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1. 71 40038 Hose Barb 45 3 8 Barb x 1 4 MPT 72 572 042 Solution Hose 1 4 Blue Neptune HP 73 572 100 Clear Braided Hose 1 4 74 572 120 Hose 3 8 Silicone 75 270 11A Q C 1 8 Male Shutoff 76 270 11 Q C 1 8 Fem Shutoff 77 580 115 1 8 Male open see notes 78 580 140 Q C 3 8 Fem open 79 581 015 Crimp Ftng 1 4 HP Hose 1 4 MPT SVL 80 582 005 90 3 Street Blk 81 582 027 Nipple x 4 82 582 069 Hose Barb 3 x 3 NPT Plated 83 759 030 Jar 16 oz White 84 759 035 Cap White 16 oz Jar 85 835 300 Baseplate Shaft 1 x 18 86 845 365 Brkt Blower PD 87 845 380 Baseplate PD 37 5 lt x z x S RECOVERY TANK SERIAL NO REF PARTNO DESCRIPTION FROM 1 305 310 Switch Mercury Float 2 325 303 Power Lock Terminal Red 3 325 305 Power Lock Terminal Yellow 4 325 320 Power Lock Insert 5 57245 Locknut 1 4 x 20 Nylon SS 6 57297 Locknut 3 8 x 16 Nylon SS 7 400 250 Well nut 1 4 x 20 Neoprene 8 70018 Bolt 1 4 x 1 SS 9 405 118 Bolt 3 8 x 1 1 2 SS 10 70070 Bolt 3 8 x 2 SS 11 415 035 LW 3 8 SS 12 87013 FW 1 4 SS 13 87003 FW 3 8 SS 14 87136 FW 1 2 SS 15 03 000246 Clamp 8 hose 1 2x 1 16 435 040 Handwheel Cross M 17 435 044 Knob Thumb M 18 435 045 H
2. 70 Shelf Assembly Optional 72 Water Tank Dual w Demand Pump Optional 74 Hose Reel 78 80 IMPORTANT SAFETY INSTRUCTIONS When using this machine basic precautions must always be followed including the following READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE ACAUTION These symbols mean WARNING or CAUTION Failure to follow warnings and cautions could result in fatality personal injury to yourself and or others or property damage Follow these instructions carefully Read the operator s manual before installing or starting this unit Failure to adhere to instructions could result in severe personal injury or could be fatal Operate this unit and equipment only in a well ventilated area Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality DO NOT run this unit in an enclosed area DO NOT operate this unit where the exhaust may enter any building doorway window vent or opening of any type DO NOT siore any type of flammable material in the vehicle DO NOT operate engine if gasoline is spilled Avoid creating any ignition until the gasoline has been cleaned up Never use gasoline as a cleaning agent DO NOT place hands feet hair or clothing near rotating or moving parts Avoid any contact with mo
3. MOBILE CLEANING UNIT Operating Instructions ENG MODELS PDF POWER DIRECT FORD PDFX POWER DIRECT XTRA FORD PDG POWER DIRECT GM PDT POWER DIRECT WATER TANK PDT POWER DIRECT WATER TANK Read instructions before operating the machine 980185 11 30 04 MACHINE DATA LOG OVERVIEW MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE YOUR DEALER NAME ADDRESS PHONE NUMBER Welcome and congratulations on the purchase of your Mobile Cleaning Unit This instruction manual is a guide for operating and servicing your unit Read this manual completely before installing or operating this unit This unit offers you personal convenience All of your instrumentation and controls have been positioned to give you easy access for operation and daily maintenance Proper operation and service are essential to the efficient functioning of this unit When maintained correctly this unit will have a long trouble free life The service methods described in this manual are explained in such a manner that servicing may be performed accurately and safely Proper service varies with the choice of procedure the skill of the mechanic and the tools or parts available Before attempting any repair make certain that you are thoroughly familiar with this equipment and are equipped with the proper tools Any questions pertaining to operating or servicing this unit should be directed to your nearest
4. 24 Vacuum Inlet Filter 24 Vacuum Relief Valve 24 Vacuum Drive Belts 24 Pressure Regulator 25 Vacuum 25 High Pressure 25 Optional Waste Pump out 25 Engine Coolant Replacement 25 Waste Tank Strainer Basket 26 Troubleshooting 27 PARTS LIST Front Panels neces 30 Baseplate Water Pump Blower 32 Recovery Tank sure ei 38 Fresh Water Tank Optional 40 Mini Water Tank Optional 42 Heat Exchanger 44 Silencer System 46 Post Heat System 48 PIO MM q qhaya 50 Wiring uyu a ee 52 Hose 56 Automatic Pumpout Optional 58 Wand Titanium Six Jet 62 Wand Quad Jet Optional 64 Wand Tri Jet Optional 66 Stair Tool Optional 68 Upholstery Tool Optional
5. DECAL WD HD CAST SS NOT SHOWN NOT SHOWN 66 808169 REP WD VLV INCLUDES PARTS 27 29 amp 31 33 65 6 N P 6 66 WAND TRI OPTIONAL REF PARTNO DESCRIPTION ROMA NOTES 89233 WAND TJW 9502 COMPLETE 89232 WAND TJW 95015 CUBXL COMPLETE 89234 WAND TJW 9503 COMPLETE 1 56012 NIPPLE 1 4 FPT QD 2 17 503010 CONN 1 4P X 11 16 16M 3 17 803006 WASHER NYLON 4 14806512 STRAINER JET 50MESH 5 17 803036 CONN 1 4 11 16 168 BR 6 56015 NIPPLE 1 4 HEX 7 09 805359 SLEEVE WD HDL 95 8 52 501619 TRIGGER WD VLV 9 00 000317 SCR 10 32X 1 1 4 SOCH 10 57090 NUT 10 32 HEX NYLOCK SS 11 61 950496 ASSY EXTRCTR 12 12 800060 CONN 1 4P X 1 4T BR 13 10 805253 HOSE 3 16X49 1 8P X 1 4FT 14 04 000053 TIE CABLE 8 WHT 15 00 000282 SCR CAP 1 4 20 X 1 1 4 SOC 16 52501569 HOLD DOWN WD HDL 17 52501568 BODY WD HDL 18 56501712 WAND 8 HEAD TRIJET WD 19 17 803002 TIP SPRY 9502X1 8P SST 89233 19A 17 803001 SPRY 9501 1 8 SST 89232 198 17 803046 TIP SPRY 9503X1 8P SST 89234 20 70162 SOR 10 32 X 3 8 PPHMS SS 21 87165 WASHER 10 SPLIT LOCK 22 57014 NUT 10 32 HEX SS 23 56 501739 MANIFOLD WD TRI JET 24 11 800206 PLUG 1 8 SOCHD BR 25 16 808229 HOLDER VLV STEM EXTRCT
6. Not Shown 45 LEO eb SL PowerDwwe SILENCER SYSTEM PARTS LIST 46 SILENCER SYSTEM SERIAL NO REF PARTNO DESCRIPTION FROM NOTES 850 020 Silencer 425 114 Clamp 3 850 005 Muffler 3 E 1 2 3 850 044 Tube 3 SLP 4 5 850 046 Pipe 3 90 Degree 47 3 gt 7 lt I 7 48 POST HEAT SYSTEM SERIAL REF DESCRIPTION NO FROM NOTES 1 263 014 HP Hose Assy 32 1 2 2 263 021 HP Hose Assy 57 1 2 3 263 022 HP Hose Assy 52 1 2 4 57111 Nut 3 8 x 16 Zinc 5 405 156 Bolt 3 8 x 4 Allthread Zinc 6 87163 LW 3 8 Zinc 7 87171 FW 3 8 Zinc 8 425 040 Clamp 56 Hose 9 425 116 Clamp Muffler 3 1 2 10 425 152 Muffler Hanger 11 490 150 Post Heat Coil 12 551 005 Valve Press Limiter 1000 PSI Kingston 13 14076 Bushing 3 8 M x 1 4 F 14 555 115 Comp FTG 5 8T x 3 8NPT 90 15 555 134 Coupling 3 8 16 030 16 Elbow 90 1 4 Street Extruded 17 78308 Tee 1 4 Street Extruded 18 11 800352 Tee 3 8 FPT 19 575 035 All Flex Hose 3 1 2 ID 20 850 005 Muffler 3 21 850 046 Elbow 3 90 Degree 49 i 8 0 PTO SHAFT SERIAL NO REF PARTNO DESCRIPTION FROM NOTES 1 365 010 Clutch assy serpintine 2 380 551 Key 5 32 x 5 8 3 380 200 Snap Ring 2 4 380 205 Snap Ring 1 380 525 Bearing 835 305 Shaft inner 5 6 7
7. PLATE INSTALL MT 15 57119 9 NUT 3 8 16 HEX NYLOCK 41458 1 SHLR CHEM 10 GAL JUG NOT SHOWN 75 WATERTANK DEMAND PUMP OPTIONAL 980185 11 30 04 76 WATER TANK DEMAND PUMP OPTIONAL REF PARTNO QTY DESCRIPTION NOTES 1 70305 4 SCR 5 16 18 X 3 4 HHCS 385 PL TDL 2 87083 4 WASHER 5 16 SPLIT LOCK PLTD 3 02 000143 4 WASHER 5 16 FLAT 4 03 000113 6 CLAMP HOSE 12 SST 5 09 805278 1 HOSE WATER 3 4 X 3 6 09 805357 1 HOSE WATER 75 X 5 5 7 09 805446 1 HOSE WATER 5 8 X 55 8 12 800345 1 FTTG BRB 3 8P X 5 8H BR 9 13 806009 1 DISCONNECT 3 8M X 3 8FP 10 14 806553 1 FILTER DEMAND PUMP 11 41 905049 1 PUMP WATER BOOSTER FLOJET 2 12 48 809423 1 KIT PORT 13 11 800275 1 ELBOW ST 3 8 BR 14 65240 1 PUMP ONLY TM DEMAND NOT SHOWN 15 47449 1 KIT SERVICE DEMAND PMP FJ NOT SHOWN 980185 11 30 04 77 LIE RY HOSE REEL OPTIONAL 13 1 NN d gt 14 3 4 25 1 2 19 OVERALL 47 TALL MOUNTING DETAIL DIMENSIONS 29 WIDE 44 1 2 DEEP Hose Reel Mount 2 I 20 1 N I mu ES I N f m m HOSE REEL OPTIONAL REF PARTNO QTY DESCRIPTION ee NOTES 56501962 1 REEL VACUUM HOSE GRAY 2 03 000124 2 CLAMP MFLR 1 3 4 3 52501685 2 BUSHING HOSE REEL 4
