TABLE OF CONTENTS

Section 1 - Safety and Precautions

1. Safety First
2. Danger
3. Warning
4. Caution
5. Identification
6. Safety & Precautions

Section 2 - General Information

1. Welcome letter
2. General Information
3. Operation Systems
4. Machine Specifications
5. Spare Parts Recommendations

Section 3 - Responsibilities

1. Purchaser’s Responsibilities
2. Distributor’s Responsibilities
3. RMA Procedure

Section 4 - Installation

1. General Installation Notes

2. Tools Required
3. Vehicle Preparation
4. Placing Machine Into Vehicle
5. Blower Exhaust Installation
6. Overflow Installation
7. Fuel Line Hookup
8. High Altitude Operations
9. Local Water Precautions
10. Water Softener
11. Waste Water Disposal
12. Submount Water Tank Procedure
13. Recovery Tank Pump Out System
14. Pump Out Operation

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Section 5 - Operations

1. Fluid Levels
2. Chemical Mix
3. Close Following Valves
4. Open Following Valves
5. Set Face Panel Switches
6. Hoses and Quick Connectors
7. Start Engine and Prime Chemical Pump
8. Machine Adjustments and Tests
9. Machine Shutdown Instructions
10. Winter Operation and Winterization
11. Water Extraction Operation
12. Upholstery Cleaning Operation

Section 6 - Cleaning and Chemicals

1. Cleaning and Chemicals

2. Chemical Mixing
3. Over Wetting

Section 7 - Maintenance

1. Overall Machine Maintenance

2. Operational Maintenance
3. Engine
4. Blower
5. Pump
6. Filters
7. Plumbing
8. Waste Tank Recovery
9. Battery
10. Hose Reels
11. Machine Body
12. Waste Drain Valve
13. Hoses
14. Heat Exchangers
15. Pulse Pump
16. Chemical System
17. Heat Diverter
18. Wands
19. Accessories

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Section 8 - Troubleshooting

1. Engine Troubleshooting
2. Vacuum Troubleshooting
3. Blower Troubleshooting
4. High Pressure Pump Troubleshooting
5. Heating System
6. Electrical Troubleshooting
7. Belt(s) Troubleshooting

Section 9 - Warranty

1. KOHLER® Certification Letter

2. Platinum Guarantee Warranty Plan

Section 10 - General Parts Identification

1. External Features and Benefits

2. Internal Features and Benefits

Section 11 - Parts & Drawings

1. Accessories
2. High Pressure Schematic
3. Engine Assembly
4. Blower Assembly
5. Heat Exchange Assembly
6. Pump Assembly
7. Water Box
8. Temperature Control Assembly
9. Face Panel Assembly (Lower)
10. Face Panel Assembly (Hydraulic)
11. Face Panel Assembly (Electrical)
12. Wiring Schematic

Section 12 - Component Manuals

1. KOHLER® Owner’s Manual

2. ROOTS™ Blower Manual
3. CAT PUMP® Service Manual
4. CAT PUMP® 5CP Specification Sheet
5. CAT PUMP® Crankcase Oil Material Safety Data Sheet

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You will find symbols and stickers throughout this manual and on the components of this
truck mounted carpet cleaning machine. The labels and notes are there to warn of the possi-
bility of personal injury. There are warnings throughout this manual that will aid you in the
safe and proper use of this equipment.

READ ALL INSTRUCTIONS CAREFULLY

BEFORE ATTEMPTING TO OPERATE
(or) INSTALL THIS EQUIPMENT.

You will also find the major component manuals, which have their own specific operational/
safety instructions. Each of these components are also specifically labeled warning of the
potential of personal injury and safe operations.

Careful operation and your full understanding on how the components work is your best in-
surance against any accident and your best opportunity for the machines longevity. All op-
erators of this machine should have a full understanding of the operation, maintenance and
safety requirements. It is the equipment owner’s responsibility for the safe operation and
instruction of other operator’s use of the equipment.

DANGER
• Know your equipment and the limitations of it.
• Always keep your machine in good working condition.
• Follow the maintenance schedule and recommendations for your equipment.
• Always instruct other operators to the full extent required for safe & effective operation.
• DO NOT modify your equipment from it’s original condition.
• Unauthorized modifications to the machine and it’s related components could severely
impede the safety and function of the unit as well as VOID the warranty.

WARNING
• DO NOT operate the machine while under the influence of alcohol,
drugs, medication or if fatigued.
• DO NOT wear loose clothing as the unit has moving/rotating parts.
• Be aware of your surroundings and the machine’s operation.
• DO NOT remove the machine’s cover during operation. This helps direct the proper air
flow around the unit and protects you from moving parts.
• Always remove the starter key when not in operation.

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 WARNING
• Keep the machine clean.
• Keep the unit free from debris, rags and any flammable fluids to avoid fire.
• NEVER operate your machine from a portable fuel container.
• DO NOT smoke around the machine or it’s components. Fuel is extremely flammable
and explosive under certain conditions.
• Always operate your machine with the van doors open for proper ventilation, a roof vent
may be recommended.

DANGER
• Engine exhaust fumes are very harmful.
• Poisonous carbon monoxide gas hazard.
• This machine must be operated only in a well ventilated area.
• DO NOT remain in vehicle with machine in operation.
• Carbon Monoxide is an odorless, tasteless gas that can cause severe sickness or death.

WARNING

• DO NOT operate the unit near exposed materials that could catch fire
(dry grass, oil, combustible materials, etc.).
• Check that wires and cabling are in good condition and all connections clean.
• Bare or frayed wires can cause a shock and sparks could result in fire.

CAUTION
• Hot water under pressure.
• DO NOT operate this machine at higher pressures or temperatures
than recommended. Doing so may cause component failure and thus serious injury.
• Be cautious of any escaping liquid, the machine achieves very high temperatures which
could result in injuries/burns.
• This unit contains pressurized systems, be careful around all fittings, hoses and compo-
nents.
• Be alert of pressure when disconnecting any device from the system.
• Always relieve any pressure when disconnecting devices or working on the machine.

WARNING
• This machine gets hot. To avoid burns always assume the unit is hot and allow
enough time for the unit to properly cool before attempting to touch any part of
the unit.
• Extreme heat danger.
• Stay clear of engine exhaust components, heat exchangers and hot water plumbing com-
ponents. Failure to do so may cause severe burns.

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 CAUTION

• DO NOT operate this machine with heat shields removed.

• The battery is an explosive hazard.
• Keep all sparks and flames away from the battery.
• Properly slow charge the battery when required.
• Never charge a frozen battery, explosion may occur.
• Use common sense.

WARNING

• Keep hands and clothes clear of all rotating equipment.

• DO NOT run this machine unless all guards are in place. Failure to heed this warning
may cause severe injury.
• Be sure that all parts have stopped rotating before attempting to check or make adjust-
ments to the unit.
• Keep body parts and materials away from rotating parts or personal injury could result.
• DO NOT run the machine with any of the safety guards or covers detached.

Important:
• Discard any used oil in accordance with used motor oil (HAZARDOUS WASTE).
• Follow your specific local codes for disposal in your area.
• Be mindful of the environment.
• Before draining any fluid or waste observe all regulations for the disposal of such items.
• DO NOT pour waste onto the ground, down a drain, or into any water source.

DANGER
• Keep a fire extinguisher and first aid kit available at all times.
• Keep all warning/caution labels clean and free of obstructions.
• Replace any damaged or missing labels with new labels.

DANGER
• NEVER recover flammable liquid or chemicals during any phase of water recovery.
• Flammable liquids or Chemicals can become explosive.
• Use extreme caution and know what you are recovering into the system before you start
any job.

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OWNER’S MANUAL (SAFETY & PRECAUTIONS) Section 1, Page 3
 IDENTIFICATION
(Identification of stickers, symbols and notes.)

Universal Symbols

FUMES MOVING PARTS HOT EXPLOSION SHOCK FIRE

White Magic Inc. White Magic Inc.

EXTREME HEAT label. KEEP HANDS CLEAR label.

White Magic Inc.

PROUDLY MADE label.

White Magic Inc. NOTICE label.

White Magic Inc. White Magic Inc. White Magic Inc.

VALVE label. GREASE WEEKLY label. SERIAL NUMBER plate.

White Magic Inc. White Magic Inc.

WARNING label. CAUTION label.

DANGER
Indicates an imminently hazardous
situation which, if not avoided, WILL TROUBLESHOOTING
result in death or serious injury.
Identifies a specific area or component
section for troubleshooting a problem.
WARNING
Indicates an potentially hazardous situation Important:
which, if not avoided, COULD result in death
serious injury or property damage.
Indicates that equipment or property
damage could result if instructions are
WARNING not followed.

Indicates an potentially hazardous situation

which, if not avoided, COULD result in FIRE NOTE:
causing death, serious injury or property damage.
Gives helpful information

CAUTION
PROBLEM
PROBLEM:
Indicates an potentially hazardous situation
which, if not avoided, MAY result in minor/
moderate injury or property damage. Identifies a specific problem or
specific problem area.

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OWNER’S MANUAL (SAFETY & PRECAUTIONS) Section 1, Page 4
(Excerpt from: KOHLER AEGIS® Engine Owners Manual Command Series LH 630-775 Liquid Cooled - Horizontal Crankshaft, pg 2.)
(See Kohler Manual for full instructions)

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OWNER’S MANUAL (SAFETY & PRECAUTIONS) Section 1, Page 5
(Excerpt from: KOHLER AEGIS® Engine Owners Manual Command Series LH 630-775 Liquid Cooled - Horizontal Crankshaft, pg 3.)
(See Kohler Manual for full instructions)

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OWNER’S MANUAL (SAFETY & PRECAUTIONS) Section 1, Page 6
SAFETY & PRECAUTIONS

• This equipment should be operated by fully trained personnel familiar

with all the information contained within this manual.

• Read this manual carefully before operating the ma-

chine. It contains important information on how to
run your machine safely and efficiently.

• Do not operate the machine with unau-

thorized people in or around the vehicle.
You should post caution signs.

• Be aware and cautious around moving parts in the machine

(e.g. belts, pulleys, etc.).

CAUTION

• Use caution in handling the wand and hose. Check for any leaks. Extreme hot wa-
ter will cause severe burns. Never point chemical tool at anything other than the
task at hand. Hot water under high pressure will damage finishes and is unsafe for
people or pets.

DANGER
• Assure that the machine engine exhaust is vented out of the vehicle properly. Never
allow people inside the vehicle with the doors closed and the machine running.

• Machines using internal combustion engines must not be enclosed within a vehicle
with the doors closed. Excessive temperatures within the engine will
result in engine failure and VOID the warranty. Always operate the
machine with the vehicle doors open. A roof vent may be required.

WARNING
• Be cautious when drilling holes through the vehicles floor. Many vehicles have
critical components mounted directly below the floor that could be damaged.

• Only experienced technicians should be allowed to install the machine.

• Assure that the machine is adequately bolted to the floor.

Periodically check and re-tighten the bolts if necessary.

• When not in operation, always remove the key from the machines ignition.

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WARNING
• When installing the machine, never use an electrical device to cut the gas line.

NEVER:
Under any circumstances may a portable fuel container be used or carried in
a vehicle equipped with White Magic Equipment. This practice is unsafe and
illegal in most areas. Only approved systems are permitted to fuel White
Magic Equipment. NEVER
• Be sure to put exhaust diverter switch to “Water Recovery”
when performing water extraction.

CAUTION
• Never operate the system with the pump pressure set less than 300 PSI or more than
1200 PSI.

• Never fill fresh water tank/water box with warm or hot water.

• Never allow system to freeze. Refer to winterization procedure.

• Never operate the machine without water in the water box; system components will be
damaged.

• Never operate machine with chemical pulse pump turned on and no chemical
in chemical jug. The chemical pulse pump will become damaged.

• Never operate machine using hard water. Mineral deposits will result and cause fail-
ures. Water softeners must be used to prevent this build-up. Periodic descaling may
also be necessary to remove deposits.

• Never operate machine with engine running at speeds higher than recommended.
[3600 RPM at 13”-14” Hg.]

• Never shut-down system without first reducing engine speed to idle [1000 RPM at 13”-
14” Hg.] (or) without reducing the water temperature to below 150˚.

• Never use chemicals not recommended for truck mount use.

• Never operate machine with blower vacuum reading higher than 14” Hg. at the inlet
of the blower.
CAUTION
• Never:
Plug overflow elbow on face of machine. A short piece of hose can be run through
the floor if desired. Plugging the overflow elbow will result in permanent damage to
system components and could cause unsafe pressure build up.

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OWNER’S MANUAL (SAFETY & PRECAUTIONS) Section 1, Page 8
 White Magic Inc.
Manufacturer of Truck Mounted Carpet Cleaning Systems & Air Duct Cleaning Systems

Dear Customer:

Thank you for selecting White Magic Carpet Cleaning Equipment, we at

White Magic take pride in the innovative design and the quality of our
equipment and accessories and your selection indicates your approval.

Your purchase is just the beginning of a long relationship between our two
companies. The equipment White Magic manufactures should serve you
well for years to come. You will be able to properly and safely operate this
equipment with the help of your distributor and this manual for reference.

As a White Magic Equipment Owner, you not only have the relationship of
the Distributor you bought the equipment from, but also have the support
of the White Magic manufacturing family. White Magic will send any bulle-
tins, changes, improvements and new information regarding your equip-
ment to both you and your distributor.

Thank you again for choosing White Magic Incorporated. We will, as we

have in the past, continue to do everything possible to ensure that you re-
main a proud and satisfied White Magic Equipment Owner.

Sincerely,

The White Magic Family

“OUR FUTURE DEPENDS ON YOUR COMPLETE SATISFACTION”

11 Main Street, Salisbury, MA 01952 - Tel (978) 465-2287 - Fax (978) 462-9170 - Web www.whitemagicinc.com

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 1
GENERAL INFORMATION

This manual contains installation and operation instructions as well as information re-
quired for proper maintenance, adjustment and repair of this machine. Since the first
and most important part of repair work is the correct diagnosis of the problem, compo-
nent manual troubleshooting charts and diagrams have been included for your conven-
ience.

It is important to remember that carpet cleaning machines have many functions to per-
form at the same time.

• The engine has to run at a consistent RPM.

• The vacuum blower has to recover dirty water.
• The high pressure pump has to deliver proper water flow.
• The chemical solution has to be injected at the right time.
• The heat must be maintained at the proper temperature.
• The machine must store the dirty water that is recovered.

It is important that you read this manual in full and make yourself familiar with all of
the components. This will help ensure the continuing life of your carpet cleaning ma-
chine.

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 2
OPERATION SYSTEMS

The Commander & Commander HO heat exchange system is a highly engineered sys-
tem design by the White Magic Corporation. The heating system is comprised of ex-
haust and blower heat that is captured for free heat.

Water is fed into the machine under tap pressure and it flows to the water box. The
water is then picked up by the high pressure pump and pressurized to the desired pres-
sure level. The water then splits as demanded by the technician.

The water demanded by the technician flows from the water pressure pump through
the heat exchangers then out to the cleaning tool.

When the cleaning solution reaches a preset temperature set by the cleaning technician
the machine will go into a divert mode until it calls for more heat, then it goes back into
the heat mode. The HeatSmarttm Technology is the first of its kind in the carpet clean-
ing industry. There is no dumping of fresh water into the recovery tank.

White Magic has put no guess work into this highly advanced cleaning machine. This
manual will help you understand, maintain and service your cleaning machine. Follow
the directions carefully and you should receive many years of profitable and trouble
free operation.

It is important that no section be overlooked in your reading of this manual.

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 3
MACHINE SPECIFICATIONS

Frame: 27” W x 46” L 30” H

Steel with Epoxy Finish

Weight: 570 lbs. (Commander), 620 lbs. (HO)

Engine: KOHLER AEGIS® 24 HP Engine, 3600 RPM (Commander)

KOHLER AEGIS® 28 HP Engine, 3600 RPM (HO)
Liquid Cooled, Pressurized with Lubrication
Oil Filter, Oil Protection Switch, Temp Protection Switch

Ignition: Electronic, Key start

Vacuum Blower: ROOTS™ 45 Blower, 14’’ Hg. (Commander)

ROOTS™ 47 Blower, 14’’ Hg. (HO)

Pump: CAT PUMP® 5 CP, 5 gpm 1200 PSI Pump

Pump Clutch for Water Damage
Pulsation Dampener

Chemical System: Last Step Chemical Injection

Operating Pressure: Up to 1200 PSI

Heating System: Engine Exhaust Heat

Blower Exhaust Heat

Instruments: Water Pressure Gauge, Liquid Filled

Hour Meter, Machine Run Time
Tachometer, Engine RPM
Vacuum Gauge, Liquid Filled
Temperature Gauge
Key Start Ignition, Start/Stop
Temperature Adjustment Control
Chemical Adjustment Control
Pressure Adjustment Control

Recovery Tank: 120 Gallon Full Capacity

Aluminum, Epoxy Finish
2’’ Drain
Automatic High-Level Shut-off
(Optional Automatic Pump Out)

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 4
Cleaning Wand: Stainless Steel S-Bend Wand #2-Jet
Re-buildable Solution Valve

High Pressure Hose: High Temperature Steel Braid / Vinyl Covered

Hose Rated to 3000 PSI

Vacuum Hose: 2’’ Reinforced Flexible Hose

Standard Equipment: Platinum Guarantee Warranty Plan

Commander / HO Framed Assembly
HeatSmarttm Technology
Bypass-Less Heat Technology
Working Temperature 230˚+
Dual Mode Heat Exchangers
Automatic Heat Diverter
120 Gallon Recovery Tank
150 ft. Solution Hose
150 ft. 2’’ Vacuum Hose
2-Jet Carpet Cleaning Wand
Chemical Jug
Battery Box
Pump Disengagement Clutch
Last Step Chemical Injection
Full Instrumentation Panels
Engine, Blower & Pump Oil Drain
Machine Installation Package
Operation Manual

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 5
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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 9
Spare Parts Recommendation

Downtime can be very expensive and irritating, because your truck-mount can gener-
ate several hundred dollars per day. It is recommended by the manufacturer that you
purchase and keep in you truck the parts listed below.

How to Order Parts:

To order parts please call your sales representative (Distributor) from whom you pur-
chased your new White Magic Machine. The distributor more than likely has all of
these parts in stock. If further assistance is needed you may call the factory for help.

Distributor Phone Number: __________________________

White Magic Parts Dept: 1-978-465-2287

White Magic Sales Dept: 1-800-422-1128

Spare Parts List:

QTY. P/N DESCRIPTION

1 A005P-2 PULSE PUMP DIAPHRAGM
2 A005P-3 PULSE PUMP CHECK VALVE
1 A005P-5 PULSE PUMP WAFER
2 A005P-9 “O” RING, VALVE CAP
1 A005P-10 “O” RING, MAIN BODY
4 B001 1/4” MALE QUICK DISC. BRASS
2 B002 3/8” MALE QUICK DISC. BRASS
4 B003 1/4” FEMALE QUICK DISC. BRASS
30” B011 1/4 ID BLACK TUBE
1 B039-8 CMP VALVE REPAIR KIT
4 B063 1/4” BALL VALVE (LOW PRESSURE)
1 B147 1/4” SHUT OFF VALVE
1 A026 1/2” FLOAT VALVE
1 A0285 RECOVER TANK FLOAT SWITCH
2 G036 36” BLOWER V BELT
2 G038 38” PUMP V BELT
1 B135P POP OFF VALVE

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 10
NOTE:

Engine Oil: 30 weight motor oil with a minimum standard of SE, SF, SG.
(see charts below)

(Excerpt from: KOHLER AEGIS® Engine Owners Manual Command

Series LH 630-775 Liquid Cooled - Horizontal Crankshaft, pg 4, 5.)
(See Kohler Manual for full instructions)

Blower Oil: 50 weight, ISO-220 premium grade industrial type non-detergent

oil with: foam, oxidation and rust inhibitors. Automotive type oils
are NOT recommended.

Blower Grease: NLGI #2 premium grade, synthetic grease with high temperature
300° service temperatures, moisture resistant and good mechani-
cal stability. (such as Shell Darina NLGI grade 2 or equal)
Note: Lithium base greases are NOT recommended.

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 11
(Excerpt from: Dresser ROOTS™ Installation operational Maintenance Manual Universal RAI & RAM SERIES, pg 13.)
(See Dresser ROOTS™ Manual for full instructions)

(Excerpt from: Dresser ROOTS™ Installation operational Maintenance Manual Universal RAI & RAM SERIES, pg 23.)
(See Dresser ROOTS™ Manual for full instructions)

Pump Oil: CAT PUMP® Oil, (approx. 19 Oz.)

or ISO 68 Multi-viscosity petro-
leum based non-detergent Hydrau-
lic oil. (oil level is increased slightly
above the center dot to assure ade-
quate lubrication for reverse
pump rotation)

(Excerpt from: CAT PUMP® CP PLUNGER PUMP SERVICE MANUAL

rev F 11217, preventative maintenance check-list)
(See CAT PUMP® Manual for full instructions)

Important: Discard any used oil in accordance with used motor oil (HAZARDOUS
WASTE) in your area. Be mindful of the environment. Before draining any
fluid or waste observe all regulations for the disposal of such items.

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OWNER’S MANUAL (GENERAL INFORMATION) Section 2, Page 12
PURCHASER’S RESPONSIBILITIES:
• To purchase a heavy duty 42-60 amp hour garden tractor battery and have it slow charged.

• If the battery is not fully charged, damage can occur to the engine charging system of the
machine.

• While the machine is being installed it is your responsibility to read the operation manual
and to get familiarized with the information contained within.

• Special Attention should be paid to all warnings and cautions that are in the operations
manual.

It is the RESPONSIBILITY of the OPERATOR to make every effort to diagnose

a problem should one occur BEFORE calling your DISTRIBUTOR for assis-
tance. This operational and service manual has been specifically developed for
SELF-HELP and DIAGNOSIS. Most if not all problems can be simply diag-
nosed with common sense, a good understanding of how your machine works
and this guide.
PLEASE take the time to fully read and understand this manual before operat-
ing the equipment. This manual should always be in your truck for easy refer-
ence. You will need this manual handy if you ever have the need to call for assis-
tance. You will be asked to refer to this manual should a problem arise that you
cannot diagnose. It is standard practice to go through EACH step in the trouble-
shooting section while diagnosing the equipment over the phone with your DIS-
TRIBUTOR.

IF A PROBLEM SHOULD ARISE …

STEP 1 : DIAGNOSE THE PROBLEM YOURSELF.

Go through the manual and try to self-diagnose the problem.
Remember that most problems that occur are minor and just re-
quire a good understanding of your equipment and its opera-
tion.

STEP 2 : CALL YOUR DISTRIBUTOR.

Let your knowledgeable distributor diagnose/repair any issue
that may be occurring. If need be your distributor may contact
White Magic directly for further diagnosis or parts ordering.
Note that you cannot order parts directly from the factory or get
pricing for parts. You must contact your distributor for this in-
formation.

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OWNER’S MANUAL (RESPONSIBILITIES) Section 3, Page 1
DISTRIBUTOR RESPONSIBILITIES:

ACCEPTANCE OF SHIPMENT:

− If the equipment shows any outward signs of damage, DO NOT sign the delivery
receipt until you have closely inspected the machine and the shipment.
− Damage must be noted on the delivery receipt for any freight claim to be made.
− If damage has occurred it is YOUR responsibility to make a claim with the freight
company unless shipment was PRE-PAID.

RESPONSIBILITIES:

It is the responsibility of the salesperson that sold the equipment to the customer for super-
vising the correct installation of the equipment package in the vehicle. The salesperson is
responsible for thoroughly training the customer in the safe operation and maintenance of the
equipment.

• Fully complete the Truckmount Document Package with all pertinent information and re-
turn to White Magic Inc.

• Give a full copy of the Truckmount Document Package to the purchaser for their records
and serial number information.

• Thoroughly review the operation manual with the customer.

• How to correctly start and shut down the machine.

• How to correctly clean with the machine.

• Where and how often to check and change component oil levels.

• How the machine systems work.

• How to troubleshoot the machine.

• How to do basic repairs.

• Safety precautions and their importance.

• Freezing damage and how to avoid it.

• Hard water damage and how to avoid it.

• Review of warranty procedures.

• Use of Water Softening Systems and why to use them.

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OWNER’S MANUAL (RESPONSIBILITIES) Section 3, Page 2
(RMA) PROCEDURE:
By following these steps we will be able to help you faster and more accurately thus saving
everyone’s time.

As we develop new and innovative ways to better serve you we will require some consis-
tency in the way that information is exchanged. Whether you are calling to replace a part or
are having technical problems with a machine by providing the serial number to us (or) your
distributor when you call we will be able to bring your machine up on our computers. This
will allow us to address your issues and tie it all back to the equipment for any future refer-
ences that may be needed.

Please make sure the Very Important Truckmount Document Package is returned back to
White Magic Inc. fully completed as soon as the installation is completed. This will be en-
tered into our system upon return.

RMA is procedure is as follows: Faulty part is called into White Magic Inc. White Magic
confirms failure over the phone by further diagnosis. If part is determined to be failed, RMA
number is issued and part is shipped and billed according to account type. To be covered
under warranty the defective parts must be returned with an authorized RMA# to White
Magic Inc. within (14) DAYS of failure. When part is recieved, it is evaluated and credit is
approved or denied based upon testing and evaluation. Credits will be issued once a month
at the end of every month. No liability shall be attached to White Magic Inc. until products
have been paid for.

If a claim is denied you will need to decide what you want us to do with the merchandise. If
no response is given within the timeframe given the items will be discarded. Items returned
without the proper paperwork, information or pre-authorization will NOT be considered.
Once a RMA# is issued you will have 14 days to return the items to us, if the items are not
returned with in the given timeframe all rights to a warranty claim will be forfeited. All
claims need to be documented with the service department within 30 days of discovery.

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OWNER’S MANUAL (RESPONSIBILITIES) Section 3, Page 3
INSTALLATION:
Read the entire installation procedure carefully before starting to assure a correct
and safe installation. The most common machine installation is into a full size van
with the machine being mounted facing out the side door (See Fig. 4-1). For installa-
tions into cube vans, mini vans, trailers, etc., consult the factory for special instruc-
tions. The engine MUST have access to adequate fresh air to avoid overheating. Fail-
ure to provide adequate ventilation will VOID the warranty. Roof vents or forced
ventilation may be required. Prior to installation, unpack the machine and check the
parts against the packing list. Contact White Magic factory immediately before start-
ing if a discrepancy exists.

The following is a summary of the installation process.

• Assure that a vehicle of proper load carrying capacity is used.

• Assure that a suitable layout plan is available for this van with the equipment and
accessories used.
• Install through-floor fittings for gasoline fuel lines and fuel tank system (if required).
• Place the machine, recovery tank and accessories properly into the vehicle and secur-
ing them with the proper bolts.
• Connect gasoline lines.
• Connect the battery.
• Connect machine recovery tank and accessories.
• Check the pump, vacuum blower and engine oil levels prior to starting the machine.
• Start the machine to check the engine to see that all systems function normally.
• Check all hoses, wands and accessories for correct operation.
• The machine may have been winterized for shipment. Make sure the process is re-
versed before operation.

TOOLS REQUIRED:

The following is a list of tools needed to install the slide-in-machine.

• Fork Lift
• Electric Drill
• Reciprocating saw
• Common Hand Tools (wrenches, hammers, allen wrenches, etc.)
• 1/2’’ and 7/16’’ Drill Bits
• 1’’ and 3/4’’ Hole Saw (3’’ hole saw is required if running exhaust through the floor,
5” hole saw if adding a fuel tank)
• Tube of Clear Silicone
• Tube of High Temperature Silicone Gasket Maker

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 1
VEHICLE PREPARATION:

When selecting a truck, remember the preferable vehicle for a Commander HO instal-
lation is a cargo van with heavy-duty suspension package and a half ton capacity.
When using a fresh water tank, hose reel, shelf’s, etc., a three quarter ton or larger ca-
pacity vehicle with a 2,400 pound payload is required. An extended van is preferred
for either case to provide adequate storage.

The manufacturer recommends that the floor of the vehicle should be protected with a
spray on coating (such as ‘LINEX’ or ‘RHINO LINER’).

PLACING MACHINE INTO VEHICLE:

Side Door Installation:

Most truckmounts are installed through the side door. This gives good weight distribu-
tion and allows for rear access for accessories and hoses as well as access to side of the
machine for service. This will make it easier to perform maintenance or repairs on the
machine.

Placement of Major Components

Figure 4-1 shows the approximate location of major components in a typical van in-
stallation. The Vacuum Hose Reel, Floor Mount Solution Hose Reel and Filter Box are
optional equipment.

Figure 4-1: Location of Major Components in Van

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 2
Signature Series Layouts

The Rebel, Commander, Commander H.O. have been specifically designed and engineered
to be installed into a standard size van (Chevy, Ford, Dodge) with the machine and hose
reels accessible though the side door. This does not prevent a similar package to be devel-
oped for a customer with hose reels accessible through the back door if required.

Commander H.O. with 130 gallon Re-

RE500 Electric Hose Reel covery Tank.
With Hinge

RE 110 w/ Live Swivel Kit E225 Vacuum Connector

SIDE DOOR VIEW

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 3
Signature Series Layouts

RE500 electric hose reel shown with the RE025 Lay Down Hose Reel Hinge. The RE 025
allows for the hose reel to be swung back toward the rear of the van. Once the reel is placed
backwards it provides additional space to service the machine. This hose reel layout is also
available for PRO-1900 installs as well.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 4
Signature Series Layouts

Cutaway & Tilt Cab Box Truck

Commander H.O w/
130 Gal.

RE 700– 250’ Electric Hose

RE110 Deluxe Floor

Mounted Solution Reel

TA70—70 Gallon Fresh

Water

5 gallon chemical Jug w/

Stainless Steel Tray

Side Door View

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 5
Signature Series Layouts

Cutaway & Tilt Cab Box Truck

Shelving

TARFS3-C In-line Filter

Recovery System

Plenty of floor space for hauling equipment

Installed into a 14’ cube the Commander H.O. takes up minimum space. Perfect for Restora-
tion contractors. This Layout provides exceptional platform for delivering large numbers of
Dryers and Dehumidifiers to the job site. Allowing less trips by technicians back to the shop
for additional gear.

Rear Door View

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 6
Installation:
CAUTION Use all standard precautions when working on the vehicle. Place ve-
hicle in park, remove key, disconnect negative battery cable, chock
wheels, etc.
Filter Housing
• Install auxiliary fuel tank system if required.

• Remove Commander HO top and side console covers as

applicable.

• Place recovery tank (Refer to Fig. 4-2) into van locating it This Side Faces The
directly behind the driver seat with drain towards front. Side Door Of The Van
Do not mount recovery tank at this time.

• Position the Commander HO and fresh water tank into Sight Tube
the vehicle using a fork lift.
Tank Drain
• Position the recovery tank and machine as shown in the Figure 4-2: Recovery Tank
recommended placement pictures. Check for adequate
** Drain now on right side of tank
motion of the driver’s seat in the upright position.

• Move the driver’s seat fully to the rear position. Position the recovery tank and
Commander HO framed assembly as close as possible toward back wall and next to
the driver’s seat. For vehicle seats without built in head rests, allow 12’’ minimum
clearance between the seat and the tank.

• Check that there is enough room to remove and clean filter assembly when tank is
installed.

• Be cautious when drilling any holes

through the vehicle floor. Many vehicles
have critical components mounted di-
rectly below the vehicle floor that could
be damaged by a misplaced drill bit.

• Mount the recovery tank to the vehicle

floor by drilling two (2) 7/16’’ clearance
holes in the front and rear of both tank
mounting tab’s, (4) holes total. Mount
the machine to the floor by drilling one
(1) 7/16’’ clearance hole in each mount- Figure 4-3: Bolt Configuration
ing tab. Tighten the hardware fur-
nished with the machine securely. (Fig. 4-3)

• Before mounting machine to the floor, attach mounting brackets on the rear of ma-
chine to the recovery tank in two (2) places.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 7
Rear Door Installation:

• Rear mounting the machine is usually not recommended. (Except in a cube truck –
consult the factory for recommendations)

Recovery Tank and Drain Installation: Filter Housing Assembly

(Filter On Inside)
• Install the filter and housing assembly Spring
onto the top of the recovery tank using Blower Input Hose
the six (6) hand turn knobs. (see Fig. 4-4)
Assure that the output connector of the fil-
ter assembly slips into the blower input
hose properly.

• Connect (1) of (2) brown wires from recov-

ery tank to green wire (Ground from face
of recovery tank). Connect the second Hand Turn Knob
brown wire to the black wire from the kill (Typ. 6 Places)
override switch.
Recovery Tank
• The recovery tank drain piping exits to-
ward the front and immediately turns 90˚ Figure 4-4: Recovery Tank Top
and runs toward the vehicle’s side door.
The A.B.S. piping parts should be assembled
together with the pipe being cut to the
proper length before the parts are glued.
(see Fig. 4-5)

• Disassemble drain parts and reassemble,

gluing each part in its proper place. To glue
parts together, apply glue liberally to the
part being glued, then slip together and rap-
idly rotate parts to the desired position.
This glue sets up in a matter of seconds.

• After the connections are glued together, in-

stall the drain clamp by sliding it around the
Figure 4-5: Drain Assembly
pipe locating it next to the drain valve.

• Check beneath the vehicle floor and if the drain pipe clamp position is correct, drill
two (2) holes in the floor. Install the bolts with washers and tighten securely.

• Connect (2) brown wires from the recovery tank to the (2) black wires in the har-
ness located at the right rear side of main machine.

• Connect hose to recovery tank from chemical prime valve.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 8
BLOWER EXHAUST INSTALLATION:

The blower and engine exhaust join internally and exit out the front of the machine.
A 3’’ hole can be placed in the floor for exhaust to blow out under the vehicle if de-
sired. Use High Temperature Silicone to seal around the hole.

DANGER This system produces carbon monoxide which is an odorless, but

deadly gas. It is the operator’s responsibility to assure that the
exhaust is directed away from building entrances, etc. during op-
eration.

The manufacture also recommends the installation of roof vents in the vehicle to
allow excessive heat to escape.

OVERFLOW INSTALLATION:

The pressure relief, water box and water tank (if equipped) overflow hoses combine
internally and relieve through a fitting on the face panel. It is imperative that this
open fitting NOT be plugged or damage will result. A relief cut is necessary at the
end of the hose so ice cannot form a plug.

FUEL LINE HOOKUP:

***Refer to installation instructions supplied with the fuel tap kit purchased

The machine is equipped with a secondary fuel pump which pumps fuel into
NOTE: the engine at a pressure of 2-1/2 PSI maximum. Secondary fuel pumps are
required for the White Magic Commander HO and should be mounted as
near the vehicles fuel tank as possible. Fuel pumps are designed to push fuel
more than suck fuel.

WARNING Do not start vehicle, or use any electrical devices which could
accidentally ignite gasoline while installing any of the connec-
tions into the fuel tank. Use an industrial knife to cut hoses.

WARNING Never operate this machine with a portable gas container in-
side the vehicle. Doing so increases the risk of a fire or explo-
sion.

Vehicles are constantly changing fuel system requirements due to EPA, DOT and other
agencies regulations. White Magic Inc. has hook-ups for many older vans. Please con-
sult the factory for information and instruction on the newest or older applications.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 9
Fuel Pump Installation
Install the fuel pump on or as close to floor as possible in a convenient location away from the
exhaust system and any moving parts. Position fuel pump with input heading in the direction
towards the vehicle fuel tank. Verify input and output as shown on fuel pump body. Connect
the fuel line being installed to the input and output of the fuel pump. Tighten fuel lines onto
fuel pump using stainless steel hose clamps.

A red wire is wired into the machine’s electrical system to provide power for the fuel pump.
The wire is located in the terminal block. The red wire is provided with a female connector.
Connect this wire to the fuel pump’s positive connection. Assure that the black fuel pump lead
wire is properly grounded.

At this time the fuel pump installation and all hose connections should be complete. To test the
fuel pump, turn on machine key and listen for the fuel pump to start clicking. After the pump
builds up pressure and fills the carburetor and lines, it will stop clicking. When this happens,
turn off key and proceed to the next step.

