Prochem Legend SE AD User Manual

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Page 1

980059

Operating Instructions (

ENG)

MODELS: LEGEND SE

Read

instructions before operating the machine.

MOBILE CLEANING UNIT

WITH AUTO HEAT DIVERTER

12/02/03

Page 2

MACHINE DATA LOG/OVERVIEW

YOUR DEALER

Address: __________________________________________________________________________________________

MODEL _______________________________________ DATE OF PURCHASE __________________________

SERIAL NUMBER ______________________________ SALES REPRESENTATIVE # _____________________ DEALER NAME ________________________________ OPERATIONS GUIDE NUMBER ___________________

PUBLISHED ____________________________________

Name: ____________________________________________________________________________________________

Phone Number: ____________________________________________________________________________________

Welcome…and congratulations on your purchase of the LEGEND SE Mobile Cleaning Unit. This instruction manual is a guide for operating and servicing your PROCHEM unit. Read this manual completely before

installing or operating this unit.

This unit offers you personal convenience. All of your instrumentation and controls have been positioned to give you easy access for operation and daily maintenance. Proper operation and service are essential to the efficient functioning of this unit. When maintained correctly, this unit will have a long, trouble-free life. The service methods described in this manual are explained in such a manner that servicing may be performed accurately and safely. Proper service varies with the choice of procedure, the skill of the mechanic, and the tools or parts available. Before attempting any repair, make certain that you are thoroughly familiar with this equipment and are equipped with the proper tools. Any questions pertaining to operating or servicing this unit should be directed to your nearest PROCHEM dealer.

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

MAKE CERTAIN THAT THE WARRANTY CARD IS FILLED OUT BY THE DISTRIBUTOR FROM WHOM YOU PURCHASED THIS UNIT AND RETURNED TO PROCHEM!

This operation and service manual is written specifically for the PROCHEM Legend SE Mobile Cleaning Unit which is manufactured by:

PROFESSIONAL CHEMICALS CORPORATION 325 SOUTH PRICE ROAD CHANDLER, AZ 85224

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

LEGEND SE 980059 07/23/02

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TABLE OF CONTENTS

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

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

HOW TO USE THIS MANUAL

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

SAFETY

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

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

INSTALLATION & OPERATION

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

Receiving Your Unit.......................................3-2

Installation......................................................3-3

Fuel.................................................................3-3

Engine Oil.......................................................3-3

Chemicals & Water........................................3-4

Lifting Unit.......................................................3-5

Positioning Unit In Vehicle.............................3-5

Bolting Down Unit And Waste Tank..............3-5

Dimensional Data...........................................3-6

Waste Tank To Console Connection...........3-7

Battery Installation........................................3-7

Fire Extinguisher..........................................3-7

Auxiliary Water Tank Connection................3-9

Decal locations.............................................3-10

Water Pumping System..............................3-11

Heat Transfer System.................................3-12

Vacuum System..........................................3-15

Chemical System........................................3-16

Water Supply connection............................3-17

Instrumentation...........................................3-18

High Pressure Hose ....................................3-19

Vacuum Hose.............................................3-19

Starting Unit (Cleaning Mode)....................3-19

Chemical Pump Priming.............................3-20

Waste Pump...............................................3-20

Cleaning......................................................3-21

Upholstery Cleaning....................................3-21

Stair Tool Cleaning......................................3-21

Flood Restoration........................................3-22

Shutdown & Daily Maintenance..................3-22

Freezing Protection.....................................3-23

Removing Anti-freeze..................................3-24

MAINTENANCE & SERVICE

Maintenance

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

Engine......................................................4-2

Vacuum Pump.........................................4-3

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

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

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

Float Valve, Water Pump Inlet Filter.......4-5

Strainer Basket (Waste Tank).................4-5

Bypass Manifold......................................4-5

Outlet Y-Strainer, Check Valve...............4-5

Chemical Pump, Chemical &

Heat Bypass Valves............................4-5

Nitrogen Accumulator..............................4-5

Pressure Regulator..................................4-5

Vacuum Hoses ........................................4-5

Battery.....................................................4-6

Engine Exhaust Heat Exchanger............4-6

Vacuum Exhaust Heat Exchanger..........4-7

High Pressure Hoses..............................4-7

Optional Waste Pump-out.......................4-7

Temperature Probe Packing...................4-7

General Service Adjustments

Engine Speed..........................................4-8

Vacuum Relief Valve...............................4-8

Vacuum Pump Drive Belts......................4-8

Water Pump Drive Belt............................4-8

Float Valve...............................................4-8

Bypass Manifold......................................4-9

Check Valve............................................4-9

Chemical Pump.......................................4-10

Packing Nut Adjustment (Chemical Metering & Selector Valves...4-10

Pressure Regulator..................................4-10

Temperature Solenoid.............................4-11

Temperature Capillary.............................4-12

Troubleshooting.......................................4-12

LEGEND SE 980059 06/19/03

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PARTS LIST

Front Panel.........................................5-1

Framework.........................................5-3

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

Engine Starter....................................5-7

Vacuum Pump...................................5-9

Water Pump.......................................5-11

Chemical Pump ..................................5-15

Vacuum Exhaust Heat

Exchanger & Silencer........................5-17

Engine Exhaust Heat Exchanger.......5-19

Bypass Manifold.................................5-21

Solution Manifold ................................5-23

Water Box ..........................................5-25

Pressure Regulator Manifold.............5-27

Temperature Solenoid

& Bypass Valve ..................................5-29

Diverter Valve....................................5-31

Air Pump............................................5-33

Waste Tank........................................5-35

Waste Pump......................................5-37

Hose Accessories ..............................5-39

Wand-Quad-Jet..................................5-41

Wand-Tri-Jet......................................5-43

Wand-Stair Tool.................................5-45

Upholstery Tool..................................5-47

Shelf Assembly..................................5-49

Water Tank-Dual

With Demand Pump ...........................5-51

Water Tank- Demand Pump ..............5-53

Hose Reel..........................................5-55

Water Box With

Auxiliary Water Tank..........................5-57

Wiring Diagram..................................5-59

Warranty ............................................5-62

TABLE OF CONTENTS

LEGEND SE 980059 06/19/03

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HOW TO USE THIS MANUAL

This manual contains the following sections:

- HOW TO USE THIS MANUAL

- SAFETY

- INSTALLATION REQUIREMENTS

- INSTALLATION

- 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 # ___________________ DEALER NAME ______________________________ OPERATIONS GUIDE NUMBER __________________

PUBLISHED ________________________________

The model and serial number of your machine is on the lower front as shown.

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

- Drive Belts, Pulleys & Hubs

- Chemical Pumps

- Hoses

- 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:

- 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.

LEGEND SE 980059 07/23/02

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IMPORTANT SAFETY INSTRUCTIONS

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

When using this machine, basic precaution

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 diverter valve or any part of 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.

LEGEND SE 980059 07/23/02

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Page 7

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 prevent possible explosions.

DO NOT damage the vehicle in any manner during installation. When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle. Avoid any contact with moving parts, areas of high temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects.

DO NOT 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 by vehicle vibration abrasion.

DO NOT exceed your vehicle's weight limit. The console with waste tank and accessories weighs approximately 886 lbs (976 lbs. if mounted on water tank). 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. This unit is equipped with a low pressure shutdown device. DO NOT bypass or operate this unit without the low pressure shut-down switch.

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.

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LEGEND SE 980059 07/23/02

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HAZARD INTENSITY LEVEL

The following WARNING LABELS are found on your LEGEND SE console. These labels point out important Warnings and Cautions which should be followed at all times. Failure to follow warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage. Follow these instructions carefully! DO NOT remove these labels.

Order Part #48-941212 to get a complete set of decals (safety and instrumentation) for your LEGEND SE cleaning unit. The following decals must be placed in a prominent spot on the vehicle that your unit is to be installed in where access is given to operate the unit. See Figure 12 on page 3-17 for suggested locations for these decals.

Decal, Fuel Clean-Up Decal, Carbon Monoxide Part #48-941317 Part #48-941316

LEGEND SE 980059 07/23/02

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TECHNICAL SPECIFICATIONS

ITEM DIMENSION/CAPACITY

Engine speed 2600 rpm (high speed in H.E. position)

1400 rpm (idle speed in Muffler position waster pump OFF. Water pump rpm 1395 rpm Vacuum pump rpm 3195 rpm Water flow rate 3.5 GPM (maximum) Water pump pressure 1000 PSI (maximum) Vacuum relief valve 13” Hg (13” Legend Hg - SE) Waste tank capacity 70 gallons (60 gallons to shut-off) Console weight 640 lbs. (730 lbs. If mounted on water tank) Console weight (with waste tank & accessories) 886 lbs (976 lbs. If waste tank is full)

(1467 lbs. If waste tank is full)

(1566 lbs. If auxiliary water tank is full)

TORQUE VALUES

Engine hub 264 inch lbs 22 foot/lbs Vacuum pump hub 192 inch/ lbs 16 foot/lbs

JET SIZING:

Prochem recommends floor tool tip sizing not exceed a total of “.045”. Using larger jet sizes on your LEGEND SE may reduce cleaning temperatures.

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

015 x 3 = 045

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

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LEGEND SE 980059 07/23/02

Page 10

RECEIVING YOUR UNIT

DEALER RESPONSIBILITY

The PROCHEM dealer from whom you purchased this mobile cleaning unit is responsible for the correct installation of this machine. The dealer is also responsible for initial training of your operators and maintenance personnel in the proper operation and maintenance of this unit.

ACCEPTANCE OF SHIPMENT

Every part of your Prochem LEGEND SE 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 common carrier immediately.

2. Check your equipment and packing list. The standard Prochem LEGEND SE cleaning unit should arrive equipped with the following items (unless otherwise specified) and any optional accessories which were ordered:

EQUIPMENT LIST

10. Waste tank filter and strainer basket.

11. 100 ft. of 2” vacuum hose.

12. 1 vacuum hose connector.

13. 100 ft. of 1/4" high pressure hose with quick connects.

14. 50 ft. water supply hose with quick connect.

15. 5 gallon jug and holder.

OPTIONAL EQUIPMENT

15. Winterizing loop hose. Part #10-805380.

16. Upholstery tool and stair tool.

#78513/78519 #78521

17. Extra wands.

18. Hose reel. #65-950393

19. Extra vacuum hoses. Part #10-805060.

20. Extra vacuum hose connectors. Part #12-800078.

1. LEGEND SE console.

2. Operation and service manual with engine, water pump, and vacuum pump manuals.

3. Installation bolting kit.

4. Installation mounting plates.

5. Fittings and hoses for fuel supply installation.

6. Hose clamps for fuel & vacuum hoses.

7. External fuel pump installation kit.

8. Carpet wand.

9. Waste tank w/float switch.

21. Extra high pressure water hoses. Part #10-805122.

22. Van storage unit. Part #65-950392.

23. Dual auxiliary water tanks with demand pump. Part #66-945260.

24. H.D Automatic waste pump kit. Part #66945553

25. Galvanized drip tray. Part #56-501845 (Part #56-501930 if mounted on water tank.)

26. Water softener. Part #66-945430.

LEGEND SE 980059 07/23/02

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Page 11

INSTALLATION

°C -30 -20 -10 0 10 20 30 40

5W-20, 5W-30

Prior to starting the installation, first read the ENTIRE "Installation” section of this manual. Since the LEGEND SE cleaning unit (with waste tank and accessories) weighs approximately 886 pounds (976 lbs. if mounted on water tank), consider the following recommendations before installing this unit.

1. The unit should NOT be mounted in any motor vehicle of less than 1/2 ton capacity, or 3/4 ton if equipped with one or more auxiliary fresh water tanks.

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 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 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.

RECOMMENDED SAE VISCOSITY GRADE

10W-30

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 galvanized drip tray under the console (Part #56-501845, or Part #56-501930 for units mounted on a water tank.)

7. If using a trailer, the LEGEND SE console should be positioned so that it balances properly with respect to the axle. Ten percent (10%) of the overall unit weight (without accessories or water) should be on the tongue.

°F -20 0 20 32 40 60 80 100

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

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LEGEND SE 980059 07/23/02

Page 12

INSTALLATION

CHEMICAL REQUIREMENTS

The Prochem LEGEND SE, 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.

LEGEND SE 980059 07/23/02

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Page 13

INSTALLATION

All units must be bolted to the floor of the vehicle by a PROCHEM DISTRIBUTOR.

LIFTING THE UNIT ONTO THE VEHICLE

Since the Prochem LEGEND SE console weighs approximately 640 lbs. (730 lbs. if mounted on water tank), we recommend using a fork lift to lift the unit onto the vehicle. Position the forks under the unit from the front and make CERTAIN that the forks are spread to the width of the base.

POSITIONING THE UNIT IN THE VEHICLE

Because vehicles vary in size and openings, individuals have their own preference as to where they want their units installed. We strongly recommend a side door installation for the LEGEND SE and DO NOT recommend a rear door installation.

BOLTING DOWN THE UNIT AND WASTE TANK

NOTE: When positioning the waste tank with respect to the console, hook up the vacuum hoses to the waste tank. This will ensure that the waste tank is positioned correctly. Once the unit and waste tank are positioned in the vehicle in the desired location, you may proceed.

Before drilling any mounting holes in the vehicle floor, make certain that when drilling, you will not do any damage to the fuel tank, fuel lines, or any vital component which might affect the operation or safety of the vehicle.

1. Using the console and waste tank mounting

holes as a template, drill six 13/32" diameter holes for mounting the console and six more 13/32" diameter holes for mounting the waste tank.

2. Using the installation hardware kit:

1. Enough space should be provided to assure

adequate engine ventilation and room for service and maintenance.

2. The unit with waste tank and accessories must NOT exceed the vehicle's axle weight limit.

3. DO NOT position the console closer than 12"

from the bottom of the driver and passenger seats.

