TruckMaster

Duct Cleaner for Use With Truck Mount

Carpet Vacuums

OPERATING INSTRUCTIONS MANUAL

Topic Page

Unpacking 2

Safety 2

Parts Locations 3

Accessory Pictures 4

Duct Cleaning Instructions

Motor Replacement

5

6

Specifications 8

Parts List

Bristle Replacement

Trouble Shooting

8

9

12

Glossary 13

Warranty 14

Part #: FG0100

MM0146

TruckMaster Manual

Updated 07/18/12

Air-Care is a Division of D.P.L. Enterprises, Inc.

3868 E. Post Road, Las Vegas, NV 89120 (702) 454-5515, Fax (702) 454-5225

Website: www.air-care.com, E-mail: [email protected]

Page 1 of 15

Inspect all of the packing material for small parts before discarding packaging material. Report all damage to Air-Care immediately. Any attempt at repairing suspected damages may void warranty.

Check that all parts are present

Air-Care TruckMaster Duct Cleaner

Main Control Case

16 Gauge Grounded Power Cord

Vacuum Hose, 1 ½” x 35 feet with 12” Pancake Flex-E-Bristle Brush, 1500 Watt Motor and

Power Cord

Handheld Remote Control Transmitter -

Instruction

Safety Precautions

Always use safe and common sense precautions when working with Air-Care equipment. Do not block walkways with equipment, and remove delicate and breakable articles from the immediate work area. The following are precautions that should be reviewed by all persons who will be involved in the cleaning activity.

Other than replacing the brush motor on the end of the vacuum hose, there are no user serviceable components in Air-Care TruckMaster. Only trained technicians should attempt to make internal repairs on this equipment.

Always unplug the power cord before removing the covers or working on the wiring.

Inspect AC power plug to be sure the ground pin is in place.

Never connect power to Air-Care equipment unless all covers and safety shields are in place.

Mechanical and electrical parts could activate and cause injury.

Never allow anyone but a properly trained technician to use the equipment or cleaning products.

All Air-Care equipment is designed for US standard 115 volt, 60 Hz AC. The Air-Care

TruckMaster is optionally available in 220/240 Volt, 50/60 Hz Power. Always check the specifications on the equipment before connecting electrical power to Air-Care Equipment.

If you have questions about the safe use of any Air-Care product, call 702-454-5515

Equipment specifications and part numbers are subject to change without notice.

Page 2 of 15

Dual Latches

Gasket for

Watertight seal

Remote Control stored for transport

Air Filter

Fold away handle

Remote Storage with Velcro

Power ON

Light

Cooling fan

Pressure

Release

AC Power Receptacle

Fuse compartment with Spare

Secondary

Brush FWD/REV switch

Main Power Switch

Remote IR

Dual Sensor

Page 3 of 15

Secondary

Brush RUN switch

Brush Power

Connector

Velcro to secure

Remote in Case

Clip for

Pocket or Belt

12” Flex-E-Bristle Brush for

4”-12” Ducts is Standard on

1.5” hose

9 Volt Battery

Compartment

Battery Compartment

Cover

Truck Mount Solution

Hose connection

Infrared Window

Truck Mount Vacuum

Hose Connection

Dust Damper

1.5” p/n CE1815

2” p/n CE1816

Red LED

Indicator

Brush Motor RUN and STOP Button

Brush Motor

Forward and

Reverse Button

Connection to TruckMaster

Vacuum Hose

Bristles are replaceable

1500 Watt Brushless

Outrunner Motor

1.5” Crushproof Hose is Standard, 2” hose optional with 18”

Bristle Brush

Maximum Opening in Vacuum Hose

Flexible Spring

Protects Motor Wires

Flexible Steel Motor Mount to

Negotiate Sharp Corners

Page 4 of 15

Duct Cleaning with the Air-Care TruckMaster

The Air-Care TruckMaster has a unique dual function. The motorized brush on the end of the vacuum hose assembly agitates the dust and debris in the air duct, while the Truck Mount Vacuum functions as the debris collector. This method of cleaning only requires that the supply and return grills be removed and the air system is turned off. Caution, some air systems may automatically cycle in the

OFF position on the Thermostat, so it is best to also shut off the main power breaker to the furnace while cleaning.

Before applying power, be sure that all 3 Switches on the Control Box are in the

OFF (0) position. After connecting the Air-Care TruckMaster power cord to the

Power Inlet, wait 20 seconds before attempting to turn on the Brush. Connect the 1 ½” X 35’ hose assembly (or the optional 2” X 35’ hose assembly) to your

Vacuum Source Hose. The electrical cord from the hose will plug in to the

TruckMaster control box. Unless your truck vacuum has provision for “Dry Dust”, you should install the “Dust Damper” between the Truck vacuum hose and the

TruckMaster Hose and attach the solution hose to the trucks solution hose. This wets the dust so it will not damage the vacuum blower wheel.

