Congratulations On Your Purchase Of The THERMALWAVE 5M Truck Mount Cleaning Unit 49 022 MANUAL,SUPER EXTRACTION SYSTEM &file=49
User Manual: 49-022 MANUAL,SUPER EXTRACTION SYSTEM
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SUPER EXTRACTION SYSTEM Service and Operation Manual BLUELINE Equipment Co. LLC 2604 Liberator Dr., Prescott, AZ 86301 1-928-445-3030 Congratulations on your purchase of the Super Extraction System ® truck mount unit. This instruction/parts manual is a guide for operating and servicing your BLUELINE unit. Proper operation and service are necessary to ensure the outstanding performance of this unit. When properly maintained, your truck mount extraction unit will have a long and trouble free life. The following service methods outlined in this manual are detailed in a manner that operation and servicing may be performed properly and safely. Because service levels vary due to the skill of the mechanic, tools and parts availability, ensure that prior to attempting any repair, you are familiar with this equipment and have the proper tools. Any questions regarding the operation, service, or repair of this unit should be directed to your nearest BLUELINE dealer. The headings WARNING and CAUTION are utilized to warn you that steps must be taken to prevent personal injury or damage to the equipment. Please make sure that you have read and understand these instructions entirely before proceeding with the operation of this unit. THIS UNIT MUST BE INSTALLED BY THE DEALER THAT YOU PURCHASED IT FROM IN ACCORDANCE WITH THE BLUELINE INSTALLATION PROCEDURES. PLEASE ENSURE THAT THE WARRANTY CARD IS FILLED OUT BY THE INSTALLATION SERVICE CENTER THAT INSTALLED THIS UNIT AND IS RETURNED TO BLUELINE EQUIPMENT LLC. Record your units serial number here for future reference or if you should need to contact the factory in the future for any reason. S/N: This service and operations manual is written specifically for Super Extraction System ® truck mount extraction units manufactured by: BLUELINE EQUIPMENT LLC 2604 Liberator Drive Prescott, AZ 86301 USA The information contained in this document is subject to change without notice and does not represent a commitment on the part of BLUELINE EQUIPMENT LLC. All rights reserved. Copyright 2005 by BLUELINE EQUIPMENT LLC. No part of this work may be used or reproduced in any form or means without the express written consent and permission of BLUELINE EQUIPMENT LLC. Published by BLUELINE EQUIPMENT LLC. First printing: Printed in USA BLUELINE Super Extraction System MANUAL ® PART# 49-022 December, 2005 Super Extraction System® I LIMITED WARRANTY BLUELINE warrants your machine to be free of defects in material and workmanship. This warranty shall extend to the designated parts for the specific period of time listed from the date of delivery to the user. If BLUELINE receives notice of any defects during the warranty period, BLUELINE will either, at its option, repair or replace products that prove to be defective. Any transportation, related service labor, normal maintenance and diagnostic calls are not included. Gasoline Engine (Through manufacturer or local dealer)_______1 year Vacuum Pump (Through manufacturer or local dealer) ________18 months Waste Tank __________________________________________1 year Battery (pro-rated) ____________________________________1 year All Other Components__________________________________1 year This warranty shall not apply to defects caused by improper installation or operation, inadequate maintenance by the customer, unauthorized modification or misuse, improper repair, freezing or damage due to hard water scaling. Electrical components, disposable filters, belts, hoses, fittings, o-rings and other service maintenance items are not under warranty. Components supplied by BLUELINE, but provided by other manufacturers, will only be warranted to the extent that they are warranted to BLUELINE. To receive warranty service, products must be returned to a BLUELINE designated service facility. The customer shall prepay shipping charges for products returned to BLUELINE for warranty evaluation and BLUELINE shall pay for the return of products to the customer. BLUELINE makes no other warranty, expressed or implied, with respect to this product. BLUELINE disclaims the implied warranties of merchantability and fitness for a particular purpose. Any implied warranty of merchantability or fitness is limited to the specific duration of this limited warranty. This warranty gives the customer specific legal rights, and you may also have other rights that may vary from state to state, or province to province. The remedies provided herein are the customer’s sole and exclusive remedies. In no event shall BLUELINE be liable for any direct, indirect, special, incidental, or consequential damages, whether based on contract, tort, or any other legal theory. II Super Extraction System® Table of Contents SECTION ONE: GENERAL INFORMATION 1 1. SAFETY Safety, Specifications, Installation, Fuel, Engine Oil 2 2. RECEIVING YOUR TRUCK MOUNT UNIT Dealer Responsibility, Acceptance of Shipment, Equipment Listing, Optional Equipment 7 SECTION TWO: INSTALLATION 8 3. INSTALLATION Lifting the Unit into the Vehicle, Positioning the Unit into the Vehicle, Fastening Down the Unit, Dimensional Diagrams, Installation of Fuel Lines, Trailer Fuel Tank and Fuel Line Installation, Battery Connection, Fire Extinguisher SECTION THREE: OPERATION 9 12 4. SYSTEMS Vacuum System 13 5. OPERATION Equipment setup, Instrumentation, Starting Your Unit, Waste Pump, Extraction Process, Shut Down and Daily Maintenance, Freeze Protection. 