TOMCAT

FACTORY CAT MODEL 52

TOMCAT Model 5100
Industrial Rider Scrubber

52/5100

Operator's Manual
Parts & Service Book

PS-52-ENG
 TOMCAT MODEL 5100 RIDER SCRUBBER
Operator's Manual & Parts Book
TABLE OF CONTENTS

READ THIS FIRST!

Safety Warnings: Page 2
Short List of Do's and Don'ts Page 4

OPERATING YOUR MACHINE Page 6

Identifying the Controls Page 7
How It Works Page 9
General Operating Instructions Page 10
Spray and vac wand Page 14
Recycling System Page 16

SPECIAL OPERATING TIPS Page 18

How to Scrub Page 19

MAINTAINING YOUR MACHINE Page 21

Daily Clean-up Page 22
Daily Pre-Check Page 23
Squeegee & Vac System Adjustments Page 24
About Batteries Page 25
General Machine Maintenance Page 26

TROUBLESHOOTING AND REPAIR Page 28

Central Command Page 29
Troubleshooting Guide Page 31

SPARE PARTS SECTION Begins Page 35

Copyright Mid-Central. Corporation 2001

World Rights Reserved.

Page 1
 SAFETY WARNINGS!
THESE WARNINGS ARE NOT MEANT TO BE A COMPLETE LIST AND ONLY THE
OPERATOR'S INTELLIGENCE, GOOD SENSE AND CARE OF UNIT WILL ASSURE
THAT MOST HAZARDS WILL BE AVOIDED.

1. READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING,

ADJUSTING OR REPAIRING THIS MACHINE.
If you have a question concerning the machine or its operation, or would like extra
copies of this book, you may call the Factory at 1-(800)-450-9824, or Fax your
questions to us at 1-(262)- 632-6961.

2. CHARGING THE BATTERIES WILL PRODUCE EXPLOSIVE HYDROGEN GAS.

Do not smoke or allow open flame near a charging battery. Do not smoke while
working around the machine. Do not charge battery with the hood (lid) of the
machine closed or hydrogen gas may accumulate within.

3. TO AVOID ACCIDENTALLY STARTING UP THE MACHINE, ALWAYS TURN OFF

THE KEY SWITCH BEFORE GETTING ON OR OFF UNIT. OTHERWISE
BUMP ING THE FOOT CONTROL COULD CAUSE UNIT TO START UP.
A green warn ing light on the right-hand control panel shows when power is on.

4. WHEN YOU LEAVE THE MACHINE UNATTENDED, ALWAYS SHUT OFF

THE UNIT AND TAKE THE KEY.

5. DRESS SAFELY
Do not wear rings or metal wrist watches while working on this machine. They can
cause an electrical short, which, in turn, can cause burns.

Do not work on this machine while wearing a tie, scarf or other dangling neckware.
These can tangle in the rotating brooms, belts and pulleys and cause serious injury
or even death.

6. DO NOT USE THE MACHINE AS A STEP LADDER OR CHAIR.

7. IF YOU MUST LIFT UNIT OFF OF GROUND, DO NOT WORK ON UNDERSIDE

OF MACHINE WITHOUT PROPERLY SUPPORTING UNIT.

8. NO RIDERS! Model 5100 was meant to carry only the operator.

9. NO TIGHT, FAST TURNS! While negotiating turns, reduce speed, steering in a

smooth motion. Do not turn around while on a ramp!

10. NOT INTENDED FOR USE ON STREETS OR SIDEWALKS. Common sense

dictates that driving in traffic is dangerous to the operator of a slow vehicle, while
operation on sidewalks can endanger pedestrians.
11. WARNING: USING FLAMMABLE CLEANING CHEMICALS, OR VACUUMING UP
FLAMMABLE CHEMICAL FROM THE FLOOR CAN CAUSE AN EXPLOSION.
The vacuum motors can create sparks that will set off volatile chemicals.
Page 2
SAFETY WARNINGS! (Continued)
12. WARNING: 24 VOLT POWER CAN CAUSE BURNS. DO NOT DROP TOOLS ON
LIVE CONNECTIONS. DO NOT WEAR JEWELRY WHILE WORKING ON
ELECTRICALS. Your machine is equipped with rubber covers over the battery
terminals. Be sure these stay in good condition and continue to cover the terminals.

13. BEFORE WORKING ON THE MACHINE, TURN THE KEY OFF, REMOVE KEY,
AND DISCONNECT THE BATTERY. Be aware that the brush and vacuum motors can
start if someone else pushes on the foot pedal while the key is turned on, even though the
machine makes no noise, and appears "off". Do not work on machine while someone
else is sitting in operator's seat. They could accidentally turn on the power while you
work.

14. ALWAYS UNPLUG CENTRAL COMMAND FROM BATTERIES BEFORE USING

AN EXTERNAL CHARGER. A power surge from a "dumb" charger could damage Central
Command's electronics. This could destroy Central Command's ability to control traction motor
speed, and could lead to a "runaway" machine. We do not recommend the use of a "dumb"
(non-electronic) charger! If you must use one, you must be sure the battery back is discon-
nected from the Central Command module before connecting the charger.

15. STOPPING: UNDERSTAND THE AUTOMATIC BRAKING SYSTEM BEFORE YOU

OPERATE THE MACHINE ON SLICK RAMPS. Machine does not coast. Releas-
ing pedal applies braking force. You control the amount of braking by the sudden-
ness (or smoothness) with which you release the foot pedal. After you stop, the parking
brake will set automatically.

16. PARKING: MAKE SURE THE PARKING BRAKE IS WORKING PROPERLY

BEFORE PARKING MACHINE. WE DO NOT RECOMMEND PARKING MACHINE
ON RAMPS OR SLOPES.

17. TO AVOID TIPOVER, DO NOT MAKE TIGHT TURNS SIDEWAYS ON A RAMP.

TURN AROUND ON FLAT GROUND OR FLOOR ONLY. DO NOT MAKE SHARP
TURNS AT HIGH SPEED.

18. WHILE WORKING ON THE SQUEEGEE SYSTEM, BE SURE KEY IS REMOVED

FROM KEYSWITCH. Inadvertent operation by another person of the powerful squeegee
lift mechanism while hands or fingers are in the way could pinch.

18. DO NOT OPERATE THE MACHINE IF ANY PARTS HAVE BEEN REMOVED
FROM IT. Do not remove or paint over Warning decals. If Warning decals are damaged,
they must be replaced.

19. AUTHORIZED , TRAINED OPERATORS ONLY.This machine should only be operated

by a trained operator. As part of his training, he/she must read this manual thoroughly. If
extra copies are needed, contact your local dealer, or the Factory directly at
1-800-450-9824.

20. DO NOT OPERATE MACHINE IF IT IS IN UNSAFE CONDITION.

If the machine is in need of repair or is in any way unsafe or contributes to an un
safe condition, the matter should be reported immediately to the shift supervisor.
Page 3
 Model 5100: SHORT LIST OF DO'S AND DONT'S
1. AUTOMATIC OPERATION: Key Switch must be on. When the "Vac" switch
is in off ("0") mode, stepping on foot pedal will automatically:

1. Release parking brake.

2. Turn on brush motors (if brush head is down)
3. Turn on vacuum blowers (if vacuum squeegee is down)
4. Turn on the solution flow.
5. Accelerate you forward.

