AquaCat Owners Manual Aquacat_c79 &file=aquacat C79
User Manual: aquacat_c79
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6 AQUA CifTMANUAL INDEX PAGE I NI)EX 2, WARRANTY POLICY 2A, WARRANTY CLAIMS 3, PARTS ORDER 3Ao PARTS ORDER INSTRUCTIONS 4, SPECIFICATIONS 4A, SPECIFICATIONS 4B , SPECIFICATIONS 5, GENERAL FORMS INSTRUCTIONS INFORMATION MAINTENANCE 6A, MAINTENANCE 6B, AQUA CAT MAINTENANCE 6C, BLOWER LUBRICANT 6D, AQUA CAT COMPONENT DRAWING 7, TRUCK 7A, UNIT LOCATION #l 7B , UNIT LOCATION #2 7C, TRUCK 7De FLOOR GAS HOOK-UP 8, OPERATING 9, FREEZE PROTECTION PROCEDURE 9A. FREEZE PROTECTION PROCEDURE LOG DRAWING DRAWING PREPARATION PREPARATION INSTRUCTIONS DRAWING DRAWING PRECAUTIONS 10aTROUBLESHOOTING - ENGINE 11 n TROUBLESHOOTING - BLOWER 12, TROUBLESHOOTING - PUMP/COUPLER 1 — –— INDEX CONT, b .< PAGE 13, TROUBLESHOOTING - PRESSURE LOSS 14, TROUBLESHOOTING - CHEMICAL FLOW LOSS 15, TROUBLESHOOTING - WATER FLOW 16, TROUBLESHOOTING - OVERWETTING PRODUCT SUPPORT BULLETINS 17, SEE PRODUCT SUPPORT BULLETIN INDEX HOSE DIAGRAMS AQUA CAT 18a AQUA - CAT FLOW DIAGRAM 19, AQUA CAT CHEMICAL 20, BY-PASS 21, INCOMING 22, HYDRA-HOE ASSEMBLY 23, HYDRA-HOE VALVE 24, HYDRA-HOE NOZZLE 25, AQUA CAT EXHAUST 26, AQUA CAT HEAT EXCHANGER DRAWING 27, AQ(IA CAT FUEL SYSTEM 28, AQUA CAT ELECTRICAL VALVE FLOW DIAGRAM DRAWING WATER REGULATOR ONAN ENGINE MANUAL ONAN ENGINE PARTS DRAWING DRAWING ASSEMBLY DRAWING END ASSEMBLY DRAWING DRAWING DRAWING DRAWING 8 SERVICE CATALOG PUMP MANUAL PRODUCT SHEETS ADVERTISING & PROMOTIONAL AIDS 1A I I I I I I I @ ,,. PRODUCT SUPPORT BULLETIN INDEX CARBON REMOVAL ENGINE VALVE CLEANING - ADJUSTMENTS STROKE PSB - HM - I.00 ENGINE ONAN - PSB - HI!- 101 PSB - HM - 102 PROCEDURE WATER SOFTENER PSB - HM - 103 CHEMICAL PSB - HM -104 BUILD-UP VACUUM TANK CLEATS FILTER FOR SECURING VAC RELIEF VALVE PSB - HM - 105 BAGS UNITS To VAN MODIFICATION PSB - HM - 106 PSB - H1’1 - 107 HEATER REGULATOR SCREEN PSB - HM - 109 LUBRICATION OF UNIV, COUPLER BEARINGS PSB - HM - 111 REMOVAL & REATTACHMENT OF FITTINGS ON HEAT EXCHANGER PSB - HM - 112 USE OF A WATER SOFTENER PSB - HM - 113 SYNTHETIC OILS IN ONAN ENGINE PSB - HM - 115 USE OF DE-ICERS IN ONAN ENGINES PSB - HM - 116 SERVICE MEMO PSB - HM -119 * . * MANUFACTURER’S LIMITED WARRANTY Hydra-Master manufactured ~orporatlon or supplied - extends to the orlglnal purchaser of goods fOr use, the fOllOwlng WarranlY by Hydra-Master, subject to the qualifications indicated. COVerln9 goods THEREIS NO OTHEREXPRESSED WARRANTY IN NO EVENTIS HYDRA-MASTERLIABLE FOR INCIDENTALOR CONSEQUENTIALDAMAGES. 1. Hydra-Master corporation warrants to original purchaser for the periods set forth herein that goods manufactured or supplled by It wIII be free from defects In workmanship and material, provided such goods crre Installed, operated and maintained in accordance with Hydra-Master’s written Instructions and fhat such installations are performed or inspected by Hydra-Master’s Authorized Representatives. PRODUCT OR SYSTEM CLEANING UNIT Engine VacuumlBlower High Pressure Pump Heater System Frame Instruments & Instrument Panel Hoses (Internal] Cleanlng Tools Hose Reel(s] Tanks Fuel Vacuum HOSESAND HITINGS (EXTERNAL] Internal Controls & Valves All Fittings (Internal) Main Power coupler [Eng, to Vacuum) One Year or11000 hours from date of purchase. High Pressure Hose Vacuum Hose Quick Connectors or Solutlon Couplers Pulley Belts Garden Hose Three Months [90 Days) from date of purchase. Warranty expires upon aftalnlng either of the above NOTE:The Ninety day limitation on Warranty regarding hoses and quick connect fittings equals or exceeds warranties extended by respective manufacturers/suppliers, 2. Hydra-Master’s sole Ilabllify and purchaser’s sole remedy for a faiiure of goods under this Warranfy and for any and all other ciaims arising out of the purchase and use of the goods, includlng negligence on the part of the manufacturer, shall be limited to the repair of the product by the repair or replacement, at Hydra-Master’s option, of parts that do not conform to this Warranty. Product or part(s) must be returned to HydraMaster Corporation, 20309- 64th Ave. W,, Lynnwood, Washington 98036, transporfatlon charges prepaid, 3. WARRANTY DOES NOT INCLUDE: reimbursement for iabor, travel t}me, mileage or work ~oss kmurred In the removal, reinstallation or replacement of parts and/or equipment approved under the provisions of this Warranty. 