HYDRAMASTER BOB CAT 2-290 User Guide

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I

@

INDEX

PAGE

General Information

Warranty ............................................................................................................................... 2

a

Warranty Information
Warranty Procedure

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

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

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

2

3
3

I

a

Purchaser’s Responsibility

Truck Preparation Information ...............................................................................................

Truck Preparation Illustration
Propane Tank Location/illustration
Hard Water Area Map

Machine Specifications

Spare Parts Fiecommendation/Parts Orders

Water %1Chemical Flow Operation

Water Flow Diagram
Chemical Flow Diagram

High Pressure Pump Information

Bypass Valve Assembly Illustration
High Pressure Pump/Chemical System Troubleshooting
Model 290 Cat Pump Operating Instructions

Chemical Proportioning and Level Control Illustration .........................................................

Chemical Tank Troubleshooting

Heating System Information

bleater Operating Instruction
Heater Troubleshooting

Vacuum System Information

Vacuum Flow Diagram
Vacuum Tank Filter Bag
Vacuum Blower Lubrication (Diagram)

Vacuum System Warranty ...................................................................................................

Vacuum System Troubleshooting

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5-6

7&16

4

4
4
5
5

5

6

6
6

7
7

16
16

16

18
18
18
18
19

20

Engine Manual/Warranty
Engine Troubleshooting

Electrical Diagram

Electrical Troubleshooting

Machine Installation Information

w

0

Machine Tie Down Cleat Information
Propane Hook-Up Illustration

Gas Hook-Up Illustration
Water Softener Information
Jet Assembly
Wand Assembly
Valve Assembly

Machine Operation Instructions

Control Panel
Operation Precautions
Freeze Protection

Cleaning and Chemical Precautions and Information ......................................................... 34

Cleaning Stroke Procedure/Over-Wetting

Maintenance Procedures

Overall Care of Machine
Maintenance Log

....................................................................................................................... 32

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...@............................................................................................................ 34

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............$...................................................................... 31

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.......$.............................................................................................. 35

21-28

29

33

34

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GENERAL

INFORMATION

This manual contains installation and operation instructions as well
as information required for proper maintenance, adjustment and re­pair of this
isttw cm’rectd[agnasis ofthe trouble, a general troubleshooting sec­tion and cm”ryxment manual troubleshooting charts have beert in­cluded far yaur oortvermiencxa

Unlike the garden tractor, Iavvnmower and cement mixer, all having
one or two functions to perform, the truck-mounted carpet cleaning
plant has many functions to perform simultaneously.

@ Engine has to run crmsistent RPM.
@
e Water pump provides stable pressure at proper water flow for

@ Chemical has to be injected into the water stream at the right

@ Heater must maintain proper heat.
a Vacuum tank must store dirty water until drained.

As you can see, it is not just

ta worry about, Dcmmit start?!

In-E SYSTEMS WORK As

FOLLOWS:

The water system takes incoming water at tap (low) pressure, com­bines it with chemical from the chemical system automatically,
pumps it under high pressure through the heating system and out to

the chsaning toQ:l.After being sprayed into the carpet being cleaned,

the wtMer/chwmical/soil solution is extracted by the vacuum system
and returned to th@waste recovery tank.

As there is no guess work in the manufacture of these highly ad­vanced cleaning plants, there must be none inpreparing itto get the
job done in the field. It isthe purpose ofthis manual to help you

erly understand, maintain and service your cleaning plant. Follow
the directions carefully and

ble trauble-frwe operation.

is imperativ~ that no section be overlooked when preparing forop-

It

@ratienof this equipment.

Uink. Wrkcm the first and most important part of repair work

VWUUrn has to pull air and dirtywater back from cleaning site.

cleaning.

consistency.

a turn key operation with only one thing

prop-

you wil~be rewarded with years of profita-

The manufacturer uses this symbol

throughout the

manual to warn of

possible injury or death.

HYDRA=MASTER

WARRANTY IPOLNXf

Effective October 1, 19$31

HYDRA-MASTER warranty covers only defective rnatawkalssmhr
workmanship for the periods listed. Labor,

andfor diagnostic reim-

bursement is specifically excluded.

LIMITED WARRANTY

HYDRA-MASTER warrantsproductsof itsmanufactureto be free
from defects in material and workmanship if properly rw.tailed, maint­ained, and operated under normal conditions with competent super­vwiion. No person, agent, representative or dealer is authorized to
give any warranties on behalf o?HYDRA-MASTER nor to assume for
HYDRA-MASTER any other liability m connection with any of
HYDRA-MASTER’S products. This warranty shall extend for tlm
periods listed by component below from date of installation. Ifrepaws
or replacements are made by the Purchaser without HYDflA-MAS­TER’S written consent, HYDRA-MASTER’S warranty shall cease to
be in effect. No allowance will be granted for any repairs or alttwa­tions made by the Purchaser without HYDRA-MASTER’S prior writ­ten consent.

Machinery, equipment and accessories furnished by l-fYf2FlA-MAS­TER, but manufactured by others, are warranted only to the extent of
the original manufacturer’s warranty to HYDRA-MASTER.

