Prochem Everest CARB User Manual

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Page 1

Operating Instructions (ENG)

MODELS: EVEREST LP

EVEREST HP

980086 03/22/06

Read instructions before operating the machine.

Page 2

MACHINE DATA LOG/OVERVIEW

YOUR DEALER

ADDRESS: _______________________________________________________________________________________________

MODEL _______________________________________ DATE OF PURCHASE __________________________ SERIAL NUMBER ______________________________ SALES REPRESENTATIVE # _____________________

NAME: _________________________________________________________________________________________________

PHONE NUMBER: _________________________________________________________________________________________

Welcome…and congratulations on the purchase of your Mobile Cleaning Unit. This instruction manual is a guide for operating and servicing your unit. Read this manual completely before installing or operating this unit. This unit offers you personal convenience. All of your instrumentation and controls have been positioned to give you easy access for operation and daily maintenance.

Proper operation and service are essential to the efficient functioning of this unit. When maintained correctly, this unit will have a long, trouble-free life.

The service methods described in this manual are explained in such a manner that servicing may be performed accurately and safely. Proper service varies with the choice of procedure, the skill of the mechanic, and the tools or parts available. Before attempting any repair, make certain that you are thoroughly familiar with this equipment and are equipped with the proper tools. Any questions pertaining to operating or servicing this unit should be directed to your nearest dealer.

THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCORDANCE WITH THE PRESCRIBED INSTALLATION PROCEDURES.

MAKE CERTAIN THAT THE WARRANTY CARD IS FILLED OUT AT THE TIME OF INSTALLATION AND IS RETURNED TO YOUR DEALER.

PROFESSIONAL CHEMICALS CORPORATION 325 SOUTH PRICE ROAD CHANDLER, ARIZONA 85224

Information in this document is subject to change without notice and does not represent a commitment on the part of Professional Chemicals Corporation.

EVEREST 980086 02/18/03

Page 3

TABLE OF CONTENTS

Machine Data Log/Overview..........................1

Table of Contents...........................................2

Receiving Your Unit.......................................4

HOW TO USE THIS MANUAL

How to use this Manual..................................1-1

SAFETY

Safety Instructions.........................................2-1

Hazard Intensity Level...................................2-3

OPERATION & SYSTEMS

Technical Specifications................................3-1

Installation Requirements..............................3-2

Fuel Requirements.........................................3-2

Engine Oil Requirements...............................3-2

Chemicals & Water........................................3-3

Water Pumping and

Components.................................................3-4

Heat Transfer Systems................................3-8

Chemical Injection System..........................3-11

Vacuum System...........................................3-12

Pre-run Inspections......................................3-13

Priming the Chemical Pump........................3-14

Waste Pump................................................3-14

Cleaning.......................................................3-14

Upholstery Cleaning.....................................3-15

Shutdown and Daily Maintenance(LP)........3-15

High Pressure System.................................3-15

High Pressure Shutdown & Return to Low

Pressure.......................................................3-16

De-flooding Operations................................3-16

Freezing Protection......................................3-16

Winterizing Your Unit...................................3-17

Removing Anti-freeze from Unit...................3-18

MAINTENANCE & SERVICE

Maintenance

Maintenance Schedule............................4-1

Key Maintenance Checkpoints ...............4-3

Engine......................................................4-4

Vacuum Pump.........................................4-5

Water Pump .............................................4-6

Vacuum Inlet Filter...................................4-6

Vacuum Relief Valve...............................4-6

Vacuum Drive Belts, Pulleys And Hubs..4-6

Water Pump Drive Belt............................4-7

Float Valve (Water Box)..........................4-7

Waste Tank Strainer Basket...................4-7

Y-Strainer (Outlet)...................................4-7

Check Valve (Outlet)...............................4-7

Chemical Pump.......................................4-7

Chemical Simulator Valve.......................4-7

Nitrogen Accumulator..............................4-8

Pressure Regulator..................................4-8

Vacuum Hoses ........................................4-8

High Pressure Hoses..............................4-8

Optional Waste Pump-out.......................4-8

Engine Coolant Replacement.................4-8

General Service Adjustments

Engine Speed..........................................4-9

Check Valve (Solution Outlet).................4-11

Chemical Pump.......................................4-11

Packing Nut Adjustment (Chemical Metering & Selector Valves)..4-12

Pressure Regulator..................................4-12

Adding/Draining Engine Coolant.............4-12

Troubleshooting.......................................4-13

EVEREST 980086 02/18/03

Page 4

PARTS LIST

Framework...................................................5-1

Side Panel, Right..........................................5-5

Side Panel, Left............................................5-7

Chemical Panel............................................5-9

Control Panel................................................5-11

Engine..........................................................5-13

Engine Governor..........................................5-19

Engine Coolant.............................................5-21

Vacuum Blower............................................5-23

Water Pump-PP...........................................5-25

Water Pump-PPHP......................................5-27

Vacuum/Exhaust Heat Exchanger

And Silencer.................................................5-31

Solution Temperature Control Valve...........5-33

Heli-Coil Heat Exchanger............................5-35

Solution Outlet..............................................5-37

Water Box-PP .............................................5-39

Water Box-PPHP.........................................5-41

Pressure Regulator Manifold-PP.................5-43

Pressure Regulator Manifold-PPHP............5-45

Waste Tank –80 Gal. & 100 Gal..................5-47

Hose Accessories ........................................5-49

Battery-Floor Mount.....................................5-51

Automatic Pumpout (Optional).....................5-53

Wand- Titanium Six Jet (Optional)...............5-57

Wand - Quad-Jet (Optional).........................5-59

Wand – Tri-Jet (Optional)............................5-61

Stair Tool (Optional).....................................5-63

Upholstery Tool (Optional)...........................5-65

Shelf Assembly (Optional)...........................5-67

Water Tank, Dual With

Demand Pump (Optional)............................5-69

Water Tank-Demand Pump (Optional)........5-71

Hose Reel (Optional)...................................5-73

Wiring Diagram............................................5-75

Hose Diagram-PP........................................5-76

Hose Diagram-PPHP...................................5-77

Warranty ......................................................5-78

TABLE OF CONTENTS

EVEREST 980086 06/26/03

Page 5

RECEIVING YOUR UNIT

ACCEPTANCE OF SHIPMENT

Every part of your cleaning unit was carefully checked, tested, and inspected before it left our manufacturing plant. Upon receiving the unit, make

the following acceptance check:

1. The unit should not show any outward signs of

damage. If damaged, notify the delivering carrier immediately.

2. Check your equipment and packing list. The cleaning unit should arrive equipped with the following items (unless otherwise specified).

NOTE: Your distributor 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.

EQUIPMENT LIST:

1. Console.

2. Waste tank

3. Hose clamps for vacuum hoses.

4. 150 ft. of 2” vacuum hose.

5. 2 vacuum hose connectors.

6. 150 ft. of 1/4" high pressure hose with quick

connects.

7. 50 ft. water supply hose with quick connect.

8. Installation bolting kit.

9. Installation mounting plates.

10. Operation and service manual for engine, water

pump, and vacuum pump manuals.

EVEREST 980086 12/31/02

Page 6

HOW TO USE THIS MANUAL

1-1

This manual contains the following sections:

- HOW TO USE THIS MANUAL

- SAFETY

- INSTALLATION REQUIREMENTS

- SYSTEMS

- OPERATIONS

- MAINTENANCE & SERVICE

- PARTS LIST

The HOW TO USE THIS MANUAL section will tell you how to find important information for ordering correct repair parts.

Parts may be ordered from authorized dealers. When placing an order for parts, the machine model and machine serial number are important. Refer to the MACHINE DATA box which is filled out during the installation of your machine. The MACHINE DATA box is located on the inside of the front cover of this manual.

MODEL _____________________________________

DATE OF PURCHASE ________________________ SERIAL NUMBER ____________________________

SALES REPRESENTATIVE # ___________________

The SAFETY section contains important information regarding hazard or unsafe practices of the machine. Levels of hazards is identified that could result in product or personal injury, or severe injury resulting in death.

The OPERATIONS section is to familiarize the operator with the operation and function of the machine.

The MAINTENANCE section contains preventive maintenance to keep the machine and its components in good working condition. They are listed in this general order:

- Engine

- Vacuum Pump

- Water Pump

- Drive Belts, Pulleys & Hubs

- Chemical Pumps

- Hoses

- Vac/Exhaust Heat Exchanger

- General Service Adjustments

- Troubleshooting

The PARTS LIST section contains assembled parts illustrations and corresponding parts list. The parts lists include a number of columns of information:

The model and serial number of your machine is on the side approximately where shown.

- REF – column refers to the reference number on the parts illustration.

- PART NO. – column lists the part number for the part.

- DESCRIPTION – column is a brief description of the part.

- SERIAL NO. FROM – column indicates the first machine the part number is applicable to. When the machine design has changed, this column will indicate serial number of applicable machine. The main illustration shows the most current design of the machine. The boxed illustrations show older designs. If column has an asterisk (*), call manufacturer for serial number.

- NOTES – column for information not noted by the other columns.

NOTE: If a service or option kit is installed on your machine, be sure to keep the KIT INSTRUCTIONS which came with the kit. It contains replacement parts numbers needed for ordering future parts.

NOTE: The 98# on the lower left corner of the front cover is the part number for this manual.

EVEREST 980086 03/24/03

Page 7

IMPORTANT SAFETY INSTRUCTIONS

These symbols mean WARNING or CAUTION. Failure to follow warnings and

When using this machine, basic precautions

must always be followed, including the following:

READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.

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.

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 any gasoline or flammable material in the vehicle. Fumes may accumulate inside the vehicle and ignite, causing an explosion.

DO NOT store any type of flammable material in the vehicle. This unit must be operated with the vehicle or trailer doors open in order to ensure adequate

engine ventilation. DO NOT operate engine if gasoline is spilled. Avoid creating any ignition until the gasoline has been

cleaned up. Never use gasoline as a cleaning agent. DO NOT place hands, feet, hair, or clothing near rotating or moving parts. Avoid any contact with

moving parts! Rotating machinery can cause injury or fatality. Never operate this unit without belt guards. 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. 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.

DO NOT touch the exhaust system while this unit is running. Severe burns may result. 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.

2-1

EVEREST 980086 02/18/03

Page 8

DO NOT leave the vehicle engine running while operating this unit. Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with

skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.

Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. When disconnecting the battery, ALWAYS disconnect the negative (-) terminal FIRST.

DO NOT smoke around the unit. Gas fumes may accumulate and be ignited. The battery is also extremely flammable. This will prev en t possib le 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 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 only the provided abrasion resistant fuel hose for fuel lines. When traversing the vehicle floor with fuel lines, always use a bulkhead adapter. This will prevent leakage and ensure that the hose is not punctured b y vehicle vibrat io n abr as ion .

DO NOT exceed your vehicle's weight limit. The console with waste tank and accessories weighs approximately 1840 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 attached and turned on. The water pump and other vital

components may be seriously damaged if this unit is permitted to operate dry without water.

DO NOT operate this unit without the filter installed in the waste tank. Keep your vehicle work area clean. Wands, stair tools, and other accessories must be securely fastened before

driving the vehicle. All high pressure hoses must be rated for 3000 PSI at 250°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.

The winterizing loop hose assembly, Part #10-805380, is for winterizing use only. If used improperly, live steam may escape from this hose, causing it to whip around. Burns or injury may result.

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. 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.

EVEREST 980086 05/19/04

2-2

Page 9

HAZARD INTENSITY LEVEL

Front panel decal-PP

Caution label

(2) Warning labels required

Warning label

The following WARNING LABELS are found on your cleaning unit . 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.

NOTE: If at any time the labels become illegible, promptly replace them.

Part # 500707

Caution Tag Part # 500706

Part # 790454

SOLUTION

PRESSURE

HIGH PRESSURE

1000-3000 PSI

LOW PRESSURE

50-1000 PSI

LOW PRESSURE

SOLUTION REGULATOR

HIGH PRESSURE

SOLUTION REGULATOR

SOLUTION PRESSURE

REGULATOR

HIGH PRESSURE

SOLUTION OUTLET

CHEMICAL

CHECK VALVE

LOW PRESSURE

SOLUTION SCREEN

LOW PRESSURE

SOLUTION OUTLETS

CARPET AND

UPHOLSTERY

SOLUTION

CHEMICAL

CHECK VALVE

SOLUTION SCREEN

SOLUTION OUTLETS

CARPET AND

UPHOLSTERY

SOLUTION

SOLUTION TEMPERATURE

WARM HOT

CONDENSED OPERATING INSTRUCTIONS

STARTING

1. CONNECT WATER HOSES TO WATER INLET CONNECTIONS AND TURN ON WATER SUPPLY.

2. CONNECT CLEANING AND VACUUM HOSES TO THE DESIRED CLEANING TOOL AND CONSOLE.

3. PULL OUT ENGINE CHOKE,TURN SOLUTION PUMP TO OVERRIDE AND TURN IGNITION KEY TO START.

4. PUSH IN ENGINE CHOKE AFTER ENGINE HAS STARTED.

5. SET THROTTLE AT LOW POSITION.

6. INSERT CHEMICAL INLET AND PRIME TUBING INTO CHEMICAL CONTAINER.

7. TURN CHEMICAL PRIME VALVE TO PRIME AND ALLOW CHEMICAL TO CIRCULATE. AFTER ALL AIR BUBBLES HAVE BEEN REMOVED FROM THE CHEMICAL TUBING, TURN THE VALVE TO THE OFF POSITION, OPEN THE CHEMICAL FLOW AND FLOW SIMULATOR VALVES. SET THE DESIRED CHEMICAL FLOW RATE WHILE OBSERVING THE FLOW METER INDICATOR. FLOW SIMULATOR VALVE MUST BE IN THE OPEN POSITION TO SET CHEMICAL FLOW. WHEN DESIRED FLOW IS REACHED, TURN FLOW SIMULATOR VALVE OFF.

8. FOR QUICK HEAT-UP, REFER TO OPERATING INSTRUCTIONS.

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 AND SPRAY WD40 (OR EQUIVALENT) INTO THE VACUUM LUBRICATION CUP. THIS WILL PREVENT CORROSION DUE TO MOISTURE.

