Download AquaCat Owners Manual

6
AQUA CifTMANUAL
INDEX
PAGE
I NI)EX
2,
WARRANTY POLICY
2A,
WARRANTY CLAIMS
3,
PARTS
ORDER
3Ao
PARTS
ORDER INSTRUCTIONS
4,
SPECIFICATIONS
4A,
SPECIFICATIONS
4B ,
SPECIFICATIONS
5,
GENERAL
FORMS
INSTRUCTIONS
INFORMATION
MAINTENANCE
6A,
MAINTENANCE
6B,
AQUA CAT MAINTENANCE
6C,
BLOWER LUBRICANT
6D,
AQUA CAT COMPONENT DRAWING
7,
TRUCK
7A,
UNIT
LOCATION
#l
7B ,
UNIT
LOCATION
#2
7C,
TRUCK
7De
FLOOR GAS HOOK-UP
8,
OPERATING
9,
FREEZE
PROTECTION
PROCEDURE
9A.
FREEZE
PROTECTION
PROCEDURE
LOG
DRAWING
DRAWING
PREPARATION
PREPARATION
INSTRUCTIONS
DRAWING
DRAWING
PRECAUTIONS
10aTROUBLESHOOTING
-
ENGINE
11 n
TROUBLESHOOTING
-
BLOWER
12,
TROUBLESHOOTING
-
PUMP/COUPLER
1
—
–—
INDEX CONT,
b
.<
PAGE
13,
TROUBLESHOOTING
-
PRESSURE
LOSS
14,
TROUBLESHOOTING
-
CHEMICAL
FLOW LOSS
15,
TROUBLESHOOTING
-
WATER FLOW
16, TROUBLESHOOTING
-
OVERWETTING
PRODUCT SUPPORT BULLETINS
17,
SEE PRODUCT SUPPORT
BULLETIN
INDEX
HOSE DIAGRAMS
AQUA CAT
18a AQUA
-
CAT FLOW DIAGRAM
19,
AQUA CAT CHEMICAL
20,
BY-PASS
21,
INCOMING
22,
HYDRA-HOE
ASSEMBLY
23,
HYDRA-HOE
VALVE
24,
HYDRA-HOE
NOZZLE
25,
AQUA CAT EXHAUST
26,
AQUA CAT HEAT
EXCHANGER DRAWING
27,
AQ(IA CAT FUEL
SYSTEM
28,
AQUA CAT ELECTRICAL
VALVE
FLOW DIAGRAM
DRAWING
WATER REGULATOR
ONAN ENGINE
MANUAL
ONAN ENGINE
PARTS
DRAWING
DRAWING
ASSEMBLY
DRAWING
END ASSEMBLY
DRAWING
DRAWING
DRAWING
DRAWING
8 SERVICE
CATALOG
PUMP MANUAL
PRODUCT SHEETS
ADVERTISING
& PROMOTIONAL
AIDS
1A
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,,.
PRODUCT SUPPORT BULLETIN
INDEX
CARBON REMOVAL
ENGINE
VALVE
CLEANING
-
ADJUSTMENTS
STROKE
PSB - HM - I.00
ENGINE
ONAN
-
PSB - HI!- 101
PSB - HM - 102
PROCEDURE
WATER SOFTENER
PSB - HM - 103
CHEMICAL
PSB - HM -104
BUILD-UP
VACUUM TANK
CLEATS
FILTER
FOR SECURING
VAC RELIEF
VALVE
PSB - HM - 105
BAGS
UNITS
To
VAN
MODIFICATION
PSB - HM - 106
PSB - H1’1
- 107
HEATER REGULATOR SCREEN
PSB - HM - 109
LUBRICATION OF UNIV, COUPLER BEARINGS
PSB - HM - 111
REMOVAL & REATTACHMENT OF FITTINGS
ON HEAT EXCHANGER
PSB - HM - 112
USE OF A WATER SOFTENER
PSB - HM - 113
SYNTHETIC OILS IN ONAN ENGINE
PSB - HM - 115
USE OF DE-ICERS IN ONAN ENGINES
PSB - HM - 116
SERVICE MEMO
PSB - HM -119
*
.
*
MANUFACTURER’S
LIMITED WARRANTY
Hydra-Master
manufactured
~orporatlon
or supplied
-
extends to the orlglnal purchaser of goods fOr use, the fOllOwlng WarranlY
by Hydra-Master, subject to the qualifications indicated.
COVerln9 goods
THEREIS NO OTHEREXPRESSED
WARRANTY
IN NO EVENTIS HYDRA-MASTERLIABLE
FOR INCIDENTALOR CONSEQUENTIALDAMAGES.
1. Hydra-Master corporation
warrants to original purchaser for the periods set forth herein that goods manufactured
or
supplled by It wIII be free from defects In workmanship and material, provided such goods crre Installed, operated
and maintained in accordance
with Hydra-Master’s written Instructions and fhat such installations are performed or inspected by Hydra-Master’s Authorized Representatives.
PRODUCT OR SYSTEM
CLEANING UNIT
Engine
VacuumlBlower
High Pressure Pump
Heater System
Frame
Instruments & Instrument Panel
Hoses (Internal]
Cleanlng Tools
Hose Reel(s]
Tanks
Fuel
Vacuum
HOSESAND HITINGS (EXTERNAL]
Internal Controls & Valves
All Fittings (Internal)
Main Power coupler [Eng, to Vacuum)
One Year or11000
hours from date
of purchase.
High Pressure Hose
Vacuum Hose
Quick Connectors or
Solutlon Couplers
Pulley Belts
Garden Hose
Three Months [90 Days)
from date of purchase.
Warranty expires
upon aftalnlng
either of the above
NOTE:The Ninety day limitation on Warranty regarding
hoses and quick connect fittings equals or
exceeds warranties extended by respective
manufacturers/suppliers,
2. Hydra-Master’s sole Ilabllify and purchaser’s sole remedy for a faiiure of goods under this Warranfy and for any and all
other ciaims arising out of the purchase and use of the goods, includlng negligence
on the part of the manufacturer,
shall be limited to the repair of the product by the repair or replacement,
at Hydra-Master’s option, of parts that do not
conform to this Warranty. Product or part(s) must be returned to HydraMaster
Corporation, 20309- 64th Ave. W,, Lynnwood, Washington 98036, transporfatlon charges prepaid,
3. WARRANTY DOES NOT INCLUDE: reimbursement for iabor, travel t}me, mileage or work ~oss kmurred In the removal,
reinstallation or replacement
of parts and/or equipment approved
under the provisions of this Warranty.
