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A WARNING

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1. EMPERATURE SENDER 34 905019 LOCATED ON FRONT OF ENGIN WASTE PUMP SHUT OFF SWITCH 61 951132 WASTE TANK WASTE PUMP 41 809141 4 23 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings CONSOLE WIRING WATER PRESS OVERRIDE PUMP SWITCH amp OIL PRESS OVERRIDE SWITCH ORG 12Ga AES UH WHT GRN eg note below 5 61 9 34 900099 pen WHT Sa CIRCUIT BRKR E 53 900161 RED BLK RED 5 CIRCUIT BRKR 153 900163 TEMP GAUGE 18 IGNITION SWITCH lt 32 900198 TERMINAL BLOCK Locoted neor rodiotor on left side of console RED CIRCUIT BRKR 453 900163 WASTE OUT SWITCH 452 900180 CONNECTOR FOR WINTERIZING KIT OPTION BLK BLU Ei THE WATER PRESS OVERRIDE A AD AND OL WATER RUMP IHRES PRES ARE STACKED UN Fail NS 1 aru Prochem Power Vac 2 Operation amp Service Manual A 24
2. 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 front of the unit Connect the hose to the water supply faucet Prochem Power Vac II Operation amp Service anual Operation 2 Turn the water supply faucet on The water will fill the water box 4 HIGH PRESSURE HOSE 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 5 VACUUM HOSE Connect the vacuum hose to one of the vacuum inlet connections at the front of the console Plug the other vacuum inlet connection Connect the other end of the vacuum hose to the hard surface cleaning tool 6 STARTING THE UNIT 1 Before proceeding be certain that the control panel indicators are at the following settings Engine IDLE Throttle Lever Out Engine choke PULL OUT NOTE It will not be necessary to pull the choke out if the engine is already warmed up 2 Turn the ignition switch to the START position while holding the water pump switch to the left override position The engine will Start NOTE If your unit shuts down after 15 seconds check for adequate oil pressure 25 Section Three Operation NSTRUMENTATI RED CHARGING LIGHT OIL
3. 2 Next attach the black negative battery cable from the console ground to the negative terminal on the battery and tighten the holding nut BATTERY HOOK UP GROUND CONNECTION ON CONSOLE STARTER SOLENOID ON CONSOLE 8 FIRE EXTINGUISHER We recommend that a fire extinguisher preferably rated for A B amp C type fires be installed inside the vehicle 17 Section Two Installation Figure9 WASTE TANK TO CONSOLE CONNECTION 2 HOSE TO CONNECT WASTE TANK OUTLET TUBE TO VACUUM PUMP RELIEF VALVE 4 CONNECT CONSOLE ENGINE SHUTOFF 2 7 CORD END TO UPPER WASTE TANK LEVEL SENSOR LEVEL SENSOR ENGINE SHUTOFF 1 HOSE TO CONNECT VAC INLET TUBE TO WASTE TANK INLET TUBE LEVEL SENSOR WASTE PUMP 3 HOSE TO CONNECT WASTE REMOVAL TUBE TO WASTE TANK 5 CONNECT CONSOLE WASTE PUMP CORD TANK LEVEL SENSOR SPECIAL INSTRUCTIONS TANK LEVEL SENSOR 1 Cut hoses to fit if necessary 2 When cutting hoses make certain that the cutting blade is facing away from your hands fingers or any other part of your body to avoid injury 3 Do not install hoses with excessive bends or kinks 4 Place clamps on hoses before installing 5 Tighten all hose clamps firmly Prochem Power Vac 11 Operation amp Service Manual 18 SECTION 3 OPERATION 4 SYSTEM Water pumping system 20 Vacuum system 20 Chemi
4. COVER LENS RETRY SWITCH 32 02 000038 LOCKWASHER 1 4 11 33 900161 BREAKER CIRCLUT 33 1 1 800168 PLUG 1 2 BR HXHD 12 49 802516 CABLE CHOKE 34 50 501956 HOOD LEFT 13 33 900163 BREAKER CIRCUIT 20 AMP 35 01 000259 RECEPTACLE SNAP IN 1 4 TURN 14 32 900198 SWITCH START W KM 36 00 000272 STUD 1 4 TURN FASTENER 15 32 900180 SWITCH RETRY ILLUMINATED 37 02 000268 RETAINER SPLIT RING 1 4 TURN 16 50 501955 HOOD RIGHT 38 58 700023 PAD 1 4 TURN FASTENER 17 50 501949 LEVER THROTTLE CONTROL J NOTCH 39 00 000337 SCREW 10 32 x 1 SOCHD 18 64 950383 CABLE RETAIN VACUUM PLUG 40 01 000273 NUT WELL 10 32 19 52 501679 PLUG VACUUM INLET 41 48 941285 DECAL CONDENSED OPER INSTRUCT 20 43 810081 0 1 3 BID x 1 3 400 42 48 941369 DECAL CONSOLE POWER VAC 2 21 66 945236 KIT INLET PLUG 43 52 502019 ELBOW VACUUM EXHAUST INCLUDES M 19 amp 20 44 00 000410 SCREW SET 1 4 20 x 3 8 22 13 806035 DISCONNECT 1 M x 1 FP PLASTIC 45 55 501672 TUBE EXHAUST DEFLECTO 23 15 806008 DISCONNECT 3 8F BRASS 9 NOT SHOWN 48 941212 5 COMPLETE UNIT DECAL 56 501845 DRIP Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings STRUCTURAL FRAMEWORK ASSEMBLY 1 00 000055 5 1 4 20 x 3 4 H
5. Debris interfering in the normal operation of pump or check valve Pump out circuit breaker on the control panel has been tripped Broken wiring leading to the waste pump Worn out waste pump Prochem Power Vac II Operation amp Service Manual GORRE GLEE Remove obstructions from pump and check valve After inspecting the waste pump to determine the cause of the tripped circuit breaker press the RESET button Check for voltage at the pump If no voltage find the broken connection and repair Check for voltage at the pump If there is voltage and the pump does not run replace the pump 47 Section Four Maintenance amp Service 9 WASTE PUMP IS MALFUNCTIONING OR NOT OPERATING NORMALLY continued from previous page Check valve is stuck open or closed Inspect and clean check valve If damaged replace check valve Belt loose or broken Re tension or replace as needed Prochem Power Vac II Operation amp Service Manual 48 Section Four Maintenance amp Service ILLUSTRATION INDEX in alphabetical order DEMAND PUMP ASSEMBLY A 21 ELECTRIC FUEL PUMP ASSEMBLY A 18 ENGINE ASSEMBLY A 3 A 4 ENGINE COOLANT DETAIL A 7 ENGINE GOVERNOR DETAIL A 5 FLOAT VALVE DETAIL A 14 FRAMEWORK ASSEMBLY A 2 FRONT VIEW PARTS 1 HEAT EXCHANGER ASSEMBLY A 8 HOSE REEL ASSEMBLY A 21 MUFFLER ASSEMBLY A 6 PRESSURE REGULATOR MANIFOLD ASSEMBLY A 15 SHELF ASSEMBLY A 19 VACUUM EXHAUST ASSEMBLY A 10 VACUUM PUMP ASSEMB
6. 52 2 03 000111 ve HOSE CLA 812 800093 B ARBFITTING 16 EXISTING HOSE 10 805319 2 STAINLESS STEEL HOSE CUT HOSE 3 FROM END OF HOSE CUT 52 501625 3 4 OUT ADAPTOR TUBE OF HOSE EXISTING HOSE BOTTOM OF FUELTANK Prochem Power Vac Operation amp Service Manual 14 Section Two Slide one of the seals over the threads of the bulkhead adapter against the hexagon area Next attach the 25 36 or 45 stainless steel hose to the 1 8 steel elbow Choose a length that will reach through the filler neck to the bottom of the fuel tank If the selected hose is too short or too long the unit will run out of fuel before the vehicle fuel tank is empty 11 Insert the stainless steel hose bulkhead connector first into the filler neck until the male threads on the bulkhead connector are protruding through the 1 2 hole Slide the other seal over the threads and tighten the hex head nut over the seal Figure 5 Attach the 1 8 street elbow and 1 8P x 5 16H barb fitting to the bulkhead connector outside the filler neck Make certain the fuel hose and fittings remain positioned parallel to the filler neck Figure 6 12 Using a hose clamp connect one end of the 5 16 fuel hose to the fittings on the outside of the filler neck Figure 5 13 Re install the filler neck on the vehicle 14 Insert the filler neck fuel hose into the fuel tank and ma
7. Mobile Cleaning Unit DECEMBER 2001 OPERATION amp SERVICE MANUAL Welcome and congratulations on your purchase of the POWER VAC 2 Mobile Cleaning Unit This instruction manual is a guide for operating and servicing your PROCHEM 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 PROCHEM dealer The headings CAUTION or WARNING are used to warn you that steps must be taken to prevent damage to the unit and or personal injury Make certain that you read all instructions entirely before proceeding with the operation of the unit THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCO
8. 1 apo 40 42 5 8 49 1 2 1 3 4 MOUNTING PLATE E INSTALLATION HEX HEAD SCREW FLATWASHER OIL DRAIN PAN OPTIONAL VAN SIDE DOOR STALLATION Prochem Power Vac Operation amp Service M anual 11 Section Two 4 INSTALLING FUREL LINE ON THE VEHICLE READ THESE INSTRUCTIONS ENTIRELY BEFORE PROCEEDING A Under NO circumstances should you splice any of the vehicle fuel lines Severe injury or fatality may result A 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 WARNING CAUTION The following text applies to vehicles other than 1992 or later Fords See Figure 7 for 1992 or later Ford fuel line installation 1 Select a location on the vehicle floor to drill a hole for the bulkhead adapter This location should be situated in a position that eliminates the possibility of fuel line contact by either the operator s or accessories during the working hours or maintenance periods We supply steel braid fuel hose Make certain that the hose will reach the location you choose A CAUTION Before drilling the fuel line hole in the vehicle floor make certain when drilling you will not do any dam
9. 4 Mount the fuel tank where it will be protected from any vehicle collision 5 When installing the fuel line from the tank to the unit use the proper size fuel line 15 Section Two STUDY ALL FUEL LINE INSTALLATION INSTRUCTIONS COMPLETELY BEFORE FROCEEDING Figure 9 EXTERNAL ELECTRIC FUEL PUMP ABRASION MOUNTING HOSE CUT TO FIT INSTRUCTIONS COVER assemble as shown with provided hardware Installation A WARNING DO NOTINSTALL THIS ASSEMBLY IN ANY MANNER OR POSITION WHICH IN SO DOING MAY CAUSE DAMAGE TO THE VEHICLE OR ANY COMPONENT WHICH MIGHT AFFECT THE OPERATION OR SAFETY OF THE VEHICLE 1 DETERMINE THE POSITION WHERE THE BOX ASSEMBLY WILL BE MOUNTED WARNING DO NOT MOUNT THIS ASSEMBL Y NEAR THE CATALYTIC CONVERTER EXHAUST OR ANY AREAS OF HIGH TEMPERATURE 2 USING THE COVER AS A TEMPLATE DRILL TWO 5 16 DIA HOLES IN THE VEHICLE FRAME BOX 3 MOUNT THE COVER TO THE TO VEHICLE FLOOR ASSEMBLY BULKHEAD ADAPTOR 4 CONNECT THE HOSES AND DETAIL CORD AS SHOWN TIGHTEN HOSE ABRASION CLAMPS RESISTANT FUEL CAUTION WHEN ROUTING THE FUEL POSE PUM HOSE AND CORD UNDERNEATH THE VEHICLE MAKE CER TA IN THAT YOU DO NOT PLACE THEM IN ANY LOCATION WHERE DAMAGE MAY OCCUR TO THE HOSE CORD OR VEHICLE FROM AVOID ANY CONTACT WITH CONSOLE MOVING PARTS AREAS OF HIGH TEMPERATURE OR SHARP OBJECTS 5116 ABRASION RESISTANT FUEL HOSE
10. formulated especially for positive displacement blower service to provide maximum blower protection at any temperature One filling of AEON PD will last a minimum of 2 times longer than a premium mineral oil AEON PD Part OS 008039 is the oil that the manufacturer puts in the vacuum pump at the factory Topping off or adding petroleum oil to synthetic oil is NOT recommended If not using AEON PD synthetic blower lubricant use oils with rust and oxidation inhibitors anti foam additives the viscosities listed on the chart on the following page Check the oil level weekly to assure the proper level With the vacuum pump cold the engine off and the unit on level ground the oil level should be slightly below the top of the oil level sight gauge Use the following illustration as a guide when adding oil PROPER LEVEL cannot be overemphasized Too little oil will ruin bearings and gears Too much oil will cause overheating 33 Section Four VACUUM PUMP OIL LEVEL VACUUM PUMP side view with vacuum pump cold engine off and LEVEL SIGHT GAIJGE 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 plug all vacuum inlets Then fill the lubrication cup with WD 40 or a similar lubricant while the unit is running Do this a
11. the loop hose and possibly causing serious injury 9 Turn the water pump switch OFF Set the pressure unloader to its lowest pressure setting Add approximately two gallons of 10096 glycol base anti freeze to the water box DO NOT add so much anti freeze that the float valve closes The float valve must remain open Attach the loop hose 10 805453 to the solution outlet connection and the water inlet connection Turn the water pump switch ON Allow the unit to run for approximately 3 minutes with the loop hose attached 10 Remove chemicals from the chemical injector lines After completing these procedures shut the unit down The unit is now winterized Prochem Power Vac Operation amp Service Manual Operation REMOVING THE ANTI FREEZE FROM YOUR UNIT 1 Connect one end of the loop hose to the solution outlet connection Connect the female quick disconnect attachment to the male quick disconnect on the other end of the loop hose Place this end of the loop hose into an approved container 2 Start the unit Turn the water pump switch ON Allow anti freeze to flow into the container until the supply in the water box is exhausted Turn the water pump switch OFF 3 Fill the water box with fresh water and repeat step 2 as necessary until anti freeze is completely removed from the system 4 Connect the water inlet hose to the water inlet connection on the console Turn the water supply on 5 Connec
