MODEL _______________________________________
DATE OF PURCHASE __________________________
SERIAL NUMBER ______________________________
SALES REPRESENTATIVE # _____________________
DEALER NAME ________________________________
OPERATIONS GUIDE 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
Page 3
TABLE OF CONTENTS
2
Machine Data Log/Overview..........................1
Table of Contents...........................................2
HOW TO USE THIS MANUAL
How to use this Manual..................................1-1
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
Page 6
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
2-1
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.
2-2
LEGEND SE 980059 07/23/02
Page 8
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-UpDecal, Carbon Monoxide
Part #48-941317Part #48-941316
LEGEND SE 980059 07/23/02
2-3
Page 9
TECHNICAL SPECIFICATIONS
ITEMDIMENSION/CAPACITY
Engine speed2600 rpm (high speed in H.E. position)
1400 rpm (idle speed in Muffler position waster pump OFF.
Water pump rpm1395 rpm
Vacuum pump rpm3195 rpm
Water flow rate3.5 GPM (maximum)
Water pump pressure1000 PSI (maximum)
Vacuum relief valve13” Hg (13” Legend Hg - SE)
Waste tank capacity70 gallons (60 gallons to shut-off)
Console weight640 lbs. (730 lbs. If mounted on water tank)
Console weight (with waste tank & accessories)886 lbs (976 lbs. If waste tank is full)
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
3-2
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 UNITAND 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
3-3
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
3-4
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
3-6
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.
Before disconnecting the negative (-) ground
cable, make sure all switches are OFF. If ON, a
spark will occur at the ground cable terminal
which could cause an explosion if hydrogen gas
or gasoline vapors are present. When
disconnecting the battery, ALWAYS disconnect
the negative (-) terminal FIRST.
1. Attach the red positive (+) battery cable from the
console starter solenoid to the positive (+)
terminal on the battery and tighten the holding
nut.
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.
3-9
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.
LEGEND SE 980059 06/19/03
Page 19
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
LEGEND SE 980059 06/19/03
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
LEGEND SE 980059 06/19/03
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
LEGEND SE 980059 06/19/03
Page 26
OPERATION
3-18
FIGURE 18
EXHAUST
DIVERTER
SOLENOID ROTARY
LEGEND SE 980059 06/19/03
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 vacuumhose to the cleaningtool.
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
LEGEND SE 980059 06/19/03
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.
LEGEND SE 980059 06/19/03
Page 29
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.
LEGEND SE 980059 06/19/033-21
Page 30
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 tocool 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
wastetank. 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.
LEGEND SE 980059 06/19/03
Page 31
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 waterpump 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.
LEGEND SE 980059 06/19/03
Page 33
MAINTENANCE
Vacuum Pump
Engine
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
EngineDaily
Daily
Water PumpDaily
Vacuum Inlet Filter (In Waste Tank)Daily
Vacuum HosesDaily
Automatic Waste PumpDaily
Vacuum pumpWeekly*
Weekly
Weekly
Weekly*
BatteryWeekly*
Weekly*
Solution outlet Y-StrainerMonthly*
High pressure hoses25 hrs
Engine25 hrs
Pressure regulator50 hrs
Engine100 hrs
Engine100 hrs
Battery100 hrs*
Engine100 hrs
Engine100 hrs
Engine200 hrs
Heat bypass and chemical valves200 hrs*
200 hrs
Temperature solenoid200 hrs*
Vacuum exhaust heat exchanger200 hrs
Water pump500 hrs
250 hrs
Pulley set screws & hub cap screws500 hrs
Drive pulley500 hrs
500 hrs
Drive belts500 hrs
500 hrs
Chemical pump & check valves1000 hrs
1000 hrs
Vacuum pumpyearly
Yearly*
Nitrogen accumulatorYearly*
EngineYearly*
EngineYearly*
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
LEGEND SE 980059 07/23/02
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 sparkplug gap every 100 hours.
8. Remove the cooling shrouds and clean thecooling 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 10W45
SAE 20100
SAE 40200
SAE 50250
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 workingday.
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 vacuumpump 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
LEGEND SE 980059 07/23/02
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 first50hours 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
COMPONENTINCH/LBSFOOT/LBS
Engine hub72060
Vacuum pump hub19216
2. Check for pulley groove wear, clean belts and
pulley grooves, check for worn belts, proper belt
tension, and pulley alignment after the first 25hours 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.
LEGEND SE 980059 07/23/02
Page 37
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 everymonth. 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 every100 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.
LEGEND SE 980059 07/23/02
Page 39
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 todrive 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 hoursthereafter. 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!
