HYDRAMASTER BmbCat, HmuaCat 3.5 User Manual

BmbCat/HmuaCat

130bCat(frorit view, feaMresltiled) .........................................................'

BotICat (side tiew.featureslabled) ..........................................................'

AquaCat (front view, feaWreslabIed) .......................................................i

AquaCat (side view, featumslabled) ........................................................

Cat Pump Model 290 ................................................................................l

DWrrantiing Cat Pump .............................................................................l

Vanguad OHVEngine ............................................................................2

GENERAL lNFORMAllON

Piywood Instailatiin (ontwck&d) ..............................................................4

Aswot@and RmfVent ...............................................................................4

MactiwConfiguration ...............................................................................5

Machine Tie Down Cleats,BobCat Only ......................................................5

Propane Tank Piumbing, MbCatOnly ......................................................5

Thru-floor Gas Hook-upand lnshliation ....................................................5

.Nater Mrdww Map .................................................................................6

Water%fiewrHook.up .............................................................................6

WATER & CHEMICAL SYSTEMS

Bob&tWaterHow ..................................................................................lO

AquaCat Water Flow ...............................................................................l O

Chemiml ProWfiioningand Levei Conhoi ...............................................lO ,

CAT PUMP

Pumping Section Cut.awy .....................................................................l3

NstonMo&i~OExpbded Mew ..............................................................l4

Bypass Vaive A~mbly ..........................................................................l7

AquaCat Water Fiow ...............................................................................l7

VACUUM SYSTEM

Vawum Fbw ...........................................................................................l8

Va@um Tank fiiWrBag ...........................................................................l8

Blower Lube Pofl .....................................................................................l E

Vawum Blowr Motor Lubri~tion ...........................................................2O

PST

HOURS

Monday -- Friday

8:00 am To 5:00 pm

PACIFIC STANDARD TIME

ROCK MT.

TELEPHONE NUMBERS (206) 776-7272 General Offices (206) 776-7276 Parts Department

(206) 775-7275 ServiceA!Varranty (206) 771-7156 FAX

CENTRAL

EASTERN

VANGUARDOHVENGINE

aiMm9~ckti ....................................................................................22

OiHliandDip Stick ..................................................................................22

Enghe Compnents ................................................................................22

Engine Compwnts(mntinued) .............................................................23

Carburetor Adjustment Screws ...............................................................23

Govemd idle Sping ...............................................................................23

Oii Filter/Oii Drain

Round Duai AirCieaner Element .......

Square Dual Air Cleaner Element ............

Round Dual Element ...............................................................................25

Coating System .......................................................................................25

s~kPiug ...............................................................................................25

Fuei Hlter ................................................................................................25

ELECTRICAL SYSTEM

Electrical Diagram ...................................................................................3l

CLEANING & CHEMICALS

pHChafi ..................................................................................................33

Cleaning Stroke Method ..........................................................................33

BOBCAT HEATING SYSTEM

Pro~ne Riot tight ..................................................................................34

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

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

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

@1991 HydraMaster Corp.

Printed in LLS.A.

CLEANING WANI)

WandVaiveAswmbly .............................................................................35

Jet Assembly

Wand Aswmbly ......................................................................................35

...........................................................................................35

Iacuum Biower Troub~ Shooting Guide .................................................l9

!acuum BlowerWarran~ ........................................................................2O

(acuum Blower Lubtitnn .....................................................................2O

GENERAL lNFOf?MAllON

Warning and Caution .................................................................................2

How the Systems Wotis ..............................................................................2

HydraMaster Hours&Phone Numhrs ......................................................2

BobCat Machine SWcifiMtions .................................................................3

AquaCat Machine S~cifimtions ...............................................................3

Purchaser’s Res~nsitili~ ........................................................................4

Sales Representative’s ResWnsitih~ ......................................................4

TwckPre~ration ......................................................................................4

Placement of Unit in Vehicle .......................................................................4

Truck Preparation lllustmtion .....................................................................4

Machine lnstdlation ...................................................................................5

Propane Tank Location, BobCatOnly ........................................................5

Spare Parts Recommendation ..................................................................5

PaflsOrder ................................................................................................5

Hard Water Area Map ................................................................................6

Water Sofiener ..........................................................................................6

Wastewater Disposal Advim~ ..................................................................6

BOBCAT OPERATING lNSTRUCTfONS

StaflUp ......................................................................................................7

ShutDoM .................................................................................................7

Flood Damage Work ..................................................................................7

AQUACAT3.5 OPERATING INSTRUCTIONS

StatiUp ......................................................................................................8

Shut DoM .................................................................................................8

Flood Damage Work ..................................................................................8

OPERATING PRECAUTIONS

MactineAdjustments ................................................................................9

Cautionsand Warning% ............................................................................9

WATER&CHEMICAL SYSTEMS

Water/Chemical Fiow OWration ...............................................................9

BobCat Water Flow ..................................................................................lO

AquaCat Water Fiow ...............................................................................lO

ChemiMiSystem Maintenance ................................................................lO

Chemical Tank Trouble Shooting Guide

CAT PUMP

Cat Pump Modei 2900perating instructions

Cat Pump S~cifiMtions .........................................................................l 1

General information for Cat Pump Re~ir ................................................l2

Servicing the Discharge Vaives& Valve Seats .........................................l2

Servicing the Pumping Section ................................................................l2

Servicing Sleeves and Seals ...................................................................l2

Sewice Nts ..............................................................................................l3

