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HydraCat 4.0,4.5 High Performance c. 1991 - Owners

1. 32 31 OverallCareofUnit U eni 32 One Final 3i Purchaser s Responsibility 1 l l enero 3 MaintenanceLogs 33 Sales Representative s Responsibility csse 3 M ecu m 4 4 36 4 Warranty 36 Truck Preparation Illustration Limited Warranty Inside back cover Placementof Unitin Vehicle esee cerit EMMM Propane Tank Location esee eene tentaret tentent neto 51 Hard Water Area 5i S Water Softener eee ie 5i Wastewater Disposal Advisory 6 i 22 Machine Adjustments nnne 6 Machine Tie Down Ceas III 4 Machine Contiguration l u 5 OPERATING INSTRUCTIONS amp PRECAUTIONS Propane TankPlumbing tee 5 SITUB ua cords eiddsquen mau Ru dofus 6 Hard Water 5 6 WalerSo
2. 13 i Vacuum Blower Motor Lubrication s 13 Vacuum Blower Lubrication s 13 i Pilot Burner Adjustment l u uu u u 15 Vacuum Blower Trouble Shooting 14 Model 290 Exploded 17 i Pumping Section Cutaway I a 18 Heating System In ormation l a 14 i HydraCat Electrical 22 Heater Operating 15 Basic Dimensions 224 23 Heater Trouble Shooting Guide sss ERREUR 1 5 i Basic Dimensions 220 23 Ri p a 25 at Pump Model OS La me la gro RTT 26 en Pb 2 i P220 Crankcase 4 ee Model 290 aaa 17 P224Crankcase 4 4 4 44 0 26 General Information for Cat Pump Repair CERE TURPE 18 Servicing Spark Plug 27 Servicing the Valve Assemblies ceases te 18 i Air Cleaner Assembly 28 Servicing the Pumping Section
3. 19 i Specific Gravity Test 28 Servicing Sleeves and Seals es 19 Battery Cable Connection ass 28 Servicing Crankcase 1 1 21 21 19 Cat Pump Trouble Shooting 20 LIST OF PHOTOS HydraCat Electrical System 22 i HydraCat front view featureslabeled 7 HydraCat side view 1 7 Onan Performer Engine Specs uu 23 CatPump Model290 u u Lee retia 16 General Information about 24 i Servicing the Pump uu a 19 i Onan Performer Gasoline 23 ENGINE MAINTENANCES l uu 25 i Spark Plug Diagnosis recette rtt aaa 27 o ss a UU II a 25 2 GENERAL INFORMATION MACHINE SPECIFICATIONS This manual contains installation and operation instructions as well asin formation required for proper maintenance adjustment and repair of this unit Since the first and most important part of repair work is the correct diagnosis of the trouble a general troubleshooting section and compon
4. i STORING BATTERY If the engine is to be stored for more than 30 days remove the battery With the electrolyte level at the bottom of the split ring i charge the battery before storing it After every 30 days the battery is in i storage bring it back up to full charge To reduce self discharge store the battery as cool a place as possible so long as the electrolyte does not Disconnect negative ground strap from the battery before working on any part of the electrical system or engine Disconnect positive terminal before charging battery to avoid damaging ignition system alternator or regulator Ignition of explosive battery gases can result in severe personal injury Do nat smoke or allow any ignition source near the battery freeze Specific Gravity Test Specific Gravity Reading should be 1 260 at 77 F 25 We s Bas BATTERY TERMINALS CLEANING BATTERY Keep the battery clean by wipingit with a damp cloth 4 Keep the battery terminals clean and tight Push the cable terminal down i flush with or slightly below the top of the battery post After making connec if corrosion is present around the terminal connections remove battery whenever dirt appears excessive consisting of 1 4 pound of baking soda added to 1 quart of water cells Be sure the vent plugs are tight to prevent cleaning solution from entering After cleaning flush the outside of the
5. 4 Be aware that solution lines laying on frozen ground may freeze 5 Contact local propane dealer about cold weather propane use i SHUT DOWN 1 heater to off position Spray wand for at least 3 minutes to allow the heater coils to cool 2 Close valve on propane tank and through floor hook up i 3 Remove vacuum hose i 4 Flush clear water through chemical system for 10 seconds Vinegar adjustments to achieve optimum performance i e altitude may require carb should be rinsed through system weekly Tum off chemical flow meter 5 Tumon cleaning too to flush chemical from unithoses and cleaning tool NOTE If freeze guard is necessary perform steps 1 amp 2 of freeze guard procedure at this time 6 At this time the blower should be lubricated with Pennzguard 7 Shut engine down 8 Drain vacuum tank Vacuum filter should be cleaned prior to mobilization of van NOTE If freeze guard is necessary perform steps 3 7 of freeze quard procedure at this time Vacuum Gauge Circuit Breakers PRM Gauge Hour Meter Pressure Gauge Temp Gauge Vacuum Tank Inlets Chemical Choke Flow Meter Vacuum Pump _ Lubrication Port Ignition Chemical Jug Machine Exhaust Vacuum Tank Dump Valve Incoming Exhaust Water Bypass Valve High Pressure Cleaning Solution Chemical High Pressure Water Pump Mix Tank Wa
6. Corporation Bi vPERFOHWANCGE lt gt lt OWNERS 1991 HydraMaster Corp Printed in U S A TABLE OF CONTENTS PLC NE 27 Cooling System 27 Exhaust Syslern U DNE 27 GENERAL INFORMATION eie 27 How the System Works u u 2i pur E 28 Spare Parts Recommendalion aaa 2 Periodic Maintenance Schedule 29 Machine Specifications ttt 2 Engine Trouble Shooting l n rac arti 30 Warning and Caution L 2 3 Maintenance
7. Replace bearing 20 CAT PUMP TROUBLE SHOOTING GUIDE Cause Solution Wom ball bearing from excessive tension on drive belt Replace ball bearing Properly tension belt Cause Solution May be caused by humid air condensing into water inside the crankcase Change oil at 3 month or 500 hour intervals using Cat pump crankcase oil other approved oil every month or 200 hours P N 06100 Leakage of manifold inlet seals and or piston rod sleeves O Ring Replace seals sleeves and O Rings Cause Solution Wom crankcase piston rod seals Replace seals sleeve and O Rings Cause Solution Damaged or improperly installed oil gauge or crankcase rear cover O Ring and Replace oil gauge or cover O Ring and drain plug O Ring drain plug O Ring Cause Solution Loose drain plug or worn drain plug O Ring Tighten drain plug or replace O Ring Cause Solution Pulley loose on crankshaft Check key and tighten set screw roken worn bearing Replace bearings PROBLEM Frequent or premature fallure of the inlet manifold seals Cause Solution Scored rods or sleeves Replace rods and sleeves Over pressure to inlet manifold Reduce inlet pressure per instructions PROBLEM Short cup life Cause Solution Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Excessive pressure and or tem
8. guide to locate causing factors i PROBLEM Engine cranks but will not start i Solution mpty fuel tank Clogged fuel line lug leads disconnected Keyswitch or kill switch in off position i PROBLEM Engine runs but misses i Solution i Dirt or water in fuel system i Spark plug leads loose Loose wires or connections which intermittently short kill terminal of ignition module to ground I Carburetor improperly adjusted PROBLEM Engine will not idle Solution Idle speed adjusting screw improperly set i Dirt or water in fuel system Faulty spark plugs Faulty ignition module Dirt or water in fuel system i Idle fuel adjusting screw improperly set i Restricted fuel tank vent PROBLEM Engine starts but does not keep running Solution Restricted fuel tank vent Dirt or water in fuel system Faulty choke or throttle controls cables Loose wires or connections which kill terminal of ignition module to ground Carburetor improperly adjusted PROBLEM Engine overheats i Solution Grass screen cooling fins shrouding clogged i Excessive engine load Low crankcase oil level Faulty cylinder head gaskets i High crankcase oil level Faulty fuel pump PROBLEM Engine starts hard Solution Loose wires or connections Dirt or water in fuel system Clogged or restricted fuel lines Faulty choke or throt
9. short or hot cut kit 6 piston sleeve rings 3 Prrm A Lube seals 1 bottle Cat oil Read instructions thoroughly supplied in the Cat pump manual prior to dis assembly and follow directions as stated all seals thoroughly prior toin stallation Remember a newly scarred seal is no better than one you just took out SERVICING THE VALVE ASSEMBLIES DISASSEMBLY 1 Remove the fasteners securing the discharge manifold to the crankcase of the pump 2 Support the discharge manifold and tap from the backside and a soft mallet to separate from the crankcase and gradually work free from cylinders 3 Valve assemblies will remain in the manifold Pump models with the o ring groove on the outside of the valve seat require the assistance of a reverse pliers to remove the valve seat The valve spring and retainer will then fall out when the manifold is inverted Pump models without the o ring groove on the outside of the valve seat permit the seat valve spring and retainer to fall out when manifold is inverted REASSEMBLY 1 Place retainers in manifold chambers 2 Next insert spring into center of retainer 3 Inspect the valves for wear ridges or pitting and replace if necessary NOTE Seating side of flat valves may be lapped on flat surface using 240 grit paper Quiet valves due to their shape must be replaced Insert valve over spring with recessed dish side down 4 Nex
10. 1 211 IR loi FILTER 2 REMOVAL 275 x 699 21 53R 2 SLOTS NO 10 32 UNF 4 FOLES ON A 2672 67 87 200 Sog KEY 3 8 16 UNC 4 HOLES 4 3250 182 55 162514128 378 24 UNF 28 1125 2857 CRANK STUB 6375 63 4 LOT MALE 23 894 2271 2 wey i 350 2 ean 2 HOLES Dimensions in inches millimeters shown in parentheses 41 10 4 4 2 MTG HOLES Dimensions in inches millimeters shown in parentheses ONAN ENGINE DETAIL Cycle 4 Cylinders 2 horizontally opposed Compression Ratio 7 0 to 1 Piston Speed 1800 fom 9144 mm s at 3600 rpm Net Weight 127 lb 57 6 kg dry approximate Breather System Closed recirculating Cooling System Pressure air cooled radial flow blower Cooling air volume 1000 1699 m hr at 3600 rpm Fuel System Modem downdraft carburetor with fixed main jet limited adjustment idle system Semi automatic choke operation with anti flooding feature Combustion air required at 3600 rpm 50 cfm 85 m hr i Governor Constant speedcam gear driven Adjustable mechanical flyball 300 rpm drop to 3600 rpm Ignition System Solid state breakerless ignition with fixed timing 12 volt negative ground suppression spark plug wires meet UL and CSA interference requirements Starter Positive engagement solenoid type starter 12 volt negative ground Lubrication System Positive displa
11. cylinder head Follow a regular schedule of inspection and servicing based on operating hours Keep an accurate logbook of maintenance serving and operating efficient engine life Regular service periods are recommended for normal etc service more frequently Neglecting routine maintenance can result in engine failure or permanent damage Service Center Maintenance Schedule Footnotes 1 Check for fuel leaks With engine running visually and audibly check time Use the factory recommended Periodic Maintenance Schedule based on favorable operating conditions to serve as a guide to get long rs i 2 Perform more often when running under severe operating conditions service and operating conditions For severe duty extreme temperature 3 Required for initial break in only exhaust system for leaks E I i 4 For detailed maintenance contactan Onan Service Center or refer to the For any abnormalities in operation unusual noises from the engine or accessories loss of power overheating contact your nearest Onan i 5 Clean carbon more frequently when running under continuous light load SERVICE MANUAL and or on leaded fuel Use of Onan 4C carburetor and combustion cleaner is recommended every 200 hours to help reduce carbon buildup i Breathing exhaust gases can result in severe personal injury or death Do i notuse air cleaner exhaust elbow or connect
12. 1 year components not specifically referenced in the above schedule are covered under this warranty for a period of one 1 year excepting those parts which are considered by HydraMaster to be expendable in normal use Freezing of any water or chemical related component will VOID all warranties on water or chemical related components internal or external of this equipment Deposits and build up in the water system chemical system or heater system due to hardness in the water used or chemicals which result in deposits will void all warranties on affected components REV 5 92 3 wll Corporation 1 E a E
13. 174 004 Flat washer 5 16 US 1 64 174 018 Lock washer 5 16 US 1 GENERAL INFORMATION FOR CAT PUMP REPAIR As you remove your discharge manifold there is set of 3 check valves which usually fall out during dis assembly If the surfaces of these check valves are dirty or show signs of chemical build up itis probable that they would remain open causing pressure loss or pulsation Upon inspecting the valves make sure that the teflon button in the valve spring retainers are still intact Also examine the discharge manifold Look for problems such as cracks chemical buildup or warpage due to freezing If this discharge manifold is warped it will cause the check valves to stick and will result loss of pressure The Cat pump cups are often the source of pressure loss Upon inspection they may appear melted or torn but often they will look good Replace them anyway There is sure method of visually inspecting the cups HydraMas 1 o i NOTE Lubricate o rings on cylinder and exercise caution when slipping ter recommends changing cups whether they look good or not Anytime your pump is being dismantled HydraMaster recommends re i placement of all 0 rings and seals This is merely a convenience to the customer to make sure that the Cat pump is in top operating condition defective Prrrrrm A Lube seal Replace them all bling make sure you have the proper parts required 1
