HYDRAMASTER AQuaCat 3.9 User Guide

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HGauaCat

HYDRA##!iiS-EY%

3+9

Corporation

AquaCat(fiontview.featureslabeled).......................t.............................8

AquaCat(sideview.featureslabeled).............................................t.........8

CatPumpModel290

DismantlingCatPump

VanguardOHVEngine.........................................................................2l

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HOURS

Monday -- Friday

8:00 am To 5:00 pm

PACIFICSTANDARDTIME

GENERAL INFORMATION

'l~oodlnstallation (ontmckbed)..............................................................4

4strotuti installation..............................t.......................................c....l.4

Machinebnfiguration ........................................t......................................5

~ru.floorGas Hook.upandlnshllation...................................................5

WaterHardnessMap............................t................................................6

WaterSofienerMok.up.............................................................................6

WATER & CHEMICAL SYSTEMS

AquaGtWaterFlow ............................................................................lO

ChemicalPropotioningandLeveltintrol ..............................................lO

CAT PUMP

PumpingSectionCut.awy .................ll......4..c............l.......j....+o.4(..q4...l3

PistonModel290ExplodedMew...

BypassValveNsemb& .........................................................................l7

AquaGtWaterFlow ..........................................................................l7

VACUUM SYSTEM

Vacuum Flow............l..l...l.................4......c..........................c....l..l...l8

VacuumTankRlterBag...........t............................................................l8

BlowerLubePoR..................................................................................l8

VacuumBlowerMotorLubrication.........................................................2O

VANGUARD OHV ENGINE

OilMscos~Chti ...................................................................................~

OilRllandUpStick......................t.........................................................~

EngineComponenk..........................................................................~

EngineComponents(continued)

CarburetorAdjustmentScreW........t....................................................23

GovemedldleSpring...............................................................................23

Oil Filter/ Oil Drain

RoundDualArCleanerElement...........................................................24

SquarehalNrCleanerElement ...........................................................24

RoundDualElement.........t.................................................................25

CoolingSystem..

Sparkplug..............................................................................................25

FuelFilter................................................................................................25

ELECTRICAL SYSTEM

ElectricalElagram

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ROCK MT.

TELEPHONE NUMBERS

(206)775-7272 (206)775-7276

(206)775-7275 (206)771-7156

G 1991HydraMasterCorp.

Printedin U.S.A.

.~<jj$~.’

CENTRAL

GeneralOffices Parts Department ServlWarranty

FAX

“Yl:;j’%

EASTERN

CLEANING & CHEMICALS

pH~afl ..................................................................................................W

CleaningSkokeMethod.....................t.................................................~

CLEANING WAND

WandValve~sembly .......................................................................~

Jetksembly ..........................................t....t..........................................~

Wand%sembIy....................................................................................~

GENERAL INFORMATION WarningandCaution

HowtheSystemsWoks ...........................................................................2

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Naming:DONOT

Naming:DO...........................................................................................

3eforeStartfng

2ilRecommendations.............................................................................

‘uel Recommendations :arburetorAdjustments

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..........................................................................23

..........................................................a.t.............23

21 22

~draMasterHoum& PhoneNumb~ ....................................................2

AquaCatMactine Spcifications ............................................................3

Purchaser’sResponsibiiii

SalesRepresentative'sResWnsibilw....................................................4

TruckPreparation

PlacementofUnitinVehicle......................................................................4

TruckPreparationillustration.................t.................................................4

Machineinstallation................................................................................5

S~re PaflsRecommendation..t...............................!.............................5

PartsOrder,.,,...4.....!..................................!,,......................!......................

HardWaterAreaMap

WaterSofiener.........................................................................................6

WastewaterUs~salAWlso~ .......t.........................................................6

AQUACAT 3.90 PERATING INSTRUCTIONS

Sta~Up. ...............................................................................................8

Shutmw ........................t......................................................................8

FloodDamageWork .

OPERATING PRECAUTIONS

MachineAdjus~enb .............................................................................9

Cautions and Warnings................................................................9

WATER & CHEMICAL SYSTEMS

Water/~emicai FlowO~ration ...............................................................g

AquaUtWaterFiow. t....t.....................................i...............................lO

ChemicalSystemMaintenance ChemicalTankTroubleShootingGuide

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:NGiNEMAiNmNANcE .........l.....r$o...................................................24

3iiChange

Nr~eanerMaintenance ........................................................................24

:Iean Engine,RotatingScreen,CoolingSystem,SparkArrester..........25

~epiaceSparkPiugs,ReplaceFueiFilters EngineMaintenanceSchedule SeneraiInformationaboutEngine

3toragelnstiudons ................<......c......l..............c..l......l.......t.t.l....o...$(.27

3ewice& Repairinkrmation...................................t..............................27

UanguardEngineWarranty

SuprsedingWarran~ ....................................................................!28

UmtiedWarmn~forVanguard ~gines ..................................................28

Waran~Period .....................................................................................29

ENGINETROUBLESHOOTING............................................................W

ELECTRICAL SYSTEM ElectricalSystemandTroubieShootingGuide

FREEZE PROTECTION AquaCat

CLEANING & CHEMICALS

Precautions

CleaningStrokeProcedure/Over.Wetiing............................................W

CLEANING WAND

Wand,Jet%sembly&WandAsembiy Paflstists ................................W

MAINTENANCE Procedures

OverallCareofUnit..................................l..................................o.....oct..

MaintenanceLogs........................................................................37.38

...........................................................................<..............24

..,,..,..,,,,,.,.,...........................25

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.....................................................................28

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CAT PUMP

CatPumpMode12900~ ratinginstmctions...........................................ll

CatPumpSWcifiMtions ................t....cc..l..cc..c.........t........................l...ll

GeneraiinfimationhrCat PumpRepair................................................l2

SewicingtheDschargeValves& ValveSeats.........................................l2

Sewicingtie PumpingSection.........l.............................l.......................l2

SewicingSleevesandSeals..............................................................l2

SewiceKk...c.......c.(.......o...........r....cc...l............r..................l..............l3

Modei2WPafls Dst..............................................................................l4

CatPumpTroubie ShootingGuide...............................................l5.l6

HighPressurePumpTroubleshootingGuide

BypassPatistist ...................................................................................l7

VACUUM SYSTEM

Information

VacuumTankHlterBags..................................t.....................................l8

VacuumBlowrTrouble ShootingGuide..............................................ls

VacuumBiowerWaman~...................................................................2C

VacuumBiowerLubri@tion................................t.................................2C

VANGUARD OliV ENGiNE

Operating&MaintenanceforModel303400(16HP)Engine.......21........2l

internationalSymbolsUsedinthisManual...........................................2l

InTheInterestofSafety

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.........................................

HYDRAMASTER WARRANIY Warrantyinformation

Waman~Procedure................................................................................39

HowtoOrderParts PartsOrders OneFinalNote

AquaCat LimitedWarranty Plan.................t......................................4O

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39 39 39

This manualcontains installationand operation instructionsas well as informationrequiredforpropermaintenance,adjustmentandrepairofthis unit, Sincethefirst and mostimportantpart of repairworkis the correct diagnosisofthetrouble,ageneraltroubleshootingsectionandcomponent manualtroubleshootingchartshave beenincludedforyour convenience.

Unlikeagardentractor,lawnmowerorcementmixer,allhavingoneortwo functionsto perform,the truck-mountedcarpetcleaningplanthas many functionsto performsimultaneously.

*Engine hasto run ata consistentRPM, *Vacuum hasto pullair anddirty water backfromcleaningsite.

*Water pumpprovidesstablepressure atproperwaterflowforcleaning.

* Chemicalhasto beinjectedinto the waterstreamat the

right concentration. * Heatermustmaintainproperheat. *Vacuum tank muststoredirtywater until drained.

l%ere is no guess work in the manufactureof these highly advanced cleaningplants,Iikewke, theremustbenoneinpreparingitto getthejob done in the field. It is the purpcse of this manualto help you properly

understand,maintainandserviceyourcleaningplant.Followthedirections carefully and you will be rewardedwith years of profitabletrouble-free operation.

Itisimperativethat nosectionbeoverlookedwhenpreparingforoperation of thisequipment,

AQUACAT MACHINESPECIFICATIONS

FRAME: 21”W, 56” L, 28” H.Steelwith baked-onepoxyfinish,

As youcan see,it is notjust aturn key operationwithone thingto wony about,Does It start?l

The manufacturer uses this symbol throughout themanual to warn

of possible Injury or death.

Thki symbol k used to warn of possible equipment damage.

HOURS

Monday -- Friday

8:00 am To 5:(HI pm

PACIFICSTANDARDTIME

TELEPHONE NUMBERS

(206) 775-7272 General Offfces (206)775-7276 Parts Department

(206)775-7275 ServiceAVarrantv ~20~ 771-7156 FAX “

HOWTHESYSTEMSWORK

THE AQLIACAT’3,9 SYSTEMWORKS AS FOLLOWS: The AquaCat3.9 HighPerformanceHeat Exchangersystemis a highly engineeredcleaningplant,designed by HydraMasterCorp.The system utilizesadynamicheatingsystemcomprisedoftwoseparateexhaustheal exchangersfor capturing“free heat”.

Waterisfedintothemachineattappressure.Itiscombinedautomatically withcleaningsolutionasitentersthemixtank,Thesolutionisthenpicked up by thehigh pressurepumpand pressurizedto the desiredlevel.The solutionthentravelstothe bypassassemblywhereit isdistributedoutto

the wand and back into the machine, The solution goingback into the machinesplitsflowandtravelsthroughthetvmexhaustheatexchangers.

After beingheated,the solutionreturnstothe mixtankwhere it is picked

up bythe pumpagain,

Whenthe cleaningsolutionreachesa pre-settemperature,it isreleased fromthesystemanddirectedto the recoverytank,hen cool waterenters the systemto regulatethetemperature,

WEIGHT: 500Ibs.complete.

COWLING: Steelwith baked-onEpoxyfinish.

ENGINE:16HPBriggs&StrattonV-Twin,steelsleevedcylinders,ducted.

IGNITION: Magnetokeystafl, solid stateignition.

HI-PRESSUREPUMP:Tri-Plexpiston--Cat290-- 3.5 GPM

--1200 PSI --(Q1200 RPM.

VACUUM BLOWER: 3LFSSutorbiltw/12HGsafetyrelief.

CHEMICAL SYSTEM: Electro-mechanical,flow metercontrolled.

HEATER: 2stainlesssteel exhaustheatexchangers.[shellandtube

for engineand blowerheat]

INSTRUMENTS:0-1000Highpressuregauge,Temperaturegauge,

Vacuumgauge, Hourmeter,Chemicalflowmeter,

Ignitionswitch.

RECOVERYTANK: 70 gallonmarinegradealuminum,epoxyfinish.

CLEANING WAND: Stainless steel 11” with heat cover handle, and forwardguide handle,

HI-PRESSUREHOSE: 1/4”High-temperatureIinedvkrylcovered,safety

orangewithbrassquickconnects.

VACUUM HOSE:2“ Reinforcedsafetyorange.

1 It? reinforcedsafetyorange.

STANDARDEQUIPMENT Powerconsole,Soundsuppressionpackage, Leveltemperatureexchangeheater,Vacuumrecoverytank,Carpetcleaning wand, Chemicaljug, Chemicaljug holder,OwnersManual,100’-2 vacuumhose, 10’-11/2”vacuumhose,1CQ’Super-flexsolutionhose,10-

1 1/2”drain hose,Batteryboxwithholder,Fuelsystemkit,Vandecal,Van

installationkit.

DESIGNCHANGES:This informationis accurateat thetimeof printing, However, the design and specificationsof HydraMasterequipmentare subjectto continuedchangeand refinement.

PIACEMENTOFUNIT INVEHICLE

THEREARETWO RECOMMENDEDUNITPLACEMENTS: A.SIDEDOOR:Mostinstallationsaresidedoor,Thisprovidesrearaccess for accessoriesandhosesaswell asunobstructedaccessto componenff workingsideofmachine,thusmakingitabiteasiertoperformmaintenance and/orrepairwithoutremovingunit fromthe truck,

B.REARDOOR:Althoughthislocationpartlylimitsworkingaccess,itdoes

directthenoiseawayfromthecleaningsite. Somecleanersinthecolder areaspreferthis locationbecauseit puts the weight massover the rear wheelsfor bettertractionin iceandsnow,Rearmountingrequiresthe unit tobeslidtotherightsideasfaraspossible.l%isnotonlyprovidesadequate workingspaceon the componentside of the unit but alsomakes better weightdistributioninsidethe van (engineand componentweightline up overdriveshaft).Also,itisphysicallyeasierto load unit into reardoordue to heightofvan bed,

Ensure that machine is well secured to the floor of van with hardware supplied. Sudden or crash stop willcause machine to sliderlmvard,,.. all

500 /bs.worth!Protect yourself and the machine. SECURE lTI

TRUCKPREPARATION

[ILLUSTRATION

FIRST,coverthetruckbedwith!Y8”plywoodusingmetalscrewstosecure it asshown.

PlyWoo

connectingallgasolinelines;connectingbattery;checkingpump,vacuum dower and engineoil levels, prior to startingunit; startingunit to check mgine toseethat allsystemsfunctionnormallfi alsocheckingallhoses, wands,etc.,for correctoperation,

TRAININGSHALL INCLUDE:Thoroughreviewofthe operationmanual NWpurchaser;instructionandfamiliarizationin:howto correctlystartup andshut downunit howto correctlycleanwith the unit how, whereand how often to check and change component oil levels; how the unit’s systemswork;howtotroubleshoottheunit howtodobasicrepairs;safety precautionsandtheirimportance;freezingdamageandhowto avoiditand athoroughreviewofthe unitwarrantyandwarrantyprocedures.

TRUCKPREPARATION

Themanufacturerrecommendstheinstallationofplywoodflooringcovered withpoly propylene backedastroturf (donot use rubber-backed)in the vehiclepriorto installationof machine,This providesa ‘metal-to-cushion’ mountingratherthan metal to metal,provides insulationand makesan attractivevan interior.Astroturfshouldbe colorkeyedto vaninterior.

MaterialsNeeded:

1.2 sheets4x8x5B”exteriorplywood

2.flxl 2’piece ofcommercialastroturf

3.16-1 lPMsheetmetalscrews

4.1 quart marineadhesive(optional)

5.1 staple hammerwh’z” staples

Seeillustrationfor conectplacementof woodfloorin

lWRCHASERISREsPckIBILii

PRIORTOARRIVAL OF UNIT

1.Install5/8” exteriorplywoodflooring invehicleand coverwithartificial turf.

2, Purchase heavy duty 42-60amp hour battery and have battery Wow’

charged if new, If baltery is not fully charged damage can occur to the engine charging regu/ator.

Selectthe appropriatecolor astroturfto match your van and cover the plywoodandstapleinplace.Astandardvanrequiresa piece6 feetby 12 feet.

AstrohIti SALES REPRESENTA7%’E’S

RESPONSIBILITY

ACCEPTANCEOF SHIPMEN’E

1. If unit showsany outwardsigns of damage, do not sign the delivery receiptuntilyouhavecloselyinspectedthe unitandmotedanydamageon thedeliveryreceipt.Havethefreightcompanyrepresentativeacknowledge

the damageby signingthe notationof damageon thedeliveryreceipt.

2. l%e salesmanfrom whomyou purchasedyour unit is responsiblefor supervisingthecorrectinstallationoftheunitinyourvehicleandthoroughly trainingyouin itsoperation,maintenanceand preca~”ons,

CORRECT INSTALLATION INCLUDES: Installation of through-floor fittingsforgasolinefuellines; securingthem withbottsortie downcleats;

READINGOF OWNERSMANUAL: It is thepurchasers responsibility to read the unit operation manual and to familiarize himself with the informationcontainedtherein.Special attention should be paid to all CAUTIONSand WARNINGS.

MACHINEINSTALLATION

Therearetwolocationstoplacethemachine,intheside door or intherea door,asmentionedinthesectiontitled “Placementof Unit,”Thestandart waytoconfiguretheunitis,asshown in theillustration,with therecove~ tankbesidetheunit.Analternativemethod,notshown,wouldbetoputttv recoveqftankbehindtheunit.(Thestandardmachinedoes notcomewftl enoughhardwaretoallowformountingofthetank behindthe machine.I thisconfigurationischosenpleasecontactHydraMasterfor moreinforms tion,)

HydraMasterrecommendsthat the exhaust for the machine be pipe{ throughthefloorofthevehicle.Itis importantthat the machine be place{ ascloseto thedoor aspossibleso that outside aircan be pulledintoth[ engineforpropercooling.

