Prochem PEAK Operating Instructions Manual

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Page 1

Operating Instructions (ENG)

MODELS: PEAK

86037220 03/12/09 PRV NO. 980116

Read instructions before operating the machine.

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Page 3

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

THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU 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

PEAK 86037220 02/12/07

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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

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

Water Pumping And Heat

Transfer System ......................................... 3-7

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

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

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

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

Waste Pump...............................................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, Pulleys And Hubs..4-6

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

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

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

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

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

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

Chemical 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

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

General Service Adjustments

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

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

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

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

Chemical And Heat Bypass Valves.........4-9

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

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

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

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PARTS LIST

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

Side Panel...................................................5-7

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

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

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

Vacuum Blower...........................................5-15

Water Pump................................................5-17

Vacuum/Exhaust Heat Exchanger

And Silencer................................................5-21

Heli-Coil Heat Exchanger............................5-23

Solution Manifold ........................................5-25

Water Box ..................................................5-27

Pressure Regulator Manifold ......................5-29

Waste Tank.................................................5-31

Hose Accessories.......................................5-33

Battery-Floor Mount....................................5-35

Automatic Pumpout (Optional)....................5-37

Wand- Titanium Six Jet (Optional)..............5-41

Wand - Quad-Jet (Optional)........................5-43

Wand – Tri-Jet (Optional)............................5-45

Stair Tool (Optional)....................................5-47

Upholstery Tool (Optional)..........................5-49

Shelf Assembly (Optional) ..........................5-51

Water Tank, Dual With

Demand Pump (Optional)...........................5-53

Water Tank-Demand Pump (Optional) .......5-55

Auxiliary Water Tank With Pump................5-57

Hose Reel (Optional) ..................................5-59

Wiring Diagram...........................................5-61

Hose Diagram.............................................5-62

Warranty .....................................................5-64

TABLE OF CONTENTS

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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 va cuum 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 connect.

8. Installation bolting kit.

9. Installation mounting plates.

10. Operation and service manual for engine, water

pump, and vacuum pump.

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HOW TO USE THIS MANUAL

This manual contains the following sections:

- HOW TO USE THIS MANUAL

- SAFETY

- INSTALLATION REQUIREMENTS

- SYSTEMS

- OPERATIONS

- MAINTENANCE & SERVICE

- PARTS LIST

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

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

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

The 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.

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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 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!

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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 waste tank and accessories weighs approximately 990 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 n ot 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.

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HAZARD INTENSITY LEVEL

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.

Front panel decal With warning labels

86179290 PRV NO. 500875

LUBRICATE REGULATOR SEALS

EVERY 50 HOURS.

RECOMMENDED LUBRICANT:

SYNCO SUPER LUBE

SOLUTION PRESSURE

REGULATOR

CHEMICAL

CHECK VALVE

SOLUTION SCREEN

SOLUTION OUTLET

CONDENSED OPERATING INSTRUCTIONS

STARTING

1. CONNECT WATER HOSE TO WATER INLET CONNECTION AND TURN O N WATER SUPPLY.

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

3. PULL OUT ENGINE CHOKE,T URN SOLUTION PUMP TO OVER RIDE AND TURN IGNITION KE Y TO START.

4. PUSH IN ENGINE CHOKE AFTER ENGINE HAS STARTED.

5. SET THROTTLE AT IDLE (PUS H THROTTLE CABLE IN)

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

7. TURN CHEMICAL PRIME VAL VE TO PRIME AND ALLOW CHEM ICAL TO CIRCULATE. AFTER A LL AIR BUBBLES HAVE BEEN R EMOVED FROM THE CHEMICAL TUBING, TURN THE CHEMICAL P RIME VALVE TO THE ON POSIT ION AND OPEN THE CHEMICAL FL OW VALVE. WITH THE TOOL ATT ACHED AND THE CHEMICAL FLOW VALVE OPEN, SET THE DESIRED CHEMICAL FLOW RATE WHI LE OBSERVING THE FLOW METER INDICATOR.

8. FOR QUICK HEAT-UP, REF ER TO OPERATING INSTRUCTION S.

SHUTDOWN AND DAILY MAINTENANCE

1. CLOSE CHEMICAL METERING VALVE.

2. ALLOW THE UNIT TO RUN FO R 2 MINUTES WITH THE VACUUM HOSE DISCONNECTED TO REM OVE MOISTURE AND SPRAY WD4 0 (OR EQUIVALENT) INTO THE VACUUM LUBRICATION CUP. THIS WILL PREVENT CORROSION D UE TO MOISTURE.

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

4. TURN OFF IGNITION SWITCH.

5. DISCONNECT ALL HOSES AND TOOLS.

6. DRAIN WASTE TANK INTO AN APPROVED SOURCE AND RINSE WITH C LEAN WATER.

(2 Warning labels required (1) Top of belt guard (1) Top of rear engine panel

Warning label

86186520 PRV NO. 500769

Caution label

86186530 PRV NO. 500770

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OPERATION

TECHNICAL SPECIFICATIONS

ITEM DIMENSION/CAPACITY

Engine speed 2850 rpm (high speed) Water Pump ON

1200 rpm (idle speed) Water Pump OFF. Water pump rpm 1750 rpm Vacuum pump rpm 3250 rpm Water flow rate 3.5 GPM (maximum) Water pump pressure (low pressure) 1000 PSI (maximum) Vacuum relief valve 13” Hg Waste tank capacity 60 gallons Console weight 770 lbs. Console weight (with waste tank & waste tank accessories)

TORQUE VALUES

Engine hub 300 inch lbs 25 foot/lbs Vacuum pump hub 300 inch/lbs 25 foot/lbs Front engine pulley 216 inch/lbs 18 foot/lbs Water pump clutch shaft bolt 300 inch/lbs 25 foot/lbs

JET SIZING:

Recommended floor tool tip sizing not exceed a total of “.045”. Using larger jet sizes on your cleaning unit may reduce cleaning temperatures.

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

015 X 3 = 045

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

990 lbs.

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OPERATION

INSTALLATION REQUIREMENTS

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

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

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

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 shoul d be removed before installing this unit.

6. We highly recommend using a aluminum drip tray under the console (Part #86055040, PRV NO.

790552).

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

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

FUEL REQUIREMENTS2. FUEL

REQUIREMENTS

Use unleaded gasoline ONLY. DO NOT use any

gasoline additives. We recommend the use of clean, fresh, unleaded gasoline intended for automotive use. High octane gasoline should NOT be used with the engine on this unit.

ENGINE OIL REQUIREMENTS3 OIL

REQUIREMENTS

Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.

OIL TYPE

Use high quality detergent oil of API (American Petroleum Institute) service class SG, SH, SJ or higher. Synthetic oils may be used. Select the viscosity based on the air temperature at the time of operation as shown in the following table.

RECOMMENDED SAE VISCOSITY GRADES

10W-30

-20 0

-30

e a

5W-20, 5W-30

-20

-10

i o

Kohler “Command”

° v

(

)

(

)

60 80

100

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

A logo or symbol on oil containers identifies service class and SAE viscosity grade. See figure below.

Oil Change Logo

SPECIAL ALTITUDE REQUIREMENTS

Operation at higher altitudes may require a special carburetor fuel nozzle. If you operate unit your above 5000 feet, you should order the Kohler high altitude kit Part #48102.

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OPERATION

CHEMICAL REQUIREMENTS4.

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

WATER REQUIREMENTS

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

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

HARD WATER MAP

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

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

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

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OPERATION

LUBRICATE REGULATOR SEALS

EVERY 50 HOURS.

RECOMMENDED LUBRICANT:

SYNCO SUPER LUBE

SOLUTION PRESSURE

REGULATOR

CHEMICAL

CHECK VALVE

SOLUTION SCREEN

SOLUTION OUTLET

CONDENSED OPERATING INSTRUCTIONS

STARTING

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

4. PUSH IN ENGINE CHOKE AFTER ENGINE HAS STARTED.

5. SET THROTTLE AT IDLE (PUSH THROTTLE CABLE IN)

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

7. TURN CHEMICAL PRIME VALVE TO PRIME AND ALLOW CHEMICAL TO CIRCULATE. AFTER ALL AIR BUBBLES HAVE BEEN REMOVED FROM THE CHEMICAL TUBING, TURN THE CHEMICAL PRIME VALVE TO THE ON POSITION AND OPEN THE CHEMICAL FLOW VALVE. WITH THE TOOL ATTACHED AND THE CHEMICAL FLOW VALVE OPEN, SET THE DESIRED CHEMICAL FLOW RATE WHILE OBSERVING THE FLOW METER INDICATOR.

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

SHUTDOWN AND DAILY MAINTENANCE

1. CLOSE CHEMICAL METERING VALVE.

2. ALLOW THE UNIT TO RUN FOR 2 MINUTES WITH THE VACUUM HOSE DISCONNECTED TO REMOVE MOISTURE AND SPRAY WD40 (OR EQUIVALENT) INTO THE VACUUM LUBRICATION CUP. THIS WILL PREVENT CORROSION DUE TO MOISTURE.