14 SECTION FOUR: MAINTENANCE and SERVICE 17 MAINTENANCE CHART 6. MAINTENANCE 7. GENERAL SERVICE ADJUSTMENTS 8. TROUBLESHOOTING SECTION FIVE: PARTS and ACCESSORIES 9. ILLUSTRATED PARTS LISTINGS 10. ACCESSORIES Super Extraction System® III 18 19 21 22 27 28 35 SECTION 1: GENERAL INFORMATION 1. SAFETY Safety Specifications Installation requirements Fuel requirements Engine oil requirements 2 5 6 6 6 2. RECEIVING YOUR TRUCK MOUNT UNIT Dealer responsibility Acceptance of shipment Equipment listing Optional equipment Super Extraction System® 7 7 7 7 1 1. SAFETY For Your Safety! The following WARNING labels are on your BLUELINE Super Extraction System® console. These labels point out important WARNINGS and CAUTIONS, which must be followed at all times. Failure to follow warnings could result in personal injury, fatality, to yourself and/or others or property damage. Please follow these instructions carefully! DO NOT remove these decals. 2 Super Extraction System® SECTION 1 ! 1. Read the operator's manual before starting this unit. Failure to adhere to instructions could result in severe personal injury or could be fatal. 2. Operate this unit and equipment only in a well ventilated area. Exhaust fumes contain carbon monoxide, which is an odorless and deadly poison that can cause severe injury or death. DO NOT run this unit in an enclosed area. DO NOT operate this unit where the exhaust may enter a building doorway, window, vent or other opening. 3. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings and away from sparks or flames. Never carry gasoline or any flammable materials in the vehicle. Fumes could accumulate inside of the vehicle and ignite, causing an explosion. 4. This unit must be operated with the vehicle doors open in order to ensure adequate ventilation to the engine. 5. DO NOT operate unit if gasoline is spilled. Do not turn ignition switch until the gasoline has been cleaned up. Never use gasoline for cleaning purposes. 6. DO NOT place hands, feet, hair, clothing or any body parts near rotating or moving parts. Rotating machinery can cause severe injury or death. parts, such as belts and pulleys, should be avoided while the unit is running. Severe injury, fatality or damage may result. 8. NEVER service this unit while it is running. High speed mechanical parts as well as high temperature components may result in injury or severed limbs. 9. Engine components will be extremely hot from operation. To prevent severe burns, DO NOT touch these areas while the unit is running or shortly after the unit is shut off. 10. DO NOT touch any part of the exhaust system while the system is running or for 20 minutes after the unit is shut off. Severe burns could result. 11. NEVER leave the vehicle engine running while the unit is in operation. 12. Battery acid contains sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries also produce explosive hydrogen gases while charging. To prevent fire or explosion, charge batteries only in a well ventilated area. Keep sparks, open flames, as well as other sources of ignition away from battery at all times. Remove all jewelry prior to servicing batteries. Keep batteries out of the reach of children. Before disconnecting the negative (-) ground cable, ensure that all switches are in the off position. If on, a spark could occur at the ground connection terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. ALWAYS disconnect the negative (-) terminal first. 7. NEVER operate this unit without belt and safety guards. High speed moving Super Extraction System® 3 13. DO NOT smoke around the machine. Gas fumes could accumulate and ignite. Battery gases are extremely flammable. This will prevent possible explosions. 14. DO NOT damage the vehicle in any way during the installation. When routing fuel lines DO NOT configure the hose in any locations where the hose or vehicle could be damaged. Avoid contact with moving parts, areas of high temperature, brake lines, fuel lines, catalytic converters, exhaust pipes, mufflers or sharp objects. 15. NEVER cut or splice any of the vehicle fuel lines during fuel line installation. This will result in fuel leaks and potentially dangerous conditions. Use only the provided fuel hose for fuel lines. When going through the vehicle floor with fuel lines, always utilize bulkhead adaptors. This will prevent fuel leaks and ensure that hoses are not punctured by vehicle vibration abrasion. 16. DO NOT exceed your vehicles weight limit. The console with waste tank and accessories weighs approximately 625 pounds. Make certain that the vehicle has the correct axle rating. This will prevent unsafe or hazardous driving conditions. 17. High back seats are required for all vehicles that units are to be installed for head and neck protection. Metal partitions between the seats and equipment are strongly recommended. 18. Always keep your vehicle clean and orderly. Wands, tools and accessories must be securely stowed while driving the vehicle. 4 Super Extraction System® 19. Ensure that you have received proper training from the distributor that you purchased the unit from prior to operation. 22. DO NOT modify this unit in any manner. Any modification could result in serious injury or fatality. 25. California Proposition 65 WARNING: Engine exhaust from this product contains chemicals known by the State of California to cause cancer, birth defects, or other reproductive harm. SECTION 1 SPECIFICATIONS Engine Speed 3000 rpm (High Speed No Load) 1400 rpm (Idle No Load) Vacuum Pump RPM Vacuum Relief Valve Waste Tank Capacity Console Weight (with waste tank & accessories) 3000 rpm 13 in. HG 120 Gallons at shutoff 625 lbs. TORQUE VALUES Engine Hub Vacuum Pump Hub 720 inch/lbs. 60 ft/lbs. 192 inch/lbs. 16 ft/lbs. Super Extraction System® 5 INSTALLATION REQUIREMENTS FUEL REQUIREMENTS Prior to beginning the installation, read the ENTIRE “Installation” section of this manual. Since the BLUELINE Super Extraction System® truck mount unit weighs (with accessories) approximately 625 lbs., please adhere to the following recommendations prior to installing the unit. Use unleaded fuel ONLY. NEVER use any gasoline additives. Use only fresh, clean unleaded gasoline intended for normal automotive use. DO NOT use high-octane gasoline with this unit. 1. The unit should NOT be installed in any motor vehicle of less than ½ ton capacity. ! The console and waste tank with accessories must NOT exceed the vehicles axle weight limit. 