4. THIS WARPANIY A. B. C. D. E. F. G. H. 1. SHALL NOT APPLY TO: Cost of maintenance, adjustments, installation and start-up. Failures due to normal wear, accident, misuse, abuse, negligence or Improper installation, Products which are altered or modified in manner not authorized by Hydra-Master Corporation in writing. Failure of goods caused by defects in the system or application in which the product is Installed, i.e. truck, van, building, etc. Telephone, telegraph, telety~ or other communications expense. Living and travei expenses of persons performing service excepting those authorized by Hydra-Master under prior contract. Rentai equipment used whiie Warranty repairs are being performed. Overtime labor requested by purchaser. Parts, sub-assemblies, assemblies or major components affected dkectly or indlrecfly by freezing. IMPORTANT: Freeze Guard Systems incorporated within units either as standard equipment or as options are convenience items only, Hydra-Master assumes no respansibllify for their failure, power failures affecting their performance or any resultlng damage. Items susceptible a. b. c. d. e. f. to damage by freezing are as followS Pressure & Solutlon Gauges Flow Meters High Pressure Pumps Heater or heat exchanger components Hoses Fittings (steel, brass and PJastlc) g. h. L j. k. 1. Solufion quick connect fltfings (couplers] Reiief valves or high pressure by-pass valves Cleaning tools and their respective controls/valves Regulators and solenolds Solution & pressure switches Pump clutches damaged by frozen pumps 5. No @rson Is authorized to extend any other warranties or fo assume any other Iiabillfy on Hydra-Master’s behalf unless made or assumed In writing by an officer of HydraMaster Corporation and no person is authorized to give any warranties or assume any ofher liabilities on behalf of seller unless made or assumed In writing by seller. Claim WARRANTY DATE Customer CLAIM No. CLAIM FILED Name Address city State Equipment Model Serial Purchased From Date No. of Hours Briefly Used Describe Defective zip No. Purchased Part Defect Signature ****************************************************************** Factory Date Part Describe Action Use Only Received Inspected By Findings: Taken: Amount 2030964th Ave. W@Lynnwood, Washington98036 of Claim $ ●(206)775-7272 ,.. @ PARTS Dear ORDERS Customer, To expedite your parts needs, please call your In most instances, Regional Sales Representative. he either stocks or has access to parts through a Regional Service Center. In the event parts are unavailable locally, your Sales/Service Representative will contact Hydra-Master If this becomes necessary, and coordinate your needs. always indicate the method of shipment you desire, i.e. UPS, UPS Blue Label, Air Freight, Air Express, Etc.. Thank you for your compliance with the above and we shall do our best to fulfill your needs. WARRANTY request NEEDS Hydra-Master Warranty is second to none and provides you the assurance of continued reliability. We realize the importance of minimum down time which can The only be achieved through manufacturers support. following procedure defines the steps necessary to Compliance with i.t i.s essprovide you this service. ential if parts are required. 1. Call (206) Hydra-Master 775-7275) Corporation and provide the following: A. Name of Company and address B. Model of equipment 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 the problem I. Pressure readings on high pressure crau~e with wand turned on and-tu~ned off - 2. Method of shipment - UPS, Air Freight, Air Express, Auto Freight, Etc.. 2030964thAve. W.*Lynnwood,WA 93036.(206)775-7272 Air Mail, 3. DO NOT give malfunctioning part(s) to a sales/ service representative. All parts must be returned, freight prepaid, to Hydra-Master Corp, oration for evaluation. Hydra-Master’s warranty policy provides parts without charge for thirty days to customer maintaining good credit rating. Malfunctioning parts must be returned directly to Hydra-Master Corporation for final disposition. Un-approved warranty evaluations and/or failure to return part(s) for warranty consideration will result in appropriate charges. Detailed instructions always accompany each shipment to outline both your obligations and options to the warranty procedure. Any questions you have regarding the warranty pro– gram should be directed to service personnel at HydraMaster Corporation. We shall endeavor to be fair in our evaluation of your warranty claim and always provide you a complete analysis of our findings. AQUA 9 CAT SPECIFICATIONS GENERAL Warranty * One Year Dimensions * 48” L x 32” W x 34” H Weight * 550 Lbs. or 1000 Hours COMPONENTS * 20 Horsepower Onan Industrial WaterCooled A. Engine RPM * 2600 Factory mended Fue 1 * Unleaded Oil Capacity * 3+ Quarts * 2600 Factory mended RPM c. W/Filter * Positive Displacement (Lobe Type) B. Vacuum/Blower Water Lift Recom- & Air Flow Recom- * 195-210 inches 275 CFM Pre-set Oil * 40 S.A.E. Grease * High * Positive Displacement Piston W/Stainless Cylinders Oil * Special Cat Oil Lubricant Pressure * 300 PSI Factory Pre-Set Adjustment Pulley * 5L380 * 900 Water Pump Belt R.P.M. * Tube D. Heat Exchanger * 190 Heat Setting Tank - Exchanger Temperature Storage Type - 200 Bearing Stainless Max * Anodized Aluminum (Non-Corrosive) E. Frame * Legs Construction * Steel ,, * Retractable Wheels Recovery * Anodized Tank W/Castered Aluminum F. Hoses * Teflon forced Internal W/Steel Sheath Rein- External Solution * High Pressure - Non Marking 2500 P.S.I. Rated External Vacuum * Heavy Duty Flexible and Non-Marking G. Tools Hydra-Hoe Stair Carpet Sprayer Stair Vacuum H. Battery I. Safety Features Wand * Stainless Steel W/Adjustable Handle and High Pressure Valve Jet Size 8006E * Replaceable * Hand Held W/Single 8006E * Cast Aluminum * 12 VDC * Enclosed * Automatic Vacuum Tank Limit Switch * Over Temp Limit Switch W/Auto Pump Out * Over Temp Engine Shut Down * Incoming Water Pressure Switch W/Auto Shut Down Capability * * * * 0-1000 PSI Glycerine 100-200 Degrees Lips Jet - VW Type Frame J. Instrumentation Pressure Gauge Temperature Gauge Vacuum Gauge Hour Meter Chemical Flow Meter Choke Service Computer 0-30 Filled HG Total Lapse Time and Te”nths * 0-10 Gallons/Hour * Mechanical * Electronic in Hours Over, ’l?emperature Indicator Eng. Temp. & Water Temp Switch Master Fuse Charging Fuse K. Options Systems and Auxillary PANEL 20 15 AMP AQUA CAT STEEL 0-1000 PSI GLYCERINE FILLED 100-200 DEGREES 0-30 HG HOURS & TENTHS OF HOURS 0-10 GPH CHARGING FUSE FREEZE GUARD FUSE VISUAL ON INDICATOR HI-TEMP INDICATOR AUX. PUMP INDICATOR SERVICE REQUIRED LIGHT & WATER Switch AMP STAINLESS HIGH PRESSURE GAUGE TEMPERATURE GAUGE VACUUM GAUGE HOUR METER CHEMICAL FLOW METER MASTER POWER FUSE CHOKE ENGINE TEMP AUX. PUMP Auto Bulb Electrical * Pump-in System W/Aux. Pump & Holding Tank For Transporting Water supply . SPECIFICATIONS DASH * * * * TEMP 30 AMP 15 AMP 15 AMP AUTO TYPE AUTO TYPE AUTO TYPE AUTO TYPE PULL TYPE ELECTRICAL ELECTRICAL BULB BULB BULB BULB SWITCH SWITCH flri GENERAL INFORMATION This manual contains installation and operation instructions as well as information 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 component manual troubleshooting charts have been included for your convenience. Unlike the garden tractor, lawnmower and cement mixer all having one and maybe two functions to perform, the Hydra-Master truck mounted carpet cleaning plant has many functions to perform simultaneously. 1. Engine has to run consistent RPM. 2. Vacuum has to pull air and dirty water back from cleaning site. 3. Water pump provides stable pressure at proper water flow for cleaning. 4. Chemical has to be injected into the water stream at the right consistency. 5. Heater must fire on demand and maintain proper heat. (Except for Aqua Cat). 6. Vacuum tank must store dirty water until drained. with As you can see it is n’ot just a turn key operation only one thing to worry about, DOES IT S~AR~?l As there is no guesswork in the manufacture of these highly advanced cleaning plants, there nust be none in preparing it to get the job done in the field. It is the purpose of this manual to help you properly understand, maintain and service your Hydra-Master cleaning plant. Follow the directions carefully and you will be rewarded with years of profitable trouble-free operation. It is imperative that no section be overlooked preparing for operation of this equipment. when = Hydra-Master uses this symbol throughout the manual to warn of possible injury or death. = This symbol is used to warn possible equipment damage. of MAINTAIN GOOD PROFIT - WITH GOOD MAINTENANCE In the past 3 years, we at Hydra-Master have become alarmed increasing number of calls pertaining to service problems. at the Our findings are that 85% of all down time is a direct result of poor maintenance habits. If maintenance is a difficult function to schedule into your busy operation, here is one important parallel that may influence your thinking toward maintenance procedure: Each hour of machine A hour average 5+ operation day equals is equal 31O 5 day week or 27+ hours Each month an average of 8660 miles of average machine = 2062.5 operation miles. is put on the machine. is equal Compare this to your car and the maintenance for this many miles of trouble-free driving! Enclosed is a maintenance machine and kept in force GOOD PROFITS HYDRA-MASTER to 103,920 you would log sheet that should be attached by a responsible operator. AND GOOD MAINTENANCE WANTS of driving. 