HydraMaster CrossFire 4.2 Owner'S Manual Download Page 48

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Summary of Contents for CrossFire 4.2

Page 1: ...996 HYDRAMASTER Corporation Lynnwood Washington 182 022 No part of this manualmay be reproduced or used in any form or by any means i e graphic electronic photocopyingor electronic retrieval systems w...

Page 2: ...m u r 1 w I...

Page 3: ...c End Troubleshooting Assembly Drawings and Parts Lists CLEANING WAND ASSEMBLY PARTS Valve Jet Wand Assembly Drawings Parts List VACUUM SYSTEM Blower Troubleshooting Blower Specifications Sheet Blower...

Page 4: ...iagnostic Center 10 3 MACHINE MAINTENANCE Sectionll Daily 11 1 Weekiy Monthly 11 2 Quarterly De scaling 11 3 Overall Care 11 3 Maintenance Logs HOW TO ORDERPARTS WARRANTY INFORMATION s Golden Guarante...

Page 5: ...aving one or two functions to perform the truck mounted carpet cleaning plant has many functions to perform simultaneously F The engine has to run at a consistent RPM F The vacuum has to pull air and...

Page 6: ...manual to warn of possible injury or death This symbol is used to warn of possible equipment damage HOURS TELEPHONE Monday Friday 206 775 7276 8 00 am to 5 00 pm 206 775 7275 PACIFIC STANDARD TIME 80...

Page 7: ...ck through the secondary exhaust heat exchanger and back to the mix tank The water demanded by the operator flows from the water pump through the primary exhaust heat exchanger then out to the cleanin...

Page 8: ...egulated Integrated Governor Pressurized Oil System with Filter Pressurized Cooling System Triple Row Radiator Vacuum Blower Proprietary Dual Shaft Roots 45 RAI J WhispAirTM Chemical System Electro me...

Page 9: ...Blower Lubrication Port 70 gallon Aluminum Epoxy Finish Stainless Steel with Heat Shield Grip and Replaceable Vacuum Lips with Stainless Steel Solution Valve High Pressure Hose M High temperature Line...

Page 10: ...Supply Line 150 ft Super Flex Solution Line Dual Wand Vacuum Fittings Dual Wand Solution Fittings Freeze Guard System Battery Box with Holder Telescoping Console Legs with Casters Van Decal Package V...

Page 11: ...or has access to parts through a regional service center If further assistance is needed contact the factory and coordinate your needs If this becomes necessary always indicate the method of shipment...

Page 12: ...nnect 440 Male Quick Connect 440 Female Quick Connect 660 Male Quick Connect 660 Female Gasket Recovery Tank All Jet 6 S S Hydra Hoe Gauge Hi PSI O 1 000 Meter Chemical Flow CDS Kit Diaphragm 3 GPM H...

Page 13: ...It is the purchaser s responsibility to read the unit operation manual and to familiarize himself with the information contained therein Special attention should be paid to afl Cautions and Warnings T...

Page 14: ...and see that all systems function normally Checking all hoses wands etc for correct operation TRAINING SHALL INCLUDE F A thorough review of the operation manual with purchaser P Instruction and famil...

Page 15: ...us when drilling any holes through the van floor Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit See Product Support Bulletins 92...

Page 16: ...t working side of the machine thus making it a bit easier to perform maintenance and or repair without removing the unit from the truck B REAR DOOR Although this location partly limits working access...

Page 17: ...CrossFire 4 2 Section 1 13 Figure 1 1 Plywood Installation G _ igure 1 2 Astroturf and Roof Vent km igure 1 3 Tie Down Cleats Minimum HydraMaster Corporation 4 11 95...

Page 18: ...ite Always park the truck so the exhaust is blowing away from the job site The manufacturer also recommends the installation of aluminum vents in the truck roof to allow heat to escape Mount a fire ex...

Page 19: ...CrossFire 4 2 Section 1 15 Do not use a portable propane tank dangerous and illegal in most states nside of the truck or van t is HydraMaster Corporation 4 11 95...

Page 20: ...s pumps valves and water cooled engines For other countries hard water area maps can be obtained from geological societies WATER SOFTENER Cleaning efficiency and equipment life is increased chemical u...

