Hydramaster Bobcat 3.0, Bobcat 3.5 User Manual

o

INDEX

PAGE

General Information

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

Warranty Information .

Warranty Procedure .............................................................................................................. 3

Purchaser’s Responsibility ................................................................................................ 4

Truck Preparation Information ............................................................................................... 4

Truck Preparation Illustration ................................................................................................. 4

Propane Tank Location/illustration ........................................................................................ 5

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

Machine Specifications ....................................................................................................... 5

Spare Parts Flecommendation/Parts Orders .................................................................... 5-6

Water& Chemical Flow Operation ..................................................................................... 6

Water Flow Diagram ................................................... ... .................................................... .

Chemical Flow Diagram

High Pressure Pump Information ......................................................................................... 7

Bypass Valve Assembly Illustration ....................................................................................... 7

High Pressure Pump/Chemical System Troubleshooting ............................................. 7 & 16

Model 290 Cat Pump Operating Instructions .................................................................. 8-15

Chemical Proportioning and Level Control Illustration ......................................................... 16

Chemical Tank Troubleshooting ..........................................................................................

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

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

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

16

2

3

5

6
6

Heating System Information ............................................................................................... 16

Heater Operating Instruction ................................................................................................

Heater Troubleshooting ....................................................................................................... 17

Vacuum System Information .............................................................................................. 18

Vacuum Flow Diagram ........................................................................................................

Vacuum Tank Filter Bag ...................................................................................................... 18

Vacuum Blower Lubrication (Diagram) ................................................................................ 18

Vacuum System Warranty

Vacuum System Troubleshooting ........................................................................................

Engine Manual/Warranty ............................................................................................. 21-28

Engine Troubleshooting .......................................................................................................

Electrical Diagram

Electrical Troubleshooting ................................................................................................... 30

Machine installation Information ....................................................................................... 31

Machine Tie Down Cleat Information ................................................................................... 31

Propane Hook-Up Illustration ............................................................................................... 31

Gas Hook-Up Illustration ...................................................................................................... 31

Water Softener Information .................................................................................................. 32

Jet Assembly

Wand Assembly ................................................................................................................... 32

Valve Assembly

Machine Operation Instructions ......................................................................................... 33

Controi Panel
Operation Precautions

Freeze Protection ....

.............................................................................................................. 30

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

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

...................................................................................................................... 33

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

PO

29

........................................................................................................ 33

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

17

18

19

Cleaning and Chemical Precautions and information ......................................................... 34

Cleaning Stroke Procedure/Over-Wetting ........................................................................... 34

Maintenance Procedures .

Overaii Careof Machine ...................................................................................................... 35

Maintenance Logs .......................

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

.................................................................................... 36-38

35

GENERAL

INFORMATION

This manual contains installation and operation instructions as well

information required for proper maintenance, adjustment and re-

as
pair of this unit. Since the first and most important part of repair work
is the correct diagnosis of the trouble, a general troubleshooting sec­tion and component manual troubleshooting charts have been in­cluded for your convenience.

Unlike the garden tractor, Iawnmower 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 consistent RPM.
Vacuum has to pull air and dirty water back from cleaning site.
Water pump provides stable pressure at proper water flow for
cleaning.
Chemical has to be injected into the water stream at the right
consistency.
Heater must maintain proper heat.
Vacuum tank must store dirty water until drained.

As you can see, it is not just a turn key operation with only one thing
to worry about, Does

THE SYSTEMS WORK AS

FOLLOWS:

The water system takes incoming water at tap (low) pressure, com-

bines it with chemical from the chemical system automatically,

pumps it under high pressure through the heating system and out to
the cleaning tool. After being sprayed into the carpet being cleaned,
the water/chemical/soil solution is extracted by the vacuum system

and returned

As there is no guess work in the manufacture of these highly ad­vanced cleaning plants, there must be none in preparing it to get the
job done in the field. It is the purpose of this manual to help you prop-

erly understand, maintain and service your cleaning plant. Follow
the directions carefully and you will be rewarded with years of profita-

ble trouble-free operation.

It is imperative that no

eratirm of this equipment.

to the waste recovery tank.

Imm@!l

it start?!

section be overlooked when preparing for op-

The manufacturer uses this symbol
throughout the manual to warn of

possible injury or death.

This symbol is used to warn of

possible equipment damage.

HYDRA-MASTER WARRANTY POLICY

Effective January 1, 1989
HYDRA-MASTER warranty covers only defective materials and/or

workmanship for the periods listed, Labor, and/or diagnostic reim­bursement is specifically excluded,

YEAR GOLDEN GUARANTEE@

2

LIMITED WARRANTY PLAN

HydraMaster warrants products of Its manufacture to be free from
defects In material and workmanship If properly Installed, malr-
ta!ned, and o~erated under normal cond{llons with competent
superwslon No person,
authorized 10 give any warranties on behalf of Hydra Master [nor to

assume for Hydra Masler any other Iabdrty m connection with any
of HydraMaster’s products ‘his ‘warranty shall extend for the
pertods Ilsted by component below from date of nstallatton If
repatrs or replacements are made by the Purchaser wtthout
HydraMaster’s written consent
cease 10 be [n effect No allowance WIII be granted for anv repairs
or alterations made Dy {he PJrchaser wltnout HydraMaster s prtor
written consent

Machinery, equipment and accessories furnished bv
HydraMaster, but manufactured by others are warranled only 10
the extent of the orlglnal manufacturer s warran!v to HvdraMaster

Hydra Master agrees at Its option to repair at the potnt of st?lpment,
or to replace without charge any parts or parts of products O{
Hydra Master s manufacture. which wlthn the specified warranty
period shall be DrOved to HvctraMaster’s satsfactron to have been
defective when shpped. provided the Purchaser promptly nohfles
HvdraMaster {n wrttng of such alleged defect HydraMaster will
Day all freight and transportation charges via ‘?ormal ground
shipping means for replacement ~f Darts covered undel Ihls
,warrantv

Hydra Master s Iablllty :C Purchaser wnelher ,7co171racl or m ‘ort
arlsl fig Jut of warranties, ,eDresertatlon wstructlons, or detects
from ,]nv (cause SILIII be lr~ted :C repar\17g CI replac:~lg Ihe defec
[Ive part or parts

No habilrty whatsoever shall attach to HydraMaster untl said
prOObCtS have Oeell pdld tOr

Exceot as stated r this secton and 10the Drecedng secfton tiled

Warrantv and except as !O ttle there are nc guarantees or
warranties ot merchant ablhtv tltness performance or otherwise
lcxpress
Ihabtlrty for consequential mcldental or other damages, howsoever
caused

FRAME/COVER ASSEMBLIES: . . . . . . . . . . . . . . . . . . . . . ..3 years

VACUUM RECOVERY TANK/CHEMICAL MIX TANKS: .,3 years

CHEMICAL PROPORTIONING SYSTEM: . . . . . . . . . ., .,: years

CLEANING WAND:.........,....,.. . . . . . . . . . . . . . . . ..z years

ENGINE: \T)7ru orlg]nal blan~taclurer Or> Elrecl Dllve umrs

seeorlclnal blar7ufac! Lrersiv Jrrra,7!\ J ., ., . . . . . . . . . . ..L

Y

INTERNAL MACHINE I+OSES ..,., .,. , . . . . . . . . . . . . . . ..yea.s

VACUUM BLOWER: (Thru orgnal Manufacturer See

1!

Cooper Industries warranty I

(

HIGH PRESSURE BY PASS VALVE . . . . . . . . . . . . . . . . . ..2vears

BELTS, FITTINGS, FILTER SCREENS, GAUGES: . . . . ...1 year

WATER HEATER OR HEAT EXCHANGER, ., ., . . . ...1 year

HIGH PRESSURE PUMP (Thru or[glnal Manufacturer 1 ..1 year

~- VACUUM HOSE, SOLUTION HOSE,

QUICK CONNECTORS, O-RINGS, SEALS:. ., ., . . . ...90 days

Freez)ng of any water or chemical related component WIII VOID all
warranties on water or chemical related components internal or

external, of ths equpment
Deposits and build-up m the water chemcal or heater systems,

$ due [o hardness m the water used or poor quallty chemicals wh!ch

1 __

5 resulf In deposi!s will vod all warranl!es on affected compo~en!s

k
J,@n

-. w .-.

~43=17x .

Implled or statu[or~

agent, representative or dealer IS

HydraMaster’s warranty shall

ar)u f+vdra Mas[er snail t7ave no

- ~ea,s

. . . . . . . . . . . . . . . . . . . . . . . . . ,c !/ears

—.. .

I

2

parts shipment will be sent to the customer for the amount of the

WARRANTY INFORMATION

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

ENGINE: operation at speed in excess of 2800 R.P.M. 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.

BLOWER: Failure to lubricate impellers daily with LPS-1 or 1. Call Hydra-Master Warranty/Service Dept. at [phone]
WD-40 lubricant. Failure to lubricate bearings as recommended in
blower manual. Failure to maintain proper oil levels in the blower. 2. Give the Warranty/Service Representative the following informa­Failure to use the correct oil grade and viscosity as recommended in tion:
blower manual. Failure to properly maintain blower safeguard sys­tems such as waste tank filter screen, vacuum safety relief valve in A. Name of your company and your address.
vacuum tank lid and waste tank automatic shut-off svstem. B. Eauipment Model (i.e. Hvdra-Cat, Bobcat 2, etc.)

HIGH PRESSURE WATER PUMP: operation of pump at

pressures over 1200 PSI. Failure to maintain proper oil level as rec­ommended in pump manual. Failure to change oil in pump 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.

abuse or neglect.

parts sent. The customer’s faulty parts must be
tion prior to the expiration of the thirty (30) day period. Upon warranty
approval, a credit will be issued the customer for the replacement
parts invoice.
parts ‘within the thirty (30) day period allowed will result in the
customer being charged for the replacement parts sent.

Wsrranty disapproval or failure to return the faulty

HOW TO ORDER

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

C. D&e of purchase. ” “
D. Hours on the unit.
E. Serial number of unit.
F. Name of person authorized to order parts.
G. Salesman unit purchased from.
H. Description of malfunction.

1. Pressure readings on high pressure gauge with wand turned on
and off.

returned for evalua-

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.

VAC TANK: Failure to properly maintain filtering devices in tank.

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

CHEM. PRO PORTIONER: use of improper chemical. Failure

to use water softener in hard water area. Operating machine without
proper chemical filter screen. Failure to protect against freezing.

3. If warranty replacement parts are needed, please specify method
of shipment desired.
freight collect, 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 Ser­vice Representative. All parts must be returned directly to Hydra-

Master, freight prepaid.

NOTE: All replacement parts are sent

CONTROL PANEL: Failure to motect flow meter and water ONE FINAL NOTE:

pressure gauge against freezing. ‘

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

VACUUM AND SOLUTION HOSES: Failure to protect Corporation.

hoses against freezing. Failure to protect hoses against burns from

engine/blower exhaust. Damage to hoses from being run over by ve- We shall always endeavor to be fair in our evaluation of your war-

hicles. Kinking or cracking from failure to store or unroll hoses cor- rarity claim, and shall provide you with a complete analysis of our
rectly. Normal wear and tear from everyday use.

findings.

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 Warrsnty

Dept. at the above address, or call the Warranty/Service Dept. at
[phone]. No collect calls will be accepted. Hours of the

Warranty/Service Dept. are 8:00-11:30 am and 12:30-5:00 pm,

Pacific Time.