HYDRA-MASTER agrees at its option to repair at the p@int of ship­ment or to replace without charge f.o. b. point of shipment, any parts

or parts of products of HYDRA-MASTER’S manufacture, which with-

in the specified warranty period shall be proved to PiYD RA-M.4S­TER’S satisfaction to have been defective when shipped, provided
the Purchaser promptly notifies HYDRA-MASTER, in writing, of

such alleged defect,

HYDRA-MASTER’S liability to Purchaser, whether in contract or in

tori arising out of warranties, representation, instructions, or d@fwXs

from any cause shall be limited to repafring or replacing of the the r.$e-

factive part or parts as aforesaid, f,o.b. point of shipment.

No liaMlity whatsoever shall attach to HYDRA-MASTER un~[ said
products have been paid for.

Except as stated in this section and in the prwcedhtg aractlon
titled ‘Warranty” andexcept astotitle, thare are no $wmrarmtwm
orwarrantiesofmrarchantabiHty,fitness, prwformanoeorWver- (
wise, express, implied or statuatmy, and WW3RA-MASTER ~ ‘{
shall have no liability for consequential, im%drmtalor othsr I ~
damages, howsoever caused.

ENGINE: (Thru ongmal Manufacturer See 13nggs
& Stratton Warranty)
VACIJtJM BLOWER: (Thru original Manufacturer.

See Fuller warranty)

PROPANE HEATER:

VACUUM RECOVERY TAMtWCkfEMICAL MIX TANKS:
FRAME/Ct3VEFt ASSIEMB!JES:
HIGH PRESSURE PtJMP: (Thru ongmal Manufacturer
See Cat Pump warranty)

HIGH PRESSURE BY PASS VALVE:
CHEMICAL PROPORTIONING SYSTEM:

GAUGES, METERS, SWITCHES, WIRE HARNESS,

FUEL PUMP: 90 days 1~,
INTERNAL MACHINE HOSE:
EXTERNAL VACUUM HOSE, SOLI,JTION HOSE,

QUICK CON NECTOf?S:

SS CLEANING WAND: (Except valve& let assembly)
BELTS, FITTINGS, O RINGS, FILTER SCREENS:
FILTER BAGS:

Freezing of any one water or chem!cal related component WIII VOID I@ —
all other implied warranty on all water or chemical related comPo- E~
nents. internal or external, of this equipment

.- -# .-

$iwi.m!iiiriii

/ ~ @;3.’,m.7’rL-m —7F.F%-m.titijrm

.---, --’-.--’ -.-..--++- -+- 4..-.

Not Covered by Warranty ~~j

d

1 year

1 year

1

year -,

1 year -}

1 year “j

1year

90 days
90 days ““

‘odays ‘~$

2.Odavs ,~?

6 montk ~~

30 days iq’

a

1$’

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WARRANTYINFORMATION

To-avoid misunderstandings which might occur between machine
owners and manufacturer, we are listing causes of component fail­ure that specifically voids warranty coverage. Such causes as listed
below shall constitute abuse or neglect.

EN~fl~E: Operation at speed in excess of 2600 RPM. Failure to
maintain proper oil level (oil should be checked every 5 running
hours). Failure to use the proper oil viscosity and type (see engine
manual). Use of other than manufacturer’s recommended spark
plug in engines. Failure to perform recommended maintenance as
described on pages 3 and 4 of engine manual.

parts shipment will be sent to the customer for the

sent. The customer’s faulty parts must be returned forevalua-

parts

tion priorto the expiration of the thirty(30) day period. Upon warranty
approval, a credit will be issued the customer for the replacement
parts invoice. Werranty disapproval or faiiure to return the fauity
parts withhr the thirty (30) day period allowed will result In the
customer being charged for the replacement parts sent.

amount of the

HOW TO ORDER

To obtain a proper diagnosis of your malfunction, and to order war­ranty replacement parts, it is important you foiiow the below proce­dure:

9

~~~~~~: Failure to lubricate impellers daily with LPS-1 or
WD-40 lubricant. Failure to lubricate bearings as recommended in
blower manual. Failure to maintain proper oil levels in the blower.
Failure to use the correct oil grade and viscosity as recommended in
blower manual. Failure to properly maintain blower safeguard sys­tems such as waste tank filter screen, vacuum safety relief valve in
vacuum tank lid and waste tank automatic shut-off system.

~1~1+
pressures over 1200 PSI. Failure to maintain proper oil level as rec­ommended in pump manual. Failure to change oil inpump at recom­mended intervals. Failure to protect pump against freezing. Failure

to maintain pump protection shut-off system. Failure to use water

softener in hard water areas. Use of improper chemicals.

PRESSURE WATER PUMP: Operation of pump at

HEATER: Operation of heater without adequate water supply.

Changing factory set propane regulator. Operating heater without
proper ventilating. Failure to protect heater against freezing. Operat­ing machine at water pressures over 1000 PSI. Overfilling of pro­pane tank. Use of improper chemicals. Failure to use water softener

in hard water areas.

WACTANK: Failure to properly maintain filtering devices intank.

Failure to clean tank as recommended by manufacturer. Failure to
maintain vacuum safety release in tank lid. Use of improper chemi­cals.