8. Observe the following guidelines while cleaning 1 Before proceeding make sure the nozzles are functioning properly a Tocheck hold the wand about one foot above the surface to be cleaned and open the wand valve A full spray should be observed from the cleaning nozzles b If the nozzle are not showing a full spray pattern adjust nozzles for proper pattern clean or replace nozzles if required Nomally chemical is applied on the push stoke of the wand when cleaning and vacuuming is done on the pull stroke For heavily soiled carpets the wand may be used in a scrubbing manner apply chemical in both push and pull strokes Always finish up an area with a vacuum stroke 3 When cleaning keep the working opening mouth flat on the surface being cleaned Keep the wand moving when the valve is open 4 The unit will automatically shut down when the waste tank is full This will prevent water being drawn into the vacuum pump If shut down occurs empty the waste tank before proceeding UPHOLSTERY CLEANING Upholstery tool 1 Settemperature as desired and use Upholstery Mode on the unit switch 2 Use one 1 80015 spray tip in tool SHUTDOWN AND DAILY MAINTENANCE 1 Close chemical metering valve 2 Allow the unit to run for 2 minutes with the vacuum hose disconnected to remove moisture Spray WD 40 or equivalent into the vacuum lubrication cup This will prevent corrosion due to moisture 3
9. 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 CHECK FOR ADEQUATE FUEL Check the fuel tank to be certain there is adequate fuel to complete the job This unit uses approximately 95 to 2 1 gallons of fuel per hour depending on the speed setting REMOVE TOOLS FROM VEHICLE Remove any tools or hoses from the van which you will require WATER SUPPLY CONNECTION NOTE Before connecting your water hose to the supply faucet flush out the faucet until the water is free of any debris Flush out any debris which may be in your water inlet hose 1 Connect the water supply hose to the water inlet quick connect at the left front of the console Connect the hose to the water supply faucet NOTE Never use your waste pump outlet hose as a water inlet hose Use only clean hoses for water inlet 2 Turn the water supply faucet on The water will fill the water tank 17 OPERATION 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 VACUUM HOSE Connect the vacuum hose to the vacuum inlet connection at the front of the unit Connect the other end of the vacuum hose to the cleaning tool FILTERS Ensure all filters on machine and in waste tank are free of debris CLEANING
10. seconds to replace the bypass loop with antifreeze Turn the pump and main switch off then hook up the high pressure hoses and wand to the panel Turn main switch to Upholstery Mode and the pump switch to the ON position 10 With the primer hose valve closed open the wand valve until antifreeze appears repeat this for all other tools 19 OPERATION RETURNING CLEANING UNIT BACK INTO SERVICE 1 Close fresh water valve 1 2 Fill tank with fresh water 3 Close valve 3 and open valve f 4 4 Place chemical feed hose 6 into chemical jug open flow meter valve 5 Place primer hose into empty container 6 Turn main switch to Upholstery Mode and pump switch to the ON position 7 Open the primer hose valve to evacuate the antifreeze from the system remember to open and close this valve a couple of times during this process to clear the bypass loop 8 Turn the pump and main switch off hook up the high pressure hoses and wand Turn the main switch to Upholstery Mode and the pump switch to the ON position 9 Open the valve on the wand and recover the antifreeze repeat this for all other tools ralo Mog ETIDE 2 N 5 MAINTENANCE SERVICE SCHEDULE Van Engine Daily Check engine oil level Fill to proper level Van Engine Daily Check coolant level in overflow bottle Vacuum Pump Daily Spray WD 40 in lubrication cup at fr
11. 1 4H X 1 1 2T GRY 20 16 808229 1 HOLDER STEM EXTRCTR VL 21 43 810063 1 O RING 551 ID 691 OD 22 16 806228 1 SEAT EXTRCTR VLV 23 16 808189 1 STEM EXTRCTR VLV 24 43 810064 1 BACK UP 250DIA 25 43 810062 1 O RING 144 ID 254 OD 26 16 808190 1 SPRING EXTRCTR VLV 27 00 000306 2 SCR 632 X 1 SCHD SS 28 17 803033 1 TIP SPRY 80015X1 8P SST 29 56 500638 1 CSTG TRIGGER CLMP 30 00 000307 2 SCR CAP 6 32X3 8 SOCHD 31 52501623 1 VALVE UPHLST TL 32 52 501626 1 VALVE ADJ UPHLST TL VLV 33 43 810016 1 O RING 5 321DX9 320D VIT 34 43 807513 1 GASKET UPHLST TL VLV 35 10 805348 1 HOSE 3 16X6 1 2 1 8P BS 36 13 806030 1 DSC 1 8MX1 8FP SST 37 00 000408 1 SCR SET 3 32 X 1 4 SOCHD E 48 941164 1 DECAL UPHLST TL NOT SHOWN NOT SHOWN 66 808169 1 KIT REPAIR WAND INCLUDES PARTS 20 22 amp 24 26 71 SHELF ASSEMBLY OPTIONAL o 3 pal 1 a el lt lt HA lt 2 65 SHELF ASSEMBLY OPTIONAL REF PARTNO QTY DESCRIPTION NOTES 65 950392 1 STORAGE UNIT COMPLETE 1 56 501921 1 SHELF LWR 2 02 00066 FLATWASHER 1 4 3 87162 WASHER 1 4 SPLIT LOCK 4 70721 SHOULDER BOLT 182 OD X 2 25 L 5 70270 SCR 1 4 20 X 3 4 HHCS PLTD 6 50 501840
12. 20 43 810101 1 O RING 800 1000 072 21 43 810106 4 O RING 1 13 16 ID X 2 OD HDWP 22 45 801927 4 BRG SHFT PUMP OUT 23 49 876301 1 VENT UPR SHFT BRNG HSG 24 50 502025 1 PL CVR TOP PUMP OUT 25 50 502026 1 PL CVR SD PUMP OUT 26 70094 8 SCR 1 4 20 X 1 2 SHCS SS 27 11 800504 1 GA FLOW SIGHT 3 8 NPT 28 52 501828 1 BTM PLNGR WST TNK PMP OUT 29 52 501829 1 SHT 3 4 STROKE WST TNK 30 52 501914 1 RD CONNECT WST PMP OUT PART OF 31 31 52 501915 1 GUIDE PLNGR WST PUMP OUT INCL 32 18 30 32 52 501921 1 PIN WRIST PUMP OUT 33 52 501934 1 TOP PLNGR PUMP OUT 34 52 501950 1 BUSH THREADED 35 52 502062 1 CVR INLET WST PMP OUT 36 56 502428 1 BRKT PMP OUT SW CCT BRKR 37 52 501821 1 TOP WST TNK PUMP OUT 38 52 501820 1 BASE WST TANK PMP OUT 39 52 502063 1 BDY INLET WST PMP OUT 980185 11 30 04 61 LAAN WAND TITANIUM SIX JET OPTIONAL 62 WAN TITANIUM SIX JET OPTIONAL REF PARTNO DESCRIPTION NOTES 1 00 000282 SCR CAP 1 4 20 X 1 1 4 SOC 2 00 000317 SCR CAP 10 32 X 1 1 4 8008 3 70228 SCR 10 32 X 1 4 PPHMS SS 4 57090 NUT 10 32 HEX NYLOCK SS 5 04 000093 TIE CABLE 13 6 09805603 HOSE INT VAC 4 1 2 X 48 7 10 805504 HOSE 3 16 X 44 1 2 8 56015 NIPPLE 1 4 HEX 9 11 800206 PLUG 1 8 SOCHD BR 10 12 800060 CONN 1 4P X 1 4T BR 11 1
13. 9501 PC COMPLETE 89235 WAND TM QJW 9501 NO DECAL COMPLETE 1 56012 NIPPLE 1 4 FPT QD 2 17 503010 CONN 1 4P X 11 16 16M 3 17 803006 WASHER NYLON 4 14806512 STRAINER JET 50 MESH 5 17 803036 CONN 1 4 11 16 168 BR 6 56015 NIPPLE 1 4 HEX 7 09 805359 SLEEVE WD HDL 9 5 8 52 501619 TRIGGER WD VLV 9 00000317 SCR CAP 10 32X 1 1 4 SOCH 10 57090 NUT 10 32 HEX NYLOCK SS 11 61 950496 ASSY EXTRCTR 12 12 800060 CONN 1 4P X 1 4T BR 13 10 805387 HOSE 3 16 X 43 1 2 1 8P X 1 4 14 04 000053 TIE CABLE 8 WHT 15 00 000282 SCR CAP 1 4 20 X 1 1 4 SOC 16 52 501569 HOLD DOWN WD HDL 17 52 501568 BODY WD HDL 18 56 501940 WAND amp HEAD CAST SST 19 11 800206 PLUG 1 8 SOCHD BR 20 56 501966 ASSY L S BEND MNFLD 21 00 000347 SCR CAP 10 24 1 4 SOCHD 22 87165 WASHER 10 SPLIT LOCK 23 17803001 TIP SPRY 95015 1 8 SST 89238 23A 17 803002 TIP SPRY 9502X1 8P SST 89239 89237 238 17 803018 TIP SPRY 9501X1 8P SST o 24 56501986 ASSY RT S BEND MNFLD 25 12800322 CONN 1 8PX1 4T COMP BR 26 56501967 ASSY S BEND MNFLD 27 16808229 HOLDER VLV STEM EXTRCTR VL 28 43 810063 O RING 551 ID 691 OD 29 16 808228 SEAT EXTRCTR VLV 30 16 808189 STEM EXTRCTR VLV 31 43 810064 BACK UP 250 DIA 32 43 810062 O RING 144 ID 254 OD 33 16 808190 SPRING EXTRCTR VLV 34 52 501590 BODY EXTRCTR VLV 48 941186
