HYDRAMASTER BOB CAT 2-290 User Guide

INDEX

PAGE

General Information

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

Warranty Information Warranty Procedure

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3 3

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 5 5

6 6

7 7

16 16

18 18 18 18 19

Engine Manual/Warranty Engine Troubleshooting

Electrical Diagram

Electrical Troubleshooting

Machine Installation Information

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

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21-28

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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-

@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

1 year

year -,

1 year -}

1 year “j

1year

90 days 90 days ““

‘odays ‘~$

2.Odavs ,~?

6 montk ~~

30 days iq’

1$’

~~,

‘t

!? .

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:

~~~~~~: 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 (206) 775-7275

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

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

Hours on the unit.

Seriai number of unit.

Name of person authorized to order parts.

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 (206) 775-7275. 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:

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:

@ 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

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).

the tank you select and purch-

MACHINE SPECIFICATIONS

SPECIFICATIONS:

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

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

with one quart af

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 (206) 775-7276.

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,

v 7

—

INCOMING WATER

LOWWATER SAFETYSHUT

OFF FLOAT

/-’---

CHEMICAL& WI%TE17 MIXTANK

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

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

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.

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 (612) 7805440 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

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

west Germany

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’

HORSEPOWER REQUIREMENTS

PRESSURE

Flow

LIM

;PM

3.5 13

3.0 11

2.5 9

800

Psl Psl

BAR

1.9 2.4

1.7

1.4

1000

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

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

.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,

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

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.

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.

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.

—

EXPLODED VIEW

MODEL 290

❑

’15

‘ 57

ITEM

PARTS LIST

CAT PUMP MODEL 290

2 3 4 5 8

9 10 11 12 15

16 17 18 19 2’0 21

23 24 25 26

2!2

3’0

PART No

28766 856W)

14177 43211 26(M37 26105

22289

23170

25625 %2520

43804

14487

24159

26536

27950

92519

101799 101‘Boo

16948 20017 25301 25327 25392 28771 29003 29614 26854 28597 25128 25635

30315

30325

Dmclllm’lc)l’i!

QTY.

Crankcase Stud (M8 x 82)

Cl-Ring, Oil Filler Cap

Oil Filler Cap O-Ring, Crarrkcase Cover Crankcase Cover Oil Gauge O-Ring, Drain Plug

Drain Plug

Sems Comb l-lead

Screw (IM6 x 20)

Crankshaft

Rearing Oil Seal Q. Ring, Oil Seal Case Oil Seal Case Semrs

Comb. Head Screw (M6 x 16) Confecting Rod

Piston Rod Piston Pin

Seal Washer

Oil Sea!

Harrier Slinger O-Ring, Sleeve O-Rina, Sleeve (Viton)

Back-U”p Ring, Sleeve

Sleeve (29743 Lfnchrorned) 3

Seal Washer

Seal Retainer 3

Inlet Manifold

Inlet Manifold-Stainless

Steel

Prrrrrm-A-Lube Seal Prrrrrm-A-Lube Seal(Viton) 3

PART NO.

ITEM

;

27004

30543

30544

1 1 1 1 1

42 43 44 45 46

47 4a

2 2 2

43172

27983 27002 27006

18956 14158

101802

23172

11377 21985 24459 25634

DESCFUPTIC)N

Inlet Valve f3ac-Cup Piston Bat-Cup Ring (Teflon) Cup (Viton} Piston Spacer Piston Retairw Conical Washer-SS (M6) Nut-SS (M6) Cotterpin Cylinder (43834 Unch) O-Ring, Cylinder O-Ring, Cylinder (Viton] Bat-Up Ring, Cylinder

Discharge Manifold Discharge Manifold-

3 3

3 3 3’ 3 3 3 3 6 6 3

Stainless Steel

3 3 3 3 3 3 3 3

51 52

53 54 56 57 58 59

43442 43360 43723 43434 81109

101804

25130

26246

30901

30920

30910

30032

30047

Valve Spring Retainer Valve Spring Valve

Discharge Valve

Seat

Hex Nut (MS)

Hex Flange Nut (M8) Shaft Protector Angle Rail

Hex Cao Screw

(5/16 x23A)

Split Lockwasher

(5116 US)

I’-lex Nu~ (5/16 LfS)~

Pulley 5“ w{2 Set screws Key (M5)

30612

Mk,ng

30246

Pulley Asbly

; 3

3 3 2 2

;

2 2

1 1

30023

3 6

1 1

3’0305

3 3

30431

3 3

Cup Kit cup O-Ring, Cylinder Cotterpin Instruction Sheet Cup Inserter

Seal Kit

Prrrrrm-A-Lube Seal Cotterpin Abrasive Paper Instruction Sheet

Slt?eve

and Seal Kit

Prrrrrm-A-Lube Seal

Barrier Slinger Cotterpin Sleeve O-Ring, Sleeve

instruction Shee’

SERVICE KITS

30686

3 3 3

30860

6 3

: 3

Vahm Kit

Valve Spring Retainer

Valve Spring Valve Valve Seat O-Ring, Cylinder

Instruction Sheet

Piston Kit

O-Ring, Cylinder Back-Up Ring, Cylinder Bat-Cup Piston i3ac-Cup Ring

cup

Piston Spacer

Piston Retain@r

3 3

Conical Washer (M6)

Nut (!v16)

3 3

Cotterpin

Inlet Valves

Instruction Shr3e!

SERVICING DISCHARGE VALVES

& VALVE SEATS

DISASSEMBLY

Loosen the 2 (M8) locking nuts approximately one turn.

Then remove the 2 (M8) flange nuts.

Grasp the discharge manifold with 3 fingers on the underside and tap with a soft mallet to remove

Valve assemblies will remain with the manifold. in-

4. vert manifold and discharge valve assemblies should fall out.

Inspect discharge valves for wear or ridges.

(Sperical valves due to their shape must be replac-

ed when worn.)

REASSEMBLY:

Place retainer in manifold chamber.

Next insert spring into center of retainer

Place valve over spring with spherical (mooned) side down.

Next insert the valve seat. Position manifold back onto pump. NOTE: Exer-

cise caution when inserting cylinders into manifold

to avoid damaging cylinder o-rings.

Replace flange nuts on studs and hand tighten

6. both sides. Then torque each side to

pounds.

Hand tighten locking nut.

CAUTION: When restarting the pump, check to see

that there is no cy/inder motion as this will cause premature failure of the cylinder o-rings. Center cy/inder motion canbe eliminated by switching with one of the endcylinders,

125 inch

SERVICING THE PUMPING SECTION

DISASSEMBLY:

Remove discharge manifold as described above.

Slip cylinders out of inlet manifold.

NOTE: Identify cylinders so they will be re/apced in

their origional position. (Front to back)

Remove cotterpin, nut, and washer.

Next remove piston retainer, spacer, and piston

assembly. Remove inlet valve.

A WEASSEMBLY:

Exarnirm inlet valve surface and reverse if damaged. {both sides are lap surf aces.)

Examine piston assembly for clean inlet surface.

If damag~d, replace and lubricate.

lWITE CUP INW”M.LAT[QN: Wipe cup Inswfer Iight/y with oii. Slip Me-cup ring onto

pisfon. Force cup over inserter and square with all sur-

faces. Faulty cup installation causes premature fa)lure.

Next replace piston spacer and retainer.

Slip washer onto rod, screw on nut and torque to 60 inch pounds. NOTE: ALWAYS REPLACE WITH

NEW CQT7ERPIN.

Examine cylinder walls for scoring or etching.

These conditions will cause premature wear of

your piston assemblies. replace if worn or dam-

aged.

Lubricate cylinder and replace o-rings and back-

up rings (if defective).

SERVICING THE SEALS

AND SLEEVES

DISASSEMBLY:

Remove discharge manifold and piston a.sst?m -

blies as describ~d .

Remove both (M8) locking nuts from studs

2. With soft ma[let, tap inlet manifcdd lcms@ from

3. crankcase.

Place inlet manifold on pair of clearance Mocks

with crankcase side down. and drive out seals.

Invert inlet manifold with CRANKCASE SIDE UP.

Lubricate circumfrance of new Prrmrrn-A-Lube

6. seals, position in manifold with GARTER SPRING DOWN and drive into place.

Examine sleeves for scoring or other damage

before removing

If worn, grasp sleeve with pliers

8. NOTE: This procedure will mar the s[et?ve so LJiW only it sleeve is to be replaced,

Remove o-ring and back-up rings from piston rod.

and pull off.

Position cylinders in their origional order into manifold chambers and carefully slip over rod ends onto the pump.

Replace flange nuts on studs and hand tighten

both sides. Then torque each side to 125 inch pounds.

Hand tighten locking nuts.

PISTON SPACER . . EIAC.CUP

coTTER”N1 \Y

BAC.CUP RING

+--- INLET VALVE

IliE--4l

REASSEMBLY:

Place barrier slinger on rod.

Lubricate new o-rings and back-up rings. Install first o-ring in the o-ring groove on the piston rod. Position back-up ring against the shoulder in front of the first o-ring, then the second o-ring. lilt? careful to avoid damaging the o-rings whtan slip-

ping them over the piston rod threaded ends.

Immerse sleeve in oil carefully twist and push

onto rod. (machined counter bore end first].

Replace seal retainers.

Exercise caution when replacing inlet manifold, so

the inlet seals are not damaged by the threaded rod ends.

Replace locking nuts on studs.

Reassemble piston assemblies and discharge

manifold as described.

CYLINDER ~

PUMPING SEGTION CUTAWAY

Consult factory for your local distributor for crankcase servicing.

●

DIAGNOSIS AND MAINTENANCE

PROBLEM

Pulsation Faulty PulsationDampener Check Precharge

Pressure

Low

Wmps runs axtremely rough, wessure very low

:yfinder O.rings blown nexf to iacharge manifold

Warped manifold

eakage atthe cylinder O.rings Loose cyl!nders. Cylinder motion t fhe discharge manifold and lack, powdery substanca in fhe discharge manifold rea of the O.rings

later leakage from under the Worn Inlet manifold seala. Leaking Installaeals If piston rodsleevea prescored, det manifold

ii leak between crankcase

nd pumping section

il leaking in the area of

rankahaft

cau5ed by improper shrmming of the

sIeeve O-ring

Worn crankcase piston rod seals

Excess 011 from wicks

Worn crankshaft seal or Improperly

Installed oil seal retainer packing gasket andlor seala

Bad bearing

PROBABLECAUSE

new one