14. At no time should a chemical solution with a pH of less than 7 or higher than 10 be used in the unit pH CHART 1 2 34 5 6 7 8 9 10 11 12 13 14 4 NEUTRAL ALKALINE i Failure to adopt this procedure can result in increased chance of clean 5 Continue to add anti freeze solution until mixture comes out of wand set i Sonn aga Out ana longar at yg INCORRECT METHOD CORRECT METHOD Between Strokes d 1 1 4 h 2 Tool pum Second Cleaning Cleaning Stroke Stroke OVER WETTING r wetting is annoyi l metimes leaves bad im wening annoi all concemed and somelmasiea i i from the wand until the quart of vinegar is exhausted the repeat the process with one quart of clear water to void all lines of vinegar THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER WETTING I pression of the cleaning process used 1 Too few vacuum strokes or improper saw tooth vacuum strokes as shown in the previous illustration 2 Obstructed kinked or cut hoses 3 Vacuum tank drain valve left partially open 4 Clogged vacuum blower filter or vacuum tank lid not sealing properly 5 Cleaning a heavily foam saturated carpet without defoamer We recom i mend crystal type WATER AND CHEMICAL FLOW OPERATION This electro mechanical system has been designed to be simple and trouble free Inco
15. Inlet restrictions and or air leaks Damaged cup or stuck inlet or discharge valve Replace wom cup or cups clean out foreign material replace wom valves Worn inlet manifold seals Prrrrrm A Lubes PROBLEM Cylinder O Rings blown next to discharge manifold Replace worn seals Cause Pressures in excess of rated PSI Solution Check for plugged nozzle closed valves or improperly adjusted b valve arped manifold Freezing Replace manifold PROBLEM Leakage at the cylinder O Rings at the discharge manifold and black powdery substance In the area of the O Ring Cause Solution Loose cylinders Cylinder motion caused by improper torque on the discharge Retighten Do not tighten too much or the ears of the manifold will be bowed causing manifold looseness in the center cylinder PROBLEM Water leakage from under the inlet manifold Cause Worn inlet manifold seals Prrrrrm A Lube Leaking sleeve O Ring Solution Install seals If piston rod sleeves are scored replace sleeves and sleeve O Rings PROBLEM Oil leak between crankcase and pumping section Cause Solution Worn crankcase pision rod seals Replace crankcase piston rod seals PROBLEM Oil leaking In the area of the crankshait Cause Solution Wom crankshaft seal or improperly installed oil seal retainer packing Remove seal retainer and replace damaged gasket and or seals Bad bearing
16. WIRING check for chafting CHEMICAL SYSTEM flush w vinegar MONTHLY SERVICE ENGINE change BLOWER grease bearing ENGINE AIR CLEANER clean BY PASS VALVE grease cup amp stem QUARTERLY SERVICE 3 MONTHS BLOWER change ENGINE compression SPARK PLUGS change 34 WARRANTY INFORMATION To avoid misunderstandings which might occur between machine owners and manufacturer we are listing causes of component failure that specifi cally voids warranty coverage Such causes as listed below shall constitute abuse or neglect BLOWER Failure to lubricate impellers daily with LPS 1 WD 40 lubri oil grade and viscosity as recommended in blower manual Failure fo screen vacuum safety relief valve and waste tank automatic shut off system Allowing foam to pass through blower HIGH PRESSURE WATER PUMP Failure to maintain proper oil level as recommended in pump manual Failure to change oil in pump at recom mended intervals Failure to protect pump against freezing Failure to maintain pump protection shut off system Failure to use water softener in hard water areas Use of improper chemicals WARRANTY PROCEDURE Warranty coverage is available to you ONLY through HydraMaster Corpo ration 20309 64th Ave West Lynnwood Washington 98036 When war i ranty parts are needed write HydraMaster Warranty Dept at the above ad
17. battery the battery compartment and surrounding areas with clear water Keep the battery terminals clean and tight After making connections coat i the terminals with a light application of petroleum jelly or non conductive grease to retard corrosion CHECKING SPECIFIC GRAVITY Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 F 27 C or subtracting four gravity points for every five degrees below 80 F 27 C A fully charged battery will have a corrected ule Page 29 for checking electrolyte level interval tions coat the terminals with light application of petroleum jelly or grease cables and wash the terminals with an ammonia solution or a solution 9 retard corrosion Battery Cable Connection Battery Post d Cable Terminal i Poor contact at the battery cable connections is often a source of trouble Hold the hydrometer vertical and take the reading Correct the reading by Make sure battery cables are in good condition and that contacting surfaces are clean and tightly connected Do not reverse battery leads Use recom mended battery tools when disconnecting leads to avoid mechanical battery damage Specific gravity of 1 260 Charge the battery if the reading is below 1 215 i BATTERY JUMP STARTING CHECKING ELECTROLYTE LEVEL Re
18. filter in recovery tank thoroughly clean removing all lint build up inspect for damage and reinstall i Remove filter bag thoroughly clean and reinstall if torn replace empty i chemical from chemical container wash out thoroughly to remove any i chemical build up inspect chemical feed line strainer and use 50 white vinegar water solution to remove any chemical build up thoroughly clean i wand and inspect for clogged jet debris in vacuum slot and leaking fittings atvalve Apply light coat of auto wax to wand Thoroughly clean vacuum and high pressure hoses including hose cuffs inspect for wear or damage to hoses and quick connect fittings Inspect garden hose connect adapter screen for debris remove and clean thoroughly inspect all lines for wear or abrasions that may cause possible leaks MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine ail check Clean vac tank filter bag after every job Garden hose screen clean Blower inlet spray with LPS 1 after last job Machine general inspection WEEKLY SERVICE MAX HRS SERVICE DATE HAS DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS 25 BLOWER check oil level We 25 25 ORIVE SHAFT SYSTEM tighten set screws 25 BELTS amp PULLEYS check tightness 25 HIGH PRESSURE LINES check for chafing 25 NUTS amp BOLTS check tightness 25 BATTERY LEVELS check 25 VACUUM TANK clean 25 WIRING check for chafting 25 CHEMICAL SYSTEM flush w
19. intothe Chemical Jug To check this screen for proper function remove from the plastic hose If you cannot blow through it then rinse il out wilh vinegar Check the Chemical How Meter 6 for obstructions or a sticking float incoming water pressure less than 30 PSI Cracked or defective Chemical Flow Meter 6 Check the filter screen in the Solenoid Control Valve 1 PROBLEM Inability to adjust chemical with the Fiow Meter Salution Debris lodged behind teflon seat in Flow Meter valve Teflon seat on the valve stem may be loose If deteriorated replace O Ring PROBLEM Solution reversing from Mix Tank filling the Chemical Jug Solution Anti siphon device clogged by chemical build up Anti siphon device is located in I the Chemical Injactor 2 body see page 9 Water Flow illustration Check for debris PROBLEM Mix Tank overflows Solution loat switch 4 in the Mix Tank not moving freely or defective m1 be power through the switch Tocheckswitch With a 12 volt test light and the float inthe up position there should I To check relay First check wiring against diagram With 12 test light and the Float Switch 4 inthe up position there should NOT be power at the Solenaid i Valve With the Float Switch in the down position there should be power at the Sloenoid Valve Solenoid Valve defective Remove Solenoid Valve disassemble a
20. many surfaces on the machine will i become very hot When near the van for any reason care must be taken not to touch any hot surface such as heater engine exhaust eic MOVING PARTS i Never touch any part of the machine that is in motion severe bodily injury may result 1 RT ET CL E E CARBON MONOXIDE i This unit generates toxic fumes Position the vehicle so that the fumes will i be directed AWAY from the job site i DO NOT PARK where exhaust fumes can enter a building through open i doors or windows air conditioning units or kitchen fans FREEZE PROTECTION Any freezing of this machine is not covered by warranty and during the THE FOLLOWING PRECAUTIONS ARE RECOMMENDED 1 Run machine before leaving for the first job to insure nothing has frozen I carpet cleaning trade and it can produce only as good a job as the person the night before including hoses and wand 2 Insulate the garden hose from the cold ground by running it through an extra 1 1 2 inch vacuum hose 3 In colder climates insulating the truck walls and floor boards will help protect the unit in extremely cold climates the possibility of it going out is higher If the machine and truck are left machine cleaning tools and hoses They freeze also TO DRAIN THE MACHINE FOLLOW THESE STEPS 1 Siphon a 50 50 mixture of anti freeze and water through the chemical flow meter 2 Drain the mix tank
21. needed QUARTERLY Change oil in blower Check engine compression Check for combustion chamber carbon deposit Change spark plugs IMPORTANT Record date and machine hours on maintenance chart 2 Maintenance troubleshooting and repair is much easier to accomplish i ona clean well maintained unit Regular cleaning of the machine offers you an opportunity to visually inspect all facets of the machine and spot potential problems before they occur FOLLOWING MAINTENANCE IS RECOMMENDED BY THE MANUFAC TURER THE FREQUENCY INDICATED i AFTER EACH JOB Check recovery tank s s filter and filter bag as required DAILY Wipe machine down thoroughly with a damp cloth flush recovery tank out i thoroughly Empty filter bag and inspect for rips tears etc replace as i needed remove thoroughly clean and reinstall stainless steel filter screen in recovery tank inspect and clean vacuum slot on cleaning wand check wand head for sharp edges that could tear carpet file down as needed clean wand to maintain original appearance wipe down vacuum and high i pressure hoses as needed visually inspect for cuts etc i WEEKLY i Wipe down entire unitas needed apply good coat of auto wax to all painted i Surfaces inside and out and to control panel thoroughly clean recovery tank using high pressure hot water unit with optional high pressure cleaning gun may be used for this remove stainless steel
22. per specifications with Cat Pump oil or equilvalent SAE 40 weight hydraulic oil with antiwear and rust inhibitor additives Change initial fill after 50 hour run in period Change oil every three months or at 500 hour intervals thereafter Prrrrm a lube seals need no lubrication Blue dot seals and wick must receive three drops of Cat Pump oil per wick every 50 hours of operation GOOD LUBRICATION IS THE EASIEST MOST EFFICIENT AND LEAST EXPENSIVE OF PREVENTATIVE MAINTENANCE RPM and PRESSURE Pump operation must be within RPM and pressure specifications Pressure relief valve must be installed DO NOT PUMP ACIDS OR ABRASIVE FLUIDS with this unit Consult Cat Pumps for additional information on questionable fluids FREEZING CONDITIONS Pump must be protected from freezing conditions USE OF OTHER THAN CAT PUMP PARTS OR THEIR EQUIVALENT VOIDS THE WARRANTY 16 PISTON MODEL 290 Exploded View PARTS LIST MODEL 290 DESCRIPTION QTY PART NO DESCRIPTION QTY 1 20285 O Ring Buna N 1 35 30315 Prrmm A Lube seal 3 2 44274 Crankcase 1 30325 Prrrrrm A Lube seal Viton 3 3 85680 Stud M8 x 82 2 38 27004 Inlet valve 3 4 44377 O Ring oil filler cap 1 39 30543 Bac Cup piston 3 5 44374 filler cap 1 40 30544 Bac Cup ring Teflon 3 8 43340 O Ring c
23. seal externally for drying cracking or leaking 5 Consult factory or your local distributor if crankcase service is evidenced PUMP TROUBLE SHOOTING GUIDE PROBLEM Pulsation Cause Solution Debris in discharge valves of pump Clean or replace discharge valves Worn Prirrrm A Lube seals Replace PROBLEM Low pressure Cause Solution Warm nozzle Replace nozzle of proper size slippage Tighten or replace use correct belt Air leak in inlet plumbing Relief valve stuck partially plugged or improperly adjusted valve seat worn Inlet suction strainer clogged or improper size Worn piston assembly Abrasives in pumped fluid or serve cavitation Inadequate water supply Fouled dirty inlet or discharge valves Disassemble reseal and reassemble Clean and adjust relief valve check for worn and dirty valve seats Kit available Clean Use adequate size Check more frequently Install proper filter Suction at inlet manifold must be limited to lifting less than 20 feet of water or 8 5 PSI vacuum Clean inlet and discharge valve assemblies Leaky discharge hose Replace worn valves valve seats Replace discharge hose PROBLEM Pump runs extremely rough pressure is very low Cause Solution Restricted inlet or air entering the inlet plumbing Proper size inlet plumbing check for air tight seal
24. these highly advanced I 2 cleaning plants There must also be no guess work in preparing it to get the RECOVERY TANK 70 gallon aluminum Epoxy finish job done the field It is the purpose of this manual to help you properly understand maintain and service your cleaning plant Follow the directions i CLEANING WAND Stainless steel with heat shield Grip and replaceable carefully and you will be rewarded with years of profitable trouble free i vacuum jpa with solo vak HIPRESSURE HOSE 1 4 High temperature lined vinyl covered Hose isimperative that no section be overlooked when preparing for operation rated to 1250 PSI VACUUM HOSE 2 reinforced 1 1 2 reinforced system and returned to the waste recovery tank operation of this equipment SPARE PARTS RECOMMENDATION STANDARD EQUIPMENT Power console Sound suppression package Electric Pump Clutch Water heater Vacuum Recovery tank Carpet Cleaning wand Chemical jug Chemicaljugholder Chemical jugfill line Op eration manual 150 ft 2 vacuum hose 10 ft 1 1 2 vacuum hose 150 ft Because your truck mounted unit is capable of generating several hundred dollars per day down time on the unit can be very expensive We Freeze guard system Battery box with holder Van decal package Fuel system kit Installation kit In order to minimize such down time it is strongly recommended by the manufacturer that yo
