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