HydraCat 4.0,4.5 High Performance C. 1991 Owners Manual Hydcat40_45hp_c91 &file=hydcat40 45hp C91

User Manual: hydcat40_45hp_c91

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Page Count: 39

HudraCat

HYDl?A&#ASREZ.

Corporation

I

1

I

I1319W HydraMaster Corp.

Printed in U.S.A.

GENERAL INFORMATION

Howlhe System Works..............................................................................2

Spare Parts Recommendation ..................................................................2

Machine S~cifi~tions .............................................................................2

Warning and Caution.................................................................................2

HowtoOrder ..............................................................................................3

PatisOrders ..............................................................................................3

One Final Note..........................................................................................3

Purchaser’s Responsititi~ ........................................................................3

Sales Representative’s Responsitili~ ......................................................3

TwckSelection ..........................................................................................4

TmckPre~ration ......................................................................................4

Tmck Pre~ration illustration .....................................................................4

Placementof Unitin Vehicle.......................................................................4

Machine installation ...................................................................................4

Propane Tank Location.............................................................................5

HardWaterArea Map................................................................................5

WaterSofiener ..........................................................................................5

Wastewater Disposal AdviwW ..................................................................6

Mactine A~ustments ................................................................................6

OPERATING INSTRUCTIONS &PRECAUTIONS

shdup ......................................................................................................6

ShutDom .................................................................................................6

Cautions and Warnings.............................................................................7

Freeze Protection......................................................................................8

Alternative Protection UsingAnti.Freeeze .................................................8

Cleaning and Chemical Precautions ..........................................................8

Cleaning Stroke Procedure/Over.wetiing .................................................8

Water and Chemical FlowOperation .........................................................9

Chemical System Maintenance .................................................................9

Chemical TankTrouble Shooting Guide..................................................lQ

Water Flow Trouble Shooting Guide........................................................ll

Vacuum System Information...................................................................l2

VacuumTank filter Bags.........................................................................l2

Vacuum Blower Wanan~ ........................................................................l3

~,,..:VacuumBlower Lubri~tion .....................................................................l3

Vacuum Blower Trouble Shooting Guide %--14

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

Heating System Information .....................................................................l4

HeaterOperating lnstmctions ..................................................................15

HeaterTroubleShmtingGuide...................................................................l5

CatPump Mode12900prating lnstwctions ............................................l6

Cat Pump Wman~ .................................................................................l6

Mode1290PartsList .................................................................................l7

General Information forCat Pump Repair................................................l8

Servicing the ValveAswmblies ...............................................................l8

Servicing the Pumping Section................................................................l9

Servicing Sleeves and Seals...................................................................l9

Servicing Crankcase Section..................................................................l9

Cat Pump Trouble Shooting Guide..........................................................2O

HydraCat Electrical System.....................................................................22

Onan Performer Engine SPCS ...............................................................23

General Information about Onan.............................................................24

ENGINEMAINTENANCE........................................................................25

OilSystem...............................................................................................25

1

ignition....................................................................................................27

Cooling System.......................................................................................27

Exhaust System.......................................................................................27

AirCleaner...............................................................................................27

Batie~ .........................................................................................................28

Periodic Maintenance Stiedule ................................................................29

Engine Trouble Shooting.........................................................................3o

Maintenance Procedures........................................................................32

Overall CareofUnit..................................................................................32

Maintenance Logs....................................................................................33

Warranty Information ...............................................................................36

Warran~Pro~dure ................................................................................36

Limited Warranty Plan.....................................................lnside back cover

LIST OF ILLUSTRATIONS

Plywood lnstallation(ontwck &d) ..............................................................4

AstiotudandRoof Vent...............................................................................4

Machine XeDow Cleats...........................................................................4

~chine Configuration ...............................................................................5

Pro~neTankPlumting .............................................................................5

HardWakrMap .........................................................................................5

WaterSofienerHook.up .............................................................................6

pHChati .....................................................................................................8

CleaningStroke Procedure........................................................................8

Chemiwl SystemWring ............................................................................9

WaterFlow .................................................................................................9

Chemical Proportioning and Level Control..................................................9

WandValveAssembly ..............................................................................lO

JetAswmbly ............................................................................................lO

WandAswmbly .......................................................................................ll

Wand Valve StemAswmbly ....................................................................ll

By~ss ValveAswmbly ...........................................................................ll

VacuumFlow............................................................................................l2

VacuumTankRlterBags ..........................................................................l2

BlowerLubPofi ......................................................................................l2

VacuumBlower Motor Lubrication ............................................................l3

RlotBwnerAdjustment ............................................................................l5

Model 290 Exploded Mew.......................................................................l7

Pumping ~ction Cubway .......................................................................l8

HydraCat Electrical Diagram....................................................................22

BasicUmensions. P224..........................................................................23

Basic Dmensions. P220..........................................................................23

OIMmsi~ ..............................................................................................25

OlfilterLoMtion ......................................................................................26

P220CmnkMWBreather ........................................................................26

P224CmnkMWBreather ........................................................................26

SewicingS~rkPlug ................................................................................27

ArCleanerAswmbly ...............................................................................28

SWcificGravi~Test .................................................................................28

BatieqCaMeConnection .........................................................................28

LIST OF PHOTOS

HydraCat (kontview.features labled) .......................................................7

HydraCat(sidetiew. featureslahled) .......................................................7

CatPumpMode1290 ................................................................................l6

Semicingtie Pump...................................................................................l9

Onan Performer Gasoline Engim .............................................................23

SparlrPlugDiagnosis ...............................................................................27

GENERAL UWWWIATION

T’hwmanual contains installation and operation instructions as wII as in-

formation rquired tar proper maintenance, adjustment and repair of this

unit. Since the first and mast important part of repair work is the correct

diagnosk of the trouble, ageneral troubleshooting section and component

manual troubleshooting charts have fxen included for your convenience.

IMikea garden tractw, Iawmnower arcement mixer, all having one ortwo

functions 10fwrtarm, thebuck-mounted carpet cleaning plant has many

functions to pwform simultaneously.

*Engine has to run at aconsistent RPM.

‘Vacuum has ta pull air and d@ water bad from cleaning site.

●Waler pump provides stable pressure at proper water flow for cleaning.

*Chemical has to be injected into the water stream at the

right cmcentration.

*Heater must maintain proper hsat.

*Vacuum tank must store dirty water until drained.

HOW THE SYSTEM WORKS

The water system takes incoming water at tap (low) pressure, combines it

wilh chemicals from the chemical system and pumps it under pressure

through theheatingsystern, anctouttothec]eaning tool.After being sprayed

into the carpet, Ihe water/chemicaf/soil solution isextracted by the vacuum

system and returrwd to the waste recovery tank.

There is no guess wrk in the manufacture of these highly advanced

cleaning pfmts.There must also be noguess work in preparing ittoget the

job done in the field. his the purpose of this manual to help you prqwty

understand, maintain and service your cleaning pfant. Follow thedirections

carefully and you will be rewarded with years of profitable trouble-free

operation.

It isimperatfvethat nw$eclfonbeoverlookedwhen preparing foroperation

of this equipment.

SPARE PARTS

RECOMMENDATION

Because your truck-mounted unit iscapabfe of generating several hundred

dollars Wr day, down-time on the unit can be very expensive.

In order to minimize such down-time, it is strongly recommended by the

marwfacturcx that PU pumhase and keep inyour truck the following spare

palls:

PART NO. 0ESC13fPTKIN WY.

078-015 Flow meterkit 1

4178-(119 Wand vafve dunger kit 1

Wlf4XJ4 Pressurebypassvafvekti 1

076-005 Spray @W06E 1

048-029 Recovwv tankfitterbag 2

078-001 cat 290 short cqp kdstandard 1

078-004 f%t 290 hoi CUPkit (~ tionat) 1

048-023 Screen, qarden hose 6

0624W0 440 Mafequick conned 1

052-051 440 Femete quick conned 1

052-052 660 Male quick conned 1

a52-a53 660 F@mafequick mned 1

106-015 Ermine@plug 2

010-021 HydraCalpumpdrivebelt 1

MACHINE SPECIFICATIONS

‘RAME: 2~ W, 59 L, 3& H. Steef with baked-on epoxy finish.

VEIGWE HydraCat 4.0:630 tbs. (dry ‘might)

HydraCat 4.5:750 Ibs (dry weight)

;OWUNG: Steel with baked-on Epoxy finish.

NGINE: HydraCat 4.0: P22020 BHP Onan

HydraCat 4.5:P22424 BHP Onan

GNfTfON: Electronic, Keystart.

ii-PRESSURE PUMP: Tri-Plex piston -- Cat 290- 3.5 W%!

-1200 PSI -- @1200 RPM.

fACUUM BLOWER: HydraCat 4.0: 4ML

HydraCat 4.5: 4LL

Sutorbuift W/l 2HG Safety Relief.

:HEM[CAL SYSTEM: Electro-mechanical, meter Conlro!l@d.

WATER: Propane fired, thermostatically controlled (180,000 BTU).

NSTRUMENTS: 0-1000 High pressure gauge, Temperature gauge,

/acuum gauge, Hourmeter, Chemical flow meter, ignition key, Startandon

ndicator fights, Pump clutch switch, Circuit breakers.

?ECOVERY TANK: 70 gallon aluminum, Epoxy finish.

;LEANING WAND: Stahless steel with heat shield, Grip and replaceable

racuum fips with stainless steel solution valve.

+f-PRESSURE HOSE I/& High-temperature linecflvin~ covered, Hose

ated to 1250 PSI.

IACUUM HOSE: 2’ reinforced, 11/2’ reinforced.

STANDARD EQUIPMENT: Power conso!e, Sound suppression Packagq

Electric Pump Clutch, Water heater, Vacuum Recovery tank, Carpet

cleaning wand, Chemical jug, Chemicafjugholder, Chemkal@gfill line,(lp

eration manuaf, 150 ft. 2’ vacuum hose, 10 ft. 11/2” vacuum hose, 150ft.

Super-flex solution fine, 10 ft. drain line, 50 ft. water supply line, ~

!d! Freeze guard system, Battery boxwithholder, Vandeca! package, Fuel

system kit, Installation kit.

ADDITtONAL EQUIPMENT, HYDRACAT4.5: Oversize airhandling pack-

age, High-output component power pack, Super dual silencer system,

electronic tachometer.

The manufacturer uses this symbol throughout We rnarwai to wwrr

Qfposslbie injury ardt?alh.

This symbol is used 10warn of possible ei@gme?rMdamage.

2

HOW TO ORDER PARTS

To obtain aproper diagnosis of your malfunction, and to order warranty

replacement parts, itis important that you proceed in the following mannec

1. Call HydraMaster Warranty/Service Department at (206) 775-7275.

2. Give the Warranty/SeM”ce representative the following information:

A. Name of your company and your address.

B. Equipment model (i.e. HydraCat, Bobcat 2, etc.).

C. Date of purchase.

D. Hours on the unit.

E. Serial number of unit.

F. Name of person authorized to order parts.

G. Salesman unit purchased from.

H. Description of malfunction.

1.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. U.P.S. D. Air Express

B. Air Freight E. Auto Freight

C. Air Mail

4. Do not give malfunctioning parts to aHydraMaster sales or service

representative. All parts must be returned dlrectfy to HydraMaster,

Freight prepaid.

PARTS ORDERS

To expedite your parts needs, please caii your saies representative.

Inmost instance, heeither stocks or has access to parts through aregionai

service center. Intheevent parts are unavailable iocaliy, contact the factory

and coordinate your needs. ifthis becomes necessary, always indicate the

method of shipment you desire, i.e. UPS. Blue Label, Air Freight, Air

Express, etc.

HydraMaster Parts Department. Phone (206) 775-7276.

ONE FINAL NOTE

Anyquestionsyou have regarding thewarranty program shouid bedirected

to the Warranty/Servkxr Department personnei at HydraMaster Corpora-

tion.

We shallalwaysendeavorto befairinourevaiuationof yourwarrantyclaim,

and shali provide you with acomplete analysis of our findings.

HydraMaster Warranty Poiicy (inside back cover)

Effective February 1,1989

HydraMaster warranty covers oniy defective materiais andlor workman-

ship for the periods listed. Labor, and/or diagnostic reimbursement is

specifically excluded.

PURCHASER’S RESPONSIBILITY

PRiOR TO ARRIVAL OF UNiT

1.lnstali 5/8” extenorplywoodflooring invehicle and cover with artificial turf.

2. Have beiiy mounted propane tank installed on vehicie. Tank must be

propane vapor type.

3. Purchase heavy duty 42-60 amp hour battery and have battery ‘slow’

chargedjfnew. Ifbatteryisnotfully chargeddamage can occurto tie engine

charging regulator.

READiNG OF OWNERS MANUAL: it isthe purchaser’s responsibility to

read the unit operation manuai and to familiarize himself with the informa-

fioncontainedtherein. Speciai attention shouidbepaidtoaii Cautions

and WARNINGS.

SALES REPRESENTATIVE’S

RESPONSIBILITY

ACCEPTANCE OF SHiPMENT:

1.ifunitshowsanyoutward signsof damage, donot signthedeiiveryreceipt

untii you have closely inspected the unit and noted any damage on the

deiiveryreceipt. Havethe freightcompanyrepresentativeacknowledgethe

damage by signing the notation of damage on the delivery receipt.

2. The salesman from whom you purchased your unit is responsible for

supervising thecomectinstallation ofthe unit in your vehicle and thoroughly

training you in its operation, maintenance and precautions.

CORRECT iNSTALLATION iNCLUOES: Installation of through-floor fit-

tings for propane and gasoline fuel lines; installing propane regulator

included with unit,outside vehicie; placing unit and recovery tank invehicle

and securing themwith bolts or tiedown cleats ;connecting all propane and

gasoline Iinew connecting battery; checking pump, vacuum biower and

engine oil ieveis, prior to starting unit; starting unit to check engine to see

that ail systems function normaily; aiw checking ail hoses, wands, etc., for

carect operatiin.

TRAfNiNG SHALL iNCLUDE: Thorough review of the operation manual

with purchase~ instruction and familiarization in: how to correctiy start up

andshut down unit; howtocorrectiyciean with the unit; how,where andhow

often to check and change component oil ievels; how the unit’s systems

worlc how to troubleshoot the unib how to do basic repairs; safety precau-

tions and their importance; freezing damage and how to avoid it and a

thorough review ~the unit warran~ and w&ranty procedures.

HOURS TELEPHONE NUMBERS

Monday -- Friday (206) 775-7272 Generai offices

8:00 am To 5:00 pm (206) 775-7276 Parts Department

PACIFICSTANDARDTIME (206) 775-7275 Service/Warranty

(206) 771-7156 FAX

3

TRUCK SELECTION

The preferable vtllclefor HydraCat iristallationis apam?lvan with aheavy-

duty swyx?nsirm package. The capacity of Iho van should be a heavy-duty

1/2 ton at ttm minimum and more preferably a3/4 ton o&pacity.

TRUCK PREPARATION

The manufacmrarmmmmands theinslallation ofpl~od flooring covered

wiftr paly propylene backed astroturf (do not use rubber-backed) in the

vehicl~ prior to installation of machine. This provides ametal to cushion

mounting rather than metal to metal, provides insulation and makes an

attractive van interior. Aslroturf should be color keyed to van interior.