NOTE: For individuals who wish to make an engineering layout prior to positioning the unit, refer to Figure 2 for waste tank and console dimensions.

a) Insert six 3/8-16 x 2" hex head cap screws

with flat washers through the mounting holes in the Prochem LEGEND SE console, and six 3/8-16 x 2" hex head cap screws with flat washers through the mounting holes in the waste tank.

b) Install the mounting plates underneath the

vehicle floor.

c) Screw the 3/8-16 hex head locknuts on

the mounting screws and tighten them until the console and the waste tank are firmly secured to the vehicle floor.

3-5

LEGEND SE 980059 07/23/02

Page 14

INSTALLATION

LEGEND SE 980059 07/23/02

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Page 15

INSTALLATION

WASTE TANK TO CONSOLE CONNECTION

NOTE: Before connecting any hoses to the waste tanks, make certain the hose clamps are on each hose.

1. See Figure 11. Connect the 12” long section of 2” I.D. internal vac hose to the 2” dia. vac inlet tube on the console and the 2” dia. inlet tube on the waste tank. Tighten the hose clamps.

2. Connect the 25” long section of 2-7/8" I.D. internal vac hose to the 2-7/8” dia. vac outlet tube on the waste tank and to the vacuum pump relief valve on the console. It may be necessary to cut this hose to fit. Tighten the hose clamps.

3. Connect the 2” I.D. waste removal hose to the 2” dia. tube at the bottom of the waste tank. Tighten the hose clamps.

4. Connect the 5/16" I.D. water box hose to the barb fitting (pointed downward) on the waste tank, which is mounted on the outside of the waste tank. Tighten the hose clamps.

5. Connect the console engine shut-off cord to the waste tank level sensor cord.

BATTERY CONNECTION

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 wellventilated 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.

1. Attach the red positive (+) battery cable from the

console starter solenoid to the positive (+) terminal on the battery and tighten the holding nut.

2. Next, attach the black negative (-) battery cable from the console ground to the negative (-) terminal on the battery and tighten the holding nut.

BATTERY HOOK-UP

3-7

FROM GROUND CONNECTION ON CONSOLE

FIRE EXTINGUISHER

We recommend that a fire extinguisher, preferably rated for A, B, & C type fires, be installed inside the vehicle.

LEGEND SE 980059 06/19/03

FROM

STARTER

SOLENOID

ON CONSOLE

BATTERY

WASTE

TANK

Page 16

INSTALLATION

3-8

FIGURE 11

SPECIAL INSTRUCTIONS:

1. Cut hoses to fit, if necessary.

2. When cutting hoses, make certain that the cutting

blade is facing away from you hands, fingers, or any other part of your body to avoid injury.

LEGEND SE 980059 06/19/03

3. Do not install hoses with excessive bends or kinks.

4. Place clamps on hoses before installing.

5. Tighten all hose clamps firmly.

Page 17

INSTALLATION

FIGURE 12

AUXILIARY WATER TANK CONNECTION

Your cleaning unit may be equipped with an auxiliary water tank mounted underneath the console. If so, you will need to install the demand pump assembly. (See “Illustrated Parts Listings” for demand pump dimensions.)

The demand pump should be situated in a location where it is easily accessible. We have provided hoses which are long enough to reach their connections on the console and auxiliary water tank.

Figure 12 illustrates how the demand pump works with the auxiliary water tank and how it connects to the console.

1. Connect the ¾” I.D. water hose coming from the in-line strainer on the demand pump to the barb fitting at the bottom rear, right side of the water tank. Trim the hose for the best fit. Tighten the hose clamps.

2. Connect the demand pump cord to the 2-pole connector on the console (located on the left side of the console near the vacuum pump.)

When using the auxiliary water tank as your water source, be sure you have enough water in the tank to complete the job.

1. Connect the hose from the demand pump to the water inlet at the front of the console.

2. Turn the demand pump toggle switch “ON.”

3. See “Operation” section in this manual for instructions on filling the auxiliary water tank.

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LEGEND SE 980059 06/19/03

Page 18

INSTALLATION

3-10

The decals should be placed in a prominent spot on the vehicle where access is given to operate the unit. The illustrations above suggest the location and placement of the decals.

When placing the decals, be sure the area is clean of any dirt and possible wax build-up. Place the decal by starting at on edge and smoothing he decal over to the other edge. This will help eliminate air bubbles and allow the decal to adhere better. After a time the decals may become damaged or worn. If they become unreadable, they should be replace.

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OPERATION

This chapter of the operator’s manual divides the unit up into systems and explains how each system works. Before proceeding into the operation and maintenance sections of this manual, we recommend acquiring a basic knowledge of how this unit functions. Read the next section of this manual carefully and completely.

WATER PUMPING SYSTEM

See Figures 14 and 15. Cold water enters the console through the water inlet connection located on the lower front panel. The water flows to the water box through a float valve, which shuts off water flow when the water box is full.

Water then flows from the water box, through a strainer, into the water pump where it is pressurized. This pressurized water 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 pulsation’s. In addition, the manifold also contains a low-pressure switch and a high-pressure switch. These switches will shut the unit down if the water pressure drops below 50 PSI or exceeds 1200 PSI.

If the tool valve is closed, water flows from the pressure regulator through the vacuum exhaust radiator-type heat exchanger, where heat is transferred from the vacuum pump exhaust to the water.

The heated water then returns to the water box. If the temperature in the water box exceeds

180°F, a temperature relief valve will open and bleed a small amount of hot water into the waste tank, allowing cool water to flow into the water box.

When the tool valve is open, water flow is from the pressure regulator to the engine exhaust heat exchanger, where the water is super-heated by engine exhaust.

A bypass manifold, located next to the water box, constantly bleeds a small amount of hot water from the engine exhaust heat exchanger outlet to the water box.

Next, the hot water flows through the check valve manifold which contains a check valve and Y-strainer. This is where chemical injection occurs.

The hot solution then flows through the solution outlet manifold to the cleaning tool.

Temperature is adjusted primarily using the thermostatic temperature control. This control opens a solenoid valve if the water exceeds the temperature setting. When open, this valve allows hot water to be drawn into the waste tank. The temperature sensor for this control is located in the thermostat manifold en route to the solution outlet.

In addition, a heat bypass valve on the lower front panel lowers the solution temperature manually with a knob adjustment. When open, this valve allows hot water to be drawn into the waste tank.

An additional temperature sensor on the engine exhaust heat exchanger outlet will shut down the

engine if the water temperature exceeds 285°F. If this occurs, consult the “Trouble-shooting” section of this manual to determine the cause of overheating before restarting your unit.

3-11

LEGEND SE 980059 06/19/03

Page 20

OPERATION

3-12

HEAT TRANSFER SYSTEM

See Figures 14 and 15. Water is heated through a two stage heat exchange system which uses vacuum pump exhaust and engine exhaust.

Stage one utilizes vacuum exhaust heat blowing over a radiator-type heat exchanger prior to discharging the exhaust into the atmosphere. When the tool valve is closed, the water bypasses from the pressure regulator manifold back to the water box through the vacuum exhaust heat exchanger. The water is heated as it flows through this heat exchanger.

When the tool valve is open, the water flows from the pressure regulator manifold and through the stage two engine exhaust heat exchanger system where it is super-heated by extremely hot engine exhaust.

The engine exhaust heat exchanger is an engine exhaust chamber containing a stainless steel heating coil and catalytic converter. Water flows through the coil and is heated by the engine exhaust as is leaves the engine. The catalytic converter, combined with the injection of air pumped into the exhaust manifold, re-burns the exhaust waste gases. This results in super-heated water flowing through the solution outlet to the cleaning tool.

CATALYTIC ENGINE EXHAUST

HEAT EXCHANGER

VACUUM EXHAUST HEAT EXCHANGER

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Page 21

OPERATION

FIGURE 14

LEGEND SE 980059 06/19/033-13

Page 22

3-14

FIGURE 15

OPERATION

LEGEND SE 980059 06/19/03

Page 23

OPERATION

FIGURE 16

VACUUM SYSTEM

An exhaust diverter valve is located on the engine exhaust system. This directs the exhaust either to the heat exchanger for high temperature cleaning or to the exhaust muffler for low temperature cleaning or extraction, such as for flood restoration.

When the diverter valve is in the MUFFLER position, a relay automatically shuts off the water pump. An override switch on the control panel will enable you to turn the water pump ON, for low temperature cleaning.

See Figure 16. Vacuum flow is initiated by the vacuum pump, with air and water being drawn into the vacuum inlet at the front of the con-sole.

The mixture then flows through a strainer basket into the waste tank. Air exits the waste tank through a 100-mesh filter, and then flows into the vacuum pump. A vacuum pump relief valve has been provided for vacuum pump protection.

The air is discharged from the vacuum pump through the stage one heat exchanger where the heated vacuum exhaust blows across a radiatortype heat exchanger before discharging into the atmosphere.

A level sensor switch located near the top of the waste tank will shut the unit down before the waste tank reaches its full capacity. This protects the vacuum pump from water damage.

Use of a DEFOAMER will help prevent damage to the unit by a build-up of foam in the waste tank, which may be caused by some chemicals (foam build-up will not activate float switches).

3-15

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Page 24

OPERATION

3-16

FIGURE 17

CHEMICAL PUMPING SYSTEM

See Figure 17. The chemical is drawn from the chemical container through a strainer into the flow meter. The flow meter indicates the rate of chemical flow.

The chemical then flows through a check valve into a pulse-powered chemical pump. Next, the chemical pump injects the chemical through a check valve to the 3-way selector valve on the control panel. This valve may turn the chemical flow ON, OFF, or PRIME the chemical pump.

The chemical then flows through a metering valve to the solution outlet. This valve controls the rate of flow of chemical injection into the cleaning solution, which is indicated on the flow meter.

LEGEND SE 980059 06/19/03

Page 25

OPERATION

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 1.25 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

FILLING AUXILIARY WATER TANK

1. Your cleaning unit may be equipped with an

auxiliary water tank mounted underneath the console. To fill the auxiliary water tank, open the ball valve on the water box by turning the handle on the valve to the vertical position.

2. Connect the water supply hose to the water inlet quick-connect at the front of the unit.

Connect the hose to the water supply faucet.

3. Turn the water supply faucet on. The water will flow through the water box and fill the

auxiliary water tank.

4. When the auxiliary water tank is full, close the ball valve on the water box by turning the

handle on the valve to the horizontal position. Disconnect the water supply hose from the unit and plug the hose from the demand pump into the water inlet quick-connect at the front of the unit.

5. Turn ON the toggle switch at the front of the demand pump.

NOTE: Before connecting your water hose to the

supply faucet, flush out the faucet until the water is free of any debris. Flush out any debris which may be in your water inlet hose.

1. Connect the water supply hose to the water inlet quick-connect at the front of the unit.

Connect the hose to the water supply faucet.

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 .

NOTE: Make sure you turn on the demand pump before you start the unit.

3-17

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OPERATION

3-18

FIGURE 18

EXHAUST

DIVERTER SOLENOID ROTARY

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Page 27

OPERATION

HIGH PRESSURE HOSE

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

pressure hose.

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

STARTING THE UNIT

1. For carpet and upholstery cleaning set the temperature control on the control panel to the desired cleaning temperature. The thermostatic temperature control will allow you to increase or decrease the solution temperature automatically. Simply turn the control knob to the desired temperature setting.

2. For flood extraction operations set temperature control to 50°. This temperature setting energizes the rotary solenoid to hold the Exhaust Diverter in muffler position.

3. Close the heat bypass valve by turning the knob clockwise. DO NOT over-tighten.

The heat bypass valve allows you to decrease the solution temperature manually. Opening the valve (counter-clockwise) decreases the temperature by allowing hot water to bypass to the waste tank.

Before proceeding, be certain that the control panel indicators are at the following settings:

Engine – IDLE (Throttle Control In) Engine Choke – PULL OUT

NOTE: It will not be necessary to pull the choke out if the engine is already warmed up.

4. Turn the ignition switch to the START position while holding the water pump switch to the left (override position). The engine will start. For cleaning operation turn pump switch clockwise to on position. For flood extraction operations leave switch in off or straight up position.

NOTE: If your unit fails to build water pressure after 15 seconds, check for adequate water supply. If necessary, see “Loss of Water Pump Pressure” in the “Troubleshooting” section of this manual.

5. After starting the engine, push the choke in. After the engine has warmed up, pull the throttle all the way out and lock it in the full throttle position.

Allow adequate time for the unit to warm up before beginning the cleaning operation, approximately 5-15 minutes.

3-19

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Page 28

OPERATION

3-20

PRIMING THE CHEMICAL PUMP

NOTE: Prochem recommends that the chemical

pump be primed whenever the water pump is ON. This will eliminate possible pressure fluctuations and water pump pulsation’s related to a dry chemical pump.

1. Place the chemical inlet tube and the chemical prime tube into the chemical container.

NOTE: When placing the chemical inlet tube into the chemical container, make certain that it stays fully submerged since the chemical pump will not function if air is allowed to enter the inlet line. DO NOT operate the chemical pump without the inlet strainer properly installed.

2. Turn the chemical selector valve on the control panel to the PRIME position. The chemical will then flow from the chemical container through the chemical prime tube.

If the chemical does not flow, then: a. Put the chemical prime tube into the vacuum

inlet on the unit and seal off the vacuum inlet. The vacuum will quickly pull chemical from the chemical container. When the chemical starts to flow, turn the chemical selector valve to OFF, place the chemical prime tube back into the container, and turn the chemical selector valve back to PRIME to continue the procedure.

b. Once continuous chemical flow without air

bubbles has been achieved, turn the chemical

selector valve from PRIME to METER. With the cleaning tool open, observe the flow meter and

adjust the chemical metering valve until the desired rate of chemical flow is obtained (the chemical metering valve is located on the control panel below the temperature control.)

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.

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.

OPERATION

Once you have completed steps 1 through 10, proceed with the cleaning operation. Your unit should be in the full throttle position when cleaning 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.