Worn nozzle Replace nozzle, of proper alze May be caused by humid ah Change oIl at 3 month or 500 hour intervals

Belt Sllppage

Alrleakir inlet plumbing

Pressuregaugeinoperativeor not Check

registering accurately

Relief valvestuck, partiallypluggedor Improperlyadjusted;valve seat worn

Inlet suctionstrainerclogged or Impropersize

Worn p]ston assembly Abrasivesin pumped fluid or severe cavitation. must be Iimited to lifting less than 20 feet of Inadequate water supply. water or -8.5 PSI vacuum.

Fouled or dirty inlet or discharge Clean inlet and discharge valve assemblies.

valves

Worn Inlet or discharge valves

Leaky discharge hose

Restricted !nlet or air entering the inlet plumbing

Inlet restnctionsa ndlorair leaks. Replace worn cup or cups, clean out foreign Damaged cup or stuck inlet or

discharge valve

Worn Inlet manifold seala Replace worn seals.

Worn Inlet seals allow pump to draw Install new inlat manifold seals. air.

Preaaures In excesaof rated PSI Check for plugged nozzle, closed valves or

Tighten or replace; use correct belt

Disassemble,reseal, andreassemflle

with new gaugq replace worn or

damaged gauge, P.N. 06090 Oil leaking from underside of Worn crankcase piston rod seals

Clean, andadjusl reliefvalve;check for worn and dirtyvalveseata. KitAvailable. Damagedor improperlyinstalledod

Clean. Useadquatesize. Checkmore frequently.

Install proper falter. Suction at inlet manifold

Replace worn valves, valve seats andlor

discharge hose.

Proper size inlet plumbing; check for air tight seal

material, replace worn valves

—

!mproperly adjusted bypass valve Chrome plating of cylinders damaged

Replace manifold

Remove spacer shims on manifold studs. Do not Strong surging at the inlet and remove too many shims orthe ears of the manifold will be bowed when the manifold is side discharge valves retightened, causing looseness in the center

cylinder

replace sleeves and aleeve O.rings.

RePIaCe crankcase piston rod Seak

Reduce quantity of oil per oiling

Remove oil seal retainer and replace damaged

Replace bearing

SOLUTION

if low recharge it or install a

PROBLEM PROBABLECAUSE SOLUTION

Excessiva play in the end of tha crankshaft pulley

Water in crankcase crankcase oil every month or200houra) P.N. 06100,

Worn main ball bearing from excessive tension on drive belt

condensing into water inside the

Leakageof manifold inletseals andlm Replace seals,sleeve andO.mgs,

piston rod sleeve O.nng

Replace ball bearing. Properly tenaion belt.

using Cat Pump Crankcase Oil (other approved

crankcase

Replaceoil gaugeor coverO-ring,and drainplu Oil leakingat tha rear portionof the crankcase

Oil leakage from drain plug

Loud knocking noise in pump

Frequent or premature failure of

the inlat manifold seals

Shortcup life

low preaaure on

the discharge

gaugeor crankcaaerear coverO.ring, anddrain plug

Loose drain plug or worn drain plug O.ring

Pulley Ioose on crankshaft Check key and tighten set screw.

Broken or worn bearing

Scored mds or sleeves

Over preaaure to inlet manifold

Damaged or worn chrome plating of Replace cylinders the cylinders

Abraswe material mthe fluid being Install proper filtration on pump inlet plumbing pumped

Excassive pressure andlor temperature of fluid being pumped

Over pressure of pumps Reduce pressure

Running Pump dry Do not run pump without water

Front edge of piston sharp

causing excessive wear of cups. Maybe compatible with chrome caused by pumping acid solution.

Foreign particles in the inlet or

discharge valve or worn inlet andlm

O.ring

O-ring

Tighten drain plug or replace O.ring

Replace bearings

Replace rods and sleeves.

Reduce inlet pressure per instructions

Check pressures and fluid inlat temperature; be Sure they arewithinapecified range

Replace with new piston

Install new cups and cylinders. Pump only fluld

check for smooth lap surfaces on inlet and

discharge valve seats. Discharge valve seats a nd inlet Valve seats may belapped on a very fine oil stone; damaged cups and discharge valves cannot ba lapped but must be replaced.

as it passes thrcwgh”thahose. Therefore, it is necessary to increase the pwwsure at the machine 40 PSI for eve~ additional 50 feet of cleaning

solution hos~ over 1100feet.

CHEMICAL PROPORTIONING AND

LEVEL CONTROL ILLUSTRATION

PROI=QRTIONING VALVE REPAIR KIT

Pm VE

MIX

TANK OVERFL~W$

1. Float ball in mix tank hanging up (not moving frissdy).

2. Extension bracket pinching the float lever, restricting full a@km of the lever.

3. Plunger not seating properly cmthe vakm. (Remove the 2 screws

which hold the extension assembly to th~ valve. Do not Iasti or drop thisscrews. Remove the wtmwion assembly. Turn itupsk.ka down. Inspect the plunger for proper seating. If tl%ra is no obstructing the vahm or plunger, the plunger maybe nut of adj,ustme.nt. To adjust, loosen thes@ screw on ths ball nut rarncfmow tho ball toward the end of the rod 1/16“. Retighten set scxww. Place wtension assembly back into position. Tighten the two screws.

MIX TANK DOESN’T’ KEEP UP WITH WATER CM$TPWF

Check garden hose quick connect assembly screen. Check garden hose

kinks or blockage.

Float ball in mix tank hanging up. (Not moving freely).

Extension bracket pinching float lever, restricting full action of lever.

Valve plunger not o~eninq fullv. To adiust, remmm tlm which “hold-theextension >sse-mbly to ‘the‘valve. (Do not lose w drop the screws). Remove the extension assemb[y, turn it upside down. To adjust, loosen the setscrew on tho bait nut. Place your thumb on the plunger and pressitin1/16“ and siide the ball nut WI set screw toward the plunger end 1/16“, Tighhan the s~t screw. Place the extension assembly back into position. Ifthe tank to overfill, the ball nut is too c[ose to the valvo plunger and should

be moved back away from the valve plunger slightly.

mdlor feed hose to the mix tank far clog,

ckbris

2 screws

starts

iaw

CHEMICAL TANK

TROUBLESHOOTING

WIm LawCHEMICALFmw

Chack that hoses in the tank are secured. Check that the hose from the top of the flow with no kinks, Check the hose from ttm bottom ofthe flow meter to the them. Jug for

ICheck th~ foot valve and goes into the mix tank. To check Wis screw for proper function, remove it fmrm the plastic hose. You should ba able to suck through the hcwmbarb end, but you should through the hose barb end. (If you rinso it out with vinegar). When screen is removed the chemical bsl hose should kmIifkadinto a vertical position so the ball in the foot valve will seat by gravity. (This isonly a tempora~ fix for low

watfiwfwessuns areas.)

3. Check flmv metcwfor float obstruction.

4. Check ta h’ummethat the adjusting screw on proportioning venturi is ‘b~cked out.

5. ls proportioning wimturiclmsed? Soak in warm water or vinegar Soh.ltkm.

& Is incoming waihwpressure lIsss

7. Cracked or defective ch@micalflow meter?

IWITE!: If YOUam in a low water pressure area and find that the volumo of water entering the mixtank is notenough to allow yourventuri to siphon chemical, unsc~ew the spring and rwmmmthe

IEMJ3MJW To ADJUST CWWKL5L WITH THE

Debris lodged L@tincfteflon seat inflow meter knob.

2. TIMlcmsaat dismcmnting from flow meter knob.

spring.

mieterto the sid~ of the mix tank issecured

kinks or cracks.

screen on the end of the hose which

not be able to blow

can not suck through it then

than 20 PSI.?

from the foot valve screen

mow METER

PUMP PULSATES WHEN W-METANK [$ IN

1.Check that the hose which goes from the gray plastic venturi to

the bottom of the tank is not directed toward the Cat pump pickup port. If it is, aim it in another direction.

HEATIN INFOR

The propane heater incoporatad in this equipment is of special d@sign for use in the carpet cleaning industry. [t’s high pressure coils and thermostatic temperature control make it simple to operate and

reliable. One@tlw desired temperature is set, the heater’ will then go

‘on’and ‘off according tothe water temperature within the heater. As water is used through the cleaning tool, cold water entering tlw heater will ati]vate the thermostatically controlled firing the heater to maintain a consistent fiow of hot water. One@tho

cleaning wand is shut off and the flow of water through the heatfw

stops, the heater will continue to burn until the set tempimatwe is at-

tained.

It ispossible th~n with this design that the flame maybe on when tlm

wand is off, likewise, it is possible the flame may be off when the

wand is on.

~ This beater is desicmed to burn warm mopane

gas only. Any liquid propane entering tke heater may c~use damage

to the control valve on the heater. Itwill also

and a soot build-upon the coils. Therefore, itis necessary to shut off the heater and close the valve at the tank bfftween cleaning locations. Failure to do this allows sloshing liquid to enter

line to the heater.

G SYSTEM

MATION

A FM. MODE

propane valve thereby

cause improptmburning

t17E3vapor feed

W31JJTiClN REVERSlklG FIWWd MM TANK To CHEMICAL JUG

1. Anti-siphon scnwanremoved from chemical jug hose.

2. Debris in anti-siphon wmsen.

Overfilling of the propane tank will this, advise the attendant filling the tank rmt W fftil We t$snk tmmr

!307.. When filling the tank, watch the 10?6 valve and imm~diately

cause many problems. To avoid

stop filling when whke liquid starts spurting from the 107. valve. To

prevent damage to the propane regulator, always close the valve on the tank before filling.

When venting the heater through the roof of the van, it is necessary to install a draft diverter on top of the heater. This will prevent down drafts from blowing out the pilot light.

The propane regulator is pre-set at the factory at 6 oz. of propane. This reading is taken at the control valve on the heater (see figure A #6). To prevent road dust and moisture from entering the propane regulator, keep the white Tupperware cover (supplied) on the regulator at all times.

To avoid restriction of airflowat base of heater, keep articles such as

chemical containers, hose, boxes, etc. from within 18 inches of base of heater. NOTE: This restricted situation also creates an over rich condition which results in soot build-up.

IMPORTANT: If a new propane tank has been installed or hoses have been disconnected, air may enter propane hoses and must be purged prior to attempting to light the pilot burner. Should this condi-

tion exist, operator must depress the pilot buttonfor 1-5 minutes and