IMPORTANT

Hydra-Master’s warranty policy provides replacement parts without

charge for thirty (30) days to customers maintaining current account
status. An invoice dated thirty (30) days from date of replacement

3

PURCHASER’S

.—

RESPONSIBILITY

PRIOR TO ARRIVAL OF UNIT:

● Install %“ exterior plywood flooring in vehicle and cover with I

artificial turf.

a Have belly mounted propane tank installed on vehicle. Tank

must be propane

vapor type

Materials Needed:

1. 2 sheets 4 x 8 x 5A” exterior plywood

2. 6’ x 12’ piece of commercial astroturf

3. 16-1 lA” sheet metal screws

4. 1 quart marine adhesive (optional)

5. 1 staple hammer w/’/z” staples

(See

illustration for correct placement of plywood flooring)

IPLACEMENT OF UNIT IN
VEHICLE

There are two recommended unit placements:

~ P.rchaseheavyd.ty 42-60 amp hour
battery and have battery ‘slow’ charged if new. If battery is not
fully charged darnage can occur to the engine charging
regulator.

ACCEPTANCE OF SHIPMENT:

e If unit shows any outward signs of damage, do not sign the

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.

READING OF C9PERAT10N MANUAL:

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

manual and to familiarize himself with the information contained
therein.

SALES REPRESENTATNE

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 its operation and
maintenance.

CCNIRECT INSTALLATION INCLUDES:
Supervising 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 gasoline lines; connecting battery; checking

pump, vacuum blower and engine oil levels, prior to starting

unit; starting unit to check engine to see that all systems
funti[on normally; also checking all hoses, wands, etc., for
correct operation.

TRAINING SHALL INCLUDE:

Thorough review of the operation manual with purchaser;

*

instruction and familiarization 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.

A, SIDE DOOR: Most installations are side door. This provides rear
access for accessories and hoses as well as unobstructed access to
component/working 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 Iocatlon 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. IWs not only provides adequate working space on the
component side of the unit but also makes better weight distribution
inside the van (engine
shaft). Also, it is physically easier to load unit into rear door due to
height of van bed.

floor of van with hardware supplied. Sudden or crash stop will

and component weight line up over drive

Ensure that machine is well secured

to the

cause machine to rocket fonward, al! 350 Ibs. worth! Protect

yourself and the machine: SECURE IT!

TRUCK PREPARATION
!ILLUSTRATION

FIRST, cover the truck bed with 54” plywood using metal screws to
secure it as shown.

SECOND, select the appropriate color astro turf to match your van
and cover the plywood and staple in place. A standard van requ~res
piece 6 feet by 12 feet.

THIRD, for added ventilation, an aluminum roof vent should be
added over the location selected for mounting the rnachme. This WIII
allow hot air from the heater to escape.

,, +Lw,mm

s

a

TRUCK PREPARATION

Manufacturer recommends the installation of plywood flooring
covered with poly propylene backed astroturf (do not use rubber­backed) in the vehicle prior to installation of machine. This provides a
metal to cushion mounting rather than metal to metal, provides insu­lation and makes

keyed to van interior.

an attractive van interior. Astroturf should be color

4

PROPANE TANK LOCATION

1

Either the 10 gallon or 16.5 gallon propane tank will fit this location.

Have your local propane dealer install the tank you select and purch-

ase. The machine will come with the proper propane regulator.

(Tank must have vapor outlet).

truck or van. Besides being dangerous it is unlawful

Do not use a portable propane tank inside the

Ww

L

in most states.

TANKFILLVALVE

HARD WATER AREA MAP

The quality of water varies greatly throughout the United States and
influences the reliability arid efficiency of equipment in direct propor-

tion 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 gallon. Using the legend as a reference, determine the
quality of water in your area and take action immediately should it be
necessary.

(For installation ; ~ ~~’;’ ‘,’

diagram see

machine
installation section)

GRAINS
PER GALLON

~]

- 31/. -7 _ 10%ANDABOVE

0- 3~/2

.

F*

w

‘q

MACHINE
SPECIFICATIONS

FRAME: 18“ W, 53”L, 34”H, Steel With Baked-On Epoxy

WEIGHT:

COWLING: Steel With Baked-On Epoxy Finish.

ENGINE:

IGNITION: Magneto Key Start. Solid State Ignition.

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

VACUUM Model 3.03 MB Sutorbilt W/l 4 HG Safety Relief.
BLOWER:

CHEM, SYSTEM: Electro-Mechanical, Flow Meter Controlled.

HEATER:

INSTRUMENTS:

RECOVERY

TANK:

CLEANING
WAND:

HI-PRESSURE
HOSE:

l-l

VACUUM HOSE: 2“ Reinforced Safety Orange, 1M“’ Reinforced

STANDARD
FEATURES: S/S Cleaning Wand, 100’ M“ High Pressure

OPTIONAL
FEATURES: Vacuum Hose in 50’ Lengths, Additional %“

Finish.

Model 3.0:485 pounds.
Model 3.5:500 pounds.

16 HP Briggs & Stratton Opposed Twin Piston.
Steel Sleeved Cylinders, Ducted.

(@ 1200 RPM.

Model 3,5: 3LFS Sutorbilt W/12 HG Safety Relief.

Propane Fired, ThermostaticallyControlled.

20,000 BTU).

(1

1-1000 High Pressure Gauge, Hour Meter,
Chemical Flow Meter, ignition Key Start,
Temperature Gauge,

Model 3.0:52 Gallon Aluminum Epoxy Finish.

Model 3.5:65 Gallon Aluminum Epoxy Finish,

S/S 11” W/Heat Cover Handle - and Forward
Guide Handle,

M“ High Temp Lined/Vinyl Covered Safety
Orange W/Brass Quick Connects.

Safety Orange.

Power Console, Vacuum Recovery Tank, 11”

Hose, 100’- 2“ Vacuum Hose, 10’-1 M“
Vacuum Hose, Through Floor Connections For
Gasoline and Propane Hook-up, Tie-Down
Cleats, Vacuum Hose Connections, 5 Gallon
Chemical Jug, Operation Manual.

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

Pressure Hose In 50’ Lengths, Pressure
Washing Gun, Spare Patis Package.

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 vour truck the fol­Iowing spare parts:

QUANTITY

PART NUMBER

2

1

1
1
1
2 000-049-028
6

000-078-015
000-078-024
000-078-034
000-076-007

000-049-023

DESCRIPTION

Engine Spark Plug

Flow Meter Kit
Wand Valve Plunger Kit
Press. Bypass Valve Kit
Spray Jet 8008E
Recovery Tank Filter Bag
Screen Garden Hose

PARTS ORDERS

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

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

regional service center.

In the event parts are unavailable locally, contact the factory and co-

ordinate your needs. If this 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-Master Parts Dept. phone [phone].

QUANTITY

5

1

1
1
1

1
1
1

000-078-001

000-078-004
000-052-050
000-052-051

000-052-052
000-052-053

000-010-019

PART NUMBER

DESCRIPTION

Cat 290

Standard
Cat 290 Hot Cup Kit (Optional)

440 Male Quick Connect
440 Female Quick Connect
660 Male Quick Connect
660 Female Quick Connect
Belt, Pump Drive. AX-26

Shori Cup Kit

OPERATION

This electro-mechanical system has been designed to be simple
and trouble free. Incoming water flows first through the Solenoid
Control Valve (1) and the low pressure Chemical Injector (2) which
are both mounted on the exterior of the mlx tank. As the water
passes through the Chemical Injector, it IS automatically propor­tioned with a predetermined quantity of detergent. The MIX (3)
Tank is equipped with two different float switches, the Water Level

Float (4) responds to the level in the tank and will maintain the
proper volume of solution to be reserved for the water pump. The

secondary, Low Water Float switch (5) is a safety switch that is
designed to protect your system from sudden or unexpected loss
of water supply. If, for example, the water source at the house were
turned off, the water level of the mix tank would drop, activating the

secondary switch, which automatically dmengages the system and

prevents the water pump from running dry.

The desired chemical InjectIon ratio may be obtained by an adjust-

ment of the Chemical Flow Meter (6) during the fill cycle of the mlx

tank. Water must be flow!ng into the mix tank In order to adjust the

chemical mix. The chemical WIII flow from the Chem!cal Jug (7) to

the Chemical Flow Meter, then to the Chemical Injector where It IS

proportioned into the MIX Tank at the desired chemtcal setting.

NOTE: With th[s unique chemical system, the chemical flow is

proportioned only during the filling cycles of the Mix Tank, not dur-

ing the direct spraying of the wand, Therefore, !t is possible that as

your wand IS spraying, you may have no chemical flow. Also, the

converse is true [n that you may not be spray!ng your wand, but if

the mix tank is In a filllng cycle. your Chemical Flow Meter may be
actwe at the desired flow rate.

The chemical proportlomng system will mix chemical with water at

a t to 30 ratio when the Flow Meter is set at 5 GPH, or a 1 to 15
ratio when the Flow Meter is set at 10 GPH.

At this point in the flow, solution (water with chemical) will now be
siphoned from the bottom of the Mix Tank to the inlet of the Water
Pump (8), When the wand IS not us!ng solution by spraying, the
solution will be bypassed from the bottom of the brass Pressure
Relief Valve (9), back to the MIX Tank.

When the wand is spraying, the solution continues its flow to the
Water Heater (1O). The coils of this heater have a capacity of up to
2 gallons, therefore it IS extremely important that all air pockets are
bled out of the heater prior to initial start-up. This may be achieved
by running the water system, without the heater on, for approx­imately 60 seconds,

WATER FLOW

Chemical

‘~

Injector -

Sole;oid -~

Control

1 “’

d

6- Chemical Flow Meter 12 - Incoming Water
7- Chemical Jug 13- Tank Dratn
8- High Pressure Pump

+ High Pressure

3

}

Y-

10- Heater COII
1? - Pressure Guage

14- To Wand

-+ Low Pressure

CHEMICAL PROPORTIONHUG AND
LEVEL CONTROL

6FA 6uFS

.1

I

II

Relay

MIX Tank

{

CHEMICAL SYSTEM MAINTENANCE

The chemical lines may need to be flushed with vinegar periodical-

ly to prevent abnormal chemical build-up. This flushing may be
done by removing the clear plastic hose from the Chemical Jug
and inserting it into a one quart container of vinegar, This should
be done with the Chemical Flow Meter setting on 10 GPH and the
Water Heater “off”. Simply spray water from the wand until the
quart of vinegar is exhausted, the repeat the process with one
quart of clear water to void all lines of vinegar.

CHEMICAL SYSTEM WIRING DIAGRAM

Solenoid Valve

“!!+!!%::=*

GFD

“L.._J

~.

‘“ @!

Check Va ve
Spring

~ ‘ ~ ~ ‘“’’”0’ 60”’
O S S Ball

o check Valve

l!)

Cap
Nut

~ Che.[cal L — F/r .

Mounmg

*~=L—lJ ,~wate,

12 vDC

Coil Plate

T-

6

Mounting

Inlet

GENERAL

INFORMATION FOR

CAT PUMP REPAIR

As you remove your discharge manifold, there is a set of 3 check val-

ves (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 pul­sation. 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. If this discharge manifold is warped, it
will cause the check valves to stick and will result in loss of pressure.

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 of visually in­specting 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

1/4the size of a penny. Ifthese ‘o’ rings are 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 right away, change oil
frequently. Repair the pump as soon as possible so as to not dam­age bearing or connecting rods.

Repairing of Cat pumps is not a difficult task. However, before disas-

sembling 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. 011 all seals

thoroughly prior to installation. (Remember, a newly scarred seal is

no better than one you just took out.)

BYPASS VALVE
ILLUSTRATION

Bypass Valve Parts List

REF. NO. PART NO.

3. 000-105-101 Thrust Plate, Bypass

4.

000-105-102 Piston

5. 000-078-101 Kit, Seal for Bypass

7.

000-148-004 Seat & O-Ring, Bypass

8. 000-097-005 O-Ring, Bypass Valve

DESCRIPTION

Valve 1

QTY.

Plate, Bypass

Valve 1

Valve

Valve

Fittina

1

1

1

BYPASS VALVE
169=101

HIGH PRESSURE PUMP

TROUBLESHOOTING

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

PROBLEM:

● 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. Disassemble 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 portion 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 1lA GPM 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.

7

(Continued on Page 16).