~~~~. ~~~f%)~~~~~~~: Use of improper chemical. Failure

to use water softener inhard water area. Operating machine without

proper chemical filter screen. Failure to protect against freezing.

1. Call Hydra-Master Warranty/Service Dept. at [phone]

2. Give the Warranty/Service Representative the following informa­tion:

A.

Name of your company and your address.
Equipment Model (i.e. Hydra-Cat, Bobcat 2, etc.)
Date of purchase.

:.

Hours on the unit.

D.

Seriai number of unit.

E.

Name of person authorized to order parts.

F.

Salesman unit purchased from.

G.
H.

Description of malfunction.

i. Pressure readings on high pressure gauge with wand turned on

and off.

3. ifwarranty replacement parts are needed, piease specify method
of shipment desired. NOTE: Ail replacement parts are sent
freight coiiect, via:

A. U.P.S.
B. Airfreight
C. Air mail
D. Air express

E. Auto Freight

4. Do not give malfunctioning parts to a Hydra-Master Sales or Ser-

vice Representative. All parts must be returned directiy to Hydra­Master, freight prepaid.

~ONTFlO~
pressure gauge against freezing.

PANEL: Failure to protect flow meter and water

VACUUM AND SOLUTION HOSES: Failure to protect

hoses against freezing. Failure to protect hoses against burns from
enginelblower exhaust. Damage to hoses from being run over by ve­hicles. Kinking or cracking from failure to store or unroll hoses cor­rectly. Normal wear and tear from everyday use.

CLEANING WAND: Failure to protect against freezing. Obvi-

ous physical abuse of wand.

WARRANTY PROCEDURE

Warranty coverage is available to you ONLY through Hydra-Master
Corporation, 20309 64th Ave. West, Lynnwood, Washington 98036;
When warranty parts are needed, write Hydra-Master Warranty

Dept. at the above address, or call the Warranty/Service Dept. at
[phone]. No collect calls will be accepted. Hours of the
Warranty/Service Dept. are 8:00-11:30 am and 12:30-5:00 pm,

Pacific Time.

IMPORTANT

Hydra-Master’s warranty poiicy provides replacement parts without
charge forthirty (30) days to customers maintaining current account
status. An invoice dated thirty (30) days from date of replacement

ONE FINAL NOTE:

Any questions you have regarding the warranty program shouid be
directed to the Warranty/Service Dept. Personnel at Hydra-Master
Corporation.

We shall always endeavor to be fair in our evaluation of your war­ranty claim, and shall provide you with a compiete anaiysis of our
findings.

PURCHASER’S

@3ESPONSlBlLlTY

PF$MWITo AFWWtfALOF WWT:

@ install %+”extmicwplywood flooring in vehicle and cover with I

artificial turf.

@ Have belly mounted pfioparretank installed on vehicle. Tank

must br3propane vapor type.

Materials Needed:

1. 2 sheets 4 x 8 x

2. 6’ x 12’ piece of commercial astroturf

3. 16-1

4. 1 quart marine adhesive (optional)

5. 1 staple hammer w/’/z” staples

(See

‘/2” sheet metal screws

illustration for correct placement of p!ywood ffooring)

5/a” exterior plywood

PLACEMENT OF UNIT’IN
VEHICLE

There are two recommended unit placements:

m

batte~ and have battery ‘slow’ ch&ge6 ifnew. If battery is not
fully charged damage can occur to the engine charging
regulator.

AWHHW,AFJCE OF S&l[PMENT:

@ If unit shows any outward signs of

delivery receipt until you have closely inspected the unit and
noted any damage on the delivery receipt. Have the freight

company representative acknowledge the damage by signing

the notation of damage on the delivery receipt.

EADING (W CIPERATIION MANUAL:

I%

@ It is the purchaser’s responsibility to read the unit operation

manual and to familiarize himself with the information contained

therein.

Purchase heavv dutv 42-60 amn hour

damage, do not sign the

SALES REPRESENTATIVE

RESPONSIBILITY

e The salesman from whom you purchased your unit is

responsible for supervising the correct installation of the unit in

your vehicle and thoroughly training you in itsoperation and

maintenance.

(X2RREGT INSTALLATION INCLUDES:
Supewising the purchaser in the following:

@ Installation of through-floor fittings 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
pump, vacuum Mower and engine oil levels, prior to starting
writ; starting I-NMto check engine to see that all systems
function normally; also checking ali hoses, wands, etc., for
correct operation.

TR%MNING SHALL INCLUDE:

Thorough revi~w of the operation manual with purchaser;

@

instruction arndfamiliarization in: how to correctly start up and
shut down unit; how to correctly clean 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 precautions and their importance;
freezing damage and how to avoid it and a thorough review of
the unit warranty and warranty procedures.

gasoline lines; connecting battery; checking

A. SIDE DOOR: Most installations are side door. This providw roar
access for accessories and hoses as well as unobstructed access to
componenffworking side of machine, thus making it a bit easier to
perform maintenance and/or repair without removing unit from the
truck.