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.
4-7
LEGEND SE 980059 07/23/02
Page 40
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
CAPO-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
3.
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
5.
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
LEGEND SE 980059 07/23/02
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
or
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.
LEGEND SE 980059 07/23/02
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.
LEGEND SE 980059 07/23/02
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-ringsCheck 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 brokenRe-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 gasolineAdd gasoline to the fuel tank.
Waste tank is fullEmpty 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 pumpReplace 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
2587162WASHER, 1/4 SPLIT LOCK
2600-000210SCR, 1/4-20 X 3/4 SOCHD
2748-941197DECAL, CONDENSED INSTRUCT.
2819-800075CUP, OIL FILL 1/8P
2936-900182SOLENOID, ROTARY
3061-950660ASSY, L HOOD
3150-501723HOOD, L
3215-808106VALVE, METER 1/8FP
3315-808022VALVE, 3-WAY BALL 1/8FP
3435-900182CONTR, TEMP 275DEG F
3533-900193MICROSW, TEMP CONTR
3618-808513FLOWMETER 1/8FP
3700-000337SCR, 10-32 X 1” SOCHD SST
3801-000273NUT, WELL 10-32
3948-941499DECAL, FLOOD EXTRACTION
-48-941184DECAL, PNL LEGENDNOT SHOWN
-48-941441DECAL, PNL LEGEND SENOT SHOWN
-48-941212DECAL, WARN. & INTRUMNTNOT SHOWN
-48-941195DECAL, HOOD PROCHEMNOT 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
8
18
17
16
15
14
21
8
7
9
2
22
19
20
1
1
2
22
6
10
1
2
5
1
4
1
2
3
27
2
28
1
1
11
12
2
3
27
2
22
13
3
2
1
1
26
24
25
2
23
5-3
19
LEGEND SE 980059 07/23/02
Page 54
FRAMEWORK
REFPART NO.DESCRIPTION
102-000066FLATWASHER, 1/4
287162WASHER, 1/4 SPLIT LOCK
370270SCR, 1/4-20 X 3/4 HHCS PLTD
456-501992GUARD, BELT
570075SCR, 1/4-20 X 4.5 HHCS PLTD
656-502025BRKT, R HOOD PC BLU
756-502026BRKT, CTR HOOD PC BL
800-000216SCR, CAP 1/4-20 X 1/2 FLTSO
950-501768GUARD, R BELT
1087144WASHER, .531ID C 1.25 X .1 FLT PLT
1187176WASHER, 7/16 SPLIT LOCK PLTD
1200-000222SCR, CAP, 7/16-14 X 1.5 HX
1354-501653SPCR, BELT GUARD
1456-501993PNL, ENG INS
1542-902282GUARD, FLYWHEEL(PART OF ENGINE)
1687139WASHER, 3/16 FLAT
1787165WASHER, #10 SPLIT LOCK
1870497SCR, #10-24 X 1/2 SHCS
1957006NUT, 1/4-20 HEX
2056-501929MOUNT, CONTR PNL BLUE
2158-700024PAD, VIBR CONTR PNL MT
2200-000286SCR, CAP 1/4-20 X 2.75 HXHD
2300-000210SCR, 1/4-20 X 3/4” SOCHD
24790074PANEL, LWR FR
25790070BASE, AD SOL
2656-501857BRKT, FUEL LINE
2770105SCR, 1/4-20 X 1.75 HHCS PLTD
2856-502050BRKT, HOOD MTG
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-4
Page 55
ENGINE
5-5
27
26
2
1
29
28
3
24
FROM BULHEAD
ADAPTER ON
VEHICLE FLOOR
20
21
19
22
25
23
18
17
16
15
14
TO EXHAUST
DIVERTER VALVE
