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1. 64 BLUELINE COBALT 3 POS STARTER SWITCH RED VOLTAGE REGULATOR KOHLER ze 29 007 BLUE STARTER KOHLER STA
2. Disconnect the level sensor shut off switch Does the engine start Yes No See Engine Won t Start 41 SECTION 4 Heating System Note Make sure the engine and water pump systems are working properly NOTE WATER MAY BE HOT AND UNDER PRESSURE EXTREME CAUTION SHOULD BE USED MAKE SURE THE MACHINE HAS COOLED DOWN _ ALLOW THE UNIT TO COOL UNTIL IT IS SAFE TO INSPECT Is the thermal valve inside the water box bypassing water to the waste tank when the water box reaches the preset temperature setting Replace the thermal valve inside the water box Is the temperature valve open hooked up correctly Are the machine hoses Close the valve Yes 211 Have machine serviced by authorized If you still have a problem BLUELINE service center restart from the beginning 42 BLUELINE COBALT SECTION 5 PARTS amp ACCESSORIES 9 ILLUSTRATED PARTS LISTINGS Sheet Metal 44 Engine 48 Water Transfer System 50 Vacuum Exhaust System 56 Chemical Pumping System 60 Decals 62 Electrical Diagram 64 Optional Eguipment 65 10 ACCESSORIES Accessories 68 BLUELINE COBALT 43 SECTION 5 64 SHEET METAL FRAME No Part Number Qty Description 1 61346 1 ASSY BASE COBALT 2 60000 1 PNL CONTROL C
3. 1 To adjust the engine RPM refer to the Kohler Engine Operation and Service Manual for specific instructions WARNING DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 2800 RPM VACUUM RELIEF VALVE With the unit running at full RPM block off the airflow at the vacuum inlet port and read the vacuum gauge If adjustment is required shut the unit down and adjust the locking nut tension on the vacuum relief valve Re start the unit and read the vacuum gauge Repeat this process until the vacuum relief valve opens at 13 Hg VACUUM PUMP DRIVE BELTS The COBALT unit is equipped with an Adjustable Belt Tensioning system This eliminates the need for sliding the vacuum pump for belt adjustment Periodic checking of the belts and pulley condition is all that is required WATER PUMP DRIVE BELT To tighten the water pump belt BLUELINE COBALT SECTION 4 1 Loosen the four nuts which hold the water pump base to the frame 2 Adjust the position of the belt tensioning adjusting bolt until the proper belt tension is achieved 3 4 deflection in the center of the belts half way between the pulleys Do not over tighten damage to pump may occur 3 While checking the alignment tighten the nuts that hold the water pump to the base A CAUTION Over tightening of belts may cause damage to pump casing causing it to fail FLOAT VALVE WATER BOX The float valve should only be a
4. 1 MUFFLER COBALT ENGINE EXHAUST 4 61 353 1 ASSY ENG MUFFLER HEAT EXCH 5 36 016 1 GASKET EXHAUST ONAN 8154 2747 6 1 ASSY HEAT EXCHANGER Cobalt GASKET HIGH TEMP SILENCER EXHST 8 61 352 1 ASSY ENG EXHAUST BAFFLE COBALT 9 61548 1 ASSYENG BLWR EXHAUST COBALT BLUELINE COBALT 39 SECTION 5 5 25 CHEMICAL PUMPING SYSTEM Part Number Qty Description STRAINER SUCTION END 1 8FP FTTG BRB 1 8 PX 5 16 H BR 16 006 60 HOSE BRAIDED 5 16 300FT BULK 5 16006 7 25 HOSE BRAIDED 5 16 IN 300FT BULK 6 46012 1 PUMP CHEMICAL STAINLESS STEEL 11 3 16 24 14 1 8 2230277 1 VLV 3 WAYBALL18FPSS 9 18 062 1 HOSE3 16X10 1 4FTBS HOSE 3 16 X 22 1 4FT BS 15 16 006 ___ 60 HOSE BRAIDED 5 16 IN 300FTBULK 60 BLUELINE COBALT SECTION 5 13 X 14 ic Y gt n 4 Z _ at s 5 26 46 012 CHEMICAL PUMP STAINLESS STEEL tem No PartNumber Qty Description 1 66 008 1 BODY CHEMICAL PUMP STAINLESS 2 36004 2 CHECK HYPRO 41 07 2 ORING 7 8 ID 1 1 16 OD 4 66 006 2 CAP CHECK VALVE CHEM PUMP SS 5 3603 1 016 22 6 3600 1 DIAPHRAGM CHEMICALPUMP 21 038 1 1 8 9 21 007 1 FT
5. 1 HOSE 1 2X30 1 2FT X1 2FTWICVR 14 11 HOSE 1 2 24 1 2FT X1 2FTWICVR 161102 Hose Pressure Reg to 54 BLUELINE COBALT SECTION 5 4 E From Pressure E 4 Regulator 4 11 3 ABS 7 F I lt G Ma a as u 1 4 C ia i 1 Mr 120 D To Waste Tank To Pressure 7 2 3 a Regulator RT se gt m 3 T os _ 4 Oi k 46 21 4 From Solenoid 2 v CX Switch To Chemical SD Selector Switch 69 142 ASSY Y STRAINER COBALT PartNumber Qty Description 1 66 075 1 MANIFOLD CHECK VALVE BW YSTRAIN 2 2500 1 DSC 1 4X1 4FP BR 3 21 055 1 ELL 1 8 PX 1 4 T 45DEG BRASS 4 21040 3 ELL STREET 3 8 IN BRASS 5 3400 1 SENDER TEMP 140 320 DEGREE 6 200188 1 SCREEN CHECK VALVE MANIFOLD VLV CHECK CHECK VLV MANIFOLD 8 2102 1 NIP 3 8 X 1 4 HEX BRASS _9 2100 1 NIP HEX1 2X3 8BRASS _19 1 HOSE 1 2 15 1 2 2 1 Hose3 16x70 1 4FTx14FT HOSE 3 16 X 10 1 4FT BS BLUELINE COBALT 55 SECTION 5 5 20 No Part Number Qty Description 1 4602 1 VACUUM 1406 2 69039 1 ASSYVACBRAKE3LAM 56 BLUELINE COBALT SECTION 5 5 21 VACUUM
6. D 10 i To Pressure 56 4 Regulator 17 15 414 To Water Pump 46 10 5 11 69 050 ASSY WATER BOX COBALT tem No Part Number Qty Description 1 51 002 1 MOLDING WATER BOX DISCOVERY 2 21 025 1 1 5 IN WATER BOX TANK BLACK 3 2302 1 FLOAT WTR BOX 11001 2 581 420 8 64000 1 ROD FLOATSS 6 28 001 8 20001 1 STRAINER SUCTIONEND3 4FP 9 21034 2 FLL STREETU2BRASS 10 21032 6 FTTG BARB1 2PX3 4HBRASS CLAMP HOSE 12 BLUELINE COBALT 51 SECTION 5 a 64 16 gt 15 To a j Regulator 20 M x Water Box i Supply gt a 7 s 5 12 69 140 ASSY WATER PUMP COBALT Part Number 46 021 PUMP CAT 3CP1120CS 3 HOT amp DRY 36 116 CAP OIL FILL 3CP CAT 4 45690 35 001 CLUTCH ELECT CAT3CP 16 5MM 29 004 SWITCH PRESS 50PSI 29 005 SWITCH PRESS 1000PSI 66 002 ADAPTOR CHEMICAL PUMP 46 012 PUMP CHEMICAL STAINLESS STEEL 8 66 102 FTTG ACCUMULATOR ADAPTOR 9 46 020 ACCUMULATOR CAT 6026 21 061 ELL 3 8 P X 1 2 T BRASS 21 034 ELL STREET 1 2 BRASS 21 032 FTTG BARB 1 2 P X 3 4 H BRASS 21 050 CONN 1 4 P X 1 4 T BRASS 18 030 HOSE 3 16 X 14 3 4 FT X 1 4 FT 21 065 PLUG 1 2 SOLID BRASS HEX HD 21 146 PLUG 3 8 NPT BRASS 61 347 ASSY WATER PUMP MOUNT COBALT 10 008 SCREW MACH 8MM 1
7. lt gt 22 5 45 68 018 ASSY 10 GAL CHEM RACK 5 5 5 46 68 019 SPRAY BOTTLE HOLDER SS 78 BLUELINE COBALT SECTION 5 5 47 68 022 ASSY DBL PMP UP SPRAY RK SS 5 48 68 024 ASSY SNG PMP UP SPRAY RK SS BLUELINE COBALT 79 SECTION 5 5 50 68 025 ASSY HOSE REEL HIGH PROFILE 80 BLUELINE COBALT SECTION 5 68 033 ASSY HOSE REEL H PROFILE W MTR BLUELINE COBALT 81 SECTION 5 68 043 ASSY HOSE REEL LAY DOWN KIT 82 BLUELINE COBALT BLUELINE COBALT 68 045 ASSY WATER SOFTENER SECTION 5 83
8. antifreeze waste tank is empty and you have at least a half tank of gasoline Is the battery connected Is battery fully charged Eos Connect batte Above 12 6 volts 77 Install new battery Note Check to see if the alternator is working _ properly While the engine is running the battery volts should read between 13 0 and 14 8 volts Is main circuit breaker popped Push in circuit breaker Note If circuit breaker continues to trip you have 4 2 When you turn the key to the RUN position do an electrical problem Have machine serviced by ee you hear the fuel pump turn on an authorized BLUELINE service center With an electrical meter do your have at least 12 6 volts or higher at the ignition switch BAT terminal Is the small wire connected and tight to the starter a Yes Connect wire Yes No Replace ignition switch Disconnect small wire from the starter With an electrical meter do you have at least 12 6 volts when the ignition switch is turned to the START position Repair wire going from the Starter Battery terminal on the starter to the BAT on the ignition switch Remove the blower belts Pp un Does the engine start in di See Blower Vacuum Pump Yes No Repair the wir
9. is ot 4 p U 8 5 q N Fuel Suction Line gt lt 2 24 h 1 5 4 gt lt gt S 9 9 5 ES Fuel Return Line To Bottom of Tank 5 36 69 003FI KIT FUEL HOOKUP 97 4 2002 FI No Number Gy Description 1 14010 2 2 2 66030 1 ADAPTOR FUEL FILLER NECK CHEVY 3 7 16 1 __ _ 1 8FP9ODEGBRONZE 14011 6 CLAMP HOSE FUEL 5 200 2 FTTGBRB1U8PX516HBR _6 18027 2 HOSE 3 16X51 8PX1 8P NOCVR 8 21039 2 FLL Y4INLGSTREETBRASS _ 210388 1 FLL STREETU 8IN BRASS 70 BLUELINE COBALT SECTION 5 2003 CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION Pa 1 4 _ Cut Hose And Remove i ve 0 Flapper Valve O 4 4 4 wt j Trim Fuel Fi er Neck 1 14 5 Reinstall Flapper Valve 47 za 42 Inside Of Fuel Filer Hose 1 et ze 5 a P 46 5 5 37 69 018 KIT FUEL HOOKUP 2003 CHEVY FI Number Qty Description 1 66034 1 ADAPTOR FUELFLRCHVY 2003 2 1400 2 CLAMPHOSEZ20 3 18028 1 3 16 25 1 8PX 8 1401 6 HOSEFUEL 6 0 2 35 1 STREET1 8IN BRASS 6 21007 2 FTTGBRBU8PX516HBR 8 246 4 BRBIAPXS AOHBR 9 2 06 2 FTTG BULKHEAD14IN BRASS BLUELINE COBA
10. AND RETURNED TO BLUELINE BLUELINE COBALT Record your units serial number here for future reference or if you should need to contact the factory in the future for any reason This service and operations manual is written specifically for BLUELINE COBALTe Truck Mount Cleaning units manufactured by BLUELINE EQUIPMENT LLC 2604 Liberator Drive Prescott AZ 86301 USA The information contained in this document is subject to change without notice and does not represent a commitment on the part of BLUELINE EQUIPMENT LLC rights reserved Copyright 2007 by BLUELINE EOUIPMENT LLC No part of this work may be used or reproduced in any form or means without the express written consent and permission of BLUELINE EQUIPMENT LLC Published by BLUELINE EQUIPMENT LLC First printing September 2007 Printed in USA COBALT MANUAL PART 49 033 September 2007 Table of Contents SECTION ONE GENERAL INFORMATION 1 1 SAFETY Safety Specifications Installation Fuel Engine Oil Chemical Water Reguirements 2 RECEIVING YOUR TRUCK MOUNT UNIT Dealer Responsibility Acceptance of Shipment Eguipment Listing Optional Eguipment SECTION TWO INSTALLATION 8 3 INSTALLATION Lifting the Unit into the Vehicle Positioning the Unit into the Vehicle Fastening Down the Unit and Waste Tank Dimensional Diagrams Installation of Fuel Lines Trailer Fuel Tank and Line Installation Battery Connection Fire Extingui
