HYDRAMASTER HYDRA-CAT-M User Guide

Ei’YDMkiI-C?AT/M

General Information

General information . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2

Howthe System Works . . . . . . . . . . . . . . . 2

Machine Specifications, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Spare Parts Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Howto Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Parts Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Purchaser’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Sales Representative’s Responsibility . . . . . . . . . . . . . . . . . . . . . . 3

Truck Preparation

Truck Preparation&illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Placement of Unitin Vehicle . . . . . . . . ., . . . . . . . . . . . . . . . . . . . . ...4

Machine installation . . . . . . . . . . . . . . .,, . . . . . . . . . . . . . . . . . . . . ...5

PropaneTank Location&Plumbing . . . . . . . . . . . . . . . . . . . . . 5

Water Softening

Hard Water Area Map& Water Softener . . . . . . . . . . . . . . . . . . . . 6

Hydra-Cat Operation

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

Cleaning Stroke Procedure/Over-Wetting . . . . . . . . . . . . . . . . 8

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

Water Flow illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

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

ChemicalTankTroubleShooting Guide . . . . . . . . . . . . . . . . . . . . 10

Valve Assembly illustration, . . . . . . . . . ., . . . . . . . . . . . . . . . . . ...11

Jet Assembly illustration . . . . . . . . . . . . . . . . . . 11

Wand Assembly illustration ...,..... . . . . . . . . . . . . . . . . . . . . . . 11

Stem Assembly illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Bypass Valve &Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Flow Water Trouble Shooting Guide.. . ...,................,,12

Vacuum System

Vacuum System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13

Vacuum Flow illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,13

Vacuum Tank Filter Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13

Blower Lubricant illustration ...,... . . . . . . . . . . . . . . . . . . . . . . ...13

Vacuum Blower Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14

Vacuum Blower Lubrication...,,.. . . . . . . . . . . . . . . . . . . . . . . ...14

Vacuum BlowerTrouble Shooting Guide . . . . . . . . . . . . . . . . . . ...15

Heating System

Heating System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

Heater Operating Instructions ...,. . . . . . . . . . . . . . . . . . . . . . . ...16

Heater Trouble Shooting Guide .,,... . . . . . . . . . . . . . . . . . . . . ...17

Cat Pump Model 290

Cat Pump Mode12900perating instructions , . . . . . . . . . . . . . ...17

Cat Pump Specifications . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . ...17

Cat Pump Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

General Information for Cat Pump Repair . . . . . . . . ...18

Piston Mode1290Exploded View &Parts List , . . . . . . . . . . . . ...19

Pumping Section Cutaway illustration . . . . . . . . . . . . . . . . . . . . ...20

Servicing the Pumping Section . . . , . . . . . . . . . . . . . . . . . . . . . . ...21

Servicing Sleeves and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Servicing Crankcase Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Cat Pump Troubleshooting Guide . . . . . . . . . ...22.23

Hydra-Cat Electrical System

Electrical System Troubleshooting HydraCat S/Series Electrical Diagram Hydra-Cat M/Series Electrical Diagram

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

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

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

CCKB Engine

Service Guide, Hydra-Cat S/Series. . . .

Specifications . . . . . . . . . . . . . . . . . . . . . .

Outof Service Protection . . . . . . . . . . .

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . .

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...26

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...26

Crankcase Breather illustration . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Spark Plug Gaplllustration ..,,... . . . . . . . . . . . . . . . . . . . . . . . ...27

Air Cleaner illustration . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . ...27

Oil Filter illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Adjustments, Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...28

Engine Safety Precautions . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . ...28

Periodic Service Guide & Maintenance Schedule , . . . . . . . . . ...29

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Kohler Engine

Service Guide, Hydra-Cat M/Series . . . . . . . . . . . . . . . . ..3o

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Periodic Maintenance.......,,.. . . . . . . . . . . . . . . . . . . . . . . . ...30

Oil . . . . . . . . . . . . . . . . . . . . . . . . . ,,, ,,. . ... ,,, . . . . . . ,,

Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32

Cylinder Heads.................,,.. . . . . . . . . . . . . . . . . . ...33

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...33

Kohler Engine Trouble Shooting Guide ,, . . . . . . . . . . . . . . . . . ...34

Kohler Engine Carburetor

Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35

Carburetor Troubleshooting Guide . . . . . . . . . . . . . . . . . . . ...37

Kohler Engine Lubrication System

Operation & Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...38

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . . . . . . ...38

Kohler Engine Electrical Systems

Systems and Components ...,.... . . . . . . . . . . . . . . . . . . . . . . ...39

