HYDRAMASTER CrossFire 3.7 User Manual

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Page 1

HYDRAMASTER

6323 204th Street SW, Lynnwood, WA 98036

CrossFire 3.7

Corporation

Machine Serial Number

HYDRAMASTER@ Corporation

Lynnwood, Washington

182-020

No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or electronic retrieval systems) without the express written permission of the HYDRAMASTER” Corporation. All rights reserved.

Revised January 25, 1996

Page 2

CrossI%e 3.7

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-1

Telephone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-2

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-3

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-4

Spare Parts Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . ...1-6

Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-6

Purchaser’s/Salesman’sResponsibility . . . . . . . . . . . . . . . . . . . . . . 1-8

Vehicle Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-10

Installation Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . ...1-11

Local Water Precautions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-15

Wastewater Disposal Advisory . . . . . . . . . . . . . . . . . . . . . . . 1-16

Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

CLEANING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1

PH Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-4

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-2

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-3

FREEZE GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-1

Vacuum Freeze Guard Procedure . . . . . . . . . . . . . . . . . . . . . . . ...4-1

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CrossFire 3.7

Anti-Freeze Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-2

WATER AND CHEMICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-1

Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1

Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3

Proportioned Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-4

Chemical Tank Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

HIGH PRESSURE PUMP..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-1

Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-1

Pump Service (Wet End)..... . . . . . . . . . . . . . . . . . . . . . . . . ...6-3

Pump Service (Hydraulic End). . . . . . . . . . . . . . . . . . . . . . . . . ...6-9

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-14

Assembly Drawing (Wet End) . . . . . . . . . . . . . . . . . . . . . . . . . ...6-16

Parts List (Wet End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-17

Assembly Drawing (Hydraulic End) . . . . . . . . . . . . . . . . . . . . . . . ..6-18

Parts List (Hydraulic End)... . . . . . . . . . . . . . . . . . . . . . . . . . ...6-19

CLEANING WAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-1

Valve, Jet, Wand Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . 7-1

Valve, Jet, Wand Parts List.... . . . . . . . . . . . . . . . . . . . . . . . . .. 7-4

VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1

Blower Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-3

Blower Instruction Booklet

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CrossFire 3.7

—

ENGINE INFORMATION..,...,,, . . . . . . . . . . . . . . . . . . . . . . . . . . ,. 9-1

Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .,..,,9-1

Briggs &Stratton Engine Specifications

Briggs &Stratton Operator’s Manual

ELECTRICAL SYSTEM .,....... . . . . . . . . . . . . . . . . . . . . . . . . . . . ..10-1

Wiring Diagram Machine...,.. . . . . . . . . . . . . . . . . . . . . . . . . ..10-2

MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,11-1

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,,11-1

Weekly, Monthly, Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-2

De-scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , .,....11-3

Overall Care . ..m. ..m . . . . . . . . . . . . . . . . . . . . . . . . . , . . . ...11-3

Maintenance Logs

HOW TO ORDER PARTS.... . . . . . . . . . . . . . . . . . . . . . . ,,, .,,.,..12-1

WARRANTY INFORMATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13-1

Golden Guarantee@

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14-1

PRODUCT UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-1

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Introduction

CrossFire 3.7 section 1-1

his manual contains installation and operation instructions as well as

information required for proper maintenance, adjustment and repair of this unit. Since the first and most important part of repair work is the correct diagnosis of the problem, component manual troubleshooting charts have been included for your convenience.

Unlike a garden tractor, lawn mower or cement mixer, all having one or

two functions to perform, the truck-mounted carpet cleaning plant has

many functions to perform simultaneously.

F The engine has to run at a consistent RPM. F The vacuum has to pull air and dirty water back from cleaning

site.

F The water pump provides stable pressure at proper water flow for

cleaning.

F The chemical has to be injected into the water stream at the right

concentration. F The heating system must maintain proper heat. F The vacuum tank must store dirty water until drained.

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

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CrossFire 3.7

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.

Section l-2

HOURS

Monday - Friday

8:00 am to 5:00 pm

PACIFIC STANDARD T ME

(206) 775-7276 Parts

206) 775-7275

800) 426-4225

TELEPHONE

Service Parts / Service FAX

HydraMaster Corporation 7118/95

Page 7

System Operation

CrossFire 3.7 Section 1-3

he CrossFire heat exchanger system is a highly engineered cleaning

plant designed by HydraMaster Corporation. The system utilizes a dynamic heating system comprised of three separate exhaust heat exchangers for capturing “free heat. ”

The water flow is as follows:

Water is fed into the machine under tap pressure. It flows through one pre-heater and then is automatically combined with a cleaning solution as it enters the mix tank. The solution is then picked up by the high pressure pump and pressurized to the desired level. The water then splits flow, as demanded by the operator. The majority of the water flows to the by-pass valve assembly, then back through the secondary exhaust heat exchanger, and back to the mix tank.

-F. –,–. .!–-–––.––1––1 1--- Cl–– –.––.. –L –.. Cl –-.-– c..–.. – L1–– .- –.–.

I ne wa_cer aemanaea ~y Tne opera~or TIOWS worn ~ne wa~er pump through the primary exhaust heat exchanger then out to the cleaning tool .

When the cleaning solution reaches a pre-set high temperature, it is

released from the system and directed to the recovery tank. Then cool

water enters the system to regulate the temperature.

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 properly understand,

maintain and service your cleaning plant. Follow the directions carefully and you will be rewarded with years of profitable, trouble-free operation.

It is imperative that no section be overlooked when preparing for operation of this equipment.

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Page 8

Machine Specifications

CrossFire 3.7 Section 1-4

Frame: 23”W x 59”L x 37”H

Weight: Crossfire 3.7: 650 Ibs,

Cowling: Steel with baked-on Epoxy finish.

Engine:

Ignition:

Vacuum

Chemical System:

Heating System:

Instruments:

Vanguard 16 HP Briggs and Stratton.

Electronic, Keystart.

Blower: Proprietary Dual Shaft Roots

Water Pressure gauge, liquid filled, 0-1000 PSI Water Temperature gauge, 0-280° F Vacuum Level gauge, 0-30” HG

Hour Meter, machine runtime Keyed Ignition, start/stop

36 RAI J WhispAirTM

Electro-mechanical, meter controlled.

1 Stainless steel exhaust exchanger.

1 Copper shell and tube exchanger. 1 Copper and aluminum block exchanger.

Chemical Flowmeter, clear acrylic, 0-10 GPH Circuit Breaker, resettable.

Recovery Tank: 70 gallon aluminum, Epoxy finish.

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CrossFire 3.7

Section 1-5

Cleaning Wand: vacuum lips with stainless steel solution valve.

High Pressure Hose: rated to 1250 PSI.

Vacuum Hose: 2“ reinforced, 1 %” reinforced.

Standard Equipment:

Stainless steel with heat shield. Grip

%” High temperature lined/vinyl

Machine Power Console Full Instrumentation WhispAirTM Vacuum Blower CrossFire~ Water Heating Package Deluxe Sound Suppression Package Vacuum Recovery Tank Carpet Cleaning Wand

Chemical Jug Chemical Jug Holder

100 ft, 2“ Vacuum Hose

and replaceable

covered.

Hose

10 ft, 1 %” Wand Whip-line 10 ft, 1 %” Recovery Drain Line 100 ft, Super Flex Solution Line

Freeze Guard System Battery Box with Holder Van Decal Package Van Installation Kit

Operation Manual

HydraMaster Jacket

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Spare Parts

Crossfire 3.7 Section 1-6

own-time on the unit can be very expensive, because your truck-

mounted unit is capable of generating several hundred dollars per day. In order to minimize such down-time, it is strongly recommended by the manufacturer that you purchase and keep in your truck the parts listed below.

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. If further assistance is needed, contact the factory and coordinate your needs. If this becomes necessary, always indicate the method of shipment you desire, i.e. UPS, Blue Label, Air Freight, Air Express, etc.

HydraMaster Parts Dept. Phone . . . . . . . . (206) 775-7276

HydraMaster Parts Dept. Toll Free Fax . . , 1-800-426-4225

Parts List (078-095) PART NO

010-014 Belt, #9341 Pump Drive 010-018 018-005 Breaker, 20 amp Circuit 025-011 049-014 049-007 049-015

DESCRIPTION

Belt, BX 59-MuItiCat Drive

Cable, Aqua 5’ Choke Filter, 16 HP Oil Filter, S/S Vacuum Pump Filter, 1/2” Replacement Y

QTY

1 1 1 1 1

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CrossFire 3.7

Section l-7

PART NO DESCRIPTION

049-016 049-023 049-012

049-030 052-050 052-051 052-052 052-053 057-043 076-045 074-003 074-020 078-018 078-015 078-019 078-101

106-016 131-037 149-011 149-013 157-001 157-007 157-008 157-022 157-111 169-022 169-062 169-120

Filter, 1/4” Replacement Screen, Garden Hose Filter, 16 HP Air Filter Bag, 92+ Truck Mount Quick Connect, 440 Male Quick Connect, 440 Female Quick Connect, 660 Male Quick Connect, 660 Female

Gasket, Recovery Tank - All Jet, #4 S/S Gauge, Hi PSI (O-1 000) Meter, Chemical Flow - CDS

Kit, Diaphragm 3 GPM H-M Hi PSI

Kit, Chem Flowmeter

Kit, H/M Solution Valve

Kit, Seal & Spring Hi PSI

Plug, Vanguard Spark Wrap, Exhaust Insulation Thermostat, Aqua 185 Deg. Sensor, 245 Degree - Hot Switch, Tethered Mercury Switch, 12V DC Lited Switch, Ignition Switch, Relay - A/C, B/C, CDS Switch, Chrome Momentary Valve, 1 1/2” Full Port Valve, 1/4 Anti-Siphon Valve, Chemical System

QTY

1 1 1

2 3 2

1 1 1

1 1 1 1 1 1 1

1 1 1

1 1

1 1 1 1

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Responsibilities

Crossl%e

3.7

Section l-8

he Purchaser’s responsibilities are:

Prior to arrival of unit, install 5/8” exterior plywood flooring in the vehicle and cover it with artificial turf.

Purchase heavy duty 42 ‘slow’ charge if new. If the battery is not fully charged, damage can

occur to the engine charging regulator.

Reading of owner’s manual: It is the purchaser’s responsibility to read the

60 amp hour battery and have the battery

unit operation manual and to familiarize himself with the information contained therein.

Warnings.

The Sales Representative’s responsibilities

ACCEPTANCE OF SHIPMENT:

1. If the unit shows any outward signs

delivery receipt until you have closely any damage on the delivery receipt.

