HYDRAMASTER SpitFire 4.0 User Manual
HYDRAMASTER
For machine parts lists, please call HydraMaster Customer Service at 1-425-775-7276
11015 47th Avenue W, Mukilteo, WA 98275
SpitFire 4.0
Corporation
Machine Serial Number:________________________
Copyright© 2000
HYDRAMASTER© Corporation
Mukilteo, Washington
D-182-031
No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or
electronic retrieval systems) without the express written permission of the HYDRAMASTER© Corporation. All rights
reserved.
Revised February 4, 2000
SpitFire 4.0
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11/24/98
HydraMaster Corporation
SpitFire 4.0
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Table of Contents
SpitFire 4.0
GENERAL INFORMATION .............................................................. Section 1
Telephone Numbers ............................................................. 1-2
Precautions ........................................................................ 1-3
System Operation ............................................................... 1-7
Machine Specifications ........................................................ 1-8
Spare Parts Recommendation ............................................... 1-10
Spare Parts List ......................................................... 1-10
Responsibilities ................................................................... 1-12
Vehicle Preparation ............................................................. 1-14
Installation Suggestions .............................................. 1-15
Local Water Precautions ...................................................... 1-19
Wastewater Disposal Advisory .................................... 1-21
Hard Water Map ........................................................ 1-23
Machine Assembly Parts (Standard) ...................................... 1-24
Machine Assembly Parts (With Exhaust Diverter) .................... 1-58
CLEANING AND CHEMICALS ........................................................ Section 2
pH Chart ............................................................................ 2-4
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OPERATING INSTRUCTIONS ......................................................... Section 3
Start Up ............................................................................ 3-1
Shut Down ......................................................................... 3-2
Exhaust Diverter System ..................................................... 3-3
FREEZE GUARD ................................................................................ Section 4
WATER AND CHEMICAL SYSTEM .........................................................Section 5
Water Flow and Diagrams Diagram ....................................................... 5-1
Bypass Valve Assembly ...................................................................... 5-5
Water System Troubleshooting .............................................................5-6
Chemical System Troubleshooting ...................................................... 5-16
HIGH PRESSURE PUMP ........................................................................Section 6
Pump Maintenance ............................................................................. 6-1
Service ............................................................................................ 6-3
Pump Troubleshooting ........................................................................ 6-6
CLEANING WAND ..............................................................................Section 7
Cleaning Wand Assembly Drawings and Parts Lists .................................. 7-1
VACUUM SYSTEM .............................................................................Section 8
Blower Troubleshooting ....................................................................... 8-3
Roots Blower Instruction Booklet
ENGINE INFORMATION ........................................................................Section 9
Engine Troubleshooting ....................................................................... 9-1
Operators Manual
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ELECTRICAL SYSTEM ........................................................................ Section 10
Wiring Schematic and Diagrams (Standard) .......................................... 10-2
Wiring Schematic and Diagrams (With Exhaust Diverter System) .............. 10-5
Electrical Troubleshooting .................................................................. 10-8
MACHINE MAINTENANCE ............................................................... Section 11
Daily, Weekly ................................................................................. 11-1
Monthly, Quarterly, De-scaling ......................................................... 11-2
Overall Maintenance ....................................................................... 11-4
Maintenance Logs
HOW TO ORDER PARTS .................................................................. Section 12
WARRANTY INFORMATION ............................................................. Section 13
Golden Guarantee
ACCESSORIES ............................................................................... Section 14
PRODUCT UPDATES ....................................................................... Section 15
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General Information
SpitFire 4.0
Section 1-1
his manual contains installation and operation instructions as well as information
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required for proper maintenance, adjustment and repair of this unit. Since the
first and most important part of repair work is the correct diagnosis of the problem,
component manual troubleshooting charts have been included for your convenience.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two functions to perform, the truckmounted carpet cleaning plant has many functions to
perform simultaneously.
• The engine has to run at a consistent RPM.
• The vacuum has to pull air and dirty water back from cleaning site.