Ignition System Trouble Shooting Guide . . . . . . . . . . . . . . . . . ...41

Spark Plug Condition Diagnosis., . . . . . . . . . . . . . . . . . . . . . . . ...42

Battery Charging System . . . . . . . . . ., . . . . . . . . . . . . . . . . . . . . ...43

Electric Starter illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..44

Trouble Shooting Guide, 15 Amp Battery Charging System . ..44

Maintenance

Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45

Overall Careof Unit, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45

Maintenance Log............,.. . . . . . . . . . . . . . . . . . . . . . . . ...46

Warranty

Warranty Information . . . . . . . . . . . . . . . . . . . . . .Inside back cover

24 24 24

25 25 25 25

GENERAL INFORMATION

This manual contains installation and operation instructions as well as information required for proper maintenance, adjustment and repair of thki unit. Since the first and most important part of repair work is the correct diagnosis of the trouble, a general troubleshooting section and component manual troubleshooting charts have been included for your convenience.

Unlike the garden tractor, Iawnmower and cement mixer, all having one or two functions to perform, the truck-mounted carpet cleaning plant has many functions to perform simultaneously.

● Engine has to run consistent RPM,

● Vacuum has to pull air and dirty water back from cleaning site.

* Water pump provides stable pra%sure at proper water flow for

cleaning.

● Chemical has to be injected into the water stream at the right

ccmsistency.

* Heater must maintain proper heat.

* Vacuum tank must store dirty water until drained. As you can see, it is not just a turn key operation with only one

thing to worry about, Does it start?!

HOW THE SYSTEM WORKS

The water system takes incoming water at tap (low) pressure, combines it with chemical from the chemical system automatically,

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

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

properly understand, maintain and service your cleaning plant.

Follow the directions carefully and you will be rewarded with years of profitable trouble-free operation.

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

The manufacturer uses this

symbol throughout the manual to

warn of possible injury or death.

This symbol is used to warn of

possible equipment damage.

MACHINE SPECIFICA~ONS

FRAME: 21 “W, 56”L, 34”H. Steel with Baked-on Epoxy Finish. WEIGHT: 800 pounds. COWLING: Steel with Baked-on Epoxy Finish. ENGINE: M/Series 20 BHP Kohler M20 Electronic Ignition.

S/Series CCKB 20BHP Onan Opposed, Two Cylinder, Four Cycle.

IGNITION: Standard Points (Kohler-Electronic), Keystart,

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

PSI - @ 1200 RPM.

VACUUM BLOWER: 4MF Sutorbuilt W/14 Hg Safety Relief.

CHEM. SYSTEM: Auto Proportioning Flow Meter Controlled.

HEATER: Propane Fired, Thermostatically Controlled.

(180,000 BTU).

INSTRUMENTS: 1-1000 High Pressure Gauge, Temp. Gauge,

Vacuum Gauge, Hour Meter, Chemical Flow Meter, Ignition Key

Start and on lnd. Lights. RECOVERY TANK: 65 Gallon Aluminum Epoxy Finish, CLEANING WAND: Stainless Steel w/Heat SMeld Grip and

Replaceable Vacuum Lips.

HI-PRESSURE HOSE: M“ High Temp LinedNinyl Covered,

Hose rated to 2750 PSI, Q.C. rated to 800 PSI

VACUUM HOSE: 2“ Reinforced, 11/2”Reinforced.

STANDARD FEATURES: Basic Console, 65 Gallon Vacuum Tank;

11” S1S Cleaning Wand; 100’ 2“ Vacuum Hose; 50’ 11~2Vacuum Hose; 150’ H.P. M“ Solution Hose; Battery Box; Through Floor

Connections for Gasoline and Propane Hook-up; Tie Down

Cleats; Vacuum Hose Connections; Operation Manual; Steel Legs with Casters; Clutch; Freeze Guard,

OPTIONAL FEATURES: Stair Tool, Additional 2“ Vacuum Hose in

50’ Lengths; additional

1/4” Pressure Hose in 50’ Lengths; Rotary

Jet Extractor.

SPARE PARTS RECOMMENDATION

Because your truck-mounted unit is capabte of generating several hundred dollars per day, down-time on the unit can be very expensive.

In order to minimize such down-time, it is strongly recommended by the manufacturer that you purchase and keep in you truck the following spare parts:

PART NO. DESCRIPTION 000-078-015 000-078-019 000-078-034 000-076-007 000-049-029 ‘ 000-078-001 000-078-004 000-049-023

000-052-050 . .. .... .