25. to protect against freezing CONTROL PANEL Failure to protect flowmeter and water pressure gauge against freezing VACUUM AND SOLUTION HOSES Failure to protect hoses against freezing Failure to protect hoses against bums from engine blower ex haust Damage to hoses from being run over by vehicles Kinking cracking from failure to store or unroll hoses correctly Normal wear and tear from everyday use abuse of wand CLEANING WAND Failure to protect against freezing Obvious physical WATER HEATER Over pressurization of the system recommended maximum working pressure 800 PSI Failure to protect against freezing Modification of the gas delivery system 36 E E DN Im T ET Pm LDEN GUAI LIMITED VARRANTY PL HydraMaster warrants truckmount machines of its manufacture to be free from defects in material and workmanship if properly installed maintained and operated under normal conditions with competent supervision No person agent representative or dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in connection with any of HydraMaster s products This warranty shall extend to the original purchaser of said equipment for the periods listed by component below from date of installation If repairs or replacements are made by the Pur
26. vented oil fill plug on gear end Remove oil level plug B located in the head plate Fill gear case until oil drips out of the 100 level hole Use lubricants as listed Add fresh oil as required to maintain opa 200 proper level The oil should be drained flushed and replaced every 1500 hours more frequently if inspection so indicates The drain plug is at C NOTE Older units may have the fill level and drain holes located in the cast iron gear case instead of in the head plate Bearings on drive end of blower require grease lubrication every 100 hours of operation Bearings which require grease lubrication will have a grease fitting D at each bearing When regreasing the old grease will be forced out of the vents during operation To prevent damage to seals these vents must be kept open at all times over 135 C SAE 50 applications with extreme variations in ambient temperature a 20W 50W multiple viscosity ail is recommended FOR GREASE LUBRICATED BEARINGS Service every 500 hours of operation BLOWER DISCHARGE TYPE TEMPERATURE GREASE 40 10 275 F 2 40 10 120 C Bearing Grease EVERY 100 HOURS VACUUM BLOWER TROUBLE SHOOTING GUIDE PROBLEM Loss of pressure Cause Collapsed vacuum hose between blower and vacuum tank Solution Remove and replace hose NOTE A special reinforced hose is required for replaceme
27. vinegar L ee M MONTHLY SERVICE 100 100 BLOWER grease bearing 100 ENGINE AIR CLEANER clean 100 BY PASS VALVE grease cup amp stem ff Ig PEE QUARTERLY SERVICE 3 MONTHS 300 ENGINE compression 300 SPARK PLUGS change fe a MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine ail check Clean vac tank filter bag after every job Garden hose screen clean Blower inlet spray with LPS 1 after last job Machine general inspection WEEKLY SERVICE MAX HRS SERVICE DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS 25 OCET Y YE TICT Tm check oil level 25 PUMP OIL check PUMP OIL check top of sight gauge of sight gauge 25 DRIVE SHAFT SYSTEM 19 set screws 25 25 25 25 25 VACUUM TANK clean 25 WIRING check for chating 25 CHEMICAL SYSTEM flush w vinegar Ee sss meee MONTHLY SERVICE 100 ENGINE OIL change 100 BLOWER grease bearing 100 ENGINE AIR CLEANER clean QUARTERLY SERVICE 3 RE EEEE BLOWER OIL change pz ENGINE compression SPARK PLUGS change es MEM HRS 25 25 25 25 25 25 25 28 28 25 300 300 300 MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine ail check Garden hose screen clean Machine general inspection
28. when operating under severe operating conditions Service by gently i tapping element see illustration on next page on a flat surface ELEMENT WRAPPER If Equipped Refer to Periodic Maintenance Schedule Page 29 for element wrapper service interval Wash in water and detergent and squeeze dry like a sponge Ring with water Allow to dry i Continues next page 27 Continued from previous page element Air Cleaner Assembly i ga Wing Nut S DU Cover UM w me Element Cover 5 Element Wrapper Air Cleaner Element Air Deflector Plate BATTERY Fill the battery cells to the bottom of the filler neck If cells are low on water then coat evenly with two tablespoons 28 grams of SAE 30 engine oil Knead into and wring out excess oil from element wrapper Failure to adequately wring out excess oil from wrapper may cause drop in engine horsepower due to an increased restriction of inlet air Install over air cleaner add distilled water and recharge If one is low check case for leaks Keep the battery case clean and dry An accumulation of moisture will lead to a more rapid discharge and battery failure CAUTION Water added to battery electrolyte in freezing weather can damage the battery Do not add water to battery unless the engine is run long enough I two or three hours to ensure a thorough mixing of water and electrolyle
29. 3 Connect the freeze guard hose to the recovery tank 4 Connect the other end of the freeze guardfitting to the freeze guard fitting i located on the side of the machine 8 Connect an open 440 quick connect to the fittings marked cleaning solution on the front of the machine An alternative would be to connect your solution hoses and wand so as to freeze guard them also If you choose to do this you will also need to hold the trigger down on the wand 6 Start the unit allowing the vacuum from the machine to drain the lines 7 Remove the garden hose inlet adapter from the end of the gardenhose CLEANING STROKE PROCEDURE OVER WETTING i PURPOSE To eliminate excess moisture remaining in the carpet fiber and i the sawtooth appearance which results from diagonal movement of the i cleaning tool on all types of carpet Connect the adapter to the incoming water quick connect on the front of ihe machine 8 Place a vacuum hose over the garden hose quick connect and allow the vacuum from the machine to drain the lines An alternative to 7 amp 8 would be to make an adapter to allow you to use the premade freeze guard hose NOTE Prior to freeze guarding your machine make sure the heating system PROCEDURE Always move the cleaning tool in smooth forward and back i ward strokes Apply slight pressure to the forward stroke while the solution i is injected into the carpet When extracting drying apply firm pressu
30. ACHIEVE PROPER CARPET CLEANING TEMPERATURE 1 Complete procedures 8 B chemical containers hose boxes etc from within 18 inches of base of heater NOTE This restricted situation also creates an over rich condition i which results in soot build up IMPORTANT new propane tank hasbeeninstalledorhoseshavebeen disconnected air may enter propane hoses and must be purged prior to attempting to light the pilotburner Should this condition exist operatormust depress the pilot button for 1 5 minutes and attempt to ignite the pilot light at 15 second intervals A very slight hissing noise should be evident while performing this operation 2 With 100 of hose turn cleaning wand on for 5 minuies and the temperature should stabilize 3 Once a constant temperature is established turn cleaning wand off The flame on the heater should remain on for 10 15 seconds A If the flame expires prior to 10 seconds turn the thermostat dial to a higher reading then repeat C 1 3 B If the flame remains lit after 15 seconds tum the thermostat dial to a lower reading then repeat C 1 3 D TO SHUT DOWN HEATER 1 Tum upper dial 1 to off position Check heater for propane leaks regularly as loading and unloading hoses 0015 may accidentally bump against heater fitting or pipes SEE ADDITIONAL CAUTIONS IN OPERATION PRECAUTIONS SECTION PAGE 7 HEATER OPERATING INSTRUCTIONS He
31. NAL SA Harmoniestraat 29 B 2000 Antwerp Belgium Phone 03 237 72 24 Telex 33947 i CAT PUMP WARRANTY This Cat Pump product is warranted by the manufacturer to be free from defects in workmanship and material for one year from date of manufacturer s shipment This warranty is limited to repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty shall be returned Cat Pumps Corp Minneapolis Minnesota 55430 U S A for examination repair or replacement The express warranty set forth herein is in of all other warranties express or implied including without limitation any warranties of merchantability or fitness for a particular purpose and all such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided hereunder and the manufacturer shall not be liable for any further loss damages or expenses including incidental or consequential damages directly or indirectly arising from the sale or use of this product This warranty is subject to the following warranty conditions important Conditions LUBRICATION fill crankcase to the top of oil gauge window
32. NIT IS i IMPORTANT FOR TWO REASONS 1 lt represents big dollar investment for your cleaning business and its appearance should reflect that fact A dirty machine is not professional on next page it is recommended that you affix a copy of the log on vehicle door near your unit for convenience and to serve as a maintenance reminder DAILY Check engine oil level Inspect garden hose screen clean as needed Visually inspect machine for loose wires oil leaks water leaks etc inspect recovery tank s s filter and filter bag for tears holes etc clean repair or replace as needed Lubricate blower with Pennzguard through blower inlet WEEKLY Change engine oil 25 30 hours of operation Check engine air cleaner filter clean as necessary Check h gh pressure pump add as necessary Check drive coupler set screws tighten as needed Check pump drive belt for wear tighten as needed Check pump pulleys tighten as needed Check fuel lines for wear chafing Check all nuts and bolts tighten as needed Check heater bumer assy union for tightness leaks Clean vacuum tank thoroughly with high pressure washer Flush water and chemical system with 50 50 white vinegar solution Check engine RPM s adjust to 2600 rpm on 4 5 2800 rpm on 4 0 MONTHLY Grease blower bearing fittings Remove pressure bypass valve stem grease cup and stem reinstall Check water level in battery Clean connections as
33. WEEKLY SERVICE SERVICE BLOWER check oil level PUMP check top sight gauge DATE HRS Clean vac tank filter bag after every job Blower inlet spray with LPS 1 after last job DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS DATE HRS DRIVE SHAFT SYSTEM lig BELTS amp PULLEYS check tightness HIGH PRESSURE LINES check tor chafing NUTS BOLTS check tightness BATTERY LEVELS check WIRING check tor chatting s CHEMICAL SYSTEM flush w vinegar MONTHLY SERVICE ENGINE OIL change grease bearing ENGINE AIR CLEANER clean BY PASS VALVE grease cup amp stem QUARTERLY SERVICE 3 MONTHS 300 BLOWER change ENGINE compression SPARK PLUGS change MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine ail check Garden hose screen clean Machine general inspection WEEKLY SERVICE SERVICE DATE HRS Clean vac tank filter bag after every job Biower inlet spray with LPS 1 after last job DATE HRS DATE HRS BLOWER check oil tevel DATE HRS DATE HRS DATE HRS DATE HRS PUMP OIL check top of sight gauge DRIVE SHAFT SYSTEM tighten set screws BELTS amp PULLEYS check tightness HIGH PRESSURE LINES check for chafing NUTS amp BOLTS check tightness BATTERY LEVELS check VACUUM TANK clean
34. alfunction and to order warranty i replacement parts itisimportant that you proceed in the following manner PURCHASER S RESPONSIBILITY PRIOR TO ARRIVAL OF UNIT 1 Install 5 8 exterior plywood flooring in vehicle and cover with artificial turf i 2 Have belly mounted propane tank installed on vehicle Tank must be 1 Call HydraMaster Warranty Service Department at 206 775 7275 2 Give the Warranty Service representative the following information Name of your company and your address B Equipment model i e HydraCat BobCat 2 etc C Date of purchase D Hours on the unit E Serial number of unit F Name of person authorized to order parts G Salesman unit purchased from H Description of malfunction Pressure readings on high pressure gauge with wand turned and off 3 If warranty replacement parts are needed please specify method shipment desired NOTE All replacement parts are sent freight collect A U P S D Air Express B Air Freight E Aulo Freight C Air Mail 4 Do not give malfunctioning parts to a HydraMaster sales or service representative All parts must be returned directly to HydraMaster Freight prepald propane vapor type 3 Purchase heavy duty 42 60 amp hour battery and batiery slow chargedifnew If battery is not fully charged damage can occur to the engine i charging regulator READING OF OWNERS MANUAL It is the purchase
35. ater must be filled with water prior to igniting A TO START PILOT 1 Adjust thermostat control knob on unitrol to desired setting 3 2 Adjust upper dial to pilot position 1 3 Depress pilot button 2 4 Depress sparking button to light pilot 4 IF PILOT FAILS TO LIGHT Is propane tank full Is propane tank valve open Has air been properly bled from propane line Is ignitor system working WHEN PILOT LIGHTS Wait ten seconds depressing button manually then release button 2 wand on for 3 5 minutes to cool heater core If heater core isnotcooled itis possible that the heat retained in the core will cause boiling back into chemical mix tank This results in damages to Cat pump 3 Close propane tank valve while wand is on the heater is cooling i 2 Adjust pilot key to provide properly 3 Replace pilot adjustment cap Always keep face away from main opening to avoid ignition flash burn B TO MAIN BURNER 1 upper knob to position Flame will come i Allen head pipe plug 6 can be to read propane ounces HEATER TROUBLE SHOOTING i PROBLEM Excessive heat Flames protruding outside the lower openings Cause Solution i 1 Maladjustment of propane regulator NOTE Propane regulators are factory PILOT BURNER ADJUSTMENT 1 Remove pilot adjustment cap 5 sized flame removed for monometer insertio
36. ation point Atthe end of each day LPS 1 or Pennzguard should be sprayed in before shutting down the machine See blower lubrication illustration If you fail to lubricate vacuum blower daily rust deposits and moisture will decrease the life of the vacuum blower Read the vacuum blower manual carefully for proper oil change and grease application The maintenance log may differ slightly from the manual but the truck mounted carpet cleaning machine application is very demanding of the vacuum blower and therefore it should be maintained more regularly NOTE Vacuum tank is protected from overflowing by a vacuum tank float kill switch This switch is not activated by foam only by liquid Vacuum Flow Vacuum Blower B Vacuum Hose To Blower Exhaust Silencer VACUUM TANK FILTER BAGS HydraMaster filter bags are designed to trap all of the lint sand and dirt that would normally collect at the bottom of your vacuum tank The use of these bags if emptied at the end of each job will eliminate the build up of much of the debris in the tank The drawstring top of these bags is designed to be i tied to the incoming dirty water inlet in the vacuum tank Because of the close tolerances between the lobes and housing of the vac To reorder bags use part number 049 029 Vacuum Tank Filter Bags Vacuum Tank Inlet b Vacuum Tank Blower Lube Port Spray lubricant into b
