HYDRAMASTER HYDRA-CAT-M User Guide

Ei’YDMkiI-C?AT/M

o

TABLE OF CONTENTS

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

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

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

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

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

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

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

26

30

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

_——

1

1

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 [phone].

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

4,

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 [phone].

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

o

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

[phone]
[phone]

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.

I

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

I

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

e

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

In

;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

1

234567891011121314

I

+ACID

I I I I

— NEUTRAL

—“’’A””’ ~

I 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

II

@ LJ ~:

u

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:

1.

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

2,

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

H

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.

1

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—

I

+--Retainer

w

~

_C)-Ring

I

I

@—

I
1

O-Ring

JET ASSEMBLY

Brass Cap

,a”0a<800~St~bilizer

WAND ASSEMBLY

See “Valve Assembly”

/

Body

‘--% “

@

P

BYPASS VALVE ASSEMBLY

?@8

.. ————

BYPASS PARTS LIST

S.S. Handle

REF. NO. PART NO. DESCRIPTION

3. 000-105-101 Thrust Plate, Bypass

4.

000-105-102 Piston Plate, Bypass

5.

000-078-101 Kit, Seal for Bypass

7.

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

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

Valve -‘

Valve

Valve

Valve

Fittina

QTV.

1

1

1

1

1

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

1

FACTORY AUTHORIZED SERVICE CENTER NEAREST YOIJ

.,

Ila

-.

1

ZJ

$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.

=n m7fiC2~lL’”

1 wu E vnu

:lx
cc I

SUTORBILT/industrial MACHINERY
2966 E. Victoria Street
Compton, CA 90224
[phone]
Telex: 244337SUT
FAX: [phone]

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

F

SAE 20 100

c)

SAE 40 ?Iln

-,.,

)

o

45

250

1

Ott.

1

I

VACUUM BLOWER TROUBLESHOOTING GUIDE

PROBLEM: Loss of Vacuum
Cause
Collapsed vacuum hose between blower and vacuum tank.

Clogged stainless steel filter.
Defective vacuum tank seal.
Defective or ‘open’ vacuum tank dump valve.

Fractured weld on vacuum tank.
Collapsed or kinked vacuum hose.
Plugged vacuum hose.
Restriction in cleaning tool.

Worn end plates or lobes in vacuum blower.

Loose drive shaft between clutch and blower.

PROBLEM: Blower is Seized
Cause
Rust.

Foreign matter.

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

Solution
Remove and replace hose. NOTE: A special reinforced hose

is reauired for replacement.
Remove and clean or replace stainless steel filter.
Remove and replace vacuum tank seal.
Close valve.

Replace valve.
Re-weld as required or replace tank.
Reshape hose if possible and/or eliminate kinks.
Remove obstruction by reversing the vacuum hose.
Remove obstruction.
Replace worn components. NOTE: Must be accomplished by

a qualified technician.

The set “screws may come loose causing blower to stand still

while engine may be turning properly. NOTE: Unless the

blower is seized or making a knocking noise, your vacuum

loss is not caused by a bad blower.

Solution
Spray rust dissolving lubricant onto lobes to emulsify rust and

attempt to rotate vacuum lobes.
Disassemble and remove foreign matter and repair as

required. NOTE: Disassembly must be accomplished by

aualified technician.

PROBLEM: Noise in Vacuum Blower
Cause
Worn Gears.

Lack of Lubrication. NOTE: Permanent damage may have

resulted from lack of lubrication.

Worn bearings.

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

steel filter is provided in vacuum inlet located in vacuum

blower components.

Loose or missina mountina bolts. Tiahten or reinstall mountina baits.

Solution
Remove and replace gears. NOTE: Replacement of gears

must be accomplished by a qualified technician.

Timing of vacuum blower has been changed due to worn

components. Replacement of components must be
accomplished by a qualified technican.

Lubricate as specified by applicable vacuum blower manual.

See index.

Remove and replace bearings as required. Must be

accomplished bv aualified technician.

Disassemble vacuum blower and remove foreign material.

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

HEATING SYSTEM INFORMATION

The propane heater incorporated in this equipment is a special
design for use in the carpet cleaning industry. It’s high pressure
coils and thermostatic temperature control make it simple to
operate and reliable. Once the desired temperature is set, the

heater will then go ‘on’ and ‘off’ according to the water temperature
within the heater. As water is used through the cleaning tool, cold
water entering the heater will activate the thermostatically con­trolled propane valve thereby firing the heater to maintain a con-

skitant flow of hot water. Cmce the cleaning wand is shut off and

the flow of water through the heater stops, the heater will continue
to burn until the set temperature is attained.

It is possible then with this design that the flame may be on when

the wand is off, likewise, it is possible the flame may be off when
the wand is on.

CAUTION: This heater is designed to burn vapor propane gas

only. ArJy liquid propane entering the heater may cause damage
to the control valve on the heater. it will also cause improper

burning and a soot build-up on the coils. Therefore, it is
necessary to shut off the heater and c/ose the valve at the tank

bet ween cleaning locations. Failure to do this allows sloshing li-

quid to enter the vapor feed line to the heater.

IMPORTANT Overfilling of the propane tank will cause many
problems. To avoid this, advise the attendant filling the tank not

to fill the tank over 80%. When filling the tank, watch the 10%

valve and immediately stop filling when white liquid starts spurt-

ing from th@ 10°4 valve. To prevent damage to the propane

regulator’, always close the vaive on the tank before filling.

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 pro-

pane 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.

IMPORTANT If a new propane tank has been installed or hoses
have been disconnected, air may enter propane hoses and must
be purged prior to attempting to light the pilot burner. Should this
condition exist, operator must depress the pilot button for 1-5
minutes and attempt to ignite the pilot light at 15 second intervals.
A very slight hissing noise should be evident while performing this
operation.

CAUTION: Check heater for propane leaks regularly as loading

and unloading hoses, too/s, etc., may accidentally bump against
heater fittings or pipes.

HEATER- OPERATING INSTRUCTIONS

CAUTION: Heater must be fi//ed with water prior to igniting.

A. TO START PILOT

1. Adjust thermostat control knob on unitrol to desired setting.

2. Adjust upper dial to pilot position.

3. Depress pilot button.

4. Depress sparking button to light pilot.
IF PILOT FAILS TO LIGHT:

Is propane tank full?
Is propane tank valve open?

Has air been properly bled from propane line?

WHEN PILOT LIGHTS:

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

CAUTION: Always keep face away from main burner opening to

avoid ignition flash burn.

B. TO LIGHT MAIN BURNER:

1. Turn upper knob to “on” position. Flame will come on.
If you do not get the burner to flame, the pilot has expired. You

must turn upper dial to “off” position. Do not attempt to re-light
the pilot for 60 seconds. To light the main burner, repeat instruc­tions as above (TO START PILOT), 1 through 4.

OR,
Water may already be at controlled temperature.

Flame will turn off when thermostat senses maximum
temperature.

C. TO ACHIEVE PROPER CARPET 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. Once a constant temperature is established, turn cleaning
The flame on the heater burner should remain on for 10-15

‘off’.

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

dial to a higher reading, then repeat C 1-3.

B. If the flame remains lit after 15 seconds, turn the thermostat

dial to a lower reading, then repeat C 1-3.

D. TO SHUT DOWN HEATER:

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

2. CAUTION: Turn cleaning wand on for 3 to 5 minutes to cool

heater core. If heater core is not cooled, it is possib(e that the
heat retained in the core will cause boiling back into a

chemical mix tank.

3. Close propane tank valve While wand IS on and heater w

cooling.

wand

PILOT BURNER ADJUSTMENT

1. Remove pilot adjustment cap #5.

2. Adjust pilot key to provide
properly sized flame.

3. Replace pilot adjustment cap.

Allen head pipe plug #6 can be

removed for monometer insertion
to read propane ounces.

@

@l’@

HEATER TROUBLESHOOTING

PROBLEM: Excessive Heat

Flames Proturding Outside The Lower Openings

Cause lSolution:

1. Thermostatic control dial set too high.

A. Turn dial to lower setting.

2. Maladjustment of propane regulator. NOTE: Propane regulators
are factory preset and may be readjusted by authorized
personnel.

A. Contact manufacturer to determine correct procedure.

B. Have your local propane dealer use a monometer at the

unitrol to reset the propane regulator to 7 oz. maximum.

3. Overfilled propane tank. NOTE: Propane heater is designed to

operate on vapor propane only. Over-filling a propane tank

allows liquid propane to enter all heater related components

and permits an over-rich burning condition to occur. This condi­tion usually requires the heater core to be cleaned of soot and
carbon deposits. Cleaning is a messy, dirty job and very

inconvenient, so don’t let it ha~~en to you!

PROBLEM: Pilot Light
Cause lSolution:

1. Pilot light will not ignite. NOTE: Do not use a needle or pin to
clean pilot orifice - use compressed air or solvent only.
A. Verify propane reaching igniter. NOTE: A kinked or crushed

hose may impede propane flow.

B. Remove and clean orifice.

C. Verify iqnitor spark is operating correctly.

CAT PUMP Model 290
OPERATING INSTRUCTIONS

CAUTION: CAT PUMPS are positive displacement pumps.

Therefore, a properly designed pressure relief mechanism MUST

be installed in the discharge piping. Failure to install such relief
mechanism could result in personal injury or damage to the pump

or system. Cat Pumps Corporation does not assume any liability or

responsibility for the operation of a customer’s high pressure
system.

SPECIFICA~ONS

Volume:3.5 GPM (13 L/M)

DischargePressure:1200 PSI (83 BAR)
MaximumInlet Pressure -8.5 to + 40 PSI (-0.6 to + 2.8

RPM: 1200 RPM (1200 RPM)
Bore: 0,787” (20mm)
Stroke 0.472” (12mm)
Crankcase Capacity: 10 oz. (.3 L)
Maximum Fluid Temperature: 180”F (71 “C)

Inlet Port (l): 1/2’: NPT (1/2” NPT)

Chemical Injection Port (1): 1/4” NPT (1/4” NPT)

Discharge Ports (2): 3/8” NPT (3/8” NPT)

(l): 1/2” NPT (1/2” NPT)
Pulley Mounting: Either side (Either side)
Shaft Diameter 0.650” (16.5mm)
Weight: 12.1 Ibs. (5.5 kg)
Dimensions: 10.77’’x9.O6’’XI.I 4“ (273,5 x230x130.5 mm)

BAR)

Products described hereon are covered by one or more of
the following U.S. patents: 3558244, 3652188, 3809508,
3920356, and 3930756

—-. _

JP*-*+

.3

CO RPOF7ATION

SS5 MINNEAPOLIS, MN 55440

PO. Box

Phone [phone] – Telex 294276 Phone [phone] — Telex 41 ffi713

● N V CAT PuMPS INTERNATIONAL S.A. s

Harmonlestraat 29

S 2000 Antwerp, Belglum

Pho”e (03] 237.72.24 — Telex 33947

● CAT PUMPS — A,G.0

Loretohoehe 5

CH.6300 ZUG, Switzerland

Phone [phone] — Telex S$5 160 cpag ch

9

CAT PuM’PS DEuTSCH LAND GmbH ●

Restocker SIrasse 9

6200 Wlesbaden.Blerstadt, West Germany

● CAT PUMPS (u.K ) LTO 9

27 StatIon Industrial Estate, Fleet

Hampshtre GU13 80Y, England

Phone Fleet 22031 — Telex S5SS9S

CAT PUMP WARRANTY

This Cat Pump (“product”) is warranted by the manufacturer to

be free from defects in workmanship and material for one year
from date of manufacturer’s shipment. This warranty is limited
to repairing or replacing products which manufacturer’s in-

vestigation shows were defective at the time of shipment by the

manufacturer. All products subject to this warranty shall be

returned F.O.B. Cat Pumps Corp., Minneapolis, Minnesota

55430, U.S.A. for examination, repair or replacement.

The express warranty set forth herein is in lieu of all other war-

ranties, express or implied, includingwithout limitationany war-

ranties of merchantability or fitnessfor a particularpurpose 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 liable for any fur-

ther loss, damages or expenses, including incidental or conse-

quential damages, directly or indirectly arising from the sale or

use of this product.

This warranty is subject to the following warranty conditions:

Important Ccmditions

LUBRICATION - fill crankcase

per specifications with Cat Pump oil or equivalent SAE 40

to the top of oil gauge window

weight hydraulic oil with antiwear and rust inhibitor additives,
Change initial fill after 50 hour run-in period. Change oil every
three months or at 500 hour intervals thereafter. Prrrrrm-a-lube
seals need no lubrication. Blue dot seals and wicks must
receive three drops of Cat Pump oil per wick every 50 hours of
operation.