Materials Needed:

1.2 sheets 4x8x5/fY exterior plywood

2. &xl 2’ piwe of commercial astrotwf

3. 16-f lM sheet metal screws

4.1 quart marine adhesive (optional)

5.1 staple hammar wII12” staples

(See illustration for correct placement of plywood flooring)

TRUCK PREPARATION

ILLUSTRATION

FIRST, covtwth~ truck kd with 5/8’ p@vood using metal screws to secure

it as shown.

Plywood Immlwcm 5/8” Plywood

SECOND, wlecttWappro@ate coloras!roturfto match yourvan andcm

tie plywood and staple in place. Astandard van requires apiece 6feet b]

12feet.

THIRD, Hydrafdasler strongly recommends an aluminum roof vent be in

stalIed over Ihe location selected for mounting the machine. HydraMaste

alsohighly recommends aflue be installed between the lop of the heate

and the roof vent. Thiswillallow hot air from the heater to escape.

ILACEMENT OF UNIT

4VEHICLE

we are two recommended unit placements:

SIDE DOOR: Most installations are side door. This provides rearamss

paccessories and hoses as well as unobstructed access to compmwnti

]rfdngside of machirw, thus making itabiteasiw’ io perform maintenance

IWorrepair without removing unit from the truck.

REARDOOf%Afthaugh this location partly limits working access, itdoes

wet the noise away from the cleaning site. Some cleaners in the colder

eas prefer this location because if puts the weight mass ow?rthe rear

~eelsfor better traction in ice and snow. Rear mounting requires ttw unit

beslid tothe right side as faras possible. This not only provides adequate

xking space on the component side of the unit but also makes better

sight distribution inside the van (engine and cornponer?tweight line up

~erdrive shaft). Also, it is physically easier to load unit into rear door due

height of van bed.

rrsure that machine is well secured to the floor of van with hwchvafe

~pplied.Sudden orwash stop Wlcause machine torocket foru%wd,all 750

s. wrth! Protect yourself and the machimz SECURE lT#

Machine Tie f?own Cleats I

UIACHINE INSTALLATION

‘hereare twoways of positioning the machine inthe truck as shown.Thwu

re also two locations for the vacuum recovw’y tank to be pasitiom?d.l%%

w?standard way with fhe tank directly alongside the machine. %?cond,with

Ie tank across the back of the machine as shown on the illustration on the

Iextpage; this location is most spaca eflicient. Whichew?r way YOUsdect,

lake sure the tank and machirm aresecured tothe tloorof thevan toinsure

Iriver safety.

tis important that the machine lx?placed as close to the door as possibh?

othat outside air can bpulled into the engine for proper cooling.

4

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Machine Configuration

E

::

———

0.UrloidB----

:

Iiisrecommendedbyfhe manufacturerthatthe exhaustfi’om the frontofth

machine be venfeddown under the truck toprevent carbon monoxide frof

entering ihspb We. Aiwaysparkthefruckso theexhaustis bfowiq

away torn Ihejob site.

Themanufactureraiso recommends that instillation of aluminum vents i

the truck roof to a//ow heat from the heater to escape.

Never operate this machine with aportable propane tank oraportable ga

can inside the truck, doing so increases the risk of afire or explosion.

Mount afire extinguisherjusf inside the rear or side door foremergencie:

PROPANE TANK LOCATION

Either the 10gallon or 16.5 gallon propane tank will fit this location. Hav

you local propane dealer install the tank you select and purchase. Th

machine will come with the proper propane regulator. fTank must hav

vaporoutiet.)

Professions/insta//ation offudsystems is strongly recommended. Aiwq

ensure compliance with stite andlocdregulations pertaining tofueiinsta

Iations.

HARD WATER AREA MAP

The quality of water variis greatly throughout the United States and

influences the reiiibility and effiiienoy of equipment in direct proportion to

its !evelof hardness. The map below detinesareas which cornprumise fluid

related components such as hoses, fittings, heaters, pumps, valves and

water cooled engines.

Cleaning efficiency and equipment life is increased, chemical use de-

creased 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 31/2 grains per

oallon. Using the legend as areference, determine the quality of water in

~our area aid take ;ction immediately should it be nece&a~.

IWater Hardness

Grains ..

Per Galbn

n‘-3iQ =7-101/2

Izzzz 31/2-7 _101/2 and above

WATER SOFTENER

Many areas of the country have an excess of minerals in the water which

results in what is commonly called “hard water”. These minerals tend to

adhere tothe insides ofheater coils andotherpartsof themachines causing

damage and a loss of cleaning effectiveness.

Reports from several of our machine users commending the results of the

useofwater softeners inconjunctionwith their machines prompts usto rec-

ommend the procedure to everyone in a“hard water” area.

The relatively lowcost ofawater softener service is more than made upfor

intheincreased Iifeof machine parts andcontinuedcleaning efficiency. The

water softener will also increase fhe effectiveness of thecleaning chemical

being used, therefore, less chemical will be needed.

Contactawatersoftener distributor inyour area forinformationon therental

ofasimple water treatment unit tocarry inyour truck. Be sure tochange the

water softener in accordance with the capability of the softener. Example:

Ifthe softener will treat 900 gallons ofwater and machines uses anaverage

of30 gallons perhourof use, andanaverageof 5hours aday, wouidbe 150

gallons aday. 5days would equal 750 gallons of water, therefore, the

softener would be changed every 6working days for maximum softening.

(s6eil@laum,wpi?#e)

5

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—C#

h-morning VVatar

From Faucet

Garden I-fose

Water Softener

WASTEWATER DISPOSAL

ADVISORY

Them are laws inmost communities prohibiting the dumping of recovers

‘gray” water from carpet cleaning in any place but asanitary treatmel

system.

This cleaning rinse water, reccwred into your unit%vacuum tank, contair

materials such as dete~ents, which must be procwed before being se

for streams, rivers and reservoirs.

IN ACCCMM2AMCEWITtf THE EPA, STATE AND LOCAL MWS, D

MM MWW$f OF WASTEWATER MK7 GUTTERS, ST0f?h4 DRAIN

STllEAA@ RESEJ?Vt’WS, ETC.

Inmost cases, anacoep!ab[e method ofwastewaterdisposal istodischarf

into amunicipal sewage treatment syst@m after first filtering out sol

material suctwmrrpetfiber. Access tothe sanifwy system can beobtaim

through atoilet, laundry drain, carwash drain, RV dump, etc. Permissi[

should first be obtained from any concerned party or agency.

One dis~sal rmtfwd which usually complies with the law isto accumula

the wastewater and haul it toan appropriate dump site. Another solution

the disposal pmblam is !0 equip yourself with an Automatic Pump-O

System. Thetm systems afie designed 10 remove wastewater from tl

tixtractor’s rwoovery system and actively pump the water through hoses

asuitable disposal drain. Properfydesignecf, they will continuously monii

tie Iml of wasttwvaler and pump it out simultaneously to the cleanil

operalion. Tim hidden benefit of this procm is thatthe operator does

have to stop his cleaning to empty the recovery tank. HydraMaster mak

an A.P.O. System available which can be ordered with new equipment

installed Iat@r.

Thi?penalties for nwr+ompliance can be serious. Always check local la’

and n?gufaticmsMbe sum you are in compliance.

MACHINE AthKISTMENTS

Although MS unit has been factory adjusted, it may require additiol

adjustmentsto achieve optimum performance; i.e.altitude may require u

adjustment and ambient temperatures may require heat control adju

ment. When required, cansult an authorized ~epresentative.

START UP

1.Perform daily/periodic mainttrnance as specifbd by the owrws manual.

2. Connect all required hws.

,3. Connect c!eaning tool to length of hose required to perform clwaning.

LMix tankmust&M/priorto @rithmr.

.Start engine (choke as required}. Engine is at operating speed (r@cam

mended -2600 RPM). Allow warm-uP period of 2-5 minutes.

I6. Spray wand to void al air from system: When the mix tank tmgins afill

cycle, the chemical flow meter may be adjusted to your desired setting.

NOTE: Recommended carpet cleaning pressure is 300 PSI.

7. Once all air is voided frum system, heatw may be ignited.

NOTE: Ifnot familiar with operation of this healer, 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 200W.

9. Commence cleaning operation.

NOTE: Chemical flow meter set at 5GPH isa 1to 30 mix ratio and 10GPH

is 1to 15 ratio.

NOTE: Hot cfbnate opw’ation [above 90°F].

When operating this unit inahot climate, HydraMaster highly recommends

some additional precautions.

1. Operate with side and rear doors fully open.

2. Vent heater through the top of van.

3. Ifvapor lock conditions arise, machine cover may need to be raised to

allow additional heat to escape from canpwtmt?nt.

NOTE: Cold cfimate operation (below O°F).

When operating this unit inacold weather application, HydraMaster highly

recommends some additional precautions.

1. Ifnossible carrv Your own fresh water SUDDI%

2. Hookup to ho~wkder source if possible to’keep your incoming garden

hose ~m freezing.

3. Do not close van doors in front of machine.

4. Be aware that solution lines laying on frozm ground may frewe.

5. Contact local propane dealer about cold weather propane use.

SHUT DOWN

1.Turn heater to ‘off” position. Spray wand for at least 3minutes to allow

the heater coils to cool.

2. Close valve on propane tank and through floor hookup.

3. Remove vacuum hose.

4. Flush clear water through chemical system for 10 seconds. (Vinegar

should be rinsed through system weekly.] Turnoff chemical flow meter.

5.Tumon cleaning tool toflush chemical from unit hoses and cleaning tool.

NOTE If freeze guard is necessary, perform steps 1&2of freeze guard

procedure at tlls time.

6. At this time, the blower should be lubricated with Pennz@xwd.

7. Shut engine down.

8. Drainvacuum tank. Vacuum filter should @cleaned prior 10mobilization

of van. NOTE Iffreeze guard is necessary, pwtorm st~ps 3-7 of fr@ez@

guard procedure at this time.

6

Vacuum

Hour Gauge Circuit

Meter, IBreakers

/

Pressure

Gauge, \I1’,J:ue/va:%Tank

Temp.

I

\\l l/~

Gauge ,,

Choke “

Vacuum Pump ;J

Lubrication Port &;

)~’

I

High Pressure ~]

Pump Switch ‘~l

#

!!‘/

$;

#

Machine _

Exhaust

/‘Machine‘vacuum‘ank

Incoming /1 Exhaust Dump Valve

Water Bv~ass

Hiah Pressure’ Valve

Cle%ing Solution

Chemical High Pressure Water Pump

. . —Water PumD Clutch

Engin6

/’

Heater Control Coupler \‘Freeze Guard

Valve Fitting

Vacuum Mix Tank

Hydra-Heater Pump Drain Valve

ENGINE COOLING

Units employingaircooledengines mustnotln? enclosed withina van with

doors and ~ndows closed. Excessive temperatures within the engine will

resultinpremature engine failure anda compromise ofappiicable warranty.

LEVEL OPERATION

During operation, van or tiailer must be parked on /eve/ ground not to

excwed +or -1P. Failure to insure proper leveling may prevent proper

internal lubrication of engine, vacuum anoYorhigh pressure components.

FREEZE PROTECTION

Mother nature oives little wamin~ as to her cold s@ls. Therefore, wtect-

irrg this equifient from fi’eezing will save cosfly down-time. Placing an

electric heater in the Puck or parking the truck indoors, will help to insure

against fleezing.

LIGHTING HEATER

Neverputyourface down close to the opening of the heater when lighting.

STRONG PROPANE ODOR

Never light the heater if you smell astrong odor of propane around the

heater.

HOT SURFACES

During the operation of this equipment many surfaces on the machine wili

become vetyhot. When near the vanforanyreason care mustbe taken not

to touch any hot sudace, such as heater, engine, exhaust, etc.

NO SMOKING

ftis unsafe to smoke in or around the vehicle.

7

MOVING PARTS

Never touch any pad of tie machine that is in motion, severe bodily injury

may result.

CARBON MONOXIDE

This unit generates toxic fumes. Position the vehic/e so that the fumes will

be directed AWAYfrom thejob site.

DO NOT PARK where exhaust fumes can enter abui/dif?g through open

doors or windows, air conditioning units or kitchen fans.

FREEZE PROTECTION

Any frw~zing of this machine is not covefied by warranty and during the

~ldelrmantisofo~mtion, careful protection should beof utmost concern.

THE FQLLWW4G PRECAUTIONS ARE RECOMMENDED:

1.Run machine befcm leaving for the first job to insure nothing hasfrozen

ha night lmfore, including hoses and wand.

2. Insulak the gafidt?nhose from the cold ground by running it through an

extra 11/2 inch vacuum hose.

3. In colder dirnates, insulating the truck walls and floorboards will help

prutoct the unit.

4, Don’tprocrastinate during thec!eaning operation or the hotwater solution

line will alw freeze an the ground. The solution iine should be insulated

in exlrerrmly cold climates.

!$.Whenever ~ssible, the truck and machine should be stored in aheated

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

apropane 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 aheater, you should first drain of possible water from the

machine cleaning tools and hoses. (They freeze also.)

TO DRAIN THE MACHINE FOLLOW THESE STEPS

1. Siphon a 50150mixture of anti-freeze and water through the chemical

ftow meter.

2. Drain the mix tank.

3. Connect Ma freeze guardhow?to the rwxwery tank.

4.Connect Ihecdher ond ofthe freeze guard fitting tothe freeze guard fitting

Iocatfid on the sido of the machine.

5. Connect an open 440 quick connect to the fittings marked “cleaning

solution” on the front oithe machine. (An alternative would beto connect

your solution hww and wand, was to freeze guard them also. Ifyou

choose todo thisycw will also need tohold the !riggerdown onthe wand.)

6. Start the unit, allowing the vacuum from the machine to drain the lines.

7.* Remove tfregarden hose inlet adapter from the end ofthe garden hose.

Conrmct the adapter to the incoming water quick connect on the front of

9hemachine.

8.’ Place avacuum hose over the garden hose quick connect and allow the

vacuum from the machine to drain the lines.

*i4nalternative to #7 &8would be lo make an adapter to allow you to us@

the premade freeze guard hose.

NQTE: Priortofreezo guarding your rnachinemake suretheheating system

has been cooled down.

ALTERNATE PROTECTION USING

ANTI-FREEZE:

1. Follow Wedraining procedure.

2. Cmnect solution hoses and wand tomachine.

3. Pour a50/50 ariti-$reeze sokJtion into mix tank.

4. Turn on machine and engage clutch. Spray the wand.

5.Continue to add anti-freeze solution until mixture comes out ofwand set.

6. Remove and store hoses.

If you are using an anti-freeze solution to protect your machine from

freezing. 1[is ne~ssary to flush the machine inpreparation for use. Simply

connect the unit tofresh water and spray the wand until anti-freeze solution

is discharged. The anti-freeze soiution maybe recovered by spraying into

an empty container. This solution can be used several times.

BE SURE IT’S PROTECTED! Freezing will cause GRIEF, MONEY and

DOWF&TIME. Don’t mess with Mother Nature!

CLEANING AND CHEMICAL

PRECAUTIONS

Yourmobile carpet cleaning plant has been engineered using the!at@stand

nest sophisticated technology available, to produce the finest carp@t

~eaning results possible. Despite this, however, itremains onlya toolofthe

xpet cleaning trade, and itcan produce only as good ajob as Me person

]Perating it.

Thereare not short cuts to good ca~t cleaning. Itrequirwstime, cleaning

mowledge and the use of good chemicals.