37. cal Flow Meter setting on 10 GPH and the Water Heater off Simply spray water Chemical System Wiring Solenoid Valve p d GND To Ignition Switch 2 Chemical Injector Control Valve Bypass Valve 10 Heater Coil 11 Pressure Guage 6 Chemical Flow Meter 12 Incoming Water 7 Chemical Jug 13 Tank Drain 8 High Pressure Pump 14 To Wand High Pressure Low Pressure Chemical Proportion and Level Control Mix Tank 6FA 6UFS a Spon Injector Body S S lt Check Valve O Ring Chemical Adjusting Chemical Adjusting Cap Piston C Mmm gt Piston Piston Housing Spring Diaphgram Filter Screen gt 2 Solenoid Valve Body Mounting Water Inlet Plate CHEMICAL TANK TROUBLE SHOOTING GUIDE PROBLEM Little no chemical flow Solution Check that hoses at the Mix Tank 3 are secure Check that the hose from the top of the Flow Meter 6 to the Chemical Injector 2 is secure with no kinks leaks Check that the adjusting cap on the side of the injector is not screwed i all the way in Check the s s check valve inside the injector for chemical build i up and proper operation Check the hose from the bottom of the Flow Meter i to the Chemical Jug 7 lor kinks cracks or bubbl s Check the screen on the end of the hose which goes
38. ce of cleaned carpets enhanced when water i Softeners are incorporated in hard water areas Manufacturer strongly i urges the use of water softener units in areas exceeding 3 1 2 grains per i gallon Using the legend as a reference determine the quality of water in i your area and take action immediately should it be necessary Water Hardness Grains Per Gallon o 2v Z w 7 7 1012 101 2 and above WATER SOFTENER Many areas of the country have an excess of minerals in the water which results in what is commonly called hard water These minerals tend to i adhere to the insides of heater coils and other parts of the machines causing i damage and a loss of cleaning effectiveness Reports from several of our machine users commending the results of the i use of water softeners in conjunction with their machines prompts us to rec i ommend the procedure to everyone in a hard water area i The relatively low cost of a water softener service is more than made up for inthe increased life of machine parts and continued cleaning efficiency The i water softener will also increase the effectiveness of the cleaning chemical being used therefore less chemical will be needed i Contacta water softener distributor in your area for information on the rental ofa simple water treatment unit to carry in your truck Be sure to change the water softener in accordance with the capability of the softener Example If the
39. cement gear design oil pump Full pressure lubrication to main and connecting rod bearings and governor Fixed bypass oil pressure control Oil fill tube and level indicator Removable aluminum oil base Capacity 2 7 qt 2 56 L add 0 3 qt 0 3 L for qil filter Power Take Off Rear mount PTO pilot and keyed crankshaft extension Rotation CCW when facing PTO shaft Front mount PTO pilot Main Bearings Steel backed aluminum precision inserts replaceable I D 2 in 50 8 mm Length 1 in 25 4 mm Camshaft Cast iron alloy Replaceable lead babbitt bearings 2 Connecting Rods Forged steel Replaceable bearings Crankshaft Ductile iron Machined in oil passages Simultaneous oil feed from both ends of crankshaft Cylinders Crankcase Aluminum alloy with integrally cast pearlitic iron cylinder liners Cylinder Heads Removable aluminum alloy High turbulence combustion chambers Pistons Aluminum alloy Three ring two compression one oil control Cooled and lubricated by oil spray Tappets Barrel type adjustable Valves Exhaust chrome colbalt faced Intake steel alloy Replaceable valve guides Valve Seats Replaceable intake and exhaust Valve Rotators Exhaust valves GENERAL INFORMATION Engine Model Reference Identify your model by referring to the model and specification spec letter as shown on the unit nameplate Always use Incorrect service or replacement of parts can resultin severe personal in
40. cept as stated in this section and in the preceding section titled Warranty and except as to title there are no guarantees or warranties of merchantability fitness performance or otherwise express implied or statutory and HydraMaster shall have no liability for consequential incidental or other damages howsoever caused FRA MB COV ER ASSEMBLIES saoi 3 years VACUUM RECOVERY TANK CHEMICAL 8 22 22 3 years ENGINE Through original Manufacturer On Direct Drive units see original Manufacturer s warranty s sssesssesssssseessessescessessesessotasesnsneesseentscesessneseaserscrseeseseneneee 2 years VACUUM BLOWER Through original Manufacturer See Cooper Industries warranty ccssccessesseseetcssesesssescessesseesessvesseanseeesensnessesesseracensenacousenesentneeneneeene 2 years CHEMICAL PROPORTIONING 1 year CLEANING WAND EE 1 year INTERNAL MACHINE 1 year HIGH PRESSURE MESZ ERAT o Tacan g aident idana 1 year EXTERNAL MACHINE HOSES BELTS FITTINGS FILTER SCREENS GAUGES u 1 year WATER HEATER OR HEAT EXCHANGER u inani 1 year HIGH PRESSURE PUMP Through original 420 4 0
41. chaser without HydraMaster s written consent Hydramaster s warranty shall cease to be in effect No allowance will be granted for any repairs or alterations made by the Purchaser without HydraMaster s prior written consent Machinery equipment and accessories furnished by HydraMaster but manufactured by others are warranted only to the extent of the original manufacturer s warranty to HydraMaster HydraMaster agrees at its option to repair at the point of shipment or to replace without charge any parts or parts of products of HydraMaster s manufacture which within the specified warranty period shall be proved to HydraMaster s satisfaction to have been defective when shipped provided the Purchaser promptly notifies HydraMaster in writing of such alleged defect HydraMaster will pay all freight and transporation charges via normal ground shipping means for replacement of parts covered under this warranty This warranty covers parts as specified and does not cover labor which may be necessary in completing repairs HydraMaster s liability to Purchaser whether in contract or in tort arising out of warranties representation instructions or defects from any cause shall be limited to repairing or replacing the defective part or parts To qualify for warranty coverage defective parts must be returned to HydraMaster within 30 days No liability whatsoever shall attach to HydraMaster until said products have been paid for Ex
42. d provided the Purchaser promptly notifies FULLER in writing of such alleged defect FULLER S liability to Purchaser whether in contract or in tort arising out of warranties representations instructions or defects from any cause shall be limited to repairing or replacing of the defective part or parts as aforesaid f o b point of shipment No liability whatsoever shall attach to FULLER until said products have been paid for EXCEPT AS STATED IN THIS SECTION AND IN THE PRECEDING SECTION TITLED WARRANTY AND EXCEPT AS TO TITLE THERE ARE NO GUARANTEED OR WARRANTIES OF MERCHANTABILITY FITNESS PERFORMANCE OR OTHERWISE EXPRESS IMPLIED OR STATUTORY AND FULLER SHALL HAVE NO LIABILITY FOR CONSEQUENTIAL INCIDENTAL OR OTHER DAMAGES HOWSOEVER CAUSED DATE INSTALLED SERIAL FULLER COMPANY 2966 East victoria Street Compton California 90224 VACUUM BLOWER LUBRICATION At the gear end the timing gear teeth are lubricated by being partially submerged The gear teeth serve as oil slingers for gear end bearings At i the drive end of the bearings are grease lubricated i Blower Motor Lubrication LUBRICATION INSTRUCTIONS FOR OIL LUBRICATED GEARS AND BEARINGS Add fresh oil as required to maintain proper leval Orain and refill every 1500 hours of operation under normal service more fre quent q 9 9 i BLOWER OIL VISCOSITY FILLING PROCEDURE i TEMPERATURE USA eames Remove square head
43. d other harmful blow by materials from the crankcase These vapors are routed to the carburetor where they are mixed with incoming air and burned in the combustion chamber A sticky breather valve can cause oil leaks high oil consumption rough idle reduced engine power and rapid formation of sludge and varnish within the engine CRANKCASE BREATHER SERVICE ifthe crankcase becomes pressurized as evidenced by oil leaks at the seals i or excessive oil in the air cleaner housing use the following procedure to Service Most part cleaning solvents are flammable and can cause severe personal injury or death if used improperly Follow the manufacturer s recommenda tions when cleaning parts P220 Spec Aand 8 Remove the breather tube from the valve cover P220 Crankcase Breather illustration Remove capscrew flatwashers valve cover pack spring washer reed valve and breather baffle Discard gasket and clean all parts parts cleaning solvent CAUTION Overtightening ihe valve cover can cause engine damage Do not over i tighten valve cover The reed valve must be flat with no sign of a crease Assemble using new i gasket Refer to ASSEMBLY TORQUES for valve cover capscrew torque i specification i P216 P218 P220 Beginning Spec C The crankcase breather does not require servicing Replace breather if it s broken or cracked or if crankcase i becomes pressurized as evidenc
44. dress or call the Warranty Service Dept at 206 775 7275 No collect calls will be accepted Hours of Warranty Service Dept are 8 00 am to 5 00 pm Pacific Time cant Failure to lubricate bearings as recommended in blower manual i Failure to maintain proper oil levels in the blower Failure to use the correct IMPORTANT HydraMaster s warranty policy provides replacement parts without charge for thirty 30 days to customers maintaining currentaccount properly maintain blower safeguard systems such as waste tank filter status An invoice dated thirty 30 days from date of replacement parts shipment will be sent to the customer for the amount of the parts sent The i customers faulty parts must be returned for evaluation prior to the expira ton of the thirty 30 day period Upon warranty approval a credit will be t issued the customer for the replacement parts invoice Warranty disap proval or failure to return the faulty parts within the thirty 30 day period allowed will result in the customer being charged for the i replacement parts sent VAC TANK Failure to properly maintain filtering devices in tank Failure to clean tank as recommended by manufacturer Failure to maintain vacuum safety release in tank lid Use of improper chemicals CHEMICAL PROPORTIONER Use of improper chemical Failure to use water softener in hard water area Operating machine without proper chemical filler screen Failure
45. ed by oil leaks at the seals or excessive i in the air cleaning housing i P224 Remove hose clamp and breather hose from cap and valve assem Loosen clamp and remove cap and valve assembly and wash in i solvent Replace cap and valve assembly if balls do not move freely after washing in solvent Remove screen and pack Wash pack in solvent Install i pack in breather tube and position screen as shown in P224 illustration shownbelow Install cap and valve tighten clamp and attach breather hose i and hose clamp P220 Crankcase Breather Breather Tube Hex Head clamp Capscrew Washer Valve Cover 1 D Gasket amp Flat Washer Reed Valve cC Breather Batfle P224 Crankcase Breather Breather Hose Cap and Valve ied O Ring Clamp Screen Breather Pack Tube 26 IGNITION SPARK PLUGS Refer to Periodic Maintenance Schedule for spark plug service interval Replace spark plugs that show signs of fouling or electrode erosion Refer to Specifications for spark plug gap Spark Plug Wire Gauge 0 025 Gap Ground Etectrode Servicing Spark Plug Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more than the correct gap Replace a worn spark plug immediately SOLID STATE IGNITION Ignition timing is set at the factory and is not i adjustable The solid state ignition components are not ad
46. ent manual troubleshooting charts have been included for your convenience COWLING Steel with baked on Epoxy finish Unlike a garden tractor lawnmower or cement mixer all having one or two functions to perform the truck mounted carpet cleaning plant has many functions to perform simultaneously Engine has to run at a consistent RPM Vacuum has to pull air and dirty water back from cleaning site Water pump provides stable pressure at proper water flow for cleaning Chemical has to be injected into the water stream at the right concentration Heater must maintain proper heat Vacuum tank must store dirty water until drained HOW THE SYSTEM WORKS i ENGINE HydraCat 4 0 P220 20 BHP Onan IGNITION Electronic Keystart HI PRESSURE PUMP Tri Plex piston Cat 290 3 5 GPM VACUUM BLOWER HydraCat 4 0 4ML CHEMICAL SYSTEM Electro mechanical meter controlled The water system takes incoming water at tap low pressure combines it with chemicals from the chemical system and pumps it under pressure i HEATER Propane fired thermostatically controlled 180 000 BTU through the heating system and outto the cleaning tool After being sprayed into the carpet the water chemical soil solution is extracted by the vacuum Vacuum gauge Hour meter Chemical flow meter ignition key Startandon i indicator lights Pump clutch switch Circuit breakers There is no guess work in the manufacture of
