Titan 875
Owner’s Manual
HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-33180 Rev. 0 March 23, 2012
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 HydraMaster. Specications and information in this document are
subject to change without prior notice.
(182-077-D)
All rights reserved. © 2012 HydraMaster
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i: Titan 875 Owner’s Manual
Titan 875 Owner’s Manual: ii
Table of Contents
GeNeRAL INFORMATION ...........................................................................SeCTION 1
System Concept ...................................................................................... 1-3
Contact Information ................................................................................. 1-4
Warnings, Cautions and Notices ............................................................. 1-5
Responsibilities .......................................................................................1-9
Machine Specications ...........................................................................1-12
Spare Parts List.......................................................................................1-14
High Altitude Operation ...........................................................................1-15
Local Water Precautions .........................................................................1-15
INSTALLATION INFORMATION ..................................................................SeCTION 2
Fuel Pump Installation Guidelines...........................................................2-1
Operating the Titan 875 In Hot Weather .................................................2-4
Setting Up the Titan 875..........................................................................2-7
CLeANING AND CHeMICALS .....................................................................SeCTION 3
Preparing the Carpet for extraction.........................................................3-2
Rinse and Recover..................................................................................3-3
Overwetting .............................................................................................3-3
Streaking .................................................................................................3-3
Cleaning Tool Tips ...................................................................................3-4
Severe Cleaning Situations ..................................................................... 3-9
MACHINe MAINTeNANCe ..........................................................................SeCTION 4
Operational Maintenance ........................................................................4-2
Overall Machine Maintenance.................................................................4-5
engine Maintenance ...............................................................................4-6
High Pressure Pump Maintenance .........................................................4-10
Vacuum System Maintenance .................................................................4-19
Descaling Procedure (Required) ............................................................. 4-20
Freeze Guarding .....................................................................................4-21
OPeRATING INSTRUCTIONS .....................................................................SeCTION 5
Start-Up Procedure .................................................................................5-3
Shut-Down Procedure ............................................................................. 5-5
Setting the Temperature ..........................................................................5-7
Machine Safeties.....................................................................................5-8
WATeR AND CHeMICAL SySTeM .............................................................SeCTION 6
Water and Chemical Flow Operation ......................................................6-1
iii: Titan 875 Owner’s Manual
eLeCTRICAL SySTeM ................................................................................SeCTION 7
TROUbLeSHOOTING .................................................................................SeCTION 8
Heating System ....................................................................................... 8-2
Chemical System ....................................................................................8-3
engine .....................................................................................................8-4
High Pressure System
Vacuum System
......................................................................................8-9
............................................................................8-7
MACHINe ASSeMbLIeS AND PARTS LISTS .............................................SeCTION 9
Machine Assembly Parts List ..................................................................9-6
Frame Assembly Parts List
.....................................................................9-9
engine Assembly Parts List.....................................................................9-13
Solenoid Assembly Parts List ..................................................................9-14
Idler Pulley Tensioner Assembly Parts List ............................................. 9-15
blower Assembly Parts List .....................................................................9-18
Air Actuator Assembly Parts List ............................................................. 9-19
Pump and Silencer Assembly Parts List ................................................. 9-20
Pump Assembly Parts List ......................................................................9-23
exhaust Assembly Parts List ...................................................................9-25
blower Heat exchanger Assembly Parts List .......................................... 9-28
Coolant Heat exchanger Assembly Parts List.........................................9-30
Lower Instrument Panel Assembly Parts List ..........................................9-34
PSI Regulator Valve (0 - 3,200 psi) Assembly Parts List ........................9-35
Orice Manifold Assembly Parts List .......................................................9-36
Hi Pressure Out Manifold Assembly Parts List........................................ 9-37
3-Way Valve Assembly Parts List ............................................................ 9-38
2-Way Valve Assembly Parts List ............................................................ 9-39
Water box 8 Gallon Assembly Parts List .................................................9-41
Diffuser Assembly Parts List ...................................................................9-42
Upper Dash Assembly Parts List.............................................................9-43
Dash Gauge Panel Assembly Parts List ................................................. 9-45
Grill Assembly Parts List .........................................................................9-46
electrical Panel Assembly Parts List ....................................................... 9-48
Catalytic Cover Assembly Parts List
.......................................................9-50
Top Cover - Machine Assembly Parts List...............................................9-52
Left Side Cover - Machine Assembly Parts List
...................................... 9-53
Right Side Cover - Machine Assembly Parts List ....................................9-54
100 Gallon Universal Recovery Tank Assembly Parts List ......................9-56
100 Gallon Universal Recovery Cover Tank Assembly Parts List
Vacuum Relief Valve Assembly Parts List
...............................................9-59
........... 9-58
Machine Hose Routings ..........................................................................9-60
Titan 875 Owner’s Manual: iv
HOW TO ORDeR PARTS ............................................................................SeCTION 10
Warranty Parts Orders ............................................................................10-1
Parts Orders ............................................................................................ 10-1
emergencies ...........................................................................................10-1
WARRANTy INFORMATION .......................................................................SeCTION 11
blower ....................................................................................................11-2
High Pressure Water Pump ...................................................................11-2
Vacuum Tank
Chemical System
Control Panel
Vacuum and Solution Hoses
.......................................................................................... 11-2
...................................................................................11-2
.........................................................................................11-2
.................................................................. 11-3
Cleaning Wand .......................................................................................11-3
Water Heating System
Hard Water Deposits
...........................................................................11-3
..............................................................................11-3
Warranty Procedure ................................................................................11-3
ACCeSSORIeS AND CHeMICAL SOLUTIONS ..........................................SeCTION 12
v: Titan 875 Owner’s Manual
List of Figures
Figure 1-1. Hard Water Map of Continental United States ..........................................1-16
Figure 2-1. Fuel Pump Diagram ....................................................................................2-2
Figure 2-2. Location of Roof Vents in Vehicle ...............................................................2-3
Figure 2-3. Recommended Location of Titan 875 in Van ..............................................2-5
Figure 4-1. Remove Valve Cap and Valve Assembly .................................................4-11
Figure 4-2. Inspect Manifold and Old Valves .............................................................4-11
Figure 4-3. Replace Center Inlet Check Valve With Modied Check Valve .............. 4-12
Figure 4-4. Apply Grease and Install Valves .............................................................. 4-12
Figure 4-5. Replace Valve Cap and Torque to 95 ft lbs .............................................4-12
Figure 4-6. Separate Manifold from Crankcase......................................................... 4-13
Figure 4-7. Seal Assemblies May Come Off with Manifold ........................................ 4-13
Figure 4-8. examine Ceramic Plungers..................................................................... 4-13
Figure 4-9. Remove Stainless Steel Plunger bolt and Ceramic Plunger ................. 4-14
Figure 4-10. Install O-ring, Apply Sealant and Slide Plunger over Plunger Guide .... 4-14
Figure 4-11. extract Retainers and Seals ..................................................................4-15
Figure 4-12. Seal Kit and Insertion Tool for Seal Installation ..................................... 4-16
Figure 4-13. Install Seal Assembly Using O-Ring Grease ......................................... 4-16
Figure 4-14. Install Retainers into Cavities ................................................................ 4-17
Figure 4-15. Press Low Pressure Seal Assembly into Cavity.................................... 4-17
Figure 4-16. Re-install Manifold and Torque Fasteners ............................................. 4-18
Figure 4-17. Torque Sequence in “X” Pattern ............................................................ 4-18
Figure 4-18. Torque bolts to 22 ft lbs ......................................................................... 4-18
Figure 4-19. Recirculation Fitting............................................................................... 4-20
Figure 5-1. Titan 875 Upper Dash Assembly .................................................................5-1
Figure 5-2. Titan 875 Lower Dash Assembly .................................................................5-2
Figure 5-3. blower Port Located on Lower Dash Assembly ..........................................5-5
Figure 5-4. Set Heat Selector Valve ..............................................................................5-7
Figure 5-5. Rotate Thermostat Dial and Select engine rpm ..........................................5-7
Figure 6-1. Flow Diagram - View 1 of 3 .........................................................................6-3
Figure 6-2. Flow Diagram - View 2 of 3 .........................................................................6-4
Figure 6-3. Flow Diagram - View 3 of 3 .........................................................................6-5
Titan 875 Owner’s Manual: vi
Figure 7-1. electrical Schematic ....................................................................................7-2
Figure 7-2. Wiring Diagram - View 1 of 3
Figure 7-3. Wiring Diagram - View 2 of 3
Figure 7-4. Wiring Diagram - View 3 of 3
......................................................................7-3
......................................................................7-4
......................................................................7-5
Figure 7-5. Schematic of Wire Harness -
Fuel Pump Manifold to Machine - View 1 of 2 ....................................................7-6
Figure 7-6. Schematic of Wire Harness -
Fuel Pump Manifold to Machine - View 2 of 2 ....................................................7-7
Figure 9-1. Machine Assembly - View 1 of 4 .................................................................9-2
Figure 9-2. Machine Assembly -View 2 of 4 ..................................................................9-3
Figure 9-3. Machine Assembly - View 3 of 4 .................................................................9-4
Figure 9-4. Machine Assembly -View 4 of 4 .................................................................9-5
Figure 9-5. Frame Assembly - View 1 of 2 ....................................................................9-7
Figure 9-6. Frame Assembly - View 2 of 2 ....................................................................9-8
Figure 9-7. engine Assembly - View 1 of 3 ..................................................................9-10
Figure 9-8. engine Assembly - View 2 of 3 ..................................................................9-11
Figure 9-9. engine Assembly - View 3 of 3 ..................................................................9-12
Figure 9-10. Solenoid Assembly ..................................................................................9-14
Figure 9-11. Idler Pulley Tensioner Assembly ..............................................................9-15
Figure 9-12. blower Assembly - View 1 of 2 ................................................................9-16
Figure 9-13. blower Assembly - View 2 of 2 ................................................................9-17
Figure 9-14. Air Actuator Assembly .............................................................................9-19
Figure 9-15. Pump and Silencer Assembly .................................................................9-20
Figure 9-16. Pump Assembly - View 1 of 2 .................................................................9-21
Figure 9-17. Pump Assembly - View 2 of 2 .................................................................9-22
Figure 9-18. exhaust Assembly ...................................................................................9-24
Figure 9-19. blower Heat exchanger Assembly - View 1 of 2 .....................................9-26
Figure 9-20. blower Heat exchanger Assembly - View 2 of 2 .....................................9-27
Figure 9-21. Coolant Heat exchanger Assembly.........................................................9-29
Figure 9-22. Lower Instrument Panel Assembly - View 1 of 3 .....................................9-31
Figure 9-23. Lower Instrument Panel Assembly - View 2 of 3 .....................................9-32
Figure 9-24. Lower Instrument Panel Assembly - View 3 of 3 .....................................9-33
Figure 9-25. PSI Regulator Valve (0 - 3,200 psi) Assembly .......................................9-35
Figure 9-26. Orice Manifold Assembly .......................................................................9-36
Figure 9-27. Hi Pressure Out Manifold Assembly........................................................9-37
Figure 9-28. 3-Way Valve Assembly ............................................................................9-38
Figure 9-29. 2-Way Valve Assembly ............................................................................9-39
vii: Titan 875 Owner’s Manual
Figure 9-30. Water box 8 Gallon Assembly .................................................................9-40
Figure 9-31. Diffuser Assembly ...................................................................................9-42
Figure 9-32. Upper Dash Assembly.............................................................................9-43
Figure 9-33. Dash Gauge Panel Assembly .................................................................9-44
Figure 9-34. Grill Assembly .........................................................................................9-46
Figure 9-35. electrical Panel Assembly .......................................................................9-47
Figure 9-36. Catalytic Cover Assembly .......................................................................9-49
Figure 9-37. Top Cover - Machine Assembly ...............................................................9-51
Figure 9-38. Left Side Cover - Machine Assembly ......................................................9-53
Figure 9-39. Right Side Cover - Machine Assembly ....................................................9-54
Figure 9-40. 100 Gallon Universal Recovery Tank Assembly ......................................9-55
Figure 9-41. 100 Gallon Universal Recovery Tank Cover Assembly ...........................9-57
Figure 9-42. Vacuum Relief Valve Assembly ...............................................................9-59
Titan 875 Owner’s Manual: viii
1- General Information
The Titan 875 truckmount carpet cleaning and restoration machine is powered by the 61
HP GM 4-cylinder, fuel injected engine and the Tuthill Competitor Plus™ 5009 Tri-Lobe
dual oil bath blower.
For superior carpet and upholstery cleaning, the Titan 875 provides temperatures up
to 270° F at 1,200 psi *. It also provides non-heated pressure washing at 3,000 psi for
cleaning hard surfaces.
* Patented Heat exchanger System - U.S. Patent No. 8,032,976
1-1: General Information
The Titan 875 also features:
a simple 3-panel maintenance access•
keyless ignition•
last-step chemical injection which reduces scale buildup •
Standard equipment includes:
100 Gallon MaxAir™ Recovery Tank
•
5 gallon chemical jug•
150 ft long, 2” diameter vacuum hose•
150 ft long, 1/4” diameter solution hose•
Optional pieces of equipment available are:
Dura-Flow™ Automatic Pump Out (APO)
•
2.5” adaptor kit for triple wand capability•
It is the purpose of this manual to help you properly understand, maintain and service
the Titan 875. by following these guidelines carefully, you can expect years of reliable
operation.
Other topics covered in this section of the manual are:
Contact Informatio n
Warnings, Cautions and Notice s
Responsibilitie s
Machine Specication s
Spare Parts Lis t
High Altitude Operatio n
Local Water Precaution s
General Information: 1-2
sysTeM cOncepT
The Titan 875’s system utilizes an internal combustion engine to provide the power
necessary to turn both the vacuum blower and the high pressure water pump.
The heat from the engine and blower exhausts is transferred to the high pressure water
in the nned tube heat exchanger and copper tube and shell of the system. Finally, the
chemical is injected into the pressurized water stream and the heated solution is delivered
to the cleaning tool.
Solution is recovered by the vacuum generated by the vacuum blower and is collected in
the recovery tank for proper disposal.
water Box
water
pump
engine
silencer
Vacuum
Blower
Finned Tube
heat exchanger
1-3: General Information
cOnTacT InFORMaTIOn
If you have any questions regarding the operation, maintenance or repair of this machine,
please contact your local distributor.