Machhe Configuration

;PAREPARTSRECOMMENDATION

?causeyourtruck-mountedunitiscapableofgeneratingseveralhundred JIlarsper day,down-timeon the unit can bevery expense, Inorderto inimizesuchdown-time,itisstronglyrecommendedbythemanufacturer atyou purchaseand keepinyourtruck the partslistedbelow.

Jexpedite your parts needs, please call your sales representative. Inmost instance,heeitherstocksorhasacce~stopartsthr~ugharegional servicecenter.Intheeventpartsareunavailablelocally,contactthefactory andcoordinateyourneeds,Ifthisbecomesnecessary,alwaysindicatethe methodof shipment you desire, i.e. UPS. Blue Label, Air Freight,Air Express,etc.HydraMasterPartsDepartment.Phone(206)775-7276.

/t is recommended by lhe manufacturer that the exhaust from the front c the machine be vented down under the truck to prevent carbon monoxid, from entering the job site. Always park the truck so the exhaust/. blowhrg away from the job site.

Never operate thismachine withaportable propane tank oraportable ga can inside the truck, doing so increases the risk of a tire or explosion.

Mount afire extinguisher just inside the rear or side door for emergencies

HARDWATERAREAMAP

The quality of water varies greatiy throughout the United States ant

influencesthereliabil”~andefficiencyofequipmentindirect proportiontf itslevelofhardness,Themapbelowdefinesareaswhichcompromiseflui[ relatedcomponentssuchashoses,fittings, heaters, pumps,valvesan~ watercooledengines.

108-030 Enginespark plug

049-012 049438 049-014 078-015 Flow meter kfi 078-024 Wand valve plur 078434 076-005

0764)03 049-028

$9-023

784Q4 Cat 290 hot cup kit AquaCat

52-050

57-051

.. .. .

52452

52-053 660 F

1rmxl

.- ---

Round air cleaner Square engine air cleaner Ermine oil filter

ngerkit

Pressurebypassvaive kti

Spray jet 8006E

Spray jet 8004E

Recove~ tank filter b: Screen, garden hose

440 Male auick conn~

Female quid connect

440

660 !

We quick connect ‘emale quick connect

Rdtrmmo driie Ax-25 1

--.. r-...r

—

,,,,,-”.

HARD WATER AREA MAP

BobCat

AquaCat

2 1 1

1 1 1 1

6 1

f 1 1 1

Cleaningefficiency and equipmentlife is increased, chemical use de creasedand the appearanceof cleaned carpets enhancedwhen wate softeners are incorporatedin hard water areas. Manufacturer strongl urgestheuseofwatersoftenerunits inareas exceeding31 /2 grainspe gallon.Usingthe legendasa reference,determinethe qualityof wateri! your areaand take actionimmediatelyshould it be necessary. Wate SoftenerHook-up WaterHardnessWATERSOfTENER Manyareasof thecountryhaveanexcessof mineralsin the waterwhicl resultsinwhat is commonlycalled“hard water”,These mineralstend t[ adhere to the insides of heater coils and other parts of the machine causingdamageand alossof cleaningeffectiveness.

Reportsfromseveralofourmachineuserscommendingtheresultsofth useof watersoftenersin conjunctionwith their machines promptsust recommendthe proceduretoeveryonein a “hardwater” area.

GRAINS PERGALLON

~] 0-3/2 H 7-10/2

- ~/,-i’ _

10%ANDABOVE

START UP 1,

Performdaily/periodicmaintenanceasspecifiedinthis OwnersManual

(page36).

2. Connectall requiredhoses.

3. Connectcleaningtool tolength ofhose requiredto performcleaning.

Hour Meterl

Gauge

Pressure

Gauge

.JM#%#\ 1

Vacuum

,Gauge

4. Mixtank musfbe fullm’iortoiar?ition.

5.Startengine (chokeasrequired),Engineis atoperatingspeed (recommended-3000RPM).Allowwarm-upperiodof 2-5 minutes.

6. Spraywandtovoid allairfromsystem.Whenthe mixtankbeginsa fill cycle,thechemicalflowmetermaybeadjustedto yourdesiredsetting.

NOTE:Chemicalflowmetersetat5GPHisa 1to 30mixratioand 10GPH

is 1to 15ratio.Whenflowmeteris setatIOGPH, you will beusingwhat

mostchemicalmanufacturersrecommendat 5 GPH.

Run machine for severalminutesunderload(8to10“ HG)until desired

7. temperatureisacheived.

& Commencecleaningoperation, NOTE: Recommendedcarpetcleaningpressureis 250-300PSI.

SHUT DOWN

1. Removevacuumhose.

2. Flushclear water throughchemocalsystem for 10 seconds (vinegar shouldberinsedthroughsystemweekly).Turnoffchemicalflowmeter.

3.Turnoncleaningtooltoflushchemicalfromunithosesandcleaningtool.

NOTE: Iffreezeguardis necessary,performsteps1 &2 offreeze guard

procedureatthis time(page32)

6.At thistime, the blowershouldbe lubricatedwith LPS1.

7. Shutenginedown.

8.Drainvacuumtank.Vacuumfiltershouldbecleanedpriortomobilization

of van.

NCITE;Iffreezeguardis necessary,performsteps 3-4offreeze

guardprocedureatthis time.

gnition _

Switch

Fuse

## X?//...

‘7/-\\

Vacuum Pump’

‘Lubrication ‘on Engine

Choke

Exhaust Heat Exchangers,

; Stationary

Pressure

Adjustment

Outlet

Engine Guard

Valve

:’1

..,

Incoming

Water

High Pressure

cleaning Solution

Flood Damage Work

Caution must be exercised to prevent the water pump from overheating during long periods of vacuum work such as water damage

Silencer

Assembly Chemical

Mix Tank

Vacuum

Pomn

High Pressure

Pump

Engine Oil

Filter

ThrwF/oor Gas Hook-up and Installation

-c.-.

1’

TherelativelyIowcost of awater softenerserviceismorethan madeupfor

in theincreasedlife of machinepartsand continuedcleaningefficiency.

The water softener will also increasethe effectivenessof the cleaning

chemicalbeingused,therefore,lesschemicalwillbe needed.

Contacta water softenerdistributorin your area for information onthe rentalof a simple watertreatmentunitto carry inyour truck. Be sureto changethewatersoftenerinaccordancewiththecapabilityofthesoftener. Example:IfthesoftenerwilltreatWOgallonsofwaterandmachinesuses anaverageof30gallonsperhourofuse,andanaverageof 5hoursaday, would be 150 gallonsa day, 5 dayswould equal 750 gallons of water, therefore, the softener would be changed every 6 worldng days for maximumsoftening.

WASTEWATERDISPOSAL ADVISORY

Therearelawsinmostcommunitiesprohibitingthedumpingofrecovered “gray”water from carpetcleaningin any place but a sanitarytreatment system.

WATER SOFTENER HOOKUP

GAROkN HOSE

,., -

‘1

Thiscleaningrinsewater,recoveredintoyourunit’svacuumtank,contains materialssuchasdetergents,whichmustbeprocessedbeforebeingsafe for streams,riversand reservoirs.

IN ACCORDANCE WITHTHE EPA, STATE AND LOCAL LAWS, DO NOTDLSPOSE OF WASTEWATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.

In most cases, an acceptable method of wastewater disposal is to dischargeintoamunicipalsewagetreatmentsystemafterfirst filteringout solidmaterialsuchas carpetfiber,Accesstothe sanitarysystemcan be

obtainedthrough a toilet, laundrydrain, carwash drain, RV dump, etc.

Permissionshouldfirstbeobtainedfromanyconcernedpartyor agency.

OnedisposalmethodwhichusuallycomplieswiththeIawis toaccumulate thewastewaterandhaul itto anappropriatedump site. Anothersolution to thedisposalproblemisto equipyourselfwithanAutomatic Pump-Out

System, These systemsare designedto remove wastewater from the

extractor’srecoverysystemandactivelypumpthewaterthroughhosesto

asuitabledisposaldrain.Properlydesigned,theywillcontinuouslymonitor

the level of wastewaterand pumpit out simultaneouslyto the cleaning

operation,Thehiddenbenefitof thisprocessis thatthe operatordoesn’t

haveto stophiscleaningtoemptytherecoverytank. HydraMastermakes

anA.P,O.Systemavailablewhichcanbeorderedwith newequipmentor

installedlater,

Thepenaltiesfornon-compliancecanbeserious.Alwayschecklocallaws

andregulationsto besureyouarein compliance,

MACHINEADJUSTMENTS

Although this unit has been factory adjusted, it may require additional

adjustmentsto achieve optimum performance;i.e. attitudemay require carb adjustment and ambient temperatures may require heat control adjustment.Whenrequired,consult anauthorizedrepresentative.

ENGINECOOLING

Units employing air cooled engines musinot be enclosed within a van with doors and windowsclosed. Excessive temperatures within the engine will

r~ult in premature engine failure and a compromise of applicable war-

ranty,

LEVEL OPERATtON

Dunhg operation, van or trailer must be parked on level ground not to exceed + or -10’. F~”lure to insure proper leveling may prevent proper internal /ubricetion of engine, vacuum arroYorhigh pressure components,

FREEZEPROTECTtON

Mother nature gives litf/e warning as to her cold spelk. Therefore,

protecting thisequipment from freezing willsave costly down-time, Placing

electric heaferin the truckor parking the truck indoors, wi//he/p to insure

an against freezing.

WATER/CHEMICALFLOWOPERATION

This electro-mechanicalsystem has been designedto be simple and troublefree. IncomingwaterflowsfirstthroughtheSolenoidControlValve

(1)(seeillustrationonnext page)andthe lowpressureChemicalInjector

(2)whichare both mountedonthe exteriorofthe mix tank. As thewater passesthroughthe ChemicalInjector,itisautomaticallyproportionedwith a predeterminedquantityofdetergent.The MixTank(3)is equippedwith twodifferentfloatswitches,theWaterLevelFloat(4)respondstothelevel

inthe tankandwill maintainthepropervolumeof solutionto be resewed forthewaterpump.Thesecondary,LowWater Floatswitch(5)isasafety switchthat isdesignedto protectyoursystemfromsuddenorunexpected lossof watersupp~. If,for example,thewatersourceatthe housewere turned off, the water level of the mix tank would drop, activating the

secondaryswitch,which automaticallydisengagesthe systemand pre-

ventsthe waterpumpfrom runningdry.

Thedesiredchemicalinjectionratiomaybeobtainedbyanadjustmentof theChemicalFlowMeter(6)duringthefillcycleofthemixtank.Watermust be flowing into the mix tank in order to adjust the chemical mix. The

chemicalwill flowfrom theChemicalJug (7)to theChemicalFlowMeter, thentothe ChemicalInjectorwhereit is proportionedintothe MixTankat

thedesired chemicalsetting.

NOTE: Wih this unique chemical system,the chemicalflow is proportionedonly duringthe filling cyclesofthe MixTank,notduringthe direct

sprayingofthewand,Therefore,itispossiblethatasyourwandisspraying, youmayhavenochemicalflow,Also,theconverseistrueinthatyoumay

not be sprayingyour wand, but if the mix tank is in a filling cycle,your

ChemicalFlowMeter maybe activeatthe desiredflowrate.

HOTSURFACES

During the operation of this equipment many suriaces on the machine will become veryhot, When near the van foranyreason care must be takennol to /ouch any hot surface,such as heater, engine, exhaust, etc.

NOSMOKING

It is unsafe to smoke in or around the vehicle.

MOVINGPARTS

Never touch anypari of the machine that is in motion, severe bodily injury may result.

CARBONMONOXIDE 77risunitgenerates toxic fumes, Position the vehicleso thatfhe rl.imes will

be directed A WAY from the job site. DO NOT PARK where exhausf fumes can enfer a bui)ding through open doors or windows, air conditioning unifs or kifchen fans.

TOXICFLUMES

Do not occupy the vehicle when the cleaning equipmentis opera fing, Toxic fumes may accumu/afe inside a stationary vehic/e.

The chemicalproportioningsystemwillmix chemicalwithwaterat a 1to

ratio when the Flow Meteris setat 5GPH,ora 1to 15ratiowhenthe

FlowMeter isset at 10 GPH.

nextpage)

@nliwes,

AQUACATWATERFLOW

Atthis pointintheflow,solution(waterwithchemical)willnowbesiphoned from the bottomof theMixTankto the inletoftheWater Pump(8),In the

pump the water is pressurizedand then dischargedthrough a rubber pulsationhose downto the pressurereliefvalve (9), Fromthe pressure reliefvalvethewaterisautomaticallydistributedtothecleaningwand and bypassedbackto the mixtank,dependingon water usageat the wand.

Asthewatertravelsbacktowardthe mixtankfromthepressurereliefvalve it flows through two exhaust heat exchangerswhich heat the cleaning water.

CHEMICALSYSTEMMAINTENANCE

The chemical lines may needto be flushed withvinegar periodicallyto prevent abnormal chemical build-up. This flushing may be done by removingtheclearplastichosefromthe ChemicalJugandinsertingitinto a one quartcontainerof vinegar.This shouldbedonewiththe Chemical Flow Metersettingon 10 GPHandthe Water Heater‘off”. Simplyspray waterfromthewanduntilthequartofvinegarisexhausted,therepeatthe

process with one quart of clear water to void all lines of vinegar.

CHEMICALTANK TROUBLESHOOTINGGUIDE

PROBLEM:Llttieor nochemicalflow

Sotution

Check that hoses at tie Mix Tank (3) are secure. Check that the hose from the top

of the Flow Meter(6)tothe ChemicaJInjector(2)issecurewith no kinks or leaks. Chad that the adjustingcap onthe side of the injector is notscrewed alithe way in.Check the sls checkvalve insidethe injectorfor chemical buikf-

up and proper operation. Check the hosefrom the bottom of the Flow Meter

to the Chemical Jug (7’)for kinks, crad(s, or bubbles.

Checkthescreen ontheendofthehose whiihgoe.sintothe Chemical Jug.Tocheck

tMs screen for properfunction,remove itfrom the plastic hose. Ifyou cannot

b!ow through i$ then rinse itout with vinegar. Check the Chemical Flow Meter (6) for obstructionsor a sticking float. Is incoming water pressure iess than 30 Cracked or defective Chemical Flow Meter (6)? Check the fiiter semenin the SolenoidContioi Valve (1).

PROBLEM: inabiiity to adjust chemical with tie Flow Meter

Solution

Debrii lodgedbehindteflon seatin flow Metervaive.

Teflon seat on the valve stem maybe loose. If deteriorated, repiaca O-Ring.

Insufficient water pressure. Locate new source.

PSI?

LOW PRESSURE

HIGH PRESSURE

VAC EXHAUST LINE

EXHAUST FLOW

HIGH TEMP BY-PASS mm=mmmmmmmmnnaam BY-PASS PRE-HEAT

CONTROL

PANEL

INCOMING

WATER

———

OUTGOING

CLEANING

SOLUTION

, I&= L

PRESSURE u

ADJUSTMENT

,—

BY-PASS

.... ..-

——— ——— ———

-W------=

● **e*o**e ****e ● 9

SENDER

‘1

:::::::::................-...* .:$.+.>-..-..+..:.:.-..:?:?..:?-:.:

...............................................

............. .........

VACUUM

n’

/000-068-098 #14 /

#12

AQUA CAT 3.9 DX

WATER FLOW DIAGRAM

HYDRAMASTER CORP. 29 JUNE 1992

HEAT ~ /

EXCHGR

STG 3

A ooo-068-2~1 , #29

m N

m m

TANK 11-TEMP Y-PASS

LINE

+Z r’ 00’0’’03’‘o <

.—— — ———— ———. ———— ———

000-088-099 #17

‘~

PROBLEM: Mix Tank Overflows

Solution

Float switch (4) in the mix tank not moving freely, or defective.

To Check Switch: With a 12volttest Iightand the floatinthe ‘up’ position, there should be power through the switch.

To Check Relay First, check wiring against diagram. Wti 12 volt test light

and the float switch (4) solenoid valve. Wtth the

power at the

solenoid valve.

Solenoid valve defective: Remove solenoid valve, dsassamble and inspect diaphragm

for cracks or tears.

in the ‘up’ position, there should NOT be power at the

float switch in the ‘down’ position, there should be

CATPUMPMODELZ9(I OPERATINGINSTRUCTIONS

PROBLEM: Mix Tank Does Not Keep Up With Water Output

Solutlon:

Check Incoming water pressure. Check garden hose quick cannect assembly

screen. Check garden hosesmd/orfeed hose tothe mix tankforclog,kinks or blockage. float switch (4) inmix tank hanging up (notmoving freely). Check filterscreen in Solenoid valve (1).