Themanufacturer recommends the use of spotting agents, and traffic lane

nleaners prior to the actual cleaning of carpeting, as required.

Theuse of some chemicals through your mobile carpet cleaning plant can

seriously damage the internal plumbing, high pressure pump and heater.

(Chemical such as concentrated acids, solvents, and some paint oil and

grease removers w/high cwwentration of solvents.)

The manufacturer recommends only the use of chemicals containing rust

and corrosion inhibitors and water softening agents to prevent chemical

build-up which may lead to component failure and warranty invalidation.

NOTE: At no time should achemical solution with apH of less than 7or

higher than 10 be used in the unit.

IpH CHART I

1234567891O 1?12 13 14

)I1I I III I IIII

+AOD -*

NEUTRAL ‘ALKALINE~

CLEANING STROKE

PROCEDUREIOVER-WEUING

PIJRPOSE:TOeliminate excess moisture rernainirrg inthe carpet fiber and

the sawtooth appearanw? which results from diagonal movement of the

cleaning tool on all types of carpet.

PROCEDURE: Always move thecleaning tool in smooth foward anciMck-

ward strokes. Apply slight pressureto the forward stroke while the solution

is injected into the carpet. When extracting (drying), applyfirm pressure on

the foiward stroke to ensure apositive “lock” for the vacuum and minimize

the “hopping” effect resulting on unsmooth carpet. During the forward and

reverse strokes, movement to the right or left should only be a~omplishexi

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 tie rear of the cleaning stroke.

Failure to adoot this mocedure can result in increased chance of “clean

streaks”, fiber’shrinkage, brown out, and longer drying pdods.

INCORRECT METHOD CORRECT MEWMN2

Overla~ Between Strokes

pfl~q-!,ir!‘<!,.

Cbanmg Cleaning

Stroke Stroke

8

OVm”wmmlci

Over-wetting isannoying to all concerned and sometimes leaves a bad im-

pression of the cleaning process used.

THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER”WEITING:

1.Too Iew vacuum strokes or improper sawtooth vacuum strokes as

shown in the previous illustration.

2. Obstructed, kinked or cut hoses.

3. Vacuum tank drain valve left partially open.

4. Clogged vacuum blower filter or vacuum tank lid not sealing propxly.

5.Cleaning aheavily foam-saturated carpet without defoamer. (We recom-

mend crystal type.)

WATER AND CHEMICAL 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 mix tank. As the water passes through the Chemical

Injector, it is automatically proportioned with apredetermined quantity of

detergent. The MixTank(3)isequippedwith twodifferent float switches, the

Water Level Float (4) responds to the level in the tank and will maintain the

proper volume of solution to be reserved for the water pump. The secon-

dary, LowWater Float switch(5) isasafetyswitch that isdesignedto protect

your system from sudden or unexpected loss of water supply. If, for

example, the water source at the house were turned off, the water level of

the mix tank would drop, activating the secondary switch, which automati-

callydisengages thesystem and pn?ventsthewater pump from running dry.

The desired chemical injection ratio may be obtained by an adjustment of

the Chemical Flow Meter (6)during the fillcycle ofthe mix tank. Water must

beflowing intothe mixtankinorderto adjustthechemical mix. Thechemical

will flow from the Chemical Jug (7) to the Chemical Flow Meter, then to the

Chemical Injector where it is proportioned into the Mix Tank at the desired

chemical setting.

NOTE: %Mththisuniquechemical system, thechemicalflow isproportioned

only during the filling cycles of the MIXTank, not during the direct spraying

ofthewand. Therefore, itis possible that as your wand is spraying, you may

have no chemical flow. Also, the converse is true in that you may not be

spraying your wand, but if the mix tank is in afilling cycle, your Chemical

Flow Meter may be active at the desired flow rate.

The chemical proportioning system will mix chemical with water ata 1to30

ratiowhen the Flow Meter is set at 5GPH, or a 1to 15 ratio when the Flow

Meter is set at 10 GPH.

Atthis point inthe flow, solution (water with chemical) will now be siphoned

from the bottom of the Mix Tank to the inlet of the Water Pump (8). When

the wand is not using solution by spraying, the solution will be bypassed

fromthebottom ofthe brass Pressure Relief Valve(9), back tothe MixTank.

When the wand is spraying, the solution continues its flow to the Water

Heater (10). The coils of this heater have acapacity of up to 2gallons,

therefore it is extremely important that all air pockets are bled out of the

heater prior to initial start-up. This maybe achieved by running the water

system, without the heater on, for approximately 80 seconds.

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 remov-

ing the clear plastic hose from the Chemical Jug and inserting it into a one

uart container of vinegar. This should be done with the Chemical Flow

!eter setting on 10 GPH and the Water Heater “off’. Simply spray water

om thewa~d until the quart ofvinegar isexhausted, the repeat the@wess

ith one quart of clear water to void all lines of vinegar.

Chemical System Wiring

Solenoid Valve

Relay ,.~

Float E,.~

Switch GND

X!/’ To Ignition Switch

88 ~. 85

h.

G~D ‘--l

‘..

Water Flow

11 -Pressure Guage

6- Chemical Flow Meter 12- Incoming Water

7- Chemical Jug 13- Tank Drain

8- High Pressure Pump 14- To Wand

+High Pressure +Low Pressure

Chemical Proportion and Level Contra\

M,, Tank

6FA-6UFS I$

=eCk=

fl

-0

~u

B.‘“’W’”’ B””’

Swng

oSIs Ball

&Check valve ;

*:5$3’’HeFj~jii$

g;zj_:Dlen;n

q~

,-,4, va,vech,y

Mo.n!tng

+wJw ,3)

(la ‘Water

Idet

—-, .— -

—.

+-=” –d

12 Voc Mo.ntlng

cm Plato

9

CHEMICAL TANK

TROUBLE SHOOTING GUIDE

PRQHLEW. Uttla or no chemical flow

%hldon

Chackthtat hoses af the Mix Tank(3) are secure. Check that the hose fromthe top

of tkw Flow MrXar (6) to the Chemical lnject~ (2) is seam with no kinks or

leaks, (M& thal the ad~ustingcap on tho side ofthe injector is INI!screwed

af!ttw way in.Clmcklhe $/s check vafveirw.idethe injedorforchemical build-

up and pqer qwration. Chec& the hose fromthe botiom of the Ffow Meter

to the Ctmrnicaf Jug (7) for kinks, cracks, or bubbles.

Cf’mckthwxraen ontheemdof thehose whichgces intotheChemicaf Jug. Tochack

thii scram forproper function, remove itkom Itw plastic hose. If you csnnot

blow Ihrough if,tti rinse ifout with vinegar.

Check the Chemical flow Meter (6) for obstructionsor astickingfloat.

Is incoming waler pressura less than 30 PSI?

Cracked wcle!ective Chemical Flow Meter (6)?

Check the fitterwren in the Solenoid Control Valve(1).

PROBLEM frmbillty to adjust chemical with the Flow Meter

Sahtion

Debrii Iodued &hind Mlon %at in Flow Meter valve.

Tdhm seat on the valve stem maybe hose. If deteriorated, replace O-Ring.

PHCWLEM: Solution rmmrsbrg from Mix Tank, ffllhrg the Chemical Jug

Sohlfk?n

Anti-siphon dwice cfogged by chemical build-up (Anti-siphon device is bcated in

the Chemical Injedor (2) body —see page 9, Water F!aw illustrakon).

Check for debrii.

PRQBLEM FAxTank overflows

mlution

Float awitc+r(4) inthe Mix Tank nd moving ireely, or d~fadive.

TochmckswitctrWNma 12voht@[ghiandtheilut inthe”up”position, there should

bpower through the swhh.

To check relay: First check wiringagainst dmgram. W* 12 volt lest fight,and the

FloafSw%ch(4} inIfre”up”posilierrthere sf?cmklNOT@owerat !heSolenoid

Vahw. Wth !he Float Switch inthe “down”position there should be power af

the SIoarwid Vafve.

EKderroidValve defectiwx Remove Solenoid Vafve, disassemble and inspect

diaphragm Iw cracks wtears.

PRQ5LE~ Mix Tank does not keep up with water output

SOlufhltl

Check incoming water pressure. Check gaden hoaa quickconned

assembfy screen.

Check garden hose ardor feed hose 10the Mix Tank for dog, kinks,

or blockage.

Float Swifd (4) inMix Tank hanging up (rmf moving freely). Check fifterscmn in

Solenoid Vafve (1).

Wand Valve Asswnbfy

Ekldy

-T

II I*C

Compression I

QI *=*I6

Fitting

~? *--~;~’ :11“?’<F~@

\

Spring

3’L%

.\ O-Ring

O-Ring iPlunger Quick

Connect

cap

[Cl-Ring

Keeper Ring

\

Jet Assembly Ekdy

Wand Assembly

Ha

‘b”

I

I

I

I

I

~

I

10

IWand Valve Stem Assembly

I

@+— Retainer

Keeper Ring ———+~

(

Plunger —

O-Ring

u

I

@— O-Ring

I

Bypass Valve Assembly

BYPASS PARTS LIST

REF. NO. PART NO. DESCRIPTfON QTY.

3OOO-105-1OI Thrustplate,Bypassvatve 1

4OOO-105-1O2 Piilon plate,Bypassvalve 1

5OOO-O78-1O1 Kt, sealfor Bypass vafve 1

7000-14B-oo4 Seat &C43ing, Bypass vafve 1

8000-097-005 O-Ring, Bypass valve fitting 1

WATER FLOW TROUBLE SHOOTING GUIDE

PRoBLEkk LOSSof pressure

Cslrse solution

=ve or blocked check vafves in highpressure pump cyfinder head. Disassemble cylinder head and replace or cfean applicabfa check valve.

Delaminated, Idnkedor dogged hose between the mix lank and fhe high Remove and replace defective hose.

pressure pump,

Defective pressure refief valve or debris inpressure relief valve. NOTE lle high Disassemble and clean pressure relief valve as illustrated in drawing above.

pressure bypass vafve is desgned to fully dose when the cleaning teal is

turned on.Any foregn matter colleding onthe pistonwillprevent iullclosure Replace defective or worn out bypass cup.

offhe valve id allow aportionofthe water to continueto circulate instead of

being routed to the ciaaning tool. To correct this situation, the bypass vafve Replace bypass valve.

must be disassembled and dearrad (refer to illustrationprovided abve for

bypass disassembly).

Oelective or worn cups. Remove and replace piston cups as defined by pump manuat.

Loose driie belt Ior highpressure pump. Readjust belt as required or replaos ifdefective.

Pump inletYstrainer dogged Check lank for water. Clean strainer. Clutch disengaged?

PROBLEM: Excessive water flow

cause Solution

Worn out spray jet. NOTE: Cleaning toolsdesigned to spray aconstant fbw of Remove and replace spray jet.

1112GPM willaverage 1gafbn of flowper minute inadual working situations

sincelbwis notcontinuous.An average flowof 1GPM resultsin6000gallons

offbwforevery 100hoursof unito~ration. Spray tipsarecapableof fbwrates

forapproximately 20,000 gallons.They shouldberaplacedtherefore, approxi-

mately every 350 hours,Worn spray jets allow agreater average rate of flow

thus reducing desired temperature fevels.

Reduction of flow. Due to increased length ofsloutionhose. NOTE For every 50feat ofhose, bevond

,

100faet intotdlength,ame~urtile losoffbwisexpenencd. Ttiscondition

is aresult of the increased fridion experienced by the water as it passes

through the hose. Therelore, if is necessary to increase the pressure at the

machine 40 PSI for every additional 50 feet of cleaning solutionhose over

100feat.

11

—

VACUUM SYSTEM INFORMATION

The vacuum blcwwrincmporated inthis machine isapositive displacement

Iokwtype, manufactured by Cooper Industries. The performance and fifeoi

this unit is gfieatiy dependent on the care and proper maintenance it re

Ceiv@$.

Becauw?of the CIOWtcdmum.esbetween the lobes and housing ofthe vac

uum blower, did objects entwing the inlet will damage the internal lobes,

g~ars and bearing or direct drhm coupler.

To p~eventthis, astainless steel filter screen has been placed at the vac

uurn inlet inside the vacuum recovery tank. This stainless steel screen is

finger tight and should be removed for cleaning weekly.

When machine is Ming run fir iesi purposes and the vacuum inlef on fo~

of machine is open, caution should h? used.

To protect Ih@vacuum blower from overloading and damaging itself, thert

isavacuum rdi~f sys!em installed on the vac tank. When the vacuum tan}

inlet is completely sealed off, amaximum of 14 HG will be attained. Ahok

on thetop blower pipe eltmw acts as the lubrication point. Attheend ofeact

day, LPS 1or Pennzguard should be sprayed in before shutting down th[

machine. See blower lubrication W4ration. If you fail 10Iubricaie tfw

vacuum blower daily, rust doposils and moisture will decrea~ the lifeof ttw

vacuum Mower.

Read thevacuum blower rnanualcarefully forpmperoil change and greaw

application. The maintmarm log may differ slightly from the manual, bu

the truck-mounted carpet cleaning machine application isvery demandiry

of thevacuum blowerandtherefore itshould be maintained more regularly

NOTE: Vacuum tank isprotecfedfrom ow?rflowirrgbya vacuum tank, flea

kill swi[ch. This swiich is not acfiwated byfoam, only byliquid.

vacuumFlow

S/S Filter Recovery Tank

\Filter Bag

/

MXIUM TANK FILTER BAGS

/drafdasler filter bags are designed to trap all ofthe lint, sand anddirltha!

wld normally collect atthe bottom of your vacuum tank. The w? of these

lgs, if emptiid at the end of each job; will eliminate the build-up cdmuch

thedebt%

inthe tank. Th@drawstring top of these bags isckmigrwdto be

dto the incoming dirty water inlet in the vacuum tank.

Jreorder bags use part number 049-029.

Vacuum Tank Filf@r Bags

.Vacuum Tank MM

\:7

Blower LubePort

I

\/

L

Spray lubricant into bloww’ lube port for 3to 5seconds,

then immediately shut off machine. Use only LPS 1or

Pennzguard moisture displacing lubricants.

12

VACUUM BLOWER WARRANTY

FULLERwarrants products of its manufacture to be free from defects in malerial and workmanship if properly installed, maintained, arid operated

under normal conditions with competent supervision.

Noperson, agent, representative or dealer is authorized to give any warranties on behalf of FULLER nor toassume for FULLER any other liability

in connection with any of FULLER’S products.

This warranty shall extend for two (2) years from date of installation provided this equipment has been put into servicw within six months after

shipment from tie FULLER factory. If repairs or replacements are made by the Purchaser without FULLER’S prior Mitten consent, FULLER’S

warranfyshall cease tobeineffect. Noallowance will begranted forany repairs oralterations made bythe Purchaser without FULLER’s priorwritten

consent.

Machinery, equipment and accessories furnished by FULLER, but manufactured by others, are warranted only to the extent of the original

manufacturer’s warranty to FULLER.

FULLER agrees at its option to repair at the point of shipment or to replace without charge f.o.b. point of shipment, any part or parts of products

of FULLER’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 limited to repairing or replacing of the defective part or parts as aforesaid, f.o.b. point of shipment.

