REVISED: 4-07-07 1
Olympus M1200 Operating Manual TABLE OF CONTENTS TOPIC PAGE # • Introduction • Technical Specifications • Optional Equipment 3 4 5 SECTION 1: Operational Safety • Electrical Safety • Mechanical Safety 6 7 SECTION 2: Operation Procedures • Electrical Supply • Water Supply & Chemicals • Chemical Metering Tips • Water Supply • Pump Priming • Solution & Vacuum Hoses • Pump-Out System • Pressure Adjustments • Shutdown Procedures • Troubleshooting • Solution Flow Path • Wiring Diagrams 8 9 10 11 12 13 15
Introduction Congratulations on your purchase of the Hydro-Force Olympus M1200. The M1200 is designed to give truckmount-level performance in a portable machine that combines versatility with ease of transport. Years of experience, engineering, and planning have gone into the design and manufacturing of the M1200. We take a great deal of pride in the M1200; our goal is no less than your complete satisfaction.
Technical Specifications M1200 High Pressure Extractor Height: 38” Length: 28” Width: 19-1/2” Weight: 141 lbs. Solution Tank Capacity: Recovery Tank Capacity: 12 gallon 12 gallon Solution Pump: Pump-Tec #356 pump with 1-1/2 HP Motor 0-1200 psi – 2.2 gpm Vacuum Motors: Two AMETEK Lamb 5.7” diameter – tangential discharge One two stage & One three stage – Mounted in series Pump-out Pump: Little Giant 120VAC 8-20 gpm Maximum psi 11.4 – Maximum pumping height 26 ft. Power Draw: Cord #1 – 17.
Additional / Optional Equipment Carpet Wand: SX-12 Hard Surface Tool: SX-7 Tile & Grout Tool: Gekko Tile & Grout Wand: Gekko Hand Tool: Gekko SX-7 Tool: 1-1/2” Vacuum Hose: (Sold per foot – No cuffs) 2” cuff for 1-1/2” Vac Hose: 1-1/2” cuff for 1-1/2” Vac Hose: 2” Hose Connector PVC: 1-1/2” Hose Connector PVC: HP Solution Hose: (Does not include Quick Connects) 1/4” Male Quick Connect: 1/4” Female Quick Connect: Pump-out Hose: Replacement Bags for Hydro-Filter: Metering Tip Kit: AW29 AW104 AW29 AW104 AW
1 Section Safety CAUTION! This machine is an electrical appliance. Care must be taken to reduce the risk of electrical shock. • READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE OPERATING THE M1200. • To reduce the risk of property damage or injury, repairs to electrical systems should only be performed by experienced technicians. Contact your distributor for assistance. • Unplug machine power cord from outlet before performing any repairs on the extractor. • Plug unit into grounded outlets only.
WARNING! This machine must be protected from conditions which may damage the pump, tank, hoses and other components. • Freezing of water in this machine will cause serious damage. The M1200, solution hoses, and tools must be protected from freezing temperature. Store, transport, and use this equipment only in temperatures well above freezing. (32ºF or 0ºC). If you suspect the M1200 has been frozen, do not plug in or turn on machine until you are sure it has thawed completely.
2 Section Operation Procedures Knowledge of the proper operation of the M1200 is required to ensure user safety and efficient performance of the extractor. SET UP AND OPERATION 1. Electrical Cords: Two 50’ power cords are supplied with the Olympus M1200. Cord #1 powers both vacuum motors; Cord #2 powers the high pressure solution pump and the waste pump.
2A. Water Supply & Chemical Mixing– Manual Fill: • • • Pour up to 12 gallons of hot water into the solution tank at the front of the machine. The water temperature cannot exceed 180°F. Measure and add the appropriate amount of the desired liquid chemical to the water in the solution tank. The amount of chemical will vary depending on the type of chemical used, the amount of water in the tank, and the material being cleaned; consult the chemical packaging for specific mixture ratios.