ASSEMBLY
13
12
11
4
5
6
7
10
8
9
LEGEND SE 980059 07/23/02
Page 56
ENGINE
REFPART NO.DESCRIPTION
140-902152ENG, KOHLER 20HP
242-902299KOH ELEM, AIR CLNR#470830
342-902297KOH PMP, FUEL PULSE #2439316L P
442-902289KOH SPK PLG #1213202
542-902296KOH FLTR, FUEL #2505003
603-000065CLAMP, HOSE #4 SST
709-805091HOSE, FUEL 1/4 X 27 1/2
812-800062PLUG, 1/2T
910-805291HOSE, HP 3/8 X 10 (3/8 X1/2 FT)
1042-902365SUB 42-902396 KOH KIT, VO
1142-902277KOH FLTR, OIL #1205001
1256-502090MNFLD, ENG EXH
1342-902212ONAN GSKT, EXH #154-2747
1444-802237BELT, AX42 GOODYEAR MATCH
1554-500412KEY, 1/4 SQ X 1.88
1652-501660PULL, ENG
1744-802182HUB, P2X1-1/8
1844-802240BELT, 3V X265
1900-000311SCR, 1/4-20 X 1/2 SHCS SS
2044-802311BLET, AX29 GOODYEAR MTCH MKR
2152-501661PULL, OUTR ENG
2200-000340SCR, MACH 5/16-18 X 1” GR 8
2312-800041FTTG, BARB 1/8P X 1/4H
24790605EL, 90DEG 1/8 X 5/16HB
2556-501857BRKT, FUEL LINE
2687083WASHER, 5/16 SPLIT LOCK PLTD
2757054NUT, M8
28790626GSKT, EXHST, KHLR 25HP
2942-902293KOH CARB, #2485335S
-42-902286KOH SE, OIL PRESSNOT SHOWN
-42-902287KOH GSKT, CYL HD #2404108NOT SHOWN
-42-902359KOH ASSY, VLV CVR #2475574NOT SHOWN
-42-902360KOH ASSY, VLV CVR (OIL)NOT SHOWN
-42-902291KOH DRIVE PINIONNOT SHOWN
-42-902294KOH KIT, CARB REP #2475703NOT SHOWN
-42-902295KOH 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
1
3
2
4
TO BATTERY
NEGATIVE (-)
TERMINAL
5
9
7
8
TO BATTERY
POSITIVE (+)
TERMINAL
6
5
LEGEND SE 980059 07/23/02
Page 58
ENGINE STARTER
REFPART NO.DESCRIPTION
142-902292KOH SOLENOID #5243502
264-950514CABLE, BAT X 101” RED
342-902290KOH STARTER #1209803
457031NUT, 5/16-18 HEX
587083WASHER, 5/16 SPLIT LOCK PLTD
602-000143FLATWASHER, 5/16
770601SCR, 5/16-18 X 2.75 HHCS GR5
864-950515CABLE, BAT X 111” BLK
970262SCR, M8 X 20 HHMS PLTD
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-8
Page 59
VACUUM PUMP
5-9
28
29
16
FROM WASTE
TANK
10
27
24
3
30
26
23
25
VENT CAP
3
1
12
2
6
11
10
13
14
TO VACUUM
MUFFLER
4
5
7
8
9
22
21
1920
LEGEND SE 980059 07/23/02
17
15
12
18
16
Page 60
VACUUM PUMP
REFPART NO.DESCRIPTION
141-905021PUMP, VAC 4M-L
254-501593NIP, VAC EXH OUTL
303-000112CLAMP, HOSE #48
409-805396HOSE, INT VAC 2.88 X 2.0 BLK
554-501735KEYSTOCK, 3/16 X 1 5/8
644-802237BELT, AX42 GOODYEAR MATCH
744-802218PULLEY, 2TA46
844-802204HUB, P1 X 3/4”
900-000340SCR, MACH 5/16-18 X 1” GR5
1087171WASHER, 3/8 FLAT
1187163WASHER, 3/8 SPLIT LOCK
1270266SCR, 3/8-16 X 1” HHCS GR 5 PLT DL
1312-800101ELL, 1/4FP X 1/4 POLY BR
1418-808525GAUGE, VACUUM 30” HG
1519-800075CUP, OIL FILL 1/8P
1612-800059CONN, 1/8P X 1/4 POLY BR
1709-805224TUBING, IMPOL 1/4 X 50
1809-805440TUBING, IMPOLENE X 35”
1902-000057FLATWASHER, 1/2” HEAVY
2000-000323SCR, 1/2-13 X 3 1/2 HHCS FULL THD
2170357SCR, 1/2-13 X 3 FULL THREADS
2256-502324BRKT, VAC ADJ LEGEND SE
2361-950451ASSY, VAC REL VLV
2409-805341HOSE, VAC 2.88 X 25.0 BLK
2557114NUT, 7/16-14 HEX
