BobCat 3.0 3.5 Owners Manual Bobcat30 35hp_c_unkn &file=bobcat30 35hp C Unkn

User Manual: bobcat30-35hp_c_unkn

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INDEX
PAGE
.........................................................................................................,, ,,.
General Information
Warranty
...............................................................................................................................
Warranty Information
....................................................................... ... .... ...........................
Warranty Procedure
..............................................................................................................

2
2
3
3

Purchaser’s
Responsibility
................................................................................................
Truck Preparation
Information
...............................................................................................
Truck Preparation
Illustration
.................................................................................................
Propane Tank Location/illustration
........................................................................................
Hard Water Area Map ..................................................................................................... ... .

4
4
4
5
5

Machine Specifications
....................................................................................................... 5
Spare Parts Flecommendation/Parts
Orders .................................................................... 5-6
Water&
Chemical Flow Operation
..................................................................................... 6
Water Flow Diagram ................................................... ... .................................................... . 6
Chemical Flow Diagram ......................................................................................................,,. 6
High Pressure Pump Information
......................................................................................... 7
Bypass Valve Assembly Illustration
....................................................................................... 7
High Pressure Pump/Chemical
System Troubleshooting
............................................. 7 & 16
Model 290 Cat Pump Operating Instructions
.................................................................. 8-15
Chemical Proportioning
and Level Control Illustration
......................................................... 16
Chemical Tank Troubleshooting
.......................................................................................... 16
Heating System Information
............................................................................................... 16
Heater Operating Instruction
................................................................................................ 17
Heater Troubleshooting
....................................................................................................... 17
Vacuum System Information
..............................................................................................
Vacuum Flow Diagram
........................................................................................................
Vacuum Tank Filter Bag ......................................................................................................
Vacuum Blower Lubrication
(Diagram)
......................... .......................................................
Vacuum System Warranty
.................................... .... ... .... .... .................. .... ...................
Vacuum System Troubleshooting
........................................................................................
Engine Manual/Warranty
Engine Troubleshooting

18
18

18
18
19
PO

............................................................................................. 21-28
....................................................................................................... 29

Electrical Diagram .............................................................................................................. 30
Electrical Troubleshooting
................................................................................................... 30
Machine installation
Information
.......................................................................................
Machine Tie Down Cleat Information
...................................................................................
Propane Hook-Up Illustration
...............................................................................................
Gas Hook-Up Illustration
......................................................................................................
Water Softener Information
..................................................................................................
Jet Assembly
.......................................................................................................................
Wand Assembly
...................................................................................................................
Valve Assembly
...................................................................................................................

Machine Operation
Instructions
.........................................................................................
Controi Panel ......................................................................................................................
Operation Precautions
........................................................................................................
Freeze Protection
.... ...........................................................................................

33
33
34

Cleaning
Cleaning

31
31
31
31
32
32
32

and Chemical Precautions
and information
......................................................... 34
Stroke Procedure/Over-Wetting
........................................................................... 34

Maintenance
Procedures
........................................ .. . ................................................... 35
Overaii Careof Machine
...................................................................................................... 35
Maintenance
Logs ....................... .................................................................................... 36-38

HYDRA-MASTER

GENERAL
INFORMATION

Effective

pair 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.

Engine has to run 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
consistency.
Heater must maintain proper heat.
Vacuum tank must store dirty water until drained.
As you can see, it is not just a turn key operation
to worry about, Does it start?!

YEAR GOLDEN GUARANTEE@
LIMITED WARRANTY PLAN
HydraMaster
warrants products
of Its manufacture
to be free from
defects In material and workmanship
If properly
Installed,
malrta!ned,
and o~erated
under normal cond{llons
with competent
superwslon
No person,
agent,
representative
or dealer
IS
authorized
10 give any warranties
on behalf of Hydra Master [nor to
assume for Hydra Masler any other Iabdrty m connection
with any
of HydraMaster’s
products
‘his ‘warranty
shall extend
for the
pertods
Ilsted by component
below from date of nstallatton
If
repatrs
or replacements
are made
by the Purchaser
wtthout
HydraMaster’s
written
consent
HydraMaster’s
warranty
shall
cease 10 be [n effect
No allowance
WIII be granted for anv repairs
or alterations
made Dy {he PJrchaser
wltnout HydraMaster
s prtor
written consent

Unlike the garden tractor, Iawnmower and cement mixer, all having
one or two functions to perform, the truck-mounted carpet cleaning
plant has many functions to perform simultaneously.

Machinery,
equipment
and
accessories
furnished
bv
HydraMaster,
but manufactured
by others
are warranled
only 10
the extent of the orlglnal manufacturer
s warran!v to HvdraMaster

with only one thing
Hydra Master agrees at Its option to repair at the potnt of st?lpment,
or to replace
without charge
any parts or parts of products
O{
Hydra Master s manufacture.
which wlthn the specified
warranty
period shall be DrOved to HvctraMaster’s
satsfactron
to have been
defective
when shpped.
provided
the Purchaser
promptly
nohfles
HvdraMaster
{n wrttng
of such alleged defect
HydraMaster
will
Day all freight
and transportation
charges
via ‘?ormal ground
shipping
means
for replacement
~f Darts covered
undel
Ihls
,warrantv

THE SYSTEMS WORK AS
FOLLOWS:
The water system takes incoming water at tap (low) pressure, combines it with chemical from the chemical system automatically,
pumps it under high pressure through the heating system and out to
the cleaning tool. After being sprayed into the carpet being cleaned,
the water/chemical/soil
solution is extracted by the vacuum system
and returned to the waste recovery tank.

Hydra Master s Iablllty
:C Purchaser
wnelher
,7 co171racl or m ‘ort
arlsl fig Jut of warranties,
,eDresertatlon
wstructlons,
or detects
from ,]nv (cause SILIII be lr~ted :C repar\17g CI replac:~lg Ihe defec
[Ive part or parts
No habilrty whatsoever
shall
prOObCtS have Oeell pdld tOr

As there is no guess work in the manufacture of these highly advanced cleaning plants, there must be none in preparing it to get the
job done in the field. It is the purpose of this manual to help you properly understand, maintain and service your cleaning plant. Follow
the directions carefully and you will be rewarded with years of profitable trouble-free operation.

Exceot as
Warrantv
warranties
lcxpress
Ihabtlrty for
caused

when preparing for op-

The manufacturer
uses this symbol
throughout
the manual to warn of
possible injury or death.
This symbol is used to warn of
possible equipment
damage.

attach

to HydraMaster

untl

said

stated r this secton and 10 the Drecedng
secfton tiled
and except
as !O ttle
there are nc guarantees
or
ot merchant ablhtv
tltness
performance
or otherwise
Implled or statu[or~
ar)u f+vdra Mas[er snail t7ave no
consequential
mcldental or other damages,
howsoever

FRAME/COVER
VACUUM

Imm@!l

WARRANTY POLICY

1, 1989

HYDRA-MASTER
warranty covers only defective materials and/or
workmanship for the periods listed, Labor, and/or diagnostic reimbursement is specifically excluded,

This manual contains installation and operation instructions as well
adjustment and reas information required for proper maintenance,

It is imperative that no section be overlooked
eratirm of this equipment.

January

ASSEMBLIES:

RECOVERY

. . . . . . . . . . . . . . . . . . . . . ..3 years

TANK/CHEMICAL

CHEMICAL

PROPORTIONING

CLEANING

WAND:.........,....,..

MIX TANKS:

SYSTEM:

ENGINE: \T)7ru orlg]nal blan~taclurer
seeorlclnal
blar7ufac! Lrersiv Jrrra,7!\

.,3 years

. . . . . . . . . ., .,:

years

. . . . . . . . . . . . . . . ..z

years

Or> Elrecl Dllve umrs
J ., ., . . . . . . . . . . ..L- ~ea,s

INTERNAL

VACUUM BLOWER:
(Thru orgnal
Manufacturer
See
Cooper Industries warranty
I . . . . . . . . . . . . . . . . . . . . . . . . . ,c !/ears

(

MACHINE

HIGH PRESSURE

BY PASS

BELTS,

FITTINGS,

FILTER

WATER

HEATER

OR HEAT

HIGH PRESSURE
~-

I+OSES

PUMP

..,.,

VALVE

.,.

, . . . . . . . . . . . . . . ..yea.s

. . . . . . . . . . . . . . . . . ..2vears

SCREENS,

GAUGES:

EXCHANGER,

(Thru or[glnal

., .,

Manufacturer

VACUUM
HOSE, SOLUTION
HOSE,
QUICK CONNECTORS,
O-RINGS,
SEALS:.
Freez)ng of any water or chemical
warranties
on water or chemical
external,
of ths equpment

related
related

. . . . ...1

year

. . . ...1

year

..1 year

., ., . . . ...90

component
components

days

WIII VOID all
internal or

Deposits and build-up
m the water
chemcal
or heater systems,
$
due [o hardness m the __water used or poor quallty chemicals
wh!ch
1
5 resulf In deposi!s
will vod all warranl!es
on affected compo~en!s
k
J,@n
-. ~43=17x
w .-.
.
. —..

WARRANTY INFORMATION
To avoid misunderstandings
which might occur between machine
owners and manufacturer, we are listing causes of component failure that specifically voids warranty coverage. Such causes as listed
below shall constitute abuse or neglect.
ENGINE:
operation at speed in excess of 2800 R.P.M. Failure to
maintain proper oil level (oil should be checked every 5 running
hours). Failure to use the proper oil viscosity and type (see engine
manual). Use of other than manufacturer’s
recommended
spark
plug in engines. Failure to perform recommended
maintenance as
described on pages 3 and 4 of engine manual.
BLOWER:
Failure to lubricate impellers daily with LPS-1 or
WD-40 lubricant. Failure to lubricate bearings as recommended
in
blower manual. Failure to maintain proper oil levels in the blower.
Failure to use the correct oil grade and viscosity as recommended in
blower manual. Failure to properly maintain blower safeguard systems such as waste tank filter screen, vacuum safety relief valve in
vacuum tank lid and waste tank automatic shut-off svstem.

HIGH PRESSURE
WATER PUMP: operation of pump at
pressures over 1200 PSI. Failure to maintain proper oil level as recommended in pump manual. Failure to change oil in pump at recommended 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.
HEATER:
Operation of heater without adequate water supply.
Changing factory set propane regulator. Operating heater without
proper ventilating. Failure to protect heater against freezing. Operating machine at water pressures over 1000 PSI. Overfilling of propane tank. Use of improper chemicals.
Failure to use water softener
in hard water areas.
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.
CHEM.

PRO PORTIONER:

use of improper chemical. Failure

to use water softener in hard water area. Operating machine without
proper chemical filter screen. Failure to protect against freezing.

CONTROL
pressure

PANEL: Failure
gauge against freezing.

VACUUM

to motect
‘

flow meter and water

AND

hoses against
engine/blower
hicles. Kinking
rectly. Normal

SOLUTION
HOSES:
Failure
freezing. Failure to protect hoses against
exhaust. Damage to hoses from being run
or cracking from failure to store or unroll
wear and tear from everyday use.

to protect
burns from
over by vehoses cor-

CLEANING
WAND: Failure to protect against freezing.
ous physical abuse of wand.

Obvi-

WARRANTY PROCEDURE
Warranty coverage is available to you ONLY through Hydra-Master
Corporation, 20309 64th Ave. West, Lynnwood, Washington 98036;
When warranty parts are needed, write Hydra-Master
Warrsnty
Dept. at the above address, or call the Warranty/Service
Dept. at
(206) 775-7275.
No collect calls will be accepted.
Hours of the
Warranty/Service
Dept. are 8:00-11:30
am and 12:30-5:00
pm,
Pacific Time.

IMPORTANT
Hydra-Master’s

warranty policy provides replacement parts without
charge for thirty (30) days to customers maintaining current account
status. An invoice dated thirty (30) days from date of replacement
3

parts shipment will be sent to the customer for the amount of the
parts sent. The customer’s faulty parts must be returned for evaluation prior to the expiration of the thirty (30) day period. Upon warranty
approval, a credit will be issued the customer for the replacement
parts invoice. Wsrranty disapproval or failure to return the faulty
parts ‘within the thirty (30) day period allowed will result in the
customer
being charged for the replacement
parts sent.

HOW TO ORDER
To obtain a proper diagnosis of your malfunction, and to order warranty replacement parts, it is important you follow the below procedure:
1. Call Hydra-Master

Warranty/Service

2. Give the Warranty/Service
tion:
A.
B.
C.
D.
E.
F.
G.
H.
1.

Dept. at (206) 775-7275

Representative

the following informa-

Name of your company and your address.
Eauipment Model (i.e. Hvdra-Cat, Bobcat 2, etc.)
D&e of purchase. ”
“
Hours on the unit.
Serial number of unit.
Name of person authorized to order parts.
Salesman unit purchased from.
Description of malfunction.
Pressure readings on high pressure gauge with wand turned on
and off.

3. If warranty replacement parts are needed, please specify method
of shipment desired. NOTE: All replacement
parts are sent
freight collect, via:
A.
B.
C.
D.
E.

U.P.S.
Airfreight
Air mail
Air express
Auto Freight

4, Do not give malfunctioning parts to a Hydra-Master
Sales or Service Representative.
All parts must be returned directly to H ydraMaster, freight prepaid.

ONE FINAL NOTE:
Any questions you have regarding the warranty program should be
directed to the Warranty/Service
Dept. Personnel at Hydra-Master
Corporation.
We shall always endeavor to be fair in our evaluation of your warrarity claim, and shall provide you with a complete analysis of our
findings.

PURCHASER’S
RESPONSIBILITY
PRIOR TO ARRIVAL

OF UNIT:
Install %“ exterior plywood flooring in vehicle and cover with I
artificial turf.
a Have belly mounted propane tank installed on vehicle. Tank
must be propane vapor type

Materials Needed:
1. 2 sheets 4 x 8 x 5A” exterior plywood
2. 6’ x 12’ piece of commercial astroturf
3. 16-1 lA” sheet metal screws
4. 1 quart marine adhesive (optional)
5. 1 staple hammer w/’/z” staples
(See illustration for correct placement of plywood

flooring)

●

IPLACEMENT OF UNIT IN
VEHICLE
There are two recommended

~
P.rchaseheavyd.ty
42-60 amp hour
battery and have battery ‘slow’ charged if new. If battery is not
fully charged darnage can occur to the engine charging
regulator.
ACCEPTANCE
OF SHIPMENT:
e If unit shows any outward signs of damage, do not sign the
delivery receipt until you have closely inspected the unit and
noted any damage on the delivery receipt. Have the freight
company representative
acknowledge the damage by signing
the notation of damage on the delivery receipt.

unit placements:

A, SIDE DOOR: Most installations are side door. 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.

READING
OF C9PERAT10N MANUAL:
e It is the purchaser’s responsibility to read the unit operation
manual and to familiarize himself with the information contained
therein.

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 Iocatlon 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. IWs 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 weight line up over drive
shaft). Also, it is physically easier to load unit into rear door due to
height of van bed.

