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HYDRAMASTER AQuaCat 3.9 user manual

Contents

1. 17 AquaCat Water Flow eere nennen 17 i VACUUM SYSTEM E Vacuum qe dte uu a iS are 18 i Vacuum Tank Filter Bag enne 18 Blower Lube Port esent 18 i Vacuum Blower Motor nnns 20 VANGUARD ENGINE 5 5 Chat rdi qui irridet 22 OilFilland Dip Stick eee tnnt 22 Engine Components esent 22 Engine Components continued enn 23 i Carburetor AdjustmentScrews eene 23 Governedidle Spring 23 Oil Filter DEBIT ac orna itte repere acies eri e 24 Round Dual Air Cleaner Element sse 24 i Square Dual Air Cleaner Element seen 24 Round Dual eene 25 Cooling Systemm M 25 Spark PRI Ga arrivati ierit stage asta 25 Fuel Filler eese teret tte treno rini t 25 1 ELECTRICAL SYSTEM Electrical Diagram eee 31 i CLEANING 4 CHEMICALS pH m 33 Cleaning Stroke 33 CLEANING WAND Wand Valve 35 1 5 3
2. E 5 Superseding Warranty nn Limited Warranty for Vanguard Engines eene 28 Parts Recommendation eene nennen 5 Warranty oe a sa MO SPON MOS 29 aris OFCOM ciens rmi ates vc 5 ENGINE TROUBLE SHOOTING eee 30 ard Water Area erret WaterSoftener eene 6 ELECTRICAL SYSTEM Wastewater Disposal Advisory eese 6 Electrical System and Trouble Shooting 31 AQUACAT 3 90PERATING INSTRUCTIONS FREEZE PROTECTION iun MM MM 32 SHUR DOW nr 8 CLEANING 8 CHEMICALS 33 OPERATING PRECAUTIONS Cleaning Stroke Procedure Over Wetting eene 33 Machine Adjustments eee 9 i Cautions and Warnings eeeenennnnnnnnnnntns g CLEANING WAND i Wand Jet Assembly amp Wand Assembly Parts Lists ees 35 WATER amp CHEMICAL SYSTEMS Water Chemical Flow Operation MAINTENANCE AquaCat Water Flow eene Procedures A E A T 36 Chemical System Maintenance CMI Tidy Overall Care of Unit m 36
3. Tank Trouble Shooting Guide PE dons hho AR TEA So 1 1 i Maintenance Logs 37 38 CAT PUMP HYDRAMASTER WARRANTY Cat Pump Mode 290 Operating Instructions NRI a 1 1 Warranty Information SMe PeAnaeapsanseveenerteneeeeeneeenatereeeben Deas en eae Enea ROUGE SEPP ER EDEL ESO CGE 39 Cat Pump Specifications Woot ca ich 1 1 Warranty Procedure 39 General Information for Cat Pump Repair 1 2 Howto Order Parts 39 Servicing the Discharge Valves 12 i Parts eene nennen 39 Servicing the Pumping Section eene 12 One Final Note nnne nennen 39 Servicing Sleeves and Seals 12 AquaCat Limited Warranty Plan 40 Service 13 Model 290 Parts 14 i Cat Pump Trouble Shooting Guide eee 15 16 High Pressure Pump Trouble Shooting Guide 17 Bypass Parts List sesenta 17 VACUUM SYSTEM 18 Vacuum Tank Filter dnb etae rub ers 18 Vacuum Blower Trouble Shooting Guide ees 19 V
4. may result CARBON VARNING e This unit generates toxic fumes Position the vehicle so that the fumes will i be directed AWAY from the job site i DO NOT PARK where exhaust fumes can enter a building through doors or windows air conditioning units or kitchen fans i TOXIC FLUMES Do not occupy the vehicle when the cleaning equipmentis operating Toxic fumes may accumulate inside a stationary vehicle WATER amp CHEMICAL SYSTEMS WATER 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 see illustration on next page 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 itis automatically proportioned with a predetermined quantity of detergent The Mix Tank 3 is equipped with two different float switches the Water Level Float 4 responds to the level in the tank and will maintain the proper volume of solution to be reserved for the water pump The secondary Low Water Float switch 5 is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply If for example the water source at the house were turned off the water level of the mix tank would drop activating the secondary switch which automatically disengages the system and pre vents
5. 1200 PSI 83 BAR Maximum Inlet Pressure 8 5 to 40 PSI 0 6 to 2 8 BAR RN 1200 Mo M rU 0 787 20mm KG 0 472 12mm i Crankcase Capacity 10 02 30 Inlet Port 1 1 2 NPT 1 2 NPT Chemical Injection Port 1 1 4 NPT 1 4 NPT Discharge Ports 2 3 8 NPT 3 8 1 1 2 NPT 1 2 NPT Pulley Mounting Either side Either side Shaft Diameter 0 650 16 5mm 12 1 Ibs 5 5 Dimensions 10 77 x9 06 x5 14 273 5x230x130 5mm 10 GENERAL INFORMATION FOR CAT PUMP REPAIR As you remove your discharge manifold there is a set of 3 check valves which usually fall out during dismantling If the surfaces of these check valves are dirty or show signs of chemical build up itis probable thatthey would remain open causing pressure loss or pulsation Uponinspectingthe valves make sure that the teflon button in the valve spring retainers are still intact Also examine the discharge manifold Look for problems such as cracks chemical buildup or warping due to freezing If this discharge manifold is warped it will cause the check valves to stick and will resultin loss of pressure The Cat pump cups are often the source of pressure loss Upon inspection they may appear melted or torn but often they will look good Replace them anyway There is no
6. 90010 1500 meters or higher may require the installation of a high altitude carburetor main jet to achieve best engine performance If erratic perfor mance is observed contacta Briggs amp Stratton Authorized Service Center for a high altitude jet Governed Idle Spring GOVERNED IDLE SPRING RED OR WHITE X EXHAUST MANIFOLD To service cartridge sees Remove knob and cover plate b Remove cartridge and clean by tapping gently on flat surface OO If very dirty replace wash in a non sudsing detergent and warm water solution Rinse thoroughly with water from inside out until TO PREVENT ACCIDENTAL STARTING when servicing the engine or water equipment always remove spark plug wires from spark plugs Disconnect negative wire from battery terminal if equipped with 12 volt starting system runs Clear Let cartridge dry thoroughly before using ET CHECK OIL LEVEL REGULARLY Check after each 8 hours of Petroleum solvents such as kerosene are not to be used to clean operation or daily SURE OIL LEVEL IS MAINTAINED X cartridge They may cause deterioration of the cartridge DO NOT OIL d CARTRIDGE DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY CHANGE OIL AS RECOMMENDED CARTRIDGE Change oil after first 8 hours of operation Thereafter under normal operating conditions change oil after every 50 hours of operation or every i season whichever occurs first C
7. COOPER 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 COOPER 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 COOPER SHALL HAVE NO LIABILITY FOR CONSEQUENTIAL INCIDENTAL OR OTHER DAMAGES HOWSOEVER CAUSED DATE INSTALLED MODEL SERIAL ___ COOPER GARDENER DENVER 1800 Gardener Expway Quincy IL 62305 4024 VACUUM BLOWER LUBRICATION hours or more frequently if inspection so indicates The oil drain plug is 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 NOTE Older units may have the oil fill level and drain holes locatedin the castiron gear case instead of in the head plate Bearings on drive end of FILLING PROCEDURE blower require grease lubrication every 100 hours of operation Bearings Remove square head vented oil fill plug A on gea
8. Clean fins on thecylin der cylinder head and flywheel regularly 5 Damage or wear caused by dirt which enters the engine because of improper air cleaner maintenance is not covered by Warranty Clean 29 See engine section of this manual beginning on page 21 to assist you resolving engine related problems PROBLEMS ENGINE FAILS TO START ENGINE RUNS ROUGH ENGINE BACKFIRES ENGINE FAILS TO ACCELERATE ENGINE REDUCES SPEED TO LOW RPM UNDER LOAD CAUSES AND OR SOLUTION 1 Loss of fuel A Empty gas tank B Plugged fuel line or filter C Defective fuel pump Replace with mfg suggested pacaman parts only D Gas line kinked crushed or quick disconnect inside the truck not connected 2 Blown master fuse Electrical short B Defective fuse 3 Defective spark plugs A Remove and replace Clean and regap 4 Defective spark plug wires A Spark plug wires along with many others may at certain points come in contact with heated parts exhaust manifold or abrasive parts sharp metal teflon hose This may be taken into consid eration for electrical shorts Remove and replace ignition module 5 Low compression A Defective valve B Stuck valve C Worn compression rings D Defective piston 6 Float switch in recovery tank inoperative NOTE Temporary repair permits disconnection of float switch wire between tank and machine Continued operation with this condi
9. MANIFOLD ASSY SHORT CLAMP 1 EXHAUST INNER CLAMP 1 EXHAUST OUTER CLAMP 1 1 8 MUFFLER CLAMP 44 ELBOW 1 4 BRASS HOSE 3 8 x 24 LONG TEE 1 4 MALE BRASS HOSE 3 8 x 13 TEFLON SENDER S W TEMP HOSE 1 2 x 16 RUBBER FITTING 4M 6UFS SILENCER ASSEMBLY HOSE 3 8 x 43 TEFLON CLAMP 3 MUFFLER ELBOW ASSY 2 180 HOSE 3 8 x 55 THROB CORE A C HEAT EXCHANGER BUSHING 1 2 MALE x 3 8 FEMALE ELBOW 3 8 BRASS FITTING 6MT 6F 6F 6MA 6UFS 8MA 6UFS HOSE 3 8 x 34 TEFLON 6M 6UFS HOSE 3 8 x 34 TEFLON HOSE 3 8 x 68 TEFLON INSULATION 3 1 8 1 0 FOAM ADAPTER A C REAR HT EXCHGER UPPER ADAPTER A C REAR HT EXCHGER LOWER CLAMP 2 3 4 FILTER 3 8 INLINE ELBOW 2 BLACK STEEL HOSE 3 8 x 58 BRACKET MTG HT EXCHGER SILENCER BRACKET MTG HT EXCHGER SILENCER HOSE 3 8 x 30 TEFLON BRACKET RETRO FIT SILENCER BRACKET RETRO FIT SILENCER NOT INCLUDED IN KIT 000 078 033 NOT SHOWN 20309 64th Avenue West Lynnwood WA 98036 HYDRAMASTER CORPORATION PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS USE OF WATER SOFTENERS For quite some time HYDRAMASTER has encouraged the use of water softeners in concert with its equipment With the introduction of the 3 5 AQUA CAT last year the issue of water softeners has once again come up Our increased use of exhaust gas heat ex changers requires us to reiterate our position con cerning water s
10. SPARK PLUGS change MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine oil check Clean vac tank filter bag after every job Garden hose screen clean Blower inlet spray with LPS 1 after last job Machine general inspection WEEKLY SERVICE SERVICE DATE HAS DATE HAS OATE HRS BLOWER check oil level PUMP QIL check top of sight gauge BELTS amp PULLEYS check tightness HIGH PRESSURE LINES check for chating NUTS amp BOLTS check tightness BATTERY LEVELS check i VACUUM TANK clean WIRING check for chafting DATE HRS DATE HRS DATE HRS DATE HRS CHEMICAL SYSTEM flush w vinegar ENGINE OIL CHANGE MONTHLY SERVICE BLOWER grease bearing ENGINE AIR CLEANER clean BY PASS VALVE grease cup amp stem OIL FILTER CHANGE QUARTERLY SERVICE 3 MONTHS 300 BLOWER change 300 ENGINE compression 300 SPARK PLUGS change 37 HYDRAMASTER WARRANTY WARRANTY INFORMATION To avoid misunderstandings which might occur between machine owners and manufacturer we are listing causes of component failure that specifi cally voids warranty coverage Such causes as listed below shall constitute abuse or neglect BLOWER Failure to lubricate impellers daily with LPS 1 lubricant Failure to lubricate bearings as recommended in blower manual Failure to maintain proper oil levels in the blow
11. cover the truck bed with 5 8 plywood using metal screws to secure it as shown Plywood Installation Select the appropriate color astroturf to match your van and cover the plywood and staple in place A standard van requires a piece 6 feet by 12 feet Astroturf SALES REPRESENTATIVE S RESPONSIBILITY ACCEPTANCE OF SHIPMENT Materials Needed i 1 2 sheets 4 8 5 8 exterior plywood i 2 6X12 piece of commercial astroturf 13 16 1 1 2 sheet metal screws 4 1 quart marine adhesive optional 5 1 staple hammer w t 2 staples See illustration for correct placement ONSI floorin URCHASER S RESPONSIBILI PRIOR TO ARRIVAL OF UNIT i 1 Install 5 8 exterior plywood flooring in vehicle and cover with artificial Po tuf 2 Purchase heavy duty 42 60 amp hour battery and have battery slow i charged if new If battery is not fully charged damage can occur to the engine charging regulator READING OF OWNERS MANUAL It is the purchaser s responsibility to read the unit operation manual and to familiarize himself with the information contained therein Special attention should be paid to all CAUTIONS and WARNINGS 1 If unit shows any outward signs of damage do not sign the delivery receipt until you have closely inspected the unit and noted any damage the delivery receipt Have the freight company representative acknowledge the damage by signing the notation of da
12. tion will compromise vac blower A Switch stuck on upright position by foreign material B Defective float switch 7 Engine will not turn over A Dead battery Loose terminal connection on battery or ignition switch Defective starter D Seized engine or blower 8 Defective Carburetor or gas leakage A Clean carb B Replace carb C Choke locked in closed position D When replacing fuel pump insure that it is the same pressure rating recommended by manufacturer 9 Improperly adjusted carb i NOTE A comprehensive manual is available and defines i necessary adjustments i A Incorrect air mixture ratio adjustment B Incorrect float level adjustment 10 Carbon build up in cylinders i NOTE Carbon build up can be minimized by using unleaded regular gas Should carbon removal be necessary reinstall i heads with new gaskets A Carbon build up may be excessive if carb or valves are i improperly adjusted engine RPM too low improper spark f plug gap B B Remove cylinder heads and eliminate carbon build up with wire brush 11 Incorrect ignition module air gap A Regap ignition module to specifications 1 12 Dirty air cleaner A If exhaust gaskets not seat properly or heat exchanger gasket is bad exhaust may heat and melt the air cleaner requiring much clean up repair i 13 Clogged fuel filter A Remove and replace 14 Low oil level or malfunctioning oil pump