000-052-051 000-052-052 000-052-053

000-11 -)6- 04?I

------ ---

010-022

010-017

Flow Meter Kit Wand Valve Plunger Kit Pressure Bypass ~alve Kit Soray Jet 8008E Recovery Tank Filter Ba~ Cat 290 ‘Short CUP Kit S~andard Cat 290 Hot Cup Kit ~mntifin=~~

Scr,

_-.”een Garden Hose

44o Male Quick Connect

44o Fer 660 Mal~ 66o Ferr---- _-,.

Fnnin~ Snark PII

_,, =...-

nale Quick Connect Ie Quick Connect

nab C)L;ickconnect

-r -.. . Pump Drive Belt, m-!3elt S Cat Belt

,-,- ..-..-.,

.Ug 2

QTY.

1 1 1 1 2

_——

6 1 7 1 1

1 1

HOW TO ORDER

—

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

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

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

A. Name of your company and your address. B. Equipment Model (i.e. Hydra-Cat, 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 parts are sent freight collect, via:

A. U.P.S. B, Air Freight C. Air Mail D. Air Express E. Auto Freight

Do not give malfunctioning parts to a HydraMaster Sales or

Service Representative. All parts must be returned directly

to HydraMaster, freight prepaid.

PARTSORDERS

To expedite your parts needs, please call your sales representative. In most instances, he either stocks or has access to parts through a regional service center.

In the event parts are unavailable locally, contact the factory and coordinate your needs. If this becomes necessary, always indicate the method of shipment you desire, i.e. U.P.S. Blue Label, Air

Freight, Air Express, etc.

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

ONE FINAL NOTE

Any questions you have regarding the warranty program should be directed to the Warranty/Service Dept. Personnel at HydraMaster Corporation.

We shall always endeavor to be fair in our evaluation of your warranty claim, and shall provide you with a complete analysis of our findings.

PURCHASER’SRESPONSIBILITY

PRIOR TO ARRIVAL OF UNIT:

● Install 5/8” exterior plywood flooring in vehicle and cover with

artificial turf.

● Have belly mounted propane tank installed on vehicle. Tank

must be propane vapor type.

● Caution Purchase heavy duty 42-60 amp hour battery and have

battery ‘slow’ charged if new. If battery is not fully charged damage can occur to the engine charging regulator.

READING OF OWNERS MANUAL:

Itis the purchaser’s responsibility to read the unit operation

manual and to familiarize himself with the information contained therein.

SALESREPRESENTATIVE’S RESPONSIBILITY

ACCEPTANCE OF SHIPMENT:

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

delivery receipt until you have closely inspected the unit and noted any damage on the delivery receipt. Have the freight company representative acknowledge the damage by signing the notation of damage on the delivery receipt.

● The salesman from whom you purchased your unit is responsi-

ble for supervising the correct installation of the unit in your vehicle and thoroughly training you in its operation and maintenance.

CORRECT INSTALLATION INCLUDES:

Supervising the purchaser in the following:

● Installation of through-floor fittings for propane and gasoline fuel

lines; installing propane regulator included with unit, outside

vehicle placing unit and recovery tank in vehicle and securing them with bolts or tie down cleats; connecting all propane and gasoline lines; connecting battery; checking pump, vacuum blower and engine oil levels, prior to starting unit; starting unit to check engine to see that all systems function normally also checking all hoses, wands, etc., for correct operation.

TRAINING SHALL INCLUDE:

● Thorough review of the operation manual with purchaser; in-

struction and familiarization in: how to correctly start up and shut down unit; how to correctly clean with the unit; how, where and how often to check and change component oil levels; how the unit’s systems work; how to troubleshoot the unit; how to do basic repairs; safety precautions and their importance; freezing damage and how to avoid it and a thorough review of the unit warranty and warranty procedures.

HydraMaster warranty policy (Inside back cover)

Effective May 1, 1988 HydraMaster warranty covers only defective materials and/or

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

HOURS:

MONDAY THROUGH FRIDAY

am TO 6:00 pm

8:00

PACIFIC STANDARD TIME

@ @ @ @ ,AX ANDhIlARKETIt4G~~~~~

PST

..!:\;.::::*”..

ROCK MT.

CENTRAL

~:;;>;.$%,

EASTERN

TELEPHONE NUMBERS

GENERAL OFFICES: PARTS DEPT SERVICE/WARRANTY: NEW EQUIPMENT SALES

(206) 775-7272 (206) 775-7276

TRUCK PREPARATION

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

Materials Needed:

1.2 shaets 4x8x5f8° exterior plywood

2. 67X12’ piece of commercial astroturf

3. 16.1 VZ”sheet metal screws

4.1 quart marine adhesive (optional)

5.1 staple hammer w/VZ” staples (See illustration for correct placement of plywood flooring)

TRUCK PREPARATION ILLUSTRATION

FIRST, cover the truck bed with 5/8” ~lvwood usmq metal screws

to secure it as shown.