SALES REPRESENTATNE
RESPONSIBILITY

to the
Ensure that machine
is well secured
floor of van with hardware
supplied.
Sudden or crash stop will
cause machine to rocket fonward, al! 350 Ibs. worth! Protect
yourself and the machine: SECURE IT!

e 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 and
maintenance.
CCNIRECT INSTALLATION
INCLUDES:
Supervising the purchaser in the following:
● Installation of through-floor
fittings for propane and gasoline
fuel lines: installing propane regulator included with unit, outside vehicle; placing unit and recovery tank in vehicle and
securing them with bolts or tie down cleats: connecting all
propane and gasoline lines; connecting battery; checking
pump, vacuum blower and engine oil levels, prior to starting
unit; starting unit to check engine to see that all systems
funti[on normally; also checking all hoses, wands, etc., for
correct operation.

TRAINING SHALL INCLUDE:
* Thorough review of the operation manual with purchaser;
instruction and familiarization in: how to correctly start up and
shut down unit; how to correctly clean with the unit; how, where
and how often to check and change component oil levels; how
the unit’s systems work; how to troubleshoot the unit; how to
do basic repairs; safety precautions and their importance;
freezing damage and how to avoid it and a thorough review of
the unit warranty and warranty procedures.

TRUCK PREPARATION
!ILLUSTRATION
FIRST, cover the truck bed with 54” plywood using metal screws to
secure it as shown.
,, +Lw,mm

SECOND,
select the appropriate color astro turf to match your van
and cover the plywood and staple in place. A standard van requ~res a
piece 6 feet by 12 feet.
THIRD,
for added ventilation, an aluminum roof vent should be
added over the location selected for mounting the rnachme. This WIII
allow hot air from the heater to escape.

TRUCK PREPARATION
Manufacturer recommends the installation of plywood flooring
covered with poly propylene backed astroturf (do not use rubberbacked) in the vehicle prior to installation of machine. This provides a
metal to cushion mounting rather than metal to metal, provides insulation and makes an attractive van interior. Astroturf should be color
keyed to van interior.

4
.—

PROPANE TANK LOCATION
Either the 10 gallon or 16.5 gallon propane tank will fit this location.
Have your local propane dealer install the tank you select and purchase. The machine will come with the proper propane regulator.

MACHINE
SPECIFICATIONS

(Tank must have vapor outlet).
propane tank inside the
truck or van. Besides being dangerous it is unlawful in most states.

FRAME:

18“ W, 53”L, 34”H, Steel With Baked-On
Finish.

WEIGHT:

Model 3.0:485
Model 3.5:500

COWLING:

Steel With Baked-On

ENGINE:

16 HP Briggs & Stratton Opposed
Steel Sleeved Cylinders, Ducted.

IGNITION:

Magneto

HI-PRESSURE
PUMP:

Tri-Plex Piston - Cat 290 -3.5 GPM -1200
(@ 1200 RPM.

VACUUM
BLOWER:

Model 3.03 MB Sutorbilt W/l 4 HG Safety Relief.
Model 3,5: 3LFS Sutorbilt W/12 HG Safety Relief.

CHEM, SYSTEM:

Electro-Mechanical,

HEATER:

Propane Fired, ThermostaticallyControlled.
(120,000 BTU).

INSTRUMENTS:

1-1000 High Pressure Gauge, Hour Meter,
Chemical Flow Meter, ignition Key Start,
Temperature Gauge,

RECOVERY
TANK:

Model 3.0:52
Model 3.5:65

CLEANING
WAND:

S/S 11” W/Heat Cover Handle - and Forward
Guide Handle,

HI-PRESSURE
HOSE:

M“ High Temp Lined/Vinyl Covered Safety
Orange W/Brass Quick Connects.

Do not use a portable

TANKFILLVALVE

HARD WATER AREA MAP
The quality of water varies greatly throughout the United States and
influences the reliability arid efficiency of equipment in direct proportion to its level of hardness. The 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
decreased and the appearance of cleaned carpets enhanced when
water softeners are incorporated in hard water areas. Manufacturer
strongly urges the use of water softener units in areas exceeding 3%
grains per gallon. Using the legend as a reference, determine the
quality of water in your area and take action immediately should it be
necessary.
l-l

(For installation

;

diagram see
machine

~ ~~’;’

‘,’

0- 3~/2
31/. -7

10%ANDABOVE

PSI

Flow Meter Controlled.

Gallon Aluminum Epoxy Finish.
Gallon Aluminum Epoxy Finish,

OPTIONAL
FEATURES:

Stair Tool, Steel Legs W/Casters, Additional 2“
Vacuum Hose in 50’ Lengths, Additional %“
Pressure Hose In 50’ Lengths, Pressure
Washing Gun, Spare Patis Package.

To expedite your parts needs, please call your sales representative.
In most instances, he either stocks or has access to parts through a
regional service center.

Because your truck-mounted unit is capable of generating several
hundred dollars per day, down-time on the unit can be very expensive.
In order to minimize such down-time, it is strongly recommended by
the manufacturer that you purchase and keep in vour truck the folIowing spare parts:

PART NUMBER

Key Start. Solid State Ignition.

PARTS ORDERS

SPARE PARTS
RECOMMENDATION

QUANTITY
2

Twin Piston.

Power Console, Vacuum Recovery Tank, 11”
S/S Cleaning Wand, 100’ M“ High Pressure
Hose, 100’- 2“ Vacuum Hose, 10’-1 M“
Vacuum Hose, Through Floor Connections For
Gasoline and Propane Hook-up, Tie-Down
Cleats, Vacuum Hose Connections, 5 Gallon
Chemical Jug, Operation Manual.

‘q

Epoxy Finish.

STANDARD
FEATURES:

installation section) F*

pounds.
pounds.

VACUUM HOSE: 2“ Reinforced Safety Orange, 1M“’ Reinforced
Safety Orange.

GRAINS
PER GALLON

Epoxy

DESCRIPTION

000-078-015

Flow Meter Kit

000-078-024

Wand Valve Plunger Kit

000-078-034

Press. Bypass Valve Kit

000-076-007

Spray Jet 8008E

000-049-028

Recovery

000-049-023

Screen Garden Hose

Hydra-Master

QUANTITY
1

Engine Spark Plug

In the event parts are
ordinate your needs.
method of shipment
Freight, Air Express,

Tank Filter Bag

unavailable locally, contact the factory and coIf this becomes necessary, always indicate the
you desire, i.e. U. P.S., U.P. S. Blue Label, Air
etc..

Parts Dept. phone (206) 775-7276.

PART NUMBER
000-078-001

DESCRIPTION
Cat 290 Shori Cup Kit

000-078-004

Standard
Cat 290 Hot Cup Kit (Optional)

000-052-050

440 Male Quick Connect

000-052-051

440 Female Quick Connect

000-052-052

660 Male Quick Connect

000-052-053

660 Female Quick Connect

000-010-019

Belt, Pump Drive. AX-26

WATER FLOW

OPERATION
This electro-mechanical
system has been designed to be simple
and trouble free. Incoming 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 mlx tank. As the water
passes through the Chemical Injector, it IS automatically
proportioned with a predetermined
quantity of detergent. The MIX (3)
Tank 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
secondary,
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 automatically dmengages the system and
prevents the water pump from running dry.

‘~

Chemical
Injector

Sole;oid
Control

-~
d

Relay

“’
.1
I

}

The desired chemical InjectIon ratio may be obtained by an adjustment of the Chemical Flow Meter (6) during the fill cycle of the mlx
tank. Water must be flow!ng into the mix tank In order to adjust the
chemical mix. The chemical WIII flow from the Chem!cal Jug (7) to
the Chemical Flow Meter, then to the Chemical Injector where It IS
proportioned
into the MIX Tank at the desired chemtcal setting.
NOTE: With th[s unique chemical system, the chemical flow is
proportioned only during the filling cycles of the Mix Tank, not during the direct spraying of the wand, Therefore, !t is possible that as
your wand IS spraying, you may have no chemical flow. Also, the
converse is true [n that you may not be spray!ng your wand, but if
the mix tank is In a filllng cycle. your Chemical Flow Meter may be
actwe at the desired flow rate.

Y-

678+

The chemical proportlomng system will mix chemical with water at
a t to 30 ratio when the Flow Meter is set at 5 GPH, or a 1 to 15
ratio when the Flow Meter is set at 10 GPH.
At this 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 us!ng solution by spraying, the
solution will be bypassed from the bottom of the brass Pressure
Relief Valve (9), back to the MIX Tank.

Chemical Flow Meter
Chemical Jug
High Pressure Pump
High Pressure

Heater COII
Pressure Guage
Incoming Water
Tank Dratn
To Wand
Low Pressure

CHEMICAL PROPORTIONHUG AND
LEVEL CONTROL
MIX

6FA 6uFS

When the wand is spraying, the solution continues its flow to the
Water Heater (1 O). The coils of this heater have a capacity of up to
2 gallons, therefore it IS extremely important that all 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,

‘“

Check Va ve
Spring
~
‘
O S S Ball

CHEMICAL SYSTEM MAINTENANCE
The chemical lines may need to be flushed with vinegar periodically to prevent abnormal chemical build-up. This flushing may be
done by removing the clear plastic hose from the Chemical Jug
and inserting it into a one quart container of vinegar, This should
be done with the Chemical Flow Meter setting on 10 GPH and the
Water Heater “off”. Simply spray water 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.

CHEMICAL

101? 12 1314-+

check Valve

l!)
@!

~ ‘“’’”0’

60”’

Cap
Nut

Che.[cal

—

F/r

SYSTEM WIRING DIAGRAM
Solenoid

*~=L—lJ , ~wate,

Valve

Mounmg

Inlet

“!!+!!%::=*
GFD

Tank
{

T-

12 vDC
Coil

“L.._J

Mounting
Plate

GENERAL
INFORMATION FOR
CAT PUMP REPAIR

BYPASS VALVE
169=101

@’ ?

As you remove your discharge manifold, there is a 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, it is
probable that they would remain open causing pressure loss or pulsation. Upon inspecting the valves, make sure that the teflon buttons
in the valve spring retainers are still itact. 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 in 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 no sure method of visually inspecting the cups. Hydra-Master
recommends
changing cups
whether they look good or not.

A pump instruction brochure on pages Et-15 may assist you in resolving a pump related problem.

Anytime your pump is being dismantled, Hydra-Master
recommends
replacement of all ‘o’ rings and seals. This is merely a convenience
to the customer to make sure that the Cat pump is in top operating
condition.

PROBLEM:

Within the piston sleeve cylinders there are 6 ‘o’ rings that are about
1/4 the size of a penny.
If these ‘o’ rings are bad, water will be pumped
back into the oil. If this has occured the oil will raise in level and will
appear milky. If you are unable to repair seals right away, change oil
frequently. Repair the pump as soon as possible so as to not damage bearing or connecting rods.
Repairing of Cat pumps is not a difficult task. However, before disassembling make sure you have the proper parts required.
short (or hot) cup kit
piston sleeve ‘o’ rings
Prrrm-a-lube seals
bottle Cat oil

Read instructions thoroughly, supplied in the Cat pump manual,
prior to disassembly and follow directions as stated. 011 all seals
thoroughly prior to installation. (Remember,
a newly scarred seal is
no better than one you just took out.)

BYPASS VALVE
ILLUSTRATION
Bypass Valve Parts List
REF.

NO.

PART

NO.

DESCRIPTION

000-105-101

Thrust
Valve

000-105-102

Piston Plate, Bypass

1. Clogged Filter Screen in garden hose quick connect
coupler.
A. Remove and clean or replace filter.
2. Low water pressure at source.
A. Determine rate of flow and select an alternate source of
supply if water pressure is inadequate.
3. Defective or blocked check valves in high pressure pump
cylinder head.
A. Disassemble cylinder head and replace or clean applicable
check valve.
4. Delaminated,
kinked or clogged hose between the mix tank
and the high pressure pump.
A. Remove and replace defective hose.
5. Defective
pressure relief valve or debris in pressure relief
valve. NOTE: the high 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 of the
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 must be disassembled
and cleaned
(refer to drawing provided in this manual for bypass disassembly).
A. Disassemble and clean pressure relief valve as illustrated in
drawing.
B. Replace defective or worn out bypass cup.
C. Replace bypass valve.
6. Defective or worn cups.
A. Remove and replace piston cups as defined by pump manual.
7. Loose drive belt for high pressure pump.
A. Readjust belt as required or replace if defective.

QTY.

LOSS OF PRESSURE
CAUSE AND/OR SOLUTION:

●

The prrrm-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 defective prrrm-a-lube seal. Replace them all.

1631-

HIGH PRESSURE PUMP
TROUBLESHOOTING

Plate, Bypass
1

Valve

WATER FLOW
1. Worn out spray jet. NOTE: Cleaning tools designed to spray a
constant flow of 1 lA GPM will average 1 gallon of 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 consistent flow rates for
approximately 20,000 gallons. They should be replaced therefore,
approximately
every 350 hours. Worn spray jets allow a greater
average rate of flow thus reducing desired temperature levels.
A. Remove and replace spray jet.
(Continued on Page 16).

000-078-101

Kit, Seal for Bypass
Valve

000-148-004

Seat & O-Ring,
Valve

Bypass
1

000-097-005

O-Ring,
Fittina

Valve

Bypass

,$%,

r~~

Model 290
OPERATING INSTRUCTIONS

‘
-.

CAUTION: CAT PUMPS are positive displacement pumps. Therefore,
a properly designed pressure relief mechanism MUST be installed in
the discharge piping. Failure to install such relief mechanism could
result in personal injury or damage to the pump or system. Cat
Pumps Corporation does not assume any liability or responsibility
for the operation of a customer’s high pressure system.

SPECIFICATIONS

,
M@tr[c Measure
(13 MM)

U.S. Measure
volume ........................................................................................................................... 3.5 GpM
13ischarge Pressure ...................................................................................................... 1200 psi
Maximum Inlet Pressure ...................................................................................8.5 to + 40 psl
RPM ....................................................................................... ...................................... 1200 RPM
Bore . ...................................................................................................................................O.78O''
Stroke ................................................................................................................................O.472''
oz.
Crankcasa Capacity .......................................................................................................... 10
Maximum Fluid Temperature .......................................................................................... 160” F
Inlet Port (I) .............................. ........................................................................ .............l/2'' NpT
Dlschar e Fort (2) .........................................................................................................3/8'' NPT
Pulley J ounting ........................................................................................................ Either side
Shaft Diameter ..................................................................................................................O.65O''
Weight ............................................................................................................................l
2.1 Ibs.
Dimensions .......................................................................................................l O.6 X 9.1 X 5.7”

(-0.6 to+!%
g~!~
(1200 RPM)
(20mm)
(12mm)
(0.3 L)
(71 “c)
(1/2”

NPT)

(3/8” N PT)
(Either Side)
(16.5 mm)
(5.5 kg)
(268 x 230x 146mm)

CAT PUMP WARRANTY
This Cat Pump Vpraduct”) is warranted by tha 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.
Ail products sub.ect to Ma warranty shall be returned F.O.B. Cat
Pumps Corp., M / nneapolis, Minnesota 55430, U.S.A. for examhtailon, repair or replacement.
The express warranty sat forth herein is in lieu 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 discteimed and excluded by the manufac
turer. 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 Ioas, dama es or
expermea, including incidental or consequential damages, d?rectly
or indirectly ariahrg from the sale or use of this product.
This warranty is subject to the following warranty conditions:
Products descr,bed hereon

—-.

-)
>*/A#p’
.,.,
.
,’.,

C,,,,,.,

are covered

?%..
- ,;
,?,

...