B. REAR DOOR: Although this location partly limits working ac­cess, it does direct the noise away from the cleaning site. Some
cleaners in the colder areas prefer this location because it puts the
weight mass over the rear wheels for better traction in ice and snow.
Rear mounting requires the unit to be slid to the right side as far as
possible. This not only provides adequate working space on tlm
component side of the unit but also makes better weight distribution
inside the van (engine and component weight line up over drive
shaft). Also, it is physically easier to load unit into
height of van bed.

Ensure that machino is !R@l secured to tl’m
floor of van with hardwar@ supplied. %Miran m’
cause machine to rocket forward, all 350 lb. worth! Pratect
yourself and the machine: SECURE IT!

TRUCK PREPARATION

rem’ door due to

crash atop will

ILLUSTRATION

FIRST, cover the truck bed with
secure it as shown.

SECOND, select the appropriate color astro turf to match your van

and cover the plywood and staple inplace. A standard
piece 6 feet by 12 feet.

THIRD, for added ventilation, an aluminum roof vmt should be

added over the location selected for mounting the machine. This will
allow hot air from the heater to escape.

5/8” plywood using metal screws to

PLYWOOD

%

van requires a

a

TRUCK PREPARATION

Manufacturer recommends the installation of plywood flooring
covered with poly pnopylene backed astroturf (do not use rubber-

backed) in the vehicle pricwtoinstallation 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.

PROPANE TANK LOCATION

Either the 10 gallon or 16.5 gallon propane tank will fit this location.
Have your local propane dealer install

ase. The machine will come with the proper propane regulator.
(Tank must have vapor outlet).

0

the tank you select and purch-

MACHINE
SPECIFICATIONS

SPECIFICATIONS:

E

Do not use a portable propane tank inside the

truck or van. Besides being dangerous it is unlawful in most states.

-.. —

HARD WATER AREA MAP

The quality of water varies greatly throughout the United States and
influences the reliability and efficiency of equipment in direct propor­tion to its level of hardness. The map below defines areas which
compromise fluid related components such as hoses, fittings, heat­ers, pumps, valves and water cooled engines.

Cleaning efficiency and equipment life is increased, chemical use
decreased and the appearance of cleaned carpets enhanced when
water softeners are incorporated in hard water areas. Manufacturer

strongly urges the use of water softener units in areas exceeding 3%
grains per
quality ofwater inyour area and take action immediately should it be

necessary.

gallon. Using the legend as a reference, determine the

FRAME:

WEIGHT: 325 Pounds.

COWLING: Steel With Baked-On Epoxy Finish.

ENGINE:

IGNITION:

HI-PRESSURE Tri-Plex Piston - Cat 290- 3.5GPM -1200 PSI-@
PUMP:

VACUUM
BLOWER:

CHEM. SYSTEM: Auto Proportioning Flow Meter Controlled.

HEATER: Propane Fired, Thermostatically Controlled.

INSTRUMENTS: 1-1000 High Pressure Gauge, Hour Meter,

RECOVERY

TANK:

CLEANING
WAND:

HI-PRESSURE ‘A”
HOSE:

18“ W, 46’ L, 33’ H. Steel With Baked-On Epoxy
Finish.

16 HP Briggs & Stratton Opposed Pk3crn. Steel
sleeved cylinders, ducted.

Magneto Key Start or Auxiliary Rope Start

1200 RPM

3 MB Sutorbilt W/l 4 HG Safety Relief.

(120,000 BTU).

Chemical Flow Meter, Ignition Key Start.

52 Gallon Aluminum Epoxy Finish.

S1S 11” W/Heat Covered Handle - and Forward

Guide Handle

High Temp LinedlVinyl Covered Safety

Orange W/Brass Quick Connects.

(For installation diagram see machine installation section)

—..

PE-R--GALLON

,,.

u 0-31’2 E%E$%i37-’0”2

Izzzn “/2-7 - ‘01’2ANDAB0vE

VACUUM HOSE: 2“ Reinforced Safety Orange, 1%“ Reinforced

Safety Orange.

STANDARD
FEATURES:

OPTIONAL
FEATURES: Vacuum Hose in 50’ Lengths, Additional

Basic Console, 52 Gallon Vacuum Tank, 11”

S/S Cleaning Wand, 100’ lA” High Pressure

Hose, 90-2’ Vacuum Hose, 10’-1 l/.” Vacuum
Hose, Batte~ Box, Through Floor Connections
For Gasoline and Propane Hook-up, Tie-Down
Cleats, Vacuum Hose Connections, Operation
Manual.

Stair Tool, Steel Legs W/Casters, Additional 2’

Pressure

Gun, Spare Parts Package.

Hose In 50 Lengths, Pressure Washing

1/4”

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 expen­sive.