PLACEMENT OF UNIT IN VEHICLE

There are two recommended unit placements: A. SIDE DOOR: Most installations are side door. This provides

rear access for accessories and hoses as well as unobstructed access to component/working side of machine, thus making it a bit easier to perform maintenance andlor repair without removing unit from the truck.

B. REAR DOOR: Although this location partly limits workina

access, it does direct the noise away from the cleaning sit; Some cleaners in the colder areas prefer this location because it puts the weight mass over the rear wheels for better traction in ice and snow, Rear mounting requires the unit to be slid to the right side as far as possible. This not only provides adequate working space on the component side of the unit but also makes better weight distribution inside the van (engine and component weight line up over drive shaft). Also, It is physically

easier to load unit into rear door due to height of van bed, WARNING: Ensure that machine IS we// secured to the floor of

van with hardware supplied. Sudden or cra.sn stop will cause machine to rocket forward, all 750 Ibs. worth I Protect yourself and the machine: SECURE IT!

MACHINE TIE DOWN CLEAT

M & S Series

SECOND, select the appropriate color astroturf to match your van and cover the plywood and staple in place. A standard van requires a piece 6 feet by 12 feet.

THIRD, for added ventilation, an aluminum roof vent should be added over the location selected for mounting the machine. This

‘ill allow hot air from the heater to escape, -

&L--J

MACHINE INSTALLATION

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

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

PROPANE TANK LOCATION

Either the 10 gallon or 16.5 gallon propane tank will fit this location. Have your local propane dealer install the tank you select and purchase. The machine will come with the proper propane

regujator. (Tank must have vapor outlet.)

WARNING: Do not use a portable DroDane tank inside the truck

or van. Besides being dangerous ii is “unla wful in most states.

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

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

It is important that the machine be placed as close to the door as possible so that outside air can be pulled into the engine for proper cooling.

WARNING:

haust from the front of the machine be vented down under the truck to prevent carbon monoxide from entering the job site. Always park the truck so the exhaust is blowing away from the

job site.

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

WARNING: Never operate this machine with a portable propane

tank or a portable gas can inside the truck. The heater is an open flame type and could cause a fire or explosion.

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

Itis recommended by the manufacturer that the ex-

wn Ive

PROPANE TANK PLUMBING

Iator

HARI) WA~R AREA MAP

The quality of water varies greatly throughout the United States

and influences the reliability and efficiency of equipment in direct proportion to its level of hardness. The map below defines areas which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water cooled engines.

Cleaning efficiency and equipment life is increased, chemical use decreased and the appearance of cleaned carpets enhanced when water softeners are incorporated in hard water areas. Manufacturer strongly urges the use of water softener units in areas exceeding 31A grains per gallon. Using the legend as a reference. determine the cmalitv of water in vow area and take action imm~diately should ii be ~ecessary. ‘

(For installation diagram see machine installation section)

WATERSOFTENER

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

Reports from several of our machine users commending the results of the use of water softeners in conjunction with their machines prompts us to recommend the procedure to everyone in a “hard water” area.

The relatively low cost of a water softener service is more than made up for in the increased life of machine parts and continuad cleaning efficiency, The water softener will also increase the effectiveness of the cleaning chemical being used, therefore, less chemical will be needed.

Contact a water softener distributor in your area for information on the rental of a simple water treatment unit to carry in your truck. Be sure to change the water softener in accordance with the capability of the softener, Example: If the softener will treat 900 gallons of water and the machines uses an average of 30 gallons per hour of use, and an average of 5 hours a day, would be 150 gallons a day, 5 days would equal 750 gallons of water, therefore. the softener would be changed every 6 working days for maximum softening.

Grains Per Gallon

u 0-31’2

- 3% -7

= 7- 107/2

_ 101/2 and above

— d“

Incoming Water

From Faucet

Water Sottener

hPERATINGINSTRUCTIONS

MACHINE CONTROL PANEL

Hour Meter

;on

Blower Engine Exhaust’

START UP

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

2. Connect all required hoses.

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

4. Caution: Mix tank must be full prior to ignition.

5. Start engine (choke as required). Engine is at operating speed (recommended -2600 RPM). Allow warm-up period of 2-5 minutes.

6. Spray wand to void all air from system. As the mix tank is in a fill cycle, the chemical flow meter may be adjusted to your desired setting. NOTE: Recommended carpet cleaning pressure is 250-300 PSI.