EXHAUST DIVERTER VALVE

The automatic exhaust diverter valve directs exhaust through either:

a. The high temperature heat exchanger or through

the muffler. This is fully automatic and is controlled through the temperature setting dial for cleaning operations.

b. Set temperature control to desired temperature or

for flood extraction set to 50°.

WASTE PUMP

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.

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OPERATION

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.

2. Normally, chemical is applied on the push stroke 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, applying chemical in both push and pull strokes. Always finish up an area with a vacuum pull stroke.

3. When cleaning, keep the working opening (mouth) flat on the surface being cleaned. Keep the wand moving when the valve is open.

UPHOLSTERY CLEANING

Upholstery Tool, Part #78513

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

2. Slow engine speed down to minimize excess heat.

3. Use one (1) "80015" spray tip in the tool.

4. Pressure adjustment below 300 PSI should be

made at the tool itself, by using the adjusting knob located on the valve.

STAIR TOOL CLEANING

Stair Tool, Long, Part #78519 Stair Tool, Short, Part #78521

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

2. Slow engine speed down to minimize excess heat.

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.

NEVER dispose of waste in storm drains, waterways, or onto the ground. Always dispose of waste in accordance with Local, State, and Federal laws.

3. Use one (1) "9502" spray tip in your stair tool.

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OPERATION

3-22

FLOOD RESTORATION

Set the temperature control on the control panel to 50°.

SHUTDOWN AND DAILY MAINTENANCE

1. Run fresh water through the chemical injection system to flush out chemicals.

2. We recommend removing as much moisture from

your vacuum hoses as is reasonable. This will prevent spillage of solution in your vehicle when replacing hoses.

3. Position the throttle control to about 3/4 of the way out, but no less than 1/2 of the way out.

4. Disconnect the vacuum hoses from the unit.

5. Set temperature dial to 50°, and allow the unit to cool down to 180°F or less.

6. Push the throttle all the way in to idle and allow

the unit to run for 1 minute in order to remove all moisture from the vacuum pump.

NOTE: If finishing for the day: Pull the throttle all the way out, plug the vacuum inlet and spray WD40 (or equivalent) into the vacuum lubrication cup (located at front of console) for 5 seconds. This will lubricate the vacuum pump. Pull the throttle back to idle and continue to step #7.

7. Turn the ignition switch to the OFF position.

8. Turn the water supply faucet off. Bleed the

pressure out of the water supply hose by loosening the hose at the water supply. Unhook the water supply hose and store in vehicle.

9. Relieve pressure from the cleaning tools and pressure hoses by activating the valve on the

tools. Disconnect the tools and pressure hoses from the unit and store all items.

10. Drain the waste tank and dispose of waste in a proper manner.

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.

11. Remove the strainer basket from the waste

tank, clean out any accumulated debris, and reinstall. Inspect the vacuum inlet filter inside the waste tank. If there is any lint or debris, remove and clean filter.

NOTE: When removing the vacuum inlet filter, grip the plastic hexagonal section of filter. Grasping filter by the screen may collapse or ruin the filter. Re-install the filter hand-tight. NEVER operate this unit with this filter removed, damaged or improperly installed.

NOTE: When replacing this filter, we recommend using the stainless steel Prochem filter, Part #14-806518, only.

12. At the end of your work day, rinse out the waste tank with fresh water. DUO Deodorizer may be added to the waste tank to inhibit the growth of bacteria.

13. Clean the unit, tools, hoses, van interior, etc., as needed. Inspect ALL equipment for any damage, wear, leaks, etc.

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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.

7. Turn the water 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 water pump switch ON.

WINTERIZING LOOP

HOSE ASSEMBLY, #10-805380

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 anti-freeze. 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.

ADDING ANTI–FREEZE TO YOUR UNIT:

1. Shut off the water supply. Disconnect the water inlet hose from the front of your console.

2. Connect all high pressure hoses and tools

that may have water in them.

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

4. Start the unit , turn water pump off and open the tool valve pressure drops and water stops lowing.

LOOP HOSE

ATTACHMENT

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

8. Prime the chemical system with a 50/50 antifreeze/water mix. Insert the chemical inlet and prime tubes into the anti-freeze container. Turn the chemical valve to PRIME until antifreeze begins to flow out of the prime hose. Now turn the chemical valve to the ON (CHEMICAL) position, making certain that the flow meter indicates flow. Make certain that all anti-freeze drains out of the chemical hose into an approved container.

After 20 seconds, turn the chemical valve to the OFF position.

5. Turn the water pressure override switch to the override position and start the unit. Turn the

water 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.

Close the heat bypass valve by turning the knob all the way clockwise.

3-23

LEGEND SE 980059 06/19/03

9. Open the heat bypass valve by turning the knob counter-clockwise. After 10 seconds, close the heat bypass valve .

Hold switch in override position for 10 seconds.

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

Page 32

OPERATION

3-24

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.

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. Where permitted, we recommend disposal in sanitary sewer systems. Do not drain onto the ground or into storm drainage systems.

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Page 33

MAINTENANCE

Vacuum Pump

Engine

Water pump inlet filter (In water box)

Bypass manifold orifice & strainer

Engine

Vacuum pump

Drive pulley

Drive belts

Check valve (solution outlet)

Vacuum inlet filter (in waster tank)

* Or as often as required

SERVICE SCHEDULE

Engine Daily

Daily

Water Pump Daily

Vacuum Inlet Filter (In Waste Tank) Daily

Vacuum Hoses Daily

Automatic Waste Pump Daily

Vacuum pump Weekly*

Weekly Weekly

Weekly*

Battery Weekly*

Weekly*

Solution outlet Y-Strainer Monthly*

High pressure hoses 25 hrs

Engine 25 hrs

Pressure regulator 50 hrs

Engine 100 hrs Engine 100 hrs

Battery 100 hrs*

Engine 100 hrs Engine 100 hrs Engine 200 hrs

Heat bypass and chemical valves 200 hrs*

200 hrs

Temperature solenoid 200 hrs*

Vacuum exhaust heat exchanger 200 hrs

Water pump 500 hrs

250 hrs

Pulley set screws & hub cap screws 500 hrs

Drive pulley 500 hrs

500 hrs

Drive belts 500 hrs

500 hrs

Chemical pump & check valves 1000 hrs

1000 hrs

Vacuum pump yearly

Yearly*

Nitrogen accumulator Yearly*

Engine Yearly* Engine Yearly*

Check engine oil level. *** Fill to proper level Spray WD-40 in lubrication cup at front of console for 5 sec. Check oil level.** Fill to proper level Clean filter, inspect, replace if damaged Wash out with clean water Inspect and remove any debris or sediment Check oil level. Fill to proper level Examine air intake and cooling areas. Clean, if required. Check air cleaner for dirty, damaged, or loose parts. Check for debris and clean Check for proper fluid level. Fill with distilled water only Inspect and remove any debris or blockage Inspect and remove any debris or blockage Inspect for damage or impending damage Service pre-cleaner element. Lubricate stem and o-ring Change engine oil*** Service air cleaner elements Clean battery terminals Remove cooling shrouds and clean areas Check condition & re-set gap on spark plugs Change oil filter*** Inspect and/or adjust packing nuts Check radiator hoses and clamp tightness Remove any hard water deposits Inspect core and remove debris Change oil** Lubricate bearing on pulley end with grease 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**** Replace diaphragm and check valves Inspect, clean, and repair, if needed Drain, flush, and replace oil ***** Replace Check and have re-charged with nitrogen, if required Replace in-line fuel filter on engine Replace air cleaner element

** 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

4-1

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Page 34

4-2

°C -30 -20 -10 0 10 20 30 40

5W-20, 5W-30

WARNING

DANGER

MAINTENANCE

RECOMMENDED SAE VISCOSITY GRADE

W ARNING

10W-30

ELECTRICAL S HOC K COULD CAUSE SE V ERE BURNS OR INJURY. DO NO T TOUCH ELECTRICAL W IRE S OR COMPONE NTS W HILE THE ENGINE IS RUNNING. DISCONNECT THE BATTERY BEFORE S E RV ICIN G THIS UN IT TO PRE VE NT ACCIDENTAL S TART ING.

WAT ER UNDE R HI G H P RE SSURE AT HI GH TE M PE RATURE CAN CAUS E BURNS , S E VE RE P E RS ONAL I NJURY, OR COULD BE F ATAL . S HUT DOW N M ACHINE , ALL O W T O COO L DOW N, AND RE LI E VE S Y ST EM OF ALL P RE S SURE BE FO RE RE MO VI NG V ALV E S , CAP S, P LUGS , FI TT I NGS , FI LT ERS AND BO L TS.

R OTATIN G MACHINERY C AN CAUSE INJURY OR C OULD BE FATAL. K EE P ALL GUARDS AN D SAFETY DEV IC ES IN PLACE.

CAUTION

HOT SURFACE

D O N OT

TOU CH

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.

°F -20 0 20 32 40 60 80 100

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

2. It is important that the engine break-in oil is changed after the first five hours of operation. Afterwards, change the engine oil every 100

hours.

3. Examine air intake and cooling areas weekly.

Clean if required.

4. Check the air cleaner weekly for dirty, damaged, or loose parts.

5. Service the pre-cleaner element every 100 hours.

6. Service the air cleaner element every 100 hours.

7. Check the condition of the spark plugs and spark plug gap every 100 hours.

8. Remove the cooling shrouds and clean the cooling areas every 100 hours.

ENGINE

Major repairs should NOT be attempted without a thorough knowledge of all components of the engine. Therefore, we strongly recommend having service or repairs performed by an authorized engine dealer.

General maintenance, filter changes, oil changes, etc., should be performed as recommended by the Kohler Engine Operation and Maintenance Manual. Use the engine manual as a detailed guide for all matters concerning the engine. The following is a condensed version of maintenance procedures:

1. Check the engine oil level daily, when in use. Make certain that proper oil level is maintained. NEVER overfill. 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.

9. Change the oil filter every 200 hours.

NOTE: Perform these maintenance operations more frequently under extremely dirty or dusty conditions.

LEGEND SE 980059 07/23/02

Page 35

MAINTENANCE

unit on level ground)

Figure 19 VACUUM PUMP OIL LEVEL

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 this page.

1. Check the oil level weekly 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 Figure 19 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.

VACUUM PUMP LUBRICANT

BLOWER

DISCHARGE

TEMPERATURE

-40° TO 32°F

(-40° TO 0°C) 32° TO 100°F

(0° TO 38°C)

100° TO 275°F

(38° TO 135°C)

OVER 275°F

(135°C)

* In applications with extreme variations in ambient

temperature a 20W-50W multiple viscosity oil is

FOR GREASE LUBRICATED BEARINGS

Service every 500 hours or operation

Blower Discharge

Temperature

-40° to 275°F

(-40° TO 120°C)

OIL

GRADE

U.S.A.

SAE 10W 45

SAE 20 100 SAE 40 200 SAE 50 250

recommended.

OIL VISCOSITY,

CENTISTOKES

Type Grease

Non-corrosive bearing

grease

@ 40°C

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 inlet is sealed. Do this at the end of each working day.

VACUUM PUMP (side view)

OIL LEVEL

(with vacuum pump cold, engine off, and

OIL LEVEL SIGHT GAUGE

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. The bearings on the pulley end of the vacuum pump requires grease lubrication every 500 hours. Pack the bearings until grease comes

out of the vent holes. Use extreme pressure bearing grease of the specification NLGI Grade 2 EP.

4-3

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Page 36

MAINTENANCE

4-4

FIGURE 20

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 Figure 20 as a guide when checking the oil level. If the level has dropped, check for the source of leakage and repair.

2. Change the crankcase oil with Cat Pump Crankcase Oil, 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.

3. Other Cat approved oil equivalents are: Mobil

DTE 16, Amoco Rykow 68, and Shell Tellus T68.

DRIVE BELTS, PULLEYS, & HUBS

1. Check pulley set screws and/or hub cap screws

after the first 25 hours and then again at 100 hours. Re-torque these screws with a torque wrench, using the values on the chart on the next page. Check pulley set screws and/or hub cap screws every 500

hours thereafter.

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 720 60

Vacuum pump hub 192 16

2. 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. In multiple groove drives, belt ride should be uniform, not more than 1/16" above or below top of pulley groove.

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.

2. Inspect the vacuum inlet filter inside the waste tank. If there is any lint or debris, remove and clean filter. Re-install the filter hand-tight. Replace this filter yearly.

When removing the vacuum inlet filter, grip the plastic hexagonal section of filter. Grasping filter by the screen may collapse or ruin the filter.

NOTE: When replacing this filter, we recommend using only a stainless steel Prochem filter, Part #14-806518.

Check groove wear area for wear. Side wall of groove should be straight, not dished out. Bottom of groove should show no signs of belt contact.

Inspect belts for contaminants, such as oil or grease. Wipe belts clean with detergent and water. Inspect pulley grooves for buildup of such material and remove, if necessary.

Check wear surfaces of belt for excessive wear. If they have a slick, glazed look, belts are slipping. Check belt tension. Never replace one belt in a used set, as used belts will elongate. Replace entire set if replacement is necessary.

Place a straight-edge across the top of belt. There should be no more than 1/2" deflection in the center of the belt, halfway between the pulleys. If there is too much slack, tighten belt, making sure that it stays properly aligned.

See the "General Service Adjustments” section in this manual for details.

Check alignment with straight-edge, string, or machinist level. Correct alignment to as near perfect as possible.

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MAINTENANCE

FLOAT VALVE (WATER BOX)

Check the float valve at least once a month for proper operation. If overfilling is a problem, check the plunger for a proper seat. Replace tip on plunger if needed or damaged. Water level in the water box should be about 5-1/2" to 6”.

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

INLET FILTER (TO WATER PUMP)

The filter inside and on the bottom of the water box is rubber with a stainless steel screen. This should be inspected and cleaned on a weekly basis. Replace, if damaged.

NOTE: Vacuum all excess water and debris from water box prior to removing strainer.

WASTE TANK STRAINER BASKET

The strainer basket located inside the waste tank should be removed and cleaned whenever it is full of debris. This should be done on at least a daily basis.