Modei290PartsList

Cat PumpTrouble Shooting Guide .....................................................l5.l6

High Pressure Pump Troubie Shooting Guide .........................................l 7

BypassPartsList .....................................................................................l7

VACUUMSYSTEM

infomation ................................................................................................l8

Vacuum Tank filter Bags .........................................................................l8

.................................................................................l4

..................................................l 1

............................................1 1

IANGUARDOHVENGINE

)perating & Maintenance for Modei 303400 (16 HP) Engine ..................2l

Iternatiinai Symbois Used in this Wnuai ..............................................2l

ntheinterestofSafety .............................................................................2l

Wrning: DO NOT ...................................................................................2l

Yarning: DO ...........................................................................................22

khmshti~ .........................................................................................22

)iI *mmetitbns .............................................................................22

‘uei Rwmmetitions ..........................................................................23

laWmtor Mjustments ..........................................................................23

ENGiNEMAiNTENANCE ........................................................................24

lil Change ...............................................................................................24

W Cieaner Maintenance .........................................................................24

lean Engine, Rotating Screen, Cooling System, Spark Arrester,. ........25

?epiace Spark Piugs, Repiace Fuel Riters .........................................25.26

~ngine Maintenance Scheduie ...............................................................26

;enerai information about Engine ...........................................................27

Storage instructions

;ervice & Repair information ...............

/anguard Engine Wamany .....................................................................28

superseding Wamnty ............................................................................28

.imited Warranty for Vanguard Engines ..................................................28

rVarranty Period ......................................................................................29

ENGINE TROUBLE SH~TING ............................................................3O

SLECTRICALSYSTEM 3ectricaiSystemand TroubieShootingGuide

FREEZE PROTECTION

Bobcat .....................................................................................................32

*uaCat ......................................................................................................32

CLEANING & CHEMICALS

Prmutions ................................................................................................33

Cleaning Stroke Procedure / @er.Wetiing .............................................33

BOBCAT HEATING SYSTEM

infomation ................................................................................................33

HeaterOperating instructions Heater Trouble Shooting Guide

CLEANING WAND

Wand, Jet Assembly &Wand Assembly Parts Lists ................................35

MAINTENANCE

Pr~dures .................................................................................................36

Overail Care of Unit..................................................................................36

Maintenam Logs ...............................................................................37.38

HYDRAMASTER WARRANTY

Warranty lnfomation ................................................................................39

Warranty Procedure

How to Order Pafls ...................................................................................39

PatisOrders ............................................................................................39

One Rnal Note .........................................................................................39

BobCat/AquaCat Limited Warranty Plan .................................................M

................................................................................27

....................................................27

.......................................31

..................................................................34

...................................................................34

................................................................................39

This manual contains installation and opation instructions as well as informaticm required for proper maintenance, adjustment and repair of this

unit Since the first and most important part of repair work is the correct diagnosis otthe trouble, a gemwal trouble shooting section and component manual trothlwahooting charts have been included for your convenierm.

HOW THE SYSTEMS WORK

THE BOBCAT SYSTEM WORKS AS FOLLOWS: The water system takes incoming water at tap(!ow) pressure, automatically combines it with chemicals from the chemical system, pumps it under pressure tfmugh the heating syslern and out to the cleaning tcml. Afhw being sprayed into the carp?~ the water/chemic-alhoil solution is extfacted by the vacuum system and returned to the wasJe recmry tank.

Unlike a gamf%ntracfur, lawn mower or~ment mixer, al! hating one or W functions M perform, tha truck-mounted carpet cleaning ptant has many functions to pwform simuitaneouqy.

* Engine has to run at a consistent RPM.

‘ Vacuum has to pull air and dirty water baok from cleaning site.

* Waler pump provides stabte pressure at proper water flow for cleaning.

‘ Chemical has 10be injected into the water stream at the

right concentration. * Heater must maintain proper heat. *Vacuum tank must store dirty water until drained.

As you can see, it is not just a turn key operation with one ttlng to worry about, Does H starl?!

TM manufacturer uses this

symfmi throughout themanual to warn

of possible Injury or death.

?’hissymbol k used ?0warn of

pxs!b!e equipment damage.

There is no guess work in the marwtacture of these highly adw%$d chxrning ptants. There must also be no guess vmrk in prqwing it to g@tthe job done in the field. It is the purfxm of this manual to fwlp YOUproperly understand, maintain and service your cleaning plant. Follow tfmdirections carefully and you will be rewarded witi years of profitable tro@le-f#e operation.

Itis imperative that no sectirxr twoverfookecl when preparing foroperatirm

of this equipment.

THE AQUACAT 3.5 SYSTEM WOHKS AS FOLLOWS: The AquaCat 3.5 High Perlorrnance Heat Exchanger system is engineered cleaning plant, designed by HydraMaster Corp. The system

utilizes a dynamic heating system comprised of two separate exhaust h@at

exchangers for capturing ‘free heat=.

Water is fed into the machine at tap pressure. It is combined automatically with cleaning solution as it enters the mix tank. The solution is then picked

up by the high pressure pump and pressurized to the desired level. Th8

solution then travels to the bypass assembly where it is distributed out to ttw

wand and back into the machine. The solution going back into the machine

splits flow and travels through the two exhaust heat exchangers. NW’ being heated, the solution returns to the mixtankwhere it is picked up by the pump again.