47. fer to Periodic Maintenance Sched Occasionally it may be necessary to jump start charge a weak battery usinga charged booster battery If jump starting is necessary the following 28 procedure is recommended to prevent starter damage battery damage and personal injuries 1 Disconnect engine load 2 Use a battery of the same voltage 12V as is used with your engine 3 Attach one end of the positive booster cable red to the positive terminal of the booster battery Attach the other end of the positive cable to the positive terminal of your engine battery a e PERIODIC MAINTENANCE SCHEDULE SERVICE THESE ITEMS AFTER EACH CYCLE OF INDICATED HOURS 8 25 50 100 200 500 1000 Inspect Engine Generally x Check Oil Level Service Air Cleaner Element and Element Wrapper x Change Crankcase Oil all engines without filter x2 Change Crankcase Oil standard base with filter x3 x Change Crankcase Oil high capacity base with filter x3 x Replace Oil Filter x3 X Check Battery Electrolyte Level Clean Cooling Fins x2 Replace Air Cleaner Element Replace Fuel Filter Check or Replace Spark Plugs Check Valve Clearnace standard engines Check Valve Clearance LP amp natural gas conversion engines Check Valve Clearance extended service life engines Clean Carbon and Lead Deposits
48. ftenerHookcup 6 i DOM MEME gut M 8 Deum c ci ee 8 Alternative Protection Using Anti Freeeze Boe Paice SSS COS PEAS 8 i Chemical System Wiring 1 9 e Y 9 Cleaning and Chemical Precautions e 8 ChemicalProportioningand Level Cleaning Stroke Procedure Over wetting 8 i Wand Valve Assembly N 0 Water and Chemical Flow Operation s 9 JetAssembly Chemical System Maintenance 9 E Wand Assembly mO 11 Chemical Tank Trouble Shooting Guide 10 Wand Valve Stem 1 Water Flow Trouble Shooting Guide a 11 Bypass Valve Assembly esee 11 1 VACUUM Flow u a Q 12 Vacuum System Information J JJI I I u 12 Vacuum Tank Filter Bags 8 12 Vacuum Tank Filter Bags us a a s 12 Blower Lube Port essas 12 Vacuum Blower
49. h floor fit tings for propane and gasoline fuel lines installing propane regulator included with unit outside vehicle placing unit and recovery tank in vehicle i and securing them with bolts or tie down cleats connecting all propane and gasoline lines connecting battery checking pump vacuum blower and i engine oil levels prior to starting unit starting unit to check engine to see that all systems function normally also checking all hoses wands etc for Correct operation We shall always endeavor to be fair in our evaluation of your warranty claim and shall provide you with a complete analysis of our findings TRAINING SHALL INCLUDE Thorough review of the operation manual i with purchaser instruction and familiarization in how to correctly start up HydraMaster Warranty Policy inside back cover Effective February 1 1989 HydraMaster warranty covers only defective materials and or workman ship for the periods listed Labor and or diagnostic reimbursement is specifically excluded HOURS Monday Friday 8 00 am To 5 00 pm PACIFIC STANDARD TIME ROCK MT CENTRAL EASTERN and shut down unit how to correctly clean with the unit how where andhow often to check and change component oil levels how the unit s systems t work how to troubleshoot the unit how to do basic repairs safety precau i tions and their importance freezing damage and how to avoid it and a i thorough revie
50. hus reducing desired temperature levels Reduction of flow Due to increased length of sloution hose NOTE For every 50 feet of hose beyond 100 feet in total length a measurable loss of flowis experienced This condition is a result of the increased friction experienced by the water as it passes through the hose Therefore it is necessary to increase the pressure at the machine 40 PSI for every additional 50 feet of cleaning solution hose over 100 feet VACUUM SYSTEM INFORMATION The vacuum blower incorporated in this machine is a positive displacement lobe type manufactured by Cooper Industries The performance and life of this unit is greatly dependent on the care and proper maintenance it re ceives uum blower solid objects entering the inlet will damage the internal lobes gears and bearing or direct drive coupler To prevent this a stainless steel filter screen has been placed at the vac I uum inlet inside the vacuum recovery tank This stainless steel screen is finger tight and should be removed for cleaning weekly When machine is being run test purposes and the vacuum inlet on top of machine is open caution should be used protect the vacuum blower from overloading and damaging itself there is a vacuum relief system installed on the vac tank When the vacuum tank inlet is completely sealed off a maximum of 14 HG will be attained Ahole on the top blower pipe elbow acts as the lubric
51. if worn replace and lubricate before installing on piston NOTE CUP INSTALLATION Wipe cup inserter with oil Slip bac cup ring i when used onto piston Push cup over inserter and square wilh all surfaces Faulty cup installation causes premature cup failure 4 Next replace piston spacer and retainer on rod 5 Replace washer thread on nut and torque per specification chart SERVICING SLEEVES AND SEALS i DISASSEMBLY 1 Remove discharge manifold and piston assemblies as described 2 Remove inlet manifold containing seals 3 Grasp sleeves and with a pulling and twisting motion remove the sleeves from the piston rod i NOTE Grasp sleeve with pliers only if replacing worn sleeves as this procedure will mar the sleeves 4 Next remove seal retainer i 5 Remove and examine o rings and or back up rings on piston rod for wear and replace REASSEMBLY i 1 Lubricate newo rings and or back uprings and slip onto pistonrod Install the first o ring in the groove on the piston rod Next position back up ring against the shoulder in front of the first o ring Then install the second o ring Exercise caution as you slip the o ring over the thread end of the piston rod 2 Examine sleeves for scoring or etching and replace Immerse sleeves in oil and carefully twist and push sleeve onto rod machined counter bore end first i 3 Next install seal retainers If wicks are used replace wicks thoroughly saturate with
52. indication of the general condition of piston rings valves and carburetor Normal and faulty spark plugs are shown in the photos shown above Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fue could be caused by operating the engine with too much choke Oil in the combustion chamber is usually caused by worn piston rings or valve D Chalky White Deposits Chalky white colored deposits indicate overheating This condition is usually accompanied by excessive gap erosion A clogged grass screen clogged cooling fins and lean carburetion are some causes of over heating COOLING SYSTEM Refer to Periodic Maintenance Schedule Page 29 for cooling system i service interval Clean cooling fins and chaff screen sooner if required i j Remove any dust dirt or oil which may have accumulated EXHAUST SYSTEM i Makeregular visual and audible inspections of the exhaust system through out the entire life of the engine Locate leaks in muffler and piping while the engine is operating Repair all leaks immediately after they are detected for personal safety i Breathing exhaust gases can result in severe personal injury or death Inspect exhaust system audibly and visually for leaks daily and repair leaks immediately i AIR CLEANER i ELEMENT Refer to Periodic Maintenance Schedule Page 29 for air cleaner service and replacement interval Service or replace more often i
53. ing parts as a supporting step i Damage to these and connecting parts can cause an exhaust leak ENGINE TROUBLE SHOOTING GASOLINE ENGIN FUEL SYSTEM THROTTLE AND GOVERNOR ignition Timing Wrong INTERNAL ENGINE wil LUBRICATION SYSTEM STARTING SYSTEM Defective Oil Gauge Check Lean Fuel Mixture COOLING SYSTEM AIR COOLED Loose at Corroded Battery Connection Poor Circulation Low or Discharged Battery Governor Spring Sensitivity Too Great Linkage Binding mm Bad Ignition Module or Trigger Ring Rich Fuel Mixture or Choke Stuck Engine Flooded Valve or Valve Seal Leaking Piston Rings Worn or Broken Wrong Bearing Clearance Dirty or Oily Cooling Fins Biown Head Gasket Oil Too Light or Diluted Linkage Worn or Disconnected Wrong Spark Plug Gap Broken Valve Spnng Gad ignition Retief Valve Stuck Carburetor Dirty Cleaner Faulty Pump Dirty Oil or Filter Too Heavy iliac Poo Quay Fuet poem M Faulty Spark Plug Wires Out of Fuel 30 ENGINE TROUBLE SHOOTING GUIDE When troubles occur be sure to check the simple causes which atfirst seem too obvious to be considered For example starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed below use this as
54. is possible the flame may be off when the wand is on This heater is designed to burn vapor propane gas only Any liquid propane entering the heater may cause damage to the control valve on the heater It will also cause improper buming and a soot build up on the coils Therefore it is necessary to shut off the heater and close the valve at the tank between cleaning locations Failure to do this allows sloshing liquid to enter the vapor feed line to the heater IMPORTANT Overfilling of the propane tank will cause many problems avoid this advise the attendant filling the tank not to fill the tank over 90 When filling the tank watch the 10 valve and immediately stop filling when 14 white liquid starts spurting from the 10 valve To prevent damage to the light the main bumer repeat instructions as above TO START i 1 through 4 i OR propane regulator always close the valve on the tank before filling The propane regulator is pre set at the factory at 6 of propane This i reading is taken at the control valve on the heater see figure No 6 prevent road dust and moisture from entering the propane regulator keep the white plastic cover supplied on the regulator all times To avoid restriction of air flow at base of heater keep articles such as Water may already be at controlled temperature Flame will turn off when thermostat senses maximum temperature i C TO
55. jury and or equipment damage Service personnel must be qualified to perform i electrical and or mechanical service HOT WEATHER OPERATION When operating the engine in temperature above 1009 pay particular attention to the following items to prevent damage 1 Keep the engine cooling fins clean and free of obstruction CAUTION dais 1 i Plugged or clogged cooling fins can cause overheating and engine dam age Ensure cooling fins are kept clean and debris does not accumulate Contact with rotating machinery can result in severe personal injury or death Stay clear of rotating components and ensure protective shields and i guards in place and secured before operating machinery 2 See that nothing obstructs air flow to and from the engine 3 Ensure that you are using the proper grade and weight of oil for ambient temperatures Check the oil level each time you fill the fuel tank 4 Check the battery water more frequently High temperatures can cause i faster evaporation 5 Change crankcase oil and filter more frequently i COLD WEATHER OPERATION i When the engine is being used in temperatures below 32 F 09C check the i following items closely i 1 Use the correct grade and weight of oil the temperature conditions Change the oil only when the engine is warm If an unexpected temper ature drop occurs when the engine is filled with summer oil before
56. justable and i require no routine maintenance Carbon Fouled Soft sooty black deposits indicate incomplete combustion incomplete combustion is usually caused by overrich carburetion weak ignition or poor compression Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be regapped and reused SPARK PLUGS CONDITION DIAGNOSIS Engine misfire or starting problems are often caused by spark plugs in poor condition or with improper gap setting SERVICE Every 100 operating hours remove the spark plugs check condition and reset gaps or replace with new plugs as necessary see illustration above 1 Before removing the spark plugs clean the area around the base of plugs to keep dirt and debris out of the engine 2 Remove the plugs and check condition Replace the plugs if worn or reuse is questionable Do not clean the spark plugs in a machine using abrasive grit Some grit could remain in spark plugs and enter the engine causing extensive wear and damage 3 Check the gaps using wire feeler gauge Adjust gaps to 0 025 by carefully bending the ground electrode 4 Reinstall the spark plugs into cylinder heads Torque plugs to 10 15 ft Ib INSPECTION Inspect the spark plugs as soon as they are removed from the cylinder heads The deposits on the tips are an
57. justment and ambient temperatures may require heat control adjust ment When required consult an authorized representative OPERATING INSTRUCTIONS START UP 1 Perform daily periodic maintenance as specified by the owners manual 2 Connect all required hoses 3 Connect cleaning tool to length of hose required to perform cleaning 4 Mix tank must be full prior to ignition 5 Start engine choke as required Engine is at operating speed recom mended 2600 RPM Allow warm up period of 2 5 minutes i 6 Spray wand to void all air from system When the mix tank begins a fill cycle the chemical flow meter may be adjusted to your desired setting NOTE Recommended carpet cleaning pressure is 300 PSI 5 T 7 7 Once is voided system heater be ignited There are laws in most communities prohibiting the dumping of recovered NOTE If not familiar with operation of this heater refer to heater section of gray water from carpet cleaning any place but a sanitary treatment the manual A Open propane valve on the tank ignite pilot on the heater To ignite burner turn dial to position i NOTE If you suspect that the unit has been frozen DO NOT light the heater Thaw the heater and check for leaks 8 Tum burner adjust dial to normal or slightly below for 200 F NOT DISPOSE OF WASTEWATER INTO GUTTERS STORM DRAINS NOTE Chemical flow
58. k must have vapor outlet Professional installation of fuel systems is strongly recommended Always i ensure compliance with state and local regulations pertaining to fuel instal lations Propane Tank EA Propane Hose 16 5 Gal Tank Shown hy Tank Shut Off Valve Propane to Heater bo Propane Shut Off Valve M i E eii Propane Propane Fitting 8 Fitting i n act valve Tank Fill Valve gt ine Carriage Bolt Bolts NC 1 Carriag Propane Vapor Valve Tank Fili Valve 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 The manufacturer also recommends that installation of aluminum vents in i Never operate this machine with a portable propane tank or a portable gas Mount a fire extinguisher just inside the rear or side door for emergencies i HARD WATER AREA i The quality of water varies greatly throughout the United States and t influences the reliability and efficiency of equipment in direct proportion to i its level of hardness map below defines areas which compromise fluid related components such as hoses fittings heaters pumps valves and water cooled engines Cleaning efficiency and equipment life is increased chemical use de i creased and the appearan
