Prochem Legend XL User Manual

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MOBILE CLEANING UNIT

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Operating Instructions (ENG)

MODELS: LEGEND XL

BB

86037400 06/30/09
PRV NO. 980157

Read instructions before operating the machine.

MACHINE DATA LOG/OVERVIEW

Name: ________________________________________________________________________________________

Address: ______________________________________________________________________________________

Phone Number:

_________________________________________________________________

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

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

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

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

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

PROFESSIONAL CHEMICALS CORPORATION
325 SOUTH PRICE ROAD
CHANDLER, ARIZONA 85224

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

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

YOUR DEALER

86037400 02/16/07

1

TABLE OF CONTENTS

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

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

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

HOW TO USE THIS MANUAL

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

SAFETY

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

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

OPERATION & SYSTEMS

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

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

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

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

Chemical Requirements ...............................3-3

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

Water Pumping And Heat

Transfer System ......................................... 3-8

Chemical Injection System ......................... 3-9

Vacuum System.......................................... 3-10

Pre-run Inspections..................................... 3-11

Water Supply Connections......................... 3-11

High Pressure Hose.................................... 3-11

Vacuum Hose............................................. 3-11

Filters.......................................................... 3-11

Priming the Chemical Pump....................... 3-12

Waste Pump (Optional) .............................. 3-12

Cleaning...................................................... 3-12

Upholstery Cleaning ................................... 3-13

Shutdown and Daily Maintenance.............. 3-13

De-flooding Operations............................... 3-13

Freezing Protection..................................... 3-13

Winterizing Your Unit.................................. 3-14

Removing Anti-freeze from Unit.................. 3-15

MAINTENANCE & SERVICE

Maintenance

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

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

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

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

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

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

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

Vacuum Drive Belts ................................4-6

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

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

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

Waste Tank Float Valve..........................4-7

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

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

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

Chemical And Heat

Bypass Valves ........................................4-7

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

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

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

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

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

Service Adjustments

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

Check Valve (Solution Outlet).................4-9

Water Box...............................................4-9

Chemical Pump.......................................4-9

Drive Belts for Water Pump

and Vacuum Pump .................................4-9

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

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

Troubleshooting...........................................4-11

2

86037400 02/16/07

PARTS LIST

Frame................................................5-1

Side Panel.........................................5-3

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

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

Water Pump & Chemical Pump........5-11

Heat Exchanger................................5-15

Pressure Regulator &

Temperature Bypass.........................5-17

Water Box.........................................5-19

Waste Tank.......................................5-21

Hose Accessories.............................5-23

Battery-Floor Mount..........................5-25

Automatic Pumpout-Optional............5-27

Wand-Titanium Six Jet-Optional.......5-31

Wand-Quad Jet-Optional..................5-33

Wand-Tri Jet-Optional.......................5-35

Stair Tool-Optional............................5-37

Upholstery Tool-Optional..................5-39

Shelf Assembly-Optional...................5-41

Water Tank, Dual With

Demand Pump-Optional ...................5-43

Water Tank-Demand Pump-Optional5-45

Auxiliary Water Tank With Pump......5-47

Auxiliary Water Tank-Optional..........5-49

Hose Reel-Optional...........................5-51

Wiring Diagram.................................5-53

Hose Diagram...................................5-54

Warranty ...........................................5-56

TABLE OF CONTENTS

86037400 09/06/07

3

RECEIVING YOUR UNIT

ACCEPTANCE OF SHIPMENT

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

make the following acceptance check:

1. The unit should not show any outward signs of

damage. If damaged, notify the delivering carrier
immediately.

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

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

EQUIPMENT LIST:

1. Console.

2. Waste Tank

3. Hose Clamps For Vacuum Hoses.

4. 100 Ft. Of 2” Vacuum Hose.

5. 1 Vacuum Hose Connection.

6. 100 Ft. Of 1/4" High Pressure Hose With Quick

Connects.

7. 50 Ft. Water Supply Hose With Quick Conne ct.

8. Installation Bolting Kit.

9. Installation Mounting Plates.

10. Operation And Service Manual For Engine,

Water Pump, And Vacuum Pump.
Each unit will require a fuel system installation kit

that is purchased separately from the unit and is
specific for each manufacturer and model year of
van.

4

86037400 02/16/07

HOW TO USE THIS MANUAL

This manual contains the following sections:

- HOW TO USE THIS MANUAL

- SAFETY

- SYSTEMS

- OPERATIONS

- MAINTENANCE & SERVICE

- PARTS LIST

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

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

MODEL _____________________________________
DATE OF PURCHASE ________________________
SERIAL NUMBER ____________________________
SALES REPRESENTATIVE # ___________________

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

- Water Pump

- Drive Belts, Pulleys & Hubs

- Chemical Pump

- Hoses

- Vac/Exhaust Heat Exchanger

- General Service Adjustments

- Troubleshooting

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

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

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

- PRV NO. – reference number

- DESCRIPTION – column is a brief

description of the part.

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

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

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

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

86037400 02/16/07

1-1

IMPORTANT SAFETY INSTRUCTIONS

When using this machine, basic precautions

must always be followed, including the following:

READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.

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 th is 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 or hoods. The high speed moving parts, such as belts and pulleys,

should be avoided while this unit is running. Severe injury, damage, or fatality may result.
DO NOT service this unit while it is running. The high-speed mechanical parts as well as high temperature

components may result in severe injury or severed limbs.
Never touch electrical wires or components while the engine is running. They can be sources of electrical

shock.
Engine components can get extremely hot from operation. To prevent severe burns, DO NOT touch these

areas while the engine is running - or immediately after the engine is turned off.

DO NOT touch the exhaust system while this unit is running. Severe burns may result.
Before servicing this unit, allow it to "cool down." This will prevent burns from occurring.

Water under high pressure at high temperature can cause burns, severe personal injury, or fatality. Shut
down machine, allow to cool down, and relieve system of all pressure before removing valves, caps,
plugs, fittings, filters, and bolts.

Always wear hearing protection when unit is running. Always comply with your company’s Personal
Protection Equipment (PPE) plan. Always comply with local noise ordinance when operating units.

These symbols mean WARNING or CAUTION. Failure to follow warnings and
cautions could result in fatality, personal injury to yourself and/or others, or
property damage. Follow these instructions carefully!

2-1

86037400 02/16/07

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

Use only ProChem supplied fuel installation kits. Ensure to use the kit specific for the truckmount model and
van model being used. 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 empty waste tank and accessories weighs
approximately 770 lbs. Make certain to account for any additional accessories in your weight and balance
calculations. Make certain that the vehicle has the correct axle rating. This will prevent unsafe vehicle driving
conditions.

We require high-back seats on all vehicles in which units are to be installed for head and neck protection.

We recommend using a metal partition between the seats and equipment.
DO NOT operate this unit without the water supply attached and turned on. The water pump and other vital

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

DO NOT operate this unit without the filter installed in the waste tank.

Keep your vehicle work area clean. Wands, stair tools, and other accessories must be securely fastened before
driving the vehicle.

All high pressure hoses must be rated for 3000 PSI at 250°F. Thermoplastic hoses do not meet these
specifications and should not be used. Severe burns and injury may result if the hoses do not meet these
requirements.

The winterizing loop hose assembly, Part #86260700, PRV NO. 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. Running with out adequate water
supply could damage water pump. Ensure always to have an adequate water supply.

86037400 02/16/07

2-2

HAZARD LEVEL INTENSITY

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

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

Lower front panel decal
With warning labels
86186630
PRV NO. 500836

Caution label
86186530
PRV NO. 500770 (2)

Warning label
86186520
PRV NO. 500769 (3)

2-3

86037400 02/16/07

TECHNICAL SPECIFICATIONS

ITEM DIMENSION/CAPACITY

Engine speed 2850 rpm

1400 rpm (idle speed)
Water pump rpm 1625 rpm
Vacuum pump rpm 2850 rpm
Water flow rate 3.5 GPM (maximum)
Water pump pressure 1000 PSI (maximum)
Vacuum relief valve 13” Hg
Waste tank capacity 60 gallons
Console weight 560 lbs. (650 lbs. If mounted on water tank)
Console weight (with waste tank & accessories) 770 lbs (If waste tank is empty)

(1285 lbs. If waste tank is full)

(1800 lbs. If auxiliary water tank and waste tank are full)

TORQUE VALUES

Engine 264 inch lbs 22 foot lbs
Engine rear vac pump 264 inch lbs 22 foot lbs
Engine front water pump drive pulley hub on sub­shaft
Water pump clutch:
M8 x 2.5 shaft screw 300 inch lbs 25 foot lbs
Mounting plate screw, M6 55 inch lbs 4.4 foot lbs
Coil plate,1/4” screw 55 inch lbs 4.4 foot lbs

JET SIZING:

Prochem recommends floor tool tip sizing not exceed a total of “.030”. Using larger jet sizes on your
may reduce cleaning temperatures.

Example: Tri-jet wand uses three 95010 jets (95° spray angle w/ 010 orifice).
01 x 3 = 030

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

168 inch lbs 14 foot lbs

86037400 02/16/07

3-1

OPERATION

INSTALLATION REQUIREMENTS

Prior to starting the installation, first read the
ENTIRE "Installation” section of this manual. Since
the cleaning unit (with empty waste tank and
accessories) weighs approximately 770 lbs.
(860 lbs. if mounted on water tank), consider the
following recommendations before installing this
unit.

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

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

2. If mounting in a trailer, make certain that the
trailer is rated for the total weight of the UNIT
AND TRAILER. Electric or hydraulic brakes
should be provided, and a strict compliance with
any State and Federal vehicle laws must be
maintained.

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 #86050370, PRV
NO. 56-501845, or Part #86050380, PRV NO.
56-501930 for units mounted on a water tank.)

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

3-2

86037400 02/16/07

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

5W -20, 5W -30

°F -20 0 20 32 4 0 6 0 8 0 100
°C -3 0 -20 -10 0 1 0 2 0 30 4 0

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

ALTITUDE REQUIREMENTS

Engines perform differently with
increases/decreases in altitude. Be sure to check
engine speeds during initial installation. See engine
speeds in Technical Specifications section.

CHEMICAL REQUIREMENTS

The unit, due to its chemical injection pump design,
can be used with a variety of water-diluted chemical
compounds (either acidic or alkaline), depending on
the job to be done. However, to obtain optimum
results with this unit, we recommend using the
Prochem line of chemicals. For information on using
the cleaning compounds, refer to the 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.

OPERATION

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, your dealer has a
model to meet your needs. Please contact your
nearest distributor for information, price, and
availability.

86037400 02/16/07

3-3

OPERATION

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86037400 02/16/07

OPERATION

1. VACUUM GAUGE

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

2. WASTE PUMPOUT AND AUXILIARY WATER

PUMP SWITCH

This two position switch is for activating the waste
pumpout device.

3. SOLUTION PRESSURE GAUGE

This gauge registers the amount of pressure in the
system.

4. SOLUTION TEMP GAUGE

This gauge measure the temperature of the
cleaning solution exiting the machine.

5. CHOKE

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

6. SOLUTION PUMP SWITCH

This switch serves to energize the magnetic clutch,
to turn the pump on and off. Turn clockwise to
activate the pump and counter clockwise for de­activating the pump.

7. KEY SWITCH

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

8. THROTTLE

The throttle cable is used to set the speed of the
engine (rpm). The engine speed (rpm) may be
increased by releasing the collar lock, pushing in
the red button on the end of the handle, and pulling
the handle straight out. Engine speed may be
changed in smaller increments by rotating the
throttle handle clockwise or counter-clockwise. The
collar lock can be tightened to prevent the throttle
from slipping and changing the engine speed.

9. CIRCUIT BREAKERS

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

10. HOUR METER

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

11. OIL CUP

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

12. VACUUM INLET

The vacuum inlet serve as connecting point for
vacuum hoses.

13. WATER INLET

This quick connect allows the

14. WASTE PUMPOUT (OPTIONAL)

This two-position switch is for activating the
waste pumpout device. For turning on pump,
rotate clockwise. For turning off pump, rotate
counter clockwise.

15. TEMPERATURE BYPASS VALVE

This valve allow the operator to control the
solution temperature by bypassing hot water to
the waste tank, for low temperature cleaning
such as upholstery. Turning the valve counter
clockwise opens the valve. Turning clockwise
closes the valve and has the effect of stopping
water from bypassing.

86037400 05/22/08

3-5

OPERATION

16. PRESSURE CONTROL REGULATOR

The pressure regulator sets the pressure of the
solution system. This spring loaded valve can
be adjusted up or down setting the pressure of
the unit by turning the valve clockwise. The
pressure is increased or reduced by turning the
valve counter clockwise. (This valve must be

maintained in accordance with this manuals
maintenance table.)

17. SOLUTION OUTLET

The solution outlet is the connecting point for the
high pressure cleaning hoses. This outlet has a
quick disconnects that allow hoses to be
plugged into the unit.

18. FLOW METER

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

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

20. CHEMICAL METERING VALVE

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

3-6

86037400 02/16/07

OPERATION

E

PRESSURE REGULATOR

NITROGEN ACCUMULATOR

SOLUTION OUTLET

OUTLET Y-STRAINER

OUTLET CHECK VALVE

VACUUM EXHAUST

RADIATOR-TYPE

HEAT EXCHANGER

KOHLER

COMMAND

ENGINE

VACUUM

EXHAUST

TEMPERATURE CONTROL VALVE

WATER INLET

VACUUM INL

WATER BOX

145°

WASTE TANK

VERY HOT WATER FLOW
HOT WATER FLOW
WARM WATER FLOW
COLD WATER FLOW
BYPASS FLOW
ENGINE EXHAUST FLOW
VACUUM EXHAUST FLOW
VACUUM FLOW

WATER PUMP

TEMPERATURE

RELIEF VALVE

86037400 02/16/07

3-7

OPERATION

W

Always wear hearing protection and proper
personal protection equipment when operating
unit.