BYPASS MANIFOLD (STRAINER AND JET BLOCK)

Check the strainer and the jet weekly. Remove any debris or blockage.

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

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.

CHEMICAL PUMP

Rebuild the chemical pump every 1000 hours. This involves changing the diaphragm and check valves.

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

CHEMICAL AND HEAT BYPASS VALVES

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.

Y–STRAINER (OUTLET)

Inspect the Y-strainer after the first week of running the unit by unscrewing the screen and removing 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.

4-5

LEGEND SE 980059 07/23/02

Page 38

MAINTENANCE

4-6

PRESSURE REGULATOR

Lubricate the o-rings every 100 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.

CATALYTIC AIR PUMP

Check and/or replace the air pump every 1500 hours. When replacing, it will also be necessary to

replace the air pump pulley.

TEMPERATURE SOLENOID

Remove hard water deposits from the temperature solenoid every 200 hours or as often as required.

1. Check the fluid level in the battery every 25 hours or once a week. If low, fill to the recommended level with distilled water ONLY.

NOTE: DO NOT overfill the battery. Poor performance or early failure due to loss of electrolyte will result.

2. Keep the cables, terminals, and external surfaces of the battery clean. A buildup of

corrosive acid or grime on the external surfaces can cause the battery to self-discharge. Selfdischarge occurs rapidly when moisture is present.

The battery terminals should be cleaned every 100 hours to prevent corrosion build-up. Wash the cables, terminals and external surfaces with a mild baking soda and water solution. Rinse thoroughly with clear water.

DO NOT allow the baking soda to enter the battery cells as this will destroy the electrolyte.

For the procedure, see the “General Service Adjustments” section in this manual.

BATTERY

Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times.

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

ENGINE EXHAUST HEAT EXCHANGER

If the engine and/or air pump are not properly maintained, the exhaust gases may deposit carbon on the outside of the heat exchanger coil and affect the cleaning solution temperature and damage the catalytic converter. If this condition exists, remove the heat exchanger from the unit and clean the carbon off the coil. This may be done by taking it to a radiator dealer and having it boiled out. The catalytic

converter must be completely removed before cleaning carbon deposits or damage may result.

Proper maintenance of the unit, such as regular tuneups, proper fuel, and a properly operating air pump will help prevent carbon build-up on the coil and increase the life of the unit.

Using A212 ULTRA CLEAN INDUSTRIAL CLEANER or A217-1 ULTRAPAC RENO-VATE will also greatly enhance the removal of carbon deposits. Soak the coil and casing ONLY, NEVER soak the catalytic converter core.

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MAINTENANCE

VACUUM EXHAUST HEAT EXCHANGER

1. Cleaning the vacuum exhaust pre-heater core is

recommended as needed or if the unit was operated with the vacuum inlet filter damaged, removed, or improperly installed. Pull out the core and remove all debris, being careful not to drive debris deeper into the core. We recommend removing the debris with water by either submerging the core and moving it back and forth until the debris loosens and falls off or by spraying the debris out of the core. Allow the core to dry before reinstalling.

2. Remove and inspect the vacuum exhaust preheater core every 200 hours.

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.

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. Remove the waste pump unit from the waste tank and clean inside the screen at least once a week,

or more frequently if required.

TEMPERATURE PROBE PACKING

Examine the temperature packing assembly for leaks every 200 hours. Tighten the packing nut fitting just enough to stop leaks. DO NOT overtighten.

For the procedure, see the “General Service Adjustments” section in this manual.

DO NOT attempt to repair high pressure hoses! Repairing high pressure hoses may result in severe burns and serious injury!

4-7

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MAINTENANCE

4-8

GENERAL SERVICE ADJUSTMENTS

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.

ENGINE SPEED

2. To adjust the engine RPM, refer to the Kohler

Engine Operation and Service Manual for specific instructions.

DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 2600 RPM.

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 13" Hg for LEGEND, 14” Hg for the LEGEND SE.

VACUUM PUMP DRIVE BELTS

4. After adjusting, re-tighten the four nuts which

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

5. Readjust and check air pump belt. DO NOT over-tighten belt. Re-tighten the two nuts which hold the air pump mount in place. Check belt alignment with straight-edge.

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.

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.

To tighten the vacuum pump belts:

1. Loosen the two nuts which hold the air pump mount in place.

2. Loosen the four nuts which hold the vacuum pump mount in place.

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).

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.

LEGEND SE 980059 07/23/02

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.

Page 41

MAINTENANCE

(

use 5/16 Allen

wrench to remove)

O-RING

TEFLON SEAT

SPRING

O-RING

CHECK

VALVE CAP

POPPET

ORIFICE

BYPASS MANIFOLD

Clean the bypass strainer and orifice using the following guidelines:

1. Remove the strainer. Clean and re-install. DO NOT over-tighten strainer.

2. Remove the cap. Remove the orifice, using a

3/16" Allen wrench (the 3/16" Allen wrench is provided with Part #66-945280, the bypass maintenance kit.)

BYPASS MANIFOLD DETAIL

O-RING

STRAINER

CAP O-RING

MANIFOLD

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.

CHECK VALVE DETAIL

Tight wrap

on spring

3. Re-install the cap and run the unit with the water pump ON for 15 seconds to flush out the bypass manifold.

4. Remove the cap and re-install the cleaned orifice, using the 3/16" Allen wrench. Tighten orifice just enough to seat. DO NOT over tighten. Re-install cap. DO NOT over-tighten cap.

NOTE: If o-ring seals leak, replace them. If strainer is damaged, replace strainer.

Re-assemble the check valve. Start the seat by

hand, tighten using a 5/16" Allen wrench. DO NOT over-tighten seat.

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.

4-9

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Page 42

MAINTENANCE

4-10

VALVE

PACKING NUT

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.

PACKING NUT ADJUSTMENT FOR CHEMICAL METERING, BYPASS, & CHEMICAL SELECTOR VALVES

Examine the packing nut on the chemical metering, heat bypass, 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 over-tighten. Keeping the valve packings properly adjusted will eliminate possible leakage from the valve stems and add to overall valve life.

PRESSURE REGULATOR

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

To adjust:

Remove knob By loosening set Screw to access Packing nut.

CHEMICAL SELECTOR

PACKING NUT (use 5/16"

open end wrench to adjust)

CHEMICAL METERING

HEAT BYPASS

VALVE

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. Turning the knob clockwise increases pressure, turning the knob counterclockwise decreases pressure.

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Page 43

MAINTENANCE

TEMPERATURE SOLENOID SERVICING

#49-876132

#49-876116

TEMPERATURE SOLENOID

The temperature solenoid may become seized due to hard water deposits. Make certain that the core moves freely in the stem. Also, the plunger must move freely within the guide. Clean with #0000 steel wool.

Check the seat to make sure that it is not distorted. Clean the seat, using a 3/64” drill bit. ROTATE THE DRILL BIT WITH YOUR FINGERS ONLY.

NOTE: DO NOT over-tighten nut when reassembling temperature solenoid. Overtightening the nut will damage the coil.

SPANNER WRENCHES for

OLD STYLE

SOLENOID

4-11

LEGEND SE 980059 07/23/02

Page 44

4-12

TEMPERATURE CAPILLARY & PACKING ASSEMBLY

INSTALLATION INSTRUCTIONS

1. Using thread sealant, thread the tapered end of the union fitting into the thermostat manifold and tighten.

2. Slide the jam nut over the capillary bulb with the threaded end toward the end of the capillary bulb.

MAINTENANCE

3. Insert the capillary bulb through the union fitting and into the thermostat manifold.

4. Place the rubber seal onto the capillary tube with the split facing 90° from the top (see the capillary

union detail).

5. Fit the four brass disks onto the capillary tube, with two of the brass disks on each side of the rubber seal. Face the notch on one brass disk toward the nearby brass disk to lock the brass disks together. Then face the notches on the brass disks 90° from the split in the rubber seal.

NOTE: Lubricating the facing sides of the brass disks will hold them together on the capillary

tube during installation .

6. Insert the rubber seal and brass disks into the union fitting, hand tight.

7. Position the capillary bulb in the temperature manifold as shown in the illustration. When positioning the capillary bulb, do not allow the bulb to compress against the support fitting.

8. Tighten the jam nut lightly, about 1-1/2 turns.

9. Examine the capillary union assembly for leaks and tighten the union fitting just enough to stop leaks. DO NOT over-tighten.

TROUBLESHOOTING

DO NOT service this unit while it is running. The high-speed mechanical parts as well as high temperature components may result in severe injury, severed limbs, or fatality.

This chapter of the operator’s manual explains how to look for and repair malfunctions which may occur.

Intelligent, accurate troubleshooting is based on a complete and thorough understanding of the WATER, VACUUM, CHEMICAL, HEAT TRANSFER, SAFETY and WIRING systems on this unit.

If there is a malfunction occurring in a system which you do not fully understand, turn back to the "Operation" section of this manual and review "Systems".

In addition, prior to proceeding, you can save time by checking that:

1. The water supply is ON.

2. The engine speed at full throttle is 2600 RPM,

with the diverter valve in the HEAT EXCHANGER position.

3. Check that water pump volume is correct. Check the pump volume with the cleaning tool closed. Measure the water flow returning to the water box from the pressure regulator. The flow rate should be 3.0 GPM. An additional .2 GPM of water should be flowing through the bypass manifold orifice, which is adjacent to the water box. If you block the heat bypass flow, the flow rate will be

3.2 - 3.3 GPM.

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Page 45

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 or exceeds 1200 PSI, the unit will automatically shut down.

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

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

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. Bypass minifold orifice not installed or

installed improperly (threads damaged in manifold). Debris clogging water lines or water inlet disconnect.

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 2600 RPM. Re-adjust in accordance with the Kohler Engine Operation and Serive Manual.

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. Check bypass manifold and orifice for

proper installation and repair, if necessary.

Clean or replace as needed.

Loss of solution volume at cleaning tool orifice.

Water gauge reads normal.

4-13

Belt 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 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.

Engine exhaust heat exchanger is scaled on inside of coil.

LEGEND SE 980059 07/23/02

Unplug or replace orifice and/or screen Inspect all lines, remove accumulated

debris which in blocking proper flow. Replace any defective hoses. Remove, inspect, and clean the Y-strainer screen. De-scale unit and install a water softner, if necessary. Examine the check valve, remove any debris Replace defective quick-connects(s) on high pressure hoses(s).

De-scale coil, and install the water softner, if necessary, to protect the equipment. If water contains 3-1/2 grains or more of water hardness, a water softener is needed.

Page 46

PROBLEM CAUSE SOLUTION

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

Inspect all lines, remove accumulated debris Inspect the gasket. Repair seal or replace Re-position lid.

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 damgaed, 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 damage 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 par. 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 gasket 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 exchanges are plugged with lint.

Vacuum pump is wore out. Replace the vacuum pump. Chemcial 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

LEGEND SE 980059 07/23/02

4-14

Page 47

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

If the blue light is OFF, check the water pump circuit breaker on the control panel. Press the ciruit breaker reset button.

If the blue light is OFF and the water pump circuit breaker is not tripped, examine switch, electrical connections, and wiring. Repair any defective connections. If there is power going to the switch but not going out, replace the defective switch.

Adjust activator arm to assure contact and activation of the microswitch. If the microswitch is defective or damage, replace.

If the blue light is ON, check the white wire which leads from the switch to the clutch. If there is power in the switch, but 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.

Refer to Kohler Engine Operation and Serive Manual.

Turn water pump switch to the override position. If the unit shuts back down, refer to the “Loss of Water Pump Pressure” in the “Troubleshooting” section of this manual. 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. Disconnect the float switch plugs and bypass the switch. If the unit starts, repair or replace the defective float switch.

Test these components. If any are defective, replace. Consult the to Kohler Engine Operation and Serive Manual.

Water pump does not engage when the diverter valve is in the “Heat Exchanger” position

Engine will not start The engine does not turn over

Starter turns over engine, but will not start

Water pump circuit breaker has been tripped

Defective electrical connection in the console wiring or defective switch.

Water pump has not been activated 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 belt. Tighten or replace belt. Main circuit breaker on the control

panel has been tripped. Loose or corroded battery.

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

Engien Problem. Vacuum pump seized. Refer to Sutorbilt Service & Repair Manual.

Waste tank is full. Empty the waste tank. Water pressure has not reached

50 PSI, triggering the pressure switch to prevent starting.

Engine temperature has exceeded 285°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 soenoid (located on engine), high temperature switch (located on engine).

4-15

LEGEND SE 980059 07/23/02

Page 48

PROBLEM CAUSE SOLUTION

Defective 285°F high temperature

Starter turns over engine, but will not start

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

Excessive heating

shutdown switch (located at rear of exhaust heat exchanger).

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

Waste tank is full Empty waste tank. Water pressure has dropped below

50 PSI, triggering the the pressure switch to shut the unit down.

Water pressure has exceeded 1200 PSI, triggering the pressure switch to shut the unit down.

Main circuit breaker on the control panel has been tripped.

Solution temperature has exceeded 285°F, causing the unit to shut down. 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 285°F engine coolant

high-temperature shudown switch. Loss of oil pressure in engine. 285°F solution temperature switch is

defective. Defective engine oil pressure switch. No ignition in the engine or engine is malfunctioning. Check instrumentation settings: Diverter valve is in the HEAT EXCHANGER position. Temperature bypass valve is closed. Temperature control is set at a high temperature. Strainer or orifice is bypass manifold is closed position. Defective solenoid-remains in closed position. Bypass valve is completely closed and unit is left running for a long period fo time without using water. Defective temperature control or temperature control microswitch

Flow restriction caused by hard water scaling.

Test. If necessary, replace. Refer to Kohler Engine Operation and

Service Manual.

Check water supply to your unit. Check water pump inlet screen in water box. Check supply hose for kinks.

Check pressure regulator for proper setting. After inspecting the unit to determine the

cause of the tripped circuit breaker, press the reset button.