?@’

. ,$%, ,,

I

—

@

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-. .-

&

SPECIFICATIONS

volume ...........................................................................................................................3.5 GpM

13ischarge Pressure ...................................................................................................... 1200 psi

Maximum Inlet Pressure ...................................................................................8.5 to +

RPM ............................................................................................................................. 1200 RPM

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

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

Stroke

Crankcasa Capacity ..........................................................................................................

Maximum Fluid Temperature .......................................................................................... 160” F

Inlet Port (I) ...................................................................................................................l/2'' NpT

Dlschar e Fort (2)

Pulley ounting ........................................................................................................ Either side

J
Shaft Diameter
Weight

............................................................................................................................l2.1 Ibs.

Dimensions .......................................................................................................l O.6

This Cat Pump Vpraduct”) is warranted by tha manufacturer to be

from defects in workmanship and material for one year from

free

date of manufacturer’s shipment. This warranty Is limited to repair-

ing or replacing products which manufacturer’s investigation
shows were defective at the time of shipment by the manufacturer.
Ail products

ilon, repair or replacement.
The express warranty sat forth herein is in
ties, express or Implied, including without limitation any warranties
of merchantability or fitness for a particular purpose and all such

warranties are hereby discteimed and excluded by the manufac

turer. Repair or replacement of defective products as provided

above is the sole and exclusive remedy provided hereunder and the

manufacturer shall not be liable for any further Ioas, dama es or

expermea, including incidental or consequential damages, d rectly

or indirectly ariahrg from the sale or use of this product.

This warranty is subject to the following warranty conditions:

sub.ect to Ma warranty shall be returned F.O.B. Cat

/Pumps Corp., M nneapolis, Minnesota 55430, U.S.A. for examhta-

.........................................................................................................3/8'' NPT

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

CAT PUMP

lieu of all other warran-

?

Model 290

OPERATING INSTRUCTIONS

CAUTION: CAT PUMPS are positive displacement pumps. Therefore,

a properly designed pressure relief mechanism MUST be installed in
the discharge piping. Failure to install such relief mechanism could
result in personal injury or damage to the pump or system. Cat
Pumps Corporation does not assume any liability or responsibility
for the operation of a customer’s high pressure system.

U.S. Measure

40 psl

10oz.

X 9.1 X 5.7”

WARRANTY

IMPORTANT CONDITIONS

LLlaRICATION — ftll crankcase 10 dot on oil gauge window per Srxmtlcatmns wllh Cat
Pump 011 or equllvalenl SAE 60 weight hydraulic 011wtlh afltlW@aland rust lnhlbitor ad-

ditives. Change

500 hour Intervals thereafter Prrrrrm-a-lube seals need no lubrication Blue dot seals and
wicks must recewe three drops 0! Cat Pump 0!1 Per w!ck every 50 hours of operallon.

GOOO

PREVENTATIVE MAINTENANCE.
RPMand PRESSURE—

Pressure reltef valve must be ,nstalled
DO NOT

tlonal information on questionable
FREEZING CONDITIONS — Pump must ba protected from !reez!ng condtllons

inltnal fill after 50 hour run.in period. Chnage 011every three months or at

LUBRICATION IS THE EASIEST, MOST EFFICIENT IW40 LEAST ExPENSIVE OF

Pump operatton musl be woth(n RPM ano pressure specd!cattons

PUMP ACIDS OR ABRASIVE FLUIOS with this und Consult Cat Pumpe tor add!.

USEOF OTHER THAN CAT PUMP PARTSOR
THEIR EQUIVALENT VOIOS THE WARRANTY

flu!ds

M@tr[c Measure

(-0.6 to+!% g~!~

(268 x 230x 146mm)

(13 MM)

(1200 RPM)

(20mm)
(12mm)

(0.3

(71 “c)

(1/2” NPT)

(3/8” NPT)

(Either Side)

(16.5 mm)

(5.5 kg)

L)

,

I

Products descr,bed

hereon are covered by one or more of the following U S patenls 3558244 3652188 3809508 3920356 and 3930~56

—-.

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-)

- ,;

>*/A#p’

,.,

,’., C,,,,,.,

. . .

P O Box 685 MINNEAPOLIS MN 55440

Phone [phone] Telex 29.0276

N V CAT PUMPS INTERNATIONAL S A

Harmmmeslraat 29

!3.2000 Anlwerp. Belq!um

,?, ...

*

LoretohOhe 5

CH 6300. ZUG Switzerland

CAT PUMPS DEuTSCHLAND GmbH

Roslocker StraSSe 9

6200 Wlesbaden. Bterstadt

Wesl Germany

CAT PUMPS (U K ) LTD

17A K,ngs Road Fleet

HamDshlre Gu13 9AA

‘!

●

●

D/str/buted BY

8

3

~,o.55,2~3”g4’100)

/8’

3

\

.5

1

IMPORTANT DRIVE INFORMATION

I

Pulley

HORSEPOWER REQUIREMENTS

PRESSURE

Flow

;PM

3.5

3.0

2.5

UM

13 1.9
11

9 1.4

800 1000 1200

Psl

55

BAR

1.7

Psl Psl

69 83

BAR BAR

2.4

2.1

1.7 2.1

2.9

2.5

Selection
Using 5“
Pump Pulley

Motor

RPM

1200
1029

P:J:y

3.5

3.0

858 2.5

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 perfor­mance. These precautions will eliminate most
problems, minimize corrective maintenance,

and give many, many added hours of trouble
free operation. Cat PumDs Cor~oration does

not assume any
the operation of
system.

Iiability”or responsibility for

a customer’s high pressure

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
GPM of the

put desired.

Pump RPM and GPM output are ap­proximate values due to variations in
pulleys, belts and motors between
manufacturers and a + – 5°!0

output tolerance.
Horsepower figures shown are brake

horsepower figures. For gas engine
requirements,
manufacturer’s recommendations.
In general, use a gas engine with ap-

proximately double the electric
motor horsepower.

/

S HUT c$F “bJ.VE

approximate pump out-

follow engine

II

F,LTROT,CM Ixv,cc

—

L

u

NOTEIl&ed s“.!,.” ,eq”,ml.“
plungertype pump,

pump

9

GENERAL INFORMATION

INTERPRETING PRESSURE READINGS: Pressure

readings that differ

normal for

a particular set-up indicate a problem,

from the rated PSI or those

but not necessarily a pump problem!

Before any servicing of the pump, carefully check
the following; inlet plumbing for size, restriction
and/or air leaks, restricted or worn orifice and con­dition of the by-pass valve and pressure gauge.
Check 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
or look in the Yellow Pages under PUMPS.

ORDERING OF PARTS: When ordering parts, be
sure to give the “model number” and “serial
number”,

“description”, and “quantity” of the

items desired.

INSTALLATION

Optimum performance of the pump is dependent upon the entire fluid system and will

be obtained only with the proper selection and installation of plumbing and accessories,

MATERIAL RETURNS: If necessary to return a Cat

Pump, please secure an approved “RETURN
GOODS AUTHORIZATION” form from Cat Pumps
Corporation and complete a “PRODUCT

REPORT” form detailing the application and the

conditions of operation. Any material AUTl-fORIZ-

ED for return must be shipped FREIGHT

PREPAID.

FILTER lNSPECTICIN: 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—several to plug an inlet screen
or filter, or if the particles are abrasive, to damage
packings, valves, valve

seats, or plunger%

Inspect filters and screens on a schedule com­mensurate with the material being pumped and
whenever a low pressure problem develops.

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

Lubrication: Fill crankcase with oil as covered under

warranty conditions.

Pulley Selection: Select size of motor pulley required to

deliver the desired volume from Horse Power Require-

ment and Pulley Selection Chart.

Motor $electicm: The motor or engine driving the pump

must be of adequate horsepower to maintain full RPM

when the pump is under load. Select a motor from the

Horse Power Requirement Chart according to required
pump discharge volume and maximum pressure at the

pump!

Mount the

ner to permit drainage of crankcase oil. An uneven

pump on a rigid, horizontal suface in a man-

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.

Inlet Plumbing must be at least the same diameter as
the inlet port, preferably one size larger. Restriction in
the inlet plumbing will cause cavitation in the pump,
drastically reducing packing life. All joints must be air

tight.

Inlel Pressure: Optimum performance is obtained with

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

bing, the pump will perform very satisfactorily 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 pulsation dampening
device mounted directly to the discharge line and

precharged to a pressure calibrated for operating con­ditions.

A reliable 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 insta//ed to prevent over-pressure in the event the
discharge or downstream plumbing becomes plugged
or is turned off. Severe damage to the pump will result
if this condition occurs without a relief valve in the line.
CAUTION: Failure to install such a valve will void the
warranty on the pump.

10

S’8

EXPLODED VIEW

MODEL 290

63

‘ 57

11

ITEM

PARTS LIST

CAT PUMP MODEL

2
3
4
5
a

9
10
11
12
15

16

17
18
19

20

21

23
24
25
26
27

28

2$3

30

:;

33

34

35

PART No

28766
85680
14177
43211
26087
26105
22289
23170
25625
92520

43804

14487
24159
26536
27950
92519

101799
101800

16948

20017

25301

25327

25392

28771

29003

29614

26854

28597

25128

25635

30315

30325

DESCRIPTION

QTY.

Crankcase
Stud (M8

X 82)

O-Ring, Oil Filler Cap
Oil Filler Cap

O-Ring, Crankcase Cover
Crankcase Cover
Oil Gauge
O-Ring, Drain Plug
Drain Plug
Sems Comb Head

Screw (M6 x 20)

Crankshaft

Rearing
Oil Seal
O-Ring, Oil Seal Case
Oil Seal Case
Sems Comb. Head

Screw (M6x 16)
Connecting Rod

Piston Rod

Piston Pin

Seal Washer

Seal

Oil

Barrier Slinger

O-Ring, Sleeve

O-Ring, Sleeve (Viton)

Back-UD Rirm, Sleeve

Sleeve (2974 ~’Unchromed) 3

Seal Washer 3

Seal Retainer 3

Inlet Manifold 1

Inlet Manifold-Stainless

Steel 1

Prrrrrm-A-Lube Seal

Prrrrrm-A-Lube Seal(Viton) 3

ITEM PART NO.

1

2
1

38
39
40

27004
30543

30544
1
1
1
1
1

1

6
1

41
42
43
44
45
46
47
48

2
2
2

49

50

2

43172

27983

27002

27006

18956
14158

101802

23172
11377

21985

24459
25634

DESCRIPTION

Inlet Valve 3

Bat-Cup Piston 3

Bat-Cup Ring
(Teflon)
Cup (Viton) 3

Piston Spacer

Piston Retainer
Conical Washer-SS (M6) 3

Nut-SS (M6)
Cotterpin 3
Cylinder (43834 Unch) 3
O-Ring, Cylinder
O-Ring, Cylinder (Viton)

BacJJp Ring, Cylinder 3

Discharge Manifold 1

Discharge Manifold-

QTY.

3

3
3

3

:

Stainless Steel

8
3
3
3
3
3
3
3

3

51
52
53

54
56
57
58
59
60

3

61

62
63

64

43442
43360
43723
43434
81109

101804

25130
26246
30901

30920

30910
30032

30047

Valve Spring Retainer
Valve Spring
Valve

Discharge Valve Seat 3

Hex Nut (M8)

Hex Flange Nut (M8) 2
Shaft Protector
Angle Rail

Hex Cap Screw
(5/16 x23A)

30612

Split Lockwasher i%%%ng

(5/16 US)

Hex Nut (5/16 US) 2

Puiiey 5“ w/2

Set screws

Key (M5)

1

30246
Pulley

J

Asbly

;
3
3

2

1
2

2
2

?

