HYDRAMASTER HydraCat User Guide

HudraCat

HYDl?A&#ASREZ.

Corporation

I

1

I

I1319W HydraMaster Corp.

Printed in U.S.A.

GENERAL INFORMATION

Howlhe System Works..............................................................................2

Spare Parts Recommendation ..................................................................2

Machine S~cifi~tions .............................................................................2

Warning and Caution.................................................................................2

HowtoOrder ..............................................................................................3

PatisOrders ..............................................................................................3

One Final Note..........................................................................................3

Purchaser’s Responsititi~ ........................................................................3

Sales Representative’s Responsitili~ ......................................................3

TwckSelection ..........................................................................................4

TmckPre~ration ......................................................................................4

Tmck Pre~ration illustration .....................................................................4

Placementof Unitin Vehicle.......................................................................4

Machine installation ...................................................................................4

Propane Tank Location.............................................................................5

HardWaterArea Map................................................................................5

WaterSofiener ..........................................................................................5

Wastewater Disposal AdviwW ..................................................................6

Mactine A~ustments ................................................................................6

OPERATING INSTRUCTIONS & PRECAUTIONS

shdup . ....... ................... ................. ................... ........................ ...............6

ShutDom .................................................................................................6

Cautions and Warnings .............................................................................7

Freeze Protection......................................................................................8

Alternative Protection Using Anti.Freeeze .................................................8

Cleaning and Chemical Precautions ..........................................................8

Cleaning Stroke Procedure/Over.wetiing .................................................8

Water and Chemical Flow Operation .........................................................9

Chemical System Maintenance .................................................................9

Chemical Tank Trouble Shooting Guide..................................................lQ

Water Flow Trouble Shooting Guide
Vacuum System Information

VacuumTankfilter Bags.........................................................................l2

Vacuum Blower Wanan~ ........................................................................l3

~,,..:VacuumBlower Lubri~tion .....................................................................l3

Vacuum Blower Trouble Shooting Guide
Heating System Information

HeaterOperating lnstmctions ..................................................................15

HeaterTroubleShmtingGuide...................................................................l5

CatPump Mode12900prating lnstwctions ............................................l6

Cat Pump Wman~ .................................................................................l6

Mode1290PartsList

General Information forCatPump Repair................................................l8

Servicing the ValveAswmblies ...............................................................l8

Servicing the Pumping Section ................................................................l9

Servicing Sleeves and Seals...................................................................l9

Servicing Crankcase Section..................................................................l9

Cat Pump Trouble Shooting Guide..........................................................2O

HydraCat Electrical System
Onan Performer Engine

General Information about Onan
ENGINEMAINTENANCE

OilSystem

...............................................................................................25

.................................................................................l7

.....................................................................22

SPCS . ..... .................. ................................. .. ....23

........................................................................25

........................................................ll

...................................................................l2

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

.....................................................................l4

.............................................................24

%--14

ignition....................................................................................................27

Cooling System
Exhaust System
AirCleaner

Batie~ .........................................................................................................28

Periodic Maintenance Stiedule ................................................................29

Engine Trouble Shooting

Maintenance Procedures........................................................................32

Overall Care ofUnit..................................................................................32

Maintenance Logs

Warranty Information

Warran~Pro~dure ................................................................................36

Limited Warranty Plan.....................................................lnside back cover

.......................................................................................27

.......................................................................................27

...............................................................................................27

.. .......... ...................... ............. ................... .......3o

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

...............................................................................36

LIST OF ILLUSTRATIONS

Plywood lnstallation(ontwck &d) ..............................................................4

AstiotudandRoof Vent...............................................................................4

Machine XeDow Cleats...........................................................................4

~chine Configuration ...............................................................................5

Pro~neTankPlumting .............................................................................5

HardWakrMap .........................................................................................5

WaterSofienerHook.up .............................................................................6

pHChati .....................................................................................................8

CleaningStroke Procedure........................................................................8

Chemiwl System Wring ............................................................................9

WaterFlow .................................................................................................9

Chemical Proportioning and Level Control..................................................9

WandValveAssembly ..............................................................................lO

JetAswmbly ............................................................................................lO

WandAswmbly .......................................................................................ll

Wand Valve Stem Aswmbly ....................................................................ll

By~ss ValveAswmbly ...........................................................................ll

VacuumFlow............................................................................................l2

VacuumTankRlterBags ..........................................................................l2

BlowerLubPofi ......................................................................................l2

VacuumBlower Motor Lubrication............................................................l3

RlotBwnerAdjustment ............................................................................l5

Model 290 Exploded Mew.......................................................................l7

Pumping ~ction Cubway .......................................................................l8

HydraCat Electrical Diagram....................................................................22

BasicUmensions. P224..........................................................................23

Basic Dmensions. P220..........................................................................23

OIMmsi~ ..............................................................................................25

OlfilterLoMtion ......................................................................................26

P220CmnkMWBreather ........................................................................26

P224CmnkMWBreather ........................................................................26

SewicingS~rkPlug ................................................................................27

ArCleanerAswmbly ...............................................................................28

SWcificGravi~Test .................................................................................28

BatieqCaMeConnection .........................................................................28

LIST OF PHOTOS

HydraCat (kontview.features labled) .......................................................7

HydraCat(sidetiew. featureslahled) .......................................................7

CatPumpMode1290 ................................................................................l6

Semicingtie Pump...................................................................................l9

Onan Performer Gasoline Engim .............................................................23

SparlrPlug Diagnosis

1

...............................................................................27

GENERAL UWWWIATION

T’hwmanual contains installation and operation instructions aswII as in­formation rquired tar proper maintenance, adjustment and repair of this
unit. Since the first and mast important part of repair work is the correct
diagnosk of the trouble, ageneral troubleshooting section and component
manual troubleshooting charts have fxen included for your convenience.

IMikea garden tractw, Iawmnower arcement mixer, all having one ortwo
functions 10fwrtarm,
functions to pwform simultaneously.

thebuck-mounted carpet cleaning plant has many

MACHINE SPECIFICATIONS

‘RAME: 2~ W, 59 L,3& H. Steef with baked-on epoxy finish.
VEIGWE HydraCat 4.0:630 tbs. (dry ‘might)

HydraCat 4.5:750 Ibs (dry weight)
;OWUNG: Steel with baked-on Epoxy finish.
NGINE: HydraCat 4.0: P22020 BHP Onan

HydraCat 4.5:P22424 BHP Onan

* Engine has to run at a consistent RPM.
‘ Vacuum has ta pull air and d@ water bad from cleaning site.

● Waler pump provides stable pressure at proper water flow for cleaning.

*Chemical has to be injected into the water stream at the

right cmcentration.

* Heater must maintain proper hsat.

Vacuum tank must store dirty water until drained.

*

HOW THE SYSTEM WORKS

The water system takes incoming water at tap (low) pressure, combines it
wilh chemicals from the chemical system and pumps it under pressure
through theheatingsystern, anctouttothec]eaning tool.After being sprayed
into the carpet, Ihe water/chemicaf/soil solution isextracted by the vacuum

system and returrwd to the waste recovery tank.

There is no guess wrk in the manufacture of these highly advanced

cleaning

pfmts.There must also be no guess work inpreparing ittoget the

job done in the field. his the purpose of this manual to help you prqwty
understand, maintain and service your cleaning pfant. Follow the directions
carefully and you will be rewarded with years of profitable trouble-free
operation.

It isimperatfvethat nw$eclfonbeoverlookedwhen preparing for operation
of this equipment.

SPARE PARTS

RECOMMENDATION

Because your truck-mounted unit is capabfe of generating several hundred

dollars Wr day,

In order to minimize such down-time, it is strongly recommended by the
marwfacturcx that PU pumhase and keep in your truck the following spare
palls:

PART NO.

078-015 Flow
4178-(119 Wand vafve dunger kit 1

Wlf4XJ4 Pressurebypass

076-005 Spray @ W06E

048-029 Recovwv

078-001 cat 290
078-004 f%t 290 hoi CUPkit (~ tionat) 1

048-023
0624W0 440
052-051

052-052

a52-a53 660 F@mafequick mned

106-015

010-021

down-time on the unit can be very expensive.

0ESC13fPTKIN

meterkit

vafvekti

tankfitterbag

short cqp kdstandard 1

Screen, qarden hose

Mafequick conned 1

440 Femete quick conned 1
660 Male quick conned 1

Ermine@plug 2
HydraCalpumpdrivebelt

WY.

1
1

1

2

6

1

1

GNfTfON: Electronic, Keystart.
ii-PRESSURE

PUMP: Tri-Plex piston -- Cat 290- 3.5 W%!

-1200 PSI -- @ 1200 RPM.

fACUUM BLOWER: HydraCat 4.0: 4ML

HydraCat 4.5: 4LL

Sutorbuift W/l 2 HG Safety Relief.
:HEM[CAL SYSTEM: Electro-mechanical, meter Conlro!l@d.
WATER: Propane fired, thermostatically controlled (180,000 BTU).
NSTRUMENTS: 0-1000 High pressure gauge, Temperature

gauge,

/acuum gauge, Hour meter, Chemical flowmeter, ignition key, Start andon
ndicator fights, Pump clutch switch, Circuit breakers.

?ECOVERY TANK: 70 gallon aluminum, Epoxy finish.
;LEANING WAND: Stahless steel with heat shield, Gripand replaceable

racuum fips with stainless steel solution valve.
+f-PRESSURE HOSE I/& High-temperature linecflvin~ covered, Hose

ated to 1250 PSI.
IACUUM HOSE: 2’ reinforced, 1 1/2’ reinforced.

STANDARD EQUIPMENT: Power conso!e, Sound suppression Packagq
Electric Pump Clutch, Water heater, Vacuum Recovery tank, Carpet
cleaning wand, Chemical jug, Chemicafjugholder, Chemkal@gfill line,(lp
eration manuaf, 150ft. 2’ vacuum hose, 10 ft. 1 1/2” vacuum hose, 150ft.
Super-flex solution fine, 10 ft. drain line, 50 ft. water supply line, ~
!d! Freeze guard system, Battery boxwithholder, Vandeca! package, Fuel
system kit, Installation kit.

ADDITtONAL EQUIPMENT, HYDRACAT4.5: Oversize air handling pack­age, High-output component power pack, Super dual silencer system,
electronic tachometer.

The manufacturer uses this symbol throughout We rnarwai to wwrr

Qfposslbie injury ardt?alh.

This symbol is used 10warn of possible ei@gme?rMdamage.

2

HOW TO ORDER PARTS

To obtain a proper diagnosis of your malfunction, and to order warranty
replacement parts, it is important that you proceed inthe following mannec

1. Call HydraMaster Warranty/Service Department at [phone].

2. Give the Warranty/SeM”ce representative the following information:
A. Name of your company and your address.

B. Equipment model (i.e. HydraCat, Bobcat 2, etc.).
C. Date of purchase.
D. Hours on the unit.
E. Serial number of unit.
F. Name of person authorized to order parts.
G. Salesman unit purchased from.
H. Description of malfunction.

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

3. If warranty replacement parts are needed, please specify method of
shipment desired. NOTE: All replacement partsare sent freight collect, via:

A. U.P.S.

B. Air Freight
C. Air Mail

4. Do not give malfunctioning parts to a HydraMaster sales or service
representative. All parts must be returned dlrectfy to HydraMaster,
Freight prepaid.

D. Air Express
E. Auto Freight

PARTS ORDERS

To expedite your parts needs, please caii your saies representative.

Inmost instance, he either stocks orhas access toparts through aregionai
service center. Inthe event parts are unavailable iocaliy, contact the factory
and coordinate your needs. ifthis becomes necessary, always indicate the
method of shipment you desire, i.e. UPS. Blue Label, Air Freight, Air
Express, etc.
HydraMaster Parts Department. Phone [phone].

ONE FINAL NOTE

Anyquestionsyou have regarding the warranty program shouid bedirected
to the Warranty/Servkxr Department personnei at HydraMaster Corpora­tion.

We shallalwaysendeavorto befairinourevaiuationof yourwarrantyclaim,
and shali provide you with a complete analysis of our findings.

HydraMaster Warranty Poiicy (inside back cover)
Effective February 1,1989
HydraMaster warranty covers oniy defective materiais andlor workman­ship for the periods listed. Labor, and/or diagnostic reimbursement is
specifically excluded.

PURCHASER’S RESPONSIBILITY

PRiOR TO ARRIVAL OF UNiT

1.lnstali 5/8” extenorplywoodflooring invehicle and cover with artificial turf.

2. Have beiiy mounted propane tank installed on vehicie. Tank must be
propane vapor type.

3. Purchase heavy duty 42-60 amp hour battery and have battery ‘slow’

chargedjfnew. Ifbatteryisnotfully chargeddamage can occurto tie engine
charging regulator.

READiNG OF OWNERS MANUAL: it is the purchaser’s responsibility to

read the unit operation manuai and to familiarize himself with the informa­fioncontainedtherein. Speciai attention shouidbepaidtoaii Cautions
and WARNINGS.

SALES REPRESENTATIVE’S

RESPONSIBILITY

ACCEPTANCE OF SHiPMENT:

1.ifunit showsanyoutward signsof damage, do not signthedeiiveryreceipt
untii you have closely inspected the unit and noted any damage on the
deiiveryreceipt. Have thefreightcompanyrepresentativeacknowledgethe
damage by signing the notation of damage on the delivery receipt.

2. The salesman from whom you purchased your unit is responsible for
supervising thecomectinstallation ofthe unit inyour vehicle and thoroughly
training you in its operation, maintenance and precautions.

CORRECT iNSTALLATION iNCLUOES: Installation of through-floor fit­tings for propane and gasoline fuel lines; installing propane regulator
included with unit, outside vehicie; placing unitand recovery tank invehicle
and securing them with bolts or tiedown cleats ;connecting all propane and
gasoline Iinew connecting battery; checking pump, vacuum biower and
engine oil ieveis, prior to starting unit; starting unit to check engine to see
that ail systems function normaily; aiw checking ail hoses, wands, etc., for
carect operatiin.

TRAfNiNG SHALL iNCLUDE: Thorough review of the operation manual
with purchase~ instruction and familiarization in: how to correctiy start up
andshut down unit; howtocorrectiyciean withthe unit; how,where andhow
often to check and change component oil ievels; how the unit’s systems
worlc how to troubleshoot the unib how to do basic repairs; safety precau­tions and their importance; freezing damage and how to avoid it and a
thorough review ~ the unit warran~ and w&ranty procedures.

HOURS

Monday -- Friday

8:00 am To 5:00 pm

PACIFICSTANDARDTIME

TELEPHONE NUMBERS

[phone] Generai offices
[phone] Parts Department
[phone] Service/Warranty
[phone] FAX

3

TRUCK SELECTION

The preferable vtllclefor HydraCat iristallationis apam?lvanwith aheavy­duty swyx?nsirm package. The capacity ofIho van should be a heavy-duty

1/2 ton at ttm minimum and more preferably a 3/4 ton o&pacity.

TRUCK PREPARATION

The manufacmrarmmmmands theinslallation ofpl~od flooring covered
wiftr paly propylene backed astroturf (do not use rubber-backed) in the
vehicl~ prior to installation of machine. This provides a metal to cushion
mounting rather than metal to metal, provides insulation and makes an
attractive van interior. Aslroturf should be color keyed to van interior.