2. TO GO: Step on the foot pedal. GO EASY! As with any electric vehicle, hard
acceleration wastes power, and will run the batteries down sooner.

TO STOP: Let go of the foot pedal. The faster you release the pedal, the faster you
will stop. Practice stopping smoothly.

When machine comes to a complete stop, parking brake will automatically set. Go
slow until you get accustomed to the automatic braking. Allow at least one
machine length to come to a stop on level ground, more on hills.

3. DO NOT "SLAM-SHIFT" OR "PLUG". This machine has dynamic braking. Always

come to a full stop before shifting from forward to reverse, or from reverse to for
ward. Otherwise, you could damage the transaxle's drive coupling.

4. TO SCRUB: The brushhead has to be lowered, and the brushes on the ground.
Brushes will start and stop with the foot pedal (in automatic mode). You can build
pressure on the brushes with the brushhead switch. REMEMBER THAT EXCESS
BRUSH PRESSURE WASTES BATTERY POWER AND WILL GREATLY
LOWER RUN TIME ON A CHARGE.

5. TO SQUEEGEE Lower the squeegee. Vacuum will start when you step on the foot
pedal (in automatic mode), and will stop 15 seconds after you release the pedal.
Squeegee will automatically lift when you select reverse.

6. DON'T RUN BATTERIES ALL THE WAY DOWN! Machine will begin to slow
down--a lot--as batteries near the end of their charge. It is a bad idea to run the
battery this far down. Watch the battery gauge on the left side of the operator's
seat. Stop before "Empty".

7. TO RECHARGE: To recharge battery, be sure the key switch is off. Open the
hood, and plug in the external charger supplied with the machine. A green light will
come on. When the light goes out, battery is charged. LEAVE THE BATTERY
BOX COVER OPEN WHILE THE BATTERY IS CHARGING.

Page4
8. CLEAN OUT THE MACHINE AT END OF DAY. You can inspect the recovery
(pick-up) tank's condition by opening the door on top and looking in. If after you
flush it out there is still dirt on the bottom, open the clean-out door and clean out
using water and/or the cleanout tool provided with the machine.

9. NEVER USE FLAMMABLE OR EXPLOSIVE CHEMICALS IN THE MACHINE.

Sparks from the vacuum motor will ignite flammable fluids kept in the tank. This
could cause an explosion. Such chemicals include, but are not limited to cleaning
fluid, gasoline, kerosene or other petroleum-based products. If in doubt about
flammability, refer to the chemical product's M.S.D.S. sheet before using.

10. DO NOT DRIVE MACHINE OVER BUMPS MORE THAN 2" HIGH UNDER ANY
CIRCUMSTANCES. If in doubt, get off the machine to check clearance with the
brushhead of the unit.

11. MUST SCRUB GREAT. Simply working "OK" isn't good enough. If your scrubber
isn't scrubbing or vacuuming up really well, or seems hard to use, or is making
strange noises, something is wrong. Here's what to do:

A. Read this book.

B. Then call your dealer for info or service.
Or you can call us at the Factory toll free: 1-800-450-9824.
We'll talk you through the problem.

Page 5
OPERATING YOUR
MACHINE

Page 6
CONTROLS & FUNCTIONS

1. Foot Pedal: Controls Forward speed and

braking. Also turns on and shuts off solu-
tion, brushes, and vacuum .
2. Yellow "Low Solution" Light: Glows when
Solution tank is nearly empty.
3. Red "Recovery Tank Full" Light. Glows
when Recovery Tank is full.
4. Brush Downpressure Indicator. Shows 1
relative pressure on the brushes by vertical
LED readout.
5. Squeegee Lift Switch. Lifts and lowers
squeegee and turns the recovery tank's 2 3
vacuum on and off automatically.
6. Brush Downpressure Switch. Pushing on 4
the front edge of this switch lowers the
brushes, and, when they reach the floor, 6
increases pressure. Pushing on the back 5
reduces pressure and then raises the
brushes off the floor. 7
7. Auto-Manual Switch. In "Auto" mode, the
solution, brush rotation and vacuum will 8
automatically stop when the operator 9 10
releases the foot pedal. In manual mode,
these items will keep running until the 11
operator stops them manually.
8. Solution Flow Control. Varies the amount 12
of solution that is laid down on the brushes. 13
Pull up on the knob to increase solution
flow.
9. Power-On Light. Glows green when the
key is on and battery power is available.
10. Forward-Reverse Switch. Push the
forward edge of the switch to go for
ward, and the back to reverse. In reverse
mode the squeegee will automatically lift. Do
not shift from forward to reverse unless A
you are stopped!!!
11. Key Switch. Insert key and turn either
direction to turn power on.
12. Battery Indicator. Shows relative battery B
strength with an LED readout--like a fuel
gauge. Note that this gauge will reset to
"full" whenever you unplug the batteries,
whether or not the batteries are recharged.
C F
When light flashes, you must stop to
recharge!
13. Hour Meter. Runs when keyswitch is on.

D E

Page 7
COMPONENT LOCATIONS

A. Batteries. (Under the Operator's Seat.

Check water every two weeks. Read
battery section of this book.
B. Battery Connector (Red 175 Connec
tor). Disconnect this from the Central G
Command control panel, and connect to
the charger to recharge batteries. I
Leave the battery box door open
during recharging!
C. Solution Tank Door. Add detergent
and water here.
D. Recovery Air-Out Door. Used for daily H
clean-up and flushing out of the
Recovery Tank.
E. Vac Motor Housing. Vacuum motors
for recovery are kept here. Open the
box for access.
F. Tank Retaining Strap. This black
polypropylene strap keeps the solution
and recovery tanks (which are remov-
J K
able) in place. The strap tensioner,
which is at the base of the rear bumper,
is adjustable.
G. Recovery Drain Hose. Drain and flush
out the recovery tank every evening. If
necessary, clean out the tank using H.
Recovery Cleanout Door. L
H. Recovery Cleanout Door. Gives ac-
cess to tank interior. Do not open until M&N
tank is first drained. Be sure you clean
the sealing surface before clamping the
door back on or door may leak.
I. Recovery Hose. Connects between
squeegee and recovery tank. Hose is
easily removed if clog occurs. Clog will
generally occur at the squeegee.
J. Squeegee.
K. Squeegee Pitch Adjustment. Adjust
for maximum effectiveness. Moves front L. Optional Vac Wand. Unplug (I.) Recov-
of squeegee up and down. ery Hose, and plug in this wand for
remote cleaning. Stores as shown on
In general, back blades of squeegee must touch bumper-mounted bracket.
the floor in the corners. If squeegee trails in the M. Optional Vac Wand Solution Tap.
middle--it is pitched too far forward. If it trails at Blue solution flow hose for wand plugs
the edges, it is pitched too far back. Behind left corner of bumper.
N. Pump Switch for Optional Vac Wand.
Turn on for solution flow. Found behind
left corner of bumper. Be sure to
Page 8 turn the pump off when it is no longer
needed!
 HOW IT WORKS

1. Three Scrub brushes, under ma Recovery

Tank
chine, rotate under pressure on the
floor. Pressure is applied to them by Batteries Solution
Tank
the operator downpressure control.