4. THIS WARPANIY
A.
B.
C.
D.
E.
F.
G.
H.
1.
SHALL NOT APPLY TO:
Cost of maintenance,
adjustments, installation and start-up.
Failures due to normal wear, accident, misuse, abuse, negligence
or Improper installation,
Products which are altered or modified in manner not authorized by Hydra-Master Corporation in writing.
Failure of goods caused by defects in the system or application
in which the product is Installed, i.e. truck, van,
building, etc.
Telephone, telegraph,
telety~
or other communications
expense.
Living and travei expenses of persons performing service excepting those authorized by Hydra-Master under prior
contract.
Rentai equipment used whiie Warranty repairs are being performed.
Overtime labor requested by purchaser.
Parts, sub-assemblies, assemblies or major components affected dkectly or indlrecfly by freezing.
IMPORTANT: Freeze Guard Systems incorporated within units either as standard equipment or as options are convenience items only, Hydra-Master
assumes no respansibllify for their failure, power failures affecting their performance or any resultlng damage.
Items susceptible
a.
b.
c.
d.
e.
f.
to damage
by freezing
are as followS
Pressure & Solutlon Gauges
Flow Meters
High Pressure Pumps
Heater or heat exchanger
components
Hoses
Fittings (steel, brass and PJastlc)
g.
h.
L
j.
k.
1.
Solufion quick connect fltfings (couplers]
Reiief valves or high pressure by-pass valves
Cleaning tools and their respective controls/valves
Regulators and solenolds
Solution & pressure switches
Pump clutches damaged
by frozen pumps
5. No @rson Is authorized to extend any other warranties or fo assume any other Iiabillfy on Hydra-Master’s behalf unless
made or assumed In writing by an officer of HydraMaster
Corporation and no person is authorized to give any warranties or assume any ofher liabilities on behalf of seller unless made or assumed In writing by seller.
Claim
WARRANTY
DATE
Customer
CLAIM
No.
CLAIM
FILED
Name
Address
city
State
Equipment
Model
Serial
Purchased
From
Date
No. of Hours
Briefly
Used
Describe
Defective
zip
No.
Purchased
Part
Defect
Signature
******************************************************************
Factory
Date Part
Describe
Action
Use Only
Received
Inspected
By
Findings:
Taken:
Amount
2030964th
Ave. W@Lynnwood,
Washington98036
of Claim
$
●(206)775-7272
,..
@
PARTS
Dear
ORDERS
Customer,
To expedite your parts needs, please call your
In most instances,
Regional Sales Representative.
he either stocks or has access to parts through a
Regional Service Center.
In the event parts are unavailable
locally, your
Sales/Service
Representative
will contact Hydra-Master
If this becomes necessary,
and coordinate
your needs.
always indicate the method of shipment you desire, i.e.
UPS, UPS Blue Label, Air Freight, Air Express, Etc..
Thank you for your compliance with the above
and we shall do our best to fulfill your needs.
WARRANTY
request
NEEDS
Hydra-Master
Warranty is second to none and provides you the assurance of continued reliability.
We
realize the importance
of minimum down time which can
The
only be achieved through manufacturers
support.
following procedure
defines the steps necessary
to
Compliance
with i.t i.s essprovide you this service.
ential if parts are required.
1. Call
(206)
Hydra-Master
775-7275)
Corporation
and provide the
following:
A. Name of Company and address
B. Model of equipment
c. Date of purchase
D. Hours on the unit
E. Serial number of unit
F. Name of person authorized
to order parts
G. Salesman unit purchased from
H. Description
of the problem
I. Pressure readings on high pressure crau~e
with wand turned on and-tu~ned
off - 2. Method of shipment - UPS, Air Freight,
Air Express, Auto Freight, Etc..
2030964thAve.
W.*Lynnwood,WA
93036.(206)775-7272
Air Mail,
3. DO NOT give malfunctioning
part(s) to a sales/
service representative.
All parts must be returned, freight prepaid, to Hydra-Master
Corp,
oration for evaluation.
Hydra-Master’s
warranty
policy provides parts without charge for thirty days to customer maintaining
good
credit rating.
Malfunctioning
parts must be returned
directly to Hydra-Master
Corporation
for final disposition.
Un-approved
warranty evaluations
and/or failure
to return part(s) for warranty consideration
will result
in appropriate
charges.
Detailed instructions
always
accompany each shipment to outline both your obligations
and options to the warranty procedure.
Any questions
you have regarding the warranty pro–
gram should be directed to service personnel
at HydraMaster Corporation.
We shall endeavor to be fair in
our evaluation
of your warranty claim and always provide you a complete analysis of our findings.
AQUA
9
CAT SPECIFICATIONS
GENERAL
Warranty
* One Year
Dimensions
* 48” L x 32” W x 34” H
Weight
* 550 Lbs.
or 1000 Hours
COMPONENTS
* 20 Horsepower Onan
Industrial WaterCooled
A. Engine
RPM
* 2600 Factory
mended
Fue 1
* Unleaded
Oil Capacity
* 3+ Quarts
* 2600 Factory
mended
RPM
c.
W/Filter
* Positive Displacement
(Lobe Type)
B. Vacuum/Blower
Water
Lift
Recom-
& Air Flow
Recom-
* 195-210
inches
275 CFM
Pre-set
Oil
*
40 S.A.E.
Grease
*
High
*
Positive Displacement
Piston W/Stainless
Cylinders
Oil
*
Special Cat Oil
Lubricant
Pressure
*
300 PSI Factory
Pre-Set Adjustment
Pulley
*
5L380
*
900
Water
Pump
Belt
R.P.M.