• The water pump provides stable pressure at proper water flow for cleaning.
• The chemical has to be injected into the water stream at the right
concentration.
• The heating system must maintain proper heat.
• The vacuum tank must store dirty water until drained.
As you can see, it is not just a turnkey operation with one thing to worry about,
Does it start?
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WARNING
The manufacturer uses this symbol throughout the manual to warn of
possible injury or death.
CAUTION
This symbol is used to warn of possible equipment damage.
Hours Telephone Numbers
Monday - Friday (425) 775-7276 Parts
8:00 am to 5:00 P.M. (425) 775-7275 Service
PACIFIC STANDARD TIME (800) 426-4225 Parts / Service FAX
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Precautions
lthough this unit has been factory adjusted, it may require additional adjustments
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to achieve optimum performance, for instance altitude may require carburetor
adjustment and ambient temperatures may require heat control adjustment. When
required, consult an authorized representative.
CAUTION
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through
the van floor. Many vans have critical components mounted directly
below the van floor that could be damaged by a misplaced drill bit. (See
Product Support Bulletins 92102, 94062 and 94063 at the end of the
manual.)
CAUTION
ENGINE COOLING: Units employing internal combustion engines must
not be enclosed 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.
CAUTION
LEVEL OPERATION: During operation, van or trailer must be parked on
level ground not to exceed + or - 10 degrees. Failure to insure proper
leveling may prevent proper internal lubrication of engine, vacuum and/
or high pressure components.
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WARNING
MOVING PARTS: Never touch any part of the machine that is in mo-
tion. Severe bodily injury may result.
CAUTION
ACID RINSE AGENTS: The increased demand for “clear water” rinsing
results in the need for special care when using these acid based chemicals in your equipment. The negative side of these products is the
corrosive effects the acid can have on metals, including swivels, pumps,
heat exchangers, etc.
HydraMaster’s ClearWater Rinse has been formulated to protect vital components.
HydraMaster will not warranty parts that have been damaged from using unprotected
acid products that have obviously caused failures.
CAUTION
HARD WATER PROTECTION: Failure to take appropriate measures to
prevent scale build up can result in system failure and loss of warranty
on affected parts. Test the water in your immediate and surrounding
areas with hard water test strips. Assume all water obtained from wells
is hard. If you are operating in a “Hard Water Area” (3.5 grains or more
per gallon), use a water softening system.
CAUTION
FREEZE PROTECTION: There is often little warning before a cold spell.
Therefore, not protecting this equipment from freezing will result in costly
downtime. Placing an electric heater in the truck or parking the truck
indoors will help to insure against freezing, but should not be the primary
method of freeze protection.
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CAUTION
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel,
plastic or wood products) to come in contact with the exhaust system.
WARNING
HOT SURFACES: During the operation of this equipment, many sur-
faces on the machine will become very hot. When near the van for any
reason care must be taken not to touch any hot surface, such as heater,
engine, exhaust, etc.
WARNING
HEARING PROTECTION: The Occupational Safety and Health Adminis-
tration (OSHA) recommends the use of hearing protection when a technician is exposed to an average of 85 decibels (this is an average of
exposure over an 8 hour period). This equipment can produce 85 decibels to a distance of 10 feet. Please check with your local state agencies to see if OSHA standards apply to your application.
NO SMOKING: It is unsafe to smoke in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the
vehicle so that the fumes will be directed away from the job site. Do not
park where exhaust fumes can enter a building through open doors,
windows, air conditioning units or kitchen fans.
HydraMaster Corporation
WARNING
WARNING
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WARNING
TOXIC FUMES: Do not occupy the vehicle when the cleaning equip-
ment is operating. Toxic fumes may accumulate inside a stationary
vehicle.
WARNING
ENGINE EXHAUST: The engine exhaust from this product contains
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WARNING
PORTABLE GAS TANK: Never operate this machine with a portable
gas can inside the truck. Doing so increases the risk of a fire or explosion.
WARNING
PORTABLE PROPANE TANK: Do not use a portable tank inside of the
truck or van. It is dangerous and illegal in most states.