2. The salesman from whom you purchased your unit is responsible for supervising the correct installation of the unit in your vehicle and

Special attention should be paid to all Cautions and

are:

of damage, do not sign the

inspected the unit and noted

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CrossFire 3.7

thoroughly training you in its operation, maintenance and precautions.

CORRECT INSTALLATION INCLUDES:

Installation of through-floor fittings for gasoline fuel lines;

Placing the unit and recovery tank in your vehicle and securing them with bolts or tie down cleats;

Connecting gasoline lines; Connecting the battery; Checking the pump, vacuum blower and engine oil levels prior to

staring the unit;

Starting the unit to check engine and see that all systems function normally;

Section l-9

Checking all hoses, wands, etc. for correct operation.

TRAINING SHALL INCLUDE:

A thorough review of the operation manual with purchaser;

Instruction and familiarization in: how to correctly start up and shut

down the unit, how to correctly clean with the unit, 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, hard water damage and how to avoid it; A thorough review of the unit warranty and warranty procedures.

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Page 14

Vehicle Prep

CrossFire 3.7 Section 1-10

he preferable vehicle for a CrossFire or ProFire installation is a cargo

T’

van witha heavy-duty suspension package. The van should have 3/4

ton capacity.

TRUCK PREPARATION

The manufacturer recommends the installation of plywood flooring, covered with polypropylene backed astroturf (do not use rubber-backed), in the vehicle prior to installation of machine.

CAUTION +

Be cautious when drilling any holes through the van floor, Many vans have critical components mounted directly below

the van floor that could be damaged by a misplaced drill bit.

(See product Support Bulletins 92102,

the end of this manual. )

This provides a metal-to-cushion mounting rather than metal-to-metal,

insulation and makes an attractive van interior. The astroturf should be color keyed to the van interior.

Materials Needed:

1. 2 sheets 4x8xYs” exterior plywood

2. 6’xI 2’ piece of commercial astroturf

3. 16- 1 %” sheet metal screws

4. 1 quart marine adhesive (optional)

94062 and 94063 at

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CrossFire 3.7

5. 1 staple hammer with %” staples (See illustration for correct placement of plywood flooring)

ROOF VENTS

HydraMaster strongly recommends installation of roof vents in all

truckmount installations.

heaters, these must be vented through the roof of the van.

When installing equipment with propane

Section 1-11

PLACEMENT OF

There are two

illustrated in the

A, SIDE DOOR: access for accessories and hoses as well as unobstructed access to the component/working side of the machine, thus making it a bit easier to

perform maintenance and/or repair without removing the unit from the

truck.

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

line up over drive shaft). Also, it is physically easier to load the unit into

UNIT IN VEHICLE

recommended unit placements described below and

following diagrams.

Most installations are side door.

This provides rear

the rear door due to the height of the van bed.

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CrossFire 3.7

Section 1-12

Figure 1-1: Plywood Installation

Figure

-3: Machine Tie Down Cleats

‘igure 1-2: Astroturf and Roof Vent

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CrossFire 3.7

Ensure that the machine is well secured to the floor of the van with the

hardware supplied. A sudden or crash stop will cause the machine to

rocket forward, all 750 Ibs. worth! Protect yourself and the machine.

SECURE IT!

Section 1-13

It is recommended by the manufacturer that the exhaust from the front of

the machine be vented down under the truck to prevent carbon monoxide from entering the job site.

blowing away from the job site.

The manufacturer also recommends the installation of aluminum vents in

the truck roof to allow heat to escape.

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

Never operate this machine with a portable gas can inside the truck.

Doing so increases the risk of a fire or explosion.

Transportation in a vehicle of any vented fuel container that presently

Always park the truck so the exhaust is

holds or has ever held a flammable liquid is strictly forbidden by

HydraMaster Corporation and by federal and state regulation.

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CrossFire 3.7

Do not use a portable propane tank inside of the truck or van. It is

dangerous and illegal in most states.

Section 1-1

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Page 19

—..———

Local Water Precautions

CrossFire 3.7

Section 1-15

he quality of water varies greatly.

minerals in the water which results in what is commonly called “hard water”. other parts of the machines causing damage and a loss of cleaning effectiveness. This influences the reliability and efficiency of equipment in direct proportion to the level of hardness.

HARD WATER AREA MAP

The following map defines areas in the United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water cooled engines. be obtained from geological societies.

WATER SOFTENER

These minerals tend to adhere to the insides of heater coils and

For other countries, hard water area maps can

Many areas have an excess of

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. The manufacturer strongly urges the use of water softener units in areas exceeding 3 1/2 grains per gallon, Using a hard water area map as a reference, determine the quality of water in your area and take action immediately, if necessary.

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.

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CrossFire 3.7

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 and, 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, For example: the machine uses an average of 30 gallons per hour, for an average of 5

hours a day, this equals 150 gallons per day. In 6 days the machine would use 900 gallons of water. Therefore, the softener would need to

be changed every 6 working days for maximum softening.

If the softener will treat 900 gallons of water and

Section 1-16

WASTE WATER DISPOSAL ADVISORY

There are laws in most communities prohibiting the dumping of recovered

“gray” water from carpet cleaning in any place but a sanitary treatment system.

This cleaning rinse water, recovered into your unit’s vacuum tank, contains materials such as detergents. being safe for streams, rivers and reservoirs.

IN ACCORDANCE WITH THE EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.

In most cases, an acceptable method of waste water disposal is to discharge into a municipal sewage treatment system after first filtering out solid material such as carpet fiber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV dump, etc. Permission should first be obtained from any concerned party or agency.

These must be processed before

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CrossFire 3.7

One disposal method which usually complies with the law is to accumulate the waste water and haul it to an appropriate dump site. Another solution to the disposal problem is to equip yourself with an Automatic Pump-Out System. These systems are designed to remove waste water from the extractor’s recovery system and actively pump the water through hoses to a suitable disposal drain. Properly designed, they will continuously monitor the level of waste water and pump it out

Section 1-17

simultaneously to the cleaning operation. process is that the operator does not have to stop his cleaning to empty

the recovery tank. HydraMaster makes an A.P. O. System available which

can be ordered with new equipment or installed later.

The penalties for non-compliance can be serious. A

laws and regulations to be sure you are in compliance

The hidden benefit of this

ways check local

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CrossFire 3.7

Figure 1-4: Hard Water Map

Section 1-18

Grains

Per Gallon

n 0- 31/’,

3% -7

HydraMaster Corporation

10I’2

7 “

10% and above

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Page 23

Cleaning and Chemicals

CrossFire 3.7

Section 2-1

our 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.

PRECAUTIONS

There are no short cuts to good carpet cleaning. it requires time, cleaning

knowledge and the use of good chemicals. Therefore, the manufacturer recommends the use of spotting agents and traffic lane cleaners, as required, prior to the actual cleaning of carpeting,

The use of some chemicals through your mobile carpet cleaning plant can

seriously damage the internal plumbing, high pressure pump and heater.

These harmful chemicals include concentrated acid (see the pH chart at

the end of this section), solvents, and some paint, oil, and grease

removers with a high concentration of solvents.

The manufacturer recommends only the use of chemicals containing rust and corrosion inhibitors and water softening agents to prevent chemical build-up which may lead to component failure and warranty invalidation.

+ CAUTION +

The increased demand for “clear water” rinsing results in the need for

special care when using these acid based chemicals in your equipment,

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CrossFire 3.7

The negative side of these products is the corrosive effects the acid can

have on metals, including swivels, pumps, heat exchangers, etc.

Section 2-2

HydraMaster’s

components.

damaged from

caused failures.

CLEANING STROKE PROCEDURE

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.

Procedure: Always move the cleaning tool in smooth, forward and

backward strokes. Apply slight pressure to the forward stroke while the

solution 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 carpet that is not smooth.

During the forward and reverse strokes, movement to the right or left

C/earWater Rinse has been formulated to protect vital

HydraMaster will not warranty parts that have been

using unprotected acid products that have obviously

should only be accomplished at the extreme rear of the stroke.

Overlapping is also important to ensure even application of solution and

prevent saturation when cleaning wand is stopped twice at the same

point at the rear of the cleaning stroke. This is illustrated at the end of this section.

Failure to adopt this procedure can result in increased chance

streaks’, fiber shrinkage, brown-out and longer drying periods.

OVER-WETTING

Over-wetting is annoying to all concerned, and sometimes leaves a bad

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CrossFire 3.7

Section 2-3

impression of the cleaning process used.

THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER-WETTING

1. Too few vacuum strokes or improper saw-tooth vacuum strokes as

shown in the following illustration.

2. Obstructed, cut or kinked 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. )

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CrossFire 3.7

Figure 2-1

112345678910 I1I2I3 14

Section 2-4

PH CHART

+— ACK)—

NEUTRAL —

ALKALINE~

Figure 2-2: CLEANING STROKE PROCEDURE

A correct cleaning stroke

overlaps between strokes.

I I

I I I /

I I I I I

I 1 I I [ I

, I 1

HydraMaster Corporation

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4/13/95

Page 27

CrossFire 3.7

Section 3-1

START UP

Operating Instructions

Perform daily/periodic maintenance as specified in this Owner Manual.

Connect all required hoses.

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

the cleaning.

CAUTION: Mix tank must be full prior to ignition.

Start engine (choke as required). The machine is preset at operating speed.

Spray the wand to void all air from the system. When the mix tank begins a fill cycle, the chemical flowmeter may be adjusted to your desired setting. Set your cleaning pressure at 300 PSI. NOTE: A chemical flowmeter set at 5 GPH is a 1 to 30 mix ratio and 10 GPH is a 1 to 15 ratio. When the flowmeter is set at 10 GPH, you will be using what most chemical manufacturers recommend at 5 GPH.

Run the machine for several minutes under load (8 to 10“ HG) until your desired temperature is achieved.

Commence cleaning operation.

HydraMaster Corporation

4/13/’95

Page 28

CrossFire 3.7

SHUT DOWN

Section 3-2

Remove the vacuum hose.

Flush clear water through the chemical system for 10 seconds. Vinegar should be rinsed through the system weekly. Turn off chemical flowmeter, NOTE: monthly.

Turn on the cleaning tool to flush the chemical from unit the hoses

and cleaning tool.

At this time, the blower should be lubricated with an oil based

lubricant. NOTE: If freeze guarding is necessary, perform the freeze guard procedure at this time.

Turn the machine off.

De-scaler should be rinsed through the entire system

Drain the vacuum tank. The vacuum filter should be cleaned prior

to mobilization of the van.

FLOOD DAMAGE WORK

+ CAUTION +

Caution must be exercised to prevent overheating during

vacuum work such as water damage.

machine during extended vacuum work.