The Remote uses an Infrared Light beam similar to a Television Remote. The operator must be in sight of the DuctMaster Control Panel where the Remote

Receiver is located for it to operate. The operator can be across the room or up

Cleaning Ceiling Ducts on a ladder and the remote will function as long as there are no obstructions between the operator and the sensor on the TruckMaster Panel. The remote will

NOT work between rooms.

When using the Remote, BOTH Switches on the control box for the brush MUST BE OFF (0)! These switches can be used to manually

START/STOP or control FWD/REV directions of the brush if the

Handheld Remote Transmitter is lost or has a dead battery. When these switches are ON (1), it deactivates the Remote.

Once the technician inserts the brush into the duct, use the Remote’s

ON/OFF Button to start the brush and gently work the vacuum hose and brush into the duct. STOP the brush before removing it from the duct.

When the technician cannot push the vacuum hose in any farther,

Cleaning Floor Ducts press the FWD/REV button on remote to “reverse” the brush rotation to allow it to go deeper into the ducts. Repeat this process for each supply and return duct. Pull the hose partially out of the duct with the motor running, but stop it before removing the brush from the duct.

Where you have long ducts, such as main trunk lines without access doors, you must make “cut-ins”, to access the entire length of the duct.

After cleaning each duct, each opening should then be decontaminated by fogging them with our EPA registered Envirocon sanitizer, Soot Set sealer and Liquid Odor Kill deodorizer.

Page 5 of 15

Brush Motor Replacement Kit

Updated Coaxial Spring Mount

This new version of the Brush Motor and Mount retains all the advantages of the original and includes some improvements to reliability, durability, and Debris Collection.

This motor and Hose mount will replace all previous motors and mounts.

KEEP THE NEW MOTOR FULLY ASSEMBLED!

First remove the OLD motor and mount from your hose:

1. Remove the screws holding the metal collar on the end of the hose and save the screws and nuts to mount the new motor and mount.

2. Cut the 3 wires for the motor leaving enough cord to crimp (or solder) the wires to the new motor wires. All 3 wires will need to be the same length for this new Motor Connection.

3. You will no longer need any of the parts in the original motor assembly unless you are returning it to Air-Care with an RMA for warranty evaluation.

Installing the NEW motor assembly.

1. Be sure you have all the parts for the installation. a. Your original Screws, 10-32 x 5/8” long machine screws, b. 10-32 Hex Nuts with built in Lock Washers.

2. Remove the outer insulation from the black power cord in the hose to expose the 3 insulated motor wires about 2 inches long.

3. Strip the insulation off of all 3 wires about ½” back from the ends.

4. Slide the black Shrink Tubing over the cable. It will be slid over the new connections after the wires are connected.

5. Slide the 3 pieces of shrink tubing over each of the motor wires. The connections can be made by Crimping the new connectors or soldering them. If you are planning to solder the connections, be sure the blue shrink tubing is far enough away from the heated ends to prevent it from shrinking prematurely.

6. The wires may be different colors from the Motor than the ones from the hose cable. The order is not important, the brush will operate with any combination of wires, but it may turn in the opposite direction in some cases, but will still reverse as before.

7. Each of the 3 wires from the hose can now be inserted into the Crimp connectors on the new motor. Try to twist the wires tight enough so that all of the strands go into the silver

Page 6 of 15

8. Slide the Blue shrink tubing over the metal connector; Heat the tubing to shrink it in place.

A hair dryer, heat gun or even a cigarette lighter can be used. Be careful to not burn yourself, the plastic hose or heat the other shrink tubing at this time.

9. Connect the other 2 wires following the same procedure.

10. When all 3 wires are connected and insulated, slide the black shrink tubing over them and as far towards the motor as possible. Heat this shrink tubing to shrink it on to the wires.

11. Next, slip the Nylon Loop Strap over the wires. This will hold the wires in place and minimize strain on the connections. The Loop Strap will be held in place with one of the

10-32 x 5/8” screws used to hold the black nozzle on the hose.

12. Insert the screws into the mounting holes in the Nozzle and thread the screws into the original holes in the hose if possible. If this is difficult, you may need to drill new holes in the hose using the 2 holes in the Black Nozzle as a guide. Use a 3/16” diameter drill.