Materials Needed:

1.2 sheets 4x8x5/fY exterior plywood

2. &xl 2’ piwe of commercial astrotwf

3. 16-f lM sheet metal screws

4.1 quart marine adhesive (optional)

5.1 staple hammar wII12” staples
(See illustration for correct placement of plywood flooring)

ILACEMENT OF UNIT
4VEHICLE

we are two recommended unit placements:

SIDE DOOR: Most installations are side door. This provides rearamss
p accessories and hoses as well as unobstructed access to compmwnti
]rfdngside of machirw, thus making it abiteasiw’ io perform maintenance
IWorrepair without removing unit from the truck.

REARDOOf%Afthaugh this location partly limits working access, itdoes
wet the noise away from the cleaning site. Some cleaners in the colder
eas prefer this location because if puts the weight mass ow?rthe rear
~eelsfor better traction in ice and snow. Rear mounting requires ttw unit

beslid tothe right side as faras possible. This not only provides adequate
xking space on the component side of the unit but also makes better
sight distribution inside the van (engine and cornponer?tweight line up
~erdrive shaft). Also, it is physically easier to load unit into rear door due

height of van bed.

rrsure that machine is well secured to the floor of van with hwchvafe
~pplied.Sudden orwash stop Wlcause machine torocket foru%wd,all 750
s. wrth! Protect yourself and the machimz SECURE lT#

TRUCK PREPARATION
ILLUSTRATION

FIRST, covtwth~ truck kd with 5/8’ p@vood using metal screws tosecure
it as shown.

Plywood Immlwcm

SECOND, wlecttWappro@ate coloras!roturfto match yourvan andcm
tie plywood and staple in place. A standard van requires a piece 6 feet b]

12feet.

THIRD, Hydrafdasler strongly recommends an aluminum roof vent be in

stalIed over Ihe location selected for mounting the machine. HydraMaste

alsohighly recommends a flue be installed between the lop of the heate

and the roof vent.

Thiswillallow hot air from the heater to escape.

5/8” Plywood

Machine Tie f?own Cleats

I

UIACHINE INSTALLATION

‘hereare twoways of positioning the machine inthe truck as shown.Thwu
re also two locations for the vacuum recovw’y tank to be pasitiom?d.l%%
w?standard waywith fhe tankdirectly alongside the machine. %?cond,with
Ie tank across the back of the machine as shown on the illustration on the
Iextpage; this location is most spaca eflicient. Whichew?rway YOUsdect,
lake sure the tank and machirm aresecured tothe tloorof thevan to insure
Iriver safety.

tis important that the machine lx?placed as close to the door as possibh?
o that outside air can b pulled into the engine for proper cooling.

4

Machine Configuration

::

———

0 .UrloidB----

:

E

Iiisrecommendedbyfhe manufacturerthatthe exhaustfi’om thefrontofth
machine be venfeddown under the truck toprevent carbon monoxide frof

I

I

entering ihspb We.

away torn Ihejob site.

Aiwaysparkthe fruckso theexhaustis bfowiq

HARD WATER AREA MAP

quality of water variis greatly throughout the United States and

The

influences the reiiibility and effiiienoy of equipment in direct proportion to
its !evelof hardness. The map below detinesareas which cornprumise fluid
related components such as hoses, fittings, heaters, pumps, valves and

water cooled engines.

Cleaning efficiency and equipment life is increased, chemical use de­creased and the appearance of cleaned carpets enhanced when water
softeners are incorporated in hard water areas. Manufacturer strongly
urges the use of water softener units in areas exceeding 3 1/2 grains per
oallon. Using the legend as a reference, determine the quality of water in
~our area aid take ;ction immediately should it be nece&a~.

The

manufactureraiso recommends that instillation of aluminum vents i

$

the truck roof to a//ow heat from the heater to escape.

Never operate this machine
can inside the truck, doing so increases the risk of a fire or explosion.

Mount afire extinguisherjusf inside the rear or side door foremergencie:

with aportable propane tank oraportable ga

PROPANE TANK LOCATION

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

t

you local propane dealer install the tank you select and purchase. Th
machine will come with the proper propane regulator. fTank must hav

vaporoutiet.)

Professions/insta//ation offudsystems is strongly recommended. Aiwq
ensure compliance withstite andlocdregulations pertaining to fueiinsta

Iations.

Water Hardness

I

Grains
Per Galbn

n ‘-3iQ

Izzzz 31/2-7

=

_ 101/2 and above

7-101/2

..

WATER SOFTENER

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

Reports from several of our machine users commending the results of the
useofwater softeners inconjunctionwith their machines prompts usto rec­ommend the procedure to everyone ina “hard water” area.

The relatively lowcost of awater softener service is more than made upfor
inthe increased Iifeof machine parts andcontinuedcleaning efficiency. The
water softener will also increase fhe effectiveness of thecleaning chemical
being used, therefore, less chemical will be needed.

Contactawatersoftener distributor inyour area forinformationon therental
ofa simple water treatment unit to carry in your truck. Be sure tochange the
water softener in accordance with the capability of the softener. Example:

Ifthe softener will treat 900 gallons ofwater and machines uses anaverage
of30gallons perhourof use,andanaverageof 5 hours aday, wouidbe 150
gallons a day. 5 days would equal 750 gallons of water, therefore, the

softener would be changed every 6working days for maximum softening.

(s6eil@laum,wpi?#e)

5

Garden I-fose

— C#

h-morning VVatar

From Faucet

Softener

Water

WASTEWATER DISPOSAL

START UP

1.Perform daily/periodic mainttrnance as specifbd by the owrws manual.

2. Connect all required hws.

, 3. Connect c!eaning tool to length of hose required to perform clwaning.

tankmust&M/priorto @rithmr.

L Mix

. Start engine (choke as required}. Engine is at operating speed (r@cam

mended -2600 RPM). Allow

I 6. Spray wand to void al air from system: When the mix tank tmgins a fill

cycle, the chemical flow meter may be adjusted to your desired setting.

NOTE: Recommended carpet cleaning pressure is 300 PSI.

warm-uP period of 2-5 minutes.

ADVISORY

Them are laws inmost communities prohibiting the dumping of recovers
‘gray” water from carpet cleaning in any place but a sanitary treatmel

system.
This cleaning rinse water, reccwred intoyour unit%vacuum tank, contair

materials such as dete~ents, which must be procwed before being se
for streams, rivers and reservoirs.

IN ACCCMM2AMCEWITtf THE EPA, STATE AND LOCAL MWS, D
MM MWW$f OF WASTEWATER MK7 GUTTERS, ST0f?h4 DRAIN
STllEAA@ RESEJ?Vt’WS, ETC.

Inmost cases, anacoep!ab[e method ofwastewaterdisposal istodischarf
into a municipal sewage treatment syst@mafter first filtering out sol
material suctwmrrpetfiber. Access tothe sanifwy system can beobtaim

through a toilet, laundry drain, carwash drain,

should first be obtained from any concerned party or agency.

One dis~sal rmtfwd which usually complies with the law is to accumula

the wastewater and haul it toan appropriate dump site. Another solution

the disposal pmblam is !0 equip yourself with an Automatic Pump-O

System. Thetm systems afie designed 10 remove wastewater from tl

tixtractor’s rwooverysystem and actively pump the water through hoses

asuitable disposal drain. Properfydesignecf, theywill continuously monii

tie Iml of wasttwvaler and pump it out simultaneously to the cleanil

operalion. Tim hidden benefit of this procm is

have to stop his cleaning to empty the recovery tank. HydraMaster mak

an A.P.O. System available which can be ordered with new equipment
installed Iat@r.

RV dump, etc. Permissi[

thatthe operator does

7. Once all air is voided frum system, heatw may be ignited.
NOTE: Ifnot familiar with operation of this healer, refer to heater section of

the manual.

A. Open propane valve on the tank.
B. Ignite pilot on the heater.
C. To ignite burner, turn dial to “on” position.

NOTE: Ifyou suspect that the unit has been frozen -DO NOT light the

heater. Thaw the heater and check for leaks.

8. Turn on burner, adjust dial to normal or slightly below for 200W.

9. Commence cleaning operation.
NOTE: Chemical flow meter set at 5 GPH isa 1to 30 mix ratio and 10GPH

is 1 to 15ratio.

NOTE: Hot cfbnate opw’ation [above 90°F].
When operating this unit ina hot climate, HydraMaster highly recommends
some additional precautions.

1. Operate with side and rear doors fully open.

2. Vent heater through the top of van.

3. Ifvapor lock conditions arise, machine cover may need to be raised to
allow additional heat to escape from canpwtmt?nt.

NOTE: Cold cfimate operation (below O°F).
When operating this unit in a cold weather application, HydraMaster highly
recommends some additional precautions.

1. If nossible carrv Yourown fresh water SUDDI%

2. Hookup to ho~wkder source if possible to’keep your incoming garden
hose ~m freezing.

3. Do not close van doors in front of machine.

4. Beaware that solution lines laying on frozm ground may frewe.

5. Contact local propane dealer about cold weather propane use.

Thi?penalties for nwr+ompliance can be serious. Always check local la’
and n?gufaticmsM be sum you are in compliance.

I

MACHINE AthKISTMENTS

Although MS unit has been factory adjusted, it may require additiol
adjustmentsto achieve optimum performance; i.e.altitude may require u
adjustment and ambient temperatures may require heat control adju
ment. When required, cansult an authorized ~epresentative.

SHUT DOWN

1.

Turn heater to ‘off” position. Spray wand for at least 3 minutes to allow

the heater coils to cool.

2. Close valve on propane tank and through floor hookup.

3. Remove vacuum hose.

4. Flush clear water through chemical system for 10 seconds. (Vinegar

should be rinsed through system weekly.] Turnoff chemical flow meter.

5.Tumon cleaning tool toflush chemical from unithoses andcleaning tool.
NOTE If freeze guard is necessary, perform steps 1 & 2 of freeze guard

procedure at tlls time.

6. At this time, the blower should be lubricated with Pennz@xwd.

7. Shut engine down.

8. Drain vacuum tank. Vacuum filter should @cleaned prior 10mobilization
of van. NOTE Iffreeze guard is necessary, pwtorm st~ps 3-7 of fr@ez@

guard procedure at this time.

6

Pressure

Gauge,

Temp.

Gauge ,,

Choke “

Vacuum Pump ;J

Lubrication Port &;

High Pressure ~]

Pump Switch ‘~l

Machine _
Exhaust

I

)

Incoming

Hiah Pressure’

Cle%ing Solution

Vacuum

Hour Gauge

Meter,

\

I

I1’,J:ue/va:%Tank

/

Circuit

Breakers

\\l l/~

~’

#

I

!!

$;

‘/

#

/ ‘Machine‘vacuum‘ank

Water

/1

Exhaust

Bv~ass

Valve

Dump Valve

ENGINE COOLING

Units employingaircooledengines mustnotln? enclosed withina van with
doors and ~ndows closed. Excessive temperatures within the engine will
resultinpremature engine failure anda compromise ofappiicable warranty.

LEVEL OPERATION

During operation, van or tiailer must be parked on /eve/ ground not to
excwed + or -1P. Failure to insure proper leveling may prevent proper
internal lubrication of engine, vacuum anoYorhigh pressure components.

FREEZE PROTECTION

Mother nature oives little wamin~ as to her cold s@ls. Therefore, wtect-

irrg this equifient from fi’eezing will save cosfly down-time. Placing an

electric heater in the Puck or parking the truck indoors, will help to insure

against fleezing.

LIGHTING HEATER

Chemical

. . — Water PumD Clutch

Heater Control

Valve

Hydra-Heater

High Pressure Water Pump

Coupler

Vacuum

Pump Drain Valve

\

Mix Tank

Engin6

/’

‘Freeze Guard

Fitting

Neverputyourface down close to the opening of the heater when lighting.

STRONG PROPANE ODOR

Never light the heater if you smell a strong odor of propane around the

heater.

HOT SURFACES

During the operation of this equipment many surfaces on the machine wili
become vetyhot. Whennear the vanforanyreason care mustbe takennot
to touch any hot sudace, such as heater, engine, exhaust, etc.

MOVING PARTS

Never touch any pad of tie machine that is in motion, severe bodily injury

may result.

NO SMOKING

ft

is unsafe to smoke in or around the vehicle.

CARBON MONOXIDE

This unit generates toxic fumes. Position the vehic/e so that the fumes will
be directed

DO NOT PARK where exhaust fumes can enter a bui/dif?gthrough open
doors or windows, air conditioning units or kitchen fans.

7

AWAYfrom thejob site.

FREEZE PROTECTION

pfl~q-!,ir!‘<!,.

Any frw~zing of this machine is not covefied by warranty and during the
~ldelrmantisofo~mtion, careful protection should be of utmost

THE FQLLWW4G PRECAUTIONS ARE RECOMMENDED:

1.Run machine befcm leaving for the first job to insure nothing
ha night lmfore, including hoses and wand.

2. Insulak the gafidt?nhose from the cold ground by running it through an

extra 1 1/2 inch vacuum hose.

3. In colder dirnates, insulating the truck walls and floorboards will help

prutoct the unit.

4, Don’tprocrastinate during thec!eaning operation or the hotwater solution

line will alw freeze an the ground. The solution iine should be insulated

in exlrerrmly cold climates.

!$.Whenever ~ssible, the truck and machine should be stored in a heated

garage at night or over the weekend. If not possible, place a 1500 watt

electric heater inside the truck, aimed directly at the machine. Never use

a propane heater-it causes excessive moisture on the truck ceiling and
the possibility of it going out is higher. Ifthe machine and truck are left
outside with a heater, you should first drain of possible water from the

machine cleaning tools and hoses. (They freeze also.)

TO DRAIN THE MACHINE FOLLOW THESE STEPS

1. Siphon a50150 mixture of anti-freeze and water through the chemical
ftow meter.

2. Drain the mix tank.

3. Connect Ma freeze

4.Connect Ihecdher ond of the freeze guard fitting tothe freeze guard fitting
Iocatfid on the sido of the machine.

5. Connect an open 440 quick connect to the fittings marked “cleaning
solution” on the front oithe machine. (An alternative would be to connect

your solution hww and wand, w as to freeze guard them also. Ifyou

choose to do thisycw will also need tohold the!riggerdown onthe wand.)

6. Start the unit, allowing the vacuum from the machine to drain the lines.

7.* Remove tfre garden hose inlet adapter from the end ofthe garden hose.
Conrmct the adapter to the incoming water quick connect on the front of
9hemachine.

8.’ Place a vacuum hose over the garden hose quick connect and allow the
vacuum from the machine to drain the lines.

*i4n alternative to #7 & 8 would be lo make an adapter to allow you to us@

the premade freeze guard hose.

guardhow?to the rwxwery tank.

concern.

hasfrozen

CLEANING AND CHEMICAL
PRECAUTIONS

Yourmobile carpet cleaning plant has been engineered using the!at@stand
nest sophisticated technology available, to produce the finest carp@t
~eaning results possible. Despite this, however, itremains onlya toolofthe
xpet cleaning trade, and it can produce only as good a job as Me person
]Perating it.

Thereare not short cuts to good ca~t cleaning. Itrequirws time, cleaning
mowledge and the use of good chemicals.

Themanufacturer recommends the use of spotting agents, and traffic lane
nleaners prior to the actual cleaning of carpeting, as required.

Theuse of some chemicals through your mobile carpet cleaning plant can
seriously damage the internal plumbing, high pressure pump and heater.
(Chemical such as concentrated acids, solvents, and some paint oil and
grease removers w/high cwwentration 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.

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

pH CHART

I

1234567891O 1?12

I 1

)

+AOD - *

I I

I

I

NEUTRAL

I I

‘ALKALINE~

I

I

CLEANING STROKE
PROCEDUREIOVER-WEUING

PIJRPOSE:TOeliminate excess moisture rernainirrg in the carpet fiberand
the sawtooth appearanw? which results from diagonal movement of the
cleaning tool on all types of carpet.