7. Once all air is voided from system, heater may be ignited. NOTE: If not familiar with operation of this heater, refer to heater section of the manual. A. Open propane valve on the tank. B. Ignite pilot on the heater. C. To ignite burner, turn dial to on position. NOTE: If you 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 200° F.

9. Commence cleaning operation. NOTE: Chemical flow meter set at 5 GPM is a 1 to 30 mix ratio and 10 GPH is 1 to 15 ratio. When flow meter is set at 10 GPH,

you will be using what most chemical manufacturers recom-

mend at 5 GPH.

Hi-pressure set at 300 psi with 100’ hose

Bypass Valve

1. Turn heater to off position. Spray wand for a least 3 minutes to allow the heater coils to cool.

2. Close valve on propane tank.

3. Remove vacuum hose.

4. Flush clear water through chemical system for 10 seconds. (Vinegar should be rinsed through system weekly.) Turn off

chemical flow meter.

5. Turn on cleaning tool to flush chemical from unit hoses and

cleaning tool.

NOTE: If freeze guard is necessary, perform steps 1 & 2 of

freeze guard procedure at this time.

6. At this time, the blower should be lubricated with LPS 1 or WD

40.

7. Shut engine down.

8. Drain vacuum tank. Vacuum filter should be cleaned prior to

mobilization of van. NOTE: If freeze guard is necessary, perform steps 3-7 of freeze

guard procedure at this time.

OPERATION PRECAUTIONS

MACHINE ADJUSTMENTS:

Although this unit has been factory adjusted, it may require

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

authorized representative.

ENGINE COOLING:

CAUTION: Units employing air cooled engines must not be

incapacitated within a van with doors and windows closed.

Excessive temperatures within the engine will result in premature

engine failure and a compromise of applicable warranty.

LEVEL OPERATION:

CAUTION: During operation, van or trailer must be parked on

level ground not to exceed i- or- 10°. Failure to insure proper leveling may prevent proper internal lubrication of engine, vacuum andlor high pressure components.

FREEZE PROTECTION:

CAUTION: Mother nature gives /itt/e warning as to her cold

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

LIGHTING HEATER:

WARNING: Never put your face down close to the opening of the

heater when lighting.

STRONG PROPANE ODOR:

WARNING: Never light the heater if you smell a strong odor of

propane around the heater.

FREEZEPROTECTION

Any freezing of this machine is not covered by warranty and during the colder months of operation, careful protection should be of utmost concern.

THE FOLLCWING PRECAUTIONS ARE RECOMMENDED:

1. Run machine before leaving for the first job to insure nothing has frozen the night before, including hoses and wand.

2. Insulate the garden hose from the cold ground by running it through an extra 1

3. Leave truck doors closed until time cleaning begins, then open slightly.

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

5. In colder climates, insulating the truck walls and floor boards will help protect the unit.

6. Don’t procrastinate during the cleaning operation or the hot water solution line will also freeze on the ground. The solution line should be insulated in extremely cold climates.

T. Whenever possible, 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. If the machine and truck are left outside with a heater, you should first drain all possible water from the machine cleaning tools and hoses. (They freeze also.)

TO DRAIN THE MACHINE, FOLLOW THESE STEPS: A. Before shutting off the machine, remove the chemical line from

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

B. Loosen the petcock valve on your bypass drain hose and allow

the water to drain thoroughly from the mix tank.

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

guard which is a small air compressor. Using the correct connectors, first blow air into the high pressure solution male quick connect. This will force the water through the heater back through the pump and into the chemical mix tank to be drained out through the petcock valve to the ground. By loosening the bypass knob, the air will be allowed to flow more freely through the system. Next, blow the air into the incoming water quick connect and force that water into the chemical mix tank to be drained out.

D. Remember to close the drain valve prior to next operation of

your unit.

BE SURE ITS PROTECTED! Freezing will cause GRIEF, MONEY and DOWN-TIME. Don’t mess with Mother Nature!

V2 inch vacuum hose.

CAUTION: When c/caning cut-pile acri/an p/u.sh carpefs, using

high heat setting may result in fiber damage on this type of carpet.

The use of some chemicals through your mobile carpet cleaning

plant can seriously damage the internal plumbing, high pressure pump and heater. (Chemical such as concentrated acids and some paint oil and grease removers w/high concentration of solvents.)

