SpitFire 4.0 Owner's Manual - HydraMaster · SpitFire 4.0 11/24/98 HydraMaster Corporation For machine parts lists, please call HydraMaster Customer Service at 1-425-775-7276

HYDRAMASTERCorporation

11015 47th Avenue W, Mukilteo, WA 98275

SpitFire 4.0

Machine Serial Number:________________________

Copyright© 2000HYDRAMASTER© Corporation

Mukilteo, Washington

D-182-031

No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying orelectronic retrieval systems) without the express written permission of the HYDRAMASTER© Corporation. All rightsreserved.

Revised February 4, 2000

For machine parts lists, please call HydraMaster Customer Service at 1-425-775-7276

SpitFire 4.0

HydraMaster Corporation11/24/98


SpitFire 4.0

HydraMaster Corporation 11/24/98

Table of Contents

GENERAL INFORMATION .............................................................. Section 1

Telephone Numbers ............................................................. 1-2

Precautions ........................................................................ 1-3

System Operation ............................................................... 1-7

Machine Specifications ........................................................ 1-8

Spare Parts Recommendation ............................................... 1-10

Spare Parts List ......................................................... 1-10

Responsibilities ................................................................... 1-12

Vehicle Preparation ............................................................. 1-14

Installation Suggestions .............................................. 1-15

Local Water Precautions ...................................................... 1-19

Wastewater Disposal Advisory .................................... 1-21

Hard Water Map ........................................................ 1-23

Machine Assembly Parts (Standard) ...................................... 1-24

Machine Assembly Parts (With Exhaust Diverter) .................... 1-58

CLEANING AND CHEMICALS ........................................................ Section 2

pH Chart ............................................................................ 2-4

SpitFire 4.0


SpitFire 4.0


OPERATING INSTRUCTIONS ......................................................... Section 3

Start Up ............................................................................ 3-1

Shut Down ......................................................................... 3-2

Exhaust Diverter System ..................................................... 3-3

FREEZE GUARD ................................................................................ Section 4

WATER AND CHEMICAL SYSTEM .........................................................Section 5

Water Flow and Diagrams Diagram ....................................................... 5-1

Bypass Valve Assembly ...................................................................... 5-5

Water System Troubleshooting............................................................. 5-6

Chemical System Troubleshooting ...................................................... 5-16

HIGH PRESSURE PUMP ........................................................................Section 6

Pump Maintenance............................................................................. 6-1

Service ............................................................................................ 6-3

Pump Troubleshooting ........................................................................ 6-6

CLEANING WAND ..............................................................................Section 7

Cleaning Wand Assembly Drawings and Parts Lists .................................. 7-1

VACUUM SYSTEM .............................................................................Section 8

Blower Troubleshooting....................................................................... 8-3

Roots Blower Instruction Booklet

ENGINE INFORMATION........................................................................Section 9

Engine Troubleshooting ....................................................................... 9-1

Operators Manual


SpitFire 4.0


ELECTRICAL SYSTEM........................................................................Section 10

Wiring Schematic and Diagrams (Standard) .......................................... 10-2

Wiring Schematic and Diagrams (With Exhaust Diverter System).............. 10-5

Electrical Troubleshooting.................................................................. 10-8

MACHINE MAINTENANCE ............................................................... Section 11

Daily, Weekly ................................................................................. 11-1

Monthly, Quarterly, De-scaling .........................................................11-2

Overall Maintenance .......................................................................11-4

Maintenance Logs

HOW TO ORDER PARTS .................................................................. Section 12

WARRANTY INFORMATION ............................................................. Section 13

Golden Guarantee

ACCESSORIES ............................................................................... Section 14

PRODUCT UPDATES ....................................................................... Section 15


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SpitFire 4.0 Page 1-1

HydraMaster Corporation 9/01

General InformationSpitFire 4.0

Section 1-1

This manual contains installation and operation instructions as well as informationrequired for proper maintenance, adjustment and repair of this unit. Since the

first and most important part of repair work is the correct diagnosis of the problem,component manual troubleshooting charts have been included for your convenience.

Unlike a garden tractor, lawn mower or cement mixer, all having one or two func-tions to perform, the truckmounted carpet cleaning plant has many functions toperform simultaneously.

• The engine has to run at a consistent RPM.• The vacuum has to pull air and dirty water back from cleaning site.• The water pump provides stable pressure at proper water flow for cleaning.• The chemical has to be injected into the water stream at the right concentration.• The heating system must maintain proper heat.• The vacuum tank must store dirty water until drained.

As you can see, it is not just a turnkey operation with one thing to worry about,Does it start?

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Page 1-2 SpitFire 4.0

HydraMaster Corporation9/01

The manufacturer uses this symbol throughout the manual to warn ofpossible injury or death.

This symbol is used to warn of possible equipment damage.

Hours Telephone NumbersMonday - Friday (425) 775-7276 Parts

8:00 am to 5:00 P.M. (425) 775-7275 ServicePACIFIC STANDARD TIME (800) 426-4225 Parts / Service FAX

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CAUTION

WARNING




Precautions

Although this unit has been factory adjusted, it may require additional adjustmentsto achieve optimum performance, for instance altitude may require carburetor

adjustment and ambient temperatures may require heat control adjustment. Whenrequired, consult an authorized representative.

THROUGH-FLOOR DRILLING: Be cautious when drilling holes throughthe van floor. Many vans have critical components mounted directlybelow the van floor that could be damaged by a misplaced drill bit. (SeeProduct Support Bulletins 92102, 94062 and 94063 at the end of themanual.)

ENGINE COOLING: Units employing internal combustion engines mustnot be enclosed within a van with doors and windows closed. Excessivetemperatures within the engine will result in premature engine failureand a compromise of applicable warranty.

LEVEL OPERATION: During operation, van or trailer must be parked onlevel ground not to exceed + or - 10 degrees. Failure to insure properleveling may prevent proper internal lubrication of engine, vacuum and/or high pressure components.

CAUTION

CAUTION

CAUTION

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MOVING PARTS: Never touch any part of the machine that is in mo-tion. Severe bodily injury may result.

ACID RINSE AGENTS: The increased demand for “clear water” rinsingresults in the need for special care when using these acid based chemi-cals in your equipment. The negative side of these products is thecorrosive effects the acid can have on metals, including swivels, pumps,heat exchangers, etc.

HydraMaster’s ClearWater Rinse has been formulated to protect vital components.HydraMaster will not warranty parts that have been damaged from using unprotectedacid products that have obviously caused failures.

HARD WATER PROTECTION: Failure to take appropriate measures toprevent scale build up can result in system failure and loss of warrantyon affected parts. Test the water in your immediate and surroundingareas with hard water test strips. Assume all water obtained from wellsis hard. If you are operating in a “Hard Water Area” (3.5 grains or moreper gallon), use a water softening system.

FREEZE PROTECTION: There is often little warning before a cold spell.Therefore, not protecting this equipment from freezing will result in costlydowntime. Placing an electric heater in the truck or parking the truckindoors will help to insure against freezing, but should not be the primarymethod of freeze protection.

WARNING

CAUTION

CAUTION

CAUTION

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EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel,plastic or wood products) to come in contact with the exhaust system.

HOT SURFACES: During the operation of this equipment, many sur-faces on the machine will become very hot. When near the van for anyreason care must be taken not to touch any hot surface, such as heater,engine, exhaust, etc.

HEARING PROTECTION: The Occupational Safety and Health Adminis-tration (OSHA) recommends the use of hearing protection when a tech-nician is exposed to an average of 85 decibels (this is an average ofexposure over an 8 hour period). This equipment can produce 85 deci-bels to a distance of 10 feet. Please check with your local state agen-cies to see if OSHA standards apply to your application.

NO SMOKING: It is unsafe to smoke in or around the vehicle.

CARBON MONOXIDE: This unit generates toxic fumes. Position thevehicle so that the fumes will be directed away from the job site. Do notpark where exhaust fumes can enter a building through open doors,windows, air conditioning units or kitchen fans.

CAUTION

WARNING

WARNING

WARNING

WARNING

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TOXIC FUMES: Do not occupy the vehicle when the cleaning equip-ment is operating. Toxic fumes may accumulate inside a stationaryvehicle.

ENGINE EXHAUST: The engine exhaust from this product containschemicals known to the State of California to cause cancer, birth de-fects or other reproductive harm.

PORTABLE GAS TANK: Never operate this machine with a portablegas can inside the truck. Doing so increases the risk of a fire or explo-sion.

