 Tighten the locknuts on the C bolts and tighten the B bolts Repeat steps 1 3 to check adjustment re adjust if necessary _...

Page 79: ...d To remove the idler arm assembly on the right end of the broom 1 Open the lower access door on the right side of the machine and the inner broom housing door 2 See Figure 2 Loosen the locknut and tu...

Page 80: ...Figure 4 Loosen locknut H and use a vicegrips or pliers to remove rod I from the hub FIGURE 4 HERE _____________________________________________________________________________________________________...

Page 81: ...___________________________________________________________________________________________________________________________________________________________________________ BROOM MOTOR REMOVAL REPLACEM...

Page 82: ...____________________________________________________________________________________________________________________________________ BROOM BELT ADJUSTMENT REMOVAL To adjust the broom belt 1 See Figure...

Page 83: ...OUSING 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 For good sweeping performance all of the...

Page 84: ...sary reposition the skirt so that it is 1 8 to 1 4 inch 3 to 6 mm off of the floor Note The machine will not sweep properly if the front skirt drags on the floor Trim the skirt if necessary to obtain...

Page 85: ...ng cables so that the bottom edge of the skirt is 3 8 inch 10 mm off of the floor FIGURE 8 HERE FIGURE 8 X X Y Z Front X X Y 3 8 3 8 3 Adjust the DOWN position of the right skirt Loosen the lock nuts...

Page 86: ...itch defective 3 Broom motor solenoid defective ________________________________________________________________________________________________________________________________________________________...

Page 87: ...__________________________________________________________________________________________________________ GENERAL INFORMATION The Steer Wheel at the back of the machine is operated by a chain which c...

Page 88: ..._____________________ STEERING CHAIN ADJUSTMENT To adjust the steering chain 1 Drain and remove the recovery tank 2 See Figure 2 Remove the cover over the steering spindle sprocket A FIGURE 2 Front A...

Page 89: ..._______ STEER WHEEL SPINDLE REMOVAL 1 Turn the steering wheel so the rear wheel is straight 2 Drain and remove the recovery tank and the squeegee tool from the machine 3 See Figure 3 Disconnect the 2...

Page 90: ...10 See Figure 5 Lift nut lock L off of the spindle and remove large spindle nut M _____________________________________________________________________________________________________________________...

Page 91: ...STEER WHEEL REMOVAL 1 Drain the recovery and solution tanks and remove the squeegee tool 2 Jack up the rear of the machine high enough to allow access to the rear wheel WARNING NEVER WORK UNDER THE M...

Page 92: ...d of the parking brake lever to release tension on the brake cables 3 Adjust the brake cables under the floor panel for 1 inch 25 4 mm of pedal travel 4 Hold the brake pedal down and check the brake c...

Page 93: ...RMATION 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...

Page 94: ...ecycling Filter Cartridge Clean Out Cover Drain Hose Front FIGURE 2 ____________________________________________________________________________________________________________________________________...

Page 95: ...________________________________________________________________________________________________________________________________________________________ SOLUTION PUMP REMOVAL 1 Open the right side acc...

Page 96: ..._________________________________________________________________________ SOAP METERING BARB REMOVAL AND CLEANING 1 Open the front access panel The metering barb A is located on the front of the solut...

Page 97: ..._______________________________________________________________ Problem Water Does Not Transfer From Recovery Tank To Solution Tank 1 See Figure 4 Clogged recycling filter cartridge 2 Recovery tank fl...

Page 98: ..._________________________________________________________________________________________________________________________________________________________________ Problem Chemical Does Not Inject 1 See...

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...

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