2. Solution (detergent and water) flows Squeegee

from the solution tank just behind the 3 Brushes
operator, via plumbing to the
brushes.
Air
3. The solution and brushing clean the
floor.

4. The squeegee, at rear of machine,

picks up the dirty water from the
floor.

5. The recovery tank stores the dirty Water

water for later dumping.

6. The rear wheel drive system uses a Air & Water

variable speed motor. The motor
Motors in the top of the tank create vacuum,
drives a transaxle, and through it, the
which pulls through the squeegee.
two rear tires. The motor's speed,
rate of acceleration and decelaration
are controlled through the "Central
Command" system located in the
control panel on the operator's right-
hand side.
9. Central Command turns these
7. When the operator lets up on the foot motors on whenever the foot pedal
pedal, Central Command brings the is depressed, and turns them off after
machine to a smooth stop, and then the sweeper comes to a stop (in
automatically sets the parking brake "Auto" mode only).
on the transaxle.
10. All motors take their energy from a
8. Power for the brushes and 24-Volt deep-cycle battery set.
vacuum impelers come from individ-
ual motors.

Page 9
OPERATING INSTRUCTIONS
1. PLEASE READ WARNINGS ON PAGE
TWO OF THIS MANUAL CAREFULLY. SCRUBBING TIP 1:
Save Battery Power!
Refer to Page 4 for Location of Controls.
The main consumer of power on your scrub-
2. To make the machine move under ber is the scrub brushes. The more pressure
its own power--without scrubbing you use in scrubbing the faster the batteries
will wear down. Use the least amount of
--Turn on Key Switch.
--Make sure brush head is off ground. scrub pressure that will do your job, and you
(See Steps 5 & 6 Below) will be able to scrub more on a charge.
--Gently step on foot pedal.

3. To stop: Let go of foot pedal.

SCRUBBING TIP 2:
Machine will automatically come to a stop. Save the Juice!
At this time, the parking brake will be
automatically set by the machine's Central The solution that flows through your scrubber
Command unit. costs a good deal more than the scrubber
itself. Do not overmix it--don't use more
4. Solution:
detergent than necessary. Often, using too
Pull out the solution flow knob until you have
the desired amount. To save expense, use little water with your detergent will lower the
the least amount of solution that will do the effectiveness of its cleaning.
job.
Limit the solution flow to the minimum need-
5. To scrub: ed.
Be sure you have solution in the solution
tank. While driving forward slowly, push on Generally speaking, the less solution you use,
the brush up/down control until you read the the faster the vac system can pick up what's
desired brush pressure on the LED readout. on the floor.
SPECIAL NOTE: The more downpressure
you use, the faster you will consume
battery power. Use the LEAST AMOUNT
of pressure that will do the job.
SCRUBBING TIP No. 3:
6. To vacuum up the solution: Save the Brushes
Turn on the squeegee and vacuum with the
squeegee switch. The brushes used for scrubbing are plenty
Note that when you turn this switch off, tough, but plenty expensive as well. The less
the squeegee will quickly raise, but the pressure you use, and the less aggressive
vacuum will continue to operate for about
the solution, the longer the brushes will last.
15 seconds. This is to clear the pickup
hose of solution.
Rotate the brushes daily! Move the Right
brush to the left, the left to the middle and the
middle brush to the right.

It is a good idea to rinse off the brushes at

the end of the day, and to remove accumulat-
Page 10 ed wire and thread that may be caught in
them. They are easy to remove.
OPERATING INSTRUCTIONS To Clean the Recovery Tank:

○ ○○
6. To Double Scrub ○○
When you first start using your new scrubber,
you may find the floor of your building espe
cially dirty. It may be necessary to "double
scrub" to really clean the floor. To double
scrub, simply turn off the vacuum system
(raise the squeegee), and slowly scrub back-
and-forth over the same area several times.
Once you have laid down solution, you can
shut off the solution flow with the black knob.
All you need is "enough" solution. Too much
just wastes money.
Use the drain hose at the rear of the machine to
7. Watch Out For Low Battery. empty the tank, then, with the drain hose still in
NOTE: The Central Command unit will cut place, use the "flush-out" door on top of the tank
power back when battery voltage gets toolow. to rinse out the tank. Inspect the tank through the
Low voltage could otherwise damage the airout door. If necessary, you can scrape out the
motors. tank through the cleanout door.

Don't let this happen to you. Return back to

base for a recharge as soon as the battery RECHARGING: SAFETY TIP
gauge shows you nearing empty. Depending
upon the batteries your machine has on 1. To charge the batteries, you must
board, and how hard you work the machine, turn the Key Switch off and
you should have between three and eight disconnect the Batteries from the
hours of run time on a charge. machine. Otherwise you could
damage the Central Command.
8. Reverse the Brushes
To get the maximum life out of your brushes,
exchange the left brush with the right brush 2. Always Leave the Hood (Lid)
each day. Then flip the switch at the rear of open when recharging.
the panel. This switch reverses the center Otherwise, explosive hydrogen
brush. gas could build up inside the
battery box.
By reversing the brushes in this fashion, you
re-sharpen the tips of the fiber, so they clean
more aggressively. You also about double the
life of the brush.
Battery Condition Meter
9. Safety Motor Stop
See Page 4, Item 3.
The Central Command will turn off the
brush motors momentarily if one of them is
This meter shows relative charge. If you unplug the
overloaded. The brushes will turn on by
batteries while the batteries are low, and then replug
themselves if you raise the brush head, and
them into Central Command, you will "fool" the battery
wait 30 seconds before continuing to scrub.
gauge into thinking they are fully charged.
This Safety Stop is most likely to occur if you
To correct the gauge, recharge the batteries, then
start scrubbing on a dry floor with too much
unplug and replug the battery set's Grey 50 connector.
downpressure.

The central brush will stop by itself if over

loaded. The outer two brushes will stop
together if either of them is overloaded.
Page 11
OPERATING INSTRUCTIONS BATTERY SAFETY WARNING!
10. Recharging Battery
Charging a battery produces explosive
Using the Factory Cat Supplied Console-Type hydrogen gas.
Charger:
*Turn off the machine
*Open the battery box. Leave the battery box lid open while the
*Unplug the Red 175 connector between battery is charging to avoid buildup of gas
Central Command and the batteries. inside machine.
*Plug the charger's Red 175 terminal into
the battery pack. Do not smoke or expose open flame or spark
*Leave the battery box lid open during to area around battery during charging.
charging.
*Plug in the charger to a wall outlet with Follow the instructions that came with your
the correct voltage. charger. Tomcat chargers are automatic,
*The charger's charge gauge will show a
However many chargers are not automatic
positive reading.
and can over-heat the battery if not properly
In North America, our chargers are usually equipped set. Such overcharging will void the
for single-phase 110 Volt, 60 Hz. operation, the same warranty on the batteries.
power as used in houses. The three prong-plug
requires a grounded outlet. Do not use without Watch for battery acid! If acid gets in the
grounding. This Factory Cat charger is completely eye, wash out with water for twenty minutes
automatic. Its electronic circuitry will tell it and call a physician.
when the battery is charged, and to shut itself off.