PORTABLE PROPANE TANK: Do not use a portable tank inside of thetruck or van. It is dangerous and illegal in most states.

TRANSPORTATION OF FUEL CONTAINERS: Transportation in a ve-hicle of any vented fuel container that presently has or has ever con-tained a flammable liquid is strictly forbidden by HydraMaster Corpora-tion and by federal and state regulation

WARNING

WARNING

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WARNING

WARNING

WARNING




System Operation

The SpitFire heat exchanger system is a highly engineered cleaning plant designedby HydraMaster Corporation. The system utilizes a dynamic heating system com-

prised of three separate exhaust heat exchangers for capturing “free heat.”

The water flow is as follows:Water is fed into the machine under tap pressure. It flows through one pre-heater and then is automatically combined with a cleaning solution as it entersthe mix tank. The solution is then picked up by the high pressure pump andpressurized to the desired level. The water then splits flow, as demanded by thetechnician. The majority of the water flows to the bypass valve assembly, thenback through the secondary exhaust heat exchanger, and back to the mix tank.

The water demanded by the technician flows from the water pump through theprimary exhaust heat exchanger then out to the cleaning tool.

When the cleaning solution reaches a preset high temperature, it is releasedfrom the system and directed to the recovery tank. Then cool water enters thesystem to regulate the temperature.

As there is no guess work in the manufacture of these highly advanced cleaningplants, there must be none in preparing it to get the job done in the field. It is thepurpose of this manual to help you properly understand, maintain and service yourcleaning plant. Follow the directions carefully and you will be rewarded with yearsof profitable, trouble-free operation.

It is imperative that no section be overlooked when preparing for operation of thisequipment.

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Machine Specifications

Frame: 24" W x 33" L x 29" HSteel with Baked-on Epoxy Finish

Weight: 370 lbs.

Engine: Vanguard 20 HP Briggs and StrattonPressurized Oil SystemSpin-on Filter and Oil PSI Protection Switch

Ignition: Electronic, Keystart

Vacuum Blower: Roots 45 URAIJ

Chemical System: Electro-mechanical, Meter Controlled

Heating System: 1 Stainless Steel Exhaust Exchanger1 Copper Shell and Tube Exchanger1 Copper and Aluminum Block Exchanger

Instruments: Water Pressure Gauge, Liquid Filled, 0-1000 PSIHour Meter, Machine RuntimeKeyed Ignition, Start/StopChemical Flowmeter, Clear Acrylic, 0-10 GPHVacuum GaugeTemperature Gauge

Recovery Tank: 50 Gallon Aluminum, Epoxy Finish

Cleaning Wand: Stainless Steel with Heat ShieldReplaceable GripRebuildable Solution Valve

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High Pressure Hose: 4" High Temperature Lined/Vinyl CoveredHose Rated to 1250 PSI

Vacuum Hose: 2" Reinforced, 12" Reinforced.

Standard Equipment: Machine Power ConsoleFull InstrumentationRoots Vacuum BlowerSpitFireTM Water Heating PackageVacuum Recovery TankCarpet Cleaning WandChemical Jug100 ft, 2" Vacuum Hose10 ft, 12" Wand Whip Line100 ft, Super Flex Solution LineBattery BoxVan Decal PackageVan Installation KitOperation ManualHydraMaster Jacket

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Spare Parts

Downtime on the unit can be very expensive, because your truckmounted unit iscapable of generating several hundred dollars per day. In order to minimize such

downtime, it is strongly recommended by the manufacturer that you purchase andkeep in your truck the parts listed below.

Parts OrdersTo expedite your parts needs, please call your sales representative. In most in-stances, he either stocks or has access to parts through a regional service center. Iffurther assistance is needed, contact the factory and coordinate your needs. If thisbecomes necessary, always indicate the method of shipment you desire, i.e. UPS,Blue Label, Air Freight, Air Express, etc.

HydraMaster Parts Dept. Phone.................. (425) 775-7276HydraMaster Parts Dept. Toll Free Fax ......... 1-800-426-4225

Spare Parts List (078-100)

PART NO DESCRIPTION QTY

010-015 Belt, Gates AX31 1049-014 Filter, Vanguard Oil 2049-007 Filter, S/S Vacuum Pump 1049-016 Filter, 4” Replacement Y 1049-023 Screen, Garden Hose 1049-012 Filter, Vanguard Air 1049-030 Filter Bag, 92+ Truck Mount 2052-050 Quick Connect, 440 Male 3

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PART NO DESCRIPTION QTY

052-051 Quick Connect, 440 Female 2052-052 Quick Connect, 660 Male 1052-053 Quick Connect, 660 Female 1057-043 Gasket, Recovery Tank 1074-003 Gauge, Hi PSI (0-1000) 1074-013 Meter, Chemical Flow 1078-015 Kit, Chemical Flowmeter 1078-101 Kit, Seal & Spring Hi PSI 1078-140 Kit, Hypro Seal 1106-016 Plug, Vanguard Spark 2106-045 Plug, HD4 Coupling - 1" OD x d” LG, EPDM 8131-037 Wrap, Exhaust Insulation 1157-001 Switch, Tethered Mercury 1157-115 Mini-Rocker with Terminal 1157-022 Switch, Relay 2169-022 Valve, 12” Full Port 1169-062 Valve, 4 Anti-Siphon 1169-120 Valve, Chemical System 1

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Responsibilities

The Purchaser’s responsibilities are:

Prior to arrival of unit, install s” exterior plywood flooring in the vehicle and cover itwith artificial turf.

In Dodge vans the fuel tanks are located directly against the floor.Caution must be used when drilling any holes through the floor. (SeeProduct Support Bulletin 94062 at the end of this manual.)

To purchase heavy duty 42 - 60 amp hour battery and have the battery ‘slow’ chargeif new.

If the battery is not fully charged, damage can occur to the enginecharging regulator.

Reading of owner’s manual: It is the purchaser’s responsibility to read the unitoperation manual and to familiarize himself with the information contained therein.Special attention should be paid to all Cautions and Warnings.

The Sales Representative’s responsibilities are:

ACCEPTANCE OF SHIPMENT:

1. If the unit shows any outward signs of damage, do not sign the deliveryreceipt until you have closely inspected the unit and noted any damage onthe delivery receipt.

CAUTION

CAUTION

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2. The salesman from whom you purchased your unit is responsible for supervising the correct installation of the unit in your vehicle and thoroughlytraining you in its operation, maintenance and precautions.

CORRECT INSTALLATION INCLUDES:

• Vehicle of proper load carrying capacity (recommendation: ½ ton).• Installation of through-floor fittings for gasoline fuel lines.• Placing the unit and recovery tank in your vehicle and securing them with bolts or tie down cleats.• Connecting gasoline lines.• Connecting the battery.• Checking the pump, vacuum blower and engine oil levels prior to staring the unit.• Starting the unit to check the engine and see that all systems function normally.• Checking all hoses, wands, etc. for correct operation.

TRAINING:

• A thorough review of the operation manual with purchaser• Instruction and familiarization in: how to correctly start up and shut down

the unit, how to correctly clean with the unit, where and how often tocheck and change component oil levels, how the unit’s systems work,how to troubleshoot the unit, how to do basic repairs, safety precautionsand their importance, freezing damage and how to avoid it, hard waterdamage and how to avoid it;

• A thorough review of the unit warranty and warranty procedures.• A thorough review of hard water precautions and warnings.• How to determine hard water areas.• Use of water softening systems.

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Vehicle Prep

When selecting a truck, remember the preferable vehicle for a SpitFire 4.0installation is a cargo van with a heavy-duty suspension package and a half

ton capacity. If a fresh water tank is added, a three quarter ton or larger capacityvan, with a 2,400 pound payload capacity, is required.

TRUCK PREPARATIONThe manufacturer recommends the installation of plywood flooring, covered withpolypropylene backed Astroturf (do not use rubber-backed), in the vehicle prior toinstallation of machine.

Be cautious when drilling any holes through the van floor. Many vanshave critical components mounted directly below the van floor thatcould be damaged by a misplaced drill bit. (See Product Support Bulletin94062 at the end of this manual.)

This provides ‘metal to wood’ mounting rather than ‘metal to metal’, provides insula-tion and makes an attractive van interior. Astroturf should be color-keyed to the vaninterior. See Figure 1-1 for correct placement of the plywood flooring.