I

13 14

I

I

NQTE: Prior tofreezo guarding your rnachinemake surethe heating system

has been cooled down.

ALTERNATE PROTECTION USING
ANTI-FREEZE:

1. Follow We draining procedure.

2. Cmnect solution hoses and wand

3. Pour a 50/50 ariti-$reeze sokJtion into mix tank.

4. Turn on machine and engage clutch. Spray the wand.

5.Continue to add anti-freeze solution until mixture comes out ofwand set.

6. Remove and store hoses.
If you are using an

freezing. 1[isne~ssary to flush the machine in preparation for use. Simply
connect the unit tofresh water and spray the wand until anti-freeze solution
is discharged. The anti-freeze soiution maybe recovered by spraying into
an empty container. This solution can be used several times.

BE SURE IT’S PROTECTED! Freezing will cause GRIEF, MONEY and
DOWF&TIME. Don’t mess with Mother Nature!

anti-freeze solution to protect your machine from

tomachine.

PROCEDURE: Always move the cleaning toolin smooth foward anciMck-

ward strokes. Apply slight

is injected into the carpet.

the foiward stroke to ensure a positive “lock” for the vacuum and minimize
the “hopping” effect resulting on unsmooth carpet. During the forward and

reverse strokes, movement to the right or left should only be a~omplishexi

at the extreme rear of the stroke. Overlapping is also important to ensure
even application of solution to prevent saturation when cleaning wand is
stopped twice at the same point at tie rear of the cleaning stroke.

Failure to adoot this mocedure can result in increased chance of “clean
streaks”, fiber’shrinkage, brown out, and longer drying pdods.

INCORRECT METHOD

pressureto the forward stroke while the solution

When extracting (drying), applyfirm pressure on

CORRECT MEWMN2

Overla~ Between Strokes

Cbanmg
Stroke Stroke

8

Cleaning

OVm”wmmlci

Over-wetting isannoying toall concerned and sometimes leaves a bad im­pression of the cleaning process used.

THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER”WEITING:

1.Too Iew vacuum strokes or improper sawtooth vacuum strokes as
shown in the previous illustration.

2. Obstructed, kinked or cut hoses.

3. Vacuum tank drain valve left partially open.

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

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

uart container of vinegar. This should be done with the Chemical Flow
!eter setting on 10 GPH and the Water Heater “off’. Simply spray water
om thewa~d until thequart of vinegar isexhausted, the repeat the @wess
ith one quart of clear water to void all lines of vinegar.

Chemical System Wiring

Solenoid Valve

Float

Switch

G~D

Relay

88

E ,.~
X!/’

~. 85

h.

,.~

To Ignition Switch

‘--l

‘..

GND

WATER AND CHEMICAL FLOW
OPERATION

This electro-mechanical system has been designed to be simple and
trouble free. Incoming water flows first through the Solenoid Control Valve
(1)and the low pressure Chemical Injector (2)which are both mounted on
the exterior of the mix tank. As the water passes through the Chemical
Injector, it is automatically proportioned with a predetermined quantity of
detergent. The MixTank(3)isequippedwith twodifferent float switches, the
Water Level Float (4) responds to the level in the tank and will maintain the
proper volume of solution to be reserved for the water pump. The secon­dary, LowWater Float switch(5) isasafetyswitch thatisdesignedto protect
your system from sudden or unexpected loss of water supply. If, for
example, thewater source at the house were turned off, the water level of
the mix tank would drop, activating the secondary switch, which automati­callydisengages thesystem and pn?ventsthewater pump from running dry.

The desired chemical injection ratio may be obtained by an adjustment of
the Chemical Flow Meter (6)during the fill cycle ofthe mix tank. Water must
beflowing into themixtankinorderto adjustthechemical mix. Thechemical
will flow from the Chemical Jug (7) to the Chemical Flow Meter, then to the
Chemical Injector where it is proportioned into the Mix Tank at the desired
chemical setting.

NOTE: %Mththisuniquechemical system, thechemicalflow isproportioned
only during the filling cycles of the MIXTank, not during the direct spraying
ofthewand. Therefore, itispossible that asyour 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
Flow Meter may be active at the desired flow rate.

Water Flow

6- Chemical Flow Meter 12- Incoming Water
7- Chemical Jug 13- Tank Drain
8- High Pressure Pump 14- To Wand

+ High Pressure

11 - Pressure Guage

+ Low Pressure

Chemical Proportion and Level Contra\

6FA-6UFS

I

M,, Tank

$

The chemical proportioning system will mix chemical with water at a 1to30
ratiowhen the Flow Meter is set at 5 GPH, or a 1to 15 ratio when the Flow
Meter is set at 10 GPH.

Atthis point in the flow, solution (water with chemical) will now be siphoned
from the

bottom of the Mix Tank to the inlet of the Water Pump (8). When

the wand is not using solution by spraying, the solution will be bypassed
fromthe bottom ofthe brass Pressure Relief Valve(9), back to the MixTank.

When the wand is spraying, the solution continues its flow to the Water

Heater (10). The coils of this heater have a capacity of up to 2 gallons,
therefore it is extremely important that all air pockets are bled out of the
heater prior to initial start-up. This maybe achieved by running the water
system, without the heater on, for approximately 80 seconds.

CHEMICAL SYSTEM MAINTENANCE

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

prevent abnormal chemical build-up. This flushing may be done by remov-

ing the clear plastic hose from the Chemical Jug and inserting it into a one

=eCk=

Swng

B . ‘“’W’”’ B””’
o SIs Ball

& Check valve ;

-0

fl

~u

*:5$3’’HeFj~jii$

g;zj_:Dlen;n

Mo.n!tng

+wJw ,3)

—-, .— -

—.

+-=” –d

(la ‘

12 Voc

cm

9

q~

Mo.ntlng

Plato

,-,4, va,vech,y

Water
Idet

I

I

I

~

I

CHEMICAL TANK

TROUBLE SHOOTING GUIDE

PRQHLEW. Uttla
%hldon
Chackthtat hoses af the Mix Tank(3) are secure. Check that the hose fromthe top

of tkw Flow MrXar (6) to the Chemical lnject~ (2) is seam with no kinks or
leaks, (M& thal the ad~ustingcap on tho side ofthe injectoris INI! screwed
af!ttw way in. Clmcklhe $/s check vafveirw.idethe injedorforchemical build­up and pqer qwration. Chec& the hose from the botiom of the Ffow Meter
to the Ctmrnicaf Jug (7) for kinks, cracks, or bubbles.

Cf’mckthwxraen ontheemdof the hose which gces intotheChemicaf Jug.Tochack

thii scram forproper function, remove itkom Itw plastic hose. If you csnnot
blow Ihrough if, tti rinse if out with vinegar.

Check the Chemical flow Meter (6) for obstructions or a sticking float.

Is incoming waler pressura less than 30 PSI?

Cracked w cle!ective Chemical Flow Meter (6)?

Check the fitterwren inthe Solenoid Control Valve(1).

PROBLEM frmbillty to adjust chemical with the Flow Meter

Sahtion

Debrii Iodued &hind Mlon %at in Flow Meter valve.
Tdhm seat on the valve stem maybe hose. Ifdeteriorated, replace O-Ring.

or no chemical flow

Wand Valve Asswnbfy

Ekldy

Compression

Fitting

~?

*

--~;~’

-T

Spring

O-Ring

cap

3’L%

II I *C

QI *

I

=*I6

:11“?’<F~@

\

.\

i

[

\

O-Ring

Plunger Quick

Connect

Cl-Ring

Keeper Ring

I

I

PHCWLEM: Solution rmmrsbrg from Mix Tank, ffllhrg the Chemical Jug
Sohlfk?n
Anti-siphon dwice cfogged by chemical build-up (Anti-siphon device is bcated in

the Chemical Injedor (2) body — see page 9, Water F!aw illustrakon).
Check fordebrii.

PRQBLEM FAxTank overflows

mlution

Float awitc+r(4) inthe Mix Tank nd moving ireely, or d~fadive.
TochmckswitctrWNma 12voht@[ghiandtheilut inthe”up”position, there should

b power through the swhh.

To check relay: First check wiring against dmgram. W* 12 volt lest fight, and the

FloafSw%ch(4} in Ifre”up”posilierr there sf?cmklNOT@owerat !heSolenoid
Vahw. Wth !he Float Switch in the “down”position there should be power af
the SIoarwid Vafve.

EKderroidValve defectiwx Remove Solenoid Vafve, disassemble and inspect

diaphragm Iw cracks w tears.

PRQ5LE~ Mix Tank does not keep up with water output
SOlufhltl

Check incoming water pressure. Check gaden hoaa quick conned

assembfy screen.

Check garden hose ardor feed hose 10the Mix Tank for dog, kinks,

or blockage.

Float Swifd (4) in Mix Tank hanging up (rmf moving freely). Check fifterscmn in

Solenoid Vafve (1).

Jet Assembly

Wand Assembly

Ha

Ekdy

‘b”

10

Wand Valve Stem Assembly

I

Keeper Ring ———+

Plunger —

I

@

~

(

Bypass Valve Assembly

+— Retainer

O-Ring

u

I

@—

I

O-Ring

BYPASS PARTS LIST

REF. NO. PART NO.

3

OOO-105-1OI
4 OOO-105-1O2 Piilon plate,Bypassvalve
5 OOO-O78-1O1 Kt, seal

7 000-14B-oo4 Seat & C43ing, Bypass vafve
8 000-097-005 O-Ring, Bypass valve fitting

DESCRIPTfON QTY.

Thrustplate,Bypassvatve 1

for Bypass vafve

WATER FLOW TROUBLE SHOOTING GUIDE

PRoBLEkk
Cslrse
=ve or blocked check vafves in high pressure pump cyfinder head.
Delaminated, Idnked or dogged hose between the mix lank and fhe high Remove and replace defective hose.

Defective pressure refief valve or debris in pressure reliefvalve. NOTE lle high Disassemble and clean pressure relief valve as illustrated in drawing above.

Oelective or worn cups. Remove and replace piston cups as defined by pump manuat.
Loose driie belt Ior high pressure pump. Readjust belt as required or replaos if defective.
Pump inletYstrainer dogged Check lank for water. Clean strainer. Clutch disengaged?

LOSSof pressure

solution

Disassemble cylinder head and replace or cfean applicabfa check valve.

pressure pump,

pressure bypass vafve is desgned to fully dose when the cleaning teal is
turned on. Any foregn matter colleding onthe piston willprevent iull closure
offhe valve id allow a portionof the water to continue to circulate instead of
being routed to the ciaaning tool. To correct this situation, the bypass vafve Replace bypass valve.

must be disassembled and dearrad (refer to illustrationprovided abve for
bypass disassembly).

Replace defective or worn out bypass cup.

1

1
1
1

PROBLEM: Excessive water flow

cause

Worn out spray jet. NOTE: Cleaning tools designed to spray a constant fbw of Remove and replace spray jet.

1112GPM will average 1 gafbn of flow per minute inadual workingsituations

since lbwis not continuous.An average flowof 1GPM resultsin6000gallons
offbwforevery 100hoursof unito~ration. Spray tipsarecapableof fbwrates
forapproximately 20,000 gallons. They should beraplacedtherefore, approxi­mately every 350 hours,Worn spray jets allow a greater average rate of flow
thus reducing desired temperature fevels.

Reduction of flow.

Solution

Due to increased length of sloutionhose. NOTE For every 50feat ofhose, bevond

100faet intotdlength,ame~urtile losoffbwisexpenencd. Ttiscondition
is a result of the increased fridion experienced by the water as it passes
through the hose. Therelore, if is necessary to increase the pressure at the
machine 40 PSI for every additional 50 feet of cleaning solution hose over

100feat.

11

,

VACUUM SYSTEM INFORMATION

The vacuum blcwwrincmporated inthis machine is apositive displacement

Iokwtype, manufactured by Cooper Industries. The performance and fifeoi
this unit is gfieatiy dependent on the care and proper maintenance it re
Ceiv@$.

Becauw?of the CIOWtcdmum.esbetween the lobes and housing ofthe vac
uum blower, did objects entwing the inlet will damage the internal lobes,

g~ars and bearing or direct drhm coupler.
To p~event this, a stainless steel filter screen has been placed at the vac

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

When machine is Ming run fir iesi purposes and the vacuum inlef on fo~

of machine is open, caution should h? used.

To protect Ih@vacuum blower from overloading and damaging itself, thert
isa vacuum rdi~f sys!em installed on the vac tank. When the vacuum tan}
inlet is completely sealed off, a maximum of 14
on thetop blower pipe eltmw acts as the lubrication point. Atthe end ofeact
day, LPS 1or Pennzguard should be sprayed in before shutting down th[
machine. See blower lubrication W4ration. If you fail 10 Iubricaie tfw
vacuum blower daily, rust doposils and moisture will decrea~ the life ofttw
vacuum Mower.

HG will be attained. A hok

—

MXIUM TANK FILTER BAGS

/drafdasler filter bags are designed totrap all ofthe lint, sand anddirltha!
wld normally collect at the bottom of your vacuum tank. The w? ofthese
lgs, if emptiid at the end of each job; will eliminate the build-up cd

thedebt%

d to the incoming dirty water inlet in the vacuum tank.

Jreorder bags use part number 049-029.

Vacuum Tank Filf@r Bags

inthe tank. Th@drawstring top of these bags is ckmigrwdto be

.Vacuum Tank MM

much

Read thevacuum blower rnanualcarefully forpmperoil change and greaw
application. The maintmarm log may differ slightly from the manual, bu
the truck-mounted carpet cleaning machine application isvery demandiry
of thevacuum

NOTE: Vacuum tank isprotecfedfrom ow?rflowirrgbya vacuum tank, flea
kill swi[ch. This swiich is

blowerandtherefore itshould bemaintained more regularly

not acfiwated byfoam, only byliquid.

vacuumFlow

S/S Filter

\

Recovery Tank

Filter Bag

/

\:7

Blower Lube Port

I

\/

L

Spray lubricant into bloww’ lube port for 3 to 5 seconds,

then immediately shut off machine. Use only LPS 1or

Pennzguard moisture displacing lubricants.

12

VACUUM BLOWER WARRANTY

FULLERwarrants products of its manufacture tobe free from defects in malerial and workmanship ifproperly installed, maintained, arid operated

under normal conditions with competent supervision.
Noperson, agent, representative or dealer isauthorized togive any warranties on behalf of FULLER nor toassume for FULLER any other liability

in connection with any of FULLER’S products.
This warranty shall extend for two (2) years from date of installation provided this equipment has been put into servicw within six months after

shipment from tie FULLER factory. Ifrepairs or replacements are made by the Purchaser without FULLER’S prior Mitten consent, FULLER’S
warranfyshall cease to beineffect. Noallowance will begranted forany repairs or alterations made bythe Purchaser without FULLER’s prior written
consent.

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

FULLER agrees at its option to repair at the point of shipment or to replace without charge f.o.b. point of shipment, any part or parts of products
of FULLER’S manufacture, which within the specified warranty period shall be proved to FULLER’S satisfaction to have been defective

shipped, provided the Purchaser promptly notifies FULLER, in writing, of

FULLER’S liability to Purchaser, whether in contract or in tort arising out of warranties, representations, instructions, or defects from any cause
shall be limited to repairing or replacing of the defective part or parts as aforesaid, f.o.b. point of shipment.