Water must be supplied to the

ong periods of

HydraMaster Corporation 4/’13/95

Page 29

Precautions

CrossFire 3.7 Section 3-3

Ithough this unit has been factory adjusted, it may require additional

adjustments to achieve optimum performance, i.e. altitude may require carb adjustment and ambient temperatures may require heat control adjustment. When required, consult an authorized representative.

THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor. Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit. (See product

Support Bulletins 92102, 94062 and 94063 at the end of the manual.)

ENGINE COOLING: Units employing air cooled engines must not be enclosed within a van with doors and windows closed.

temperatures within the engine will result in premature engine failure and

a compromise of applicable warranty.

LEVEL OPERATION: During operation, van or trailer must be parked on level ground not to exceed + or - 10 degrees. Failure to insure proper leveling may prevent proper internal lubrication of engine, vacuum and/or high pressure components.

HydraMaster Corporation

Excessive

10/12/95

Page 30

CrossFire 3.7

Section 3-4

MOVING PARTS: Never Severe bodily injury may result.

ACID RINSE AGENTS: The increased demand for “clear water” rinsing results in the need for special care when using these acid based chemicals in your equipment. effects the acid can have on metals, including swivels, pumps, heat exchangers, etc.

HydraMaster’s C/earWater Rinse has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from using acid products that have obviously caused failures.

touch any part of the machine that is in motion.

The negative side of these products is the corrosive

FREEZE PROTECTION: Mother nature gives little warning as to her cold spells, Therefore, not protecting this equipment from freezing will result

in costly down-time. Placing an electric heater in the truck or parking the truck indoors will help to insure against freezing, but should not be the

primary method of freeze protection.

EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic

or wood products) to come in contact with the exhaust system.

HydraMaster Corporation

10/12/95

Page 31

CrossFire 3.7

WARNING +

HOT SURFACES: During the operation of this equipment, many surfaces on the machine will become very hot. When near the van for any reason, care must be taken not to touch any hot surface, such as the heating system, engine, exhaust, etc.

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

Section 3=5

WARNING +

CARBON MONOXIDE: This unit generates toxic fumes. Position the

vehicle so that the fumes will be directed away from the job site. Do not

park where exhaust fumes can enter a building through open doors, windows, air conditioning units or kitchen fans.

TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment

is operating. Toxic fumes may accumulate inside a stationary vehicle.

ENGINE EXHAUST: The engine exhaust from this product contains

chemicals know to the State of California to cause cancer, birth defects or other reproductive harm.

HydraMaster Corporation

10/12/95

Page 32

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Page 33

Freeze Guard

CrossFire 3.7

Section 4-1

he Vacuum Freeze Guard procedure is good to 25° F. If below this

temperature, please refer to the Anti-Freeze Procedure.

VACUUM FREEZE GUARD PROCEDURE

Begin by attaching your garden hose, or pump-in hose, to the machine. Now, remove the chemical line from the chemical jug and

place it in a 50/50 mixture of anti-freeze and water. Turn ignition switch on. Open the mix tank drain valve and allow the mix tank to drain to the point that it starts to demand water. Allow the mix tank to draw the anti-freeze solution through the chemical flowmeter and the hoses back to the mix tank.

Remove the garden hose, or pump-in hose.

Using the freeze guard hose provided with the machine, freeze guard the unit. recovery tank. Then, with the pressure regulating valve unscrewed,

plug the other end of the hose into the high pressure cleaning solution fitting on the front of the machine.

First, plug the rubber stopper into the outlet of the

HydraMaster Corporation

Start the machine and allow it to run, drawing the water from the

machine. At the same time, depress the freeze guard button and

hold until the engine stops.

Open the mix tank drain valve and drain out the remainder of the water.

4/13/’95

Page 34

CrossFire 3.7

ANTI-FREEZE PROCEDURE

Section 4-2

Begin by attaching your garden hose, or pump-in hose, to the

machine. Now, remove the chemical line from the chemical jug and

place it in a 50/50 mixture of anti-freeze and water. Turn ignition

switch on. Open the mix tank drain valve and allow the mix tank to

drain to the point that it starts to demand water. Allow the mix tank to draw the anti-freeze solution through the chemical flowmeter and the hoses back to the mix tank.

Remove the garden hose, or pump-in hose. Now, open the mix tank

drain valve and drain all the water from the machine,

With the machine drained of water, close the

pour one (1) gallon of 50/50 anti-freeze and chemical mix tank.

Start the machine and allow

With the machine running,

it to run for two (2) minutes.

depress the dump solenoid manual

mix tank drain and

water mix into the

override switch and hold for

Remove the garden hose inlet fitting from the end of your garden

hose and plug it into the front of the machine. Leave it plugged in

until the next time the machine is used.

With the hoses and wand connected, run the machine and spray the water/anti-freeze solution out of the wand until the ‘low water’ switch in the mix tank shuts the machine off. Your machine is now freeze-protected.

Solution hose and wand freeze guard procedure (optional): Attach the solution hoses and wand to the machine. (Dependent upon the

amount of hose attached, more anti-freeze solution may be needed

HydraMaster Corporation

thirty (30) seconds.

4/13/95

Page 35

CrossFire 3.7

Section 4-3

in the chemical mix tank). wand into a container to recapture the anti-freeze solution.

Continue to spray the wand until the machine shuts down by itself.

Recovering anti-freeze for re-use:

Open the mix tank drain valve and allow the anti-freeze solution to drain into a sealable container so that it may be used again.

Before cleaning with the machine again, flush the remaining anti-freeze solution from the system by spraying water through

With the machine running, spray the

One manufacturer of antifreeze cautions: “WHEN DISPOSING OF USED ANTIFREEZE COOLANT: Follow local laws and regulations. If required, dispose at facilities licensed to accept household hazardous waste. If

permitted, dispose in sanitary sewer systems. Do not discard into storm sewers, septic systems, or onto the ground. ”

-1

This warning appears on the label of one brand of antifreeze: “HARMFUL

OR FATAL IF SWALLOWED. Do not drink antifreeze coolant or solution.

If swallowed, induce vomiting immediately. Call a physician. Contains

Ethylene Glycol which caused birth defects in animal studies. Do not store in open or unlabeled containers.

KEEP OUT OF REACH OF CHILDREN AND ANIMALS. ”

HydraMaster Corporation

4/13/95

Page 36

Water and

Chemical System

CrossFire 3.7

Section 5-1

This electro-mechanical system has been designed to be simple and

~ trouble free.

WATER/CHEMICAL FLOW OPERATION

Incoming water flows first through the Solenoid Control Valve and the Ow

pressure Chemical injector which are both mounted on the exterior of the

mix tank.

automatically proportioned with a predetermined quantity of detergent. The Mix Tank is equipped with two different float switches, the Water

Level Float 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 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

disengages the system and prevents the water pump from running dry.

The desired chemical injection ratio may be obtained by an adjustment of the Chemical Flowmeter during the fill cycle of the mix tank. Water must

be flowing into the mix tank in order to adjust the chemical mix. The

chemical will flow from the Chemical Jug to the Chemical Flowmeter, then to the Chemical injector where it is proportioned into the Mix Tank

at the desired chemical setting.

As the water passes through the Chemical injector, it is

NOTE: With this unique chemical system, the chemical flow is

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

HydraMaster Corporation

4/13/’95

Page 37

CrossFire 3.7

direct spraying of the wand. Therefore, it is possible that as your wand

is spraying, you may have no chemical flow. Also, the converse is true

in that you may not be spraying your wand, but if the mix tank is in a filling cycle, your Chemical Flowmeter may be active at the desired flow

rate.

The chemical proportioning system will mix chemical with water at a 1 to

30 ratio when the Flowmeter is set at 5 GPH, or a 1 to 15 ratio when the

Flowmeter is set at 10 GPH.

CHEMICAL SYSTEM MAINTENANCE

The chemical lines may need to be flushed with vinegar periodically to

Section 5-2

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.

Flowmeter setting 10 GPH. Simply spray water from the wand until the quart of vinegar is exhausted. Then repeat the process with one quart of clear water to void all lines of vinegar,

This should be done with the Chemical

HydraMaster Corporation

4/13/95

Page 38

CrossFire 3.7

Figure 5-1

LOW PRESSURE HIGH PRESSURE

VAC EXHAUST

EXHAUST FLOW •oos~oaaaoc..,.a HIGH TEMP BY-PASS •mmmmmmmnn~mm~m~ BY.PASSPRE-HEAT

CONTROL

PANEL

INCOMING

WATER

OUTGOING

CLEANING SOLUTION r

‘a

LINE

——.

WWA:S

ENGINE

.—

m-m-mum-m

TEMP

sENDER

Section 5-3

WATER FLOW DIAGRAM

HYDRAMASTERCORP.

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21 JAN 1994

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●

MUFFLER

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ADJUSTMENT

A]=

#20

BLCCKHEATER

—.—

LINE

HydraMaster Corporation

4/13/95

Page 39

CrossFire 3.7

Figure 5-2: PROPORTIONER DIAGRAM

Secti49n5-4

Mix Tank

n Check Valve

6FA-6UFS

Injector

Body

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t+,

/’

Cap Nut

12 VDC

Coil

Hydraikfaster Corporation

enoid ve Body

Mo;nting

Plate

4/13/95

Page 40

CrossFire 3.7

Figure 5-3: By-Pass Valve Assembly

Section 5-5

169-101 Valve, By-Pass Truckmount

ITEM

2 105-102 3 4 148-004

5 097-005

6 155-019

Not Shown:

PART NO

105-101

097-028

078-102 078-101

HydraMaster Corporation

DESCRIPTION

Thrust Plate, By-pass Valve Piston Plate, By-pass Valve Seal Set for By-pass Valve Seat and O-Ring, By-pass Valve O-Ring, By-pass Valve Fitting Spring, High PSI By-pass

Kit, By-pass Repair (Includes Items 1-5) Kit, Seal and Spring High PSI By-pass (Includes Items 3 and 7)

CITY

1 1 1 1 1 1

1 1

6/15/95

Page 41

CrossFire 3.7 Section 5-6

Chemical Tank

Troubleshooting

Problem / Possible Cause

There is a loss of water pressure.

1.1

1.2 The mix tank water suppiy hose is

1.3 Foreign material is blocking the

1.4 Foreign material is blocking the

There is a clogged fi/ter in the water supply to the pump.

missing. This will cause aeration and turbulence in the tank.

outlet hole for the pump in the bottom of the mix tank.

water suppiy hose leading to the

pump from the mix tank.

Solution

If a filter is present in the water

supply line to the pump, remove and discard it.