How To Change the Metering Tip: • Remove the chemical feed hose from the barb on the side of the proportioning valve. • Unscrew and remove the old tip. • Screw in the proper tip for your chemical tip and place the hose back on the barb Proportioning Valve Turquoise Tip Dilution 256 - 1 Red Tip Dilution 85 - 1 Metering Tip Kit – PDE001 Metering Tip Kit (Hydro-Force Item# PDE001) contains 14 different colored metering tips, allowing dilution rates from 11:1 up to 427:1.
Water Supply: • Once the correct metering tip is in place: o Connect the Auto-Fill Water Supply Hose to the water inlet (the male quick-connect on the front of the machine.) o Connect the other end of the hose to a water faucet, and then turn on the water. • Hot water can be used as long as the temperature does not exceed 180°F. • Faucet adapter kits (Hydro-Force item #AX21 & AX22) are available that allow connection to different types of faucets if needed.
3. Priming the High-Pressure Pump: Once water is in the solution tank, the high-pressure solution pump must be primed: • There is a prime valve located on the front lower portion of the machine. • Turn on both vacuums and the water pump. Press the priming lever for a few seconds while you block off the vacuum inlet with your hand. The Vacuum will pull solution through the pump and prime valve into the vacuum tank. • Let off the prime valve and your pump is then primed.
4. Connection of Solution Hose: Connect the high pressure solution hose to the solution outlet (female quick connect on the front of the machine). Connect the other end of the hose to the male quick connect on the cleaning tool. When you are ready to start cleaning, turn the solution pump switch to the ON position Connect the male end of the HP Solution Hose Assembly to the female solution outlet fitting on the machine. Connect the female end to the cleaning tool.
Foam can decrease vacuum lift and eventually ruin the vac motor. The Foam Downer kills foam as waste water enters the machine. It uses a hook to hang a jug of liquid defoamer from your portable. Foam Downer injects defoamer into the vac hose. Your portable suffers no power loss from foam and your motor suffers no damage.
6. Connection of Pump-out Hose: The pump-out hose is a 50’ section of 3/4” garden hose. • Remove the cap from the pump-out outlet fitting on the back of the machine. • Connect the pump-out hose to the outlet fitting. • Place the other end of the hose in a commode or drain connected to the sanitary sewer system. • Secure hose end to prevent movement during pumping. Use defoamer to prevent foam build-up in recovery tank during cleaning and to keep foam/moisture from entering vacuums.
7. Pressure Adjustment: When the high-pressure solution pump is on and primed, pressure will show on the gauge only while the tool is being sprayed. When the tool is sprayed the gauge will display the pressure being delivered to the tool. When the tool is not being sprayed the gauge will return to zero. • To decrease the pressure, turn the black knob on the pressure regulator to the left (counterclockwise.) • To increase the pressure, turn the black knob on the pressure regulator to the right (clockwise.
Shutdown Procedures: • If using the auto-fill system, turn the water supply off before finishing each job. This will allow use of the water and chemical already in the tank, and will reduce the amount of excess water to be disposed of later. • When finished cleaning, turn off all switches. • If the auto-fill system was used and there is still water in the solution tank, push the float down to release the water inlet hose pressure before disconnecting the hose from the faucet.
2 Section Troubleshooting Troubleshooting – Olympus M1200 Problem Cause Solution Machine not turning on No power Building circuit breaker tripped. Faulty power cord Faulty switches or internal wiring Reset breakers or move cords to other outlets Replace cord Check wiring & test switches - Repair as needed * Building circuit breaker tripped.
Problem Cause Solution Pump-out not working Building circuit breaker tripped.