Products described hereon are covered by

oneor more ofthe follovnng

US. patents:3558244,3652188,3809508, 3920356,and3930756

c CAT PUMPS – A G. ●

LorelohcebO 5

CH+3W zuo. swnzerland

J&&p

CORPORATION

PO. Box LW5 MINNEAPOLIS, MN 55440

Phone (6 12) 7@0.s440 – Telex 290276

4N V CAT PuMPS INTERNATIONAL S A.*

Harmooleslraal 29 27 Slallon Inoustr,al E31ale, Fleet

B 2C4N Antwerp, Belgium

Phom (03) 237.72-24 — Telex 33947

Ph+ne (42) 21.3140 — Telex S65 160

9 CAT WMPS DEuTSCHLAND GmbH ●

RoslochIx Stmsse 9

6X0 W!es&9den-Bmrsladl, Wesl Germany

Phooe GB12.560301i2 – Telex 41 M713

PuMPS (U K) LTD ●

● CAT

Harwsh$w GU13 80Y, En.#and

PIIO,WJ F!ec,l 22o31 - Telex 85fL998

CPWJ ch

;PECIFICATIONS

,,,..,.,,.,,.,,,,,...,..,..,,..,3,5GPM(l3uM)

olume

ischargePressure..............1200PSI(83EAR)

IaximumInlet Pressure......-

PM,.,,,,,,,,.,..,,....................l2~

,.,,,.,,,,.,,,,,.,,.,.,..,...,......0.787’ (20mm)

ore

,,,,,,,,,,,.,,.,,.................0<472”(12mm)

troke

rankcaseCapacity.............10 oz. (.3L)

IletPort (l),...l ....................l/2” NPT(l/2’ NPT)

heroical Iniection Port (1),., 1/4” NPT(1/4’ NPT)

ischarge Ports (2) ....18. NPT (3/8’ Npq (1):~...2”2”NpT (1/2” NpT)

ulley Mounting

haft Diameter

,.,,..,..,,.,..,...,,.,,..,......12.1 Ibs.(5.5kg)

Ieight

,,.,,,,,.,,,.,.....Eitherside(Eitherside)

....................0.650” (16.5mm)

imensions.....l................l...

8.5to+ 40 PSI(-0.6to +2.8 BAR)

10,77”x9.06’x5,14“ (273.5x230x130,5mm)

GENERALINFORMATIONFOR CATPUMPREPAIR

Asyou removeyourdischargemanifold,there isa set of 3 checkvalves

(whichusuallyfall out duringdismantling),Ifthe surfacesofthese check valvesaredirty,orshowsignsofchemicalbuild-up,itisprobablethatthey wouldremainopencausingpressurelossorpulsation,Uponinspectingthe valves,makesurethatthetetlon buttoninthevalvespringretainersareSW

intact,Also examinethe dischargemanifold,Lookfbr problemssuch as cracks, chemical buildup or warping due to freezing. If this discharge

manifoldiswarped,itwill causethe checkvalvesto stickandwill resultin

lossof pressure, TheCatpumpcupsareoftenthesourceofpressureloss.Uponinspection

theymayappearmeltedortorn,butoftentheywillIookgood,Replacethem anyway. Thereis no sure method of visually inspectingthe cups, HydraMasterrecommendschanging

cupswhetherthey lookgoodor not.

When restarting thepump, check tosee that there isno cylindermotion as

this will causepremature failure of the cy/inder o-rings. Center cylinder motion can be eliminated by switching withone of the end cylinders.

SERVICINGTHEPUMPINGSECTION

DISMANTLING 1, Removedischargemanifoldas describedinthe lastsection. 2,Slipcylindersoutofinletmanifold,NOTE: Identifycylinderssotheywill

bereplacedin theiroriginalposition(frontto back),

3. Removecotterpin,nut,andwasher. 4, Nextremovepistonretainer,spacer,and pistonassembly. 5, Removeinlet valve

Anytimeyour pump is being dismantled,HydraMasterrecommendsreplacementof ail ‘o’ ringsand seals.This is merelyaconvenienceto the customerto makesure thatthe Catpumpis intop operatingcondition,

The Prrrrrm-A-Lubeseals locatedwithinthe intakemanifoldwill allowair to enterthe pumpif theyareworn,Again, it is difficulttovisuallypinpoint a defectivePrrrrrm-A-Lubeseal,Replacethemall,

RepairingofCatpumpsisnotadifficulttask. However,beforedismantling makesureyouhavethe properpartsrequired.

1- short (orhot)cut kit 6- pistonsleeve ‘o’rings 3- Prrrrrm-A-Lubeseals

Readinstructionsthoroughly,suppliedin the Cat pumpmanual priorto dismantlingandfollowdirectionsasstated.Oilallsealsthoroughlypriorto installation.(Remember,anewlyscarredsealisnobetterthanoneyoujust tookout.)

1- bottle Catoil

SERVICINGDISCHARGEVALVES &VALVESEATS

DISMANTLING

1. Loosenthe 2 (M8)lockingnuts approximatelyoneturn. 2, Thenremovethe 2 (M8)flangenuts. 3, Graspthe dischargemanifoldwith3 fingersonthe undersideandtap

with

a softmalletto remove,

4. Valveassemblieswill remainwiththe manifold,Invertmanifoldand

dischargevalve assembliesshouldfall out,

5,Inspectdischargevalvesforwearor ridges,(Sphericalvalvesduetotheir

shapemustbe replacedwhenworn.)

REASSEMBLY

1. Placeretainerin manifoldchamber,

2. Nextinsertspringintocenterof retainer, 3, Placevalveover springwithspherical(mooned)sideup.

4, Nextinsertthe valveseat, 5, Positionmanifoldbackonto pump. NOTE:Exercisecautionwheninsertingcylindersinto manifoldto avoid

damagingcylindero-rings,

6,Replaceflangenutsonstudsandhandtightenbothsides,Thentorque

eachsideto 125 inchpounds.

7. Handtighten lockingnut.

REASSEMBLY

1.Examineinletvalvesurfaceandreverseifdamaged(bothsidesarelap surfaces).

2. Examinepistonassemblyfor clean inletsurface,If damaged,replace and lubricate,

NOTECUPINSTALLATION: Wipecupinserter lightlywithoil. Slip bac-

cupring ontopiston.Forcecupover inserterandsquarew“thall

surfaces.Fauhycup installationcausesprematurefdure.

3, Nextreplacepistonspacerand retainer.

4.Slipwasher ontorod,screwon nutandtorque to 60 inch pounds.

NOTE:ALWAYS REPLACE WITH NEW C071ERPlN.

5, Examinecylinderwallsfor scoringoretching,Theseconditionswill

causeprematurewear ofyour pistonassemblies.Replaceifworn

ordamaged,

6, Lubricatecylinderand replaceo-ringsand backuprings(if defective), 7, Positioncylindersintheiroriginal orderintomanifoldchambersand

carefullyiip over rodends;nto the pump.

8.Replaceflangenutsonstudsandhandtighten bothsides,Thentorque

eachsideto 125inchpounds.

9. Handtighten lockingnuts,

SERVICINGTHESEALSANDSLEEVES

DISMANTLING 1,Removedischargemanifoldandpistonassembliesasdescribed,

2.Removeboth(M8)lockingnutsfrom studs,

3,Wtihsoft mallet,tap inletmanifoldloosefrom crankcase. 4,Placeinletmanifoldon pair ofclearance blockswith crankcaseside

downanddriveout seals,

5,Invertinlet manifoldwith CRANKCASE SIDE UP.

6. Lubricatecircumferenceofnew Prnwrn-A-Lubeseals,positionin

manifoldwith GARTER SPRING DOWN and driveinto place,

7,Examinesleevesforscoringor otherdamagebeforeremoving,

6.Ifworn, graspsleevewith pliers andpull off.

NOTE:This procedurewill marthesleeve souse onlyif sleeveis

to be replaced.

\ 9, Removeo-ringand back-upringsfrompistonrod.

REASSEMBLY 1, Placebarrierslingeron rod, 2, Lubricatenewo-ringsandback-uprings,Installfirst o-ringintheo-ring

grooveon thepistonrod. Positionback-upringagainsttheshoulderin flont of thefirst o-ring,thenthe second o-ring.Becarefulto avoid damagingthe o-ringswhenslipping themoverthe pistonrod

threadedends.

3. Immersesleevein oil carefuliytwistand pushonto rod(machined counterboreendfirst).

4, Replaceseal retainers.

5,Exercisecautionwtrenreplacinginletmanifold,sothe inletsealsarenot

damagedby thethreadedrod ends. 6, Replacelockingnuts onstuds, 7, Reassemblepistonassembliesanddischargemanifoldas described.

Consultfactoryfor yourlocal distributorfor crankcaseservicing,

DISMANTLINGCATPUMP

Pumping Section Cut-away

PISTON

PISTON RETAINER \

CUP WASHER

COTTER PIN

NUT -f

SPACER _,

BACSCUP

BAC~CUP RING

PISTON ROD SLEEVE

SERVICEKITS

07S-001 Cup Kit BobCat

3cup

Ofling, Cylinder

CotterPin

1 Instruction Sheet t Cup Inserter

076-004 Hot 3 cup 6 O-Ring, Cylinder

3 Cotterpin

1 Instruction Sheet 1 Cup inserter

Cup Ki$ AquaCat 3 prmm.A~u@ Sed 1 Instruction Sheet

CYLINDER Y

076-003SealKit 3Prrrrm-A.LubeSeai 3CotterPin 2Abrasive

1 Instruction Sheet 30431 Sleeve and Seal Kit

3 Barrier Siinger 3 CotterPin

3 Sieeve 6 O-Ring, Sleeve 1 instruction Sheet

Paper

30666ValveKit 3ValveSpring Retainer

3 Valve Spring 3 Valve 3 Valve Seat 3 O-Ring, Cylinder

30660PistonKit BobCat

6 O-Riig,

3 Back-UpRing,Cylinder 3 Bat-Cup P~ton

3 Bat-Cup Ring 3 Cup 3 Piston Spacer 3 Piston Retainer 3 Conical Washer(M6) 3 Nut (M6) 3 Cotterpin 3 Inlet Valves 1 instruction Sheet

Cyliider

PISTON MODEL 290 Exploded View

●-

‘ 57

PARTSLISTMODEL290

ITEM

11 12 15 16 43804 Crankshaft 17 14487 Rearing 18 t9 0974107 O-Ring, oil seal case

21 23 101799 Connecting rod 24 101800 25 26 20017 Seal washer 3 27 147-006 Oil seal 3 28 29 097408 O-Rina. sleeve 3

30 29003 31 32 26654 Seal washer 3 33 1384)01 Seal rea”ner 3 34 25128

35 35

PARTNO, DESCRIPTION QTY.

1 20285 Ofling (Buns-N)

44274 Crankcase

2 3 156408 Stud(M8X

4 097404 O-Ring, oil tillercap 5 027-007 8 43340

43339 Crankcasa cover 1

074-021 Bubble oilgauge 23170 O-Ring,drainplug 25625 Drain plug 1 92520 Sems comb head screw (M6 x 20) 6

1474Q5 Oil seal (Buns-N) 2

041-021 Oilseal case 2 92519 Sems comb head screw (M6 x 16) 8

16948 Piston pin 3

25327 Barriir slinger 3

28771 O-Ring, sleeve (WOn) 3

29614 Sleeve (29743 Unchromed)

25635 Inlet man”tild - stainless steel 1 147-008 Pm’rrm-A-Lube seal 3 30325 Prrrrrm-A-Lube seal (Vrron] 3

Oil fillercap 1 O-Ring, crankcase cover 1

Piston rod 3

Back-up ring, Sleeve (Teflon)

Inlet manifold 1

82)

ITEM

1 1

2 1

1 1

1 2

3 3

38 39 40

39-41

42 27963 43 44 45 46 47 46

49 50 090-005

51 43442 52 53 54 56 57 58

Electric Clutch Aesembly

59 152-005 60 61 036-005 62 143464 63 174034 Flat washer (5/t6 US) 64

PARTNO. 27004 30543

0974)25 Bat-Cupring(Teflon) 044-001

43474 078401 BobCat CUpkii 0781U34

27002 27006 27000

14156 Cotterpin

0454X)4

097-012 O-Ring, cylinder (Buns-N)

11377 097~24 Bat-Cup ring, cylinder

25&4

43360 Valve spring 43723 Valve 43434 Discharge valve seal 81109 Hex nut (M8)

101804 Hex ffange nut (M8)

108403 Shaft protector

077-005 Key, electric clutch

174-018 Lock washer (5/16 US)

DESCRIPTION Inletvalve Bat-Cuppiston

Cup (t4ton) Bat-Cup assembly

AquaCat cup kti Piston spacer Piston retainer Conical washer - SIS(M6)

S/S(M6)

Nut -

Cylinder(43634 Unch)

O-Ring, cyIinder win)

Discharge manifold Discharge manifold - SIS Valve spring retainer

Tapered sleeve

6’ electric clutch 8~ mm socket head screw

Q-W.

3 3 3

3 3

1 3 3 3 3 3 3 6 6 3 1

1 3 3 3 3 2 2

1 1 1 1 1 1

—

CATPUMPTROUBLESHOOTINGGUIDE

PROBLEM: Pulsatlon

Cause

-n discharge valves of pump. Worn Prrrrrm-A-Lube seals. Excessive temperature.

Soiution

Clean or replace discharge valves. Replace. Check pump solenoid.

PROBLEM:

Cause Worn nozzle. Belt slippage. Air leak in inletplumbing,

Relief valve stuck, partially plugged or improperly adjusted; valve seat worn. Inlet suction strainer clogged Worn piston assembly. Abrasives in pumped fluid or serve cavitation. Inadequate

Fouled or ditty inletor discharge valves. Leaky discharge hose. Replace worn valves, valve seats.

PROBLEM: Pump runs extremely rough,

Cause

Restricted inlet orair entering the inlet plumbing. Proper size inlet plumbing; check for air tight seal. Inlet restrictions and/or air leaks, Damaged cup or stuck inlet or discharge valve. Replace worn cup or cups, clean out foreign materiel, replace worn valves. Worn inlet manifold seals. Prrrrrrn-A-Lubes, Replace worn seals.

PROBLEM: Cylinder O-Rings biown next to discharge manifoid

Cause Pressures in excess of rated PSI, Check for piugged nozzle, closed valves or imprope Warped manifold. Freezing. Replace manifold.

LOWpt%SSU~

water supply,

orimproper size.

Solution Replace nozzksof proper size.

lighten or replacw use correct belt.

Dismantle, reseal, and reassemble. Clean and adjust relief vaivq check for worn and dirty valve seats. Kit available. Clean. Use adequate size. Check more fraquemty. Install properfiiter. Suction at inlet manifold must be limited to liftingless than 20

feet of water or -B.5 PSI vacuum.

Clean inlet and discharge valve assemblies.

Replace discharge hose,

prassurwis verylow

Solution

Soiution

rlyadjusted bypass valve.

PROBLEM: Leakage at the cyiinder O-Rings at the discharge manifoid and

powderysubetancein the area of the O-Ring

biack,

Cause

Loose cylinders Cylinder motion caused by improper torque on the discharge Retighten. ~nottighbntmmuch ortieemoftiemmtioidwill be~wed,causing

manifoid.

PROBLEM: Water ieakage from under the inlet manifoid

Solution

looseness in the center cylinder.

Cause Soiution

Worn iniet manifold seals. Prrrrrm-A-Lube. Leaking sleave O-Ring. installseals. If piston rod sleeves are scored, repiace sieeves and sleeve O-Rings.

PROBLEM: Oii ieak betwean crankcase and pumping section

Cause Soiution

Worn crankcase piston rodseais.

PROBLEM: Oil ieaking in the area of the crankshaft

Cause Worn crankshaft seal or improperly instaiied oil seal, Remove oil seal retainer and repiace damaged gasket and/or seals. Bad bearing.

Repiace crankcase piston rod seals.

Soiution

Repiace bearing.

(cmthues, nextpsge)

CATPUMPTROUBLESHOOTINGGUIDE

PROBLEM Excessive play in the end of the crankshaft puliey

Cause Worn ball bearing from excessive tension on drive beit.

PROBLEM: Water in crankcase

Cause

May be caused by humid air mndensing intowater inside the crankcase.

Leakage of manifold inlet seals and/or piston rodsleeves O-Ring.

PROBLEM: Oil leaking from underside of crankcase

Cause Worn crankcase piston rod seals.

