PowerClean Liberty XT User manual

Owners Manual
Powerful Cleaning Solutions
Liberty XT
Multi Surface Cleaning System
Please read the entire manual completely prior to installing or starting
your equipment. Pay close attention to the unit Advisories and
Cautions located on pages 14 & 15. If you do not completely
understand the functionality and maintenance of your equipment,
contact your dealer or PowerClean Industries directly.
All warranty paperwork must be completed and returned to
PowerClean Industries within 10 days.
Your questions and comments are welcome and encouraged.
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Powerful Cleaning Solutions
CONGRATULATIONS and Thank You!
You have purchased an industry leader in Slide in Truckmounted
Multi Surface Cleaning Systems. PowerClean Industries and our
Dealers are committed to ensuring your satisfaction for years to come
with the purchase of your new Multi Surface Cleaning System.
PowerClean Industries has forged a reputation for reliability, ease of
operation, hi-level performance, simplicity of maintenance and the
highest manufacturing standards in our industry today.
Over 35 years of experience and a true commitment to quality and
innovation truly put PowerClean Industries in a class of their own. On
going research, development, computer-aided design, and
implementation of the latest technology are all part of our continued
commitment to the cleaning industry.
Welcome to our family AND Thank you for trusting us to provide you
with the equipment you need to earn your living!
From Our Team Members at PowerClean Industries.
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MANUAL INDEX Page
Introduction 2
General Information 4
Specifications 5-6
Water Conditions 7
Waste water disposal 7
Cleaning Solutions 8
Operating Instructions 9
Equipment Start-Up 10-11
Equipment Shut-Down 12
Freeze guard 13
Advisories / Cautions 14-15
Orientation
High Pressure Pump 16
Water Flow 17-18
Vacuum System
Blower Manual
APO Manual
19-20
20A
20B
Electrical system 22
Heat Exchange System 23
Power Plant
Engine Manual 24 24A
Upper and Lower Control Panel 25
Waste Water Tank 26
Maintenance 27-28
Heat Exchanger flush / Descaling 29
Troubleshooting Guide 66-68
Warranty & Maintenance Guidelines 30-31
Service Bulletins 32-33
Warranty Enrollment Forms, IMPORTANT 34-40
Installers Checklist 41-48
15 Hour Checklist 49-50
Helpful Hints 51-56
System Installation 57-65
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GENERAL INFORMATION
The Liberty XT Mobile cleaning plant has been engineered for the
professional cleaner who demands a high performance-cleaning unit.
Dependable performance is the guiding principal in the design and
construction of the Liberty XT. Although all PowerClean truckmounts
are designed with simplicity in mind, they perform many functions
simultaneously to deliver the performance you need.
•Engine has to run at the desired, continuous RPM.
•High-pressure water pump provides steady pressure at the
proper flow for cleaning.
•Vacuum blower provides a constant desired amount of
vacuum to deliver soiled water to the recovery tank.
•Cleaning solution has to be delivered to the water at the right
concentration.
•Heating system must deliver and maintain proper heat.
•The vacuum recovery tank stores soiled water for proper
disposal.
As you can see, there is more to the equipment than just starting the
unit and cleaning. Regular care and maintenance must be practiced
in order for all of the components to function properly and
simultaneously.
This manual contains operation instructions as well as information
required for proper maintenance, and repair of this unit. To assist with
proper diagnostics and problems, we have also included a general
troubleshooting guide for your convenience.
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MACHINE SPECIFICATIONS Liberty XT
HIGH PRESSURE PUMP •2000 psi
•General Emperor series
VACUUM BLOWER •Roots RAI 33 Rotary
blower •Kunkle vacuum relief
CHEMICAL SYSTEM •Injection siphon
INSTRUMENT PANEL •Ignition switch
•Throttle
•Choke
•Tachometer
•GPH Meter
•Rocker switch APO
•Thermostat knob
•Water temperature gauge
•Water pressure
adjustment
•Water pressure gauge
•Vacuum gauge
•Engine oil drain
•Pump oil drain
•Blower oil drain
•Blower oil lube port
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RECOVERY TANK •Standard filtration tank
•Optional 65-gallon stainless
steel
CLEANING WAND •Stainless steel wand
•Dual Jet S bend
•Splash guards
•Insulated handle sleeve
•Adjustable handle
STANDARD EQUIPMENT •Main power unit
•Vacuum recovery tank
•Chemical jug
•Battery box and accessories
(Battery not included)
•Operation manual
•Service record manual
OPTIONAL EQUIPMENT •Fuel Tap Kit (if ordered)
•Fresh water tanks (if ordered)
•Hose reels (if ordered)
•Shelving units (if ordered)
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LOCAL WATER CONDITIONS
The quality of water varies greatly throughout North America. This
can influence the reliability and efficiency of your equipment. Many
areas have an excess of minerals in the water, which results in what
is known as hard water. These minerals adhere to the inside of heat
exchangers and other major components causing damage and loss
of cleaning effectiveness.
Cleaning effectiveness and equipment life is increased when water
softeners are used in hard water areas. The low cost of a water
softener is more than made up for the increased life, reliability
and overall cleaning efficiently.
WASTE WATER DISPOSAL
There are laws that prohibit the dumping of soiled water from carpet
cleaning equipment in any place but a sanitary treatment system.
The water recovered into your unit’s recovery tank contains materials
such as detergents and soil. These materials must be processed
properly before they are safe to re-enter our streams, rivers and
reservoirs.
AS PER FEDERAL, STATE AND LOCAL LAWS DO NOT DISPOSE
OF WASTEWATER INTO STORM DRAINS, GUTTERS, STREAMS,
and RESERIVORS ETC.
Contact your local Environmental Protection Agency for specific
instructions on proper wastewater disposal.
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CLEANING SOLUTIONS AND CLEANING
Your Liberty XT Mobile Cleaning Plant has been designed with the
latest technology to produce the highest quality cleaning results
possible. However it is only one of the many tools of the carpet
cleaning trade, and can produce only as good as the person
operating it. There are no short cuts to quality. It takes time,
knowledge, and the proper use of quality cleaning products.
PowerClean Industries recommends that you follow the label
directions on all PowerClean cleaning solutions, to obtain quality
results and safety. The improper use of cleaning solutions in your
Truckmount can cause serious damage to the internal components of
the unit. (PowerClean Industries does not recommend running
products through your unit such as solvents, or grease removers with
high concentrations of solvents, these products will cause damage to
the system).
Only approved PowerClean Industries products are
recommended. Use of other cleaning agents can damage internal
components and void your warranty.
If you wish to use products other than PowerClean Industries
products, Please consult your dealer prior to using products
other than PowerClean Industries.
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OPERATING INSTRUCTIONS
NOTE: Before operating the unit, make sure you are in a well-
ventilated area. Exhaust fumes from the cleaning unit contain carbon
monoxide and are hazardous to your health and your client’s health.
DO NOT OPERATE THE UNIT NEAR ANY BUILDING
DOORWAYS, WINDOWS, OR OPENINGS OF ANY KIND. The unit
must be run in a well-ventilated area.
1. Check to make sure you have enough fuel for the job.
2. Check to make sure you have an adequate amount of fresh water
in your fresh water tank to complete the entire job. If not, fill the
fresh water tank prior to starting the job or hook up the garden
hose to the front of the unit prior to starting.
3. Check your chemical jug to ensure that you have enough
concentrated solution to finish the job. If not, mix and fill the
chemical jug with the desired solution.
4. Connect all hoses required. When connecting the cleaning hoses,
start from the farthest point to be cleaned and work your way back
towards the unit. This will ensure that you have the appropriate
length required.
5. Once at the unit, connect the high pressure hose to the water “out”
quick disconnect on the front panel. Then repeat the same
process with the vacuum hose and connect it to the vacuum port
on the waste tank.
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START UP
(Always check the fluids prior to starting the unit)
1. Make sure your vehicle is in a well-ventilated area and away from
windows, doors and entryways.
2. Check your water supply to make sure you have adequate water
to the unit. NEVER RUN THE MACHINE WITHOUT ADEQUATE
WATER SUPPLY. DAMAGE MAY OCCUR TO THE SYSTEM IF
RUN WITHOUT ADEQUATE WATER.
3. Check the chemical supply for adequate solution.
4. For cold starts, pull the choke button out. For warm starts, this is
usually not necessary.
5. Turn the ignition to the start position. The engine will start.
Immediately, push the choke in. Allow the engine to warm up for
approximately 5 minutes prior to “throttling up” the unit. To
increase the throttle, turn the throttle counter clockwise. To
decrease the throttle, turn the knob clockwise. You will notice the
engine RPM increasing or decreasing depending on how you turn
the throttle.
6. Check the pressure setting on the water pressure gauge. Standard
carpet cleaning pressures should be between 300 – 500 psi.
Upholstery cleaning pressures should be between 100 and 200
psi.
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7. Check the thermostat for the desired cleaning water temperature.
Most cleaners run their unit from 180-210 degrees depending on
the type of surface being cleaned. For example; to running the unit
at full speed with generate more heat. When cleaning upholstery,
it is only necessary to run the unit at about 65% of its maximum
speed to achieve optimum cleaning temperatures for upholstery.
8. Connect the vacuum and solution hoses to the machine and the
cleaning wand.
9. Attach the Automatic Pump-out hose and place it in a secure
approved dumpsite.
10. You are now ready for cleaning.
NOTE: The machine will automatically shut down when the optional
recovery tank reaches full capacity due to the high-level float switch
located inside the recovery tank. When this occurs, empty the
recovery tank at the approved disposal site.
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SHUT DOWN
1. Lay the vacuum hose out prior to shutting the unit down.
This allows all of the moisture to be removed from the
vacuum hose and prevents any spillage of soiled water in
your vehicle when storing the hoses.
2. Slowly turn the throttle down until the unit is at a low idle.
3. Turn the temperature thermostat to the lowest setting.
4. Turn the chemical GPH meter to the off position.
Flush the system prior to shutting it down. Run the unit with
the thermostat set to the lowest position and key the wand.
This will allow the unit to cool down within a short period of
time. This is a very important procedure that will prevent the
water from over heating if the unit shuts off hot.
5. Disconnect the high-pressure hose, vacuum hose and the
APO hose.
6. While the unit is running at a low idle, wrap up all of the
hoses. This will allow the unit to “COOL” while you are
wrapping up the hoses.
7. Place the carpet wand and any tools that were on the job
site into the van.
8. Shut the unit down by turning the ignition key to the “OFF”
position.
9. Remove the lift out lint basket located inside the recovery
tank, clean and replace the lint basket back into the recovery
tank.
10.Drain the recovery tank at an approved disposal site.
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FREEZE GUARD PROCEDURE
(If equipped)
1. Drain the fresh water and recovery tanks completely. Any water
left inside the tank will freeze. To prevent any damage, make sure
ALL water is drained.
2. Remove the chemical jug and store in a heated area.
3. If you have an in line transfer pump, it will be necessary to
purchase the freeze guard system from your local dealer.
4. Close the ball valve, which leads from the fresh tank to the transfer
pump, and open the ball valve, which leads from the inlet side of
the transfer pump to the antifreeze.
5. Attach the fill/bleeder hose to the front high pressure quick
disconnect on the unit.
6. Turn the ignition key to the “ON” position, engage the transfer
pump and allow it to feed antifreeze to the unit.
7. Once the transfer pump has primed itself with antifreeze, you may
start the unit.
8. Take the fill/bleeder hose and insert the open end into the
antifreeze jug. This will allow the unit to recycle the antifreeze.
9. Insert the chemical feed hose into the antifreeze jug and open the
GPH meter two complete turns. Prime the chemical feed if
necessary. This will allow the antifreeze to circulate through the
chemical feed system.
10. You will notice water flowing into the jug at first. Once you notice
anti-freeze exiting the unit, check the chemical GPH meter to ensure
that there is adequate anti-freeze in that part of the system as well.
11. Once you see that the GPH meter is full of antifreeze, and the
fill/bleeder hose is sending antifreeze through, the freeze guard is
finished.
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UNIT ADVISERIES / CAUTIONS
PLEASE READ CAREFULLY.
LEVEL OPERATION:
During operation, the van must be parked on a level surface.
Failure to insure correct leveling may prevent proper internal
lubrication of the engine, vacuum blower, and high-pressure
pump.
HOT SURFACES:
During operation of this unit, many surfaces become very hot!
When near the van caution must be taken not to touch any hot
surfaces? Serious injury will occur if proper caution is not
exercised.
NEVER OPERATE THE EQUIPMENT WITH THE COVERS
REMOVED:
The covers and panels are guards against moving parts. Never
operate the equipment with the covers removed. This is a
serious safety hazard and serious injury can occur.
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UNIT ADVISERIES / CAUTIONS
PLEASE READ CAREFULLY.
MOVING PARTS:
Never touch any part of the machine that is in operating motion.
Also, caution must be used if wearing loose clothing when near
machinery with moving parts. Severe bodily injury may occur.
Never remove the covers while the unit is running! Serious
injury can occur.
CARBON MONOXIDE:
The unit produces carbon monoxide exhaust fumes, which must
be directed away from the job site. Carbon Monoxide can be
deadly. Run the unit in a well-ventilated area. Never run indoors.
MAINTENANCE:
It is very important that when performing your regular
maintenance routines such as oil changes to use only factory
approved lubricants. Improper lubricants will void your warranty
on those specific components.
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HIGH PRESSURE PUMP
Your Liberty XT is equipped with a state of the art General Triplex
plunger pump. Triplex pumps are built to last, with three ceramic
plungers, high-pressure valves and an oil cooled crankshaft system.
With the Triplex pump, you have the ability of performing carpet
cleaning and high power washing, with the pressure outlet ranging
from 30 psi to 2000 psi. If 2000 psi is exceeded, it will cause damage
to the heat exchange system and drive system of the unit. All units
are equipped with a high-pressure pop-off valve to release the
pressure if it exceeds the operating specifications. This is a safety
valve and by no means will it prevent the system from over
pressurizing.
Your Powerclean Industries distributor will present your machine with
the pressure preset to 300 –500 psi during installation. We have
found this pressure range to be the optimal setting for carpet
cleaning. When cleaning upholstery a simple adjustment of the
unloader on the lower front panel will lower your pressure to 100 psi,
which is recommended for upholstery cleaning.
When power washing you must remember that the Liberty XT is set
up for carpet cleaning. Even though your Triplex pump has a
maximum rating of 2000 psi, this pump is set up for carpet cleaning
and will give you a maximum rating of 2000 psi for light power
washing. With 2000 psi and the heat from the heat exchangers it
makes power washing simple. Never perform power washing with
the engine rpm lower than full throttle, always run the engine at
full throttle when power washing.
NOTE: Pressure settings in excess of 2000 psi will cause damage to
the unit. And void your warranty. Do not exceed these parameters.
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LIBERTY XT WATER FLOW SYSTEM
The water flow system on the Liberty XT has been designed to be
simple and trouble free. The incoming water flows from either the
transfer pump or garden hose through the incoming water shut off
valve. The incoming valve is what controls the water level inside the
mix tank.
The predetermined quantity of cleaning solution is determined by the
chemical flow meter located on the front panel. Usually 2-4gph on the
meter is adequate. With this advanced last step chemical injector,
the chemical flow is injected only when there is a demand for
water at the wand.
After passing through the high-pressure pump the pressure is then
controlled by the unloader valve.
Once the water passes through the unloader, the unused portion of
the water is sent through the blower pre-heater to the mix tank. The
high-pressure water is then sent to the liquid heat exchangers, which
pre-heats the water.
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After the pre-heated water exits the liquid heat exchangers, it is then
sent to the exhaust heat exchanger for the added heat boost needed
for high temperature cleaning. The exhaust heat exchanger consists
of a single heat exchanger. The upper heat exchanger heats the
water to the pre determined setting set by the thermostat on the front
control panel. The water is then sent out the front of the machine for
cleaning.
NOTE: The water flow plumbing system may need to be flushed
periodically with descaler to prevent abnormal chemical or hard water
build-up. This can be done by simply filling the mix tank with descaler
and running or flushing the system with descaler.
Consult your authorized dealer for specific descaling instructions.
Never use over the counter descalers, internal damage may occur to
the unit. Use only PowerClean Industries recommended descaler.
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WATER EXTRACTION
Your Liberty XT may be used for water extraction. It is very
important to follow proper procedures when doing so to prevent
the unit from overheating and causing damage to the heating
system, hoses etc.
1. Check your water to make sure you have adequate supply to the
machine.
2. Turn the chemical feed GPH meter off. This will prevent any waste
of chemicals.
3. Hook a “bleeder hose” to the front of the machines water out quick
connect. (A bleeder hose is a hose which has an open end and
allows the water to flow freely)
4. Turn the water pressure down between 300-400 psi.
5. If equipped, make sure the water pump clutch is in the “on”
position.
6. Start and run the machine with the “bleeder” hose running. This
will keep the entire heat exchange system cool while performing
water extraction.
Remember, it is very important to make sure you have an
adequate water supply to the machine. Failure to allow the
machine to cool while performing water extraction will cause
excessive heat and damage to the system and void your
warranty.
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VACUUM SYSTEM
The vacuum system of the Liberty XT is a Roots Universal RAI 33
positive displacement rotary lobe blower. This high performance
blower provides incredible air flow and water lift making sure carpets
are left as dry as possible. The blower is factory set for maximum
efficiency and longevity at 14 h.g. Never exceed 15 h.g. On the
vacuum gauge. Damage may occur to the system if 15 h.g is
exceeded. The performance and life of the blower greatly depends on
the care and proper maintenance it receives.
The Roots blower has a very close internal tolerance between the
lobes. Solid objects entering the inlet of the blower can damage the
interior. To prevent this, PowerClean Industries installs a stainless
steel filter screen on the vacuum inlet inside the recovery tank or filter
box. This stainless steel filter should be removed daily and
cleaned. When reinstalling the filter only thread the filter on until
finger tight and use a WD-40 type of lubricant on the threads for easy
replacement and removal.
For further information on the Roots Vacuum Blower refer to the
enclosed Roots Universal Blower manual.
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