13. When the screws are in place, place the loop strap hole over one of the screws and install one of the nuts then tighten the screw with a screwdriver. It may be necessary to use a screw driver to thread the screws through the loop strap.

14. If your hose has a metal stiffener, install its loop over the other screw, install the nut and tighten it. If there is no stiffener, just install the nut and tighten the screws.

15. Your repair and upgrade is now complete and ready to test. If you have any questions, please call Air-Care Tech Support, 800-322-9919.

Page 7 of 15

Specification

Size

Weight

Power requirements:

Power Cord

Hose Attachments

Specifications

Description

11” W x 10” D x 7” H

7.5

115 Volt AC, 60Hz, 5 AMPS

(Optional: 220/240 Volt, 50/60 Hz, 3 AMPS)

16 gauge, 3 wired grounded to Computer type Receptacle

Hose, 1 ½” X 35’ TruckMaster Brush and Motor Assembly.

Includes: 12” Pancake Brush, .021” BLK Level Bristles

Power Brush RPM is 2,000 max. with 1500watt Motor and

Power

Connector

Dust Damper for use with Truckmount carpet machines connects between Truck Vacuum hose and TruckMaster vacuum hose.

25 to 125 Deg F (-4 to 50Deg C) Operating Environment

Case Durable Poly case with dual latches and waterproof lid

Operating Controls,

TruckMaster

ON/OFF main power with Red LED power indicator

Wireless Handheld IR Remote Control with 2 Activating Buttons to Start/Stop and change direction of brush rotation.

Secondary Brush On/Off and Brush Fwd/Rev switches on panel

Description

TruckMaster Duct Cleaning system

Parts List

Part

Number

Notes

FG0100

Power & Control Box, 1.5” x35 ft Hose,

12” brush 1500 watt Motor, Dust Damper,

AC cord and Bag

SATM0019 Power Cord NOT included TruckMaster Power and Control Box

Remote Transmitter, hand held, 2 button, Belt/Pocket clip

Battery for remote (9 Volt)

Brush, Motor, Vacuum hose Assembly 1.5”

SATM0014 9 Volt Battery Included

COM0018 Standard 9 Volt Battery

FG0074 Includes 12” Pancake Brush

Brush, Motor, Vacuum hose Assembly 2.0”

Replacement Brush Motor Kit, 1500 Watt w/ Instructions

Replacement Flex-E-Bristle Brush with Pancake Hub, 12”

Replacement Flex-E-Bristle Brush with Hub 18”

Bristles, set of 3 bundles, 12” x .021” Dia Level

Bristles, 1 hank, 18” x .032” Dia Level

Power Cord, 15 ft, 18 ga x 3 wire grounded

Coil N Carry

Dust Damper, 2.0”

Fuse, 10 Amp, 5mm x 20mm

FG0075

SADM0054

Includes 18” brush

SAO0307 .021” Diameter Nylon, Black, Level

SATM0013 .032” Diameter Nylon, Black, Level

SAO0310 1 Replacement

BA0003 Enough for 5 replacements

EC0012

FG0102

FG0051

EC0038

Standard Computer type end

TruckMaster has 1 SPARE fuse in holder

Page 8 of 15

Pancake Brush P/N SAO0307

12” Bristle Replacement Instructions

Updated: 9/10/12

The configuration of the 12” brush (0.021 Dia

Bristles) for the TruckMaster and DuctMaster

1.5” vacuum hose and Motor has been changed to a Shorter, “Pancake” hub that allows it to negotiate sharp turns in smaller air ducts than the previous type hub. This 12” Brush directly replaces the original 12” Brush asm.

The 2” Vacuum Hose and motor still use the 18” brush with 0.032” dia Bristles in the traditional, longer hub.

This 12” Brush will work on the 2” hose.

While the 18” Brush will fit on the 1.5” hose, there are some situations where the 18” brush may not start properly (Due to the brush being held

HIGHER by the 2” hose, so the thicker bristles are easier for the motor to turn it).

Description P/N Quantity

Hub, Pancake-Style, Top

Hub, Pancake-Style Cover (Bottom)

SAO0287 1

SAO0288 1

Screws, 6-32 x 3/8” L Flat Head Phillips SS NBS0045 3

Set Screw, 8-32 x ½” NBS0152 1

Bristle bundle, 12” Long, 0.021” dia, Level SAO0306 .03 Hank (.3 to .4 oz)

Bristle Replacement set (3 Bundles)

Bristles, Master Hank

Shrink Tubing, ¼”

Rubber Band (#19)

SAO0310

CB0001

3

1 Hank

SHOP0011 1.4 Inch (0.12 Ft)

COM0328 1

Allen Key (Wrench) 5/64” L Shape Not Included

Instructions to Change Bristles COM0327 1

The new Pancake Brush hub bristles are replaceable, but the process is different and the replacement bristles are pre-assembled into 3 bundles that are retained with ¼” shrink tubing that is bent to match the shape of the grooves in the Pancake Hub.