No liability whatsoever shall attach to FULLER until said products have been paid for. EXCEPT AS STATED IN THIS SECTION AND IN THE

PRECEDING SECTION TITLED ‘WARRANTY’ AND EXCEPT AS TO TITLE, THERE ARE NO GUARANTEED OR WARRANTIES OF

MERCHANTABILITY, FITNESS, PERFORMANCE OR OTHERWISE, EXPRESS, IMPLIED OR STATUTORY, AND FULLER SHALL HAVE NO

LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR OTHER DAMAGES, HOWSOEVER CAUSED.

DATE INSTALLED MODEL SERIAL #

FULLER COMPANY 2966 East victoria Street Compton, California 90224

VACUUM BLOWER LUBRICATION

At the gear end the timing gear teeth are lubricated by being partially

submerged. The gear teeth serve as oil slingers for gear end bearings. At

the drive end of 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 tomaintain

proper level. The oil should be drained, flushed and replaced every 1500

hours or more frequently if inspection so indicates. 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 agrease 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.

.

Vacuum Blower Motor Lubrication

1

13

VACIKJM BLOWER TROUBLE SHOOTING GUIDE

PIW5LEM Loss cdprw$si.irn

Carkm Solution

Collapsed vacuum hose between blowm and vacuum kink. Remove and replam hose. NOTil A.speckdr@irrfcmd hose is requirwd

for replacement.

Chfjgad skddese steel Ikmr, Remove and dean or replaca stainless steel filter.

IMwAive vacuum lank seat. Remove and raplw vacuum lank seal.

Dekctive or %p@ vacuum tank pump valve. Close valve.

Replace valve.

Fraclured weld on vacuum tank. Re-weld as required or replace tank.

Gallapsed wkinked vacuum hmw. Reshape h= ifpo~ibla andlor eliminate kinks.

P%Jggedvacwn hose. Remove obstructionsby reversing the vacuum hose.

Restriction in cleaning tool. Remove obstruction.

Worn @ndplates or lobes in vacuum blower. Replace worn components. NOTE Must be accomplished bya qualifiedtechnical,

IM3ctive relief valve. Inspect and replace if necessary.

WNIBLEW B!mver k+seized

Cause Solution

Rust. Spray rusI dissolving lubricant onto lobes to emulsify rust and attwnpt to ro$at~

vacuum lobes.

Foreign matter. Disassambieand remove foreign matter and reptiras r~quired. NOTE: Disassem-

bly must be accomplished by qualified tedrrrican.

tite: fie ahvernwrtiorred, Nst foreignrmaftt?rarrdseizingare oftencausal from

foam traveling through the Mewer.

lWOtN.EW Nab in vacuum blower

calm Soiutfon

Worn gears. Remove and rap[~ gears. NOTE: Replacement of gears must be accoinplishwl

by qualifii tedrnicarr.

Timingofvacuumblowerhasbeen changed duetow-orncomprmnts. Replacement

of components must be accomp!iihad by qualified technican.

Lack of lubrication. NOTE Permanent damage may have resulted from lack Lubriite as specified by applicable vacuum blower manual. Sea index.

of lubrication.

wormbwing$. Remove and replace bearings as required. Must be accmpliihad by qutified

technican.

Ikbris and/or foreignmaterii build-up. NOTE: Asfahdess steel filterisprovided in Disassemble vacuum blower and remove foregn materii. NOTE: DkmssomMy

vacuum inlel located in vanmm blower carnpcments. should be accampliihsd by qualified $echnkxrr only, Replacemwrt of worn

parts is nwssay.

Lcme ar missirmgmmm[ing bats. Tighten or reinstall mounting bolts.

I-IEAIING SYSTEM INFORMATION

The propane heater incorporated in tfls equipment is aspecial design for

WM?inthe carpet cleaning industry. It’shigh pressure coils and thermostatic

temperature control make itsimple tooperate andreliable. Once thedwired

temp%ratumis set,theheater willthen go ‘em’and ‘off’according tothewater

terrpwatum within the heater. As water is wed through the cleaning tool,

cold water entwing the heater will activate the thermostatically controlled

propane valve thereby firing the heater to maintain aconsistent flow of hot

wattw. Once the cleaning wand is shut off and the flow ofwater through the

kmater stop% the treater will continue to burn until the set temperature is

attainfid.

Itis pwsible with this design that the flame may be on when thewand isoff,

likewise, it is passible the flame may be off when the wand is on.

Thisheaferis designedfo &urrJvaporproparreg’as oniy Anyiiquidpropar?e

entering the healer may cause damage to tfm contmi valve on the heater.

tt wili also cause improper burning and a soot buiki-up on the coil,%

Therefore, if is necessary to shutoff fhe h@a@rand close tho waiveat th@

tarrkbetween ciearring icmations. Failure to do ff?isaliows sloshing /iquid fo

enfer the vapor feed iine to the heater.

IMPORTANT: Overfilling ofthe propane tank will caus$ many problems. To

avoid this, advise the attendant filling the tank not tcttill the tank mrer$tl%.

When filling thetank, watch the 10%valve and immediately stop fillirtgwhen

14

white fiquid starts spurting from the 10% valve. To prevent damage to the

propane regulator, always cfose the valve on the tank before fflfing.

The propane regulator is pre-set at the factory at 6oz. of propane. This

reading is taken at the control valve on the heater (see figure ANo. 6). To

prevent road dust and moisture from entering the propane regulator, keep

the white plastic cover (supplied) on the regulator at all times.

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.

lMPORTANf7 Ifa newpropanetank has been installed orhoses havebeen

disconnected, air may enter propane hoses and must be purged prior to

attempting tolight 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 15second intervals. Avery slight hissing noise should be evident while

performing this operation.

Check heater forpropane leaks regularly as loading andunioadinghoses,

tools, etc., mayaccidentally bump against heater fitting or pipes.

HEATER OPERATING

INSTRUCTIONS

Heater must be fi)led with water prior to igniting.

A. TO START PILOll

1.Adjust thermostat control knob on unitrol to desired setting (#3).

2. Adjust upper dial to pilot position (#l).

3. Depress pilot button (#2).

4. Depress sparking button to fight pilot (#4).

IF PILOT FAILS TO LfGfiT:

Is propane tank full?

Is propane tank valve open?

Has air Men properly bled from propane line?

Is igniter system working?

WHEN PiLOTUGH7S:

Wait ten seconds, depressing button manually, then release button.

Always keep face away from main burner opening to avoid ignition

flash bum.

B. TO UGHT MAIN BURNER:

1.Turn up~r knob to “on” position. Flame will come on.

Ifyou do not get the burner to flame, the pilot has expired. You must turn

upWrdial to“or position. Donotattempt to re-light the pilot fort24seconds.

To fightthe main burner, repeat instructions as above (TO START PILOT),

1through 4.

OR,

Water may already beat controlled temperature.

Flame will turn off when thermostat senses maximum temperature.

C. TO ACHIEVE PROPER CARP~ CLEANING TEMPERATURE:

1. Complete procedures A & B.

2. with 100’of hose, turn cleaning wand on for 5minutes and the

temperature should stabilize.

3.Oncea constant temperature isestablished, turn cleaning wand ‘off’.The

flame on the heater burner should remain on for 10-15 seconds.

A. Ifthe flame expires prior to 10 seconds, turn the thermostat dial to

ahigher reading, then repeat C1-3.

B. Ifthe ffame remains lit after 15 seconds, turn the thermostat dial to

alower reading, then repeat C1-3.

D.TO SHUT DOWN HEATER:

1.Turn upper dial #1 to ‘off’ position.

2. Tumcieaning wandon for3 to5minutestocoo/heatercore. Ifi?eafercore

isnotcooled, itispossible tha(theheat retainedin the core wiilcause boiling

back into achemical mix tank. This results in damages to Cat pump.

3. Close propane tank valve while

wand is on the heater is coofing.

PILOT BURNER ADJUSlllENT:

1. Remove pilot adjustment cap #5.

2. Adjust pilot key to provide properly

sized flame.

3. Replace pilot adjustment cap.

Allen head pipe pfug #6 can be

removed for monometer insertion

to read propane ounces.

HEATER TROUBLE SHOOTING

PROBLEM: Excessive heat. Flamesprotruding outside theiower openings.

Csuee/So/ution

1. Maladjustment of propane regulator. tWTE Propane regulators are factory

preset and may be readjusted by authoriiad personnei.

A. Contact manufacturer to determine correct procedure.

B. Have your local prcpane deafer use amarromeler at the Unitrolto reset the

propane ragufaforto 7oz. maximum.

2. Overfilled propane tank. Propane heaters are designed to operate on vapor

propane only. Overfilling apropane tank affows ~quid propane to enter ail

heater reiatad components and permits an over-rich burning condition to

occur. This condiion usually requires the core to be deaned of soot and

carbon dapadts. Cleaning isamessy, dirtyjob and very inconvenient, so do

not iet if happen to you!

PROBLEM Pilot light

Cause/Solution

1.Pibt lightwillnotignite.NOTE: Do not use anaedleorpin to dean pilotorifii—

use compressed air or solvent only.

A. Verify propane reaching igniter. NOTE Atinkad or crushed hose may

impede propaneflow.

B. Remove and clean orifii.

C. Verify igniterspark is operating correctly.

15

CAT PUMP MODEL 290

OPERATING Ihlsmwmolw

CAT PUMPS am positive dispkwrmti pumps. Therefore, aproperfy

desigr?ed prt?ssurt?relief mffchanisrn IUUST be irstalled in Me discharge

piping. Fajlure toinstall suchmliefmechanism ~uidmsultin~rsonalinju~

ordamage to ffwpwnparsystwn. Cat Pumps CorporabOndoesnot assume

afly liability ormsfxmsibility forthe operatiorr ofacustomer’s high pressure

system.

Pracfuctsdescribed hereon ar~covered byoneor more ofthe following U.S.

patr?rls: 3558244,3652188,3809508, 3920356, and 3930756

.~..

,. p#ziltH3ilm*y

C0F7P0RArt0N

PO 130K BS5 MINNEAPOLIS MN 5S440

PbmIfI (6 12) 780.s440 —Telex 290278

aNVCAT PUMPS INTERNATIONAL SA*

Hmmonmstraat 29

82LlQtJAntwerp, 13elgwm

Phone (03) 2377224 -T@E,x 33947

*CAT PUMPS — AG 0

LorelohOelIe 5

CH.63CQ ZUG. Swtzerlana

Phone (42) 213140 – Telex 865 160 CPag ch

OCAT PUMPS DEuTSCHLAND Grnot+@

ROSlocker Sttesse g

62L12 Wlesbaden BIef3tadl West Germany

Phone 0612.5600 01(2 –Telex 41 86713

-CAT PuMPS [U K) LTD 0

27 Stallon Ina.strml Estets, Flee!

H.9MD9hW3 Gu13 8QY.EnglamJ

Phone Fbl 22021 – Telex 8SSS93

SPECIFICATIONS

Volume: 3.5 GPM (13 UM)

Discharge Pressure: 1200 PSI (83 BAR)

Maximum inlet Pressure: -8.5 to+ 40 PSI (-0.6 to +2.8 BAR)

RPM: 1200

Bore: 0.78~ (20mm)

Stroke: 0.472’ (12rnrn)

Crankcase Capacity: 10 oz. (.3 L)

Maximum Fluid Temperature: 1800F(71°C)

Inlet Port (1): 1/2” NPT (1/2” NPT)

Chemical Injection Port (l): 1/4” NPT (1/4” NPT)

Discharge Ports (2): 3/8” h!PT(3/8” NPT) (l): 1/2’ NPT(1/2’ NPT)

Pulley Mounting: Either side (Either side)

Shaft Diameter: 0.65(Y (16.5mm)

Weigh& 12.1 Ibs. (5.5 kg)

Dimensions: 10.77’’x9.08’’x14n4n(273.5x230x130 .5rnm)

CAT IPUMP WARRANTY

This Cat Pump (“product”) is warranted by the manufacturer to be free from defects in workmanship and material for orw year hum dat~ of

manufacturer’s shipment. This warranty is limited to repairing or replacing products which manufacturers investigation shows were defective

al the time of shipment by the manufacturer. All products subject to this warranty shall bt?returned F,O.B. Cat Pumps Corp., Minneapolis,

Minnesata 55430, U.S.A. for examination, repair or replacement

The express warranty set forth herein is in fieu of all other warranties, express or implied, incfuding without limitation any warranties of

merchantability or fitness for aparticular purpose and all such warranties are hereby disclaimed and excluded by the manufacturer. Repair or

replacement of defective products as provided above is the sole and exclusive remedy provided hereunder and the manufacturer shall not be

Iiablo for any further 10ss,damages or expenses, including incidental or consequential damages, directiy or indirectlyarising from the sale or

use of this product.

This warranty is subject to the following warranty conditions:

impmlant Conditions- LUBRICATION -fill crankcase to the top of oil gauge window per specifications with Cat Pump oil or equivalent SAE

40 weight hydraulic ail with antiiear and rust inhibitor additives. Change initial fill after 50 hour run-in period. Change oil every three months

or at 500 hour intervals thereafter. FWrrrn-a-lube seals need no lubrication. Blue dot seals and wick must receive three drops of Cat Pump oil

per wick every 50 hours of operation.

GCXMILUBR1CATK3NISTHE EASIEST, MOST EFFICIENT AND LEAST EXPENSIVE OF PREVENTATIVE MAINTENANCE.

RPM and PRESSURE -Pump operation must be within RPM and pressure specifications. Pressure relief valve must tw installed.

00 NOT PUMP ACIDS OR ABRASh/E FLUIDS with this unit. Consult Cat Pumps for additional information on questionable fluids.

FREEZING CONDITIONS -Pump must be protected from freezing conditions.

USE CWOTHER THAN CAT PUMP PARTS OR THEIR EQUIVALENT VOIDS THE WARRANTY

16

—

,

PISTON MODEL 290 Exploded View

—. ——— .—— ———

PARTS LIST MODEL 290

fTEM PART NO. DESCRIPTION QTY.

1 202e5 O-Rino (Buns-N\ 1

244274 Crankcaee 1

385880 Stud (M8 X82) 2

444377 O-Ring, oilfillercap 1

544374 Oil fillercap 1

843340 O-Ring, crankcase cover 1

9 43339 Crankcase cover 1

10 43987 Bubble oilgauge 1

11 23170 O-Ring, drain plug t

12 25625 Drain plug 1

15 92520 Sems comb head screw (M6 x20) 6

16 438o4 Crankshaft 1

17 14487 Rearing 2

18 24159 Oil seat (Buns-N) 2

19 2653$ O-Ring, oilseal case 2

20 27950 oil sealcase 2

21 92519 Sems comb head screw (M6 x16) 8

23 101789 Conneding rod 3

25 lMkUt

24 Iolmo Pston rod 3

Pston pin 3

26 20017 Seal washer 3

27 25301 oil seal 3

28 25327 Barrier slinger 3

29 25392 O-Ring, sleeve 3

28771 O-Ring, sleeve (Viion) 3

30 29003 Back-up ring, Sleeve (Teflon) 3

31 29614

32 26854

33 28597

34 25128

25635

Sleeve (28743 Unchromed) 3

Seal washer 3

Seat relainer 3

Inlet manifold 1

Inlet manifold -stainless steel 1

fTEM PART NO. DESCRIPTION QTY.

35 30315 Prrrrrm-A-Luba seat 3

30325 Prrrrrm-A-Lube seal (Won) 3

38 27004 Intel valve 3

39 30543 Bat$-Cuppiston 3

40 30544 Bat-Cup ring (Teflon) 3

41 43172 Cup (Viton) 3

43474 t3ac-Cup assembly 3

42 27983 Piston spacer 3.