When the cleaning solution reaches a pre-sat high terrqwature, it is released from the system and directed to the recovery tank, then cool water enters the system to regulate the temperature.

a highly

As there is no guess work in the manufacture of these highly advanc%d cleaning plants, there must lx?none in pre~”ng it to get tha job dons in the field. It is the purpose of this manual to help you property urrcf$wskmt, maintain and service your cleaning ptant. Follow the ciirectionscarefully and you will 5e rewarded with years of protlfable trouble-free opxation.

[t is imperative that no section be overlooked when preparing for opmtion

of this equipment.

BOBCAT

hQUACAT

MACHINE SPECIFICATIONS .

FRAME: 16” W, 5~ L, 34’ H. Steel with baked-on epoxy finish.

WEIGHT: Model 3.0:465 Ibs. (dry weight).

Model 3.5:500 Ibs (dry weight).

COWUNG: Steel with baked-on Epoxy finish.

ENGINE: 16t-fP Briggs& Sfratton V-Twin. Steel sleeved cylinders, ducte( IGNITION: Magneto key start. Solid state ignition.

HI-PRESSURE PUMP: Tri-Plex piston -- Cat 290-- 3.5 GPM

-1200 PSI -- @ 1200 RPM.

VACUUM BLOWER: Model 3.0: 3ML Sutorbilt w/14 HG safety relief.

Model 3.5: 3LFS Sutorbilt w/12 HG safety relief.

CHEMICAL SYSTEM: Electro-mechanical, flow meter controlled. HEATER: Propane fired, thermostatically controlled (120,000 BTU).

INSTRUMENTS: 0-1000 High pressure gauge, Temperature gauge,

Vacuum gauge, Hour meter, Chemical flow meter,

Ignition key start.

RECOVERY TANK: Model 3.0:52 gallon aluminum, epoxy finish.

Model 3.5:70 gallon aluminum, epoxy finish.

llACtIllNE SPECIFiCATIONS

‘RAME 21” W, 5(Y L, 26’ H. Steel with baked+m epoxy finish.

lfEtGHT: 500 Ibs. complete.

)OWUNG: Steel with baked-on Epoxy finish.

MINE: 16 HP Briggs & Stratton V-Twin, steel sleeved cylinders, ducted.

GNfflON: Magneto key start, solid state ignition. II-PRESSURE PUMP: Tri-Pk?x piston--(X290 -3.5 GPM

--1200 PSI -- @ 1200 RPM.

/ACUUM BLOWER:3LFSSutorbiltw/12 HG safety relief. 2HEMICAL SYSTEM: Electro-mechanical, flow meter controlled.

4EATER: 2 exhaust heat exchangers.

NSTRUMENTS: O-1000 High pressure gauge, Temperature gauge,

Vacuum gauge, Hour meter, Chemical flow meter,

ignition switch.

3ECOVERY TANK: 70 gallon aluminum, epoxy finish.

2LEANING WAND: Stainless steel 11“with heat cover handle, and fo~ard

guide handle.

CLEANING WAND: Stainless steel 1l“withheat cover handle, andforwai

guide handle.

HI-PRESSURE HOSE: l/V High-temperature Iinedhinyl covered safe!

orange with brass quick connects.

VACUUM HOSE: 2“ Reinforced safety orange.

1/2” Reinforced safety orange.

STANDARD EQUIPMENT: Power consale, Vacuum recoveiy tank, 1

stainless steel cleaning wand, 100’-1/4’ high pressure hose, 100’-2”vacuu

hose, 10’-1/2” vacuum hose, Through floor connections for gasoline al

propane hook-up, Tiedown cleats, Vacuum hose connections, 5 galk chemical jug, Cwners manual.

OPTIONAL FEATURES: Stair tool, Steel legs w/Casters, additional vacuum Hose in 50’ lengths, Additional 11~ pressure hose in 50’ lengt

Prwsure washing gun, Spare parts package.

DESIGN CHANGES: This information is accurate at the time of printi However, the design and specifications of HydraMaster equipment ~ subject to continued change and refinement.

rll-PRESSURE HOSE: 1/4’ High-temperature Iinedlvinyl covered, safety

orange with brass quick connects.

VACUUM HOSE: 2“ Reinforced safety orange.

1 M? reinforced safety orange.

STANDARD EQUIPMENT: Power console, Sound suppression package, Level temperatureexchange heater, Vacuum recovery tank, Carpet cleani~ wand, Chemical jug, Chemical jug holder, Owners Manual, 100 ‘- 2“ vacuum hose, l(Y-1

IL? drain hose, Battery box with holder, Fuel system kit, Van decal, Van

1 installation kit.

DESIGN CHANGES: This information is accurate at the time of printing. However, the design and specifications of HydraMaster equipment are subject to continued change and refinement.

1/2” vacuum hose, 100’ Super-flex solution hose, 10’-

PLIWWER’S RESPONSIBILITY

PRIOR T(3 ARRIVAL OF UNIT:

1. lrMal15N’ ~xteriorplywood flooring invehicie andcoverwi~ artificial turf.

2. Have belly mmmt~d propane tank installed on vehicle. Tank must be propane vapor typ4 (for BobCat only).

3. Purchase heavy duty 42-6d amp hour battery arrd have battery ‘slow’

ct?argedifrww. lfhti~~isnotblty chargeddamagemfl occurfo the engine charging mgulakw.

WADING OF QWERS MANUAL: it is the purchaser’s responsibility to read the unit operation manual and to familiarize himself with the informs

tion contained therein. Special attention sf?ouldbe paldtoail CAUTIONS

and WARMNGS.