WATER PUMPING AND HEAT
TRANSFER SYSTEM

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

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

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

A certain amount of water is by-passed from the
pressure regulator due to over pumping capacity of
the water pump. Water that is not called for in the

= COLD WATER
= WARM WATER
= HOT WATER
= NO WATER

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

The next stage of plumbing and heat exchange
takes place in the 2nd and 3rd heater core located in
the heater box. This is the hottest point of the
gases coming from the vacuum pump and the
engine. These hot gases are forced through heater
core #2 and #3 creating the second stage of heat
transfer to the cleaning solution.

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

The cleaning solution then passes through high­pressure hoses and is distributed by the cleaning
tool to a surface that is being cleaned, completing
the water pumping and heating cycle of the cleaning
unit.

VACUUM EXHAUST

HEAT EXCHANGERS

3-8

TO PRESSURE

ATER

INLET

PRESSURE REGULATOR

GUAGE

SOLUTION

WATER BOX

OUTLET

WATER PUMP

THERMO

RELIEF

ACCUMULATOR

WASTE TANK

TEMPERATURE

CONTROL BYPASS

CHEMICAL

INJECTION

OUTLET CHECK VALVE

OUTLET Y STRAINER

86037400 02/16/07

KOHLER ENGINE

CHEMICAL INJECTION SYSTEM

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

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

NITROGEN ACCUMULATOR

CHEMICAL PUMP

OPERATION

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

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

PRESSURE REGULATOR

SOLUTION OUTLET

OUTLET Y-STRAINER

OUTLET CHECK VALVE

CHEMICAL JUG

COLD WATER FLOW
BYPASS FLOW
VACUUM FLOW

CHEMICAL INJECTION

TEMPERATURE CONTROL VALVE

WATER INLET

VACUUM INLET

WATER PUMP

WATER BOX

FLOAT VALVE

145°

TEMPERATURE

RELIEF VALVE

WASTE TANK

86037400 02/16/07

3-9

OPERATION

VACUUM SYSTEM

The engine turning an air pump generates vacuum.
The air is channeled in one side of the vacuum
pump, compressed and discharged on the opposite
side, creating airflow.

The movement of air is used to do the work
necessary for the extraction process. A vacuum
nozzle applied to the carpet surface removes
moisture, dirt and spent chemicals. These elements
are conveyed back to a separating tank utilizing
hoses and the force of air. Particles of moisture and
dirt are separated in the vacuum tank using a series
of changes in direction and velocity. The air is then
filtered and rushes into the vacuum pump.

VACUUM EXHAUST

OUTLET

FROM PRESSURE

REGULATOR

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

The engine and blower speeds are factory set to
maximize vacuum pressure and provide sustained
system life. Do not alter the engine or vacuum
speeds outside the recommended ranges shown in
the Technical Specifications section.

TO WATER BOX

FROM PRESSURE

REGULATOR

TO

SOLUTION OUTLET

VACUUM

INLET

VACUUM

SILENCER

VACUUM EXHAUST

"RADIATOR TYPE"

COPPER

HEAT EXCHANGER

VACUUM EXHAUST

"RADIATOR TYPE"

STAINLESS STEEL

HEAT EXCHANGER

VACUUM EXHAUST

"RADIATOR TYPE"

STAINLESS STEEL

HEAT EXCHANGER

VACUUM

BLOWER

VACUUM
RELIEF
VALVE

LUBRICATION

CUP

VACUUM

GAUGE

3-10

STRAINER

LEVEL SENSOR

(ENGINE SHUT-OFF SWITCH)

FILTERS

WASTE TANK

86037400 02/16/07

PRE-RUN INSPECTION

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

Operate this unit and equipment only in a well­ventilated area. Exhaust fumes contain carbon
monoxide which is an odorless and deadly
poison that can cause severe injury or fatality.
DO NOT operate this unit where the exhaust may
enter any building doorway, window, vent, or
opening of any type.

CHECK FOR ADEQUATE FUEL

Check the fuel tank to be certain there is adequate
fuel to complete the job. This unit uses
approximately .75 – 1.00 gallons of fuel per hour,
depending on the speed setting.

REMOVE TOOLS FROM VEHICLE

Remove any tools or hoses from the van which you
will require.

WATER SUPPLY CONNECTION

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

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

console. Connect the hose to the water supply
faucet.

NOTE: Never use your waste pump outlet hose
as a water inlet hose. Use only clean hoses for
water inlet.

2. Turn the water supply faucet on. The water will
fill the water box.

OPERATION

HIGH PRESSURE HOSE

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

DANGER

ROTATING
MACHINERY.
WATER UNDER
PRESSURE AT HIGH
TEMPERATURE.
IMPROPER
MODIFICATION OF
EQUIPTMENT CAN
CAUSE SEVERE

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.

PERSONAL INJURY
OR COULD BE
FATAL.

VACUUM HOSE

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

FILTERS

Ensure all filters on machine and in waste tank are
free of debris.

DANGER

DO NOT MODIFY
UNIT WITHOUT
WRITTEN
PERMISSION
FROM
MANUFACTURER

86037400 05/22/08

3-11

OPERATION

PRIMING THE CHEMICAL PUMP

1. Connect water hose to water inlet connection

and turn on water supply.

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

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

4. Pull out engine choke and turn ignition key to
start.

5. Push in engine choke after engine has started.

6. Set throttle to idle speed.

7. Turn on water pump.

8. Fill chemical container and inspect chemical

filter.

9. Turn chemical prime valve to prime and allow
chemical to circulate. After all air bubbles have
been removed from chemical tubing, turn the
valve to the horizontal (off) position and open
the chemical metering valve, triggering the
solution flow on the cleaning tool. Set the
desired chemical flow rate while observing the
flow meter indicator.

10. Set throttle to maximum position with vacuum
port blocked off for quick unit heat up.

WASTE PUMP (OPTIONAL)

1. If your unit is equipped with an automatic waste

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

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

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

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

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

Once you have completed steps 1 through 8,
proceed with the cleaning operation. Your unit
should be in the correct throttle position for your
cleaning operation or extracting. A float switch
located inside the waste tank will automatically shut
down the unit when it reaches its full capacity.
When this occurs, empty the waste tank before
continuing.

CLEANING

Observe the following guidelines, while cleaning:

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

a. To check , hold the wand about one foot above

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

b. If the nozzles are not showing a full spray

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

2. Normally chemical is applied on the push stoke
of the wand when cleaning and vacuuming is
done on the pull stroke. For heavily soiled
carpets the wand may be used in a scrubbing
manner, apply chemical in both push and pull
strokes. Always finish up an area with a vacuum
stroke.

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

4. The unit will automatically shut-down when the
waste tank is full. This will prevent water being
drawn into the vacuum pump. If shut-down
occurs, empty the waste tank before proceeding.

3-12

86037400 05/22/08

UPHOLSTERY CLEANING

Upholstery tool, part #86285260, PRV NO. 78513

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

2. Use one (1) “86229980, PRV NO. 80015” spray
tip in tool.

SHUTDOWN AND DAILY MAINTENANCE

1. Close chemical metering valve.

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

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

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

4. Turn off ignition switch.

5. Disconnect all hoses and tools.

6. Drain waste tank and rinse with clean water.

DE-FLOODING OPERATIONS

De-flooding operations involve removal of water from
carpet and flooring. This differs from normal
cleaning operations in that no water or solution is
required. An automatic waste pump-out is highly
recommended for all de-flooding operations due to
the large amount of water removal often required.

1. Start unit.

2. Set pressure regulator at 100 psi.

3. Shut off water pump.

4. Begin de-flooding operations.

5. Under almost all conditions, the unit will
sufficiently cool itself. If you find yourself
operating in extreme heat: Hook up a water
supply; turn on the water pump at 100 psi, and
crack the bypass valve slightly to provide
additional cooling.

86037400 02/16/07

OPERATION

FREEZING
PROTECTION

If the unit is exposed to freezing weather the
water in the unit may freeze, causing SERIOUS
DAMAGE to the unit. To avoid this, the following
is recommended during the cold weather
season.

When the unit is not in use, always park it in a
heated building.

While in operation, avoid long shutdowns as the unit
provides heat while running. Shut it down just prior
to leaving for the next job.

If a heated building is not available, we recommend
that you winterize the unit with 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.

OVERHEATING PROTECTION

Air cooled engines rely on the flow of air over the
engine for cooling operations. Ensure that there is
sufficient air flow in the van. Never operate the unit
with all the vehicle doors closed and no alternate
ventilation system.

3-13

OPERATION

WINTERIZING YOUR UNIT

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

2. Connect all high pressure hoses and tools

that may have water in them.

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

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

5. Turn the solution pump switch ON.

6. Open the tool valve until anti-freeze begins to

come out of the tool. Recover ALL anti-freeze
that comes out of the tools into an approved
container. We strongly recommend that you re­cycle and re-use the anti-freeze.

Repeat this procedure with all the remaining
tools. After all tools and pressure hoses have
been filled with anti-freeze, disconnect and store
them.

7. Turn the solution pump switch OFF. Attach the
winterizing loop hose with attachment,
Part #86260700, PRV NO.10-805380, to the
solution outlet connection and the water inlet
connection. Turn the solution pump switch
ON.

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

Open bypass valve and allow anti-freeze to flow
to waste tank.

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

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

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

3-14

86037400 05/22/08

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. Turn on the water pump. Allow
the anti-freeze to flow into the container until
flow stops.

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

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

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

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

86037400 05/22/08

OPERATION

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

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

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

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

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

3-15

MAINTENANCE

SERVICE SCHEDULE

Vacuum Pump

Water Pump

Solution Inlet Tube Strainer

Vacuum Inlet Filter (In Waste Tank)

Vacuum Hoses

Automatic Waste Pump

Chemical Filter

Vacuum Pump

Water Box Float Valve

Water Pump Inlet Filter

Solution Outlet Y-Strainer

High Pressure Hoses

Pressure Regulator
Pressure Regulator

Belts/Pulleys

Automatic Waste Pumpout

Float Valve Seal

Fuel Pump

Chemical Valves

Heat Bypass Valve

Engine

Battery

Engine
Engine
Engine
Battery

Engine

Engine

Daily Check engine oil level. *** Fill to proper level
Daily

Daily Check oil level.** Fill to proper level
Daily Check strainer for blockage, remove any debris
Daily Clean filter, inspect, replace if damaged
Daily Wash out with clean water
Daily Inspect and remove any debris or sediment
Daily Inspect daily

Weekly* Check oil level. Fill to proper level

Weekly Check for proper seating and shut-off
Weekly* Check for debris and clean
Weekly* Check for proper fluid level. Fill with distilled water only
Weekly* Inspect and remove any debris or blockage

25 hrs Inspect for damage or impending damage
50 hrs Lubricate o-rings

50 hrs Lubricate plug behind spring
100 hrs Change engine oil***
100 hrs Change oil filter***
100 hrs Check fan belt tightness

100 hrs* Clean battery terminals

100 hrs Check belt wear an d tension. Check pulley alignment.
100 hrs Clean inlet and outlet ports

200 hrs. Replace seal

200 hrs Service air cl eaner elements*
200 hrs Check hose connections
200 hrs Check spark plugs for carbon deposits and proper gap
200 hrs Inspect and/or adjust packing nuts
200 hrs Inspect and/or adjust packing nuts

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

4-1

86037400 02/16/07

Vacuum pump

Vacuum Exhaust Heat Exchanger

Pulley Set Screws & Hub Cap

Screws, Water Pump Clutch Shaft

Chemical Pump & Check Valves

Vacuum Lubrication Lines

Check Valve (Solution Outlet)

Vacuum Pump

Waste Tank Shut-off Float Switch

Vacuum pump

Nitrogen Accumulator

Waste Tank Filters/Strainers

Water Pump

Bolts

Drive Pulley
Drive Pulley

Drive Belts
Drive Belts

Engine

Heater Core

Engine

Engine

Engine
Engine

MAINTENANCE

SERVICE SCHEDULE

250 hrs
500 hrs

500 hrs
500 hrs

500 hrs
500 hrs
500 hrs
500 hrs
500 hrs
500 hrs Check for line obstructions. Replace tubing if cracked

500 hrs
500 hrs

1000 hrs
1000 hrs

250 hrs

Monthly

Yearly

Yearly

Yearly*

Yearly
Yearly

3 years

Lubricate bearing on pulley end with grease
Inspect cores and remove debris.
Change oil**

Check for proper torque valves. Re-torque, if
required****

Inspect, clean and check for pulley groove wear****
Check pulley alignment****
Inspect and clean****
Check belt tension****
Replace diaphragm and check valves.

or damaged
Replace in-line fuel filter on engine.
Clean and inspect.
Replace spark plugs.
Inspect, clean, and repair, if needed.
Lubricate bearing on pulley with grease
Check for debris hindering movement
Flush radiator and change engine coolant.
Drain, flush and replace oil*****
Replace Accumulator.
Check for damage and blockage. Replace if needed.
Replace air cleaner element
Replace ignition wires.

* Or as often as required
** Change water pump crankcase oil after the first 50 hours
***Change engine crankcase oil and filter after the first 50 hours
****Perform drive belt, pulley and hub maintenance after the first 25 hours of operation,
and then again at 100 hours
*****If using AEON PD synthetic lubricant, 4500 hours or every 2 years, whichever comes first

86037400 02/16/07

4-2

MAINTENANCE

KEY CHECKPOINTS

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

EXTERNAL FUEL PUMP MAINTENANCE

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

CHEMICAL SUPPLY SYSTEM
MAINTENANCE

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

4-3

86037400 02/16/07

HEAT EXCHANGER SYSTEM
MAINTENANCE

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

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

VACUUM PUMP MAINTENANCE

(Refer to manufacturer’s manual for specific
maintenance instructions)

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

DO NOT service this unit

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

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

ENGINE

(Refer to manufacturer’s manual (P/N 86269720,
PRV NO. 67-945310) for specific maintenance
instructions)

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

Make certain that proper oil level is maintained.