2604-000091SPRING, VAC REL VLV
2752-501573ELL, VAC REL VLV
2856-501615STEM, VAC REL VLV #4 VAC
2943-807074DIAPHRAGM, VAC REL VLV
-05-008039OIL, AEON PD (28G24 SUTORBILT)NOT SHOWN
-05-008032GREASE, MA3830150NOT SHOWN
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-10
Page 61
WATER PUMP
5-11
2
1
10
FROM
WATER BOX
FROM TOP OF
FLOW METER
TO CHEMICAL
ON/OFF PRIME
VALVE
TO PRESSURE
MANIFOLD
33
32
31
29
28
27
22
34
30
23
24
11
26
21
25
9
3
8
1112
13
14
7
6
5
4
12
13
18
19
15
20
15
16
5
7
17
LEGEND SE 980059 09/10/02
Page 62
WATER PUMP
REFPART NO.DESCRIPTION
110-805424HOSE, HP 3/8 X 10 1/2”
212-800225ELL, 3/8P X 1/2T BR
341-809153PUMP, WATER CAT 3CP1140
411-800224PLUG, 3/8 SOCHD BR
587171WASHER, 3/8 FLAT
687163WASHER, 3/8 SPLIT LOCK
757111NUT, 3/8-16 HEX
812-800060CONN. 1/4P X 1/4T BR
910-805316HOSE, 3/16 X 5 (1/4FT BS) MET
1012-800029PLUG, 1/4T BR
1111-800342CONN, 1/2P X 1/2FP BR
1202-000066FLATWASHER, 1/4
1389162WASHER, 1/4 SPLIT LOCK
1470260SCR, M6 X 1 X 16MM HHCS
1536-900140CLUTCH, ELC WTR PUMP CAT
1644-802311BELT, AX29 GOODYEAR MTCH MKR
1731-900185CONN, BULLET M (.156)
1856-502248BRKT, PUMP ADJ
1911-800069PLUG, 1/2 SOCHD BR
2000-000277SCR, MACH 6MM X 14MM
2100-000336SCR, CAP 3/8-16 X 3 ALL THD
2210-805300HOSE, 3/16 X 45” HP W/1 1/4FT
2312-800040ELL, 1/8P X 1/4T BR
2441-809158PUMP, CHEM (O-RING CAP)
2552-809125ADPT, CAT CHEM PUMP
2652-809123RETAIN, VALVE SPRING
2709-805363HOSE, BRD 5/16 X 52
2803-000065CLAMP, HOSE #4 SPOTTER SST
2912-800093FTTG, BRB 1/8P X 5/16H
3011-800014ELL, STREET 1/8 BR
3139619HOSE, WTR 3/4 X 10”
3203-000113CLAMP, HOSE #12 SST
3312-800278FTTG, BRB 1/2P X 3/4H BR
3411-800041ELL, STREET 1/2 BR
-05-008016OIL, CAT- WTR PUMPNOT SHOWN
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/22/03
5-12
Page 63
WATER PUMP
7
1
4
3
2
5
12
11
13
10
15
17
16
14
6
7
17
5-13
8
9
18
LEGEND SE 980059 07/23/02
Page 64
WATER PUMP
REFPART NO.DESCRIPTION
142-809238CAP, OIL FILLER
242-809239O-RING, OIL FILL CAP
343-807063GASKET, OIL GAUGE
442-902380GAUGE, OIL LEVEL
542-809401COVER, CRANKCASE
642-809402O-RING, CRANK CVR
742-809394O-RING, BEARING CVR
842-809403MANIFOLD, HEAD
942-809404PLUG, VALVE
1042-809406BOLT, MNFLD HD M8 X 65
1142-809405RETAINER, SEAL
1242-809407RETAINER, PNLGR W/STUD
1342-809408PLUNGER
1442-809249WASHER, KEYHOLE M18
1542-809381SLINGER, BARRIER
1642-809409SEAL, OIL CRANKCASE
1742-809410KIT, SEAL
1866-950441KIT, 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
23
22
21
20
17
19
19
18
18
17
1
4
FROM
WATER
PUMP
14
6
5
9
4
8
13
16
8
15
TO SOLUTION
OUTLET
12
11
5
24
10
4
5
TO CHEMICAL
RESERVOIR
6
9
3
4
2
5
4
7
LEGEND SE 980059 07/23/02
Page 66
CHEMICAL SYSTEM
REFPART NO.DESCRIPTION
118-808513FLOW METER 18FP
287162WASHER, 1/4 SPLIT LOCK
300-000065SCR, 10-32 X 3/8” PNHD
412-800093FTTG, BRB 1/8P X 5/16H
503-000065CLAMP, HOSE #4 SPOTTER SST
609-805088HOSE, BRD 5/16X64
