Tornado Marathon 800 Manual

TORNADO INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
[phone] FAX [phone]
www.tornadovac.com
Tornado
£
Operations & Maintenance Manual
For Commercial Use Only
Marathon Carpet Rinser/Dryers
Models 800 & 1200
MODEL NO.
98166 & 98168 (115V, 60Hz)
For parts list see L2669LFP
Effective 12/16/2005
L2669LF Revised 12/05 ¤2006 Tornado Industries All rights reserved.

NOTES

3
Write your machine serial number here:______________________________
This illustrated instruction book covers:
VERSION 800 1200
MODEL NO. 98166 98168
VOLTS 115 115
SERIES F F
ALL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
TABLE OF CONTENTS:
Warranty 4
Safety Instructions 5
Preparation and General Instructions 6
Cleaning Tips 9
Machine Specifications 10
Operation Instructions 11
Maintenance Issues 12
Troubleshooting Table 13
Service Parts Table 13

4
Thank you for choosing Tornado products. We are proud to offer the most
complete line of commercial and industrial cleaning equipment in the industry.
Our reputation for quality, innovation and durability is unsurpassed.
* Effective January 1st, 2005. Terms subject to change without notice.
1) Windshear™ Blower-Dryer, Insulation Blowers, T191, T201, T12/1, CV 30, CV 38, CW 50, CW
100, Pro PAC Vacs, Duo-Upright Carpetkeepers™, Gas & Electric Pressure Washers, 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.
Note: Tornado, The Latest Dirt, Floorkeeper, Carpetkeeper, Carpetrinser, Carpetrinser/Dryer,
Headmaster, Taskforce, PAC-VAC, T-Lite, Glazer, Windshear, Max-Vac, CV 30, CV 38, and
Trot-Mop are trademarks of Tornado Industries.
1-800-VACUUMS
Chicago area: [phone]
Fax: [phone]
7401 W. Lawrence Avenue
Chicago, IL 60706

5
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

6
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 Tornado’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
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.

7
GENERAL PRECAUTIONS
xMake 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.
xDisconnect power cord from the outlet before attempting maintenance or repair work. Do not
leave machine connected to an electrical outlet when unattended.
xDon’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.
xDo not immerse this machine in standing water. Such use can cause electrical shock.
xDo 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.
xIf an extension cord is necessary, use a 3 conductor grounding cord, 12-gauge wire to prevent
motor burnout, overheating of the wiring.
xTo 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.
xDo not use the machine for dry vacuuming. This machine is not fitted with a dry filter.
xUse defoamer in the recovery tank at all times to prevent damaging the vacuum motor.
xDo not use water in excess of 140 degrees F (62 degrees C).
xUse 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 may result in the intake screen clogging or
damage to the pump.
xDo not expose machine to freezing temperatures.
xDo 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.
xDo 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

8
ELECTRICAL
This machine operates on a standard, 15 AMP, 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 tab, 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.
SKETCH A SKETCH B SKETCH C

9
CLEANING TIPS
xCheck 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.
xLocate 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.
xRemove 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.
xClean the area first with a Clean-Air Carpetkeeper, upright vacuum. Do not use the Marathon
800/1200 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.
xIdentify 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.
xPlan your cleaning route. Always try to have the cord to the right of the Marathon 800/1200
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.
xTo decrease dry time, go over the carpet without pressing carpet spray switch. To further
decrease the drying time, use the Windshear 3000 Carpet Blower.
xWhen running the extractor, do not overfill the recovery tank. Do not allow the water level to rise
above the standpipe intake filter inside the recovery tank.
xIf the spray jets become clogged, remove the individual spray tips and soak them in a mild acid or
anti-browning chemical to dissolve normal alkaline chemical buildup.
xWhen the Marathon 800/1200 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.

