HYDRAMASTER AQuaCat 3.9 User Guide

HGauaCat

HYDRA##!iiS-EY%

3+9

Corporation

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

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

CatPumpModel290

DismantlingCatPump

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

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

....................................%...............<.....#...................

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

.............................................................................24

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

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

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

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

@@@@

,,,.y)!:,yiy’

PST

‘$@$&*:.

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

.,,,,...........................,,,,,,,,.,,,,....,,..,,,,,,.!,,,................#

Naming:DONOT

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

3eforeStartfng

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

‘uel Recommendations :arburetorAdjustments

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

!....0......,,.......................................................................!...

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

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

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

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

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

..#...........l...!..!...!.................##.....!......l...!.!lo

..........!......!.!..........t#...#..............ll

: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

...............................................................26

..,,<..,,,,.....................,,,,,............,,...!..0.

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

.,..............!......................31

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

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

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

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

....!.....l..<.!...........................................!c!.........c.....c...........la

.................................#).......!.!..........!....................2l

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

HYDRAMASTER WARRANIY Warrantyinformation

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

HowtoOrderParts PartsOrders OneFinalNote

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

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

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

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

,...,,,,.,,,,!..............,,$,..................................!.....................!

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

+ 35 hidden pages