3. SET ENGINE THROTTLE AT IDLE POSITION AND OPEN FLOW SIMULATOR VALVE, ALLOWING THE WATER TEMPERATURE TO COOL DOWN.

4. TURN OFF IGNITION SWITCH.

5. DISCONNECT ALL HOSES AND TOOLS.

6. DRAIN WASTE TANK INTO AN APPROVED SOURCE.

CONDENSED OPERATING INSTRUCTIONS

STARTING

1. CONNECT WATER HOSES TO WATER INLET CONNECTIONS AND TURN ON WATER SUPPLY.

5. SET THROTTLE AT LOW POSITION.

6. INSERT CHEMICAL INLET AND PRIME TUBING INTO CHEMICAL CONTAINER.

8. FOR QUICK HEAT-UP, REFER TO OPERATING INSTRUCTIONS.

SHUTDOWN AND DAILY MAINTENANCE

1. CLOSE CHEMICAL METERING VALVE.

3. SET ENGINE THROTTLE AT IDLE POSITION AND OPEN FLOW SIMULATOR VALVE, ALLOWING THE WATER TEMPERATURE TO COOL DOWN.

4. TURN OFF IGNITION SWITCH.

5. DISCONNECT ALL HOSES AND TOOLS.

6. DRAIN WASTE TANK INTO AN APPROVED SOURCE.

CONTROL VALVE

SOLUTION TEMPERATURE

WARM HOT

CONTROL VALVE

2. CONNECT CLEANING AND VACUUM HOSES TO THE DESIRED CLEANING TOOL AND CONSOLE.

3. PULL OUT ENGINE CHOKE,TURN SOLUTION PUMP TO OVERRIDE AND TURN IGNITION KEY TO START.

4. PUSH IN ENGINE CHOKE AFTER ENGINE HAS STARTED.

REACHED, TURN FLOW SIMULATOR VALVE OFF.

Front panel decal-PPHP Part # 790453

2-3

(1) Top of belt guard (1) top of rear engine panel

Part # 500769

Caution label Part # 500770

EVEREST 980086 05/21/03

Page 10

OPERATIONS

TECHNICAL SPECIFICATIONS

ITEM DIMENSION/CAPACITY

Engine speed 2400 rpm (high speed) Water Pump ON

900 rpm (idle speed) Water Pump OFF. Water pump rpm 1655 rpm Vacuum pump rpm 2800 rpm Water flow rate 4.5 GPM (maximum) Water pump pressure (low pressure) 1000 PSI (maximum) Water pump pressure (high pressure) 3000 PSI (maximum) Vacuum relief valve 14” Hg Waste tank capacity 80 or 100 gallons Console weight 860 lbs. Console weight (with waste tank & waste tank accessories)

TORQUE VALUES

Engine hub 480 inch lbs 40 foot/lbs Vacuum pump hub 192 inch/lbs 16 foot/lbs Water pump shaft bolt 300 in//lbs 25 foot/lbs

JET SIZING:

Recommended floor tool tip sizing not exceed a total of “.06”. Using larger jet sizes on your cleaning unit may reduce cleaning temperatures.

1110 lbs (1840 lbs. If waste tank is full)

Example: Tri-jet wand uses three 9502 jets (95° spray angle w/ 02 orifice).

02 x 3 = 06

When using two floor tools while cleaning with this unit, it is recommended that each tool tip size does not exceed a total of “.045”.

Example: Tri-jet wand uses three 95015 jets (95° spray angle w/ 015 orifice).

015 x 3 = 045……….045 x 2 tools = 09

Upholstery tool jet size: 80015 Stair tool jet size: 9502

EVEREST 980086 05/05/04

3-1

Page 11

OPERATIONS

INSTALLATION REQUIREMENTS DEALER RESPONSIBILITY

1. The unit should NOT be mounted in any motor vehicle of less than 3/4 ton capacity.

The console 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.

FUEL REQUIREMENTS2. 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 engine on this unit.

ENGINE OIL REQUIREMENTS3 OIL

REQUIREMENTS

Use high quality detergent oil of at least 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 less than service class SF or SG oil or extending oil change intervals longer than recommended can cause engine damage. The recommended SAE viscosity grade is 20W-50.

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 highly recommend using a drip tray under the console (Part #790552).

7. If using a trailer, the console should be positioned so that it balances properly with respect to the axle. Ten percent (10%) of the overall unit weight should be on the tongue.

Example: If loaded trailer weight is 2,000 lbs., tongue weight needs to be a minimum of 200 lbs. to tow properly.

3-2

EVEREST 980086 04/06/04

Page 12

OPERATIONS

CHEMICAL REQUIREMENTS4.

This cleaning unit, due to its chemical injection pump 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 cleaning compounds, refer to the PROCHEM chemical manual.

WATER REQUIREMENTS

Hard water deposits will adversely affect the plumbing and heat exchange systems on this unit. The map below will give you an idea of where areas of high water hardness may occur. However, any water supply obtained from a well is almost always hard water and a water softener will be needed to protect your equipment.

NOTE: Equipment malfunction or component failure caused by hard water scaling is NOT covered under the warranty.

If you are operating this unit in an area where the unit will be using water in which the hardness exceeds 3-1/2 grains, we highly recommend a suitable water softener be installed. If using a water softener, it must have a five (5) GPM (or greater) flow capacity without any hose constrictions.

Using a water softener will reduce maintenance and decrease down time caused by hard water scaling. It will also allow cleaning chemicals to be more effective in lower concentrations.

If you require a water softener, PROCHEM has a model to meet your needs. Please contact your nearest distributor for information, price, and availability.

HARD WATER MAP

EVEREST 980086 02/18/03

3-3

Page 13

COMPONENTS

3-4

2 3

5 6

7 8

SOLUTION PRESSURE

HIGH PRESSURE

1000-3000 PSI

LOW PRESSURE

50-1000 PSI

LOW PRESSURE

SOLUTION REGULATOR

HIGH PRESSURE

SOLUTION REGULATOR

HIGH PRESSURE

SOLUTION OUTLET

CHEMICAL

CHECK VALVE

LOW PRESSURE

SOLUTION SCREEN

LOW PRESSURE

SOLUTION OUTLETS

CARPET AND

UPHOLSTERY

SOLUTION

SOLUTION TEMPERATURE

WARM

CONTROL VALVE

CONDENSED OPERATING INSTRUCTIONS

STARTING

1. CONNECT WATER HOSES TO WATER INLET CONNECTIONS AND TURN ON WATER SUPPLY.

2. CONNECT CLEANING AND VACUUM HOSES TO THE DESIRED CLEANING TOOL AND CONSOLE.

3. PULL OUT ENGINE CHOKE,TURN SOLUTION PUMP TO OVERRIDE AND TURN IGNITION KEY TO START.

4. PUSH IN ENGINE CHOKE AFTER ENGINE HAS STARTED.

5. SET THROTTLE AT LOW POSITION.

6. INSERT CHEMICAL INLET AND PRIME TUBING INTO CHEMICAL CONTAINER.

8. FOR QUICK HEAT-UP, REFER TO OPERATING INSTRUCTIONS.

SHUTDOWN AND DAILY MAINTENANCE

1. CLOSE CHEMICAL METERING VALVE.

3. SET ENGINE THROTTLE AT IDLE POSITION AND OPEN FLOW SIMULATOR VALVE, ALLOWING THE WATER TEMPERATURE TO COOL DOWN.

4. TURN OFF IGNITION SWITCH.

5. DISCONNECT ALL HOSES AND TOOLS.

6. DRAIN WASTE TANK INTO AN APPROVED SOURCE.

HOT

13 14

1822 21 20

EVEREST 980086 03/24/03

Page 14

COMPONENTS

3-5

1. WASTE TANK FULL INDICATOR LIGHT

This indicator light is activated when the waste tank is full. When lit the unit will shutdown protecting the equipment from damage. This also indicates that the waste tank must be emptied before the unit can be brought back in service.

NOTE: Never dispose of waste water in storm drains, water ways or on ground areas. Always dispose of waste in accordance with local state and federal laws.

2. LOW WATER PRESSURE SHUTDOWN INDICATOR

This light indicates the pumping system has not achieved 50 PSI. Reasons for this may be a plugged water box strainer or problems with the water supply. When this light is activated, the water pump has shutdown and trouble shooting is required.

3. ENGINE HIGH TEMPERATURE SHUTDOWN INDICATOR

This light when activated signals an over heat condition with the engine. When this occurs, troubleshooting is required.

8. SOLUTION PUMP SWITCH

This switch serves to energize the magnetic clutch to turn the water pump on or off. Turn clockwise for activating the pump and counter clockwise for deactivating the pump.

9. CHOKE

The choke cable is for restricting air to the carburetor, this enriches the fuel mixture. The primary purpose is for starting in cold temperatures. When the cable is pulled out air is restricted, when pushed in the engine is in run position.

10. THROTTLE

This serves to set the speed of the engine by pushing the throttle lever in, it serves to increase the speed and letting it out has the effect of slowing down the engine. The lever has notches cut into it, which serves to lock in given speeds. The first notch is calibrated for 1250 rpm. The second notch is calibrated for 1900 rpm and the third notch is calibrated for 2400 rpm.

11. KEY SWITCH

4. VACUUM GAUGE

This gauge indicates in inches of mercury how much vacuum the system is producing at any given time.

5. SOLUTION PRESSURE GAUGE

This gauge registers the amount of pressure in the system.

6. SOLUTION TEMPERATURE GAUGE

This gauge measures the temperature of the cleaning solution as it exits the machine.

7. WASTE PUMPOUT AND AUXILIARY WATER PUMP SWITCH

This four-position switch is for activating the waste pumpout device. It also serves to activate the fresh water transfer pump. For turning on pumps, rotate clockwise. For turning off pumps, rotate counter clockwise.

The key switch controls the power for the machine. To turn the machine on, rotate the key clockwise until the starter engages the engine. When machine is running let off the switch and engine will continue to run. To turn power off, rotate key counter clockwise to stop position, engine will then stop.

12. HOUR METER

The hour meter records the number of hours the unit has run. This serves as a time recorder for servicing the machine.

13. CIRCUIT BREAKERS

These serve to protect the circuits from electrical spike and over loads and protects wires from damage and fire.

EVEREST 980086 02/18/03

Page 15

COMPONENTS

3-6

14. SOLUTION TEMPERATURE CONTROL VALVE

This valve enables additional heat exchangers to contribute more heat to the system if necessary. By rotating the lever to the right it adds more heat, by rotating to the left it removes heat.

15. OIL CUP

The oil cup allows lubricant spray to reach the vacuum blower.

16. VACUUM INLETS

The vacuum inlets serve as connecting point for vacuum hoses.

17. SOLUTION OUTLETS

The solution outlets are the connecting point for the high pressure cleaning hoses. These outlets are quick disconnects that allow hoses to be plugged into the unit.

18. SOLUTION SCREEN

The solution screen is located on the front of the machine. The function of this screen is to trap foreign particles from exiting the machine and plugging the orifices of the cleaning tools. This screen is part of the machine maintenance cleaning.

21. HIGH PRESSURE REGULATOR

The regulating valve controls the amount of pressure in the pressure washing circuit by turning the handle clockwise, It has the effect of increasing the pressure. Turning it clockwise has the effect of lowering the pressure.

22. WASTE OUTLET

This valve allows the waste tank to be emptied. Turning clockwise opens the valve.

NOTE: This valve must be open during operation.

23. WASTE PUMPOUT

This auxiliary pump serves to empty the waste collection tank automatically. A float located inside the tank automatically turns off and on when the solution level reaches certain points.

24. WARM WATER OUTLET

The warm water outlet allows the cleaning technician to drain hot water from the water box for mixing chemical.

Water from this valve is hot.

25. WATER INLET

19. CHEMICAL CHECK VALVE

The chemical check valve allows chemicals to enter the system and travel in a singular direction to the wand. The chemical check valve prevents chemicals from traveling upstream into the solution system of the unit.

20. HIGH PRESSURE SOLUTION OUTLET

The control valve 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 valve clockwise. The pressure is increased or reduced by turning the valve counter clockwise.

EVEREST 980086 02/18/03

This quick connect allows the water supply hose to be connected to the unit.

26. SOLUTION PRESSURE

This selector valve allows the technician to switch from high pressure to low pressure by moving the handle to the up position. The high pressure circuit is activated allowing the unit to be used as a pressure washer by positioning the valve handle to the down position. The low pressure circuit is activated allowing the unit to be used for carpet cleaning.

Page 16

COMPONENTS

3-7

27. LOW PRESSURE REGULATOR

This pressure regulating valve allows the low pressure circuit to be adjusted by turning the handle clockwise the pressure will increase, by turning counter clockwise the pressure will decrease.

28. FLOW METER

The flow meter is a gauge to indicate how much liquid chemical is being introduced in the water system. The quantity can be increased by turning the chemical flow knob counter clockwise.

29. CHEMICAL PRIME CONTROL VALVE

This valve allows the chemical to circulate through the chemical system with little or no restriction. It also purges out air that may be trapped in the lines and cavities of the chemical pump. By turning the valve clockwise the injection system is enabled.

30. CHEMICAL METERING VALVE

31. FLOW SIMULATOR VALVE

This valve allows solution to move through the machine and chemical to be injected simulating the cleaning process. This allows the operator to set the chemical flow level without connecting tools to the machine. It is also useful in troubleshooting. The valve is turned off by rotating the knob clockwise and opened by turning the knob counter clockwise.

32. PANEL LIGHT

This light is useful if the machine is used in a poorly lit area or night use. It is helpful in reading the instruments and gauges.

The chemical metering valve regulates the amount of chemical that is injected into the system. Clockwise rotation of the knob closes the valve. Counter clockwise rotation opens the valve, allowing more chemical to enter the system.

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Page 17

OPERATIONS

3-8

WATER PUMPING AND HEAT TRANSFER SYSTEM

Cold water enters the console through the water inlet. When the water box is full the valve will automatically shut off.

The third stage of plumbing and heat exchange takes place in the 2nd heater core located in the heater box. This is the hottest point of the gases coming from the vac pump and the engine. These hot gases are forced through heater core #2 creating the third stage of heat transfer to the cleaning solution.

Water then flows from the water box, through a strainer, into the water pump where it is pumped to the pressure regulator manifold where the pressure regulator provides and maintains the desired pressure setting.

The pressure regulator manifold includes a nitrogen charged accumulator which helps reduce pressure spikes from the pump.

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 through a heat exchanger box into the first heater core from the front of the unit. This bypass water may circulate several times through the bypass heat exchanger allowing the water to be pre-warmed.

The next stage of heating and water flow is to the helicoil, when water is called for in the cleaning process it flows to the helicoil under pressure. Heat from the engine coolant is exchanged to the cleaning solution through a series of 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.

Finally, the hot solution passes to the outlet manifold where cleaning chemicals are injected from the chemical pulse pump. This manifold serves as a temperature sensing point and a connecting point for the high-pressure hoses. Also a check valve is located in this outlet manifold prohibiting chemicals from backing up into the system.