14. BASKET The strainer basket located inside the waste tank should be removed and cleaned whenever it is full of debris This should be done at the end of each job WASTE TANK FLOAT VALVE The float valve in the waste tank shuts the unit down once the waste tank becomes full Check the float valve for debris at least once a month 26 MAINTENANCE MAINTENANCE PROBLEM CAUSE SOLUTION 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 or improperly adjusted Turn the water supply on or up Check for kinks in the water supply hose Examine the float valve and adjust or replace Water pump inlet supply line is plugged or drawing air Examine the water inlet filter inside the water box Remove accumulated debris and replace if required Check for suction leaks and loose clamps or fittings Tighten any loose fittings or clamps Replace any ruptured hose s Pressure regulator o rings are dry Lubricate o rings using o ring lubricant Pressure regulator has worn o rings Check o rings If necessary replace Pressure regulator is dirty stuck open or improperly adjusted Clean or repair regulator Adjust to working pressure Lubricate o rings using o ring lubricant Low pump volume Measure the amount of water being returned to the It shou
15. X 75 9 12 800052 1 CAP HOSE 3 4 BR 10 12 800367 1 BRB 1PX1H BR 11 12 800444 1 1 1 4P X 1 H BR 12 43 807008 1 WASHER HOSE 5 8 ID 1 OD 13 50 502055 1 BRKT CTR HOOD FR 14 52 000123 1 NUT 1 3 16 12 UN HXHD 15 52 501993 1 CONN HOSE WATER OUTL 16 61 951306 1 PUMP HD AUTO 17 61 951319 1 ASSY LVL SENS SHUT OFF SW 18 23719 1 CORD ASM CNCTN SIDE 19 72185 1 SWITCH ASSEMBLY 980185 11 30 04 59 AUTOMATIC PUMPOUT OPTIONAL P 2 26 980185 11 30 04 60 AUTOMATIC PUMPOUT OPTIONAL SERIAL NO REF PARTNO QTY DESCRIPTION FROM NOTES 1 00 000210 4 SCR 1 4 20 X 3 4 SOCHD 2 52 502064 1 CVR OUTLET WST PMP OUT 3 00 000312 8 SCR CAP 1 4 X 1 SOCHD 4 00 000399 1 SCR CAP 1 4 X 1 3 8 SOC 5 00 000241 8 SCR CAP 10 32 X 2 SOCHD SS 6 57245 8 NUT 1 4 20 HEX NYLOCK SS 7 87162 1 WASHER 1 4 SPLIT LOCK 8 87165 8 WASHER 10 SPLIT LOCK 9 04 000312 1 RING RETAIN EXT 1 2 10 04 000334 2 BALL NYL ID 11 04 000335 2 RING SNAP 1 7 8D 12 04 000342 1 SPRING PUMP OUT BALL PRESS 13 52 502061 1 BDY INLET WST PMP OUT 14 16 808241 1 DIAPH WST TNK PMP OUT 15 40 902151 1 MOTOR 1 8HP 12V 16 43 807117 1 GSKT CVR TOP PMPOUT 17 43 807118 1 GSKT CVR SD PMPOUT 18 43 810091 1 SEAL PUMPOUT SHFT 19 43 810100 1 SEAL PUMPOUT CAM
16. adjustment Vacuum pump is worn out Replace the vacuum pump Adjust throttle to set desired vacuum pressure Vacuum obstruction Inspect hoses for obstructions Vacuum relief valve requires The strainer at the inlet end of the chemical inlet line is clogged adjustment Readjust the vacuum relief valve Unclog the strainer If damaged replace Suction leak in the inlet line leading Inspect inlet lines and flow meter for air leaks or into the pump damage and replace if required chemical prime on off valve or chemical metering valve is defective Replace valve s Defective cylinder in the water pump 28 Measure the pump volume If the pump volume is less than normal refer to Loss of Pump Volume in the Troubleshooting section in this manual MAINTENANCE PROBLEM CAUSE SOLUTION Chemical flow meter External leak in chemical piping Tighten fittings Re apply thread sealant indicates flow with the where required If any fittings are damaged tool valve closed replace Defective electrical connection inthe Examine switch electrical connections and wiring console wiring or defective switch Repair any defective connections If there is power going to the switch but not going out replace the defective switch Water pump does not Water pump has not been activated Turn solution pump switch to on engage Defective water pump clutch NOTE The clutch may
17. alteration including the use of incompatible or corrosive chemicals or overloading of capacity 2 Products that have experienced shipping or freight damage 3 Repairs necessary to correct any failure due to imp roper pre delivery service and inspection by the selling dealer 4 Time for cleaning units in preparation for repair 5 repairs resulting from poor initial service work or improper diagnosis 6 Anydesign alterations performed by an organization not authorized or specified by PROCHEM 7 unit which is improperly repaired 8 Damage due to hard water scaling 9 Exposure to freezing temperature conditions 10 Electrical components exposed to moisture The warranty commences on the purchase date by the original end user from an authorized PROCHEM agent subject to proof of purchase The warranty is non transferable and is intended for the original purchaser only The Machine Registration Card must be completed and returned within 10 day of the time of purchase If proof of purchase cannot be identified the warranty start date is 90 days after the date of sale to an authorized PROCHEM distributor If difficulty develops during the warranty period contact the authorized PROCHEM agent from whom the product was purchased PROCHEM may elect to require the return of components to validate a claim Any defective part to be returned must be shipped freight prepaidto an authorized PROCHEM Distributor Service Center or to the PROCH
18. be manually set by inserting two 14 20 x1 2 bolts If there is power in the switch but not power at the Line up the holes on the clutch and clutch replace the defective wire If there is power insert the bolts To disengage the at the clutch replace the defective switch pump remove the bolts Loose or broken water pump belts Tighten or replace belts 29 Y 1 lt ml 5 u ela 30 FRONT PANEL SERIAL NO REF DESCRIPTION FROM NOTES 1 360 210 Tachometer Hour Meter 2 360 225 Solution Pressure Gauge 3 360 205 Solution Temp Gauge 4 360 215 Vacuum Gauge 5 551 028 Solution Temp Control 6 530 105 Pressure Regulator 7 305 090 Rock Switch 6 Pole White 8 305 085 Rock Switch White 9 580 010 Coupler FM 1 4 Closed 10 551 075 Oil Cup Port 11 580 135 Coupler M 3 8 Closed 12 498 066 Chrome Plug 13 360 125 Flow Meter 14 759 011 20 LT Jug 15 545 012 Ball Valve 1 4 16 845 242 Top Panel 17 845 243 Bottom Panel 18 845 244 Chem Jug Bracket 19 845 241 Panel Frame 20 498 035 Rubber Grommet 31 gt lt N SS E 32 SHAFT amp BASE PLATE ASSEMBLY Power LLAMA 33 gt J LU Y 0 lt 34 gt m Y 65 lt SI 35 BASEPL
19. dealer THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCORDANCE WITH THE PRESCRIBED INSTALLATION PROCEDURES MAKE CERTAIN THAT THE WARRANTY CARD IS FILLED OUT AT THE TIME OF INSTALLATION AND IS RETURNED TO YOUR DEALER PROFESSIONAL CHEMICALS CORPORATION 325 SOUTH PRICE ROAD CHANDLER ARIZONA 85224 Information in this document is subject to change without notice and does not represent a commitment on the part of Professional Chemicals Corporation TABLE OF CONTENTS Machine Data Log 02 Table of Contents 03 Parts ISE a uw w 04 SAFETY Safety Instructions 05 OPERATION amp SYSTEMS Technical Specifications 07 Panel Overview 08 Water Pumping and Heat Transfer 10 Chemical Injection System 15 Vacuum System 16 Pre run Inspections 17 GIEANINQ 17 Upholstery Cleaning 18 Shutdown and Daily Maintenance 18 De flooding Operations 18 Freezing Protection 18 Winterizing Your Unit 19 Removing Anti Freeze from Unit 19 MAINTENANCE amp SERVICE Maintenance Schedule 21 Key Maintenance Checkpoints 23 Vacuum 23 Water Pump
