Aircare TruckMaster II Instruction Manual

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TruckMaster II
Duct Cleaner for Use with Truck Mount
Carpet Vacuums
OPERATING INSTRUCTIONS MANUAL
MM0205
TruckMaster Manual
Updated 04/19/2016
TruckMaster II Duct Cleaning System
Part #: FG0193

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Inspect all of the packing material for small parts before discarding packaging material. Report all
damage to Air-Care immediately. Any attempt at repairing suspected damages may void warranty.
Check that all parts are present
Air-Care TruckMaster Duct Cleaner
Main Control Case
Vacuum Hose, 1 ½” x 35 feet with 12” Pancake Flex-E-Bristle Brush, 1500 Watt Motor and
Power Cord
Handheld Remote Control Transmitter –2 button
Instruction (This Document)
Safety Precautions
Always use safe and common sense precautions when working with Air-Care equipment. Do not
block walkways with equipment, and remove delicate and breakable articles from the immediate work
area. The following are precautions that should be reviewed by all persons who will be involved in
the cleaning activity.
Other than replacing the brush and motor on the end of the vacuum hose, there are no user
serviceable components in Air-Care TruckMaster II. Only trained technicians should attempt to
make internal repairs on this equipment.
Always unplug the power cord before removing the covers or working on the wiring.
Inspect AC power plug to be sure the ground pin is in place.
Never connect power to Air-Care equipment unless all covers and safety shields are in place.
Mechanical and electrical parts could activate and cause injury.
Never allow anyone but a properly trained technician to use the equipment or cleaning products.
All Air-Care equipment is designed for US standard 115 volt, 60 Hz AC. The Air-Care
TruckMaster II will operate from 100 to 240 Volt AC, 50/60 Hz Power. Always check the
specifications on the equipment before connecting electrical power to Air-Care Equipment.
If you have questions about the safe use of any Air-Care product, call 702-454-5515
Equipment specifications and part numbers are subject to change without notice.

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TruckMaster II
Parts Locations

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Clip for
Pocket or Belt
Battery Compartment
Cover
2 x AA Battery
Compartment
Brush Motor
Forward and
Reverse Button
Brush Motor RUN
and STOP Button
Red LED
Indicator
Infrared Window
Truck Mount Vacuum
Hose Connection
Connection to TruckMaster
Vacuum Hose
Truck Mount Solution
Hose connection
12” Flex-E-Bristle Brush for
4”-12” Ducts is Standard on
1.5” hose
1500 Watt Brushless
Out runner Motor
Maximum Opening
in Vacuum Hose
Brush Hub & Bristles
Replaced as a unit
Flexible Steel Motor Mount to
Negotiate Sharp Corners
Flexible Spring
Protects Motor Wires
1.5” Crushproof Hose
is standard, 2” hose
optional with 18”
Bristle Brush
OPTIONAL 2”Hose (Blue) &
18” Flex-E-Brush with Replaceable Bristles

