Advance acoustic HydroCat 5015B User manual

Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
HydroCat
5015B
Models 45 020, 45 025
8/93 Form Number 043020
SERVICE
TM

Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
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Batter ............................................................................................................10
Brake Adjustment...........................................................................................89
General Information & Safet ...........................................................................1
H dro-Max Recover Tank Removal .............................................................92
H dro-Max Solution Pump Removal..............................................................92
H dro-Max Solution Tank Removal................................................................17
H dro-Max S stem Rec cling Information.....................................................90
H dro-Max S stem Troubleshooting..............................................................94
Scrub Brush Belt & Coupler Replacement.....................................................22
Scrub Brush Belt Tension Adjustment............................................................21
Scrub Brush Drive Gear Case - Oil Check.....................................................25
Scrub Brush Drive Gear Case Removal ........................................................29
Scrub Brush S stem Information ...................................................................20
Scrub Brush Drive Limit Switches & Actuator ................................................33
Scrub Brush Drive Motor Removal ................................................................24
Scrub Brush Drive Shaft Replacement ..........................................................26
Scrub Brush Drive Skirt Adjustment...............................................................32
Scrub Brush S stem Troubleshooting............................................................37
Scrub Brush Motor - Carbon Brush Inspection ..............................................23
Solution Control Valve Removal ....................................................................16
Solution S stem Information & Maintenance .................................................14
Solution S stem Troubleshooting ..................................................................19
Solution Tank Removal-Std............................................................................17
TABLE OF CONTENTS

Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
Specifications & Scheduled Maintenance........................................................5
Squeegee Blade Replacement & Adjustment ................................................46
Squeegee Lift Actuator Replacement & Adjustment ......................................49
Steering Chain Adjustment ............................................................................85
Steering S stem Spindle & Wheel Removal..................................................86
Sweeping Broom Bearing Replacement ........................................................76
Sweeping Broom Belt Adjustment & Replacement ........................................79
Sweeping Broom Maintenance & Adjustments ..............................................73
Sweeping Broom Motor - Carbon Brush Inspection.......................................78
Sweeping Broom Motor Removal & Replacement.........................................78
Sweeping Broom Skirt Adjustments & Removal ............................................80
Sweeping S stem Troubleshooting................................................................83
Vacuum Motor Removal & Carbon Brush Inspection.....................................45
Vacuum S stem Information & Maintenance .................................................43
Vacuum S stem Troubleshooting ..................................................................53
Wheel Drive Motor & Differential Removal ....................................................57
Wheel Drive Switches & Potentiometer .........................................................59
Wheel Drive S stem Information & Maintenance ..........................................55
Wheel Drive S stem Troubleshooting............................................................64
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
TABLE OF CONTENTS
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Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
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OTHER MANUALS AVAILABLE FOR THE HYDRO-CAT 5015B
The following manuals are available from the Advance Literature Service Department:
•H dro-Cat 5015B Parts List - Advance Form Number 042265
•H dro-Cat 5015B Operation Manual - Advance Form Number 041252
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TRANSPORTING THE MACHINE
CAUTION!
Before driving the machine up a ramp and onto a truck or trailer, remove the squeegee tool and the
brushes from the machine to avoid damage.
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that . . .
• The solution tank cover is strapped or taped closed.
• The recovery tank cover is strapped or taped closed.
•The broom access door is latched securely.
• The scrub brushes are installed and in the down position.
• The squeegee is installed and in the down position.
• The sweeping broom lever is in the down position.
• The operator’s seat is strapped or taped down.
• The machine is tied down securely - see tie-down locations in Figure 1.
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Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
FIGURE 1
2 Tie-Downs, 1 under
each roller bumper 2 Tie-Downs under
front edge of machine
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TOWING
If the machine must be towed or pushed, do not move the machine faster than walking speed.
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Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
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SYMBOLS
Advance uses the s mbols below to signal potentiall dangerous conditions. Alwa s read this information
carefull and take the necessar steps to protect personnel and propert .
DANGER!
Is used to warn of immediate hazards that will cause severe personal injur or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injur .