43 27002 Pston retainer 3—

44 27006 Conical washer -s/s (M6) 3

45 270Q0 Nut -S/S(tvf6) 3

46 14156 Cotterpin 3

47 101802 Cylinder (43834 Unch) 3

48 23172 O-Ring, cylinder (Buns-N) 6

11377 O-Ring, cylinder (Viton) 6

49 21985 Bat-Cup ring,cylinder 3

50 24459 Discharge manifold 1

25634 Discharge manifold -SIS 1

51 43442 Vaive spring retainer 3

52 43360 Valve spring 3

53 43723 Valve 3

5443434 Discharge vatve seal 3

58 81108 Hex nut (M8) 2

57 101804 Hex flange nut (M8) 2

58 25130 Shaft protector 1

Electric Clutch Assembly

59 152-005 Tapered sleeve 1

80 077-005 Key, electric clutch 1

61 036-005 8’ elednc clutch 1

62 143-084 8-30 mm socket head screw 1

63 174-004 Flat washer (5/16 US) 1

64 174-018 Lock washer (5/16 US) 1

17

GENERAL INFORMATION

FOR CAT PUMP REPAIR

As you mwnow!ym.trdischarge manifold, there is aset of 3check valves

{which usually fall OUIduring dis-assarnbly). Ifthe surfaces of these check

vtives am dirty, OFshow signs of chemical build-up, it is pmbahle that they

would mrnain awn causing pmssum Iossc!r pulsation. Upon inspecting the

valwas,make sum Ihatthe tefkm button inthevalve spring retainers are still

intact. Also examine the discharge manifold. Look for problems such as

cracks, chwnical buildup or warpage ch.mMhewing. If this discharge

manifold is warped, itwill cause th~ check valves to stick and will result in

loss of pnlssure.

The Cat pump cups am Men the source of pressure loss. Upon inspection

they rnayappearmeked ortorn, but often they will look good. Replace them

anyway. Thereisrw sure rnethodofvisualfyinspecting thecups. HydraMas-

tw recommends changing cups whether they look good or not.

Anytim@your pump is being dismantled, HydraMaster recommends re-

placermnt dall ‘o’ rings and seals. This is merely aconvenience to the

customer to make sure that the Cat pump is in top operating condition.

The Prmwm-A-Lube Mals located within the intake manifold will atlowair to

@nt@rthe pump if they are vmrn. Again, it is difficult to visually pinpoint a

defective Prrrrrm-A-Lutw seal. Replace them al.

Repairing of Cat pumps is not adifficult task. However, before disassem-

Ming make swa you hava tie proper parts required.

1- ShOti (Of hot) CLd kit 6-piston sleeve ‘o’ rings

3- Prmrrn-A-Lube seals 1- bottle Cat oil

Readinstructions thoroughly, suppfied in the Cat pump manual prior todis-

assernbly and fallow directions as stated. Oilall seals thoroughly ~“or toin-

stallation. (Remember, anewiy scarred seal is no better than one you just

took aut.)

SERVICING THE VALVE

ASSEMBLIES

DISASSEMBLY

1.Remove th@fastmers securing the discharge manifold to the crankcase

of the pump.

2. Support ~discharge manifold and tap from the bac~lde and a soft

mallet to separate hum the crankcase and gradually work free from

qdh’ld$rs.

3. Valve assemblies will remain in the manifold. Pump models with the

o-ring groove an lhe outside of the valve seat require the assistanw of

areverse pliers to remove the valve seat. The valve, spring and retainer

will then fall out wlwn the manifold is inverted.

Pump models without the o-ring groove on the outside of the valve seat

pwmii the s@a~valve, spring and retainer all to fall out wf’ten manifold is

inwwted.

mmsfihllm~

1.Place retainers in manifold chambers.

2. Next insert spring into center of retainer.

3. Inspect tie valv~s for wear, ridges or pitting and replace if necessary.

NOTE: Seating side of flat valves may@ !apwd on flat surfa~ usin9 24c

grit paper. Quiet valves due to their sha~ must b? replaced. -

Insert valve over spring with recessed (dish) side down.

Nextexamine the seating surface of the flalvalve seats and lap with ?.40

grit paper or replace if evicklnco of excessivw wow. (Met valve S43ats

should be replatwd if vmrn. Lap new quiet valve and seat to assure

positive seal.

Some pump models have o-rings for easa of installation and to avoid

damaging elastomers.

DTE First install o-ring ingroove on sea! (towards seating surface), then

back-up ring.

DTE: Modelswithout outer groove on mat require the o-ring to beplaced

on lip of retainer.

Insert valve seats into manifold chambers.

Position manifold back onto pump.

OTE: Lubricate o-rirms on cylinder and exercise caution when slkmino

manifold over cylind~rs to avoid damaging cylinder o-rings. ‘‘ “‘

Replace fasteners and toque per specification chart.

OTE: Replace all original shims when used. When new manifold is used

reshim pump.

L5ensfartirrg thepurnp, chock tos@ethat there isrm qdindermotim? as this

ill cause premature failure of the cylinder o-rings. Cmmwcylidw motion

mbe eliminatedbyswitchingwithoneoftheendcyhders.

Pumping Section Cut-away

Bat-Cup

Piston Spacer /’

I13ac-CupRmg

iston

‘“i’*“R”ds’eev”

f

Cylinder’

76-001 @Kit

Cup6O-Ring, Cylinder

Cotterpin

Instnrdion Sheet

Cup Inserter

76-W3 Seel Kit

Prrrrm-A-Lube Sesl

COth@n

Abrasive Paper

InstructionSheet

0431Steeveand SealKlt

Prrrrrn-A-Lube Seal

Barrier Slinger

C##:in

O-Ring, Sleeve

Instruclkm Sheet

07s-006 valve Kit

3Velve Spring Retainer

3Vehw Spring

3valve

3Velve Sesl

3O-fling, Cylidw

1kwtrucikm Sheet

306$0 PI$tmn Kit

6O-Ring, Cyliider

3Back-l@ Ring, Cylinder

3Bac@up PkM2n

3Bat-Cup Ring

3cup

3Piston S+nacar

3F%stoInRetainer

3Cankal Washer (M6)

3Nm (M6)

3Catterpin

3Inlet Vaks

1InstructicmSheei

SERVICING THE PUMP

DISASSEMBLY

1. Remove discharge manifold as described.

2. Grasp cyfinders by hand and with an up and down motion, pull cylinders

from inlet manifold.

3. Remove cotterpin, nut, and washer from piston rod.

4. Next remove retainer, spacer, and piston/wp assembly.

5. Remove inlet valve.

REASSEMBLY

?.Examine inlet valve surfaces for pitting, scale or grooves. Reverse valve

and sand infet side of valve using 240 grit paper for clean surface or

mpiace if evidence of excessive wear. Slip onto rod.

2.Examine piston seating surfacesand sandcleanonflat surface using240

grit paper. Ifextreme pilling or shar edges, replace piston.

3. Examine cup for wear, cracking, tearing or separation from the piston.

Ifworn replace and lubricate before installing on piston

NOTE CUP lNSTALLATfON: Wipe cup inserter with oil. Slip bactup ring

(when used) onto piston. Push cup over inserter and square with all

surfaces. Faulty cup installation causes premature cup failure.

4. Next replace piston spacer and retainer on rod.

5. Replace washer, thread on nut and torque per specification chart.

NOTE: Always replace with new StaMess Steel CotterPin and turn

ends under.

6. Examine cyfinder walls for scoring or etching which causes premature

wear of cups and reptace if worn.

7. Lubricate cylinder walls for scoring or etching which causes premature

wear of cups and repface if worn.

8. Position discharge manifold onto pump, repface fastenersand torque per

.

SERVICING SLEEVES ANI) SEALS

DISASSEMBLY

1. Remove discharge manifold and piston assemblies as descritxd.

2. Remove inlet manifold containing seals.

3.Grasp steevesand witha pulfing and twisting motion remove the sleeves

from the piston rod.

NOTE Grasp sleeve with pliers only if reptacing worn sleeves, as this

procedure will mar the sleeves.

4. Next wmove seal retainer,

5.Remove and examine o-rings and/or back-up ringson piston rod forwear

and replace.

REASSEMBLY

1.Lubriite newo-ringsandorback-upringsandsliponto piston rod. Install

the first o-ring inthe groove on the piston rod. Next position back-up ring

against the shoulder in front of the first o-ring. Then install the second

o-ring. Exercise caution as you slip the o-ring over lhe thread end of the

piston rod.

2. Examine sleeves for scoring or etching and replace. Immerse sleeves in

oil and carefully twist and push sleeve onto rod (machined counter bore

end first).

3. Next install seal retainers. Ifwicks are used, replace wicks, thoroughly

saturate with oil, place in seal retainer and install retainer.

4. Placeinlet manifold onpairof clearance blockswithcrankcase sidedown

and drive out old seals.

5. Invert inlet manifold with crankcase side up and install new seals.

Lubficate circumference of seal and install Prrrrm-A-Lube seal with

garder spring down. Ifusing blue dot seal, blue dot should be facing up

when installed.

6. Stiplubricated seal inserters onto piston rod ends, position inlet manifold

onto pump and remove seal inserters.

NOTE Replace original quantity washers on studs before replacing inlet

manifold.

NOTE: Some models secure inlet manifold to crankcase. Replace

fasteners and torque per specification chart.

7. Reassemble piston assemblies and discharge manifold as described.

SERVICING CRANKCASE

1.White inlet manifold, sleeves and seal retainers are removed, examine

crankcase seals for wear.

2. Check oil level and for evidence of water in oil.

3. Rotate crankshaft by hand to feel for smooth bearing movement.

4. Examine crankshaft oil seal externally for drying, cracking or leaking.

5.Consult factory oryourlocal disttibutorif crankcase service isevidenced.

19

CAT FWMPTROUBLE SHOOTING GUIDE

FRCMILEW pulsation

Csrma sdufkxr

Llabrisirldiiharge Vafvee of prmp. Ckrarror replaca discharge vafves.

Worn F%rrm-A-Luba saals. Replace.

PFWMWEM: Law mrrswrm

Cmrsa ‘Sohrtkrlr

WwriMlozzkl Replace nozzle 01propar size.

Belt slippage. Tighten or replace; use corwcl belt.

Mleak in infrdplumbing. Disassemble, reseal, and reassemble.

Relief vafve stuck, parmiaf!yplugged or impropdy adjusted; valve seat worn. Clean and adjust relief vdv~ check for worn and dirtywtve wits, Kti avahl%.

Mel suction strainer clogged or improper size. Clean, Use adequate size. Check more frequently.

Wormpiston assmbly. Abrasives inpumped fluid or serve cavitation, Inadequate Instaflproperfifter. Suclionat inletmanifold mustbe fimittitofiftfng lessilmrr20fe$t

water W@y. of waler or -8.5 PSI wmr.rum.

Fouled csdirty inlet wdhcharge valves. Clean inlet and disdrarge vafve assernbfies.

Ld%y db~ hose. Replace worn vafvss, vahreseats.

Raplarx dischwge hose.

tWIHLEhk IWrmr runs wdrentrdv rrmah. twessura Is verv low

-d inletor air wdering the infe!plumbing. -

Proper size inletp[umbing; check for airtight S@

Intel restridions andhw air Iwks. Damaged oup or stuck inletor discharge vafve. ReplaccIworn cup or cups, clean out foreign material, replace worn valves.

Worn inlet manifold seats. f%mrn-A-Luks. Recdars worn waka

PHOBLEM Cylinder (l-Flings blown next to discharge manifold

Gwrstr Solution

%sstwas inexcx3ssof rated PSI. Check for plugged nozzle, dosed vafves or improperly adjusted bypass valve,

Warpad manildd, Freezing. Replace manifokf.

FWCNUEM: Leakage at tf’mcylinder C&RIngs at the discharge manifold and

black, powdory @stanca In the areaof tfm O-Ring -

fame Solution

-~finders. Cyfinder motion causal by improper torque on the dischwge Retighten. Do nottightentoo muchortheears ofthe manifoidwil[bebovwc, causing

manifold. looseness inthe center cylinder,

PROBLEM Watar leakage from under the inlet manifold

Cmrsa !blu tion

---------

Worn mht manifold seats. l%rm-A-LutM. Leaking sleeve O-Ring. Installseals, Ifpistonrodsleeves are scored, replarx sleeves and SIWMWO-Rings,

PFWXW.EM: ClllIoak betwrm crankcase and pumping section

Carrsw !%luiian

------- ..

Wkwncwrnkcase piston rrxl seals. Replace crankcase piston rod seals.

fWt2f!fl.Ekk LNlleaking In the ma of the crankshaft

Cares Solution

Worn crankahafl swd or impmperlyinstalled oilseal retainer packing. Remove oilseal retainer and replace damaged yrs.lwt and/or ~als.

Badbearing. Re@ace Mwing.

xi

CAT PUMP TROUBLE SHOOTING GUIDE

PROBLEM: Exceealve r)lav In the end of the crankshaft oullav

!. ,,

cause Solution

Worn bailbearing from excessive tension on drive belt. Replace ball bearing. Property tension belt.

PROBLEiW Water In crankcase

cause Solution

May be caused by humid air condensing intowater inside the crankcase. Change oil at 3month or 500 hour intervals using Cat pump crankcase oil (other

qqwovad oilevery month or 200 hours) P.N.: 06100.

Leakage oi manifold inletseals arrd/orpiston rod sleeves (Ming. Replace seats, sleeves and O-Rings.

PROBLEM: Oil leaking from underside of crankcase

cause Solution

Worn wankcasa piston rodseals. Replace seals, sleeve and O+tings.

PROBLEM: Oil leaking at the rear portion of the crankcase

Cerise Solution

Damaged or improperly instatledoiigauge or crankcase rear cover O-Ring, and i%piace oil gauge or cover O-Ring, and drain plug O-Ring.

drain rriuaO+ina.

PROBLEM Oii ieakage from drain plug

&use Solution

Loose drain plug or worn drain plugORing. Tighten drain plugor replaca O-Ring.

PROBLEM Loud knocking noise in pump

cause Soiution

Puliey ioose on crankshaft. Check key and tighten set screw.

Broken worn bearing. Replace bearings.

PROBLEM Frequent or prematura faiiure of the iniet manifold seais

Cause Soiution

Scored rodsor sleeves. Replace rods and sleeves.

Over pressure to inietmanifold. Reduce inletpressure per instructions.

PROBLEM Short cup iife

Cause Soiution

Abrasive material in the fluidbeing pumped. Instaii proper filtrationon pump inlet plumbing.

Excmsive pressure and/or temperature of fluidbeing pumped. Check pressures and fluidinlettemperature; besuretheyare withinspecified range.

Over pressure of pumps. Reduce pressure.

Runningpump dry. Do not runpump without water.

Frontedge of piston sharp. Repiace with new piston.

PROBLEM: Strong surging at the inletand Iowpressureon the discharge side

cause Solution

Foreignparficiesintheiniet ordischargevaiveor worninietand/ordischarge vafves, Check forsmooth iap surfaces on inletand discharge vaive seats, Discharge valve

seats, and inletvalve seats may be l-don avery tine oilstone; damaged

cups and discharge valves cannat be lapped but must be replaced.