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

4. TURN OFF IGNITION SWITCH.

5. DISCONNECT ALL HOSES AND TOOLS.

6. DRAIN WASTE TANK INTO AN APPROVED SOURCE AND RINSE WITH CLEAN WATER.

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1. WASTE TANK FULL INDICATOR LIGHT

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

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

2. ENGINE HIGH TEMPERATURE SHUTDOWN INDICATOR

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

3. VACUUM GAUGE

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

4. SOLUTION PRESSURE GAUGE

This gauge registers the amount of pressure in the system.

5. 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.

6. SOLUTION TEMPERATURE GAUGE

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

7. WASTE PUMPOUT AND AUXILIARY WATER PUMP SWITCH

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

OPERATION

8. 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.

9. SOLUTION PUMP SWITCH

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

10. 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.

11. THROTTLE

This serves to set the speed of the engine. Handle pushed in sets engine to idle. Handle pulled out sets engine speed to maximum. Handle clockwise to lock in position and counter clockwise to move or change throttle settings.

12. CIRCUIT BREAKERS

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

13. HOUR METER

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

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OPERATION

14. OIL CUP

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

15. VACUUM INLET

The vacuum inlet serve as connecting point for vacuum hoses.

16. WATER INLET

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

17. WASTE PUMPOUT (OPTIONAL)

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

18. 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.

19. SOLUTION SCREEN

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

20. CHEMICAL CHECK VALVE

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

21. 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.

22. 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.

23. 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.

24. 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.

25. FLOW SIMULATOR VALVE

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

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

The next stage of heating and water flow is to the helicoil, when water is called for in the cleaning process it flows to the helicoil under pressure. Heat from the engine coolant is exchanged to the cleaning solution through a series of spiraled copper tubing. This allows the engine coolant to travel in a counter rotating direction to the cleaning water during the exchange process creating a very efficient transfer of heat out of the engine and into the cleaning solution.

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OPERATION

The third stage of plumbing and heat exchange takes place in the 2nd heater core located in the heater box. This is the hottest point of the gases coming from the vacuum pump and the engine. These hot gases are forced through heater core #2 creating the third 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 temperature sensing point and a connecting point for the high-pressure hoses. Also a check valve is located in this outlet manifold prohibiting chemicals from backing up into the system.

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

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OPERATION

WATER PUMPING AND HEAT TRANSFER SYSTEM

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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.

OPERATION

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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

HEATER COIL #1

INLET

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

HEATER COIL #2

SILENCER

WASTE TANK

STRAINER

VACUUM GAUGE

LUBRICATION

CUP

VACUUM

PUMP

VACUUM

RELIEF VALVE

LEVEL SENSOR

FILTER

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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

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OPERATION

PRIMING THE CHEMICAL PUMP

1. Connect water hose to water inlet conne ction

and turn on water supply.

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

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

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

5. Push in engine choke after engine has started.

6. Set throttle to idle speed.

7. Fill chemical container and inspect chemical

filter.

8. Turn on the water pump.

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 op ening (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.

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Page 23

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, crack the bypass valve slightly to provide additional cooling.

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OPERATION

FREEZING PROTECTION

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

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

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.

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

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

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

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

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.

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

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

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REMOVING ANTI-FREEZE FROM THE UNIT

1. Connect one end of the winterizing loop hose

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

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

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

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

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

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

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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.

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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

Pressure Regulator Pressure Regulator

High Pressure Hoses

Float Valve Seal

Fuel Pump

Chemical Valves

Engine Engine

Battery

Engine Engine Engine

Battery

Engine Engine

Engine

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

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

50 hrs Lubricate o-rings

50 hrs Lubricate plug behind spring 100 hrs Inspect for damage or impending damage 100 hrs Change engine oil***

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

100 hrs* Clean battery terminals 200 hrs. Replace seal

200 hrs Service air cleaner elements* 200 hrs Check radiator hoses and clamp tightness 200 hrs Check hose connections 200 hrs Check spark plugs for carbon deposits and proper gap 200 hrs Inspect and/or adjust packing nuts

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

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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

Nitrogen Accumulator

Waste Tank Filters/Strainers

Water Pump

Bolt

Drive Pulley Drive Pulley

Drive Belts Drive Belts

Engine

Heater Core

Engine

Engine Engine

MAINTENANCE

SERVICE SCHEDULE

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

1500 hrs

Monthly

Yearly

Yearly* Yearly*

Yearly 2 years 3 years

Inspect cores and remove debris. Change oil**

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

Inspect, clean and check for pulley groove wear****

Check pulley alignment****

Inspect and clean**** Check belt tension**** 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. Drain, flush, and replace oil ***** Check for debris hindering movement Flush radiator and change engine coolant.

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

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

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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.

ENGINE COOLANT SYSTEM (RADIATOR) MAINTENANCE

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

EXTERNAL FUEL PUMP MAINTENANCE

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

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.

HEAT EXCHANGER SYSTEM MAINTENANCE

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

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

VACUUM PUMP MAINTENANCE

(Refer to manufacturer’s manual (P/N 86269820, PRV NO. 980129) 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.

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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 86269810, PRV NO. 980128) 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 (PN 34412). USING ANY OTHER TYPE OIL FILTER WILL VOID YOUR ENGINE WARRANTY.

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

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

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MAINTENANCE

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

4. Check the spark plugs eve ry 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.

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

6. Check the engine idle RPM every 200 hours and adjust, if necessary. NEVER adjust engine RPM without a tachometer. Refer to Kohler Engine Operation and Service Manual.

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

hours. 70:30 mixture guards against corrosion.

8. Replace the in-line gas filter yearly.

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.

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MAINTENANCE

VACUUM PUMP

Refer to the Vacuum Pump Operation and Service Manual (P/N 86269820, PRV NO. 980129) for specific instructions.

Lubrication: We recommend that you use AEON PD Synthetic Blower Lubricant in both ends 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 which PROCHEM puts in the vacuum pump at the factory. 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.

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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.

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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 le v e l daily to assure the proper level. Use the illustration as a guide when checking the oil level. If the level has dropped, check for the source of leakage and repair.

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

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

every 500 hours thereafter.

4. Other Cat approved oil equivalents are: Mobil

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

WATER PUMP CLUTCH

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

Torque Value

Component Water pump

shaft bolt

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.

Inch pounds Foot pounds

300 25

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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 screws which hold the vacuum pump mount in place.

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

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

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

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

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

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

Torque Value

Component Inch/lbs Foot/lbs

Rear Engine Hub 300 25

Vacuum Pump Hub 300 25

Front Engine Pulley 216 18

4. Check for pulley groove wear, clean belts and pulley grooves, check for worn belts, proper belt tension, and pulley alignment after the first 25 hours and then again at 100 hours. Check for belt ride in the groove.

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MAINTENANCE

WATER PUMP DRIVE BELT

To tighten the water pump belt:

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

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

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

FLOAT VALVE (WATER BOX)

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

1. If the box is overflowing, remove, and check the float valve for debris or damage.

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

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

2. Disassemble the valve and check the piston and

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

WASTE TANK STRAINER BASKET

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

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.

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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.

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NITROGEN ACCUMULATOR

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

PRESSURE REGULATOR

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

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.

PEAK 86037220 05/22/08

MAINTENANCE

ENGINE COOLANT REPLACEMENT

Annually the coolant in the Prochem machine should be replaced. This coolant is an integral part of the heating system and needs to be maintained as any other working part of the system. We recommend that this procedure be accomplished by the following steps.

DRAINING COOLANT:

1. Reference Kohler Manual for specifi c coolant draining instructions. Drains are located at the bottom of the radiator and on the engine block next to the oil filter.

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

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

REPLACING COOLANT:

1. Fill radiator with 50/50 anti-freeze water mix.

2. Start unit and run on first notch.

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

with a 50/50 mix.

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

5. Fill radiator with 50/50 coolant mix.

6. Re-install radiator cap.

7. Shutdown unit.

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

4-8

Page 34

MAINTENANCE

SERVICE GENERAL ADJUSTMENTS

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

ENGINE SPEED

1. This unit uses a governor to set and maintain

engine speed. The engine speed is adjusted by pulling the throttle cable out to maximum travel for high speed operation. For lower temperature or vacuum setting, rotate knob clockwise two turns or as needed to obtain desired temperature and vacuum settings. Pushed in, the engine is at idle speed (1200 rpm). With throttle control pulled out, engine operates at maximum rpm (2800).

CHECK VALVE (SOLUTION OUTLET)

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

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

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

or replace Teflon seat if needed.

4. Clean the poppet and spring, inspect fo r 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-rin g 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 #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

PEAK 86037220 02/12/07

Page 35

PACKING NUT ADJUSTMENT FOR CHEMICAL METERING 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.

CHEMICAL METERING VALVE

PACKING NUT

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.

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.

86265430 PRV NO. 05-008035

PEAK 86037220 02/02/08

4-10

Page 36

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 1200 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.

PEAK 86037220 05/22/0807

Page 37

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

PEAK 86037220 02/12/07

4-12

Page 38

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

4-13

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.

Engine temperature has exceeded 255°F, triggering the high temperature switch to shut the unit down.

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

waste tank float switch. Defective float switch in the waste tank. Oil pressure switch (located on engine), fuel shut-off solenoid (located on engine), high temperature switch (located on engine).

PEAK 86037220 02/12/07

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.

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

Repair or replace any broken electrical connections. Check switch for proper operation, replace as necessary.

