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MOBILE CLEANING UNIT Operating Instructions (ENG) MODELS: PDF PDFX PDG PDT PDT POWER DIRECT (FORD) POWER DIRECT XTRA (FORD) POWER DIRECT (GM) POWER DIRECT WATER TANK POWER DIRECT WATER TANK Read instructions before operating the machine. C 980185 11/30/04 MACHINE DATA LOG/OVERVIEW MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE # YOUR DEALER NAME: ADDRESS: PHONE NUMBER: Welcome…and congratulations on the purchase of your Mobile Cleaning Unit. This instruction manual is a guide for operating and servicing your unit. Read this manual completely before installing or operating this unit. This unit offers you personal convenience. All of your instrumentation and controls have been positioned to give you easy access for operation and daily maintenance. Proper operation and service are essential to the efficient functioning of this unit. When maintained correctly, this unit will have a long, trouble-free life. The service methods described in this manual are explained in such a manner that servicing may be performed accurately and safely. Proper service varies with the choice of procedure, the skill of the mechanic, and the tools or parts available. Before attempting any repair, make certain that you are thoroughly familiar with this equipment and are equipped with the proper tools. Any questions pertaining to operating or servicing this unit should be directed to your nearest dealer. THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCORDANCE WITH THE PRESCRIBED INSTALLATION PROCEDURES. MAKE CERTAIN THAT THE WARRANTY CARD IS FILLED OUT AT THE TIME OF INSTALLATION AND IS RETURNED TO YOUR DEALER. PROFESSIONAL CHEMICALS CORPORATION 325 SOUTH PRICE ROAD CHANDLER, ARIZONA 85224 Information in this document is subject to change without notice and does not represent a commitment on the part of Professional Chemicals Corporation. 2 TABLE OF CONTENTS Machine Data Log ………………….02 Table of Contents …………………..03 Parts list ……………………………..04 MAINTENANCE & SERVICE Maintenance Schedule……….….21 Key Maintenance Checkpoints.…23 Vacuum Pump…………………….23 Water Pump……………………….24 Vacuum Inlet Filter………………..24 Vacuum Relief Valve……………..24 Vacuum Drive Belts……………….24 Pressure Regulator……………….25 Vacuum Hoses…………………….25 High Pressure Hoses……………..25 Optional Waste Pump-out………..25 Engine Coolant Replacement……25 Waste Tank Strainer Basket……..26 Troubleshooting…………………...27 SAFETY Safety Instructions ………………….05 OPERATION & SYSTEMS Technical Specifications …..……….07 Panel Overview...…………………....08 Water Pumping and Heat Transfer System……………………..10 Chemical Injection System…………15 Vacuum System……………………..16 Pre-run Inspections………………….17 Cleaning………………………………17 Upholstery Cleaning…………………18 Shutdown and Daily Maintenance…18 De-flooding Operations……………..18 Freezing Protection………………….18 Winterizing Your Unit………………..19 Removing Anti-Freeze from Unit…..19 3 PARTS LIST Front Panel………….………………………………….. Baseplate-Water Pump-Blower………………………. Recovery Tank…………………………………………. Fresh Water Tank – Optional…………………………. Mini Water Tank – Optional…………………………… Heat Exchanger………………………………………… Silencer System………………………………………… Post Heat System………………………………………. PTO Shaft……………………………………………….. Wiring Diagrams……………………………………...… Hose Accessories………………………………………. Automatic Pumpout – Optional…………………...…… Wand – Titanium Six Jet – Optional.………………….. Wand – Quad – Jet – Optional………………………… Wand – Tri-Jet – Optional……………………………… Stair Tool – Optional……………………………………. Upholstery Tool – Optional…………………………….. Shelf Assembly – Optional……………………………... Water Tank, Dual w/Demand Pump – Optional……… Hose Reel – Optional…………………………………… Warranty…………………………………………………. 4 30 32 38 40 42 44 46 48 50 52 56 58 62 64 66 68 70 72 74 78 80 IMPORTANT SAFETY INSTRUCTIONS When using this machine, basic precautions must always be followed, including the following: READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE These symbols mean WARNING or CAUTION. Failure to follow warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage. Follow these instructions carefully! Read the operator’s manual before installing or starting this unit. Failure to adhere to instructions could result in severe personal injury or could be fatal. Operate this unit and equipment only in a well-ventilated area. Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality. DO NOT run this unit in an enclosed area. DO NOT operate this unit where the exhaust may enter any building doorway, window, vent, or opening of any type. DO NOT store any type of flammable material in the vehicle. DO NOT operate engine if gasoline is spilled. Avoid creating any ignition until the gasoline has been cleaned up. Never use gasoline as a cleaning agent. DO NOT place hands, feet, hair, or clothing near rotating or moving parts. Avoid any contact with moving parts! Rotating machinery can cause injury or fatality. Never operate this unit without belt guards or hoods. The high speed moving parts, such as belts and pulleys, should be avoided while this unit is running. Severe injury, damage, or fatality may result. DO NOT service this unit while it is running. The high-speed mechanical parts as well as high temperature components may result in severe injury or severed limbs. Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Before servicing this unit, allow it to “cool down.” This will prevent burns from occurring. Water under high pressure at high temperature can cause burns, severe personal injury, or fatality. Shut down machine, allow to cool down, and relieve system of all pressure before removing valves, caps, plugs, fittings, filters, and bolts. Always wear hearing protection when unit is running. Always comply with local noise ordinance when operating units. 5 Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. When disconnecting the battery, ALWAYS disconnect the negative (-) terminal FIRST. DO NOT smoke around the unit. Gas fumes may accumulate and be ignited. The battery is also extremely flammable. This will prevent possible explosions. DO NOT damage the vehicle in any manner during installation. When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle. Avoid any contact with moving parts, areas of high temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects. DO NOT exceed your vehicle’s weight limit. The console with waste tank and accessories weights approximately 800 lbs. Make certain to account for any additional accessories in your weight and balance calculations. Make certain that the vehicle has the correct axle rating. This will prevent unsafe vehicle driving conditions. We require high-back seats on all vehicles in which units are to be installed for head and neck protection. We recommend using a metal partition between the seats and equipment. DO NOT operate this unit without the water supply attachment and turned on. The water pump and other vital components may be seriously damaged if this unit is permitted to operate dry without water. DO NOT operate this unit without the filter installed in the waste tank. Keep your vehicle work area clean. Wands, stair tools, and other accessories must be securely fastened before driving the vehicle. All high pressure hoses must be rated for 3000 PSI at 250 deg F. Thermoplastic hoses do not meet these specifications and should not be used. Severe burns and injury may result if the hoses do not meet these requirements. Make certain that you receive complete training by the distributor from whom you purchased this unit. This unit uses high pressure and temperature. Improper or irresponsible use may result in serious injury. Do not modify this unit in any manner. Improper modification can cause severe personal injury or fatality. 