WARNING
TRANSPORTATION OF FUEL CONTAINERS: Transportation in a ve-
hicle of any vented fuel container that presently has or has ever contained a flammable liquid is strictly forbidden by HydraMaster Corporation and by federal and state regulation
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System Operation
he SpitFire heat exchanger system is a highly engineered cleaning plant designed
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by HydraMaster Corporation. The system utilizes a dynamic heating system com-
prised of three separate exhaust heat exchangers for capturing “free heat.”
The water flow is as follows:
Water is fed into the machine under tap pressure. It flows through one preheater and then is automatically combined with a cleaning solution as it enters
the mix tank. The solution is then picked up by the high pressure pump and
pressurized to the desired level. The water then splits flow, as demanded by the
technician. The majority of the water flows to the bypass valve assembly, then
back through the secondary exhaust heat exchanger, and back to the mix tank.
The water demanded by the technician flows from the water pump through the
primary exhaust heat exchanger then out to the cleaning tool.
When the cleaning solution reaches a preset high temperature, it is released
from the system and directed to the recovery tank. Then cool water enters the
system to regulate the temperature.
As there is no guess work in the manufacture of these highly advanced cleaning
plants, there must be none in preparing it to get the job done in the field. It is the
purpose of this manual to help you properly understand, maintain and service your
cleaning plant. Follow the directions carefully and you will be rewarded with years
of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this
equipment.
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Machine Specifications
Frame: 24" W x 33" L x 29" H
Steel with Baked-on Epoxy Finish
Weight: 370 lbs.
Engine: Vanguard 20 HP Briggs and Stratton
Pressurized Oil System
Spin-on Filter and Oil PSI Protection Switch
Ignition: Electronic, Keystart
Vacuum Blower: Roots 45 URAIJ
Chemical System: Electro-mechanical, Meter Controlled
Heating System: 1 Stainless Steel Exhaust Exchanger
1 Copper Shell and Tube Exchanger
1 Copper and Aluminum Block Exchanger
Instruments: Water Pressure Gauge, Liquid Filled, 0-1000 PSI
Hour Meter, Machine Runtime
Keyed Ignition, Start/Stop
Chemical Flowmeter, Clear Acrylic, 0-10 GPH
Vacuum Gauge
Temperature Gauge
Recovery Tank: 50 Gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel with Heat Shield
Replaceable Grip
Rebuildable Solution Valve
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High Pressure Hose: 4" High Temperature Lined/Vinyl Covered
Hose Rated to 1250 PSI
Vacuum Hose: 2" Reinforced, 12" Reinforced.
Standard Equipment: Machine Power Console
Full Instrumentation
Roots Vacuum Blower
TM
SpitFire
Vacuum Recovery Tank
Carpet Cleaning Wand
Chemical Jug
100 ft, 2" Vacuum Hose
10 ft, 12" Wand Whip Line
Water Heating Package
100 ft, Super Flex Solution Line
Battery Box
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket
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Spare Parts
owntime on the unit can be very expensive, because your truckmounted unit is
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capable of generating several hundred dollars per day. In order to minimize such
downtime, it is strongly recommended by the manufacturer that you purchase and
keep in your truck the parts listed below.
Parts Orders
To expedite your parts needs, please call your sales representative. In most in-
stances, he either stocks or has access to parts through a regional service center. If
further assistance is needed, contact the factory and coordinate your needs. If this
becomes necessary, always indicate the method of shipment you desire, i.e. UPS,
Blue Label, Air Freight, Air Express, etc.