Each of these bundles should weigh between 0.3 ounces and 0.4 ounces and contain between 115 and 124 individual bristles that are 0.021” diameter by 12 inches long. The Bristles will be slipped into a piece of ¼” heat-shrink Tubing (Before it is heated) P/N SHOP0011.

Page 9 of 15

Installing Bristles into the Pancake Brush (SAO0307)

1. Be sure all parts are available to assemble the 12” pancake brush. See List at top.

2. Layout the Pancake Brush Hub “TOP” piece with the 3 deep grooves facing up.

3. Install the pre-formed bundle of bristles (SAO0306) into one of the grooves as shown. It must be centered with the Shrink Tubing NOT extending out of the groove.

4. Install the Second and third bundles of bristles and push them deep into the groove. None of the bristles can be allowed to be out of the groove when the assembly is complete.

5. Place the Bottom of the Pancake Hub over the bristles in the Grooves of the top of the Hub, and turn it over so the

3 screws can be installed.

Page 10 of 15

6. Line up the screw into one of the holes, and screw it in a short way – DO NOT TIGHTEN ANY

SCREWS until ALL 3 SCREWS are in place.

7. This is the time to slowly tighten each of the 3 screws to be

SNUG. At this point, be sure that there are no bristles outside of the grooves. If a bristle is between the Top and Bottom of the

Hub, it must be pushed back into the groove before final tightening.

INCORRECT CORRECT

8. Tighten all 3 screws to be secure. Inspect the brush one more time, and it is ready to install on the TruckMaster or DuctMaster 1.5” Vacuum Hose with Motor.

Page 11 of 15

Air-Care TruckMaster

Troubleshooting Guide

Symptom Possible Causes Suggested Action

Remote does not operate

Brush

1. Be sure Handheld Remote is pointed at the Remote

Locate the DuctMaster so the remote has an unobstructed view

Receiver sensor in the center of the control panel. of the center of the panel.

If the red LED does not flash,

2. Check that the Red indicator replace the battery. on the Handheld remote flashes (Once) when any button is pressed

Brush & hose cannot be inserted far enough into duct.

1. Duct is too small for hose

(Less than 2” wide opening).

2. Duct makes two 90 turns in less than 12 inches.

 Be sure you are using the 1 ½” X

35’ Hose, Brush and Motor

Assembly

Try to access the duct from another opening.

Brush Motor does not turn.

1. The Brush Switch on the Be sure the Brush Switch on the

Panel was “ON” when the Panel is OFF. power cord was plugged in

2. Electronic Torque control

Turn OFF power switch for 30 seconds, and then turn on – wait shut down brush motor 20 seconds before attempting to power.

3. There was a power loss in the building or a power run motor.

Be sure the Brush Switch on the

Panel is OFF. Try using remote surge. again.

Be sure Brush Power Cable is fully come loose. inserted into the Panel Connector

There are holes in the red vacuum hose.

1. The “crush proof” hose is very durable, but if it is pulled excessively hard, it

Call Air-Care for an RMA for a quote to have the vacuum hose repaired or replaced. can separate at the grooves.

Call Air-Care 800-322-9919 or

702-454-5515 [email protected]

Page 12 of 15

Glossary & Acronyms

1. ACGIH—American Conference of Government Industrial Hygienists

2. ASHRAE—American Society of Heating, Refrigerating, and Air Conditioning Engineers

3. Air Handler/ AHU—The Furnace or air conditioner that heats, cools and moves the air.

4. Antimicrobial—Agent that kills Bacteria, Molds and viruses. See “Sanitizer

5. Arrestance – An ASHRAE standard procedure to measure air filter efficiency (52.1)

6. Bioaerosols— Molds and bacteria that are found floating in the air.

7. Biological Contaminants— Bacterial, Mold/Fungus, viruses and their waste, byproducts and decomposition materials that can be inhaled and cause many types of health effects.

8. Building Related Illness—Diagnosable illness whose symptoms can be identified and whose cause can be directly attributed to airborne building pollutants (e.g., Legionnaire’s disease, and hypersensitivity Pneumonitis).

9. CFM—Cubic Feet per Minute, a measure of how much air is flowing in an air system.

10. CO—Carbon Monoxide, an odorless, toxic gas produced during combustion.

11. CO

2

—Carbon Dioxide an odorless, non-toxic gas produced during combustion and exhaled by people.