To nd a local distributor, please visit our website at
http://hydramaster.com/HowTobuy/DealerLocator.aspx
If your question cannot be resolved by your distributor or by the information within
the Owner’s Manual, you may contact HydraMaster direct using the following phone
numbers.
hOuRs TeLephOne nuMBeRs e-MaIL aDDResses
Monday-Friday
Technical support
(425) 775-7275
FAX : (800) 426-4225
techsupport@hydramaster.com
Technical support
7:00 a.m. to 5:00 p.m.
Pacic Standard Time
customer service/parts
(425) 775-7276
FAX: (425) 771-7156
customer service/parts
parts@hydramaster.com
When calling your distributor, be sure to reference the serial number and date of
purchase.
FOR yOUR ReFeReNCe:
Serial No. ____________________________________________________
Date of Purchase: _____________________________________________
Purchased From (Distributor): ____________________________________
General Information: 1-4
waRnIngs, cauTIOns anD nOTIces
HydraMaster uses this WARNING symbol throughout the manual to warn of
possible injury or death.
This CAUTION symbol is used to warn of possible equipment damage.
This NOTICe symbol indicates that federal or state regulatory laws may apply,
and also emphasizes supplemental information.
1-5: General Information
Warnings and Cautions specic to the Titan 875 include the following:
During the operation of the truckmount many components are in motion. Never
touch any part of the truckmount that is in motion. Serious injury may result.
During the operation of the truckmount many surfaces will become extremely hot.
Never touch hot surfaces. Serious injury may result.
The operation of this truckmount can produce noise levels exceeding 85 decibels
to a distance of 10 ft. The Occupational Safety and Health Administration (OSHA)
recommends the use of hearing protective equipment if a person is exposed
to an average of 85 decibels over an 8-hour period. Check with local and state
agencies concerning hearing conservation rules.
During the operation of the truckmount carbon monoxide and other toxic fumes
are produced. Position the vehicle so that any fumes produced will be directed
away from inhabited areas and any points of building entry (doors, windows, air
conditioning units, fans, etc.). Do not occupy the vehicle while the truckmount is
in operation. Serious injury may result.
During the operation of the truckmount, chemicals known to the State of California
to cause cancer, birth defects and other reproductive harm are produced by the
engine exhaust.
Never operate the truckmount with a portable gas container inside the vehicle.
Doing so will increase the risk of re and explosion. Serious injury or death may
result.
General Information: 1-6
Transporting a vented fuel container that presently contains, or has ever contained
in the past, a ammable liquid is strictly forbidden by HydraMaster and by federal
and state regulations. Doing so will increase the risk of re and explosion. Serious
injury or death may result.
Never smoke in or around the truckmount. Doing so will increase the risk of re
and explosion. Serious injury or death may result.
During the operation of the truckmount the exhaust system will become extremely
hot. Keep all ammable materials away from the truckmount exhaust system.
Failure to do so will increase the risk of re and explosion. Serious personal injury
and property damage may result.
Never operate the truckmount when the vehicle is tilted more than 10 degrees in
any direction. Doing so will result in improper lubrication of the internal components,
and will increase the risk serious component or engine damage.
Never perform cleaning operations when the truckmount engine is running at the
IDLe throttle position. Failure to do so will increase the risk of serious component
or engine damage.
Never operate the truckmount with the vehicle doors closed. Doing so results in
extremely high temperatures inside the vehicle and will lead to serious component
or engine damage.
Never use concentrated acids or solvents (including d-limonene) in the truckmount
water system or chemical system. Use of these products will cause serious
component damage.
1-7: General Information
Never operate the truckmount with a water hardness reading measuring 3.0
grains per gallon or higher. Using reading than 3.0 grains per gallon will cause
scale to build up inside the truckmount water system. Scale build up causes
serious component damage. Test all water prior to use and use water softening
equipment if necessary.
Never allow water to freeze inside the truckmount. Serious component damage
will occur. Perform all freeze guarding procedures as outlined in Section 4 of this
Owner’s Manual.
Many vehicles have critical components mounted directly below the oor that
can easily be damaged. Before drilling holes in the oor of the vehicle inspect
the underside of the vehicle for critical components. Failure to do so may result
in damage to the vehicle.
Use of the vacuum recovery system when stripping or otherwise removing wax
from oors is specically excluded as an approved use of the truckmount. Failure
to follow this exclusion may lead to component failure and will invalidate your
warranty.
Use of the vacuum recovery system for “dry cleaning”, without corresponding
solution application (i.e. duct cleaning), is specically excluded as an approved
use of the truckmount. Failure to follow this exclusion may lead to component
failure and will invalidate your warranty.
If concentrated acids or solvents are used to pre-treat surfaces before power
washing, do not recover them through the vacuum system. Failure to follow this
exclusion may lead to component failure and will invalidate your warranty.
General Information: 1-8
RespOnsIBILITIes
purchaser’s Responsibilities
Prior to purchasing a van, ensure that the payload is suitable for all of the equipment •
that will be installed and transported. This includes and is not limited to: the truckmount,
recovery tanks, fresh water tanks, on-board water, hose reels, hoses, cleaning tools,
chemicals and drying equipment. Payload capacity information is available through
the auto dealer, the manufacturer’s web site, and is also located on the door pillar of
the driver’s side door.
Purchase a heavy duty Group 24 (500+ CC Amps) battery for this truckmount. This is
•
normally available from the installation dealer.
Prior to dropping your van off at the distributor for the truckmount to be installed, have
•
a spray-on bed liner applied to the oor such as Rhino Lining® or Line-X®.
Plywood and carpet are not recommended.
Prior to operating the truckmount, read this manual in its entirety and familiarize •
yourself with the information contained here. Special attention should be paid to all
Warnings and Cautions.
The distributor is responsible for the correct installation of the truckmount. The
•
distributor is also responsible to train you in the correct and proper operation and
maintenance of the truckmount.
Any modication of the truckmount may void the warranty.
1-9: General Information
Distributor’s Responsibility
Acceptance of Shipment
before accepting the truckmount, check the following:
The truckmount should be free from any damage during shipping. Do not sign the 1.
delivery receipt until you have closely inspected the truckmount and noted any
damage on the delivery receipt. Hidden damage may be present even if the box looks
okay. It is recommended that the box be opened before you sign for the shipment.
Check the packing list and verify that all items are accounted for.
2.
Installation Responsibilities
ensure proper payload capacity. It is the distributor’s responsibility to verify that the •
equipment package does not exceed the vehicle capacity.
Ensure installation of a safe fuel tap system and through-oor ttings as provided by
•
HydraMaster.
ensure proper placement of the truckmount, recovery tank, fresh water tank, and •
accessories in the vehicle, and check that they are secured with bolts and back up
plates. The distributor should verify that the owner is in agreement with the layout.
ensure proper connection of the fuel lines.•
ensure proper connection and installation of the battery. Verify that the battery is in •
accordance with HydraMaster’s recommendation.
Check the pump, vacuum blower and engine oil levels prior to starting the
•
truckmount.
Start and run the truckmount and check that all systems function properly.
•
Test all hoses, wands and other accessories for correct operation.•
ensure timely return of the document package.•
General Information: 1-10
Training
The distributor should provide a thorough review of the operation manual with the
purchaser along with instruction and familiarization in:
How all the truckmount’s systems function.
1.
All safety precautions and their importance.2.
How to correctly start and shut down the truckmount.3.
How to correctly clean with the truckmount.4.
Where and how often to check and change component oil levels.5.
Freezing damage and how to avoid it. This includes explaining proper freeze 6.
guarding procedures.
How to do basic troubleshooting of the truckmount.
7.
Hard water damage and how to avoid it. This includes how to determine if hard 8.
water exists in your area and the installation and use of water softening systems.
The truckmount’s warranty and warranty procedures.
9.
1-11: General Information
MachIne specIFIcaTIOns
Overall Dimensions
22" W x 29" D x 29" H
(Console Only)
Weight 1,187 lbs.
engine - GM, 1.6L, 4
Cylinder eFI, 61 HP
Oil Type 10W-30 (Synthetic not
recommended)
Capacity Approx. 4 quarts (128 oz.)
when changing oil and lter
engine rpm High 2,700 rpm
Mid 2,500 rpm
Low 2,150 rpm
Vacuum blower- Tuthill
5009 Competitor Plus SL
Oil Type PneuLube™ or other ISO 100
rating
(Dual Splash Lubrication)
Gear end Capacity Approx. 9.6 oz.
Drive end Capacity Approx. 7 oz.
blower rpm 2,250 rpm
Pump- General Pump Oil Type 15W-40
Capacity Approx. 40 oz.
Pump Rate 5.5 gallons per minute
Pump rpm 1,450 rpm
Operating Pressure 0-1,200 psi (heated) 0-3,000 (no heat)
Chemical System Last Step Chemical
Injection
Heating System Finned Tube Heat
Copper Tube and Shell
exchanger
General Information: 1-12
Standard equipment High Pressure Hose 1/4" High Temperature Lined/
Vinyl Cover - 150 ft.
Vacuum Hose 2" Vacuum Hose - 150 ft.
1-1/2" Wand Whip Line - 10 ft.
Recovery Tank 100 gallon MaxAir Universal
Tank
Cleaning Wand Stainless Steel S-bend
Replaceable Grip
Rebuildable Solution Valve
Chemical Jug 5 gallon
battery box
Van Decal
Van Installation Kit
Owner’s Manual
(on CD)
Owner’s Guide
(printed)
Optional equipment Third Wand Adapter for
Recovery Tank
Automatic Pump Out
(APO)
2.5 Vacuum Port
(P/N 000-078-875)
Dura-Flow APO
(P/N 000-079-091)
Thru Floor exhaust 4” Thru Floor exhaust Kit
(P/N 000-079-129)
Pressure Washing Pressure Wash Kit
(P/N 000-079-123)
1-13: General Information
spaRe paRTs LIsT
part no. Description Qty
engine and Drivetrain Components
000-106-125 Plug, Spark 4
000-049-097 Filter, Fuel 1
000-049-250 Filter, Oil 1
000-049-251 Filter, Primary Air 1
000-049-252 Filter, Secondary Air 1
000-010-127
000-010-128
000-010-129
000-010-134
belt, 3VX464 Super HC 4
belt, HD 9330 2
belt, Timing 1
belt, Alternator 1
electrical Components
000-056-010 Fuse, 25 Amp 1
000-056-008 Fuse, 15 Amp 1
000-157-040 Switch, 20 Amp Rocker 2
000-157-022 Switch, Relay, 12 V 2
Hydraulic Components
000-052-050 Quick Connect, 440 Male 2
000-052-051 Quick Connect, 440 Female 2
000-052-052 Quick Connect, 660 Male 1
000-052-053 Quick Connect, 660 Female 1
000-046-011 Diaphragm, Chemical Pump 1
000-169-219 Valve, 80 psi, Last Step Chemical 1
000-180-003 Orice, 0.046 dia. 1
000-074-167 Gauge, High PSI (0 - 3,000) 1
000-049-023 Screen, Garden Hose 1
000-078-005 Kit, Seal, and Spring High PSI
Regulator
1
General Information: 1-14
hIgh aLTITuDe OpeRaTIOn
It is not required to change or adjust the fuel system due to altitude differences. The engine
electronic control system constantly monitors the barometric pressure and fuel mixture in
the exhaust. Using these 2 inputs, the engine can compensate for any elevation. This will
be done each time the engine is turned on.
LOcaL waTeR pRecauTIOns
The 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 tend to adhere to
the insides of heater coils and other parts of the machines causing damage and a loss of
cleaning effectiveness. This inuences the reliability and efciency 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” (3.0 grains or more per gallon) be tted with a water
softening system, or a properly installed magnetic-type descaler must be used and
maintained. Periodic descaling 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 descalers or softeners may require additional
periodic use of descaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all areas
be tted with a water softening system for improved operation and reliability.
Failure to take appropriate measures to prevent scale build up can result in
system failure and loss of warranty on affected parts.
1-15: General Information
hard water area Map
The hard water map, shown in Figure 1-1, denes hard water areas in the continental
United States which compromise uid related components such as hoses, ttings, heaters,
pumps, valves and water-cooled engines. For other countries, hard water area maps can
be obtained from geological societies.
hard water Map of continental united statesFigure 1-1.
The map shown in Figure 1-1 is provided for general reference only. Water
hardness in your geographical location should be conrmed by testing.
General Information: 1-16
water softener
Cleaning efciency and equipment life is increased, chemical use decreased, and the
appearance of cleaned carpets enhanced when water softeners are incorporated in hard
water areas. HydraMaster strongly urges the use of water softener units with the Titan 875
in areas exceeding 3.0 grains per gallon.
Failure to use a water softener in these areas will invalidate the machine’s warranty.
Referring to the hard water area map shown Figure 1-1, determine the quality of water
in your area and take immediate action if the water hardness exceeds 3.0 grains per
gallon.
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 efciency. The
water softener will also increase the effectiveness of the cleaning chemicals, 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 charge 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/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 charged every 6 working days for maximum softening.
1-17: General Information
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.
The cleaning rinse water, recovered into your unit’s vacuum tank, contains materials
such as detergents, and must be safely processed before entering streams, rivers and
reservoirs.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after rst ltering out solid material such as carpet
ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV
dump, etc. Permission should rst 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 your Titan 875 with an Automatic Pump-Out System (APO). 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.
HydraMaster makes an APO System which can be ordered with new equipment or
installed later.
When properly congured, the systems will continuously monitor the level of waste water
and pump it out simultaneously with the cleaning operation. The hidden benet of this
process is that the technician does not have to stop his/her cleaning to empty the recovery
tank.
IN ACCORDANCe WITH ePA, STATe AND LOCAL LAWS, DO NOT DISPOSe OF
WASTe WATeR INTO GUTTeRS, STORM DRAINS, STReAMS, ReSeRVOIRS,
eTC.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.
General Information: 1-18
2 - Installation Information
FueL puMp InsTaLLaTIOn guIDeLInes
general
The 1.6L GM engine on the Titan 875 is fuel injected. This is a high pressure system and
requires approved components and hose to operate within the specications. The average
operating pressure at the fuel rail should be 40 - 50 psi. This pressure is controlled via
an pressure manifold that is placed inline with the fuel pump. The fuel system should be
hooked up in the following order:
Fuel Tank Tap
1.