Problem Solution Tank not filling Cause Water source turned off Float not on valve arm Float valve faulty Water hose restricted Quick connects faulty Solution Turn on faucet or find other water source Reconnect float to valve arm - Adjust to proper height/level Repair or replace float valve Un-kink, clean out or replace hose Clean out or replace quick connects Solution tank overflowing Float too heavy/ Filled with water Float & chain tangled Float too high Float valve faulty Replace float Make sure flo
M1200 Solution Flow Path Inlet Quick Connect Float Valve Solution Tank Outlet Quick Connect Filter Gauge Chemical Jug Pump – AP48 Pressure Regulator / Unloader – PT019 Denotes incoming water flow Denotes Water flow in high pressure hose Denotes by-pass water flow from pressure regulator 21 Denotes Chemical flow
M1200 Wiring Diagram VACUUM #2 2-Stage WHITE BLACK SOLUTION PUMP BLUE BLACK 12 GA RED BLACK YELLOW Vacuum #1 VACUUM #1 3-Stage BLACK FLOAT SWITCH BLACK BLACK 12 GA BLACK Vacuum #2 BLACK Solution Pump Waste Pump CORD #1 WASTE PUMP TO COMMON GROUND FOR ALL COMPONENTS WHITE BLUE WHITE GREEN WHITE BROWN TO COMMON GROUND FOR ALL COMPONENTS GREEN BLACK 22 CORD #2
OLYMPUS SWITCH PANEL: Vacuum #1 – Power from Cord #1. When the switch is turned to the ON position power is supplied to the vacuum motor. (3-Stage Vacuum) Solution Pump Switch – Power from Cord #2. When the switch is turned to the ON position power is supplied to the solution pump motor. When not using solution (Extracting Only) do not turn this switch ON. Vacuum #2 – Power from Cord #1. When the switch is turned to the ON position power is supplied to the vacuum motor.
3 Section Maintenance Proper maintenance is required to keep the M1200 operating properly, prevent downtime and to extend the life of your equipment. WARNING: Disconnect electrical power before performing any service or maintenance inside machine base or before testing or repairing switches or power cords. Failure to do so may result in severe personal injury or death.
CLEAN CHEMICAL FEED FILTER & FOOT VALVE: The Filter & Foot Valve is on the end of the chemical feed hose that is placed in the chemical jug as part of the chemical feed system. Regularly examine the filter and clean as needed. To test the Foot Valve: • Remove the Filter & Foot Valve from the end of the chemical feed hose and rinse in fresh water. • Blow through the valve from the filter side of the barb.
CLEAN THE HYDRO-FILTER: Build-up of debris in the filter bag of the Hydro-Filter will reduce the vacuum air flow and may cause a significant decrease in water recovery. A torn filter bag will allow debris past the filter and into the recovery tank. This debris can clog the Waste Pump and the Vacuum Shutoff Assembly. The Hydro-Filter must be examined and cleaned regularly to keep the M1200 functioning properly: • Push the latch lever and open the Hydro-Filter lid. • Remove the filter bag.
CLEAN WASTE PUMP-OUT PUMP: Build-up of fine silt inside the Waste Pump can clog the pump even if the pump is not used, so this maintenance procedure should be performed regardless of whether the Waste Pump has been used. • After cleaning out the recovery tank, remove the cap and connect the Pump-Out hose to the Waste Pump outlet fitting on the back of the machine; run the hose to a drain.. • With Cord #2 plugged in, turn the Waste Tank switch to the ON position.
FLUSH SOLUTION TANK AND PUMP: (continued from previous page) Direct the end of the prime hose into the recovery tank vacuum barb CLEAN PUMP INLET FILTER Vacuum acid solution out of Solution Tank A restricted Pump Inlet Filter can prevent the solution pump from providing adequate pressure for cleaning. A restriction or air leak on the pump inlet can also damage the solution pump check valves and plunger seals. CAUTION: Before proceeding with this procedure, make sure both power cords are disconnected.
FLUSH CHEMICAL SYSTEM: Chemical build-up in the chemical system can prevent the system from drawing chemical. • Rinse the chemical system with fresh water (For heavy chemical buildup, a mild acid can be added to the rinse water.) Place Chemical Feed Hose into • Remove the chemical feed hose from the solution tank and place the Rinse Solution end of the hose in a bucket of fresh water or mild acid solution.
LUBRICATE PRESSURE REGULATOR O-RINGS: To maintain consistent adequate pressure delivery to the cleaning tool, the o-rings on the stem of the M1200 pressure regulator must be lubricated regularly. 1. Remove nut from the end of the regulator stem. 2. Remove the black knob from the regulator stem. 3. Remove the spring plate, spring, and spring washer from the regulator stem. 4. Remove the jam nut and washer from the shoulder of the regulator stem retainer. (The set point nuts do not need to be removed.
