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SOLUTION SYSTEM

TigerCat, Hydro-Retriever 4500

Service Manual

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SOLUTION VALVE REMOVAL

1

Remove the lower-right body panel (behind the broom door) from the machine.

2

Loosen the clamps on the inlet and outlet hoses and remove them from the hose barbs.

3

Remove the nuts holding the end of the solution cable onto the valve arm.

4

Remove the (4) nuts holding the valve onto it’s mounting bracket.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

SOLUTION VALVE CABLE REMOVAL

Raise the hopper and install the safety support on the hopper lift cylinder.

WARNING!

Never work under the hopper without the hopper safety support installed on the hopper lift cylinder.

1

Remove the nuts holding the end of the solution cable onto the solution control lever.

2

Loosen the nuts holding the lever-end of the cable housing onto it’s mounting bracket and pull the cable
assembly free.

3

Remove the lower-right body panel (behind the broom door) from the machine.

4

Remove the nuts holding the valve-end of the cable onto the solution valve arm.

5

Loosen the nuts holding the cable housing onto it’s mounting bracket and pull the cable free.

6

From the front of the machine, pull the lever-end of the cable out of the cable housing as far as possible.
Then work the cable assembly forward and out of the machine.

7

Remove the ball joints from the old cable and install them on the new one.

Follow instructions in reverse order to install cable.

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Содержание Hydro-Retriever 4500 462000

Страница 1: ...Hydro Retriever 4500 Models 462000 462001 463144 463408 463409 463394 SERVICE TM TigerCat 4500 Models 462000 462001 463144 463408 463409 463394 TM Machine Manual Only 12 91 Form Number 043013...

Страница 2: ...ts 61 Drive Wheel Drive Motor Steering Spindle Removal 62 Dust Control Filter 24 Dust Control Shut off Adjustment 28 Dust Control System General Information 23 Dust Control System Troubleshooting 29 E...

Страница 3: ...eegee 44 Squeegee Lift Cylinder Removal 55 Squeegee Lift System Troubleshooting 56 Sweeping System General Information 9 Sweeping System Troubleshooting 22 Up And Down Limit Switch Adjustment 53 Upper...

Страница 4: ...__________________________________________________________________________________________________________________________________________________________________________ TRANSPORTING THE MACHINE CAUT...

Страница 5: ..._____________________________________________________________________________________________________________________________________________________________ TOWING The rear drive wheel should be lift...

Страница 6: ...Carefully read information beginning with these words and take necessary steps to protect personnel and property WARNING Never work under the hopper with out the hopper safety support installed on the...

Страница 7: ...WARNING Remove all jewelry when working near electrical components DANGER Keep sparks and open flame away from the fuel tank battery and engine compartment ___________________________________________...

Страница 8: ...imum Aisle for U turn 120 inches 305 cm Recovery Tank Capacity 85 gal 322 l Scrub Brush System Brush Diameter 12 inches 38 cm Brush Pressure 350 lbs 159 kg Brush Speed 200 RPM 200 RPM Scrub Path 45 in...

Страница 9: ...________________________________________________________________________________________________________________________________________________________________________________________ DIMENSIONS 108...

Страница 10: ...of operation 15 30 100 300 check engine coolant level check hydraulic oil level drain and flush solution tank flush solution valves inspect squeegee blades inspect rotate main broom adjust main broom...

Страница 11: ...ive type anti freeze Every 1500 hours of operation have a sample of the hydraulic oil analyzed for contamination Change the oil if necessary See page 74 for more information Every 1500 hours of operat...

Страница 12: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Страница 13: ...2 1 2 inches 6 3 cm wide Note Adjusting the broom for a pattern wider than specified decreases sweeping performance and increases broom wear 4 If the polished strip is too wide or too narrow remove th...

Страница 14: ...rent main brooms are available for the TigerCat The 8 row polypropylene broom part number 505071 is an all purpose broom for light litter or dust The 8 row proex and wire broom is best for heavier deb...

Страница 15: ...laced when its bristles are worn to a length of 2 inches 5 cm or less To rotate or replace the main broom 1 Raise the hopper stop the engine set the parking brake and put the hopper safety support on...

Страница 16: ...d broom motor F Install a seal kit or replace the motor if it is leaking hydraulic oil 7 Inspect the rubber skirts on the sides and the back of the broom housing replace any skirt that s torn or damag...

Страница 17: ...Loosen the lock nut B see Figure 1 and loosen bolt C one turn 5 Remove the 6 screws from the broom housing end panel 6 Remove set screw F and the 2 A bolts from motor arm G and pull the motor and arm...

Страница 18: ...roper contact with the floor Hopper Skirt The hopper skirt is mounted on the hopper and drags on the floor in front of the main broom It acts as a ramp to help guide the litter off the floor and into...