13. 061 007 Handle grip Hydra hoe 1 i _Not shown in illustrations 154 001 Spacer 1 4 x 5 16 s s sol valve 5 169 055 Valve assembly s s Hydra hoe 1 i 143 004 Screw 1 4 20 x 1 5 HHC s s 2 094 009 Nut 1 4 20 s s nylock 1 MAINTENANCE PROCEDURES To avoid costly repairs and down time it is imperative to develop and practice good maintenance procedures from the beginning These proce dures fall into daily weekly monthly and quarterly increments and are outlined below We have provided a maintenance log for your convenience on next page it is recommended that you affix a copy of the log on the vehicle door near your unit for convenience andto serve as a maintenance reminder DAILY Check engine oil level Inspect garden hose screen clean as needed Visually inspect machine for loose wires oil leaks water leaks etc z nspect recovery tank s s filter and filter bag for tears holes etc clean AFTER EACH JOB repair or replace as needed Lubricate blower with LPS 1 through blower inlet WEEKLY Change engine oil 50 hours of operation Check engine air cleaner filter clean as necessary Check high pressure pump oil add as necessary Check drive coupler set screws tighten as needed Check pump drive belt for wear tighten as needed Check pump pulleys tighten as needed Check fuel lines for wear chafing Check all nuts and bolts tighten as needed Check heater bumer assy uni
14. conditions under whichit has to operate Some applications such as tillers trash pumps rotary mowers are very often usedin dusty or dirty conditions which can cause what appears to be premature wear Such wear when caused by dirt dust spark plug cleaning grit or other abrasive material which has entered the engine because of improper maintenance is not covered by Warranty ABUSE OR NEGLECT 1 Bentor brokencrankshafts Such damageis normally theresultofabuse such as striking a solid object with the cutter blade on a rotary lawn mower and is not covered by Warranty 2 Engine repairs required from the use of contaminated or stale fuel are not covered by Warranty Such failures would include sticking valves and carburetors and fuel pipes which are clogged by gum deposits which form through the use of stale fuel Always use clean fresh regular gasoline 3 Parts which are scored or broken because an engine was operated without sufficient lubricating oil the proper grade of lubricating oil contaminated lubricating oil are not covered by Warranty Check oil level at least every five hours and refill when necessary Change oil at recommended intervals 4 Damage caused by overheating or overspeeding is not covered by Warranty Overspeeding or overheating occurs if the cooling fins be come plugged with dirt grass or debris or if an engine is operated in a confined area without sufficient ventilation
15. diagnostic reimbursement is specifically excluded The customer s faulty parts must be returned for evaluation prior to the expiration ofthe thirty 30 day period Upon warranty approval a creditwill be issued the customer for the replacement parts invoice Warranty disapproval or failure to return the faulty parts within the thirty 30 period allowed will resuit in the customer being charged for the replacement parts sent 39 AquaClat 2 YEAR LIMITED WARRANTY PLAN HydraMaster warrants products 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 represen tative 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 the 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 manufacture
16. heating performance Deposits of this kind result from hard water deposits excessive chemical use improper chemicals etc The frequency with which descaling procedures are required will vary If your area has particularly hard water or you see evidence of deposits in the water system you may have to descale monthly To descale your system add an appropriate descaler chemical to your mix tank circulate in the heater let stand flush and repeat as necessary Clean all screens and strainers and check them frequently following descaling 36 MAINTENANCE LOG DAILY CLEANING amp INSPECTION Engine ail check Clean vac tank filter bag after every job Garden hose screen clean Blower inlet spray with LPS 1 after last job Machine general inspection WEEKLY SERVICE SERVICE DATE HRS DATE HRS DATE HRS DATE HRS 5 DATE HRS DATE HRS BLOWER check oil level PUMP OIL check top of sight gauge BELTS amp PULLEYS check tightness HIGH PRESSURE LINES check for chafing NUTS amp BOLTS check tightness BATTERY LEVELS check VACUUM TANK clean WIRING check for chatting CHEMICAL SYSTEM flush w vinegar ENGINE OIL CHANGE MONTHLY SERVICE 100 BLOWER 100 ENGINE AIR CLEANER clean 100 BY PASS VALVE grease cup amp stem 100 OIL FILTER CHANGE QUARTERLY SERVICE 3 MONTHS 300 BLOWER OIL change 300 ENGINE compression
17. inlet filter or worn pump seals Cleaning ofthe pump N inlet filter and or replacement of the pump seals may be necessary to correct the problem HYDRAMASTER CORPORATION 20309 64th Avenue West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN ALL HYDRAMASTER DISTRIBUTORS DATE 29 1992 RE 3 9 AQUACAT FREEZE GUARD PSB 92104 1 Begin by attaching your garden hose or pump in hose to the machine Now remove the chemical line from the chemical jug and place it in a 50 50 mixture of anti freeze and water turn the ignition switch on Open the mix tank drain valve and allow the mix tank to drain to the point that it starts to demand water Allow the mix tank to draw the anti freeze solution through the chemical flow meter and the hoses back to the mix tank 2 Remove the garden hose or pump in hose Now open the mix tank drain valve and drain all the water from the machine 3 With the machine drained of water close the mix tank drain and pour one 1 gallon of 50 50 anti freeze and water mix into the chemical mix tank 4 Start the machine and allow it to run for two 2 minutes 5 Far machines equipped with a manual override switch with the machine running depress the dump solenoid manual override switch and hold for thirty 30 seconds 6 Remove the garden hose inlet fitting from the end of your garden hose and plug it into the front of the machine Leave it plugged in until the next time the
18. operate this machine with a portable propane tank or a portable gas can inside the truck doing so increases the risk of a fire or explosion Mount a fire extinguisher just inside the rear or side door for emergencies HARD WATER AREA The quality of water varies greatly throughout the United States and influences the reliability and efficiency of equipment in direct proportion to its level ofhardness The map belowdefines areas which compromise fluid related components such as hoses fittings heaters pumps valves and water cooled engines Cleaning efficiency and equipment life is increased chemical use 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 3 1 2 grains per gallon Using the legend as a reference determine the quality of water in your area and take action immediately should it be necessary Water Softener Hook up Water HardnessWATER 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 recommen
19. piston rod REASSEMBLY 1 Place barrier slinger on rod 2 Lubricate new o rings and back up rings Install first o ring in the o ring groove on the piston rod Position back up ring against the shoulder in front of the first o ring then the second o ring Be careful to avoid damaging the o rings when slipping them over the piston rod threaded ends 3 Immerse sleeve in oil carefully twist and push onto rod machined counter bore end first 4 Replace seal retainers 5 Exercise caution when replacing inlet manifold so the inlet seals are not damaged by the threaded rod ends 6 Replace locking nuts studs 7 Reassemble piston assemblies and discharge manifold as described DISMANTLING CAT PUMP AY Consult factory for your local distributor for crankcase servicing Pumping Section Cut away PISTON SPACER _ BAC CUP BAC CUP RING TON RETAINER SSS ERY I F BAC CUP PISTON CUP WASHER COTTER PIN A 7 ims T Tes mr NUT P PISTON ROD SLEEVE II CYLINDER INLET VALVE SERVICE KITS 078 001 Cup Kit BobCat 078 003 Seal Kit 30686 Valve Kit 30860 Piston Kit BobCat 3 Cup 3 Prirm A Lube Seal 3 Valve Spring 6 O Ring Cylinder 6 Oing Cylinder 3 Cotterpin Retainer 3 Back Up Ring Cylinder 3 Cotterpin 2 Abrasive Paper 3 Valve Spring 3 Bac Cup Piston 1 Instrucon Sheet 1 Instruction Sheet Valve 3 Bac Cup Ring 1 Cup Inserter 3 Valve Seat 3 304
20. re align The exchanger must not be under load at any connection HYDRAMASTER CORPORATION 20309 64th Avenue West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS DATE 5 FEB 1993 RE REMOVAL AND REPLACEMENT OF PSB 93024 AQUA CAT HEAT EXCHANGERS In an effort to maintain our high standard of performance in both our equipment and our service HYDRAMASTER is issuing this update covering the removal and replacement of heat exchangers on the AQUA CAT cleaning unit It has come to our attention that in the past this removal has been achieved by the bending of the mounting brackets to allow the removal of the heat exchanger past the frame As a direct result the bending process weakens the heat exchanger and promotes failure This is not a practice adopted by YDRAMASTER and we would like to take this opportunity to illustrate the proper method of removal and replacement In ALL cases the best way is to remove the silencer unit first This allows the heat exchanger to then be unscrewed and removed without further modifications to it s surroundings note if small diameter heat exchangers are being used removal may not be necessary Before installing the replacement heat exchanger use a aligning jig shown in illustration A to insure correct placement of the unit DO NOT use the heat exchanger as an alignment tool To do so would place unnatural stress on the end plate thereby wea
21. sure method of visually inspecting the cups Hy draMaster recommends changing cups whether they look good or not Anytime your pump is being dismantled HydraMaster recommends re placement of all o rings and seals This is merely a convenience to the customer to make sure that the Cat pump is in top operating condition The Prrrtrm A Lube seals located within the intake manifold will allow air to enter the pump if they are worn Again it is difficult to visually pinpoint a defective Prrrrrm A Lube seal Replace them all Repairing of Cat pumps is nota difficult task However before dismantling make sure you have proper parts required 1 short or hot cut kit 6 piston sleeve o rings 3 Prirrrm A Lube seals 1 bottle Cat oil Read instructions thoroughly supplied in the Cat pump manual prior to dismantling and follow directions as stated Oil all seals thoroughly priorto i installation Remember a newly scarred sealis no better than one youjust took out SERVICING DISCHARGE VALVES amp VALVE SEATS DISMANTLING 1 Loosen the 2 M8 locking nuts approximately one turn 2 Then remove the 2 M8 flange nuts i When restarting the pump check to see that there is no cylinder motion as this will cause premature failure of the cylinder o rings Center cylinder i motion can be eliminated by switching with one of the end cylinders i SERVICING THE PUMPING SECTION i DISMANTLING 1 Remo
22. the debris in the tank The drawstring top of these bags is designed to be tied to the incoming dirty water inlet in the vacuum tank 2 To reorder bags use part number 049 028 i Vacuum Tank Filter Bags VACUUN PROTECTIVE lt MOLDING E 5 RECOVERY Spray lubricant into blower lube port for 3 to 5 seconds then immediately shut off machine Use only LPS 1 moisture displacing lubricant Vacuum Flow Kill Switch Vacuum Blower ves Vacuum 1 Exhaust Silencer VACUUM BLOWER TROUBLE SHOOTING GUIDE e ra Sc Sv ES AS EP IP TP TS RUE IE 07 DC o ER UR ny SS a SIE SOO RUE Eg t IL SR LETS PROBLEM Loss of pressure Cause Solution Collapsed vacuum hose between blower and vacuum tank Remove and replace hose NOTE A special reinforced hose is required for replacement Clogged stainless steel liner Remove and clean or replace stainless steel filter Defective vacuum tank seal Remove and replace vacuum tank seal Defective or open vacuum tank dump valve Close valve Replace valve Fractured weld on vacuum tank Re wek as required or replace tank Collapsed or kinked vacuum hose Reshape hose if possible and or eliminate kinks Plugged vacuum hose Remove obstructions by reversing the vacuum hose Restriction in cleaning tool Remove obstruction end plates or lobes in vacuum blo
23. 2 051 440 Female quick connect 1 1 052 052 660 Male quick connect 1 052 053 660 Female quick connect 1 010 020 Belt pump drive Ax 25 1 HARD WATER AREA MAP J INPNNSIITI X INS I 3 GI Gf r0 GRAINS PER GALLON ___ 7 10 3 MENO 10 anv 232532315 51 1 21 1 8 35 2 225 E0225 E 022122 1122 12122732 IZ EUST EE PEE EIU 2333 233330 IBIDIIIDIIIIIDITIIIIIISI II ISII32 gt START UP 1 Perform daily periodic maintenance as specified in this Owners Manual page 36 2 Connect all required hoses 3 Connect cleaning tool to length of hose required to perform cleaning ENENIEX 4 Mix tank must be full prior to ignition 5 Start engine choke as required Engine is at operating speed recom mended 3000 RPM Allow warm up period of 2 5 minutes ETE ETT 6 Spray wand to void all air from system When the mix tank begins a fill i cycle the chemical flow meter may be adjusted to your desired setting i NOTE Chemical flow meter set at 5 GPHis a 1 to 30 mix ratio and 10 GPH is 1 to 15 ratio When flow meter is set at 10 you will be using what most chemical manufacturers recommend at 5 GPH 7 Run machine for several minutes under load 8 to 10 HG until desired temperature is acheived 8 Commence cleaning operation NOTE Recommended carpet cleaning pressure is 250 300 PSI SHUT DOWN 1 Remove vacuum hose 2 Flush c