10
MACHINE SPECIFICATIONS
Q
ELECTRICAL: 115 V, 15 A, 60 HZ.
Q
DURABLE EXTENSION CORD: 50’
Q
DRIVE SYSTEM: SELF-PROPELLED
Q
VACUUM MOTOR: 3 STAGE, 2 HP
Q
VACUUM SHOE: 20” WIDE, POLYETHYLENE, NON-ADJUSTABLE PIVOT MOUNT
Q
BRUSH: 17” LONG
Q
BRUSH SPEED: 900 RPM
Q
SOLUTION PUMP: 100 PSI, DIAPHRAGM STYLE
Q
SOLUTION CAPACITY: MARATHON 800: 8-GAL; MARATHON 1200: 12-GAL
Q
RECOVERY CAPACITY: MARATHON 800: 10-GAL; MARATHON 1200: 14-GAL
Q
WHEELS: 10” DIA.
Q
SPRAY SYSTEM: (4) QUICK-CHANGE JETS
Q
EMPTY WEIGHT: 100 LBS.
Q
FULL WEIGHT: MARATHON 800: 150 LBS; MARATHON 1200: 175 LBS
Q
LENGTH: 38.5”
Q
HEIGHT: 36”
Q
WIDTH: 20”

11
OPERATION INSTRUCTIONS
Main Controls:
Your Marathon 800/1200 extractor is equipped with three labeled main switches that control the water
spray system, the brush motor, and the vacuum motor.
In addition, there is one main circuit breaker, (located on the lower left of the main control panel).
This (2.5 amp@250VAC) circuit breaker protects the brush drive motor.
Set Up and Operation:
Your Marathon 800/1200 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
Marathon 800/1200 extractor.
1. Remove the recovery tank cover (rear) from the top of the tank.
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 solution tank cover (front) of the tank and fill with hot water. Add liquid cleaning solution to
proper dilution ratio.
4. Use separate buckets to fill and empty extractor. Avoid using undissolved soap or chemicals that
could potentially plug the spray jets.
5. Plug the unit’s power cord into a grounded power outlet. Add a 12-gage extension cord as
needed.
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.
6. Activate the vacuum motor switch (left).
7. Activate the brush motor switch (right).
8. Hold down the water spray system switch (center). Remember to release this switch at least 6”
from the end of each cleaning pass.
9. Pull the machine backward across the surface to be cleaned.
10. 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.
11.The recovery tank can be drained by removing the drain hose from its support plug. The standpipe
in the recovery tank is equipped with a metal screen cap. This cap is accessible by removing the
recovery tank cover. It is recommended that this cap be cleaned after every machine use.
12.The solution tank level can be monitored by looking through the clear cover. The water in the
solution tank can be drained using the separate siphon hose supplied with the unit.
13. Soiled high-traffic areas and spots can be pre-sprayed using the optional spray hand tool. The
same tool can also be used to spray and extract hard-to-reach areas. The spray hose is attached
to a quick disconnect, and is pressurized when the solution switch is turned on. The attachment’s
vac hose is installed by replacing the onboard vac hose connection at the rear.

12
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 lid. In addition, remove and clean
the recovery screen cap.
2. Drain the solution tank with the supplied siphon drain hose, 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:
xIt is highly recommended that once a month you flush the Marathon 800/1200 out with an 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.
xIf 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.
xIf the spray jets drip after the pump is turned off, the solenoid valve may need to be cleaned.
xOnce a month, inspect all electrical cables, hoses, filters and connections in the Marathon
800/1200. 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.
xBe 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.
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.

13
Troubleshooting Table:
Problem Solution
No power, nothing works * Plug in cord
* Check for loose wiring
* 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
and clean spray jets
* Check pump – remove spray jets
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
* Check for loose wiring
* Call Service
Service Parts List:
P/N Description
02661 Wheel-10”
16091 Clamp-Hose (screw) 1-1/4”-2”
16620 Siphon Hose (1-1/2” X 23-1/2” Lg.)
19097 Filter-Vac Motor Intake
19119 Gasket-Vac Motor
19129 Access Cover-Tank
19154 Spray Nozzle1/8” (V-Jet)
19159 Brush Roller 17”
19233 Belt-Timing 150 X L X 3/8”
32178 Inline Strainer 3/8” NPT
32203 Kit-Pump w/Fittings