59. l spark plugs 5 Service air cleaner as outlined in MAINTENANCE i 6 Clean governor linkage and protect by wrapping with a clean cloth 7 Plug exhaust outlet to prevent entrance of moisture dirt bugs etc 8 Wipe entire unit Coat rustable parts with a light of grease or oil i 9 Provide a suitable cover for the entire unit 24 10 If battery equipped disconnect and follow standard battery storage procedure RETURNING UNIT TO SERVICE 1 Remove cover and all protective wrapping Remove plug from exhaust outlet i 2 Checktagonoilbase and verify thatoil viscosity is still correct for existing ambient temperatures i 3 Clean and check battery Measure specific gravity 1 260 at 77 F 25 C and verify level to be at a split ring If specific gravity is low charge until correct value is obtained If the level is low add distilled water and charge until specific gravity is correct 4 Check that fuel filter and fuel lines are secure with no leaks 5 Check that carburetor throttle lever and governor linkage move freely 6 Connect battery 7 Start Engine Exhaust smoke is normal when the engine is started and is usually caused by the rust inhibitor oil i i 3 Inspect air cleaner system for leaks Make certain all clamps and fittings are tight and free of potential leaks 4 Check crankcase oil level with the engine off Ifengine has been run allow a minimum of 10 minutes for the oil to d
60. lower lube port for 3 to 5 seconds then immediately shut off machine Use only LPS 1 or Pennzguard moisture displacing lubricants 12 VACUUM BLOWER WARRANTY FULLER warrants products of its manufacture to be free from defects in material and workmanship if properly installed maintained and operated under normal conditions with competent supervision No person agent representative or dealer is authorized to give any warranties on behalf of FULLER nor to assume for FULLER any other liability in connection with any of FULLER S products This warranty shall extend for two 2 years from date of installation provided this equipment has been put into service within six months after shipment from the FULLER factory If repairs or replacements are made by the Purchaser without FULLER S prior written consent FULLER S warranty shall cease to be ineffect No allowance will be granted for any repairs or alterations made by the Purchaser without FULLER s prior written consent Machinery equipment and accessories furnished by FULLER but manufactured by others are warranted only to the extent of the original manufacturer s warranty to FULLER FULLER agrees at its option to repair at the point of shipment or to replace without charge f o b point of shipment any part or paris of products of FULLER S manufacture which within the specified warranty period shall be proved to FULLER S satisfaction to have been defective when shippe
61. meter set at5 GPH is 1 to 30 mix ratio and 10 is 1 to 15 ratio 25 IS Je NOTE Hot climate operation above 9006 into a municipal sewage treatment system after first filtering out solid When operating this unit hot climate HydraMaster highly recommends ained some additional precautions through a toilet laundry drain carwash drain RV dump etc Permission 1 Operate with side and rear doors fully open i 2 Vent heater through the top of van i 3 If vapor lock conditions arise machine cover may need to be raised to One disposal method which usually complies with the law is to accumulate F the wastewater and haul it to an appropriate dump site Another solution to the disposal problem is to equip yourself with an Automatic Pump Out NOTE Cold climate operation below 0 F i When operating this unit cold weather application highly extractor s recovery system and actively pump the water through hoses to recommends some additional precautions a suitable disposal drain Properly designed they will continuously monitor allow additional heat to escape from compartment 1 If possible carry your own fresh water supply 2 Hook up to hot water source if possible to keep your incoming garden operation The hidden benefit of this process is that the operator doesn t 4 2 99 hose from freezing 3 Do not close van doors in front of machine
62. ming water flows first through the Solenoid Control Valve 1 and the low pressure Chemical Injector 2 which are both mounted on the exterior of the mix tank As the water passes through the Chemical Injector it is automatically proportioned with a predetermined quantity of detergent The Mix Tank 3 is equipped with two different float switches the Water Level Float 4 responds to the level in the tank and will maintain the proper volume of solution to be reserved for the water pump The secon dary Low Water Float switch 5 is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply If for example the water source at the house were turned off the water level of the mix tank would drop activating the secondary switch which automati cally disengages the system and prevents the water pump from running dry The desired chemical injection ratio may be obtained by an adjustment the Chemical Flow Meter 6 during the fill cycle of the mix tank Water must be flowing into the mix tank in order to adjust the chemical mix The chemical will flow from the Chemical Jug 7 to the Chemical Flow Meter then to the Chemical Injector where it is proportioned into the Mix Tank at the desired chemical setting NOTE With this unique chemical system the chemical flow is proportioned only during the filling cycles of the Mix Tank not during the direct spraying of
63. mption high operating temperatures and oil foaming Do not over fill crankcase Crankcase pressure can blow out hot oil which can cause severe personal injury Do not check while the engine is running a Oil level should be to the FULL mark of the dipstick Start engine and run for i a short time to check for oil leaks around the drain plug 25 Filter Location Cooling Fins Always replace tightly or oil leakage may occur __ FULL Caution Do not overfill ADD Refer to amount on dipstick OIL FILTER CHANGE Refer to Periodic Maintenance Schedule Page 29 for filter change interval If operating in extremely dusty high ambient or low ambient conditions change oil filter more often Spin off oil filter element and discard it Thoroughly clean filter mounting surface and make sure new gasket is inserted in the element Apply thin film of clean oil to the gasket Spin element down by hand until gasket just touches mounting pad and then turn down an additional 1 2 3 4 tum Do not avertighten With oilincrankcase start engine and check for leaks around filter element Retighten only as much as necessary to eliminate leaks notovertighten CRANKCASE BREATHER The crankcase breather prevents pressure from building up in the crank case It also prevents oil contamination by removing moisture or gasoline vapors an
64. n preset and may be readjusted by authorized personnel A Contact manufacturer to determine correct procedure B Have your local propane dealer use a manometer al the Unitrol to reset the propane regulator to 7 oz maximum 2 propane tank Propane heaters are designed to operate on vapor propane only Overlilling a propane tank allows liquid propane to enter all heater related components and permits an over rich burning condition to occur This condition usually requires the core to be cleaned of soot and carbon deposits Cleaning is a messy dirty job and very inconvenient so do not let it happen to you PROBLEM Pilot light i Cause Solution If you do not get the bumer to flame the pilot has expired You must tum i upper dial to off position Do not attempt to re light the pilot for 60 seconds 1 Pilot light will not ignite NOTE Do not use a needle or pin to clean pilot orifice use compressed air or solvent only A Verify propane reaching ignitor NOTE A kinked or crushed hose may impede propane fiow B Remove and clean orifice C Verify ignitor spark is operating correctly 15 Ee CAT PUMP MODEL 290 OPERATING INSTRUCTIONS CAUTION CAT PUMPS are positive displacement pumps Therefore a properly designed pressure relief mechanism MUST be installed in the discharge 1 piping Failure install such relief mechanism could result in personal injury or damage
65. nd connection Examine terminal and remove corrosion if necessary PROBLEM Inoperative hour meter Cause Solution Time is not advancing correctly Verify 12 volt DC is available at the hour meter with the ignition switch turned on This can be accomplished with a volt meter or a test lamp Remove and replace hour meter if 12 volt is available A nylon gear within the clock may have been jammed due to sudden jolt of the machine or truck You may try simply tapping on the meter to try to free the nylon gear HydraCat Electrical Diagram MIX TANK CUT OFF RED WHITE RED REC TANK CUT OEF PRESSURE SOLENO10 GND SWITCH CONTROL VALVE i PERFORMANCE CHARACTERISTICS i RECOMMENDED FOR VARIABLE SPEED OR CONTINUOUS DUTY TO 3600 RPM Production engines when shipped will develop after deduction for non standard accessories not less than 85 of maximum corrected bhp After run in to reduce friction and the performance of service engines should develop not less than 9596 of maximum corrected bhp ONAN PERFORMER Gasoline Engine Air Cooled 24 bhp 17 9 kw at 3600 rpm 20 bhp 14 9 kw at 3600 rpm Engine power decreases approximately 3 596 for each 1000 ft 305 m above sea level and 1 for each 10 F 5 5 C above 60 F 15 5 C For continuous duly at constant load do not exceed 8076 of available horse power For heavy duty applications requiring maximum output the E
66. nd inspect i diaphragm for cracks or tears PROBLEM Mix Tank does not keep up with water output Solution Check incoming wat r pressure Check garden hose quick connect assembly screen Check garden hosa and or leed hose to the Mix Tank for clog kinks or blockage Float Switch 4 in Mix Tank hanging up not moving freely Check filter screen in Solenoid Valve 1 10 Wand Valve Assembly Jet Assembly Body p Stabilizer Brass Cap NO ey 8008 Wand Assembly Handle Sleeve Handle a Nut yap en Handle Jm Screw See Jet Assembly S S Solution hase Wand Valve Stem Assembly C2 Retainer Keeper Ring C lt O Ring Bypass Valve Assembly Plunger BYPASS PARTS LIST REF DESCRIPTION QTY 3 000 105 101 Thrust plate Bypass valve 4 000 105 102 Piston plate Bypass valve 5 000 078 101 Kit seal for Bypass valve 7 000 148 004 Seat amp O Ring Bypass valve 8 000 097 005 O Ring Bypass valve fitting iji WATER FLOW TROUBLE SHOOTING GUIDE PROBLEM Loss of pressure Cause Solution Defective or blocked check valves in high pressure pump cylinder head Disassemble cylinder head and replace or clean applicable check valve Delaminated kinked or clogged hose between the mix tank and the high Remove and replace defective hose as
67. nder 078 001 Cup Kit 078 006 Vaive Kit 3 Cup 6 O Ring Cylinder 3 Valve Spring Retainer 3 3 Valve Spring f Instruction Sheet 3 Valve i 1 Cup Inserter 3 Valve Seat 3 O Ring Cylinder i 078 003 Seal Kit 1 Instruction Sheet 3 Prrm A Lube Seal 3 Cotterpin 30860 Piston i 2 Abrasive Paper 6 O Ring Cylinder i 1 Instruction Sheet 3 Back Up Cylinder E 3 Bac Cup Piston i 30431 Sleeve and Seal Kit 3 Bac Cup Ring 1 3 Prmm A Lube Seal 3Cup 3 Barrier Slinger 3 Piston Spacer 3 3 Piston Retainer 3 Sleave 3 Conical Washer M6 6 O Ring Sleeve 3 Nut M6 i 1 Instruction Sheet Inlet Valves 1 Instruction Sheet 18 SERVICING THE PUMP DISASSEMBLY 1 Remove discharge manifold as described 2 Grasp cylinders by hand and with an up and down motion pull cylinders from inlet manifold 3 Remove cotterpin nut and washer from piston rod 4 Next remove retainer spacer and piston cup assembly 5 Remove inlet valve REASSEMBLY 1 Examine inlet valve surfaces for pitting scale or grooves Reverse valve and sand inlet side of valve using 240 grit paper for clean surface or replace if evidence of excessive wear Slip onto rod 2 Examine piston seating surfaces and sand clean on flat surface using 240 grit paper If extreme pitting or shar edges replace piston 3 Examine cup for wear cracking tearing or separation from the piston
68. nology available to produce the finest carpet Cleaning results possible Despite this however it remains only a tool of the operating it There not short cuts to good carpet cleaning It requires time cleaning i knowledge and the use of good chemicals 4 Don t procrastinate during the cleaning operationor the hot water solution i line will also freeze on the ground The solution line should be insulated 4 i cleaners prior to the actual cleaning of carpeting as required 5 Whenever possible the truck and machine should be stored ina heated garage at night or over the weekend If not possible place a 1500 electric heater inside the truck aimed directly at the machine Neveruse a propane heater it causes excessive moisture on the truck ceiling and i grease removers w high concentration of solvents outside with a heater you should first drain of possible water from the The manufacturer recommends only the use of chemicals containing rust and corrosion inhibitors and water softening agents to prevent chemical i build up which may lead to component failure and warranty invalidation The manufacturer recommends the use of spotting agents and traffic lane The use of some chemicals through your mobile carpet cleaning plant can seriously damage the internal plumbing high pressure pump and heater Chemical such as concentrated acids solvents and some paint oil and i NOTE