Refer to “Excessive Heating” in the “Troubleshooting” section of this manual.

Determine the cause of the overheating before restarting the unit. Refer to the Kohler Engine Operation and Service Manual.

Disconnect the float switch plugs and bypass the float switch. If the unit starts, repair or replace the defective float switch.

Test switch. If necessary, replace. Check for proper oil level or wrong type of

oil being used. Test switch. If necessary, replace.

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

Service Manual. Turn diverter valve to the MUFFLER

position.(If cleaning , make certain that the water pump switch is in the ON position). Open the heat bypass valve. Set temperature control to a lower setting.

Clean strainer screen and orifice. replace, if needed. Inspect solenoid for proper operation. Clean, or replace, if needed.

Open bypass valve and allow system to cool down.

Inspect temperature control for proper operation. Repair, or replace, if necessary. Descale unit, repair or replace damaged plumbing components as necessary. Install water softener.

TROUBLESHOOTING

LEGEND SE 980059 07/23/02

4-16

Page 49

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Heat exchanger leaks

Inspect heat exchanger for leaks. On preNOTE: The engine 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 waster 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 water tight seal.

Engine and vacuum exhaust heat exchanger are damaged from frozen water

Check instrumentation settings: Diverter valve is in the MUFFLER position. Temperature bypass valve is open. Temperature control is set at a low temperature. Defective solenoid - remains in open position. Temperature relief valve on water box is stuck open.

Engine RPM is low. Defective air pump (catalytic

converter not burning). Engine exhaust heat exchnager is

carbon-coated on outside of coil (defective air pump).

Engine exhaust heat exchanger is scaled on inside of coil. Excessive bypass due to loose or damaged orifice. Debris interfering in the normal operation of pump, pump check valve, or float switch.

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

Defective waste pump float switch. Replace float switch. Worn out waste pump. Water has penetrated the electrical

connectors. Broken wiring leading to the waste

pump. Weak battery. Battery charge to low

to maintain pump-out operation. Pump wired incorrectly. Pump

impeller rotates backwards

heaters visually inspect for damage.

Pressure check both styles after removing

them from the unit. (Maximum test

pressure engine exhaust H.E. 1200 PSI

vacuum pre-heaters 300 PSI).

Turn diverter valve to the HEAT

EXCHANGER position. Close the heat

bypass valve. Set the temperature control

to a higher setting.

Inspect solenoid for proper operation.

Clean, or replace, if needed.

Clean temperature relief valve and test.

Replace, if necessary.

Test gauge and sensor. Replace failed

component.

Replace air pump.

Soak coil at a machine shop. Boil tank or

soak in an industrial cleaner. Check air

pump, replace if needed. DO NOT soak

catalytic core.

De-scale coil. Install water softener if

needed.

Inpect bypass orifice. Repair or replace as

needed.

Remove pump-out from waste tank,

thoroughtly check all components, inspeck

for proper operation.

After inspecting the waste pump to

determine the cause of the tripped circuit

breaker, press the reset button. (Check for

debris in the impeller inside the pump

head).

Check for voltage at the pump. If there is

voltage and the pump does not run, replace

the pump.

Reseal or replace electrical connectors.

Check for voltage at the pump. If no

voltage, find broken connection and repair.

Charge or replace battery, if needed. If no

voltage, find the broken connection and

repair.

Verify rotation using arrow marking on

bottom of pump housing. Inspect using a

voltage meter.

4-17

LEGEND SE 980059 07/23/02

Page 50

4-18

THIS PAGE LEFT BLANK INTENTIONALLY

LEGEND SE 980059 07/23/02

Page 51

FRONT PANEL

37,38

34,35

30,31

2 3

6,7

7,8 9

13,14

15-18

25,26

24,24A

5-1

LEGEND SE 980059 07/01/02

Page 52

FRONT PANEL

REF PART NO. DESCRIPTION

1 50-501745 PANEL, CNTRL, LEGEND 2 18-808530 GA, WTR TEMP 320DEG BC 3 18-808526 GAUGE, WATER PRESSURE 4 34-903000 HOURMETER 5 18-808525 GAUGE, VACUUM 30” HG 6 61-950738 ASSY, OIL/WTR OVRRD SW TB 7 34-900114 CVR, LENS-RTRY SW 99 8 32-900205 SW, RTRY NON-ILLUM TM

9 33-900163 BREAKER, CIRC 20 A 10 49-802518 CABLE, CHOKE 11 49-802505 CABLE, THROTTLE 12 32-900174 KEY SWITCH 13 61-950659 ASSY, RT HOOD 14 50-501771 HOOD, RT 15 01-000259 RECPT, SNAPIN 1/4 TURNFAST 16 00-000272 STUD, 1/4 TURNFAST #85 OV 17 02-000268 SPLITRING, RETAIN, 1/4 TURN 18 58-700023 PAD, 1/4 TURN VIBR 19 15-808068 REG, PRESS 20 15-808107 VLV, MET 1/8FP (BYPASS) RT 21 22015 COUPLER, 1/4 QD 22 13-806008 DSC, 3/8F X 3/8 FP 23 55-501672 TUBE, EXH DVFTR 24 56-501845 PAN, DRIP OPTIONAL

24A 56-501930 PAN, DRIP

25 87162 WASHER, 1/4 SPLIT LOCK 26 00-000210 SCR, 1/4-20 X 3/4 SOCHD 27 48-941197 DECAL, CONDENSED INSTRUCT. 28 19-800075 CUP, OIL FILL 1/8P 29 36-900182 SOLENOID, ROTARY

30 61-950660 ASSY, L HOOD 31 50-501723 HOOD, L

32 15-808106 VALVE, METER 1/8FP 33 15-808022 VALVE, 3-WAY BALL 1/8FP 34 35-900182 CONTR, TEMP 275DEG F 35 33-900193 MICROSW, TEMP CONTR 36 18-808513 FLOWMETER 1/8FP 37 00-000337 SCR, 10-32 X 1” SOCHD SST 38 01-000273 NUT, WELL 10-32 39 48-941499 DECAL, FLOOD EXTRACTION

- 48-941184 DECAL, PNL LEGEND NOT SHOWN

- 48-941441 DECAL, PNL LEGEND SE NOT SHOWN

- 48-941212 DECAL, WARN. & INTRUMNT NOT SHOWN

- 48-941195 DECAL, HOOD PROCHEM NOT SHOWN

SERIAL NO.

FROM

NOTES:

OPTIONAL, UNITS ON WATER TANK

INCLUDES PARTS 16-18, 31 AND DECAL

LEGEND SE 980059 07/23/02

5-2

Page 53

FRAMEWORK

5-3

LEGEND SE 980059 07/23/02

Page 54

FRAMEWORK

REF PART NO. DESCRIPTION

1 02-000066 FLATWASHER, 1/4

2 87162 WASHER, 1/4 SPLIT LOCK

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

4 56-501992 GUARD, BELT

5 70075 SCR, 1/4-20 X 4.5 HHCS PLTD

6 56-502025 BRKT, R HOOD PC BLU

7 56-502026 BRKT, CTR HOOD PC BL

8 00-000216 SCR, CAP 1/4-20 X 1/2 FLTSO

9 50-501768 GUARD, R BELT 10 87144 WASHER, .531ID C 1.25 X .1 FLT PLT 11 87176 WASHER, 7/16 SPLIT LOCK PLTD 12 00-000222 SCR, CAP, 7/16-14 X 1.5 HX 13 54-501653 SPCR, BELT GUARD 14 56-501993 PNL, ENG INS 15 42-902282 GUARD, FLYWHEEL (PART OF ENGINE) 16 87139 WASHER, 3/16 FLAT 17 87165 WASHER, #10 SPLIT LOCK 18 70497 SCR, #10-24 X 1/2 SHCS 19 57006 NUT, 1/4-20 HEX 20 56-501929 MOUNT, CONTR PNL BLUE 21 58-700024 PAD, VIBR CONTR PNL MT 22 00-000286 SCR, CAP 1/4-20 X 2.75 HXHD 23 00-000210 SCR, 1/4-20 X 3/4” SOCHD 24 790074 PANEL, LWR FR 25 790070 BASE, AD SOL 26 56-501857 BRKT, FUEL LINE 27 70105 SCR, 1/4-20 X 1.75 HHCS PLTD 28 56-502050 BRKT, HOOD MTG

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-4

Page 55

ENGINE

5-5

FROM BULHEAD ADAPTER ON VEHICLE FLOOR

TO EXHAUST DIVERTER VALVE ASSEMBLY

LEGEND SE 980059 07/23/02

Page 56

ENGINE

REF PART NO. DESCRIPTION

1 40-902152 ENG, KOHLER 20HP

2 42-902299 KOH ELEM, AIR CLNR#470830

3 42-902297 KOH PMP, FUEL PULSE #2439316L P

4 42-902289 KOH SPK PLG #1213202

5 42-902296 KOH FLTR, FUEL #2505003

6 03-000065 CLAMP, HOSE #4 SST

7 09-805091 HOSE, FUEL 1/4 X 27 1/2

8 12-800062 PLUG, 1/2T

9 10-805291 HOSE, HP 3/8 X 10 (3/8 X1/2 FT) 10 42-902365 SUB 42-902396 KOH KIT, VO 11 42-902277 KOH FLTR, OIL #1205001 12 56-502090 MNFLD, ENG EXH 13 42-902212 ONAN GSKT, EXH #154-2747 14 44-802237 BELT, AX42 GOODYEAR MATCH 15 54-500412 KEY, 1/4 SQ X 1.88 16 52-501660 PULL, ENG 17 44-802182 HUB, P2X1-1/8 18 44-802240 BELT, 3V X265 19 00-000311 SCR, 1/4-20 X 1/2 SHCS SS 20 44-802311 BLET, AX29 GOODYEAR MTCH MKR 21 52-501661 PULL, OUTR ENG 22 00-000340 SCR, MACH 5/16-18 X 1” GR 8 23 12-800041 FTTG, BARB 1/8P X 1/4H 24 790605 EL, 90DEG 1/8 X 5/16HB 25 56-501857 BRKT, FUEL LINE 26 87083 WASHER, 5/16 SPLIT LOCK PLTD 27 57054 NUT, M8 28 790626 GSKT, EXHST, KHLR 25HP 29 42-902293 KOH CARB, #2485335S

- 42-902286 KOH SE, OIL PRESS NOT SHOWN

- 42-902287 KOH GSKT, CYL HD #2404108 NOT SHOWN

- 42-902359 KOH ASSY, VLV CVR #2475574 NOT SHOWN

- 42-902360 KOH ASSY, VLV CVR (OIL) NOT SHOWN

- 42-902291 KOH DRIVE PINION NOT SHOWN

- 42-902294 KOH KIT, CARB REP #2475703 NOT SHOWN

- 42-902295 KOH KIT, HIGH ALTITUDE (9840 FT) NOT SHOWN

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 12/02/03

5-6

Page 57

ENGINE STARTER

5-7

TO BATTERY NEGATIVE (-) TERMINAL

TO BATTERY POSITIVE (+) TERMINAL

LEGEND SE 980059 07/23/02

Page 58

ENGINE STARTER

REF PART NO. DESCRIPTION

1 42-902292 KOH SOLENOID #5243502

2 64-950514 CABLE, BAT X 101” RED

3 42-902290 KOH STARTER #1209803

4 57031 NUT, 5/16-18 HEX

5 87083 WASHER, 5/16 SPLIT LOCK PLTD

6 02-000143 FLATWASHER, 5/16

7 70601 SCR, 5/16-18 X 2.75 HHCS GR5

8 64-950515 CABLE, BAT X 111” BLK

9 70262 SCR, M8 X 20 HHMS PLTD

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-8

Page 59

VACUUM PUMP

5-9

FROM WASTE TANK

3 30

VENT CAP

TO VACUUM MUFFLER

1920

LEGEND SE 980059 07/23/02

Page 60

VACUUM PUMP

REF PART NO. DESCRIPTION

1 41-905021 PUMP, VAC 4M-L

2 54-501593 NIP, VAC EXH OUTL

3 03-000112 CLAMP, HOSE #48

4 09-805396 HOSE, INT VAC 2.88 X 2.0 BLK

5 54-501735 KEYSTOCK, 3/16 X 1 5/8

6 44-802237 BELT, AX42 GOODYEAR MATCH

7 44-802218 PULLEY, 2TA46

8 44-802204 HUB, P1 X 3/4”

9 00-000340 SCR, MACH 5/16-18 X 1” GR5 10 87171 WASHER, 3/8 FLAT 11 87163 WASHER, 3/8 SPLIT LOCK 12 70266 SCR, 3/8-16 X 1” HHCS GR 5 PLT DL 13 12-800101 ELL, 1/4FP X 1/4 POLY BR 14 18-808525 GAUGE, VACUUM 30” HG 15 19-800075 CUP, OIL FILL 1/8P 16 12-800059 CONN, 1/8P X 1/4 POLY BR 17 09-805224 TUBING, IMPOL 1/4 X 50 18 09-805440 TUBING, IMPOLENE X 35” 19 02-000057 FLATWASHER, 1/2” HEAVY 20 00-000323 SCR, 1/2-13 X 3 1/2 HHCS FULL THD 21 70357 SCR, 1/2-13 X 3 FULL THREADS 22 56-502324 BRKT, VAC ADJ LEGEND SE 23 61-950451 ASSY, VAC REL VLV 24 09-805341 HOSE, VAC 2.88 X 25.0 BLK 25 57114 NUT, 7/16-14 HEX 26 04-000091 SPRING, VAC REL VLV 27 52-501573 ELL, VAC REL VLV 28 56-501615 STEM, VAC REL VLV #4 VAC 29 43-807074 DIAPHRAGM, VAC REL VLV