12. whichever comes first Daily maintenance Prochem Power Vac 0 peration amp Service Manual 31 Section Four AINTENANCE This chapter of the operators manual contains the maintenance information for this unit Initiation of a planned preventative maintenance program will assure that your PROCHEM POWER VAC II cleaning unit has optimal performance a long operating life and a minimal amount of down time AWARNING DANGER A WARNING ELECTRICAL SHOCK 17 COULD CAUSE SEVERE 22 BURNS OR INJURY DO ass NOT TOUCH ELECTRICAL WATER UNDER PRESSURE AT ROTATING MACHINERY WIRES OR COMPONENTS WHILE THE ENGINE 1 RUNNING DISCONNECT THE BATTERY BEFORE SERVICING THIS UNIT TO PREVENT ACCIDENTAL STARTING CAN CAUSE INJURY OR COULD BE FATAL KEEP ALL GUARDS AND SAFETY DEVICES IN PLACE RE USE BURNS SEVERE PERSONAL INJURY 0 BEFORE REMOVING VALVES CAPS PLUGS FITTINGS FILTERS AND BOLTS A WARNING 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 severed limbs or fatality 1 GASOLINE ENGINE 1 Check the engine oil level daily when in use MARE CERTAIN THAT PROPER OIL LEVEL IS MAINTAINED NEVER overfill Maintenance amp Service 2 Change the break in oil after the first 50 hours of operation Thereaf
13. 195 W HOLE 02 000066 FLATWASHER 19 50 501729 MOUNT TUBE amp SHELL HEAT EXCHANGER 03 000246 CLAMP HOSE 20 ANGLE MOUNTING HEAT EXCHANGER 03 000248 CLAMP HOSE 16 21 MOUNT TUBE amp SHELL HEAT EXCHANGER 09 805375 HOSE RADIATOR 1 1 8 5 1 2 22 FITTING BARB x 1 H 09 805423 HOSE RADIATOR 1 1 8 x 4 1 2 23 HEAT EXCHANGER TUBE amp SHELL HYDRAFLUID 09 805432 HOSE RADIATOR 1 1 8 x 13 1 2 24 CASTING COOLANT MANIFOLD 09805552 HOSE RADIATOR 1 1 8 x 18 25 52 502020 ADAPTOR COOLANT 1 1 800041 ELBOW ST 1 2 BR Prochem Power Vac 2 Operation amp Service Manual A 8 Illustrated Parts Listings PERFORMER 405 VACUUM PUMP ASSEMBLY 61 951071 27 TO WASTE TANK GREASE FITTINGS 00 000095 5 3 8 16 x 1 F 00 000323 i 00 000324 3 5 is TD VACUUM GAUGE vines A ON CONTROL PANEL 4 00 000420 5 1 6 1 8 x 1 1 2 SOCHD 5 02 000057 FLATWASHER 1 2 HEAVY 6 02 000074 FLATWASHER 3 8 I MUT 7 02 000075 LOCKWASHER 3 8 8 05 008039 01L A E N P p 28024 SUTORBILT N NOT SHOWN 9 09 805566 TUBING IMPOLENE 1 4 x 57 10 09 805429 TUBING IMPOLENE 1 4 x 42 11 41 905026 PUMP VAC 4LL 12 44 802196 HUB P1x 7 8 13 44 802245 PULLEY 2 58 14 44 802254 PULLEY VACUUM PUMP LEFT 15 44 802307 BELT BX42 16 54
14. 4 02 000066 FLATWASHER 1 4 03 000254 CLAMP HOSE 6 09 805345 HOSE FUEL 5 16 157 ABR RESIST 09 805417 HOSE FUEL 5 16 x 3 1 2 9 31 900017 CONN C 0 R D 1 2 10 31 900067 BUSHING SNAP HEYCO2140 11 41 809132 KBT PMP FUEL 101 12 42 902311 KBT ASSY FUEL FILTER 12581 43012 13 50 501739 COVER FUEL PUMP BRACKET 14 56 501880 BRACKET FUEL PUMP MOUNTING 15 67 945340 INSTRUCT EXTERNAL FUEL PUMP KIT NOT SHOWN O01 Prochem Power Vac 2 Operation amp Service Manual A 18 Illustrated Parts Listings EXTERNAL ELECTRIC FUEL PUMP 9 ASSEMBLEY d 66 945201 TO BULKHEAD ADAPTER 1 00 000055 5 1 4 20 x 3 4 HXHD 2 00 000078 5 CAP 1 4 20 1 HXHD GRD 8 3 0100007 NUT 1 4 20 HXHD BAN 4 02 000038 LOCKWASHER 1 4 5 02 000066 FLATWASHER 1 4 6 03 000254 CLAMP HOSE 6 7 09 805345 HOSE FUEL 5 16 157 ABR RESIST 8 09 805417 HOSE FUEL 5 16 x 3 1 2 9 31 900017 CONN CORD 1 2 10 31 900067 BUSHING SNAP HEYCO2140 11 4180912 KBT PMP FUEL 101 12 42 902311 KBT ASSY FUEL FILTER 12581 45012 13 50 501739 COVER FUEL PUMP BRACKET 14 56 501880 FUEL PUMP MOUNTING 15 67 945340 INSTRUCT EXTERNAL FUEL PUMP KIT Nor SHOWN Concrete Science Power Vac II Operation amp Service Manual A
15. 501642 NIP VAC OUTL 411 17 56 502386 BRKT VAC ADJ 4LL 18 61 950732 ASSY VAC RELIEF VLV INCLUDES PARTS 19 25 19 01 000224 NUT 7 16 14 HXHD of S 20 02 000074 FIATWASHER 3 8 21 04 000091 5 VAC RELIEF VLV VACUUM RELIEF 22 12 800059 1 8P x 1 4POLY BR 23 45 807106 SAPHIRA UAC VLV VALVE DETAIL 20 2 24 52 501684 ELL VAC RELIEF VLV 411 61 950732 25 56 501994 STEM VAC RELIEF VLV 4LL 19 26 03 000250 CLAMP HOSE 450 27 09 805425 5 INT VAC 3 1 2 x 5 28 09 805426 5 INT VAC 3 1 2 x 25 A 9 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings VACUUM EXHAUST OUTLET ASSEMBLY 61 951663 00 000078 SCREW 1 4 20 1 HXHD 01 000037 NUT 1 4 20 HXHD 02 000038 LOCKWASHER 1 4 02 000066 FLATWASHER 1 4 03 000250 CLAMP HOSE 60 03 000257 CLAMP MUFFLER 3 1 4 09 505425 HOSE INT VAC 3 1 2x 5 43 807108 VAC HEAT EXCHANGER INLET 96 502184 ASSEMBLY VACUUM EXHAUST OUTLET 0 57 520101 MUFFLER VACUUM 1 2 3 4 5 8 7 8 9 1 Prochem Power Vac 2 Operation amp Service Manual A 10 TU WATER BUX TO PRESSURE REGULATOR 1 00 000237 SCREW 8mm x 1 25 x 25mm HXHD 18 2 00 000336 SCREW 5 8 1 8 x3 ALL THREAD 19 3 01 000073 NUT 3 8 1 6 HXHD 20 4 02 000040 LO
16. Manual 9 Section Two K INSTALLATION A WARNING All units must be bolted to the floor of the vehicle by a PROCHEM DISTRIBUTOR LIFTING THE UNIT ON THE VEHICLE Since the PROCHEM POWER VAC II console weighs approximately 889 pounds we recommend using a forklift to lift the unit onto the vehicle Position the forks under the unit from the front and make CERTAIN that the forks are spread to the width of the base 2 POSITIONING THE UNIT IN THE VEHICLE Because vehicles vary in size and openings individuals have their own preference as to where they want their units installed We strongly recommend a side door installation for the POWER VAC II cleaning unit and DO NOT recommend a rear door installation 1 Enough space should be provided to assure adequate engine ventilation and room for service and maintenance 2 The unit with waste tank and accessories must not exceed the vehicle s axle weight limit 3 DO NOT position the console closer than 12 from the bottom of driver and passenger seats NOTE For individuals who wish to make an engineering layout prior to positioning the unit refer to Figure 1 for console and waste tank dimensions Installation 3 BOLTING DOWN THE UNIT AND WASTE TANK NOTE When positioning the waste tank with respect to the console first hook up the vacuum hoses to the waste tank This will ensure that the waste tank is positioned CORRECTLY Once the console a
17. Prochem Power Vac Operation amp Service Manual General Information 7 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 could be fatal 6 Never operate this unit without belt guards 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 9 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 10 Never touch electrical wires or components while the engine is running They can be sources of electrical shock 11 Engine components can get extremely hot from operation To prevent severe burns DO NOT touch these areas while the engine is running or immediately after the engine is turned off 12 Before servicing this unit allow it to cool down This will prevent burns from occurring 13 DO NOT leave the vehicle engine running while operating this unit 14 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
18. completely emptied This console lower front panel protects the waste pump from running dry and being damaged The waste pump is belt driven by the engine through an electric clutch A WARNING The operator begins waste pump operation using a control panel switch A level sensor DO NOT dispose of waste in any manner which in so doing would violate any Local State or Federal Law Figure 13 WASTE PUMP SYSTEM CHECK VALVE OPERATOR CONTROL E PANEL SWITCH WASTE TANK Prochem Power Vac II Operation amp ServiceManual 24 Section Three OPERATION This chapter of the operators manual explains how to prepare start operate shut down and maintain the PROCHEM POWER VAC II cleaning unit Operation of the unit is simple However only trained personnel should proceed A CAUTION 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 1 CHECK FOR ADEQUATE FUEL Check the fuel tank to be certain there is adequate fuel to complete the job This unit uses approximately 1 to 1 25 gallons per hour depending on the speed setting 2 REMOVE TOOLS FROM VEHICLE Remove any tools or hoses from the van which you will require 3 WATERSUPPLY CONNECTION
19. is necessary 35 Section Four Place a straightedge across the top of belt There should be no more than 1 2 deflection in the center of the belt halfway between the sheaves If there is too much slack tighten belt making sure that it stays properly aligned See General Service Adjustments section in this manual for details Check alignment with straightedge string or machinist level Correct alignment to as near perfect as possible 6 FLOAT VALVE water box Check the float valve at least once a month for proper operation If overfilling is a problem check the plunger for a proper seat Replace tip on plunger if needed or damaged Water level in the water box should be about 6 1 2 7 INLET FILTER to water pump The filter inside the water box on the bottom is rubber with a stainless steel screen This should be inspected and cleaned on a weekly basis If damaged replace NOTE Vacuum all excess water and debris from water box prior to removing strainer 8 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 on at least a daily basis 9 PRESSURE UNLOADER Lubricate the O rings every 100 hours Use O ring lubricant 05 008035 Maintenance amp Service 10 VACUUM HOSES To assure maximum hose life we recommend that the hoses be washed out with clean water at the end of each work
20. line installation zene lineinstallation connecting waste tank to console battery installation e fire extinguisher SECTION THREE OPERATION 4 SYSTEMS 22 water pumping system heat transfer system vacuum system chemical system S OPERATION 28 equipment setup e instrumentation starting your unit epriming the uznoxuse neon e sm neon e Operation e upholstery cleaning stair tool cleaning e flood restoration e shut down and daily maintenance FREE Yo 0004 mexcm SECTION FOUR MAINTENANCE amp SERVICE MAINTENANCE CHART 36 6 MAINTENANCE 37 engine vacuum pump e water pump vacuum inlet filter drive belts pulleys and hubs float valve e xsene e strainer basket bypass manifold e y strainer e check valve lt m noxnse neon e chemical amp heat bypass valves e accumulatore pressure regulator e vacuum hoses battery e heat exchangers high pressure hoses neon 7 GENERAL SERVICE ADJUSTMENTS 44 engine vacuum relief valve vacuum pump drive belts water pump drive belt e float valve bypass manifold check valve chemicalpump packing nut adjustments pressure regulator 8 TROUBLESHOOTING 48 malfunction causes and solutions ILLUSTRATED PARTS LISTINGS 1 parts breakdowns wiring diagram Section One General Information Pa sarery A WARNING For Your Safety The following WARNING LABELS are found on your POWE
21. period PROCHEM will either at its option repair or replace products which prove to be defective Any local or distant transportation related service labor normal maintenance and diagnostic calls are not included Gasoline Engine through manufacturer or local dealer 2 years Vacuum Pump through manufacturer or local dealer 18 months Engine Heat Exchanger 1 year Water Pump 2 years Waste Pump 1 year Wands Except shut off valve and orifices year Waste amp Water Tanks year Pressure Regulator year All other components year Battery through dealer only pro rated 1 year 1 800 350 8068 This warranty shall not apply to defects resulting from improper installation or operation inadequate maintenance by the customer unauthorized modification misuse a unit which is improperly repaired exposure to freezing temperature conditions or damage due to hard water scaling Disposable filters electrical components belts fittings hoses o rings and other maintenance items are not under warranty Components provided by PROCHEM but supplied by other manufacturers will only be warranted to the extent that they shall be warranted to PROCHEM To obtain warranty service products must be returned to a service facility designated by PROCHEM Customer shall prepay shipping charges for products returned to PROCHEM for warranty service and PROCHEM shall pay for return of the products to customer PROCHEM makes no other warranty e