2. If mounting the unit in a trailer, ensure that the trailer is rated for the total weight of the unit and trailer. Electric or hydraulic brakes must be provided, and strict compliance with all State and Federal laws must be maintained. 3. If mounting in a trailer, the BLUELINE Super Extraction System® console must be positioned so that it balances properly with respect to the trailer axle. Ten percent (10%) of the units total overall weight (w/o accessories or water) should be on the tongue. 4. The vehicle tires must have a load rating in excess of the combined unit and vehicle weight. 5. BLUELINE does not recommend using any type of flooring materials that absorb water. This condition will result in rust and corrosion of the vehicle floor. 6. Insulation under rubber mats should be removed prior to installation of the unit. 6 Super Extraction System® ENGINE OIL REQUIREMENTS The engine is shipped with Castrol Syntec Blend® SAE 10W-30 motor oil. We recommend that you use high quality synthetic oil that meets at least API (American Petroleum Institute) service class SG, SH, SJ or higher. NOTE: the use of less than service class SG, SH or SJ oil or extending oil change intervals longer than recommended can cause engine damage. USE 10W-30 API SG,SH,SJ OR HIGHER 32 59 104 °F -22 -4 14 °C -30 -20 -10 0 15 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE SECTION 1 2. RECEIVING YOUR TRUCK MOUNT UNIT DEALER RESPONSIBILITY THE BLUELINE DEALER THAT YOU PURCHASED THIS TRUCK MOUNT CLEANING UNIT FROM IS RESPONSIBLE FOR THE PROPER INSTALLATION OF THIS MACHINE. THE DEALER IS ALSO RESPONSIBLE FOR THE PROPER INITIAL TRAINING OF YOUR OPERATORS AND MAINTENANCE PERSONNEL. ACCEPTANCE OF SHIPMENT Your BLUELINE Super Extraction System® truck mount unit was thoroughly tested, checked and inspected in its entirety prior to leaving our manufacturing facility. When receiving your unit, please make the following acceptance check: 1. The unit should not show any signs of damage. If there is damage, notify the common carrier immediately. G. 100 ft. of 2 in. vacuum hose H. 1 vacuum hose connector OPTIONAL EQUIPMENT A. Additional lengths of vacuum hose Part # 18-003 B. Additional vacuum hose connectors Part # 21-003 C. Automatic waste pump kit Part # 68-003 D. KIT, FUEL HOOKUP CHEVY 97 & NWR. FI Part # 69-003FI E. KIT, FUEL HOOKUP CHEVY/DODGE FI Part # 69-004FI F. KIT, FUEL HOOKUP FORD FI Part # 69-005 FI G. KIT, FUEL HOOKUP 2003 CHEVY FI Part #69-018FI H. KIT, 2004 TF ADAPTER CHEVY Part # 69-032 I. KIT, 2004 TF FUEL INJ. CHEVY Part # 69-033 J. ADAPTOR, 2004 FORD FUEL Part # 69-041 K. ADAPTOR, 2004 FUEL INJ. FORD Part #69-047 2. Carefully check your equipment and packing list. The standard BLUELINE Super Extraction System® truck mount unit should arrive with the following items as well as any optional accessories: EQUIPMENT LISTING A. BLUELINE Super Extraction System® console. B. Operation and Service manual C. Installation mounting plates and bolt down kit D. Hose clamps for vacuum and fuel hoses E. Waste tank with shutoff switch F. Waste tank filter and stainless steel strainer baskets. Super Extraction System® 7 SECTION 2: INSTALLATION 3 INSTALLATION Lifting the unit into the vehicle Positioning the unit into the vehicle Fastening down the unit Dimensional diagrams Installation of fuel lines Trailer fuel tank and fuel line installation Battery Connection Fire extinguisher 8 Super Extraction System® 9 9 9 10 11 11 11 11 SECTION 2 3. INSTALLATION !!! This unit must be bolted to the floor of the vehicle by an authorized BLUELINE DISTRIBUTOR. LIFTING THE UNIT INTO THE VEHICLE The BLUELINE SUPER EXTRACTION SYSTEM® weighs approximately 625 lbs., a forklift is necessary to place the unit into the vehicle. Make CERTAIN that the forks are spread to the maximum width of the unit. POSITIONING THE UNIT INTO THE VEHICLE Vehicles vary in size and openings. Owners have different preferences on where in the vehicle they want their units positioned. BLUELINE strongly recommends a side door installation for the SUPER EXTRACTION SYSTEM®. We DO NOT recommend a rear door installation. 1.Ensure that enough space is provided to assure adequate engine ventilation as well as room for service and maintenance. FASTENING DOWN THE UNIT AND WASTE TANK !!! Prior to drilling any holes in the vehicle floor, ensure that while drilling, you will not damage the fuel tank, fuel lines, or any other vital components, which could affect the safety and or operation of the vehicle. A. The waste tank mounting holes will serve as a template. Drill ten (10) 13/32 in. diameter holes for the waste tank. B. Using the provided mounting hardware kit: 1. Insert ten (10) 3/8-16 x 2 ½ in. hex head cap screws with flat washers through the waste tank mounting holes. 2. Install the provided mounting plates underneath the vehicle floor. 3. Screw the provided 3/8-16 hex head lock nuts on to the mounting bolts and tighten until the waste tank is firmly attached to the vehicle floor. 2. The complete unit and accessories MUST NOT exceed the vehicle’s axle weight limit. 