24. 31 Sleeve and Seal Kit 3 O Ring Cylinder 3 Piston Spacer 078 004 Hot Cup AquaCat 3 Prrrrm A Lube Seal 1 Instruction Sheet 3 Piston Retainer 3 Cup 3 Barrier Slinger 3 Conical Washer M6 6 O Ring Cylinder 3 Cotterpin 3 Cotterpin 3 Sleeve mi 1 Instruction Sheet 6 O Ring Sleeve 3 Inlet Valves 1 Cup Inserter 1 Instruction Sheet 1 Instruction Sheet 13 PISTON MODEL 290 Exploded View d 2 f GW 5 n db f ar RN 15 PARTS LIST MODEL 290 ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 20285 O Ring Buna N 1 38 27004 Inlet valve 3 2 44274 Crankcase 1 39 30543 Bac Cup piston 3 3 156 008 Stud M8 x 82 2 40 097 025 Bac Cup ring Teflon 3 4 097 004 O Ring oil filler cap 1 41 044 001 Cup Viton 3 5 027 007 Oil filler cap 1 43474 Bac Cup assemb 3 8 43340 O Ring crankcase cover 1 39 41 078 001 BobCat cup kit 9 43339 Crankcase cover 1 39 41 078 004 AquaCat cup 1 10 074 021 Bubble oil gauge 1 42 27983 Piston spacer 3 11 23170 O Ring drain plug 1 43 27002 Piston retainer 3 12 25625 Drain plug 1 27006 Conical washer s s M6 3 92520 Sems comb head screw M6 x 20 6 45 27000 Nut s s M6 3 16 43804 Crankshaft 1 46 14158 Cotterpin 3 17 14487 Rearing 2 47 045 004 Cylinder 43834 Unch 3 18 147 005 Oil seal Buna N 2 48 097 012 O Ring cylinder Buna N 6 19 097 007 O Ring oil seal case 2 11377 O
25. 5 Wand 35 i i i i E i i TABLE OF CONTENTS arri DONO det veel artes 21 Waming 22 Before Starting nennen entente tette 22 GENERAL INFORMATION Oil Recommendations eere 22 Warning and 2 Fuel Recommendations eene 23 Howthe Systems Works eene tentent ireren E CarburetorAdjustments 23 HydraMaster Hours amp Phone 2 ENGINE MAINTENANCE 24 Oil Changa aire ert ecrit ie qr n eee 24 AquaCat Machine Specifications eee 3 picto T MAMMA CREME AE 24 M Clean Engine Rotating Screen Cooling System Spark Arrester 25 5 P Ete eon AEAEE 4 Replace Spark Plugs Replace Fuel Filters s 25 ales Representative s Responsibility u nennen 4 Engine Maintenance Schedule 26 i General Information about Engine zu 02 RR Storage Instructions eren PlacementofUnitin Vehicle 4 amp SONA RET Truck Preparation lllustration ettet 4 Vanguard Engine Warranty Machine Installation E A
26. 8 in 68 mm i cT 2 60 in 66 mm Displacement eene 29 3 cu in 480 cc 290400 12 HP 3600 RPM i 294400 14 HP 9 3600 RPM i secsseesessesteseeseesessessenvenvenseneees 303400 16 HP 3600 RPM i MODEL SERIES 350400 BON e pauio damn 2 83 in 72 mm i Stroken 2 76 in 70 mm Displacement 34 7 cu in 570 cc sssssssssscsssessscsessecersercetsensorsesces 18 HP 3600 RPM H TUNE UP SPECIFICATIONS DESCRIPTION B amp S PART NO Air Cleaner Pre cleaner round eene 271271 i Air Cleaner Cartridge round eee 394018 Air Cleaner Pre Cleaner 5 805113 i Air Cleaner Cartridge square eene 805267 i Air Cleaner Pre cleaner with fuel tank 271794 i Air Cleaner Cartridge with fuel 1 393957 i Fuel Filter without fuel pump eene 298090 Fuel Filter with fuel pump eere 394358 OU FURR 491056 Resistor Spark plug Champion 12 491055 NOTE Walking finger
27. A Oil pressure sensors can be installed on the engine This will eliminate many problems which may occur 15 Vacuum tank full A Empty vacuum tank ELECTRICAL SYSTEM The entire electrical system operates on 12 volts DC which is provided by NOTE When new battery is installed insure it is properly charged before a battery Battery levels are sustained by a 16amp alternator designed with installation or damage to the charging regulator may occur the engine cnet tt i et SSS PROBLEM Low battery voltage Cause Solution Defective battery Remove and replace Corroded battery terminals Clean terminals and battery posts Low battery fluid Add water to appropriate level Loose wiring within electrical system Examine all terminal connections and verify that they are secure Electrical short in wiring system Examine electrical systems for bare wires Poor ground connection Examine terminal and remove corrosion if necessary PROBLEM inoperative hour meter Cause Solution Time is not advancing correctly Verity 12 volt DC is available at the hour meter with the ignition switch turned on This can be accomplished with a volt meter or a test lamp Remove and replace hour meter if 12 volt is available A nylon gear within the clock may have been jammed due to sudden jolt of the machine or truck You may try simply tapping on the meter to try to free the nylon gear FLOAT Swi T
28. ADJUSTMENTS Although this unit has been factory adjusted it may require additional adjustments to achieve optimum performance i e altitude may require carb adjustment and ambient temperatures may require heat control adjustment When required consult an authorized representative ENGINE COOLING i Units employing air cooled engines must not be enclosed within a van with doors and windows closed Excessive temperatures within the engine will result in premature engine failure and a compromise of applicable war ranty LEVEL OPERATION CAUTION During operation van or trailer must be parked on level ground not to exceed or 10 Failure to insure proper leveling may prevent proper internal lubrication of engine vacuum and or high pressure components FREEZE PROTECTION Mother nature gives little warning as to her cold spells Therefore protecting this equipment from freezing will save costly down time Placing an electric heater in the truck or parking the truck indoors will help to insure i against freezing HOT SURFACES During the operation of this equipment many surfaces on the machine will become very hot When near the van for any reason care must be taken not to touch any hot surface such as heater engine exhaust etc NO SMOKING i It is unsafe to smoke in or around the vehicle MOVING PARTS ie WARING Never touch any part of the machine that is in motion severe bodily injury
29. Briggs amp Stratton Corporation P O Box 1144 Milwaukee WI 53201 Attention Service Division The shop manual shown here includes Theories of Operation com mon specifications and detailed informa lion covering the adjustment tuneup and repair of Briggs amp Stratton OHV twin cylin der 4 cycle engines and is available from any Briggs amp Stratton Authorized Service Center You can also order directly from the factory at the above address Request manual Part No 272144 Part No 272144 ABOUT THE WARRANTY ON THE VANGUARD ENGINE if warranty service is needed contact your nearest Authorized Briggs amp Stratton Service Center For prompt attention your Center will need to know the engine model type and code numbers the trouble experienced and the total number of hours the engine was run BRIGGS amp STRATTON WARRANTY COVERS ONLY DEFECTIVE MATERIAL AND OR WORKMANSHIP Briggs amp Stratton Corporation welcomes the opportunity to make justified warranty repairs by any of its Authorized Service Centers In most instances the requests for warranty repair are handled in a quick and routine manner However some requests for warranty are received which appear not justified In these cases though engine owners may be aware of it the premature failure of their engine was caused by abuse neglect or the equipment on which it was mounted rather than the engine If you differ with the decision
30. CH VACUUM ROYA GAUGE BLACK SOLENOID VALVE RED RED STARTER SOLENOID FUEL 3 1 1 gt a FLOAT Z switen SENSOR FUSASLE 2 HIS LIMIT i d TEMP SUITCH RELAY BLACK ENGINE US TEAP KILL SOLENOID aWiTCH i L OPTIONAL WIRING m SWITCH BATTERY RED RED XILL SWITCH MIK TNK m XILL SWITCH ae Carporation FREEZE PROTECTION AQUACAT Any freezing of this machine is not covered by warranty and during the colder months of operation careful protection should be ofutmost concern THE FOLLOWING PRECAUTIONS ARE RECOMMENDED 1 Run machine before leaving for the first job to insure nothing has frozen the night before including hoses and wand 2 Insulate the garden hose from the cold ground by running it through and extra 1 1 2 inch vacuum hose 3 Leave truck doors closed until time cleaning begins then open slightly for ventilation of air cooled engine 4 In colder climates insulating the tuck walls and floor boards will help protect the unit 5 Dont procrastinate during the cleaning operation or the hot water solution line will also freeze on the ground The solution line should be insulated in extremely cold climates 6 Whenever possible the truck and machine should be st
31. MMMLEEDDDU EAMM III nn 32 CLEANING WAND Wand Valve Assembly 169 005 WAND VALVE JET amp WAND PARTS LIST i ITEM PART NO DESCRIPTION QTY 167 013 Trigger cast Hydra hoe valve 1 2 094 009 Nut 1 4 20 s s nylock 2 3 107 130 Valve body HydraMaster valve 1 4 052 152 1 4 Male comp fitting Hydra hoe 1 5 155 003 Spring HydraMaster solution valve 1 i 6 097 011 O Ring HMaster solution valve cap 1 7 027 001 Cap s s HMaster solution valve 1 8 139 004 Ring solution valve retaining 1 9 139 003 Ring keeper HMaster solution valve 1 10 097 010 O Ring HM valve plunger large 1 B 11 097 022 O Ring solution valve fw mtr small 1 12 107 129 Plunger HydraMaster solution valve 1 19 052 050 440 Male quick connect wiviton 1 14 052 071 Nipple 1 4 brass hex 1 15 052 082 Elbow 1 4 brass 45 street 1 16 143 002 Screw 1 4 20 x 1 HHC s s 1 17 052 153 Brass stabilizer housing 1 i 18 186 001 Stabilizer 1 19 076 005 Jet 6 s s Hydra hoe BobCat 1 076 003 Jet 4 s s Hydra hoe AquaCat 1 20 094 028 Nut brass jet assembly grou 1 061 006 Handle pressure guide wand 1 H 22 094 035 Nut 5 16 18 s s nylock half nut 2 Jet Assembly 23 143012 Screw 5 16 18 x 3 4 5 5 HHC 2 i 24 173006 Wand s s Hydra hoe stock 1 __25 082 001 Lips s s Hydra hoe 2 piece set 1 26 168 001 Tube s s Hydra hoe solution 1 27
32. NG Disconnect the negative wire from the battery terminal if equipped with a 12 volt starting system 2 DO keep cylinder fins and governor parts free of grass and other debris which can affect engine speed 3 DO pull starter cord slowly until resistance if felt Then pull cord rapidly to avoid kickback and prevent hand or arm injury 4 DO examine muffler periodically to be sure itis functioning effectively Aworn or leaking muffler should be repaired or replaced as necessary 5 DOuse fresh gasoline Stale fuel can gum carburetor and cause leakage 6 DO check fuel lines and fittings frequently for cracks or leaks Replace if necessary NOTE Use Original Briggs amp Stratton Service Replacement Parts when servicing your engine Briggs amp Stratton Authorized Service Centers carry a stock of such parts The use of Briggs amp Stratton Parts preserves the original design of your engine Imitation replacement parts offer potential risk including the risk of personal injury Contact any Briggs amp Stratton Authorized Service Center for Original Briggs amp Stratton Re placement Parts BEFORE STARTING READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS OIL RECOMMENDATIONS We recommend use ofa high quality detergent oil For Service SC SD SE SF or SG such as Briggs amp Stratton high quality detergent 30 weight oil part no 100005 or 10W 30 weight oil part no 272001 Detergent
33. NT Power console Sound suppression package Leveltemperature exchange heater Vacuum recovery tank Carpet clean ing wand Chemical jug Chemical jug holder Owners Manual 100 2 vacuum hose 10 1 1 2 vacuum hose 100 Super flex solution hose 10 1 1 2 drain hose Battery box with holder Fuel system kit Van decal Van installation kit DESIGN CHANGES This information is accurate at the time of printing However the design and specifications of HydraMaster equipment are subject to continued change and refinement PLACEMENT OF UNIT IN VEHICLE THERE ARE TWO RECOMMENDED UNIT PLACEMENTS A SIDE DOOR Mostinstallations are side door This provides rear access for accessories and hoses as well as unobstructed access to component working side of machine thus makingita bit easier to perform maintenance and or repair without removing unit from the truck B REAR DOOR Although this location partly limits working access itdoes 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 slidto 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 weight line up over drive shaft Also itis physically easier to load unit into
34. ONOT 1 DO NOT run engine in an enclosed area Exhaust gases contain carbon monoxide an odorless and deadly poison 2 DO NOT place hands or feet near moving or rotating parts 3 DO NOT store spill or use gasoline near an open flame or devices such as a stove furnace or water heater which use a pilot light or devices which can create a spark 4 DO NOT refuel indoors where area is not well ventilated Outdoor refueling is preferred 5 DO NOT fill fuel tank while engine is running Allow engine to cool for 2 minutes before refueling Store fuel in approved safety containers 6 DO NOT remove fuel tank cap while engine is running 7 DO NOT operate engine when smell of gasoline is present or other explosive conditions exist 8 DO NOT operate engine if gasoline is spilled Move machine away from the spill and avoid creating any ignition until the gasoline has evaporated 9 00 NOT transport engine with fuel in tank 10 00 NOT smoke when filling fuel tank i 11 DO NOT choke carburetor to stop engine Whenever possible gradually reduce engine speed before stopping t 12 00 NOT run engine at excessive speeds This may result in injury 13 00 NOT tamper with govemor springs governor links or other parts which may increase the governed engine speed INTERNATIONAL SYMBOLS USED IN THIS 14 00 NOT tamper with the engine speed selected by the original SECTION OF MANUAL _ equipment manufacturer 15 DO NOT check for spark with spar
35. OWNER S MANUAL LIST OF PHOTOS AquaCat front view features labeled een 8 AquaCat side view features labeled eee 8 Cat Pump 290 11 Dismantling Cat 13 9 21 HOURS Monday Friday 8 00 am To 5 00 pm PACIFIC STANDARD TIME CENTRAL EASTERN ROCK MT TELEPHONE NUMBERS 206 775 7272 General Offices 206 775 7276 Parts Department 206 775 7275 Service Warranty 206 771 7156 FAX Q 1991 HydraMaster Corp Printed in U S A LIST OF ILLUSTRATIONS GENERAL INFORMATION Plywood Installation 4 Astroturf Installation 4 t Machine 5 Thru floor Gas Hook up and 5 Water Hardness 6 i Water Softener 6 WATER amp CHEMICAL SYSTEMS AquaCat Water Flow seen 10 Chemical Proportioning and Level Control eene 10 CAT PUMP i Pumping Section 13 Piston Model 290 Exploded View ene 14 Bypass Valve