In order to minimize such down-time, it is strongly recommended by
the manufacturer that you purchase and keep in your truck the fol­lowing spare parts:

CWANTITY

2

1

1

1

1

2

1

1

6

1

1

PAFIT NLMBER’i

000-0?8-015

000-07’$-024

000-078-034’

000-076-007’

000-049-028

000-078-001

000-078-004

000-049-023

000-052-050

000-052-051

DESGR!PT!OM

Engine Spark Plug

Flow Meter Kit

Wand Valve Plunger Kit

Press. Bypass Valve Kit

Spray Jet 800BE

Recovery Tank Filter Bag

Cat 290 Short Cup Kit

Standard

Cat 290 Hot Cup Kit
(Clpticmal)

Screen Gard@nHose

44o Male Quick Connect

440 Female Quick Connect

cycle of the mix tank. The chemical will flow from the chwrrical jug to
the chemical flow meter, then to the proportuonerwhere it is cWatri­buted intothe mix tank at your desired propo~lon. This line ~h~u~db~
flushed with vinegar weekly to prevent abnormal chemical build-up.
This may be done by removing the clear plastic hose from the c!wm+
cal jug and inserting it into
should be done with the chemical flow meter sisttirq on 10 GPl+ with
heater “off’. Simply spray the wand for the duration of the vinegar in
the one quart cantainer, then repeat the process
clear water to void all lines of vinegar.

NOTE: with this unique chemical system, your chemical flow is pro­portionedtothe filling cycles of the mix tank, nottha direct spraying af
the wand. Therefore, itispossible that as your wand is spraying, you

may have no chemical flow. Also, the converse is true in that you
may not be spraying your wand but, if the mix tank is ina fillingcycle,
your chemical flow meter may read your desired flow.

This chemical system will mix a 1to30 ratio when flow meter isset at “
5 GPH. Most chemical suppliers will recommend a 1 to 15 ratio,
therefore you can either set the flow meter at 10 GPH, giving you a 1
to 15 ratio of chemical to cleaning water, or double the recomm-

ended strength of chemical in the 5 gallon jug and set the flow

meter at 5 GPH, thereby attaining a 1to 15 ratio. (It is recommended
that you set the flow meter at 10 GPH for overall best results.)

a one quart container of vinegar. This

a

with one quart af

1

1

1

PARTS

To expoditrayour

In most instances, he either stocks or has access to parts through a

regional service center.

[nthe event parts are unavailable locally, contact the factoy and co-

ordinate your needs. Ifthis becomes necessary, always indicate the

method of shipment you desire, i.e. U.P.S., U.P.S. Blue Label, Air
Freight, Air Express, etc..

Hydra-fwfaster Parts Dept. phone [phone].

MJO-052-052

000-052-053

4 L 280

ORDERS

parts newts, please call your sales representative.

660 Male Quick Connect

660 Female Quick Connect

Belt, Pump Drive.

WATER AMID
ICHEMICAL FLOW
OPERATIONI

The water will now be siphoned from the bottom of the mixtank to the

Cat Pump. If the wand is not spraying, the water will bypass from the
bottom of the brass pressure relief

If the wand is spraying, the water will then flow to the heater. This
heater has a capacity of up to 2 gallons, therefore it isextremely im­portant that all air is bled out of the heater prior to initial start-up. This
may be achieved by running the system, without the beater on, for
approximately 60 seconds.

valve tothe mix tank.

WATER FLOW DIAGRAM

BOB

CAT 2/290

WDRA CAT “S” SEFMES

CHEMICAL
TANK

& ‘;:

MIXTANK

PRESSURE
GAUGE HEATER

~

+

This systam has been designed to be the most simple and trouble-

frwe ever.

This incoming water flows directly tothe mix tank. Water will nowflow
through a pmpcwtioning valve which will simultaneously mix the

chemical to achiew your desired solution. The mix tank isequipped
with 2 different float valves, one of which responds to the water level

af the tank and will maintain the proper volume of solution to be re-

swwed for the cat pump. The secondary float valve is a safety valve

that is desigmsd to protect your system from sudden or unexpected

loss of water supply. if, for example, the water source at the house

was turned off, the water level of the mix tank would drop, activating

the secondary valve which automatically kills the engine.

[n conjunction with the incoming
tained by an adjustment crfthe chemical flow meter during the fill

flow, the chemical ratio maybe ob-

CHEMICAL FLOW DIAGRAM

v
CHEMICAL
FLOWMETER d

-IEMICAL
lNK

r - -K,

{~

1

v 7

.=

.

—

v

z

INCOMING
WATER

LOWWATER
SAFETYSHUT

OFF FLOAT

/-’---

t

CHEMICAL& WI%TE17
MIXTANK

&

I

.

As you remove your discharge manifold, there isa set of 3 check val­ves (which usually fall out during dis-assembly). If the surfaces of
these check valves are dirty, or show signs of chemical build-up, it is

probable that they would remain open causing pressure loss or pul-

sation. Upon inspecting the valves, make sure that the teflon buttons

in the valve spring retainers are still itact. Also examine the dis­charge manifold. Look for problems such as cracks, chemical build­up or warpage due to freezing. Ifthis discharge manifold iswarped, it
will cause the check valves to stick and will result in lossofpressure.

The Cat pump cups are often the source of pressure loss. Upon in­spection they may appear melted or torn, but often they will look
good. Replace them anyway. There is no sure method ofvisually in-

specting the cups. Hydra-Master recommends changing cups
whether they look good or not.