11. BLUELINE COBALT SECTION 3 system drops below 50 PSI for more than 5 seconds The high pressure switch will automatically shut down the unit if the water pressure in the system exceeds 1200 PSI for more than 5 seconds 1 Set the throttle cable control to the idle position 2 Pull the choke cable out 3 Turn the ignition switch to the right intermediate position Hold the switch in this position for approximately 3 seconds allowing the fuel pump to pump fuel 4 Turn the ignition switch to the furthest right position This will engage the starter and start the engine 5 After starting the engine push the choke in 6 After the engine is running at its idle setting select the desired speed setting using the throttle control cable 7 Turn the water pump switch to the ON position NOTE Ifthe unit does not build water pressure after 5 seconds check for adequate water supply See Loss of Water Pump Pressure in the Troubleshooting section of this manual Allow adequate time for the water temperature to warm up before cleaning approximately 7 10 minutes PRIMING THE CHEMICAL PUMP NOTE BLUELINE recommends that the chemical pump be primed whenever the water pump is on This eliminates possible pressure 21 fluctuations and water pump pulsations related with running the chemical pump dry 1 Insert the chemical prime tube and the chemical inlet tube into the chemical jug NOTE When insert
12. COBALT unit features a stainless steel chemical pump and metering system The chemical 34 BLUELINE COBALT SECTION 4 pump requires only the replacement of the diaphragm and check valves To replace the diaphragm unscrew the cover from the body When replacing the diaphragm lube the outer edges of the diaphragm with o ring lubricant Part 13 003 and reassemble To replace the check valves remove the check valve caps replace the check valves and reassemble using new o rings DO NOT attempt to reuse o rings after the check valves have been removed PACKING NUT ADJUSTMENT CHEMICAL METERING SELECTOR VALVES Inspect the packing nut for proper tension on the chemical metering and chemical selector valves every 200 hours When turning the knob there should be some resistance If not slightly tighten the packing nut DO NOT over tighten Keeping the packing properly adjusted will eliminate possible leaks and will add to the overall life of the valves Chemical Prime Valve Adjust The Packing Nut By Turning The Packing Bolt Clockwise In 1 16 PL 9 increments Loosen Set Screw And Remove Knob Chemical Metering Valve Packing Nut PRESSURE REGULATOR The pressure regulator holds water pressure at a preset point and bypasses the excess water back to the water box To adjust 1 With the unit running close the cleaning tool valve Check the pressure gauge Open the tool valve Set the pressure reg
13. Replace gaskets Repair or replace waste tank ES When you start the machine does the Yes vacuum feel normal but the vacuum See gauge reads something different Replace vacuum gauge YesiNo 2223 When you start the machine does the vacuum feel different than the vacuum gauge reads Remove the filters from the waste tank Are the filters clean and not crushed Start the machine and set the throttle control to carpet Seal the vacuum ports Does the gauge read 15 HG There is a blockage between the machine and the waste tank 38 BLUELINE COBALT Clean or replace filters Vacuum system is normal ku lt Yes No 2 Adjust repair or replace vacuum relief valve SECTION 4 Engine Won t Start Note Make sure the engine has oil waste tank is empty and you have at least a half tank of gasoline Turn off all of your switches PUMP SWITCH TRANSFER PUMP SWITCH and WASTE PUMP SWITCH Does the engine start See Water Pump When you turn the key to the RUN position do you hear the fuel pump turn on Disconnect the fuel hose from the machine With electrical meter turn the key to the Attach a separate hose Run the hosetoa p
14. Vehicles vary in size and openings Owners have different preferences on where in the vehicle they want their units positioned BLUELINE strongly recommends a side door installation for the COBALT We DO NOT recommend a rear door installation 1 Ensure that enough space is provided to assure adequate engine ventilation as well as room for service and maintenance 2 The complete unit with waste tank and accessories MUST NOT exceed the vehicle s axle weight limit 3 NEVER position the console closer than 12 inches from the bottom rear of the driver and passenger seats BLUELINE COBALT SECTION 2 FASTENING DOWN THE UNIT AND WASTE TANK IN CAUTION Prior to drilling any holes in the vehicle floor ensure that while drilling you will not damage the fuel tank fuel lines or any other vital components which could affect the safety and or operation of the vehicle A The console and waste tank mounting holes will serve as a template Drill six 6 13 32 in diameter holes for the console and four 4 13 32 in diameter holes for the waste tank B Using the provided mounting hardware kit 1 Insert six 6 3 8 16 x 2 in hex head cap screws with flat washers through the COBALT console mounting holes and four 4 3 8 16 x 2 in hex head cap screws with flat washers through the waste tank mounting holes 2 Install the provided mounting plates underneath the vehicle floor 3 Screw the provided 3 8 16 hex
15. is any lint or debris present NOTE To remove the vacuum inlet filter grip the plastic hexagon section of the filter Gripping the filter by the screen will collapse or destroy the filter Replace the filter after cleaning until hand tight NEVER operate this unit with the filter removed damaged or improperly installed 13 At the end of the work day rinse out the waste tank with fresh water A deodorizer may be added to prevent bacterial growth 24 BLUELINE COBALT SECTION 3 14 Clean the vehicle interior unit tools hoses etc as needed Inspect ALL equipment and accessories for any damage leaks wear etc FREEZE PROTECTION CAUTION If the unit is exposed to freezing weather conditions the water inside of the unit may freeze resulting in SERIOUS DAMAGE to the unit The following is recommended to prevent this from occurring during the cold weather season 1 Always park the unit in a heated building when not in use 2 While out in operation avoid long periods of shut down as the unit generates heat while running Keep the unit running just prior to leaving for the next job 3 Ifa heated building is not available winterize the unit with anti freeze It is not possible to winterize units that have auxiliary water tanks If the unit has an auxiliary water tank s it must be stored in a heated building WINTERIZING YOUR UNIT WITH ANTI FREEZE 1 Shut off the water supply to the unit and di
16. least 3 minutes The unit is now winterized REMOVING ANTI FREEZE FROM THE UNIT 1 Connect the solution hoses to the unit with a tool attached to the opposite end Start the unit Turn the water pump on Open the tool BLUELINE COBALT SECTION 3 valve and ensure that the anti freeze goes into an approved container Allow the anti freeze to flow into the container until the low pressure switch shuts the unit down 2 Fill the water box with fresh water and repeat step 1 3 Connect the water inlet hose to the unit and turn the water supply on Connect all tools and solution hoses that were winterized to the solution outlet connection Open all tool valves and drain the anti freeze into an approved container until the water runs clear and all of the anti freeze is purged from the hoses and tools 4 Insert the chemical prime hose into the approved container Submerge the chemical hose into fresh water Turn the chemical valve to the PRIME position until the water runs clear through the prime hose Remove the prime hose from the container 5 Turn the chemical valve to the ON chemical position This will allow water to flow to the other side of the system After all of the anti freeze has been removed the unit is ready to operate The anti freeze in your approved storage container will eventually become diluted with water When the anti freeze level drops below 70 of the total mixture properly dispose of it an
17. overfill the battery Early failure or poor performance will result due to loss of electrolyte 2 Keep cables terminals and external surfaces of the battery clean and dry A buildup of corrosive acid or grime on the external surfaces could cause the battery to self discharge 3 Battery terminals should be cleaned every 100 hours to prevent corrosion buildup Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with fresh water DO NOT allow baking soda to enter the battery cells as this will destroy the electrolyte resulting in battery failure HIGH PRESSURE SOLUTION HOSES Inspect your high pressure solution hoses for wear after the first 100 hours Thereafter inspect every 25 hours If the hoses show any signs of damage or impending rupture replace the hoses Z WARNING NEVER attempt to repair high pressure solution hoses Repairing high pressure solution hoses may result in severe burns and serious injury All high pressure solution hoses must be rated for 3000 PSI at 250 deg F Thermoplastic hoses do not meet this requirement and should not be used Severe burns and injury may result if the hoses do not meet these requirements 7 GENERAL SERVICE ADJUSTMENTS IB WARNING DO NOT attempt to service this unit while it is running High speed parts as well as high temperature components may result in severe injury severed limbs or fatality ENGINE SPEED
18. prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as other sources of ignition away from battery at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are in the off position If on a spark could occur at the ground connection terminal which could cause an explosion if hydrogen gas or gasoline vapors are present ALWAYS disconnect the negative terminal first 14 DO NOT smoke around the machine Gas fumes could accumulate and ignite Battery gases are extremely flammable This will prevent possible explosions 15 DO NOT damage the vehicle in any way during the installation When routing fuel lines DO NOT configure the hose in any locations where the hose or vehicle could be damaged Avoid contact with moving parts areas of high temperature brake lines fuel lines catalytic converters exhaust pipes mufflers or sharp objects 16 NEVER cut or splice any of the vehicle fuel lines during fuel line installation This will result in fuel leaks and potentially dangerous conditions Use only the provided fuel hose for fuel lines When going through the vehicle floor with fuel lines always utilize bulkhead adapto