22. 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 Section One hydrogen gas or gasoline vapors are present When disconnecting the battery AL WAYS disconnect the negative terminal FIRST 15 DO NOT smoke around the unit This will prevent possible explosions Gas fumes may accumulate and be ignited by smoking material The battery is also extremely flammable 16 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 17 DO NOT cut or splice any of the vehicle fuel lines during fuel line installation This may result in fuel leaks and potentially dangerous conditions There is no fuel solenoid shut off on this unit Use the provided abrasion resistant fuel hose only for fuel lines When transversing the vehicle floor with fuel lines always use a bulkhead adapter This will prevent leakage and ensure that the hose is not punctured by vehicle vibration abrasion 18 DO NOT exceed your vehicle s weight limit The console with waste tank and accessories weig
23. 0432 CAP WATER BOX 12 800269 FTTG BRB 1 2P x 5 8H BR 12 800278 FTTG BRB 1 2P x 3 4H BR 14 806540 STRNR SUC END 1 2FP 15 808110 VALVE FLOAT BALL FLOAT 50 501763 HOLD DOWN WATER BOX 54 501715 ROD FLOAT 1 4 20x6 SST TRAY WATER BOX 98 500781 MLDG BOX Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings FLOAT VALVE DETAIL 15 808110 1 5 10 32 x 1 SOCHD SST 2 01 000241 LOCKNUT 19 39 HY HD SST 5 16 80821 6 PIVOT FLOAT VALVE 4 16 808217 BODY FLOAT VALVE FLOAT VALVE 5 ARRRAR219 PISTON FLOAT VALVE 6 52 501706 NUT FLOAT VALVE Prochem Power Vac 2 Operation amp Service Manual A 14 Illustrated Parts Listings PRESSURE REGULATOR ASSEMBLY ol 9950730 TD CHEMICAL RESERVOIR HOSE SUPPLIED WITH DEMA VALVE TO WATER BOX TO WATER PUMP 1 00 000210 5 1 4 20 x 3 4 SOCHD 2 02 000038 LOCKWASHER 1 4 3 02 000088 FLATWASHER 5 8 HEAVY 4 11 800069 PLUG 1 2 SOCHD BR 5 11 800224 PLUG 3 8 SOCHD BR 6 11 800345 PLUG 1 4 SOCHD BR 7 11 800429 NIP HEX 3 8 SST 8 11 800464 ELBOW 3 B ZINC PLATED 9 11 800492 INJ CHEMICAL DEMA 20285 10 12 800031 ELBOW 1 4P x 1 4 BR 11 12 800282 CONN 3 8P x 1 2T BR 12 12 800345 BRB 3 8P x 5 8H BR 13 13 806033 DISCONNEC
24. 18 e N O O o lt cO O O O O 95 N o o co gt UJ NJ uuu 10 01 000105 11 56 501922 12 50 50 1749 13 56 501920 14 46 802506 15 50 501755 16 50 501754 17 48 941 152 NOT SHOWN 66 945424 A 19 ui SHELF LOWER GRAY FLAT WASHER 1 4 LOCK WASHER 1 4 SCREW 1 4 20x1 2 HXHD SCREW 1 4 20x3 4 HXHD BRACKET ADJUST MTG SLOT BRACKET ADJUST MTG HLDR BRACKET SHELF MOUNTING HOLDER STAIR TOOL LOCK NUT 1 4 20 HXHD PANEL SHELF END GRAY WASHER NYLON DRWR SHLF GRAY LATCH ADJ GRIP HLDR UP TL HOS HLDR UPHLST TL DECAL PROCHEM KIT ADJ BRACKET Includes items 6 7 4 amp mtg hardware 2 10 ____ e bs Illustrated Parts Listings SHELF ASSEMBLY 165 950392 P d 11 OVERALL DIMENSIONS 41 1 2 TALL 50 1 8 WIDE 57 WIDE with tool holders 7 7 8 DEEP DIMENSIONAL DATA 8 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings JUAL WATER TANK v DEMAND PUMP ACCESSORIES NOT SHOWN 166 945260 JUG HOLDER MOUNTS ON OF TANK 56 502027 INGLE WATER TANK DEMAND PUMP 66 945265 To Demand Pump OVERALL DIMENSIONS 32 1 2 TALL 2 3 0 WIDE 50 501774PC HOL D DOWN SA
25. 5 GPM maximum Water pump pressure 3500 PSI maximum Vacuum pump rpm 2870 rpm Vacuum relief valve 12 Hg Waste tank 66 Gallons Console weight 889 Ibs Console weight with 1134 Ibs 155 1165 if waste tank is full waste tank and accessories TORQUE VALUES Component inch Ibs foot Ibs Engine hub 720 60 Vacuum pump hub 192 16 Prochem Power Vac II Operation amp Service Manual Section One INSTALLATION REQUIREMENTS Prior to starting the installation first read the ENTIRE Installation Section 2 of this manual Since the Power Vac II cleaning unit with waste tank and accessories weighs 1134 pounds consider the following recommendations before installing this unit 1 The unit should not be mounted in any motor vehicle of less than 3 4 ton capacity A CAUTION The unit with waste tank and accessories must NOT exceed the vehicle s axle weight limit 2 If mounting in a trailer make certain that the trailer is rated for the total weight of the UNIT AND TRAILER Electric or hydraulic brakes should be provided and a strict compliance with any State and Federal vehicle laws must be maintained 3 The vehicle tires should have a load rating above the combined vehicle and unit weight 4 We do not recommend using flooring materials that absorb water This could result in rust and corrosion of the vehicle floor 5 Padding under rubber floor mats should be removed before installing this unit 6 We hi
26. 797717 4 cim o o o0 mox BDD 04 o00001D0 5 31109 o NK sr in O a sa a a a Ir M gt 2 e e NI rof No won n Ex a AD gt lt e gt N XM ET z Lomt X o te Dro Gom uy 2 Ny cc lt ciz of uQ a Gul K9 aka DET Eun ol lt Z lt SEC 25 zc aa P 5 lt gt lt Lu 2 am 22206610 x 2 Ses 0 2 09 9 esr rh Woo ono c7 Ne s N Nem o on o O DoQ os nm i de LE ml d pte rh CN 8955 OH 588 DE 240426 Tang mw coo ee Prochem Power Vac 2 Operation amp Service Manual A 7 Illustrated Parts Listings HEAT EXCHANGER ASSEMBLY 61 951227 PART 09 805428 TO WATER BOX PART 09 805428 TO WATER INLET CUT HOSE TO FIT 00 000055 5 CAP 1 4 20 x 3 4 HXHD 14 11 800045 ELBOW ST 1 4 R 00 000078 SCREW 1 4 20 1 HXHD GRD8 15 11 800427 BUSHING 1 1 2 BR 00 000142 SCREW 1 4 20 x 2 1 2 HXHD 16 12 800269 FITTING BARB 1 2P x 5 8H BR 01 000037 NUT 1 4 20 HXHD 17 15 808073 COCK DRAIN 1 4P x 1 4 HOS ELBOW BR 02 000038 LOCKWASHER 1 4 18 35 900202 THERMOSTAT
27. 84 RETAINER SEAL 10 42 809385 BOLT MNFLD HD M8x70 11 42 809386 RING BACK UP VALVE 12 42 809387 MANIFOLD HEAD 13 42 809388 ADAPTER MALE 14 42 809390 SEAL 15 42 809391 O RING CRANK COVER 16 42 809392 CRANKCASE 17 42 809393 OILL FILLER 18 42 809394 0 RING BEARING COVER 19 42 809398 RING BACK UP SEAT 20 42 902380 GAUGE OIL LEVEL 21 43 807063 GASKET OIL GAUGE 22 66 950440 KIT VALVE Prochem Power Vac 2 Operation amp Service Manual A 12 TO LOWER FR NT PANEL TO PRESSURE REGULATUR 00 000122 00 000142 00 000335 01 000037 j SCREW 1 4 20x1 3 4 HXHD 2 3 4 5 01 000045 6 7 8 9 SCREW 1 4 20 8 HXHD NUT 1 4 20 HXHD NUT 1 4 20 HXHD SST LOCKWASHER 1 4 FLATWASHER 1 4 CLAMP HOSE 12 03 000246 CLAMP HOSE 8 10 09 805428 HOSE WTR 5 8 x 58 11 09 805436 HOSE WTR 3 4 x 21 12 09 805544 5 WTR 5 8 x 56 1 2 13 1 1 800041 ELBOW ST 1 2 BR 14 11 800069 PLUG 1 2 SOCHD BR 02 000038 02 000066 03 000113 A 13 SCREW 1 4 20x2 1 2 H XH D 1 1 800299 16 17 19 20 21 22 23 24 25 2 2 28 6 96 501902 Illustrated Parts Listings WATER BOX ASSEMBLY 61 95107 ELBOW ST 1 2 457 BR 11 800300 NIPPLE 1 2 x CLOSE BR 1 1 800345 PLUG 1 4 SOCHD BR 11 800361 ELBOW 1 2BR 1 1 80
28. CKWASHER 5 1 6 21 5 02 000074 FLATWASHER 3 8 22 6 02 000075 LOCKWASHER 3 8 23 7 02 000143 FLATWASHER 5 1 6 24 8 03 000113 CLAMP HOSE 12 25 9 05 008016 21 oz CAT PUMP 26 NOT sHown 27 10 09 805436 HOSE BRAID 3 4 x 21 11 10 80531 6 HOSE 3 16 x 5 12 10 805448 HOSE HP 1 2 x 55 1 2FT BS 4000 5 1 13 11 800069 PLUG 1 2 SOCHD BR 15 12 800029 PLUG 1 4T B R 16 12 800060 CONN 1 4 x 1 4T B R 17 12 800225 ELBOW 3 8P x 1 2T R 1 1 Illustrated Parts Listings WATER PUMP ASSEMBLY 61 951075 12 800278 BRB 1 2P x 3 4H BR 31 900185 CONN BULLET M 156 36 900141 CLUTCH ELECTRIC WTR PMP SCP 37 900140 L00M 1 4 FAB HIGH TEMP 41 809150 PUMP WATER CAT 5CP3120 44 80231 6 BELT 41 GOODYEAR MATCHMAKER 52 800315 ELBOW ST 1 2 CAP PUMP 54 501650 SPACER BELT GUARD 56 500753 BRACKET CLUTCH MOUNT WATER PUMP 56 502233 BRACKET PUMP ADJ Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings WATER PUMP DETAIL 1 05 008016 0IL CAT WATER PUMP NOT SHOWN 2 42 809239 0 81 OIL FILL 3 42 809249 WASHER KEYHOLE MI 8 4 42 809320 PLUG VALVE 5 42 809380 SEAL OIL CRANKCASE 6 42 8093841 SLINGER BARRIER 7 42 809382 PLUNGER 8 42 809383 RETAINER PLNGR W STUD 9 42 8093
29. CUT TO FIT FUEL FILTER 2 5 INSTALL THE FUEL PUMP ASSEMBLY ON TO THE COVER WITH THE PROVIDED HARDWARE WHITE WIRE cord from console WHT BLK INSERT FUEL PUMP POWER GROUND Mame CORD CONNECT POWER WIRE CORD WHITE WIRE TO FUEL FROM HOSE fuel pump fuel WIRE PUMP BLACK WIRE GROUND VEHICLE CLAMP MOUNTING pump cord from POWER CORD BLACK WIRE FUEL HARDWARE console AND TIGHTEN CORD HOLDER TANK SCREWS FILLER NECK BULKHEAD INSTALLATION viewed from underneath van FROM CONNECTOR VEHICLE FUEL LINE 5 16 ABRASION ELECTRIC FUEL PUMP BOX FUEL FROM RESISTANT ASSEMBLY NOTE this is a 2 Ib TANK UEL HOSE FRONT OF VAN ff 5 16 ABRASION RESISTANT FUEL HOSE FROM VEHICLE FUELT ELECTRIC FUEL PUMP POWER CORD Prochem Power Vac II Operation amp Service Manual EE PM E I DE RAMIS x 2 TH en PC SR acies 16 Section Two WASTE TANK TO CONSOLE CONNECTION See Figure 9 NOTE Before connecting any hoses to the waste tanks make certain the hose clamps are on each hose 1 Connect the 6 1 2 long section of 3 LD internal vacuum hose to the 3 diameter vacuum inlet tube on the console and the 3 diameter inlet tube on the waste tank Tighten the hose clamps 2 Connect the 25 long section of 3 1 2 LD internal vacuum hose to the 3 1 2 diameter vacuum outlet tube on the w
30. DDLF TANK GRAY 15 1 2 02 000074 FLAT WASHIER 3 8 LOCK WASHER 3 8 SCREW 3 8 16x2 HXHD CAP WATER BOX ELL STREET 1 2 BRASS FITTING BARB 1 2Px3 4H BR CLAMP HOSE 12 09 805456 HOSE WTR 3 4 8 cut to fit 10 11 800085 TEE 1 2 BRASS 11 56 502000PC ASSY BASE SADDL GRY 12 58 50066 1 MOLDING WATER TANK 13 11 800168 PLUG 1 2 BRASS HXHD 14 50 500511 PLATE INSTALL MT 15 01 000158 LOCK NUT 3 8 16 HXHD NYLOK Prochem Power Vac 2 Operation amp Service Manual 20 lllustrated Parts Listings DEMAND PUMP ASSEMBLY 66 945614 00 00021 5 SCREW 5 16 18 x 3 4 02 000040 LOCKWASHER 5 1 6 02 000143 FLATWASHER 5 1 6 03 000113 CLAMP HOSE 12 09 805278 HOSE WATER 3 4 x 3 09 805357 HOSE WATER 3 4 x 5 1 2 09 805446 HOSE WATER 5 8 x 55 12 800345 FITTING BRB 3 8P x 5 8H BR 13 806009 DISCONNECT 3 8M x 3 8 R 0 14 8065553 FILTER DEMAND PUMP 1 41 905049 PUMP WATER BOOSTER FLOJET 2840 100 4 co Ui amp A 21 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings CCESSORIES NOT SHOWN OSE REEL VACUUM HOSE ONLY 65 950438 HOSE REEL OOR MOUNT HP HOSE REEL 65 950482 ASSEMBLY 65 950393 16 1 950854 LATCH ASSEMBLY DETAIL 56 501962PC REEL VACUUM HOSE GRAY 03 000124 CLAMP MUFFLER 1 3 4 3 52 501685 BUSHIN
31. G HOSE REEL 56 501960 5 HOSE REEL GRAY 6 56 502207 BRACKET LOCKOUT HOSE REEL OVERALL 6 1 950854 ASSEMBLY LATCH HOSE REEL DIMENSIONS 7 02 000066 TT FLAT WASHER 1 4 47 TALL 8 02 000038 10 WASHER 1 4 19 wing 9 00 000055 SCREW 1 4 20 3 4 44 1 27 DEEP 10 21 000041 NT 5 15 18 f item 2 TTE 501968PC REEL 3 12 45 802138 BEARING HOSE REEL DIMENSIONAL DATA 13 02 000143 FLAT WASHER 5 16 14 02 000040 LOCK WASHER 5 16 15 00 000039 SCREW 5 16 18x1 16 44 802122 FLANGE 47MST 17 56 501961 PC BODY HOSE GRAY 18 00 000072 SCREW 5 8 1 6x2 19 50 5005 11 PLATE INSTALL MOUNT 20 02 000074 FLAT WASHER 3 8 2101 000158 LOCK NUT 3 8 18 HXHD Ny 22 55 501789 PIN LOCK HOSE REEL 23 50 501812 BRACKET HOSE REEL 24 04 00 033 0 SPRING LOCK LOCK PIN Assy 25 04 000303 CLIP RETAINER LOCK PIN ASSY Prochem Power Vac 2 Operation amp Service Manual p 22 Illustrated Parts Listings WIRING DIAGRAM ENGINE HIGH TEMP SWITCH Located on back of engine 35 ANTI DIESELING SOLENOID 442 902149 DISTRIBUTOR 442 902355 TERMINAL BLOCK Loceted near radiator on left wide of console HOOK UP FOR DEMAND PUMP POS NEG BATTERY 36 900056 ENGINE SHUT OFF SWITCH 61 950621
32. HAT 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 MODIFY UNIT WITHOUT WRITTEN PERMISSION FROM MANUFACTURER The engine exhaust from this product contains chemicals known tothe Slate of California to cause cancer birth defects and other reproductive harm Order 48 9412 12 to get a complete set of decals safety and instrumentation for your Power Vac II cleaning unit The following decals must be placed in a prominent spot on the vehicle that this unit is to be installed WARNING CLEANUP ANY SPILLED FUEL INSIDE VEHICLE PRIOR TO OPERATION OF ANY EQUIPMENT IN VEHICLE GASOLINE IS EXTREMELY FLAMMABLE ENGINES PRODUCT CARBON MONOXIDE AND ITS VAPORS CAN WHICH IS AN ODORLESS DEADLY POISON EXPLODE IF IGNITED DO NOT OPERATE IN AN ENCLOSED AREA NGER Decal Fuel Clean up Decal Carbon Monoxide Part 48 941317 Part 48 941316 Prochem Power Vac 11 Operation amp Service Manual 2 SECTION 1 GENERAL INFORMATION Safety Specifications Installation requirements Fuel requirements Engine oil requirements Chemical requirements 2 RECEIVING YOUR UNIT 7 Dealer responsibility Acceptance of shipment Equipment list Optional equipment NNW O MN LO M oM oM Prochem Power Vac peration amp Service M anual Secti