CAUTION!
Is used to call attention to a situation that could cause minor personal injur or damage to the machine or other
propert ..
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GENERAL SAFETY INSTRUCTIONS
Specific Cautions and Warnings are included to warn ou of potential danger of machine damage or bodil
harm.
WARNING!
Keep sparks, flame and smoking materials awa from the batteries. Explosive gasses are vented during
normal operation.
Remove all jewelr when working near electrical components.
Turn the Master Ke Switch OFF and disconnect one of the batter terminals when servicing electrical compo-
nents.
Never work under a machine without safet stands or blocks to support the machine.
Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas
where flammable liquids exist.
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Hydro Cat 5015B Service Manual
GENERAL INFORMATION AND SAFETY
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GENERAL SAFETY INSTRUCTIONS (continued...)
CAUTION!
Before performing an service function, carefull read all instructions pertaining to that service function.
Take precautions to prevent hair, jewelr , or loose clothing from becoming caught in moving parts.
Keep the Batter Compartment Cover OPEN while charging the batter . Charging produces highl explosive
h drogen gas. Charge onl in well-ventilated areas, awa from open flame. Do not smoke while charging the
batter .
Use caution when moving the machine in below freezing temperature conditions. An water in the solution or
recover tanks or in the hose lines could freeze.
Do not leave the machine unattended without first turning the Master Ke Switch OFF and appl ing the
Parking Brake.
Turn the Master Ke Switch OFF before changing the brushes or broom, and before opening an access
panels or adjusting the Solution Flow Control Valves.
Do not operate the machine on ramps or inclines of more than 5 degrees.
Use care when using scarifier discs and grinding stones. Advance wiil not be held responsible for an damage
to floor surfaces caused b scarifiers or grinding stones.
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SPECIFICATIONS AND MAINTENANCE
Hydro Cat 5015B Service Manual 5
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SPECIFICATIONS
Dimensions English (Metric)
Scrub Brush Diameter 13.5 inches (34 cm)
Scrub Brush Path 50 inches (127 cm)
Scrub Brush Pressure 285 lbs (12 kg)
Scrub Brush Speed 120 rpm (120 rpm)
Machine Length 81 inches (206 cm)
Machine Width 54 inches (137 cm)
Machine Height 57 inches (145 cm)
Machine Height With Overhead Guard 7 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 (18 litre)
Hopper Capacity 3/4 cubic foot (21 litre)
Coverage Rate 84,000 sq ft (7,805 m2) per hour
Turning Radius 66 inches (168 cm)
Machine Weight 2,226 lbs (1,010 kg) net w/o batteries
3,425 lbs (1,553 kg) net w batteries
Battery Weight 1,200 lbs (544 kg)
Battery Compartment Dimensions
Height 23 inches (58 cm)
Width 16 inches (40 cm)
Length 40 inches (102 cm)
General S ecifications
Brush Motor 36 volt, 2 1/4 hp dc motor
Wheel Drive Motor 36 volt, 4 hp dc motor
Vacuum Motor 36 volt, 1 hp dc motor
Broom Motor 36 volt, 1 hp
Squeegee Type 4 sided, curved, self tracking
Battery 36 volt 475 AH

Hydro Cat 5015B Service Manual
SPECIFICATIONS AND MAINTENANCE
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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 Ins ected 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 Skirt on Front of Broom Housing 81
Check Skirts on Sides of Broom Housing 81, 82
Check Front Skirts (next to scrub brushes) 32
Check Gaskets That Seal Against Bottom of Recovery Tank (standard model only) 46
Check Gasket Around Recovery Tank Cover 46
Clean Built-Up Dirt From Squeegee Tool and Blades N/A
Inspect Squeegee Blades, Replace if Necessary 47, 48
Clean and Inspect Vacuum Filter 44
Inspect Vacuum Hoses N/A
Check Drive Differential Oil Level 57
Check Battery Electrolite Level 12
Test Brakes, Adjust if Necessary 8
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SPECIFICATIONS AND MAINTENANCE
Hydro Cat 5015B Service Manual
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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 N/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 Gaskets On Recovery Tank N/A
Inspect Squeegee Blades 47, 48
Lubricate Squeegee Lift Actuator
Lubricate All Grease Fittings 8
Check Battery Water Level 12
Check Tension On All Belts N/A
Check Sweeping Broom Pattern 73
Check Differential Oil Level 57
Flush Solution Tank 15
Clean Vacuum Filter 44
100 Hours
Rotate Sweeping Broom 75
Inspect Carbon Brushes In Vacuum Motor 45
Inspect Carbon Brushes In Wheel Drive Motor 57
Inspect Carbon Brushes In Brush Drive Motor 23
Inspect Carbon Brushes In Broom Drive Motor 78
Check Oil Level In Brush Drive Gear Cases 25
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Hydro Cat 5015B Service Manual
SPECIFICATIONS AND MAINTENANCE
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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.