Look inside the mix tank and determine if a water inlet hose is present. If the hose is missing, order a new hose from your HydraMaster distributor and install it.

Inspect the outlet hole leading to the pump in the bottom of the mix tank. Remove any foreign material blocking the hole.

Remove the water supply hose between the mix tank and the pump. Sight through the hose. Remove any foreign material from the hose. Reattach the hose.

1.5 The water supp/y hose from the mix tank to the pump is kinked or blocked.

HydraMaster Corporation

Remove the hose and clean it. If it is kinked, order a replacement hose from your HydraMaster distributor.

4/13/95

Page 42

CrossFire 3.7

Section 5-7

1.6 The end of the mix tank water

1.7

1.8 There is an air leak in the water Inspect the supply hose for worn

1.9

Problem / Possible Cause

Inspect the mix tank and determine supply hose is pointed directly at the orientation of the water hose. the pump inlet hole in the bottom If it is pointing directly at the pump of the mix tank. inlet hole in the bottom of the

tank, reposition the hose to point towards the opposite side of the tank from the inlet.

The mix tank supply hose is The water inlet hose may have to blocking the outlet hole leading to be shortened or lengthened to the pump in the bottom of the mix tank.

supply hose from the mix tank to or damaged areas. Also check for the pump. loose fittings. Replace the hose or

The water supply hose from the Allow the machine to reach full mix tank to the pump collapses water operating temperature when the machine is running hot. (approximately 10 minutes).

avoid blocking the outlet hole.

fittings if necessary.

Inspect the water supply hose between the mix tank and the pump. If the hose appears to be collapsing, remove the hose and order a replacement hose from your HydraMaster distributor. Reinstall the new hose. NOTE: Older model machines will require an additional 8M 12 UFS fitting for the pump end of the hose.

Solution

1.10 There is foreign material in the inlet Inspect the valves and remove any or outlet valves of the pump.

foreign material.

HydraMaster Corporation

1/’25/96

Page 43

CrossFire 3.7

Section 5-8

1.11 The controlled orifice is loose and

1.12 The by-pass valve is

Problem /

water is flowing around it.

malfunctioning.

Possible Cause

Solution

Clean the orifice and tighten the

fittings around it. This may require

adding an “O” ring around the jet. Also, check the fitting for wear. if there is excessive wear, replace the fitting with part #052-025.

In the CrossFire 4.4 only, remove the face mounted filter screen to get to the orifice behind the filter.

Retighten the orifice with a 3/16“ Allen wrench.

NOTE: If your machine was built

before 10/1 2/95, update the controlled orifice to the new style orifice with part numbers 180-002, 052-423 and 052-013.

Remove the plunger and lube the

“O” rings. Clean the walls of the by-pass valve with a bristle brush and de-scaler. NOTE: Use a water resistant high temperature lube.

1.13 There is a loss of prime in the cells of the

low.

pump because the oil level is

HydraMaster Corporation

Add oil to the pump reservoir. Adjust the pressure regulator for high pressure and run the pump for

20 to 30 minutes until it reprimes

itself.

1/25/96

Page 44

CrossFire 3.7

Section 5-9

1.14 There is a broken or cracked Inspect the water in the mix tank.

1.15 The pump “O” rings are forced out

Problem /

diaphragm in the pump.

of their grooves from overpressurization (freezing).

Possible Cause

If there is oil in the water, a diaphragm has ruptured. Inspect the oil level in the pump. If there is no oil in the pump, a diaphragm has ruptured. For older model pumps, a new cushion plate should also be installed. Contact your

HydraMaster distributor to determine if you machine requires a cushion plate. Order a diaphragm replacement kit from your HydraMaster distributor.

Remove the pump. Replace the diaphragm. pump. See your owner’s manual for the procedure.

Inspect the “O” rings. Replace them if necessary. See your owner’s manual for the procedure.

Solution

Refill and reinstall the

1.16 The pump manifold is warped from over-pressurizing the system

(freezing).

1.17 The valve spring retainers in the valve manifold are loose. (Retainers should fit snug. )

Inspect the manifold with a straight edge. Replace it if necessary.

Install a valve kit.

HydraMaster Corporation

1/25/96

Page 45

CrossFire 3.7

Section 5-10

No Problem / Possible Cause

The water temperature is too low.

2.1

2.2

2.3

2.4 There is an exhaiist leak.

2.5 There is excessive

The water dump (system control) solenoid is stuck open.

The orifice (spray nozzle) in the cleaning tool is worn, defective, or the wrong size.

The incoming water supp/y is extremely cold.

pressure.

Solution

Remove the electrical wires from the solenoid. If the solenoid

continues to dump, disassemble

and check for residue. Clean and

replace the solenoid.

Replace or change the orifice size.

The CrossFire uses a 8006E T-jet.

Keep the incoming water supply hoses away from ice and snow

during winter months.

Inspect the exhaust system for leaks. Tighten any loose clamp welds or replace any broken parts.

Adjust the pressure regulator for less pressure.

2.6 There is exhaust wrap missing.

2.7

2.8

2.9

The 1850 dump sensor is shorted or is operating prematurely.

In the CrossFire 4.4 only, the adjustable temperature control dial is set too low or malfunctioning.

In the CrossFire 4.4 only, the temperature control knob is turned to “On”.

HydraMaster Corporation

Replace any missing wrap. Test the sensor. Replace it if

necessary.

If returning the temperature control dial to maximum does not work, check the water temperature in the mix tank. At maximum the system control light should come on at

approximately 187° - 190°. If

not, replace the temperature

control unit.

Turn the temperature knob to

“off”.

1/25/96

Page 46

CrossFire 3.7

Section 5-11

2.10 lnthe CrossFire4.4 only, the

2.11 The engine speed is low.

2.12 A heat exchanger is scaled.

2.13 A heat exchanger is carbon-coated.

Problem /

preheating system is malfunctioning.

Possible Cause

Solution

With a test light, determine which

incoming solenoid is being activated (EV-I or EV-2). If EV-I is being activated and the outgoing water temperature is below 235°, check relay CR-3 and switch SW-

6. The coil on CR-3 should not be activated. There should be a continuum between post 30 and 87a. SW-6 should be open.

Repair or replace as necessary. Reset the engine speed. Refer to

the Engine Operation and

Maintenance manual. De-scale the heat exchanger or

remove it and take it to a radiator shop to be boiled out.

a. For a stainless steel heat

exchanger, clean it with a one inch wire brush and oven cleaner.

b. For a copper tube heat

exchanger, carefully unplug the tubes by poking a small rod through them. Then take the

heat exchanger to a radiator shop to be boiled out.

2.14 The temperature gauge sending unit is defective.

HydraMaster Corporation

Check the sending unit. The unit and temperature gauge must be manufactured by the same company (ie. an Isspro gauge works only with an Isspro sending

unit and an S&W gauge works only with an S&W sending unit).

1/25/96

Page 47

CrossFire 3.7

Section 5-12

1’

No I

2.15 The temperature gauge is

Problem / Possible Cause

defective.

Solution

Place the end of a grounded wire

to terminal 9a on the Diagnostic

Center while watching the

temperature gauge. The ground

should make the needle on the gauge read maximum temperature. Replace the gauge if necessary.

HydraMaster Corporation

1/25/96

Page 48

CrossFire 3.7

Section 5-13

Problem /

Possible Cause

3 The water temperature is

excessive.

3.1 The fi/ter in front of the controlled

orifice is clogged.

3.2 The controlled orifice is clogged.

3.3 The dump solenoid (system

control) valve is not opening.

3.4 The dump (system control) sensor

is not working.

3.5 The engine speed is too low or too

high.

Solution

Inspect the filter. Clean it if necessary.

Inspect the controlled orifice. Clean it if necessary.

Short out the dump sensor. If the dump solenoid valve has 12 volts across the terminals and does not open, replace it.

The sensor switch is normally open. It closes its hidden contacts at 185° F. Replace it if it is necessary.

Reset the engine speed. Refer to

the Engine Operation and

Maintenance manual.

3.6 The temperature gauge is

defective.

Place the end of a grounded wire

to terminal 9a on the diagnostic

center terminal block while watching the temperature gauge.

The gauge should read maximum temperature. If it does not, replace the gauge.

HydraMaster Corporation 1/25/96

Page 49

CrossFire 3.7

Section 5-14

4 There is pressure on the

Problem / Possible Cause

gauge, but no water coming out of the wand.

4.1 The wand jet is plugged. I I

4.2

4.3

4.4

4.5

The quick connect on one or more of the high pressure hoses is

defective.

The cleaning tool has a clogged

valve.

The high pressure quick connect on the front of the machine is clogged.

The inner lining on a hose is constricted.

Inspect and clean the jet. Remove and clean or replace the

defective quick connect(s).

Remove the valve stem. Clean the

valve. Replace the “O” rings and

stem if they are bad. Remove and clean or replace the

quick connect.

Remove the restriction or replace

the hose.

Solution

HydraMaster Corporation

1/25/’96

Page 50

CrossFire 3.7

Section 5=15

No Problem / Possible Cause

Solution

5 The water in the mix tank

will not

keep up with the

wand.

5.1

5.2 The upper float is bad. Remove the wire on terminal 17b

5.3 The mix tank reia y is bad.

There is dirt in the solenoid valve along side of the mix tank.

Take the valve apart and clean it.

at the Diagnostic Center. With a

volt-OHM meter check for

continuity from the end of the wire you removed and terminal 20 on the Diagnostic Center. There should be no continuity reading on the meter with the float in the down position. necessary.

With the upper float in the mix tank in the up position, there should be no voltage reading on terminal 16 at the Diagnostic Center. With the float in the down position, there should be + 12 volts on terminal 16. Replace the relay if it is defective.

Replace the float if

5.4 The water supply is improperly adjusted.

5.5 The water inlet supply hose filter is clogged or the hose is kinked.

5.6

There is a problem with the pump-

in pump.

The water supply should be two

(2) gallons per minute or more.

Remove the obstructions.

Check the amount of water the pump-in pump is supplying. It should supply a minimum of 2 GPM if you use one wand or one

RX20. It should supply a minimum

of 3 GPM if you use two wands.

HydraMaster Corporation 1/25/96

Page 51

CrossFire 3.7

Section 5-16

6.1

6.2

6.3

6.4

Problem / Possible Cause

There is water coming out of the exhaust.

There are small amounts of water usually seen at start up.

One of the heat exchangers is damaged from frozen water.

The recovery tank is full.

There is excessive foam in the recovery tank.

Solution

This is norms/! There is no solution! The water is condensation.

Determine which heat exchanger is bad. Replace it if it is necessary.

Empty the tank.

Apply a powdered or liquid defoamer to counteract this reaction to the excessive chemical in the carpet.