Anytime your’pump is being dismantled, Hydra-Master recommends

replacement of all ‘o’ rings and seals. This is merely a convenience
to the customer to make sure that the Cat pump is in top operating
condition.

The prrrm-a-lube seals located within the intake manifold will allow
air to enter the pump if they are worn. Again, it is difficult to visually

pinpoint a defective prrrm-a-lube seal. Replace them all.

Within the piston sleeve cylinders there are 6 ‘o’ rings that are about

‘/4 the size of a penny. If these ‘o’ ringsare bad, water will be pumped

back into the oil. If this has occured the oil will raise in level and will

appear milky. If you are unable to repair seals rightaway, change oil

e

frequently. Repair the pump as soon as possible so as to not dam-

age bearing or connecting rods.

Repairing of Cat pumps isnota difficulttask. However, before disas­sembling make sure you have the proper parts required.

1- short (or hot) cup kit
6- piston sleeve ‘o’ rings
3- Prrrm-a-lube seals

1- bottle Cat oil

Read instructions thoroughly, supplied in the Cat pump manual,

prior to disassembly and follow directions as stated. Oil all seals
thoroughly prior to installation. (Remember, a newly scarred seal is
no better than one you just took out.)

BYPASS VALVE
ILLUSTRATION

TO SERVICE BYPASS VALVE

@ Unscrew knurled knob and remove.
@ Wiggle protruding shaft with fingers or pliers, pull up and

remove from main body.

SPECIAL INSTRUCTIONS - BYPASS VALVE

#4 - 5/16“ fine thread

#6 - CUD seal {ifleather, redate or lube with leather oil).

#7 - Brass bushing

#8- Shaft - if cup needs replacement, place thin end of shaft only in

a

vise and remove 5/1 6“ nut. Fat end is “seating” surface and
must be free of abrasion to mo~erlv seat. NOTE: lMPORTANT

-when replacing seals, only”wrenc~ nut #4to where cup will not
turn on shaft. Ifcup is too loose, bypass will leak. Too tight, cup
will flange and bypass will leak.

HIGH PRESSURE PUMP

TROUBLESHOOTING

A pump instruction brochure on pages 8-15 may assist you in resol­ving a pump related problem.

Plmmmvl:

o LOSS OF PRESSURE

CAUSE AND/OR SOLUTION:

1. Clogged Filter Screen in garden hose quick connect
coupler.

A. Remove and clean or replace filter.

2. Low water pressure at source.

A. Determine rate of flow and select an alternate source of

supply if water pressure is inadequate.

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

A. Ok-assemble cylinder head and replace or clean applicable

check valve.

4. Delaminated, kinked or clogged hose between the mix tank
and the high pressure pump.

A. Remove and replace defective hose.

5. Defective pressure relief valve or debris in pressure relief
valve. NOTE: the high pressure bypass valve is designed to
fully close when the cleaning tool is turned on. Any foreign
matter collecting on the piston will prevent full closure of the
valve and allow a potilon of the water to continue to circulate

instead of being routed to the cleaning tool. To correct this

situation, the bypass valve must be disassembled and cleaned

(refer to drawing provided in this manual for bypass disas­sembly).

A. Disassemble and clean pressure relief valve as illustrated in

drawing.

B. Replace defective or worn out bypass cup.

C. Replace bypass valve.

6. Defective or worn cups.
A. Remove and replace piston cups as defined by pump manual.

7’.Loose drive belt for high pressure pump.

A. Readjust belt as required or replace if defective.

WATER FLOW

1. Worn out spray jet. NOTE: Cleaning tools designed to spray a

constant flow of 1‘/2GPM will average 1 gallon of flow per minute in
actual working situations since flow is not continuous. An average
flow of 1 GPM results in 6000 gallons of flow for every 100 hours of
unit operation. Spray tips are capable of consistent flow rates for
approximately 20,000 gallons. They should be replaced therefore,
approximately every 350 hours. Worn spray jets allow a greater
average rate of flow thus reducing desired temperature levels.

A. Remove and replace spray jet.

(Continued on Page 16).

OPERATING INSTRUCTIONS

CAUTION: CAT PUMPS

a properly designed pressure reltef mechanism MUST’be installed in
the discharge piping. Failure to install

result in personal injury or damage to the pump or system. Cat
Pumps Corporation does not assume arty liability or responsibility
for the operation of a customer’s high pressure system.

SPECIFICATIONS

vdurrme ...........................................................................................................................3.5 Gf?M

lMdmarfJcr Pressur@......................................................................................................1200 PSI

#~m#num Ink$t Press ure ............................................................... .... .... . .......... -8.5 to + 40

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

................................................................................ ..... ..... .... ..... ......... ........ ................O.78O''

B’occr

Stroke .................................................................................... . ........ ..... .... . .... ..... .... .... ........O.472''

Crankcase Capacity ..........................................................................................................10 oz.

Maximum Fluid Tmpmtlm

Inlet Port (l) ............................" ................................................................... . ........ ......... 1/2” N

LNschargaPcwt

I%dky MQunting ........................................................................ .... ..... .... ................... Eit her Side

Shaft fJimmrt@r

Wtright ............................................................................................................................