Chemical Jug Tray

Install the chemical jug tray onto the van floor at the left side of machine using two screws. It
may be necessary to drill two small pilot holes in bottom of tray for easier mounting of TEK
screws. Place the chemical jug into the tray.

Covers, Shields, Etc.

CAUTION
The Commander HO has pulley shields over the engine & pump belts,
and heat shields to protect from the areas of hot engine exhaust.

DO NOT operate these machines without guards in place.

Water Requirements
White Magic recommends that you test the water you will be using in your machine for water
hardness, primarily minerals. Calcium and magnesium deposits in a water supply will “scale”
or build up during heating. Most, if not all, scaling occurs down stream of the heat exchanger
and in the heat exchanger. If you will be filling your machine from an area of hard water, espe-
cially calcium and magnesium deposits, and use a water softener device, you must also follow
the maintenance schedule to prevent scaling (see Descaling). A filter will not extract all de-
posits. Contact your White Magic distributor for assistance in choosing the proper water sof-
tener for your area of operation.

Optional Equipment

1.) Hose Reels

• Vacuum Hose Reel: Position hose reel and bolt to floor of van, (see Fig. 4-1) for placement.
Connect hose reel to inlet of vacuum on the recovery tank or the inlet of the optional filter
box.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 10
• Electric Vacuum Hose Reels only: Connect a 10 gauge wire from the positive terminal of
the vehicle’s battery to the power supply wire of the hose reel.

CAUTION Install a proper size or fusible link.

Attach the ground wire of the Electric Hose Reel to the frame of the vehicle when bolting
down reel.

• Floor Mount Solution Hose Reel: Position hose reel and bolt to floor of van, (see Fig. 4-1).
Connect hose reel to one of the Output Wand disconnects on the face panel.

2.) Filter Box

• Position filter box in vehicle and bolt to floor, (see Fig. 4-1). Connect inlet side to wand or
hose reel and outlet side to vacuum inlet on recovery tank.

3.) Automatic Pump Out—(see pg. 14 - 15)

4.) Water Tank

• Positioned under main machine assembly, bolt to floor with supplied hardware. (4 Places)
See Following Procedures for Signature Series (PN#TA70) Fresh Water Tank installation.

HIGH ALTITUDE OPERATION (Over 5,000 Feet): WARNING

The new versions of KOHLER® Engines used on the Commander HO machine are C.A.R.B.
(California Air Resources Board) compliant. However, a significant loss of power is to be ex-
pected at higher altitude operation, because there is less oxygen available. High Altitude Jets
are available and need to operate at high altitude. Major damage will occur if a high altitude jet
kit is equipped and machine is operated at lower altitudes. Water will boil at a lower tempera-
ture and the system may need to be adjusted accordingly to prevent “live steam” at the end of
the tool.

LOCAL WATER PRECAUTIONS:

The quality of water varies depending where you are in the country. Many areas have an excess
of minerals in the water which results in what is referred to as hard water. These minerals tend
to adhere to the insides of the heater coils and many other parts of the machines parts causing
damage and loss of effective cleaning.

Hard water deposits that might occur within the water system of the machine can be a serious
problem. The precision technology of the machines heat system is intolerant of any foreign ma-
terial building up within the heat exchangers. Hard water deposits will decrease the perform-
ance of the system and reliability and VOID the warranty.

To maintain the warranty of a White Magic machine it is required that all machines operating in
areas with 3.5 grains or more of hardness per gallon be fitted with a water softening system.
De-scaling of the water system by using a de-scaling agent or acid-rinsing agent may not be
enough in these areas.
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OWNER’S MANUAL (INSTALLATION) Section 4, Page 11
White Magic does recommend that all machines be fitted with water softening systems for
improved operation and performance.

NOTE
NOTE::
White Magic does not endorse or prohibit use of “ionic” type softeners or conditioners (the
ones that utilize strong magnets that the water flows over). However, if used they must be
used in the by-pass loop of the pumping system and NOT the input side.

CAUTION Failure to take appropriate care to prevent scale build up can result in
system failure and loss of warranty on the affected parts .

WATER SOFTENER:
The use of a water softener will increase cleaning efficiency and equipment life, chemical
use decreased and the appearance of cleaned carpets enhanced when water softeners are in-
corporated with equipment use in hard water areas. The manufacture strongly urges the use
of water softeners in areas where the hardness exceeds 3.5 grains per gallon. Failure to do so
may invalidate the warranty of the equipment.

The low cost of a water softener service will increase the life of not only the machine but of
all the tools that are used in cleaning. The water softener will also increase the cleaning and
use of less chemical in the day to day operation of the cleaning plant.

Contact a water softener distributor in your area for information on the rental of a simple wa-
ter treatment unit to carry in the truck. Be sure to change (or) recharge the water softener
within manufacturers specifications.

Example: Softener will treat 900 Gallons of water. If 30 gallons per hour is used for 5
days this is 150 gallons per day; in 6 days this would be 900 gallons. This
would mean the softener should be changed every 6 days.

WASTE WATER DISPOSAL:

There are laws in most areas of the country prohibiting the dumping of recovered water from
carpet cleaning. This is called gray water.

The only place that this water can be dumped is into a sanitary treatment sewer. This clean-
ing rinse water recovered into your unit’s vacuum recovery tank contains materials such as
detergents. These must be processed before being safe for streams, rivers and reservoirs.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 12
Important:
The penalties for noncompliance can be serious. Always check local laws and regulations to
be sure you are in compliance. An acceptable method of waste disposal is to discharge into
municipal sewage treatment system after first filtering out solid material such as carpet fiber
such as using an inline filter box. Check your local codes for proper access to a sanitary
system (i.e. a toilet, laundry drain, RV dump, etc.).

An easer method would be to use a White Magic Automatic Pump-Out- System (APO).
This System is designed to pump the dirty water from the waste recovery tank to the sanitary
system with out the tank filling up to force the cleaning to stop. This helps in the cleaning
production.

This system can be installed with a new machines or machines that have been in operation
for a while.

NOTE:

A pump out cannot be installed unless the system has a filter box.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 13
Recovery Tank Pump Out System: (PO50 installation procedure)

• Completely empty the recovery tank of any wastewater if the pump out is to be installed on an
existing machine. Otherwise lay the tank on it’s back before installation to easier facilitate the
necessary tank modifications.
• Park the vehicle on a flat surface, chock the wheels and remove the keys from the ignition.
• Remove the negative battery cable from the battery on the machine.
• Align the template on the recovery tank where the pump out float switch is to be installed.
• Center punch the holes onto the tank with a Ø.25” transfer punch. Lightly scour the area below
the template with a piece of Scotch Brite or fine sand paper to help prevent any leaks. Drill “F”
size and tap as noted on the template, 5/16-18 UNC in 6 places around the outside edge, drill
Ø2.5” in the upper middle center punch, Drill Ø1.5” in the lower middle center punch.
• Bolt the float plate assembly to the tank with the six supplied 5/16-18 X 5/8” BHS. Assure that
the float is over the output and is on the inside of the tank. Be sure to apply a good amount of
Teflon tape to all male threads.
• Place the pump out assembly on the floor in an easily accessible location. The pump placement
can be located anywhere desired but must be located on the floor and the hose between the tank
and the pump must not exceed 36” in length. Be certain that there are no wires, cables or hoses
in the way under the floor. Drill thru and bolt the pump out assy to floor. The hose must have a
steady downward slope toward the pump with no humps or valleys.
• TEK screw the output floor mount valve assembly to the floor in the desired location. (The as-
sembly must be screwed to floor before the barb can be installed)

• Cut and fit the black hose to the pump, tank, and valve. Tightly hose clamp all hose fittings.
• See following page for wiring schematic.

Pump Out Operation:

• Attach the supplied garden hose to the floor mount output and run it to the desired waste loca-
tion.
• Open the output valve to the hose.
• Flip the switch on the facepanel to “AUTO” or “MANUAL” the pump will operate until the
float switch level is reached and the pump will shut off.
• Always leave the output valve in the closed position when not in use or spillage may occur.
• Never run the pump with the output valve in the closed position.
• If the pump should come into an overloaded condition (closed valve, clog, or kinked hose) the
circuit breaker will trip and need to be reset.
• Running the pump dry for short periods of time will not cause any damage to the pump.
• Be sure to pump the system completely dry and close the output valve if freezing conditions are
likely to occur.

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OWNER’S MANUAL (INSTALLATION) Section 4, Page 14
 JULY 2007 v2.0
OWNER’S MANUAL (INSTALLATION) Section 4, Page 15
OPERATING PROCEDURE
WARNING NEVER run your carpet cleaning machine with vehicle engine running!!!

Start-Up Initial Procedure

STEP 1: FLUID LEVELS

• Check engine coolant level.

• Check engine oil level.
• Check pump oil level through sight indicator.
• Check blower oil level through rear sight indicator.
• Check for evidence of grease oozing out of both relief fittings on blower.
• Check for enough fuel to complete the job.

STEP 2: CHEMICAL MIX

Mix chemical and fill chemical jug according to manufacturers recommendation. We recom-
mend liquid chemical although a good quality powder is OK if properly mixed.

STEP 3: CLOSE THE FOLLOWING VALVES (see Fig. 5-1)

• PVC Drain valve on right hand side of recovery tank.

• Drain valve on front of fresh water tank. (If Equipped) CLOSED: Valve handle is
perpendicular to valve
OPEN: Valve handle is
parallel to valve body.
body.
Figure 5-1: Ball Valve
• When operating Commander HO with optional water tank,
the following steps must be taken:
1. When using the water tank, have 1” valve on the right side of the water tank open.
2. Have the handle of the valve directly below and in front the CAT PUMP® pointing
down towards the water tank.
• If not using the optional water tank and you are running the machine with incoming water
hooked up to the face panel, the following steps must be taken:
1. Close 1” valve on right side of optional water tank.
2. Close valve located directly below and in front of CAT PUMP®.

STEP 4: OPEN THE FOLLOWING VALVES

• Rotate the face panel chemical adjust black knob fully counter clockwise (See Fig. 5-2).

• Turn Unloader (pressure adjust) knob fully counter clockwise. Turn clockwise slowly until resis-
tance is felt, (contact is made with spring) then turn clockwise another 1 1/2 turns max. This valve is
located on the face panel.

• Open the pressure pump output marked “AUX OUTPUT” valve located on machine face panel.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 1
• Turn chemical priming valve to “PRIME” (assure system has vac load). Air
bubbles will flow from the clear chemical draw line and chemical flow meter PRESSURE GAUGE
toward the pulse pump. When the flow meter shows no air bubbles turn the
flow meter indicator valve to the “ON” position. (Adjust the chemical
knob while spraying solution from the cleaning tool as necessary during UNLOADER
operation).
NOTE: CHEM ADJUST

(HOW THE CHEMICAL SYSTEM WORKS...)

CHEM SWITCH
The chemical pump draws the chemical from the inlet filter which is in
the chemical container. It flows through the flow meter indicating the
GPH of chemical being used. The chemical then flows through the
FLOW METER
chemical pump to the chemical selector valve. The chemical valve can
be used to prime the pump (let air from the system) inject chemical into
WAND 1
the system or turn the chemical flow off. In the “ON” position, chemi-
cal flows through the metering valve, and is injected into the heated wa- WAND 2
ter path just prior to its leaving the machine. The desired chemical in-
jection ratio may be obtained by an adjustment of the chemical flow Figure 5-2: Pressure Panel
meter during the spraying of water through the cleaning tool.

STEP 5: SET FACE PANEL SWITCHES WATER INPUT OVERFLOW

AUX OUTPUT OIL DRAIN

• Water Recovery switch to “NORMAL” position.

• Pump out system switch (if equipped) to its “CENTER” position.

STEP 6: HOSES AND QUICK CONNECTORS

Figure 5-2a: Lower Face Panel

• Connect solution hose to “WAND 1” or “WAND 2” and cleaning wand. Make sure solu-
tion hose shut-off valve is OPEN.

• Connect garden hose to input water supply and to external water source. Turn on water.
Water will automatically shut off when water box is full or when water tank is full. (If so
equipped)

• Connect auxiliary hose to “AUX OUTPUT” valve on the lower face panel.

• Connect vacuum hose from recovery tank to cleaning wand . This may be through the op-
tional filter box assembly and optional vacuum hose reel.

Assure that the garden hose connector is tight (and that the o-ring is in place) at the water input
quick connect. This fitting can allow air into the pumping system, which WILL cause pump
problems and potential failure.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 2
 STEP 7: START ENGINE AND PRIME CHEMICAL PUMP

NOTE: READ THIS ENTIRE STEP BEFORE PROCEDING.

1. Make sure pressure pump output auxiliary valve on face panel is open and place open
ended hose attached to valve in a bucket. This will allow water to free flow from ma-
chine when the engine starts.

2. Pull engine throttle control, located on right side of face panel, out slightly to increase
engine speed as it starts.

3. Pull out choke control located on right side of face panel.

4. Turn engine key switch to “RUN” position. The face panel gauge lights will illuminate.
The fuel pump (typically) located beneath the vehicle will click as the fuel pressure
builds up.
5. Start engine by rotating key switch to start position and releasing back to run position as
engine starts. Run engine for approximately 10 seconds and push choke in slowly until
choke is fully in the off position. The water should start flowing from the hose which is
attached to the auxiliary valve at this time. If water does not flow immediately, shut-off
engine and review previous steps. If second attempt fails, consult service center.
Important: DO NOT run engine if water will not flow out auxiliary valve.
This will cause EXTENSIVE DAMAGE to pump.
6. With engine running, increase engine throttle to full engine speed. The machine cannot
be run in the idle position for cleaning upholstery, carpet or floor extraction. This may
VOID the warranty. Run the machine at half to full throttle. Water flow from auxiliary
water hose will increase. When water flow maximizes from hose, slowly close auxiliary
valve until pressure rises slightly. The chemical pulse pump should start to prime itself at
this point. Air bubbles will flow from clear chemical draw line and chemical flow meter
toward pulse pump. When the flow meter indicator reads full scale and there are no
bubbles in the chemical draw line turn chemical prime valve to “ON” position and ro-
tate chemical adjust knob clockwise until flow meter reads approximately 2 GPH. Close
pressure pump output auxiliary valve located on face panel.

Figure 5-3: Vacuum Gauge Figure 5-4: Water Pressure Gauge Figure 5-5: Temperature Gauge

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 3
STEP 8: MACHINE ADJUSTMENTS AND TESTS

1. With throttle set for maximum machine operating speed, seal the end of the vacuum hose
and assure that the vacuum gauge reads between 13-14” Hg. and that air flow is adequate.
The vacuum reading must not exceed 14” under any condition, blower and/or engine dam-
age will result. (See Fig. 5-3)

2. Open shut off valve at end of solution hose and depress cleaning wand trigger. With water
flowing from tool, adjust the machine’s water pressure for 400-500 PSI (See Fig. 5-4). In
order to achieve consistent adjustable temperatures, an operating pressure of 200-500 PSI
must be maintained. The water pressure can be adjusted by rotating the pump pressure
adjust knob clockwise to increase and counter clockwise to decrease pressure. The pump
pressure adjustment knob is located directly beneath the pressure gauge on the face panel .
The gauge reading should drop nearly to zero when no water is being pumped.

3. With water flowing from the cleaning wand, adjust the chemical adjust knob fully counter
clockwise and assure that the chemical flow reading on the chemical flow meter reaches at
least 4 GPH. Adjust the chemical adjust knob fully clockwise and assure that the chemical
flow stops. Adjust flow rate as desired which is normally between 1-3 GPH.

4. With vacuum sealed and the cleaning wand not spraying, allow system to heat up until the
green water bypass light on the face panel illuminates. Depressing wand trigger for a cou-
ple seconds at a time during this procedure will allow the temperature to rise more
quickly. After a few seconds, the temperature will rise and then will decrease until the
green light extinguishes. This light will go on and off indicating proper heat-divert system
operation. Depending on incoming water temperature and other factors, the system may
not stop diverting until you use some water from the wand. The system will not provide a
high volume of hot water until all components are fully heated. Holding the valve open
and watching the temperature gauge at this time is meaningless (Refer to Fig. 5-5). Under
long periods of no flow conditions, the diverter light may come on momentarily. This in-
dicates that the machine has gone into divert mode to control the water temperature. This
is normal and is a designed feature.

At this point, pre-operating tests have been performed and the machine is ready for op-
eration. Shut down the machine in accordance with instructions.

MACHINE SHUTDOWN INSTRUCTIONS

• Flush clear water through the chemical system for 10-20 seconds.

• Turn OFF chemical flow.

• Lower the throttle to MID-RANGE and allow to run.

• Cool the machine by lowering the adjustable thermostat to “LOW” while spraying the
cleaning tool into the vacuum hose for 3-5 minutes. The chemical will be flushed from the
machine and cleaning tool at this time.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 4
• Depress switch on face panel to water recovery.

• Remove the vacuum hose.

• Turn key to off position and depress face panel switch back to normal position. Machine is
now ready for the next cleaning operation. Disconnect set up and proceed to approved
waste dump site if necessary.

• At this time, the blower should be lubricated with a water displacement lubricant.

Important:
(In accordance with the EPA, state and local laws, DO NOT dispose of waste water into gut-
ters, storm drains, streams, reservoirs, etc. Use only approve sewage treatment systems).

Winter Operation and Winterization

Extreme care must be taken to assure that the machine and its associated tools are protected
from freeze damage. Freeze damage is expensive to repair and is NOT covered under the war-
ranty. The van must be either garaged in a heated area or the equipment must be winterized if
below freezing temperatures (32°F) or (0°C) are forecasted or expected. Winterization is the
process of draining the water from the equipment and replacing it with antifreeze during periods
of non-use or storage.

WHITE MAGIC, INC. WILL NEITHER PROVIDE WARRANTY COVERAGE NOR BE

HELD RESPONSIBLE FOR DAMAGE CAUSED BY FREEZING
FREEZING..

NOTE:
• Undiluted windshield washing antifreeze is sufficient for temperatures down to 0°F (-6°C).
• Ethylene glycol (engine antifreeze) or RV antifreeze must be used for lower temperatures.
• Antifreeze must be flushed from the machine before any cleaning operation.

The Winterization Process

• Follow normal shutdown procedure (as previously mentioned).

• Drain the recovery tank.

• Inject a water displacement lubricant into the blower lubrication cup.

• Remove the chemical line from the chemical jug and place it into a container with 2 gallons
(8 liters) of antifreeze. Add additional antifreeze if necessary while winterizing system.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 5
• Check that the chemical pulse pump prime valve is in the “ON” position.

• Start machine.

• Place a second empty 2 gallon container under the auxiliary output valve on the face
panel and open that valve. Watch for antifreeze to flow from its container through the
clear hose, to the flow meter and on to the pulse pump.

• Increase the chemical flow to 2 GPH using the Chemical Adjust Knob (refer to Fig. 5-2).

• Allow antifreeze to flow through the clean draw line to the flow meter, then to the pulse
pump. Once the antifreeze is observed entering pulse pump, allow the antifreeze to flow
for approximately 10 seconds then fully close the chemical adjust knob on the face panel.
Turn the chemical prime valve to “PRIME” for 2-3 seconds and then to off.

• Shut off the machine.

• Drain fresh water tank (if equipped). Do not close the auxiliary output valve or remove
the second container.

• Disconnect input water hose from the face panel

• Run the machine in water tank mode until water is cleared in the hoses to the tank. Shut
the 1” valve on the water tank and switch the valve on the input of the pump to waterbox
operation. Pour 1-2 gallons of anti-freeze into the waterbox. If no water tank, simply
run water box empty, fill with antifreeze.

The water box capacity is approximately 2–1/2 gallons.

CAUTION Winterizing 150’ or more of solution hose may require
you to add additional antifreeze to the water box during
the Winterization process.

• Connect cleaning tool to solution hose.

• Restart engine.
Figure 5-6: Temp. Control Valve
• Pull trigger on cleaning tool until antifreeze is observed coming
from tool. (Winterize all cleaning tools at this time).

• Once antifreeze is observed coming from tool, release trigger.

• “OPEN” auxiliary output valve until antifreeze is observed flowing.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 6
 • Close valve and flip “OPEN” the temperature control valve on the unloader behind the
face panel momentarily. Flip valve handle back to “CLOSED” position and turn off ma-
chine.

• Process is complete.

NOTE:
• Always winterize the machine through “WAND 1” and/or “WAND 2”.
• Antifreeze through the auxiliary output does NOT winterize the heat exchangers.
• (Be sure that the temperature control valve is “CLOSED”).

REMEMBER:
Before resuming cleaning operation, connect a clean water supply and start machine.
CLEAR antifreeze from the lines and tools.

NOTE
NOTE::
***If your machine is equipped with an external pumpout system, connect hose to
pumpout output valve and turn on pump until all water has been pumped out. This
takes only seconds. Turn pumpout pump off once water has stopped flowing from the
output hose.

Water Extraction Operation:

DANGER
NEVER recover flammable liquid or chemicals during any phase of water recovery.

NOTE
NOTE:: It is highly recommended to have the optional recovery filter box for this operation.

• Start engine with throttle position at “IDLE”.

• Allow engine to warm up for 2-3 minutes.

• Connect vacuum hose to the recovery tank or filter box.

• Connect extraction tool.

• Set throttle to “HIGH”. Figure 5-7: Filter Box

• Be sure water box is full of water. Flip switch to “WATER RECOVERY.”

• Turn pumpout switch to “ON”. (if applicable)

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 7
• Turn chemical prime valve to “OFF”. (see Fig. 5-2).

• Begin extraction using the vacuum hose.

Upholstery Cleaning Operation:

White Magic recommends the use of Upholstery Tools designed for truck-mount pressure hav-
ing an automatic high pressure solution bleed-off.

• Start engine with throttle in “IDLE”

• Allow the machine to warm up for 2-3 minutes.

• Connect hoses.

• Connect the upholstery tool.

• Adjust the throttle to “HIGH”.

• Turn cleaning switch to “NORMAL”.

• Set temperature to desired level.

• Turn pumpout switch to “ON”. (if applicable)

• Set cleaning pressure to desired level.

• Prime/Set chemical if needed.

• Start cleaning.

NOTE:
Remember:
• Clean only items recommended for wet cleaning.
• Take all necessary precautions recommended by upholstery manufacturer to ensure sat-
isfactory cleaning results.
• Use a chemical recommended especially for upholstery cleaning.
• Clean only items recommended for wet cleaning.

Take all necessary precautions recommended by upholstery manufacturer to ensure satisfactory

cleaning results.

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OWNER’S MANUAL (OPERATIONS) Section 5, Page 8
CLEANING AND CHEMICALS:
Your mobile carpet cleaning unit has been engineered using the latest and most up to date tech-
nology available today. Even with this in mind, it remains only a tool of the carpet cleaning
trade and can produce only as good a job as the person operating it.

There are no shortcuts to good carpet or upholstery cleaning. It requires time, knowledge and
proper use of cleaning products.

White Magic recommends the use of spotting agents and taffic lane cleaners, as required, prior
to the actual cleaning of carpet or upholstery.

The use of some chemicals through your machine can seriously damage the internal plumbing,
high pressure pump and heater. These harmful chemicals include concentrated acid solvents,
some paint, oil, and grease removers with a high concentration of solvents.

White Magic recommends only the use of chemicals containing rust and corrosion inhibitors
and water softening agents to prevent chemical buildup. This may lead to component failure
and warranty invalidation.

The increase demand for acid rinsing results in the need for special care while using these acid
based chemicals in your equipment. The negative side of these products is the corrosive effects
they have on the metals, pumps, heat exchangers and fittings in the equipment.

When and if you have the need to use such a product, you must neutralize your equipment im-
mediately after its use.

CHEMICAL MIXING:
Mix chemical and fill the chemical jug by referring to the table below. Insert chemical draw
tube into the chemical jug and screw on the cap.

pH CHART
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACID NEUTRAL ALKALINE

To neutralize an acid:

• Use an alkaline to bring the pH up to neutral.

• Use an acid to bring the pH down to neutral.
• By using pH paper and this chart above this can be accomplished.

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OWNER’S MANUAL (CLEANING & CHEMICALS) Section 6, Page 1
When cleaning a carpet always move the cleaning tool in smooth forward and backward
strokes. Apply slight pressure to the forward stroke while the solution is applied to the carpet.
If you make (2) two wet strokes and finish with (1) one dry stroke you will find that the carpets
will clean with ease and the heat of the machine will be maximized.

OVER WETTING:
There are several reasons for over wetting a carpet.
• Too few vacuum strokes or improper vacuum stroke technique.
• Obstructed, cut or kinked hoses.
• Vacuum tank drain valve left partially open.
• Vacuum tank drain valve bad.
• Clogged vacuum blower filter bag or filter screen.
• Vacuum tank clean out lid not sealing properly.
• Cleaning carpet with to much foam (excess soap) left from a previous cleaning.

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OWNER’S MANUAL (CLEANING & CHEMICALS) Section 6, Page 2
 MACHINE MAINTENANCE
To avoid costly repairs and down time, it is important to develop and practice good mainte-
nance procedures from the beginning. These procedures fall into daily, weekly, monthly and
quarterly service and are outlined below. All recommended maintenance should be per-
formed by competent service personnel.

Always record the date and machine hours when service is done.

Important: OVERALL MACHINE MAINTENANCE:

Maintaining the original appearance of your machine is important for two reasons:

1. It represents a big dollar investment for your cleaning business and its appearance should
reflect that fact. A dirty machine is not professional.
2. Maintenance, troubleshooting, and repair is much easier to accomplish on a clean, well
maintained machine. Regular cleaning of the machine offers you an opportunity to visu-
ally inspect all facets of the machine and spot potential problems before they occur.

OPERATIONAL MAINTENANCE:
NOTE:
• A new machine must be serviced after the first 50 hours.
• All the following maintenance points should be checked/performed at this service.

DAILY:

• Check engine coolant level.

• Check engine oil level.
• Check high pressure pump oil. (Add as necessary)
• Check blower oil level.
• Visually inspect machine for loose wires, oil leaks, water leaks, etc.
• Check that system pressure drops to zero when wand trigger is released.
(If not see pump system troubleshooting)
• Lubricate blower with a water displacement lubricant through blower inlet.
• Wipe machine down with a damp cloth.
• Empty recovery tank out thoroughly.
• Inspect and clean vacuum slot on cleaning wand.
• Clean wand to maintain original appearance.
• Wipe down Vacuum and solution hose.
• Clean in filter box if so equipped.
• Remove the check ball screen, clean and/or replace if necessary.
• Check the spray pattern of the wand.
• Check that vacuum is 14” max (fully sealed) and engine rpm are 3200 - 3300 max.
• When machine is running under vacuum load and machine is cool, check that the exhaust
diverters function back and forth when the water recovery switch is activated (pump
should also turn ON & OFF).

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 1
WEEKLY: (25 hours)

• Do all daily checks.

• Inspect vacuum tank s/s filter and in-line filter bag for tears, holes, etc. (Clean, repair or
replace as needed).
• Check all fasteners, clamps, etc. for tightness. Tighten as needed.
• Check pump and blower belts for tension, wear, etc. and pulleys for alignment.
• Check high pressure water lines for wear.
• Inspect vacuum relief valve. Clean and lubricate. Be sure spring actuates smoothly by
hand.
• Check all wiring
• Flush water chemical system with 50/50 white vinegar solution.

MONTHLY: (100 hours)

• Perform all daily & weekly checks

• (See Kohler Engine recommendations)
• Change oil filter (Every other oil change).
• Check engine air cleaner filter. (Clean or replace)
• Check pressure adjustment valve. (Grease as necessary/replace)
• Check water level in battery. (Clean battery connections as needed)
• Change engine oil.
•
QUARTERLY: (250 hours)

• Check fuel lines.

• Clean and gap spark plugs.
• Check drive belts for cracks or wear. (Replace as necessary)
• Change blower oil.
• Change pump oil.
• Grease blower bearing fittings.

WARNING
The engine oil should be changed after the first day of operation. When
changing or checking the engine oil NEVER exceed the full line on the dipstick. When
checking the oil on a new machine it is very difficult to see the amount of oil on the dipstick
because it is colorless. You must take the dipstick out and wipe it off, then re-insert it to get
an accurate level of oil. This will still be difficult to see, but if it is held at an angle to the
light you should be able to accurately read the oil level line.

The maintenance interval that the machine should be de-scaled is based upon the condition
of the water being used in the machine. If the water is 3.5 grams or more in hardness the
machine should be de-scaled every week.

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 2
 THE FOLLOWING IS A GENERAL MAINTENANCE TABLE THAT SHOULD BE FOLLOWED.
25 HRS 100 HRS 200 HRS 500 HRS
OPERATION DAILY OR OR OR OR
WEEKLY MONTHLY 3 MONTHS 6 MONTHS
Check engine oil X
Change engine oil and Filter X
Check engine spark plugs X
Check Coolant level X
Check blower oil X
Lubricate blower X
Check belt tension X
Change blower oil X
Check pump oil X
Change pump oil X
Clean recovery filter X
Check diverter operation X
Inspect/clean waste tank float X
Battery (clean and add water) X
Grease hose reels X
Lube electric hose reel chains X
Waste drain valve cleaning X
De-scale machine
Check vacuum reading X
Recharge Pulsation Dampener X
Check filter box gaskets(proper seal) X
Check water tank filter X
Check waterbox filter X
Check anode & tank for deposits X
Check pump pressure goes to Ø X

ENGINE: (See Kohler Engine owner’s manual - Section 12)

The Commander is equipped with a 24 HP Aegis liquid cooled 2-cylinder engine.

The Commander HO is equipped with a 28 HP Aegis liquid cooled 2-cylinder en-
gine. The maximum speed is factory preset at 3200 RPM with a vacuum load of 13-
14’’ Hg. Do not to increase this setting. Doing so will VOID the warranty. The en-
gine is set to properly operate both the blower and the pump. Excessive engine speed
may result in premature failure to the engine, blower, pump or any rotating part.
(See Section 12)

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 3
 Frequency Maintenance Required
Daily or Before • Check oil level, add as necessary.
Starting Engine • Check coolant level.
Every 200 Hrs • Check spark plug condition and gap, change if necessary.
• Change oil and oil filter. (Never exceed the FULL mark on dipstick)
Every 500 Hrs • Change spark plugs.
Every 1000 Hrs / 2 Yr • Change coolant.

Oil and Spark Plug:

The spark plug gap should be adjusted to (0.030in for the 27 Hp.)

Spark plug tightening torque should be 24.4 – 29.8N.m(18-22 ft. lb.)

BLOWER: (See ROOTS™ Blower owner’s manual - Section 12)

The Commander HO is equipped with a ROOTS™ 47 positive displacement

Blower. These rotary lobe blowers employ two double-lobe impellers mounted
on parallel shafts and rotating in opposite directions.
(See Section 12)

• Oil level should be between the lines on oil sight gauge when machine is on a level sur-
face.
• Use premium grade 50 weight, non-detergent oil with rust, oxidation and foam inhibi-
tors. (ex. MOBILE DTE BB, TEXACO R&O 220, or AMOCO 220)
• Use a NLGI #2 premium grade, petroleum base grease with high temperature (300 de-
gree service temperature), moisture resistance and good mechanical stability such as
Shell Darina Grease NLGI grade 2 or equal. DO NOT use lithium base grease.
• Consult the Blower Owner’s Manual for proper grease application.
• A blower oiling cup has been provided to oil the impellers during periods of non-use.
• After a long shutdown, consult the Blower Owner’s Manual for proper grease replace-
ment.
• Please consult the Blower Owner’s Manual for all other maintenance and specifications.

Figure 7-1 : Blower Configuration

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 4
 Frequency Maintenance Required
Daily Check oil, Lubricate with water displacement lubricant.
Weekly Lubricate Blower.
Every 3 Months Check belt tension.
Yearly Change oil.
PUMP: (See CAT PUMP® owner’s manual - Section 12)

The Commander HO is equipped with a CAT PUMP® Model 5CP Pump. This
pump is a triple plunger pump. The oil level should be checked every day and
belt tension should be checked every 3 months.

• Use Cat Pump Oil (or) ISO 68 multi-viscosity petroleum based non-detergent (See Section 12)
hydraulic oil.
• Oil capacity is approximately 19 oz. for the Commander HO series.
• Oil level should be half way between the dot and top of oil gauge window when vehicle
is parked on a level surface.
• Note that the Oil level is increased slightly higher in sight level due to direction of rota-
tion.
• Please consult the CAT PUMP® Owner’s Manual for all other maintenance and specifi-
cations.

FILTERS:

Filters in the recovery system are as important as the units engine, blower and heating sys-
tem. They are there for a reason and that is to keep particles from going into the vacuum
blower and to keep the recovery tank clean. Change the filter if it is damaged or has a tear in
it. The housing unit should be thoroughly cleaned of all foreign material that forms.

• Check all Filters at the end of every day.

• Open the recovery filter housing by unscrewing the six (6) knobs
and lifting the housing with the hose still attached.
• Unscrew the inner filter element counterclockwise until it can be
removed. The filter element is made of stainless steel and plastic.
• Rinse the filter element with warm water. Apply high pressure
water and or use a fine steel brush if necessary.
• Let filter dry or blow off with air before replacing.

PLUMBING:

Visually inspect the plumbing monthly. Check the piping, plastic

Figure 7-2 : Recovery Filter Assy.
strainer, fittings for leaks, hard water deposits, bends for cracks etc.
Immediately change any defective or damage parts.

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 5
 Garden hose washer w/ Filter Screen:
Visually inspect the plumbing monthly. Check the piping, plastic strainer, fittings for leaks,
hard water deposits, bends, cracks, etc. Immediately change any defective or damaged parts.

Inlet Line Strainer:

Clean the Line Strainer monthly or as needed. The strainer is located at inside the waterbox.
• Shut machine off and allow to cool.
• Open wand valve for several seconds to relieve pressure.
• Remove cover on the waterbox and inspect the filter. (Clean or replace as necessary)
• Check anode when cover of water tank is off and also inspect tank for mineral deposits
accumulating in bottom.

WASTE RECOVERY TANK:

The waste tank has an automatic float switch located inside the tank and below the recovery
filter. This switch shuts the machine off when the
recovery tank is full. The push button Engine Kill
Override switch on the panel overrides this auto-
matic float switch. Inspect and clean the float every
month.

Important:
The switch works when dirty water fills up the re-
covery tank and moves the switch upward. This
shuts the machine down so overflow does not occur.
NOTE: Figure 7-3: Float Switch Location

(Foam will not activate the switch. When cleaning

carpets that have an excess of soap in them a de-
foamer is needed).

• Drain the waste tank.

• Remove the filter housing.
• Reach inside the tank and manually check that
the float moves up and down freely. There is a
manual lever on the side of the switch.
• To remove switch, unscrew bracket and remove
both bracket and attached switch from inside of
tank. (Caution: be sure you mark the orientation
of the bracket)
• Once outside, unscrew the switch from the
bracket and clean. After cleaned, reverse this
procedure to install the switch.
• Turn the machine on and manually raise the
switch up and verify that the machine shuts off. Figure 7-4 : Recovery tank Connections

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 6
NOTE:
Switch may waterlog. Manual activation does not mean that switch floats.

BATTERY:

The battery (a heavy duty 42-60 amp hour garden tractor battery that has been slow
charged) is located to the left of the machine in front of the recovery tank.

• Check and add water monthly if needed.

• Check the battery cables terminals, clean and put a little grease on them if needed.
NOTE:
The machine will keep a fully charged battery up, but may not charge a completely dead bat-
tery. If this happens you will have to remove the battery from the machine put in onto a bat-
tery charger or replace the battery.

Hose Reels:

Electric Hose Reels: (See Fig. 7-5)

• Lubricate chain every 3 months.

• Adjust chain tension by loosening the four motor
mounting bolts located on the motor mounting
bracket. Slide motor to slacken or tighten chain.
• Fuse is located in the electrical box.

Oil the bearing that supports the axle on the opposite

side of the assembly from the motor every 3 months.
Figure 7-5 : Electric Hose Reel
Manual Hose Reels: (See Fig. 7-6)

• Grease axle swivel every 3 months.