PROBLEM: 011 leaking at ths rear portion of the crankcase

Cause

Damaged or improperly installed oilgauge or crankcase rear cover O-Ring, and

drain plug O-Ring.

PROBLEM Oil leakage from drain plug

Cause

Loosedrain

plugor worndrainplugOfling.

solution

Replam ball bearing. Properly tension belt.

Solution

Change oil at 3 month or 500 hour intervals using Cat pump crankcase oil (other

approved oilevery month or 200 hours).

Replace seals, sleeves and O-Rings.

Solution

Replace seals, sleeve end O-Rings.

SoMion

Replace oil gauge or cover O-Ring, and drain plug O-Ring.

solution

Tighten drain plug

orreplace O-Ring.

PROBLEM: Loud knocking noise

in pump

Cause Solution

Pulley loose on crankshaft,

Broken worn bearing. Replace bearings.

PROBLEM: Frequent or premature faiiura of the inlet manifold seals

Check key end tighten set screw.

Cause So/ution

Scored rods or sleeves.

Over pressure to inlet manifold,

PROBLEM: Short cup life

Cause

Abrasive materiel in the fluid being pumped.

Excessive pressure and/or temperature of fluid being pumped. Check pressures endfluid inlettemperetur~ besuretheyare withinspecifiedrange.

Over pressure of pumps. Reduce pressure.

Running pump dry.

Front edge of piston sharp,

PROBLEM: Strong surging attheinletandlow preasureonthedischargeside

Replace rods end sleeves. Reduce inlet pressure per kvmmtions.

Solution

Install proper filtration on pump inlet plumbing,

Do not run pump wiihout water. Replace with new piston,

Cause Soiution

Foreignparticles intie in!etordischargevalve orworn inletand/ordischergevalves.

Check forsmooth lapsurfaces oninletand discharge valve seats. Discharge velve

seats, and inletvalve seats may be lapped on a very fine oilston% damaged cups and discharge valves cannot be lapped but must be replaced.

HIGHPRESSUREPUMP TROUBLESHOOTINGGUIDE

PROBLEM: LOSS of D1’eSSUi’e

Qi4MWd@

1.Cloggedfilterscreen ingarden hose quick connect coupler.

A. Remove and clean or replace filter.

2. Low water pressure at sourcs.

A.Determine rate of flow end select an alternative source of supply ifwater

pressure is inadequate.

3. Defective or blocked check vatves in high pressure pump cylinder head.

A.Dismantlecylinder head andreplaceordeanapplicablecheckvalve,

4.Delaminated,kinkedorcloggedhosebetweenthemixtankandthe high pressurepump.

5.Defectivepressurereliefvalve

h!@pressure bypassvafve isdesigned tofullyclose when thedeaningtool isturned on. Any foreign matter collecting on the piston will prevent full closure ofthe valve and allow a partianofthewaterta continueto circulate instead of being routed to tie cleaning tool. To correct this situation, the bypass valve mustbedismantled and cleaned (referto illustiationprovided for bypass dismantling),

A. Dismantle and dean pressure relief valve as shown in illustration.

B. Replace defective or worn out bypass cup.

C, Replace bypass valve.

6. Defective or worn cups.

A. Remove endreplace piston cups as defined by pump section of this

manual.

7. Loose driie belt for high pressure pump.

A. Readjust belt as required or replace if defective.

or debris in pressure reliefvalve. NOIE: The

Bypass Valve Assembly

‘?(D”

IYPASSPARTSLIST

IEF. NO.

PART NO, DESCRIPTION

3 000-105-101

000-105-102 Piston plate: Bypass valve

4 5 000-076-101 Kfl, seal for Bypass valve 7 COO-I48-004 8 000-0974)05 O-Rirra. Bvr)ass valve fittina

Thrust date, Bvr)ass valve

Seat & O-Ring, Bypass valve

QTY,

1 1 1 1 1

INFORMATION

Thevacuum blowerincorporatedin Urismachineis a positivedisplacementlobetype,manufacturedbyCooperIndustries.Theperformanceand lifeofthis unitis greatlydependenton the care and proper maintenance t receives,

PROBLEM: Insufficient or excessive water flow

Cause/Solution

Wornout spray jet. NOTE: Cleaning tools designed to spray a canstant flow of

11/2 GPM will average 1gallon offiowperminute inactual workingsituations sinceflow isnoncontinuous.Anaverage fbwof 1GPM results in6000 gallons of fbw for evey 100 hours of unit operation. Spray tips are capable of consistent flow rates for epproximatety 20,000 gallons. They should be replaced therefore approximately every 350 hours. Worn spray jeis albw a greater average rate of fbw thus reduang

A, Remove andreplacesprayjet.

2. Redur%on offlow. A. Due to increased length of solutionhose. NOTE: For every 50 feet of hose

beyond 100 feet intotal length,a measurable !css offlow is experienced. This

cond~on is a result of the increased friction experienced by the water as it

passes through the hose. Therefore, itis necwssaiyto increase the pressure at the machine 40 PSI for every additional 50 feet of cleaning solution hose

over 100 feet.

desiredtemperaturelevels.

3ecauseof the closetolerances betweenthe lobes and housingofthe ~acuumblower,solid objectsenteringthe inlet will damagethe internal

obes,gearsandbearingordirect drivecoupler.

To preventthis, a stainless steel filter screen has been placed at the #acuuminletinsidethevacuumrecoverytank.This stainlesssteelscreen

s fingertightandshould beremovedforcleaningweekly.

When machine is being run fortestpuposes and the vacuum inlet on top ofmachine b open, caution should be used.

Toprotectthevacuumblowerfromoverloadinganddamagingitself,there savacuumreliefsysteminstalledonthevactank,Whenthevacuumtank

nletiscompletelysealedoff,a maximumof12HGwillbeattained.A hole mthetop blowerpipeelbowactsasthelubricationpoint.Attheendofeach jay, LPS 1or Pennzguardshouldbesprayedin beforeshuttingdownthe machine.See blower lubrication illustration, If you fail to lubricatethe iacuum blowerdaily,rustdepositsand moisturewill decreasethelife of thevacuumblower.

Readthevacuumblowermanualcarefullyforproperoilchangeandgrease application.Themaintenancelogmaydifferslightlyfromthe manual,but :hetruck-mountedcarpetcleaningmachineapplicationisverydemanding )fthe vacuumblowerandthereforeitshouldbemaintainedmoreregularly,

MOTE: Vacuum tankisprotacted from ovetiowingbya vacuum tank, frbat W switch. This switch is not activated by foam,only by ijquid.

Blower Lube Port

Spray lubricant into blower lube port for 3to 5 seconds,

then immediatelyshutoff machine.Useonly LPS 1

moisturedisplacinglubricant,

VACUUMTANKFILTERBAGS

HydraMasterfilter bags are designedto trap all of the lint, that would normallycollectatthebottomofyourvacuumtank.The useofthesebags, ifemptiedatthe endofeachjob, will eliminatetie build-upof muchof the debrisinthetank.

the incomingdirtywater inlet~nke vacuum~~k. -

To reorderbagsusepart number049-028.

Vacuum Tank Filter Bags

PROTECTIV

HOLDING RECOVERY

The drawstring top of these bags is designed to b tied

TANK

Vacuum Flow

S/S Fil

Vacuum

Relief

Vacuu

Kill Swi

VACUUMBLOWERTROUBLESHOOTINGGUIDE

PROBLEM:

Cause solution Collapsed

Cloggedstainless steel finer, Defective vacuum tank seal.

Defectiveor“open”vacuumtankdumpvafve.

Fracturedwekfonvacuumtank.

Collapsed or kinked vacuum hose.

Pluggedvacuumhose.

Restiiclion in cleaning tool. Worn end plates or lobes in vacuum b!ower.

Defectivereliefvalve.

PROBLEM:Blower Isseized

Cause

Rust.

Foreignmatter.

Note: Theabovementioned, rust foreignmatterandseizing areoftencaused from

Loss of pressure

vacuum hose between blower and vacuumtank. Remove and replace hose. NOTE: A special reinforcxxfhoseisrequired

for replacement.

Remove end clean or replace stainless steel filter.

Removeand replacevacuumtank seal. Closevalve, Replacevalve.

Re-weld as required or replace tank.

Reshapehose if possibleand/oreliminatekinks.

Remove obstructionsbyreversingthevacuumhose. Remove obstruction.

Replaceworncomponents.NOTE:Mustbeaccompliihedbyaqualifiedtechnican. Inspectand replaceifnecessary.

Solution

Sprayrustdissolvinglubricantonto lobesto emulsifyrustandattempt to rotate

vacuumlobes.

Dismantfeandremoveforeign mattarand repairas required.NOTE:Dismantling

mustbeaccomplishedbyqualifledtechnican.

foamLwvehrgthroughthe Mower.

PROBLEM:NoiseIn vacuum blower

Cause

Worngears.

Lackoflubrication.NOTE:Permanentdarnagemayhaveresultedfrom lack

of lubrication.

Wornbearings.

Debrisand/orforeignmaterialbuild-up.NOTE:A stainlesssteelfilter isprovided

in vacuuminletlocatedin vacuum blower components.

Lcoseormissingmountingbofts.

Solutlon

Removeandreplacegears.NOTE:Replacementofgearsmustbeaccomplished

byqualifiedtechnican.

Timing of vacuum blowerhas beenchanged dueto worncomponents.NOTE:

Replacementofcomponentsmustbeaccamplihed byqualifiedtechnican.

Lubricateasspecifiedbyapplicablevecuumblowermanual.SeeTableofContents.

Removeand replace bearings as required. NOTE:Must be acmmplished by

qualifiedtechnican.

Dismantfevacuumblowerandremoveforeignmaterial.NOTE:Ilsmantfingshould

beaccomplishedby quafifi+s-dtechnicanonty.Replacementofwornpartsis necessary.

or reinstallmounting bofts.

Tighten

VACUUMBLOWERWARRANTY

COOPERwarrantsproductsofitsmanufacturetobefreefromdefectsinmaterialandworkmanshipifproperlyinstalled,maintained,andoperated undernormalcondtiionswith competentsupervision.

Noperson,agent,representativeordealeris authorizedtogiveanywarrantiesonbehalfofCOOPERnortoassumeforCOOPER anyotherliability in connectionwithany of COOPERSproducts.

Thiswarrantyshallextendfortwo (2)yearsfrom dateof installationprovidedthis equipmenthas beenput into servicewithin six monthsafter shipmentfromtheCOOPERfactory,IfrepairsorreplacementsaremadebythePurchaserWithoutCOOPER’Spriorwrittenconsent,COOPER’S warrantyshallceaseto beineffect. No allowancewillbegrantedfor anyrepairsor alterationsmadebythe PurchaserwithoutCOOPER’Sprior vwittenconsent,

Machinery,equipmentand accessoriesfurnishedby COOPER,but manufacturedbyothers, arewarrantedonly to the extentof the original manufacturer’swarrantyto COOPER,

COOPERagreesatitsoptionto repairatthe pointofshipmentortoreplacewithoutchargef.o,b.pointofshipment,anyparl orpartsofproducts of COOPER’Smanufacture,whichwithinthe specifiedwarrantyperiodshallbeprovedto COOPER’Ssatisfactiontohavebeendefectivewhen shipped,providedthe PurchaserpromptlynotifiesCOOPER,inwriting,ofsuch alleged defect

COOPER’Sliabilityto Purchaser,whetherincontractorintori arisingoutofwarranties,representations,instructions,ordefectsfromanycause shallbe limitedto repairingor replacingofthe defectivepartor partsasaforesaid,f.o.b, pointof shipment.

NoliabilitywhatsoevershallattachtoCOOPERuntilsaidproductshavebeenpaidfor, EXCEPTASSTATEDINTHISSECTIONANDINTHE PRECEDINGSECTION TITLED ‘WARRANTY’AND EXCEPTAS TO TITLE, THERE ARE NO GUARANTEEDOR WARRANTIESOF MERCHANTABILITY,FITNESS,PERFORMANCEOROTHERWISE,EXPRESS,IMPLIEDORSTATUTORY,AND COOPERSHALLHAVE

NOLIABILITYFORCONSEQUENTIAL,INCIDENTALOROTHERDAMAGES,HOWSOEVERCAUSED. DATEINSTALLED

MOD~

COOPER/GARDENER-DENVER1800GardenerExpway Quincy,IL 62305-4024

VACUUMBLOWERLUBRICATION

At the gear end the timing gear teeth are lubricatedby being partially

hoursor moretlequentiy ifinspectionso indicates,The oildrainplugis

at (C), submerged,Thegearteethserveasoilslingersfor gearendbearings.At the driveendofthe bearingsaregreaselubricated.

NOTE:Olderunitsmayhavetheoilfilllevelanddrainholeslocatedinthe

castirongearcaseinsteadofinthe headplate.Bearingsondriveendof FILLING PROCEDURE Removesquareheadventedoilfillplug (A)on gearend. Removeoillevel plug(B)locatedinthe headplate.Fill gearcaseuntiloildripsoutofthe oil levelhole(B),Uselubricantsaslisted.Addfreshoilasreuuiredtomaintain

blowerrequiregreaselubricationevery100hoursofoperation.Bearings

which requiregrease lubricationwill have a greasefitting (D)at each

bearing.Whenregressing,the oldgreasewillbeforcedoutof the vents

duringoperation,Topreventdamagetoseals,theseventsmustbekept properle~el:Theoil should bedrained,flushedand replacedevery300 ~ open}t all times. -

Vacuum Blower Motor Lubrication

‘In ●pplicstiorts with extreme variations. in

qnbiertt t.rnpwsture 8 20W - 50W multtplc wscosi

-LOWER DISCHARGE

SERl~

SAE10W

n)” SAE40

Uw ZVJ- F

/**C*PI

w 011ISracommend~d.

FOR GREASE LUBRICATED BEARINGS

Ssrviccsverv 600 hours of oporstion

TEMPERATURE

-400 to 275*

(-4@ to

12rPc)

SAE50

6;:A~E

B-=ri

200 250

TVPE

ng.Groins

INTHEINTERESTOFSAFETY

BEFORE STARTING ENGINE,READ AND UNDERSTAND THE “OPERATING AND MAINTENANCE INSTRUCTIONS. ‘

OPERATINGANDMAINTENANCE INSTRUCTIONSFORMODELSERIES 303400(16HP)

,...................................Read Operator’s Manual

..............................,!...!.

..................................!.

..!!..,,.,,...............,,,,,....!.

Warning/Caution

oil

Fuel

THIS SYMBOL M&4NS WARNING OR CAUTION.

DEATH, PERSONAL lNJURYAND/OR PROPERWDAMAGE

MAY OCCUR UNLESS INSTRUCTIONS ARE FOLLOWED

CAREFUUY.

[WARNING: Do NOT...

1, DONOTrun engine in an enclosedarea,Exhaustgasescontaincarbon

monoxide,an odorlessanddeadtypoison.

2,D0 NOTplacehandsor feetnear movingorrotatingparts.

3,DO NOTstore,spill,or usegasolinenearan open flame,or devicessuch

as astove,furnace,or waterheaterwtich usea pilot light ordevices whichcan createaspark

4.DO NOTrefuel

refueling is preferred.

NOTfill fueltankwhile engineis running,Allowengineto coolfor

5.DO

2 minutesbeforerefueling.Storefuel in approvedsafetycontainers.

NOT remove fuel tank capwhileengineis running.

6,DO

NOT operate engine when smellof gasolineis presentor other

7.DO explosiveconditionsexist.

8,DO NOToperateengine ifgasolineis spilled.Movemachineawayfrom

thespill andavoidcreatingany ignitionuntilthe gasolinehas evaporated.

9.DONOTtransportenginewith fuel in tank.

10.DONOTsmokewhenfilling fueltank.

11,DO NOT choke carburetor to stop engine. Whenever possible,gradually

reduceenginespeed beforestopping.

12.DONOTrun engineat excessivespeeds.This mayresult ininjufyt

13.DONOTtamperwith governorsprings,governorlinksor otherpatis whichmay increasethe governedenginespeed.

14.DONOTtamperwiththe enginespeedselectedbythe original

equipmentmanufacturer.

15,DONOTcheckforspafi withspark plug or spark plug wireremoved.

Usean approvedtester.

16.DONOTcrankenginewith sparkplugremoved.If engineisflooded,

placethrottlein

17.DONOTstrikeffywheelwitha hardobjector metaltool asthis maycause flywheelto shatterinoperation.Usepropertoolsto serviceengine.

18,D0 NOToperateenginewithouta muffler,Inspectperiodicallyand

replace,ifnecessary.If engineisequippedwith muffferdeflector,inspect

periodicallyand replace,ifnecessary,with correctdeflector.