NOTE, however, that if the batteries are Battery Layouts: Battery posts must face as
allowed to run down to below 18 volts, the shown. System is 24 Volts.
automatic charger will not start its charge
cycle. You must then bring the battery
voltage back by charging the batteries twice--that is
letting it run through two automatic cycles. (In this Front of Machine
case, the first charge, which takes three hours, will
bring the battery voltage past 18 volts. The second
charge will put "real power" back into the battery, and
will take about ten hours. - + - +

USING AN EXTERNAL BATTERY CHARGER:

If , for some reason, you use an external
charger, always disconnect the batteries using the - + - +
"Red 175" connector provided. Otherwise you can
seriously damage the Central Command module
and void the warranty.
- + - +
NOTE: Some battery chargers are not automatic, and
will not shut off when the battery is charged. You can
seriously damage a battery by overcharging it.

BATTERY CONDITION METER

(See page 4 for location). This gauge shows
the relative condition of the battery, and
reads like a fuel gauge in a car. Stay above
empty!!!

NOTE: This gauge will reset itself everytime you

disconnect the batteries. To avoid incorrect
readings, recharge the batteries, then disconnect Page 12
and reconnect when the batteries are fully
charged.
 TO RELEASE THE AUTOMATIC
OPERATING INSTRUCTIONS EMERGENCY & PARKING BRAKE:

Brake System: Pull the Brake Release Handle outward as

Model 5100 has two separate braking systems: shown.

For Normal Stopping:

Model 5100 stops quickly and smoothly when the
operator lifts his foot from the foot pedal. The faster he
lifts his foot, the faster the machine stops.

For Emergency Stops and Parking:

In addition an automatic emergency & parking brake is Lever is Under Floor, and Inside the Rear Bumper
provided. This brake operates directly on the transmis- On the Lefthand Side
sion, and affects both the rear wheels. The emer-
gency/parking brake will engage automatically under
any of these three conditions:

1. About two seconds after the

operator releases the foot pedal and
the machine comes to a stop.
2. About two seconds after the key
switch is turned off.
3. If a power failure occurs.

This automatic emergency & parking brake is spring-

engaged. It is released by an electric solenoid. The
solenoid is operated by the Central Command energy
management system.

To Check the Brake System:

Never park on a ramp without being absolutely
certain that the automatic parking brake works
properly. You can check the emergency parking
brake by trying to push the machine on level ground
when the key is off. If you can push it, then the brake
system needs checking. To release brake Pull this lever out and twist to
right to lock.
Releasing the Automatic Brake
Since the parking brake is automatic, Model 5100
cannot and should not be pushed by hand.

If you need to move the machine, and it cannot move

under its own power, you must first release the parking
brake. This is done by pulling on the handle inside the
rear bumper as shown in the right column.

DO NOT push the machine without first releasing the

brake. Do not drive the machine under power with the
emergency/parking brake disengaged.
Page 13
SPRAY JET & VAC WAND
Model 52 is available with the Spray Jet--a pump SAFETY WARNING: Never spray
powered system that permits spraying solution at or near co-workers. The solu-
into remote areas--and a Vac Wand that permits tion in your Model 52's solution
pickup in remote areas--or both together.
tank could be harmful to people.
Both systems are options.
Pump Switch is here

SPRAY JET: System comes with 12 foot hose,

and an automatic pump that responds to pres-
sure in the system. It pulls solution from Model
52's solution tank. Pulling on the "trigger" on the
spray nozzle will automatically turn on the pump-
-when the pump switch is on.

To operate:
1. Turn pump switch on. It is located
under the steering wheel.
2. Pull the black solution flow knob up all RACK STORAGE:
the way.
3. Aim carefully.
4. Pull the trigger.
5. Be sure to turn steering column switch
off after you are done.
6. Never run system dry! You could
destroy the pump!
7. Never let water in pump freeze!
If machine must be stored in freezing
temperature, add antifreeze to
solution tank and let flow through
system.

Problem with Freezing? Call 800 450-9824

Vac hose and/or spray jet hose store on
same rack. A nylon strap at the top holds
items in place.

Clamps are supplied to hold the vac

wand in place. Its nozzle mounts toward
bumper.

Page 14
 Plug Vac Hose In Here
VAC HOSE

The vac hose plugs into the recovery tank and

uses system vacuum. The tool furnished with
the system squeegees up water efficiently.

The first time you use the wand, you must

adjust the squeegee wheels. Use the knob
on the base of the vac nozzle. Set properly,
wheels are set a bit below base of squeegee
blade. Try it and adjust. Should vacuum
perfectly both pushing and pulling the wand.
Adjust Nozzle Wheels so Squeegee
To operate vac wand: works efficiently both pushing and pull-
ing.
1. Unplug Model 52's red vac hose
where it plugs into recovery tank.

2. Plug in the black vac hose to

the tank--and the other end to
the wand.

3. Auto manual switch must be in

manual mode.

4. Squeegee must be lowered (to

turn on vac motors).

5. Put tools back neatly after use. Tie

hose at top with nylon buckle and Knob at rear of nozzle tool adjusts tool
belt provided. Clamp wand securely wheels so squeegee rubbers touch floor
into its two clamps. properly.

6. Plug red hose back into tank.

Page 15
RECYCLING SYSTEM Recycling System
On-Off Switch
This system is optional on Model 5100. It can be
field installed as well as factory installed.

WHAT IT IS
The recycling system is intended to extend the
time the machine can operate on a tank fill by
reusing solution.
(Left Hand Side View of Machine)
This system is intended for use in relatively
clean environments. Dirty water is not as effec-
tive a cleaning agent as clean water.

HOW IT WORKS To access tanks, lift the recycling unit

When switched on, it pumps solution from the
recovery tank, and adds it to the solution tank. A
filter inside the recovery tank removes most of
the grit in the water.

An automatic switch in the recovery tank switch-

es on the pump when the tank is about three-
fourths full. An automatic switch in the solution
tank switches the pump off when the solution
tank is about three-quarters full. (Top View of Machine)

TO OPERATE THE SYSTEM

Fill solution tank as you normally would. The 1
recycling system's cover acts as the door to
both tanks. Unscrew clamps and raise the lid.

You can also, at your option, fill the recovery tank

no more than half full.
2 2
Switch on the switch on the outside of the hous-
ing.
3
When you notice that the machine no longer
cleans satisfactorily, change the water in both
tanks. Solution Tank Recovery Tank
3
TO MAINTAIN THE SYSTEM
Very important: The filter in the recovery tank Explanation: 1 = pump; 2 = magnetic
must be cleaned after every day of use. You float switches; 3 = filter
must never operate the recycling system
with the filter missing.
Page 16
RECYCLING (Continued)

To remove filter for cleaning:

1. Push the button in the recovery

tank hose mount in to release the
lower hose.

2. Lower Hose can now be withdrawn Push this button in to release the
from top of tank. hose clamp that holds the filter.

3. At your option, you can also unscrew

the filter from the hose.

4. Filter is to be washed with clean

water. If necessary, brush filter
screen with light brush, such as a
tooth brush.
(Side View of Recovery Tank)
5. Never use a filter that is visibly
damaged!