Страница 19: ...E bolts and the straps holding the middle skirt in place When installing the new middle skirt position it so that area of the skirt marked F is on the inside broom side of panel G not between the the...

Страница 20: ...skirt at the back of the broom housing 1 Raise the hopper and install the hopper safety support 2 Open the broom access door and remove the broom from the machine 3 If the heads of the skirt mounting...

Страница 21: ...de broom is designed to move dust and debris from along a curb or wall into the path of the main sweeping broom Side Broom Height Adjustment The side broom should be positioned so that the bristles fr...

Страница 22: ...ment with the side broom running The broom should touch the floor from the 10 o clock position to the 3 o clock position as viewed from the operator s seat Side Broom Motor Removal 1 Raise hooper and...

Страница 23: ...om housing to see if the seals at the sides of the hopper opening are parallel to and sealed against the sides of the broom housing 3 If they are not adjust hopper angle bolts A see Figure 6 Turn the...

Страница 24: ...op of the hopper loosen the lock nut on the hopper cylinder rod and turn the rod clockwise to increase downward flex of channel B or counter clockwise to decrease downward flex of channel B 3 Close th...

Страница 25: ...___________________ SWEEPING SYSTEM TROUBLESHOOTING Problem Debris left on the floor Possible Cause and Remedy 1 Operator running machine with engine speed switch in the IDLE position instruct operato...

Страница 26: ...broom through the broom housing through the hopper and into the dust control filter The dust gets trapped in the filter The air continues through the filter through the dust control lower impeller th...

Страница 27: ...y 30 hours of operation To inspect the filter 1 Open the hinged cover on top of the hopper If there is dirt under this cover the gasket around the filter may be damaged or the filter may be punctured...

Страница 28: ...WARNING Wear eye protection while servicing the filter CAUTION Be careful not to puncture the filter while cleaning 1 Use a vacuum cleaner to remove as much dirt as possible from the filter 2 Blow com...

Страница 29: ..._________________ LOWER IMPELLER BELT SHAFT OR BEARING REPLACEMENT 1 Drain cooling system using drain valve A see Figure 2 FIGURE 2 D C A Front B 2 Disconnect the electrical connector and the vacuum h...

Страница 30: ...s a matched set only Follow steps in reverse order to re assemble Follow the additional steps below to replace the lower impeller shaft or bearings 9 Remove hose guard K from the frame Two bolts at th...

Страница 31: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Страница 32: ...ever in the OFF position Instruct operator to put dust control lever in ON position when sweeping on dry floors 3 Dust control filter clogged Hold dust control lever in SHAKE position for 15 seconds L...

Страница 33: ...r Problem Shaker motor will not run Possible Cause and Remedy 1 Blown fuse F5 replace fuse 2 Bad shaker switch replace switch __________________________________________________________________________...

Страница 34: ...ain solution valve located behind the broom housing near the center of the machine Solution flows out of the main valve through the proportioning valve through the solution manifolds and onto the floo...

Страница 35: ...______________________________________________________________________ SOLUTION VALVE CABLE REMOVAL Raise the hopper and install the safety support on the hopper lift cylinder WARNING Never work under...

Страница 36: ...ed on the right side of the machine below the operator s seat 2 Remove the access panel from the left side of the operator s compartment loosen the clamp on the drain hose and remove the hose from the...

Страница 37: ...starts when the brushes are lowered and stops when they are raised ____________________________________________________________________________________________________________________________________...

Страница 38: ...SCRUB BRUSH SYSTEM TigerCat Hydro Retriever 4500 Service Manual F B D E A C FIGURE 1 35...

Страница 39: ...n nut B counterclockwise and push the motor downward to release tension on the drive belt see Figure 1 5 Remove the 3 F bolts from the motor pulley and screw them into the threaded holes in the pulley...

Страница 40: ...h WARNING Never work under the hopper without the hopper safety support installed on the hopper lift cylinder If the connector appears loose push it firmly onto the switch and try the brushes again If...

Страница 41: ...machine for access to the cylinder control valve Turn the key switch to the on position but do not start the engine Put the brush switch on the dashboard in the BRUSHES ON position Check the voltage...

Страница 42: ...n the S4 solenoid valve or coil 0 volts go to step 3 5 Locate the gray red wire connected to the brush up limit switch Measure voltage between this wire and the frame of the machine 12 volts replace t...

Страница 43: ...ear body panel from the right side of the machine for access to the motor control valve Problem Brushes go up and down but will not turn 1 Connect a pressure gauge to the piston end of the brush lift...

Страница 44: ...ank The main parts of the vacuum system are shown in Figure 1 In order for the vacuum system to operate properly all the air moved by the vacuum upper impeller must enter the system through the squeeg...

Страница 45: ...the engine speed control switch in HIGH Also make sure that the recovery tank cover is closed tightly 3 Hold the waterlift gauge tightly against the adapter as shown in Figure 2 Hold the adapter so t...