36. Pump Mix Tank Vacuum Pumn Thru Floor Gas Hook up Installation FITTING QUICK CONNEC T 1 BRS STA ELBOW Oe 257 SCREW screw P e ICUT TO LENGTH THAU FLOOR GAS HOOK UP BNET WATER SOFTENER HOOKUP GARDEN HOSE WATER SOFTENER FROM SA WATER FAUCET The relatively low cost of a water softener service is more than made up for i in the increased life of machine parts and continued cleaning efficiency The water softener will also increase the effectiveness of the cleaning chemical being used therefore less chemical will be needed Contact a water softener distributor in your area for information on the rental of a simple water treatment unit to carry in your truck Be sure to change the water softener in accordance with the capability of the softener Example If the softener will treat 900 gallons of water and machines uses an average of 30 gallons per hour of use and an average of 5 hours a day i would be 150 gallons a day 5 days would equal 750 gallons of water i therefore the softener would be changed every 6 working days for maximum softening WASTEWATER DISPOSAL ADVISORY There are laws in most communities prohibiting the dumping of recovered i gray water from carpet cleaning in any place but a sanitary treatment i system This cleaning rinse water recovered into your unit s vacuum tank contains materials such as detergents which must be processed b
37. Ring cylinder Viton 6 20 041 021 Oil seal case 2 49 097 024 Bac Cup ring cylinder 3 21 92519 Sems comb head screw M6 x 16 8 50 090 005 Discharge manifold 1 23 101799 Connecting rod 3 25634 Discharge manifokl s s 1 24 101800 Piston rod 3 51 43442 Valve spring retainer 3 25 16948 Piston pin 3 52 43360 Valve spring 3 26 20017 Seal washer 3 53 43723 Valve 3 27 147 006 Oil seal 3 54 43434 Discharge valve seal 3 28 25327 Barrier slinger 3 56 81109 Hex nut M8 2 29 097 008 O Ring sleeve 3 57 101804 Hex flange nut M8 2 28771 O Ring sleeve Viton 3 58 108 003 Shaft protector 1 30 29003 Back up ring Sleeve Teflon 3 Electric Clutch Assembly 31 29614 Sleeve 29743 Unchromed 3 59 152 005 Tapered sleeve 1 32 26854 Seal washer 3 60 077 005 Key electric clutch 1 33 138 001 Seal retainer 3 61 036 005 6 electric clutch 1 34 25128 Inlet manifold 1 62 143 084 8 30 mm socket head screw 1 25635 Inlet manifold stainless steel 1 63 174 004 Flat washer 5 16 US 1 35 147 008 Primm A Lube seal 3 64 174 018 Lock washer 5 16 US 1 35 30325 Prirmrm A Lube seal Viton 3 CAT PUMP TROUBLE SHOOTING GUIDE PROBLEM Pulsation Cause Solution Debris in discharge valves of pump Clean or replace discharge valves Worn Prrmm A Lube seals Replace Excessive temperature Check pump solenoid Cause Solution Wom nozzle Replace nozzle of proper size s
38. a I E E E i I I I I L L i I I I I I I I I i I L a L L E L I L I I I E E E L L LS B D I D D 40 HYDRAMASTER 20309 64th Ave W Lynnwood WA 98036 USED ON 21 RETRO FIT ONLY HYDRAMASTER AQUA CAT 3 9 HEAT EXCHANGER SYSTEM ITEM SHOWN IS SOLD AS ONE COMPLETE UNIT EXPLODED VIEW PARTS LIST Oman oO ok ON 000 038 019 000 131 037 000 090 036 000 090 035 000 033 070 000 033 071 000 033 042 000 033 012 000 052 085 000 068 210 000 052 090 000 068 215 000 149 002 000 068 098 000 052 013 000 093 013 000 068 099 000 033 034 000 052 268 000 068 039 000 038 018 000 052 086 000 052 086 000 052 023 000 052 020 000 052 033 000 068 211 000 052 019 000 068 211 000 068 214 000 131 035 000 052 267 000 052 266 000 033 052 000 049 033 000 052 210 000 068 213 000 015 037 000 015 038 000 068 079 000 015 038 000 015 037 PARTS LIST CORE FINNED S S INSULATION WRAP MANIFOLD ASSY LONG
39. ace spark plugs and crank slowly to distribute oil 4 Clean dirtand chaff from cylinders cylinder head fins blower housing rotating screen and muffler areas SERVICE amp REPAIR INFORMATION service or repair is needed contact a Briggs amp Stratton Authorized Service Center To serve you promptly and efficiently a Service Center will need model type and code numbers from your engine Your nearest Service Center may be located in the YellowPages directory under Engines Gasoline Gasoline Engines or similar category You may also locate the Service Center in your mailing zip code area by calling 1 800 233 3723 There are over 30 000 _ Authorized Service Centers worldwide available to TM serve you Authorized Service Centers carry a stock of Original Briggs amp Stratton Service Replacement Parts and are equipped with special service tools Ask for and use ONLY original Briggs amp Stratton Service Replacement Paris which preserve the original design of your engine Imitation replacement parts offer potential risks in internal construction as well as fit finish and warranty back up Trained mechanics offer expert service Major engine repairs require proper tools and a thorough knowledge of internal combustion engine repair proce dure Briggs amp Stratton publishes illustrated shop manuals parts lists and owner s manuals for every engine it manufactures To re ceive alistof available publications write to
40. acuum 20 Vacuum Blower Lubrication sees 20 VANGUARD OHV ENGINE Operating amp Maintenance for Model 303400 16 Engine 21 International Symbols Used inthis Manual see 21 In The lui restof Gafely rotto tracer bene 21 i 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 trouble shooting section and component manual troubleshooting charts have been included for your convenience Unlike a garden tractor lawn mower or cement mixer all having one or two functions to perform the truck mounted carpet cleaning plant has many functions to perform simultaneously Engine has to run at a consistent RPM Vacuum has to pull air and dirty water back from cleaning site Water pump provides stable pressure at proper water flow for cleaning Chemical has to be injected into the water stream at the tight concentration Heater must maintain proper heat Vacuum tank must store dirty water until drained H H H i As you can see it is not just a tum key operation with one thing to worry about Does start an EE The manufacturer uses this symbol throughout the manual to warn of poss
41. ble to produce the finest carpet cleaning results possible Despite this however it remains only a tool of the carpet cleaning trade and it can produce only as good a job as the person operating it There are not short cuts to good carpet cleaning It requires time cleaning knowledge and the use of good chemicals The manufacturer recommends the use of spotting agents and traffic lane cleaners prior to the actual cleaning of carpeting as required B The use 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 concentration 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 a chemical solution with a pH of less than 7 or higher than 10 be used in the unit pH CHART 123 4 5 6 7 8 9 CLEANING STROKE PROCEDURE OVER WETTING PURPOSE To eliminate excess moisture remaining in the carpet fiber and the sawtooth appearance which results from diagonal movement of the cleaning tool on all types of carpet 10 11 12 13 14 NEUTRAL ALKALINE PROCEDURE Always move the cleaning tool in smooth forward and ba
42. buse of wand WATER HEATER Over pressurization of the system recommended maximum working pressure 800 PSI Failure to protect against freezing Modification of the gas delivery system WARRANTY PROCEDURE Warranty coverage is available to you ONLY through HydraMaster Corpo ration 20309 64th Ave West Lynnwood Washington 98036 When warranty parts are needed write HydraMaster Warranty Dept at the above address or call the Warranty Service Dept at 206 775 7275 No collect calls will be accepted Hours of Warranty Service Dept are 8 00 am to 5 00 pm Pacific Time IMPORTANT HydraMaster s warranty policy provides replacement parts without charge for thirty 30 days to customers maintaining current account status An invoice dated thirty 30 days from date of replacement parts shipment will be sent to the customer for the amount ofthe parts sent HOW TO ORDER PARTS To obtain a proper diagnosis of your malfunction and to order warranty replacement parts itis important that you proceed in the following manner 1 Call HydraMaster Warranty Service Department at 206 775 7275 i 2 Give the Warranty Service 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 Descr
43. cc cece cece e cece eee e nee n ence hehehe 2 years CLEANING WAND 2 ccc cece cree EE 2 years ENGINE Thru original Manufacturer On Direct Drive units see original Manufacturer s warrr nty oe ccc cece cence nett ete 2 years INTERNAL MACHINE HOSES 2 cc ccc cect cere eae cence hehehe ee eee eas ni et nho 2 years VACUUM BLOWER Thru original Manufacturer See Cooper Industries warranty scosso cee cee ewe ri eee teeta hh eer het 2 years HIGH PRESSURE BY PASS VALVE oo ccc ccc cece eter treet eee nen eee teen herr 2 years EXTERNAL MACHINE 8 eee e ee he hehehe nnn 1 year BELTS FITTINGS FILTER SCREENS GAUGES lees nnn 1 year WATER HEATER OR HEAT EXCHANGER ccc cece eee ehh ahh hn 1 year HIGH PRESSURE PUMP Thru original Manufacturer 0 cece cee cece cere teen eee n 1 year All components not specifically referenced in the above schedule are covered under this warranty for a period of one 1 year except those parts which are considered expendible in normal use Freezing of any water or chemical related component will VOID all warranties on water or chemical related components internal or external of this equipment Deposits and build up in the water chemical or heater systems due to hardness in the water used or poor quality chemicals which result in deposits will void all warranties on affected components r
44. ckward strokes Apply slight pressure to the forward stroke while the solution is injected into the carpet When extracting drying apply firm pressure on the forward stroke to ensure a positive lock for the vacuum and minimize the hopping effect resulting on unsmooth carpet During the forward and reverse strokes movement to the right or left should only be accomplished at the extreme rear of the stroke Overlapping is also important to ensure even application of solution to prevent saturation when cleaning wand is stopped twice at the same point at the rear of the cleaning stroke Failure to adopt this procedure can result in increased chance of clean streaks fiber shrinkage brown out and longer drying periods INCORRECT METHOD CORRECT METHOD en Strokes Overlap Betwe 1 E i Cleaning Tool Second Cleaning Stroke First Cleaning Stroke OVER WETTING Over wetting is annoying to all concerned and sometimes leaves a bad impression of the cleaning process used ESE ARE SEVERAL AREAS THAT WILL CAUSE OVER WETTING 1 Too few vacuum strokes or improper saw tooth vacuum strokes as shown in the previous illustration 2 Obstructed cut or kinked hoses 3 Vacuum tank drain valve left partially open 4 Clogged vacuum blower filter or vacuum tank lid not sealing properly 5 Cleaning a heavily foam saturated carpet without defoamer We recom mend crystal type ni TT OAS A AA
45. cylinder head and replace or clean applicable check valve 4 Delaminated kinked or clogged hose between the mix tank and the high pressure pump 5 Defective pressure relief valve or debris in pressure relief valve NOTE The high pressure bypass valve is designed to fully close when the cleaningtool is turned on Any foreign matter collecting on the piston will prevent full closure ofthe valve and allow a portion of the water to continue to circulate instead of being routed to the cleaning tool To correct this situation the bypass valve mustbe dismantled and cleaned refer to illustration provided for bypass dismantling A Dismantle and clean pressure relief valve as shown in illustration Replace defective or worn out bypass cup Replace bypass valve 6 Defective or worn cups A Remove and replace piston cups as defined by pump section of this manual 7 Loose drive belt for high pressure pump A Readjust belt as required or replace if defective PROBLEM Insufficient or excessive water flow Cause Solution 1 Worn out spray jet NOTE Cleaning tools designed to spray a constant flow of i 1 1 2 GPM will average 1 gallon of flow per minute in actual working situations since flowis notcontinuous An average flow of 1 GPM results in 6000 gallons i of flow for every 100 hours of unit operation Spray tips are capable of consistent flow rates for approximately 20 000 gallons They should be replaced there
46. d black powdery substance In the area of the O Ring Cause Solution Loose cylinders Cylinder motion caused by improper torque on the discharge Retighten Donottighten too much orthe ears of the manifold will be bowed causing manifold looseness in the center cylinder PROBLEM Water leakage from under the inlet manifold Cause Solution Worn inlet manifold seals Prrrrrm A Lube Leaking sleeve O Ring Install seals If piston rod sleeves are scored replace sleeves and sleeve O Rings PROBLEM Oil leak between crankcase and pumping section Cause Solution Wom crankcase piston rod seals Replace crankcase piston rod seals PROBLEM Oil leaking in the area of the crankshaft Cause Solution Worn crankshaft seal or improperly installed oil seal Remove oil seal retainer and replace damaged gasket and or seals ad bearing Replace bearing continues next page 15 Cause Solution Worn ball bearing from excessive tension on drive belt Replace ball bearing Properly tension Cause Solution May be caused by humid air condensing into water inside the crankcase Change oil at 3 month or 500 hour intervals using Cat pump crankcase oil other approved oil every month or 200 hours Leakage of manifold inlet seals and or piston rod sleeves O Ring Replace seals sleeves and O Rings Damaged or improperly installed oil gauge or crankcase rear cover O Ring an
47. d Replace oil gauge or cover O Ring and drain plug O Ring drain plug O Ring Loose drain plug or worn drain plug O Ring Tighten drain plug or replace O Ring PROBLEM Loud knocking noise pump Cause Solution Pulley loose on crankshaft Check key and tighten set screw Broken worn bearing Replace bearings PROBLEM Frequent or premature failure of the inlet manifold seals Cause Solution cored rods or sleeves Replace rods and sleeves Over pressure to inlet manifold Reduce inlet pressure per instructions PROBLEM Short cup Ilfe Cause Solution Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Excessive pressure and or temperature of fluid being pumped Checkpressuresandfluid inlettemperature be sure they are within specified range Over pressure of pumps Reduce pressure Running pump dry Do not run pump without water Front edge of piston sharp Replace with new piston cups and discharge valves cannot be lapped but must be replaced HIGH PRESSURE PUMP TROUBLE SHOOTING GUIDE PROBLEM Loss of pressure Cause Solution 1 Clogged filter screen in garden hose quick connect coupler A Remove and clean or replace filter 2 Low water pressure at source i A Determine rate of flow and select an alternative source of supply if water pressure is inadequate 3 Defective or blocked check valves in high pressure pump cylinder head A Dismantle