* Tube
D. Heat Exchanger
* 190
Heat Setting
Tank - Exchanger
Temperature
Storage
Type
-
200
Bearing
Stainless
Max
* Anodized Aluminum
(Non-Corrosive)
E. Frame
*
Legs
Construction
* Steel
,,
* Retractable
Wheels
Recovery
* Anodized
Tank
W/Castered
Aluminum
F. Hoses
* Teflon
forced
Internal
W/Steel
Sheath
Rein-
External
Solution
* High Pressure - Non
Marking 2500 P.S.I. Rated
External
Vacuum
* Heavy Duty Flexible
and Non-Marking
G. Tools
Hydra-Hoe
Stair
Carpet
Sprayer
Stair Vacuum
H. Battery
I. Safety
Features
Wand
* Stainless Steel
W/Adjustable
Handle
and High Pressure Valve
Jet Size 8006E
*
Replaceable
*
Hand Held W/Single
8006E
*
Cast Aluminum
*
12 VDC
*
Enclosed
*
Automatic Vacuum
Tank Limit Switch
*
Over Temp Limit
Switch W/Auto Pump Out
*
Over Temp Engine
Shut Down
*
Incoming Water Pressure
Switch W/Auto Shut Down
Capability
*
*
*
*
0-1000 PSI Glycerine
100-200 Degrees
Lips
Jet
- VW Type
Frame
J. Instrumentation
Pressure Gauge
Temperature
Gauge
Vacuum Gauge
Hour Meter
Chemical Flow Meter
Choke
Service Computer
0-30
Filled
HG
Total Lapse Time
and Te”nths
* 0-10 Gallons/Hour
* Mechanical
* Electronic
in Hours
Over, ’l?emperature Indicator
Eng. Temp. & Water Temp Switch
Master Fuse
Charging Fuse
K. Options
Systems
and Auxillary
PANEL
20
15 AMP
AQUA
CAT
STEEL
0-1000
PSI
GLYCERINE
FILLED
100-200
DEGREES
0-30
HG
HOURS & TENTHS
OF HOURS
0-10
GPH
CHARGING FUSE
FREEZE GUARD FUSE
VISUAL
ON INDICATOR
HI-TEMP
INDICATOR
AUX. PUMP INDICATOR
SERVICE REQUIRED LIGHT
& WATER
Switch
AMP
STAINLESS
HIGH
PRESSURE
GAUGE
TEMPERATURE
GAUGE
VACUUM GAUGE
HOUR METER
CHEMICAL
FLOW METER
MASTER
POWER FUSE
CHOKE
ENGINE
TEMP
AUX.
PUMP
Auto Bulb
Electrical
* Pump-in System W/Aux.
Pump & Holding Tank
For Transporting
Water
supply .
SPECIFICATIONS
DASH
*
*
*
*
TEMP
30 AMP
15 AMP
15 AMP
AUTO TYPE
AUTO TYPE
AUTO TYPE
AUTO TYPE
PULL TYPE
ELECTRICAL
ELECTRICAL
BULB
BULB
BULB
BULB
SWITCH
SWITCH
flri
GENERAL
INFORMATION
This manual contains installation
and operation
instructions
as well as information
required for proper maintenance,
adjustment and repair of this unit.
Since the first and most important part of repair work
is the correct diagnosis of the trouble, a general
troubleshooting
section and component manual troubleshooting charts have been included for your convenience.
Unlike the garden tractor, lawnmower and cement
mixer all having one and maybe two functions to perform, the Hydra-Master
truck mounted carpet cleaning
plant has many functions to perform simultaneously.
1. Engine has to run consistent RPM.
2. Vacuum has to pull air and dirty water back
from cleaning site.
3. Water pump provides stable pressure at proper
water flow for cleaning.
4. Chemical has to be injected into the water
stream at the right consistency.
5. Heater must fire on demand and maintain
proper
heat.
(Except for Aqua Cat).
6. Vacuum tank must store dirty water until drained.
with
As you can see it is n’ot just a turn key operation
only one thing to worry about, DOES IT S~AR~?l
As there is no guesswork in the manufacture
of these
highly advanced cleaning plants, there nust be none in
preparing
it to get the job done in the field.
It is the
purpose of this manual to help you properly understand,
maintain and service your Hydra-Master
cleaning plant.
Follow the directions
carefully and you will be rewarded
with years of profitable
trouble-free
operation.
It is imperative
that no section be overlooked
preparing
for operation of this equipment.
when
=
Hydra-Master
uses this symbol
throughout the manual to warn
of possible injury or death.
=
This symbol is used to warn
possible equipment damage.
of
MAINTAIN
GOOD
PROFIT
-
WITH GOOD MAINTENANCE
In the past 3 years, we at Hydra-Master
have become alarmed
increasing number of calls pertaining
to service problems.
at the
Our findings are that 85% of all down time is a direct result of poor
maintenance
habits.
If maintenance
is a difficult function to schedule
into your busy operation,
here is one important parallel that may influence your thinking toward maintenance
procedure:
Each
hour
of machine
A
hour
average
5+
operation
day equals
is equal
31O
5 day week
or 27+ hours
Each month
an average
of 8660 miles
of average
machine
= 2062.5
operation
miles.
is put on the machine.
is equal
Compare this to your car and the maintenance
for this many miles of trouble-free
driving!
Enclosed is a maintenance
machine and kept in force
GOOD
PROFITS
HYDRA-MASTER
to 103,920
you would
log sheet that should be attached
by a responsible
operator.
AND GOOD MAINTENANCE
WANTS
of driving.
11’ti.leS.
An average
One year
to 75 miles
GO HAND
YOU TO BE A TROUBLE-FREE
give
to the
IN HAND
DRIVER!
miles.
it
HYDRA-MASTER CORPOUTION
DATE
MAINTENANCE LOG
SERVICE ITEMS’
020)
DATE
DATE
DATE
.
DATE DATE
HOURS HOURS HOURS
HRS. HOURS HOURS HOURS HOURS
Inspect Machine Generally
8
8
Check Engine Oil
8
Check Pump Oil
Glean Vac holding tank, Nylon
8
fi~rer bag & S/S fi.1.L~r
Wlbrush
Change Eng. oil (Summer SAE 30)
Winter SAE 20) 3 Qts. W/O oil
.
fi L.@r % Qtis. W/OiJ_.&lt@r
. 30
Disassemble H/P bypass valve &
c?)