No liability whatsoever shall attach to FULLER until said products have been paid for. EXCEPT AS STATED IN THIS SECTION AND IN THE
PRECEDING SECTION TITLED ‘WARRANTY’ AND EXCEPT AS TO TITLE, THERE ARE NO GUARANTEED OR WARRANTIES OF
MERCHANTABILITY, FITNESS, PERFORMANCE OR OTHERWISE, EXPRESS, IMPLIED OR STATUTORY, AND FULLER SHALL HAVE NO
LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR OTHER DAMAGES, HOWSOEVER CAUSED.

such alleged defect.

when

DATE INSTALLED MODEL SERIAL #
FULLER COMPANY 2966 East victoria Street Compton, California 90224

VACUUM BLOWER LUBRICATION

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

FILLING PROCEDURE
Remove square head vented oil fill plug (A) on gear end. Remove oil level
plug (B) located in the head plate. Fill gear case until oil drips out of the oil
level hole (B). Use lubricants aslisted. Add fresh oil as required to maintain
proper level. The oil should be drained, flushed and replaced every 1500
hours or more frequently ifinspection so indicates. The oil drain
at(C).

NOTE: Older units may have the oil fill level and drain holes located in the
cast iron gear case instead of in the head plate. Bearings on drive end of

blower require grease lubrication every 100 hours of operation. Bearings
which require grease lubrication will have a grease fitting (D) at each
bearing. When regressing, the old grease will be forced out of the vents
during operation. To prevent damage to seals, these vents must be kept
open at all times.

plug is

Vacuum Blower Motor Lubrication

.

13

1

VACIKJM BLOWER TROUBLE SHOOTING GUIDE

PIW5LEM Loss cd prw$si.irn

Carkm

Collapsed vacuum hose between blowm and vacuum kink.

Chfjgad skddese steel

IMwAive vacuum lank seat.
Dekctive or %p@ vacuum tank pump valve.

Fraclured weld on vacuum tank.

Gallapsed w kinked vacuum hmw.

vacwn hose. Remove obstructionsby reversing the vacuum hose.

P%Jgged
Restriction in cleaning tool. Remove obstruction.
Worn @nd plates or lobes in vacuum blower.

IM3ctive relief valve.

WNIBLEW B!mver k+seized

Cause Solution

Rust. Spray rusI dissolving lubricant onto lobes to emulsify rust and attwnpt to ro$at~

Foreign matter.

tite: fie

ahvernwrtiorred, Nst foreignrmaftt?rarrdseizingare oftencausal from

foam traveling through

Ikmr,

the Mewer.

Solution
Remove and replam hose. NOTil A .speckdr@irrfcmd hose is requirwd

for replacement.
Remove and dean or replaca stainless steel filter.
Remove and raplw vacuum lank seal.
Close valve.
Replace valve.
Re-weld as required or replace tank.

Reshape h= ifpo~ibla andlor eliminate kinks.

Replace worn components. NOTE Must be accomplished bya qualifiedtechnical,
Inspect and replace ifnecessary.

vacuum lobes.

Disassambieand remove foreign matter and reptiras r~quired. NOTE: Disassem-

bly must be accomplished by qualified tedrrrican.

lWOtN.EW Nab in

vacuum blower

calm

Worn gears.

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

of lubrication.

wormbwing$.

Ikbris and/or foreign materii build-up. NOTE: A sfahdess steel filter isprovided in

vacuum inlel located in vanmm blower carnpcments.

Lcme ar missirmgmmm[ing bats.

I-IEAIING SYSTEM INFORMATION

The propane

WM?inthe carpet cleaning industry. It’shigh pressure coils andthermostatic
temperature control make itsimple tooperate and reliable. Once thedwired
temp%ratumis set,the heater willthen go ‘em’ and‘off’according tothe water
terrpwatum within the heater. As water is wed through the cleaning tool,
cold water entwing the heater will
propane valve thereby firing the heater to maintain a consistent flow of hot
wattw. Once the cleaning wand is shut off and the flow ofwater through the

kmater stop% the treater will continue to burn until the set temperature is
attainfid.
Itis pwsible with this design thatthe flame may be on when the wand is off,
likewise, it is passible the flame may be off when the wand is on.

heater incorporated in tfls equipment is a special design for

activate the thermostatically controlled

Soiutfon

Remove and rap[~ gears. NOTE: Replacement of gears must be accoinplishwl

by qualifii tedrnicarr.

Timingofvacuumblowerhasbeen changed duetow-orncomprmnts. Replacement

of components must be accomp!iihad by qualified technican.

Lubriite as specified by applicable vacuum blower manual. Sea index.

and replace bearings as required. Must be accmpliihad by qutified

Remove

technican.

Disassemble vacuum blower and remove foregn materii. NOTE: DkmssomMy

should be accampliihsd by qualified $echnkxrr only, Replacemwrt of worn
parts is nwssay.

Tighten or reinstall mounting bolts.

Thisheaferis designedfo &urrJvaporproparreg’as oniy Anyiiquidpropar?e
entering the healer may cause damage to tfm contmi valve on the heater.
tt wili also cause improper burning and a soot buiki-up on the coil,%

Therefore, if is necessary to shutoff fhe h@a@rand close tho waiveat th@
tarrkbetween ciearring icmations.Failure todo ff?isaliows sloshing /iquid fo

enfer the vapor feed iine to the heater.

IMPORTANT: Overfilling ofthe propane tankwill caus$ many problems.

To

avoid this, advise the attendant filling the tank not tcttill the tank mrer$tl%.

When filling thetank, watch the 10% valve and immediately stop fillirtgwhen

14

white fiquid starts spurting from the 10% valve. To prevent damage to the

propane regulator, always cfose the valve on the tank before fflfing.

The propane regulator is pre-set at the factory at 6 oz. of propane. This
reading is taken at the control valve on the heater (see figure A No. 6). To

prevent road dust and moisture from entering the propane regulator, keep

the white plastic cover (supplied) on the regulator at all times.
To avoid restriction of air flow at base of heater, keep articles such as

chemical containers, hose, boxes, etc. from within 18 inches of base of

heater. NOTE This restricted situation also creates an over rich condition

which results in soot build-up.

lMPORTANf7 Ifa newpropanetank hasbeen installed or hoses have been

disconnected, air may enter propane hoses and must be purged prior to

attempting to light thepilot burner. Should this condition exist, operator must
depress the pilot button for 1-5 minutes and attempt to ignite the pilot light
at 15 second intervals. Avery slight hissing noise should be evident while
performing this operation.

Check heater forpropane leaks regularly as loading andunioadinghoses,

tools, etc., mayaccidentally bump against heater fitting or pipes.

To fight the main burner, repeat instructions asabove (TO START PILOT),

1through 4.
OR,
Water may already beat controlled temperature.

Flame will turn off when thermostat senses maximum temperature.

C. TO ACHIEVE PROPER CARP~ CLEANING TEMPERATURE:

1. Complete procedures A& B.

2. with 100’of hose, turn cleaning wand on for 5 minutes and the

temperature should stabilize.

3.Oncea constant temperature isestablished, turncleaning wand ‘off’.The

flame on the heater burner should remain on for 10-15 seconds.

A. Ifthe flame expires prior to 10 seconds, turn the thermostat dial to

a higher reading, then repeat C 1-3.

B. If the ffame remains lit after 15 seconds, turn the thermostat dial to

a lower reading, then repeat C 1-3.

D.TO SHUT DOWN HEATER:

1.Turn upper dial #1 to ‘off’ position.

2. Tumcieaning wandon for3 to5minutestocoo/heatercore. Ifi?eafercore

isnotcooled, itispossible tha(theheat retainedin thecore wiilcause boiling
back into a chemical mix tank. This results in damages to Cat pump.

3. Close propane tank valve while
wand is on the heater is coofing.

HEATER OPERATING
INSTRUCTIONS

Heater must be fi)led with water prior to igniting.

A. TO START PILOll

1.Adjust thermostat control knob on unitrol to desired setting (#3).

2. Adjust upper dial to pilot position (#l).

3. Depress pilot button (#2).

4. Depress sparking button to fight pilot (#4).
IF PILOT FAILS TO LfGfiT:

Is propane tank full?
Is propane tank valve open?
Has air Men properly bled from propane line?
Is igniter system working?

WHEN PiLOTUGH7S:

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

PILOT BURNER ADJUSlllENT:

1. Remove pilot adjustment cap #5.

2. Adjust pilot key to provide properly

sized flame.

3. Replace pilot adjustment cap.
Allen head pipe pfug #6 can be

removed for monometer insertion
to read propane ounces.

HEATER TROUBLE SHOOTING

PROBLEM: Excessive

Csuee/So/ution

Maladjustment of propane regulator. tWTE Propane regulators are factory

1.

preset and may be readjusted by authoriiad personnei.
A. Contact manufacturer to determine correct procedure.
B. Have your local prcpane deafer use a marromeler at the Unitrolto reset the

propane ragufafor to 7 oz. maximum.

2. Overfilled propane tank. Propane heaters are designed to operate on vapor
propane only. Overfilling a propane tank affows ~quid propane to enter ail
heater reiatad components and permits an over-rich burning condition to
occur. This condiion usually requires the core to be deaned of soot and
carbon dapadts. Cleaning is a messy, dirtyjob and very inconvenient, so do
not iet if happen to you!

heat. Flamesprotruding outside theiower openings.

Always keep face away from main burner opening to avoid ignition
flash bum.

B. TO UGHT MAIN BURNER:

1.Turn up~r knob to “on” position. Flame will come on.
Ifyou do not get the burner to flame, the pilot has expired. You must turn

upWrdial to“or position. Donotattempt to re-light the pilot fort24seconds.

PROBLEM Pilot

Cause/Solution

1. Pibt lightwill notignite. NOTE: Do not use a naedleorpin to dean pilotorifii—
use compressed air or solvent only.

A. Verify propane reaching igniter. NOTE A tinkad orcrushed hose may

impede
B. Remove and clean orifii.
C. Verify igniter spark is operating correctly.

light

propaneflow.

15

CAT PUMP MODEL 290

—

OPERATING Ihlsmwmolw

CAT PUMPS am positive dispkwrmti pumps. Therefore, a properfy
desigr?edprt?ssurt?relief mffchanisrn IUUST be irstalled in Me discharge
piping. Fajlure toinstall suchmliefmechanism ~uidmsultin~rsonalinju~
ordamage toffwpwnparsystwn. Cat Pumps CorporabOndoesnot assume
afly liability ormsfxmsibility for the operatiorr of a customer’s high pressure

system.

Pracfuctsdescribed hereon ar~covered byone or more ofthe following U.S.

patr?rls: 3558244,3652188,3809508, 3920356, and 3930756

SPECIFICATIONS

Volume: 3.5 GPM (13 UM)
Discharge Pressure: 1200 PSI (83 BAR)
Maximum inlet Pressure: -8.5 to+ 40 PSI (-0.6 to + 2.8 BAR)
RPM: 1200
Bore: 0.78~ (20mm)

Stroke: 0.472’ (12rnrn)
Crankcase Capacity: 10 oz. (.3 L)
Maximum Fluid Temperature: 1800F(71°C)
Inlet Port (1): 1/2” NPT (1/2” NPT)
Chemical Injection Port (l): 1/4” NPT (1/4” NPT)
Discharge Ports (2): 3/8” h!PT(3/8” NPT)
Pulley Mounting: Either side (Either side)
Shaft Diameter: 0.65(Y (16.5mm)
Weigh& 12.1 Ibs. (5.5 kg)

Dimensions: 10.77’’x9.08’’x14n4n(273.5x230x130 .5rnm)

(l): 1/2’ NPT(1/2’ NPT)

.~..

p#ziltH3ilm*y

,.

C0F7P0RArt0N

P O 130KBS5 MINNEAPOLIS MN 5S440

PbmIfI (6 12) 780.s440 — Telex 290278

a N V CAT PUMPS INTERNATIONAL S A *

Hmmonmstraat 29

8 2LlQtJAntwerp, 13elgwm

Phone [phone] - T@E,x 33947

*CAT PUMPS — AG 0

LorelohOelIe 5

CH.63CQ ZUG. Swtzerlana

Phone [phone] – Telex 865 160 CPag ch

OCAT PUMPS DEuTSCHLAND Grnot+@

ROSlocker Sttesse g

62L12 Wlesbaden BIef3tadl West Germany

Phone [phone](2 – Telex 41 86713

-CAT PuMPS [U K) LTD 0

27 Stallon Ina.strml Estets, Flee!

H.9MD9hW3 Gu13 8QY.EnglamJ

Phone Fbl 22021 – Telex 8SSS93

CAT IPUMP WARRANTY

This Cat Pump (“product”) is warranted by the manufacturer to be free from defects in workmanship and material for orw year hum dat~ of

manufacturer’s shipment. This warranty is limited to repairing or replacing products which manufacturers investigation shows were defective

al the time of shipment by the manufacturer. All products subject to this warranty shall bt?returned F,O.B. Cat Pumps Corp., Minneapolis,
Minnesata 55430, U.S.A. for examination, repair or replacement

The express warranty set forth herein

merchantability or fitness for a particular purpose and all such warranties are hereby disclaimed and excluded by the manufacturer. Repair or
replacement of defective products as provided above is the sole and exclusive remedy provided hereunder and the manufacturer shall not be
Iiablo for any further 10ss,damages or expenses, including incidental or consequential damages, directiy or
use of this product.

This warranty is subject to the following warranty conditions:

impmlant Conditions- LUBRICATION -fill crankcase tothe top of oil gauge window per specifications with Cat Pump oil or equivalent SAE
40 weight hydraulic ailwith antiiear and rust inhibitor additives. Change initial fill after 50 hour run-in period. Change oil every three months
or at 500 hour intervals thereafter. FWrrrn-a-lube seals need no lubrication. Bluedot seals and wick must receive three drops of Cat Pump oil
per wick every 50 hours of operation.

is in fieu of all other warranties, express or implied, incfuding without limitation any warranties of

indirectlyarising from the sale or

GCXMILUBR1CATK3NISTHE EASIEST, MOST EFFICIENT AND LEAST EXPENSIVE OF PREVENTATIVE MAINTENANCE.

RPM and PRESSURE - Pump operation must be within RPM and pressure specifications. Pressure relief valve must tw installed.
00 NOT PUMP ACIDS OR ABRASh/E FLUIDS with this unit. Consult Cat Pumps for additional information on questionable fluids.

FREEZING CONDITIONS - Pump must be protected from freezing conditions.

USE CWOTHER THAN CAT PUMP PARTS OR THEIR EQUIVALENT VOIDS THE WARRANTY

16

PISTON MODEL 290 Exploded View

——— .——

—.

———

PARTS LIST MODEL 290

fTEM PART NO.

1 202e5

44274

2
385880 Stud (M8
4

44377

5

44374 Oil filler cap

43340 O-Ring, crankcase cover

8

9 43339 Crankcase cover 1
10
11 23170 O-Ring, drain plug t
12 25625 Drain plug
15
16 438o4 Crankshaft
17 14487 Rearing 2
18 24159 Oil seat (Buns-N) 2
19

20

21 92519 Sems comb head screw (M6 x 16) 8
23 101789
24

,

25
26
27 25301 oil seal 3
28 25327 Barrier slinger
29

30 29003 Back-up ring, Sleeve (Teflon)
31 29614
32 26854
33
34 25128

43987 Bubble oil gauge

92520

2653$ O-Ring, oil seal case 2

27950 oil seal case 2

Iolmo
lMkUt

20017

25392 O-Ring, sleeve
28771

28597

25635

DESCRIPTION
O-Rino (Buns-N\
Crankcaee

X82) 2

O-Ring, oilfillercap 1

Sems comb head screw (M6 x 20) 6

Conneding rod

Pston rod 3
Pston pin

Seal washer

O-Ring, sleeve (Viion) 3

Sleeve (28743 Unchromed) 3
Seal washer
Seat relainer
Inlet manifold
Inlet manifold - stainless steel

QTY.