Fuel Pump2.
Fuel Filter3.
Fuel Pressure Manifold4.
Thru Floor Kit5.
Machine6.
Failure to use the specied fuel hose can result in equipment failure or bodily
injury. Fuel hose specication: Fuel injection hose carb no. C-4-06-002 SAE
30R9 180 psi.
Failure to use this hose can result in non-compliance nes set forth by the EPA.
The fuel lter must be on the outlet side of the pump, failure to do so may cause
the engine to run poorly.
It is important that the order of the fuel supply components are installed correctly,
failure to do so may cause the engine or fuel components may not function
properly or be damaged.
All components should be replaced with approved OeM parts.
2-1: Installation Information
The fuel pump has a “domed” end and an end with the electrical terminations. The “domed”
end is the inlet of the pump and the side with the terminations is the output.
The fuel pressure manifold has three ports. The side with the two ports is the return and
the inlet, the side with the single port is the output. The dual port side has one connection
almost in the center of the block; this is the inlet. The connection that is slightly offset is
the return to the fuel tank.
The electrical plug must be positioned at the top when the manifold is installed.
The supplied fuel quick connects are required per the engine certication requirements.
The fuel hose is specic to the Titan 875, this is required by the EPA to maintain the
engine certication as well as the pressure requirements.
Locating components
The Titan 875 is equipped with a fuel pump mounting bracket assembly. This bracket
should be located as close to the fuel source as possible. It should be oriented so the
fuel pressure manifold plug is oriented upwards (see Figure 2-1).
Installation Information: 2-2
Figure 2-1. Fuel pump Diagram
Although there are many different heavy duty vehicles used for carpet cleaning equipment,
the preferable vehicle for a Titan 875 installation is a cargo van with a heavy-duty
suspension package and a 3/4 HD ton capacity. If a fresh water tank is added, a one ton
or larger capacity van is required.
Prior to installing the Titan 875, HydraMaster recommends installing a spray-on bed liner
in the vehicle. This provides ‘metal to cushion’ mounting rather than ‘metal to metal’ and
makes for an attractive van interior.
HydraMaster also recommends installing roof vents in
vehicles operated in hot weather locations. Roof vent
positions are shown in Figure 2-2. Consult your local RV
distributor about selection and/or installation of powered
roof vents.
For best results, the fan should draw air into the vehicle
which will supply cooler air to the air cleaner intake.
Location of Figure 2-2.
Roof Vents in Vehicle
2-3: Installation Information
OpeRaTIng The TITan 875 In hOT weaTheR
HydraMaster recommends the following steps when operating the Titan 875 during periods
of hot weather (95º F or higher). This will help ensure that your Titan 875 continues to run
at 100% capacity during even the hottest days.
A minimum of 9” of clearance is required on both sides of the Titan 875, when
1.
installed. ensure that additional equipment or other materials are not stored at the
sides or on top of the Titan. Unobstructed airow around the unit is critical for cooling
the engine and other components. The covers must be on the machine at all times
to ensure proper cooling.
For side-door vans with “barn doors”, open the doors as wide as their construction
2.
will allow. be sure to open the doors beyond their standard “straight-out” position,
if possible, by releasing the stops and putting the doors in their fully extended
position.
Provide cross-ventilation. When possible, keeping the rear doors open while the
3.
Titan is running will substantially reduce the temperature inside the van and will
provide a path for cooling air ow. For rear-mount installations, open up the other
doors in the van.
Consider adding powered roof vents to the vehicle (if not already installed). These
4.
vents can signicantly reduce interior temperatures and will result in much cooler
operation.
Run the Titan 875 in HOT mode when outdoor temperatures are high. Running the
5.
Titan in WARM mode is not “easier” on the machine. In fact, it cuts the coolant heat
exchanger out of the cleaning solution loop, in effect reducing the engine-cooling
capacity. The Titan was designed to deliver solution at the optimum temperature
to clean carpets when in the HOT mode. The WARM mode is intended for delicate
materials like upholstery.
Installation Information: 2-4
Use caution when drilling any holes through the van oor. Many vans have critical
components mounted directly below the vehicle oor that could be damaged by
a misplaced drill bit.
LOcaTIng The TITan 875 In VehIcLe
There are two recommended entry points on the vehicle for the Titan 875 installation: the
side door or the rear doors.
Most installations are through the 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 mounting requires the unit to be slid to the right side as far as possible Although
installing the Titan 875 through the rear door partly limits working access, it does direct
the noise away from the cleaning site.
In addition, rear mounting 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). Some cleaners in colder geographical areas prefer this
placement for better traction in ice and snow. Also, it is physically easier to load the unit
into the rear door due to the height of the vehicle bed.
Recommended Location of Titan 875 in VanFigure 2-3.
secure Installation
No matter how the unit is installed, check to see if the Titan 875 is properly secured to
the oor of the van with the hardware provided. This safety measure will ensure that the
machine will not slide inside the van. See Figure 2-3 for the correct installation.
2-5: Installation Information
A sudden or crash stop will cause the machine to rocket forward if not properly
secured. To prevent serious personal injury, ensure that the Titan 875 is well
secured to the oor of the vehicle with the hardware supplied. Protect yourself
and the machine.
HydraMaster strongly recommends 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.
Never operate this machine with a portable gas can inside the truck. Doing so
increases the risk of a re or explosion.
Mount a re extinguisher just inside the rear or side door for emergencies.
Do not use a portable propane tank inside of the truck or van. It is dangerous and
illegal in most states.
Transporting any vented fuel container that presently holds or has ever held
a ammable liquid in a vehicle containing the Titan 875 is strictly forbidden by
HydraMaster Corporation and by federal and state regulation.
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
Installation Information: 2-6
seTTIng up The TITan 875
Prior to operating the Titan 875, follow these steps:
Adjust the vacuum relief located on the recovery tank by capping all the vacuum
1.
inlets (the full throttle condition). The machine should be set to 14” Hg maximum.
Setting the vacuum level higher than the recommended value can result in an
increased risk of serious component damage.
The Titan 875 is shipped from the factory with antifreeze added to the solution system.
Recover this antifreeze and dispose of the recovered antifreeze as stated in the local laws
and regulations.
KeeP ANTIFReeZe OUT OF ReACH OF CHILDReN AND ANIMALS. Drinking
antifreeze can cause death.
If required, dispose of antifreeze at facilities licensed to accept household
hazardous waste. If permitted, dispose of antifreeze in sanitary sewer systems.
Do not pour antifreeze into storm sewers, septic systems, or onto the ground.
Doing so causes health and environmental dangers.
ensure the antifreeze is completely drained from the solution system. If any
antifreeze remains in the system, it could damage machine components and
damage fabric.
2-7: Installation Information
Installation Information: 2-8
3 - Cleaning and Chemicals
your HydraMaster truckmount has been engineered using the latest and most sophisticated
technology available to produce the nest carpet cleaning results possible. Despite this,
it remains only a tool of the carpet cleaning trade and can produce only as a good a job
as the person operating it.
hydraMaster strongly recommends attending the clean Trust (formerly known as
as possible and to always follow the clean Trust guidelines when cleaning carpets
and hard surfaces.
This section describes the carpet cleaning procedure in the following areas:
Precaution
s
Preparing the Carpet for extractio n
Rinse and Recove r
Over-Wettin g
Streakin g
Cleaning Tool Tip s
Severe Cleaning Situation s
The use of some chemicals (such as concentrated acids and/or solvents) in
your truckmount can seriously damage the internal plumbing and high pressure
pump.
HydraMaster strongly recommends purchasing a water softener system to prevent the
buildup of scale and hard water deposits in your truckmount.
HydraMaster also 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.
3-1: Cleaning and Chemicals
Increased demand for a neutralizing rinse results in the need for special care
when using these acid based chemicals in your truckmount The negative side
of these products is the corrosive effects the acid can have on metals, including
ttings, 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 acid products
that have obviously caused failures.
pRepaRIng The caRpeT FOR exTRacTIOn
pre-vacuum the carpet
Whether you instruct the customer to pre-vacuum or you offer it as part of your service,
proper vacuuming will make your job easier with superior end results. The more time
spent removing loose particulate soil, the easier it will be to remove the oily soil stuck to
the bers.
pre-treat the carpet
This process of applying trafc lane type chemicals to the carpet (whether by sprayer or
rotary scrubber) is essential prior to extraction with your truckmount.
by applying cleaning agents to the carpet and letting them dwell 10-20 minutes prior to
rinsing, you allow the product to dissolve and emulsify the oily, sticky binders holding the
soil to the ber. This will allow more soil to be removed in one or two cleaning passes and
help prevent over-wetting.
Remember the solution coming out of your cleaning tool is only in contact with the carpet
ber for a few seconds. Relying on the rinse detergent to do the majority of the cleaning
will result in overly long dry times and excess detergent residue left in the carpet.
HydraMaster recommends the use of our pre-sprays: Fastbreak™ for residential carpet
and Blitz™ for commercial carpet needs.
Cleaning and Chemicals: 3-2
RInse anD RecOVeR
Whether you are using a wand or an RX-20™, you should clean an area approximately
3 ft. x 3 ft. with the solution valve open then immediately go over that area with vacuum
only to remove any excess moisture.
Olen ber is becoming more popular, particularly in commercial installations. The
process mentioned above can leave excessive residual moisture because olen bers
will not absorb any of the cleaning solution. you must only apply solution during the
backward stroke of the wand so it can be immediately captured by the vacuum head.
RX-20™ users should follow each pass with a dry pass. Failure to follow this procedure
will cause solution to ow to the back of the carpet along with some of the soil. This, along
with any soil imbedded in the backing, will be wicked to the surface of the bers as the
carpet dries.
HydraMaster recommends the following rinse aids: Alkaline - Hydra-Dri Powder™ or
Hydra-CleanLiquid™. Acid - Clear Water Rinse™.
OVeRweTTIng
Overwetting is an annoyance to all concerned. extended drying times will leave the
customer with a negative impression of both the cleaning company and the process
used.
There are several factors that will cause over-wetting:
Too few vacuum strokes.
1.
Clogged vacuum blower lter or vacuum tank lid not sealing properly.2.
Vacuum tank drain valve left partially open.3.
Obstructed, cut or kinked vacuum hoses.4.
Obstructed vacuum hoses while cleaning a heavily foam-saturated carpet (it is 5.
recommended to use a crystal type defoamer distributed evenly over the carpet).
sTReakIng
Streaks in the carpet can appear in both clean or dirty areas and normally appear in
heavily soiled, light colored carpets.
Possible reasons of streaking may include:
Clogged or improperly angled spray nozzles.
1.
Spray nozzles that overlap, concentrating the solution.2.
A partially clogged vacuum head.3.
Inconsistent solution temperature.4.
3-3: Cleaning and Chemicals
cLeanIng TOOL TIps
wands
With a wand, keep cleaning strokes short, front to back, and run a “dry pass”.
After pulling the wand for a strip of 3 or 4 ft (0.9 m or 1.2 m) long with the solution trigger
activated, go back up to the top of the stroke, and make a “dry “ pass [i.e. no solution
owing]. This gives the wand a second chance to pick up the solution on the carpet.
If you do not run a dry pass, the carpet can take longer to dry, and, possibly, the pad under
the carpet can become saturated.
be aware of the carpet seams; try to use strokes that are parallel with the seam. Avoid
pulling the want across the seam. every stroke can peel the seam connection and pull
the carpet off the oor.
Also, tilt the wand handle down [head up] to move the tool forward, and away from you,
on the carpet. This means less pull on the carpet and less work for you.
Cleaning and Chemicals: 3-4
3-5: Cleaning and Chemicals
Cleaning and Chemicals: 3-6
Rotary Tool: Rx-20
Rotary tools are easier to move on the carpet, but harder to control at rst. With a rotary
tool, remember to keep strokes short and side-to-side.
before turning on the RX-20, adjust the handle; it should rest right below or even with the
bottom of your pants’ front pockets, with the tool resting at on the oor. Take your time
in adjusting the tool’s height; make sure the head of the tool is at with the oor while you
are holding the handle. Relax your posture; the more difcult it is to hold the tool’s head
at on the oor surface, the more quickly you will tire.
While the tool is running, control the left and right movements of the tool by tilting the head
to the front and back, and lifting the handles up and pushing the handles down. The tool
can be driven to the forward and backward by tilting the head of the unit to the left and
right. The head must be turning to use the self driving feature of the tool, and only requires
a slight bit of pressure to handles to get the head to move the tool across the oor.
As with the wand, drying times will be improved if you run a dry pass between wet passes.
Hold down the solution trigger and move the unit left or right across the oor 3 or 4 ft, then
immediately back across the same pass, without the solution owing, to make the dry
pass. Make the next pass half-overlapping the previous pass.
Use the RX-20 in very heavily trafcked areas or if it has been a long time since the carpet
has been cleaned. beware of the seam edges of carpets and transition edges between
oor surfaces. Use extreme caution when cleaning these areas.
Sometimes it is necessary to use an edge tool or wand to run the perimeter of the room
on in difcult-to-reach areas where the circular head of the rotary units will not reach.
3-7: Cleaning and Chemicals
upholstery Tool: DriMaster
Upholstery Tool
Part #000-163-012
Grip
Part #000-061-144
Use the upholstery tool on small rugs and furniture. When you clean rugs, be sure that the
temperature and chemicals are safe for that particular type of rug.
As with the larger tools, do not leave the surface of the upholstery too wet. Adjust the
volume of water on the tool without it touching any surface: the water should just barely
come out of the tool before the vacuum pulls it back in. The water will only just spray the
top layer of the furniture and the vacuum will pull the dirty water back into the tool.
If you nd it necessary to do a dry pass, keep strokes short to limit the amount of water
that comes into contact with the fabric surface.
Cleaning and Chemicals: 3-8
seVeRe cLeanIng sITuaTIOns
When your truckmount is used for hard-surface cleaning or pressure washing, some jobs
may involve severe cleaning situations. In these cases, certain precautions will need to
be taken in order to ensure that the recovery tank and various internal components are
not damaged
The following are examples of severe cleaning situations. (This list is not intended to be
complete.)