48. d the procedure to everyone in a hard water area SPARE PARTS RECOMMENDATION Because your truck mounted unit is capable of generating several hundred dollars per day down time on the unit can be very expense In order to minimize such down time itis strongly recommended by the manufacturer that you purchase and keep n your truck the parts listed below PARTS ORDERS To expedite your parts needs please call your sales representative In most instance he either stocks or has access to parts through a regional service center Inthe event parts are unavailable locally 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 2311 3IIN TII BISTIGIIIIDR 222 212112330 313232 12 11 PART NO DESCRIPTION QTY 106 030 Engine spark plug 2 1 049 012 Round air cleaner BobCat 1 i 049 038 Square engine air cleaner AquaCat 1 049 014 Engine filter 1 078 015 Flow meter kit i 078 024 Wand valve plunger kit 1 078 034 Pressure bypass valve kit 1 076 005 Spray jet 8006E 1 1 076 003 Spray jet 8004E 1 049 028 Recovery tank filter bag 2 049 023 Screen garden hose 6 078 004 Cat 290 hot cup kit AquaCat 1 052 050 440 Male quick connect 1 05
49. d washing with a commercial solvent REPLACE FUEL FILTER Replace In Line filter every season or more often if required Contact any t Briggs amp Stratton Authorized Service Center for correct replacement 25 Fuel Filter ENGINE MAINTENANCE SCHEDULE Follow the hourly calendar intervals whichever occur first More frequent service may be required t temperatures ien igh ambi ions or when airborne debris is present perating under heavy load or in hi then after every 50 hours or every season og gt N TE 5 poa sa Got zc ot ou 2 670 BH ai 2a BRIGGS amp STRATTON AUTHORIZED SERVICE CENTERS ARE READY TO SERVE YOU AND COMMITTED TO QUALITY SERVICE 26 GENERAL INFORMATION ABOUT ENGINE This is atwin cylinder overhead valve air cooled engine All drilled tapped holes and fasteners on this engine are ISO metric However where equipment attaches to engine SAE standards apply On mobile equipment this engine will operate satisfactorily atany angle at which operator and equipment can function safely i MODEL SERIES 290400 294400 amp 303400 NOTE For practical operation the horsepower loading should not exceed 8556 ofthis rating Engine power will decrease 3 1 296 for each 1 000 feet 305 above sea level and 196 foreach 10 F 5 6 C above 77 F 25 i i BOTE 2 6
50. efore being safe for streams rivers and reservoirs IN ACCORDANCE WITH THE EPA STATE AND LOCAL LAWS DO NOT DISPOSE OF WASTEWATER INTO GUTTERS STORM DRAINS STREAMS RESERVOIRS ETC In most cases an acceptable method of wastewater disposal is to discharge into a municipal sewage treatment system after first filtering out solid material such as carpet fiber Access to the sanitary system can be obtained through a toilet laundry drain carwash drain RV dump etc Permission should first be obtained from any concerned party or agency One disposal method which usually complies with the lawis to accumulate the wastewater and haul it to an appropriate dump site Another solution to the disposal problem is to equip yourself with an Automatic Pump Out System These systems are designed to remove wastewater from the i extractor s recovery system and actively pump the water through hoses to asuitable disposal drain Properly designed they will continuously monitor the level of wastewater and pump it out simultaneously to the cleaning i operation The hidden benefit of this process is that the operator doesn t i have to stop his cleaning to empty the recovery tank HydraMaster makes i an A P O System available which can be ordered with new equipment or i installed later i The penalties for non compliance can be serious Always check local laws and regulations to be sure you are in compliance OPERATION PRECAUTIONS MACHINE
51. er Failure to use the correct oil grade and viscosity as recommended in blower manual Failure to properly maintain blower safeguard systems such as waste tank filter screen vacuum safety relief valve and waste tank automatic shut off system Allowing foam to pass through biower HIGH PRESSURE WATER PUMP Failure to maintain proper oil level as recommended in pump manual Failure to change oil in pump at recom mended intervals Failure to protect pump against freezing Failure to maintain pump protection shut off system Failure to use water softener in hard water areas Use of improper chemicals VAC TANK Failure to properly maintain filtering devices in tank Failure to clean tank as recommended by manufacturer Failure to maintain vacuum safety release in tank lid Use of improper chemicals CHEMICAL PROPORTIONER Use of improper chemical Failure to use water softener in hard water area Operating machine without proper chemical filter screen Failure to protect against freezing CONTROL PANEL Failure to protect flow meter and water pressure gauge against freezing VACUUM AND SOLUTION HOSES Failure to protect hoses against freezing Failure to protect hoses against burns from engine blower exhaust Damage to hoses from being run over by vehicles Kinking or cracking from failure to store orunrollhoses correctly Normal wear and tear from everyday use CLEANING WAND Failure to protect against freezing Obvious physical a
52. fore approximately every 350 hours Worn spray jets allow a greater average rate of flow thus reducing desired temperature levels A Remove and replace spray jet 2 Reduction of flow A Due to increased length of solution hose NOTE For every 50 feet ofhose beyond 100 feetin total length measurable loss of flow is experienced This condition is a result of the increased friction experienced by the water as it passes through the hose Therefore itis necessary to increase the pressure i atthe machine 40 PSI for every additional 50 feet of cleaning solution hose over 100 feet BYPASS PARTS LIST i NO PART NO DESCRIPTION QTY 3 000 105 101 Thrust plate Bypass valve 1 4 000 105 102 Piston plate Bypass valve 1 5 000 078 101 Kit seal for Bypass valve 1 7 000 148 004 Seat amp O Ring Bypass valve 1 8 000 097 005 O Ring Bypass valve fitting 1 VACUUM SYSTEM INFORMATION The vacuum blower incorporated in this machine is a positive displace ment lobe type manufactured by Cooper Industries The performance and life of this unit is greatly dependent on the care and proper maintenance it receives Because of the close tolerances between the lobes and housing of the vacuum blower solid objects entering the inlet will damage the internal lobes gears and bearing or direct drive coupler To prevent this a stainless steel filter screen has been placed at the vacuum inlet inside the vac
53. g recommendations that are shown in your manual for more information please contact your local HYDRAMASTER representative HYDRAMASTER CORPORATION 20808 64th Avenue West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS SERVICE CENTERS AQUA CAT OWNERS DATE 29 APRIL 1992 RE IMPROPER AQUA CAT OPERATION PSB 9243 no pressure indicated on pressure gauge The HYDRAMASTER 3 5 AQUA CAT machine must have pressure indicated on the pressure gauge before the unit will operate When starting your HYDRAMASTER 3 5 AQUA CAT it is of utmost importance that care be taken to verify a working pressure reading on the pressure gauge within the first 30 seconds of operation If this does not occur shut the machine down IMMEDIATELY and follow the procedure outlined below 1 Remove mix tank lid and verify the presence of water in the mix tank 2 If water is present in the mix tank use the FEMALE QUICK freeze guard hose provided with the ma CONNECT chine to purge air from the system 3 Attach the female quick connect to the front 2 of the machine and place the rubber stopper in recovery tank v 4 Start the machine water becomes visible the clear freeze guard hose stop machine L ats disconnect freeze guard hose and proceed EH with cleaning operations The problem of low or no pressure may be symptomatic of either a clogged pump
54. grit can remain in the plug and later enter the engine i 7 Warranty does not cover the tune up or adjustment of an engine unless i the need for such repair is the result of defects in material or workman ship or both If equipment is assembled and adjusted by the owner the engine operating and maintenance instructions are sufficiently clear to permit the average owner to make minor adjustments Such minor adjustments are NOT covered by Warranty 8 Broken parts which result from excessive vibration caused by loose engine mounting loose cutter blades blade unbalance improperly attaching equipment to engine crankshaft overspeeding or abuse in operation are not covered by warranty 1 9 Repair oradjustment of associated parts orassemblies such as clutches transmissions remote controls etc which are not of Briggs amp Stratton i manufacture will not be covered by Briggs amp Stratton Warranty 10 Only ORIGINAL Briggs amp Stratton parts or parts approved by Briggs Stratton may be covered by Warranty WARRANTY IS AVAILABLE ONLY THROUGH SERVICE CENTERS WHICH HAVE BEEN AUTHORIZED BY THE BRIGGS amp STRATTON i CORPORATION YOUR NEAREST SERVICE CENTER IS LISTED IN THE YELLOW PAGES OF YOUR TELEPHONE DIRECTORY UNDER ENGINES GASOLINE OR GASOLINE ENGINES replacementand service to perform well It should be remembered thatthe service life of any engine is dependent on the care it receives and the
55. hange oil every 25 hours if engine is i operated under heavy load or at high ambient air temperatures Remove 2 Reinstall air cleaner cover and reattach clips to sides of air cleaner body oil drain plug and drain oil while engine is warm Replace drain plug Remove dipstick and refill with newoil of correct grade and weight Replace Round Dual Air Cleaner Element dipstick d Reinstall cartridge cover plate knob and pre cleaner CHANGE OIL FILTER Replace oil filter after every 100 hours of operation or every season which CLIPS ever occurs first Before installing newfilter lightly oil filter gasket with fresh clean engine oil Screw filter on by hand until gasket contacts oil filter COVER adapter Tighten 1 2 to 3 4 turn more Start and run engine at idle to check for oil leaks Recheck oil level and add oil if required i PLATE CR CARTRIDGE OPTIONAL OIL PART FILTER 491056 AIR CLEANER MAINTENANCE SERVICE AIR CLEANER Square Dual Air Cleaner Element i COVER Remove and service foam pre cleaner every 25 hours or every season 7 whichever occurs first Service paper cartridge every 100 hours or every SS PRE CLEANER season whichever occurs first f 3 NOTE Service air cleaner more often under dusty conditions 2 CARTRIDGE ROUND DUAL ELEMENT 1 Unhook clips on both sides of air cleaner and remove cover To service pre cleaner a Slide foam pre cleaner
56. hould NOT be power at the solenoid valve With the float switch in the down position there should be power at the solenoid valve Solenoid valve defective Remove solenoid valve disassemble and inspect diaphragm for cracks or tears PROBLEM Mix Tank Does Not Keep Up With Water Output Solution Check incoming water pressure Check garden hose quick connect assembly Screen Check garden hoseand or feed hose to the mix tank for clog kinks or blockage Float switch 4 in mix tank hanging up not moving freely Check filter screen in Solenoid valve 1 CAT PUMP MODEL 290 OPERATING INSTRUCTIONS Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 and 3930756 i TM CAT PUMPS AG e y Loretohoehe 5 CH 6300 ZUG Switzerland Prone 42 21 31 40 Telex 865 160 cpag ch CAT PUMPS DEUTSCHLAND GmbH Rostocker Strasse 9 6200 Wiesbaden Brerstad West Germany Phone 0812 56 00 01 2 Telex 41 86713 CAT PUMPS U K LTD 27 Station Industrial Estate Fleet Hampshire GU13 BOY England Phone Fleel 22031 Telex 858898 APU PS CORPORATION Box 885 MINNEAPOLIS MN 55440 Phone 612 780 5440 Telex 29 0276 CAT PUMPS INTERNATIONAL S A Harmoniestraal 29 B 2000 Antwerp Belgium Phone 03 237 72 24 Telex 33947 SPECIFICATIONS Volume 3 5 13 L M 1 Discharge Pressure
57. ible injury or death CAUTION This symbol is used to warn of possible equipment damage There is no guess work in the manufacture of these highly advanced cleaning plants likewise there must be none in preparing it to get the job done in the field It is the purpose of this manual to help you properly understand maintain and service your cleaning plant Follow the directions carefully and you will be rewarded with years of profitable trouble free operation Itis imperative that no section be overlooked when preparing for operation of this equipment AQUACAT MACHINE SPECIFICATIONS FRAME 21 W 56 L 28 H Steel with baked on epoxy finish WEIGHT 500 Ibs complete COWLING Steel with baked on Epoxy finish ENGINE 16 HP Briggs amp Stratton V Twin steel sleeved cylinders ducted IGNITION Magneto key start solid state ignition HI PRESSURE PUMP Tri Plex piston Cat 290 3 5 GPM 1200 PSI 1200 RPM VACUUM BLOWER 3LFS Sutorbilt w 12 HG safety relief Es TELEPHONE NUMBERS 5908 LT 206 775 7272 General Offices onday Friday 206 775 7276 Parts Department 8 00 am To 5 00 pm 206 775 7275 Service Warranty PACIFIC STANDARD TIME 206 771 7156 FAX HOW THE SYSTEMS WORK THE AQUACAT 3 9 SYSTEM WORKS AS FOLLOWS The AquaCat 3 9 High Performance Heat Exchanger system is a highly engineered cleaning plant designed by HydraMaster Corp The system utilizes a dynamic heati