SALES REPRESENTATIVE’S

RESPQNW31UTY

ACCEPTANCE OF WIPMEm f. Ifunit shows any outward signs of damage, do not sign the delivery receipt until you have closely inspecied the unit and noted any damage on the delivery rewipt. Have the freight company representative acknowledge the damage by signing Me notation of damage on the delivery receipt.

2. Tim salesman from whom you purchased your unit is responsible for Supawising tfm Wrrect installation of the unit in your vehicle and thoroughly training you in its operation, maintenarwa and precautions.

LACENIENT OF LINIT 4VEHICLE

IERE ARE TWO RECOMMENDED UNIT PLACEMENTS:

SIDE DOOR: Most installations are side door. This provides rear

‘accessories

Mng side of machine, thus making it a bit easier to perform maintenance !d/or repair without removing unit from the truck.

REAR DOOR: Afthough this location partly limits working access, itdoes rect the noisa away from the cleaning site. Some cleane~ in the colder aas prefer this location twcause it puts the weight mass over the rear Ieels for better traction in ice and snow. Rear mounting requires+tt%?unit

b slid 10the right side as faraspossible.This not only provides adequate inking space on the component side of the unit but al~ makes better sight distribution inside the van (engine and component weight line up Ier drive shaft). Also, it is physically easier to load unit into rear door due

height of van bad.

nsure that machine is well secured to the floor of van with hardware

Jpp/ied. Sudden or crash stop wili cause machine 10rocket forward, d 70 lbs. worth! Protect yourself and the maclrirw. SEC(N?E IT?

and hoses as well as unobstructed access to cornpmntf

access

“IWCK PREPARATION lmLWTRATION

IRST, cover the truck bed with 5/8mpJywood using metal screws to secure

as shown.

CORRECT’ INSTALLATION INCLUDES: Installation of through-floor fit-

tings for propane and gasoline fuel lines; installing propane regulator included with unit, outside vehicle; placing unit and recovery tank in vehicle

and securing them with bolts or tie down cleats; connecting all propane and gasoline lines; carmecting battery; checking pump, vacuum blower and engine oil levels, prior to starting unit starting unit to check engine to see

that all systems function normally; also checking all hoses, wands, etc., for correct opwation.

TRAINING SHALL INCLUDE: Thorough review of the operation manual

with purchawq instruction and familiarization in: how to correctly startup

and shutdown unit; how to cwrec!lyclean with the unit; how, where and how

often to check and change component oil levels; how the unit’s systems

work how to troubleshoot the unit how to do basic repairs; safety precau

lions and their imporfanoe; freezing damage and how to avoid it and a

ihorough review crl the unit warranty and warranty procedures.

TRLICK PREPARATION

Th~ manufacture recommends the installation of plywood flooring covered with poly propylene backed astroturf (do not use rubber-backed) in the vehiclo prior to installation of machine. This provides a metal to cushion mOunting rather than metal to metal, provides insulation and makes an attractive van interior. Astroturf should be color keyed to van interior.

Materials Needed:

1.2 sheets 4x8x9$* exterior plywood

2. 6x12’ piew of commwcial astroturf

3.16-1112” sheet metal screws

4.1 quart marim! adhesiv~ (optional)

5. f staple hammer w/1/2” staples

ECOhfD, select the appropriate colorastroturfto match yourvanandcover

Ie plywood and staple in place. A standard van requires a pieca 6 feet by 2 feet.

HIRD, HydraMaster strongly recommends an aluminum roof vent be lstalled over the location selected for mounting the machine. I-fydrafdaster Iso highly recommends a flue be installed between the tap of the heater nd the roof vent. ~is will allow hot air from the heater to escape.

Astrowrf& Roof Venf

pies

(See illustration for correct placement of plywood flooring)

MACHINE INSTALLATION

There are two locations to place the machine, in the side duor or in the real door, as mentioned in the section titled “Placement of Unit.” The standara way to configure the unit is, as shown in the illustration, with the recoveq tank beside the unit. An alternative method, not shown, would be to put tfw recovery tank behind the unit. (The standard machine does not come witt enough hardware to allow for mounting of the tank behind the mactrhe. I this configuration is chosen please contact HydraMaster for more infer mation.)

HydraMaster recommends that the exhaust for the machine be P@ through the floor of the vehicle. It is important that the machine be placw as cfose to the door as possible so that outside air can be pulled into tlw engine for proper cooling.

Machjne

Conflguraflon

ltisrecommendedbvthe marrufacturerthatthe exhaustkom the frontoffh

machine be vented down under the truck to prevent carbon monoxide frofi

entering lhe job site. Afways

away from the job site.

,,,,,””

,*,r’”

park the truck so the exfrauat Is &/ow/nj

Thru-iloor Gas Hook-up and h?stallafjon

The manufacturer also recommends lhat insta/iation of aluminum vents i the truck roof to allow heat from the heater to escape.

Never operate this machine with aporlablepropane tank oraportabie ga

can inside Ihe truck, doing so increases zhe risk of a fire or expfosion.