NEVER overfill.

2. Change the break-in oil after the first 50 hours

of operation. Thereafter, change oil every 100
hours of operation. USE ONLY KOHLER

BRAND OIL FILTERS (P/N 86186320, PRV NO.
42-902277). USING ANY OTHER TYPE OIL
FILTER WILL VOID YOUR ENGINE
WARRANTY. Torque drain plug to 10 ft lbs.

Oil Recommendation. See “ENGINE OIL
REQUIREMENTS” in Operations section.

NOTE: Using other than service class SG, SH,
SJ or higher oil or extending oil change intervals
longer than recommended can cause engine
damage.

86037400 02/16/07

MAINTENANCE

3. Check the spark plugs every 200 hours. Clean
if necessary. Replace the spark plugs every
1000 hours. NOTE: Never sandblast spark
plugs. Spark plugs should be cleaned by
scraping or wire brushing.

4. Replace the air cleaner element every year.

5. Replace the in-line gas filter every 500 hrs..

NOTE: For additional engine service
information, obtain a “Kohler Repair Manual”
from any authorized Kohler Service Center. If
service or repair is required, contact an
authorized Kohler Service Center. You will need
to provide the serial number of the engine.

4-4

MAINTENANCE

VACUUM PUMP

Refer to the Vacuum Pump Operation and Service
Manual (P/N 86036610, PRV NO. 67-945307) 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 many times longer than a premium
mineral oil.
NOTE: AEON PD (Part# 86189090, PRV NO.

05-008039) is the oil in the vacuum pump.
Topping off or adding petroleum oil to synthetic
oil is NOT recommended.

1. Check the oil level daily to assure the proper

2. To prevent rust from building up inside the

4-5

level. PROPER LEVEL cannot be
overemphasized. Too little oil will ruin bearings
and gears. Too much oil will cause overheating.
Use the illustration as a guide when adding oil.

vacuum pump (if moisture exists) we have
provided a lubrication cup on the front of the
unit.

First run the unit at least 1 minute to remove
any moisture from the vacuum pump. Next, fill
the lubrication cup with WD-40, or a similar
lubricant, for 5 seconds while the unit is running
and the vacuum inlets are sealed. Do this at the
end of each working day.

86037400 02/16/07

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. Vacuum pump lubrication is vital to performance

of our pump. Failure to follow the maintenance
schedule in the “Maintenance Schedule” can
lead to permanent damage to your blower.

Refer to the Vacuum Pump Operation and
Service Manual (P/N 86036610, PRV NO.
67-945307) for specific instructions.

5. Bearings on the drive end of the blower require
grease lubrication every 250 hours of operation.

WATER PUMP

Refer to the Water Pump Operation and Service
Manual for specific instructions (P/N 86269900, PRV
NO. 67-945621).

1. Check the crankcase oil level daily to assure the
proper level. Use the illustration as a guide
when checking the oil level. If the level has
dropped, check for the source of leakage and
repair.

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

3. Change the crankcase oil with Cat Pump
Crankcase Oil, Part #86189080, PRV NO.
05-008016, after the first 50 hours of operation.
Drain and refill the crankcase oil with Cat Pump
Crankcase Oil every 500 hours thereafter.

4. Other Cat approved oil equivalents are: Mobil
DTE 16, Amoco Rykow 68, and Shell Tellus
T68.

WATER PUMP CLUTCH

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

Component
Water pump

shaft bolt

After removing or
replacing water pump

Torque Value

Inch pounds Foot pounds

300 25

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.

86037400 02/16/07

MAINTENANCE

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.

VACUUM PUMP DRIVE BELTS

To tighten the vacuum pump belts:

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

2. Loosen the hose connecting the pump to
vacuum muffler.

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

4. Retighten all nuts and hose clamps previously
loosened at the vacuum muffler.

NOTE: When adjusting belt tension, make certain
that the engine shaft and vacuum pump shaft
remain parallel, and the belt tension is equal
throughout the belt width.

5. After adjusting, re-tighten the four nuts which
hold the vacuum pump mount in position. Check
belt alignment with straight-edge.

Make certain that when

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

6. Check for pulley groove wear, clean belts and

pulley grooves, check for worn belts, proper belt
tension, and pulley alignment after the first 25
hours and then again at 100 hours.

4-6

MAINTENANCE

WATER PUMP DRIVE BELT

To tighten the water pump belt:

1. Loosen the bolts 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.

4. Check belt and pulleys every 100 hrs.

FLOAT VALVE (WATER BOX)

1. Check the float valve weekly for proper

operation. If overfilling is a problem, check the
plunger for a proper seal. Replace tip on
plunger (PN 86192380, PRV NO. 16-808164) if
needed.

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

When replacing float
ball, DO NOT over-

tighten, as the rod can puncture the ball. Make
sure to tighten the nuts on the rod.

2. Disassemble the valve and check the piston and

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

WASTE TANK STRAINER BASKET

The strainer basket located inside the waste tank
should be removed and cleaned whenever it is full of
debris. This should be done on at the end of each
job.

WASTE TANK FLOAT VALVE

The float valve in the waste tank shuts the unit down
once the waste tank becomes full. Debris can
collect around the hinge of the float valve. Check
the float valve for debris at least once a month.

4-7

86037400 02/16/07

Y-STRAINER (OUTLET)

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

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

CHECK VALVE (OUTLET)

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

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

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

CHEMICAL PUMP

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

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

NOTE: Inspect chemical filter daily.

CHEMICAL AND 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.

NITROGEN ACCUMULATOR

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

PRESSURE REGULATOR

Lubricate the o-rings and bullet every 50 hours.
Use o-ring lubricant Part #86265430, PRV NO.
05-008035.

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

VACUUM HOSES

To assure maximum hose life, we recommend that
the hoses be washed out with clean water at the end
of each working day.

HIGH PRESSURE HOSES

Inspect your high pressure hoses for wear after
the first 100 hours of use. Inspect every 25 hours
thereafter. If hoses show any signs of damage or
impending rupture, replace the hose.

86037400 02/16/07

MAINTENANCE

DO NOT attempt to

repair high pressure
hoses! Repairing high pressure hoses may
result in severe burns and serious injury!

All high pressure hoses must be rated for 3000
PSI at 250°F. Thermoplastic hoses do not meet
these specifications and should not be used.
Severe burns and injury may result if the hoses
do not meet these requirements.

OPTIONAL WASTE PUMP-OUT

At the end of each work day, make certain that you

remove any debris or sediment which may be inside
the waste pump by pumping fresh water through the
pump.

4-8

MAINTENANCE

SERVICE GENERAL ADJUSTMENTS

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

ENGINE SPEED

This unit uses a factory installed Kohler engine
governor. The engine speed is adjusted using the
throttle control. Pushed in the engine is at idle
speed (1400 rpm). With throttle control pulled out,
engine operates at maximum rpm (2850).

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.

Re-assemble the check valve. Start the seat by

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

NOT over-tighten seat.

Tight wrap
On spring

Use 5/16 Allen
Wrench to remove

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

6. Lubricate the o-rings with o-ring lubricant
Part #86265430, PRV NO. 05-008035 and
reinstall.

WATER BOX

1. Check inlet strainer for debris and blockage. A

blocked strainer could damage the water pump if
water flow is restricted.

2. Inspect water box float valve for freedom of
movement and water leaking past valve.

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 #86265430,
PRV NO. 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.

DRIVE BELTS FOR WATER PUMP
AND VACUUM PUMP

Use only exact replacement for system drive belts.
Use only exact manufacturer and models for
replacements.

4-9

86037400 05/22/08

PACKING NUT ADJUSTMENT FOR
CHEMICAL METERING BYPASS AND
CHEMICAL SELECTOR VALVES

Examine the packing nut on the metering and
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 stem
and add to overall valve life.

Remove knob
by loosening set
screw to access
packing nut.

CHEMICAL
SELECTOR
VALVE

PACKING NUT

open end wrench to adjust)

CHEMICAL
METERING &
HEAT BYPASS
VALVE

(use 5/16"

MAINTENANCE

We recommend that you lubricate the pressure
regulator o-ring every 50 hours, or whenever
required. If you do not, the stem may become
seized due to inadequate lubrication. If this occurs:

a) Shutdown the unit.
b) Relieve all pressure from the water system.
c) Remove the cap from the pressure regulator and

remove the stem with long nose pliers.
d) Clean and lubricate stem.
e) Reassemble pressure regulator.

PACKING NUT

PRESSURE REGULATOR

The pressure regulator serves to maintain water
pressure at a preset point and to bypass this water
back to the water box.

To adjust:

1. With your unit running, close the cleaning tool.
Check the pressure gauge. Open the tool valve.
We recommend setting the pressure regulator
so that the pressure gauge reads 450 PSI with
the tool valve open.

When the tool valve is opened, there is an
approximate drop of 50 PSI in pressure. If there

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

2. If the pressure regulator requires adjustment,

loosen the locking nut, then turn the adjusting
body (cap) (while observing the pressure gauge
on the control panel) until the desired pressure
is obtained. Retighten the locking nut.

DO NOT loosen the adjusting body (cap) all the
way (counterclockwise) or remove it while the
unit is running.

86037400 02/16/07

PART #86265430
PRV NO. 05-008035

4-10

MAINTENANCE

PROBLEM CAUSE SOLUTION

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 2850 RPM. Idle
engine speed is 1400 RPM. Refer to the
“engine speed” section for instructions on
how to re-adjust.
Lubricate o-rings, using o-ring lubricant Part
#86265430, PRV NO. 05-008035.

Clean or repair regulator. Adjust to working
pressure. Lubricate o-rings, using o-ring
lubricant Part #86265430, PRV NO.
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.

Clean or replace as needed.

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

which is blocking proper flow. Replace any
defective hoses. Remove, inspect, and clean
the Y-strainer screen. De-scale unit and
install a water softener, if necessary.

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

Check for air leaks. Replace faulty parts.

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

the water pressure gauge
reads below the normal
operating pressure.

Loss of solution volume at
cleaning tool orifice.

Water gauge reads normal.

4-11

Water supply is turned off or the float
valve is stuck or improperly adjusted.

Water pump inlet supply line is plugged
or drawing air.

Improper engine speed

Pressure regulator o-rings are dry.
Pressure regulator has worn o-rings Check o-rings. If necessary, replace.

Pressure regulator is dirty, stuck open,
or improperly adjusted.

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

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

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

inlet disconnect.

Belts loose or broken Re-tension or replace as needed.
Loss of pump prime Manually prime water pump.

Plugged orifice and/or screen in the
cleaning tool.

Internal block between the pressure
regulator manifold and the outlet Y­strainer, or the Y-strainer screen is
clogged

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

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

Hose inner lining is constricted. Remove restriction or replace hose.
Air leak in chemical supply line, priming

valve or metering valve.

86037400 02/16/07

PROBLEM CAUSE SOLUTION

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

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

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

basket.

Drain the waste tank. Close drain valve, if
open. Remove the dump valve and, after
inspecting, replace the defective
components.
Re-adjust the vacuum relief valve. If the
vacuum does not increase, remove and
inspect the relief valve diaphragm. If
damaged, replace

Remove and clean.

Adjust throttle to set desired vacuum
perssure.

Readjust the vacuum relief valve.
Refer to chemical pump priming

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

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

Replace valve(s).
Disassemble the chemical pump and

replace the damaged diaphragm.
Measure the pump volume. If the pump
volume is less than normal, refer to “Loss
of Pump Volume” in the Troubleshooting
section in this manual.

Loss of vacuum
While cleaning, the vacuum is

not up to specification. Engine
RPM is normal.

Excessive Vacuum

Loss of chemical
With the cleaning tool valve

open, no chemical

Vacuum gauge is giving an improper
reading.

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

Loose vacuum pump drive belts. Tighten the drive belts

Waste tank drain valve is damaged
or left open, causing a vacuum leak.

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

Vacuum exhaust heat exchangers
are plugged with lint.

Vacuum pump is worn out. Replace the vacuum pump.
Improper throttle adjustment.
Vacuum obstruction Inspect hoses for obstructions.

Vacuum relief valve requires
adjustment.

Chemical pump is improperly
primed.
The strainer at the inlet end of the
chemical inlet line is clogged
Suction leak in the inlet line leading
into the chemical pump.

Chemical pump check valve(s) is
clogged

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

Defective cylinder in the water pump.

MAINTENANCE

86037400 02/16/07

4-12

MAINTENANCE

PROBLEM CAUSE SOLUTION

Tighten fittings. Re-apply thread sealant

Chemical flow meter indicates
flow with the tool valve closed

Water pump does not engage

Engine will not start
The engine does not turn over

Starter turns over engine, but
will not start

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.

Solution pump circuit breaker has
been tripped

Defective electrical connection in
the console wiring or defective
switch.

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

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

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

panel has been tripped.
Loose or corroded battery.

Dead battery. Recharge or replace battery.

Defective ignition switch.

Defective starter motor. Test the starter motor. If necessary replace.
Vacuum pump seized.
Waste tank is full. Empty the waste tank.

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), fuel shut-off solenoid
(located on engine).

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.

Check the solution pump circuit breaker on
the control panel. Press the ciruit breaker
reset button.
Examine switch, electrical connections, and
wiring. Repair any defective connections. If
there is power going to the switch but not
going out, replace the defective switch.