CAUTION

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Materials Needed:1. Two sheets of 4 x 8 x s” exterior plywood2. One 6' x 12' piece of commercial Astroturf3. Sixteen 12” sheet metal screws4. One quart marine adhesive (optional)5. One staple hammer with 2” staples

PLACEMENT OF UNIT IN VEHICLEThere are two recommended unit placements:

SIDE DOOR:Most installations are side door. This provides rear access for accessories andhoses as well as unobstructed access to the component/working side of the ma-chine, thus making it a bit easier to perform maintenance and/or repair withoutremoving the unit from the truck.

REAR DOOR:Although this location partly limits working access, it does direct the noise awayfrom the cleaning site. Some cleaners in the colder areas prefer this locationbecause it puts the weight over the rear wheels for better traction in ice andsnow. Rear mounting requires the unit to be slid to the right side as far as pos-sible. This not only provides adequate working space on the component side of theunit but also improves weight distribution inside the van (engine and componentweight line up over drive shaft). Also, it is physically easier to load the unit intothe rear door due to the height of the van bed.

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Figure 1-3 Recommended Placement

Machine Tie Down CleatsSecure the machine to the floor of the van with the four tie down cleats provided.This safety measure will ensure that the machine will not slide inside the van. Seethe following illustration for the correct installation.

Figure 1-4 Installation using Tie-down Cleats

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Ensure that the machine is well secured to the floor of the van with thehardware supplied. A sudden or crash stop will cause the machine torocket forward! Protect yourself and the machine. SECURE IT!

It is recommended by the manufacturer that the exhaust from the frontof the machine be vented down under the truck to prevent carbonmonoxide from entering the job site. Always park the truck so theexhaust is blowing away from the job site.

The manufacturer also recommends the installation of aluminum ventsin the truck roof to allow heat to escape..

Never operate this machine with a portable gas can inside the truck.Doing so increases the risk of a fire or explosion.

Mount a fire extinguisher just inside the rear or side door for emergencies

Do not use a portable propane tank inside of the truck or van. It isdangerous and illegal in most states.

Transportation in a vehicle of any vented fuel container that presentlyholds or has ever held a flammable liquid is strictly forbidden by Hydra-Master Corporation and by federal and state regulation.

WARNING

WARNING

WARNING

WARNING

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The engine exhaust from this product contains chemicals known to theState of California to cause cancer, birth defects or other reproductiveharm.

WARNING

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Local Water PrecautionsSpitFire 4.0

Section 1-19

The quality of water varies greatly. Many areas have an excess of minerals in thewater which results in what is commonly called “hard water.” These minerals

tend to adhere to the insides of heater coils and other parts of the machines causingdamage and a loss of cleaning effectiveness. This influences the reliability and effi-ciency of equipment in direct proportion to the level of hardness.

HARD WATER ADVISORY

HydraMaster recognizes that any hard water deposits which might occur within thewater system of our truckmounts is a serious problem. The precision technology oftruckmount heat exchanger systems is intolerant of any foreign material. Hard waterdeposits will ultimately decrease the performance of the system and are expected toseriously lower the reliability of the machine.

To validate a machine’s warranty, HydraMaster requires that all machines operating indesignated ”Hard Water Areas” (3.5 grains or more per gallon) be fitted with a watersoftening system or a properly installed magnetic-type de-scaler must be used andmaintained. Periodic de-scaling or acid-rinsing alone is not adequate in these areas.

HydraMaster does not recommend any particular type or brand, however the rela-tive effectiveness of some types of magnetic de-scalers or softeners may requireadditional periodic use of de-scaling agents.

HydraMaster also recommends, in the strongest possible terms, that machines in allareas be fitted with a water softening system for improved operation and reliability.

HydraMaster has included five hard water test strips with your machine. These

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can be used to test the water in your immediate and surrounding areas as they canvary greatly. Assume all water obtained from wells is hard.

Failure to take appropriate measures to prevent scale build up canresult in system failure and loss of warranty on affected parts.

HARD WATER AREA MAP

The following map defines areas in the United States which compromise fluid re-lated components such as hoses, fittings, heaters, pumps, valves and water cooledengines. For other countries, hard water area maps can be obtained from geologicalsocieties.

WATER SOFTENER

Cleaning efficiency and equipment life is increased, chemical use decreased, andthe appearance of cleaned carpets enhanced when water softeners are incorpo-rated in hard water areas. The manufacturer strongly urges the use of water soft-ener units in areas exceeding 32 grains per gallon. Failure to use a water softener inthese areas will invalidate the machine’s warranty. Using a hard water area map asa reference, determine the quality of water in your area and take action immedi-ately, if necessary.

Reports from several of our machine users commending the results of the use ofwater softeners in conjunction with their machines prompts us to recommend theprocedure to everyone in a “hard water” area.

The relatively low cost of a water softener service is more than made up for by anincreased life of machine parts, reduced chemical costs and continued cleaningefficiency. The water softener will also increase the effectiveness of the cleaningchemicals, therefore less chemical will be needed.

CAUTION

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Contact a water softener distributor in your area for information on the rental of asimple water treatment unit to carry in your truck. Be sure to change the watersoftener in accordance with the capability of the softener. For example: If thesoftener will treat 900 gallons of water and the machine uses an average of 30gallons per hour, for an average of 5 hours a day, this equals 150 gallons per day. In6 days the machine would use 900 gallons of water. Therefore, the softener wouldneed to be changed every 6 working days for maximum softening.

WASTE WATER DISPOSAL ADVISORY

There are laws in most communities prohibiting the dumping of recovered “gray”water from carpet cleaning in any place but a sanitary treatment system.This cleaning rinse water, recovered into your unit’s vacuum tank, contains materi-als such as detergents. These must be processed before being safe for streams,rivers and reservoirs.

IN ACCORDANCE WITH THE EPA, STATE AND LOCAL LAWS, DONOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS,STREAMS, RESERVOIRS, ETC.

In most cases, an acceptable method of waste water disposal is to discharge into amunicipal sewage treatment system after first filtering out solid material such ascarpet fiber. Access to the sanitary system can be obtained through a toilet, laundrydrain, RV dump, etc. Permission should first be obtained from any concerned partyor agency.

One disposal method which usually complies with the law is to accumulate thewaste water and haul it to an appropriate dump site. Another solution to the dis-posal problem is to equip yourself with an Automatic Pump-Out System. Thesesystems are designed to remove waste water from the extractor’s recovery systemand actively pump the water through hoses to a suitable disposal drain. Properlydesigned, they will continuously monitor the level of waste water and pump it outsimultaneously to the cleaning operation.

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The hidden benefit of this process is that the technician does not have to stop hiscleaning to empty the recovery tank. HydraMaster makes an A.P.O. System avail-able which can be ordered with new equipment or installed later.

The penalties for noncompliance can be serious. Always check local laws andregulations to be sure you are in compliance.

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Cleaning and ChemicalsSpitFire 4.0

Section 2-1

Your mobile carpet cleaning plant has been engineered using the latest and mostsophisticated technology available to produce the finest carpet cleaning results

possible. Despite this, however, it remains only a tool of the carpet cleaning trade,and it can produce only as good a job as the person operating it.

PRECAUTIONS

There are no short cuts to good carpet cleaning. It requires time, cleaning knowl-edge and the use of good chemicals. Therefore, the manufacturer recommends theuse of spotting agents and traffic lane cleaners, as required, prior to the actualcleaning of carpeting.

The use of some chemicals through your mobile carpet cleaning plant can seriouslydamage the internal plumbing, high pressure pump and heater. These harmfulchemicals include concentrated acid (see the pH chart at the end of this section),solvents, and some paint, oil, and grease removers with a high concentration of sol-vents.

The manufacturer recommends only the use of chemicals containing rust and corro-sion inhibitors and water softening agents to prevent chemical buildup which maylead to component failure and warranty invalidation.

The increased demand for “clear water” rinsing results in the need forspecial care when using these acid based chemicals in your equipment.The negative side of these products is the corrosive effects the acidcan have on metals, including swivels, pumps, heat exchangers, etc.

CAUTION

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HydraMaster’s ClearWater Rinse has been formulated to protect vital components.HydraMaster will not warranty parts that have been damaged from using unprotectedacid products that have obviously caused failures.

CLEANING STROKE PROCEDURE

Purpose:To eliminate excess moisture remaining in the carpet fiber and the sawtooth appear-ance which results from diagonal movement of the cleaning tool on all types of car-pet.

Procedure:Always move the cleaning tool in smooth, forward and backward strokes. Applyslight 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 posi-tive “lock” for the vacuum and minimize the “hopping” effect resulting on carpet thatis not smooth. During the forward and reverse strokes, movement to the right or leftshould only be accomplished at the extreme rear of the stroke. Overlapping is alsoimportant to ensure even application of solution and prevent saturation when cleaningwand is stopped twice at the same point at the rear of the cleaning stroke. This isillustrated at the end of this section.