33. LY A 9 VACUUM RELIEF VALVE DETAIL A 9 WASTE PUMP ASSEMBLY A 16 WASTE TANK ASSEMBLY A 17 WATER BOX ASSEMBLY A 13 WATER PUMP ASSEMBLY 11 WATER PUMP DETAIL A 12 WATER TANK w DEMAND PUMP A 20 WIRING DIAGRAM A 23 A 24 Prochem Power Vac II Operation amp Service Manual 49 Illustrated Parts Listings E FRONT VIEW OQ 9 ASSEMBLY 2 1 O maw OZBOO0000R00000B80N0000000 EDCZCOB GDDBOUENNODOBSOSOUOUODESOUOD 300800000090069006080000890900 DoSDUDDBEDDOODDOBBOSSDOMOETALB D DODO goar T D u D B 1 50 501925 PANEL CONTROL CE 124224 56501686 TUBE WASTE DUMP 2 187808534 GAUGE WATER PRESSURE 2 25 15 805080 PE VALVE BALL PVC 1 1 2 BS j 18 808530 GAUGE WATER TEMP 520 ENGINE 13 806037 DISCONNECT 3 8FP x 3 8FP 10 THRU 5 54 905000 15 8085 V GUUM 30 Hg 11 800429 HEX 3 8SST ae huurme IER 26 02 000088 5 8 HEAVY 6 34 9000995 LIGHT TNDICATTN DOME RED 29 15 808139 UNLOADER PRESSURE 7 33 900169 BULB ROTARY SWITCH 30 19 800075 cup OIL Ful 1 8P a 34 900103 vCRVE AF NOD 31 000 10 ner R 1 4 SOCHD 9 61 950739 5 SEHPMM Y UOVERRIDEUSWITCH 00 000210 SCREW 1 420 x 3 4 10 34 900101
34. NOR REQUIRES 1 1 2 FLUID oz Figure 15 FLL PLUG DIPSTICK PLUG DRAIN PLUG ISON OPPOSITESIDE 6 Check the spark plugs every 200 hours Clean if necessary Replace every 1000 hours NOTE Never sandblast spark plugs Spark plugs should be cleaned by scraping or wire brushing 7 Clean the air cleaner element every 200 hours Replace the element every 2 years 8 Check the engine idle RPM every 200 hours and adjust if necessary Never adjust engine RPM without a tachometer Refer to Nissan Engine Operation and Service Manual 9 Check the coolant level in the radiator overflow container on a daily basis If no coolant is seen remove the radiator cap and add coolant Change the coolant with 70 30 coolant water ratio every 1000 hours Prochem Power Vac II Operation amp Service anual Maintenance amp Service 10 Replace in line fuel filter yearly NOTE For additional engine service information obtain a Nissan 4 15 Service and Repair Manual from any authorized Nissan Service Center If service or repair is required contact an authorized Nissan Service Center You will need model type and code number on the engine 2 VACUUM PUMP Refer to Vacuum Pump Operation and Service Manual for specific instructions Lubrication We recommend that you use AEON PD Synthetic Blower Lubricant in the gear end of the vacuum pump for ALL operating temperatures AEON PD is
35. O NOT dispose of waste in any manner which in so doing would violate any Local State or Federal law 10 SHUTDOWN AND DAILY MAINTENANCE 1 We recommend removing as much moisture from your vacuum hoses as is reasonable This will prevent spillage of solution in your vehicle when replacing hoses 2 Pull the throttle control all the way out to idle speed 3 Disconnect the vacuum hoses from the unit 4 Allow the unit to run at idle speed for 1 minute in order to remove all moisture from the vacuum pump NOTE If finishing for the day Push the throttle control all the way in to the third notch full speed plug all vacuum inlets and spray WD 40 or equivalent into the vacuum lubrication cup located at front of 27 Section Three the console for 5 seconds This will lubricate the vacuum pump Pull the throttle control all the way out to idle speed and continue to step 5 5 Turn the ignition switch to the OFF position 6 Turn the water supply faucet off Bleed the pressure out of the water supply hose by loosening the hose at the water supply Unhook water supply hose and store in vehicle 7 Relieve pressure from the cleaning tools and pressure hoses by activating the valve on the tools Disconnect the tools and pressure hoses from the unit and store away all equipment 8 Drain the waste tank and dispose of waste in a proper manner A WARNING NEVER dispose of waste in storm drains water
36. OR Illustrated Parts Listings ENGINE GOVERNOR DETAIL CONNECT CARBURETOR LINKAGE BOLTS FROM BACK OF GOVERNOR 10 00 000055 11 02 000066 SCREW 1 4 20 x 3 4 FIATWASHER 1 4 12 50 501949 LEVER THROTTLE CONTROL 13 01 000023 LOCKNUT 1 4 20 14 44 802221 PULLEY GOVERNOR PART OF GOVERNOR 15 44 802311 BELT AX29 16 01 000041 NUT 5 1 6 18 HXHD Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings EXHAUST MUFFLER ASSEMBLY 61 951664 00 000078 SCREW CAP 1 4 20 x 1 HXHD GRD 8 01 000037 NUT 1 4 20 HXHD 02 000038 LOCKWASHER 1 4 03 000081 CLAMP MUFFLER 1 2 54 501650 SPACER 98 5021RR RISKR EXHAUST NISSAN A 15 57 520102 MUFFLER EXHAUST M O0 ne Prochem Power Vac 2 Operation amp Service Manual A 6 Illustrated Parts Listings ENGINE COOLANT DETAIL Sue NN Tima 9 gt lt sun 5 50 SHS 111 Sougaes a lt FG lt Oaa aO A o gt se ui Li uj s x gt lt lt lt 0 509 EUOOOz rrorrro ONS OBNO N A N 659 ann q 5 O MOOLCOKANTITO e QU S SQ O CI O CJ 10 10 10 OD e 597404
37. PRESSURE OVERRIDE WATER HOURMETER PUMP SWITCH ENGINE TEMPERATURE GUAGE CIRCUIT BREAKER _ CHOKE CONTROL WATER PUMP mm SM VACUUM GAUGE LL po EN UN UFF i IGNITION WATER 1 GEM NEM SWITCH PRESSURE GAUGE brad us a PUMP OUT EDSBBGDDOOBODOGUGOOOBUAB USSSSODODOOGD CIRCUIT PDDOD UBDZDDDODDODOBDOODODBOUBDDDODUD NS CDBBBINUDDBUDOODNSOCDOUBDOSOEOBOSOOU F BREAKER amp EOSBBBSDDODOUOOUZSSUpDoOSsgazug Egg VACUUM 0 00 80 0080000 PUMP OUT LUBRICATION mmf 080 SWITCH CUP Lu bd L THROTTLE CONTROL PRESSURE UNLOADER VACUUM EXHAUST OUTLET VACUUM INLETS SOLUTION WATER INLET WASTE PUMP OUT OUTLET ENGINE EXHAUST OUTLET ONDENSED OPERATING INSTRUCTIONS ENGINE OIL DRAIN SERIAL PLATE Prochem Power Vac 11 peration amp Service Manual 26 Section Three 3 After starting the engine push the choke in After the engine has warmed up push in the throttle lever to the third notch and lock it in the full throttle position 7 WASTE PUMP Connect one end of the 1 ID waste pump hose to the pump out connection on the console and the other end to an appropriate waste disposal Turn the pump out switch on the control panel to the ON position The waste pump will operate automatically throughout the cleaning operation The
38. Push the throttle adjustment lever and lock at the third notch position high speed The lever should lock firmly Check the limit screw If the screw is not positioned firmly against the arm tighten the screw and locking nut until firm Do not over tighten IDLE SPEED ADJUSTMENT Engine Running with the Water Pump Off Pull the throttle adjustment lever all the way out to the idle position Using a tachometer turn the idle adjustment screw until 900 RPM is indicated HIGH SPEED ADJUSTMENT Engine Running with the Water Pump On Push the throttle adjustment lever and lock at the third notch position high speed Using a tachometer adjust the spring tension nut until 2600 RPM is indicated A CAUTION Under no circumstance should this unit operate over 2600 RPM Permanent damage may occur Prochem Power Vac 11 Operation amp Service Manual 38 Section Four Maintenance amp Service NISSAN ENGINE SPEED CONTROL ADJUSTMENT IDLE ADJUSTMENT SCREW CARBURETOR LINKAGE GOVERNOR LIMIT SCREW THROTTLE ADJUSTMENT LEVER 3rd NOTCH we 1st NOTCH HIGH SPEED LOW SPEED 2nd NOTCH GOVERNOR MED SPEED SPRING TENSION NUT 7 7 25 gt I DISCONNECT NKAGE Ot gt SHOWN LINKAGE THROTTLE lt ARM BALL Cal LOCKING NUT THROTTL RM BAL LINKAGE GOVERNOR LINKAGE Prochem Power Vac O peration amp Servi
39. R VAC II console These labels point out important Warnings and Cautions which should be followed at all times Failure to follow warnings and cautions could result in fatality personal injury to yourself and or others or property damage Follow these instructions carefully DO NOT remove these labels AWARNING AWARNING CAUTION HOT SURFACE 7 ROTATING MACHINERY CAN CAUSE INJURY OR COULD SE FATAL KEEP ALL GUARDS AND SAFETY DEVICES IN PLACE ELECTRICAL SHOCK COULD CAUSE SEVERE BURNS OR INJURY DO NOT TOUCH ELECTRICAL WIRES OR COMPONENTS WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE READ THE OPERATORS MANUAL BEFORE INSTALLING OR STARTING THIS UNIT FAILURE TO ADHERE TO INSTRUCTION CAN RESULT IN SEVERE PERSONAL INJURY OR COULD BEFATAL REPLACEMANETMANUALS CAN BE PURCHASED FROM SERVICING THIS UNIT TO BEFORE REMOVING VALVES Professional Chemicals Corporation PREVENT ACCIDENTAL CAPS PLUGS FITTINGS FILTERS 325 8 Price Rd STARTING KANO BOLTS Chandler Az 85224 DO NOT TOUCH ROTATING MACHINERY WATER UNDER PRESSURE AT HIGH TEMPERATURE IMPROPER MODIFICATION OF EQUIPMENT CAN CAUSE SEVERE PERSONAL INJURY OR COULD BE FATAL WARNING OPERATE THIS UNIT AND EQUIPMENT ONLY IN A WELL VENTILATED AREA EXHAUST FUMES CONTAIN CARBON MONOXIDE WHICH IS AN ODORLESS AND DEADLY POISON T
40. RDANCE WITH PRESCRIBED PROCHEM IN STALLATION PROCEDURES MARE CERTAIN THAT THE WARRANTY CARD IS FILLED OUT BY THE DISTRIBUTOR FROM WHOM YOU PURCHASED THIS UNIT AND RETURNED TO PROCHEM Please record your unit serial number here for future information or if you should need to contact the factory for any reason PF This operation and service manual is written specifically for the PROCHEM POWER VAC 2 Mobile Cleaning Units which are manufactured by 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 All rights reserved Copyright 2001 by Profes sional Chemicals Corporation No part of this work may be reproduced or used in any form or by any means graphic electronic photocopying taping or electronic retrieval systems without the express written permission of Professional Chemicals Corporation Published by Professional Chemicals Corporation First printing August 1998 Second printing December 2001 Printed in USA POWER VAC 2 MANUAL 67 945735 LIMITED WARRANTY PROCHEM warrants your machine to be free of defects in material and workmanship This warranty shall extend to the designated parts for the specific time period listed from the date of delivery to the user If PROCHEM receives notice of such defects during the warranty
41. REW 8mm 1 25 x 25mm NOT SHOWN 10 805357 FUEL HOSE 3 16 38 03 000249 CLAMP CABLE 1 4 ID 42 902134 GASKET OIL PAN 04 000350 VACUUM MOUNTS UNDERSIDE OF AIR CLEANER Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings ENGINE ASSEMBLY RIGHT 61 951074 40 902145 E NG JNE NISSAN A 15 02 000075 LOCKWASHER 3 8 42 902140 FILTEB ATI 12 800177 ELL 42 902381 CARBURETOR 15 FGESTX 1 21 1 2 3 i 4 42 902149 SOLENOID ANTI DIESEL 5 12 B00 TE CONN 1 29 1221 5 6 42 902138 VALVE PCV lo 805315 HOSE HP 3 8 x 13 7 42 902199 GOVERNOR 11 800045 ELL STREET 1 4 42 902349 PUMP WATER 02 000040 LOCKWASHER 5 4 6 1 42 902350 01 000210 NUT 8mm 1 25 HXHD 42 902209 56 501953 RIGHT ENGINE 42 902253 10 00 000095 SCREW 3 8 16 1 44 802230 BELT 11720 77702 11 00 000295 SCREW 3 8 16 3 42 902258 CAP OIL FILLER 12 02 000074 FLATWASHER 3 8 NOT SHOWN 42 902198 KIT CARBURETOR REPAIR Prochem Power Vac 2 Operation amp Service Manual A 4 A 5 1 2 5 4 5 6 7 8 9 56 501869 02 000225 00 000298 02 000040 BRACKET GOVERNOR LOCKWASHER 7 16 SCREW 1 Omm x 20mm LOCKWASHER 5 16 SCREW 5 16 1 6 x 1 56 501870 BRACKET REAR GOV 42 902411 ASSY ROD GOV LINK 04 000288 5 GOVERNOR 42 902199 GOVERN
42. T 3 8M x 3 8FP ST SST 14 13 806037 DISCONNECT 3 8F x 3 8FP ST SST 15 15 808147 REGULATOR PRESSURE 16 52 501807 MANIFOLD REGULATOR 17 67 645660 INSTRUCT PRESSURE REGULATOR Nor SHOWN 18 03 000246 CLAMP HOSE B 19 09 805544 HOSE WATER 5 8 x 56 1 2 20 10 805131 HOSE 3 16 x 20 1 2 1 4FT BS MET 21 10 805448 HOSE 3 8 x 55 1 2FT BS 4000 P S I A 15 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings TO LOWER FRONT PANEL i WASTE PUMP ASSEMBLY 61 991077 1 00 000200 SCREW 3 8 16 1 1 4 HXHD 2 01 000073 NUT 3 8 16 HXHD TO WASTE TANK 3 02 000074 FLATWASHER 3 8 4 02 000075 LOCKWASHER 3 8 5 03 000248 CLAMP HOSE 18 6 09 805473 HOSE WATER 1 x 29 BLACK 7 09 805538 HOSE WATER 1 x 13 1 2 BLACK 8 11 800455 BUSHING 1 1 4 X 1 55 9 11 800459 NIPPLE 1 HEX BRASS 10 11 800484 ELBOW ST 1 BRASS 11 11 800493 ELBOW 1 BRASS 12 12 800367 FITTINH BARB 1 P x 1 BRASS 13 15 808126 VALVE SWING CHECK 1 FP BRASS 14 31 900185 BULLET M 1583 15 36 900138 CLUTCH 5 0 11870 005 16 41 809141 WASTE JABSCO 11870 0005 17 44 802317 BELT AX45 GOODYEAR MATCHMAKER ONLY Prochem Power Vac 2 Operation amp Service Manual A 16 Illustrate