P O Box 685 MINNEAPOLIS
MN 55440
Phone (612) 780.5440 0 Telex 29.0276
*
N V CAT PUMPS

INTERNATIONAL

Harmmmeslraat
29
!3.2000 Anlwerp. Belq!um

S A

by one

or more

of the

following

IMPORTANT

CONDITIONS

LLlaRICATION — ftll crankcase 10 dot on oil gauge window per Srxmtlcatmns wllh Cat
Pump 011or equllvalenl SAE 60 weight hydraulic 011wtlh afltlW@aland rust lnhlbitor additives. Change inltnal fill after 50 hour run.in period. Chnage 011every three months or at
500 hour Intervals thereafter
Prrrrrm-a-lube seals need no lubrication
Blue dot seals and
wicks must recewe three drops 0! Cat Pump 0!1 Per w!ck every 50 hours of operallon.

LUBRICATION IS THE EASIEST, MOST EFFICIENT IW40 LEAST ExPENSIVE OF
PREVENTATIVE MAINTENANCE.
RPM and PRESSURE— Pump operatton musl be woth(n RPM ano pressure specd!cattons

GOOO

Pressure

reltef valve must be ,nstalled

PUMP ACIDS OR ABRASIVE FLUIOS with this und Consult Cat Pumpe tor add!.
tlonal information on questionable flu!ds
FREEZING CONDITIONS — Pump must ba protected from !reez!ng condtllons
USE OF OTHER THAN CAT PUMP PARTS OR
THEIR EQUIVALENT VOIOS THE WARRANTY

DO NOT

U S

patenls

‘!
LoretohOhe 5
CH 6300. ZUG Switzerland
●
CAT PUMPS DEuTSCHLAND
GmbH
Roslocker StraSSe 9
6200 Wlesbaden. Bterstadt
Wesl Germany
●
CAT PUMPS (U K ) LTD
17A K,ngs Road Fleet
HamDshlre Gu13 9AA

3558244

3652188

D/str/buted

3809508

3920356

and

3930~56

—

3/8’
3
.5 1

~,o.55,2~3”g4’100)
IMPORTANT

DRIVE INFORMATION
Pump
speed
and
pump
output
in
gallons
per minute
as tabulated
is
based upon a 1725 RPM drive motor.
Select
motor
pulley
size to provide
pump
outGPM of the approximate

Pulley

HORSEPOWER

REQUIREMENTS

Selection
Using 5“
Pump Pulley

PRESSURE

800

Flow

Psl

;PM

put

1000

1200

Psl

BAR

desired.

Pump
RPM
and GPM
output
are approximate
values
due to variations
in
pulleys,
belts
and
motors
between
manufacturers
and a + – 5°!0 pump

Motor
P:J:y
RPM

output

3.5

1.9

2.4

2.9

1200

3.5

3.0

1.7

2.1

2.5

1029

3.0

2.5

1.4

1.7

2.1

858

2.5

tolerance.

Horsepower
figures
shown are brake
horsepower
figures.
For gas engine
requirements,
follow
engine
manufacturer’s
recommendations.
In general,
use a gas engine
with approximately
double
the
electric
motor horsepower.

TYPICAL INSTALLATION
The illustration at the right shows the basic
elements for the proper installation of a high-pressure pump.
Each component
offers
potential problems that too often are ascribed
to a perfectly functioning pump. A clogged
strainer, a partially closed shut-off valve or a
faulty pressure gauge or pressure regulating
unloader may be the source of trouble.
Proper system installation, routine lubrication and monitoring of components are your
best and guarantees of optimum pump performance. These precautions will eliminate most
problems, minimize corrective maintenance,
and give many, many added hours of trouble
free operation. Cat PumDs Cor~oration does
not assume any Iiability”or responsibility for
the operation of a customer’s high pressure
system.
9

S HUT

c$F

“bJ.VE

u
II —

F, LTROT,CM

Ixv,cc

NOTEIl&ed s“.!,.” ,eq”,ml.“
plunger
typepump,

GENERAL INFORMATION

INTERPRETING
readings

PRESSURE
READINGS:
Pressure
from the rated PSI or those
that differ
set-up
indicate
a problem,
for a particular

MATERIAL
RETURNS:
If necessary
to return a Cat
Pump,
please
secure
an approved
“RETURN
GOODS AUTHORIZATION”
form from Cat Pumps
Corporation
and
complete
a “PRODUCT
REPORT”
form detailing
the application
and the
conditions
of operation.
Any material
AUTl-fORIZED for
return
must
be
shipped
FREIGHT
PREPAID.

normal
but not necessarily
a pump problem!
Before any servicing
of the pump, carefully
check
the following;
inlet plumbing
for size, restriction
and/or air leaks, restricted
or worn orifice and condition
of the by-pass
valve and pressure
gauge.
Check any shut-off
valves in the inlet or discharge
plumbing
to be sure they are fully open. Seven out
of ten problems
are other than pump problems!
FOR SERVICE
contact
your local
or look in the Yellow
Pages under

FILTER
pressure

lNSPECTICIN:
A
is due to foreign

frequent

source

low

matter in the fluid being
pumped.
It takes but one small particle
to partially
hold open a valve—several
to plug an inlet screen
or filter, or if the particles
are abrasive,
to damage
packings,
valves, valve seats, or plunger%
Inspect
filters and screens
on a schedule
commensurate
with the material
being pumped
and
whenever
a low pressure
problem
develops.

representative
PUMPS.

ORDERING
OF PARTS: When ordering
parts, be
sure to give the “model
number”
and “serial
number”,
“description”,
and “quantity”
of the
items desired.

NOZZLES:
pressure.

A worn

nozzle

will

result

loss

INSTALLATION
Optimum
be obtained

performance
only

Lubrication:
Fill crankcase
warranty
conditions.

with

of the pump
the

oil

proper

is dependent

selection

as covered

under

Pulley Selection:
Select size of motor pulley required
to
deliver the desired
volume
from Horse Power Requirement and Pulley Selection
Chart.
$electicm:
The motor or engine driving
the pump
must be of adequate
horsepower
to maintain
full RPM
when the pump is under load. Select a motor from the
Horse Power Requirement
Chart according
to required
pump discharge
volume
and maximum
pressure
at the
pump!
Motor

Mount
ner

the pump
permit

on a rigid, horizontal
drainage
of crankcase

suface
in a manoil. An uneven

mounting
surface
will cause extensive
damage
to the
pump base. Use the correct
belt; make sure pulleys are
aligned.
Excessive
belt tension
may be harmful
to the
bearings.
Inlet Plumbing
must be at least the same
diameter
as
the inlet port, preferably
one size larger.
Restriction
in
the inlet plumbing
will cause
cavitation
in the pump,
drastically
reducing
packing
life. All joints
must be air
tight.

Inlel Pressure:
Optimum
performance
is obtained
+ 20 PSI inlet pressure.
With adequate
size inlet
bing, the pump
will perform
very satisfactorily

with
plumwith

and

upon the entire

installation

fluid system

of plumbing

and

and will
accessories,

flooded
suction.
The pump
can operate
with
pressure
up to 40 PSI. Use of excessive
pressure
void the warranty.

inlet
will

inlet Accessories:
Install
an inlet strainer
of twice the
rated capacity
of the pump.
A stand
pipe to help maintain
a positive
pressure
head in the inlet line is desirable.
A shut-off
valve
is recommended
to facilitate
maintenance.
Discharge
Plumbing:
Install
a pulsation
dampening
device
mounted
directly
to the discharge
line and
precharged
to a pressure
calibrated
for operating
conditions.
A reliable
pressure
gauge
should
be installed
near
the discharge
outlet
of the high pressure
manifold.
This
is extremely
important
for adjusting
pressure
regulating
devices and also for proper sizing of the nozzle or restricting
orifice.
The pump is rated for a maximum
pressure;
this is the pressure
which
would
be
read at the discharge
manifold
of the pump, not at the
gun or nozzle end of a long hose.
A pressure
regulating
relief valve or unloader
must
be insta//ed
to prevent
over-pressure
in the event the
discharge
or downstream
plumbing
becomes
plugged
or is turned off. Severe damage
to the pump will result
if this condition
occurs without
a relief valve in the line.
CAUTION:
Failure
to install
such a valve will void the
warranty
on the pump.

EXPLODED VIEW
MODEL 290

S’8

‘

PARTS LIST
CAT PUMP MODEL
ITEM
PART
2
3
4
5
a
9
10
11
12
15
16
17
18
19
20
21
23
24
25
26
27
28
2$3
30
:;
33
34

28766
85680
14177
43211
26087
26105
22289
23170
25625
92520
43804
14487
24159
26536
27950
92519
101799
101800
16948
20017
25301
25327
25392
28771
29003
29614
26854
28597
25128
25635
30315
30325

DESCRIPTION

Crankcase
Stud (M8 X 82)
O-Ring, Oil Filler Cap
Oil Filler Cap
O-Ring, Crankcase
Cover
Crankcase
Cover
Oil Gauge
O-Ring, Drain Plug
Drain Plug
Sems Comb Head
Screw (M6 x 20)
Crankshaft
Rearing
Oil Seal
O-Ring, Oil Seal Case
Oil Seal Case
Sems Comb. Head
Screw (M6x 16)
Connecting
Rod
Piston
Rod
Piston Pin
Seal Washer
Oil Seal
Barrier Slinger
O-Ring, Sleeve
O-Ring, Sleeve (Viton)
Back-UD Rirm, Sleeve
Sleeve (2974 ~’Unchromed)
Seal Washer
Seal Retainer
Inlet Manifold
Inlet Manifold-Stainless
Steel
Prrrrrm-A-Lube
Seal
Prrrrrm-A-Lube
Seal(Viton)

QTY.

ITEM

38
39
40

27004
30543
30544

43172
27983
27002
27006
18956
14158
101802
23172
11377
21985
24459
25634

2
1
1
1
1
1
1

42
43
44

45
46
47
48

6
1
2
2
2
2

49
50

57
58
59
60

30920

62
63

30910
30032

30047

54
56

1
3
3

NO.

43442
43360
43723
43434
81109
101804
25130
26246
30901

51
52
53

8
3
3
3
3
3
3
3
3
3
3
3
3
1

PART

DESCRIPTION

Inlet Valve
3
Bat-Cup
Piston
3
Bat-Cup
Ring
(Teflon)
3
Cup (Viton)
3
Piston Spacer
3
Piston Retainer
3
Conical
Washer-SS
(M6)
3
Nut-SS (M6)
3
Cotterpin
3
Cylinder
(43834 Unch)
3
O-Ring, Cylinder
O-Ring, Cylinder
(Viton)
:
BacJJp Ring, Cylinder
3
Discharge
Manifold
1
Discharge
ManifoldStainless
Steel
Valve Spring
Retainer
;
Valve Spring
3
Valve
3
Discharge
Valve Seat
3
Hex Nut (M8)
2
Hex Flange
Nut (M8)
2
1
Shaft Protector
Angle Rail
2
Hex Cap Screw
30612
(5/16 x23A)
2
Split Lockwasher
i%%%ng
2
(5/16 US)
1
Hex Nut (5/16
US)
2
Puiiey 5“ w/2
30246
Pulley
?
Set screws
Asbly
Key (M5) J
1

SERVICE KITS
30023
3
6
3
1
1

Cup Kit
cup
O-Ring, Cylinder
Cotterpin
Instruction
Sheet
Cup Inserter

30686
3
3
3
3
3
1

Valve Kit
Valve Spring Retainer
Valve Spring
Vaive
Valve Seat
O-Ring, Cyiinder
Instruction
Sheet

30305
3
3
2
1

Seal Kit
Prrrrrm-A-Lube
Seal
Cotterpin
Abrasive
Paper
Instruction
Sheet

30431

Sleeve

30860
6
3
3
3
3
3
3
3
3
3
3
1

Piston Kit
O-Ring, Cylinder
Back-Up
Ring, Cylinder
Bat-Cup
Piston
Bat-Cup
Ring
cup
Piston Spacer
Piston Retainer
Conical
Washer (M6)
Nut (M6)
Cotterpin
Inlet Valves
Instruction
Sheet

3
3
3

and Seal Kit
Prrrrrm-A-Lube
Seal
Barrier
Slinger
Cotterpin

3
6
1

Sleeve
O-Ring,
Sleeve
Instruction
Sheet
12

QTY.

SERVICING DISCHARGE VALVES
& VALVE SEATS
DISASSEMBLY

1. Loosen

the 2 (M8) locking

nuts

approximately

one

turn.

Then

remove

the 2 (M8) flange

nuts.

Grasp the discharge
manifold
with 3 fingers
on
the underside
and tap with a soft mallet to remove

Valve assemblies
will remain with
vert manifold
and discharge
valve
should fall out.

Inspect
discharge
valves for wear or ridges.
(Sperical
valves due to their shape must be replaced when worn.)

the manifold.
assemblies

in-

REASSEMBLY:

1. Place

retainer

in manifold

chamber

Place valve
side down.

over spring

the valve

Position
manifold
back onto pump. NOTE:
cise caution
when inserting
cylinders
into
to avoid damaging
cylinder
o-rings.

Replace
flange nuts on studs and hand tighten
both sides. Then torque each side to 125 inch
pounds.

Hand

insert

spring

tighten

into

locking

center
with

of retainer
spherical

(mooned)

seat.
Exermanifold

nut.

CAUTION:
When restarting
the pump, check to see
that there is no cylinder
motion
as this will
failure
of the cylinder
o-rings.
cause premature
Center cylinder
motion
canbe eliminated
by swit.
thing
with one of the endcylinders.

SERVICING THE PUMPING SECTION
DISASSEMBLY:
1.

Remove

Slip

discharge

cylinders

NOTE: Identify
their origional

——
13

out of inlet
cylinders
position.

Remove

Next remove
assembly.

piston

Remove

valve.

cotterpin,

inlet

manifold

as described

above.

manifold.
so they will be relapced
(Front to back)

nut, and washer.
retainer,

spacer,

and

piston

SERVICING THE SEALS
AND SLEEVES
DISASSEMBLY

REASSEMBLY:
1

Examine
inlet valve surface
and reverse
aged. (both sides are lap surf aces.)

if dam-

Remove discharge
blies as described

‘2

Examine
piston assembly
If damaged,
replace
and

surface.

Remove

With soft
crankcase.

Place inlet manifold
with crankcase
side

on pair of clearance
down. and drive out

Invert

with

Lubricate
circumfrance
of new Prrrrrm-A-Lube
seals, position
in manifold
with GARTER SPRING
DOWN and drive into place.

Examine
sleeves
before removing

If worn. grasp sleeve with pliers and pull off.
NOTE: This procedure
wit! mar the sleeve so use
only if sleeve is to be repiaced.

Remove

for clean
lubricate.

inlet

NOTE CUP INSTALLATION:
Wipe cup inserter
lightly with oil. Slip bat-cup
ring onto
piston.
Force cup over inserter
and square with all surfaces. Faulty cup insta//ation
causes premature
faiture.
3.
4.

replace

piston

spacer

and

SliP washer onto rod, screw on nut and torque to
60 inch pounds.
NOTE: ALWAYS
REPLACE
WITH

Examine
cylinder
walls for scoring
or etching.
These conditions
will cause premature
wear of
your piston assemblies.
replace
if worn or damaged.
Lubricate
up

rings

cylinder
and
(if defective).

replace

(M8) locking

mallet,

inlet

and

tap

nuts

inlet

manifold

piston

from

manifold

assem

studs
loose

CRANKCASE

from

blocks
seals.
SIDE

UP.

retainer.