CLEANING OUT THE SOLUTION TANK

What goes in must come out. The grit that is fed OPERATING SYSTEM WITH FILTER OFF
into the solution tank will eventually build up. COULD VOID YOUR WARRANTY
Never operate recycling system with filter off.
The solution tank's filter is arranged so that Doing so will clog all downstream plumbing, and
about an inch of grit can build up in the bottom of possibly damage the machine's flow valves.
the tank before the filter is affected.
Take care of the filter, and the system will work
Before the grit reaches this filter, you should well for you. Don't take care of it, and you'll have
clean out the tank as follows: problems.

1. Remove the solution tank filter.

2. Open the solution tank dump valve
(directly underneath the tank on the
lefthand side).
3. Flush out the tank with a hose.

Filter

Solution Tank Drain Valve Location

Page 17
SPECIAL OPERATING TIPS

Page 18
 HOW TO SCRUB

Good Scrubbing Requires:

1. Knowledge of your floor surface. What is it sensitive to? Be careful not

to use chemicals that will hurt the floor surface, or to apply too much brush
pressure or use the wrong kind of brush on your floor.

2. The right chemical. The chemical does most of the work. There are
chemical formulas made specially for General Cleaning, Emulsification &
Removal of Oil, Polishing, Removal of Tire Marks and others.

U.S. law requires that you maintain the "M.S.D.S." sheet that comes with
the chemical you use in a specific place in your plant.

For safety's sake, you must never use flammable chemicals in the
scrubber. Arcing inside the vacuum motors could create an explosion.

For safety's sake, you should not use chemicals with potassium hydroxide in
the formulas if you will be picking up aluminum particles. This material mixes
with aluminum to form hydrogen, an explosive gas.

3. The right brushes. Tomcat can supply you with many different brush
types to suit your application. Four of the most popular brushes are:

1. Nylon. Soft, and long lasting, but can't scrub hard.

2. Poly. Scrubs harder than nylon. Still pretty soft.
3. Nylogrit. Flexible bristles combined with grit.
4. Stratogrit. Tough, non-flexing bristles, combined with grit.
Recommended for tough, industrial applications. Best for
removing build-up.

Brushes are very expensive, but, treated right can have a long service life.
We strongly recommend that you remove your brushes from the machine
after each day's work. Clean them off with cold water. Remove entangled
wire, and etc, from them. Then install them on the opposite side to reverse
the wear pattern on the bristles. This greatly extends brush life, while
improving scrubber performance.

Page 19
4. Brush pressure. You can vary the pressure on Model 52 with the dash
board button. Use as little pressure as will do the job. Excessive pressure
will shorten the machine's run time on a battery charge, can shorten the life
of your brushes, and could even damage some floors.

5. Chemical Residence Time on the Floor. Scrubbing slowly may improve the
scrubbing job you do. By scrubbing slowly, the brushes stay longer over
each square yard of surface, and so scrub more, and the chemical stays
longer on the floor before being picked up by the squeegee.

For especially bad spots, you can "double-scrub". To double-scrub, leave the
vacuum squeegee up and off. Scrub back-and-forth several times until the grit and
grime on the floor has been loosened. Then vacuum it and the solution up.

6. Adjust that Squeegee! When your machine was new, it scrubbed and picked up
perfectly--the best in the business. How's it picking up now? Not so hot? Then
you should check the following:

A. Blades in good shape? The rear blade on the squeegee is especially impor
tant. It can be reversed front to back and from top to bottom, and so can be
rotated four times. Look at the condition of the rear rubber's leading edge. If still
sharp, it should work well for you. If worn flat, it will smear like an old windshield
wiper blade. (See squeegee section of this manual for info on how to rotate the
blades).

B. Pitch angle? The rear corners of the back blade of the squeegee must both
touch the floor. Otherwise, the squeegee will only pick up in the middle of its
path. To adjust, turn the knob. (See Squeegee Section of this manual).

C. All Clear? Scrubbers pick up strange stuff, and lots of it. Is your recovery tank
cleaned out? Is the path clear inside the squeegee? In the hose? In the inlet to
the tank? Remove the vac motors and check the foam filters under them.

7. STILL NEED HELP? Please call your dealer for advice.

Page 20
MAINTAINING YOUR
MACHINE

Page 21
 DAILY CLEAN-UP

After you're done for the day, please lift the brush head with the dashboard switch, lift the
squeegee with the vacuum switch, and push the solution control button all the way down. Drive
to your service area and stop.

Before you turn off the key, lower the brush head a half inch from the top. Turn off and remove
the key. Lift the side wiper on one side of the machine. While lifting it, open the side door.
Once the door opens, then turn the brush on that side until you see the "scissors handles"
control. Push the scissors together to release the brush.

Remove the drain hose from its bracket. Carefully lower the hose to the drain. WATCH OUT--
MOVE TOO FAST AND YOU'LL GET WET. You can squeeze the hose shut with your hand
until you position it where you want it.

Drain the tank. Open the door on top of the recovery tank (the back one), and using cold
water and a spray nozzle, wash the dirt that has accumulated in the tank out toward the drain
hose. If you succeed in cleaning the tank well enough, you do not need to use the cleanout
door.

If the machine is still full of debris, open the cleanout door after the tank has drained its water.
You can use the tool provided with the machine to help scoop out debris. Rinse again with the
hose if necessary.

Rinse off the brushes. Remove any debris that may have gotten caught in them. Remember to
reverse the brushes daily.

Rinse squeegee with water. Wipe off the edges of the blades with a cloth.

If machine needs washing, use a regular garden hose to wash it, not a pressure
washer. Do not spray the dashboard or the batteries. Wipe dry with a soft towel. Do not use
paper towels or dirty shop towels, or you will scratch the powder paint finish. We recommend
you wipe down your machine each day with a dry cloth and a liberal dose of Johnson Wax
Pledge furniture wax (or an equivalent product). This will keep the "paint", (it's really a thin
plastic coating that encases the steel structure to prevent rust), lustrous and scratch free for
years.

Store the machine in a clean dry place.

To recharge batteries, leave the box open, and unplug the machine from the batteries. Plug
the red connector from the batteries into the charger provided with the machine. Use only the
charger provided or an equivalent "smart" charger. Do not use a "dial type".

Page 22
 DAILY PRE-CHECK AND INSPECTION
Before each shift (every eight hours of operation), It is the operator's responsibility to carry out the following
checks and inspections before beginning operation of the sweeper:

* WARNING DEVICES: Battery condition gauge. Green "ignition-on" light.

And on units so equipped: backup alarm, horn, rotating beacon, headlight.

* BATTERIES: Visually inspect connections. Look for spills & Wipe Them Up. Use baking
soda to neutralize spilled acid.

* AUTOMATIC PARKING BRAKE: This machine has "dynamic braking" which slows the
machine until it stops. After it stops, a separate parking brake is set by a spring. This
parking brake will automatically set, as well, if there is a power failure.

If you can push machine when it is stopped, the parking brake needs adjustment.
If machine lacks pep, and appears to drag, the parking brake may not be releasing. Check
manual for inspection procedure, in this case.

If brake fails to release, automatic release mechanism may have an object jammed in it, or
may need repair or adjustment. A dragging brake will result in :

A. Damage to brake linings.

B. Possible damage to traction motor.

* STEERING: Should have no play, and should turn freely without binding.

