MOBILE CLEANING UNIT
Operating Instructions (ENG)
MODELS: PEAK GTX
1.001-132.0
Read instructions before operating the machine.
86325860 - AY 08/29/13
Left intentionally blank
Machine Data Log / Overview
Welcome…and congratulations on the purchase of your Mobile Cleaning Unit. This instruction manual is a guide for operating and servicing your unit. Read this manual completely before installing or operating this unit. This unit offers you personal convenience. All of your instrumentation and controls have been positioned to give you easy access for operation and daily maintenance.
Proper operation and service are essential to the efficient functioning of this unit. When maintained correctly, this unit will have a long, trouble-free life.
The service methods described in this manual are explained in such a manner that servicing may be performed accurately and safely. Proper service varies with the choice of procedure, the skill of the mechanic, and the tools or parts available. Before attempting any repair, make certain that you are thoroughly familiar with this equipment and are equipped with the proper tools. Any questions pertaining to operating or servicing this unit should be directed to your nearest dealer.
THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCORDANCE WITH THE PRESCRIBED INSTALLATION PROCEDURES.
Information in this document is subject to change without notice and does not represent a commitment on the part of PROCHEM.
Warranty Registration
Thank you for purchasing a Prochem product. Warranty registration is quick and easy.
Your registration will allow us to serve you better over the lifetime of the product.
To register your product go to : www.prochem.com/WarrantyRegistration.aspx
For customer assistance: 1-800-776-2436
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Table of Contents
Machine Data Log / Overview . . . . . . . . . . . . . . . . . 1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Receiving Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4
Acceptance of Shipment . . . . . . . . . . . . . . . . . . . . . 4 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . 5
Safety
IMPORTANT SAFETY INSTRUCTIONS. . . . . . . . . 6
Hazard Intensity Level . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation
Dealer Responsibility . . . . . . . . . . . . . . . . . . . . . . . 10 Vehicle Requirements . . . . . . . . . . . . . . . . . . . . . . 10 Lifting Unit Onto Vehicle . . . . . . . . . . . . . . . . . . . . 11 Positioning Unit In Vehicle . . . . . . . . . . . . . . . . . . . 11 Bolting Down Unit And Waste Tank. . . . . . . . . . . . 11 Layout with 60 Gallon Waste Tank . . . . . . . . . . . . 12 Layout with 100 Gallon Waste Tank . . . . . . . . . . . 13 Waste Tank To Console Connection . . . . . . . . . . . 14 Fuel Pump Assembly Installation. . . . . . . . . . . . . . 14 Van Bulkhead Installation . . . . . . . . . . . . . . . . . . . 15 Fuel Supply & Return Line Installation. . . . . . . . . . 16 Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . 17 Initial Operational Settings . . . . . . . . . . . . . . . . . . . 18
Operations
Technical Specifications . . . . . . . . . . . . . . . . . . . . 19 Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine Oil Requirements . . . . . . . . . . . . . . . . . . . . 20 Altitude Requirements . . . . . . . . . . . . . . . . . . . . . . 20 Chemical Requirements. . . . . . . . . . . . . . . . . . . . . 20 Water Requirements . . . . . . . . . . . . . . . . . . . . . . . 21 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vacuum System. . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Water Pumping and Heat Transfer System . . . . . . 26 Chemical Injection System. . . . . . . . . . . . . . . . . . . 28 Pre-Run Inspection / Setup . . . . . . . . . . . . . . . . . . 29 Priming the Chemical Pump . . . . . . . . . . . . . . . . . 30 Waste Pumpout (Optional). . . . . . . . . . . . . . . . . . . 30 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Upholstery Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 31 Shutdown and Daily Maintenance . . . . . . . . . . . . . 31 De-flooding operations. . . . . . . . . . . . . . . . . . . . . . 31 Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . 31 Winterizing Your Unit . . . . . . . . . . . . . . . . . . . . . . . 32 Removing Anti-Freeze From the Unit . . . . . . . . . . 33
Maintenance
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Key Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine Coolant System (Radiator) Maintenance. . 36