3. NEVER position the console closer than 12 inches from the bottom rear of the driver and passenger seats. Super Extraction System® 9 DIMENSIONAL DIAGRAM 10 Super Extraction System® SECTION 2 INSTALLATION OF FUEL LINES !!! READ THESE INSTRUCTIONS IN THEIR ENTIRETY PRIOR TO PROCEEDING. D. Always mount fuel tanks where they will be protected from any vehicle collision. E. When installing fuel lines from the fuel tank to the unit, use the proper size fuel line. BATTERY CONNECTION ! The Vehicle fuel lines should NOT be spliced under ANY circumstances. Severe injury or fatality could result. DO NOT damage the vehicle in any way during the installation. When routing fuel lines DO NOT configure the hoses in any location where the hoses or vehicle could be damaged. Avoid contact with moving parts, areas of high temperature, brake lines, fuel lines, catalytic converters, exhaust pipes, mufflers or sharp objects. TRAILER FUEL TANK AND FUEL LINE INSTALLATION ! Explosive gases, Dangerous gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries also produce explosive hydrogen gases while charging. To prevent fire or explosion, charge batteries only in a well ventilated area. Keep sparks, open flames, as well as any other sources of ignition away from batteries at all times. Remove all jewelry prior to servicing batteries. Keep batteries out of the reach of children. A. Strict compliance with all federal and state laws must be maintained. Before disconnecting the negative (-) ground cable, ensure that all switches are in the OFF position. If ON, a spark could occur at the ground connection terminal, which could cause an explosion if hydrogen gas or gasoline vapors are present. ALWAYS disconnect the negative (-) terminal first. B. Use only fuel tanks that are manufactured specifically for gasoline, have proper vented filling caps, and outlet connections that are the same size as the inlet and return connections on the unit. A. Attach the red positive (+) battery cable from the starter solenoid on the console to the positive (+) terminal on the battery and tighten down the nut. C. DO NOT install fuel tanks inside any type of enclosed trailer or vehicle. B. Attach the black negative (-) battery cable from the ground on the console to the negative (-) terminal on the battery and tighten down the nut. The following are recommendations for trailer installations: ! NEVER carry gasoline or flammable materials in an enclosed trailer or vehicle. NEVER store any type of flammable material in an enclosed trailer or vehicle. Super Extraction System® FIRE EXTINGUISHER BLUELINE, and many government agencies, recommend that a fire extinguisher rated for A, B, and C type fires be installed into any commercial vehicle. 11 SECTION 3: OPERATION 4. SYSTEMS Vacuum system 13 5. OPERATION Preparation Starting the unit Automatic waste pump Extraction process Shut down and daily maintenance Freeze protection 12 Super Extraction System® 14 15 15 15 15 16 SECTION 3 on the front of the console. The mixture flows through a strainer basket in the waste tank. The air exits the waste tank through a 100 mesh filtration system, into the vacuum pump. A vacuum pump relief valve is installed for vacuum pump protection. 4. SYSTEMS NOTE: Read and understand this section of the manual entirely before proceeding. Prior to proceeding into the operations and maintenance sections of this manual it is recommended that you acquire a basic understanding of how the unit functions. The air is discharged from the vacuum pump through a spiral silencer. A level shut off sensor is located on the front of the waste tank and will shut down the unit before the tank is at full capacity. This protects the vacuum pump from water damage. Note: Waste tank level shut off will not shut the unit off due to high levels of foam. VACUUM SYSTEM See figures 3-1 and 5-2. The vacuum flow is initiated by the vacuum pump, or blower. An air and water mixture is drawn into the vacuum inlet 3-1 Super Extraction System® 13 5. OPERATION PREPARATION This section of the operator’s manual explains how to prepare, start, operate, shut down and maintain your BLUELINE Super Extraction System® truck mount unit. The BLUELINE Super Extraction System® unit is easy to operate. However only trained operator’s should proceed. 14 Super Extraction System® ! Operate this unit and equipment only in a well ventilated area. Exhaust fumes contain carbon monoxide, which is an odorless and deadly poison that can cause severe injury or death. DO NOT run this unit in an enclosed area. DO NOT operate this unit where the exhaust may enter a building doorway, window, vent or any other opening. SECTION 3 ENSURE THERE IS ADEQUATE FUEL Check the fuel tank to ensure there is adequate fuel to complete the job and transport the vehicle. This unit consumes approximately .95 US gallons of fuel per hour, when unit is run under full load. AUTOMATIC WASTE PUMP 1. If your unit is equipped with an optional automatic waste pump, connect one end of the 5/8 inch or larger garden hose to the pump-out connection and the other end to an acceptable waste disposal. REMOVE TOOLS FROM THE VEHICLE 2. The waste pump will now operate automatically throughout the extraction process. Remove any tools, accessories or hoses from the vehicle that you will require. DO NOT use an outlet hose that is smaller than 5/8 in. I.D. VACUUM HOSE Connect the vacuum hose to the vacuum inlet connection at the front of the console. Connect the opposite end of the vacuum hose to the extraction tool. ! NEVER dispose of waste water in a storm drain, water way or on ground areas. Always dispose of waste in accordance with Local, State and Federal laws. STARTING THE UNIT 1. Set the throttle control lever to the idle position (right). 2. Set the choke lever to the full choke position (left). 3. Turn the ignition switch to the right intermediate position. Hold the switch in this position for approximately 3 seconds, allowing the fuel pump to pump fuel. 4. Turn the ignition switch to the furthest right position. This will engage the starter and start the engine. 