1(30
Remove Machine from Truck for
Complete inspection of:
100
Battery Electrolytes
100
Belts and Pulleys
Fuel Lines
100
Nuts and Bolts
100
100
Heater cover (Except Aqua Cat)
Heater Burner Assy. (Ex.Aqua Cat) 100
Service Air Cleaner
100
Clean Vacuum Tank (free float
100
hinge of lint & lube)
Spray Quick Connectors (all)
with WD 40
100
Lightly Oil Direct Drive Shafts
100
Check for Chafing Wires
100
Tighten Exhaust Manifold Clamps
100
Tighten Dodge Coupler (direct
drive) (DO NOT OVERTORQUE)
100
Replace Engine Oil Filter
200
Replace Spark Plugs (LP gas
gap .018/gas gap .025}
200
Change Blower Oil (40 wt. nondeter~ent)
200
Replace Points & Condenser
(fZP,
DATE
—
—
—
300
Greas~ Blower Fittings
300
Change Pump Oil (Cat Oil)
300
Lube Throttle Lever
300
Heater Slide & Button Assembly
300
Check Engine Valve Clearance &
Decarbon Heads
500
1000
Replace Pump Short Cup Kit
Inspect Valves (grind if net.)
1000
Charge Battery W/Lead Wires
Disconnected
* Engine Oil
Summer 30 SAE
* Blower Oil
40 SAE Non-Detergent
* Pump Oil
Special Cat Oil
Recommended Fuel - Unleaded Gasoline
SERVICE REMINDER - The Service Reminder operates on 50 hr. cycle. When Service
Reminder light is on it is time for 50 hr. check. On completion of 50 hr. check,
set switch located on the computer (on back of dash panel). After re-setting
switch to the opposite position the computer is ready for another 50 hr. cycle.
Be sure to follow the maintenance log suggestions supplied with the manual.
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-HEAT
EXCHANGER
CHEMICAL
TANK
FUEL
I
H - M
TRUCK
Truck Prep.:
Decide
Materials
location
PREPARATION
needed:
of machine
1-79
1. 6’ x 12’ Ozite indoor/outdoor
carpet
2. 4x8x5/8° Plywood (1 side good)
1+” sheet metal screws
3.64.1l“xI’’xI8” angle iron
5.32“x5/16” bolts
5/16” flat washers
6.35/16” lock washers
7.38.35/16” nuts
9. 1 can marine adhesive
10. 1 staple hammer or glue gun
11. 1 gas hook-up (thru floor mount)
in Van.
are side door.
A. Side door: Most installations
This
provides rear access for accessories and hoses as
well as unobstructed access to component/working
side of machine, thus making it a bit easier to
perform maintenance and/or repair without removing
unit from the truck.
B. Rear door: Although this location partly limits
working access, it does direct the noise away from
the cleaning site.
Some cleaners in the colder
areas prefer this location because it puts the
weight mass over the rear wheels for better traction in ice and snow.
Rear mounting requires the
unit to be slid to the right side as far as POSSible.
This not only provides adequate working
space on the component side of the unit but also
makes better weight distribution
inside the Van
(engine and component wt. line up over drive shaft).
Also, it is physically easier to load unit into
rear door due to height of Van bed.
When carrying
water, tank will then be located over center of Van.
EEEl
Ensure that machine is well secured to the floor
of Van w/hardware supplied.
Sudden or crash stop
will cause machine to rocket forward, all 550 lbs.
worth ! Protect your driver and machine. SECURE IT!
II
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UNIT LOCATION
—-——..._II
D~y@J&
4“3-79
5CA&
@ 1978
D&NAwN~JR.
.A?PRwD
DATE
HYDRA MASTER CORPORATION
1
7,-
.
a&1. 611002
2. 613024
3. 619130
4. 625701
5. 637104
6. 620104
7. 612090
8. 613025
9. 620305
.0.625700
PART
DESCRIPTION
QUICK CONN.SOCKET
HOSE BARB
SCREW
PLATE
HOSE
HOSE CW
FITTING
HOSE BARB
TIE WRAP
THRU FLOOR GAS HOOK
UP (Kit)
!TY ,
n
ISEI
-
1
2
2
1
1
4
1
2
6
1
I
‘f-r
/-Lrfi!a77”
8
(3
.
Uba Z%M 10 b&.Mf?
iO
al
rninhq
/J+2
8“
A
I
Q
43
(
FLOOR GAS DIAGRAM
T- @%@g
Xo ,
tabi-tize
hohe ,DF(wG NO
@om the Exhutik ,
HM-12A
the@am(z
and
—w
@
[email protected]
1978
o
DATE
]?WANT,JRPPPRV”
14-4-79
HYDRA MASTER CORPORATION
AQUA
OPERATION
MACHINE
ENGINE
ADJUSTMENTS:
COOLING:
CAT
PRECAUTIONS
ALTHOUGH THIS UNIT HAS BEEN FACTORY
ADJUSTED IT MAY REQUIRE ADDITIONAL
ADJUSTMENTS
TO ACHIEVE OPTIMUM PERFORMANCE ; I.E. ALTITUDE MAY REQUIRE
CARB ADJUSTMENT AND AMBIEIJT TEMPERATURES MAY REQUIRE HEAT CONTROL ADJUSTMENT.
WHEN REQUIRED, RE-ADJUST–
MENT MUST BE ACCOMPLISHED
BY AN AUTHORIZED HYDRA-MASTER
REPRESENTATIVE
OR
WARRANTY MAY BE INVALIDATED.
UNITS EMPLOYING AIR COOLED ENGINES
MUST NOT BE INCAPACITATED
WITHIN A
VAld WITH DOORS AND WINDOWS CLOSED.
EXCESSIVE TEMPERATURES
WITHIN THE
ENGINE WILL RESULT IN PREMATURE
ENGINE FAILURE AND A COMPROMISE
OF
APPLICABLE
WARRANTY
A. WHEN RUNNING THE AQUA CAT
THE COLD WATER SOURCE MUST
BE CONNECTED TO KEEP ENGINE
PROPERLY COOLED.
LEVEL :
DURING OPERATION,
VAN OR TRAILER MUST
BE PARKED ON LEVEL GROUND NOT TO EXCEED
+ OR - 10 DEG..
FAILURE TO INSURE PROPER LEVELING MAY PREVENT PROPER INTERNAL
LUBRICATION
OF ENGINE, VACUUM AND/,OR
HIGH PRESSURE PUMP COMPONENTS.