GOOD LUBRICATION IS THE EASIEST, MOST EFFICIENT
AND LEAST EXPENSIVE OF PREVENTATIVE
MAINTENANCE.

RPM and PRESSURE - Pump operation must be wltttin RPM
and pressure specifications. Pressure relief valve must be
installed.

DO NOT PUMP ACIDS OR ABRASIVE FLUIDS with this unit.
Consult Cat Pumps for additional information on questionable
fluids.

FREEZING CONDITIONS - Pump must be protected from
freezing conditions.

USE OF OTHER THAN CAT PUMP PARTS OR THEIR

EQUIVALENT

VC)IDS THE WARRANTY

GENERAL INFORMATION FOR CAT PUMP REPAIR

As you remove your discharge manifold, there is a set of 3 check
valves (which usually fall out during dis-assembly). If the surfaces
of these check valves are dirty, or show signs of chemical build-up,
it is probable that they would remain open causing pressure loss
or pulsation. Upon inspecting the valves, make sure that the teflon
buttons in the valve spring retainers are still intact. Also examine
the discharge manifold. Look for problems such as cracks,
chemical buildup or warpage due to freezing. If this discharge
manifold is warped, it will cause the check valves to stick and will
result in loss of pressure.

The Cat pump cups are often the source of pressure loss. Upon in­spection they may appear melted or torn, but often they will look
goad. Replace them anyway. There is no sure method of visually
inspecting the cups. HydraMaster recommends changing cups
whether they look gaod or not.

Anytime your pump is being dismantled, HydraMaster recom­mends replacement of all ‘o’ rings and seals. This is merely a con­venience to the customer to make sure that the Cat pump is in top
operating condition.

The prrm-a-lube seals located within the intake manifold will allow
air to enter the pump ifthey are worn. Again, it is difficult to visually
pinpoint a defective prrrm-a-lube seal. Replace them all.

Within the piston sleeve cylinders there are 6 ‘o’ rings that are

1/4 the size of a penny. If these ‘o’ rings are bad, water will be

about
pumped back into the oil. If this has occurred the oil will raise in
level and appear milky. If you are unable to repair seals right away,
change oil frequently. Repair the pump as soon as possible so as
to not damage bearing or connecting rods.

Repairing of Cat pumps is not a difficult task, However, before
disassembling make sure you have the proper parts required.

1 - short (or hot) cup kit 3- Prrrm-a-lube seals
6- piston sleeve ‘o’ rings

Read instructions thoroughly, supplied in the Cat pump manual,
prior to disassembly and follow directions as stated. Oil all seals
thoroughly prior to installation. (Remember, a newly scarred seal
is no better than one you just took out.)

1 - bottle Cat oil

PISTON MODEL 290 Exploded View

PARTS LISTModel 290

ITEM PART NO. DESCRIPTION

1 20285 O-Ring (Buns-N) 1
2 44274 Crankcase 1
3 85660 Stud (M8
4 44377 O-Ring, Oil Filler Cap 1
5
8

9
10 43987 Bubble Oil Gauge 1
11
12
15

4R Aannd

,“ . . . . .

17 14467
18
19 26536

20
21

23
24
25
26 20017 Seal Washer 3
27 25301 Oil Seal 3
28 25327 Barrier Slinger 3
29 25392 O-Ring, SIeeva 3

30
31
32
33
34

44374
43340 O-Ring, Crankcase Cover 1
43339

23170
25625 Drain Plug
92520 Sems Comb Head Screw

Oil Filler Cap

Crankcase Cover 1

O-Ring, Drain Plug 1

(M6 x

Crankshaft

Rearing 2
~il Seal (Buns-N) 2

24159

27950
92519

101799
101800 Piston Rod
16946 Ptston Pin

28771 O-Ring, Sleeve (Viton) 3

u

)-Ring, Oil Seal Case 2

o

Oil Seal Case 2
Sems Comb. Head Screw

(M6x 16) 8
Connecting Rod 3

29003 Back-UpRing,Sleeve (Teflon) 3
29614 Sleeve (29743 Unchromed) 3
26854 Seal Washer 3
28597 Seal Retainer 3
25126 Inlet Manifold

25635

Inlet Manifold-StainlessSteel 1

X 62)

20) 6

QTY.

2

1

1

1

3
3

1

ITEM

35 30315

38
39 30543
40
41 43172

42
43
44 27006 Conical Washar-SS (M6)

45

46 14158 Cotterpin
47 101602
48

49 21985 Bat-Up Ring, Cylinder

50 24459 Discharge Manifold

51 43442 Valve Spring Retainer

52 43360 Valve Spring

53 43723 Valve

54 43434 Discharge Valve Seat

56 81109

57

58 25130

PART NO. DESCRIPTION

Prrrrrm-A-Lube Seal
30325
27004 Inlet Valve 3

30544

Prrrrrm-A-Lube Seal (Viton)

Bat-Cup Piston

Bat-Cup Ring (Teflon)

Cup (Viton)

43474
27983 Piston Spacer 3
27002 Piston Retainer 3

27000 Nut-SS (M6)

23172
11377 O-Ring, Cylinder (Viton)

25634 Discharge Manifold-S.S.

101804 Hex Flange Nut (M8)

Bat-Cup Assembly 3

Cylinder (43634 Unch) 3

O-Ring, Cylinder (Buns-N)

Hex Nut (M6)

Shaft Protector 1

Electrlc Clutch Assembly

59 152-005 Tapered Sleeve 1
60 077-005
61 036-005 6“ Electric Clutch
62 143-084
63
ii

174-004

174-0;8 Lock Washer (5/1 6 US)

Key, Electric Clutch

8-30 mm Socket H

Flat-Washer (5/16 US)

. . . . . .Iead Screw 1

Wry.

3
3

3
3
3

3
3
3

6
6
3
1
1
3

3
3
3
2
2

1

1

1

1

PUMPING SECTION CUTAWAY

\

6ac-Cup

Piston Spacer

I /

/

Nut

078-001 cup Kit

3

cup
6 O-Ring, Cylinder
3 Cotterpin
1 Instruction Sheet
1

Cup Inserter

078-003 Seal Kit

30431

Prrrrrm-A-Lube Seal

3
3

Cotterpin
2

Abrasive Paper
1

Instruction Sheet

Sleeve and Seal Kit

Prrrrrm-A-Lube Seal

3
3

Barrier Slinger

3

Cotterpin

3

Sleeve
O-fling, Sleeve

6
1

Instruction Sheet

l-l

Cylinde~

I 11P

/

078-006 Valve Kit

3

;
3
3
1

30860

6
3
3
3
3
3
3
3
3
3
3
1

Bat-Cup Ring

/

iston

Piston Rod Sleev~

Valve Spring Retainer
Valve Spring
Valve
Valve Seat
O-Ring, Cylinder
instruction Sheet

Piston Kit
O-Ring, Cylinder
Back-Up Ring, Cylinder
Bat-Cup Piston
Bat-Cup Ring
cup
Piston Spacer
Piston Retainer
Conical Washer (M6)
Nut (M6)
Cotterpin
Inlet Valves
Instruction Sheet

SERVICING THE VALVE ASSEMBLIES

DISASSEMBLY

1. Remove the fasteners securing the discharge manifold to the
crankcase of the pump.

2. Support the discharge manifold and tap from the backside
and a soft mallet to separate from the crankcase and
gradually work free from cylinders.

3. Valve assemblies will remain in the manifold. Pump madt?ls
with the o-ring groove on the outside of the
require the assistance of a reverse pliers to remove th~
valve seat. The valve, spring and retainer will then fall out
when the manifold is inverted.

Pump models without the o-ring groove on the outside of the
valve seat permit the seat, valve, spring and retainer all to fall
out when manifold is inverted,

REASSEMBLY:
1, Place retainers in manifold chambers

2. Next insert spring into center of retainer

3. Inspect the valves for wear, ridges or pitting and replace if
necessary.

NOTE: Seating side of fiat valves maybe lapped on flat

face using 240 grit paper. Quiet valves due to their shape
must be replaced.

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

4

Next examine the seating surface of the flat valve seats and
lap with 240 grit paper ;r replace if evidence of excessive

wear. Quiet valve seats should be replaced if worn, Lap new
quiet valve and seat to assure positive seal.

5. Some pump models have o-rings and back-up rings on the

valve seat, Examine and replace if worn. Always lubricate
o-rings for ease of installation and to avoid damaging
elastomers.

NOTE: First install o-ring in groove on seat (towards seating

surface), then back-up ring.
NOTE: Models without outer groove on seat require the

o-ring to be placed on lip of retainer.

6. Insert valve seats into manifold chambers.

7

Position manifold back onto pump.
NOTE: Lubricate o-rings on cylinder and exercise caution

when slipping manifold over cylinders to avoid damaging
cylinder o-rings.

Replace fasteners and torque per specification chart.

8.
NOTE: Replace ali original shims when used. When new

manifold is used reshim pump.

CAUTION: When starting the pump, check to see (hat there IS ‘

no cylinder motion as this will cause premature failure of the
cylinder o-rings. Center cylinder motion can be eliminated by
switching with one of the end cylinders.

va!ve seat

sur-

SERVICING THE PUMPING SECTION

DISASSEMBLY:

1.

Remove discharge manifold as described.

2.

Grasp cylinders 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/cup assembly.

5.

Remove inlet valve.

REASSEMBLY:

1. Examine inlet valve surfaces for pitting, scale or grooves.

Reverse valve and sand inlet side of valve using 240 grit
paper for clean surface or replace if evidence of excessive
wear. Slip onto rod.

2. Examine piston seating surfaces and sand clean on flat sur­face using 240 grit paper. If extreme pitting or sharp edges,

replace piston.

3, Examine cup for wear, cracking, tearing or separation from

the piston. If worn replace and lubricate before installing on
piston.

NOTE CUP INSTALLATION: Wipe cup inserter with oil. Slip

bat-cup 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 Stainless Steel Cotterpin

and turn ends under.

6. Examine cylinder walls for scoring or etching which causes

premature wear of cups and replace if worn.

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

SERVICING SLEEVESAND SEALS

DISASSEMBLY:

1. Remove discharge manifold and piston assemblies as
described.

2. Remove inlet manifold containing seals.

3. Grasp sleeves and with a pulling and twisting motion remove
the sleeves from the piston rod.

NOTE: Grasp sleeve with pliers only if replacing worn sleeves,

as this procedure will mar the sleeves.

4. Next remove seal retainer.

5. Remove and examine o-rings and/or back-up rings on piston

rod for wear and replace.

REASSEMBLY:

1. Lubricate new o-rings and/or back-up rings and slip onto 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 the thread end of the piston rod.

2. Examine sleeves for scoring 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. If wicks are used, replace wicks,

thoroughly saturate with oil, place in seal retainer and install re­tainer.

4. Place inlet manifold on pair of clearance blocks with crankcase

side down and drive out old seals.

5, Invert inlet manifold with crankcase side up and instal new

seals. Lubricate circumference of seal and install Prrrrrm-A­Lube seal with garder spring down. If using blue dot seal, blue
dot should be facing up when installed.

6. Slip lubricated seal inserters 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 SECTION

1. While 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 for drying, cracking or
leaking.

5. Consult factory or your local distributor if crankcase service is
evidenced.

CAT PIMP TROIUBLESHOOTING GUIDE

PROBLEM: Pulsation

Cause Solution

Debris in discharge valves of pump. Clean or replace discharge valves.

FITOBLEM: Low Pressure
cause Solution
Worn nozzle. Replace nozzle, of proper size.
Belt Slippage.
Air ieak in inlet plumbing. Disassemble, reseal, and reassemble.
Pressure gauge inoperative or not registering accurately. Check with new gauge; replace worn or damaged gauge,

Relief valve stuck, partially plugged or improperly adjusted;

valve seat worn.
Inlet suction strainer clogged or improper size. Clean. Use adequate size. Check more frequently.
Worn piston assembly. Abrasives in pumped fluid or severe install proper filter, Suction at inlet manifold must be limited

cavitation. Inadequate water supply.
Fouled or dirty inlet or discharge valves. Clean inlet and discharge valve assemblies.
Worn inlet or discharge valves. Replace worn valves, valve seats.
Leaky discharge hose. Replace discharge hose.

PROBLEM: Pumps runs extremeiy rough, pressure very iow
Cause
Restricted inlet or air entering the inlet plumbing.
Inlet restrictions andlor air leaks. Damaged cup or stuck inlet Replace worn cup or cups, clean out foreign material, replace

or discharge valve.

Wom inlet manifold seals. Replace worn seals.

Tighten or replace: use correct belt.

P.N. 06090

Clean, and adjust relief valve; check for worn and dirty valve

seats. Kit available.

to lifting less than 20 feet of waer or -8.5 PSI vacuum.

