Cleaning Unit Maintenance Guide Table of Contents

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1 Cleaning Unit Maintenance Guide Table of Contents Maintenance Schedule... 2 Annual Maintenance Parts... 3 Belt Sizes and Part Numbers... 4 Kubota Valve Adjustment Sequence... 5 Ford Valve Adjustment Sequence... 6 Tools etc. for Cleaning Unit Repair and Maintenance... 7 The following and all other data therein are proprietary to Stanley Steemer International and are properly considered to be trade secrets, and are intended for the use of Stanley Steemer Officers, Supervisory, Employees, Franchise Owners, and their respective Employee Designees. This information may not be reproduced by or for, or shown to, any person other than the above stated without written permission in advance from Stanley Steemer s Legal Department. Copyright herein claimed as an unpublished work, U.S.C. Sections 101-2,

2 Maintenance Schedule All Units Daily! Check engine oil level! Check coolant level! Clean dump basket and foam filter and rinse dump tank Weekly Quarterly Yearly! Clean water inlet and Cat pump strainers (Do not lose gasket!)! Check belt tension and condition! Inspect radiator and heat exchanger hoses for leaks! Change engine oil and filter (Do not exceed 200 hours)! Check air filter (Change as needed)! Grease blower (If applicable. Only 2004 and older blowers)! Change coolant! Change fuel filter(s)! Change air filter! Replace spark plugs (Spark plug gaps are as follows: Kubota WG / Kubota WG / Ford 1.3 liter -.040)! Kubota Replace distributor cap and rotor (Note: 750 and 752 engines only The Kubota 972 engine does not have a cap and rotor)! Adjust valve clearance Replace valve cover gasket! Kubota 972 Seal breather cover on valve cover with RTV sealant if leaking. 750/752 Clean breather filter in valve cover.! Ford Clean inside of oil filler cap - make sure valve moves freely! Change oil in Cat Pump use Cat Pump brand ISO68 oil filled to dot at center of indicator window on the back of the pump.! Change oil in both sides of blower (50w). Re-grease at both fittings if applicable.! Dismantle, inspect, and grease balanced regulators. (Use waterproof grease)! Clean and inspect check-valve at discharge pump prime (Be careful not to lose the orifice plate.)! Check entire system for leaks and broken parts! Kubota 972 Inspect spark plug caps and wires replace as needed! Kubota 750 and Inspect spark plug wires and coil wire replace as needed! Ford Inspect spark plug wires replace as needed! Inspect belts Tighten or replace as needed. (Replace 5450 fan belt every year. Replace 5500/5700 blower belt every year.)! Inspect radiator hoses and heat exchanger hoses tighten hose clamps and replace hoses as needed 2

3 Annual Maintenance Parts 5200/5400 (Kubota WG 750 or 752 engine) Cleaning Units Quantity Part # Description Kubota Fuel Filter Kubota Sparkplug (NGK Part # on plug is BKR4E) Kubota Valve Cover Gasket Kubota Distributor Cap Kubota Distributor Rotor Air Filter 5400/5450/5600 (external type) Cat Pump Oil (for Cat Pumps Only)(can fill 2 pumps per bottle) 5450/5500/5700/7000/7300 (Kubota WG 972 engine) Cleaning Units Quantity Part # Description Kubota Fuel Filter Air Filter 5400/5450/5600 (or) Air Filter 5500/5700/7000/ Kubota Sparkplug (NGK Part # on plug is BKR4E) Valve Cover Gasket 972 (Meant for 4-bolt valve cover but can also be used on 6-bolt cover)(kub part # 1G ) Cat Pump Oil (For Cat Pumps Only)(can fill 2 pumps per bottle) 5600 (Ford 1.3L engine) Cleaning Units Quantity Part # Description Ford EFI Inline Fuel Filter (for fuel-injected Fords) (or) Kubota Fuel Filter (for carbureted Fords) (and) Ford Fuel Filter Carb Mount (for carbureted Fords) Air Filter 5400/5450/ Ford Sparkplug (Champion part # 302) Ford Valve Cover Gasket Cat Pump Oil (For Cat Pumps Only)(can fill 2 pumps per bottle) Other Parts That May Be Necessary Quantity Part # Description? Kubota Spark Plug Cap for 972 (requires 3 per engine if damaged)? Seal kit for Regulator (replaced only if deteriorating)? ft ¾ Heater Hose? ft ¾ Horizon Hose Red? ¼ Hose Clamp? ½ Hose Clamp? /8 Radiator Shutoff Valve (petcock for heat exchangers) 3