Concrete cleaning
•
Concrete stripping•
Parking lot cleaning•
Extremely greasy oors•
Cleaning that results in the recovery of extensive particulate residue•
Cleaning that results in extensive foam production•
When your truckmount is used in severe cleaning situations:
A pre-lter must be used on the vacuum hose. A ne-mesh lter (i.e. nylon) should be
•
installed into the pre-lter. Contact your distributor for more information.
The recovery tank should be inspected and cleaned daily.
•
The recovery tank inlet lter screen should be rinsed after every job.•
The rectangular blower lter should be rinsed after every job.•
Special care should be taken to clean debris from the recovery tank oat switches; •
they should be inspected daily to ensure that they are fully operational.
Any cleaning job that induces excessive foam production should be halted until an
•
approved de-foaming agent can be added to the tank.
Failure to follow these recommendations may lead to component failure and
warranty invalidation.
Use of the vacuum recovery system when stripping or otherwise removing wax
from oors is specically excluded as an approved use of the truckmount. Failure
to follow this exclusion may lead to component failure and will invalidate your
warranty.
3-9: Cleaning and Chemicals
Use of the vacuum recovery system for “dry cleaning”, without corresponding
solution application (i.e. duct cleaning), is specically excluded as an approved
use of the truckmount. Failure to follow this exclusion may lead to component
failure and will invalidate your warranty.
If concentrated acids or solvents are used to pre-treat surfaces before power
washing, do not recover them through the vacuum system. Failure to follow this
exclusion may lead to component failure and will invalidate your warranty.
Cleaning and Chemicals: 3-10
4 - Machine Maintenance
To avoid costly repairs and downtime, it is imperative to develop and practice good
maintenance procedures. These procedures fall into daily, weekly, monthly and quarterly
increments and are outlined below. All maintenance must be performed by qualied
service personnel.
A maintenance log is provided in the Owner’s Guide. This log must be maintained and
may be required to be furnished to hydraMaster before a warranty claim is honored.
It is recommended that the log be afxed to the vehicle door near the truckmount for
convenience and to serve as a maintenance reminder.
This section describes how to properly maintain the truckmount in the following areas:
Operational Maintenance
Overall Machine Maintenance
High Pressure Pump Maintenance
Vacuum System Maintenance
Descaling Procedure (Required)
Freeze Guarding
4-1: Machine Maintenance
OpeRaTIOnaL MaInTenance
Daily Maintenance:
Check the engine oil level. Add oil (non-synthetic
•
only) if needed.
Check the high pressure pump oil. Add oil if
•
needed.
Check the oil level in the blower. Add oil if needed.
•
Check coolant overow bottle level. Add coolant if •
needed.
Check the blower drive belt.
•
Inspect and clean the recovery tank lters.•
Inspect and clean the orice and lter.•
HydraMasterProducts#p/u/4/
Daily Inspection
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Inspect and clean the garden hose screen.•
Inspect the truckmount for water and oil leaks, loose •
electrical connections, etc. and repair as needed.
Lubricate the blower with a HydraMaster-recommended spray lubricant.
•
weekly Maintenance:
Inspect the recovery tank lters for tears, holes, etc. Repair or replace as needed.•
Inspect the vacuum relief valve. Clean and lubricate •
as necessary.
Clean the recovery tank thoroughly with pressure
•
washer.
Check the pump drive belt and blower drive belt for
•
wear and proper tension. Tighten as needed.
Check all the hoses and wiring for wear and chang.
•
Secure as needed.
Flush the water and chemical systems with solution
•
of equal parts white vinegar and water.
Check all the nuts and bolts. Tighten as needed.
•
One time change of the high pressure pump oil •
after 50 hours of operation. (every 500 hours
thereafter.)
One time change of the engine oil after 25 hours of
•
engine Oil Change
Procedure
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operation.
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Machine Maintenance: 4-2
Monthly Maintenance:
Change the engine oil every 150 hours. (every 100 •
hours if operating in high ambient temperatures.)
Change the oil lter every oil change.
Check the engine primary air lter. Clean or replace
•
as necessary.
Check the water level in battery. Fill as needed.
•
Clean the battery terminals as needed.•
Change the blower oil after rst 100 hours of use; •
change every 500 hours thereafter.
Quarterly Maintenance:
Check the fuel lines. Repair or replace as needed.
•
Clean and gap the spark plugs to 0.031” - 0.035”. •
Replace if excessive carbon buildup is visible.
Replace the high pressure pump drive belt.
•
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Air Filter Maintenance
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4-3: Machine Maintenance
500 hours:
Change the blower oil.•
Replace the blower drive belt•
Change the high pressure pump oil.•
Replace spark plugs.•
Change primary fuel lter.•
Check the engine fan belt.•
800 hours:
Change engine coolant.•
1,000 hours:
Replace spark plugs.•
Change secondary air lter.•
Clean and inspect the blower heat exchanger.•
Replace the engine fan belt.•
Refer to the Interval in Hours Maintenance Chart
in the Owner’s Guide or on HydraMaster’s website
for more information.
Machine Maintenance: 4-4
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Interval Maintenance
Schedule
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Portals/0/Manuals/Titan_875/
Maint_Schedule_Titan_875.
pdf
OVeRaLL MachIne MaInTenance
Maintenance, troubleshooting and repair are much easier tasks to accomplish on a clean
truckmount. Regular cleaning of the truckmount offers the user an opportunity to visually
inspect all facets of the truckmount and spot potential problems before they occur. In
addition to the operational maintenance the following “housekeeping” duties should be
performed.
after each job
Check the recovery tank and the recovery tank lters. Empty and clean as •
necessary.
Daily
Wipe the truckmount down thoroughly with a damp cloth.
•
Wipe down the vacuum and high pressure hoses as needed.•
Inspect and clean the vacuum slot on the cleaning wand.•
Check the wand head for sharp edges that could tear carpet. File down as needed.•
Clean the wand to maintain original appearance.•
Visually inspect the hoses for abrasions, cuts, etc. Repair or replace as needed.•
weekly
empty the chemical container. Wash out thoroughly to remove any chemical buildup.•
Inspect the chemical feed line strainer and use solution of equal parts white vinegar •
and water to remove any chemical buildup.
Thoroughly clean the wand and inspect for clogged jets, debris in vacuum slot and
•
leaking ttings at valve.
Thoroughly clean the vacuum and high pressure hoses including quick releases and
•
cuffs.
4-5: Machine Maintenance
engIne MaInTenance
engine Oil
engine Oil Level Check
The engine oil level should be checked daily. It is recommended that the oil be checked
just before the engine is started for the rst time for that day. The oil level should be
between the ‘Add’ and the ‘Full’ marks on the dipstick.
Do not operate the engine with the oil level below the bottom of the ‘Add’ mark on
the dipstick, or above the top of the ‘Full’ mark.
Adding engine Oil
It is normal to add some oil in the period of time between oil changes. The amount will
vary with the severity of operation. When adding or replacing engine oil, be sure the oil
meets or exceeds the recommended specication.
Changing engine Oil and Filter
The engine oil and lter must be changed every 150 hours or every three months whichever
occurs rst. The oil and lter should be changed more often if the engine is operating in
dusty or extremely dirty areas, or during cold weather.
engine Oil Quality
To achieve proper engine performance and durability, it is important that you use only
engine lubricating oils of the correct quality in you engine. Proper quality oils also provide
maximum efciency for crankcase ventilation systems, which reduces pollution.
Use only engine oils displaying the American Petroleum Institute (API) “starburst”
certication mark ‘FOR GASOLINE ENGINES’ on the container.
engine Oil Recommendation
Multi-viscosity oils are recommended. SAe 10W-30 is recommended for your engine from
0° F or above. If ambient temperatures are consistently below 0° F, SAe 5W-30 oil should
be used. Synthetic oils are not recommended for industrial or stationary engines.
Machine Maintenance: 4-6
Oil Filter
The GM powertrain engines use a AC Delco oil lter as the original equipment. An
equivalent or better oil lter must be used when servicing the engine.
To replace the lter, use a proper lter wrench to remove the lter.
Clean the lter mounting base and lightly coat the gasket surface of the new lter with
engine oil. Hand tighten the lter until the gasket contacts the base, then tighten another
½ turn. Fill the engine with the correct amount of oil, run the engine and check for oil leaks
at the drain plug and oil lter gasket.
spark plugs
Always use the recommended spark plugs for your engine. Hotter or colder plugs, or similar
plugs that are not exact equivalents to the recommended plugs, can cause permanent
engine damage, reduce the engines useful life, and cause many other problems such as
hard starting, spark knock and run-on. Installing new spark plugs regularly is one of the
best ways to keep your engine at peak performance.
air cleaner
Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe
damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston
rings will cause high oil consumption and shorten engine life.
A restricted or dirty air cleaner will also cause a rich fuel mixture. Thus, it is extremely
important that the air cleaner be serviced properly at the recommended intervals.
Service the air cleaner more frequently under severe dusty or dirty conditions.
Failure to do so can result in machine failure.
Remove the primary air cleaner element from the air cleaner assembly and inspect
1.
the element for foreign material restrictions or signs of excessive wear or damage.
Replace the element if necessary.
2.
Remove all dust and foreign matter from the air cleaner housing. 3.
Re-install the air cleaner element. 4.
Re-install the air cleaner cup, and securely fasten the retaining clips.5.
Safety element
If your engine is equipped with an air cleaner which utilizes a safety element, ensure that
the element is properly in place before installing the primary element.
Change the safety element annually.
4-7: Machine Maintenance
cooling system
Coolant Level
Check the coolant level of the radiator daily and only when the engine is cool. Generally
a good time to do this is just prior to starting the engine for the rst time each day.
Maintain the coolant level at 3/4 to 1 1/2” below the ller neck seat of the radiator when
the coolant is cold. Whenever coolant level checks are made, inspect the condition of the
radiator cap rubber seal. Make sure it is clean and free of any dirt particles which would
keep it from seating on the ller neck seat. Rinse off with clean water if necessary. Also
make sure that the ller neck seat is free of any dirt particles.
Never remove the radiator cap under any conditions while the engine is operating.
Failure to follow these instructions could result in damage to the cooling system,
engine, or cause personal injury. To avoid having scalding hot coolant or steam
blowout of the radiator, use extreme caution when removing the radiator cap
from a hot radiator. If possible, wait until the engine has cooled, then wrap a thick
cloth around the radiator cap and turn slowly to the rst stop. Step back while the
pressure is released from the cooling system. When all the pressure has been
released, press down on the cap and remove it slowly.
The engine manufacturer recommends the cooling system be lled with a 50/50
mixture of antifreeze and water. The use of DexCool® “Long Life” or equivalent
type coolant is required. This antifreeze is typically bright orange in color and
should meet requirements issued by the engine supplier. Failure to use this type
of antifreeze may result in corrosion of the cooling system.
DO NOT add coolant to any engine that has become overheated until the engine
cools. Adding coolant to an extremely hot engine can result in a cracked block or
cylinder head.
Machine Maintenance: 4-8
bleeding Air from Cooling System
It is necessary to remove all of the air from the engine to prevent overheating. If the coolant
has been drained for any reason, it will be necessary to follow the bleed procedure.
When the engine is cold, remove the radiator cap.
1.
Fill the radiator until it is to the top of the ller neck. 2.
Start the engine and run in the low rpm position, pump clutch off, and no vacuum 3.
load.
Allow the engine coolant to heat up and open the thermostat several times. As all
4.
the air is removed from the system, the level of the radiator should lower below the
internal tubes. This process should take approximately 5 - 10 minutes.
Top off the coolant and install the cap.
5.
In the event you experience a coolant shutdown due to overheat, allow the machine 6.
to cool down and repeat this procedure.
A kit is available which allows you to add a valve to the radiator to improve bleeding
the air. Ask HydraMaster Technical Support for P/N 000-078-891 Titan Coolant
bleed Valve Kit (INS-33141).
Radiator
Inspect the exterior of the radiator for obstructions. Remove all debris with a soft brush or
cloth. Use care to avoid damaging the core ns.
Fuel Filter
The fuel lter is located between the fuel pump and the fuel pressure manifold underneath
the vehicle. This is a high pressure fuel system and should be replaced with the properly
specied lter.
4-9: Machine Maintenance
hIgh pRessuRe puMp MaInTenance
Daily
Check the oil level and the condition of the oil. The oil
level should be up to the center of the sight glass on
the side or rear of the pump or between the “MIN” and
“MAX” lines on the dipstick. The dipstick may be found
by removing the oil cap.
periodically
Change the oil after the initial 50 hours of operation
and every 500 hours after that. It may be necessary to
replace the pump seals and check valves at 500 hours
if the truckmount has been running in high ambient
temperatures.
If the oil becomes discolored or contaminated one of
the oil seals may be damaged. Do not operate the
pump if the crankcase oil has become contaminated.
Do not rotate the drive shaft without oil in the crankcase
reservoir.
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High Pressure Pump
Maintenance
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The pump should never be run dry. Running the pump dry will cause premature
wear on the seals, packing and plungers. Running the pump dry for a prolonged
period of time may cause damage that cannot be repaired and voids warranty.
Do not run the pump with frozen water in the manifold. If there is a risk of freezing,
freeze guard the truckmount. See the Freeze Guarding section of this manual.
service
The next few pages explain how to disassemble and inspect all user serviceable parts of
the pump.
Do not disassemble the pump unless you are a skilled mechanic. For assistance,
contact HydraMaster or your local HydraMaster distributor.
The pump service repair kit is P/N 000-078-912; it includes the pump packing
lubricant and the insertion tool (see Figure 4-12).
Machine Maintenance: 4-10
servicing Valves on the high pressure pump
Removing a Valve
To remove the valve cap (30 mm) and extract the valve assembly (see Figure 4-1).
Remove Valve cap and Valve assemblyFigure 4-1.
1.
Remove the valve assembly (retainer, spring, valve plate, valve seat) from the valve
cavity.
Remove the O-ring and support from the valve cavity.2.
examine the O-ring and replace if there is any evidence of cuts, abrasion, or 3.
distortion.
Inspect the manifold for wear or damage (see 4. Figure 4-2).
Inspect the old valves for wear or damage. Only one valve kit (P/N 078-519) is 5.
necessary to repair all the valves in the pump. (The kit includes new supports,
O-rings, valve seat, valve poppet, spring and retainer; all are pre-assembled.)