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

Page 39

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. Engine coolant temperture has

exceeded 245-255°F, triggering the high temperature switch to shut the unit down.

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

waste tank. Defective 245-255°F engine coolant high-temperature shudown switch.

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

No ignition in the engine or engine is malfunctioning.

Flow restriction caused by hard water scaling.

Not enough water flow. Check jet size of tool.

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

Check switch for proper operaton. Replace as necessary.

Test switch. If necessary, replace. 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

PEAK 86037220 05/22/08

4-14

Page 40

FRAME

5-1

PEAK 86037220 01/12/08

Page 41

REF PART NO. PRV NO. QTY DESCRIPTION

1 86282850 790635 2 TRIM, SEAL 5/8” BULB, 1.5 2 86282840 790634 2 TRIM, SEAL 5/8” BULB, 16 3 86043940 791056 1 ASSY, RAD CLOSEOUT, PEAK NEW 4 86274000 70069 4 SCR, 3/8-16 X 3 HHCS GR5 5 86279510 87171 8 WASHER, 3/8 FLAT 6 86191570 01-000259 7 RECPT SNAPIN 1/4 TURNFAST 7 86055900 790985 1 PNL, REAR HOOD MTG, PEAK 8 86005770 57119 4 NUT, 3/8-16 HEX NYLOCK

9 86273180 00-000078 8 SCR, 1/4-20 X 1” HXHD BRD8 10 86273330 00-000286 4 SCR, CAP 1/4-20 X 2.75 HXHD 11 86270330 02-000066 15 FLATWASHER, 1/4 12 86233390 80887 2 CLAMP, 7/8 DIA “P” CUSHIONED 13 86043840 790793 1 ASSY, FRAME 14 86010780 87162 8 WASHER, 1/4 SPLIT LOCK 15 86046170 790961 1 BRKT, FUEL/LEFT HOOD MTG 16 86054600 790010 1 PNL, BELT GUARD, REAR 17 86057160 790437 1 BRKT, 1/8 ALUM COUPLER

18 86179620 790487 1 DIPSTICK, CAT PUMP OIL 5CP 19 86176170 64-950383 1 CABLE, RETAIN VAC PLG 800 20 86177210 03-000051 1 CLMP, CABL 7/16 ID 1/4 BLT 21 86005680 57047 2 NUT, 1/4-20 HEX NYLOCK

FRAME

SERIAL NO.

FROM NOTES:

1000141381

10010770000119

WAS 61410

WAS 790393

WAS 790099

WAS 790573

PEAK 86037220 01/12/08

5-2

Page 42

FRAME

2 9

5-3

PEAK 86037220 01/12/08

Page 43

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273180 00-000078 5 SCR, 1/4-20 X 1” HXHD GRD8

2 86010780 87162 2 WASHER, 1/4 SPLIT LOCK

3 86270330 02-000066 7 FLATWASHER, 1/4

4 86055130 790637 1 PNL, LFT HD SUP

5 86054450 61413 1 PNL, FRAME SUPPORT

6 86005680 57047 2 NUT, 1/4-20 HEX NYLOCK

7 86273330 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD

8 86054350 61403 1 PNL, FRNT HD PEAK, PC

9 86186740 500887 1 LABEL, MAIN 10 86276100 70597 2 SCR, 1/4-20 X 3/4 PPHMS BLK 11 86279400 87151 2 WASHER, 1/4 SPLIT LOCK BLK 12 86010760 87142 2 WASHER, .344 X .69 X .066 FLAT PLT 13 86233390 80887 1 CLAMP, 7/8 DIA “P” CUSHIONE D 14 86046180 790997 1 BRKT, CNTR HOOD PEAK 15 86186740 500887 1 LABEL, MAIN, PEAK, NEW 16 86189050 790464 2 NUT, WELL 1/4-20 HD 17 86191570 01-000259 6 RECEPT, SNAPIN 1/4 TURNFA

18 86273260 00-000216 2 SCR, CAP 1/4-20 X 1/2 FLTSO 19 86270990 57090 2 NUT, 10-32 HEX NYLO CK SS 20 86279340 87139 2 WASHER, 3/16 FLAT 21 86053020 791084 1 PNL, GRILLE, PEAK 22 86043900 791024 1 ASSY, FRONT HOOD PEAK

FRAME

SERIAL NO.

FROM NOTES:

1000141381 1000141381 1000141381 1000141381 1000141381

1000141381 1000141381 1000141381 1000141381

WAS 500784

PEAK 86037220 02/12/07

5-4

Page 44

FRAME

5-5

PEAK 86037220 01/12/08

Page 45

REF PART NO. PRV NO. QTY DESCRIPTION

1 86030810 61445 1 PANEL ASM, RT HD PEAK

2 86193550 00-000272 12 STUD, 1/4 TURN FAST

3 86193220 02-000268 12 SPLIT RING, RETAIN, 1/4 TRUN

4 86054560 61472 1 PNL, LWR FR

5 86179290 500875 1 LABEL, LWR FR PNL

6 86277730 790465 4 SCR, 1/4-20 X 2.75 BHCS BLK

7 86270330 02-000066 4 FLATWASHER, 1/4

8 86005680 57047 4 NUT, 1/4-20 HEX NYLOCK

9 86030800 61444 1 PANEL ASM, LEFT HD PEAK 10 86189660 58-700023 12 PAD, 1/4 TURN FAST, .188 THK 11 86027070 790999 1 ASSY, HD, PEAK, 1 PC

FRAME

SERIAL NO.

FROM NOTES:

1000141381

INCLUDES 2,3,10

PEAK 86037220 02/12/07

5-6

Page 46

SIDE PANEL

5-7

PEAK 86037220 02/12/07

Page 47

REF PART NO. PRV NO. QTY DESCRIPTION

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

2 86186820 790599 1 LABEL, WTR & VAC INLET BRKT

3 86043790 790596 1 ASSY, WTR & VAC INLET BRKT

4 86181360 12-800269 1 FTTG, BRB 1/2P X 5/8H BR

5 86188210 11-800354 1 NIP, 1/2 X 3/8 HEX BR

6 86179710 13-806008 1 DSC, 3/8F X 3/8FP

7 86180700 32064 1 END CAP, VAC INLET, 1 1/2

8 86178700 19-800075 1 CUP, OIL FILL 1/8P

SIDE PANEL

SERIAL NO.

FROM NOTES:

1000158501

PEAK 86037220 02/12/07

5-8

Page 48

CHEMICAL CONTROL PANEL

5-9

PEAK 86037220 02/12/07

Page 49

REF PART NO. PRV NO. QTY DESCRIPTION

1 86027720 61397 1 PNL, CHEM CNTRL

2 86186900 500771 1 LBL, CHEM CNTRL

3 86180360 12-8000 40 1 ELL, 1/8P X 1/4T BR

4 86055700 790910 1 PNL, CHEMICAL CONTROL

5 86186890 500692 1 LABEL, CHEM CNTRL PN

6 86181170 18-808513 1 FLOWMETER 1/8 FP

7 86181300 12-8000 93 3 FTG, BRB 1/8P X 5/16H

8 86180140 11-8000 14 1 ELL, STREET 1/8 BR

9 86297070 - 1 VALVE, 3-WAY BALL 1/8P 10 86247720 56032 1 NIPPLE, 1/8 CLOSE 11 86274290 70162 2 SCR, 10-32 X 3/8 PPHMS SS 12 86279470 87165 2 WASHER, #10 SPLIT LOCK 13 86189050 790464 2 NUT, WELL 1/4-20 HD 14 86273180 00-000078 2 SCR, 1/4-20 X 1” HXHD GRD8 15 86270330 02-000066 2 FLATWASHER, 1/4

16 86177660 12-800065 3 CONN, 1/8P X 1/4T 17 86195050 15-808106 2 VALVE, METER 1/8FP

CHEMICAL CONTROL PANEL

SERIAL NO.

FROM NOTES:

1000141381 1000141381 1000141381 1000141381

1000141381

QTY WAS 2 QTY WAS 1

PEAK 86037220 03/01/08

5-10

Page 50

CONTROL PANEL

5-11

PEAK 86037220 02/02/08

Page 51

REF PART NO. PRV NO. QTY DESCRIPTION

1 86056010 791075 1 PNL, INSTR PANEL, PEAK

2 86179410 791076 1 LBL, INSTR PANEL, PEAK

3 86186930 51387 1 LIGHT, WARNING, IDEC AP2M

4 86181930 36225 1 GAUGE, 0-1500 PSI

5 86181950 36227 1 GAUGE, VACUUM 30” HG

6 86181960 36229 1 GAUGE, TEMP, DATCON

7 86193850 730202 1 SWITCH, 4-WAY

8 86193760 32-900206 1 SW, RTRY W/BYPASS NON-ILL

9 86246890 54092 1 METER, 0-60 VDC HOUR 10 86255920 73811 2 STANDOFF, 3-32 X 1/2 HEX NYL 11 86175620 140654 1 BRKR, CIRCUIT, 25A 12 86175600 140624 2 BRKR, CIRCUIT, 15A 13 86186020 32-900174 1 KEYSWITCH 14 86180360 12-800040 1 ELL, 1/8P X 1/4T BR 15 86195050 15-808106 1 VALVE, METER 1/8FP 16 86177660 12-800065 1 CONN, 1/8P X 1/4T 17 86180380 12-800101 1 ELL, 1/4FP X 1/4 POLY BR

18 86180350 12-800035 1 ELL, 1/4FP X 1/4T BR 19 86176120 49-802518 1 CABLE, CHOKE 20 86194380 791096 1 CABLE, THROTTLE, PEAK 21 86298280 - 1 BRKR, CIRCUIT, 20A 22 86175680 140702 1 BRKT, WIKA MOUNTING 23 86182990 790587 1 HARN, WIRING PEAK 24 86027730 61411 1 PNL, INS CONTROL 25 86186910 500772 1 LBL, INSTRUMEN CNTRL 26 86176110 49-802505 1 CABLE, THROTTLE 27 86136310 57086 4 NUT, M5 HEX 28 86005610 57016 2 NUT, 7/8 DIA PUSH LOCK 29 86191740 35-900188 2 RELAY, ENG SHT DWN 30 86186940 790787 1 LIGHT, WARNING, AMBER, IDEC

CONTROL PANEL

SERIAL NO.