HydraMaster Parts Dept. Phone.................. (425) 775-7276
HydraMaster Parts Dept. Toll Free Fax ......... 1-800-426-4225
Spare Parts List (078-100)
PART NO DESCRIPTION QTY
010-015 Belt, Gates AX31 1
049-014 Filter, Vanguard Oil 2
049-007 Filter, S/S Vacuum Pump 1
049-016 Filter, 4” Replacement Y 1
049-023 Screen, Garden Hose 1
049-012 Filter, Vanguard Air 1
049-030 Filter Bag, 92+ Truck Mount 2
052-050 Quick Connect, 440 Male 3
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PART NO DESCRIPTION QTY
052-051 Quick Connect, 440 Female 2
052-052 Quick Connect, 660 Male 1
052-053 Quick Connect, 660 Female 1
057-043 Gasket, Recovery Tank 1
074-003 Gauge, Hi PSI (0-1000) 1
074-013 Meter, Chemical Flow 1
078-015 Kit, Chemical Flowmeter 1
078-101 Kit, Seal & Spring Hi PSI 1
078-140 Kit, Hypro Seal 1
106-016 Plug, Vanguard Spark 2
106-045 Plug, HD4 Coupling - 1" OD x d” LG, EPDM 8
131-037 Wrap, Exhaust Insulation 1
157-001 Switch, Tethered Mercury 1
157-115 Mini-Rocker with Terminal 1
157-022 Switch, Relay 2
169-022 Valve, 12” Full Port 1
169-062 Valve, 4 Anti-Siphon 1
169-120 Valve, Chemical System 1
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Responsibilities
he Purchaser’s responsibilities are:
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Prior to arrival of unit, install s” exterior plywood flooring in the vehicle and cover it
with artificial turf.
CAUTION
In Dodge vans the fuel tanks are located directly against the floor.
Caution must be used when drilling any holes through the floor. (See
Product Support Bulletin 94062 at the end of this manual.)
To purchase heavy duty 42 - 60 amp hour battery and have the battery ‘slow’ charge
if new.
CAUTION
If the battery is not fully charged, damage can occur to the engine
charging regulator.
Reading of owner’s manual: It is the purchaser’s responsibility to read the unit
operation manual and to familiarize himself with the information contained therein.
Special attention should be paid to all Cautions and Warnings.
The Sales Representative’s responsibilities are:
ACCEPTANCE OF SHIPMENT:
1. If the 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.
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2. The salesman from whom you purchased your unit is responsible for super
vising the correct installation of the unit in your vehicle and thoroughly
training you in its operation, maintenance and precautions.
CORRECT INSTALLATION INCLUDES:
• Vehicle of proper load carrying capacity (recommendation: ½ ton).
• Installation of through-floor fittings for gasoline fuel lines.
• Placing the unit and recovery tank in your vehicle and securing them
with bolts or tie down cleats.
• Connecting gasoline lines.
• Connecting the battery.
• Checking the pump, vacuum blower and engine oil levels prior to
staring the unit.
• Starting the unit to check the engine and see that all systems
function normally.
• Checking all hoses, wands, etc. for correct operation.
TRAINING:
• A thorough review of the operation manual with purchaser
• Instruction and familiarization in: how to correctly start up and shut down
the unit, how to correctly clean with the unit, where and how often to
check and change component oil levels, how the unit’s systems work,
how to troubleshoot the unit, how to do basic repairs, safety precautions
and their importance, freezing damage and how to avoid it, hard water
damage and how to avoid it;
• A thorough review of the unit warranty and warranty procedures.
• A thorough review of hard water precautions and warnings.
• How to determine hard water areas.
• Use of water softening systems.
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Vehicle Prep
hen selecting a truck, remember the preferable vehicle for a SpitFire 4.0
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ton capacity. If a fresh water tank is added, a three quarter ton or larger capacity
van, with a 2,400 pound payload capacity, is required.
TRUCK PREPARATION
The manufacturer recommends the installation of plywood flooring, covered with
polypropylene backed Astroturf (do not use rubber-backed), in the vehicle prior to
installation of machine.
installation is a cargo van with a heavy-duty suspension package and a half
CAUTION
Be cautious when drilling any holes through the van floor. Many vans
have critical components mounted directly below the van floor that
could be damaged by a misplaced drill bit. (See Product Support Bulletin
94062 at the end of this manual.)