43. TOR 8 42 902188 ALTERNATOR 9 32 900029 SWITCH OIL PRESSURE 10 11 800014 ELL STREET 1 8 11 42 902139 FILTER OIL 12 50 501915 PLATE FUEL PUMP COVER 13 42 902152 GASKET FUEL PUMP 14 56 502006 BRACKET LEFT HOOD 15 56 502007 MOUNT LEFT ENGINE 16 42 902146 STARTER 17 42 902147 SOLENOID STARTER 18 00 000222 5 7 16 1 4 HXHD 19 02 000074 FLATWASHER 3 8 20 02 000225 LOCKWASHER 7 16 21 01 000224 NUT 7 1 6 1 4 HXHD 22 00 000072 SCREW 3 8 16 HXHD 23 02 000075 LOCKWASHER 3 8 24 01 000073 NUT 3 8 1 6 HXHD A 3 PS ry St AA pss aS Illustrated Parts Listings ENGINE ASSEMBLY FEET 61 951074 xe B ANO 23 02 000075 LOCKWASHER 3 8 24 01 000073 3 8 16 HXHD 25 00 000428 SCREW 1 25 25 SOCHD 26 52 501806 PULLEY ENGINE PV2 27 02 000066 FLAT WASHER 1 4 28 02 000038 LOCK WASHER 1 4 29 00 000055 SCREW 1 4 20 x 3 4 HXHD 30 42 902144 COIL 31 35 900050 SENSOR TEMPERATURE 240deg 32 42 902137 GASKET VALVE COVER 33 42 902148 SPARK PLUG 34 42 902196 DISTRIBUTOR 35 42 902271 CAP DISTRIBUTOR 36 42 902153 SEAL DISTRIBUTOR CAP 37 42 902272 ROTOR 38 42 902352 MODULE IGNITION 39 42 902143 WIRE SET SPARK PLUG 40 00 000237 SC
44. XHD 16 50 501944 PNL CVR L LWR BASE 2 00 000122 SCREW 1 4 20 1 3 4 H XHD i 50 501950 PNL I 3 00 000142 SCREW 1 4 20 x 2 1 2 HXHD 5 ee ieee ACIE 4 00 000210 SCREW 1 4 20 x 3 4 SOCHD SST 3 56501022 MOUNT BELT GUARD 5 00 000216 SCREW 1 4 20 x 1 2 FLTSOCHD 21 56502005 BRKT RIGHT HOOD 6 00 000226 SCREW 6mm x 1 25 x 20mm HXHD 22 56 502050 BRACKET HOOD MTG RT SD 7 00 000286 SCREW 1 4 20 x 2 3 4 HXHD 23 56 502179 PANEL LOWER FRONT 6 00 000363 SCREW CAP 5 8 11 2 HXHD 24 56 502183 BASE POWER VAC 2 9 01000037 NUT 1 4 20 HXHD 25 56 502187 CENTER HOQD 10 02 000038 LOCKWASHER 1 4 26 56 502230 MOUNT CONTROL PANEL 11 02 000040 LOCKWASHER 5 16 27 56 502231 BRACKET REAR HOOD 1220200056 Ed 28 59 502465 PNI CLOSE OUT 13 02 000088 FLATWASHER 5 8 HE AW 96 502466 14 02000143 FM WASHER 5 16 30 58 700024 PAD VIBR CONTR PNL MT 15 02 000232 LOCKWASHER 5 8 Prochem Power Vac 2 Operation amp Service Manual A 2 OF 4 M v LOIS 02032977 O amp 42 902132 HOUSING HHEM BIS BYT NISSAN 3 00 000144 SCREW 5 18 18 x 1 1 2 HXHD 4 35 900202 195 W HOLE 5 02 000040 LOCKWASHER 5 1 6 6 01000041 5 1NUT 8 HXHD 7 56 501740 GUARD ALTERNA
45. age to the fuel tank s fuel lines brake lines or any other vital Installation component which might affect the operation or safety of the vehicle 2 Drill a 5 8 625 diameter hole through the vehicle floor 3 Install the 1 8 bulkhead adapter by inserting the adapter and tightening the nut on the opposite side of the van floor Figure 3 4 Attach a 1 8P x 1 4T elbow to the bulkhead adapter on one end Figure 3 Attach a 1 8 street elbow and a 1 8P x 5 16H barb fitting to the other end of the bulkhead adapter 5 Connect one 45 1 2 stainless steel hose from the fuel inlet on the console to the bulkhead adapter 6 Disconnect from the filler neck the 2 hoses which connect the filler neck and the fuel tank by loosening the hose clamps 7 Remove the filler neck from the vehicle Refer to the vehicle manual for instructions and cautions 8 Select a suitable location for drilling the hole in the filler tank The desired location for this hole may vary It is important that you are able to re install the filler neck without interference from the fittings which you are adding Therefore choose this location wisely before proceeding 9 Drill a 1 2 diameter hole in the filler neck after you are certain that you have chosen the proper location Figure 4 A CAUTION When assembling pipefittings Teflon thread sealant must be used 10 Attach a 1 8 street elbow to one end of the short bulkhead adapte
46. aning compounds refer to the Prochem chemical manual Prochem Power Vac 11 Operation amp Service Manual Section One 2 RECEIVING YOUR UNIT This chapter of the manual contains information on receiving your PROCHEM POWER VAC II cleaning unit DEALER RESPONSIBILITY THE PROCHEM DEALER FROM WHOM YOU PURCHASED THIS MOBILE CLEANING UNIT IS RESPONSIBLE FOR THE CORRECT INSTALLATION OF THIS MACHINE THE DEALER IS ALSO RESPONSIBLE FOR INITIAL TRAINING OF YOUR OPERATORS AND MAINTENANCE PERSONNEL IN THE PROPER OPERATION AND MAINTENANCE OF THIS UNIT ACCEPTANCE OF SHIPMENT Every part of your PROCHEM POWER VAC II cleaning unit was carefully checked tested and inspected before it left the manufacturing plant Upon receiving the unit make the following acceptance check 1 Check the unit for any outward signs of damage If damaged notify the common carrier IMMEDIATELY 2 Check your equipment and packing list The standard PROCHEM POWER VAC II cleaning unit should arrive equipped with the following items unless otherwise specified and any optional equipment which was ordered EQUIPMENT LIST A PROCHEM POWER VAC II cleaning unit console Prochem Power Vac II O peration amp Service Manual General Information B Operation and service manual with engine water pump and vacuum pump manuals C Installation bolting kit D Installation mounting plates E Fittings and hoses for standard fuel supply installa
47. aning unit utilizes a governor to set and maintain the engine speed The engine speed is adjusted by shifting the throttle adjustment lever located on the front panel The adjustment lever has four positions First position is idle 900 RPM At this position the adjustment lever is pulled all the way out and remains unlocked Push in the lever to the first of the three notches and lock in position for low speed approx 1800 RPM Push and lock in lever at the second notch for medium speed approx 2300 RPM Push and lock in lever at the third notch for high speed 2600 RPM The throttle adjustment lever is attached to a governor The governor has internal weights that apply pressure to a shaft gear with an extending arm Attached to the arm is the carburetor linkage adjusting engine speed NOTE Units are pre set at the factory Engine RPM should drop approximately 150 200 RPM when the vacuum inlets are covered LINKAGE ADJUSTMENT Engine Off Maintenance amp Service Unsnap the tip of the linkage from the throttle arm ball Figure 16 Pull the throttle adjustment lever all the way out idle position While holding the throttle arm down with your finger position the linkage underneath the ball The ball should barely touch the top of the adjustment arm If adjustment is required loosen the locking nut adjust the linkage to the proper length and re tighten the locking nut THROTTLE ARM ADJUSTMENT Engine Off
48. anks must be stored in a heated building or completely drained when not in use While in operation avoid long shutdowns as the unit provides heat while running Shut it down just prior to leaving for the next job ADDING ANTI FREEZE TO YOUR UNIT 1 Shut off the water supply Disconnect the water inlet hose from the front of your console 2 Connect all high pressure hoses and tools that may contain water in the lines hoses or valves 3 Start your unit 4 Open the tool valve until the water in the water box is exhausted Prochem Power Vac 11 Operation amp Service Manual 28 Section Three 5 Shut the unit down 6 Fill the water box with approximately two gallons of 100 glycol base anti freeze 7 Turn the oil pressure override switch to the override position and start the unit Turn the water pump switch ON 8 Open the tool valve until anti freeze begins to come out of the tool Recover ALL anti freeze that comes out of the tools into an approved container We strongly recommend that you re cycle and re use the anti freeze Repeat this procedure with all the remaining tools After all tools and pressure hoses have been filled with anti freeze disconnect and store them A WARNING The pressure unloader must be at its lowest pressure setting and the water box float valve must be open before the winterizing loop hose is attached to the unit This will prevent excessive pressure from rupturing
49. any loose fittings or clamps Replace any ruptured hose s Using a tachometer check the engine speed Full throttle engine speed is 2600 RPM Idle speed is 900 RPM Re adjust in accordance with instructions on pages 38 40 in this manual Lubricate O rings using O ring lubricant 05 008035 Check O rings If necessary replace Clean or repair the pressure unloader Adjust to working pressure Lubricate O rings using O ring lubricant 05 008035 Examine the check valves plunger cups and cylinder head on the water pump Repair whenever required Refer to the water pump service manual Replace gauge Replace nozzle or change nozzle size Clean or replace as needed Re tension or replace as needed 43 Section Four Maintenance amp Service 2 LOSS OF SOLUTION VOLUME AT CLEANING TOOL ORIFICE Water pressure gauge reads normal Plugged orifice in the cleaning tool Unplug orifice Outlet valve is plugged Examine the check valve remove any debris Defective quick connect on one of more of the high pressure hoses Cleaning tool valve is malfunctioning Hose inner lining is constricted Replace defective quick connect s on high pressure hose s Repair or replace valve Remove restriction or replace hose Vacuum hose s is damaged causing a suction leak Waste tank gasket not sealing properly not positioned properly Debris and lint is trapped in vacuum line betwee
50. aste tank and to the vacuum pump relief valve on the console It may be necessary to cut this hose to fit Tighten the hose clamps 3 Connect the 2 I D waste removal hose to the 2 diameter tube at the bottom of the waste tank Tighten the hose clamps 4 Connect the console engine shut off cord to the upper waste tank level sensor cord 5 Connect the console waste pump cord to the lower waste tank level sensor cord 7 BATTERY CONNECTION A WARNING 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 Prochem Power Vac II Operation amp Service Manual Installation 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 1 Attach the red positive battery cable from the console starter solenoid to the positive terminal on the battery and tighten the holding nut
51. cal system 20 Waste pump system 24 25 Starting unit 25 Instrumentation 26 Waste pump 2 Operation 27 Cleaning 21 Shutdown amp daily maintenance 27 Freezing Protection 28 Prochem Power Vac Operation amp Service Manual Section Three FisvsrEws This chapter of the operator s manual divides the unit up into systems and explains how each system works Before proceeding into the operation and maintenance section of this manual we recommend acquiring a basic knowledge of how this unit functions Read the next section of this manual carefully and completely 1 WATER PUMPING SYSTEM See illustrations on the following pages Cold water enters the console through the water inlet connection located on the lower front panel The water flows to the water box through a float valve which shuts off water flow when the box is full Water then flows through a strainer into the water pump where it is pressurized This pressurized water is pumped to the pressure manifold where the unloader provides and maintains the desired pressure setting If the tool valve is closed water flows from the unloader bypass back to the water box When the tool valve is opened water flows from the pressure manifold through a chemical injection orifice This is where chemical injection occurs The solution then flows to the cleaning tool 2 VACUUM SYSTEM Vacuum flow is initiated by the vacuum pump with ai