1
1

1
1

1

1

1

3

3

3

3
3

3

3
3

1

1

fTEM PART NO. DESCRIPTION QTY.

35 30315 Prrrrrm-A-Luba seat 3

30325 Prrrrrm-A-Lube seal (Won) 3

38 27004

39 30543 Bat$-Cup piston
40 30544
41 43172 Cup (Viton)

43474
42
43 27002
44 27006 Conical washer - s/s (M6) 3
45 270Q0 Nut ­46 14156 Cotterpin 3
47 101802 Cylinder (43834 Unch) 3
48 23172

49
50

51 43442
52 43360 Valve spring
53 43723 Valve
5443434 Discharge vatve seal
58 81108 Hex nut (M8)
57 101804 Hex flange nut (M8)
58 25130 Shaft protector

Electric Clutch Assembly

59 152-005
80 077-005 Key, electric clutch
61 036-005 8’ elednc clutch
62 143-084 8-30 mm socket head screw
63 174-004
64 174-018

27983 Piston spacer

11377 O-Ring, cylinder (Viton)

21985 Bat-Cup ring, cylinder 3
24459 Discharge manifold
25634

Intel valve 3

Bat-Cup ring (Teflon) 3

t3ac-Cup assembly 3

Pston retainer

S/S(tvf6) 3

O-Ring, cylinder (Buns-N)

Discharge manifold - SIS
Vaive spring retainer

Tapered sleeve

Flat washer (5/16 US)
Lock washer (5/16 US)

3

3

3.
3—

6
6

1
1
3
3
3
3
2
2
1

1
1
1
1
1
1

17

GENERAL INFORMATION
FOR CAT PUMP REPAIR

As you mwnow!ym.trdischarge manifold, there is a set of 3 check valves
{which usually fall OUIduring dis-assarnbly). Ifthe surfaces of these check
vtives am dirty, OFshow signs of chemical build-up, it is pmbahle that they

would mrnain awn causing pmssum Iossc!r pulsation. Upon inspecting the

valwas,make sum Ihatthe tefkm button inthe valve spring retainers are still
intact. Also examine the discharge manifold. Look for problems such as
cracks, chwnical buildup or warpage ch.mM hewing. If this discharge
manifold is warped, it will cause th~ check valves to stick and will result in
loss of pnlssure.

Nextexamine the seating surface of the flalvalve seats and lapwith ?.40
grit paper or replace if evicklnco of excessivw wow. (Met valve

S43ats

should be replatwd if vmrn. Lap new quiet valve and seat to assure

seal.

positive
Some pump models have o-rings for easa of installation and to avoid
damaging elastomers.

DTE First install o-ring ingroove on sea! (towards seating surface), then

back-up ring.

Modelswithout outer groove onmat require the o-ring to be placed

DTE:

on lip of retainer.

The Cat pump cups am Men the source of pressure loss. Upon inspection
they rnayappearmeked ortorn, butoften they will look good. Replace them
anyway. Thereisrw surernethodofvisualfyinspecting thecups. HydraMas-

tw recommends changing cups whether they look good or not.
Anytim@your pump is being dismantled, HydraMaster recommends re-

placermnt d all ‘o’ rings and seals. This is merely a convenience to the

customer to make sure that the Cat pump is in top operating condition.
The Prmwm-A-Lube Mals located within the intake manifold will atlowair to

@nt@rthe pump if they are vmrn. Again, it is difficult to visually pinpoint a
defective Prrrrrm-A-Lutw seal. Replace them al.

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

Ming make swa you hava tie proper parts required.

ShOti (Of hot) CLd kit

1­3- Prmrrn-A-Lube seals

6-piston

sleeve ‘o’ rings

1- bottle Cat oil

Readinstructions thoroughly, suppfied in the Cat pump manual prior todis­assernbly and fallow directions as stated. Oil all seals thoroughly ~“or toin­stallation. (Remember, a newiy scarred seal is no better than one you just
took aut.)

SERVICING THE VALVE
ASSEMBLIES

DISASSEMBLY

1.Remove th@ fastmers securing the discharge manifold tothe crankcase
of the pump.

2. Support ~ discharge manifold and tap from the bac~lde and a soft
mallet to separate hum the crankcase and gradually work free from
qdh’ld$rs.

3. Valve assemblies will remain in the manifold. Pump models with the
o-ring groove an lhe outside of the valve seat require the assistanw of

a reverse pliers to remove thevalve seat. The valve, spring and retainer

will then fall out wlwn the manifold is inverted.

Pump models without the o-ring groove on the outside of the valve seat
pwmii the s@a~valve, spring and retainer all to fall out wf’ten manifold is
inwwted.

mmsfihllm~

1.

Place retainers in manifold chambers.

2. Next insert spring into center of retainer.

3. Inspect tie valv~s for wear, ridges or pitting and replace if necessary.
NOTE: Seating side of flat valves may@ !apwd on flat surfa~ usin9 24c

grit paper. Quiet valves due to their sha~ must b? replaced. -

Insert valve over spring with recessed (dish) side down.

Insert valve seats into manifold chambers.
Position manifold back onto pump.

OTE: Lubricate o-rirms on cylinder and exercise caution when slkmino

manifold over cylind~rs to avoid damaging cylinder o-rings. ‘‘ “ ‘
Replace fasteners and toque per specification chart.

OTE: Replace all original shims when used. When new manifold is used

reshim pump.

L5ensfartirrgthepurnp, chock tos@ethat there isrm qdindermotim? as this
ill cause premature failure of the cylinder o-rings. Cmmw

eliminatedbyswitchingwithoneoftheendcyhders.

m be

cylidw motion

Pumping Section Cut-away

Piston Spacer

‘“i’*“R”ds’eev”

76-001 @ Kit

6 O-Ring, Cylinder

Cup

Cotterpin
Instnrdion Sheet
Cup Inserter

76-W3 Seel Kit

Prrrrm-A-Lube Sesl
COth@n
Abrasive Paper
InstructionSheet

0431Steeveand SealKlt

Prrrrrn-A-Lube Seal
Barrier Slinger
C##:in

O-Ring, Sleeve

Instruclkm Sheet

Cylinder’

Bat-Cup

/’

I

13ac-CupRmg

f

07s-006 valve Kit
3 Velve Spring Retainer
3 Vehw Spring
3

valve

3 Velve Sesl
3 O-fling,

1

306$0 PI$tmn
6 O-Ring, Cyliider
3 Back-l@ Ring, Cylinder
3 Bac@up PkM2n
3 Bat-Cup Ring
3

3 Piston S+nacar
3 F%stoInRetainer
3 Cankal Washer (M6)
3 Nm (M6)
3 Catterpin
3 Inlet Vaks

1 InstructicmSheei

Cylidw

kwtrucikm Sheet

cup

iston

Kit

SERVICING THE PUMP

DISASSEMBLY

1. Remove discharge manifold as described.

2. Grasp cyfinders by hand and with an up and down motion, pull cylinders
from inlet manifold.

3. Remove cotterpin, nut, and washer from piston rod.

4. Next remove retainer, spacer, and piston/wp assembly.

5. Remove inlet valve.

REASSEMBLY

?.Examine inlet valve surfaces for pitting, scaleor grooves. Reverse valve

and sand infet side of valve using
mpiace if evidence ofexcessive wear. Slip onto rod.

2.Examine piston seating surfacesand sandcleanonflat surface using 240
grit paper. Ifextreme pilling or shar edges, replace piston.

3. Examine cup for wear, cracking, tearing or separation from the piston.
Ifworn replace and lubricate before installing on piston

NOTE CUP lNSTALLATfON: Wipe cup inserter with oil. Slip bactup ring

(when used) onto piston. Push cup over inserter and square with all
surfaces. Faulty cup installation causes premature cup failure.

4. Next replace piston spacer and retainer on rod.

5. Replace washer, thread on nut and torque per specification chart.

NOTE: Always replace with new StaMess Steel CotterPin and turn

ends under.

6. Examine cyfinder walls for scoring or etching which causes premature
wear of cups and reptace if worn.

7. Lubricate cylinder walls for scoring or etching which causes premature
wear of cups and repface if worn.

8. Position discharge manifold onto pump, repface fastenersand torque per

240 grit paper for clean surface or

.

SERVICING SLEEVES ANI) SEALS

DISASSEMBLY

1. Remove discharge manifold and piston assemblies as descritxd.

2. Remove inlet manifold containing seals.

3.Grasp steevesand witha pulfing and twisting motion remove thesleeves
from the piston rod.

NOTE Grasp sleeve with pliers only if reptacing worn sleeves, as this

procedure will mar the sleeves.

4. Next wmove seal retainer,

5.Remove and examine o-rings and/or back-up ringson piston rodforwear
and replace.

REASSEMBLY

1.Lubriite newo-ringsandorback-upringsandsliponto piston rod. Install

the first o-ring in the groove on the piston rod. Next position back-up ring
against the shoulder in front of the first o-ring. Then install the second

o-ring. Exercise caution as you slip the o-ring over lhe thread end of the

piston rod.

2. Examine sleeves forscoring or etching and replace. Immerse sleeves in
oil and carefully twist and push sleeve onto rod (machined counter bore
end first).

3. Next install seal retainers. Ifwicks are used, replace wicks, thoroughly
saturate with oil, place in seal retainer and install retainer.

4. Placeinlet manifold on pairof clearance blockswithcrankcase sidedown
and drive out old seals.

5. Invert inlet manifold with crankcase side up and install new seals.
Lubficate circumference of seal and install Prrrrm-A-Lube seal with
garder spring down. If using blue dot seal, blue dot should be facing up
when installed.

6. Stiplubricated sealinserters onto piston rod ends, position inlet manifold
onto pump and remove seal inserters.

NOTE Replace original quantity washers on studs before replacing inlet

manifold.

NOTE: Some models secure inlet manifold to crankcase. Replace

fasteners and torque per specification chart.

7. Reassemble piston assemblies and discharge manifold as described.

SERVICING CRANKCASE

1.White inlet manifold, sleeves and seal retainers are removed, examine
crankcase seals for wear.

2. Check oil level and for evidence of water in oil.

3. Rotate crankshaft by hand to feel for smooth bearing movement.

4. Examine crankshaft oil seal externally fordrying, cracking or leaking.

5.Consult factory oryourlocal disttibutorif crankcase service is evidenced.

19

CAT FWMPTROUBLE SHOOTING GUIDE

FRCMILEW pulsation

Csrma
Llabrisirl diiharge Vafvee of prmp.
Worn F%rrm-A-Luba saals.

sdufkxr

Ckrarror replaca discharge vafves.

Replace.

PFWMWEM: Law

Cmrsa ‘ Sohrtkrlr

Wwri

Mlozzkl Replace nozzle 01propar size.

Belt slippage. Tighten or replace; use corwcl belt.
M leak in infrdplumbing. Disassemble, reseal, and reassemble.

Relief vafve stuck, parmiaf!yplugged or impropdy adjusted; valve seat worn. Clean and adjust relief vdv~ check for worn and dirty wtve wits, Kti avahl%.

Mel suction strainer clogged or improper size. Clean, Use adequate size. Check more frequently.
Wormpiston assmbly. Abrasives inpumped fluid or serve cavitation, Inadequate Instaflproperfifter. Suclionat inletmanifold must be fimittitofiftfng less ilmrr20fe$t

water W@y.
Fouled cs dirty inlet w dhcharge valves.
Ld%y db~ hose.

tWIHLEhk IWrmr runs wdrentrdv rrmah. twessura Is verv low

-d inlet or air wdering the infe! plumbing.

Intel restridions andhw air Iwks. Damaged oup or stuck inlet or discharge vafve. ReplaccIworn cup or cups, clean out foreign material, replace worn valves.

Worn inlet manifold seats. f%mrn-A-Luks.

PHOBLEM Cylinder (l-Flings blown next to discharge manifold
Gwrstr
%sstwas inexcx3ssof rated PSI. Check for plugged nozzle, dosed vafves or improperly adjusted bypass valve,

Warpad manildd, Freezing.

mrrswrm

of waler or -8.5 PSI wmr.rum.
Clean inletand disdrarge vafve assernbfies.
Replace worn vafvss, vahre seats.
Raplarx dischwge hose.

­Proper size inlet p[umbing; check for airtight S@

Recdars worn waka

Solution

Replace manifokf.

FWCNUEM: Leakage at tf’mcylinder C&RIngs at the discharge manifold and

powdory @stanca In the areaof tfm O-Ring -

black,

fame

-~finders. Cyfinder motion causal by improper torque on the dischwge
manifold.

PROBLEM Watar leakage from under the inlet manifold

Cmrsa

-

Worn mht manifold seats. l%rm-A-LutM. Leaking sleeve O-Ring.

PFWXW.EM: ClllIoak
Carrsw

-

Wkwn cwrnkcase piston rrxl seals.

fWt2f!fl.Ekk LNlleaking In the

Cares

Worn crankahafl swd or impmpe

betwrm crankcase and pumping section

ma of the crankshaft

rly installed oil seal retainer packing. Remove oilseal retainer and replace damaged yrs.lwt and/or

Badbearing.

Solution

Retighten. Do nottightentoo muchortheears ofthe manifoidwil[bebovwc, causing

looseness inthe center cylinder,

tion

!blu

--------

Installseals, Ifpiston rod sleeves are scored, replarx sleeves and SIWMWO-Rings,

!%luiian

------ ..

Replace crankcase piston rod seals.

Solution

~als.

Re@ace Mwing.

xi

CAT PUMP TROUBLE SHOOTING GUIDE

PROBLEM: Exceealve r)lav In the end of the crankshaft oullav

!.

,,

cause Solution

Worn bail bearing from excessive tension on drive belt. Replace ball bearing. Property tension belt.

PROBLEiW Water In crankcase

cause Solution

May be caused by humid air condensing into water inside the crankcase.

Leakage oi manifold inlet seals arrd/or piston rod sleeves (Ming.

PROBLEM: Oil leaking from underside of crankcase

cause Solution

Worn wankcasa piston rod seals. Replace seals, sleeve and O+tings.

PROBLEM: Oil leaking at the rear portion of the crankcase
Cerise
Damaged or improperly instatled oii gauge or crankcase rear cover O-Ring, and i%piace oil gauge or cover O-Ring, and drain plug O-Ring.

drain rriuaO+ina.

PROBLEM Oii ieakage from drain plug
&use Solution

Loose drain plug or worn drain plug ORing. Tighten drain plug or replaca O-Ring.

Change oil at 3 month or 500 hour intervals using Cat pump crankcase oil (other

qqwovad oil every month or 200 hours) P.N.: 06100.

Replace seats, sleeves and O-Rings.

Solution

PROBLEM Loud knocking noise in pump
cause Soiution
Puliey ioose on crankshaft.

Broken worn bearing. Replace bearings.

PROBLEM Frequent or prematura faiiure of the iniet manifold seais
Cause
Scored rods or sleeves. Replace rods and sleeves.

Over pressure to iniet manifold. Reduce inlet pressure per instructions.

PROBLEM Short cup iife

Check key and tighten set screw.

Soiution

Cause Soiution

Abrasive material in the fluid being pumped.

Excmsive pressure and/or temperature of fluid being pumped. Check pressures and fluidinlettemperature; be suretheyare within specified range.
Over pressure of pumps. Reduce pressure.
Running pump dry.
Front edge of piston sharp.

PROBLEM: Strong surging at the inletand Iowpressureon the discharge side

cause

Foreignparficiesintheiniet ordischargevaiveor worninietand/ordischarge vafves,

Instaii proper filtrationon pump inlet plumbing.