Figure 4-2. Inspect Manifold and Old Valves
4-11: Machine Maintenance
Replace the center inlet check valve with a modied check valve (P/N 000-169-212 6.
- see Figure 4-3).
Figure 4-3. Replace center Inlet check Valve
Apply O-ring grease to O-rings and 7. install valves (see Figure 4-4).
Figure 4-4. apply grease
and Install Valves
Replace valve cap and torque to 95 ft. lbs. (see
8. Figure 4-5).
Remove the fasteners retaining the manifold
9.
Machine Maintenance: 4-12
Figure 4-5. Replace Valve cap and Torque
to 95 ft lbs
Separate manifold from crankcase (see 10. Figure 4-6).
Figure 4-6. separate Manifold from crankcase
It may be necessary to rotate crankshaft or tap manifold with rawhide or plastic
mallet to loosen.
When sliding manifold from crankcase, use caution not to damage ceramic
plungers.
11. Figure 4-7).
The seal assemblies may come off with the manifold (see
examine the ceramic plungers. The surface should be smooth and free from scoring, 12.
pitting or cracks (see Figure 4-8); if not, replace.
Figure 4-7. seal assemblies May come Off with
Manifold
Figure 4-8. examine
ceramic plungers
4-13: Machine Maintenance
Loosen the stainless steel plunger bolt.13.
Remove the stainless steel plunger bolt and ceramic plunger from the plunger guide 14.
(see Figure 4-9).
If the slinger washer is removed, be certain it is re-installed or replaced.
15.
Separate plunger bolt from ceramic plunger (see 16. Figure 4-9).
Figure 4-9. Remove stainless steel plunger Bolt and ceramic plunger
Install new Teon17. ® back-up ring and O-ring on the plunger bolt. Apply a lm of O-ring
grease on the outside of the O-ring (see Figure 4-10).
Apply removable anaerobic thread sealant (Loctite
18.
542) to the threads of the
®
plunger bolt, carefully pressing the plunger bolt into ceramic plunger.
Slide new ceramic plunger over the plunger guide.
19.
Torque plunger to 14.5 ft. lbs.20.
Install O-ring, apply sealant and slide plunger over plunger guideFigure 4-10.
Machine Maintenance: 4-14
extracting Seals
With manifold removed from crankcase:
Insert proper extractor collet through main seal retainer.
1.
Tighten the collet and extract retainers and seals.2.
The Teon seals of the HT series will be damaged during disassembly so new
ones with have to be installed.
extract Retainers and sealsFigure 4-11.
4-15: Machine Maintenance
Replacing the Seal Assemblies
Only one seal kit (P/N 000-078-518) is necessary to repair all the seals in the pump (see
Figure Figure 4-12). Use the insertion tool located in the pump service repair kit for seal
installation (see page 4-10).
Figure 4-12. seal kit and Insertion Tool for seal Installation
To install a seal assembly:
Apply a lm of O-ring grease on the O-ring on the outside of the new high pressure seal.
1.
Insert the high pressure seal into the cavity with the “U” shape down.2.
Press high pressure seal into place.3.
Apply a lm of grease on the O-ring on the brass retainer (see 4. Figure 4-13).
Figure 4-13. Install seal assembly using O-Ring grease
Machine Maintenance: 4-16
.To install the intermediate retainers and the low pressure seals:
Insert the brass intermediate retainer into the cavity.1.
Press the new low pressure seal into the brass low pressure seal retainer and install 2.
a new O-ring on the outside (see Figure 4-14).
Figure 4-14. Install Retainers into cavities
Press the low pressure seal assembly into the cavity (see
3. Figure 4-15).
press Low pressure seal assembly into cavityFigure 4-15.
4-17: Machine Maintenance
Re-Installing Manifold
1
3
4
2
5
8
7
6
1
3
4
2
5
8
7
6
Position the outer plungers at the same position (see 1. Figure 4-16).
Re-install manifold and torque the fasteners in an “X” pattern to 50% of specication
2.
and then retorque to 100% specication (see Figure 4-17 and Figure 4-18)
Figure 4-16. Re-install Manifold and Torque Fasteners
Torque sequence Figure 4-17.
in “x” pattern
Machine Maintenance: 4-18
Torque Bolts to Figure 4-18.
22 ft lbs
VacuuM sysTeM MaInTenance
The vacuum pump in this machine is commonly referred to as a “rotary positive
displacement blower” or “blower” for short. The performance and life of the truckmount is
greatly dependent on the care and proper maintenance it receives. The manual for the
blower has been included. Review the manual for a better understanding of this piece of
machinery.
To protect the blower from overloading and damaging itself, there is a vacuum relief
system installed on the vacuum tank. When the vacuum tank inlet is completely sealed
off, a maximum of 14” Hg will be attained.
Solid objects entering the blower will cause serious damage to the internal
components of the blower. extreme caution should be used when the truckmount is
being run for test purposes with the inlet to the blower open to the atmosphere.
Foam passing through the blower can lead to serious problems with the truckmount.
It is important to keep the vacuum tank free of foam. The tank is protected from
overowing by a oat kill switch; however, this switch is not activated by foam.
Daily
At the end of each day the internal components of the blower need to be lubricated. This
helps to prevent rust deposits and prolongs the life of the truckmount.
To lubricate the blower:
Allow the unit to run for a few minutes with the vacuum hose disconnected in order
1.
to remove moisture from the blower.
Cap off the inlet(s) to the vacuum tank.
2.
Spray a HydraMaster-recommended spray lubricant into the “bLOWeR LUbe 3.
PORT” for about 5 to 10 seconds while the unit is running.
Allow machine to run additional 2 to 5 minutes under load to ush off lubricant.
4.
Uncap the inlet(s) and run the unit for another minute to allow the blower to cool 5.
down.
periodically
Change the oil in both ends of the blower after the initial 100 hours of use. The oil is to be
changed each 500 hours of use thereafter.
4-19: Machine Maintenance
Scale deposits on the interior of the heating system can cause a noticeable loss in heating
performance. Deposits of this kind result from hard water deposits. The frequency with
which descaling procedures are required will vary. If the area has particularly hard water,
you may have to de-scale often.
To de-scale the system, add an appropriate de-scaler chemical to the water box. Circulate
it through the system. Let it stand. Flush and repeat as necessary. Clean all screens and
strainers, and check them frequently following descaling.
If using TM DeScaler™ through the ow meter, make sure to run clean water
through the owmeter after this procedure.
To descale using the recirculation kit (P/N 000-078-058), start with an empty water box.
Fill a third of the water box with TM DeScaler™. Follow the recommendations on the TM
DeScaler™ label for proportions. Verify that the oat is not lying horizontal, but oats
below.
Attach the recirculation tting provided in the kit to the garden hose quick connect (see
Figure 4-19) and this combination to the front of the truckmount.
Attach one section of the solution hose to the outgoing solution tting on the front of the
truckmount and the other end to the garden hose and recirculation tting combination
that is attached to the front of the truckmount. Additional hoses may be attached inline if
descaling of hoses is needed.
Start the truckmount and allow it to run for three to ve minutes. Do not leave the TM
DeScaler™ solution in the system. Flush the system with clean water and turn the
truckmount OFF.
Figure 4-19. Recirculation Fitting
Machine Maintenance: 4-20
FReeze guaRDIng
To avoid permanent damage to the truckmount it is imperative to follow the Freeze Guard
Procedure whenever the possibility of freezing temperatures exists.
When disposing of antifreeze follow local laws and regulations. Do not discard
into storm sewers, septic systems, or onto the ground.
Antifreeze is harmful or fatal if swallowed. Do not store in open or unlabeled
containers. Keep out of reach of children and animals.
When draining solution from the machine, wear protective eye wear and ensure
the solution temperature is cold. Failure to follow this caution can result in personal
injury.
Freeze guard procedure
With the truckmount turned off and the incoming 1.
water line disconnected, open the water box
drain valve on the front of the truckmount. Allow
the system to fully drain. Close the water box
drain valve.
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In some extreme cold-temperature locations, you
may nd it necessary to disconnect the pressure
gauge hose from the high pressure pump and
drain the hose. Reconnect the hose to the pump
before proceeding to step 2.
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Freeze Guarding
Procedure
C0cSvaqmudQ
2. Add 2 gallons of 50/50 antifreeze and water mix
to the water box.
Attach a section of solution hose to the outgoing solution tting on the front of the
3.
machine. Attach the opposite end to the recirculation tting. (If more sections of
hose are to be freeze guarded attach those inline.)
Start the truckmount and allow it to run for 2 to 3 minutes. This will distribute antifreeze
4.
solution throughout the truckmount.
Remove the chemical feed line from the chemical jug. Turn the selector valve to
5.
“PRIMe.” This will vacuum the chemical remaining in the lines to the recovery
tank.
4-21: Machine Maintenance
when using the recirculation kit, skip ahead to step 7.
Remove the quick connect tting from the garden hose. Attach the quick connect to
6.
the machine. Using a vacuum hose attached to the recovery tank, vacuum the water
out of the quick connect. This will freeze guard the feed line to the water box.
7. Remove the quick connect from the truckmount.
Loosen the tting at the back of the pressure gauge with a wrench after the antifreeze
8.
has been added to the machine to purge the coolant out of the tting.
Re-tighten the tting.
9.
Spray the antifreeze and water mix out of the truckmount and into a container to 10.
reclaim the solution. Run the truckmount until it stops.
The truckmount is now freeze guarded.
11.
system prior to carpet cleaning. see the following procedure.
The reclaimed antifreeze solution may be used three times before being
discarded.
To freeze guard the hoses and wand, perform Step 7 with the items to be freeze
guarded, attached.
Recovering antifreeze for Re-use
Attach all hoses and wands which have been freeze guarded to the truckmount.1.
Attach the incoming water source to the front of the truckmount.2.
Start the truckmount.3.
Spray the solution through the hoses and wands into a sealable container until all 4.
signs of antifreeze are gone.
Freeze protection of the pump-In system
Drain the fresh water tank.1.
Remove the garden hose adapter from the pump-in pump hose and position the 2.
hose so it is pointing outside the van.
Turn on the pump-in pump and run for 1 - 2 minutes until all the water is purged from
3.
the hose.
The next time the truckmount is used it may take a few minutes before the water
box begins to ll.
Machine Maintenance: 4-22
5 - Operating Instructions
This section describes how to operate the Titan 875, starting with a description of the
dash assembly (see Figure 5-1).
power switch
Throttle Rotary
switch
hour Meter
Vacuum
gauge
Temperature
gauge
pump clutch
switch
auto pump-Out
switch
check engine
Light
Temperature
control Dial
Diverter Valve
switch
pump-In system
switch
Titan 875 upper Dash assemblyFigure 5-1.
The front dash assembly controls the:
System’s power on/off and engine speed
•
Pump clutch•
Automatic Pump-Out (APO) if included in the conguration•
Pump-In system if included in the conguration•
The front dash assembly also includes the solution temperature control dial; the
temperature, vacuum and pressure gauges; and the hour meter.
5-1: Operating Instructions:
The lower dash assembly controls the:
Water pressure•
Chemical metering•
Water box drain•
Heat selection for carpet cleaning (HOT) or upholstery cleaning (WARM) - see •
Figure 5-2
heat selector Valve
pressure
selector Valve
pressure
gauge
pressure adjustment
Valve
chemical
selection Valve
Titan 875 Lower Dash assemblyFigure 5-2.
The lower dash assembly also houses the blower lube port and three high pressure
cleaning solution ports where the wand/tools connect to the Titan 875.
Photographs and illustrations included in this document can represent optional
equipment as well as standard equipment.
Operating Instructions: 5-2
sTaRT-up pROceDuRe
Perform all daily and periodic maintenance as 1.
specied in Section 4 of this manual.
Connect a garden hose to supply water to the
2.
truckmount. If used, turn the “PUMP-IN” switch to
the “ON” position.
Connect the cleaning tool to the length of hose
3.
required to perform the cleaning job.
Start the truckmount with;
4.
The throttle rotary switch in “IDLe”.a.
The “PUMP CLUTCH” switch in the “OFF” b.
position.
The “DIVeRTeR VALVe” switch in the “HeAT c.
byPASS” position.
After the engine starts allow the truckmount to run in “IDLe” for 1-2 minutes to warm 5.
up.
Rotate the throttle switch clockwise to “LOW”, “MID”, or “HIGH”.
6.
Turn the “PUMP CLUTCH” switch to the “ON” position.7.
Turn the “DIVeRTeR VALVe” switch to the “HeAT MODe” position.8.
Set the “HeAT SeLeCTOR” valve to the desired position.9.
Set to the “COOL” position for upholstery or single wand cleaning.a.
Set to the “HOT” position for dual or triple wand cleaning.b.
Set “PReSSURe SeLeCTOR” valve to the desired position.10.
“Pressure Washing Mode” for 1,200-3,000 psi (Non-Heat).a.
“Carpet Cleaning Mode” for 0-1,200 psi (Heated).b.
If used, turn the “AUTO PUMP-OUT” switch to the “ON” position.11.
Set the cleaning pressure to the desired level.12.
Suggested settings:a.
Carpet Cleaning: 300 - 400 psi.
Hard Surface Cleaning: 1,000 psi or as indicated on the tool.
High Pressure Cleaning: 3,000 psi or as indicated on the tool.
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Start-up Procedure
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5-3: Operating Instructions:
Turn the “CHeMICAL SySTeM” switch to the “PRIMe” position to purge any air 13.
from the system (see Figure 5-2).
With the truckmount running at “MID” or “HIGH”, block off the vacuum intake
a.
to the recovery tank. The vacuum gauge should read 12” Hg. This will assist in
priming the chemical system.
Allow the chemical to ow through the chemical meter at full ow for 30
b.
seconds.
Turn the “CHeMICAL SySTeM” switch to “ON.” The restriction can now be c.
removed from the vacuum inlet.
While spraying solution from the cleaning tool, adjust the chemical ow by
d.
turning the “CHeMICAL MeTeRING CONTROL” knob.
begin cleaning. 14.
While spraying solution from the cleaning tool, adjust the chemical ow by a.
turning the “CHeMICAL MeTeRING CONTROL” knob.
Operating Instructions: 5-4
shuT-DOwn pROceDuRe
Flush clean water through the chemical system for 1.
10 seconds. Turn the “CHeMICAL SeLeCTION
VALVe” to “OFF.”