Страница 46: ...hose to back flush the squeegee hose This will remove most built up dirt 3 Reach into the recovery tank inlet tube where the squeegee hose was connected and remove any built up dirt 4 Inspect the hos...

Страница 47: ...he squeegee blades replace or reposition them as needed see Squeegee Blade Service 2 Lower the squeegee and loosen the 4 A bolts see Figure 3 3 Lift the squeegee by hand to make sure that the center a...

Страница 48: ...small slots The middle blade wipes the water off the floor The rear blade supports the middle blade The blades work best when there is a sharp corner on the front edge of the middle blade As the sque...

Страница 49: ...the recovery tank off the machine the tank is not bolted to the frame _________________________________________________________________________________________________________________________________...

Страница 50: ...___________________________________________________________________________________________________________________ UPPER IMPELLER BELT REPLACEMENT 1 Drain the cooling system using drain valve A see F...

Страница 51: ...k nut on bolt H and turn the bolt to release tension on the 2 I impeller belts Note Replace these belts as a matched set only 9 Remove the lubrication hose from the top of bearing block G ____________...

Страница 52: ...4 Reach in from the radiator side of the machine and work the belt past hose guard N over bearing block G and out of the machine 15 Follow steps in reverse order to re assemble To replace the lower im...

Страница 53: ..._____________________________________________ LOWER IMPELLER BEARING REMOVAL 1 Clean all dirt from the impeller shaft using emery cloth a file or a wire brush and loosen the W set screws see Figure 9...

Страница 54: ...0 onto chamber B 2 Remove the 4 C screws and loosen the clamp on hose D 3 Pull chamber B and hose D off the impeller housing 4 Remove impeller cover E 4 bolts hold it in place 5 Remove the bolt from t...

Страница 55: ...VACUUM SYSTEM TigerCat Hydro Retriever 4500 Service Manual FIGURE 10 I J K G H L F D B C A E Radiator 52...

Страница 56: ..._________________________________________________________________________________________________________________________________ DOWN LIMIT SWITCH ADJUSTMENT The squeegee lift linkage is designed to...

Страница 57: ...he lowest squeegee blade The distance should be between 2 1 4 and 2 1 2 inches 2 Move the up limit switch the one on your left see Figure 11 to the left to increase the distance from the floor Move th...

Страница 58: ...n neutral or forward ___________________________________________________________________________________________________________________________________________________________________________________...

Страница 59: ...____________ SQUEEGEE LIFT SYSTEM TROUBLESHOOTING Problem Squeegee will not go up stuck in down position 1 Start the engine and check to see if the hopper will move up and down and if the dump door wi...

Страница 60: ...EE LIFT SYSTEM TROUBLESHOOTING continued 3 Remove the cover panel at the lower left corner of the machine for access to the cylinder control valve Turn the key switch to the on position but do not sta...

Страница 61: ...cover panel at the lower left corner of the machine for access to the cylinder control valve and check for a problem in the S9 solenoid valve or coil see Figure 13 0 volts go to step 6 6 Locate the gr...

Страница 62: ...p 3 3 Remove the cover panel at the lower left corner of the machine for access to the cylinder control valve Turn the key switch to the on position but do not start the engine Put the squeegee switch...

Страница 63: ...lts replace the squeegee switch 0 volts go to step 7 7 Locate the orange wire connected to the reverse switch located in the engine compartment next to the propulsion pump Measure voltage between the...

Страница 64: ...ine could move during adjustment causing property damage or bodily injury 2 Check the cable between the pedal and the propulsion pump for free movement lubricate or replace the cable if necessary 3 Ch...

Страница 65: ...e drive wheel 1 Raise the hopper and install the hopper safety support WARNING Never work under the hopper with out the hopper safety support installed on the hopper lift cylinder as shown below FIGUR...

Страница 66: ...ic system 10 Turn the steering wheel all the way counterclockwise and disconnect the elbows closest to the drive motor 11 Remove the 4 bolts holding the wheel motor in place and work the motor out of...

Страница 67: ...nch 32 mm Valve Lash Intake cold 009 inch 22 mm ________________________________________________________________________________________________________________________________________________________...

Страница 68: ...ry outer and a secondary inner filter element The primary element may be cleaned twice before it needs to be replaced The secondary element should be replaced every third time that the primary element...

Страница 69: ...or On gasoline machines the engine idle speed is controlled by an anti dieseling solenoid On LP machines the engine idle speed is controlled by an idle speed adjustment screw on the carburetor Note A...

Страница 70: ...engine speed switch in the HIGH SPEED position If the tachometer reading is too high or too low adjust the MAX screw in the governor controller see Figure 2 for the proper speed CAUTION When adjustin...