6 TECHNICAL SPECIFICATIONS ITEM Engine speed Water pump rpm Vacuum pump rpm Water flow rate Water pump pressure (low pressure) Vacuum relief valve Waste tank capacity Console weight (with waste tank) DIMENSION/CAPACITY 1450 rpm (high speed) Water Pump ON 850 rpm 2850 rpm 4 GPM (maximum) 1000 PSI (maximum) 14" Hg 120 gallons 800 lbs. JET SIZING: Recommended floor tool tip sizing not exceed a total of “.045”. Using larger jet sizes on your cleaning unit may reduce cleaning temperatures. Example: Tri-jet wand uses three 95015 jets (95 deg spray angle w/ 015 orifice). 015 x 3 = 045 Upholstery tool jet size: Stair tool jet size: 80015 9502 7 NOTES: 8 1. OPERATION Tachometer/Hour Meter The tachometer shows the rpm of the vacuum pump and the hour meter records the number of hours the unit has run. This serves as a time recorder for servicing the machine. 2. 9. 10. Solution Temperature Gauge This gauge measures the temperature of the cleaning solution as it exits the machine. 4. 11. Vacuum Gauge 12. Solution Temperature Control 13. 14. Waste Tank Pumpout Outlet This port is filled with a chrome plug unless the (Optional) Waste Pumpout has been installed, then there will be a garden hose fitting to attach a hose to. 15. Flow Meter The flow meter is a gauge to indicate how much liquid chemical is being introduced in the water system. Turning the knob on the flow meter clockwise can increase the quantity. Carpet/Upholstery Mode Switch This switch serves to energize the magnetic clutch to turn the PTO and set the engine speed for the desired operation of cleaning. Turning the switch to the Upholstery Mode for lower speed and turning the switch to Carpet Mode for higher speed of the vacuum pump. 8. Oil Cup The oil cup allows lubricant spray to reach the vacuum blower. Pressure Control Regulator The pressure regulator sets the pressure of the solution system. This spring loaded valve can be adjusted up or down setting the pressure of the unit by turning the knob clockwise. The pressure is increased or reduced by turning the valve counter clockwise. This valve must be maintained in accordance with this manual maintenance table. 7. Water Inlet This quick connect allows water supply hose to be connected to the unit. This valve allows the operator to control the solution temperature by adjusting the valve from cold to hot. 6. Solution Outlets The solution outlets are the connecting points for the high pressure hoses. These outlets have quick disconnects that allow hoses to be plugged into the unit. This gauge indicates in inches of mercury how much the vacuum system is producing at any given time. 5. Waste Pumpout Switch This switch controls the (Optional) auxiliary pump to empty the waste collection tank automatically. A float located inside the tank automatically turns off and on when the solution level reaches a certain point. Solution Pressure Gauge This gauge registers the amount of pressure in the system. 3. Interior Lights This switch controls the spot lights located in the van cargo area. 16. Solution Pump Prime This valve is used to purge the system when air is slowed to enter. Example, empties chemical container or empty water storage tank. Open and close valve with chemical flow meter open and adequate water supply. When solution pressure gauge indicator needle remains stable, all air has been evacuated. Solution Pump Switch This switch serves to energize the magnetic clutch to turn the water pump on or off. 9 OPERATION Water Pumping and Heat Transfer System: Cold water enters the panel through the water inlet. When the water tank is full the valve will automatically shut off. Water then flows from the water tank, through a strainer, into the water pump where chemical is introduced at this point. Then it is pumped to the pressure regulator that provides and maintains the desired pressure setting. A certain amount of water is by-passed from the pressure regulator due to over pumping capacity of the water pump. Water that is not called for in the cleaning process is channeled to the by-pass coil in the recovery tank then flows to the inlet side of the pump to be circulated again. The heating stage occurs when the water leaving the pressure regulator and directed to the first of two heat exchangers. Heat from the vehicle engine coolant is exchanged to the cleaning solution spiraled copper tubing. This allows the engine coolant to travel in a counter rotating direction to the cleaning water during the exchange process creating a very efficient transfer of heat out of the engine and into the cleaning solution. The hot solution then exits the second heat exchanger where it enters the outlet manifold. The manifold serves as a sensing point and connection for the high-pressure hoses. Finally, the cleaning solution then passes through pressure hoses and is distributed by the cleaning tool to a surface that is being cleaned, completing the water pumping and heating cycle of the cleaning unit. 10 OPERATION Optional Post Heat With the Optional Post Heat, the cleaning solution goes to a second stage of plumbing and heating which takes place in the heater core located just after the vacuum pump. This is the hottest point of exhaust air coming from the vacuum pump. The hot exhaust air is forced through the post heat core, creating the second stage of heat transfer to the cleaning solution. 11 12 13 14 OPERATION CHEMICAL INJECTION SYSTEM: The chemical injection system utilizes the natural inlet draw of the high-pressure pump to move the chemical into the main pressure stream. The chemical is picked up from the container and fed through the flow meter at a desired amount of chemical which is adjusted through the metering valve. The chemicals and water are mixed in the highpressure pump and then forced through the heat exchangers and outlet manifold where then it is distributed to high-pressure hoses out to the cleaning tool. 15 OPERATION VACUUM SYSTEM The PTO turning an air pump generates vacuum. The air is channeled in one side of the vacuum pump, compressed and discharged on the opposite side, creating airflow. The movement of air is used to do the work necessary for the extraction process. A vacuum nozzle applied to the carpet surface removes moisture, dirt and spent chemicals. These elements are conveyed back to the waste tank using a series of changes in direction and velocity. The air is then filtered and rushes into the vacuum pump. The vacuum pump compresses and heats the incoming air. The hot discharged air is forced down stream into a silencer for noise abatement. Finally the hot air is exhausted outside. VACUUM RELIEF VALVE FILTER VACUUM PUMP WASTE TANK SILENCER STRAINER LUBE CUP VACUUM GAUGE 16 OPERATION PRE-RUN INSPECTION: HIGH PRESSURE HOSE Note: Operation of this unit is simple. However, only trained personnel should proceed. Before starting the unit, connect the pressure hose to the outlet connection at the front of the unit. Connect the cleaning tool to the pressure hose. VACUUM HOSE Operate this unit and equipment only in a well-ventilated area. Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality. DO NOT operate this unit where the exhaust may enter any building doorway, window, vent, or opening of any type. Connect the vacuum hose to the vacuum inlet connection at the front of the unit. Connect the other end of the vacuum hose to the cleaning tool. FILTERS Ensure all filters on machine and in waste tank are free of debris. CLEANING CHECK FOR ADEQUATE FUEL Check the fuel tank to be certain there is adequate fuel to complete the job. This unit uses approximately .95 to 2.1 gallons of fuel per hour, depending on the speed setting. REMOVE TOOLS FROM VEHICLE Remove any tools or hoses from the van which you will require. WATER SUPPLY CONNECTION NOTE: Before connecting your water hose to the supply faucet, flush out the faucet until the water is free of any debris. Flush out any debris which may be in your water inlet hose. 1. Connect the water supply hose to the water inlet quick-connect at the left front of the console. Connect the hose to the water supply faucet. Observe the following guidelines, while cleaning: 1. Before proceeding make sure the nozzles are functioning properly. a. To check, hold the wand about one foot above the surface to be cleaned and open the wand valve. A full spray should be observed from the cleaning nozzles. b. If the nozzle are not showing a full spray pattern, adjust nozzles for proper pattern, clean, or replace nozzles, if required. 2. Nomally chemical is applied on the push stoke of the wand when cleaning and vacuuming is done on the pull stroke. For heavily soiled carpets the wand may be used in a scrubbing manner, apply chemical in both push and pull strokes. Always finish up an area with a vacuum stroke. NOTE: Never use your waste pump outlet hose as a water inlet hose. Use only clean hoses for water inlet. 3. When cleaning, keep the working opening (mouth) flat on the surface being cleaned. Keep the wand moving when the valve is open. 2. Turn the water supply faucet on. The water will fill the water tank. 4. The unit will automatically shut-down when the waste tank is full. This will prevent water being drawn into the vacuum pump. If shut-down occurs, empty the waste tank before proceeding. 17 OPERATION FREEZING PROTECTION UPHOLSTERY CLEANING Upholstery tool 1. Set temperature as desired and use Upholstery Mode on the unit switch. If the unit is exposed to freezing weather the water in the unit may freeze, causing SERIOUS DAMAGE to the unit. To avoid this, the following is recommended during the cold weather season. 2. Use one (1) “80015” spray tip in tool. SHUTDOWN AND DAILY MAINTENANCE When the unit is not in use, always park it in a heated building. 1. Close chemical metering valve. While in operation, avoid long shutdowns as the vehicle provides heat while running. 2. Allow the unit to run for 2 minutes with the vacuum hose disconnected to remove moisture. Spray WD-40 (or equivalent) into the vacuum lubrication cup. This will prevent corrosion due to moisture. 3. Turn off Unit and Pump switch. 4. Disconnect all hoses and tools. 5. Drain waste tank and rinse with clean water. DE-FLOODING OPERATIONS De-flooding operations involve removal of water from carpet and flooring. This differs from normal cleaning operations in that no water or solution is required. An automatic waste pump-out is highly recommended for all de-flooding operations due to the large amount of water removal often required. 1. Start unit in Carpet Mode. 2. Leave Pump switch OFF. 3. Begin de-flooding operations. 18 OPERATION WINTERIZING YOUR UNIT RETURNING CLEANING UNIT BACK INTO SERVICE 1) Drain fresh water tank by opening the ball valve (# 1 ) 2) Close ball valve (# 4 ) 3) Place hose (# 3 ) into container of 100% glycol base antifreeze 4) Place chemical feed hose (# 6 ) into container of antifreeze, open flow meter valve 5) Open ball valve (# 3 ) 6) Place primer hose into empty container 7) Turn main switch to “Upholstery Mode” and pump switch to the “ON” position 8) Open ball valve on primer hose until antifreeze comes out, then turn the primer hose valve off and on for another 30 seconds to replace the bypass loop with antifreeze. 9) Turn the pump and main switch off, then hook up the high pressure hoses and wand to the panel. Turn main switch to “Upholstery Mode” and the pump switch to the “ON” position. 10) With the primer hose valve closed, open the wand valve until antifreeze appears, repeat this for all other tools. 1) Close fresh water valve (# 1 ) 2) Fill tank with fresh water 3) Close valve (# 3 ) and open valve (# 4) 4) Place chemical feed hose (# 6 ) into chemical jug, open flow meter valve 5) Place primer hose into empty container 6) Turn main switch to “Upholstery Mode” and pump switch to the “ON” position 7) Open the primer hose valve to evacuate the antifreeze from the system, remember to open and close this valve a couple of times during this process to clear the bypass loop. 8) Turn the pump and main switch off, hook up the high pressure hoses and wand. Turn the main switch to “Upholstery Mode” and the pump switch to the “ON” position. 9) Open the valve on the wand and recover the antifreeze, repeat this for all other tools. 19 20 MAINTENANCE SERVICE SCHEDULE Van Engine Van Engine Vacuum Pump Water Pump Solution Inlet Tube Strainer Vacuum Inlet Filter (In Waste Tank) Vacuum Hoses Automatic Waste Pump Chemical Filter Vacuum Pump Water Tank Float Valve Water Pump Inlet Filter Pressure Regulator Pressure Regulator PTO Shaft High Pressure Hoses Van Engine Van Engine Van Engine Van Battery Float Valve Seal Daily Daily Daily Daily Daily Daily Daily Daily Daily Weekly* Weekly Weekly* 50 hrs 50 hrs 50 hrs 100 hrs 100 hrs 100 hrs 100 hrs 100 hrs* 200 hrs Check engine oil level.*** Fill to proper level Check coolant level in overflow bottle Spray WD-40 in lubrication cup at front of console for 5 sec. Check oil level.** Fill to proper level Check strainer for blockage, remove any debris Clean filter, inspect, replace if damaged Wash out with clean water Inspect and remove any debris or sediment Inspect daily Check oil level. Fill to proper level Check for proper seating and shut-off Check for debris and clean Lubricate o-rings Lubricate plug behind spring Grease v-joints Inspect for damage or impending damage Change engine oil*** Change oil filter*** Check fan belt tightness Clean battery terminals Replace seal 21 MAINTENANCE SERVICE SCHEDULE Water Pump Pulley Set Screws & Hub Cap Screws Drive Pulley Drive Pulley Drive Belts Drive Belts Vacuum Lubrication Lines Heater Core Vacuum Pump Waste Tank Shut-off Float Switch Van Engine Waste Tank Filters/Strainers Van Engine 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 1500 hrs Monthly Yearly Yearly 2 years Change oil** Check for proper torque valves. Re-torque, if required**** Inspect, clean and check for pulley groove wear**** Check pulley alignment**** Inspect and clean**** Check belt tension**** Check for line obstructions. Replace tubing if cracked or damaged Clean and inspect. Drain, flush, and replace oil***** Check for debris hindering movement Flush radiator and change engine coolant. Check for damage and blockage. Replace if needed. Replace radiator hoses and hose clamps. * Or as often as required ** Change water pump crankcase oil after the first 50 hours *** Change vacuum pump crankcase oil and filter after the first 50 hours **** Perform drive belt, pulley and hub maintenance after the first 25 hours of operation, and then again at 100 hours ***** If using AEON PD synthetic lubricant, 4000 hours or every 2 years, whichever comes first 22 MAINTENANCE VACUUM PUMP 3. Drain, flush and replace oil every 1500 hours or yearly, whichever comes first. Change oil more frequently if inspection so indicates. With AEON PD synthetic lubricant, perform the oil change maintenance every 4000 hours or every 2 years, whichever comes first. Refer to the Vacuum Pump Operation and Service Manual for specific instructions. Lubrication: We recommend that you use AEON PD Synthetic Blower Lubricant in the vacuum pump for all operation temperatures. AEON PD is formulated especially for positive displacement blower service to provide maximum blower protection at any temperature. One filling of AEON PD will last many times longer than a premium mineral oil. 4. Vacuum pump lubrication is vital to performance of our pump. Failure to follow the maintenance schedule in the “Maintenance Schedule” can lead to permanent damage to your blower. NOTE: AEON PD is the oil which PROCHEM puts in the vacuum pump at the factory. Topping off or adding petroleum oil to synthetic oil is NOT recommended. 