FROM NOTES:

1000141381 1000141381

1000141381

NOT SHOWN

PEAK 86037220 04/04/08

5-12

Page 52

ENGINE

SUPPLIED WITH ENGINE

SUPPLIED WITH

ENGINE

2 40 3

4 44

SUPPLIED WITH

ENGINE

8 43

SUPPLIED WITH

ENGINE

5-13

PEAK 86037220 02/12/07

Page 53

ENGINE

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86136270 57053 2 NUT, M6 HEX ZINC PLATED 2 86279140 87085 2 WASHER, M6 SPLIT LOCK DIN127B 3 86193580 790614 2 STUD. 6MM X 95MM 4 86182720 790622 2 GSKT, THERM, KHLR, 25HP 5 86184890 790594 1 HOSE, THERM ADPT TO HELICOIL 6 86177310 03-000248 6 CLAMP, HOSE #16 1-1/2 MIN 1-3/4 7 86181430 12-800367 1 FTG, BRB 1P X 1H BR 8 86173560 790581 1 ADAPTER, THERMOSTAT TOP AEGIS 9 86180880 790532 1 ENG, 25 HP KOHLER, AEGIS

10 86191260 790584 1 PULLEY, AEGIS WTR PMP

- OPEN - - - 12 86174950 44-802217 1 BELT, AX43 GOODYEAR MATCH 13 86006760 70305 2 SCR, 5/16-18 X 3/4 HHCS 14 86051510 790396 1 PLT, ENG MTG, PEAK 15 86010790 87163 2 WASHER, 3/8 SPLIT LOCK 16 86275190 70377 2 SCR, 3/8-16 X 1.25 HHCS SS 17 86005770 57119 6 NUT, 3/8-16 HEX NYLOCK 18 86279510 87171 20 WASHER, 3/8 FLAT 19 86274000 70069 2 SCR, 3/8-16 X 3 HHCS GR5 20 86179930 790606 3 EL, 90 DEG 1/8NPT X 1/4HB 21 86179920 790605 2 EL, 90 DEG 1/8 X 5/16HB 22 86176990 03-000065 2 CLAMP, HOSE #4 SST NOT SHOWN

23 86286150 34413 1 FILTER, AIR, KOHLER AEGIS 24 86282450 790611 1 HOSE, FUEL 1/4 X 16.5”

25 86282750 790609 1 HOSE, FUEL 5/16 X 13” 26 86006820 70385 4 SCR, 3/8-16 X 2.0 HHCS GR5 PLT 27 86181620 14-806574 1 FUEL FILTER 28 86043780 790593 1 ASSY, FUEL LINE BRKT 29 86184910 790612 1 HOSEBARB, 1/8MPT X 5/16H 45 BR 30 86182730 790626 3 GSKT, EXHST, KHLR 25HP 31 86049890 790540 1 MNFLD, ENG EXH, KOHLER 32 86191060 44-802245 1 PULL, 2TB58 33 86185350 44-802214 1 HUB, P1X1-1/8 34 86174780 140976 1 BELT, GY2/BX42 HY-T BANDED V 1000161261 WAS PART 44-802307 35 86005650 57031 2 NUT, 5/16-18 HEX 36 86279130 87083 2 WASHER, 5/16 SPLIT LOCK PLTD 37 86194770 790535 1 TUBE, EXH ENG TO VAC BOX 38 86270480 48052 1 KEY, 1/4 X 1/4 X 2 1/2 39 86273440 00-000340 3 SCR, MACH 5/16-18 X 1” GR8 40 86279070 87056 2 WASHER, M6 FLAT 41 86180940 34412 1 FILTER, OIL KOHLER AEGIS 42 86174460 42-902172 1 FILTER, B & S, FUEL

-- 86181670 344 17 1 FUSE, 30 AMP, ENG, AEGIS NOT SHOWN

-- 86192970 730 343 2 SPARKPLUG, KOHLER RV14YC NOT SHOWN

-- 86277890 70856 1 SCREW, M5-8 X 25 MM STL, ZNC

-- 86137300 870 84 1 WASHER, M5 SPLIT LOCK PLTD

-- 86254140 791 176 1 SOLENOID, KOH# 25-435-05-S NOT SHOWN 43 86194360 791178 1 THERMOSTAT, 190 DEG PEAK 44 86318100 - 1 THERMOSTAT, 205 DEGREES AEGIS 45 76177390 791166 4 CLMP, F.I., SAE 12, 1/4" HOSE 46 86177400 791167 4 CLMP, F.I., SAE 14, 5/16” HOSE 100153405 47 86180990 790556 1 FITTING, LOWER RAD HOSEO Y 100153405

- 98407380 - - KIT, T HERMOSTATS, 190/205 AEGIS

FROM

NOTES:

PRIMARY & SECONDARY FILTER

NOT SHOWN THROTTLE CLAMP SCR

NOT SHOWN THROTTLE CLAMP LOCK WASHER

PEAK 86037220 11/13/08

5-14

Page 54

VACUUM BLOWER

5-15

PEAK 86037220 08/20/08

Page 55

REF PART NO. PRV NO. QTY DESCRIPTION

86188600 52-501573 1 ELL, VAC REL VLV

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

86193230 04-000091 1 SPRING, VAC REL VLV

86279510 87171 7 WASHER, 3/8 FLAT

86271070 57114 2 NUT, 7/16-14 HEX

86175400 140618 1 BLWR, 3FLW, 4M, TI406

86191270 790585 1 PULL, VAC PMP, 4M TRI

86185390 790444 1 HUB, P1 X 1-1/4

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

9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24

OPEN - 86056810 790443 2 SPACER, BLOWER 86010790 87163 8 WASHER, 3/8 SPLIT LOCK 86277740 790467 4 SCR, 3/8-16 X 1.25 SHCS PLTD 86273420 00-000336 2 SCR, CAP 3/8-16 X 3 ALL THD 86005730 57111 2 NUT, 3/8-16 HEX 86051520 790442 1 PLT, BLOWER ADJUSTING 86275190 70377 4 SCR, 3/8-16 X 1.25 HHCS SS

86005770 57119 4 NUT, 3/8-16 HEX NYLOCK 86062290 70069 4 SCR, 3/8-16 X 3 HHCS GR5 86189310 790571 2 O-RING, 2.75 X 2.938 OD VITON 86188580 790572 1 NIPPLE, VAC OUTL 4M TRIFLOW 86179580 43-807074 1 DIAPHRAM, VAC REL VLV 86311600 - 1 WASHER, VAC REL VLV #4 VAC 86273320 00-000284 1 SCR, CAP 7/16-14 X 4 HXHD

VACUUM BLOWER

SERIAL NO.

FROM NOTES:

PEAK 86037220 08/20/08

5-16

Page 56

WATER PUMP

TO WATER BOX

TO FLOWMETER

TO CHEMICAL VALVE

5-17

PEAK 86037220 01/12/08

Page 57

REF PART NO. PRV NO. QTY DESCRIPTION

86174950 44-802217 1 BELT, AZ43 GOODYEAR MATCH

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

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

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

86249610 790610 1 BRKT, CLTCH, WTR PMP, 3CP CAT

6 86190490 11-800101 1 PLUG, 1/8P 7 86177660 12-800065 1 CONN, 1/8P X 1/4T 8 86190540 12-800029 1 PLUG, 1/4T BR

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

86241860 48099 1 KEY, .20 X .20 X 1.45, 3CP CAT

86190760 790559 1 PMP, WTR, 3CP, 3.6GPM

86190480 11-800069 1 PLUG, 1/2 SOCHD BR

86190520 11-800224 1 PLUG, 3/8 SOCHD BR

86005750 57113 2 NUT, 5/16-18 HEX NYLOCK

86278830 02-000143 6 WASHER, 5/16 FLAT PLTD

86276130 70601 2 SCR, 5/16-18 X 2.75 HHCS GR5

86043770 790544 1 ASSY, PMP ADJ BRKT

86180360 12-800040 1 ELL, 1/8P X 1/4T BR

86191780 52-809123 1 RETAIN, VALVE SPRING

86173750 52-809125 1 ADPT, CAT CHEM PMP

86191440 791173 1 PUMP, CHEM, PULSE, GP

86179920 790605 1 EL, 90 DEG 1/8 X 5/16 HB

86176990 03-000065 1 CLAMP, HO SE #4 SST

86181370 12-800278 1 FTTG, BRB 1 / 2P X 3/4H BR

86177020 03-000113 2 CLAMP, HO SE #12 SST

86180410 12-800225 1 ELL, 3/8 X 1/2T BR

86279130 87083 4 WASHER, 5/16 SPLIT LOCK PLTD

86195120 65248 1 VALVE CAP, 303 SST, OUTPUT

86279820 87240 1 WSHR, .328 ID X 1.00 OD X .119 ZNC

86273700 140644 1 BLT, 5/16-18 X 1, SOC, ZNC

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

86195100 65245 2 VALVE CAP, 303 SST, INPUT

86189290 65249 2 O-RING, DURO,.862ID X .103CS

33 34

86195110 65247 2

86173440 43-810105 1 86249220 65252 1 PLASTIC DISC

86179550 42-809047 1 DIAPHRAGM, CHEM PUMP

86194630 65250 1 PULSE PUMP, TOP COVER INLET

86191340 65253 1 PULSE PUMP, BODY

86192920 65246 1 SPACER RING, 303 SST

VALVE KIT, ASM, CHEM, PULSE PUMP O-RING, 1-5/8OD X 1-3/4 OD/40D VITON

WATER PUMP

SERIAL NO.