attempt to ignite the pilot light at 15 second intervals. A very slight hissing noise should be evident while performing this operation.

HEATER - OPERATING

INSTRUCTIONS

Heater must be Wed with water

mm!z!ilpriortoignmg.

A. TO START PILOT:

1. Adjust thermostat control knob on unitrolto ‘normal’. @ Fig. A.

2. Adjust upper dial to ‘pilot’position. @Fig. A.

3. Depress pilot button. @Fig. A.

4. While pilot button is depressed with the left hand, use your right hand forefinger to depress the electric spark pilot igniter button several times in rapid succession, then look to see if pilot is lit. If not, depress in rapid succession again until lit. If this fails, use the resourceful match.

NOTE: Whenever ignitingpilot, hold litmatch in front of pilotsight

opening before inspection. Move lit match toward pilot burner. The pilot should ignite.

IF HEATER FAILS TO LIGHT:

Is propane tank full?

Is propane tank valve open? Has air been properly bled from propane line? Once pilot is litcontinue depressing button for 10 seconds to

insure thermo coupler has been heated.

B. TO LIGHT MAIN BURNER:

1. Turn upper knob to ‘on’ position. Flame will come on.

IF NOT: Pilot has expired.

Turn upper dial to ‘off position. @Fig. A. Do not attempt to relight pilot for 60 seconds. Then repeat instructions A -#1 -4. Water may already beat controlled temperature.

IF YES: Flame will turn off when thermostat senses maximum temp.

C. TO ACHIEVE PROPER CARPET CLEANING TEMPERATURE:

1. Complete procedures A & B

2. With 100’ of hose, turn cleaning wand on for 5 minutes and the temperature should stabilize.

3. Once a constant temperature is established, turn cleaning wand ‘off. The flame on the heater burner should remain on for 10-15 seconds.

A. If the flame expires priorto 10 seconds, turn the

thermostat dial to a higher reading, then repeat C 1-3.

B. If the flame remains lit after 15 seconds, turn the

thermostat dial to a lower reading, then repeat C 1-3.

D. W SHUT 12N3WWNHEATER:

1. Turn upper dial to ‘off position. @ Fig. A.

_ 2. Turncleaningwandonfor3 t05min.testo

cool heater core. If heater core is not cooled, it is impossible that the heat retained in the core will cause boiling back into the chemical mix tank.

3. Close propane tank valve while wand is on and heater is cooling.

PILOT BURNER

FIG

ADJUSTMENT

1. Remove pilot adjustment cap@

2. Adjust pilot key to provide properly sized flame

3. Replace pilot adjustment cap

ALLEN HEAD PIPE PLUG ~ CAN BE REMOVED

FOR MONOMETER INSERTION

TO HEAD PROPANE OUNCES.

HEATER

TROUBLESHOOTING

o EXCESSWE HEAT o FLAMES PROTRUDING OUTSIDE

THE ILOWER OPENINGS

CAUSE ANDOR SOLUTION:

Thermostatic control dial set too high

A. Turn dial to lower setting

2. Maladjustment of propane regulator. NOTE: Propane regulators

are facto~ preset and maybe readjusted by authorized personnel.

A. Contact manufacturer to determine correct procedure.

B. Have your local propane dealer use a monometer at the

unitroi to re-set the propane regulator to 7 oz. maximum.

3. Overfilled propane tank. NOTE: Propane heater is designed to

operate on vapor propane only. Over-filling a propane tank allows liquid propane to enter all heater related components and permits an over-rich burning condition to occur. This condition usually requires the heater core to be cleaned of soot and carbon deposits. Cleaning is a messy, dirty job and very inconvenient, so don’t let it happen to you!

PROBLEM:

● PILOT LIGHT

CAUSE AND/OR SOLUTION:

1. Pilot lightwillnot ignite. NOTE: Do not use a needle or pinto clean pilot orifice - use compressed air or solvent only.

A. Veri@ propane reaching igriitor. NOTE: A kinked or crushed

hose may impede propane flow.

B. Remove and clean orifice.

C. Verify igniter spark isoperating correctly.

VACUUM SYSTEM

~lNFORMATIoN

Tlw vacuum Mcwwwincorporated in this machine is a positive dis-

placement marwmand lifeofthis unit isgreatly dependent on the care and propisrmaintiarnancait mtmives.

lobe type, manufactured byFuller Company. The perfor-

‘VACUUMTANK FILTER BAGS ‘

Hydra-fwlashsrfilter bags are dirt that would normally The use ofthese bags, if the build-up of much ofthe debris inthe tank and customer’s driveway or street. The drawstring top of thwse bags is designed to be tied to the incominq dirtv water irrlet in the vacuum tank. Tore-order bags use part numbw

designed to trap all c#tfm lint, sand and

collect at the bottom of your vacmmrntank.

emptied at the end of @achjob, will fflimhvata

avoid a moss on th~

049-02$

Bacausa of ti’mclose tolerances between the lobes and housing of the vacuum blower, solid objects entering the inlet will darnage the internal lobes, gears and bearing or direct drive coupler.

TCIprevent this, a stainless steel filter screen has been placed at the

vacuum inlet inside the vacuum recovery tank. This stainless steel screen is finger tight and should be removed for cleaning weekly.

~ Should be used when machine is heirm run for

test purposa and the vacuum inlet orI top of machine is op~n. TCIprotect the vacuum Mower from overloading and damaging itself,

thrwe is a vacuum relief system installed on the vac tank

th~ vacuum tank inlet is completely sealed off, a maximum of 14 HG wi!l‘b@attained. A hole on the top blower pipe elbow acts as the lubri-

caticm point; atthe end ofeach day, LPS 1orWD-40 issprayed in before shutting down the machine. See blower lubrication illustration. If

you fail to lubricate the vacuum blower daily, rustdeposits and moisture will decrease the life of the vacuum blower.

FMad the vacuum blower manual carefully for proper oil change and grease application. The maintenance log may differ slightly from the manual, but the truck-mounted carpet cleaning machine application is very demanding of the vacuum blower and therefore it should be maintained more regularly.

lid. When

INCOMING DIRTY

a“”””””

((i

VACX.JUM

TANK

WALL

ILTER BAG

BLOWER LUBRICANT

VACUUM FLOW DIAGRAM

VACUUM RECOVERY TANK

VACUUM RELIEF

S/S FILTER

VN3JLM

BLOWER

EXHAUST

TOXIC FUMES

a:**

= E’xc

HOSE K) VAC TANK

FII-TER BAG

SPRAY LUBRICANT INTO VACUUM RELIEF HOLE FOR 3

TO 5 SECONDS, THEN IMMEDIATELY SHUT OFF MACHINE.

USE ONLY LPS 1 OFI WD-4(1 MOISTURE DISPLACING

LUBRICANTS.

WARRANTY

FULLER

installed, maintained, and operated under normal conditions with competent supervision. No person, agent, representative or dealer isauthorized togiveany warranties on behalf of FULLER norto assume for

FULLER any other liability in connection with any of FULLER’S products. This warranty shall extend for one (1) year from date of installation provided this equipment has been put into service

within six months after shipment from the FULLER factory. If repairs or replacements are made by the Purchaser without FULLER’S prior written consent, FULLER’S warranty shall cease to be in effect. No allowance will be granted for any repairs or alterations made by the Purchaser without FULLER’S prior written consent.

Machinery, equipment and accessories furnished by FULLER, but manufactured by others, are warranted only to the extent of the original manufacturer’s warranty to FULLER.

FULLER agrees at its option to repair at the point of shipment or to replace without charge f.o.b.

any part or parts of products

FULLER’S satisfaction to have been defective when shipped, provided the Purchaser promptly notifies FULLER, in

writing, of such alleged defect.

FULLER’S liability to Purchaser, whether in contract or in tort arising out of warranties, representations, instructions,

or defects from any cause shall be limited to repairing or replacing of the defective part or parts as aforesaid, f.o.b.

point of shipment, No liability whatsoever shall attach to FULLER until said products have been paid for. EXCEPT’ AS STATED IN THIS SECTION AND IN THE PRECEDING SECTION TITLED “WARRANTY” AND

EXCEPT AS TO TITLE, THERE ARE NO GUARANTEES OR WARRANTIES OF MERCHANTABILITY, FITNESS,

PERFORMANCE OR OTHERWISE, EXPRESS, IMPLIED OR STATUTORY, AND FULLER SHALL HAVE NO

LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR OTHER DAMAGES, HOWSOEVER CAUSED.

DATE installed ______

MODEL ____

SERIAL #——--–-

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

point of shipment,

of FULLE R’S manufacture, which within the specified warranty period shall be proved to

FULLER COMPANY

2966 East Victoria Street

Compton, California 90224

FACTORY AUTI-ICRL?ED SERVICE CENTERS

FOR SLJTOF?BILT PRODUCTS

FULLER COMPANY / COMPTON DIVISION

2966 E. VICTORIA ST., COMPTON, CAL. 90224

BAYLISS IMACHINE & WELDING CO.

ASSOCIATED TECHNICAL SERVICES, INC.

2131636-9821 or 639-7’600

2901 8TH AVENUE NORTH

BIRMINGHAM, ALABAMA 35203

BARNEY’S PUMPS INC.

205/323-61 21

3907 HIGHWAY 98 SOUTH

LAKE LAND, FLORIDA 33802

81 3/686-819!5

1229 WAIMANU STREET #21

HONOLULU, HAWAll 96814

8081537-1206

WM. W. MEYER & SONS

8261 ELMWOOD AVENUE SKOKIE, IL LINOIS 60076

312/673-0332

GREGORV-SALISBURY & CO.

SOUTH FRONT STREET

805

NEW ORLEANS, LOUSIANA 70130

5041524-6207

FULLER COMPANY / MANHEIM

236 SOUTH CHERRY STREET

MANHElM. PENNSYLVANIA 17545

CAROTEK INCORPORATED

MATHEWS, N. CAROLINA 28105

“7771665-2224

640 SAM NEWELL ROAD

70418474406

DIVISION

DYNMAC CORPORATION

7925 E. 40TH STREET

TULSA, OKLAHOMA 74145

918f627-lM 10

OLIVER %sLAUGHTER EQUIPMENT CO.

10450 WESTOFFICE

HOUSTON, TEXAS 77042

7131977-2577

ELECTRIC CRAFTS LTD.

3936 EDMONTON TRAIL N.E.

CALGARY, ALBERTA T2E 3P6

403f276-8676

PUMPS & POWER LTD.

1380 NAPIER STREET

VANCOUVER, B.C., CANADA

604/255-4341

SCHWARZ FOUNDRY COMPANY

2001 WEST FORT STREET

DETROIT, MICHIGAN 48216 SCARBOROUGH, ONTARIO, CANADA

373/496-7880

GATX-FULLER LTD.

721 PROGRESS AVENUE

416/438-6540

FLJLLIEFB C~MPANY

d+ril

A GATX COMPANY 2966

POST OFFICE, BOX 430B, COMPTONJ, CALIFORNIA 90224 TEL: [=?=] 639-7600 (Q131 636-9821 TELEX: GT-4607

EAST VICTORIA STREET

At the gear end the timing gear teath are lubricated by being partially subrrrewged.The graartw?th serve as oil slingers for gear end bearings. At thisdrive end the bearings are grease lubricated.

FILLING PROCEDURE

l%rnove squzws level plug (B) located in the head plate. Fill gear case until oil drips out ctfthe oil lev@lhale (B).

Use lubricants as

Add Mmh oil as required to maintain proper k?vei.The oil should be