4 Belt Sizes and Part Numbers This list applies to most of the cleaning units. There have been some minor variations over the years so you will need to look at the belts of your cleaning units to be sure. Fan belts have not changed Kubota 750 or 752 engine (rear-mounted) Kubota fan belt Jabsco belt (AX 36) Blower belt (BX 38) Cat pump belt (AX 29) 5400 Kubota 752 engine (mid-mounted) Kubota fan belt Cat pump belt (AX 42) Jabsco belt (AX 36) (or) Blower belt (BX 42) Cat pump belt (AX 39) 5450 Kubota 972 engine (mid-mounted) Kubota fan belt Discharge (Jabsco or Johnson pump) belt (AX 36) Cat pump belt (AX 42) Blower belt (BX 42) 5500 Kubota 972 engine (mid-mounted square engine cover 2012 and older) Kubota fan belt Discharge (Johnson or Jabsco) to blower belt (AX 42) Cat pump belt (AX 30) (or) Blower belt (BX 41) Discharge (Johnson or Jabsco) to blower belt (AX 46) (Units built before late 2010) 5700 Kubota 972 engine (mid-mounted square engine cover with catalytic converter and newer) Kubota fan belt Blower belt (BX 41) Cat pump belt (AX 29) Discharge (Johnson or Jabsco) to blower belt (AX 42) 5600 Ford 1.3 liter carbureted or fuel injected engine Ford fan belt Jabsco belt (XL 7435) Cat pump belt (AX 42) Blower belt (BX 42) 6000 Hydraulic Box Truck Blower belt (BX 54) Cat pump belt (AX 48) Jabsco belt (AX 35) 7000/7300 Kubota 972 engine (square engine cover in box truck) Kubota fan belt Cat pump belt (AX 29) (2013 or newer) (or) Cat pump belt (AX 30) (2012 or older) Discharge (Jabsco) to blower belt (AX 44) Blower belt (BX 41) 4

5 KUBOTA VALVE ADJUSTMENT SEQUENCE VALVE CLEARANCE MEASUREMENT.007in (.178mm) FOR INTAKE AND EXHAUST VALVES 1. With No. 1 cylinder at T.D.C. compression, adjust the valves indicated in black. 2. With No. 1 cylinder at T.D.C. exhaust, adjust valves indicated in white. A B C D E F VALVE CLEARANCE VALVE SPRING VALVE STEM PUSH ROD VALVE CLEARANCE ADJUSTER ROCKER ARM To find the compression stroke on No.1 cylinder, align the 1TC timing mark on the flywheel with the timing mark on the rear engine plate to the right side of the flywheel. The piston of the No.1 cylinder will be at its highest point. (No. 1 cylinder is closest to the radiator.) Remove the valve cover and rotate the engine back and forth about an inch. Watch the valve rocker arms on No.1 cylinder. If they do not move, you are on the compression stroke. If they move, you are on the exhaust stroke. ATTENTION: If the engine has run that day, do not perform the valve adjustment. The engine must be at room temperature to properly adjust the valves. 5

6 FORD VALVE ADJUSTMENT SEQUENCE VALVE CLEARANCE MEASUREMENT INTAKE.203mm (.008in) EXHAUST.508mm (.020in) 1. Rotate engine (crankshaft pulley) clockwise (Flywheel will be turning counter-clockwise) until the piston of NO. 1 CYLINDER is at the top of the compression stroke. (No. 1 cylinder is closest to the radiator.) Adjust both valves. 2. Rotate the crankshaft 180 (half of a turn). Adjust both valves on NO. 2 CYLINDER. 3. Rotate the crankshaft 180 (half of a turn). Adjust both valves on NO. 4 CYLINDER. 4. Rotate the crankshaft 180 (half of a turn). Adjust both valves on NO. 3 CYLINDER. A B C D E F VALVE CLEARANCE VALVE SPRING VALVE STEM PUSH ROD VALVE CLEARANCE ADJUSTER ROCKER ARM Note: To find the compression stroke on No.1 cylinder, align the timing marks on the crankshaft pulley and the front of the engine (on the alternator side). The piston of the No.1 cylinder will be at its highest point. Remove the valve cover and rotate the engine back and forth about an inch. Watch the valve rocker arms on No.1 cylinder. If they do not move, you are on the compression stroke. If they move, you are on the exhaust stroke. Marking the flywheel with Wite-Out at the top and bottom after you have initially found the compression stroke will make the job easier. ATTENTION: If the engine has run that day, do not perform the valve adjustment. The engine must be at room temperature to properly adjust the valves. 6