• The drag brake assembly is designed to prevent the
wheel from free spinning. Tighten the drag brake
bolts occasionally as needed.

Machine Body:
The machine body is made of aluminum. The exterior
is painted to prevent oxidation. The front tank or tank
below the machine is the fresh water tank. The rear
tank is the recovery/waste tank. Figure 7-6 : Manual Hose Reel

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 7
• Drain the recovery/waste tank daily.
• Periodically remove the (-) negative battery cable from the battery and clean the exterior
of the machine. Replace the cable when finished.
• Inspect the whole body occasionally for any leaks, deterioration, loose hardware, etc.

Holes may leak water if bolts are loosened.

• When replacing a bolt to the water tank Teflon tape to the bolts.
• DO NOT use silicone sealants on water tanks or water boxes.
• DO NOT over tighten these bolts. (may result in stripping the aluminum threads)

WASTE DRAIN VALVE: Ball Assembly

• Clean and check drain valve every 3 months.

• Unscrew the collars at each side of valve body.
• Remove valve assembly.
• Clean the inside of the valve thoroughly with soap and water.
Figure 7-7 : Waste Drain Valve
(The ball does not have to be removed)
• Reassemble the valve and reattach to machine.

HEAT EXCHANGERS:

There is no specific maintenance required for the heat exchangers except the proper winter-
ization and operation of the unit. If the heat exchanger body leaks the shell must be welded.
If the coils are leaking or clogged the heat exchanger must be replaced.

PULSE PUMP: (chemical pump)

The stainless steel pulse pump, requires no normal maintenance.

Never run the chemical system dry or unprimed.

CAUTION Running it in this manner WILL damage the internal
components of the pulse pump system.

• A torn or damaged diaphragm is one cause of pump failure.

• Check valves on the input and output side of the pulse pump need to Figure 7-8 : Pulse Pump
be cleaned periodically or when ever the pulse pump is serviced. Be sure when reinstall-
ing check valves to orientate the flow in the proper direction.
• Rinsing the pulse pump with water and vinegar every other week will help the pulse
pump to be trouble free.

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 8
CHEMICAL SYSTEM:

The chemical lines may need to be flushed with vinegar periodically to prevent abnormal
chemical build-up. This flushing may be done by removing the clear plastic hose from the
chemical jug and inserting it into a container of vinegar and water 50/50 mix. This should be
done with the chemical meter set at its highest setting. Simply spray water from the wand,
upholstery tool or such until you have exhausted at least one quart of vinegar and water.
Then repeat the process with one quart of clear water to void all the lines of vinegar.

Liquids are recommended, but powders may be Ok when

properly mixed. Unmixed powders may tend to build up
and clog the system. Always use good quality chemicals
when operating White Magic equipment.

HEAT DIVERTER:

The heat diverter needs no scheduled maintenance. If the

heat diverter should stick open, check/adjust the vacuum
actuator bracket. Check that actuator has sufficient vac-
uum when water recovery switch is activated with the ma-
chine cold. A stuck heat diverter will cause high, low or
Figure 7-9 : Heat Diverter Assy. - Exploded View
erratic water temperature and must be repaired immedi-
ately.

WANDS:

The wand and all of the cleaning tools should be periodi-

cally cleaned and checked. Taking dirty tools into the job
is not the proper thing to do.

• Check and clean the jets.

• Check the inline filter screen.
• Clean the wand with a good stainless steel cleaner.
• Check valve for dripping (rebuild if necessary). Drip-
ping may be valve or check ball screen.
• Check for good spray pattern, properly pointed behind Figure 7-10 : Wand Assembly
back plate of wand.

ACCESSORIES:

When taking care of your carpet cleaning equipment you should never forget to take care of
accessories.

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 9
 HOSES:

• Clean and check vacuum hose for air leaks.

• Clean and check disconnects for water leaks (solution hose).
• Hoses should be checked regularly for leakage, tears, fatigue, cracks, etc.

NOTE:
SPECIAL NOTE: You are in the cleaning business. When you go to a customers home
or business to do cleaning for them you need to look the part. You and your truck,
equipment and tools are a reflection of your business and how much you care. By
spending a few minutes every day you will be able to keep your cleaning plant in tip top
shape, the equipment will last longer and you will automatically increase your business.

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OWNER’S MANUAL (MAINTENANCE) Section 7, Page 10
TROUBLESHOOTING GUIDE
This guide provides specific instructions to aid in troubleshooting most
of the possible problems during the use of this cleaning system. This
guide has been provided to help reduce your down time. If the problem
continues contact your local White Magic Distributor who you purchased
your cleaning equipment from.

KOHLER®
ENGINE TROUBLESHOOTING
TROUBLESHOOTING:: 800-456-5691

PROBLEM
PROBLEM:

The engine will not turn over:

There is a problem with the fuse.

⇒ Check the fuse located on the right side of the engine.

The battery cable is loose or the terminals are corroded.

⇒ Clean and check the battery terminals connections.

The battery is dead.

⇒ Recharge or replace the battery.
Figure 8-1 : Starter Solenoid

There is a problem with the starter solenoid.

⇒ With the ignition switch in the “Start’’ position, check for 12 volts.
• Small wire from the ignition switch to the starter solenoid (blue).
• The large terminal with the cable from the battery.
• The large terminal with the Cable going to the starter.
⇒ The voltage is present on the first two checkpoints, but not on the large ter
minal going to the starter (Replace the solenoid).

The CAT PUMP® (or) ROOTS™ blower is tight or seized.

⇒ Check that the pump and blower are not seized or frozen (with the engine ig-
nition turned off).
⇒ The ROOTS™ blower should rotate freely by hand when the belts are re-
moved. (Refer to Blower Troubleshooting)

The starter motor is defective.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 1
 CAUTION
⇒ Remove ignition key.
⇒ Remove the belts from the engine.
⇒ Check to see if the engine will turn over manually. Be sure spark plug wires
are removed.
⇒ Check that the engine is grounded to the minus side of the battery.
⇒ With the ignition key in the Start position, check the starter motor for +12
volts.
⇒ If all of the above conditions are met and the starter will not turn, (Replace).

The ground cable underneath the Motor has fallen or broken off.
⇒ Reattach the cable.

PROBLEM
PROBLEM::

The starter turns the engine over, but the engine will not start:

The machine is shut down due to engine kill.

⇒ Try to run with engine kill override switch pushed in.

Engine turns over but will not start.

⇒ Engine oil is low. (Add if necessary) (See Kohler En- Figure 8-2 : Engine Kill Override
gine Manual)
⇒ Engine oil switch is defective, or oil pump is failed or weak.
⇒ Engine is overheated - allow to cool.

Recovery tank is full.

⇒ Empty the recovery tank.

Recovery tank float is causing the engine to shut down.

⇒ Disconnect the float. If the unit Starts, replace the defective float.

NOTE: A switch may function when lifted manually, but may not float.
Machine has overheated.
⇒ Allow to cool down by running engine at half throttle with override button in
and water flowing cleaning tool.

CAUTION
“Caution Hot Water Causes Severe Burns’’
⇒ With engine at half throttle press trigger of cleaning tool to relieve system
pressure and cool the machine down.
⇒ The engine will not run with out the override button pushed in until the unit
has cooled down below the kill thermostat setting.

Oil pressure switch is malfunctioning or engine has low oil pressure.

⇒ Check the engine oil level. If it is at the proper level, then disconnect the oil
pressure switch.
JULY 2007 v2.0
OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 2
 ⇒ If the engine starts, check oil pressure to KOHLER® specs, if OK, then re-
place the switch.

CAUTION
Do not run engine with the switch bypassed. The engine may have low or no oil pressure
even when properly filled with oil.

Engine turns over but will not start.

⇒ *Check for spark at the spark Plugs.
⇒ If there is no spark, push in kill override and recheck.

WARNING
Explosive Fuel can cause fires and severe burns.

Fuel pump is defective.

⇒ Remove the fuel line from the engine and place it in a container to see if the
fuel is being pumped when the ignition is on.
⇒ Replace the fuel pump if it is defective.

Fuel pump has no power.

⇒ Check for 12 volts at the fuel pump.

Poor battery ground to the fuel pump.

⇒ Repair the loose ground connection.

Fuel pump is sucking air between the fuel source and the inlet side of the fuel pump.
⇒ Examine the gas inlet side of the fuel pump.
⇒ Tighten any loose fittings or clamps.
⇒ Replace any ruptured hoses.

Fuel filter is clogged.

⇒ Inspect the filter. Replace it if necessary.

PROBLEM
PROBLEM::

The engine runs poorly or dies after running for a while:

Air or gas filter is clogged

⇒ Inspect both filters.
⇒ Replace the clogged one.

Poor battery ground to the fuel pump.

⇒ Inspect the electrical grounds.
⇒ Repair any loose ground connections.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 3
The engine and machine can be completely separated by changing wiring as shown. DO NOT
run machine for more than 2-3 minutes.

(SEE ENGINE BYPASS PROCEDURE PG.20)

Fuel pump is sucking air between the gas tank and the fuel pump.
⇒ Examine the pump’s gas inlet side.
⇒ Tighten any loose fittings or clamps.
⇒ Replace hoses.

Fuel pump is defective.

⇒ Remove the fuel line from the engine and place it in a container to see if fuel is
being pumped when the ignition is turned on.
⇒ Replace the fuel pump if it is Defective.

Excessive engine load.

⇒ Clean and adjust the recovery tank relief value.
⇒ Adjust for 14 inches of lift under full load.

Poor ventilation causing engine to overheat. (Engine overheats)

⇒ Remove any air restriction from the engine.
⇒ Add a roof vent or external fan, if necessary.
⇒ Never run your equipment with the van doors closed.

Carbon build up in the combustion chamber. (Engine overheats)

⇒ Refer to a local KOHLER® engine dealer.

Too much oil in the crankcase. (Engine overheats)

⇒ Check the oil level and correct.

The engine is malfunctioning.

⇒ Refer to the engine operation maintenance manual or see local KOHLER® dealer.

A PCV valve is defective.

⇒ Remove and check the air cleaner for oil saturation.
⇒ If it is saturated, replace the PCV valve and air filter.

VACUUM SYSTEM TROUBLESHOOTING

The vacuum generator in this machine is commonly referred to as a positive displacement lobe
type blower. The performance and life of this system is greatly dependent on the care and
proper maintenance it receives.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 4
CAUTION
Because of the close clearance between the lobes and the housing of the vac-
uum blower, solid objects entering the inlet will damage the internal lobes,
gears, bearings or drive system.

To prevent this, a stainless steel filter screen has been placed at the vacuum
inlet inside the recovery tank. This filter should be removed for cleaning Figure 8-2 : Blower Lube Port
weekly.

Do not run machine unless ROOTS™ blower inlet and SS inlet screen are intact and in place.

Foam passing through the blower could lead to serious problems. It is important to keep the
vacuum tank free from foam (use an anti-foaming agent).

To protect the vacuum blower from overloading and damaging itself, there is a vacuum relief
system installed on the vacuum tank near the stainless steel filter. When the vacuum tank
inlet is completely sealed off, a maximum of 14” Hg. will be attained with the engine at a
maximum RPM.

At the end of each day, a water displacement lubricant should be sprayed into the blower lu-
brication port before shutting down the machine. Lubricate the vacuum blower daily to pre-
vent rust deposits and moisture that will decrease the life or seize the vacuum blower.

Read the vacuum blower manual carefully for proper oil change and grease application. The
maintenance log may differ slightly from the manual, but the truck-mounted carpet cleaning
application is very demanding of the vacuum blower and should be maintained as per White
Magic’s suggestions and recommendations.

The vacuum tank is protected from overflowing by a vacuum tank float kill switch.
The switch is not activated by foam, only by liquid.

OPTIONAL FILTER SYSTEM

Figure 8-3 : Filter Box
White Magic has designed an optional filter system that when used will eliminate any
particles from going into the recovery tank. The filter system has its own high grade
filter to trap lint, sand and dirt along with carpet fibers. When emptied at the end of
each job no debris will ever reach the recovery tank.

This option is required for operation with optional pump out system. Figure 8-4 : Filter

The following pages will give troubleshooting tips when loss of vacuum or vacuum
problems may arise.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 5
 ROOTS™
BLOWER TROUBLESHOOTING 281-496-8384

PROBLEM
PROBLEM::

There is no vacuum or there is a loss of vacuum:

Stainless steel filter is clogged.

⇒ Clean or replace the filter.

Belts are loose or glazed and are slipping.

⇒ Replace belts with correct size.

Filter system bag is clogged.

⇒ Clean or replace the filter bag.

Vacuum tank dump valve is open or defective.

⇒ If water drips from the dump valve when the machine is not running, the valve
will cause a vacuum loss when the machine is running.
⇒ Replace if it is defective.

Vacuum hose is plugged.

⇒ Remove the obstruction by reversing the vacuum hose.

Restriction in the cleaning tool.

⇒ Check and remove the obstruction.

Vacuum tank gasket is defective.

⇒ Check and replace gaskets.

Filter box cover and/or gasket is defective.

⇒ Check and replace as necessary

Hose from the blower to the recovery tank is kinked or has collapsed inside.
⇒ Replace or reshape the hose.
(Note: A special reinforced hose is required for replacement.)

Hole in the recovery tank.

⇒ Inspect the tank for leaks using smoke and weld the tank if it is required.

Hole in the vacuum hose.

⇒ Repair or replace the hose.

Vacuum relief is loose.

⇒ The vacuum relief should be set at 14” Hg.
⇒ Check and readjust.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 6
 CHECK: VACUUM GAUGE
• Using an auxiliary vacuum meter to assure gauge is display-
ing a proper reading.
• Tubing to gauge for cracks or leaks.

CHECK: ROOTS™ BLOWER Figure 8-5 : Vacuum Gauge

• Belts for proper tension.
• Slipping belts (This will not allow the blower to turn at the proper speed).
(Note: This is usually indicated by a squealing sound)
• Excessive belt wear. (Replace belts as needed)
• Blower is not getting excessively hot. (This is usually indicated by the scent
and or the appearance of burning paint on the blower).
• Remove the drive belts from the engine and assure that the blower turns
freely by hand and that there is no free play in the input shaft.

Engine speed is too low.

⇒ Check engine speed and adjust.

Back pressure (Excessive).

⇒ Check for restrictions in the blower exhaust system (including heat exchang-
ers) and assembly.
⇒ Clean or replace.

The vacuum blower’s end plates or lobes are worn.

⇒ Replace the worn components.
⇒ This must be accomplished by a qualified technician.

The blower is out of oil or the gears may be bad.

⇒ Permanent damage may result from a lack of lubrication.
⇒ Add oil.
⇒ If the noise continues, replace the gears or blower.
⇒ Must be accomplished by a qualified technician.

The blower lobes are locked up because of rust.

Important:
Procedure:
Most burnt foam and rust can be removed by soaking the lobes with liquid wrench or
diesel fuel directly into the blower, allow to sit for 20 minutes or so then try to free
the blower by hand until it spins freely. It may help to loosen end plate bolts (1) turn
and tapping endplates to free blower. When blower is free start machine and run
excess fluid from blower. You can clean the blower by pouring 2 cups of hot soapy
water directly into the blower. Allow the machine to run an additional 5 minutes af-
ter your finished to dry the blower completely out. Spray a water displacement lubri-
cant into the lubrication port when finished.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 7
 There is debris in the blower
⇒ Remove the debris.
⇒ A stainless filter is provided at the vacuum inlet on the vacuum recovery tank
to prevent this problem.

The blower has broken gears.

⇒ Call Roots™ for authorized service center (See Roots™ owner’s manual -
Section 12)
⇒ Have the blower rebuilt or replaced, unauthorized attempts at equipment re-
pair may void Roots™ warranty.

HIGH PRESSURE PUMP TROUBLESHOOTING

COMMANDER HO 5CP CAT PUMP® PLUNGER PUMP

DAILY:
Check that system pressure drops to zero or near zero when the CAT PUMP®
trigger wand is released. If not or if pressure “spikes” it is an in- 763-780-5440
dication of a leak, air in the system or other problems.

Check the oil level and the condition of the oil. The oil level should be halfway between dot
in center and the top of the sight glass on the back of he pump. (See picture below)

NOTE: White Magic Inc. recommends CAT PUMP® oil or

equivalent is used.

CAUTION

If the oil becomes discolored and contaminated, one of the oil

seals may be damaged. (Refer to the Service Section).

CAUTION
Figure 8-6 : CAT PUMP® Oil Level

Do not leave contaminated oil in the pump housing or leave the housing empty. Remove
contaminated oil as soon as it is discovered and replace it with clean oil.

Change the oil after the first 100 hours of operation, and every 250 operating hours after.
When changing, open the ball valve on the pressure pump then remove the drain plug on the
front of the machine, open the ball valve on the front of the machine to drain the oil into a
catch container.
Important:
Discard any used oil in accordance with used motor oil (HAZARDOUS
WASTE) in your area. Be mindful of the environment. Before draining any
fluid or waste observe all regulations for the disposal of such items.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 8
CAUTION
Do not start machine or turn the crankshaft of the pump with no oil in the reservoir.

CAUTION

Always protect the pump from freezing.

PUMP TROUBLE SHOOTING

A pumping system cannot put out what it cannot take in. This means that you should assure
that the pump input is adequate (restriction free) and that it is not drawing air or pump dam-
age will occur.
If the input line to the pump is blocked it will cause cavitation in the pump resulting in pre-
mature pump failure.

TO TEST THE PUMP:

It may be necessary to disconnect the input and output plumbing and replace it with short
pieces of hose connected directly to the pump. This will determine if the pumping system
failure is internal or external to the pumping system. Operate the CAT PUMP® 5CP pump
at normal speed and have the chemical adjust valve turned “OFF”. The CAT PUMP® output
should be approximately (4) GPM for the Commander HO.

PROBLEM
PROBLEM:

LEAKS
LEAKS:: This is indicated by “spiking” or un-maintained pressure when wand is released.

⇒ Leaky disconnects.
⇒ Leaky swivel.
⇒ Leaky hose reel(s).
⇒ Leaky wand valve or check ball screen.
⇒ Internal Heat Exchanger leak.
⇒ Leaky hoses or fittings on the machine itself.
⇒ Leaky pop-off valve.
⇒ Any place water might drip or trickle.

A faulty Unloader, leaking or pinched pump input hose or fitting will also cause spiking or
pressure.

PROBLEM
PROBLEM:

NO (or) LOW WATER FLOW IN SYSTEM (or low erratic pressure)

pressure)::
⇒ Check the water tank/water box has water.
⇒ Check that the correct size jets are on the wand.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 9
 ⇒ Remove and clean check ball screen filter installed behind the jet, assure that
the check valve spring is functioning properly.
⇒ Check for plugged or defective quick disconnects. Test disconnects on all
solution lines. (Replace a needed)
⇒ Swap solution lines, then swap from WAND1 to WAND2 to troubleshoot
disconnects.

NOTE: A disconnect can be an intermittent problem.

⇒ Check machine for mineral deposits in the system. The machine will need to
be de-scaled with a de-scaling solution.

NOTE: The pressure gauge may still read (0) zero even with restrictions.

⇒ Check all lines and hoes for any pinches or kinks, between the water tank and
pump input.
⇒ Check the filter screen in the water tank/water box.
⇒ Check for sediment build up in the fresh water tank.
⇒ Check fresh water tank over flow vent hose may be plugged or pinched.
⇒ Check that water selection valve at pump and water tank are properly set.
⇒ Check that “WATER RECOVERY” switch is in “NORMAL” position.
(CAT PUMP® clutch is engaged)

PROBLEM
PROBLEM:

LOW OR NO PUMP PRESSURE

PRESSURE::

1. The system may have a leak.

CHECK: Figure 8-7 : Unloader

⇒ The pressure relief valve may be defective or incorrectly adjusted.

⇒ Check for incoming water leaks.
⇒ Check for defective disconnect or ball valve on the fresh water tank (if
equipped) causing the pump to pump air.
⇒ Check all hoses for pinholes, leaks, cuts or crimped.
(Replace as necessary)
⇒ Check pump input on the front of the machine is not loose or defective also
check the rubber hose washer is not damaged or missing.
(Replace any defective parts)

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 10
2. The CAT PUMP® (or) pressure regulating Unloader may be defective or damaged.

WARNING

Without using water carefully (BE CAREFUL HOSE DOES NOT BLOW OFF) squeeze
bypass hose (3/8” hose from Unloader to water box). The pressure on gauge should in-
crease. This means that the CAT PUMP® is capable of pressure. If pressure does not
increase that means that the CAT PUMP® is not capable of putting out pressure. If the
pump is pumping, but pressure cannot be increased by adjusting unloader, (the unloader is
defective).

CHECK:

⇒ The inlet seals may be allowing the CAT PUMP® to pump air.
⇒ The check valves may be faulty or dirty and not properly functioning, allow-
ing water to flow both ways. (Clean or replace)
⇒ The pump may have a damaged or defective high or low-pressure seals.
(Replace damaged seals with new ones)
⇒ Check input strainer for debris and clean if necessary. Also check strainer
gasket for any defects. (Replace if necessary)

3. There may be a leak inside the main Heat Exchanger System.

Top H.E.

CHECK:

⇒ If the First Stage (Bottom) or Second Stage (Top) Heat Exchanger

is leaking, the machine will discharge water out of the Heat Ex- Bottom H.E.

changer exhaust. Make sure that the discharge is not just condensed
water normally produced by combustion engines. Have the heat
exchanger professionally repaired or replace as necessary.

4. The machine may have massive or multiple leaks. Figure 8-8 : Heat Exchangers

CHECK:

⇒ Hoses, fittings, connectors and valves. (This damage is usually attributed to

freeze damage)
⇒ The machine should be checked out thoroughly for ALL damage when re-
paired.

5. The system may be suffering from a mechanical problem.

LOCATE & REPAIR:

⇒ The CAT PUMP® (RPM) may not be turning properly.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 11
 ⇒ The machine engine may NOT be operating at the proper (RPM).
⇒ The Engine may be excessively worn.
• Due to improper use.
• Lack of maintenance.
• Excessive hours of operation.

6. The engine may be in need of a scheduled tune up.

7. The engine may not be getting an adequate supply of fuel.

CHECK:

⇒ for any blocked, pinched or restricted fuel lines. (Replace as needed)

8. The engine air filter may need to be replaced.

CHECK:

⇒ Air filter may be clogged, dirty, or restricted. (Replace as necessary)

9. The belts on the machine may be slipping or missing all together.

CHECK:

⇒ Belts. (See poor vacuum section)

10. There may be a severe mechanical problem with the CAT PUMP®.

CHECK: (Refer to drawing PA2200 in Section 11 for identification)

⇒ Crankshaft. (Broken - Repair or replace as necessary)

⇒ Connecting rod (s). (Repair or replace as necessary)
⇒ Plunger (s). (Repair or replace as necessary)

PROBLEM
PROBLEM:
LOW OR NO PULSE/CHEMICAL PUMP PRESSURE
PRESSURE::

Check pump inlet plumbing, filter, etc. and check pump output volume before the fol-
lowing items.

1. There is no chemical flow and the Pulse Pump WILL NOT prime.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 12
 CHECK:

⇒ Prime hose from the chemical switch is securely at-

tached to the Recovery Tank.
⇒ Hose is not kinked, pinched, cut or damaged.
⇒ There is at least 10’’Hg of vacuum from the recovery
tank.
⇒ Check to assure that the filter screen in the chemical
jug is clean. Some deposits from certain chemicals Figure 8-9 : Chemical Pump Parts
are clear or white causing the filter to appear clean
when it is really clogged.
⇒ Check to make sure the chemical flow meter is func-
tioning properly by the following:
1. Remove the clear plastic hose from the input
side of the Pulse Pump.
2. Remove the line from the chemical jug, filter
and all.
3. Clean the end of the chemical pick up hose and Figure 8-10 : Chemical Pump
filter thoroughly and rinse off in clean water.
4. Blow air in through the filter into the chemical pick up line. The metal
ball in the Flow Meter should rise in a smooth motion when you blow
air in the hose, if not the pick up screen is clogged or the ball is jammed.
(Repair or replace the affected part)

2. There is still no chemical.

CHECK:

⇒ Replace the clear plastic hose from the chemical jug to the Pulse Pump. The
hose may have holes or cracks allowing air to enter the line. Once replaced
try to prime the system again.
⇒ Remove the pulse Pump from the CAT PUMP® assembly.
⇒ Check the Pulse Pump for faulty check valves, diaphragm or disc.
⇒ Be sure the disc is properly installed with the slot facing away from the dia-
phragm.
⇒ (Repair and replace all parts necessary)
⇒ Be sure both check valves are installed in the proper direction, reinstall the
Pulse Pump on the machine.
⇒ Try to prime the system once again.
⇒ The check valve located between the Pulse Pump and the face panel output
manifold may be clogged, damaged or installed in the wrong flow direction.
(Repair or replace)

NOTE: If the Pulse Pump still will not prime the problem must lie in the main pump or
in poor pump inlet condition. See section Low or No CAT PUMP® system pres-
sure troubleshooting.
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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 13
3. There is little chemical flow and the Pulse Pump WILL prime.

CHECK:

⇒ There may be a restriction in the chemical injection system.

⇒ Check the cleaning tools. An improperly working cleaning tool will affect
chemical output.
⇒ Check to make sure the chemical adjust valve is functioning properly and is
not clogged or defective.
⇒ Check the three way chemical valve may be clogged. (Clean or replace)
⇒ Check the S/S tubing between the chemical valve and the chemical adjust
valve may be clogged or corroded. (Clean or replace)
⇒ Remove the Pulse Pump from the CAT PUMP® .
- Disassemble.
- Clean and inspect it as out lined in the section above.
- Look for any obstruction.
⇒ Check system for any air leaks.
- There may be a air leak in the pumping system.

NOTE:
(Air bubbles in the sys tem act as cushions in the CAT PUMP® and prevent
the necessary pressure pulse needed to effectively move the diaphragm and
thereby stop the pumping action.)
NOTE:
A simple way to check for air in the pumping system is to place the Aux-
iliary Output hose in a bucket of water. With the end of the hose sub-
merged, you should be able to tell of there is excessive air in the output
of the system. Also, a very small air leak in the inlet seals of the CAT
PUMP® or the inlet plumbing can cause problems. Often the plumping
system will suck air in through a leak when the machine is running and
will not leak water when the machine is off. Any air leaks that are lo-
cated must be repaired.

HEATING SYSTEM
SYSTEM::
(HOW THE HEATING SYSTEM WORKS...)

The commanders heat exchange system is a highly engineered system designed

by the White Magic Corporation. The heating system is comprised of exhaust and
blower heat that is captured for free heat.

Water is fed into the machine under tap pressure and it flows to the water box.
The water is then picked up by the high pressure pump and pressurized to the desired

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 14
 pressure level. The water then splits as demanded by the technician.

The water demanded by the technician flows from the water pressure pump
through the heat exchangers then out to the cleaning tool.

When the cleaning solution reaches a preset temperature set by the cleaning tech-
nician the machine will go into a divert mode until it calls for more heat, then it goes
back into the heat mode. The HeatSmart™ technology is the first of its kind in the
carpet cleaning industry. There is no dumping of water into the recovery tank.

PROBLEM
PROBLEM:

LOW WATER TEMPERATUR

TEMPERATURES
ES:
ES:
The causes of low water temperature are usually easy to locate.

CHECK:

⇒ The temperature control thermostat maybe inadvertently set to its lowest set-
ting. (Reset temperature control dial).
⇒ Check vacuum load on system. The actuators require 10” Hg. minimum to
operate. The systems heat is maximized by running 12”-14” Hg.
(Set at a full load)
⇒ The temperature control thermostat may be defective.
- If the temperature control thermostat has failed the heat diverting
system will stay open.
- This will divert all heat away from the heat exchanger.
⇒ Check thermostat. (Replace as necessary)

1. Heat diverter is operating incorrectly:

The heat diverter may not be operating correctly allowing heat to bypass heat exchangers
and exhaust through the muffler system. Diverter should pull away from the engine when
the machine is started. (If not, check the following):

1. Diverter may be defective:

Check that diverter can be actuated by hand, that it is not mechanically stuck.

2. Vacuum solenoid switch may be defective:

Hook the vacuum line from the blower elbow directly to vacuum actuator and restart ma-
chine. If vacuum actuator pulls away from engine and holds vacuum solenoid switch, it is
defective or has become disconnected. (Repair or replace switch.)

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 15
3. Vacuum actuator diaphragm may be defective:

If by putting vacuum directly from blower elbow to vacuum actuator doesn’t allow vacuum
actuator to hold vacuum, check vacuum tubing. If it is OK, (Replace vacuum actuator).

4. Engine is running at Low RPM:

The engine may be operating below the proper RPM range. Increase the engine throttle until
the proper RPM range is reached. Check for proper vacuum level.

5. Machine may be using too large a volume of water:

Assure that the wand jets are the proper size.

6. Heat Exchanger may be defective:

CHECK:

⇒ Leaking.
⇒ Blocked.

If either is true, water will fill up in the heat exchanger and blow out of the exhaust port in
front of the machine. (Replace the heat exchanger as necessary.)

7. Pump pressure may be adjusted too high:

CHECK:

⇒ Turn system pressure down with the unloader valve.

⇒ Normal carpet cleaning pressure is 300-500 psi.

8. Solution line may be losing heat:

CHECK:

⇒ May be losing directly due to contact with cold surfaces.

(Such as ice or snow)
⇒ Take proper steps to insulate the line from such conditions.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 16
ELECTRICAL TROUBLESHOOTING

PROBLEM
PROBLEM:

MACHINE WILL NOT STA

START
RT:
RT:
1. Circuit Breaker:

CHECK:
⇒ Circuit breaker.
⇒ Breaker may have tripped.
-Try to reset the breaker.
⇒ If the circuit breaker trips again
- Check all wiring for loose connections.
⇒ The circuit breaker may have to be replaced.

2. Engine Oil:

CHECK:
⇒ Engine oil level.
⇒ Press machine override switch.
- If machine starts there may be a defective oil pressure switch. Remove the
green wire running to the face panel from the white wire running to the
KOHLER® engine. This will bypass the oil pressure switch. If the machine
starts, the switch is bad. (Replace as necessary)
⇒ See Engine Troubleshooting section for more info.

3. Recovery Tank:

CHECK:
⇒ Recovery tank is not full of dirty water.
⇒ Float switch is not stuck open. (Debris or buildup around switch)
⇒ Float switch by removing a black wire from the float. If the machine operates
correctly with the wire removed, clean or replace float switch.
(Do NOT run machine with out replacing switch.)
⇒ Lamp light sockets shorts on the face panel. (Remove and replace as neces-
sary.)

4. Wires:

CHECK:
⇒ Machine wires.
- Cuts.
- Loose connections.
- Burnt. (Especially near the engine or rotating parts).

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 17
 ⇒ Good ground for the machine. (Sometimes when a machine is installed in a
vehicle with a wood floor you could loose the ground. This could cause in ter-
minate power problems).
⇒ Kill switch wiring short to ground. (Any short to ground will cause the engine
to stop).
⇒ Wiring for containing chemical solution on them. (Sometimes a chemical re-
action on the wiring along with water can ground them out).
⇒ Kill switch. (Switch itself can have an internal short to ground that will kill
machine).
⇒ Ignition key. (Switch shuts the machine off by grounding the Kill wiring. A
defective switch may have an internal short to ground present which will pre-
vent the machine from running).

Overheating?

If the machine stops after running for a while it could be the machine is
overheating. At approximately 290˚ the machine Kill switch will trip stop-
ping the machine. The switch may be defective. To test the switch, re-
move the power wire from the switch. If the unit does start with the power
wire removed and the system cool (below 200˚) the switch will need to be
replaced.

Other things to check for:

⇒ Diverters (not functioning properly)
⇒ Solenoids
⇒ Temperature Thermostat

HORSEPOWER TROUBLESHOOTING

PROBLEM
PROBLEM:
THE MACHINE HAS EXCESSIVE HORSEPOWER DRAW:

1. Excessive Horsepower draw can be caused from:

CHECK:

⇒ Vaccuum.
⇒ Pressure settings.
⇒ Seized bearings in idlers, etc.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 18
BELT(S) TROUBLESHOOTING

PROBLEM
PROBLEM:

THE MACHINE IS HAVING PROBLEMS WITH BELTS:

Correct belt alignment is critical for proper machine operation.

CHECK:

⇒ Belt alignment.

Symptoms:

⇒ The machine drive belts consistently fall off the pulleys.

⇒ There is excessive wear on the pulleys, idler and blower shaft bearings.
⇒ The drive belts wear and fail prematurely.
⇒ The machine causes excessive vibration and noise.
⇒ The belts may slip and not supply adequate power to the machine.

Solutions for alignment:

1. Run a straight edge from Pulley 1

(Engine pulley) at an angle diagonally
to the edge of Pulley 2 (Roots™ Blower
pulley, or CAT PUMP® pulley). Jockey
the Roots™ blower into place until the
pulleys line up on the straight edge.
(See diagram following) The idler pul-
leys must also be aligned.
2. Move the straight edge to the opposite
end of Pulley 1 and run at an angle di-
agonally to the opposite edge of Pulley
2. The two pulleys should still line up.
If not the Roots™ blower will need to
be jockeyed around until both pulleys
line up in with the straight edge held in both positions. (See diagram)
Align the idler pulley in the same manner.
3. Idler pulleys must be aligned.
4. It is important to align the Roots™ blower pulley with the engine pul-
ley before attempting to align the CAT PUMP® pulley to the engine
pulley.

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OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 19
 Machine / Engine Bypass Procedure
(Commander & Commander HO 4-21-04)

1.) Disconnect the red wires at

POINT “E”.
(NOTE** Tag or otherwise note
B C
wires before disconnecting)

D 2.) Disconnect red wire w/ yellow

E fuse holder from POINT “B”.
(NOTE** Tag or otherwise note
wires before disconnecting)

A 3.) Connect red wire w/ yellow fuse

holder to coiled red wire from “+” of
starter.
DISC
ON N
ECT 4.) Disconnect yellow wire of engine
Fig. 1
from red wire and POINT “C”.
(NOTE** Tag or otherwise note
wires before disconnecting)

5.) Disconnect white wire form white

wire at POINT “D”.

6.) Disconnect green wire from green

wire at POINT “A”.

Engine can now be started and run

CONNEC
without any effect from the machine.
T **DO NOT run any longer than nec-
essary in this fashion as there are no
B+E controls for heat.

Fig. 2 7.) Reverse the above process to put

equipment back to the original wiring.
(Check wiring diagram if necessary or
if there is any possibility of having
wires improperly connected.)

JULY 2007 v2.0

OWNER’S MANUAL (TROUBLESHOOTING) Section 8, Page 20
White Magic Inc. warrants truckmount machines of its manufacture to be free from defects in material and workmanship if prop-
erly installed and operated under normal conditions with competent supervision as is illustrated within the White Magic Inc. in-
structional/operational Owners Service Manual.

No person, agent, representative or dealer (distributor) is authorized to give any warranties on behalf of White Magic Inc. or to
assume for White Magic Inc. any liability in connection with any White Magic Inc. products.

This warranty extends to the original purchaser of equipment upon date of installation listed in the truckmount document package.
The truckmount document package MUST be returned in order to activate the truckmount warranty. Failure to return document
package will result in the warranty start date being the date of shipment from the factory.

To ensure the functionality and safety of equipment the White Magic Inc. Platinum Guarantee Warranty Plan shall cease to be in
effect if modifications are made without the express consent of White Magic Inc.

Machinery, equipment, and accessories furnished by White Magic Inc., but manufactured by others, are warranted only to the ex-
tent of the original manufacturer's warranty to White Magic Inc. unless specified otherwise by White Magic Inc. This applies to
the blower, engine, and pump on the truckmount or vehicle manufacturer for the vehicle. Any claim that falls under the Original
Manufacturer’s warranty should be made in accordance with Original Manufacturer’s policies for warranty claims. Always follow
Original Manufacturer’s warranty policy in affect at time of purchase. Specific questions in regards to warranty should be directed
toward the White Magic Inc. Service Dept or the manufacturer of the specific component. Contact information can be found inside
your Owners Service Manual “Extra Manuals” section.