5. After starting the engine, return choke lever to the run position (right). 6. After the engine is running at its idle setting, set the throttle control lever to the fast position (left). Super Extraction System® EXTRACTION PROCESS After you have completed the previous steps, proceed with the extraction process. Place the throttle control lever to the fast speed for extraction. A float shut-off switch is located inside of the waste tank. It will automatically shut down the unit if the tank reaches its full capacity. If this occurs, empty the waste tank before continuing. SHUT DOWN AND DAILY MAINTENANCE 1. Remove as much moisture from the vacuum hoses as possible. This will prevent spillage of wastewater in your vehicle when returning hoses. 2. Disconnect the vacuum hose from the front of the console. 15 3. Push the throttle control lever to the slow position. or destroy the filter. Replace the filter after cleaning until hand tight. 4. Allow the unit to run for at least 2 minutes. This will help remove any moisture from the vacuum pump. NEVER operate this unit with the filter removed, damaged or improperly installed. NOTE: If shutting down for the day: Plug the vacuum inlets, and set the throttle control to fast speed. Spray WD-40 (or equivalent) into the blower lubrication cup, located on the front of the console for 5 seconds. This will lubricate the vacuum pump. Next, return the throttle control lever to the slow position, and continue step 4. 5. Turn the ignition switch to the OFF position. 6. Drain the waste tank, disposing of wastewater in a suitable and proper location. ! NEVER dispose of wastewater in a storm drain, water way or on ground areas. Always dispose of waste in accordance with Local, State, and Federal laws. 9. At the end of the work day, rinse out the waste tank with fresh water. A deodorizer may be added to prevent bacterial growth. 10. Clean the vehicle interior, unit, tools, hoses etc., as needed. Inspect ALL equipment and accessories for any damage, leaks, wear, etc. FREEZE PROTECTION ! If the unit is exposed to freezing weather conditions, the water inside of the unit may freeze, resulting in SERIOUS DAMAGE to the unit. The following is recommended to prevent this from occurring during the cold weather season: 1. Always park the unit in a heated building when not in use. 7. Remove the strainer basket from the waste tank. Clean out any debris and re-install. 2. While out in operation, avoid long periods of shut down. NOTE: Damage may occur to the vacuum pump. 3. Completely drain the waste tank and leave gate valve open. Replacement and maintenance of the filters will prevent rust and corrosion from entering the vacuum pump. 8. Inspect the vacuum inlet filters inside the waste tank weekly. Remove and clean the filters if there is any lint or debris present. NOTE: To remove the vacuum inlet filter, grip the plastic hexagon section of the filter. Gripping the filter by the screen will collapse 16 Super Extraction System® SECTION 4: SERVICE & MAINTENANCE 6. MAINTENANCE Maintenance Chart Engine Vacuum Pump Vacuum Inlet Filter Drive Belts, Pulleys and Hubs Strainer Basket Vacuum Hoses Battery 18 19 20 20 20 21 21 21 7. GENERAL SERVICE ADJUSTMENTS Engine Vacuum Relief Valve Vacuum Pump Drive Belts 21 22 21 8. TROUBLESHOOTING Blower / Vacuum Pump Engine Will Not Start Engine Does Not Crank Engine Runs for 5 Seconds Super Extraction System® 23 24 25 25 17 MAINTENANCE CHART Engine Vacuum Pump Vacuum Inlet Filter Strainer Basket Vacuum Hoses Waste Pump-Out (Optional) Daily Daily Daily* Daily Daily Daily* Engine Engine Vacuum Pump Vacuum Inlet Filter Battery Engine Engine Vacuum Pump Battery Engine Engine Engine Pulleys and Hubs Engine Vacuum Pump Engine Weekly Weekly Weekly* Weekly Weekly* Monthly 100 Hours 100 Hours 100 Hours 200 Hours 200 Hours 500 Hours 500 Hours 1000 Hours 1000 Hours 2000 Hours Check engine oil level.** Fill to proper level. Spray WD-40 (or Equivalent) into the lubrication cup for 5 seconds. Inspect filter, clean and or replace if required. Empty and clean stainless steel basket. Rinse with fresh water. Inspect and remove any debris or sediment. Check air cleaner for damaged, dirty, or loose parts. Inspect air intake and cooling areas. Clean if required. Check vacuum pump oil level. Fill to proper level. Do not overfill. Remove filter and clean. Check fluid level. Fill with distilled water only. Do not overfill. Inspect drive belts for wear. Replace as needed. Change engine oil and filter. Grease bearings with extreme pressure bearing grease. Clean battery terminals. Check spark plugs and clean if necessary. Clean engine air filter. Replace in-line fuel filter.*** Check pulley and hub set screws for proper torque.** Replace spark plugs. Drain, flush, and replace oil.**** Replace air filter element. To maximize the operating life and performance, use only recommended oils, filters and greases. *Or as often as required. **Change engine oil and oil filter after first 50 hours of operation. **Check pulley and hub set screws after first 50 hours of operation, and again at 100 hours of operation. ***Or every 6 Months. Whichever comes first. ****Or Yearly. Whichever comes first. 18 Super Extraction System® SECTION 4 6. MAINTENANCE This section of the operator’s manual contains the service and maintenance information for the BLUELINE Super Extraction System®. A planned preventative maintenance program will ensure that your BLUELINE Super Extraction System® has optimum performance, long operating life, and a minimum amount of down time. USE ONLY KOHLER BRAND OIL FILTERS. USE OF ANY OTHER TYPE OF OIL FILTER WILL VOID ENGINE WARRANTY. Oil Recommendation. The engine is shipped with Castrol Syntec Blend® SAE 10W-30 synthetic motor oil. Use only high quality synthetic oil of at least API (American Petroleum Institute) service class SG, SH, SJ or higher. USE 10W-30 API SG,SH,SJ OR HIGHER 32 59 104 °F -22 -4 14 °C -30 -20 -10 0 15 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE NOTE: The use of less than service class SG, SH, SJ or higher, or extending the oil change intervals longer than recommended can result in engine damage. 