drained, flushed and rr@aced every 1500 hours or more frequently if inspection so indicates. The oil drain plug is at (C).

Nt3TE: CMJer in the cast iron gear case instead of in the head plate.

Bearings on drive end of blower require grease lubrication every 100 hours of operation. Bearings which require grease lubrication will have a greasa fitting {13) at each bearing. VVhen regressing, the old grease will be forced out of the vents during operation. To prevent damage to soaks, these vents must be

head vented oilfillplug (A) on gear end. Remove oil

listed.

units may have the oil fi!l level and drain holes located

kept open at all times.

LIJBHICATION INSTRUCTIONS FOR

OIL l.IDBFliICATEDGEARS AND BEARINGS

Add fresh oil as required to maintain propar leml. Orain and refill every 1500 hours of oporation under normal service, more fre. quently when required. Use a good quality

BLOWER

DISCHARGE

TEMPERATURE U.S.A.*

~~j$;~ 3;[)

100°F

K!”to

O“to 38”C)

(

100’to275° F

38°to 135” c) ‘AE 40

over275°F

135”C)

(

*ln applications with axtreme variations in

ambient temperature a 20W 50W multiple

visco$ityoil isrecommended.

FOR GREASE LMBRICATEO BEARINGS

Serviceevery 500 hoursof operation

8LOWER DISCHARGE

TEMFERATUFIE

–40” to 275” F

(–@o”to

GRADE

SAE10W

SAE 20

SAE 50

12W’C)

OIL

VISCOSITY

CEN&S’l&KES’

BearingGrease

100

200

250

TYPE

GREASE

No. 2

oil.

VACIJIJMBLOWER

TROUBLESHOOTING Fwmmul:

a~~s~QFv~cu~~

CAUSE AND/CWl SOLUTION:

1. Collapsed vacuum hose between blower and vacuum tank.

A. FMmave and replace hose. hKYl%R

is required for ~eplacement.

A special reinforced hose

2. Clogged stainless steel filter. A. Remove and clean or replace stainless st~el filter.

3. Defective vacuum tank seal. A. Remove and replace vacuum tank

4. Defective or ‘open’ vacuum tank dump valve. A. Close valve. B. Replace valve.

5. Fractured weld on vacuum tank. A. Re-weld as required or replace tank.

6. Collapsed or kinked vacuum hose. A. Reshape hose if possible ar?d/or eliminate kinks.

7. Plugged vacuum hose. A. Remove obstruction by reversing th~ vacuum hose.

8. Restriction in cleaning tool. A. Remove obstruction.

9. Worn end plates or lobes in vacuum

A. Replace worn components. NOTE: Must be accomplished by

a qualified technician,

10. Loose coupling system between engine and blower.

The set screws may come loose causing blower to stand still

while engine may be turning properly. NOTE: Unless the

blower isseized or making a knocking noise, your vacuum loss is not caused by a bad

blower.

seal.

blower.

‘PFmmuEllwl:

BLOWER 1SSEKZED

CAUSE AND/OR SOLUTION:

1. Rust.

A. Spray rust dissolving lubricant onto lobes to emulsify rust and

attempt to rotate

2. Foreign matter. A. Disassemble and remove foreign matter and repair as

required. NOTE: Disassembly must be accomplished by

qualified technician.

3. Seized.

A. If you suspect that your blower has seized, remave coupling

element, then run engine for a few seconds. This way you

confuse similiar problems.

won’t

NOTE: The above mentioned, rust, foreign matter and s@izingam

often caused from foam traveling through the blower.

vacuum lobes.

PROBLEM :

NOLSE IN VACUUM BLCNVEB3

CAUSE AND/CW! SOLUTION:

1. Loose Direct Drive Coupler.

A. Examine coupler for defects and rsdighten lock boks. B. Replace coupler boot if it is either torn or punctured.

2. Worn Gears. A. Remove and replace gears. NOTE: Replacement of gears

must be accomplished by a qualified technician.

B. Timing of vacuum blower has been changed clue to worn

components. Replacement of components must be accom-

plished by a qualified technician.

3. Lack of Lubrication. NOTE: Permanent damage may hava

resulted from lack of lubrication.

A. Lubricate as specified by applicable vacuum blower manual.

See index.

4. Worn bearings

A. Remove and replace bearings as r~quired. Must be

accomplished by qualified technician.

5. Debris and/or foreign material build-up. NOTE: A stainkms steel

filter is provided in vacuum inlet Iocat@din vacuum t~k to pr@@~t vacuum blower components.

A. Disassemble vacuum blower end

NOTE: Disassembly should be accomplished

technician only. Replacement of worn parts is recommw’wkf

ifthis procedure is necessary.

6. Loose or missing mounting bolts.

A. Tighten or reinstall mounting bolts.

remove foreign material.

by qualified

Briggs & Stratton

-%w%--...

OPERATING AND MAINTENANCE (

INSTRUCTIONS

MODELS

401400 to 401499

421400 to 421499

IN THE INTEREST OF SAFETY

... ..— —. -.. —.

DO NOT RUN ENGINE AT EXCESSWE SPEEDS. Operating an engine at excessive weeds increases the hazard of personal injury.

DO NOT TAMPER WITH PARTS WHICH MAY INCREASE THE GOVERNED SPEED.

For rotary Iawnmower safety, A. N.S. I. Standard Safety Specifications for power Lawn Mowers specify a maximum blade tip speed of 19,000 feet per minute (96.5 meters per second), primarily to reduce the hazard from thrown objects.

Rotary Iawnmower manufacturers select the governed top speed of the en9ine based on the length and design of the cutter blade and desbgn of other mower parts. All rotary Iawnmowers should be checked for conformance to the A. N.S. I. Standard Safety Specifications for Power Lawn Mowers on blade tip speed, if the engine is repaired or replaced, or if mower parts are changed.

DANGER: GASOLINE VAPOR IS HIGHLY FLAMMABLE. Refuel outdoors preferably, or only in well ventilated areas.

DO NOT STORE, SPILL OR USE GASOLINE NEAR AN OPEN FLAME or devices such as

pilot light, or devices that can create a spark.

If gasoline is accidentally spilled, move machine away from area of spill and avoid creatin9 any source of ignition until gasoline vapors have dissipated.

DO NOT REFUEL GASOLINE TANK WHILE ENGINE IS RUNNING. DO NOT RUN THE ENGINE IN AN ENCLOSED AREA. Exilaust gases contain carbon

TC) PREVENT ACCIDENTAL STARTING always remove the spark plugs from the engine, before working on the engine or equipment

driven by the engine.

Except for adjustment; DO NOT operate engine if air cleaner orcoverdirectly over carburetor air intake is removed. Removal of such part

could create a fire hazard.

DO NOT OPERATE

create a fire hazard. Inspect periodically and replace If necessary.

DO NOT STRIKE FLYWHEEL with a hard objector metal tool as this may,cause flywheel to shatter in operation, causing personal injury or property damage. Use Briggs & Stratton approved tools only, and If m doubt, contact your Authorized Briggs & Stratton Service Center.

ALWAYS KEEP HANDS AND FEET CLEAR OF ROTATING PARTS.

A muffler which leaks because of rust or damage can permit an increased exhaust noise leVel. Therefore, examine the muffler periodical y to be sure it is functioning effectively. To purchase a new muffler, see SERWCE AND REPAIR INFORMATION.

WARNING: If this engine is not equipped with a spark arrester and is to be used on any fOre5t covered, brush covered, or grass covered

unimproved land, before using on such land a spark arrester must be added to the muffler. The arrester must be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. See your Authorized Briggs & Stratton Service Center for spark arrester muffler options.

WITHOUT A M,UFFLEROR TAMPEFI WITH THE EXHAUST SYSTEM. Damaged mufflers or spark arresters could

IN THE INTEREST OF ENVIRONMENT

a stove,furnace, water heater which utilize a

monoxide, an odorless and deadly poison.

SERVICE & REPAIR INFORMATION

If service or repair is needed, contact an Authorized Briggs & This illustrated book includes common Stratton Service Center. To serve you promptly and efficiently, the Service Center will need the model, type and code number on your engine.

Each Authorized Service Center carries a stock of original Briggs & Stratton repair parts and isequipped with special service tools. Trained mechanics assure expert repair service on all Briggs & Stratton engines.

Major engine repairs should not be attempted unless you have the proper tools and a thorough knowledge of internal combustion engine repair procedure.

Your nearest service center is listed in the “Yellow

WJWPs!W

Pages” under “Engines, Gasoline” or “Gasoline Engines.”

dealers avaiiable to serve you.

He is one of over 25,000 authorized

BRIGGS & STRAITON

w’

specifications, and detailed information covering the adjustment, tune-up and repair procedures Cylinder models. It is available from any Authorized Briggs & Stratton Service Center. Order as Part Number

271172.

for Twin

BRIGGS & STRATTON CORP.

Milwaukee, Wisconsin 53201

Ali? CLEANER

CARBURETOR

MANIFOLD

BEFORE STARTING

READ THE OPERATING INSTRUCTIONS OF

THE EQUIPMENT THIS ENGINE Pt2WERS

mPE START

PULLEY

- “—~

HLOWER

HOUSING

-r .Wb

EXTENDED

OIL FILL

Use a high quality detergent

SE or MS. ” Oetergent OIIS keep the engine cleaner and

SC), retard the formation of gum and varnish deposits, Nothing should be added to the recommended 011

011 classified “ForService SC,

RECOMMENDEDSAE Vlscosmf GRADES

‘F 20 0

“c 30

TEMPERATuRE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

“If not available, a synthetic oli may b%used hawng 5W-20, 5W-30

or 5W-40 vwcoslty.

FILL CRANKCASE WITH OIL

Place engine level. Clean area around oil fill before removing dipstick,

EXTENDED OIL FILL, Remove cap and dipstick. FILL TO FULL MARK on dipstick, POUR SLOWLY. Capacit-s (1 ,42 liters). When checking oil level, push dipstick

assembly firmly but slowly until cap bottom on tube. Djl

NOT OVERFILL. Dipstick assembly must be securely

assembled Into tube at all times when engine w operating.

20 40

–lo

lCO

OIL DRAIN

PLUG

EXTEN

OIL F

CHARGE BATTERY Charge battery before use on eng~nes equipp~d with

(OPTIONAL) 12 volt electric starter motor. See equipment

manufacturers’ recommendations.

FILL FUEL TANK

Use clean, fresh, “regular grade leaded or low-lead”

gasoline. DO NOT MIX OIL WITH GASOLINE. NOTE: The use of ‘“lead-free” gasoline produces fewer

combustion deposits, but may shorten valve life if carburetor adjustment is too tean.

—

STARTING

OPEN FUEL VALVE on engines so equipped

CHOKE ENGINE: Move equipment control lever to “CHOKE” position.

CHOKE

PULL OUT TO CHOKE

NOTE: This should fully close choke on carburetor. If it does not, remote control must be re-adjusted. See ADJUSTMENT section.

NOTE: A warm engine requires less choking than a cold engine.