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

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

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

Refer to Gardner Denver Service & Repair
Manual.

Repair or replace any broken electrical
connections.
Check switch for proper operation, replace
as necessary.
Test these components. If any are
defective, replace. Consult the Kohler
Engine Operation and Maintenance Manual.

4-13

86037400 05/22/08

PROBLEM CAUSE SOLUTION

Starter turns over engine, but
will not start

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

Excessive heating

Heat exchanger leaks
NOTE: The heat exchanger will

produce water condensation
discharge at times during
normal operation. DO NOT
confuse this with a leak.

Loss of temperature
The heat output of the unit is

LESS than normal.

Automatic waste pump is
malfunctioning or not operating
normally

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

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

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

the control panel has been tripped.
Defective fuel pump. Replace fuel pump.

Defective float switch inside the
waste tank.

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

No ignition in the engine or engine
is malfunctioning.

Flow restriction caused by hard
water scaling.

Not enough water flow. Check jet size of tool.

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

Temperature relief valve on water
box is stuck open.

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

Broken diaphragm. Replace diaphragm.
Weak battery.

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

Refer to Kohler Engine Operation and
Maintenance Manual.

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

Check switch for proper operaton. Replace
as necessary.

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

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

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

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

Test gauge and sensor. Replace failed
component.

Charge or replace battery if needed.

Check charging station.

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

MAINTENANCE

86037400 06/30/09

4-14

FRAME

19

16

17

18

1

2

8

3

4

3

8

14

4

6

7

20

11

21

5

8

3

15

5-1

12

86037400 02/16/07

13

9

8

3

4

10

3

8

4

REF PART NO. PRV NO. QTY DESCRIPTION

1 86191570 01-000259 14 RECPT, SNAPIN 1/4 TURNFAST
2 86046090 790724 1 BRKT, HOOD
3 86010780 87162 12 WASHER, 1/4 SPLIT LOCK PLTD
4 86274750 70270 11 SCR, 1/4-20 X 3/4 HHCS PLTD
5 86054520 61458 1 PNL, LWR FRNT
6 86177040 03-000149 3 CLAMP, CABLE 1-1/4 ID 5/16 BLT
7 86176170 64-950383 1 CABL, RETAIN VAC PLG 800
8 86270330 02-000066 6 FLATWASHER, 1/4

9 86179620 790487 1 DIPSTICK, CAT PUMP OIL 5CP
10 86047930 790726 1 GUARD, PUMP
11 86279400 87151 4 WASHER, 1/4 SPLIT LOCK BLK
12 86045290 56-501857 1 BRKT, FUEL LINE
13 86273180 00-000078 1 SCR, 1/4-20 X 1” HXHD GRD8
14 86043810 790675 1 ASSY, FRAME XL
15 86275460 70481 4 SCR, 1/4-20 X 3/4 BHCS BLK
16 86193220 02-000268 14 SPLITRING, RETAIN, 1/4 TURN
17 86189660 58-700023 14 PAD, 1/4 TURN FAST, .188 THK

18 86193550 00-000272 14 STUD, 1/4 TURN FAST
19 86029750 61461 1 PNL, HOOD ASM LGND X L
20 86186630 500836 1 LABEL, LWR FRONT PNL
21 86279520 87172 4 WASHR, 1/4 ID FLAT BLK

SERIAL NO.

FROM

FRAME

NOTES:

86037400 02/16/07

5-2

SIDE PANEL

1

2

11

10

9

6

7

5

4

8

3

5-3

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

1 86046080 790702 1 BRKT, WATER & VAC INLET XL

2 86180370 12-800099 1 ELL, 1/8P X 1/4 POLY BR

3 86274750 70270 2 SCR, 1/4-20 X 3/4 HHCS PLTD

4 86270330 02-000066 2 FLATWASHER, 1/4

5 86181360 12-800269 1 FTTG, BRB 1/2P X 5/8 H BR

6 86188210 11-800354 1 NIP, 1/2 X 3/8 HEX BR

7 86179710 13-806008 1 DCS, 3/8F X 3/8FP

8 86010780 87162 2 WASHER, 1/4 SPLIT LOCK PLTD

9 86180700 32064 1 END CAP, VAC INLET, 1 1/2
10 86178700 19-800075 1 CUP, OIL FILL 1/8P
11 86186820 790599 1 LABEL, WTR & VAC INLET BRKT

SIDE PANEL

SERIAL NO.

FROM NOTES:

1000158501

86037400 02/16/07

5-4

CONTROL PANEL-UPPER

31

2

1

3

2

5

7

34

6

10

9

7

24

23

21

22

27

26

25

29

4

13

11

37

35

12

38

32

8

14

16

17

28

30

5-5

18

20

33

19

86037400 01/12/08

REF PART NO. PRV NO. QTY DESCRIPTION

1 86195050 15-808106 1 VALVE, METER 1/8FP

2 86177660 12-800065 2 CONN, 1/8P X 1/4T

3 86247720 56032 1 NIPPLE, 1/8 CLOSE

4 86017360 140675 1 BRKT, FLOW METER

5 86297070 - 1 VALVE, 3-WAY BALL 1/8P

6 86180140 11-800014 1 ELL, STREET 1/8 BR

7 86181300 12-800093 3 FTTG, BRB 1/8P X 5/16H

8 86255920 73811 2 STANDOFF, 3-32 X 1/2 HEX NYL

9 86274290 70162 4 SCR, 10-32 X 3/8 PPHMS SS
10 86279470 87165 4 WASHER, #10 SPLIT LOCK PLTD
11 86180380 12-800101 1 ELL, 1/4FP X 1/4T BR
12 86180350 12-800035 1 ELL, 1/4FP X 1/4T BR
13 86049750 61457 1 PNL, FRNT, LGND XL, PC
14 86246890 54092 1 METER, 0-60VDC HOUR
15 86270330 02-000066 4 FLATWASHER, 1/4
16 86010780 87162 4 WASHER, 1/4 SPLIT LOCK PLTD
17 86274750 70270 4 SCR, 1/4-20 X 3/4 HHCS PLTD

18 86181960 36229 1 GAUGE, TEMP, DATCON
19 86175510 33-900163 2 BREAKER, CIRC 20A
20 86186020 32-900174 1 KEYSWITCH
21 86193760 32-900206 1 SW, RTRY W/BYPASS NON-ILL
22 86193750 32-900205 1 SW, RTRY NON-ILLUM TM
23 86181930 36225 1 GAUGE, 0-1500 PSI
24 86181950 36227 1 GAUGE, VACUUM 30” HG
25 86186640 500835 1 LABEL, CONTROL PNL LEGEND XL
26 86186620 500834 1 LABEL, CHEM PNL XL
27 86181170 18-808513 1 FLOWMETER, 1/8FP
28 86176120 49-802518 1 CABLE, CHOKE
29 86177540 791081 1 CNTRL, THRTL, BLZRXL, CLR/CLNR
30 86024760 790742 2 PAD, PNL
31 86186640 500837 1 LABEL, FRNT HD, LXL, PC
32 86191740 35-900188 1 RELAY, ENG SHTDWN
33 86175490 33-900161 1 BREAKER, CIRC 30A
34 86270920 57049 4 NUT, 6-32 HEX NYLOCK SS
35 86175680 140702 1 BRKT, WIKA MOUNTING
36 86183000 790716 1 HARN, LEGEND XL
37 86136310 57086 4 NUT, M5 HEX
38 86005720 57106 1 NUT, 8-32 W/STAR WASHER

CONTROL PANEL-UPPER

SERIAL NO.

FROM NOTES:

1000163020

NOT SHOWN

86037400 01/12/08

5-6

ENGINE

19

23

21

24

22

25

20

20

37

17

6

26

33

34

5

4

1

3

2

27

36

7

9

8

28

11

12

10

16

3

13

14

34

35

5-7

19

18

15

86037400 04/28/08

REF PART NO. PRV NO. QTY DESCRIPTION

1 86186430 42-902299 1 KOH ELEM, AIR CLNR #470830

2 86179670 790677 1 DRIVESHAFT, FRONT KOHLER 20HP

3 86049230 54-500412 1 KEY. 1/4 SQ X 1.88

4 86191280 790719 1 PULLEY, 1B36SH

5 86185400 790720 1 HUB, SH1

6 86273180 00-000078 3 SCR, 1/4-20 X 1” HXHD GRD8

7 86275830 70549 4 SCR, M8 X 25 HHCS GR8 PLTD

8 86137310 87098 4 WASHER, M8 SPLIT LOCK

9 86186360 42-902289 1 KOH SPK PLG#1213202
10 86186400 42-902296 1 KOH FLTR, FUEL #2505003
11 86176990 03-000065 4 CLAMP, HOSE #4 SST
12 86280150 09-805447 1 HOSE, FUEL 1/4 X 9
13 86179930 790606 1 EL, 90DEG 1/8NPT X 1/4HB
14 86190550 12-800062 1 PLUG, 1/2T
15 86183600 10-805291 1 HOSE, HP 3/8 X 10 (3/8 X 1/2FT)
16 86186320 42-902277 1 KOH FLTR, OIL #1205001
17 86191030 44-802212 1 PULLEY, 2TA54

18 86185310 44-802182 1 HUB, P2X1-1/8
19 86273440 00-000340 3 SCR, MACH 5/16-18 X 1” BG8
20 86182730 790626 3 GSKT, EXHST, KHLR 25HP
21 86279130 87083 2 WASHER, 5/16 SPLIT LOCK PLTD
22 86005650 57031 2 NUT, 5/16-1 8 HEX
23 86136280 57054 4 NUT, M8
24 86137310 87098 4 WASHER, M8 LOCK
25 86187230 790710 1 MNFLD, ENG EXH, KHLR, XL
26 86186380 42-902293 1 KOH CARB # 2485335S
27 86186410 42-902297 1 KOH PMP, FUEL PULSE #24393165
28 86180760 40-902152 1 ENG, KOHLER 20 HP
29
30
31
32
33 86005770 57119 4 NUT, 3/8-16 HEX NYLO CK
34 86279510 87171 8 WASHER, 3/8 FLAT
35 86277830 00-000072 4 SCR, 3/8-16 X 2” HXHD
36 86277930 70119 1 SET SCREW, 1/4-20 X 3/8 KCP
37 86254140 791176 1 SOLENOID, KOH# 25-435-05-S

- 86177130 791083 1 CLAMP, CABLE, THRT/CHOKE

- 86277890 70856 1

OPEN
OPEN
OPEN
OPEN

SCREW, M5-8 X 25MM STL, ZNC
(CLAMP SCREW)

ENGINE

SERIAL NO.

FROM NOTES:

86037400 05/22/08

5-8

VACUUM PUMP

21

17

18

19

9

16

15

14

13

20

12

1

2

3

4

5

6

7

8

5-9

11

86037400 08/20/08

9

SUPPLIED
WITH PUMP

10

VACUUM PUMP

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86177010 03-000112 2 CLAMP, HOSE #8

2 86184490 09-805478 1 HOSE, VAC 2.88 X 2.5 BLK

3 86188500 54-501593 1 NIP, VAC EXH OUTLET

4 86175030 44-802250 2 BELT, AX38 GOODYEAR MATCH

5 86191030 44-802212 1 PULLEY, 2TA54

6 86185320 44-802196 1 PULL, AKG1H

7 86273440 00-000340 3 SCR, MACH 5/16-18 X 1” GR8

8 86005770 57119 4 NUT, 3/8-18 HEX NYLOCK

9 86279510 87171 5 WASHER, 3/8 FLAT
10 86270320 02-000057 2 FLATWASHER, 1/2” HEAVY
11 86273400 00-000323 2 SCR, 1/2-13 X 3 1/2 HHCS FULL THDS
12 86046120 790874 1 BRKT, VAC ADJ ASM XL
13 86190700 41-905021 1 PMP, VAC 4M-L
14 86271070 57114 2 NUT, 7/16-24 HEX
15 86193230 04-000091 1 SPRING, VAC REL VLV
16 86180600 52-501573 1 ELL, VAC REL VLV
17 86311600 - 1 WASHER, VAC REL VLV #4 VAC

18 86179580 43-807074 1 DIAPHRAM, VAC REL VLV
19 86177640 12-800059 2 CONN, 1/8P X 1/4 POLY BR
20 86271740 57249 2 NUT, 1/2-13 JAM
21 86273320 00-000284 1 SCR, CAP 7/16-14 X 4 HXHD

FROM NOTES:

1000124348

WAS 44-802314

86037400 08/20/08

5-10

WATER PUMP & CHEMICAL PUMP

26

25

1

3

TO WATER BOX

TO FLOWMETER

19

18

42

28

29

34

33

30

41

24

35

21

17

22

16

39

38

40

12

11

37

10

38

4

13

SUPPLED

WITH CLUTCH

36

37
38

13

14

9

6

7

31

5

2

20

23

5-11

33

34

32

86037400 08/21/07

WATER PUMP & CHEMICAL PUMP

REF PART NO. PRV NO. QTY DESCRIPTION

1 86190540 12-800029 1 PLUG, 1/4T BR

2 86273710 140645 4 SCR, 1/4-20 X 3/8, SER FLNG

3 86180340 12-800031 1 ELL, 1/4P X 1/4T BR

4 86190670 41-809153 1 PMP, WTR CAT 3CP1140

5 86175110 44-802315 1 BELT, AX40

6 86282770 51372 1 LOOM, 1/4, HIGH TEMP 10”

7 86265780 31-900185 1 CONN, BULLET M (.156)