Soiution
Proper size inlet plumbing; check for air tight seal.

worn valves.

—

—

PROBLEM: Cylinder O-rings blown next to discharge manifold
Cause
Pressures in excess of rated PSi.

Warped manifold. Replace manifold.

PROBLEM: Leakage at the cyiincfer O-rings at the discharge manifold and black, powdery substance in the area af the

O-rings
cm.lse Solution
Loose cyiinders, Cylinder motion caused by improper

shimming of the discharge manifold. - many shims or the ears of the manifold will be bowed

PROBLEM: Water leakage from under the inlet manifold
Cause Solution
Worn inlet manifold seals. Leaking sleeve O-ring.

PROBLEM: Oii ieak between crankcase and cwm~ina section
Cause
Worn crankcase Diston rod seals.
Excess oii from wicks.

PI?OHLEM: (Iii leaking in the area of Crankshaft
Cause
Worn crankshaft seal or improperly installed oil seal retainer

packing.

Bad bearing,

Soiution

Check for plugged nozzle, closed valves or improperly

adjusted by-pass valve.

Remove spacer shims on manifold studs. Do not remove too

when the manifold is retightened, causing looseness in
the center cylinder.

Install seals. [f piston rod sleeves are scored, replace sleeves

and sleeve O-rings.

Solution

RerNace crankcase Diston rod seals.
Reduce quantity of oil per oiling.

Soiution

Remove oil seal retainer and replace damaged gasket andlor

seals.

Replace bearing.

PROBLEM: Excessive play in the end of the crankshaft pulley
Cause
Worn main ball bearing from excessive tension on drive belt.

PROBLEM: Water in crankcase

Cause

May be caused by humid air condensing into water inside the

crankcase.

Leakage of manifold inlet seals and/or piston rod sleeve

PROBLEM: Oil leaking from underside of crankcase

Cause
Worn crankcase piston rod seals.

PROBLEM: Oil leaking at the rear portion of the crankcase

Cause

Damaged or improperly installed oil gauge or crankcase rear

cover O-ring, and drain plug O-ring.

PROBLEM: Oil leakage from drain plug

Cause

Loose drain plug or worn drain plug O-ring

PROBLEM: Loud knocking noise in pump

Cause

Pulley loose on crankshaft.

Broken or worn bearing.

Solution

Replace ball bearing. Properly tension belt.

Solution

Change oil at 3 month or 500 hour intervals using Cat Pump

Crankcase Oil (other approved oil every month or 200
hours) P.N.: 06100.

Replace seals, sleeve and O-rings.

Solution
Replace seals, sleeve and O-rings.

Solution

Replace oil gauge or cover O-ring, and drain plug O-ring.

Solution
Tighten drain plug or replace O-ring.

Solution

Check key and tighten set screw.
Replace bearings.

PROBLEM: Frequent or premature failure of the inlet manifold seals

Cause

Scored rods or sleeves.

Over pressure to inlet manifold.

Solution

Replace rods and sleeves.
Reduce inlet pressure per instructions.

PROBLEM: Short cup life

Cause

Damaged or worn chrome plating of the cylinders.

Abrasive material in the fluid being pumped.

Excessive pressure and/or temperature of fluid being pumped.

Solution
Replace cylinders.
Install proper filtration on pump inlet plumbing.
Check pressures and fluid inlet temperature; be sure they

are within specified range.
Over pressure of pumps.
Running Pump dry.
Front edge of piston sharp.
Chrome plating of cylinders damaged causing excessive wear

of cups. May be caused by pumping acid solution.

Reduce pressure.
Do not run pump without water.
Replace with new piston.
Install new cups and cylinders. Pump only fluid compatible

with chrome.

PROBLEM: Strong surging at the inlet and low pressure on the discharge side

Cause

Foreign particles in the inlet or discharge valve or worn inlet

and/or discharge valves.

Solution
Check for smooth lap surfaces on inlet and discharge valve

seats. Discharge valve seats and inlet valve seats may be

lapped on a very fine oil stone; damaged cups and

discharae valves cannot be

laDDf?d but must be reDlaced.

HYDW-CAT ELECTRICAL SYSTEM

The entire electrical system operates on 12 volts DC which is pro­vialed by a battery. Battery levels are sustained by a 15 amp alter­nator designed within the engine.

Pf?Of3LEM: Low Battery Voltage
Cause
Defective battery.
Corroded battery terminals.
Low battery fluid.
Loose wiring within electrical system.

Electrical short in wiring system.

ground connection.

Poor

PROBLEM: Inoperative Hour Meter

cause
Time is not advancing correctly.

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

Solution
Remove and replace.
Clean terminals and battery posts.

Add water to appropriate level.

Examine all terminal connections and verify that they are

secure.

Examine electrical systems for bare wires.

Examine terminal and remove corrosion if necessary,

Solution
Verify 12 volts DC is available at the hour meter with the

ignition switch turned on. This can be accomplished with
a volt meter or a test lamp.

Remove and replace hour meter if 12 volts is available.
A nylon gear within the clock may have been jammed due to

a sudden jolt of the machine or truck. You may try simply
tapping on the meter to try to free the nylon gear,

Z

=
$

$
JIJ*

m

,:.. .

,,,.

(?!)%?

Fuel

HYDRA-CAT

S/Series

~

-.. .

1% z’”

w

Voltage Reg

Starter
Solenoid

..$...

,**V = :‘YE ‘“~ecovery

Red/White

‘ed Mix Tank

$?V* ‘“

.

“ Guard

Pump

Cut-Off Switch

P
I I Tank Cut-Off

)

~Jswi’ch””- -

HYDRA-CAT

M/Series

Engine Kill

s witch

T

I

uV_--43-l~oi,,r.ssur.

w

Switch

CCKB ENGINE SERVICEGUIDE

Onan Model
HydraCat S/Series

SPECIFICATIONS

Engine Design: Opposed two cylinder, four cycle, L head and air

cooled

Bore: 3Vi” (82.55 mm)

Stroke: 3“ (76.20 mm)

Displacement: 49.6 cu inch (616,22 ems)

H.P. - Garden Tractor Service: 191/2 hp at 3600 rpm; 20 hp max. at

3900 rpm
Oil Capacity with Filter Changa: 4 qts. (3.78 lit)
Oil Capacity without Filter Change: 3% qts. (3.31 lit)

Tune-Up Specifications
Spark Plug Gap (Gasoline): .025 (0.69 mm)
Spark Plug Gap (LPG): .018 (0,46)

Breaker Point Gap: .020 (0.51 )

Valve Lash:

Intake: .008 to .008 (0.152 to 0.203 mm)

Exhaust: .015 to .017 (0.381 to 0,432 mm)

Ignition Timing:

Standard Electric Start (Stopped or Running) 200BTC

Manual Start with Spark Advance: 1“ATDC (Stopped)

Electric Start with Magneto and Spark Advance 5° (Stopped)

Engine Model Reference

Identify your model by referring to the MODEL and SPEC
(specification) NO. as shown on the unit nameplate. Always use
this number and the engine serial number when making reference

to your engine.

How to interpret MODEL and SPEC NO.

CCKB - MS I 2853 J

TTTT

1

1. Factory code for general identification purposes.

2. Specific Type
S - MANUAL STARTING

MS - ELECTRIC STARTING

3. Factory code for optional equipment supplied,

4. Specification (Spec Letter) advances with factory production

modification.

If your engine needs service or repair, contact an Onan Service
Center. Trained mechanics will assure expert repair service on
your Onan engine.

2

24”BTC (Running)

24°BTC (Running)

34

OUT OF SERVICE PROTECTION

Protect an engine that will be out-of-service for more than 30

days as follows:

1. Run engine until thoroughly warm (5 to 10 minutes).

2. Turn off fuel supply and run until engine stops.

3. Drain oil from oil base while still warm. Refill and attach a
warning tag stating oil vicosity used.

4. Remove spark plugs. Pour one ounce (two tablespoons) of
rust inhibitor (or SAE #50 oil) into the cylinders. Crank
engine over a few times. Install spark plugs.

5. Service air cleaner.

6. Clean governor linkage and protect by wrapping with a clean
cloth.

7. Plug exhaust outlet to prevent entrance of moisture, dirt,
bugs, etc.

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

9. Provide a suitable cover for the entire unit.

10. If battery is used, disconnect and follow standard battery
storage procedure.

WARNING: Carbon monoxide is an odorless, colorless gas formed

by incomplete combustion

is a dangerous gas that can cause unconsciousness and is poten ­tially lethal. Some of the symptoms or signs of carbon monoxide
inhalation are:

● Dizziness

● Intense Headache

● Weakness and Sleepiness

● Vomiting

● Muscular Twitching

o Throbbing in Temples

If you experience any of the above symptoms, get out into fresh air
immediately.
The best protection against carbon monoxide inhalation is
inspection of the complete exhaust system, If you notice a change in
the sound or appearance of exhaust system, shut the unit down
immediately and have it inspected and repaired at once by a
competent mechanic.

Before Starting
Check the engine to make sure it has been filled with oil and fuel.
The chart below lists oil andfuet-recomrnendeticrns.

CRANKCASE OIL: Fil the crankcase with a good quality oil that
meets the API (American Petroleum Institute) service designation
SE or SE/CC. Recommended oil numbers for expected ambient

temperatures are as follows:

TEMPERATURE GRADE
Below O°F (18°C)
Below 32°F (O”C)
Above 32°F (O°C)

Fill to “Full” mark on dipstick.

CAUTION: Do not overfill crankcase. Do not use service DS oil.

Do not mix brands nor grades of motor oil.

Refer to Periodic Service section for recommended oil change
intervals.

RECOMMENDED FUEL Use clean, fresh, non-leaded or regular
grade, automotive gasoline. Do not use highly leaded premium
types.

For new engines, the most satisfactory results are obtained by
using nonleaded gasoline. For older engines that have previously

of hydrocarbon fuels. Carbon monoxide

a regular

SAE 5W30
SAE 5W30 or 10W40
SAE 30

used leaded gasoline, heads must be taken off and all lead
deposits removed from engine before switching to nonleaded
gasoline.

WARNING: Never check oil level while errgirre is running. Hot oil
discharged from the engine could cause personal injury.

Cap and oil level

indicator

Keep oil

at this level _- __~

T

Never operate ------

engine with oil

below this level

r

Crankcase Oil Fill

CAUTION: If lead deposits are not removed from engine before

switching from leaded to nonieaded gasoline, preignition cou/d

occur, causing severe damage to the engine.
WARNING: Never fill the fuel tank when the engine is running.

Gasoline could ignite, causing a serious injury.

INSPECTION: Inspect the engine visually before starting. Check
for loose or missing parts and any damage which may have
occurred in shipment.

Always replace cap
tightly, or oil
leakage may occur

FULL

LOW

STARTING

If your engine has a START-RUN-STOP switch, press switch
toggle to START, then release to RUN when engine starts. Press
toggle to STOP, to stop engine.

1. Turn on ignition switch, pull the choke lever way out (for a cold
engine) and push the start switch. When the engine starts,
gradually push the choke lever in until the engine runs smoothly.

2. Black smoke from the exhaust and a rough running engine

usually indicate over-choking.

3. To stop engine, turn ignition switch to off position.

OPERATION

Break-in Procedure
Controlled break-in with proper oil and a conscientiously applied
maintenance program will help assure satisfactory service for
many hours from your Onan engine.

Break-in or ideal fitting of all internal moving metal parts can best
be achieved by maintaining proper cooling and correct lubrication
during the running-in period. Run the engine at about half load for
the first three hours with intermittent periods of full load to control
engine break-in. Engine damage can be caused by using the
wrong grade and weight of oil and high engine operating
temperatures during break-in.

Check the oil level at least every five operating hours. Add oil to
keep it at the proper level, but never overfill as overfilling may

cause the oil to foam and enter the breather system.

Hot Weather Operation
When operating the engine in temperatures above 75°F (24° C)
pay particular attention to the following items to prevent damage:

1. Keep the engine cooling fins clean and free of obstruction which
would decrease air flow to and from the engine.

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

3. Ensure that you are using the proper grade and weight of oil for
the temperature the engine is being used in. Check the oil level

each time you fill the fuel tank.

4. Check the battery water level more frequently than every 50

hours which is recommended under normal conditions. High
temperatures cause faster evaporation.

Cold Weather Operation
When the engine is being used in temperatures below 32°F (0° C),
check the following items closely:

1. Use the correct grade and weight of oil for the temperature con­ditions. Change the oil only when the engine is warm. tf an unex­pected temperature drop occurs when the engine is filled with
summer oii, move to a warm location until the oil will flow freely

before starting the engine.