1. Check the oil level daily to assure the proper level. PROPER LEVEL cannot be overemphasized. Too little oil will ruin bearings and gears. Too much oil will cause overheating. Use the illustration as a guide when adding oil. 2. To prevent rust from building up inside the vacuum pump (if moisture exists) we have provided a lubrication cup on the front of the unit. First run the unit at least 1 minute to remove any moisture from the vacuum pump. Next, fill the lubrication cup with WD-40, or a similar lubricant, for 5 seconds while the unit is running and the vacuum inlets are sealed. Do this at the end of each working day. 23 MAINTENANCE WATER PUMP VACUUM PUMP DRIVE BELTS 1. Check the crankcase oil level daily to assure the proper level. Use the illustration as a guide when checking the oil level. If the level has dropped, check for the source of leakage and repair. To tighten the vacuum pump belts: 1. 2. Change the crankcase oil with Cat Pump Crankcase Oil, after the first 50 hours of operation. Drain and refill the crankcase oil with Cat Pump Crankcase Oil every 500 hours thereafter. Loosen the four screws which hold the vacuum pump mount in place. 2. Turn the adjusting bolt until the proper belt tension is achieved (1/2” deflection in the center of the belt, halfway between the pulleys). 3. Re-tighten all bolts previously loosened at the vacuum muffler. 3. Other Cat approved oil equivalents are: Mobil DTE 16, Amoco Rykow 68, and Shell Tellus T68. NOTE: When adjusting belt tension, make certain that the PTO shaft and vacuum pump shaft remain parallel, and the belt tension is equal throughout the belt width. VACUUM INLET FILTER (IN WASTE TANK) 1. The vacuum filter in the waste tank should be removed and cleaned daily. If this is done, the filter will last for a long period of time. 4. After adjusting, re-tighten the four screws which hold the vacuum pump mount in position. Check belt alignment with straight-edge. VACUUM RELIEF VALVE Make certain that when you re-torque these screws, that you use a clockwise pattern and continue until proper torque is achieved. While the unit is running at full RPM, block the air flow at the vacuum inlet connection and read the vacuum gauge. If adjustment is required, shut the unit down and adjust the vacuum relief valve locking nut tension. Start your unit and read the vacuum gauge. Repeat this process until the relief valve opens at 14” Hg. TORQUE VALUES COMPONENT INCH/LBS FOOT/LBS Rear PTO Hub Vacuum Pump Hub 300 300 25 25 5. Check for pulley groove wear, clean belts and pulley grooves, check for worn belts, proper belt tension, and pulley alignment after the first 25 hours and then again at 100 hours. Check for belt ride in the groove. 24 MAINTENANCE PRESSURE REGULATOR ENGINE COOLANT REPLACEMENT Lubricate the o-rings and bullet every 50 hours. Use o-ring lubricant. Annually the coolant in the Vehicle Engine should be replaced. This coolant is an integral part of the heating system and needs to be maintained as any other working part of the system. We recommend that this procedure be accomplished by the following steps. For the procedure, see the “General Service Adjustments” section in this manual for details. VACUUM HOSES DRAINING COOLANT: To assure maximum hose life, we recommend that the hoses be washed out with clean water at the end of each working day. 1. Remove one end of Heater core “Y”. Open Heat Exchanger Petcock’s. NOTE: Be sure that used coolant is collected in a proper container and disposed of in accordance with local laws. HIGH PRESSURE HOSES Inspect your high pressure hoses for wear after the first 100 hours of use. Inspect every 25 hours thereafter. If hoses show any signs of damage or impending rupture, replace the hose. REPLACING COOLANT: 1. Fill radiator with 60/40 anti-freeze water mix. 2. Start unit at idle. 3. As the unit warms up, maintain a full radiator with a 60/40 mix. DO NOT attempt to repair high pressure hoses! Repairing high pressure hoses may result in severe burns and serious injury! 4. Open petcocks slightly on Heat Exchanger to allow any trapped air to escape. When coolant runs out of Heat Exchangers, close petcocks. All high pressure hoses must be rated for 3000 PSI at 250 deg F. Thermoplastic hoses do not meet these specifications and should not be used. Severe burns and injury may result if the hoses do not meet these requirements. 5. Fill radiator with 60/40 coolant mix. 6. Re-install radiator cap. 7. Shutdown unit. OPTIONAL WASTE PUMP-OUT Check radiator overflow bottle. Add coolant to proper “cold” level. At the end of each work day, make certain that you remove any debris or sediment which may be inside the waste pump by pumping fresh water through the pump. 25 MAINTENANCE WATER PUMP DRIVE BELT To tighten the water pump belt: 1. Loosen the nuts which hold the water pump mount to base. 2. Adjust the position of the belt tension adjusting bolt until the proper belt tension is achieved. (1/2” deflection in the center of the belt, halfway between the pulleys). 3. While checking the alignment, tighten the nuts which hold the water pump mount to base. WASTE TANK STRAINER BASKET The strainer basket located inside the waste tank should be removed and cleaned whenever it is full of debris. This should be done at the end of each job. WASTE TANK FLOAT VALVE The float valve in the waste tank shuts the unit down once the waste tank becomes full. Check the float valve for debris at least once a month. 