NEW CO JTERPIN.
5.

both

manifold
.

o-rings

and

back-

Position
cylinders
in their origional
order into
manifold
chambers
and carefully
slip over rod
ends onto the pump.

Replace
flange
nuts on studs
both sides. Then torque each
pounds.

o-ring

for scoring

and

back-up

or other

rings

damage

from

piston

rod.

REASSEMBLY:

Hand

tighten

PISTON

locking

and hand tighten
side to 125 inch

1. Place

SPACER

BAC.CUP

BACCUP

RING

CUP WA

twist and push
Immerse
sleeve in oil carefully
onto rod. (machined
counter
bore end first}.

Replace

Exercise
caution
when replacing
the inlet seals are not damaged
rod ends.

Replace

‘uT~”
PUMPING

SECTION

PISTON ROD SLEEVE

CUTAWAY

on rod.

Lubricate
new o-rings and back-up
rings. Install
first o-ring in the o-ring groove on the piston
rod.
Position
back-up ring against
the shoulder
in front
of the first o-ring, then the second
o-ring.
Be
careful
to avoid damaging
the o-rings when slipping them over the piston
rod threaded
ends.

COTTERP

slinger

2.
nuts.

PISTON R

barrier

Reassemble

manifold

seal

retainers.

locking

nuts

~iston

inlet manifold,
by the threaded

on studs.

assemblies

and

discharae

as described.

Consult
factory
for your
crankcase
servicing.

local

distributor

for

DIAGNOSIS AND MAINTENANCE
PROBABLECAUSE

PROBLEM

Faulty Pulsation Oampener

Pulsation

Low Pressure

SOLUTION
Check precharge; if low recharge it or Install a

Excessive play in the end of the

new one

crankshaft

Worn nozzle

Replace nozzle, of proper size

Belt Slippage

Tighten or replacq

use correct belt

Air leak in inlet plumblng

Disassemble,

Pressure gauge inoperative or not
regtstermg accurately

Check with new gauge; replace worn or
damaged gauge, P.N. 06090

Relief valve stuck, partially plugged or
Improperly adjusted; valve seat worn

Clean, and adjust relief valv~ check for worn
and dirty valve seats. Kit Available.

I!Ilet suction strainer clogged or
improper mze

Clean. Use adquate size. Check more frequently.

Worn piston assembly Abrasives m
pumped flwd or severe cavitation.
Inadequate water supply,

Install proper fitter. Suction at inlet manifold
must be limited to lifting less than 20 feet of
water or -8.5 PSI vacuum.

Fouled or dirty Inlet or discharge
valves

Clean relet and discharge valve assemblies.

pulley

Replace worn valves, valve seats andlor
dmcharge hose.

Water in crankcase

lumps runs extremely
messure very low

rough,

inlet or arr entering the relet

Oil Ieeking from undereide of
crenkcase

Replace worn cup or cups, clean out foreign
material, replace worn valves

Worn Inlet manifold seals

Replace worn seals,

Worn inlet seals allow pump to draw
a Ir

Install new Inlet manitold seals,

Pressures In excess of rated PSI

c heck

Warped man(fold

Replace manifold

eakage at the cylinder O.rings
st the discharge manifold and
>Iack, powdery substanca in the
~raa of the O.rings

LOose Cyllnders Cyllnder motion
caused by Improper shlmmlng of the
d ,scharge mamfold

Remove spacer shims on manifold sluds, Do not
remove too many shims or the ears of the
manlfold WIII be bowed when the man!f old IS
r et!ghtened,
causing looseness in the center
cylinder
—

Nater leakage from under the
nlet manifold

w orn

Install seals If Piston rod sleeves are scored,
rePlace sleeves and sleeve O.rmgs

)il leak between crankcase
md pumping section

w orn cra~kcase

:ylinder O.rings blown next 10
Iischarge manifold

Change 011at 3 month or 500 hour ,nterval~
using Cat Pump Crankcase 011 (other approved
011every month or 200 hews) P.N. 06100,

Leakage of manifold !nlet seals andlor
piston rod sleeve O.rmg

Replace seals, sleeve and O.rings.

Worn crankcase proton rod seals
—

Oil leaking at the rear portfon of
the crankcase

Oamaged or improperly installed oil
gauge or crankcase rear cover O.ring,

Replace 011gauge or cover O-ring, and drain plu{
O.ring

and drain plug O.ring

Oil leakage from drain plug

Loose drain plug or worn dram plug
O.ring
—

Tighten drain plug or replace O.ring

Loud knocking noise in pump

Pulley loose on crankshaft

Check key and tighten set screw.

Broken or worn bearing

Replace bearings

Frequent or premature failure of
the inlet manifold seals

Scored rods or sleeves

Replace rods and sleeves.

over pressure to inlet manifold

Reduce inlet pressure per instructmns

Oamaged or worn chrome plating of
the cylinders

Replace cylinders

Abrasive material in the fluid being
pumped

Install proper fdtration cm pump Inlet

Excessive pressure andlor
temperature of fluid being pumped

Check pressures and fluid relet temperature;
s ure they are within specifi~d range

Over pressure of pumps

Reduce pressure

Proper size inlet plumbing; check for air tight
seal

Inlet restrictions andlor air leaks,
Oamaged cup or stuck inlet or
dwcharge valve

May be caused by humid air
condensing into water inside the
crankcase

Leaky discharge hose
Restricted
plumbing

PROBABLECAUSE
SOLUTION
—
Wornmain ball bearingfromexcesswe Replace ball bearing, Properly temaon belt
tenston on drive belt

reseal, and reassemble

-Worn Inlet or discharge valves

PROSLEM

Short cup life

for plugged nozzle, closed valves or
Impropedy adjusted bypass valve

Running Pump dry

Do not run pump w!thout water

F rent edge of piston sharp

Replace with new piston

Install new cups and cylinders
c hrome plating of cylinders damaged
causing excesswe wear of cups. May be compatible with chrome
caused by pumping ac]d soluflon

pl”rnbl”~
be

Pump only fluid

——

)il leaking in the area of
: rankshaft

Inlet mancfold seals
51eeve O.ring

Leak, ng

piston rod seals

Replace crankcase

pwton rod seals

Excess 011from wicks

Reduce quant!ty of 011per otlsng

w orn

crankshaft seal or Improperly
n stalled o(I seal retatner packing

Remove 011seal retatner and replace damaged
gaaket andlor seals

Bad

Replace bearing

bearing

strong surging

al the infet and
Iow pressure on the discharge
side

—
F ore!gn particles In the relet or
d ischarge valve or wom relet arldlor
d IsCharge valves

c heck

for smooth lap surfaces on inlet and
d ischarge valve seats Dmcharge valve seats
a nd relet valve seats may be lapped cm a very
flne 011stone; damaged cups and discharge
valves cannot be lapped but must be replaced.

2. Fkfucticm of Flow.

MIX TANK OVERFLOWS
1. Float ball in mix tank hanging up (not moving freely).
2. Extension bracket pinching the float lever, restricting full action of
the lever.
3. Plunger not seating properly on the valve. (Remove the 2 screws
which hold the extension assembly to the valve. Do not lose or
drop the screws. Remove the extension assembly. Turn it upside
down. Inspect the plunger for proper seating. If there is no debris
obstructing the valve or plunger, the plunger may be out of adjustment. To adjust, loosen the set screw on tf?e ball nut and move
the ball toward the end of the rod 1 H 6“, Retighten set screw.
Place extension assembly back into position. Tighten the two
screws.

A. Due to increased length of solution hose.
Nt3TE: for every 50 feet of hose, beyond 100
feet in total length, a measurable loss of flow
is experienced. This condition is a result of the
increased friti~on 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.
—-—‘ WATER FLOW

2
Chemmal
lnpctor

Sale\ old
Control
Valve

....
2’

~
%

li&a;

“ .
~:

‘8L
,29

‘
bq
:::
..%>

~ >
‘“

F=” ;

~
I

‘Q%
;-

‘,3

J$&

~Ap

Flow Meter
6. Chem!cal
Jug
? - Chemical
S - High Pressure Pump
4 High Pressure
.

.. . ... .... ...

‘
9 - Bypass Valve
10- Heater COII
11 - Pressure Guage
12Incoming Water
*3 - Tank Drann
14- To Wand
4

Low

PUMP PULSATES
WHEN THE TANK KIN A FILL MODE
1. Check that the hose which goes from the gray plastic venturi to
the bottom of the tank is not directed toward the Cat pump pickup
port. If it is, aim it in another direction.

Pressure
I

CHEMICAL TANK””
TROUBLESHOOTING

MIX TANK DOESN’T KEEP UP WITH WATER OUTPUT
1, Check garden hose quick connect assembly screen.
2. Check garden hose and/or feed hose to the mix tank for clog,
kinks or blockage.
3. Float ball in mix tank hanging up. (Not moving freely),
4. Extension bracket pinching float lever, restricting $uII action of
lever.
5. Valve plunger not opening fully. To adjust, remove the 2 screws
which hold the extension assembly to the valve. (Do not lose or
drop the screws). Remove the extension assembly, turn it upside
down. To adjust, loosen the setscrew on the ball nut. Pface your
thumb on the plunger and press it in 1,’16” and slide the ball nut w)
set screw toward the plunger end 11 6“. Tighten the set screw.
Place the extension assembly back into position. If the tank starts
to overfill, the ball nut is too close to the valve plunger and should
be moved back away from the valve plunger slightly,

“--

NO OR LOW CHEMICAL
FLOW
1. Check that hoses in the tank are secured. Check that the hose
from the top of the flow meter to the side of the mix tank is secured
with no kinks. Check the hose from the bottom of the flow meter to
the them. Jug for kinks or cracks.
2. Check the foot valve and screen on the end of the hose which
goes into the mix tank. To check this screen for proper function,
remove! it from the plastic hose. You should be able to suck
through the hose barb end, but you should not be able to blow
through the hose barb end. (If you cart not suck through It then
rinse it out with vinegar). When screen is removed the chem!cal
fuel hose should be lifted into a vertical position so the ball in the
foot valve will seat by gravity. (This is only a tempora~ fix for low
water pressure areas.)
3. Check flow meter for float obstruction.
4. Check to insure that the adjusting screw on proportioning venturi
is backed out.
5. is proportioning venturi closed? Soak in warm water or vinegar
solution.
6 IS incoming water pressure less than 20 PSI.?
7 Cracked or defective chemical flow meter?
NOTE: If you are in a low water pressure area and find that the volume of water entering the mix tank is not enough to allow your venturi
to siphon chemical, unscrew the spring from the foot valve screen
and remove the spring.
INABILITY TO ADJUST’ CHEMICAL
WITH THE FLOW
1. Debris lodged behind teflon seat in flow meter knob.
2. Teflon seat dismounting from flow meter knob.

METER

SOLUTION REVERSING FROM MIX TANK TO CHEMICAL JUG
1. Anti-siphon screen removed from chemical jug hose.
2. Debris in anti-siphon screen.

HEATING SYSTEM
INFORMATION
The propane heater incoporatad in thm equipment is of special design for use in the carpet cleaning industry. It’s high pressure coIls
and thermostatic temperature control make It slmpte to operate and
reliable. Once the desired temperature IS set, the heater WIII then go
‘on’ and ‘off according to the water temperature within the heater. As
water is used through the cleamng tool, cold water entering the heater will activate the thermostatically controlled propane valve thereby
firing the heater to mamtain a consistent flow of hot water. Once the
cleaning wand is shut off and the fiow of water through the heater
stops, the heater will continue to burn until the set temperature is attained.
It is possible then with this design that the flame maybe on when the
wand is off, Iikewlse, t is possible the flame may be off when the
wand is on.

~~-N

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 burning
and a soot build-upon 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.
Overfilling of the propane tank will cause many problems. To avoid
this, advise the attendant filling the tank notto fill the tank aver
80”/o. When filling the tank, watch the 10%, valve and immediately
16

stop filling when white liquid starts spurting from the 10°% valve. To
prevent damage to the propane regulator, always close the valve on
the tank before filling.

C. TO ACHIEVE PROPER CARPET CLEANING
TEMPERATURE:
1. Complete procedures A & B
2. Wtth 100’ of hose, turn cleaning wand on for 5 minutes and
the temperature should stabilize.
3. Once a constant temperature is established, turn cleaning
wand ‘off. The flame on the heater burner 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, turn the
thermostat dial to a lower reading, then repeat C 1-3.

When venting the heater through the roof of the van, it is necessary
to install a draft diverter on top of the heater. This will prevent down
drafts from blowing out the pilot light.
The propane regulator is pre-set at the factory at 6 oz. of propane.
This reading is taken at the control valve on the heater (see figure A
#6). To prevent road dust and moisture from entering the propane
regulator, keep the white Tupperware cover (supplied) on the regulator at all times.
I
To avoid restriction of air flow at base of heater, keep articles such as
chemical containers, hose, boxes, etc. from within 18 inches of base
of heater. NOTE: This restricted situation also creates an over rich
condition which results in soot build-up.
IMPORTANT:
If a new propane tank has been installed or hoses
have been disconnected, air may enter propane hoses and must be
purged prior to attempting to light the pilot burner. Should this condition exist, operator must 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.

D. TO SHUT DOWN HEATER:
1. Turn upper dial to ‘off position.

-2.

Turncleaningwandonfor3to
5minutesto
cool heater core. If heater core is not cooled, it is impossible
that the heat retained in the core will cause boiling back into
the chemical mix tank.
3. Close propane tank valve while
wand is on and heater is cooling.

PILOT BURNER
ADJUSTMENT

ALLEN HEAD PIPE PLUG G
o
CAN BE REMOVED
FORMONOMETERINSERTION
TO READ PROPANEOUNCES.

Heater must be fWecf with water
.

A.
1.
2.
3.
4.

---

prkwtokmjthg.
-.. --

lU=l
Atf I PILUI:
Adjust thermostat control knob on unitrol to desired setting.
Adjust upper dial to pilot position.
Depress pilot button.
Depress sparking button to light pilot.

HEATER
TROUBLESHOOTING
●

IF PILOT FAILS TO LIGHT:
Is propane tank full?
Is propane tank valve open?
Has air been properly bled from propane
WHEN PILOT LIGHTS:
Wait ten seconds, depressing
release button.

FIG

1. Remove pilot adjustment cap@
2. Adjust pilot key to provide
-properly sized flame
3. Replace pilot adjustment cap

HEATER - OPERATING
INSTRUCTIONS
KZ@@l!l

@ Fig. A.

●
line?

button manually,

EXCESSIVE HEAT
FLAMES PROTRUDING OUTSIDE
THE LOWER OPENINGS

CAUSE AND/OR SOLUTION:
1. Thermostatic control dial set too high
then

B. TO LIGHT MAIN BURNER:
1. Turn upper knob to “on” position. Flame will come on,
If you do not get the burner to flame, the pilot has expired. You
must turn upper dial to “off’ position. Do not attempt to re-light
the pilot for 60 seconds. To light the maih burner, repeat

instructions as above (TO START PILOT), 1 through 4.