The warranty period for the equipment, and parts, (except those listed above) is (1) ONE YEAR from the date of installation or (18)
EIGHTEEN MONTHS from the date of shipment from the factory, whichever comes first. White Magic Inc. agrees, at its option,
to repair or replace without charge any defective parts or products of White Magic Inc.'s manufacture, which within the warranty
period.

General parts orders, replacement parts, & out of warranty parts replacement carry a 90 day warranty from date of shipment. All
parts returns are subject to a 15% restocking fee.

White Magic Inc. will pay freight and transportation charges within the United States under normal ground shipping for replace-
ment of warranted parts for a period of (1) ONE YEAR. The shipment of warranted parts any faster than ground will not be cov-
ered.

The White Magic Inc. warranty covers parts. It covers labor for the period (90) DAYS from date of installation which may be nec-
essary for the completion of repairs. This labor must be preauthorized by the White Magic Inc Service Dept. The warranty is lim-
ited to repair or replacement of defective parts using new or remanufactured parts.

RMA is procedure is as follows: Faulty part is called into White Magic Inc. White Magic confirms failure over the phone by fur-
ther diagnosis. If part is determined to be failed, RMA number is issued and part is shipped and billed according to account type.
To be covered under warranty the defective parts must be returned with an authorized RMA# to White Magic Inc. within (14)
DAYS of failure. When part is recieved, it is evaluated and credit is approved or denied based upon testing and evaluation. Credits
will be issued once a month at the end of every month. No liability shall be attached to White Magic Inc. until products have been
paid for.

As stated in White Magic Inc.’s warranty, only the parts and the equipment is covered. White Magic Inc. shall have no liability for:
consequential, incidental, or other damages caused. This included, but is not limited to: lost business, downtime, lodging or any
other incidentals. Parts covered under this warranty will be warranted for only the remaining time left in the original warranty
period of the equipment.

All items that are considered by White Magic Inc., to be expendable or normal wear items in normal use, including paint and other
cosmetic parts or features are not covered under the warranty. Normal maintenance procedures (oil, filter changes, etc.) are not
covered. Freezing of any water or chemical related components would VOID all warranties on water or chemical related compo-
nents, internal or external, of the equipment.

Corrosions, deposits and build up in the water, chemical, recovery or heating systems due to hardness in the water used or chemi-
cals which results in deposits, will VOID all warranties in the affected components and areas. The use of any chemical or solvents,
which may damage metal, rubber, plastic, or painted parts, will VOID all warranties on those parts.

(All features, specifications and warranty are subject to change without notice on White Magic Inc. or Original Manufacturer’s warranty.)

© Effective 7/1/2007 White Magic Inc. 11 Main Street, Salisbury, MA. 01952 (800) 422 - 1128
 Commander & H.O. External Parts Identification

4) (PN# A094A) 5) (PN# A094)

3) (PN# A031) 6) (PN# J304)

2) (PN# J412-4) 7) (PN# K012)

1) (PN# A405) 8) (PN# A010)

9) (PN# B073)
31) (PN# A109)

10) (PN# A0305)

30) (PN# A151M)

29) (PN# B086) 11) (PN# J412-3)

12) (PN# A015A)

28) (PN# A019)

13) (PN# A101)

27) (PN# B085)
14) (PN# A061-15)

15) (PN# A138M)

16) (PN# J032-3)

26) (PN# B001)

17) (PN# B301)

25) (PN# B002)

18) (PN# B115)

19) (PN# L003)

24) (PN# TA70)

20) (PN# B0385)

23) (PN# B097) 21) (PN# E268)
External View
22) (PN# E021) Fig. 1
JULY 2007 v2.0
OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 1
External View Fig. 1:

1.) (PN# A405) Console Assembly, Commander & HO: Console assembly is conveniently re-
moved to access the internal components of your Slide-In Carpet Cleaning Machine.

2.) (PN# J412-4) Choke Cable: A heavy duty choke cable controls the choke on your machine.

3.) (PN# A031) Handle - Console Assembly, Commander & HO: Convenient handle for lifting
the top console on and off your machine.

4.) (PN# A094A) Indicator Light, Red: The machine will tell the operator the status of the operat-
ing features of the machine. When these lights are activated they will inform the operator which
system shut down the unit. These safety features include: low engine oil switch, full recovery
tank & high solution temperature.

5.) (PN# A094) Indicator Light, Green: A green light to indicate a your if truckmount is in diverter
mode.

6.) (PN# J304) Ignition Switch, Kohler Engines: Remote Ignition located on the front of the face
panel allows for easy starting the machine.

7.) (PN# K012) Flexible Draw Latch: An easily manipulated rubber draw latch that seals your con-
sole assembly closed.

8.) (PN# A010) Tiny Tach / Hourmeter: White Magic slide-in machines are all equipped with a
digital tachometer and hour meter. Produced by KOHLER® this precise gauge gives the true
RPM of the engine.

9.) (PN# B073) 20 Amp Circuit Breaker: Protects the electrical components of your White Magic
Truckmount.

10.) (PN# A0305) Temperature Gauge: Designed for ease of operation simply, pull the trigger and
watch your temperature soar. The gauge will read up 330°F and its sending unit is placed right
before the heated solution exits the machine. This added benefit allows the operator to know
the exact temperature output (within a few degrees), at the wand.

11.) (PN# J412-3) Throttle Cable: User friendly, the choke and throttle cables easily pull out and
with just a twist locks at the desired setting.

12.) (PN# A015A) Vacuum Gauge: This glycerin filled gauge displays the vacuum lift of the
blower, routine check of this gauge during operation will help determine if maintenance of the
vacuum system is required.

13.) (PN# A101) Blower Lubrication Port: Conveniently located on the face panel of the machine,
allows for proper lubrication of the blower.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 2
External View Fig. 1 (continued…):

14.) (PN# A061-15) Water Recovery Switch: With just a flip of this switch the machine can go
from normal carpet cleaning operation in to water extraction. When this switch is activated it
automatically turns the pump clutch off and closes both of the heat diverters. Now with no
heat entering the heat exchange system and the pump not working the machine can run for
days with out ever having to supply the machine with water. This is an absolute must for wa-
ter damage operations.

15.) (PN# A138M) Temperature Controller: This fully adjustable feature controls the
HeatSmartTM system. When the desired temperature is selected the machine automatically
regulates the exhaust diverters to maintain the proper temperature.

16.) (PN# J032-3) Engine Kill Override: When one of the three kill switches shuts the machine
down, by pressing this button it allows the operator to diagnose the systems and make correc-
tions to restart the machine.

17.) (PN# B301) Auto Pump-out Control: Every White Magic machine is pre-wired for our ex-
ternal Auto Pump-out System regardless if the machine is ordered with one or not, its there
for future use if necessary.

18.) (PN# B115) Magnesium Sacrificial Anode: Protect your water storage tank with this magne-
sium anode. Replace every 6 months or as needed.

19.) (PN# L003) Ceramic Coated Exhaust Tip: Chrome plated will look great even after years of
use. The exhaust from both the blower and engine exit the machine through the face panel. It
can also be installed so the exhaust may be run down through the floor of the vehicle.

20.) (PN# B0385) Water Tank Drain Valve: A 1” ball valve used to drain the fresh water tank.

21.) (PN# E268) Oil Drain Valve: All the oil drains on the machines are installed into a central
line that is accessible in the front of the machine. This allows for simple oil changes with lit-
tle or no mess to clean up after. No more spilling oil all over the inside of the machine.

22.) (PN# E021) Overflow Protection: This port allows for the proper operation of both the water
box and fresh water tank (if equipped) and prevents premature failure of the water system.

23.) (PN# B097) Auxiliary Output Valve: This allows access to warm water straight out of the
face panel on the machine. It is an outstanding benefit for filling sprayer or diluting chemi-
cals.

24.) (PN# TA70) 70 Gallon Submount Fresh Water Tank (Optional): An optional submount
water tank that conveniently saves space in your van and holds 70 gallons of fresh water to
feed your machine.

25.) (PN# B002) Water Supply Input: Whether the machine is equipped with a fresh water tank
or not, the water supply is connected here.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 3
External View Fig. 1 (continued…):

26.) (PN# B001) Solution Disconnects: Two disconnects gives this machine limited dual wand
capabilities. Located far away from any electrical components. The disconnects allow for
easy hook up of live reels or wands.

27.) (PN# B085) Chemical Selector Valve: This three-way valve allows the operator to turn on,
off, or prime the chemical system. The priming mechanism is vacuum assisted which allows
a complete & instantaneous prime each and every time.

28.) (PN# A019) Chemical Flow Meter: The chemical flow meter displays the flow of chemical
going to the cleaning tool. Read in GPH (gallons per hour) this is a more consistent chemical
flow compared to other systems that meter CCM.

29.) (PN# B086) Chemical Adjustment Knob: By turning this knob it allows the operator to ad-
just the chemical flow from 0-5 GPH.

30.) (PN# A151M) Unloader Valve: This allows the operator to adjust the working pressure of
the pumping system of the machine. Unlike a pressure regulator system the unloader valve
releases the pressure off of the pump and pump components preventing premature failure of
the pumping system.

31.) (PN# A109) Pressure Gauge: The pressure gauge tells the operator the setting of the
unloader valve and the pressure output of the pump.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 4
 1) (PN# A405-1L) 3) (PN# A103-50)
5) (PN# A103-70) 7) (PN# B098)
2) (PN# J340)
(PN# J345) 4) (PN# A103) 6) (PN# WB300)

8) (PN# A1005)
(PN# A1010)

9) (PN# J680)
(PN# J735)

OWNER’S MANUAL (GENERAL PARTS)

10) (PN# MF2100)
16) (PN# J710)
14) (PN# G036) 12) (PN# B0786)

JULY 2007 v2.0

Section 10, Page 5
Internal Right Side
15) (PN# G038) 13) (PN# B0085) 11) (PN# J745) View
Fig. 2A
Internal Right Side View Fig. 2A:

1.) (PN# A405-1L) Front Console w/Partition Baffle: (face panel) One of the most important fea-
ture of any slide in system, but the most over looked is the Partition Baffle. The Partition Baf-
fle is responsible in preventing the re-circulation of heated air generated by the engine & heat
exchange system. All White Magic slide-ins have been designed with this feature in mind.
The signature series partition baffles are connected by gasket materials to the air intake of the
engine housing to insure proper air flow of the machine is achieved.

2.) (PN# J340, J345) Engine(s): 24 HP KOHLER AEGIS® Liquid Cooled Engine (Commander) .
28 HP KOHLER AEGIS® Liquid Cooled Engine (Commander HO). KOHLER AEGIS® Engines
are designed with overhead -valves, exclusive hydraulic valve lifters, full pressure lubrication.

3.) (PN# A103-50) Pump Disengagement Clutch: This allows the machine to quickly go between
carpet cleaning operations to flood extraction work. With just a flip of the switch the pump
clutch disengages, stopping the pump from functioning. The clutch & belts are covered by an
aluminum safety guard, protecting the operator and machine from harm.

4.) (PN# A103) CAT PUMP® 5CP Pump: Far superior from any other pump manufacturers,
CAT PUMP® delivers outstanding reliability and performance. Mounted in the machine high
above all other components allows for quick and easy service of the pump. While performing
service the pump does not need to be un-bolted or readjusted, all service can be done in place.
This saves hours of down time and expense to the equipment owner.

5.) (PN# A103-70) Pulsation Hose: As the ceramic plungers of the CAT Pump push water into the
system, a vibration is given off. The pulsation or vibration is absorbed helping prevent prema-
ture failure of fittings and components.

6.) (PN# WB300) Water Box: Constructed from Stainless Steel, the water box provides the incom-
ing water to the pump. The box can contain a max. of (2) gallons of water and has a whole
host of features. Located above all of the other components the water box is hung in place and
secured with only (1) ¼” 20 bolt, allowing the box to be quickly removed if service is neces-
sary. The water box has (4) easy to remove thumb-screws that holds down the gasketed cover,
preventing water from spilling over on to the machine. The water box also has overflow pro-
tection, filtered input and allows for simple winterization of the machine in cold weather cli-
mates.

7.) (PN# B098) Water Pressure Reducer: Located on the input of the water box the pressure re-
ducer assures that the input water pressure is consistent, for extra protection of the internal float
valve.

8.) (PN# A1005, A1010) ROOTS™ 45 Blower (Commander), ROOTS™ 47 Blower (HO): White
Magic has selected DRESSER ROOTS™ as our exclusive vendor for Vacuum Blowers. The
Commander is outfitted with the ROOTS™ 45 blower providing 345 CFM and 14”Hg of vac-
uum lift. The Commander HO is outfitted with the ROOTS™ 47 blower providing 460 CFM
and 14”Hg of vacuum lift. These blowers are capable of producing exceptional performance
for all aspects of upholstery cleaning to water extraction. The dual lobe blower design is far
superior and more reliable to the new tri-lobe blower designs available in the cleaning industry.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 6
Internal Right Side View Fig. 2A (continued….):

9, 11.) (PN# J680, J685, J735, J745) Progressive Silencing System: White Magic engineers
have worked tirelessly to maximize performance without restricting airflow. The Progres-
sive Silencing system works by stepping down the noise generated by the carpet cleaning
system at specific locations throughout the machine.

10.) (PN# MF2100) Frame Assembly: Constructed from heavy gauge steel, the frame also
provides easy lifting with its built in fork lift pads.

12.) (PN# B0786) 3” Muffler Clamp: High Quality, Heavy Duty muffler clamps hold the ex-
haust system in our truckmounted cleaning systems.

13.) (PN# B0085) Blower Oil Lever Sight Tube: Made of High Quality TYGON Tubing, this
sight tube provides easy views of the blower oil level.

14.) (PN# G036) Blower V-Belts: (2) 36” Industrial Strength V-Belts drive your vacuum
blower.

15.) (PN# G038) Pump V-Belts: (2) 38” Industrial Strength V-Belts drive your high pressure
pump.

16.) (PN# J710) Exhaust Pipe: Directs exhaust gasses out of the front of your machine and out
of the van.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 7
 3) (PN# A380) 5) (PN# A383)
2) (PN# B135P) 4) (PN# A381) 6) (PN# H017) 7) (PN# H425)

8) (PN# H0155)
1) (PN# HE2200-1)

9) (PN# H016)

10) (PN# H016)

21) (PN# J0347)

11) (PN# H011)

OWNER’S MANUAL (GENERAL PARTS)

20) (PN# H011)

12) (PN# H0155)

18) (PN# D0029B) 16) (PN# J720) 14) (PN# A140M)

JULY 2007 v2.0

Section 10, Page 8
Internal Left Side
19) (PN# HE2200-2) 17) (PN# J715) 15) (PN# J790) 13) (PN# H013) View
Fig. 2B
Internal Left Side View Fig. 2A:

1., 19) (PN# HE2200-1, HE2200-2) Heat Exchange System: Making up the heart of the
Heatsmart™ Technology is our double barrel heat exchanger. Constructed using White Magic
exclusive High Efficiency Finned Copper Coil, this coil is far superior to other coil designs
found elsewhere in the United States. The heat exchanger is designed to maximize both air-
flow and heat transfer. As the water flows through the heat exchanger it enters at the coolest
point and exits the heat exchanger at the hottest point. This is commonly referred to as Re-
verse Flow.

2.) (PN# B135P) Pressure Relief Valve: This valve is factory set to prevent over pressurization
of the machine. When the machine reaches its setting the valve opens to relieve excess pres-
sure being developed by the pumping system. This valve allows the operator to adjust the pres-
sure up to 1200 PSI for tile and grout cleaning.

3, 4, 5.) (PN# A380, A381, A383) Vacuum Actuators: Opens and closes the Heat Diverters to
maintain and control water temperature.

6, 8 - 12, 20.) (PN# H011, H0155, H016, H017) Stainless Steel Braided Hoses: White Magic
uses only Stainless Steel high-pressure hoses to interconnect the systems solution and pumping
system.

7.) (PN# H425) Flexible Hose, Air Input: Connects the Air Cleaner on your machine to the fresh
outside air.

13.) (PN# H013) Chemical Jug Input Line: Connects your chemical pump to your mixed chemi-
cal in the chemical jug.

14.) (PN# A140M) Vacuum Solenoid: As the temperature reaches its predetermined setting es-
tablished by the operator, the Temperature Sensor sends an electrical signal to the vacuum so-
lenoid which activates the Vacuum Pods to open and close the Heat Diverters to maintain the
desired operating solution temperatures.

15.) (PN# J790) Tube Clamp: Connects your chemical pump to your mixed chemical in the
chemical jug.

16.) (PN# J720) Engine Exhaust Diverter: This component operates by directing the flow of hot
gases produced by the engine. During operation of the machine the heat generated by the en-
gines exhaust will flow into the heat exchange system to heat the cleaning solution. Once the
cleaning solution has reach the pre-determined temperature set by the operator the temperature
sensor will activate the vacuum diverter control closing the Exhaust Diverter preventing the
hot gases from entering the heat exchange systems. The Heat Diverters internal components
are made from Stainless Steel and are nickel-plated to extend life of the diverter.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 9
Internal Left Side View Fig. 2A (continued…):

17.) (PN# J715) Blower Exhaust Diverter: Working in conjunction with the engine exhaust di-
verter is White Magic’s exclusive blower exhaust diverter. This diverter protects the system
from over heating. After the engine exhaust diverter has closed, and if the solution tempera-
ture continues to rise, the blower exhaust diverter will then activate, preventing any of the
heat generated by the blower from entering the Heat Exchange System. This is an excep-
tional feature for water recovery operations. When the machine is placed into water recovery
mode both the Engine Exhaust Diverter and Blower Exhaust Diverter are activated. This
prevents any heat generated from entering the heat exchange system, allowing the machine to
run continuously for hours with no water in the system.

18.) (PN# D0029B) Heavy Duty Spring: Assists the blower diverter in closing while under a
vacuum load.

21.) (PN# J0347) High Temperature Kill Switch: This safety feature protects the operator, by-
standers and the machine from dangerous overheating of the systems water temperature rat-
ing. This Safety Kill Switch will shut the machines engine down if the solution temperature
exceeds 275°F. If this occurs the operator can quickly determine the cause or the shut down
by looking at the indicator lights on the face panel of the machine.

JULY 2007 v2.0

OWNER’S MANUAL (GENERAL PARTS) Section 10, Page 10
 OWNER'S MANUAL
KOHLER AEGIS®
LH630, LH640, LH685, LH690, LH755, LH775
LIQUID-COOLED
HORIZONTAL CRANKSHAFT
 Safety Precautions

To ensure safe operations please read the following statements and understand their meaning.
Also refer to your equipment owner's manual for other important safety information. This manual
contains safety precautions which are explained below. Please read carefully.

WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.

CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury
or property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result
in injury to yourself and others.

WARNING WARNING WARNING

Explosive Fuel can cause fires and Hot liquid can cause severe burns. Hot Parts can cause severe burns.
severe burns.
Do not loosen radiator cap while Do not touch engine while operating
Stop engine before filling fuel tank. engine is operating or warm to the or just after stopping.
touch.
Explosive Fuel! Hot Liquid! Hot Parts!
Gasoline is extremely flammable The liquid coolant can get extremely Engine components can get
and its vapors can explode if hot from operation. Turning the extremely hot from operation. To
ignited. Store gasoline only in radiator cap when the engine is hot prevent severe burns, do not touch
approved containers, in well can allow steam and scalding liquid these areas while the engine is
ventilated, unoccupied buildings, to blow out and burn you severely. running, or immediately after it is
away from sparks or flames. Do not turned off. Never operate the engine
fill the fuel tank while the engine is Shut off machine. Only remove with heat shields or guards
hot or running, since spilled fuel radiator cap when cool enough to removed.
could ignite if it comes in contact touch with bare hands. Slowly
with hot parts or sparks from loosen cap to first stop to relieve California
ignition. Do not start the engine near pressure before removing Proposition 65 Warning
spilled fuel. Never use gasoline as a completely.
cleaning agent. Engine exhaust from this product
contains chemicals known to the
State of California to cause
cancer, birth defects, or other
reproductive harm.

2
 Safety Precautions (Cont.)

WARNING WARNING WARNING

Accidental Starts can cause severe Carbon Monoxide can cause Explosive Gas can cause fires and
injury or death. severe nausea, fainting or death. severe acid burns.
Charge battery only in a well
Disconnect and ground spark plug Do not operate engine in closed or ventilated area. Keep sources of
leads before servicing. confined area. ignition away.
Accidental Starts! Lethal Exhaust Gases! Explosive Gas!
Disabling engine. Accidental Engine exhaust gases contain Batteries produce explosive
starting can cause severe injury or poisonous carbon monoxide. hydrogen gas while being charged.
death. Before working on the engine Carbon monoxide is odorless, To prevent a fire or explosion,
or equipment, disable the engine as colorless, and can cause death if charge batteries only in well
follows: 1) Disconnect the spark plug inhaled. Avoid inhaling exhaust ventilated areas. Keep sparks, open
lead(s). 2) Disconnect negative (-) fumes, and never run the engine in flames, and other sources of ignition
battery cable from battery. a closed building or confined area. away from the battery at all times.
Keep batteries out of the reach of
CAUTION WARNING children. Remove all jewelry when
servicing batteries.

Before disconnecting the negative

(-) ground cable, make sure all
switches are OFF. If ON, a spark will
Electrical Shock can cause injury. Rotating Parts can cause severe occur at the ground cable terminal
injury. which could cause an explosion if
Do not touch wires while engine is hydrogen gas or gasoline vapors
running. Stay away while engine is in
are present.
operation.
Electrical Shock! Rotating Parts!
Never touch electrical wires or Keep hands, feet, hair, and clothing
components while the engine is away from all moving parts to
running. They can be sources of prevent injury. Never operate the
electrical shock. engine with covers, shrouds, or
guards removed.

Congratulations – You have selected a fine four-cycle, twin cylinder, liquid-cooled engine. Kohler designs long
life strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you
can count on. Here are some reasons why:

• Efficient overhead valve design, and pressure lubrication provide maximum power, torque, and reliability
under all operating conditions.

• Dependable, maintenance-free electronic ignition ensures fast, easy starts time after time.

• Kohler engines are easy to service. All routine service areas (like the dipstick and oil fill, air cleaner, spark
plugs, and carburetor) are easily and quickly accessible.

• Parts subject to the most wear and tear (like the cylinder liner and camshaft) are made from precision
formulated cast iron.

• Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service
support is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

3
 Heavy-Duty Air Cleaner

Oil Fill Reservoir

Cap Dipstick

Rectifier-
Regulator
Spark
Plug Spark Plug

Radiator Electric Starter

Oil Filter

Oil Drain Plug Oil Drain Plug

Figure 1. Typical Kohler Aegis® Carbureted Engine.

Heavy-Duty Air Cleaner

Reservoir
Radiator
Fuel Injector

Ignition Coil

ECU
Fuse Holders Wire Harness

Figure 2. Typical Kohler Aegis® EFI Engine.

Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the ** *
correct oil, or using dirty oil, causes premature engine
wear and failure.

Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class SG, SH, SJ or
*Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
higher. Synthetic oils may be used. Select the viscosity up to 4°C (40°F).
based on the air temperature at the time of operation as **Synthetic oils will provide better starting in extreme cold below
shown in the following table. 23°C (-10°F).
Figure 3. Viscosity Grades Table.

NOTE: Using other than service class SG, SH, SJ or

higher oil or extending oil change intervals
longer than recommended can cause engine
damage.

4
NOTE: Synthetic oils meeting the listed classifications Unleaded gasoline is recommended as it leaves less
may be used with oil changes performed at combustion chamber deposits and reduces harmful
the recommended intervals. However to allow exhaust emissions. Leaded gasoline is not
piston rings to properly seat, a new or rebuilt recommended and must not be used on EFI engines,
engine should be operated for at least 50 or on other models where exhaust emissions are
hours using standard petroleum based oil regulated.
before switching to synthetic oil.
Gasoline/Alcohol blends
A logo or symbol on oil containers identifies the API Gasohol (up to 10% ethyl alcohol, 90% unleaded
service class and SAE viscosity grade. See Figure 4. gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.

Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.

Figure 4. Oil Container Logo. Coolant Recommendations

Use equal parts of ethylene glycol (anti-freeze) and
Refer to “Maintenance Instructions” beginning on water only. Distilled or deionized water is
page 8 for detailed oil check, oil change, and oil recommended, especially in areas where the water
filter change procedures. contains a high mineral content. Propylene glycol
based anti-freeze is not recommended.
Fuel Recommendations
This mixture will provide protection from -37°C (-34°F)
WARNING: Explosive Fuel! to 108°C (226°F). For protection and use outside the
Gasoline is extremely flammable and its vapors can indicated temperature limits, follow the anti-freeze
explode if ignited. Store gasoline only in approved manufacturers instructions on the container, but do not
containers, in well ventilated, unoccupied buildings, exceed 70% anti-freeze.
away from sparks or flames. Do not fill the fuel tank
while the engine is hot or running, since spilled fuel DO NOT use anti-freeze with stop-leak additive(s), or
could ignite if it comes in contact with hot parts or put any other additives in the cooling system.
sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent. Engine Identification Numbers
When ordering parts, or in any communication
General Recommendations involving an engine, always give the Model,
Purchase gasoline in small quantities and store in Specification, and Serial Numbers of the engine.
clean, approved containers. A container with a capacity
of 2 gallons or less with a pouring spout is The engine identification numbers appear on a decal,
recommended. Such a container is easier to handle affixed to the engine. The primary location is on the
and helps eliminate spillage during refueling. side of the flywheel cover. Placement may vary due to
OEM requirements and specific options involved.
Do not use gasoline left over from the previous season,
to minimize gum deposits in your fuel system and to Record your engine identification numbers on the
insure easy starting. identification label (Figure 5) for future reference.

Do not add oil to the gasoline. Do not overfill the fuel

tank. Leave room for the fuel to expand.

Fuel Type
For best results use only clean, fresh, unleaded
gasoline with the pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90 octane minimum.

5
For Models LH630, LH640, LH685, LH690 Refer to certification label for engine displacement.

Exhaust Emission Control System for models LH630,

IMPORTANT ENGINE INFORMATION LH640, LH685, LH690 and LH755 is EM. Exhaust
THIS ENGINE MEETS U.S. EPA AND CA 2005 Emission Control System for model LH775 is EM,
AND LATER AND EC STAGE II (SN:4) EMISSION
O2S, ECM, MFI.
REGS FOR SI SMALL OFF–ROAD ENGINES
FAMILY
Model Designation
TYPE APP
Model LH690 for example: L designates liquid cooled,
DISPL. (CC)
H designates horizontal crankshaft, and 690 is the
MODEL NO.
model designation. A letter suffix designates a specific
SPEC. NO.
version as follows:
SERIAL NO.
BUILD DATE
Suffix Designates
OEM PROD. NO.
EMISSION COMPLIANCE PERIOD:
S Electric Start
EPA: CARB:
CERTIFIED ON:
REFER TO OWNER'S MANUAL FOR HP RATING,
Operating Instructions
SAFETY, MAINTENANCE AND ADJUSTMENTS Also read the operating instructions of the equipment
1-800-544-2444 www.kohlerengines.com this engine powers.
KOHLER CO. KOHLER, WISCONSIN USA

For Models LH755 and LH775 Pre-Start Checklist

• Check oil level. Add oil if low. Do not overfill.

IMPORTANT ENGINE INFORMATION • Check coolant level. Add coolant if low.

THIS ENGINE MEETS EMISSION REGS FOR U.S.
EPA 2005 AND LATER AND EC STAGE II (SN:4) SI
SMALL OFF-ROAD ENGINES AND CA 2005 AND • Check fuel level. Add fuel if low.
LATER LSI ENGINES
FAMILY • Check radiator, cooling air intake areas and
TYPE APP external surfaces of engine. Make sure they are
clean and unobstructed.
DISPL. (CC)
MODEL NO.
• Check that the air cleaner components and all
SPEC. NO.
shrouds, equipment covers, and guards are in
SERIAL NO.
place and securely fastened.
BUILD DATE
OEM PROD. NO.
• Check that any clutches or transmissions are
EMISSION COMPLIANCE PERIOD:
EPA: CARB: disengaged or placed in neutral. This is especially
CERTIFIED ON: important on equipment with hydrostatic drive. The
REFER TO OWNER'S MANUAL FOR HP RATING, shift lever must be exactly in neutral to prevent
SAFETY, MAINTENANCE AND ADJUSTMENTS
1-800-544-2444 www.kohlerengines.com
resistance which could keep the engine from
KOHLER CO. KOHLER, WISCONSIN USA starting.
Figure 5. Engine Identification Label.
WARNING: Lethal Exhaust Gases!
Engine exhaust gases contain poisonous carbon
The Emission Compliance Period referred to on the
monoxide. Carbon monoxide is odorless, colorless,
Emission Control or Air Index label indicates the
and can cause death if inhaled. Avoid inhaling exhaust
number of operating hours for which the engine has
fumes, and never run the engine in a closed building or
been shown to meet Federal and CARB emission
confined area.
requirements. The following table provides the Engine
Compliance Period (in hours) associated with the
category descriptor found on the certification label.
Cold Weather Starting Hints
1. The cooling system must be filled with coolant
Emission Compliance Period (Hours) capable of providing proper protection against
freezing at the lowest temperature expected (see
Category C Category B Category A ‘‘Coolant Recommendations’’ on page 5).
EPA
250 Hours 500 Hours 1000 Hours
Moderate Intermediate Extended 2. Be sure to use the proper oil for the temperature
CARB
125 Hours 250 Hours 500* Hours expected. See Figure 2 on page 4.
*Extended hours for Models LH755 and LH775 is 1000.

6
 3. Declutch all possible external loads. If the starter does not turn the engine over, shut
off starter immediately. Do not make further
4. A warm battery has much more starting capacity attempts to start the engine until the condition is
than a cold battery. corrected. Do not jump start using another battery
(refer to “Battery” on page 7). See your Kohler
5. Use fresh winter grade fuel. NOTE: Winter grade Engine Service Dealer for trouble analysis.
gasoline has higher volatility to improve starting.
Do not use gasoline left over from summer. Carbureted Engines Only:
3. For a Cold Engine – Gradually return the choke
Starting control to the “off” position after the engine starts
1. Place the throttle control midway between the and warms up.
“slow” and “fast” positions. Place the choke
control (non-EFI engines only) into the “on” The engine/equipment may be operated during
position. the warm-up period, but it may be necessary to
leave the choke partially on until the engine warms
2. Start the engine by activating the key switch. up.
Release the switch as soon as the engine starts.
4. For a Warm Engine – Return choke to “off”
EFI Engines Only – Initial Starting or After position as soon as engine starts.
Running out of Fuel (Dry System)
a. Turn the key switch to the “on” position for Stopping
one minute. Allow the fuel pump to cycle and 1. Remove the load by disengaging all PTO driven
prime the system. Turn the key switch “off”. attachments.

b. Turn the key switch to the “start” position, 2. For Carbureted Engines Without A Shutdown
crank and start engine. Solenoid: Move the throttle to the “slow” or
“low” idle position. Allow the engine to run at idle
c. If the engine fails to start, repeat steps “a” and for 30-60 seconds; then stop the engine.
“b”. If the engine does not start after two
priming intervals, contact your Kohler Engine For Carbureted Engines Equipped With A
Service Dealer for further assistance. Shutdown Solenoid: Position the throttle control
somewhere between half and full throttle; then
NOTE: Do not crank the engine continuously for stop the engine.
more than 10 seconds at a time. If the
engine does not start, allow a 60 second For EFI Engines: Move the throttle to the "slow"
cool down period between starting or "idle" position; turn key ‘‘off’’ to stop engine.
attempts. Failure to follow these
guidelines can burn out the starter motor. Battery
A 12 volt battery is normally used. Refer to the
NOTE: Upon start-up, a metallic ticking may operating instructions of the equipment this engine
occur. This is caused by hydraulic lifter powers for specific battery requirements.
leakdown during storage. Run the engine
for 5 minutes. The noise will normally If the battery charge is not sufficient to crank the
cease in the first minute. If noise engine, recharge the battery (see page 15).
continues, run the engine at mid-throttle
for 20 minutes. If noise persists, take the Operating
engine to your local Kohler Service outlet.
Angle of Operation
NOTE: If the engine develops sufficient speed to This engine will operate continuously at angles up to
disengage the starter but does not keep 20°. Check oil level to assure crankcase oil level is at
running (a false start), engine rotation the “F” mark on the dipstick.
must be allowed to come to a complete
stop before attempting to restart the Refer to the operating instructions of the equipment
engine. If the starter is engaged while the this engine powers. Because of equipment design or
flywheel is rotating, the starter pinion and application, there may be more stringent restrictions
flywheel ring gear may clash resulting in regarding the angle of operation.
damage to the starter.

7
NOTE: Do not operate this engine continuously at 3. Check the system for external leaks.
angles exceeding 20° in any direction. Engine
damage could result from insufficient 4. If the cause is none of the above or cannot be
lubrication. identified, contact an Authorized Kohler Engine
Dealer for appropriate diagnosis and correction.
Cooling
NOTE: If debris builds up on the radiator, cooling WARNING: Hot Parts!
system, or other external areas, stop the Engine components can get extremely hot from
engine immediately and clean. Operating the operation. To prevent severe burns, do not touch these
engine with blocked or dirty cooling system areas while the engine is running, or immediately after
areas can cause extensive damage due to it is turned off. Never operate the engine with heat
overheating. See ‘‘Clean Air Intake/Cooling shields or guards removed.
Area’’, page 14.
Engine Speed
High Temperature Sensor NOTE: Do not tamper with the governor setting to
Some engines are equipped with a high temperature increase the maximum engine speed.
sensor mounted in the cooling system. If the safe Overspeed is hazardous and will void the
operating temperature is exceeded, it will either shut engine warranty. The maximum allowable high
off the engine or activate a warning signal, depending idle speed for these engines is 3750 RPM.
on the application.
Maintenance Instructions
If the warning light illuminates or engine kills indicating Maintenance, repair, or replacement of the
excessive operating temperatures: emission control devices and systems, which are
1. Make sure all air intake and cooling surfaces are being done at the customers expense, may be
clean and free of debris. performed by any non-road engine repair
establishment or individual. Warranty repairs must
2. After engine has sufficiently cooled, check the be performed by an authorized Kohler service
coolant level in system to make sure it is not low. outlet.
See ‘‘Checking Coolant Level’’, page 10.

WARNING: Accidental Starts!

Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery
cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
Frequency Maintenance Required
• Fill fuel tank.
Daily or Before • Check oil level.
Starting Engine • Check coolant level.
• Check air cleaner for dirty1, loose, or damaged parts.
• Check air intake screen, radiator, and cooling areas, clean as necessary1.
Every 100 Hours • Clean and check cooling areas2.
• Change oil and oil filter (more frequently under severe conditions).
Annually or • Check spark plug condition and gap.
Every 200 Hours • Replace fuel filter (carbureted engines).
Every 250 Hours • Replace air cleaner element and check inner element1.
Annually or • Replace spark plugs.
Every 500 Hours
Every 2 Years or • Change engine coolant.
Every 1000 Hours
Every 1500 Hours • Replace fuel filter1 (EFI engines),
1
Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2
Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing
shrouds.
8
Check Oil Level NOTE: To prevent extensive engine wear or
The importance of checking and maintaining the proper damage, always maintain the proper oil
oil level in the crankcase cannot be overemphasized. level in the crankcase. Never operate the
Check oil BEFORE EACH USE as follows: engine with the oil level below the “L”
mark or over the “F” mark on the dipstick.
1. Make sure the engine is stopped, level, and is Oil Sentry™
cool so the oil has had time to drain into the sump. Some engines are equipped with an optional Oil
Sentry™ oil pressure switch monitor. If the oil pressure
2. To keep dirt, debris, etc., out of the engine, clean decreases below an acceptable level, the Oil Sentry™
the area around the dipstick before removing it. will either shut off the engine or activate a warning
signal, depending on the application.
3. Remove the dipstick; wipe oil off. Reinsert the
dipstick into the tube and press all the way down. NOTE: Make sure the oil level is checked BEFORE
See Figure 6. EACH USE and is maintained up to the “F”
mark on the dipstick. This includes engines
equipped with Oil Sentry™.