1

3

30023 Cup Kit

cup

3

O-Ring, Cylinder

6

Cotterpin

3

1 Instruction Sheet
1

Cup Inserter

30305 Seal Kit

Prrrrrm-A-Lube Seal

3

Cotterpin

3

Abrasive Paper

2

Instruction Sheet

1

30431 Sleeve and

Prrrrrm-A-Lube Seal

3

Barrier Slinger

3

Cotterpin

3

Sleeve

3

O-Ring, Sleeve

6

Instruction Sheet

1

Seal Kit

SERVICE KITS

12

30686

30860

Valve Kit

Valve Spring Retainer

3

Valve Spring

3

Vaive

3

Valve Seat

3

O-Ring, Cyiinder

3

Instruction Sheet

1

Piston Kit

O-Ring, Cylinder

6

Back-Up Ring, Cylinder

3

Bat-Cup Piston

3

Bat-Cup Ring

3

cup

3

Piston Spacer

3

Piston Retainer

3

Conical Washer (M6)

3

Nut (M6)

3

Cotterpin

3

Inlet Valves

3

1

Instruction Sheet

L

SERVICING DISCHARGE VALVES

& VALVE SEATS

DISASSEMBLY

Loosen the 2 (M8) locking nuts approximately one

1.

turn.

2.

Then remove the 2 (M8) flange nuts.

3.

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

4.

Valve assemblies will remain with the manifold. in-

vert manifold and discharge valve assemblies
should fall out.

Inspect discharge valves for wear or ridges.

5.
(Sperical valves due to their shape must be replac­ed when worn.)

REASSEMBLY:

Place retainer in manifold chamber

1.

2.

Next insert spring into center of retainer

Place valve over spring with spherical (mooned)

3.

side down.

Next insert the valve seat.

4.

Position manifold back onto pump. NOTE: Exer-

5.

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 125 inch
pounds.

Hand tighten locking nut.

7.

CAUTION: When restarting the pump, check to see

that there is no cylinder motion as this will
cause premature
Center cylinder motion canbe eliminated by swit.
thing with one of the endcylinders.

failure of the cylinder o-rings.

SERVICING THE PUMPING SECTION

DISASSEMBLY:

1.

Remove discharge manifold as described above.

2.

Slip cylinders out of inlet manifold.

NOTE: Identify cylinders so they will be relapced in

their origional position. (Front to back)

3.

Remove cotterpin, nut, and washer.

4.

Next remove piston retainer, spacer, and piston
assembly.

5.

1,

——

13

Remove inlet valve.

REASSEMBLY:

SERVICING THE SEALS

AND SLEEVES

DISASSEMBLY

1 Examine inlet valve surface and reverse if dam-

aged. (both sides are lap surf aces.)

‘2 Examine piston assembly for clean inlet surface.

If damaged, replace and lubricate.

NOTE CUP INSTALLATION:

Wipe cup inserter lightly with oil. Slip bat-cup ring onto

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

faces. Faulty cup insta//ation causes premature
faiture.

Next replace piston spacer and retainer.

3.

4.

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

NEW CO JTERPIN.

Examine cylinder walls for scoring or etching.

5.
These conditions will cause premature wear of
your piston assemblies. replace if worn or dam­aged.

Lubricate cylinder and replace o-rings and back-

6.

up rings (if defective).

Position cylinders in their origional order into

7.

manifold chambers and carefully slip over rod

ends onto the pump.

Replace flange nuts on studs and hand tighten

8.

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

Hand tighten locking nuts.

9.

1.

Remove discharge manifold and piston assem ­blies as described .

Remove both (M8) locking nuts from studs

2

3

With soft mallet, tap inlet manifold loose from

crankcase.

4.

Place inlet manifold on pair of clearance blocks
with crankcase side down. and drive out seals.

Invert inlet manifold with CRANKCASE SIDE UP.

5

6.

Lubricate circumfrance of new Prrrrrm-A-Lube
seals, position in manifold with GARTER SPRING
DOWN and drive into place.

7.

Examine sleeves for scoring or other damage
before removing

If worn. grasp sleeve with pliers and pull off.

8.
NOTE: This procedure wit! mar the sleeve so use

only if sleeve is to be repiaced.

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

9.

REASSEMBLY:

Place barrier slinger on rod.

1.

2.

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. Be
careful to avoid damaging the o-rings when slip-

ping them over the piston rod threaded ends.

PISTON SPACER BACCUP

PISTON R

CUPWA

COTTERP

‘uT~”

PUMPING SECTION CUTAWAY

BAC.CUP RING

T

d

PISTON RODSLEEVE

Immerse sleeve in

3.
onto rod. (machined counter bore end first}.

Replace seal retainers.

4.

ON

J

Exercise caution when replacing inlet manifold, so

5.

the inlet seals are not damaged by the threaded

ends.

rod

Replace locking nuts on studs.

6.

Reassemble ~iston assemblies and discharae

7.

manifold as described.

Consult factory for your local distributor for

crankcase servicing.

oil carefully twist and push

DIAGNOSIS AND MAINTENANCE

PROBLEM

Pulsation

Low Pressure

,

lumps runs extremely rough,
messure very low

:ylinder O.rings blown next 10
Iischarge manifold

eakage at the cylinder O.rings
st the discharge manifold and
>Iack, powdery substanca in the d
~raa of the O.rings

Nater leakage from under the

nlet manifold

)il leak between crankcase
md pumping section

)il leaking in the area of
: rankshaft

PROBABLECAUSE

Faulty Pulsation Oampener

Worn nozzle Replace nozzle, of proper size

Belt Slippage

Air leak in inlet plumblng

Pressure gauge inoperative
regtstermg accurately

Relief valve stuck, partially plugged or
Improperly adjusted; valve seat worn

I!Ilet suction strainer clogged or
improper mze

Worn piston assembly Abrasives m
pumped flwd or severe cavitation.
Inadequate water supply,

Fouled or dirty Inlet or discharge

valves

Worn Inlet or discharge valves

Leaky discharge hose

Restricted inlet or arr entering the relet Proper size inlet plumbing; check for air tight
plumbing

Inlet restrictions andlor air leaks,
Oamaged cup or stuck inlet or
dwcharge valve

Worn Inlet manifold seals Replace worn seals, Short cup life Over pressure of pumps

Worn inlet seals allow pump to draw Install new Inlet manitold seals, Running Pump dry
a Ir

Pressures In excess of rated PSI

Warped man(fold Replace manifold

LOose Cyllnders Cyllnder motion
caused by Improper shlmmlng of the

,scharge mamfold

worn Inlet mancfold seals Leak, ng

51eeve O.ring rePlace sleeves and sleeve O.rmgs

w orn cra~kcase piston rod seals

Excess 011from wicks

worn crankshaft seal or Improperly

n stalled o(I seal retatner packing

ad bearing

B

or not

Check precharge; if low recharge it or Install a

new one

Tighten or replacq use correct belt

Disassemble, reseal, and reassemble

Check with new gauge; replace worn or
damaged gauge, P.N. 06090

Clean, and adjust relief valv~ check for worn
and dirty valve seats. Kit Available.

Clean. Use adquate size. Check more frequently.

Install proper fitter. Suction at inlet manifold
must be limited to lifting less than 20 feet of

water or -8.5 PSI vacuum.

Clean relet and discharge valve assemblies.

Replace worn valves, valve seats andlor
dmcharge hose.

seal Abrasive material in the fluid being

Replace worn cup or cups, clean out foreign
material, replace worn valves

check for plugged nozzle, closed valves or

Impropedy adjusted bypass valve

Remove spacer shims on manifold sluds, Do not
remove too many shims or the ears of the
manlfold WIII be bowed when the man!f old IS

r

et!ghtened, causing looseness in the center

cylinder

Install seals If Piston rod sleeves are scored,

Replace crankcase pwton rod seals

Reduce quant!ty of 011per otlsng

Remove 011seal retatner and replace damaged
gaaket andlor seals

Replace bearing

--

—

SOLUTION

PROSLEM

Excessive play in the endof the Wornmainball bearingfromexcesswe

crankshaft pulley tenston on drive belt

Water in crankcase crankcase

Ieekingfrom undereide of Worn crankcase proton rod seals

Oil
crenkcase

Oil leaking at the rear portfon of
the crankcase

Oil leakage from drain plug

Loud knocking noise in pump Pulley loose on crankshaft

Frequent or premature failure of

the inlet manifold seals

strongsurging al the infet and

Iow pressure on the discharge
side dIsCharge valves and relet valve seats may be lapped cm a

-.

——

PROBABLECAUSE

—

May be caused by humid air
condensing into water inside the

Leakage of manifold !nlet seals andlor Replace seals, sleeve and O.rings.
piston rod sleeve O.rmg

Oamaged or improperly installed oil Replace 011gauge or cover O-ring, and drain plu{
gauge or crankcase rear cover O.ring,
and drain plug O.ring

Loose drain plug or worn dram plug
O.ring

Broken or worn bearing

Scored rods or sleeves

over pressure to inlet manifold

Oamaged or worn chrome plating of

the cylinders

pumped

Excessive pressure andlor Check pressures and fluid relet temperature; be
temperature of fluid being pumped

Frent edge of piston sharp Replace with new piston

chrome plating of cylinders damaged

causing excesswe wear of cups. May be c
caused by pumping ac]d soluflon

Fore!gn particles In the relet or

discharge valve or wom relet arldlor

—

SOLUTION

Replace ball bearing, Properly temaon belt

Change 011at 3 month or 500 hour ,nterval~
using Cat Pump Crankcase 011 (other approved
011every month or 200 hews) P.N. 06100,

O.ring

Tighten drain plug or replace O.ring

—

Check key and tighten set screw.

Replace bearings

Replace rods and sleeves.

Reduce inlet pressure per instructmns

Replace cylinders

Install proper fdtration cm pump Inlet

sure they are within specifi~d range

Reduce pressure

Do not run pump w!thout water

Install new cups and cylinders Pump only fluid

ompatible with chrome

check for smooth lap surfaces on inlet and

discharge valve seats Dmcharge valve seats

flne 011 stone; damaged cups and discharge
valves cannot be lapped but must be replaced.

pl”rnbl”~

very

—

2. Fkfucticm of Flow. MIX TANK OVERFLOWS

A. Due to increased length of solution hose.

Nt3TE: for every 50 feet of hose, beyond 100

feet in total length, a measurable loss of flow

is experienced. This condition is a result of the
increased friti~on experienced by the water
as it passes through the hose. Therefore, it is
necessary to increase the pressure at the
machine 40 PSI for every additional 50 feet of
cleaning solution hose over 100 feet.

—-—-

WATER FLOW

‘

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

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

3. Plunger not seating properly on the valve. (Remove the 2 screws

which hold the extension assembly to the valve. Do not lose or
drop the screws. Remove the extension assembly. Turn it upside
down. Inspect the plunger for proper seating. If there is no debris
obstructing the valve or plunger, the plunger may be out of adjust-

ment. To adjust, loosen the set screw on tf?e ball nut and move

the ball toward the end of the rod 1H 6“, Retighten set screw.

Place extension assembly back into position. Tighten the two
screws.

2

Chemmal

lnpctor

Sale\old

Control

Valve

....

.4

.! ~ ;,

%

bq

::: ~ > F=” ;

“ .

~: ..%> ‘“

~

9 - Bypass Valve

10- Heater COII
11 - Pressure Guage

12- Incoming Water

Tank Drann

*3 -

I

I

I

li&a; < # ‘

‘8L

.,

,29

‘Q%

‘,3 J$& ~Ap ‘

;-

Chem!cal Flow Meter

6.

Chemical Jug

? ­S - High Pressure Pump 14- To Wand

High Pressure 4 Low Pressure

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

4

2’

CHEMICAL TANK”” “--

TROUBLESHOOTING

NO OR LOW CHEMICAL FLOW

1.

Check that hoses in the tank are secured. Check that the hose
from the top of the flow meter to the side of the mix tank is secured
with no kinks. Check the hose from the bottom of the flow meter to
the them. Jug for kinks or cracks.

2.

Check the foot valve and screen on the end of the hose which
goes into the mix tank. To check this screen for proper function,
remove! it from the plastic hose. You should be able to suck
through the hose barb end, but you should not be able to blow
through the hose barb end. (If you cart not suck through It then
rinse it out with vinegar). When screen is removed the chem!cal
fuel hose should be lifted into a vertical position so the ball in the
foot valve will seat by gravity. (This is only a tempora~ fix for low

water pressure areas.)