A. Turn dial to lower setting
2. Maladjustment of propane regulator. NOTE: Propane regulators
are factory preset and may be readjusted by authorized
personnel.
A. Contact manufacturer to determine correct procedure.
B. Have your local propane dealer use a monometer at the
unitrol to re-set the propane regulator to 7 oz. maximum.
3. Overfilled propane tank. NOTE: Propane heater is designed to
operate on vapor propane only. Over-filling a propane tank
allows liquid propane to enter ail heater related components
and permits an over-rich burning condition to occur. This
condition usually requires the heater core to be cleaned of soot
and carbon deposits. Cleaning is a messy, dirty job and very
inconvenient,
so don’t let it happen to you!

OR,

PROBLEM:
Water may already

beat controlled

temperature.

PILOT LIGHT
CAUSE AND/OR SOLUTION:
1. Pilot light will not ignite. NOTE: Do not use

●
Flame will turn off when thermostat
temperature.

senses maximum

a needle or pinto clean
pilot orifice - use compressed air or solvent only.
A. Verify propane reaching igniter. NOTE: A kinked or crushed
hose may impede propane flow.
B. Remove and clean orifice.
C. Verify igniter spark is operating correctly.

VACUUM TANK FILTER BAGS

VACUUM SYSTEM
INFORMATION
The vacuum blower incorporated in this machine is a positive displacement lobe type, manufactured by Fuller Company. The performance and life of this unit is greatly dependent on the care and proper m ainten ante it receives,

Hydra-Master filter bags are designed to trap all of the~nt, ~a~d~nd
dirt that would normally collect at the bottom of vour vacuum tank.
The use of these bags, jf emptied at the end of eac’h job, will eliminate
the build-up of much of the debris in the tank and avoid a mess on the
customer’s driveway or street. The drawstring top of these bags is
designed to be tied to the incommg dirt~ water inlet in the vacuum
tank.
649-028
To re-order bags use part number

Because of the close tolerances between the lobes and housing of
the vacuum blower, solid objects entering the inlet will damage the
internal lobes, gears and bearing or direct drive coupler.

INCOMING DIRTY
<’WATER
TO VACUUM

TANK

To prevent this, a stainless steel filter screen has been placed at the
vacuum inlet inside the vacuum recovery tank. This stainless steel
screen is finger tight and should be removed for cleaning weekly.

~
Should be used when machine is beirm run for
test purpose and the vacuum inlet on top of machine is op&

To protect the vacuum blower from overloading and damaging itself.
there is a vacuum relief system installed on the vac tank lid. When
the vacuum tank inlet is completely sealed off, a maximum of 14 HG
will be attained. A hole on the top blower pipe elbow acts as the lubrication point; at the end of each day, LPS 1 or WD-40 is sprayed in before shutting down the machine. See blower lubrication illustration. If
you fail to lubricate the vacuum blower daily, rust deposits and moisture will decrease the life of the vacuum blower.

BAG

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.

BLOWER LUBRICANT
VACUUM FLOW DIAGRAM
HOSE
VACUUM

RECOVERY

TO VAC TANK

TANK

ELBOW ON TOP OF
VAC””MBLOVVE13

~
BAG

S/S FILTER
A

VACUUM
BLOWER

w
w

SPRAY LUBRICANT
INTO VACULfM RELIEF HOLE FOR 3
TO 5 SECONDS, THEN IMMEDIATELY
SHUT OFF
MACHINE.
USE ONLY LPS 1 OR WD-40 MOISTURE DISPLACING
LUBRICANTS.
18

WARRANTY
FULLER
installed,

warrants products of its manufacture
to be fre~ from defects in material and workmanship
maintained,
and operated under normal conditions with competent supervision.

No person, agent, representative or dealer isauthorized
togiveany
FULLER
any other liability in connection with any of FULLER’S

warranties
products.

on behalf of FULLER

if properly

nortoassulme

for

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
warranty shall cease to be in effect. No allowance will be
without
FULLER’S
prior written consent, FULLER’S
granted for any repairs or alterations made by the Purchaser without FULLER’S
prior written consent.
Machinery, equipment and accessories furnished by FULLER,
extent of the original manufacturer’s warranty to FULLER.

but manufactured

by others, are warranted

only to the

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 parts of products of FULLE R’S manufacture, which within the specified warranty period shall be proved to
FULLER’S
satisfaction to have been defective when shipped, 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 Iim;ted 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 GUARANTEES
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

FULLER

MODE L
SERIAL

COMPANY

2966 East Victoria Street
California 90224
Compton,

FACTORY AUTHORIZED SERVICE CENTERS
FOR SUTORBILT PRODUCTS
FULLER

FULLER
COMPANY
/ COMPTON
DIVISION
2966 E. VICTORIA ST., COMPTON, CAL. 90224
213/636-9821

COMPANY
/ MANHEl M DIVISION
236 SOUTH CHERRY STREET

MANHEl

or 636-7600

M, PENNSYLVANIA

17545

7771665-2224

BAYLISS

MACHINE&

WELDING

CO.

CAROTEK

2901 8TH AVENUE
NORTH
BIRMINGHAM,
ALABAMA
35203
205/323-6121

BARNEY’S

PUMPS

INC.

3907 HIGHWAY
98 SOUTH
LAKELAND,
FLORIDA
33802
81 3/686-8195

ASSOCIATED

TECHNICAL

SERVICES,

INC.

OLIVER

1229 WAIMANU
STREET #21
HONOLULU,
HAWAII 96814
808/637-1 206

WM. W. MEYER

& SONS

FOUNDRY

& CO.

& LAUGHTER

PUMPS

COMPANY

FULLER
GATX

E. 40TH STREET
OKLAHOMA
74145
918/627-0110

EQUIPMENT

CRAFTS

LTD.

3936 EDMONTON
TRAIL N.E.
CALGARY,
ALBERTA
T2E 3P6
4031276-8676

0
lY-

2001 WEST FORT STREET
OETROIT,
MICHIGAN
48216
3131486-1880

CORPORATION

7925
TULSA,

ELECTRIC

805 SOUTH FRONT STREET
NEW ORLEANS,
LOUSIANA
70130
504/524-5207

SCHWARZ

DYNMAC

10450 WESTOFFICE
HOUSTON, TEXAS 77042
7131977-2577

8261 ELMWOOD AVENUE
SKOKIE, ILLINOIS
60076
31 2/673-0312

GREGORY-SALISBURY

INCORPORATED

640 SAM NEWELL ROAD
MATHEWS,
N. CAROLINA
28105
704/847-4406

& POWER

GATX-FULLER

MPANV

LTD.

721 PROGRESS AVENUE
SCARBOROUGH,
ONTARIO,
CANAOA
4161438-6540

COMPANY

.2966
EAST
VICTORIA
STREET
POST
OFFICE,
E30X 4308,
COMPTON,
TEL: [2131 639-7600
[2131 636-9821

LTD.

1380 NAPIER STREET
VANCOUVER,
B.C., CANADA
6041255-4341

CALIFORNIA
90224
TELEX:
67-4607

CO.

At ttse gear end the timing gear teeth are lubricated by being partially
submerged. The gear teeth serve as oil slingers for gear end bearings. At the drive end the bearings are grease lubricated.

FILLING PROCEDURE
Remove
square head vented oil fill plug (A) on gear end. Remove oil
level plug (B) located in the head plate. Fill gear case until oil drips

out of the oil level hole (B).
Use lubricants as listed.
Add fresh oil as required to maintain proper level. The oil should be
drained, flushed and replaced every 1500 hours or more frequently if
inspection

so indicates.

Clogged stainless steel filter.
A. Remove and clean or replace stainless stea?lfilter.
3. Defective vacuum tank seal.
A. Remove and replace vacuum tank seal.
4. Defective or ‘open’ vacuum tank dump valve.
A. Close valve.
B. Replace valve.
5. Fractured weld on vacuum tank.
A. Re-weld as required or replace tank.
6. Collapsed or kinked vacuum hose.
A. Reshape hose if possible and/or eliminate kinks.
7. Plugged vacuum hose.
A. Remove obstrutilon by reversing the vacuum hose.
8. Restriction in cleaning tool.
A. Remove obstruction.
9. Worn end plates or lobes in vacuum blower.
A. Replace worn components. NOTE: Must be accomplished by
a qualified technician.
10. Loose coupling system between engine and blower.
A. The set screws may come loose causing blower to stand still
while engine may be turning properly. NOTE: Unless the
blower is seized or making a knocking noise, your vacuum loss
is not caused by a bad blower.
2.

LUBRICATION

The oil drain plug is at (C).

NOTE: Older units may have the oil 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 regressing, 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.

iPFKIHUEM:
@ iBLIOWE!3[S SEIZED
CAUSE AND/OR SOLUTION:
1. Rust.

LUBRICATION lNSTRlf CTIONS FOR
OIL LUftRICATEO GEARS ANtr BEARINGS
Add fresh oil as required to mamtain proper
level.
Drain and refill every 1500 hours of
operation under normal kervice, more frequently when required. Use a good quality oil.
OIL VISCOSITY,
OIL
BLOWER
GRAOE
CEN;~;~KES
OISCHARGE
, TEMPERATURE
U.S. A.*
-40°to
320 F
45
(-40°to
r
32°to 1000 F
100
SAE 20
OOto 38° C)
(
100 “to 275o k
200

c) ‘AE‘ow

38°to 135°c)
over 275° F
( 135” C)

SAE 40

‘*E

250

●ln

applications with extreme variations in
ambient temperature a 20W
50W multlple
viscosity oil is recommended.
FOR GREASE LUBRICATE
BEARINGS
Service every 500 hours of operatton

VACUUM BLOWER
TROUBLESHOOTING
PROBLEM:
e ~o$s OF VACUUM
CAUSE ANIXIR

SOLUTION:

1. Collapsed vacuum hose between blower and vacuum tank.
A. Remove and replace hose. NOTE: A special reinforced hose
is required for replacement.

A. Spray rust dissolving lubricant onto lobes to emulsify rust and
attempt to rotate vacuum lobes.
2. Foreign matter.
A. Disassemble and remove foreign matter and repair as
required. NOTE: Disassembly must be accomplished by
qualified technician.
3. Seized.
A. If you suspect that your blower has seized, remove coupling
element, then run engine for a few seconds. This way you
won’t confuse similiar problems.
NOTE: The above mentioned, rust, foreign matter and seizing are
often caused from foam traveling through the blower.

PROBLEM:
e NOISE IN VACUUM

BLOWER

CAUSE AND/OR SOLUTION:
1. Loose Direct Drive Coupler.
A. Examine coupler for defects and retighten lock bolts.
B. Replace coupler boot if it is either torn or punctured.
2. Worn Gears.
A. Remove and replace gears. NOTE: Replacement
of gears
must be accomplished by a qualified technician.
B. Timing of vacuum blower has been changed due to worn
components. Replacement
of components must be accomplished by a qualified technician.
3. Lack of Lubrication. NOTE: Permanent damage may have
resulted from lack of lubrication.
A. Lubricate as specified by applicable vacuum blower manual.
See index.
4. Worn bearings
A. Remove and replace bearings as required. Must be
accomplished
by qualified technician.
5. Debris and/or foreign material build-up. NOTE: A stainless steel
filter is provided in vacuum inlet located in vacuum tank to proteact
vacuum blower components.
A. Disassemble vacuum blower and remove foreign material.
NOTE: Disassembly should be accomplished by qualified
technician only. Replacement
of worn parts is recommended
if this procedure is necessary.
6. Loose or missing mounting bolts.
A. Tighten or reinstall mounting bolts.

~.r.u-

Briggs & Stratton
OPERATING AND MAINTENANCE

,.,..

)

INSTRUCTIONS
MODELS

401400
421400

,,.

to 401499
to 421499

IN THE INTEREST

OF SAFETY

DO NOT RUN ENGINE AT EXCESSIVE SPEEDS. Operating an engine at excessive speeds increases the hazard of personal injury.
DO NOT TAMPER WITH PARTS WHICH MAY INCREASE THE GOVERNED SPEED.
for Power Lawn Mowers specify a maximum blade tip speed of
For rotary Iawnmower safety, A. N.S. I. Standard Safety Specifications
19,000

feet per minute

Rotary
design

Iawnmower
manufacturers
of other mower parts.

(96.5

meters

per second),

primarily

select the governed

to reduce

top speed

the hazard

of the engine

from thrown

All rotary Iawnmowers
should be checked for conformance
to the A. N.S. I. Standard Safety
blade tip speed, if the engine is repaired or replaced, or if mower parts are changed.

DANGER:

GASOLINE

VAPOR

IS HIGHLY

FLAMMABLE.

DO NOT STORE, SPILL OR USE GASOLINE
NEAR
pilot light, or devices that can create a spark.
If gasoline is accidentally
have dissipated,
DO NOT

REFUEL

spilled,

GASOLINE

DO NOT RUN THE ENGINE
TO PREVENT
ACCIDENTAL
driven

move machine

TANK

WHILE

outdoors

FLAME

preferably,

or devices

and design

Specifications

of the cutter blade and

for Power

or only in well ventilated

such as a stove, furnace,

away from area of spill and avoid creating

ENGINE

IN AN ENCLOSED
STARTING
always

Refuel

AN OPEN

objects.

based on the length

any source

Lawn Mowers

areas.

water heater which

of ignition

until gasoline

utilize a
vapors

IS RUNNING.

AREA.
remove

Exilaust gases contain carbon monoxide,
an odorless and deadly poison.
the spark plugs from the engine, before working on the engine or equipment

by the engine.

Except for adjustment;
DO NOT operate
could create a fire hazard.

engine

if air cleaner

orcoverdirectly

DO NOT OPERATE
WITHOUT
A MUFFLER
OR TAMpER
WITH THE
create a fire hazard. Inspect periodically
and replace if necessary.

over carburetor

EXHAUST

SYSTEM.

air intake is removed.
Damaged

Removal

of such part

mufflers or spark arresters could

DO NOT STRIKE FLYWHEEL
with a hard objector
metal tool as this may cause flywheel to shatter in operation, causing personal Injury
or property damage.
Use Briggs & Stratton approved tools only, and if in doubt, contact your Authorized
Briggs & Stratton Service

Center.
ALWAYS KEEP HANDS AND FEET CLEAR OF ROTATING

PARTS.

IN THE INTEREST

OF ENVIRONMENT

A muffler which leaks because of rust or damage can permit an increased exhaust noise level. Therefore, examine
to be sure it is functioning
effectively.
To purchase a new muffler, see SERVICE
AND REPAIR INFORMATION.

the muffler

periodically

WARNING:
If this engine is not equipped with a spark arrester and is to be used on any forest covered, brush covered, or grass covered
unimproved
land, before using on such land a spark arrester must be added to the muffler. The arrester must be maintained
in effective
working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal laws apply on federal lands. See your Authorized
Briggs & Stratton Serwce Center
for spark arrester muffler options.

SERVICE

& REPAIR INFORMATION

If service or repair is needed, contact an Authorized
Efriggs &
Stratton Service Center. To serve you promptly and efficiently, the
Service Center will need the model, type and code number on
your engine.

This illustrated book includes common
specifications,
and detailed
information covering the adjustment,
tune-up
and
repair
procedures
for
Twtn
Cylinder
models.
It is available
from
any
Authorized
Bnggs
& Stratton
Service Center, Order as Part Number
271172.

Each Authorized
Service
Center
carries
a stock of original
Briggs & Stratton repair parts and is equipped with special service
tools. Trained
mechanics
assure expert repair service on all
Briggs & Stratton engines.
Major engine repairs should not be attempted
the proper tools and a thorough
knowledge
bustion engine repair procedure.

unless you have
of internal com-

Your nearest service center is listed in the “Yellow
Pages” under “Engines,
Gasoline”
or “Gasoline
Engines.”
He is one of over 25,000 authorized
dealers available to serve you.
n
@owmEfss

G!G:
.WL

.-,4

):+>.