Change Oil and Filter

Change the oil and oil filter every 200 hours or
annually, whichever comes first (more often under
severe conditions). Refill with service class SG, SH, SJ
or higher oil, as specified in the ‘‘Viscosity Grades’’
table (Figure 3) on page 4. Always use a genuine
Kohler oil filter. Use chart below to determine part
number to order.

Oil Filter Part No. Length

12 050 01-S 2-1/2"
Figure 6. Checking Oil Level. 52 050 02-S 3-3/8"

4. Pull the dipstick out and check the oil level. Change the oil while the engine is still warm. The oil
will flow more freely and carry away more impurities.
The oil level should be up to, but not over, the “F” Make sure the engine is level when filling, checking, or
mark on the dipstick. See Figure 7. changing the oil.

Change the oil and oil filter as follows (see Figure 8):

1. To keep dirt, debris, etc., out of the engine, clean

"F" Mark the area around the oil fill cap before removing it.

2. Remove one of the oil drain plugs and the oil fill
Operating cap. Be sure to allow ample time for complete
Range drainage.

3. Before removing the oil filter, clean the area

around the oil filter to keep dirt and debris out of
the engine. Remove the old filter and wipe off the
filter adapter with a clean cloth.
Figure 7. Oil Level Dipstick.
4. Reinstall the drain plug. Make sure it is tightened
to 13.6 N·m (10 ft. lb.) torque.
5. If the level is low, add oil of the proper type, up to
the “F” mark on the dipstick. (Refer to “Oil Type”
5. Place a new replacement filter in a shallow pan
on page 4.) Always check the level with the
with the open end up. Pour new oil, of the proper
dipstick before adding more oil.
type, in through the threaded center hole. Stop
pouring when the oil reaches the bottom of the
threads. Allow a minute or two for the oil to be
absorbed by the filter material.

9
 6. Apply a thin film of clean oil to the rubber gasket • To prevent engine damage, do not use anti-freeze
on the new filter. with stop-leak additive(s) or put other additives in
the cooling systems.
7. Install the new oil filter to the filter adapter. Hand
tighten the filter (clockwise) until the rubber gasket Maintenance
contacts the adapter, then tighten the filter an This engine is liquid-cooled, circulating a mixture of
additional 2/3 to 1 turn. ethylene glycol and water for dependable operation. A
pump is used to circulate the coolant through the
8. Fill the crankcase with new oil of the proper type, system and radiator. A thermostat contained in the
to the ‘‘F’’ mark on the dipstick. Refer to ‘‘Oil Type’’ system assures automatic temperature control and
and ‘‘Check Oil Level’’ on pages 4 and 9. Always rapid warm-up. Maintaining the correct coolant level
check the level with the dipstick before adding and cleaning any debris accumulation from the inlet
more oil. screen and radiator surfaces are critical to ensuring
long life, proper system performance, and preventing
9. Reinstall the oil fill cap and tighten securely by overheating. Check the coolant level in the overflow
turning to the right. reservoir, and clean away any debris accumulation
daily or before each use. At the same time, inspect the
hoses and all connections for signs of leakage.

Servicing
Engine coolant should be changed every 2 years or
every 1000 hours, whichever comes first. When
changing the engine coolant, the system should also
be flushed to remove any contaminants left behind
during draining. Following are recommended
procedures for checking, draining, flushing, and filling
the cooling system.
Oil Drain Plug
Checking Coolant Level
The coolant level should be checked at the overflow
reservoir, located within the formed supports of the fan
shroud. See Figure 9.

Oil Filter

Oil Drain Plug

Figure 8. Oil Drain Plugs and Oil Filter.
Cooling System Maintenance and Service
Important service notes:

• Do not operate the engine without coolant in

the system.

• Do not remove the radiator cap when hot. Engine

coolant is hot and under pressure and can cause Figure 9. Overflow Reservoir Location.
severe burns.
1. Check the coolant level in the overflow reservoir.
• To prevent engine overheating and damage, use Coolant level should be between the ‘‘FULL’’ and
the recommended anti-freeze mixture in the ‘‘ADD’’ marks on the reservoir. See Figure 10. Do
cooling system. not operate the engine with the coolant level
below the ‘‘ADD’’ mark.
• To prevent engine damage, do not pour cold water
into a hot engine. Add coolant to the overflow reservoir as required.
Use equal parts of ethylene glycol and water only
• Cooling system capacity is approximately 2 L (distilled or deionized water is recommended).
(2.18 qt.).
10
 3. If equipped, remove the coolant drain plugs
located on each side of the engine block. See
Figure 11. Drain the coolant into a suitable
container. After the coolant has drained
completely, apply pipe sealant with Teflon®
(Loctite® No. 592 or equivalent), to the threads and
reinstall the plugs. Torque the two plugs to 13.5
N·m (120 in. lb.).

Figure 10. Coolant Levels on Reservoir.

Draining Cooling System Coolant

1. Stop the engine and allow it to cool sufficiently. Drain Plug

2. Check if the radiator is cool to the touch. Slowly

loosen the radiator cap to the first stop and allow
any pressure to bleed off. Then loosen it fully and
remove it. Loosen/remove radiator drain plug and
allow coolant to drain. See Figure 11. Figure 12. Coolant Drain Plug (Some Models).

4. Remove overflow hose from reservoir. Unhook

inboard retainer and slide reservoir out of
supports. See Figure 13. Pour out the contents
and wash or clean as required. Dispose of all the
old coolant properly according to local regulations.

Radiator
Drain Plug

Radiator
Drain Plug

Figure 13. Removing Reservoir.

5. Reinstall the reservoir cap. Do not kink/pinch the

hose.

6. Flush the cooling system (see ‘‘Flushing Cooling

System’’).

Figure 11. Radiator Drain Plug Location. Flushing Cooling System

With system properly drained:

1. Fill the cooling system with clean water and a

cooling system cleaner recommended for
aluminum engines. Follow the directions on the
container.
11
 2. Reinstall and tighten the radiator cap.

3. Start and run the engine for five minutes, or until it

reaches operating temperature. Stop the engine
and allow it to cool.
Inner
4. Drain the cooling system (Refer to "Draining Element
Cooling Systems).

5. Fill the cooling system (see ‘‘Filling Cooling

System’’).
Air Cleaner
Filling Cooling System Element
1. Check the condition of cooling system hoses,
clamps, and associated components. Replace as Figure 14. Air Cleaner Element and Inner Element.
required.
The air cleaner system should be inspected daily or
2. Mix equal parts of ethylene glycol anti-freeze and before starting the engine, for a buildup of dirt and
distilled or deionized water (see ‘‘Coolant debris, or for any damaged or loose components. Keep
Recommendations’’ on page 5). For extremely the system clean and properly secured. Replace any
cold temperature applications or protection damaged air cleaner comments. Do not operate the
outside the limits listed in the ‘‘Coolant engine without the complete air cleaner system
Recommendations’’ Section, refer to the anti- installed and properly secured.
freeze manufacturers instructions on the
container, but do not exceed 70% anti-freeze. NOTE: Operating the engine with loose, damaged, or
missing air intake components can allow
3. Fill the radiator with the coolant mixture. Allow unfiltered air into the engine, causing
coolant to drain into the lower areas. Fill the premature wear and failure.
overflow reservoir to a level between the ‘‘FULL’’
and ‘‘ADD’’ marks. See Figure 9. Reinstall the To Service
radiator and reservoir caps. Every 250 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
4. Start and run the engine for five minutes. Stop the element and check the inner element. Follow these
engine and allow to cool. steps.

5. Recheck the coolant level in the reservoir. Coolant 1. Unhook the two retaining clips and remove the end
level should be between the ‘‘FULL’’ and ‘‘ADD’’ cap from the air cleaner housing. See Figure 15.
marks. Add coolant to reservoir if required. See
Figure 9.

Air Cleaner Element and Inner Element

Service
This engine is equipped with a heavy-duty high density
paper air cleaner element surrounding a canister style
inner element. Cleaning is not recommended, each
element should be replaced when dirty. See Figure 14.

Figure 15. Removing End Cap.

2. Pull the air cleaner element out of the housing.

See Figure 16.

12
 Dust Ejector
Valve

Figure 16. Removing Air Cleaner Element. Figure 18. Air Cleaner Assembly.

3. After the main element is removed, check the Air Intake System and Air Cleaner
condition of the inner element. It should be Components
replaced whenever it appears dirty, typically every
other time the main element is replaced. Clean the Air Cleaner Housing/End Cap Assembly
area around the base of the inner element before Make sure air cleaner housing including the dust
removing it, so dirt does not get into the engine. ejector valve and the end cap is in good condition and
See Figure 17. not cracked. The two retainer clips should positively
lock when cap is installed.

Air Cleaner Hose

Inspect the air cleaner hose to make sure it is not
cracked, split or damaged. Check that the air cleaner
hose is securely clamped to both the air cleaner outlet
and the inlet elbow on the carburetor.

Air Cleaner Mounting Base

Make sure the base is securely fastened to the upper
valve cover screw locations and the screws securing
the clamp bracket for the air cleaner housing are
properly installed and tight.

Figure 17. Removing Inner Element. Breather Tube

Make sure the tube is in good condition and is properly
4. Do not wash the paper element and inner secured to both the breather cover and elbow adapter.
element or use pressurized air, this will damaged
the elements. Replace dirty, bent, or damaged Cooling Fan Assembly, Belt, and Drive Pulleys
elements with new genuine Kohler elements as The cooling fan assembly, used to draw the air in and
required. Handle new elements carefully; do not across the radiator, is attached to a hub and pulley
use if the sealing surfaces are bent or damaged. assembly with sealed ball bearings. It is belt driven by
a lower split pulley attached to the flywheel and
5. Check all parts for wear, cracks, or damage. requires very little service or maintenance. DO NOT
Replace any damaged components. operate the engine without the fan and cooling
system functioning properly, or engine damage will
6. Install the new inner element, Kohler Part No. occur. See Figure 19.
25 083 04-S followed by the outer element, Kohler
Part No. 25 083 01-S. Slide each fully into place in
the air cleaner housing.

7. Reinstall the end cap so the dust ejector valve is

down and secure with the two retaining clips. See
Figure 18.

13
 Every 100 hours of operation (more often under
Cooling
extremely dusty, dirty conditions), thoroughly clean the
Fan
radiator cooling fins, fan assembly, intake system and
Pulley external surfaces of the engine. Make sure all parts are
Assembly reinstalled before starting the engine.
Belt
Clean the cooling fins of the screen and radiator with a
soft brush or blow out, using clean, compressed air.
See Figure 20. Do not use a high pressure washer, to
avoid damaging the cooling fins.
Lower
Split Pulley NOTE: Operating the engine with a restricted air
Assembly Radiator intake screen or radiator, damaged/broken fan
Support assembly, or missing fan shroud will cause
Figure 19. Cooling System Belt Drive (Cover and engine damage due to overheating.
Radiator Removed For Clarity).

1. Inspect the fan for any cracks, damaged/missing

fan blades, and secure mounting.

2. The bearings, within the bearing carrier in the

hub of the pulley, should rotate smoothly, without
roughness, binding, or play/wobble.

3. The v-groove of each pulley (upper and lower)

should not be bent, nicked, or damaged. Pulley
mounting areas and lower pulley shims should be
free of any cracks or elongation. See Figure 20.

Figure 21. Clean Radiator Cooling Fins and Screen.

Ignition System

Carbureted Engines - Use an electronic Capacitive

Discharge (CD) ignition system. Other than periodically
checking/replacing the spark plugs, no maintenance,
timing, or adjustments are necessary or possible with
this system.

EFI Engines - Incorporate a computer-controlled

battery ignition system with individual coils. Other than
periodically checking/replacing the spark plugs, no
Figure 20. Pulley and Drive Belt. maintenance, timing, or adjustments are necessary or
possible with this system.
4. The drive belt is designed and constructed for this
application. Do not use a substitute belt. Check
the overall condition of the belt. If belt is cracked,
damaged, or adequate tension does not exist,
have necessary servicing performed by an
authorized Kohler Engine Service Dealer.

Clean Air Intake/Cooling Areas

To ensure proper air circulation and cooling, make sure
the serviceable screen, radiator cooling fins, fan
assembly and external surfaces of the engine are kept
clean at all times.

Figure 22.
14
In the event starting problems should occur, which are Battery Charging
not corrected by replacing the spark plugs, see your
Kohler Engine Service Dealer for trouble analysis. WARNING: Explosive Gas!
Batteries produce explosive hydrogen gas while being
Check Spark Plugs charged. To prevent a fire or explosion, charge
Annually or every 200 hours of operation (whichever batteries only in well ventilated areas. Keep sparks,
comes first), remove the spark plugs, check condition, open flames, and other sources of ignition away from
and reset the gap or replace with new plugs as the battery at all times. Keep batteries out of the reach
necessary. Every 500 hours of operation replace the of children. Remove all jewelry when servicing
spark plugs. The standard spark plug is a Champion® batteries.
RC14YC (Kohler Part No. 66 132 01-S). Equivalent
alternate brand plugs can also be used. Before disconnecting the negative (-) ground cable,
make sure all switches are OFF. If ON, a spark will
1. Before removing the spark plug, clean the area occur at the ground cable terminal which could cause
around the base of the plug to keep dirt and debris an explosion if hydrogen gas or gasoline vapors are
out of the engine. present.

2. Remove the plug and check its condition. Replace NOTE: Do not apply 12 volt DC to kill terminal of
the plug if worn or reuse is questionable. ignition module.

NOTE: Do not clean the spark plug in a machine Fuel Filter

using abrasive grit. Some grit could Carbureted Engines: Most engines are equipped with
remain in the spark plug and enter the an in-line fuel filter. Periodically inspect the filter and
engine, causing extensive wear and replace every 200 operating hours. Use a genuine
damage. Kohler filter, Part No. 24 050 10-S.

3. Check the gap using a wire feeler gauge. Adjust EFI Engines: A special, high volume, high pressure
the gap to 0.76 mm (0.030 in.) by carefully filter with greater filtration capabilities and internal
bending the ground electrode. See Figure 23. surface area is used. See Figure 24.

4. Reinstall the spark plug into the cylinder head.

Torque the spark plug to 24.4-29.8 N·m
(18-22 ft. lb.). Fuel Filter

Wire Gauge

Spark Plug
Fuel Line

Figure 24. EFI Fuel Filter and Line.

Replacement is recommended every 1500 hours, or

more frequently under extremely dusty or dirty
conditions. When replacement is necessary, always
use genuine Kohler parts.

Fuel Line
EFI Engines: A special fuel line, capable of
Ground
0.76 mm withstanding the high pressure of the EFI fuel system,
Electrode
(0.030 in.) Gap is used (must meet SAE R9 specifications). See Figure
Figure 23. Servicing Spark Plug. 24. If fuel line must be replaced, see your Kohler
Engine Service Dealer.

15
Carburetor Troubleshooting and • Make sure the air cleaner element and precleaner
Adjustments are clean and properly secured.
In compliance with the government emission
standards, the carburetor is calibrated to deliver the • Make sure the air intake screen, blower housing,
correct fuel-to-air mixture to the engine under all and cooling surfaces of radiator are clean and free
operating conditions. The carburetor cannot be of dirt and debris.
adjusted, except for low idle speed (RPM). Carburetor
servicing is to be performed by an authorized Kohler If, after checking the items listed above, the engine is
Engine Service Dealer only. See Figure 25. hard to start, runs roughly, or stalls at low idle speed, it
may be necessary to adjust or service the carburetor.
NOTE: To ensure correct engine operating at
altitudes above 1525 meters (5000ft.), it may Adjust Carburetor
be necessary to have an authorized Kohler Start the engine and run at half throttle for 5 to 10
dealer install a special high-altitude jet kit in minutes to warm up. The engine must be warm before
the carburetor. If a high-altitude kit has been making final settings.
installed, the engine must be reconverted to
the original jet size, before it is operated at Low idle speed (RPM) setting:
lower altitudes, or overheating and engine 1. Place the throttle control into the “idle” or “slow”
damage can result. position. Set the low idle speed to 1200 RPM*
(± 75 RPM) by turning the low idle speed adjusting
screw (cable w/knob on some models) in or out.
Check the speed using a tachometer.

*NOTE: The actual low idle speed depends on the

application – refer to equipment
manufacturers recommendations. The
standard low idle speed is 1200 RPM.

2. If proper operation is not restored after adjusting

the low idle speed, carburetor servicing by an
authorized Kohler Engine Service Dealer may be
Knob required.
Idle Speed Adj.

Figure 25. Carburetor and Idle Speed Adjustment. Electronic Fuel Injection (EFI) System
The EFI system is a complete, electronically-controlled
Troubleshooting fuel management system, designed to deliver a
If engine troubles are experienced that appear to be precisely controlled fuel flow under all operating
fuel system related, check the following areas before conditions. The electronic control unit (ECU), the
adjusting the carburetor. ‘‘brain’’ of the system, automatically adjusts fuel
• Make sure the fuel tank is filled with clean, fresh delivery and ignition timing based upon load, speed,
gasoline. operating temperature, and exhaust emission levels.
The low idle speed is the only manual adjustment
• Make sure the fuel tank cap vent is not blocked possible.
and that it is operating properly.
The ECU continuously monitors operation of the EFI
• If the fuel tank is equipped with a shut-off valve, system. If it detects a problem or fault within the
make sure it is open. system, it will illuminate the malfunction indicator light
(MIL), which is mounted in view of the operator. This is
• If the engine is equipped with an in-line fuel filter, a signal that normal, programmed operation has been
make sure it is clean. Replace the filter if it is dirty affected, and service by an authorized Kohler Engine
or restricted. Dealer is required.

• Make sure fuel is reaching the carburetor. This NOTE: The EFI system requires a rather complex
includes checking the fuel lines and fuel pump for wiring harness to carry the electrical signals
restrictions or faulty components, replace as between the sensors and the ECU. Do not
necessary. spray water at the wiring harness or any of the
electrical components, especially the ECU, as
• Make sure cooling system is filled to the proper level. it could cause malfunction, damage, or failure.

16
Troubleshooting *NOTE: The actual low idle speed depends on the
If the MIL comes on, or the engine becomes hard to application -- refer to equipment
start, runs roughly, or stalls at low idle speed, initial manufacturer's recommendations.
checks should be made in the following areas:
When an EFI engine is started cold, the ECU will be
• Make sure the fuel tank is filled with clean, fresh using internal programming for cold running, and the
gasoline, and shut-off valve (if so equipped) is idle speed may vary from the manual setting. Do not
opened completely. attempt to perform any readjustment during this
‘‘warm-up’’ period.
• Make sure fuel tank vent cap is not blocked and it
is operating properly. If adjustment is to be made, the engine must be at
operating temperature, air cleaner in place, and check
• Make sure the air cleaner element and precleaner engine light must be off (no fault codes present).
are clean and all components are properly
secured. Clean or replace as necessary. 1. Start the engine and run at half throttle for 5 to 10
minutes to warm up.
• Make sure the proper fuel filter is being used, and
it is clean and unobstructed. Replace filter only 2. Place the throttle control into the ‘‘idle’’ or ‘‘slow’’
with genuine Kohler parts. position.

• Make sure all connections to sensors, ECU, and 3. Turn the low idle speed adjusting screw in or out
fuel injectors are properly secured. and check RPM with a tachometer. See Figure 26.

• Make sure a good 12 volt battery is being used

and is fully charged.

If these checks do not correct the problem, or the MIL

remains on, further diagnosis and servicing by an
authorized Kohler Engine Dealer is necessary.

Adjustment – EFI Throttle Body

Low Idle Speed (RPM) is the only adjustment that can

be made. All other fuel calibrations are permanently
preset and controlled by the ECU. The standard low
idle speed is 1500 RPM* (+ 75 RPM).
Figure 26. EFI Throttle Body Manifold.

Troubleshooting
When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered.
For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles
are listed in the following table.

Do not attempt to service or replace major engine components, or any items that require special timing or
adjustment procedures. Have your Kohler Engine Service Dealer do this work.

Possible Cause No Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty
Problem Fuel Fuel Fuel Line/SystemGrass Screen Oil Level Overloaded Cleaner Spark Plug
Will Not Start • • • • • • •
Hard Starting • • • • • •
Stops Suddenly • • • • • • •
Lacks Power • • • • • • •
Operates Erratically • • • • • •
Knocks or Pings • • • • •
Skips or Misfires • • • • •
Backfires • • • • •
Overheats • • • • • •
High Fuel Consumption • • •

17
Storage 5. Remove the spark plugs. Add one tablespoon of
If the engine will be out of service for two months or engine oil into each spark plug hole. Install plugs,
more, use the following storage procedure: but do not connect the plug leads. Crank the
engine two or three revolutions.
1. Clean the exterior surfaces of the radiator and
engine. On EFI engines, avoid spraying water at 6. On units with EFI engines, disconnect the
the wiring harness or any of the electrical negative (-) battery cable or use a "battery minder"
components. trickle charger while the unit is in storage.

2. Change the oil and filter while the engine is still 7. Store the engine in a clean, dry place.
warm from operation. See “Change Oil and Filter”
on page 9. Parts Ordering
The engine Specification, Model, and Serial Numbers
3. The coolant (anti-freeze) mixture should be in are required when ordering replacement parts from
good condition and tested to guard against your Kohler Engine Service Dealer. These numbers are
freezing in cold temperatures. The recommended found on the identification plate which is affixed to the
50/50 mixture will normally provide protection engine shrouding. Include letter suffixes if there are
down to temperatures of -37°C (-34°F). If storage any. See “Engine Identification Numbers” on page 5.
temperatures will fall below this, the cooling
system should be drained completely. A note Always insist on genuine Kohler parts. All genuine
should then be attached to the equipment and/or Kohler parts meet strict standards for fit, reliability, and
engine as a reminder to refill the cooling system performance.
before starting.
Major Repair
4. The fuel system must be completely emptied, or Major repair information is available in Kohler Engine
the gasoline must be treated with a stabilizer to Service Manuals. However, major repair generally
prevent deterioration. If you choose to use a requires the attention of a trained mechanic and the
stabilizer, follow the manufacturers use of special tools and equipment. Your Kohler
recommendations, and add the correct amount for Engine Service Dealer has the facilities, training, and
the capacity of the fuel system. Fill the fuel tank genuine Kohler replacement parts necessary to
with clean, fresh gasoline. Run the engine for 2-3 perform this service. For Sales & Service assistance
minutes to get stabilized fuel into the carburetor. call 1-800-544-2444 (U.S. & Canada) or contact your
Close fuel shut-off valve when unit is being stored Kohler Engine Dealer or Service Distributor, they're in
or transported. the Yellow Pages under Engines-Gasoline.

To empty the system, run the engine until the tank

and system are empty.

Specifications
Model: ........................................................
LH630/640 ............... LH685/690 ................ LH755 ....................... LH775
Bore: ..................................... in. (mm) ......
3.03 (77) .................. 3.15 (80) ................... 3.3 (83) ..................... 3.3 (83)
Stroke: ................................... in. (mm) ......
2.64 (67) .................. 2.64 (67) ................... 2.7 (69) ..................... 2.7 (69)
Displacement: ....................... in3 (cm3) ...... 38.1 (624) ................ 41.1 (674) ................. 45.6 (748) ................. 45.6 (748)
Power (Max. @3600 RPM): .. HP (kW) ...... 22* (16.4) ................. 25* (18.6) .................. 28* (20.9) .................. 31* (23.1)*
24* (17.9) ................. 26* (19.4)
Peak Torque: ........ N.m (ft. lb.) @RPM ...... 35.4 (48)@2200 ....... 40.1 (54.4)@2200 .... 45.4 (61.6)@2800 .... 47.7 (64.7)@2400
38.3 (51.9)@2400 .... 42.9 (58.2)@2400
Compression Ratio: ................................... 8.5:1 ......................... 8.5:1 .......................... 8.7:1 ......................... 8.7:1
Dry Weight: ............................. lb. (kg) ...... 114 (51.7) ................. 114 (51.7) ................. 114 (51.7) ................. 114 (51.7)
Coolant/Anti-Freeze: ........... U.S. qts. (L) Equal Parts of Water and Ethylene Glycol 2.18 (2.0)
Lubrication: ............................................ Full Pressure w/full Flow Filter
Oil Capacity (w/filter) - approximate,
determined by oil filter used: 1.6-1.8 L (1.7-1.9 U.S. qt.)

Exhaust Emission Control System for models LH630, LH640, LH685, LH690, and LH755 is EM.
Exhaust Emission Control System for models LH775 is EM, O2S, ECM, MFI.

* Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940. Actual engine horsepower is
lower and affected by, but not limited to, accessories (air cleaner, exhaust, charging, cooling, fuel pump, etc.), application,
engine speed and ambient operating conditions (temperature, humidity, and altitude). Kohler reserves the right to change
product specifications, designs and equipment without notice and without incurring obligation.

18
LIMITED 3 YEAR KOHLER AEGIS® ENGINE WARRANTY
Kohler Co. warrants to the original retail consumer that each new KOHLER AEGIS® engine sold by Kohler Co. will be free from
manufacturing defects in materials or workmanship in normal residential service for a period of three (3) years from date of purchase,
provided it is operated and maintained in accordance with Kohler Co.’s instructions and manuals.

Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044,
or at a service facility designated by us of such parts as inspection shall disclose to have been defective.

EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers,
which are warranted for two (2) years.

This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide
reasonable and necessary maintenance.

The following items are not covered by this warranty:

Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by
Kohler Co. These are subject to the warranties, if any, of their manufacturers.

KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement
of defective parts.

IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor
is any one authorized to make any on our behalf.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

TO OBTAIN WARRANTY SERVICE:

Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website,
www.kohlerengines.com, and click on SALES AND SERVICE to use the locator function, consult your Yellow Pages or telephone
1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
KOHLER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD AND CLASS 1 LSI ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain
the Federal and California Emission Control Systems Warranty on your off-road equipment engine. For California, small off-road
engines produced in 1995 and later, and Class 1 LSI (Large Spark Ignited engines at or below 1.0 liter) produced in 2002 and later,
must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and later model year
engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must be free
from defects in materials and workmanship, which cause it to fail to conform with U.S. EPA standards for the first two years of engine
use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of
time listed above, provided there has been no abuse, neglect or improper maintenance.

The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic
converter. Also included are the hoses, belts and connectors and other emission related assemblies.

Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is
performed at an authorized dealer), parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

Small off-road engines produced in 1995 or later, and Class 1 LSI engines produced in 2002 and later, are warranted for two years in
California. In other states, 1997 and later model year engines are warranted for two years. If any emission related part on the engine is
defective, the part will be repaired or replaced by Kohler Co. free of charge.

OWNER’S WARRANTY RESPONSIBILITIES

(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co.
recommends that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the
lack of receipts or for your failure to assure that all scheduled maintenance was performed.

(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.

(c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call
1-800-544-2444 or access our website at: www.kohlerengines.com, for the names of the nearest service centers. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days. Continued on next page.
19
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an
Engine Service representative.

COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at
the time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that
the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a
period of two years.

Small off-road engines produced in 1995 or later, and Class 1 LSI engines produced in 2002 and later, are warranted for two years in
California. For 1997 and later model years, EPA requires manufacturers to warrant engines for two years in all other states. These
warranty periods will begin on the date the engine is purchased by the initial purchaser. If any emission related part on the engine is
defective, Kohler Co. will replace the part at no cost to the owner. Kohler Co. is liable for damages to other engine components caused
by the failure of a warranted part still under warranty.

Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at
an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.

Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may
require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:

• Carburetor assembly • Ignition module(s) with high tension lead

• Throttle body (EFI Systems) • Spark advance module (if equipped)
• Catalytic muffler (if equipped) • Oxygen, speed, throttle position, and temperature sensors (if equipped)
• Fuel metering valve (if equipped) • Electronic control unit (if equipped)
• Crankcase breather • Fuel injectors (EFI Systems)
• Fuel pressure regulator (EFI Systems) • Air filter, fuel filter, and spark plugs (only to first scheduled replacement point)

LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:

(a) repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements
not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,

(b) replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled
replacement point,

(c) consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,

(d) diagnosis and inspection fees that do not result in eligible warranty service being performed, and

(e) any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.

MAINTENANCE AND REPAIR REQUIREMENTS

The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering
the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the
maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine
has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or
failure to keep maintenance records.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or
individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that is
equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations
of the engine manufacturer.

FORM NO.: 66 590 02

ISSUED: 12/04
REVISED: 1/05
MAILED:
LITHO IN U.S.A.

FOR SALES AND SERVICE INFORMATION

IN U.S. AND CANADA, CALL 1-800-544-2444

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

INSTALLATION OPERATION MAINTENANCE
BLOWERS EXHAUSTERS COMPRESSORS

ROOTS
™

US $3.00, Canada $4.50

UNIVERSAL RAI & RAM ® ™

SERIES

CONTENTS

INFORMATION SUMMARY . . . . . . . . . . . 1 TROUBLESHOOTING . . . . . . . . . . . . . . . 9

SAFETY PRECAUTIONS . . . . . . . . . . . . 2 MAINTENANCE/REPLACEMENTS
UNIVERSAL RAI® SERIES BLOWERS ...........10
OPERATING LIMITATIONS . . . . . . . . . . . 2
RAM™ SERIES BLOWERS .........................14
INSTALLATION . . . . . . . . . . . . . . . . . . . 3 FIGURES ...........................................18
LUBRICATION . . . . . . . . . . . . . . . . . . . 6 TABLES .............................................22
OPERATION . . . . . . . . . . . . . . . . . . . . 7 ASSEMBLY DRAWINGS .........................26

OPERATING CHARACTERISTICS ..............8 PARTS LIST .......................................31

DO THESE THINGS TO GET THE MOST FROM YOUR ROOTS™ BLOWER

❏ Check shipment for damage. If found, file claim ❏ In event of trouble during installation or operation,
with carrier and notify ROOTS. do not attempt repairs of ROOTS furnished
equipment. Notify ROOTS, giving all nameplate
❏ Unpack shipment carefully, and check contents information plus an outline of operating conditions
against Packing List. Notify ROOTS if a
and a description of the trouble. Unauthorized
shortage appears.
attempts at equipment repair may void ROOTS
❏ Store in a clean, dry location until ready for warranty.
installation. Lift by methods discussed under
INSTALLATION to avoid straining or distorting the
❏ Units out of warranty may be repaired or adjusted
by the owner. It is recommended that such work be
equipment. Keep covers on all openings. Protect
limited to the operations described in this manual,
against weather and corrosion if outdoor storage
using ROOTS™ parts. Good inspection and
is necessary.
maintenance practices should reduce the need
❏ Read OPERATING LIMITATIONS and for repairs.
INSTALLATION sections in this manual and plan
NOTE: Information in this manual is correct as of the
the complete installation.
date of publication. ROOTS reserves the right to make
❏ Provide for adequate safeguards against accidents design or material changes without notice, and without
to persons working on or near the equipment during obligation to make similar changes on equipment of
both installation and operation. See SAFETY prior manufacture.
PRECAUTIONS.
For your nearest ROOTS Office, dial our Customer
❏ Install all equipment correctly. Foundation design Service Hot Line toll free; 1 877 363 ROOT(S) (7668)
must be adequate and piping carefully done. Use or direct 281-966-4700.
recommended accessories for operating protection.
❏ Make sure both driving and driven equipment is
correctly lubricated before start-up.
See LUBRICATION.
❏ Read starting check points under OPERATION. Run
equipment briefly to check for installation errors and
make corrections. Follow with a trial run under
normal operating conditions.

IRB-180-102
Rev. 2.04
ROOTS™ products are sold subject
to the current General terms of
Sale, GTS-5001 and Warranty
Policy WP-5020. Copies are
available upon request.
Contact your local ROOTS Office
or ROOTS Customer Service
Hot Line 1.877.363.ROOT(S) (7668).
SAFETY PRECAUTIONS
It is important that all personnel observe safety • Stay clear of open inlet piping (suction area) of
precautions to minimize the chances of injury. pressure blowers, and the open discharge blast
Among many considerations, the following should from vacuum blowers.
be particularly noted:
• Stay clear of the blast from pressure relief valves
• Blower casing and associated piping or accessories and the suction area of vacuum relief valves.
may become hot enough to cause major skin burns
on contact. • Use proper care and good procedures in handling,
lifting, installing, operating and maintaining the
• Internal and external rotating parts of the blower equipment.
and driving equipment can produce serious physical
injuries. Do not reach into any opening in the • Casing pressure must not exceed 25 PSI
blower while it is operating, or while subject to (1725 mbar) gauge. Do not pressurize vented
accidental starting. Protect external moving parts cavities from an external source, nor restrict the
with adequate guards. vents without first consulting ROOTS.

• Disconnect power before doing any work, and avoid • Do not use air blowers on explosive or
bypassing or rendering inoperative any safety or hazardous gases.
protective devices. • Other potential hazards to safety may also be
• If blower is operated with piping disconnected, associated with operation of this equipment. All
place a strong coarse screen over the inlet and personnel working in or passing through the area
avoid standing in the discharge air stream. should be trained to exercise adequate general
CAUTION: Never cover the blower inlet with safety precautions.
your hand or other part of body.