Cool the truckmount down by turning the 2.
“DIVeRTeR VALVe” switch to “HeAT byPASS”.
Spray the cleaning wand into the vacuum hose
for 3 - 5 minutes. The chemical is now ushed
from the truckmount, hoses and cleaning tool.
Remove the vacuum hose.
3.
Lubricate the blower to prevent it from rusting 4.
internally.
Allow the unit to run for a few minutes with
a.
the vacuum hose disconnected in order to remove moisture from the blower.
Cap off the inlet(s) to the vacuum tank.
b.
Spray a HydraMaster-recommended spray lubricant into the “bLOWeR LUbe c.
PORT” for about 5 to 10 seconds while the unit is running (see Figure 5-3).
Allow machine to run additional 2 to 5 minutes under load to ush off lubricant.
d.
Uncap the inlet(s) and run the unit for another minute to allow the blower to cool e.
down.
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Shut-down Procedure
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Blower port
Figure 5-3. Blower port Located on Lower Dash assembly
5-5: Operating Instructions:
If freeze guarding is necessary perform the procedure at this time. See Freeze 5.
Guarding section of this Owner’s Manual.
Rotate the engine throttle to the “IDLe” position.6.
Never perform cleaning operations when the truckmount engine is running at the
IDLe throttle position. Failure to heed this caution will increase the risk of serious
component or engine damage.
Turn the ignition switch to “OFF.”
7.
Drain the water box using the valve.8.
Drain the vacuum tank in an appropriate location.9.
In accordance with the ePA, state and local laws, do not dispose of water into
gutters, storm drains, streams, reservoirs, etc.
Perform daily maintenance as specied in this Owner’s Manual.
10.
Operating Instructions: 5-6
seTTIng The TeMpeRaTuRe
Due to the high performance designed into the Titan 875, there will be times where you
will not need the maximum heat and vacuum available. There are a few different ways
you can optimize the Titan 875 to the size of the job.
The different scenarios can be dened as follows:
Maximum
1. – Triple wands or rotary machine usage. This means that all available
power is required.
high heat/Reduced Vacuum2. – Dual wand with short hose runs or single wand at
longer hose runs to the job site.
Reduced heat/Full Vacuum3. – Single wand with
short hose runs to the job site.
Low heat/Reduced Vacuum4. – Upholstery or any
reduced solution ow cleaning.
Maximum
1.
Set the Heat Selector valve to “Hot” (see a.
Figure 5-4).
Rotate the thermostat dial to “260” (see
a.
Figure 5-5).
Increase engine rpm to “High”.
b.
high heat/ Reduced Vacuum2.
Set the Heat Selector valve to “Hot”.a.
Figure 5-4. set heat
selector Valve
Rotate the thermostat dial to “260”.b.
Increase engine rpm to “Low” or “Mid”.c.
Reduced heat/ Full Vacuum3.
Set the Heat Selector valve to “Warm”.a.
Rotate the thermostat dial to “Desired Level”.b.
Increase engine rpm to “High”.c.
Low heat/ Reduced Vacuum4.
Set the Heat Selector valve to “Warm”.a.
Rotate the thermostat dial to “Desired Level”.b.
Increase engine rpm to “Low”.c.
Figure 5-5. Rotate
Thermostat Dial and select
engine rpm
5-7: Operating Instructions:
MachIne saFeTIes
This machine is equipped with four safeties that shut down the clutch and three safeties
that shut down the machine.
pump protection safeties1. – When these safeties are activated, they will latch the
pump clutch relay. This will prevent the clutch from re-engaging after the condition
is below the set point of the safety. To reset the circuit, you must rst turn the pump
clutch switch off and they back on again.
Low Water boxa.
Pressure Switchb.
Low Pressure Solution Overheat Protectionc.
High Pressure Solution Overheat Protectiond.
Machine protection safeties 2. When these safeties activate, they will shut the
machine down.
Oil Pressure Switch
a.
Coolant Temperature Switchb.
Recovery Tank High Water Floatc.
The Recovery Tank High Water Float circuit has a 10-second delay.
Operating Instructions: 5-8
6 - Water and
Chemical System
This section describes the water and chemical systems in the following areas:
Water and Chemical Flow Operation
Water and Chemical Flow Diagrams
waTeR anD cheMIcaL FLOw OpeRaTIOn
Fresh water is brought through the front of the truckmount into the water box. The level of
water in the box is maintained by the use of a oat valve. The water is then gravity fed to
the pump where it is pressurized.
Next, the pressurized water enters the bypass valve. This valve allows manual adjustment
of the pressure level. When the valve at the wand is closed, nearly all of the water in the
system is recirculated to the water box at this point. When solution is being used at the
wand the necessary amount of high pressure water passes through the bypass valve and
to the heat exchangers.
In the tube and shell heat exchanger the temperature is raised. The heat necessary to do
this is provided by the engine coolant. The heated water then travels to the blower heat
exchanger. In this nned tube heat exchanger the temperature of the water is raised once
again. The heat necessary to do this is provided by both the engine and blower exhausts.
The heated water nally travels to the high pressure manifold.
The high pressure manifold houses both the temperature sensor for the heat control
system that also acts as a high temperature shutdown switch. There is one orice located
in the manifold. This is referred to as a recirculation orice and allows a small amount
of high pressure, high temperature water to pass back to the water box. This prevents
excessive pressure building up in the heat exchanger when the wand valve is closed and
no solution is exiting the truckmount.
Water that is recirculated through the pressure regulator back to the water box travels
past a low pressure temperature sensor. This sensor monitors the water box temperature.
When the controller senses the water in the water box has reached its set point it opens
the low pressure solenoid on the side of the water box and closes once the temperature
drops back below the set point.
6-1: Water and Chemical System
The water that is being called for by the wand then exits the manifold and passes through
a check valve. Finally, the water joins the chemical where the solution is created.
The chemical is pressurized by the HydraMaster diaphragm chemical pump attached
to the head of the water pump. This pump pulls the chemical from the jug through the
chemical meter. After being pressurized the chemical travels through the metering valve
and is injected into the high pressure stream. This solution then exits the front of the
truckmount and is delivered to the cleaning tool.
Water and Chemical System: 6-2
6701 Rev. A
Flow Diagram - View 1 of 3Figure 6-1.
6-3: Water and Chemical System
6701 Rev. A
Flow Diagram - View 2 of 3Figure 6-2.
Water and Chemical System: 6-4
6701 Rev. A
Flow Diagram - View 3 of 3Figure 6-3.
6-5: Water and Chemical System
Water and Chemical System: 6-6
7 - electrical System
This section describes the following:
electrical System Information
electrical Schematic
Wiring Diagram
The Titan 875 electrical system operates on 12 V DC which is provided by the battery.
battery levels are maintained by a 70 Amp generator mounted on the engine.
When a new battery is installed, ensure that it is properly charged before installation
or damage to the charging system may occur.
7-1: electrical System
6700 Rev. D
87
87a
86
85
30
87
87a
86
85
30
87
87a
86
30
85
+
-
(#4 GA.)
HOUR
METER
HI-1
GM ENGINE
MTR-1
STARTER
12V
BATTERY
PS-1
86
85
87
87A
30
RELAY SCHEMATIC
(SHOWN IN "OFF" POSITION)
STARTER
SOLENOID
SOL-1
FUEL
PUMP
PMP-2
PUMP-IN PUMP
ON
OFF
PMP-1
FS-1
S
I
B
ON
BAT
FUSE 30A
FU-7
ST
ST
ON
OFF
CL-1
FUSE
25A
FU-3
GND
GND
GND
TEMPERATURE
SENDER
TT-1
SOLUTION PUMP
SWITCH
SW-3
N.O.
N.C.
SW-8
TS-1
THERMOSTAT
APO SWITCH
SW-4
GND
GND
TB1
-9
TEMPERATURE
GAUGE
TI-1
G
GND
GND
L-1
L-2
LOW WATER BOX
RELAY
CR-1
100°F
TR16
250°F
TR6
TR12 TR11
TR7
TR13
TR14
TR15
TR9
TR8
TR1
TR5
TR3
TR2
TR4
TR10
100°F 250°F
SW-9
VAC. TANK
HIGH WATER
FLOAT
FS-2
TB2
-2
TB2
-1
L-4
L-3
GND
GND
WATER BOX
OVERHEAT
LIGHT
D-1
D-2
D-4
L-6
GND
LOW
WATER BOX
LIGHT
TB1
-4
L-5
GND
RECOVERY
TANK FULL
LIGHT
TB1
-5
TB1
-1
TB1
-3
GND
APO PUMP
FS-3
GND
D-8
D-5
D-7
D-6
(#12 GA.)
(#12 GA.)
IGNITION SWITCH
SW-5
L-8
DASH
LIGHT
PRESSURE
SWITCH
SW-6
VSW
TB1
-9
D-3
TB1
-10
ALT EXCITE INPUT
FUEL PUMP +
FUEL PUMP -
CHECK
ENGINE
LIGHT
L-7
ENG CHK LIGHT OUTPUT
GND
GOV SELECT 2
GOV SELECT 1
ON
OFF
ECM
LOW TEMP PSI CIRCUIT
HIGH TEMP PSI CIRCUIT
LOW WATER
BOX FLOAT
ENG SHUTDOWN INPUT
REC TANK SHUTDOWN
RELAY
CR-3
TB1
-7
GND
TB1
-2
TB1
-2
ST COMMAND INPUT
AUTO PUMP OUT OPTION
PMP
-3
APO
FLOAT
TB4
-2
TB1-8TB2-3TB4
-6
APO PUMP
RELAY
CR-2
TB4
-1
TB4-5TB2
-6
PUMP-IN PUMP OPTION
TB1
-7
PUMP-IN
SWITCH
SW-2
TEMPERATURE
CONTROLLER
TC-1
DUMP SOLENOID
ADJUSTMENT
(SETPOINT 145°F)
PUMP OVERHEAT
PROTECTION ADJUSTMENT
(SETPOINT 190°F)
TB3
-3
TB3-2TB1
-6
TB1
-7
V-2
DIV. SOL.
"DIV MODE"
HEAT BYPASS
LIGHT
TB3
-1
TB3-2TB1
-6
V-3
DIV. SOL.
"HOT MODE"
TB1
-8
HX MODE
LIGHT
TB1
-10
DUMP
SOLENOID
V-1
DIVERT VALVE
SWITCH
SW-1
HEAT
BYPASS
HEAT
MODE
TB1
-8
HIGH PRESSURE
OVERHEAT
LIGHT
TB3
-2
TB1
-6
PUMP
CLUTCH
TB1
-9
FUSE
10A
FU-2
FUSE
10A
FU-6
FUSE
10A
FU-5
FUSE
10A
FU-4
FUSE
10A
FU-1
4
IDLE
LOW
HIGH
MID
1
2
4
SPEED
SWITCH
SW-7
3
D-10
D-9
LOW PRESSURE
TEMPERATURE SENSOR
HIGH PRESSURE
TEMPERATURE SENSOR
TB1
-6
electrical schematicFigure 7-1.
electrical System: 7-2
30
87a
87
85 86
86
30
87
87a
85
25(RED) 12GA.
(ORG)
B-2
(ORG)
30A IN-LINE FUSE
FU-7
25(RED) [TO IGN. SWITCH SW-6 #2 - 12 GA.]
1
TB-1
8(RED/BLK)
11(PUR/BLK)
49(RED)
)KLB(6
27(ORG/WHT)
28(BLK)-14 GA.
26(BLK) 12 GA.
55(PUR)
58(WHT)
31(BLU/WHT)
40(ORG)
41(YEL)-16GA
54(RED) 16 GA.
37(WHT)
33(WHT/BLU)
34(WHT) 12 GA.
50(WHT)
36(WHT/BLK)
35(WHT) 14 GA.
36(WHT/BLK) [TO PUMP IN PUMP PMP-1]
35(WHT) [TO REC TANK PLUG P-5 #C-14 GA.]
9(BRN/WHT) [TO TB-3 #3 - DIV SOLENOID]
10(GRN/WHT) [TO TB-3 #1 - HX SOLENOID]
43(BLK/WHT) [TO LOW WATER BOX FLOAT FS-1]
37(WHT) [TO TB-3 #2-GND]
5(RED)
)ULB(7
4(BLK)
3(WHT)
TR16
TR3
TR2
TR5
TR4
TR1
TR8
TR9
TR14
TR15
TR13
TR10
9(BRN/WHT)
10(GRN/WHT)
14(RED)
12(RED)
50(WHT)
49(RED)
48(RED/BLK)
11(PUR/BLK) [TO DUMP SOLENOID V-1]
43(BLK/WHT)
53(BLK/WHT)
52(ORG)
51(GRN/BLK)
*ALL WIRES ARE 18 GAUGE UNLESS OTHERWISE STATED
D2
D1
D4
16(RED)
18(RED)
52(ORG)
51(GRN/BLK)
56(BLK)
29(PUR/WHT)
56(BLK)
42(PUR)
42(PUR) [TO LOW WATER BOX FLOAT FS-1]
55(PUR)
22(RED)
20(RED)
1(WHT)
2(BLK)
10A
FU-1
10A
FU-2
25A
FU-3
10A
FU-6
10A
FU-5
10A
FU-4
34(WHT) [TO ENGINE GROUND-12 GA.]
33(WHT/BLU) [TO TEMP GAUGE TI-1 #G]
31(BLU/WHT) [TO IGN SWITCH SW-5 #6]
30(YEL/BLK) [TO SOLUTION PUMP SWITCH SW-3 #3]
28(BLK) [TO PUMP OUT SWITCH SW-4 #2 - 14 GA.]
27(ORG/WHT) [TO PUMP IN SWITCH SW-2 #2]
26(BLK) [TO IGN SWITCH SW-6 #3-12 GA.]
8(RED/BLK) [TO DIV SWITCH SW-1 #3]
7(BLU) [TO THERMOSTAT TS-1]
6(BLK) [TO THERMOSTAT TS-1]
5(RED) [TO THERMOSTAT TS-1]
3(WHT) [TO HIGH PSI TEMP SENSOR SW-9 -20 GA.]
4(BLK) [TO HIGH PSI TEMP SENSOR SW-9 -20 GA.]
2(BLK) [TO LOW PSI TEMP SENSOR SW-8 -20 GA.]