3.

Check flow meter for float obstruction.

4.

Check to insure that the adjusting screw on proportioning venturi
is backed out.

is proportioning venturi closed? Soak in warm water or vinegar

5.
solution.

IS incoming water pressure less than 20 PSI.?

6
7

Cracked or defective chemical flow meter?

NOTE: If you are in a low water pressure area and find that the vol­ume of water entering the mix tank is not enough to allow your venturi
to siphon chemical, unscrew the spring from the foot valve screen
and remove the spring.

INABILITY TO ADJUST’ CHEMICAL WITH THE FLOW METER

1.Debris lodged behind teflon seat in flow meter knob.

2. Teflon seat dismounting from flow meter knob.

MIX TANK DOESN’T KEEP UP WITH WATER OUTPUT
1, Check garden hose quick connect assembly screen.

2. Check garden hose and/or feed hose to the mix tank for clog,

kinks or blockage.

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

4. Extension bracket pinching float lever, restricting $uII action of
lever.

5. Valve plunger not opening fully. To adjust, remove the 2

screws

which hold the extension assembly to the valve. (Do not lose or
drop the screws). Remove the extension assembly, turn it upside
down. To adjust, loosen the setscrew on the ball nut. Pface your
thumb on the plunger and press it in 1,’16” and slide the ball nut w)
set screw toward the plunger end 11 6“. Tighten the set screw.

Place the extension assembly back into position. If the tank starts

to overfill, the ball nut is too close to the valve plunger and should

be moved back away from the valve plunger slightly,

PUMP PULSATES WHEN THE TANK KIN A FILL MODE

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.

HEATING SYSTEM

INFORMATION

The propane heater incoporatad in thm equipment is of special de-

sign for use in the carpet cleaning industry. It’s high pressure coIls
and thermostatic temperature control make It slmpte to operate and
reliable. Once the desired temperature
‘on’ and ‘off according to the water temperature within the heater. As
water is used through the cleamng tool, cold water entering the hea­ter will activate the thermostatically controlled propane valve thereby
firing the heater to mamtain a consistent flow of hot
cleaning wand is shut off and the fiow of water through the heater
stops, the heater will continue to burn until the set temperature is at­tained.

It is possible then with this design that the flame maybe on when the
wand is off, Iikewlse, t is possible the flame may be off when the
wand is on.

~~-N This heater IS designed to burn vapor proPane

gas only, Any liquid propane entering the heater may cause damage

to the control valve on the heater. It will also cause improper burning

and a soot build-upon the coils. Therefore, it is necessary to shut off
the heater and close the valve at the tank between cleaning loca­tions. Failure to do this allows sloshing liquid to enter the vapor feed
line to the heater.

IS set, the heater WIII then go

water. Once the

SOLUTION REVERSING FROM MIX TANK TO CHEMICAL JUG

1. Anti-siphon screen removed from chemical jug hose.

2. Debris in anti-siphon screen.

Overfilling of the propane tank will cause many problems. To avoid
this, advise the attendant filling the tank

nottofill the tank aver

80”/o. When filling the tank, watch the 10%, valve and immediately

16

stop filling when white liquid starts spurting from the 10°% valve.

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.

I

To avoid restriction of air flow at 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 condi­tion exist, operator must depress the pilot button for 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.

To

C. TO ACHIEVE PROPER CARPET CLEANING

TEMPERATURE:

1. Complete procedures A & B

2. Wtth 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 prior to 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.TO SHUTDOWN HEATER:

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

-2. Turncleaningwandonfor3to 5minutesto
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.

PILOTBURNER

FIG

ADJUSTMENT

1. Remove pilot adjustment cap@

HEATER - OPERATING
INSTRUCTIONS

Heater must be fWecf with water

KZ@@l!l

. -- --- -- -.. --

A.

lU=l Atf I PILUI:

1.

Adjust thermostat control knob on unitrol to desired setting.

2.

Adjust upper dial to
Depress pilot button.

3.

4.

Depress sparking button to light pilot.

IF PILOT FAILS TO LIGHT:

Is propane tank full?
Is propane tank valve open?
Has air been properly bled from propane line?

WHEN PILOT LIGHTS:

Wait ten seconds, depressing button manually, then
release button.

B. TO LIGHTMAINBURNER:

1.Turn upper knob to “on” position. Flame will come on,

If you do not get the burner to flame, the pilot has expired. You
must turn upper dial to “off’ position. Do not attempt to re-light

the pilot for 60

instructions as above (TO START PILOT), 1 through 4.

OR,

Water may already beat controlled temperature.

Flame will turn off when thermostat senses maximum

temperature.

prkwtokmjthg.

pilot position.

seconds. To light the maih burner, repeat

2. Adjust pilot key to provide -­properly sized flame

3. Replace pilot adjustment cap

ALLENHEADPIPEPLUG G
CANBEREMOVED

FORMONOMETERINSERTION

TOREADPROPANEOUNCES.

o

HEATER

TROUBLESHOOTING

● EXCESSIVE HEAT

● FLAMES PROTRUDING OUTSIDE

THE LOWER OPENINGS

CAUSE AND/OR SOLUTION:

1.

Thermostatic control dial set too high

A. Turn dial to lower setting

2. Maladjustment of propane regulator. NOTE: Propane regulators

are factory preset and may be readjusted by authorized

personnel.
A. Contact manufacturer to determine correct procedure.
B. Have your local propane dealer use a monometer at the

unitrol 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 ail 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 light will not ignite. NOTE: Do not use a needle or pinto clean
pilot orifice - use compressed air or solvent only.

A. Verify propane reaching igniter. NOTE: A kinked or crushed

hose may impede propane flow.
B. Remove and clean orifice.
C. Verify igniter spark is operating correctly.

17

VACUUM SYSTEM

INFORMATION

The vacuum blower incorporated in this machine is a positive dis­placement lobe type, manufactured by Fuller Company. The perfor­mance and life of this unit is greatly dependent on the care and prop­er mainten ante it receives,

VACUUM TANK FILTER BAGS

Hydra-Master filter bags are designed to trap all of the~nt, ~a~d~nd
dirt that would normally collect at the bottom of vour vacuum tank.
The use of these bags, jf emptied at the end of eac’h job, will eliminate
the build-up of much of the debris in the tank and avoid a mess on the
customer’s driveway or street. The drawstring top of these bags is
designed to be tied to the incommg dirt~ water inlet in the vacuum
tank.
To re-order bags use part number

649-028

Because of the close tolerances between the lobes and housing of
the vacuum blower, solid objects entering the inlet will damage the
internal lobes, gears

To prevent 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 beirm run for

test purpose and the vacuum inlet on top of machine is op&

To protect the vacuum blower from overloading and damaging itself.

there is a vacuum relief system installed on the vac tank lid. When
the vacuum tank inlet is completely sealed off, a maximum of 14 HG
will be attained. A hole on the top blower pipe elbow acts as the lubri­cation point; at the end of each day, LPS 1 or WD-40 is sprayed in be­fore shutting down the machine. See blower lubrication illustration. If
you fail to lubricate the vacuum blower daily, rust deposits and mois­ture will decrease the life of the vacuum blower.

Read 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.

and bearing or direct drive coupler.

VACUUM FLOW DIAGRAM

VACUUM RECOVERY TANK

~

BAG

~ <’WATER TO VACUUM TANK

BLOWER

ELBOW ON TOP OF

VAC””MBLOVVE13

INCOMING DIRTY

M

BAG

LUBRICANT

HOSE TO VAC TANK

S/S FILTER

VACUUM
BLOWER

w

w

A

ti

SPRAY LUBRICANT INTO VACULfM RELIEF HOLE FOR 3

TO 5 SECONDS, THEN IMMEDIATELY SHUT OFF

MACHINE.
USE ONLY LPS 1 OR WD-40 MOISTURE DISPLACING
LUBRICANTS.

18

WARRANTY

FULLER warrants products of its manufacture to be fre~ from defects in material and workmanship if properly

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

FULLER any other liability in connection with any of FULLER’S products.
This warranty shall extend for two (2) years 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,
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. point of shipment,
any part or parts of products of FULLE R’S manufacture, which within the specified warranty period shall be proved to

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 Iim;ted 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

MODE L

SERIAL #

FULLER’S warranty shall cease to be in effect. No allowance will be

FULLER COMPANY

2966 East Victoria Street

Compton,

California 90224

FACTORY AUTHORIZED SERVICE CENTERS

FOR SUTORBILT PRODUCTS

FULLER COMPANY / COMPTON DIVISION

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

BAYLISS MACHINE& WELDING CO.

ASSOCIATED TECHNICAL SERVICES, INC.

SCHWARZ FOUNDRY COMPANY

213/636-9821 or 636-7600

2901 8TH AVENUE NORTH

BIRMINGHAM, ALABAMA 35203

205/323-6121

BARNEY’S PUMPS INC.

3907 HIGHWAY 98 SOUTH

LAKELAND, FLORIDA 33802

81 3/686-8195

1229 WAIMANU STREET #21

HONOLULU, HAWAII 96814

808/637-1 206

WM. W. MEYER & SONS

8261 ELMWOOD AVENUE
SKOKIE, ILLINOIS 60076

31 2/673-0312

GREGORY-SALISBURY & CO.

805 SOUTH FRONT STREET

NEW ORLEANS, LOUSIANA 70130

504/524-5207

2001 WEST FORT STREET

OETROIT, MICHIGAN 48216

3131486-1880

FULLER CO MPANV

A GATX COMPANY

.2966 EAST VICTORIA STREET

POST OFFICE, E30X 4308, COMPTON, CALIFORNIA 90224
TEL: [2131 639-7600 [2131 636-9821 TELEX: 67-4607

m

lY-

0

19

FULLER COMPANY / MANHEl M DIVISION

236 SOUTH CHERRY STREET

MANHEl M, PENNSYLVANIA 17545

7771665-2224

CAROTEK INCORPORATED

640 SAM NEWELL ROAD

MATHEWS, N. CAROLINA 28105

704/847-4406

DYNMAC CORPORATION

7925 E. 40TH STREET

TULSA, OKLAHOMA 74145

918/627-0110

OLIVER & LAUGHTER EQUIPMENT CO.

10450 WESTOFFICE

HOUSTON, TEXAS 77042

7131977-2577

ELECTRIC CRAFTS LTD.

3936 EDMONTON TRAIL N.E.
CALGARY, ALBERTA T2E 3P6

4031276-8676

PUMPS & POWER LTD.

1380 NAPIER STREET

VANCOUVER, B.C., CANADA

6041255-4341

GATX-FULLER LTD.

721 PROGRESS AVENUE

SCARBOROUGH, ONTARIO, CANAOA

4161438-6540

LUBRICATION

At ttse gear end the timing gear teeth are lubricated by being partially
submerged. The gear teeth serve as oil slingers for gear end bear­ings. At the drive end the bearings are grease lubricated.

FILLING PROCEDURE

Remove square head vented oil fill plug (A) on gear end. Remove oil

level plug (B) located in the head plate. Fill

out of the oil level hole (B).
Use lubricants as listed.
Add fresh oil as required to maintain proper level. The oil should be

drained, flushed and replaced every 1500 hours or

inspection so indicates. The oil drain plug is at (C).

NOTE: Older units may have the oil fill level and drain holes located
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 grease fitting (D) at each bearing. When regressing, the old
grease will be forced out of the vents during operation. To prevent
damage to seals, these vents must be kept open at all times.

LUBRICATION lNSTRlf CTIONS FOR

OIL LUftRICATEO GEARS ANtr BEARINGS

Add fresh oil as required to mamtain proper

level. Drain and refill every 1500 hours of

operation under normal kervice, more fre-

quently when required. Use a good quality oil.