External Fuel Pump Maintenance . . . . . . . . . . . . . 36
Chemical Supply System Maintenance . . . . . . . . . 36
Heat Exchanger System Maintenance. . . . . . . . . . 36
Vacuum Pump Maintenance . . . . . . . . . . . . . . . . . 36
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Solution Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Solution Pump Clutch . . . . . . . . . . . . . . . . . . . . . . 39
Vacuum Inlet Filter (In Waste Tank) . . . . . . . . . . . 39
Vacuum Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 39
Vacuum Pump Drive Belts . . . . . . . . . . . . . . . . . . . 39
Solution Pump Drive Belt . . . . . . . . . . . . . . . . . . . . 40
Float Valve (Water Box). . . . . . . . . . . . . . . . . . . . . 40
Waste Tank Float Valve. . . . . . . . . . . . . . . . . . . . . 40
Waste Tank Strainer Basket . . . . . . . . . . . . . . . . . 40
Waste Tank Vacuum Inlet Filter. . . . . . . . . . . . . . . 40
Solution Screen (Outlet). . . . . . . . . . . . . . . . . . . . . 40
Check Valve (Outlet) . . . . . . . . . . . . . . . . . . . . . . . 40
Chemical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chemical And Temperature Control Valves. . . . . . 41
Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . 41
Vacuum Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
High Pressure Solution Hoses . . . . . . . . . . . . . . . . 41
Optional Waste Pump-Out . . . . . . . . . . . . . . . . . . . 41
Engine Coolant Replacement . . . . . . . . . . . . . . . . 41
General Service Adjustments . . . . . . . . . . . . . . . . 42
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check Valve (Solution Outlet) . . . . . . . . . . . . . . . . 42
Water Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chemical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Solution and Vacuum Pump Drive Belts . . . . . . . . 42
Packing Nut Adjustments For Chemical Valves. . . 43
Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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86325860 PEAK GTX PROCHEM |
Parts
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Side Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chemical Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Solution Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Vacuum / Exhaust Heat Exchanger and Silencer . 72
Helicoil Heat Exchanger . . . . . . . . . . . . . . . . . . . . 74
Helicoil Heat Exchanger . . . . . . . . . . . . . . . . . . . . 76
Solution Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Water Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
60 Gallon Waste Tank . . . . . . . . . . . . . . . . . . . . . 84
100 Gallon Waste Tank . . . . . . . . . . . . . . . . . . . . 86
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Battery Floor Mount . . . . . . . . . . . . . . . . . . . . . . . 90
Chemical Jug Floor Mount . . . . . . . . . . . . . . . . . . 92
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Hose Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table of Contents
Options
Hose Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 98 Exhaust - Optional . . . . . . . . . . . . . . . . . . . . . . . 100 Heater Core - 3rd - Optional . . . . . . . . . . . . . . . . 102 Automatic Pumpout - Dual Diaphragm - Optional 104 Wand - Titanium Six Jet - Optional . . . . . . . . . . . 106 Wand - Ergo Titanium Six Jet - Optional. . . . . . . 108 Wand - Quad Jet - Optional . . . . . . . . . . . . . . . . 110 Wand - Tri Jet -Optional . . . . . . . . . . . . . . . . . . . 112 Stair Tool - Optional . . . . . . . . . . . . . . . . . . . . . . 114 Upholstery Tool - Optional . . . . . . . . . . . . . . . . . 116 Shelf Assembly - Optional. . . . . . . . . . . . . . . . . . 118 Water Tank Dual with Demand Pump - Optional 120 Water Tank - Demand Pump - Optional . . . . . . . 122 Auxiliary Water Tank with Pump-Optional . . . . . 124 Hose Reel - Optional. . . . . . . . . . . . . . . . . . . . . . 126 Motorized Hose Reel - Tank - Optional. . . . . . . . 128 Motorized Hose Reel - Optional . . . . . . . . . . . . . 130 E Z - Charge Water Softener - Tank & Tray -
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 E Z - Charge Water Softener - Filter - Optional . 134 E Z - Charge Water Softener - Brine System -
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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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 common carrier immediately.