714-806506SCREEN, 1/8FP
812-800040ELL, 1/8P X 1/4R BR
911-800014ELL, STREET 1/8 BR
1015-808022VALVE, 3-WAY BALL 1/8FP
1156032NIPPLE, 1/8 CLOSE
1215-808106VALVE, METER 1/8FP
1341-809158PUMP, CHEM (O-RING CAP)
1452-809125ADPT, CAT CHEM PMP
1510-805278HOSE, 3/16X54 (1/4FT BS)MET
1610-805131HOSE, 3/16 X 20-1/2
1716-808237CAP, CHK VALVE CHEM. PUMP
1843-810079O-RING, 7/8 ID X 1-1/16 OD
1942-809265CHECK VALVE, CHEM. PUMP
2042-809358BODY, CHEM PUMP
2142-809264DISK, CHEM PUMP
2242-809047DIAPHRAGM, CHEM PUMP
2342-809045COVER, CHEM PUMP
2450-501663WASHER-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
34
2
FROM PRESSURE
REGULATOR
MANIFOLD
18
5
6
1
7
FROM VACUUM
PUMP
9
10
6
5
7
4
FROM DIVERTER
VALVE
8
19
11
16
12
4
13
14
5
4
17
16
TO WATER
BOX
15
LEGEND SE 980059 07/23/02
Page 68
VACUUM EXHAUST HEAT
EXCHANGER AND SILENCER
1PART NO.DESCRIPTION
156-501928EXH OUTLET
203-000081CLAMP, MFLR 1-1/2 ZNC PL
357-520099MUFFLER, ENG EXH VERSION D (FLNG)
402-000066FLATWASHER, 1/4
587162WASHER, 1/4 SPLIT LOCK
670270SCR, 1/4-20 X 3/4 HHCS PLTD
703-000112CLAMP, HOSE #48
809-805344HOSE, INT VAC 2.88 X 3.0 BLK
956-501892HOUSING VAC HE
1057-520082MUFFLER, VACUUM
1109-805396HOSE, INT VAC 2.88 X 2.0 BLK
1200-000078SCR, 1/4-20 X 1” HXHD GRD8
1343-807080GASKET, VAC HE INLET
1458-700027PAD, VAC HE CORE
1509-805368HOSE, WTR 5/8 X 29
1603-000246CLAMP, HOSE #8 SST
1761-950696VAC HE CORE
1809-805384HOSE, WTR 5/8 X 16
1943-807081GASKET, VAC HE CORE
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-18
Page 69
ENGINE EXHAUST HEAT EXCHANGER
5-19
6
22
21
20
FROM HELI-COIL
HEAT EXCHANGER
5
FROM DIVERTER
VALVE
18
19
4
7
8
22
21
20
11
1
16
17
3
2
TO SOLUTION
OUTLET
15
14
13
12
LEGEND SE 980059 07/23/02
Page 70
ENGINE EXHAUST HEAT EXCHANGER
REFPART NO.DESCRIPTION
-61-950628ASSY, CAT HEINCLUDES PARTS 1-14
101-000271NUT, 1/4-20 HXHD BR
252-501643SHEILD, CAT HE
358-700028PAD, CAT HT SHEILD
456-501759CVR, CAT HE END BC
543-807086GSKT, EXH FLG
657-520074ASSY, COIL MOUNT & CASING
757006NUT, 1/4-20 HEX
802-000044LOCKWASHER, 1/4 SST
970015SCR, 1/4-20 X 3/4 HHCS SS
1052-501654NUT, ADAPT BUSH
1164-950546ASSY, HIGH TEMP SHUTOFF
1235-900184SENSOR, TEMP 285DEG
1352-501671FTTG, TEMP SENS ADPT TM
1412-800171ELL, 1/2P X 1/2T BR
1510-805376HOSE, 1/2 X 4 1/2 (1/2 FT BS)
1602-000274LOCKWASHER, 5/16 (ALLEN SCREW)
1700-000315SCR, CAP 5/19-18 X 7/8 SOCHD
1842-902212ONAN CAKT, EXH #154-2747
1910-805275HOSE, 1/2 X 19 (1/2FT BS) MET
2002-000066FLATWASHER, 1/4
2187162WASHER, 3/8 SPLIT LOCK
2200-000078SCR, 1/4-20 X 1” HXHD GRD8
-66-945532KIT, EXH HE CORE
-57-520070HE, EXH CATINCLUDES 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
9
12
6
11
10
4
8
6
7
13
3
4
1
2
5
TO WATER
BOX
17
14
15
16
LEGEND SE 980059 07/23/02
Page 72
BYPASS MANIFOLD
REFPART NO.DESCRIPTION
110-805357HOSE, 3/16 X 38 (1/4FT BS) MET
212-500040ELL, 1/8P C 1/4T BR
356-501906 ASSY, BRKT, BYPASS MTG