19. these decals HOT SURFACE DO NOT TOUCH 22 A WARNING OR 1 ROTATING MACHINERY SERVICING THIS UNIT TO PREVENT ACCIDENTAL STARTING 2 BLUELINE COBALT WARNING OPERATE THIS UNIT AND EQUIPMENT ONLY INA WELL VENTILATED AREA EXHAUST FUMES CONTAIN CARBON MONOXIDE WHICH I3 AN ODORLESS AND DEADLY FATALITY DO NOT RUN THIS UNIT IN AN ENCLOSED DO NOT OPERATE THIS UNIT WHERE THE EXHAUST MAY ENTER ANY BUILDING DOOHWAY WINDOW VENT OR OPENING OF ANY TYPE A DANGER DO NOT RUN ENGINE WITH COVER OFF VOIDS WARRANTY ZN WARNING 1 Read the operator s manual before starting this unit Failure to adhere to instructions could result in severe personal injury or could be fatal 2 Operate this unit and eguipment only well ventilated area Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or death DO NOT run this unit in an enclosed area DO NOT operate this unit where the exhaust may enter a building doorway window vent or other opening 3 Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings and away from sparks or flames Never carry gasoline or any flammable materials in the vehicle Fumes could accumulate inside of the vehicle and ignite causing an explosion 4 This unit must be operated with the veh
20. 2 59 30 20 10 0 15 TEMPERATURE RANGE EXPECTED BEFORE NEXT CHANGE NOTE The use of less than service class SG SH SJ or higher oil or extending the oil change intervals longer than recommended can result in engine damage 3 Check the spark plugs every 200 hours and clean if necessary Replace spark plugs every 1000 hours NEVER sandblast spark plugs Spark plugs should be cleaned only by scraping or wire brushing 4 Clean the engine air filter element every 200 hours Replace the element every 2000 hours Replace the in line fuel filter yearly NOTE Additional engine service information can be obtained from the provided Kohler Operation and Maintenance manual If service or repair is reguired contact an authorized Kohler Service Center They will reguire the serial number of the engine 29 VACUUM PUMP NOTE Refer to the provided Vacuum Pump Operation and Service Manual for specific instructions Lubrication BLUELINE recommends that you use only AEON PD Synthetic Blower Lubricant in both sides of the vacuum pump for all operating temperatures AEON PD is formulated specifically for positive displacement blower service to provide maximum blower protection at any temperature One filling of AEON PD will last a minimum of twice as long as a premium mineral oil NOTE AEON PD Part 13 004 is the only oil that BLUELINE puts in the vacuum pump at the factory Adding petroleum oil to synthetic oil
21. 5 RED N O BROWN SWITCH N O 69 000 idi PUMP OUT H L j Cobalt 10 12 07 l N 5 5 31 67 001 WAND LOW PROFILE 2 IN No Part Number Qty _ 1 67 001 1 WANDLOWPROFLE2IN 2 2500 1 DSC 14MX14FPBR 4 2 50 1 CONN 14PX14TBRASS 5 18071 1 HOSE 3 16X511 4FTX14FT 6 24 00 4 TIP SPRAY 95015X1 8P SST _ 40 070 1 HANDLE WANDREPLACENT BLUELINE COBALT 65 SECTION 5 67 003 WAND ERGONOMIC W SPRAYER No Part Number Qty Description 1 6700 1 WAND ERGONOMIC W SPRAYER 3 23 035 1 VLV SPRAYER HYPRO 3381 0032 4 2 50 1 CONN 14PX14TBRASS 5 18071 1 HOSE 3 16X511 4FTX14FT 6 27 00 4 TIP SPRAY 95015X1 8PSST 66 BLUELINE COBALT SECTION 5 68 116 ASSY WASTE TANK COBALT No Number Qty Description 1 6134 1 TANK COBALT 2 61 061 1 ASSY WSTTANKLIDCHAMP 4 2009 1 STRAINER WSTTNK2 1 2IN 100M 5__ 6 42 1 BASKET STRAINERWASTE TANK _6 21118 05 NIP ALUM21 2X4NPT SCHED40 5506 1 TBG ALUM27 8ODX 188WALL 21 289 1 Tee 1 4MX 1 4F X 1 AM Waste Tank 15 11000 6 NUT 5 16 18ZINC 1 1 17 12016 6 LKWSR 5 16 ZINC 18 10023 6 SCREW MACH 5 16 18 x 1 1 4 SS HXHD BLUELINE COBALT 67 SECTIO
22. 6 X 1 25MM 14 000 CLAMP HOSE 12 18 033 HOSE 1 2 X 10 1 2FT X 1 2FT W CVR 10 004 SCREW MACH 3 8 16 X 1 1 4 HEXHD 12 014 LKWSR 3 8 ZINC 12 013 WASHER FLAT 3 8 SAE 52 BLUELINE COBALT SECTION 5 5 13 No Part Number Qty 1 6135 1 o __ _ C o U 7 BLUELINE Description ASSY HEAT EXCHANGER BOX COBALT ASSY ENG EXHAUST BAFFLE COBALT ASSY ENG BLWR EXHAUST COBALT ASSY SILENCER EXHAUST COBALT ASSY ENG MUFFLER HEAT EXCH COBALT HTBX LID GASKET HIGH TEMP SILENCER EXHST GASKET EXHAUST ONAN 154 2747 1 ASSY ENG GROMMET 1 ID X 1 3 40D 53 SECTION 5 48 Gauge MD j 42 di To Dual G gt Heat Exchanger From Temperatue y 3 Control Valve 7 d 19 To Solution Outlet gt E Y Strainer 21 5 9 a EX D To Water Box NN A J J A 2 k 3 P att 5 14 69 141 ASSY PRESSURE REGULATOR COBALT No PartNumber 7 Description 1 29023 1 REG 7670 VITON 2 2100 1 FTTG BULKHEAD3 8BRASS 3 21 602 3 TEE 3 8FXMXFBRASS 4 2t07 1 CONN 38PX1 2TBRASS 5 4706 1 NIP 3 BIN 6 2453 2 FLL 3 8PX14TBRASS 8 21014 1 FTTGBRB38PX12HBR 9 21061 2 FLL 3 8PX12TBRASS
23. Any time you have a water pump problem we are actually looking for a water pump volume problem NOTE WATER MAY BE HOT AND UNDER PRESSURE EXTREME CAUTION SHOULD BE USED Do you have any pressure gauge when the machine is turned off pump pressure reading on the Replace pressure gauge Check the condition of the pump belt Are the belts in good condition and properly adjusted With the key in the run position turn on the pump switch Do you hear the pump clutch engage Is the pump circuit breaker popped Replace pump belt a Remove the lid on the water box Are the filters clean and not crushed Push in the circuit breaker Note If the circuit breaker continues to trip you have an electrical problem Have machine serviced by an authorized BLUELINE service center Clean or replace filters Remove M filters on the outlet manifold Are the filters clean and not crushed Disconnect the wire at the pump clutch With an electrical meter do you have at least 12 6 volts or higher at the pump clutch Replace pump clutch Clean or replace filters Remove and inspect the stainless steel accumulator Make sure the stainless steel accumulator boot is not torn or ripped Make sure the stainless steel accumulator is charged with 300 PSI of dr
24. Cobalt Service and Operation Manual BLUELINE Equipment Co LLC 2604 Liberator Dr Prescott AZ 86301 1 928 445 3030 Congratulations on your purchase of the truck mount cleaning unit This instruction parts manual is a guide for operating and servicing your BLUELINE truck mount unit Proper operation and service are necessary to ensure the outstanding performance of this unit When properly maintained your truck mount will have a long and trouble free life The following service methods outlined in this manual are detailed in a manner that operation and servicing may be performed properly and safely Because service levels vary due to the skill of the mechanic tools and parts availability ensure that prior to attempting any repair you are familiar with this equipment and have the proper tools Any questions regarding the operation service or repair of this unit should be directed to your nearest BLUELINE dealer The headings WARNING and CAUTION are utilized to warn you that steps must be taken to prevent personal injury or damage to the equipment Please make sure that you have read and understand these instructions entirely before proceeding with the operation of this unit THIS UNIT MUST BE INSTALLED BY THE DEALER THAT YOU PURCHASED IT FROM IN ACCORDANCE WITH THE BLUELINE INSTALLATION PROCEDURES PLEASE ENSURE THAT THE WARRANTY CARD IS FILLED OUT BY THE DISTRIBUTOR THAT YOU PURCHASED THIS UNIT FROM
25. D ASSEMBLY tem No Part Number 58 262 PNL COBALT L 2 58 268 PNL RIGHT COBALT 58 267 PNL LEFT HOOD COBALT 4 11 007 NUT THUMB 1 4 20 FKWR HEAD KNOB BLUELINE COBALT 47 SECTION 5 ENGINE INSTALLATION PartNumber Qty ________ Description 1 4500 1 ENGINE KOHLER 20HP CHAMP 2 63040 1 EXHAUST KOHLER PIPE 3 60010 1 PNL MOTOR PULLEY MNTCOBALT 4 5826 1 PNL SHROUDCOBALT 5 23800 1 PULLEY AK4IH 6 03801 21 046 BOX BATTERY HOLDER SCREW MACH 3 8 16 X 3 HXHD 12 014 8 48 BLUELINE COBALT SECTION 5 5 7 ENGINE FUEL SYSTEM No Part Number Qty Description 1 16034 HOSE FUEL 1 4 30R7 2 3607 1 FILTER FUELKUBOTA 3 41017 __ 1 GROMMET 34O0DX12ID ______ 4 16034 HOSE FUEL 1 4 30R7 5 2 06 2 4 6 ___ 6 14042 5 CLAMBHOSEZ8 00000000 8 36019 1 FILTER OIL KOHLERA1205001 ________ BLUELINE COBALT 49 SECTION 5 5 10 WATER TRANSFER SYSTEM Part Number Qty _______ 1 1 2500 1 5 3 8 _____ __2 69140 1 WATERPUMPCOBALT _______ VLV SOLEN 1 4FPX 1 4FP GAUGE WTR PRESS1500PSIDUAL GAUGE WTR TEMP 320 DEG 50 BLUELINE COBALT SECTION 5 13 755 24 Water Input 12 1 4
26. EXTINGUISHER BLUELINE and many government agencies recommend that a fire extinguisher rated for A B and C type fires be installed into any commercial vehicle SECTION 2 CONSOLE TO WASTE TANK CONNECTION 7 Waste Tank e Waste Tank To ta Vacuum Brake an Waste Tank To Waste Pump Waste Pump On Switch Shown with optional waste pump out kit 68 003 BLUELINE COBALT 13 SECTION 3 OPERATION 4 SYSTEMS Water pumping system 15 Heat transfer system 16 Vacuum system 17 Chemical pumping system 18 5 OPERATION Preparation 19 Starting unit 21 Priming the chemical pump 21 Automatic waste pump 22 Operation 22 Cleaning 23 Upholstery cleaning 23 Stair tool cleaning 23 Flood restoration extraction 23 Shut down and daily maintenance 23 Freeze protection 24 14 BLUELINE COBALT 4 SYSTEMS NOTE Read and understand this section of the manual entirely before proceeding This portion of the manual divides the unit up into systems and describes how each system works Prior to proceeding into the operations and maintenance sections of this manual it 15 recommended that you acguire a basic understanding of how the unit functions WATER PUMPING SYSTEM Cold water enters the console through the water inlet connection located on the lower right corner of the right lower front panel The water then flows to the water box through a float valve which shuts off the water when the water bo