12. Ceiling Plenum – The area above a suspended ceiling that may be used as a return path to the Air Handler.

13. Conditioned Air – The air that has been filtered, heated or cooled by the air handler.

14. Dampers – Flaps or valves in the air duct that control the amount of airflow in the duct.

15. Diffusers & Grilles & Registers – The covers at the end of supply and return ducts that control the amount and direction of the air-conditioned air entering or leaving a room.

16. Electrostatic Filter – A High Efficiency (95% Arrestance) Air filter that generate static electricity from the air movement through the air handler and captures dust from the air while the clean air move freely through it.

17. EPA—Environmental Protection Agency

18. Duct – A metal, plastic or fiberglass tube that transports air to and from the Air Handler. They can be round, square or rectangular.

19. Duct Board – Compressed fiberglass material used to make air ducts, particularly in the southern U.S.

20. Fiberglass Filter – A disposable, very low efficiency filter (approx. 10% arrestance).

21. Flex duct – Plastic fabric duct with a spiral wire support. It is used extensively in the Western U.S.

22. HEPA—High Efficiency Particulate Air

23. HVAC—Heating, ventilation and air-conditioning

24. IAQ—Indoor Air Quality

25. MSDS—Material Safety Data Sheet

26. Make-up Air – Fresh “outside” air that is brought into a Commercial building.

27. NADCA-National Air Duct Cleaners Association

28. NAFA – National Air Filter Association

29. NIOSH—National Institute for Occupational Safety and Health

30. Negative building pressure – A condition that allows air to flow into a building when a door is opened.

31. NSC -- Nevada Safety Counsel

32. NSF International – An independent testing laboratory for Air filters

33. OSHA—Occupational Safety and Health Administration

34. Positive building Pressure – A condition when air will come out of a building when a door is opened.

35. Re-entrainment – The flow of dust and debris removed from an air system back into the same building

36. Return/Return Duct

37. Sanitizer – A material designed to kill mold, bacteria, and viruses.

38. Sick Building Syndrome – A group of symptoms such as headache and watery eyes that disappear after the sufferer leaves the building for a few hours.

39. Supply/ Supply Duct—The opening and related ductwork that delivers conditioned air to a room.

40. VAV—Variable air volume system – A system that varies the amount of flow of air to regulate temperature.

41. VOC’s—See “Volatile Organic Compounds”

42. Volatile Organic Compounds (VOC’s)—Chemicals that release gasses into the air such as solvents.

Page 13 of 15

LIMITED WARRANTY

TRUCKMASTER

Air-Care warrants this product to be free from defects in materials and workmanship to the original purchaser for a period of Two (2) years from the date of purchase. Components listed below are excluded from this Two year period and are covered for periods described below:

Circuit Board & Remote 1 Year

Hose & Motor Assembly 90 Days

Brush Assembly No Warranty

Warranty covers both parts and labor (labor is to be performed at Air-Care’s facility located at 3868 E.

Post Road; Las Vegas, Nevada).

Warranty is extended to the original purchaser and is not transferrable.

This warranty does not extend to any damage to a product caused by or attributable to freight damage, abuse, misuse, improper or abnormal usage. Warranty is also void if the product has been modified or altered in any way.

The purchaser is responsible for the cost of shipping the equipment to Air-Care’s facility for evaluation. If found to be defective and covered by the terms of this warranty, Air-Care will pay

FedEx ground shipping charges on the repaired or replaced item back to the purchaser’s location.

Any additional expedited service charges for quicker shipping shall be born by the purchaser. If the product or component is not found to be a warranty issue, the purchaser will be responsible for return shipping charges.

Air-Care is not responsible or liable for indirect, special, or consequential damages arising out of or in connection with the use of performance of the product; damages with respect to any economic loss, loss of property, loss of revenues or profits, loss of use, or other incidental or consequential damages of whatsoever nature.

The warranty extended hereunder is in lieu of any and all other warranties, and any implied warranties of any type.

This warranty gives you specific rights. These rights and others vary from state to state.

Division of D.P.L. Enterprises Inc.

3868 East Post Road, Las Vegas, Nevada 89120, (702) 454-5515, FAX (702) 454-5225

Website: www.air-care.com; E-mail: [email protected]

Page 14 of 15

Air-Care is a Division of D.P.L. Enterprises, Inc.

3868 E. Post Road, Las Vegas, NV 89120 (702) 454-5515, Fax (702) 454-5225

Website: www.air-care.com, E-mail: [email protected]

Page 15 of 15