2.Check your equipment and packing list. The standard cleaning unit should arrive equipped with the following items (unless otherwise specified) and any optional accessories which were ordered:
Equipment List
1.Console.
2.Waste tank
3.Fuel pump assembly
4.100 ft. of 2" vacuum hose.
5.1 vacuum hose connector.
6.100 ft. of 1/4" solution 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.
11.Hose clamps for vacuum hoses.
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86325860 PEAK GTX PROCHEM |
This manual contains the following sections:
•How to Use This Manual
•Safety
•Installation
•Operations
•Maintenance & Service
•Parts List
The HOW TO USE THIS MANUAL section will tell you how to find important information for ordering correct repair parts.
Parts may be ordered from authorized dealers. When placing an order for parts, the machine model and machine serial number are important. Refer to the MACHINE DATA box which is filled out during the installation of your machine. The MACHINE DATA box is located on the inside of the front cover of this manual.
Model:
Date of Purchase:
Serial Number:
Dealer:
Address:
Phone Number:
Sales Representative:
The model and serial number of your machine is located approximately where shown.
The SAFETY section contains important information regarding hazardous or unsafe practices for this machine. Levels of hazards are identified that could result in product damage, personal injury, or severe injury resulting in death.
How to Use This Manual
The INSTALLATION section contains information on how to properly install the unit in your vehicle.
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
•Solution Pump
•Drive Belts, Pulleys & Hubs
•Chemical Pump
•Hoses
•Vac / Exhaust Heat Exchanger
•General Service Adjustments
•Machine 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.
•QTY – column lists the quantity of the part used in that area of the machine.
•DESCRIPTION – column is a brief description of the part.
•SERIAL NO. FROM – If this column has an (*) and a Reference number, see the SERIAL NUMBERS page in the back of your manual. If column has two asterisk (**), call manufacturer for serial number. The serial number indicates the first machine the part number is applicable to. The main illustration shows the most current design of the machine. When a boxed illustration is shown, it displays the older design.
•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 manual part number is located on the lower left corner of the front cover.
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Safety
IMPORTANT SAFETY INSTRUCTIONS
When using this machine, basic precaution must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
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!
Read the operator's manual before installing or starting this unit. Failure to adhere to instructions could result in severe personal injury or could be fatal.
Operate this unit and equipment only in a well-ventilated area. Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality. DO NOT run this unit in an enclosed area. DO NOT operate this unit where the exhaust may enter any building doorway, window, vent, or opening of any type.
Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings away from sparks or flames. Never carry any gasoline or flammable material in the vehicle. Fumes may accumulate inside the vehicle and ignite, causing an explosion.
DO NOT store any type of flammable material in the vehicle.
This unit must be operated with the vehicle or trailer doors open in order to ensure adequate engine ventilation.
DO NOT operate engine if gasoline is spilled. Avoid creating any ignition until the gasoline has been cleaned up. Never use gasoline as a cleaning agent.
DO NOT place hands, feet, hair, or clothing near rotating or moving parts. Avoid any contact with moving parts! Rotating machinery can cause injury or fatality.
Never operate this unit without belt guards 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.
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86325860 PEAK GTX PROCHEM |
Safety
DO NOT leave the vehicle engine running while operating this unit.
Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.
Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. When disconnecting the battery, ALWAYS disconnect the negative (-) terminal FIRST.
DO NOT smoke around the unit. Gas fumes may accumulate and be ignited. The battery is also extremely flammable. This will help to 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 help to prevent leakage and ensure that the hose is not punctured by vehicle vibration abrasion.