BRIGGS & STRATTON

BRIGGS
e

v’

Milwaukee,

& STRATTON
Wisconsin

CORP.
53201

BEFORE
CARBURETOR
MANIFOLD

All? CLEANER

READ
THE

THE OPERATING
lNSTRLJCTIONSOF
EQUIPMENT
THIS ENGINE
POWERS

Use a high quallty
SD,

SE or MS

retard

the

should

STARTING

detergent

“ Detergent

formation

be added

011classified

oils keep

of qum

and

varnish

to the-recommended

RECOMMENDED

“For

theengtne

Service

SC<

cleaner

and

deoosits.

Nothlna

011

SAE ‘vISCOSiTY

GRADES

I
1

980s
I
8

‘>
F

“c 30
20
TEMPERATURE

20
–lo
RANGE

’10

FILL
Place

CRANKCASE
engine

remowng

EXTENDED
OIL FILL
‘“”~
“?

e~:

—-------

MOOEL, TYPE AND
COOE NUMBER ON
IDE COVER

oil may be used hawn~

WITH
level.

103

10
b
2a
30
4’0
ANTICIPATED BEFORE NEXT OIL CHANGE

“If not avatlable, a synthetic
or 5W40
wsco.wty.
8LOWER
HOUSING

1~~
I

Clean

5W-20,

5W-30

OIL
area

around

oil

fill

before

d[pstick.

EXTENDED
OIL FILL. Remove cap and dipstick. FILL TO
FULL MARK on dipstick, POUR SLOWLY.
Capac!ty 3 pints
(142
liters).
When
checking
ml level, push dipstick
assembly firmly but slowly until cap bottom on tube. DO
NOT
OVERFILL.
Dipstick
assembly
must be securely
assembled
into tube at all times when engine is operating.

EXTENOE
OIL FILL
5

L__-4”1

/w@’

EL~CTRIC
STARTER MOTOR

OIL D“RAIN
PLuG

CHARGE

BATTERY

Charge
battery
before
use on engines
(OPTIONAL)
12 volt electric starter motor.
manufacturers’
recommendations,
FILL

FUEL

equtpped
with
See equipment

TANK

grade
Use clean, fresh, “regular
gasoline. DO NOT MIX OIL WITH

leaded or low-lead”
GASOLINE.

NOTE: The use of “lead-free”
gasoline produces
combustion
deposits,
but may shorten
valve
carburetor
adjustment
is too lean.

fewer
life if

Electric Starter, Turn key to “Start” position
starter button on powered equipment.
When
open choke gradually.

STARTING

and/or
engine

press
starts

l.=
Of F

OPEN

FUEL

VALVE

CHOKE
“CHOKE’

ENGINE:
position.

CHOKE

on engines
Move

so equipped.

equipment

control

lever

STARTER
SWITCH

to
DEPRESS
BUTTON
1

PULL OUT TO CHOKE

When equipment
is not in operation,
from direct exposure to weather,

COLD
NOTE: This should fully close choke on carburetor.
does
not, remote
control
must
be re-adjusted.
ADJUSTMENT
section.
NOTE:
engine.

A warm

engine

requires

less choking

If it
See

than a cold

GCVERNOR
SPEED
CONTROL
LEVER: Move
speed
control
lever
to “RUN,”
“FAST”
or
p’osition if so equipped.

WEATHER

STARTING

1. Be sure
expected.

2. Declutch

all possible

3. Set throttle

use

the

protection

HINTS

proper
external

at part-throttle

oil

for

the

temperature

loads.

position.

4. A slightly
richer fuel mixture,
obtained
by turning
carburetor
needle valve 1/8 turn counterclockwise,
will
usually improve cold starting.

governor
“START’

5. A warm battery
cold battery.
6. Use fresh winter

has much
grade

NOTE:
Winter
grade
improve
starting,
Do
summer.
TO STOP
Turn
TO START

provide

more starting

capacity

than a

fuel.

gasoline
not use

has higher
volatility
to
gasoline
left over from

ENGINE

key to “OFF”

~osition.

ENGINE

DANGER:
ALWAYS
KEEP HANDS AND
MOWER
BLADE OR OTHER
ROTATING

FEET CLEAR
MACHINERY.

Rope Starter. Wind the starter rope around the pulley in
direction shown by arrow. Pull the rope with a quick full arm
stroke to overcome
compression
and prevent kickback.,
Repeat
if necessary
with choke opened
slightly.
When
engine starts open choke gradually.

CAUTION:
equipment

Always remove key from switch when leaving
unattended
or when equipment
is not in use.

MAINTENANCE
CHECK
OIL LEVEL regularly
— after each five hours
operation.
BE SIJ RE OIL LEVEL IS MAINTAINED.

CHANGE
OIL after first five hours of operation. Thereafter
change oil every 25 hours of operation.
Remove oil drain
plug and drain oil while engine is warm. Replace drain plug.
Remove dipstick and refill with new oil of proper grade.
Replace dipstick.

CAUTION:
When using rope starter to crank engine, use
caution so knotted end of rope does not strike persons
standing nearby.

‘-s:-:”---”

GENERAL INFORMATION
These

engines

are two-cylinder

MODEL
Bore . . . . . . . . . . .
Stroke . . . . . . . . .
Displacement
..
Horsepower
....
Torque (Ft. -Lbs.)

.
.
.
.

SERIES
.
.
.
.
.

.
.
.
.
.

MODEL
Bore . . . . . . . . . .
Stroke . . . . . . . .
Displacement
.
Horsepower
...
Torque (Ft,-Lbs,)

.
.
.
.

.
.
.
.
.

SERIES
.
.
.
.
.

.
.
.
.
.

L-head,

401400
.
.
.
.
.

.
.
.
.
.

type.

...
3-7/16”
(87.31 mm)
. . . . . . ..2-5/32’’
(54.77 mm)
. . ...40.00
cu. in. (656.0 cc)
..l6
l-fPMax.
Q3600
RPM
25.8 Max, Q 2700 RPM

421400
.
.
.
.
.

air-cooled

to 401499

.
.
.
.
.

Champion
J-8
RJ-8

Spark Plug Gap...........,,,,,,.
Ignition Point Gap...........,,,,
Intake Valve Clearance*”
Exhaust Valve Clearance”-.
“’w}th

valve spring

Smlmn

,_-..-----1
G,*

Autoiite
295
306

a, ‘All fuel should be removed from the tank. Run the engine
until It stops from lack of fuel. The small amount of fuel
that remains In the sump of the tank should be removed
by absorbing
it with a clean, dry cloth,

. . . . . ..030’’
(.76 mm)
, . . . . . .. 020’’(.51
mm)
004’’ -.006”(
10 - 1.5mm)
007”- 009”(
18- 23mm)

WARNING
For electrical safety always remove cable from
negative
(-) side of the battery before attempting
any
repairs or maintenance
ARE MADE UNDER
327’6439

b. While engine IS still warm, drain 011 from crankcase,
Refill with fresh oil.
(29 6cc)of engine
c. Remove spark plugs, pour oneounce
011 Into each cylinder and crank slowly to dlstnbute 011
Replace spark plugs.
d

2999491

3 194224
32369.37

3305
3457

,!23
80J

357.? 218
3572307

3242741

3465

:40

3625492

3 118,433

3,252449

J 650354
3745393
3738345

Clean dirt and chaff from cyllnders, cyllncier
blower housing, rotating screen and muffler

e. Store

ONE OR MORE OF THE FOLLOWING
3625071
3526146

2.99’2562
3114851

lNSTRIJCTiONS

to be stored over 30 days should be completely
of fuel to prevent
gum deposits
forming
on
carburetor
parts, fuel filter and tank.

NOTE: The use of a fuel additive, such as STA-BIL,
or an
equivalent, WIII mini mlzetheformation
of fuel gum depos!ts
during storage.
Such an additive
may be added to the
gasollne in the fuel tank of the engine, ortothegasoline$n
a
storage container.

installed.

BRIGGS & STRATTON
ENGINES
3 149618
28960

=-----J

STORAGE
Engines
drained
essential

SPECIFICATIONS

Spark Plug Type
Long Plug
Resistor Long Plug

Tri-Circuit

requires the use of a resistor spark
Ignition signals. If an engine was
resistor spark plugs, besureto
use
plugs for replacement.

TUNE-UP

. . . . . . 3-7/16”
(87.31 mm)
. . . . ..2-9/32’’
(57.94 mm)
...42.33
cu. in, (694.0 cc)
. . . . 18 HP Q3600
RPM
. . . . . ..28,6
Q2600
RPM

The horsepower
ratings listed above are established
in
accordance
with the Society of Automotive
Engineers Test
Code -J607,
For practical
operation,
the horsepower
loading should not exceed 85 °/oof this rating. Engine power
3i,40/0 for each
1,000
feet
(304,8
m) above
will decrease
sea level and 1°/0 for each 10” above 60” F (16° C).
In some areas, local law
plug so as to suppress
originally equipped with
the same type of spark

L*7

LW.

to 421499

PATENTS
3831 268
3882336
J 901 199
3961

724

In a clean
3968854
.1971

353

.) 991 152
4 168288

and dry area

head fins.
areas

CAUTION:
Petroleum
solvents, such as kerosene, are not
to be used to clean cartridge, They maycausedeterioration
of the cartridge,
DO NOT OIL CARTRIDGE,
DO NOT USE
PRESSURIZED
AIR TO CLEAN OR DRY CARTRIDGE.

CLEAN
COOLING
SYSTEM
— Grass, chaff or dirt may
clog the rotating
screen
and the air cooling
system,
especially
after prolonged
service
In cutting
tall dry
grasses, Yearly or every 100 hours, whichever occurs first,
remove the blower housing and clean the areas shown to
avoid overspeeding,
overheating
and engine
damage.
Clean more often if necessary.

TO SERVICE

DUAL

ELEMENT

AIR CLEANER

Clean and re-oil foam pre-cleaner
at three month
or every 25 hours, whichever
occurs first.
NOTE:
tions.

Service

1. Remove

air cleaner

often

under

dusty condi-

knob and cover,

2. Remove foam
cartridge.

pre-cleaner

by sliding

3. a. Wash foam pre-cleaner
gent and water.

in kerosene

b. Wrap

intervals

foam

pre-cleaner

in cloth

c. Saturate foam pre-cleaner
remove excess 011.
4. Install
foam
pre-cleaner
assemble cover and screw

it off the paper
or liquid

and squeeze

in engine
over paper
down tight.

deterdry.

oil. Squeeze
cartridge.

to
Re-

-“’”
~
@zz2Ez::HER

DANGER:
Periodically
clean muffler
grass, dirt and combustible
debris.

area

to remove

SPARK PLUGS — C“lean and reset gap at .030” every
hours of operation.

all
100

~u~

CARTRIDGE

FOAM
PRE-CLEANER

CAUTION:
Do not blast clean spark plugs. Spark
should
be cleaned
by scraping
or wire brushing
washing with a commercial
solvent.
Sparking
can occur
spark plugs. Reform

REMOVE
COMBUSTION
DEPOSITS
every 100-300 hours
of operation.
Remove cylinder
heads and cylinder
head
shields. Scrape and wire brush the combustion
deposits
from cylinder,
cylinder heads, top of pistons and around
valves. Use a soft brush to remove deposits. Re-assemble
gaskets, cylinder
heads and cylinder
head shields. Turn
screws down finger tight, with the three longer screws
around the exhaust valve, if so equipped. Torque cylinder
head screws in a staggered
sequence to 165 inch pounds
(18.65 Nm).

Yearlv or everv 100 hours. whichever
occurs first. remove
pape; cartridgb.
Clean by’ tapping gently on flat “surface.
If very dirty, replace cartridge,
or wash in a low or nonsudsing
detergent
and
warm
water
solution.
Rinse
thoroughly
with flowing water from inside out, until water
is clear. Cartridge
must be allowed to stand and air dry
thoroughly
before using. Service more often if necessary.

SPARK
ARRESTER
EQUIPPED
MUFFLER
— If engine
muffler is equipped
with spark arrester screen assembly,
remove
every
50 hours for cleaning
and inspection.
Replace if damaged.

—

if wire terminals
do not fit firmly
terminals if necessary.

plug
and

NOTE: Governed
proper operation,
governor, even at
at idle, the engine
be no lower than

ADJUSTMENTS
CARBURETOR

ADJUSTMENTS

Minor carburetor
adjustment
pensate
for differences
in
or load.

may be required
fuel, temperature,

INITIAL
ADJUSTMENT
— Turn
clockw!se until they just close.
CAU’Tl ON: Valves
far.

idle

may be damaged

and

needle

by turning

Needle

to comaltitude

(High

Speed)

Place governor speed control lever in fast position, Then
turn needle valve in slowly clockwise
(lean) until engine
misses or RPM slows, Then turn needle vaive ‘4 turn
counterclockwise.

valves

If engine does not accelerate
properly,
readjust needle
valve approximately
‘4 turn counterclockwise
(richer).

them in too

Now open needle
and idle valves
1’/2 turns counterclockwise.
This tnitlal adjustment
will permit the engine
to be started and warmed up prior to final adjustment.
NOTE: All carburetor
adjustments
air cleaner on engine.
‘

Valve

idle must be adjusted on all engines for
The smaller spring keeps the engine on
idle speed. If moderate loads are applied
will not stall. Governed idle speed should
1100 RPM.

CONTROL

ADJUSTMENTS

Proper choke and speed control operation
is dependent
upon proper adjustment
of remote controls on the powered
equipment.

must be made with the

TO CHECK

OPERATioN

OF CHOKE

CONTROLS:

Move
remote
control
lever to “choke”
carburetor
choke should be closed.
TO ADJUST

position,

The

CHOKE:

Place remote control
lever on equipment
In “CHOKE”
position, Loosen control casing clamp screw. Move control
casing and wire until choke is completely
closed, Tighten
casing clamp screw,

!--

1>
FINAL

“ IDLE

SCREW

/
THROTTLE
1 FvFR

ADJUSTMENT

Idle Valve
Place

SPEED

ADJUSTING

“M,:;:RE
VALVE

N::::
(HIGH

CHOKE
CLQSEO

SPEEO]

PROCEDURE

Mixture

governor

speed

control

lever

in governed

“IDLE”

against idle stop and set idle
speed adjusting screw to obtain 1400 RPM. Turn idle valve
slowly clockwise
(lean mixture)
until engine misses or
RPM slows. Then turn idle valve % turn counterclockwise.
position,

f-told

throttle

lever

CASIN
CLAMP
SCFiEW

Governed Idle
Hold throttle
lever against
idle speed adjusting
screw.
Adjust idle speed screw to obtain 900 RPM. Release the
throttle. With governor
speed control lever In governed
“IDLE” position, align %“ diameter
holes in control plate
and lever as shown.
Re-adjust
governor
speed control
casing and wire if required. See Governor
Speed Control
Adjustment
section. Adjust tang “A” to obtain 1400 RPM
governed idle.

