Transcript
I HOW TO ORDER
I
ONE FINAL NOTE:
To obtain a proper diagnosis of your malfunction, and to order warranty replacement parts, it is important that you proceed in the following manner:
Any questions you have regarding directed to the Warranty Service Corporation.
1. Call
We shall always endeavor to be fair in our evaluation of your warranty claim, and shall prowde you with a complete analysis of our findings,
HydraMaster
2. Give the information: A. B. C. D. E. F. G. H. 1,
Warranty/Service
Warranty/Service
Dept. at (206)
Representative
775-7275,
the
following
Name of your company and your address, Equipment Model (i.e. CDS). Date of purchase. Hours on the unit. Serial number of unit. Name of person authorized to order parts. Salesman unit purchased from. Description of malfunction. Pressure readings on high pressure gauge with wand on and off.
HydraMaster Effective
April
HydraMaster workmanship reimbursement
warranty covers only defective for the periods Iwted. Labor. is specifically excluded.
turned
U.P.S. Air freight Air mail Air express Auto Freight
4. Do not give malfunctioning parts Service Representative. All parts to HydraMaster, freight prepaid.
Policy
1, 1987
MONDAY
3. If warranty replacement parts are needed, please specify method of shipment desired. NOTE: All replacement parts are sent freight collect, via: A. B. C. D, E.
Warranty
the warranty program should be Dept. Personnel at HydraMaster
HOURS: THROUGH
materials and/or and/or diagnostic
FRIDAY
7:00 am TO 6:00 pm PACIFIC
STANDARD
TIME
@@@@ to a HydraMaster must be returned
Sales or directly
PST
ROCK
MT.
TELEPHONE GENERAL OFFICES: PARTS DEPI SERVICE/WARRANTY NEW EQUIPMENT SALES AND MARKETING:
CENTRAL
EASTERN
NUMBERS (206) 775-7272 (206) 775-7276 (206) 775-7275 1-800-426.1301
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Table
tlllsll JllllllMll.,lu,llnm,,n'l!hlln'll,,tll,'lbll~l,,tm,,,,lm,,,,,,l,,,,t',l,,,,,,l!,lll,,,lM
of Contents
Parts Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Flow Diagram ...................................... Water and Chemical Flow Operation ....................... Water Softener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Softener Hook-up Diagram ... .. ....... ....... Jet Assembly ............................................ Wand Assembly .......................................... Valve Assembly .......................................... Stem Assembly .......................................... Vacuum System Information ............................... Vacuum Flow Diagram, ................................... Vacuum Tank Filter Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7 Blower Lubricant ......................................... Vacuum Blower Warranty ............ ....... ....... . Factory Authorized Service Centers for Sutorbilt Products ........................... Lubrication (Vacuum Blower Motor) . . . . . . . . . . . . . . . . . . . . . ...10 Filling Procedure (Vacuum Blower Motor) . . . . . . . . . . . . . . . . ...10 Vacuum Blower Troubleshooting Guide . . . . . . . . . . . . . . . . . ...11 Cat Pump Model 290, Operating Instructions &Specifications . . . . . . . . . . . . . . . . . . . . . . . . . ...13 Cat Pump Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14 General information for Cat Pump Repair . . . . . . . . . . . . . . . . ...15 Bypass Valve illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15 Chemical Proportioning and Level Control illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16 Chemical Tank Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . ...16 Pump-in System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . ...18 Cat PumpDimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18 Important Drive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19 Specifications (pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19 Piston Mode1290 Exploded View,.. . . . . . . . . . . . . . . . . . . . . ...20 Parts List Mode1290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20
2
2 3 3 4 4 4 5 5 6 6 7 8 9
Service Kits Mode1290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...22 Servicing the Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . ...23 Servicing the Pumping Section .,, . . . . . . . . . . . . . . . . . . . . . . ...24 Servicing Sleeves and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25 Servicing Crankcase Section . . . . . . . . . . . . . . . . . . . . . . . . . . . ...26 Cat Pump Trouble Shooting Guide.. . . . . . . . . . . . . . . . . . . . . ...27 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...33 Cleaning and Chemical Precautions Information. . . . . . . . . . ...33 Cleaning Stroke Procedure/Over-Wetting. . . . . . . . . . . . . . . . ...34 Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35 Overall Careof Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35 Freeze Protection of Clutch Drive with Pump-In System . . . ...36 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...36.39 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40 Warranty Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40 HydraMaster Limited Warranty. .Inside back cover
Machine Serial No. Q 1987 HydraMaster Corp.
PARTS ORDERS To expedite your parts needs, please call your sales representative. In most instances, he either stocks or has access to parts through a regional service center.
WATER FLOW DIAGRAM
In the 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. U. P.S., U.P.S. Blue Label, Air Freight, Air Express, etc. HydraMaster REPLACEMENT PART
NO.
Parts
Dept.
phone
(206)
775-7276.
PARTS DESCRIPTlON Meter
QTY.
000-078-015
Flow
Kit
000-078-019
Wand
000-078-034
Pressure
000-076-00s
Spray
000-049-028
Recovery
000-078-001
Cat 290 Short
000-078-004
Cat 290 Hot Cup Kit (Optional)
1 6
Valve
Bypass
Kit
Valve
1 Kit
Tank
000-049-023
Screen 440
Male
Garden
000-052-051
440
Female
000-052-052
660 Male
000-052-053
660 Female
000-0”
Belt, Pump
1 1
Jet 80r2$E
000-052-050
0-019
1
Plunaer
Filter
Bag
Cup Kit Standard Hose
Quick
Connect
Quick
Quick
Connect
Quick Drive.
Connect Connect AX-26
2 1
1 1 1 1 1
A. B. C. D, E. F.
Pressure Gauge Hot Water Shut-Off Valve Control Bypass Valve High Pressure Solution Outlet incoming Water Drain
G. Radiator
Water (Out) H. Proportioner 1. Chemical Mix Tank
J. K. L. M. N. O. P. Q.
Pump Intake Heat Exchangers Radiator Water (In) Pump Output Bypass R&turn Chemical Flow Meter Chemical Jug High Pressure Pun’Ip
WATER AND CHEMICAL FLOW OPERATION This system free ever.
has been designed
to be the most simple
is in a filling flow. and trouble-
The incoming water flows directly to the mix tank. Water will now flow through a proportioning valve which will simultaneously mix the chemical to achieve your desired solution. The mix tank is equipped with 2 different float valves, one of which responds to the water level of the tank and will maintain the proper volume of solution to be reserved for the cat pump. The secondary float valve is a safety valve that is designed to protect your system from sudden or unexpected loss of water supply. If, for example, the water source at the house was turned off, the water level of the mix tank would drop, activating the secondary valve which automatically disengages the electric pump clutch. In conjunction with the incoming flow, the chemical ratio may be obtained by an adjustment of the chemical flow meter during the fill cycle of the mix tank. The chemical will flow from the chemical jug to the chemical flow meter, then to the proportioner where it is distributed into the mix tank at your desired proportion. This line should be flushed with vinegar weekly to prevent abnormal chemical build-up, This may be done by removing the clear plastic hose from the chemical jug and inserting it into a one quart container of vinegar. This should be done with the chemical flow meter setting on 10 GPH with heater “off”. Simply spray the wand for the duration of the vinegar in the one quart container, then repeat the process with clear water to void all lines of vinegar. NOTE: With this unique chemical system, your chemical flow is proportioned to the filling cycles of the mix tank, not the direct spraying of the wand. Therefore, it is possible that as your wand is spraying, you may have no chemical flow, Also, the converse is true in that you may not be spraying your wand but, if the mix tank
cycle your chemical
flow meter
may read your desired
This chemical system will mix a 1 to 30 ratio when flow meter is set at 5 GPH, Most chemical suppliers will recommend a 1 to 15 ratio therefore you can either set the flow meter at 10 GPH, giving you a 1 to 15 ratio of chemical to cleaning water, or double the recommended strength of chemical in the 5 gallon jug and set the flow meter at 5 GPH, thereby attaining a 1 to 15 ratio. (It is recommended that you set the flow meter at 10 GPH for overall best results.) The water will now be siphoned from the bottom of the mix tank to the Cat Pump. If the wand is not spraying, the water will bypass from the bottom of the brass pressure relief valve to the mix tank.