* CLEAN THE RECOVERY TANK. Drain it completely every day through the drain hose.
Hose out and check condition by looking in the flush-out door on top of the tank. If still full of
debris, open the cleanout door (at back of the tank) and clean out the floor of the tank.

* CLEAN OFF MACHINE: If dusty, clean machine with compressed air. To maintain paint,
use S.C. Johnson's "Pledge" furniture polish and soft cloth, or an equivalent product.
We do not recommend washing, and especially do not recommend pressure washing
this machine as misdirected water could damage electricals.

IF THE MACHINE IS IN NEED OF REPAIR OR IN ANY WAY UNSAFE OR CONTRIBUTES TO AN UNSAFE CONDITION, THE
MATTER MUST BE REPORTED IMMEDIATELY TO THE SHIFT SUPERVISOR. DO NOT OPERATE THE MACHINE UNTIL IT IS
RESTORED TO PROPER OPERATING CONDITION.

MONTHLY INSPECTION

In addition to shift inspections, perform the following each month:

* Check battery charge with an external volt meter. If "fully-charged battery does not attain
at least 24 volts, further investigation is required.

* Grease front wheel; two "zerk" fittings are provided for this.

PAGE 23
 SQUEEGEE AND VAC SYSTEM
The vacuumized squeegee drags on the floor constantly while in use, and so is the most sensitive
part of an automatic scrubber. Lucky for you, Tomcat 5100's 's squeegee and vacuum system are
simple, straight-forward and easy to access.

GENERAL MAINTENANCE: Squeegees pick up all kinds of stuff. When the rubber blades are
dirty, they streak. If you have a wad of newspaper stuck in the squeegee, it may not work at all. If
the squeegee isn't performing right, raise the squeegee (while going forward slowly), and drop it
on the floor again. This may dislodge whatever is stuck in it, and may help clean off the blade. Still
streaking? Inspect the blade. If it is coated with tar or some other industrial goo, you may have
to wash it off or replace it.

ADJUSTMENT: Model 5100's squeegee is self-adjusting except for the "pitch" the angle the
squeegee's blades make with the floor. This pitch adjustment is very sensitive. One eighth turn
left or right can make a difference. Your machine's squeegee should be adjusted to your floor at
delivery. Thereafter, readjustment is seldom necessary. To adjust properly,:
Loosen the two locknuts at back of squeegee adjusting screw.
Drop squeegee to floor.
With vacuum running, drive machine forward so rubber of squeegee flares out.
Turn the Adjustment Knob until the rear squeegee blade touches the floor evenly
across the entire width. At this point the wheels at rear should just start to touch
floor.
Test results on floor.
From this point, adjust squeegee knob clockwise to improve performance on
squeegee edges, and counterclockwise to improve performance in middle.

If squeegee is properly adjusted from a pickup standpoint, but your squeegee fishtails left to right,
try changing the squeegee's trailing wheels. Normally these are changed when blade rubbers are
changed.

REVERSING OR CHANGING THE BLADES: Bad blades don't work. Inspect the blade edge
where it touches the floor. Is it still sharp, or is it blunt and frayed. If worn, you'll have to change it.
Both blades are important. You can reposition Model 52's squeegee blades four times. The back
one is easy: just undo the buckle on the steel strap, and remove the two wing nuts. Turn the blade
upside down for the first change out. For the second one, flip it around front-to-back. For the third
change out, turn it upside down again. For the front blade, there are some nuts to undo. Better to
remove the squeegee from the machine for this one. When the time comes to replace the blades,
order Tomcat's "Blade Kit" for Model 5100. This includes the two blades, and two replacement
wheels for the back of the squeegee.
Squeegees are normally supplied with Gum Rubber, a tan-colored material. If your application
requires that the machine run in oil, you might want to try Neoprene seals instead. Neoprene does
not wipe as well as Gum, to our experience, but it is much more oil resistant than Gum. For
speciality applications, we can supply Linatex rubber seals. Linatex is super abrasion-resistant,
and squeegees well too, but is about as sensitive as gum rubber to oil.
Page 24
 ABOUT BATTERIES:
We do not recommend use of anything but deep-cycle batteries, made to run a long time between recharging.
Automotive batteries, designed to be recharged (by the car's alternator) right after short use, will give poor
service.

Your unit came with a "smart" electronic external charger. If for some reason you use another
charger, do not use a "dumb" or dial-type charger. Do not use an external charger of any type
without first disconnecting the batteries from the Central Command unit!

Always leave the battery box open when recharging. Otherwise hydrogen gas could build up inside
the battery box.

GENERAL RULES FOR BATTERY CARE:

1. KEEP THE BATTERY CLEAN. Dirt on the battery transmits electricity and can cause quicker
discharge.

2. KEEP THE BATTERY WATER AT THE CORRECT LEVEL. The correct level is above the plates,
just to the bottom of the "ring" found inside each of the six cell caps.

A low water level can ruin the battery very quickly. Water should always cover the
plates inside the battery. (You see the tops of them when you remove the cap). Many batteries
have "rings" that are visible inside the cell holes. In these batteries, fill to ring. We recommend you
use only distilled water. The minerals in ordinary water can coat the lead plates, shortening
battery life.
3. CHARGE THE BATTERY WITH THE CAPS IN PLACE. Do not remove the caps for a normal
charge. These caps include proper venting, and will keep the charging process from projecting a thin
layer of acid on surrounding machine parts.

EXCEPTION: Quick-Charging. Follow the instructions that came with the quick charger. You may
be asked to remove the battery caps. Note that quick-charging is not a good idea; it can lower
battery life.

4. ACID! Batteries contain corrosive sulfuric acid. As mentioned above, leave the vented caps in
place when charging, so acid will not bubble out of the battery. Take care that acid does not fall on
the steel surfaces of the machine; eventually it will cause the machine to rust.

Treat acid spills with water to dilute the acid. To clean up: use solution of water and baking soda,
applied with a small brush. Keep using the solution until the fizzing stops. This will neutralize the
acid.

5. MAKE SURE CONNECTIONS TO THE BATTERY ARE TIGHT. Loose connections will cause
arcing, which will eat into and destroy the battery terminals.

6. WATCH THE GREASE. Never put grease on the inside of the connector. The grease will cause
arcing and deterioration of the connector. You can put grease on the outside of the terminal after it
is mounted to the battery.

7. DO NOT HAMMER ON THE BATTERY OR ITS CONNECTORS: Batteries are heavy but fragile.
Hammering on the posts on the battery can break the connectors inside. Use a puller to remove
connectors, not a hammer or a screwdriver.

Page 25
 GENERAL
MACHINE MAINTENANCE
BATTERIES: The highest maintenance item on your
machine will be its storage batteries. Please read the
"About Batteries" section of this book.

BRUSHES: Replace the brushes when they stop scrubbing

to your standards. Note that choice of the proper brush
fiber is very important to good scrubbing. There are
several different fibers available. Rotate brushes often
(every 8 hours of use). TO OPEN THE BRUSH ACCESS DOORS
Fibers include: polypropylene, nylon, Strato-Grit, Nylo-
Grit, and Scrub-Grit. Please ask your dealer for his brush
Be sure the brush-head is mid-point off the
recommendation. floor.