52. ce Manual 39 Section Four A CAUTION DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 2600 RPM Permanent damage may occur 2 VACUUM RELIEF VALVE While the unit is running at full RPM block the air flow at all vacuum inlet connections and read the vacuum gauge If adjustment is required shut the unit down and adjust the locking nut tension Start your unit and read the vacuum gauge Repeat this process until the relief valve opens at 12 Hg 3 VACUUM PUMP DRIVE BELTS To tighten the vacuum pump belts 1 Loosen the 4 nuts that hold the vacuum pump mount in place and the 2 clamps that hold the hose leading to the vacuum muffler 2 Turn the adjusting bolts until the proper belt tension is achieved 1 2 deflection in the center of the belt halfway between the sheaves NOTE When adjusting belt tension make certain that the engine shaft and vacuum pump shaft remain parallel and the belt tension is equal throughout the belt width 3 After adjusting re tighten the 4 nuts that hold the vacuum pump in position Check pulley alignment with straight edge 4 Adjust the alignment of the hose leading to the vacuum muffler and tighten the 2 clamps Maintenance amp Service 4 WATER PUMP DRIVE BELTS To tighten the water pump belts 1 Loosen the nuts that hold the water pump mount to base 2 Adjust the belt tension adjusting bolt until the proper belt tension i
53. crews and or bushing hub cap screws after the first 25 hours and Prochem Power Vac 0 peration amp Service Manual Maintenance amp Service then again at 100 hours Check sheave set screws and or bushing hub cap screws every 500 hours thereafter Re torque these screws with a torque wrench using the values on the chart below A WARNING Make certain that when you re torque these screws that you use a clockwise pattern and continue until proper torque is achieved TORQUE VALUES inch Ibs foot Ibs Component Engine hub 720 60 Vacuum pump hub 192 16 2 Check for sheave groove wear clean belts and sheave grooves check for worn belts proper belt tension and sheave alignment after the first 25 hours and then again at 100 hours Check for belt ride in the groove In multiple groove drives belt ride should be uniform not more than 1 16 above or below top of sheave groove Check groove area for wear Sidewall of groove should be straight not dished out Bottom of groove should show no signs of belt contact Inspect belts for contaminants such as oil or grease Wipe belts clean with detergent and water Inspect sheave grooves for buildup of such material and remove if necessary Check wear surfaces of belt for excessive wear If they have a slick glazed look belts are slipping Check belt tension Never replace one belt in a used set as used belts will elongate Replace entire set if replacement
54. d Parts Listings ASTE TANK ASSEMBL Y TO WASTE 1 00 000078 5 CAP 1 4 20 x 1 HXHD GRD 8 36 900056 300 CCA 2 00 000167 5 MACH 1 4 20 x 6 HXHD 15 43 807559 GASKET WASTE TANK LID 3 00 000171 3 16 x 5 1 6 ALUM 208020 LATON DRAW EIN 4 01 000037 NUT 1 4 20 HXHD 95 7 HEAT 5 02 000038 1 4 48 941297 ARROW WASTE TANK LID 6 02 000066 FM WASHER 1 4 50 501697 5 BATTERY SHELF MOUNTING 7 5 56 500188 BATTERY 03 000242 CLAMP CABLE 3 4ID 1 4BLT 7 56 501779 TRAY BATTERY 1 1 800345 PLUG 1 4 SOCHD BR 56 501788 40 WASTE TANK 10 11 800402 PLUGHIMELBOW 1 4 1 HXHD PVC 56 501793 STRAINER Sr Y 56 502189 TANK WASTE 11 12 500387 FITTING BARB 1P x 1H BR 61 950621 ASSY LEVEL SENSOR SHUTOFF SWITCH 12 14 806509 STRAINER WST TNK 2in 100MESH 61 951132 ASSY LEVEL SENSOR SHUTOFF SWITCH 13 31 900179 COVER BATTERY TERMINAL A 17 Prochem Power Vac 2 Operation amp Service Manual Illustrated Parts Listings EXTERNAL ELECTRIC FUEL PUMP 509 ASSEMBLEY 66 945201 TO BULKHEAD ADAPTER CORD FROM CONSOLE 00 000055 SCREW CAP 1 4 20 3 4 HXHD 00 000078 SCREW CAP 1 4 20 1 HXHD GRD 8 01 000037 NUT 1 4 20 HXHD 02 000038 LOCKWASHER 1
55. eck if water pump volume is correct check the pump volume with the cleaning tool closed Measure the water flow returning to the water box from the pressure unloader The flow rate should be approximately 4 5 GPM Prochem Power Vac II Operation amp ServiceManual 42 Section Four Maintenance amp Service SPECIFIC PROBLEMS 1 LOSS OF WATER PUMP PRESSURE With the cleaning tool open the water pressure gauge reads below the normal operating pressure Water supply is turned off or the float valve is stuck Turn the water supply on or up Check for kinks in the water supply hose Examine the float valve and adjust or replace Water inlet supply line is plugged or drawing air Improper engine speed Pressure unloader O rings are dry Pressure unloader has worn O rings Pressure unloader is dirty stuck open or improperly adjusted lt Low pump volume Measure the amount of water being returned to the water box from the pressure unloader It should till a gallon container every 13 3 seconds Defective water pressure gauge Orifice spray nozzle in the cleaning tool is worn defective or the wrong size Debris clogging water lines or water inlet disconnect Belts loose or broken Prochem Power Vac II Operation amp Service Manual Examine the water inlet filter inside the water tank Remove accumulated debris and replace if required Check for suction leaks and loose clamps or fittings Tighten
56. ector is attached to a quick disconnect which plugs into the solution outlet on the console lower front panel The unit can be operated with or without chemical injection Prochem Power Vac II O peration amp Service Manual 20 Section Three Operation Figure 10 WATER PUMPING SYSTEM WATER INLET VACUUM INLET VACUUM mm IRESSURIZED WATER BYPASS WATER gt UNPRESSURIZED WATER RESSURE MANIFOLD i Sid L Prochem Power Vac II 0 peration amp Service Manual 21 Section Three O peration Figurell VACUUM SYSTEM VACUUM VACUUM EXHAUST INIE OUTLET 5 VACUUM GAUGE LUBRICATION CUP f VACUUM SILENCER RELIEF VALVE SENSORS a WASTE TANK 5 00090649 660oo60 0G Prochem Power Vac II Operation amp Service Manual 22 Section Three Operation Figure12 CHEMICAL SYSTEM PRESSURIZED WATER PRESSURE MANIFOLD PRESSURE UNLOADER SOLUTION CHEMICAL OUTLET INJECTOR SOLUTION CHEMICAL CHEMICAL CONTAINER CHEMICAL STRAINER Prochem Power Vac 1 peration amp Service Manual 23 Section Three O peration 4 WASTE PUMP SYSTEM switch located near the lower part of the waste The recovered waste flows through the waste tank will disable the waste pump before the pump and a check valve before exiting the waste tank is
57. ghly recommend using a galvanized drip tray under the console 56 501845 7 using trailer the Power Vac II console should be positioned so that it balances properly with respect to the axle Ten percent 10 of the overall unit weight without accessories or water should be on the tongue General Information FUEL REQUIREMENTS Use unleaded gasoline ONLY DO NOT use any gasoline additives We recommend the use of clean fresh unleaded gasoline intended for automotive use High octane gasoline SHOULD NOT be used with the gasoline engine on this unit ENGINE OIL REQUIREMENTS Use high quality detergent oil of API American Petroleum Institute service class SF or SG Select the viscosity based on the air temperature at the time of operation as shown in the following table NOTE Using other than service class SF or SG oil or extending oil change intervals longer than recommended can cause engine damage RECOMMENDED SAE VISCOSITY GRADE 20W 20 20W 40 20W 50 22 4 14 32 59 104 C 30 20 10 0 15 Temoerature Range Expected Before Next Oil Chanee CHEMICAL REQUIREMENTS The PROCHEM POWER VAC II cleaning unit due to its chemical injection design can be used with a variety of water diluted chemical compounds either acidic or alkaline depending on the job to be done However to obtain optimum results with this unit we recommend using the PROCHEM line of chemicals For information on using the cle
58. hs approximately 1134 Ibs Make certain that the vehicle has the correct axle rating This will prevent unsafe vehicle driving conditions 19 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 20 Keep your vehicle work area clean Wands cleaning tools and other accessories must be securely fastened before driving the vehicle This will prevent damage to yourselves or your equipment in the event of sudden stops General Information 21 All high pressure hoses must be rated for 3500 PSI at 2502 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 22 Make certain that you receive complete training by the distributor from whom you purchased this unit 23 Do not modify this unit in any manner Improper modification can cause severe personal injury or could be fatal 24 CALIFORNIA PROPOSITION 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Prochem Power Vac 21 Operation amp Service Manual 4 Section One General Information SPECIFICATIONS Engine speed 2600 rpm high speed 2300 rpm medium speed 900 rpm idle speed water pump off Water pump rpm 1575 rpm Water flow rate 4
59. ing day 11 BATTERY 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 1 Check the fluid level in the battery every 25 hours or once a week If low fill to the recommended level with distilled water ONLY A CAUTION DO NOT overfill the battery Poor performance or early failure due to loss of electrolyte will result 2 Keep the cables terminals and external surfaces of the battery clean A buildup of corrosive acid or grime on the external surfaces can cause the battery to self discharge Self Prochem Power Vac 0 peration amp Service Manual 36 Section Four discharge occurs rapidly when moisture is present The battery terminals should be cleaned every 100 hours to prevent corrosion build
60. ither expressed or implied with respect to this product PROCHEM disclaims the implied warranties of merchantability and fitness for a particular purpose Any implied warranty of merchantability or fitness is limited to the specific duration of this limited warranty This warranty gives you specific legal rights and you may also have other rights which may vary from state to state or province to province The remedies provided herein are the customer s sole and exclusive remedies In no event shall PROCHEM be liable for any direct indirect special incidental or consequential damages whether based on contract tort or any other legal theory Your PROCHEM unit is designed to give you years of reliable service However if a problem should arise after the warranty period follow the troubleshooting procedures in the Operation and Service Manual If you are still unable to determine the cause and solution to the problem contact your nearest PROCHEM Service Center for details of the services available II TABLE OF CONTENTS SECTION ONE GENERAL INFORMATION 1 SAFETY 2 safety specifications installation requirements e fuel engine oil chemical and water requirements 2 RECEIVING YOUR UNIT 8 dealer responsibility acceptance of shipment equipment list optional equipment SECTION TWO INSTALLATION 3 INSTALLATION 11 lifting andpositioning unit bolting down unit and waste tank dimensional data fuel
61. ke certain the end is at the bottom of the tank 15 Re connect the hoses that connect the filler neck and the fuel tank Make certain they are clamped correctly 16 Route the 5 16 fuel hose underneath the van from the filler neck to the inlet side of the external electric fuel pump Figure 8 Use the cable ties to secure the hose Cut off any excess hose and attach to the barb fitting with hose clamp 17 Attach the remaining hose to the outlet side of the external electric fuel pump with a hose clamp Prochem Power Vac 11 Operation amp Service Manual Installation 18 Using the 5 16 hose and hose clamps connect the fuel pump box to the bulkhead adapter A CAUTION When routing this hose underneath the vehicle make certain that you 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 muffler catalytic converter or sharp objects INSTALLING THE FUEL TANK AND FUEL LINE TRAILER For trailer installations we recommend the following 1 Strict compliance with all State and Federal laws must be maintained 2 Provide a safe fuel tank which is manufactured specifically for gasoline has a proper filling cap and an outlet connection that is the same size as the inlet connection on the unit The minimum size outlet connection is 1 8 NPT 3 DO NOT mount the fuel tank inside an enclosed trailer or van