HydraMaster Corporation

1/25/96

Page 52

CrossFire 3.7

Section 5-17

No Problem / Possible Cause

7.1

7.2

7.3 The chemical relay is bad or, in the

The mix tank

The upper fioat in the mix tank is malfunctioning.

There is dirt in the solenoid valve next to the mix tank.

CrossFire 4.4 only, the CR-2 re/ay.

overflows.

Solution

With water in the mix tank, connect one end of a 12 inch piece of wire to terminal 20 (see the

Diagnostic Center) and touch the other end to terminal 17. If the water stops flowing with the key on, replace the float.

Remove one of the wires from

terminal 16 (see the Diagnostic

Center) and turn the key on. If the water continues to flow, then take the solenoid apart and remove the foreign matter. Replace the solenoid valve if necessary.

Check the relay with a volt-OHM meter. With the ignition key

turned on, there should be 12 volts

between pin 85 and 86. If the voltage is present, check the voltage between ground and pin

87a on the relay. If voltage is

present at 87a, replace the relay.

HydraMaster Corporation

1/25/96

Page 53

CrossFire 3.7

Section 5-18

No Problem / Possible Cause

Solution

8 The water pump is pulsing,

8.1 The hoses are restricted due to

hard water deposits andlor chemical build-up.

8.2

8.3 The in/et hose is drawing air.

8.4 The valves are obstructed. Clean or replace the valves.

8.5 There is a pin hole in one or more

8.6 The valve spring is broken.

The throb hose is hardened due to Replace the throb hose. age or heat and cannot absorb spikes.

of the diaphragms, small enough to lose the prime but not to leak any oil into the water or water into the oil.

Descale the machine.

Reseal the fittings. Tighten the hose clamps.

Replace all of the diaphragms. One could be replaced temporarily, however all should be replaced.

Replace the valves.

Or replace the hose.

HydraiWaster Corporation 1/25/96

Page 54

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Page 55

Pump Maintenance

Crossllre 3.7

Section6-1

DAILY

Check the oil level and the condition of the oil. The oil level should be 3/4

inch from the top of the fill port to the line on the oil fill plug’s dipstick (63).

Use a 5-30 weight synthetic motor.

-1

If you are losing oil but don’t see any external leakage, or if the oil

becomes discolored and contaminated, one of the diaphragms (17) may

be damaged. Refer to the Service Section.

Do not operate the pump with a damaged diaphragm!

Do not leave contaminated oil in the pump housing or leave the housing empty. Remove contaminated oil as soon as discovered and replace it with clean oil.

PERIODICALLY

Change the oil after the first 100 hours of

operating hours thereafter. When changing,

operation, and every 400

remove the drain plug (60)

HydraMaster Corporation

4/’13/95

Page 56

CrossFire 3.7

at the bottom of the pump so all oil and accumulated sediment will drain out.

1===1

Section 6-2

Do not turn the drive shaft while the oil reservoir

+ CAUTION +

Protect the pump from freezing.

is empty.

HydraMaster Corporation 4/13/95

Page 57

Service of Wet End

CrossFire 3.7 Section 6-3

his section explains how to disassemble and inspect all easily-

serviceable parts of the pump. Repair procedures for the hydraulic end (oil reservoir) of the pump are included in a later section of the manual.

CAUTION +

Do not disassemble the For assistance, contact HydraMaster (206-775-7275) or the distributor in your area.

1. Remove Manifold (3) and Valve Plate (12)

Remove all eight bolts (1) around the manifold.

Remove the manifold (3) and valve plate (1 2).

Inspect the manifold for warping or wear around the inlet and outlet

ports. If wear is excessive, replace the manifold.

To check if the manifold is warped, remove the O-rings (4) and place

a straightedge across it. A warped manifold (.003 inches or greater) should be replaced.

Inspect the valve plate in the same manner as the manifold.

hydraulic end unless you are a skilled mechanic.

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CrossFire 3.7

Section 6-4

2. Inspect Valves

The three inlet and the opposite direction),

Check the spring retainer (1 O), and replace if worn.

Check the valve spring (8).

replace it (don’t just stretch the old spring).

Check the valve poppet (7). [f worn excessively, replace it.

Remove the valve seat (6).

Inspect the valve seat for wear, and replace it if necessary. A new

O-ring (5) should be installed.

(5-11)

three outlet valve assemblies are identical (but face in

Inspect each valve as follows:

If it is shorter than a new spring,

Check the dampening washer (1 1), and replace if worn.

Reinstall the valve assemblies:

E Clean the valve ports and shoulders with emery cloth, and

lubricate them with lubricating gel or petroleum jelly.

E Install the O-Ring (5) on the valve seat (6).

D Inlet (3 upper valves in the illustration below). Insert the

spring retainer (1O) into the valve plate, then insert the spring, valve, Tetra seal, valve seat, and dampening washer

(8,7,9,6.1 1). A flat O-Ring [Tetra seal] (5) goes between the

retainer and seat.

D outlet (3 upper valves in the illustration).

Insert the

HydraMaster Corporation

4/13/95

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CrossFire 3.7

dampening washer, valve and spring, then the retainer. Install

the flat O-ring between the retainer and seat.

3. Inspect and Replace Diaphragms (17)

Remove the two cap screws (14) from the valve plate (1 2).

Lift a diaphragm by one edge and turn the pump shaft until the

diaphragm moves up to “top dead center. ” This will expose

machined cross-holes in the plumber shaft behind the diaphragms.

Insert a hex wrench through one of the machined cross holes, to

hold the diaphragm up. (Don’t remove the tool until the new

diaphragm is installed in step “g” below.)

Section 6-5

Unscrew the diaphragm. counterclockwise.

Inspect the diaphragm carefully. A ruptured diaphragm generally

indicates a pumping system problem, and replacing only the diaphragm will not solve the larger problem. Inspect the diaphragm

for the following:

D Small Puncture. Usually caused

the fluid, or by an ice particle.

E Diaphragm pulled away from the side. Usually caused by fluid

being frozen in the pump, or by over-pressurization of the pump.

D Diaphragm becoming stiff

caused by pumping a fluid

Use a 5/16 in. open end wrench, and turn

by a sharp foreign object in

and losing flexibility.

which is incompatible

Usually

with the

—

diaphragm material.

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Page 60

CrossFire 3.7

Section 6-6

b Diaphragm edge chewed away.

pressurizing the system.

f. Clean away any spilled oil. Apply Loctite #242 Threadlocker to the

screw of the new diaphragm (or the old one, as appropriate).

g. Install the diaphragm and tighten to 10 in-lbs.

h. Repeat the above inspection procedure

necessary) with the other two diaphragms.

4. Flush Contaminant from Hydraulic End

(only if a diaphragm has ruptured)

With the valve plate, manifold, and diaphragm cushion plate still

removed (see above), remove the oil drain cap (63) and allow all oil and contaminant to drain out.

Usually caused by over-

and replacement, if

Fill the reservoir with kerosene or solvent. Manually turn the pump

shaft to circulated the kerosene. Drain.

If you have EPDM diaphragms, or if food grade oil is in the reservoir, do not use kerosene or solvents. Instead, flush with the same lubricant that is in the reservoir. Pumps with have “E” as the 7th digit of the Model Number.

Repeat the flushing procedure (step “B” above)

Fill the reservoir with fresh oil. Manually turn

circulate the oil. And drain once again.

EPDM diaphragms

the pump shaft to

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CrossFire 3.7

e. Refill the reservoir. If the oil appears milky, there is still contaminate

in the reservoir. Repeat the flushing procedure until the oil appears clean.

5. Prime the Hydraulic Cells

With the pump horizontal, fill the reservoir with the appropriate

Hydra oil for the application.

All air in the oil within the hydraulic cell (behind the diaphragms)

must be forced out by turning the shaft (and thus pumping the

piston). A shaft rotator is included in the Wanner Tool Kit.

Turn the shaft until a bubble-free flow of oil comes from behind all the diaphragms.

low during priming, air will be drawn into the pistons (inside the

Watch the oil level in the reservoir.

Section 6-7

If it gets too

Hydraulic end). This will cause the pump to run rough, and you will have to start over again with priming the hydraulic cells.

Wipe excess oil from the diaphragm plate and diaphragms.

6. Reinstall Valve Plate (12) and Manifold (3)

Reinstall the valve plate (1 2), with the valve assemblies outlined above, onto the diaphragm plate (1 8).

Reinstall the O-rings (4) on the rear side of the manifold. Use

petroleum jelly or lubricating gel to hold them in place.

Reinstall the manifold onto the valve plate.

Insert all bolts (1) around the edge of the manifold, and alternately

tighten opposite bolts until all are secure. Torque to 15 ft-lbs.

nstalled as

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CrossFire 3.7

e. Recheck all bolts for tightness.

Section 6-8

HydraMaster Corporation

4/13/’95

Page 63

Service of

Hydraulic End

CrossFire 3.7 Section 6-9

his section explains how to disassemble and inspect the hydraulic end

(oil reservoir) of the pump.

CAUTION +

Do not disassemble the hydraulic end unless you are a skilled mechanic. For assistance, contact HydraMaster (206-775-7275) or the distributor in your area.

Depending on the repair you are attempting, you may or may not have to

remove the motor from a direct-drive pump/motor unit.

Internal piston components (21

the motor or crankshaft. The motor and crankshaft must be removed to service the connecting rod (59), piston housing (20), crankshaft (57), front bearing (68), back bearing (55), or seal (54).

TO SERVICE PISTONS WITHOUT REMOVING MOTOR OR CRANKSHAFT

1. Disassemble Pistons

With the manifold, valve plate, diaphragm cushion, diaphragm plate, and diaphragm removed, and the oil drained from the pump (see the basic

Service Section):

a, Remove the snap ring (27) from one of the pistons, using a standard

- 27) can be serviced without removing

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CrossFire 3.7

snap-ring pliers.

Pull out the valve plunger (24). This also removes the washer (26) and spring (35).

section 6-10

Insert a hook through the center hole pull the cylinder out of the piston. piston.

Inspect all parts, and replace the O-ring and any other parts which

are worn or may be damaged.

Repeat steps “a” through “d” for the remaining pistons.

2. Reassemble Pistons

Tip the pump so the

Drop a ball (21) into

Insert a valve plunger (24) into a valve cylinder (22). Slide a spring (25) over the plunger, inside the valve cylinder.

of the valve cylinder (22), and

Be careful not to damage the

pistons are vertical.

the opening in the bottom of the piston.

Slide the assembled valve cylinder, plunger, and spring (22-25) into

the piston (20).

Insert a washer (26) over the plunger.

Insert a snap ring (27) into the piston. Use the snap-ring pliers.

