Tornado MARATHON 2000 Installation and operating instructions

TORNADO
MARATHON 2000
FORWARD ONLY EXTRACTOR
CATALOG NO.
98190 (115V, 60HZ)
OPERATIONS/SERVICE MANUAL
Form No. L8190AD FOR COMMERCIAL USE ONLY
ã2001 TornadoâIndustries, Inc. All rights reserved.
TORNADO
®
INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
[phone] FAX [phone]
www.tornadovac.com

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This illustrated parts book covers:
CATALOG NO. 98190
SERIES “D”
SIZE 22”
CAPACITY 20 Gal.
VOLTS 115V
AMPS 15
All specifications are subject to change without notice.
TABLE OF CONTENTS:
Safety Instructions 3, 4 & 5
Preparation & General Precautions 5, 6 & 7
Cleaning Tips 8
Machine Specifications 9
Operation Instructions 10,11,12
Maintenance Issues 12,13
Trouble Shooting Table 14
Main Assembly 15
Upper Tank Assembly 16,17
Lower Tank Assembly 18,19, 20
Control Panel Assembly 21,22
Brush Assembly 23,24
Pump Assembly 25
Recovery Dome Assembly 26
Wiring Diagram 27, 28
Tornado®Standard Warranty Program*
10 Years: All plastic tanks and rotationally-molded bodies
2 Years: Parts and Labor on all Tornado and Tornado/Karcher cleaning equipment **
1 Year: Warranty on batteries, one full year, not pro-rated.
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.
* Effective January 1st, 2000. Terms subject to change without notice.
** Windshear™ Blower-Dryer, Insulation Blowers, CW 50, CW 100, and Duo Upright Carpetkeepers™ are warranted
for 1 (one) year for parts and labor.

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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
 ELECTRICAL : 115 V, 15 A, 60 HZ.
 DURABLE EXTENSION CORD : 75’
 DRIVE SYSTEM : TRANSAXLE W/ VARIABLE SPEED, (0-100 FT/MIN)
 VACUUM MOTOR: 3 STAGE, 1 HP., 120 CFM
 VACUUM SHOE : 22” WIDE, CAST ALUMINUM, ADJUSTABLE, FLOATING ARM
 BRUSH : 19” LONG
 BRUSH SPEED / HP : 1000 RPM / 1/4 HP
 SOLUTION PUMP : 100 PSI, DIAPHRAGM STYLE
 SOLUTION CAPACITY : 20 GALLONS
 RECOVERY CAPACITY : 20 GALLONS
 WHEELS : FRONT (4” DIA.), REAR (10” DIA.)
 SPRAY SYSTEM : (4) QUICK CHANGE JETS, LEVER TRIGGER SPRAY WAND
 EMPTY WEIGHT : 190 LBS.
 FULL WEIGHT : 350 LBS.
 LENGTH : 51”
 HEIGHT : 37.5”
 WIDTH : 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. 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.
3. 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.
4. Activate the main power switch. NOTE : THE MAIN
POWER SWITCH WILL TURN OFF ALL THE OTHER
CONTROLS ON THE MACHINE
5. 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.
6. Activate the vacuum motor switch.
7. Activate the brush motor switch.
8. Activate the spray bar switch. Remember to turn off this
switch about 6” from the end of each cleaning pass.
9. 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.

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12. 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.
13.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.
14.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.
15.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.
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.

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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.
PROTECT FROM FREEZING
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.
1. Add a half gallon of window washer antifreeze to the solution tank, turn on the brush
switch and press the spray switch until the antifreeze solution fills the solution lines.
- Always allow the unit to reach room temperature before turning on the
Marathon to expel the antifreeze.

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Trouble Shooting 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

16
UPPER TANK ASSEMBLY
(REF. #30642)

17

18
LOWER TANK ASSEMBLY
(REF. #98190)

19
LOWER TANK ASSEMBLY
(REF. #98190)

20
CONTROL PANEL ASSEMBLY
(REF. # 30644)