GOVERNOR

.\-

SPEED

CONTROL

ADJUSTMENT

Theacceptable
operating speed range IS 1800to 3600 RPM,
Idle speed IS 1400 RPM The manufacturer
of the equipment on which the engine
IS used, specifies
the top
governed
no load speed at which the engine
may be
operated
DO NOT EXCEED
this speed.
Engine speed IS controlled
by movement
of the control
on
equ{pment,
“D”, 10 slowest
lever
U,ove control lever
engine speed possible Throttle lever on carburetor
should
touch Idle speed ad)ustlng screw To adjust. loosen control
Casing clamp screw “C “ Move control casing and wtre In
dlrectlon shown by arrow until throttle lever touches Idle
speed ad]ustlng
screw on carburetor
Retlghten
casing
lever
“D”
to “FAST’(
clamp
screw “C “ Move control
posltlon
If engine
exceeds
equipment
manufacturer’s
maximum governed no load RPM, move lever” D” to obtain
recommended
speed Bend tang “6” to touch lever “A “
CAUTION

OECREASE

Throttle

lever

speed adlustlng screw
slowest posltlon

on carburetor

when equipment

MUST

control

touch

Idle

lever IS In

BRIGGs a STRATTON ENGINE WARRANTY pOLICY
FOR INDUSTRIAL/COMMERICAL

(l/C) SERIES

AND SNO/GARD

ENGINES

ONLY

EffectiveJanuary’1,1983
When warranty
Centers.

repair

is justified,

Briggs & Stratton

Corporation

welcomes

such repair

by any of its Authorized

Service

In most instances, the requests for warranty brought to the attention of our Service Accounts are handled in a prompt routine
manner with no question regarding their validity. However, some requests for warranty are received which appear not justified.
In these cases, though engine owners may not be aware that the premature failure of their engine was the result of abuse or
neglect, or that the difficulty which they experience is caused by the equipment rather than the engine, investigation is made to
determine the applicability of warranty.
BRIGGS

& STRATTON

WARRANTY

LIMITED

covers only DEFECTIVE

WARRANTY

FOR l/C SERIES

MATERIAL

and/or WORKMANSHIP.

AND SNO/GARD

ENGINES

ONLY

“For two years from date of purchase, Briggs & Stratton Corporation will replace for the original purchasers, free
of charge, any part, or parts of the engine, found upon examination by any Factory Authorized Service Center, or
by the Factory at Milwaukee, Wisconsin, to be defective in material or workmanship or both. This is the exclusive
remedy.
“For five years from date of puchase, Briggs & Stratton Corporation will replace for the orginal purchasers, free of
charge, any part, or parts of the MAGNETRON@
Ignition System (excluding the spark plug), found upon examination by any Factory Authorized Service Center, or by the Factory at Milwaukee, Wisconsin, to be defective in
material or workmanship, or both, so as to result in the loss of ignition. This is the exclusive remedy.
“All transportation charges on parts submitted for replacement under this Warranty must be borne by purchaser.
For warranty service contact your nearest Authorized Service Center as listed in the ‘Yellow Pages’ under
‘Engines, Gasoline’ or ‘Gasoline Engines.’ THERE IS NO OTHER EXPRESS
WARRANTY.
IMPLIED WARRANTIES, INCLUDING
THOSE
OF MERCHANTABILITY
AND FITNESS
FOR A PARTICULAR
PURPOSE
ARE
LIMITED TO ONE YEAR FROM PURCHASE
AND TO THE EXTENT
PERMITTED
BY LAW ANY AND ALL
IMPLIED WARRANTIES
ARE EXCLUDED.
LIABILITY FOR CONSEQUENTIAL
DAMAGES
UNDER ANY AND
ALL WARRANTIES
ARE EXCLUDED
TO THE EXTENT EXCLUSION
IS PERMITTED
BY LAW. Some jurisdictions do not allow limitations on how long an implied warranty lasts, and some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to
you. This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction
to jurisdiction.”
Briggs & Stratton

Corporation

A%!!zf#%j#!
v
F.P. Stratton, Jr.
President and Chief Executive

Officer

NO REGISTRATION (WARRANTY) CARD IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON
ENGINES. FILL IN THE REQUIRED INFORMATION AND RETAIN FOR YOUR RECORD:
(Engine Model, Type and Code Numbere ere Located on the Blower Housing, Cylinder Head Shield or Backplane.)
Type No.

Engine Model No.
Dealer Purchased

Code No.

From

Type of Equipment
Name or Trademark

of Equipment

Manufacturer

If warranty service is needed contact your nearest Authorized Service Center. For prompt attention your center will need to
know the engine model, type and code number, the trouble experienced and the total number of hours the engine has run. If
you differ with the decision of the Service Center on a warranty claim, ask the Service Center to submit all suppotiing facts to
the Factory for review. If the Factory decides that your claim is justified, you will be fully reimbursed for those items accepted
as defective.

To avoid misunderstandirms
which miciht occur between enqine owners and authorized Brims & Stratton service accounts,
we are listing some of the ~auses of en~ine failure, where rep=ir or replacement is NOT cover~~ by Briggs & Stratton warranty.

NORMAL

WEAR:

Warranty wilt not cover repair where normal use has exhausted the life of a part or engine. Engines, like all mechanical
diwices, need periodic parts replacement and service to perform well. It should be remembered that the service life of any
engine is dependent on the care it receives and the conditions under which it has to operate. Some applications, such as
tillers, trash pumps, rotary mowers, are very often used in dusty or dirty conditions, which can cause what appears to be
premature wear. Such wear, when caused by dirt, dust, spark plug cleaning grit or other abrasive material, which has entered
the engine because of improper maintenance, is not covered by Warranty.

ABUSE OR NEGLECT
1. Bent or broken

crankshafts:

Such damage

is normally the result of abuse,
by Warranty.

such as striking a solid object with the cutter

blade on a rotary lawn mower, and is not covered
2. Engine

repairs

requied

from the use of contaminated

elude sticking valves, and carburetors
stale fuel. Always

or stale fuel are not covered

by Warranty, Such failures would inwhich form through the use of

and fuel pipes which are clogged by gum deposits

use clean fresh regular

gasoline.

3. Parts which are scored or broken because an engine was operated without sufficient lubricating oil, the proper grade of
lubricating oil or contaminated
lubricating oil are not covered by Warranty. Check oil level at least every five hours and
refill when necessary. Change oil at recommended
intervals.
is not covered by Warranty. Overspeeding
or overheating occurs if the
4. Damage caused by overheating or overspeeding
cooling fins become p~ugged with dirt, grass or debris, or if an engine is operated in a confined area without su~lcient
ventilation. Clean fins on the cylinder, cylinder head and flywheel regularly.
5. Damage or wear caused by dirt which enters the engine
Warranty. Clean and re-oil the air cleaner regularly.

because

of improper

air cleaner

maintenance

is not covered

6. Damage or wear caused by grit from blast cleaning sprak plugs is not covered by Warranty. We do not approve of cleaning
spark plugs on an abrasive blast cleaning machine, since grit can remain in the plug, and later enter the engine.
7, Warranty does not cover the tune-up or adjustment of an engine unless the need for such repair is the result of defects in
material or workmanship
or both. If equipment is assembled
and adjusted by the owner, the engine Operating and
Maintenance
Instructions are sufficiently clear to permit the average owner to make minor adjustments.
Such minor
adjustments are NOT covered by Warranty.
vibration caused by loose engine mounting, loose cutter blades, blade
8. Broken parts, which result from excessive
unbalance, improperly attaching equipment to engine crankshaft, overspeeding
or abuse in operation, are not covered by
Warranty.
remote controls,
9 Repair or adjustment of associated parts or assemblies such as clutches, transmissions,
not of Briggs & Stratton manufacture
will not be covered by Briggs & Stratton
Warranty.
10, Only ORIGINAL

13riggs & Stratton

parts, or parts approved

by Briggs & Stratton

may be covered

etc., which are

by Warranty,

WARRANTY IS AVAILABLE ONLY THROUGH SERVICE CENTERS WHICH HAVE BEEN AUTHORIZED BY THE BRIGGS
& STRATTON CORPORATION. YOUR NEAREST SERVICE CENTER IS LISTED IN THE YELLOW PAGES OF YOUR
TELEPHONE INRECTORY, UNDER “ENGINES, GASOLINE” OR “GASOLINE ENGINES.”

Carbon build-up may be excessive if carb. or valves are
improperly adjusted, engine Rl%l too low, improper sparkplug
gap.
B, Remove cylinder heads and eliminate carbon build-up with
wire brush:
12. Incorrect timing
A. ~iming may become offset if point box is not secure or if
points are out of adjustment. (Onan only).
13. Dirty air cleaner
A. If exhaust gaskets do not seat properly or heat exchanger
gasket is bad, exhaust may heat and melt the the air cleaner
requiring much clean-up repair.
14. Clogged fuel filter
A. Remove and replace
15. Low oil level or malfunctioning oil pump
A. Oil pressure sensors can be installed on the engine. This will
eliminate many problems which may occur.

ENGINE
An engine instruction brochure is included with this manual (see,
index) which may assist you in resolving engine related problems.

PROBLEMS:
ENGINE FAILS TO START
o ENGINE RUNS ROUGH
o ENGINE BACKFIRES
● ENGINE FAILS TO ACCELERATE
● ENGINE REDUCES SPEED TO LOW RPM
UNDER LOAD
●

CAUSES AND1ORSOLUTION:
1. Loss of fuel

16. Vacuum tank full
A. Empty vacuum tank

A. Empty gas tank.
B. Plugged fuel line or filter.
C. Defective fuel pump. (Replace with mfg. suggested
replacement parts only).
D. Gas line kinked, crushed or quick disconnect inside the truck
not connected.
2. Blown master fuse.

A. Electrical short.
B. Defective fuse.
3. Worn or maladjusted points (Onan eng. Only) (Briggs has
electronic ignition).
A. Remove and replace points and condenser.
B. Clean and adjust points,
4. Defective spark plugs

A. Remove and replace.
B. Clean and regap.
Defective spark plug wires
A. Sparkplug wires along with many others may, at certain points
come in contact with heated parts (exhaust manifold) or
abrasive parts (sharp metal, teflon hose). This may be taken
into consideration for electrical shorts.
B. Remove and replace.
Low compression
A. Defective valve.
B. Stuck valve.
C. Worn compression rings.
D. Defective piston.
Float switch in recovery tank inoperative. NOTE: Temporary
repair permits disconnection of float switch wire between tank
and machine. Continued operation with this condition will
compromise vac blower.
A. Switch stuck on upright position by foreign material.
B. Defective float switch.
Engine will not turn over
A. Dead battery
B. Loose terminal connection on battery or ignition switch.
C. Defective starter.
D. Seized engine or blower.
Defective Carburetor or gas leakage.
A. Clean carb.
B. Replace carb.
C. Choke locked in closed position.

D. When replacing fuel pump insure that it is the same pressure
rating recommended
by mfg.
10.

Improperly adjusted carb. NOTE: A comprehensive
manual is
available and defines necessary adjustments.
A. Incorrect air mixture ratio adjustment.
B. Incorrect float level adjustment.
11. Carbon build-up in cylinders. NOTE: Carbon build-up can be
minimized by using unleaded regular gas. Should carbon
removal be necessary, reinstall heads with new gaskets.

ELECTRICAL

SYSTEM

tlectncal snort m wlrmg system
A. Examme electrical systems for bare wires.

, ,Oorgroundmnnection
A. Examine terminal and remove corrosion if necessary,
6. Follow ground wire from (-) of battery to where it grounds at the
frame. If it is grounded to painted steel then scratch some of
the paint off to allow for circuit to be completed through the
steel.

The entire electrical system operates on 12 volts DC which is provialed by a battery. Battery levels are sustained by a 3 amp alternator
designed within the engine.
NOTE: When new battery is installed insure it is properly charged
before installation or damage to the charging regulator may occur.

PROBLEM:
* LOW BA’TTERYVOLTAGE

INOPERATIVE HOUR METER

CAUSE AND/OR SOLUTION:
1. Defective battery
A. Remove and replace.
2. Corroded battery terminals
A. Clean terminals and battery posts.
3. Low battery fluid
A. Add water to appropriate level.
4. Loose wiring within electrical system.
A. Examine all terminal connections and verify that they are
secure. NOTE: Give special attention to ignition switch
terminals.

CAUSE AND/OR SOLUTION:
1. Time is not advancing correctly
A. Verify 12 volts 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.
B. Remove and replace hour meter if 12 volts is available.
C. A nylon gear within the clock may have been jammed due to
a sudden jolt of the machine or truck. You may try simply
tapping on the meter to try to free the nylon gear,

BOB CAT 2/290
ELECTRICAL DIAGRAM

,—

BLACK

wOUR

METER

BLUE

—
START

TEMP

~.. .

‘!, ~“o

WHITE
85

WIRE

GOING

AND BLACK

SHOULD

WIRE

BE REVERSED

TO TERMINAL
TO 87A

SOLENOID

PROPANE TANK PLUMBING

MACHINE
INSTALLATION
INFORMATION

IL.

----

There are two ways of positioning the machine in the truck as shown
on the following page. There are also two locations for the vacuum
recovery tank to be positioned. First, the standard way with the tank
directly alongside the machine. Second, with the tank across the
back of the machine as shown below; this location is most space efficient.
PROPANETANK
165 GAL

CARRIAGE

‘7q~
FLAT.WAS-HER H -R

LOCKWASHER

%f_h%%%IJMTOR

Whichever way you select, make sure the tank and machine are secured to the floor of the van to insure driver safety.

\J’=~

PROPANEVAPOR VALVE
TANKFILLVALVE

It is important that the machine be placed as close to the door as possible so that outside air can be pulled into the engine for proper cooling.

THRU-FLOOR GAS HOOK-UP
AND INSTALLATION

It is recommended
by the manufacturer that the
exhaust from the front of the machine be vented down under the
truck to prevent carbon monoxide from entering the job site. Always
park the truck so the exhaust is blowing away from the job site.

FITHNG
(’4 BRS STR ELBOW}

The manufacturer
also recommends that installation of aluminum
vents in the truck roof to allow heat from the heater to escape.

&Q
SCREW

this machine with a portable
propane tank or a portable gas can inside the truck. The heater is
an open flame type and could cause a fire or explosion.
Never

autcK CONNECT
SOCKET

operate

\&_’’_

SCREW

o
PLATE
&

/
Q

Mount a fire extinguisher
emergencies.

just

inside

the

rear

or side

door for

BP%

/
uOsE CLAMPbilf

MACHINE TIE DOWN CLEAT
ILLUSTRATION
10 MAXIMUM

SET BACKOF
MACHINE FROM DOORWAY
PLACEAS CLOSE TO

‘!3

\
NOTE USE TIES TO SECURE T.FI~ING
TO THE FRAMEAND TO STABILIZE
HOSE ATA MINIMUM 6 FROM
THE EXHAUSTPIPE

II Il.

‘CUT ‘0 ‘ENGm)

WAND ASSEMBLY

WATER SOFTENER

HANDLE
SLE~VE

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 to everyone in a “hard
water” area.

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. The water softener will also increase the effectiveness of
the cleaning chemical being used, therefore, less chemical will be
needed.

FRAME

S S SOLUTION

HOSE

ill,”

q
\<

VALVE

TU8E

Contact a water softener distributor in your area for information on the
rental of a simple water treatment unit to carry in your truck. Be sure
to change the water softener in accordance with the capability of the
softener. Example: If the softener will treat 900 gallons of water and
the 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

JET

ASSY

/
WAND LIP

VALVE ASSEMBLY
GARDEN HOSE

L
WATER
SOflENEe
W?