Repeat the above procedure for the other two pistons.

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CrossFire 3.7

TO SERVICE THE REMAINDER OF THE HYDRAULIC END

1, Remove Pump Housing

Remove the manifold, valve plate, diaphragm cushion, and

diaphragms, as outlined in the basic Service Section.

Drain the oil from the pump housing by removing the drain plug

(60).

Stand the pump on end, with the drive shaft up.

Remove the bolts (50) that secure the back cover (52) to the

housing (78). Use a 3/8 in. socket wrench. Save the O-rings (51).

Section 6-11

Remove the cover and the cover O-ring (53).

Remove the crankshaft (57) by pulling it through the connecting

rods (59),

2. Remove and Replace Pistons

To remove the pistons (20), first remove the connecting rod (59) and pin (58) by pressing the pin through the connecting rod.

Reverse the process to reinstall the pistons.

Refer to Step 5 and 6 below to replace

reassemble the pump.

3. Reassemble Housing and Casting

NOTE: Inspect the shaft seal (54) before continuing. If it looks

the diaphragm and

damaged in any way, replace it. Refer to “Replace Shaft Seal”

HydraMaster Corporation 4/13/95

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CrossFire 3.7

Section 6-12

below.

a. Stand the pump on end.

b. With the pistons and connecting rods in place, reinstall the

crankshaft by threading it through the connecting rods.

c. Reinstall the back cover, cover O-ring, and bolts (with their O-rings).

4. Replace Shaft Seal

Press the back bearing (55) and seal (54) out of the back cover (52).

Discard the seal.

Apply a coating to Loctite High-Performance Pipe Sealant with Teflon, or a comparable product, to the outer surface of a new seal and the inside surface of the opening in the back cover (52) where the seal will rest.

Press the new seal into the back cover.

Inspect the bearing (55). If pitted or damaged, replace it.

Apply a coating of Loctite Rc-609 retaining Compound or

comparable product to the outer surface of the bearing. Press the bearing into the back cover until it rests on the shoulder. The shield on the bearing must face away from the back cover.

5. Reinstall Diaphragms

a. Screw the plunger puller (from the Tool Kit or Repair

plunger (24). Pull out to expose the cross holes in

Kit) into the

the plunger.

Rotate the shaft until the piston is at top dead center.

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CrossFire 3.7

Insert a diaphragm hex wrench (from the Tool Kit), or similar dowel-

type object, through the plunger holes to hold the plunger away

from the diaphragm place (18), and to keep the plunger from turning when the diaphragm is being installed.

Apply a small amount of Loctite #242 to the threads of the

diaphragm screw (be sure the threads are clean}.

Set the diaphragm (17) on the plunger (24), ridge-side out. Screw

the diaphragm onto the plunger.

Hold the diaphragm hex wrench, and tighten the diaphragm to 10 in.-lbs of torque.

Section 6-13

Repeat the above procedure for the plungers and diaphragms of the

other two cylinders.

Fill the reservoir with fresh oil and prime the pump, as outlined in

9. the basic Service Section.

Reassemble Pump

Reassemble the pump as outlined in the basic Service Section.

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Page 68

CrossFire 3.7 Section 6-14

Cavitation

Inadequate fluid supply because of:

-Inlet line collapsed or clogged

-Air leak in inlet line

-Worn or damaged inlet hose Fluid too hot for inlet suction piping system. Air entrained in fluid piping system. Aeration and turbulence in supply tank. Inlet suction vacuum too high.

Symptoms of Cavitation:

-Excessive pump valve noise

Pump Troubleshooting

Drop

-Premature failure of spring or retainer (8, 10)

-Volume or pressure drop

-Rough-running pump.

in Volume or Pressure

Air leak in suction piping.

Clogged suction line or suction strainer. Suction line inlet above fluid level in tank. Inadequate fluid supply. Pump not operating at proper RPM.

Worn pump valve parts.

Foreign material in inlet or outlet valves.

Loss of oil prime in cells because of low oil level. Ruptured diaphragm.

Cavitation.

Warped manifold from over-pressurized system.

O-rings forced out of their grooves from over-pressurization.

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CrossFire 3.7

Air leak in suction line strainer or gasket.

Water Pulsations

Foreign object lodged in pump valve. Loss of prime in hydraulic cells because of low oil level. Air in suction line. Valve spring broken.

Cavitation.

Aeration or turbulence in supply tank.

Valve Wear

Normal wear.

Section 6-15

Loss

Premature Failure of Valve Spring or Retainer

of Oil

External seepage. Rupture of diaphragm. Frozen pump.

Worn shaft seal.

Oil drain piping or fill cap loose. Valve plate and manifold bolts loose.

Cavitation. Foreign object in the pump. Pump running too fast. Spring/retainer material incompatible with fluid being pumped. Excessive inlet pressure.

HydraMaster Corporation

4/13/95

Page 70

CrossFire 3.7

Figure 6-1

DETAIL “N

(Piston Assembly)

Section 6-16

(

i’

HydraMaster Corporation

4113/95

Page 71

CrossFire 3.7

Section 6=17

PARTS LIST

REF. NO.

2 3

6 7 8

10 11 12 14 16 17 18

19 20 21 22 23 24 25 26 27

PART NO.

D03-024-2010 C22-01 4-2000 D03-004-I 010 D03-073-21 10 C24-009-21 10 D03-020-1002 D03-021 -1002 D03-022-31 14 D03-092-21 10 D03-023-2310 D03-125-2310 D03-003-I 010 D03-029-2010 D03-088-2010 D03-01 8-1220 D03-002-1000 D03-075-21 10 D03-01 4-1004 DIO-015-3010 D03-043-1000 D03-034-21 10 D03-044-1000 D03-045-31 10 D03-049-1000 D03-048-2210

DESCRIPTION

Bolt, 3“ hex-head

Washer, 5/1 6“

Manifold, brass, NPT O-ring, manifold, Buna O-ring, valve seat, Buna Valve Seat, 17-4 SST Valve, 17-7 SST Valve Spring, Elgiloy Tetra Seal, Buna

Retainer, valve spring, Celcon Washer, dampening, Celcon Valve Plate, brass Cap Screw, socket-head, 1 “ Cap Screw, socket-head 1/2” Diaphragm, Buns-N-XS Diaphragm Plate O-ring, diaphragm plate, Buna Piston Ball Valve Cylinder

O-ring, valve cylinder, Buna Valve Plunger

Spring, sleeve valve Washer

Snap Ring

QTY. PER PUMP

8 8

1 2 6 6 6 6 6 6 6 1 2 2 3 1 3 3 3 3 3 3 3 3 3

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CrossFire 3.7

Section 6-18

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4/13/95

Page 73

CrossFire 3.7

Section 6-19

PARTS LIST CONTINUED...

REF. NO.

50 51 52 53 54 55 56 57

58 59 63 64 68 69 70 71 78

PART NO.

D03-086-2010 D03-036-21 10 D03-131-1000 D03-037-21 10 D03-031 -2110 D03-01 1-2910 D03-085-2210 D03-009-1003

D03-133-1000 D03-132-1000 000-027-006 DI 0-080-2110 D03-01 0-2910 D03-087-201 O D40-074-21 10 D03-I 30-1000 D03-001 -1001 M13-001-1001 D 10-040-2410

DESCRIPTION

Cap Screw, hex-head, with washer O-ring, back cover screws, Buna

Back Cover O-ring, back cover, Buna Seal, Buna

Back Bearing

Key, shaft Crank Shaft, shaft-driven,

3.0 GPM @ 1725 RPM

Pin Connecting Rod Cap, HydraPump w/ vent & O-ring O-ring, oil fill, Buna

Front Bearing Cap Screw, hex-head, 1/2” O-ring, front cover, Buna Front Cover Pump Housing [D-03, M-031 Pump Housing [M-1 3] Name Plate

QTY. PER PUMP

4 4

1 1 1 1 1

1 3 3

1 4

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8/1/95

Page 74

Cleaning Wand Parts

CrossFire 3.7

Section 7-1

Figure 7-I : VALVE ASSEMBLY

-----

----Y”

t ‘“ ‘--

-2,

1[ 1,0

i?2?z’’3/14

‘r

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4/’13/95

Page 75

CrossFire 3.7

Figure 7-2: JET ASSEMBLY

Section 7-2

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4/’13/95

Page 76

CrossFire 3.7

Figure 7-3: WAND ASSEMBLY

Section 7-3

Jet Assembly

Valve Assembly

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Page 77

CrossFire 3.7

Section 7-4

Valve, Jet, Wand Parts List

ITEM NO PART NO

1 167-013

2 094-009 3

4 052-152

5 6 7 027-001 8

9 10 097-010 11 097-022 12 13 14 052-071 15 16 17 052-153 18 186-001 19 076-005

20 094-028 21 22 23 24 25 26 27 061-007

Not Shown: 154-001

600-012-001

155-003

097-011

139-004 139-003

107-129

052-050

052-082

143-002

061-006 094-035

143-012 173-001

082-004

168-001

169-055

143-005 094-009 052-151 081-015

174-003

174-065

DESCRIPTION QTY

Trigger, Cast Hydra Hoe Valve Nut, 1/4 -20 Valve Body - HydraMaster Valve

1/4 Male Comp. Fitting - Hydra Hoe Spring, HydraMaster Solution Valve O-Ring, HMaster Solution Valve Cap Capr s/s HMaster Solution Valve Ring, Solution Valve Retaining Ring Keeper, HMaster Solution Valve O-Ring, HM Valve Plunger - Large O-Ring, Solution Valve/Flowmeter - small

Plunger, HydraMaster Solution Valve

440 Male Quick Connect with Viton

Nipple, 1/4 Brass Hex Elbow, 1/4 Brass 45 Street

Screw, 1/4 -20 x 1” HHC SIS

Brass Stabilizer Housing Stabilizer Jet, #6 s/s Hydra Hoe

Nut, Brass - Jet Assembly Group

Handle, Pressure Guide Wand

Nut, 5/1 6-18 s/s Nylock Half Nut

Screw, 5/1 6-18 x 3/4” s/s HHC Wand, s/s Hydra Hoe - Stock

Lips, 12“ s/s Hydra Hoe (2 piece set) Tube, s/s Hydra Hoe Solution

Handle Grip - Hydra Hoe

Spacer, 1/4 x 5/16 - s/s Sol. Valve

Valve Assembly, s/s Hydra Hoe

Screw, 1/4 -20 x 1.75” HHC s/s

Nut 1/4 -20

Compression, %“ Female Hydra Hoe Fitting

Label, “Hydra-Man” - Wand Washer, %” SIS Washer, .438” x 1” x .083” s/s

S/S Nylock

1 1 1 1 1 1 1 1 1 1 1 1 ‘1 1 1 1 1 1 1 2

1 1 1 1 5

1 1

1 4 2

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Page 78

Vacuum System

Crossl%e 3.7

section 8-1

he vacuum blower in this machine is a positive displacement lobe

T’

type. The performance and life of this unit is greatly dependent on

the care and proper maintenance it receives.