WATER SOFTENER Many areas of the country have an excess of minerals in the water which results in what is commonly called “hard water”, These minerals tend to adhere to the insides of heater coils and other parts of the machines causing damage and a loss of cleaning effectiveness. Reports from several of our machine users commending the results of the use of water softeners in conjunction with their machines prompts us to recommend the procedure to everyone in a “hard water” area. The relatively low cost of a water softener service is more than made up for in the increased life of machine parts and continued cleaning efficiency. The water softener will also increase the effectiveness of the cleaning chemical being used, therefore, less chemical will be needed, next page) ! contmea
(Softener,
I
continued)
Contact a water softener distributor in your area for information on the rental of a simple water treatment unit to carry in your truck. Be sure to change the water softener in accordance with the capability of the softener. Example: If the softener will treat 900 gallons of water and the machines uses an average of 30 gallons per hour of use on an average of 5 hours a day would be 150 gallons a day would be treated. Five days would equal 750 gallons of water, therefore, the softener would be changed every 6 working days for maximum softening.
JET ASSEMBLY
Body
,...
\
@ Brass
Cap
P
,&’@<80~S~’bzer
WATER SOFTENER HOOK-UP WAND ASSEMBLY Garden
oo~ .mme.
Hose
See Cw
m
~ram,
Incoming Water From Faucet
\+: ~--
. .-
/“’
‘“’”
@
Handle
S.S. Solut[on l-lose
,/’
o 0 0
.~:::
,,,/”~
‘rube\
w @
Jw Water Softener
————
Assembly”
.X= ‘v=
\
J
“Valve
\~,:’sJ;crew-%’
Sleeve
S.S. Handle , (Guide) “ .
Assembly”
\ s. d
@ ‘“M
\
@
Handle +& \\Wand
Lip
Clip
7
‘“Y
Nylock Nut
STEM ASSEMBLY
VALVE ASSEMBLY
I +----Retainer
w Keeper
Ring—
~ _O-Ring 9
Plunger+ Nylock . . . ..
‘J@~
@j\-Body
l!!
O-Ring=A @+ Quick’ Connect
w I
—
O-Ring
VACUUM SYSTEM INFORMATION The vacuum blower incorporated in this machine is a positive displacement lobe type, manufactured by Fuller Company. The performance and life of this unit is greatly dependent on the care and proper maintenance it receives.
VACUUM FLOW DIAGRAM
Filter
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.
Bag
Recovery
/
Tank
To prevent this, a stainless steel filter screen has been placed at the vacuum inlet inside the vacuum recovery tank. This stainless steel screen is finger tight and should be removed weekly for cleaning. Caution should be used when machine is being run for test purpose and the vacuum inlet on top of machine is open. To protect the vacuum blower from overloading and damaging itself, there is a vacuum 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 blower lube port is located above the vacuum gauge; at the end of each day, LPS 1 or WD-40 is sprayed in before shutting down the machine. See blower lubrication illustration. If you fail to lubricate the vacuum blower daily, rust deposits and moisture will decrease the life of the vacuum blower. Caution: problems, free.
Foam passing through the blower could lead to serious therefore, it is important to keep the vacuum tank foam
Cleaning Wand
w Vacuum
\ Blower
Blower Exhaust Silencer
VACUUM TANK FILTER BAGS HydraMaSter filter bags are designed to trap most of the lint, sand and dirt that would normally collect at the bottom of your vacuum tank. The use of these bags, if emptied at the end of each job, will eliminate the build-up of much of the debris in the tank and avoid a mess. The drawstring top of these bags is designed to be tied to the incoming dirty water inlet in the vacuum tank. To re-order
bags
use part number
BLOWER LUBRICANT
049-029.
VACUUM TANK FILTER BAGS ty Water
Tank
Spray lubricant into blower lube port for 3 to 5 seconds, then immediately shut off machine. Use onlv LPS lubrican~s. ‘Filter
Bag
1 or WD-40
moisture
displacin9
VACUUM BLOWER WARRANTY FULLER warrants products of its manufacture defects In material and workmanship if properly tained, and operated under normal conditions superwwon,
to be free from installed, mainwith competent
FULLER’S Ilabllity to Purchaser, whether in contract or [n tort arising out of warranties. representations. instructions. or defects from any cause shall be Iimlted to repalrlng or replaclng of the defectwe part or parts as aforesaid, f.o. b. point of shipment.
No person, agent, representative or dealer is authorized to give any warranties on behalf of FULLER nor to assume for FULLER any other habllity in connection with any of FULLER’S products.
No Ilabllity whatsoever shall attach ducts have been paid for.
This warranty shall extend for one (1) year from date of installation provided this equipment has been put into serwce within SIX months after shipment from the FULLER factory. If repairs or replacements are made by the Purchaser wrthout FULLER’S prior written consent, FULLER’S warranty shall cease to be in effect. No allowance will be granted for any repairs or alterations made by the Purchaser without FULLER’S prior written consent.
EXCEPT AS STATED IN THIS SECTION AND IN THE PRECEDING SECTION TITLED ‘WARRANTY’” AND EXCEPT AS TO TITLE, THERE ARE NO GUARANTEES OR WARRANTIES OF MERCHANTABILITY, FITNESS, PERFORMANCE OR OTHERWISE, EXPRESS, IMPLIED OR STATUTORY, AND FULLER SHALL HAVE NO LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR OTHER DAMAGES, HOWSOEVER CAUSED.
Machinery, equipment and accessories furnished by FULLER, but manufactured by others, are warranted only to the extent of the original manufacturer’s warranty to FULLER. FULLER agrees at its option to repair at the point of shipment or to replace without charge f.o.b. point of shipment, any part or parts of products of FULLER’S manufacture, which within the specified warranty period shall be proved to FULLER’S satisfaction to have been defective when shipped, prowded the Purchaser promptly notifies FULLER, in writing, of such alleged defect.
Date Installed Model Serial
#
FULLER COMPANY 2966 East V[ctoria Street Compton, California 90224
to FULLER
until said pro-
},
FACTORY AUTHORIZED SERVICE CENTERS FOR SUTORBILT PRODUCTS FULLER COMPANY / COMPTON DIVISION 2966 E. Victoria St., Compton, CA 90224 213/636-9821 or 639-7600 FULLER COMPANY / MANHElM 236 South Cherry Street Manheim, Pennsylvania 17545 71 7/665-2224 BAYLISS MACHINE & WELDING 2901 8th Avenue North Birmingham, Alabama 35203 205/323-6121
70130
r
SCHWARZ FOUNDRY COMPANY 2001 West Fort Street Detroit, Michigan 48216 313/496-1880
PUMPS & POWER LTD. 1380 Napier Street Vancouver, B. C., Canada 604/255-4341
CAROTEK INCORPORATED 640 Sam Newell Road Mathews, N. Carolina 28105 704/847-4406
GATX-FULLER 721 Progress Scarborough, 4 16/438-6540
CO. LTD. Avenue Ontario,
I Canada
DYNMAC CORPORATION 7925 E. 40th Street Tulsa, Oklahoma 74145 918/627-0110
ASSOCIATED TECHNICAL 1229 Waimanu Street #21 Honolulu, Hawaii 96814 8081537 -’I 206
SERVICE,
INC.
WM. W. MEYER & SONS 8261 Elmwood Avenue Skokie, Illinois 60076 31 2/673-0312 OLIVER & LAUGHTER 10450 Westoffice Houston, Texas 77042 713/977-2577
ELECTRIC CRAFTS LTD. 3936 Edmonton Trail NE. Calgary, Alberta T2E 3P6 403/276-9676
& CO.
DIVISION
BARNEY’S PUMPS INC. 3907 Highway 98 South Lakeland, Florida 33802 81 3/686-8195
[
GREGORY-SALISBURY 805 South Front Street New Orleans, Lousiana 504/524-5207
EQUIPMENT
CO.
a Ail u
FULLER A GATX
— .—
MI=A
I
COMPANY
2966
East
Victoria
Post
Office
Box
Tel:
CO Street 4308,
(21 3) 639-7600
I
Compton, (213)
California
636-9821
Telex:
90224 67-4607
LMBIUCATION 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 the bearings are grease lubricated.
FILLING PROCEDURE Remove square head vented oil fill plug (A) on gear Remove oil level plug (B) located in the head plate. Fill case until oil drips out of the oil level hole (B). Use lubricants
as listed.
Add fresh oil as required should be drained, flushed more frequently (f inspection at (C). NOTE: located
end. gear
to maintain and replaced so indicates.
proper level. The oil every 1500 hours or The oil drain plug is
Older units may have the oil fill level and drain in the cast iron gear case instead of in the head
holes plate.
Bearings on drive end of blower require grease lubrication every 100 hours of operation. Bearings which require grease lubrication will have a grease fitting (D) at each bearing. When regressing, the old grease will be forced out of the vents during operation. To prevent damage to seals, these vents must be kept open at all times.