19.DONOToperateenginewithan accumulationof grass, leaves,dirt or

othercombustiblematerialinthe mufflerarea,

20. DONOTusethis engineonanyforest covered,brush covered,orgrass coveredunimprovedland unlessa sparkarresteris installedonthe

mufffer,The arrestermustbemaintainedin effectiveworkingorderby

theoperator.In theState ofCaliforniathe above is requiredby law

(Section4442of the CaliforniaPublicResourcesCode).Otherstates

mayhavesimilarlaws. Federallawsapplyon Federallands,

21,DONOTtouchhot muffler,cylinder,orfins becausecontactmay

indoors where area is not well ventilated, Outdoor

“FAST” position and crank until enginestarts.

. .. . .. ,.,,.,.,..,..,.,.....AirCleaner......Air Cleaner

.:.

WARNING: DO

1.ALWAYSDOremovethe wirefrom the sparkplugwhen servicingthe engineor equipmentTO PREVENT ACCIDENTAL STARTING. Disconnectthe negativewirefromthe batteryterminalifequippedwith

a 12volt startingsystem.

2, DOkeepcylinderfinsandgovernorpartsfreeofgrassandotherdebris

whichcanaffectenginespeed.

3. DOpullstartercordslowlyuntilresistanceif fett. Then pullcordrapidly to avoidkickbackandpreventhand or arminjury.

4. DOexaminemufflerperiodicallyto be sure itis functioningeffectively. Awornorleakingmuffiershouldberepairedorreplacedasnecessary.

5.DOusefreshgasoline.Stalefuelcangumcarburetorandcauseleakage.

6. DOcheckfuellinesandfittingsfrequentlyfor cracksor leaks.Replace

if necessaty.

NOTE:UseOriginalBriggs& Stratton Service ReplacementPartswhen

servicingyour engine, Briggs& Stratton AuthorizedServiceCenters carryastockofsuchparts.TheuseofBriggs&StrattonPartspreserves the oriiinal designof your engine. Imitation replacementparts offer

potentialriskincludingtheriskof personalinjury.Cantactany Briggs& StrattonAuthorizedServiceCenterfor OriginalBriggs& StrattonReplacementParts,

DFILL CRANKCASEWITH OIL

lace enginelevel.Cleanareaaroundoilfill.Removedipstick.POUR OIL

LOWLY. Fill to FULLmark ondipstick, DO NOT OVERFILL 0Ti5 Afterstartingengine,stopafter30seconds.Checkoillevelandadd

if necessary, Without filter, oil capacity is approximately 1-1/2 q~.

(48OZS.or 1,42Itrs),With oilfilter, oil capacityisapproximately1-3/4

(560zs. or 1,65Itrs.

0 CHECKOIL LEV L laceenginelevel.Removedipstickandwipe oil fromit with cleancloth. crewdipstickintotube untilcapbottomsontube.Removeandcheckoil vel, Dipstickmustbe firmlyscrewed intotubewhenengineis running.

Oii Fill and Dip Stick

BEFORESTARTING

READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THISENGINE POWERS.

OIL RECOMMENDATIONS

We recommenduseofahigh qualitydetergentoil “ForServiceSC,SD,SE,

SF,orSG,”suchas Briggs&Strattonhigh qualitydetergent30weight oil (partno.1CC005),or 10W-30weight oil (partno.272001). Detergentoils keeptheenginecleanerandretardformationofgumandvarnishdeposits.

Use no special additives with recommendedoils.

RECOMMENDEDSAE VISCOSITYGRADES

.20 0

‘F

‘c -30

* UseSAE30 oilin hightemperature,high loadapplications. w 10W-40oil maybesubstitutedif 10W-30is not available. * Use synthetic oil having 5W-20, 5W-30 or 5W-40 viscosity, If not

.20

TEMPERATURERANGEANTICIPATEDBEFORENEXTOILCHANGE

available,a petroleum-basedmulti-grade oil may be used having

5W-20 or 5W-30viscosity.

20 40 60 80

-lo 0

20 30

100

Engine Components

1,Air Cleaner

2. FuelShut-offValve

3. Carburetor

4. RewindStarter

5. BlowerHousing 6, OilDrain Plug

r-d

7,12 Veil ElectricStarter

8, Model,Type and

CodeNumbers

9, SparkPlug

10,ValveCover

Fuel Tank (Optional)

11,

NOTE:Using multigradeoils (5W-20, 5W-30, 5W-40,and 10W-30)will increaseoil consumption.Check oil level more frequently when using them.

FUELRECOMMENDATIONS

Carburetor Ao’justment Screws

Thisenginewilloperatesatisfactorilyonanygasolineintendedforautomo- ‘ tive use. A minimum of 85 octane is recommended.DO NOT MIX OIL

W/Tf-l GASOL/NE.

Useclean,fresh,lead-freegasoline,We recommendtheuse of Briggs& StrattonGasolineAdditive,partno.5041.Purchasefuelinquantitythatcan beusedwithin30days.This willassurefuelfreshnessandvolatilitytailored tothe season,Leadedgasolinemaybe usedif lead-freeis notavailable. Useof lead-freegasolineresultsin fewercombustiondepositsand longer valvelife,

NOTE: We DO NOT recommend the use of gasoline which contains

alcohol, such as gasohol.

MUST NOT contain more than 10 percent Ethanol and MUST be \

removed from the engine during storage. DO NOT use gasoline i

contain-

ing Methanol.See STORAGEINSTRUCTIONS(page27),

DO/vC)7’REMOVEfuel~ while engineisrunning. DO ~O~~lLL fuelfank j idje stop, turn idle mi~ure screw W clockwise (lean)untilspeed~

topointofoveflowing. A1/owapproximately 1/4 in. (5mm) of tank space for ~ tiel expansion.

However,if gasolinewith alcoholis used, it ~

I \ FINALADJUSTMENT

~Start engine and place equipmentspeed controlin ‘IDLE” or “SLOW ~position.Hold carburetorthrottle lever againstidle stop and adjust idle ~speedscrewtoobtain1300to1500RPM.Stillholdingthroffleleveragainst

~ startstoslowandthenWcounterclockwise (rich)untilenginejuststarts ~to slow.Finally,turnscrewto midpointbetweenrichand lean.

--l

IDLE

SPEED

SCREW

IDLE

MIXTURE

SCREW

~ng~fle Co~~Ofle~ts

12.Fuel Pump 13, Dipstick 14,Exhaust Manifold1

15.Crankshaft

16.Oil Filter 17,Air Cleaner

CARBURETORADJUSTMENTS

Minor carburetor adjustment may be required to compensate

encesinfuel,temperature,altitudeorload.Aircleanerandaircleanercover

mustbe assembledto carburetorwhen runningengine,

TWIN CYLINDER CARBURETOR ADJUSTMENT IS UNIQUE.

ADJUST CARBURETOR FUEL MIXTURE IN THE ORDER STATED

AS FOLLOWS: INITIALADJUSTMENT Gentlyturn idlemixturescrewclockwiseuntilitjustcloses.Turningscrew in too far may damage it, Then turn idle mixture screw 1-1/2 turns counterclockwise.This initial adjustment will permit the engine to be startedandwarmedup(approximately5minutes)priortofinaladjustment.

for differ-

adjust idle speed screw to obtain 1200 RPM, if governed idle spring

~Now ~isred,or900 RPM,ifgovernedidlespringisvhite. Releasethrottle lever,

If engine does not accelerate smoothly, readjust idle mixture screw approximately1/8turncounterclockwise(rich).

NOTE:Enginesoperatedataltitudesof approximately3000to 5000fee

(900to1500meters)orhighermayrequiretheinstallationofahighaltitude

carburetormainjet to achievebestengineperformance.Ifematicperfor-

manceisobserved,contacta Briggs&StrattonAuthorizedServiceCenter

for ahigh altitudejet.

Governed Idle Spring

GOVERNED IDLE SPRING

(RED OR WHITE)

EXHAUST MANIFOLD =

TO PREVENT ACCIDENTAL STARTING when servicing the engine or equipment, always remove sparkplug wires from sparkplugs. Disconnect

negative wire from battery terminal ifequipped wlh 12voltstarthgsystem.

Toservicecartridue:

a. Removeknobandcover plate, b. Removecartridgeand cleanbytappinggentlyonflat surface. c. Ifvery dirty,replaceorwash in a non-sudsingdetergentandwarm

water solution, Rinsethoroughlywithwater from insideout until

water

runsclear. Letcartridgedrythoroughlybeforeusing,

CHECKOILLEVELREGULARLY Checkaftereach8hoursof

operationor daily, BESUREOIL LEVELISMAINTAINED.

CHANGE OIL AS RECOMMENDED Change oil after first 8

operatingconditionschangeoil afterevery50hoursof operationoreverv

season, ‘tiichever occu~ first, Change‘oil eve~ 25 hours if engine is

operatedunderheavy loador athighambientairtemperatures.Remove oil drain plug and drain oil while engine is warm. Replace drain plug.

Removedipstickandrefillwithnewoilofcorrectgradeandweight.Replace

dipstick,

CHANGEOIL FILTER Replaceoilfilterafterevery10Ohoursofoperationoreveryseason,which

ever occurs first.Beforeinstallingnewfilter,Iightlyoilfiltergasketwithfresh

clean engine oil, Screw filter on by hand until gasket contacts oil filter adapter,Tighten1/2to 3/4turn for oil leaks,Recheckoil leveland addoil if reauired.

hours of operation. Thereafter, under normal

more, Starl and run engineatidletocheck

Oil Filter/ 011Drain ,

Petroleum solvents, such as kerosene, are not to be used to clean

cartridge. They may cause deterioration of the cartridge. DO NOT OIL

CARTRIDGE, DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY

CARTRIDGE.

d. Reinstallcartridge,coverplate,knobandpre-cleaner,

2, Reinstallaircleanercoverand reattachclipstosidesofaircleanerbody.

Round Dual Air Cleaner Element

OIL /

DRAIN

OIL PART NO.=

FILTER

491056 ~

AIRCLEANERMAINTENANCE

SERVICE AIR CLEANER

Removeand servicefoam pre-cleanerevery25 hoursor every season, whicheveroccursfirst, Servicepapercartridgeevery1(Xlhours oreve~ season,whicheveroccursfirst,

NOTE:Serviceair cleanermoreoften underdustyconditions.

f?OUNDDUAL ELEMENT 1, Unhookclips on bothsidesof aircleanerand removecover.

To servicepre-cleaner:

a, Slidefoam pre-cleaneroff cartridge. b, Washit in liquiddetergent andwater. c. Squeezeit dry ina clean cloth, d, Saturateit in engineoil, Wrapit inclean, absorbentcloth and

squeezeto remove EXCESSoil,

e, Reinstallpre-cleanerover cartridge,

f, Reinstallair cleanercover andreattachclipstosides of air

cleanerbody.

Square Dual Air Cleaner Element

$QUA&llUAL

ELEMEN~

1.Loosenknobandremovecoverassembly,

2. Removecartridgeand pre-cleanerfrom cover,

To service me-cleanec

a, Washpre-cleanerin liquiddetergentand water,

b, Squeezeit dry ina clean cloth, c.Saturateitinengineoil.Wrap it in clean,absorbentclothand

squeezeto removeall EXCESS oil.

To service cartridae:

a. Cleanbytappinggently onflat surface, b, Ifverydirty, replaceorwash in a nonsudsingdetergentand

warmwatersolution,Ilnse thoroughlywithwaterfrominside

outuntilwater rumsclear, Letcartridgedrythoroughly beforeusing.

Petroleum solvents, such as kerosene, are not to be used to clean cartridge, hey may uruse deterioration of the cartridge, DO NOT OIL CARTRIDGE. DO NOT USEPRESSURIZEDAIR TO CLEAN OR DRY CARTRIDGE.

Reinstall pre-cleaner in cover with foam toward cover.

4, Reinstall cartridge in cover with tabs on cartridge in slots in cover.

Reinstallcoverassemblyonair cleanerbody,

CLEAN ENGINE

Remove dirt and debris with a cloth orbrush, CleaningwitA aforcefulspray

ofwaterisnotrecommendedaswatercouldcontaminatethefuelsystem,

CLEAN ROTATINGSCREEN(ELECTRICSTART ENGINES) ORREWINDSTARTERGARD Brushgrass,chaffanddirtfromrotatingscreenor rewindstartergarddaily (moreoften ifneeded)to preventenginedamagecausedbyoverheating and/oroverspending,

LEAN COOLINGSYSTEM rass,chaffordirt

may clog the rotatingscreenandtheaircoolingsystem.

very100hoursoreveryseason,Whicheveroccursfirst,removetheblower xrsing andcleanthe areashownto preventoverspeeding,overheating

ld enginedamage,Clean moreoftenif necessary.

Coding System

CLEAN AREAS

OF ALL DIRT

LEAN SPARKARRESTERSCREEN

engine muffler isequipped with spark arrester screen assembly, remove

rery 50 hours or every seasonfor cleaningand inspection.Replaceif amaged,Contactany6riggs & StrattonAu~horizedServiceCenter.

~EPLACESPARK PLUGS

Spark Plug ,

,76 mm(.030 m.) ~

Toassuresrncmth operation, keep governorcontrols and linkage clean and free of debris.

Periodically clean mfier area to remove all grass, dirtand combusf-

ible debris,

-7.

. .

eplace every 100 hours of operation or every season, whichever ccursfirst,

OTE:Donotblastcleanspati plugs,Sparkplugs shouldbecleanedby

:rapingor wirebrushingand washingwith a commercialsolvent.

parking cannot occur if wire termira/ does not fit firmly on spark plug. !eform termina/ if necessary.

/ REPLACEFUEL FILTER i ReulaceIn-Linefilter evervseasonor moreoftenif required.Contactany

iggs & StrattonAuthori~edServiceCenterfor correctreplacement. -

Fuel Fjlter

ENGINEMAINTENANCESCHEDULE

Followthe hourlyorcalendarintervals,whicheveroccurfirst, Morefrequentservicemaybe required.

Changeoilafterfirst 8 hours,thenafterevery 50hoursoreveryseason, Note 1:Changeoil every25 hourswhen operatingunderheavyloador in highambienttemperatures, Note2 Clean moreoftenunderdustyconditionsorwhenairbornedebris is present.

BRIGGS& STRATTONAUTHORIZEDSERVICECENTERSAREREADYTO SERVEYOU AND COMMlllED TO QUALITY SERVICE.

GENERALINFORMATION ABOUTENGINE

Thisisatwincyiinder,overheadvalve,aircooledengine,Alldrilled/tapped holes and fasteners on this engine are ISO metric. However, where equipmentattachesto engine,SAE standardsapply.

Onmobileequipment,thisenginewilloperatesatisfactorilyatanyangleat

operator and equipment can function safely,

which

STORAGEINSTRUCTIONS

Enginesto be storedover 30days needto be protectedor drainedof fuelto prevent gum from forming in the fuel system or on essential

mrburetorparts. i. Forengine protection,we recommendthe useof Briggs& Stratton

GasolineAdditive, PartNo,5041,availablefrom anyBriggs& StrattonAuthorizedServiceCenter,MixAdditivewithfuelinfueltank orstoragecontainer.Runenginefir a shorttimeto circulateAdditive

throughcarburetor,Engineandfuel canbestored up to 24 months.

MODELSERIES290400,294400 & 303400

.............................................................2.W in, (68 mm)

Bore

Stroke,.............................0....................1..0..0.

Disriacement

Ho~epower ,.,,.,,.............................,..!,!,,......

RPM

Horsepower,.................................................

RPM

Home~wer ..................................................3OMW

RPM

,,,..................................!,..,....,.

2.60in. (66 mm) 29,3cu. in. (480cc) 290400

294400

12”HP d 3600

3600

MODELSERIES350400

.,.,..,......................................................2.83 in. (72mm)

Bore

..,.,,.,..,,.,,,,,,,,,,,,,,,.,,.,.......,..,,,,,.,,.,,.,.,.2.76in, (70mm)

Stroke

Displacement................................................

Horsepower NOTE:Forpracticaloperation,thehorsepowerloadingshouldnotexceed

85%ofthis rating.Enginepowerwill decrease3-1/2%for each1,000feet (305m)abovesealeveland1%foreach 109F(5.tYC)above77’ F (25QC).

TUNE-UPSPECIFICATIONS DESCRIPTION Air CleanerPre-cleaner(round)

Air CleanerCartridge(round),...................................,!.,,!..

Air CleanerPre-Cleaner(square)...................................... 805113

Air ~eaner Cartridge(square)...........................................

Air CleanerPre-cleaner(withfuel tank) .............................271794

Air CleanerCartridge(withtiel tank).................................393957

FuelFilter (withoutfuel pump)...........................................

FuelFilter (withfuel pump)

Oil Hlter...........................................l......................o.........491056

ResistorSparkplug (ChampionRC 12YC)........................ 4910E6

NOTE:Walkingtingerslogoand“Yellowpages”areregisteredtrademarks

invariousjurisdictions. CLEARANCES

SparkPlugGap..,..,...................................... .030in. (.76mm)

IntakeValve*,,.,,,,,,,.,,.,,.,..............................

ExhaustValve*..............................0..............

*Check whenengine iscold,

In some areas, local law requires the use of a resistor spark plug to suppress ignition signals. If an engine was originally equippedwith a

resistor spark plug, be sure to use the same type of spark plug for

replacement.

.,,..,.,,.,.,,,.,,................................

....................................,..,,

.,,,,,,,,,,..................................!..

34,7cu. in. (570cc)

18 HP@3600RPM

B&S PARTNO.

271271

394018

805267

298090

394358

DIMENSION

,004-036 in. (.1O-.l5mm)

,004-,006in, (,1O-,15rnm)

If Additive is not used or if engine is operating on gasoline containing alcohol, remove all tiel from tank end run engine until if stops from lack

of fuel.

2.Whileengineisstillwarm,drainoilfromcmnkcase.Refillwithfreshoil, 3, Remove spark plugs and pour approximately 1 ounce (30 ml) of

engineoil intoeachcylinder, Replacesparkplugs andcrankslowly to distributeoil.

4,Cleandirtandchafffromcylinders,cylinderheadfins,blowerhousing,

rotatingscreenandmufflerareas.

SERVICE& REPAIRINFORMATION

If service or repair is needed,contact a Briggs & StrattonAuthorized ServiceCenter.Toserveyou promptiyandefficiently,aServiceCenter will needmodel,type andcode numbersfrom yourengine.

YournearestServiceCentermay belocatedin the “YellowPageY’directoryunder“Engines,Gasoline,” “Gasoline Engines,”orsimilar category.Youmay also

locatethe ServiceCenterinyour mailingzip codearea

AuthorizedServiceCenterscarrya stockof Original Briggs&Stratton ServiceReplacementPartsandareequippedwithspecialservicetools. Askfor anduse~ originalBriggs &StrattonServiceReplacement

Parts which preserve the original design of your engine. Imitation replacementpartsofferpotentialrisksininternalconstructionaswellas fit,finishandwarrantyback-up,Trainedmechanicsofferexpertservice.

Majorenginerepairsrequirepropertools andathoroughknowledgeof internal combustionengine repair procedure.

Briggs&Strattonpublishesillustratedshop

manuals,partslists andowner’smanuals for every engine it manufactures.To receivealistofavailablepublications,writeto

Briggs & Stratton Corporation,P,O, Box

1144, Milwaukee, WI 53201, Attention: ServiceDivision.Theshop manualshown

hereincludes“TheoriesofOperation,”com-

mon specificationsand detailed information coveringthe adjustment,tuneupand

repairof Briggs&StrattonOHV,twincylin-

der, 4 cvc~- ermines and is available from anv Brictgs& Stratton Authori~ed

order directiyfrom the factoryat the above address,Requestmanual,

PartNo. 272144.

by calling: 1-800-233-3723.There areover30,000

.W AuthorizedServiceCentersworldwideavailableto

.W1

serveyou,

‘Service

Center.

Yoti

‘~an also

ABOUTTHEWARRANTYONTHE VANGUARDENGINE

If warrantyserviceis needed,contactyour nearestAuthorizedBriggs& StrattonService Center,For prompt attention,your Centerwill need to knowthe enginemodel,typeandcodenumbers,thetroubleexperienced andthetotal numberof hoursthe enginewas run.

BRIGGS & STRA’ITON WARRANTY COVERS ONLY DEFECTIVE MATERIAL AND/ORWORKMANSHIP.

Briggs& StrattonCorporationwelcomesthe opportunitytomakejustified warranty repairs by any of its Authorized Service Centers. In most instances,the requestsfbr warranty repair are handled in a quick and routinemanner.However,somerequestsforwarrantyarereceivedwlich appearnot justified. Inthese cases, thoughengine ownersmay not be awareofit, theprematurefailure oftheirenginewascausedby abuseor neglect,ortheequipmentonwhichitwasmounted,ratherthantheengine,

Ifyoudifferwith thedecisionofyour ServiceCenter,investigationwill be

madeto determinetheapplicabilityofwarranty.Askthe ServiceCenterto submitall supportingfactstotheFactoryfor review.Ifthe Factorydecides that your claim is justified, you will be fully reimbursedfor those items accepted as defective. To avoid misunderstandingwhich might occur betweenengineownersandAuthorizedBriggs&StrattonSewiceCenters, we listbelowsomeof thecausesof enginefailurethat Briggs&Stratton warrantydoesnotcoverfor repairor replacement.

LIMITEDWARRANIY

FORVANGUARDENGINES

“Fortwoyearsfromdateof purchase,Briggs&StrattonCorporation

w“llreplacefor theoriginalpurchasers,free ofcharge,anypart, or

partsoftheengine,founduponexaminationbyanyFactoryAuthorizedServiceCenter,orbythe FactoryatMilwaukee,Wisconsin,to bedefectiveinmatenalorworkmanshiporboth.Thisistheexclusive remedy,

“For’fiveyearsfromdateof purchase,Briggs&StrattonCorporation

will replacefur theoriginalpurchasers,freeof charge,anypart,or

partsofthe MAGNETROhK@IgnitionSystem(excludingthe spark

plug),founduponexaminationbyany FactoryAuthorizedService

Center,or bythe Factoryat Milwaukee,Wisconsin,to bedefective in materialor workmanship,or bolh, so as to result inthe loss of ignition,Thisis the exclusiveremedy.

“All transportation charges on parts submitted for replacement under this Wamantymust be borne by purchaser, For warranty servicecontactyournearestAuthorizedServiceCenteraslistedin the‘YellowPages’under‘Engines,Gasoline’or‘GasolineEngines.’

THEREISNOTOTHEREXPRESSWARRANTY,IMPLIEDWAR-

RANTIES, INCLUDINGTHOSE OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSEARE LIMITED TO ONEYEARFROMPURCHASEANDTOTHE EXTENTPERMITTED BY LAWANY ANDALL IMPLIEDWARRANTIESAREEX-

CLUDED,LIABILl~FORCONSEQUENTIAL DAMAGESUNDER ANYANDALLWARRANTIESAREEXCLUDEDTOTHEEKENT

EXCLUSIONIS PERMllTED BY L4W.

Somejurisdictionsdo notallow limitationson howlong animplied warrantylasts,andsomejurisdictionsdonotallowthe exclusionor

limitationof incidentalor consequentialdamages, so the above

limitationand exclusionmay notapplyto you,This warrantygives you specificlegalrightsandyou may alsohaveother rightswhich varyfrom jurisdictionto jurisdiction.”

Briggs&StrattonCorporation

F.P,Stratton,Jr.

Chairmanand ChiefExecutiveOfficer

WARRANTYPERIOD

ENGINES CONSUMERUSF tion COMMERCIALUS13 tion

*For purposesofthiswarrantypolicy,“consumeruse”shallmeanpersonal residentialhouseholduse by the original retailconsumer, “Commercial use” shall mean all other uses, including use for commercial, income producingorrentalpurposes.Oncean enginehasexperiencedcommercialuse,it shallthereafterbeconsideredas acommercialuseenginefor purposesof thiswarrantypolicy.

- Lifetimelimitedwarrantyofthe Magnetronignitionshallcoverpartsand laborfor the firstfive (5)yearsftom thedate of purchase;thereafteronly

parts, “Lifetime” shall mean lifetime of the engine in the hands of the originalpurchaser,

- Appliesto equipmentretailed inthe U.S.A.and Canada.In all other

com#i:Ethe warrantyfor CONSUMERUSEis thesameas COMMER-

.........................All Vanguardand l/Cengines.

.,..,.,,.,,2 year-engine Ltietimew-Magnetrorv13igni-

........2 year-engine Ltietime*-Magnetrorx10igni-

andre-oilthe aircleanerregularly.

6,Damageorwearcausedby gritfrom blastcleaningsparkplugs is not

coveredbyWananty,Wedonotapproveofcleaningsparkplugsonan abrasiveblastcleaningmachine,sincegritcan remainintheplug,and

laterenterthe engine.

7.Warrantydoesnotcoverthetune-uporadjustmentofan engineunless theneedforsuchrepairisthe resultof defectsin materialorworkmanshiporboth.Ifequipmentisassembledandadjustedbytheowner,the engineoperatingandmaintenanceinstructionsaresufficientlyclearto

permittheaverageownerto makeminoradjustments.Such minor adjustmentsare NOTcoveredbyWarraniy,

8, Brokenparts,which result from excessivevibrationcaused by loose

engine mounting,loose cutter blades, blade unbalance, improperly attachingequipmentto engine crankshaft,overspendingor abusein operation,are notcoveredbywarranty.

9,Repairoradjustmentofassociatedpartsorassembliessuchasclutches,

transmissions,remotecontrols,etc.,whicharenotofBriggs&Stratton

manufacturewill notbe coveredby Briggs& StrattonWarranty, 10,Only ORIGINALBriggs&Strattonparts,or partsapprovedbyBriggs &

Strattonmaybecoveredby Warranty.

NO REGISTRATION (WARRANIY) CARD IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON ENGINES. SAVE YOUR PURCHASERECEIPT. PROOFOF PURCHASE DATE

andauthorizedBriggs&S~attonservi~eaccounts,wearelis~ngsomeof thecausesofenginefailure,whererepairorreplacementisNOTcovered by Brlggs & Stratton warranty.

NORMALWEAR: Warrantywill notcoverrepairwherenormaluse hasexhaustedthelifeof apart orengine,Engines,likeallmechanicaldevices,needperiodicparts replacementandserviceto performwell.Itshouldberememberedthatthe servicelife of any engine is dependenton the care it receives andthe conditionsundervhichit hastooperate,Someapplications,suchastillers, trashpumps,rotaymowers, areveryoftenused industyordirtyconditions, whichcan causewhat appearsto be prematurewear, Suchwear,when causedby dirt, dust,spark plugcleaninggrii or other abrasivematerial, which hasenteredthe engine becauseof impropermaintenance,is not coveredby Wamanty.

ABUSE ORNEGLECT

1.Bentorbrokencrankshafts:Suchdamageisnormallytheresultofabuse, such as strikinga solid objectwith the cutter bladeon a rotary lawn mower,andis notcoveredbyWarranty,

2, Enginerepairsrequiredfromthe useof contaminatedorstalefuel are not

‘coveredbvWarrantv,Suchfailureswouldincludestickingvalves,and

carburetor andfue~pipeswtich are cloggedbygum d~positswhich formthroughthe useof stalefuel. Always usecleanfresh regulargasoline.

Partswhich are scored or broken becausean engine was operated

withoutsufficient lubricatingoil, the proper gradeof lubricatingoil or contaminatedlubricating oil are not coveredby Warranty.Check oil level at leastevery five hoursand refill whennecessary.Changeoil at recommendedintervals,

Damagecaused by overheating or overspeedingis not covered by

Warranty,Overspendingor overheatingoccurs ifthe coolingfins becomepluggedwithdirt, grassordebris, or if an engineis operatedin a confinedarea without sufficientventilation.Cleanfins on thecylinder,cylinderheadandflywheelregularly,

5, Damageor wear causedby dirt which entersthe engine becauseof

improperaircleaner maintenanceis notcoveredby Warranty,Clean

WARRANTYIS AVAILABLE ONLY THROUGH SERVICECENTERS WHICH HAVEBEEN AUTHORIZEDBY THE BRIGGS & STRATTON CORPORATION.YOUR NEAREST SERVICE CENTER IS LISTED IN THE YELLOW PAGES OF YOUR TELEPHONE DIRECTORY, UNDER‘ENGINES, GASOLINE” OR “GASOLINE ENGINES.”

Seeenginesectionof thismanualbginning on page21to assistyouin resolvingenginerelatedproblems.

PROBLEMS:

ENGINEFAILSTO START ENGINERUNSROUGH ENGINEBACKFIRES ENGINEFAILSTO ACCELERATE ENGINEREDUCESSPEEDTO LOWRPMUNDERLOAD

B.DefectiveCarburetororgas leakage.

A, Cleancarb,

B, Replacecarb, C.Choke lockedin closedposition,

D. When replacing tielpump insure that it is the same

pressure rating recommended by manufacturer.

CAUSESAND/ORSOLUTION:

1. Lossof fuel. A. Emptygastank.

B, Pluggedfuel lineor filter. C, Defectiiefuel pump(Replacewithmfg.suggestedreplacement

partsonly),

D,Gaslinekinked,crushedor quickdisconnectinsidethetrucknot

connected.

2, Blownmasterfuse,

A, Electricalshort. B. DefectivefUse.

3. Defectivespark plugs, A. Removeandreplace.

B,Cleanand regap.

4, Defectivesparkplug wires,

A, Sparkplugwiresalongwith manyothersmay,at certainpoints

comeincontactwithheatedparts(exhaustmanifold)orabrasive parts(sharpmetal,teflonhose).This maybe taken intoconsiderationforelectricalshorts.

B, Removeand replaceignitionmodule,

5. Lowcompression, A, Defectivevalve.

B.Stuckvalve. C,Worncompressionrings. D, Defectivepiston.

6, Floatswitch inrecoverytankinoperative.

NOTE:Temporaryrepairpermitsdisconnectionoffloatswitchwire

betweentankandmachine,Continuedoperationwiththiscondi-

tionwill compromisevac blower. A. Switchstuckon uprightpositionbyforeignmaterial. B, Defectivefloat switch.

9. Improperlyadjustedcarb. NO~: A comprehensivemanualisavailableanddefines

necessaryadjustments.

A. Incorrectairmixtureratioadjustment.

B, Incorrectfloat leveladjustment.

10.Carbonbuild-upin cylinders. NOTE:Carbonbuild-upcanbe minimizedby usingunleaded

regulargas.Shouldcarbonremovalbenecessary,reinstall headswithnew gaskets.

A, Carbonbuild-upmaybe excessiveifcarb, orvalvesare

improperlyadjusted,enginaRPMtoo low,improperspark pluggap,

B.Removecylinderheadsandeliminatecarbonbuild-upwith

wire brush.

11.Incorrectignitionmoduleairgap.

A. Regapignitionmoduleto specifications.

12, Dirtyair cleaner,

A. Ifexhaustgasketsdo notseat pmpetly or heatexchanger

gasketis bad,exhaustmay heatandmeltthe air cleaner

requiringmuchclean-uprepair.

13.Cloggedfuelfilter.

A. Removeand replace.

14.Lowoil levelor malfunctioningoil pump.

A. Oilpressuresensorscan beinstalledonthe engine,Thiswill

eliminatemanyproblemswhichmayoccur.

15, Vacuumtankfull.

A, Emptyvacuumtank.

7, Enginewill notturnover,

A. Deadbattery. B. Looseterminalconnectionon batteryor ignitionswitch, C, Defectivestarter. D,Seizedengineor blower.

The entire electrical system operates on 12 volts DC which is provided by NOTE: When new battery is installed insure it is properlychargedbefore

abattery.Batterylevelsaresustainedbya 16ampalternatordesignedwith

installationor damageto the chargingregulatormayoccur.

the engine.

PROBLEM: Low battery voltage

Cause

Defectivebattery. Corrodedbatteryterminals. Cleanterminalsand batteryposts. Lowbatteryfluid. Lwse wiringwithh electricalsystem.

Electricalshortinwiring system.

Poor ground connection.

PROBLEM: Inoperative hour meter Cause

Time is not advancing c.mrectfy.

Soiution

Removeand replace.

Addwaterto

Examineall terminalconnectionsandverifythat hey are secure.

appropriatelevel,

Examineelectrical systems for he wires.

Examine terminal and remove corrosion it necessary.

So/ution

Verii f2 volt DC is available at the hour meter with the ignitkm switch turned on.

This can be amomplished with a voltmeter or a test lamp.

Remove and replace hour meter if 12 volt is available.

A nylon gear wiihin the

machine or truti. You mayW simptytappingonthemetertoby to free the

nylon gear.

dock mayhave been jammed due to sudden jolt of the

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AQUACAT

Any freezing of this machineis not coveredby wamantyandduring the coldermonthsofoperation,carefulprotectionshouldbeofutmostconcern.