Because of the close

vacuum blower, solid

lobes, gears, bearings

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.

When machine is being run for test purposes and

of the machine is open, caution should be used.

To protect the vacuum blower from overloading and damaging itself, there is a vacuum relief system installed on the vac tank. When the vacuum

tolerances between the lobes and housing of the

objects entering the inlet will damage the internal

or drive system.

the vacuum inlet on top

tank inlet is completely sealed off, a maximum of 12 HG will be attained.

At the end of each day, an oil based lubricant should be sprayed into the

blower lubrication port before shutting down the machine. If you fail to lubricate the vacuum blower daily, rust deposits and moisture will

decrease the life of the vacuum blower.

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CrossFire 3.7

Foam passing through the blower could lead to serious problems.

Therefore, it is important to keep the vacuum tank foam free.

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

Section 8=2

demanding of the vacuum blower and therefore

more regularly.

-1

The Vacuum tank is protected from overflowing

kill switch. The switch is not activated by foam, only by liquid.

VACUUM TANK FILTER BAGS

HydraMaster filter bags are designed to trap lint, sand and dirt that would

normally collect at the bottom of your vacuum tank. The use of these

bags, if emptied at the end of each job, will eliminate the build-up of much

of the debris in the tank. The drawstring top of these bags is designed to be slipped around the incoming dirty water inlet in the vacuum tank.

it should be maintained

by a vacuum tank float

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Page 80

Blower Troubleshooting

CrossFire 3.7

Section 8-3

No Problem / Possible Cause

There is no vacuum or a loss

Solution

of vacuum.

1.1 The stainless steel filter is clogged. Clean or replace the filter.

1.2 The filter bag is clogged.

1.3 The vacuum tank dump valve is “open”

1.4 The hose on the live hose reels is collecting water.

1.5 The vacuum hose is plugged.

1.6 There is a restriction in the

cieaning tool.

or defective.

Clean or replace the filter bag.

If water drips from the valve when the machine is not running, the valve will cause a vacuum loss

when the machine is running.

Replace it if it is defective. Unroll the entire length of the hose

each time you use it.

Remove the obstruction by

reversing the vacuum hose.

Remove the obstruction.

1.7 The vacuum tank seal is defective.

1.8 The hose from the blower to the recovery tank is kinked or has collapsed inside.

1.9 There is a hole in the recovery

tank.

1.10 There is a hole in the vacuum

hose.

1.11 The vacuum release is loose.

1.12 The engine speed is too low.

HydraMaster Corporation

Replace the seal. Replace or reshape the hose.

NOTE: A special reinforced hose is required for replacement.

Inspect the tank for leaks using smoke and weld the tank if it is required.

Repair or replace the hose.

Readjust the vacuum release. Adjust the speed.

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CrossFire 3.7

Section 8-4

1.13 The vacuum blower’s end plates or Replace the worn components.

1.14 There are vacuum leaks around the A vacuum leak can usually be

Problem / Possible Cause

lobes are worn.

top collector box.

NOTE: This must be accomplished by a qualified technician.

detected by spraying a mist of WD40 or blowing smoke towards the leak. The mist or smoke will

be sucked into the leak. When you

Solution

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CrossFire 3.7

Section 8-5

Problem / Possible Cause

2 The blower is noisy.

2.1 There is an exhaust leak between the blower and the silencer.

2.2 The b/ower is out of oil or the gears may be bad. NOTE: Permanent damage may result from a lack of lubrication.

2.3 The silencer is bad.

2.4 The lobes are hitting.

2.5 The engine is running at the wrong speed. the blower noise increases with speed.

This is noticeable because

Solution

Inspect the fittings to determine where the air leak is. Repair as necessary.

Add oil. If the noise continues,

replace the gears or blower. NOTE: Replacement of the gears must be accomplished by a

qualified technician.

Inspect it for an external hole. Repair or replace the silencer.

Replace the blower. Adjust the engine to run at the

proper speed.

2.6 The bearings are worn.

Remove and replace the bearings as required. NOTE: This process must be accomplished by a qualified technician.

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CrossFire 3.7

Section 8-6

No Problem / Possible Cause

3 The blower will not turn,

3.1 The lobes are locked up because of rust, burnt chemical foam, or a sugar-like substance has been

vacuumed up from the carpet.

3.2 There is debris in the b/ower.

Solution

a. Most burnt foam and rust can

be removed by soaking the

lobes with liquid wrench. After

soaking the lobes, with the

machine running, pour a half gallon of hot water into the top of the blower. Then spray WD40 or Pennz Lube into the top of the blower to displace the water.

b. Any sugar-}ike substances can

be removed by soaking the

lobes with hot water.

Remove the debris. A stainless steel filter is provided at the

vacuum inlet in the vacuum tank to

prevent this problem.

3.3 The blower has broken gears or shattered /obes.

Rebuild or replace the blower. NOTE: Rebuilding the blower must be accomplished by a qualified

technician.

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CrossFire 3.7

Section 8-7

4.1

Problem / Possible Cause

The shaft turns, but the lobes do not.

The shaft is broken inside the blower.

Replace the blower.

Solution

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Page 85

Engine Troubleshooting

CrossFire 3.7 section 9-1

1.1

1.2

1.3

1.4

1.5

Problem / Possible Cause

The engine will not turn over.

The circuit breaker on the control panel has tripped.

There is a loose battery cable or corroded battery

The battery is dead. There is a problem with the fuse

link. There is a problem with the starter

solenoid.

terminals.

Solution

Press the reset button. Inspect the

unit to determine the cause of the tripped circuit breaker and correct the problem.

Clean and tighten the battery terminal connections,

Recharge or replace the battery. Check the link. If it is defective,

re~lace it. With the ignition switch in the

“Start” position, check the following on the solenoid. Check for + 12 volts on: a. the small terminal with the blue wire from the ignition switch, b. the large terminal with the cable from the battery, and c. with the cable going to the starter.

If the voltage is present on the first two checkpoints, but not on the large terminal going to the starter, replace the solenoid.

the large terminal

1.6

1.7

The ignition switch is defective.

The vacuum blower has seized.

HydraMaster Corporation

Test the switch for entering voltage. If there is voltage entering but no voltage exiting the center post when the switch is fully engaged, then replace the switch.

Refer to The Blower, Chapter ?O.

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CrossFire 3.7

Section 9-2

No Problem / Possible Cause

1.8 The starter motor is defective.

1,9 There is an

1.10 The ground cable underneath the

motor has fallen or broken off.

engine problem.

Solution

Remove the belt(s) from the engine. Check to see if the engine will turn over manually. Check that the engine is grounded to the minus side of the battery. With the ignition key in the start position, check the starter motor for + 12 volts. If ail of the above conditions are met and the starter will not turn, replace it.

Refer to the engine operation and maintenance manual in owner’s manual or see the local Briggs & Stratton engine repair facility,

Reattach the cable.

your

HydraMaster Corporation 1/25/96

Page 87

CrossFire 3.7

Section 9-3

No Problem / PossibleCause

The starter turns the engine over, howeverthe engine will not start. (There is no spark+. )

2.1

2.2

2.3

2.4

The recovery tank is full.

The recovery tank float is causing

the engine to shut down.

The engine is malfunctioning.

The magnetron is malfunctioning.

Solution

● Check for spark at the spark plugs. If

;!lGl?s;Zo?;~kg$~Y[;vZe However, if

there is no gas, see troubleshooting problem number 3 on the following page for possible fuel problems.

Empty the tank. Disconnect the float. If the unit

starts, replace the defective float.

Refer to the Briggs & Stratton Engine Maintenance manual included in your owner’s manual.

Check the magnetron. If it is adjusted properly, all the wires tight, and none of the wires are grounding out, then remove all the wires from the engine kill lug. If there is still no spark, replace it.

2.5

2.6

2.7

2.8

A spark plug is faulty.

The engine ki!l relay is

malfunctioning.

The oii pressure switch is causing the engine to shut down.

The high temperature shutdown switch is defective.

Check for worn, fouled or improperly gapped spark plugs. Replace if necessary. CAUTION: Allow the engine to cool completely before attempting to remove the plugs.

Remove either end of the wire that runs from the relay to the engine kill lug. If the engine starts, replace the relay,

Check the engine oil level. If it is at the proper level, then disconnect the oil pressure switch. If the unit starts, then replace the switch.

Disconnect the switch. If the engine starts, then test the switch. The switch operates at 2450 F.

Replace it if it is defective.

HydraMaster Corporation

4/’13/95

Page 88

CrossFire 3.7

Section 9=4

Problem / PossibleCause

The starter turns the engine

over, however the engine

will not start. (There is no

gas+.)

3.1

3.2 There is a poor battery ground to

3.3 The fuel pump is sucking air

3.4

The fuel pump is defective.

the fuel pump.

between the gas tank and the inlet side of the fuel pump.

The fue/ fi/ter is clogged.

Solution

Check for spark at the spark plugs. If

there is no spark, see troubleshooting

problem number 2 on the previous page. However if there is a spark, examine the above troubleshooting guide for possible fuel problems.

Remove the fuel line from the engine and place it in a container to see if the fuel is being pumped when the ignition is on. Replace the fuel pump if it is defective.

Repair the loose ground connection.

Examine the gas inlet side of the fuel pump. Tighten any loose

fittings or clamps. Replace any ruptured hose.

Inspect the filter and replace if necessary.

3.5

3,6 The engine’s carburetor solenoid

The quick connect in the fuel line

is clogged.

valve is defective.

3.7

In CrossFire machines only, the

wer float in the chemical mix

tank, which also activates the fuel solenoid at the carburetor, is

defective.

Clean or replace the quick connect.

With the ignition on, check for 12 volts going to the valve. If the voltage is present, the valve should be open. Replace the valve if it is defective.

Push in the freeze guard switch

located on the lower control panel.

(This is recommended because it is

possible for the float switch to

carry enough continuity to light a test probe but not enough to open the solenoid. ) If the engine starts

and runs with the switch engaged, then replace the defective float.

HydraMaster Corporation

4/13/95

Page 89

CrossFire 3.7

Section 9-5

3.8

3.9

3.10 In CrossFire machines only, the

Problem / PossibleCause

In CrossFire machines only, the chemical mix tank is out of water caused by a defective upper float

in the mix tank.