10. Apply thread sealant to the threads of the stem retainer and screw the retainer back into the regulator body. Tighten using wrenches. Screw stem retainer back into regulator body Apply thread sealant to stem retainer 11. Place the regulator back into the opening on the base wall. Reconnect any hoses which were removed to access the regulator. (Use thread sealant when reconnecting hoses.) 12. Reconnect vacuum hose to vacuum manifold.
CLEAN RECOVERY TANK DRAIN Debris and sand accumulation in the drain valve can damage the valve or prevent it from closing completely. This will result in dirty water leaking from the valve. Use of the Hydro-Filter and regular cleaning of the recovery tank will help prevent this, but occasionally the drain valve will require cleaning or replacement. Drain the recovery tank before attempting to service the drain valve.
Storage Prep and Freeze Protection Procedures: Your Olympus M1200 must be protected from freezing. Freezing can cause serious damage to the pump, pump-out, auto-fill float valve, and any other component containing water. If the M1200 is transported or stored in freezing temperatures, the following procedures should be performed. ALSO, if the M1200 is stored for an extended period of time, the following procedure should be performed to prevent the pump seals from drying out. 1.
3 Section Parts Replacement parts available for repair of your M1200.
PUMPTEC #356 PUMP – AP48 ITEM DESCRIPTION QTY PART NUMBER 1 PLUNGER 1 0311-0006-0002 2 PLUNGER GUIDE 2 0311-0009 3 O-RING FOR PLUNGER GUIDE 2 C0100-1124 4 U-CUP 2 C0220-1075 5 U-CUP BACKING RING 2 0311-0011 6 PUMP HEAD 2 0356-0002-0001 7 PUMP MANIFOLD 1 0356-0004-0001 8 VALVE ASSEMBLY 4 0205-0012 8A VALVE SEAT (Part of #8 - Valve Assembly) 4 0205-0017 8B VALVE POPPET (Part of #8 - Valve Assembly) 4 0205-0013 8C VALVE SPRING (Part of #8 - Valve Assembly) 4 C1220
OLYMPUS AUTO-FILL FLOAT VALVE ASSEMBLY Part Number 16-3 25-78 34-17 34-22 35-12 35-18 35-31 35-32 35-33 35-35 35-36 35-37 41-1-8 41-7-25 41-15-5 61-121 61-122 61-107-2 61-22-3 63-35 63-37 63-38 63-46 63-87 100-3 100-11P 100-12 100-15 37 Description 3’ Discharge Tubing Pipe Nipple 16” Chain with Connector Backflow Preventer Float Hanger Clip – PDE35-12 Float Assembly – PHY005-003 Magnet Housing Magnet Holder Spring Float Hanger Wire – PDE35-42 Valve Body Flange Spring Enclosing Tube Diaphragm Elbow 90º St
1 1A 2 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 NS 1A 3A 16 17 DESCRIPTION REGULATOR BODY REGULATOR KNOB SPRING SPRING PLATE SPRING WASHER CAP / RETAINER O-RING (QTY 3) POPPET O-RING POPPET POPPET SPRING RETAINING RING SPRING – BALL SEAT BALL STEM NUT OUTLET ADAPTER CAP INLET ADAPTER CAP STEM RETAINER SEAT STEM NUT – SET POINT LOCK (QTY 2) STEM O-RING STEM SPACER (QTY 2) SMALL STEM O-RING SMALL STEM SPACER (QTY 2) ROLL PIN PT019A - REGULATOR REPAIR KIT (Includes: 4, 5, 6, 7, 8, 9, 10, 15,
4 Section Limited Warranty Your Olympus M1200 is designed to give you years of reliable service. If a problem should arise use the troubleshooting section in the operation manual to diagnose and correct the problem if possible. If you are unable to determine the cause or solution to the problem contact your distributor or Hydro-Force for assistance.