FROM NOTES:

1000151479

1000151479 1000151479

1000151479 WAS 42-809265 1000151479

1000151479

1000151479 1000151479 1000151479

WAS 41-809158

WAS 16-808237

WAS 16-808237 WAS 43-810079

WAS 42-809264

WAS 52-502053 WAS 52-502052

PEAK 86037220 3/12/09

5-18

Page 58

WATER PUMP

5-19

PEAK 86037220 02/12/07

Page 59

REF PART NO. PRV NO. QTY DESCRIPTION

1 86176520 42-809238 1 CAP, OIL FILLER 2 86189200 42-809239 1 O-RING, OIL FILL CAP 3 86195580 42-809249 1 WASHER, KEYHOLE M18

4 86024830 42-809381 1 SLINGER, BARRIER 5 86189210 42-809394 2 O-RING, BEARING CVR 6 OPEN - - 7 86024780 42-809402 1 O-RING, CRANK CVR 8 OPEN - - -

9 86190560 42-809404 2 PLUG, VALVE 10 86024810 42-809405 1 RETAINER, SEAL 11 OPEN - - 12 86024820 42-809407 1 RETAINER, PNLGR W/STUD 13 86190600 42-809408 1 PLUNGER 14 86192260 42-809409 1 SEAL, OIL CRANKCASE 15 86186090 42-809410 1 KIT, SEAL 16 86181970 42-902380 1 GAUGE, OIL LEVEL 17 86181800 43-807063 1 GASKET, OIL GAUGE

18 86286260 66-950441 - KIT, VLV CAT 3CP1140, 33258

WATER PUMP

SERIAL NO.

FROM NOTES:

ORDER 1 EACH

ORDER 1 EACH TO REPLACE ALL VALVES

PEAK 86037220 02/12/07

5-20

Page 60

VAC/HEAT EXCHANGER WITH SILENCER

5-21

PEAK 86037220 05/22/08

Page 61

VAC/HEAT EXCHANGER WITH SILENCER

REF PART NO. PRV NO. QTY DESCRIPTION

1 86279510 87171 15 WASHER, 3/8 FLAT 2 86181840 790039 1 GSKET, VAC HE BOX TO MUFFLER 3 86005770 57119 7 NUT, 3/8-16 HEX NYLOCK 4 86059270 790616 1 VAC MUFFLER 5 OPEN - - 6 86274910 70325 1 SCR, 5/16-18 X 1.25 HHCS GR5PLT 7 86270330 02-000066 22 FLATWASHER, 1/4 8 86010780 87162 22 WASHER, 1/4 SPLIT LOCK PLTD

9 86273180 00-000078 18 SCR, 1/4-20 X 1” HXHD GRD8 10 86051550 790578 1 PLT, BLNK CVR VAC HE 11 86043150 790388 1 ASSEMBLY, HEATER CORE SS 12 86177700 12-800282 2 CONN, 3/8P X 1/2T BR 13 86187210 790038 2 MANIFOLD, HEATER CORE 14 86190520 11-800224 4 PLUG, 3/8 SOCHD BR 15 86177260 03-000111 1 CLMP, HOSE #10 9/16 MIN 16 86181330 12-800161 1 FTTG, BRB 3/8P X 1/2H BR 17 86177060 03-000246 1 CLAMP, HOSE #8 SST

18 86181400 12-800345 1 FTTG, BRB 3/8P X 5/8H BR 19 86180220 11-800276 2 ELL, 3/8 BR 20 86182190 36238 1 GROM, 1/2IDX1-14OD 1/8G 5/16W 21 86051220 620023 1 PLT, HEATER CORE CV R, STL

22 86051230 620024 1 23 86181850 790050 3 GASKET, VAC HE CVR

24 86189720 790343 2 PAD, BTM VAC HTR CO RE 25 86189730 790423 2 PAD, REAR VAC HTR CORE 26 86272970 00-000064 14 RIV, 1/8 X 3/8 ALUM 27 86274000 70069 4 SCR, 3/8-16 X 3 HHCS GR5 28 86029780 790505 1 CORE, HTR COPPER 29 86051410 790051 6 PLT, NUT-VAC HE HSG 30 86049180 790064 1 HSG, VAC HE 31 86051490 790329 1 PLT, LOWER EXHAUST 32 86184410 730420 1 SEAL, 5.813 DIA., GRAPH, BRAID SQ 33 86051480 790328 1 PLT, UPPER EXHAUST 34 86051460 790121 1 PLT, VAC MUFFLER MT G 35 OPEN - - 36 86278830 02-000143 2 WASHER, 5/16 FLAT PLTD 37 86005750 57113 1 NUT, 5/16-18 HEX NYLOCK

38 86277680 70937 4 SCR, 1/4-20 X 1 1/4 HXHD GR8

PLT, HEATER CORE CVR FRONT, STL

SERIAL NO.

FROM

INCLUDES 20 & 22

1000161005 WAS 790330

NOTES:

PEAK 86037220 02/12/07

5-22

Page 62

HELI-COIL HEAT EXCHANGER

TO RADIATOR

TO PRESSURE REGULATOR

5-23

PEAK 86037220 02/12/07

Page 63

REF PART NO. PRV NO. QTY DESCRIPTION

86181430 12-800367 2 FTTG, BRB 1 P X 1H BR

86177310 03-000248 4 CLMP, HOSE #16 1-1/2 MIN 1-3/4

86181420 12-800361 2 FTTG, BRB 3 / 4P X 1H BR

86180260 11-800401 1 ELL, 3/4 ST BR

86180990 790556 1 FITTING, LOWER RAD HOSE Y

86180430 12-800326 2 ELL, 3/4P X 1/2T BR

86005770 57119 2 NUT, 3/8-16 HEX NYLOCK

86279510 87171 4 WASHER, 3/8 FLAT

86275860 70554 2 SCR, 3/8-16 X 3.5 HHCS GR5 PLTD

86046060 790445 1 BRKT, RIGHT HOOD MTG

86191570 01-000259 1 RECPT, SNAPIN 1/4 TURNFAST

86048290 57-520073 1 HE, HELI-COIL

86177560 15-808073 1 COCK, DRN 1/4P X 1/4 HOSE ELL

86180000 31093 1 ELBOW, ¾” 45° BRASS ST

86197360 31016 1 ELBOW, 1/4NPT STREET

86233410 81270 1 CLAMP, 3/4 DIA CUSHION .406 DIA

HELI-COIL HEAT EXCHANGER

SERIAL NO.

FROM NOTES:

PEAK 86037220 02/12/07

5-24

Page 64

SOLUTION MANIFOLD

TO ELBOW ON TOP OF SECOND

HEAT EXCHANGER CORE

TO CHEMICAL PRIME

5-25

PEAK 86037220 05/22/08

Page 65

REF PART NO. PRV NO. QTY DESCRIPTION

1 86180410 12-800225 1 ELL, 3/8P X 1/2T BR

2 86175920 11-800118 1 BUSH, 3/8 X 1/8 BR

3 86192490 34-903019 1 SENDER, TE MP 140-320 DEG

4 86180420 12-800261 1 ELL, 1/8P X 1/4T 45 DEG

5 86187220 790324 1 MANIFOLD, SOLUTION

6 86180420 12-800261 1 ELL, 1/8P X 1/4T 45 DEG

7 86177660 12-800065 1 CONN, 1/8P X 1/4T

8 86274750 70270 4 SR, 1/4-20 X 3/4 HHCS PLTD

9 86010780 87162 4 WASHER, 1/4 SPLIT LOCK

10 86190520 11-800224 1 PLUG, 3/8 SOCHD BR 11 86272720 11-800345 1 PLG, 1/4 SOCHD BRASS 12 86247680 56015 1 NIPPLE, 1/4 HEX 13 86002450 22015 1 COUPLER, 1 / 4 QD 14 86192210 14-806549 1 SCREEEN, CHECK VALVE 15 86195030 15-808094 1 VALVE, CHECK 16 86192210 14-806549 1 SCREEN, CHECK VALVE 17 86189260 43-810053 1 O-RING 18 86189230 43-810008 1 O-RING 19 86192390 16-808223 1 SEAT, CHK VLV ASSY 20 86194250 16-808225 1 TEFLON SEAT 21 86190910 16-808226 1 POPPET, CHK VLV ASSY 22 86193260 16-808224 1 SPRING 23 86189270 43-810079 1 O-RING, 7/8 ID 1-1/16 OD 24 86176350 16-808222 1 CAP

SOLUTION MANIFOLD

SERIAL NO.

