Hydramaster Bobcat 3.0, Bobcat 3.5 User Manual

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

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

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

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

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

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

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

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

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

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

Maintenance Procedures .

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

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

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

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

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@

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

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

VACUUM BLOWER: (Thru orgnal Manufacturer See

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

—.. .

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 (206) 775-7275 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 (206) 775-7275. No collect calls will be accepted. Hours of the

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

Pacific Time.

IMPORTANT

Hydra-Master’s warranty 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

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

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

PROPANE TANK LOCATION

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

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

‘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).

1-1000 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

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 (206) 775-7276.

QUANTITY

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 “’

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

+ High Pressure

}

Y-

10- Heater COII 1? - Pressure Guage

14- To Wand

-+ Low Pressure

CHEMICAL PROPORTIONHUG AND LEVEL CONTROL

6FA 6uFS

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-

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

000-105-102 Piston

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

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

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

DESCRIPTION

Valve 1

QTY.

Plate, Bypass

Valve 1

Valve

Fittina

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.

(Continued on Page 16).

?@’

. ,$%, ,,

—

r~~ ‘

-. .-

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)

Products descr,bed

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

—-.

?%..

- ,;

>*/A#p’

,.,

,’., C,,,,,.,

. . .

P O Box 685 MINNEAPOLIS MN 55440

Phone (612) 780.5440 0 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

~,o.55,2~3”g4’100)

/8’

IMPORTANT DRIVE INFORMATION

Pulley

HORSEPOWER REQUIREMENTS

PRESSURE

Flow

;PM

3.5

3.0

2.5

13 1.9 11

9 1.4

800 1000 1200

Psl

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

F,LTROT,CM Ixv,cc

—

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

pump

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.

S’8

EXPLODED VIEW

MODEL 290

‘ 57

+ 26 hidden pages