This provides ‘metal to wood’ mounting rather than ‘metal to metal’, provides insulation and makes an attractive van interior. Astroturf should be color-keyed to the van
interior. See Figure 1-1 for correct placement of the plywood flooring.
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Materials Needed:
1. Two sheets of 4 x 8 x s” exterior plywood
2. One 6' x 12' piece of commercial Astroturf
3. Sixteen 12” sheet metal screws
4. One quart marine adhesive (optional)
5. One staple hammer with 2” staples
PLACEMENT OF UNIT IN VEHICLE
There are two recommended unit placements:
SIDE DOOR:
Most installations are side door. This provides rear access for accessories and
hoses as well as unobstructed access to the component/working side of the machine, thus making it a bit easier to perform maintenance and/or repair without
removing the unit from the truck.
REAR DOOR:
Although this location partly limits working access, it does direct the noise away
from the cleaning site. Some cleaners in the colder areas prefer this location
because it puts the weight over the rear wheels for better traction in ice and
snow. Rear mounting requires the unit to be slid to the right side as far as possible. This not only provides adequate working space on the component side of the
unit but also improves weight distribution inside the van (engine and component
weight line up over drive shaft). Also, it is physically easier to load the unit into
the rear door due to the height of the van bed.
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Figure 1-3 Recommended Placement
Machine Tie Down Cleats
Secure the machine to the floor of the van with the four tie down cleats provided.
This safety measure will ensure that the machine will not slide inside the van. See
the following illustration for the correct installation.
Figure 1-4 Installation using Tie-down Cleats
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Ensure that the machine is well secured to the floor of the van with the
hardware supplied. A sudden or crash stop will cause the machine to
rocket forward! Protect yourself and the machine. SECURE IT!
WARNING
It is recommended by the manufacturer that the exhaust from the front
of the machine be vented down under the truck to prevent carbon
monoxide from entering the job site. Always park the truck so the
exhaust is blowing away from the job site.
The manufacturer also recommends the installation of aluminum vents
in the truck roof to allow heat to escape..
WARNING
Never operate this machine with a portable gas can inside the truck.
Doing so increases the risk of a fire or explosion.
Mount a fire extinguisher just inside the rear or side door for emergencies
WARNING
Do not use a portable propane tank inside of the truck or van. It is
dangerous and illegal in most states.
WARNING
Transportation in a vehicle of any vented fuel container that presently
holds or has ever held a flammable liquid is strictly forbidden by HydraMaster Corporation and by federal and state regulation.
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WARNING
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
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Local Water Precautions
SpitFire 4.0
Section 1-19
he quality of water varies greatly. Many areas have an excess of minerals in the
water which results in what is commonly called “hard water.” These minerals
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tend to adhere to the insides of heater coils and other parts of the machines causing
damage and a loss of cleaning effectiveness. This influences the reliability and efficiency of equipment in direct proportion to the level of hardness.
HARD WATER ADVISORY
HydraMaster recognizes that any hard water deposits which might occur within the
water system of our truckmounts is a serious problem. The precision technology of
truckmount heat exchanger systems is intolerant of any foreign material. Hard water
deposits will ultimately decrease the performance of the system and are expected to
seriously lower the reliability of the machine.
To validate a machine’s warranty, HydraMaster requires that all machines operating in
designated ”Hard Water Areas” (3.5 grains or more per gallon) be fitted with a water
softening system or a properly installed magnetic-type de-scaler must be used and
maintained. Periodic de-scaling or acid-rinsing alone is not adequate in these areas.
HydraMaster does not recommend any particular type or brand, however the relative effectiveness of some types of magnetic de-scalers or softeners may require
additional periodic use of de-scaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all
areas be fitted with a water softening system for improved operation and reliability.
HydraMaster has included five hard water test strips with your machine. These
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can be used to test the water in your immediate and surrounding areas as they can
vary greatly. Assume all water obtained from wells is hard.
CAUTION
Failure to take appropriate measures to prevent scale build up can
result in system failure and loss of warranty on affected parts.