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STEERING SYSTEM LUBRICATION
• Remove the recovery tank and turn the steering wheel so that the grease fittings on the (2) “A” sprockets
(see figure 1) are accessable. Grease both fittings.
• Grease (1) fitting “B” on the steering wheel spindle.
• Grease (1) fitting “C” on the end of the steering wheel axle.
• Grease (1) fitting “D” on the universal joint (near the bottom of the steering column). Open the access
panel on the front of the machine for access.
A
B
C
D
FIGURE 1
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SPECIFICATIONS AND MAINTENANCE
Hydro Cat 5015B Service Manual
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SQUEEGEE LIFT ACTUATOR LUBRICATION
• Lower the squeegee and remove the recovery tank.
• Apply a light coating of grease to the actuator shaft.
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DIFFERENTIAL OIL
Remove the dipstick under the operator’s seat to check the differential oil level. Add 0W gear lube if neces-
sary, to bring the oil level up to the indentation on the dipstick.
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BRUSH DRIVE GEAR CASE OIL
Remove the vented plug from the top of the gear case to check the oil level. Add 140W gear lube if the oil
level is more than 1-1/2 inch (3.8 cm) below the top of the gear case.
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Hydro Cat 5015B Service Manual
BATTERY
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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. se 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.
Note: Always use a spreader bar to prevent excessive pressure on the ends of the battery.
FIGURE 1
FIGURE 2
Machine Connector
Battery Connector
POS
NEG
•See Figure 2. Connect the battery connector to the machine connector, located inside the right rear
access door.
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BATTERY
Hydro Cat 5015B Service Manual
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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.
•se an overhead hoist or a fork lift to lift the battery up and out the machine.
Note: Always use a spreader bar to prevent excessive pressure on the ends of the battery.
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Hydro Cat 5015B Service Manual
BATTERY
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BATTERY MAINTENANCE
WARNING!
se 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.
When working with batteries:
• Remove all jewelry
• Wear safety glasses
• Do not smoke
• Do not allow tools to touch more than one battery terminal at a time
• Work in a well ventilated area
Proper maintenance of electric vehicle batteries can greatly extend their life.
There are 3 simple rules for good battery maintenance:
•Ma nta n Proper Electrolyte Level - se 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, fill each
cell to the bottom of the filler tube. Do not over-f ll the battery(s)! Do not add ac d to batter es!
•Keep the Battery(s) Charged - Batteries should be charged each time that a machine is used for more
than 1 hour. Machine operators should open all battery access doors to avoid a concentrated build-up of
hydrogen gas. Operators should follow the instructions provided with their specific battery charger, to
determine how long the battery(s) should be charged. Even when a machine is stored, the battery(s)
should be charged once a month to prevent the battery(s) from “sulfating”. Almost all battery caps are
vented, so there’s no need to loosen or remove them for charging.
•Keep the Batter es Clean - se a damp cloth to wipe dirt and liquid from the top of the battery(s).
Battery terminals must be clean and tight. If the top of the battery(s) is wet after charging, the battery(s)
has probably been over-filled.
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BATTERY
Hydro Cat 5015B Service Manual
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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.
Note: Always charge batteries before testing.
There are 2 ways to find a dead cell:
• se a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell
is one that reads 50 points (or more) lower than the other cells.