FROM NOTES:

1000141381

WAS 11-800206

PEAK 86037220 05/22/08

5-26

Page 66

WATER BOX

PART OF

ITEM 1

REAR

TO WATER INLET

5-27

PEAK 86037220 05/22/08

Page 67

REF PART NO. PRV NO. QTY DESCRIPTION

1 86195060 15-808110 1 VALVE, FLOAT

2 86270770 57006 2 NUT, 1/4-20 HEX

3 86056660 790411 1 ROD, FLOAT (1/4-20 X 4”) SS

4 86174540 19-807014 1 BALL, FLOAT

5 86181360 12-800269 3 FTTG, BRB 1/2P X 5/8H BR

6 86177060 03-000246 6 CLAMP, HOSE #8 SST

7 86190480 11-800069 2 PLUG, 1/2 SOCHD BR

8 86181370 12-800278 1 FTTG, BRB 1/2P X 3/4H BR

9 86177020 03-000113 2 CLAMP, HOSE #12 SST

10 86180570 31098 1 ELL, STREET 1/2 BR 11 86180250 11-800361 1 ELL, 1/2 BR 12 86188180 11-800300 1 NIP, 1/2 X CL 13 86193440 14-806540 1 STRAINER, SUC END 1/2FP 14 86189780 00-000268 2 SCR, CAP 1/4-20 X 2.75 HXHD 15 86270330 02-000066 2 FLATWASHER, 1/4 16 86005680 57047 2 NUT, 1/4-20 HEX NYLO CK 17 86031950 75436 1 TANK, WATER BOX

18 86046550 11-800432 1 CAP, WATER BOX 19 86195340 15-808075 1 VLV, TEMP REL 145 DEG 20 86180420 12-800261 1 ELL, 1/8P X 1/4 T, 45 DEG 21 86189010 52-501706 1 NUT, FLOAT VALVE

86309160 - 1 BDY, FLOAT VALVE WAS 16-808217

86308950 - 1 SCR, HHSS, M5 X 20MM, SS WAS 00-000337

86309140 - 1 ARM, PIVOT-FH VALVE WAS 16-808216

24 25 86189870 16-808219 1 PISTON, FH VLV 26 86192380 16-808164 1 SEAT, FLOAT VLV 27 86024750 94028 1 NUT, M5 HEX NYLOCK SS

WATER BOX

SERIAL NO.

FROM NOTES:

WAS 57090

PEAK 86037220 12/12/08

5-28

Page 68

PRESSURE REGULATOR

FROM UPPER

CONNECTION ON

FRONT HEATER

CORE IN VAC HE

ASSEMBLY

FROM LOWER

ELBOW ON HELICOIL

ASSEMBLY

TO PRESSURE GUAGE

OUTER

SEAT

INNER

SEAT

CAP

BODY

STEM

SPRINGS

86029480 - PRV NO. 15-808081

PRESSURE REGULATOR DETAIL

5-29

PEAK 86037220 02/12/07

Page 69

REF PART NO. PRV NO. QTY DESCRIPTION

86173460 790106 1 ACCUMULATOR, 250 PSI CAT 6026

86180360 12-800040 1 ELL, 1/8P X 1/4T BR

86175920 11-800118 1 BUSH, 3/8 X 1/8 BR

86180450 12-800347 1 ELL, 3/8P X 1/2T 45 DEG BR

86177060 03-000246 2 CLAMP, HO SE #8 SST

86184900 790601 1 HOSEBARB, 1/4MPT X 1/2H 45 BR

86191630 15-808081 1 REG, PRES W/O INNER SPRING

86188130 11-800151 1 NIP, 3/8 X 1/4 HX BR

86190480 11-800069 1 PLUG, 1/2 SOCHD BR

86180450 12-800347 1 ELL, 3/8P X 1/2T 45 DEG BR

86273330 00-000286 2 SCR, CAP 1/4-20 X 2.75 HXHD

86010780 87162 2 WASHER, 1/4 SPLIT LOCK PLTD

86270330 02-000066 2 FLATWASHER, 1/4

86187770 790901 1 MNFLD, PRESS EFI

14 15

86186040

16-808193

KIT, REPAIR PRESSURE REG

PRESSURE REGULATOR

SERIAL NO.

FROM NOTES:

PEAK 86037220 03/20/08

5-30

Page 70

WASTE TANK

5-31

8 9

9 11

PEAK 86037220 02/12/07

Page 71

WASTE TANK

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

1 86049690 790652 1 LID, 60G WST TNK

2 86043190 56-501793 1 STRAINER BOWL

3 86182710 790620 1 GSKT, PEAK WASTE TANK

4 86193430 14-806518 1 STRAINER, WST TANK 2-1/2”

5 86058550 790588 1 TNK, WST 60G PEAK, PC

6 OPEN - -

7 86180340 12-800031 3 ELL, 1/4P X 1/4T BR

8 86277830 00-000072 12 SCR, 3/8-16 X 2” HXHD

9 86279510 87171 24 WASHER, 3/8 FLAT

10 86249550 62986 12 PLATE, TRUCKMOUNT SHIPPING 11 86005770 57119 12 NUT, 3/8-16 HEX NYLOCK 12 86193870 791066 1 SWITCH, FLOAT, N.C. HARWIL 13 86190530 11-800402 2 PLUG, 1-1/4 HXHD PVC 14 86186860 46-802510 2 LATCH, DRAW 2-7/8 SST 15 86273020 67006 4 RIVET, 3/16 OD X 5/8 AL

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

FROM NOTES:

1000141381

QTY WAS 2

PEAK 86037220 05/22/08

5-32

Page 72

HOSE ACCESSORIES

5-33

PEAK 86037220 02/12/07

Page 73

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:

PEAK 86037220 02/12/07

5-34

Page 74

BATTERY-FLOOR MOUNT

5-35

PEAK 86037220 05/03/08

Page 75

REF PART NO. PRV NO. QTY DESCRIPTION

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

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

86174580 36-900056 1 BATTERY

86012060 - 1 BOX, BATTERY, MODIFIED

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

86270330 02-000066 8 FLATWASHER, 1/4

86010780 87162 8 WASHER, 1/4 SPLIT LOCK PLTD

86270770 57006 8 NUT, 1/4-20 HEX

86309890 - 1 BRKT, BATTERY BOX MTG

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

BATTERY-FLOOR MOUNT

SERIAL NO.

FROM NOTES:

PEAK 86037220 05/03/08

5-36

Page 76

AUTOMATIC PUMPOUT-OPTIONAL

5 4

9,12,15

5-37

PEAK 86037220 02/12/07

Page 77

AUTOMATIC PUMPOUT-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

1 86274150 70105 4 2 86273190 00-000132 2 3 86270770 57006 4 4 86010780 87162 4 5 86270330 02-000066 4 6 86177050 03-000176 4 7 86280680 09-805591 1 8 86184780 10-805484 1

9 86176420 12-800052 1 10 86181430 12-800367 1 11 86181440 12-800444 1 12 86195820 43-807008 1 13 86175720 50-502055 1 14 86188970 52-000123 1 15 86162270 52-501993 1 16 86191380 61-951306 1 17 86174260 61-951319 1

18 86195860 23719 1 19 86195910 72185 1

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

CORD ASM, CNCTN SIDE SWITCH ASSEMBLY

SERIAL NO.

FROM NOTES:

PEAK 86037220 02/12/07

5-38

Page 78

AUTOMATIC PUMPOUT-OPTIONAL

5-39

PEAK 86037220 05/22/08

Page 79

AUTOMATIC PUMPOUT-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273250

2 86178820

3 86192020

4 86273550

5 86273280

6 86005810

7 86010780

8 86279470

9 86024840 10 86174520 11 86024850 12 86193250 13 86174700 14 86179530 15 86187870 16 86182540 17 86182550

18 86192300 19 86192350 20 86189600 21 86189280 22 86175530 23 86195190 24 86050890 25 86024860 26 86274110 27 86181680 28 86175830 29 86192690 30 86191550 31 86182810 32 86024870 33 86194640 34 86176020 35 86178810 36 86045790 37 86024880

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

00-000210 52-502064 00-000312 00-000399 00-000241

57245 87162

87165 04-000312 04-000334 04-000335 04-000342 52-502061 16-808241 40-902151 43-807117 43-807118 43-810091

43-810100 43-810101 43-810106 45-801927 49-876301 50-502025 50-502026

70094 11-800504 52-501828 52-501829 52-501914 52-501915 52-501921 52-501934 52-501950 52-502062 56-502428 52-501821