11’ti.leS. An average One year to 75 miles GO HAND YOU TO BE A TROUBLE-FREE give to the IN HAND DRIVER! miles. it HYDRA-MASTER CORPOUTION DATE MAINTENANCE LOG SERVICE ITEMS’ 020) DATE DATE DATE . DATE DATE HOURS HOURS HOURS HRS. HOURS HOURS HOURS HOURS Inspect Machine Generally 8 8 Check Engine Oil 8 Check Pump Oil Glean Vac holding tank, Nylon 8 fi~rer bag & S/S fi.1.L~r Wlbrush Change Eng. oil (Summer SAE 30) Winter SAE 20) 3 Qts. W/O oil . fi L.@r % Qtis. W/OiJ_.<@r . 30 Disassemble H/P bypass valve & c?) 1(30 Remove Machine from Truck for Complete inspection of: 100 Battery Electrolytes 100 Belts and Pulleys Fuel Lines 100 Nuts and Bolts 100 100 Heater cover (Except Aqua Cat) Heater Burner Assy. (Ex.Aqua Cat) 100 Service Air Cleaner 100 Clean Vacuum Tank (free float 100 hinge of lint & lube) Spray Quick Connectors (all) with WD 40 100 Lightly Oil Direct Drive Shafts 100 Check for Chafing Wires 100 Tighten Exhaust Manifold Clamps 100 Tighten Dodge Coupler (direct drive) (DO NOT OVERTORQUE) 100 Replace Engine Oil Filter 200 Replace Spark Plugs (LP gas gap .018/gas gap .025} 200 Change Blower Oil (40 wt. nondeter~ent) 200 Replace Points & Condenser (fZP, DATE — — — 300 Greas~ Blower Fittings 300 Change Pump Oil (Cat Oil) 300 Lube Throttle Lever 300 Heater Slide & Button Assembly 300 Check Engine Valve Clearance & Decarbon Heads 500 1000 Replace Pump Short Cup Kit Inspect Valves (grind if net.) 1000 Charge Battery W/Lead Wires Disconnected * Engine Oil Summer 30 SAE * Blower Oil 40 SAE Non-Detergent * Pump Oil Special Cat Oil Recommended Fuel - Unleaded Gasoline SERVICE REMINDER - The Service Reminder operates on 50 hr. cycle. When Service Reminder light is on it is time for 50 hr. check. On completion of 50 hr. check, set switch located on the computer (on back of dash panel). After re-setting switch to the opposite position the computer is ready for another 50 hr. cycle. Be sure to follow the maintenance log suggestions supplied with the manual. J !i4- r= . I , I Ii Ad WV @ i mL t h-l II ~ I I Ir-nn \ [al ‘W AL——I I 111111 i z ) ~ 1+ I I’M I JI flR / SIGH /\ 1, \ 1>! -HEAT EXCHANGER CHEMICAL TANK FUEL I H - M TRUCK Truck Prep.: Decide Materials location PREPARATION needed: of machine 1-79 1. 6’ x 12’ Ozite indoor/outdoor carpet 2. 4x8x5/8° Plywood (1 side good) 1+” sheet metal screws 3.64.1l“xI’’xI8” angle iron 5.32“x5/16” bolts 5/16” flat washers 6.35/16” lock washers 7.38.35/16” nuts 9. 1 can marine adhesive 10. 1 staple hammer or glue gun 11. 1 gas hook-up (thru floor mount) in Van. are side door. A. Side door: Most installations This provides rear access for accessories and hoses as well as unobstructed access to component/working side of machine, thus making it a bit easier to perform maintenance and/or repair without removing unit from the truck. B. Rear door: Although this location partly limits working access, it does direct the noise away from the cleaning site. Some cleaners in the colder areas prefer this location because it puts the weight mass over the rear wheels for better traction in ice and snow. Rear mounting requires the unit to be slid to the right side as far as POSSible. This not only provides adequate working space on the component side of the unit but also makes better weight distribution inside the Van (engine and component wt. line up over drive shaft). Also, it is physically easier to load unit into rear door due to height of Van bed. When carrying water, tank will then be located over center of Van. EEEl Ensure that machine is well secured to the floor of Van w/hardware supplied. Sudden or crash stop will cause machine to rocket forward, all 550 lbs. worth ! Protect your driver and machine. SECURE IT! II /’I L&-—u- /(i l\ k===f=sii~ % –====J-====( y \ ,, ‘J ,1 . \\ ‘ ,\ \\ .\A. ~\ - -.r- \\_ \ ‘i \\ \ \\ _\’sJ&$# – \ \\ \‘\ _’___—/ ‘ ,~< \\ 1LF==\ ‘ . . 7A . UNIT LOCATION —-——..._II D~y@J& 4“3-79 5CA& @ 1978 D&NAwN~JR. .A?PRwD DATE HYDRA MASTER CORPORATION 1 7,- . a&1. 611002 2. 613024 3. 619130 4. 625701 5. 637104 6. 620104 7. 612090 8. 613025 9. 