20. hours of operation Drain and refill the crankcase oil with Cat Pump Crankcase Oil every 500 hours thereafter 3 Other Cat approved oil equivalents are Mobil DTE 16 Amoco Rykow 68 and Shell Tellus T68 VACUUM INLET FILTER IN WASTE TANK 1 The vacuum filter in the waste tank should be removed and cleaned daily If this is done the filter will last for a long period of time VACUUM RELIEF VALVE While the unit is running at full RPM block the air flow at the vacuum inlet connection and read the vacuum gauge If adjustment is required shut the unit down and adjust the vacuum relief valve locking nut tension Start your unit and read the vacuum gauge Repeat this process until the relief valve opens at 14 Hg 24 MAINTENANCE VACUUM PUMP DRIVE BELTS To tighten the vacuum pump belts 1 Loosen the four screws which hold the vacuum pump mount in place 2 the adjusting bolt until the proper belt tension is achieved 1 2 deflection in the center of the belt halfway between the pulleys 3 Re tighten all bolts previously loosened at the vacuum muffler NOTE When adjusting belt tension make certain that the PTO shaft and vacuum pump shaft remain parallel and the belt tension is equal throughout the belt width 4 After adjusting re tighten the four screws which hold the vacuum pump mount in position Check belt alignment with straight edge Make certain that when you re torque these scr
21. tension Vacuum Lubrication Lines 500 hrs Check for line obstructions Replace tubing if cracked or damaged Heater Core 500 hrs Clean and inspect Vacuum Pump 1500 hrs Drain flush and replace oil Waste Tank Shut off Float Switch Monthly Check for debris hindering movement Van Engine Yearly Flush radiator and change engine coolant Waste Tank Filters Strainers Yearly Check for damage and blockage Replace if needed Van Engine 2 years Replace radiator hoses and hose clamps Or as often as required Change water pump crankcase oil after the first 50 hours Change vacuum pump crankcase oil and filter after the first 50 hours Perform drive belt pulley and hub maintenance after the first 25 hours of operation and then again at 100 hours If using AEON PD synthetic lubricant 4000 hours or every 2 years whichever comes first 22 VACUUM PUMP Refer to the Vacuum Pump Operation and Service Manual for specific instructions Lubrication We recommend that you use AEON PD Synthetic Blower Lubricant in the vacuum pump for all operation temperatures AEON PD is formulated especially for positive displacement blower service to provide maximum blower protection at any temperature One filling of AEON PD will last many times longer than a premium mineral oil NOTE AEON PD is the oil which PROCHEM puts in the vacuum pump at the factory Topping off or
22. 1 BRKT ADJUST MTG SLOT 7 56 502067 1 BRKT ADJUST HLDR 8 56 501942 1 BRKT SHELF MOUNTING 9 50 501753 1 HOLDER STAIR TOOL 10 01 000105 LOCK NUT 1 4 20 HXHD 11 56 501922 2 PANEL SHLF END 12 50 501749 WASHER NYLON 13 56 501920 1 DRAWER SHELF GRAY 14 46 802506 1 LATCH ADJ GRIP 15 50 501755 1 HOLDER UP TO HOSE 16 50 501754 1 HOLDER UPHST TL 17 48 941152 1 DECAL PROCHEM INCLUDES PARTS 6 7 amp 66 945424 1 KIT ADJ BRKT 73 WATER TANK DUAL WITH DEMAND PUMP OPTIONAL OVERALL DIMNSION 32 1 2 TALL 62 5 8 WIDE 15 1 2 DEEP 74 WATER TANK DUAL WITH DEMAND PUMP OPTIONAL PARTNO DESCRIPTION 5 E 66 945260 TANK DUAL SADDLE W DMD PUMP COMPLETE 66 945265 SINGLE SADDLE TANK W DMND PMP COMPLETE 1 50 501774 4 HOLD DOWN SADDLE TANK GRAY 2 87171 16 WASHER 3 8 FLAT 3 87163 16 WASHER 3 8 SPLIT LOCK 4 00 00072 16 SCR 3 8 16 X2 HXHD 5 11800432 4 CAP WATER BOX 6 1180004 2 ELL STREET 1 2 BR 7 12800278 4 FTTG BRB 1 2P X 34H BR 8 03 000113 4 CLAMP HOSE 12 SST 9 09 805456 1 HOSE WTR 3 4 X 96 10 11800085 1 TEE 1 2 BRASS 11 56 502000 2 ASSY BASE SADDLE TANK GRAY 12 58500661 2 MOLDING WATER TANK 13 11800168 2 PLUG 1 2 BRASS HXHD 14 50 500511 1
23. 2 800322 CONN 1 8P X COMP BR 12 56012 NIPPLE 1 4 FPT QD 13 14806512 STRAINER JET 50 MESH 14 17 803018 TIP SPRAY 9501 X 1 8P SST 15 17 803006 WASHER NYLON 16 17 803010 CONN 1 4P X 11 16 16M 17 17 803036 CONN 1 4FP X 11 16 16F BR 18 17 803078 TIP SPRAY 8001 SST 1 8 VJET 19 52501619 TRIGGER WD VALVE 20 52 502008BK BODY WD HDL 2 TB BK 21 52 502009 HOLD DN WD HDL 2 TUBE 22 52 502057 MANFOLD LEFT 23 52 502058 MANIFOLD RIGHT 24 56 502548 ASSY MNFLD S BEND 25 56502534 WD amp HD TITANIUM 26 61 950496 ASSY EXTRACTOR VALVE 27 16 808189 STEM EXTRACTOR VALVE 28 16 808190 SPRING EXTRACTOR VALVE 29 16 808228 SEAT EXTRACTOR VALVE 30 16808229 HLDR VLV STEM EXTRACTOR VL 31 43 810062 O RING 11410 2540D 32 43810063 O RING 55110 6910D 33 43 810064 BACK UP 250DIA 34 52 501590 BDY EXTRACTOR VLV 35 48 941462 DEC WD HD TITANIUM 48 941296 BLB INSPECTION QC PINK 63 lt 9 E gt 5 5 gt m i 2 X d a 64 WAND QUAD JET OPTIONAL REF PARTNO DESCRIPTION ae NOTES 89238 WAND TM QUW 95015 COMPLETE 89239 WAND QJW 9502 COMPLETE 89237 WAND QUW
24. 23 40033 H Barb 90 1 2 Barb x 3 8 MPT 24 40013 H Barb 1 2 Barb x 3 8 MPT 25 555 516 Red ADPT 3 4 MPT x 1 2 F 26 11 800354 Red Nipple 1 2 MPT x 3 8 MPT 27 11 800352 Tee 3 8 FPT 28 560 113 Filter Inline 1 2 TM 29 572 106 Clear Hose 1 2 ID 30 22011 Q C 3 8 FEM Closed 31 585 210 Clear Cover 6 C W Ring 32 590 404 PVC Hose Barb 1 33 597 065 Valve Diaphragm Auto Fill 34 860 305 F W Tank PD C W Holders 41 PROCHER MINI WATER TANK 42 SERIAL F DESCRIPTION FROM 87088 FW 5 8 S S 480 105 Clear Hose 1 4 ID 11 800276 Elbow 90 3 8 FPT 955 322 H Barb 90 1 4 Barb x 1 4 MPT 555 329 H Barb 90 1 2 Barb x 5 8 MPT 40013 H Barb 1 2 Barb x 3 8 MPT 555 516 Red ADPT 3 4 FPT x 1 2 FPT 11 800354 Red Nipple 1 2 MPT x 3 8 MPT 597 065 Valve Diaphragm Auto Fill 0 710 125 SMS 8 x 5 8 Pan ROB S S 1 993 225 208 Mini Water Tank 43 A HEAT EXCHANGER PARTS LIST 44 HEAT EXCHANGER SERIAL NO REF PARTNO DESCRIPTION FROM NOTES 1 555 114 Comp Fitting 3 8 x 3 8 2 555 164 Drain Cock 14 3 555 100 Comp Fitting 90 3 8 x 3 8 4 555 134 Coupling 3 8 5 555 432 Nipple Long 3 8 x 2 6 800 081 Cap 6 7 475 065 Gasket 7 14 Heat Exch 8 490 110 Casings Heat Exch 9 70018 Bolt 1 4 x 1 ss 10 87013 F Washer 14 ss 11 57245 Locknut 1 4 ss 12 485 100 Coil 3 8 x 25
25. 43810063 O RING 551 ID 691 OD 18 16 808228 SEAT EXTRCTR VLV 19 16 808189 STEM EXTRCTR VLV 20 43 810064 BACK UP 250DIA 21 43 810062 O RING 114 ID 254 OD 22 16 808190 SPRING EXTRCTR VLV 23 52 501590 BODY EXTRCTR VLV 5 48 941163 DECAL STAIR TL NOT SHOWN NOT SHOWN 1 66 808169 KIT REP WD VLV INCLUDES PARTS 16 19 amp 20 22 69 AA L OPTIONAL 7444 UPHOLSTERY UPHOLSTERY TOOL OPTIONAL UPHOLSTERY TOOL OPTIONAL REF PARTNO DESCRIPTION E NOTES 78513 1 UPHOLST 80015 COMPLETE 1 09 805131 2 HOSE VAC 1 1 4X10 BLU 2 08 805243 1 CUFF SWIV 1 1 4HX1 1 4T 3 10 805347 1 HOSE 3 16X119 1 2 1 8PX1 4FT 4 13 806023 1 DSC 1 8FC1 8FP SST 5 56 500639 1 UPHOLSTERY TL TRIGGER 6 00 000310 1 SCR 4 40 7 32 SHCS SS 7 04000282 1 SPRING VAC ADJ BUTT 8 52 501624 1 BUTTON VAC ADJ 9 52 501842 1 TOOL UPHOLSTERY INCLUDES PARTS 10 61 950570 1 ASSY UPHLST TL 52222222 11 560012 1 NIPPLE 1 4 NPT QD 12 17 803010 1 CONN 1 4P X 11 16 16M 13 17 803006 1 WASHER NYLON 14 14 806512 1 STRAIRNER JET 50MESH 15 17 803036 1 TCONN 1 4FPX11 16 16F BR 16 11 800404 1 1 4X5 SST 17 52 501585 1 COUPLER UPHLST TL 18 12 800065 1 CONN 1 8P X 1 4T 19 08 805138 1 CUFF 1