We recommend Tomcat brushes. (Obviously!, you Then open the latch on the door.
say. But there are reasons). They are designed
specifically for our machine and have the right amount of Then raise the Wiper off the floor so it
bristle to maximize performance. Their solution feed unhooks from the scrubhead.
holes are located in the right spot. They are concentric
(oval brushes, and most will-fits are oval, damage the Then open the door.
motor drive gears). Their fiber is high quality and long-
lasting, and use plastic cores with integral clutch plates
that are tougher than the wood cores + bolt-on clutch Looking Down on the Brush Head
plates most "will-fit" makers provide. The clips that hold
them on have the proper spring tension and don't fall off.
Finally, we believe you will find them reasonably priced.

INSTALLING BRUSHES: The Easy Way

Clip one side of brush mount to the "driver" (the part

on the machine). Then push up the opposite side.
1. Clip on one side of brush to driver.

Push "Scissors" Together to Release

REMOVING BRUSHES:
Turn the brush until you see the
"scissors handles".

Then push the scissors handles together,

2. Then, push down on that same side of and brush will fall to floor.
the brush.

3. Brush will swing up and latch on! Page 26

SCRUB BRUSH DRIVE SYSTEM GEARBOX NOTE: The gearboxes will run hot
for their first few hours of operation, as their
The scrub brush drive system has three electric gearsets break in. During this time, the gear-
motors, each coupled to a worm-gear drive box. boxes will soak up extra motor energy as well.

The motor brushes should be changed every You should notice considerably less generation
2,000 hours. of heat after the first 8-10 hours of operation,
and better scrubbing performance.
The gear drive box oil should also be changed
every 2,000 hours. Gearbox Oil: Use only Worm-gear lubricants.

Your authorized dealer can perform this mainte- Recommended:

nance for you. Shell Omala 460
Mobil Extra Hecla Super
If you have lost contact with your dealer, or if you Texaco Meropa 680
wish advice on how to perform this service
yourself, you can call the Factory Service Tollfree Fill to halfway point by using the half-way
Hotline (800 634-4060) for advice. plug

Page27
TROUBLESHOOTING GUIDE

Page 28
CENTRAL COMMAND

Model 5100 Rider Scrubber is very simple mechanically.

This simplicity is possible in large part, because of the
sophisticated "Central Command" control unit. This
unit, which forms the righthand control panel, directly
controls the brushes, the recovery vacuum blowers, the
traction motor, and the dynamic and parking brakes. To
conserve battery reserve power, Central Command
turns motors off when they are not needed, and controls
Wiring Connections for
them so as to minimize strain and maximize compo- Central Command:
nent life. In replacing Central command, the installer will have to match
harnesses. To simplify troubleshooting, the system uses 10
Do not attempt to service the Central Command independent number-coded harnesses, each with color-
unit during the warranty period without written coded wires. These harnesses are as follows:
permission of the Factory or of your Authorized
Tomcat Dealer. Doing so will void the warranty. CODE: FUNCTION & WIRES:
1. To Traction Motor
Red 50 Connector. 6 Gauge cables.
2. To Scrub Motors
Red 50 Connector. 6 Gauge cables.
3. To Vacuum Motors
Grey 50 connectors. 6 Ga. Cables.
4. From Batteries
Red 175 Connector, large (I/O)
cables.
5. Auxiliary Harness
4 Thin Wires Together; 4 prong
"Molex" Connector. This is for
accessories. Your machine may not
use this harness. Wire colors are blue,
red, black and white.
6. Foot Pedal Harness
3 Wires with black outer
insulation; 3 prong Molex. Colors,
green, white and black.
7. Brake Solenoid and Cooling Motor
Harness
4-Pin Molex. Colors are blue, black,
red, black.
8. Solution Valve & Overflow Switch
Harness.
Four-pin Molex with Green, Yellow,
black and orange wires.
9. Squeegee Harness:
4-pin Molex. Colors: pink, orange,
green and white.
10. Scrub Head Actuator Harness.
Four pin molex, wires colored yellow,
When Servicing Central Command, blue, white, pink.
Always Disconnect the Battery Cable
(Item 4) First, and Reconnect It Last
Page 29
 ACCESS TO EXTERNAL
WIRE CONNECTIONS

If a wiring fault occurs, chances are greater it is

in the wiring leading to the Central Command
unit than in the Central Command itself. To Access the Wire Trough
Open the Right-Hand Brush Access Door
To make your Central Command unit easy to
service, we have made all harnesses that lead
to the Central Command so they are easy to
disconnect.

But scrubbers do their work in dirt and water and

corrosive chemicals, all of which are harmful to
electrical connections.

These connections are therefore housed in a

"trough" found directly under the Central Com-
mand unit, and protected by a frame rail and the Wire Connections are Behind This
floor on two sides, and by a cover on the other Frame Section and Are Accessed
two sides. From Behind

Should you need to, you can access the connec- (Cut-Away View From Front)
tions in the trough by removing the cover. Be
careful when reinstalling this cover that Wires are in this channel
you do not cut any wires. Each harness
inside is numbered as shown on the previous
page.

The connections are coated with Conformal Trough is held in

Coating, a modern version of Cosmoline, de- place with two nuts
signed to keep the connections dry, and to keep
any detergent solution from corroding the metal
terminals. If you service a connection, you
should re-coat it with Conformal Coating, which
sprays on. This can be obtained through any
electronics supply house, or through the Tomcat
Parts System (Conformal Coating Part No.
5-299).

Page 30
MODEL 5100: BASIC Troubleshooting Guide
GENERAL: Model 5100 is mechanically simple, but has a sophisticated "brain" to operate it in the
form of the Central Command unit. This unit should be as reliable as the microprosessor for a
modern automobile.

In most cases, the big question is to determine if the problem is :

A. Mechanical, or
B. Electrical, but in the wires or devices.
C. Electrical, inside the Central Command.

If your problem is not easily solvable, please call us at 1-800-450-9824. We can put you in touch
with your local dealer.

ELECTRICAL PROBLEMS

1. Key On, But Nothing Happens: No Noise, No Action--Nothing!

A. Operator is familiar with machine and knows that you have to step on the foot
pedal before anything will operate.

B. Battery Set is properly connected, and puts out at least 24 Volts. (24 volts is dis
charged; 25.6 is fully charged; deep cycle batteries provide most of their run time
between these two voltages).

C. Battery is load checked. Battery must not drop below 20 volts under load.

NOTE: Central Command is extremely fussy about wire connections from the
battery into it. A half-loose connection is sensed by the electronics and will
not allow the machine to operate. Check and double check the battery connections!

D. All Following Wires are Connected, Unbroken and Tight.

1. Wires From Central Command to Traction Motor. (Inside wire trough)
2. Battery Cables To Central Command. (Inside battery box).
3. Foot Pedal Three Wire Cable to Central Command. (Inside wire trough).

E. Unplug the Battery Pack (Red 175 connector inside battery box).Then, carefully
remove Sidel Panel from Central Command. Reconnect battery box. Check
for voltage to and from the keyswitch.

F. Call Dealer Page31

MODEL 5100: Troubleshooting Guide
For each symptom, run through steps in order shown.
Electrical Problems

2. Key On Gets "Click", and Green Light Comes On, But Stepping on Pedal gets
No Action.

A. Check the batteries. Central Command will shut down the traction system com
pletely if voltage is at 16 volts or below, and will slow the machine to 20% power at 20
volts or below. The system reads the voltage under load, and so should you to test it.