620305 .0.625700 PART DESCRIPTION QUICK CONN.SOCKET HOSE BARB SCREW PLATE HOSE HOSE CW FITTING HOSE BARB TIE WRAP THRU FLOOR GAS HOOK UP (Kit) !TY , n ISEI - 1 2 2 1 1 4 1 2 6 1 I ‘f-r /-Lrfi!a77” 8 (3 . Uba Z%M 10 b&.Mf? iO al rninhq /J+2 8“ A I Q 43 ( FLOOR GAS DIAGRAM T- @%@g Xo , tabi-tize hohe ,DF(wG NO @om the Exhutik , HM-12A the@am(z and —w @ S@.LE 1978 o DATE ]?WANT,JRPPPRV” 14-4-79 HYDRA MASTER CORPORATION AQUA OPERATION MACHINE ENGINE ADJUSTMENTS: COOLING: CAT PRECAUTIONS ALTHOUGH THIS UNIT HAS BEEN FACTORY ADJUSTED IT MAY REQUIRE ADDITIONAL ADJUSTMENTS TO ACHIEVE OPTIMUM PERFORMANCE ; I.E. ALTITUDE MAY REQUIRE CARB ADJUSTMENT AND AMBIEIJT TEMPERATURES MAY REQUIRE HEAT CONTROL ADJUSTMENT. WHEN REQUIRED, RE-ADJUST– MENT MUST BE ACCOMPLISHED BY AN AUTHORIZED HYDRA-MASTER REPRESENTATIVE OR WARRANTY MAY BE INVALIDATED. UNITS EMPLOYING AIR COOLED ENGINES MUST NOT BE INCAPACITATED WITHIN A VAld WITH DOORS AND WINDOWS CLOSED. EXCESSIVE TEMPERATURES WITHIN THE ENGINE WILL RESULT IN PREMATURE ENGINE FAILURE AND A COMPROMISE OF APPLICABLE WARRANTY A. WHEN RUNNING THE AQUA CAT THE COLD WATER SOURCE MUST BE CONNECTED TO KEEP ENGINE PROPERLY COOLED. LEVEL : DURING OPERATION, VAN OR TRAILER MUST BE PARKED ON LEVEL GROUND NOT TO EXCEED + OR - 10 DEG.. FAILURE TO INSURE PROPER LEVELING MAY PREVENT PROPER INTERNAL LUBRICATION OF ENGINE, VACUUM AND/,OR HIGH PRESSURE PUMP COMPONENTS. FREEZE PROTECTION: ALL UNITS ARE EQUIPPED WITH FREEZE PROTECTION DEVICES AND/OR INSTRUCTIONS PROVIDED ON OPERATING LABELS FOR THE PREVENTION OF FREEZE DAMAGE. a FAILURE TO PERFORM RECOMMENDED STEPS OR USE SYSTEMS DESIGNED FOR THIS PURPOSE CAN RESULT IN EXPENSIVE COST, DOWN TIME AND COMPROMISE TO APPLICABLE WARRANTY . 8 FREEZE PROTECTION PROCEDURE Protecting the Aqua Cat from accidental freezing is a relatively easy task if the following procedure is complied with. Failure to adopt it in sub-freezing climates may result in costly repair or replacement of components. 1. Drain the water from the hot water tank with the drain hose provided. recirculating 2. Pour 5 gallons of 50/50 antifreeze and water into the recirculating hot water holding tank. Lid on tank must be removed to perform this step and then replaced. NOTE: Antifreeze solution must be checked with each use to ensure safe levels are maintained since dilution will occur. It is recommended that levels are monitored frequently and antifreeze added as necessary to provide an added ten degree margin of safety. 3. To effectively pump antifreeze solutions throughout fittings, hoses, engine, pumps, etc. , start unit without incoming water attached and with safety pressure switch locked out using the switch provided for this purpose located on the dash panel. 4. With solution hoses and cleaning tool attached, draw antifreeze solution or alcohol through the chemical flow meter and hoses for 20 - 30 seconds. Unit is effectively freeze guarded when antifreeze solution starts to discharge from cleaning tool. 5. Prior to turning unit off, move rocker lock-out switch to its opposite setting to open the overtemperature solenoid on the hot water discharge This ensures total elimination of water line. from all remaining water lines. 6. Prior to starting future cleaning following must be performed. A. Drain antifreeze sealed container operations the solutions into a 5 gallon and save for future use. 9 t B. Attach incoming water supply hose just prior to starting unit and flush antifreeze from unit by turning cleaning tool on. Cleaning operation can resume once antifreeze no longer is emitted from the cleaning tool. NOTE: All hoses containing antifreeze must be cleared in this manner to prevent possible discoloration to carpet fibers. 7. Repeat operations 1 through for the day or when placing 5 when retiring the unit unit into storage. M HOSE \ FIGURE A HOSE BARB TROUBLESHOOTING I. ENGINE ONAN INDUSTRIAL (Ref. Onan Operation PROBLEMS FAILS TO START ENGINE STOPS WHILE CLEANING ROUGH RUNNING BACK FIRING CAUSE - 1. Loss of fuel 2. Blown Manual AND/OR - Sect. 12) SOLUTION : Plugged fuel line. Defective fuel pump. Empty gas tank. Kinked fuel line. fuse: Electrical short\coil open. Coil wires not fully inserted in coil. 3. Maladjusted 4. Oil on points: Drill 1/8” hole in point box cover approx. 3/8” from bottom. Clean points. 5. Check plugs: Remove and/or replace/clean. Check for spark. 6. Check compression: 7. Float valves 8. Bad starter: 9. Plugged Points. Possible in recovery tank: Stuck in upright position or defecNOTE: Disconnect tive. float wire. Check for loose wire connection. Carburetor 10. Lack of engine 11. Choke jammed hung valve. or jet. oil: Engine seized. (on gas models) push of carburetor. to rear 12. Too lean a gas mixture: Adjust at T-Handle on bottom of carburetor. 13. Dead Battery: No water. 14. Loose cable 15. Engine high temp. switch on block defective or stuck open.. (Will short to ground). 