8 86177510 790613 1 CLUTCH, ELE, WTR PMP CAT 3CP

9 86249610 790610 1 BRKT, CLUTCH, WTR PMP, 3CP CAT
10 86278830 02-000143 2 WASHER, 5/16 FLAT PLTD
11 86276130 70601 2 SCR, 5/16-18 X 2.75 HHCS GR5
12 86043770 790544 1 ASSY, PMP ADJ BRKT
13 86241860 48099 1 KEY, .20X.20X1.45, 3CP CAT
14 86005750 57113 2 NUT, 5/16-18 HEX NYLO CK
15 86190520 11-800224 1 PLUG, 3/8 SOCHD BR
16 86191780 52-809123 1 RETAIN, VALVE SPRING
17 86180360 12-800040 1 ELL, 1/8P X 1/4T BR

18 86179920 790605 1 EL, 90DEG 1/8 X 5/16HB
19 86176990 03-000065 1 CLAMP, HOSE #4 SST
20 86279820 87240 1 WSHR, .328 ID X 1.00 OD X .119 ZNC
21 86191440 791173 1 PUMP, CHEM, PULSE, GP
22 86173750 52-809125 1 ADPT, CAT CHEM PMP
23 86273700 140644 1 SCR, 5/16-18 X 1, SOC, ZNC
24 86177020 03-000113 1 CLAMP, HOSE #12 SST
25 86181370 12-800278 1 FTTG, BRB 1/2P X 3/4H BR
26 86180230 11-800299 1 ELL, STREET 1/2 45 DEG
27 86180410 12-800225 1 ELL, 3/8P X 1/2T BR
28 86194630 65250 1 PULSE PUMP, TOP COVER INLET
29 86179550 42-809047 1 DIAPHRAGM, CHEM PUMP
30 86249220 65252 1 PLASTIC DISC
31 86173440 43-810105 1 O-RING, 1-58 ID X 1-3/4 OD VITON
32 86195100 65245 1 VALVE CAP, 303 SST, INPUT
33 86195110 65247 2 VALVE KIT, ASM, CHEM, PULSE PUMP
34 86189290 65249 2 O-RING, DURO,. 862ID X .103CS
35 86191340 65253 1 PULSE PUMP, BODY
36 86006740 70266 3 SCR, 3/8-16 X 1” HHCS GR 5 PLTD
37 86010790 87163 4 WASHER, 3/8 SPLIT LOCK PLTD

38 86279510 87171 3 WASHER, 3/8 FLAT
39 86177320 03-000249 1 CLMP, CABL 1/4ID 3/8BLT
40 86273420 00-000336 1 SCR, CAP 3/8-16 X 3 ALL THD
41 86192920 65246 1 SPACER RING, 303 SST

42 86195120 65248 1 VALVE CAP, 303 SST, OUTPUT

SERIAL NO.

FROM NOTES:

1000151479

1000151479

1000151479
1000151479
1000151479
1000151479
1000151479
1000151479

1000151479
1000151479

WAS 41-809158

WAS 52-502053

WAS 42-809264

WAS 16-808237
WAS 42-809265
WAS 43-810079
WAS 52-502052

WAS 16-808237

86037400 08/21/07

5-12

WATER PUMP

7

1

4

3

2

5

12

11

13

10

15

18

16

14

6

7

18

5-13

8

9

17

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

86176520

1

86189200

2

86181800

3

86181970

4

86024770

5

86024780

6

86189210

7

86024790

8

86190560

9

86024800

10

86024810

11

86024820

12

86190600

13

86195580

14

86024830

15

86192260

16
17 86286260

18 86186090

42-809238
42-809239
43-807063
42-902380
42-809401
42-809402
42-809394
42-809403
42-809404
42-809406
42-809405
42-809407
42-809408
42-809249
42-809381
42-809409

66-950441

42-809410

CAP, OIL FILLER

1

O-RING, OIL FILL CAP

1

GASKET, OIL GAUGE

1

GAUGE, OIL LEVEL

1

COVER, CRANKCASE

1

O-RING, CRANK CVR

1

O-RING, BEARING CVR

1

MANIFOLD, HEAD

1

PLUG, VALVE

3

BOLT, MNFLD HD M8 X 65

8

RETAINER, SEAL

3

RETAINER, PNLGR W/STUD

3

PLUNGER

3

WASHER, KEYHOLE M18

3

SLINGER, BARRIER

3

SEAL, OIL CRANKCASE

3

KIT, VLV

3

KIT, SEAL

3

WATER PUMP

SERIAL

NO. FROM NOTES:

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

86037400 02/16/07

5-14

HEAT EXCHANGER

3

13

29

4
5

28

24

2

1

31

7

11

SST CORE

12

14

19

8

9

10

4

27

2

26

26

25

11

SST CORE

12

14

19

14

6

5

15

22

COPPER CORE

14

20

30

19

15

5-15

23

18

17

16

15

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

1 86056820

2 86278830

3 86192110

4 86274750

5 86010780

6 86270330

7 86029430

8 86181810

9 86175920
10 86192490
11 86043150
12 86047250
13 86059020 790708 1
14 86177700
15 86180220
16 86181400
17 86182190

18 86190520
19 86187210 790038 3

20 86047260 790680 1
21 OPEN - - ­22 86030280 790801 1
23 86189730 790423 6
24 86181850 790050 3
25 86005650 57031 3
26 86279130 87083 6
27 86273440 00-000340 3
28 86049190 790671 1
29 86177000 03-000086 1
30 86181330 12-800161 1
31 86010740 87090 6

790714

02-000143

790721

70270
87162

02-000066

790707
43-807080
11-800118
34-903019

790388

790668

12-800282
11-800276
12-800345

36238

11-800224

3

SPACER, ENG SUPPORT

9

WASHER, 5/16 FLAT PLTD

3

SCR, 5/16-18 X 4.0 HHMS PLATED

26

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

24

WASHER, 1/4 SPLIT LOCK PLTD

18

FLATWASHER, 1/4

1

MUFFLER, VAC W/EXH TUBE

1

GASKET, VAC HE INLET

1

BUSH, 3/8 X 1/8 BR

1

SENDER, TEMP 140-320 DEG

2

ASSEMBLY, HEATER CORE SS

1

COVER, SST CORE VAC HE

TUBE, SILENCER/EXH MNFLD

2

CONN, 3/8P X 1/2T BR

3

ELL, 3/8 BR

1

FTTG, BRB 3/8P X 5/8H BR

6

GRONR, 1/2ID X 1-1/4OD 1/8G 5/16W

6

PLUG, 3/8 SOCHD BR

MANIFOLD, HEATER CORE
COVER, COPPER CORE VAC HE

ASSY, HEATER CORE COPPER
PAD, REAR VAC HTR CORE
GASKET, VAC HE CVR
NUT, 5/16-18 HEX
WASHER, 5/16 SPLIT LOCK PLTD
SCR, MACH 5/16-18 X 1” GR8
HSG, VAC HE
CLAMP, MFLR 1-1/4
FTTG, BRB 3/8P X 1/2H BR
WASHER, 1/4 ID X 3/4 OD PLTD

HEAT EXCHANGER

SERIAL NO.

FROM NOTES:

INCLUDES 17 & 20

86037400 02/16/07

5-16

PRESSURE REGULATOR & TEMPERATURE BYPASS

10

11

12

12

20

19

9

13

6

29

22

23

7

24

25

26

8

9

5

CHECK VALVE DETAIL

27

28

1

16

15

2

3

3

4

BODY

18

OUTER

INNER

SEAT

STEM

PRESSURE REGULATOR DETAIL

SEAT

SPRINGS

21

CAP

5-17

86037400 05/22/08

PRESSURE REGULATOR & TEMPERATURE BYPASS

REF PART NO. PRV NO. QTY DESCRIPTION

1 86173460
2 86187250
3 86188110
4 86191630
5 86180040
6 86188390
7 86192210
8 86195030

9 86180360
10 86180410
11 86174010
12 86177660
13 86180450
14 86177680
15 86279400
16 86275460
17 86278970

18 86002450
19 86195050
20 86278970
21 86186040

790106

790713
11-800128
15-808081

790722
11-800429
14-806549
15-808094
12-800040
12-800225
15-808131
12-800065
12-800347
12-800141

87151
70481 2 SCR, 1/4-20 X 3/4 BHCS BLK
87012

22015

15-808106

87012

16-808193

1

ACCUMULATOR , 250PSI CAT 6026

1

MANIFOLD, PRESSURE REG

2

NIP, HEX 1/4 SST

1

REG, PRE W/O INNER SPRING

1

ELBOW, 1/4MP X 1/2H 90DEG

1

NIP, HEX 3/8 SST

1

SCREEN, CHECK VALVE

1

VALVE, CHECK

2

ELL, /18P X 1/4T BR

1

ELL, 3/8P X 1/2T BR

1

MNFLD, CHK VLV

2

CONN, 1/8P X 1/4T

1

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

1

CONN, 1/2P X 1/2T

2

WASHER, 1/4 SPLIT LOCK BLK

1

WASHER, 7/16 STAR

1

COUPLER, 1/4 QD

1

VALVE, METER 1/8FP

1

WASHER, 7/16 STAR

1

KIT, REPAIR PRESSURE REG

SERIAL NO.

FROM NOTES:

INCLUDES 7&8

86037400 02/16/07

5-18

WATER BOX

22

19

21

29

19

12

30

18

20

28

23

17

24

27

26

16

25

1

2

3

4

13

5

6

7

5-19

15

8

14

10

3

9

12

11

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273410
2 86010780
3 86270330
4 86048360
5 86187820
6 86174540
7 86177660
8 86195340

9 86058750
10 86274750
11 86181370
12 86180570
13 86181150
14 86188180
15 86193440
16 86272720
17 86270770

18 86177060
19 86181360
20 86270990
21 86177020
22 86180250
23 86195060
24 86046550
25 86189010
26 86174610
27 86277850
28 86173820
29 86189870
30 86192380

00-000335

87162
02-000066
50-501763
58-500781
19-807014
12-800065
15-808075

790696

70270
12-800278

31098
54-501715
11-800300
14-806540
11-800345 1 PLUG, 1/4 SOCHD BRASS

57006
03-000246

12-800269

57090
03-000113
11-800361
15-808110
11-800432
52-501706
16-808217
00-000337
16-808216
16-808219
16-808164

4

SCR, 1/4-20 X 8 HXHD

4

WASHER, 1/4 SPLIT LOCK PLTD

4

FLATWASHER, 1/4

1

HOLD DOWN WTR BOX

1

MOLDING, WATER BOX

1

BALL, FLOAT

1

CONN, 1/8P X 1/4T

1

VLV, TEMP REL 145DEG

1

TRAY, WTR BX

4

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

1

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

2

ELL, STREET 1/2 BR FORGED

1

FLOAT ROD

2

NIP, 1/2 X CL

2

STRAINER, SUC END 1/2FP

2

NUT, 1/4-20 HEX

2

CLAMP, HOSE #8 SST

2

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

1

NUT, 10-32 HEX NYLOCK SS

2

CLMP, HOSE #12 SST

1

ELL, 1/2 BR

1

VALVE, FLOAT

1

CAP, WATER BOX

1

NUT, FLOAT VALVE

1

BODY, FLOAT VLV

1

SCR, 10-32 X 1” SOCHD SST

1

ARM, PIVOT-FH VLV

1

PISTON, FH VLV

1

SEAT, FLOAT VLV

WATER BOX

SERIAL NO.

FROM NOTES:

86037400 05/22/08

5-20

WASTE TANK

1

13

2

4

3

5

6

5-21

14

12

13

7
8

9

8
10

12

11

86037400 02/16/07

WASTE TANK

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86049690 790652 1 LID, 60G WST TNK
2 86043190 56-501793 1 ASSY, BSKT. STRNR WST TNK
3 86182710 790620 1 GSKT, WASTE TANK
4 86193430 14-806518 1 STRAINER, WST TANK 2-1/2”
5 86058600 790733 1 TNK, WST 60G, XL
6 86180340 12-800031 2 ELL, 1/4P X 1/4T BR
7 86277830 00-000072 9 SCR, 3/8-16 X 2” HXHD
8 86279510 87171 18 WASHER, 3/8 FLAT

9 86249550 62986 6 PLATE, TRUCKMOUNT SHIPPING
10 86005770 57119 9 NUT, 3/8-16 HEX NYLO CK
11 86193870 791066 1 SWITCH, FLOAT, N.C. HARWIL
12 86190530 11-800402 3 PLUG, 1-1/4 HXHD PVC
13 86186860 46-802510 2 LATCH, DRAW 2-7/8 SST
14 86273020 67006 8 RIVET, 3/16 OD X 5/8 AL

- 86048960 09-805332 1 HOSE, INT VAC 2.0 X 120.0 BLK

- 86195180 84196 1 VALVE, BALL 1.5 FNPT

- 86264850 05-008002 1 ADH, GSKT (ADHESIVE) NOT SHOWN

FROM NOTES:

NOT SHOWN
NOT SHOWN

86037400 05/16/08

5-22

HOSE ACCESSORIES

1

2

3

2

12

13

15

11

14

10

17

21

4

5

7

6

9

8

18

19

5-23

16

20

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

1 86180980

2 86178640

3 86184510

4 86247680

5 86002450

6 86005580

7 86184530

8 86184520

9 86182800
10 86194990
11 86189240
12 86189250
13 86188210
14 86184570
15 86179630
16 86184620
17 86002450

18 86184520
19 86182800
20 86005580
21 86184540

12-800078
08-805147
10-805060

56015
22015

56012
10-805108
10-805077
08-805155
15-808012
43-810014
43-810019
11-800354
10-805157
13-806009
10-805295

22015
10-805077

08-805155

56012
10-805122

1 FITTING, BRB 2H BS PVC
2 CUFF, 2”
1 HOSE, VAC 2”X50’ W/ CUFFS & HOSE
1 NIPPLE, 1/4 HEX
1 COUPLER, 1/4 QD
1 NIPPLE, 1/4 FPT QD
1 HOSE, HP 1/4 X 50FT W/QD & VLVE
1 HOSE, HP 1/4 X 50’
2 GUARD, HOSE VINYL
1 VALVE, BALL 1/4FP
2 O-RING, 7/32ID X 11/32OD
2 O-RING, 3/8 ID X 1/2 OD
1 NIP, 1/2 X 3/8 HEX BR
1 HOSE, WATER 1/2 X 50’
1 DISCONNECT 3/8M X 3/8FP
1 HOSE, WATER 1/2 X 50’
1 COUPLER, 1/4 QD

1 HOSE, HP 1/4 X 50’
2 GUARD, HOSE VINYL
1 NIPPLE, 1/4 FPT QD
1 HOSE, HP 1/4 X 50FT W/QD

HOSE ACCESSORIES

SERIAL NO.