2. Use fresh fuel. Fill the fuel tank after each days use to protect

against moisture condensation.

3. Keep battery in a well-charged condition,

MAINTENANCE

OIL LEVEL Check oil level at least every eight hours of operation.
Check more frequently on a new or overhauled engine as oil con­sumption is higher until piston rings seat properly,

OIL CHANGE: Change crankcase oil after the first 2.5 hours of
operation; change every 50 hours after that. if operating in ex­tremely dusty conditions, change oil more frequently.

OIL FILTER (If used): Replace oil filter every 100 hours; replace

more often in dusty conditions. Tighten the filter finger-tigh! plus

one quarter to one half turn. Be sure to replace rubber ring around

filter.
CRANKCASE BREATHER: This engine uses a crankcase

breather vaive for maintaining crankcase vacuum, No
maintenance is generally required. If the crankcase becomes
pressurized as evidenced by oil leaks at the seals, clean the
crankcase breather cap and valve assembly, and the breather

tube baffle in suitable solvent. To remove breather cap and valve

assembly, remove the breather hose clamp and breather tube

clamp.

MOISTENED FOAM AIR CLEANER: This air cleaner consists of a
synthetic sponge over a metal retainer. The base and cover are
similar to those of the dry paper kind. Wash the sponge periodical­ly, moisten in oil and squeeze dry.

COOLING SYSTEM: Check and clean cooling fins at least every
50 hours. Remove any dust, dirt or oil which may have ac­cumulated.

CAUTION: Plugged or clogged cooiing fins can cause

overheating and engine damage.

SPARK PLUGS: Check, clean and reset spark plugs every 100

operating hours. Replace spark plugs that show signs of fouling or

electrode erosion. Replace plugs every 250 operating hours.
BREAKER POINTS: Check, clean and reset breaker points every

200 operating hours. Replace points if they are pitted or burned.
See ADJUSTMENT section.

Spark Plug Gap

Spark Plug Gap 0.025”

Oil Filter

ADJUSTMENTS

CARBURETOR

The carburetor has an idel jet and a main jet. The idle jet which is

adjustable, effects engine operation at low speed. The main jet
usually affects operation under load (high speed). Under normal
circumstances, factory carburetor adjustments should not be
disturbed. If the idle adjustment has been disturbed, turn the
needle (counterclockwise) off its seat 1 to 11/2turns to permit star­ting the engine, then readjust as follows:

Carburetor Idle Adjustment

1. Allow the engine to run at least 10 minutes to warm it up.

2. Turn the idle needle out (counterclockwise) until engine begins
to slow down or run unevenly. Remember this position.

3. Turn needle in (clockwise) past the position where the engine

runs smoothly until it begins to slow down or run unevenly.
CAUTION: Do not force the need/e against its seat; doing so

will damage it.

4. Back the needle out to

between the two positions. This should provide a smooth runn­ing idle.

CAUTION: Loosen the packing nut before making main fue/ ad-

justment and then tighten the nut to a snug fit after the adjustment

has been made. This procedure makes it easier to use the
carburetor adjusting tool and prevents fuel leaks around the
packing nut. Fuel leaks cause hard starting because the float
level become 10wer than normal.

Idle Spe

a position approximately halfway

Fuel

Adjustment

BREAKER POINTS
To maintain maximum efficiency from the engine, check condition
of the beaker points every 200 hours of operation, Proceed as
follows:

1,

Remove the two screws and the cover on the breaker box.

2.

Remove both spark plugs so engine can be easily rotated by
hand. If plugs have not bee changed within the last 100 hours,
clean and regap or replace them with new ones after setting the
breaker points.

Remove the two mounting screws (A) and pull the points out of

3.
the box just far enough so screw (B) can be removed. Replace

points with a new set (if needed) but do not completely tighten
mounting screws (A),

4.

Rotate the engine clockwise (facing flywheel) by hand until TC
mark on gear cover aligns with TC mark on flywheel, Turn screw

(C) until point gap measures .020” (0.508 mm) with a flat

thickness gauge.
Tighten mounting screws and recheck gap.

5.

Reference

Approximate Timing

for

Breaker Point Adjustment

/

.

Loosen Screws

and shift box

To ADVANCE or RETARD ,

Packing Nut

‘~7

Carburetor Adjustments

Carburetor Main (Load) Adjustment
If engine runs unevenly at half or full load due to faulty carburetion,
the main adjusting needle needs readjustment. For initial start-up,
turn main adjustment 1 to 1

1.

Wart engine arrd allow it to warm up.

2.

Set idle adjustment so engine runns smoothly.

Release governor mechanism to allow engine to accelerate. If

3.
engine accelerates evenly and without hesitation, main adjust­ment is correct. If not, turn needle outward about 1/2 turn and
again slow the engine down and relase the mechanism. Con­tinue until the engine accelerates evenly and without hesitation
after relasing the governor.

4,

If engine tends to hunt (alternate increase and decrease of
speed), open the main adjusting needle a little more. Do not
open more than 1/2 turn beyond the maximum power point.

V2 turns (counterclockwise) off its seat.

Main Fuel Adjustment

ENGINE SAFETY PRECAUTIONS

It is recommended that you read your engine manual and become

thoroughly acquainted with your equipment before you start the
engine.

WARNING: This symbo/ is used through th;s manual to warn of

possib/e serious personal injury.

CAUTION: This symbol refers to possible equipment damage.
Fuels, electrical equipment, batteries, exhaust gases and moving

parts present potential hazards that could result in serious,
personal injury. Take care in following these recommended pro­cedures.

Safety Codes

● All local, state and federal codes should be consulted and com-

plied with.

General

o Provide appropriate fire extinguishers and install them in conve-

nient locations. Use an extinguisher rated ABC by NFPA.

● Make sure that all fasteners on the engine are secure, Tighten

supports and clamps, keep guards in position over fans, driving
belts, etc.

o If it is necessary to make adjustments while the engine is runn-

ing, use extreme caution when close to hot exhausts, moving
parts, etc.

Protect Against Moving Parts
* Do not wear loose clothing in the vicinity of moving parts, such

as PTO shafts, flywheels, blowers, couplings, fans, belts, etc.

* Keep your hands away from moving parts.

Batteries

● Before starting work on the engine, disconnect batteries to pre-

vent inadvertent starting of the engine.

● DO NOT SMOKE while servicing batteries. Lead acid batteries

give off a highly explosive hydrogen gas which can be ignited by
flame, electrical arcing or by smoking.

● Verify battery polarity before connecting battery cables. Connect

negative cable last.

Fuel System

● DO NOT fill fuel tanks while engine is running, unless tanks are

outside engine compartment.

“ DO NOT smoke or use an open flame in the vicinity of the engine

or fuel tank. Internal combustion engine fuels are highly flam­mable.

* Fuel lines must be of steel piping, adequately secured, and free

from leaks. Piping at the engine should be approved flexible line.
Do not use copper piping on flexible lines as copper will work
harden and become brittle enough to break.

● Be sure all fuel supplies have a positive shutoff valve.

Exhaust System

● Exhaust products of any internal combustion engine are toxic

and can cause injury, or death if inhaled. All engine installations,
especially those within a confine, should be equipped with an ex­haust system to discharge gases to the atmosphere.

● Do not use exhaust gases to heat a compartment.

● Make sure that your exhaust system is free of leaks. Ensure that

exhaust manifolds are secure and are not warped by bolts
unevenly torqued.

Cooling System

● Coolants under pressure have ahigher boiling point than water.

DO NOT open a radiator pressure cap while the engine is runn­ing. Bleed the system pressure first.

Keep the Unit and Surrounding Area Clean

● Make sure that oily rags are not left on or near the engine.

● Remove all oil deposits. Remove all unnecessary grease and

oil from the unit. Accumulated grease and oil can cause
overheating and subsequent engine damage and may pre­sent a potential fire hazard.

PERIODIC SERVICEGUIDE

Regularly scheduled maintenance is the key to lower operating
costs and longer service life for the unit. The following schedule
can be used as a guide. However, actual operating conditions
under which a unit is run should be the determining factor in
establishing a maintenance schedule. When operating in very
dusty or dirty conditions, some of the service periods may have to
be reduced. Check the condition of the crankcase oil, the filters,
cooling fins, etc. frequently until the proper service time periods
can be established.

For any abnormalities in operation, unusual noises from engine or
accessories, loss of power, overheating, etc., contact your nearest
Onan Service Center.

PERIODIC MAINTENANCE SCHEDULE

Service These Items

Inspect Engine Generally
Check Oil Level

Service Air Cleaner

Change Crankcase Oil

Check Battery Electrolyte Level

Clean Cooling Fins x
Clean and Regap Spark Plugs

(Replace at 250 hours)

Replace Oil Filter

Clean Breather Valve
I Check Breaker Points
I Replace Air Cleaner Element

Check Valve Clearance

Remove Carbon and Lead Deposits

Irwmect Valves. Grind If Necessarv

.

Complete Reconditioning (If Required)

XI - Perform more often in extremely dusty conditions.
X2- For detailed maintenance, contact art .C)nanService Center.
X3- Check for fuel leaks, exhaust leaks, etc.

8

x3

I

x

I

I
I

1

I
I

1

After Each Cycle of Indicated Hours

50

100 200

I

400

xl
xl
x

xl

x
x
xl

1000

x2

x2

x2

x2

KOHLERENGINE SEEVICE GUIDE

Magnum Model M20
HydraCcd M/Series

SPECIFICATIONS

General
Horsepower (~ 3,600 rpm): 20
Displacement (cu. in.): 46.98
Bare: 3.12
Stroke: 3.06
Compression Ratio: 6.6:1
Approx. Weight (lb.): 130
,4pprox. Oil Capacity’ (U.S. Quarts): 1.5

*For best results, fill to “F” mark on dipstick as opposed to adding
a given quantity of oil. Always check level on dipstick before
adding more oil. On engines equipped with oil filter, an additional
1/2 U.S. pint of oil is required when oil filter is replaced.

Valves and Tappets

Intake Valve to Tappet Clearance - Cold: .003/.006
Exhaust Valve to Tappet Clearance - Cold: .016/,019
Intake Valve Minimum Lift - Zero Lash: .274
Exhaust Valve fdinimum Lift - Zero Lash: .274
Intake Valve Minimum Stem 0.0.:.3103
Exhaust Valve Minimum Stem O.D.: .3086
Nominal Valve Seat Angle 45°
Valve Guide Reamer Size: .3125

Intake Valve Guide I.D. Max. Wear Limit: .007

Fuel Recommendations
WARNING: Explosive Fuels! Gasoline is extremely flammable,
and its vapors can explode if ignited. Store gasoline

proved containers, in well-ventilated, unoccupied buildings, away
from sparks

running since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition. Do not start engine near spilled fuel;
wipe up spills immediately. Never use gasoline as a cleaning
agent.

For best results, use only clean, fresh, regular-grade, unleaded
gasoline with a pump sticker octane rating of 87 or higher. In coun­tries using the Research method, it should be 90 octane minimum.

Unleaded is recommended since it leaves less combustion
chamber deposits. Regular-grade, leaded gasoline may also be
used; however, be aware that the combustion chamber and
cylinder head will require more frequent service. Refer to the

“Periodic Maintenance” section.

or flames. Do not fill fuel tank while the engine is hot or

only in ap-

Always use fresh gasoline. Fresh gasoline is blended for the
season and reduces gum deposits which could c[og the fuel
system. Do not use gasoline left over from the previous season.

Do not add oil to the gasoline,
Keep the vent hole in fuel tank cap open. If vent hole is plugged,

pressure may build up
dangerous spraying of gasoline when tank cap is removed. A
vacuum may also be created during operation which could stop
fuel flow to the carburetor.

in tank, causing carburetor flooding or

PERIODIC MAINTENANCE KOHLER
ENGINE

Required Maintenance
These required maintenance procedures should be performed at
the frequency stated in the table:

Required Maintenance

Check Oil Level . . . . . . . . . . . . . . . . . . . . ,.. ,,, ,., ... ,Daily. Daily

Clean Grass Screen............,,, . . . . . . . . . . . . . . . . . . .. Daily*

Check/Replace Fuel Filter. . . . . .As Required

Change Oil and Filter ., .As Specified in “Oil Change

Clean Foam Precleaned . . . . . . . . . . . . . . . . . . . . . . . .. fours” l-fours”

Clean Cooling Fins and External Surfaces .50 Hours”

Clean Paper Air Cleaner Element . . ..100 Hours”

Check Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..100 Hours

Check Valve-To-Tappet Clearance ., . . . . . . . . . . . ...500 Hours

Clean Cylinder Heads and Combustion Chambers . ..500 Hours””
Service Starter Motor Drive. .Annuailyor 500 Hours

‘Perform these maintenance procedures more frequently when
engine is operated under extremely dusty and dirty conditions.