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

NOTE: At no time should a chemical solution with a Pti of less than

7 or higher than 10 be used in the unit,

pli CHART

234567891011121314

+ACID

I I I I

— NEUTRAL

—“’’A””’ ~

I I

CLEANING STROKE PROCEDURE/ OVER-WVETTING

Purpose:

To eliminate excess moisture remaining in the carpet fiber and the

sawtooth appearance which results from diagonal movement of

the cleaning tool on all types of carpet,

Procedure:

Always move the cleaning tool in smooth forward and backward

strokes. Apply slight pressure to the forward stroke while the solu-

tion is injected into the carpet. When extracting (drying), apply firm pressure on the forward stroke to ensure a positive “lock” for the vacuum and minimize the “hopping” effect resulting on unsmooth carpet. During the forward and reverse strokes, movement to the right or left should only be accomplished at the extreme rear of the stroke, Overlapping is also important to ensure even application of solution to prevent saturation when cleaning wand is stopped twice at the same point at the rear of the cleaning stroke,

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

periods.

INCORRECT METHOD CORRECT METHOfJ

\cleaning Tool ‘

v“

Overlao Between Strokes

/-4

@ LJ ~:

11,1

First

““

Cleanina Stroke -

Second Cleaning Stroke

‘1

CLEANING AND CHEMICAL PRECAUTIONS

Your mobile carpet cleaning plant has been engineered using the latest and most sophisticated technology available, to produce the finest carpet cleaning results possible. Despite this however, it remains only a tool of the carpet cleaning trade, and it can produce cmly as good a job as the person operating it.

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

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

Over-Wetting

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

These are several areas that will cause over-wetting:

Too few vacuum strokes or improper saw tooth vacuum strokes as shown above.

Obstructed, kinked or cut hoses, Vacuum tank drain valve left partially open.

3. 4,

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

Cleaning a heavily foam-saturated carpet without defoamer.

5. (We recommend crystal type,)

This system has been designed to be the most simple and troublefree ever.

The incoming water flows directly to the mix tank. Water will now flow through a proportioning valve which will simultaneously mix the chemical to achieve your desired solution, The mix tank is equipped with 2 different float valves, one of which responds to the water level of the tank and will maintain the proper volume of solution to be reserved for the cat pump. The secondary float vahe is a safety valve that is designed to protect your system from sudden or unexpected loss of water supply. If, for example, the water source at the house was turned off, the water level of the mix tank would drop, activating the secondary valve which automatically kills the engine,

UNIT WITH CLUTCH: If mix tank water level drops, clutch will disengage.

In conjunction with the incoming flow, the chemical ratio may be obtained by an adjustment of the chemical flow meter during the fill cycle of the mix tank. The chemical will flow from the chemical jug to the chemical flow meter, then to the proportioner where it is distributed into the mix tank at your desired proportion. This line

should be flushed with vinegar weekly to prevent abnormal

chemical build-up. This may be done by removing the clear plastic

hose from the chemical jug and inserting it into a one quart container of vinegar. This should be done with the chemical flow meter

setting on 10 GPH with heater “off”. Simply spray the wand for the duration of the vinegar in the one quart container, then repeat the

process with one quart of clear water to void all lines of vinegar.

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

proportioned to the filling cycles of the mix tank, not the direct

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

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

true in that you may not be spraying your wand but, if the mix tank

is in a filling cycle your chemical flow meter may read your desired

flow.

This chemical system will mix a 1 to 30 ratio when flow meter is set

at 5 GPH. Most chemical suppliers will recommend a 1 to 15 ratio

therefore you can either set the flow meter at 10 GPH, giving you a

1 to 15 ratio of chemical to cleaning water, or double the recommended strength of chemical in the 5 gallon jug and set the flow meter at 5 GPH, thereby attaining a 1 to 15 ratio. (It is recommended that you set the flow meter at 10 GPH for overall best results.)

The water will now be siphoned from the bottom of the mix tank to the Cat Pump. If the wand is not spraying, the water will bypass from the bottom of the brass pressure relief valve to the mix tank.

If the wand is spraying, the water will then flow to the heater. This heater has a capacity of up to 2 gallons, therefore it is extremely important that all air is bled out of the heater prior to initial start-up. This may be achieved by running the system, without the heater on, for approximately 60 seconds.

WATER FLOW

A - Chemical Jug B - Pressure Guage C - Chemical Flow Meter D - High Pressure Pump E - Incoming Water F - Tank Drain G - To Wand H - Bypass Valve I - Proportioner J - Heater Coil

-+ High Pressure + Low Pressure

CHEMICAL PROPORTIONING AND LEVEL CONTROL

Diaphragm

CHEMICAL TANK TROUBLESHOOTING GUIDE

PROBLEM: No or Low Chemical Flow Solution

Check that hoses in the tank are secured. Check that the

hose from the top of the flow meter to the side of the mix tank is secured with no kinks. Check the hose from the bottom of the flow meter to the chemical jug for kinks or cracks.