58. iption of malfunction 1 Pressure readings on high pressure gauge with wand turned and off 3 warranty replacement parts are needed please specify method of shipmentdesired NOTE All replacement parts are sent freight collect via i U P S D Air Express B Air Freight E Auto Freight Air 4 Do not give malfunctioning parts to a HydraMaster sales or service i representative All parts must be returned directly to HydraMaster Freight prepaid PARTS ORDERS To expedite your parts needs please call your sales representative In most instance he either stocks or has access to parts through a regional service center Inthe event parts are unavailable locally contact the factory and coordinate your needs If this 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 i ONE FINAL NOTE i Any questions you have regarding the warranty program should be i directed to the Warranty Service Department personnel at HydraMaster Corporation We shall always endeavorto be fairin our evaluation ofyour warranty claim and shall provide you with a complete analysis of our findings HydraMaster Warranty Policy Effective February 1 1989 HydraMaster warranty covers only defective materials and or workman ship for the periods listed Labor and or
59. k plug or spark plug wire removed Use an approved tester i 16 00 NOT crank engine with spark plug removed If engine is flooded i place throttle in FAST position and crank until engine starts 17 DO NOT strike flywheel with a hard object or metal tool as this may cause Read Operator s Manual i flywheel to shatter in operation Use proper tools to service engine i 18 DO NOT operate engine without a muffler Inspect periodically and i replace if necessary If engine is equipped with muffler deflector inspect A i periodically and replace if necessary with correct deflector ERES Waming Caution 19 DO NOT operate engine with an accumulation of grass leaves dirt or i other combustible material in the muffler area i 20 DO NOT use this engine on any forest covered brush covered or grass covered unimproved land unless a spark arrester is installed on the ed Oil muffler The arrester must be maintained in effective working order by the operator In the State of California the above is required by law i Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on Federal lands Fuel 21 00 NOT touch hot muffler cylinder or fins because contact may 21 WARNING WARNING DO 1 ALWAYS DO remove the wire from the spark plug when servicing the engine or equipment TO PREVENT ACCIDENTAL STARTI
60. kening the weld integrity To fabricate an alignment tool you need only a length of pipe about 18 and a 1 1 2 coupler welded to one end see illus HYDRAMASTER CORPORATION 6323 204th Street S W Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS DATE 28 MAY 1993 RE 3 5 to 3 9 AQUA CAT Conversions PSB 93051 Poor performance has been noted in several instances regarding the sions from 3 5 AQUA CATs to 3 9 AQUA CATs Such indications may appear as low RPM or discharging fuel from the carburetor The most probable cause would be back pressure To correct the situation we recommend that you remove the third heat exchanger from the rear of the machine and remove any rust or foreign material that may be blocking the copper tubes If at all possible prior to installing the third heat exchanger run the machine with the silencer unrestricted This will allow larger particulates to flow through the system and avoid any build up
61. lear water through chemocal system for 10 seconds vinegar should be rinsed through system weekly off chemical flow meter 3 Tum on cleaning tool to flush chemical from unit hoses and cleaning tool NOTE If freeze guard is necessary perform steps 1 amp 2 of freeze guard procedure at this time page 32 6 At this time the blower should be lubricated with LPS 1 7 Shut engine down 8 Drain vacuum tank Vacuum filter should be cleaned prior to mobilization of van NOTE If freeze guard is necessary perform steps 3 4 of freeze guard procedure at this time Flood Damage Work Caution must be exercised to prevent the water pump from overheating during long periods of vacuum work such as water damage RAAERESSEEEER99 000372831800 0202 0 VRISPEU pass RERSYRERRIISI08309 1391 Vacuum Pump Lubrication Port Exhaust Heat Exchangers Silencer Assembly Chemical Gauge Pressure Vacuum Gauge Chemical Flow Meter Stationary Engine Guard Pressure Adjustment Valve High Pressure incoming Cleaning Solution Engine 3 Water Outlet Choke Vanguard Engine Engine Oil High Pressure Filter
62. lippage Tighten or replace use correct belt Air leak in inlet plumbing Dismantle reseal and reassemble Relief valve stuck partially plugged or improperly adjusted valve seat wom Clean and adjust relief valve check for worn and dirty valve seats Kit available Inlet suction strainer clogged or improper size Clean Use adequate size Check more frequently Wom piston assembly Abrasives in pumped fluid or serve cavitation Inadequate Install proper filter Suction at inlet manifold must be limited to lifting less than 20 water supply feet of water or 8 5 PSI vacuum Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Leaky discharge hose Replace worn valves valve seats Replace discharge hose PROBLEM Pump runs extremely rough pressure is very low Cause Solution Restricted inlet or air entering the inlet plumbing Proper size inlet plumbing check for air tight seal Inlet restrictions and or air leaks Damaged cup or stuck inlet or discharge valve Replace worn cup or cups clean out foreign material replace worn valves Worn inlet manifold seals Prrrmm A Lubes Replace wom seals PROBLEM Cylinder O Rings blown next to discharge manifold Cause Solution Pressures in excess of rated PSI Check for plugged nozzle closed valves or improperly adjusted bypass valve Warped manifold Freezing Replace manifold PROBLEM Leakage at the cylinder O Rings at the discharge manifold an
63. luding use for commercial income producing or rental purposes Once an engine has experienced commer cial use it shall thereafter be considered as a commercial use engine for purposes of this warranty policy Lifetime limited warranty of the Magnetron ignition shall cover parts and labor for the first five 5 years from the date of purchase thereafter only parts Lifetime shall mean lifetime of the engine in the hands of the original purchaser Applies to equipment retailed in the U S A and Canada In all other countries the warranty CONSUMER USE is the same as COMMER CIAL USE NO REGISTRATION WARRANTY CARD IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS amp STRATTON ENGINES SAVE YOUR PURCHASE RECEIPT PROOF OF PURCHASE DATE WILE REQUIRED TO AIN WARRANTY avoid misunderstandings which might occur between engine owners and authorized Briggs amp Stratton service accounts we are listing some of the causes of engine failure where repair or replacement is NOT covered by Briggs amp Stratton warranty NORMAL WEAR Warranty will not cover repair where normal use has exhausted the life of a part or engine Engines like all mechanical devices need periodic parts andre oilthe air cleaner regularly 6 Damage or wear caused by grit from blast cleaning spark plugs is not i covered by Warranty We do not approve of cleaning spark plugs on an abrasive blast cleaning machine since
64. machine is used With the hoses and wand connected run machine and spray the water anti freeze solution out of the wand until the low water switch in the mix tank shuts the machine off Your machine is now freeze protected 7 Solution hose and wand freeze guard procedure optional Attach the solution hoses and wand to the machine Dependent upon the amount of hose attached more anti freeze solution may be needed in the chemical mix tank With the machine running spray the wand into a container to recapture the anti freeze solution Continue to spray the wand until the machine shuts down by itself Recovering anti freeze for re use Open the mix tank drain valve and allow the anti freeze solution to drain into a sealable container so that it may be used again Before cleaning with the machine again flush the remaining anti freeze solution from the system by spraying water through the hoses and wand until all signs of anti freeze are gone Unscrew damaged heat exchanger as per instructions and remove If smaller heat exchangers are used removal of the silencer may not be necessary Length of pipe with 1 1 2 coupler attached used as alignment tool Screw onto male thread of manifold allowing sufficientthread engagement preventing dam age to the threads After alignment the replacement heat exchanger should install without ANY load factor whatsoever If this is not the case remove the heat exchanger and
65. mage on the delivery receipt 2 The salesman from whom you purchased your unit is responsible for i supervising the correctinstallation ofthe unitin your vehicle andthoroughly training you in its operation maintenance and precautions CORRECT INSTALLATION INCLUDES Installation of through floor fittings for gasoline fuel lines securing them with bolts or tie down cleats MACHINE INSTALLATION There are two locations to place the machine in the side door or in the rear door as mentioned in the section titled Placement of Unit The standard way to configure the unit is as shown in the illustration with the recovery tank beside the unit An alternative method not shown would be to put the recovery tank behind the unit The standard machine does not come with enough hardware to allow for mounting of the tank behind the machine If this configuration is chosen please contact HydraMaster for more informa tion HydraMaster recommends that the exhaust for the machine be piped through the floor of the vehicle Itis important that the machine be placed as close to the door as possible so that outside air can be pulled into the engine for proper cooling Machine Configuration It is recommended by the manufacturer that the exhaust from the front of machine be vented down under the truck to prevent carbon monoxide from entering the job site Always park the truck so the exhaust is blowing away from the job site Never
66. ng system comprised of two separate exhaust heat exchangers for capturing free heat Water is fed into the machine at tap pressure It is combined automatically with cleaning solution as it enters the mix tank The solution is then picked up by the high pressure pump and pressurized to the desired level The solution then travels to the bypass assembly where it is distributed out to the wand and back into the machine The solution going back into the machine splits flow and travels through the two exhaust heat exchangers After being heated the solution returns to the mix tank where it is picked up by the pump again When the cleaning solution reaches a pre set temperature it is released from the system and directed to the recovery tank then cool water enters the system to regulate the temperature CHEMICAL SYSTEM Electro mechanical flow meter controlled HEATER 2 stainless steel exhaust heat exchangers shell and tube for engine and blower heat INSTRUMENTS 0 1000 High pressure gauge Temperature gauge Vacuum gauge Hour meter Chemical flow meter Ignition switch RECOVERY TANK 70 gallon marine grade aluminum epoxy finish CLEANING WAND Stainless steel 11 with heat cover handle and forward guide handle 1 HI PRESSURE HOSE 1 4 High temperature lined vinyl covered safety orange with brass quick connects VACUUM HOSE 2 Reinforced safety orange 1 12 reinforced safety orange STANDARD EQUIPME
67. o remove 4 Valve assemblies will remain with the manifold Invert manifold and discharge valve assemblies should fall out 5 Inspect discharge valves for wear or ridges Spherical valves due to their shape must be replaced when wom REASSEMBLY 1 Place retainer in manifold chamber 2 Next insert spring into center of retainer 3 Place valve over spring with spherical mooned side up 4 Next insert the valve seat 5 Position manifold back onto pump NOTE Exercise caution when inserting cylinders into manifold to avoid damaging cylinder o rings 6 Replace flange nuts on studs and hand tighten both sides Then torque each side to 125 inch pounds 7 Hand tighten locking nut SERVICING THE SEALS AND SLEEVES DISMANTLING 1 Remove discharge manifold and piston assemblies as described 2 Remove both M8 locking nuts from studs i3 With soft mallet tap inlet manifold loose from crankcase 4 Place inlet manifold on pair of clearance blocks with crankcase side i down and drive out seals 1 5 Invert inlet manifold with CRANKCASE SIDE UP i 6 Lubricate circumference of new Prirrm A Lube seals position in manifold with GARTER SPRING DOWN and drive into place 7 Examine sleeves for scoring or other damage before removing 18 If worn grasp sleeve with pliers and pull off NOTE This procedure will mar the sleeve so use only if sleeve is to be replaced 9 Remove o ring and back up rings from
68. of your Service Center investigation will be made to determine the applicability of warranty Ask the Service Center to submit all supporting facts to the Factory for review If the Factory decides that your claim is justified you will be fully reimbursed for those items accepted as defective To avoid misunderstanding which might occur between engine owners and Authorized Briggs amp Stratton Service Centers we list below some of the causes of engine failure that Briggs amp Stratton warranty does not cover for repair or replacement LIMITED WARRANTY FOR VANGUARD ENGINES Fortwo years from date of purchase Briggs amp Stratton Corporation will replace for the original purchasers free of charge any part or parts of the engine found upon examination by any Factory Autho rized Service Center or by the Factory at Milwaukee Wisconsin to be defective in material or workmanship or both This is the exclusive remedy For five years from date of purchase Briggs amp Stratton Corporation will replace for the original purchasers free of charge any part or parts of the MAGNETRON Ignition System excluding the spark plug found upon examination by any Factory Authorized Service Center or by the Factory at Milwaukee Wisconsin to be defective in material or workmanship or both so as to result in the loss of ignition This is the exclusive remedy All transportation charges on parts submitted for replacement under thi