16. Incoming pressure lack of-incoming fective. battery at battery. switch water not closed due to or switch is de10 I I I AQUA CAT t TROUBLESHOOTING (CONT.) II. VACUUM BLOWER - SUTORBILT - POSITIVE DISPLACEMENT Ref. Blower Operation/Maintenance Manual Section NOISE IN BLOWER: 1. Loose direct 2. Skip timing. 3. Worn Gears. drive coupler. II (Do not use) . 4. No oil or grease. 5. Foreign material (internal). 6. Bad bearings. 1. Obstructed plumbing. LOSS OF VACUUM: or pinched 2. Pop-off/Relief Repair/lube. * 3. Stainless valve Steel hoses in vacuum malfunction filter - is plugged. * 4. Open dump valve. 5. Lint build-up between Blower and waste tank (not using recovery tank filter bags). * 6. Tank lid not sealed material. * Most due to worn coping frequent. 11 TROUBLESHOOTING (CONT.) t III. PUMP: (See Cat Pump Manual Section 10)FAILS HIGH PRESSURE for Charts, PUMP Terminology & Number Code 1. Chemical build-up due to non-compliance with standard operating (Start-up & Shut-down). procedures. TO OPERATE: 2. Damaged or worn 3. Damaged cylinder 4. Damaged 5. Debris spring piston cup piston “O” rings “O” rings lodged in discharge assembly valve WATER IN OIL: 6. Damaged piston rod seal, washer or Replace “O” ring (piston sleeve). or rebuild WATER LEAK: 7. Cracked (hairline) charge manifolds 8. Loose Iv. VIBIWTION: MISALIGNMENT DIRECT DRIVE or damaged inlet fittings or disor elbow COUPLER Tighten bolts and Allen screws. (Also Allen screws that secure Coupler to shafts of engine and Blower) . : Due to loose bolts Blower mounts. on engine or * A~UA CAT TROUBLESHOOTING V. LOSS OF HIGH (CONT.) PRESSURE: 1. Air leaks in low pressure chemical flow lines. side of system or 2. Relief valve malfunction - disassemble and clean. apply a light coat of grease (Lubriplate) to spring and ‘o’ ring assembly when re-assembling. 3. Damaged 4 High high pressure 5. Crumpled, pressure NOTE : - reads incorrectly. pump malfunction. collapsed or twisted 6. Check the garden hose water quick connector material. 7. gauge garden hose. screen behind the incoming for blockage by foreign Slipping pulley on pump, key in key-way Allen screws gone, worn belt. gone, By isolating or checking one function at a time the problem shows up much quicker and negates any possible damage to the machine. 13 .> TROUBLESHOOTING VI . LOSS OF CHEMICAL NOTE : (CONT.) FLOW: 1. Plugged filter 2. Crimped hoses. 3. Jammed flow meter float ball at bottom usually due to chemical build-up. 4. Improper 5. Low or improper flow of water through system/measure water flow at cleaning tool. This flow should measure 1.5 gallons per minute with machine running at 300 PSI. 6. Broken 7. Clogged 8. Flow mixing wire in chemical jug. (5 gal.) of meter, of chemicals. to chemical solenoid switch screen solenoid on top of Cat pump. valve. malfunction. Again we remind consistent high you that chemical flow depends on pressure flow to the cleaning tool. 14 A@A CAT TROUBLESHOOTING VII. FREEZING: WATER (CONT.) FLOW If unit has been exposed to freezing conditions, the Prior to trying to start, entire water flow may be affected. attach water supply and thoroughly check for leaks or malfunctions. Freezing - Loss of or reduced solution flow. (The following are possible and/or probable problems which occur during freezing) . DAMAGED: Quick connect couplers - replace Incoming water regulator and incoming pressure switch - replace Heater water flow regulator - rebuild (Except Aqua Cat). Expanded, warped or cracked inlet or discharge manifolds on Cat pump. (Hi pressure/Lo pressure) Ref. #31,54 Cat Pump Manual. Broken and/or damaged seals or retainers on pump piston rod assemblies, Ref. Inlet Manifold. Hi-pressure relief valve warped. Cracked chemical check valve - (Except Aqua Cat) . Cracked chemical flow meter. Expanded valve damage to trigger assem(Plunger). “ blies on all cleaning tools. NOTE : On Aqua Cat, check heat exchanger for any Also check solenoids cracks or leaks. and hoses where applicable. Inspect all fittings or damage. and hoses for leaks H-M VIII leaves OVER 1-79 - WETTING Over-wetting is annoying to all concerned a bad impression of the cleaning process There are several areas 1. Too few vacuum 2. Obstructed, 3. Vacuum 4. Clogged strokes kinked tank drain vacuum that will cause and sometimes used. over-wetting: or improper vacuum strokes. or cut hoses. valve blower left partially open. filter. 