62. m NOTE For the maintenance schedule see page 3 for specific details Prochem Power Vac Operation amp Service Manual Maintenance amp Service 1 To drain the coolant remove the radiator cap and turn the lower engine radiator draincock counterclockwise 2 To add coolant first turn the lower engine radiator draincock clockwise until it is closed Next fill the radiator with the coolant water mixture Then add to the overflow container fill ONLY halfway between the add and full marks After running the unit add more coolant if necessary into the overflow container only 41 Section Four Maintenance amp Service E TROUBLESHOOTING A WARNING 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 severed limbs or fatality This chapter of the operator s manual explains how to look for and fix malfunctions which may occur Intelligent accurate troubleshooting is based on a complete and thorough understanding of the WATER VACUUM CHEMICAL SAFETY and WIRING systems on this unit If there is a malfunction occurring in a system that you do not fully understand turn back to OPERATION section 3 of this manual and review SYSTEMS In addition prior to proceeding you can save time by checking that 1 The water supply is ON 2 The engine speed at full throttle at full speed is 2600 RPM 3 To ch
63. n cleaning tool amp waste tank Plugged vacuum line leading to vacuum gauge Waste tank filter or strainer basket is plugged Loose vacuum pump drive belts Waste tank drain valve is damaged or left open causing a vacuum leak Vacuum relief requires adjustment or has a vacuum leak due to damaged gasket Vacuum pump is worn out GIILO NI Inspect the vacuum hose s Repair any damage or replace Inspect the gasket Repair or replace if required Re position lid Locate obstruction and remove Unplug or replace the vacuum line Clean or replace filter Clean strainer basket Tighten the drive belts Drain the waste tank Close drain valve if open Remove the dump valve and after inspecting replace the defective components Re adjust the vacuum relief valve If the vacuum does not increase remove and inspect the relief valve gasket If damaged replace Replace the vacuum pump Prochem Power Vac II Operation amp Service Manual 44 Section Four Maintenance amp Service osx _ With the cleaning tool valve open chemical The strainer at the inlet end of the chemical inlet line is clogged Obstruction in chemical injector orifice Suction leak in the inlet line leading into the chemical injector Defective cylinder in the water pump Unclog the strainer If damaged replace Unclog the orifice Inspect inlet line for damage and replace if required Measure the p
64. nd waste tank are positioned in the vehicle in the desired location you may proceed A CAUTION Before drilling any mounting holes in the vehicle floor make certain that when drilling you will not do any damage to the fuel tank fuel lines or any vital component which might affect the operation or safety of the vehicle 1 Using the console and waste tank mounting holes as a template drill six 13 32 diameter holes for mounting the console and six more 13 32 diameter holes for mounting the waste tank 2 Using the installation hardware kit a Insert six 3 8 16x2 hex head cap screws with flat washers through the mounting holes in the PROCHEM POWER VAC II console and six 3 8 16 hex head cap screws with flat washers through the mounting holes in the waste tank b Install the mounting plates underneath the vehicle floor See Figure 2 c Screw the 3 8 16 hex head locknuts on the mounting screws and tighten them until the console and waste tank are firmly secured to the vehicle floor Prochem Power Vac Operation amp Service Manual 10 Section Two Installation san Figure2 DIMENSIONAL DATA CONSOLE ee 1 e 19 1 2 48 314 1332 DIAMETER DOBBBODDODODDDOZSSODOGDSDED BOBBBBODDUDDDOSSEDOOSBSCD 900008900509000000800890080 DODDDODDOSOUOGDODDODOGSPO5BOU 7 3 4 MINIMUM WASTE TANK US HEIGHT OF WASTE TANK WITH HANDLES 36 1 2 h il iu
65. on One A This symbol means 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 A WARNING 1 Read the operator s manual before installing or starting this unit Failure to adhere to instructions can result in severe personal injury or could be fatal 2 This unit uses high pressure Improper or irresponsible use may result in serious injury 3 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 4 Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Never carry extra gasoline in the vehicle Fumes may accumulate inside the vehicle and ignite causing an explosion DO NOT store any flammable containers in the vehicle 5 This unit must be operated with the vehicle doors open in order to ensure adequate engine ventilation 6 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
66. r Figure 5 Prochem Power Vac 11 Operation amp Service Manual 12 Section Two Installation FUEL LINE INSTALLATION 1 5 STAINLESS STEEL HOSE FUEL LINE INSTALLATION KIT 3 E 1 8P x 1 4T Part 66 945153 For Vehicles other TO FUEL INLET ELBOW VEHICLE than 1992 or Later Fords ON CONSOLE FLOOR 1 LONG E 1 ADAPTOR FIGURE 5 1 i FILLER NECK 1 22244122 STREET 1 5 FUEL HOSE BARB ELBOW HOSE FITTING FIGURE 4 BREATHER TUBE POSSIBLE HOLE LOCATION OPPOSITE BREATHER TUBE SHORT BULKHEAD SELS BULKHEAD ADAPTOR ADAPTOR NUT 1 8P x 1 4 1 8P STREET ELBOW FILLER 2 L NECK ANB L BREATHER 57 TUBE HOSE CLAMP 8 DE i FUEL STAINLESS i HOSE STEEL TO FROM HOSE FILLER NECK FUEL PUMP BOTTOM OF FUEL TANK TH FIGURE 6 BREATHER TUBE p FIGURE 7 M BOTTOM OF wed a da Prochem Power Vac II Operation amp Service Manual 13 Section Two Installation IF THE VEHICLE IN WHICH YOU ARE INSTALLING YOUR UNIT IS A 1992 or later FORD IT WILL BE NECESSARY TO FOLLOW THE FOLLOWING INSTRUCTIONS Figure 8 1992 or later FORD FUEL LINE MODIFICATION FUEL LINE INSTALLATION KIT Part 66 945171 For 1992 or later Fords me 0 x ELECTRIC FILLER NEC K FUEL PUMP BOX BREATHER TUBE 03 000254 HOSE CLAMP she 09 805345 5 16 ABRASION BREATHER TUBE RESISTANT zd
67. r and water being drawn into the vacuum inlets at the front of the console From the vacuum inlet tube at the front of the console the air and water mixture flows through a strainer basket in the waste tank Air then exits the waste tank through two 100 mesh filters and flows into the vacuum pump vacuum silencer and is discharged at the console lower front panel A level sensor switch located near the top of the waste tank will shut the unit down before the waste tank reaches its full capacity This protects the vacuum pump from water damage A CAUTION Use of a DEFOAMER will help prevent damage to the unit by a build up of foam in the waste tank which may be caused by some chemicals Foam build up will not activate float switches 3 CHEMICAL SYSTEM The chemical is drawn from the chemical container through a strainer into the chemical injector A pressure differential at the chemical injector draws chemical into the pressurized water stream The pressure differential is increased and the chemical flow is started by screwing in the differential screw on the chemical injector Once a steady chemical flow has begun the rate of chemical flow is adjusted with the flow screw on the chemical injector Chemical flow is increased by backing out the flow screw The operator can stop the chemical flow by backing out the differential screw to decrease the pressure differential at the chemical injector orifice The chemical inj
68. ropped check for the source of leakage and repair SIGHT GLASS ON CAT WATER PUMP CRANKCASE COVER OIL LEVEL WITH UNIT STOPPED amp ON LEVEL GROUND RED DOT Prochem Power Vac l Operation amp Service Manual 34 Section Four 2 Refill the oil to the proper level if required with Cat Pump Crankcase Oil SPECIAL FORMULA PREMIUM 10W30 GRADE NON DETERGENT HYDRAULIC Oil Other CAT approved oil equivalents are Mobil DTE 16 Amoco Rykow 68 Shell Tellus T68 3 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 4 VACUUM INLET FILTER in waste tank The vacuum filters in the waste tank should be removed and cleaned daily If this is done the filters will last for a long period of time Inspect the vacuum inlet filters inside the waste tank If there is any lint or debris remove and clean filters Re install the filters hand tight A CAUTION When removing the vacuum inlet filters grip the plastic hexagonal section of filters Grasping filters by the screen may collapse or ruin the filters Replace these filters at least once a year NOTE When replacing these filters we recommend using the stainless steel filter 14 806509 This will prevent rust and corrosion from entering the vacuum system 5 DRIVE BELTS SHEAVES amp BUSHINGS 1 Check sheave set s
69. rt 46 Starter turns over but engine will not start 46 Engine stops running 47 Waste pump is malfunctioning or not operating normally 47 Prochem Power Vac 0 peration amp Service Manual 30 Section Four Maintenance amp Service MAINTENANCE CHART 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 daily Check oil level Fill to proper level Vacuum Inlet Filter in waste tank Clean filter inspect replace if damaged Wash out with clean water Automatic Waste Pump Inspect and remove any debris or sediment Check oil level Fill to proper level Water Pump Inlet Filter in water Check for debris and clean box Check for proper fluid level Fill with distilled water only Check for proper drive belt tension after first 25 hours Lubricate o rings Change oil filter Engine Engine Water Pump Change oil i Inspect clean and check for groove wear Inspect and clean 500 1000 1000 i 1000 Engine Engine Or as often as required Change water pump crankcase oil after the first 50 hours of operation Change engine crankcase oil and filter after the first 50 hours of operation Perform drive belt pulley amp hub maintenance after the first 25 hours of operation and then again at 100 hours w f using AEON PD synthetic lubricant 4500 hours or every 2 years
70. s achieved 1 2 deflection in the center of the belt halfway between the sheaves 3 While checking the alignment tighten the pump mount hold down nuts S WASTE PUMP DRIVE BELT To tighten the waste pump belt 1 Loosen the nuts that hold the waste pump mount to the console base 2 Adjust the position of the waste pump until the proper belt tension is achieved 1 2 deflection in the center of the belt halfway between the sheaves 3 While checking the alignment tighten the nuts on the mounting 6 PRESSURE UNLOADER The pressure unloader unloads water pump pressure whenever the cleaning tool is closed and allows water to bypass the pressure manifold and return to the water box Adjust as follows To adjust With your unit running open the cleaning tool valve Check the pressure gauge We recommend setting the pressure unloader so Prochem Power Vac 11 Operation amp Service Manual 40 Section Four that the console pressure gauge reads 3000 PSI with the tool valve open When the chemical injector is used and the tool valve is open there is an approximate drop of 500 PSI in pressure across the chemical injector This drop is necessary for the chemical injector to operate Jf there is a pressure drop of greater than 500 PSI it may be necessary to lubricate the O rings in the pressure unloader 7 ADDING DRAINING ENGINE COOLANT Use 70 30 coolant water ratio in this unit s cooling syste
71. ss the reset button Loose or corroded battery Clean tighten or replace the battery terminals Dead battery Recharge or replace battery Defective ignition switch Test ignition switch for power going into the switch If there is power going in but NO power going out replace the switch Defective starter motor Test the starter motor If necessary replace Engine problem Refer to the Nissan Engine Operation and Maintenance Manual Vacuum pump is seized Refer to Sutorbilt service amp repair manual 7 STARTER TURNS OVER ENGINE BUT ENGINE WILI NOT START Waste tank is full Empty the waste tank Engine coolant temperature has exceeded 240 F Determine the cause of overheating before triggering the high temperature switch to restarting the unit Test switch Replace switch shut the unit down if defective Defective fuel pump Replace the fuel pump Loose or broken wires leading to upper waste Repair or replace any broken electrical tank level sensor connections Defective upper waste tank level sensor Disconnect the upper level sensor plugs and bypass the sensor If the unit starts replace the defective level sensor float switch Oil pressure switch located on engine Test these components if any are defective anti diesel solenoid located on engine replace Consult engine service high temperature switch located on engine manual Engine is malfunctioning Refer to