27. INE COBALT mobile cleaning unit The COBALT unit is easy to operate however only trained operators should proceed Choke Cable Ignition Switch Throttle Cable Low Water Pressure Override Switch Water Pump Switch Light Switch Transfer Pump Switch __ 30 Amp Main Waste Pump Switch Circuit Breaker 20 Amp Water Pump Circuit Hour Meter 20 Amp TransferPump Circuit Breaker 20 Amp Waste Pump Circuit Breaker _ Chemical Flow Gauge Vacuum Pressure Gauge Water Temperature Gauge Water Pressure _ Chemical Meterin Gauge Valve Chemical Prime Valve BLUELINE COBALT 19 SECTION 3 a SNMP ENSURE THERE IS ADEQUATE FUEL Check the fuel tank to ensure there is adequate fuel to complete the job and transport the vehicle This unit consumes approximately 1 2 to 1 8 US gallons of fuel per hour depending on the speed setting REMOVE TOOLS FROM THE VEHICLE Remove any tools accessories or hoses from the vehicle that you will require WATER SUPPLY CONNECTION NOTE Prior to connecting your water inlet hose to any supply faucet flush out the faucet until the water is free of any debris Also flush out any debris from your water inlet hose 20 BLUELINE COBALT Strainer Check Valve Y Strainer Screen Solution Outlet 4D o __ Temperature Control Valve eid Water Supply 1 Connect the water
28. LT 71 SECTION 5 1997 2002 DODGE FULL SIZE VAN FUEL LINE INSTALLATION 24 lt K Remove Existing Hose 4 And Cut in Half S AL S CAUTION lt 5 Do Not Remove Bali 7 1249 les i Suction Line 24 S 14 4 24 0 S Y 4 9 i lt S JI Fuel Return Line x gt ian To Bottom of Tank gt 5 38 69 004FI KIT FUEL HOOKUP CHEVY DODGE FI No PartNumber Qty Description 1 1400 2 32 Clamp 40 63mm 2 66030 1 ADAPTOR FUELFILLERNECK 2 58 1 STREET 1 8IN BRASS 4 14011 6 CLAMP HOSEFUELAE 5 2007 2 FTTGBRB18PX5 16HBR 6 71808 1 HOSE 3 16X25 1 8PX 8 NOCVR 8 21060 4 14MNPTx5 16 HoseBab 9 24359 2 EL W4INLGSTREETBRASS T 72 BLUELINE COBALT SECTION 5 gt gt o 69 032FI KIT 2004 TF ADAPTOR CHEVY BLUELINE COBALT 73 74 BLUELINE COBALT SECTION 5 69 047 ADAPTOR 2004 FUEL FORD SECTION 5 5 39 68 002 KIT DEMAND PUMP W PLUMBING SS 5 40 68 013 ASSY VAN STORAGE UNIT SS BLUELINE COBALT TS SECTION 5 A 2 5 41 68 014 ASSY SINGLE 5 GAL JUG HOLDER 5 42 68 015 ASSY FURN BLOCK HOLDER SS 76 BLUELINE COBALT SECTION 5 5 43 68 016 RACK DOUBLE CHEMICAL 5 44 68 017 ASSY FIN 120 GAL WTR TNK BLUELINE COBALT 77 SECTION 5
29. N 5 10 ACCESSORIES 10 18 Ba pm 43 11 12 14 gom S LEA M p des 4 Mej 7 7 i tp 3 ET z 9 NG gt 4 5 5 3 2 _ 0 5 12 5 34 68 003 KIT WASTE PUMP EXTERNAL No Part Number Qty 000 6 11005 2 NUT 5 16 18 ZINC 8 6602 1 ADAPTOR HOSE WASTE PUMP 66023 1 NUT HOSE WASTE PUMP 68 BLUELINE COBALT SECTION 5 1992 TO 2002 FORD FUEL LINE INSTALLATION 13 _ Cut Existing Vent Tube 3 From Hose End 4 4 Fuel Suction Line 2 2 4 1 ASD 5 p e f L 7 AL Fuel Return Line gt To Bottom of Tank 5 35 69 005FI KIT FUEL HOOKUP FORD FI No PartNumber Qty Description 1 66031 1 ADAPTOR FUEL FILLERNECK FORD 3 1808 1 HOSE 3 16X 25 1 8P X 1 8P 4 2 06 2 FTTG BULKHEAD 1 4 IN BRASS 5 27406 4 FTTG BRB 1 4PX5 16HBR__ 6 2109 2 4INLGSTREETBRASS ___ 7 145011 6 CLAMP HOSEFUELAE 210388 1 STREET 1 8IN BRASS 9 21007 2 FTTG BRBUBPX516HBR BLUELINE COBALT SECTION 5 CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION Remove Existing Hose And Cut In Half i t 14 7 lt 2 CAUTION a 411 G SA Do Not Cut 4 2 U Inner Hose
30. OBALT 60 010 1 PNL MOTOR PULLEY MNT COBALT 4 61 151 1 ASSY SUPPORT GUARD BLOWER 5 60 009 1 PNL RIGHT REAR HOOD SUPPORT COBALT 6 58270 1 PNL REAR HOOD SUPPRT COBALT 8 600412 1 PNLBELTTENSIONERCOBALT 9 6001 1 PNL BELTGUARDCOBALT 44 BLUELINE COBALT SECTION 5 5 2 Front Sheet Metal No Part Number Qty Description 1 6 58 1 55 00000000 2 58260 1 PNL LWRFRONTCOBALT T 582601 1 PNLLWRRIGHT COBALT 000000 4 5804 1 BRKT FLUIDCONTROL COBALT 5 61357 1 ASSY OILDRAIN BRACKET COBALT _6 6 5 1 ASSY VACUUMINLET COBALT 8 2505 1 DSC 8 8 2800 1 CUP OLFLL1 P 02000000 BLUELINE COBALT 45 SECTION 5 5 5 1 bip P te r 9 Z 4 UNI pm RA an Niz aa 9 oo u K 20 1 2 19 w 21 ar h a IL 21615 99 ir ES 17 24 9 25 22 5 3 COBALT CONTROL PANEL ASSEMBLY PartNumber Qty 6 29012 3 SWITCH PUMP AND AUX DSCVRY _____ 8 2901 11 SWITCH PUSH BUTTON OVERRIDE 9 3007 1 BREAKER 30AMP ______ 46 BLUELINE COBALT SECTION 5 SERRE a v 2 7 t a 55223352 222987 5 4 HOO
31. PUMP ASSY Part Number Qty Description 000000 1 61077 1 STEM VACUUMRELIEF VLV3L AMM 2 41010 1 DIAPHRAGM RELIEF VLV3L 4M 3 6600 1 VAC BRAKE MACHINED 3L 4M 4 2101 2 ELL 8PXTAPOLYBR 5 1500 1 SPRING RELIEF VALVE 6 12021 1 WASHER FLAT 7 16 ZINC 6106 1 ASSY ADAPTORVAC STANDPIPE 9 4602 1 1 VACUUMPUMPTI 406 ______ 61 with sub mount water tank 61 with 100 gallon water tank BLUELINE COBALT 57 SECTION 5 5 22 IDLER PULLEY ASSEMBLY tem No Part Number 1 37 039 2 BELT 5VX630 2 38 017 1 TENSIONER RIGID CHAMP i zam 66 051 1 IDLER BELT TENSIONER 4 66 080 1 SHAFT BEARING SUPPORT 5 66 082 1 PULLEY TENSIONER 5 0 2G 6 39 018 2 BEARING 35MM X 72MM X 17MM 38 019 HUB SK 1 1 8 8 10 037 SCREW MACH 5 16 18 X 2 HXHD 12 016 LKWSR 5 16 21 64 005 KEYSTOCK 1 4 SOUARE X 2 IN 38 027 PULLEY 5V630SK 2G 38 032 HUB SK 1 1 4 10 029 SCREW MACH 3 8 16 X 1 HXHD 12 013 WASHER FLAT 3 8 SAE 12 014 LKWSR 3 8 ZINC 11 016 1 NUT 5 8 11 11 006 2 NUT 3 8 16 ZINC 5 5 16 18 HEX BOLT 19 6 5 16 LOCK WASHER 58 BLUELINE COBALT SECTION 5 MUFFLER EXHAUST ASSEMBLY Part Number Qty Description 1 36 024 2 GASKET EXHT KOHLER 2404102 S EXHAUST KOHLER PIPE 63 092
32. RTER 1 3 RED FUEL SOLENOID ENGINE 88 GREEN PRESSURE HARNESS SACKOE PURPLE VOLTAGE REGULATOR Auxiliary PLUG FACE OF 8 Starter a q PLUG x 4 WHITE BLUE si RED 86 88 ignition H 3 a WHITE BA 6 30 BREAKER b BROWN z 42 30 007 SWITCH SWITCH SWITCH SWITCH 29 001 29 012 29012 7 29 012 4 8 PO ITION TERMINAL Eu ra 5 3 BLOCK 30 019 5 2 5 2 5 21 47 RED 8 4 1 4 ds 4 1 48 L 7 8 7 8 2 2 2 W PUMP T PUMP PUMP o e Somi GRN BLK 3 WHITE DE ORANGE RED z s O 5 gt gt 2 8 2 2 C RED amp d 6 20 AMP BREAKER 3 30 008 FUEL PUMP 36 125 BLK WHT 2 F b HOUR ____ METER 26 010 23 014 VLV SOLEN 1 4FPX X 1 4FP 30 ss a BLUE WHT 340 29 031 SWITCH PUSH LN H PUMP SENDER 140 320 BUTTON OVERRIDE 46 017 34 000 H SHUT OFF OPTIONAL WASTE m ORANGE PUMP KIT WASTE SWITCH SS 68 003 PUMPON T MOH switch f 5 69 002 OH J Low O E PRESSURE 5 E 5 SWITCH BLUE NIC TRANSFER 29 004 RED NIO 81 a 85 i 3 GREEN L LO PUMP 27 KO un BLACK C 82 O PRESSURE BLACK 90 jn SWITCH BLUE SHUT OFF WHITE 89 4 WASTE 29 00
33. TGBRB1 8PX5 6HBR 2121 HOSE 3 16 X24 1 4 X 1 AFT BLUELINE COBALT 61 SECTION 5 WARNING PHIR UNIT AND EGUWUESEMY v A WELL VONTLATED FUMES CONTAIN MOOOC Wi Ich 15 CONE SA AND D y VEREIN THAT CAN EXHAUST FATALITY DO NOT Pure THES UNT ax AN ENCLOSED DO NOT OPERATE Mola Max ENTIA Aber Ble OO DOOPIWAY weis VENT OH Okt OF ANY VACUUM INLETS FATAL DO NOT RUN ENGINE WITH COVER OFF p VOIDS WARRANTY stile pu PFE DRAIN 88381 TE A UNLEADED GASOLINE ONLY OUTLETS SOLUTION TES AWARNING AWARNING n e O Vira WASTE OUTLET 2 PRESSURE 2504 REGULATOR CAN GA FI EET er ESSE Rj SAFETY DEVICE AMO are TT Maset LUBRICATION MW PLACE ya omm 44 000 DECAL SHEET WARNING amp CONTROLS TEMPERATURE CONTROL 44 024 DECAL TEMPURATURE CONTROL 62 BLUELINE COBALT SECTION 5 _ US as pt et INE CSBALT EQUIPMENT CO 44 056 DECAL CONTROL PANEL Cobalt BLUELINE COBALT 63 ELECTRICAL DIAGRAM SECTION 5
34. ank and accessories 1000 Ibs please adhere to the following recommendations prior to installing the unit 1 The unit should NOT be installed in any motor vehicle of less than 3 4 ton capacity CAUTION The console and waste tank with accessories must NOT exceed the vehicles axle weight limit 2 If mounting the unit in a trailer ensure that the trailer is rated for the total weight of the unit and trailer Electric or hydraulic brakes must be provided and strict compliance with all State and Federal laws must be maintained 3 If mounting in a trailer COBALT console must be positioned so that it balances properly with respect to the trailer axle Ten percent 10 of the units total overall weight w o accessories or water should be on the tongue This unit has an air cooled engine and adequate ventilation must be provided to prevent over heating 4 The vehicle tires must have a load rating in excess of the combined unit and vehicle weight 5 BLUELINE does not recommend using any type of flooring materials that absorb water This condition will result in rust and corrosion of the vehicle floor 6 Insulation under rubber mats should be removed prior to installation of the unit FUEL REQUIREMENTS Use unleaded fuel ONLY NEVER use any 6 BLUELINE COBALT SECTION 1 gasoline additives Use only fresh clean unleaded gasoline intended for normal automotive use DO NOT use high octane gasoline with thi
35. ble materials in an enclosed trailer or vehicle NEVER store any type of flammable material in an enclosed trailer or vehicle 12 BLUELINE COBALT SECTION 2 D Always mount fuel tanks where they will be protected from any vehicle collision E When installing fuel lines from the fuel tank to the unit use the proper size fuel line BATTERY CONNECTION WARNING Explosive gases Dangerous gases Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as any other sources of ignition away from batteries at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are in the OFF position If ON a spark could occur at the ground connection terminal which could cause an explosion if hydrogen gas or gasoline vapors are present ALWAYS disconnect the negative terminal first A Attach the red positive battery cable from the starter solenoid on the console to the positive terminal on the battery and tighten down the nut B Attach the black negative battery cable from the ground on the console to the negative terminal on the battery and tighten down the nut FIRE