FREEZE
PROTECTION:
ALL UNITS ARE EQUIPPED WITH FREEZE
PROTECTION DEVICES AND/OR INSTRUCTIONS PROVIDED ON OPERATING LABELS
FOR THE PREVENTION
OF FREEZE DAMAGE.
a
FAILURE TO PERFORM RECOMMENDED
STEPS
OR USE SYSTEMS DESIGNED FOR THIS PURPOSE CAN RESULT IN EXPENSIVE COST, DOWN
TIME AND COMPROMISE
TO APPLICABLE
WARRANTY .
8
FREEZE
PROTECTION
PROCEDURE
Protecting
the Aqua Cat from accidental
freezing is a
relatively easy task if the following procedure
is complied
with.
Failure to adopt it in sub-freezing
climates may
result in costly repair or replacement of components.
1. Drain the water from the hot water
tank with the drain hose provided.
recirculating
2. Pour 5 gallons of 50/50 antifreeze and water into
the recirculating
hot water holding tank.
Lid on
tank must be removed to perform this step and then
replaced.
NOTE:
Antifreeze
solution must be checked with
each use to ensure safe levels are maintained since dilution will occur.
It is
recommended
that levels are monitored
frequently and antifreeze added as necessary to provide an added ten degree
margin of safety.
3.
To effectively
pump antifreeze solutions throughout
fittings, hoses, engine, pumps, etc. , start unit
without incoming water attached and with safety
pressure switch locked out using the switch provided
for this purpose located on the dash panel.
4.
With solution hoses and cleaning tool attached, draw
antifreeze
solution or alcohol through the chemical
flow meter and hoses for 20 - 30 seconds.
Unit is
effectively
freeze guarded when antifreeze
solution
starts to discharge from cleaning tool.
5. Prior to turning unit off, move rocker lock-out
switch to its opposite setting to open the overtemperature
solenoid on the hot water discharge
This ensures total elimination
of water
line.
from all remaining water lines.
6.
Prior to starting future cleaning
following must be performed.
A. Drain antifreeze
sealed container
operations
the
solutions into a 5 gallon
and save for future use.
9
t
B. Attach incoming water supply hose just prior
to starting unit and flush antifreeze
from
unit by turning cleaning tool on.
Cleaning
operation
can resume once antifreeze
no longer
is emitted from the cleaning tool.
NOTE:
All hoses containing
antifreeze
must
be cleared in this manner to prevent
possible discoloration
to carpet
fibers.
7. Repeat operations
1 through
for the day or when placing
5 when retiring the unit
unit into storage.
M HOSE
\
FIGURE
A
HOSE
BARB
TROUBLESHOOTING
I.
ENGINE
ONAN
INDUSTRIAL
(Ref. Onan Operation
PROBLEMS
FAILS TO START
ENGINE STOPS WHILE
CLEANING
ROUGH RUNNING
BACK FIRING
CAUSE
-
1. Loss of fuel
2. Blown
Manual
AND/OR
- Sect.
12)
SOLUTION
: Plugged fuel line.
Defective
fuel pump.
Empty gas tank.
Kinked fuel line.
fuse:
Electrical
short\coil open.
Coil wires not fully inserted in coil.
3.
Maladjusted
4.
Oil on points:
Drill 1/8” hole in point
box cover approx. 3/8”
from bottom. Clean points.
5.
Check
plugs:
Remove and/or replace/clean.
Check for spark.
6.
Check
compression:
7.
Float
valves
8.
Bad starter:
9.
Plugged
Points.
Possible
in recovery tank: Stuck in
upright position or defecNOTE: Disconnect
tive.
float wire.
Check for loose wire
connection.
Carburetor
10.
Lack of engine
11.
Choke
jammed
hung valve.
or
jet.
oil:
Engine
seized.
(on gas models) push
of carburetor.
to rear
12. Too lean a gas mixture: Adjust at T-Handle
on bottom of carburetor.
13.
Dead Battery:
No water.
14.
Loose
cable
15.
Engine high temp. switch on block defective
or stuck open.. (Will short to ground).
16.
Incoming pressure
lack of-incoming
fective.
battery
at battery.
switch
water
not closed due to
or switch is de10
I
I
I
AQUA
CAT
t
TROUBLESHOOTING
(CONT.)
II. VACUUM BLOWER - SUTORBILT - POSITIVE DISPLACEMENT
Ref. Blower Operation/Maintenance
Manual Section
NOISE
IN BLOWER:
1. Loose
direct
2. Skip
timing.
3. Worn
Gears.
drive
coupler.
II
(Do not use) .
4. No oil or grease.
5. Foreign
material
(internal).
6. Bad bearings.
1. Obstructed
plumbing.
LOSS OF VACUUM:
or pinched
2. Pop-off/Relief
Repair/lube.
* 3. Stainless
valve
Steel
hoses
in vacuum
malfunction
filter
-
is plugged.
* 4. Open dump valve.
5. Lint build-up between Blower and waste
tank (not using recovery tank filter bags).
* 6. Tank lid not sealed
material.
*
Most
due to worn
coping
frequent.
11
TROUBLESHOOTING
(CONT.)
t
III. PUMP:
(See Cat Pump Manual
Section 10)FAILS
HIGH PRESSURE
for Charts,
PUMP
Terminology
& Number
Code
1. Chemical build-up due to non-compliance with standard operating
(Start-up & Shut-down).
procedures.
TO OPERATE:
2. Damaged
or worn
3. Damaged
cylinder
4.
Damaged
5. Debris
spring
piston
cup piston
“O” rings
“O” rings
lodged in discharge
assembly
valve
WATER
IN OIL:
6. Damaged piston rod seal, washer or
Replace
“O” ring (piston sleeve).
or rebuild
WATER
LEAK:
7.
Cracked
(hairline)
charge manifolds
8. Loose
Iv.
VIBIWTION:
MISALIGNMENT
DIRECT
DRIVE
or damaged
inlet
fittings
or disor elbow
COUPLER
Tighten bolts and Allen screws.
(Also Allen screws that secure
Coupler to shafts of engine and
Blower) .