GCVERNOR SPEED CONTROL LEVER: Move governor st)eed control lever to “RUN,” “FAST” or “START” position if so equipped.

Electric Starter. Turn key to “Start” position and/or press starter button on powered equipment. When engine starts

open choke gradually.

10--

STARTER

SWITCH

DEPRESS

BUTTON .+

When equipment is not in operation, provide protection

from direct exposure to weather.

COLD WEATHER STARTING HINTS

Be sure to use the proper oil for

expected.

Declutch ail possible external loads.

Set throttle at part-throttle position.

slightly richer fuel mixture, obtained by turning

A carburetor needle valve 1/$ turn counterclockwise, will usually improve cold starting.

A warm battery has much more starting capacity than a

5. cold battery.

Use fresh winter grade fuel.

NOTE: Winter grade gasoline improve starting. Do not use summer.

has higher volatility to

gasoline left over from

OFF

the temperature

TO START ENGINE

DANGER: ALWAYS MOWER BLADE OR OTHER ROTATING MACHIN~RY.

Rope Starter. Wind the starter rope around the pulley in direction shown by arrow. Pull the rope with a quick full arm stroke to overcome compression and prevent kickback..

Repeat if necessary with choke opened slightly. When engine starts open choke gradually.

CAUTION: When using rope starter to crank engine, use

caution so knotted end of rope does not strike persons

standing nearby.

KEEP HANDS AND FEET CLEAR OF

TO STOP ENGINE

Turn key to ‘IOFF” position.

CAUTION: Always remove key from switch when leaving

equipment unattended or when equipment is not in use.

MAINTENANCE

CHECK OIL LEVEL regularly — after each five hours of operation. BE SLJ

CHANGE OIL change oil every 25 hours of operation. Remove oil drain

plug and drain oil while engine iswarm. Fleplacedrain plug. Remove dipstick and refill with new oil of proper grade. Replace dipstick.

RE OIL LEVEL IS MAINTAINED.

after first five hours of operation. Thereafter

“%

—---

“D”

‘LA = b

---

“B”

)

,,,.

_.—”

1’

GENERAL INFORMATION

These engines are two-cylinder L-head, air-cooled type.

MODEL

Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-7/16’’ (87.31 mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-5/32’’ (54.77 mm)

Displacement . . . . . . . . . . . . . . . . . ..4t10cucin in. (656.0 CC)

Horsepower . . . . . . . . . . . . . . . . . . 16 HP Max. @3600 RPfvf

Torque (Ft,-Lbs. ) . . . . . . . . . . . . . . . 25.8 Max. @2700 RPfM

MQDEL SERIES 421400

Bore.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . 18 f-fP@3600RpM

Torque (Ft.-Lbs.) . . . . . . . . . . . . . . . . . . .. 28.6 @2600 RPfM

?he horsepower ratings listed above are established in accordancowith the Societyof Automotive Engineers Test

Code-J607. For practical operation, the horsepower Ioading should notexceed85?b ofthisrating. Engine power will decrease Sealeveiand l%for,each 10° above60° F(16° C).

lnsomearea~,local lawrequiresthe useofaresistor spark plug seas to suppress ignition signals. lfan engine was originally equipped withresistorspark plugs,besureto use thesame type of spark plugs for replacement.

Spark PIug Type

Plug

Long

Flesistor Long Plug

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . ..030’’ (.76 mm)

lgnit~on Po~nt Gap . . . . . . . . . . . . . . . . . . . . . ..020’’ (.51 mm)

Intake Valve Clearance”* . . . . . .

Exhaust Valve Clearance “*. . . . .

““with valve spring installed.

WARNING, For electrical safety always remove cable from

negative (-) side of the battery before attempting any

repairs or ma~ntenance,

BRIOGS & STRATTON ENGINES ARE MAOE uNo ER ONE OR MORE OF THE FOLLOWING PATENTS

28,960

2,999,491 3,194224

2.999,562

3.114,851

3.118,433

SERIES401400to 401499

tO 42T499

.3-7/16’’ (87.31 mm)

2-9/32” (57.94 mm}

. . . . . . . . . .

S%”/O for each 1,0010 feet (304.8 m) above

TUNE-LIP SWECIFICMTIONS

3.149618 3,276439

3,236937 3242741 3252449

3305223 3,457804

3,465740

42.33 cu. in. (694.0 cc)

Champion

J-8

RJ-8

.004’’ -. 0(6’’(.l O-.l5mm) .007’’ -,00(,18,23 mm)3mm)

3,526,146

3572.218 3572307 3625492 3738345

Autolite

295 306

3625.071 3650354 3 745.393

Engines to be stored over 30 days should be completely drained of fuel to prevent gum deposits forming an essential carburetor

NOTE: The use of a fuel additive, such as STA-131L, or’ an

equwalent, will minim izetheformation of fuel gum deposits

during storage. Such an additive may be add&d to the

gasoline in the fuel tank of the engine, ortothegasalino ina ~

storage container.

a. ‘All fue[ should be removed from the tank. Run theerngine

3831 268 3882336 3971 .753 3,901 199

3,961 724 4 168288

TrbClmult

STORAGE INSTRUCTIONS

parts, fuel fitter and tank.

until it stops from lack of fuef. The smafl amount of fuel that remains in the sump of the tank should be removed

by absorbfng It with a clean, dry cloth.

While engine is still warm, drain oil from crankcase.

Refill with fresh oil.

Remove spark

011 Into each cyl]nder and crank slowly to distribute ml, Replace spark plugs,

Clean dirt and chaff from cyllnders, cyllnder head ftns, blower housing, rotating screen and muffler areas,

Store In a clean and dry area.

plugs, pour one ounce (29 6CC) ofenglrw

3968854

3991 152

TO SERVICE DUAL ELEMENT AIR CLEANER Clean and re-oil foam pre-cleaner at three month intervals

or every 25 hours, whichever occurs first. NOTE: Service air cleaner

tions.

more often under dusty condi-

1. Remove knob and cover.

Remove foam pre-cleaner by sliding it off the paper

cartridge.

3. a. Wash foam pre-cleaner in kerosene or liquid detergent and water.

b. Wrap foam pre-cleaner in cloth and squeeze dry. c. Saturate foam pre-cleaner in engine oil. Squeeze to

remove excess 011.

4. Install foam pre-cleaner over paper cartridge. Re-

assemble cover and screw down tight

CAUTION: Petroleum solvents, such as kerosene, are not to be used to clean cartridge. They maycause deterioration of the cartridge. DO NOT OIL CARTRIDGE. DO NOT USE

PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE. CLEAN COOLING SYSTEM

clog the rotating screen and the air cooling system, especially after prolonged service in cutting tall dry grasses. Yearly or every 100 hours, whichever occurs first, remove the blower housing and clean the areas shown to avoid overspeeding, Clean more often if necessary.

overheating and engine damage.

— Grass, chaff or dirt may

-. . ..-

“— “-

Yearly or every 100 hours, whichever occurs first, remove paper cartridge. Clean by tapping gently on flat surface.

If very dirty, replace cartridge, or wash in a low or nonsudsing detergent and warm water solution. Rinse thoroughly with flowing water from inside out, until water

is clear. Cartridge must be allowed to stand and air dry thoroughly before using. Service more often if necessary.

CARTRIDGE

FOAM

PRE-CLEANER

DANGER: Periodically clean muffler area to remove all

grass, dirt and combustible debris, SPARK PLUGS — C’”lean and reset gap at .030” every 100

hours of operation.

CAUTION: Do not blast clean spark plugs. Spark plug should be cleaned by scraping or wire brushing and washing with a commercial solvent.

Sparking can occur if wire terminals do not fit firmly on spark plugs. Reform terminals if necessary,

REMOVE COMBUSTION DEPOSITS every 100-300 hours of operation. Remove cylinder heads and cylinder head shields. Scrape and wire brush the combustion deposits from cylinder, cylinder heads, top of pistons and around valves. Use a soft brush to remove deposits. Re-assemble gaskets, cylinder heads and cylinder head shields. Turn screws down finger tight, with the three longer screws around the exhaust valve, if so equipped. Torque cylinder head screws in a staggered sequence to 165 inch pounds (18.65 Nm).

SPARK ARRESTER EQUIPPED MUFFLER — If engine muffler is equipped with spark arrester screen assembly, remove every 50 hours for cleaning and inspection. Replace if damaged.

ADJUSTMENTS

CARBURETOR ADJUSTMENTS

carburetor adjustment may be required to com-

Minor

pensate for differences in fuel, temperature, altitude or load.

INITIAL ADJUSTMENT — Turn idle and needle valves clockwise until they just close.

CAIJTION: Valves may be damaged by turning them in too far.

Now open needle and idle valves 1‘h turns counterclockwise, This initial adjustment will permit the engine to be started and warmed up prior to final adjustment.

NOTE: All carburetor adjustments must be made with the

air ckwtner on ‘engine. -

NOTE: Governed idle must be adjusted on all ongirtes for

proper operation. The smaller spring

governor, even at idle speed. If mod.arate loads are applied at idle, the engine will not stall. Governed idle speed should be no lower than 1100 RPM.

keeps tho engine on

Needle Valve (High Speed)

Place governor speed control lever in fast position. Then turn needle valve In slowly clockwise (lean) until engine misses or RPM slows. Then turn needle valve M turn counterclockwise.

If engine does not accelerate properly, readjust ntmdle valve approximately % turn counterclockwise (richer).

CQNTROL ADJUSTMENTS Proper choke and speed control operation IS dependent

upon proper adjustment of remote controls on the powered equipment.

TO CHECK OPERATION OF CHOKE CONTROLS: Move remote control lever

carburetor choke should be closed. TO ADJUST CHOKE: Place remote control lever on equipment in “CHOKE”’

pcsition. Loosen control casing clamp screw. Move control casing and wire until choke is completely closed. Tighten casing clamp screw.

to “choke” position. The

FINAL, ADJUSTMENT PROCEDURE Idle Vahm Mixtuw

governor speed control lever in governed “IDLE”

Place

position. Hold throttle lever against idle stop and set idle Spewl adjusting screw to obtain 1400 RPM. Turn idle valve slowly clockwise (lean mixture) until engine misses or RPM slows. Then turn idle valve ‘/2 turn counterclockwise.

t2mN?rll@d Idle Hold throttle lever against idle speed adjusting screw,

Adjust idle speed screw to obtain 900 RPM. Release the throttle. WJith governor speed control lever in governed “IDLE” posjtion, align %“ diameter holes in control plate and lever as shown. Re-adjust governor speed control casing and wire if required. See Governor Speed Control Adjustment section. Adjust tang “A” to obtain 1400 RPM governed idle.

1’ DECRFAS’E

CtiOKF

CLAMP

SCREW