.........................................................................................................3/8'' N

(2)

..................................................................................................................O.65O''

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

Dim@n$iQn$.......................................................................................................10.6X 9.1 X 5.7”

U.S. Measuro

PSI

1200 RPM

k30”F

12.1 tbs.

PT

PT

Model 290

are positive displacement pumps. Therefore,

such relief mechanism could

Metric Measure

(-0.6 to+ !2!8::;;;

(268 x 230x 146mm)

[13 L./M)

(1200 RPM)

(20mm)
(12mm)

(0.3 L)

(71“c)
(1/2” NPT)
(3/8” NPT)

Side)

(Either

(l~5\mk~]

CAT IPUMP

This Cat Pump ($’prackt”) is warranted by the manufacturer to be

Moe from dttrf~ctsin
dat@of rmmufactumr’s
ing or ropltmhr~ products which manufacturer’s investigation
Mrcmrawara ddmtiv~ at the time of shipment by the manufacture.
AIUproducts sub@ to this warranty

Pumps

tkm,impairor raplacament.

Tim express
tkm, exprcmsor
d merdrmatrahility or
wwrarotle%+
turm’. Repsrtr cmI’E@WMIWtnt Qf defectiw products as provided

Corp., M mmnwpdis,Mhmeaota 55430, tJ.S.A. for axamina.

warranty set fcwthhwwin is IFIlhw of all other warren.

are Iwwekwdisclaitmatf and exc!uded by the mamdac-

la the501@ 8rIud exclusive remmty providad hereunder and tha

abwm
mmnufactumr shall mrt be liable for any further loss, dama ea or
tmfmnwwi, irmc!udim’u$Incktwrtal m consequential damages, d rectly
or irrdlrectly arisiq Irm the
Thla warranty it?

Products df3$Cr(b@dhereon are covered by one or more of the follo’w,og U S Patems 3558244 3652188 3809508 3920356 and 3930 T56

~Hq&g&”

,,!,f+,.,~f{.., ,,, >

BOX 885 MW4NEAPOLK. MN 55440

P O

Phone [phone] m Telex 290276

N V CAT PUMPS INTERNATIONAL SA

0.2000 Antwerp Belwum

workmanship and matr3rial for one year from

sh@’rmwTl. This warranty is I!mifed to repair-

/

hrmplid,hclmfhg without limitation any warranties

fitness for a particular purpose and all such

shall be retumad F.0.k%Cat

7

aub@ct tothe following warranty condition

.

Harmonteslraal 29

sale m trae o~ this product.

CH 6300. ZUG Switzerland

CAT PUMPS DEUTSCHLANO GmbH

Restocker Strasse 9

6200 Wlesbaden.Blersladl

CAT PUMPS (U K ) LTO

17A K,ngs RoaIY Fleet

Hampsh, re GU13 9AA

LorelohOhe 5

e

west Germany

e

England

WARRANTY

LUaFIICATION

Pump 011 or equivalent SAE 40 weight hydraulic 011with antlwear and rust Inhibitor ad.
dttives. Change mltml fill after 50 hour run.m parmd, Chwage O(I %V%Wibrme months or at
S00 hour lflterWdS thereafter. Prrrrrm.a-lube seals need no Iubrlcatton. Blu% dot WX3113and
wicks mu$t r9C91v9 three drops of Cat Pump 011 per wick every 54 hour8 of operation.

GOOD

PREVENTATIVE MAINTENANCE.

IIPMmd PRESSURE

Pressure relkef valve must be [nstalled,

DO NOT PUMPACIDS OR AL!RASIVEFUJIOS wdh this unit Consult Cat Pumps km addl.

tlonal #nf0rr17at10n on questionable flulds.
FREEZING CONDITIONS - Pump must be protectect 1rom iroez!ng cond!l

,.

IMPORTANT t2C)NKNTlCJNS

crankcase to dot on o(I gauge window per specifications with Cat

- fill

LUBRICATION IS WE EASIEST, MOST EFFfC!ENT AND LEAST EXPW4SWE OF

Pump oper@#o” must be wlthm RPM and pmasure specttlcat(ons

-

USE OF OTHER THAN CAT PUMP PARTSOr?

THEIR EQUIVALENT VOIOS THE WAWIAMIT

Ions.

3/8’

1

\

HORSEPOWER REQUIREMENTS

PRESSURE

Flow

LIM

;PM

3.5 13

3.0 11

2.5 9

800

Psl Psl

55

BAR

1.9 2.4

1.7

1.4

1000

69

BAR

2.1

1.7

1/2”-’

1.34[34]4 ! L- ~ap

IMPORTANT DRIVE INFORMATION

Pump speed and pump output in
gallons per minute as tabulated is
based upon a 1725 RPM drive motor.
Select motor pulley size to provide
GPfvl of the approximate pump out­put desired.

Pump RPM and GPM output are ap­proximate values due to variations in
pulleys, belts and motors between
manufacturers and a + –

output tolerance.

Horsepower figures

horsepower figures. For gas engine
requirements,
manufacturer’s recommendations.
In general, use a gas engine with ap­proximately double the electric
motor horsepower.