THE FOLLOWINGPRECAUTIONSARE RECOMMENDED:

1,Runmachinebefore

the nightbefore, includinghosesandwand.

2. Insulatethegardenhosefromthecoldgroundbyrunningitthroughand extra 1-1/2inchvacuumhose.

3. Leavetruckdoorscloseduntiltime cleaningbegins,thenopenslighfly

for

ventilationof air cooledengine.

4, In colderclimates,insulatingthetuck wallsandfloor boardswill help

protectthe unit.

5, Donl procrastinate during the cleaning operation or the hot water

solution

linewillalsofreezeontheground.Thesolutionlineshouldbeinsulated

in extremelycoldclimates,

6.Wheneverpossible,thetruckandmachineshouldbestoredinaheated garageatnightorovertheweekend.Ifnotpossible,placea 1500watt

electricheater insidethetruck, aimeddirectiyatthe machine,Never

use

apropaneheater-it causesexcessivemoistureonthetruckceilingand the possibilityof itgoingoutishigher. Ifthe machineandtruck are left

outsidewithaheater,youshouldfirst drainallpossiblewater fromthe machinecleaningtoolsand hoses,(Theyfreezealso.)

TO DRAINTHE MACHINE,FOLLOWTHESESTEPS: 1, Before shutting off the machine, removethe chemical line from the

chemicaljugandplaceinamixtureof50/50anti-fTeezeandwater.Wtth

the cleaningtoolon, allowmixturetofill chemicalsystembackto the

chemicalmix tank.

2,Loosenthepetcockvalveonyourbypassdrainhoseandallowthewater

to drainthoroughlyfromthe mix tank.

3,Usingthefreezeguardhoseprovidedwiththemachine,freezeguardthe

unit. Firstplugtherubberstopperinto the outletof therecoverytank, Thenwiththe pressureregulatingvalveunscrewed,plugtheotherend ofthefreezeguardhoseintothehighpressurecleaningsolutionfitting

on thefront of the machine.Runthe unituntiltheenginestops.

4.Openthe

mix tank drain valve and drain out the remainder of the water.

The unit is now freeze guarded.

leaving for the first job to insurenothinghasfrozen

seriouslydamagetheinternalplumbing,highpressurepumpandheater

(Chemicalsuchasconcentratedacids,solvents,endsomepaintoiland

greaseremoverswhigh concentrationofsolvents).

Themanufacturerrecommendsonlytheuseofchemicalscontainingrust andcorrosioninhibitomandwatersofteningagentsto preventchemical build-upwhichmayleadtocomponentfailureandwarrantyinvalidation.

NOTE:AtnotimeshouldachemicalsolutionwithapHof lessthan 7or higherthan 10be usedinthe unit.

pH CHART

234567891011 12

+AciD — 4NEUTRAL

‘ALKALINE ~

I I

13 14

CLEANINGSTROKE PROCEDUR130VER-WElliNG

PURPOSE:TOeliminateexcessmoistureremaininginthecarpetfiberand the sawtoothappearancewhichresultsfrom diagonalmovementof the cleaningtoolon alltypesof carpet.

PROCEDURE:Always movethe cleaningtool in smooth forward and

backwardstiokes.Apply slightpressureto the forwardstroke whilethe

solutionis injected intothe carpet.Whenextracting (drying),applyfirm

pressureonthe forwardstroketoensureapositive“lock”forthe vacuum

andminimizethe“hopping”effectresultingonunsmoothcarpet,Duringthe

forwardandreversestrokes,movementtothe rightorleft should onlybe

accomplishedat the extreme rear of the stroke. Overlapping is also

importanttoensureevenapplicationofsolutiontopreventsaturationwhen

cleaning wand is stopped twice at the same point at the rear of the

cleaningstroke.

Failureto adoptthis procedurecan resultin increasedchanceof ‘clean streaks’,fiber shrinkage,brown-outandlongerdryingperiods.

INCORRECT METHOD

CORRECT METHOD

Overlap Between Strokes

PRECAUTIONS

Yourmobilecarpetcleaningplanthasbeenengineeredusingthelatestand

most sophisticated technology available, to producethe finest carpet

cleaningresults possible.Despite

the carpet cleaning trade, and it can produce only as good a job as the

personoperatingit.

Therearenotshortcuts togoodcarpetcleaning.Itrequirestime,cleaning knowledgeandthe useof goodchemicals.

Themanufacturerrecommendstheuseofspottingagents,andtrafficlane cleanerspriorto the actualcleaningofcarpeting,asrequired.

Theuseofsomechemicalsthroughyourmobilecarpetcleaningplantcan

this, however, it remains only a tool of

d ng

Stroke

OVER-WETTING

Over-wetting is annoying to all concerned and sometimes, leaves a bad impression of the cleaning process used.

THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER-WElllNG:

1. Too few vacuum strokes or improper saw-tooth vacuum strokes as

in the previous illustration.

2. Obstructed, cut or kinked hoses.

3. Vacuum tank drain valve left partiallyopen.

4. Clogged vacuum blower filter orvacuum tank lid notsealing properly.

5. Cleaning a heavily foam-saturated carpet without defoamer. (1% recoin mend crystal type.)

shown

Wand Valve Assembly 169-005

Jet Assembly

WANDVALK, JET& WAND PARTSLIST

] ITEM PART NO. DESCRIPTION

167-013

2 094-009

lo7-13Jl Valve body - Hy

3 4 052-152

5 i55-oo3

6 097-011 7 027-Cal

8 139-004 Ring, sohrdonvaive retaining

139-003 Ring keeper

9 10 097-010 11 097Q22 O-Rhg, solu$on vake / flw mtr - small 1 12 107-129 13 052-050 14 052-071 15 16 143402 17 052-153 Brass stabilizer housing 18 186-001 19

21 061-0Q6 Handle, pressure guide wand 22 23 24 173-CM Wand, s/s Hydra hoe - stock 25 082-001 26 27

Not shown in illustrations

052-082 Elbow, i/4 brass 45 street

076-005 Jet, #6 s/s 076003 Jet, #4 s./s 094428 Nut, brass - jet assembly group

094-035 Nut, 5/16-18 sLsnylock half nut

143-012

168-OQI Tube, s/s Hydra hoe solution 061-0Q7 Handle grip - Hydra hoe

154031 169-055 Valveassembly,s/sHydrahoe

1434N4 094-009

Tfgger, castHydrahoevaive Nut, 1/4-20 s/snylock

draMaster vaJve 1

1/4 Male comp. fitting - Hydrahoe

Spring,

HydraMastersolution vaJve 1

O-Ring, HMaster solution valve cap Cap, s/s HMaster solution valve

, HMaster solution valve 1

O-Ring, HM valve plunger - large

Plunger, HydraMaster solutionvalve 1 440 Male quick connect wlviion NippIe, 1/4 brass hex

Screw, 1/4 - 20x 1* HHC ski

Stabilizer

Hydra hoe, BobCat Hydra hoe, AquaCat

Screw, 5/16 - 18x 3/4’ SISHHC

Lips Sk Hydra hoe (2 piece set)

Spacer, 1/4 x 5/16 - s/s sol. vaNe 5

Screw,1/4-20x 1.5’ HHC ski

Nut, 1/4 -20 s/s nylock

QTY,

1 1 1

1 1 1 1

1 1 1 1 1 1

2 1 i 1 1

Wand Assembly

q$t!&)w

23 -

0“

See Jet assembly

/’”

(’

Wand assembly

See

PROCEDURES

To avoid ccstly repaim and down-time, it is imperative to develop and practicegoodmaintenanceproceduresfrom thebeginning,Theseprocedures fall intodaily, weekly, monthlyand quarterly increments, andare outiinedbelow.Wehaveprovidedamaintenancelogforyourconvenience on next page;it is recommendedthat you affix a copy of the log onthe vehicledoornearyourunitforconvenienceandtoserveasamaintenance

reminder.

DAILY

Checkengineoil level.

Inspectgardenhose screen-clean as needed.

Visuallyinspectmachineforloose wires,oil leaks, water leaks, etc.

Inspectrecoverytanks/s filterand filter bagfor tears, holes,etc. - clean,

repairor replaceasneeded.

Lubricateblowerwith LPS-1through blowerinlet.

OVERALLCAREOFUNIT

MAINTAININGTHE ORIGINAL APPEARANCEOFYOUR UNITIS MPORTANTFORTWO REASONS: 1,It representsabig dollarinvestmentfor yourcleaningbusinessandits

appearanceshouldreflectthatfact.A dirtymachineisnotprofessional!

?.Maintenance,troubleshooting,andrepairismucheasierto accomplish

onacleanwellmaintainedunit,Regularcleaningofthe machineoffers

youanopportun”~tovisuallyinspectallfacetsofthemachineandspot

potentialproblemsbeforethey occur.

~fJLLOW]NG MAINTENANCE JS RECOMMENDED BY THE MANUFACTURERAT THE FREQUENCYINDICATED.

AFTEREACH JOB: :heck recovey tank, sls filterand filterbag asrequired.

WEEKLY

Changeengineoil. (50hours ofoperation,) Checkengineaircleanerfilter - clean as necessary. Checkhighpressurepumpoil - add as necessary. Checkdrivecouplersetscrews- tighten as needed.

Checkpumpdrivebeltfor wear- tighten as needed. Checkpumppulleys-tighten as needed. Checkfuellinesfor wear/chafing, Checkallnuts andbolts- tightenas needed, Checkheater burnerassy.unionfortightnesslleaks. Cleanvacuumtankthoroughlywith high pressurewasher.

Flush water and chemical systemwith 50/50 white vinegarsolution.

MONTHLY

Greaseblowerbearingfittings. RemovepressureBypassValve stem, greasecup andstem, reinstall. Checkwaterlevelin battery.Cleanconnectionsas needed

QUARTERLY

Changeoilin blower. Checkenginecompression, Checkforcombustionchambercarbon deposit. Changespark plugs.

IMPORTANT: Recorddate andmachinehoursin maintenancelog.

DAILY: Wipemachinedownthoroughlywithadampcloth;flushrecoverytankout :horoughly. leeded;remove,thoroughlycleanandreinstallstainlesssteelfilterscreen

nrecoverytank; inspectandcleanvacuumsloton cleaningwand;check wandheadfor sharpedgesthat couldtearcarpet - file downasneeded; deanwandto maintainoriginalappearance;wipedownvacuumandhigh pressurehosesasneeded- visualiyinspectforcuts, etc,

WEEKLY: Wipedownentireunitasneeded-applygoodcoatofautowaxtoall painted surfacesinsideand out, andto control panel;thoroughlycleanrecovery tank using high pressure hot water (unit with optional high pressure cleaning tank,thoroughlycleanremovingall lint build-up,inspectfor damageand reinstall.Removefilterbag,thoroughlycleanandreinstall-iftom,replace; emptychemicalfrom chemicalcontainer,washoutthoroughlyto remove anychemicalbuild-up;inspect chemicalfeedline strainerand use 50% whitevinegar/watersolutiontoremoveanychemicalbuild-up;thoroughly cleanwandandinspectforcloggedjet,debrisinvacuumslotandleaking fittingsatvalve, Apply lightcoat of auto waxto wand.Thoroughlyclean vacuumandhighpressurehosesincludinghosecuffs-inspectforwearor damagetohosesandquickconnectfittings,Inspectgardenhoseconnect/ adapterscreenfor debris,removeandcleanthoroughly,Inspectalllines forwearor abrasionsthat maycause possibleleaks.

Empty filter bag and inspectfor rips, tears,etc. - replaceas

gunmaybeusedforthis);removestainlesssteelfilterinrecovery

AS REQUIRED: DESCALING

Scaledepositsontheinteriorof heater tubes can causea noticeableloss

in heating performance, Deposits of this kind result from hard water deposits,excessivechemicaluse,improperchemicals,etc.Thefrequency

withwhichdescalingproceduresare requiredw“llvary,

Ifyourareahasparticularlyhardwater or yousee evidenceof depositsin the water system, you may have to descale monthly, To descaleyour system,add anappropriatedescalerchemicaltoyour mixtank,circulate inthe heater,letstand,flushand repeatas necessary,Cleanallscreens andstrainers,andcheckthemfrequentlyfollowing descaling.

MAINTENANCELOG

DAILY CLEANING & INSPECTION

oil - check

Engine

Garden hose screen - clean Machine - general inspection

WEEKLY SERVICE

Clean vac tank filter bag af!er every job Blower inlet - spray with LPS 1 after last job

MAINTENANCELOG

DAILY CLEANING & INSPECTION Engine oil - check Garden hose screen - clean

Machine - general inspection

wEEKLY SERVICE

MAX

fiRS

BLOWER check 011 level

PUMP OIL check (top ot sighl gauge)

BELTS & PULLEYS check hghtness

HIGH PRESSURE LINES check for chafing

NUTS & BOLTS check t!ghtness

BATTERY LEVELS check

VACUUM TANK clean

WIRING check for chaftmg

25 CHEMICAL SYSTEM flush wlvmqar

50 ENGINE OIL CHANGE

SERVICE

MONTHLY SERVICE

100

BLOWER grease bearing

100

ENGINE AIR CLEANER clean

100

BY PASS VALVE grease cup & stem

100

OIL FILTER CHANGE.

QUARTERLY SERVICE (3 MONTHS)

300

HLOWE~

300

ENGINE compression

300

SPARK PLUGS change

OIL change

Clean vac tank filter bag atter every 10b

Blower relet - spray with LPS 1 after last job

I OATE,HRS I DATE,HRS I

DATE;HRS I DATE!HRS I C)ATE/tiRS I DATE/HRS ] DATE,HRS

—

WARRANTYINFORMATION

Toavoidmisunderstandingsvhich mightoccurbetweenmachineowners andmanufacturer,wearelistingcausesofcomponentfailurethatspecificallyvoidswarrantycoverage,Suchcausesaslistedbelowshallconstitute abuse or neglect.

BLOWER:FailuretolubricateimpellersdailywithLPS-1lubricant,Failure to lubricate bearings as recommendedin blower manual, Failure to maintainproperoil levelsinthe blower,Failureto usethecorrectoilgrade and viscosity as recommended in blower manual, Failure to properly maintain blower safeguard systems such as waste tank filter screen, vacuum safety relief valve and waste tank automatic shut-off system. Allowingfoamto passthroughblower.

HIGHPRESSUREWATERPUMP:Failureto maintainproperoillevelas

recommendedin pumpmanual.Failureto changeoil in pumpat recommended intervals,Failure to protect pump against freezing. Failureto maintainpumpprotectionshut-offsystem,Failureto usewatersoftenerin hardwaterareas,Useof improperchemicals.

VAC TANK Failureto properlymaintainfilteringdevicesintank, Failure to clean tank as recommended by manufacturer. Failureto maintain vacuumsafetyreleaseintank lid. Useof improperchemicals.

CHEMICALPROPORTIONED:Useof improperchemical.Failureto use

water softener in hard water area. Operating machine without proper

chemicalfilter screen,Failureto protectagainstfteezing.

CONTROL PANEL: Failure to protect flow meter and water pressure gaugeagainstfreezing.

VACUUM AND SOLUTION HOSES: Failure to protect hoses against freezing. Failure to protect hoses against burns horn engine/blower exhaust.Damageto hoses from being runover by vehicles. Kinkingor crackingfromfailuretostoreorunrollhosescorrectly.Normalwearandtear fromeverydayuse.

HOWTOORDERPARTS

Toobtaina properdiagnosisof your malfunction,and to orderwarranty ‘emplacementparts,itisimportantthatyouproceedinthefollowingmanner

I. tiII HydraMaster Warranty/ServiceDepartmentat (206)775-7275.

2,GwetheWarranty/Servicerepresentativethefollowing information:

A, Nameofyour companyand youraddress. B. Equipmentmodel (i.e.HydraCat,BobCat2, etc.). C, Dateof purchase.

D, Hourson the unit.

E,Seriai numberof unit, F, Nameof personauthorizedto order parts. G, Salesmanunit purchasedfrom.

H. Descriptionof malfunction.

1,Pressurereadingson highpressuregaugewith wandturned

on and off. 3, If warrantyreplacementparts are needed, pleasespecify methodof shipmentdesired,NOTE:Allreplacementpartsaresentfreightcollect,via:

AsLLPS,

B.Air Freight C.Air Mail

4. Do not give malfunctioningparts to a HydraMastersales or service representative.All parts must be returnaddirectfyto HydraMaster,

Freightprepaid.

D,Air Express E.Auto Freight

PARTSORDERS

Toexpediteyour partsneeds,pleasecallyoursales representative.