7 Tools etc. for Cleaning Unit Repair & Maintenance Tools 1. Toolbox Best configuration is a small to medium rolling chest (several drawers 5-7) with a toolbox on top (get toolbox drawer liners) 2. Socket set with 1/4 and 3/8 ratchets in both standard and metric sizes (1/2 ratchets are worth having)(sears and Home Depot often have good deals on sets both with lifetime guarantees) Keep them in the original organized box if included or get socket organizers. 3. Set of wrenches standard and metric (must have 3/8, 7/16, 1/2, 9/16, 5/8, 11/16, 3/4, 7/8, 15/16 and 10mm, 12mm, 13mm, 17mm, 19mm) - invest in wrench organizers 4. Gear Wrench brand wrenches are extremely helpful in sizes 7/16, 9/16, and 12mm (available at Sears, NAPA, and several other automotive parts stores) 5. Full set of Allen wrenches (Also called Hex Keys) -Home depot has a good set with both standard and metric sizes including an organizer for about $ Screwdrivers Buy a standard set but make sure you also get a stubby flat, a stubby Phillips, and a few precision screwdrivers 7. Nutdrivers sizes 1/4, 5/16, 1/2, 9/16, and 7mm are a necessity. (Don t try to use screwdrivers on hose clamps or pliers on the nuts of electrical switches, as you won t get a good enough grip to tighten them sufficiently.) 8. Various pliers (must have needle-nose, standard slip-joint, channel-locks, and vice grips)(watch out! These will end up on the trucks if you don t keep careful track of them) 9. Quality pair of multi-task electrical pliers and wire cutters -Also order from manufacturing a couple dozen Waldom connectors (male and female including insulators - order twice as many female than male) and get a crimper from Napa for automotive electrical connections (Belden Part# ) 10. Retaining ring pliers -Sears has an easy to use set of two for about $20. (Craftsman 2 pc. Convertible Retaining Ring Pliers Set Model # 47385) 11. Heavy-duty hammer (3 lb. drilling hammer or similar) 12. Multi-meter (About $20 will get a good one from Sears) 13. Test light 14. Good utility knife and a set of hose cutters 15. Miscellaneous wire brushes and a chisel type paint scraper. 16. Compressor -A small portable upright will be sufficient costing between $250 and $350. A tire chuck with gauge and a blowgun are a must. A 3/8 air ratchet is very helpful. Invest in a 50 ft. rubber air hose. The plastic ones are difficult to roll up. 17. Quality vise -Don t be afraid to spend some money on this. It should last many, many years. 7

8 18. Workbench -You may be lucky enough to have someone build one for you. Otherwise, pre-built workbenches are available at some stores. Make sure the top is sturdy enough to mount the vise. 19. Safety glasses 20. Specialized but necessary tools that can be ordered from manufacturing a. TOOL BELT ADJUSTMENT Part # b. TOOL BEARING JABSCO PUMP Part # c. WRENCH SPANNER (JABSCO) Part # d. BOLT "T" HANDLE (JABSCO) Part # e. Vacuum gauge Part # Attach to the cup of a recirculator to make an effective vacuum testing tool 21. Specialized tools (many for annual maintenance and for the most part very inexpensive) a. E-Z out set b. Center punch and medium-sized chisel c. 3/32 pin punch (for removing the handle of the Giant gun) d. Pick set (they look like dental picks) e. Feeler gauges f. Spark plug gapper g. Tape measure h. Hobby knife i. Hacksaw j. Coolant pressure tester (Invaluable for annuals and checking for coolant leaks.) -AutoZone part # 9300 (Best option. Rent for $75 and keep it.) -Stant part # or Napa Balkamp part # (About $120) 22. Lever action grease gun -Buy marine grease cartridges, as they are ok for blower lubrication and excellent for rebuilding balanced regulators (A grease gun is not necessary if none of the blowers require grease but the grease itself is a must have.) 23. Quality floor jack -Get a decent one from Grainger or another dealer for $100 plus. If you buy a cheap jack you ll be in the market for another one within a couple of years or less. (Spend a little more now to avoid spending more later.) 24. Jack stands 6 ton capacity 25. Creeper 26. Parts bins Preferably open bins with I.D. tags for part numbers and descriptions 27. Several cans of carb and choke cleaner for use as a solvent. (A few cans of engine degreaser are also good to have on hand.) 28. WD Loctite glue (part # 22221) or similar for gluing dump tank gaskets back on. (Best practice is to completely remove the gasket, wire brush it, clean it, and re-glue the old gasket back on.) 30. Shop rags - Red rags or disposable blue rags are best for oil and grease 31. Several quarts of: a. 5w20 oil Ford van engines b. 5w30 oil Chevy van engines c. 10w30 oil for Kubota and Ford cleaning unit engines d. 50w for blowers e. Cat pump oil (Comes in 21oz. bottles - Order from manufacturing Part # 15132) 8

9 32. Good hand cleaner and a fingernail brush Parts necessary but not usually on hand 1. Part # SEAL KIT FOR REGULATOR (Much cheaper to rebuild balanced regulators than to replace them) 2. Part # PISTON # FOR REGULATOR 3. Part # /8MPT X 3/8 HOSEBARB STAINLESS (To replace failing hose barbs on the 600psi balanced regulators) 4. Part # FLOAT SWITCH GASKET FOR REVERE (gasket for 90 degree float in fill and dump tanks) Handy accessories 1. Water Saver Nozzle (This is an extremely durable spray nozzle for cleaning vans that many branches utilize.) The nozzle can be found at Lonn Manufacturing Part number: 05RP R Water Saver-Jet Stream 9

Section 2 Table of Contents

Section 2 Table of Contents Kubota Valve Adjustment Sequence... 2 Ford Valve Adjustment Sequence... 3 Maintenance Schedule for Cleaning Units with Kubota WG972 engine... 4 Maintenance Schedule for Units