VACUUM BLOWER TROUBLE SHOOTING GUIDE PROBLEM:
Loss
of Vacuum
Cause
Solution
Collapsed
vacuum
Clogged
hose
stainless
steel
Defective
vacuum
Defective
or ‘open’
Fractured
weld
Colla~sed
or kinked
Plugged
Loose
drive
PROBLEM:
plates
and vacuum
tank.
filter.
vacuum
tank
dump
valve.
shaft
tool.
Blower
in vacuum
between
clutch
Remove
and, clean
Remove
and
blower.
and
Re~lace
valve.
Re-weld
as required hose
obstruction
Remove
obstruction,
The
Spray rust dissolving attempt to rotate Disassemble required. aualified
matter.
above
reinforced
steel
hose
filter.
seal,
or replace
tank.
and/or
by reversing
eliminate
kinks.
the vacuum
NOTE:
Must
hose.
be accomplished blower NOTE: noise,
by
to stand still Unless the your vacuum
is Seized Solution
The
tank
set screws may come loose causing while engine may be turning properly. blower is seized or making a knocking loss is not caused by a bad blower.
Rust.
NOTE:
stainless
vacuum
components. technician.
Cause
Foreign
or replace
if Dossible
Remove
Replace worn a aualified
blower,
re~lace
A special
valve.
flesha~e
hose.
hose,
or lobes
Remove and replace hose. NOTE: is reauired for replacement.
Close
tank.
vacuum
in cleaning
end
blower
seal.
on vacuum
vacuum
Restriction Worn
tank
between
mentioned,
rust,
foreign
matter
and seizing
are often
caused
lubricant onto vacuum lobes.
and remove foreign NOTE: Disassembly technician. from
foam
traveling
lobes
to emulsify
matter and repair as must be accomplished through
rust
and
by
the blower. fconl!nued
next page)
VACUUM BLOWER TROUBLE SHOOTING GUIDE PROBLEM:
Noise
in Vacuum
Blower Solution
Cause Loose
Worn
(continued]
Direct
Drive
Coupler.
Gears.
Examine
universal
shaft
for defects
and
retighten
Replace
universal
shaft.
Remove must
and replace gears. NOTE: Replacement of gears be accomplished by a qualified technician.
Timing of vacuum blower has been changed components. Replacement of components accomplished by a qualified technican. Lack of Lubrication. NOTE: Permanent resulted from lack of lubrication. Worn
may
have
Lubricate
as specified.
See
Remove and replace bearings accomplished bv aualified
bearings,
Debris and/or steel filter tank. Loose
damage
foreign material build-up. NOTE: A stainless is provided at vacuum inlet located in vacuum
or missing
mounting
bolts.
lock
bolts.
due to worn must be
index. as required. technician.
Must
be
Disassemble vacuum blower and remove foreign material. NOTE: Disassembly should be accomplished by qualified technician only, Replacement of worn parts is recommended if this procedure is necessary. —...—. Tighten
or reinstall
mounting
bolts.
CAT PUMPS Model 290 OPERATING INSTRUCTIONS CAUTION: CAT PUMPS are positive displacement pumps, Therefore, a properly designed pressure relief mechanism MUST be installed in the discharge piping, Failure to install such relief mechanism could result in personal injury or damage to the pump or system. Cat Pumps Corporation does not assume any liability or responsibility for the operation of a customer’s high pressure system,
SPECIFICATIONS Volume: 3,5 GPM (13 L/M) Discharge Pressure: 1200 PSI (83 BAR) Maximum Inlet Pressure: -8.5 to + 40 PSI (-0.6 to + 2.8 BAR) RPM: 1200 RPM (1200 RPM) Bore: 0.787” (20 mm) Stroke 0.472;’ (12 mm) Crankcase Capacity: 10 oz. (,3 L) Maximum Fluid Temperature 160”F (71 ‘C) Inlet Ports (1): 1/2” NPT (1/2” NPT) Chemical Injection Port (l): 1/4” NPT (1/4” NPT) Discharge Ports (2): 3/8” NPT (3/6” NPT) (l): 1/2” NPT (1/2” NPT) Pulley Mounting: Either side (Either side) Shaft Diameter: 0.650” (16.5 mm) Weight: 12.1 Ibs. (5.5 kg) Dimensions: 10.77’’x9.06’’x5 .14” (273,5 x230x130.5 mm)
Products described hereon are covered by one or more the following U.S. patents: 3558244, 3652188, 3809508, 3920356, and 3930756
-,
● CAT PUMPS — AG ● LOrOtOhoehe 5 CH-6300 ZUG Switzerland Phone (42) 21-3140 – Ts(m 865160
J~’Map~-T
P O Box S85 MINNEAPOLIS, MN 55440 Phone (612) 780-5440 – Telex 294276 N V CAT PUMPS INTERNATIONAL SA Harrno”,estraal 29 B 20Q0 Antwerp, Belg,um Phone (03) 237.72.24 — Telex 33947
ccmg ch
CAT PUMPS
OEUTSCHLANO Gmbw ● Rostocke, StraSSC, 9 6200 Wlesbaden.B!erst.9dt West Germany Phone 0612.56000712 — Telex 41 86713 ●
CORPORATION
●
of
●
● CAT PUMPS (U K , LTD ● 27 Stalkon Indu.str,al Estate, Fleet Hampshire GU13 8QY, Engla.d Phone Fleet 22031 — Telex 856898
CAT PUMP WARRANTY This Cat Pump (“product”) is warranted by the manufacturer to be free from defects in workmanship and material for one year from date of manufacturer’s shipment. This warranty is limited to repairing or replacing products which manufacturer’s investigation shows were defective at the time of shipment by the manufacturer. All products subject to this warranty shall be returned F.O. B. Cat Pumps Corp., Minneapolis, Minnesota 55430. U.S.A. for exammation, repair or replacement. The express warranty set forth herein is in lieu of all other warranties, express or implied, including without limitation any warranties of merchantability or fitness for a particular purpose and all such warranties are hereby dtsclalmed and excluded by the manufacturer. Repair or replacement of defective products as provided above is the sole and exclusive remedy provided hereunder and the manufacturer shall not be liable for any further loss, damages or expenses, including incidental or consequential damages, directly or indirectly arising from the sale or use of this product. This warranty is subject to the following warranty conditions: Important Conditions: LUBRICATION - fill crankcase to the top of oil gauge window per specifications with Cat Pump oil or equivalent SAE 40
weight hydraulic oil with antlwear and rust lnhibltor addltwes. Change initial fill after 50 hour run-in period, Change 011every three months or at 500 hour Intervals thereafter. Prrrrrm-a-lube seals need no lubrication. Blue dot seals and wicks must recewe three drops of Cat Pump 011per wick every 50 hours of operation. GOOD LUBRICATION IS THE AND LEAST EXPENSIVE MAINTENANCE,
EASIEST, OF
MOST EFFICIENT PREVENTATIVE
F(PM and PRESSURE - Pump operation must be wlthln RPM and pressure specifications. Pressure relief valve must be [nstalled, DO NOT PUMP ACIDS OR ABRASIVE FLUIDS with this unit. Consult Cat Pumps for addlt!onal information on questionable fluids. FREEZING CONDITIONS freezing conditions.
- Pump
must
be protected
from
USE OF OTHER THAN CAT PUMP PARTS OR THEIR EQUIVALENT VOIDS THE WARRANTY
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 dis-assembly). If the surfaces of these check valves are dirty, or show signs of chemical build-up, it is probable that they would remain open causing pressure loss or pulsation. Upon inspecting the valves, make sure that the teflon buttons in the valve spring retainers are still intact. Also examine the discharge manifold. Look for problems such as cracks, chemical buildup or warpage due to freezing. If this discharge manifold is warped, it will cause the check valves to stick and will result in loss of pressure. The Cat pump cups are often the source of pressure loss. Upon inspection they may appear melted or torn, but often they will look good, Replace them anyway. There is no sure method of visually inspecting the cups. HydraMaster recommends changing cups whether they look good or not. Anytime your pump is being dismantled, HydraMaster recommends replacement of all ‘o’ rings and seals. This is merely a convenience to the customer to make sure that the Cat pump is in top operating condition. The prrm-a-lube seals located within the intake manifold will allow air to enter the pump if they are worn. Again, it is difficult to visually pinpoint a defective prrrm-a-lube seal. Replace them all. Within the piston sleeve cylinders there are 6 ‘o’ rings that are about V4 the size of a penny. If these ‘o’ rings are bad, water will be pumped back into the oil. If this has occurred the oil will raise in level and appear milky. If you are unable to repair seals right away, change oil frequently. Repair the pump as soon as possible so as to not damage bearing or connecting rods.