412-800065CONN, 1/8P X 1/4T
510-805130HOSE, 3/16 X 13-1/2 (1/4FT BS)
687162WASHER, 1/4 SPLIT LOCK
700-000132SCR, 1/4-20 X 1-1/2 HXHD
815-808112ASSY, BYPASS MNFLD
910-805130HOSE, 3/16 X 13-1/2 (1/4FT BS)
111-800101PLUG, 1/8P
212-800040ELL, 1/8P X 1/4T BR
310-805357HOSE, 3/16 X38 (1/4 FT BS) MET)
411-800342CONN, 1/2P X 1/2FP BR
512-800391UNION, CAPILLARY-THERM
635-900182CONTR, TEMP 275 DEG
712-800065CONN, 1/8P X 1/4T
810-805205HOSE, 3/16 X 15-1/8 (1/4FT BS)
912-800329CONN, 1/4P X 1/2T SST
1031017ELBOW, 1/4FPT X 1/4PT
1122015COUPLER, 1/4 QD
1210-805376HOSE, 1/2 X 14-1/2 (1/2FT BS)
1312-800282CONN, 3/8P X 1/2T BR
1411-800276ELL, 3/8 BR
1502-000066FLATWASHER, 1/4
1687162WASHER, 1/4 SPLIT LOCK
1757006NUT, 1/4-20 HEX
1856-501910BRKT, SOL OUT MTG
1970105SCR, 1/4-20 X 1.75 HHCS PLTD
2015-808095ASSY, CHK VLV
2152-501621MANIFOLD, CHK VLV
2214-806549SCREEN, CHECK VALVE
2343-810053O-RING, .676ID X .816OD
2415-808094VALVE, CHECK
2511-800429NIP, NEX 3/8 SST
2652-502066MANIFOLD, THERMOSTAT
2756-501974BRKT, THERM MANIFOLD MOUNTING
2834-903019SENDER, TEMP 140-320 DEG
2900-000132SCR, 1/4-20 X 1-1/2 HXHD
3052-501680FTTG, SENS SUPT TM
3116-808223SEAT, CHK VLV ASSY TM
3243-810008O-RING
3316-808226POPPET CHK VLV ASSY
3416-808225TEFLON SEAT
3543-810079O-RING, 7/8ID X 1-1/16 OD
3616-808224SPRING
3716-808222CAP
3835-901039SENSOR, TEMP, 260°
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-24
Page 75
WATER BOX
5-25
24
25
23
26
32
23
22
33
34
27
31
21
30
29
28
1
2
3
18
17
16
6
5
4
7
21
19
15
14
LEGEND SE 980059 07/23/02
8
9
10
14
SEE WATER PUMP
11
12
13
Page 76
WATER BOX
REFPART NO.DESCRIPTION
111-800432CAP, WATER BOX
258-500781MOLDING, WATER BOX
350-501763HOLD DOWN WTR BOX
402-000066FLATWASHER, 1/4
587162WASHER, 1/4 SPLIT LOCK
600-000335SCR, 1/4-20 X 8 HXHD
709-805099HOSE, BRD 5/16 X40
803-000065CLAMP, HOSE #4 SST
912-800093FTTG, BRB 1/8P X 5/16H
1015-808083VALVE, TEMP REL 180 DEG F
1103-000113CLAMP, HOSE #12 SST
1212-800278FTTG, BRB 1/2P X 3/4H BR
1311-800041ELL, STREET 1/2 BR
1411-800300NIP, 1/2 X CL
1514-806540STRAINER, SUC END 1/2FP
1619-807014BALL, FLOAT
1754-501715FLOAT ROD
1857006NUT, 1/4-20 HEX
1910-805206HOSE, 3/16 X 14-3/4 (1/4FT BS)
2012-800356ELL, 1/4P X 1/4T 45 DEG BR
2156-501901TRAY, WTR BOX
2209-805368HOSE, WTR 5/8 X 29
2303-000246CLAMP, HOSE #8 SST
2412-800269FTTG, BRB 1/2P X 5/8H BR
2509-805330HOSE, WTR 5/8 X 53”
2611-800361ELL, 1/2 BR
2715-808110VALVE, FLOAT
2852-501706NUT, FLOAT VALVE
2916-808217BODY, FLOAT VLV
3000-000337SCR, 10-32 X 1” SOCHD SST
3116-808216ARM, PIVOT- FH VLV
3216-808219PISTON, FH VLV
3316-808164SEAT, FLOAT VLV
3457090NUT, 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
17
15
1
7
3
2
7
19
11
16
12
TO EXHAUST
HEAT EXCHANGER
4
5
6
8
10
13
TO VACUUM EXHAUST
HEAT EXCHANGER
14
9
FROM WATER PUMP
20,21
20
22
20,21
20
20,21
LEGEND SE 980059 11/07/02
Page 78
PRESSURE REGULATOR MANIFOLD