“250 Hours when leaded gasoline is used.

WARNING: Accidental Starts! Before servicing the engine or

equipment, always remove the spark plug leads to prew.?nt the
engine from starting accidentally. Ground the leads to prevent
sparks that could cause fires.

.

Frequency

Intervals” Table

OIL

Oil Filter
Some engines are equipped with an oil filter. Replace the oil filter
every othw oil change, in accordance with the “iOilChange inter­vals” table. Always use a genuine Kohler replacement oil filter,

Check Oil Level
The importance of checking and maintaining the proper oil level in
crankcase cannot be overemphasized. Check oil BEFORE EACH
USE as follows:

1. Make sure the engine is stopped, level, and is cool so the oil has
had time to drain into the sump,

2. Clean the area around dipstick before removing to keep dirt,
grass clippings, etc., out of the engine.

3. Remove dipstick and wipe oil off. Reinse~ dipstick and push it

all the way down into tube. Remove dipstick and check the level.
The oil level should be up to, but not over, the “F”’ mark on the

dipstick. Refer to Figure 1.

01 F

Range

Operating
Range

--L-

L

Ii!i

Figure 1. Oil Level Range

4. Add the proper type of oil if the level is low. Always check the
level with dipstick before adding more oil.

CAUTION: Never operate the engine with the oil level below “L”

mark or over “F” mark on dipstick.

Oil Sentry’M

m

Some engines are equipped with optional Oil Sentry oil pressure

monitor. Oil Sentry will either stop the engine or activate a “low oil”
warning light, if the oil pressure gets low. Actual Oil Sentry use will
vary depending on the engine application.

CAUTION: Oil Sentry is not a substitute for checking oil level

BEFORE EACH USE. Make sure the oil level is maintained up to

the “F” mark on dipstick.

Change Oil
For new engine, change oil after the first 5 hours of operation.
Thereafter, change oil as specified in the “Oil Change
Intervals” table.

For an overhauled engine or those rebuilt with a new short-

b/ock, use straight 30-weight Service Class SF oil for the first 5

hours of operation. Change the oil after this initial run-in period.
Thereafter, change the oil as specified in the “Oil Change inter­vals” table.

Drain oil while the engine is still warm from operation. The oil
will flow more freely and carry away more impurities. Change oil
as follows:

1. Remove the oil drain plug and dipstick. Refer to Figure 2. Tilt the

engine slightly towards the drain hole to obtain better drainage.

2. Reinstall the drain plug. Make sure it is tightened securely.

3. Fill with new oil of the proper type to the “F” mark on the
dipstick. Always check the” Ieve-l”on dipstick before adding

more oil. Make sure the engine is level when filling and
checking oil.

Change Oil Filter
Change the oil filter every other oil change, in accordance with
the “Oil Change Intervals” table. Always use a genuine Kohler
oil filter and change as follows:

1. Drain crankcase oil, then remove old filter.

2. Before installing replacement filter, apply a thin coating of oil
on surface of the rubber seal.

3. Turn filter clockwise until rubber seal contacts the filter
adapter, then tighten the filter an additional turn.

4. Add an additional 1/2 pint of oil for the filter capacity.

5. Start the engine and check for and correct any oil leaks,

AIR SYSTEM

Service Air Cleaner

Magnum engines are equipped with a high-density paper air
cleaner element. Some specifications are also equipped with an
oiled foam precleaned which surrounds the paper element. Refer to

Figure 3.
Also refer to the “Air Cleaner” section for disassembly and

reassembly procedures for all styles of air cleaners used on
these engines.

Precleaned

If so equipped, wash and reoil the precleaned every 25
operating hours (more often under extremely dusty, dirty
conditions).

1. Remove precleaned from paper element. Wash the
precleaned in warm water with detergent.

2. Rinse precleaned thoroughly until all traces of detergent are
eliminated. Squeeze out excess water (do not wring). Allow

precleaned to air dry.

Base Element

\

Cover Seals

Element Cover

/

Figure 2. Oil Filter, Oil Drain Plug Location

OIL CHANGE INTERVALS

Temperature

I

ABOVE
32°F (O°C)

BELOW

320F (Ooc)

I

“25 hours for continuous andlor heavy duty operatfon

SAE 30

Multwmcosny

Multiwscosity

I

Oil

Type

Engine Type Interval

With Filter 50 Hours”

Without Filter 25 Hours

WKh Filter

Without Ftlter 25 Hours

With Filter

Without Filter 25 Hours

t

25 Hours

50 Hours

Optional ­Preclaaner

Pape)Element

Figure 3. Air Cleaner Components

3. Saturate precleaned in clean, fresh engine oil. Squeeze out
excess oil.

4. Reinstall precleaned over paper element.

1

Paper Element
Every 100 operating hours (more often under extremely dusty,
dirty conditions), check the paper element. Clean or replace
element as follows:

1. Remove the precleaned (if so equipped), element cover
seals, element cover, and paper element.

2. Gently tap the flat side of element to dislodge dirt. Replace a
dirty, bent, or damaged element with a new genuine Kohler

element. Handle new elements carefully; do not use if sur-

‘r’vep’n;pGea

faces are bent or damaged.

CAUTION: Do not wash the paper element or use compressed

air as this will damage element.

3. Reinstall the paper element, element cover, and element cover
seals.

4. Install the precleaned (cleaned and oiled) over paper
element.

5. Install air cleaner cover and wing nuts. Tighten wing nuts 1/2
to 1 full sturn after nuts contact cover—do not overtighten.

Inspect Air Cleaner Components
Whenever the air cleaner cover is removed, or the element or
precleaned serviced, check the following components:

● Air Cleaner Base - Make sure it seals tightly against intake

elbow, and is not bent or damaged.

● Element Cover and Element Cover Seals - Make sure element

cover is not bent or damaged. Make sure element cover seals
are in place to ensure element is sealed tightly between ele­ment cover and air cleaner base.

● Breather Tube - Make sure it is sealed tightly in air cleaner

base and breather cover.

CAllTIQN: Damaged, worn, or loose air cleaner components

could allow unfiltered air into the engine causing premature wear

and failure. Replace all damaged or worn components.

Gauge

3. Check gaps using a wire feeler gauge. Adjust gaps to 0.025” by
carefully bending the ground electrode.

4. Reinstall spark plugs into cylinder heads. Torque plugs to 10/1 5
ft. lb.

IGNITION

IGNITION SYSTEM SERVICE
Magnum engines are equipped with a dependable electronic
magneto ignition system. Other than periodically checking/replac­ing the spark plugs, no maintenance, timing, or adjustments are
necessary or possible with this system,

SERVICE STARTER MOTOR DRIVE

500 operating hours, or annually (whichever occurs first),

Every
clean and lubricate the drive splines of the Bendix-drive electric
starter motor. Refer to Figure 5.

1. Remove starter from crankcase. (Refer to the “Disassembly”
section.)

2. Remove dust cover, stop nut, stop gear spacer, spring, dust
cover spacer, and drive pinion.

3. Clean the drive shaft splines with solvent. Dry splines throughly.

4. Apply a small amount of Kohler electric starter drive lubricant

(Part No. 52357 01) to splines.

CAUTION: Koh/er starter

must be used on
other /ubricants can cause the drive to stick or bind.

5. Apply a small amount of Loctite” No. 271 to stop nut threads.

Assemble drive parts in reverse order of removal. Tomue sto~

nut to 160 in. lb:

6. Reinstall starter to crankcase.

all Kohler electric starter drives, The use of

drive lubricant (Part No. 523570 1)

0.025” Gap

J@’;

Ground Eiectrode

Figure d. Servicing Spark Plugs

Check Spark Plugs

Every 100 operating hours, remove the spark plugs, check condi-

tion and reset gaps, or replace with new plugs as necessary. Refer
to Figure 4.

1. Before removing spark plugs, clean the area around the base of
plugs to keep dirt and deb~s out of engine.

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

CAUTION: Do not clean the spark plugs in a machine using

af?rasive grit. Some grit could remain in spark plugs and enter
the engine causing extensive wear and damage.

\ Salines

\Jf(j-

.

Dust Cover

Spacer

Figure 5. Starter Drive Components

Fuel Filter

Figure 6. In-1ine Fuel Filter

Check Fuel Filter’
Some engines are equipped with an in-line fuel filter. Visually in­spect the filter periodically, Replace when dirty with a genuine

Kohler filter.

‘d

-@@?& 7cer

‘“rin:t<>~

Dust Cover ~

1al I

CYLINDER HEADS

CLEAN CYLINDER HEADS AND COMBUSTION CHAMBERS

Every 500 operating hours (250 hours when leaded gasoline is

used), remove cylinder heads and clean combustion chambers.

Refer to Figure 7.

1. Remove cylinder head baffles and cylinder heads.

2. Clean away combustion deposits using a wooden or plastic
scraper.

3. Reinstall cvlinder heads using new gaskets. Torque cylinder

head faste;ers to 15/20 ft. lb. in th; sequence specfied in
Figure 7,

@\?

@

P-7

@

I

@

@

I

REMOVE AIR CLEANER, VALVE COVERS, BREATHER, AND
SPARK PLUGS

1. Disassemble air cleaner. Disconnect breather tube from air
cleaner base. Remove base from air intake elbow and intake
manifold.

2. Remove the valve cover and breather assembly from the #1

cylinder barrel. Remove the valve cover from the #2 cylinder

barrel.

3. Remove the spark plugs.

MEASURE VALVE-TO-TAPPET CLEARANCE
IMPORTANT: The piston must beat top dead center (TDC) of the

compression stroke to measure valve-to-tappet clearance. By

rotating the flywheel and observing the valves and tappets for
movement, it can be determined if a cylinder is at TDC.

If, for example, the flywheel is rotated and movement is noticed in
the #2 side valve box—the opposite cylinder (#1 side) will be at
TDC and valve-to-tappet clearance can be measured.

Rotating the flywheel one complete revolution (360°) will then

cause movement in the #1 side valve box—the #2 side cylinder
will be at TDC, enabling measurement of valve-to-tappet

clearance for that side.

Intake Valve (Closest to Flywheel): .003’’/.006”

Exhaust Valve (Closest to PTO): .016 “/.019“

1. Rotate the flywheel and look into the valve boxes. The valves
and tappets will move in only one of the boxes. Measure the
valve-to-tappet clearance for the cylinder in which no movement
was observed—use a flat feeler gauge. Refer to Figure 8.

2. Rotate the flywheel 360° and measure the valve-to-tappet
clearance for the remaining cylinder.

3. If clearance is too small, remove the valves and grind the valve
stems until the correct clearance is obtained. Make sure valve
stems are ground perfectly flat and smooth.

if clearance is too large, replace the valves and recheck
clearance.

NOTE: Large clearances can also be reduced by grinding the

valves and/or valve seats.

w

1

Figure 7. Cleaning Cylinder Heads / Combustion

Chambers And Tightening Sequence

VALVE CLEARANCE

Figure 8. Measuring Valve-To-Tappet Clearance
CHECK VALVE-TO-TAPPET CLEARANCE

Every 500 operating hours, remove breather/valve covers and 2. Drain the fuel tank and fuel system (or run engine until fuel tank
check valve-to-tappet clearance with a fIat feeler gauge. Refer to
Figure 8. The engine must be cold when checking this clearance.

REINSTALL SPARK PLUGS, BREATHER, VALVE COVERS,

AND AIR CLEANER

1. Reinstall spark plugs and torque to 10/15 ft. lb.

2. Reinstall valve cover to #2 cylinder barrel. Reinstall breather

assembly and valve cover to #1 cylinder barrel. Make sure
breather is assembled correctly using new gaskets.

3. Reinstall air cleaner base to intake manifold and air intake

elbow using new gasket.

4.

Insert end of breather tube through hole in air cleaner base.

CAUTION: Make sure breather tube seals tightly in breather

cover and in air cleaner base to prevent unfiltered air from
entering engine.

5. Reasemble remaining air cleaner components and tighten wing

nut(s) 1/2 to 1 full turn after nut contacts cover. Do not

overtighten.

6. Reconnect spark plug leads.

STORAGE

If the engine will be out of service for approximately two months or

more, use the following storage procedure:

1. Change the oil and filter when engine is still warm from opera­tion. Refer to “Chanae Oil.” Run the encrinefor a few minutes to

distribute the clean ;il.

and fuel system are empty).

(continuednextpage)

3. Remove the spark plugs. Add one tablespoon of engine oil into
each spark plug hole. Install plugs, tmt do not connect plug
leads. Crank the engine two or three revolutions.

4. Clean the exterior surfaces of engine. Spread a light film of oil
over any exposed metal surfaces of engine to prevent rust.