B. Be sure pedal wiring is tight and unbroken. This is the three-wire set going
into the Central Command. The wire is integral with the foot pedal. (Connection is
in the wire trough).

If you think the pedal is defective, please call your dealer for test procedure to
verify its condition.

C. Most likely problem inside Central Command is one of the the relays, rather than the
brain box. Call your dealer to have him check them.

3. Machine Runs Fine in Forward, But Cannot Be Shifted Into Reverse.

A. Remove Rear Control Panel from Central Command and Check Connection to
Forward-Reverse Switch. This switch receives power from the key switch, and
sends it back to Central Command's microprocessor. No power = forward; power
on = reverse.
B. Check Switch Output.
C. Call Dealer.

PAGE 32
Model 5100: Troubleshooting Guide For each symptom, run through steps in order shown.

Electrical Problems

4. Traction Circuit Runs Fine, And one or more, but not all of the Following Work
Properly: Vacuum Motors; Brush Motors; Parking Brake Release.

Check each defective circuit as follows:

A. Vacuum Motors.

1. MicroSwitches. The vac motors shut off when the squeegee is raised. The
squeegee actuator unit has two microswitches on it, one (on the lefthand side ) serves
to turn the vac on while it and the switch on the right side serve as well to turn the
actuator off at each end ofstroke.

2. Wiring from Central Command. Check continuity between the motors and the
Central Command's output to the vac motors.

Connection is made inside the Wire Trough. Wires then go through the air duct
inside the solution tank to the vac motor housing atop the solution tank.

B. Brush Motors.
Check first to be sure the problem is electrical. It is possible the plastic "clutchplate' on the
brush is damaged.

Note too that if there is too much pressure applied to the brushhead on an abrasive or dry
surface, the motors will not have enough power to start, and so will kick off the circuit
breaker inside Central Command. This will reset itself when power to the brushes is turned
off for more than 30 seconds. Just raise the brushhead.
.
Microswitch. There is a microswitch on the brushhead that turns the motors
on. It must be checked out. It is situated on the brushhead on the right hand
side. Access it through the brush access door.

C. Parking Brake Solenoid

This solenoid, accessed by removal of the machine's lefthand rear side panel, is
mounted to the transmission. The transmission's disk brake is spring applied; the solenoid
pulls the brake lever against the spring into released position--straight up and down.

The solenoid has two wires coming to it--a plus and a minus. Both wires come from Central
Command.

1. Check that the wires to the solenoid provide 24 Volt power when the key is
on and the pedal is depressed. (To do this, you will need to jack up one of
the rear wheels off the ground and remove the righthand rear side panel).

2. If power is OK, check the solenoid.

3. If power is not OK, the problem is most likely in the 6 amp breaker inside the
Page 33 Central Command. Call dealer for advice.
Model 5100: Troubleshooting Guide For each symptom, run through steps in order shown.

Electrical Problems
5. Machine Works Well Otherwise, But Insufficient Tractive Power.

A. Is operator used to the machine? Is it developing its normal power?

B. Machine has lost most of its power--power loss came on very suddenly.

Batteries are down. Central Command will automatically reduce available

power when battery voltage drops below 18 to 20 volts. Recharge Immediately..

6. Charger Does Not Charge

The automatic, electronic, console-type charger responds to the battery's condition. It rarely fails.

We note that: If the battery is already charged, the charger will switch on for only a few minutes
before stopping the charging cycle. If the battery is very discharged (below 18 volts at time the
charger is turned on) the charger will not "see" that batteries are connected, and will not give the
batteries a real charge.

However, every time you turn on the charger, the charge cycle finishes with a three-hour "de-gassing"
cycle, in which dissonant wave frequency current is introduced at high voltage (about 29 volts) and low
amperage . The degassing cycle does not add "charge" to the battery, and should not be confused with
charging.

If you have too low a voltage at the batteries for the charger to charge properly, charge the batteries two
times. The first "de-gas" charge (which lasts three hours) will bring voltage up to 18 or so, while the
second charge (which can take 10 hours), will bring voltage up to full charge.

Preliminary System Checkouts:

1. Are batteries full of distilled water? Water should be halfway between plates and ring.
2. Are all connections tight?
3. Check system voltage: Above 18 volts?
4. Remove harness from batteries. Check voltage. Do all batteries have voltage above 9
volts?
5. Are batteries two years old or newer? If not, then check out with resistance check.
6.. Do you have proper electricity to the charger? Is this power source uninterrupted, or is it
shut off accidentally at night when the lights are shut off?

Please Call Your Dealer For Further Info

Page 34
 SPARE PARTS SECTION FOR
Factory Cat Model 52
Tomcat Model 5100
Factory Cat & Tomcat spare parts are sold through franchised dealers. If you have forgotten
your dealer's name, or have moved the machine to a new location, please call us at 1-(800)
450-9824, or FAX us at 1(262) 632-6961, and we will re-establish dealer contact for you.

TO ORDER PARTS:
Please give Machine Serial Number with your order. Normally, ordinary parts orders are
shipped out the same day received.

EMERGENCY ORDERS:
Within the Continental United States, we can supply any part that weighs under 70 pounds
within 3 workdays, not counting weekends or National Holidays.

However, if parts are ordered on an "emergency" basis, this means that the Factory will ship
them by fastest means, generally by air courier service.

The emergency service is for breakdowns only. Please do not use it to order stock items.

FREIGHT:
Within the United States, normal shipments are shipped by customer choice of shipment
method, while emergency shipments are by Factory's choice--normally by fastest means. This
means that emergency orders will generally cost the customer more than normal ones.

In both cases, the customer is responsible for payment for freight.

Page 35

Copyright 2001 RPS Corporation. World Rights Reserved

For a detailed list of transaxle parts within Transaxle 8-604, please refer to
pages at the back of this section.

NOTE: This transmission was supplied on units

built thru December, 1999. All serial numbers
before 52-2000 had this as standard, but many
units were field-converted to the new transaxle.
Note: This transaxle was installed on all units beginning with January,
2000 production and with serial number 52-2000. However many units
were retrofitted in the field with this transaxle design. To be certain
ask the customer if the drive motor is between the tanks or under
the floor.
Note: This transaxle was installed on all units beginning with January,
2000 production and with serial number 52-2000. However many units
were retrofitted in the field with this transaxle design. To be certain
ask the customer if the drive motor is between the tanks or under
the floor.
NOTE: This transaxle was used on Model 52/5100
through December, 1999. Units with Serial 52-2000
and beyond have the "new style" axle shown after
Page 61 of this parts manual.
NOTE: This transaxle was used on Model 52/5100
through December, 1999. Units with Serial 52-2000
and beyond have the "new style" axle shown after
Page 61 of this parts manual.
NOTE: This transaxle was used on Model 52/5100
through December, 1999. Units with Serial 52-2000
and beyond have the "new style" axle shown after
Page 61 of this parts manual.
NOTE: This transaxle was used on Model 52/5100
through December, 1999. Units with Serial 52-2000
and beyond have the "new style" axle shown after
Page 61 of this parts manual.