The cleaning solution then passes through highpressure 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.

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3-9

SINGLE SYSTEM WATER FLOW DIAGRAM

LOW PRESSURE

WASTE TANK

OPERATIONS

= COLD WATER

= WARM WATER

= HOT WATER = NO WATER

WATER BOX

TO PRESSURE

GUAGE

WATER PUMP

THERMO

RELIEF

ENGINE

THERMOSTAT

TO PRESSURE

GUAGE

ACCUMULATOR

ENGINE

RADIATOR

VACUUM EXHAUST

HEAT EXCHANGERS

HELI-COIL ENGINE

COOLANT HEAT

EXCHANGER

3-WAY

BALL VALVE

WATER

INLET

MANIFOLD

LOW PRESSURE REGULATOR

OUTLET

CHECK

VALVE

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CHEMICAL INJECTION

SOLUTION

OUTLETS

OUTLET Y-STRAINER

SOLUTION OUTLET

MANIFOLD

Page 19

OPERATIONS

3-10

DUAL SYSTEM WATER FLOW DIAGRAM

HIGH PRESSURE

WASTE TANK

= COLD WATER

= WARM WATER

= HOT WATER = NO WATER

REGULATOR

BYPASS

WATER BOX

TO PRESSURE

MANIFOLD

WATER PUMP

GUAGE

THERMO

RELIEF

ENGINE

THERMOSTAT

ACCUMULATOR

ENGINE

RADIATOR

VACUUM EXHAUST

HEAT EXCHANGERS

HELI-COIL ENGINE

COOLANT HEAT

EXCHANGER

3-WAY

BALL VALVE

WATER

INLET

SOLUTION

OUTLET

3-WAY

BALL VALVE

HIGH PRESSURE REGULATOR

REGULATOR ASSEMBLY

MANIFOLD

LOW PRESSURE REGULATOR

OUTLET

CHECK

VALVE

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CHEMICAL

INJECTION

SOLUTION

OUTLETS

OUTLET Y-STRAINER

SOLUTION OUTLET

MANIFOLD

Page 20

OPERATIONS

CHEMICAL INJECTION SYSTEM

The chemical injection system is unique in that it utilizes the pressure spikes generated by the highpressure water pump to move chemical into the main pressure stream. The high pressure spikes move the diaphragm in the chemical pulse pump forcing small amounts of liquid chemical to be moved in a single direction of flow with the aid of two check valves.

The chemical is picked up from the container and fed through the flow meter to the chemical pulse pump where it is pressurized.

After reaching the chemical pulse pump the chemicals can either go into a bypass loop to purge air from the system. The chemical can then be directed by the chemical selector valve to the metering valve. The metering valve creates an orifice allowing the correct amount of chemical to enter the outlet manifold. The outlet manifold assembly is complete with a check valve that will not allow the chemicals to travel upstream into the plumbing system of the unit.

The chemicals are then mixed with hot pressurized water that make up a solution for cleaning application.

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Page 21

OPERATIONS

VACUUM SYSTEM

The engine 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 a separating tank utilizing hoses and the force of air. Particles of moisture and dirt are separated in the vacuum tank using a series of changes in direction and velocity. The air is then filtered and rushes into the vacuum pump.

VACUUM

HEATER COIL #1

INLET

The vacuum pump compresses and heats the incoming air. The hot discharged air is forced down stream into a silencer for noise abatement. After exiting the silencer, this hot air is mixed with hot air and gases from the engine. This mixture of hot air and gases are then forced through 3 radiators serving as heat collectors. Heat from the engine and vacuum pump is then transferred into the plumbing system raising the water temperature for better cleaning.

HEATER COIL #2

HEATER COIL #3

SILENCER

WASTE TANK

STRAINER

VACUUM

GAUGE

LUBRICATION

CUP

VACUUM

PUMP

VACUUM

RELIEF

VALVE

LEVEL SENSOR

FILTER

3-12

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Page 22

OPERATION

PRE-RUN INSPECTION

NOTE: Operation of this unit is simple. However, only trained personnel should proceed.

Operate this unit and equipment only in a wellventilated 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.

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 1.18 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

HIGH PRESSURE HOSE

Before starting the unit, connect the pressure hose(s) to the outlet connection(s) at the front of the unit. Connect the cleaning tool(s) to the pressure hose(s).

DANGER

WATER UNDER HIGH PRESSURE AT HIGH TEMPERATURE CAN CAUSE BURNS, SEVERE PERSONAL INJURY, OR COULD BE FATAL. SHUT DOWN MACHINE, ALLOW TO COOL DOWN, AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES, CAPS, PLUGS, FITTINGS, FILTERS AND BOLTS.

ROTATING MACHINERY. WATER UNDER PRESSURE AT HIGH TEMPERATURE. IMPROPER MODIFICATION OF EQUIPTMENT CAN CAUSE SEVERE PERSONAL INJURY OR COULD BE FATAL.

DANGER

DO NOT MODIFY UNIT WITHOUT WRITTEN PERMISSION FROM MANUFACTURER

VACUUM HOSE

Connect the vacuum hose(s) to the vacuum inlet connection(s) at the front of the unit. Connect the other end of the vacuum hose(s) to the cleaning tool(s).

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 box .

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Page 23

OPERATIONS

PRIMING THE CHEMICAL PUMP

1. Connect water hose to water inlet connection

and turn on water supply.

2. Connect cleaning and vacuum hoses to the desired cleaning tool and console.

3. Insert chemical inlet and prime tubing into chemical container.

4. Pull out engine choke, turn solution pump switch to override, and turn ignition key to start.

5. Push in engine choke after engine has started.

6. Set throttle to low speed.

7. Fill chemical container and inspect chemical

filter.

8. Turn chemical prime valve to prime and allow chemical to circulate. After all air bubbles have been removed from chemical tubing, turn the valve to the horizontal (off) position and open the chemical metering valve, and the simulation valve. Set the desired chemical flow rate while observing the flow meter indicator. Simulator valve must be in the open position to set chemical flow. When desired flow is reached turn simulator valve off.

NEVER dispose of waste in storm drains, water ways, or on ground areas. Always dispose of waste in accordance with Local, State, and Federal laws.

Once you have completed steps 1 through 8, proceed with the cleaning operation. Your unit should be in the correct throttle position for your cleaning operation or extracting. A 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.

CLEANING

Observe the following guidelines, while cleaning:

1. Before proceeding make sure the nozzles are functioning properly.

a. To check , hold the wand about one foot

above the surface to be cleaned and open the wand valve. A full spray should be observed from the cleaning nozzles.

b. If the nozzles are not showing a full spray

pattern, adjust nozzles for proper pattern, clean, or replace nozzles, if required.

9. Set throttle to maximum position with vacuum ports blocked off for quick unit heat up.

WASTE PUMP (OPTIONAL)

1. If your unit is equipped with an automatic waste

pump, connect one end of a garden hose to the pump-out connection on the console and the other end to an appropriate waste disposal.

2. Turn the pump-out switch on the control panel to the ON position. The waste pump will operate automatically throughout the cleaning operation.

We recommend that you use a 3/4" I.D. water hose as a waste pump outlet hose. DO NOT use a hose smaller than 5/8" I.D.

NEVER use your automatic waste pump outlet hose as a water inlet hose.

2. Normally 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.

3-14

EVEREST 980086 02/18/03

Page 24

OPERATIONS

UPHOLSTERY CLEANING

Upholstery tool, part #78513

1. Set temperature as desired and slow down the engine speed to minimize excess heat.

2. Use one (1) “80015” spray tip in tool.

SHUTDOWN AND DAILY MAINTENANCE (LOW PRESSURE)

1. Close chemical metering valve.

2. Allow the unit to run for 2 minutes with the

vacuum hose disconnected to remove moisture. Spray WD40 (or equivalent) into the vacuum lubrication cup. This will prevent corrosion due to moisture.

3. Set engine throttle at idle position and allow the water temperature to cool down, unitizing the simulator valve in the open position to bleed off residual hot water left in the system.

4. Turn off ignition switch.

OPERATION

The “HP” units are equipped with a water pump and water delivery system that can support pressurewashing operations up to 4.5 gallons per minute at 3000 PSI. This system is normally used for highpressure washing and hard surface cleaning.

1. Move the temperature selection valve from the “hot” position to the “warm” position.

2. Adjust low-pressure regulator to set pressure at 100 PSI

3. Allow water temperature to cool to below 160 deg F.

4. Close ball valve located between the chemical pump and the water pump.

Failure to close this valve will result in severe damage to the chemical pump diaphragms.

5. Connect hose and pressure washer gun to high pressure disconnect.

5. Disconnect all hoses and tools.

6. Drain waste tank.

HIGH PRESSURE SYSTEM OPERATION

The high-pressure water system can produce water pressures in excess of 3000psi. Water at these pressures will cause severe injury. DO NOT direct any discharges at persons. If contact with a person does occur and penetration of the skin does seem possible, contact medical personnel immediately. This machine is to be used by trained cleaning professionals only. Ensure all operators are trained in the operation of this equipment. Keep cleaning area clear of all persons and objects.

Ensure that proper Personal Protective Equipment (PPE) is used during the operation of this equipment. Failure to use proper PPE could result in injury. Ensure required ventilation and/or breathing apparatuses are used with a chemical injection system. Check with your chemical vendor for proper safety requirements.

6. Move the pressure selection valve from the “low pressure” position to the “high pressure” position.

7. Adjust high-pressure regulator to desired operational pressure.

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3-15

Page 25

OPERATIONS

HIGH PRESSURE SHUTDOWN & RETURN TO LOW PRESSURE SYSTEM

1. Adjust High Pressure regulator to set pressure at 400 psi.

2. Bleed off excessive pressure build-up by operating pressure washer gun for 5 seconds.

3. Move solution selector control valve from “High Pressure” operations to “Low Pressure” operations.

4. Squeeze pressure washer gun trigger again to remove any residual pressure

5. Disconnect high pressure gun and hose from high pressure disconnect.

6. Operate under normal low pressure instruction or follow normal shutdown procedures.

Pro-Chem recommends the use of the Pro- Chem chemical injector (P/N 61-951538) for use in combination with any chemical/detergent additives.

Pro-Chem also recommends the use of ProChem high-pressure spray wands. Pro-Chem offers a basic pressure wand (P/N 60-950168 ) or a dual barrel wand (P/N 60-950505). Contact your Pro-Chem dealer for recommendations in your particular application. The operation of the high-pressure system also requires a high-pressure hose capable of handling the increased pressure loads of the high-pressure system. NEVER use your lowpressure system hoses with the high-pressure system. Pro-Chem offers a special high pressure hose, P/N 10-805513, rated for pressure washer activities. Only use Pro-Chem approved hoses and fittings. Ensure that your hoses and fittings are rated for your operational pressures.

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. Move the temperature selection valve from the “hot” position to the “warm” position.

2. Ensure that the system is operating in lowpressure mode (HP units only). Adjust lowpressure regulator to set pressure at 100 psi.

3. Allow solution temperature to cool below 160 deg F.

4. Begin de-flooding 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 unit provides heat while running. Shut it down just prior to leaving for the next job.

If a heated building is not available, we recommend that you winterize the unit with antifreeze. At present, it is only possible to winterize units, which do not have an auxiliary water tank. Units with auxiliary water tanks must be stored in a heated building when not in use.

3-16

EVEREST 980086 02/18/03

Page 26

OPERATIONS

WINTERIZING 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 have water in them.

3. Start the unit and turn water pump on. Open the tool valve until water pressure drops and water stops flowing.

4. Fill the water box with approximately two gallons of 100% glycol base anti-freeze.

5. Turn the solution pump override switch to the override position and start the unit. Turn the

solution pump switch ON.

6. 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 recycle 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.

8. Prime the chemical system with 50/50 antifreeze/water mix. Insert the chemical inlet and prime discharge tubes into the anti-freeze container. Turn the chemical valve to PRIME until anti-freeze begins to flow out of the prime hose.

9. Now turn the chemical valve and flow simulator valves to the open position, making certain that the flow meter indicates flow and that all antifreeze drains out of the chemical hose into an approved container, after 30 seconds, turn off both valves.

HIGH PRESSURE

Turn solution pressure valve to high pressure and key the high pressure wand until anti-freeze begins to come out of the wand. Recover all anti-freeze into an approved container. We strongly recommend that you recycle and re-use the anti-freeze.

After completing these procedures, shut the unit down. The unit is now winterized.

7. Turn the solution pump switch OFF. Attach the winterizing loop hose with attachment, Part #10-805380, to the solution outlet connection and the water inlet connection. Turn the solution pump switch ON.

Allow the unit to run for approximately 3 minutes with the winterizing loop hose attached.

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3-17

Page 27

OPERATIONS

3-18

REMOVING ANTI-FREEZE FROM THE UNIT

1. Connect one end of the winterizing loop hose

to the solution outlet connection. Place the other end of the loop hose, without the attachment, into an approved container.

2. Start the unit. Allow the anti-freeze to flow into the container until flow stops.

3. Fill the water box with fresh water and repeat step #2.

4. Connect the water inlet hose to the water inlet connection on the console. Turn the water supply on.

5. Connect all solution hoses and any tools which require purging of anti-freeze to the solution outlet connection(s).

6. Open the tool valves and drain the anti-freeze into an approved container until the flow is clear and all anti-freeze is purged from the tools and hoses.

7. Place the chemical prime hose into the approved container. Submerge the chemical inlet hose in water. Turn the chemical valve to the PRIME position until clear water comes through the prime hose, and then remove the prime hose from the container.

Turn the chemical valve to the ON (CHEMICAL) position. This will allow water to flow into the other side of the system.

Once all of the anti-freeze is removed, the unit is ready to use.

Eventually, the anti-freeze in your storage container will become diluted with water. If the anti-freeze level drops below 50% of the total, dispose of it and start with fresh 100% antifreeze.

When disposing of used anti-freeze, observe local laws and regulations. Do not drain onto the ground or into storm drainage systems.

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Page 28

THIS PAGE LEFT BLANK INTENTIONALLY

NOTES:

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3-19

Page 29

MAINTENANCE

SERVICE SCHEDULE

Engine Daily Check engine oil level. *** Fill to proper level Engine Daily Check coolant level in overflow bottle

Vacuum Pump Daily

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 Box Float Valve Weekly Check for proper seating and shut-off

Water Pump Inlet Filter Weekly* Check for debris and clean

Governor Weekly Fill oil to proper level.