,L&!?J?’
\_
,

--—%
WATER
FAUCET

JET ASSEMBLY

f!=

O-RING
KEEPER

.s+--BODY

BRASS CAP

-,
STABILIZER

@J-

!!’

‘

‘008’

I
32

cLip

RING

ASSY

MACHINE CONTROL PANEL

OPERATING
INSTRUCTIONS

HOUR M!3ER

START UP
1: Perform daily aperiodic maintenance as specified by the owner’s
manual.
2. Connect ail required hoses.
3. Connect cleaning tool to length of hose required to perform
cleaning.
4. Caution: Mix tank must be full prior to ignition.
5. Start engine (choke as required). Engine is at operating speed
(recommended
-2600 RPM). Allow warm-up period of 2-5
minutes.
6. Spray wand to void all air from system. As the mix tank is in a fill
cycle, the chemical flow meter may be adjusted to your desired
carpet cleaning pressure is 250setting. NOTE: Recommended

INCOMING
wATER CONNECTION

ADJUSTABLE HIGH PRESSURE
BYPASS VALVE
‘(CLOCKWISE
TO INCF4EASE)

‘“

1
BLOwEfl,ENGINE EXHALW

300 Psi.
7. Once all air is voided from system, heater maybe ignited. NOTE:
If not familiar with operation of this heater, refer to heater section
of the manual.
A. Open propane valve on the tank.
B. Ignite pilot on the heater.
C. To ignite burner, turn dial to on position.
NOTE: If you suspect that the unit has been frozen -DO NOT light
the heater. Thaw the heater and check for leaks.
8. Turn on burner, adjust dial to normal or slightly below for 200
Deg. F.
9. Commence cleaning operation
NOTE: Chemical flow meter set at 5 GPM is a 1 to 30 mix ratio
and 10 GPH is 1 to 15 ratio. When flow meter is set at 10 GPH,
you will be using what most chemical manufacturers recommend
at 5 GPH.

2.
3.
4.
5.

Turn heater to off position. Spray wand for a least 3 minutes to
allow the heater coils to cool.
Close valve on propane tank.
Remove vacuum hose.
Flush clear water through chemical system for 10 seconds.
(vinegar should be rinsed through system weekly). Turn off
chemcial flow meter.
Turn on cleaning tool to flush chemical from unit hoses and
cleaning tool.
NOTE: If freeze guard is necessary, perform steps 1 & 2 of freeze
guard procedure at this time.
At this time, the blower should be lubricated with LPS 1 or WD 40.

6.
7. Shut engine down.
8. Drain vacuum tank. Vacuum filter should be cleaned prior to

PRECAUTIONS

MACHINE ADJUSTMENTS:
Although this unit has been factory adjusted, it may require additional adjustments to achieve optimum performance;
i.e. altitude
may require carb adjustment and ambient temperatures may require
heat control adjustment. When required, consult an authorized representative.

ENGINE COOLING:
~
be incapacitated

Units employing air cooled engines must not
within a van with doors and windows closed. Exen-

LEVEL OPERATION:
_
Duringoperation,
vanortrailermustbeparkedon
level ground not to exceed + or – 10 deg.. Failure to insure proper
leveling may prevent proper internal lubrication of engine, vacuum
andlor high pressure components,

FREEZE PROTECTION:
_
Mother nature gives little warning astohercold
spells. Therefore, protecting 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.

mobilization of van.
NOTE: If freeze guard is necessary,
guard procedure at this time.

OPTIONAL
!
~
LEG HOLES ~,x TANK DRA,N
I
HIGH PRESSURE
PETcOCK VALVE
CLEANING SOLUTION
& HOSE
CONNECTION

cessive” temperatures
within the engine will result in premature
gine failure and a compromise of applicable warranty.

SHUT DOWN
1.

OPERATION

~~-”

perform steps 3-9 of freeze

LIGHTING HEATER:
Never put your face down close to the opening of
the heater when lighting.

STRONG PROPANE ODOR:
propane

Never light the heater if you smell a strong odor of
around the heater.

HEATER:

IznmiEl

Never pile things around the heater, i.e. hoses,
boxes, chemical jugs, etc., as this will block the flow of air required for
a clean burning heater.

OPEN FLAME:

kw!!2il Fl

emember that this heater is an open flame,
therefore, do not remove engine gas line while troubleshooting or
store any flammable material in the truck with heater operating.

FREEZE PROTECTION
Any freezing of this machine is not covered by warranty and during
the colder months of operation,
most concern.

THE FOLLOWING

careful protection

PRECAUTIONS

ARE RECOMMENDED:

5. In colder climates, insulating the truck walls and floor boards will
help protect the unit.
6. Don’t procrastinate during the cleaning operation or the hot water
solution line will also freeze on the ground. The solution line
should be insulated in extremely cold climates.
7 Whenever ~ossible. the truck and machine should be stored in a
heated garage at night or over the weekend. if not possible, place
a 1500 watt electric heater inside the truck, aimed directly at the
machine, Never use a propane heater-it causes excessive moisture on the truck ceiling and the possibility of it going out is higher.
If the machine and truck are left outside with a heater, you should
first drain all possible water from the machine cleaning tools and
hoses. (They freeze also.)

Your mobile carpet cleaning plant has been engineered
using the
latest and most sophisticated technology available, to produce the
finest carpet cleaning results possible. Despite this however, it remains only a tool of the carpet cleaning trade, and it can produce only
as good a job as the person operating it.
There are no short cuts to good carpet cleaning, it requires
cleaning knowledge and the use of good chemicals.

time,

should be of ut-

1. Run machine before leaving for the first job to insure nothing has
frozen the night before, including hoses and wand.
2. Insulate the garden hose from the cold ground by runmng It
through an extra 1 % inch vacuum hose.
3. Leave truck doors closed until time cleaning begins, then open
slightly for ventilation of air cooled engine.
4. On extremely coid days propane does not vaporize as quickly,
therefore, venting the warm exhaust over to blow on the propane
tank will stabilize the propane flow. (This is necessary if you
notice a drop in heat or a low burning flame in the heater.)

TO DRAIN THE MACHINE.

CLEANING AND
CHEMICAL
PRECAUTIONS
INFORMATION

THESE

Next, blow the air into the incoming water quick connect and
force that water into the chemical mix tank to be drained out.
between quick

8. BE SL.WIE [T’S PROTECTED!
Freezing will cause GRIEF, MONEY and DOWN-TIME. Don’t
mess with mother nature! Remember to close the petcock
valve prior to next operation of your BobCat 2/290.

recommends
the use of spotting agents. and traffic
prior to the actual cleaning of carpeting, as required.

Manufacturer recommends setting heater thermostat at ‘normal’ setting when cleaning synthetic fiber carpets, and at ‘warm’ setting
when cleaning natural fiber carpets.

~
When cleanma cut-txleacrilan
dush camets, set
heater at ‘warm’ setting. Using fiighe’r treater se~ing may ’result in
fiber damage on this type of carpet.
The use of some chemicals through your mobile carpet cleaning
plant can seriously damage the internal plumbing, high pressure
pump and heater. (Chemicals such as concentrated acids and some
paint oil and grease removers w/high concentration of solvents.)
Manufacturer recommends only the use of chemicals containing rust
and corrosion inhibitors and water softening agents to prevent
chemical build-up.

NOTE:
At no time should a chemical solution with a PH of less than 7 or
higher than 10 be used in the unit.

Pbf CHART

STEPS:

A. Before shutting off the machine, remove the chemical line from
the chemical jug and place in a mixture of 50/50 anti-freeze and
water. Wtth the cleaning tool on, allow mixture to fill chemical systwn back to the chemical mix tank.
5. Loosen the petcock valve on your bypass drain hose and allow
the water to drain thoroughly from the mix tank.
c. To remove the water from the heater and pump use the freeze
guard kit which is a small air compresor that can be plugged into
the dash board lighter in the truck, or air at the gas station. Using
the correct connectors, first blow air into the high pressure solution male quick connect. This will force the water through the
heater back through the pump and into the chemical mix tank to
be drained out through the petcock valve to the ground.

To be sure all water is out of the system, alternate
connectors several times.

Manufacturer
lane cleaners

1234567891011

ACID —NEUTRAL

12131~

‘ALKALNF~

CLEANING STROKE
PROCEDURE/OVER-WETTING
PURPOSE:
To eliminate excess moisture remaining in the carpet fiber and the
sawtooth appearance which results from diagonal movement of the
cleaning tool on all types of carpet.

‘PROCEDURE:
Always move the cleaning tool in smooth forward and backward
strokes. Apply slight pressure to the fonvard stroke while the solution is injected into the carpet. When extracting (drying), apply firm
pressure on the forward stroke to ensure a positive “lock”’ for the
vacuum and minimize the “hopping’” effect resulting on unsmooth
carpet. During the fofward and reverse strokes, movement to the
34

right or left should only be accomplished at 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.
Failure to adopt this procedure can result in increased chance of
“clean streaks”, fiber shrinkage,
brown out, and longer drying
periods.

INCORRECT

METHOD

CORRECT

.
.
‘
.

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’s as
needed.

IMPORTANT:
chart.

Record date and machine

hours on maintenance

MONTHLY

METHOD

e Grease blower bearing fittings.
● Remove,
clean and reinstall engine air cleaner filter.
o Remove pressure by pass valve stem, grease cup and stem,
reinstall.
● Check water level in battery. Clean connections
as needed.

OVERIAP
BETWEEN STROKES

IMPORTANT:

Record date and machine

hours on maintenance

chart.
‘w
: ~

QUARTERLY

OVER-WEITING
Over-wetting is annoying to all concerned and sometimes
bad impression of the cleaning process used.

Ieaves a

There are several areas that will cause over-wetting:
1. Too few vacuum strokes or improper saw tooth vacuum
strokes as shown above.
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 recommend crystal type.)

OVERALL CARE OF UNIT
MAINTAINING
IMPORTANT

To avoid costly repairs and down-time, it is imperative to develop
and practice good maintenance
procedures from the beginning.
These procedures fall into daily, weekly, monthly and quarterly increments, and are outlined below. We have provided a maintenance
log for your convenience on the following pages; it is recommended
that you affix a copy of the logon the 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.
machine for loose wires, oil leaks, water leaks,
e Visually irrspect
etc..
. Inspect recovery tank s/s filter and filter bag for tears, holes, etc. clean, repair or replace as needed.
. Lubricate blower with LPS-I or WD-40 through blower inlet.

●

WEEKLY
●

Change

engine oil. (25-30

hours of operation)

. Check engine air cleaner filter - clean as necessary.
o Check high pressure pump oil - add as necessary.
.

Check
Check
o Check
● Check
● Check
. Check
●

THE ORIGINAL APPEARANCE
FOR TWO REASONS:

OF YOUR

UNIT IS

1. It represents a big dollar investment for your cleaning business
and its appearance should reflect that fact. A dirty machine is not
professional!
2. Maintenance,
troubleshooting,
and repair is much easier to
accomplish on a 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.

MAINTENANCE
PROCEDURES

●

Change oil in blower (see blower manual).
. Check engine compression.
@ Check for combustion chamber carbon deposit
—t131J&,er
e Change spark plugs (see engine manual).

●

drive coupler setscrews - tighten as needed.
pump drive belt for wear - tighten as needed.
pimppulleys - tighten as needed.
fuel lines for wearlchafing.
all nuts and bolts - tighten as needed.
heater burner assy. union for tightness/leaks.

FOLLOWING
MAINTENANCE
IS RECOMMENDED
BY THE MANUFACTURER
AT THE FREQUENCY
INDICATED.
AFTER EACH JOB: Check recovery tank, Sk filter and filter bag as

required.
DAILY: Wipe machine down thoroughly with a damp cloth; flush recovery tank out thoroughly. Empty filter bag and inspect for rips,
tears, etc. - replace as 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 with
stainless steel cleaning compound to maintain original appearance
(available through grocery stores); wipe down vacuum and high
pressure hoses as needed - visually inspect for cuts, etc..
WEEKLY:
Wipe down entire unit as needed - apply good coat of
auto wax to all painted 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 filter in recovery tank, thoroughly clean removing all lint build-up, inspect for damage and reinstall. Remove filter
bag, thoroughly clean and reinstall - if torn, replace; empty chemical
from chemical container, wash out thoroughly to remove any chemical build-up; inspect chemical feed line strainer and use 50% white
vinegar/water
solution to remove any chemical build-up; thoroughly
clean wand and inspect for clogged jet, debris in vacuum slot and
leaking fittings at valve. 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 propane and gas lines for
wear or abrasions that may cause possible fuel leaks.

DAILY CLEANING & INSPECTION
Engine oil - check
Garden hose screen - clean
Machine - general inspection
Clean vac tank filter bag after every job
Blower inlet - spray with LPS 1 after last job

MAINTENANCE

LOG

WEEKLY SERVICE
SERVICE

MAX HRS
25

ENGINE

BLOWER

PUMP OIL check

DRIVE

BELTS & PULLEYS

FUEL LINES check for chafing

DATE/HRS
I

OIL change

DATEIHRS

DATE/t-iRs

DATE/HRS

check oil level

COUPLER

tighten set screws
check tightness

25
25
25
25
25
25

WIRING

check for chafing

CHEMICAL

SYSTEM

flush w/vineaar

MONTHLY SERVICE
100

BLOWER

100

ENGINE

100

BY PASS VALVE grease cup& stem

grease bearing
AIR CLEANER

clean

QUARTERLY SERVICE (3 MONTHS)
300
300
300

SPARK PLUGS change

I
I

DATE/HR{

DAILY CLEANING & INSPECTION
Engineoil- check
Garden hose screen - clean
Machine - general inspection
Clean vac tank filter bag after every job

MAINTENANCE

LOG

Blowerinlet- spraywithLPS1 afterlastjob

WEEKLY SERVICE
SERVICE

MAX HRS
25

ENGINE

BLOWER

OIL change

PUMP OIL check

check oil level

DRIVE COUPLER

BELTS & PULLEYS

25
25

FUEL LINES check for chafing
NUTS & BOLTS check tightness
BATTERY LEVELS check
HEATER BURNER ASSM tightnesslleaks
VACUUM TANK clean
WIRING check for chafing

CHEMICAL6YSTEM

25
25

tighten set screws

check tightness

flush w/vinegar

MONTHLY SERVICE
100

100
100

BLOWER grease bearing
ENGINE AIR CLEANER clean
BY PASS VALVE grease cup& stem

QUARTERLY SERVICE (3 MONTHS)
300
300
300

BLOWER OIL change
ENGINE compression
SPARK PLUGS change

DATE/HRS

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : Yes
Encryption                      : Standard V1.2 (40-bit)
User Access                     : Print, Copy, Annotate, Fill forms, Extract, Assemble, Print high-res
Creator                         : sdse122.tmp
Create Date                     : 2000:04:17 08:14:18
Producer                        : Acrobat PDFWriter 2.01 for Windows
Title                           : BobCat 3.0 3.5 Owners Manual
Author                          : HydraMaster Corporation
Subject                         : 
Modify Date                     : 2001:06:19 07:25:05-07:00
Page Count                      : 38
Page Mode                       : UseOutlines

EXIF Metadata provided by EXIF.tools

BobCat 3.0 3.5 Owners Manual Bobcat30 35hp_c_unkn &file=bobcat30 35hp C Unkn

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