• se a volt meter to check the voltage of the battery(s) with 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).
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BATTERY SPECIFICATIONS
Advance Part Number 454400
Height 19 1/2 inches (50 cm)
Length 38 1/2 inches (98 cm)
Width 15 9/16 inches (40 cm)
Weight 1,200 lbs (544 kg)
36 Volts - 18 Cells
475 AH @ 6 hour rating
1/0 cable, 30 inches (78 cm) from case (at positive terminal) to connector.
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BATTERY CHARGER SPECIFICATIONS
Advance Part Number 448133
Single phase, 230 / 460 volt in, 36 volt 100 amp out.
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Hydro Cat 5015B Service Manual
SOLUTION SYSTEM
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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 ottom of the tank keeps dirt out of the solution valves. The solution tank can e drained y
removing the plug from the solution drain hose, located ehind the lower-left door panel.
Three valves are used to control flow of solution to the scru rushes. The main valve is operated y a lever
on the control panel. It should only e used to turn the solution ON or OFF. The (2) flow control valves should
only e used to regulate the the AMOUNT of solution flowing to the rushes.
The linkage from the solution lever to the main valve is connected to the rush lift system, so the lever auto-
matically moves to the OFF position when the rushes are raised. The solution lever cannot e moved ack
to the ON position until the rushes are lowered.
To Scru Brushes
To Scru Brushes
Flow Control
Valves
Tank
FIGURE 1
Main Valve
Filter Screen
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Hydro Cat 5015B Service Manual
SOLUTION SYSTEM
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SOLUTION SYSTEM MAINTENANCE
The solution system should e flushed every 15 hours of operation to prevent a uild-up of soap residue in the
solution valves. To flush the system...
1Park the machine outdoors or near a floor drain and open the solution tank drain valve.
2When the tank is empty, close the drain valve and put a out 6 inches (15 cm) of clean, warm water in the
tank.
3Reach under the front of the machine and open the (2) flow control valves all the way.
4Turn the key switch ON and put the scru rush switch in the ON (I) position. When the rushes are all
the way down , turn the key switch OFF.
5Push the solution lever (on the control panel) forward, to the full-on position. Allow all of the warm water
to drain through the valves.
6Return the flow control valves to their original position.
Note: See the Hydro-Max II chapter for additional maintenance on machines equipped with this option.
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Hydro Cat 5015B Service Manual
SOLUTION SYSTEM
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MAIN SOLUTION VALVE REMOVAL
The main solution valve is located at the front of the machine, just elow the horn.
Replace the valve if water leaks from the center of the rush holders with the solution lever in the OFF posi-
tion. To replace the main solution valve...
1Turn the key switch ON and put the
scru rush switch in the down posi-
tion. When the rushes are all the way
down, turn the key switch OFF.
2See Figure 2. Open the electrical
access panel on front of the machine
and remove the 3 hoses from valve
“A”.
3Disconnect the control linkage from the
valve arm. Be careful not to lose the
ushing and washers.
4Remove the 2 “B” olts and remove
the valve from the machine.
5Remove the hose fittings and the
mounting racket from the old valve
and install them on the new valve.
6Follow steps in reverse order to install
the new valve.
Note: The valve control linkage should e
connected to the hole closest to the end of
the valve arm.
B
A
FRONT
FIGURE 2
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Hydro Cat 5015B Service Manual
SOLUTION SYSTEM
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SOLUTION TANK REMOVAL
1MACHINES WITHOUT HYDRO-MAX II OPTION - Open door “C” (see Figure 3), drain the solution tank,
remove the drain hose and valve from the ottom of the tank.
*MACHINES WITH HYDRO-MAX II OPTION - Open door “D” drain the solution tank and remove the drain
hose from the ack of the tank.
2Loosen all of the screws holding the hinge for door “D” against the frame.
3Remove the ( 3 ) screws from access panel “E” and open the panel.
4Remove racket “F” from the frame (2 screws).
5Remove tank cover “G” ( 6 screws ).
FIGURE 3
D
G
H
C
F
E
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