69. off cartridge b Wash it in liquid detergent and water c Squeeze it dry in a clean cloth d Saturate it in engine oil Wrap it in clean absorbent cloth and squeeze to remove EXCESS oil e Reinstall pre cleaner over cartridge f Reinstall air cleaner cover and reattach clips to sides of air cleaner body 24 U E 1 Loosen knob and remove cover assembly 2 Remove cartridge and pre cleaner from cover To service pre cleaner a Wash pre cleaner in liquid detergent and water b Squeeze it dry in a clean cloth C Saturate it in engine oil Wrap itin clean absorbent cloth and squeeze to remove all EXCESS oil To service cartridge 8 Clean by tapping gently on flat surface b If very dirty replace or wash in a nonsudsing detergent and warm water solution Rinse thoroughly with water from inside out until water runs clear Let cartridge dry thoroughly before using Petroleum solvents such as kerosene are not to be used to clean cartridge They may cause deterioration of the cartridge DO NOT OIL CARTRIDGE DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE 3 Reinstall pre cleaner in cover with foam toward cover 4 Reinstall cartridge in cover with tabs on cartridge in slots in cover 5 Reinstall cover assembly on air cleaner body CLEAN ENGINE CLEAN COOLING SYSTEM i Grass chaff or dirt may clog the rotating screen and the air cooling system Every 100hours or every season whiche
70. ofteners and the subsequent invalida tion of machine warranty claims due to hard water and or chemical deposits Included ineach HY DRAMASTER manual is a hard water area map The map graphically portrays the average hardness of water in each region of the United States This map does not excuse anyone living in a soft water area from Water Hardness Grains Per Gallon 7 101 42 and above DATE 17 FEB 92 PSB 9221 using water softeners if circumstances require it Under the heading of water softeners the manual states Many areas of the country have an excess of minerals in the water which result in what is commonly refered to as hard water These minerals tend to adhere to the insides of heater coils and other parts of the machine causing damage as well as loss of cleaning effectiveness the relatively low cost of a water softener service is more than made up for in the increased life of machine parts and continued cleaning efficiency The manuals also have advice on de scaling procedures As stated in the manual any deposits that form on the inside of the machine may cause dam age Any damages resulting from hard water or chemical deposits are considered abuse and or ne glect and will not be covered by the HYDRAMASTER WARRANTY Avoid costly repairs and downtime by using whatever wa ter softening method that is readily available Also remem ber to follow up the de scalin
71. oils keep the engine cleaner and retard formation of gum and varnish deposits Use no special additives with recommended oils RECOMMENDED SAE VISCOSITY GRADES or 20 20 PC 30 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE 10 0 10 20 30 40 Use SAE 30 oil in high temperature high load applications 10W 40 oil may be substituted if 10W 30 is not available Use synthetic oil having 5W 20 5W 30 or 5W 40 viscosity If not available a petroleum based multi grade may be used having 5W 20 5W 30 viscosity NOTE Using multigrade oils 5W 20 5W 30 5W 40 and 10W 30 will increase oil consumption Check oil level more frequently when using them TO FILL CRANKCASE WITH OIL Place engine level Clean area around oil fill Remove dipstick POUR OIL SLOWLY Fill to FULL mark on dipstick DO NOT OVERFILL NOTE After starting engine stop after 30seconds Check oil level and add if necessary Without filter oil capacity is approximately 1 1 2 qts 48 ozs or 1 42 Itrs With oil filter oil capacity is approximately 1 3 4 qts 56 028 or 1 65 Itrs TO CHECK OIL LEVEL Place engine level Remove dipstick and wipe oil from it with clean cloth i Screw dipstick into tube until cap bottoms on tube Remove and check oil level Dipstick must be firmly screwed into tube when engine is running Oil Fill and Dip Stick 7 12 Volt Electric Starter 8 Model Type and Code Numbe
72. on for tightness leaks Clean vacuum tank thoroughly with high pressure washer Flush water and chemical system with 50 50 white vinegar solution MONTHLY Grease blower bearing fittings Remove pressure Bypass Valve stem grease cup and stem reinstall Check water level in battery Clean connections as needed QUARTERLY Change oil in blower Check engine compression Check for combustion chamber carbon deposit Change spark plugs IMPORTANT Record date and machine hours in maintenance log AS REQUIRED DESCALING H i i OVERALL CARE OF UNIT MAINTAINING THE ORIGINAL APPEARANCE OF YOUR UNIT IS IMPORTANT FOR TWO REASONS 1 It represents a big dollar investment for your cleaning business and its appearance should reflect that fact A dirty machine is not professionall 2 Maintenance trouble shooting and repair is much easier to accomplish ona clean well maintained unit Regular cleaning of the machine offers you an opportunity to visually inspect all facets of the machine and spot potential problems before they occur i FOLLOWING MAINTENANCE IS RECOMMENDED BY THE i MANUFACTURER AT THE FREQUENCY INDICATED Check recovery tank s s filter and filter bag as required i DAILY i Wipe machine down thoroughly with a damp cloth flush recovery tank out thoroughly Empty filter bag and inspect for rips tears etc replace as needed remove thoroughly clean and reinstall stainless steel filter screen in recover
73. or missing mounting bolts Tighten or reinstall mounting bolts 19 VACUUM BLOWER WARRANTY COOPER warrants products ofits 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 COOPER nor to assume for COOPER any other liability in connection with any of COOPER S products This warranty shall extend for two 2 years from date of installation provided this equipment has been put into service within six months after shipment from the COOPER factory If repairs or replacements are made by the Purchaser without COOPER S prior written consent COOPER S warranty shall cease to be in effect No allowance will be granted for any repairs or alterations made by the Purchaser without COOPERS prior written consent Machinery equipment and accessories furnished by COOPER but manufactured by others are warranted only to the extent of the original manufacturer s warranty to COOPER COOPER 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 COOPER S manufacture which within the specified warranty period shall be proved to COOPER S satisfaction to have been defective when shipped provided the Purchaser promptly notifies COOPER in writing of such alleged defect
74. ored in a heated garage at night or over the weekend If not possible place a 1500 watt electric heater inside the truck aimed directly at the machine Never use 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 a heater you should first drain all possible water from the machine cleaning tools and hoses They freeze also TO DRAIN THE MACHINE FOLLOW THESE STEPS 1 Before shutting off the machine remove the chemical line from the chemical jug and place mixture of 50 50anti freeze and water With the cleaning tool on allow mixture to fill chemical system back to the chemical mix tank 2 Loosen the petcock valve on your bypass drain hose and allow the water to drain thoroughly from the mix tank 3 Using the freeze guard hose provided with the machine freeze guard the unit First plug the rubber stopper into the outlet of the recovery tank Then with the pressure regulating valve unscrewed plug the other end ofthe freeze quard hose into the high pressure cleaning solution fitting on the front of the machine Run the unit until the engine stops 4 Open the mix tank drain valve and drain out the remainder of the water The unit is now freeze guarded CLEANING AND CHEMICALS PRECAUTIONS i i Yourmobile carpet cleaning planthas been engineeredusingthelatestand most sophisticated technology availa
75. ough it then rinse it out with vinegar Check the Chemical Flow Meter 6 for obstructions or a sticking float Is incoming water pressure less than 30 PSI Cracked or defective Chemical Flow Meter 6 Check the filter screen in the Solenoid Control Valve 1 PROBLEM Inability to adjust chemical with the Flow Meter Solution Debris lodged behind teflon seat in Flow Meter valve seat on the valve stem may be loose If deteriorated replace O Ring Insufficient water pressure Locate new source LOW PRESSURE HIGH PRESSURE VAC EXHAUST LINE EXHAUST FLOW HIGH TEMP BY PASS BY PASS PRE HEAT CONTROL PANEL INCOMING WATER OUTGOING CLEANING SOLUTION PRESSURE ADJUSTMENT AQUA CAT 3 9 DX WATER FLOW DIAGRAM m HYDRAMASTER CORP 29 JUNE 1992 000 068 215 EXHAUST SILENCER AK 000 093 013 VACUUM 000 068 098 1447 OUTLET lt 000 068 214 30 SR ERR RRR RHEE 000 068 2311 29_ CONTROLLED ORIFICE rn 000 068 213 37 PROBLEM Mix Tank Overflows Solution Float switch 4 in the mix tank not moving freely or defective To Check Switch With a 12 volt test light and the floatin the up position there should be power through the switch Check Relay First check wiring against diagram With 12 volt test light and the float switch 4 in the up position there s
76. quired to compensate for differ ences infuel temperature altitude or load Air cleaner andair cleaner cover must be assembled to carburetor when running engine TWIN CYLINDER CARBURETOR ADJUSTMENT IS UNIQUE ADJUST CARBURETOR FUEL MIXTURE IN THE ORDER STATED AS FOLLOWS i INITIAL ADJUSTMENT Gently turn idle mixture screw clockwise until it just closes Turning screw in too far may damage it Then turn idle mixture screw 1 1 2 turns counterclockwise This initial adjustment will permit the engine to be started and warmed up approximately 5 minutes prior to final adjustment 23 Carburetor Adjustment Screws MIXTURE SCREW FINAL ADJUSTMENT Start engine and place equipment speed control in IDLE SLOW position Hold carburetor throttle lever against idle stop and adjust idle speed screwto obtain 1300to 1500 RPM Still holding throttle lever against idle stop turn idle mixture screw slowly clockwise lean until speed just starts to slowand then slowly counterclockwise rich until engine just starts to slow Finally tum screw to midpoint between rich and lean Now adjust idle speed screw to obtain 1200 RPM if govemed idle spring t is red or 900 RPM if governed idle spring is white Release throttle lever If engine does not accelerate smoothly readjust idle mixture screw approximately 1 8 tum counterclockwise rich NOTE Engines operated at altitudes of approximately 3000 to 5000 fee
77. r end Remove oil level which require grease lubrication will have a grease fitting at each plug located in the head plate Fill gear case until oil drips out ofthe oil bearing When regreasing the old grease will be forced out of the vents level hole B Use lubricants as listed Add fresh oil as requiredto maintain during operation To prevent damage to seals these vents must be kept proper level The oil should be drained flushed and replaced every 300 open at all times Vacuum Blower Motor Lubrication LUBRICATION INSTRUCTIONS FOR OIL LUBRICATED GEARS AND BEARINGS Add fresh oil as required ta maintain proper level Drain and refill every 1500 hours of barvice more fre operation under normal quentiy when required Use tn applications with extreme variations in ambient temperature 20W SOW multiple oil is recommended FOR GREASE LUBRICATED BEARINGS 1 Service svery 500 hours of SLOWER DISCHARGE TYPE TEMPERATURE GREASE iM EVERY 100 HOURS 40 to 275 No 2 40 to 120 C Bearing Greasa THE INTEREST OF SAFETY BEFORE STARTING ENGINE READ AND UNDERSTAND THE OPERATING AND MAINTENANCE INSTRUCTIONS OPERATING AND MAINTENANCE THIS SYMBOL MEANS WARNING OR CAUTION INSTRUCTIONS FOR MODEL SERIES DEATH PERSONAL INJURY AND OR PROPERTY DAMAGE MAY OCCUR UNLESS INSTRUCTIONS ARE FOLLOWED 303400 16 HP CAREFULLY WARNING D
78. r 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 HydraMaster s manufacture which within the 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 HydraMaster will pay all freight and transportation charges via normal ground shipping means for replacement of parts covered under this warranty HydraMaster s liability to Purchaser whether in contract or in tort arising out of warranties representation instruc tions 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 implied or statutory and HydraMaster shall have no liability for consequential incidental or other damages howsoever caused FRAME COVER ASSEMBLIES eeoa creena cere reece 3 years VACUUM RECOVERY TANK CHEMICAL MIX TANKS cece cece cee ennt 3 years CHEMICAL PROPORTIONING SYSTEM 2 c
79. rear door due lo height of van bed connecting all gasoline lines connecting battery checking pump vacuum blower and engine oil levels prior to starting unit starting unit to check t engine to see that all systems function normally also checking all hoses i wands etc for correct operation i TRAINING SHALL INCLUDE Thorough review of the operation manual with purchaser instruction and familiarization in how to correctly start up t and shut down unit how to correctly clean with the unit how where and how often to check and change component oil levels how the units systems work howto troubleshoot the unit how to do basic repairs safety i precautions and their importance freezing damage and howto avoid it and a thorough review of the unit warranty and warranty procedures TRUCK PREPARATION i Themanufacturer recommends the installation of plywood flooring covered with poly propylene backed astroturf do not use rubber backed in the vehicle prior to installation of machine This provides metal to cushion mounting rather than metal to metal provides insulation and makes an attractive van interior Astroturf should be color keyed to van interior Ensure that machine is well secured to the floor of van with hardware supplied Sudden or crash stop will cause machine to slide forward 500 Ibs worth Protect yourself and the machine SECURE ITI TRUCK PREPARATION ILLUSTRATION FIRST