72. t the end of each working day 3 Drain flush and replace oil every 1500 hours or yearly whichever comes first Change oil more frequently if required With AEON PD synthetic lubricant perform the oil change maintenance every 4500 hours or every 2 years whichever comes first 4 The bearings on the pulley end of the vacuum pump require grease lubrication every 500 hours Re pack the bearings until grease comes out of the vent holes Use extreme pressure bearing grease of the specification NLGI Grade 2 EP Maintenance amp Service VACUUM PUMP LUBRICANT Blower Oil viscosity Discharge Centistokes Temperature 40 c 40 to 32 F SAE 10W 45 40 to 0 C 32 to 100 F SAE 20 100 0 to 38 C 100 to 275 F SAE 40 200 38 to 135 C over 275 F SAE 50 250 135 C n applications with extreme variations in ambient emperature a 20W 50W multiple viscosity is recommended For Grease Lubricated Bearings Service every 500 hours of operation Blower Discharge Temuerature Type Grease 40 to 275 F No 2 40 to 120 C Non Corrosive Bearing Grease 3 WATER PUMP Refer to the Water Pump Operation and Service Manual for specific instructions 1 Check the crankcase oil level daily to assure the proper level With the unit stopped and on level ground the oil level should be slightly below the top of the oil sight glass Use the following illustration as a guide when adding oil If the level has d
73. t all solution hoses and any tools which require purging of anti freeze to the solution outlet connection 6 Turn the water pump switch ON Open the tool valves and drains the anti freeze into an approved container until anti freeze is purged from the tools and hoses and the flow is clear Once all of the anti freeze is removed the unit is ready to use Eventually the anti freeze in the storage container will become diluted with water If the anti freeze drops below 50 of the total dispose of it and start with fresh 100 anti freeze A WARNING When disposing of used anti freeze observe local laws and regulations We recommend that you recycle Do not drain on to the ground or into storm drainage systems 29 SECTION 4 MAINTENANCE amp SERVICE 6 MAINTENANCE 32 Maintenance chart 3 Engine 32 Vacuum pump 33 Water pump 34 Vacuum inlet filter Drive belts sheaves amp bushings 35 Float valve Inlet filter Strainer basket Pressure unloader Vacuum hoses Battery 36 High pressure hoses Waste pump 37 7 GENERAL SERVICE ADJUSTMENTS 38 Engine speed 38 Vacuum relief valve Vacuum pump drive belts Water pump drive belts Waste pump drive belt Pressure unloader 40 Adding Draining engine coolant 41 8 TROUBLESHOOTING 42 Loss of water pump pressure 43 Loss of solution volume at cleaning tool orifice 44 Loss of vacuum 44 Loss of chemical 45 Water pump does not engage 45 Engine will not sta
74. ter change oil every 100 hours of operation Oil Recommendation Use high quality detergent oil of API American Petroleum Institute service class SF or SG Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADE 20W 20 20W 40 20W 50 22 4 C 30 20 10 1 Temoerature Ranee Expected Before Next Chanee NOTE Using other than service class SF or SG oil or extending oil change intervals longer than recommended can cause engine damage 3 Change the oil filter after the first 50 hours of operation Afterwards change the engine oil every 100 hours USE ONLY NISSAN BRAND OIL FILTERS USING ANY OTHER TYPE OIL FILTER WILL VOID YOUR ENGINE WARRANTY 4 Re torque the manifold and exhaust tube nuts cylinder head bolts and carburetor attaching nuts after the first 200 hours of use 5 Check the oil level in the engine governor every 250 hours When empty the governor requires approximately 1 1 2 fluid ounces of 30 weight non detergent oil see Figure 15 Drain and refill the engine governor every 500 hours Prochem Power Vac 1 Operation amp Service Manual 32 Section Four ENGINE GOVERNOR CHECK ENGINE GOVERNOR OIL LEVEL EVERY 250 HOURS WHEN PILLING REMOVE THE GOVERNOR FLLL PLUG AND USING A SYRINGE OR OTHER MEASURABLE FILLING DEVICE ADD 30 WEIGHT NON DETERGENT OIL REPLACE THE FILL PLUG WHEN EMPTY THE GOVER
75. the Nissan Engine Operation and Maintenance Manual Prochem Power Vac II Operation amp Service Manual 46 Section Four Maintenance amp Service While doing normal cleaning the engine stops running Engine is out of gasoline Add gasoline to the fuel tank Waste tank is full Empty waste tank Main circuit breaker on the control panel has been tripped After inspecting the unit to determine the cause of the tripped circuit breaker press the reset button Engine coolant temperature has exceeded 240 F triggering the high temperature switch to shut the unit down Defective fuel pump Defective upper level sensor inside the waste tank Determine the cause of overheating before restarting the unit Refer to Nissan Engine Operation and Maintenance Manual Replace fuel pump Disconnect the upper level sensor plugs and bypass the switch If the unit starts replace the defective upper level sensor float switch Defective 240 engine coolant high temperature shutdown switch Oil pressure switch has shut down engine due to insufficient oil pressure No ignition in the engine or engine is malfunctioning Test switch If necessary replace Refer to Nissan Engine Operation and Maintenance Manual DO NOT restart the engine until the cause is determined and corrected Refer to Nissan Engine Operation and Maintenance Manual 9 WASTE PUMP IS MALFUNCTIONING OR NOT OPERATING NORMALLY
76. tion F Hose clamps for fuel amp vacuum hoses G External fuel pump installation kit H Waste tank w float switches I Waste tank filters and strainer basket J 100 ft of 2 vacuum hose K 1 vacuum hose connector L 100 ft of 3 8 high pressure hose with quick connects M 50 ft water supply hose with quick connect N 13 ft waste dump hose with quick connect OPTIONAL EQUIPMENT 0 Hose reel P Hard Surface Cleaner tool Part 60 950462 blue or 60 950504 black Q Dual lance pressure wash gun Part 60 950505 R Oil fired solution heater Part 65 950496 S Van Storage Unit Part 65 950392 Section One T Galvanized drip pan Part 56 501845 U Auxiliary water tank w demand pump Part 66 945265 V Extra vacuum hoses Part 10 805060 W Extra vacuum hose connectors Part 12 800078 General Information X Extra high pressure water hoses Part 10 805334 Y 1992 or later Ford fuel line installation kit Part 66 945171 Z Winterizing loop hose Part 10 805453 Prochem Power Vac 11 Operation amp Service Manual 8 SECTION 2 INSTALLATION 3 INSTALLATION 10 Lifting unit 10 Positioning unit in vehicle 10 Bolting down unit amp waste tank 10 Dimensional data Fuel line installation 12 Fuel line installation trailer 15 Waste tank to console connection 17 Battery connection 17 Fire extinguisher 17 Prochem Power Vac II Operation amp Service
77. ump volume If the pump volume is less than normal examine the check valves plunger cups and cylinder head on water pump Repair as required 5 WATER PUMP DOES NOT ENGAGE Water pump clutch circuit breaker has been tripped Defective electrical connection in the console wiring or defective switch Defective water pump clutch BGORREGIBSU If the blue light is OFF check the water pump clutch circuit breaker on the control panel Press RESET button If the blue light is OFF and the circuit breaker is not tripped examine switch electrical connections and wiring Repair any defective connections If there is power going to the switch but not going out replace the defective switch If the blue light is ON check the white wire which leads from the switch to the clutch If there is power in the switch but no power at the clutch replace the defective wire If there is power at the clutch replace the defective switch Belts loose or broken Re tension or replace as needed NOTE The clutch may be MANUALLY set by inserting two 1 4 20 x 1 2 bolts Line up the holes and insert the bolts To disengage the pump remove the bolts Prochem Power Vac II Operation amp Service Manual 45 Section Four Maintenance amp Service The engine does not turn over Main circuit breaker on the control panel has After inspecting the unit to determine the cause of been tripped the tripped circuit breaker pre
78. up Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with clear water A CAUTION DO NOT allow the baking soda to enter the battery cells as this will destroy the electrolyte 12 HIGH PRESSURE HOSES Inspect your high pressure hoses for wear after the first 100 hours of use and every 25 hours thereafter If hoses show any signs of damage or impending rupture replace the hose Prochem Power Vac 11 Operation amp Service Manual Maintenance amp Service A WARNING DO NOT attempt to repair high pressure hoses Repairing high pressure hoses may result in serious injury All high pressure hoses must be rated for 3500 PSI at 250 F Thermoplastic hoses do not meet these specifications and should not be used Injury may result if the hoses do not meet these requirements 13 WASTE PUMP At the end of each work day make certain that you remove any debris or sediment which may be inside the waste pump After the waste tank has been emptied partially fill the waste tank with fresh water Drain the fresh water with the waste pump to remove sediment from the waste pump 37 Section Four GENERAL SERVICE ADJUSTMENTS A WARNING 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 severed limbs or fatality 1 ENGINE SPEED The PROCHEM POWER VAC II cle
79. waste pump will cease operating when the waste level falls below that of the bottom level sensor on the waste tank This will protect the waste pump from damage by running dry The waste pump can be turned off at any time by turning the pump out switch on the control panel to the OFF position A WARNING DO NOT dispose of waste in any manner which in so doing would violate any Local State or Federal law 8 OPERATION Once you have completed steps through 7 proceed with the cleaning operation The upper float switch located inside the waste tank will automatically shut down the unit when it reaches its full capacity When this occurs empty the waste tank before continuing 9 CLEANING Observe the following guidelines while cleaning Prochem Power Vac II O peration amp Service M anual Operation 1 If you intend to operate the hard surface cleaner make sure the hard surface cleaner nozzles are functioning properly before proceeding If the nozzles are not showing a full spray pattern adjust nozzles for proper pattern clean or replace nozzles if required 2 When cleaning keep the working opening mouth flat on the surface being cleaned KEEP THE TOOL MOVING WHEN THE VALVE IS OPEN 3 The unit will automatically shut down when the waste tank is full This will prevent water being drawn into the vacuum pump If the unit shuts down automatically empty the waste tank before proceeding A WARNING D
80. ways or on ground areas Always dispose of waste in accordance with Local State or Federal law 9 Remove the strainer basket from the waste tank clean out any accumulated debris and re install Inspect the vacuum inlet filters inside the waste tank If there is any lint or debris remove and clean filters NOTE When removing the vacuum inlet filters grip the plastic hexagonal section of filters Grasping filters by the screen may collapse or ruin the filters Re install the filters hand tight NOTE When replacing these filters we recommend using the stainless steel 14 806509 filters This will prevent rust and corrosion from entering the vacuum system Operation 10 At the end of your workday rinse out the waste tank with fresh water DUO Deodorizer may be added to the waste tank to inhibit the growth of bacteria 11 Clean the unit tools hoses van interior etc as needed Inspect ALL equipment for any damage wear leaks etc A CAUTION 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 When the unit is not in use always park it in a heated building If a heated building is not available we recommend that you winterize the unit with anti freeze At present it is only possible to winterize units that do not have an auxiliary water tank Units with auxiliary water t

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