21

HY13RACAT ELECTRICAL SYSTEM

Tk entfro dectrical system operates on 12 volts DCwhich is provided by NOTE: When new battery is installed insure it is properly charg@dbefore

abatttwy.Battwy Itwalsam sustained by a20 amp alternator cfesignedwifh installation or damage to the charging regulator may occur.

the engine.

FRW.EW M.nwba:twy voltag~

Ctwfaa solution

&kXe MWY. Remove andre@ace.

Carmdd batteq wrrnirds. Ckn Ierminak andbaMY pm+t$.

Lowbatwryfluid. Add Wat6f to ~cpriate Iml.

Lmxm wiring wkhin decfrid system. Examine allterminal concoctions andvwfiy thaf they are secure.

Elecfrii sharlin wirings@em. Examineelectricalsys!emsforbarewires.

PQQr

ground cnrmeciion. Examine Ierminal and remove corrosion if rwwwary.

PFNWLEM Inoperathm hour meter

cWa@ SoMrn

fiml advancing cmedy. Verify 12volf DCisavailableatthe hourmetwviththeignition switchturnedan.This

can be accomplished wth avolt meter or atest lamp.

Remove and replace hour meter if 12 volt isavailable.

Anyton gear withk the dcwk may have txwn jammed due to sudden joif of the

machine or truck. You may try simply tapping on the m~ter lo try to free the

n~on gear.

,FICH

SENDING

JN!T

-yowl-lr-l‘-M=TkA I

H?.&l= ‘r’”=

11: -w- <A

IdFuEL 2

PUMP

.:

2

&“[[ ,INK

I

,L, T,>(r

OL1

PREsSURE 50 LENOI0 C~D

SWITCH CONTROL *

VALVE

—+

COIL

%1 K1

GNO

*

*GNO

22

ONANPERFORMER

Gasoline Engine

Air Cooled

24 bhp (17’.9 kw) at 3600 rpm

20 bhp (14.9 ‘k@ at 3600 rpm

ONAN ENGINE STANDARD FEATURES

Electronic Ignition

Electric Starter, Solenoid Type

Mechanical Flyball Governor (variable speed)

Top Access Oil Fill and Level Indicator

Oil Pump

Fuel Filter

Anti-Flood Choke

Replaceable Dry Element Air Cleaner with Polyurethane Wrapper

Rotating Blower Semen

Valve Rotators {exhaust)

Cobalt Alloy Exhaust Seats

Chrome Cobalt Faced Exhaust Valves

Intake Valve Stem Seals

High Capacity Oil Base

Full-Flow, S@non Oil Filter

OPTIONAL FEATURES

Fixed Speed Governor

Crossover Exhaust Manifolds

Vacuum Pulse Fuel Pump

Exhaust silencers

Low Oil Pressure Switch

Flywheel Alternator, 20 or 35 amp with Regulator

(installed on cylinder air housing)

Stationary Blower Wheel Guard

High Capacity Air Cleaner

Engine Control Panel

PTO Modifications: Internally Splined Crankshafts, Hydraulic Pump

Adapters, Front PTO Shaft

PERFORMANCE CHARACTERISTICS

RECOMMENDED FORVARIABLE SPEED OR CONTINUOUS DUTYTO

3600 RPM.

Production engines when shipped will develop after deduction for non-

standard accessories, not less than 85% of maximum corrected bhp. After

run-in to reduce friction and the performance of service, engines should

develop not less than 95% of maximum corrected bhp.

Engine power decreases approximately 3.5% for each 1000 ft. (305 m)

atwve sea level and 1% for each 10°F (5.5W) above 60°F (15.5%). For

ntinuous duty at constant load do no~exceed 80% of av~lable horse-

wer. For heavy duty applications requiring maximum output, the Ex-

Ided Service Life package is recommended. Performance curves ob-

ned and corrected in conformance with SAE J607b.

Dlm3tls!o”s

,“ ,“ches

nulllmeters shown mparfmmsss.

Basic Dimensions -P220

NO <032 “W 6HOLES

E-

GN A267,,5, ?,,, .. w

,,4 .,,4 “,2WC0, .Ey

T

3!8 ?6 UK 4HOLkS

-,250 {8?55,

[.37, ,6? 92, ,,,., ~,,

63,.,1689? D!menstons mmchw

m,ll,meters show. mparemheses

ONAN ENGINE DETAIL

Cyckx

4

Cylindm 2, horizonRa[lyopposed

Cmpmskm ma: 7.0to 1

Piston Spe@: 1800 fpm (9144 rnnls) at 3iNll rpm

Nat W@lgh& 127 lb (57.6 kg) dry, approximate.

Brwlti’mf System: CIossd, recirculating.

Cw.a!lng Systkwm FWMsumairooled, radial flow blower. Cooling air

volurm 1000 cim (1699 rnMw] at 3600 rpm.

Fud Syst@rm Modwn downdraft carbur’otor with fixed main jet, limited

adjusfmvmt idle system. Smni-automatic choke operation with anti-

fkmding featut’e.Combustion air required at3600 rpm, 50 cfrn (85 mVhr).

Gavwmcw bnsmts~odmm-~ardflv@ n.A~ustaNemecMniMl flybd,

300 rpm drop to 3640 rpm.

Ign!don !?qrstwn: Solid state kweakerk?ssignition with fixed timing, 12volt

rmgative ground. RFI suppression spark plug wires meet UL and CSA

int~rferencw requirements.

SMIWM:Positive engagement sdanoid type starter. 12volt negative

gruund.

Lukwfcat!on f3yst@n’KPositive displacement, gear-design oil pump. Full

presw.m lubrication to main and connecting rod bearings and governor.

FMd bypass, oil pressure control. Oil fill tube and level indicator.

Removable aluminum oil base. Capacity, 2.7 qt (2.56 L); add 0.3 qt

(0.3 L) for oil filler.

Paw@r.1’akMIW R@armount PTO pilot and keyed crankshaft extension.

Rotation, CCW whtm facing PTO shaft. Front mount PTO pilot.

Main W.wftlgs: Steel-backed aluminum precision inserts, replaceable.

I.D.: 2in (50.8 mm); Length: 1in (25.4 mm).

Camshaft: Cast iron alloy. Replaceable lead babbitt bearings (2).

Conm?cting Rods: Forged steel. Replaceable bearings.

Crankshaft Ductile inm. Machined-in oil passages. Simultaneous oilfeed

from both ends of crankshaft.

Cylindw’s, Crankcaaw Aluminum alloy with integrally cast pearlitic iron

cylinder tiners.

CYIIIMM Hawk: Rerrwwable,aluminum alloy. Highturbulence combustion

chamtwrs.

PistIons: Aluminum alloy. Three ring, two compression, one oil control.

Cooled and Iubricat@dby oil spray.

TqqwXs: Barrtit ty~, adjustable.

Vabms: Exhaust, chome-cdbalt faced. Intake, steel alloy. Replaceable

valve guides.

V$IIV6Seats: Replaceable@intake and exhaust.

Valve lMMWurs: Exhaust valves.

GENERAL INFORMATION

Engine Mockil Refemrioa Identify your model by referring to the model and

s~cificatir.m (spec Mter) as shown on the unit nameplate. Always use

thesonumbers and the engine seria! number when making reference to

your engine.

HOW TO MM’ERPRH’ MODEL AND W+C !0

1234567

1. Factory code for general identification of basic engine series.

2, Number of cylindtws.

3. f3HPrating.

4. Fual required (G= horizontal shaft, V=vertical shaft).

5. Engine duty CYCIQ.

6. Factory cm% for designated optional equipment, if any.

?. Spwificaticm (SWCletter) which advances with factory

production modifications.

hcorrectservkw orreplacemefff ofparfs ~msultinsevorepnonaliflju~

W/or equiprrwrrf damag~. .9?rviw personnel musf&qualtied foptwform

3/ecfric4/arWof mechanical servica

%X WEATHEROPERAT!QN

Nhen operating the engine in temperature above 1OO°F,pay particular

Mention to the following items to prewimt danaagw

1.Keep the engine moling fins clean andfreeof obstruction.

W@ged or clogged cooiing fins car?cause ov.erfwating and engine darn-

~ge.Ensure cooling fins are kepf clean and debris does nof accumulate.

Contact w“fh rotating machirwy can resulf in sewre flersonal im’urv or

death Stayclearofr6tatilJg com@M@s ai?denwwe pro~ective shie~dsar?d

guards are irrplace and secured Mm? operating rn~chinery.

2. See that nothing obstructs air flow to and from the engine.

3.Ensure that you are using the proper graok and weight of oil for ambient

temperatures. Check the oil level each time you fit the fuel tank.

4.Check the battery water more frequently. High temperatures c-ancause

faster evaporation.

5. Change crankcase oil and filter more frequently.

NM WEATHEFI QPERATK3N

Whenthe engine is being us@dintemperatures bdmv 32°F(O°C),check the

following items closely:

1. Use the correct grade and weight of oil for tk tmnperature conditions.

Change the oil only when the engine is warm.Ifan unexpectedW’nper-

aturedrop occurs when the engine is filled with summer oil, beforestart-

ing the engine, move it to awarm location until ‘theoil wfil flow frtmly,

2. Use fresh fuel. Fill the fuel tank after each day’suse to protect against

moisturecondensation.

3. Keep the battery in awell-charged oondition.

DUST AND DIRT

1.Keep unit clean. Keep cmolingsystem cl~an.

2. Service air cleaner as frequently as required.

3. Change crankcase oil and filter more than.

OUT-OF-SERVICE PROTECTION

Protect an engine that will be out-of-service tar more Man 30 days as

follows:

1. Run the engine until it reachas normal operating tempwature.

2. Turn off the fuel supply and run the @ngineuntil it stops.

3. Drain oil from oil base while the engine is still warm. Refill with fresh

crankcase oil and attach atag stating viscosity wad.

4. Remove spark plugs. Pour 1ounm (2 tablespoons or 28 grams) of rust

inhibitor or SAE #50 oil into tie cylinders. Crank the engine over afew

times. Reinstall spark plugs.

5. Service air cleaner as outiin~d in tbfANfTENANCE.

6. Clean governor linkage and protect by wrapping with acl@ancloth.

7.Plugexhaust outlet to prevent entmc@ of moisture, dirt, bugs, @tc.

8. Wipe entire unit. Coat rustable parts with alight film of greasa or oil.

9. Provide asuitable cover for the entire unit.

24

10. Ifbattery equipped, disconnect and follow standard battery

storage procedure.

RETURNING UNfT TO SERVICE

1. Remove cover and all protective wrapping. Remove plug from

exhaust outlet.

2.Check tagonoil base andverifythat oil viscosity isstill correct for existing

ambient temperatures.

3.Clean and check battery. Measure specific gravity (1.260 at 770F[25%])

and verify level to be at asplit ring. if specific gravily is low, charge until

correct value isobtained. Ifthe level is low, add distilled water and charge

until specific gravity is correct.

4. Check that fuel filter and fuel lines are secure, with no leaks.

5.Check that carburetor throttle lever and governor linkage move freely.

6. Connect battery.

7. Start Engine. Exhaust smoke is normal when the engine is started and

is usually caused by the rust inhibitor oil.

EXHAUST GAS IS DEADLY!

Exhaust gases from all fuels (including diesel, gasoline, liquid propane,

natural gas) contain carbon monoxide, an odorless and colorless gas.

Carbon monoxide is poisonous and can cause unconsciousness and

death. Symptoms of &rbon monoxide poisoning can include:

Dizziness 7hrobbing in Temples

Nausea Muscular Twitching

Headache Vomiting

Weakness and Sleepiness /nability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF

THESE SYMPTOMS, GET OUT INTO THE FRESH AIR

IMMEDIATELY.

/fsymptomspersist, seek medicalattentrnn. Shutdown the unit and do not

opwale untilithas baeninspectedandrepaired. Protection against carbon

monoxide inhalation includes proper instal/ation8 ventilation and regu/ar,

frequent visual and audible inspections of the complete exhaust system.

Accidental starting of the engine can result in severe personal injury or

death. Disconnect the negative battery cable and spark plug wires while

servicingengine, contiols, or associated equipment.

DAfLY CHECKS OR EVERY 8HOURS

The operator should daily make acomplete visual and audible inspection

oftheengine. Check thefollowing before starting theengine forthe first time

each day:

1. Check all fuel lines and fittings for possible leakage.

2. Inspect exhaust system forpossible leakage and cracks. Locate leaks in

muffler and piping while fhe engine is operating. Repair all leaks immedi-

ately after they are detected for personal safety.

3. Inspect air cleaner system for leaks. Make certain all clamps and fittings

are tight and free of potential leaks.

4.Checkcrankcaseoil Ievelwiththeengine off. Ifengine has been run,allow

aminimum of 10 minutes for the oil to drain down before checking. Ifoil

level is at or below ADD mak on dipstick (Figure 1), add sufficient oil of

the proper viscosity as specifiid in ENGINE SET-UP to bring oil level to

the FULL mark. Donot operate engine with oil level below the ADD mark

or above the FULL mark.

OIL SYSTEM

CRANKCASE OIL CHANGE

RefertoPeriodic Maintenance Schedule (located intheOperator’s Manual)

for oil change interval. Ifoperating inextremely dusty, high ambient, or low

ambient conditions, change oil more often.

Runengineuntii thoroughlywarm before draining oil. Stoptheengine, plats

a pan under the drain outlet and remove the oil drain plug. After the oil is

completely drained, clean and replace the drain plug. Fill crankcase with

correct amount of oil. Refer to SPECIFICATIONS for crankcase capacity.

Use oils meeting the API classification SF, SF/C, or SF/CD. Refer tochart

todetermine the proper viscosity grade of oil to use Straight weight oils are

recommended for severe dutv use and at temperatures above 32°F KIWI

for minimum oil consumption- .,

IOil VkcosMy

—II

I1

~f

,1I111

F-20 0 20 40 60 60 100

c~”-”””-— “’ ‘“

-10 0 70 —co K- –T

TEMPER~TuRERANGEYOUEXPECTBEFO~ENEXTOILCHANGE

Hot crankmse oilcan cause bums if ii comes in contact with skin. Wear

protective clothing and keep fingers and hands clear when draining oil

Excess oil can cwse high oil consumption, h@hoperating temperatures,

and oil foaming. Do not overfill crankcase.

Crankcase pressure can b/owouthotoi/, which cwcause severe personal

injury. Do not check oil while the engine is running.

Oillevel should be tothe FULLmark of the dipstick. Start engine and run for

ashort time to check for oil leaks around the drain plug.

25

mFmw’ Ltlcamfl

I

Oil

(Always replace

tightly or oil

leakage may occur

1

_FULL -- C%ufk?n: Do not overfill

=ADD -- Refer to amount on dipstick

OIL FILTER CHANGE

Refer hPWiOdii2Maintenance Schedule (Page 29) for oil filter changl

interval. If operating in extremely dusty, high ambient, or low ambier

conditions, change oil filter more often.

Spin oti oil filter element and discard it. Thoroughly clean filter mountinl

surface and make surenew gasket is inserted inthe element. Apply athi

film of clean oil to tho gasket. Spin element down by hand until gasket ju:

touches rrmunting padand then turndown an additional 1/2-3/4 turn. Do n(

overtighten.