OPERATING LIMITATIONS
A ROOTS™ blower or exhauster must be operated • Measured temperature rise must not exceed listed
within certain approved limiting conditions to enable values when the inlet is at ambient temperature.
continued satisfactory performance. Warranty is Ambient is considered as the general temperature
contingent on such operation. of the space around the unit. This is not outdoor
temperature unless the unit is installed outdoors.
Maximum limits for pressure, temperature and speed
are specified in TABLE 1 for various models & sizes • If inlet temperature is higher than ambient, the
of blowers & exhausters. These limits apply to all units listed allowable temperature rise values must be
of normal construction, when operated under reduced by 2/3 of the difference between the
standard atmospheric conditions. Be sure to arrange actual measured inlet temperature and the
connections or taps for thermometers and pressure ambient temperature.
or vacuum gauges at or near the inlet and discharge
connections of the unit. These, along with a good • The average of the inlet and discharge temperature
tachometer, will enable periodic checks of must not exceed 250°F. (121°C).
operating conditions. SPEED – These blowers & exhausters may
PRESSURE – The pressure rise, between inlet and be operated at speeds up to the maximum listed for
discharge, must not exceed the figure listed for the the various frame sizes. They may be direct coupled
specific unit frame size concerned. Also, in any system to suitable constant speed drivers if pressure/tempera-
where the unit inlet is at a positive pressure above ture conditions are also within limits. At low speeds,
atmosphere a maximum case rating of 25 PSI gauge excessive temperature rise may be a limiting factor.
(1725 mbar) should not be exceeded without first Special Note: The listed maximum allowable tempera-
consulting the ROOTS. Never should the maximum ture rise for any particular blower & exhauster may
allowable differential pressure be exceeded. occur well before its maximum pressure or vacuum
On vacuum service, with the discharge to atmospheric rating is reached. This may occur at high altitude, low
pressure, the inlet suction or vacuum must not be vacuum or at very low speed. The units’ operating limit
greater than values listed for the specific frame size. is always determined by the maximum rating reached
first. It can be any one of the three: Pressure,
TEMPERATURE – Blower & exhauster frame sizes are Temperature or Speed.
approved only for installations where the following
temperature limitations can be maintained in service:

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 2
INSTALLATION
ROOTS™ blowers & exhausters are treated after factory Supervision of the installation by a ROOTS Service
assembly to protect against normal atmospheric Engineer is not usually required for these units.
corrosion. The maximum period of internal protection Workmen with experience in installing light to
is considered to be one year under average conditions, medium weight machinery should be able to produce
if shipping plugs & seals are not removed. Protection satisfactory results. Handling of the equipment needs
against chemical or salt water atmosphere is not to be accomplished with care, and in compliance with
provided. Avoid opening the unit until ready to start safe practices. Unit mounting must be solid, without
installation, as corrosion protection will be quickly lost strain or twist, and air piping must be clean, accurately
due to evaporation. aligned and properly connected.
If there is to be an extended period between installa- Bare-shaft Units: Two methods are used to handle
tion and start up, the following steps should be taken a unit without base. One is to use lifting lugs bolted
to ensure corrosion protection. into the top of the unit headplates. Test them first for
tightness and fractures by tapping with a hammer.
❏ Coat internals of cylinder, gearbox and drive end In lifting, keep the direction of cable pull on these
bearing reservoir with Nox-Rust VCI-10 or bolts as nearly vertical as possible. If lifting lugs are
equivalent. Repeat once a year or as conditions not available, lifting slings may be passed under the
may require. Nox-Rust VCI-10 is petroleum cylinder adjacent to the headplates. Either method
soluble and does not have to be removed before prevents strain on the extended drive shaft.
lubricating. It may be obtained from Daubert
Chemical Co., 2000 Spring Rd., Oak Brook, Ill. Packaged Units: When the unit is furnished mounted
60521. on a baseplate, with or without a driver, use of lifting
slings passing under the base flanges is required.
❏ Paint shaft extension, inlet and discharge flanges, Arrange these slings so that no strains are placed on
and all other exposed surfaces with Nox-Rust the unit casing or mounting feet, or on any mounted
X-110 or equivalent. accessory equipment. DO NOT use the lifting lugs in
❏ Seal inlet, discharge, and vent openings. It is not the top of the unit headplates.
recommended that the unit be set in place, piped Before starting the installation, remove plugs, covers
to the system, and allowed to remain idle for or seals from unit inlet and discharge connections
extended periods. If any part is left open to the and inspect the interior completely for foreign material.
atmosphere, the Nox-Rust VCI-10 vapor will If cleaning is required, finish by washing the cylinder,
escape and lose its effectiveness. headplates and impeller thoroughly with a petroleum
❏ Protect units from excessive vibration solvent. Turn the drive shaft by hand to make sure
during storage. that the impellers turn freely at all points. Anti-rust
compound on the connection flanges and drive
❏ Rotate shaft three or four revolutions every shaft extension may also be removed at this time
two weeks. with the same solvent. Cover the flanges until ready
❏ Prior to start up, remove flange covers on both to connect piping.
inlet and discharge and inspect internals to insure
absence of rust. Check all internal clearances. Mounting
Also, at this time, remove gearbox and drive end Care will pay dividends when arranging the unit
bearing cover and inspect gear teeth and bearings mounting. This is especially true when the unit is
for rust. a “bare-shaft” unit furnished without a baseplate.
The convenient procedure may be to mount such a
Because of the completely enclosed unit design, unit directly on a floor or small concrete pad, but
location of the installation is generally not a critical this generally produces the least satisfactory results.
matter. A clean, dry and protected indoor location is It definitely causes the most problems in leveling and
preferred. However, an outdoor location will normally alignment and may result in a “Soft Foot” condition.
give satisfactory service. Important requirements are Correct soft foot before operation to avoid unnecessary
that the correct grade of lubricating oil be provided for loading on the casing and bearings. Direct use of building
expected operating temperatures, and that the unit be structural framing members is not recommended.
located so that routine checking and servicing can be
performed conveniently. Proper care in locating driver For blowers without a base, it is recommended that a
and accessory equipment must also be considered. well anchored and carefully leveled steel or cast iron
mounting plate be provided. The plate should be at

3
least 1 inch (25 mm) thick, with its top surface Table 1 for allowable speeds of various unit sizes.
machined flat, and large enough to provide leveling A flexible type coupling should always be used to
areas at one side and one end after the unit is mount- connect the driver and unit shafts.
ed. It should have properly sized studs or tapped holes
located to match the unit foot drilling. Proper use of a Coupling halves must be accurately aligned, and a
high quality machinist’s level is necessary for adequate sufficient gap between shaft ends provided so that side
installation. strains and end thrust on either shaft are avoided or
minimized. This will require considerable care in the
With the mounting plate in place and leveled, set the mounting of the driver. The two shafts must be in as
unit on it without bolting and check for rocking. If it is near perfect alignment in all directions as possible, and
not solid, determine the total thickness of shims the gap must be established with the motor armature
required under one foot to stop rocking. Place half of on its electrical center if end-play exists.
this under each of the diagonally-opposite short feet,
and tighten the mounting studs or screws. Rotate the The following requirements of a good installation are
drive shaft to make sure the impellers turn freely. If the recommended. Coupling halves must be fitted to the
unit is to be direct coupled to a driving motor, consider two shafts with a line to line thru .001” interference fit.
the height of the motor shaft and the necessity for it to Coupling halves must be warmed up per coupling
be aligned very accurately with the unit shaft. Best unit manufacturer’s recommendations. Maximum deviation
arrangement is directly bolted to the mounting plate in offset alignment of the shafts should not exceed
while the driver is on shims of at least 1/8 inch (3mm) .005” (.13 mm) total indicator reading, taken on the two
thickness. This allows adjustment of motor position in coupling hubs. Maximum deviation from parallel of the
final shaft alignment by varying the shim thickness. inside coupling faces should not exceed .001” (.03
mm) when checked at six points around the coupling.
Aligning When a unit is BELT DRIVEN, the proper selection of
When unit and driver are factory mounted on a sheave diameters will result in the required unit speed.
common baseplate, the assembly will have been This flexibility can lead to operating temperature prob-
properly aligned and is to be treated as a unit for lems caused by unit speed being too low. Make sure
leveling purposes. Satisfactory installation can be the drive speed selected is within the allowable range
obtained by setting the baseplate on a concrete slab for the specific unit size, as specified under Table 1.
that is rigid and free of vibration, and leveling the top
of the base carefully in two directions so that it is free Belt drive arrangements usually employ two or more
of twist. The slab must be provided with suitable anchor V-belts running in grooved sheaves. Installation of the
bolts. The use of grouting under and partly inside the driver is less critical than for direct coupling, but its
leveled and shimmed base is recommended. shaft must be level and parallel with the unit shaft.
The driver should be mounted on the inlet side of
It is possible for a base-mounted assembly to become a vertical unit (horizontal piping) and on the side
twisted during shipment, thus disturbing the original nearest to the shaft on a horizontal unit. The driver
alignment. For this reason, make the following checks must also be mounted on an adjustable base to permit
after the base has been leveled and bolted down. installing, adjusting and removing the V-belts. To
Disconnect the drive and rotate the unit shaft by hand. position the driver correctly, both sheaves need to be
It should turn freely at all points. Loosen the unit foot mounted on their shafts and the nominal shaft center
hold-down screws and determine whether all feet are distance known for the belt lengths to be used.
evenly in contact with the base. If not, insert shims as
required and again check for free impeller rotation. Install the unit sheave so that its inner hub face is not
Finally, if unit is direct coupled to the driver, check more than 1/4 inch (6mm) from the drive end cover.
shaft and coupling alignment carefully and make any See page 18 for minimum sheave diameter and
necessary corrections. maximum sheave width. The shaft fit should be such
that the sheave can be worked into place by hand or
In planning the installation, and before setting the unit, by very light tapping. A tight or driving fit can damage
consider how piping arrangements are dictated by the a bearing, and may cause internal unit damage by
unit design and assembly. Drive shaft rotation must be forcing the impeller out of its normal operating position.
established accordingly and is indicated by an arrow A loose fit or wobbly sheave will cause vibration, and
near the shaft. may result in shaft breakage.
Typical arrangement on vertical units has the drive CAUTION: Couplings as well as sheave bushings
shaft at the top with counterclockwise rotation and must have a slight slide fit with the unit shaft such
discharge to the left. Horizontal units are typically that they can be installed in place by hand. Any force
arranged with the drive shaft at the left with counter- used to install them could change unit end clearance
clockwise rotation and discharge down. See Figure 3 resulting in unit damage. If interference fit is desired for
and 4 for other various unit arrangements and the coupling, the coupling hub should be heated and
possible conversions. shrunk on the shaft. For engine drives, use “locktite”
between the coupling hubs and the shafts and on the
When a unit is DIRECT COUPLED to its driver, the
threads of the coupling set screws.
driver RPM must be selected or governed so as not to
exceed the maximum speed rating of the unit. Refer to

For your nearest Roots Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 4
The driver sheave should also be mounted as close to Figure 2 represents an installation with all accessory
its bearing as possible, and again should fit the shaft items that might be required under various operating
correctly. Position the driver on its adjustable base so conditions. Inlet piping should be completely free of
that 2/3 of the total movement is available in the valves or other restrictions. When a shut-off valve can
direction away from the unit, and mount the assembly not be avoided, make sure a full size vacuum relief is
so that the face of the sheave is accurately in line with installed nearest the unit inlet. This will protect against
the unit sheave. This position minimizes belt wear, and unit overload caused by accidental closing of the
allows sufficient adjustment for both installing and shut-off valve.
tightening the belts. After belts are installed, adjust
their tension in accordance with the manufacturer’s Need for an inlet silencer will depend on unit speed and
instructions. However, only enough tension should be pressure, as well as sound-level requirements in the
applied to prevent slippage when the unit is operating general surroundings. An inlet filter is recommended,
under load. Excessive tightening can lead to early especially in dusty or sandy locations. A discharge
bearing failures or shaft breakage. silencer is also normally suggested, even though
Whispair units operate at generally lower noise levels
Before operating the drive under power to check initial than conventional rotary blowers. Specific recommen-
belt tension, first remove covers from the unit dations on silencing can be obtained from ROOTS.
connections. Make sure the interior is still clean, then
rotate the shaft by hand. Place a coarse screen over Discharge piping requires a pressure relief valve, and
the inlet connection to prevent anything being drawn should include a manual unloading valve to permit
into the unit while it is operating, and avoid standing starting the unit under no-load conditions. Reliable
in line with the discharge opening. Put oil in the sumps pressure/vacuum gauges and good thermometers at
per instructions under LUBRICATION. both inlet and discharge are recommended to allow
making the important checks on unit operating condi-
Piping tions. The back-pressure regulator shown in Figure 2
is useful mainly when volume demands vary while the
Before connecting piping, remove any remaining
unit operates at constant output. If demand is constant,
anti-rust compound from Unit connections. Clean pipe
but somewhat lower than the unit output, excess may
should be no smaller than unit connections. In addition,
be blown off through the manual unloading valve.
make sure it is free of scale, cuttings, weld beads, or
foreign material of any kind. To further guard against In multiple unit installations where two or more units
damage to the unit, especially when an inlet filter is not operate with a common header, use of check valves
used, install a substantial screen of 16 mesh backed is mandatory. These should be of a direct acting or free
with hardware cloth at or near the inlet connections. swinging type, with one valve located in each line
Make provisions to clean this screen of collected between the unit and header. Properly installed, they
debris after a few hours of operation. It should be will protect against damage from reverse rotation
removed when its usefulness has ended, as the wire caused by air and material back-flow through an
will eventually deteriorate and small pieces going into idle unit.
the unit may cause serious damage.
After piping is completed, and before applying power,
Pipe flanges or male threads must meet the unit rotate the drive shaft by hand again. If it does not move
connections accurately and squarely. DO NOT attempt with uniform freedom, look for uneven mounting, piping
to correct misalignment by springing or cramping the strain, excessive belt tension or coupling misalignment.
pipe. In most cases this will distort the unit casing and
cause impeller rubbing. In severe cases it can prevent DO NOT operate the unit at this time unless it has
operation or result in a broken drive shaft. For similar been lubricated per instructions.
reasons, piping should be supported near the unit to
eliminate dead weight strains. Also, if pipe expansion is
likely to occur from temperature change, installation of
flexible connectors or expansion joints is advisable.

5
LUBRICATION
LUBRICATION: For Units with a Grease Lubricated Table 3. Use a good grade of industrial type non-
Drive End detergent, rust inhibiting, anti-foaming oil and of correct
viscosity per Table 2. *ROOTS™ synthetic oil (ROOTS
A simple but very effective lubrication system is P/N 813-106-) is highly recommended. ROOTS™ does
employed on the drive shaft end bearings. Hydraulic NOT recommend automotive type lubricants, as they
pressure relief fittings are provided to vent any excess are not formulated with the properties mentioned above.
grease, preventing pressure build-up on the seals.
A restriction plug and metering orifice prevent loss of The oil level should not fall below the middle of the site
lubricant from initial surges in lubricant pressure but gauge or overflow plug on URAI (ref. pg.20) when the
permit venting excess lubricant under steadily rising blower is idle. It may rise or fall on the gauge during
pressures. operation, to an extent depending somewhat on oil
temperature and blower speed.
When servicing drive end bearings, use a NLGI #2
premium grade aluminum complex* grease with 300°F Proper lubrication is usually the most important single
(149°C) service temperature and moisture resistance consideration in obtaining maximum service life and
and good mechanical stability. Using a pressure gun, satisfactory operation from the unit. Unless operating
slowly force new lubricant into each drive end bearing conditions are quite severe, a weekly check of oil level
housing until traces of clean grease comes out of and necessary addition of lubricant should be suffi-
the relief fitting. cient. During the first week of operation, check the oil
levels in the oil sumps about once a day, and watch
After a long shutdown, it is recommended that the for leaks. Replenish as necessary. Thereafter, an
grease fittings be removed, the old grease flushed out occasional check should be sufficient. It is recommended
with kerosene or #10 lubricating oil, drained thoroughly, that the oil be changed after initial 100 hours of opera-
and bearings refilled with new grease. Be sure grease tion. Frequent oil changing is not necessary unless
relief fittings are reinstalled. Grease should be added the blower is operated in a very dusty location.
using a hand operated grease gun to the drive end
bearings at varying time intervals depending on duty Normal life expectancy of petroleum based oils is about
cycle and RPM. Table 4 has been prepared as a 2000 hours with an oil temperature of about 180°F
general greasing schedule guide based on average (82°C). As the oil temperature increases by increments
operating conditions. More frequent intervals may be of 15-18°F (8°C - 10°C), the life is reduced by half.
necessary depending on the grease operating Example: Oil temperatures of 210-216°F (99°C - 102°C)
temperature and unusual circumstances. *ROOTS™ will produce life expectancy of 1/4 or 500 hours.
synthetic grease (ROOTS P/N T20019-) is highly Therefore, it is considered normal to have oil change
recommended. periods of 500 hours with petroleum based oils.
LUBRICATION: For Units with Splash Lubrication Normal life expectancy of ROOTS™ Synthetic Oil is
on Both Ends about 4000 to 6000 hours with an oil temperature of
about 180°F (82°C). As the oil temperature increases
Bearings and oil seals are lubricated by the action of by increments of 15-18°F (8°C - 10°C), the life is
the timing gears or oil slingers which dip into the main reduced by half. Example: Oil temperatures of 210-
oil sumps causing oil to splash directly on gears and 216°F (99°C - 102°C) will produce life expectancy of
into bearings and seals. A drain port is provided below 1/4 or 1000 to 1500 hours. Therefore, it is considered
each bearing to prevent an excessive amount of oil in normal to have oil change periods of 1000-1500 hours
the bearings. Seals located inboard of the bearings in with ROOTS™ Synthetic Oil.
each headplate effectively retain oil within the sumps.
Any small leakage that may occur should the seals NOTE: To estimate oil temperature, multiply the dis-
wear passes into a cavity in each vented headplate charge temperature of the blower by 0.80. Example: if
and is drained downward. the discharge air temperature of the blower is 200° F,
it is estimated that the oil temperature is 160° F.
Oil sumps on each end of the blower are filled by
removing top vent plugs, Item (21), and filling until oil *ROOTS™ Synthetic Oil & Grease is superior in performance to
reaches the middle of the oil level sight gauge, Item petroleum based products. It has high oxidation stability, excellent
(37), or the overflow plug. corrosion protection, extremely high film strength and low coefficient
of friction. Typical oil change intervals are increased 2-3 times over
Initial filling of the sumps should be accomplished with petroleum based lubricants. Also, ROOTS™ Synthetic Oil is 100%
the blower not operating, in order to obtain the correct compatible with petroleum based oils. Simply drain the oil in the
oil level. Approximate oil quantities required for blowers blower and refill the reservoirs with ROOTS™ Synthetic Oil to maintain
of the various models and configurations are listed in optimum performance of your ROOTS™ blower.

NOTE: Lithium based greases are not compatible with the

ROOTS™ synthetic grease used during manufacturing.

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 6
OPERATION
Before operating a blower under power for the first instruments will show whether pressure or temperature
time, recheck the unit and the installation thoroughly ratings of the blower are being exceeded.
to reduce the likelihood of avoidable troubles. Use the
During the final run, check operating conditions
following procedure check list as a guide, but consider
frequently and observe the oil levels at reasonable
any other special conditions in the installation.
intervals. If excessive noise or local heating develops,
❏ Be certain that no bolts, tools, rags, or debris have shut down immediately and determine the cause. If
been left in the blower air chamber or piping. either pressure rise or temperature rise across the
blower exceeds the limit specified in this manual, shut
❏ If an outdoor intake without filter is used, be sure down and investigate conditions in the piping system.
the opening is located so it cannot pick up dirt and Refer to the TROUBLESHOOTING CHECKLIST for
is protected by a strong screen or grille. Use of the suggestions on various problems that may appear.
temporary protective screen as described under
INSTALLATION is strongly recommended. The blower should now be ready for continuous duty
operation at full load. During the first few days make
❏ Recheck blower leveling, drive alignment and periodic checks to determine whether all conditions
tightness of all mounting bolts if installation is not remain steady, or at least acceptable. This may be
recent. If belt drive is used, adjust belt tension particularly important if the blower is supplying air to a
correctly. process system where conditions can vary. At the first
❏ Turn drive shaft by hand to make sure impellers opportunity, stop the blower and clean the temporary
still rotate without bumping or rubbing at any point. inlet protective screen. If no appreciable amount of
debris has collected, the screen may be removed.
❏ Ensure oil levels in the main oil sumps are correct. See comments under INSTALLATION. At this same
❏ Check lubrication of driver. If it is an electric motor, time, verify leveling, coupling alignment or belt tension,
and mounting bolt tightness.
be sure that power is available and that electrical
overload devices are installed and workable. Should operating experience prove that blower capacity
❏ Open the manual unloading valve in the discharge is a little too high for the actual air requirements, a
small excess may be blown off continuously through
air line. If a valve is in the inlet piping, be sure it is open.
the manual unloading or vent valve. Never rely on the
❏ Bump blower a few revolutions with driver to check pressure relief valve as an automatic vent. Such use
that direction of rotation agrees with arrow near may cause the discharge pressure to become
blower shaft, and that both coast freely to a stop. excessive, and can also result in failure of the valve
itself. If blower capacity appears to be too low, refer to
After the preceding points are cleared, blower is
the TROUBLESHOOTING CHECKLIST.
ready for trial operation under “no-load” conditions.
The following procedure is suggested to cover this Vibration Assessment Criteria
initial operation test period.
With measurements taken at the bearing locations
a. Start blower, let it accelerate to full speed, then on the housings, see chart below for an appropriate
shut off. Listen for knocking sounds, both with assessment guide for rotary lobe blowers rigidly
power on and as speed slows down. mounted on stiff foundations.
b. After blower comes to a complete stop, repeat In general, blower vibration levels should be monitored
above, but let blower run 2 or 3 minutes. on a regular basis and the vibration trend observed for
Check for noises, such as knocking sounds. progressive or sudden change in level. If such a
change occurs, the cause should be determined
c. After blower comes to a complete stop, operate through spectral analysis.
blower for about 10 minutes unloaded. Check oil
levels. Observe cylinder and headplate surfaces As shown on the chart below, the level of all pass
for development of hot spots such as burned paint, vibration will determine the need to measure discrete
indicating impeller rubs. Be aware of any notice- frequency vibration levels and the action required.
able increase in vibration.
Assuming that all trials have been satisfactory, or that All Pass Vibration Discrete Frequency Action
necessary corrections have been made, the blower (in/sec) Vibration (in/sec)
should now have a final check run of at least one hour 0.45 or less N/R Approved
under normal operating conditions. After blower is Greater than 0.45 0.45 or less @ Approved
restarted, gradually close the discharge unloading but 1.0 or less any frequency
valve to apply working pressure. At this point it is Greater than 0.45 @ ROOTS™ Approval
recommended that a good pressure gauge or any frequency Required
manometer be connected into the discharge line if Greater than 1.0 Less than 1.0 ROOTS™ Approval
not already provided, and that thermometers be in Required
both inlet and discharge lines. Readings from these Greater than 1.0 ROOTS™ Approval
Required

7
OPERATING CHARACTERISTICS
ROOTS™ rotary blowers and exhausters, as covered in One complete revolution of the driving shaft alternately
this manual, are available in basic frame sizes ranging traps four fixed and equal volumes of air (two by each
from 2 inch to 7 inch gear diameter. Various models, impeller) and pushes them through to the discharge.
within this gear diameter range, are available with dif- The volume capacity of a lobe blower operating at a
ferent case lengths to produce reasonable steps in flow constant speed therefore remains relatively independ-
capacity. The shorter case lengths have lower ent of reasonable inlet of discharge pressure variations.
volumetric capacities, but are capable of operating To change capacity, it is necessary either to change
against higher pressures. All models are available for speed of rotation or blow off some of the discharge air.
air service and there are specifically designed models
for gas service. No attempt should ever be made to control capacity
by means of a throttle valve in the intake or discharge
The basic ROOTS™ rotary lobe blower is a positive piping. This will not only increase the power load on the
displacement type unit. Flow capacity is determined by driver, but can also overload and seriously damage the
frame size, operating speed and pressure conditions. blower. If a possibility does exist that flow to the blower
It employs two impellers mounted on parallel shafts inlet may be cut off during normal operation of a
rotating in opposite directions within a cylinder closed process, then an adequate vacuum relief valve must
at the ends by head-plates. As the impellers rotate, be installed near the blower. A pressure type relief
gas is drawn into one side of the cylinder and forced valve in the discharge line near the blower is required
out the opposite side. The pressure or vacuum for protection against cut-off or blocking in this line.
developed depends on the resistance of the piping Refer to FIGURE 3 for a complete piping schematic.
and process system.
When a belt drive is installed, blower speed can usually
The unit is a precision engineered product with very be adjusted to obtain desired capacity by changing the
fine clearances between the rotating impellers and diameter of one or both sheaves. In a direct coupled
stationary case. Since there is no actual contact arrangement a variable speed motor or transmission
between these surfaces, internal lubrication is not is required, or excess air may be blown off through
required. Clearances are maintained by a pair of a manually controlled unloading valve and silencer.
accurately machined timing gears, mounted on the If returned to the blower inlet, the air must be cooled
two shafts extended outside the blower casing. to 100°F (38°C) through a by-pass arrangement to
maintain acceptable blower temperatures.
Operation of the familiar basic rotary lobe blower is
illustrated in FIGURE 1, where air flow is left to right Before making any change in blower capacity, or
from inlet to discharge with the top impeller rotating operating conditions, contact ROOTS for specific
clockwise. In Position 1 it is delivering a known volume information applying to your particular blower. In all
(B) to the discharge, while space (A) between the cases, operating conditions must be maintained within
lower impeller and cylinder wall is being filled. the approved range of pressures, temperatures and
Counterclockwise rotation of this impeller then traps speeds as stated under LIMITATIONS. The air blower
equal volume (A) in Position 2, and further rotation must not be used to handle liquids or solids as serious
delivers it to the discharge in Position 3. damage to the rotating parts may result.

FIGURE 1 – FLOW THROUGH A BASIC ROTARY LOBE BLOWER

B B B

A
A
A

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 8
TROUBLESHOOTING
Trouble Item Possible Cause Remedy

No flow 1 Speed too low Check by tachometer and compare with published
performance
2 Wrong rotation Compare actual rotation with Figure 1 or 2
Change driver if wrong
3 Obstruction in piping Check piping, valves, silencer to assure open flow path
Low capacity 4 Speed too low See item 1, If belt drive, check for slippage and readjust
tension
5 Excessive pressure rise Check inlet vacuum and discharge pressure and compare
with Published performance
6 Obstruction in piping See item 3
7 Excessive slip Check inside of casing for worn or eroded surfaces causing
excessive clearances
Excessive power 8 Speed too high Check speed and compare with published performance
9 Excessive pressure rise See Item 5
10 Impeller rubbing Inspect outside of cylinder for high temperature areas, then
check for impeller contact at these points. Correct blower
mounting, drive alignment
11 Scale, sludge, rust Clean blower appropriately
or product build up
Overheating of 12 Inadequate lubrication Check oil sump levels in gear and drive end headplates
bearing or gears 13 Excessive lubrication Check oil levels. If correct, drain and refill with clean oil of
recommended grade
14 Excessive pressure rise See Item 5
15 Coupling misalignment Check carefully. Realign if questionable
16 Excessive belt tension Readjust for correct tension
Vibration 17 Misalignment See Item 15
18 Impellers rubbing See Item 10
19 Worn bearings/gears Check gear backlash and condition of bearings, and replace
as indicated
20 Unbalanced or rubbing Scale or process material may build up on casing and
impeller impellers, or inside impellers. Remove build-up to restore
original clearances and impeller balance
21 Driver or blower loose Tighten mounting bolts securely
22 Piping resonances Determine whether standing wave pressure pulsations are
present in the piping
23 Scale/sludge build-ups Clean out interior of impeller lobes to restore dynamic
balance
24 Casing strain re-work piping alignment to remove excess strain
Driver stops, or 25 Impeller stuck Check for excessive hot spot on headplate or cylinder.
will not start See item 10. Look for defective shaft bearing and/or
gear teeth
26 Scale, sludge, rust or Clean blower appropriately
product build-up
Excessive breather 27 Broken seal Replace seals
Blow-by or excessive 28 Defective O-ring Replace seals and O-ring
oil leakage to vent area
Excessive oil leakage 29 Defective/plugged breather Replace breather and monitor oil leakage
in vent area

9
MAINTENANCE & REPLACEMENTS: UNIVERSAL RAI® SERIES BLOWERS
A good program of consistent inspection and mainte- vent cavity becomes excessive or when the blower is
nance is the most reliable method of minimizing repairs disassembled for any reason. Sealing effectiveness
to a blower. A simple record of services and dates will can vary considerably from seal to seal and is also
help keep this work on a regular schedule. Basic affected to surprising degree by shaft finish under the
service needs are: seal lip. Because of these normal variables, minor seal
leakage should not be considered as indicating
• Lubrication seal replacement.
• Checking for hot spots Timing gear wear, when correct lubrication is main-
• Checking for increases or changes in vibration tained, should be negligible over a period of years.
and noise Gear teeth are cut to provide the correct amount of
backlash, and gears correctly mounted on the shafts
• Recording of operating pressures and temperatures will accommodate a normal amount of tooth wear
Above all, a blower must be operated within its without permitting contact between lobes of the two
specified rating limits, to obtain satisfactory service life. impellers. However, too high an oil level will cause
churning and excessive heating. This is indicated by
A newly installed blower should be checked often unusually high temperature at the bottom of the gear
during the first month of full-time operation. Attention housing. Consequent heating of the gears will result
thereafter may be less frequent assuming satisfactory in loss of tooth-clearance , backlash and rapid wear of
performance. Lubrication is normally the most impor- the gear teeth usually will develop. Continuation of this
tant consideration and weekly checks of lubricant tooth wear will eventually produce impeller contacts
levels in the gearbox and bearing reservoirs should (knocking), and from this point serious damage will be
be customary. Complete oil change schedules are unavoidable if blower operation is continued. A similar
discussed under LUBRICATION. situation can be produced suddenly by gear tooth
Driver lubrication practices should be in accordance fracture, which is usually brought on by sustained
with the manufacturer’s instructions. If direct connected overloading or momentary shock loads.
to the blower through a lubricated type coupling, the Problems may also develop from causes other than
coupling should be checked and greased each time internal parts failure. Operating clearances within a
blower oil is changed. This will help reduce wear and blower are only a few thousandths of an inch. This
prevent unnecessary vibration. In a belted drive makes it possible for impeller interference or casing
system, check belt tension periodically and inspect rubs to result from shifts in the blower mounting, or
for frayed or cracked belts. from changes in piping support. If this type of trouble
In a new, and properly installed, unit there is no contact is experienced, and the blower is found to be clean, try
between the two impellers, or between the impellers removing mounting strains. Loosen blower mounting
and cylinder or headplates. Wear is confined to the bolts and reset the leveling and drive alignment. Then
bearings (which support and locate the shafts) the oil tighten mounting again, and make sure that all piping
seals, and the timing gears. All are lubricated and wear meets blower connections accurately and squarely
should be minimal if clean oil of the correct grade is Foreign materials in the blower will also cause trouble,
always used. Seals are subject to deterioration as well which can only be cured by disconnecting the piping
as wear, and may require replacement at varying periods. and thoroughly cleaning the blower interior.

Shaft bearings are designed for optimum life under A wide range of causes & solutions for operating
average conditions with proper lubrication and are troubles are covered in the TROUBLE SHOOTING
critical to the service life of the blower. Gradual CHECKLIST. The remedies suggested should be
bearing wear may allow a shaft position to change performed by qualified mechanics with a good
slightly, until rubbing develops between impeller and background, using procedures detailed in this manual.
casing. This will cause spot heating, which can be Major repairs generally are to be considered beyond
detected by observing these surfaces. Sudden bearing the scope of maintenance, and should be referred
failure is usually more serious. Since the shaft and to ROOTS.
impeller are no longer supported and properly located, Warranty failures should not be repaired at all, unless
extensive general damage to the blower casing and specific approval has been obtained through ROOTS
gears is likely to occur. before starting work. Unauthorized disassembly within
Oil seals should be considered expendable items, to the warranty period will void the warranty.
be replaced whenever drainage from the headplate

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 10
It is recommended that major repairs be performed 3. GEAR REMOVAL: CAUTION: Do not remove gear
at an authorized ROOTS facility. However, it is nuts (17) completely before the gears are unseated
recognized that this may not always be practical. If a from the taper fits or damage/injury may result.
blower is out of warranty, mechanical adjustments and For this operation, the impellers should be wedged,
parts replacement may be undertaken locally at the as shown in Table 5. Back off gear clamping nuts
owner’s option and risk. It is recommended that (17) about 1/4”. Use a suitable puller or wedge. As
ROOTS™ parts be used to insure fit and suitability. The the puller set screw is torqued, the puller will have
maintenance of a small stock of on-hand spare parts a tendency to turn and contact teeth of the other
can eliminate possible delays. When ordering parts gear. To prevent this contact, hold the puller corner
give item numbers and their word descriptions from the nut with a wrench while torquing the set screw.
appropriate sectional drawings. Also specify quantities Once the gear is unseated, remove the puller.
required and the blower model and serial number from Remove gear nuts (17) and the gear.
the nameplate.
4. GEAR INSTALLATION: Place impellers in correct
Repairs or adjustments are best performed by person- position as previously marked. Be sure shafts and
nel with good mechanical experience and the ability to gear bores are clean, oil free and free of scratches.
follow the instructions in this manual. Some operations Clean the shaft tapered fits. Place hardwood
involve extra care, patience, and a degree of precision wedges as shown in Table 5. Install drive gear
work. This is especially true in timing impellers and in (4) and gear nut (17). Tighten the drive gear nut
handling bearings. Experience indicates that high to the torque given below. Blower assembly
percentages of bearing failures are caused by dirt must be fastened down for torquing operation.
contamination before or during assembly. Therefore,
the work area should be cleaned before starting 5. Installing driven gear (4) – Insert a long, metal
disassembly, and new or re-usable parts protected feeler gauge between the impellers’ lobes at the
during progress of the work. fronts or backs as shown below. Feeler
gauge thickness to be a middle value from Table 5
In the following repair procedures, numbers shown in for fronts and backs. Install nut (17). Tighten lightly
brackets ( ) correspond to the item numbers used with a small wrench, then check front and back
in sectional drawings. It is recommended that the clearances against Table 5 for each 45° position.
procedures be studied carefully and completely, with Both fronts and backs should be about the same
frequent reference to the drawings, before starting and within the specified range in Table 5. Adjust
work. This will produce better efficiency through an gear position, if necessary, then insert the
understanding of what work is to be done, and the corrected feeler gauge and wedges and use a
order of doing it. Before disassembly, mark all parts torque wrench to tighten the gear nut to the torque
so that they may be returned to original locations or specified in below. Remove wedges and rotate
relative positions. the drive shaft by hand to make sure there are no
gear tight spots or impeller contacts. CAUTION!
Requirements for special tools will depend on the work Keep fingers away from impellers and gears.
to be done. If impeller clearances and float are to be
checked or re-set, a dial indicator and a set of long
feeler gauges will be needed. Work involving removal
of the timing gears cannot be accomplished without a UNIVERSAL RAI® SERIES BLOWER GEAR NUT TORQUE
suitable puller.
Frame Size Torque
Design of ROOTS™ blower is simple, and most repair
operations are straightforward. For this reason, the lb.-ft. (kg-m)
following procedures are intended mainly to indicate 22, 24, 60 (8.3)
a preferred work order and to call out points to be 32, 33, 36 110 (15.2)
observed. Where special operations are required,
42, 45, 47 190 (26.3)
detailed coverage is given.
53, 56, 59 250 (34.6)
A – Replacing Timing Gears
65, 68, 615 400 (55.3)
1. Drain all oil from the gearhouse by removing drain 76, 711, 718 550 (76.1)
plug (21) in the bottom. Remove gearhouse by
taking out all cap screws (23) in its flange. It may
be necessary to bump the sides with a wood block
or mallet to break the flange joint.
2. Reach through one of the blower pipe connections
and place a chalk mark on the strip of one impeller
and the mating waist of the other, so that they
may easily be returned to their original relative
positions.

11
 6. Check the end clearances between impellers and bar with recessed end that will bear on the outer
headplates. Adjust clearances per B-15 below. metal edge of seal enclosure. Seal lip should
point toward the driving tool. Seals to be flush
7. When clearances are correct, clean and re-install
without board bore face. Apply a light coat of oil or
the gearhouse. Check condition of flange gasket
grease to the seal lips. In a similar fashion, install
(7) and replace if questionable. Fill gearhouse to
lip seals into the drive end headplate.
correct level with proper grade oil.
8. Place cylinder on a flat surface. Assemble gear
B – Replacing Shaft Bearings and Impellers
end headplate to cylinder after checking flange
Remove coupling or sheave from the drive shaft. punch marks. Drive in the two locating dowel pins
Drain and remove gearhouse, and pull the timing before tightening flange screws. Also install gear
gears. If gears are to be re-used, mark them so end foot using the same longer cap screws (32)
they may be returned to the same shafts. and washers (41). (On 6” & 7” UNIVERSAL RAI®
blower install both gear end feet.)
1. Break corners and deburr the keyway. Remove
bearing end cover at the drive end. Remove 9. Place the assembly horizontally on steel blocks
bearing clamp plates (34). with gear end headplate on bottom. The height
of the blocks should be sufficient to clear gear
2. Make single and double identifying punch marks end shaft extensions. Assemble impellers into
on the mating edges of headplate and cylinder the cylinder with the drive shaft (longer shaft)
flanges at the two ends of the blower. in same location as in original assembly. Before
3. At the drive end, drive out the two dowel pins and starting the shafts through the headplate holes,
remove all capscrews holding headplate to make sure shaft ends have no sharp or rough
cylinder. By inserting jacking screws into the two edges to damage seal lips. Position impellers at
threaded flange holed, and turning them in evenly, 90° to each other in the cylinder, using lobe-and-
the headplate will be separated from the cylinder. waist match marks if original impellers are being
As the headplate comes off the shafts it will bring re-installed. Install drive end headplate and feet in
bearings with it. 2-1/2” and 3-1/2” gear diameter same manner as gear end.
units do not have tapped holes for jack screws in 10. It is recommended that new bearings be used for
the drive end headplates. Remove dowel pins and rebuild. Apply thin film of machine oil on the shaft
all capscrews holding headplate to cylinder and bearing fit, bearing I.D., and headplate bearing
foot on the drive end. Support unit under gear end bore. Install drive end bearings into headplate.
cylinder flange with the shafts vertical. Using soft Use a tube with flanged end that will contact both
metal block against gear end shafts, push them bearing faces simultaneously. Refer to Assembly
out of gear end headplate. Drawing for proper bearing depths.
4. For 2-1/2” and 3-1/2” gear diameter units, support NOTE: Cylindrical drive bearing should be
the drive end headplate on the underside, and installed with inner race large shoulder
using soft metal block against drive end shafts, facing outboard.
push them out of drive end headplate. 11. Place blower on its feet on a flat surface.
For 4”, 6” & 7” gear diameter units, from the gear Loosen feet capscrews (32) and square up unit.
end, using a wood or soft metal block against the Re-tighten capscrews (32). Clamp unit down to
ends of the shafts, drive them out of the head a solid base for further assembly.
plate. If they are to be reused, protect them from 12. Oil the gear end bearing fits as described
damage in this operation. previously. Install 2-1/2” thru 5” blower gear end
5. If blower interior surfaces need cleaning, it may be bearings flush with the headplate bearing
advisable to separate the gear end headplate from shoulders using proper drivers. On 6” & 7”
the cylinder. Use the same general procedure as gear diameter units, install thrust washer
employed at the drive end. (29) in bearing bores then install gear end
bearings so they protrude 1/16” (1.6mm) above
6. Working from the back (flat) face of each head headplate surface.
plate, push or tap out the bearings and seals. Use
a round bar or tube that will pass through the shaft 13. Install bearing clamp plates (34). On 6” & 7”
clearance holes in the headplates. All lip seals will gear diameter units, blower impeller end
be damaged during removal and must be clearances are also to be set during this step.
replaced. Install clamp plates (34) with capscrews (31)
making sure that the gap between the clamp plates
7. Clean bearing and seal pockets in headplates and and the headplate is even all around. At the same
remove burrs or rough edges. (Apply a thin coating time, set end clearances per Table 5.
of sealant on seal O.D.) Press new seals (27) into
gear end headplate using a round tube or 14. Install gears and time impellers as in (A).