FROM NOTES:

86037400 02/16/07

5-24

BATTERY-FLOOR MOUNT

2

1

10

3

4

5

9

6

7

8

5-25

86037400 05/03/08

REF PART NO. PRV NO. QTY DESCRIPTION

1

86273780 70015 2 SCR, 1/4-20 X 3/4 HHCS SS NP

2

86005680 57047 2 NUT, 1/4-20 HEX NYLOCK

3

86174580 36-900056 1 BATTERY

4

86012060 - 1 BOX, BATTERY, MODIFIED

5

86273190 00-000132 4 SCR, 1/4-20 X 1-1/2 HXHD

6

86270330 02-000066 8 FLATWASHER, 1/4

7

86010780 87162 8 WASHER, 1/4 SPLIT LOCK PLTD

8

86270770 57006 8 NUT, 1/4-20 HEX

9

86309890 - 1 BRKT, BATTERY BOX MTG

10

86011470 - 4 BOLT, ELEVATOR, 1/4-20 X 1

BATTERY-FLOOR MOUNT

SERIAL NO.

FROM

NOTES:

86037400 05/03/08

5-26

AUTOMATIC PUMPOUT-OPTIONAL

11

16

17

19

6

10

7

18

13

10

1

4

3

5

5

7

2

5

6

14

5
4

3

5-27

8

9,12,15

86037400 02/16/07

AUTOMATIC PUMPOUT-OPTIONAL

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86274150
2 86273190
3 86270770
4 86010780
5 86270330
6 86177050
7 86280680
8 86184780

9 86176420
10 86181430
11 86181440
12 86195820
13 86175720
14 86188970
15 86162270
16 86191380
17 86174260

18 86195860 23719 1 CORD ASM, CNCTN SIDE
19 86195910

70105

00-000132

57006

87162
02-000066
03-000176
09-805591
10-805484
12-800052
12-800367
12-800444
43-807008
50-502055
52-000123
52-501993
61-951306
61-951319

72185

4 SCR, M4 X 60 PH
2 SCR, 1/4-20 X 1/ 1/2 HXHD
4 NUT, 1/4-20 HEX
4 WASHER, 1/4 SPLIT LOCK PLTD
4 FLATWASHER, 1/4
4 CLAMP, HOSE #16
1 HOSE, WASTE PUMP 1” X 8’
1 HOSE, GARDEN 3/4 X 75’
1 CAP, HOSE 3/4 BR
1 FTTG, BRB 1PX1H BR
1 FTTG, 1-1/4P X 1” H BR
1 WASHER, HOSE 5/8 ID 1” OD
1 BRKT, CTR HOOD FR
1 NUT, 1-3/16-12 UN HXHD
1 CONN, HOSE WATER OUTL
1 PUMP, HD AUTO
1 ASSY, LVL SENS SHUT OFF SW

1 SWITCH ASSEMBLY

FROM NOTES:

86037400 02/16/07

5-28

AUTOMATIC PUMPOUT-OPTIONAL

15

1

26

36

23

24

16

3

27

19

39

11

32

37

22

22

11

17

26

29

30

25

20

34

33

9

31
18

5

14

13

28

7

4

8

35

6

21

10

5-29

8

21

38

10

21

12

21

2

5

86037400 05/22/08

AUTOMATIC PUMPOUT-OPTIONAL

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273250 00-000210 4 SCR, 1/4-20 X 3/4 SOCHD
2 86178820 52-502064 1 CVR, OUTLET WST PMP-OUT
3 86192020 00-000312 8 SCR, CAP 1/4 X 1 SOCHD
4 86273550 00-000399 1 SCR, CAP 1/4 X 1 3/8 SOC
5 86273280 00-000241 8 SCR, CAP 10-32 X 2 SOCHD SS
6 86005810 57245 8 NUT, 1/4-20 HEX NYLOCK SS
7 86010780 87162 1 WASHE R, 1/4 SPLIT LOCK
8 86279470 87165 8 WASHE R, #1 0 SPLIT LOCK

9 86024820 04-000312 1 RING, RETAIN EXT 1/2
10 86174520 04-000334 2 BALL, NYL ID
11 86024850 04-000335 2 RING, SNAP 1-7/8D
12 86193250 04-000342 1 SPRING, PUMP-OUT BALL PRESS
13 86174700 52-502061 1 BDY, INLET WST PMP-OUT
14 86179530 16-808241 1 DIAPH, WST TNK PMP-OUT
15 86187870 40-902151 1 MOTOR, 1/8HP 12V
16 86182540 43-807117 1 GSKT, CVR TOP PMPOUT
17 86182550 43-807118 1 GSKT, CVR SD PMPOUT

18 86192300 43-810091 1 SEAL, PUMPOUT SHFT
19 86192350 43-810100 1 SEAL PUMPOUT CAM

20 86189600 43-810101 1 O-RING, 800/1000 .072
21 86189280 43-810106 4 O-RING, 1-13/16 ID X 2 OD HDWP
22 86175530 45-801927 4 BRG, SHFT PUMP-OUT
23 86195190 49-876301 1 VENT, UPR SHFT BRNG HSG
24 86050890 50-502025 1 PL, CVR TOP PUMP-OUT
25 86024860 50-502026 1 PL, CVR SD PUMP-OUT
26 86274110 70094 8 SCR, 1/4-20 X 1/2 SHCS SS
27 86181680 11-800504 1 GA, FLOW SIGHT 3/8 NPT
28 86175830 52-501828 1 BTM, PLNGR WST TNK PMP-OUT
29 86192690 52-501829 1 SHT, 3/4” STROKE WST TNK
30 86191550 52-501914 1 RD, CONNECT WST PMP-OUT PART OF 31
31 86182810 52-501915 1 GUIDE, PLNGR WST PUMP-OUT INCL. 32, 18, 30
32 86024870 52-501921 1 PIN, WRIST PUMP-OUT
33 86194640 52-501934 1 TOP, PLNGR PUMP-OUT
34 86176020 52-501950 1 BUSH, THREADED
35 86178810 52-502062 1 CVR, INLET WST PMP-OUT
36 86045790 56-502428 1 BRKT, PMP-OUT SW/CCT BRKR
37 86024880 52-501821 1 TOP, WST TNK PUMP-OUT

38 86174550 52-501820 1 BASE, WST TANK PMP-OUT
39 86174710 52-502063 1 BDY, INLET WST PMP-OUT

FROM NOTES:

86037400 02/16/07

5-30

WAND-TITANIUM SIX JET-OPTIONAL

9

11

3

3

9

22

23

12

16

15

26

17

18

14

18

20

24

21

6

2

8

10

4

19

13

32

30

1

7

5

25

29

33

27

31

35

28

34

5-31

86037400 02/16/07

WAND-TITANIUM SIX JET-OPTIONAL

5-32

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273310 00-000282 2 SCR, CAP 1/4-20 X 1 1/4 SOC
2 86192030 00-000317 2 SCR, CAP 10-32 X 1 1/4 SOCH
3 86006680 70228 4 SCR, 10-32 X 1/4 PPHMS SS
4 86270990 57090 2 NUT, 10-32 HEX NYLOCK SS
5 86264910 04-000093 2 TIE, CABLE 13”
6 OPEN - - -
7 86184270 10-805504 1 HOSE, 3/16 X 44-1/2
8 86247680 56015 1 NIPPLE, 1/4 HEX

9 86190180 11-800206 2 PLUG, 1/8 SOCHD BR
10 86177650 12-800060 1 CONN, 1/4P X 1/4T BR
11 86177710 12-800322 2 CONN, 1/8P X 1/4T COMP BR
12 86005580 56012 1 NIPPLE, 1/4 FPT QD
13 86193490 14-806512 1 STRAINER, JET 50 MESH
14 86194450 17-803018 2 TIP, SPRAY 9501 X 1/8P SST
15 86195570 17-803006 2 WASHER, NYLON
16 86177860 17-803010 1 CONN, 1/4P X 11/16-16M
17 86177870 17-803036 1 CONN, 1/4FP X 11/16-16F BR
18 86194580 17-803078 4 TIP, SPRAY 8001 SST \1/8 VJET
19 86194650 52-501619 1 TRIGGER, WD VALVE
20 86174680 52-502008BK 1 BODY, WD HDL, 2” TB, BK
21 86198180 52-502009 1 HOLD DN-WD HDL 2” TUBE
22 86187610 52-502057 1 MANFOLD, LEFT
23 86187620 52-502058 1 MANIFOLD, RIGHT
24 86174060 56-502548 1 ASSY, MNFLD S-BEND
25 86285440 56-502534 1 WD & HD, TITANIUM
26 86174120 61-950496 1 ASSY, EXTRACTOR VALVE
27 86193360 16-808189 1 STEM, EXTRACTOR VALVE
28 86193200 16-808190 1 SPRING, EXTRACTOR VALVE
29 86192410 16-808228 1 SEAT, EXTRACTOR VALVE
30 86183160 16-808229 1 HLDR, VLV STEM-EXTRACTOR VL
31 86189510 43-810062 1 O-RING, .114 ID .254OD
32 86189520 43-810063 1 O-RING, .551ID .691OD
33 86174500 43-810064 1 BACK-UP, .250DIA
34 86174630 52-501590 1 BDY, EXTRACTOR VLV
35 86179250 48-941462 1 DEC, WD HD TITANIUM

FROM

NOTES:

86037400 02/16/07

WAND-QUAD JET-OPTIONAL

27

30

33

28

29

31

32

12

14

13

16

17

15

14

34

8

7

4

2

9, 10

11

6

5

3

1

21, 22

25

26

19, 20

19, 24

23, 23A, 23B

5-33

86037400 02/16/07

WAND-QUAD JET-OPTIONAL

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

- 86285570 89238

- 86285580 89239

- 86285560 89237

- 86285540 89235

1 86005580 56012
2 86177860 17-803010 1 CONN, 1/4P X 11/16-16M
3 86195570 17-803006 1 WASHER, NYLON
4 86193490 14-806512 2 STRAINER, JET 50 MESH
5 86177870 17-803036 1 CONN, 1/4FP,11/16-16R BR
6 86247680 56015
7 86280020 09-805359 1 SLEEVE, WD HDL 9.5
8 86194650 52-501619 1 TRIGGER, WD VLV

9 86192030 00-000317 3 SCR, CAP 10-32X 1-1/4 SOCH
10 86270990 57090
11 86174120 61-950496 1 ASSY, EXTRCTR VLV
12 86177650 12-800060 1 CONN, 1/4P X 1/4T BR
13 86183970 10-805387 1 HOSE, 3/16 X 43-1/2 (1/8P X 1/4)

14 86265730 04-000053 3 TIE, CABLE 8” WHT
15 86273310 00-000282 2 SCR, CAP 1/4-20 X 1-1/4 SOC

16 86198160 52-501569 1 HOLD DOWN, WD HDL
17 86182840 791150
18 OPEN ­19 86190180 11-800206 2 PLUG, 1/8 SOCHD BR
20 86043300 56-501966 1 ASSY, L S-BEND MNFLD
21 86273450 00-000347 4 SCR, CAP 10-24 X1/4 SOCHD
22 86279470 87165
23 86194400 17-803001 4 TIP, SPRY 95015X1/8P SST 89238

23A 86194410 17-803002 4 TIP, SPRY 9502X1/8P SST 89239
23B 86194450 17-803018 4 TIP, SPRY 9501X1/8P SST

24 86043310 56-501986 1 ASSY, RT S-BEND MNFLD
25 86177710 12-800322 2 CONN, 1/8PX1/4T COMP BR
26 86174030 56-501967 1 ASSY, S-BEND MNFLD

27 86183160 16-808229
28 86189520 43-810063 1 O-RING, .551 ID .691 OD

29 86192410 16-808228 1 SEAT, EXTRCTR VLV
30 86193360 16-808189 1 STEM, EXTRCTR VLV
31 86174500 43-810064 1 BACK-UP, .250 DIA

32 86189510 43-810062 1 O-RING, .144 ID .254 OD
33 86193200 16-808190 1 SPRING, EXTRCTR VLV
34 86174630 52-501590 1 BODY, EXTRCTR VLV

- 86179020 48-941186 1 DECAL, WD HD (CAST SS) NOT SHOWN

- 86186160 66-808169 KIT, REP-WD VLV

-

WAND, TM, QJW (95015) PC COMPLETE

-

WAND, TM, QJW (9502) PC COMPLETE

-

WAND, TM QJW (9501) PC COMPLETE

-

WAND, TM, QJW, (9501) NO
DECAL

-

NIPPLE, 1/4 FPT QD

1

NIPPLE, 1/4 HEX

3

NUT, 10-32 HEX NYLOCK SS

1

BODY, WD HDL

1

4

WASHER, #10 SPLIT LOCK

1

HOLDER, VLV STEM-EXTRCTR
VL

-

86037400 02/16/07

FROM NOTES:

COMPLETE

89237
89235 (NO DECAL)

NOT SHOWN
IINCLUDES PARTS 27­29 & 31-33

5-34

WAND- TRI JET- OPTIONAL

25

26

7

32

27
29

30

9, 10

8

4

6

5

28

31

11

12

14

16

17

13

15

2

3

1

24

23

20, 21, 22

19, 19A, 19B

5-35

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

-

-

­1
2
3
4
5
6
7
8
9

10
11
12
13
14

15
16

17
18

19
19A
19B

20

21

22

23

24

25

26

27

28

29

30

31

32

-

-

86285520
86285510
86285530
86005580
86177860
86195570
86193490
86177870
86247680
86280020
86194650
86192030
86270990
86174120
86177650
86183970
86265730

86273310
86198160

86182840

OPEN
86194410
86194400
86194520
86274290
86279470
86270800
86187700

86190180
86183160

86189520
86192410
86193360
86174500
86189510
86193200
86179020

86179020

86186160

89233 - WAND, TJW (9502) PC
89232 - WAND, TJW, (95015) CUBXL
89234 - WAND, TJW, (9503) PC

56012 1 NIPPLE, 1/4 FPT QD
17-803010 1 CONN, 1/4P X 11/16-16M
17-803006 2 WASHER, NYLON
14-806512 1 STRAINER, JET 50MESH
17-803036 1 CONN, 1/4FP,11/16-16R BR

56015 1 NIPPLE, 1/4 HEX
09-805359 1 SLEEVE, WD HDL 9.5
52-501619 1 TRIGGER, WD VLV
00-000317 3 SCR, CAP 10-32X 1-1/4 SOCH

57090 3 NUT, 10-32 HEX NYLOCK SS
61-950496 1 ASSY, EXTRCTR VLV
12-800060 1 CONN, 1/4P X 1/4T BR
10-805253 1 HOSE, 3/16X49 (1/8P X 1/4FT)
04-000053 3 TIE, CABLE 8” WHT

00-000282 1 SCR, CAP 1/4-20 X 1-1/4 SOC
52-501569 1 HOLD DOWN, WD HDL

791150 1 BODY, WD HDL

- 1 ­17-803002 3 TIP, SPRY 9502X1/8P SST
17-803001 3 TIP, SPRY 9501X1/8P SST
17-803046 3 TIP, SPRY 9503X1/8P SST

70162 2 SCR, 10-32 X 3/8 PPHMS SS
87165 2 WASHER, #10 SPLIT LOCK
57014 2 NUT, 10-32 HEX SS

56-501739 1 MANIFOLD, WD TRI-JET
11-800206 2 PLUG, 1/8 SOCHD BR

16-808229 1
43-810063 1 O-RING, .551 ID .691 OD

16-808228 1 SEAT, EXTRCTR VLV
16-808189 1 STEM, EXTRCT VLV
43-810064 1 BACK-UP, .250DIA
43-810062 1 O-RING, .114ID .254OD
16-808190 1 SPRING, EXTRCTR VLV
52-501590 1 BODY, EXTRCTR VLV

48-941166 - DECAL, WD HD

66-808169 - KIT, REP-WD VLV

HOLDER, VLV STEM-EXTRCTR
VL

WAND- TRI JET-OPTIONAL

SERIAL

NO. FROM

COMPLETE
COMPLETE
COMPLETE

89233
89232
89234

NOT SHOWN

NOT SHOWN

INCLUDES PARTS 25­27 & 29-31

NOTES:

86037400 02/16/07

5-36

STAIR TOOL-OPTIONAL

18

19

22

17

23

16

20
21

2

3

4

6

5, 5A

7

8

9, 10

11

12

14

15, 15A

13

5-37

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

-

­1A
1B

2
3
4
5

5A

6
7
8

9
10
11
12
13

14
15

15A

16
17
18
19
20
21
22
23

-

-

86285350
86285290

OPEN

OPEN
86198080
86198170
86265730
86183710
86184000
86194410
86273310
86177650
86192030
86270990
86174120
86247680
86005580

86194650
86280020

86040950
86183160
86189520
86192410
86193360
86174500
86189510
86193200
86174630
86178970

86186160

78519 - TL, STAIR, LNG, TM DJ (80015)
78521 - TL, STAIR, SHT, TM (80015)

- - -

- - ­52-501576 1 BODY, WD HDL PORT
52-501577 1 HOLD DOWN, WD HDL PORT
04-000053 2 TIE, CABLE 8” WHT
10-805330 1 HOSE, 3/16X13-3/4 (1/8PX1/4)
10-805397 1 HOSE, 3/16X7-1/2 (1/8P X 1/4F)
17-803002 1 TIP, SPRY 9502X1/8P SST
00-000282 2 SCR, CAP 1/4-20 X 1-1/4 SOC
12-800060 1 CONN, 1/4P X 1/4T BR
00-000317 3 SCR, CAP 10-32X1-1/4 SOCH

57090 3 NUT, 10-32 HEX NYLOCK SS

61-950496 1 ASSY, EXTRCTR VLV

56015 1 NIPPLE, 1/4 HEX

56012 1 NIPPLE, 1/4 FPT QD
52-501619 1 TRIGGER, WD VLV
09-805359 1 SLEEVE, WD HDL 9.5

09-805504 1 SLEEVE, STAIR TL HDL 7-1/8
16-808229 1 HOLDER, VLV STEM-EXTRCTR VL
43-810063 1 O-RING, .551 ID .691 OD
16-808228 1 SEAT, EXTRCTR VLV
16-808189 1 STEM, EXTRCTR VLV
43-810064 1 BACK-UP, .250DIA
43-810062 1 O-RING, .114 ID .254 OD
16-808190 1 SPRING, EXTRCTR VLV
52-501590 BODY, EXTRCTR VLV
48-941163 DECAL, STAIR TL

66-808169 KIT, REP-WD VLV

STAIR TOOL-OPTIONAL

SERIAL NO.

FROM

NOT SHOWN

NOTES:

COMPLETE
COMPLETE

NOT SHOWN

INCLUDES
PARTS 16-19
& 20-22

86037400 02/16/07

5-38

UPHOLSTERY TOOL-OPTIONAL

21

20

36

37

1

22
24

25
26

35

34

33

3

23

32

4

27

31

28

29

30

8

6

7

11

10

9

12

14

5

16

2

13

18

15

19

5-39

17

3

86037400 02/16/07

REF PART NO. PRV NO. QTY DESCRIPTION

-

86285260

1

86280240

2

86178660

3

86184670

4

86179720

5

86178550

6

86273370

7

86193050

8

86176080

9

86194590

10
11

12
13
14
15
16

17
18

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

37

-

86174140
86005580

86177860
86195570
86193490
86177870
86188320

86178520
86177660

86178630
86183160
86189520
86192410
86193360
86174500
86189510
86189510
86273350
86194500
86178540
86273360
86195210
86195530
86189460
86182570
86183770
86179740

86192070
86178980

- 86186160

78513 1
09-805131 2
08-805243 1
10-805347 1
13-806023 1
58-500639 1
00-000310 1
04-000282 1
52-501624 1
52-501842 1

61-950570 1 ASSY, UPHLST TL VLV

56012 1
17-803010 1
17-803006 1
14-806512 1
17-803036 1
11-800404 1

52-501585 1
12-800065 1

08-805138 1
16-808229 1
43-810063 1
16-808228 1
16-808189 1
43-810064 1
43-810062 1
16-808190 1
00-000306 2
17-803033 1
58-500638 1
00-000307 2
52-501623 1
52-501626 1
43-810016 1
43-807513 1
10-805348 1
13-806030 1

00-000408 1
48-941164 1

66-808169 1 KIT, REPAIR-WAND VLV

TL, UPHOLST, PC (80015)
HOSE, VAC 1-1/4X10’ BLU
CUFF, SWIV 1-1/4HX1-1/4T
HOSE, 3/16X119-1/2 (1/8PX1/4FT)
DSC, 1/8FC1/8FP SST
UPHOLSTERY TL TRIGGER
SCR, CAP 4-40 X7/32 SHCS SS
SPRING, VAC ADJ BUTT
BUTTON, VAC ADJ
TOOL, UPHOLSTERY

NIPPLE, 1/4 NPT QD
CONN, 1/4P X 11/16-16M
WASHER, NYLON
STRAIRNER, JET 50MESH
CONN, 1/4FPX11/16-16F BR
NIP, 1/4X5 SST

COUPLER, UPHLST TL
CONN, 1/8P X 1/4T
CUFF, 1 1/4H X 1 1/2T GRY
HOLDER, VLV STEM-EXTRCTR VL
O-RING, .551 ID .691 OD
SEAT, EXTRCTR VLV
STEM, EXTRCTR VLV
BACK-UP, 250DIA
O-RING, .144 ID .254 OD
SPRING, EXTRCTR VLV
SCR, 6-32 X 1 SCHD SS
TIP, SPRY 80015X1/8P SST
CSTG, TRIGGER CLMP
SCR, CAP 6-32X3/8 SOCHD
VALVE, UPHLST TL
VALVE, ADJ-UPHLST TL VLV
O-RING, 5/32IDX9/32OD VIT
GASKET, UPHLST TL VLV
HOSE, 3/16X6-1/2 (1/8P BS)
D SC, 1/8MX1/8FP SST

SCR, SET 3-32 X 1/4 SOCHD
DECAL, UPHLST TL

UPHOLSTERY TOOL-OPTIONAL

SERIAL NO.

FROM

NOTES:

COMPLETE

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

NOT SHOWN
NOT SHOWN

INCLUDES PARTS
20-22 & 24-26

86037400 02/16/07

5-40

SHELF ASSEMBLY-OPTIONAL

16

4

3

2

4

3

2

15

4

10

5

2

12

2

11

10

14

17

1

2

3

4

3

2

5

7

2

9

4

6

8

3

4

5-41

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

DIMENSIONAL DATA

5

7

1

86037400 02/16/07

13

50 1/8

10

10

2

5

2

12

11

REF PART NO. PRV NO. QTY DESCRIPTION

- 86285410 65-950392 1 VAN STORAGE UNIT
1 86192680 56-501921 1 SHELF, LWR
2 86270330 02-000066 20 FLATWASHER, 1/4
3 86010780 87162 20 WASHER, 1/4 SPLIT LOCK
4 86274760 70271 20 SCR, 1/4-20 X 1/2 HHCS PLTD
5 86274750 70270 4 SCR, 1/4-20 X 3/4 HHCS PLTD
6 86175710 50-501840 1 BRKT, ADJUST MTG SLOT
7 86175730 56-502067 1 BRKT, ADJUST MTF HLDR
8 86198090 56-501942 1 BRKT, SHELF MOUNTING
9 86285120 41460 1 HOLDER, STAIR TOOL

10 86270620 01-000105 4 LOCK NUT, 1/4-20 HXHD
11 86024890 56-501922 2 PANEL, SHLF END
12 86278840 50-501749 2 WASHER, NYLON
13 86021920 56-501920 1 DRAWER, S HELF G RAY
14 86186850 46-802506 1 LATCH, ADJ GRIP
15 86183180 50-501755 1 HOLDER, UP TL HOSE
16 86183170 50-501754 1 HOLDER, UPHST TL
17 86179350 48-941152 1 DECAL, PROCHEM

- 86162440 66-945424 1 KIT, ADJ BRKT.

SHELF ASSEMBLY-OPTIONAL

SERIAL NO.

FROM NOTES:

INCLUDES PARTS 6,7

COMPLETE

& MOUNTING
HARDWARE

86037400 05/22/08

5-42

WATER TANK, DUAL WITH DEMAND PUMP-OPTIONAL

1

13

1

4
3
2

11

13

12

9

8

6

7

2

3

4

5

6

7

9

7

10

7

8

8

TO DEMAND
PUMP

5-43

OVERALL DIMENSION:
32-1/2" TALL
62-5/8" WIDE
15-1/2" DEEP

14

86037400 02/16/07

WATER TANK, DUAL WITH DEMAND PUMP-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

-

­1
2
3
4
5
6
7
8
9

10
11
12
13
14
15

-

86041730
86041710
86048310
86279510
86010790
86277830
86176400
86180170
86181370
86177020
86280590
86194120
86043320
86030990
86190500
86190170
86005770
86285190

66-945260 - TANK, DUAL SADDLE W/DMD PUMP
66-945265 - SINGLE SADDLE TANK W/DMND PMP
50-501774 4 HOLD DOWN, SADDLE TANK GRAY

87171 16 WASHER, 3/8 FLAT

87163 16 WASHER 3/8 SPLIT LOCK
00-000072 16 SCR, 3/8-16 X 2’ HXHD
11-800432 4 CAP, WATER BOX
11-800041 2 ELL, STREET 1/2 BR
12-800278 4 FTTG, BRB 1/2P X 3/4H BR
03-000113 4 CLAMP, HOSE #12 SST
09-805456 1 HOSE, WTR 3/4 X 96”
11-800085 1 TEE, 1/2 BRASS
56-502000 2 ASSY, BASE SADDLE TANK GRAY
58-500661 2 MOLDING, WATER TANK
11-800168 2 PLUG, 1/2 BRASS HXHD
50-500511 1 PLATE, INSTALL MT

57119 9 NUT, 3/8-16 HEX NYLOCK

41458 1 SHLR, CHEM, 10-GAL JUG

SERIAL NO.