5. Cleaning a heavily foam-saturated defoamer. (We recommend crystal carpet type). without due 6. Vacuum relief valve not operating properly, to wear and misalignment, or adjustment may be required to increase vacuum to original factory setting. (14-15 HG). NOTE : 1979 model has vacuum relief tank lid and has been preset valve built in to at the factory. - IF. . @ HYDRA ~jj MASTER % % No. PSB-HM-1OO Date: 8-11-77 CORPORATION PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): HYDRA-CAT, BOB-CAT & AQUA CAT Subject: CARBON REMOVAL Units removal hours comply could will result void the engine service must carbon Service expense removal throughout 2030964thAve. with warranty is relatively the Onan W.*Lynnwood,WA 500 Failure and costly as tune-ups, carbon every Manual. the country. be scheduled in the same manner require approximately manufacturers in unnecessary to perform gasoline chambers by the Onan sive but does vary Center on regular from combustion The cost this Section Insert#: - ENGINE operating as defined Publications and down Service 98036.(206)775-7272 time. inexpen- Normally etc.. to PSB-HM-~()] No. Date: January 1977 TM PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): Publications Section Insert#+: ALL Subject: ONAN ENGINE VALVE ADJUSTMENTS To ensure continued reliability from the ONAN engines incorporated in our units, it is NECESSARY to adjust both intake and exhaust valves after 300 hours of use. Fai~ to comp~with this suggestion m~necessi=te a valve repair after 500 hours of use and can compromise engine warranty during the warranty period. The condition which will often occur if valves are not adjusted is power loss and damage to valves and valve seats. Instructions for preventive maintenance procedures, i.e. tune-up, oil changes, carburetor breather filter, fuel adjustment, valve adjustments, etc. are outlined in the ONAN Your Service Manual contained in the Hydra-Master Manual. local small engine service shops as well as ONAN Service Centers are qualified to perform necessary adjustments. 2030964thAve. W.@Lynnwood,WA 98036.(206)775-7272 PSB-HM-102 No. 1~7~ ~dd?: JANUARY FIWDRA4 MASTE= CORPORATION PRODUCT SUPPORT BULLETIN Service/Parts/Publications Model(s): Section Insert#$: ALL Subject: CLEANING STROKE PROCEDURE PURPOSE : To eliminate excess moisture and the sawtooth appearance which of the cleaning tool. remaining in the carpet fiber results from diagonal movement SCOPE : All types of carpet. PROCEDURE: Always move the cleaning tool in smooth forward and backApply slight pressure on the forward stroke ward strokes. When extractwhile the solution is injected into the carpet. ing (drying) , apply firm pressure on the forward stroke to ensure a positive “lock” for the vacuum and minimize the During the “hopping” effect resulting on unsmooth carpet. forward and reverse strokes, movement to the right or left should only be accomplished at the extreme rear of the stroke. A drawing is provided below to illustrate this technique. Overlapping is also important to ensure even application of solution to prevent saturation. fiber F-.ilure to adopt the above procedure can result in increased shrinkage, brown out, and longer drying periods. INCORRECT METHOD CORRECT METHOD I Kz a CLEANING I TOOL STROKE L STROKE FORM 2030964thAve. I W.*Lynnwood,WA 9?3036*(206)775-7272 # m PSB-HM-103 No. Date:~ PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): ALL Subject: WATER Publications Section hsert#: 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 adhere to the insides of heater coils and other parts of the machines causing damage and a loss of cleaning effectiveness. Reports from several of our machine users commending the results of the use of water softeners in conjunction with their machines prompts us to recommend the procedure everyone in a “hard water” area. to The relatively low cost of a water softener service is more than made up for in the increased life of machine parts and continued cleaning efficiency. Contact a water softener distributor in your area foe information on the rental of a simple water treatment unit to carry in your truck. See installation diagram below. FORM 2030964thAve. W.*Lynnwood,WA 98036.(206)775-7272 # No. Date:~ m PRODUCT SUPPORT BULLETIN Service/Parts/Publications Model(s): ALL Subject: CHEMICAL TO IS THE Section Insert#: SAVE KEY CUSTOMERS HOURS OF MAY THESE ICAL WATER TO OR EVERY HOSE VINEGAR LEAVE IN SYSTEM OCCUR TO INTERNAL THE SAME BREAKDOWN LIFE FOR WHITE MANNER BUILD-UP YOUR SUCH OF - HOURS MACHINE OF PULLED LONGER WHITE THE AND 45 THAN VINEGER PREVENT THE THE WITH WAS COSTLY BUILD- MACHINE FOLLOW PLACE AND TURN SYSTEM. MINUTES WARM INJECTED. THIS DOWN AND TIME, CHEMON TOOL DO NOT OR DAMAGE CLEAR 40 TYPES VINEGAR. VINEGAR FLUSH AFTER CHEMICAL RUNNING, THROUGH COMPONENTS. AS WITH OUR DIFFERENT FLUSH IS OF MACHINES HEAT, PROBLEM, 40 SOME THE AND MAINTENANCE MAY WATER WILL LONGER MACHINE. VINEGAR AS BE THEIR THIS BOTTLE ANY REMOVAL/BREAKDOWN ENTS 35 A WILL FLUSH BECAUSE WHILE IN 93THE IN TO FIGHT PROTECTIVE OPERATIONS. CONDITIONS, INSTRUCTIONS: FEED REMEMBER SUCCESSFUL REMEMBER, OCCUR. WEEK MONEY, NEGLECTING USE. UP AND MANY ARE CHEMICALS, A TIME TO OF ONCE BUILD–UP HOSES, IS A MILD OF EXCESSIVE FITTINGS ACID AND WILL CHEMICAL AND CONTRIBUTE BUILD-UP HEATERS. I I PsB-HM-lo4 2030964thAve. W.oLynnwood,WA 98036.