HARD WATER AREA MAP
The following map defines areas in the United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water cooled
engines. For other countries, hard water area maps can be obtained from geological
societies.
WATER SOFTENER
Cleaning efficiency and equipment life is increased, chemical use decreased, and
the appearance of cleaned carpets enhanced when water softeners are incorporated in hard water areas. The manufacturer strongly urges the use of water softener units in areas exceeding 32 grains per gallon. Failure to use a water softener in
these areas will invalidate the machine’s warranty. Using a hard water area map as
a reference, determine the quality of water in your area and take action immediately, if necessary.
Reports from several of our machine users commending the results of the use of
water softeners in conjunction with their machines prompts us to recommend the
procedure to everyone in a “hard water” area.
The relatively low cost of a water softener service is more than made up for by an
increased life of machine parts, reduced chemical costs and continued cleaning
efficiency. The water softener will also increase the effectiveness of the cleaning
chemicals, therefore less chemical will be needed.
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Contact a water softener distributor in your area for information on the rental of a
simple water treatment unit to carry in your truck. Be sure to change the water
softener in accordance with the capability of the softener. For example: If the
softener will treat 900 gallons of water and the machine uses an average of 30
gallons per hour, for an average of 5 hours a day, this equals 150 gallons per day. In
6 days the machine would use 900 gallons of water. Therefore, the softener would
need to be changed every 6 working days for maximum softening.
WASTE WATER DISPOSAL ADVISORY
There are laws in most communities prohibiting the dumping of recovered “gray”
water from carpet cleaning in any place but a sanitary treatment system.
This cleaning rinse water, recovered into your unit’s vacuum tank, contains materials such as detergents. These must be processed before being safe for streams,
rivers and reservoirs.
IN ACCORDANCE WITH THE EPA, STATE AND LOCAL LAWS, DO
NOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS,
STREAMS, RESERVOIRS, ETC.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after first filtering out solid material such as
carpet fiber. Access to the sanitary system can be obtained through a toilet, laundry
drain, RV dump, etc. Permission should first be obtained from any concerned party
or agency.
One disposal method which usually complies with the law is to accumulate the
waste water and haul it to an appropriate dump site. Another solution to the disposal problem is to equip yourself with an Automatic Pump-Out System. These
systems are designed to remove waste water from the extractor’s recovery system
and actively pump the water through hoses to a suitable disposal drain. Properly
designed, they will continuously monitor the level of waste water and pump it out
simultaneously to the cleaning operation.
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The hidden benefit of this process is that the technician does not have to stop his
cleaning to empty the recovery tank. HydraMaster makes an A.P.O. System available which can be ordered with new equipment or installed later.
The penalties for noncompliance can be serious. Always check local laws and
regulations to be sure you are in compliance.
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Cleaning and Chemicals
SpitFire 4.0
Section 2-1
our mobile carpet cleaning plant has been engineered using the latest and most
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sophisticated technology available to produce the finest carpet cleaning results
possible. Despite this, however, it remains only a tool of the carpet cleaning trade,
and it can produce only as good a job as the person operating it.
PRECAUTIONS
There are no short cuts to good carpet cleaning. It requires time, cleaning knowledge and the use of good chemicals. Therefore, the manufacturer recommends the
use of spotting agents and traffic lane cleaners, as required, prior to the actual
cleaning of carpeting.
The use of some chemicals through your mobile carpet cleaning plant can seriously
damage the internal plumbing, high pressure pump and heater. These harmful
chemicals include concentrated acid (see the pH chart at the end of this section),
solvents, and some paint, oil, and grease removers with a high concentration of solvents.
The manufacturer recommends only the use of chemicals containing rust and corrosion inhibitors and water softening agents to prevent chemical buildup which may
lead to component failure and warranty invalidation.
CAUTION
The increased demand for “clear water” rinsing results in the need for
special care when using these acid based chemicals in your equipment.
The negative side of these products is the corrosive effects the acid
can have on metals, including swivels, pumps, heat exchangers, etc.
HydraMaster Corporation
7/29/97
1/1/01
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