With oilincrankoase, statiengine and check for!eaks around filter elemen

Retighten only as much as necessary toeliminate leaks; do notovertighter

CRANKCASE BREATHER

Tht?crankcaso breather pwents pressure from building up in the cranl

case. IIalso prevents oil contamination by removing moisture or gasolin

vapors and other harmful blow-by materials from the crankcase. Thes

vapors am routed to the carburetor where they are mixed with incoming a

and burned in the combustion chamber. Asticky breather valve can caus

oil Ioaks, high oil consumption, rough idle, reduced engine power, and

rapid formation of s[udge and varnish within the engine

CRANKCASE BREATHER SERVICE

[fthe crankcaso becomes pressurized as evidt?ncedbyoil leaks atthe sea

or excessive oil in the air cleaner housing, use the following procedure 1

service.

Mostpat’tdear?ir?gsdvenkaretlammab~eand can cause severe persorI

injury ordt?a!h ifi,wed imprcy?er~y.Fcdiowthe manufacturer’s recommend,

tior?swhen cleaning parts.

P220(Spec Aand H):Remove thebreather tube fromthe valve cover(P22

Crankcase Breather il[ustrafion). Remove capscrew, ffatwashers, valv

cmmr, pack, spring, washer, reedvalve, and breather baf~le.Discard gask[

and clean all parts in parts cleaning solvent.

CWertighterringthe valve cover can cause engine damage. QQno! owr-

tighfen valve cover.

The reed valve must be flatwith no sign of acrease. AssmMe using arw?w

gasket. Refer to ASSEMBLY TORQUES for valve cwer capscrew torquo

specification.

P216,P218, P220 (Beginning Spot C): The crankcase breathw’ does not

require swvicing. Replac@breather ifit’s broken orcracked, or ifcrankcaso

becomes pressurized as evidenced by oilleaks atthe seals orexcessive oil

in the air cleaning housing.

P224: Remove hos@clamp and breather hose from cap and valve assem-

bly. Loosen clamp and remove cap and valve assembly and wash in

solvent. Replace Mp and valve assembly if balls do not move freely aftw

washing insolvent. Remove screen andpack. Wash pack insolvent. Install

pack in breather tube and position screen as shown in P224 illustration

shown below. Installcap andvalve, tighten clamp and attach breather hose

and hose clamp.

RHOcrankcase Bn?ath?r

Val

_C3-- Flat Washer

Read Valve -?=v Brteath@r

o

/Baffle

~.~’n ,\

-.. ‘-,.%’-

1

f3reather

Hose

(-

mp

26

IGNITION i

SPARK PLUGS Refer to Periodic Maintenance Schedule for sparkplug ~SOLID STATE lGNfTION: Ignition timing is set at the factory and is not

service interval. Replace spark plugs that show signs of fouling orelectrode !adjustable. The solid state ianition components are not adjustable and

erosion. Refer to S“Wcifi~tions fo; spark plug gap. ~n+uire no routine maintenan-~. ‘

J=’0.025” G8p

+-

Ground E?ectmde

Servicing Spark Plug

Worn: On aworn Dlua. the center electrode WIII be

rounded and the iap-will be eroded .010 or more than

the correct gap. Ffeplace aworn spark plug Immediately

Carbon Fouled Soft, sooty, DlacK aeposms malcate

recomplete combustion. Incomplete combustion !s

usually caused by overnch carburetion, weak ignltton,

or poor compression

Normab Aplug faken from an engine operating under

normal conditions will have light tan or gray colored

deposits Hthe center electrode is not worn, aplug in

this condition could be regapped and reused.

Wet Fouled: Awet plug is caused by excess fuel, or oil

in the combustion chamber Excess fuel could be

caused by operating theeng!ne with too much choke

Oil in the combustion chamber IS usually caused by

worn piston rings or valve guides.

Chalky White Deposits Chalky white colored deposits

Indicate overheating This condition IS usually

accompanied by excesswe gap erosion Aclogged gra:

screen, clogged cooling fins, and lean carburefion are

some causes of over-hemmg

SPARK PLUGS CONDITION DIAGNOSIS

Engine misfire or starting problems areoften caused by spark plugs in poor

condition or with improper gap setting.

SERVICE

Every 100 operating hours remove the spark plugs, check condition, and

reset gaps or replace with new plugs as necessary (see illustration above).

1.Before removing the spark plugs, clean the area around the base ofplugs

to keep dirt and debris out of the engine.

2. Remove the plugs and check condition. Replace the plugs ifworn or if

reuse is questionable.

Do noi clean the sparkplugs in amachine using abrasive grit. Some grit

could remain in spark p/ugs and enfer the engine causing extensive wear

and damage.

3. Check the gaps using awire feeler gauge. Mjust gaps to 0.025” by

carefully bending the ground electrode.

4. Reinstall the sparkplugs intocylinder heads. Torque plugs to 10/15 ft. lb.

INSPECTION

Inspect the spark pfugs as soon as they are removed from the cylinder

heads. The deposits onthetips are an indication of the general condition of

piston rings, vafves, and carburetor. Normal and faulty spark plugs are

shown in the photos shown above.

Refer to Periodic Maintenance Schedule (Page 29) for cooling system

service interval. Clean cooling fins and chaff screen sooner if required.

Remove any dust, dirt or oil which may have accumulated.

EXHAUST SYSTEM

Makeregular visual andaudibleins~ctionsof the exhaust system through-

out theentire life of the engine. Locate leaks in muffler and piping while the

engine isoperating. Repair all leaks immediately after they are detected for

personal safety.

Breathing exhaust gases can result in severe personal injury or death.

/nspectexhaust system audibly and visualiyforleaks daily andrepairleaks

immediately.

AIR CLEANER

ELEhlEtW Refer to Periodic Maintenance Schedule (Page 29) for air

cleaner service and replacement interval. Service or replace more often

when operating under severe operating conditions. Service by gently

tapping element (see illustration on next page) on a flat surface.

ELEMENT WRAPPER (ff Equipped): Refer to Periodic Maintenance

Schedule (Page 29) for element wrapper service interval. Wash in water

and detergent and squeeze dry fikeasponge. Ringwith water. Allow todry,

(C0ntinm32, nextpage)

27

fcmlimdfrom#+wkw6 J2sgtl)

thwrcoat mmriy with two tablespoons (28grams)ofSAE30engineoil.

Km?ad

into and wring out IBxci?ssoil from element wrapper. Failure to

adoquab?lywring out oxoess oil from wrappm’ may cause drop in engine

horsepowerduoto anincfieased restriction ofir’ktair. Installovwaircleaner

o[ament.

“-’ ‘rc’caner

tidy=’

BATTERY

Okconnect rregativo ground strap from the battery before working on any

part of tfm electrical system or engine. Disconnect positive terminal before

charging battery to avoid damaging ignition system alternator or regulator.

CLEANING BATTERY: Keepttw?batteryclean bywiping itwith adampcioth

whiwwer dirt appears excessive.

If cmosim’1 is present arcwmd the terminal connections, remove battery

cables and wash the terminals with an ammonia solution or asolution

consisting of 1/4 pa-red of baking soda added to 1quart of water.

Ha N.re th@wentplugs are tight to prevent cleaning solution from entering

the cells.

Afl@rcleaning,fksbthe outsideof thebattery, thebattery compartment, and

surrounding areas with ckar water.

Keep the battery terminals clean and tigh!. After making connections, coat

the Wminak with a6ighlapplication of petroleum jelly or non-conductive

greas@10retard corrosion.

CHECKING SPECIFIC GRAVITY: Use abattery hydrometer to check the

specific gravity of tlw el@ckolytein each battery cell.

Hold the hycfrwneter vertical and take the reading. Carrect the reading by

adding four gravity points(0.004)for evey five degrees the electrolyte

temperature is above 130°F

(2PC) or subtracting fourgravity points forevery

fiv@dagmes b@mv8@F(27%). Afully charged battery will have acorrected

spt?cik grawityof 1.260. Charge the battery if the reading is below 1.215.

CHECKING ELECTROLYTE LEVEL: Referto PeriodicMaintenance Sched-

ule (Page 29) for checking electrolyte level interval.

Fill the battery cells to the bottom of the filler neck. If CWIISare lowonwater,

add distilledwaterandrecharge. If one cetl is low, check cast?for leak

Keepthe battery case clean and dry. An accumulation of moistww wilt lead

to amore rapid discharge and battery failure.

STORING 13ATTEllY:lf the engine is to be stor~d for more than 30 days,

remove the battery. With the electrolyte level at the bottom of th@split ring,

charge the battery before storing it. After every 30 days tlw battery is in

storage, bring it backup to full charge. To reducxeselfdischarge, store the

battery in as cool aplace as possible so long as the electrolyte does not

freeze.

L

Reading

‘%

(25”C)

BATTERY TERMINALS

Keep V%?battery terminals clean and tight. Push the cable terminal down

flush with or stightly below tie top of the battery post. Aft@rmaking connec-

tions, coat the terminals with alight application of petroleum jelly or grease

toretard corrosion.

,/’- Battery Post

,-- Cable Terminal

Poor contact at the battery cable connections is often asource of trouble.

~Make sure battery cables are ingood conditicm and thatcontacting surfaces

~are clean and tightly cmnected. Donot reverse batfe~ leads, Us@reconr-

~mended battery tools when disconnecting leads to avoid mechanical

~battery darr~ag@.

~BATTERY JUMP STARTING

:Occasionally, it may Wnecessary to jump start(charg@]aweal{battery

~using acharged booster battery. Ifjump starting is necessary, the following

28

procedure is n?commended to prevent starter damage, battery damage,

and personal injuries.

1. Disconnect engine load.

2. Use abattery of the same voltage(12V) as is used with your engine.

3. Attach one end of the positive booster cable (red) to the positive(+)

terminal ofthe booster battery. Attach the other end of the positive cable

to the positive(+) terminal of your engine battery.

PERIODIC MAINTENANCE SCHEDULE

AFTER EACH CYCLE OF INDICATED HOURS

SERVICE THESE ITEMS 825 50 100 200 500 1000

Inspect Engine Generally xl

Check Oil Level x

SerViCe Air Cleaner Element and Element Wrapper )(2

Change Crankcase Oil (all engines without filter) X2

Change Crankcase 011 (standard base with filter) X3 X2

Change Crankcase Oil (high capacity base with filter) X3 X2

Replace Otl Filter )(3 Xz

Check Battery Electrolyte Level x

Clean Cooling Fins Xz

Replace Air Cleaner Element )(2

Replace Fuel Filter x

Check or Replace Spark Plugs x

Check Valve Clearnace (standard engines) X4

Check Valve Clearance (LP &natural gas conversion engines) )(4

Check Valve Clearance (extended service life engines) X4

Clean Carbon and Lead Deposits (cylinder head) )(5

Follow aregular schedule of inspection and servicing, based on operating

hours. Keep an accurate logbook of maintenance, serving, and operating

time. Usethefactoryrecommended Periodic Maintenance Schedule (based

on favorable operating conditions) to serve as aguide to get long and

efficient engine life. Regular service periods are recommended for normal

service and operating conditions. For severe duty, extreme temperature,

etc., service more frequently. Neglecting routine maintenance can result in

engine failure or permanent damage.

For any abnormalities in operation, unusual noises from the engine or

accessories, loss of power, overheating, etc., contact your nearest Onan

Service Center.

Maintenance Schedule Footnotes:

1- Check for fuel leaks. With engine running, visually and audibly check

exhaust system for leaks.

2-Performmore often when running under severe operating conditions.

3- Required for initial break-in only.

4- Fordetailed maintenance, contact an Onan Service Centerorreferto the

SERVICE MANUAL.

5-Clean carbon more frequently when running under continuous light load

and/or on leaded fuel. Use of Onan 4C carburetor and combustion

cleaner is recommended every 200 hours to help reduce

carbon buildup.

Breathrhg exhaust gases can result in severe personal injury or death. Do

notuse aircleaner, exhaustelbow, orconnectingparts asa supporting step.

Damage to these and connecting pads can cause an exhaust leak.

29

TROUBLE SHOOTING

IGNITION SYSTEM

30

—

ENGINE TROUBLE SHOOTING

GUIDE

Wherrtroublesoccur, besuretocheckthe simple causeswhich, atfirst, may

seem too obvious to be considered. For example, astarting problem could

be caused by an empty fuel tank.

Some common causes of engine troubles are fisted Mow-use this asa

guide to locate causing factors.

PROBLEW.Engine cranks but will not start

Solution

Empty fuel tank.

Clogged fuel line.

Spark plug leads dsconnscted.

Keyswitch or killswitch in “off position.

Faufty sparkplugs.

Fauftv ianitionmodule,

Dirtor water infuel svstem.

PROBLEM Engine starts but does not keep running

Solution

Restricted fuel tank venl.

Dirtor water infuel system.

Fauhy chake or throtile controls.kables.

Loose wires or connections which killterminal of ianitionmodule to around.

Cshuretor improperly adjusted.

Fautty cylinder head gaskets,

Faufty fuel pump.

PROBLEM:Engine starts hard

Soiution

hose wires or connections.

Dirtor waler infuel svstem.

Cloggedor restricted fuel lines.

Faulty choke orthrottle cantrolsksbles.

Faulty spark plugs.

Carburetor improperly adjusted.

Incorrect vafvc+t~teppet deerence.

Low compression.

PROBLEM:Enaine will not crank

Battery isdischarged.

Loose or fauffywires orconnections.

Faufty keyswitch or ignitionswitch.

Faulty electric starterktartar solenoid.

Seized internal engine components.

PROBLEM Engine runs but misses

Solutian

------ ..

Dirlor water infuel system.

Spark plug leads boss.

Loosewires orconnections which intermiltentlyshorl killterminal ofignitionmodule

to ground.

Carburetor imorooerlv adiusted.

Engine overtreating.

IncorrectvafvstcAappet dearsnce.

Faulty gnition module.

PROBLEM Engine wfll not idle

Solution

------ ..

Idfespeed adjusting screw improperly set.

Dirtor water in fuel system.

Idle fuel adjusting screw improperly set.

Restricted fuel tank vent.

Faultv soark DIUOS.

Incorrect vafveto-tsppst dearsnce.

Low compression

PROBLEM:Engine overheats

Soiulion

Grass screen, cooling tins,or shrouding clogged.

Excessive enaine load.

Low crankcase oillevel.

High crankcase oillevel.

Carburetor improperly adjusted.

PROBLEM: Engine knocks

Soiution

Lowcrankcaseoillevel.

Excessive enaine load.

PROBLEM Engine loses power

Soiution

Low crankcase oil Ievet.

High crankcase oil level.

Restricted air cleaner etement.

Dirlor water infuel line.

Excessive engine load.

Enaine overheating

Faultv soark oluas,

Carburetor improperly adjusted.

Low compression.

PROBLEM:Engine uses excessive amount of oil

Soirrtion

Incarred oilviscositv of twre.

Cloaaed or imorcmerfvassembled breather svstem.

Worn or broken piston rings

Worn cyliiderbares.

Worn valve stems and/or vefve guides.

31

MAINTENANCE PFKKEDl!RES

T~ avoid costly mpaim and down-time, it is imperative to develop and

practi~ good mainttmarm procmfuwis from the beginning. These proce-

dures fall into daily, WWWIY,monthly and quarterly increments, and are

mdirwd twlmv. W@have provided amaintwwmca log for your convenience

on next pag@;it is remwmww.!ed that you affix acopy of the logon the

whit% door rmaryour unit for convenience and to sawe as amaintenance

Check engine oil Iwal.

IHSWCIgarden hose screen-clean as needed.

Visually inspect machine for loose wires, ail leaks, water leaks, etc.