Failure to adopt this procedure can result in increased chance of “clean streaks,” fibershrinkage, brown-out and longer drying periods.

OVER-WETTING

Over-wetting is annoying to all concerned, and sometimes leaves a bad impressionof the cleaning process used.

THESE ARE SEVERAL AREAS THAT WILL CAUSE OVER-WETTING

1. Too few vacuum strokes or improper saw-tooth vacuum strokes as shownin the following illustration.

2. Obstructed, cut or kinked hoses. 3. Vacuum tank drain valve left partially open. 4. Clogged vacuum blower filter or vacuum tank lid not sealing properly.

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5. Cleaning a heavily foam-saturated carpet without defoamer. (Werecommend crystal type.)

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HydraMaster Corporation1/1/019/22/99




Operating InstructionsSpitFire 4.0

Section 3-1

START UP1. Perform daily and periodic maintenance as specified in this Owner’s Manual.2. Connect all required hoses.3. Connect the cleaning tool to the length of hose required to perform

the cleaning.4. CAUTION: Mix tank must be full prior to ignition.5. Place the throttle in the ‘Slow’ position. This is approximately 1800 RPM.6. Start engine (choke as required).NOTE: If the engine will not start depress the oil pressure bypass switch

and hold until the engine begins running.

Allow the engine to run for 3 to 5 minutes. Then increase the engine RPMto ‘Fast’ for normal carpet cleaning. This is approximately 3000 RPM.

7. Spray the wand to void all air from the system. When the mix tank beginsa fill cycle, the chemical flowmeter may be adjusted to your desiredsetting. Set your cleaning pressure at 300 PSI.

NOTE: A chemical flowmeter set at 5 GPH is a 1 to 30 mix ratio and 10 GPH is a 1 to 15 ratio. When the flowmeter is set at 10 GPH, you will be using what most chemical manufacturers recommend at 5 GPH.

8. Run the machine for several minutes under load (8 to 10" HG) until yourdesired temperature is achieved.

9. Commence cleaning operation.




SHUT DOWN1. Flush clear water through the chemical system for 10 seconds. Turn off

chemical flowmeter.

2. Cool the machine by spraying the cleaning wand into the vacuum hose forthree to five minutes. The chemical will be flushed from the unit, hosesand cleaning tool.

NOTE: If the machine is not properly cooled, the mix tank can overflow.3. Remove the vacuum hose.

4. At this time, the blower should be lubricated with an oil based lubricant.

NOTE: If freeze guarding is necessary, perform the freeze guard procedure at this time.

5. Throttle the machine down.

6. Turn the machine off.

7. Drain the mix tank.

8. Drain the vacuum tank. The vacuum filter should be cleaned prior tomobilization of the van.

NOTE: In accordance with the EPA, state and local laws, do not dispose of waste water into gutters, storm drains, streams, reservoirs, etc.

FLOOD DAMAGE WORK FOR STANDARD SPITFIRE

When using equipment for flood damage, you must have a fresh watersource hooked up at all times to allow a cold water source into themachine. This will prevent overheating during long periods of vacuumrecovery.

CAUTION

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Exhaust Diverter System

The Exhaust Diverter System consists of two components; the diverter valve andthe pump clutch. The diverter valve directs the flow of the exhaust through the

triple heat exchanger or directly out of the machine via the diverter exhaust muffler.The pump clutch allows the pump to be turned on and off through a switch. This willenable the machine to be used for flood extraction without the need for an inletgarden hose connected to the machine. Thus preventing excessive filling of therecovery tank through the temperature control system.

The SpitFire can run in two different modes:

Cleaning ModeTo run the machine in Cleaning mode:Push in the heat exchanger bypass lever. It is not necessary to turn the pump clutchswitch to the “ON” position due to a micro-switch that turns the pump clutch onautomatically.

Note: This means that the pump clutch cannot be manually turned off when runningin this mode.

Flood Damage ModeTo run the machine in Flood Damage mode:Pull out the heat exchanger bypass lever. Turn the Pump Clutch to the “OFF” posi-tion.

HOT SURFACES: When the machine is being run or after it has beenshut down, caution should be used around the muffler and the exhaustdiverter surfaces as they become hot during operation

CAUTION




Do not use excessive force when engaging and disengaging the heatexchanger bypass lever. This may cause damage to the exhaustdiverter.

In order for the valve to operate properly, it should periodically beengaged and disengaged.

WARNING

WARNING




Freeze GuardSpitFire 4.0

Section 4-1

VACUUM FREEZE GUARD PROCEDURE:

To freeze guard your machine:

1. Start the machine.2. Spray all of the water out of the system until the engine stops.3. Add a half gallon of 50/50 antifreeze and water mix to the chemical

mix tank and draw the antifreeze into the flow meter.

When using the recirculation kit (part no.078-058), fill a third of the mix tank witha 50/50 antifreeze mix. Verify that theupper float is not lying horizontal, butfloats below.

Attach the recirculation fitting providedin the kit to the garden hose quickconnect (see illustration to right) and thiscombination to the front of the machine.

Attach one section of female/female solution hose to the outgoing solutionfitting on the front of the machine andthe other end to the garden hose andrecirculation fitting combination that is attached to the front of the machine(oras many sections as you want, if you wish to freeze guard your hoses).

4. Start the machine. Allow it to run for 2 to 3 minutes.With the recirculation kit, skip ahead to step 6.

5. Remove the quick connect fitting from the end of the garden hose.Attach the garden hose quick connect to the machine. Using a vacuumhose attached to the recovery tank, vacuum the water out of thegarden hose quick connect.

9/22/99




6. Spray the antifreeze and water mix out of the machine and into a containerto reclaim the solution. Run the machine until it stops.

NOTE: The reclaimed antifreeze solution may be used 3 times before being discarded.

NOTE: To freeze guard hoses and wand, perform the above step with all the hoses and wand attached.

The machine is now freeze guarded. Remember to flush antifreeze from the systemprior to carpet cleaning.

Recovering Antifreeze For Re-use:Before cleaning with the machine again, flush the remaining anti-freeze solution from the system into a sealable container so that itmay be used again. To do this, spray water through the hoses andwand until all signs of antifreeze are gone.

One manufacturer of antifreeze cautions: “WHEN DISPOSING OF USEDANTIFREEZE COOLANT: Follow local laws and regulations. If required,dispose at facilities licensed to accept household hazardous waste. Ifpermitted, dispose in sanitary sewer systems. Do not discard into stormsewers, septic systems, or onto the ground.”

This warning appears on the label of one brand of antifreeze: “HARM-FUL OR FATAL IF SWALLOWED. Do not drink antifreeze coolant orsolution. 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.

“KEEP OUT OF REACH OF CHILDREN AND ANIMALS.”

CAUTION

WARNING

7/29/97




FREEZE PROTECTION OF THE PUMP-IN SYSTEM

1. Drain the fresh water tank.2. Remove the garden hose adapter from the pump-in pump hose and

position the hose so it is pointing outside the van.3. Turn on the pump-in pump and run for 1-2 minutes till all the water is

purged from the hose.

NOTE: The next time the unit is used it may take a few minutes before the mix tank begins to fill.

1/6/98




This page intentionally left blank.




Figure 5-3: Bypass Valve Assembly

169-101 Valve, Bypass Truckmount

ITEM PART NO DESCRIPTION QTY1 105-101 Thrust Plate, Bypass Valve 12 105-102 Piston Plate, Bypass Valve 13 097-028 Seal Set for Bypass Valve 14 148-044 Seat and O-Ring, Bypass Valve 15 097-005 O-Ring, By-Pass Valve Fitting 16 155-019 Spring, High PSI Bypass 1

Not Shown:078-102 Kit, By-Pass Repair (Complete, Incl. 078-101) 1078-101 Kit, Seal and Spring High PSI Bypass 1

(Includes Items 3 and 6)




SpitFire 4.0

Section 6-1

DAILYCheck the oil level and the condition of the oil. The oil level should be up to the centerof the sight glass on the back of the pump.

Use a 30 weight, non-detergent oil.

If the oil becomes discolored and contaminated, one of the oil sealsmay be damaged. Refer to the Service Section.

Do not operate the pump if the crankcase has been contaminated withwater.

Do not leave contaminated oil in the pump housing or leave the housingempty. Remove contaminated oil as soon as it is discovered and replaceit with clean oil.

PERIODICALLYChange the oil after the first 100 hours of operation, and every 400 operating hoursthereafter. When changing, remove the drain plug on the oil drain center located onthe frame so all oil and accumulated sediment will drain out.

Pump Maintenance

CAUTION

CAUTION



9/21/99 HydraMaster Corporation

Do not turn the drive shaft while the oil reservoir is empty.

Protect the pump from freezing.

CAUTION

CAUTION




The next few pages explain how to disassemble and inspect all easily-serviceableparts of the pump.

Do not disassemble the hydraulic end unless you are a skilled mechanic.For assistance, contact HydraMaster (425-775-7275) or the distributorin your area.

1. Servicing the Valves (See Figure 6-1)

A. Remove the hex valve plugs (top—discharge, bottom—Inlet).

B. Unthread the valve plug and examine the o-ring under the plug for cutsor distortion. Replace it if it is worn. Lubricate new o-rings before installing.

C. Grasp the valve retainer by the tab at the top with needle-nose pliers, thenremove the o-ring at the bottom of the valve chamber.

D. Inspect all valve parts for pitting, gouges, or wear. If wear is excessive,replace valve assembly.

E. Reinstall valve assemblies:1. Using a clean towel, clean the valve chamber.2. Install the o-ring into the high pressure manifold.3. Install the valve assemblies into the high pressure manifold (the metal side

of the valve faces the manifold).4. Replace the o-ring on the hex valve plug.5. Torque the plug to 30 foot pounds.

Service

CAUTION




Figure 6-1 Servicing the Valves

2. Removing the High Pressure Manifold

A. Using an M6 allen wrench, remove all eight of the socket head bolts.

B. Rotate the crankshaft by hand to start separation of the manifold head fromthe crankshaft.

C. Insert two flat-head screwdrivers on opposite sides to further separate themanifold from the crankshaft.




To avoid damage to either plunger or seal, keep the manifold properly aligned with theceramic plungers when removing it.

D. Remove the seal retainer from the manifold and inspect for wear.

E. Examine the ceramic plunger for cracks or scoring (refer to Servicing thePlungers for replacement).

3. Servicing the Low Pressure Seals and High Pressure Seals (See Figure 6-1)

A. Remove the low pressure seal from the seal retainer using a 90 degree picktool.

B. Remove the high pressure seal from the manifold

C. Inspect the low pressure seal and high pressure seal for wear and replaceif necessary.

D. Reinstall the low pressure seal:1. Install the low pressure seal into the seal retainers with the garter

spring down.

E. Reinstall the high pressure seal:1. Lubricate the seal chamber in the manifold.2. Carefully square the high pressure seal into position by hand with the grooved

side down (metal back facing out).

3. Examine the seal retainer’s o-ring and replace if worn. Lubricate the newo-ring before installing.

4. Next, press the seal retainers into the manifold until completely seated.

4. Servicing the Plungers

A. Using a hex tool, loosen the plunger retainer about three to four turns. Pushthe back to separate it from the retainer and finish unthreading the plungerretainer by hand.

B. Unthread the plunger retainer with sealing washer.

CAUTION




C. Remove the ceramic plunger, keyhole washer and barrier slinger from theplunger rod.

5. Reinstall the ceramic plungers:

1. Examine the sealing washer on the plunger retainer and replace it if it iscut or worn. Lubricate the new sealing washer for ease of installationand to avoid damage.

2. Apply Loctite 242™ to the threads of the plunger retainer and press it into theceramic plunger. Thread hand tight, then torque the bolt to 4.4 foot pounds.

3. Install the seal retainer with holes to the top and bottom, and forward.

6. Reinstall High Pressure Manifold

A. Slip the seal retainer over the ceramic plungers with the holes to the top andbottom and forward.

B. Turn the shaft by hand to line up the plungers so that the end plungers areparallel.

C. Lightly lubricate the plungers and carefully slide the manifold head onto theplungers while supporting it from the underside to avoid damaging theplungers.

D. Reinstall the socket head bolts and torque to 4.4 foot pounds.

7. Servicing the Crankcase

A. While manifold, plungers, and seal retainers are removed, examine the crank-case seals for wear.

B. Rotate the crankshaft oil seal externally for drying, cracking or leaking.C. Consult your HydraMaster distributor if crankcase servicing is necessary.

9/21/99




Figure 6-2: Cat Pump




Cat Pump Parts List

ITEM PART NO. DESCRIPTION QTY

2 30047 Key, M5 15 92519 Screw, Sems HHC, Bearing Cover, M6x16 88 46901 Cover, Bearing 210 14028 O-Ring, Bearing Cover 111 43222 Seal, Oil, Crankshaft 215 14480 Bearing ½20 46743 Rod, Connecting, Assembly 225 46829 Crankshaft, Dual End 332 45690 Cap, Oil Filler 133 14179 O-Ring, Oil Filler Cap 137 43987 Gauge, Oil, Bubble 138 44428 Gasket, Flat, Oil Gauge 140 92519 Screw, Sems HHC, Crankcase Cover, M6x16 448 25625 Plug, Drain, 4” x 11 149 23170 O-Ring, Drain Plug 150 46939 Cover, Crankcase 151 14041 O-Ring, Crankcase Cover 153 46534 Crankcase 164 46615 Pin, Plunger Rod 365 46975 Rod, Plunger 370 147-013 Seal, Crankcase Oil for 3CP Cat Pump 375 43900 Slinger, Barrier 388 45697 Washer, Keyhole 390 46976 Plunger, M43 398 46730 Seal, Washer 399 48201 Retainer, Plunger with Stud, M6 3100 46541 Retainer, Seal 3106 43243 Seal, LPS with Spring 3120 46625 Case, Seal 3121 13976 O-Ring, Seal case 3125 46652 Seal, HPS 3139 22179 Plug, Inlet 2” 1




Cat Pump Parts List


163 17547 O-Ring 85, Valve Seat 6164 46658 Seat 6166 43723 Valve 6167 43750 Spring 6168 44565 Retainer, Spring 6172 17615 O-Ring 75, Valve Plug 6174 46756 Plug, Valve 6185 46616 Manifold, Head 1193 87870 Bolt, HSH, Manifold Head (M8x65) 8196 22187 Plug, Discharge a“ 1250 108-055 Protector, 3CP Cat Pump Shaft 1260 114-003 Rail Angle, 3CP Cat 1265 30651 Complete Mounting Kit 1270 30246 Pulley and Key Assembly 1299 814841 Complete Head 1300 078-271 Kit, Seal for 3CP Cat Pump 1310 078-270 Kit, Valve for 3CP Cat Pump 1350 30696 Valve Seal Removal Tool 1








Pump Troubleshooting

Cavitation• Inadequate fluid supply because of:

-inlet line collapsed or clogged- air leak in inlet line-worn or damaged inlet hose

• Fluid too hot for inlet suction piping system• Air entrained in fluid piping system• Aeration and yurbulence in supply tank• Inlet suction vacuum too high• High pressure seals worn• Worn pump valve parts.

Symptoms of Cavitation:-Excessive pump valve noise (chattering)-Premature failure of spring or retainer-Volume or pressure drop-Rough-running pump.

Drop in Volume or Pressure• Air leak in suction piping.• Clogged suction line.• Pressure gauge inoperative or not registering accurate.• Suction line inlet above fluid level in tank.• Inadequate fluid supply.• Pump not operating at proper RPM.• Worn pump valve parts.• Foreign material in inlet or outlet valves.• Worn low pressure seals.• Cavitation.• Belt slippage.




Water Pulsations• Foreign object lodged in pump valve.• Air in suction line.• Valve spring broken.• Cavitation.• Aeration or turbulence in supply tank.• Stuck inlet or discharge valve.

Valve Wear• Normal wear.

Loss of Oil• External seepage.• Frozen pump.• Worn crankshaft seal.• Oil drain piping or fill cap loose.

Premature Failure of Valves or Seals• Excessive cavitation.• Foreign object in the pump.• Pump running too fast.• Valve or seal material incompatible with fluid being pumped.• Excessive inlet pressure.• Scored plungers.• Running pump dry for excessive periods of time.• Excessive temperatures of fluid being pumped.




Cleaning Wand Parts

SpitFire 4.0

Section 7-1




Wand Assembly Parts List


1 061-007 Handle Grip 12 015-203 Bracket, Low Pressure Wand Valve Holder 13 167-018 Trigger, Wand Low PSI 14 052-082 Elbow, ¼” Brass 45 Street 15 052-072 Nipple, ¼ Brass Close 16 052-050 Quick Connect, 440 Male with Viton 17 169-074 Valve, High PSI Brass 18 052-152 Compression, ¼” Male HydraHoe Fitting 29 168-001 Tube, HydraHoe Solution ¼” OD s/s 110 061-024 Handle Kit, Wand – Pressure Guide (see below) 111 052-450 Elbow, For Jet Assembly Wands 112 076-004 Jet, #11004 ¼” VV s/s 1

Handle Assy (Item 10)094-035 Nut, 5/16-18 s/s Nylock Half 2143-012 Bolt, 5/16-18 x ¾” HHC s/s 2061-006 Handle, Pressure Guide 1




Vacuum SystemSpitFire 4.0

Section 8-1

The vacuum pump in this machine is commonly referred to as a ‘positive dis-placement ‘lobe’ type blower. The performance and life of this unit is greatly

dependent on the care and proper maintenance it receives.

Because of the close tolerances between the lobes and housing of the vacuum blower,solid objects entering the inlet will damage the internal lobes, gears, bearings or drivesystem.

To prevent this, a stainless steel filter screen has been placed at the vacuum inletinside the vacuum recovery tank. This stainless steel screen is ‘finger’ tight andshould be removed for cleaning weekly.

Caution should be used when machine is being run for test purposes and thevacuum inlet on top of the machine is open.

To protect the vacuum blower from overloading and damaging itself, there is a vacuumrelief system installed on the vacuum tank. When the vacuum tank inlet is completelysealed off, a maximum of 12 HG will be attained.

At the end of each day, an oil based lubricant should be sprayed into the blowerlubrication port before shutting down the machine. Lubricate the vacuum blower dailyto prevent rust deposits and moisture that will decrease the life of the vacuum blower.

CAUTION




Foam passing through the blower could lead to serious problems.It is important to keep the vacuum tank foam free.

Read the vacuum blower manual carefully for proper oil change and grease applica-tion. The maintenance log may differ slightly from the manual, but the truckmountedcarpet cleaning machine application is very demanding of the vacuum blower andtherefore it should be maintained more regularly.

The vacuum tank is protected from overflowing by a vacuum tank float killswitch. The switch is not activated by foam, only by liquid.

VACUUM TANK FILTER BAGSHydraMaster filter bags are designed to trap lint, sand and dirt that would normallycollect at the bottom of your vacuum tank. The use of these bags, if emptied at theend of each job, will eliminate the build-up of much of the debris in the tank. Thedrawstring top of these bags is designed to be slipped around the incoming dirtywater inlet in the vacuum tank.

UNCONTESTED WARRANTYThe Roots Division of Dresser Industries, Inc. states in their February 1993 RootsBlower specification sheet, “Roots is the leader in blower warranties - the first tointroduce an uncontested warranty that guarantees repair or replacement of any Uni-versal RAI-J™ that malfunctions for any reason. We’ll protect you or your customerfor a full 18 months from date of original start-up or 24 months from date of ship-ment, whichever occurs first.”

CAUTION

CAUTION




Blower Troubleshooting

No. Problem/Possible Cause Solution

1.0 There is no vacuum or a lossof vacuum.

1.1 The stainless steel filter is clogged. Clean or replace the filter.

1.2 The filter bag is clogged. Clean or replace the filter bag.

1.3 The vacuum tank dump valve is If water drips from the valve when“open” or defective. the machine is not running, the

valve will cause a vacuum losswhen the machine is running.Replace it if it is defective.

1.4 The vacuum hose is plugged. Remove the obstruction byreversing the vacuum hose.

1.5 There is a restriction in the cleaning Remove the obstruction.tool.

1.6 The vacuum tank seal is defective. Replace the seal.

1.7 The hose from the blower to the Replace or reshape the hose.recovery tank is kinked or has NOTE: A special reinforced hose iscollapsed inside. required for replacement.

1.8 There is a hole in the recovery tank. Inspect the tank for leaks usingsmoke and weld the tank if it isrequired.

1.9 There is a hole in the vacuum hose. Repair or replace the hose.

1.10 The vacuum release is loose. Readjust the vacuum release.

1.11 The engine speed is too low. Adjust the speed.

SpitFire 4.0Section 8-3





1.12 The vacuum blower’s end plates or Replace the worn components.lobes are worn. NOTE: This must be accomplished

by a qualified technician.

1.13 There are vacuum leaks around the A vacuum leak can usually betop collector box. detected by spraying a mist of

WD40 or blowing smoke towardsthe leak. The mist or smoke willbe sucked into the leak. Whenyou see the leak, repair it.





2.0 The blower is noisy.

2.1 There is an exhaust leak between Inspect the fittings to determinethe blower and the silencer. where the air leak is. Repair as

necessary.

2.2 The blower is out of oil or the Add oil. If the noise continues,gears may be bad. replace the gears or blower.NOTE: Permanent damage may NOTE: Replacement of the gearsresult from a lack of lubrication. must be accomplished by a

qualified technician.

2.3 The silencer is bad. Inspect it for an external hole.Repair or replace the silencer.

2.4 The lobes are hitting. Replace the blower.

2.5 The engine is running at the wrong Adjust the engine to run at thespeed. This is noticeable because proper speed.the blower noise increases withspeed.

2.6 The bearings are worn. Remove and replace the bearingsas required.NOTE: This process must beaccomplished by a qualifiedtechnician.





3.0 The blower will not turn.

3.1 The lobes are locked up because of a. Most burnt foam and rust canrust, burnt chemical foam, or a be removed by soaking thesugar-like substance has been lobes with liquid wrench. Aftervacuumed up from the carpet. soaking the lobes, with the

machine running, pour a halfgallon of hot water into the topof the blower. Then sprayWD40 or Pennz Lube into thetop of the blower to displaceThe water.

b. Any sugar-like substances canbe removed by soaking thelobes with hot water.

3.2 There is debris in the blower. Remove the debris. A stainlesssteel filter is provided at thevacuum inlet in the vacuum tankto prevent this problem.

3.3 The blower has broken gears or Rebuild or replace the blower.shattered lobes. NOTE: Rebuilding the blower

must be accomplished by aqualified technician.





4.0 The shaft turns, but the lobesdo not.

4.1 The shaft is broken inside the Replace the blower.blower.




SpitFire 4.0

Section 9-1


1.0 The engine will not turn over.

1.1 The battery cable is loose or Clean and tighten the batterythe terminals corroded. terminal connections.

1.2 The battery is dead. Recharge or replace the battery.

1.3 There is a problem with the fuse Check the link. If it is defective,link. replace it.

1.4 There is a problem with the With the ignition switch in the “Start”starter solenoid. position, check the following on the

solenoid. Check for+12 volts on:a. The small terminal with the blue wire from the ignition switch,b. The large terminal with the cable from the battery.c. The large terminal with the cable going to the starter.If the voltage is present on the firsttwo checkpoints, but not on thelarge terminal going to the starter,replace the solenoid.

1.5 The ignition switch is defective. Test the switch for entering voltage.If there is voltage entering the switchbut not exiting the center post whenthe switch is fully engaged, then

replace it.

1.6 The vacuum blower has seized. Refer to the Blower, Chapter 10.

Engine Troubleshooting





1.0 The engine will not turn over.(cont.).

1.7 The starter motor is defective. Remove the belt(s) from the engine.Check to see if the engine will turnover manually. Check that theengine is grounded to the minus sideof the battery. With the ignition keyin the Start position, check the startermotor for +12 volts. If all of theabove conditions are met and thestarter will not turn, replace it.

1.8 The engine is malfunctioning. Refer to the Engine Operation andMaintenance manual included in yourOwner’s manual or see the localengine repair facility.

1.9 The ground cable underneath the Reattach the cable.motor has fallen or broken off.




*Check for spark at the spark plugs. If thereis no spark, examine the Troubleshootingguide below. However if there is a spark,see Troubleshooting Problem Number 3.0on the following pages for possible fuel prob-lems.


2.0 The starter turns the engine over,however the engine will not start.(There is no spark*.)

2.1 The recovery tank is full. Empty the tank.

2.2 The recovery tank float is causing Disconnect the float. If the unitthe engine to shut down. starts, replace the defective float.

2.3 The engine is malfunctioning. Refer to the Engine Operation andMaintenance manual included inyour Owner’s manual.

2.4 The magnetron is malfunctioning. Check the magnatron. If it isadjusted properly, all of the wiresshould be tight and not groundedout. Remove all of the wires fromthe engine kill lug. If there is still nospark, replace it.

2.5 A spark plug is faulty. Check for worn, fouled or improperlygapped spark plugs. Replace ifnecessary.CAUTION: Allow the engine tocool completely before attemptingto remove the plugs.

2.6 The engine kill relay is malfunctioning. Remove either end of the wire thatruns from the relay to the engine killlug. If the engine starts, replace therelay.

2.7 The oil pressure switch is causing Check the engine oil level. If it is atthe engine to shut down. the proper level, then disconnect

the oil pressure switch. If the unitstarts, then replace the switch.

2.8 The lower float in the chemical mix Unplug the wire from terminal 86 ontank is defective. the kill relay. If there is water in the

mix tank and the engine starts,replace the switch.





3.0 The starter turns the engine over,however the engine will not start.(There is no gas*.)

3.1 The fuel pump is defective. Remove the fuel line from theengine and place it in a containerto see if the fuel is being pumpedwhen the ignition is on. Replacethe fuel pump if it is defective.

3.2 There is a poor battery ground Repair the loose ground connection.to the fuel pump.

3.3 The fuel pump is sucking air Examine the gas inlet side of thebetween the gas tank and the fuel pump. Tighten any looseinlet side of the fuel pump. fittings or clamps. Replace any

ruptured hose.

3.4 The fuel filter is clogged. Inspect the filter. Replace ifnecessary.

3.5 The quick connect in the fuel Clean or replace the quick connect.line is clogged.

*Check for spark at the spark plugs. If thereis no spark, examine the Troubleshootingguide below. However if there is a spark,see Troubleshooting Problem Number 3.0on the following pages for possible fuel prob-lems.





4.0 The engine runs poorly or diesafter running for awhile.

4.1 The air or gas filter is clogged. Inspect both filters. Replace theclogged one.

4.2 There is a poor battery ground to Inspect the electrical grounds. Repairthe fuel pump. any loose ground connections.

4.3 The fuel pump is sucking air Examine the pump’s gas inlet side.between the gas tank and the Tighten any loose fittings or clampsfuel pump. Replace ruptured hoses.

4.4 The fuel pump is defective. Remove the fuel line from the engineand place it in a container to see ifthe fuel is being pumped when thethe ignition is turned on. Replace thefuel pump if it is defective.

4.5 There is excessive engine load. Clean and adjust the recovery tankrelief valve. Adjust for 14 inches oflift under a full load.

4.6 The engine overheats from poor Remove any air restriction fromventilation. around the engine. Add a roof vent

or external fan, if necessary.

4.7 The engine overheats from carbon Refer to a local engine dealer.build up in the combustion chamber.

4.8 The engine overheats from too Check the oil level and correct ifmuch oil in the crankcase. necessary.

4.9 The engine is malfunctioning. Refer to the Engine Operation andMaintenance manual or see the Briggs& Stratton dealer.





4.0 The engine runs poorly or diesafter running for awhile. (cont.)

4.10 A clogged heat exchanger is This will cause the engine to run slowcausing back pressure. and spit gas from the carburetor.

Remove the stainless steel hose fromthe end of the stainless steel heatexchanger. If the engine runs goodwithout the hose, remove the copperheat exchanger under the machineand clean the debris.

4.11 On duel tank Fords, the engine Do not try to pull gas from both gasis pulling through the ‘Tank tanks.Switching Valve’.

4.12 A PCV valve is defective. Remove and check the air cleanerfor oil saturation. If it is saturated,replace the PCV valve and air filter.




Electrical System-Standard

SpitFire 4.0

Section 10-1

The SpitFire electrical system, in keeping with the entire machine concept, hasbeen kept to a minimum so as to keep any necessary troubleshooting as easy as

possible.

The entire electrical system operates on 12 volts DC which is provided by a battery.Battery levels are sustained by a 16 amp alternator inside the engine.

NOTE: When a new battery is installed, check that it is properly charged beforeinstallation or damage to the charging regulator may occur.

The orange wire going from the engine starter solenoid to terminal #5 on the ignitionswitch is a fusible link and provides protection to the electrical system in case offailure.

Ignition Switch:

Terminal No. Wire Color Function1 Not Used2 White To Carburetor Solenoid (when used)3 Black To Stop Switch Terminal on Engine4 Yellow To Solenoid (tab terminal)5 Orange To Battery (battery terminal on solenoid)6 Red To Regulator / Rectifier

Switch Position Continuity

1 Off 1 + 3 + 62 Run 2 + 5 + 63 Start 2 + 4 + 5




Figure 10-1 Wiring SchematicD3212 Rev G

2/25/00



HydraMaster Corporation

Figure 10-3 Wiring DiagramD3213, Sht 1 Rev K




Figure 10-4 Wiring DiagramD3213, Sht 2 Rev K




Electrical Systemwith Exhaust Diverter System

Figure 10-4 Wiring SchematicD4111 Rev C

2/25/00





2/25/00




Figure 10-3 Wiring DiagramD4110, Sht 1 Rev B




Figure 10-4 Wiring DiagramD4110, Sht 2 Rev B




Electrical Troubleshooting


1.0 The engine is not charging the battery.

1.1 The regulator/rectifier is bad. Check the B+ voltage from theregulator/rectifier to ground. Withthe engine running at normal RPMthe voltage should be 12.5 to 14.5DC volts. If necessary, replace theregulator/rectifier.

1.2 The stator winding is bad. Check for AC voltage at the regulator/rectifier. The stator should be pro-ducing an AC voltage of around 25 to40 volts. Check your Owner’s manualfor the exact voltage. If necessary,replace the stator winding.





2.0 The fusible link is blown.

2.1 The fusible link is weak or there is Replace the weak link.an electrical short in the system. Check the unprotected wires for a

short circuit. Check under the dashpanel for a loose wire or a wire thathas rubbed it’s insulation off and isshorting out to ground. Unscrew eachindividual wire (except the whitewires)one at a time until the breaker does nottrip. Then trace that circuit.




Machine MaintenanceSpitFire 4.0

Section 11-1

T o avoid costly repairs and down-time, it is imperative to develop and practicegood maintenance procedures from the beginning. These procedures fall into

daily, weekly, monthly and quarterly increments, and are outlined below. All recom-mended maintenance must be performed by competent service personnel.

Important: Record the date and machine hours on the maintenance log.

We have provided a maintenance log for your convenience at the end of this section.

Records of maintenance must be kept and copies may be required to be furnished toHydraMaster before the warranty is honored.

It is recommended that you affix a copy of the log on the vehicle door near your unitfor convenience and to serve as a maintenance reminder.

OPERATIONAL MAINTENANCE

DAILY:• Check engine oil level.• Check high pressure pump oil. Add as necessary.• Inspect garden hose screen. Clean as needed.• Visually inspect machine for loose wires, oil leaks, water leaks, etc.

• Lubricate blower with an oil based lubricant through blower inlet.

WEEKLY:• Inspect vacuum tank s/s filter and filter bag for tears, holes, etc.

Clean, repair or replace as needed.• One time change of oil and oil filter after first 20 hours of use.




WEEKLY (cont.):• Check oil level in blower.• Check drive system screws. Tighten as needed.• Check pump drive belt for wear.• Check pump pulleys.• Check high pressure water lines for wear or chafing.• Check all nuts and bolts. Tighten as needed.• Inspect vacuum relief valve. Clean and lubricate as necessary.• Clean vacuum tank thoroughly with high pressure washer.• Check wiring for chafing.• Flush water and chemical system with 50/50 white vinegar solution.• Change engine oil (every 50 hrs.).

MONTHLY:• Change oil filter (every other oil change).• Check engine air cleaner filter. Clean as necessary.• Remove pressure bypass valve piston plate. Grease plate. Reinstall.

• Check water level in battery. Clean connections as needed.

QUARTERLY:• Check fuel lines.• Clean and gap spark plugs.• Check drive coupler for cracks or wear. Replace as necessary.• Change oil in blower.• Change pump oil.• Grease blower bearing fittings.

AS REQUIRED: DE-SCALING

Scale deposits on the interior of the heating system can cause a noticeable loss inheating performance. Deposits of this kind result from hard water deposits, exces-sive chemical use, improper chemicals, etc. The frequency with which de-scalingprocedures are required will vary. If your area has particularly hard water or you seeevidence 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 heating system. Let it stand. Flush and repeat as necessary.Clean all screens and strainers, and check them frequently following de-scaling.

NOTE: If you are using T.M. DeScaler through the flow meter, make sure to run cleanwater through the flow meter after this procedure.

To de-scale using the recirculation kit (part no. 078-058), start with an empty mixtank. Fill a third of the mix tank with T.M. DeScaler. Follow the recommendationson the T.M. DeScaler label for proportions. Verify that the upper float is not lyinghorizontal, but floats below.

Attach the recirculation fitting provided in thekit to the garden hose quick connect (see illus-tration) and this combination to the front of themachine.

Attach one section of female/female solutionhose to the outgoing solution fitting on the frontof the machine and the other end to the gardenhose and recirculation fitting combination thatis attached to the front of the machine (or asmany sections as you want, if you wish to de-scale your hoses).

Start the machine and allow it to run for three to five minutes. Do not leave the T.M.DeScaler solution in the system. Flush the system with clean water and turn themachine OFF.

OVERALL MACHINE MAINTENANCE

Maintaining the original appearance of your unit is important for two reasons:

1. It represents a big dollar investment for your cleaning business and its appear-ance should reflect that fact. A dirty machine is not professional.

2. Maintenance, troubleshooting, and repair is much easier to accomplish on aclean, well maintained unit. Regular cleaning of the machine offers you anopportunity to visually inspect all facets of the machine and spot potentialproblems before they occur.




The following maintenance is recommended by the manufacturer at the frequencyindicated.

AFTER EACH JOB

• Check recovery tank, s/s filter and filter bag as required.

DAILY

• Wipe machine down thoroughly with a damp cloth.• Flush recovery tank out thoroughly.

• Empty filter bag and inspect for rips, tears, etc. Replace as needed.

• Remove, thoroughly clean and reinstall stainless steel filter screen inrecovery tank.

• Inspect and clean vacuum slot on cleaning wand.• Check wand head for sharp edges that could tear carpet. File down

as needed.• Clean wand to maintain original appearance.• Wipe down vacuum and high pressure hoses as needed.• Visually inspect hoses for cuts, etc.

WEEKLY

• Wipe down entire unit as needed.

• Apply good coat of auto wax to all painted surfaces inside and out, andto control panel.

• Thoroughly clean recovery tank using high pressure hot water(unit with optional high pressure cleaning gun may be used for this).

• Remove stainless steel filter in recovery tank and thoroughly clean,removing all lint build-up. Inspect for damage and reinstall.

• Remove filter bag. Thoroughly clean and reinstall. If the bag is torn,replace it.




• Empty chemical from chemical container. Wash out thoroughly to removeany chemical build-up.

• Inspect chemical feed line strainer and use 50% white vinegar/watersolution to remove any chemical build-up.

• Thoroughly clean wand and inspect for clogged jet, debris in vacuumslot and leaking fittings at valve.

• Apply light coat of auto wax to wand.

• Thoroughly clean vacuum and high pressure hoses including hose cuffs.

• Inspect for wear or damage to hoses and quick connect fittings.

• Inspect garden hose connect/adapter screen for debris. Remove andclean thoroughly.

• Inspect all lines for wear or abrasions that may cause possible leaks.








How to Order PartsSpitFire 4.0

Section 12-1

T o obtain a proper diagnosis of your malfunction, and to order warranty replacement parts or repairs, it is important that you proceed in the following manner:

WARRANTY PARTS ORDERS1. Call the local distributor where you purchased your equipment and ask for

the Service Department.

2. Have the following information ready:A. Equipment ModelB. Date of PurchaseC. Hours on the UnitD. Unit Serial NumberE. Description of Malfunction

3. Once it has been determined which parts are needed to correct the problemwith your machine, make arrangements with your distributor to either performthe repairs or ship the parts to you.

PARTS ORDERS

Call your local distributor. In most instances, they either stock or have access toparts through a regional service center.




EMERGENCIES

If, for any reason, your distributor is unable to supply you with the necessary parts,they may call us and arrange for expedited shipping.

HydraMaster sells parts only through authorized distributors and service centers.

ONE FINAL NOTE

Any questions you have regarding the warranty program should be directed to the:

HydraMaster Customer Service Department(425) 775-7275,8 a.m. to 5 p.m.

Monday through Friday (PST).

We shall always endeavor to be fair in our evaluation of your warranty claim, and shallprovide you with a complete analysis of our findings.

HydraMaster warranty covers only defective materials and/or workmanship for theperiods listed. Labor and/or diagnostic reimbursement is specifically excluded.




Warranty InformationSpitFire 4.0

Section 13-1

T o avoid misunderstandings which might occur between machine owners andmanufacturer, we are listing causes of component failure that specifically voids

warranty coverage. Such causes as listed below shall constitute abuse or neglect.

BLOWER:

• Failure to lubricate impellers daily with an oil based lubricant.

• Failure to lubricate bearings as recommended in blower manual.

• Failure to maintain proper oil levels in the blower.

• Failure to use the correct oil grade and viscosity as recommended inblower manual.

• Failure to properly maintain blower safeguard systems such as waste tankfilter screen, vacuum safety relief valve and waste tank automatic shut-offsystem.

• 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 intervals.

• Failure to protect pump against freezing.

• Failure to maintain pump protection shut-off system.

• Failure to use water softener in hard water areas.

• Use of improper chemicals.

VACUUM TANK:

• Failure to properly maintain filtering devices in tank.

• Failure to clean tank as recommended by manufacturer.

• Failure to maintain vacuum safety release in tank lid.

• Use of improper chemicals.




CHEMICAL PROPORTIONER:

• Use of improper chemical.

• Failure to use water softener in hard water area.

• Operating machine without proper chemical filter screen.

• Failure to protect against freezing.

CONTROL PANEL:• Failure to protect flowmeter and water pressure gauge against freezing.

VACUUM AND SOLUTION HOSES:

• Failure to protect hoses against freezing.

• Failure to protect hoses against burns from engine/blower exhaust.

• Damage to hoses from being run over by vehicles.

• Kinking or cracking from failure to store or unroll hoses correctly.

• Normal wear and tear from everyday use.

CLEANING WAND:

• Failure to protect against freezing.

• Obvious physical abuse of wand.

WATER HEATING SYSTEM:• Over pressurization of the system (recommended maximum working

pressure-800 PSI).• Failure to protect against freezing.

HARD WATER DEPOSITS:• Failure to use or maintain a water softening system or a properly installed

magnetic-type de-scaler with machine operating in designated“Hard Water Areas” (3.5 grains or more per gallon).




WARRANTY PROCEDURE

Warranty coverage is available to you ONLY through:

HydraMaster Corporation11015 47th Avenue W, Mukilteo, WA 98275.

When warranty parts are needed, write HydraMaster Warranty Dept. at the aboveaddress, or call:

Warranty/Service Dept. (425) 775-7275.8:00 am to 5:00 pm Pacific Time.

No collect calls will be accepted.

When calling, be sure to have machine information and serial number ready for theservice representative.

IMPORTANT: HydraMaster’s warranty policy provides replacement parts withoutcharge for thirty (30) days to customers maintaining current account status. Aninvoice will be sent to the customer for the amount of the parts sent. The customer’sfaulty parts must be returned for evaluation prior to the expiration of the thirty (30)day period. Upon warranty approval, a credit will be issued the customer for thereplacement parts invoice. Warranty disapproval or failure to return the faulty partswithin the thirty (30) day period allowed will result in the customer being charged forthe replacement parts sent.

FOR FUTURE REFERENCE:

Model No._________________________________________________________

Serial No. _________________________________________________________

Date of Purchase:__________________________________________________

Purchased From (Distributor): _______________________________________








AccessoriesSpitFire 4.0

Section 14-1

Genuine HydraMasterAccessories & Detergents

This section of your Owners Manual is devoted to Accessories and Detergentswhich we have found to be helpful and useful. These products can enhance your

cleaning and reduce your labor costs!

HydraMaster Machine accessories are the most innovative collection available in thecleaning industry. Our patented RX-20 Rotary Extractors have changed the shape ofsteam cleaning. Our hoses and tanks are of the finest quality construction.

SafeClean Detergents have been specially prepared, not only to give you exceptionalcleaning, but also to optimize your truckmount’s operation and reliability. Most deter-gents don’t work well under the high heat, high pressure conditions of truckmountuse. SafeClean will maintain your machines’s water pump and water heating systemsat peak efficiency and help ensure fewer breakdowns.

For more information, or to order

Genuine HydraMaster Accessories and Detergents

Call your nearest authorized HydraMaster Distributor.








Product UpdatesSpitFire 4.0

Section 15-1






Documents

SpitFire 4.0 Owner's Manual - HydraMaster · SpitFire 4.0 11/24/98 HydraMaster Corporation For machine parts lists, please call HydraMaster Customer Service at 1-425-775-7276