Mount afire extinguisher just inside the rear or side door foremergencie:

Machh?e Tie

Down Cleats,

BobCat On/y

PROPANE TANK LOCAnON, BOBCAT

Either the 10 gallon or 16.5 gallon proparw tank till fit this location. Hav you local propane dealer install the tank you select and purchase. Th machine will come with the proper propane regulator. (Tank must

vapor outlet)

Professional installation of fuel systems is strorrglyremmmerrdad. Alwaj ensure compliance with state and local regulations pertaining to fu installations.

hat

SPARE PARTS RECOMMENDATION

Because your truck-mounted unit is capable of generating several hundred dollars per day, down-time on the unit can be very expense. [n order to minimize such down-time, it is strongly recommended by the manufacturer that you purchase and keep in your truck the parts listed Mow.

PARTS ORDERS

To expedite your parts needs, please call your sales representative.

Inmost instance, he either stocks or has access to parts through a regional service center. In the event parts are unavailable locally, contact the factory and coordinate your needs. Ifthis Eecomes necessaty, always indite the method of shipment you desire, i.e. UPS. Blue Label, Air Freight, Ar

Express, etc. HydraMaster Parts Department. Phone (206) 775-7276.

PART NO.

106-030 Ermine spark pluq

)49-012 Round air cleaner )49036 Square emaineair cleaner )4%014 )7s-015 Flow meter M

)7S-024 Wand 07s-034 076-005 Spray iel 6CX16E 076-003 SPraYiet 6004E

049-028 049-023 07a-ool 07s-004 Cat 290 hot CUPkitAquaCa! 052aw 052451 052-052 052453 660 Female quick conned 010-020 Belt pump drive Ax-25

DESCRIPTfON

Erwrineoil fifter

VSk3 r)iuntler kit

Preswre bvpas

Recoverv tank filler baq %merr, mrden hcse Cat 29o shorr

440 Male @ck conned

440 Female quick conned

W Male Quid conned

s valve M

CUP kt BobCar

BobCaI

A(auaCat

QTY.

1 1 1 1

1 1

1 1 2 6

1 1 1 1

HAM) WATER AREA MAP

The quality of vvatw varies greatly throughout the United States an{ influences the reliability and efficiency of equipment in direct proportion t{ its leve~of hardness. The map bdowdefines areas which compromise flui( related cwmfxmwms such as hoses, fittings, heaters, pumps, valves an~ water cooled engines.

Cleaning dficioncy and equipment life is increased, chemical use de crwumd and the appearance cd cleaned carpets enhanced when wate softeners are incaporated in hard water areas. Manufacturer strong! urges the use of watr3r softener units in areas exceeding 3 1/2 grains pe gallon. Using We legend as a reference, determine tie quality of water ii your arm and tak~ action immediately should it be necessary.

INATEI?SOFTENER

dany areas of the country have an excess of minerals in the watw which esults in what is commonly called ‘hard water”. These minerals t~nd to idhere to the insides of heaterwils and other pans of the machines causing !amage and a loss of cleaning effectiveness.

?e~rts from several of our machine usk+rscommending the rwx.dts of Me Ise of water softeners in conjunction with their machines prompts us to ecommencf the procedure to everyone in a “hard watw’” area.

~herelatively low crestof a water Wtener service is mor~ than made up for nfhe increaw+d life of machine parts and continu@d deaningefficiemcy. The vater softener will also increase the effectiveness of the cleaning chemical wing used, therefore, less chemical will be needed.

;Ontact a water softener distributor in your area for information cmthe rental ]f a simple water treatment unit to carry in your truck. Be sure to change ttw vater softener in accordance with the capability of the softener. Example: fthe softener will treat 900 gal!ons of water and machines uses an average }f30 gallons per hour of use, and an average of 5 hoursa day,woukf be 150 ]allons a day. 5 days would equaf 750 gallons of water, therefore, the ;oftener would be changed every 6 working days for maximum softening.

WASTEVIATER IDISPOSAL ADVISORY

rhere are laws in most communities prohibiting the dumping of recovered ‘gray” water from carpet cleaning in any place but a sanitary treatrrmt ;ystem.

Per Gdbn

W’MerSiMttM9erMwk-up

G.iROEN HOSE

&~.,

::____J=’~w

FAUCET

Wriscleaning rinse water, recovered into your unit’s vacuum tank, contains naterials such as detergents, which must be processed txfore being safe br streams, rivers and reservoirs.

N ACCO171?ANCE W/TH 77iE EPA STATE Al@ LOCAL LAW% IX? NOT DiSPOSE OF WASTEWATEI? Mf7TJ GU?TKUS, STCiFfMOl?A#dS,

STREAMS, RESERVOIRS, ETC.

n mostcases, an arxx?ptablerrtrathodofwastwvaterdisposalistodwharge nto a municipal sewage treatment system after ftrst filtering out sofii natenal such ascar@fiber.Access @the sanitary systerncanbeobtain~d through a toilet, laundry drain, carwash drain, flV dump, etc. Permission ]hould first be obtained from any cmcerned party or agwwy.

One disposal method whti usuatly complies witf’i the law is to accumulate he wastewater and haul it to an appropriate dump site. Anather solution to he disposal problem is to equip yourself with an Automatii Pump.Qut System. These systems are designed to remove wastewater from the Wactot% recovery system and actively pump the water Wugh hoses to asuitable disposal drain. Properiy designed, they will continuously monitor the level of wastewater and pump it ouf simultarwously to thre ckaaning opmtion. The hidden benefit of fhis process is that the operator doesn’t have to stop his cleaning to empty the recovery tank. Hydrah%tstm makes an A.P.O. System availakle which can M ordered wifh rww equipment or

installed later.