69. nt Clogged stainless steel liner Remove and clean or replace stainless steel filter Defective vacuum tank seal Remove and replace vacuum tank seal Defective or open vacuum tank pump valve Close valve Replace valve Fractured weld on vacuum tank Re weld as required or replace tank Collapsed or kinked vacuum hose Reshape hose if possible and or eliminate kinks Plugged vacuum hose Remove obstructions by reversing the vacuum hose Restriction in cleaning tool Remove obstruction Worn end plates or lobes in vacuum blower Replace wom components NOTE Must be accomplished by a qualified technican Defective ralief valve Inspect and replace if necessary PROBLEM Blower is seized Cause Solution Rust Spray rust dissolving lubricant onto lobes 10 emulsify rust and attempt to rotate vacuum lobes Foreign matter Disassemble and remove foreign matter and repair as required NOTE Disassem bly must be accomplished by qualified technican Nota The above mentioned rust foreign matter and seizing are often caused from foam traveling through the blower PROBLEM Noise In vacuum blower Cause Solution Worn gears Remove and replace gears NOTE Replacement of gears must be accomplished by qualified technican Timing of vacuum blower hasbeen changed dueto wom components Replacement of components must be accomplished by qualified technican Lack of lubrica
70. nting the machine HydraMaster also highly recommends a flue be installed between the top of the heater and the roof vent This will allow hot air from the heater to escape PLACEMENT OF UNIT _IN VEHICLE i There are two recommended unit placements i A SIDE DOOR Most installations are side door This provides rear access i for accessories and hoses as well as unobstructed access to component working side of machine thus making bit easier to perform maintenance and or repair without removing unit from the truck The manufacturer recommends the installation of plywood flooring covered with poly propylene backed astroturf do not use rubber backed in the B REAR DOOR Although this location partly limits working access it does i direct the noise away from the cleaning site Some cleaners in the colder areas prefer this location because it puts the weight mass over the rear i wheels for better traction in ice and snow Rear mounting requires the unit to be slid to the right side as far as possible This not only provides adequate i working space on the component side of the unit but also makes better i weight distribution inside the van engine and component weight line up i over drive shaft Also itis physically easier to load unit into rear door due lo height of van bed i Ensure that machine is well secured to the floor of van with hardware supplied Sudden or crash stop will cause machine to r
71. ocket forward 750 105 worth Protect yourself and the machine SECURE IT Machine Tie Down Cleats 10 Minimum Astroturf amp Roof Vent gt Position 2 v2 Staples Position 1 MACHINE INSTALLATION i Thereare two ways of positioning the machine in the truck as shown There are also two locations for the vacuum recovery tank to be positioned First i the standard way with the tank directly alongside the machine Second with the tank across the back of the machine as shown on the illustration on the next page this location is most space efficient Whichever way you select i make sure the tank and machine are secured to the floar of the van to insure i driver safety U It is important that the machine be placed as close to the door as possible i that outside air can be pulled into the engine for proper cooling Machine Configuration YS eme T i REND itis recommended by the manufacturer that the exhaust from the front of the away from the job site the truck roof to allow heat from the heater to escape M ERI can inside the truck doing so increases the risk of a fire or explosion PROPANE TANK LOCATION Either the 10 gallon or 16 5 gallon propane tank will fit this location Have you local propane dealer install the tank you select and purchase The machine will come with the proper propane regulator Tan
72. oil place in seal retainer and install retainer i 4 Place inlet manifold on pair of clearance blocks with crankcase side down NOTE Always replace with new Stainless Steel Cotterpin and tum ends under 6 Examine cylinder walls for scoring or etching which causes premature wear of cups and replace if worn i 7 Lubricate cylinder walls for scoring or etching which causes premature wear of cups and replace if worn 8 Position discharge manifold onto pump replace fasteners and torque specification chart and drive out old seals 5 Invert inlet manifold with crankcase side and install new seals Lubricate circumference of seal and install Prrm A Lube seal with garder spring down If using blue dot seal blue dot should be facing up when installed 6 Slip lubricated seal inserters onto piston rod ends position inlet manifold onto pump and remove seal inserters i NOTE Replace original quantity washers on studs before replacing inlet manifold NOTE Some models secure inlet manifold to crankcase Replace fasteners and torque per specification chart 7 Reassemble piston assemblies and discharge manifold as described SERVICING CRANKCASE 1 While inlet manifold sleeves and seal retainers are removed examine crankcase seals for wear Check oil level and for evidence of water in oil 3 Rotate crankshaft by hand to feel for smooth bearing movement 1 4 Examine crankshaft oil
73. perature of fluid being pumped Check pressures and fluid inlet temperature be sure they are within specified range Over pressure of pumps Reduce pressure Running pump dry Do not run pump without water ront edge of piston sharp Replace with new piston PROBLEM Strong surging at the inlet and low pressure the discharge side Cause Solution Foreign particles inthe inlet or discharge valve or worn inlet and or discharge valves Check for smooth lap surfaces on inlet and discharge valve seats Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone damaged cups and discharge valves cannot be lapped but must be replaced 21 HYDRACAT ELECTRICAL SYSTEM The entire electrical system operates on 12 volts DC which is provided by NOTE When new battery is installed insure it is properly charged before a battery Battery levels are sustained by a 20 amp altemator designed with installation or damage to the charging regulator may occur the engine PROBLEM Low battery voltage Cause Solution Defective battery Remove and replace Corroded battery terminals Clean terminals and battery posts Low battery fluid Add water to appropriate lovel Loose wiring within electrical system Examine all terminal connections and that they are secure Electrical short in wiring system Examine electrical systems for bare wires Poor grou
74. r s responsibility to read the unit operation manual and to familiarize himself with the informa i fioncontained therein Special attention should be paid toall CAUTIONS and WARNINGS SALES REPRESENTATIVE S RESPONSIBILITY ACCEPTANCE OF SHIPMENT 1 Ifunitshows any outward signs of damage do not sign the delivery receipt PARTS ORDERS To expedite your parts needs please call your sales representative In most instance he either stocks or has access to parts through a regional service center In the event parts are unavailable locally contact the factory and coordinate your needs if this becomes necessary always indicate the method of shipment you desire UPS Blue Label Air Freight Air Express etc i HydraMaster Parts Department Phone 206 775 7276 ONE FINAL NOTE Any questions you have regarding the warranty program should be directed to the Warranty Service Department personnel at HydraMaster Corpora tion until you have closely inspected the unit and noted any damage on the delivery receipt Have the freight company representative acknowledge the damage by signing the notation of damage on the delivery receipt I 2 The salesman from whom you purchased your unit is responsible for supervising the correct installation of the unit in your vehicle and thoroughly training you in its operation maintenance and precautions CORRECT INSTALLATION INCLUDES Installation of throug
75. rain down before checking if oil level is at or below ADD mark on dipstick Figure 1 add sufficient oil of the proper viscosity as specified in ENGINE SET UP to bring oil level to the FULL mark Do not operate engine with oil level below the ADD mark or above the FULL mark OIL SYSTEM CRANKCASE OIL CHANGE i Refer to Periodic Maintenance Schedule locatedin the Operators Manual for oil change interval If operating in extremely dusty high ambient or low i ambient conditions change oil more often i Run engine until thoroughly warm before draining oil Stop the engine place pan under the drain outlet and remove the oil drain plug After the oil is completely drained clean and replace the drain plug Fill crankcase with EXHAUST GAS IS DEADLY i Exhaust gases from all fuels including diesel gasoline liquid propane natural gas contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include i Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the unit and do not operate until it has been inspected and repaired Protection againstcarbon monoxide inhalation includes p
76. rankcase cover qs 41 43172 Cup Viton 3 9 43339 Crankcase cover 1 49474 Bac Cup assembly 3 10 43987 Bubble oil gauge 1 42 27983 Piston spacer 3 11 23170 O Ring drain plug 1 43 27002 Piston retainer 3 12 25625 Drain plug 1 44 27006 Conical washer s s M6 3 15 92520 Sems comb head screw M6 x 20 6 45 27000 Nut s s M6 3 16 43804 Crankshaft 1 46 14158 Cotterpin 3 17 14487 Rearing 2 47 101802 Cylinder 43834 Unch 3 18 24159 seal Buna N 2 48 23172 O Ring cylinder Buna N 6 19 26536 O Ring oil seal case 2 11377 O Ring cylinder Viton 6 20 27950 Oil seal case 2 49 21985 Bac Cup ring cylinder 3 21 92519 Sems comb head screw M6 x 16 8 50 24459 Discharge manifold 1 23 101799 Connecting rod 3 25634 Discharge manifold s s 1 04 101800 Piston rod 3 51 43442 Valve spring retainer 3 25 16948 Piston pin 3 52 43360 Valve spring 3 26 20017 Seal washer 3 53 43723 Valve 3 27 25301 Oil seal 3 54 43434 Discharge valve seal 3 28 25327 Barrier slinger 3 56 81109 Hex nut 2 29 25392 O Ring sleeve 3 57 101804 Hex flange nut M8 2 28771 O Ring sleeve Viton 3 58 25130 Shaft protector 1 30 29003 Back up ting Sleeve Teflon 3 Electric Clutch Assembly 31 29614 Sleeve 29743 Unchromed 3 59 152 005 Tapered sleeve 1 32 26854 Seal washer 3 60 077 005 Key electric clutch 1 33 28597 Seal retainer 3 61 036 005 6 electric cluich 1 34 25128 Inlet manifold 1 62 143 084 8 30 mm socket head screw 1 25635 Inlet manifold stainless steel 1 63
77. re the forward stroke to ensure a positive lock for the vacuum and minimize the hopping effect resulting on unsmooth carpet During the forward and reverse strokes movement to the right or left should only be accomplished the extreme rear of the stroke Overlapping is also important to ensure even application of solution to prevent saturation when cleaning wand is stopped twice at the same point at the rear of the cleaning stroke has been cooled down ALTERNATE PROTECTION USING ANTI FREEZE 1 Fallow the draining procedure 2 Cannect solution hoses and wand to machine 3 Pour 50 50 anti lreeze solution into mix tank 4 Tum on machine and engage clutch Spray the wand 6 Remove and store hoses If you are using an anti freeze solution to protect your machine from freezing itis necessary to flush the machine in preparation for use Simply connect the unit to fresh water and spray the wand until anti freeze solution is discharged The anti freeze solution may be recovered by spraying into an empty container This solution can be used several times DOWN TIME Don t mess with Mother Nature BE SURE IT S PROTECTED Freezing will cause GRIEF MONEY and CLEANING AND CHEMICAL PRECAUTIONS ider months of operation careful protection should be of concem aie i Your mobile carpet cleaning plant has been engineered using the latest and i Most sophisticated tech
78. roper installation ventilation and regular frequent visual and audible inspections of the complete exhaust system i ENGINE MAINTENANCE Accidental starting of the engine can result severe personal injury or I death Disconnect the negative battery cable and spark plug wires while servicing engine controls or associated equipment DAILY CHECKS OR EVERY 8 HOURS The operator should daily make a complete visual and audible inspection of the engine Check the following before starting the engine for the firsttime each day 1 Check all fuel lines and fittings for possible leakage 2 Inspect exhaust system for possible leakage and cracks Locate leaks muffler and piping while the engine is operating Repair all leaks immedi ately after they are detected for personal safety correct amount of oil Refer to SPECIFICATIONS for crankcase capacity Use oils meeting the API classification SF SF C or SF CD Refer to chart to determine the proper viscosity grade of oil to use Straight weight oils are recommended for severe duty use and at temperatures above 32 F 0 C for minimum oil consumption Oil Viscosity USE THESE SAE VISCOSITY GRADES TEMPERATURE RANGE YOU EXPECT BEFORE NEXT OIL CHANGE Hot crankcase oil can cause bums if it comes in contact with skin Wear protective clothing and keep fingers and hands clear when draining oil Excess oil can cause high oil consu
79. softener will treat 900 gallons of water and machines uses an average of 30 gallons per hour of use and an average of 5 hours a day would be 150 gallons a day 5 days would equal 750 gallons of water therefore the softener would be changed every 6 working days for maximum softening See illustration next page Water Softener Hook up Garden Hose Law Incoming Water From Faucet x CENE Ic Water x Sound WASTEWATER DISPOSAL ADVISORY system This cleaning rinse water recovered into your unit s vacuum tank contains materials such as detergents which must be processed before being safe for streams rivers and reservoirs STREAMS RESERVOIRS ETC Inmostcases anacceptable method of wastewater disposal is to discharge material suchas carpet fiber Access to the sanitary system can be obtained should first be obtained from any concerned party or agency System These systems are designed to remove wastewater from the the level of wastewater and pump it out simultaneously to the cleaning have to stop his cleaning to empty the recovery tank HydraMaster makes an System available which can be ordered with new equipment installed later The penalties for non compliance can be serious Always check local laws and regulations to be sure you are in compliance MACHINE ADJUSTMENTS Although this unit has been factory adjusted it may require additional ad