1(WHT) [TO LOW PSI TEMP SENSOR SW-8 -20 GA.]
30(YEL/BLK)
53(BLK/WHT)
LOW PSI
DUMP SOL
PUMP PROTECT
SHUTDOWN
OVRHT PROTECT
SHUTDOWN
TR12 TR11
TR7 TR6
DIV MODE
SOLENOID
HT MODE
SOLENOID
DIV
SWITCH
LOW PSI
SENSOR
HIGH PSI
SENSOR
POTENTIOMETER
GROUND
SECONDARY POWER
PRIMARY POWER
TEMPERATURE
CONTROLLER
TC-1
47(GRY)-16 GA
44(ORG/BLK)
40(ORG) [TO REC TANK PLUG P-5 #A]
44(ORG/BLK) [TO REC TANK PLUG P-5 #B]
2
3
4
5
6
7
8
10
9
48(RED/BLK)
LOW WATER BOX
RELAY
CR-1
58(WHT)
FUSE
BLOCK
FB-1
13(BLK)
12(RED)
HEAT
BYPASS LIGHT "GREEN"
L-1
HX
MODE LIGHT "YELLOW"
L-2
14(RED)
15(BLK)
ERUSSERP IH
"DER" THGIL TAEHREVO
3-L
17(BLK)
16(RED)
WATER BOX
LOW WATER LIGHT "RED"
L-6
18(RED)
RECOVERY TANK
FULL LIGHT "RED"
L-5
22(RED)
23(BLK)
WATER BOX
OVERHEAT LIGHT "RED"
L-4
21(BLK)
20(RED)
29(PUR/WHT) [TO DIV SWITCH SW-1 #2]
57(BLK)
13(BLK)
15(BLK)
21(BLK)
17(BLK)
19(BLK)
23(BLK)
24(BLK) [TO STARTER SOLENOID SOL-1 - 12 GA.]
B-1
24(BLK) 12GA.
[ENGINE GROUND INPUT] (BLK)
60(PNK/BLK) [TO SPEED SWITCH SW-7 #4]
59(PNK) [TO SPEED SWITCH SW-7 #3]
45(PNK/WHT)
45(PNK/WHT) [TO PRESSURE SWITCH SW-6]
46(BLU/BLK) [TO PRESSURE SWITCH SW-6]
38(WHT/GRN)
[START COMMAND INPUT] (LT BLU/PNK)
[FUEL PUMP + OUTPUT] (PNK/YEL)
[ALT EXCITE INPUT] (PUR)
[FUEL PUMP - OUTPUT] (BLK/RED)
[VSW] (PNK)
[ENG CHECK LIGHT OUTPUT] (GRN/YEL)
J-2
FEMALE
TERMINALS
PRIMARY ENGINE PLUG
SECONDARY ENGINE PLUG
41(YEL)-16GA
38(WHT/GRN)
62(RED) [TO FUEL PUMP "+" PMP-2 ]
61(WHT) [TO FUEL PUMP "-" PMP-2 ]
54(RED)-16GA
47(GRY)-16GA
63(GRN) [TO CHECK ENGINE LIGHT L-7]
P-2
MALE
TERMINALS
32(WHT/RED)
32(WHT/RED) [TO DUMP SOLENOID V-1]
[GOV SELECT 1] (GRY/DK BLU)
[GOV SELECT 2] (GRY/ORG)
ENGINE HARNESS TO ELECTRICAL BOX JUNCTION
46(BLU/BLK)
A
B
C
D
E
F
G
H
S
R
P
N
M
L
K
J
J
K
L
M
N
P
R
S
H
G
F
E
D
C
B
A
H
G
F
E
D
C
B
A
J
K
L
M
N
P
R
S
S
R
P
N
M
L
K
J
F
G
H
E
D
C
B
A
19(BLK)
P-1
MALE
TERMINALS
J-1
FEMALE
TERMINALS
D3
66(GRN/BLK)
66(GRN/BLK) [TO J-8 @ PUMP CLUTCH]
39(BLK)
96(WHT)
97(ORG)
REC TANK SHUTDOWN
RELAY
CR-3
95(WHT)
39(BLK)
[ENGINE SHUTDOWN INPUT] (DK BLU/YEL)
95(WHT)
ELECTRICAL PANEL
97(ORG)
wiring Diagram - View 1 of 3Figure 7-2.
000-179-007 Rev. H
QR Tag:
How to Change Fuses
http://www.youtube.com/user/
HydraMasterProducts#p/u/5/
u240WDOCGz8
7-3: electrical System
wiring Diagram - View 2 of 3Figure 7-3.
4
3
1
2
26(BLK) [TO FB-1 @ STUD -12 GA.]
26(BLK) 12 GA.
31(BLU/WHT)
31(BLU/WHT) [TO TB-1 #3]
25(RED) [TO FU-7 - 12 GA.]
25(RED) 12 GA.
33(WHT/BLU) [TO TB-1 #10]
72(BLK)
*ALL WIRES ARE 18 GAUGE UNLESS OTHERWISE STATED
HOUR METER
HI-1
DIVERT VALVE
SWITCH
SW-1
PUMP IN
SWITCH
SW-2
PUMP OUT
SWITCH
SW-4
THERMOSTAT
TS-1
2
3
3
2
3
2
3
2
+
7(BLU)
5(RED)
6(BLK)
G
S
I
8(RED/BLK)
30(YEL/BLK)
29(PUR/WHT)
65(GRY)
27(ORG/WHT)
28(BLK)-14 GA.
64(ORG)
33(WHT/BLU)
27(ORG/WHT) [TO FUSE BLOCK #FU-2]
65(GRY) [TO PUMP IN PUMP - 16 GA. PMP-1]
[TO REC. TANK PLUG P-5 #F - 14 GA.] 67(BRN)
[TO TEMP SENDER - TT-1] 64(ORG)
[TO FUSE BLOCK #FU-3 - 14 GA.] 28(BLK)
8(RED/BLK) [TO TEMPERATURE CONTROLLER TC-1 #TR-10]
[TO LOW WATER BOX RELAY CR-1 #30] 30(YEL/BLK)
73(PNK)
BACK
D5
B-3
SOLUTION PUMP
SWITCH
SW-3
69(WHT)
2
3
IGNITION
SWITCH
SW-5
6
5
SPEED
SWITCH
SW-7
(IGN)
(ST)
(BAT)
(ON)
[TO TEMP CONTROLLER #TR-3] 6(BLK)
[TO TEMP CONTROLLER #TR-5] 5(RED)
[TO TEMP CONTROLLER #TR-2] 7(BLU)
74(RED)
59(PNK) [TO SECONDARY ENG PLUG P-1 #J]
60(PNK/BLK) [TO SECONDARY ENG PLUG P-1 #K]
TEMPERATURE
GAUGE
TI-1
[TO LOW WATER BOX RELAY CR-1 #87A] 29(PUR/WHT)
CHECK
ENGINE
L-7
67(BRN)-14 GA.
(RED)
68(BLK)
68(BLK)
P-11
J-11
63(GRN)
(BLK)
63(GRN) [TO PRIMARY ENG PLUG P-2 #G]
8(RED/BLK)
27(ORG/WHT)
65(GRY)
33(WHT/BLU)
63(GRN)
31(BLU/WHT)
59(PNK)
60(PNK/BLK)
29(PUR/WHT)
6(BLK)
5(RED)
7(BLU)
30(YEL/BLK)
28(BLK)
67(BRN)
60(PNK/BLK)
ORIENTATION REF. FROM BACK OF PLUG
74(RED)
(RED)
(BLK)
70(WHT)
H
G
E
F
B
A
C
D
J
K
L
M
N
P
R
S
H
G
F
E
D
C
B
A
J
K
L
M
N
P
R
S
73(PNK)
DASH
LIGHT
L-8
71(RED/WHT)
B-4
71(RED/WHT)
72(BLK)
69(BLK)
(RED)
P-8
FEMALE
TERMINALS
J-8
MALE
TERMINALS
59(PNK)
D9
D10
75(WHT)
70(WHT)
GRD-2
(RED)
000-179-007 Rev. H
electrical System: 7-4
30
87a
87
8586
HI-PSI MANIFOLD ASSEMBLY
TEMP. SENDER
TT-1
WATER BOX ASSEMBLY
LOW WATER
BOX FLOAT
FS-1
6
5
4
3
2
1
(WHT)
(BLK)
TB2
VACUUM TANK
HIGH WATER
FLOAT
FS-2
PUMP IN PUMP
PMP-1
EXISTING
12V BATTERY
PS-1
+
-
FUEL PUMP
PMP-2
(BLK)(BLK)
PUMP IN PUMP (OPTIONAL)
3(WHT) - 20 GA.
4(BLK) - 20 GA.
(BLK)
(BLK)
(BLK)
DIVERTER
SOLENOID
"DIVERT MODE"
V-2
DIVERTER
SOLENOID
"HOT MODE"
V-3
DIVERTER
ACTUATOR
"HEAT MODE"
ACTUATOR ARM
RETRACTED
"DIVERT MODE"
ACTUATOR ARM
EXTENDED
VACUUM HOSE
#2#2
43(BLK/WHT)
81(BRN/WHT)
78(GRN/WHT)
40(ORG)
62(RED)
77(RED) 6 GA.
76(BLK) 6 GA.
42(PUR)
61(WHT)
44(ORG/BLK)
79(WHT)
80(WHT)
65(GRY) 16 GA.
77(RED) 6 GA.
36(WHT/BLK)
(BLK)
64(ORG)
67(BRN) 14 GA.
34(WHT) 12 GA.
P-4
J-4
J-6
P-6
J-7
P-7
D8
*ALL WIRES ARE 18 GAUGE UNLESS OTHERWISE STATED
10(GRN/WHT) [TO TEMP CONTROLLER TC-1 #TR-7]
37(WHT) [TO TB-1 #6]
9(BRN/WHT) [TO TEMP CONTROLLER TC-1 #TR-6]
34(WHT) [TO TB-1 #9 - 12 GA.]
43(BLK/WHT) [TO TB-1 #1]
64(ORG) [TO TEMPERATURE GAUGE TI-1 #S]
42(PUR) [TO TB-1 #3]
3(WHT) [TO TEMP CONTROLLER TC-1 #TR-1 -20 GA.]
67(BRN) [TO PUMP OUT SWITCH SW-4 #3-14 GA.]
66(GRN/BLK) [TO LOW WATER BOX RELAY CR-1 #87A]
4(BLK) [TO TEMP CONTROLLER TC-1 #TR-4 - 20 GA.]
40(ORG) [TO TB-1 #4]
44(ORG/BLK) [TO TB-1 #1]
11(PUR/BLK) [TO TEMP CONTROLLER TC-1 #TR-12]
65(GRY) [TO PUMP IN SWITCH SW-2 #3 - 16 GA.]
36(WHT/BLK) [TO TB-1 #7]
35(WHT) 14 GA.
35(WHT) [TO TB-1 #8 - 14 GA.]
1(WHT) - 20 GA.
2(BLK) - 20 GA.
1(WHT) [TO TEMP CONTROLLER TC-1 #TR-9 -20 GA.]
2(BLK) [TO TEMP CONTROLLER TC-1 #TR-8 - 20 GA.]
4
3
2
1
TB3
10(GRN/WHT)
9(BRN/WHT)
37(WHT)
D7
D6
80(WHT)
81(BRN/WHT)
DUMP SOLENOID
V-1
BYPASS
MANIFOLD ASSEMBLY
66(GRN/BLK)
APO FLOAT
FS-3
87(WHT)-14 GA.
(BLK)
(RED)
(BLK)
J-10
B
A
P-10
APO TERMINAL
BLOCK
TB-4
(WHT)
5
6
2
4
3
1
APO PUMP
RELAY
CR-2
89(WHT/RED)
90(WHT/BLU)
91(BLK)-14 GA.
92(WHT)-14 GA.
89(WHT/RED)
93(WHT)-14 GA.
94(BLK)-14 GA.
AUTO
PUMP OUT
PMP-3
88(BLK)-14 GA.
92(WHT)-14 GA.
AUTO PUMP OUT OPTION
24(BLK) 12 GA.
24(BLK) [TO FU-7 - 12 GA.]
61(WHT) [TO PRIMARY ENG PLUG #C]
62(RED) [TO PRIMARY ENG PLUG #D]
P-9
J-9
32(RED/WHT) [TO TB-1 #10]
11(PUR/BLK)
32(WHT/RED)
46(BLU/BLK) [TO FUSE BLOCK FB-1 D-3]
45(PNK/WHT) [TO TB-1 #1]
PRESSURE
SWITCH
SW-6
J-3
P-3
BLK/WHT
GRN/WHT
GRN
WHT/GRN
BLK/GRN
GRN/WHT
WHT/GRN
GRN/RED
CONNECTS TO
FUEL PRESSURE
MANIFOLD
NOTE: LOCATED
UNDERNEATH VEHICLE
CONNECTS TO
ENGINE HARNESS
GND-1
GM ENGINE
MTR-1
SOL-1
P-12
J-12
J-13
P-13
P-14
J-14
P-15
J-15
RECOVERY TANK ASSEMBLY
HIGH PRESSURE
TEMPERATURE SENSOR
SW-9
LOW PRESSURE
TEMPERATURE SENSOR
SW-8
PUMP CLUTCH
CL-1
COM
N/O
FUEL PRESSURE
MANIFOLD
FPM-1
000-179-007 Rev. H
wiring Diagram - View 3 of 3Figure 7-4.
7-5: electrical System
18.0
17.0
16.0
15.0
90.0
7'-8 1/8"
3
2
4
1
8 7 6 5
BLK / WHT
GRN / WHT
GRN
WHT / GRN
BLK / GRN
GRN / WHT
GRN / RED
WHT / GRN
1111
1.
2.
2.
2.
2.
3. 3. 3.3. 3.
3.
3.
5.
66.0
18.0
EXISTING WIRE HARNESS (SHOWN W/ LOOM)
VEHICLE SIDE
MACHINE SIDE
1
1
1
CUT LINE
90.0
9
INSIDE 1/4" LOOM
7799
schematic of wire harness - Fuel pump Manifold to Machine - View 1 of 2Figure 7-5.
electrical System: 7-6
18.0
17.0
16.0
15.0
90.0
7'-8 1/8"
3
2
4
1
8 7 6 5
BLK / WHT
GRN / WHT
GRN
WHT / GRN
BLK / GRN
GRN / WHT
GRN / RED
WHT / GRN
1111
1.