:
Due to loose bolts
Blower mounts.
on engine
or
*
A~UA
CAT
TROUBLESHOOTING
V. LOSS OF HIGH
(CONT.)
PRESSURE:
1. Air leaks in low pressure
chemical flow lines.
side of system
or
2. Relief valve
malfunction
- disassemble
and clean.
apply a light coat of grease (Lubriplate) to
spring and ‘o’ ring assembly when re-assembling.
3. Damaged
4 High
high
pressure
5. Crumpled,
pressure
NOTE :
- reads
incorrectly.
pump malfunction.
collapsed
or twisted
6. Check the garden hose
water quick connector
material.
7.
gauge
garden
hose.
screen behind the incoming
for blockage by foreign
Slipping pulley on pump, key in key-way
Allen screws gone, worn belt.
gone,
By isolating or checking one function at a time
the problem shows up much quicker and negates
any possible damage to the machine.
13
.>
TROUBLESHOOTING
VI .
LOSS OF CHEMICAL
NOTE :
(CONT.)
FLOW:
1.
Plugged
filter
2.
Crimped
hoses.
3.
Jammed flow meter float ball at bottom
usually due to chemical build-up.
4.
Improper
5.
Low or improper flow of water through system/measure
water flow at cleaning tool.
This flow should measure
1.5 gallons per minute with machine running at 300 PSI.
6.
Broken
7.
Clogged
8.
Flow
mixing
wire
in chemical
jug.
(5 gal.)
of meter,
of chemicals.
to chemical
solenoid
switch
screen
solenoid
on top of Cat pump.
valve.
malfunction.
Again we remind
consistent high
you that chemical flow depends on
pressure flow to the cleaning tool.
14
A@A
CAT
TROUBLESHOOTING
VII.
FREEZING:
WATER
(CONT.)
FLOW
If unit has been exposed to freezing conditions,
the
Prior to trying to start,
entire water flow may be affected.
attach water supply and thoroughly check for leaks or malfunctions.
Freezing - Loss of or reduced solution flow.
(The following
are possible and/or probable problems which occur during
freezing) .
DAMAGED:
Quick connect couplers - replace
Incoming water regulator and incoming
pressure switch
- replace
Heater water flow regulator - rebuild
(Except Aqua Cat).
Expanded, warped or cracked inlet or
discharge manifolds on Cat pump. (Hi
pressure/Lo
pressure) Ref. #31,54 Cat
Pump Manual.
Broken and/or damaged seals or retainers
on pump piston rod assemblies,
Ref.
Inlet Manifold.
Hi-pressure
relief valve warped.
Cracked chemical check valve - (Except
Aqua Cat) .
Cracked chemical flow meter.
Expanded valve damage to trigger assem(Plunger). “
blies on all cleaning tools.
NOTE :
On Aqua Cat, check heat exchanger
for any
Also check solenoids
cracks or leaks.
and hoses where applicable.
Inspect all fittings
or damage.
and hoses
for leaks
H-M
VIII
leaves
OVER
1-79
- WETTING
Over-wetting
is annoying to all concerned
a bad impression
of the cleaning process
There
are several
areas
1. Too few vacuum
2. Obstructed,
3. Vacuum
4. Clogged
strokes
kinked
tank drain
vacuum
that will
cause
and sometimes
used.
over-wetting:
or improper
vacuum
strokes.
or cut hoses.
valve
blower
left partially
open.
filter.
5. Cleaning a heavily foam-saturated
defoamer.
(We recommend crystal
carpet
type).
without
due
6. Vacuum relief valve not operating properly,
to wear and misalignment,
or adjustment may be
required to increase vacuum to original factory
setting.
(14-15 HG).
NOTE :
1979 model has vacuum relief
tank lid and has been preset
valve built in to
at the factory.
-
IF.
.
@
HYDRA
~jj
MASTER
%
%
No.
PSB-HM-1OO
Date:
8-11-77
CORPORATION
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
HYDRA-CAT, BOB-CAT
& AQUA CAT
Subject:
CARBON
REMOVAL
Units
removal
hours
comply
could
will
result
void
the engine
service
must
carbon
Service
expense
removal
throughout
2030964thAve.
with
warranty
is relatively
the Onan
W.*Lynnwood,WA
500
Failure
and costly
as tune-ups,
carbon
every
Manual.
the country.
be scheduled
in the same manner
require
approximately
manufacturers
in unnecessary
to perform
gasoline
chambers
by the Onan
sive but does vary
Center
on regular
from combustion
The cost
this
Section Insert#:
- ENGINE
operating
as defined
Publications
and
down
Service
98036.(206)775-7272
time.
inexpen-
Normally
etc..
to
PSB-HM-~()]
No.
Date: January 1977
TM
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
Publications
Section Insert#+:
ALL
Subject: ONAN ENGINE VALVE ADJUSTMENTS
To ensure continued reliability
from the ONAN engines
incorporated
in our units, it is NECESSARY to adjust both
intake and exhaust valves after 300 hours of use. Fai~
to comp~with
this suggestion m~necessi=te
a valve
repair after 500 hours of use and can compromise engine
warranty during the warranty period.
The condition which will often occur if valves are
not adjusted is power loss and damage to valves and valve
seats.
Instructions
for preventive maintenance
procedures,
i.e. tune-up, oil changes, carburetor breather filter, fuel
adjustment,
valve adjustments,
etc. are outlined in the ONAN
Your
Service Manual contained in the Hydra-Master
Manual.
local small engine service shops as well as ONAN Service
Centers are qualified to perform necessary adjustments.
2030964thAve.
W.@Lynnwood,WA
98036.(206)775-7272
PSB-HM-102
No.
1~7~
~dd?: JANUARY
FIWDRA4
MASTE=
CORPORATION
PRODUCT SUPPORT BULLETIN
Service/Parts/Publications
Model(s):
Section Insert#$:
ALL
Subject: CLEANING
STROKE
PROCEDURE
PURPOSE :
To eliminate excess moisture
and the sawtooth appearance which
of the cleaning tool.
remaining in the carpet fiber
results from diagonal movement
SCOPE :
All types
of carpet.
PROCEDURE:
Always move the cleaning tool in smooth forward and backApply slight pressure on the forward stroke
ward strokes.