Battery Weekly* Check for proper fluid level. Fill with distilled water only

Solution Outlet Y-Strainer Weekly* Inspect and remove any debris or blockage

High Pressure Hoses 100 hrs Inspect for damage or impending damage

Pressure Regulators 100 hrs Lubricate o-rings

Engine 100 hrs Change engine oil*** Engine 100 hrs Change oil filter*** Engine 100 hrs Check fan belt tightness

Battery 100 hrs* Clean battery terminals

Float Valve Seal 200 hrs. Replace seal

Engine 200 hrs Service air cleaner elements* Engine 200 hrs Check radiator hoses and clamp tightness

Fuel Pump 200 hrs Check hose connections

Engine 200 hrs Check spark plugs for carbon deposits and proper gap

Flow Simulator And Chemical Valves 200 hrs Inspect and/or adjust packing nuts

Spray WD-40 in lubrication cup at front of console for 5 sec.

4-1

EVEREST 980086 02/18/03

Page 30

MAINTENANCE

SERVICE SCHEDULE

Vacuum Exhaust Heat Exchanger

Water Pump

Pulley Set Screws & Hub Cap

Screws, Water Pump Clutch Shaft

Bolts

Drive Pulley Drive Pulley

Drive Belts Drive Belts

Engine

Governor

Chemical Pump & Check Valves

Heater Core

Engine

Check Valve (Solution Outlet)

Vacuum Pump

Engine Engine Engine

Nitrogen Accumulator

Waste Tank Filters/Strainers

Engine Engine

500 hrs 500 hrs

500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs

1000 hrs 1000 hrs

1500 hrs

Yearly Yearly* Yearly* Yearly*

Yearly 2 years 3 years

Inspect cores and remove debris. Change oil**

Check for proper torque valves. Re-torque, if

required****

Inspect, clean and check for pulley groove wear**** Check pulley alignment**** Inspect and clean**** Check belt tension**** Drain and refill engine governor oil. Drain and refill. Replace diaphragm and check valves. Clean and inspect. Replace spark plugs. Inspect, clean, and repair, if needed.

Drain, flush, and replace oil ***** Flush radiator and change engine coolant. Replace in-line fuel filter on engine.

Replace air cleaner element. Replace Accumulator. Check for damage and blockage. Replace if needed. Replace radiator hoses and hose clamps. Replace ignition wires.

* Or as often as required ** Change water pump crankcase oil after the first 50 hours ***Change engine 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, 4500 hours or every 2 years, whichever comes first

EVEREST 980086 05/05/04

4-2

Page 31

MAINTENANCE

KEY CHECKPOINTS

HEAT EXCHANGER SYSTEM MAINTENANCE

Note: Initiation of a planned preventative maintenance program will assure that your unit has optimum performance, a long operating life, and a minimal amount of "down" time.

ENGINE COOLANT SYSTEM (RADIATOR) MAINTENANCE

Your engine radiator coolant system is an important part of the power plant operation. In addition, this heat exchange system is used to provide heat for cleaning operations is also highly dependent on the engine coolant system. Follow the recommended coolant system maintenance in the Maintenance Schedule in this manual and your Nissan A-15 engine owner’s manual. Refer any additional questions to your dealer.

EXTERNAL FUEL PUMP MAINTENANCE

The power plant for unit receives fuel from the main gas tank of your van/truck. An external fuel pump that provides this fuel is located on the underside of the van/truck. Loose fittings and hose connections will cause your unit to perform poorly. Follow the recommended fuel pump maintenance in the Maintenance Schedule in this manual. Refer any additional questions to your dealer.

SOLUTION SUPPLY SYSTEM MAINTENANCE

The chemical supply system pulls chemicals from your chemical bottle utilizing a pump that works off the water pump pulsing. Any clogged filters or loose connections will result in a chemical supply system malfunction or a malfunction at the cleaning tool. Maintenance of the solution outlet check valve and strainer are vital to effective cleaning operation and minimal unit downtime. Additionally, the hoses related to supplying water and chemical to the outlet manifold are under high pressures and experience thermal expansion and contraction. Periodic inspections of these hoses for tears, cracks, and failing connectors are necessary to avoid unwanted leaks. To keep your solution supply system functioning properly, follow the chemical pump and solution outlet maintenance in the Maintenance Schedule in this manual. Refer any additional questions to your dealer.

The heat exchange system in your unit transfers energy between the unwanted heat of the power plant and the solution supply system of the unit. The heat transfer of this system is highly dependent on the surface area contact in the heat exchanger cores located in the heat exchanger box. This surface area amount is adversely minimized when the supplied water is not softened to recommended levels. Hard water will result in scaling on the inside walls of the heat exchanger tubes. It is recommended that you use a dealer approved water softener to avoid premature heat exchanger core failure. Contact your local dealer for advice on the water hardness levels in your area.

Additionally, the heat exchanger tubes are very sensitive to freezing conditions. As the water freezes during cold conditions, it expands in the heat exchanger tubes and causes damage. Often the tubes are cracked and require the replacement of the heat exchanger core. Refer to the Freeze Protection instructions section in this manual. Refer any additional questions to your dealer.

VACUUM PUMP MAINTENANCE

The total function of the unit is based around the performance of the vacuum pump. Heat transfer used to raise the temperature of the solution is gained from the air drawn by the vacuum pump and solution is removed from the carpet with the vacuum suction of the vacuum pump. General maintenance actions for the vacuum pump as listed in this manual are vital to prolonged vacuum pump operations. Daily lubrication of the pump is required to avoid seizure of the system. Also, waste tank filters and strainers must be maintained to prevent unwanted debris from entering the vacuum pump.

4-3

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Page 32

MAINTENANCE

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.

NOTE: Use the hour meter as a guide for coordinating the maintenance schedule.

ENGINE

1. Check the engine oil level daily, when in use.

Make certain that proper oil level is maintained.

NEVER overfill.

2. Change the break-in oil after the first 50 hours of operation. Thereafter, change oil every 100 hours of operation. USE ONLY NISSAN

BRAND OIL FILTERS. USING ANY OTHER TYPE OIL FILTER WILL VOID YOUR ENGINE WARRANTY.

Oil Recommendation. Use high-quality detergent oil of at least API (American Petroleum Institute) service class SF or SG. The recommended SAE viscosity grade for summer is 20W-50, and 20W-40 winter.

NOTE: Using less than service class SF or SG oil or extending oil change intervals longer than recommended can cause engine damage.

3. Re-torque the manifold and exhaust tube nuts, cylinder head bolts, and carburetor attaching nuts after the first 200 hours of use.

4. Check the oil level in the engine governor every 100 hours . When empty, the governor requires 1.5 fl oz. Mobile 1 synthetic.

Drain and refill the engine governor every

500 hours.

5. Check the spark plugs every 200 hours. Clean

if necessary. Replace the spark plugs every 1000 hours. NOTE: Never sandblast spark plugs. Spark plugs should be cleaned by scraping or wire brushing.

Clean the air cleaner element every 200 hours. Replace the element every 2400 hours

6. 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.

7. Check the coolant level in the radiator overflow container daily. If no coolant is seen, remove the cap and add coolant. Change the coolant with a 70:30 coolant to water ratio every 1000

hours.

8. Replace the in-line gas filter yearly.

NOTE: For additional engine service information, obtain a “Nissan A-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 to provide the serial number of the engine.

EVEREST 980086 02/18/03

4-4

Page 33

MAINTENANCE

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 gear end of the vacuum pump for all operating 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 a minimum of 2 times longer than a premium mineral oil. NOTE: AEON PD (Part# 05-008039) is the oil

which PROCHEM puts in the vacuum pump at the factory. Topping off or adding petroleum oil to synthetic oil is NOT recommended.

If not using AEON PD synthetic blower lubricant, use oils with rust and oxidation inhibitors, anti-foam additives and the viscosity’s listed on the chart on the next page.

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.

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 4500 hours or

every 2 years, whichever comes first.

4-5

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Page 34

MAINTENANCE

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. 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. Use the provided dipstick. Remove red filler cap and insert dipstick. Oil level should be between marks on the dipstick or use a mirror and refer to the illustration.

3. Change the crankcase oil with Cat Pump Crankcase Oil, Part #05-008016, after the first 50 hours of operation. Drain and refill the crankcase oil with Cat Pump Crankcase Oil

every 500 hours thereafter.

VACUUM PUMP DRIVE BELTS

To tighten the vacuum pump belts:

1. Loosen the four screws which hold the vacuum pump mount in place.

2. Loosen the 6 nuts at the vacuum muffler outlet to heat exchanger box and loosen the bolt at the back of the machine connecting the muffler bracket to the frame.

3. Turn the adjusting bolts until the proper belt tension is achieved (1/2” deflection in the center of the belt, halfway between the pulleys).

4. Retighten all bolts previously loosened at the vacuum muffler.

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 four screws which hold the vacuum pump mount in position. Check belt alignment with straight-edge.

4. 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.

Make certain that when you re-torque these screws, that you use a clockwise pattern and continue until proper torque is achieved.

TORQUE VALUES

COMPONENT INCH/LBS FOOT/LBS

Engine hub 480 40

Vacuum pump hub 192 16

4. 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.

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MAINTENANCE

WATER PUMP DRIVE BELT

To tighten the water pump belt:

1. Loosen the nuts which hold the water pump mount to base.

2. Adjust the position of the belt tension adjusting bolt until the proper belt tension is achieved. (1/2" deflection in the center of the belt, halfway between the pulleys).

3. While checking the alignment, tighten the nuts which hold the water pump mount to base.

WATER PUMP CLUTCH

After removing or

replacing water pump clutch, make certain that bolt is re-torqued to the proper value.

Torque Value

Component Water pump

shaft bolt

Inch pounds Foot pounds

300 25

Y-STRAINER (OUTLET)

Inspect the Y-strainer after the first week of running the unit by unscrewing the screen and remove any accumulated debris. Inspect the strainer again at 2 and 4 weeks.

The Y-strainer should then be inspected every month. However, if the Y-strainer has a frequent build-up of debris it should be inspected and cleaned more often.

CHECK VALVE (OUTLET)

Inspect the check valve when rebuilding the chemical pump or as needed. Remove and disassemble the check valve. Check the Teflon seat for debris or abnormal wear. Clean or replace seat if needed.

NOTE: Improper seating of the check valve poppet, damaged spring, or o-rings will cause poor operation of the chemical system.

For the procedure, see the "General Service Adjustments” section in this manual for details.

FLOAT VALVE (WATER BOX)

The float valve should only be adjusted if the water box is overflowing or the water level in the box is lower than 5-1/2".

1. If the box is overflowing, remove, and check the

float valve for debris or damage.

NOTE: If the float ball has any water inside it must be replaced.

When replacing float ball, DO NOT over- tighten, as the rod can puncture the ball. Make sure to tighten the nuts on the rod.

2. Disassemble the valve and check the piston and

seat for damage, replace if needed. See the “Illustrated Parts Listing” for a parts break-down.

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 the end of each job.

CHEMICAL PUMP

Rebuild the chemical pump every 500 hours. This involves changing the diaphragm and check valves.

For the procedure, see the "Chemical Pump” section in this manual for details.

NOTE: Inspect chemical filter daily.

CHEMICAL AND SIMULATOR VALVE

Examine the packing nut on the chemical selector valve, heat bypass valve, and chemical metering valve every 200 hours. Keeping these valve packings properly adjusted will eliminate possible leakage from the valve stems and add to overall valve life.

For the procedure, see the "General Service Adjustments” section in this manual for details.

4-7

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MAINTENANCE

NITROGEN ACCUMULATOR

The nitrogen accumulator is pressurized to 250 PSI and must be replaced periodically. The accumulator cannot be repaired or recharged. We recommend replacement every 1000 hours of use.

PRESSURE REGULATOR

Lubricate the o-rings every 50 hours. Use o-ring lubricant Part #05-008035.

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.

ENGINE COOLANT REPLACEMENT

Annually the coolant in the Prochem machine 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. Add 7/16” hose or a 1/4” plastic hose into the radiator drain petcock. Turn counter clockwise to open and drain coolant. After draining approximately 1/2 gallon, open bleed petcock in heli-coil to assure that heli-coil drains also. Allow the coolant to completely drain.

NOTE: Be sure that used coolant is collected in a proper container and disposed of in accordance with local laws.

2. After draining is complete, close both the radiator and heli-coil petcocks. Draining is complete.

REPLACING COOLANT:

1. Fill radiator with 70/30 anti-freeze water mix.

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°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 waste pump by pumping fresh water through the pump.

2. Start unit and run on first notch.

3. As the unit warms up, maintain a full radiator with

a 70/30 mix.

4. Open petcock slightly on heli-coil to allow any trapped air to escape. When coolant runs out of heli-coil, close petcock.

5. Fill radiator with 70/30 coolant mix.

6. Re-install radiator cap.

7. Shutdown unit.

Check radiator overflow bottle. Add coolant to proper “cold” level.

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Page 37

MAINTENANCE

SERVICE GENERAL ADJUSTMENTS

USE EXTREME CAUTION while servicing while machine is running. The high-speed mechanical parts as well as high temperature components may result in severe injury, severed limbs, or fatality.

ENGINE SPEED

1. This unit uses a governor to set and maintain

engine speed. The engine speed is adjusted by shifting the throttle adjustment lever located on the front panel. The throttle adjustment lever has four positions. The first position is idle, 900 RPM. At this position the throttle adjustment lever is pulled out and is not locked in at the console. The throttle adjustment lever has three notches at its base. Push in the throttle adjustment lever to the first notch and lock in position for low speed, 1250 RPM. Push in and lock the throttle adjustment lever at the second notch for 1900 RPM, and the third notch for 2400 RPM.

2. The throttle adjustment lever is attached to a governor. The governor has internal weights that apply pressure to a shaft with an extending arm. Attached to the arm is the carburetor linkage, adjusting engine speed. NOTE: Units are pre-set at the factory.

LINKAGE ADJUSTMENT (Engine Off)

Unsnap the tip of the linkage from the throttle arm ball, See “Linkage Adjustment” illustration. Pull the throttle adjustment lever all the way out to the idle position.

While holding the throttle arm down with your finger, position the linkage underneath the ball as shown in See “Linkage Adjustment” illustration. 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 retighten the locking nut.

IDLE SPEED ADJUSTMENT (Engine Running)

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. See “Throttle Adjustment” illustration.

HIGH SPEED ADJUSTMENT (Engine Running, pump off)

Push the throttle adjustment lever in and lock at the third notch position (high speed). Using a tachometer, adjust the spring tension nut, until 2400 RPM is indicated. See “Throttle Adjustment” illustration.

DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 2500 RPM . Permanent damage may occur.

3. Engine RPM should drop approximately

100 RPM on high and low speed when the vacuum inlets are covered.

4-9

EVEREST 980086 02/18/03

Page 38

MAINTENANCE

st NOTCH

nd NOTCH

3 rd NOTCH

(HIGH SPEED) approx. 2400 RPM

(LOW SPEED) approx. 1250 RPM

(MEDIUM SPEED) approx. 1900 RPM

EVEREST 980086 02/18/03

4-10

Page 39

MAINTENANCE

Use 5/16 Allen

Tight wrap

CHECK VALVE (SOLUTION OUTLET)

Inspect the check valve whenever doing service on the chemical pump or if flow problems occur in the chemical system:

1. Remove the check valve. Be sure the small oring for the seat comes out with the check valve.

2. Remove the seat, using a 5/16" Allen wrench. Check the Teflon seat for debris or wear. Clean

or replace Teflon seat if needed.

4. Clean the poppet and spring, inspect for wear or damage, and replace as needed.

Re-assemble the check valve. Start the seat by

5. hand, tighten using a 5/16" Allen wrench. DO

NOT over-tighten seat.

On spring

CHEMICAL PUMP

The only repairs which the chemical pump may require is the replacement of the diaphragm or check valves. To replace the diaphragm, unscrew the cover from the body. When replacing the diaphragm, lubricate the outer edges of the diaphragm with o-ring lubricant Part #05-008035 and reassemble. To replace the check valves, unscrew the check valve caps. Replace the check valves and reassemble, using new o-rings.

DO NOT attempt to re-use o-rings once the check valves have been removed. See the “Illustrated Parts Listing” for a parts break-down on the chemical pump.

Wrench to remove

NOTE: Improper seating of the check valve poppet, damaged spring or o-rings will cause poor operation of the chemical system.

6. Lubricate the o-rings with o-ring lubricant

Part #05-008035 and reinstall.

4-11

EVEREST 980086 02/18/03

Page 40

MAINTENANCE

PACKING NUT ADJUSTMENT FOR CHEMICAL METERING AND CHEMICAL SELECTOR VALVES

Examine the packing nut on the chemical metering, flow simulator, and chemical selector valves for proper tension every 200 hours. When turning the knob, there should be a small amount of resistance. If not, slightly tighten the packing nut. DO NOT overtighten. Keeping the valve packings properly adjusted will eliminate possible leakage from the valve stems and add to overall valve life.

HIGH PRESSURE REGULATOR

To adjust: Set the high pressure regulator to desired pressure,

up to 3000 PSI. Adjust as necessary to meet you cleaning needs.

PRESSURE REGULATORS

The pressure regulators serve only to hold locked up water pressure at a preset point and to bypass this water back to the water box.

LOW PRESSURE REGULATOR

To adjust:

1. With your unit running, close the cleaning tool.

Check the pressure gauge. Open the tool valve. We recommend setting the pressure regulator so that the pressure gauge reads 350 PSI with the tool valve open.

When the tool valve is opened, there is an approximate drop of 100 PSI in pressure. If

there is a pressure drop greater than 100 PSI, it may be necessary to lubricate the o-rings in the pressure regulator.

2. If the pressure regulator requires adjustment,

turn the adjusting knob (while observing the pressure gauge on the control panel) until the desired pressure is obtained.

ADDING/DRAINING ENGINE COOLANT

Use a 70:30 coolant to water ratio in this unit’s cooling system. NOTE: See the “Maintenance Chart” for specific details.

1. To drain the coolant, remove the radiator cap and turn the lower engine radiator draincock counterclockwise.

EVEREST 980086 02/18/03

4-12

Page 41

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Loss of water pump pressure. With the cleaning tool open,

the water pressure gauge reads below the normal operating pressure. NOTE:

If the water pump pressure drops below 50 PSI, the water pump will automatically be turned OFF.

Water supply is turned off or the float valve is stuck or improperly adjusted. NOTE: This may also cause the water pressure switch to disengage pump.

Water pump inlet supply line is plugged or drawing air. NOTE: This may also cause the water pressure disengage pump.

Improper engine speed

Pressure regulator o-rings are dry. Pressure regulator has worn o-rings Check o-rings. If necessary, replace. Pressure regulator is dirty, stuck open,

or improperly adjusted. Low pump volume. (Measure the

amount of water being returned to the water box from the pressure regulator. It should fill a gallon container about every 17 seconds).

Defective water pressure gauge. Replace gauge Orifice (spray nozzle) in the cleaning

tool is worn, defective, or wrong size. Debris clogging water lines or water

inlet disconnect. Clean or replace as needed.

Turn the water supply on or up. Check for kinks in the water supply hose. Examine the float valve and adjust or replace.

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). Using a tachometer, check the engine speed. Full throttle engine speed is 2400 RPM. Idle engine speed is 900 RPM. Refer to the “engine Speed” section for instructions on how to re-adjust. Lubricate o-rings, using o-ring lubricant Part #05-008035.

Clean or repair regulator. Adjust to working pressure. Lubricate o-rings, using o-ring lubricant Part #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 Nozzle or change nozzle size.

Loss of solution volume at cleaning tool orifice.

Water gauge reads normal.

4-13

Belts loose or broken Re-tension or replace as needed. Plugged orifice and/or screen in the

cleaning tool. Internal block between the pressure

regulator manifold and the outlet Ystrainer, or the Y-strainer screen is clogged

Outlet check valve is plugged Examine the check valve, remove any debris Defective quick-connect on one or more

of the high pressure hoses. Cleaning tool valve is malfunctioning. Repair or replace valve.

Hose inner lining is constricted. Remove restriction or replace hose.

EVEREST 980086 02/18/03

Unplug or replace orifice and/or screen 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.

Replace defective quick-connects(s) on high pressure hoses(s).

Page 42

4-14

PROBLEM CAUSE SOLUTION

Examine the tubing between the vacuum relief valve and the vacuum gauge and remove any blockage.

Inspect hose(s), repair or replace. Inspect the gasket. Repair seal or replace

Re-position lid(s). Unplug vacuum hose or inlet plumbing. Clean or replace filter. Clean strainer

basket.

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 diaphragm. If damaged, replace

Remove and clean.

Refer to chemical pump priming instructions.

Unclog the strainer. If damaged, replace. Inspect inlet lines and flow meter for

damage and replace, if required. Remove any debris from the chemical check valve(s). Replace chemical check valve(s) or seals, if necessary.

Replace valve(s). Disassemble the chemical pump and

replace the damaged diaphragm. 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. Tighten fittings. Re-apply thread sealant where required. If any fittings are damaged, replace. Close the chemical valve on the instrument panel. If the flow meter does not indicate flow, remove debris or replace check valve, if necessary. Close the chemical valve on the instrument panel. If the flow meter still indicates flow, replace the chemical pump diaphragm. Tighten valve packing nut (see “General Service Adjustments” section in this manual). Replace valve, if necessary.

Loss of vacuum While cleaning, the vacuum is

not up to specification. Engine RPM is normal.

Loss of chemical With the cleaning tool valve

open, no chemical

Chemical flow meter indicates flow with the tool valve closed

Vacuum gauge is giving an improper reading.

Vacuum hose(s) is damaged, causing a suction leak. Waste tank gaskets not sealing properly, not positioned properly Plugged vacuum hose or vacuum plumbing between vacuum inlet and strainer basket. Waste tank filter or strainer basket is plugged.

Loose vacuum pump drive belts. Tighten the drive belts Waste tank drain valve is damaged

or left open, causing a vacuum leak.

Vacuum relief valve requires adjustment or has a vacuum leak due to damaged diaphragm.

Vacuum exhaust heat exchangers are plugged with lint.

Vacuum pump is worn out. Replace the vacuum pump. Chemical pump is improperly

primed. The strainer at the inlet end of the

chemical inlet line is clogged Suction leak in the inlet line leading into the chemical pump.

Chemical pump check valve(s) is clogged

Chemical prime/on-off valve or chemical metering valve is defective. Chemical pump diaphragm is ruptured.

Defective cylinder in the water pump.

External leak in chemical piping

Outlet check valve is full of debris or damaged, not allowing it to close properly

Chemical pump diaphragm is ruptured

Internal leak in chemical valve causing continual flow through prime tube returning to container.

TROUBLESHOOTING

EVEREST 980086 02/18/03

Page 43

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Check the solution pump circuit breaker on the control panel. Press the ciruit breaker reset button.

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 there is power in the switch, but not power at the clutch, replace the defective wire. If there is power at the clutch, replace the defective switch.

After inspecting the unit to determine the cause of the tripped circuit breaker, press the reset button. Clean, tighten, or replace the battery terminals.

Test ignition switch for power going into the switch. If there is power going in but NO power going out, replace the switch.

Determine the cause of overheating before restarting the unit. See “Excessive Heating” in the “Troubleshooting” section of this manual.

Repair or replace any broken electrical connections.

Check switch for proper operation, replace as necessary.

Test these components. If any are defective, replace. Consult the Nissan Engine Operation and Maintenance Manual.

Water pump does not engage

Engine will not start The engine does not turn over

Starter turns over engine, but will not start

Solution pump circuit breaker has been tripped

Defective electrical connection in the console wiring or defective switch.

Water pump has not been activated Turn solution pump switch to on. Defective water pump clutch.

NOTE: The clutch may be manually set by inserting two 1/4-20 x 1/2 bolts. Line up the holes on the clutch and insert the bolts. To disengage the pump, remove the bolts.

Loose or broken water pump belts. Tighten or replace belts. Main circuit breaker on the control

panel has been tripped. Loose or corroded battery.

Dead battery. Recharge or replace battery. Defective ignition switch. Defective starter motor. Test the starter motor. If necessary replace.

Vacuum pump seized. Refer to Sutorbilt Service & Repair Manual. Waste tank is full. Empty the waste tank.

Engine temperature has exceeded 240°F, triggering the high temperature switch to shut the unit down.

Defective fuel pump. Replace the fuel pump. Loose or broken wires leading to

waste tank float switch. Defective float switch in the waste

tank. Oil pressure switch (located on engine), anti-diesel solenoid (located on engine), high temperature switch (located on engine).

4-15

EVEREST 980086 02/18/03

Page 44

PROBLEM CAUSE SOLUTION

Starter turns over engine, but will not start

Engine stops running While doing normal cleaning, the engine stops running

Excessive heating

Heat exchanger leaks

Engine is malfunctioning Engine is out of gasoline Add gasoline to the fuel tank.

Waste tank is full Empty waste tank. Main or engine circuit breaker on

the control panel has been tripped. Engine coolant temperture has

exceeded 240°F, triggering the high temperature switch to shut the unit down.

Defective fuel pump. Replace fuel pump. Defective float switch inside the

waste tank. Defective 240°F engine coolant high-temperature shudown switch.

Oil pressure gauge on engine has shut down, due to insufficient oil pressure.

No ignition in the engine or engine is malfunctioning.

Flow restriction caused by hard water scaling.

Not enough water flow. Check jet size of tool.

Refer to Nissan Engine Operation and Maintenance Manual.

After inspecting the unit to determine the cause of the tripped circuit breaker, press the reset button. Determine the cause of the overheating before restarting the unit. Refer to the Nissan Engine Operation and Maintenance Manual.

Check switch for proper operaton. Replace as necessary.

Test switch. If necessary, replace. Refer to the Nissan Engine Operation and

Maintenance Manual. DO NOT restart the engine until the cause is determined and corrected. Refer to the Nissan Engine Operation and Maintenance Manual.

Descale unit, repair or replace damaged plumbing components as necessary. Install water softener.

TROUBLESHOOTING

NOTE: The exhaust heat exchanger will produce water condensation discharge at times during normal operation. DO NOT confuse this with a leak.

Loss of temperature The heat output of the unit is

LESS than normal. Automatic waste pump is

malfunctioning or not operating normally

NOTE: When replacing either the pump or float switch, use new electrical connectors and heat shrink. Inspect connection for watertight seal.

Engine/vacuum exhaust heat exchangers are damaged from frozen water.

Temperature relief valve on water box is stuck open.

Engine RPM is low. Reset engine RPM. Defective temperature gauge. Defective waste pump float switch. Replace float switch.

Broken diaphragm. Replace diaphragm. Weak battery.

Pump-out circuit breaker on control panel has been tripped.

Inspect heat exchangers for leaks. Visually inspect for damage. Pressure check after removing from the unit. (Maximum test pressure 1200 PSI).

Clean temperature relief valve and test. Replace, if necessary.

Test gauge and sensor. Replace failed component.

Charge or replace battery if needed. Check charging station.

After inspecting waste pump to determine the cause of the tripped circuit breaker, press the reset button.

EVEREST 980086 02/18/03

4-16

Page 45

FRAMEWORK

5-1

EVEREST 980086 02/18/03

Page 46

FRAMEWORK

REF PART NO. QTY DESCRIPTION

1 61383 1 PNL, CNTR HOOD BRKT 2 02-000066 18 FLATWASHER, 1/4 3 87162 17 WASHER, 1/4 SPLIT LOCK 4 00-000078 17 SCR, 1/4-20 X 1” HXHD GRD8 5 70069 2 SCR, 3/8-16 X 3 HHCS GR5 6 87171 7 WASHER, 3/8 FLAT 7 790099 1 ASSY, FRAME 8 57047 1 NUT, 1/4-20 HEX NYLOCK

9 790135 1 BRKT, LEFT HOOD 10 01-000259 13 RECEPT, SNAPIN 1/4 TURNFAST 11 790010 1 PNL, BELT GUARD, REAR 12 790007 1 PNL, REAR ENGINE/HOOD, MTG 13 57111 2 NUT, 3/8-16 HEX 14 03-000242 2 CLAMP ID X 1/4 BLT 15 00-000336 1 SCR, CAP 3/8-16 X 3 ALL THD 16 57119 5 NUT, 3/8-16 HEX NYLOCK 17 00-000286 1 SCR, CAP 1/4-20 X 2.75 HXHD 18 61400 1 ASSY, RADIATOR BRKT 19 03-000242 2 CLAMP, CABLE 3/4ID 1/4BLT 20 03-000249 1 CLMP, CABL 1/4ID 3/8BLT

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-2

Page 47

FRAMEWORK

5-3

11A 11B

15A

15B

EVEREST 980086 05/21/03

Page 48

FRAMEWORK

REF PART NO. QTY DESCRIPTION

1 70802 16 STUD, 1/4 TURN FAST LONG

2 02-000268 16 SPLITRING, REATIN. 1/4 TUR

3 61394* 1 PAN, PIN HOOD RIGHT INCLUDES 1,2 & 4

4 61395 16 PAD, 1/4 TURN. FAST, .188 THK

5 70597 2 SCR, 1/4-20 X 3/4 PPHMS BLK

6 87151 2 WASHER, 1/4 SPLIT LOCK BLK

7 02-000066 6 FLATWASHER, 1/4

8 61389* 1 PNL, FRONT HOOD

9 57090 4 NUT, 10-32 HEX NYLOCK SS 10 61390 1 PNL, , GRILLE

11A 790409 1 PANEL, LOWER FRONT LP LP ONLY 11B 790100 1 PANEL, LOWER FRONT HP HP ONLY

12 790465 4 SCR, 1/4-20 X 3-3/4 BHCS BLK 13 57047 5 NUT, 1/4-20 HEX NYLOCK 14 61393* 1 PANEL, HOOD LEFT INCLUDES 1,2 & 4

15A 500697 1 LABEL, FT HOOD LP LP ONLY 15B 500698 1 LABEL, FT HOOD HP HP ONLY

16 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD 17 790551 1 PLT, HIGH PRESSURE LCK HP ONLY 18 73698 1 SPACER, .50D X .28ID X 38L NYL 19 70489 1 SCR, 1/4-20 X 1.0 BH BLK PLATE 20 87172 2 WASHER, 1/4 ID FLAT BLK 21 87139 4 WASHER, 3/16 FLAT 22 58-700023 1 PAD, 1/4 TURN VIBR

SERIAL NO.