26. 48040 Key 1 4 x 1 8 9 840 030 Shaft outer housing 70584 Bolt 1 4 x 20 x 3 4 FH SOC 0 230 820 Shaft rear GM 1 230 830 Shaft rear Ford Not Shown 51 LAROS WIRING HARNESS ROUTING INLINE FUSE POWER DISTRIBUTION BOX CLUTCH NOTE KEEP THE WIRING HARNESS INSIDE VAN THROUGH FIREWALL AND DISTRIBUTE TO COMPONENTS IN THE ENGINE COMPPARTMENT DRANGE SERVO RED WHITEPOWER YELLOW CLUTCH RED POWER 52 LALA GLE ASI ELECTRIC WIRING P 1 GREEN 14 RED GREEN YELLOW 14 GA TEMP SENDER PURPLE 14 GA REEN 14 GA YELLOW 14 GA GREY 14 GA YELLDW 14 GAD RED 12 GAD ORANGE 14 GA BLACK 14 GA YELLOW 14 GA RED WHITE GA 53 ELECTRIC WIRING 2 MALE 12 PIN PLUG INSIDE VIEW GREY 14 ORANGE 14 GAD BROWN 14 GA RECOVERY TANK SWITCH BLACK 14 GA GREEN 14 GA RED WHITE 414 GAD WHITE 14 GAD 20 AMP FUSE RED GAD PUMP DUT PUMP PUMP CLUTCH POWER DISTRIBUTION BOX PURPLE 14 GA PTO CLUTCH YELLOW 14 GA YELLOW 14 GA FROM WIRING HARNESS PARK BRAKE PURPLE 14 GA RELAY POST NUMBERING 54 LANDMAN YELLOW 14 GA FROM WIRING HARNESS 55 PARK BRAKE WIRING PTO CLUTCH YELLOW 14 GA PARK BRAKE PURPLE 14 GA RELAY POST NUMBERING 22 05 2003 ul LU LU Y O I 5
27. 56501960 1 BASE HOSE RL 250 5 56502207 1 BRKT LOCKOUT HOSE REEL 6 61 950854 1 LATCH ASSEMBLY 7 02 000066 2 FLATWASHER 1 4 8 87162 2 WASHER 1 4 SLPIT LOCK 9 70270 2 SCR 1 4 20 X 3 4 HHCS PLTD 10 57031 2 5 16 18 HEX 11 56501968 1 REEL HP HOSE GRAY 12 45 802138 2 BEARING HOSE REEL 13 02 000143 4 FLATWASHER 5 16 14 87083 4 WASHER 5 16 SPLIT LOCK PLTD 15 70302 4 SCR 5 16 18 X 1 HHCSGRBPLT 16 44 802122 4 FLANGE 47MST 17 56501961 1 BODY HP HOSE GRAY 18 00 000072 10 SCR 3 8 16 X gt HXHD 19 50 500511 1 PLATE INSTALL MT 20 87171 10 WASHER 3 8 FLAT 21 57119 10 NUT 3 8 16 HEX NYLOCK 22 55 501789 1 PIN LOCK HOSE REEL 23 50 501812 1 BRKT HOSE REEL LOCK 24 04 000302 1 SPRING LOCK LOCK PIN ASSY 25 04 000303 1 CLIP RETAINER LOCK PIN ASSY 79 PROCHEM New Truck Mount Machine Caste Rock Industries company Limited Warranty warrants new machines against defects in material and workmanship under normal use and service to the origina purchaser Any statutory implied warranties including any warranty of merchantability or fitness for a particular purpose are expressly limited to the duration of this written warranty PROCHEM will not be liable for any other damages including but not limited to indirect or special consequential damages arising out of or in connection with the furnishing performa
28. 6 HOSE ACCESSORIES REF PARTNO DESCRIPTION pisc NOTES 1 12 800078 1 FITTING BRB 2H BS PVC 2 08 805147 2 CUFF 2 3 10 805060 1 HOSE 250 W CUFFS amp HOSE 4 56015 1 NIPPLE 1 4 HEX 5 22015 1 COUPLER 1 4 QD 6 56012 1 NIPPLE 1 4 QD 7 10 805108 1 HOSE HP 1 4 X SOFT W QD amp VLVE 8 10 805077 1 HOSE HP 1 4 X 50 9 08 805155 2 GUARD HOSE VINYL 10 15808012 1 VALVE BALL 1 4FP 11 43 810014 2 O RING 773210 X 1173200 12 43810019 2 O RING 3 8 ID X 1 2 OD 13 11 800354 1 NIP 1 2 X 3 8 HEX BR 14 10 805157 1 HOSE WATER 1 2 X 50 15 13 806009 1 DISCONNECT 3 8M X 3 8FP 16 10 805295 1 HOSE WATER 1 2 X 50 17 22015 1 COUPLER 1 4 QD 18 10 805077 1 HOSE HP 1 4 X 50 19 08 805155 2 GUARD HOSE VINYL 20 56012 1 NIPPLE 1 4 FPT QD 21 10 805122 1 HOSE HP 1 4 X SOFT 57 AUTOMATIC PUMPOUT OPTIONAL P 1 17 18 980185 11 30 04 58 AUTOMATIC PUMPOUT OPTIONAL REE PARTNO DESCRIPTION 7 NOTES 1 70105 4 SCR X 60 PH 2 00 000132 2 608 1 4 20 X 1 1 2 HXHD 3 57006 4 NUT 1 4 20 HEX 4 87162 4 WASHER 1 4 SPLIT LOCK PLTD 5 02 000066 4 FLATWASHER 1 4 6 03 000176 4 CLAMP HOSE 16 7 09 805591 1 HOSE WASTE PUMP 8 8 10 805484 1 HOSE GARDEN 3 4
29. ASS LOOP WASTE TANK WATER PUMP PRESSURE CHEMICAL INJECTION REGULATOR Mi SOLUTION OUTLET HEAT EXCHANGERS COOLANT ROUTE COOLANT RETURN gt COLD WATER oer 2 Optional Post Heat OPERATION With the Optional Post Heat the cleaning solution goes to a second stage of plumbing and heating which takes place in the heater core located just after the vacuum pump This is the hottest point of exhaust air coming from the vacuum pump The hot exhaust air is forced through the post heat core creating the second stage of heat transfer to the cleaning solution WATER TANK BYPASS WASTE TANK WATER PUMP PRESSURE CHEMICAL INJECTION POST HEAT COIL SOLUTION OUTLET COOLANT RETURN ROUTE 0 gt renes 11 HEAT EXCHANGER TROCHE COOLANT HOSE ROUTING 5 8 Y INSTALLED INTO 3 4 HEATER CORE LINE RUN ALONG TOP OF FRAME RAIL COOLANT MANIFOLD S S Y INSTALLED INTO TOP RAD HOSE NOTE USE 3 TUBE CLAMPS AND TIE STRAPS TO PREVENT HOSES FROM DROPPING OR COMING IN CONTACT WITH HOT SURFACES OR MOVING PARTS 13 SILENCER SYSTEM OPERATION CHEMICAL INJECTION SYSTEM The chemical injection system utilizes the natural inlet draw of the high pressure pump to move the chemical into the main pressure stream The chemical is picked up from the container and fed through the flow meter at a desired amoun
30. ATE BLOWER AND PUMP SERIAL NO REF PARTNO DESCRIPTION FROM NOTES 1 263 205 HP Hose Assy 3 8 x 43 2 315 009 Conduit Plastic 1 4 3 325 230 Terminal Ring 10 Blue 4 325 300 Power Lock Terminal Black 5 325 315 Power Lock Terminal Green 6 7 8 325 320 Power Lock Insert 358 906 Blower 47 Whispair Urai 360 220 Tach Sender 9 36 900141 Cat Clutch 2 GRV 7 20MM 10 380 550 Keystock 1 4 11 385 015 Bushing H 7 8 12 385 016 Bushing H 1 13 385 118 Pulley 2BK40H 14 385 119 Pulley AK44H 15 385 171 Pulley 7 75 O D 16 385 525 Bearing 1 Flange Complete Unit 17 44 802311 Belt AX29 18 397 039 Belt BX32 19 57111 Nut 3 8 x 16 Zinc 20 57031 Hex Nut 5 16 Zinc 21 57090 Locknut 10 x 32 Nylon SS 22 400 151 Locknut 12 x 1 25 Nylon 23 70266 Bolt 3 8 x 1 GR5 Zinc 24 405 110 Bolt 3 8 x 1 1 4 GR5 Zinc 25 405 396 Bolt 12MM x 35MM 1 25 26 70088 MS 10 32 x 1 2 Panphil SS 27 87163 LW 3 8 Zinc 28 87083 LW 5 16 Zinc 29 87171 FW 3 8 Zinc 30 02 000143 FW 5 16 Zinc 31 425 114 Muffler Clamp 3 32 425 140 Clamp Tube 3 4 33 425 180 O Clamp 19 32 34 465 090 Brkt Grease Line Blower 35 465 091 Brkt Grease Line F Bearing 36 465 092 Brkt Blower Belt Guard Roots 37 465 680 Brkt Pump Baseplate 38 480 100 Tubing 1 8 Nylon 39 480 105 Tubing 1 4 Nylon 40 790435 C
31. EM factory Use Of Parts Not Approved By PROCHEM Will Void All Warranties PROCHEM reserves the right to change its warranty policy without notice 1 PROCHEM 2 a Castle Rock Industries company 1351 W Stanford Ave 7 303 762 1800 800 444 7654 7 FAX 303 865 2800
32. R VL 26 43 810063 O RING 551 ID 691 OD 27 16 808228 SEAT EXTRCTR VLV 28 16 808189 STEM EXTRCT VLV 29 43 810064 BACK UP 250DIA 30 43810062 O RING 11410 25400 31 16808190 SPRING EXTRCTR VLV 32 52501590 BODY EXTRCTR VLV 48 941166 DECAL WD HD NOT SHOWN NOT SHOWN 66 808169 KIT REP WD VLV INCLUDES PARTS 25 27 amp 29 31 67 lt E lt 6 68 STAIR TOOL OPTIONAL REF PARTNO DESCRIPTION SENA NOTES 78519 TL STAIR LNG TM DJ 80015 COMPLETE 78521 TL STAIR SHT TM 80015 COMPLETE 56 501715 WAND amp HEAD STAIR TL 1B 56 501907 WAND amp HEAD SHRT STAIR TL 2 52 501576 BODY WD HDL PORT 3 62 501577 HOLD DOWN WD HDL PORT 4 04 000053 TIE CABLE 8 WHT 10 805330 HOSE 3 16X13 3 4 1 8PX1 4 5B 10 805397 HOSE 3 16X7 1 2 1 8P X 1 4F 6 17 803002 TIP SPRY 9502X1 8P SST 7 00000282 SCR 1 4 20 X 1 1 4 SOC 8 12 800060 CONN 1 4P X 141 BR 9 00 000317 SCR CAP 10 32X1 1 4 SOCH 10 57090 NUT 10 32 HEX NYLOCK SS 11 61 950496 ASSY EXTRCTR 12 56015 NIPPLE 1 4 HEX 13 56012 NIPPLE 1 4 FPT QD 14 52 501619 TRIGGER WD VLV 15A 09 805359 SLEEVE WD HDL 9 5 158 09 805504 SLEEVE STAIR TL HDL 7 1 8 16 16808229 HOLDER VLV STEM EXTRCTR VL 17