80. start i ing the engine move it to a warm location until the will flow freely 2 Use fresh fuel Fili the fuel tank after each day s use to protect against moisture condensation 3 Keep the battery well charged condition i DUST AND DIRT i 1 Keep unit clean Keep cooling system clean 2 Service air cleaner as frequently as required 3 Change crankcase oil and filter more than these numbers and the engine serial number when making reference to your engine HOW TO INTERPRET MODEL AND SPEC NO 2 20 0 1 10464 1234567 1 Factory code for general identification of basic engine series 2 Number of cylinders 3 BHP rating 4 Fuel required G horizontal shaft V vertical shaft 5 Engine duty cycle 6 Factory code for designated optional equipment if any 7 Specification spec letter which advances with factory production modifications OUT OF SERVICE PROTECTION i Protect an engine that will be out of service for more than 30 days as i follows 1 Run the engine until it reaches normal operating temperature i 2 Tum off the fuel supply and run the engine until it stops 3 Drain oil from oil base while the engine is still warm Refill with fresh i crankcase oil and attach a tag stating viscosity used i 4 Remove spark plugs Pour 1 ounce 2 tablespoons or 28 grams of rust i inhibitor or SAE 50 oil into the cylinders Crank the engine over a few times Reinstal
81. sure pump Defective pressure relief valve or debris in pressure relief valve NOTE The high Disassemble and clean pressure relief valve as illustrated in drawing above pressure bypass valve is designed to fully close when the cleaning tool is turned on Any foreign matter collecting on the piston will prevent full closure Replace defective or worn out bypass cup ofthe valve and allow a portion of the water to continue to circulate instead of being routed to the cleaning tool To correct this situation the bypass valve Replace bypass valve must be disassembled and cleaned refer to illustration provided above for bypass disassembly Defective or worn cups Remove and replace piston cups as defined by pump manual Loose drive belt for high pressure pump Readjust belt as required or replace if defective Pump inlet Y strainer clogged Check tank for water Clean strainer Clutch disengaged PROBLEM Excessive water flow Cause Solution Wom out spray jet NOTE Cleaning tools designed to spray a constant flow of Remove and replace spray jet 11 2 will average 1 gallon flow per minute in actual working situations since flow is not continuous An average flow of 1 GPM results in 6000 gallons of flow for every 100 hours of unit operation Spray tips are capable of flow rates for approximately 20 000 gallons They should be replaced therefore approxi mately every 350 hours Wom spray jets allow a greater average rate of flow t
82. t examine the seating surface of the flat valve seats and lap with 240 grit paper or replace if evidence of excessive wear Quiet valve seats should be replaced if worn Lap new quiet valve and seat to assure positive seal 5 Some pump models have o rings for ease of installation and to avoid damaging elastomers NOTE First install o ring in groove on seat towards seating surface then back up ring NOTE Models without outer groove on seat require the o ring to be placed on lip of retainer 6 Insert valve seats into manifold chambers 7 Position manifold back onto pump manifold over cylinders to avoid damaging cylinder o rings 8 Replace fasteners and torque per specification chart i NOTE Replace all original shims when used When new manifold is used The Prrrrrm A Lube seals located within the intake manifold will allow air to enter the pump if they are worn Again it is difficult to visually pinpoint a reshim pump When starting the pump check to see that there is no cylinder motion as this Repairing of Cat pumps is a difficult task However before disassem be eliminated by switching with one of the end cylinders will cause premature failure of the cylinder o rings Center cylinder motion Pumping Section Cut away Bac Cup Piston Spacer Ring Piston Retainer Cup Washer Cotter Pin lis Piston Nut Cyli
83. ter Pump Clutch Chemical Solenoid Chemical Injector Engine Freeze Guard Fitting Heater Control Coupler Valve F Mix Tank Drain Valve Vacuum L Hydra Heater Pump OPERATION PRECAUTIONS NO SMOKING itis unsafe to smoke in or around the vehicle 4 H Never light the heater if you smell strong odor of propane around the i heater ENGINE COOLING i Units employing air cooled engines must not be enclosed within van with I doors and windows closed Excessive temperatures within the engine will resultin premature engine failure anda compromise of applicable warranty p M Had LEVEL OPERATION i During operation van or trailer must be parked on level ground not 10 i exceed or 10 Failure to insure proper leveling may prevent proper internal lubrication of engine vacuum and or high pressure components ea a a rr cg FREEZE PROTECTION Mother nature gives little warning as to her cold spells Therefore protect ing this equipment from freezing will save costly down time Placing an electric heater in the truck or parking the truck indoors will help to insure against freezing LIGHTING HEATER Never put your face down close to the opening of the heater when lighting p STRONG PROPANE ODOR HOT SURFACES e WARNING During the operation of this equipment
84. the wand Therefore itis possible that as your wand is spraying you may have no chemical flow Also the converse is true in that you may not be spraying your wand but if the mix tank is in a filling cycle your Chemical Flow Meter may be active at the desired flow rate The chemical proportioning system will mix chemical with water at a 1 to 30 ratio when the Flow Meter is set at 5 GPH or a 1 to 15 ratio when the Flow i Meter is set at 10 GPH Atthis point in the flow solution water with chemical will now be siphoned from the bottom of the Mix Tank to the inlet of the Water Pump 8 When the wand is not using solution by spraying the solution will be bypassed from the bottom of the brass Pressure Relief Valve 9 back to the Mix Tank When the wand is spraying the solution continues its flow to the Water Heater 10 The coils of this heater have a capacity of up to 2 gallons therefore it is extremely important that air pockets are bled out of the heater prior to initial start up This may be achieved by running the water system without the heater on for approximately 60 seconds CHEMICAL SYSTEM MAINTENANCE The chemical lines may need to be flushed with vinegar periodically to prevent abnormal chemical build up This flushing be done by remov ing the clear plastic hose from the Chemical Jug and inserting it into a one quart container of vinegar This should be done with the Chemi
85. tion NOTE Permanent damage may have resulted from lack of lubrication Lubricate as specified by applicable vacuum blower manual See index Wom bearings Remove and replace bearings as required Must be accomplished by qualified technican Debris and or foreign material build up NOTE A stainless steel filter is provided in vacuum inlet located in vacuum blower components Disassemble vacuum blower and remove foreign material NOTE Disassembly should be accomplished by qualified technican only Replacement of worn parts is necessary Loose or missing mounting bolts Tighten or reinstall mounting bolts HEATING SYSTEM INFORMATION The propane heater incorporated in this equipment is a special design for use inthe carpet cleaning industry It s high pressure coils and thermostatic temperature control make it simple to operate and reliable Once the desired temperature is set the heater will then go and off according to the water temperature within the heater As water is used through the cleaning tool cold water entering the heater will activate the thermostatically controlled propane valve thereby firing the heater to maintain a consistant flow of hot water Once the cleaning wand is shut off and the flow of water through the heater stops the heater will continue to burn until the set temperature is attained itis possible with this design that the flame may be on when the wand is off likewise it
86. tle controls cables Carburetor improperly adjusted i PROBLEM Engine knocks Solution i Low crankcase oil level i Excessive engine load i PROBLEM Engine loses power Faulty spark plugs i Carburetor improperly adjusted i Solution Incorrect valve to tappet clearance Low crankcase oil level Low compression i High crankcase oil level i Restricted air cleaner element Dirt or water in fuel line PROBLEM Engine will not crank Loose or faulty wires or connections Faulty keyswitch or ignition switch Faulty electric starter starter solenoid Seized internal engine components i Excessive engine load En ine overheatin 5 lugs Carburetor improperly adjusted Low compression PROBLEM Engine uses excessive amount of oil Solution Incorrect oil viscosity or type Clogged or improperly assembled breather system Worn broken piston rings Wor cylinder bores i Worn valve stems and or valve guides 31 MAINTENANCE PROCEDURES To avoid costly repairs and down time it is imperative to develop and practice good maintenance procedures from the beginning These proce dures fall into daily weekly monthly and quarterly increments and are outlined below We have provided a maintenance log for your convenience OVERALL CARE OF UNIT MAINTAINING THE ORIGINAL APPEARANCE OF YOUR U
87. to the pumpor system Cat Pumps Corporation doesnotassume SPECIFICATIONS i Volume 3 5 GPM 13 Discharge Pressure 1200 PSI 83 BAR Maximum Inlet Pressure 8 5 to 40 PSI 0 6 to 2 8 BAR i RPM 1200 i Bore 0 787 20mm i Stroke 0 472 12mm Crankcase Capacity 10 oz 3 L Maximum Fluid Temperature 1602 71 C i Inlet Port 1 1 2 1 2 NPT i Chemical Injection Port 1 1 4 NPT 1 4 NPT i Discharge Ports 2 3 8 NPT 3 8 NPT 1 1 2 NPT 1 2 NPT Pulley Mounting Either side Either side Shaft Diameter 0 650 16 5mm Weight 12 1 Ibs 5 5 kg Dimensions 10 77 x9 06 x5 14 273 5 230 130 5 any liability or responsibility for the operation of a customer s high pressure i system Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 and 3930756 i CAT PUMPS AG y Loretohoehe 5 CH 6300 ZUG Switzerland 4 Phone 42 21 31 40 Telex 865 160 ch CAT PUMPS DEUTSCHLAND GmbH Rostocker Strasse 9 6200 Wiesbaden West Germany Phone 0612 56 00 01 2 Telex 41 86713 PUMPS UK LTD 27 Station Industriat Estate Fleet Hampshire GU13 8QY England Phone Flest 22031 Telex 858898 CORPORATION PO Box 885 MINNEAPOLIS MN 55440 Phone 612 780 5440 Telex 29 0276 CAT PUMPS INTERNATIO
88. u purchase and keep in your truck the following spare The manufacturer uses this symbo throughout the manual to parts PART NO DESCRIPTION 078 015 Flow meter kit 1 078 019 Wand valve plunger kit 27 078 034 Pressure bypass valve kit ju 076 005 Spray jet 8006E NE 049 029 Recovery tank filler bag 2 078 001 Cat 290 short cup kit standard 1 078 004 Cat 290 hot cup kit Optional 1 049 023 Screen garden hose 6 052 050 440 Male quick connect 1 052 051 440 Female quick conned 1 052 052 660 Male quick connect 1 052 053 660 Female quick connect 1 106 015 Engine spark plug 2 010 021 HydraCat pump drive d 2 i age High output component power pack Super dual silencer system i electronic tachometer FRAME 23 W 59 L 34 H Steel with baked on epoxy finish WEIGHT HydraCat 4 0 630 Ibs dry weight HydraCat 4 5 750 Ibs dry weight HydraCat 4 5 P224 24 BHP Onan 1200 PSI 1200 RPM HydraCat 4 5 4LL Sutorbuilt W 12 HG Safety Relief INSTRUMENTS 0 1000 High pressure gauge Temperature gauge Super flex solution line 10 ft drain line 50 ft water supply line ADDITIONAL EQUIPMENT HYDRACAT 4 5 Oversize air handling pack 4 WARNING of possible injury or death CAUTION This symbol is used to warn of possible equipment damage HOW ORDER PARTS obtain a proper diagnosis of your m
89. w of the unit warranty and warranty procedures TELEPHONE NUMBERS 206 775 7272 General Offices 206 775 7276 Parts Department 206 775 7275 Service Warranty 206 771 7156 FAX TRUCK SELECTION The preferable vehicle for HydraCat installation is a panel van withaheavy duty suspension package The capacity of the van should be a heavy duty 1 2 ton at the minimum and more preferably a 3 4 ton capacity TRUCK PREPARATION vehicle prior to installation of machine This provides metal to cushion mounting rather than metal to metal provides insulation and makes attractive van interior Astroturf should be color keyed to van interior Materials Needed 1 2 sheets 4 8 5 8 exterior plywood 2 amp x12 piece of commercial astroturf 3 16 1 1 2 sheet metal screws 4 1 quart marine adhesive optional 5 1 staple hammer w 1 2 staples See illustration for correct placement of plywood flooring TRUCK PREPARATION ILLUSTRATION it as shown FIRST cover the truck bed with 5 8 plywood using metal screws to secure Plywood Installation T koa oo 918 oo 5 8 Plywood T ed SECOND select the appropriate color astroturf to match your van and cover the plywood and staple in place standard van requires a piece 6 feet by 12 feet THIRD HydraMaster strongly recommends an aluminum roof vent be i in stalled over the location selected for mou
90. x tended Service Life package is recommended Performance curves ob tained and corrected in conformance with SAE J607b ONAN ENGINE STANDARD FEATURES Electronic Ignition Electric Starter Solenoid Type Mechanical Flyball Governor variable speed Top Access Oil Fill and Level Indicator Oil Pump Fuel Filter Anti Flood Choke Replaceable Dry Element Air Cleaner with Polyurethane Wrapper Rotating Blower Screen Valve Rotators exhaust Cobalt Alloy Exhaust Seats Chrome Cobalt Faced Exhaust Valves Intake Valve Stem Seals High Capacity Oil Base Full Flow Spin on Oil Filter OPTIONAL FEATURES Fixed Speed Crossover Exhaust Manifolds Vacuum Pulse Fuel Pump Exhaust Silencers Low Pressure Switch Flywheel Alternator 20 or 35 amp with Regulator installed on cylinder air housing Stationary Blower Wheel Guard High Capacity Air Cleaner Engine Control Panel PTO Modifications Internally Splined Crankshafts Hydraulic Pump Adapters Front PTO Shaft Basic Dimensions P224 2075 827 AIR CLEANER 225 REMOVAL 2 7 1 OIL FILTER s REMOVAL 88 9 NO 10 32 UNF 4 HOLES 2672 67 87 BC 3 8 16 UNC 4 HOLES 325018255 2373 PILOT 1625 4128 2376 FEMALE 3 8 24 UNF 2B 16032 1125 2857 1124 2855 CRANK STUB 06192 8374 16199 PLOT MALE Basic Dimensions P220 1 AIR CLEANER 225 REMOVAL 2 i

HydraCat 4.0,4.5 High Performance c. 1991 - Owners

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