2.
2.
2.
2.
3. 3. 3.3. 3.
3.
3.
5.
48.0
4'-2 7/8"
1
3
2
GRN / RED
WHT / GRN
GRN / WHT
BLK / GRN
BLK / GRN
GRN / WHT
GRN / RED
WHT / GRN
4.
4.
18.0
EXISTING WIRE HARNESS (SHOWN W/ LOOM)
VEHICLE SIDE
MACHINE SIDE
48.0
1
6.
90.0
9
NOTES:
CUT EXISTING WIRE HARNESS TO LENGTH AT DIMENSION SHOWN.
1.
CUT VEHICLE SIDE WIRES TO LENGTH AT DIMENSION SHOWN.
2.
ADD ITEMS 2, 3, 4, 5, 6, 7 AND 8 AS SHOWN TO VEHICLE SIDE OF HARNESS.
3.
ADD ITEMS 2 AND 3 AS SHOWN TO MACHINE SIDE OF HARNESS.
4.
ADD ITEM 9 TO VEHICLE SIDE OF HARNESS.
5.
CUT EXISTING WIRE LOOM TO LENGTH AT DIMENSION SHOWN.
6.
INSIDE 1/4" LOOM
INSIDE EXISTING 1/4" LOOM
7799
schematic of wire harness - Fuel pump Manifold to Machine - View 2 of 2Figure 7-6.
harness assembly parts List
Item part number Description Qty
1 - - - Wire Harness 1
2 000-037-072 Terminal, Fully Insulated Male, 22-16ga 2
3 000-037-071 Terminal, Fully Insulated Female, 22-16ga 6
4 000-037-033 Connector, #22 Pink butt 4
Item part number Description Qty
6 000-178-097 Wire, GXL, 18 Ga, Green 72”
7 000-178-114 Wire, GXL, 18 Ga, White / Green Stripe 73”
8 000-178-066 Wire, GXL, 18 Ga, black / White Stripe 74”
9 000-063-021 Harness Wrap, 1/4 Split 90”
5 000-178-092 Wire, Awg, 18 Ga Green / White Stripe 71”
7-7: electrical System
electrical System: 7-8
8 - Troubleshooting
This section describes the standard troubleshooting procedures for:
Heating System
Chemical System
engine
High Pressure System
Vacuum System
8-1: Troubleshooting
heaTIng sysTeM
The truckmount overheats and shuts down.1.0.
possible cause solution
1.1. The orice or lter screen
are restricted.
1.2. The low pressure dump
solenoid is restricted.
1.3. The dump solenoid is
faulty.
unable to achieve normal cleaning solution temperature.2.0.
possible cause solution
Remove and inspect. Clean as necessary.
Inspect the solenoid and the hose that delivers
water to it. Clean or replace as necessary.
Check the main fuse. If the fuse is blown, inspect
electrical system for worn or shorted wires. Repair
or replace as necessary.
Inspect dump the solenoid and test for functionality.
If the solenoid is operable, refer to a qualied
service technician to test the temperature controller
and sensor.
2.1. Temperature control knob
is turned down.
2.2. The dumb solenoid is
faulty.
2.3. Excessive solution ow
at tool.
2.4. The heat exchanger has
hard water scale buildup.
2.5. The heat exchanger has
blockage on the exhaust
side.
2.6. The heat selector valve is
in the wrong position.
Inspect the knob. Adjust if necessary.
Inspect the solenoid and test for functionality. If the
solenoid is operable, refer to a qualied service
technician to test the temperature controller and
sensor.
The cleaning tool jet is too large or worn. Inspect the
jet. Replace if necessary.
Descale the system.
Inspect the interior of heat exchanger. Remove the
debris and clean as necessary.
Move the heat selector valve to the “HOT” position.
Troubleshooting: 8-2
cheMIcaL sysTeM
system will not prime3.0.
possible cause solution
3.1. The check valves in
chemical pump are faulty
3.2. The chemical pump
diaphragm is faulty
3.3. The check valve in high
pressure pump is faulty
(piston which chemical
pump is attached to)
3.4. The lter on feed line in
chemical jug is clogged
3.5. The feed line from
chemical jug is loose,
pinched or damaged
3.6. The chemical selector
valve is faulty
Remove the valves and inspect. Clean or replace as
necessary.
Remove and inspect. Replace as necessary.
Remove the valve and inspect. Clean or replace as
necessary.
Inspect and clean.
Inspect and repair.
Inspect the valve for leaks between ports. Replace
as necessary.
4.0.
possible cause solution
4.1. Air is in the lines Check that all ttings and connections are tight and in
good condition. Repair or replace as necessary.
4.2. The lter screen in the
Inspect and clean.
chemical jug is partially
obstructed
4.3. The chemical selector
valve is faulty
4.4. The chemical metering
valve is faulty
4.5. The high pressure check
valve is faulty
Inspect the valve for leaks between ports. Replace
as necessary.
Remove and inspect the valve. Clean or replace as
necessary.
Remove and inspect the valve. Clean or replace as
necessary.
chemical is present in water box\5.0.
possible cause solution
5.1. The chemical pump
diaphragm is faulty.
5.2. The high pressure check
valve is faulty.
Remove and inspect the chemical pump diaphragm.
Replace as necessary.
Remove and inspect the valve. Clean or replace as
necessary.
8-3: Troubleshooting
engIne
The engine will not turn over.1.0.
possible cause solution
1.1. A loose or corroded
Clean and tighten the battery terminal connections.
battery terminal
1.2. The battery is dead Recharge or replace the battery. Test the charging
system. Repair if necessary.
Do not attempt to jump start the truckmount
from a running vehicle. The amperage output
from an automobile will damage the charging
system of the truckmount.
1.3. The main fuse is blown Check the main fuse.
If the fuse is blown, inspect the electrical system
for worn or shorted wires. Repair or replace as
necessary.
1.4. The vacuum blower has
seized
Attempt to turn the coupler by hand. If it will not
turn refer to the Vacuum System Troubleshooting
Section, page 8-9
1.5. The ignition switch is
faulty
1.6. The starter solenoid is
faulty
Test to see if there is power both to and from the
switch. Refer to Section 7.
Test to see if there is power to solenoid with ignition
in “Start” position. Refer to Section 7.
1.7. The starter motor is faulty Test to see if there is power to the motor with the
ignition in “Start” position. Refer to Section 7.
1.8. None of the above Refer to a qualied service technician for further
troubleshooting.
The engine turns over but will not start. There is nO spaRk. 2.0.
possible cause solution
2.1. The recovery tank is full. Drain the tank.
2.2. The recovery tank oat is
Inspect the oat. Repair or replace as necessary.
faulty.
2.3. The engine ignition
system is faulty.
Troubleshooting: 8-4
Refer to a qualied service technician for further
troubleshooting.
The engine turns over but will not start. There Is spaRk. note: To check for 3.0.
spark, refer to engine manual.
possible cause solution
3.1. Fuel is not reaching the
Test for power to the fuel pump. Refer to Section 7.
injector rail.
If power is present, inspect the fuel pump. Replace if
necessary.
Inspect the fuel lines between the source and the
carburetor. Repair or replace as necessary.
3.2. The engine is ooded Remove spark plug and dry.
3.3. The spark plugs are worn
Inspect and replace as necessary.
or dirty
3.4. None of the above Refer to a qualied service technician for further
troubleshooting.
The engine will not come up to normal operating rpm note: engine should be 4.0.
adjusted to run at 3,150 rpm under a vacuum load of 14” hg.
possible cause solution
4.1. excessive load on the
engine.
4.2.
excessive back pressure
on the engine exhaust.
Runs rough at high speed. 5.0.
possible cause solution
5.1. The spark plug(s) are
faulty.
5.2. The spark plug wire(s)
are faulty.
5.3. Inadequate fuel supply to
the fuel rail.
Inspect and clean the recovery tank lters. Inspect
the recovery tank to the blower hose. Repair or
replace as necessary.
Inspect for blockage in the heat exchanger. Clean or
replace as necessary.
Remove and inspect the plugs. Clean or replace as
necessary.
Inspect the wires and connectors for damage or
loose connections. Repair or replace as necessary.
Check for blockage in the lter. Repair or replace as
necessary.
8-5: Troubleshooting
6.0.
possible cause solution
6.1. A dirty air lter. Inspect and replace as necessary.
6.2.
excessive fuel to the fuel
rail.
Refer to a qualied service technician for further
troubleshooting
engine overheats. 7.0.
possible cause solution
7.1. Poor ventilation in the
van
Open all the van doors. Install a roof vent in the van.
Remove any dividers or other objects impeding
airow around the truckmount.
7.2. Low oil level Check the level and ll as necessary.
7.3.
excessive back pressure
on the engine exhaust
Inspect for blockage in the heat exchanger. Clean or
replace as necessary.
7.4. Low coolant Check radiator level. Check overow bottle level.
Use phosphate-free antifreeze.
7.5. Poor coolant mixture Check the coolant with a test to determine mixture;
adjust as necessary.
Troubleshooting: 8-6
hIgh pRessuRe sysTeM
The pump will not come up to normal cleaning pressure 1.0.
possible cause solution
1.1. The pressure adjusting
Inspect the valve. Repair or replace if necessary.
valve is faulty
1.2. Worn seals or valves in
the pump
Test the pump output volume directly from the pump
at normal running rpm. If the volume is below the
manufacturer’s specications, replace the seals and
inspect for defective valves.
1.3. The pump rpm is too low Check for a loose pump belt. Adjust or replace as
necessary. Check the engine rpm and adjust as
necessary to 3,150 rpm under a 14” Hg vacuum
load.
1.4. The primary orice is
missing or loose
1.5. The primary and
Remove and inspect. Tighten or replace as
necessary.
Inspect and reverse if necessary. Refer to Section 9.
secondary orices have
been installed incorrectly
1.6. The primary orice is
worn
Measure the orice size and replace as necessary.
Correct size is 0.033”
no pressure reading on gauge 2.0.
possible cause solution
2.1. The pump belt is broken Inspect and replace if necessary.
2.2. The gauge is faulty Replace the gauge.
The psi gauge reads normal; low pressure from wand 3.0.
possible cause solution
3.1. Restriction in the
cleaning tool
Inspect the tool jet(s) and clean or replace as
necessary. Inspect any lters in the cleaning tool
and clean or replace as necessary.
3.2. Faulty quick connect in
the system
3.3. Restriction in one of the
solution hoses
3.4. Hard water deposits
Inspect each quick connect and replace as
necessary.
Remove the quick connects and inspect hoses.
Clean or replace as necessary.
De-scale the truckmount.
restricting the system
8-7: Troubleshooting
pressure pulsation. 4.0.
possible cause solution
4.1. Air leak between the
water box and pump
4.2. The check valve(s) in the
pump are faulty
5.0.
possible cause solution
5.1. Restriction in the water
supply system
5.2. The oat valve in the
water box is faulty
6.0.
possible cause solution
6.1. The oat valve in the
water box is faulty.
6.2. The oat has absorbed
water and lost buoyancy.
6.3. The oat has come out of
adjustment.
Check all the hoses and ttings for cuts, breaks,
cracks, etc. Repair as necessary.
Remove each valve and inspect for correct
operation. See the Section 4.
Inspect the supply system from the source through
the incoming quick connect.
Disassemble and inspect the valve. Repair or
replace as necessary.
Disassemble and inspect the valve. Repair or
replace as necessary.
Detach the oat and check to see if it will oat to the
surface. Replace as necessary.
Adjust the oat as necessary.
Troubleshooting: 8-8
VacuuM sysTeM
a weak vacuum at wand. The gauge reads normal.1.0.
possible cause solution
1.1. blockage in the hoses or
wand tube
1.2.
excessive length of
hose connected to the
truckmount
a weak vacuum.2.0.
possible cause solution
2.1. Air leak somewhere in
the vacuum system
2.2. The vacuum blower is
turning too slowly
2.3. The vacuum gauge is
defective
Disconnect the hoses and check for an obstruction.
Do not attach excessive lengths of hose.
Check the vacuum relief valve for proper
adjustment.
Carefully check all the vacuum hoses for a cut or
break.
Check the recovery tank lid gasket.
Make sure the recovery tank drain valve is fully
closed.
Check the rpm of the engine. Adjust as necessary to
3,150 rpm under a 14” Hg vacuum load.
Test the gauge and replace if necessary.
The vacuum gauge reads too high with no hoses attached.3.0.
possible cause solution
3.1. The lter in recovery tank
is clogged
3.2. The hose from recovery
tank to the vacuum
blower is collapsed
internally
Remove and clean or replace as necessary.
Inspect and replace as necessary.
8-9: Troubleshooting
excessive noise produced by the blower.4.0.
possible cause solution
4.1. The blower is low on oil Inspect the oil levels and replenish as necessary.
Running the blower with low oil levels can cause
severe damage. If this situation occurs the
blower should be inspected by a qualied service
technician.
4.2. The vacuum blower has
Refer to a qualied service technician.
internal damage
The vacuum blower is locked and will not turn. 5.0.
possible cause solution
5.1. Truckmount has been
inactive for a period of
time and the blower was
not properly lubricated
prior to nal shutdown.
Rust has possibly built up
on the internal surfaces.
Spray HydraMaster-recommended oil into the
blower and let sit for at least 1 hour. Then very
carefully use pipe wrench on the outer diameter of
the pulley on the coupler to attempt to free lobes
of the blower. Do not use a wrench directly on the
blower shaft.
If unable to free up the blower in this manner, refer
to a qualied service technician.
5.2. There is internal damage
Refer to a qualied service technician.
to the blower
water in truckmount exhaust. 6.0.
possible cause solution
6.1. The recovery tank has
been lled with foam or
over lled with water
Inspect the recovery tank. If full, drain the tank.
Inspect the high level shutoff switch for proper
operation. Clean or replace the switch as necessary.
If foam is in recovery tank, use defoamer on the
carpet being cleaned.
6.2. Condensation in system This will be more common in cool weather and
humid climates. If this is the cause it should
dissipate after a few minutes of running.
6.3. The heat exchanger is
Inspect and repair or replace as necessary.
leaking water
Troubleshooting: 8-10
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