26 MAINTENANCE PROBLEM CAUSE SOLUTION Water supply is turned off or the Turn the water supply on or up. Check for float valve is stuck or improperly kinks in the water supply hose. Examine adjusted. the float valve and adjust or replace. Water pump inlet supply line is Remove accumulated debris and replace if required. Examine the water inlet filter inside the water box. plugged or drawing air. Check for suction leaks and loose clamps or fittings. Tighten any loose fittings or clamps. Replace any ruptured hose(s). Loss of water pump Pressure regulator o-rings are dry. Lubricate o-rings, using o-ring lubricant. pressure. Pressure regulator has worn o-rings. Check o-rings. If necessary, replace. Pressure regulator is dirty, stuck Clean or repair regulator. Adjust to working With the cleaning open, or improperly adjusted. pressure. Lubricate o-rings, using o-ring lubricant. tool open, the water pressure gauge reads Low pump volume. (Measure the Examine the check valves, plunger cups, amount of water being returned to the and cylinder head on the water pump. below the normal water box from the pressure regulator. Repair, whenever required (refer to the It should fill a gallon container about water pump service manual). operating pressure. every 17 seconds). Defective water pressure gauge. Replace gauge Orifice (spray nozzle) in the cleaning Replace Nozzle or change nozzle size. tool is worn, defective, or wrong size. Debris clogging water lines or Clean or replace as needed. water inlet disconnect. Belts loose or broken Re-tension or replace as needed. Loss of pump prime Manually prime water pump. Plugged orifice and/or screen in Unplug or replace orifice and/or screen the cleaning tool. Internal block between the Inspect all lines, remove accumulated debris which pressure regulator manifold and is blocking proper flow. Replace any defective Loss of solution the outlet Y-strainer, or the hoses. Remove, inspect, and clean the Y-strainer volume at cleaning Y-strainer screen is clogged tool orifice. Water gauge reads normal. screen. De-scale unit and install a water softener, if necessary. Defective quick-connect on one or Replace defective quick-connects(s) on more of the high pressure hoses. high pressure hoses(s). Cleaning tool valve is malfunctioning. Repair or replace valve. Hose inner lining is constricted. Remove restriction or replace hose. Air leak in chemical supply line, Check for air leaks. Replace faulty parts. metering valve. 27 MAINTENANCE PROBLEM CAUSE SOLUTION Vacuum gauge is giving an improper Examine the tubing between the vacuum relief valve and the vacuum gauge and remove any reading. blockage. Vacuum hose(s) is damaged, causing Inspect hose(s), repair or replace. a suction leak. Waste tank gaskets not sealing Inspect the gasket. Repair seal or replace properly, not positioned properly Re-position lid(s). Loss of vacuum Plugged vacuum hose or vacuum While cleaning, the strainer basket. plumbing between vacuum inlet and Unplug vacuum hose or inlet plumbing. vacuum is not up to Waste tank filter or strainer basket is specification. Engine plugged. Clean or replace filter. Clean strainer basket. RPM is normal. Loose vacuum pump drive belts. Tighten the drive belts Waste tank drain valve is damaged or Drain the waste tank. Close drain valve, if open. left open, causing a vacuum leak. Remove the dump valve and, after inspecting, Vacuum relief valve requires Re-adjust the vacuum relief valve. If the vacuum adjustment or has a vacuum leak due does not increase, remove and inspect the relief replace the defective components. Excessive Vacuum to damaged diaphragm. valve diaphragm. If damaged, replace. Vacuum pump is worn out. Replace the vacuum pump. Improper throttle adjustment. Adjust throttle to set desired vacuum pressure. Vacuum obstruction Vacuum relief valve requires adjustment Inspect hoses for obstructions. Readjust the vacuum relief valve. The strainer at the inlet end of the Unclog the strainer. If damaged, replace. chemical inlet line is clogged. Loss of chemical Suction leak in the inlet line leading Inspect inlet lines and flow meter for air leaks or into the pump. damage and replace, if required. With the cleaning tool chemical prime/on-off valve or Replace valve(s). valve open, no chemical chemical metering valve is defective. Defective cylinder in the water pump. 28 Measure the pump volume. If the pump volume is less than normal, refer to "Loss of Pump Volume" in the Troubleshooting section in this manual. MAINTENANCE PROBLEM CAUSE SOLUTION Chemical flow meter External leak in chemical piping. Tighten fittings. Re-apply thread sealant indicates flow with the where required. If any fittings are damaged, tool valve closed replace. Defective electrical connection in the Examine switch, electrical connections, and wiring. console wiring or defective switch. Repair any defective connections. If there is power going to the switch but not going out, replace the defective switch. Water pump does not Water pump has not been activated Turn solution pump switch to on. engage. Defective water pump clutch. NOTE: The clutch may be manually set by inserting two ¼-20 x1/2 bolts. If there is power in the switch, but not power at the Line up the holes on the clutch and clutch, replace the defective wire. If there is power insert the bolts. To disengage the at the clutch, replace the defective switch. pump, remove the bolts. Loose or broken water pump belts. 29 Tighten or replace belts. 30 FRONT PANEL REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NO. 360-210 360-225 360-205 360-215 551-028 530-105 305-090 305-085 580-010 551-075 580-135 498-066 360-125 759-011 545-012 845-242 845-243 845-244 845-241 498-035 DESCRIPTION Tachometer/Hour Meter Solution Pressure Gauge Solution Temp Gauge Vacuum Gauge Solution Temp Control Pressure Regulator Rock Switch 6 Pole White Rock Switch White Coupler FM 1/4 Closed Oil Cup Port Coupler M 3/8 Closed Chrome Plug Flow Meter 20 LT Jug Ball Valve 1/4 Top Panel Bottom Panel Chem Jug Bracket Panel Frame Rubber Grommet 31 SERIAL NO. FROM NOTES: 32 33 34 35 BASEPLATE, BLOWER AND PUMP REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO. 263-205 315-009 325-230 325-300 325-315 325-320 358-906 360-220 36-900141 380-550 385-015 385-016 385-118 385-119 385-171 385-525 44-802311 397-039 57111 57031 57090 400-151 70266 405-110 405-396 70088 87163 87083 87171 02-000143 425-114 425-140 425-180 465-090 465-091 465-092 465-680 480-100 480-105 790435 516-210 545-012 DESCRIPTION HP Hose Assy 3/8 x 43" Conduit, Plastic 1/4" Terminal Ring, #10 - Blue Power Lock Terminal - Black Power Lock Terminal - Green Power Lock Insert Blower (47) Whispair Urai Tach/Sender Cat Clutch 2-GRV-7"/20MM Keystock, 1/4" Bushing, H 7/8 Bushing, H 1 Pulley, 2BK40H Pulley, AK44H Pulley, 7.75 O.D. Bearing, 1" Flange Complete Unit Belt AX29 Belt BX32 Nut, 3/8 x 16 Zinc Hex Nut, 5/16 Zinc Locknut, 10 x 32 Nylon SS Locknut, 12 x 1.25 Nylon Bolt, 3/8 x 1 GR5 Zinc Bolt, 3/8 x 1 1/4 GR5 Zinc Bolt, 12MM x 35MM (1.25) MS, 10-32 x 1/2 Panphil SS LW, 3/8 Zinc LW, 5/16 Zinc FW, 3/8 Zinc FW, 5/16 Zinc Muffler Clamp 3" Clamp, Tube 3/4" O-Clamp 19/32 Brkt, Grease Line Blower Brkt, Grease Line F/Bearing Brkt, Blower Belt Guard (Roots) Brkt, Pump (Baseplate) Tubing, 1/8" Nylon Tubing, 1/4" Nylon Cat Pump Model 5CP2120W Shaft Protector Ball Valve 1/4 36 SERIAL NO. FROM NOTES: 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 550-030 550-040 551-070 11-800109 555-104 555-106 11-800341 31028 030-16 31026 555-254 11-800022 11-800102 40043 40011 40014 12-800345 12-800269 555-406 66017 555-454 04066 555-520 11-800354 11-800352 555-642 555-660 555-914 40038 572-042 572-100 572-120 270-11A 270-11 580-115 580-140 581-015 582-005 582-027 582-069 759-030 759-035 835-300 845-365 845-380 Check Valve, 1/8 FPT Check Valve, 1/2 FM x FM Thermal Valve, 3/8 NTP (140F) Bushing, 1/2 MPT x 3/8 FPT Comp. Fitting, 1/8 x 1/8 Male Comp. Fitting, 1/4 x 1/8 MPT Elbow 45, 3/8" Street Extruded Elbow 90, 1/8" Street Forged Elbow 90, 1/4" Street Extruded Elbow 90, 3/8" Street Extruded Ferrule, 3/8" Hose Hex Nipple, 1/8" Hex Nipple, 3/8" Hose Barb 90, 3/8 Barb x 3/8 MPT Hose Barb, 1/4 Barb x 1/8 MPT Hose Barb, 3/8 Barb x 1/4 MPT Hose Barb, 5/8 Barb x 3/8 MPT Hose Barb, 5/8 Barb x 1/2 MPT Locknut, 1/8" Brass Plug, 1/4 MPT