HydraMaster CrossFire 4.2 User manual

HYDRAMASTER
Corporation
6323 204th Street SW, Lynnwood, WA 98036
CrossFire 4.2
Machine Serial Number
Copyrighte1996
HYDRAMASTER@ Corporation
Lynnwood,Washington
182-022
No part of this manualmay be reproducedor used in any form or by any means(i.e. graphic,electronic,photocopyingor
electronicretrievalsystems} without the express written permissionof the HYDRAMASTERe Corporation, All rights reserved,
RevisedJanuary25, 1996

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CrossFire 4.2
Anti-Freeze Procedure ..............................
WATER AND CHEMICAL SYSTEMS.. .......................
Water Flow ......................................
Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proportioned Diagram ..,. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chemical Tank Troubleshooting ........................
PRESSURE PUMP ,
Pump
Pump
Pump
Pump
Maintenance
Service (Wet
................................
.................................
End) .............................
Service (Hydraulic End)..... ....................
Troubleshooting ..............................
Assembly Drawings and Parts Lists .....................
CLEANING WAND ASSEMBLY PARTS . . . . . . . . . . . . . . . . . . . . . . .
Valve, Jet, Wand Assembly Drawings ....................
Parts List .......................................
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Specifications Sheet
Blower Instruction Booklet
ENGINE INFORMATION .......
Engine Troubleshooting . . .
Kawasaki FD620D Owner’s
..........................
...........................
Manual
. . . 4-2
Section 5
... 5-1
. . . 5-3
. . . 5-4
. . . 5-5
Section 6
. . . 6-1
. . . 6-3
. . . 6-9
...6-14
. . . 6-16
Section 7
... 7-1
. . . 7-4
Section 8
... 8-3
9
. . . 9-1
HydraMaster Cwpratim 4/11/95

CrossFire 4.2
Kawasaki Engine Specifications Sheet
ELECTRICAL SYSTEM,,.,.,,,, .,, ..................... Section 10
Wiring Diagram Machine . . . . . . . . . . . . . . . . . . . . . . . . , ..,..,.10-2
Diagnostic Center.,.,,,, .....................,, .,..,.10-3
MACHINE MAINTENANCE .............................. Sectionll
Daily ..........................................,.11-1
Weekiy, Monthly.,,...,,, ......................., ....11-2
Quarterly, De-scaling, .,.,. . . . . . . . . . . . . . . . . . . . . . . . . . ...11-3
Overall Care,..,...,,,. .............................11-3
Maintenance Logs
HOW TO ORDERPARTS ...............................
WARRANTY INFORMATION, .,.,. ,,. .. s. . . . . . . . . . . . . . . . .
Golden Guarantee@
ACCESSORIES, ,, .,,..... ,, .,, ,,, . .,, . . . . . . . . . . . . . . .
PROIXJCT UPDATES......,,,.. ................ s......
Section 12
Section 13
Section 14
Section 15
HydraMaster Corporation 4/25/95

Introduction
CrossFire 4.2
Section 1-1
This manual contains installation and operation instructions as well as
information required 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 agarden tractor, lawn mower or cement mixer, all having one or
two functions to perform, the truck-mounted carpet cleaning plant has
many functions to perform simultaneously.
FThe engine has to run at aconsistent RPM.
FThe vacuum has to pull air and dirty water back from cleaning
site.
*The water pump provides stable pressure at proper water flow for
cleaning.
FThe chemical has to be injected into the water stream at the right
concentration.
EThe heating system must maintain proper heat.
FThe vacuum tank must store dirty water until drained.
As you can see, it is not just aturn-key operation with one thing to worry
about, Does it start?!
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section I-2
The manufacturer uses this symbol throughout the manual to warn of
possible injury or death.
This symbol is used to warn of possible equipment damage,
HOURS TELEPHONE
Monday -Friday [phone]
8:00 am to 5:00 pm [phone]
PACIFIC STANDARD TIME [phone] Service
Parts /Serv
Parts
ce FAX
HydraMaster Corporation 7/18/’95

System Operation
CrossFire 4.2
Section 1-3
The CrossFire heat exchanger system is ahighly engineered cleaning
plant designed by HydraNlaster Corporation. The system utilizes a
dynamic heating system comprised 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 acleaning
solution as it enters the mix tank. The solution is then picked up by
the high pressure pump and pressurized to the desired level. The
water then splits flow, as demanded by the operator. The majority
of the water flows to the by-pass valve assembly, then back through
the secondary exhaust heat exchanger, and back to the mix tank.
The water demanded by the operator flows from the water pump
through the primary exhaust heat exchanger then out to the cleaning
tool.
When the cleaning solution reaches apre-set high temperature, it is
released from the system and directed to the recovery tank. Then cool
water enters the system to regulate the temperature.
As there is no guess work in the manufacture of these highly advanced
cleaning plants, there must be none in preparing it to get the job done in
the field. It is the purpose of this manual to help you properly understand,
maintain and service your cleaning plant. Follow the directions carefully
and you will be rewarded with years of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for
operation of this equipment.
HydraMaster Corporation 4/11/95
1

Machine Specifications
CrossFire 4.2
Section 1-4
Frame: 23”W x59”L x37”H
Weight: Crossfire 4.2: 750 Ibs,
Cowling: Steel with Baked-on Epoxy Finish
Engine: Kawasaki Liquid Cooled V-Twin
Displacement: 617 cc
Ignition: Electronically Triggered Coils (1 per cyl.)
12 vElectric Starter Motor
12 v, 20 amp Alternator, Regulated
Integrated Governor
Pressurized Oil System with Filter
Pressurized Cooling System
Triple Row Radiator
Vacuum Blower: Proprietary Dual Shaft Roots
45 RAI JWhispAirTM
Chemical System: Electro-mechanical, Meter Controlled
Heating System: 1Stainless Steel Heat Exchanger
2Copper Shell and Tube Heat Exchangers
Instruments and Controls: Water Pressure Gauge,
Liquid Filled, 0-1000 PSI
Water Temperature Gauge, 0-280° F
Vacuum Level Gauge, 0-30” Hg
Hour Meter, machine run time
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section1=5
Recovery Tank:
Cleaning Wand:
Chemical Flowmeter, clear acrylic, 0-10 GPFI
“Run” Indicator Lamp
Full “Vat Tank” Lamp
Mix Tank “Temp” Lamp
Keyed Ignition
Resettable Circuit Breakers
Accessory Switches
Manual Engine Throttle
Mix Tank Drain Valve
Recovery Tank Drain Valve
Panel Mounted Pressure Adjustment Valve
Manual Engine Choke
Blower Lubrication Port
70 gallon Aluminum, Epoxy Finish
Stainless Steel with Heat Shield.
Grip and Replaceable Vacuum Lips with Stainless Steel
Solution Valve.
High Pressure Hose: M” High temperature, Lined, Vinyl Covered
Hose rated to 1250 PSI.
Vacuum Hose: 2“ Reinforced, 1%” Reinforced
Standard Equipment: Machine Power Console
Full Instrumentation
WhispAirTM Vacuum Blower
CrossFireTM Water Heating Package
Deluxe Sound Suppression Package
Vacuum Recovery Tank
Carpet Cleaning Wand
5gallon Chemical Jug
Chemical Jug Holder
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section1-6
Chemical Jug Fill Line
150 ft, 2“ Vacuum Hose
10 ft, 1k“ Wand Whip-line
10 ft, 1%” Recovery Drain Line
50 ft, Water Supply Line
150 ft, %” Super Flex Solution Line
Dual-Wand Vacuum Fittings
Dual-Wand Solution Fittings
Freeze Guard System
Battery Box with Holder
Telescoping Console Legs with Casters
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket
Optional Equipment: Please refer to Section 14.
HydraMaster Corporation 4/11/95

Spare Parts
Crossl%e 4.2
Section 1-7
Down-time on the unit can be very expensive, because your truck-
mounted unit is capable of generating several hundred dollars per
day. In order to minimize such down-time, it is strongly recommended by
the manufacturer that you purchase and keep in your truck the parts listed
below.
Parts Orders
To expedite your parts needs, please call your sales representative. In
most instances, he either stocks or has access to parts through aregional
service center. If further assistance is needed, contact the factory and
coordinate your needs, If this becomes necessary, always indicate the
method of shipment you desire, i.e. UPS, Blue Label, Air Freight, Air
Express, etc.
HydraMaster Parts Dept. Phone .....i. . [phone]
HydraMaster Parts Dept. Toll Free Fax . . . [phone]
Spare Parts List (078-093)
PART NO DESCRIPTION QTY
010-014 Belt, #9341 Pump Drive 1
070-018 Belt, 5X 59-MultiCat Drive 2
018-004 Breaker, 25 amp Circuit 1
018-005 Breaker, 20 amp Circuit 1
025-011 Cable, Aqua 5’ Choke 1
049-048 Filter, Oil -20 HP Kawasaki 1
HydraMaster Corporation 4/11/95

CrossFire 4.2 Sectionl-8
PART NO DESCRIPTION QTY
049-007
049-015
049-016
049-023
049-047
049-030
052-050
052-051
052-052
052-053
057-043
076-005
074-003
074-020
078-018
078-015
078-019
078-101
106-032
131-037
149-011
149-013
157-001
157-007
157-008
157-022
157-111
169-022
169-062
169-120
Filter, S/S Vacuum Pump
Filter, 1/2” Replacement Y
Filter, 1/4” Replacement Y
Screen, Garden Hose
Filter, Air -20 HP Kawasaki
Filter Bag, 92+ Truck Mount
Quick Connect, 440 Male
Quick Connect, 440 Female
Quick Connect, 660 Male
Quick Connect, 660 Female
Gasket, Recovery Tank -All
Jet, #6 S/S -Hydra Hoe
Gauge, Hi PSI (O-1 000)
Meter, Chemical Flow -CDS
Kit, Diaphragm 3GPM H-M High PSI
Kit, Chem Flowmeter
Kit, H/M Solution Valve
Kitr Seal &Spring Hi PSI
Plug, 20 HP Kawasaki, Spark
Wrap, Exhaust Insulation
Thermostat, Aqua 185 Deg.
Sensor, 245 Degree -Hot
Switch, Tethered Mercury
Switch, 12V DC Lited
Switch, Ignition
Switch, Relay -A/C, B/C, CDS
Switch, Chrome Momentary
Valve, 11/2” Full Port
Valve, 1/4 Anti-Siphon
Valve, Chemical System
1
1
1
1
1
2
3
2
1
1
1
1
1
1
1
1
1
1
2
1
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1
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2
1
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Elydraiklastim Corporation 4/11/95

.
Responsibilities
CrossFire 4.2
Section 1-9
T’ he Purchaser’s responsibilities are:
Prior to arrival of unit, install 5/8” exterior plywood
and cover it with artificial turf.
II +CAUTION +II
uq
Purchase heavy duty 42 -60 amp hour battery
‘slow’ charge if new. If the battery is not fully
occur to the engine charging regulator,
flooring in the vehicle
and have the battery
charged, damage can
Reading of owner’s manual: It is the purchaser’s responsibility to read the
unit operation manual and to familiarize himself with the information
contained therein. Special attention should be paid to afl Cautions and
Warnings.
The Sales Representative’s responsibilities
ACCEPTANCE OF SHIPMENT:
1, If the unit shows any outward signs
delivery receipt until you have closely
any damage on the delivery receipt,
are:
of damage, do not sign the
inspected the unit and noted
2. The salesman from whom you purchased your unit is responsible for
supervising the correct installation of the unit in your vehicle and
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section1-10
thoroughly training you in its operation, maintenance and precautions.
CORRECT INSTALLATION INCLUDES:
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 engine and see that all systems function
normally;
Checking all hoses, wands, etc. for correct operation.
TRAINING SHALL INCLUDE:
FAthorough review of the operation manual with purchaser;
PInstruction and familiarization in: how to correctly start up and shut
down the unit, how to correctly clean with the unit, where and how
often to check and change component oil levels, how the unit’s
systems work, how to troubleshoot the unit, how to do basic
repairs, safety precautions and their importance, freezing damage
and how to avoid it, hard water damage and how to avoid it;
*Athorough review of the unit warranty and warranty procedures.
HydraMaster Corporation 4/11/95

Vehicle Prep
CrossFire 4.2
Section 1-11
The preferable vehicle for aCrossFire or ProFire installation is acargo
van with aheavy-duty suspension package. The van should have 3/4
ton capacity.
TRUCK PREPARATION
The manufacturer recommends the installation of plywood flooring,
covered with polypropylene backed astroturf (do not use rubber-backed),
in the vehicle prior to installation of machine.
Be cautious when drilling any holes through the van floor.
Many vans have critical components mounted directly below
the van floor that could be damaged by amisplaced drill bit.
(See Product Support Bulletins 92102, 94062 and 94063 at
the end of this manual. )
This provides ametal-to-cushion mounting rather than metal-to-metal,
insulation and makes an attractive van interior. The astroturf should be
color keyed to the van interior.
Materials Needed:
1. 2sheets 4x8x%” exterior plywood
2. 6’xI 2’ piece of commercial astroturf
3. 16- 1%” sheet metal screws
4. 1quart marine adhesive (optional)
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section 1-12
5. 1staple hammer with %” staples
(See illustration for correct placement of plywood flooring)
ROOF VENTS
HydraMaster strongly recommends installation of roof vents in all
truckmount installations. When installing equipment with propane
heaters, these must be vented through the roof of the van.
PLACEMENT OF
There are two
illustrated in the
A. SIDE DOOR:
UNIT IN VEHICLE
recommended unit placements described below and
following diagrams.
Most installations are side door. This provides rear
access for accessories and hoses as well as unobstructed access to the
component/working side of the machine, thus making it abit easier to
perform maintenance and/or repair without removing the unit from the
truck.
B. REAR DOOR: Although this location partly limits working access, it
does direct the noise away from the cleaning site. Some cleaners in the
colder areas prefer this location because it puts the weight over the rear
wheels for better traction in ice and snow. Rear mounting requires the
unit to be slid to the right side as far as possible. This not only provides
adequate working space on the component side of the unit but also
improves weight distribution inside the van (engine and component weight
line up over drive shaft), Also, it is physically easier to load the unit into
the rear door due to the height of the van bed.
HydraMaster Corporation 4/’11/95

CrossFire 4.2 Section1-13
Figure 1-1: Plywood Installation
‘-$’-
G“ _
‘igure 1-2: Astroturf and Roof Vent
km
‘igure 1-3: Tie Down Cleats
Minimum
HydraMaster Corporation 4/11/95

CrossFire 4.2 Section1-14
Ensure that the machine is well secured to the floor of the van with the
hardware supplied. Asudden or crash stop will cause the machine to
rocket forward, all 750 Ibs. worth! Protect yourself and the machine.
SECURE IT!
1===1
II 1[
It is recommended by the manufacturer that the exhaust from the front of
the machine be vented down under the truck to prevent carbon monoxide
from entering the job site. Always park the truck so the exhaust is
blowing away from the job site.
The manufacturer also recommends the installation of aluminum vents in
the truck roof to allow heat to escape.
Mount afire extinguisher just inside the rear or side
1====1
Never operate this machine with aportable gas
Doing so increases the risk of afire or explosion.
-
door for emergencies.
can inside the truck.
Transportation in avehicle of any vented fuel container that presently
holds or has ever held aflammable liquid is strictly forbidden by
l-lydraMaster Corporation and by federal and state regulation.
HydraMaster Corporation 4/11/95
L

CrossFire 4.2 Section1-15
Do not use aportable propane tank
dangerous and illegal in most states, nside of the truck or van. tis
HydraMaster Corporation 4/11/95

Local Water Precautions
CrossFire 4.2
Section 1-16
of water varies greatly. Many areas have an excess of
the water which results in what is commonly called “hard
The quality
minerals in
water”. These minerals tend to adhere to the insides of heater coils and
other parts of the machines causing damage and a loss of cleaning
effectiveness. This influences the reliability and efficiency of equipment
in direct proportion to the level of hardness.
HARD WATER AREA MAP
The following map defines areas in the United States which compromise
fluid related components such as hoses, fittings, heaters, pumps, valves
and water cooled engines. For other countries, hard water area maps can
be obtained from geological societies.
WATER SOFTENER
Cleaning efficiency and equipment life is increased, chemical use
decreased, and the appearance of cleaned carpets enhanced when water
softeners are incorporated in hard water areas. The manufacturer strongly
urges the use of water softener units in areas exceeding 3 1/2 grains per
gallon. Using ahard water area map as areference, determine the quality
of water in your area and take action immediately, if necessary.
Reports from several of our machine users commending the results of the
use of water softeners in conjunction with their machines prompts us to
recommend the procedure to everyone in a“hard water” area.
HydraMaster Corporation 4/11/95