Double K Industries Challeng Air AIRMAX User manual

REQUIRED MAINTENANCE
FILTERS:
(Procedures below must be performed regularly or as needed to protect dryer warranty status.)
FILTER CLEANING: Both the external and internal lters of the CHALLENGAIR AirMax® should be
kept clean. If the lters become heavily coated with hair and/or dirt, it will reduce the air output of
your dryer and can cause damage to the motors or cause the motors to overheat.
*Never operate the dryer without all lters in place.
To clean external lter: Vacuum or shake o dirt and hair daily. Filter may be rinsed in water if
necessary. Let lter dry completely before reinstalling on dryer.
To clean the internal motor lter of the CHALLENGAIR AirMax®:
1. Unplug dryer.
2. Slide o the back cover of the dryer. This is a compression t and will come o with
a little eort.
3. Remove the lter from the internal lter housing.
4. Clean motor lter disk by vacuuming o hair and dirt, or wash lter gently in cool
water. Shake o excess water and allow to air dry completely. (Replace lter if necessary)
5. Place the lter back in the lter housing.
6. Replace dryer back cover.
Any maintenance not explained in this manual should be performed by Double K Industries or
an Authorized Service Center. Call Double K Industries for the name of an Authorized Service
Center nearest you. All warranty service must be performed by an Authorized Service Center (or
Double K Industries) to protect your warranty status.
8
Attachment List
Attachment P/N Description Qty.
825-6, 8,10, Hose 1½” Black on Blue 1
12 or 15
896 1½” Air Sweep Nozzle 1
897 1½” Regular Nozzle 1
2036 Hose to Dryer 1½” Locking Adaptor 1
2068 1½”-¾” Hi-Velocity Nozzle 1
2070 Nozzle - Super Hi-Velocity 1
TM
TM
INSTRUCTION MANUAL
PLEASE READ ALL INSTRUCTIONS AND SAFETY
PRECAUTIONS BEFORE OPERATING PRODUCT!
SAVE FOR FUTURE REFERENCE; WARRANTY
PERTINENT CONTENT.
Product Specications:
Model -
Voltage: 115v Voltage: 230v
Amperage: 16.4 Amperage: 5.8
Hertz: 60 Hertz: 50/60
Wattage: 1886 Wattage: 1334
Horse Power: 3 each motor Horse Power: 3 each motor
Motor Air Volume: 123 CFM each Motor Air Volume: 123 CFM each
9711 Mason Avenue, Chatsworth, CA 91311
[phone] • [phone] • fax: [phone]
www.DoubleKIndustries.com • [email protected]
®
®
8/18/14
ANIMAL DRYER

7
BRUSHES
Your CHALLENGAIR AirMax® has two brush-type motors. The brushes should be checked for
wear after approximately 500 hours of use. If the carbon brushes are worn shorter than 1/4
inch, the brushes should be replaced. Brushes may be ordered from Double K Industries or
an Authorized Service Center (you will need 2 sets, 1 set for each motor). Please be sure to
specify that your dryer is an AirMax®, as the brushes are slightly dierent from one dryer
model to another.
To check and/or replace brushes:
1. Unplug electrical cord from wall outlet.
Disassembly:
2. Slide o the back cover from the dryer. This is a compression t and will come o with a
little eort.
3. Remove all screws on the outside of the dryer that hold the two halves of dryer housing
in place. Remove the o-ring on the snout of the dryer. It may be best to lay the dryer on
its side while removing these screws. Lift o the top half.
4. Each motor will be sitting in place inside the rubber silicone motor mounts. Removing
the rubber silicone motor mounts from the motor is not necessary to replace brushes.
5. Disconnect the motor power wires. Note where wires connect.
6. Front motor:
A. Loosen the two brush assembly retainer screws (Fig. 3, Ref # 3) to loosen the
brush assembly retainer (Fig. 3, Ref # 2). Remove the brush assembly (Fig. 3, Ref
# 1) and replace it with a new one. (Note: IMPORTANT - the brush has a small
tab on the bottom that MUST be tted into the slot on the motor frame for
proper positioning) (Fig. 3, Ref # 4)
B. After the new brush assembly is seated, tighten the brush assembly retainer
screws.
C. Repeat steps A-B for the brush on other side of motor.
Rear motor:
A. Follow steps A-C above, as outlined for the front motor.
Reassembly:
7. Inspect the motor mounts for cracks or damage -- replace if necessary. Set the motors
back into their original positions in the dryer housing. Each motor mount has slots that
t over corresponding alignment tabs on the inside of the dryer housing. These slots
and tabs must match up for proper t and function. (Note: In the event that the motor
mount is removed from the motor, simply replace it by being mindful to align the
contours of the motor mount with corresponding contours on the motor housing.)
8. Reattach the screws around the outside of the dryer making sure the two halves are
matching up.
9. After the two halves of the dryer housing have been put together, replace motor lter on
back motor and push the back cover onto the rear of the dryer. Replace exterior lter
onto back cover. Always make sure all lters are in place before operating dryer.
Replace o-ring on snout.
2
IMPORTANT SAFEGUARDS
WARNING: IMPORTANT SAFETY PRECAUTIONS! PLEASE READ
COMPLETELY BEFORE USING PRODUCT!
When using electrical appliances, especially in the presence of children and animals, basic
safety precautions should always be followed to reduce the risk of re, electric shock, and
personal injury, including but not limited to the following:
DO NOT TURN ON DRYER WITHOUT FIRST HOLDING THE DRYER HOSE, as the air volume from
the dryer can cause the hose to whip or move rapidly and may cause injury.
1. Do not leave dryer OR the animal unattended while product is in use.
2. Unplug unit when not in use.
3. Do not use extension cords with dryer.
4. Do not unplug unit by pulling on cord.
5. Do not expose dryer to rain or water.
6. Do not use or store dryer where it can fall or be pulled into tub or sink or standing water.
If dryer falls into water . . . UNPLUG IT . . . Do not reach into the water!
7. Unplug unit before attempting any maintenance or service.
8. Do not put any object into dryer openings.
9. Keep loose clothing, jewelry and hair away from dryer openings.
10. Do not direct dryer air towards eyes or ears of people or pets.
11. Never use dryer if it has a damaged cord or plug, has been dropped, damaged or
exposed to rain or water. Return to Double K Industries or an Authorized Service
Center for service.
12. This dryer should not be used as a cage dryer, for cage drying please consider our model
560 Cage dryer.
13. This product is for use on animals only.
14. Recommended operation by adults only. Use caution when working around children.
15. Do not use attachments not recommended by Double K Industries.
16. Do not operate without lters in place. Keep lters clean, as dirty lters limit air intake
and may damage the motor or cause overheating.
17. Plug only into a properly grounded receptacle. Always make sure the amperage of the
electrical outlet is sucient for the amperage rating of the product. (See Product Speci-
cations for amperage rating of this product).
18. Do not use product for anything other than its intended purpose.
19. Do not attempt to perform any service or maintenance not outlined in instruction
manual.
20. Do not attempt any product modications or alterations. Do not use, if any parts or
switches are damaged. Send to an Authorized Service Center or Double K Industries
for service.
21. When servicing, use only Double K Industries parts.
WARNING: DISCONNECT POWER SUPPLY BEFORE SERVICING
AVERTISSMENT: COUPER L’ALIMENTATION AVANT
L’ENTRETIEN ET LE DÉPANNAGE

6 3
Fig. 3
Top Down
Motor Part
# 2069
Brush Assembly
Retainer (Ref #2)
Brush Assembly
Retainer (Ref #2)
Male Terminal
Brush Assembly with
Metal Body (Ref #1)
Brush Assembly with
Metal Body (Ref #1)
Part #2065
Brush Retainer
Arm must slide into
the Male Terminal
Brush Assembly
Retainer Screw
(Ref #3)
Brush Assembly
Tab (Ref #4)
Brush Assembly
Retainer Screw (Ref #3)
Congratulations!
You’ve just purchased the Double K CHALLENGAIR AirMax® Forced Air Dryer, which produces
warm, high velocity air under pressure, to make your animal grooming tasks easier. Your new
dryer is designed to provide long, reliable service.
Please read this manual carefully and completely before beginning operation of your dryer
and keep in a convenient and safe place for future reference.
A warranty card is included with your dryer and should be lled out completely and mailed to
Double K Industries within 30 days of the purchase date of your dryer to validate your
warranty. Online registration is available at www.DoubleKIndustries.com
Your CHALLENGAIR AirMax®has a two-year warranty covering the unit against defects in
materials and workmanship. Regular maintenance items such as brushes and lters are not
included (see warranty card for complete warranty information). It is also important to retain
your sales receipt as proof of purchase should service ever be needed.
Your CHALLENGAIR AirMax®has two brush-type motors. It is important that the brushes be
changed when they become worn down to prevent damage to your dryer motor (brushes are
maintenance components and are not covered under the warranty). We suggest checking the
motors’ brushes after every 500 hours of dryer use. Please see section on BRUSHES in this
manual for instructions.
A NOTE ABOUT HEAT: Your CHALLENGAIR AirMax®has no heating element. The
CHALLENGAIR AirMax®produces heat by a “ow-thru” motor system, meaning the air is
pushed through the motors and is warmed by the natural heat of the motors that occurs
during operation. This means greater electrical savings and eciency for you. The dryer will
reach its maximum air temperature after about 2-4 minutes of operation. (Note: The higher
the room temperature, the warmer the air from the dryer will be.)
ASSEMBLY
To attach hose to dryer: Your dryer hose has a black hose adapter that will screw onto the
hose in a counter-clockwise motion. The adapter with hose attached then ts onto the dryer
with a half-twist motion that locks the adapter onto the dryer.
First, place the adapter over the snout of the dryer with the Double K logo facing up, then turn
hose counter-clockwise until the adapter locks in place, the Double K logo should then be
sitting horizontally.
To remove hose from adapter: Turn the hose clockwise.
ATTACHMENTS: Your dryer is equipped with one hose and 4 twist-on nozzles. To attach
nozzles to hose, twist the nozzles counter-clockwise. Twist clockwise to remove.
OPERATION - Switches and Controls:
1. 2-Speed:
a. Low Speed / Standard Heat - Turn on the top motor switch.
b. High Speed / High Heat - Turn on both motor switches.
2. Variable Speed (optional)
a. Maximum Output - Turn the dial speed control clockwise to its maximum.
b. Variable Output - Turn the dial speed control clockwise to desired air output.
c. O Position - Turn the dial speed control counter-clockwise until it clicks o.
Fig. 2 TopFig. 1 Side

4
MODEL
EXPLODED DIAGRAM
TM
24
23
22
21
20
19
10
12
11
13
15
7
6
534
2
2
14
1
1
7
7
9
7
8
17
16
18
25
28
*
26
*
27
*
35
29
30
31
34
33
32
Variable Speed Diagram
2-SPEED WIRING
DIAGRAM
CORD
Black
Green
Green
Blue
Black Black
White
Green
Red Red #10101
Blue #806
Switch #2148
Switch #2148
#5537 Wire Nut
White #5512
White #5512
#5539 #5539
#5537
Front Motor Assy.
#2069
Rear Motor Assy.
#2069
®
®
VARIABLE WIRING
DIAGRAM
Speed Control
Board
CORD
Triac
Blue
Red
Gray
Blue
Blue
MTR
#1
MTR
#2
Green
Green
#5539
#5537 Wire Nut
Black
(Blue 230v)
White (Brown 230v)
Black
Black
Green
small
prong
MTR #1
PN#
2064
MTR #2
PN#
2064
Black
Black
Blue
230V
2-SPD WIRING
DIAGRAM
Switch #2148
Switch #2148
Wire Nut Wire Nut
Wire Nut
Blue
Blue
Brown
Cord
Brown
Brown
Red
Green
Green
Green Green
Item# Part# DESCRIPTION Qty.
1 2167 Screw 2600 Series Housing 12
2 2123 Housing Plug (models w/o stand) 2
3 2603 Decal, AirMax Switch Side 1
4 2148 Switch Rocker 20A 125VAC 2-Pos 2
5 2198 Barrel Bolt (1/4 Barrel 24 Thread) 1
62157-1 Long Black Housing, Right Side 1
2155-1 Long Blue Housing, Right Side
72065 Motor Brushes, 115v 4
2214 Motor Brushes, 230v
8 2159 Wire Grommet, 4-Hole 2
9 2108 Housing O-Ring for Hose Adapter 1
10 2157-2 Long Black Housing, Left Side 1
2155-2 Long Blue Housing, Left Side
11 2197 Screw, 1/4 Shoulder (#10-24 Thread) 1
12 2131 Shim .24 OD x .190 ID x .015 1
13 2221 Decal, 115v AirMax 1
2222 Decal, 230v AirMax
14 2187 Cork Disk Filler 1
881-3 Assy. Cord Set 115v
403 230v GB Cord Set UK-Ireland
15 404 230v China Cord 1
405 230v Eur. Cord Set Continental Europe
408 230v Aus Cord Set New Zealand
16 5539 Nut, Orange Hard Plastic Wire 3
17 2119 Blue Terminal Flag 16-14ga 4
18 2160 Silicone Rubber Molded Motor Mount 115v 2
2164 Silicone Rubber Molded Motor Mount 230v
19 2191 Internal Filter Housing 1
20 2196 Internal Filter 1
21 2009 Sound Control Foam Disk 2
22 2049 End Cap Assembly (incl. 5538 and 2009) 1
23 5538 Velcro for External Filter 1
24 2027 External Filter 1
25 2069 Motor 120v AirMax 5.1” Single Stage 2
2064 Motor 230v AirMax 5.1”Single Stage
*26 2177 Year 2010 - Filter Assy. *
*27 2178 Year 2010 Filter Pack Pack 3 Per Order *
*28 2100 Year 2009 Internal Snap-In Filter *
29 2215 VS Decal, 115v Airmax, Product Data Side 1
30 2168 Speed Control Board (115v) 1
31 2145N Nut, Rheostat Speed Control - VS 1
32 5509 Knob Switch Black 1
33 2217 Decal VS Pot Side: Variable Speed Units 1
34 2153 3/8 External-Tooth Lock Washer 1
35 640-1 Triac (115v), Assy. w/ Heat Sink 1
PARTS LIST