Do not run pump without water.
Repiace with new piston.

Solution

Check forsmooth iap surfaces on inletand discharge vaive seats, Discharge valve

seats, and inlet valve seats may be l-don a very tine oilstone; damaged
cups and discharge valves cannat be lapped but must be replaced.

21

HY13RACAT ELECTRICAL SYSTEM

Tk entfro dectrical system

abatttwy. Battwy Itwalsam sustained by a
the engine.

FRW.EW M.nwba:twy voltag~
Ctwfaa

&kXe MWY.

Carmdd batteq wrrnirds.
Lowbatwryfluid.

Lmxm wiring wkhin decfrid system. Examine all terminal concoctions andvwfiy thaf they are secure.

Elecfrii sharl inwirings@em.

ground cnrmeciion. Examine Ierminal and remove corrosion if rwwwary.

PQQr

PFNWLEM Inoperathm hour meter

cWa@

fiml advancing cmedy. Verify 12volf DCisavailableatthe hourmetwviththeignition switchturned an.This

operates on 12 volts DCwhich is provided by NOTE: When new battery is installed insure it is properly charg@dbefore

20 amp alternator cfesignedwifh

installation or damage to the charging regulator may occur.

solution

andre@ace.

Remove

Ckn Ierminak andbaMY pm+t$.

Add Wat6f to ~

cpriate Iml.

Examineelectricalsys!emsforbarewires.

SoMrn

can be accomplished wth a volt meter or a test lamp.

Remove and replace hour meter if 12 volt is available.

A nyton gear withk the dcwk may have txwn jammed due to sudden joif of the

machine or truck. You may try simply tapping on the m~ter lo try to free the
n~on gear.

%1 K

1

*

,FICH

SENDING

JN!T

-yowl-lr-l‘-M=TkA I

H ?.&l= ‘r’”=

11:

Id

.:
2
&

I

FuEL
PUMP

2

-w- <

A

“[[ ,INK

,L, T ,>(r

GNO

OL1

PREsSURE

SWITCH

— +

50 LENOI0 C~D

CONTROL

VALVE

COIL

*

*

GNO

22

ONANPERFORMER

Gasoline Engine
Air Cooled
24 bhp (17’.9 kw) at 3600 rpm
20 bhp (14.9 ‘k@ at 3600 rpm

PERFORMANCE CHARACTERISTICS

RECOMMENDED FORVARIABLE SPEED OR CONTINUOUS DUTYTO

3600 RPM.

Production engines when shipped will develop after deduction for non­standard accessories, not less than 85% of maximum corrected bhp. After
run-in to reduce friction and the performance of service, engines should
develop not less than 95% of maximum corrected bhp.

Engine power decreases approximately 3.5% for each 1000 ft. (305 m)
atwve sea level and 1% for each 10°F (5.5W) above 60°F (15.5%). For

ntinuous duty at constant load do no~exceed 80% of av~lable horse­wer. For heavy duty applications requiring maximum output, the Ex­Ided Service Life package is recommended. Performance curves ob­ned and corrected in conformance with SAE J607b.

ONAN ENGINE STANDARD FEATURES

Electronic Ignition
Electric Starter, Solenoid Type
Mechanical Flyball Governor (variable speed)
Top Access Oil Fill and Level Indicator
Oil Pump
Fuel Filter
Anti-Flood Choke
Replaceable Dry Element Air Cleaner with Polyurethane Wrapper
Rotating Blower Semen
Valve Rotators {exhaust)
Cobalt Alloy Exhaust Seats
Chrome Cobalt Faced Exhaust Valves
Intake Valve Stem Seals
High Capacity Oil Base
Full-Flow, S@non Oil Filter

OPTIONAL FEATURES

Fixed Speed Governor
Crossover Exhaust Manifolds
Vacuum Pulse Fuel Pump

Exhaust silencers

Low Oil Pressure Switch

Flywheel Alternator, 20 or 35 amp with Regulator

(installed on cylinder air housing)
Stationary Blower Wheel Guard
High Capacity Air Cleaner
Engine Control Panel
PTO Modifications: Internally Splined Crankshafts, Hydraulic Pump

Adapters, Front PTO Shaft

Basic Dimensions - P220

E-

[.37, ,6? 92, ,,,., ~,,

63,.,1689?

NO <032 “W 6 HOLES
GN A 267,,5, ?,,, .. w

,,4 .,,4 “ ,2WC0, .Ey

3!8 ?6 UK 4 HOLkS

-,250 {8?55,

T

,“ ,“ches

Dlm3tls!o”s

nulllmetersshown m parfmmsss.

D!menstons m

m,ll,meters show. m paremheses

mchw

ONAN ENGINE DETAIL

Cyckx

4

Cylindm 2, horizonRa[lyopposed

Cmpmskm ma: 7.0to 1

Piston Spe@: 1800 fpm (9144 rnnls) at 3iNll rpm
Nat W@lgh& 127 lb (57.6 kg) dry, approximate.
Brwlti’mf System: CIossd, recirculating.

Cw.a!lng Systkwm FWMsumairooled, radial flow blower. Cooling air

volurm 1000cim (1699 rnMw] at 3600 rpm.

Fud Syst@rm Modwn downdraft carbur’otor with fixed main jet, limited

adjusfmvmt idle system. Smni-automatic choke operation with anti-

fkmding featut’e. Combustion airrequired at3600 rpm, 50 cfrn (85mVhr).

Gavwmcw bnsmts~odmm-~ardflv@ n.A~ustaNemecMniMl flybd,

300 rpm drop to 3640 rpm.

Ign!don !?qrstwn: Solid state

rmgative ground. RFI suppression spark plug wires meet UL and CSA

int~rferencw requirements.

SMIWM:Positive engagement sdanoid type starter. 12 volt negative

gruund.

Lukwfcat!on f3yst@n’KPositive displacement, gear-design oil pump. Full

presw.m lubrication to main and connecting rod bearings and governor.
FMd bypass, oil pressure control. Oil fill tube and level indicator.
Removable aluminum oil base. Capacity, 2.7 qt (2.56 L); add 0.3 qt
(0.3 L) for oil filler.

Paw@r.1’akMIW R@armount PTO pilot and keyed crankshaft extension.

Rotation, CCW whtm facing PTO shaft. Front mount PTO pilot.

Main W.wftlgs: Steel-backed aluminum precision inserts, replaceable.

I.D.: 2 in (50.8 mm); Length: 1in (25.4 mm).
Camshaft: Cast iron alloy. Replaceable lead babbitt bearings (2).
Conm?cting Rods: Forged steel. Replaceable bearings.
Crankshaft Ductile inm. Machined-in oil passages. Simultaneous oilfeed

from both ends of crankshaft.

Cylindw’s, Crankcaaw Aluminum alloy with integrally cast pearlitic iron

cylinder tiners.
CYIIIMM Hawk: Rerrwwable,aluminum alloy. Highturbulence combustion

chamtwrs.

PistIons: Aluminum alloy. Three ring, two compression, one oil control.

Cooled and Iubricat@dby oil spray.
TqqwXs: Barrtit ty~, adjustable.

Vabms: Exhaust, chome-cdbalt faced. Intake, steel alloy. Replaceable

valve guides.

V$IIV6Seats: Replaceable@intake and exhaust.
Valve lMMWurs: Exhaust valves.

kweakerk?ssignition with fixed timing, 12volt

hcorrectservkw orreplacemefff ofparfs ~msultinsevorepnonaliflju~
W/or equiprrwrrf damag~. .9?rviw personnel
3/ecfric4/arWof mechanical servica

WEATHEROPERAT!QN

%X

Nhen operating the engine in temperature above 1OO°F,pay particular
Mention to the following items to prewimt danaagw

1.Keep the engine moling fins clean

W@ged or clogged cooiing fins car?cause ov.erfwating and engine darn­~ge.Ensure cooling fins are kepf clean and debris does nof

Contact w“fh rotating machirwy can resulf in sewre flersonal im’urv or
death Stayclearofr6tatilJg com@M@s ai?denwwe pro~ective shie~dsar?d
guards are irr place and secured Mm? operating rn~chinery.

2. See that nothing obstructs air flow to and from the engine.

3.Ensure that you are using the proper graok and weight of oil for ambient
temperatures. Check the oil level each time you fit the fuel tank.

4.Check the battery water more frequently. High temperatures c-an

faster evaporation.

5. Change crankcase oil and filter more frequently.

NM WEATHEFI QPERATK3N
Whenthe engine is being us@d intemperatures bdmv 32°F (O°C),checkthe
following items closely:

1. Use the correct grade and weight of oil for tk tmnperature conditions.
Change the oil only when the engine is

ature

drop occurs when the engine is filled with summer oil, beforestart-

ing the engine, move it to a warm location until ‘theoil wfil flow frtmly,

2. Use fresh fuel. Fill the fuel tank after each

musf& qualtied foptwform

andfreeof obstruction.

accumulate.

cause

warm.If an unexpectedW’nper-

day’suse to protect against

moisturecondensation.

3. Keep the battery in a well-charged oondition.

GENERAL INFORMATION

Engine Mockil Refemrioa Identify your model by referring to the model and
s~cificatir.m (spec Mter) as shown on the unit nameplate. Always use

thesonumbers and the engine seria! number when making reference to

your engine.

HOW TO MM’ERPRH’ MODEL AND W+C !0

1234567

1. Factory code for general identification of basic engine series.

2, Number of cylindtws.

3. f3HPrating.

4. Fual required (G= horizontal shaft, V =vertical shaft).

5. Engine duty CYCIQ.

6. Factory cm% for designated optional equipment, if any.
?. Spwificaticm (SWCletter) which advances with factory

production modifications.

DUST AND DIRT

1.Keep unit clean. Keep cmoling system cl~an.

2. Service air cleaner

3. Change crankcase oil and filter more

OUT-OF-SERVICE PROTECTION
Protect an engine that will be out-of-service tar more Man 30 days as
follows:

1. Run the engine until it reachas normal operating tempwature.

2. Turn off the fuel supply and run the @ngineuntil it stops.

3. Drain oil from oil base while the engine is still warm. Refill with fresh

crankcase oil and attach a tag stating viscosity wad.

4. Remove spark plugs. Pour 1ounm (2 tablespoons or 28 grams) of rust
inhibitor or SAE #50 oil into tie cylinders. Crank the engine over afew
times. Reinstall spark plugs.

5. Service air cleaner as outiin~d in tbfANfTENANCE.

6. Clean governor linkage and protect by wrapping with a

7.Plug

exhaust outlet to prevent entmc@ of moisture, dirt, bugs, @tc.

Wipe entire unit. Coat rustable parts with a light film of greasa or oil.

8.

9. Provide a suitable cover for the entire unit.

as frequently as required.

than.

cl@ancloth.

24

10. If battery equipped, disconnect and follow standard battery
storage procedure.

RETURNING UNfTTO SERVICE

1. Remove cover and all protective wrapping. Remove plug from

exhaust outlet.

2.Check tag onoil base andverifythat oil viscosity isstill correct forexisting

ambient temperatures.

3.Clean and check battery. Measure specific gravity (1.260 at 770F[25%])
and verify level to be at a split ring. if specific gravily is low, charge until

correct value isobtained. Ifthe level is low,add distilled water and charge

until specific gravity is correct.

4. Check that fuel filter and fuel lines are secure, with no leaks.

5.Check that carburetor throttle lever and governor linkage move freely.

6. Connect battery.

7. Start Engine. Exhaust smoke is normal when the engine is started and

is usually caused by the rust inhibitor oil.

EXHAUST GAS IS DEADLY!
Exhaust gases from all fuels (including diesel, gasoline, liquid propane,

natural gas) contain carbon monoxide, an odorless and colorless gas.

Carbon monoxide is poisonous and can cause unconsciousness and

death. Symptoms of &rbon monoxide poisoning can include:

Dizziness
Nausea
Headache

Weakness and Sleepiness

7hrobbing in Temples

Muscular Twitching

Vomiting

/nability to Think Coherently

3. Inspect air cleaner system for leaks. Make certain all clamps and fittings
are tight and free of potential leaks.

4.Checkcrankcaseoil Ievelwiththeengine off. Ifengine hasbeen run, allow

a minimum of 10 minutes for the oil to drain down before checking. Ifoil
level is at or below

ADD mak on dipstick (Figure 1), add sufficient oil of

the proper viscosity as specifiid inENGINE SET-UP tobring oil level to
the FULL mark. Do not operate engine with oil level below the ADD mark

or above the FULL mark.

OIL SYSTEM

CRANKCASE OIL CHANGE

Referto Periodic Maintenance Schedule (located intheOperator’s Manual)
for oil change interval. Ifoperating in extremely dusty, high ambient, orlow
ambient conditions, change oil more often.

Runengineuntii thoroughlywarm before draining oil. Stopthe engine, plats
a pan under the drain outlet and remove the oil drain plug. After the oil is
completely drained, clean and replace the drain plug. Fill crankcase with
correct amount of oil. Refer to SPECIFICATIONS for crankcase capacity.
Use oils meeting the API classification SF, SF/C, or SF/CD. Refer to chart
todetermine the proper viscosity grade of oil to use Straight weight oils are
recommended for severe dutv use and at temperatures above 32°F KIWI
for minimum oil consumption-

Oil VkcosMy

I

—

II

1

I

~f

.,

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF

THESE SYMPTOMS, GET OUT INTO THE FRESH AIR

IMMEDIATELY.

/fsymptomspersist, seek medicalattentrnn. Shutdown theunit and do not
opwale untilithas baeninspectedandrepaired. Protection against
monoxide inhalation includes proper instal/ation8 ventilation and regu/ar,
frequent visual and audible inspections of the complete exhaust system.

Accidental starting of the engine can result in severe personal injury or
death. Disconnect the negative battery cable and spark plug wires while

servicingengine, contiols, or associated equipment.

DAfLY CHECKS OR EVERY 8 HOURS
The operator should daily make a complete visual and audible inspection
oftheengine. Check the following before starting theengine forthe firsttime
each day:

1. Check all fuel lines and fittings for possible leakage.

2. Inspect exhaust system forpossible leakage and cracks. Locate leaks in

muffler and piping while fhe engine is operating. Repair all leaks immedi-

ately after they are detected for personal safety.

carbon

,

1 I

F -20

c~”-”””-— “’ ‘“

TEMPER~TuRERANGEYOUEXPECTBEFO~ENEXTOILCHANGE

0 20

-10

40

0 70 — co

1

60

1 1

60 100

K-

–T

Hot crankmse oilcan cause bums if ii comes in contact with skin. Wear
protective clothing and keep fingers and hands clear when draining oil

Excess oil can cwse high oil consumption, h@h operating temperatures,
and oil foaming. Do not overfill crankcase.

Crankcase pressure can b/owouthotoi/, which cwcause severepersonal
injury. Do not check oil while the engine is running.

Oillevel should be tothe FULL mark ofthe dipstick. Start engine and run for
a short time to check for oil leaks around the drain plug.

25

m Fmw’ Ltlcamfl

CWertighterringthe valve cover can cause engine damage. QQno! owr­tighfen valve cover.

I

Oil

Always replace

tightly or oil

leakage may occur

(

_ FULL -- C%ufk?n: Do not overfill

= ADD -- Refer to amount on dipstick

1

OIL FILTER CHANGE

Refer h PWiOdii2Maintenance Schedule (Page 29) for oil filter changl
interval. If operating in extremely dusty, high ambient, or low ambier

conditions, change oil filter more often.