BLOWER

OISCHARGE

, TEMPERATURE U.S. A.*

-40°to 320 F

(-40°to r

32°to 1000 F

OOto 38° C)

(

100

“to 275ok

38°to 135°c)

over275°

(

●ln applications with extreme variations in

135”C) ‘*E 50

ambient temperature a 20W 50W multlple
viscosity oil is recommended.

FOR GREASE LUBRICATE BEARINGS

Service every 500 hours of operatton

OIL

GRAOE CEN;~;~KES

c) ‘AE‘ow

SAE 20

SAE 40

F

gear case until oil drips

more frequently if

OIL VISCOSITY,

45

100

200

250

VACUUM BLOWER
TROUBLESHOOTING

PROBLEM:

e~o$s OF

CAUSE ANIXIR SOLUTION:

1. Collapsed vacuum hose between blower and vacuum tank.
A. Remove and replace hose.

is required for replacement.

VACUUM

NOTE: A special reinforced hose

2. Clogged stainless steel filter.

A. Remove and clean or replace stainless stea?lfilter.

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

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

B. Replace valve.

5. Fractured weld on vacuum tank.

A. Re-weld as required or replace tank.

6. Collapsed

A. Reshape hose if possible and/or eliminate kinks.

7. Plugged vacuum hose.
A. Remove obstrutilon by reversing the vacuum hose.

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

9. Worn end plates or lobes in vacuum blower.

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

10. Loose coupling system between engine and blower.
A. The set screws may come loose causing blower to stand still

valve.

or kinked vacuum hose.

a qualified technician.

while engine may be turning properly.
blower is seized or making a knocking noise, your vacuum loss

is not caused by a bad blower.

NOTE: Unless the

iPFKIHUEM:

@

iBLIOWE!3[SSEIZED

CAUSE AND/OR SOLUTION:

1.

Rust.

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

attempt to rotate vacuum lobes.

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, remove coupling

element, then run engine for a few seconds. This
won’t confuse similiar problems.

NOTE: The above mentioned, rust, foreign matter and seizing are
often caused from foam traveling through the blower.

way you

PROBLEM:

e NOISE

CAUSE AND/OR SOLUTION:

1. Loose Direct Drive Coupler.
A. Examine coupler for defects and retighten lock bolts.
B. Replace coupler boot if it is either torn or punctured.

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

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

3. Lack of Lubrication. NOTE: Permanent damage may have
resulted from lack of lubrication.

A. Lubricate as specified by applicable vacuum blower manual.

4. Worn bearings
A. Remove and replace bearings as required. Must be

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

filter is provided in vacuum inlet located in vacuum tank to proteact
vacuum blower components.

A. Disassemble vacuum blower and remove foreign material.

6. Loose or missing mounting bolts.
A. Tighten or reinstall mounting bolts.

20

INVACUUM BLOWER

must be accomplished by a qualified technician.

components. Replacement of components must be accom-

plished by a qualified technician.

See index.

accomplished by qualified technician.

NOTE: Disassembly should be accomplished by qualified
technician only. Replacement of worn parts is recommended
if this procedure is necessary.

~.r.u-

,.,..

Briggs & Stratton

OPERATING

)

AND MAINTENANCE

INSTRUCTIONS ,,.

MODELS

401400 to 401499

421400 to 421499

IN THE INTEREST OF SAFETY

DO NOT RUN ENGINE AT EXCESSIVE SPEEDS. Operating an engine at excessive speeds increases the hazard of personal injury.
DO NOT TAMPER WITH PARTS WHICH MAY INCREASE THE GOVERNED SPEED.

For rotary Iawnmower safety,

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 engine based on the length and design of the cutter blade and
design 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 a stove, furnace, water heater which utilize a

pilot light, or devices that can create a spark.

If gasoline is accidentally spilled, move machine away from area of spill and avoid creating 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 monoxide, an odorless and deadly poison.

TO 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 WITHOUT A MUFFLER OR TAMpER WITH THE EXHAUST SYSTEM. Damaged
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 in doubt, contact your Authorized Briggs & Stratton

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 periodically
to be sure it is functioning effectively. To purchase a new muffler, see SERVICE AND REPAIR INFORMATION.

WARNING: If this engine is not equipped with a spark arrester and is to be used on any forest 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 Serwce Center

for spark arrester muffler options.

A. N.S. I. Standard Safety Specifications for Power Lawn Mowers specify a maximum blade tip speed of

mufflers or spark arresters could

Service

IN THE INTEREST OF ENVIRONMENT

SERVICE & REPAIR INFORMATION

If service or repair is needed, contact an Authorized Efriggs &
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 is equipped 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

Pages” under “Engines, Gasoline” or “Gasoline

Engines.” He is one of over 25,000 authorized

n

@owmEfss

dealers available to serve you.

BRIGGS & STRATTON

v’

e

This illustrated book includes common

specifications, and detailed informa­tion covering the adjustment, tune-up
and

repair procedures for Twtn
Cylinder models. It is available from
any Authorized Bnggs & Stratton
Service Center, Order as Part Number

271172.

.

BRIGGS & STRATTON CORP.

Milwaukee, Wisconsin 53201

21

.WL

G!G:

.-,4

):+>.

BEFORE STARTING

All? CLEANER

8LOWER

HOUSING

e~:

‘“”~

—-------

CARBURETOR

MANIFOLD

EXTENDED

OIL FILL

“? MOOEL, TYPE AND

COOE NUMBER ON

1

IDE COVER

READ THE OPERATING lNSTRLJCTIONSOF

THE EQUIPMENT THIS ENGINE POWERS

Use a high quallty detergent 011classified

SD, SE or MS “ Detergent oils keep theengtne cleaner and
retard the formation of qum and varnish deoosits. Nothlna

should be added to the-recommended 011

RECOMMENDED SAE ‘vISCOSiTY GRADES

I

1

980s

I

I I

20

–lo

EXTENOE

OIL FILL

8

I

20

4,

‘>

F 20 0

“c 30

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

“If not avatlable, a synthetic oil may be used hawn~ 5W-20, 5W-30

or 5W40 wsco.wty.

FILL CRANKCASE WITH OIL
Place engine level. Clean area around

remowng d[pstick.
EXTENDED OIL FILL. Remove cap and dipstick. FILL TO

FULL MARK on dipstick, POUR SLOWLY. Capac!ty 3 pints
(142 liters). When checking ml level, push dipstick
assembly firmly but slowly until cap bottom on tube. DO
NOT OVERFILL. Dipstick assembly must be securely

assembled into tube at all times when engine is operating.

I

1~~

*

’10

10

b

“For Service SC<

1

WI 80

2a 30

oil fill before

~

103

4’0

.

/w@’

OIL D“RAIN

PLuG

EL~CTRIC

STARTER

MOTOR

5

L__-4”1 I

I

CHARGE BATTERY

Charge battery before use on engines equtpped with
(OPTIONAL) 12 volt electric starter motor. See equipment

manufacturers’ recommendations,

FILL FUEL TANK
Use clean, fresh,

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 lean.

22

“regular grade leaded or low-lead”

STARTING

OPEN FUEL VALVE on engines so equipped.

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

1

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
speed control lever to “RUN,” “FAST” or “START’
p’osition if so equipped.

CHOKE

PULL OUT TO CHOKE

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

l.=

#

DEPRESS

BUTTON +

1

% %

1

When equipment is not in operation, provide protection
from direct exposure to weather,

COLD WEATHER STARTING HINTS

1. Be sure to use the proper oil for the temperature
expected.

2. Declutch all possible external loads.

3. Set throttle at part-throttle position.

4. A slightly richer fuel mixture, obtained by turning
carburetor needle valve 1/8 turn counterclockwise, will
usually improve cold starting.

5. A warm battery has much more starting capacity than a
cold battery.

6. Use fresh winter grade fuel.

NOTE: Winter grade gasoline has higher volatility to
improve starting, Do not use gasoline left over from
summer.

STARTER

SWITCH

I

Of F

t

[\

J

TO START ENGINE

DANGER: ALWAYS KEEP HANDS AND FEET CLEAR OF
MOWER BLADE OR OTHER ROTATING MACHINERY.

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.

TO STOP ENGINE

Turn key to “OFF” ~osition.

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 SIJ RE OIL LEVEL IS MAINTAINED.

CHANGE OIL after first five hours of operation. Thereafter
change oil every 25 hours of operation. Remove oil drain
plug and drain oil while engine is warm. Replace drain plug.
Remove dipstick and refill with new oil of proper grade.
Replace dipstick.

23

\

‘-s:-:”---”

GENERAL INFORMATION

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

MODEL SERIES 401400 to 401499

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

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

Displacement . . . . . . . . . . . . . . . . ...40.00 cu. in. (656.0 cc)

Horsepower . . . . . . . . . . . . . . . . ..l6 l-fPMax. Q3600 RPM

Torque (Ft. -Lbs.) . . . . . . . . . . . 25.8 Max, Q 2700 RPM

MODEL SERIES 421400

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

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-9/32’’ (57.94 mm)

Displacement . . . . . . . . . . . . . . . . ...42.33 cu. in, (694.0 cc)

Horsepower . . . . . . . . . . . . . . . . . . . . . . 18 HP Q3600 RPM

Torque (Ft,-Lbs,) . . . . . . . . . . . . . . . . . . ..28,6 Q2600 RPM

The horsepower ratings listed above are established in
accordance with the Society of Automotive Engineers Test

Code -J607, For practical operation, the horsepower
loading should not exceed 85 °/oof this rating. Engine power
will decrease

sea level and 1°/0

In some areas, local law requires the use of a resistor spark
plug so as to suppress Ignition signals. If an engine was
originally equipped with resistor spark plugs, besureto use

the same type of spark plugs for replacement.

Spark Plug Type
Long Plug
Resistor Long Plug

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

Ignition Point Gap...........,,,, , . . . . . .. 020’’(.51 mm)

Intake Valve Clearance*” 004’’ -.006”( 10 -

Exhaust Valve Clearance”-. 007”- 009”( 18- 23mm)
“’w}th valve spring installed.

WARNING For electrical safety always remove cable from
negative (-) side of the battery before attempting any
repairs or maintenance

BRIGGS & STRATTON ENGINES ARE MADE UNDER ONE OR MORE OF THE FOLLOWING PATENTS

28960

2999491 3 194224

2.99’2562 32369.37
3114851
3 118,433

3i,40/0 for each 1,000 feet (304,8 m) above

for each 10” above 60” F (16° C).

TUNE-UP SPECIFICATIONS

Champion Autoiite
J-8
RJ-8

3 149618 327’6439

3242741
3,252449

3305 ,!23
3457 80J 3572307
3465 :40

to 421499

3526146

357.? 218

3625492

295

306

1.5mm)

3625071 3831 268

J 650354 3882336
3745393
3738345 3961 724

Engines to be stored over 30 days should be completely
drained of fuel to prevent gum deposits forming on
essential carburetor parts, fuel filter and tank.

NOTE: The use of a fuel additive, such as STA-BIL, or an

equivalent, WIII mini mlzetheformation of fuel gum depos!ts

during storage. Such an additive may be added to the

gasollne in the fuel tank of the engine, ortothegasoline$n a

storage container.

a, ‘All fuel should be removed from the tank. Run the engine

b.

c.

d

6 e.

J 901 199

LW. L*7 Smlmn -

1 I , =-----J

Tri-Circuit

STORAGE lNSTRIJCTiONS

until It stops from lack of fuel. The small amount of fuel
that remains In the sump of the tank should be removed

by absorbing it with a clean, dry cloth,

While engine IS still warm, drain 011 from crankcase,

Refill with fresh oil.
Remove spark plugs, pour oneounce (29 6cc)of engine

011 Into each cylinder and crank slowly to dlstnbute 011

Replace spark plugs.

Clean dirt and chaff from cyllnders, cyllncier head fins.
blower housing, rotating screen and muffler areas

Store In a clean and dry area

3968854

.1971 353
.) 991 152
4 168288

,_-..

I ,, G,*

-----1

I

24

CAUTION: Petroleum solvents, such as kerosene, are not

—

I

I

I

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 more often under dusty condi-

tions.