36. d start over with fresh 100 anti freeze ZM WARNING DO NOT drain used anti freeze on the ground or into storm drains Dispose of anti freeze only in an approved location Observe Local State and Federal laws when disposing of anti freeze 25 SECTION 4 SERVICE amp MAINTENANCE 6 MAINTENANCE Maintenance Chart 28 Engine 29 Vacuum Pump 30 Water Pump 30 Vacuum Inlet Filter 30 Drive Belts Pulleys and Hubs 31 Water Box Water Pump Inlet Filter 31 Strainer Basket 31 Y Strainer Outlet 31 Check Valve Outlet 31 Chemical Pump Chemical Metering System 31 Accumulator 32 Pressure Regulator 32 Vacuum Hoses 32 32 High Pressure Solution Hoses 32 7 GENERAL SERVICE ADJUSTMENTS Engine 33 Vacuum Relief Valve 33 Vacuum Pump Drive Belts 33 Water Pump Drive Belt 33 Float Valve 33 Solution Outlet Check Valve 33 Chemical Pump 34 Packing Nut Adjustment Chemical Metering amp Selector Valves 34 Pressure Regulator 35 26 BLUELINE COBALT 8 TROUBLESHOOTING Water Pump 36 Chemical System 37 Blower Vacuum Pump 38 Engine Will Not Start 39 Engine Does Not Crank 40 System Safety Shut Down 41 Heating System 42 BLUELINE COBALT 27 MAINTENANCE CHART Engine Vacuum Pump Water Pump Vacuum Inlet Filter Waste Tank Strainer Basket Vacuum Hoses Waste Pump Out Optional a 100 Hours Change engine oil and filter Pressure Regulator 100 Hours Lubricate o rings Use only o ring lubricant
37. djusted if the water box is overflowing or the water level in the water box is low 1 If the water box is overflowing remove and check the float valve for damage or debris If the float ball has any water inside of it it must be replaced A CAUTION If replacing the float ball DO NOT over tighten the float rod as it can puncture the ball Ensure that the nuts are tightened on the rod SOLUTION OUTLET CHECK VALVE Inspect the check valve whenever performing service on the chemical pump or if flow problems are occurring in the chemical system 1 Remove the check valve ensuring that the small o ring on the seat comes out with it 33 2 Next remove the seat using a 5 16 in Allen wrench 3 Check the Teflon seat for wear or debris Clean and replace the seat if necessary 4 Inspect the poppet and the spring for wear or damage Clean and replace as necessary 5 Re assemble the check valve Thread the seat by hand until snug Then tighten with a 5 16 in Allen wrench DO NOT over tighten 4 3 2 1 23 063 VLV CHECK CHECK VLV MANIFOLD CAP CHECK VALVE ORING 7 8 ID X 1 1 16 SPRING CHECK POPPET CHECK INSERT SEAT CHK SEAT CHECK VALVE Note Improper seating of the check valve seat poppet damaged spring or o rings will result in poor performance of the chemical system 6 Lubricate the o rings with o ring lubricant Part 13 003 and re install CHEMICAL PUMP The
38. e going from the ST terminal on the ignition switch to the starter Replace starter 40 BLUELINE COBALT SECTION 4 System Safety Shut Down Note Your BLUE WAVE console is eguipped with various safety shut down systems If the system shuts down during operation it may be due to one of these safety shut downs Engine cranks but won t start Do you have at least a half tank of fuel o8 No Add fuel Are the fuel lines and filter clean and unobstructed l Is battery fully charged Above 12 6 volts Is main circuit breaker popped Yes No See Engine Won t Start Disconnect the wires to the oil pressure switch Does the engine start Yes Yes No gt u Replace battery Push in circuit breaker Note If circuit breaker continues to trip you have an electrical problem Have machine serviced by an authorized BLUELINE service center Replace switch switch Does the engine start Replace switch Yes No Is the waste tank full BLUELINE COBALT Empty tank Yes No Replace switch Disconnect the wires to the high temperature See Engine Does Not Crank
39. efficiency in lower concentrations 2 RECEIVING YOUR TRUCK MOUNT UNIT DEALER RESPONSIBILITY THE BLUELINE DEALER THAT YOU PURCHASED THIS TRUCK MOUNT CLEANING UNIT FROM IS RESPONSIBLE FOR THE PROPER INSTALLATION OF THIS MACHINE THE DEALER IS ALSO RESPONSIBLE FOR THE PROPER INITIAL TRAINING OF YOUR OPERATORS AND MAINTENANCE PERSONNEL ACCEPTANCE OF SHIPMENT Your COBALT truck mount cleaning unit was thoroughly tested checked and inspected in its entirety prior to leaving our manufacturing facility When receiving your unit please make the following acceptance check 1 The unit should not show any signs of damage If there is damage notify the common carrier immediately 2 Carefully check your equipment and packing list The standard BLUELINE COBALT unit should arrive with the following items as well as any optional accessories EQUIPMENT LISTING A BLUELINE COBALT console B Operation and Service manual C Installation mounting plates and bolt down kit D Hose clamps for vacuum and fuel hoses E Carpet wand F Waste tank with shutoff switch H Waste tank filter and stainless steel strainer basket BLUELINE COBALT SECTION 1 I 100 ft of 1 4 in high pressure solution hose with quick connects J 100 ft of 2 in vacuum hose K 1 vacuum hose connector L 50 ft water supply hose with quick connect OPTIONAL EQUIPMENT A Additional lengths of vacuum hose Part 18 003 B Additio
40. emperature is at or below 180 deg F This will also help to remove any excess moisture from the vacuum pump NOTE If shutting down for the day Plug the vacuum inlet on the front of the unit and set the throttle control cable to high Spray WD 40 or equivalent into the blower lubrication cup located above the vacuum inlet for 5 seconds This will lubricate the vacuum pump Next return the throttle control cable to idle position and continue step 4 7 Turn the ignition switch to the OFF position 23 8 Turn the water supply faucet off Loosen the water supply hose at the water supply to bleed off any pressure Unhook the water supply hose and return it to the vehicle 9 Activate the valves on all cleaning tools This will relieve any remaining pressure Disconnect the cleaning tools and solution hoses and return them to the vehicle 10 Drain the waste tank disposing of wastewater in a suitable and proper location WARNING NEVER dispose of wastewater in a storm drain water way or on ground areas Always dispose of waste in accordance with Local State and Federal laws 11 Remove the strainer basket from the waste tank Clean out any debris and re install NOTE Damage may occur to the vacuum pump Replacement and maintenance of the filter will prevent rust and corrosion from entering the vacuum pump 12 Inspect the vacuum inlet filter inside the waste tank weekly Remove and clean the filter if there
41. for proper seating Also check the float rod for proper adjustment 2 The filter on the bottom of the inside of the water box is produced out of rubber with a stainless steel screen This filter should be inspected and cleaned on a weekly basis and replaced if damaged NOTE Prior to removing strainer vacuum all excess water and debris from water box WASTE TANK STRAINER BASKET The strainer basket located in the waste tank should be emptied and cleaned on a daily basis Y STRAINER OUTLET Unscrew the screen and inspect the Y strainer after the first week of operation Remove any debris present Inspect again after 2 and 4 weeks Thereafter inspect the Y strainer and screen at least monthly If a frequent build up of debris is noticed inspect and clean more frequently CHECK VALVE OUTLET Inspect the check valve when servicing the chemical pump or as needed Remove the check valve from the Y strainer assembly and disassemble Check the Teflon seat for abnormal wear or debris Replace the Teflon seat if necessary Improper seating of the check valve poppet damaged spring or o rings will result in poor operation of the chemical system CHEMICAL PUMP The chemical pump should be rebuilt every 1000 hours This involves changing the diaphragm check valves and inspecting the disk 31 CHEMICAL METERING SYSTEM Check and inspect the packing nut on the chemical selector and metering valves every 200 hours Keepin
42. g the valve packings properly adjusted will prevent leaks and add to the overall life of the valves ACCUMULATOR Sealed 250 pound nitrogen accumulator Change every 2000 hours or as needed PRESSURE REGULATOR Lubricate the o rings in the pressure regulator every 100 hours Use only o ring lubricant Part 13 003 VACUUM HOSES To ensure maximum hose life BLUELINE recommends that you wash out the hoses with fresh water daily BATTERY WARNING Explosive gases Dangerous acid Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as any other sources of ignition away from batteries at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are in the OFF position If ON a spark could occur at the ground connection terminal which could cause 32 BLUELINE COBALT SECTION 4 an explosion if hydrogen gas or gasoline vapors are present ALWAYS disconnect the negative terminal first 1 If you do not have a maintenance free sealed battery check the fluid level in the battery at least once a week If low fill to the recommended level ONLY with distilled water DO NOT
43. head lock nuts on to the mounting bolts and tighten until the console and waste tank are firmly attached to the vehicle floor SECTION 2 DIMENSIONAL DIAGRAM REAR MOUNT TANK 38 1 2 10 BLUELINE COBALT SECTION 2 DIMENSIONAL DIAGRAM w SUB MOUNT WATER TANK BLUELINE COBALT 11 1 INSTALLATION FUEL LINES IN CAUTION READ THESE INSTRUCTIONS IN THEIR ENTIRETY PRIOR TO PROCEEDING Z WARNING The Vehicle fuel lines should NOT be spliced under ANY circumstances Severe injury or fatality could result DO NOT damage the vehicle in any way during the installation When routing fuel lines DO NOT configure the hoses in any location where the hoses or vehicle could be damaged Avoid contact with moving parts areas of high temperature brake lines fuel lines catalytic converters exhaust pipes mufflers or sharp objects TRAILER FUEL TANK AND FUEL LINE INSTALLATION The following are recommendations for trailer installations A Strict compliance with all federal and state laws must be maintained B Use only fuel tanks that are manufactured specifically for gasoline have proper vented filling caps and outlet connections that are the same size as the inlet and return connections on the unit C DO NOT install fuel tanks inside any type of enclosed trailer or vehicle IN WARNING NEVER carry gasoline or flamma