Spin oti oil filter element and discard it. Thoroughly clean filter mountinl
surface and make
film of clean oil to tho gasket. Spin element down by hand until gasket ju:
touches rrmunting padand then turndown anadditional
overtighten.

surenew gasket is inserted in the element. Apply a thi

1/2-3/4 turn. Do n(

The reed valve must be flat with no sign of a crease. AssmMe using
gasket. Refer to ASSEMBLY TORQUES for valve cwer capscrew torquo
specification.

P216,P218, P220 (Beginning Spot C): The crankcase breathw’ does not
require swvicing. Replac@ breather if it’s broken orcracked, or ifcrankcaso
becomes pressurized as evidenced by oilleaks atthe seals orexcessive oil

in the air cleaning housing.

P224: Remove hos@ clamp and breather hose from cap and valve assem-

bly. Loosen clamp and remove

solvent. Replace Mp and valve assembly ifballs do not move freely aftw

washing insolvent. Remove screen

pack in breather tube and position screen

shown below. Installcap andvalve, tighten clamp and attach breather hose

and hose clamp.

cap and valve assembly and wash in

andpack. Wash pack insolvent. Install

as shown in P224 illustration

a rw?w

RHOcrankcase Bn?ath?r

Val

With oil incrankoase, statiengine andcheck for!eaks around filter elemen
Retighten only as much as necessary to eliminate leaks; do notovertighter

CRANKCASE BREATHER

Tht?crankcaso breather pwents pressure from building up in the cranl
case. IIalso prevents oil contamination by

vapors and other harmful blow-by materials from the crankcase.

vapors am routed to the carburetor where they are mixed with incoming a
and burned in the combustion chamber. A sticky breather valve can caus
oil Ioaks, high oil consumption, rough idle, reduced engine power, and
rapid formation of s[udge and varnish within the engine

CRANKCASE BREATHER SERVICE

[fthecrankcaso becomes pressurized asevidt?ncedbyoil leaks atthe sea
or excessive oil in the air cleaner housing, use the following procedure 1
service.

Mostpat’tdear?ir?gsdvenkaretlammab~eand can cause severe persorI

injury ordt?a!h ifi,wed imprcy?er~y.Fcdiowthe manufacturer’s recommend,

tior?swhen cleaning parts.

P220(Spec Aand H):Remove the breather tube fromthe valve cover(P22

Crankcase Breather il[ustrafion). Remove capscrew, ffatwashers, valv

cmmr, pack, spring, washer, reedvalve, and breather baf~le.Discard gask[

and clean all parts in parts cleaning solvent.

removing moisture or gasolin

Thes

Read Valve -?=v

1

(-

_C3-- Flat Washer

/

~.~’n ,

-..

o

‘-,.%’-

Brteath@r

Baffle

\

f3reather
Hose

mp

26

IGNITION

i

SPARK PLUGS Refer to Periodic Maintenance Schedule for sparkplug ~ SOLID STATE lGNfTION: Ignition timing is set at the factory and is not
service interval. Replace spark plugs that show signs of fouling or electrode ! adjustable. The solid state ianition components are not adjustable and
erosion. Refer to S“Wcifi~tions fo; spark plug gap.

0.025” G8p

+-

Ground E?ectmde

J=’

Servicing Spark Plug

Worn: On a worn Dlua. the center electrode WIII be
rounded and the iap-will be eroded .010 or more than
the correct gap. Ffeplace a worn spark plug Immediately

~ n+uire no routine maintenan-~. ‘

Carbon Fouled Soft, sooty, DlacK aeposms malcate
recomplete combustion. Incomplete combustion !s
usually caused by overnch carburetion, weak ignltton,
or poor compression

Normab A plug faken from an engine operating under
normal conditions will have light tan or gray colored
deposits H the center electrode is not worn, a plug in
this condition could be regapped and reused.

Wet Fouled: A wet plug is caused by excess fuel, or oil
in the combustion chamber Excess fuel could be
caused by operating theeng!ne with too much choke

Oil in the combustion chamber IS usually caused by

worn piston rings or valve guides.

SPARK PLUGS CONDITION DIAGNOSIS

Engine misfire or starting problems areoften caused by spark plugs in poor

condition or with improper gap setting.
SERVICE

Every 100 operating hours remove the spark plugs, check condition, and
reset gaps or replace with new plugs as necessary (see illustration above).

1.Beforeremoving the spark plugs, clean thearea around the base ofplugs
to keep dirt and debris out of the engine.

2. Remove the plugs and check condition. Replace the plugs ifworn or if
reuse is questionable.

noi clean the sparkplugs in a machine using abrasive grit. Some grit

Do
could remain in spark p/ugs and enfer the engine causing extensive wear
and damage.

3. Check the gaps using a wire feeler gauge. Mjust gaps to 0.025” by

carefully bending the ground electrode.

4. Reinstall the sparkplugs into cylinder heads. Torque plugs to 10/15 ft. lb.
INSPECTION

Inspect the spark pfugs as soon as they are removed from the cylinder
heads. The deposits onthetips are an indication of the general condition of
piston rings, vafves, and carburetor. Normal and faulty spark plugs are
shown in the photos shown above.

Chalky White Deposits Chalky white colored deposits
Indicate overheating This condition IS usually
accompanied by excesswe gap erosion A clogged gra:
screen, clogged cooling fins, and lean carburefion are
some causes of over-hemmg

Refer to Periodic Maintenance Schedule (Page 29) for cooling system
service interval. Clean cooling fins and chaff screen sooner if required.
Remove any dust, dirt or oil which may have accumulated.

EXHAUST SYSTEM

Makeregular visual andaudibleins~ctionsof theexhaust system through­out the entire life of the engine. Locate leaks in muffler and piping while the
engine isoperating. Repair all leaks immediately after they are detected for
personal safety.

Breathing exhaust gases can result in severe personal injury or death.

/nspectexhaust system audibly and visualiyforleaks daily andrepairleaks
immediately.

AIR CLEANER

ELEhlEtW Refer to Periodic Maintenance Schedule (Page 29) for air
cleaner service and replacement interval. Service or replace more often
when operating under severe operating conditions. Service by gently
tapping element (see illustration on next page) on a flat surface.

ELEMENT WRAPPER (ff Equipped): Refer to Periodic Maintenance
Schedule (Page 29) for element wrapper service interval. Wash in water
and detergent and squeeze dry fike a sponge. Ringwith water. Allow to dry,

27

(C0ntinm32, nextpage)

fcmlimdfrom#+wkw6 J2sgtl)

thwrcoat mmriy with two tablespoons (28grams)ofSAE30engineoil.
Km?ad

into and wring out IBxci?ssoil from element wrapper. Failure to

adoquab?lywring out oxoess oil from wrappm’ may cause drop in engine
horsepowerduoto anincfieased restriction ofir’ktair. Installovwaircleaner
o[ament.

Fill the battery cells to the bottom ofthe filler neck.

distilledwaterandrecharge. If one cetl is low, check cast? for leak

add
Keepthe battery case clean and dry. An accumulation of moistww wilt lead
to a more rapid discharge and battery failure.

If CWIISarelow on water,

“-’ ‘rc’caner

tidy=’

BATTERY

Okconnect rregativo ground strap from the battery before working on any
part of tfm electrical system or engine. Disconnect positive terminal before

charging battery to avoid damaging ignition system alternator or regulator.

CLEANING BATTERY: Keep ttw?batteryclean bywiping itwith adamp cioth
whiwwer dirt appears excessive.

cmosim’1 is present arcwmd the terminal connections, remove battery

If

cables and wash the terminals

consisting of 1/4 pa-red of baking soda added to 1quart of water.

with an ammonia solution or a solution

STORING 13ATTEllY:lf the engine is to be stor~d for more than 30
remove the battery. With the electrolyte level at the bottom of th@ splitring,
charge the battery before storing it. After every 30 days tlw battery is in
storage, bring it backup to full charge. To reducxeselfdischarge, store the
battery in as cool a place as possible so long as the electrolyte does not
freeze.

Reading

‘%

(25”C)

L

BATTERY TERMINALS

Keep V%?battery terminals clean and tight. Push the cable terminal down
flush with or stightly below tie topof the battery post. Aft@rmaking connec­tions, coat the terminals with

to

retard corrosion.

alight application ofpetroleum jelly or grease

days,

Ha N.re th@ wentplugs are tight to prevent cleaning solution from entering
the cells.

Afl@rcleaning,fksbthe outsideof the battery, the battery compartment, and
surrounding areas with ckar water.

Keep the battery terminals clean and tigh!. After making connections, coat
the Wminak with a 6ighlapplication of petroleum jelly or non-conductive
greas@10retard corrosion.

CHECKING SPECIFIC GRAVITY: Use
specific gravity of tlw el@ckolytein each battery cell.

Hold the hycfrwneter vertical and take the reading. Carrect the reading by
adding four gravity
temperature isabove 130°F
fiv@dagmes b@mv8@F(27%). Afully charged batterywill have a corrected
spt?cik grawity of 1.260. Charge the battery if the reading is below 1.215.

CHECKING ELECTROLYTE LEVEL: Referto Periodic Maintenance Sched-

ule (Page 29) for checking electrolyte level interval.

points(0.004)for evey five degrees the electrolyte

(2PC) or subtracting four gravity points forevery

a battery hydrometer to check the

Battery Post

,/’-

Poor contact at the battery cable connections is often a source oftrouble.

~ Make sure battery cables are ingood conditicm and thatcontacting

are clean and tightly cmnected. Do not reverse batfe~ leads, Us@reconr-

~

~ mended battery tools when
~ battery darr~ag@.

BATTERY JUMP STARTING

~

Occasionally, it may W necessary to jump start(charg@]a weal{battery

:

~

using a charged booster battery. Ifjump starting is necessary, the following

28

disconnecting leads to avoid mechanical

Cable Terminal

,--

surfaces

procedure is n?commended to prevent starter damage, battery damage,
and personal injuries.

1. Disconnect engine load.

2. Use a battery of the same voltage(12V) as is used with your engine.

3. Attach one end of the positive booster cable (red) to the positive(+)
terminal of the booster battery. Attach theother end of the positive cable

to the positive(+) terminal of your engine battery.

PERIODIC MAINTENANCE SCHEDULE

SERVICE THESE ITEMS 8

Inspect Engine Generally
Check Oil Level

SerViCe Air Cleaner Element and Element Wrapper

Change Crankcase Oil (all engines without filter)
Change Crankcase 011 (standard base with filter)
Change Crankcase Oil (high capacity base with filter)
Replace Otl Filter
Check Battery Electrolyte Level
Clean Cooling Fins
Replace Air Cleaner Element
Replace Fuel Filter
Check or Replace Spark Plugs
Check Valve Clearnace (standard engines)
Check Valve Clearance (LP & natural gas conversion engines)
Check Valve Clearance (extended service life engines)
Clean Carbon and Lead Deposits (cylinder head)

AFTER EACH CYCLE OF INDICATED HOURS

25 50

xl

x

)(2

X2

X3 X2

X3 X2

)(3 Xz

100 200 500

x

Xz

)(2

x

X4

1000

x

)(4

X4

)(5

Follow a regular schedule of inspection and servicing, based on operating
hours. Keep an accurate logbook of maintenance, serving, and operating

time. Usethefactoryrecommended Periodic Maintenance Schedule (based

on favorable operating conditions) to serve as a guide to get long and
efficient engine life. Regular service periods are recommended for normal

service and operating conditions. For severe duty, extreme temperature,
etc., service more frequently. Neglecting routine maintenance can result in
engine failure or permanent damage.

For any abnormalities in operation, unusual noises from the engine or

accessories, loss of power, overheating, etc., contact your nearest Onan

Service Center.

Maintenance Schedule Footnotes:
1- Check for fuel leaks. With engine running, visually and audibly check

exhaust system for leaks.

2-Performmore often when running under severe operating conditions.

3- Required for initial break-in only.
4- Fordetailed maintenance, contact an Onan Service Centerorreferto the

SERVICE MANUAL.

5-Clean carbon more frequently when running under continuous light load

and/or on leaded fuel. Use of Onan 4C carburetor and combustion
cleaner is recommended every 200 hours to help reduce
carbon buildup.

Breathrhg exhaust gases can result in severe personal injury or death. Do

notuse aircleaner, exhaustelbow, orconnectingparts asa supporting step.

Damage to these and connecting pads can cause an exhaust leak.

29

TROUBLE SHOOTING

—

IGNITION SYSTEM

30

ENGINE TROUBLE

SHOOTING

GUIDE

Wherrtroublesoccur, besure tocheckthe simple causeswhich, atfirst, may

seem too obvious to be considered. Forexample, a starting problem could

be caused by an empty fuel tank.

Some common causes of engine troubles are fisted Mow-use this asa

guide to locate causing factors.

PROBLEW.Engine cranks but will not start
Solution
Empty fuel tank.

Clogged fuel line.

Spark plug leads dsconnscted.
Keyswitch or killswitch in “off position.
Faufty sparkplugs.
Fauftv ianition module,

Dirtor water infuel svstem.

PROBLEMEngine starts but does not keep running

Solution

Restricted fuel tank venl.
Dirtor water infuel system.
Fauhy chake or throtile controls.kables.
Loose wires or connections which killterminal of ianition module to around.

Cshuretor improperly adjusted.

Fautty cylinder head gaskets,
Faufty fuel pump.

PROBLEMEngine runs but misses

Solutian

------ ..

Dirlor water infuel system.
Spark plug leads boss.
Loosewires or connections which intermiltentlyshorl killterminal ofignitionmodule

to ground.
Carburetor imorooerlv adiusted.
Engine overtreating.
Incorrect vafvstcAappet dearsnce.
Faulty gnition module.

PROBLEM Engine wfll not idle

Solution

------ ..

Idfe speed adjusting screw improperly set.
Dirtor water infuel system.
Idle fuel adjusting screw improperly set.
Restricted fuel tank vent.
Faultv soark DIUOS.
Incorrect vafveto-tsppst dearsnce.
Low compression

PROBLEM:Engine overheats

Soiulion

Grass screen, cooling tins, or shrouding clogged.
Excessive enaine load.
Low crankcase oil level.
High crankcase oil level.
Carburetor improperly adjusted.

PROBLEM:Engine starts hard

Soiution

wires or connections.

hose

Dirtor waler infuel svstem.

Cloggedor restricted fuel lines.

Faulty choke or throttle cantrolsksbles.
Faulty spark plugs.
Carburetor improperly adjusted.
Incorrect vafvc+t~teppet deerence.
Low compression.

PROBLEM:Enaine will not crank

Battery is discharged.
Loose or fauffy wires or connections.
Faufty keyswitch or ignitionswitch.
Faulty electric starterktartar solenoid.
Seized internal engine components.

PROBLEM: Engine knocks

Soiution

Lowcrankcaseoillevel.

Excessive enaine load.

PROBLEM Engine loses power

Soiution

Low crankcase oil Ievet.

High crankcase oil level.

Restricted air cleaner etement.
Dirl or water infuel line.
Excessive engine load.
Enaine overheating
Faultv soark oluas,

Carburetor improperly adjusted.

Low compression.

PROBLEM:Engine uses excessive amount of oil

Soirrtion
Incarred oil

Cloaaed or imorcmerfvassembled breather svstem.
Worn or broken piston rings
Worn cyliiderbares.
Worn valve stems and/or vefve guides.

viscositv of twre.

31

MAINTENANCE PFKKEDl!RES

T~ avoid costly mpaim and down-time, it is imperative to develop and
practi~ good mainttmarm procmfuwis from the beginning. These proce­dures fall into daily, WWWIY,monthly and quarterly increments, and are

mdirwd twlmv. W@have provided a maintwwmca logfor your convenience
on next pag@;it is remwmww.!ed that you affix a copy of the logon the
whit% door rmar your unit for convenience and to sawe as a maintenance

Check engine oil Iwal.