Remove knob and cover,

1.

2.

Remove foam pre-cleaner by sliding it off the paper
cartridge.

3.

a. Wash foam pre-cleaner in kerosene or liquid deter-

gent and water.

b. Wrap foam pre-cleaner in cloth and squeeze dry.

c. Saturate foam pre-cleaner in engine oil. Squeeze to

remove excess

4.

Install foam pre-cleaner over paper cartridge. Re-

assemble cover and screw down tight.

011.

to be used to clean cartridge, They maycausedeterioration

of the cartridge, DO NOT OIL CARTRIDGE, DO NOT USE
PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE.

CLEAN COOLING SYSTEM — Grass, chaff or dirt may
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, overheating and engine damage.

Clean more often if necessary.

-“’”

~

@zz2Ez::HER

Yearlv or everv 100 hours. whichever occurs first. remove
pape; cartridgb. 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.

~u~

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.

25

ADJUSTMENTS

CARBURETOR ADJUSTMENTS

Minor carburetor adjustment may be required to com­pensate for differences in fuel, temperature, altitude
or load.

INITIAL ADJUSTMENT — Turn idle and needle valves
clockw!se until they just close.

CAU’Tl ON: Valves may be damaged by turning them in too
far.

Now open needle and idle valves 1’/2 turns counter-

clockwise. This tnitlal 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 cleaner on engine. ‘

NOTE: Governed idle must be adjusted on all engines for
proper operation, The smaller spring keeps the engine on
governor, even at idle speed. If moderate loads are applied
at idle, the engine will not stall. Governed idle speed should
be no lower than 1100 RPM.

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 vaive ‘4 turn

counterclockwise.

If engine does not accelerate properly, readjust needle

valve approximately ‘4 turn counterclockwise (richer).

CONTROL 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 to “choke” position, The

carburetor choke should be closed.
TO ADJUST CHOKE:

Place remote control lever on equipment In “CHOKE”

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

!--

1>

“ IDLE SPEED

ADJUSTING THROTTLE

SCREW

/ “M,:;:RE N:::: -

1 FvFR

VALVE (HIGH SPEEO]

FINAL ADJUSTMENT PROCEDURE
Idle Valve Mixture

governor speed control lever in governed “IDLE”

Place

position, f-told throttle lever

against idle stop and set idle
speed adjusting screw to obtain 1400 RPM. Turn idle valve
slowly clockwise (lean mixture) until engine misses or
RPM slows. Then turn idle valve % turn counterclockwise.

Governed Idle

Hold throttle lever against idle speed adjusting screw.
Adjust idle speed screw to obtain 900 RPM. Release the
throttle. With governor speed control lever In governed
“IDLE” position, 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.

OECREASE

I

CHOKE

CLQSEO

CASIN

CLAMP
SCFiEW

.\-

GOVERNOR SPEED CONTROL ADJUSTMENT
Theacceptable operating speed range IS 1800to 3600 RPM,

Idle speed IS 1400 RPM The manufacturer of the equip­ment on which the engine IS used, specifies the top

governed no load speed at which the engine may be

operated DO NOT EXCEED this speed.

Engine speed IS controlled by movement of the control
lever U,ove control

lever on equ{pment, “D”, 10 slowest

engine speed possible Throttle lever on carburetor should
touch Idle speed ad)ustlng 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 ad]ustlng screw on carburetor Retlghten casing

clamp screw “C “ Move

control lever “D” to “FAST’(

posltlon If engine exceeds equipment manufacturer’s
maximum governed no load RPM, move lever” D” to obtain
recommended speed Bend tang “6” to touch

CAUTION Throttle lever on carburetor MUST touch Idle

I

speed adlustlng screw when equipment control lever IS In

slowest posltlon

lever “A “

26

BRIGGs a STRATTON ENGINEWARRANTY pOLICY

FOR INDUSTRIAL/COMMERICAL (l/C) SERIES AND SNO/GARD ENGINES ONLY

EffectiveJanuary’1,1983

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 our Service Accounts are handled in a prompt routine
manner with no question regarding their validity. However, some requests for warranty are received which appear not justified.
In these cases, though 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 caused by the equipment rather than the engine, investigation is made to

determine the applicability of warranty.
BRIGGS & STRATTON WARRANTY covers only DEFECTIVE MATERIAL and/or WORKMANSHIP.

LIMITED WARRANTY FOR l/C SERIES AND SNO/GARD ENGINES ONLY

“For two years 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.

“For five years from date of puchase, Briggs & Stratton Corporation will replace for the orginal purchasers, free of
charge, any part, or parts of the MAGNETRON@ Ignition System (excluding the spark plug), 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, so as to result in the loss of ignition. This is the exclusive remedy.

“All transportation charges on parts submitted for replacement under this 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.’ THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRAN­TIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
LIMITED TO ONE YEAR FROM PURCHASE AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL
IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND
ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some jurisdic­tions do not allow limitations on how long an implied warranty lasts, and some jurisdictions do not allow the exclu­sion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to
you. This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction

to jurisdiction.”

Briggs & Stratton Corporation

A%!!zf#%j#!

F.P. Stratton, Jr.
President and Chief Executive Officer

v

NO REGISTRATION (WARRANTY) CARD IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON
ENGINES. FILL IN THE REQUIRED INFORMATION AND RETAIN FOR YOUR RECORD:
(Engine

Engine Model No.

Dealer Purchased From

Type of Equipment

Name or Trademark of Equipment Manufacturer

If warranty service is needed contact your nearest Authorized Service Center. For prompt attention your center 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 the Service Center on a warranty claim, ask the Service Center to submit all suppotiing facts to
the Factory for review. If the Factory decides that your claim is justified, you will be fully reimbursed for those items accepted
as defective.

Model, Type and Code Numbere ere Located on the Blower Housing, Cylinder Head Shield or Backplane.)

Type No.

Code No.

27

To avoid misunderstandirms which miciht occur between enqine owners and authorized Brims & Stratton service accounts,

we are listing some of the ~auses of en~ine failure,

where rep=ir or replacement is NOT cover~~ by Briggs & Stratton warranty.

NORMAL WEAR:

Warranty wilt not cover repair where normal use has exhausted the life of a part or engine. Engines, like all mechanical

diwices, need periodic parts replacement and service to 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 applications, such as

tillers, trash pumps, rotary

mowers, are very often used in dusty or dirty conditions, which can cause what appears to be

premature wear. Such wear, when caused by dirt, dust, spark plug cleaning grit or other abrasive material, which has entered

the engine because of improper maintenance, is not covered by Warranty.

ABUSEOR NEGLECT

Bent or broken crankshafts: Such damage is normally the result of abuse, such as striking a solid object with the cutter

1.

blade on a rotary lawn mower, and is not covered by Warranty.

Engine repairs requied from the use of contaminated or stale fuel are not covered by Warranty, Such failures would in-

2.

elude sticking valves, and carburetors and fuel pipes which are clogged by gum deposits which form through the use of

stale fuel. Always use clean fresh regular gasoline.

Parts which are scored or broken because an engine was operated without sufficient lubricating oil, the proper grade of

3.
lubricating oil or contaminated lubricating oil are not covered by Warranty. Check oil level at least every five hours and
refill when necessary. Change oil at recommended intervals.

Damage caused by overheating or overspeeding is not covered by Warranty. Overspeeding or overheating occurs if the

4.
cooling fins become p~ugged with dirt, grass or debris, or if an engine is operated in a confined area without su~lcient
ventilation. Clean fins on the cylinder, cylinder head and flywheel regularly.

Damage or wear caused by dirt which enters the engine because of improper air cleaner maintenance is not covered by

5.
Warranty. Clean and re-oil the air cleaner regularly.

Damage or wear caused by grit from blast cleaning sprak plugs is not covered by Warranty. We do not approve of cleaning

6.
spark plugs on an abrasive blast cleaning machine, since grit can remain in the plug, and later enter the engine.

Warranty does not cover the tune-up or adjustment of an engine unless the need for such repair is the result of defects in

7,

material or workmanship or both. If equipment is assembled and adjusted by the owner, the engine Operating and

Maintenance Instructions are sufficiently clear to permit the average owner to make minor adjustments. Such minor

adjustments are NOT covered by Warranty.

Broken parts, which result from excessive vibration caused by loose engine mounting, loose cutter

8.

unbalance, improperly attaching equipment to engine crankshaft, overspeeding or abuse in operation, are not covered by

Warranty.

Repair or adjustment of associated parts or assemblies such as clutches, transmissions, remote controls, etc., which are

9

not of Briggs & Stratton manufacture will not be covered by Briggs & Stratton Warranty.

10,

Only ORIGINAL 13riggs & Stratton parts, or parts approved by Briggs & Stratton may be covered by Warranty,

blades, blade

WARRANTY IS AVAILABLE ONLY THROUGH SERVICE CENTERS WHICH HAVE BEEN AUTHORIZED BY THE BRIGGS

& STRATTON CORPORATION. YOUR NEAREST SERVICE CENTER IS LISTED IN THE YELLOW PAGES OF YOUR

TELEPHONE INRECTORY, UNDER “ENGINES, GASOLINE” OR “GASOLINE ENGINES.”

28

ENGINE

An engine instruction brochure is included with this manual (see,

index) which may assist you in resolving engine related problems.

PROBLEMS:

● ENGINEFAILS TO START

o ENGINERUNS ROUGH
o ENGINEBACKFIRES

● ENGINEFAILS TO ACCELERATE

● ENGINEREDUCES SPEED TO LOW RPM

UNDER LOAD

CAUSES AND1ORSOLUTION:

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

not connected.

Blown master fuse.

2.

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, teflon hose). This may be taken
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.

quick disconnect inside the truck

A

Carbon build-up may be excessive if carb. or valves are
improperly adjusted, engine Rl%l too low, improper sparkplug
gap.

B,

Remove cylinder heads and eliminate carbon build-up with
wire brush:

12. Incorrect timing
A. ~iming may become 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

15. Low oil level or malfunctioning oil pump

A. Oil pressure 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.

29

a. tlectncal snort m wlrmg system

ELECTRICAL SYSTEM , ,Oorgroundmnnection

The entire electrical system operates on 12 volts DC which is pro­vialed by a battery. Battery levels are sustained by a 3 amp alternator

designed within the engine.

NOTE: When new battery is installed insure it is properly charged
before installation or damage to the charging regulator may occur.

A. Examme electrical systems for bare wires.

A. Examine terminal and remove corrosion if necessary,

6. Follow ground wire from (-) of battery to where it grounds at the
frame. If it is grounded to painted steel then scratch some of
the paint off to allow for circuit to be completed through the
steel.

PROBLEM:

*

LOW BA’TTERYVOLTAGE

CAUSE AND/OR SOLUTION:

1. Defective battery
A. Remove and replace.

2. Corroded battery terminals
A. Clean terminals and battery posts.

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

4. Loose wiring within electrical system.
A. Examine all terminal connections and verify that they are

secure. NOTE: Give special attention to ignition switch
terminals.

INOPERATIVE HOUR METER

CAUSE AND/OR SOLUTION:

1. Time is not advancing correctly
A. Verify 12 volts DC is available at the hour meter with the

ignition switch turned on. This can be accomplished with a volt

meter or a test lamp.
B. Remove and replace hour meter if 12 volts is available.
C. A nylon gear within the clock may have been jammed 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,

TEMP GA

‘!, ~“o

~.. .

,—

I

BLACK

BOB CAT 2/290

ELECTRICAL DIAGRAM

!~ wOUR METER

BLUE

—

START SOLENOID

I I I

WHITE WIRE GOING TO TERMINAL

85 AND BLACK WIRE TO 87A

SHOULD BE REVERSED

1

30

MACHINE

INSTALLATION

PROPANE TANK PLUMBING

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

recovery tank to be positioned. First, the standard way with the tank
directly alongside the machine. Second, with the tank across the
back of the machine as shown below; this location is most space effi­cient.