GOVERNOR SPEED CONTROL ADJUSTMENT The acceptable operatlnq s~eed ranae IS ?800t03600 RPM,

Idle speed is 1400 RPM- T’he manu~acturer of the equ!pment on which the engtne governed no load speed at wh[ch the engine may be operated. DO NOT EXCEED this speed,

Engine speed

lever Move contro( lever on equipment, “O”, to slow~sf engine speed possible Throttle lever on carburetor shoutd touch Idle speed adjusting screw. To adjust, loosen control casing clamp screw “C.”’ Move control casing and wtre In dlrectlon shown by arrow until throttle lever touches Idle speed adlusting screw on carburetor. Retighten casing

clamp screw “C.” Move control lever “D” to

posltlon.

maximum governed no load RPM, move lever “D” Ioobtaln recommended speed Bend tang “B” to touch lever “A.”

CAUTION Throttle lever on carburetor MUST touch tdle

speed adjusting screw when equipment control lever

slowest

posltlon.

IS controlled by movement of the control

If engine exceeds equipment manufacturer’s

.\--

IS used, specifies the top

‘<FAST”

IS in

●

Superseding Warranty

BIUGGS & STRAT7’ON ENGINE WARRANTY POLICY

effective October 1, 1976

Replaces all undated previous Warranties and all Warranties

dated before October 1, 1976

When warranty repair is justified. Briggs & Stratton Corporation welcomes such repair by any of its Authorized

Service Centers. In most instances, the requests for warranty brought to the attention of

prompt routine manner with no question regarding their validity. However. some requests for warranty are received which are not justified. In these cases. engine owners may not be aware that the premature failure of their engine was the result of abuse or neglect. or that the difficulty which they experience is

our service accounts are handled in a

caused by the equipment

rather than the engine.

BRIGGS & STRATTON WARRANTY covers only DEFECTIVE MATERIAL tind/or WORKMANSHIP.

ONE YEAR LIMITED WARRANTY

“For one year from date of purchase, Briggs & Stratton Corporation will replace for the original purchasers, free of charge, any part, or parts of the engine, found upon examination by any Factory Authorized Service Center,

or by the Factory at Milwaukee, Wisconsin, to be defective in material or workmanship or both; this is-the exclusive remedy. All transportation charges on parts submitted for replacement under thjs warranty must be borne

by purchaser. For warranty service contact your nearest Authorized Service Center as listed in the ‘Yellow Pages’

under ‘Engines, Gasoline’ or ‘Gasoline Engines.’

TIES, INCLUDING THOSE OF MERCHANTABILITY AND

ONE YEAR FROM PURCHASE AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRAN.

TIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER

EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some states do not allow limitations on how

an implied warranty lasts, and some states do not allow the exclusion or limitation of incidental or con-

long sequential damages, so the above Iimitatian and exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.”

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRAN-

FITNESSFOR A PARTICULARPURPOSEARE LIMITED

ANY AND ALL WARRANTIES ARE

NO REGISTRATION (WARRANTY) CARD IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON ENGINES. FILL IN THE REQUIRED INFORMATION AND RETAIN FOR YOUR RECORD: (See Decal on Blower Housing for Model, Type and Code Number)

Engine Model No. Dealer Purchased From Type of Equipment Name or Tracfemark of Equipment Manufacturer

If warranty service is needed contact your ne:lrest Authorized Service Center. For prompt attention your will need to know the engine model. type and code number. the trouble experienced and the total number of hours the engine has run. If you differ with the decision of a Service Center on a warranty claim. ask the Service Center to submit all supporting f~lcts to the Factory for review. If the Factory decides tha_t your claim is justified,

you will be fully reimbursed for those items accepted as defective.

Type No.

(o\’er)

Code No.

center

❑

~a avoitl mismderstandimgs which might occur between engine owners and authorizrcl Briggs & Stratton service acommts, we are listing causes of engine failures, Stratton warranty.

a *

where repair or replacement is NOT covered by !3ri~s &

NWMAL WEAR:

Warranty wil[ not cover repair where normal use hasexhaustedthe life of a part or engine. Engines, like a[l mechanical devices, need periodic parts replacement and serviceto perform well. It should be remembered that the service life of any engine is dependent on the care it receives and the conditions under which it has to operate. Some appli-

cations, such as tillers, trash pumps, rotary mowers, are very often used in dusty or dirty conditions. which can cause what appears abrasive material, which has entered the engine because of improper maintenance. is not cw~’ered by Warranty,

to be premature wear. Such wear, when caused by dirt. dust, spark plug cleaning grit or other

ABUSE OR NEGLECT:

Brnt or broken crankshafts: Such damage is normally the result of abuse,

the cutter black on a rotary lalvn mower, and is not covered by \Varranty.

Engine repairs rquircd from the use of old or stale fm>l arc not covered by lVarranty. Such failures would include sticking va[ves, through the use of stale fuel. .Always use cIwn fresh regular gasoline.

Parts which are scorecl or broken !wcause an engine was opc>ratecl without sufficient lubricating oiI or the

proper grade of Iubricat ing oi 1 are not covered by \\’arranty. Check oil level at least ev(>ry five hours ond refill when necessary. Change oil at recommended intervals.

-1.

Damage caused by o~whcating or overspeeding is not covered by TVarranty, occurs if the cooling fins become plugged with dirt, grass or dt>bris, or if an engine is operat[’d in a confined area without sufficient ventilation. Clean fins on the cylinder, cylinclcr head and fiywhecl rx’gularly.

Damage or wear caused by dirt \vhich cmters the engine

not covered by lVarranty. Clean and re-oil the air cleaner regularly,

Damage or wear caused by grit from blast cleaning spark plugs is not covered by lVarranty. \ve do l]ot approvt~ of cleaning spark plugs on an abrasive blast cleaning machine, since grit later entm the engine.

lVarranty does not cover the tune-up or a(ljustrncnt of an (mgin{ unl(ws the ncxd for such repair is the result

of defects i]) material or workmanship or both. If c(luipmcnt is ass(mll)led and adjust(, d l)v the owner, the

cmgint’ Op(’rating and \laintcmance

minor acljustmwts.

13rolwm parts. ~thich result from exc{,ssive vibration ca~]sed by IOOSC(ngine mo~lnting, loosr clltter blades,

blad[’ Ilnlmlallc(’.

arr not cot(’rc(l I)y \Varranty.

impropi’rly attaching c(]uipment to engine crankshaft, uv(~rspetding or abuse in operation,

and carburetors and fuel pipes which are clogged by gum d(~posits tvhich form

becausr of improper air cleaner maintenance is

Instructions arc s(lfficicmtly cl(ar to p(mnit the a~x’rag~ owner to make

Such minor adjustments are NOT covered by kVarranty.

such as striking a soIid object with

Ov<’rspecding or overheating

cm] remain in th(’ plug, a]]d

Repair or adimsttn(mt of associated parts or asselnblies such as clutches, which tw( not of Briggs & Stratton manufactllrc, \vilI not I]c coi(m’d by Briggs & Stratton lf’arranty.

10,

OrLly ORICIIN:\L Briggs & Stratton parts, kVarrantyu

WARRANTY !S AVAILABLE 0NL% THROUGH SERVICE CENTERS WHICH HAVE BEEN AUTHORIZED BY THE BRIGG$ & STRATTON CORPORATION. Y~UR NEAREST SERVICE

hone

DIRECTORY, UNDER “ENGINES, GASOI.INE” OR “GASOf.lhfE ENGINES.”

or parts approved b? Briggs & Stratton ]nav be cwered by

CEN’TERIS LISTED IN THE YELLOW PAGES OF YOUR Telep-

transmissions, remote controls, etc.,

ENGINE

engine instruction brochure is included with this manual (see

Arr

index) which may assist

ROBLEMS:

ENGINE FAILS “m START

o IENGH4E RUNS ROUGH o ENGINE BACKFIRES

ID ENGINE FAILS TO ACCELERATE

* ENG!NE REDUCES SPEED TO Low RPM

UNDER ILOAD

CAUSES AND/OR SOLUTION:

1. Loss of fuel A. Empty gas tank.

B. Plugged fuel line or filter. C. Defective fuel pump. (Replace with mfg. suggested

replacement parts only).

D. Gas line kinked, crushed or quick disconnect inside the truck

not connected.

2. Blown master fuse. A. Electrical short.

B. Defective fuse.

3. Worn or maladjusted points (Onan eng. Only) (Briggs has

electronic ignition).

A. Remove and replace points and condenser.

B. Clean and adjust points.

4. Defective spark plugs A. Remove and replace.

B. Clean and regap.

5. Defective spark plug wires A. Sparkplug wires along with many others may, at certain points

come in contact with heated parts (exhaust manifold) or

abrasive parts (sharp metal, tefIon hose).

into consideration for electrical shorts.

B. Remove and replace.

6. Low compression A. Defective valve.

B. Stuck valve. C. Worn compression rings. D. Defective piston.

7. Float switch in recovery tank inoperative. NOTE: Temporary

repair permits disconnection of float switch wire between tank and machine. Continued operation with this condition will

compromise vac blower.

A. Switch stuck on upright position by foreign material.

B. Defective float switch.

8. Engine will not turn over

A. Dead battery B. Loose terminal connection on battery or ignition switch.

C. Defective starter.

D. Seized engine or blower.

9. Defective Carburetor or gas leakage.

A. Clean carb. B, Replace carb.

C. Choke locked in closed position.

you in resolving engine related problems.

This maybe taken

Carbon build-up may be excessive if carb. or valves are improperly adjusted, engine RPM too low, improper spark plug gap.

Remove cylinder heads and eliminate carbon build-up with

wire brush.

12. Incorrect timing A. Timing may ~ecome offset if point box is not secure or if

points are out of adjustment. (Onan only).

13. Dirty air cleaner A. If exhaust gaskets do not seat properly or heat exchanger

gasket is bad, exhaust may heat and melt the the air cleaner

requiring much clean-up repair.

14. Clogged fuel filter A. Remove and replace

Low oil level or malfunctioning oil pump

15. A. 011pressure sensors can be installed on the engine. This will

eliminate many problems which may occur.

16. Vacuum tank full A, Empty vacuum tank

●

D. When replacing fuel pump insure that it is the same pressure

rating recommended by mfg.