When extractwhile the solution is injected into the carpet.
ing (drying) , apply firm pressure on the forward stroke to
ensure a positive “lock” for the vacuum and minimize the
During the
“hopping” effect resulting on unsmooth carpet.
forward and reverse strokes, movement to the right or left
should only be accomplished
at the extreme rear of the stroke.
A drawing is provided below to illustrate this technique.
Overlapping
is also important to ensure even application
of
solution to prevent saturation.
fiber
F-.ilure to adopt the above procedure can result in increased
shrinkage, brown out, and longer drying periods.
INCORRECT
METHOD
CORRECT
METHOD
I
Kz a
CLEANING
I
TOOL
STROKE
L
STROKE
FORM
2030964thAve.
I
W.*Lynnwood,WA
9?3036*(206)775-7272
#
m
PSB-HM-103
No.
Date:~
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
ALL
Subject:
WATER
Publications
Section hsert#:
SOFTENER
Many areas of the country have an excess of minerals
in the water which results in what is commonly called “hard
water” . These minerals tend to adhere to the insides of
heater coils and other parts of the machines causing damage
and a loss of cleaning effectiveness.
Reports from several of our machine users commending
the results of the use of water softeners in conjunction
with their machines prompts us to recommend the procedure
everyone in a “hard water” area.
to
The relatively
low cost of a water softener service is
more than made up for in the increased life of machine parts
and continued cleaning efficiency.
Contact a water softener distributor
in your area foe
information
on the rental of a simple water treatment unit
to carry in your truck.
See installation
diagram
below.
FORM
2030964thAve.
W.*Lynnwood,WA
98036.(206)775-7272
#
No.
Date:~
m
PRODUCT SUPPORT BULLETIN
Service/Parts/Publications
Model(s):
ALL
Subject:
CHEMICAL
TO
IS
THE
Section Insert#:
SAVE
KEY
CUSTOMERS
HOURS
OF
MAY
THESE
ICAL
WATER
TO
OR
EVERY
HOSE
VINEGAR
LEAVE
IN
SYSTEM
OCCUR
TO
INTERNAL
THE
SAME
BREAKDOWN
LIFE
FOR
WHITE
MANNER
BUILD-UP
YOUR
SUCH
OF
-
HOURS
MACHINE
OF
PULLED
LONGER
WHITE
THE
AND
45
THAN
VINEGER
PREVENT
THE
THE
WITH
WAS
COSTLY
BUILD-
MACHINE
FOLLOW
PLACE
AND
TURN
SYSTEM.
MINUTES
WARM
INJECTED.
THIS
DOWN
AND
TIME,
CHEMON
TOOL
DO NOT
OR DAMAGE
CLEAR
40
TYPES
VINEGAR.
VINEGAR
FLUSH
AFTER
CHEMICAL
RUNNING,
THROUGH
COMPONENTS.
AS
WITH
OUR
DIFFERENT
FLUSH
IS
OF
MACHINES
HEAT,
PROBLEM,
40
SOME
THE
AND
MAINTENANCE
MAY
WATER
WILL
LONGER
MACHINE.
VINEGAR
AS
BE
THEIR
THIS
BOTTLE
ANY
REMOVAL/BREAKDOWN
ENTS
35
A
WILL
FLUSH
BECAUSE
WHILE
IN
93THE
IN
TO
FIGHT
PROTECTIVE
OPERATIONS.
CONDITIONS,
INSTRUCTIONS:
FEED
REMEMBER
SUCCESSFUL
REMEMBER,
OCCUR.
WEEK
MONEY,
NEGLECTING
USE.
UP
AND
MANY
ARE
CHEMICALS,
A
TIME
TO
OF
ONCE
BUILD–UP
HOSES,
IS
A
MILD
OF
EXCESSIVE
FITTINGS
ACID
AND
WILL
CHEMICAL
AND
CONTRIBUTE
BUILD-UP
HEATERS.
I
I
PsB-HM-lo4
2030964thAve.
W.oLynnwood,WA
98036.(206)775-7272
IN
TO
THE
COMPON–
‘?Ibl
No.
pSB-HM-105
Date:
JANUARY
1979
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
ALL
Subject:
VACUUM
Section lnsert#:
TANK FILTER
We have available,
designed
bags,
for your purchase,
at the bottom
if emptied
the day, will
tank.
BAGS
to trap all of the lint,
really collect
these
Publications
eliminate
The drawstring
to the incoming
water
sand and dirt
of your
vacuum
at the end of each
the buildup
top of these
inlet
bags
bags
(~
of the debris
CMl?TY
.
M TANK
BAG
FORM #
W.*Lynnwood,WA
98036-(206)775-7272
in the
to be tied
tank.
\
2030964thAve.
nor-
job or at the end of
WATER TO VACUUM TAN‘K
//
are
The use of
is designed
in the vacuum
that
that would
tank.
of much
INCOMING
II
filter
TM
No.
PSB-HM-106
Date:
April, 1979
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
Subject:
Section hsert#:
Cleats
to Van
Cleats
ment.
prior
The benefits
to be removed
equipment
with
Units
cleats
without
W.*Lynnwood,WA
which
for units
manufactured
as standard
operator
in an accident.
requirements
from the vehicle
2030964thAve.
are now available
and increase
is involved
installation
units
28, 1979.
equipped
are obvious
the vehicle
defines
Hydra-Master
to February
that date have been
the event
below
for securing
floors
for securing
manufactured
after
Publications
safety
in
The drawing
enables
excessive
equip-
the unit
difficulty.
9S036*( 206)775-7272
TM
PSB-HM-107
No.
Date: A~ri.1~ 1979
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
Publications
Section hsert#:
Subject: VACUUM RELIEF VALVE MODIFICATION
Units manufactured prior to March 1, 1979 incorporated a brass plunger type
Vacuum Relief Valve which required daily lubrication. Excessive plunger shaft
wear would result through either lack of lubrication or excessive vibration and
compromised vacuum strength at the cleaning tool.
Units manufactured after March 1, 1979 now incorporate the Vacuum Relief valve
depicted below which requires no daily lubrication. A modification kit is available which can be adapted to existing equipment in the field at a moderate price.
This revision will minimize the over-wetting condition of carpets which can result
through the excessive shaft wear described above.
ZU3UY64thAve.