5. Store the engine in a clean, dry place.

KOHLER ENGINE

TROUBLE

When troubles occur, be sure to check the simple causes which,

at first, may seem too obvious to be considered. For example, a
starting problem could be caused by an empty fuel tank.

Some common causes of engine troubles are listed below—use

this as a guide to locate causing factors.

PFfQBLEM: Engine Cranks But Will Not Wart

Solution

Empty fuel tank.
Clogged fuel line.
Spark plug leads disconnected.
Keyswitch or kill switch in “off” position.
Faulty spark plugs.
Faulty Ignition module.
Dirt or water in fuel system.

PROBLEM: Engine Starta But Does Not Keep Running

solution

Restrictocl fuel tank vent.

Dirt or water in fuel system.

Faulty choke or throttle controls/cables.
Loose wires or connections which short kill terminal of

ignition module to ground.
Carburetor improperly adjusted.
Faulty cylinder head gaskets.
Faulty fuel pump.

PROBLEM: Engine Starts Hard
Solution
Loose wires or connections.

Dirt or water in fuel system.
Clogged or restricted fuel lines.
Faulty choke or throttle controls/cables.
Faulty spark plugs.
Carburetor improperly adjusted.
Incorrect valve-to-tappet clearance.
Low compression.

SHOOTING GUIDE

PROBLEM: Engine Runs But Misses
Solution
Dirt or water in fuel system.

Spark plug leads loose.

Loose wires or connections which intermittently short kill

terminal of ignition module to ground.
Carburetor improperly adjusted.
Engine overheating,
Incorrect valve-to-tappet clearance
Faulty ignition module.

PROBLEM: Engine Will Not Idle
Solution
Idle speed adjusting screw improperly

Dirt or water in fuel system,
Idle fuel adjusting screw improperly set.
Restricted fuel tank vent.
Faulty spark plugs,
Incorrect valve-to-tappet clearance.
Low compression.

PROBLEM: Engine Overheats
Solution
Grass screen, cooling fins, or shrouding clogged.

Excessive engine load.
Low crankcase oil level
High crankcase oil level.
Carburetor improperly adjusted.

PROBLEM: Engine Knocks

Solution

Low crankcase oil level.
Excessive engine load.

PROBLEM: Engine Loses Power

Solution

Low crankcase oil level.
High crankcase oil level.
Restricted air cleaner element.
Dirt or water in fuei system.
Excessive engine load
Engine overheating.
Faulty spark plugs.
Carburetor improperly adjusted.
Low compression.

set,

PROBLEM: Engine Will Not Crank
!30h.ltlofl

Battery is discharged.
Loose or faulty wires or connections.

Faulty keyswitch or ignition switch.
Faulty electric starter/starter solenoid.
Seized internal engine components.

PROBLEM: Engine Uses Excessive Amount of Oil
Solution
Incorrect oil viscosity or type.

Clogged or improperly assembled breather system
Worn or broken piston rings.
Worn cylinder bores.
Worn valve stems and/or valve guides.

CARBURETOR

This subsection covers the adjustment, disassembly, cleaning,
inspection, repair, and reassembly of Kohler-built, side draft, ad­justable jet carburetors.

WARNING: Explosive Fuel! Gaso/ine may be present in the

carburetor and fuel system. Gasoline is extremely flammable and
its vapors can explode if ignited. Keep sparks, open flame and
other sources of ignition away from engine. Wipe up spilled fuel
immediately.

ADJUSTMENT

The carburetor is designed to deliver the correct fuel/air mixture to
the engine under all operating conditions. Carburetors are set at
the factory and normally do not need adjustment. If the engine ex­hibits conditions like those found in the table below, it may be
necessary to adjust the carburetor.

Turning the adjusting needles in (clockwise) decreases the supply
of fuel to the carburetor. This gives a leaner fuel/air mixture. Turn­ing the adjusting needles out (counterclockwise) increases the
supply of fuel to the carburetor. This gives a richer fuei/air mixture.
Refer to Figures 9 and 10.

CAUTION: Incorrect settings can cause a fouled spark plug,

overheating, excessive valve wear, and other problems. To
ensure correct settings, make sure the following adjustment

procedures are used.

Make carburetor adjustments after the engine has warmed.

1. Stop the engine. Turn the main fuel and idle fuel adjusting
needles in (clockwise) until they bottom lightly.

CAUTION: The ends of the main fuel and idle fuel adjusting

needles are tapered to critical dimensions. Damage to needles
and seats will result if the needles are forced.

2. Preliminary Settings: Turn the main fuel and idle fuel adjusting

needles out (counterclockwise) from lightly bottomed as follows:
Main Fuel Needle 21/2Turns
Idle Fuel Needle 1 Turn

3. Start the engine and run at half-throttle for 5-10 minutes to warm
up. Engine must be warm before making final settings (steps
4-5).

4. Final Setting - Main fuel: Place throttle in wide open position;

and if possible, place engine under load. Turn main fuel ad­justing needle out (counterclockwise) from preliminary setting
until the engine speed decreases (rich). Note the position of the
needle.

Now turn the adjusting needle in (clockwise). The engine speed
may increase, then it will decrease as the needle is turned in
(lean). Note the position of the needle.

Set the adjusting needle midway between the rich and lean set­tings noted.

5. Final Setting - Idle Fuel: Place throttle into idle or slow position.

Set idle fuel adjusting needle using the same procedure as in
step 4.

Idl
Fu
Needle

u

Figure 9. Kohler-Built Adjustable Jet Carburetor

Adjust To
Midpoint

Rich — _ —

Lean

,+

I

[

t

&

Figure 10. Carburetor Adjustment

CLEANING

WARNING: Flsmmsble Solvents! Carburetor c/caners and
solvents are extremely flammable. Keep sparks, flames, and
other sources of ignition away from area. Follow the cleaner
manufacturer’s warnings and instructions on its proper and safe
use. Never use gasoline as a cleaning agent.

To Replace Throttle and Choke Shafts
WARNING: Prevent Eye Injury! Suitable eye protection (safety

glasses, goggles, or face hood) should be worn for any
procedure involving the use of compressed air, punches, ham­mers, chisels, drills, or grinding tools.

Disassembly

1. Remove the bowl retaining screw, retaining screw gasket, and
fuel bowl.

2. Remove the float pin, float, fuel inlet needle, baffle gasket, and
bowl gasket.

3. Remove the fuel inlet seat and inlet seat gasket. Remove the
idle fuel and main fuel adjusting needles and springs. Remove

the idle speed adjusting screw and spring.

4. Further disassembly to remove the throttle and choke shafts is
recommended only ifthese parts are to be replaced. (Figure 12)

Idle Speed

%-raw Smlrm II

------

—r.....

a“ r’–=h–

I

,,

L

K

Spring

/ Body

Carburetor

Throttle $h.fi -4 St”l,.

For Medal. &i18 and M20 (7. C.rL.)

Choke D,tmt

,.,lA”d:;:$;&’T$

,3.a.7/32- ch.k. PIOIO

‘rall~r$,r(e:’t;rn::

\

!+9.68.7/32’ ‘y=J\

\

p—————— :*~&w”r

Thmttl.
Lw.r
[Reused)

:/ -/ Bowi

Fw?iini

&

Seat -

‘~ &znge

,...”.