Check the foot valve and screen on the end of the hose

which goes into the mix tank. To check this screen for proper function, remove it from the plastic hose. You should be able to suck through the hose barb end, but you should not be able to blow through the hose barb end. (If you can not suck through it then rinse it out with vinegar, ) When screen is removed the chemical fill hose should be lifted into a vertical position will seat by gravity. (This is only a temporary fix for low

water pressure areas. ) Check flow meter for float obstruction. Check to insure that the adjusting screw on proportioning

venturi is backed out.

Is proportioning venturi closed? Soak in warm water or

vinegar solution. Is incoming water pressure less than 20 PSI? Cracked or defective chemical flow meter? NCITE: If you are in a low water pressure area and find that

volume of water entering the mix tank is not enough to

the allow your venturi to siphon chemical, unscrew the spring from the foot valve screen and remove the spring.

so the ball in the foot valve

PROBLEM: Mix Tank Doesn’t Keen UCIWith Water Outnut Solution Check garden hose quick connect assembly screen.

Check garden hose andlor feed hose to the mix tank for clog,

kinks or blockage. Float ball in mix tank hanging up. (Not moving freely.) Extension bracket pinching float lever, restricting full action of

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

screws which hold the extension assembly to the valve.

(Do not lose or drop the screws. ) Remove the extension

assembly, turn it up side down. To adjust, loosen the set

screw on the ball nut. Place your thumb on the plunger and press it In 1/16” and slide the ball nut w/set screw toward the plunger end 1/1 6“’. Tighten the set screw.

Place the extension assembly back into position. If the

tank starts to overfill, the ball nut is to close to the valve plunger and should be moved back away from the valve olunaer sliahtlv.

PROBLEM: Pump Pulsates When The Tank Is in a Fill Mode Solution Check that the hose which goes from the gray plastic venturi

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

PROBLEM: Inability to Adjust Chemical with the Flow Meter Solution Debris lodged behind teflon seat in flow meter knob,

Teflon seat dismounting from flow meter knob.

PROBLEM: Solution Reversing from Mix Tank to Chemical

solution Anti-siphon screen removed from chemical jug hose.

Debris in anti-siphon screen.

PRt3HLElW Mix Tank Overflows solution Float ball in mix tank hanging up (not moving freely).

Extension bracket pinching the float lever, restricting full

action of the lever.

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

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

just, loosen the se! screw on the ball nut and move the

ball toward the end of the rod 1/16”. Retighten set screw, Place extension assembly back into position. Tighten the

two screws.

Jug

VALVE ASSEMBLY

STEM ASSEMBLY

Keeper Ring—

+--Retainer

_C)-Ring

@—

I 1

O-Ring

JET ASSEMBLY

Brass Cap

,a”0a<800~St~bilizer

WAND ASSEMBLY

See “Valve Assembly”

Body

‘--% “

BYPASS VALVE ASSEMBLY

?@8

.. ————

BYPASS PARTS LIST

S.S. Handle

REF. NO. PART NO. DESCRIPTION

3. 000-105-101 Thrust Plate, Bypass

000-105-102 Piston Plate, Bypass

000-078-101 Kit, Seal for Bypass

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

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

Valve -‘

Valve

Fittina

QTV.

FLOW WATER TROUBLESHOOTING

PROBLEM: Loss of Pressure Cause Defective or blocked check valves in hicfh pressure pump

cylinder head.

Delaminated, kinked or clogged hose between the mix tank

and the high pressure pump.

Defective pressure relief valve or debris in pressure relief

valve. NOTE: the high pressure bypass valve is designed drawing. to fully close when the cleaning tool is turned on. Any foreign matter collecting on the piston will prevent full closure of the valve and allow a oortion of the water to continue to circulate instead of being routed to the cleaning tool. To correct this situation, the bypass valve must be disassembled and cleaned (refer to drawing provided

in this manual for bypass disassembly). Defective or worn cups. Loose drive belt for high pressure pump. Readjust belt as required or replace if defect!ve. Loss of Pressure/Unit with clutch.

PROBLEM: Water Flow Cause Solution Worn out spray jet. NOTE: Cleaning tools designed to spray

a constant flow of 1V2GPM will average 1 gallon of flow

per minute in actual working situations since flow is not continuous. An average flow of 1 GPM results in 6000 gallons of flow for every 100 hours of unit operation.

Spray tips are capable of consistent flow rates for

approximately 20,000 gallons. They should be replaced therefore, approximately every 350 hours. Worn spray jets

allow a greater average rate of flow thus reducing desired temperature levels.

Reduction of Flow.

Solution

Disassemble cylinder head and replace or clean applicable

check valve,

Remove and replace defective hose,

—

Disassemble and clean pressure relief valve as illustrated in

Replace defective or worn out bypass cup. Replace bypass valve.