FROM

NOTES:

* WHEN ORDERING INDICATE PART NUMBER AND COLOR: i.e. 61394Y Y= YELLOW

G= GREEN

EVEREST 980086 04/11/03

5-4

Page 49

SIDE PANEL, RIGHT

TO VACUUM RELIEF VALVE

TO WASTE TANK

INLET TUBES

5-5

EVEREST 980086 02/18/03

Page 50

SIDE PANEL, RIGHT

REF

1 790430 1 BRKT, VAC INLET

2 12-800099 1 ELL, 1/8P X 1/4 POLY BR

3 57047 1 NUT, 1/4-20 HEX NYLOCK

4 66-945236 2 KIT, VAC INL PLG

5 02-000066 2 FLATWASHER, 1/4

6 00-000078 1 SCR, 1/4-20 X 1” HXHD GRD8

7 19-800075 1 CUP, OIL FILL 1/8P

8 500694 1 LABEL, VAC/WTR INLET

9 09-805380 2 HOSE, INT VAC 2.0 X 60.0 BLK 10 03-000054 2 CLMP, HOSE #32 1.5625/2.5 SST

PART NO.

QTY DESCRIPTION

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-6

Page 51

SIDE PANEL, LEFT

TO WATER BOX FILL

TO WATER BOX

(SIDE)

5-7

EVEREST 980086 02/18/03

Page 52

SIDE PANEL, LEFT

REF

1 790431 1 BRKT, WTR INLET

2 11-800437 1 ADPT, 3/8 BLKHD

3 11-800102 1 NIP, 3/8 HX BR

4 13-806008 1 DSC, 3/8F X 3/8FP

5 15-808008 1 VLV, BALL 1/2FP BS

6 15-808080 1 VALVE, BALL PVC 1-1/2FP

7 500694 1 LABEL, VAC/WTR INLET

8 11-800300 1 NIP, 1/2 X CL

9 790506 1 ADAPTER, HOSE 1/2M X MGT 10 03-000176 1 CLAMP, HOSE #16 11 03-000054 2 CLMP, HOSE #32 1.5625/2.5, SST 12 12-800345 1 FTTG, BRB 3/8P X 5/8H BR 13 09-805090 1 HOSE, INT VAC 2.0 X 49.0 BLK 14 12-800269 1 FTTG, BRB 1/2P X 5/8H BR

PART NO.

QTY DESCRIPTION

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-8

Page 53

CHEMICAL CONTROL PANEL

5-9

EVEREST 980086 02/18/03

Page 54

CHEMICAL CONTROL PANEL

REF PART NO. QTY DESCRIPTION

- 61384 - ASSY, CHEM CONTRL PNL COMPLETE 1 12-800065 3 CONN, 1/8P X 1/4T 2 15-808106 2 VALVE, METER 1/8FP 3 12-800040 1 ELL, 1/8P X 1/4T BR 4 61397 1 PNL, CHEMICAL CONTROL 5 500692 1 LABEL, CHEM CNTRL PN 6 18-808513 1 FLOWMETER 1/8 FP 7 12-800093 3 FTG, BRB 1/8P X 5/16H 8 11-800014 1 ELL, STREET 1/8 BR 9 15-808022 1 VALVE, 3-WAY BALL 1/8FP

10 56032 1 NIPPLE, 1/8 CLOSE 11 70162 2 SCR, 10-32 X 3/8 PPHMS SS 12 87165 2 WASHER, #10 SPLIT LOCK 13 790464 2 NUT, WELL 1/4-20 HD 14 00-000078 2 SCR, 1/4-20 X 1” HXHD GRD8

SERIAL NO.

FROM

NOTES:

EVEREST 980086 4/11/03

5-10

Page 55

CONTROL PANEL-PP-PPHP

5A 5B

5-11

EVEREST 980086 05/05/04

Page 56

CONTROL PANEL-PP-PPHP

REF PART NO. QTY DESCRIPTION

- 61398 - ASSY, INSTRUMENT PNL LP COMPLETE

- 61381 - ASSY, INSTRUMENT PNL HP COMPLETE 1 61396 1 PNL, INSTRUMENT 2 34-903026 1 LT, INST 3 500691 1 LABEL, INS PANEL 4 51387 3 LIGHT, WARNING

5A 36226 1 GAUGE, 0-4000 PSI HP 5B 36225 1 GAUGE, 0-1500 PSI LP

6 36227 1 GAUGE, VACUUM 30” HG 7 36229 1 GAUGE, TEMP 8 730202 1 SWITCH, 4-WAY IDEC HWIS-4TP13 9 49-802518 1 CABLE, CHOKE

10 61-950739 1 ASSY, OIL W/TR OVRRD SW 11 54092 1 METER, 0-60VDC HOUR 12 73811 2 STANDOFF, 6-32 X 1/2 HEX HYL 13 140625 1 BREAKER, 30A CIRCUIT ETA 14 140624 2 BREAKER, 15A CIRCUIT ETA 15 32-900201 1 SW, START W/KEY 3 POS 16 70270 1 SCR, 1/4-20 X 3/4 HHCS PLTD 17 87162 1 WASHER, 1/4 SPLTI LOCK 18 02-000066 5 FLATWASHER, 1/4 19 61385 1 PNL, UPR INS MTG 20 790464 4 NUT, WELL 1/4-20 HD 21 00-000078 4 SCR, 1/4-20 X 1” HXHD GRD8 22 140634 1 BREAKER, 20AMP THERMAL CIRCUIT 23 140702 1 BRKT, WIKA MOUNTING

SERIAL NO.

FROM

NOTES:

EVEREST 980086 05/05/04

5-12

Page 57

ENGINE

SUPPLIED

WITH ENGINE

43,44, 45,46,47

31,32

18,19

5,6

SUPPLIED WITH ENGINE

5-13

EVEREST 980086 10/11/03

Page 58

ENGINE

REF PART NO. QTY DESCRIPTION

40-902145 - ENG, A-15, NIS, PIN SPEC COMPLETE 1 42-902140 1 NIS FLTR, AIR #16546-21000 2 42-902351 1 NIS SPCR, AIR CLNR#162703 790390 1 GSKT, ADPT, CARB/AIR CLNR 4 790391 1 STUD, AIR CLNR 5 42-902381 1 NIS CARB 6 42-902149 1 NIS SOLEN, CAR#16196-L16 7 42-902253 1 NIS BOLT, FAN#08120-64062 8 42-902137 1 NIS BSKT, VLV CVR#13270-H 9 70302 2 SCR, 5/16-18 X 1HHCS GR5PLT

10 43-807067 2 GSKT, THERM-NIS A12 11 35-900202 1 TERM, 195 DEG 12 52-502020 1 ADPT, COOLNT OUTL 13 87083 6 WASHER, 5/16 SPLIT LOCK PLTD 14 70549 2 SCR, M8 X 25 HHCS GR8 PLTD 15 790507 1 SPACER, FAN 16 42-902155 1 NIS FAN#21060-N8560 17 790399 1 PULLEY, 4 BELT A15 18 42-902349 1 NIS PMP, WTR#21010-K7700 19 42-902350 1 NIS GSKT, WTR PMP#21014-H 20 42-902134 1 NIS SET, PAN GSKT#11132-H 21 12-800177 1 ELL, #6BSTX1/2T ZNC PL 22 10-805287 1 HOSE, HP 3/8 X 10 (1/2 FT BS) 23 12-800062 1 PLUG, 1/2T 24 42-902139 1 NIS FLT, OIL#15208-55Y00 25 32-900029 1 SW, OIL PRESS 26 31090 1 ELBOW, #2 BSPT 90DEG ST BRASS 27 42-902188 1 NIS ALT (50AMP) #23100-H7711 28 70805 4 SCR, M6 X 70 HHMS PLTD 29 57054 2 NUT, M8 30 42-902152 1 NIS GSKT, FUEL PMP D24076 31 42-902146 1 NIS START#23300-H5015 32 42-902147 1 NIS, SOLEN, START#23343-B5 33 50-501915 1 PL, FUEL PMP CVR 34 56-501740 1 CVR, ALT 35 57114 2 NUT, 7/16-14 HEX 36 87176 2 WASHER, 7/16 SPLIT LOCK PLTD 37 87171 4 WASHER, .531 ID X 1.25 X 1 FLT PLT 38 00-000222 2 SCR, CAP 7/16-14 X 1.5 HX 39 87085 4 WASHER, M6 SPLIT LOCK DIN127B 40 52-502072 1 PULLEY, ENGINE A15 (BLOWER DR) 41 04-000355 1 CAP, VAC 3/8 OD 42 00-000428 6 SCR, CAP 8MM X 1.25 MM X 25MM 43 42-902352 1 NIS UNIT, TRANS#22020-G5110 44 42-902272 1 NIS ROTOR#22157-05M02 45 42-902153 1 NIS SEAL, DISTR. CAP#22185-23615 46 42-902271 1 NIS CAP, DISTR#2216278A10 47 42-902196 1 NIS DIST#22100-G5110 48 35-900050 1 SENS. TEMP 240 DEG 49 42-902148 4 NIS PLG, SPRTK#22401-M7714 50 09-805632 1 HOSE FUEL 5/16 X 10” 51 790586 1 HOSEBARB, #2 MBSPT X 5/16 52 04080 1 ADAPTER, #2 BSPT X 1/8 FNPT BR

SERIAL NO.

FROM

NOTES:

EVEREST 980086 10/11/03

5-14

Page 59

ENGINE

5-15

SUPPLIED WITH ENGINE

EVEREST 980086 02/18/03

Page 60

ENGINE

REF PART NO. QTY DESCRIPTION

1 42-902146 1 NIS START #23300-H5015 2 42-902138 1 NIS VLV, PCV#11810-A3501 3 87083 4 WASHER, 5/16 SPLIT LOCK PLTD 4 57054 4 NUT, M8 5 70377 4 SCR, 3/8-16 X 1.25 HHCS GR5 PLTD 6 87163 4 WASHER, 3/8 SPLIT LOCK 7 87171 6 WASHER, 3/8 FLAT 8 57119 2 NUT, 3/8-16 HEX NYLOCK 9 790408 2 MOUNT, ENGINE

10 42-902349 1 NIS PMP, WTR#21010-K7700 11 42-902350 1 NIS GSKT, WTR PMP #21014-H 12 02-000143 4 FLATWASHER, 5/16 13 31089 1 ELBOW, #4 BSPT 90DEG ST

SERIAL NO.

FROM

NOTES:

EVEREST 980086 10/11/03

5-16

Page 61

ENGINE

5-17

FUEL LINES

EVEREST 980086 06/07/03

Page 62

ENGINE

REF PART NO. QTY DESCRIPTION

1 790606 2 EL, 90DEG 1/8NPT X 1/4HB 2 790457 2 SCR, 3/8-16 X 3.25 HHCS PLTD 3 42-902144 1 NIS COUL #22433-52A60 4 02-000066 8 FLATWASHER, 1/4 5 87162 3 WASHER, 1/4 SPLIT LOCK 6 70270 3 SCR, 1/4-20 X 3/4 HHCS PLTD 7 87171 4 WASHER, 3/8 FLAT 8 57119 2 NUT, 3/8-16 HEX NYLOCK

9 57047 3 NUT, 1/4-20 HEX NYLOCK 10 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD 11 790573 1 BRKT, FUEL LINE W/RETURN 12 790605 1 EL, 90DEG 1/8 X 5/16HB 13 790115 1 BRKT, OIL DRAIN 14 43-807504 1 GROM, 1/4 ID X /8 OD 15 790487 1 DIPSTICK, CAT PUMP OIL 5CP 16 64-950383 1 CABLE, RETAIN 17 03-000266 1 CLMP, FUEL LINE 5/16 X 1/4B 18 57086 1 NUT, M5 19 57053 1 NUT, M6 HEX 20 70549 4 SCR, M8 X 25 HHCS GR8 PLTD 21 87083 4 WASHER, 5/16 SPLIT LOCK PLTD 22 02-000143 4 FLATWASHER, 5/16

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/07/03

5-18

Page 63

ENGINE GOVERNOR

5-19

EVEREST 980086 02/18/03

Page 64

ENGINE GOVERNOR

REF

1 140639 1 PNL, GOV BRKT

2 87176 4 WASHER, 7/16 SPLIT LOCK PLTD

3 00-000298 4 SCR, MACH 10MM X 20MM HXHD

4 87083 2 WASHER, 5/16 SPLIT LOCK PLTD

5 70302 2 SCR, 5/16 X 1 HHCS GR5 PLTD

6 56-501870 1 BRKT, R GOV

7 42-902200 1 NIS ASSY, ROD #16370-K4910

8 04-000288 1 SPG, GOV GRN BAND

9 42-902199 1 NIS GOB #19101 K7505 10 70270 1 SCR, 1/4-20 X 3/4 HHCS PLTD 11 02-000066 2 FLATWASHER, 1/4 12 790405 1 LEVER, THROTTLE CONTROL 13 57047 1 NUT, 1/4-20 HEX NYLOCK 14 44-802221 1 PULL, 12303G5110 (NISSAN) 15 44-802311 1 BELT, AX29 GOODYEAR MTCH MKR 16 57220 1 NUT, M6 X 1 HEX NYLOCK PLTD

PART NO.