3. Check the spark plugs every 200 hours and clean if necessary. Replace spark plugs every 1000 hours. NEVER sandblast spark plugs. Spark plugs should be cleaned only by scraping or wire brushing. 4. Clean the engine air filter element every 200 hours. Replace the element every 2000 hours. ! Replace the in-line fuel filter yearly. DO NOT attempt to service this unit while it is running. High speed parts as well as high temperature components may result in severe injury, severed limbs, or fatality. ENGINE NOTE: Additional engine service information can be obtained from the provided Kohler Operation and Maintenance manual. If service or repair is required, contact an authorized Kohler Service Center. They will require the serial number of the engine. 1. Check the engine oil level daily. Ensure that the proper oil level is maintained. NEVER overfill. 2. Change the oil after the first 50 hours of operation, after the “break-in” period. Thereafter, change oil every 100 hours of operation. Super Extraction System® 19 VACUUM PUMP sealed. This procedure should be done at the end of every working day. NOTE: Refer to the provided Vacuum Pump Operation and Service Manual for specific instructions. 3. Drain, flush and replace the oil every 1000 hours or yearly, whichever comes first. Lubrication: BLUELINE recommends that you use only AEON PD Synthetic Blower Lubricant in the gear end of the vacuum pump for all operating temperatures. AEON PD is formulated specifically for positive displacement blower service to provide maximum blower protection at any temperature. One filling of AEON PD will last a minimum of twice as long as a premium mineral oil. NOTE: AEON PD (Part # 13-004) is the only oil that BLUELINE puts in the vacuum pump at the factory. Adding petroleum oil to synthetic oil is NOT recommended. 1. Check the oil level weekly to ensure the proper level. Too little oil will damage and ruin the bearings and gears. Too much oil will result in overheating. VACUUM INLET FILTER 1. The vacuum inlet filter in the waste tank should be inspected daily, and removed and cleaned weekly. The filter will last for a long period of time if this is done. 2. Inspect the vacuum filter inside the waste tank. Remove and clean the filter if there is any lint or debris present. ! When removing the vacuum inlet filter(s), grip the plastic hexagon section of the filter(s). Grasping filter(s) by the screen will damage or destroy the filter(s). DRIVE BELTS, PULLEYS & HUBS 1. Check pulley set screws and hub screws after the first 50 hours of operation and again at 100 hours. Re-torque these screws with a torque wrench. Follow the torque values on the following table. Check pulley set screws and hub screws every 500 hours thereafter. ! 2. A lubrication cup has been provided at the front of the console, to prevent rust from building up inside of the vacuum pump. Run the unit for at least 2 minutes to remove any moisture from the vacuum pump. Then, spray WD-40 (or Equivalent) into the lubrication cup for 5 seconds while the unit is running and the vacuum inlet ports are 20 Super Extraction System® Ensure that when you re-torque the screws, you use a clockwise pattern and continue until the proper torque is achieved. TORQUE VALUES Component Inch/lbs Engine Hub 720 Vacuum Pump Hub 192 Foot/lbs 60 16 SECTION 4 STRAINER BASKETS The strainer baskets located in the waste tank should be emptied and cleaned on a daily basis. VACUUM HOSES To ensure maximum hose life, BLUELINE recommends that you wash out the hoses with fresh water daily. 3. Battery terminals should be cleaned every 100 hours to prevent corrosion buildup. Wash the cables, terminals and external surfaces with a mild baking soda and water solution. Rinse thoroughly with fresh water. DO NOT allow baking soda to enter the battery cells, as this will destroy the electrolyte, resulting in battery failure. 7. GENERAL SERVICE ADJUSTMENTS BATTERY ! ! Explosive gases, Dangerous acid! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries also produce explosive hydrogen gases while charging. To prevent fire or explosion, charge batteries only in a well ventilated area. Keep sparks, open flames, as well as any other sources of ignition away from batteries at all times. Remove all jewelry prior to servicing batteries. Keep batteries out of the reach of children. Before disconnecting the negative (-) ground cable, ensure that all switches are in the OFF position. If ON, a spark could occur at the ground connection terminal, which could cause an explosion if hydrogen gas or gasoline vapors are present. ALWAYS disconnect the negative (-) terminal first. 1. Check the fluid level in the battery at least once a week. If low, fill to the recommended level ONLY with distilled water. DO NOT overfill the battery. Early failure or poor performance will result due to loss of electrolyte. 