4 SCR, 1/4-20 X 3/4 SOCHD 1 CVR, OUTLET WST PMP-OUT 8 SCR, CAP 1/4 X 1 SOCHD 1 SCR, CAP 1/4 X 1 3/8 SOC 8 SCR, CAP 10-32 X 2 SOCHD SS 8 NUT, 1/4-20 HEX NYLOCK SS 1 WASHER, 1/4 SPLIT LOCK 8 WASHER, #10 SPLIT LOCK 1 RING, RETAIN EXT 1/2 2 BALL, NYL ID 2 RING, SNAP 1-7/8D 1 SPRING, PUMP-OUT BALL PRESS 1 BDY, INLET WST PMP-OUT 1 DIAPH, WST TNK PMP-OUT 1 MOTOR, 1/8HP 12V 1 GSKT, CVR TOP PMPOUT 1 GSKT, CVR SD PMPOUT

1 SEAL, PUMPOUT SHFT 1 SEAL PUMPOUT CAM 1 O-RING, 800/1000 .072 4 O-RING, 1-13/16 ID X 2 OD HDWP 4 BRG, SHFT PUMP-OUT 1 VENT, UPR SHFT BRNG HSG 1 PL, CVR TOP PUMP-OUT 1 PL, CVR SD PUMP-OUT 8 SCR, 1/4-20 X 1/2 SHCS SS 1 GA, FLOW SIGHT 3/8 NPT 1 BTM, PLNGR WST TNK PMP-OUT 1 SHT, 3/4” STROKE WST TNK 1 RD, CONNECT WST PMP-OUT 1 GUIDE, PLNGR WST PUMP-OUT 1 PIN, WRIST PUMP-OUT 1 TOP, PLNGR PUMP-OUT 1 BUSH, THREADED 1 CVR, INLET WST PMP-OUT 1 BRKT, PMP-OUT SW/CCT BRKR 1 TOP, WST TNK PUMP-OUT

SERIAL NO.

FROM NOTES:

PART OF 31 INCL. 32, 18, 30

PEAK 86037220 05/22/08

5-40

Page 80

WAND-TITANIUM SIX JET-OPTIONAL

5-41

PEAK 86037220 02/12/07

Page 81

WAND-TITANIUM SIX JET-OPTIONAL

REF PART NO. PRV NO. DESCRIPTION

1 86273310 00-000282 SCR, CAP 1/4-20 X 1 1/4 SOC 2 86192030 00-000317 SCR, CAP 10-32 X 1 1/4 SOCH 3 86006680 70228 SCR, 10-32 X 1/4 PPHMS SS 4 86270990 57090 NUT, 10-32 HEX NYLOCK SS 5 86264910 04-000093 TIE, CABLE 13”

- OPEN - - 7 86184270 10-805504 HOSE, 3/16 X 44-1/2 8 86247680 56015 NIPPLE, 1/4 HEX 9 86190180 11-800206 PLUG, 1/8 SOCHD BR

10 86177650 12-800060 CONN, 1/4P X 1/4T BR 11 86177710 12-800322 CONN, 1/8P X 1/4T COMP BR 12 86005580 56012 NIPPLE, 1/4 FPT QD 13 86193490 14-806512 STRAINER, JET 50 MESH 14 86194450 17-803018 TIP, SPRAY 9501 X 1/8P SST 15 86195570 17-803006 WASHER, NYLON 16 86177860 17-803010 CONN, 1/4P X 11/16-16M 17 86177870 17-803036 CONN, 1/4FP X 11/16-16F BR 18 86194580 17-803078 TIP, SPRAY 8001 SST 1/8 VJET 19 86194650 52-501619 TRIGGER, WD VALVE 20 86174680 52-502008BK BODY, WD HDL, 2” TB, BK 21 86198180 52-502009 HOLD DN-WD HDL 2” TUBE 22 86187610 52-502057 MANFOLD, LEFT 23 75187620 52-502058 MANIFOLD, RIGHT 24 86174060 56-502548 ASSY, MNFLD S-BEND 25 86285440 56-502534 WD & HD, TITANIUM 26 86174120 61-950496 ASSY, EXTRACTOR VALVE 27 86193360 16-808189 STEM, EXTRACTOR VALVE 28 86193200 16-808190 SPRING, EXTRACTOR VALVE 29 86192410 16-808228 SEAT, EXTRACTOR VALVE 30 86183160 16-808229 HLDR, VLV STEM-EXTRACTOR VL 31 86189510 43-810062 O-RING, .114 ID .254OD 32 86189520 43-810063 O-RING, .551ID .691OD 33 86174500 43-810064 BACK-UP, .250DIA 34 86174630 52-501590 BDY, EXTRACTOR VLV 35 86179250 48-941462 DEC, WD HD TITANIUM

- OPEN - -

SERIAL NO.

FROM

NOTES:

PEAK 86037220 12/27/06

5-42

Page 82

WAND-QUAD JET-OPTIONAL

9, 10

21, 22

19, 20

19, 24

23, 23A, 23B

5-43

PEAK 86037220 07/11/03

Page 83

REF PART NO. PRV NO. DESCRIPTION

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23

23A 23B 86194450 17-803018 TIP, SPRY 9501X1/8P SST

24 25 26 27 28 29 30 31 32 33 34

- 86186160

86285570 89238 WAND, TM, QJW (95015) PC 86285580 89239 WAND, TM, QJW (9502) PC 86285560 89237 WAND, TM QJW (9501) PC 86285540 89235 WAND, TM, QJW, (9501) NO DECAL 86005580 56012 NIPPLE, 1/4 FPT QD 86177860 17-803010 CONN, 1/4P X 11/16-16M 86195570 17-803006 WASHER, NYLON 86193490 14-806512 STRAINER, JET 50 MESH 86177870 17-803036 CONN, 1/4FP,11/16-16R BR 86247680 56015 NIPPLE, 1/4 HEX 86280020 09-805359 SLEEVE, WD HDL 9.5 86194650 52-501619 TRIGGER, WD VLV 86192030 00-000317 SCR, CAP 10-32X 1-1/4 SOCH 86270990 57090 NUT, 10-32 HEX NYLOCK SS 86174120 61-950496 ASSY, EXTRCTR VLV 86177650 12-800060 CONN, 1/4P X 1/4T BR 86183970 10-805387 HOSE, 3/16 X 43-1/2 (1/8P X 1/4) 86265730 04-000053 TIE, CABLE 8” WHT 86273310 00-000282 SCR, CAP 1/4-20 X 1-1/4 SOC 86198160 52-501569 HOLD DOWN, WD HDL 86182840 791150 HANDLE GRIP ASSEMBLY 1.75”

OPEN 86190180 11-800206 PLUG, 1/8 SOCHD BR 86043300 56-501966 ASSY, L S-BEND MNFLD 86273450 00-000347 SCR, CAP 10-24 X1/4 SOCHD 86279470 87165 WASHER, #10 SPLIT LOCK 86194400 17-803001 TIP, SPRY 95015X1/8P SST 86194410 17-803002 TIP, SPRY 9502X1/8P SST

86043310 56-501986 ASSY, RT S-BEND MNFLD 86177710 12-800322 CONN, 1/8PX1/4T COMP BR 86174030 56-501967 ASSY, S-BEND MNFLD 86183160 16-808229 HOLDER, VLV STEM-EXTRCTR VL 86189520 43-810063 O-RING, .551 ID .691 OD 86192410 16-808228 SEAT, EXTRCTR VLV 86193360 16-808189 STEM, EXTRCTR VLV 86174500 43-810064 BACK-UP, .250 DIA 86189510 43-810062 O-RING, .144 ID .254 OD 86193200 16-808190 SPRING, EXTRCTR VLV 86174630 52-501590 BODY, EXTRCTR VLV 86179020 48-941186 DECAL, WD HD (CAST SS)

66-808169

KIT, REP-WD VLV

WAND-QUAD JET-OPTIONAL

SERIAL NO.

FROM

89237

NOTES: COMPLETE COMPLETE COMPLETE COMPLETE

89238 89239

89235 (NO DECAL)

NOT SHOWN NOT SHOWN

INCLUDES PARTS

27-29 & 31-33

PEAK 86037220 02/12/07

5-44

Page 84

WAND- TRI JET- OPTIONAL

25 26 28

27 29

9, 10

20, 21, 22

19, 19A, 19B

5-45

PEAK 86037220 02/12/07

Page 85

REF PART NO. PRV NO. DESCRIPTION

86285520

86285510

86285530

86005580

86177860

86195570

86193490

86177870

86247680

86280020

86194650

86192030

86270990

86174120

86177650

86183970

86265730

86273310

86198160 17 86182840 791150 HANDLE GRIP ASSEMBLY 1.75 18

OPEN

86194410

19A

86194400

19B

86194520 20

86274290 21

86279470 22

86270800 23

86187700 24 86190180 11-800206 PLUG, 1/8 SOCHD BR

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

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

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

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

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

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

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

56-501739 MANIFOLD, WD TRI-JET

WAND- TRI JET-OPTIONAL

SERIAL NO.