REFPART NO.DESCRIPTION
1790106ACCUMULATOR
287162WASHER, 1/4 SPLIT LOCK PLTD
300-000210SCR, 1/4-20 X 3/4 SOCHD
410-805294HOSE, 3/16 X 11.5 (1/4FT BS)
512-800346ADAPTER, 1/4T X 3/8P
611-800275ELBOW, ST 3/8 BR
711-800345PLUG, 1/4 SOCHD BRASS
812-800347ELBOW, 3/8P X 1/2T 45° BR
910-805424HOSE, HP 3/8 X 10.5
1010-805275HOSE, 1/2 X 19 (1/2 FT BS) MET
1112-800282CONN, 3/8P X 1/2 T BR
1211-800224PLUG, 3/8 SOCHD BR
1309-805384HOSE, WATER 5/8 X 16
1403-000246CLAMP, HOSE #8 SST
1512-800345FITTING, BRB 3/8P X 5/8H BR
1611-800341ELL, ST 3/8 45DEG BR
17790067REGULATOR, PRESSURE
1811-800429NIP, HEX 3/8 SST
19790112MANIFOLD, PRESS REG. 1/2 “ PORT
2016-808201CAT #33246 KIT, O-RING REP
2116-808200CAT #33147 KIT, VALVE REP
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 11/07/02
5-28
Page 79
TEMPERATURE SOLENOID & BYPASS VALVE
5-29
2
1
TO VACUUM
INLET TUBE
3
17
18
4
5
8
9
FROM BYPASS
MANIFOLD
16
15
14
13
6
11
7
10
12
LEGEND SE 980059 07/23/02
Page 80
TEMPERATURE SOLENOID & BYPASS VALVE
REFPART NO.DESCRIPTION
112-800088TEE, ADPT 1/8FP X 1/8P X 1/4T
212-800040ELL, 1/8P X 1/4T BR
310-805000HOSE, 3/16 X 9 (1/4FT BS)
415-808107VALVE, METER 1/8FP (BYPASS)
512-800065CONN, 1/8P X 1/4T
610-805204HOSE, 3/16 X 23 (1/4FT BS)
731-900028TERM, INS DSC 1/4M 14-16W
831-900027TERM, INS DSC 1/4F 14-16W
915-808105VALVE, SOLENOID 1/4F X 1/4F
1011-800039BUSH, 1/4 X 1/8 BR
1187165WASHER, #10 SPLIT LOCK
1200-000065SCR, 101-32 X 3/8” PNHD
1302-000066FLATWASHER, 1/4
1487162WASHER, 1/4 SPLIT LOCK
1570270SCR, 1/4-20 X 3/4 HHCS PLTD
1650-501721BRACKET, SOLENOID
1712-800031ELL, 1/4P X 1/4T BR
1810-805311HOSE, 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
3
14
20
9
9
5
14
11
3
2
4
5
4
2
16
6
2
15
10
8
1
13
11
18
2
3
7
19
17
7
12
LEGEND SE 980059 07/23/02
Page 82
DIVERTER VALVE
REFPART NO.DESCRIPTION
100-000210SCR, 1/4-20 X 3/4 SOCHD
200-000265SCR, SET 1/4-20 X 1/4 SOCHD
300-000315SCR, CAP 5/16-18 X 7/8 SOCHD
400-000317SCR, CAP 10-32 X 1 1/4 SOCH
587031NUT, 5/16-18 HEX
657113LOCKNUT, 5/16-18 HEX NYLOCK
701-000301LOCKNUT, 10-32 SS
887162WASHER, 1/4 SPLIT LOCK
987083WASHER, 5/16 SPLIT LOCK PLTD
155-501700TUBE, RT AIR PUMP
212-800358CONN, 1/8P X 3/8T COMP
356-502090MANIFOLD, ENG EXH
411-800118BUSH, 3/8 X 1/8 BR
502-000066FLATWASHER, 1/4
687162WASHER, 1/4 SPLIT LOCK
757006NUT, 1/4-20 HEX
856-501791TEE, CAT AIR PUMP
955-501699TUBE, L AIR PUMP
1011-800341ELL, ST 3/8 45DEG BR
1170270SCR, 1/4-20 X 3/4 HHCS PLTD
1212-800161FTTG, BRB 3/8P X 1/2H BR
1303-000246CLAMP, HOSE #8 SST
1439174HOSE, WIRE BOUND X 23”
1544-802240BELT, 3VX265 GOODYEAR
1670266SCR, 3/8-16 X 1” HHCS GR5 PLTD DL
1787171WASHER, 3/8 FLAT
1852-501647PULLEY, AIR PUMP
1941-809122PUMP, AIR
2056-502117BRKT, AIR PUMP
2156-502328BRKT, LWR ARI PUMP LEGEND SE
2287083WASHER, 5/16 SPLIT LOCK PLTD
2370262SCR, M8 X 20HHCS PLTD
2487163WASHER, 3/8 SPLIT LOCK
2557111NUT, 3/8-16 HEX
SERIAL NO.