Page 21: ...of water Therefore the softener would need to be changed every 6 working days for maximum softening WASTE WATER DISPOSAL ADVISORY There are laws in most communities prohibiting the dumping of recover...

Page 22: ...the water through hoses to a suitable disposal drain Properly designed they will continuously monitor the level of waste water and pump it out simultaneously to the cleaning operation The hidden benef...

Page 23: ...CrossFire 4 2 Section 1 19 Figure 1 4 Hard Water Map Grains Per Gallon E3 0 3 2 31 7 7 10V2 10 and above HydraMaster Corporation 4 11 95...

Page 24: ...Machine Assembly Parts CrossFire 4 2 Section 1 20 Figure 1 5 Power Pack Assembly a 43Y HydraMaster Corporation 4 11 95...

Page 25: ...ump Mount Bushing H x 7 8 Pulley AK54H Pump Multi Cat Nut 3 8 16 Nylock Screw 3 8 16 x 1 1 2 HI IC Screw 1 4 20 x 3 4 w Bushing Fiiter Air 20 HP Kawasaki Washer 3 8 SS Rubber Back 8MA 8UFS Nipple 1 2...

Page 26: ...CrossFire 4 2 Section 1 22 ITEM PART NO DESCRIPTION QTY 40 090 006 Manifold 20 HP Kawasaki s s Exhaust 1 41 143 139 Screw 3 8 16 x 4 HHCS GR 8 1 Hydrailfaster Corporation 4 11 95...

Page 27: ...037 143 025 174 023 143 042 Bracket Idler Mount 4 2 Multi Cat Pulley Housing Multi Cat Idler Pulley Idler Multi Cat Single V Groove Same as above Spacer Idler 4 2 Multi Cat Screw 1 2 13 x 3 1 2 HHC S...

Page 28: ...ESCRIPTION QTY 1 090 008 Manifold High Press Brass 1 2 052 423 Bushing Mod Set Screw Orifice Housing 1 3 180 002 Orifice Set Screw 039 1 4 049 033 Filter X Inline Y 1 5 052 013 4M 6UFS 1 6 052 071 Nip...

Page 29: ...004 5 097 005 6 155 019 Not Shown 078 102 078 101 Thrust Plate By pass Valve Piston Plate By pass Valve Seal Set for By pass Valve Seat and O Ring By pass Valve O Ring By pass Valve Fitting Spring Hig...

Page 30: ...eaners as required prior to the actual cleaning of carpeting The use of some chemicals through your mobile carpet cleaning plant can seriously damage the internal plumbing high pressure pump and heate...

Page 31: ...t pressure to the forward stroke while the solution is injected into the carpet When extracting drying apply firm pressure on the forward stroke to ensure a positive lock for the vacuum and minimize t...

Page 32: ...strokes or improper saw tooth vacuum strokes as shown in the following illustration Obstructed cut or kinked hoses Vacuum tank drain valve left partially open Clogged vacuum blower filter or vacuum p...

Page 33: ...12345678910 11 12 13 14 ACID NEUTRAL ALKALINE Figure 2 2 CLEANING STROKE PROCEDURE A correct cleaning stroke overlaps between strokes I I I I i I I I I I I I i I I I I I I I 1 I I E N Firs C k ing Sec...

Page 34: ...n Idle RPM is approximately 2000 Run RPM is 3100 Spray the wand to void all air from the system When the mix tank begins a fill cycle the chemical flowmeter may be adjusted to your desired setting Set...

Page 35: ...ing tool to flush the chemical from unit the hoses and cleaning tool At this time the blower should be lubricated with an oil based lubricant NOTE If freeze guarding is necessary perform the freeze gu...

Page 36: ...e van floor that could be damaged by a misplaced drill bit See Product Support Bulletins 92102 94062 and 94063 at the end of the manual ENGINE COOLING Units employing internal combustion engines must...

Page 37: ...ulated to protect vital components HydraMaster will not warranty parts that have been damaged from using unprotected acid products that have obviously caused failures F l FREEZE PROTECTION Mother natu...

Page 38: ...toxic fumes Position the vehicle so that the fumes will be directed away from the job site Do not park where exhaust fumes can enter a building through open doors windows air conditioning units or kit...

Page 39: ...ncreases the risk of a fire or explosion 1 PORTABLE PROPANE TANK Do not use a portable tank inside of the truck or van It is dangerous and illegal in most states WARNING TRANSPORTATION OF FUEL CONTAIN...

Page 40: ...e mix tank drain valve and allow the mix tank to empty Attach the freeze guard hose to the recovery tank Plug the other end of the freeze guard hose into the first freeze guard fitting left hand on th...

Page 41: ...eze solution through the chemical flowmeter and the hoses back to the mix tank Remove the garden hose or pump in hose Now open the mix tank drain valve and drain all the water from the machine With th...

Page 42: ...ix tank drain valve and allow the anti freeze solution to drain into a sealable container so that it may be used again Before cleaning with the machine again flush the remaining anti freeze solution f...

Page 43: ...reeze coolant or solution If swallowed induce vomiting immediately Call a physician Contains Ethylene Glycol which caused birth defects in animal studies Do not store in open or unlabeled containers K...

Page 44: ...t switch is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply f for example the water source at the house were turned off the water level of the mi...

Page 45: ...owmeter is set at 5 GPH or a 1 to 15 ratio when the Flowmeter is set at 10 GPH I CHEMICAL SYSTEM MAINTENANCE I The chemical lines may need to be flushed with vinegar periodically to prevent abnormal c...

Page 46: ...n m t d m m c D 2 A L...

Page 47: ...6UFS Mix Tank n J i 43 Injector Body i Check Valve I Cap Nut 7 Chemical L l Adjusting 1 Cap Diaphgram I Piston llmm B Piston Piston Housing Spring enoid 1 ve Body Mounting _ lI e Screws 3 1 Water Inle...

Page 48: ...aster distributor and install it 1 3 Foreign material is blocking the Inspect the outlet hole leading to outlet hole for the pump in the the pump in the bottom of the mix bottom of the mix tank tank R...

Page 49: ...r leak in the water Inspect the supply hose for worn supply hose from the mix tank to or damaged areas Also check for the pump loose fittings Replace the hose or fittings if necessary 1 9 The water su...

Page 50: ...he orifice with a 3 16 Allen wrench NOTE If your machine was built before 10 1 2 95 update the controlled orifice to the new style orifice with part numbers 180 002 052 423 and 052 013 1 12 The by pas...

Page 51: ...plate Order a diaphragm replacement kit from your HydraMaster distributor Remove the pump Replace the diaphragm Refill and reinstall the pump See your owner s manual for the procedure 1 15 The pump O...

Page 52: ...Inspect the exhaust system for leaks Tighten any loose clamp welds or replace any broken parts 2 5 There is excessive pressure Adjust the pressure regulator for less pressure 2 6 There is exhaust wra...

Page 53: ...Operation and Maintenance manual 2 12 A heat exchanger is scaled De scale the heat exchanger or remove it and take it to a radiator shop to be boiled out 2 13 A heat exchanger is carbon coated a For...

Page 54: ...gauge is defective Solution Place the end of a grounded wire to terminal 9a on the Diagnostic Center while watching the temperature gauge The ground should make the needle on the gauge read maximum t...

Page 55: ...s 12 volts across the terminals and does not open replace it 3 4 The dump system control sensor The sensor switch is normally is not working open It closes its hidden contacts at 185 F Replace it if i...

Page 56: ...eplace the of the high pressure hoses is defective quick connect s defective 4 3 The cleaning tool has a clogged Remove the valve stem Clean the valve valve Replace the O rings and stem if they are ba...

Page 57: ...essary 5 3 The mix tank relay is bad With the upper float in the mix tank in the up position there should be no voltage reading on terminal 16 at the Diagnostic Center With the float in the down posit...

Page 58: ...solution The water is condensation 6 2 One of the heat exchangers is Determine which heat exchanger is damaged from frozen water bad Replace it if it is necessary 6 3 The recovery tank is full Empty...

Page 59: ...Remove one of the wires from next to the mix tank terminal 16 see the Diagnostic Center and turn the key on f the water continues to flow then take the solenoid apart and remove the foreign matter Re...

Page 60: ...kes 8 3 The in et hose is drawing air Reseal the fittings Tighten the hose clamps Or replace the hose 8 4 The valves are obstructed Clean or replace the valves 8 5 There is a pin hole in one or more R...

Page 61: ...Pump 2 i 23 4 P l...

Page 62: ...or if the oil becomes discolored and contaminated one of the diaphragms 17 may be damaged Refer to the Service Section Do not operate the pump with a damaged diaphragm 1 Do not leave contaminated oil...

Page 63: ...Section 6 2 at the out bottom of the pump so all oil and accumulated sediment will drain Do not turn the drive shaft while the oil reservoir is empty Protect the pump from freezing HydraMaster Corpor...

Page 64: ...draMaster 206 775 7275 or the distributor in your area 1 Remove Manifold 3 and Valve Plate 12 a Remove all eight bolts 1 around the manifold b Remove the manifold 3 and valve plate 1 2 c Inspect the m...

Page 65: ...t for wear O ring 5 should be installed and replace it if necessary A new Check the dampening washer 1 1 and replace if worn Reinstall the valve assemblies b Clean the valve ports and shoulders with e...

Page 66: ...until the new diaphragm is installed in step g below Unscrew the diaphragm Use a 5 16 in open end wrench and turn counterclockwise Inspect the diaphragm carefully A ruptured diaphragm generally indic...

Page 67: ...e plate manifold and diaphragm cushion plate still removed see above remove the oil drain cap 63 and allow all oil and contaminant to drain out Fill the reservoir with kerosene or solvent Manually tur...

Page 68: ...the oil level in the reservoir If it gets too low during priming air will be drawn into the pistons inside the Hydraulic end This will cause the pump to run rough and you will have to start over agai...

Page 69: ...CrossFire 4 2 Section 6 8 e Recheck all bolts for tightness HydraMaster Corporation 4 11 95...

Page 70: ...irect drive pump motor unit Internal piston components 21 27 can be serviced without removing the motor or crankshaft The motor and crankshaft must be removed to service the connecting rod 59 piston h...

Page 71: ...g and any other parts which the remaining pistons at b co 2 Reassemble Pistons Tip the pump so the pistons are vertical d e f 9 Drop a ball 21 into the opening in the bottom of the piston Insert a val...

Page 72: ...in socket wrench Save the O rings 51 Remove the cover and the cover O ring 53 Remove the crankshaft 57 by pulling it through the connecting rods 59 2 Remove and Replace Pistons To remove the pistons...

Page 73: ...new seal and the inside surface of the opening in the back cover 52 where the seal will rest Press the new seal into the back cover Inspect the bearing 55 If pitted or damaged replace it Apply a coat...

Page 74: ...ads of the diaphragm screw be sure the threads are clean Set the diaphragm 17 on the plunger 24 ridge side out Screw the diaphragm onto the plunger Hold the diaphragm hex wrench and tighten the diaphr...

Page 75: ...ve noise Premature failure of spring or retainer 8 10 Volume or pressure drop Rough running pump in Volume or Pressure Air leak in suction piping Clogged suction line or suction strainer Suction line...

Page 76: ...ration or turbulence in supply tank Valve Wear Loss Normal wear of Oil External seepage Rupture of diaphragm Frozen pump Worn shaft seal Oil drain piping or fill cap loose Valve plate and manifold bol...

Page 77: ...CrossFire 4 2 Section 6 16 Figure 6 1 DETAIL A Piston Assembly DETAIL B Wve Assemblies q j 2 1 HydraMaster Corporation 4 11 95...

Page 78: ...3 1000 D03 034 21 10 D03 044 1000 D03 045 31 10 D03 049 1000 D03 048 2210 Bolt 3 hex head Washer 5 1 6 Manifold brass NPT O ring manifold Buna O ring valve seat Buna Valve Seat 17 4 SST Valve 17 7 SST...

Page 79: ...CrossFire 4 2 Section 6 18 HydraMaster Corporation 4 11 95...

Page 80: ...D03 087 201 O D40 074 21 10 D03 I 30 1000 D03 001 1001 M13 001 1001 D 10 040 2410 Cap Screw hex head with washer O ring back cover screws Buna Back Cover O ring back cover Buna Seal Buna Back Bearing...

Page 81: ...Cleaning Wand Parts CrossFire 4 2 section 7 1 Figure 7 I VALVE ASSEMBLY 1 1 3 4 I Ai i s w J 1 6 I e 12 7 10 8 I HydraMaster Corporation 4 11 95...

Page 82: ...CrossFire 4 2 section 7 2 Figure 7 2 JET ASSEMBLY 20 19 HydraMaster Corporation 4 11 95...

Page 83: ...CrossFire 4 2 Section 7 3 Figure 7 3 WAND ASSEMBLY 21 27 Valve Assembly 26 lYydraMaster Corporation 4 11 95...

Page 84: ...Ring Solution Valve Retaining Ring Keeper HMaster Solution Valve O Ring HM Valve Plunger Large O Ring Solution Valve Flowmeter small Plunger HydraMaster Solution Valve 440 Male Quick Connect with Vito...

Page 85: ...y tank This stainless steel screen is finger tight and should be removed for cleaning weekly When machine is being run for test purposes and the vacuum inlet on top of the machine is open caution shou...

Page 86: ...therefore it should be maintained more regularly CAUTION The Vacuum tank is protected from overflowing by a vacuum tank float kill switch The switch is not activated by foam only by liquid VACUUM TANK...

Page 87: ...llecting water each time you use it 1 5 The vacuum hose is plugged Remove the obstruction by reversing the vacuum hose 1 6 There is a restriction in the Remove the obstruction cieaning tool 1 7 The va...

Page 88: ...components NOTE This must be accomplished b a qualified technician 1 14 There are vacuum leaks around the top collector box A vacuum leak can usually be detected by spraying a mist of WD40 or blowing...

Page 89: ...OTE Replacement of the gears result from a lack of lubrication must be accomplished by a qualified technician 2 3 The si enter is bad Inspect it for an external hole Repair or replace the silencer 2 4...

Page 90: ...a half gallon of hot water into the top of the blower Then spray WD40 or Pennz Lube into the top of the blower to displace the water b Any sugar iike substances can be removed by soaking the lobes wit...

Page 91: ...CrossFire 4 2 Section 8 7 No I Problem Possible Cause I Solution 4 The shaft turns but the lobes do not 4 1 The shaft is broken inside the Replace the blower blower HydraMaster Corporation 4 11 95...

Page 92: ...ere is a problem with the starter With the ignition switch in the soienoid Start position check the following on the solenoid Check for 12 volts on a the small terminal with the blue wire from the ign...

Page 93: ...the ignition key in the start position check the starter motor for 12 volts If all of the above conditions are met and the starter will not turn replace it 1 9 The engine is malfunctioning Refer to t...

Page 94: ...nect the oil pressure switch If the unit starts then replace the oil pressure switch 2 4 The 10wer float in the chemical mix Push in the freeze guard switch tank is defective located on the lower cont...

Page 95: ...ated garage start the engine and look at the plug wires If there is a break in the wire you will see arcing or sparking at the damaged area f you notice arcing replace the wire 2 10 A spark plug is fa...

Page 96: ...mix tank circuit is closed Replace the float if it is defective 3 3 The chemical mix tank is out of The solenoid valve is normally water caused by a dirty or closed and should open with 12 defective s...

Page 97: ...tured hose 3 8 The fuel titer is clogged Inspect the filter Replace if necessary 3 9 The quick connect in the fuel line Clean or replace the quick connect is clogged 3 10 The carburetor solenoid is Ch...

Page 98: ...onnections 4 5 The fuelpump is sucking air Examine the pump s gas inlet side between the gas tank and the fuel Tighten any loose fittings or pump clamps Replace ruptured hoses 4 6 A clogged heat excha...

Page 99: ...Replace any ruptured hose 4 12 The carburetor solenoid valve is With the ignition switch on check defective for 12 volts at the solenoid valve If the voltage is present the valve should be open If th...

Page 100: ...spark plug wire In a dark well ventilated garage start the engine and look at the plug wires f there is a break in the wire you will see arcing or sparking at the damaged area If you notice arcing re...

Page 101: ...iring diagnostic center which allows the operator or mechanic to trace all the electrical circuits from the front of the machine The entire electrical system operates on 12 volts DC which is provided...

Page 102: ...T SWITCH eio OVERR1OE SWITCH 1 1 I L I GRN j ____ _ Immw FUSE UNX _ STARTER BRN l 4 GA r sOLENOIO ORN WHT f SLU o FUEL SHUT OFF vfivE VOLT RED f REG 81 J f I 2 GA KAWASAKI u b 2 ENGINE CH 4RGE CIRCUIT...

Page 103: ...6 TO STARTER SOL 7 TO ENGINE STOP RELAY lGNITION COIL FROM PUMP IN SWITCH a TO PUMP 1 PUMP FROM TEMP GAUGE 9 TO TEMP SENOER FROM PUMP OUT SWITCH 10 TO PUMP OUT PUMP TO ENGINE STOP RELAY E 13 TO FROM...

Page 104: ...specific maintenance intervals Records of maintenance must be kept and copies may be required to be furnished to Hydra Master before the warranty is honored It is recommended that you affix a copy of...

Page 105: ...m element in air cleaner Clean recovery tank thoroughly with high pressure washer Check wiring for any chafing Flush water and chemical system with 50 50 white vinegar solution MONTHLY Change engine o...

Page 106: ...ard water or you see evidence of deposits in the water system you may have to de scale monthly To de scale your system add an appropriate de scaler chemical to your mix tank Circulate it through the h...

Page 107: ...ughly with a damp cloth Flush recovery tank out thoroughly Empty filter bag and inspect for rips tears etc Replace as needed Remove thoroughly clean and reinstall stainless steel filter screen in reco...

Page 108: ...ghly to remove any chemical build up Inspect chemical feed line strainer and use 50 0 white vinegar water solution to remove any chemical build up Thoroughly clean wand and inspect for clogged jet deb...

Page 109: ...ghten screws 25 BELTS PULLEYS check for wear 25 HIGH PRESSURE LINES check for chafing 25 NUTS BOLTS check tightness 25 Y FILTER check and clean 25 AIR CLEANER clean foam element 25 RECOVERY TANK clean...

Page 110: ...tighten screws 25 BELTS PULLEYS check for wear 25 HIGH PRESSURE LINES check for chafing 25 NUTS BOLTS check tightness 25 t FILTER check and clean 25 AIR CLEANER clean foam element 25 RECOVERY TANK cl...

Page 111: ...it E Unit Serial Number F Name of Person Authorized to Order Parts G Sales Representative from which Unit was Purchased H Description of Malfunction 1 High Pressure Gauge Readings with the Wand Turned...

Page 112: ...raMaster Parts Dept Toll Free Fax 1 800 426 4225 HydraMaster has a 40 minimum on parts orders Orders below the minimum will be charged a 15 expediting fee ONE FINAL NOTE Any questions you have regardi...

Page 113: ...tomatic shut off system Allowing foam to pass through blower HIGH PRESSURE WATER PUMP Failure to maintain proper oil level as recommended in pump manual Failure to change oil in pump at recommended in...

Page 114: ...Warranty Dept at the above address or call the Warranty Service Dept at 206 775 7275 No collect calls will be accepted When calling be sure to have machine information and serial number ready for the...

Page 115: ...shape of steam cleaning Our hoses and tanks are of the finest quality construction SafeClean Detergents have been specially prepared not only to give you exceptional cleaning but also to optimize you...

Page 116: ...demand has recently introduced a new SafeClean chemical called ClearWater Rinse Extensive testing was conducted during the design phase because this is an acid based product The testing showed that t...

Page 117: ...ires CrossFire machines have a Y type filter located on the front lower right corner of the machine It is behind the front panel in back of the pressurized water quick connect This filter should perio...

Page 118: ...oil pressure switch is now wired to the engine kili re ay The vacuum tank float switch and the high temperature kill switch also operate the engine kill relay The system operates as follows When the...

Page 119: ...an Caution must be used when drilling any holes through the floor The attached illustration indicates the area in the rear of the van where no screws may penetrate the floor Anyone who has installed f...

Page 120: ...re limitation The mounting location of the machine and the fuel pump can effect how much fuel flow and pressure the engine sees Therefore sizing a pump is important The accompanying chart shows the op...

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