Hex Plug, 3/8 MPT Hex Head Reducing Adpt, 1/4 FPT x 1/8 MPT Reducing Bushing, 1/8 F x 1/2 M Reducing Nipple, 1/2 MPT x 3/8 MPT Tee, 3/8" FPT. Tee, 3/8" Street Extruded Union Coupling, 3/8" Comp. Fitting, 1/4 x 1/8 FPT Hose Barb 45, 3/8 Barb x 1/4 MPT Solution Hose, 1/4" Blue Neptune HP Clear Braided Hose 1/4" Hose, 3/8" Silicone Q.C. 1/8" Male Shutoff Q.C. 1/8" Fem Shutoff Q.C. 1/8" Male (open) see notes Q.C. 3/8" Fem (open) Crimp Ftng, 1/4" HP Hose - 1/4 MPT SVL 90, 3" Street Blk Mal Nipple, 3" x 4" Hose Barb, 3 x 3 NPT Plated Jar, 16 oz. White Cap, (White 16 oz. Jar) Baseplate Shaft 1" x 18" Brkt, Blower PD Baseplate PD 37 38 RECOVERY TANK REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PART NO. 305-310 325-303 325-305 325-320 57245 57297 400-250 70018 405-118 70070 415-035 87013 87003 87136 03-000246 435-040 435-044 435-045 445-050 475-135 475-140 498-023 498-032 550-035 31021 030-16 40042 560-206 560-360 572-032 572-134 590-408 620-406 860-300 DESCRIPTION Switch, Mercury Float Power Lock Terminal – Red Power Lock Terminal – Yellow Power Lock Insert Locknut, 1/4 x 20 Nylon SS Locknut, 3/8 x 16 Nylon SS Well nut, 1/4 x 20 Neoprene Bolt, 1/4 x 1 SS Bolt, 3/8 x 1 1/2 SS Bolt, 3/8 x 2 SS LW, 3/8 SS FW, 1/4 SS FW, 3/8 SS FW, 1/2 SS Clamp, #8 hose 1/2 x 1 Handwheel, Cross M Knob, Thumb M Handwheel, Cross FM Hasp Gasket, Filter Basket Lid (PD) Gasket, Vacuum Lid (PD) Grommet, 5/16 x 1 Plug Check Valve, 1/4 FM x FM Elbow 45, Street 1/4" Elbow 90, 1/4" Street Extruded H. Barb 90, 1/2 Barb x 1/4 MPT Filter, 3" All SS Filter Basket PD Hose, Blower 3" Heater Hose, 1/2 Blue Hi-Miler PVC, Hose Barb 3" Vacuum Relief Assy (PD) Rec Tank PD 39 SERIAL NO. FROM 40 WATER TANK REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PART NO. 57111 57245 405-009 70070 410-251 87163 87013 87003 87088 425-004 475-125 480-010 499-005 545-020 545-036 555-004 11-800523 11-800276 31026 11-800102 555-320 56013 40033 40013 555-516 11-800354 11-800352 560-113 572-106 22011 585-210 590-404 597-065 860-305 DESCRIPTION Nut, 3/8 x 16 Zinc Locknut, 1/4 x 20 Nylon SS Bolt, 1/4 x 3/4 SS Bolt, 3/8 x 2 SS Tek Screw 3/16 x 3/4 SS LW, 3/8 Zinc FW, 1/4 SS FW, 3/8 SS FW, 5/8 SS Clamp, Gear 1" Gasket, 6" Access Cover - Clear PVC Tubing, 1/4" ID Clear Trim, 1/2" Black Ball Valve, 3/8 Ball Valve 1" ADPT, 3/8 M x 3/8 F Close Nipple 1" Elbow 90, 3/8" FPT. Elbow 90, 3/8" Street Extruded Hex Nipple, 3/8" H. Barb 90, 1/4 Barb x 1/8 MPT H. Barb 90, 3/8 Barb x 1/4 MPT H. Barb 90, 1/2 Barb x 3/8 MPT H. Barb, 1/2 Barb x 3/8 MPT Red. ADPT, 3/4 MPT x 1/2 F Red. Nipple, 1/2 MPT x 3/8 MPT Tee, 3/8" FPT. Filter, Inline 1/2" TM Clear Hose, 1/2 ID Q.C. 3/8" FEM (Closed) Clear Cover, 6" C/W Ring PVC Hose Barb 1" Valve, Diaphragm - Auto Fill F/W Tank PD, C/W Holders 41 SERIAL NO. FROM NOTES: 42 REF 1 2 3 4 5 6 7 8 9 10 11 PART NO. 87088 480-105 11-800276 555-322 555-329 40013 555-516 11-800354 597-065 710-125 993-225-208 DESCRIPTION FW, 5/8 S.S Clear Hose 1/4 ID Elbow 90, 3/8 FPT H.Barb 90, 1/4 Barb x 1/4 MPT H.Barb 90, 1/2 Barb x 5/8 MPT H.Barb, 1/2 Barb x 3/8 MPT Red.ADPT, 3/4 FPT x 1/2 FPT Red.Nipple, 1/2 MPT x 3/8 MPT Valve, Diaphragm – Auto Fill SMS, 8 x 5/8 Pan ROB S.S Mini Water Tank 43 SERIAL FROM 44 HEAT EXCHANGER REF 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. 555-114 555-164 555-100 555-134 555-432 800-081 475-065 490-110 70018 87013 57245 485-100 DESCRIPTION Comp Fitting 3/8 x 3/8 Drain Cock ¼ Comp Fitting 90 3/8 x 3/8 Coupling 3/8 Nipple, Long 3/8 x 2 ½ Cap #6 Gasket, 7 ¼” Heat Exch. Casings, Heat Exch. Bolt, ¼ x 1 ss F/Washer, ¼ ss Locknut, ¼ ss Coil, 3/8 x 25’ 45 SERIAL NO. FROM NOTES: Not Shown 46 SILENCER SYSTEM REF 1 2 3 4 5 PART NO. 850-020 425-114 850-044 850-005 850-046 SERIAL NO. FROM DESCRIPTION Silencer Clamp 3" Tube 3" SLP Muffler 3" Pipe 3" 90 Degree 47 NOTES: 48 POST HEAT SYSTEM REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NO. 263-014 263-021 263-022 57111 405-156 87163 87171 425-040 425-116 425-152 490-150 551-005 14076 555-115 555-134 030-16 78308 11-800352 575-035 850-005 850-046 DESCRIPTION HP Hose Assy 32 1/2 HP Hose Assy 57 1/2 HP Hose Assy 52 1/2 Nut, 3/8 x 16 Zinc Bolt, 3/8 x 4 Allthread Zinc LW, 3/8 Zinc FW, 3/8 Zinc Clamp, #56 Hose Clamp, Muffler 3 1/2 Muffler Hanger Post Heat Coil Valve, Press. Limiter - 1000 PSI (Kingston) Bushing, 3/8 M x 1/4 F Comp. FTG 5/8T x 3/8NPT 90 Coupling, 3/8 Elbow 90, 1/4" Street Extruded Tee, 1/4" Street Extruded Tee, 3/8" FPT. All Flex Hose, 3 1/2" ID Muffler, 3" Elbow 3" 90 Degree 49 SERIAL NO. FROM NOTES: 50 PTO SHAFT REF 1 2 3 4 5 6 7 8 9 10 11 PART NO. 365-010 380-551 380-200 380-205 380-525 835-305 48040 840-030 70584 230-820 230-830 DESCRIPTION Clutch assy, serpintine Key 5/32 x 5/8 Snap Ring 2" Snap Ring 1" Bearing Shaft, inner Key 1/4 x 1 Shaft outer housing Bolt 1/4 x 20 x 3/4 FH SOC Shaft, rear GM Shaft, rear Ford 51 SERIAL NO. FROM NOTES: Not Shown 52 53 54 55 56 HOSE ACCESSORIES REF PART NO. QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 12-800078 08-805147 10-805060 56015 22015 56012 10-805108 10-805077 08-805155 15-808012 43-810014 43-810019 11-800354 10-805157 13-806009 10-805295 22015 10-805077 08-805155 56012 10-805122 1 2 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 2 1 1 SERIAL NO. FROM DESCRIPTION FITTING, BRB 2H BS PVC CUFF, 2” HOSE, VAC 2”X50’ W/ CUFFS & HOSE NIPPLE, 1/4 HEX COUPLER, 1/4 QD NIPPLE, 1/4 FPT QD HOSE, HP 1/4 X 50FT W/QD & VLVE HOSE, HP 1/4 X 50’ GUARD, HOSE VINYL VALVE, BALL 1/4FP O-RING, 7/32ID X 11/32OD O-RING, 3/8 ID X 1/2 OD NIP, 1/2 X 3/8 HEX BR HOSE, WATER 1/2 X 50’ DISCONNECT 3/8M X 3/8FP HOSE, WATER 1/2 X 50’ COUPLER, 1/4 QD HOSE, HP 1/4 X 50’ GUARD, HOSE VINYL NIPPLE, 1/4 FPT QD HOSE, HP 1/4 X 50FT W/QD 57 NOTES: AUTOMATIC PUMPOUT-OPTIONAL (P.1) 11 17 16 19 6 10 7 18 10 1 4 5 3 5 7 2 5 13 6 5 14 4 8 9 12 15 3 980185 11-30-04 58 AUTOMATIC PUMPOUT-OPTIONAL REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO. 70105 00-000132 57006 87162 02-000066 03-000176 09-805591 10-805484 12-800052 12-800367 12-800444 43-807008 50-502055 52-000123 52-501993 61-951306 61-951319 23719 72185 QTY 4 2 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION SERIAL NO. FROM NOTES: SCR, M4 X 60 PH SCR, 1/4-20 X 1/ 1/2 HXHD NUT, 1/4-20 HEX WASHER, 1/4 SPLIT LOCK PLTD FLATWASHER, 1/4 CLAMP, HOSE #16 HOSE, WASTE PUMP 1” X 8’ HOSE, GARDEN 3/4 X 75’ CAP, HOSE 3/4 BR FTTG, BRB 1PX1H BR FTTG, 1-1/4P X 1” H BR WASHER, HOSE 5/8 ID 1” OD BRKT, CTR HOOD FR NUT, 1-3/16-12 UN HXHD CONN, HOSE WATER OUTL PUMP, HD AUTO ASSY, LVL SENS SHUT OFF SW CORD ASM, CNCTN SIDE SWITCH ASSEMBLY 980185 11-30-04 59 AUTOMATIC PUMPOUT-OPTIONAL (P.2) 26 36 23 15 1 24 16 37 19 22 11 22 11 17 27 26 3 29 30 32 25 20 9 34 31 18 33 5 14 13 28 4 8 7 35 6 21 39 10 21 8 38 21 10 12 2 21 5 980185 11-30-04 60 AUTOMATIC PUMPOUT-OPTIONAL REF PART NO. QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 00-000210 52-502064 00-000312 00-000399 00-000241 57245 87162 87165 04-000312 04-000334 04-000335 04-000342 52-502061 16-808241 40-902151 43-807117 43-807118 43-810091 43-810100 43-810101 43-810106 45-801927 49-876301 50-502025 50-502026 70094 11-800504 52-501828 52-501829 52-501914 52-501915 52-501921 52-501934 52-501950 52-502062 56-502428 52-501821 52-501820 52-502063 4 1 8 1 8 8 1 8 1 2 2 1 1 1 1 1 1 1 1 1 4 4 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION SCR, 1/4-20 X 3/4 SOCHD CVR, OUTLET WST PMP-OUT SCR, CAP 1/4 X 1 SOCHD SCR, CAP 1/4 X 1 3/8 SOC SCR, CAP 10-32 X 2 