FROM

NOTES:

COMPLETE
COMPLETE

NOT SHOWN

86037400 02/16/07

5-44

WATER TANK-DEMAND PUMP-OPTIONAL

3

4

6

5

4

2

1

11

10

4

12

16

8

7

16

9

13

8

5-45

86037400 02/16/07

WATER TANK - DEMAND PUMP-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

86006760

1

86279130

2

86278830

3

86177020

4

86280290

5

86280420

6

86280550

7

86181400

8

86179630

9

86180900

10

86190740

11

86186120

12

86180210

13

86191390

14

86186030

15

86177060

16

70305

87083
02-000143
03-000113
09-805278
09-805357
09-805446
12-800345
13-806009
14-806553
41-905049
48-809423
11-800275

65240

47449
03-000246

4 SCR, 5/16-18 X 3/4 HHCS GR5 PL TDL
4 WASHER, 5/16 SPLIT LOCK PLTD
4 WASHER, 5/16 FLAT
4 CLAMP, HOSE #12 SST
1 HOSE, WATER 3/4 X 3”
1 HOSE, WATER .75 X 5.5
1 HOSE, 5/8ID BLU X 55”
1 FTTG, BRB 3/8P X 5/8H BR
1 DISCONNECT, 3/8M X 3/8FP
1 FILTER, DEMAND PUMP
1 PUMP, WATER BOOSTER FLOJET 2
1 KIT, PORT
1 ELBOW, ST 3/8 BR
1 PUMP ONLY, TM DEMAND
1 KIT SERVICE DEMAND PMP FJ
2 CLAMP, HOSE #8 SST

SERIAL NO.

FROM

NOTES:

NOT SHOWN
NOT SHOWN

86037400 09/06/07

5-46

AUXILIARY WATER TANK WITH PUMP

39

1

37

38

12

24

33

29

32

28

22

21

9

15

2

40

23

11

8

27

17

20

18

40

2X 16.8

26

34

2X 18.7

13

25

40

5

31

19

6

7

4

14

4X Ø.406

30

4

30.0 WIDE

16

3

36

MOUNTING DETAIL

Vehicle

Floor

34

35

10

5-47

58.6 LENGTH

30.0 TALL

86037400 09/06/07

AUXILIARY WATER TANK WITH PUMP

REF PART NO. PRV NO. QTY DESCRIPTION

1

86277830 00-000072 4 SCR, 3/8-16 X 2” HXHD

2

86277850 00-000337 1 SCR, 10-32 X 1” SOCHD SST

3

86270330 02-000066 4 FLATWASHER, 1/4

4

86177020 03-000113 4 CLAMP, HOSE #12 SST

5

86280550 09-805446 1 HOSE, 5/8 ID BLU X 55”

6

86280290 09-805278 1 HOSE, 3/4 ID WTR X 3”

7

86280420 09-805357 1 HOSE, 3/4 ID WTR X5.5”

8

86280140 09-805406 1 HOSE, 5/8 ID BLU X 30 1/2

9

86180170 11-800041 2 ELL, STREET 1/2 BR MACH

10

86180210 11-800275 1 ELL, ST 3/8 BR

11

86191600 11-800283 1 RED, 1/2FP X 3/8P BR

12

86176400 11-800432 1 CAP, WATER BOX

13

86188470 11-800524 1 NIP, 1-1/2XCL PVC (SCH80)

14

86181320 12-800095 1 FTTG, BRB 3/4PX3/4H BR

15

86181360 12-800269 1 FTTG, BRB 1/2 X 5/8H BR

16

86181400 12-800345 2 FTTG, BRB 3/8P X 5/8 BR

17

86179710 13-806008 1 DISCONNECT 3/8F X 3/8FP

18

86179630 13-806009 1 DISCONNECT 3/8M X 3/8FP

19

86180900 14-806553 1 FILTER, DEMAND PUMP

20

86195010 15-808080 1 VALVE, BALL PVC 1-1/2FP

21

86192380 16-808164 1 SEAT, FLOAT VLV TM

22

86173820 16-808216 1 ARM, PIVOT-FH VLV

23

86174610 16-808217 1 BDY, FLOAT VLV

24

86174540 19-807014 1 BALL, FLOAT

25

86190740 41-905049 1 PMP, WTR BOOSTER FLOJET 2

26

86190170 50-500511 4 PLATE, INSTALL MT

27

86189010 52-501706 1 NUT, FLOAT VALVE

28

86028860 52-800314 1 PISTON, FLOAT VLV PISTON

29

86181150 54-501715 1 FLOAT ROD, TM

30

86186120 48-809423 1 KIT, PORT DEMAND PUMP

31

86180010 31100 1 ELBOW, 1.5 STREET PVC MP X FP

32

86270770 57006 2 NUT, 1/4-20 HEX

33

86270990 57090 1 NUT, 10-32 HEX NYLOCK SS

34

86005770 57119 4 NUT, 3/8-16 HEX NYLOCK

35

86274750 70270 4 SCR, 1/4-20 X 3/4 HHCS PLTD

36

86010780 87162 4 WASHER, 1/4 SPLIT LOCK PLTD

37

86279510 87171 8 WASHER, 3/8 FLAT

38

86031000 790617 1 TANK, FRESH WATER 70GAL

39

86057170 790666 2 STRAP, WTR TNK HOLD DOWN

40

86177060 03-000246 3 CLAMP, HOSE #8 SST

SERIAL NO.

FROM NOTES:

86037400 09/06/07

5-48

AUXILIARY WATER TANK-OPTIONAL

27

25

26

24

1

19

18

20

3

4

21

23

2

16

20

19

5

DEMAND

PUMP

SUBASM

18

16

17

21

6

7

8

9

10

11

12

13

5-49

16

15

14

86037400 09/06/07

AUXILIARY WATER TANK-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

1 86176400
2 86191600
3 86180170
4 86181360
5 86177020
6 86280100
7 86179710
8 86047580

9 86030970
10 86278830
11 86279130
12 86006750
13 86050960
14 86176420
15 86195820
16 86181320
17 86280060

18 86195330
19 86180260
20 86188480
21 86177060
22 86190190
23 86050960
24 86195060
25 86181150
26 86270770
27 86174540

11-800432
11-800283
11-800041
12-800269
03-000113
09-805288
13-806008
56-502505
58-500899
02-000143

87083

70302
50-502092
12-800052
43-807008
12-800095
09-805100
15-808072

11-800401
11-800525
03-000246
11-800357
50-502092
15-808110
54-501715

57006
19-807014

1 CAP, WATER BOX
1 RED, 1/2FP X 3/8P BR
1 ELL, STREET 1/2 BR
1 FTTG, BRB 1/2P X 5/8H BR
4 CLAMP, HOSE #12 SST
1 HOSE, WATER 5/8 X 27
1 DSC, 3/8F X 3/8 FP
1 ENCL, TNK SUPT W.DEM PMP
1 MLDG, WTR TNK, 60G W/OVR

1 WASHER, 5/16 FLAT PLTD
16 WASHER, 5/16 SPLIT LOCK PLTD
16 SCR, 5/16-18 X 1” HHCS

1 PL, FRT TANK SUPPORT

1 CAP, HOSE 3/4 BR

1 WSR, HOSE 5/8 ID 1” OD

3 FTTG, BRB 3/4P X 3/4H BR

1 HOSE, WTR 3/4 X 13-1/2

2 VLV, BAL 3/4FP BS

2 ELL, 3/4 ST BR

2 NIP, 3/4 X 2-1/2 BR

3 CLAMP, HOSE #8 SST

1 PLG, 3/4 SOCHD BR

1 PL, END, TNK SUP

1 VALVE, FLOAT,TM

1 FLOAT ROD, TM

1 NUT, 1/4-20 HEX

1 BALL, FLOAT

SERIAL NO.

FROM NOTES:

86037400 09/06/07

5-50

HOSE REEL-OPTIONAL

MOUNTING DETAIL

Vehicle
Floor

21

16

13

15

12

14

16

13

11

14

12

25

15

OVERALL

23

24

17

15

22

13

14

47" TALL
44-1/2" DEEP

5

6

7

2
3

10

1

8

9

10

2
3

5

6

8

7

9

5-51

4

86037400 09/06/07

REF PART NO. PRV NO. QTY DESCRIPTION

86191620

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17

18
19
20
21
22
23
24
25

86177270
86175990
86174560
86175740
86186870
86270330
86010780
86274750
86005650
86191820
86174740
86278830
86279130
86006750
86181030
86174730

86277830
86190170
86279510
86005770
86189850
86175700
86193240
86177190

56-501962 1 REEL, VACUUM HOSE GRAY
03-000124 2 CLAMP, MFLR 1-3/4
52-501685 2 BUSHING, HOSE REEL
56-501960 1 BASE, HOSE RL (250’)
56-502207 1 BRKT, LOCKOUT HOSE REEL
61-950854 1 LATCH ASSEMBLY
02-000066 2 FLATWASHER, 1/4

87162 2 WASHER, 1/4 SLPIT LOCK
70270 2 SCR, 1/4-20 X 3/4 HHCS PLTD

57031 2 NUT, 5/16-18 HEX
56-501968 1 REEL, HP HOSE GRAY
45-802138 2 BEARING HOSE REEL
02-000143 4 FLATWASHER, 5/16

87083 4 WASHER, 5/16 SPLIT LOCK PLTD

70302 4 SCR, 5/16-18 X 1” HHCSGR5PLT
44-802122 4 FLANGE, 47MST
56-501961 1 BODY, HP HOSE GRAY

00-000072 10 SCR, 3/8-16 X 2” HXHD
50-500511 1 PLATE, INSTALL MT

87171 10 WASHER, 3/8 FLAT

57119 10 NUT, 3/8-16 HEX NYLOCK
55-501789 1 PIN, LOCK HOSE REEL
50-501812 1 BRKT, HOSE REEL LOCK
04-000302 1 SPRING, LOCK-LOCK PIN ASSY
04-000303 1 CLIP, RETAINER-LOCK PIN ASSY

HOSE REEL-OPTIONAL

SERIAL NO.

FROM

NOTES:

86037400 09/06/07

5-52

WIRING DIAGRAM

HOUR METER

#86246890-PRV NO. 54092

+

-

ENGINE

USE:
86136640 - PRV NO. 70262
86010740 - PRV NO. 87090
86137310 - PRV NO. 87098

WHT

COM

N.O.

N.C.

ENGINE SHUTOFF

SWITCH

WASTE TANK

GRN

BLK

GRN

STARTER

BLK 4Ga #86176240

PRV NO. 64-950593

BATTERY

#86174580

PRV NO. 36-900056

BACK OF PLUG ON

ENGINE HARNESS

WHT

BLK

GRN

BLK
WHT

REAR OF

CONNECTORS

RED 4Ga #86176200

PRV NO. 64-950499

POSNEG

ORG/WHT

YEL/BLK

ORG/WHT

YEL/BLK

EXTERNAL FUEL

PUMP

ENGINE CONNECTOR

PART #42-902318

F

M

F

M

BACK OF

#25-155-06

F
M

FUEL PUMP CORD

#86176930

PRV NO. 790579

SHUTDOWN RELAY

#86191740

PRV NO. 35-900188

87

86

87a

85

30

M
F

PUMPOUT SWITCH

#86193760

PRV NO. 32-900206

MAIN CIRCUIT BRKR

#86175490

PRV NO. 33-900161

30

AMP

WTR PMP/AUX CIRCUIT BRKR

#86175510

PRV NO. 33-900163

20

AMP

PUMPOUT CIRCUIT BRKR

#86175510

PRV NO. 33-900163

20

AMP

IGNITION SWITCH

#86186020

PRV NO. 32-900174

TEMPERATURE SENDER

#86192490-PRV NO. 34-903019

LOCATED ON

HEATER CORE MANIFOLD

N.C.

#86193750-PRV NO. 32-900205

WATER PUMP

TEMPERATURE GAUGE

#86181960-PRV NO. 36229

G

S

WATER PRESSURE

PUMP SWITCH

N.O. CONTACT BLOCKS

N.O.

F

M

CLUTCH

I

N.O.

A BC

FEMALE CONNECTOR

FOR PUMPOUT

A B

5-53

86037400 09/06/07

HOSE DIAGRAM

PRV NO. 10-805130 (13-1/2")

86183430

PANEL

LOWER

CONTROL

86280080

PV NO. 09-805280 (46")

86280520 - PRV NO. 09-805435 (33")

86183470 - PRV NO. 10-805204 (23")

PUMP

WATER/CHEMICAL

MUFFLER

SILENCER

86049000-PRV NO. 09-805380 (60")

BOTTLE

CHEMICAL

86184120-PRV NO. 10-805458 (40")

PRV NO. 09-805344

86176990

86181300

86193410

86176990-PRV NO. 03-000065

86280070-PRV NO. 09-805279 (21")

86176990 - PRV NO. 03-000065

86280040 - PRV NO. 09-805088 (64")

PRV NO. - 12-800093

PRV NO.. - 14-806506

PRV NO. 03 - 000065 (2)

86280040 - PRV NO. 09-805088 (64")

86183550-PRV NO. 10-805275 (19")

86184460 (3")

86280190-PRV NO.09-805040 (30")

VACUUM

BLOWER

86282770

PRV NO. 51372

86283010 (45")

PRV NO. 09-805567

86048980-PRV NO. 09-805341 (36")

86233390-PRV NO. 80887 (2)

86280260-PRV NO. 09-805234 (36")

TO WASTE TANK

86183480-PRV NO. 10-805205 (15")

86183470 (23")

PRV NO. 10-805204

86183800 (8")

PRV NO. 10-805355

86184370 (11-1/2")

PRV NO. 790416

86233390-PRV NO. 80887 (2)

86184390-PRV NO. 790418 (20")

86282470-PRV NO. 790725 (19")

86144390-PRV NO. 790418 (20")

86183600 (10")

PRV NO. 10-805291

86280150 (9")

RV NO. 09-805447

PPLIED WITH ENGINE

86037400 09/06/07

PRV NO. 10-805271

86183530 (68-1/2")

HEAT EXCHANGER

5-54