33. TION Interior Lights This switch controls the spot lights located in the van cargo area Waste Pumpout Switch This switch controls the Optional auxiliary pump to empty the waste collection tank automatically A float located inside the tank automatically turns off and on when the solution level reaches a certain point Solution Outlets The solution outlets are the connecting points for the high pressure hoses These outlets have quick disconnects that allow hoses to be plugged into the unit Water Inlet This quick connect allows water supply hose to be connected to the unit Oil Cup The oil cup allows lubricant spray to reach the vacuum blower Waste Tank Pumpout Outlet This port is filled with a chrome plug unless the Optional Waste Pumpout has been installed then there will be a garden hose fitting to attach a hose to Flow Meter The flow meter is a gauge to indicate how much liquid chemical is being introduced in the water system Turning the knob on the flow meter clockwise can increase the quantity Solution Pump Prime This valve is used to purge the system when air is slowed to enter Example empties chemical container or empty water storage tank Open and close valve with chemical flow meter open and adequate water supply When solution pressure gauge indicator needle remains stable all air has been evacuated Water Pumping and Heat Transfer System Cold water enters the panel through the wate
34. Turn off Unit and Pump switch 4 Disconnect all hoses and tools 5 Drain waste tank and rinse with clean water DE FLOODING OPERATIONS De flooding operations involve removal of water from carpet and flooring This differs from normal cleaning operations in that no water or solution is required An automatic waste pump out is highly recommended for all de flooding operations due to the large amount of water removal often required 1 Start unit in Carpet Mode 2 Leave Pump switch OFF 3 Begin de flooding operations 18 OPERATION FREEZING PROTECTION 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 While in operation avoid long shutdowns as the vehicle provides heat while running WINTERIZING YOUR UNIT Drain fresh water tank by opening the ball valve 1 Close ball valve 4 Place hose 3 into container of 100 glycol base antifreeze Place chemical feed hose 6 into container of antifreeze open flow meter valve Open ball valve 3 Place primer hose into empty container Turn main switch to Upholstery Mode and pump switch to the ON position Open ball valve on primer hose until antifreeze comes out then turn the primer hose valve off and on for another 30
35. adding petroleum oil to synthetic oil is NOT recommended 1 Check the oil level daily to assure the proper level PROPER LEVEL cannot be overemphasized Too little oil will ruin bearings and gears Too much oil will cause overheating Use the illustration as a guide when adding oil 2 To prevent rust from building up inside the vacuum pump if moisture exists we have provided a lubrication cup on the front of the unit First run the unit at least 1 minute to remove any moisture from the vacuum pump Next fill the lubrication cup with WD 40 or a similar lubricant for 5 seconds while the unit is running and the vacuum inlets are sealed Do this at the end of each working day 23 MAINTENANCE 3 Drain flush and replace oil every 1500 hours or yearly whichever comes first Change oil more frequently if inspection so indicates With AEON PD synthetic lubricant perform the oil change maintenance every 4000 hours or every 2 years whichever comes first 4 Vacuum pump lubrication is vital to performance of our pump Failure to follow the maintenance schedule in the Maintenance Schedule can lead to permanent damage to your blower WATER PUMP 1 Check the crankcase oil level daily to assure the proper level Use the illustration as a guide when checking the oil level If the level has dropped check for the source of leakage and repair 2 Change the crankcase oil with Cat Pump Crankcase Oil after the first 50
36. andwheel Cross FM 19 445 050 Hasp 20 475 135 Gasket Filter Basket Lid PD 21 475 140 Gasket Vacuum Lid PD 22 498 023 Grommet 5 16 x 1 23 498 032 Plug 24 550 035 Check Valve 1 4 FM x FM 25 31021 Elbow 45 Street 1 4 26 030 16 Elbow 90 1 4 Street Extruded 27 40042 H Barb 90 1 2 Barb x 1 4 MPT 28 560 206 Filter 3 All SS 29 560 360 Filter Basket PD 30 572 032 Hose Blower 3 31 572 134 Heater Hose 1 2 Blue Hi Miler 32 590 408 PVC Hose Barb 3 33 620 406 Vacuum Relief Assy PD 34 860 300 Rec Tank PD 39 y 2 NOILNTOS H3LVM HS344 WATER TANK SERIAL NO REF PARTNO DESCRIPTION FROM NOTES 1 57111 Nut 3 8 x 16 Zinc 2 57245 Locknut 1 4 x 20 Nylon SS 3 405 009 Bolt 1 4 x 3 4 SS 4 70070 Bolt 3 8 x 2 SS 5 410 251 Tek Screw 3 16 x 3 4 SS 6 87163 LW 3 8 Zinc 7 87013 FW 1 4 SS 8 87003 FW 3 8 SS 9 87088 FW 5 8 SS 10 425 004 Clamp Gear 1 11 475 125 Gasket 6 Access Cover Clear 12 480 010 PVC Tubing 1 4 ID Clear 13 499 005 Trim 1 2 Black 14 545 020 Ball Valve 3 8 15 545 036 Ball Valve 1 16 555 004 ADPT 3 8 M x 3 8 F 17 11 800523 Close Nipple 1 18 11 800276 Elbow 90 3 8 FPT 19 31026 Elbow 90 3 8 Street Extruded 20 11 800102 Hex Nipple 3 8 21 555 320 H Barb 90 1 4 Barb x 1 8 MPT 22 56013 H Barb 90 3 8 Barb x 1 4 MPT
37. at Pump Model 5CP2120W 41 516 210 Shaft Protector 42 545 012 Ball Valve 1 4 36 43 550 030 Check Valve 1 8 FPT 44 550 040 Check Valve 1 2 FM x FM 45 551 070 Thermal Valve 3 8 NTP 140F 46 11 800109 Bushing 1 2 MPT x 3 8 FPT 47 555 104 Comp Fitting 1 8 x 1 8 Male 48 555 106 Comp Fitting 1 4 x 1 8 MPT 49 11 800341 Elbow 45 3 8 Street Extruded 50 31028 Elbow 90 1 8 Street Forged 51 030 16 Elbow 90 1 4 Street Extruded 52 31026 Elbow 90 3 8 Street Extruded 53 555 254 Ferrule 3 8 Hose 54 11 800022 Hex Nipple 1 8 55 11 800102 Hex Nipple 3 8 56 40043 Hose Barb 90 3 8 Barb x 3 8 MPT 57 40011 Hose Barb 1 4 Barb x 1 8 MPT 58 40014 Hose Barb 3 8 Barb x 1 4 MPT 59 12 800345 Hose Barb 5 8 Barb x 3 8 MPT 60 12 800269 Hose Barb 5 8 Barb x 1 2 MPT 61 555 406 Locknut 1 8 Brass 62 66017 Plug 1 4 MPT Hex 63 555 454 Plug 3 8 MPT Hex Head 64 04066 Reducing Adpt 1 4 FPT x 1 8 MPT 65 555 520 Reducing Bushing 1 8 F x 1 2 66 11 800354 Reducing Nipple 1 2 MPT x 3 8 MPT 67 11 800352 Tee 3 8 FPT 68 555 642 Tee 3 8 Street Extruded 69 555 660 Union Coupling 3 8 70 555 914 Comp Fitting 1 4 x 1 8
38. ews that you use a clockwise pattern and continue until proper torque is achieved TORQUE VALUES COMPONENT INCH LBS FOOT LBS Rear PTO Hub 300 25 Vacuum Pump Hub 300 25 5 Check for pulley groove wear clean belts and pulley grooves check for worn belts proper belt tension and pulley alignment after the first 25 hours and then again at 100 hours Check for belt ride in the groove PRESSURE REGULATOR Lubricate the o rings and bullet every 50 hours Use o ring lubricant For the procedure see the General Service Adjustments section in this manual for details VACUUM HOSES To assure maximum hose life we recommend that the hoses be washed out with clean water at the end of each working day HIGH PRESSURE HOSES Inspect your high pressure hoses for wear after the first 100 hours of use Inspect every 25 hours thereafter If hoses show any signs of damage or impending rupture replace the hose AWARNING DO NOT attempt to repair high pressure hoses Repairing high pressure hoses may result in severe burns and serious injury All high pressure hoses must be rated for 3000 PSI at 250 deg F Thermoplastic hoses do not meet these specifications and should not be used Severe burns and injury may result if the hoses do not meet these requirements OPTIONAL WASTE PUMP OUT At the end of each work day make certain that you remove any debris or sediment which may be inside the wa