- 05-008039 OIL, AEON PD (28G24 SUTORBILT) NOT SHOWN

- 05-008032 GREASE, MA3830150 NOT SHOWN

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-10

Page 61

WATER PUMP

5-11

FROM WATER BOX

FROM TOP OF FLOW METER

TO CHEMICAL ON/OFF PRIME VALVE

TO PRESSURE MANIFOLD

11 12

12 13

LEGEND SE 980059 09/10/02

Page 62

WATER PUMP

REF PART NO. DESCRIPTION

1 10-805424 HOSE, HP 3/8 X 10 1/2”

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

3 41-809153 PUMP, WATER CAT 3CP1140

4 11-800224 PLUG, 3/8 SOCHD BR

5 87171 WASHER, 3/8 FLAT

6 87163 WASHER, 3/8 SPLIT LOCK

7 57111 NUT, 3/8-16 HEX

8 12-800060 CONN. 1/4P X 1/4T BR

9 10-805316 HOSE, 3/16 X 5 (1/4FT BS) MET 10 12-800029 PLUG, 1/4T BR 11 11-800342 CONN, 1/2P X 1/2FP BR 12 02-000066 FLATWASHER, 1/4 13 89162 WASHER, 1/4 SPLIT LOCK 14 70260 SCR, M6 X 1 X 16MM HHCS 15 36-900140 CLUTCH, ELC WTR PUMP CAT 16 44-802311 BELT, AX29 GOODYEAR MTCH MKR 17 31-900185 CONN, BULLET M (.156) 18 56-502248 BRKT, PUMP ADJ 19 11-800069 PLUG, 1/2 SOCHD BR 20 00-000277 SCR, MACH 6MM X 14MM 21 00-000336 SCR, CAP 3/8-16 X 3 ALL THD 22 10-805300 HOSE, 3/16 X 45” HP W/1 1/4FT 23 12-800040 ELL, 1/8P X 1/4T BR 24 41-809158 PUMP, CHEM (O-RING CAP) 25 52-809125 ADPT, CAT CHEM PUMP 26 52-809123 RETAIN, VALVE SPRING 27 09-805363 HOSE, BRD 5/16 X 52 28 03-000065 CLAMP, HOSE #4 SPOTTER SST 29 12-800093 FTTG, BRB 1/8P X 5/16H 30 11-800014 ELL, STREET 1/8 BR 31 39619 HOSE, WTR 3/4 X 10” 32 03-000113 CLAMP, HOSE #12 SST 33 12-800278 FTTG, BRB 1/2P X 3/4H BR 34 11-800041 ELL, STREET 1/2 BR

- 05-008016 OIL, CAT- WTR PUMP NOT SHOWN

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/22/03

5-12

Page 63

WATER PUMP

5-13

LEGEND SE 980059 07/23/02

Page 64

WATER PUMP

REF PART NO. DESCRIPTION

1 42-809238 CAP, OIL FILLER

2 42-809239 O-RING, OIL FILL CAP

3 43-807063 GASKET, OIL GAUGE

4 42-902380 GAUGE, OIL LEVEL

5 42-809401 COVER, CRANKCASE

6 42-809402 O-RING, CRANK CVR

7 42-809394 O-RING, BEARING CVR

8 42-809403 MANIFOLD, HEAD

9 42-809404 PLUG, VALVE 10 42-809406 BOLT, MNFLD HD M8 X 65 11 42-809405 RETAINER, SEAL 12 42-809407 RETAINER, PNLGR W/STUD 13 42-809408 PLUNGER 14 42-809249 WASHER, KEYHOLE M18 15 42-809381 SLINGER, BARRIER 16 42-809409 SEAL, OIL CRANKCASE

17 42-809410 KIT, SEAL 18 66-950441 KIT, VLV

SERIAL NO.

FROM

NOTES:

ORDER 1 EA. TO REPLACE ALL SEALS ORDER 1 EA. TO REPLACE ALL VALVES

LEGEND SE 980059 07/23/02

5-14

Page 65

CHEMICAL SYSTEM

5-15

18 17

FROM WATER PUMP

TO SOLUTION OUTLET

TO CHEMICAL RESERVOIR

LEGEND SE 980059 07/23/02

Page 66

CHEMICAL SYSTEM

REF PART NO. DESCRIPTION

1 18-808513 FLOW METER 18FP

2 87162 WASHER, 1/4 SPLIT LOCK

3 00-000065 SCR, 10-32 X 3/8” PNHD

4 12-800093 FTTG, BRB 1/8P X 5/16H

5 03-000065 CLAMP, HOSE #4 SPOTTER SST

6 09-805088 HOSE, BRD 5/16X64

7 14-806506 SCREEN, 1/8FP

8 12-800040 ELL, 1/8P X 1/4R BR

9 11-800014 ELL, STREET 1/8 BR 10 15-808022 VALVE, 3-WAY BALL 1/8FP 11 56032 NIPPLE, 1/8 CLOSE 12 15-808106 VALVE, METER 1/8FP 13 41-809158 PUMP, CHEM (O-RING CAP) 14 52-809125 ADPT, CAT CHEM PMP 15 10-805278 HOSE, 3/16X54 (1/4FT BS)MET 16 10-805131 HOSE, 3/16 X 20-1/2 17 16-808237 CAP, CHK VALVE CHEM. PUMP 18 43-810079 O-RING, 7/8 ID X 1-1/16 OD 19 42-809265 CHECK VALVE, CHEM. PUMP 20 42-809358 BODY, CHEM PUMP 21 42-809264 DISK, CHEM PUMP 22 42-809047 DIAPHRAGM, CHEM PUMP 23 42-809045 COVER, CHEM PUMP 24 50-501663 WASHER-SPCR, TRK MNT

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/22/03

5-16

Page 67

VACUUM EXHAUST HEAT

5-17

EXCHANGER AND SILENCER

6 5

3 4

FROM PRESSURE REGULATOR MANIFOLD

FROM VACUUM PUMP

FROM DIVERTER VALVE

TO WATER BOX

LEGEND SE 980059 07/23/02

Page 68

VACUUM EXHAUST HEAT

EXCHANGER AND SILENCER

1 PART NO. DESCRIPTION

1 56-501928 EXH OUTLET

2 03-000081 CLAMP, MFLR 1-1/2 ZNC PL

3 57-520099 MUFFLER, ENG EXH VERSION D (FLNG)

4 02-000066 FLATWASHER, 1/4

5 87162 WASHER, 1/4 SPLIT LOCK

6 70270 SCR, 1/4-20 X 3/4 HHCS PLTD

7 03-000112 CLAMP, HOSE #48

8 09-805344 HOSE, INT VAC 2.88 X 3.0 BLK

9 56-501892 HOUSING VAC HE 10 57-520082 MUFFLER, VACUUM 11 09-805396 HOSE, INT VAC 2.88 X 2.0 BLK 12 00-000078 SCR, 1/4-20 X 1” HXHD GRD8 13 43-807080 GASKET, VAC HE INLET 14 58-700027 PAD, VAC HE CORE 15 09-805368 HOSE, WTR 5/8 X 29 16 03-000246 CLAMP, HOSE #8 SST 17 61-950696 VAC HE CORE 18 09-805384 HOSE, WTR 5/8 X 16 19 43-807081 GASKET, VAC HE CORE

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-18

Page 69

ENGINE EXHAUST HEAT EXCHANGER

5-19

22 21 20

FROM HELI-COIL HEAT EXCHANGER

FROM DIVERTER VALVE

TO SOLUTION OUTLET

LEGEND SE 980059 07/23/02

Page 70

ENGINE EXHAUST HEAT EXCHANGER

REF PART NO. DESCRIPTION

- 61-950628 ASSY, CAT HE INCLUDES PARTS 1-14 1 01-000271 NUT, 1/4-20 HXHD BR 2 52-501643 SHEILD, CAT HE 3 58-700028 PAD, CAT HT SHEILD 4 56-501759 CVR, CAT HE END BC 5 43-807086 GSKT, EXH FLG 6 57-520074 ASSY, COIL MOUNT & CASING 7 57006 NUT, 1/4-20 HEX 8 02-000044 LOCKWASHER, 1/4 SST 9 70015 SCR, 1/4-20 X 3/4 HHCS SS

10 52-501654 NUT, ADAPT BUSH 11 64-950546 ASSY, HIGH TEMP SHUTOFF 12 35-900184 SENSOR, TEMP 285DEG 13 52-501671 FTTG, TEMP SENS ADPT TM 14 12-800171 ELL, 1/2P X 1/2T BR 15 10-805376 HOSE, 1/2 X 4 1/2 (1/2 FT BS) 16 02-000274 LOCKWASHER, 5/16 (ALLEN SCREW) 17 00-000315 SCR, CAP 5/19-18 X 7/8 SOCHD 18 42-902212 ONAN CAKT, EXH #154-2747 19 10-805275 HOSE, 1/2 X 19 (1/2FT BS) MET 20 02-000066 FLATWASHER, 1/4 21 87162 WASHER, 3/8 SPLIT LOCK 22 00-000078 SCR, 1/4-20 X 1” HXHD GRD8

- 66-945532 KIT, EXH HE CORE

- 57-520070 HE, EXH CAT INCLUDES PARTS 4-10

SERIAL NO.

FROM

NOTES:

INCLUDES PARTS 3,5,6 AND 18

LEGEND SE 980059 07/23/02

5-20

Page 71

BYPASS MANIFOLD

5-21

FROM Y-STRAINER/CHECK VALVE MANIFOLD

TO TEMPERATURE SOLENOID

6 7

TO WATER BOX

LEGEND SE 980059 07/23/02

Page 72

BYPASS MANIFOLD

REF PART NO. DESCRIPTION

1 10-805357 HOSE, 3/16 X 38 (1/4FT BS) MET 2 12-500040 ELL, 1/8P C 1/4T BR 3 56-501906 ASSY, BRKT, BYPASS MTG 4 12-800065 CONN, 1/8P X 1/4T 5 10-805130 HOSE, 3/16 X 13-1/2 (1/4FT BS) 6 87162 WASHER, 1/4 SPLIT LOCK 7 00-000132 SCR, 1/4-20 X 1-1/2 HXHD 8 15-808112 ASSY, BYPASS MNFLD 9 10-805130 HOSE, 3/16 X 13-1/2 (1/4FT BS)

10 70105 SCR, 1/4-20 X 1.75 HHCS PLTD 11 02-000066 FLATWASHER, 1/4 12 57006 NUT, 1/4-20 HEX 13 52-501659 MANIFOLD, BYPASS 14 52-501701 ORIF, BYP MNFLD 15 43-810053 O-RING, .676ID X .816OD 16 53-501523 CAP, CHK VALVE MANIFOLD STRNR 17 14-806552 SCREEN, BYPASS MANIFOLD

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-22

Page 73

SOLUTION OUTLET

5-23

FROM ENGINE EXHAUST HEAT EXCHANGER

20, 21

FROM CHEMICAL METERING VALVE

TO BYPASS MANIFOLD

15 16

LEGEND SE 980059 07/23/02

Page 74

SOLUTION OUTLET

REF PART NO. DESCRIPTION

1 11-800101 PLUG, 1/8P 2 12-800040 ELL, 1/8P X 1/4T BR 3 10-805357 HOSE, 3/16 X38 (1/4 FT BS) MET) 4 11-800342 CONN, 1/2P X 1/2FP BR 5 12-800391 UNION, CAPILLARY-THERM 6 35-900182 CONTR, TEMP 275 DEG 7 12-800065 CONN, 1/8P X 1/4T 8 10-805205 HOSE, 3/16 X 15-1/8 (1/4FT BS) 9 12-800329 CONN, 1/4P X 1/2T SST

10 31017 ELBOW, 1/4FPT X 1/4PT 11 22015 COUPLER, 1/4 QD 12 10-805376 HOSE, 1/2 X 14-1/2 (1/2FT BS) 13 12-800282 CONN, 3/8P X 1/2T BR 14 11-800276 ELL, 3/8 BR 15 02-000066 FLATWASHER, 1/4 16 87162 WASHER, 1/4 SPLIT LOCK 17 57006 NUT, 1/4-20 HEX 18 56-501910 BRKT, SOL OUT MTG 19 70105 SCR, 1/4-20 X 1.75 HHCS PLTD 20 15-808095 ASSY, CHK VLV 21 52-501621 MANIFOLD, CHK VLV 22 14-806549 SCREEN, CHECK VALVE 23 43-810053 O-RING, .676ID X .816OD 24 15-808094 VALVE, CHECK 25 11-800429 NIP, NEX 3/8 SST 26 52-502066 MANIFOLD, THERMOSTAT 27 56-501974 BRKT, THERM MANIFOLD MOUNTING 28 34-903019 SENDER, TEMP 140-320 DEG 29 00-000132 SCR, 1/4-20 X 1-1/2 HXHD 30 52-501680 FTTG, SENS SUPT TM 31 16-808223 SEAT, CHK VLV ASSY TM 32 43-810008 O-RING 33 16-808226 POPPET CHK VLV ASSY 34 16-808225 TEFLON SEAT 35 43-810079 O-RING, 7/8ID X 1-1/16 OD 36 16-808224 SPRING 37 16-808222 CAP 38 35-901039 SENSOR, TEMP, 260°

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-24

Page 75

WATER BOX

5-25

6 5

LEGEND SE 980059 07/23/02

SEE WATER PUMP

Page 76

WATER BOX

REF PART NO. DESCRIPTION

1 11-800432 CAP, WATER BOX 2 58-500781 MOLDING, WATER BOX 3 50-501763 HOLD DOWN WTR BOX 4 02-000066 FLATWASHER, 1/4 5 87162 WASHER, 1/4 SPLIT LOCK 6 00-000335 SCR, 1/4-20 X 8 HXHD 7 09-805099 HOSE, BRD 5/16 X40 8 03-000065 CLAMP, HOSE #4 SST 9 12-800093 FTTG, BRB 1/8P X 5/16H