IHSWCIgarden hose screen-clean as needed.

Visually inspect machine for loose wires, ail leaks, water leaks, etc.

Inspect recavery tanks/s filter and filter bag for tears, holes, etc. - clean,

repair or rapface

‘Lubricate blower wi!h Penrwguard through blower inlet.

as needed.

OVERALL CARE OF UNIT

MAIW’AINING WE (XWWJAL IWWWWCE W W3LM UNIT !S
MPORTAMT FOR IWO REASONS

repn%+ants a big dollar investment for your c%mningbusiness and its

1.It

appearanrx?should reflect that fact. A dirty machirm is not pmkwional!

2. Maintenance, troubleshooting, and repair is much easiw’ to accmpliah
on a clean well maintairwd unit. f%?gularcl~aning of MO
you an opportunity to visually insp?ct al! facets of th~ machim and spot

potential problems before tfwy ocfwr.

FOLLOWfNG MAMTEIWNCEM RECWMBIEMDED BYTHEMMUFAC.
TLJRER AT THE FREQUENCY

AKER EACH JOB:

Check recovery tank, slsl filter and filter bag as required.

INDICATED.

mwhinf!offws

WEEKLY

Change engine oil. (25-30 hours of operation.)
Check engirw air clwmer filter - clean as necessary.
Check high pressure pump oil -add as necessary.
Check drive coupler set screws - tighten as needed.
Check pump driw belt for wear-tighten as needed.
Check pump pulleys - tighbsn as needed.
Check fuel lines far wt%irlchafing.
Check all nuts and tmlts - tighten
Check heater burrow assy. union for tightnessdeaks.
Cl@an vacuum tank thoroughly with high prwssuw washer.
Flush watw and chemical system with 50/50 while tinegar solution.
Check @ngirwRPM’s - adjust102W0 rpm on 4.5

as needed.

2800 rpm on 4.0

MONTHLY

thwrseblower bearing fittings.

Rwnove pressure bypass valve stem, grease cup and stem, reinstall.
Ctwk water !evol in battery. Clean connections

as needed.

aumww’t’

Cmge oil in blower.

Check engine compression.
Check for combustion chamber carbon deposit.
Change spark plugs.

WJWTA?W:

Reoimddate and machinehours on maintenance@chart.

fMfLY:

machine down thoroughly with a damp cloth; flush recovwy tankout

Wipe

thoroughly. Empty filter bag and inspxt for rips, @ars, @tc.- replace as
needed; remove, thoroughly clean and r~install stainless steel
in recovery tank; inspect and clean vacuum slot on cleaning wand; clwck
wand head for sharp edges that could tear carpal - file down as needed;
clean wand to maintain original appearance; wipe down vacuum

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

WEEKLY:

Wipe down entire unitas needed- apply good coat of auto wax 10allpainted
surfaces inside and out, and to control panel; thoroughly cfwanrecovery
tankusing high pressure hotwater (unit withoptional highpressure c{eaning
gun may be used for this}; removo stainless steel filttw in recovery tank,
thoroughly clean removing all IMtbuild-up, ins~ct fordamageandreinstall.

Remove filter bag, Thoroughlyclean and reinstall ­chemical from chemical contakwr, wash out thoroughly to remove any
chemical build-up; inspect chemical feed Iirm strainer and use W% while
vinegarhvater solution to remove any chemical build-up; thoroughly cl@an

wand and inspect for clogged jet, debris in vacuum slat and l@akingfitings

atvalve. Apply lightcoat ofauto wax towand. Thoroughly dean vacuum and
high pressure hoses including hose cuffs - inspect for wear or damage to
hoses and quick connect fittfngs. Inspect garden how corwwctladapter
screen for debris, remove and clean thoroughly. Inspect all firmsfwiwarar
abrasions that may cause possible leaks.

iFtarn,repkmo; @mpty

fillerscretm

andhigh

32

MAINTENANCE LOG

DAILY CLEANING & INSPECTION

Engine oil - check
Garden hose screen - clean
Machine - general inspection

Clean vac tank filter bag after every job
Blower inlet - spray with LPS 1 atter last job

WEEKLY SERVICE

MAX

HRS

25 BLOWER check 011level
25 PUMP OIL check (lop of sight gauge)
25 DRIVE SHAFT SYSTEM tighten set screws
25 BELTS & PULLEYS check tightness
25 HIGH PRESSURE LINES check for chafing
25 NUTS & BOLTS check fightnese
25 13ATTERYLEVELS check
25 VACUUM TANK clean
25 WIRING check for chafting
25 CHEMICAL SYSTEM flushwlvinagar

SERVICE

MONTHLY SERVICE

100 ENGINE OIL change
100 BLOWER greasa bearing
100 ENGINE AIR CLEANER clean
100 BY PASS VALVE grease cup & stem

QUARTERLY SERVICE (3 MONTHS)

300 BLOWEROIL

change

300 ENGINE cmmcrreaaion
300 SPARKPLUGS change

DATE/1-lRS I DATE/HRS I DATE/HRS I

I

DATE/tiRS I DATE,HRS I DATE/HRS I DATE/HRS

MAINTENANCE LOG

DAILY CLEANING & INSPECTION

Engine oil - check
Garden hoee ecreen - clean
Machine - general inspection

WEEKLY SERVICE

MAX
HRS

25 BLOWER check oil level
25 PUMP OIL check (top of sight gauge)
25 DRIVE SHAFT SYSTEM tighten set screws
25 BELTS & PULLEYS check tightness
25 HIGH PRESSURE LINES chock for chafing
25 NUTS & BOLTS check tightnese
25 BATTERY LEVELS check
25 VACUUM TANK clean
25 WIRING check for chaffing
25 CHEMICAL SYSTEM flushw/vinagar

SERVICE

MONTHLY SERVICE

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

QUARTERLY SERVICE (3 MONTHS)

300 BLOWER

OIL change

300 ENGINE compression

300 SPARK PLUGS change

Clean vac tank filter bag after every job
Blower inlet - spray with LPS 1 after last job

DATE,HRS I DATE/HRS I

I

DATE/FIRS [ DATE,HRS I DATE/HRS I DATE/HRS [ DATE/HRS

33

MAINTENANCE MM

.W-..

I

DAILY GLREANING & INSPECTION

Engine od - check

Garden hose screen - clean
Machu’m - cwmmralmstmctiorf

Clean vac tank filter bag alter every job
Blower relet - spray with LPS 1 after last job

WEEKLY !3ERVICE

MM
HR-S

25 BLOWER check ml level
25 PUMP OIL check (top 01mght gauge)

2s lXWVE SHAFT SYSTEM ughterr
25 BELTS & PULLEYS check ughtrress
25 HIGH PRESSURE LINES check for chafing
25 NUTS & BQLTS check lightness
25 SATTEFW LEVELS check
2!! VACUUM TANK clean
25 WIH lf’#3 check tor chaffing
25 CkfEMICAL SYSTEM flush wlvmegar

SEIWN2E

set screws

MONTHLY SERVICE

100 ENGINE OIL change
100 EILOWER grease bearing
1cm ENGINE AlR CLEANER clean
1(M f3Y PASS VALVE grease cup & Slem

QUARTERLY SERVICE (3 MONTHS)

300 BLOWER OIL change
300 ENGINE comrwessmn
300 SPARK PLUGS change

]

DATEIHRS I DATEHRS I DATE HRS I

DATE(HRS I OATEFIFIS I f)ATEIHflS I OATEMWi

MIAMH4ANCE LOG

DAILY GLEAMING & IW3PECTION

Ermine ail - check Clean vac tank filter baa after everv 10b

Gakm hose screen - clean

Machine - general inspectlan

WEEKLY SEFWICE

MAX

fms

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

25 PUMP OIL Cheo
25 fW7WESHAFT :
25 BELTS I%PllLLE
25 HIGH ‘----’ ‘­>5 MlITS
25 ml-r
25 VAL21

96 WISSI1

‘-E

_ ..,. ...VG chock for chaff{ng

25 CHEMIICAL SYSTEM flushw/vinegar

SERVICE

k (top of sqhi gauge)
)YSTEM tqhvan sel screws
iY!3 check

rrcam.Jr4E LINES check for chafing

v

; & f3CIL.TSc!!eck t!ghtness

ERY LEVELS check

JLfMTANK cfean

MClt4TH’LV SEIRVICE

t00 ENGINE OIL change

100 BL(IWER Qfiease bearing
100 ENGINE AIR CLEANER ciean
100 EYYPASS VALVE grease cup & stem

CWkHTERLY SERVICE (3 MONTHS)

300 BLOWER OIL change

300 ENQINE compression
300 SPARK PLUGS ctrange

Eflawer relet - spray w!t~ LPS 1 after ‘last 10b

I DATE1-lRS I DATEIHRS I DATEI-IRS I DATE HRS I DATEHR5 I DATE/lil15 I fJATE/flRS

ttghtneSS

I

I

34

NOTES

35

wAJw’wrrY INFORMATION

I

To avoid misundwWandings which might occur between machine owners
and rnanufachrn?r,vm are listing causes of component failure that specifi­cally voids warranty coverage. Such causes as listed below shall constitute

alluw ar Iw2glli!ct.
MLQWER: Failuw to lubricate impllers daily with LPS-1 or WD-40 lubri-

cant. Failure to

Failure to maintain proper oil levels inthe blower. Failure to use the correct
oil grado and viscmity as recommended in blower manual. Failure to
properly maintain Mower safeguard syslems such as waste tank filter
scrwm, vacuum safety relief valve and waste tank automatic shut-off
systwn. Allowing foam to pass through blower.

PFIESSLME WATER PUMk Failure to maintain proper oil level as

HIGH
recammonded in pump manual. Failure to change oil in pump at recom-

mended intervals. Failure 10protect pump against freezing. Failure to
maintain pump fwotection shutdf system. Failure to use water softener

hard water areas. (he of improper chemicals.

VAC ‘TANK Failure to properly maintain filtering devices intank. Failure to
clean tank as recommended by manufacturer. Failure to maintain vacuum

Safaly mleas%in tank lid. U% of improper chemicals.
CHEMICAL PROWJRTIQNEF!: Use of improper chemical. Failure to use

water softoner in hard water area. Qperating machine without proper

chemical filter screen. Failure to prot~ct against freezing.

lubricatekarings as recommended in blower marwrat.

WARRANTY PROCEDURE

Warranty coverage is available to you ONLY through HydraMaster CorW.
ration, 20309 t%$thAve. West, Lyrmvmd, Washington 98036. When war­ranty parts are needed, write Hydrafblasttw Wtwrm!y [e-mail] the above
address, or call the Warranty/S.ervke Dept.

will beacceptecf, Hours of WarrantylSarwiae Dept. am 8:00 am to

calls

pm Pacific Time.

5:00

kWORTANT:

without charge forthirty (30]
status. An invoice
shipment will besent to the customer forthe amount of the parts sent. The
customets faulty parts must m returned far evaluation ptior to the @xpira­tion of the thirty (30) day period, Upon warranty approval, a credit will b
issued the customer for the replacement parts invoice. Warran~ dlmp
pmal or
period allowed w[[I result in the customer Wring charg~d for W@

in

replacement parta arm

HydraMasttWs warranty policy provides replacwmnt parts

daystocustomws maintaining cunwntaccwnt

datedthirty(30)daysfrom date of replacenwmt parts

failuro to return ha faulty parts wltlln the thirty (30] duy

at(20$} 775-7275. No calloct

CtlNTRflLPANEh Failr.wetoprotect ffowmeterandwaterpressuregauge

against freezing.
VACtJWd AN12 SOLUTION HQSE~ Failure to protect hoses against

freezing. Failure to protect hoses against burns from enginelblower ex­haust. Damag6 to Iwws from being run over by vehicles. Kinking or
cracking from failure !oslwworunroll hoses ctrrmctfy. Normal wear and tear
from everyday use.

CLEANING WJMW Failure to protect against freezirrg. Clbviousphysical

abu!w of wand.
WATER HEATER Cwer pressurization of the system (recommended

maximum working pressure -800 PSI]. Failure to protect against freezing.
Modification of the gas delivery system.

36

GOLDEN

GUARANTF+@

LIMITED

WARRANW PUN

HydraMaster warrants truckmcrunt machines of its manufacture to be free from defects in material and workmanship if properly
installed, maintained, and operated under normal conditions with competent supervision.
dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in
connection with any of HydraMaster’s products. This warranty shall extend to the original purchaser of said equipment for the
periods listed by component below from date of installation. If repairs or replacements are made by tbe Purchaser without
HydraMaster’s written consent, Hydramaster’s warranty shall cease to be in effect. No allowance will be granted for any repairs
or alterations made by the Purchaser without HydraMaster’s prior written consent.

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

HydraMaster agrees at its option to repair at the point of shipment, or to replace without charge any parts or parts of products of
Hydra Master’s manufacture, which withi n the specified warranty period shall be proved to HydraMaster’s satisfaction to have been

defective when shipped, provided the Purchaser promptly notifies HydraMaster, in writing, of such alleged defect. HydraMxiter
will pay all freight and transpiration charges, via normal ground shipping means, for replacement of parts covered under this
warranty. This warranty covers parts, as specified, and does not cover labor which may be necessary in completing repairs.

HydraMaster’s liability to Purchaser, whether in contract or in tort arising out of warranties, representation, instructions, or defects

from any cause shall be limited to repairing or replacing the defective part or parts. To qualify for warranty coverage, defective
parts must be returned to HydraMaster within 30 days. No liability whatsoever shall attach to HydraMaster until said products

have been paid for.

Except as stated in this section and in the preceding section titled “Warranty” and except as to title, there are no guarantees or
warranties of merchantability, fitness, performance or otherwise, express, ireplied or statutory, and Hydra Master shall have no
liability for consequential, incidental or other damages, howsoever

FRAMEYCOVER wsEMBLm: ................................................... ....................................................................................................................3 years

VACUUM RECOVERY TANWCHEMICAL MIX TA~: ........................................................................................................................3 years

caused.

No person, agent, representative or

ENGINIU(?ivougtI original

VACUUM BLOWER: (’fhmJsIIorigin.]Manufacturer. scc ccmpcr tnrtustics W.y.) .....................................................................................................2 yFXNS

CHEMICAL PROPORTIONING SYS~M: ....................................................................................................................................................l yew

CLEANING WA~ ...............................................................................................................................................................................................

INTERNAL MACHINE HOSW .........................................................................................................................................................................

HIGH PRESSURE BY PASS VALVE ................................................................................................................................................................

EXTERNAL MACHINE HOSE’S

BELTS, FITTINGS, FfLTER SCREENS, GAUGES

WATEH HEATER OR HEAT EXC~NG~ .................................................................................................................................................l year

HIGH PRESSURE PUMP.(?brougtIon@MtManda@w) ..........................................................................................................................................l year

AIIcomponents not specificallyy referenced in the above schedule are covered under this warranty for a period of one (1) year, exmpting those parts

which are considered, by HydraMaster, to be expendable in normal use.

Freezing of any water or chemical related romponent will VOID all warranties on waterer chemical related components. internal or external. of this
equipment.

Deposits and build-up in the water system, chemical system or beater system due to hardness in tbe water used or chemicals which result in deposits,
will void all warranties on affected components.

Manufwhmz. On f)irwt Orkunits SE orisind Mmufwhm+s wamanty.) .. ... ... ....... . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .............. . . . . . ...............z YW3fS

1 year

1 year

1 year

........................................................................................................................................................................l year

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

1 year