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 12
15. For setting end clearances on 2-1/2” thru 5” gear discharge gas pressure. Also, there exists a
diameter units, special tools, thrust adjuster fork possibility of gear end oil and drive end grease
and thrust adjuster saddle are required. Refer to leakage into the gas stream.
Table 5 for installation of tools. The flat side of the
saddle rests against the bearing inner race and the The lubricants selected must be compatible with the
flat side of the fork rests against the back side of gas. Mechanical Seal Replacement: Disassemble the
the gear. Install a shim, with thickness equal to blower. During disassembly, damage to mechanical
gear end clearance (Table 5), between the impeller seals is very likely. During rebuild, always use new
and the gear end headplates. Tap on top of the fork mechanical seals. Prior to any assembly, make sure
until the shim becomes snug. Remove the shim that all parts are completely clean and free from nicks
and check end clearances. To increase gear end and scratches.
clearance, tap on the end of the gear end shaft (1) Place head plate on an assembly table with seal
with a soft metal mallet. Set end clearances for bores pointing up. Coat the OD of the stationary
6” & 7” by turning capscrews (31) evenly in or out. seal element and install it with carbon facing up in
16. Install drive end cover (5) after packing bearing the seal bore with a seal driver that is guided by the
cavities with suitable grease. Replace drive shaft bearing bore. Drive the seal flush with front face of
seal. Lip must point toward (33) the bearing. the seal bore. Repeat this procedure for all four
Exercise care not to damage the lip as it passes seals. Apply a light coating of lubricating oil on the
over shaft keyway. sealing surface. Protect sealing faces during
assembly from any damage.
17. Install gasket item (7). Install the gear house after
cleaning out the inside. Tighten gear box cap (2) Apply teflon based sealant on the cylinder flanges
screws (23) evenly. Fill with correct grade of oil before installing head plates. Continue the assembly
until oil flows out through oil level hole. Grease procedure as outlined up to bearing installation.
drive and bearings. (See Lubrication.) Before installation of the bearings, the seal mating
rings need to be installed. Apply light film of
18. Reinstall coupling or belt sheave making sure that lubricating oil on mating ring o-rings and sealing
they have a slight slide fit with the shaft and could faces. Slide mating rings on the shaft and up to
be installed by hand. carbon faces making sure that no damage to the
o-rings occur during installation (break sharp
shaft corners to avoid damage to the o-rings during
TECHNICAL SUPPLEMENT initial preparation). Install bearings all the way
for 32, 33, 36, 42, 45, 47, 53, 56, 59, 65, 68, 615 against the back bearing bore shoulders.
UNIVERSAL RAI®-G BLOWERS
(3) Complete the rest of the assembly.Make sure all
ROOTS Universal RAI™-G rotary positive gas blowers
™
plugged holes are sealed with teflon thread
are a design extension of the basic Universal RAI™ liquid sealant.
blower model. URAI™-G blower uses (4) mechanical
seals in place of the standard in board lip seals to Note: On 6” gear diameter units, shims (44) are used
minimize gas leakage into the atmosphere. The seal between the bearing clamp plates and the head plate
vent chambers are plugged. These units are intended on the gear end.
for gases which are compatible with cast iron case Also, on size 32 and 42, washers with embedded
material, steel shafts, 300/400 series stainless steel o-rings are used on the center head plate to
and carbon seal components, viton o-rings and the cylinder bolts.
oil/grease lubricants. If there are any questions
regarding application or operation of this gas blower, After the assembly is completed, plug the blower
please contact factory. inlet and discharge connections and run static
soap bubble. Leak test to assure leak
Precaution: URAI™-G blowers: Care must be used free assembly.
when opening the head plate seal vent chamber
plugs ( 43) as some gas will escape–if it is a pres- For satisfactory operation of mechanical seals,
sure system, or the atmospheric air will leak in-if synthetic lubricants are recommended (Check
the system is under vacuum. There is a possibility suitability to gases before using.)
of some gas leakage through the mechanical seals.
Oils:
This leakage on the gear end will escape through
(1) ROOTS™ GT Synthetic Lubricant ROOTS
the gear box vent, and on the drive end, through
P/N 13-106-001 (1) one quart ISO-220
the grease release fittings. If the gas leakage is
undesirable, each seal chamber must be purged (2) Mobil SHC 600 Series Lubricating Oils
with an inert gas through one purge gas hole Grease:
(43 ) per seal . There are two plugged purge gas ROOTS™ Synthetic Grease – NLGI # 2
holes(1/8 NPT) provided per seal. The purge gas ROOTS P/N T20-019-001 (1) one 14 oz tube
pressure must be maintained one psi above the

13
MAINTENANCE & REPLACEMENTS: RAM™ SERIES BLOWERS
A good program of consistent inspection and mainte- general damage to the blower casing and gears is
nance is the most reliable method of minimizing repairs likely to occur.
to a blower. A simple record of services and dates will
Oil seals should be considered expendable items, to
help keep this work on a regular schedule. Basic
be replaced whenever drainage from the headplate
service needs are:
vent cavity becomes excessive or when the blower is
• Lubrication disassembled for any reason. Sealing effectiveness
can vary considerably from seal to seal and is also
• Checking for hot spots affected to surprising degree by shaft finish under the
• Checking for increases or changes in vibration seal lip. Because of these normal variables, minor
and noise seal leakage should not be considered as indicating
seal replacement.
• Recording of operating pressures and temperatures
Timing gear wear, when correct lubrication is main-
Above all, a blower must be operated within its tained, should be negligible over a period of years.
specified rating limits, to obtain satisfactory service life. Gear teeth are cut to provide the correct amount of
A newly installed blower should be checked often backlash, and gears correctly mounted on the shafts
during the first month of full-time operation. Attention will accommodate a normal amount of tooth wear
thereafter may be less frequent assuming satisfactory without permitting contact between lobes of the two
performance. Lubrication is normally the most impor- impellers. However, too high an oil level will cause
tant consideration and weekly checks of lubricant churning and excessive heating. This is indicated by
levels in the gearbox and bearing reservoirs should unusually high temperature at the bottom of the gear
be customary. Complete oil change schedules are housing. Consequent heating of the gears will result in
discussed under LUBRICATION. loss of tooth-clearance , backlash and rapid wear of the
gear teeth usually will develop. Continuation of this
Driver lubrication practices should be in accordance tooth wear will eventually produce impeller contacts
with the manufacturer’s instructions. If direct connected (knocking), and from this point serious damage will be
to the blower through a lubricated type coupling, the unavoidable if blower operation is continued. A similar
coupling should be checked and greased each time situation can be produced suddenly by gear tooth
blower oil is changed. This will help reduce wear and fracture, which is usually brought on by sustained
prevent unnecessary vibration. In a belted drive sys- overloading or momentary shock loads.
tem, check belt tension periodically and inspect for
frayed or cracked belts. Problems may also develop from causes other than
internal parts failure. Operating clearances within a
In a new, and properly installed, unit there is no contact blower are only a few thousandths of an inch. This
between the two impellers, or between the impellers makes it possible for impeller interferences or casing
and cylinder or headplates. Wear is confined to the rubs to result from shifts in the blower mounting, or
bearings (which support and locate the shafts) the oil from changes in piping support. If this type of trouble
seals, and the timing gears. All are lubricated and wear is experienced, and the blower is found to be clean, try
should be minimal if clean oil of the correct grade is removing mounting strains. Loosen blower mounting
always used. Seals are subject to deterioration and bolts and reset the leveling and drive alignment. Then
wear, and may require replacement at varying periods. tighten mounting again, and make sure that all piping
meets blower connections accurately and squarely
Piston ring seals (28) are designed to operate without
Foreign materials sucked into the blower will also
rubbing contact, once temperature and thermal growth
cause trouble, which can only be cured by disconnect-
have stabilized. The stationary rings will rub the rotating
ing the piping and thoroughly cleaning the blower interior.
sleeve (38) briefly as a result of temperature cycles
that occur during the startup and shutdown of the unit. A wide range of causes & solutions for operating
The sleeves are hardened and the rings are coated troubles are covered in the TROUBLE SHOOTING
with dry lubricant that provides for temporary break in CHECKLIST. The remedies suggested should be
wear. Replace piston ring seals if they become exces- performed by qualified mechanics with a good
sively worn or inspection shows more than .010” background, using procedures detailed in this manual.
(.25mm) axial clearance between ring and groove. Major repairs generally are to be considered beyond
the scope of maintenance, and should be referred
Shaft bearings are designed for optimum life under
to ROOTS.
average conditions with proper lubrication and are
critical to the service life of the blower. Gradual bearing Warranty failures should not be repaired at all, unless
wear may allow a shaft position to change slightly, until specific approval has been obtained through a Sales
rubbing develops between impeller and casing. This Office or the factory before starting work. Unauthorized
will cause spot heating, which can be detected by disassembly within the warranty period will void the
observing these surfaces. Sudden bearing failure is warranty.
usually more serious. Since the shaft and impeller are
no longer supported and properly located, extensive

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 14
It is recommended that major repairs be performed at 4. Remove bearing clamp plates (34) by unscrewing
an authorized ROOTS facility. However, it is recognized capscrews (32) and removing lock washers (35).
that this may not always be practical. If a blower is Keep shim halves (10) together exactly as removed
out of warranty, mechanical adjustments and parts by tagging them with each clamping plate.
replacement may be undertaken locally at the owner’s
5. Remove the headplate – remove all capscrews
option and risk. It is recommended that ROOTS™ parts
(23) holding headplate to the cylinder. Insert
be used to insure fit and suitability. The maintenance
jacking screws into the four threaded flange
of a small stock of on-hand spare parts can eliminate
holes and turn them in evenly. The headplate will
possible delays. When ordering parts give Item
separate from the cylinder. The lip seals (27), and
numbers and their word descriptions from sectional
bearing outer race and rollers, are removed with
drawings and parts lists. Also specify quantities
the headplate and can be pressed out later.
wanted and the blower size and serial number from
the nameplate. 6. Remove the bearing inner race and sleeve (38)
from the shaft with aid of a bearing puller by
Repairs or adjustments are best performed by
inserting the puller jaws in the groove in the sleeve
personnel with good mechanical experience and the
and applying the jacking screw against the end of
ability to follow the instructions in this manual. Some
the shaft. Protect the threaded hole and the end
operations involve extra care, patience, and a degree
of the shaft with a small, flat spacer between the
of precision work. This is especially true in timing
shaft and the puller.
impellers and in handling bearings. Experience
indicates that high percentages of bearing failures DISASSEMBLY OF GEAR END
are caused by dirt contamination before or during
assembly. Therefore, the work area should be cleaned 1. Drain oil completely from the gearbox sump by
before starting disassembly, and new or re-usable removing plugs (22) in bottom of the headplate (1).
parts protected during progress of the work. 2. Loosen all flange screws (75) in the gearbox and
In the following repair procedures, numbers shown remove all but two upper screws. Bump the gear
in brackets ( ) correspond to the Item numbers box to break the joint if it cannot be pulled free by
used in assembly drawings, and parts lists. It is hand, then remove the last two screws and lift off
recommended that the procedures be studied carefully the gearbox. Remove gasket (7).
and completely, with frequent reference to the draw- 3. Removing gears: CAUTION: Do not remove gear
ings, before starting work. This will produce better nuts (31) completely before the gears are unseated
efficiency through an understanding of what work is to from the taper fits or damage/injury may result.
be done, and the order of doing it. Before disassembly, Be sure that each gear is marked for return to the
mark all parts so that they may be returned to original same shaft in the same angular position and that
locations or relative positions. the gears have match marks for the teeth. For this
Requirements for special tools will depend on the work operation, the impellers should be wedged as
to be done. If impeller clearances and float are to be shown in Figure 8. Back off nuts (31) and slinger
checked or re-set, a dial indicator and a set of long (46). The timing gears (4) have two 1/2” – 13 holes
feeler gauges will be needed. Work involving removal for pulling purposes. Use a suitable puller.
of the timing gears cannot be accomplished without a 4. Remove bearing clamp plates (54) by unscrewing
puller suitable. Heat must be used during bearing and capscrews (32) and removing lock washers.
sleeve installation. Group the shims (10), the wavy spring washers
Design of ROOTS™ blower is simple, and most repair (29) with each clamp plate and tag for ease of
operations are straightforward. For this reason, the reassembly.
following procedures are intended mainly to indicate 5. Remove the headplate – remove all capscrews
a preferred work order and to call out points to be 23) holding the headplate to the cylinder. Insert
observed. Where special operations are required, jacking screws into the four (4) threaded flange
detailed coverage is given. holes and turn them in evenly. They headplate will
DISASSEMBLY OF DRIVE END separate from the cylinder. The lip seals (27), and
bearing outer race and rollers, are removed with
1. Remove the sheave or coupling and key from the the headplate and can be pressed out later.
drive shaft. File off any burrs or sharp edges along
the keyway. For RAM™-J WHISPAIR™ gas pump units:
The gear end headplate which is removed next
2. Drain oil by removing drain plug (22). requires a different approach from the drive end.
On this end, the shafts are forced from the bearing
3. Remove the flange screws (75). Tap the drive end
bore by using a bar across the end of the shaft
cover to loosen it, then slide it along the shaft care
with threaded rods to the headplate. Once the
fully to avoid damaging the lip seal (33) on the
headplates are removed from the assembly, the
drive shaft keyway. Remove the gasket (7).
seal housings can be pressed or driven from
Remove oil slinger (40) and cap screw (60).

15
 the headplate bores. Generally, new seals will be Inspect entering bevels to be sure they are smooth
required prior to reassembly. and clean. Locate the drive impeller correctly
(top for vertical units and toward the driver for
6. Remove the bearing inner race and sleeve (38) horizontal units). Place the seal ring gaps toward
from the shaft with the aid of a bearing puller by the inlet for pressure applications and towards dis
inserting the puller jaws in the groove in the sleeve charge for vacuum applications. Insert the impeller
and applying the jacking screw against the end of shafts in the headplate so the impellers rest on
the shaft. Protect the threaded hole and the end the headplate. Use care to avoid damaging the
of the shaft with a small, flat spacer between the lip seals.
shaft and the puller.
5. Assembly of cylinder (11) to gear end headplate
ASSEMBLY (1) – Install dowel pins (16) and secure cylinder to
Prior to any assembly operation, it is essential that all headplate with capscrews (23). Torque to 35 ft.-lbs
parts are completely clean and free from nicks and (4.5 Kg-m). Then, install drive end headplate (1)
scratches. and dowel pins (16) and secure with capscrews
(23). Install feet (76) & 77) to both headplates and
Prior to assembly, lightly coat the groove in the sleave secure with capscrews (66). Torque to 35 ft.-lbs.
with slip plate. ROOTS P/N813-314-000. (4.5 kg-m).
1. Assembly of Piston ring seals (28) – To avoid For Gas Sealed Units: Use a Teflon sealant
scratching the lip seal surface, install the Piston between headplate and cylinder joint. Assemble
ring seals (28) in the sleeves (38) from the end rotating seal – apply a light coating of oil to the
nearest the groove before assembling the sleeve O-ring and seal face. Then with flute side out
on the shaft. install the rotating seat tight to the shaft sleeve.
Unhook the gap joint and expand the ring while Check and record seal compression – With the
sliding it to the groove, then compress it so one seal body in place and the impeller against the
end of the hook joint slides over the other. Move opposite headplate, check that seal compression
the ring in the groove to be sure it is free. is adequate. This can be checked using a depth
gauge or dial indicator from the face of the head
NOTE: Care must be taken not to scratch or dent plate to the face of the mating ring. First, measure
the sleeve surface since it is the sealing surface this distance while the carbon is out at its full
for the lip seal. length. Then, push the mating ring back against its
2. Installation of sleeves (38) – heat the sleeve to stop and measure it again. The difference
300° F. (149°C) then quickly slide it on the shaft between these measurements is the compression.
tightly against the impeller. If the sleeve hangs up This can be done easily with finger pressure as the
during assembly, it can be pressed into place spring force is only 10 lbs. The correct travel is
using a tubular pressing tool with square, given below (record actual compression on
clean ends. clearance sheets).

3. Assembly of seals (27) in headplate (1) – Place SEAL COMPRESSION

headplate flat with seal bores up. Be sure the
pressing tool face is clean and square and there is Frame Minimum Maximum
a smooth, clean entering bevel in the headplate. 400 .047” .097”
Lubricate the seal lips. Place seal over the bore 600 .108” .151”
with lip facing up, then press the seal evenly until it * Prior to to assembly, lightly coat the groove in the sleave(38) with slip plate.
is flush with bore face. ROOTS™ P/N 813-314-000

For Gas Sealed Units: Assemble mechanical 6. Installation of bearings (14) – Heat bearing inner
seals (27) in headplate – (CAUTION: Care must race to 300°F (149°C) in an oven or hot oil; then
be used to avoid damaging the carbon face. slide it onto the shaft so the bearing shoulder is
Before proceeding with this step, you should have snugly against the sleeve. Note: Be sure to install
a piloted seal driver which is designed to clear the shaft shim (70) behind the shaft sleeve before
the carbon face.) with headplate positioned installing the drive end drive bearing inner race.
horizontally with seal bores up. Be sure the This is required to compensate for the oil leader for
pressing tool face is clean and square and there is shimming. Insert the bearing outer race and rollers
a smooth, clean entering bevel in the headplate. in each bore and tap lightly in place. Spray
Place the seal over the bore with carbon facing up. bearings with lubricant.
Then press the seal evenly on its steel shell using
the piloted seal driver until the driver seats against 7. Measure and record the end clearances between
the stop. the impellers and drive headplate using long feeler
gauges. Then, subtract the allowed average drive
4. Assembly of impellers (12 and 13) to headplate end clearance. See Table 6. The result is the
(1) – Place gear end headplate flat on 3 in. space required between clamping plates (34) and
(76 mm) blocks with the smallest bores facing up. bearing outer race. Place shims (10) as required
to get this clearance. Then, fasten the clamping

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 16
 plates to the headplate with capscrews (32) and 13. Right side discharge machine
lock washers (35). Installing driven gear (4) – Insert a long metal
feeler gauge between the impellers’ lobes at the
8. Installation of gear end bearings (14) – Turn the backs. Feeler gauge thickness to be minimum
blower so that the gear end headplates is up. Heat value from Table 6 for backs.
bearing inner race to 300°F (149°C) in an oven or
hot oil; then slide it onto the shaft so that the RAM™ SERIES BLOWER GEAR NUT TORQUE
bearing shoulder is snugly against the sleeve.
Insert the bearing outer race and rollers in each Frame Size Torque
bore and tap lightly into place. lb.-ft. (kg-m)
404, 406, 409, 412, 418 400 (56)
9. Measure and record the end clearance between
the impellers and gear end headplate, then sub- 616, 624 630 (88)
tract the allowed average gear end clearance. See
Table 6. The result is the space required between RAM™ SERIES BLOWER OIL SLINGER SCREW TORQUE
clamping plate (54) and bearing outer race. Place
Frame Size Torque
shims (10) as required to get this clearance. Then
lb.-ft. (kg-m)
fasten the clamping plates (54) to the headplate
using capscrews (32) and lock washers (35). Do 404, 406, 409, 412, 418 75 (10)
not install wavy-spring washers (29) at this time, 616, 624 140 (19)
as a final check of clearances is required first.
10. Final check of end clearances and float – Using Align the gear so the tooth match marks agree with
long feeler gauges, check the clearance between the drive gear and install nuts (31). Tighten lightly with
the impellers and drive end headplate. See Table a small wrench, then check front and back clearances
6. Place the blower assembly on its feet and against Table 6 for each 45° position. Both fronts
correct shimming as required. Then, force the should be about the same and backs should about
impellers as close to the gear end headplate as equal and be within the specified range in Table 6.
possible, and check the clearance between Adjust gear position if necessary, then insert the cor-
impellers and gear end headplate for agreement rected feeler gauge and wedges and use a torque
with Table 6. Adjust shimming on the gear end as wrench to tighten the gear nut to the torque specified
required. With unit securely fastened down, use a above. Remove wedges and rotate the drive shaft by
dial indicator to measure the impeller float. Again hand to make sure there are no gear tight spots or
push the impeller to one end of the cylinder. With impeller contacts. CAUTION: Keep fingers away from
indicator firmly mounted, place contact point on the impeller end gears.
end of the shaft just pushed and set dial on zero. Install slinger(s) (46),install gearbox (3) with gasket (7) and
Force the impeller to the opposite end (toward tighten the capscrews (75) evenly to 10 ft.-lbs. (1.3 kg-m).
indicator). Indicator reading will be a measurement
of the impeller float. Repeat process on second Install drive end oil slinger (40) and capscrew
impeller and compare float to Table 6. Adjust (60), apply Locktite to threads and torque to value
shimming at bearing clamp plates to obtain both specified above.
float and end clearances specified in Table 6. Install drive end cover (5) and gasket (7) with drive lock
Finally, after clearances and float have been pins (17) in place, being careful not to dent or scratch
corrected and checked, remove the gear end drive shaft lip seal surface. Tighten capscrews (75)
clamping places (54) and install wavy-spring evenly. Check seal bore for concentricity with shaft
washers (29) and reinstall shims (10) and clamping using an indicator; reposition drive lock pins, if neces-
plates (54). Be sure oil feed grooves are up and sary. Install seal (33) with lip facing inward, using care
toward bearings. to avoid tearing or scratching seal on shaft keyway. Use
a pressing tool with clean, square ends to insure cor-
11. Installing drive gear (4) – Be sure shafts and gear rect positioning of the seal. For hydrodynamic style
bores are clean and oil free with no scratches. Oil seals, the shaft rotation is critical for correct installation
gear nut threads lightly. Place hardwood wedges and proper sealing. Match the directional arrow shown
as shown in Figure 8. Install gear (4) and nut (31) on the seal faces with the required shaft rotation. An
so match mark at the tooth is at the line of installation protective sleeve is required to protect seal
engagement. Tighten the drive gear to the torque lip during installation.
given below. Blower assembly must be fastened
down for torquing operation. Install vent plug (21) in each headplate.
12. Left side discharge machine Replace oil drain plugs (22) and refill drive end and
Installing driven gear (14) – Insert a long metal gear sumps with proper grade of oil as discussed
feeler gauge between the impellers’ lobes at the under LUBRICATION.
fronts as shown in Table 6. Feeler gauge thickness Install drive sheave or coupling half and install blower,
to be a middle value from Table 6 for fronts. refer to INSTALLATION instructions.
17
FIGURE 2
ALLOWABLE OVERHUNG LOADS FOR V-BELT DRIVES UNIVERSAL RAI®/URAI™-J UNITS

252100 • Motor HP
Belt Pull lbs =
Blower RPM • Sheave Diameter

Sheave Width
Shaft Load (lb.in) = Belt Pull • (A + 1/4” + )
2

Frame Dimension Max Allowable Min Sheave

Size “A” Shaft Load (lb-in.) Diameter
22, 24 0.61 130 4.00
32, 33, 36 0.80 350 5.00
42, 45, 47 1.02 525 5.00
53, 56, 59 1.13 1,325 6.00
65, 68, 615 1.36 2,250 8.00
A 1/4" Max 76, 711, 718 1.16 2,525 9.50
NOTE:
Arc of sheave belt contact on the smaller sheave not to be less than 170°
Driver to be installed on the inlet side for vertical units, and on the drive shaft side
for horizontal units.
ROOTS recommends 3V, 5V or 8V belts and sheaves.

ALLOWABLE OVERHUNG LOADS FOR V-BELT DRIVES 400 - 600 RAM™ UNITS

275000 • Motor HP
Belt Pull lbs =
Blower RPM • Sheave Diameter

Sheave Width
Shaft Load (lb.in) = Belt Pull • (A + 1/4” + )
2

Dimension “A”
Bottom Drive Max Allowable Min
Frame Standard or Double Shaft Load Sheave
Size Unit Shaft Seal (lb-in.) Diameter
404, 406 1.90 2.11 3,200 7.10
409, 412, 418 1.90 2.11 3,200 7.10
616, 624 2.11 2.67 7,975 8.50
NOTE:
A 1/4" Max Arc of sheave belt contact on the smaller sheave not to be less than 170°
Driver to be installed on the inlet side for vertical units, and on the drive shaft side
for horizontal units.
ROOTS recommends 3V, 5V or 8V belts and sheaves.

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 18
FIGURE 3
AIR BLOWER INSTALLATION WITH ACCESSORIES
Manual Discharge Unloading Valve
Back Pressure
Regulator (optional)
Inlet Air FIlter

Pressure Relief Valve

Check Valve Vacuum Relief Valve

Temperature Gauge

Manometers

Isolation Valve Inlet

with Limit Switch Silencer

Temperature Gauge

Discharge Silencer

Temporary Screen
AIR BLOWER
Expansion Joint
*Differential Pressure &
Temperature Switches Expansion Joint with Control Unit

Above are suggested locations for available accessories.

GAS BLOWER INSTALLATION WITH ACCESSORIES

Back-Pressure By-Pass Cooler
Regulator

Normal Starting Valve

Pressure Relief Valve Inlet
Silencer
Pressure
Gauge Vacuum
Check Temperature Relief
Valve Gauge
Temperature Valve
Gauge

Discharge
Silencer

Temporary Screen
Temporary
Starting Valve GAS BLOWER Expansion Joint

Differrential Pressure & Expansion Joint with Control Unit

Temperature Switches

Above are suggested locations for available accessories.

19
FIGURE 4

BLOWER ORIENTATION CONVERSION

Special Note: WHISPAIR™ models are designed to
Model Reversible Whispair™
Rotation Design operate with only one shaft rotation direction to take
full advantage of the Whispair feature. Therefore, a
Universal RAI yes no WHISPAIR™ blower may be operated in the following
combinations.
URAI-J Whispair™ no yes
• CCW Rotation: Bottom Shaft; Right side discharge
URAI-G yes no or a Left Shaft; Bottom discharge

RAM yes no • CCW Rotation: Top Shaft; Left side discharge or a

Right Shaft; Top discharge
RAM-J Whispair™ no yes or
• CW Rotation: Bottom Shaft; Left side discharge or
RAM-GJ Whispair™ no yes a Right Shaft Bottom discharge
• CW Rotation: Top Shaft; Right side discharge or a
Left Shaft Top discharge

BLOWER ORIENTATION AND LUBRICATION POINTS: GREASE LUBRICATED DRIVE END

UNIVERSAL RAI® SERIES & URAI™-G GAS BLOWERS

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 20
FIGURE 5
BLOWER ORIENTATION CONVERSION - WHISPAIR™ UNITS
1. STANDARD ARRANGEMENT ( 3-WAY UNIVERSAL)
EXTERNAL SIGHT GLASSES (37) & BREATHERS (21) MUST BE RELOCATED AS SHOWN.
FEET (76&77) & LIFTING LUGS (63) MUST BE RELOCATED AS SHOWN.

INLET

DISCH
CCW

CCW

CCW
DISCH INLET

DISCH

INLET
TOP DRV, L.S. DISCH L.H. DRV, BTM DISCH R.H. DRV, TOP DISCH

2. NON-STANDARD ARRANGEMENT ( 3-WAY UNIVERSAL)

CYLINDER (11) MUST BE UNBOLTED FROM HEADPLATES (1) AND DISCHARGE
RELOCATED AS SHOWN. MUST HAVE AUTHORIZATION FOR CONVERSION
SO NOT TO VOID WARRANTY.
EXTERNAL SIGHT GLASSES (37) & BREATHERS (21) MUST BE RELOCATED ALSO.
FEET (76&77) & LIFTING LUGS (63) MUST BE RELOCATED AS SHOWN

DISCH
INLET

CW

CW
CW

INLET DISCH
DISCH

INLET

TOP DRV, R.S. DISCH R.H. DRV, BTM DISCH L.H. DRV, TOP DISCH

3. BOTTOM DRIVE SHAFT ARRANGEMENT "SPECIAL ORDER" (3-WAY UNIVERSAL)

SPECIAL OGE OIL SLINGER REQUIRED FOR ASSEMBLY.
MAY BE CONVERTED TO HORIZONTAL CONFIGURATION AS PREVIOUSLY SHOWN.

INLET DISCH DISCH INLET

CCW CW

BTM DRV, R.S. DISCH BTM DRV, L.S. DISCH

21
DRIVE END BREATHER ORIENTATION FOR U-RAI SERIES - DSL WITH OIL LUBE

TABLE 1
UNIVERSAL RAI® SERIES & URAI™-G GAS BLOWER, MAXIMUM ALLOWABLE OPERATING CONDITIONS
Frame Gear Speed Temp. Rise Delta Pressure Inlet Vacuum
Size Diameter (Inch) RPM F° (C°) PSI (mbar) INHG (mbar)
22 2.5 5275 225 (125) 12 (227) 15 (500)
24 2.5 5275 210 (117) 7 (483) 15 (500)
32 3.5 3600 240 (133) 15 1034 16 (539)
33 3.5 3600 225 (125) 12 (827) 15 (500)
36 3.5 3600 225 (125) 7 (483) 15 (500)
42 4.0 3600 240 (133) 15 (1034) 16 (539)
45 4.0 3600 225 (125) 10 (690) 16 (539)
47 4.0 3600 225 (125) 7 (483) 15 (500)
53 5.0 2850 225 (125) 15 (1034) 16 (539)
56 5.0 2850 225 (125) 13 (896) 16 (539)
59 5.0 2850 225 (125) 7 (483) 15 (500)
65 6.0 2350 250 (130) 15 (1034) 16 (539)
68 6.0 2350 240 (133) 14 (965) 16 (539)
615 6.0 2350 130 ( 72) 7 (483) 12 (405)
76 7.0 2050 250 (139) 15 (1034) 16 (539)
711 7.0 2050 225 (125) 10 (690) 16 (539)
718 7.0 2050 130 ( 72) 6 (414) 12 (405)

RAM™, RAM™-J WHISPAIR™ BLOWER, RAM™-GJ GAS BLOWER

MAXIMUM ALLOWABLE OPERATING CONDITIONS
Frame Gear Speed Temp. Rise Delta Pressure Inlet Vacuum
Size Diameter (Inch) RPM F° (C°) PSI (mbar) INHG (mbar)

404 4.5 4000 240 (133) 18 (1241) 16 (539)

406 4.5 4000 240 (133) 18 (1241) 16 (539)
409 4.5 4000 240 (133) 18 (1241) 16 (539)
412 4.5 4000 240 (133) 15 (1034) 16 (539)
418 4.5 4000 240 (133) 10 (690) 16 (539)
616 6.0 3000 230 (128) 15 (1034) 16 (539)
624 6.0 3000 230 (128) 10 (690) 16 (539)

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 22
TABLE 2
RECOMMENDED OIL GRADES
Ambient Viscosity Range ISO No. Approximate Use a good grade of industrial type non-
Temperature °F (°C) SSU at 100°F SAE No. detergent, rust inhibiting, anti-foaming oil
and of correct viscosity per Table 2.
Above 90° (32°) 1000-1200 320 60 *ROOTS™ synthetic oil (ROOTS P/N 813-
32° to 90° (0° to 32°) 700-1000 220 50 106-) is highly recommended. ROOTS™
does NOT recommend automotive type
0° to 32° (-18° to 0°) 500-700 150 40 lubricants, as they are not formulated with
Below 0° (-18°) 300-500 100 30 the properties mentioned above.