10 15-808083 VALVE, TEMP REL 180 DEG F 11 03-000113 CLAMP, HOSE #12 SST 12 12-800278 FTTG, BRB 1/2P X 3/4H BR 13 11-800041 ELL, STREET 1/2 BR 14 11-800300 NIP, 1/2 X CL 15 14-806540 STRAINER, SUC END 1/2FP 16 19-807014 BALL, FLOAT 17 54-501715 FLOAT ROD 18 57006 NUT, 1/4-20 HEX 19 10-805206 HOSE, 3/16 X 14-3/4 (1/4FT BS) 20 12-800356 ELL, 1/4P X 1/4T 45 DEG BR 21 56-501901 TRAY, WTR BOX 22 09-805368 HOSE, WTR 5/8 X 29 23 03-000246 CLAMP, HOSE #8 SST 24 12-800269 FTTG, BRB 1/2P X 5/8H BR 25 09-805330 HOSE, WTR 5/8 X 53” 26 11-800361 ELL, 1/2 BR 27 15-808110 VALVE, FLOAT 28 52-501706 NUT, FLOAT VALVE 29 16-808217 BODY, FLOAT VLV 30 00-000337 SCR, 10-32 X 1” SOCHD SST 31 16-808216 ARM, PIVOT- FH VLV 32 16-808219 PISTON, FH VLV 33 16-808164 SEAT, FLOAT VLV 34 57090 NUT, 10-32 HEX NYLOCK SS

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-26

Page 77

PRESSURE REGULATOR MANIFOLD

5-27

TO PRESSURE GAUGE

TO EXHAUST HEAT EXCHANGER

TO VACUUM EXHAUST

HEAT EXCHANGER

FROM WATER PUMP

20,21

LEGEND SE 980059 11/07/02

Page 78

PRESSURE REGULATOR MANIFOLD

REF PART NO. DESCRIPTION

1 790106 ACCUMULATOR 2 87162 WASHER, 1/4 SPLIT LOCK PLTD 3 00-000210 SCR, 1/4-20 X 3/4 SOCHD 4 10-805294 HOSE, 3/16 X 11.5 (1/4FT BS) 5 12-800346 ADAPTER, 1/4T X 3/8P 6 11-800275 ELBOW, ST 3/8 BR 7 11-800345 PLUG, 1/4 SOCHD BRASS 8 12-800347 ELBOW, 3/8P X 1/2T 45° BR 9 10-805424 HOSE, HP 3/8 X 10.5

10 10-805275 HOSE, 1/2 X 19 (1/2 FT BS) MET 11 12-800282 CONN, 3/8P X 1/2 T BR 12 11-800224 PLUG, 3/8 SOCHD BR 13 09-805384 HOSE, WATER 5/8 X 16 14 03-000246 CLAMP, HOSE #8 SST 15 12-800345 FITTING, BRB 3/8P X 5/8H BR 16 11-800341 ELL, ST 3/8 45DEG BR 17 790067 REGULATOR, PRESSURE 18 11-800429 NIP, HEX 3/8 SST 19 790112 MANIFOLD, PRESS REG. 1/2 “ PORT 20 16-808201 CAT #33246 KIT, O-RING REP 21 16-808200 CAT #33147 KIT, VALVE REP

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 11/07/02

5-28

Page 79

TEMPERATURE SOLENOID & BYPASS VALVE

5-29

TO VACUUM

INLET TUBE

FROM BYPASS

MANIFOLD

15 14

LEGEND SE 980059 07/23/02

Page 80

TEMPERATURE SOLENOID & BYPASS VALVE

REF PART NO. DESCRIPTION

1 12-800088 TEE, ADPT 1/8FP X 1/8P X 1/4T 2 12-800040 ELL, 1/8P X 1/4T BR 3 10-805000 HOSE, 3/16 X 9 (1/4FT BS) 4 15-808107 VALVE, METER 1/8FP (BYPASS) 5 12-800065 CONN, 1/8P X 1/4T 6 10-805204 HOSE, 3/16 X 23 (1/4FT BS) 7 31-900028 TERM, INS DSC 1/4M 14-16W 8 31-900027 TERM, INS DSC 1/4F 14-16W 9 15-808105 VALVE, SOLENOID 1/4F X 1/4F

10 11-800039 BUSH, 1/4 X 1/8 BR 11 87165 WASHER, #10 SPLIT LOCK 12 00-000065 SCR, 101-32 X 3/8” PNHD 13 02-000066 FLATWASHER, 1/4 14 87162 WASHER, 1/4 SPLIT LOCK 15 70270 SCR, 1/4-20 X 3/4 HHCS PLTD 16 50-501721 BRACKET, SOLENOID 17 12-800031 ELL, 1/4P X 1/4T BR 18 10-805311 HOSE, 3/16 X 10.5 (1/4 FT BS)

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-30

Page 81

DIVERTER VALVE

5-31

LEGEND SE 980059 07/23/02

Page 82

DIVERTER VALVE

REF PART NO. DESCRIPTION

1 00-000210 SCR, 1/4-20 X 3/4 SOCHD 2 00-000265 SCR, SET 1/4-20 X 1/4 SOCHD 3 00-000315 SCR, CAP 5/16-18 X 7/8 SOCHD 4 00-000317 SCR, CAP 10-32 X 1 1/4 SOCH 5 87031 NUT, 5/16-18 HEX 6 57113 LOCKNUT, 5/16-18 HEX NYLOCK 7 01-000301 LOCKNUT, 10-32 SS 8 87162 WASHER, 1/4 SPLIT LOCK 9 87083 WASHER, 5/16 SPLIT LOCK PLTD

10 02-000066 FLATWASHER, 1/4 11 02-000274 LOCKWASHER, 5/16 (ALLEN SCREW) 12 31-900027 TERMINAL, INS DCS 1/4F 14-16W 13 36-900182 ROTARY SOLENOID 14 42-902212 GASKET, ONAN 15 43-807501 GROMMET, 1/2ID X 7/8OD 16 50-502158 PLT, ROTARY 17 52-502067 LINK, SOL CONN-FEM 18 52-502068 LINK, DIVERTER 19 56-502541 ROD, DIVRTR CONN 20 61-950885 VALVE, EXH DIVERTER

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-32

Page 83

AIR PUMP

5-33

LEGEND SE 980059 07/23/02

Page 84

AIR PUMP

REF PART NO. DESCRIPTION

1 55-501700 TUBE, RT AIR PUMP 2 12-800358 CONN, 1/8P X 3/8T COMP 3 56-502090 MANIFOLD, ENG EXH 4 11-800118 BUSH, 3/8 X 1/8 BR 5 02-000066 FLATWASHER, 1/4 6 87162 WASHER, 1/4 SPLIT LOCK 7 57006 NUT, 1/4-20 HEX 8 56-501791 TEE, CAT AIR PUMP 9 55-501699 TUBE, L AIR PUMP

10 11-800341 ELL, ST 3/8 45DEG BR 11 70270 SCR, 1/4-20 X 3/4 HHCS PLTD 12 12-800161 FTTG, BRB 3/8P X 1/2H BR 13 03-000246 CLAMP, HOSE #8 SST 14 39174 HOSE, WIRE BOUND X 23” 15 44-802240 BELT, 3VX265 GOODYEAR 16 70266 SCR, 3/8-16 X 1” HHCS GR5 PLTD DL 17 87171 WASHER, 3/8 FLAT 18 52-501647 PULLEY, AIR PUMP 19 41-809122 PUMP, AIR 20 56-502117 BRKT, AIR PUMP 21 56-502328 BRKT, LWR ARI PUMP LEGEND SE 22 87083 WASHER, 5/16 SPLIT LOCK PLTD 23 70262 SCR, M8 X 20HHCS PLTD 24 87163 WASHER, 3/8 SPLIT LOCK 25 57111 NUT, 3/8-16 HEX

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 07/23/02

5-34

Page 85

WASTE TANK

5-35

36 26

1, 2

8, 8A

TO VACUUM PUMP

FROM WATER BOX

FROM VACUUM INLET TUBE

LEGEND SE 980059 07/23/02

Page 86

WASTE TANK

REF PART NO. DESCRIPTION

1 61-951175 ASSY, LID WST TNK 2 56-501788 LID, WST TNK 3 67006 RIVET, 3/16 OD X 5/8 AL 4 46-802510 LATCH, DRAW 2-7/8 SST 5 48-941297 DECAL, ARROW-WST TANK LID 6 43-807094 GASKET, WST TNK LID 7 56-501793 STRAINER BOWL 8 56-501829 TANK, WST BLUE

8A 56-501973 TANK, WST

9 31016 ELBOW, 1/4 NPT STREET

10 12-800092 FTTG, BRB 1/4 X 5/16H BR 11 03-000065 CLAMP, HOSE #4 SST 12 09-805099 HOSE, BRD 5/16 X 40 13 03-000054 CLAMP, HOSE #32 1.5625/2.5 SST 14 09-805415 HOSE, INT VAC 2 X 12” 15 61-950621 ASSY, LVL SNS SHTOF SW 16 09-805341 HOSE, VAC 2.88 X 25.0 BLK 17 03-000112 CLAMP, HOSE #48 18 14-806518 STRAINER, WASTE TANK 2-1/2” 19 11-800402 PLUG, 1-1/4 HXHD PVC 20 09-805332 HOSE, 2.0 X 120.0 BLK 21 15-808080 VALVE, BALL PVC 1-1/2FP 22 12-800357 FTTG, BARB 1-1/2P X 2H 23 02-000066 FLATWASHER, 1/4 24 00-000078 SCR, 1/4-20 X 1” HXHD GRD8 25 03-000242 CLAMP, CABLE 3/4ID 1/4BLT 26 87162 WASHER, 1/4 SPLIT LOCK 27 57006 NUT, 1/4-20 HEX 28 56-501779 TRAY, BATTERY 29 50-501697 SPACER, BAT SHLF MTG 30 64-950514 CABLE, BATX101” RED 31 47-700007 SHIELD, BAT MT HT 32 36-900056 BATTERY 33 64-950515 CABLE, BATX111” BLK 34 31-900179 COVER, BATTERY TERMINAL 35 56-500188 COVER, BATTERY 36 00-000167 SCR, 1/4-20 X 6” HXHD

- 05-008002 ADHESIVE, GASKET NOT SHOWN

SERIAL NO.

FROM

NOTES:

FOR UNITS MOUNTED ON AUXILIARY WATER TANK

LEGEND SE 980059 07/23/02

5-36

Page 87

WASTE PUMP

5-37

FROM CORD

1, 2

14, 15

BLK-

FROM PUMP

BLK-

BRN+

25, 46

GRY

WHT+

GRY

31-900200 CONN, BUTT W/HT SHRINK

SWITCH

FROM PUMP

MOUNTS TO FRAME

39, 46

LEGEND SE 980059 07/23/02

42, 43

Page 88

WASTE PUMP

REF PART NO. DESCRIPTION

- 66-945193 AUTOMATIC WASTE PUMP OUT COMPLETE 1 57252 NUT, 10-24 HEX NYLOCK SS 2 70497 SCR, #10-24 X 1/2 SHCS NOT SHOWN 3 41-809128 PUMP, BILGE-RULE #3700 4 42-809267 RULE BSKT, STRNR#404 5 09-805563 TUBE, HT SHRINK 3/4X7 6 31-900194 CONN, CE STRNR REL 1/2P 7 12-800095 FTTG, BRB 3/4p X 3/4H BR 8 11-800434 ELL, 3/4 45DEG BR 9 01-000119 LOCKNUT, 3/4 NPT

10 11-800419 NIP, 3/4 X 6 5/8 PVC 11 52-501666 SEAT, 1.00-20X1/2 BR 12 04-000291 BALL, NYL 3/4D 13 04-000290 PIN, 3/16D X 1-3/8 BR 14 52-501662 BODY, WST PMP VLV 15 15-808101 ASSY, WST PMP VLV INCLUDES PARTS 11-14 16 08-805262 CUFF, WST PMP 17 03-000110 CLAMP, HOSE #24 18 00-000317 SCR, CAP 10-32X1-1/4 SOCH 19 32-900183 SWITCH, PMP-RULE #37 20 57090 NUT, 10-32 HEX NYLOCK SS 21 50-501730 SPACER, WST PMP SW 22 03-000113 CLAMP, HOSE #12 SST 23 09-805436 HOSE, WTR 3/4X21 24 31-900197 CONN, WST PMP F W/CORD CR 25 12-800370 CONN, GRDN HOSE 3/4HX3/4BA 26 12-800051 CONN, GRDN HOSE 1/2PX3/4H 27 52-501651 NUT, HOSE&CD FTTG-WST PMP 28 43-807092 SEAL, WST PMP KIT 29 31-900198 CONN, WST PMP M CROUSE-HI 30 52-501649 FTTG, CD-WST PMP KIT 31 12-800278 FTTG, BRB 1/2P X 3/4H BR 32 09-805320 HOSE, WTR 3/4X105 33 15-808065 VLV, SWING CHK 3/4FP 34 00-000078 SCR, 1/4-20 X 1” HXHD GRD8 35 87162 WASHER, 1/4 SPLIT LOCK PLTD 36 02-000066 FLATWASHER, 1/4 37 56-501794 BRKT, OUTL WST PMP KIT 38 12-800360 CONN, 3/4FXHOSE CONN 39 12-800052 CAP, HOSE 3/4 BR 40 64-950541 ASSY, WST PMP CORD INCLUDES PARTS 6,27-30 41 58-500643 MOLDING, WST PMP 42 00-000210 SCR, 1/4-20 X 3/4” SOCHD 43 57245 NUT, 1/4-20 HEX NYLOCK SS 44 50-501706 GUIDE, STRAINER 45 14-806550 STRAINER, WST PMP 46 43-807008 WASHER, HOSE 5/8 ID X1” OD

47 66-950412 ASSY, OUTL WST PMP KIT

SERIAL NO.