The penalties for non-camptiance can be serious. Always ctwk$ocallaws and regulations to h sure you are in czrmpilarrrx.

START UP

Perform daily/periodic maintenance as specified in tMs Owners Manual

(WW 36).

2. Connect atl required hoses.

3. Connect cleaning tool to length of hose required to perform dearring.

4. Mix tankmust be ful/priortoignition.

5. Start engine (choke as required). Engine is at operating speed (recommended -2800 RPM). Allow warm-up period of 2-5 minutes.

6. Spray wand to void all air from system. When the mix tank begins a fill cycle, the chemical flow meter may be adjusted to your desired setting.

NOTE: Chemical flow meter set at 5

is 1to 15 ratio. When flow meter is set at 10 GPH, you will be using what most chemical manufacturers recommend at 5 GPH.

●

GPHisa 1 to 30 mix ratio and 10 GPH

;hoke Cable.

Gauge

\ L I / ,ignition Switch

t%ssure

Ga~ge

Hour Meter

Chemical

~ Fbw Meter

- Fuse

7. Once all air is voided from system, heater maybe ignited.

NOTE: Ifnot familiar with operation of this heater, ~fer to healer =ction of

this Manual (page 33). A. Open propane valve on the tank.

6. Ignite pilot on the heater. C. To ignite burner, turn dial to “on” position.

NOTE: If you suspect that the unit has been frozen-DO NOT light the

heater. Thaw the heater and check for leaks.

8. Turn on burner, adjust dial to normal or slightly below for 200QF.

9. Commence cleaning operation. NOTE: Recommended carpet cleaning pressure is 250-300 PSI.

SHUT DOWN

Turn heater to “off’ position. Spray wand for at least 3 minutes to allow

the heater coils to cool.

2. Close valve on propane tank.

3. Remove vacuum hose.

4. Flush clear water through chemical system for 10 seconds (vinegar

should be rinsed through system weekty.) Turn off chemical flow meter.

5. Turn oncleaningtool to flush chemical from unit hosesarrd cleaning tool. NOTE: If freeze guard is necessary, perform step 1 of freeze guard

procedure at this time (page 32).

6. At this time, the blower should be lubricated with LPS 1.

7. Shut engine down.

8. Drain vacuum tank. Vacuum filter should be cleaned prior to mobilization of van.

NOTE: If freeze guard is necessary, perform steps 2-3 of freeze guard

procedure at this time.

incoming Water’

Heater.

Blower

Lubrication Port

‘\

Engink310wer

Cat Pump

(below, cover)

—

Exhaust

High Pressure

Cleaning Solution

Outlet

FLOOD DAMAGE WORK

Cauthn must be exercised to prevent the waterpump from owheatiq dutinglongptwbds of vacuumworksuchas waterdamage recovery

Heatei

Vacuum Pump

Engine

-. .

Silencer

START w

1. Perform dailylp@riodic maintenance as specified in this OwrMrs Manual (page 36].

2. Connrxt afl r~quired hosas.

3. Connect cleaning toot to I@ngti of hose required to perform cleaning.

4. Mix tank r?wttw tiilpriur to @tiort

5. Start engine (choke as required). Engine is at operating speed (recom-

mended -3000 RPM). Allow warmup period of 2-5 minutes.

6. Spray wand to void all air from system. When the mix tank begins a fill

cycle, the chemical ffow meter may k adjusted to your desired setting.

N(ITE Chemical flow meter set at 5 GPH is a 11030 mix ratio and 10 GPtl

is 1to 15 ratio. When flow meter is set at 10 GPH, you will be using what most chemicai manufacturers recummend at 5 GPH.

Run machine for several minutes under toad (8 to 10” HG) until desired

7. t~mperalure is acheived.

8. Commence cleaning operation.

NOTE: Recommended carpet cieaning pressure is 250-300 PSI.

Swn’DCNMN

1. Fh3move vacuum hose.

2. Flush ck?ar water through chemacal system for 10 smcmds (vinegar

should M timed through system weekly). Turnoff chemical flow meter.

3. Turmon cleaning tool to f?ush chemical from unit hosmand cleaning tool.

NOTE: If freezo guard is necessary, perform steps 1 & 2 of freeze guard

procedure at this time (page 32).

Temp.

Gauge

Hour Meter

Ignition. Switch

Fuse

Vacuum PumD’ ~ i

Lubrication Port Eng’lne

Choke

\ Pressure

‘n~a~~g Cle;ning Solution ,

Gauge

F;.

Vacuum

w!.

Hiah Pressure

outlet

Stationary

Engine Guard

6. At this time, the blower should be Iubrfcatecf with LPS 1.

7. Shut engine down.

& Drain vacuum tank. Vacuum filter should&e dearted prior to mobilization

d van.

fWITE: If freeze guard is necessary, perform steps 3-4 of freeze

guard procedure at this time.

FLOOD DAMAGE WORK

Caution must b exercised to prwmt thewaterpump hvn overheati~ dwirq long pfiads M

Kscwrn work suctr aswater damage recovery.

Exhaust l-feat

Exchangers,

Silencer

Assembly Chem&J Pump

Mix Tank

Vacuum

Pump

High Pressure

‘Engine CM

Filter

MACHINE ADJUSTMENTS

Although this unit has been factory adjusted, it may require additional adjustments to achieve optimum performance;i.e. altitude may require carb adjustment and ambient temperatures may require heat control adjustment. When required, consult an authorized representative.