2. Keep cables, terminals and external surfaces of the battery clean and dry. A buildup of corrosive acid or grime on the external surfaces could cause the battery to self-discharge. Super Extraction System® DO NOT attempt to service this unit while it is running. High speed parts as well as high temperature components may result in severe injury, severed limbs, or fatality. ENGINE SPEED 1. To adjust the engine RPM, refer to the Kohler Engine Operation and Service Manual for specific instructions. ! DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 2800 RPM. VACUUM RELIEF VALVE With the unit running at full RPM, block off the airflow at the vacuum inlet ports and read the vacuum gauge. If adjustment is required, shut the unit down and adjust the locking nut tension on the vacuum relief valve. Re-start the unit and read the vacuum gauge. Repeat this process until the vacuum relief valve opens at 13” Hg. VACUUM PUMP DRIVE BELTS 21 The BLUELINE SUPER EXTRACTION SYSTEM® is equipped with an adjustable belt tensioning system. To adjust belts, loosen nuts on engine mounting plate and adjust belt tension by turning the tensioning bolt located on the left side of engine mounting plate. Retighten engine bolts after proper belt tension is achieved (approximately 1/2” deflection). Periodically check the belts and pulleys condition. Repair and or replace as needed. 8. TROUBLESHOOTING ! DO NOT attempt to service this unit while it is running. High-speed parts as well as high temperature components may result in severe injury, severed limbs or fatality. This section of the operator’s manual describes how to look for and repair malfunctions, which may occur. Accurate troubleshooting is based on a thorough and complete understanding of the VACUUM, SAFETY and WIRING systems featured in this unit. If there are malfunctions occurring on this unit which you do not understand, refer back to the OPERATION section of this manual and review SYSTEM or TROUBLESHOOTING 22 Super Extraction System® Blower/Vacuum Note: Make sure the blower has oil, the waste tank is empty and their filters are clean. Note: Anytime you have a Blower/Vacuum problem, you are actually looking for an air volume problem. Do you have any vacuum reading on the vacuum gauge when the machine is turned off? YES NO Replace Vacuum Gauge. Check the condition of the blower belts. Are the belts in good condition and properly tensioned? YES NO YES NO Does the Engine Crank? Remove the blower belts. Can you spin the blower pulley with your hand? YES NO Replace blower belts. See Engine Cranks but Does Not Start.. Are the dump valves closed on the waste tank? Are the gaskets in the waste tank in good condition? Are there any cracks or splits in the waste tank? Replace or rebuild blower. YES NO Close dump valves. YES NO Replace Gaskets. Repair or replace waste tank. YES NO When you start the machine, does the vacuum feel normal but the gauge reads different? Replace vacuum gauge. YES NO When you start the machine, does the vacuum feel different than the vacuum gauge reads? Remove the filters on the waste tank. Are the filters clean and not crushed? YES NO YES NO There is a blockage between the vacuum inlet and the waste tank. Start the machine and set throttle to high speed. Seal the vacuum ports. Does the vacuum gauge read 13" HG? YES NO Clean or replace filters. Super Extraction System® Vacuum system is normal.. Adjust vacuum relief valve. 23 Engine Will Not Start Note: Make sure the engine has oil, waste tank is empty, and you have at least a half tank of gasoline. Does the engine start and run for 5 seconds? YES NO See Engine Runs for 5 Seconds. Disconnect the fuel hose from the machine. Run the hose to a seperate container. Turn the key to the RUN position. Is there gasoline being pumped? YES NO YES NO Replace fuel pump and filter. When the engine is cold, test each cylinder with a compression gauge. Does each cylinder measure within 10% of each other? When you turn the key to the RUN position, do you hear the fuel pump turn on? With an electrical meter, turn the key to the RUN position. Do you have at least 12.6 volts or higher at the fuel pump? YES NO Take engine to an authorized KOHLER repair center. When the engine is cold, test for spark at each spark plug. Do you have spark at each plug? YES NO When the engine is cold, remove air filter. Is the air filter clean and undamaged? YES NO Take engine to an authorized KOHLER repair center. Replace air filter. 24 Super Extraction System® YES NO Engine Does Not Crank Note: Make sure the engine has oil, waste tank is empty, and you have at least a half tank of gasoline. Is the battery connected? Is the battery fully charged (12.6 volts or higher)? YES NO Reconnect batterty. YES NO Install new battery. Note: Check to see that alternator is charging properly and cables are clean and undamaged. When you turn the key to the RUN position do you hear the fuel pump run? Is the wire to the starter undamaged and tightly connected to the starter? YES NO With an electrical meter do you have at least 12.6 volts or higher at the ignition switch (BAT +) terminal? YES NO Replace fuel pump and filter. YES NO Replace ignition switch. Disconnect the wire from the starter. With an electrical meter do you have 12.6 volts or higher when the ignition switch is turned to the start position? Remove the blower belts. Does the engine start? See Blower/Vacuum. Super Extraction System® Repair or replace wire from starter/battery terminal on the starter to the (BAT +) on the Ignition Switch. YES NO YES NO Repair or replace wire from the (ST) terminal on the Ignition Switch to the starter. Replace starter. 25 Engine Runs for 5 Seconds Note: Make sure the engine has oil, waste tank is empty, and you have at least a half tank of gasoline. Does the engine start and run for 5 seconds? YES NO See Engine Cranks But Won't Start. Disconnect the waste tank float. Does the engine run for more than 5 seconds? YES NO Repair or replace waste tank float. Start the engine and verify that the engine builds oil pressure. Does the engine build oil pressure? YES NO Connect a continuity meter to the green wire termial on the KOHLER engine plug and the engine ground. Start the engine. Does the oil sentry switch open? Inspect and repair wiring. 