FROM
NOTES:
LEGEND SE 980059 07/23/02
5-34
Page 85
WASTE TANK
5-35
5
6
34
33
36
26
23
31
32
30
29
28
27
35
1, 2
26
7
3
8, 8A
4
9
10
11
12
23
19
18
17
16
TO
VACUUM
PUMP
14
15
FROM
WATER BOX
13
FROM VACUUM
INLET TUBE
39
37
25
23
24
21
20
40
38
36
22
LEGEND SE 980059 07/23/02
Page 86
WASTE TANK
REFPART NO.DESCRIPTION
161-951175ASSY, LID WST TNK
256-501788LID, WST TNK
367006RIVET, 3/16 OD X 5/8 AL
446-802510LATCH, DRAW 2-7/8 SST
548-941297DECAL, ARROW-WST TANK LID
643-807094GASKET, WST TNK LID
756-501793STRAINER BOWL
856-501829TANK, WST BLUE
8A56-501973TANK, WST
931016ELBOW, 1/4 NPT STREET
1012-800092FTTG, BRB 1/4 X 5/16H BR
1103-000065CLAMP, HOSE #4 SST
1209-805099HOSE, BRD 5/16 X 40
1303-000054CLAMP, HOSE #32 1.5625/2.5 SST
1409-805415HOSE, INT VAC 2 X 12”
1561-950621ASSY, LVL SNS SHTOF SW
1609-805341HOSE, VAC 2.88 X 25.0 BLK
1703-000112CLAMP, HOSE #48
1814-806518STRAINER, WASTE TANK 2-1/2”
1911-800402PLUG, 1-1/4 HXHD PVC
2009-805332HOSE, 2.0 X 120.0 BLK
2115-808080VALVE, BALL PVC 1-1/2FP
2212-800357FTTG, BARB 1-1/2P X 2H
2302-000066FLATWASHER, 1/4
2400-000078SCR, 1/4-20 X 1” HXHD GRD8
2503-000242CLAMP, CABLE 3/4ID 1/4BLT
2687162WASHER, 1/4 SPLIT LOCK
2757006NUT, 1/4-20 HEX
2856-501779TRAY, BATTERY
2950-501697SPACER, BAT SHLF MTG
3064-950514CABLE, BATX101” RED
3147-700007SHIELD, BAT MT HT
3236-900056BATTERY
3364-950515CABLE, BATX111” BLK
3431-900179COVER, BATTERY TERMINAL
3556-500188COVER, BATTERY
3600-000167SCR, 1/4-20 X 6” HXHD
112-800078FITTING, BRB 2H BS PVC
208-805147CUFF, 2”
310-805060HOSE, VAC 2”X50’ W/ CUFFS & HOSE
456015NIPPLE, 1/4 HEX
522015COUPLER, 1/4 QD
656012NIPPLE, 1/4 FPT QD
710-805108HOSE, HP 1/4 X 50FT W/QD & VLVE
810-805077HOSE, HP 1/4 X 50’
908-805155GUARD, HOSE VINYL
1015-808012VALVE, BALL 1/4FP
1143-810014O-RING, 7/32ID X 11/32OD
1243-810019O-RING, 3/8 ID X 1/2 OD
1311-800354NIP, 1/2 X 3/8 HEX BR
1410-805157HOSE, WATER 1/2 X 50’
1513-806009DISCONNECT 3/8M X 3/8FP
1610-805295HOSE, WATER 1/2 X 50’
1722015COUPLER, 1/4 QD
1810-805077HOSE, HP 1/4 X 50’
1908-805155GUARD, HOSE VINYL
2056012NIPPLE, 1/4 FPT QD
2110-805122HOSE, HP 1/4 X 50FT W/QD