80. rs 9 Spark Plug 10 Valve Cover 11 Fuel Tank Optional 1 Air Cleaner 2 Fuel Shut off Valve 3 Carburetor 4 Rewind Starter Blower Housing 6 Oil Drain Plug 22 FUEL RECOMMENDATIONS This engine will operate satisfactorily on any gasoline intended for automo tive use A minimum of 85 octane is recommended DO NOT MIX OIL WITH GASOLINE Use clean fresh lead free gasoline We recommend the use of Briggs amp Stratton Gasoline Additive partno 5041 Purchase fuel in quantity that can be used within 30 days This will assure fuel freshness and volatility tailored to the season Leaded gasoline may be used if lead free is not available Use of lead free gasoline results in fewer combustion deposits and longer valve life NOTE We DO recommend the use of gasoline which contains alcohol such as gasohol However if gasoline with alcohol is used it MUST NOT contain more than 10 percent Ethanol and MUST be removed from the engine during storage DO NOT use gasoline contain ing Methanol See STORAGE INSTRUCTIONS page 27 DO REMOVE fuel cap while engine is running DO NOT FILL fuel tank to point of overflowing Allow approximately 1 4 in 5mm of tank space for i fuel expansion f H H Engine Components 15 Crankshaft 16 Oil Filter 17 Air Cleaner 12 Fuel Pump 13 Dipstick 14 Exhaust Manifold 1 CARBURETOR ADJUSTMENTS Minor carburetor adjustment may be re
81. s Warranty must be borne by purchaser For warranty service contact your nearest Authorized Service Center as listed in the Yellow under Engines Gasoline or Gasoline Engines THERE IS NOT OTHER EXPRESS WARRANTY IMPLIED WAR RANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE YEAR FROM PURCHASE AND TO THE EXTENT PERMIT TED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EX CLUDED LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY ANDALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW Some jurisdictions do not allow limitations on how long an implied warranty lasts and some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so the above limitation and exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Briggs amp Stratton Corporation F P Stratton Jr Chairman and Chief Executive Officer WARRANTY PERIOD ENGINES ees All Vanguard and engines CONSUMER USE 2 year engine Lifetime Magnetron amp igni tion COMMERCIAL USE 2 year engine Lifetime Magnetron amp igni i tion For purposes ofthis warranty policy consumer use shall mean personal residential household use by the original retail consumer Commercial use shall mean all other uses inc
82. s logo and Yellow pages are registered trademarks in various jurisdictions i CLEARANCES DIMENSION Spark Plug Gap eene 030 in 76 mm Intake 004 006 in 10 15 Exhaust 004 006 in Cae i Check when engine is cold In some areas local law requires the use of a resistor spark plug to suppress ignition signals If an engine was originally equipped with a resistor spark plug be sure to use the same type of spark plug for replacement i STORAGE INSTRUCTIONS Engines to be stored over 30 days need to be protected or drained of fuel to prevent gum from forming in the fuel system or on essential carburetor parts 1 For engine protection we recommend the use of Briggs amp Stratton Gasoline Additive Part No 5041 available from any Briggs amp Stratton Authorized Service Center Mix Additive with fuel in fuel tank or storage container Run engine for a short time to circulate Additive through carburetor Engine and fuel can be stored up to 24 months PT _ If Additive is not used or if engine is operating on gasoline containing alcohol remove all fuel from tank and run engine until it stops from lack of fuel io TO GS EE 2 While engine is still warm drain oil from crankcase Refill with fresh oil 3 Remove spark plugs and pour approximately 1 ounce 30 ml of engine oil into each cylinder Repl
83. the water pump from running dry The desired chemical injection ratio may be obtained by an adjustment of the Chemical Flow Meter 6 during the fill cycle of the mix tank Water must be flowing into the mix tank in order to adjust the chemical mix The chemical 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 With this unique chemical system the chemical flow is propor tioned only during the filling cycles of the Mix Tank not during the direct i spraying ofthe wand Therefore itis possible that as your wand is spraying i you may have no chemical flow Also the converse is true in that you may i not be spraying your wand but if the mix tank is in a filling cycle your Chemical Flow Meter may be active at the desired flow rate The chemical proportioning system will mix chemical with water at a 1 to 30 ratio when the Flow Meter is set at 5 GPH or a 1 to 15 ratio when the Flow Meter is set at 10 GPH continues AQUACAT WATER FLOW At this pointin the flow solution water with chemical will nowbe siphoned from the bottom of the Mix Tank to the inlet of the Water Pump 8 In the pump the water is pressurized and then discharged through a rubber pulsation hose down to the pressure relief valve 9 From the pressure relief valve the water is automatically distributed to the cleaning
84. uum recovery tank This stainless steel screen is finger tight and should be removed for cleaning weekly When machine is being run for test purposes and the vacuum inlet on top of machine is open caution should be used To protect the vacuum blower from overloading and damaging itself there is avacuum relief system installed on the vac tank When the vacuum tank inlet is completely sealed off a maximum of 12 HG will be attained A hole onthe top blower pipe elbowacts as the lubrication point Atthe endofeach day LPS 1 or Pennzguard should be sprayed in before shutting down the machine See blower lubrication illustration If you fail to lubricate the vacuum blower daily rust deposits and moisture will decrease the life of the vacuum blower Read the vacuum blower manual carefully for proper oil change and grease application The maintenance log may differ slightly from the manual but the truck mounted carpet cleaning machine application is very demanding ofthe vacuum blower and therefore it should be maintained more regularly NOTE Vacuum tank is protected from overflowing by a vacuum tank float kill switch This switch is not activated by foam only by liquid Blower Lube Port i VACUUM TANK FILTER BAGS HydraMaster filter bags are designed to trap all of the lint that would normally collect at the bottom of your vacuum tank The use of these bags i ifemptied at the end of each job will eliminate the build up of much of
85. ve discharge manifold as described in the last section 2 Slip cylinders out of inlet manifold NOTE Identify cylinders so they will be replaced in their original position front to back 3 Remove cotterpin nut and washer 4 Next remove piston retainer spacer and piston assembly 5 Remove inlet valve i REASSEMBLY 1 Examine inlet valve surface and reverse if damaged both sides are lap surfaces 2 Examine piston assembly for clean inlet surface If damaged replace and lubricate NOTE CUP INSTALLATION Wipe cup inserter lightly with oil Slip bac cup ring onto piston Force cup over inserter and square with all surfaces Faulty cup installation causes premature failure 3 Next replace piston spacer and retainer i 4 Slip washer onto rod screw on nut and torque to 60 inch pounds MOIE ALWAYS REPLACE WITH NEW COTTERPIN ls Examine cylinder walls for scoring or etching These conditions will cause premature wear of your piston assemblies Replace if worn or damaged 6 Lubricate cylinder and replace o rings and backup rings if defective i 7 Position cylinders in their original order into manifold chambers and i carefully slip over rod ends onto the pump 8 Replace flange nuts on studs and hand tighten both sides Then torque each side to 125 inch pounds 9 Hand tighten locking nuts 3 Grasp the discharge manifold with 3 fingers on the underside and tap with a soft mallet t
86. ver occurs first remove the blower i housing and clean the area shown to prevent overspeeding overheating and engine damage Clean more often if necessary CLEAN AREAS OF ALL DIRT DW Cooling System CLEAN SPARK ARRESTER SCREEN i Ifengine muffler is equipped with spark arrester screen assembly remove i every 50 hours or every season for cleaning and inspection Replace if damaged Contact any Briggs amp Stratton Authorized Service Center Remove dirt and debris with a cloth or brush Cleaning with a forceful spray of water is not recommended as water could contaminate the fuel system i CLEAN ROTATING SCREEN ELECTRIC START ENGINES OR REWIND STARTER GARD Brush grass chaff and dirt from rotating screen or rewind starter gard daily more often if needed to prevent engine damage caused by overheating and or overspeeding To assure smooth operation keep governor controls and linkage clean and free of debris Periodically clean muffler area to remove all grass dirt and combust ible debris REPLACE SPARK PLUGS Spark Plug 76 mm 030 in WIRE GAUGE PART NO 491055 Replace every 100 hours of operation or every season whichever occurs first NOTE Do blast clean spark plugs Spark plugs should be cleaned by i Sparking cannot occur if wire terminal does not fit firmly on spark plug i Reform terminal if necessary scraping or wire brushing an
87. wand and bypassed back to the mix tank depending on water usage at the wand As the water travels back toward the mix tank from the pressure relief valve it flows through two exhaust heat exchangers which heat the cleaning water CHEMICAL SYSTEM MAINTENANCE The chemical lines may need to be flushed with vinegar periodically to prevent abnormal chemical build up This flushing may be done by removing the clear plastic hose from the Chemical Jug and inserting itinto one quart container of vinegar This should be done with the Chemical Flow Meter setting on 10 and the Water Heater off Simply spray water from the wand until the quart of vinegar is exhausted the repeat the process with one quart of clear water to void all lines of vinegar CHEMICAL TANK TROUBLE SHOOTING GUIDE PROBLEM Little or no chemical flow Solution Check that hoses at the Mix Tank 3 are secure Check that the hose from the top of the Flow Meter 6 to the Chemical Injector 2 is secure with no kinks or leaks Check that the adjusting cap on the side of the injector is not screwed all the way in Check the s s check valve inside the injector for chemical build up and proper operation Check the hose from the bottom of the Flow Meter to the Chemical Jug 7 for kinks cracks or bubbles Check the screen on the end ofthe hose which goes into the Chemical Jug To check this screen for proper function remove it from the plastic hose If you cannot blow thr
88. wer Replace wom components NOTE Mustbe accomplished by a qualified technican Defective relief valve Inspect and replace if necessary PROBLEM Blower Is seized Cause Solution Rust Spray rust dissolving lubricant onto lobes to emulsify rust and attempt to rotate vacuum lobes Foreign matter Dismantle and remove foreign matter and repair as required NOTE Dismantling must be accomplished by qualified technican Note The above mentioned rust foreign matter and seizing are often caused from foam traveling through the blower PROBLEM Noise In vacuum blower Cause Solution Worn gears Remove and replace gears NOTE Replacement of gears must be accomplished by qualified technican Timing of vacuum blower has been changed due to worn components NOTE Replacement of components must be accomplished by qualified technican Lack of lubrication NOTE Permanent damage may have resulted from lack Lubricate as specified by applicable vacuum blower manual See Table of Contents of lubrication Wom bearings Remove and replace bearings as required NOTE Must be accomplished by qualified technican Debris and or foreign material build up NOTE A stainless steel filter is provided Dismantle vacuum blower and remove foreign material NOTE Dismantling should in vacuum inlet located in vacuum blower components be accomplished by qualified technican only Replacement of worn parts is necessary Loose
89. y tank inspect and clean vacuum slot on cleaning wand check wand head for sharp edges that could tear carpet file down as needed clean wand to maintain original appearance wipe down vacuum and high i pressure hoses as needed visually inspect for cuts etc WEEKLY Wipe down entire unitas needed apply good coat of auto waxto all painted t surfaces inside and out and to control panel thoroughly clean recovery t tank using high pressure hot water unit with optional high pressure cleaning gun may be used for this remove stainless steel filter in recovery tank thoroughly clean removing all lint build up inspect for damage and i reinstall Remove filter bag thoroughly clean and reinstall if tom replace i empty chemical from chemical container wash out thoroughly to remove any chemical build up inspect chemical feed line strainer and use 50 white vinegar water solution to remove any chemical build up thoroughly t clean wand and inspect for clogged jet debris in vacuum slot and leaking fittings at valve Apply light coat of auto wax to wand Thoroughly clean i vacuum and high pressure hoses including hose cuffs inspect for wear or damage to hoses and quick connect fittings Inspect garden hose connect t adapter screen for debris remove and clean thoroughly Inspect all lines for wear or abrasions that may cause possible leaks Scale deposits on the interior of heater tubes can cause a noticeable loss in

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