26 Super Extraction System® Take the engine to an authorized KOHLER engine repair center. YES NO SECTION 5: SERVICE & MAINTENANCE 9. ILLUSTRATED PARTS LISTINGS Engine Vacuum-Exhaust System Waste Tank Decals Electrical Diagrams 28 29 32 33 34 10. ACCESSORIES Accessories Super Extraction System® 35 27 5-1 ENGINE INSTALLATION Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 45-012 36-025 36-019 21-046 21-073 18-004 21-027 36-097 16-034 14-007 21-006 21-039 61-018 61-176 61-123 12-013 11-006 68-030 35-004 40-004 47-002 47-001 Qty 1 1 1 1 1 1 1 1 1 5 2 1 1 1 1 5 4 1 1 1 1 1 28 Super Extraction System® Description ENGINE, KOHLER 25HP GUARD, FLYWL KOHLER#4731402-S FILTER, OIL KOHLER#1205001 NIP, 3/8 IN. HEX BRASS COUPLING, 3/8 STD BRASS HOSE, HP 3/8 X 10 IN. OIL DRAIN KOH PLUG, 1/2 T BRASS FILTER, FUEL KUBOTA HOSE, FUEL 1/4" 30R7 CLAMP, HOSE # 4 FTTG, BRB 1/4PX5/16H BR ELL, 1/4 IN LG STREET BRASS BRKT, FIN FUEL RETURN THERMAL ASSY, ENGINE ADJUSTMENT PLATE BOLT, PUMP ADJUSTMENT BW WASHER, FLAT 3/8 SAE NUT, 3/8-16 ZINC ASSY,FUEL PUMP HOUSING BATTERY, 12 VOLT LAWN & GARDEN BOX, BATTERY HOLDER ASSY, BATTERY CABLE BLK THERMAL ASSY, BATTERY CABLE RED THERMAL SECTION 5 5-2 VACUUM-EXHAUST SYSTEM Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number 46-030 61-187 69-040 16-014 64-002 14-008 16-013 63-059 63-057 61-188 63-060 14-001 55-050 10-007 Qty 1 1 1 24 1 2 4.5 1 1 1 1 2 1 4 Super Extraction System® Description VACUUM PUMP TI-408 HOR(LH) ASSY, ADAPTOR VAC STAN PIPE SES ASSY,VAC BRAKE 5M HOSE, INT VAC 3-1/2 IN 50 FT BULK NIP, HALF BLOWER OUTLET CLAMP, HOSE #72 HOSE, INT VAC 3-1/4 IN 12-1/2 FTBLK MUFFLER, VACUUM SES 3.5 TUBE, MUFFLER EXHAUST SES ASSY, GUARD MUFFLER SES MUFFLER, ENGINE EXHAUST SES CLAMP, MUFFLER 1-1/4 IN.. TBG, FLEX 1-1/4ID X 1-3/8OD SS SCREW, MACH 1/4-20 X 1/2 SOCHD SS 29 5-3 69-040 ASSY, VAC BRAKE 5M Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 61-035 41-009 66-001 58-106 58-108 15-002 50-000 58-077 11-012 21-011 Qty 1 1 1 1 1 1 1 1 2 2 30 Super Extraction System® Description STEM, VACUUM RELIEF VLV 4L,5M DIAPHRAGM, VAC RELIEF VLV 4L, 5M VAC BRAKE, MACHINED 4L SPACER, .125 X .688 X 1.625 SCREEN, SILENCER THERMAL SPRING, VAC RELIEF VALVE SILENCER, VAC BRAKE FOAM WASHER,VAC SILENCER NUT, 7/16-14 ZINC ELL, 1/8 P X 1/4 POLY BR SECTION 5 5-4 IDLER PULLEY ASSEMBLY 1 2 3 4 5 6 7 1 37-041 38-027 38-032 38-034 64-005 37-041 Super Extraction System® 2 2 1 1 6 6 2 2 BELT, 5VX550 PULLEY, 5V630SK 2G HUB, SK 1-1/4 HUB, 1-7/16 4JTU56 5/16-18 HEX BOLT 5/16 LOCK WASHER KEYSTOCK, 1/4 SQUARE X 2 IN BELT, 5VX550 31 5-5 WASTE TANK SUPER EXTRACTION SYSTEM® Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 61-174 20-021 61-002 61-177 40-003 69-000 61-175 23-036 19-009 21-097 58-137 58-140 26-012 26-004 28-000 Qty 1 1 2 1 2 1 1 1 1 2 1 1 1 1 1 32 Super Extraction System® Description ASSY, WASTE TANK SES STRAINER, FILTER BLUEWAVE BASKET, STRAINER WASTE TANK ASSY, LID WASTE TANK SES LATCH, PRE-FILTER BOX WIRING , LEVEL SENSOR SHUTOFF ASSY, BELT GUARD SES VALVE,3" STAINLESS PADDLE CAP, WASTE TANK INLET PLUG, 1-1/4 IN PVC PNL, FRONT SUPER EXTRACTION PNL, GAUGE MOUNT SES GAUGE, TINY TACH GUAGE, VAC 30in.HG DUALSCALE CUP, OILFILL 1/8P SECTION 5 44-000 DECAL SHEET, WARNING & CONTROLS 44-040 DECAL, SUPER EXTRACTION SYSTEM® 5-6 Super Extraction System® 33 ELECTRICAL DIAGRAM 34 Super Extraction System® SECTION 5 12 VOLT BATTERY 35-004 - + KOHLER STARTER + TOGGLE SWITCH 29-001 TINY-TACH 26-012 PURPLE YELLOW + WHITE BLK/WHT - FUEL PUMP 36-125 SHUT-OFF SWITCH 69-000 BLACK OPTIONAL WASTE PUMP OUT KIT 68-003 WASTE PUMP ON SWITCH 69-002 WHITE WHITE BLACK BLACK BLK/WHT WASTE BROWN PUMP-OUT 09/28/06 Super Extraction System® 35 10. ACCESSORIES 67-003 WAND, ERGO W/PISTOL GRIP 14" Item No. 1 2 3 4 5 6 7 Part Number 67-003 25-000 23-035 21-050 18-021 24-000 40-009 Qty 1 1 1 1 1 4 1 36 Super Extraction System® Description WAND,ERGONOMIC W /SPRAYER DSC, 1/4M X 1/4FP BR VLV,SPRAYER HYPRO 3381-0032 CONN, 1/4 P X 1/4 T BRASS HOSE, 3/16 X 51 1/4FT X 1/4FT TIP, SPRAY 95015X1/8P SST HANDLE, ERGO WAND COATED SECTION 5 WAND, ERGONOMIC 11 IN. WIDE Item No. 1 2 3 4 5 6 7 Part Number 67-005 25-000 23-035 21-050 18-021 24-000 40-009 Qty 1 1 1 1 1 4 1 Super Extraction System® Description WAND,ERGONOMIC 11 IN. WIDE DSC, 1/4M X 1/4FP BR VLV,SPRAYER HYPRO 3381-0032 CONN, 1/4 P X 1/4 T BRASS HOSE, 3/16 X 51 1/4FT X 1/4FT TIP, SPRAY 95015X1/8P SST HANDLE, ERGO WAND COATED 37 5-31 68-003 KIT, WASTE PUMP EXTERNAL Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number 46-016 45-008 12-017 12-016 10-040 11-005 61-003 66-022 66-023 21-071 58-006 14-006 16-004 69-000 16-018 21-036 Qty 1 1 4 2 2 2 1 1 1 1 1 4 72” 1 24” 1 38 Super Extraction System® Description PUMP, DIAPHRAGM, PUMP OUT MOTOR, GEAR BISON PUMPOUT WASHER, FLAT 5/16 SAE LKWSR, 5/16 ZINC SCREW, MACH 5/16-18 X 3-1/2 SOCHD NUT, 5/16-18 ZINC MOUNT, EXTERNAL PUMPOUT ADAPTOR, HOSE WASTE PUMP NUT, ADPTR. HOSE WASTE PUMP CAP, GARDEN HOSE 3/4 BRASS BRKT, HOSE CONN WASTE PUMP CLAMP, HOSE #20 HOSE, WTR. 3/4 IN HRZ. 500FT BULK WIRING , LEVEL SENSOR SHUTOFF HOSE, WTR. 1 IN HRZ. 100FT BULK FTTG, BRB 1-1/4 P X 1 IN. BARB SECTION 5 5-36 68-002 KIT, DEMAND PUMP W/PLUMBING SS 5-37 68-013 ASSY, VAN STORAGE UNIT SS Super Extraction System® 39 5-38 68-014 ASSY, SINGLE 5 GAL JUG HOLDER 5-40 68-016 RACK, DOUBLE CHEMICAL 40 Super Extraction System® SECTION 5 5-41 68-017 ASSY, FIN 120 GAL WTR TNK 5-42 68-018 ASSY, 10 GAL CHEM RACK S.S. Super Extraction System® 41 5-43 68-019 SPRAY BOTTLE HOLDER SS 5-44 68-022 ASSY, DBL PMP UP SPRAY RK, SS 42 Super Extraction System® SECTION 5 5-47 68-025 ASSY, HOSE REEL HIGH PROFILE 5-48 68-032 ASSY, H-REEL MOTORIZED W-H2O TNK Super Extraction System® 43 5-49 68-033 ASSY, HOSE REEL H. PROFILE W-MTR 68-037 ASSY, HOSE REEL VAC ONLY 44 Super Extraction System® SECTION 5 68-043 ASSY, HOSE REEL LAY DOWN KIT Super Extraction System® 45
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