ENGINE COOLING

Units emp/o@gaircootedengin+?s must not &? enclosed w“thina van with

doors and windows closed. Excwssive temperatures within the engine will resultinpremafure engine failure andacompromise ofappkable warranty.

LEVEL OPERATION

During operation, van or trailer must be parked on /eve/ ground noi to exceed + or -1P. Failure to insure proper leveling may prevent proper

internal lubrication of engine, vacuum ancVor high pressure components,

FREEZE PROTECTION

Mothernafuregives/ittie wamingasto hercoldspelis. There fore, protecting this equipment t70m freezing will save costfydown-time. Placingane/ectric

heater in the truck or parking the truck indoors, will hefp to insure against

freezing.

NO SMOKING It is unsafe to smoke in or around the vehicle.

MOVING PARTS

Never touch any part of the machine that is in motrnn, sewn? bodily injury

may resuft.

CARBON MONOXIDE This unit generates toxic fumes. Position the vehicie so that the fumes will be directed AWAY from the jot) site. DO NOT PARK where exhaust fumes can enter a building through open

doors or windows, air conditioning units or kitchen fans.

TOXIC FLUMES

Do not occupy the vehicle when tie cleaning equipment is operating. Toxic times may accumulate inside a stationary vehicle.

WATEFUCHEMICAL FLOW OPERA~ON

HEATER

Never pile things aroundi%e heater, i.e. hoses, boxes, chemicaljugs, etc.,

as this will block the flow of air required for a clean burning heater.

OPEN FLAME

Remember that this heater is an open flame, therefore, do not remove engine gasiine whi/e trouble shootingorstore any flammable materiaiin the truck w“th heater operating.

STRONG PROPANE ODOR

Never light fhe heater if you smell a strong odor of propane around the heater.

HOT SURFACES

During the operation of this equipment many surfaces on the machine will tk?come veryhot. When near the van foranyreasoncare must be taken not

to touch any hot surface, such as heater, engine, exhaust, etc.

LIGkfTfNG HEATER

Neverputyourface down close to the opening of the heater when bghting.

This electro-mechanical system has been designed to be simple and trouble free. Incoming water flows first through the Solenoid Control Valve (I)(seeillustration on next page) andthelowpressure Chemical injector(2) which are both mounted on the extenorof the mix tank. As the water passes through the Chemical Injector, it is automatically proponioned with a predetermined quantity of detergent. The Mix Tank(3) is equipped with two different float switches, the Water Level Float (4) respmcfsto the !evel in the tank and will maintain the proper volume of solution to be reserved for the water pump. The secondary, Low Water Float switch (5) is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply. If, for example, the waler source at the house were turned off, the water level of the mix tank would drop, activating the secondary switch, which automatically disengages the system and prevents the water pump from running dry.

The desired chemical injection ratio may be obtained by an adjustment of the Chemical Flow Meter (6) during flw fill cycle of the mix tank. Water must be flowing into the mix lank inorderto adjust the chemical mix. The chemical will flow from the Chemical Jug (7) to the Chemical F{ow Meter, then to the Chemical Injector where it is Proportioned into the Mix Tank at the desired chem”~l setting.

NOTE: With this unique chemical system, the chemical flow isproportioned only during the filling cycles of the MIX Tank, not during the direct spraying of the wand. Therefore, it is possible that as your wand is spraying, you may have no chemical flow. Also, the converse is true in that you may not 1#

spraying your wand, but if the mix tank is in a filling cycle, your Chemical

Flow Meter may be active at the desired flow rate.

The chemical profmlioning system will mix chemical with water at a 1to 30

ratio when the Flow Meter is set at 5 GPH, or a 1 to 15 ratio when the Flow

Meter is set at 10 GPI-I.

(cuntilXls,mxtpage)

BOBCAT WATER FLOW

— .————— .-

At this paint in ttw flow, solution (water with chemical) will no’ar@ siphoned ~ from M@bcdtom of lt’m Mix Tank to W inlet of tie Water Pump (8). When ~ tfw wand is no! using salution by sprayh& the solution will be bypassed ~ from the bottom of the brass Pressure Relief Valve(9), back to the MixTank. ~

Wfwn the wand is spraying, the solution continues its flow to the Water HtMar (10). The coils of MS twaler have a capacity of up to 2 gallons, therefore it is extremely important that all air pockets are bled out of the heater pricw 10 initial start-up. This maybe achieved by running the waler systtxn, wilfwut th% heater on, for approximately 60 seconds.

Valve .-.-–

1!~ Ii

AQUACAT WATER FLOW

At this point in the flow, solution (wakw with chemicat) will now be siphorwd from the bottom of the Mix Tank to the inlet of the Water Pump (8). In ttw pump the water is pressurized and then discharged through a rubber pulsation hose down to Uiepressureretief valve (9). From tfwpressure relief valve the water is automatically distributed to the cleaning wand and bypawd back to the mix tank, depending on water usage at tfw wand.

As the water travels back toward the mix tank from the Wessum relk?f vatve it flows through M exhaust heat exchangers which heat the cleaning water.

CHEMICAL SYSTEM MAINTENANCE

The chemical lines may need to be flushed with vinegar wriodiily to prevent abnormal chemical build-up. This flushing may be dom by removingthe clear pfastic hose from the Chemical Jug and inserting it into a one quart cmtainer of ki’wgar. This should k done with the Chemical flow Meter setting on 10 GPH and the Water Heater ‘off’. Simply spray water from the wand until the quart of vinegar isexhausted, the repeat W pmc$ss with one quart of dear water to void all fines of vinegar.