QTY DESCRIPTION

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-20

Page 65

COOLANT SYSTEM

THERMOSTAT HOUSING

FROM ENGINE

5-21

EVEREST 980086 02/18/03

Page 66

COOLANT SYSTEM

REF PART NO. QTY DESCRIPTION

1 00-000216 2 SCR, CAP 1/4-20 X 1/2 FLTSO

2 140642 1 KBT BTL, OVRFL #19059-70

3 790429 1 RADIATOR

4 03-000065 2 CLAMP, HOSE #4 SST

5 49-802010 1 CAP, RAD, STANT AGX2643-01

6 02-000143 6 FLATWASHER, 5/16

7 52-502038 2 MT, RAD

8 57113 2 NUT, 5/16-18 HEX NYLOCK

9 04-000296 2 FLEX, FINGER (BUSH) 10 50-501761 2 WASHER, RAD 11 57285 2 NUT, 5/16-18 NYLOCK THIN SS 12 03-000248 2 CLMP, HOSE #16 1-1/2 MIN 1-3/4

SERIAL NO.

FROM

NOTES:

EVEREST 980086 03/24/03

5-22

Page 67

VACUUM BLOWER

5-23

18 17

EVEREST 980086 07/08/03

Page 68

VACUUM BLOWER

REF

1 57114 2 NUT, 7/16-14 HEX

2 87171 16 WASHER, 3/8 FLAT

3 04-000091 1 SPRING, VAC REL VLV

4 12-800099 2 ELL, 1/8P X 1/4 POLY BR

5 43-807106 1 DIAPH, VAC REL VLV

6 52-501684 1 ELL, VAC REL VLV

7 56-501994 1 STM-VAC REL VLV

8 140611 1 BLWR, TRI-FLOW

9 44-802245 1 PULL, 2TB58 10 790444 1 HUB, P1 X 1-1/4 11 52-502071 1 NIPPLE, VAC OUTL TRI-FLOW 12 43-810104 2 O-RING, 3-1/4 X 3-1/2 OD 13 790443 2 SPACER, BLOWER 14 790442 1 PLT, BLOWER ADJUST 15 44-802319 2 BELT, BX46 GOODYEAR MATCH 16 790467 4 SCR, 5/16-18 X 1.25 SHCS 17 70377 4 SCR, 3/8-16 X 1.25 HHCS BR5PLT 18 87163 8 WASHER, 3/8 SPLIT LOCK 19 70069 4 SCR, 3-8-16 X 3 HHCS BR5 20 57119 4 NUT, 3/8-16 HEX NYLOCK 21 00-000336 2 SCR, CAP 3/8-16 X 3 ALL THD 22 57111 3 NUT, 3/8-16 HEX 23 00-000340 3 SCR, MACH 5/16-18 X 1” GR 8

PART NO.

QTY DESCRIPTION

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-24

Page 69

WATER PUMP-PP

5 2

TO WATER BOX

TO TOP OF FLOWMETER

1117

41 42

TO CHEMICAL PRIME VALVE

5-25

EVEREST 980086 06/26/03

Page 70

WATER PUMP-PP

REF PART NO. QTY DESCRIPTION

1 00-000286 1 SCR, CAP 1/4-20 X 2.75 HXHD

2 02-000066 1 FLATWASHER, 1/4

3 11-800101 1 PLUG, 1/8P

4 57047 1 NUT, 1/4-20 HEX NYLOCK

5 12-800225 1 ELL, 3/8P X 1/2T SST

6 790446 2 BELT, NAPA A41

7 12-800065 1 CONN, 1/8P X 1/4T

8 03-000113 2 CLAMP, HOSE #12 SST

9 12-800278 1 FTTG, BRB 1/2P X 3/4H BR 10 790434 1 BRKT, 1/8 ALUM COUPLER 11 52-809123 1 RETAIN, VALVE SPRING 12 790317 1 ADAPTER, CEHM PMP (5CP3120) 13 41-809158 1 PUMP, CHEM (O-RING) SS 14 11-800014 1 ELL, STREET 1/8 BR 15 12-800093 1 FTTG, BRB 1/8P X 5/16H 16 14076 1 BUSHING, 3/8MPT X 1/4 FPT HEX 17 03-000065 2 CLAMP, HOSE #4 SST 18 32-900184 1 SW, PRESS 50 PSI 19 12-800040 1 ELL, 1/8P X 1/4T BR 20 140646 1 BRKT, CLTCH, WTR PMP, 2 GRV 21 140645 4 BLT, 1/4-20 X 3/8, SER FLNG 22 70262 4 SCR, M8 X 20 HHMS PLTD 23 790436 2 STRAP, WTR PMP HOLDDOWN 24 790602 1 PNL, WTR PMP BRKT 25 11-800275 1 ELL, ST 3/8 BR 26 11-800069 1 PLUG, 1/2 SOCHD BR 27 790435 1 PUMP, WATER 5CP CAT 28 31087 1 ELL, 1/4P X 1/4T SS 29 31-900185 1 CONN, BULLET M (.156) 30 51372 1 LOOM, 1/4, HIGH TEMP 10” 31 790398 1 CLUTCH, ELEC WTR PMP 32 57119 4 NUT, 3/8-16 HEX NYLOCK 33 87171 4 WASHER, 3/8 FLAT 34 87240 1 WASHER, .328ID X 1.00 OD X .119, ZNC 35 10-805288 1 HOSE, 3/16 X 17” 36 140644 1 BLT, 5/16-18 X 1, SOC, ZNC 37 70807 4 BLT, 8MM X 14MM, SER FLNG, PH 38 48098 1 KEY, .25 X .25 X 1, CAT WTR PMP

39 57302 4 NUT, 3/8 PUSH PLATE 40 16-808237 2 CAP, CHK VALVE CHM. PUMP

41 43-810079 2 O-RING, 7/8 ID X 1-1/16OD 42 42-809265 2 CHECK VALVE, CHEM PUMP 43 43-810105 1 O-RING, 1-5/8OD X 1-3/4 OD/40D VITON 44 42-809264 1 DISK, CHEM PUMP 45 42-809047 1 DIAPHRAGM, CHEM PUMP 46 52-502053 1 CVR, CHEM PUMP 47 52-502052 1 BDY, CHEM PMP

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/26/03

5-26

Page 71

WATER PUMP-PPHP

TO PRESSURE

MANIFOLD

TO WATER BOX

TO TOP OF FLOWMETER

TO CHEMICAL

PRIME VALVE

TO PRESSURE GAUGE

5-27

44 45

EVEREST 980086 06/26/03

Page 72

WATER PUMP-PPHP

REF PART NO. QTY DESCRIPTION

1 00-000286 1 SCR, CAP 1/4-20 X 2.75 HXHD

2 02-000066 1 FLATWASHER, 1/4

3 11-800101 1 PLUG, 1/8P

4 57047 1 NUT, 1/4-20 HEX NYLOCK

5 12-800446 1 ELL, 3/8P X 1/2T SST

6 140643 1 CONN, 3/8M X 1/4M SS

7 78543 1 TEE, 1/4 SS

8 03-000113 2 CLAMP, HOSE #12 SST

9 12-800278 1 FTTG, BRB 1/2P X 3/4H BR 10 790434 1 BRKT, 1/8 ALUM COUPLER 11 52-809123 1 RETAIN, VALVE SPRING 12 790317 1 ADAPTER, CHEM PMP (5CP3120) 13 41-809158 1 PUMP, CHEM SS 14 11-800014 1 ELL, STREET 1/8 BR 15 12-800093 1 FTTG, BRB 1/8P X 5/16H 16 72179 1 SWITCH, PRESSURE 50/5000 PSI 17 03-000065 2 CLAMP, HOSE #4 SST 18 790446 2 BELT, NAPA A41 19 12-800040 1 ELL, 1/8P X 1/4T BR 20 140646 4 BRKT, CLTCH, WTR PMP, 2GRV 21 1406645 4 BLT, 1/4-20 X 3/8, SER FLNG 22 70262 4 SCR, M8 X 20 HHMS PLTD 23 790436 2 STRAP, WTR PMP HOLDDOWN 24 790602 1 PL, WTR PMP BRKT 25 790397 1 ELBOW, 3/8 X 1/4T SS 26 11-800069 1 PLUG, 1/2 SOCHD BR 27 790435 1 PUMP, WATER 5CP CAT 28 12-800031 1 ELL, 1/4P X 1/4T BR 29 31-900185 1 CONN, BULLET M (.156) 30 51372 1 LOOM, 1/4, HIGH TEMP 10” 31 790398 1 CLUTCH, ELEC WTR PMP 32 57119 4 NUT, 3/8-16 HEX NYLOCK 33 87171 4 WASHER, 3/8 FLAT 34 87240 1 WASHER, .328ID X 1.00 OD X .119, ZNC 35 10-805288 1 HOSE, 3/16 X 17” 36 12-800065 1 CONN, 1/8P X 1/4T 37 70807 4 BLT, 8MM X 14MM, SER FLNG, PH 38 140644 1 BLT, 5/16-18 X 1, SOC, ZNC 39 48098 1 KEY, .25 X .25 X 1, CAT WTR PMP 40 15-808169 1 VALVE, BALL 6000 PSI 41 11-800369 1 NIP, 1/4 X CL SST 42 57302 4 NUT, 3/8 PUSH PLATE 43 16-808237 2 CAP, CHK VALVE CHEM. PUMP 44 43-810079 2 O-RING, 7/8 ID X 1-1/16 OD 45 42-809265 2 CHECK VALVE, CHEM PUMP 46 43-810105 1 O-RING, 1-5/8ID X 1-3/4OD VITON 47 42-809264 1 DIXK, CHEM PUMP 48 42-809047 1 DIAPHRAGM, CHEM PUMP 49 52-502053 1 CVR, CHEM PMP 50 52-502052 1 BDY, CHEM PMP

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/26/03

5-28

Page 73

WATER PUMP

5-29

EVEREST 980086 02/18/03

Page 74

WATER PUMP

REF PART NO. QTY DESCRIPTION

1 42-809393 1 CAT#46798 CAP, OIL FILTER

2 42-809239 1 O-RING, OIL CUP FILL CAP

3 43-807063 1 GASKET, OIL GAUGE

4 42-902380 1 GAUGE, OIL LEVEL

5 42-809392 1 CAT#46940 CVR, CRANKCASE

6 42-809391 1 CAT#14044 O-RING, CRANKCASE

7 42-809394 1 O-RING, BEARING CVR

8 42-809388 1 CAT#46618 ADAPT, MALE

9 42-809387 1 CAT#46886 MNFLD, HEAD 5CP 10 42-809320 1 CAT#45900 PLG, VLV 5CP 11 42-809386 1 CAT#48365 RNG, BK-UP VLV 12 42-809385 4 CAT#87872 BLT, MNFLD HEAD 13 42-809384 1 CAT#46749 RETAIN, SEAL 5C 14 42-809383 1 CAT#48201 RETAIN, PLNGR 15 42-809382 1 CAT#46884 PLNGR 5CP 16 42-809249 1 WASHER, KEYHOLE M18 17 42-809381 1 SLINGER, BARRIER 18 42-809380 1 CAT#46838 SEAL, OIL CRANK 19 790508 1 KIT, PISTON SEAL HI TEMP 20 42-809397 1 CAT#46886 MNFLD, HEAD 5CP

- 05-008016 1 OIL, CAT-WTR PMP

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/28/04

5-30

Page 75

VAC/HEAT EXCHANGER WITH SILENCER

2 7

5-31

EVEREST 980086 02/18/03

Page 76

VAC/HEAT EXCHANGER WITH SILENCER

REF PART NO. QTY DESCRIPTION

1 00-000078 22 SCR, 1/4-20 X 1” HXHD GRD8

2 70377 1 SCR, 3/8-16 X 1.25 HHCS GR5PLT

3 70069 4 SCR, 3/8-16 x 3 HHCS GR5

4 57119 11 NUT, 3/8-16 HEX NYLOCK

5 87162 22 WASHER, 1/4-20 SPLIT LOCK PLTD

6 02-000066 22 FLTWSR, 1/4

7 87171 12 WASHER, 3/8 FLAT

8 11-800276 3 ELL, 3/8 BR

9 12-800282 4 CONN, 3/8P x 1/2T BR 10 12-800345 12 FTTG, BRB 3/8P x 5/8H BR 11 790050 3 GASKET, VAC HE CVR 12 790388 2 ASSEMBLY, HEATER CORE 13 790064 1 HSG, VAC HE 14 790121 1 PLT, VAC MUFFLER MTG 15 620023 2 PLT, HEATER CORE CVR, STL 16 790341 1 VAC MUFFLER 17 36238 6 GROM, 1/2IDX1-1/4OD 1/8G 5/16W 18 790343 3 PAD, BTM VAC HTR CORE 19 790423 3 PAD, REAR VAC HTR CORE 20 790328 1 PLT, UPPER EXHAUST 21 790329 1 PLT, LOWER EXHAUST 22 790330 1 SEAL, CONICAL EXHAUST 23 790039 1 GASKET, VAC HE BOX TO MUFFLER 24 790051 6 PLT, NUT-VAC HE HSG 25 790038 3 FORGING, HEATER CORE MANIFOLD 26 790357 1 TUBE, EXHAUST 27 11-800224 5 PLG, 3/8 SOCHD BR 28 12-800225 1 ELL, ST 3/8 P X 1/2T BR 29 00-000064 14 RIV, 1/8 x 3/8 ALUM 30 620024 1 PLT, HEATER CORE CVR FRONT, STL 31 50-502023 1 FLG, EXH NISSAN A-15 32 790505 1 ASSEMBLY, HEATER CORE (COPPER) INCLUDES 17 & 30

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/28/04

5-32

Page 77

SOLUTION TEMPERATURE CONTROL VALVE

6 5

5-33

EVEREST 980086 12/16/03

Page 78

SOLUTION TEMPERATURE CONTROL VALVE

REF PART NO. QTY DESCRIPTION

1 12-800282 1 CONN, 3/89 X 1/2T BR

2 84192 1 VLV, BALL, 3-WAY, HI-TEMP/PRES INCLUDES REF 3

3 38317 1 HNDL, VALVE, 3-WAY, HI P/T

4 12-800225 2 ELL, 3/8P X 1/2T BR

5 02-000066 2 FLATWASHER, 1/4

6 87162 2 WASHER, 1/4 SPLIT LOCK

7 70017 2 SCR, CAP 1/4-20 X 2.50 HHCS

SERIAL NO.