10. Improperly adjusted carb. NOTE: A comprehensive manual is available and defines necessary adjustments.

A. Incorrect air mixture ratio adjustment.

B. Incorrect float level adjustment.

11. Carbon build-up in cylinders. NOTE: Carbon build-up can be minimized by using unleaded regular gas. Should carbon removal be necessary, reinstall heads with new gaskets.

ELECTRICAL SYSTEM

Tha smtire ehsctrical system operates cm 12 volts DC which is providad by a bathery. Battwy levels are sustained by a 7 amp alternator demigrwd within the engine.

NOTE: W1’risnmawbattery is installed insure it is properly charged Wore installation m damage to the cha~ging regulator may occur.

PROBLEM:

@ LOW H~lTIEFly

VOLTAGE

5. Blown charging fuse

A. Remove and replace fuse. B. Check batteiy charge. C. Check battery cells with hydrometer.

6. Electrical short in wiring system A. Examine eiecttical systems for bare wires.

7. Poor ground connection A. Examine terminal and remove corrosion if necossa~. B. Follow ground wire from (-) of battery to where itgrounds at ttwa

frame. 1$it is grounded to painted steel then scratch some of the paint off to allow for circuit to be ccwn@et@dthrough ttm steel.

CAUSE ANWOFI SOLUTION:

Defective battery

A. Remove and replace.

2. Corroded battery terminals A. Clean te!rnmirnalsand battery pasts.

3. Low battery fluid A. Add water to appropriate level.

4. Loose wiring within electrical

Examine all terminal connections and verify that they are

secure. NOTE: Give special attention to ignition switch

terminals.

system.

ELECTRICAL DIAGRAM

BLACK

INOPERATIVE HOUR METER

CAUSE AND/OR SOLUTION:

Time IS not advancing correctly

Verify 12

ignition switch turned on. This can be accomptisheci with a volt meter or a test lamp.

Remove and replace hour meter if 12 volts is available.

A nylon gear within the clock may have been iammed due to a sudden jolt of the machine or truck. You may try simply tapping on the meter to try to free the nylon gear.

BOB CAT 2/290

HOUR

MTR.

volts DC is availatile at the ~~ur meter with the

BLUE

ncu

CHAFWIE

LINE

RED

(MIX TANK)

a’”ELpuMp

_ IGN. SWITCH

WHITE

“LACK

RECOVERY TANK

‘?1

BLACK CABLE

MACHINE

INSTALLATION

INFORMATION

There are two ways of positioning the machine in the truck as shown

on the following page. There are also two locations for the vacuum recovey tank to be positioned. First, the standard way with the tank directly alongside the machine. Second, with the tank across the back ofthe machine as shown below; this location is most space efficient.

MACHINE

PROPANE TANK PLUMBING

---->

J-35’ 1~, /

-m ‘“”d

— &

SHOULD BE MOUNTED (THBu FLOOR)

CARRIAGE

-e / \\

an,

PROPANE FIT+NG

PRIJ&.:::ANK

F’”~q [// ‘“”y ~

‘OcK‘ASHY&

/ j&-Pf30PANEFim(Nc3

BOLT

Whichever way you select, make

ured to the floor of the van to insure driver safety.

It isimportant that the machine be placed as close to the door as pos-

sible so that outside air can be pulled intothe engine for proper cool-

ing.

It is recommended by the manufacturer that the exhaust from the front of the machine be vented down under the truck to prevent carbon monoxide from entering the job site. Always

park the truck so the exhaust is blowing away from the job site.

The manufacturer also recommends that installation of aluminum vents inthe truck roofto allow heat from the heater to escape.

1“’1-’.’m

propane tank or a portable gas can inside the truck. The-heater is

an open flame type and could cause afire or explosion.

Mount a fire extinguisher just inside the rear or side door for emergencies.

Never o~erate this machine with a portable

sure the tank and machine are sec-

MACHINE ‘TIE li30WWNCLEAT

llmAAstnRA-mN

10 MAXIMUM SET BACK OF MACHINE FROM DOORWAY

THRU-FLOOR GAS HOOK-UP

AND INSTALLATION

THRu FLOOR

GAS HOOK.UP

(1-10)

FITTING

(,%SRS.STR ELBOW)

SCREW

, /.\&

hi?

lb-k-’A 2-PUT’

HOSE CIAMP ,,<<

HOSE BARS

RW3

“19

FUEL

FILTER

F?’W

SOCKET

HOSE (CUT TO LENGTH)

HOSE ‘““ “Rs G

l’,

QUICKCONNE.T

Y’

FITTING

L’

HOSE E)ARS

—

NOTE: uSE TIES TO SECURE T-FITTING

TO THE FRAME AND TO STABILIZE HOSE AT A MINIMUM 6’ FROM THE EXHAUST PIPE.

-QYJ!9!Y’/---’

G---J

WATER SOFTENER

Many areas of the country have an excess of minerals in the water

which results inwhat iscommonly called “hard water”. These miner-

als tend to whsre to the insides d heater coils and other parts ofthe

machimas causing damag~ and a lass of cleaning effectiveness.

FlaPcIrts from sevw’al of our machine users commending the results

of ~ht+use af wab.m’softc$nersin conjuntilon with the~r machines prompts us to recmnm~nd the procedure to everyone in a “hard ,/’\ i water” area.

The relatively law cost of a water softener service is more than made

up for in the increased life of machine parts and continued cleaning efficiency. The water sofkmer will also increase the effectiveness of the cleaning chemical being used, therefore, less chemical will be needed.

Contact a water softener distributorinyour area for information on the

rental of a simple water treatment unit to carry in your truck. to change the water softener in accordance with the capability of the sdhwkw. Example: If the softener will treat 900 gallons of water and the machines uses an average of 30 gallons per hour of use, and an

average of 5 hours a day, would be 150 gallons a day. 5 days would equal 7!30 gallons ofwater, therefore, th@softener would be changed every Gworking days for maximum softening.

Be sure

‘\

.::,/ \,,

WAt+dDASSEMBLY

\,/,&~:_:@

FRAME TUBE

S SOLUTION TUBE

~ :;:

‘/,’

ASSEMBLY

SSXREWA

WAND LIPS

bi&NDLE CLIP

VALVE ASSEMBLY

.ASSEM13LY

HANOLE SLEEVE

&’

.-+

S S HANDLS [QU&OE)

‘s NU1

.. m

-:.$9 “

FAuCET

JET ASSEMBLY

BODY

BRASS C&P

QUICK CONNECT PLuG

LIZTE

@QJ

x“

OPERATING

INSTRUCTIONS

START UP

Perform daily/periodic maintenance as specified by the owner’s

1. manual.

Connect all required hoses. Connect cleaning tool to length of hose required to perform

cleaning.

Caution: Mix tank must be full prior to ignition. Start engine (choke as required). Engine is at operating speed

(recommended -2600 RPM). Aliow warm-up period of 2-5 minutes.

Spray wand to void all air from system. As the mix tank is in a fill cycle, the chemical flow meter may be adjusted to your desired setting. NOYE: Recommended carpet cleaning pressure is 250-

300 Psi.

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

If not familiar with operation of this heater, refer to heater section

of the manual.

A. Open propane valve on the tank. B. Ignite pilot on the heater.

C. To ignite burner, turn dial to on position. NOTE: Ifyou suspect that the unit has been frozen-DO NOT light the heater. Thaw the heater and check for leaks. Turn on burner, adjust dial to normal or slightly below for 200

Deg. F.

Commence cleanirm o~eration

NOTE: Chemical fl~w “meterset at 5 GPM is a 1 to 30 mix ratio and 10 GPH is 1 to 15 ratio. When flow meter is set at 10 GPH, vou will be usina what most chemical manufacturers recommend

&5 GPH. -

SHUT

Turn heater to off position. Spray wand for a least 3 minutes to

allow the heater coils to cool.

Close valve on propane tank. Remove vacuum hose.

Flush clear water through chemical system for 10 seconds.

(vinegar should be rinsed through system weekly). Turn off chemcial

Turn on cleaning tool to flush chemical from unit hoses and

cleaning tool. NOTE: If freeze guard isnecessary, perform steps 1 & 2 of freeze

guard procedure at this time. At thistime, the biower should be lubricated with LPS 1 orWD 40.

Shut engine down.

Drain vacuum tank. Vacuum filter should be cleaned prior to

mobilization of van. NOTE: If freeze guard is necessary, perform steps 3-9 of freeze guard procedure at this time.

DOWNI

flow meter.

MACHINE

HIGH PRESSURE GAuGE SET AT

(200 PSI WITH $00 HOSE)>

CONTROL PANEL

HOUR METER

BLOWER, E.GINE ExHAusT HIGH PRESSURE

CLEANING sOLUT10.

CONNECTION

LEG HOLES ~lx ~*NK DRAIN

PETCOCK VALVE & HOSE

OPERATION PRECAUTIONS

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, consu\t an authorized rep-

resentative.

ENGINE COOLING:

_ Units employing air cooled engines must not be incapacitated within a van with doors and windows closed. Excessive temperatures within the engine will result in premature engine failure and a compromise of applicable warranty.

LEVEL OPERATION:

level ground not to exce%d’ + or – 10 deg.. Failure to ins~re proper

leveling may prevent proper internal lubrication of engine, vacuum and)or high pressure components.

FREEZE PROTECTION:

~ Mother nature gives little warning as to her cold spells. Therefore, protecting this equipment from fr=ezing will save costly down-time. Placing an electric heater in the truck or parking the truck indoors,

Durina o~eration. van ortrailer must be ~arked on

will help to insure against freezing.

LIGHTING HEATER:

the heater when lighting.

Never put your face down close to the opening of

STRONG PROPANE ODOR:

propane around the heater.

Never light the heater if you smell a strong odor of

HEATER:

boxes, chemical jugs, etc., as this willblockthe flow ofairrequired for

a clean burning Iwlu@r.

I%evar pk3 things around the Iwater, i.e. hosas,

OPEN FLAME:

lQ?wENJR

therefore, do not remove engine gas limewhile troubleshooting or

any flammable material in the truck with heater operating.

store

ternelrnbw thatthis heater is an open flame,

FREEZEPROTECTION

Any fre~zing of this machine is not covered by warranty and during tl’m colcfar

most

THE

Run machine before Ioaving for the first job to insure nothing has

frozen the night before, including hoses and wand.

Insulate the garden hose from the cold ground by running it

through an extra 1 % L@av+etruck doors closed until time cleaning begins, then open

slightly for ventilation of air cooled ‘engine.

thmefo~e, venting the warm exhaust over to blow on the propane

tank will stabilize thra propane flow. (This is necessary if you notico a drop

!5.

help pmtf?ct ttw w-lit.

Don’t procrastinate during the cleaning operation or the hotwater

salution line will also freeze on the ground. The solution line should btrinsulated in extremely cold climates.

Whenever possible, the truck and machine should be stored ina tvaatd gfwage at night or over the weekend. Ifnotpossible, place a 1500 watt electric heater inside the truck,