Chemical Proportion i3m#Level Control

AquaCat Water Flow .

Che&lcal

ln~ac!or

SW!totd

Control

Valve

-—-—

O S/S Ball

= Check

Housing

Mounting

‘—-—-–11

+Smnvs {3,

ValV13

...... , .,;;.9

——

——.,.—

1J+

*–

‘7 ‘—

12 Voc

6FA-6UFS

-0

Inpctor Body

f’

/’

(II

r .

‘1

k40unong

Plate

!!-+(

L+i

Soleno[d

Valvo@Qdy

water

Inlet

MIX Tank

CHEMICAL TANK

TROUBLE SHOOTING GUIDE -

PROBLEM Lfttfe or no chemical flow

Solution

------- .

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

of the Flow Meter (6)10 the Chemical Injector (2) is secure with no idnks or leaks. Check that the adjusting cap on the

atllhe way in. Check the s/s chedr valve insidethe injeciorfor chemicatbuiidup and proper cperafkm. Chac+Ithe hose from the Mtom of the flow Meter 10the Chemical Jug (7) for kinks, cmcAs, or bubbles.

Checkthescmenontheendofthehosewhichgo eaintolheChemicaJJug. Tocheck

thisscfeen for proper function, remove kfrom the plastic hose. If you cannot blow through d,

Check the Chemical flow Meter (6)

Is incoming water pressure tees than 30 PSI? Cracked or defective Chemkai Ftow Meter (6)? Check the filter screen in the Solenoid Controf Vafve (l).

then rinse it out with vinegar.

for obstructions or a sticking float.

PROBLEM Inabilitv to adiust chemicai with the Flow Meter

Ilsbrii iodged behind teflon seat in Flow Meter valve.

Teflon seat on the vafve stem mav be Icase. if deteriorated. reoiace O-Rina.

insufficientwafer mssura. Locate new

side of the injector is not screwed

source.

CAT PUMP MODEL 290

OPERATING iNSTRUCTIONS

Products described hereon are covered by one or more of the foiiowrtg U.S. patents: 3558244,3652188, 3809W”, 3920358, and 3930756 -

—

Aiu#

&MM-

C017P0 RATION

PO Box S85 MINNEAPOLIS, MN 5S440

Phone 161 2) 7S0.5440 – Telex 290276

● N V CAT PUMPS tNTERNfi TIONAL S A ●

Hfmno”mstraat 29

0 261M An!vmp,

Phone 1031237.72.24 – Telex 33947

13dawm

● CAT PuMPS - A G. ●

Loretohcmhe5

CH.WOO 2uG, SwtzeNanO

21.3140- T$Jlm SS5 160 CPmO M

Plm”e (42)

PUMPS DEUTSCHLAND GmLIHG

● cAT

Roe.! ocker Strms. 9

8200 Wlesbaaen.fllamtadt, West Germany

PhO”e C812560001i2 — Tela, 41 @S713

● CAT PUMPS (U K ) LTO ●

27 Stat(O” +“dustrlal Estate. Fleet

l+arnPshl<eGU13 6QY England

Pho”eI F!mt 22031 — Totem 65SSSS

PROBLEM: Soiutfon reversing from Mix Tank, fflling the Chemicai Jug

Solution

Anti-siphondevics dogged by chemicai buiid-up (Anti-siphon device is bcated in

the Chemical Injector (2) body — seepage 10, Water Fiow illustration).

Check for debrii.

PROBLEW. MIx Tank overflows

Solution Fioat swifdr (4) in the Mix Tank not moving freeiy, or defedive.

Tochackswifch Wrha 12voiftast iightandtheffoat inthe”up”positiirr, thereshoukf

be oower throuoh the swkfr.

To check raiay First“deck wiring against diagram. Wtih 12 volt test light, and the

FioafSwifch (4) inthe’up”position there should NOT bepowerattheSoienoid Valve. Wtih the Fioat Switch inthe “down”positian there should be power at

the Sofenoid Valve.

Solenoid Veive defedive Remove Soienoid Valve, d~assembie and inspect

diaphragm forcracks or tears.

PR08LEkk Mix Tank does not keep up with water output

Soiution

Check irmming water pressure. Check garden hose quick connect

assembly screen.

Check garden hose ardor feed hose to the Mix Tank for dog, kinks,

or bfockage.

Float Switch (4) in Mix Tank hanging up (not moving freely). Check fitterscreen in

Solenoid Wdve (l).

SPECIFICATIONS

oiume

..................................3.5 GPM (13 lfM)

ischarge Pressure

i~imum iniet Pressure .......-

PM ......................................1200

ore ......................................0.787 (20mm)

troke

....................................0.472 (12mm)

rankcase Capacity .............. 10 oz. (.3 L)

liet Port(1) ..........................

heroical Injectiin Port (1).... 1/4” NPT (l/# NPT)

ischarge Ports(2) ....3hY NPT (3/8’ NPT) (1 ):....1/? NPT (1/2’ NPT

uiiey Mounting halt Diameter

/eiaht ...................................12.1 ibs. (5.5 ka)

lim%ions ...........................10.77W9~O&x51{# (273.5x230x130.5mm)

..............1200 Psi (83 BAR)

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

1/2’ NPT (1/2’ NPT)

.................... Either side (Either side)

...................... O.6!W (16.5mm)

+ 28 hidden pages