Seat

/
Fuel inlet
Needte

//

Float

Fuei

/H

Bowi

~~~ing+B*wiR*t.i.i.g

./

Gasket

Screw Gaskat

Figure 11. Kohler-Built Adjustable Jet Carburetor
Remove Choke Plate and Choke Sham Transfer Choke Lever

1.To ensure correct reassembly, mark choke plate and carburetor

body with a marking pen. Also take note of choke plate position
in bore, and choke lever position.

2. Carefully and slowly remove the screws securing choke plate to
choke shaft. Remove and save the choke plate as it will be

reused.

3. File off any burrs which may have been left on choke shaft when
screws were removed. Place carburetor on work bench with
choke side down. Remove choke shaft the detent ball and

spring will drop out.

4. Note the position of the choke lever with respect to the cutout

portion of choke shaft.

5. Carefully grind or file away the riveted portion of shaft. Remove

and sava choke Ievec discard old choke shaft.

6. install choke lever to new choke shaft from kit. Make sure lever

is installed correctly as noted in step 5. Apply Loctite to threads
of (1) #3-4$x7/32° brass screw; secure lever to shaft.

Remove Throttle Plate And Throttle Sham Transfer Throttle
Lever

To ensure correct reassembly, mark throttle plate and car-

1.

buretor body with a marking pen. Also take note of throttle plate
position in bore, and throttle lever position.

2.

Carefully and slowly remove the screws securing the throttle
plate to throttle shaft. Remove and save the throttle plate as it
will be reused.

3.

File off any burrs which may have been left on throttle shaft
when screws were removed.

4.

Remove the throttle shaft from carburetor body. Remove and

discard the foam rubber dust seal from throttle shaft.

/

I

*2.58x7132- o,
lK3-48.7/3?’
B,”* screw

Clt.k, Sh.tt _<

Bush[”g

‘%

Choke Sh.R

hay=’ <Q.,a.,..,n,., \

a

Cavb.ra,or Body

‘ =-.. ,Ow, .,*,=,

0

Tma,,k S’MII !hmhl”g
I“at,lt,, b,” Too,

Figure 12. Throttle And Choke Shaft Replscerment Kit

Bend Tab

To Adjust

Inverted Carburetor

Figure 13. Setting Float Level

5. Remove/transfer throttle lever as follows:
a. Note the position of the throttle lever with respect to the

cutout portion of throttle shaft.

b. Carefully grind or file away the riveted portion of shaft;

remove throttle lever.

c. Carefully compare the old shaft to the new shafts from kit.

Select the appropriate new shaft and discard the old shaft.

d. Install throttle lever to throttle shaft.

ed correctly as noted in step a.

e. Apply Loctite to threads of (1) #2-56x7/32° brass screw (use

#3-48 x7/32° screw with 2-49/64” shaft); secure lever to

shaft.

Reassembly

Install the fuel inlet seat gasket and fuel inlet seat into car-

1,

Make sure lever is install-

buretor body. Torque seat to 35/45 in. lb.

2.

Install the fuel inlet needle into inlet seat. Install float and slide
float pin through float hinge and float hinge towers on car­buretor body.

3.

Set float level: Invert carburetor so the float tab rests on the
fuel inlet needle. There should be 11 /64” (* 1/32”) clearance
between the machined surface of body and thct free end of
float. Bend the float tab with a small screwdriver to adjust.

Refer to Figure 13.

4.

Set float drop; Turn the carburetor over to its normal operating
position and allow float to drop to its lowest level. The float
drop should be limited to 1-1 /32” between the machined sur-

0.010 Feeler Gauge

Float

Bend Tab
To Adjust

l-s~

File [f
Necessary

Inverted Carburetor

Figure 14. Setting Float Drop Figure 15. Checking Float Clearance

[Both Sides)

r

\

Float Hinge Towers
(On Carburetor Body)

face of body and the bottom of the free end of float. Bend the
float tab with a small screwdriver to adjust. Refer to Figure

14.

5. Check float to float hinge tower clearance: Invert the car­buretor so the float tab rests on the fuel inlet needle. Insert a
,010” feeler gauge between float and float hinge towers. If the
feeler gauge cannot be inserted, or there is interference bet­ween the float and towers, file the towers to obtain the proper
clearance. Refer to Figure 15.

6. Install the bowl gasket and baffle gasket. Position baffle gasket
so the inner edge is against the float hinge towers.

7. Install the fuel bowl so it is centered on the baffle gasket. Make
sure the baffle gasket and bowl are positioned properly to
ensure a good seal.

8, Install the bowl retaining screw gasket and bowl retining

screw. Torque screw to 50/60 in. lb.

9. Install the idle speed adjusting screw and spring. Install the
idle fuel and main fuel adjusting needles and springs. Turn the
adjusting needles clockwise until they bottom lightly.

CAUTION: The ends of adjusting needles are tapered to

critical dimensions. Damage to needles and seats will result if
needles are forced.

10. Reinstall the carburetor to the engine using a new gasket.

11. Adjust the carburetor as outlined under the “Adjustment” por­tion of this section.

CARBURETORTROUBLESHOOTING GUIDE

PROBLEM: Black Sooty Exhaust Smoke*, Engine Sluggish
Cause Solution

Main fuel moisture too rich.

PROBLEM: Engine Misses and Backfires at High Speed
Cause Solution
Main fuel moisture too lean. Turn main fuel adjusting needle out (counterclockwise).

PROBLEM: Engine Starts and Then Stops Under Cold Weather Conditions
Cause
Main fuel moisture too lean.

Turn main fuel adjusting needle in (clockwise).

Solution

Turn main fuel adjusting needle out (counterclockwise).

PROBLEM: Engine Runs Roughly or Stalls at Idle Speed
Cause Solution
Idle speed too low or improper idle fuel mixture. Turn idle speed adjusting screw, then idle fuel adjusting needle.

*If black exhaust smoke is noted, check the air cleaner first. An apparent “overrich” mixture can actually be caused by a clogged air cleaner

element, If after element is replaced, black smoke or other problems continue, adjust the carburetor immediately.

LUBRICATION SYSTEM

(3PEHATIQN

Magnum Ml 8 and M20 engines use a full-pressure lubrication

system that delivers oil to the crankshaft, camshatt, and connec­ting rod journal surfaces. Under normal engine operating condi­tions, the oil pressure can be as high as 50 psi. A high-efficiency
gerotor oil pump maintains high oil flow and oil pressure, even at
low speeds and high operating temperatures. A pressure relief
valve, located in the engine crankcase behind the closure plate,

limits the maximum oil pressure in tho system. No adjustments to

relief valve are possible. Refer to Figure 16.

f

Cat.eang Roa
J.lunwl surf,...

. .
~.­?.-

.— ..— — ..—

+-----

cm”

011 P

?

Rellaf
V*1W

I

\’

011 PIQk”@

018L@”el

Figure 16. Full-Pressure Lubrication System

LUBRICATlON SYSTEM SERVICE
The oil pump cover and rotors, and pressure-relief valve can be
serviced without splitting the crankcase. Remove the rear closure

plate to service those parts.

The crankcase must be split to service the rmmp shaft. drive sear,

oil pickup, etc. Refer to F“igures17, 18, and 19.’ -

r

Figure 18. Oil Pump Assembly

I T

I

I

Figure 17. Oil Pickup

Figure 19. Oil Pressure Reli@f Valve
OIL FILTER

All basic engines are equipped with a full-flow oil filter. The filter
helps remove sludge and other combustion by-products from the
oil, extends the oil change interval, and helps cool the oil.

Oil filters are optional for special spec engines and are available in
engine-mounted or remote-mounted types. A cover plate seals the

crankcase on those engines not equipped with an oil filter.

Refer to Figures 20 & 21, Also refer to the “Periodic Maintenance”
(page 29) section for oil and oil filter change instructions.

Opllon.1

,~. .%:

,6

l--

I

.

/

!-ml switch

or

O~FPosltkm

Ke”swlloh

01

I

Figure 22. Magnum Electronic Magneto Ignition System

Figure 20. Engine Mounted Oil Filter And Oil Sentry

Pressure Switch

Oil Filter

Adapter

Gasket

/ \A ,.W

-..
Oil Filter

‘w!

‘ Screws (125 in: lb.)

Figure 21. Installation Torques—Engine Mounted Oil

ELECTRICAL SYSTEMSAND
COMPONENTS

MAGNUM ELECTRONIC MAGNETO IGNITION SYSTEM

This engine is equipped with a state-of-the-art electronic magneto

ignition system. The system consists of the following components
(refer to Figure 22).

I

● A magnet assembly, which is PERMANENTLY afftxed to the

flywheel.

● An electronic magneto ignition module, which is mounted to the

#1 side cylinder barrel.

● A kill switch (or keyswitch) which stops the engine by grounding

the ignition module.

Operation

As the flywheel rotates and the magnet assembly moves past the

ignition module, a low voltage is induced in the primary windings of

the module. When the primary voltage is precisely at its peak, the

module induces a high voltage in its secondary windinga. This high
voltage creates a spark at the tip of the spark plugs, igniting the

fuel-air mixture in the combustion chambers. The timing of the

spark is automatically controlled by the module. Therefore, no igni­tion timing adjustments are necessary or possible with this system.

CAUTION: Do not connect 12 volts to the ignition system or to

any wire connected to the ignition module.

The ignition system operates independently of the battery, starting,
charging, and other auxiliary electrical systems. Connecting 12

Figure 23. Ignition System Tester

Filter

Figure 24. Testing Module Primary
volts to the ignition module can cause the module to burn out. This

type of damage is not covered by the engine warranty.
A break-before-make type keyswitch is required to prevent

damage to the ignition module.

Ignition Module
REMOVAL

1. Remove the blower housing.

2. Remove the kill lead from killterminal of module. Refer to Figure

26.

3. Remove the hex flange screws and module from bracket on #1
cylinder barrel.

INSTALLATION

1. Install the module and hex flange screws to bracket. Move the
module as far from flywheel/magnet as possible—tighten the

hex flange screws slightly.

2. Insert a .014“ flat feeler gauge (or shim stock) between the
magnet and module. Refer to Figure 27.

Figure 2!5. Testing Module Secondary

——

__~—

---

Ignition Module

A

Figure 27. Setting Magnet-To-Module Air Gap

i-feat Shrink

Tubing

.——_-

-.—

——

“+

t

To Kill’Switch

Or OFF Position
Of Keyswilch

Diode

1

Co;ted
Fiberglass
Sleeving

.

>,

Terminal

Figure 26. Removing Ignition Module

3. Loosen the hex flange screw so the magnet pulls module 2.
against feeler gauge. Tighten the hex flange screw securely.

4. Remove the feeler gauge or shim stock. Due to the pull of the

magnet, the bracket and hardware will flex slightly. The magnet-

to-module air gap should be within the range of .008/.01 2“. a

5. Rotate the flywheel back and forth; check to make sure the
magnet does not strike the module. Check gap with feeler gauge
and readjust if necessary.

6. Install the kill lead to killterminal of module. Reinstall the blower
housing.

Kill Lead With

An optional in-li~e diode is installed in the kill lead of some

Magnum engines. This diode protects the module from burning

out, in the event voltage is applied to the kill lead. Refer to Figure

28.

The diode is rated such that diode failure (and subsequent module
burn out) is highly unlikely. In the event a module with a diode
protected kill lead does burn out, the diode should be tested.

DIODE TEST
Use an ohmmeter (or continuity tester) to test the diode.

Disconnect the

1.

tion module.

Ootional Diode

kill lead terminals from the kill switch and igni- 3. Crimp the

Figure 28. Kill Lead With In-Line Diode

Place the meter leads (or tester leads) across the kill lead

In one direction, the resistance should be infinity ohms (open
curcuit - no continuity). Reverse the test leads; some resistance
should be measured (closed circuit - continuity).

If the resistance is infinity ohms in both directions (no
continuity), the kill lead or diode is open.

Cut the protective tubing to expose the leads of diode. Perform
the resistance (or continuity) test in step 2 to the diode leads.
This will confirm if the lead or the diode is at fault.

4

If the resistance is O ohms in both directions (continuity), the

diode is shorted.

KILL LEAD/DIODE REPLACEMENT
When servicing the kill lead, the entire lead can be replaced or. just
the portion containing the diode. Refer to the appropriate Parts
Manual for lead part numbers.

To replace the lead, the blower housing must be removed. Use the
following procedure to replace just the portion of lead with diode.

1. Cut off the diode portion of kill lead approximately

terminal.

2. Strip 1/4” of insulation from kill lead.
“insulink” connector of replacement diodellead

assembly to kill lead.

4 3/4” from

IGNITION SYSTEM TROUBLESHOOTING GUIDE

The following guide will help locate and correct ignition system­related starting problems. This procedure uses a simple tester
which can be easily made by the serviceman. Refer to the “Special
Tools” section for ignition system tester construction details.

PROBLEM: Engine Will Not Start

Test

Make sure spark plug leads are connected to spark plugs.

Check condition of spark plugs, Make sure gaps are set

to .025”.

Check ignition module using test plugs (refer to Figure 23).

Remove the high-tension leads from the engine spark plugs,

and connect them to the test plugs.

NOTE: To maintain engine speeds normally obtained during

cranking, do not remove the engine spark plugs.

Make sure the engine ignition switch (kill switch) and/or

keyswitch are in the “run” position.

Crank the engine and observe the test plugs, Visible and

audible sparks should be produced.

(4) Measure the primary resistance of module using an

ohmmeter.

NOTE: Connect negative (-) lead of ohmmeter to kill terminal

B. Refer to Figures 22 and 24,
Primary Leads/Terminals - A - B
Primary Resistance -

(4b) Measure the secondary resistance of module using an

ohmmeter. Refer to Figures 22 and 25.

Secondary Leads~erminals - C - D

Secondary Resistance - 22,000/42,000 ohms If resistance is high or infinity ohms, module secondary is

1.0/1.5ohms

NOTE: Use a low voltage ohmmeter when ohmmeter is required.
Always zero ohmmeter on each scale before testing to ensure ac­curate readings.

Conclusion

If plugs are in good condition, check/adjust gaps and

reinstall.

If visible and audible sparks ARE produced, the ignition

module is OK.
If visible and audible sparks ARE NOT produced:
Make sure engine ignition switch and[or keyswitch are in the

“run” position.
Check wires and terminals of ignition module and other

components for accidental grounding and/or damaged

insulation.
If wires and terminals are OK, the ignition module is

probably faulty and should be replaced. Test module further

using an ohmmeter (Test 4).
If resistance is low or O ohms, module primary is shorted.

Replace module.
If resistance is high or infinity ohms, module primary is open.

Check keyswitch/wiring for shorts or connections which
could apply 12V to kill terminal B. Correct those conditions,
then replace module.

If resistance is within range, module primary is OK. Test

secondary (Test 4b).

If resistance is within range, module secondary is OK,
If resistance is low or O ohms, module secondary is shorted.

Replace module.

open. Replace module.

s

Gauge

Worn: On a worn plug, the center electrode wI( be

Qmu

rounded and the gap WIII be eroded 010 or more than
me correcl gap Heptace a worn spare plug ,mmea\ately

-.

Figurt? 29. Servicing Spark Plug

omml: A plug taken from an sngme operat, ng under

)rmal conditions will have light tan or gray colored
~poslts II the center electrode IS not worm a plug !n

is condition could be regapped and reused

Wet Fouled: A wet plug IScaused by excess fuel or ml

m the combustion chamber
caused by Operating the engine w(th too much choke
011 In the combustion chamber !s usually caused by
worn piston r!ngs or valve guides

SPARK PLUGS CONDITION DIAGNOSIS

Engine misfire or starting problems are often 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. Refer