SOCHD SS NUT, 1/4-20 HEX NYLOCK SS WASHER, 1/4 SPLIT LOCK WASHER, #10 SPLIT LOCK RING, RETAIN EXT 1/2 BALL, NYL ID RING, SNAP 1-7/8D SPRING, PUMP-OUT BALL PRESS BDY, INLET WST PMP-OUT DIAPH, WST TNK PMP-OUT MOTOR, 1/8HP 12V GSKT, CVR TOP PMPOUT GSKT, CVR SD PMPOUT SEAL, PUMPOUT SHFT SEAL PUMPOUT CAM O-RING, 800/1000 .072 O-RING, 1-13/16 ID X 2 OD HDWP BRG, SHFT PUMP-OUT VENT, UPR SHFT BRNG HSG PL, CVR TOP PUMP-OUT PL, CVR SD PUMP-OUT SCR, 1/4-20 X 1/2 SHCS SS GA, FLOW SIGHT 3/8 NPT BTM, PLNGR WST TNK PMP-OUT SHT, 3/4” STROKE WST TNK RD, CONNECT WST PMP-OUT GUIDE, PLNGR WST PUMP-OUT PIN, WRIST PUMP-OUT TOP, PLNGR PUMP-OUT BUSH, THREADED CVR, INLET WST PMP-OUT BRKT, PMP-OUT SW/CCT BRKR TOP, WST TNK PUMP-OUT BASE, WST TANK PMP-OUT BDY, INLET WST PMP-OUT 980185 11-30-04 SERIAL NO. FROM NOTES: PART OF 31 INCL. 32, 18, 30 61 62 WAN-TITANIUM SIX JET - OPTIONAL REF PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 - 00-000282 00-000317 70228 57090 04-000093 09-805603 10-805504 56015 11-800206 12-800060 12-800322 56012 14-806512 17-803018 17-803006 17-803010 17-803036 17-803078 52-501619 52-502008BK 52-502009 52-502057 52-502058 56-502548 56-502534 61-950496 16-808189 16-808190 16-808228 16-808229 43-810062 43-810063 43-810064 52-501590 48-941462 48-941296 SERIAL NO. FROM DESCRIPTION SCR, CAP 1/4-20 X 1 1/4 SOC SCR, CAP 10-32 X 1 1/4 SOCH SCR, 10-32 X 1/4 PPHMS SS NUT, 10-32 HEX NYLOCK SS TIE, CABLE 13” HOSE, INT VAC 4-1/2 X 48 HOSE, 3/16 X 44-1/2 NIPPLE, 1/4 HEX PLUG, 1/8 SOCHD BR CONN, 1/4P X 1/4T BR CONN, 1/8P X 1/4T COMP BR NIPPLE, 1/4 FPT QD STRAINER, JET 50 MESH TIP, SPRAY 9501 X 1/8P SST WASHER, NYLON CONN, 1/4P X 11/16-16M CONN, 1/4FP X 11/16-16F BR TIP, SPRAY 8001 SST 1/8 VJET TRIGGER, WD VALVE BODY, WD HDL, 2” TB, BK HOLD DN-WD HDL 2” TUBE MANFOLD, LEFT MANIFOLD, RIGHT ASSY, MNFLD S-BEND WD & HD TITANIUM ASSY, EXTRACTOR VALVE STEM, EXTRACTOR VALVE SPRING, EXTRACTOR VALVE SEAT, EXTRACTOR VALVE HLDR, VLV STEM-EXTRACTOR VL O-RING, .114 ID .254OD O-RING, .551ID .691OD BACK-UP, .250DIA BDY, EXTRACTOR VLV DEC, WD HD TITANIUM BLB, INSPECTION QC (PINK) 63 NOTES: 64 WAND – QUAD-JET - OPTIONAL SERIAL NO. FROM REF PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23A 89238 89239 89237 89235 56012 17-503010 17-803006 14-806512 17-803036 56015 09-805359 52-501619 00-000317 57090 61-950496 12-800060 10-805387 04-000053 00-000282 52-501569 52-501568 56-501940 11-800206 56-501966 00-000347 87165 17-803001 17-803002 WAND, TM, QJW (95015) PC WAND, TM, QJW (9502) PC WAND, TM QJW (9501) PC WAND, TM, QJW, (9501) NO DECAL NIPPLE, 1/4 FPT QD CONN, 1/4P X 11/16-16M WASHER, NYLON STRAINER, JET 50 MESH CONN, 1/4FP,11/16-16R BR NIPPLE, 1/4 HEX SLEEVE, WD HDL 9.5 TRIGGER, WD VLV SCR, CAP 10-32X 1-1/4 SOCH NUT, 10-32 HEX NYLOCK SS ASSY, EXTRCTR VLV CONN, 1/4P X 1/4T BR HOSE, 3/16 X 43-1/2 (1/8P X 1/4) TIE, CABLE 8” WHT SCR, CAP 1/4-20 X 1-1/4 SOC HOLD DOWN, WD HDL BODY, WD HDL WAND & HEAD, CAST SST PLUG, 1/8 SOCHD BR ASSY, L S-BEND MNFLD SCR, CAP 10-24 X1/4 SOCHD WASHER, #10 SPLIT LOCK TIP, SPRY 95015X1/8P SST TIP, SPRY 9502X1/8P SST 23B 17-803018 TIP, SPRY 9501X1/8P SST 24 25 26 27 28 29 30 31 32 33 34 - 56-501986 12-800322 56-501967 16-808229 43-810063 16-808228 16-808189 43-810064 43-810062 16-808190 52-501590 48-941186 ASSY, RT S-BEND MNFLD CONN, 1/8PX1/4T COMP BR ASSY, S-BEND MNFLD HOLDER, VLV STEM-EXTRCTR VL O-RING, .551 ID .691 OD SEAT, EXTRCTR VLV STEM, EXTRCTR VLV BACK-UP, .250 DIA O-RING, .144 ID .254 OD SPRING, EXTRCTR VLV BODY, EXTRCTR VLV DECAL, WD HD (CAST SS) - 66-808169 KIT, REP-WD VLV 65 NOTES: COMPLETE COMPLETE COMPLETE COMPLETE 89238 89239 89237 89235 (NO DECAL) NOT SHOWN NOT SHOWN INCLUDES PARTS 27-29 & 31-33 66 WAND – TRI - OPTIONAL SERIAL NO. FROM REF PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19A 19B 20 21 22 23 24 25 26 27 28 29 30 31 32 - 89233 89232 89234 56012 17-503010 17-803006 14-806512 17-803036 56015 09-805359 52-501619 00-000317 57090 61-950496 12-800060 10-805253 04-000053 00-000282 52-501569 52-501568 56-501712 17-803002 17-803001 17-803046 70162 87165 57014 56-501739 11-800206 16-808229 43-810063 16-808228 16-808189 43-810064 43-810062 16-808190 52-501590 48-941166 WAND, TJW (9502) PC WAND, TJW, (95015) CUBXL WAND, TJW, (9503) PC NIPPLE, 1/4 FPT QD CONN, 1/4P X 11/16-16M WASHER, NYLON STRAINER, JET 50MESH CONN, 1/4FP,11/16-16R BR NIPPLE, 1/4 HEX SLEEVE, WD HDL 9.5 TRIGGER, WD VLV SCR, CAP 10-32X 1-1/4 SOCH NUT, 10-32 HEX NYLOCK SS ASSY, EXTRCTR VLV CONN, 1/4P X 1/4T BR HOSE, 3/16X49 (1/8P X 1/4FT) TIE, CABLE 8” WHT SCR, CAP 1/4-20 X 1-1/4 SOC HOLD DOWN, WD HDL BODY, WD HDL WAND & HEAD, TRI-JET WD TIP, SPRY 9502X1/8P SST TIP, SPRY 9501X1/8P SST TIP, SPRY 9503X1/8P SST SCR, 10-32 X 3/8 PPHMS SS WASHER, #10 SPLIT LOCK NUT, 10-32 HEX SS MANIFOLD, WD TRI-JET PLUG, 1/8 SOCHD BR HOLDER, VLV STEM-EXTRCTR VL O-RING, .551 ID .691 OD SEAT, EXTRCTR VLV STEM, EXTRCT VLV BACK-UP, .250DIA O-RING, .114ID .254OD SPRING, EXTRCTR VLV BODY, EXTRCTR VLV DECAL, WD HD - 66-808169 KIT, REP-WD VLV 67 NOTES: COMPLETE COMPLETE COMPLETE 89233 89232 89234 NOT SHOWN NOT SHOWN INCLUDES PARTS 25-27 & 29-31 68 STAIR TOOL - OPTIONAL SERIAL NO. FROM REF PART NO. DESCRIPTION 1A 1B 2 3 4 5A 5B 6 7 8 9 10 11 12 13 14 15A 15B 16 17 18 19 20 21 22 23 - 78519 78521 56-501715 56-501907 52-501576 52-501577 04-000053 10-805330 10-805397 17-803002 00-000282 12-800060 00-000317 57090 61-950496 56015 56012 52-501619 09-805359 09-805504 16-808229 43-810063 16-808228 16-808189 43-810064 43-810062 16-808190 52-501590 48-941163 TL, STAIR, LNG, TM DJ (80015) TL, STAIR, SHT, TM (80015) WAND & HEAD, STAIR TL WAND & HEAD, SHRT STAIR TL BODY, WD HDL PORT HOLD DOWN, WD HDL PORT TIE, CABLE 8” WHT HOSE, 3/16X13-3/4 (1/8PX1/4) HOSE, 3/16X7-1/2 (1/8P X 1/4F) TIP, SPRY 9502X1/8P SST SCR, CAP 1/4-20 X 1-1/4 SOC CONN, 1/4P X 1/4T BR SCR, CAP 10-32X1-1/4 SOCH NUT, 10-32 HEX NYLOCK SS ASSY, EXTRCTR VLV NIPPLE, 1/4 HEX NIPPLE, 1/4 FPT QD TRIGGER, WD VLV SLEEVE, WD HDL 9.5 SLEEVE, STAIR TL HDL 7-1/8 HOLDER, VLV STEM-EXTRCTR VL O-RING, .551 ID .691 OD SEAT, EXTRCTR VLV STEM, EXTRCTR VLV BACK-UP, .250DIA O-RING, .114 ID .254 OD SPRING, EXTRCTR VLV BODY, EXTRCTR VLV DECAL, STAIR TL - 66-808169 KIT, REP-WD VLV 69 NOTES: COMPLETE COMPLETE NOT SHOWN NOT SHOWN INCLUDES PARTS 16-19 & 20-22 70 UPHOLSTERY TOOL - OPTIONAL SERIAL NO. FROM REF PART NO. QTY DESCRIPTION 1 2 3 4 5 6 7 8 9 78513 09-805131 08-805243 10-805347 13-806023 58-500639 00-000310 04-000282 52-501624 52-501842 1 2 1 1 1 1 1 1 1 1 TL, UPHOLST, PC (80015) HOSE, VAC 1-1/4X10’ BLU CUFF, SWIV 1-1/4HX1-1/4T HOSE, 3/16X119-1/2 (1/8PX1/4FT) DSC, 1/8FC1/8FP SST UPHOLSTERY TL TRIGGER SCR, CAP 4-40 X7/32 SHCS SS SPRING, VAC ADJ BUTT BUTTON, VAC ADJ TOOL, UPHOLSTERY 10 61-950570 1 ASSY, UPHLST TL VLV 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 - 560012 17-803010 17-803006 14-806512 17-803036 11-800404 52-501585 12-800065 08-805138 16-808229 43-810063 16-808228 16-808189 43-810064 43-810062 16-808190 00-000306 17-803033 58-500638 00-000307 52-501623 52-501626 43-810016 43-807513 10-805348 13-806030 00-000408 48-941164 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 NIPPLE, 1/4 NPT QD CONN, 1/4P X 11/16-16M WASHER, NYLON STRAIRNER, JET 50MESH CONN, 1/4FPX11/16-16F BR NIP, 1/4X5 SST COUPLER, UPHLST TL CONN, 1/8P X 1/4T CUFF, 1 1/4H X 1 1/2T GRY HOLDER, VLV STEM-EXTRCTR VL O-RING, .551 ID .691 OD SEAT, EXTRCTR VLV STEM, EXTRCTR VLV BACK-UP, 250DIA O-RING, .144 ID .254 OD SPRING, EXTRCTR VLV SCR, 6-32 