44. icle doors open in order to ensure adequate ventilation to the engine 5 DO NOT operate unit if gasoline is spilled Do not turn ignition switch until the gasoline has been cleaned up Never use gasoline for cleaning purposes 6 DO NOT place hands feet hair clothing or any body parts near rotating or moving parts Rotating machinery can cause severe injury or death 7 NEVER operate this unit without belt and safety guards High speed moving parts such as belts and pulleys should be avoided while the unit is running Severe injury fatality or damage may result BLUELINE COBALT SECTION 1 8 NEVER service this unit while it is running High speed mechanical parts as well as high temperature components may result in injury or severed limbs 9 Engine components will be extremely hot from operation To prevent severe burns DO NOT touch these areas while the unit is running or shortly after the unit is shut off 10 DO NOT touch any part of the exhaust system while the system is running or for 20 minutes after the unit is shut off Severe burns could result 11 Water under high pressure at high temperature can cause burns severe personal injury or fatality Shut down unit allow to cool down and relieve system of all pressure before removing caps valves plugs fittings filters or hardware 12 NEVER leave the vehicle engine running while the unit is in operation 13 Battery acid contains sulfuric acid To
45. ing the chemical tube into the chemical jug ensure that it stays fully submerged as the chemical pump will not function if air is allowed to enter the inlet line DO NOT operate the chemical pump without the inlet strainer properly installed 2 Turn the 3 way chemical selector valve located on the control panel to the PRIME position The chemical will then flow from the chemical jug through the chemical prime tube If the pump does not prime then Place the chemical prime tube into the vacuum hose and seal off the vacuum hose The vacuum will guickly draw chemical from the chemical jug A fter the flow begins turn the chemical selector valve to OFF position insert the chemical prime tube back into the jug and turn the chemical selector valve back to the PRIME position and continue the procedure 3 Once chemical flow with no air bubbles has been achieved turn the chemical selector valve from PRIME to METER With the cleaning tool open check the flow meter and adjust the chemical metering valve until the desired rate of chemical flow is achieved AUTOMATIC WASTE PUMP 1 If your unit is eguipped with an optional automatic waste pump connect one end of the 5 8 inch or larger garden hose to the pump out connection and the other end to an acceptable waste disposal 2 Turn the pump out switch located on the front console control panel to the ON position 22 BLUELINE COBALT SECTION 3 The waste pump will now operate a
46. ing valve Does the system meter where you want it to when you trigger your wand System OK Replace chemical selector valve Diaphragm in the chemical pump is ruptured Replace or rebuild chemical pump BLUELINE COBALT See Water Pump or Start from the beginning Replace chemical metering valve 37 Blower Vacuum Pump SECTION 4 Note Make sure the blower has oil the waste tank is empty and the waste tank filters are clean and not damaged Note Any time you have a blower vacuum problem we are actually looking for an air volume problem Do you have any vacuum reading on the vacuum gauge when the machine is turned off Replace vacuum gauge Yes No Does the engine crank Check the condition of the blower belts Are the belts in good condition and properly adjusted Remove the blower belts Can you spin the blower pulley with your hand 9 Noo Replace blower belts Are the dump valves closed on the waste tank See Engine Won t Start Rebuild or replace blower Are the gaskets in good condition on the waste tank Yes INo gt Close dump valves m Are there any cracks or splits in the waste tank er Ye s
47. is NOT recommended 1 Check the oil level weekly on both sides to ensure they are at the proper level Too little oil will damage and ruin the bearings and gears Too much oil will result in overheating m om 2 2 A lubrication cup has been provided at the front of the console to prevent rust from building up inside of the vacuum pump Run the unit for at least 2 minutes to remove any moisture from the vacuum pump Then spray WD 40 or Equivalent into the lubrication cup for 5 seconds while the unit is running and the vacuum inlet port is sealed This procedure should be done 30 BLUELINE COBALT SECTION 4 at the end of every working day with the waste tank empty 3 Drain flush and replace the oil every 1000 hours or yearly whichever comes first NOTE Two drains are on your blower Ensure that both sides of the vacuum pump are filled to their proper level when servicing WATER PUMP Refer to the provided Water Pump Operation Manual for specific instructions 1 Check the crankcase oil level daily to ensure the proper level If the level has dropped check for the source of leakage and repair OU Filter Cap Cd Lowel hegre Gauge Water Pump 04 2 After the first 50 hours of operation change the crankcase oil with CAT Pump Crankcase Oil Part 13 000 Change the crankcase oil every 500 hours thereafter VACUUM INLET FILTER 1 The vacuum inlet filter in the waste tank should be i
48. nal vacuum hose connectors Part 21 003 C Additional high pressure solution hoses Part 18 000 With shutoff valve Part 18 001 D Automatic waste pump kit Part 68 003 E Demand pump system Part 68 002 F KIT FUEL HOOKUP CHEVY 97 TO 2002 FI Part 69 003FI G KIT FUEL HOOKUP CHEVY DODGE FI Part 69 004FI KIT FUEL HOOKUP FORD FI Part 69 005 FI I KIT FUEL HOOKUP 2003 CHEVY FI Part 69 018FI J KIT 2004 TF ADAPTER CHEVY Part 69 032 K KIT 2004 TF FUEL INJ CHEVY Part 69 033 L ADAPTOR 2004 FORD FUEL Part 69 041 M ADAPTOR 2004 FUEL INJ FORD Part 69 041FI SECTION 2 INSTALLATION 3 INSTALLATION Lifting the unit into the vehicle Positioning the unit into the vehicle Fastening down the unit and waste tank Dimensional diagrams Installation of fuel lines Trailer fuel tank and fuel line installation Battery Connection Fire extinguisher Console to waste tank connection 8 BLUELINE COBALT 9 12 12 12 12 13 3 INSTALLATION Z WARNING This unit must be bolted to the floor of the vehicle by an authorized BLUELINE DISTRIBUTOR LIFTING THE UNIT INTO THE VEHICLE The BLUELINE COBALT weighs approximately 640 Ibs a forklift is necessary to place the unit into the vehicle Place the forks into the forklift slots from the front of the unit and make CERTAIN that the forks are spread to the maximum width of the unit POSITIONING THE UNIT INTO THE VEHICLE
49. nspected daily and removed and cleaned weekly The filter will last for a long period of time if this is done 2 Inspect the vacuum filter inside the waste tank Remove and clean filter if there is any lint or debris present A CAUTION When removing the vacuum inlet filter grip the plastic hexagon section of the filter Grasping filter by the screen will damage or destroy the filter DRIVE BELTS PULLEYS amp HUBS 1 Check pulley set screws and hub screws after the first 50 hours of operation and again at 100 hours Re torque these screws with a torque wrench Follow the torque values on the following table Check pulley set screws and hub screws every 500 hours thereafter CAUTION Ensure that when you re torque the screws you use a clockwise pattern and continue until the proper torque is achieved TORQUE VALUES Component Inch Ibs Foot lbs Engine Hub 324 27 Vacuum Pump Hub 192 16 2 The COBALT unit features an Adjustable Belt Tensioning system This system eliminates the need for sliding the vacuum pump to achieve the proper belt tension However belts and pulleys should be checked periodically for wear They should also be cleaned and inspected regularly If wear or glazing is discovered replacement is recommended WATER BOX 1 The float valve should be checked at least monthly for proper operation If overfilling is BLUELINE COBALT SECTION 4 noted check the plunger
50. ny visible leaks in the chemical system b _ lt lt Yes A Stick the prime hose into the vacuum outlet d Does the chemical system prime Yes No m Do you see any air bubbles FLOW METER _ Yes I No Repair leaks Repair leak between chemical lt Yes I No gt jug and chemical pump a Repair leak between chemical jug and FLOW METER Prime the chemical system Turn the chemical system off and look at the FLOW METER to see if chemical is flowing towards the chemical jug Is the chemical flowing towards the chemical jug Repair leak between FLOW METER and chemical pump A Turn the chemical selector valve to the CHEMICAL position Does the system pull chemical Turn the chemical selector valve to the OFF position No Does the system pull chemical Does the system pull chemical a when you trigger your wand Outlet manifold check valve is bad Replace or rebuild check valve Look at the prime hose Is there chemical coming out of the prime hose when the chemical selector valve is in the OFF position Hook up your wand Open the metering valve Does the system pull chemical when you trigger the wand Can you adjust your meter
51. o the stainless steel pulsation chemical pump Then the chemical pump injects the chemicals through the check valve to the three way selector valve located on the front panel This valve may be used to turn the chemical flow ON OFF or to PRIME the chemical pump Chemical Supply Line AN nn Flow Mater Chemical _ Prime Line 3 Way Selector Valve Chemical Metering Valve 27 4 fa Temperature Control Valve Y Connector Solution Outlet Manifold Solution Outlet 18 BLUELINE COBALT SECTION 3 The chemicals then flow through the chemical metering valve to the solution outlet This valve controls the rate of flow of chemical into the cleaning solution which is indicated on the flow meter and Low Pressure Shut Off Switches A m AL T ATE viz E TNNSS NE y lt Stainless Steel Chemical Pump SECTION 3 3 OPERATION PREPARATION N WARNING Operate this unit and equipment only in a well ventilated area Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or death DO NOT run this unit in an enclosed area DO NOT operate this unit where the exhaust may enter a building doorway window vent or any other opening This section of the operator s manual explains how to prepare start operate shut down and maintain your BLUEL