1200

Psl

83

BAR

2.9

2.5

2.1 858

Pulley

Selection
Using 5“
Pump Pulley

tblotor

RPM .

1200
1029

P; I&y

3.5

3.0
2,5

I

I

I

I

.79

k(20)

5°/0 pump

shown are brake

follow engine

TYPICAL INSTALLATION

The illustration at the right shows the basic
elements for the proper installation of a high-

-pressure pump. Each component offers

potential problems that too often are ascribed
to a perfectly functioning pump. A clogged
strainer, a partially closed shut-off valve or a
faulty pressure gauge or pressure regulating

unloader may be the source of trouble.

Proper system installation, routine lubrica-

tion and monitoring of components are your

best and guarantees of optimum pump perfor-

mance. These precautions will eliminate most

problems, minimize corrective maintenance,

a

and give many, many added hours of trouble

free operation. Cat Pumps Corporation does

not assume any liability or responsibility for

the operation of a customer’s high pressure

system.

GENERAL IINFORMATIC)N

~

It

p

INTERPRETING PRESSURE READINGS: Pressure

readings that differ from the rated IISl or those
normal far a

buf not necessarily a pump probkem!

Ehefore any servicing of the pump, carefully check

the following; inlet plumbing for size, restriction
andlor air leaks, restricted or worn orifice and con­dition of the by-pass valve and pressure gauge.
Ch@ck any shut-off valves in the inlet or discharge
plumbing to be sure they are fully open. Seven out
of ten problems are other than pump problems!

FOR SERVICE contact your local representative
cw look in the Yellow Pages under PUMPS.

ORDERING OF PARTS: When ordering parts, be
sure to give the
number”,

items desired.

particular set-up indicate a problem,

“model number” and “serial

“description”, and “quantity” of the

MATERIAL RETURNS: If necessary to return a Cat
Pump, please secure an approved “RETLfRN

GOODS AUTHORIZATION” form

from Cat Purnrm
Corporation and complete a “PRODUCT
REPORT” form detailing the application and th~
conditions of operation. Any material AIJTHQRIZ­ED for return must be shipped FREIGHT

PREPAID.

FILTER INSPECTION: A frequent source of low
pressure is due to foreign matter in the fluid being

pumped. It takes but one small particle to partially
hold open a valve—

or filter, or if the particles are

several to plug an inlet screen

abrasive,to damage

packings, valves, valve seats, or plungers.

Inspect filters and screens on a schedule comm-

ensurate with the material being pumped and

whenever a low pressure problem develops.

NOZZLES: A worn nozzle will result in loss of
pressure.

a

INSTALLATION

Optimum ptwfomantm at tfw pump is dependent upon ths entire fluid system and will

obtained only with NM?properselection and installation of plumb!ngand acmassories.

be

Lubrication: Fill crankcase with oil as covered under
warranty conditions.

PIuil@y $elactitm: Select size of motor pulley required to
deliver the desired volume from Horse Power Require-

ment and Pulley Selection Chart.

Wutar Sel@cticm: The motor or engine driving the pump

must be of adequate horsepower to maintain full RPM

when the

Horse Power Requirement Chart according to required

pIJrYIP discharge volume and maximum pressure at tfre

pump!

MourIt tl’m pump cm a rigid, horizontal suface in a

ner to permit drainage of crankcase oil.

mounting surface will cause extensive damage to the

pump base. Use the correct belt; make sure pulleys are
aligned. Excessive belt tension may be harmful to the
bearings.

Inlat Plumbing must be at least the same diameter as
the inlet port, preferably one size larger. Restriction in
the inlet plumbing will
di”autically reducing packing life. All joints must be air
tight.

Inhat

+ 20 PSI inlet. pressure. With adequate size inlet plum-

bing, the pump will perform very satisfactorily with

pump is under load. Select a motor from the

man-

An uneven

cause cavitation in the pump,

Prmwwm%x Optimum performance is obtained with

flooded suction. The pump can operate with inlet
pressure up to 40 PSI. Use of excessive pressure will
void the warranty.

Inlet Accessories: Install an inlet strainer of twice the
rated capacity of the pump.

A stand pipe to help maintain a positive pressure

head in the inlet line is desirable.

A shut-off valve is recommended to facilitate

maintenance.
Discharge Plumbing: Install a puisatian dampening

device mounted directly to the discharge line and

precharged to a pressure calibrated for operating con-

ditions.

A re/iab/e pressure gauge should be installed near
the discharge outlet of the high pressure manifold.
This is extremely important for adjusting pressure

regulating devices and also for proper sizing of the noz-

zle or restricting orifice. The pump is rated for a

max-

imum pressure; this is the pressure which would be

read at the discharge manifold of the pump, not at the

gun or nozzle end of a long hose.

A pressure regulating relief valve or unloader must

be installed to prevent over-pressure in the event the
discharge or downstream plumbing becomes plugged
or is turned off. Severe damage to the pump wif[ result
if this condition occurs without a rslief valve in the line.
CA UTIOIV: Failure to install such a valve wtil void the

warranty on the pump.

@

a

I

—

58

EXPLODED VIEW

MODEL 290

20

❑

17

’15

‘ 57