FROM

NOTES:

INCLUDE PARTS 7,33,37-39 & 46

LEGEND SE 980059 07/23/02

5-38

Page 89

HOSE ACCESSORIES

5-39

LEGEND SE 980059 06/19/03

Page 90

HOSE ACCESSORIES

REF PART NO. DESCRIPTION

1 12-800078 FITTING, BRB 2H BS PVC 2 08-805147 CUFF, 2” 3 10-805060 HOSE, VAC 2”X50’ W/ CUFFS & HOSE 4 56015 NIPPLE, 1/4 HEX 5 22015 COUPLER, 1/4 QD 6 56012 NIPPLE, 1/4 FPT QD 7 10-805108 HOSE, HP 1/4 X 50FT W/QD & VLVE 8 10-805077 HOSE, HP 1/4 X 50’ 9 08-805155 GUARD, HOSE VINYL

10 15-808012 VALVE, BALL 1/4FP 11 43-810014 O-RING, 7/32ID X 11/32OD 12 43-810019 O-RING, 3/8 ID X 1/2 OD 13 11-800354 NIP, 1/2 X 3/8 HEX BR 14 10-805157 HOSE, WATER 1/2 X 50’ 15 13-806009 DISCONNECT 3/8M X 3/8FP 16 10-805295 HOSE, WATER 1/2 X 50’ 17 22015 COUPLER, 1/4 QD 18 10-805077 HOSE, HP 1/4 X 50’ 19 08-805155 GUARD, HOSE VINYL 20 56012 NIPPLE, 1/4 FPT QD 21 10-805122 HOSE, HP 1/4 X 50FT W/QD

SERIAL NO.

FROM

NOTES:

LEGEND SE 980059 06/19/03

5-40

Page 91

WAND - QUAD-JET

5-41

9, 10

19, 20

LEGEND SE 980059 06/19/03

21, 22

23, 23A, 23B

19, 24

Page 92

WAND - QUAD-JET

5-42

REF PART NO. DESCRIPTION

- 89238 WAND, TM, QJW (95015) PC COMPLETE

- 89239 WAND, TM, QJW (9502) PC COMPLETE

- 89237 WAND, TM QJW (9501) PC COMPLETE

- 89235 WAND, TM, QJW, (9501) NO DECAL COMPLETE 1 56012 NIPPLE, 1/4 FPT QD 2 17-503010 CONN, 1/4P X 11/16-16M 3 17-803006 WASHER, NYLON 4 14-806512 STRAINER, JET 50 MESH 5 17-803036 CONN, 1/4FP,11/16-16R BR 6 56015 NIPPLE, 1/4 HEX 7 09-805359 SLEEVE, WD HDL 9.5 8 52-501619 TRIGGER, WD VLV 9 00-000317 SCR, CAP 10-32X 1-1/4 SOCH

10 57090 NUT, 10-32 HEX NYLOCK SS 11 61-950496 ASSY, EXTRCTR VLV 12 12-800060 CONN, 1/4P X 1/4T BR 13 10-805387 HOSE, 3/16 X 43-1/2 (1/8P X 1/4) 14 04-000053 TIE, CABLE 8” WHT 15 00-000282 SCR, CAP 1/4-20 X 1-1/4 SOC 16 52-501569 HOLD DOWN, WD HDL 17 52-501568 BODY, WD HDL 18 56-501940 WAND & HEAD, CAST SST 19 11-800206 PLUG, 1/8 SOCHD BR 20 56-501966 ASSY, L S-BEND MNFLD 21 00-000347 SCR, CAP 10-24 X1/4 SOCHD 22 87165 WASHER, #10 SPLIT LOCK 23 17-803001 TIP, SPRY 95015X1/8P SST 89238

23A 17-803002 TIP, SPRY 9502X1/8P SST 89239 23B 17-803018 TIP, SPRY 9501X1/8P SST

24 56-501986 ASSY, RT S-BEND MNFLD 25 12-800322 CONN, 1/8PX1/4T COMP BR 26 56-501967 ASSY, S-BEND MNFLD 27 16-808229 HOLDER, VLV STEM-EXTRCTR VL 28 43-810063 O-RING, .551 ID .691 OD 29 16-808228 SEAT, EXTRCTR VLV 30 16-808189 STEM, EXTRCTR VLV 31 43-810064 BACK-UP, .250 DIA 32 43-810062 O-RING, .144 ID .254 OD 33 16-808190 SPRING, EXTRCTR VLV 34 52-501590 BODY, EXTRCTR VLV

- 48-941186 DECAL, WD HD (CAST SS) NOT SHOWN

- 66-808169 KIT, REP-WD VLV

SERIAL NO.

FROM

NOTES:

89237 89235 (NO DECAL)

NOT SHOWN INCLUDES PARTS 27-29 & 31-33

LEGEND SE 980059 06/19/03

Page 93

WAND - TRI-JET

5-43

27 29

9, 10

20, 21, 22

19, 19A, 19B

LEGEND SE 980059 06/19/03

Page 94

WAND - TRI-JET

5-44

REF PART NO. DESCRIPTION

- 89233 WAND, TJW (9502) PC COMPLETE

- 89232 WAND, TJW, (95015) CUBXL COMPLETE

- 89234 WAND, TJW, (9503) PC COMPLETE 1 56012 NIPPLE, 1/4 FPT QD 2 17-503010 CONN, 1/4P X 11/16-16M 3 17-803006 WASHER, NYLON 4 14-806512 STRAINER, JET 50MESH 5 17-803036 CONN, 1/4FP,11/16-16R BR 6 56015 NIPPLE, 1/4 HEX 7 09-805359 SLEEVE, WD HDL 9.5 8 52-501619 TRIGGER, WD VLV 9 00-000317 SCR, CAP 10-32X 1-1/4 SOCH

10 57090 NUT, 10-32 HEX NYLOCK SS 11 61-950496 ASSY, EXTRCTR VLV 12 12-800060 CONN, 1/4P X 1/4T BR 13 10-805253 HOSE, 3/16X49 (1/8P X 1/4FT) 14 04-000053 TIE, CABLE 8” WHT 15 00-000282 SCR, CAP 1/4-20 X 1-1/4 SOC 16 52-501569 HOLD DOWN, WD HDL 17 52-501568 BODY, WD HDL 18 56-501712 WAND & HEAD, TRI-JET WD

19 17-803002 TIP, SPRY 9502X1/8P SST 89233 19A 17-803001 TIP, SPRY 9501X1/8P SST 89232 19B 17-803046 TIP, SPRY 9503X1/8P SST 89234

20 70162 SCR, 10-32 X 3/8 PPHMS SS

21 87165 WASHER, #10 SPLIT LOCK

22 57014 NUT, 10-32 HEX SS

23 56-501739 MANIFOLD, WD TRI-JET

24 11-800206 PLUG, 1/8 SOCHD BR

25 16-808229 HOLDER, VLV STEM-EXTRCTR VL

26 43-810063 O-RING, .551 ID .691 OD

27 16-808228 SEAT, EXTRCTR VLV

28 16-808189 STEM, EXTRCT VLV

29 43-810064 BACK-UP, .250DIA

30 43-810062 O-RING, .114ID .254OD

31 16-808190 SPRING, EXTRCTR VLV

32 52-501590 BODY, EXTRCTR VLV

- 48-941166 DECAL, WD HD NOT SHOWN

- 66-808169 KIT, REP-WD VLV

SERIAL NO.

FROM

NOTES:

NOT SHOWN INCLUDES PARTS 25-27 & 29-31

LEGEND SE 980059 06/19/03

Page 95

WAND - STAIR TOOL

5-45

1, 1A

20 21

5, 5A

15, 15A

9, 10

LEGEND SE 980059 06/19/03

Page 96

WAND - STAIR TOOL

5-46

REF PART NO. DESCRIPTION

- 78519 TL, STAIR, LNG, TM DJ (80015) COMPLETE

- 78521 TL, STAIR, SHT, TM (80015) COMPLETE 1A 56-501715 WAND & HEAD, STAIR TL 1B 56-501907 WAND & HEAD, SHRT STAIR TL

2 52-501576 BODY, WD HDL PORT 3 52-501577 HOLD DOWN, WD HDL PORT

4 04-000053 TIE, CABLE 8” WHT 5A 10-805330 HOSE, 3/16X13-3/4 (1/8PX1/4) 5B 10-805397 HOSE, 3/16X7-1/2 (1/8P X 1/4F)

6 17-803002 TIP, SPRY 9502X1/8P SST

7 00-000282 SCR, CAP 1/4-20 X 1-1/4 SOC

8 12-800060 CONN, 1/4P X 1/4T BR

9 00-000317 SCR, CAP 10-32X1-1/4 SOCH

10 57090 NUT, 10-32 HEX NYLOCK SS 11 61-950496 ASSY, EXTRCTR VLV 12 56015 NIPPLE, 1/4 HEX 13 56012 NIPPLE, 1/4 FPT QD

14 52-501619 TRIGGER, WD VLV 15A 09-805359 SLEEVE, WD HDL 9.5 15B 09-805504 SLEEVE, STAIR TL HDL 7-1/8

16 16-808229 HOLDER, VLV STEM-EXTRCTR VL

17 43-810063 O-RING, .551 ID .691 OD

18 16-808228 SEAT, EXTRCTR VLV

19 16-808189 STEM, EXTRCTR VLV

20 43-810064 BACK-UP, .250DIA

21 43-810062 O-RING, .114 ID .254 OD

22 16-808190 SPRING, EXTRCTR VLV

23 52-501590 BODY, EXTRCTR VLV

- 48-941163 DECAL, STAIR TL NOT SHOWN

- 66-808169 KIT, REP-WD VLV

SERIAL NO.

FROM

NOTES:

NOT SHOWN INCLUDES PARTS 16-19 & 20-22

LEGEND SE 980059 06/19/03

Page 97

UPHOLSTERY TOOL

5-47

22 24

25 26

LEGEND SE 980059 06/19/03

Page 98

UPHOLSTERY TOOL

5-48

REF PART NO. DESCRIPTION

- 78513 COMPLETE 1 09-805131 HOSE, VAC 1-1/4X10’ BLU 2 08-805243 CUFF, SWIV 1-1/4HX1-1/4T 3 10-805347 HOSE, 3/16X119-1/2 (1/8PX1/4FT) 4 13-806023 DSC, 1/8FC1/8FP SST 5 58-500639 UPHOLSTERY TL TRIGGER 6 00-000310 SCR, CAP 4-40 X7/32 SHCS SS 7 04-000282 SPRING, VAC ADJ BUTT 8 52-501624 BUTTON, VAC ADJ 9 52-501842 TOOL, UPHOLSTERY

10 61-950570 ASSY, UPHLST TL VLV 11 560012 NIPPLE, 1/4 NPT QD

12 17-803010 CONN, 1/4P X 11/16-16M 13 17-803006 WASHER, NYLON 14 14-806512 STRAIRNER, JET 50MESH 15 17-803036 CONN, 1/4FPX11/16-16F BR 16 11-800404 NIP, 1/4X5 SST 17 52-501585 COUPLER, UPHLST TL 18 12-800065 CONN, 1/8P X 1/4T 19 08-805138 CUFF, 1 1/4H X 1 1/2T GRY 20 16-808229 HOLDER, VLV STEM-EXTRCTR VL 21 43-810063 O-RING, .551 ID .691 OD 22 16-808228 SEAT, EXTRCTR VLV 23 16-808189 STEM, EXTRCTR VLV 24 43-810064 BACK-UP, 250DIA 25 43-810062 O-RING, .144 ID .254 OD 26 16-808190 SPRING, EXTRCTR VLV 27 00-000306 SCR, 6-32 X 1 SCHD SS 28 17-803033 TIP, SPRY 80015X1/8P SST 29 58-500638 CSTG, TRIGGER CLMP 30 00-000307 SCR, CAP 6-32X3/8 SOCHD 31 52-501623 VALVE, UPHLST TL 32 52-501626 VALVE, ADJ-UPHLST TL VLV 33 43-810016 O-RING, 5/32IDX9/32OD VIT 34 43-807513 GASKET, UPHLST TL VLV 35 10-805348 HOSE, 3/16X6-1/2 (1/8P BS) 36 13-806030 DSC, 1/8MX1/8FP SST 37 00-000408 SCR, SET 3-32 X 1/4 SOCHD

- 48-941164 DECAL, UPHLST TL NOT SHOWN

- 66-808169 KIT, REPAIR-WAND VLV

SERIAL NO.

FROM

NOTES:

INCLUDES PARTS 20-26, 28, & 31- 37

NOT SHOWN INCLUDES PARTS 20-22 & 24-26

LEGEND SE 980059 06/19/03

Page 99

SHELF ASSEMBLY

5-49

OVERALL DIMESNION: 41-1/2" TALL 50-1/8" WIDE 57" WIDE (WITH TOOL HOLDERS) 7-7/8" DEEP

DIMESIONAL DATA

50 1/8

LEGEND SE 980059 06/19/03

Page 100

SHELF ASSEMBLY

5-50

REF PART NO. DESCRIPTION

- 65-950392 VAN STORAGE UNIT PC 1 56-501921 SHELF, LWR 2 02-000066 FLATWASHER, 1/4 3 87162 WASHER, 1/4 SPLIT LOCK 4 70721 SHOULDER BOLT, 182 OD X 2.25 L 5 70270 SCR, 1/4-20 X 3/4 HHCS PLTD 6 50-501840 BRKT, ADJUST MTG SLOT 7 56-502067 BRKT, ADJUST MTF HLDR 8 56-501942 BRKT, SHELF MOUNTING 9 50-501753 HOLDER, STAIR TOOL

10 01-000105 LOCK NUT, 1/4-20 HXHD 11 56-501922 PANEL, SHLF END 12 50-501749 WASHER, NYLON 13 56-501920 DRWR, SHELF GRAY 14 46-802506 LATCH, ADJ GRIP 15 50-501755 HLDR, UP TO HOSE 16 50-501754 HLDR, UPHST TL 17 48-941152 DECAL, PROCHEM

- 66-945424 KIT, ADJ BRKT.

SERIAL NO.

FROM

NOTES:

INCLUDES PARTS 6,7 & MOUNTING HARDWARE

LEGEND SE 980059 06/19/03