(206)775-7272 IN TO THE COMPON– ‘?Ibl No. pSB-HM-105 Date: JANUARY 1979 PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): ALL Subject: VACUUM Section lnsert#: TANK FILTER We have available, designed bags, for your purchase, at the bottom if emptied the day, will tank. BAGS to trap all of the lint, really collect these Publications eliminate The drawstring to the incoming water sand and dirt of your vacuum at the end of each the buildup top of these inlet bags bags (~ of the debris CMl?TY . M TANK BAG FORM # W.*Lynnwood,WA 98036-(206)775-7272 in the to be tied tank. \ 2030964thAve. nor- job or at the end of WATER TO VACUUM TAN‘K // are The use of is designed in the vacuum that that would tank. of much INCOMING II filter TM No. PSB-HM-106 Date: April, 1979 PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): Subject: Section hsert#: Cleats to Van Cleats ment. prior The benefits to be removed equipment with Units cleats without W.*Lynnwood,WA which for units manufactured as standard operator in an accident. requirements from the vehicle 2030964thAve. are now available and increase is involved installation units 28, 1979. equipped are obvious the vehicle defines Hydra-Master to February that date have been the event below for securing floors for securing manufactured after Publications safety in The drawing enables excessive equip- the unit difficulty. 9S036*( 206)775-7272 TM PSB-HM-107 No. Date: A~ri.1~ 1979 PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): Publications Section hsert#: Subject: VACUUM RELIEF VALVE MODIFICATION Units manufactured prior to March 1, 1979 incorporated a brass plunger type Vacuum Relief Valve which required daily lubrication. Excessive plunger shaft wear would result through either lack of lubrication or excessive vibration and compromised vacuum strength at the cleaning tool. Units manufactured after March 1, 1979 now incorporate the Vacuum Relief valve depicted below which requires no daily lubrication. A modification kit is available which can be adapted to existing equipment in the field at a moderate price. This revision will minimize the over-wetting condition of carpets which can result through the excessive shaft wear described above. ZU3UY64thAve. W.”Lynnwood, WA98036*(206J 775-7272 ... 119 No. Date: ‘ay 1,980 w PRODUCT SUPPORT BULLETIN Service/Parts/ Model(s): Aqm-mt Subject: Service Section Insert #: Memo It has come to Hydra-Master’s in the heat exchanger temperature and exhaust replaced with an exhaust If you shell attention are breaking These pressure. a silicone that gasket which the asbestos up due to constant gaskets will part high are now being eliminate chance that your parts gasket is not adequate, (206) 775-7276 department, please or your phone of Hydra- Hydra-Master . Representative. This gaskets leak. find Master’s Publications number is 225801, Compression “-’”n EXCHANGER Gasket. m ///. SILICONE? GASKET ‘L_ ASBESTOS GASKET 203@364th Ave. W.*Kyamwood,WA 980360(206)775-7272 / I i I O“f-J! A I .lRiw#H I HOSE REF PART No. No. PART DESCRIPTION 1. 636020 GARDEN HOSE 2. 636024 SCREEN REPLACEMENT 3. 636022 INLET GDN. HOSE CONN. (Inc. Screen) 4. 611201 QUICK CONN. PLUG 5. 611101 QUICK CONN. PLUG 6. 611102 QUICK CONN. SOCKET 7. 636001 HIGH PRESSURE HOSE OTY USEI ‘) / II 1 1 1 1 1 1 % 5 1 L i&SURG /AQuA-cAT DIWW3 NO SCALE Ac-IO] ~ O 1978 DQwhl IiosE DIAGRAM BY CW?AN~JR. ~pp’vo DATE 4-3-79 HYDRA MASTER CORPORATION \\\ \.— r -PFiESSURE Gu-s %\ 1? FLOW METER L HIGH mESSURE PUMP i p C“HEMICAL t NTAK E P \\ m VELETE b. D&ETE SOLENOI C) ShLL VALVE~ FLINE TO LPRP , T-WIM& 6CuEeN, WAN= HVWT TO LPRP I.INF -- 400 BALL VALVEE FLOW; ADD T-= ITTIN5; CHAMW 6 3 L,?JE T* FUXIRC.P”UP:GE,C,,-,H ,- “W14T A r I CHGD FLOW TANK FITTINGS& . . . ET]” “-I ‘-”- REViSION- SCREEN JT @AT!S i.~.8ol CW E I ~-q 1 . JBLm t OATE LOW , v1’-4-S0 I I@] - III BY]CKid I Q?- , PRESSURE IN v 17-11-79 1 DATE I 1 1 0RAWlNf3 MO AQUA CAT FLOW DIAGRAM DRAWN Sy DATE () 4- %;;:% 5-79 : ‘z n. 1 (a HIGH PUMP r PRESSURE m o ml /- (---cc PART DESCRIPTION I P 1. DETAIL-A ~ --\ I u7&ssa%erzke t5pect&&Z: UK% 1. THERE ARE TO BE 16 D16C SPRINGS OF 2 PLACED -K TO OACK 8 SETS SHOW N ABOVE. 2.A a >
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