W.”Lynnwood, WA98036*(206J
775-7272
...
119
No.
Date: ‘ay 1,980
w
PRODUCT SUPPORT BULLETIN
Service/Parts/
Model(s):
Aqm-mt
Subject:
Service
Section Insert #:
Memo
It has come
to Hydra-Master’s
in the heat
exchanger
temperature
and exhaust
replaced
with
an exhaust
If you
shell
attention
are breaking
These
pressure.
a silicone
that
gasket
which
the asbestos
up due
to constant
gaskets
will
part
high
are now being
eliminate
chance
that your
parts
gasket
is not adequate,
(206) 775-7276
department,
please
or your
phone
of
Hydra-
Hydra-Master
.
Representative.
This
gaskets
leak.
find
Master’s
Publications
number
is 225801,
Compression
“-’”n
EXCHANGER
Gasket.
m
///.
SILICONE?
GASKET
‘L_
ASBESTOS
GASKET
203@364th
Ave. W.*Kyamwood,WA
980360(206)775-7272
/ I i I
O“f-J!
A
I
.lRiw#H
I
HOSE
REF PART
No. No.
PART
DESCRIPTION
1. 636020 GARDEN HOSE
2. 636024 SCREEN REPLACEMENT
3. 636022 INLET GDN. HOSE CONN.
(Inc. Screen)
4. 611201 QUICK CONN. PLUG
5. 611101 QUICK CONN. PLUG
6. 611102 QUICK CONN. SOCKET
7. 636001 HIGH PRESSURE HOSE
OTY
USEI
‘)
/
II
1
1
1
1
1
1
%
5
1
L
i&SURG
/AQuA-cAT
DIWW3
NO
SCALE
Ac-IO]
~
O
1978
DQwhl
IiosE DIAGRAM
BY
CW?AN~JR. ~pp’vo
DATE
4-3-79
HYDRA MASTER CORPORATION
\\\
\.—
r
-PFiESSURE
Gu-s
%\
1?
FLOW
METER
L
HIGH
mESSURE
PUMP
i
p
C“HEMICAL
t NTAK E
P
\\
m
VELETE
b.
D&ETE
SOLENOI C)
ShLL VALVE~ FLINE
TO
LPRP
, T-WIM&
6CuEeN, WAN=
HVWT TO LPRP I.INF
--
400 BALL VALVEE FLOW; ADD T-= ITTIN5; CHAMW
6
3 L,?JE
T* FUXIRC.P”UP:GE,C,,-,H
,- “W14T
A
r
I CHGD FLOW TANK
FITTINGS&
.
. .
ET]” “-I
‘-”-
REViSION-
SCREEN
JT
@AT!S
i.~.8ol
CW E
I
~-q
1
.
JBLm
t
OATE
LOW
, v1’-4-S0
I
I@]
- III BY]CKid
I
Q?-
,
PRESSURE
IN
v
17-11-79
1
DATE
I
1
1
0RAWlNf3 MO
AQUA CAT FLOW DIAGRAM
DRAWN Sy
DATE
()
4-
%;;:%
5-79
:
‘z
n.
1
(a
HIGH
PUMP
r
PRESSURE
m
o
ml
/-
(---cc
PART
DESCRIPTION
I
P
1.
DETAIL-A
~
--\
I
u7&ssa%erzke t5pect&&Z:
UK%
1. THERE
ARE
TO
BE 16 D16C SPRINGS
OF 2 PLACED
-K
TO OACK
8 SETS
SHOW N ABOVE.
2.<SEE
NOTE
Z ON DISASSEMBLY)
3. APPLY
LIGHT
cc%%~ OF LU6RICANT
SPRINGS
AkND SHAFT.
4.
FACTORY
Al
45o
PRESET
PSI
MAXi
MUM
IN
AS
PRESSURE
TO
‘L I
w
m
~cl’’”:
9
DRw
BYI%SS
G NO
14M-122
i
I
I
DISC SPRINGS (see
note 1)
16
2. 630252 BYPASS VALVE SHAFT
1
3, 630253 ‘O’ RING (Large)
1
4. 630254 BYPASS VALVE ELBOW
1
5.
PRESSURE ADJ. NUT
(Brass)
1
6.
BYPASS VALVE HOUSING 1
7.
BYPASS VALVE SHAFT
ASSY.
1
8.
BYPASS VALVE HOUSING
SEAT
1
9. 630251 ‘O’ RING (Extra Lge)
1
10.1~30250 BYPASS VALVE ASSY.
7
3
\
!TY .
[SEC
=
@ !978
DRWN
VALVE
BY
APPRVD
DATE
3-29-79
HYDRA MA~TEF? (XRP(3PATKJN
4
Q
I
-)
.
d
3
{EF PART
io .
N~ZZLE
END
ASSEMBLY
NO.
QTY.
USED
PART
DESCRIPTION
1. 629300 H/HOE COMPLETE
2. 629301 H/HOE FMME
3. 629318 H/HOE BLUE HANDLE
SLEEVE
4. 629303 S/S 3A.NDLE
5. 629304 S/S :CREW
6. 6293o5 S/S iTl_JT
7. 629306 H/HGE HANDLE CLIP
8. 629X!2 il/HOZS/S TUBE
9. 629317 H/EOE LIPS
@ 1978
HYDRA
MASTER
1
1
1
1
2
2
1
1
2
CORPORATION
REFI PART
I
NO.
PART
DESCRIPTION
NO.
I
1. 629309
2. 629302
3. 629322
4. 629313
5. 629310
6. 629312
7. 618502
8. 612080
!3.‘612042
10. 611101
11. 629311
I
,
iiiiim
(’
.-&/-W
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1978
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HYORA MASTER CORPORATION
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H/HOE PLUNGER KIT
H/HOE TRIGGER
H/HOE TRIGGER PIN
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FITTING
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PART
DESCRIPTION
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END ASSY.
2. 629324 STABILIZER
3. 629323 FITTING
4. 629321 FITTING
5. 629302 H/HOE S/S TUBE
6. 629319 NOZZLE END ASSY. W/JET
7. 629603 JET 8o05E {A/cAT,
HISTATION)
8. 629604 JET 8006E (DUAL CAT)
9. 629605 JET 8008E (HYDRA CAT)
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