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Cleaning Floor Ducts
Duct Cleaning with the Air-Care TruckMaster II
The Air-Care TruckMaster II has a unique dual function. The motorized brush on the end of the
vacuum hose assembly agitates the dust and debris in the air duct, while you’re Truck Mount Vacuum
functions as the debris collector. This method of cleaning only requires that the supply and return
grills be removed and the air system is turned off. Caution, some air systems may automatically cycle
in the OFF position on the Thermostat, so it is best to also shut off the main power breaker to the
furnace while cleaning.
Before applying power, be sure that all 3 Switches on the Control Box are in the
OFF (0) position. After connecting the Air-Care TruckMaster to an extension cord
and a wall outlet, Turn on the Circuit Breaker on the Right, then the Motor can be
started after a few seconds. Connect the 1 ½” X 35’ hose assembly (or the
optional 2” X 35’ hose assembly) to your Vacuum Source Hose. The electrical
cord from the hose will plug in to the TruckMaster control panel socket. Unless
your truck vacuum has provision for “Dry Dust”, you should install the “Dust
Damper” between the Truck vacuum hose and the TruckMaster Hose and attach
the solution hose to the trucks solution hose. This wets the dust so it will not
damage the vacuum blower wheel. A low pressure setting can be used for the
Solution hose since it is only needed to “Dampen” the dust to prevent wear of the
Truck Mount Vacuum Blower Wheel.
The Remote uses an Infrared Light beam similar to a Television Remote. The
Remote Receivers are located on the control panel and on the back of the Power
Box. The operator can be across the room or up on a ladder and the remote will
often function with the IR beam reflecting off of light colored walls and ceilings even with obstructions
to visibility.
When using the Remote, BOTH Switches on the control box for the
brush MUST BE OFF (DOWN)! These switches can be used to
manually START/STOP or Change rotation direction of the brush if the
Handheld Remote Transmitter is lost or has a dead battery. When
these switches are ON (UP), it deactivates the Remote.
Once the technician inserts the brush into the duct, use the Remote’s
ON/OFF Button to start the brush and gently work the vacuum hose
and brush into the duct. STOP the brush before removing it from the
duct.
When the technician cannot push the vacuum hose in any further,
press the FWD/REV button on the remote to change the brush rotation
to allow it to go deeper into the ducts. Repeat this process for each supply and return duct. After a
Duct Run is clean, pull the hose partially out of the duct with the motor running, but stop it before
removing the brush from the duct opening.
Where you have long ducts, such as main trunk lines without access doors, you must make “cut-ins”,
to access the entire length of the duct. The cut-in must be covered with a metal plate and screwed in
place with sheet metal screws, then taped with Aluminum tape.
Cleaning Ceiling Ducts

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After cleaning each duct, each opening should then be decontaminated by fogging with our EPA
registered Envirocon sanitizer, Soot Set sealer and Liquid Odor Kill deodorizer.
Brush Motor Replacement Kit
Updated Coaxial Spring Mount
The Brush Motor and Mount retains all the advantages of the original and includes some
improvements to reliability, durability, and Debris Collection.
This motor and Hose mount will replace all previous motors and mounts.
KEEP THE NEW MOTOR FULLY ASSEMBLED!
First remove the OLD motor and motor mount from your hose:
1. Remove the screws holding the metal collar on the end of the hose and save the screws and
nuts to mount the new motor and mount.
2. Cut the 3 wires for the motor leaving enough cord to crimp (or solder) the wires to the new
motor wires. All 3 wires will need to be the same length for this new Motor Connection.
3. You will no longer need any of the parts in the original motor assembly unless you are
returning it to Air-Care with an RMA for warranty evaluation.
Installing the NEW motor assembly.
1. Be sure you have all the parts for the installation.
a. Your original Screws, 10-32 x 5/8” long machine screws,
b. 10-32 Hex Nuts with built in Lock Washers.
2. Remove the outer insulation from the black power cord in the hose to expose the 3
insulated motor wires about 2 inches long.
3. Strip the insulation off of all 3 wires about ½” back from the ends.
4. Slide the black Shrink Tubing over the cable. It will be slid over the new connections after
the wires are connected.
5. Slide the 3 pieces of shrink tubing over each of the motor wires. The connections can be
made by crimping the new connectors or soldering them. If you are planning to solder the
connections, be sure the blue shrink tubing is far enough away from the heated ends to
prevent it from shrinking prematurely.

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6. The wires may be different colors from the Motor than the ones from the hose cable. The
order is not important, the brush will operate with any combination of wires, but it may turn
in the opposite direction in some cases, but it will still change direction of rotation as before.
7. Each of the 3 wires from the hose can now be inserted into the Crimp connectors on the
new motor. Try to twist the wires tight enough so that all of the strands go into the silver
connector, and then crimp it with a crimping tool. Alternately, the wires can be soldered, if
so, be sure they are heated to a point where the solder flows into all the strands and into
the silver connector. The Motor is a low voltage; HIGH AMP device and a poor connection
will result in faulty performance.
8. Slide the Blue shrink tubing over the metal connector; Heat the tubing to shrink it in place.
A hair dryer, heat gun or even a cigarette lighter can be used. Be careful to not burn
yourself, the plastic hose or heat the other shrink tubing at this time.
9. Connect the other 2 wires following the same procedure.
10.When all 3 wires are connected and insulated, slide the black shrink tubing over them and
as far towards the motor as possible. Heat this shrink tubing to shrink it on to the wires.
11.Next, slip the Nylon Loop Strap over the wires. This will hold the wires in place and
minimize strain on the connections. The Loop Strap will be held in place with one of the
10-32 x 5/8” screws used to hold the black nozzle on the hose.
12.Insert the screws into the mounting holes in the Nozzle and thread the screws into the
original holes in the hose if possible. If this is difficult, you may need to drill new holes in
the hose using the 2 holes in the Black Nozzle as a guide. Use a 3/16” diameter drill.
13.When the screws are in place, place the loop strap hole over one of the screws and install
one of the nuts then tighten the screw with a screwdriver. It may be necessary to use a
screw driver to thread the screws through the loop strap.
14.If your hose has a metal stiffener, install its loop over the other screw, install the nut and
tighten it. If there is no stiffener, just install the nut and tighten the screws.
15.Your repair and upgrade is now complete and ready to test. If you have any questions,
please call Air-Care Tech Support, 800-322-9919.

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Specifications
Parts List
Specification
Description
Size
14.4” W x 19.5” D x 14” H
Weight
10.1 Pounds
Power requirements:
115 Volt AC, 60Hz, 5 AMPS
(Optional: 220/240 Volt, 50/60 Hz, 3 AMPS)
Power Cord
16 gauge, 3 wired, pigtail with grounded to 3 prong plug
Hose Attachments
Hose, 1 ½” X 35’ TruckMaster Brush and Motor Assembly.
Includes: 12” Pancake Brush, .021” BLK Level Bristles
Power Brush RPM is 2,000 max. with 1500watt Motor and
Power Connector
Optional 2” x 35 ft Brush and Motor Assembly with 18” Brush
Dust Damper for use with Truckmount carpet machines
connects between Truck Vacuum hose and TruckMaster
vacuum hose.
Operating Environment
25 to 125 Deg F (-4 to 50Deg C)
Case
Durable Rotationally Molded case with built in handle
Operating Controls,
TruckMaster
ON/OFF main Breaker with Red power indicator
Wireless Handheld IR Remote Control with 2 Activating Buttons
to Start/Stop and Change Direction of brush rotation.
Secondary Brush On/Off and Brush Fwd/Rev switches on panel
Description
Part
Number
Notes
TruckMaster Duct Cleaning system
FG0193
Power & Control Box, 1.5” x35 ft Hose,
12” brush 1500 watt Motor, Dust Damper,
AC cord and Bag
TruckMaster Power and Control Box
SATM0030
Power Cord NOT included
Remote Transmitter, hand held, 2 button, Belt/Pocket clip
SAXM0003
Two AA batteries included
Battery for remote (AA Standard or Alkaline )
SHOP0074
Standard or Alkaline AA
Brush, Motor, Vacuum hose Assembly 1.5”
FG0074
Includes 12” Pancake Brush
Brush, Motor, Vacuum hose Assembly 2.0”
FG0075
Includes 18” brush
Replacement Brush Motor Kit, 1500 Watt w/ Instructions
SADM0054
Replacement Flex-E-Bristle Brush with Pancake Hub, 12”
SAXM0001
.021” Diameter Nylon, Black, Level
Replacement Pancake brush, Pkg of 5.
SAXM0002
.021” Diameter Nylon, Black, Level
Replacement Flex-E-Bristle Brush with Hub 18”
SADM0025
.032” Diameter Nylon, Black, Level
Bristles, 1 hank, 18” x .032” Dia Level
BA0003
.032” Dia., Nylon, Black, Level, 1 hank
Power Cord, 15 ft, 18 ga x 3 wire grounded
EC0012
Standard Computer type end
Coil N Carry
FG0102
Dust Damper, 2.0”
FG0051
Instruction Manual (This Document) MM0205 on Resource
CD
SAO0009

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Pancake-Style Brush P/N SAO0307
w/12” Bristles:
Updated: 7/7/14
The configuration of the 12” brush (0.021 Dia Bristles) for the TruckMaster and DuctMaster 1.5”
vacuum hose and Motor has been changed to a flat, “Pancake-Style” hub that allows it to negotiate
sharper turns in smaller air ducts than the previous type hub. This 12” Brush directly replaces the
original 12” Brush asm. This is now a DISPOSABLE brush head with a Black Molded Hub and
Permanently attached bristles. It holds the bristles more securely which extends the life of the brush.
The 2” Vacuum Hose and motor still use the 18” brush with 0.032” dia Bristles in the traditional,
longer hub. (SADM0025).
This 12” Brush will work on the 2” hose, and
the 18” Brush will fit on the 1.5” hose, there are some
situations where the 18” brush may not start properly
(Due to the brush being held HIGHER by the 2” hose, so
the thicker bristles are easier for the motor to turn it).
Description
P/N
Quantity
Set Screw, ¼-20 x 3/8”
NBS0072
1
Allen Key (Wrench) 1/8” L-
Shape
Not Included
The new Pancake-Style Brush is replaceable as a unit
and disposable.

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Air-Care TruckMaster
Troubleshooting Guide
Symptom
Possible Causes
Suggested Action
Remote does not operate
Brush
1. Be sure Handheld Remote
is pointed at the Remote
Receiver sensor in the
center of the control panel,
Or on the back of the box
2. Check that the Red indicator
on the Handheld remote
flashes (Once) when any
button is pressed
Locate the TruckMaster so the
remote has an unobstructed view
of the center of the panel.
If the red LED does not flash, when
the remote buttons are pressed
replace the batteries. Almond colored
remotes use 2 “AA” batteries.
Brush & hose cannot be
inserted far enough into
duct.
1. Duct is too small for hose
(Less than 2” wide opening).
2. Duct makes two 90turns in
less than 12 inches.
Be sure you are using the 1 ½” X
35’ Hose, Brush and Motor
Assembly
Try to access the duct from
another opening.
Brush Motor does not
turn.
1. The Brush Switches on the
Panel was “ON” when the
power cord was plugged in
2. Electronic Torque control
shut down brush motor
power.
3. There was a power loss in
the building or a power
surge.
4. Motor Connectors have
come loose.
5. Wire in Motor Head Is
broken
Be sure the Brush Switches on the
Panel is OFF.
If using the Remote, you must
press “RUN” Button again, if using
the Panel Override buttons, the
brush will restart on its own.
Be sure the Brush Switch on the
Panel is OFF. Try using remote
again.
Be sure Brush Power Cable is fully
inserted into the Panel Connector.
Contact Air Care tech support.
There are holes in the
red vacuum hose.
1. The “crush proof” hose is
very durable, but if it is
pulled excessively hard, it
can separate at the grooves.
Call Air-Care for an RMA for a
quote to have the vacuum hose
repaired or replaced.
Call Air-Care 800-322-9919 or
702-454-5515 [email protected]

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Glossary & Acronyms
1. ACGIH—American Conference of Government Industrial Hygienists
2. ASHRAE—American Society of Heating, Refrigerating, and Air Conditioning Engineers
3. Air Handler/ AHU—The Furnace or air conditioner that heats, cools and moves the air.
4. Antimicrobial—Agent that kills Bacteria, Molds and viruses. See “Sanitizer
5. Arrestance –An ASHRAE standard procedure to measure air filter efficiency (52.1)
6. Bioaerosols—Molds and bacteria that are found floating in the air.
7. Biological Contaminants—Bacterial, Mold/Fungus, viruses and their waste, byproducts and decomposition materials
that can be inhaled and cause many types of health effects.
8. Building Related Illness—Diagnosable illness whose symptoms can be identified and whose cause can be directly
attributed to airborne building pollutants (e.g., Legionnaire’s disease, and hypersensitivity Pneumonitis).
9. CFM—Cubic Feet per Minute, a measure of how much air is flowing in an air system.
10. CO—Carbon Monoxide, an odorless, toxic gas produced during combustion.
11. CO2—Carbon Dioxide an odorless, non-toxic gas produced during combustion and exhaled by people.
12. Ceiling Plenum –The area above a suspended ceiling that may be used as a return path to the Air Handler.
13. Conditioned Air –The air that has been filtered heated or cooled by the air handler.
14. Dampers –Flaps or valves in the air duct that control the amount of airflow in the duct.
15. Diffusers & Grilles & Registers –The covers at the end of supply and return ducts that control the amount and
direction of the air-conditioned air entering or leaving a room.
16. Electrostatic Filter –A High Efficiency (95% Arrestance) Air filter that generate static electricity from the air movement
through the air handler and captures dust from the air while the clean air move freely through it.
17. EPA—Environmental Protection Agency
18. Duct –A metal, plastic or fiberglass tube that transports air to and from the Air Handler. They can be round, square or
rectangular.
19. Duct Board –Compressed fiberglass material used to make air ducts, particularly in the southern U.S.
20. Fiberglass Filter –A disposable, very low efficiency filter (approx. 10% arrestance).
21. Flex duct –Plastic fabric duct with a spiral wire support. It is used extensively in the Western U.S.
22. HEPA—High Efficiency Particulate Air
23. HVAC—Heating, ventilation and air-conditioning
24. IAQ—Indoor Air Quality
25. MSDS—Material Safety Data Sheet
26. Make-up Air –Fresh “outside” air that is brought into a Commercial building.
27. NADCA-National Air Duct Cleaners Association
28. NAFA –National Air Filter Association
29. NIOSH—National Institute for Occupational Safety and Health
30. Negative building pressure –A condition that allows air to flow into a building when a door is opened.
31. NSC -- Nevada Safety Counsel
32. NSF International –An independent testing laboratory for Air filters
33. OSHA—Occupational Safety and Health Administration
34. Positive building Pressure –A condition when air will come out of a building when a door is opened.
35. Re-entrainment –The flow of dust and debris removed from an air system back into the same building
36. Return/Return Duct
37. Sanitizer –A material designed to kill mold, bacteria, and viruses.
38. Sick Building Syndrome –A group of symptoms such as headache and watery eyes that disappear after the sufferer
leaves the building for a few hours.
39. Supply/ Supply Duct—The opening and related ductwork that delivers conditioned air to a room.
40. VAV—Variable air volume system –A system that varies the amount of flow of air to regulate temperature.
41. VOC’s—See “Volatile Organic Compounds”
42. Volatile Organic Compounds (VOC’s)—Chemicals that release gasses into the air such as solvents.

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LIMITED WARRANTY
TRUCKMASTER II
Air-Care warrants this product to be free from defects in materials and workmanship to the original
purchaser for a period of Two (2) years from the date of purchase. Components listed below are
excluded from this Two year period and are covered for periods described below:
Circuit Board & Remote 1 Year
Speed Controller 1 Year
Hose & Motor Assembly 90 Days
Brush Assembly No Warranty
Warranty covers both parts and labor (labor is to be performed at Air-Care’s facility located at 3868 E.
Post Road; Las Vegas, Nevada).
Warranty is extended to the original purchaser and is not transferrable.
This warranty does not extend to any damage to a product caused by or attributable to freight
damage, abuse, misuse, improper or abnormal usage. Warranty is also void if the product has been
modified or altered in any way.
The purchaser is responsible for the cost of shipping the equipment to Air-Care’s facility for
evaluation. If found to be defective and covered by the terms of this warranty, Air-Care will pay
FedEx ground shipping charges on the repaired or replaced item back to the purchaser’s location.
Any additional expedited service charges for quicker shipping shall be born by the purchaser. If the
product or component is not found to be a warranty issue, the purchaser will be responsible for return
shipping charges.
Air-Care is not responsible or liable for indirect, special, or consequential damages arising out of or in
connection with the use of performance of the product; damages with respect to any economic loss,
loss of property, loss of revenues or profits, loss of use, or other incidental or consequential damages
of whatsoever nature.
The warranty extended hereunder is in lieu of any and all other warranties, and any implied
warranties of any type.
This warranty gives you specific rights. These rights and others vary from state to state.
Division of D.P.L. Enterprises Inc.
3868 East Post Road, Las Vegas, Nevada 89120, [phone], FAX [phone]
Website: www.air-care.com; E-mail: [email protected]