machine.

tum on the truck ceiling and the possibility of it going out is higher. Ifthe machine and truck are left outside with a heater, you should first drain hoses. (They freeze also.)

TCl DRAIN THE A.-’ “ ‘“ ‘“s “

Bemre snumng on me macnme, remove me cnemlcal Ime worn

the chemical jug and place in a mixture of 50/50anti-freeze and water. With tt%acleaning tool on, allow mixture to fillchemical system back to the chemical mix tank.

Loosen the petcock valve on your bypass drain hose and allow the To remove the water from the heater and pump use the freeze

guard kit which is a small air compresor that can be plugged into the clash board lighter inthe truck, or the correct connectors, first blow

ticm male quick connect.

heater back through the pump and into the chemical mix tank to

force that water into the chemical mix tank to be drained out.

months of operation, cafieful protection should be of ut-

cmnccwn.

FOLLOWING PRECALJTICXNS ARE RECOMMENDED:

inch vacuum hose.

extwmwly cold days propane does not vaporize as quickly,

in l’mat or a low burning flame in the heater, )

colder climates, insulating the truck wails arid floor boards will

Nrmmruse a propane heater-it causes excessive mois-

all possible water from the machine cleaning tools and

MACHINE, FOLLOW THESE STEPS:

water todrain thoroughly from the mix tank.

air into the high pressure solu-

This will force the water through the

be drakwd out through the petcock valve to the ground.

Next, MOW the air into the incoming water quick connect and

aimed directiy at the

.,, . . . .

air at the gas station. Using

CLEANINGAND CHEMICAL

PRECAUTIONS INFORMATION

Your mobile carpet cleaning plant has b~en engineered using the latest and most sophisticated technology available, to produce the

finest carpet cleaning results possible. Despite this however, it re-

mains only a tooi ofthe carpet cleaning trade, and it can produce only as good a job as the person operating it,

There are no short cuts to good carpet cleaning, it requires time, cleaning knowiedge and the use of good chramicals.

Manufacturer recommends the use of spotting agents, and traffic lane cleaners prior to the actual cleaning of carpeting, as r~quired.

Manufacturer recommends setting heater thermostat ting when cleaning synthetic fiber carpets, and at ‘warm’ setting when cleaning natural fiber carpets.

~ Wh en cieaning cut-pii~ acrilan plush carpets, set heater at ‘warm’ setting. Using bighw heater setilng may resuit

fiber damage on this type of

The use of some chemicals through your mobile carpet cleaning plant can seriously damage the internal plumbing, high prmsure pump and heater. (Chemicais such as concentrated ac~dsand some _ paint oil and grease removers wihigh concentration of solvwts.)

Manufacturer recommends only the use of chemicals containing rust and corrosion inhibitors and water softening agents to Dr&vent chemical build-up.

NOTE: At no time should a chemical solution with a pH of less than 7 or higher than 10 be used in the unit.

1234567891011 121314

I I i

4— ACl@ —NEUTRAL—

PI-4

carpet.

CHART

I I

“’h’’”’~

CLEANING STROKE PROCEDURE/OVER-WETTING

PURPOSE:

To eliminate excess moisture remaining in the carpet fiber and the sawtooth appearance which results from diagonal movement of the cleaning tool on all types of carpet.

at ‘normal’ s@t-

To bo sure

ccmnec$ors

I%waxing will cause?GRIEF, MONEY and DOWN-TIME.

mess ‘with mothw’ nature! !WlwxmbW to UAXW the petcock valve pIFkw to rmxt ,qmerath-t 0$ your EWKat

all water is out of the system, aiternate between quick

several times.

SURE IT’S PFlOTECTED!

2/290.

Don’t

PROCEDURE:

Always move the cleaning tool in smooth forward and backward

strokes. tion is injected into the carpet. When extracting (drying), apply firm

pressure on the forward stroke to ensure a positive “lock” for the vacuum and minimize the “hopping” effect resulting on unsmooth carpet. During the forward and reverse strokes, movement to the

Apply slight pressure to the forward stroko whii~ tl’m soiu-

right or left should only be accomplished at the extreme rear of the stroke. Overlapping is also important to ensure even application of solution to prevent saturation when cleaning wand is stopped twice at the same point at the rear of the cleaning stroke.

Failure to adopt this procedure can result in increased chance of

“clean

periods.

streaks”, fiber shrinkage, brown out, and longer dving

a Clean vacuum tank thoroughly with high pressure washer.

@ Flush water and chemical system with 50/50 white vinegar

solution.

@ Check

LWWRTANT: Record date and machine hours on mairrte lance chart.

engine M%4’s - adjust to 2600 FIPM’s as

needed.

INCORRECT METHOD

CORRECT METHOD

—

%YYfxq/qJJ&!,;

OVER-WETTING

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

There are several areas that will cause over-wetting:

1. Too few vacuum strokes or improper sawtooth vacuum strokes as shown above.

2. Obstructed, kinked or cut hoses.

3. Vacuum tank drain valve left partially open.

4. Clogged vacuum blower filter or vacuum tank lid not sealing properly.

5. Cleaning a heavily foam-saturated carpet without defoamer. (We recommend crystal type.)

●

—

MAINTENANCE

PROCEDURES

To avoid costly repairs and down-time, it is imperative to develop

and practice good maintenance procedures from the beginning. These procedures fall into daily, weekly, monthly and quarterly increments, and are outlined below. We have provided a maintenance

log for your convenience on the following pages; it is recommended

that you affix a copy of the logon the vehicle door near your unit for

convenience and to serve as a maintenance reminder.

DAILY

@ Check engine oil level. e Inspect garden hose screen - clean as needed.

e Visually inspect machine for loose wires, oil leaks, water leaks,

etc..

o Inspect recovery tank s/s filter and filter bag for tears, holes, etc. -

clean, repair or replace as needed.

o Lubricate blower with

WEEKLY

Change engine oil. (25-30 hours of operation) Check engine air cleaner filter - clean as necessary. Check high pressure pump oil - add as necessary. Check drive coupler set screws - tighten as needed.

Check pump drive belt for wear - tighten as needed. Check pump pulleys - tighten as needed. Check fuel lines for wear/chafing. Check all nuts and bolts - tighten as needed. Check heater burner assy. union for tightness/leaks.

LPS-I or WD-40 through blower inlet.

STROKE STROKE

OVERLAP BETWEEN STROKES

CLEANING

MONTHLY

● Grease blower bearing fittings.

aI Remove, clean and reinstall

@ Remove pressure by pass valve stem, grease cup and stem,

reinstall.

@ Check water level in battey. Clean connections as needed.

M%W3T.AFW: Record date and machine hours on maintenance

chart.

engine air cleaner filter.

QUARTERLY

s change oil in blower (see blower manual). e Check engine compression. e Check for combustion chamber carbon deposit e Change spark plugs (see engine manual).

‘—}j&&,er

OVERALL CARE OF UNIT

MAINTAINING THE ORIGINAL APPEARANCE OF YOUR UNIT IS IMPORTANT FOR TWO REASONS:

1. It represents a big dollar investment for your cleaning business and its appearance should reflect that fact. A dirty machine is not professional!

2. Maintenance, troubleshooting, and repair is much easier to accomplish on a clean well maintained unit. Regular cleaning of the machine offers you an opportunity to visually inspect allfacets of the machine and spot potential problems before they occur.

FOLLOWING MAINTENANCE IS RECOMMENDED BY THE MANUFACTURER AT THE FREQUENCY INDICATED.

AFTER EACH JOB: Check recovey tank, s/s filter and filter bag as

required.

DAILY: Wipe machine down thoroughly with a damp cloth; flush recovery tank out thoroughly. Empty filter bag and inspect for rips, tears, etc. - replace as needed; remove, thoroughly clean and

reinstall stainless steel filter screen in recovery tank; inspect and

clean vacuum slot on cleaning wand; check wand head for sharp

edges that could tear carpet - file down as needed; clean wand with

stainless steel cleaning compound to maintain original appearance

(available through grocery stores); wipe down vacuum and high

pressure hoses as needed - visually inspect for cuts, etc..

WEEKLY: Wipe down entire unit as needed - apply good coat of

auto wax to all painted surfaces inside and out, and to control panel;

thoroughly clean recovery tank using high pressure hot water (unit

with optional high pressure cleaning gun may be used for this); re-

move stainless steel filter in recovery tank, thoroughly clean remov-

ing all lint build-up, inspect for damage and reinstall. Remove filter

bag, thoroughly clean and reinstall - iftorn, replace; empty chemical

from chemical container, wash out thoroughly to remove any chemi-

cal build-up; inspect chemical feed line strainer and use 50% white

vinegar/water solution to remove any chemical build-up; thoroughly

clean wand and inspect for clogged jet, debris in vacuum slot and

leaking fittings at valve. Apply light coat of auto wax to wand;

thoroughly clean vacuum and high pressure hoses including hose

cuffs - inspect for wear or damage to hoses and quick connect fit-

tings. Inspect garden hose connect/adapter screen for debris, re-

move and clean thoroughly. Inspect all propane and gas lines for

wear or abrasions that may cause possible fuel leaks.

DAILY CLEANING & INSPECTION

Engine oil - check

Garden hose screen - clean Machine -

Clean wc tank filter bag after every job

Blower inlet - spray with U% 1 after last job

general inspection

MAINTENANCE LOG

WEEKLY

MAX HRS

25 25

25 25 25 25 25

25 25 25

ENGINE OIL change

BLOWER check oil level

PUMP OIL check ‘m’”= COUPLER tighten set screws

,.-, - .i

BAITERY LEVELS check

I-BEATERBURNER ASSfvltightness/leaks VACUUM TANK clean WIRING CHEMICAL SYSTEM flush w/vinegar

SERVICE

& PULLEYS

l#W3 check for chafing

BOLTS check tightness

check for chafing

check tightness

MONTHLY SEFWKX!

100

300

BLOWER grease bearing ENGINE BYPASS

AIR CLEANER clean

VALVE grease cup &.stem

QUARTERLY SERVICE (3 MONTHS)

SLOWER OIL change

ENGINE impression

SPARK

PLUGSchange

DATWHRS

DATE/HRS

DATE/EIRS

DATE/HRS

DATE/i-lflS

‘e

HYDRAMASTER BOB CAT 2-290 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

INDEX