Inmost instance,heeitherstocksorhasaccesstopartsthrougharegional servicecenter,Intheeventpartsareunavailablelocally,contactthefactory andcoordinateyourneeds.Ifthis becomesnecessaty,alwaysindicatethe method of shipment you desire, i.e. UPS, Blue Label, Air Freight,Air Express,etc. HydraMasterPartsDepartment.Phone(206)775-7276,

CLEANINGWAND:Failuretoprotectagainsttleezing, Obviousphysical abuseofwand.

WATER HEATER: Over pressurizationof the system (recommended maximumworkingpressure-800 PSI),Failureto protectagainstfreezing. Modificationofthe gas deliverysystem,

WARRANTYPROCEDURE

WarrantycoverageisavailabletoyouONLYthroughHydraMasterCorporation, 20309 64th Ave. West, Lynnwood, Washington 98036, When warranty partsare needed, vmiteHydraMaster Warranty Dept. at the aboveaddress,or calltheWarranty/ServiceDept.at (206)775-7275.No collect calls will be accepted. Houm of Warranty/Service Dept. are 8:00 amto 5:00pm PacificTime. IMPORTANT HydraMaster’swarrantypolicyprovidesreplacementparts without charge fir thirty (30) days to customers maintaining current accountstatus.An invoicedatedthirty (30)daysfromdateofreplacement partsshipmentwilibesenttothecustomerforthe amountofthepartssent. The customer’sfaulty partsmustbe returnedfor evaluationpriorto the expirationofthethirty(30)dayperiod.Uponwarrantyapproval,acreditwill be issued the customer for the replacement parts invoice, Warranty

disapprovaiorfaiiuretoratumthefaultypartswithinthethirty(30)day period allowed will result in the customer being charged for the

replacementpartssent.

ONEFINALNOTE

Any questions you have regarding the warranty program should be directedto theWarranty/ServiceDepartmentpersonnelat HydraMaster Corporation.

Weshallalwaysendeavortobefairinourevaluation ofyourwarrantyclaim,

md shallprovideyouwith a completeanalysisof ourfindings,

+ydraMasterWarrantyPolicy %ectiveFebruary1,1989

-lydraMasterwarrantycoversonly defectivematerialsand/orworkman~hipfor the periods listed. Labor, and/or specificallyexcluded.

diagnostic reirn~r=rnent is

H“uaEat

2 YEAR

LIMITED WARRANTY PLAN

HydraMaster warrants products of its manufacture to be free from defects in material and workmanship if properly

installed, maintained, and operated under normal conditions with competent supervision. No person, agent, representative or dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in connection with any of HydraMaster’s products. This warranty shall extend to the original purchaser of said equipment for the periods listed by component below from date of installation. If repairs or replacements are made by the Purchaser without HydraMaster’s written consent, HydraMaster’s warranty shall cease to be in effect. No allowance

be granted for any repairs or alterations made by the Purchaser without HydraMaster’s prior written consent.

will Machinery, equipment and accessories furnished by HydraMaster, but manufactured by others, are warranted only to

the extent of the original manufacturer’s warranty to HydraMaster. HydraMaster agrees at its option to repair at the point of shipment, or to replace without charge any parts or parts of

products of HydraMaster’s manufacture, which within the specified warranty period shall be proved to HydraMaster’s satisfaction to such alleged defect. HydraMaster will pay all freight and transportation charges, via normal ground shipping means, for replacement of parts covered under this warranty.

HydraMaster’s liability to Purchaser, whether in contract or in tort arising out of warranties, representation, instructions, or defects from any cause shall be limited to repairing or replacing the defective part or parts. To qualify for warranty coverage, defective parts must be returned to HydraMaster within 30 days.

No liability whatsoever shall attach to HydraMaster until said products have been paid for Except as stated in this section and in the preceding section titled

guarantees or warranties of merchantability, fitness, performance or otherwise, express, implied or statutory, and HydraMaster shall have no liability for consequential, incidental or other damages, howsoever caused.

FRAME/COVER ASSEMBLIES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VACUUM RECOVERY TANK/CHEMICAL MIX TANKS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHEMICAL PROPORTIONING SYSTEM: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING WAND: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE: (Thru original Manufacturer. On Direct Drive units

seeoriginal Manufacturer’s warrranty.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 years

INTERNAL MACHINE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VACUUM BLOWER: (Thru original Manufacturer. See

Cooper Industries warranty.) HIGH PRESSURE BYPASS VALVE

EXTERNAL MACHINE HOSES.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BELTS, FITTINGS, FILTER SCREENS, GAUGES:

WATER HEATER OR HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH PRESSURE PUMP: (Thruoriginal Manufacturer. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l year

AllcomDonents not s~ecificallv referenced in the above schedule are covered under this wamanty fora period of one (1) year; except thos; parts w~ich areconsidered expendiblein normal use.

Freezing of any water or chemical related component will VOID all warranties components, internal or external, of this equipment.

Deposits and build-up in the water, chemical or heater systems, due to hardness in chemicals which result in deposits, will void all warranties on affected components.

have been defective when shipped, provided the Purchaser promptly notifies HydraMaster, in writing, of

“Warranty” and except as to title, there are no

3 years 3 years

..2 years

... ..2 years

. . . . ..2 years

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l year

, . . . . . . . . . . . . . . . . . . . . . . ..l year

oh water or chemical related

the water used or poor quality

2 years 2 years .1 year

HYDI?A3-?.FS=ER

Corporation

HYDRAWSttti

20309 64thAve.W. / Lynnwood,WA 98036

HYDRAMASTER

corporation

AQUA CAT 3.9

HEAT EXCHANGER SYSTEM

EXPLODED VIEW

and

PARTS LIST

000-038-019 000-131-037

3 000-090-036

4 000-090-035 5 000-033-070 6

000-033-071

7 000-033-042

000-033-012 CLAMP, #44

9 000-052-085

11 12 000-068-215 13

*14

15 16 000-093-013

* 17 000-068-099

18 19

* 20

21 000-038-018 22 000-052-086 23 24 25 000-052-020 26 27 000-068-211 28 29

000-068-210

000-052-090

000-149-002 SENDER, S/W TEMP. 000-068-098 000-052-013

000-033-034 000-052-268 ELBOWASSY., 2“-180°

000-068-039

000-052-086 000-052-023 F1l-rlNG,6MT-6F-6F

000-052-033

000-052-019 000-068-211

30 000-068-214 31 000-131”035 32 000-052-267 33

000-052-266

* 34 000-033-052

% 35 000-049-033

36 000-052-210 37 000-068-213 38 000-015-037

* 40

41 000-015-038

000-015-038 000-068-079

42 000-015-037

CORE, FINNED - S/S INSULATION WRAP MANIFOLD ASSY. - LONG MANIFOLDASSY -SHORT CLAMP,l’’EXHAUST -INNER CLAMP,l’’EXHAUST -OUTER cLAMP,l-1/8’’MuFFLER

ELBOW, 1/4” BRASS HOSE,3/8’’x24°

TEE,l/4’’MALEBRAss l-10SE,3/8x13’’TEFLON

HOSE,l/2x16’’RUBBER FllTlNG,4M-6UFS SILENCER ASSEMBLY HOSE,3/8x43’’TEFLON CLAMP,3”MUFFLER

HOSE,3/8x55’’THR0B CORE,A/CHEAT EXCHANGER BUSHlNG,l/2MALE x3/8FEMALE ELBOW,3/8BRASS

6MA-6UFS 8MA-6UFS HOSE,3/8x34’’TEFLON 6M-6UFS

LONG

HOSE, 3/8 X 34” TEFLON HOSE, 3/8

X 68” TEFLON

lNSULAT10N,3-1/8° I.D.-FOAM ADAPTER,A/CREAR HT.EXCHGER-UPPER ADAPTER,A/CREAR HT.EXCHGER-LOWER CLAMP, 2-3/4” FILTER, 3/8

ELBOW,2” BLACK STEEL HOSE,3/8x58” BRACKET,

INLINE

MTG. - HT. EXCHGER/SILENCER BRACKET,MTG.- HT.EXCHGER/SILENCER HOSE,3/8x30’’TEFLON BRACKET, RETRO-FIT-SILENCER BRACKET, RETRO-FIT - SILENCER

* NOT INCLUDED IN KIT#OOO-078-033

*NOT SHOWN

20909 t34th Amuc, West

Lynnwood, WA 980S0

HYDRAM.ASTER

PRODUCT SUPPORT BULLETIN

CORPORATION

TO: ALL HYDRAMASTER DISTRIBUTORS

RE:

has encouraged the use of water softeners in concert with its equipment. With the introduction of the 3.5 AQUA CAT last year, the issue of water softeners

has once again come up.

changers requires us to reiterate our position concerning water softeners and the subsequent invalidation of machine warranty claims due to hard water and/or chemical depcsits.

is a “hard water area map”. The map graphically portrays the average hardness of water in each region of the United States. his map does not excuse anyone living in a “soft water area” from

USE OF WATER SOFTENERS

For quite some time, HYDRAMASTER

Our increased use of exhaust gas heat ex-

Irieluded ineachHYDRAMSTER manual

using water softeners if circumstances require it.

manual states:

of minerals in [he water which resull in what is

ercess

commonly refered to as ‘hard water’. These m ineraLs fend to adhere to (he insides of heater coils and of her

patis of the machine causing bmage as wel[ as lass of

cleaning water softener service is more than made up for in the increased life of machine purls and continued cleaning

ejjiciency. ” The manuals also have advice on de-

scaling procedures.

form on the inside of lhe machine may cause damage. Any damages rc.suiting from hard water or chemieal deposits are considered abuse and/or ne-

I Water Hardness

DATE: 17 FEB ’92

PSB #: 9221

Under the heading of “water softeners”, the

“Many areas of the counmy hove an

ejjectiveness... the relatively low cost of a

As stated in the manual, any deposits that

glectand will notbecovered by the

HYDRAM&XER WARR4NTY.

Avoid costly repairs

-downtime by using whatever water softening method that is readily available. Also remember to follow-up the de-scaling recommendations that are shown in your manual.

and

for more information

please contact your local

HYDRAMMSTER

representative.

20909 64th Avenue, West

Lynnwood, WA 98036

PRODUCT SUPPORT BULLETIN

TO: ALL HYf3RA/llASTE~DISTRIBUTORS

SERVICE CENTERS AQUA CAT OWNERS

HYDRANL4STER

CORPORATION

DATE: 29 APRIL 1992

RE: IMPROPER AQUA CAT OPERATION

(i.e.: no pressure indicated on pressure gauge)

The lfYlX7AlLfASTHT%5 AQUA

pressure gauge before the unit

When starting your FMJRAMASTEW3.5 AQUA CAT, it is of utmost importance that

care be taken

seconds

follow the procedure outlined below:

Remove mix tank lid and verify the presence

1). of water in the mix tank.

2).

If water is present in the mix tank, use the

freeze guard hose provided with the ma

chine to purge air from the system.

3),

Attach the female quick connect to the front

of the machine and place the rubber

stopper in the recovery tank.

4),

Start the machine.

5),

As soon as water becomes visible in the

clear freeze guard hose, stop machine, disconnect freeze guard hose and proceed with cleaning operations.

to verify a working pressure reading on the pressure gauge within the first 30

of operation. If this does not occur, shut the machine down IMMEDIATELY and

will operate.

CAT machine -t have pressure indicated on the

PSB #: 9243

FEMALE QUICK

CONNECT

The problem of low or no pressure may

be symptomatic of either a clogged pump inlet

filterer

worn pump seals. Cleaning of the pump inlet filter and/or replacement of the pump seals may be necessary to correct the problem.

PLACE IN

RECOVERY TANK

20309 f34th Avenue, West Lynnwood, WA 98096

HYDRAMASTER

CORPORATION

PRODUCT SUPPO13T BULLETIN

.Y ,

TO: ALL HYDRAMAS7EW DISTRIBUTORS

RE:

1. Begin by attaching your garden hose, or pump-in hose, to the machine. Now, remove the chemical line

from the chemical jug and place it in a 50/50 m-kture of anti-freeze and water; turn the ignition switch on. Open the mix tank drain valve and allow the m“~ tank to drain to the point that it starts to demand water. Allow the mix tank to draw the anti-freeze solution through the chemical flow meter and the hoses back to the mix tank.

2. Remove the garden hose, or pump-in hose. Now, open the mix tank drain valve and drain all the water

from the machine.

3, With the machine drained of water, close the mix tank drain and pour one (1) gallon of 50/50 anti-freeze and water mix into the chemical m“w tank.

Start the machine and allow it to run for two (2) minutes,

5. For machines equipped with a manual override switch: with the machine running, depress the dump solenoid manual override switch and hold for thirty (30) seconds,

6. Remove the garden hose inlet fitting from the end of your garden hose and plug it into the front of the machine. Leave it plugged in until the next time the machine is used.

With the hoses and wand connected, run machine and spray the water/anti-freeze solution out of the

wand until the ‘low water’ switch in the m“~ tank shuts the machine off. Your machine is now freeze-

protected.

3.9 AQUACAT FREEZE GUARD

.,-

DATE: 29 OCT 1992

PSB #:

92104

7. Solution hose and wand freeze guard procedure: (optional): Attach the solution hoses and wand to the machine. (Dependent upon the amount of hose attached, more anti-freeze solution may be needed in the chemical mix tank). With the machine running, spray the wand into a container to recapture the anti-freeze

solution, Continue to spray the wand until the machine shuts down by itself.

Recovering anti-freeze for re-use:

Open the mix tank drain valve and allow the anti-freeze solution to drain into a sealable container so that it may be used

Before cieaning with the machine again, flush the remaining anti-freeze

by spraying water through the hoses and wand untii all signs of anti-freeze are gone.

-. -

again,

. .... >.:.-*

...... .......’

soiution from the system

Unscrew damaged heat exchanger as perinstructions-and remove. If smaller heat exchangers are used, removal of the silencer may not be necessary.

Length of pipe with l-1/2’’ coupler attached, used as ‘alignment tool’.

Screw onto male thread of manifold allowing sufflcientthread engagement, preventing damage to the threads.

After alignment, the replacement heat exchanger should

install

withcwt ANY load factor whatsoever. Ifthis is notthe

case, remove the heat exchanger and re-align. The exchanger must not be under load at any connection.

20309 i34th Awenue, West Lynnwood, WA 98036

H?ZL?!STER

PRODUCT SUPPORT BULLETIN

~~: ALL HYDRAMASTE~ DISTRIBUTORS DATE: 5 FEB 1993

RE: REMOVAL AND REPLACEMENT OF

AQUA CAT HEAT EXCHANGERS

!n an effort to maintain our high standard of performance in both our equipment and our service, HYDR4MAS7EXF is issuing this update covering the removal and replacement of heat exchangers on the AQUA CAT cleaning unit.

It has come to our attention that in the past, this removal has been achieved by the bending of the mounting brackets to allow the removal of the heat exchanger past the

frame. As a direct result, the ‘bending process’ weakens the heat exchanger and

promotes failure. This is not a practice adopted by HYD~MASTE@, and we would like totake this opportunity to illustrate the proper method of

In ALL cases, the best way is to remove the silencer unit first. This+allows the heat exchanger to then be unscrewed and removed without further modifications to it’s surroundings. (note: ifsmall diameter heat exchangers are being used, removal not be necessary)

Before installing the replacement heat exchanger, use a ‘aligning jig’ (shown in illustrationA) to insure correct placement ofthe unit. KX3NOT use the heat exchanger as an alignment tool. To do so would place unnatural stress on the end plate, thereby

weakening the weld integrity. To fabricate an ‘alignment tool’, you need only a length

of pipe --

about 1$’ -- and a 1-1/2” coupler

welded to one end (see illus.).

F%B #: 93024

removal and re@acement.

may

●

HYDRAMASTER

CORPORW’ION

6929 204th Street, S. W. Lynnwood, WA 98096

PRODUCT SUPPORT BULLETIN

RE:

Poor performance has been noted in several instances regarding the conversions from 3.5 AQUA CATS to 3.9 AQUA CATS. Such indications may appear as low RPM or discharging fuel from the carburetor.

ALL HY12RAMASTElWDISTRIBUTORS

3.5

to 3.9 AQUA CAT Conversions

DATE: 28 MAY 1993

PSB #: 93051

The most probable cause would be back pressure.

To correct the situation, we recommend that you remove the third heat exchanger from the rear of the machine and remove any rust or foreign

material that may be blocking the copper tubes.

If at all possible, prior to installing the third heat exchanger, run the machine with the silencer unrestricted. This will allow larger particulate to flow through the system and avoid any build-up.

HYDRAMASTER AQuaCat 3.9 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual