Tornado Marathon 2000 98190 Manual

TORNADO INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
[phone] FAX [phone]
www.tornadovac.com
Tornado
Operation & Maintenance Manual
For Commercial Use Only
Marathon 2000 Forward Only Extractor
CATALOG NO.
98190 (115V, 60 HZ)
L8190CF 6/04 2004 Tornado Industries All rights reserved.

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NOTES

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This illustrated parts book covers:
CATALOG NO. 98190
SERIES F
SIZE 22”
CAPACITY 20 Gal.
VOLTS 115V
AMPS 15
All specifications are subject to change without notice.
TABLE OF CONTENTS:
Safety Instructions 4
Preparation & General Precautions 6
Cleaning Tips 9
Machine Specifications 10
Operation Instructions 11
Maintenance Issues 13
Troubleshooting Table 15
Main Assembly 16
Upper Tank Assembly 17
Lower Tank Assembly 19
Control Panel Assembly 22
Brush Assembly 24
Pump Assembly 26
Recovery Dome Assembly 27
Wiring Diagrams 28
Tornado®Standard Warranty Program*
10 Years:
All plastic tanks and
rotationally-molded bodies 1) 5)
2 Years:
Parts on all Tornado and Tornado/Karcher
cleaning equipment 1) 2) 3) 5)
1 Year:
Labor on all Tornado and Tornado/Karcher
cleaning equipment 2) 5)
Warranties do not cover
components subject to normal
wear or abuse and misuse, and
have other limitations not specified
here. For full details , contact your
Authorized Tornado Distributor,
Service Center, or the Tornado
Technical Service Department.
Tornado sales and service
representatives are not
authorized to waive or alter the
terms of this warranty, or to
increase the obligations of
Tornado under the warranty. 1 Year:
Warranty on batteries and chargers,
one year pro-rated.
* Effective January 1st, 2004. Terms subject to change without notice.
1) Windshear™ Blower-Dryer, Insulation Blowers, T191, T201, CV 30, CV 38, CW 50, CW 100, Pro PAC Vacs,
Duo-Upright Carpetkeepers™, and all chargers are warranted for 1 (one) year for both parts and labor.
2) Warranties on all riding sweepers including the ICC1, KM 100/100 R, KMR 1250, and KMR 1700 are 24
months parts/6 months labor OR 1000 hours of operation, whichever comes first. Warranties on the
75/140 & 90/140 are 24 months parts/12 months’ labor OR 1,000 hours of operation whichever comes
first.
3) All-non wear item parts purchased after warranty expiration are warranted for 90 days.
4) Warranty starts from the date of sale to the consumer or, at Tornado’s discretion, 6 months after dealer
purchased the unit from Tornado, whichever comes first.
5) See separate limited 2-year pressure washer policy.

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IMPORTANT SAFETY INSTRUCTIONS
FOR COMMERCIAL USE
WHEN USING AN ELECTRICAL APPLIANCE, BASIC PRECAUTIONS SHOULD
ALWAYS BE FOLLOWED INCLUDING THE FOLLOWING:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE
WARNING: TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY:
1. Do not leave machine when plugged in. Unplug from outlet when not in use and
before servicing.
2. Use indoors only. Do not use outdoors and do not expose to rain.
3. Do not allow to be used as a toy. Close attention is necessary when used by or
near children.
4. Use only as described in this manual. Use only manufacturer’s recommended
attachments.
5. Do not use with damaged cord or plug. If machine is not working as it should, has
been dropped, damaged, left outdoors, or dropped into water, return it to a service
center.
6. Do not pull or carry by cord, use cord as a handle, close a door on cord, or pull cord
around sharp edges or corners. Do not run machine over cord. Keep cord away
from heated surfaces.
7. Do not unplug by pulling on cord. To unplug, grasp the plug not the cord.
8. Do not handle plug or machine with wet hands.
9. Do not put any object into openings. Do not use with any opening blocked; keep
free of dust, lint, hair, and anything that may reduce air flow.
10. Keep hair, loose clothing, fingers, and all parts of body away from openings and
moving parts.
11. Turn off all controls before unplugging.
12. Use extra care when cleaning on stairs.
13. Do not use to pick up flammable or combustible liquids, such as gasoline or use in
areas where they may be present.
14. Connect to a properly grounded outlet only. See Grounding Instructions.
SAVE THESE INSTRUCTIONS

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BEFORE OPERATING THE MACHINE
Read the manual carefully and completely before attempting to operate the unit. This
manual has important information for the use and safe operation of the machine. Keep
this manual on file and handy. This machine will assure years of satisfactory service if
operated and maintained according to recommendations in the manual. If additional
information is needed, please contact your local distributor or call:
TORNADO INDUSTRIES, INC.
7401 W. LAWRENCE AVE.
CHICAGO, IL 60706
708/867-5100
FAX: [phone]
All information and specifications printed in the manual and parts list are current at the
time of printing. However because of Breuer’s policy of continual product improvement,
we reserve the right to make changes at any time without notice.
This machine was shipped with window washer antifreeze, during the winter months, in
the solution line system to protect the pump and valves from freezing during
transportation and storage. Before you use the unit, rinse the solution line system with
clean water (refer to Protect From Freezing).
WARRANTY
To protect your investment, promptly fill out the
required information on the warranty card that
comes with the unit and mail it back to
Tornado Industries

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GENERAL PRECAUTIONS
•Make sure the machine is plugged into an electrical outlet with the same voltage and
frequency rating as shown on the nameplate of the machine. Do not attempt to plug
a 115 volt machine in a 230 volt outlet.
•Disconnect power cord from the outlet before attempting maintenance or repair
work. Do not leave machine connected to an electrical outlet when unattended.
•Don’t abuse power cord. Never pull the machine by the cord or yank plug from the
receptacle. If this machine is operated on a wet carpet a potential shock hazard can
be caused by a damaged cord. Replace a damaged cord immediately.
•Do not immerse this machine in standing water. Such use can cause electrical
shock.
•Do not use volatile substances such as gasoline or kerosene in the machine, on or
near the surface to be cleaned. The use of such materials could cause an explosion
and fire.
•If an extension cord is necessary, use a 3 conductor grounding cord, 12 gauge wire
to prevent motor burnout, overheating of the wiring.
•To avoid electrical shock, do not expose to rain and store indoors.
WARNING
The machine was designed for use on carpeted floors as per instructions
and recommendations written in this manual. Any deviation from its proper use
or purpose and the consequential damage that may occur is the sole
responsibility of the end user.
•Do not use the machine for dry vacuuming. This machine is not fitted with a dry
filter.
•Use defoamer in the recovery tank at all times to prevent damaging the vacuum
motor.
•Do not use water in excess of 140 degree F (62 degree C).
•Use only commercially available low foaming carpet cleaners and defoamers
intended for machines of this type. Do not use dyes, bleaches, ammonia or other
additives. The use of powdered cleaning solution if not diluted properly many result
in the intake screen clogging or damage to the pump.
•Do not expose machine to freezing temperatures.
•Do not attempt to repair warranted machines. All repairs must be done by a
qualified and authorized repair center. Non warranted repairs will be billed back to
the owner of the unit.
•Do not use any replacement parts except those specified in the parts list.
Unauthorized parts will void the warranty and could cause the unit not to function
properly.
FAILURE TO COMPLY WITH THE ABOVE WARNING INSTRUCTIONS
WILL VOID THE WARRANTY

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ELECTRICAL
This machine operates on a standard, 15AMP,115 volt AC circuit and has a grounded
plug.* Make sure the machine is connected to an outlet having the same configuration
as the plug. No ungrounded adapter should be used with this machine.
*Special voltage models available.
GROUNDING INSTRUCTIONS
This machine must be grounded. If it should malfunction or breakdown, grounding
provides a path of least resistance for electric current to reduce the risk electric shock.
This machine is equipped with a cord having an equipment -grounding conductor and
grounding plug. The plug must be inserted into an appropriate outlet that is properly
installed and grounded in accordance with all local codes and ordinances.
WARNING:
Improper connection of the equipment-grounding conductor can result in a risk of
electric shock. Check with a qualified electrician or service person if you are in doubt as
to whether the outlet is properly grounded. Do not modify the plug provided with the
appliance - if it will not fit the outlet, have a proper outlet installed by a qualified
electrician.
This machine is for use on a nominal 120-volt circuit, and has a grounding plug that looks
like the plug illustrated in sketch A. A temporary adapter that looks like the adapter
illustrated in sketches B and C may be used to connect this plug to a 2-pole receptacle as
shown in sketch B if a properly grounded outlet is not available. The temporary adapter
should be used only until a qualified electrician can install a properly grounded outlet
(sketch A). The green-colored rigid car, lug, or the like extending from the adapter must
be connected to a permanent ground such as a properly grounded outlet box cover.
Whenever the adapter is used, it must be held in place by a metal screw.
NOTE: In Canada, the use of a temporary adapter is not permitted by the Canadian
Electrical Code.

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STRAIN RELIEF
Attaching the strain relief/cord retainer to the 50’ power cord.
1. Make a loop in power cord approximately 12” from
receptacle end.
2. Slide cord loop through slot in retainer and over retainer arm.
Pull slack cord back through slot to secure. Attach retainer to handle.
EXTENSION CORD
If an extension cord is used, the wire size must be at least one size larger, (12-3)
than the power cord on the machine.
REQUIRED CLEANING CHEMICALS
Use only commercial low foam cleaning chemicals that are designed for carpet
extraction.
1. General carpet extraction cleaner added to the solution tank.
2. Traffic lane per-spray usually applied with spray wand.
3. Defoamer only goes into the recovery tank.
CAUTION: Use as directed. Do not over use the cleaning chemicals.

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CLEANING TIPS
•Check the condition of the carpeting. If the carpet is loose, heavily soiled, stained,
spotted or badly worn, point this out to the person in charge.
•Locate an inconspicuous spot on the area to be cleaned. Test carpet for
colorfastness before proceeding. Pour the concentrated cleaning solution on the
spot, cover with a white towel and place a heavy object on top to absorb the
cleaning solution. Wait 10 minutes for any reaction to take place. Remove weight.
If there is no color transfer, it should be safe to clean.
•Remove the furniture from the area to be cleaned. Large pieces can be moved to
opposite end of the room from where you start cleaning and replace when it is
completed. After cleaning carpet, place a small square of aluminum foil or 6 mil poly
square under the furniture legs to prevent moisture from damaging the finish or
rusting the metal glides.
•Clean the area first with a Clean-Air Carpetkeeper, upright vacuum. Do not use the
Marathon as a dry vacuum! Heavily soiled carpet or areas of concentrated foot
traffic should be treated with recommended pre-spotting or pre-spray chemicals,
using a hand spray trigger bottle or pump up sprayer. Do not allow any spotter or
pre-spray to dry on the carpet.
•Identify the type of carpet fiber to be cleaned. Most commercial carpet fibers in use
are nylon or acrylic based. Best results in cleaning would be obtained if hot water is
used to clean these types of fibers. On the other hand, hot water could shrink
natural fiber carpeting, like wool and cotton in particular. Exercise caution when
cleaning natural fibers. Use cool water test for colorfastness and apply the least
amount of cleaning solution possible.
•Plan your cleaning route. Always try to have the cord to the right of the Marathon
extractor so you are working away from the cord. Operate the extractor in parallel
passes. Clean the perimeter last. Turn “off” spray switch in turns to conserve
cleaning solution.
•To decrease dry time, go over the carpet without pressing carpet spray switch. To
further decrease the drying time, use the Windshear 3000 Carpet Blower.
•When running the extractor, do not overfill the recovery tank. Do not allow the water
level to rise above the clear dome on top of the recovery tank.
•If the spray jets become clogged, remove the spray bar assembly or the individual
spray tips and soaks them in a mild acid or anti-browning chemical to dissolve
normal alkaline chemical buildup.
•When the extractor runs out of cleaning solution, noted by streaking or incomplete
cleaning, turn off the machine and drain the recovery tank. Refill as needed and
continue cleaning.

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MACHINE SPECIFICATIONS
QELECTRICAL : 115 V, 15 A, 60 HZ.
QDURABLE EXTENSION CORD : 75’
QDRIVE SYSTEM : TRANSAXLE W/ VARIABLE SPEED, (0-100 FT/MIN)
QVACUUM MOTOR: 3 STAGE, 1 HP., 120 CFM
QVACUUM SHOE : 22” WIDE, CAST ALUMINUM, ADJUSTABLE, FLOATING ARM
QBRUSH : 19” LONG
QBRUSH SPEED / HP : 1000 RPM / 1/4 HP
QSOLUTION PUMP : 100 PSI, DIAPHRAGM STYLE
QSOLUTION CAPACITY : 20 GALLONS
QRECOVERY CAPACITY : 20 GALLONS
QWHEELS : FRONT (4” DIA.), REAR (10” DIA.)
QSPRAY SYSTEM : (4) QUICK CHANGE JETS, LEVER TRIGGER SPRAY WAND
QEMPTY WEIGHT : 190 LBS.
QFULL WEIGHT : 350 LBS.
QLENGTH : 51”
QHEIGHT : 37.5”
QWIDTH : 22”

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OPERATION INSTRUCTIONS
Main Controls:
Your extractor is equipped with (4) main switches, which control the spray bar,
the brush motor, the vacuum motor and the main power. The main switch must be
activated before operating the transaxle drive. The machine will glide easily across the
floor when pushed forward (without power).
WARNING:
In order to avoid injury, it is recommended that the extractor be pulled in the
reverse direction (without power) in emergency situations only.
In addition, there are (4) main circuit breakers, (located on the front of the main
control panel):
- (20 amp) circuit breaker – main power
- (15 amp) circuit breaker – vacuum motor
- (2.5 amp) circuit breaker – transaxle drive
- (2.5 amp) circuit breaker – brush motor drive

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Set Up and Operation:
Your Marathon is shipped complete and ready for carpet cleaning. This style of
machine is sometimes referred to as a self-contained extractor, since everything is
included in the body of the extractor.
1. Install recovery tank cover to the top of the tank and connect the suction hose to the
cover.
2. Important! – Prior to first use: The unit has been tested with window washer fluid at
the factory, and a small amount of this fluid may remain in the system as a
precaution against freezing. Prior to first use, flush the tank and pump system with a
half-gallon of plain water.
3. Open filler door at the front of the tank and fill with hot water. Add liquid cleaning
solution to proper dilution ratio.
Use separate buckets to fill and empty extractor. Avoid using undissolved soap or
chemicals which could potentially plug the spray jets.
4. Attach a 12 gage extension cord to the pig tail plug on the machine.
WARNING:
To avoid serious injury: Plug into a grounded (earth) outlet only. Do not use an
adapter or remove ground pin on plug. Do not use a damaged cord.
5. Activate the main power switch. NOTE : THE MAIN POWER SWITCH WILL TURN
OFF ALL THE OTHER CONTROLS ON THE MACHINE
6. Lower the manual release lever and allow the brush assembly to rest on the floor.
The height of the suction nozzle may need to be adjusted using the turn knob.
7. Activate the vacuum motor switch.
8. Activate the brush motor switch.
9. Activate the spray bar switch. Remember to turn off this switch about 6” from the end
of each cleaning pass.
10.Squeeze the trip lever on the main handle to move the extractor forward. The
machine has a powered transaxle, so forward movement will be quick and easy.
Turn the variable speed control clockwise to increase the forward speed.
11.As you are cleaning, monitor the water level in the recovery tank cover. An overflow
of water in the recovery tank can damage the vacuum motor. Always be aware of
this water level.
12.The recovery tank can be drained by removing the drain hose from its support clip
and removing the drain plug. The standpipe in the recovery tank is equipped with a
metal screen cap. This cap is accessible by removing the clear dome on top of the
unit. It is recommended that this cap be cleaned after every machine use.
13.The solution tank has a clear see through drain hose, which tells the operator the
tank level. The water in the solution tank can be drained using this hose.
14.While cleaning, pre-spray traffic areas and spots using the spray wand. The spray
wand is attached to a quick disconnect and is pressurized when the MAIN SWITCH
is turned on.

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WARNING:
To avoid serious injury: Disconnect power before servicing. Electrical service
must be performed by an authorized service station or electrician. Use only
nonflammable commercial chemicals intended for machine application. Do not
use where explosive vapors or dust are present in the air. Disconnect power if
the machine is left unattended. Do not allow machine to freeze. Do not expose
to rain, store machine indoors.
Daily Maintenance:
1. Rinse out the recovery tank and clean the recovery dome. In addition, remove
and clean the recovery screen cap.
2. Drain the solution tank and clean with water.
3. Remove any debris in either the recovery or solution tank.
4. Flush the pumping system with clean warm water or white vinegar.
5. Remove lint or debris from the vacuum shoe or brush. Hint: if heavy lint build-
up is present, use a hacksaw blade with teeth down to remove the lint.
Periodic Maintenance:
•It is highly recommended that once a month you flush the Marathon out with a 8 to 1
ratio of water to white vinegar or anti-browning solution through the extractor. This
will help to prevent the build up of alkaline residue.
•If the spray jets become clogged, remove and wash them thoroughly and blow dry.
Do not use wire or pins to clean the nozzles as this will cause the spray pattern to
become distorted, thereby creating a streaking pattern on the carpeting.
•If the spray jets drip after the pump is turned off, the solenoid valve may need to be
cleaned.
•Once a month, inspect all electrical cables, hoses, filters and connections in the
Marathon. If you see something that should be repaired or replaced it should be
reported and repaired. Little things are easy to forget about, but as these little things
add up, you end up with a cluster of problems that will cost you in the long run.
CAUTION: When opening the Marathon for service and/or inspection, be sure that the
recovery hose is in its proper position. If not, the hose can become crushed and you
will not get good airflow from the vacuum nozzle.
•Be sure to use Tornado genuine parts and service is provided by an authorized
Tornado Service Center. Use of non-O.E.M. parts will void the warranty.

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PROTECT FROM FREEZING - Caution!
If it becomes necessary to store in temperatures that could drop below 40 degrees F,
the pumping system, hoses and valves must be protected from freezing with a methyl
hydrate window washer antifreeze solution. Do not use ethylene glycol or cooling
system antifreezes.
Whenever unit will be stored in temperatures below 40 degrees F, empty the solution
tank, and then pour a half-gallon of pre-mixed window washer antifreeze into the tank.
The windshield washer fluid must not be diluted with water or solution already in the
tank. Turn on the brush switch and press the spray switch until the unit runs completely
dry.
Before returning the unit back to service, allow it to reach room temperature first. Then
add a half-gallon of plain water to the solution tank and flush the system using the spray
switch.
The unit has been tested at the factory with windshield washer antifreeze solution. A
small amount of this solution may remain in the system and must be flushed out prior to
first use.

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Troubleshooting Table:
Problem Solution
No Power, Nothing Works * Plug in Cord, Check Circuit Breakers
* Activate Main Power Switch
* Check For Loose Wiring
* Call Service
Machine Will Not Move Forward * Reset Circuit Breaker
* Turn Speed Control Knob Clockwise
* Call Service
Brush Does Not Rotate * Reset Circuit Breaker
* Activate Brush Switch
* Check For Loose Wiring
* Call Service
Poor Water Spray * Spray Jets Clogged-Remove Spray
Bar and Clean Spray Jets
* Check Pump-Remove Spray Bar
And Check water Flow
* Call Service
Vacuum Motor Runs But Poor Suction * Remove Debris From Vac Shoe
* Recovery Tank Too Full-Drain Tank
* Remove Debris From Suction Hose
* Call Service
Vacuum Motor Will Not Run * Activate Vacuum Switch
* Reset Circuit Breaker
* Check For Loose Wiring
* Call Service

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MAIN ASSEMBLY

17
UPPER TANK ASSEMBLY
(REF. #30642)

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UPPER TANK ASSEMBLY
(REF. #30642)

19
LOWER TANK ASSEMBLY
(REF. #98190)

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LOWER TANK ASSEMBLY
(REF. #98190)