FROM

NOTES:

COMPLETE COMPLETE COMPLETE

89233 89232 89234

25 86183160 16-808229 26

86189520

86192410

86193360

86174500

86189510

86193200

86179020

- 86186160 66-808169 KIT, REP-WD VLV

43-810063 O-RING, .551 ID .691 OD 16-808228 SEAT, EXTRCTR VLV 16-808189 STEM, EXTRCT VLV 43-810064 BACK-UP, .250DIA 43-810062 O-RING, .114ID .254OD 16-808190 SPRING, EXTRCTR VLV 52-501590 BODY, EXTRCTR VLV

48-941166 DECAL, WD HD

HOLDER, VLV STEM-EXTRCTR VL

PEAK 86037220 02/12/07

NOT SHOWN

INCLUDES PARTS

25-27 & 29-31

5-46

Page 86

STAIR TOOL-OPTIONAL

20 21

5, 5A

9, 10

15, 15A

5-47

PEAK 86037220 02/12/07

Page 87

REF PART NO. PRV NO. DESCRIPTION

1A 1B

2 3 4 5

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

57090 NUT, 10-32 HEX NYLOCK SS

61-950496 ASSY, EXTRCTR VLV

56015 NIPPLE, 1/4 HEX

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

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

NOT SHOWN

COMPLETE COMPLETE

NOT SHOWN

INCLUDES PARTS 16-19 & 20-22

PEAK 86037220 02/12/07

5-48

Page 88

UPHOLSTERY TOOL-OPTIONAL

22 24

25 26

5-49

PEAK 86037220 02/12/07

Page 89

REF PART NO. PRV NO. QTY DESCRIPTION

86285260

86280240

86178660

86184670

86179720

86178550

86273370

86193050

86176080

86194590

86174140

86005580

86177860

86195570

86193490

86177870

86188320

86178520

86177660

86178630

86183160

86189520

86192410

86193360

86174500

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

INCLUDES PARTS 20-22 &

NOTES:

COMPLETE

INCLUDES PARTS

20-26, 28, & 31- 37

NOT SHOWN NOT SHOWN

24-26

PEAK 86037220 02/12/07

5-50

Page 90

SHELF ASSEMBLY-OPTIONAL

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

DIMENSIONAL DATA

50 1/8

5-51

PEAK 86037220 02/12/07

Page 91

SHELF ASSEMBLY-OPTIONAL

SERIAL NO.

REF PART NO. PRV NO. QTY DESCRIPTION

- 86285410 65-950392 1 VAN STORAGE UNIT COMPLETE 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, SHELF GRAY 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.

FROM NOTES:

INCLUDES PARTS 6,7 & MOUNTING HARDWARE

PEAK 86037220 05/22/08

5-52

Page 92

WATER TANK, DUAL WITH DEMAND PUMP-OPTIONAL

4 3 2

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

TO DEMAND PUMP

5-53

PEAK 86037220 02/12/07

Page 93

WATER TANK, DUAL WITH DEMAND PUMP-OPTIONAL

REF PART NO. PRV NO. QTY DESCRIPTION

86041730

86041710

86048310

86279510

86010790

86277830

86176400

86180170

86181370

86177020

86280590

86194120

86043320

86030990

86190500

86190170

86005770

86285190

66-945260 66-945265 50-501774

87171

87163 00-000072 11-800432 11-800041 12-800278 03-000113 09-805456 11-800085 56-502000 58-500661 11-800168 50-500511

57119

41458

- TANK, DUAL SADDLE W/DMD PUM P

- SINGLE SADDLE TANK W/DMND PMP

4 HOLD DOWN, SADDLE TANK GRAY 16 WASHER, 3/8 FLAT 16 WASHER 3/8 SPLIT LOCK 16 SCR, 3/8-16 X 2’ HXHD

4 CAP, WATER BOX

2 ELL, STREET 1/2 BR

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

4 CLAMP, HOSE #12 SST

1 HOSE, WTR 3/4 X 96”

1 TEE, 1/2 BRASS

2 ASSY, BASE SADDLE TANK GRAY

2 MOLDING, WATER TANK

2 PLUG, 1/2 BRASS HXHD

1 PLATE, INSTALL MT

9 NUT, 3/8-16 HEX NYLOCK

1 SHLR, CHEM, 10-GAL JUG

SERIAL NO.

FROM

NOTES:

COMPLETE COMPLETE

NOT SHOWN

PEAK 86037220 02/12/07

5-54

Page 94

WATER TANK-DEMAND PUMP-OPTIONAL

5-55

PEAK 86037220 02/12/07

Page 95

WATER TANK - 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 16

86006760 86279130 86278830 86177020 86280290 86280420 86280550 86181400 86179630 86180900 86190740 86186120 86180210 86191390 86186030 86177060

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, WATER 5/8 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

PEAK 86037220 02/12/07

5-56

Page 96

AUXILIARY WATER TANK WITH PUMP

2X 16.8

2X 18.7

4X Ø.406

MOUNTING DETAIL

30.0 WIDE

Vehicle Floor

5-57

58.6 LENGTH

30.0 TALL

PEAK 86037220 02/12/07

Page 97

AUXILIARY WATER TANK WITH PUMP

REF PART NO. PRV NO. QTY DESCRIPTION

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

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

86270330 02-000066 4 FLATWASHER, 1/4

86177020 03-000113 4 CLAMP, HOSE #12 SST

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

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

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

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

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

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

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

86176400 11-800432 1 CAP, WATER BOX

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

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

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

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

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

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

86180900 14-806553 1 FILTER, DEMAND PUMP

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

86192380 16-808164 1 SEAT, FLOAT VLV TM

86173820 16-808216 1 ARM, PIVOT-FH VLV

86174610 16-808217 1 BDY, FLOAT VLV

86174540 19-807014 1 BALL, FLOAT

86190740 41-905049 1 PMP, WTR BOOSTER FLOJET 2

86190170 50-500511 4 PLATE, INSTALL MT

86189010 52-501706 1 NUT, FL OAT VALVE

86028860 52-800314 1 PISTON, FLOAT VLV PISTON

86181150 54-501715 1 FLOAT ROD, TM

86186120 48-809423 1 KIT, PORT DEMAND PUMP

86180010 31100 1 ELBOW, 1.5 STREET PVC MP X FP

86270770 57006 2 NUT, 1/4-20 HEX

86270990 57090 1 NUT, 10-32 HEX NYLOCK SS

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

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

86010780 87162 4 WASHER, 1/4 SPLIT LOCK PLTD

86279510 87171 8 WASHER, 3/8 FLAT

86031000 790617 1 TANK, FRESH WATER 70GAL

86057170 790666 2 STRAP, WTR TNK HOLD DOWN

86177060 03-000246 3 CLAMP, HOSE #8 SST

SERIAL NO.

FROM NOTES:

PEAK 86037220 09/06/07

5-58

Page 98

HOSE REEL-OPTIONAL

MOUNTING DETAIL

Vehicle Floor

OVERALL

47" TALL 44-1/2" DEEP

2 3

5-59

PEAK 86037220 02/12/07

Page 99

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:

PEAK 86037220 02/12/07

5-60

Page 100

WIRING DIAGRAM

FUTURE USE

EXTRA WIRE FOR

FOR PUMPOUT

FEMALE CONNECTOR

#86181960

PRV NO. 36229

TEMPERATURE GAUGE

#86192490

#86246890

HOUR METER

PRV NO. 54092

TEMPERATURE SENDER

PRV NO. 34-903019

BLK 16Ga

HIGH ENGINE

TEMPERATURE LIGHT

#86186930-PRV NO. 51387

#86191740

BLK 16Ga

LOCATED ON

SOLUTION MANIFOLD

#86186930

PRV NO. 51387

WASTE TANK FULL LIGHT

WHT/GRN 16Ga

87a

WIRE)

SENDER

ORANGE

TO KOHLER

(ON ENGINE

TEMPERATURE

87a

SWITCH

TO KOHLER

(ON ENGINE

GREEN WIRE)

OIL PRESSURE

PRV NO. 35-900188

SHUTDOWN RELAY

N.C.

86027950

PRV NO. 790491

N.C. N.C.N.O.

#86193850

PRV NO. 730202

86260090

#86191740

PRV NO. 35-900188

SHUTDOWN RELAY

PUMPOUT SWITCH

PRV NO. 790492

86028850

MAIN CIRCUIT BRKT

PRV NO. 790493

AMP

#86175620-PRV NO. 140654

PUMP SWITCH

WATER PRESSURE

AMP

ENGINE CIRCUIT BRKT

#86175600-PRV NO. 140624

#25-155-06

PART #42-902318

ENGINE CONNECTOR

N.O.

N.O. CONTACT BLOCKS

#86193750-PRV NO. 32-900205

AMP

PUMP-OUT CIRCUIT BRKT

#86175600-PRV NO. 140624

WATER PUMP CIRCUIT BRKT

#86230070-PRV NO. 140634

PRV NO. 790152 86028960

CLUTCH

WATER PUMP

#86186020

IGNITION SWITCH

PRV NO. 32-900174

AMP

#86176930

PRV NO. 790579

FUEL PUMP CORD

STARTER

USE ENGINE

FOR GROUNDING

ENGINE

MOUNTING BOLTS

5-61

BATTERY

#86174580

NEG POS

PRV NO. 36-900056

GRN

WHT

BLK

N.C.

N.O.

COM

PEAK 86037220 02/12/07

RED/WHT

ORG/WHT

RED/WHT

WHT/GRN 16Ga

BLK

WHT

WHT/GRN

REAR OF

CONNECTORS

BLK

GRN

WHT

GRN

SWITCH

ENGINE SHUTOFF

WASTE TANK

PUMP

EXTERNAL FUEL