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HAZINATOR

Service and Operation Manual

BLUE

LINE Equipment Co. LLC

2604 Liberator Dr., Prescott, AZ 86301 1-928-445-3030

Summary of Contents for HAZINATOR

Page 1: ...HAZINATOR Service and Operation Manual BLUELINE Equipment Co LLC 2604 Liberator Dr Prescott AZ 86301 1 928 445 3030 ...

Page 2: ... 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 INSTALLATION SERVICE CENTER THAT INSTALLED THIS UNIT AND IS RETURNED TO BLUELINE EQUIPMENT LLC Record your units serial number ...

Page 3: ...per repair freezing or damage due to hard water scaling Electrical components disposable filters belts hoses fittings o rings and other service maintenance items are not under warranty Components supplied by BLUELINE but provided by other manufacturers will only be warranted to the extent that they are warranted to BLUELINE To receive warranty service products must be returned to a BLUELINE design...

Page 4: ...ERATION 8 3 SYSTEMS 9 Water Pumping System Vacuum System 4 OPERATION 11 Equipment setup Instrumentation Starting Your Unit Operation Hazardous Waste Removal Shut Down and Daily Maintenance Freeze Protection SECTION THREE MAINTENANCE and SERVICE 16 MAINTENANCE CHART 17 5 MAINTENANCE 18 6 GENERAL SERVICE ADJUSTMENTS 21 7 TROUBLESHOOTING 23 SECTION FOUR PARTS and ACCESSORIES 29 9 ILLUSTRATED PARTS LI...

Page 5: ......

Page 6: ...TY Safety 2 Specifications 5 Fuel requirements 6 Engine oil requirements 6 Water requirements 6 2 RECEIVING YOUR CLEAN UP UNIT Dealer responsibility 6 Acceptance of shipment 6 Equipment listing 6 Optional equipment 7 BLUELINE HAZINATOR 1 ...

Page 7: ...sole 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 these decals BLUELINE HAZINATOR 2 ...

Page 8: ...cal parts as well as high temperature components may result in injury or severed limbs 8 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 9 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 resul...

Page 9: ...Tools and accessories must be securely stowed while towing the unit 17 All high pressure hoses must be rated at 3000 PSI Severe injuries could result if hoses do not meet these requirements 18 Ensure that you have received proper training from the distributor that you purchased the unit from prior to operation 19 This unit produces high pressure Improper use could result in serious injury 20 DO NO...

Page 10: ...pacity 110 Gallons at shutoff TORQUE VALUES Engine Hub 720 inch lbs 60 ft lbs Vacuum Pump Hub 192 inch lbs 16 ft lbs JET SIZING BLUELINE recommends that the total floor tool tip size does not exceed 045 Using larger jet sizes on your BLUELINE HAZINATOR unit may reduce cleaning efficiency Example Four jet wand uses four 9501 jets 95 deg Spray angle w 01 orifice 01 x 4 04 Upholstery tool jet size 80...

Page 11: ... without any hose constrictions The use of a water softening system will reduce maintenance and reduce down time caused by hard water scaling 2 RECEIVING YOUR CLEAN UP UNIT DEALER RESPONSIBILITY THE BLUELINE DEALER THAT YOU PURCHASED THIS HAZARDOUS WASTE CLEAN UP UNIT FROM IS RESPONSIBLE INITIAL TRAINING OF YOUR OPERATORS AND MAINTENANCE PERSONNEL ACCEPTANCE OF SHIPMENT Your BLUELINE HAZINATOR haz...

Page 12: ...onal vacuum hose connectors Part 21 003 C Additional 3 8 x 50 high pressure solution hoses Part 18 093 FIRE 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 BLUELINE HAZINATOR 7 ...

Page 13: ...N 2 OPERATION 4 SYSTEMS Water pumping system 9 Vacuum system 10 5 OPERATION Preparation 11 Starting the unit 13 Operation 13 Waste Removal 14 Shut down and daily maintenance 14 Freeze protection 14 BLUELINE HAZINATOR 8 ...

Page 14: ... water tank through the water inlet connection located on the water pump The water pump is plumbed to a nitrogen charged accumulator which helps reduce pressure pulsations Simultaneously water is then pumped to the pressure regulator assembly which provides and maintains the desired pressure setting The pressure regulator assembly also includes a high pressure and low pressure shutdown switch Thes...

Page 15: ...nstalled for vacuum pump protection The air is discharged from the vacuum pump through a spiral silencer and then through an engine exhaust silencer A level shut off sensor is located near the top of the waste recovery 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 if deb...

Page 16: ...asy to operate However only trained operator s should proceed 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 3 4 BLUELINE H...

Page 17: ...necting 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 1 Connect the water supply hose to the water inlet quick connector on the water pond 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 supp...

Page 18: ...h 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...

Page 19: ...r 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 water supply hoses and return them to the vehicle 10 Drain the waste tank disposing of wastewater in a suitable and proper location NEVER dispose of wastewater in a storm drain water way or on ground areas Always dispose of waste in accor...

Page 20: ...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 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 BLUELINE HAZINATOR 15 ...

Page 21: ... Pressure Regulator 20 Vacuum Hoses 20 Battery 20 High Pressure Solution Hoses 21 7 GENERAL SERVICE ADJUSTMENTS Engine 21 Vacuum Relief Valve 21 Vacuum Pump Drive Belts 21 Water Pump Drive Belt 22 Float Valve 22 Pressure Regulator 22 8 TROUBLESHOOTING Water Pump 24 Blower Vacuum Pump 25 Engine Will Not Start 26 Engine Does Not Crank 27 Engine Runs for 5 Seconds 28 BLUELINE HAZINATOR 16 ...

Page 22: ...cuum Pump 100 Hours Grease bearings with extreme pressure bearing grease Pressure Regulator 100 Hours Lubricate o rings Use only o ring lubricant part 13 003 Battery 100 Hours Clean battery terminals Engine 200 Hours Check spark plugs and clean if necessary Engine 200 Hours Clean engine air filter Engine 500 Hours Replace in line fuel filter Water Pump 500 Hours Change crankcase oil Pulleys and Hu...

Page 23: ...ange 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 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 Determine the viscosity based on the air temperature a...

Page 24: ...le oil will damage and ruin the bearings and gears Too much oil will result in overheating 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 ...

Page 25: ...Hub 720 60 Vacuum Pump Hub 192 16 2 If wear or glazing is discovered replacement is recommended WATER POND 1 The float valve should be checked at least monthly for proper operation If overfilling is noted check the plunger for proper seating STAINLESS STEEL ACCUMULATOR Sealed 250 pound nitrogen accumulator Change every 2000 hours or as needed PRESSURE REGULATOR Lubricate the o rings in the pressur...

Page 26: ... 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 Thermoplastic hoses do not meet this requirement and should not be used Severe injury may result if the hoses do not meet these requirements 7 GENERAL SERVICE ADJUSTMENTS DO NOT attempt to service this unit while it is runnin...

Page 27: ...ris PRESSURE REGULATOR The pressure regulator holds water pressure at a preset point and bypasses this 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 regulator 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 approxima...

Page 28: ... operator s manual describes how to look for and repair malfunctions which may occur Accurate troubleshooting is based on a thorough and complete understanding of the WATER VACUUM 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 or TROUBLESHOOTING BLUELIN...

Page 29: ...r N ote if circuit breaker continues to trip you have an electrical problem H ave m achine serviced by an authorized B LU E LIN E service center D isconnect the w ire at the pum p clutch W ith an electrical m eter do you have at least 12 6 volts or higher at the pum p clutch Y ES N O R eplace pum p clutch R epair w ire from pum p sw itch to pum p clutch D isconnect all high pressure hoses from pum...

Page 30: ...the vacuum feel normal but the gauge reads different Replace vacuum gauge YES When you start the machine does the vacuum feel different than the vacuum gauge reads Start the machine and set throttle to high speed Seal the vacuum ports Does the vacuum gauge read 14 HG NO YES YES NO YES NO There is a blockage between the vacuum inlet and the waste tank Vacuum system is normal Adjust vacuum relief va...

Page 31: ... volts or higher at the fuel pump YES NO YES NO Replace fuel pump and filter When the engine is cold test each cylinder with a compression gauge Does each cylinder measure within 10 of each other When the engine is cold test for spark at each spark plug Do you have spark at each plug NO YES When the engine is cold remove air filter Is the air filter clean and undamaged NO YES Take engine to an aut...

Page 32: ...have at least 12 6 volts or higher at the ignition switch BAT terminal Is the wire to the starter undamaged and tightly connected to the starter Replace fuel pump and filter YES NO Disconnect the wire from the starter With an electrical meter do you have 12 6 volts or higher when the ignition switch is turned to the start position YES NO Replace ignition switch Repair or replace wire from starter ...

Page 33: ...ect a continuity meter to the green wire termial on the KOHLER engine plug and the engine ground Start the engine Does the oil sentry switch open YES NO Inspect and repair wiring Note Make sure the engine has oil waste recovery tank is empty and you have at least a half tank of gasoline Turn OFF all switches Water Pump and Auxillary switch Does the engine start and run for 5 seconds Disconnect the...

Page 34: ...SECTION 5 SERVICE MAINTENANCE 9 ILLUSTRATED PARTS LISTINGS Sheet Metal 30 Engine 33 Water Transfer System 35 Vacuum Exhaust System 38 Waste Tank 41 Decals 42 Electrical Diagrams 43 BLUELINE HAZINATOR 29 ...

Page 35: ...ELT HAZINATOR 4 58 127 1 PNL LEFT LOWER HAZINATOR 5 58 128 1 PNL FRONT LOWER HAZINATOR 6 58 129 1 PNL RIGHT LOWER HAZINATOR 7 12 012 32 WASHER FLAT 1 4 SAE 8 10 026 4 SCREW MACH 1 4 20 X 1 HXHD 9 12 015 28 LKWSR 1 4 ZINC 10 11 013 4 LKNUT 1 4 20 NYLOK 11 10 006 8 SCREW MACH 1 4 20 X 1 2 HEXHD 12 10 007 16 SCREW MACH 1 4 20 X 1 2 SOCHD SS BLUELINE HAZINATOR 30 ...

Page 36: ...ASSY CONTROL PANEL HAZINATOR 5 36 025 1 GUARD FLYWL KOHLER 4731402 S 6 44 030 1 DECAL HAZINATOR CONTROL PNL 7 12 012 7 WASHER FLAT 1 4 SAE 8 12 015 7 LKWSR 1 4 ZINC 9 10 006 7 SCREW MACH 1 4 20 X 1 2 HEXHD 10 11 007 12 NUT THUMB 1 4 20 FKWR HEAD KNOB 11 11 009 12 NUT 1 4 20 NYLON 12 12 016 8 LKWSR 5 16 ZINC 13 10 080 4 SCREW 10 32 X 3 4 SHCS 14 11 018 4 NUT 10 32 NYLOK BLUELINE HAZINATOR 31 ...

Page 37: ...3POSITION 5 29 012 2 SWITCH PUMP AND AUX DSCVRY 6 31 011 2 PANEL MTG END 44383 WAYTEK 7 30 007 1 BREAKER 30 AMP 8 30 008 2 BREAKER 20 AMP 9 26 010 1 HOURMETER HOBBS 10 26 008 1 GAUGE WTR PRESS 5000 PSI 11 26 004 1 GUAGE VAC 30in HG DUALSCALE 12 21 037 1 ELL 1 4 IN BRASS 13 21 076 1 BUSHING 1 4 M X 1 8 F BRASS 14 21 028 1 CONN 1 8 P X 1 4 POLY 15 21 004 1 CONN 1 4 F P X 1 4 T BRASS BLUELINE HAZINAT...

Page 38: ...B H 1 4 37 025 1 BELT AX43 MATCH 5 61 162 1 ASSY INTAKE COLLAR KOHLER 25HP 6 61 161 1 ASSY AIR INTAKE KOHLER 25HP 7 10 035 2 SCREW 1 4 X 1 HWH TEKS 3 8 10 055 4 SCREW MACH 3 8 16 X 1 3 4 HXHD 9 12 013 12 WASHER FLAT 3 8 SAE 10 12 014 8 LKWSR 3 8 ZINC 11 11 006 4 NUT 3 8 16 ZINC 12 10 029 4 SCREW MACH 3 8 16 X 1 HXHD BLUELINE HAZINATOR 33 ...

Page 39: ... 21 027 1 PLUG 1 2 T BRASS 6 36 195 1 FILTER OIL KOHLER 25HP 7 10 055 1 SCREW MACH 3 8 16 X 1 3 4 HXHD 8 16 034 2 HOSE FUEL 1 4 30R7 9 21 006 2 FTTG BRB 1 4PX5 16H BR 10 21 039 1 ELL 1 4 IN LG STREET BRASS 11 61 018 1 BRKT FIN FUEL RETURN THERMAL 12 21 125 1 ELL STREET 1 4P 1 3 16L 90 DEG 13 68 030 1 ASSY FUEL PUMP HOUSING 14 36 146 1 FILTER FUEL ZENITH C382 224 15 50 005 1 TANK FUEL 18 1 2X16 3 8...

Page 40: ...Y WATER PUMP HAZINATOR 2 26 008 1 GAUGE WTR PRESS 5000 PSI 3 69 084 1 ASSY PRESSURE REGULATOR HZ 4 18 072 1 HOSE 1 2X15 3 8 W 1 2 FMJIC SW E END 5 18 029 1 HOSE 3 16 X 11 3 4 1 4 FT X 1 4 FT 6 18 103 1 HOSE RETURN 3 4 X 108 W CVR 7 18 104 1 HOSE SUPPLY 3 4 X 90 W CVR BLUELINE HAZINATOR 35 ...

Page 41: ...22 1 SWITCH PRESS 3000PSI 9 29 004 1 SWITCH PRESS 50PSI 10 66 078 2 ADAPTOR PUMP BRASS HP 11 21 062 1 TEE 3 8 F X M X F BRASS 12 21 035 1 CONN 3 8 M X 1 2 FP 13 46 000 1 ACCUMULATOR GIANT 14 21 061 1 ELL 3 8 P X 1 2 T BRASS 15 18 072 1 HOSE 1 2X15 3 8 W 1 2 FMJIC SW E END 16 21 032 1 FTTG BARB 1 2 P X 3 4 H BRASS 17 14 000 1 CLAMP HOSE 12 18 18 104 1 HOSE SUPPLY 3 4 X 90 W CVR 19 12 013 4 WASHER F...

Page 42: ... BARB 1 2 P X 3 4 H BRASS 5 14 000 1 CLAMP HOSE 12 6 18 103 1 HOSE RETURN 3 4 X 108 W CVR 7 21 062 1 TEE 3 8 F X M X F BRASS 8 21 063 1 ELL 3 8 P X 1 4 T BRASS 9 18 029 1 HOSE 3 16 X 11 3 4 1 4 FT X 1 4 FT 10 21 057 1 CONN 3 8 P X 1 2 T BRASS 11 18 072 1 HOSE 1 2X15 3 8 W 1 2 FMJIC SW E END 12 21 2 NIP 3 8 X SS 13 21 152 1 ELL 3 8 F X 3 8 F 90 DEG 14 25 012 1 DSC 3 8FX3 8FP SS BLUELINE HAZINATOR 3...

Page 43: ... 63 042 1 TUBE EXHAUST EXT KOHLER 5 63 054 1 TUBE EXHAUST VAC HAZINATOR 6 14 025 1 CLAMP MUFFLER 2 1 2 7 63 052 1 MUFFLER VACUUM 3L 4M W MOUNT 8 26 004 1 GUAGE VAC 30in HG DUALSCALE 9 1 VACUUM PUMP ASSEMBLY 10 17 707 2 HOSE EXHAUST DUCT KIT THERMAL 11 61 103 1 ASSY BX TRUCK EXHAUST FITTING 12 14 024 4 CLAMP HOSE 48 SS 13 63 036 1 MUFFLER EXHAUST DUCT KIT BLUELINE HAZINATOR 38 ...

Page 44: ... 1 VAC BRAKE MACHINED 3L 4M 6 15 002 1 SPRING VAC RELIEF VALVE 7 12 021 1 WASHER FLAT 7 16 ZINC 8 11 012 2 NUT 7 16 14 ZINC 9 21 028 4 CONN 1 8 P X 1 4 POLY 10 61 158 1 ASSY ADPTR VAC STANDPIPE HAZ 11 46 009 1 VACUUM PUMP 3LP 12 66 058 1 NIPPLE 2 1 2 X 7 8 STEEL 13 16 011 1 HOSE INT VAC 2 7 8 IN 50 FT BULK 14 16 017 2 TUBING IMPOLENE 250FT 15 28 000 1 CUP OILFILL 1 8P 16 26 004 1 GUAGE VAC 30in HG...

Page 45: ...3 SCREW MACH 5 16 18 X 2 HXHD 10 12 016 3 LKWSR 5 16 ZINC 11 66 082 1 PULLEY TENSIONER 5 0 2G 12 2 Belt 13 66 081 1 TENSIONER ADJUSTMENT BLOCK 14 61 157 1 BOLT BELT ADJUSTMENT 12IN 15 12 013 2 WASHER FLAT 3 8 SAE 16 12 014 2 LKWSR 3 8 ZINC 17 10 029 2 SCREW MACH 3 8 16 X 1 HXHD 18 66 085 1 SHAFT TENSIONER CHOPPER 19 58 105 1 SPACER 062 X 688 X 1 625 20 39 018 2 BEARING 35MM X 72MM X 17MM 21 66 080...

Page 46: ...ATOR 108 GAL 3 20 021 1 STRAINER FILTER BLUEWAVE 4 40 003 6 LATCH PRE FILTER BOX 5 69 086 1 WIRING LEVEL SENSOR HAZINATOR 6 14 024 1 CLAMP HOSE 48 SS 7 16 011 42 HOSE INT VAC 2 7 8 IN 50 FT BULK 8 14 010 4 CLAMP HOSE 32 9 16 009 4 HOSE INT VAC 2 IN 10 21 094 4 FTTG 1 1 2 P X 2 H DRAIN 11 23 022 2 VLV BALL 1 1 2 FP PVC DUMP BLUELINE HAZINATOR 41 ...

Page 47: ...SECTION 5 DECALS WARNING DECAL CONTROL BLUELINE HAZINATOR 42 ...

Page 48: ... STARTER HOUR METER 26 010 ORANGE WHITE RED WHT RED 1 RED 2 3 GRN BLK 3 RED 9 RED WHT 9 4 BLUE BLUE 4 5 GREEN 5 GRN 6 BLUE 12 BLUE 12 12 13 BLUE 16 PURPLE WHT GRN BLUE BLK 18 10 TAN 13 19 07 20 05 HAZINATOR 1 2 4 5 3 KOHLER ENGINE HARNESS WHITE RED PURPLE RED GREEN 18 30 31 32 33 34 PIN 1 WHITE IGNITION MODULE 2 RED VOLTAGE REGULATOR BLUE STARTER 3 RED FUEL SOLENOID 4 GREEN OIL PRESSURE 5 PURPLE V...

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