to Figure 29.

1. Before removing the spark plugs, clean the area around the
base of plugs to keep dirt and debris out of the engine.

2. Remove the plugs and check condition. Replace the plugs if

worn cmif reuse is questionable.

CAUTION: Do not ciearr the spark plugs in a machine using

abrasive grit. Some grit cou/d remain in spark

the engine causing extensive wear and damage.

plugs and enter

Excess fuel could be

3. Check the gaps using

Carbon Fouled: Soft sooty, black depos$ts ,ndlcate
(ncomplete

usually caused by Overt, ch car buret, on weak ,gnmo”
or

Chalky White Deposits: Chalky wh!le colored deposrls

md, cate o.erheat(ng Th(s cond!t!on E
accompaowd by excesswe gap eros!on A clogged grass
screen clogged Cool, rg hns and lean car burel, on are
some causes of over- heallng

a wire feeler gauge. Adjust gaps to 0.025”

combustion Incomplete combustion @

poor compression

usually

by carefully bending the ground electrode.

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

INSPECTION

Inspect the spark plugs as soon as they are removed from the
cylinder heads. The deposits on the tips are an indication of the
general condition of piston rings, valves, and carburetor.

Normal and faulty spark plugs

are shown in the following photos.

BATTERY CHARGING SYSTEM

ELECTRICAL SYSTEMS WIRING DIAGRAMS AND
BATTERY CHARGING SYSTEMS

•l 15 Amp Regulated Battery Charging System

CAUTION: To prevent damage to the electrical system and

components:

1. Make sure battery polarity is correct. A negative (-) ground
system is used.

2. Disconnect the rectifier-regulator leads and/or wiring harness
plug before electric welding is done on the equipment powered
by the engine. Also disconnect other electrical accessories in

common ground with the engine.

3. Prevent the stator (AC) leads from touching or shorting. This
could permanently damage the stator. -

1.Regularly check the level of electrolyte. Add distilled water as

necessary to maintain the recommended level.

CAUTION: Do not overfill the battery. Poor performance or

early failure due to loss of electrolyte” will result.

2. Keep the cables, terminals, and external surfaces of battery

clean. A build-up of corrosive acid or grime on the external sur­faces can self-discharge the battery. Self-discharging happens
rapidly when moisutre is present.

Wash the cables, terminals, and external surfaces with a baking
soda and water solution. Rinse thoroughly with clear water.

CAUTION: Do not

cells as this

DC Voltmeter

allow the baking soda solution to enter the

will distro y the electrolyte.

Stud Terminals

Stwrk

—

—

Figure 30. Wiring Diagram - Electric Start Engines/15 Amp

Figure 31.15 Amp Stator And Rectifier-Regulator

Battery Charging

WARNING: Dangerous Acid, Explosive Gases! Batteries con-

tain sulphuric acid. To prevent acid burns, avoid contact with
skin, eyes, and clothing.

Battery Maintenance
Regular maintenance will ensure the battery will accept and hold a

charge.

Regulated Battery Charging System

Rectlfter-flegulato,

Solenoid

Case Ground

/.-> -

*

d

Tab

Terminal

Wy

Figure 32. Checking Battery

Voltage

SOLENOID
A solenoid is used on engines equipped with an instrument panel
or keyswitch. The solenoid is an electrically-actuated normally

open switch designed for heavy current loads. Refer to Figure

33.

The solenoid is used to switch the heavy current required by the

starter using the keyswitch (designed for low current loads).

Testing

1. Connect an ohmmeter or continuity tester across the stud ter­minals of solenoid.

2. Apply 12 volts DC across the tab terminal and case ground of
solenoid and observe ohmmeter or tester.

NOTE: Apply positive (+) of. voltage supply to tab terminal;
negative (–) to case ground.

3. The ohmmeter or tester should indicate continuity as long as
voltage is applied. if there is no continuity, the solenoid is pro­bably faulty and should be replaced.

Check the solenoid further using an ohmmeter (step 4).

4. Measure the resistance of the coil in the solenoid using an ohm­meter. Connect one meter lead to the case ground and one lead
to the tab terminal.

If the resistance is 5.2/6.3 ohms, the coil is OK.
If the resistance is low or Oohms, the coil is shorted. Replace

solenoid.
If the resistance is infinity ohms, the coil is open. Replace

solenoid.

Figure 33. Starter Solenoid

ELM3’RIC STARTER

These engines use a permanent magnet, bendix-drive electric
starter. Refer to Figure 34.

Commutal.,

2 A.---’

,“

P

H

{>, / “..,

End CW

~“ -Ys’’”er”’’emb”

.’.Q

A

.

./ I

Drive Shaft
Sp(lma

ml”. Pl”l.”

Dust cover
$rlacer

+)-~

Figure 34. Bendix Drive Electric Starter

TROUBLESHOOTING GUIDE 15 AMP BATTERYCHARGING SYSTEM

NOTE: Zero ohmmeters and voltmeters on each scale to ensure
accurate readings. Voltage tests should be made with engine
running at 3600 RFM - no load. Battery must be fully charged.

PRO13LEM: No Charge To Battery

Test Conclusion

Insert an ammeter in B+ lead from rectifier-regulator. With

engine running at 3600 RPM and B+ lead connected,
measure the voltage from B+ (at terminal on rectifier­regulator) to ground using a DC voltmeter.

If voltage is 13.8 volts or more, place a minimum load of 5

Amps’ on battery to reduce voltage. Observe ammeter,

*NOTE: Turn on lights, if 60 watts or more. Or place a 2.5 ohm,

100 watt resistor across batterv terminals.

Remove connector from rectifier-regulator. With engine running

at 3600 RPM, measure AC voltage across stator leads using
an AC voltmeter.

With engine stopped, measure the resistance across stator

leads using an ohmmeter.

With engine stopped, measure the resistance from each stator

lead to ground using an ohmmeter. shorted to ground).

If charge rate increases when load is applied, the charging

system is OK and battery was fully charged.

If charge rate does not increase when load IS applied, test stator

and rectifier-regulator (tests 2 and 3],

If voltage is 26 volts or more, stator is OK, Rectifier-regulator is

faulty. Replace the rectifier-regulator.

If voltage is less then 28 volts, stator is probably faulty and

should be replaced. Test stator further using an ohmmeter

(test 3).

If resistance is 0.1/0.2 ohms, the stator is OK.
If resistance is Oohms, the stator

is shorted. Replace stator,

If resistance is infinity ohms, stator is open, Replace stator.
If resistance is infinity ohms (no continuity), the stator is OK (not

If resistance (or continuity) is measured, the stator leads are

shorted to around. fleoiace stator.

PROBLEM: Battery Continuously Charges At High Rate
Test
With engine running at 3600 RPM, measure voltage from B+

lead to ground using a DC voltmeter.

Conclusion
If voltage is 14.7 volts or less the charging system is OK, The

battery is unable to hold charge. Service battery or replace
as necessary.

If voltage is more than 14.7 volts, the rectifier-regulator is

faukv. fleDlace rectifier-reaulator.

MAINTENANCE PROCEDURES

To avoid costly repairs and down-time, it is imperative to
develop and practice good maintenance procedures from the

beginning. These procedures fall into daily, weekly, monthly
and quarterly increments, and are outlined below. We have pro­vided a maintenance log for your convenience on next page; it
is recommended that you affix a copy of the log on the vehicle
door near your unit for convenience and to serve as a
maintenance reminder.

Daily

● Check engine oil level.

● Inspect garden hose screen - clean as needed.

● Visually inspect machine for loose wires, oil leaks, water leaks,

etc.

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

- clean, repair or replace as needed.

● Lubricate blower with LPS-1 or WD-40 through blower inlet.

Weekly

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

● Check engine air cleaner filter - clean as necessary.

● Check high pressure pump oil - add as necessary.

● Check drive coupler set screws - tighten as needed.

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

● Check pump pulleys - tighten as needed.

* Check fuel lines for wear/chafing.

● Check all nuts and bolts - tighten as needed.

● Check heater burner assy. union for tightnesslleaks.

● Clean vacuum tank thoroughly with high pressure washer.

● Flush water and chemical system with 50/50 white vinegar

solution.

● Check engine RPM’s - adjust to 2600 RPM’s at the pump.

Monthly

● Grease blower bearing fittings.

● Remove pressure bypass valve stem, grease cup and stem,

reinstall.

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

Quarterly

● Change oil in blower.

“ Check engine compression.

● Check for combustion chamber carbon deposit.

● Change spark plugs.

OVERALL CARE OF UNIT

MAINTAINING THE ORIGINAL APPEARANCE OF YOUR UNIT
IS IMPORTANT FOR TWO REASONS:

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

2. Maintenance, troubleshooting, and repair is much easier to ac­complish on a clean well maintained unit. Regular cleaning of
the machine offers you an opportunity to visually inspect all
facets of the machine and spot potential problems before they
occur.

FOLLOWING MAINTENANCE IS RECOMMENDED IN THE
MANUFACTURER AT THE FREQUENCY INDICATED,

After each job: Check recovery tank, s/s filter and filter bag as
required.

Daily: Wipe machine down thoroughly with a damp cloth; flush
recovery tank out thoroughly. Empty filter bag and inspect for rips,

tears, etc. - replace as needed; remove, throughly clean and

reinstall stainless steel filter screen in recovery tank; inspect and
clean vacuum slot on cleaning wand; check wand head for sharp
edges that could tear carpet - file down as needed; clean wand to

maintain original appearance; wipe down vacuum and high
pressure hoses as needed - visually inspect for cuts, etc.

Weekly: Wipe down entire unit as needed - apply good coat of
auto wax to all painted surfaces inside and out, and to control
panel; thoroughly clean recovery tank using high pressure hot
water (unit with optional high pressure cleaning gun may be used
for this); remove stainless steel filter in recovery tank, thoroughly
clean removing all lint build-up, inspect for damage and reinstall.

Remove filter bag, thoroughly clean and reinstall - if torn, replace;
empty chemical from chemical container, wash out thoroughly to
remove any chemical build-up; inspect chemical feed line strainer
and use 507. white vinegar/water solution to remove any chemical
build-up; thoroughly clean wand and inspect for clogged jet, debris
in vacuum slot and leaking fittings at valve. Apply light coat of auto
wax to wand thoroughly clean vacuum and high pressure hoses
including hose cuffs - inspect for wear or damage to hoses and
quick connect fittings. Inspect garden hose connectladapter
screen for debris, remove and clean thoroughly. Inspect all lines
for wear or abrasions that may cause possible leaks.

IMPORTANT: Record date and machine hours on maintenance
chart.

WA== INFORMATION

To avoid misunderstandings which might occur between machine
owners and manufacturer, we are listing causes of component
failure that specifically voids warranty coverage. Such causes as
listed below shall constitute abuse or neglect.

BLOWER: Failure to lubricate impellers daily with LPS-1 or
WD-40 lubricant. Failure to lubricate bearings as recommended in
blower manual. Failure to maintain proper oil levels in the blower,
Failure to use the correct oil grade and viscosity as recommended
in blower manual. Failure to properly maintain blower safeguard
systems such as waste tank filter screen,

valve in vacuum tank lid and waste tank automatic shut-off system.
Allowing foam to pass through blower.

HIGH PRESSURE WATER PUMP: Operation of pump at
pressures over 1200 PSI, Failure to maintain proper oil level as
recommended in pump manual. Failure to change oil in pump at
recommended intervals. Failure to protect pump against freezing.
Failure to maintain pump protection shut-off system. Failure to use
water softener in hard water areas. Use of improper chemicals.

VAC TANK: Failure to properly maintain filtering devices in tank.
Failure to clean tank as recommended by manufacturer. Failure to
maintain vacuum safety release in tank lid. Use of improper
chemicals.

CHEMICAL PROPORTIONER: Use of improper chemical. Failure
to use water softener in hard water area. Operating machine
without proper chemical filter screen. Failure to protect against
freezing.

CONTROL PANEL: Failure to protect flow meter and water

pressure gauge against freezing.

vacuum safety relief

VACUUM AND SOLUTION HOSES: Failure to protect hoses
against freezing. Failure to protect hoses against burns from
engine/blower exhaust. Damage to hoses from being run over by
vehicles. Kinking or cracking from failure to store or unroll hoses
correctly. Normal wear and tear from everyday use.

CLEANING WAND: Failure to protect against freezing. Obvious
physical abuse of wand.

WARRANTY PROCEDURE

Warranty coverage is available to you ONLY through HydraMaster
Corporation, 20309 64th Ave. West, Lynnwood, Washington

98036. When warranty parts are needed, write HydraMaster
Warranty Dept. at the above address, or call the Warranty/
Service Dept. at [phone]. No collect calls will be ac­cepted. Hours of Warranty/Service Dept. are 8:00 am to 6:00
pm Pacific Time.

IMPORTANT

HydraMaster’s warranty policy provides replacement parts without
charge for thirty (30) days to customers maintaining current
account status. An invoice dated thirty (30) days from date of
replacement parts shipment will be sent to the customer for the
amount of the parts sent. The customer’s faulty parts must be
returned for evaluation prior to the expiration of the thirty (30) day
period. Upon warranty approval, a credit will be issued the

customer for the replacement parts invoice. Warranty disap-

proval or failure to return the faulty parts within the thirty (30)
day period allowed will result in the customer being charged

for the replacement parts sent.

HydraMaster LIMITED WARRANTY

HydraMaster warrants products of its manufacture to be free
from defects

maintained, and operated under normal conditions with
competent supervision, No person, agent, representative or
dealer is authorized to gwe any warranties on behalf of
HydraMaster nor to assume for HydraMaster any other Ilabllity
in connechon with any of HydraMaster’s products, This war-

ranty shall extend for the periods listed by component below
from date of installation. If repairs or replacements are made by
the 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 f.o.b. point of shipment,

any parts or parts of products of HydraMaster’s manufacture,
which within 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,

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
of the defective part or parts as aforesaid, f,o, b. point of
shipment.

in material and workmanship if properly installed,

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, implied or statutory, and HydraMaster shall
have no liability for consequential, incidental or other damages,
howsoever caused,

ENGINE: (Thru original Manufacturer. )

VACUUM BLOWER: (Thru original Manufacturer.
See Cooper Industries warranty,)

VACUUM RECOVERY TANK/CHEMICAL MIX TANKS: 3 years
FRAME/COVER ASSEMBLIES:
HIGH PRESSURE PUMP (Thru original Manufacturer.

See Cat Pump warranty.)

HIGH PRESSURE BY PASS VALVE:
CHEMICAL PROPORTIONING SYSTEM:

INTERNAL MACHINE HOSE:
EXTERNAL VACUUM HOSE, SOLUTION HOSE,

2 years

3 years

1 year

90
90

1 year

days

days

QUICKCONNECTORS: 30 days

CLEANING WAND: (Except valve & jet assembly)

BELTS, FITTINGS, O-RINGS, FILTER SCREENS:
FILTER BAGS:

Freezing of any one water or chemical related component will
VOID all other imDlied warrantv on all water or chemical related
components, inte’rnal or exter; al, of this equipment,

Not Covered by Warranty

1 year

30 days