Repairing of Cat pumps is not a difficult task. However, before disassembling make sure you have the proper parts required. 1 - short (or hot) cup kit 6- piston sleeve ‘o’ rings
3- Prrrm-a-lube seals 1 - bottle Cat oil
and follow Read instructions thoroughly prior to disassembly directions as stated. Oil all seals thoroughly prior to installation. (Remember, a newly scarred seal is no better than one you just took out. )
BYPASS VALVE ILLUSTRATION To service bypass valve ● Unscrew hex knob and remove. * Wiggle protruding shaft with fingers or pliers, pull up and remove from main body. Special instructions - bypass valve #4 - 5/16“ fine thread #6 - Cup seal (if leather, replace or lube with leather oil). #7 - Brass bushing place thin end of shaft only #8 - Shaft - if CUD needs re~lacement, in vise and” remove 5;16“ nut. Fat end is “seatina” surface and must be free of abrasion to properly se~t. NOTE: IMPORTANT - when replacing seals, only wrench nut #4 to where CUD will not turn on shaft. If CUD is too loose, bwass will leak. Too tight, cup will flange and bypass will leak:
CHEMICAL TANK TROUBLE SHOOTING HEMICAL PROPORTIONING AND EVEL CONTROL ILLUSTRATION Valve /
Body
/
Valve
Repair
Ball Nut W/Set Screw
/ ‘—>%EI-+Z
Kit
i
To Valve
—F’
1)
Plunger
~~
+------Adjustment Screw
Float Assm.
-Chemical Pick Up Hose,. “F7J
8
Outlet Tube
—Proportioning Venturi —Main Valve Diaphragm
Mounting Bracket
> [ -
1
~. w L I .
‘-
@ t Foot Valve Screen
and
? -“+ [L._&
‘!q
Underwater Feed
!L— ,,/
Chemical
Flow
Check that hoses in the tank are secured. Check that the hose from the top of the flow meter to the s[de of the mix tank is secured with no kinks. Check the hose from the bottom of the flow meter to the chemical jug for kinks or cracks.
Extension Bracket \
-z
No or Low
Solution
Cap
Proportioning 000078 /
0’;?
PROBLEM:
i Float
Check the foot valve and screen on the end of the hose which goes into the mix tank. To check this screen for proper function, remove it from the plastic hose. You should be able to suck through the hose barb end, but you should not be able to b[ow through the hose barb end. (If you can not suck through it then rinse it out with vinegar. ) When screen IS removed the chemical fill hose should be lifted into a vertical position so the ball [n the foot valve will seat by grawty. (This IS only a temporary fix for low water pressure areas. ) Check
flow
meter
for float
Check to insure that venturi is backed
Is proportioning ventun vinegar solution. Is incoming Cracked
water
closed?
pressure
or defective
obstruction
the adjusting out.
less
chemical
screw
on proportioning
Soak
[n warm
than
20 PSI?
flow
water
or
meter?
NOTE: If you are in a low water pressure area and find that the volume of water entering the mix tank is not enough to allow your venturi to siphon chemical, unscrew the spring from the foot valve screen and remove the— spring. —.
I
PROBLEM:
Inability
to Adjust
Chemical
with the Flow
Meter
lodged
Teflon
seat
PROBLEM:
behind
teflon
dismounting Solution Jua
seat
from
flow
Reversing
in flow
meter
meter from
Check
knob.
Anti-siphon
knob. Mix Tank
to Chemical
screen
removed
in anti-siphon
PROBLEM:
ball
Extension action
garden
Float
ball
Extension lever.
Mix Tank
from chemical
jug hose.
screen. Overflows
Solution Float
Doesn’t
in mix tank
hanging
bracket pinching of the lever.
up (not the float
moving lever,
hose
quick
Check garden hose and/or kinks or blockage.
Solution
Debris
Mix Tank
KeeD
UP With
Water
OutRut
Solution
Solution Debris
PROBLEM:
freely)
restricting
full
Plunger not seating properly on the valve. (Remove the 2 screws which hold the extension assembly to the valve. Do not lose or drop the screws, Remove the extension assembly. Turn it upside down. Inspect the plunger for proper seating. If there is no debris obstructing the valve or plunger, the plunger may be out of adjustment. To adjust, loosen the set screw on the ball nut and move the ball toward the end of the rod 1/16”. Retighten set screw. Place extension assembly back into position. Tighten the two screws.
in mix tank bracket
connect feed
hanging
pinching
assembly hose
up. (Not float
lever,
screen.
to the mix tank moving
freely.
restricting
full
for clog, ) action
of
Valve plunger not opening fully, To adjust, remove the 2 screws which hold the extension assembly to the valve. (Do not lose or drop the screws.) Remove the extension assembly, turn it up side down. To adjust, loosen the set screw on the ball nut. Place your thumb on the plunger and press it in 1 /1 6“ and slide the ball nut w/set screw toward the plunger end 1116”. Tighten the set screw. Place the extension assembly back into position. If the tank starts to overfill, the ball nut is to close to the valve plunger and should be moved back away from the valve plunger slightly. PROBLEM:
PumD
Pulsates
When
The Tank
Is in a Fill Mode
Solution Check that the hose which goes from the gray plastic venturi to the bottom of the tank is not directed toward the Cat pump pick up port. If it is, aim it in another direction.
CAT PUMP DIMENSIONS
r
‘2-=-i~----’
0.20
3
Standard Garden Hose Screen With Pump-In System @@
Puhmm SYSTEM FLOW DZAGRAM
,7
/
Q+
~j, 1.34[34)-4
@ Incoming Water Connection
\ &------
L-3,1110 ]lIJ.775)73.5) J
[20]
IMPORTANT DRIVE INFORMATION
SPECIFICATIONS
Pump speed and pump output in gallons per minute as tabulated is based upon a 1725 RPM drive motor. Select motor pulley size and provide GPM of the approximate pump output desired.
Volume
Pump RPM and GPM output are approximate tions in pulleys, belts and motors between & 5“/0 pump output tolerance.
values due to variamanufacturers and a
U.S. Measure Discharge
Pressure
Psl
Flow I
MOTOR PULLEY SIZE
800
1000
1200
]
Using 1725 RPM Motor & Std. Pump Pulley O.D. 1
Maximum
Weight
=
“Desired” G.P.tvI. “Desired” R.P.M.
GPM X PSI 1460
=
Electric Brake H.P. Required
Motor Pulley O.D.
=
Pump Pulley O.D.
Rated G.P. M.
DETERMINING THE RECJUIREDH.P. DETERMINING klOTOR PULLEY SIZE Note
Cons.11 engine
Rated R.P.M.
Pump R.P. M. manufacturer
Motor R.P. M.
when using gas or d!esel e.glne
(1200
RPM)
(12 mm)
Capacity
. . . . . . . . ...10
Fluid Temperature,
(71 Oc)
160°F (1/2”
NPT)
Ports
.3/8” NPT
(3/8”
NPT)
. . . .Either side
(Either
side)
(16.5
mm)
Mounting Diameter
(2) ..
, . . . . . . . . . . . . ...0.650”
. . . . . . . . . . . . . . . . . . . . ..l2.llbs.
Dimensions.
(.3 L)
oz.
(l) . . . . ..2 . . . . . . . ..l/2’’NPT
. . ...10.77”
%EHEEaz DETERMINING THE PUMP R.P.M.
(-0.6 to + 2.8 BAR)
. . . . . . . . . . . . . . . . . . . . . .. O.472°
Crankcase
Pulley PRESSURE Psl Psl
P.S.I.
(20 mm)
Stroke,
Shaft
(13 L/M)
. . . . . . . . . . . . . . . . . . . . . . . . .. O.787°
Discharge REQUIREMENTS
Measure
to 40 PS.I.
RPM . . . . . . . . . . . . . . . . . . . . . ..12 00 RPM
inlet Ports
HORSEPOWER
. . ...-8.5
Metric
(85 BAR)
. . . . . ...1200
Max. Inlet Pressure Bore
Horsepower figures shown are brake horsepower figures. For gas engine requirements, follow engine manufacturer’s recommendations. In general, use a gas engine with approximately double to electric motor horsepower.
. . . . . . . . . . . ..3 . . . . .. M.5G.P.M.
x 9,06” x 5.14”
(5.5 kg) (273,5 x230x 130.5 mm)
PISTON MODEL 290
Exploded
View
PARTS LIST Mode. ITEM
PART
1
20285
2
44274
3 4 5 8 9 10 11 12 15
43340 43339 43987 23170 25825 92520
16 17 18 19 20 21
43804 14487 24159 26536 27950 92519
23 24 25 28 27 28 29
101799 101800 16948 20017 25301 25327 25392 28771 29003 29614 26854 28597 25128 25835
30 31 32 33 34
85880 44377 44374
NO.
..-
DESCRIPTION O-Ring (Buns-N) Crankcase StuJd (M8 X 82) O-Ring, Oil Filler Cap Oil Filler Cap 0-Ring, Crankcase Cover Crankcase Cover Bubble Oil Gauge O-Ring, Drain Plug Drain Plug Sems Comb Head Screw (M6 x 20) Crankshaft Rearing Oil Seal (Buns-N) O-Ring, Oil Seal Case Oil Seal Case Sems Comb. Head Screw (M6 X16) Connecting Rod Piston Rod Piston Pin Seal Washer Oil Seal Barrier Slinger O-Ring, Sleeve O-Ring, Sleeve (Viton) Back-Up Ring, Sleeve (Teflon) Sleeve (29743 Unchromed) ) Seal Washer Seal Retainer Inlet Manifold Inlet Manifold-Stainless Steel
QTV —.. 1 1 2 1 1 1
1 1 1 1 6 1 2 2 2 2 8 3 3 3 3 3 3 3 3 3 J
3 3 1 1
.
ITEM
PART
35
30315 30325 27004 30543 30544 43172 43474 27983 27002
NO.
DESCRIPTION
44
27006
Prrrrrm-A-Lube Seal Prrrrrm-A-Lube Seal (Viton) Inlet Valve Bat-Cup Piston Bat-Cup Ring (Teflon) CuD [Viton) Bat-Cup Assembly Piston Soacer Piston Retailmer Conical Washer-S: ; (M8)
45
27000
Nut-SS
38 39 40 41 42 43
46
14158
Cotte3
101802
Cylin ~der (43834
49 50 51 52 53 54 56 57 58 Electric 59 60 81 62
23172 11377 21985 24459 25634 43442 43360 43723 43434 81109 101804 25130 Clutch Assembly 152-005 077-005 036-005 143-(-H4
in
Unch) O-Ring, Cylinder (Buns-N) O-Ring, Cylinder (Viton) Bat-Up Ring, Cylinder DischarLme_ Manifold -..... _ Discharge Manifold -S.S, Valve Spring Retainer Valve Spring Valve Dischar!ge Valve Seat He!X Nut M8 Hex Flange fNut (M8) Shaft Protector Tanererl -----. ..- SleevI? Key, Elect-tric Clutch 6“ Electric Clutch FI-WI mm Socket Head Screw Flat . . Wa~k . .--,~er (5/16 US) Lock Washer (5/16 US)
ii
17i-iio4 - ‘-
64
174-I-II ---- R
3 3 3 3 3 3 3 3 3 3
(h
47
48
QTY.
3 3 6 6 3 1
1 3 3 3 3 2 2 1 1
1 1 1 1 1
SERVICE KITS 30023 3 6 3 1 1
Cup Kit
cup O-Ring, Cylinder Cotterpin Instruction Sheet Cup Inserter
30305 3 3 2 1
Seal Kit Prrrrrm-A-Lube Seal Cotterpm Abrasive Paper Instruction Sheet
30431 3 3 3 3 6 1
Sleeve and Seal Kit Prrrrrm-A-Lube Seal Barrier Slinger Cotterpin Sleeve O-Ring, Sleeve Instruction Sheet
30686 3 3 3 3 3 1
Valve Kit Valve Spring Retainer Valve Spring Valve Valve Seat O-Ring, Cylinder Instruction Sheet
PUMPING SECTION CUTAWAY
Bat-Cup Piston
Spacer / ,
I 30860 6 3 3 3 3 3 3 3 3 3 3 1
Piston Kit O-Ring, Cylinder Back-Up Ring, Cylinder Bat-Cup Piston Bat-Cup Ring cup Piston Spacer Piston Retainer Conical Washer (M6) Nut (M6) Cotterpin Inlet Valves Instruction Sheet
,,,,Bac-Cup
Ring
Plsto Iston
cup colt
‘ut’*nRods’e ? /
Cyllnder’
SERVICING THE VALVE ASSEMBLIES DISASSEMBLY: 1. Remove the fasteners securing crankcase of the pump,
the discharge
manifold
to the
2. Support the discharge manifold and tap from the backside and a soft mallet to separate from the crankcase and gradually work free from cylinders. 3. Valve assemblies will remain in the manifold. Pump models with the o-ring groove on the outside of the valve seat require the assistance of a reverse pliers to remove the valve seat. The valve, spring and retainer will then fail out when the manifold is inverted. Pump models without the o-ring groove valve seat permit the seat, valve, spring out when manifold is inverted. REASSEMBLY: 1. Replace retainers
in manifold
chambers.
2. Next insert
into center
of retainer,
3. Inspect the necessary.
on the outside of the and retainer all to fall
spring valves
for
wear,
ridges
valve
over
on seat
NOTE: Models without outer groove to be placed on lip of retainer.
on seat require
6. Insert
valve
7. Position
spring
with recessed
seats
manifold
and
replace
if
(dish)
side down.
4. Next examine the seating surface of the flat valve seats and lap with 240 grit paper or replace if evidence of excessive wear. Quiet valve seats should be replaced if worn. Lap new quiet valve and seat to assure positive seal.
into manifold back
onto
NOTE: Lubricate o-rings when slipping manifold cylinder o-rings. fasteners
NOTE: Rep/ace manifold is used
or pitting
and back-up rings on the if worn, Always lubricate and to avoid damaging
NOTE: First install o-ring in groove surface), t~en back-up ring,
8. Replace
NOTE: Seating side of flat valves may be lapped on flat surface using 240 grit paper. Quiet valves due to their shape must be replaced. Insert
5. Some pump models have o-rings valve seat. Examine and replace o-rings for ease of installation elastomers.
(towards
seating the o-ring
chambers.
pump.
on cylinder and exercise caution over cylinders to avoid damaging
and torque
per specification
all originai shims reshim pump.
when
chart. used.
When
new
CAUTION: When starting the pump, check to see that there is no cylinder motion as this will cause premature failure of the cylinder o-rings. Center cylinder motion can be eliminated by switching with one of the end cylinders.
SERVICING THE PUMPING SECTION DISASSEMBLY: 1. Remove the discharge
manifold
as described.
by hand and with an up and down 2. Grasp cylinders cylinders from inlet manifold.
motion,
pull
NOTE CUP INSTALLATION: Wipe cup inserter with oil. Slip bat-cup ring (when used) onto piston. Push cup over inserter and square with all surfaces. Faulty cup installation causes premature cup failure. Lubricate
3. Remove
cotterpin,
nut and washer
from
piston
4 Next 4, Next remove 5. Remove
retainer,
spacer
and piston/cup
assembly
and slip onto
rod,
replace
piston
spacer
and retainer
on rod.
assembly. 5 Replace chart.
inlet valve.
REASSEMBLY: 1. Examine inlet valve surfaces for pitting, scale or grooves. Reverse valve and sand inlet side of valve using 240 grit paper for clean surface or replace if evidence of excessive wear, Slip onto rod. 2. Examine piston seating surfaces using 240 grit paper. If extreme piston.
piston
rod.
and sand clean on flat surface pitting or sharp edges, replace
from the 3, Examine cup for wear, cracking, tearing or separation piston. If worn replace and lubricate before installing on piston.
washer,
thread
NOTE: Always rep/ace turn ends under. 6. Examine premature
cylinder walls wear of cups
on
nut and
with new
torque
Stainless
for scoring and replace
per
Stee/
or etching If worn.
specification Cotferpin
which
and
causes
7, Lubricate cylinder and replace o-rings and/or back-up rings if worn or damaged. Carefully slip cylinders over rod ends and push into inlet manifold in their original position, (front to back) manifold onto 8. Position discharge torque per specification chart,
pump,
replace
fasteners
and
17-22 in: Ibs.
Remove described.
250, 260, 300, 420, 500, 524, 624
M5 x 0.9
20, 260, 260, 290, 320, 333, 430.530, 550, 10 FR. 1000.
M6 X1,0
10 mm Hex
50-100 kg. cm. 60 -- in Ibs
1020, 1520, 2020
M7x 1.0
10 mm Hex
60-150 kg. cm. 52-130 in. Ibs,
2500, 25 FR.
M8 X 1,25
13 mm Hex
80.200 kg, cm, 130 in. Ibs.
4. Next
6024, 8044
M1OX 1.25
17 mm Hex
120-250 kg, cm. 160 in, Ibs,
5. Remove
6020, 6040
M14 X 1.5
22 mm Hex
200-450 kg. cm. 30 ft. lbe
8 mm Hex
30-55 kg. cm,
26-48 in. Ibs.
1024, 1044
MANIFOLD STUO NUT AND CYLINDER BOLTS WHEN USED
2. Remove
discharge
inlet
manifold
manifold
and
containing
3. Grasp sleeves and with a pulling the sleeves from the piston rod.
and twisting
NOTE: G[asp sleeve with pliers only if replacing as this procedure wi// mar the sleeves. remove
seal
and/or
TORQUE
250, 260, 280, 284, 290, 300, 333, 420, 430, 434, 530, 55o
M8 X 1,25
13 mm Hex
125 kg. cm. 125 m, Ibs.
310, 320, 500, 520, 10 FR,, 650, 1000
MIOX 1.5
17 mm Hex
250 kg, cm. 217 in. Ibs.
1024, 1044
M12x 1.25
19 mm Hex
400 kg. cm, 347 in. Ibs.
524, 624, 25 FR, 1024, 1044, 2500
M12 x1,75
19 mm Hex
400 kg, cm. 385 in, Ibs.
2 Examine sleeves for scoring or etching sleeves in oil and carefully twist and (machined counter bore end first).
6020, 6024, 6040, 6044
M16 x 2.0
22 mm Hex
650 ka. cm. 50-60-fl, Ibs.
2 . Next ‘“
8 BOLT MFLD 8135
3
2
❑
❑
❑
•1
El
Orion
1
4
6427
oun
motion
remove
worn
sleeves,
back-up
rings
on piston
REASSEMBLY: 1, Lubricate new o-rinas andlor back-uD rinas and sliD onto Diston rod. Install the first fi-ring in the groove ~n the pis~on rod’, Next position back-up ring against the shoulder in front of the first o-ring, Then install the second o-ring. Exercise caution as you slip the o-ring over the thread end of the piston rod,
TOOL SIZE
SEQUENCE
as
retainer,
and examine o-rings rod for wear and replace.
THREAD
4 BOLT MFLD
assemblies
seals.
PUMP MOOEL
TORQUE
piston
and replace. push sleeve
Immerse onto rod
install seal retainers. If wicks are used, replace wicks, thoroughly saturate with oil, place in seal retainer and install retainer.
4. Place inlet manifold on pair of clearance side down and drive out old seals. 5, Invert seals,
blocks with crankcase
inlet manifold with crankcase side up and Lubricate circumference of seal and install
install new Prrrrrm-A-
(continued
next page)
Lube seal with garder spring down. If using dot should be facing up when installed. 6. Slip lubricated manifold onto
blue dot seal,
seal inserters onto piston rod ends, position pump and remove seal inserters.
NOTE: Replace original repiacing irriet manifoid.
quantity
washers
on
NOTE: Some models secure inlet manifold Rep/ace fasteners and torque per specification 7. Reassemble described.
piston
assemblies
and
studs
blue
inlet
before
to crankcase. chart.
discharge
manifold
as
SERVICING CRANKCASE SECTION 1. While inlet manifold, sleeves and seal examine crankcase seals for wear. 2. Check
oil level and for evidence
3. Rotate crankshaft movement. 4.
Examine leaking.
crankshaft
5. Consult factory evidenced.
by
hand
oil seal
or your
local
retainers
of water to
feel
are removed,
in oil. for
smooth
externally
for drying,
distributor
if crankcase
bearing
cracking
service
or
is
CAT PUMP TROUBLE SHOOTING GUIDE PROBLEM:
Pulsation Solution
Cause Debris
in discharge
PROBLEM:
valves
Low
Clean
of pump.
Replace
nozzle.
in inlet
Pressure
gauge
~lumbina. or not registering
suction
Fouled
strainer
clogged
or improperly
or improper
or dirtv inlet
Leakv
discharae
inlet
or discharae
or discharge
adjusted;
fluid
extremely
rough,
pressure
very
reassemble,
Clean, and adjust relief seats. Kit available.
valve;
Use adequate
size,
worn check
Check
or damaged for worn
more
gauge,
and dirty
valve
frequently.
inlet
and discharae
Replace
worn
valves,
FieDlace
discharae
valve
valve
assemblies.
seats.
hose.
low Solution
Cause Restricted
inlet
restrictions or discharge
Worn
and
replace
Clean
valves.
valves.
runs
reseal.
belt.
Install proper filter. Suction at inlet manifold must be limited to lifting less than 20 feet of water or -8.5 PSI vacuum.
or severe
hose.
Pumps
size.
use correct
Check with new gauge; P.N. 06090
Clean.
size,
assembly. Abrasives in pumped Inadequate water supply.
Worn
PROBLEM:
plugged
accurately.
of proper
or replace;
Disassemble,
inoperative
Relief valve stuck, partially valve seat worn.
Worn piston cavitation.
nozzle,
Tighten
Slippage,
Air leak
Inlet
valves.
Solution
Worn
Inlet
discharge
Pressure
Cause
Belt
or replace
inlet
or air entering and/or valve.
manifold
the inlet
air leaks.
seals.
Proper
plumbing.
Damaged
cup or stuck
inlet
size
inlet
plumbing;
Replace worn
worn cup or cups, valves.
Replace
worn
check
for air tight
clean
out foreign
seal. material,
replace
seals. (continued
next page)
CAT PUMP TROUBLE SHOOTING GUIDE PROBLEM:
Cylinder
O-rings
blown
next
to discharge
manifold Solution
Cause Pressures
in excess
Warped ——
of rated
Check for plugged nozzle, closed adiusted bv-oass valve.
PSI.
Replace
manifold.
PROBLEM:
Leakage O-rirms
at the
cylinder
O-rings
at the
discharge
Cause by improper
PROBLEM:
the
Water
leakage
from
manifold
seals,
Leaking
under
inlet
manifold. and
black,
powdery
substance
in the area
of the
manifold Solution
inlet
PROBLEM:
Oil ieak
between
sleeve
crankcase
Install seals. If piston rod sleeve; and sleeve Cl-rings.
O-ring.
and
pumping
are scored,
replace
sleeves” _...-...-—.
section Solution
Cause
Excess
or improperly
Remove spacer shims on manifold studs. Do not remove too many shims or the ears of the manifold will be bowed when the manifold is retightened, causing looseness in the center cylinder. —...
Cause
Worn
manifold
—— valves
Solution
Loose cylinders, Cylinder motion caused shimming of the discharge manifold.
Worn
(continued)
crankcase oil from
PROBLEM:
oiston
ReDlace
rod seals.
Reduce
wicks.
Oil leaking
in the
piston
rod seals
of oil per oiling.
.—
area of Crankshaft
Cause Worn crankshaft Dackino.
crankcase quantity
Solution seal
or improperly
installed
oil seal
retainer
Remove oil seal seals.
retainer
and
replace
damaged
gasket
and/or
PROBLEM:
Oil leaking
in the area
of Crankshaft
Cause
Solution
Bad
Replace
bearing.
PROBLEM:
Excessive
play
in the end
from
excessive
of the
crankshaft
pulley Solution
Cause Worn
main
PROBLEM:
ball
bearing
Water
tension
on drive
belt.
by humid
Leakage of manifold O-ring. PROBLEM:
air condensing
inlet
Oil leaking
seals
from
and/or
into
piston
underside
water
inside
the
bearing.
Properly
tension
belt.
Change oil at 3 month or 500 hour intervals Crankcase Oil (other approved oil every hours) P. N.: 06100, Replace
rod sleeve
seals,
sleeve
and
O-rings,
seals,
sleeve
and
O-rings,
or cover
O-ring,
using month
Cat Pump or 200
of crankcase
Cause
Solution crankcase
PROBLEM:
piston
Oil Ieakina
Replace
rod seals. at the
rear
~ortion
of the crankcase
Cause
Solution
Damaged cover
or improperly installed O-ring, and drain plug
PROBLEM:
Oil leakage
from
oil gauge O-ring. drain
plug
plug
O-ring
or crankcase
rear
Replace
oil gauge
and drain
plug
O-ring.
Solution
Cause Loose
ball
Solution
be caused crankcase.
Worn
Replace
in crankcase
Cause May
bearing.
drain
plug or worn
drain
Tighten
drain
plug
or replace
O-ring. (continued
next page)
CAT PUMP TROUBLE SHOOTING GUIDE PROBLEM:
Loud
knocking
noise
Solution
Cause Pulley
loose
Broken
Check
on crankshaft.
or worn
PROBLEM:
bearing.
Frequent
or premature
failure
of the
inlet
manifold
seals
pressure
PROBLEM:
cup
rods and sleeves.
Reduce
to inlet manifold.
Short
_—.—
Replace
rods or sleeves.
inlet pressure
per instructions.
life Solution
Cause Damaged Abrasive
or worn material
Excessive
chrome
and/or
Install
pumped.
temperature
of fluid
being
pumped.
of piston
Strong
proper
filtration
Replace
surging
damaged causing excessive by pumping acid solution. at the
inlet
and
wear
low pressure
Inlet
plumbing
temperature:
be sure
they
pressure.
with
Install new cups with chrome. on the discharge
without
water.
new piston. and cylinde~s,
Pump
only
fluid
compatible
side
Solution
Cause Foreign particles in the inlet andlor discharge valves.
on p~mp
Check pressures and fluid inlet are within specified range. Reduce
sharp.
.—
cylinders.
Do not run pump
dry.
Chrome plating of cylinders of cups. May be caused PROBLEM:
being
—.
Replace
of the cylinders.
of pumps.
Pump
edge
plating
in the fluid
pressure
pressure
Running Front
set screw.
bearings.
Solution
Scored
Over
key and tighten
Replace
Cause
Over
(continued)
in pump
or discharge
valve
or worn
inlet
Check for smooth lap surfaces on inlet and discharge valve seats. Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone; damaged cups and discharge valves cannot be lapped b~t must be replaced.
ELECTRICAL SYSTEM The entire electrical system operates on 12 volts DC which is provialed by your truck’s battery. Battery levels are sustained by a 7 amp alternator designed within the engine. PROBLEM:
Low
Battery
Voltage
Cause
Solution
Defective
battery.
Corroded
battery
Low
battery
Loose
within
short
ground
PROBLEM:
Remove terminals.
Clean
fluid.
wiring
Electrical Poor
Add electrical
in wiring
system,
system.
connection. Inoperative
Hour
Cause Time
NOTE: When new battery is installed insure it is properly charged before installation or damage to the charging regulator may occur,
and
replace.
terminals water
and
battery
to appropriate
Examine all terminal secure. Examine
electrical
Examine
terminal
posts.
level,
connections systems
and
and verify
for bare
remove
that
they
are
wires.
corrosion
if necessary.
Meter Solution
is not advancing
correctly.
Verify 12 volts DC is available at the hour meter with the ignition switch turned on. This can be accomplished with a volt meter or a test lamp. Remove
and
replace
hour
meter
if 12 volts
is available.
A nylon gear within the clock may have been jammed due to a sudden jolt of the machine or truck. You may try simply tapping on the meter to try to free the nylon gear.
ELECTRIC ~1 1 I I
I I I ( ,
1 I 1 ( 1 t
I ! 1 I [ i_r
To Dash Panel
I
Any freezing of this machine is not covered by warranty and during the colder months of operation, careful protection should be of utmost 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 through
the garden hose from the cold an extra 1 M inch vacuum hose.
3. Leave truck slightly.
doors
closed
4. In colder climates, insulating help protect the unit.
ground
until time cleaning the truck walls
by running
begins,
it
then open
and floor boards
will
5. Don’t procrastinate during the cleaning operation or the hot water solution line will also freeze on the ground. The solution line should be insulated in extremely cold climates. 6. Whenever possible, the truck should be stored in a heated garage at night or over the weekend, If not possible, place a 1500 watt electric heater inside the truck, aimed directly at the machine, Never use a propane heater - it causes excessive moisture on the truck ceiling and the possibility of it going out is higher, If the machine and truck are left outside with a heater, you should first drain all possible water from the machine cleaning tools and hoses. (They freeze also.) TO DRAIN
THE
MACHINE,
FOLLOW
THESE
STEPS:
A. Before shutting off the machine, remove the chemical line from the chemical jug and place in a mixture of 50/50 anti-freeze and water. With the cleaning tool on, allow mixture to fill chemical system back to the chemical mix tank. B. Open the thoroughly
mix tank drain valve from the mix tank.
and
allow
the water
to drain
C. To remove the water from the heat exchanger and pump use the freeze guard which is a small air compressor. Using the correct connectors, first blow air into the high pressure solution male quick connect. This will force the water through the heat exchanger back through the pump and into the chemical mix tank to be drained out through the petcock valve to the ground. By Ioosenirig the bypass knob, the air will be allowed to flow more freely through the system. Next, blow the air into the incoming water quick connect and force that water into the chemical mix tank to be drained out. D. Remember your CDS Check
to close unit.
ENGINE
the drain
Antifreeze
valve
prior
to next
operation
and
DOWN-TIME.
of
regularly,
BE SURE IT’S PROTECTED! Freezing will cause GRIEF, mess with mother nature!
MONEY
Don’t
Your mobile carpet cleaning plant has been engineered using the latest and most sophisticated technology available, to produce the finest carpet cleaning results possible. Despite this however, it remains only a tool of the carpet cleaning trade, and it can produce only as good a job as the person operating it, There are no short cleaning knowledge Manufacturer lane cleaners
cuts to good carpet cleaning, it requires and the use of good chemicals.
time,
recommends the use of spotting agents, and traffic prior to the actual cleaning of carpeting, as required.
CAUTION when cleaning cut-pile acrilan heat setting may result in fiber damage.
plush carpets:
Using
(continued
high
next page)
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 and some paint oil and grease removers wlhigh concentration of solvents, )
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 solutlon to prevent saturation when cleaning wand is stopped twice at the same point at the rear of the cleaning stroke.
Manufacturer recommends rust and corrosion inhibitors chemical bwld-up.
Failure to adopt “clean streaks”, periods.
only the use of chemicals containing and water softening agents to prevent
NOTE: At no time should a chemical solution or higher than 10 be used in the unit.
this procedure can result in increased chance of fiber shrinkage, brown out, and longer drying
with pH of less than 7 INCORRECT
METHOD
CORRECT Overlap
METHOD
Between
Strokes
pH CHART 1
234567891011 I
J ~
I
I
I
1
I
12 1
13
14 pa::;>l=+:=ix’=!
ACID —
NEUTRAL ‘ALKALINE~
CLEANING STROKE PROCEDURE/OVER-WEl’TING Purpose: To eliminate excess moisture remalnlng in the carpet fiber and the sawtooth appearance which results from diagonal movement of the cleaning tool on all types of carpet.
u
Over-Wetting Over-wetting is annoying to all concerned bad impression of the cleaning process These
are several
Always move the cleaning tool in smooth forward and backward 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 min!mlze the “hopping” effect resulting on unsmooth
areas
that WIII cause
1, Too few vacuum strokes as shown above. 2. Obstructed,
Procedure:
Seconcf Cleaning Stroke
Cleaning Stroke
kinked
3. Vacuum
tank
dra[n
4, Clogged properly,
vacuum
or Improper
and someilmes used.
leaves
over-wetting: saw tooth
vacuum
strokes
or cut hoses. valve blower
left partially filter
open,
or vacuum
5. Cleaning a heavily foam-saturated (We recommend crystal type, )
carpet
tank
lid not sealing
without
defoamer,
a
MAINTENANCE
PROCEDURES
To avoid costly repairs and down-time, it is imperative to develop and practice good maintenance procedures from the beginning. These procedures fall into daily, weekly, monthly and quarterly inand are outlined below. We have provided a crements, maintenance log for your convenience on page 38; it is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder.
I
Check
engine
“ Inspect ●
I ●
I ●
Check
lines for wearlchafing.
●
Check
all nuts and bolts
■
Clean
●
●
vacuum
Flush water solution. Check
and
engine
IMPORTANT: chart.
tank
- tighten
thoroughly chemical
RPM’s Record
high pressure
system
- adjust date
as needed.
with
with
to 1200
and machine
50/50
RPM’s hours
washer. white
vinegar
at the pump. on maintenance
Monthly
Daily ●
●
Visually etc. Inspect - clean, Lubricate
●
oil level,
garden
hose
inspect
screen
machine
- clean
for loose
●
as needed. wires,
oil leaks,
water
leaks, ●
recovery tank s/s filter and filter bag for tears, repair or replace as needed, blower
with
LPS-1
or WD-40
through
blower
holes, etc.
●
Check
engine
air cleaner
●
Check
high
●
Check
pump
drive
●
Check
pump
pulleys
pressure
filter
pump
- clean
as necessary.
oil - add as necessary.
belt for wear - tighten
- tighten
as needed.
as needed.
blower
Remove reinstall. Check
bearing
pressure water
IMPORTANT:
level
fittings.
bypass
valve
in battery.
Record
date
and
Clean
stem,
grease
connections
machine
hours
cup
and
stem,
as needed. on maintenance
chart. inlet.
Daily: Wipe machine down thoroughly with a damp cloth; flush recovery tank out thoroughly. Empty filter bag and inspect for rips, tears, etc. - replace as needed; remove, thoroughly clean and reinstall stainless steel filter screen in recovery tank; inspect and clean vacuum slot on cleaning wand; check wand head for sharp edges that could tear carpet - file down as needed; clean wand to maintain original appearance; wipe down vacuum and high pressure hoses as needed - visually inspect for cuts, etc.
Weekly
Grease
Quarterly ●
Change
oil in blower
(see blower
manual).
OVERALL CARE OF UNIT MAINTAINING IS IMPORTANT
THE ORIGINAL APPEARANCE FOR TWO REASONS:
OF YOUR
UNIT
a big dollar investment for your cleaning business 1 It represents and its appearance should reflect that fact. A dirty machine is not professional! troubleshooting, and repair is much easier to ac2 Maintenance, complish on a clean well m~ntained 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.
6 Close chemical mix tank drain valve and allow pump-in system to refill mlx tank with anhfreeze premix solution. (fig. 5)
FREEZE PROTECTION OF CLUTCH DRIVE WITH PUMP-IN SYSTEM 1, Start 2. Drain
with
machine
chemtcal
in cleaning
mix tank.
mode.
(fig. 1)
mlx tank IS draining: Insert chemical feed hne 3. While chemical into antifreeze premix jug and allow meter to fill with premix ant] freeze for 10 seconds. Close chemical flow meter when protected. (fig. 2) As shown on page 33 #C. 4. Shut machine quick connector (fig. 3)
down. Connect short hose to high pressure and drain heat exchanger of cleaning water.
system Master Power Switch You may wanl 8 Turn off cleanlng hose out of the tank so Ii won’t freeze to to leave the pump-in the residual water in the tank. The next day, refill the tank and replace the hose. If layer of ce, the hose WIII slt on top of It and gain proper suction. 9 Reconnect
5. Remove pump-in system hose from water sert it into antifreeze premix jug. (fig. 4)
,,
Fig. 1
and spray 7. Start unit with cleanlng wand and hoses connected Into a bucket for 20 seconds to allow the armfreeze to protect [he high pressure gauge and system lines. After runmng the wand spray for 20 seconds, shut wand oft and let It run for 10 seconds to allow the bypass system to be protected. (fig. 6)
storage
hose
to water
storage
.*
mIIP’’--’wB Fig, 2
pump-in
tank and in-
Fig.
3
Fig. 4
tank.
— 10. Place bucket under drain hose of chemical mix tank and open drain valve again to reclaim antifreeze premix. When tank is empty, reconnect short hose to high pressure quick connector and drain heat exchanger into bucket. (fig, 7) 11. Shut off valves and pour all reclaimed antifreeze from bucket back into the 5 gallon antifreeze premix jug so it can be used again. (fig. 8) 12. Before excess
Fig. 5
cleaning the next day run unit for 3 minutes antifreeze from the system.
to void all
Fig. 7
Fig, 8
———
MAINTENANCE DAILY
CLEANING
Clean vactank
Garden hose screen -clean Machine -general inspection
Blower mlet-spraywtth
I I
I I
25 25 25 25 25 25 25 25 25 25
SERVICE
300 300
SERVICE
ENGINE OIL change BLOWER grease bearing ENGINE AIR CLEANER clean BY PASS VALVE grease cup& stem
QUARTERLY 300
I
BLOWER checkoll level PUMP OIL check (top of sight gauge) DRIVE SHAFT SYSTEM tighten set ecrews BELTS & PULLEYS check ttghtnees HIGH PRESSURE LINES check for chafing NUTS & BOLTS check tightness BATTERY LEVELS check VACUUM TANK clean WIRING check for chafting CHEMICAL SYSTEM flush wlwnegar
MONTHLY 100 100 100 100
filter bag affer every job
LPS 1 after last]ob
YEARLY TRUCK MAINTENANCE: * Complete Tune WI . Ca~ling System * Flu&h (New Anti-Freeze) Transmission Fluid * Change
SERVICE
MAX HRS I
&lNSPECTION
Engine oil - check
WEEKLY
I
LOG
SERVICE
❑LOWER OIL change ENGINE compression SPARK PLUGS change
(3 MONTHS)
DATE/HRS
I
DATEHRS
I
DATEIHRS I
DATEHRS
I
DA~,!HRS
I
~A~~HRS
I
DATE/HRS
WARRANTY INFORMATION To avoid misunderstandings which might occur between machine owners and manufacturer. we are listing causes of component failure that specifically voids warranty coverage. Such causes as listed below shall constitute abuse or neglect. BLOWER: Failure to lubricate impellers daily with LPS-1 or WD-40 lubricant. Failure to lubricate bearings. Failure to maintain proper oil levels in the blower. Failure to use the correct oil grade and viscosity as recommended. Failure to properly maintain such as waste tank filter screen, blower safeguard systems vacuum safety relief valve in vacuum tank lid and waste tank automatic shut-off system, Allowing foam to pass through blower. HIGH PRESSURE WATER PUMP: Operation of pump at pressure over 1200 PSI. Failure to maintain proper oil level as recommended. Failure to change oil in pump at recommended intervals. Failure to protect pump against freezing. Failure to maintain pump protection shut-off system. Failure to use water softener in hard water areas. Use of improper chemicals. 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. 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 pressure gauge against freezing.
protect
flow
meter
and
water
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. correctly.
Kinking Normal
or cracking from failure to store or unroll wear and tear from everyday use.
CLEANING WAND: Failure physical abuse of wand.
WARRANTY
to protect
against
freezing.
hoses
Obvious
PROCEDURE
Warranty coverage is available to you ONLY through HydraMaster Corporation, 20309 64th Ave. West, Lynnwood, Washington 98036. When warranty parts are needed, write HydraMaster address, or call the Warranty Warranty Dept. at the above Service Dept. at (206) 775-7275. No collect calls will be accepted. Hours of Warranty/Service Dept. are 7:001 am to 6:00 pm Pacific Time.
IMPORTANT HydraMaster’s warranty policy prowdes replacement parts without charge for thirty (30) days to customers ma~ntaining current account status, An invo[ce dated thirty (30) days from date of for the replacement parts shipment WIII be sent to the customer amount of the parts sent. The customer’s faulty parts must be of the thirty (30) day returned for evaluation prior to the expiration the period, Upon warranty approval. a credit WIII be issued customer for the replacement parts Invoice. Warranty cfisapproval or failure to return the fauity parts within the thirty (30) day period allowed will result in the customer being chargad for the replacement parts sent.
I
HydraMaster
LIMITED WARRANTY
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, representative or dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in connection with any of HydraMaster’s products. This war. rarity shall extend 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 manufacturer’s warranty to HydraMaster, HydraMaster agrees at its option to repair at the point of shipment or to replace without charge f.o.b. point of shipment, 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.
No liability whatsoever shall attach products have been paid for.
until said
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, ENGINE: (Thru original Manual warranty, ) VACUUM BLOWER: See Fuller warranty.) VACUUM
FRAME/COVER
Manufacturer. (Thru original
See Truck Manufacturer, 1 year
RECOVERY
TANK/CHEMICAL
MIX TANKS:
ASSEMBLIES:
HIGH PRESSURE PUMP: See Cat Pump warranty,) HIGH PRESSURE
Manufacturer. 1 year
BY PASS VALVE:
PROPORTIONING
INTERNAL
MACHINE
90 days
SYSTEM:
90 days
HOSE:
EXTERNAL VACUUM QUICK CONNECTORS:
HOSE,
3 years 3 years
(Thru original
CHEMICAL
1 year SOLUTION
HOSE, 30 days
(Except valve & jet assembly)
1 year
BELTS, FITTINGS, O-RINGS, FILTER SCREENS:
30 days
CLEANING
HydraMaster’s liability to Purchaser, whether in contract or in tort arising out of warranties, representation, instructions, or defects from any cause shall be limited to repairing or replacing of the defective part or parts as aforesaid, f.o.b. point of shipment.
to HydraMaster
WAND:
FILTER BAGS:
Not Covered
by Warranty
Freezing of any one water or chemical related component will VOID all other implied warranty on all water or chemical related
components,
internal or external, of this equipment.