Whichever way you select, make sure the tank and machine are sec-

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

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

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

ing.

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

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

propane tank or a portable gas can

an open flame type and could cause a fire or explosion.

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

emergencies.

It is recommended by the manufacturer that the

away from the job site.

Never operate this machine with a

inside the truck. The heater is

portable

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31

WATER SOFTENER

Many areas of the country have an excess of minerals in the water
which results in what is commonly called “hard water”. These miner­als tend to adhere to the insides of heater coils and other parts of the
machines causing damage and a loss of cleaning effectiveness.

Reports from several of our machine users commending the results

of the use of water softeners in conjunction with their machines
prompts us to recommend the procedure to everyone in a “hard
water” area.

The relatively low 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 softener will also increase the effectiveness of
the cleaning chemical being used, therefore, less chemical will be
needed.

Contact a water softener distributor in your area for information on the

rental of a simple water treatment unit to carry in your truck. Be sure
to change the water softener in accordance with the capability of the
softener. 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 750 gallons of water, therefore, the softener would be changed
every 6 working days for maximum softening.

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32

OPERATING

INSTRUCTIONS

START UP

1:

Perform daily aperiodic maintenance as specified by the owner’s
manual.

2.

Connect ail required hoses.

3.

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

4.

Caution: Mix tank must be full prior to ignition.

5.

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

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

6.

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

300 Psi.

7.

the heater. Thaw the heater and check for leaks.
Turn on burner, adjust dial to normal or slightly below for 200

8.

9.

SHUT DOWN

1.

2.

3.

4.

Turn on cleaning tool to flush chemical from unit hoses and

5.

6.

7.

8.

NOTE: Recommended carpet cleaning pressure is 250-

setting.

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

Once

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

Deg. F.
Commence cleaning operation
NOTE: Chemical flow meter set 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,
you will be using what most chemical manufacturers recommend
at 5 GPH.

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 flow meter.

cleaning tool.
NOTE: If freeze guard is necessary, perform steps 1 & 2 of freeze
guard procedure at this time.
At this time, the blower should be lubricated with LPS 1 or WD 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.

MACHINE CONTROL PANEL

HOUR M!3ER

INCOMING

wATER CONNECTION

‘“ Q ~~-” ~

BLOwEfl,ENGINE EXHALW HIGHPRESSURE

1

CLEANING SOLUTION
CONNECTION

I

ADJUSTABLEHIGH PRESSURE
BYPASS VALVE

‘(CLOCKWISE TO INCF4EASE)

OPTIONAL

~ LEG HOLES ~,x TANKDRA,N

I

!

PETcOCK VALVE
&HOSE

OPERATION PRECAUTIONS

MACHINE ADJUSTMENTS:

Although this unit has been factory adjusted, it may require addi-

tional adjustments to achieve optimum performance; i.e. altitude

may require carb adjustment and ambient temperatures may require
heat control adjustment. When required, consult an authorized rep­resentative.

ENGINE COOLING:

~ Units employing air cooled engines must not
be incapacitated within a van with doors and windows closed. Ex-

cessive” temperatures within the engine will result in premature en­gine failure and a compromise of applicable warranty.

LEVEL OPERATION:

_ Duringoperation, vanortrailermustbeparkedon
level ground not to exceed + or – 10 deg.. Failure to insure proper
leveling may prevent proper internal lubrication of engine, vacuum
andlor high pressure components,

FREEZE PROTECTION:

_ Mother nature gives little warning astohercold

spells. Therefore, protecting this equipment from freezing will save
costly down-time. Placing an electric heater in the truck or parking
the truck indoors, 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.

33

Never light the heater if you smell a strong odor of

HEATER:

IznmiEl

boxes, chemical jugs, etc., as this will block the flow of air required for

a clean burning heater.

Never pile things around the heater, i.e. hoses,

OPEN FLAME:

kw!!2il Fl

therefore, do not remove engine gas line while troubleshooting or
store any flammable material in the truck with heater operating.

emember that this heater is an open flame,

FREEZE PROTECTION

Any freezing of this machine is not covered by warranty and during

the colder months of operation, careful protection should be of ut-

concern.

most

THE FOLLOWING PRECAUTIONS ARE RECOMMENDED:

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

1.
frozen the night before, including hoses and wand.
Insulate the garden hose from the cold ground by runmng It

2.
through an extra 1 % inch vacuum hose.
Leave truck doors closed until time cleaning begins, then open

3.
slightly for ventilation of air cooled engine.

4.

On extremely coid days propane does not vaporize as quickly,
therefore, venting the warm exhaust over to blow on the propane
tank will stabilize the propane flow. (This is necessary if you
notice a drop in heat or a low burning flame in the heater.)

In colder climates, insulating the truck walls and floor boards will

5.
help protect the unit.

Don’t procrastinate during the cleaning operation or the hot water

6.

solution line will also freeze on the ground.

should be insulated in extremely cold climates.

Whenever ~ossible. the truck and machine should be stored in a

7

heated garage at night or over the weekend. if not possible, place

a 1500 watt electric heater inside the truck, aimed directly at the
machine, Never use a propane heater-it causes excessive mois­ture on the truck ceiling and the possibility of it going out is higher.
If the machine and truck are left outside with a heater, you should
first drain all possible water from the machine cleaning tools and
hoses. (They freeze also.)

TO DRAIN THE MACHINE. FOLLOW THESE STEPS:

A.

Before shutting off the machine, remove the chemical line from
the chemical jug and place in a mixture of 50/50 anti-freeze and
water. Wtth the cleaning tool on, allow mixture to fill chemical sys­twn back to the chemical mix tank.

Loosen the petcock valve on your bypass drain hose and allow

5.
the water to drain thoroughly from the mix tank.

To remove the water from the heater and pump use the freeze

c.

guard kit which is a small air compresor that can be plugged into
the dash board lighter in the truck, or air at the gas station. Using
the correct connectors, first blow air into the high pressure solu­tion male quick connect. This will force the water through the
heater back through the pump and into the chemical mix tank to

be drained out through the petcock valve to the ground.

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

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

The solution line

CLEANING AND
CHEMICAL
PRECAUTIONS
INFORMATION

Your mobile carpet cleaning plant has been engineered using the
latest and most sophisticated technology available, to produce the
finest carpet cleaning results possible. Despite this however, it re­mains only a tool of the 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 knowledge and the use of good chemicals.

Manufacturer recommends the use of spotting agents. and traffic

lane cleaners prior to the actual cleaning of carpeting, as required.

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

~ When cleanma cut-txleacrilan dush camets, set
heater at
fiber damage on this type of carpet.

The use of some chemicals through your mobile carpet cleaning
plant can seriously damage the internal plumbing, high pressure
pump and heater. (Chemicals such as concentrated acids and some

paint oil and grease removers w/high concentration of solvents.)

Manufacturer recommends only the use of chemicals containing rust

and corrosion inhibitors and water softening agents to prevent
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.

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.

‘warm’ setting. Using fiighe’r treater se~ing may ’result in

CHART

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+ ACID

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To be sure all water is out of the system, alternate between quick

connectors several times.

BE SL.WIE [T’S PROTECTED!

8.

Freezing will cause GRIEF, MONEY and DOWN-TIME. Don’t

mess with mother nature! Remember to close the petcock
valve prior to next operation of your BobCat 2/290.

‘PROCEDURE:

Always move the cleaning tool in smooth forward and backward
strokes. Apply
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 fofward and reverse strokes, movement to the

34

slight pressure to the fonvard stroke while the solu-

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

at the same point at the rear of the cleaning stroke.

Failure to adopt this procedure can result in increased chance of
“clean streaks”, fiber shrinkage, brown out, and longer drying
periods.

when cleaning wand is stopped twice

. Clean vacuum tank thoroughly with high pressure washer.
. Flush water and chemical system with 50/50 white vinegar
‘ solution.

. Check engine RPM’s - adjust to 2600 RPM’s as

needed.

IMPORTANT: Record date and machine hours on maintenance
chart.

INCORRECT METHOD

‘w: ~

CORRECT METHOD

OVERIAP
BETWEEN STROKES

OVER-WEITING

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

There are several areas that will cause over-wetting:

1. Too few vacuum strokes or improper saw tooth 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.

● Inspect garden hose screen - clean as needed.

e Visually

etc..

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

clean, repair or replace as needed.

. Lubricate blower with LPS-I or WD-40 through blower inlet.

WEEKLY

● Change engine oil. (25-30 hours of operation)

. Check engine air cleaner filter - clean as necessary.

o Check high pressure pump oil - add as necessary.

. Check drive coupler setscrews - tighten as needed.

● Check pump drive belt for wear - tighten as needed.

o Check

● Check fuel lines for wearlchafing.

● Check all nuts and bolts - tighten as needed.

. Check heater burner assy. union for tightness/leaks.

irrspectmachine for loose wires, oil leaks, water leaks,

pimppulleys - tighten as needed.

MONTHLY

e Grease blower bearing fittings.

● Remove, clean and reinstall engine air cleaner filter.

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

reinstall.

● Check water level in battery. Clean connections as needed.

IMPORTANT:

Record date and machine hours on maintenance

chart.

QUARTERLY

● Change oil in blower (see blower manual).

. Check engine compression.
@ Check for combustion chamber carbon deposit
e Change spark plugs (see engine manual).

—t131J&,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 all facets
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

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;

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 - if torn, replace; empty chemical
from chemical container, wash out thoroughly to remove any chemi­cal 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 fit­tings. Inspect garden hose connect/adapter screen for debris, re­move and clean thoroughly. Inspect all propane and gas lines for
wear or abrasions that may cause possible fuel leaks.

recovery tank, Sk filter and filter bag as

check wand head for sharp

35

DAILY CLEANING & INSPECTION

Engine oil - check

Garden hose screen - clean
Machine - general inspection
Clean vac tank filter bag after every job

Blower inlet - spray with LPS 1 after last job

WEEKLY SERVICE

MAX HRS

25
25
25
25
25
25
25
25
25
25
25

I

25

ENGINE OIL change
BLOWER check oil level

PUMP OIL check

DRIVE COUPLER tighten set screws
BELTS & PULLEYS check tightness

FUEL LINES check for chafing

WIRING check for chafing
CHEMICAL SYSTEM flush w/vineaar

SERVICE

DATE/HRS

I

I I

I

DATEIHRS

I

I

I

MAINTENANCE LOG

DATE/t-iRs

I

I I

1 DATE/HRS I DATE/HRS I DATE/HRS ~ DATE/HR{

I

I

I

I

MONTHLY SERVICE

100

100
100

BLOWER grease bearing
ENGINE AIR CLEANER clean

BY PASS VALVE grease cup& stem

QUARTERLY SERVICE (3 MONTHS)

300
300
300

SPARK PLUGS

change

DAILY CLEANING & INSPECTION

Engineoil-check

Garden hose screen - clean
Machine - general inspection
Clean vac tank filterbag after every job

Blowerinlet-spraywithLPS1afterlastjob

WEEKLY SERVICE

MAX HRS

25
25

25
25

25

25
25
25
25
25
25
25

ENGINE OIL change
BLOWER
PUMP OIL check
DRIVE COUPLER tighten set screws
BELTS & PULLEYS

FUEL LINES check for chafing
NUTS & BOLTS check tightness
BATTERY LEVELS check
HEATER BURNER ASSM tightnesslleaks

VACUUM TANK clean
WIRING check for chafing
CHEMICAL6YSTEM flush w/vinegar

SERVICE

check oil level

check tightness

DATE/HRS DATE/HRS DATE/HRS

MAINTENANCE LOG

DATE/HRS

DATE/HRS

DATE/HRS

DATE/HRS

MONTHLY SERVICE

100

100
100

BLOWER grease bearing
ENGINE AIR CLEANER clean
BY PASS VALVE grease cup& stem

QUARTERLY SERVICE (3 MONTHS)

300
300

300

BLOWER OIL change

ENGINE compression
SPARK PLUGS change