Remove and replace piston cups as defined by pump manual.

Is clutch engaged? Check tank for water,

Remove and replace spray jet.

Due to increased iength of solution hose NOTE: For every

50 feet of hose, beyond 100 feet in total length, a measurable loss of flow is experienced. This condition is a result of the increased friction experienced by the water as it passes through the hose. Therefore, it is necessary to increase the pressure at the machine 40 PSI for every additional 50 feet of cleaning solution hose over 100 feet,

VACUUM SYSTEMINFORMATION

—

The vacuum blower incorporated in this machine is a positive displacement lobe type, manufactured by Cooper Industries. The performance and life of this unit is greatly dependent on the care

and proper maintenance it receives. Because of the close tolerances between the lobes and housing of

the vacuum blower, solid objects entering the inlet will damage the

internal lobes, gears and bearing or direct drive coupler. To prevent this, a stainless steel filter screen has been placed at

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

CAUTION: Should be used when machine is be~ng run for test

purpose and the vacuum inlet on top of machine is open.

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

Read the vacuum blower manual carefully for proper oil change and grease application. The maintenance log may differ slightly

from the manual, but the truck-mounted carpet cleaning machine

application is very demanding of the vacuum blower and therefore it should be maintained more regularly.

NOTICE: Vacuum tank is protected from overflowing by a vacuum

tank, float kill switch,

CAUTION: This switch is not activated by foam, only by liquid.

VACUUM TANK FILTBRBAGS

liydraMaster filter bags are designed to trap all of the lint, sand and dirt that would normally collect at the bottom of your vacuum

tank. The use of these bags, if emptied at the end of each job, will

eliminate the build-up of much of the debris in the tank and avoid a mess on the customer’s driveway or street. The drawstring top of

these bags is designed to be tied to the incoming dirty water inlet in

the vacuum tank. To reorder bags use part number 049-029.

VACUUM TANK FILTER BAGS

ter

VACUUM FLOW

S/S Filter

\ /

Recovery Tank

Filter Bag

Spray lubricant into blower lube port for 3 to 5 seconds, then immediately shut off machine.

Use only LPS 1 or WD-40 moisture displacing lubricants.

1. All Sutorbilt California Series ‘F’ blowers are covered by this warranty.

2. Warranty period is 24 months from date of shipment, or 18 months from date of installation, whichever occurs first.

3. Sutorbilt will replace or repair any unit covered by this warranty without regard for the cause of failure.

4. Customers claiming relief under this warranty shall issue a Purchase Order to Sutorbilt for a replacement unit.

5. Customer must obtain a Return Goods Authorization number from the factory and return blower prepaid to an Authorized Factory Repair Center, as directed.

6. On receipt of the blower a credit memo will be issued to offset the P.O. issued Der (4} above.

7. Replacement unit will be shipped to customer at Sutorbilt’s expense to any destination in the US or Canada.

8. SUTORBILT reserves the right to withdraw the Uncontested Warranty where evidence indicates application outside the manufacturer’s stated performance area, or where there is evidence of abuse.

CONTACT SUTOR81LT FOR THE LOCATION OF THE

FACTORY AUTHORIZED SERVICE CENTER NEAREST YOIJ

Ila

$puggyL;

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 as listed. Add fresh oil as required to maintain proper level. The oil

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

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

Bearings on drive end of blower require grease lubrication Wery 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.

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1 wu E vnu

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SUTORBILT/industrial MACHINERY 2966 E. Victoria Street Compton, CA 90224 (213) 639-7600 Telex: 244337SUT FAX: (21 3) 639-7632

LUBRICATION IN~RUCTiONSFOR

OILLUERICATEOGEARSAMOB~ARIR~S

Add fresh od m roqulmd to mamtam proper Ieval. Dram cnd refill every 1500 hours oi cmeratbon under normal kwice. more fm. qbently when reqwred, U$e a good qualmy

BLOWER

OISCHARGE

TEhlPER+lTUBE

~!: %;, SAE1OW

% W

over

=~!, SAE 50

‘In appficat(on$ w!th extreme varmt!om In

ambient temperature a 20w 50w mulrmle viscosl~ oil ISrecommended.

FOR GREASE LUBRICATE EEARINGS

Sefwce every 500 houm of operatnon

OIL OILVISCOSl~~,

GRA#$ CENTISTOKES

SAE 20 100

SAE 40 ?Iln

-,.,

)

250

Ott.

+ 34 hidden pages

HYDRAMASTER HYDRA-CAT-M User Guide

TABLE OF CONTENTS

GENERAL INFORMATION