52. on for the COBALT unit A planned preventative maintenance program will ensure that your BLUELINE COBALT has optimum performance long operating life and a minimum amount of down time WARNING WARNING nA SHOCK 0 CASE SEVERE 1 v OR a BATTERY REPORE COULD GE FATAL KEEP ALI GUARDS AMD GATETY Of CES IN PLACE nes uwt TO PREVENT ACCIDENTAL HOT SURFACE DO NOT TOUCH 284 NWARNING DO NOT attempt to service this unit while it is running High speed parts as well as high temperature components may result in severe injury severed limbs or fatality NOTE Refer to the hour meter as a guide for coordinating a maintenance schedule BLUELINE COBALT SECTION 4 ENGINE 1 Check the engine oil level daily Ensure that the proper oil level is maintained NEVER overfill 2 Change the oil after the first 50 hours of operation after the break in period Thereafter change oil every 100 hours of operation USE ONLY KOHLER BRAND OIL FILTERS USE OF ANY OTHER TYPE OF OIL FILTER WILL VOID ENGINE WARRANTY Oil Recommendation The engine is shipped with Castrol Syntec Blend amp SAE 10W 30 synthetic motor oil Use only high quality synthetic oil of at least API American Petroleum Institute service class SG SH SJ or higher USE 10W 30 API SG SH SJ OR HIGHER F 22 4 14 3
53. osition Do you have at least 12 6 volts or higher separate container Turn the key to the RUN at the fuel pump position Is there gasoline being pumped Replace fuel pump and filter Yes No Disconnect and remove oil pressure switch and wires Install a 30 PSI gauge Start the engine and verify engine builds oil pressure Does the engine build oil pressure Install the oil pressure switch Leave the NM shutdown wires disconnected Yes No Does the engine start When the engine is cold with a compression NM gauge test each oylinder Yes No Do all the cylinders test 180 PSI 10 or between 165 PSI and 195 PSI Have machine serviced by an authorized BLUELINE service center Take engine to an authorized Kohler engine repair center 1 When engine is cold test for a spark at the ignition coil Do you have a spark T When engine is cold test for a spark at each cylinder Do you have a spark at each cylinder When engine is cold remove the air filter pru Is the air filter clean Take engine to an authorized Replace air filter Kohler engine repair center S BLUELINE COBALT 39 SECTION 4 Engine Does Not Crank Note Make sure the engine has oil
54. part 13 003 100 Hours Clean battery terminals 200 Hours Clean engine air filter 500 Hours Replace in line fuel filter Pulleys and Hubs 500 Hours Check pulley and hub set screws for proper torque 1000 Hours Replace spark plugs 1000 Hours Drain flush and replace oil 100 Hours Grease bearings with extreme pressure bearing grease 500 Hours Change crankcase oil Chemical Metering System 200 Hours Inspect packing nut on selector and metering valve Adjust as needed To maximize the operating life and performance use only recommended oils filters and greases Monthly Check float valve for proper operation Monthly Clean and remove any debris 200 Hours Check spark plugs and clean if necessary High Pressure Solution Hoses Inspect for wear damage or impending rupture Replace if damaged Or as often as required Change engine oil and oil filter after first 50 hours of operation Change water pump crankcase oil after first 50 hours of operation Inspect after first week of operation and remove any debris present Inspect again after 2 to 4 weeks Check pulley and hub set screws after first 50 hours of operation and again at 100 hours of operation Or every 6 Months Whichever comes first Or Yearly Whichever comes first 28 BLUELINE COBALT 6 MAINTENANCE This section of the operator s manual contains the service and maintenance informati
55. rs This will prevent fuel leaks and ensure that hoses are not punctured by vehicle vibration abrasion 17 DO NOT exceed your vehicles weight limit The console with waste tank and accessories weighs approximately 1000 pounds Make certain that the vehicle has the correct axle rating This will prevent unsafe or hazardous driving conditions 18 High back seats are reguired for all vehicles that units are to be installed for head and neck protection Metal partitions between the seats and eguipment are strongly recommended 19 DO NOT operate this unit without the water supply on and attached The water pump and other vital components could be seriously damaged if the unit is operated dry This unit is eguipped with a low pressure shut down switch which should NOT be bypassed 20 Always keep your vehicle clean and orderly Wands tools and accessories must be securely stowed while driving the vehicle 4 BLUELINE COBALT SECTION 1 21 All high pressure hoses must be rated at 3000 PSI and have a heat rating of 250 degrees F Thermoplastic hoses do not meet this criteria and should never be used Severe burns and other injuries could result if hoses do not meet these requirements 22 Ensure that you have received proper training from the distributor that you purchased the unit from prior to operation 23 This unit produces high pressure and high temperatures Improper use could result in serious injury 24 DO NOT modif
56. s unit ENGINE OIL REQUIREMENTS The engine is shipped with Castrol Syntec Blend SAE 10W 30 synthetic motor oil Use only high quality synthetic oil of at least API American Petroleum Institute service class SG SH SJ or higher USE 10W 30 API SG SH SJ OR HIGHER F 22 4 14 32 59 30 20 10 0 15 NOTE The use of less than service class SG SH SJ or higher oil or extending the oil change intervals longer than recommended can result in engine damage CHEMICAL REQUIREMENTS The BLUELINE COBALT truck mount unit s unique last step chemical injection system can be used with a wide variety of water diluted chemical compounds either acidic or alkaline depending on the work to be performed We recommend using only the highest quality chemistry WATER REQUIREMENTS Because hard water deposits will damage the plumbing and heat exchange systems on this unit BLUELINE recommends that a high quality water softener be used in areas where the water hardness exceeds 3 1 2 grains If a water softener is used it must have a flow capacity of at least five 5 GPM or greater without any hose constrictions The use of a water softening system will reduce maintenance and reduce down time caused by hard water scaling It will also enhance the performance of cleaning chemicals which will result in greater
57. sconnect the water inlet hose from the console 2 Connect all solution hoses and tools that may have water in them to the console 3 Start the unit with the water pump in the ON position Open a tool valve This will result in the low pressure switch shutting down the unit when the water box is emptied 4 Fill the water box with two gallons of 100 glycol based anti freeze 5 Start the unit and set the throttle control cable to the idle position Turn the water pump switch to the ON position Open a tool valve until anti freeze comes out of the tool Repeat this procedure with ALL remaining tools and hoses 6 After the tools and solution hoses have been filled with anti freeze disconnect and store them Recover all anti freeze that comes out of the tools and hoses and store in an approved container ALWAYS re use and re cycle anti freeze 7 Prime the chemical injection system with a 100 glycol based antifreeze Insert the chemical inlet and prime tube into the anti freeze container Turn the chemical valve to PRIME until anti freeze comes out of the prime hose Turn the chemical valve to the ON chemical position Ensure that the flow meter indicates flow Ensure that all anti freeze that comes out of the chemical hose goes into an approved container After 25 seconds turn the chemical valve to the OFF position 8 Adjust the temperature control valve to the cold water position Allow the unit to run for at
58. sh and pull strokes provided that the final stroke is a pull stroke with no chemical injection UPHOLSTERY CLEANING 1 Upholstery tools have a lower flow rate and smaller orifices A djust the temperature control valve to the desired temperature To maintain proper cleaning temperatures make certain that the unit has been fully heated up prior to cleaning 2 Always clean upholstery with a pressure setting below 300 PSI by using the pressure regulator on the unit STAIR TOOL CLEANING 1 Adjust the temperature control valve to the desired temperature To maintain proper cleaning temperatures make certain that the unit has been fully heated up prior to cleaning BLUELINE COBALT SECTION 3 FLOOD RESTORATION EXTRACTION A CAUTION 1 Set the throttle control cable on the front control panel to the desired setting Make certain that the water pump switch is in the OFF position Proceed into the extraction process SHUT DOWN AND DAILY MAINTENANCE 1 Flush out the chemical system with fresh water to remove any chemical residue 2 Remove as much moisture from the vacuum hoses as possible This will prevent spillage of wastewater in your vehicle when returning hoses 3 Disconnect the vacuum hose from the front of the unit 4 Adjust the throttle cable to the idle position 5 Adjust the temperature control valve to the hot water position 6 Allow the unit to run for at least 2 minutes or until the water t
59. sher Console to Waste Tank Connection SECTION THREE OPERATION 14 4 SYSTEMS Water Pumping System Heat Transfer System Vacuum System Chemical System 5 OPERATION Equipment setup Instrumentation Starting Your Unit Priming the Chemical Pump Waste Pump Operation Cleaning Upholstery Cleaning Stair Tool Cleaning Flood Restoration Shut Down and Daily Maintenance Freeze Protection SECTION FOUR MAINTENANCE and SERVICE 26 MAINTENANCE CHART 0 0000000 6 7 GENERAL SERVICE ADJUSTMENTS 0 8 TROUBLESHOOTING OJ SECTION FIVE PARTS and ACCESSORIES 43 9 ILLUSTRATED PARTS LISTINGS 10 ACCESSORIES BLUELINE COBALT HI 15 28 29 33 35 44 68 SECTION 1 GENERAL INFORMATION 1 SAFETY Safety Specifications Installation requirements Fuel requirements Engine oil requirements Chemical requirements Water requirements NNDDDMNN 2 RECEIVING YOUR TRUCK MOUNT UNIT Dealer responsibility 7 Acceptance of shipment 7 Equipment listing 7 Optional equipment Z BLUELINE COBALT 1 1 SAFETY SECTION 1 ZM WARNING For Your Safety The following WARNING labels are on your COBALT console These labels point out important Warnings and Cautions which must be followed at all times Failure to follow warnings could result in personal injury fatality to yourself and or others or property damage Please follow these instructions carefully DO NOT remove
60. supply hose to the water inlet quick connector on the front of the unit Connect the hose to the faucet NOTE Never use a waste pump outlet hose as a water inlet hose Use only clean hoses for water supply 2 Turn the water supply faucet on Water will fill the water box HIGH PRESSURE HOSE Before starting the unit connect the high pressure hose to the solution outlet connection at the front of the unit Connect the cleaning tool to the opposite end of the pressure hose 5 1 za 1 v OTA TING CAUSE On COULD UE FATAL KEEP ALI GUARDS AMD GATETY DEMCES IN PLACE VACUUM HOSE Connect the vacuum hose s to the vacuum inlet connection at the front of the unit Connect the opposite end ofthe vacuum hose s the cleaning tool JET SIZING BLUELINE recommends that the total floor tool size does not exceed 04 Using larger jet sizes on your COBALT unit may reduce cleaning temperatures Example Four jet wand uses four 95015 jets 95 deg Spray angle w 015 orifice 015x4 06 Example Four jet wand uses four 9501 jets 95 deg Spray angle w 01 orifice 01 x 4 04 x 2 tools 08 Upholstery tool jet size 80015 Stair tool jet size 9502 STARTING THE UNIT A CAUTION DO NOT operate this unit without constant water flow to the console The low pressure switch will automatically shut down the unit if the water pressure in the
61. ulator so that the pressure gauge reads 350 PSI with the tool valve open With the tool valve open there should be a normal drop of approximately 100 PSI in pressure If the drop is greater than 100 PSI it may be necessary to lubricate the pressure regulator o rings 2 To adjust the pressure regulator turn the adjusting knob while observing the pressure gauge on the control panel until you reach the desired pressure Loosen Mut aed Crewe Valve Stern Freee Vales Body To Service Senn 11 BLUELINE COBALT SECTION 4 8 TROUBLESHOOTING IN WARNING DO NOT attempt to service this unit while it is running High speed parts as well as high temperature components may result in severe injury severed limbs or fatality This section of the operator s manual describes how to look for and repair malfunctions which may occur Accurate troubleshooting is based on a thorough and complete understanding ofthe WATER CHEMICAL VACCUM HEAT TRANSFER SAFETY and WIRING systems featured in this unit If there are malfunctions occurring on this unit which you do not understand refer back to the OPERATION section of this manual and review SYSTEM 33 SECTION 4 Water Pump Note Make sure the water pump has oil the water box is full of water and the chemical system is turned off Depress the low pressure override switch and attempt to start unit before proceeding with diagnostics Note
62. utomatically throughout the cleaning period DO NOT use an outlet hose that is smaller than 5 8 in LD NEVER use a waste pump hose as a water inlet hose IN WARNING NEVER dispose of waste water in a storm drain water way or on ground areas Always dispose of waste in accordance with Local State and Federal laws OPERATION After you have completed the previous steps proceed with the cleaning or restoration operation Place the throttle control cable to the desired cleaning mode for restoration or cleaning A float shut off switch is located inside of the waste tank It will automatically shut down the unit if the tank reaches its full capacity If this occurs empty the waste tank before continuing When doing flood extraction the water pump should be in the OFF position CLEANING While cleaning observe the following guidelines 1 Before cleaning ensure that the wand nozzles are functioning properly A Hold the wand approximately one foot above the surface to be cleaned and open the wand valve A full even spray should emit from the cleaning nozzles B Ifthe nozzles are not showing a full even spray pattern adjust clean or replace the nozzles if reguired 2 Usually chemical solution is applied during the push stroke of the wand during cleaning and extraction is done on the pull stroke For heavily soiled carpets the wand may be used in a scrubbing action with chemical solution applied in both pu
63. x is full Water then flows through a strainer in the water box to the water pump The water pump is plumbed to a nitrogen charged accumulator which helps reduce pressure pulsations The water pump assembly also includes a high pressure and a low pressure shutdown switch These switches will shut down the unit if the water pressure exceeds 1200 PSI or drops below 50 PSI for more than 5 seconds Simultaneously water is then pumped to the pressure regulator assembly which provides and maintains the desired pressure setting Water then flows from the pressure regulator through the dual heat exchanger where it is super heated by the blower and engine exhaust The water then flows through the check valve manifold that contains a Y strainer and a check valve At this point the chemical injection takes place BLUELINE COBALT SECTION 3 The hot solution mixture of water and chemicals then flows through the solution outlet manifold to the cleaning tool Temperature is controlled with the temperature control valve Water temperature is maintained by mixing cooler water from the water box with heated water from the dual exhaust heat exchanger 15 SECTION 3 HEAT TRANSFER SYSTEM See figures 3 1 and 5 10 Water is heated through a Pressurized water flows through the heat dual heat exchange system that utilizes engine exchanger coils and collects heat from both the exhaust and blower exhaust The engine and engine and blower e
64. xhaust blower exhaust are directed through the dual heat exchange system Dual Exhaust Heat Exchanger Water Temperature _ Gauge Water Pressure Gauge 16 BLUELINE COBALT VACUUM SYSTEM See figures 3 2 and 5 20 The vacuum flow is initiated by the vacuum pump or blower An air and water mixture is drawn into the vacuum inlet on the waste tank The mixture flows through a strainer basket in the waste tank and then into the tank The air exits the waste tank through a 100 mesh filtration system into the vacuum pump A vacuum pump relief valve is installed for vacuum pump protection Engine Muffier Vacuum Muffler N Dual Exhaust Exchanger Vacuum Gouge BLUELINE COBALT SECTION 3 The air is discharged from the vacuum pump through a spiral silencer and then through the dual exhaust heat exchanger A level shut off sensor is located near the top of the waste tank and will shut down the unit before the tank is at full capacity This protects the vacuum pump from water damage Note Waste tank level shut off will not shut the unit off due to high levels of foam The use of a quality defoamer is recommended Q __ Filter Basket 17 CHEMICAL PUMPING SYSTEM See figures 3 3 and 5 25 The chemicals are drawn from the chemical jug through a strainer into the flow meter The flow meter indicates the rate of chemical flow The chemicals then flow through the check valve int
65. y nitrogen Is the stainless steel accumulator in good condition With an electrical meter do you have at least 12 6 volts or higher at the pump switch 2224 pump switch Repair wire going from the Replace pump switch to the pump clutch Rebuild or replace stainless steel accumulator Disconnect all the stainless steel high pressure hoses on the pump Attach a hose to the pump Attach a jumper wire on the terminal block from the bottom red wire 8 terminal to the blue wire with a black stripe 5 terminal Start the machine and set the throttle control speed to CARPET Measure the volume of water coming out of the pump Do you get at least 4 0 GPM out of the pump inspect the valves in the pump 6 total Remove jumper wire Remove and Do the valves operate properly Replace pressure regulator Rebuild or replace pump 36 BLUELINE COBALT Replace valves SECTION 4 Chemical System Note Use a jug with fresh water to diagnose the chemical system Note If the chemical system works with just fresh water your problem is with your chemicals and not the system Note Make sure the water pump system is working properly before you proceed Start the machine and engage the pump Turn the chemical selector valve to prime Does the chemical system prime Are there a
66. y this unit in any manner Any modification could result in serious injury or fatality 25 California Proposition 65 Warning Engine exhaust from this product contains chemicals known by the State of California to cause cancer birth defects or other reproductive harm SPECIFICATIONS Engine Speed Water Pump RPM Vacuum Pump RPM Water Flow Rate Water Pump Pressure Vacuum Relief Valve Waste Tank Capacity Console Weight Console Weight with waste tank amp accessories Console Weight W Submount Tank TOROUE VALUES Engine Hub Vacuum Pump Hub JET SIZING BLUELINE recommends that the total floor tool tip size does not exceed 04 Using larger jet sizes on your unit may reduce cleaning temperatures SECTION 1 2800 rpm High Speed No Load 1400 rpm Idle No Load 1485 rpm 3195 rpm 4 2 GPM maximum 1200 PSI maximum 13 in HG 70 Gallons at shutoff 640 165 1000 Ibs 1300 Ibs 324 inch lbs 27 ft lbs 192 inch Ibs 16 ft Ibs Example Four jet wand uses four 95015 jets 95 deg Spray angle w 015 orifice 015 x 4 06 Example Four jet wand uses four 9501 jets 95 deg Spray angle w 01 orifice 01x 4 04 Upholstery tool jet size 80015 BLUELINE COBALT Stair tool jet size 9502 INSTALLATION REQUIREMENTS Prior to beginning the installation read the ENTIRE Installation section of this manual Since the COBALT truck mount unit weighs with waste t

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