39. he tachometer shows the rpm of the vacuum pump and the hour meter records the number of hours the unit has run This serves as a time recorder for servicing the machine Solution Pressure Gauge This gauge registers the amount of pressure in the system Solution Temperature Gauge This gauge measures the temperature of the cleaning solution as it exits the machine Vacuum Gauge This gauge indicates in inches of mercury how much the vacuum system is producing at any given time Solution Temperature Control This valve allows the operator to control the solution temperature by adjusting the valve from cold to hot Pressure Control Regulator The pressure regulator sets the pressure of the solution system This spring loaded valve can be adjusted up or down setting the pressure of the unit by turning the knob clockwise The pressure is increased or reduced by turning the valve counter clockwise This valve must be maintained in accordance with this manual maintenance table Carpet Upholstery Mode Switch This switch serves to energize the magnetic clutch to turn the PTO and set the engine speed for the desired operation of cleaning Turning the switch to the Upholstery Mode for lower speed and turning the switch to Carpet Mode for higher speed of the vacuum pump Solution Pump Switch This switch serves to energize the magnetic clutch to turn the water pump on or off 10 11 12 13 14 15 16 OPERA
40. his unit without the filter installed in the waste tank Keep your vehicle work area clean Wands stair tools and other accessories must be securely fastened before driving the vehicle All high pressure hoses must be rated for 3000 PSI at 250 deg F Thermoplastic hoses do not meet these specifications and should not be used Severe burns and injury may result if the hoses do not meet these requirements Make certain that you receive complete training by the distributor from whom you purchased this unit This unit uses high pressure and temperature Improper or irresponsible use may result in serious injury Do not modify this unit in any manner Improper modification can cause severe personal injury or fatality TECHNICAL SPECIFICATIONS ITEM DIMENSION CAPACITY Engine speed 1450 rpm high speed Water Pump ON Water pump rpm 850 rpm Vacuum pump rpm 2850 rpm Water flow rate 4 GPM maximum Water pump pressure low pressure 1000 PSI maximum Vacuum relief valve 14 Hg Waste tank capacity 120 gallons Console weight with waste tank 800 lbs JET SIZING Recommended floor tool tip sizing not exceed a total of 045 Using larger jet sizes on your cleaning unit may reduce cleaning temperatures Example Tri jet wand uses three 95015 jets 95 deg spray angle w 015 orifice 015 x 3 045 Upholstery tool jet size 80015 Stair tool jet size 9502 NOTES Tachometer Hour Meter T
41. ld fill a gallon container about every 17 seconds water box from the pressure regulator Examine the check valves plunger cups and cylinder head on the water pump Repair whenever required refer to the water pump service manual Defective water pressure gauge Replace gauge Orifice spray nozzle in the cleaning tool is worn defective or wrong size Replace Nozzle or change nozzle size Debris clogging water lines or water inlet disconnect Clean or replace as needed Belts loose or broken Loss of pump prime Re tension or replace as needed Manually prime water pump Loss of solution volume at cleaning tool orifice Water gauge reads normal Plugged orifice and or screen in the cleaning tool Unplug or replace orifice and or screen Internal block between the pressure regulator manifold and the outlet Y strainer or the Y strainer screen is clogged Inspect all lines remove accumulated debris which is blocking proper flow Replace any defective hoses Remove inspect and clean the Y strainer screen De scale unit and install a water softener if necessary Defective quick connect on one or more of the high pressure hoses Replace defective quick connects s on high pressure hoses s Cleaning tool valve is malfunctioning Repair or replace valve Hose inner lining is constricted Remove restriction or replace hose Air leak in chemical s
42. nce use or inability to use the machine This remedy shall be the exclusive remedy of the buyer The warranty period is subject to the conditions stated below Any local or distant transportation related service labor normal maintenance and diagnostic calls are not included Parts replaced or repaired under this warranty are guaranteed for the remainder of the original warranty period or 90 days Coverage Responsibility Length of Warranty Gasoline Engine Engine Dependant 1 year Briggs amp Stratton 1 800 233 3723 Nissan Contact Customer Care Kohler 1 800 655 4356 Gardner Denver 1 800 982 3009 Heat Exchanger Water Pump Waste Pump Wands except shut off valve and jets Waste and Water Tanks Pressure Regulator All other component not excluded Battery Pro rated through battery manufacturer s 1 year local dealer 800 423 6569 When applicable Product exceptions and Exclusions e Normal wear items and maintenance items including but not limited to disposable filters any fluids electrical components belts pulleys bearings fittings hoses o rings seals gaskets diaphragms engine tune up components wand shut off valve and jets are covered parts only for 90 days e NOTE Engine warranty is administered through the engine manufacturer and must be repaired at an authorized service center This Warranty Shall Not Apply To 1 Any product that has been subject to abuse misuse neglect or unauthorized
43. nnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present When disconnecting the battery ALWAYS disconnect the negative terminal FIRST DO NOT smoke around the unit Gas fumes may accumulate and be ignited The battery is also extremely flammable This will prevent possible explosions DO NOT damage the vehicle in any manner during installation When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle Avoid any contact with moving parts areas of high temperature brake lines fuel lines muffler catalytic converter or sharp objects DO NOT exceed your vehicle s weight limit The console with waste tank and accessories weights approximately 800 lbs Make certain to account for any additional accessories in your weight and balance calculations Make certain that the vehicle has the correct axle rating This will prevent unsafe vehicle driving conditions We require high back seats on all vehicles in which units are to be installed for head and neck protection We recommend using a metal partition between the seats and equipment DO NOT operate this unit without the water supply attachment and turned on The water pump and other vital components may be seriously damaged if this unit is permitted to operate dry without water DO NOT operate t