Inspect recavery tanks/s filter and filter bag for tears, holes, etc. -clean,

repair or rapface as needed.

‘Lubricate blower wi!h Penrwguard through blower inlet.

WEEKLY

Change engine oil. (25-30 hours of operation.)

Check engirw air clwmer filter -clean as necessary.

Check high pressure pump oil -add as necessary.

Check drive coupler set screws -tighten as needed.

Check pump driw belt for wear-tighten as needed.

Check pump pulleys -tighbsn as needed.

Check fuel lines far wt%irlchafing.

Check all nuts and tmlts -tighten as needed.

Check heater burrow assy. union for tightnessdeaks.

Cl@anvacuum tank thoroughly with high prwssuw washer.

Flush watw and chemical system with 50/50 while tinegar solution.

Check @ngirwRPM’s -adjust102W0 rpm on 4.5

2800 rpm on 4.0

MONTHLY

thwrseblower bearing fittings.

Rwnove pressure bypass valve stem, grease cup and stem, reinstall.

Ctwk water !evol in battery. Clean connections as needed.

aumww’t’

Cmge oil in blower.

Check engine compression.

Check for combustion chamber carbon deposit.

Change spark plugs.

WJWTA?W:

Reoimddate and machinehours on maintenance@chart.

OVERALL CARE OF UNIT

MAIW’AINING WE (XWWJAL IWWWWCE WW3LM UNIT !S

MPORTAMT FOR IWO REASONS

1.It

repn%+antsabig dollar investment for your c%mningbusiness and its

appearanrx?should reflect that fact. Adirty machirm is not pmkwional!

2. Maintenance, troubleshooting, and repair is much easiw’ to accmpliah

on a clean well maintairwd unit. f%?gularcl~aning of MOmwhinf!offws

you an opportunity to visually insp?ct al! facets of th~ machim and spot

potential problems before tfwy ocfwr.

FOLLOWfNG MAMTEIWNCEM RECWMBIEMDED BYTHEMMUFAC.

TLJRER AT THE FREQUENCY INDICATED.

AKER EACH JOB:

Check recovery tank, slsl filter and filter bag as required.

fMfLY:

Wipe machine down thoroughly with adamp cloth; flush recovwy tank out

thoroughly. Empty filter bag and inspxt for rips, @ars, @tc.-replace as

needed; remove, thoroughly clean and r~install stainless steel fillerscretm

in recovery tank; inspect and clean vacuum slot on cleaning wand; clwck

wand head for sharp edges that could tear carpal -file down as needed;

clean wand to maintain original appearance; wipe down vacuum andhigh

pressure hoses as needed-visually inspect for cuts, etc.

WEEKLY:

Wipe down entire unitas needed- apply good coat ofauto wax 10all painted

surfaces inside and out, and to control panel; thoroughly cfwanrecovery

tankusing high pressure hotwater (unitwith optional high pressure c{eaning

gun may be used for this}; removo stainless steel filttw in recovery tank,

thoroughly clean removing allIMtbuild-up, ins~ct fordamageandreinstall.

Remove filter bag, Thoroughlyclean and reinstall -iFtarn,repkmo; @mpty

chemical from chemical contakwr, wash out thoroughly to remove any

chemical build-up; inspect chemical feed Iirm strainer and use W% while

vinegarhvater solution to remove any chemical build-up; thoroughly cl@an

wand and inspect forclogged jet, debris in vacuum slat and l@akingfitings

atvalve. Apply lightcoat ofauto wax towand. Thoroughly dean vacuum and

high pressure hoses including hose cuffs -inspect for wear or damage to

hoses and quick connect fittfngs. Inspect garden how corwwctladapter

screen fordebris, remove and clean thoroughly. Inspect allfirmsfwiwarar

abrasions that may cause possible leaks.

32

MAINTENANCE LOG

DAILY CLEANING &INSPECTION

Engine oil -check Clean vac tank filter bag after every job

Garden hose screen -clean Blower inlet -spray with LPS 1atter last job

Machine -general inspection

WEEKLY SERVICE

MAX

HRS SERVICE IDATE/1-lRS IDATE/HRS IDATE/HRS IDATE/tiRS IDATE,HRS IDATE/HRS IDATE/HRS

25 BLOWER check 011level

25 PUMP OIL check (lop of sight gauge)

25 DRIVE SHAFT SYSTEM tighten set screws

25 BELTS &PULLEYS check tightness

25 HIGH PRESSURE LINES check for chafing

25 NUTS &BOLTS check fightnese

25 13ATTERY LEVELS check

25 VACUUM TANK clean

25 WIRING check for chafting

25 CHEMICAL SYSTEM flush wlvinagar

MONTHLY SERVICE

100 ENGINE OIL change

100 BLOWER greasa bearing

100 ENGINE AIR CLEANER clean

100 BY PASS VALVE grease cup &stem

QUARTERLY SERVICE (3 MONTHS)

300 BLOWEROIL change

300 ENGINE cmmcrreaaion

300 SPARK PLUGS change

MAINTENANCE LOG

DAILY CLEANING &INSPECTION

Engine oil -check Clean vac tank filter bag after every job

Garden hoee ecreen -clean Blower inlet -spray with LPS 1after last job

Machine -general inspection

WEEKLY SERVICE

MAX

HRS SERVICE IDATE,HRS IDATE/HRS IDATE/FIRS [DATE,HRS IDATE/HRS IDATE/HRS [DATE/HRS

25 BLOWER check oil level

25 PUMP OIL check (top of sight gauge)

25 DRIVE SHAFT SYSTEM tighten set screws

25 BELTS &PULLEYS check tightness

25 HIGH PRESSURE LINES chock for chafing

25 NUTS &BOLTS check tightnese

25 BATTERY LEVELS check

25 VACUUM TANK clean

25 WIRING check for chaffing

25 CHEMICAL SYSTEM flush w/vinagar

MONTHLY SERVICE

100 ENGINE OIL change

100 BLOWER grease bearing

100 ENGINE AIR CLEANER clean

100 BY PASS VALVE grease cup &stem

QUARTERLY SERVICE (3 MONTHS)

300 BLOWEROIL change

300 ENGINEcompression

300 SPARK PLUGS change

33

MAINTENANCE MM

DAILY GLREANING &INSPECTION

Engine od -check Clean vac tank filter bag alter every job

Garden hose screen -clean Blower relet -spray with LPS 1after last job

Machu’m -cwmmralmstmctiorf

WEEKLY !3ERVICE

MM

HR-S SEIWN2E ]DATEIHRS IDATEHRS IDATE HRS IDATE(HRS IOATEFIFIS If)ATEIHflS IOATEMWi

25 BLOWER check ml level

25 PUMP OIL check (top 01 mghtgauge)

2s lXWVE SHAFT SYSTEM ughterrset screws

25 BELTS &PULLEYS check ughtrress

25 HIGH PRESSURE LINES check for chafing

25 NUTS &BQLTS check lightness

25 SATTEFW LEVELS check

2!! VACUUM TANK clean

25 WIH lf’#3 check tor chaffing

25 CkfEMICAL SYSTEM flush wlvmegar

MONTHLY SERVICE

100 ENGINE OIL change

100 EILOWER grease bearing

1cm ENGINE AlRCLEANER clean

1(M f3Y PASS VALVE grease cup &Slem

QUARTERLY SERVICE (3 MONTHS)

300 BLOWER OIL change

300 ENGINE comrwessmn

300 SPARK PLUGS change

MIAMH4ANCE LOG

DAILY GLEAMING &IW3PECTION

Ermine ail -check Clean vac tank filter baa after everv 10b

Gakm hose screen -clean Eflawer relet -spray w!t~ LPS 1after ‘last 10b

Machine -general inspectlan

WEEKLY SEFWICE

MAX

fms SERVICE IDATE1-lRS IDATEIHRS IDATEI-IRS IDATE HRS IDATEHR5 I DATE/lil15 I fJATE/flRS

-- . . . ... .. -.

.W-..

25 PUMP OIL Cheo

25 fW7WESHAFT :

25 BELTS I%PllLLE

25 HIGH ‘----’ ‘-

>5 MlITS

‘-E

25 ml-r

25 VAL21

96 WISSI1

k(top of sqhi gauge) II

)YSTEM tqhvan sel screws

iY!3 check ttghtneSS

vrrcam.Jr4E LINES check for chafing

;&f3CIL.TSc!!eck t!ghtness

ERY LEVELS check

JLfMTANK cfean

_..,. ...VG chock for chaff{ng

25 CHEMIICAL SYSTEM flush w/vinegar

MClt4TH’LV SEIRVICE

t00 ENGINE OIL change

100 BL(IWER Qfieasebearing

100 ENGINE AIR CLEANER ciean

100 EYYPASS VALVE grease cup &stem

CWkHTERLY SERVICE (3 MONTHS)

300 BLOWER OIL change

300 ENQI NE compression

300 SPARK PLUGS ctrange

34

I

NOTES

35

wAJw’wrrY INFORMATION WARRANTY PROCEDURE

To avoid misundwWandings which might occur between machine owners

and rnanufachrn?r,vm are listing causes of component failure that specifi-

cally voids warranty coverage. Such causes as listed below shall constitute

alluw ar Iw2glli!ct.

MLQWER: Failuw to lubricate impllers daily with LPS-1 or WD-40 lubri-

cant. Failure to lubricatekarings as recommended in blower marwrat.

Failure to maintain proper oil levels inthe blower. Failure to use the correct

oil grado and viscmity as recommended in blower manual. Failure to

properly maintain Mower safeguard syslems such as waste tank filter

scrwm, vacuum safety relief valve and waste tank automatic shut-off

systwn. Allowing foam to pass through blower.

HIGH PFIESSLME WATER PUMk Failure to maintain proper oil level as

recammonded in pump manual. Failure to change oil in pump at recom-

mended intervals. Failure 10 protect pump against freezing. Failure to

maintain pump fwotection shutdf system. Failure to use water softener in

hard water areas. (he of improper chemicals.

VAC ‘TANK Failure to properly maintain filtering devices in tank. Failure to

clean tank as recommended by manufacturer. Failure to maintain vacuum

Safaly mleas%in tank lid. U% of improper chemicals.

CHEMICAL PROWJRTIQNEF!: Use of improper chemical. Failure to use

water softoner in hard water area. Qperating machine without proper

chemical filter screen. Failure to prot~ct against freezing.

CtlNTRflLPANEh Failr.wetoprotect ffowmeterandwaterpressuregauge

against freezing.

VACtJWd AN12SOLUTION HQSE~ Failure to protect hoses against

freezing. Failure to protect hoses against burns from enginelblower ex-

haust. Damag6 to Iwws from being run over by vehicles. Kinking or

cracking from failure !oslwworunroll hoses ctrrmctfy. Normalwear and tear

from everyday use.

CLEANING WJMW Failure to protect against freezirrg. Clbviousphysical

abu!w of wand.

WATER HEATER Cwer pressurization of the system (recommended

maximum working pressure -800 PSI]. Failure to protect against freezing.

Modification of the gas delivery system.

Warranty coverage is available to you ONLY through HydraMaster CorW.

ration, 20309 t%$thAve. West, Lyrmvmd, Washington 98036. When war-

ranty parts are needed, write Hydrafblasttw Wtwrm!y t2@pl.at the above

address, or call the Warranty/S.ervke Dept. at(20$} 775-7275. No calloct

calls will beacceptecf, Hours of WarrantylSarwiae Dept. am 8:00 am to

5:00 pm Pacific Time.

kWORTANT: HydraMasttWs warranty policy provides replacwmnt parts

without charge forthirty (30] daystocustomws maintaining cunwntaccwnt

status. An invoice datedthirty(30)daysfrom date of replacenwmt parts

shipment will be sent to the customer for the amount of the parts sent. The

customets faulty parts must mreturned far evaluation ptior to the @xpira-

tion of the thirty (30) day period, Upon warranty approval, acredit will b

issued the customer for the replacement parts invoice. Warran~ dlmp

pmal or failuro to return ha faulty parts wltlln the thirty (30] duy

period allowed w[[I result in the customer Wring charg~d for W@

replacement parta arm

I

36

GOLDEN GUARANTF+@

LIMITED

WARRANW PUN

HydraMaster warrants truckmcrunt machines of its manufacture to be free from defects in material and workmanship if properly

installed, maintained, and operated under normal conditions with competent supervision. No person, agent, representative or

dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in

connection with any of HydraMaster’s products. This warranty shall extend to the original purchaser of said equipment for the

periods listed by component below from date of installation. If repairs or replacements are made by tbe Purchaser without

HydraMaster’s written consent, Hydramaster’s warranty shall cease to be in effect. No allowance will be granted for any repairs

or alterations made by the Purchaser without HydraMaster’s prior written consent.

Machinery, equipment and accessories furnished by HydraMaster, but manufactured by others, are warranted only to the extent

of the original manufacturer’s warranty to HydraMaster.

HydraMaster agrees at its option to repair at the point of shipment, or to replace without charge any parts or parts of products of

Hydra Master’s manufacture, which withi nthe specified warranty period shall be proved to HydraMaster’s satisfaction to have been

defective when shipped, provided the Purchaser promptly notifies HydraMaster, in writing, of such alleged defect. HydraMxiter

will pay all freight and transpiration charges, via normal ground shipping means, for replacement of parts covered under this

warranty. This warranty covers parts, as specified, and does not cover labor which may be necessary incompleting repairs.

HydraMaster’s liability to Purchaser, whether in contract or in tort arising out of warranties, representation, instructions, or defects

from any cause shall be limited to repairing or replacing the defective part or parts. To qualify for warranty coverage, defective

parts must be returned to HydraMaster within 30 days. No liability whatsoever shall attach to HydraMaster until said products

have been paid for.

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, ireplied or statutory, and Hydra Master shall have no

liability for consequential, incidental or other damages, howsoever caused.

FRAMEYCOVER wsEMBLm: .......................................................................................................................................................................3 years

VACUUM RECOVERY TANWCHEMICAL MIX TA~: ........................................................................................................................3 years

ENGINIU(?ivougtI original

Manufwhmz. On f)irwt Orkunits SE orisind Mmufwhm+s wamanty.) ..........................................................................................z YW3fS

VACUUM BLOWER: (’fhmJsIIorigin.]Manufacturer. scc ccmpcr tnrtustics W.y.) .....................................................................................................2 yFXNS

CHEMICAL PROPORTIONING SYS~M: ....................................................................................................................................................l yew

CLEANING WA~ ............................................................................................................................................................................................... 1year

INTERNAL MACHINE HOSW ......................................................................................................................................................................... 1year

HIGH PRESSURE BY PASS VALVE ................................................................................................................................................................ 1year

EXTERNAL MACHINE HOSE’S ........................................................................................................................................................................l year

BELTS, FITTINGS, FfLTER SCREENS, GAUGES ....................................................................................................................................... 1year

WATEH HEATER OR HEAT EXC~NG~ .................................................................................................................................................l year

HIGH PRESSURE PUMP.(?brougtI on@MtManda@w)..........................................................................................................................................l year

AIIcomponents not specificallyyreferenced in the above schedule are covered under this warranty for aperiod of one (1) year, exmpting those parts

which are considered, by HydraMaster, to be expendable in normal use.

Freezing of any water or chemical related romponent will VOID all warranties on waterer chemical related components. internal or external. of this

equipment.

Deposits and build-up in the water system, chemical system or beater system due to hardness in tbe water used or chemicals which result in deposits,

will void all warranties on affected components.