TABLE 3
UNIVERSAL RAI®, URAI™-J, URAI™-G UNIVERSAL URAI® SERIES-DSL WITH
OIL SUMP CAPACITIES SPLASH LUBRICATED DRIVE END

Frame Size Gear End Capacity Fl. Oz. (Liters) Frame Size Drive End Capacity Fl. Oz. (Liters)
Vertical Horizontal Vertical Horizontal
22 3.4 (.1) 6.1 (.18) 22 N/A N/A
24 3.4 (.1) 6.1 (.18) 24 N/A N/A
32 8.5 (.25) 16.0 (.47) 32 4.0 (.12) 6.5 (.19)
33 8.5 (.25) 16.0 (.47) 33 4.0 (.12) 6.5 (.19)
36 8.5 (.25) 16.0 (.47) 36 4.0 (.12) 6.5 (.19)
42 12.7 (.37) 22.8 (.67) 42 5.5 (.16) 10.8 (.32)
45 12.7 (.37) 22.8 (.67) 45 5.5 (.16) 10.8 (.32)
47 12.7 (.37) 22.8 (.67) 47 5.5 (.16) 10.8 (.32)
53 16.0 (.47) 27.6 (.82) 53 7.5 (.22) 14.8 (.44)
56 16.0 (.47) 27.6 (.82) 56 7.5 (.22) 14.8 (.44))
59 16.0 (.47) 27.6 (.82) 59 7.5 (.22) 14.8 (.44)
65 28.3 (.84) 52.1 (1.54) 65 16 (0.47) 31 (0.91)
68 28.3 (.84) 52.1 (1.54) 68 16 (0.47) 31 (0.91)
615 28.3 (.84) 52.1 (1.54) 615 16 (0.47) 31 (0.91)
76 32.3 (.96) 59.5 (1.76) 76 N/A N/A
711 32.3 (.96) 59.5 (1.76) 711 N/A N/A
718 32.3 (.96) 59.5 (1.76) 718 N/A N/A

RAM™, RAM™-J & RAM™-GJ OIL SUMP CAPACITIES

Orientation Gearbox Drive End
Fl. Oz. (Liters) Fl. Oz. (Liters)
400 (Horizontal) 36 1.06 19 .56
400 (Vertical) 18 .52 9 .27
600 (Horizontal) 95 2.81 50 1.48
600 (Vertical) 55 1.63 28 0.83

TABLE 4
UNIVERSAL URAI® SERIES WITH GREASE LUBRICATED DRIVE END:
SUGGESTED BEARING GREASING INTERVALS
Speed In RPM Operating Hours Per Day When servicing drive end bearings, use a
NLGI #2 premium grade aluminum complex*
8 16 24 grease with 300°F (149°C) service tempera-
Greasing Intervals in Weeks ture and moisture resistance and good
mechanical stability. Using a pressure gun,
750-1000 7 4 2 slowly force new lubricant into each drive end
1000-1500 5 2 1 bearing housing until traces of clean grease
comes out ofthe relief fitting.
1500-2000 4 2 1
2000-2500 3 1 1 NOTE: Lithium based greases are not
compatible with the ROOTS™ synthetic
2500-3000 2 1 1 grease used during manufacturing.
3000 and up 1 1 1

23
TABLE 5
NORMAL CLEARANCES FOR UNIVERSAL RAI® SERIES AND URAI™-G BLOWERS - INCHES (MM)
Impeller Ends Cylinder Impeller
Frame Total Drive End Gear End Inlet & Center Fronts/Backs
Size Minimum Minimum Discharge Center *
22 .006/.010 (.15-.25) .003 (.08) .003 (.08) .004/.005 (.10-.13) .002/.003 (.05-.08) .007/.01 (.18-.25)
24 .006/.010 (.15-.25) .003 (.08) .003 (.08) .004/.006 (.10-.15) .002/.003 (.05-.08) .007/.01 (.18-.25)
32 .006/.011 (.15-.28) .003 (.08) .003 (.08) .004/.006 (.10-.15) .002/.003 (.05-.08) .01/.012 (.25-.30)
33 .006/.011 (.15-.28) .003 (.08) .003 (.08) .004/.006 (.10-.15) .002/.003 (.05-.08) .01/.012 (.25-.30)
36 .006/.011 (.15-.28) .003 (.08) .003 (.08) .004/.006 (.10-.15) .002/.003 (.05-.08) .01/.012 (.25-.30)
42 .008/.011 (.20-.28) .004 (.10) .004 (.10) .005/.007 (.13-.18) .003/.004 (.08-.10) .009/.012 (.23-.30)
45 .008/.013 (.20-.33) .004 (.10) .004 (.10) .005/.007 (.13-.18) .003/.004 (.08-.10) .012/.015 (.30-.38)
47 .008/.013 (.20-.33) .004 (.10) .004 (.10) .005/.007 (.13-.18) .003/.004 (.08-.10) .012/.015 (.30-.38)
53 .008/.011 (.20-.28) .004 (.10) .004 (.10) .005/.008 (.13-.20) .003/.004 (.08-.10) .011/.013 (.28-.33)
56 .008/.013 (.20-.33) .004 (.10) .004 (.10) .005/.008 (.13-.20) .003/.004 (.08-.10) .015/.017 (.38-.43)
59 .008/.013 (.20-.33) .004 (.10) .004 (.10) .005/.008 (.13-.20) .003/.004 (.08-.10) .015/.017 (.38-.43)
65 .012/.016 (.30-.40) .008 (.20) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .010/.014 (.25-.36)
68 .014/.018 (.36-.46) .010 (.25) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .010/.014 (.25-.36)
615 .014/.018 (.36-.46) .010 (.25) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .010/.014 (.25-.36)
76 .012/.016 (.30-.40) .008 (.13) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .013/.015 (.33-.38)
711 .014/.018 (.36-.46) .010 (.25) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .013/.015 (.33-.38)
718 .014/.018 (.36-.46) .010 (.25) .004 (.10) .006/.008 (.15-.20) .006/.008 (.15-.20) .013/.015 (.33-.38)

* IMPELLER TIMING FOR STANDARD

ROTATION VIEWED FROM GEAR END

Thrust Alignment
Fork
(ROOTS P/N 12-973-00X)

Nylok Capscrew

Bearing

Thrust Alignment
Saddle
(ROOTS P/N 12-974-00X)

Clamp Plate

THRUST SETTING,
2-1/2” THRU 5”
Gap (.03"-.05) UNIVERSAL RAI® SERIES
BLOWERS
K-249392

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 24
TABLE 6
NORMAL CLEARANCES FOR RAM™-J & RAM™-GJ WHISPAIR™ BLOWERS - INCHES (MM)
End Clearance Impeller Tips to Cylinders
Blower
Frame
* Impeller Lobes
at 45° Each End Gear End
Size Without Without Spring Required Inlet
Fronts Backs Wavy Spring Installed End Float Center Discharge

Min-Max Min-Max Min-Max Min-Max Minimum Min-Max Min-Max Min-Max

404 .012-.014 .006-.009 .003-.005 .003-.008 .003 .004-.006 .002-.004 .002-.004
(.31-.36) (.15-.23) (.08-.13) (.10-.15) (.08-.20) (.08) (.05-.10) (.05-.10)
406 .012-.014 .006-.009 .003-.005 .007-.012 .006 .005-.007 .003-.005 .002-.004
(.31-.36) (.15-.23) (.08-.13) (.15-.30) (.13) (.13-.18) (.08-.13) (.05-.10)
409 .013-.015 .006-.009 .003-.005 .013-.018 .008 .005-.007 .003-.005 .002-.004
(.33-.38) (.15-.23) (.08-.13) (.31-.43) (.17) (.13-.18) (.08-.13) (.05-.10)
412 .013-.015 .006-.009 .003-.005 .016-.021 .011 .006-.008 .004-.006 .004-.006
(.33-.38) (.15-.23) (.08-.13) (.36-.48) (.28) (.15-.20) (.10-.15) (.10-.15)
418 .013-.015 .006-.009 .003-.005 .022-.027 .017 .008-.010 .004-.006 .004-.006
(.33-.38) (.15-.23) (.08-.13) (.51-.64) (.38) (.20-.25) (.10-.15) (.10-.15)
616 .012-.014 .006-.008 .004-.006 .017-.022 .011 .009-.011 .004-.006 .002-.005
(.31-.36) (.15-.20) (.10-.15) (.38-.51) (.28) (.23-.28) (.10-.15) (.05-.13)
624 .012-.015 .006-.009 .004-.006 .024-.029 .018 .013-.015 .005-.007 .002-.005
(.31-.36) (.15-.23) (.10-.15) (.61-.74) (.46) (.33-.38) (.13-.18) (.05-.13)

NORMAL CLEARANCES FOR RAM™ BLOWERS - INCHES (MM)

End Clearance Impeller Tips to Cylinders
Blower
Frame
* Impeller Lobes
at 45° Each End Gear End
Size Without Without Spring Required Inlet
Fronts Backs Wavy Spring Installed End Float Center Discharge
Min-Max Min-Max Min-Max Min-Max Minimum Min-Max Min-Max Min-Max
404 .009-.013 .009-.013 .003-.005 .003-.008 .003 .004-.006 .002-.004 .004-.006
(.23-.33) (.23-.33) (.08-.13) (.08-.20) (.08) (.10-.15) (.05-.10) (.10-.15)
406 .009-.013 .000-.013 .003-.005 .007-.012 .006 .005-.007 .003-.005 .005-.007
(.23-.33) (.23-.33) (.08-.13) (.15-.30) (.13) (.13-.18) (.08-.13) (.13-.18)
409 .010-.014 .010-.014 .003-.005 .013-.018 .008 .005-.007 .003-.005 .005-.007
(.25-.36) (.25-.36) (.08-.13) (.31-.43) (.17) (.13-.18) (.08-.13) (.13-.18)
412 .010-.014 .010-.014 .003-.005 .016-.021 .011 .006-.008 .004-.006 .006-.008
(.25-.36) (.25-.36) (.08-.13) (.36-.48) (.28) (.15-.20) (.10-.15) (.15-.20)
418 .010-.014 .010-.014 .003-.005 .022-.027 .017 .008-.010 .004-.006 .008-.010
(.25-.36) (.25-.36) (.08-.13) (.51-.64) (.38) (.20-.25) (.10-.15) (.20-.25)
616 .011-.013 .011-.013 .004-.006 .017-.022 .011 .009-.011 .004-.006 .009-.011
(.28-.33) (.28-.33) (.10-.15) (.38-.51) (.28) (.23-.28) (.10-.15) (.23-.28)
624 .011-.013 .011-.013 .004-.006 .024-.029 .018 .013-.015 .005-.007 .013-.015
(.28-.33) (.28-.33) (.10-.15) (.61-.74) (.46) (.33-.38) (.13-.18) (.33-.38)

* IMPELLER TIMING FOR STANDARD ROTATION VIEWED FROM GEAR END

25
 1 2 3 4 5 6 7 8 9 10 11
No. PATT. No.
REQ'D. PART NAME PART No.
MAT'L.

NOTES: A- INSTALL ITEM #20 (SCREW)IN ASSEMBLY

B- SEE OPERATING MANUAL IRB-180 FOR

LUBRICATION INSTRUCTION
A A

C- 2-1/2, 3-1/2, & 4" REQ'D SOC. HD. ON G.E. ONLY 46

31 25 27 1 16
E- REQ'D ON 22 & 42 ONLY
13 11 32
34 F- NUT TO BE TORQUED TO:
2-1/2---60 LB.FT.
3-1/2---110 LB.FT.
27
4-------190 LB.FT.
14 5-------250 LB.FT.
B G- FOR SIGHT GLASS UNITS ONLY. B

USE WASHER OUTSIDE OF GEARBOX.

USE RED LOCTITE ON THE THREADS.
4 26

17
14
C
38 C
SEE NOTE
"F" 5
SEE NOTE 37
8 "B"
18
SEE NOTE "A"
(DO NOT DRILL
SEE TABLE 19 42
THRU)
20 11.2378

D D
SEE NOTE
"E"
9
40
45
SEE NOTE
SEE NOTE "G" "C" 18

35
E E

3 33

23

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668).
15 39 39
21

F F

SIZE "X" ±.005

7 2 5 0.831
4 0.731
3-1/2 0.585
2-1/2 0.427
32
J ADD LIFTING LUG ITEM# 46 RK 04/15/02 T122 AGP
H ADD ITEM# 45 FOR SIGHT GLASS UNITS RK 01/15/02 BDR #27 AGP
DO NOT SCALE FOR DIMENSIONS ORDER
MFG. REF. G DELETED ITEM 41 VC 04/30/01 T-51 DATE ALL DIMENSIONS SHOWN IN BRACKETS { } ARE MILLIMETERS No. H
CONFIDENTIAL F REVISED PER ECN JHB 2-12-93 3804-V DR.

32 THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION OF E CHKD.

SECTIONAL ASSEMBLY
G INCREASED GEAR NUT TORQUE JHB 5-3-90 3577V FCR AP RM 6-18-85 2-1/2 THRU 5" U-RAI BLOWERS G
ROOTS DIVISION, DRESSER INDUSTRIES, INC. IT SHALL 9-03
BE HELD IN STRICTEST CONFIDENCE, AND BE USED ONLY D ITEM 25 REVISED PER ECN REM 3339-V APP. TAPER BORE GEARS
87 FR 6-25-85
IN CONJUNCTION WITH ROOTS DIVISION BUSINESS. 3-19
C LUBRICATION NOTE B REVISED REM FCR AP DBV AP 6-27-85
87 DIMENSIONAL TOLERANCES UNLESS OTHERWISE SPECIFIED
FINISHED DIMENSIONS
35 12 35 REF: EP938 CONCENTRICITY REDRAWN DB 10-16-86 FCR SCALE TWO PLACE DECIMALS (.XX)---±.015 FRACTIONAL--±1/64
PERPENDICULARITY THREE PLACE DECIMALS (.XXX)--±.005
FLATNESS
ANGULARITY PROFILE OF LINE
B ITEM #42 MOVED RM 8-26-86 M cC CAD FILE / DIRECTORY

PARALLELISM PROFILE OF A SURFACE REV

A REV PER ECN RM 8-7-86 FCR AP /PARTS/XXAS
TRUE POSITION ÿ DIAMETER
STRAIGHTNESS FINISH IN MICRO INCHES CHANGE
REVISIONS BY DATE CHKD. APP
64720023
NOTICE FULL J
2 3 4 5 6 7 8 9 10 11
F:\ FILE\ FORM\ DSIZE.GCM

26
ASSEMBLY OF UNIVERSAL RAI® SERIES, AIR BLOWERS, 2-1/2” THRU 5” GEAR DIAMETER
 1 2 3 4 5 6 7 8 9 10 11

27
No. PATT. No.
REQ'D. PART NAME PART No.
MAT'L.

A 0.1250
A

1 11 13

27
26
42
29

B B
0.1250
27
SEE NOTE "C" 25
34
VIEW "X" 32
14
31

14 2 38
37

C 3 C
5

18
18
0.0625

SEE NOTE "A"

(DO NOT DRILL THRU) 20
19
8
D D

SEE NOTE "D"

17 33
"X"
36
SEE NOTE "E" 45 0.0625 15 35

30 6" ONLY
E E

39
21 32

23
NOTES

A #25(.150) DRILL 1/4 DP & INSTALL

F ITEM 20 (SCREWS) IN ASSEMBLY F
35 36 16 12 36 35
B SEE OPERATING MANUAL IRB-180
FOR LUBRICATION INSTRUCTION

C INSTALL BEARINGS AS SHOWN BEFORE

SETTING END CLEARANCE

D NUT TO BE TORQUED TO: 55-1242-2

REF. 862-600-023 DO NOT SCALE FOR DIMENSIONS ORDER
MFG. REF. DATE
6"---400 LB. FT. ALL DIMENSIONS SHOWN IN BRACKETS { } ARE MILLIMETERS No.
4-21
CONFIDENTIAL ORIGINAL LOST/REDRAWN ON CAD DAC 1992 DR.
7"---550 LB. FT. 5-3 12-8
SECTIONAL ASSEMBLY
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION OF INCREASED GEAR NUT TORQUE CHKD. REM
E REM 1990 3577-V FCR AGP 1985 FOR 6" & 7" U-RAI BLOWER
G E FOR SIGHT GLASS UNITS ONLY. ROOTS DIVISION, DRESSER INDUSTRIES, INC. IT SHALL G
1-14 3-12
BE HELD IN STRICTEST CONFIDENCE, AND BE USED ONLY D REMOVED ITEM #43 REM 1988 3389-V APP. FCR 1986 WITH TAPER GEAR FIT
USE WASHER OUTSIDE OF GEARBOX. IN CONJUNCTION WITH ROOTS DIVISION BUSINESS. 9-3 8-8 DIMENSIONAL TOLERANCES UNLESS OTHERWISE SPECIFIED
C ITEM 25 REVISED REM 1987 3339-V AGP DBV AP 1986 FINISHED DIMENSIONS

USE RED LOCTITE ON THE THREADS. 3-19

REF: EP938 CONCENTRICITY B ADDED ITEM #43 REM 1987 SCALE TWO PLACE DECIMALS (.XX)---±.015
THREE PLACE DECIMALS (.XXX)--±.005
PERPENDICULARITY FRACTIONAL--±1/64
FLATNESS 2-25
ANGULARITY PROFILE OF LINE A ADDED 7" REM 1987 CAD FILE / DIRECTORY

PARALLELISM PROFILE OF A SURFACE 11-21

REDRAWN DB 1986 /PARTS/XXAS REV
TRUE POSITION ÿ DIAMETER
STRAIGHTNESS FINISH IN MICRO INCHES CHANGE 64792023 F
REVISIONS BY DATE CHKD. APP NTS
NOTICE
0.0000
2 3 4 5 6 7 8 9 10 11
F:\ FILE\ FORM\ DSIZE.GCM

ASSEMBLY OF UNIVERSAL RAI® BLOWERS, 6” AND 7” DIAMETER

 1 2 3 4 5 6 7 8 9 10 11
No. PATT. No.
REQ'D. PART NAME PART No.
MAT'L.

NOTES: A- USE LOCKTITE #2 (30515) BETWEEN HEADPLATE AND

CYLINDER JOINTS.
B- SEE OPERATING MANUAL IRB-180 FOR GAS BLOWERS
FOR LUBRICATION INSTRUCTION.
A A
C- 36,45 & 47 REQ'D SOC. HD. ON G.E. ONLY

27 1 16 13 E- REQ'D ON 32, 33 & 42 URAI-G ONLY-SEALING 46

WASHERS & BUTTONHEAD CAPSCREWS.
25 11
31 32 F- NUT TO BE TORQUED TO:
3-1/2---110 LB.FT.
VIEW "X" 4-------190 LB.FT.
34
5-------250 LB.FT.
27 B
B

14
45
5
26
4

17
38
C C
SEE NOTE 43
"F"
SEE NOTE
8 "B"
18
A

20 19 37
44
D D
SEE NOTE
" E"
A
9
40

SEE NOTE
"C" & "E"
3

E E

33
23
39

15

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668).
21

F F

7 2

32

DO NOT SCALE FOR DIMENSIONS ORDER

MFG. REF. DATE ALL DIMENSIONS SHOWN IN BRACKETS { } ARE MILLIMETERS No. H
01/10/01

CONFIDENTIAL DR. vc
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION OF CHKD.
SECTIONAL ASSEMBLY
G ROOTS DIVISION, DRESSER INDUSTRIES, INC. IT SHALL G
APP.
3-1/2 THRU 5" U-RAI GAS BLOWERS
BE HELD IN STRICTEST CONFIDENCE, AND BE USED ONLY
IN CONJUNCTION WITH ROOTS DIVISION BUSINESS.
D ADD ITEMS 8 & 20 (NAMEPLATE & SCREW) RK 08/16/02 T129 RK AGP DBV
DIMENSIONAL TOLERANCES UNLESS OTHERWISE SPECIFIED
FINISHED DIMENSIONS
12 35 REF: EP938 CONCENTRICITY C ADD LIFTING LUG ITEM # 46 RK 04/12/02 T122 RK AGP SCALE TWO PLACE DECIMALS (.XX)---±.015 FRACTIONAL--±1/64
FULL

FLATNESS PERPENDICULARITY ADD 33 URAI-G TO NOTE E AND THREE PLACE DECIMALS (.XXX)--±.005

ANGULARITY PROFILE OF LINE B DEL. FROM NOTE C RK 12/05/01 T102 RK AGP

PARALLELISM PROFILE OF A SURFACE REV
A PICTURE CHANGE VC 07/25/01 PROTO RK
TRUE POSITION ÿ DIAMETER
STRAIGHTNESS FINISH IN MICRO INCHES CHANGE
REVISIONS BY DATE CHKD. APP D
NOTICE T30099023
0.0000
F:\ FILE\ FORM\ DSIZE.GCM
2 3 4 5 6 7 8 9 10 11

ASSEMBLY OF UNIVERSAL RAI™-G SERIES GAS BLOWERS, 3-1/2”THRU 5” GEAR DIAMETER

28
 1 2 3 5 6 7 8 9 10 11
No. PATT. No.
REQ'D. PART NAME PART No.
MAT'L.

29
A A
A

0.1980

1 11 13

27
26
42
29
VIEW "X"
B B
27
25
44
34
45 32

31

14 37
2
38

C 3 C
5

B B

18

20

19
B B
D D
8 43
"X"

9 33

36
15 35
SEE NOTE "C" 17

30
E E

39
21 32

23
7

F F
16 12
NOTES

A USE LOCKTITE #2 (30515) BETWEEN

HEADPLATE AND CYLINDER JOINTS.

B SEE OPERATING MANUAL IRB-180 FOR

LUBRICATION INSTRUCTION
DO NOT SCALE FOR DIMENSIONS ORDER
MFG. REF. REF. 64792023 DATE ALL DIMENSIONS SHOWN IN BRACKETS { } ARE MILLIMETERS No.

CONFIDENTIAL DR. VC 01/12/01

C NUT TO BE TORQUED TO: SECTIONAL ASSEMBLY
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION OF CHKD.
G ROOTS DIVISION, DRESSER INDUSTRIES, INC. IT SHALL G
6"---400 LB. FT. FOR 6" U-RAI GAS BLOWERS
BE HELD IN STRICTEST CONFIDENCE, AND BE USED ONLY APP.

IN CONJUNCTION WITH ROOTS DIVISION BUSINESS.

DBV
DIMENSIONAL TOLERANCES UNLESS OTHERWISE SPECIFIED

ADD ITEMS # 8 & 20 (NAMEPLATE & SCREW) FINISHED DIMENSIONS

REF: EP938 CONCENTRICITY C RK 08/16/02 T129 RK SCALE NTS
TWO PLACE DECIMALS (.XX)---±.015 FRACTIONAL--±1/64
FLATNESS PERPENDICULARITY THREE PLACE DECIMALS (.XXX)--±.005

PROFILE OF LINE B PICTURE CHANGE VC 07/25/01 PROTO RK

ANGULARITY
PARALLELISM PROFILE OF A SURFACE REV
A ADDED DIMENSION .066 VC 06/26/01 PROTO RK
TRUE POSITION ÿ DIAMETER
STRAIGHTNESS FINISH IN MICRO INCHES REVISIONS BY DATE
CHANGE
CHKD. APP
T30110023 B
NOTICE
0.0000
2 3 4 5 6 7 8 9 10 11
F:\ FILE\ FORM\ DSIZE.GCM

ASSEMBLY OF UNIVERSAL RAI® SERIES GAS BLOWERS, 6” GEAR DIAMETER

 1 2 3 4 5 6 7 8 9 10 11
No. PATT. No.
REQ'D. PART NAME PART No.
MAT'L.
93 (600 RAM ONLY)
NOTES: BOTTOM DRIVE OPTION
27 46
ALSO SHOWN AS GAS SERVICE 46
1. DRIVE END COVER TO BE PINNED TO HEADPLATE AFTER
ALIGNING SEAL BORE WITH SHAFT WITHIN .001
38 91
2. USE TEFLON SEALANT ON ALL PIPE THREADS & CYLINDER 91
A A
TO HEADPLATE FLANGE FOR WHISPAIR GAS PUMP UNITS ONLY.

3. ITEMS 34 & 54 MUST BE INSTALLED WITH OIL GROOVE AT TOP. 70 SEE NOTE No. 8 87 SEE NOTE
NO. 8 87
4. TORQUE TO 400 FT.LBS.-400
TORQUE TO 630 FT.LBS.-600 12

5. TORQUE TO 75 FT.LBS.-400
TORQUE TO 140 FT.LBS.-600

APPLY LOCKTITE TO SCREW THREADS & BOTH FACES OF

WASHER & SLINGER.
92 (600 RAM ONLY)
6. TORQUE TO 35 FT.LBS. (HEADPLATE) 71 BOTTOM O.G.E. DRIVE ONLY

7. TORQUE TO 10 FT.LBS. (GEARBOX/END COVER)

B B
40
8. LOCKTIGHT AND TORQUE TO FT.LBS.-85

5 DETAIL A
600 RAM 400 RAM
1 75 400
WHISPAIR UNITS ONLY
23 600 FOR WATER SEALED
COMPRESSORS ONLY
WHISPAIR GAS PUMP
42 400 600 400
SEE NOTE No.3 SEE NOTE No.2
WHISPAIR UNITS ONLY 44 24 20 19 63 66 23A 23B 23 2
C C
21 90 27
35 32 54 10 22 28 1 12 16 28 22 7
21
49 50
SEE NOTE No.9 90
38

3 70

14 34 32 35

SEE NOTE No.3 23 400 SEE NOTE

D 33 63 D
SEE NOTE No.4 31 No. 6

75 400 SEE NOTE

No. 7
600 66A 66
29
14 88
400 23
8
23 600 SEE NOTE
40 No. 6 & 7
38
60 SEE NOTE No.5
E E
27 SEE NOTE No.1 17
64

10

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668).
5

75 400
22 F F SEE NOTE No. 7
23 600
F F

4 77 37
400 23 76 66

76 22 77
600 23A 66A
400 75 89 13 11 6 22A 1 89
SEE NOTE No. 7
600 23 74 74 SEE NOTE No. 6
FOR WATER SEALED
COMPRESSORS ONLY
J ADDED ITEMS 91,92,93, & DETAIL A VC 04/30/01 T52 RK AGP RAM/RAM-J/RAM-GJ/RAM-VJ
85 85
AGP AGP DO NOT SCALE FOR DIMENSIONS ORDER
MFG. REF. H ADDED ITEM #90 VC 04/04/01 T43 DATE 56-1010
ALL DIMENSIONS SHOWN IN BRACKETS { } ARE MILLIMETERS No.

85A 85A CONFIDENTIAL G ADDED ITEM #88 VC 10/05/00 T22 RK DR. NEP 11/26/96
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION OF ADDED ELBOW & COUPLING VC 11/17/00 T16 RK CHKD. BMS 11/26/96 SECTIONAL ASSEMBLY
F AGP
G ROOTS DIVISION, DRESSER INDUSTRIES, INC. IT SHALL G
E ADDED BOLT TO G.E. SLINER RDR 9/14/99 6400V RLW NEP APP. RDA 11/27/96 400/600 RAM
BE HELD IN STRICTEST CONFIDENCE, AND BE USED ONLY
IN CONJUNCTION WITH ROOTS DIVISION BUSINESS.
D ADDED ITEM No. 23B NEP 7/7/98 5964V RLW NEP DBV NEP 11/26/96
DIMENSIONAL TOLERANCES UNLESS OTHERWISE SPECIFIED
FINISHED DIMENSIONS
REF: EP938 CONCENTRICITY C REVISED FOR 600 RAM RDR 3/24/98 5767V BMS DB SCALE 6"=1'0" TWO PLACE DECIMALS (.XX)---±.015 FRACTIONAL--±1/64
FLATNESS PERPENDICULARITY REV. FOOT TO NEW STYLE DESIGNED FOR THREE PLACE DECIMALS (.XXX)--±.005

PROFILE OF LINE
B HORIZONTAL MOUNTING JPS 9/15/97 5560V BMS RDA
ANGULARITY
PARALLELISM PROFILE OF A SURFACE REV
FOR GAS SERVICE A REVISED NOTE NEP 12/5/96 5048V BMS RDA
TRUE POSITION ÿ DIAMETER
COMPRESSORS ONLY STRAIGHTNESS FINISH IN MICRO INCHES REVISIONS BY DATE
CHANGE 81881023 J
CHKD. APP
NOTICE
0.0000
2 3 4 5 6 7 8 9 10 11
F:\ FILE\ FORM\ DSIZE.GCM

ASSEMBLY OF RAM™ SERIES AIR & GAS BLOWERS

30
UNIVERSAL RAI® SERIES UNIVERSAL RAI® SERIES UNIVERSAL RAI®-DSL SERIES
BLOWERS PARTS LIST BLOWERS PARTS LIST BLOWERS PARTS LIST
2-1/2” – 5” GEAR DIAMETER 6” & 7” GEAR DIAMETER 3-1/2” – 5” GEAR DIAMETER
(Refer to drawing #64720023) (Refer to drawing #64792023) (Refer to drawing #T30356023)

Item # Part Name Qty. Item # Part Name Qty. Item # Part Name Qty.
1 Headplate Gear End 1 1 Headplate Gear End 1 1 Headplate Gear End 1
2 Headplate Drive End 1 2 Headplate Drive End 1 2 Headplate Drive End 1
3 Gearbox 1 3 Gearbox 1 3 Gearbox 1
4 Timing Gears 2 4 Timing Gears 2 4 Timing Gears 2
5 Cover-Blind (Plug Opening) 1 5 Cover-Blind (Plug Opening) 1 7 Gasket, Gear Box 1
7 Gasket, Gear Box 1 7 Gasket, Gear Box 1 11 Cylinder 1
11 Cylinder 1 11 Cylinder 1 12 Impeller & Shaft Drive 1
12 Impeller & Shaft Drive 1 12 Impeller & Shaft Drive 1 13 Impeller & Shaft Driven 1
13 Impeller & Shaft Driven 1 13 Impeller & Shaft Driven 1 14 Bearing, Ball 3
14 Bearing, Ball 3 14 Bearing, Ball 3 15 Bearing, Roller 1
15 Bearing, Roller 1 15 Bearing, Roller 1 16 Pin, Dowel 4
16 Pin, Dowel 4 16 Pin, Dowel 4 17 Gear Nut 2
17 Gear Nut 2 17 Gear Nut 2 19 Key 1
19 Key 1 19 Key 1 21 Plug, Pipe 3
21 Plug, Pipe 3 21 Plug, Pipe 3 23 Screw Hex 6
23 Screw Hex 6 23 Screw Hex Nylock 8 25 Breather (Plug Vent) 1
25 Breather (Plug Vent) 1 25 Breather (Plug Vent) 1 26 Screw, Hex *
26 Screw, Hex * 26 Screw, Hex * 27 Seal, Lip Bearing 4
27 Seal, Lip Bearing 4 27 Seal, Lip Bearing 4 31 Screw, Hex, Nylock 4
31 Screw, Hex, Nylock 4 31 Screw, Hex, Nylock 4 32 Screw, Hex 6
32 Screw, Hex 6 32 Screw, Hex 10 33 Seal Lip-Drive 1
33 Seal Lip-Drive 1 33 Seal Lip-Drive 1 34 Clamp Plate 2
34 Clamp Plate 2 34 Clamp Plate 2 35 Foot 2
35 Foot 2 35 Foot 2 39 Washer Mounting 4
37 Fitting, Grease 2 37 Fitting, Grease 2 40 Screw Socket 2
38 Fitting, Relief 2 38 Fitting, Relief 2 42 Screw Hex 2
39 Washer Mounting 4 39 Washer Mounting 4 48 DE Oil Slinger Set Screw 4
40 Screw Socket 2 *Quantities vary by blower. 50 Drive End Cover 1
42 Screw Hex 2 52 Drive End Oil Slinger 2
*Quantities vary by blower. *Quantities vary by blower.

UNIVERSAL RAI®-DSL SERIES BLOWERS PARTS LIST

6” GEAR DIAMETER
(Refer to drawing #T30383023)

Item # Part Name Qty. Item # Part Name Qty.

1 Headplate Gear End 1 21 Plug, Pipe 3
2 Headplate Drive End 1 23 Screw Hex Nylock 8
3 Gearbox 1 25 Breather (Plug Vent) 1
4 Timing Gears 2 26 Screw, Hex *
7 Gasket, Gear Box 1 27 Seal, Lip Bearing 4
11 Cylinder 1 31 Screw, Hex, Nylock 4
12 Impeller & Shaft Drive 1 32 Screw, Hex 10
13 Impeller & Shaft Driven 1 33 Seal Lip-Drive 1
14 Bearing, Ball 3 34 Clamp Plate 2
15 Bearing, Roller 1 35 Foot 2
16 Pin, Dowel 4 39 Washer Mounting 4
17 Gear Nut 2 48 DE Oil Slinger Set Screw 4
19 Key 1 50 Drive End Cover 1
52 Drive End Oil Slinger 2
*Quantities vary by blower.

31
UNIVERSAL RAI® SERIES UNIVERSAL RAI® SERIES RAM™ SERIES PARTS LIST
GAS BLOWERS PARTS LIST GAS BLOWERS PARTS LIST 4” & 6” GEAR DIAMETER
3-1/2” & 5” GEAR DIAMETER 6” GEAR DIAMETER (Refer to drawing #81881023)
(Refer to drawing #t30099023) (Refer to drawing #T3011023)

Item # Part Name Qty. Item # Part Name Qty. Item # Part Name Qty.
1 Headplate Gear End 1 1 Headplate Gear End 1 1 Headplate 2
2 Headplate Drive End 1 2 Headplate Drive End 1 3 Gearbox 1
3 Gearbox 1 3 Gearbox 1 4 Timing Gears 2
4 Timing Gears 2 4 Timing Gears 2 5 End Cover 1
5 Cover-Blind (Plug Opening) 1 5 Cover-Blind (Plug Opening) 1 7 Gasket – Gearbox/Cover 2
7 Gasket, Gear Box 1 7 Gasket, Gear Box 1 10 Shims-(.010) Lot
11 Cylinder 1 11 Cylinder 1 11 Cylinder 1
12 Impeller & Shaft Drive 1 12 Impeller & Shaft Drive 1 12 Impeller & Shaft Drive 1
13 Impeller & Shaft Driven 1 13 Impeller & Shaft Driven 1 13 Impeller & Shaft Driven 1
14 Bearing, Ball 3 14 Bearing, Ball 3 14 Bearing Roller 4
15 Bearing, Roller 1 15 Bearing, Roller 1 16 Pin, Dowel (Pull Out) 4
16 Pin, Dowel 4 16 Pin, Dowel 4 17 Pin, Dowel 2
17 Gear Nut 2 17 Gear Nut 2 19 Key Square 1
19 Key 1 19 Key 1 21 Breather 2
21 Plug, Pipe 3 21 Plug, Pipe 3 22 Plug, Pipe 12
23 Screw Hex 8 23 Screw Hex Nylock 8 23 Screw, Cap Hex Hd. *
25 Breather (Plug Vent) 1 25 Breather (Plug Vent) 1 27 Seal, Ben Binh. 4
26 Screw, Hex 14* 26 Screw, Hex 14* 28 Piston, Ring-Seal 4
27 Seal, Bearing 4 27 Seal, Bearing 4 29 Washer, Wavy Spring 2
31 Screw, Hex 4 31 Screw, Hex 4 31 Gear Nut 2
32 Screw, Hex 4 32 Screw, Hex 10 32 Scr, Cap Hex Hd. 16
33 Seal Lip-Drive 1 33 Seal Lip-Drive 1 33 Seal, Lip Drive 1
34 Clamp Plate 2 34 Clamp Plate 2 34 Brg. Clamp Plate - D. E. 2
35 Foot 2 35 Foot 2 35 Lock Washer - Spring 16
37 Fitting, Grease 2 37 Fitting, Grease 2 37 Sight Plug - Oil Level 2
38 Fitting, Relief 2 38 Fitting, Relief 2 38 Sleeve, Shaft 4
39 Washer Mounting 4 39 Washer Mounting 4 40 Slinger - D.E. (Top Drive) 1
40 Screw Socket 2 40 Screw Socket 2 46 Slinger - G.E. (Optional) 1
42 Screw Hex 2 42 Screw Hex 2 49 Oil Leader L/S 1
*Quantities vary by blower. 43 Plug 8 50 Oil, Leader-R/S 1
*Quantities vary by blower.
54 Brg Clamp Plate - G. E. 2
60 Screw, Cap Butt. HD. 1
64 Pin, Spring 1
66 Screw, Cap Hex HD. *
SUGGESTED LUBRICANTS 66.1 Whispair, Spring Lock 3/8M *
70 Shims D.E. Brg. 1
ROOTS Synthetic Oil: ISO-VG-220 Grade 75 Screw, Cap - Hex HD. *
Part Number 76 Blower Foot - RH 2
Quart 813-106-001 77 Blower Foot - LH 2
Gallon 813-106-002 85 Elb, Pipe-Black 2
85.1 Plug, Pipe 2
Case (12 qts) 813-106-008
87 Scr, Cap BH 2
88 Anti Rotation Ball 4
ROOTS Synthetic Oil: ISO-VG-320 Grade 90 BSHG-RDCG 2
Quart 813-106-004 91 Washer, Plain Flat 2
Gallon 813-106-005 92 Washer, Plain Flat 2
Case (12 qts) 813-106-007 93 Washer 2
*Quantity varies by blower.

ROOTS Synthetic Grease: NLGI #2

14.5 oz. Tube T200019-001
5 Gallon Pail T200019-003
Case (30 tubes) T200019-002

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 32
 ASSEMBLY OF UNIVERSAL RAI® SERIES - DSL WITH SPLASH LUBRICATED DRIVE END 3-5” GEAR DIAMETER

For your nearest ROOTS Office, dial our Customer Service Hot Line 1 877 363 ROOTS (7668). 33
34
ASSEMBLY OF UNIVERSAL RAI® SERIES - DSL WITH SPLASH LUBRICATED DRIVE END 6” GEAR DIAMETER
 CONTACT LIST

CUSTOMER SERVICE
Dresser ROOTS
2135 Hwy 6 South
Houston, TX 77077
Toll Free Hot Line: 1-877-363-ROOT(S) (7668)
Toll Free Fax: 1-877-357-7238
Local Fax: 281-966-4309
ROOTS Factory Service & Repair Center
11611B Tanner RD
Houston, TX 77041
Toll Free: 1-800-866-6182
Local Phone: 713-896-4810
Local Fax: 713-896-4927
Service & Warranty
Toll Free: 1-800-866-6182
Local Phone: 832-467-4614
Local Fax: 713-896-4927

Dresser, Inc.
Dresser ROOTS Dresser ROOTS - Connersville Dresser ROOTS - Holmes Operation
2135 Hwy 6 South 900 West Mount Street PO Box B7
Houston, TX 77077 Connersville, IN 47331 Off St. Andrews Rd
PH: 281-966-4700 PH: 765-827-9200 Turnbridge, Huddersfield
FX: 281-966-4309 FX: 765-827-9266 England HD1 6RB
Toll Free: 1-877-363-ROOT(S) PH: +44-1484-422222
IRB-180-102 FX: +44-1484-422668
Rev. 2.04
©2004 Dresser, Inc. all rights reserved.
website: www.rootsblower.com • email: [email protected]
ROOTS, RAM, URAI and WHISPAIR are trademarks of Dresser, Inc.
Dresser Design and Universal RAI are registered trademarks of Dresser, Inc.