FROM

NOTES:

EVEREST 980086 12/16/03

5-34

Page 79

HELI-COIL HEAT EXCHANGER

TO LOW PRESSURE REGULATOR

TO TEMPERTURE

TO SUCTION SIDE OF ENGINE WATER PUMP

CONTROL VALVE

TO THERMOSTAT ADAPTER

TO BOTTOM OF RADIATOR

5-35

EVEREST 980086 02/18/03

Page 80

HELI-COIL HEAT EXCHANGER

REF PART NO. QTY DESCRIPTION

1 70554 2 SCR, 3/8-16 X 3.5 HHCS GR5PLTD 2 87171 4 WASHER, 3/8 FLAT 3 790445 1 BRKT, RIGHT HOOD MTG 4 57-520073 1 HE, HELI-COIL 5 15-808073 1 COCK, DRN 1/4P X 1/4 HOSE ELL 6 57119 2 NUT, 3/8-16 HEX NYLOCK 7 03-000248 8 CLMP, HOSE #16 1-1/2 MIN 1-3/4 8 52-501627 2 INL, HE

9 12-800326 2 ELL, 3/4P X 1/2T BR 10 58-500654 1 CSTG, COOLANT MANFLD 11 01-000259 1 RECPT, SNAPIN 1/4 TURNFA

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-36

Page 81

SOLUTION OUTLET

FROM THREE

WAY VALVE

FROM CHEMICAL PRIME VALVE

FROM

SIMULATED CHEMICAL PRIME VALVE

5-37

EVEREST 980086 08/13/03

Page 82

SOLUTION OUTLET

REF PART NO. QTY DESCRIPTION

1 70270 4 SCR, 1/4-20 X 3/4 HHCS PLTD

2 87162 4 WASHER, 1/4 SPLIT LOCK PLTD

3 790324 1 MANIFOLD, SOLUTION

4 11-800224 1 PLUG, 3/8 SOCHD BR

5 56015 2 NIPPLE, 1/4 HEX

6 22015 2 COUPLER, 1/4 QD

7 730224 1 SCREEN, CHECK VALVE

8 15-808094 1 VALVE, CHECK

9 12-800225 1 ELL, 3/8P X 1/2T BR 10 11-800118 1 BUSH, 3/8 X 1/8 BR 11 34-903019 1 SENDER, TEMP 140-320 DEG 12 12-800261 2 ELL, 1/8P X 1/4T 45 DEG 13 11-800206 1 PLG, 1/8 SOCHD BR

SERIAL NO.

FROM

NOTES:

EVEREST 980086 08/13/03

5-38

Page 83

WATER BOX-PP

REAR

TO WASTE TANK

TO WATER INLET

5-39

FRONT

EVEREST 980086 02/18/03

Page 84

WATER BOX-PP

REF PART NO. QTY DESCRIPTION

1 11-800300 2 NIP, 1/2 X CL

2 11-800432 1 CAP, WATER BOX

3 12-800278 1 FTTG, BRB 1/2P X 3/4H BR

4 12-800269 4 FTTG, BRB 1/2P X 5/8H BR

5 14-806540 2 STRAINER, SUC END 1/2FP

6 15-808075 1 VLV, TEMP REL 145 DEG

7 75436 1 TANK, WATER BOX

8 790437 1 STRAP, WTR BOX HOLD DOWN

9 57047 2 NUT, 1/4-20 HEX NYLOCK 10 02-000066 4 FLATWASHER, 1/4 11 03-000113 2 CLAMP, HOSE #12 SST 12 03-000246 6 CLAMP, HOSE #8 SST 13 15-808110 1 VALVE, FLOAT 14 57006 2 NUT, 1/4-20 HEX 15 790411 1 ROD, FLOAT (1/4-20 X 3”) SST 16 19-807014 1 BALL, FLOAT 17 11-800299 1 ELL, STREET 1/2 45 DEG. 18 11-800361 1 ELL, 1/2 BR 19 12-800261 1 ELL, 1/8P X 1/4T 45 DEG 20 11-800041 1 ELL, STREET 1/2 BR 21 11-800069 1 PLUG, 1/2 SOCHD BR 22 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-40

Page 85

WATER BOX- PPHP

REAR

TO WASTE TANK

TO WATER INLET

5-41

FRONT

EVEREST 980086 02/18/03

TO PRESSURE REGULATOR

Page 86

WATER BOX- PPHP

REF PART NO. QTY DESCRIPTION

1 11-800300 2 NIP, 1/2 X CL

2 11-800432 1 CAP, WATER BOX

3 11-800041 1 ELL, STREET 1/2 BR

4 12-800278 1 FTTG, BRB 1/2P X 3/4H BR

5 12-800269 5 FTTG, BRB 1/2P X 5/8H BR

6 14-806540 2 STRAINER, SUC END 1/2FP

7 15-808075 1 VLV, TEMP REL 145 DEG

8 75436 1 TANK, WATER BOX

9 790437 1 STRAP, WTR BOX HOLD DOWN 10 57047 2 NUT, 1/4-20 HEX NYLOCK 11 02-000066 4 FLATWASHER, 1/4 12 03-000113 6 CLAMP, HOSE #12 SST 13 03-000113 10 CLAMP, HOSE #12 SST 14 15-808110 1 VALVE, FLOAT 15 57006 2 NUT, 1/4-20 HEX 16 790411 1 ROD, FLOAT (1/4-20 X 3”) SST 17 19-807014 1 BALL, FLOAT 18 11-800299 1 ELL, STREET 1/2 45 DEG. 19 11-800361 1 ELL, 1/2 BR 20 12-800261 1 ELL, 1/8P X 1/4T 45 DEG 21 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD

SERIAL NO.

FROM

NOTES:

EVEREST 980086 02/18/03

5-42

Page 87

PRESSURE REGULATOR-PP

FRONT HEATER CORE IN VAC HE

FROM LOWER ELBOW ON HELICOIL ASSEMBLY

FROM LOWER CONNECTION ON

ASSEMBLY

FROM WATER PUMP

5-43

EVEREST 980086 08/01/03

Page 88

PRESSURE REGULATOR -PP

REF PART NO. QTY DESCRIPTION

1 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD

2 87162 2 WASHER, 1/4 SPLIT LOCK

3 02-000066 2 FLATWASHER, 1/4

4 11-800224 2 PLUG, 3/8 SOCHD BR

5 11-800275 1 ELL, ST 3/8 BR

6 11-800429 1 NIP, HEX 3/8 SSTS

7 12-800345 1 FTTG, BRB 3/8P X 5/8 H BR

8 12-800347 2 ELL, 3/8P X 1/2T 45 DEG BR

9 790067 1 REGULATOR , PRESSURE 10 790106 1 ACCUMULATOR 11 790382 1 MANIFOLD, PRESSURE 12 11-800118 1 BUSH, 3/8 X 1/8 BR 13 12-800040 1 ELL, 1/8P X 1/4T BR 14 03-000246 1 CLAMP, HOSE #8 SST

SERIAL NO.

FROM

NOTES:

EVEREST 980086 08/01/03

5-44

Page 89

PRESSURE REGULATOR- PPHP

FROM LOWER ELBOW ON HELICOIL

ASSEMBLY

FROM UPPER CONNECTION ON FRONT HEATER CORE IN VAC HE

ASSEMBLY

FROM WATER BOX

FROM WATER PUMP

5-45

EVEREST 980086 01/28/04

Page 90

PRESSURE REGULATOR -PPHP

REF PART NO. QTY DESCRIPTION

1 790106 1 ACCUMULATOR, 250PSI CAT 6026

2 12-800347 1 ELL, 3/8P X 1/2T 45 EG. BR

3 12-800345 2 FTTG, BRB 3/8P X 5/8H BR

4 790067 1 REG, PRESS CAT #7670AWI

5 11-800275 1 ELL, ST 3/8 BR

6 11-800341 1 ELL, ST 3/8 45 DEG BR

7 11-800240 1 ELL, ST 3/8 SST

8 11-800429 2 NIP, HEX 3/8 SST

9 13-806040 1 DSC, 3/8F X 3/8FP SST 10 15-808147 1 REG, PRESS CAT #7672 7 GPM 11 11-800224 6 PLG, 3/8 SOCHD BR 12 790382 2 MNFLD, PRESS 13 02-000066 4 FLATWASHER, 1/4 14 87162 4 WASHER, 1/4 SPLIT LOCK 15 00-000286 4 SCR, CAP 3/4-16 X 6 HXHD 16 11-800069 1 PLUG, 1/2 SOCHD BR 17 11-800368 3 NIP, 3/8 X CL SST 18 84192 1 VALVE, BALL, 3-WAY, HIPRESS/HI TEMP INCLUDES ITEM 21 19 03-000246 4 CLAMP, HOSE #8 SST 20 790478 1 ELBOW, 3/8P X 1/2T 45DEG SS 21 38317 1 HNDL, VALVE, 3-WAY, HI P/T

SERIAL NO.

FROM

NOTES:

EVEREST 980086 01/28/04

5-46

Page 91

WASTE TANK- 80 GAL. & 100 GAL.

5-47

4A 4B

19 20

5A 5B

EVEREST 980086 04/11/03

Page 92

WASTE TANK-80 GAL. & 100 GAL.

REF PART NO. QTY DESCRIPTION

1 790125* 1 LID, STRAINER, WST TNK

2 790448 1 GASKET, WASTE TANK

3 56-501793 1 STRAINER BOWL

4A 790475 2 ROD, WST TNK LID SST, 100 GAL 4B 790514 2 RD, LID, ST TNK SST, 80 GAL 5A 790470* 1 TNK, WASTE, 100 GAL 5B 790509* 1 TNK, WST, 80 GAL

6 12-800031 2 ELL, 1/4P X 1/4T BR

7 11-800402 2 PLUG, 1-1/4 HXHD PVC

8 14-806569 1 STRNR, WST TNK RECT. 1.5”

9 790351 1 GASKET, WASTE TANK 10 790124* 1 LID, FILTER, WST TANK 11 70432 4 SCR, 5/16-24 X 3/4 HHCS SS 12 OPEN - 13 87029 4 WASHER, 5/16 FLAT SS 14 61-950621 1 ASSY, LVL SENS SHTOF SW 15 62986 4 PLATE TRUCKMOUNT 16 00-000072 10 SCR, 3/8-16 X 2” HXHD 17 57119 10 NUT, 3/8-16 HEX NYLOCK 18 87171 21 WASHER, 3/8 FLAT 19 70015 6 SCR, CAP 1/4-20 X 3/4 HHCS SS 20 87162 6 WASHER, 1/4 SPLIT LOCK 21 02-000066 6 FLATWASHER, 1/4 22 50-502085* 1 PNL, ACCESS- WST TNK 23 43-807574 1 GSKT, ACCESS PNL-WST TNK

SERIAL NO.

FROM

NOTES:

* WHEN ORDERING INDICATE PART NUMBER AND COLOR: i.e. 61394Y Y= YELLOW

G= GREEN

EVEREST 980086 09/25/03

5-48

Page 93

HOSE ACCESSORIES

5-49

EVEREST 980086 06/07/03

Page 94

HOSE ACCESSORIES

5-50

REF PART NO. QTY DESCRIPTION

1 12-800078 1 FITTING, BRB 2H BS PVC

2 08-805147 2 CUFF, 2”

3 10-805060 1 HOSE, VAC 2”X50’ W/ CUFFS & HOSE

4 56015 1 NIPPLE, 1/4 HEX

5 22015 1 COUPLER, 1/4 QD

6 56012 1 NIPPLE, 1/4 FPT QD

7 10-805108 1 HOSE, HP 1/4 X 50FT W/QD & VLVE

8 10-805077 1 HOSE, HP 1/4 X 50’

9 08-805155 2 GUARD, HOSE VINYL 10 15-808012 1 VALVE, BALL 1/4FP 11 43-810014 2 O-RING, 7/32ID X 11/32OD 12 43-810019 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 50FT W/QD

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/07/03

Page 95

BATTERY-FLOOR MOUNT

5-51

EVEREST 980086 06/07/03

Page 96

BATTERY-FLOOR MOUNT

5-52

REF PART NO. QTY DESCRIPTION

1 00-000167 2 SCR, 1/4-20 X 6” HXHD

2 87162 2 WASHER, 1/4 SPLIT LOCK

3 02-000066 10 FLATWASHER, 1/4

4 31-900179 1 COVER, BATTERY TERMINAL

5 36-900056 1 BATTERY

6 47-700007 1 SHIELD, BAT MT HT

7 56-500188 1 COVER, BATTERY

8 56-502049 1 TRAY, BAT FLOOR MT

9 00-000132 4 SCR, 1/4-20 X 1-1/2 HXHD 10 57006 4 NUT, 1/4-20 HEX

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/07/03

Page 97

AUTOMATIC PUMPOUT-OPTIONAL

5-53

5 4

9,12,15

EVEREST 980086 06/07/03

Page 98

AUTOMATIC PUMPOUT-OPTIONAL

REF

1 70105 4 SCR, M4 X 60 PH

2 00-000132 2 SCR, 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 1” X 8’

8 10-805484 1 HOSE, GARDEN 3/4 X 75’

9 12-800052 1 CAP, HOSE 3/4 BR 10 12-800367 1 FTTG, BRB 1PX1H BR 11 12-800444 1 FTTG, 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

PART NO.

QTY DESCRIPTION

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/07/03

5-54

Page 99

AUTOMATIC PUMPOUT-OPTIONAL

5-55

EVEREST 980086 06/07/03

Page 100

AUTOMATIC PUMPOUT-OPTIONAL

REF PART NO. QTY DESCRIPTION

1 00-000210 4 SCR, 1/4-20 X 3/4 SOCHD

2 00-000311 4 SCR, 1/4-20 X 1/2 SHCS SS

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 52-501822 2 INL, HOSE CONN WST TNK 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 20 43-810101 1 O-RING, 800/1000 .072 21 43-807116 2 GSKT, IN/OUTLT WST TNK-PM 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 00-000311 2 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 31 52-501915 1 GUIDE, PLNGR WST PUMP-OUT 32 52-501921 1 PIN, WRIST PUMP-OUT 33 52-501934 1 TOP, PLNGR PUMP-OUT 34 52-501950 1 BUSH, THREADED 35 52-501822 2 INL, HOSE CONN WST TNK 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

SERIAL NO.

FROM

NOTES:

EVEREST 980086 06/07/03

5-56