44. ont of console for 5 sec Water Pump Daily Check oil level Fill to proper level Solution Inlet Tube Strainer Daily Check strainer for blockage remove any debris Vacuum Inlet Filter In Waste Tank Daily Clean filter inspect replace if damaged Vacuum Hoses Daily Wash out with clean water Automatic Waste Pump Daily Inspect and remove any debris or sediment Chemical Filter Daily Inspect daily Vacuum Pump Weekly Check oil level Fill to proper level Water Tank Float Valve Weekly Check for proper seating and shut off Water Pump Inlet Filter Weekly Check for debris and clean Pressure Regulator 50 hrs Lubricate o rings Pressure Regulator 50 hrs Lubricate plug behind spring PTO Shaft 50 hrs Grease v joints High Pressure Hoses 100 hrs Inspect for damage or impending damage Van Engine 100 hrs Change engine oil Van Engine 100 hrs Change oil filter Van Engine 100 hrs Check fan belt tightness Van Battery 100 hrs Clean battery terminals Float Valve Seal 200 hrs Replace seal 21 MAINTENANCE SERVICE SCHEDULE Water Pump 500 8 Change oil Pulley Set Screws amp Hub Cap Screws 500 hrs Check for proper torque valves Re torque if required Drive Pulley 500 hrs Inspect clean and check for pulley groove wear Drive Pulley 500 hrs_ Check pulley alignment Drive Belts 500hrs Inspect and clean Drive Belts 500 hrs Check belt
45. r inlet When the water tank is full the valve will automatically shut off Water then flows from the water tank through a strainer into the water pump where chemical is introduced at this point Then it is pumped to the pressure regulator that provides and maintains the desired pressure setting A certain amount of water is by passed from the pressure regulator due to over pumping capacity of the water pump Water that is not called for in the cleaning process is channeled to the by pass coil in the recovery tank then flows to the inlet side of the pump to be circulated again The heating stage occurs when the water leaving the pressure regulator and directed to the first of two heat exchangers Heat from the vehicle engine coolant is exchanged to the cleaning solution spiraled copper tubing This allows the engine coolant to travel in a counter rotating direction to the cleaning water during the exchange process creating a very efficient transfer of heat out of the engine and into the cleaning solution The hot solution then exits the second heat exchanger where it enters the outlet manifold The manifold serves as a sensing point and connection for the high pressure hoses Finally the cleaning solution then passes through pressure hoses and is distributed by the cleaning tool to a surface that is being cleaned completing the water pumping and heating cycle of the cleaning unit 10 OPERATION WATER TANK BYP
46. ste pump by pumping fresh water through the pump 25 MAINTENANCE ENGINE COOLANT REPLACEMENT Annually the coolant in the Vehicle Engine should be replaced This coolant is an integral part of the heating system and needs to be maintained as any other working part of the system We recommend that this procedure be accomplished by the following steps DRAINING COOLANT 1 Remove one end of Heater core Y Open Heat Exchanger Petcock s NOTE Be sure that used coolant is collected in a proper container and disposed of in accordance with local laws REPLACING COOLANT 1 Fill radiator with 60 40 anti freeze water mix 2 Start unit at idle 3 As the unit warms up maintain a full radiator with a 60 40 mix 4 Open petcocks slightly on Heat Exchanger to allow any trapped air to escape When coolant runs out of Heat Exchangers close petcocks 5 Fill radiator with 60 40 coolant mix 6 Re install radiator cap 7 Shutdown unit Check radiator overflow bottle Add coolant to proper cold level WATER PUMP DRIVE BELT To tighten the water pump belt 1 Loosen the nuts which hold the water pump mount to base 2 Adjust the position of the belt tension adjusting bolt until the proper belt tension is achieved 1 2 deflection in the center of the belt halfway between the pulleys 3 While checking the alignment tighten the nuts which hold the water pump mount to base WASTE TANK STRAINER
47. t of chemical which is adjusted through the metering valve The chemicals and water are mixed in the high pressure pump and then forced through the heat exchangers and outlet manifold where then it is distributed to high pressure hoses out to the cleaning tool FLOWMETER 4 e INLET STRAINER CHEMICAL CONTAINER gt gt gt 15 OPERATION VACUUM SYSTEM The PTO turning an air pump generates vacuum The air is channeled in one side of the vacuum pump compressed and discharged on the opposite side creating airflow The movement of air is used to do the work necessary for the extraction process A vacuum nozzle applied to the carpet surface removes moisture dirt and spent chemicals These elements are conveyed back to the waste tank using a series of changes in direction and velocity The air is then filtered and rushes into the vacuum pump The vacuum pump compresses and heats the incoming air The hot discharged air is forced down stream into a silencer for noise abatement Finally the hot air is exhausted outside VACUUM RELIEF VALVE FILTER VACUUM WASTE TANK PUMP SILENCER STRAINER LUBE CUP 7 VACUUM GAUGE 16 PRE RUN INSPECTION Note Operation of this unit is simple However only trained personnel should proceed AWARNING Operate this unit and equipment only ina well ventilated area Exhaust fumes contain carbon monoxide which is an
48. upply line metering valve Check for air leaks Replace faulty parts 27 MAINTENANCE PROBLEM CAUSE SOLUTION Loss of vacuum While cleaning the vacuum is not up to specification Engine RPM is normal Excessive Vacuum Loss of chemical With the cleaning tool valve open no chemical Vacuum gauge is giving an improper reading Examine the tubing between the vacuum relief valve and the vacuum gauge and remove any blockage Vacuum hose s is damaged causing a suction leak Inspect hose s repair or replace Waste tank gaskets not sealing properly not positioned properly Inspect the gasket Repair seal or replace Re position lid s Plugged vacuum hose or vacuum plumbing between vacuum inlet and strainer basket Unplug vacuum hose or inlet plumbing Waste tank filter or strainer basket is plugged Clean or replace filter Clean strainer basket Loose vacuum pump drive belts Tighten the drive belts Waste tank drain valve is damaged or left open causing a vacuum leak Drain the waste tank Close drain valve if open Remove the dump valve ana after inspecting replace the defective components Vacuum relief valve requires adjustment or has a vacuum leak due to damaged diaphragm Re adjust the vacuum relief valve If the vacuum does nat increase remove and inspect the relief valve diaphragm If damaged replace Improper throttle
49. ving parts Rotating machinery can cause injury or fatality Never operate this unit without belt guards or hoods The high speed moving parts such as belts and pulleys should be avoided while this unit is running Severe injury damage or fatality may result DO NOT service this unit while it is running The high speed mechanical parts as well as high temperature components may result in severe injury or severed limbs Never touch electrical wires or components while the engine is running They can be sources of electrical shock Before servicing this unit allow it to cool down This will prevent burns from occurring Water under high pressure at high temperature can cause burns severe personal injury or fatality Shut down machine allow to cool down and relieve system of all pressure before removing valves caps plugs fittings filters and bolts Always wear hearing protection when unit is running Always comply with local noise ordinance when operating units 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 disco

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