X 1 SCHD SS TIP, SPRY 80015X1/8P SST CSTG, TRIGGER CLMP SCR, CAP 6-32X3/8 SOCHD VALVE, UPHLST TL VALVE, ADJ-UPHLST TL VLV O-RING, 5/32IDX9/32OD VIT GASKET, UPHLST TL VLV HOSE, 3/16X6-1/2 (1/8P BS) DSC, 1/8MX1/8FP SST SCR, SET 3-32 X 1/4 SOCHD DECAL, UPHLST TL - 66-808169 1 KIT, REPAIR-WAND VLV 71 NOTES: COMPLETE INCLUDES PARTS 20-26, 28, & 31- 37 NOT SHOWN NOT SHOWN INCLUDES PARTS 20-22 & 24-26 72 SHELF ASSEMBLY-OPTIONAL SERIAL NO. FROM REF PART NO. QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 65-950392 56-501921 02-000066 87162 70721 70270 50-501840 56-502067 56-501942 50-501753 01-000105 56-501922 50-501749 56-501920 46-802506 50-501755 50-501754 48-941152 1 1 1 1 1 1 1 VAN STORAGE UNIT SHELF, LWR FLATWASHER, 1/4 WASHER, 1/4 SPLIT LOCK SHOULDER BOLT, 182 OD X 2.25 L SCR, 1/4-20 X 3/4 HHCS PLTD BRKT, ADJUST MTG SLOT BRKT, ADJUST MTF HLDR BRKT, SHELF MOUNTING HOLDER, STAIR TOOL LOCK NUT, 1/4-20 HXHD PANEL, SHLF END WASHER, NYLON DRAWER, SHELF GRAY LATCH, ADJ GRIP HOLDER, UP TO HOSE HOLDER, UPHST TL DECAL, PROCHEM - 66-945424 1 KIT, ADJ BRKT. 1 1 1 1 2 DESCRIPTION NOTES: COMPLETE INCLUDES PARTS 6,7 & MOUNTING HARDWARE 73 74 WATER TANK,DUAL WITH DEMAND PUMP-OPTIONAL REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 - PART NO. 66-945260 66-945265 50-501774 87171 87163 00-000072 11-800432 11-800041 12-800278 03-000113 09-805456 11-800085 56-502000 58-500661 11-800168 50-500511 57119 41458 QTY 4 16 16 16 4 2 4 4 1 1 2 2 2 1 9 1 SERIAL NO. FROM DESCRIPTION TANK, DUAL SADDLE W/DMD PUMP SINGLE SADDLE TANK W/DMND PMP HOLD DOWN, SADDLE TANK GRAY WASHER, 3/8 FLAT WASHER 3/8 SPLIT LOCK SCR, 3/8-16 X 2’ HXHD CAP, WATER BOX ELL, STREET 1/2 BR FTTG, BRB 1/2P X 3/4H BR CLAMP, HOSE #12 SST HOSE, WTR 3/4 X 96” TEE, 1/2 BRASS ASSY, BASE SADDLE TANK GRAY MOLDING, WATER TANK PLUG, 1/2 BRASS HXHD PLATE, INSTALL MT NUT, 3/8-16 HEX NYLOCK SHLR, CHEM, 10-GAL JUG 75 NOTES: COMPLETE COMPLETE NOT SHOWN WATERTANK-DEMAND PUMP-OPTIONAL 980185 11-30-04 76 WATER TANK – DEMAND PUMP-OPTIONAL REF PART NO. QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 70305 87083 02-000143 03-000113 09-805278 09-805357 09-805446 12-800345 13-806009 14-806553 41-905049 48-809423 11-800275 65240 47449 4 4 4 6 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION SCR, 5/16-18 X 3/4 HHCS GR5 PL TDL WASHER, 5/16 SPLIT LOCK PLTD WASHER, 5/16 FLAT CLAMP, HOSE #12 SST HOSE, WATER 3/4 X 3” HOSE, WATER .75 X 5.5 HOSE, WATER 5/8 X 55 FTTG, BRB 3/8P X 5/8H BR DISCONNECT, 3/8M X 3/8FP FILTER, DEMAND PUMP PUMP, WATER BOOSTER FLOJET 2 KIT, PORT ELBOW, ST 3/8 BR PUMP ONLY, TM DEMAND KIT SERVICE DEMAND PMP FJ 980185 11/30/04 SERIAL NO. FROM NOTES: NOT SHOWN NOT SHOWN 77 78 HOSE REEL - OPTIONAL REF PART NO. QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 56-501962 03-000124 52-501685 56-501960 56-502207 61-950854 02-000066 87162 70270 57031 56-501968 45-802138 02-000143 87083 70302 44-802122 56-501961 00-000072 50-500511 87171 57119 55-501789 50-501812 04-000302 04-000303 1 2 2 1 1 1 2 2 2 2 1 2 4 4 4 4 1 10 1 10 10 1 1 1 1 SERIAL NO. FROM DESCRIPTION REEL, VACUUM HOSE GRAY CLAMP, MFLR 1-3/4 BUSHING, HOSE REEL BASE, HOSE RL (250’) BRKT, LOCKOUT HOSE REEL LATCH ASSEMBLY FLATWASHER, 1/4 WASHER, 1/4 SLPIT LOCK SCR, 1/4-20 X 3/4 HHCS PLTD NUT, 5/16-18 HEX REEL, HP HOSE GRAY BEARING HOSE REEL FLATWASHER, 5/16 WASHER, 5/16 SPLIT LOCK PLTD SCR, 5/16-18 X 1” HHCSGR5PLT FLANGE, 47MST BODY, HP HOSE GRAY SCR, 3/8-16 X 2” HXHD PLATE, INSTALL MT WASHER, 3/8 FLAT NUT, 3/8-16 HEX NYLOCK PIN, LOCK HOSE REEL BRKT, HOSE REEL LOCK SPRING, LOCK-LOCK PIN ASSY CLIP, RETAINER-LOCK PIN ASSY 79 NOTES: New Truck Mount Machine Warranty Limited Warranty PROCHEM warrants new machines against defects in material and workmanship under normal use and service to the original purchaser. Any statutory implied warranties, including any warranty of merchantability or fitness for a particular purpose, are expressly limited to the duration of this written warranty. PROCHEM will not be liable for any other damages, including but not limited to indirect or special consequential damages arising out of or in connection with the furnishing, performance, use or inability to use the machine. This remedy shall be the exclusive remedy of the buyer. The warranty period is subject to the conditions stated below. Any local or distant transportation, related service labor, normal maintenance, and diagnostic calls are not included. Parts replaced or repaired under this warranty are guaranteed for the remainder of the original warranty period or 90 days. Component Gasoline Engine* Coverage Responsibility Engine Dependant: Briggs & Stratton – 1-800-233-3723 Nissan – Contact Customer Care Kohler – 1-800-655-4356 Vacuum Pump Gardner Denver – 1-800-982-3009 Heat Exchanger PROCHEM Water Pump PROCHEM Waste Pump PROCHEM Wands(except shut off valve and jets) PROCHEM Waste and Water Tanks PROCHEM Pressure Regulator PROCHEM All other component not excluded PROCHEM Battery* Pro-rated through battery manufacturer’s local dealer. 800-423-6569 * When applicable Length of Warranty 1 year 18 months 1 year 2 years 1 year 1 year 1 year 1 year 1 year 1 year Product exceptions and Exclusions: • • Normal wear items and maintenance items including but not limited to disposable filters, any fluids, electrical components, belts, pulleys, bearings, fittings, hoses, o-rings, seals, gaskets, diaphragms, engine tune up components, wand shut off valve, and jets are covered, parts only, for 90 days. NOTE: Engine warranty is administered through the engine manufacturer and must be repaired at an authorized service center. This Warranty Shall Not Apply To: 1. Any product that has been subject to abuse, misuse, neglect or unauthorized alteration (including the use of incompatible or corrosive chemicals or overloading of capacity). 2. Products that have experienced shipping or freight damage. 3. Repairs necessary to correct any failure due to imp roper pre-delivery service and inspection by the selling dealer. 4. Time for cleaning units in preparation for repair. 5. Any repairs resulting from poor initial service work or improper diagnosis. 6. Any design alterations performed by an organization not authorized or specified by PROCHEM. 7. A unit which is improperly repaired. 8. Damage due to hard water scaling. 9. Exposure to freezing temperature conditions. 10. Electrical components exposed to moisture. The warranty commences on the purchase date by the original end user from an authorized PROCHEM agent, subject to proof of purchase. The warranty is non transferable and is intended for the original purchaser only. The Machine Registration Card must be completed and returned within 10 day of the time of purchase. If proof of purchase cannot be identified, the warranty start date is 90 days after the date of sale to an authorized PROCHEM distributor. If difficulty develops during the warranty period, contact the authorized PROCHEM agent from whom the product was purchased. PROCHEM may elect to require the return of components to validate a claim. Any defective part to be returned must be shipped freight prepaid to an authorized PROCHEM Distributor/Service Center or to the PROCHEM factory. Use Of Parts Not Approved By PROCHEM Will Void All Warranties. PROCHEM reserves the right to change its warranty policy without notice PROCHEM. ? a Castle Rock Industries company ? 1351 W. Stanford Ave. ? (303) 762-1800 ? 800-444-7654 ? FAX (303) 865-2800 1