Страница 71: ..._____________________________________________________ ALTERNATOR REPLACEMENT 1 Drain the cooling system using drain valve A see Figure 4 and disconnect the negative battery cable from the battery FIGU...

Страница 72: ...6 8 Loosen the lock nut on bolt H turn the bolt to release tension on the I impeller belts and remove them from the engine _____________________________________________________________________________...

Страница 73: ...______________________________________________________________________________________________________________________________________________________________ ALTERNATOR REPLACEMENT CONTINUED L FIGURE...

Страница 74: ...engine manuals mentioned at the beginning of this section Engine problems caused by other systems in the machine are covered below Problem Starter will not operate check for discharged battery check f...

Страница 75: ...located in front of the rear bumper next to the brush lift cylinder 1 Raise the hopper and install the hopper safety support on the hopper lift cylinder WARNING Never work under the hopper with out t...

Страница 76: ...ith the linkage that activates the switch If the gauge reads approximately 2000 PSI go to step 9 5 Put the brush switch in the ON position and the squeegee switch in the UP position If the gauge reads...

Страница 77: ...ressure gauge again If the gauge reads 200 PSI or less the hydraulic system is not causing the engine problem Look for a problem with the engine itself If the gauge reads approximately 2000 PSI go to...

Страница 78: ...cylin ders are used to raise and lower the squeegee scrub brushes hopper side broom s and to open the hopper dump door The hydraulic motors and cylinders are controlled by electric solenoid valves The...

Страница 79: ...on a large oil container not more than 24 inches high against or just below the machine s rear bumper behind the battery tray 3 Loosen fittings A B and C see Figure 1 Then remove fitting A from the pu...

Страница 80: ...alve located just to the right of the hydraulic oil tank in place Push the valve down and out of the way 7 Remove the recovery and solution tanks from the machine see Solution System section for instr...

Страница 81: ..._________ CYLINDER CONTROL VALVE The cylinder control valve is mounted on the bottom of the frame behind the lower left body panel It looks like Figure 2 below FIGURE 2 The functions controlled by thi...

Страница 82: ...______________________________________________________ MOTOR CONTROL VALVE The motor control valve is mounted on the bottom of the frame behind the lower right body panel It looks like Figure 3 below...

Страница 83: ...______________________________________________________________________________________________________________ SIDE BROOM LIFT VALVE The side broom lift valve controls the lift cylinder for the standa...

Страница 84: ...m hose that runs from the lower impeller outlet to the hydraulic oil cooler oil cooler is located at the top of the engine compartment 2 Remove fitting A see Figure 5 from the accessory pump and quick...

Страница 85: ...er disconnect the battery cables and remove the battery from the machine 2 Disconnect hose A see Figure 6 from the back of the recovery tank 3 Loosen the 4 B bolts and the 2 C bolts 4 Loosen the lockn...

Страница 86: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Страница 87: ...y pump and quickly install a plug to stop the oil flow Note The hose connected to fitting A runs directly to the bottom of the hydraulic oil tank Approximately 17 gallons of oil will drain if this hos...

Страница 88: ...egee lift system is covered in the Vacuum System section Note The squeegee lift limit switches mentioned in this section are located in the engine compartment next to the squeegee lift cylinder The br...

Страница 89: ...gain If the gauge now reads 200 PSI or less adjust or replace the squeegee down limit switch Also check for a problem with the linkage that activates the switch If the gauge reads approximately 2000 P...

Страница 90: ...k the pressure gauge again If the gauge reads 200 PSI or less the hydraulic system is not causing the engine problem Look for a problem with the engine itself If the gauge reads approximately 2000 PSI...

Страница 91: ...________________________________________________________________________________________________________________________________________________________________________________________________________...

Страница 92: ...ROOM SPEED VALVE SCRUB BRUSH MOTOR MAIN BROOM MOTOR S3 S4 S6 S7 S8 S9 S10 FLOW DIVIDER ACCESSORY PUMP PILOT CHECK VALVE IN CYLINDER VALVE PILOT CHECK VALVE IN CYLINDER VALVE HOPPER LIFT CYLINDER STAND...

Страница 93: ...__ FUSES The fuse box is located in the operator s compartment just below the solution control lever see Figure 1 The current rating for each fuse and the function it protects is listed on the chart b...

Страница 94: ...ift cylinder Squeegee Down Limit Switch in engine compartment next to squeegee lift cylinder Reverse back up alarm Switch in engine compartment on back side of propulsion pump Brush Up Limit Switch in...

Страница 95: ...ED GRN BRN YEL WHT BRN YEL D1 YEL WHT BRN BLK BRN WHT GRN WHT YEL YEL BLK 12 11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 3 2 4 RED GRN RED GRN 2 YEL VIO 3 WHT GRN 5 BLK YEL 7 BRN RED 25K GRN BLU VIO...

Страница 96: ...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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