In CrossFire machines only, the

chemical mix tank is out of water

caused by a dirty or defective

solenoid valve along side of the

mix tank.

chemical mix tank is out of water caused by a defective chemical

relay.

Solution

When the float is down, the circuit is open. When the float is circuit is closed. Replace the float

it is defective.

The solenoid valve is normally closed and should open with 12 volts across its terminals. Remove

any foreign matter from inside the valve. Replace the valve if it is defective.

Remove the wire going to the chemical relay terminal 86. Turn the ignition switch on and check for -t-12 volts on relay terminal

87a. If no voltage is present,

replace the relay.

up, the

HydraMaster Corporation

1/25/96

Page 90

CrossFire 3.7

Section 9-6

Problem / PossibleCause

The engine runs poorly or

diesafterrunningfor awhile.

4.1 The air or gas filter is clogged.

4.2

4’.3 The fuel pump is sucking air

4.4 The fue/ pump is defective.

There is a poor battery ground to

the fuel pump.

between the gas tank and the fuel pump.

Solution

Inspect both filters and replace the clogged one.

Inspect the electrical grounds and repair any loose ground connections.

Inspect for air leaks between the fuel pump and the gas tank.

Repair or replace any leaking components.

Remove the fuel line from the

engine and place it in a container to see if the fuel is being pumped

when the ignition is turned on.

Replace the fuel pump if it is

defective.

4,5 There is excessive engine load.

4.6

The engine overheats from poor

ven tiia tion.

4.7 The engine overheats from carbon build up in the combustion

chamber.

4.8 The engine overheats from too

much oil in the crankcase.

4.9 The carburetor solenoid valve is defective.

Clean and adjust the recovery tank relief valve. Adjust for 12 inches of lift under a full load.

Remove any air restriction from around the engine. Add

vent or external fan, if necessary.

Refer to a local E3riggs & Stratton dealer.

Check the oil level and correct if

necessary. With the ignition switch on, check

for 12 volts at the solenoid valve.

If the voltage is present, the valve should be open. If the valve is defective, it must be replaced.

a roof

HydraMaster Corporation

4/13//95

Page 91

CrossFire 3.7

Section 9=7

4.10 The engine is malfunctioning.

4.11 In CrossFire machines only, a

4.12

4.13 In dual tank Fords, the engine is

Problem / PossibleCause

clogged heat exchanger is back pressure.

In CrossFire machines only, the 10wer float

pulling through the ‘Tank

Switching Valve’.

in the mix tank is bad.

causing

Solution

Refer to the Engine Operation and Maintenance manual, or see local Briggs & Stratton dealer.

This will cause the engine to run

slow

carburetor. Remove the two brass

the bottom of the copper heat

and spit gas from the

plugs from the end of the stainless steel heat exchangers. If the engine runs better without the plugs, then clean the debris from

exchanger.

If the engine runs better when depressing the freeze guard switch, then teplace the lower float.

Do not try to pull gas from both tanks.

4.14

The PCV valve is defective.

Remove and check the air cleaner

for oil saturation. If it is saturated,

replace the PCV valve and air filter.

HydraMaster Corporation

1/25/96

Page 92

Electrical System

CrossFire 3.7 Section 10-1

he CrossFire electrical system has been specifically designed with the

operator in mind.

electrical failure.

The CrossFire series of machines utilizes a wiring diagnostic center which allows the operator or mechanic to trace all the electrical circuits from the front of the machine.

The entire electrical system operates on 12 volts DC which is provided by

a battery. engine. NOTE: When a new battery is installed, check that it is properly charged

Battery levels are sustained by a 20 amp alternator inside the

Often the most difficult problem to trace is an

before installation or damage to the charging regulator may occur.

HydraMaster Corporation

4/13/95

Page 93

CrossFire 3.7

Figure 10-1

CHEM. RELAY

-$CF:E=

Section 10-2

TEMP.

SEhmR

OVERRIDE

Swrron

FUEL PUMP

070

FLOAT

DUMP

SOL

ICROSSFIRE 3.7 WIRING DIAGRAMI

4 I

w 3

TEMP. GAUQE

VAC.

GAUGE

Q.%D

HydraMaster Corporation

4/’13/95

Page 94

Machine Maintenance

CrossFire 3.7 Section 11-1

o 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. All recommended maintenance must be performed by competent service personnel.

Important: Record date and machine hours in maintenance log.

VVe have provided a maintenance log for your convenience at the end of this section.

required to be furnished to Hydra Master before the warranty is honored.

It is recommended that you affix a copy of the log on the vehicle door

near your unit for convenience and to serve as a maintenance reminder.

OPERATIONAL MAINTENANCE

DAILY

Check engine oil level. Inspect garden hose screen.

Visually inspect machine for

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

Clean, repair or replace as needed.

Lubricate blower with an oil based lubricant through blower inlet.

Records of maintenance must be kept and copies may be

Clean as needed.

loose wires, oil leaks, water leaks, etc.

HydraMaster Corporation 6/28/95

Page 95

CrossFire 3.7

WEEKLY

One time check of the belt tensioning Check oil level in blower. Check high pressure pump oil. Add as necessary. Check drive system screws. Tighten as needed. Check pump drive belt for wear. Check pump pulleys. Check high pressure water lines for wear or chafing. Check all nuts and bolts. Tighten as needed. Check “Y” filter. Clean as necessary. Clean recovery tank thoroughly with high pressure washer. Check for any chafing in wiring.

Flush water and chemical system with 50/50 white vinegar solution.

after first 25 hours of use.

Section 11-2

Change engine oil every two weeks.

MONTHLY

Change oil filter. Check engine air cleaner filter. Clean as necessary. Remove pressure By-pass Valve stem. Grease stem. Reinstall. Check water level in battery. Clean connections as needed. Check the belt tensioning every 2 months.

The single belt drive system tension is approx. 3%”deflection with 8 to 9 Ibs of force, measured at midspan. The dual belt system tension is approx. measured at midspan.

QUARTERLY

3/8” deflection with 4 to 5 Ibs of force per belt,

Check engine compression. Clean and gap spark plugs.

HydraMaster Corporation

6/28/95

Page 96

CrossFire 3.7

Change oil in blower. Change oil in pump. Grease blower bearing fittings.

DE-SCALING, As Required

Scale deposits on the interior of the heating system can cause a noticeable loss in heating performance. hard water deposits, excessive chemical use, improper chemicals, etc. The frequency with which de-scaling procedures are required will vary.

If your area has particularly hard water or you see evidence of deposits

in the water system, you may have to de-scale monthly. To de-scale your

Deposits of this kind result from

Section U-3

system, add an appropriate de-scaler chemical to your mix tank. Circulate it through the heating system. Let it stand. Flush and repeat as necessary. Clean all screens and strainers, and check them frequently following de-scaling.

OVERALL MACHINE MAINTENANCE

Maintaining the original appearance of your unit is important for two reasons:

2. Maintenance,

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

troubleshooting, 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.

and repair is much easier to

HydraMaster Corporation 6/28/95

Page 97

CrossFire 3.7

The following maintenance is recommended by the manufacturer at the frequency indicated:

AFTER EACH JOB

Check recovery tank, stainless steel filter and filter bag as required.

DAILY

Wipe machine down thoroughly with a damp cloth.

Flush recovery tank out thoroughly. Empty filter bag and inspect for rips, tears, etc. Replace as needed.

Section n-4

Remove, thoroughly clean and reinstall stainless steel filter screen in

recovery tank.

Inspect and clean vacuum slot on cleaning wand.

Check wand head for sharp edges that could tear carpet. File down as

needed. Clean wand to maintain original appearance. Wipe down vacuum and high pressure hoses as needed. Visually inspect hoses 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

Remove stainless steel filter in recovery tank and thoroughly clean,

removing ail lint build-up. Inspect for damage and reinstall. Remove filter bag.

Thoroughly clean and reinstall. If torn, replace.

gun may be used for this).

HydraMaster Corporation

6/28/95

Page 98

CrossFire 3.7

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 lines for wear or abrasions that may cause possible leaks.

Section 11-5

HydraMaster Corporation

6/28/95

Page 99

MAINTENANCE LOG

MAX

I-IRS

8 8

25 25 25 25 25 25 25 25 25 25 25

DAILY SERVICE

ENGINE OIL check GARDEN HOSE SCREEN clean PUMP MACHINE general inspection RECOVERY TANK FILTER BAG clean BLOWER INLET spray with Iubricsnt

BLOWER

ENGINE 30 weight motor oil

40 weight non-detergent 5-30 weight synthetic motor oil

NOTE: overhead valve engines canusemulti-viscosity oil, but will experience incressed oil consumption.

OIL RECOMMENDATIONS

WEEKLY SERVICE DATE & HOURS

BELTS check tension BLOWER check oil level PUMP OIL check DRIVE SYSTEM tighten ecrews BELTS & PULLEYS check for wesr HIGH PRESSURE LINES check for chafing NUTS & BOLTS check tightnees

“Y” FILTER check and clean RECOVERY TANK clean WIRING check for chafing

CHEMICAL SYSTEM flush with vinegar ENGINE OIL change

Sreak-in. One time only.

MONTHLY SERVICE

100

100 100

100

200

300 300 400 400 400

OIL FILTER change

ENGINE AIR CLEANER clean

BY-PASS VALVE grease cup and stem

BATTERY WATER LEVELS check BELTS check tension

QUARTERLY SERVICE

(3 MONTHS)

ENGINE COMPRESSION check SPARK PLUGS cleen and gap

BLOWER OIL change

PUMP OIL change BLOWER grease bearing

Page 100

How to Order Parts

CrossFire 3.7

Section 12-1

o obtain a proper diagnosis of your malfunction, and to order warranty

replacement parts, it is important that you proceed in the following

manner:

WARRANTY PARTS ORDERS

Call HydraMaster Warranty/Service Department at (206) 775-7275.

Give the Warranty/Service representative the following information:

A. Your Company Name and Address

Equipment Model

Date of Purchase

Hours on the Unit

Unit Serial Number

Name of Person Authorized to Order Parts G. Sales Representative from which Unit was Purchased H. Description of Malfunction

1. High Pressure Gauge Readings with the Wand Turned On and Off

If warranty replacement parts are needed, please specify method of

shipment desired. require replacement parts overnight they will be sent freight collect, via: Air Freight, Air Mail, or Air Express.

Do not give malfunctioning parts to a HydraMaster sales or service

representative. All parts must be returned directly to HydraMaster,

freight prepaid.

HydraMaster will pay for ground UPS. If you

HydraMaster Corporation

4/13/95

HYDRAMASTER CrossFire 3.7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents