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BobCat HydraCat DualCat c.1979 - Owners Manual

Contents

1. REF PART QTY NO NO DESCRIPTION USED 1 1611001 QUICK CONNECT PLUG 2 1637110 RUBBER HOSE 3 612090 FITTING 4 1625313 FUEL PUMP 5 610001 FITTING 637006 TEFLON HOSE 1614002 PROPANE SPUDNUT 8 627000 PROPANE REGULATOR 9 1637300 PROPANE HOSE 10 614006 PROPANE FITTING 11 1616060 FLAT WASHER 12 1610211 PROPANE FITTING 3 619121 SCREWS 14 614009 PROPANE SHUT OFF VALV 15 637301 PROPANE HOSE 16 610303 FITTING gt INCOMING GASOLINE A 21 T DRAWING NO 113 PAGE JIMASTE TER STER ss DRAWN BY GRANT JR bd MA D m DATE 6 7 37 ATIS CLUTCH MOUNTING PLATE FIELD COIL T RERES SLEEVE PULLEY ROTOR ASSEMBLY ARMATURE DiSC ASSEMBLY ROM BOB DUAL HYDRA peee nr T ASSEMBLY H HOE COMPLETE FRAME H HOE BLUE HANDLE SLEEVE S S HANDLE S S SCREW 5 5 NUT H HOE HANDLE CLIP H HOE 5 5 TUBE LIPS DRAWING 126 DRAWN BYOGRANTJR Z 3 g emow 625318 637506 625721 637505 620148 638570 638072 638780 638060 620144 637501 PART FLEX HOSE MUFFLER CLAMP MARINE HOSE HOSE CLAMP PIPE ELBOW PIPE NIPPLE BUSHING PIPE NIPPLE HOSE CLAMP DISCHARGE HOSE DESCRIPTION _ EXHAUST MANI
2. Dear Customer Thank you for selecting Hydra Mastor Corporation as your equi nent manufacturer Only quality materials have been incorporated to ensure reliable performance and long lite Another benefit you receive as a Hydra Master owner will be to receive Product Support Bulletins and supp lements to this manual Our manual program is to keep you abreas of changes and or modifications to your equipment Again thank you and we shall continue to do all possible to ensure you remain a proud Hydra Master Owner Mike Palmer President Hydra Master Corp 20309 64th Ave W Lynnwood WA 98036 206 775 7272 PAGE i 2A HA 4B ac 6A 6B BE 8A 0 9B 9C 9 10 11 12 BOB HYDRA DUAL CAT MANUAL INDEX INDEX PRODUCT SUPPORT BULLETIN INDEX WARRANTY POLICY WARRANTY CLAIM FORMS Parts ORDERS INSTRUCTIONS Car SPECIFICATIONS CAT DUAL Cat SPECIFICATIONS GENERAL INFORMATION MAINTENANCE MAINTENANCE Loc Car MAINTENANCE DRAWING Hypra Cat DuaL Car MAINTENANCE DRAWING BLowER LUBRICATION DRAWING Car COMPONENT DRAWING Car DuaL Car COMPONENT DRAWING TRucK PREPARATION UNIT Location 1 DRAWING UNrT Location 2 DRAWING TRUCK PREPARATION DRAWING FLooR Gas DIAGRAM OPERATING PRECAUTIONS BoB Cat Hypra CAT DUAL Car TROUBLESHOOTING TROUBLESHOOTING ENGINE PAGE 13 14 15
3. 15 Fuse Vorme Reeuraron 2 8 STARTER 4 Srames Horor i Serevy So Box 3 Vac Hypna Car Sues Juss 21 1482 C oven Pak Sar lane ona Fresze Guarp Sw Freeze Guano Freeze Gunno Hour Lamp Temp Senper INOPERATIVE ELECTRIC CLUTCH HIGH PRESSURE PUMP The High Pressure Pump clutch is designed to operate when pressurized water is connected to the units incoming water fitting A pressure switch has been incorporated to protect the clutch from accidental activation It will also disengage the electric clutch if water pressure drops below 5 PSI 1 Clutch will not engage A With the use of a jumper wire bridge pressure switch term inals to determine integrity of pressure switch and clutch If clutch engages with pressure switch shunte replace pressure switc If clutch does not en gage verify 12 volts is available at the electric clutch NOTE Verification be omplished by using a volt meter or test lamp Verify battery is fullv charged and capable of supplying necessary voit age and current to en gage electric clutch NOTE The integrity o the battery and chargi Systems must be deter mined by a qualified technician with
4. 1 Remove clear chemical feed hose from chemical jug and insert into container of 50 50 anti freeze and water mixture 2 Run unit siphoning anti freeze mixture for 10 seconds at 10 GPH on the flow meter 3 Turn unit off Disconnect inc water supply to machine Loosen knob on bypass valve to allow air to flow through system 4 Open drain on mix tank 5 Insert freeze guard hose onto low pressure in quick connect Turn on freeze guard pump until only air is entering the mix tank 6 Disconnect freeze guard hose from low pressure in quick connect 7 Connect the alternate freeze guard hose to the high pressure out quick connect Turn on freeze guard pump until air appears in the mix tank 8 Plug in all hoses and tools which will require freeze guarding to the freeze guard quick connect Turn on freeze guard pump until water is voided from tools 9 Close drain valve on mix tank _ OPERATION PRECAUTIONS MACHINE ADJUSTMENTS ENGINE COOLING LEVEL FREEZE PROTECTION ALTHOUGH THIS UNIT HAS BEEN FACTORY ADJUSTED IT MAY REQUIRE ADDITIONAL ADJUSTMENTS TO ACHIEVE OPTIMUM PER FORMANCE I E ALTITUDE MAY REQUIRE CARB ADJUSTMENT AND AMBIENT ATURES MAY REQUIRE HEAT CONTROL AD JUSTMENT WHEN REQUIRED RE ADJUST MENT MUST BE ACCOMPLISHED BY AN AUTH ORIZED HYDRA MASTER REPRESENTATIVE OR WARRANTY MAY BE INVALIDATED UNITS EMPLOYING AIR COOLED ENGINES MUST NOT BE INCAPACITATE
5. 40 wt non detergent 9 oo 5 o olo olo o ojololojo N N e e o J ALIE N e Replace Points amp Condenser EE gap 020 300 300 E irs c 300 RUN eared 1 P s ane Decarbon Heads 400 Replace Pump Short Cup Kit es MERE E 1000 Engine Oil Summer 30 SAE Blower Oil 40 SAE Non Detergent Pump Oil Special Cat Oil Recommended Fuel Unleaded Gasoline Engine Crankcase Breather Cleaning Refer to Onan Service Manual o gt H M 1 79 TRUCK PREPARATION Truck Prep Materials needed 1 6 x 12 Ozite indoor outdoor carpet 2 4x8x5 8 Plywood 1 side good 3 6 14 sheet metal screws 4 1 1 1 18 angle iron 5 3 2 x5 16 bolts 6 3 5 16 flat washers 7 3 5 16 lock washers 8 3 5 16 nuts 9 1 can marine adhesive 10 1 staple hammer or glue gun ll 1 gas hook up thru floor mount Decide location of machine in Van A WARNING Side door Most installations are side door This provides rear access for accessories and hoses as well as unobstructed access to component working side of machine thus making it a bit easier to perform maintenance and or repair without removing unit from the truck Rear door Although this location partly
6. Hose Reel s upon attaining from date of purchase Tanks either of the above Fuel Vacuum NOTE The Ninety day limitation on Warranty regarding hoses and quick connect fittings equals or exceeds warranties extended by respective manufacturers suppliers 2 Hydra Master s sole liability and purchaser s sole remedy for a fallure of goods under thls Warranty and for any and all other claims arising out of the purchase and use of the goods including negligence on the part of the manufacturer shall be limited to the repalr of the product by the repair or replacement at Hydra Master s option of parts that do not conform to this Warranty Product or part s must be returned to Hydra Master Corporation 20309 64th Ave W Lynn wood Washington 98036 transportation charges prepald 3 WARRANTY DOES NOT INCLUDE reimbursement for labor travel time mileage or work loss Incurred in the removal reinstallation or replacement of parts and or equipment approved under the provisions of this Warranty 4 THIS WARRANTY SHALL NOT APPLY TO Cost of maintenance adjustments installation and start up Fallures due to normal wear accident misuse abuse negligence or Improper installation Products which are altered or modified in manner not authorized by Hydra Master Corporatlon In writing Failure of goods caused by defects In the system or application in which the product Is installed i e truck van bullding etc E Telephone teleg
7. position before tightening retainer plate stews B Re establish gas supply and relight pilot 3 Test for leaks with scap solution wilh GAS COCK in both and OFF positions TO RECALIBRATE THERMOSTAT The Unitrol thermostat is built to the most exacting standards and is precision instrument which should never need recalibration If how ever through misuse tampering or other conditions beyond out con trol lhe thermostat is found to be more than 20 F out of calibration qualified serviceman may tecalibrate as follows 1 Manually turn the TEMPERATURE DIAL to the 130 mark See Fig NOTE l the temperature of the waler is so high that the burner will not come on enough hot waler from a faucet 10 cause the thermostat 10 the burner Then allow the buiner to operate until the thermostat shuts it off 2 Using a suitable lhermometer 220 determine water lemperature al the heater drain cock as follows Close aff the cotd water supply to the healer this insures that burner remains off while testing b Open the nearest hot water faucet to break lock Slowly open the drain cock until a of water just sufficient to cover he thermometer bulb is obtained d When the temperature rise of the thermonicter has stabilized note the lemperalute and close the drain cock e Close hol waler faucet opened in step b and OPEN CoLD WATER SUPPLY 3 TEMPERATURE O AL to
8. BE PERFORMED IN THE SUMMER MONTHS ALSO AS EXTENSIVE PERIODS OF NON USE MAY CAUSE PISTON TO SEIZE TO THE CYLINDER THANK YOU BOB CRAM WARRANTY SERVICE CUBKICANT o ad w Sine FREEZE A Qo PRESS ON 20309 64th Ave W Lunnwood WA 98036 206 775 7272 11 No AY 1 Date AY 259 PRODUCT SUPPORT BULLETIN Service Parts Publications Model s ALL EXCEPT HYDRA STATION Section Insert AND HYDRA VANS Subject use or GASAHOL AND GASOLINE DE ICER IN ONAN BUILT ENGINES EFFECTIVE IMMEDIATELY The use of gasahol and gasoline de icers could possibly distort the internal parts of carburetors and fuel pumps and deteriorates the binders of the gaskets used on Onan built engines Because of the unknown effects of gasahol and gasoline de icers ONAN does not recommend their use in ONAN built engines Onan intends to do future testing on gasahol fuel and its effects when used in Onan engines in 1980 These test results will be published in a future Product Support Bulletin when available 20309 64th Ave W Lynnwood WA 98036 206 775 7272 Date MARCH 1981 PRODUCT SUPPORT BULLETIN Service Parts Publications Model s Section Insert Subject BYPASS VALVE READ BEFORE REPAIR TO SERVICE BYPASS 1 Unscrew knurled knob and remove 2 Wiggle protruding shaft with fingers or pliers pull up and remove from main body SPE
9. Cap 4 Adjust pilot key to provide properly sized flame Replace Pilot Adjustment Cap 4 TO CLEAN THERMOSTAT VALVE l c cn Aa w E EO Turn GAS COCK DIAL to position Remove TEMPERATURE DIAL and PILOT ADJUSTMENT CAP Turn temperature stop to match opening in caver Remove screws to remove COVER and COVER GASKET Remove SPRING and VALVE ASSEMBLY Clean VALVE and SEAT with lint free cloth of chamois and re place SPRING and VALVE ASSEMBLY Replace COVER GASKET COVER and PILOT ADJUSTMENT CAP Tighten screws NOTE Place gasket on cover and slip screws into cover belore re placing cover on body Relight 79 CT ang teas test around gasket with main burner Replace TEMPERATURE DIAL 14 TEST KIT vil MILLIVOLT METER MAGNET BASE SWITCH TERMINAL TEHMINAL RETAINER SETTING FIG 4 THERMOCOUPLE Vill IV With adaptor connected as in Figure 4 check as follows Fotlow standard tignting Procedure With closed circuit output in excess of eight millivulls blow out pilot A good magnet should remain Jocked up for a drop of five milhvolts or more from original stabilized output magnet does not operate properly replace magnet E Repeat standard Lighting Procedure Section IV does not result in start up proceed to Section V V Check switch for closure Be sure water at thermostat l
10. Rebuild or replace Repair or replace Replace Replace Repair or replace Repair or replace Repair or Replace Replace Replace Repair or replace A freeze guard system has been incorporated which minimizes and virtually eliminates possible damage resulting from freezing Fail ure to operate it properly definitely compromises the unit and will result in costly repairs not to mention the compromise to equip ment and operator safety necessary to accomplish this task L The following procedure defines the steps Draw a 50 50 mixture of antifreeze and water or alcohol into the chemical feed line for a period of 30 seconds in the same manner as would be used to draw chemical Turn off propane heater and close propane tank valve Reduce engine speed to idle Turn off chemical flow meter Disengage electric clutch on high pressure pump 6 Turn off engine 7 Disconnect high pressure solution hoses and attach drain hose e 8 Rotate ignition switch counter clockwise to accessory position and depress freeze guard button until water is no longer ejected from the drain hose 9 Turn key switch on and pump clutch switch on short out the pump protection sensor with a screwdriver turn on freeze guard pump to blow water out of the pump protection system 10 Disconnect drain hose and continue to depress freeze guard button for 15 seconds ll Reconnect drain hose to remove resi
11. U 4 1 TRUCK FLOOR T 625700 THRU FLR GAS HOOX UP I THE TRU K FLOOR 19 1 10 1 THE LOCATION SHOWN ww CQ 0 PN Fr tm 4 NOTE TO SECURE T FITTING FRAME AND HOSE AT A MINIMUM FROM THE EXHAUST PIPE DRAWING NO HM 121 DRAWN BY O GRANT JR DATE 1 6 8 THRU FLOOR GAS HOOK UP METAL SCREW CARPET PLYWOOD TRUCK BED g E P i 2 2222 osiTti com POSITION N 2252 o e cone or the DETAIL SRAME A vent placed in the van Nook oy dy Che fades E TRUCK PREPARATION DAWG NO scale ORWA BY DATE 120 O 4 4 79 1978 HYDRA MASTER CORPORATION MERDA e 90 o n IN LINE PROPANE SHUT OFF VALVE PROPANE TO REGULATOR TANK SHUT OFF VALVE TANK FILL VALVE B ORAWING NO HM 117 Pace uYDRA 9 ws PROPANE TANK LOCATION 627021 627022 627023 614002 627000 614006 637300 614006 627005 619121 610211 614009 637301 618620 616030 616231 617600 627004 PROPANE TANK A 10 Gal B 16 5 Gal C 23 Gal SPUDNUT PROPANE REGULATOR PROPANE FITTING PROPANE HOSE PROPANE FITTING PLATE THRU FLOOR SCREW PROPANE FITTING PROPANE HOSE CARRIAGE BOLT FLAT WASHE
12. and address B Model of equipment C Date of purchase D Hours on the unit E Serial number of unit F Name of person authorized to order parts G Salesman unit purchased from H Description of the problem I Pressure readings on high pressure gauge with wand turned on and turned off 2 Method of shipment UPS Air Freight Air Mail Air Express Auto Freight Etc 3 DO NOT give malfunctioning part s to a sales service representative ALL parts must be re turned freight prepaid to Hydra Master Corp oration for evaluation Hydra Master s warranty policy provides parts with out charge for thirty days to customer maintaining good credit rating Malfunctioning parts must be returned directly to Hydra Master Corporation for final dispo Sition Un approved warranty evaluations and or failure to return part s for warranty consideration will result in appropriate charges Detailed instructions always accompany each shipment to outline both your obligations and options to the warranty procedure Any questions you have regarding the warranty pro gram should be directed to service personnel at Hydra Master Corporation We shall endeavor to be fair in our evaluation of your warranty claim and always pro vide you a complete analysis of our findings KEF o CORPORATION No PRODUCT SUPPORT BULLETIN Service Parts Publications No PSB HM 100 Date IANUARY 1979 TM Model s HY
13. below defines areas which compro mise fluid related components such as hoses fittings heaters pumps valves and water cooled engines Cleaning efficiency and equipment life is increased chemical use decreased and the appearance of cleaned carpets enhanced when water soft eners are incorporated in hard water areas Hydra Master strongly urges the use of water softener units in areas exceeding 3 grains per gallon Using tne legend as a reference determine the quality of water in your area and take action immediately should it be necessary gt Oki C CX XI CO 5 5055650 RR 145550540506 DEL avs 92 OOA L ERS 2 929292021 KO OOP VON 50905051 8962005 evecare 594 059 55525050594 2 9208550 GRAINS PER GALLON ON 74 K lt 5 e sh seal x YS lt lt 5 Nt 22 3 7 KA Y KA 5 4 A CC E lt gt H Sed T IO p 2 EN aso 20309 64th Ave Lynnwood WA 98036 206 775 7272 Service Parts Publications Model s ALL Aqua Cats and Units Section Insert x employing a self contained Subiec pump in system Positive lubrication of Unive
14. better than the one you just took out HIGH PRESSURE PUMP A pump instruction brochure is included with this manual See index which may assist you in resolving a pump related problem PROBLEMS CAUSE AND OR SOLUTION LOSS OF PRESSURE 1 Clogged filter screen A Remove and clean in garden hose quick or replace filter connect coupler 2 Low water pressure at A Determine rate of source flow and select an alternate source of supply if water pressure is inade quate 3 Defective or blocked A Disassemble cylinder check valves in high head and replace or pressure pump cylinder clean applicable head check valve 4 Delaminated kinked or A Remove and replace clogged hose between defective hose the mix tank and the high pressure pump 5 Defective pressure A Disassemble and clean relief valve or debris pressure relief valve in pressure relief as illustrated in valve drawing B Replace defective or worn out bypass cup C Replace bypass valve 6 Defective or worn A Remove and replace piston cups piston cups as de fined by pump manual 7 10 Obstructions in inter nal hoses which feed water to the pump A Pump and or hoses leak A water Defective clutch NOTE If electric clutch fails to engage power cannot be transferred to high pressure pump Loose drive belt for high pressure pump Remove obstruc tion or replace affected hose Repair
15. contained automatic gas T 77 645 COCK PLUG Shut off system SHANK ASSEMBLY VALVE ASSY PILOT FILTER x BODY GASKET ie s y T7798 N 3 gt SCREWS 4 ECO SWITCH TERMINAL y 4x73 euo BODY PRESSURE PLUG i r MAGNET HOUSING ASSEMBLY SCREW EXTENSIO COVER PLOT ADJ KEY v 57 S STOP ADJUSTMENT NUT 29330 DIAL RED stor SCREW 4 TEMP ADJ SCREW PILOT CAP Z 5 5 5 lt 2 2 E x NOTES To temove GAS COCK and TEMPERATURE DIAL pull off friction fit These items available tor Field Service Replacement Order by part number shown above DECORATIVE PLASTIC SLIP ON COVER OPTIONAL ACCESSORY GENERAL DESCRIPTION i The Unitrols and are combination Water Heater thermo n stats with automatic pilot built in automatic over temperature ENERGY CUT OFF device adjustable control of main and pilot gas pilot filter i Mamm will i s 2 M k E ET with main and pilot gas cock all in one compact unit The Unitrols and be easily identified one from the other by the die cast front covers front page and by the model num Sei coven ddl p zoo COVER lite be bers the smooth side of the body NOTE These controls may be found with decorative plastic slip on WHE
16. correspond to the aclual water lemperature as determined by thermomeler 140 4 pb ue gt 4 t 140 130 4 f t tex L I 1 Lu n w cse ADELA ae n mc T ee 169 CONTROL CONTROL NOTE Mark as shown 140 Each notch on ol dial 10 either direction 3 Remove 1EM CERA PE location of stop tor refer ice and ah an lum DIAL clockwise until the conlrol snaps on Tura DIAL counterclockwise slowly unti Ihe control just snaps OFF Remove TEMPERATURE DIAL and holding STOP 10 rotation carefully loosen STOP ADJUSTMENT NUT See Figs Taking care not to move TEMPERATURE ADJUSTING SCREW tum STOP until it corresponds with reference mark previously made Hold STOP and tighten STOP ADJUSTMENT NUT Replace TEMPERATURE DIAL set to desired temp and recheck OFF temp as follows Cycle heater by drawing hot water until burner comes an Tuin off hot water faucet and allow heater to heat water until the heater automatically shuts off Check waler temperature again at drain cock comparing with temp dial setting STOP ADJ NUT TEMPERATURE ADJ SCREW TEMPERATURE DIAL TYPES MUST NOT INTER CHANGED SINCE ECO TEMPERATURES ARE MATCHED TO DIAL TYPE BUILT IN ECO TEST PROCEDURE UNITROL 110T SERIES standard procedure for lighting or relighting Adjust burner if necessary Mo heater does not
17. end of each job or at the end of the day will eliminate the buildup of much of the debris in the tank The drawstring top of these bags is designed to be tied to the incoming water inlet in the vacuum tank INCOMING DIRTY WATER TO VACUUM TANK M m ea r r o VACUUM TANK WALL FILTER BAG FORM 20309 64th Ave W Lynnwood WA 98036 206 77 7272 K 4 PRODUCT SUPPORT BULLETIN Service Parts Publications Model s AL Section Insert Subject CHEMICAL BUILD UP SAVE TIME AND MONEY REMEMBER PROTECTIVE MAINTENANCE IS THE KEY TO MANY SUCCESSFUL OPERATIONS SOME OF OUR CUSTOMERS ARE NEGLECTING TO FLUSH THEIR MACHINES AFTER 40 HOURS OF USE REMEMBER BECAUSE OF THE DIFFERENT TYPES OF CHEMICALS WATER CONDITIONS AND HEAT CHEMICAL BUILD UP MAY OCCUR TO FIGHT THIS PROBLEM FLUSH THE MACHINE ONCE A WEEK OR EVERY 35 40 HOURS WITH VINEGAR FOLLOW THESE INSTRUCTIONS WHILE MACHINE IS RUNNING PLACE ICAL FEED HOSE IN A BOTTLE OF WHITE VINEGAR AND TURN ON TOOL SO THE VINEGAR WILL BE PULLED THROUGH THE SYSTEM DO NOT LEAVE IN SYSTEM ANY LONGER THAN 45 MINUTES OR DAMAGE MAY OCCUR TO INTERNAL COMPONENTS FLUSH WITH CLEAR WARM WATER IN THE SAME MANNER AS THE VINEGER WAS INJECTED THIS WILL BREAKDOWN BUILD UP AND PREVENT COSTLY DO
18. feet in total length a 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 As has been indi cated above reduction in flow automatically reduces propane metering thereby reducing temperature The proper balance of flow can be reinstated by simply changing the cleaning tool spray jet to the next larger size Example if your cleaning tool contains an 8006E spray jet you would change it to an 8008E to compensate for any losses in flow due to the addition of solution hoses 11 12 FOREIGN MATERIAL IN HIGH PRESSURE BYPASS VALVE NOTE The high pressure bypass valve is designed to fully close when the cleaning tool is turned on Any foreign matter collecting on the piston will prevent full closure of the valve and allow a portion of the water to continue to cir culate instead of being routed to the cleaning tool To correct this situation the bypass valve must be disassembled and cleaned refer to drawing provided in this manual for bypass disassembly FROZEN OR DAMAGED QUICK A Remove and replace CONNECT FITTINGS NOTE damaged fittings Couplers which have been frozen often impede the flow of cleaning solutions and adversely affect the heater as defined by previous comments pertaining to the reduction of propane metering to the heater 18 Yellow Flame A
19. limits working access it does direct the noise away from the cleaning site Some cleaners in the colder areas prefer this location because it pu the weight mass over the rear wheels for better traction in ice and snow Rear mounting requires the unit to be slid to the right side as far as possible This not only provides adequate working space on the component side of the unit but also makes better weight distribution inside the Van engine and component wt line up over drive shaft Also it is physically easier to load unit into rear door due to height of Van bed When carrying water tank will then be located over center of Van Ensure that machine is well secured to the floor of Van with hardware supplied Sudden or crash stop will cause machine to rocket forward all 550 lbs worth Protect your driver and machine SECURE IT wan LL LJ ig UNIT LOC I AT ION NI ay D le4 O OGRANT JR 24 _ UNIT LOCATION HM fes 0 JR rob 3 79 1978 HYDRA MASTER X DESCRIPTION ISED i NO 611001 QUICK CONNECT SOCKET 1 612090 FITTING 1 8 BRS STR ELBOW ee 625701 PLATE 619121 SCREW 613025 HOSE BARB 620104 HOSE CLAMP 637105 HOSE CUT TO LENGTH 625300 FUEL FILTER 612120 FITTING e 620305 TIE WRAP NOTE ORILL 16 HOLE THROU
20. most simple and trouble free ever The incoming water flows through the incoming water regu lator which should be set at about 20 PSI at the mix tank Water will now flow through a proportioning valve which will simultaneously mix the chemical to achieve your desired solu tion 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 clutch on the Cat pump In conjunction with the incoming water 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 both heaters off Simply spray the wand f
21. of average machine operation is equal to 103 920 miles Compare this to your car and the maintenance you would give it for this many miles of trouble free driving Enclosed is a maintenance log sheet that should be attached to the e machine and kept in force by a responsible operator GOOD PROFITS AND GOOD MAINTENANCE GO HAND IN HAND HYDRA MASTER WANTS YOU TO BE A TROUBLE FREE DRIVER HYDRA MASTER CORPORATION DATE DATE DATE DATE DATE MAX HRS HOURS HOURS HOURS HOURS HOURS MAINTENANCE LOG DATE DATE n H i 1 i i HOURS HOURS SERVICE ITEMS Lubricate Blower AFTER EACH JOB nspect Machine Genera Check Pump Oil Clean Vac Holding Tank Nylon Filter Bag amp S S Filter W Brush Change Eng Oil Summer SAE 30 Winter SAE 20 3 Qts W O Oil Filter 3 Qts W O Filter Disassemble H P Bypass Valve amp Lube Stem Assy Ref Drawing Remove Machine fron Truck for Complete Inspection of Battery Electrolytes Belts and Pulleys Fuel Lines Nuts and Bolts Heater Cover Except Aqua Cat Heater Burner Assy Ex Aqua Cat Service Air Cleaner Clean Vacuum Tank free float hinge of lint amp lube Spray Quick Connectors all With WD 40 Lightly Oil Direct Drive Shafts Check for Chafing Wires Tighten Exhaust Manifold Clamps Tighten Dodge Coupler direct drive DO NOT OVER TORQUE lReplace Engine Oil Filter Replace Spark Plugs LP gas gap 018 gas agp 025 Change Blower Oil
22. regulator may require slight adjustment 3 Once a constant 180 190 degree reading is established turn cleaning wand off The flame on the heater burner should remain on for 10 14 seconds a If the flame expires prior to 5 14 seconds turn the thermostat dial to a higher reading then repeat C 1 3 b If the flame remains lit after 14 seconds turn the thermostat dial to a lower reading Then repeat C 1 3 c If a 180 degree reading cannot be achieved 1 Measure your water output This heater will heat e 1 5 gallons per minute constantly at 190 degrees If your output is more than 1 5 GPM then your temp erature will read low If your output is less than 1 5 GPM then your temperature will read high 2 If your wandis spraying constantly at 1 5 GPM and your temperature is still below 180 degrees then your burner jet may require cleaning TO REMOVE BURNER Remove pilot tube nut and thermo couple nut from the bottom of the Unitrol valve Remove sparking wire from the plug at the burner Loosen pipe union which connects the burner pipe to the gas valve pipe Remove burner assembly Slide a 17 torch tip cleaner in and out of each jet Torch tip cleaner may be found at welding supply store D TO SHUT DOWN HEATER l Turn upper dial to OFF position Spray wand for 3 minutes e to cool the coils in the heater 2 Close propane tank valve H M 1 79 OVER WETTING Over wetting
23. through point box cover and gasket to alleviate vacuum 4 Worn or malad A Remove and replace justed points points and condenser Clean and adjust points 5 Defective spark A Remove and replace e plugs B Clean and regap A 6 Defective spark Spark plug wires along plug wires with many others may at certain points come in contact with heated parts exhaust manifold or abrasive parts sharp metal teflon hose This may be taken into consideration for electrical shorts Remove and replace Defective valve Stuck valve Worn compression rings Defective piston 7 Low compression ONAN ENGINE CONT 8 Float switch in recovery tank NOTE temporary repair permits disconnection of float switch wire from point box terminal Continued opera tion with this condition will compromise Vac Blower 9 Engine will not turn over 10 Defective carb uretor 11 Improperly adj usted carb NOTE a comprehensive manual is avail able and defines necessary adjust ments Switch stuck in upright position Defective float switch Float switch may be obscured with lint or debris Dead battery Loose terminal connection on battery or igni tion switch Defective starter Seized engine or Blower pump re circulating pump could cause engine to not turn over use process of elim ination to aid in further diagnosis Often anodizing will prevent
24. 16 17 18 19 20 21 22 25 24 244 25 26 27 28 29 30 51 32 99 34 55 56 37 58 TROUBLESHOOTING VACUUM BLOWER TROUBLESHOOTING HIGH PRESSURE PUMP TROUBLESHOOTING HEATER TROUBLESHOOTING ELECTRICAL SYSTEM OvER WETTING FREEZING PRODUCT SUPPORT BULLETINS SEE PSB INDEX BoBCAT Power PACK DIAGRAM HvpRA CAT DuAL CAT Power PACK DIAGRAM Hose DIAGRAM FLow DIAGRAM DuAL CAT FLow DIAGRAM FLow ApJUSTMENT PROCEDURE BoBCAT HYDRA AT CHEMICAL FLOW DIAGRAM DUAL CAT CHEMICAL FLow DIAGRAM BoBCAT HYDRA AT PLUMBING Pump DuAL Car PLUMBING PUMP BoBcAT HYDRA AT PLUMBING HEATER DUAL CAT PLUMBING HEATER BoBcAT HvDRA CAT DUAL CAT PROPANE TANK LOCATION PROPANE TANK PLUMBING By Pass VALVE INCOMING WATER REGULATOR HEATER ConTROL REGULATOR BoBcAT HvpRA Cat DuaL Car ELECTRIC Pump CLUTCH ASSEMBLY Bopcat Hypra Cat DuaAL CaT PILOT LIGHT ASSEMBLY FuEL DIAGRAM BOBCAT EXHAUST o m a HYDRA CAT OPERATION PROCEDURE STAAT UP PERFORM DAILY PERIODIC MAINTENANCE AS SPECIFIED BY THE SERVICE MANUAL v CONNECT ALL REQUIR D HO5ES NOTE IMPORTANT 4 PURGE ALL AIR FROM INCOMING GARDEN HOSE PRIOR TO HOOKIN UP MACHINE CONNECT CLEANING TGOL TO LENGTH OF HOSE REQUIRED TO PERFORM CLEANING START ENGINE AT Low THROTTLE AND ALLOW INITIAL WARM UP PERIOD OF TWO FIVE MINUTES CHOKE AS
25. 206 775 7272 X 81 OR HYDRA STRETCH SHUT DOWN 1 Turn heater to off position spraying wand for at least 3 minutes to allow the heater coils to cool 2 Close valve on propane tank 3 Remove vacuum hose 4 Reduce engine speed to idle 1600 RPM 5 Flush clear water through chemical system for 10 seconds Vinegar should be rinsed through system weekly Turn off chemical flow meter 6 Turn on cleaning tool to flush chemical from unit hoses and Cleaning tool NOTE If freeze guard is necessary perform steps 1 and 2 of freeze guard procedure at this time 7 Disengage electric clutch on high pressure pump by turning off the control switch 8 At tbis time the blower should be lubricated 9 Turn ignition switch off 10 Drain vacuum tank Vacuum filters should be cleaned prior to mobilization of Van NOTE If freeze guard is necessary perform steps 3 9 of freeze guard procedure at this time 20309 64th Ave W Lynnwood WA 98036 206 775 7272 PROPANE HEATER VACUUM WASTE RECOVERY TANK FREEZE b GUARD MOTOR pus k PUMP a NOTE DUAL CAT OPTIONAL CHEMICAL SYSTEM NOT SHOWN INCOMAG WATER REGULATOR DUAL HYDRA CAT COMPONENTS ee i HYDRA STRETCH FREEZE GUARD PROCEDURE Freeze guarding should be performed prior to shut down with the heater off
26. 72 Date JANUARY 1981 PRODUCT SUPPORT BULLETIN Service Parts Publications Model s ALL Section Insert HYDRA HOE CLEANING TOOL Subject CRACKED VACUUM HEAD AFTER PERIODS OF USE AND STORAGE IN THE REAR OF YOUR TRUCK IT MAY BE POSSIBLE THAT THE VACUUM HEAD OF YOUR WAND MAY SHOW SIGNS OF SEVERE WEAR OR FATIGUE INSPECTION OF YOUR WAND MAY SHOW A CRACK ON EACH END ABOVE THE LIPS OF YOUR TOOL THIS MAY BE REPAIRED BY A HELI ARC WELD PRIOR TO THE WELD THE STAINLESS STEEL SURROUNDING THIS FRACTURE MUST BE EXTREMELY CLEAN AFTER REPAIR THE WELD MUST BE GROUND SMOOTH IT IS IMPORTANT THAT THESE FRACTURES ARE REPAIRED OR IT MAY SNAG CARPET FIBERS AND DAMAGE CARPETS FRACTURE POINT LIPS 20309 64th Ave W Lynnwood WA 98036 206 775 7272 HC 280 DC 430 ENGINE COUPLER BLOWER D C HIGH PRESS PUMP H C HIGH PRESS PUMP PUMP MOUNT BRACKET BLOWER SPACER BLOCKS Chrome plated POWER PACK PLATE Chrome plated SHIM Blower Spacer Block 3 HYDRA CAT DUAL mem A VACUUM AND HIGH PRESSURE s GARDEN HOSE SCREEN REPLACEMENT 1 INLET GDN HOSE CONN incl screen QUICK CONN PLUG QUICK CONN PLUG QUICK CONN SOCKET DUAL CAT SECONDARY HIGH PRESSURE HOSE HOSE NOT SHOWN ON HIGH PRESSURE THIS DRAWING LOW PRESSURE IN e BOB HYDRA7OUAL CAT sss
27. CIAL INSTRUCTIONS BYPASS 4 5 16 fine thread 6 Cup seal if leather replace or lube with leather oil 7 Brass bushing 8 Shaft if cup needs replacement place thin end of shaft only in vise and remove 5 16 nut Fat end is seating surface and must be free of abrasion to properly seat NOTE IMPORTANT when replacing cup seals only wrench nut 4 to where cup will not turn on shaft If cup is too loose Bypass will leak Too tight cup will flange and Bypass will leak uu rst w 20309 64th Ave W Lynnwood WA 98036 206 775 7272 No PSB 124 BYPASS VALVE KNOB 000 155 109 SPRING STOCK 000 155 108 HEAVY DUTY WASHER NUT WASHER 000 044 002 CUP LEATHER 000 044 003 BLACK RUBBER WASHER REPLACEMENT SHAFT BYPASS BODY K DRAWING No HM 122 PAGE DRAWN BY OSCAR GRAN 4557 H C DATE 10 17 80 32 No 12 Das PRODUCT SUPPORT BULLETIN Service Parts Publications Model s soscat Section Insert Subject ENGINE EXHAUST MANIFOLD THE HYDRA MASTER MAINTENANCE LOG IN YOUR MANUAL STATES TO TIGHTEN EXHAUST MANIFOLD CLAMPS EVERY 100 HOURS HYDRA MASTER ASKS THAT YOU PROCEED ONE STEP FURTHER AND ALSO TIGHTEN THE EXHAUST MANIFOLD STAND OFF TUBE LOCK TIGHT MAY BE REQUIRED ON SOME MODELS TO PREVENT THREAD DAMAGE IN TH
28. D WITHIN A VAN WITH DOORS AND WINDOWS CLOSED EXCESSIVE TEMPERATURES WITHIN THE ENGINE WILL RESULT IN PREMATURE ENGINE FAILURE AND A COMPROMISE OF APPLICABLE WARRANTY A WHEN RUNNING THE AQUA CAT THE COLD WATER SOURCE MUST BE CONNECTED TO KEEP ENGINE PROPERLY COOLED DURING OPERATION VAN OR TRAILER MUST BE PARKED ON LEVEL GROUND NOT TO EXCEED OR 10 DEG FAILURE TO INSURE PRO PER LEVELING MAY PREVENT PROPER INTERNAL LUBRICATION OF ENGINE VACUUM AND OR HIGH PRESSURE PUMP COMPONENTS ALL UNITS ARE EQUIPPED WITH FREEZE PROTECTION DEVICES AND OR INSTRUC TIONS PROVIDED ON OPERATING LABELS FOR THE PREVENTION OF FREEZE DAMAGE FAILURE TO PERFORM RECOMMENDED STEPS OR USE SYSTEMS DESIGNED FOR THIS PUR POSE CAN RESULT IN EXPENSIVE COST DOWN TIME AND COMPROMISE TO APPLICABLE WARR ANTY 10 ONAN ENGINE An Onan instruction brochure is included with this manual see index which may assist you in resolving an engine related problem PROBLEMS CAUSE AND OR SOLUTION ENGINE FAILS TO START 1 Loss of fuel A Empty gas tank ENGINE RUNS ROUGH B Plugged fuel line or ENGINE BACKFIRES filter ENGINE FAILS TO ACCELERATE Defective fuel pump ENGINE REDUCES SPEED TO D Gas line kinked or LOW RPM UNDER LOAD crushed 2 Blown master fuse Electrical short B Defective fuse 3 Oil on points A Consult with Onan for possible modification or replacement of seals within point box B Drill a 1 8 hose
29. DISPLACEMENT A Blower Instruction brochure is included with this manual see index which may assist you in resolving a blower related problem PROBLEMS NOISE IN VACUUM BLOWER CAUSE AND OR SOLUTION 1 Loose direct drive A coupler B 2 Worn gears A B Lack of lubrication A NOTE Permanent damage may have resulted from lack of lubrication Worn bearings 6 Debris and or foreign A material build up NOTE A stainless steel filter is pro vided in vac inlet located in vac tank to protect vacuum blower components Loose or missing mounting bolts Examine coupler boot for defects and re tighten lock bolts Refer to coupler drawing Replace coupler boot if it is either torn or punctured Remove and replace gears NOTE replace ment of gears must accomplished by qual ified technician Timing of vacuum blower has been changed due to worn components Re placement of components must be accomplished by a qualified technician Lubricate as specified by applicable vacuum blower manual See index Remove and replace bearings as required Must be accomplished by a qualified tech nician Disassemble vacuum blower and remove foreign material NOTE Disassembly should be accomplished by qualified techni cian only Replacement of worn parts is recom mended if this pro cedure is necessary Tighten or reinstall mounting bolts 13 i P
30. DRA CAT Section Insert 8 AOUA CAT Subject CARBON REMOVAL ENGINE Units operating on regular gasoline reguire carbon removal from combustion chambers approximately every 400 hours as defined by the Onan Service Manual Failure to comply will void the engine manufacturers warranty and could result in unnecessary expense and costly down time The cost to perform carbon removal is relatively inexpen sive but does vary throughout the country Normally this service must be scheduled with the Onan Service Center in the same manner as tune ups etc 20309 64th Ave W Lynnwood WA 98036 206 775 7272 No PSB HM lt REDE PRODUCT SUPPORT BULLETIN Service Parts Publications Model s Section Insert z Subject ONAN ENGINE VALVE ADJUSTMENTS To ensure continued reliability from the ONAN engines incorporated in our units it is NECESSARY to adjust both intake and exhaust valves after 300 hours of use Failure to comply with this suggestion may necessitate a valve repair after 500 hours of use and can compromise engine warranty during the warranty period The condition which will often occur if valves are not adjusted is power loss and damage to valves and valve seats Instructions for preventive maintenance procedures i e tune up oil changes carburetor breather filter fuel adjustment valve adjustments etc are outlined in the ONAN Service Manual contained in the Hy
31. E ENGINE HEAD IT IS IMPORTANT THAT THIS BECOMES A PART OF YOUR MAINTEN ANCE ROUTINE 20309 64th Ave W Lynnwood WA 98036 2061 775 7197 No __PSB HM 126 Date _NOVEMBER 1980 e CORPORATION Tm PRODUCT SUPPORT p ye Service Parts Publications Model s ALL H CATS AOUA CATS Section Insert DUAL CATS D AQUA CATS Subject MANUFACTURED PRIOR TO AUGUST 1980 TO HELP REDUCE PROBLEMS WITH ENGINE SEIZURES DUE TO MALFUNCTIONING OIL PUMPS HYDRA MASTER WILL NOW SUPPLY IT S CUSTOMERS WITH OIL PRESSURE SWITCHES THIS SWITCH IS LOCATED DIRECTLY ABOVE THE OIL FILTER A SINGLE WIRE WILL RUN FROM THIS SWITCH TO THE STUD ON THE POINT BOX IF YOUR MACHINE DOES NOT HAVE THIS ENGINE SAFETY DEVICE AND YOU WISH TO INSTALL ONE PLEASE CALL HYDRA MASTER PARTS DEPARTMENT 206 775 7276 20309 64th Ave W Lynnwood WA 98036 206 775 7272 No 58 12 Date PRODUCT SUPPORT BULLETIN Service Parts Publications Model s HYDRA CAT DUAL CAT Section BOBCAT Subject PRoPANE GASES PROPANE GASOLINE IS EASILY ACCESSIBLE ACROSS THE COUNTRY HOWEVER IT IS IMPORTANT TO REALIZE THAT THESE GASES DO VARY IN THE 5 MAJOR WINTER MONTHS PROPANE REFINERIES WILL ADD METHOL ALCOHOL THIS IS DONE TO RESTRICT MOISTURE OR CONDENSATION FROM ENTERING THE SYSTEM IF IT DOES THE METHOL ALCOHOL WILL ELIM INATE POSSIBLE FREEZING OF THAT CONDENSATION THIS ADDITIVE WI
32. FOLD 626301 638530 MODIFIED SILENCER PIPE ELBOW E NO TN eS 2 0 P EXHAUST P K EE 629320 BRASS CAP FOR NOZZLE END ASSY 629324 STABILIZER 629323 FITTING 629321 FITTING 629302 S S TUBE 629319 NOZZLE END ASSY W JET 629604 8006E DUAL 629605 8008E HYDRA e Rea DRAWING NO 128 oRaww C DATE 4 3 79 scue Arch Benq HYDRA HOE NOZZLE END pd ASSEMBLY ES i978 Mm ems mas ll HORI RETR NATO OVA o apan tr y PART DESCRIPTION H HOE VALVE COMPLETE R HOE 5 S TUBE PLUNGER KIT H HOE TRIGGER H HOE TRIGGER PIN QUICK CONNECT PLUG H HOE TRIGGER SLEEVE HOUSING H HOE VALVE HYDRA HOE VALVE jSEMBLY Bi s Z
33. INDICATOR AUTO TYPE BULB AUX PUMP INDICATOR AUTO TYPE BULB SERVICE REQUIRED LIGHT AUTO TYPE BULB CHOKE PULL TYPE AUX PUMP ELECTRICAL SWITCH X 81 OR HYDRA STRETCH OPERATIONAL PROCEDURES START UP 1 Perform daily periodic maintenance as specified by the Service Manual 2 Connect all required hoses 3 Connect cleaning tool to length of hose required to perform cleaning 4 Start engine at low throttle and allow initial warm up period of 2 5 Minutes Choke as required 5 Turn electric clutch switch to the on position if high pressure Solution is required ea engine idle 2500 RPM s 7 Spray wand or wands to void all air from unit As the mix tank is in a fill cycle the chemical flow meter may be adjusted to your desired setting NOTE Recommended carpet cleaning pressure is 300 PSI 8 Once all air is voided from system heater may be ignited NOTE If not familiar with operation of this heater refer to heater section of this manual A Open propane valve on the tank B Ignite pilot on the heater C ignite burner turn dial to position NOTE If you suspect that the unit has frozen DO NOT light the heater Refer to Service Bulletin 112 or contact your nearest Hydra Master Representative 9 Turn on burner assembly and adjust temperature to the desired setting from 130 to 200 degrees F 10 Commence cleaning operation 20309 64th Ave W Lynnwood WA 98036
34. LL HAVE NO EFFECT ON THE PERFORMANCE OF THE BURNER UNIT HOWEVER IF YOUR PROPANE IS PURCHASED IN SEPTEMBER BUT NOT USED UNTIL DECEMBER IT IS POSSIBLE THAT THE CONDENSATION MAY FREEZE SYMPTOMS OF THIS OCCURRING IN YOUR UNIT WOULD BE LOW OR NO PROPANE FLOW OR AS IF THE TANK WAS ALMOST EMPTY APPROXIMATELY 40 DEG F IS THE FREEZING POINT OF PROPANE FUEL HOWEVER BUTANE WILL FREEZE AT 32 DEG F THEREFORE IT MAY BE TO YOUR ADVANTAGE TO SEE TO IT THAT METHOL ALCOHOL IS ADDED AT YOUR BUTANE SUPPLIES REFINERY 20309 64th Ave W Lynnwood WA 98036 206 775 7272 M No HM PSB 128 Date JANUARY 1981 PRODUCT SUPPORT BULLETIN Service Parts Publications Model s a Section Insert Subject INSTRUMENTS amp GAUGES YOUR HYDRA MASTER UNIT IS EQUIPPED WITH AN INSTRUMENT PANEL WHICH CONTAINS THE APPROPRIATE GAUGES FOR YOUR UNIT THESE INSTRUMENTS ARE IMPORTANT TOOLS TO YOUR CARPET CLEANING SUCCESS WITHOUT THEM YOU WOULD NOT HAVE COMPLETE OVERSIGHT OF YOUR UNITS OUTPUT SINCE THE TEMPERATURE OF THE WATER CANNOT BE ACCUR ATELY MEASURED BY THE AMOUNT OF STEAM YOU SEE EXPELLED FROM THE WAND NOR CAN THE PRESSURE BE MEASURED BY THE FEEL OF THE WATER HITTING THE CARPET THEREFORE IF YOUR GAUGE HAS MALFUNCTIONED DON T GUESS AS TO WHAT YOU THINK IT MIGHT READ YOU MAY DAMAGE YOUR EQUIPMENT OR POSSIBLY A CARPET CAND YOUR REPUTATION 20309 64th Ave W Lynnwood WA 98036 206 775 72
35. Liquid propane entering into system due to 1 over filled propane tank 2 truck driven with propane tank valve opened 3 truck parked on an incline Hoses with liquid propane can be flushed with alcohol Propane regulator malfunction due to 1 liquid propane obstructing vapor flow 2 dirt or dust entering through vent port on the propane regulator this may be remedied by using Tupperware cover supplied by Hydra Master for propane regulator 3 over pressurization of propane regulator caused from filling propane tank with valve opened will cause warpage of the regulator Replace immediately Dirty heater core will prevent flame from being vented A blue flame is required to achieve maximum heat Oxygen must be vented with the propane to achieve maximum heat Dirty or malfunctioning burner assembly will cause insuffi cient propane and oxygen mixture 16 17 CLOGGED FILTER SCREEN IN A Clean screen or replace GARDEN HOSE QUICK CONNECT FITTING NOTE Refer to step 14 IMPORTANT Permanent removal of the filter screen may com promise the total integrity of water flow throughout the unit The incoming regulator heater water flow valve high pressure pump and high press ure bypass valve may be ad versely affected if foreign material is permitted to pass through them Alterations of this type void Hydra Master s warranty on all water related components FLAMES PROTRUDING OUTSIDE OF HEATER CO
36. N ORDERING CONTROL SPECIFY covers bearing the names UNITROL or UNITROL 400 1 MODEL UNITROL OR 110HCT SEE SMOOTH SIDE OF CASTING FOR STAMP The Unitrot 110HCT is high Capacity version of the Unitro 2 OUTLET SIZE 1 2 LF 3 8 PIPE DR AJ PAPE TUN C desipned for application on appliances having higher than average 3 SHANK LENGTH SEE FIG 1 Btu input 4 TUBE 18 m TONS The internal porting of the is larger than on the standard VERY HOT 1609 11078 NOT INTERCHANGE This results in the outlet tapping being 1 16 closer to the rear of the ABLE dA body casting and the shank protruding 3 16 further behind the body 4 The net difference then is 1 8 FIGURE t LENGE 14B control replacement is necessary a Unitrol can be substitut ed for a standard however the Unitiol must be replaced with another nitro because of gas capacity requirements Unitrot 110T8 180 must not be substituted for a Unitrol 1607 if control replacement is necessary Service procedures and lighting instructions are identical for both Controls The Unilrofs and 1LOHCT provide 1 Accurate and dependable water temperature control 2 Convenient buritan main gas pressure lap 3 Energy Cut OIf Device Complete high hiaul shut off tl all gas pilot and main burner 4 Comp
37. R LOCK WASHER NUT 1 1 1 1 1 1 2 1 PROPANE SHUT OFF VALVE 1 4 8 4 4 1 PROPANE THRU FLOOR HOOK UP Incl parts 2 11 RELIEF WALVE p PROPANE TANK 4 mounted 4 PROPANE REGULATOR on the side of the 10 VALVE truck to ALLOW 2 PROPANE VAPOR VALVE ACCESS to ALL the VALVES TANK FILL VALVE T PAGE DRAWING NO HM II6 DRAWN BY GRANT JR 31 HYDRA DUAL CAT SPECIFICATIONS Warranty Dimensions Weight Engine RPM Fuel Oil Capacity Vacuum Blower RPM Water Lift amp Air Flow 011 Grease Water Pump Oil Pressure Pulley Belt R P M Propane Heater Heat Setting GENERAL COMPONENTS One Year or 1000 Hours 48 L X 32 WX 34 H 550 Lbs 20 Horsepower Onan Industrial Air cooled 2600 Factory Recommended Unleaded 35 Quarts W Filter Positive Displacement Lobe Type 2600 Factory Recommended 195 210 inches Pre set 275 CFM 40 S A E High Temperature Bearing Positive Displacement Piston W Stainless Cylinders Special Cat Oil Lubricant Hydra Cat 300 PSI Factory Pre set adjustment Dual Cat 300 PSI Factory Pre set adjustment 5L380 900 120 090 BTU Temperature Fired 140 250 Max Frame Construction Legs Recovery Ta
38. REQUIRED NOTE STEPS 5 THROUGH 9 SHOULD BE PERFORMED WITH CLEANING TOOL ON ENGAGE ELECTRIC CLUTCH ON HIGH PRESSURE PUMP INCREASE ENGINE SPEED TO MAXIMUM FACTORY SETTING 2400 2500 RPM OPEN CHEMICAL FLOW METER APPROXIMATELY 4 5 TURNS COUNTER CLOCKWISE FROM THE CLOSED POSITION WITH CLEANING TOOL TURNED ON ADJUST INCOMING WATER REGULATOR AS REQUIRED TO ACHIEVE 9 GALLONS OF CHEMICAL FLOW PER HOUR REDUCE CHEMICAL FLOW TO DE SIRED SETTING USUALLY 5 GALLONS HOUR BY CLOSING CLOCKWISE CHEMICAL FLOW METER VALVE NOTE RECOMMENDED PRESSURGFOR CARPET CLEANING IS 300 400 P S I DUAL CAT CHEMICAL ADJUSTMENT SEE INSTRUCTIONS BELOW LIGHT PILOT LIGHT ON HEATER NOTE IF YOU SUSPECT UNIT HAS FROZEN NOT LIGHT HEATER REFER TO SERVICE BULLETIN NO 112 OR CONTACT YOUR NEAREST HYDRA MASTER REPRESENTATIVE TURN ON HEATER BURNER ASSEMBLY AND ADJUST TEMPERATURE TO DE SIRED SETTING 130 200 NOTE THE HEATER IS DEMAND OPERATED AND REQUIRES THE CLEANING TOOL TO BE TURNED ON TO STABILIZE TEMPERATURE SETTINGS COMMENCE CLEANING OPERATION SHUT DOWN RETURN TOOL AND HOSES TO TRUCK DISCONNECT VACUUM HOSE FROM TOOL LOCK HYDRA HOE ON TURN OFF CHEMICAL FLOW TURN HEATER TO OFF POSITION NOTE WAIT UNIT ALL CHEMICAL IS FLUSHED FROM UNIT FREEZE GUARDING IF NECESSARY DO IT PRIOR TO STEP 6 REDUCE ENGINE SPEED TO SLOW SETTING DISENGAGE ELECTRIC CLUTCH INJECT LPS LUBRICANT INTO BLO
39. ROBLEM LOSS OF VACUUM BLOWER IS SEIZED l0 11 1 VACUUM BLOWER CONT i CAUSE AND OR SOLUTION e Defective or mal A Examine replace if necessary adjusted vac relief and or adjust vac relief valve i valve Collapsed vac hose A Remove and replace hose NOTE between blower and a special reinforced hose is vac tank required for replacement Clogged stainless A Remove and clean or replace steel filter S S filter Defective vac tank A Remove and replace vac tank seal seal Defective or open A Close valve vac tank dump valve Replace valve Fractured weld A Re weld as required or replace vac tank tank i Collapsed or kinked A Reshape hose if possible and or vac hose eliminate kinks Plugged vac hose A Remove obstruction Restriction in A Remove obstruction cleaning tool A Replace worn components NOTE Worn end plates or must be accomplished by a lobes in vac blower qualified technician Loose coupling system A The set screws may come loose between engine and causing blower to stand still blower while engine may be turning properly NOTE unless the blower is seized or making a knocking noise your vacuum loss is not caused by a bad blower Rust A Spray rust disolving lubricant onto lobes to emulsify rust and attempt to rotate vacuum Lobes Foreign matter A Disassemble and remove foreign matter and repair as required NOTE disasse
40. STEM The entire electrical system operates on 12 volts DC which is the engine entire electrical system and it s components PROBLEM LOW BATTERY VOLTAGE 1 CAUSE AND OR SOLUTION Defective battery Corroded battery terminals Low battery fluid Defective voltage regulator Loose wiring within electrical system Blown charging fuse Electrical short in wiring system Poor ground connec tion A A A A A provided by a battery located at the rear of the vacuum holding tank Battery levels are sustained by a 15 amp alternator designed within A comprehensive schematic is provided which details the Remove and replace Clean terminals battery posts Add water to appro priate level Remove and replace voltage regulator Examine all termi nal connections and verify that they are secure NOTE give special atten tion to ignition switch terminals and voltage regula tor terminals Remove and replace fuse Check battery charge Check battery cells with hydrometer Examine electrical systems for bare wires Examine terminal and remove corrosion if necessary Follow ground wire from of battery to where it grounds at the frame If it is grounded to ano dized aluminum then scratch some of the anodizing off to allow for circuit to be completed through the aluminum INOPERATIVE TEMPERATURE GAUGE INOPERATIVE HOUR METER 9 1 Defective a
41. VER A Overfilled propan tank causing liquid instead of vapor to enter heater Heater core clogged with carbon or soot and requiring i cleaning Incorrect adjust ment propane reg ulator Defective or mal functioning burner valve assembly 16 EXCESSIVE HEAT 1 Maladjustment of propane A Contact Hydra Master regulator NOTE propane Corp to determine regulators are factory pre correct procedure set and may be readjusted by authorized Hydra Master personnel 2 Overfilled propane tank NOTE Hydra Master s propane heater is designed to operate on vapor propane only Over filling a propane tank allows liquid propane to enter all heater related components and permits an over rich burning condition to octur This condition usually requires the heater core to be cleaned of soot and carbon deposits Cleaning may be accomplished by removal of heater core and application of a household oven cleaner Following application of oven cleaner rinse residue with Clean water 4 Propane residue deposits A collecting in burner assembly NOTE Burner assemblies are factory sealed and must be cleaned by trained technicians only Failure to comply may compromise operator and equipment safety 5 Flame remains partial or A complete when wand is not spraying B C D PILOT LIGHT 1 Pilot light will not ignite A NOTE do not use a needle Or pin to clean pilot orifice use co
42. WER LUBE PORT FOR 7 8 SECONDS TURN UNIT OFF STORE HOSES PROPERLY Water Damage Vacuum Only START UP PERFORM ONLY STEPS 1 2 3 4 6 AND 10 AS DESCRIBED ABOVE SHUT DOWN PERFORM ONLY STEPS 3 AND 7 AS DESCRIBED ABOVE MANUFACTURER S LIMITED WARRANTY Hydra Master Corporation extends to the original purchaser of goods for use the following Warranty covering goods manufactured or supplied by Hydra Master subject to the qualifications indicated THERE IS NO OTHER EXPRESSED WARRANTY IN NO EVENT 15 HYDRA MASTER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES 1 Hydra Master Corporation warrants to original purchaser for the perlods set forth herein that goods manufactured or supplied by it will be free from defects workmanship and material provided such goods are installed operated and maintained In accordance with Hydra Master s wrltten instructions and that such Installations are performed or in spected by Hydra Master s Authorized Representatives PRODUCT OR SYSTEM CLEANING UNIT HOSES AND FITTINGS EXTERNAL Engine Internat Controls amp Valves High Pressure Hose Vacuum Blower Ali Fittings Internal Vacuum Hose High Pressure Pump Main Power Coupler Eng to Vacuum Quick reat naa ite or Heater System Solution Couplers Frame one Y Sar orroa 0 Pulley Belts Garden Hose Three Months 90 Days Instruments amp Instrument Panel Hoses Internal of purchase Cleaning Tools Warranty explres
43. WN TIME AND LONGER LIFE FOR YOUR MACHINE WHITE VINEGAR IS A MILD ACID AND WILL CONTRIBUTE TO THE REMOVAL BREAKDOWN OF EXCESSIVE CHEMICAL BUILD UP IN COMPON ENTS SUCH AS HOSES FITTINGS AND HEATERS 20309 64th Ave W Lynnwood WA 98036 206 775 7272 121 28 MAY 1980 Date PRODUCT SUPPORT SUPPORT BULLETIN Service Parts Publications Model s DUAL CAT amp HYDRA CAT Section Insert Z Subject pume in SYSTEM HYDRA MASTER FIELD REPORTS HAVE INCREASINGLY INDICATED A DEFICIENCY IN THE DUAL CAT amp HYDRA CAT PUMP IN SYSTEM A VALVE AND GUAGE HAS BEEN ADDED TO MAINTAIN A CONSTANT FLOW AND PRESSURE AGAINST THE SYSTEM PUMP THE GAUGE PROVIDES A READING ASSURE THIS CONSTANCY IT SHOULD READ 45 P S I TURN THE TEE HANDLE ON THE VALVE CLOCKWISE FOR PRESSURE INCREASE OR COUNTER CLOCKWISE TO DECREASE THE PRESSURE coke SURPLUS WATER PRES BACK TO TANK O INCOMING WATER 20309 64th Ave W Lynnwood WA 98036 206 775 7272 No PSB HM 113 Date August EM PRODUCT SUPPORT BULLETIN Service Parts Publications Model s ALL Section Insert Subject USE A WATER SOFTENER IMPORTANT NOTICE The quality of water varies greatly throughout the United States and influences the reliability and efficiency of equipment in direct propor tion to its level of hardness The map
44. and or replace item causing leak NOTE Worn seals within the pump will cause leak ing while clean ing tool is not in use but will suck air as ing tool is tur ed on thus result ing in a pressure loss Examine electri cal wiring and switch to ensure power is supplied to clutch Examine low water level float sensor at the bottom cf mix tank for possible restric tion Remove and replace electric clutch Readjust belt a required or re place if defec tive 14A WATER IN OIL 1 Damaged piston rod A Rebuild piston rod seal assy and replace applicable o ringd and seals NOTE Fail ure to comply may com promise the high press ure pump and cause its LOSS OF OR ERRATIC CHEMICAL FLOW l Clogged chemical A Clean or replace chem tank filter ical tank filter 2 Defective control A Remove and replace valve on chemical valve assembly flow meter 3 Cracked or split A Remove and replace chemical feed hose hose 4 Cracked chemical A Remove and replace flow meter flow meter 5 Air leak or water A Inspect hose and leak from chem fittings for possible ical flow meter fracture NOTE Even to mix tank the most minute frac ture may cause seve variance in chemical flow readings 6 Clogged or defec A Inspect and repair tive metering valve in the mix tank total destruction 14B VIBRATION MISALIGNMENT DIRECT DRIVE COUPLER Tight
45. dra Master Manual Your local small engine service shops as well as ONAN Service Centers are qualified to perform necessary adjustments 20309 64th Ave W Lynnwood WA 98036 206 775 7272 e PRODUCT SUPPORT BULLETIN Service Parts Publications Model s ALL Section Insert Subject CLEANING STROKE PROCEDURE PURPOSE To eliminate excess moisture remaining in the carpet fiber and the sawtooth appearance which results from diagonal movement of the cleaning tool SCOPE All types of carpet PROCEDURE Always move the cleaning tool in smooth forward and back ward strokes Apply slight pressure on the forward stroke while the solution is injected into the carpet When extract ing 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 A drawing is provided below to illustrate this technique Overlapping is also important to ensure even application of solution to prevent saturation Failure to adopt the above procedure can result in increased fiber shrinkage brown out and longer drying periods INCORRECT METHOD CORRECT METHOD SECON CLEANING CLEANING STROKE STROKE FORM 20309 64th Ave W L
46. dual moisture remaining within the machine 12 Turn ignition switch off NOTE Prior to turning ignition switch off it may be desirable to reconnect high pressure solution hoses and cleaning tool and repeat steps 8 9 and 10 above Failure to purge hoses and clean ing tools may damage valves and fittings CAUTION 13 If extremely cold disconnect hose to pressure gauge leave loose until next start up PARTS ORDERS Dear Customer To expedite your parts needs please call your Regional Sales Representative In most instances he either stocks or has access to parts through a Regional Service Center In the event parts are unavailable locally your Sales Service Representative will contact Hydra Master and coordinate your needs If this becomes necessary always indicate the method of shipment you desire i e UPS UPS Blue Label Air Freight Air Express Etc Thank you for your compliance with the above request and we shall do our best to fulfill your needs WARRANTY NEEDS Hydra Master Warranty is second to none and pro vides you the assurance of continued reliability We realize the importance of minimum down time which can only be achieved through manufacturers support following procedure defines the steps necessary to provide you this service Compliance with it is ess ential if parts are required l Call Hydra Master Corporation 206 775 7275 and provide the following A Name of Company
47. ea Claim No WARRANTY CLAIM DATE CLAIM FILED Customer Name Address City State Zip Equipment Model Serial No Purchased From Date Purchased No of Hours Used Defective Part Briefly Describe Defect Signature k k k k k k K k k K K K k K k k k K RK K k K KOR RO R R K K K K K K K K KO KOK R KOR K KO K K k K k K OK KOK ROK kkk Factory Use Only Date Part Received Inspected By Describe Findings Action Taken Amount of Claim GENERAL INFORMATION This manual contains installation and operation instructions as well as information required for pro per maintenance adjustment and repair of this unit Since the first and most important part of repair work is the correct diagnosis of the trouble a general troubleshooting section and component manual trouble shooting charts have been included for your 1 Unlike the garden tractor lawnmower and cement mixer all having one and maybe two functions to per form the Hydra Master truck mounted carpet cleaning Plant has many functions to perform simultaneously 1 Engine has to run consistant RPM 2 Vacuum has to pull air and dirty water back from cleaning site 3 Water pump provides stable pressure at proper water flow for cleaning 4 Chemical has to be injected into the water stream at the right consistency 5 Heater must fire on demand and maintain proper heat Except for Aqua Cat 6 Vacuum
48. ed replace magnet tollowing Magnet Replacement Instructions Page magnetis good procecd to Section CAUTION Never leave water heater with switch termina disc onmected fram magnet al conclusion of service To Check E Switch Al Bc sure water at Ihermostat level is below 120 F To in Sure this draw water from hot water outlet until ther mometer registers 120 F less Light pilot pilot does not remain 11 when reset button 15 released proceed as follows C Remove thermocouple from magnet base 0 Remove ECO terminal retainer Remove E CO switch terminal Install thermocouple in magnet base Gi Light pilot pilot remains when reset button is released aud il tests in and VII prove thermocouple and magnet are good ECO is not closing Replace entire control CAUTION Never leave water heater with switch terminal onnecied from magnet conclusion of service COMPLAINT WATER HEATER SERVICE ANALYSIS POSSIBLE CAUSE 1 int in pilot aic opening Loose inoperative thermocouple Inoperat ive clectro magnet Clogged pilot orifice Inproper pilot flame adjustment Heater subjected to strong drafts ECO switch contacts open see test procedure for ECO Thermostat setting too low Regulator pressure too low Main burner orifice too small ctop VI To Cneck Thermocouple A R
49. electrical System from ground ing properly Clean Carb Replace Carb Choke locked in closed position Often Carb float level comes out of adjustment This should be set by holding carb upside down and the float should be at 3 16 Incorrect air mix ture ratio adjust ment Incorrect float level adjustment 12 13 14 15 16 Carbon build up in cylinders NOTE carbon build up can be minimized by using unleaded reg gas Should carbon removal be necessary reinstall heads with new gaskets Incorrect timing Dirty air cleaner Clogged fuel filter Low oil level or malfunctioning oil pump A Carbon build up may be excessive if carb or valve are improperly adjusted engine RPM too low im proper spark plug gap Remove cylinder heads and elim inate carbon build up with wire brush Timing may become offset if point box is not secure or if points are out of adjustment Refer to Onan Maint enance instructions for details If exhaust gaskets do not seat prop erly or heat exchan ger gasket is bad exhaust may heat anc melt the air cleaner requiring much clear up repair PCV valve may cleaned by rinsing thoroughly with solvent Remove and replace or clean as re quired Remove and replace Oil pressure sen sors can be in stalled on the engines This will eliminate many prob lems which may occur VACUUM BLOWER POSITIVE
50. emove thermocouple nut trom Magnet Base and connect Known Good Magnet to thermocouple Heater too small Thermostat out of calibration standard Lighting Procedure holding reset butlon down al least 30 seconds after lighting pilot Ci Luck up Known Good Magnet by depressing magnet valve face If thermocouple is good magnet should re main locked up for at least 30 seconds after 15 extinguished D nemmocouple does not lock up Known Good Magnet wo t arit end To Section Thermostat setting too high Dirt on thermostat seat Thermostat out of calibration 14D 2 y TO LUBRICATE GAS COCK PLUG 1 Close gas supply at meter or line valve 2 Remove GAS COCK DIAL by pulling straight up rock dial slightly while pulling up 3 Remove C VALVE PLATE and RESET BUTTON RETAINER PLATE two screws NOTE Hold down retainer plate while removing screws 4 Remove WASHER and SPRING and pull GAS COCK PLUG straight out of cavity Rotate plug slightly if necessary 5 Remove old grease plug only Do not attempt to clean cavity as old grease or foreign malter may be pushed inlo cavily Relubricate plug only with good qualily gas cock grease suitable for aluminum gas cocks Do nol averlubticate 7 Replace GAS COCK PLUG SPRING WASHER RESET BUTTON RETAINER PLATE C VALVE PLATE Make sure GAS COCK DIAL is in PILOT
51. en bolts and allen screws Also allen screws that secure pulley to shafts of electric motor and blower Due to loose bolts on electric motor or blower mounts OVER FILLING PROPANE TANK NOTE Propane heater is designed to operate on vapor propane only NOT LIQUID PROPANE Over filling propane tanks forces liquid propane into the heat er causing an over rich condition which creates carbon or soot build up within the heater core Restric tions due to this prob lem compromise the heat ing ability of the heat er and render an unsafe condition Over filling the propane tank can be prevented if filling procedure is stopped when white vapor is first emitted from the propane tank Only authorized and trained personnel should fill propane tanks RESTRICTION OF AIR FLOW AT BASE OF HEATER A Remove any article such as chemical containers hose boxes etc within 18 inches of base of heat er NOTE This situa tion also creates an over rich condition which results in carbon build up as described above Carbon removal is accom plished in the same manner 15A LOSS OF TEMPERATURE DUE TO COLD WEATHER NOTE Climactic changes alter the output capability of the heater Example The propane heater is designed to elevate the temperature of a given amount of water ina given period of time Water emitted from a faucet ar 50 deg ona warm day may increa
52. evel is below 120 F To in sure this draw water from hot water faucet until ther mometer registers 120 F less With Test Magnet setting and dial set for maxi mum amperage check for switch closure and continuity through the switch by touching clips to opposite switch terminal contacts as shown in Figure 5 SWITCH TERMINAL TEST KIT MAGNET SETTING 1 If switch is closed essentially full amperage reading will be obtained approaching maximum necdie deflection to the right 2 Switch is open no current will De snown no meter needie deflection CI If switch contacts are open replace control D If switch contacts are closed follow standard Lighting Procedure If these checks do not resull in start up replace control Without Test Kit us Cheek Magnet Wila small screwdriver remove C O terminal retainer B With narrow blade screwdriver pry E C O terminal from magnet base slot working from both sides to avoid ter minal damage Ci Follow thermocouple installation instructions leaving Switch terminal out ot magnet base 1D Follow standard Lighting Procedure Ei After thermocouple temperature is stabilized pilot burn ing at least 2 nunutes blow out pilot if magnet is good should remain locked up for at least 30 seconds after pidot is extinguished Fj if magnet will not lock up will not remain locked up tor at teast 30 seconds atter pilot is extinguish
53. ion assembly back into position Tighten the two screws Check garden hose quick connect assem bly screen Check garden hose and or feed hose to the mix tank for clog kinks or block age Turn incoming water regulator handle clockwise to increase water inlet flow Float ball in mix tank hanging up Not e moving freely Extension bracket pinching float lever restricting full action of the lever Valve plunger not opening fully To adjust remove the 2 screws which hold the extension assembly to the valve Do not lose or drop the screws Remove the extension assembly turn it upside down To adjust loosen the Set screw on the retainer ball Place your thumb on the plunger and press it in 1 16 and slide the set screw retainer ball toward the plunger end 1 16 Tighten the set screw Place the extension assembly back into posi tion If the tank starts to overfill the retainer ball is too close to the plunger 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 HIGH PRESSURE OUT TE 2 CHEM JUG w STRAINER lA LOW PRESSURE IN HYDRA STRETCH PLUMBING Your Hydra Stretch plumbing system is unique to all other Hydra Master plumbing systems and is uncomparable throughout the carpet cleaning industry This system has been designed to be the
54. is annoying to all concerned and sometimes leaves a bad impression of the cleaning process used There are several areas that will cause over wetting NOTE l Too few vacuum strokes or improper vacuum strokes Obstructed kinked or cut hoses Vacuum tank drain valve left partially open Clogged vacuum blower filter Cleaning a heavily foam saturated carpet without defoamer We recommend crystal type Vacuum relief valve not operating properly due to wear and misalignment or adjustment may be required to increase vacuum to original factory setting 14 15 HG 1979 model has vacuum relief valve built in to tank lid and has been preset at the factory FREEZING DAMAGE BY FREEZING Although reference has been made in the preceeding pages regard ing the damage resulting from freezing the unit we shall condense and define the overall compromise of individual components 1 2 11 12 13 14 15 Quick connect couplers Incoming Water Regulator Heater water flow valve Warped or damaged High Pressure Pump manifolds High Pressure relief valve Chemical flow meter Chemical check valve Internal hoses and fittings Propane heater core Cleaning tool valves and fittings Solution hoses and fittings High pressure gauge Temperature sending unit Pump safety solenoid Chemical Pump Dual Cats Replace Rebuild or replace Rebuild or replace Rebuild pump and replace damaged parts
55. ix tank Then connect the remaining wire on the low water pressure switch to the remaining wire on the low water level kill switch Disconnect and remove all wires leading to and from relay switch and flow sensor Remove flow sensor Your chemical will now be dispensed into the mix tank in proportion to the water entering the mix tank Remove pump protection hose and insert plug NEW STYLE HEATER OPERATING INSTRUCTIONS CAUTION Heater must be fully purged with water prior to igniting A TO START PILOT 1 Adjust thermostat control knob on Unitrol to warm 2 Adjust upper dial to pilot position 3 Depress pilot button 4 Depress sparking button to light pilot Is propane tank full Is propane tank valve open Has air been properly bled from propane line IF YES Wait ten seconds depressing button manually then let off button B TO LIGHT MAIN BURNER 1 Turn upper knob to ON position Flame will come IF NO PILOT HAS EXPIRED Turn upper dial to OFF position Do not attempt to relight pilot for 60 seconds Then repeat instructions A 1 4 Water may already be at controlled temperature IF YES Flame will turn off when thermostat senses maximum temperature C TO ACHIEVE PROPER CARPET CLEANING TEMPERATURE 1 Complete procedures A amp 2 With 100 of hose turn cleaning wand on for 5 minutes The temperature should stabilize at 180 190 degrees If not propane
56. lete shut olf of all gas pilot and main burner in the event ol pilot outage 5 High capacity pilol gas filter ahead of pilot adjustment 6 Easy accessibility of all adjustments 7 Robertshaw Grayson construction which permanently divorces the water from the pas passages INSTALLATION INSTRUCTIONS PIPING Make sure thal the piping is clean and Iree from scale and burrs Apply a small amount of good qualily pipe thread compound which is suit able for the type gas being used Thread compound should be used sparingly and on male threads only leaving the first two threads clean Pipe dope or thread compound should never be used on female threads as it may be pushed into the valve body THERMOCOUPLE The thermocouple nul should be started and turned all the way in by hand additional quarter turn with a small 4 wrench will then be sufficient 10 seat the lock washer Caution Overtightening may cause damage 0 the thermocouple or magnel and is unnecessary AUTOMATIC PILOT MAGNET AND VALVE ASSEMBLY REPLACEMENT Shut off gas at line valve or meter Remove Thermocouple With small screwdriver remove red plastic TERMINAL RETAINER With narrow blade screwdriver pry blue SWITCH TERMINAL from magnet base slot working from both sides to avoid damage 5 Remove MAGNET ASSEMBLY by unscrewing 3 4 hexagon magnet assembly 6 When replacing MAGNET ASSEMBLY apply thread lube sparingly and lighten sufficiently to preve
57. lternator Temperature doesn t register or gives a false reading NOTE the integrity of the temperature gauge can be deter mined by simply turning on the ig nition switch and shorting the temp erature sending unit wire to ground If the needle on the temperature gauge deflects to maximum temperature it may be assumed that the temperature gauge is good It would then be necessary to replace the send ing unit only Temperature gauge reads maximum upon turning key to ig nition Time is not advan cing correctly A A B Remove fly wheel housing and fly wheel to expose 1 ternator and remove and replace alt nator NOTE a 1 ified technician may be necessary to per form this function Examine all wires leading to and from the gauge including the temperature send ing unit wire Remove and replace sending unit Remove and replace temperature gauge Battery terminals may be interchanged 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 4 a sudden jolt machine ot truck You may try simply tapping on the meter to try to free the nylon gear Main 25 Starter Lane Fue Pam 4 2 3 4 5
58. mbly must be accomplished by qualified technician Seized A If you suspect that your blower has seized remove coupling element then run engine for a few seconds nid way you wont confuse similar problems Jo assure correct matntenance of the blower a lubrication used pertodically 65 required Suggested s LUBRICANT LPS 25 or equcvacent BLOWER LUBRICANT DETAIL NO SCALE DRWN BY OATE HM 100 0 OGRANT JR 4 3 79 978 HYDRA MASTER CORPORATION CARBURETOR 8 C 280 D C ues 430 ENGINE DIP STICK B RESEVOIR ee m Uer VALVE OIL FILL 7 ps b GREASE FITTING u BLOWER IS FULL Torawing No HC l7 DRAWN BY DATE 5 715 78 Cat Pump 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 build up 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 Up
59. mpressed air or solvent only B 2 Remove and replace burner assembly Debris in heater water regulator Heater water regulator has frozen Replace poppit valve Check pump protection system for leakage Verify propane reach ing ignitor NOTE a kinked or crushed hog may impede propane Remove and clean Verify ignitor spark is operating correctly IMPORTANT If a new propane tank has been MAIN BURNER INOPERATIVE IMPORTANT Hydra Master s 1 propane heater will only ig nite under normal conditions with the cleaning tool turned on Any partial or full burn condition without cleaning tool turned on is abnormal and must be corrected immediately to prevent per sonal injury or equipment damage Clogged spray jet NOTE any reduction installed or hoses have been disconnected air may enter pro pane hoses and must be purged prior to attempting to light the pilot burner Should this condition exist operator must depress the pilot button for 3 5 minutes and attempt to ignite the pilot light at 30 second in tervals A very slight hissine noise should be evident while performing this operation A Remove jet and clean as reguirec in solution flow automatically limits the amount of propane metered to the burner assembly Full or partial blockage will render the heater in operative Kinked hose Damaged water flow A valve at base of heater Unki
60. nk F Hoses Internal External Solution External Vacuum G Tools Hydra Hoe Carpet Wand Stair Sprayer Stair Vacuum H Battery I Safety Features J Instrumentation Pressure Gauge Temperature Gauge Vacuum Gauge Hour Meter Chemical Flow Meter Choke Service Computer X Steel Retractable W Castered Wheels Anodized Aluminum Teflon W Steel Reinforced Sheath High Pressure Non Marking 2500 P S I Rated Heavy Duty Flexible and Non Marking Stainless Steel W Adjustable Handle and High Pressure Valve Jet Size 8008E Hydra Cat 8006E Dual Cat Replaceable Lips Hand Held W Single Jet Same as Carpet Tool Cast Aluminum 12 VDC VW Enclosed Frame Automatic Vacuum Tank Limit Switch Incoming Water Pressure Switch W Auto Shut Down Capability Electric Clutch 1 1000 PSI Glycerine Filled 100 280 Degrees 0 30 HG Total Lapse Time in Hours and Tenths 0 10 Gallons Hour Mechanical Electronic K Options and Auxiliary Systems Pump in System W Aux Pump and Holding Tank For Trans porting Water Supply SPECIFICATIONS HYDRA DUAL CAT DASH PANEL STAINLESS STEEL HIGH PRESSURE GAUGE 0 1000 PSI GLYCERINE FILLED TEMPERATURE GAUGE 100 280 DEGREES VACUUM GAUGE 0 30 HG HOUR METER HOURS AND TENTHS OF HOURS CHEMICAL FLOW METER 0 10 GPH MASTER POWER FUSE 30 AMP CHARGING FUSE 15 AMP FREEZE GUARD FUSE 15 AMP VISUAL ON
61. nk or repla hose Remove and repai or replace water valve NOTE refer to preceeding instruc tions Water valve diaphragm A ruptured or distorted through normal use See IMPORTANT Note Remove and place water valv diaphragm Next Page 156 10 11 IMPORTANT The function of the incoming water regulator is to balance the demand for water to a position whereas chemical will o be siphoned from the chemical tank Rotating the regulator counter clockwise too far results in loss of pressure loss of temperature and total loss of chemical flow and compromises internal components of the high pressure pump Clogged garden hose A Remove and clean or Strainer replace strainer Low water pressure A Locate alternate source from source Kinked garden hose A Remove kinks and verify or water supply hose flow has been re estab lished Defective propane A Remove and replace regulator regulator Loss or reduction of A Determine cause of e high pressure pressure loss and NOTE Any reduction or repair as required loss of high pressure adversely affects flow rates and may cause heat er to shut down automati cally Foreign material in A Disassemble and clean high pressure bypass bypass valve as re valve NOTE Excessive quired See drawing amounts of foreign mat erial may alter flow causing automatic shut down of the burner assembly 15H ELECTRICAL SY
62. nt gas leakage 7 Reinstall TERMINAL in magnet base slot may be necessary 10 reposition TERMINAL wires 8 Reinstall TERMINAL RETAINER snaps 9 Remstal thermocouple see installation Instructions for proper thermocouple installation 10 He establish gas supply and leak test with soap solution CAUTION Never oe Pens aate Dealer wilh switch terminal dis service PROCEDURE FOR LIGHTING RELIGHTING Turn GAS COCK DIAL 1 to OF F position Wait sutlicient length of time to allow gas which may have accumu lated in burner compartment to escape At least 5 minutes Turn GAS COCK DIAL 1 to position Depress aud hold RESET BUTTON 2 while lighang bur Allow pilot to burn approximately one half minute before RESET BUTTON If pilot does nol remain lighted un allowing longer period before releasing RESET BU adjust if necessary as noted under Pilot Burner Adjustment Turn GAS COCK DIAL 1 to posilion and turn TEMPERA TURE DIAL 3 to desired position MAIN BURNER ADJUSTMENT Gas Input 1 To adjust main burner flame loosen valve screw 5 turn valve plate 6 clockwise lo decrease the flow of gas to the main burner or counter Clockwise to increase Tighten C valve screw PILOT BURNER ADJUSTMENT 1 2 3 Remove Pilot Adjustment
63. on inspec tion they may appear melted or torn but often they will look good Replace them anyway There is no sure method of visually inspecting the cups Hydra Master recommends changing cups whether they look good or not Anytime your pump is being dismantled Hydra Master 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 prrrm a lube seals located within the intake manifold will allow air to enter the pump if they are worn Again it is difficult to visually pinpoint a defective prrrm a lube seal Replace them all Within the piston sleeve cylinders there are 6 o rings that are about 1 4 the size of a penny If these o rings are bad water will be pumped back into the oil If this has occured the oil will raise in level and will appear milky If you are unable to repair seals right away change oil frequently Repair the pump as soon as possible SO as to not damage bearing or connecting rods Repairing of Cat pumps is not a difficult task however before dis assembling make sure you have the proper parts required short or hot cup kit piston sleeve o rings Prrrm a lube seals bottle Cat oil Read instructions thoroughly supplied in the Cat pump manual prior to disassembly and follow directions as stated Oil all seals thoroughly prior to installation Remember a newly scarred seal is no
64. or the dura tion of the vinegar in the one quart container then repeat the process with one quart of 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 is in a filling cycle your chemical flow meter may read your desired flow Hydra Stretch Plumbing page 2 The water will now be siphoned from the bottom of the mix tank to the Cat pump If neither of the wands are spraying the water will bypass from the bottom of the brass pressure relief valve to the mix tank If the wand or wands are spraying the water will then flow to the desired heater This heater has a capacity of up to 5 gallons therefore it is extremely important that all air is bled out of the heater prior to initial start up This may be achieved by running the system without the heater on for approximately 60 seconds This heater is thermostatically controlled therefore upon initial ignition of the heater the burner will fire for about 1 minute Once desired temperature is achieved the thermostat within the heater will turn off the burner With the design of this heater it is possible that the flame may be on when the wand is off Likewise it is po
65. proper test equipment Remove and replace clutch if A and B reflected above indicate sufficient voltage and power is available H 1 79 HOB CAT HYDRA CAT DUAL CAT MARK IV MARK V TROUBLESIIOOTING Many of the malfunctions which can occur are minor in nature and can be rectified with minimal effort Unfortunately we fre quently have a tendency to examine the unit as a whole and not direct our attention to the actual problem which is a system within the entire unit Realizing that downtime is our worst enemy and that troubleshooting a problem can be extremely easy if we understand the functional systems components and the method with which they interplay with one another we must deter mine to become involved Example Do not address a chemical feed problem with the electrical system In the following pages we shall endeavor to identify both a problem and its probable cause and solution Only those problems which are determined to have a more frequent cyclic occurance will be reflected within this section of the manual Isolated Situations will not be included After exhausting the possibilities contained herein you are encouraged to contact either an author ized Hydra Master Service Center or Hydra Master s Service Depart ment for additional solutions A minimum of information is recom mended prior to contacting either of the above A list is pro vided for your needs 1 Engine R P M without vacuum o
66. r solution hoses attached 2 Pressure high pressure readings with both cleaning tool turned off and turned on NOTE Any pulsations should be indicated 3 Vacuum levels with intake port on vacuum recovery tank completely blocked NOTE With the use of a tachometer determine engine R P M under a maximum load condition 4 Rate of flow emitted from cleaning tool for a 60 second period NOTE Approximately 1 gallons per minute is desired with 100 solution hose attached to the clean ing tool 5 Maximum temperature as reflected by the temperature gauge This reading should be taken with 100 of solution hose attached to the cleaning tool The thermostat dial for this reading should be on Very Hot with the tool spraying For 3 minutes constantly r2 e CHEMICAL TANK TROUBLESHOOTING No or Low Chemical Flow l 2 NOTE 3 4 Inability to adjust chemical with the flow meter 1 2 Solution reversing from mix tank to chemical jug 1 2 Mix Tank overflows 1 2 Check that hoses in the tank are secured Check that the hose from the top of the flow meter to the side of the mix tank is secured with no kinks Check the hose from the bottom of the flow meter to the chem jug for kinks or cracks Check the anti siphon 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 ba
67. r ver A replacement Chest creuit millivolt check ts greater than e ght millivolts or tup C ectian Jaws not secure s ei CONVERSION FROM CHEMICAL PUMP SYSTEM TO MIX TANK SYSTEM NOTE This set up may not be applicable to those systems with Junkers heaters 1 The current incoming water line is routed from the incoming water regulator to the intake of the Cat pump This hose may now run from the incoming water regulator to the side of the mix tank which is adjacent to the proportioner The bypass return line which currently goes to the low PSI side of the Cat pump will now be routed to the bottom of the mix tank A 1 2 hose may now be run from the bottom of the mix tank to the low pressure inlet of the Cat pump The current fittings into the Cat pump must be replaced with the 8MA 8UFS fitting The chemical pump and it s 3 hoses can now be eliminated from the system The new clear plastic hose with the anti siphon device will run from the chemical jug to the bottom of the chemical flow meter The hose from the top of the chemical flow meter will now run to the inlet side of the proportioning valve The high level float should be factory set The low water level kill switch will have 2 wires The low water pressure switch by the incoming water regulator will no longer be used so disconnect one wire from the low pressure switch and connect it to one of the wires from the low water level kill switch in the m
68. raph teletype or other communications expense F Living and travel expenses of persons performing service excepting those authorized by Hydra Master under prior contract Rental equipment used while Warranty repairs are being performed Overtime labor requested by purchaser Parts sub assemblies assemblies or major components affected directly or indirectly by freezing gt IO IMPORTANT Freeze Guard Systems incorporated within units eliher as standard equipment or as optlons are conve nlence items only Hydra Master assumes no responsibility for their failure power failures affecting their perfor mance or any resulting damage Items susceptible to damage by freezing are as follows Pressure amp Solution Gauges 9 Solution quick connect fittings couplers Flow Meters h Rellef valves or high pressure by pass valves High Pressure Pumps Cleaning tools and their respective controls valves Heater or heat exchanger components Regulators and solenoids Hoses Solution amp pressure switches Fittings steel brass and plastic Pump clutches damaged by frozen pumps 5 No person is authorized to extend any other warranties or to assume any other liability on Hydra Master s behalf unless made or assumed writing by an of Hydra Master Corporation and no person is authorized to give any war rantles or assume any other liabilities on behalf of seller unless made or assumed in writing by seller S
69. rb end but you should not be able to blow through the hose barb end If you can not suck through it then rinse it out with vinegar 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 anti siphon screen and cut off 2 coils Screw the spring back into position Check flow meter for float obstruction Turn incoming water regulator clock wise to increase water flow volume Debris lodged behind teflon seat in flow meter knob Teflon seat dismounting from flow meter knob Anti siphon screen removed from chem ical jug hose Debris in anti siphon screen Float ball in mix tank hanging up not moving freely Extension bracket pinching the float lever restricting full action of the lever Mix Tank overflows Cont Mix Tank doesn t keep up with water output Pump pulsates when the tank is in a fill mode 1 Plunger nor seating properly the valve Remove the 2 screws which e 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 retainer ball and move the ball toward the end of the rod 1 16 Retighten set screw Place extens
70. rsal coupler bedrings IMPORTANT On all subject models lubrication of the universal coupler is necessary to ensure continued reliability and long life Installation of a plastic sleeve as illustrated will serve to con tain grease as the coupler rotates during normal use Prior to re installation of the coupler grease should be forced through each end until it appears at swivel joints NOTE During reinstallation of the coupler careful consideration should be given to avoid misalignment as this will result in reduced coupler life ATTENTION Upon request sleeves will be provided without charge to customers purchasing models not equipped with this modification o Plastic sleeve should be clamped as illustrated PLASTIC SLEEVE RETAINING CLAMP UNIVERSAL e No PSB HM 111 Date August 1979 No 114 PRODUCT SUPPORT none e Service Parts Publications Model s HYDRA CAT DUAL CAT Section Insert BOB CAT H VAN Subject FREEZE GUARD PUMP MAINTENANCE UP DATE DUE TO PROBLEMS ARISING WITH FREEZE GUARD COMPRESSORS I FEEL IT WOULD BE TO OUR CAND OUR CUSTOMERS ADVANTAGE TO LUBRICATE THESE PUMPS THIS CAN BE DONE EFFICIENTLY BY REMOVING THE FELT FILTER ON THE TOP OF THE PUMP HEAD AND SPRAYING A SMALL AMOUNT OF LPS 1l THIS OPERATION SHOULD BE REPEATED WEEKLY AFTER LUBRICATION THIS PUMP SHOULD BE OPERATED TO ALLOW FOR MAXIMUM LUBRICATION OF PISTON AND CYLINDER THIS PROCEDURE SHOULD
71. se in temperature as much as 20 deg before en tering the heater thus resulting in a 20 deg boost in temperature once heated An additional benefit is experienced Since warm air is also drawn into the heater and provides an additional boost in temperature e Conversely winter time operation alters the per formance of the heater capability since water leaving a faucet at 50 deg may lose 10 13 deg in temperature before entering the heater Likewise the air drawn into the heater is also colder thus reducing the overall performance This condition is natural and cannot safely be altered by any mechanical means It may therefore be assumed that efficiency levels will vary in relationship to the climate 158 9 WORN OUT SPRAY JET A Remove and replace NOTE Cleaning tools spray jet designed to spray e constant flow of 15 GPM will average 1 gallon of flow per minute on actual work ing situations since flow is not continuous An average flow of 1 GPM results in 6000 gallons of flow for every 100 hours of unit operation Spray tips are capable of consistant flow rates for approx imately 20 000 gallons They should be replaced therefore approximately every 350 hours Worn spray jets allow a greater average rate of flow thus reducing desired tempera ture levels 10 REDUCTION OF FLOW due to increased length of sol ution hose NOTE For every 50 feet of hose beyond 200
72. ssible that the flame may be off when the wand is on The thermostat dial on this heater should be set so that once the heater has achieved a temperature of 170 190 then spray the wand for a constant 60 seconds then turn the wand off Now the burner on the heater should remain on for 30 40 seconds If the flame goes out prior to 30 seconds turn the thermostat dial to a higher setting If the flame on the burner continues to burn after 40 seconds turn the thermostat dial to a lower setting This Hydra Stretch water flow technique is designed for simplicity in your achievement of proper PSI heat and chemical mixture THIS BULLETIN IS INTENDED AS A GUIDE TO QUAL IFIED FIELD SERVICEMEN INSTALLING OR REPAIR ING ROBERTSHAW GRAYSON THERMOSTATIC CON 5 TROLS AS THE MANUFACTURER OF THE CONTROL VIR GAS COCK DIAL RED WE RECOMMEND THAT REPAIR AND ADJUSTMENTS P BE LIMITED TO THE OPERATIONS LISTED BELOW iN m WHICH OUR EXPERIENCE SHOWS ARE PRACTICAL w T C VALVE PLATE FIELD SERVICE OP ERATIONS 74 uu HERE S HOW IT WORKS _ SET BUTTON RETAINER ASSEMBLY In addition to the previous features of the Unitiol the new Unitiol with built in ECO provides the following additional function in case of ex a cessive water temperature in the healer switch inside the shank ZAS COCK SPRING assembly shuts off the automatic pilol valve and all gas to the heater The Unitiol provides a completely self
73. start up immediately under standard e cedure for lighting check the following A Check Thermostalic Valve Action Thermostat valve leaks can result in overheating af tank water and resull in shutdown due to C O action valve is found to leak clean valve if valve still leaks replace thermostat B Check Thermostat Calibration at Highest Setting 160 Thermostats Hot Warm Dial If top temperature exceeds 160 F at shut olf shutdown was likely due to C O action Recalibrate so top setting is in 155 F range 180 Thermostats Very Hot Dial top temperature exceeds 180 at shut off recalibrate so setting is in 175 F range C tt none of the above conditions exist Shutdown was most likely due to other causes standard procedure for hghting does not result in slart up proceed to Sections III IV and V if Test Kit is Sections VI VIL and if Test is not available A prov en good magnet is required for tests outlined in sections VI and VIII H Test Kit is Avaitable Make closed circuit millivolt check as follows A Use Grayson Test 165 34 or equivalent meter B Connect Adaptor 75036 and Test Kit as shown in Fig ure 4 being sure connections are tight C Follow standard Lighting Procedure O Check closed circuit output ff fess than eight millivolts replace the thermocouple E Repeat standard Lighting Procedure afte
74. tank must store dirty water until drained As you can see it is not just a turn key operation with only one thing to worry about DOES IT START As there is no guesswork in the manufacture of these highly advanced cleaning plants there must be none in preparing it to get the job done in the field It is the purpose of this manual to help you properly understand maintain and service your Hydra Master cleaning plant Follow the directions carefully and you will be rewarded with years of profitable trouble free operation It is imperative that no section be overlooked when preparing for operation of this equipment Hydra Master uses this symbol WARNING throughout the manual to warn of possible injury or death This symbol is used to warn of possible equipment damage MAINTAIN GOOD PROFIT WITH GOOD MAINTENANCE In the past 3 years we at Hydra Master have become alarmed at the increasing number of calls pertaining to service problems Our findings are that 85 of all down time is a direc result of poor maintenance habits If maintenance is a difficult function to schedule into your busy operation here is one important parallel that may in fluence your thinking toward maintenance procedure Each hour of machine operation is equal to 75 miles of driving 55 hour average day equals 310 miles An average 5 day week or 27 hours 2062 5 miles Each month an average of 8660 miles is put on the machine One year
75. ynnwood WA 98036 206 775 7272 No PSB HM 103 t Date es PRODUCT SUPPORT BULLETIN Service Parts Publications Model s ac Section Insert Subject 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 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 Contact a water softener distributor in your area foe information on the rental of a simple water treatment unit to carry in your truck See installation diagram below GARDEN HOSE WATER SOF TENER 20309 64th Ave W Lynnwood WA 98036 206 775 7272 No _ PSB HM 105 Date JANUARY 1979 Service Parts Publications Model s Section Insert Subject VACUUM TANK FILTER BAGS We have available for your purchase filter bags that are designed to trap all of the lint sand and dirt that would nor mally collect at the bottom of your vacuum tank The use of these bags if emptied at the

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