DO NOT exceed your vehicle's weight limit. The console with empty 60 gallon waste tank and accessories weighs approximately 1014 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, to 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 solution pump and other vital components may be seriously damaged if this unit is permitted to operate dry without water. Running with out adequate water supply could damage solution pump. Ensure always to have an adequate water supply.
DO NOT operate this unit without the filter installed in the waste tank.
Keep your vehicle work area clean. Wands, stair tools, and other accessories must be securely fastened before driving the vehicle.
All high pressure hoses must be rated for 3000 PSI at 250°F. Thermoplastic hoses do not meet these specifications and should not be used. Severe burns and injury may result if the hoses do not meet these requirements.
The winterizing loop hose assembly, Part #86260700, is for winterizing use only. If used improperly, live steam may escape from this hose, causing it to whip around. Burns or injury may result.
Make certain that you receive complete training by the distributor from whom you purchased this unit. This unit uses high pressure and temperature. Improper or irresponsible use may result in serious injury. Do not modify this unit in any manner. Improper modification can cause severe personal injury or fatality.
CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
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Safety
The following symbols are used throughout this guide as indicated in their descriptions:
Hazard Intensity Level
There are three levels of hazard intensity identified by signal words - WARNING and CAUTION and FOR SAFETY. The level of hazard intensity is determined by the following definitions:
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which could result in minor personal injury or product or property damage.
FOR SAFETY: To Identify actions which must be followed for safe operation of equipment.
Report machine damage or faulty operation immediately. Do not use the machine if it is not in proper operating condition. Following is information that signals some potentially dangerous conditions to the operator or the equipment. Read this information carefully. Know when these conditions can exist. Locate all safety devices on the machine. Please take the necessary steps to train the machine operating personnel.
FOR SAFETY:
DO NOT OPERATE MACHINE:
Unless Trained and Authorized.
Unless Operation Guide is Read and understood.
In Flammable or Explosive areas.
In areas with possible falling objects.
WHEN SERVICING MACHINE:
Avoid moving parts. Do not wear loose clothing; jackets, shirts, or sleeves when working on the machine. Use ProChem approved replacement parts.
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Safety
Safety Labels
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.
Warning Label
P/N 86186520
CAUTION
Caution Label
P/N 86352580
Installation on vehicle fuel door.
Caution label P/N 86186530
Front panel decal with warning labels P/N 86323360
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Installation
Dealer Responsibility
Your distributor from whom you purchased this mobile cleaning unit is responsible for correct installation of this machine. The dealer is also responsible for initial training of your operators and maintenance personnel in proper operation and maintenance of this unit.
Vehicle Requirements
1.The unit should NOT be mounted in any motor vehicle of less than 3/4 ton capacity.
DO NOT exceed the vehicle’s axle weight limit. Include the console, full tanks, accessories, and operators in calculations.
2.If mounting in a trailer, make certain that trailer is rated for the total weight of UNIT AND TRAILER. Electric or hydraulic brakes should be provided, and a strict compliance with any State and Federal vehicle laws must be maintained.
3.The vehicle tires should have a load rating above the combined vehicle and unit weight.
4.We do not recommend using flooring materials that absorb water. This could result in rust and corrosion of the vehicle floor.
5.Padding under rubber floor mats should be removed before installing this unit.
6.We highly recommend using a drip tray under console (Part #86055040).
7.If using a trailer, console should be positioned so that it balances properly with respect to axle. Ten percent (10%) of the overall unit weight should be on tongue.
Example: If loaded trailer weight is 2,000 lbs., tongue weight needs to be a minimum of 200 lbs. to tow properly.
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86325860 PEAK GTX PROCHEM |
Lifting Unit Onto Vehicle
Since console weighs approximately 794 lbs. pounds, we recommend using a forklift to lift unit onto vehicle. Position forks under unit from front and make CERTAIN that forks are spread to insert into frame slots.
Positioning Unit In Vehicle
Because vehicles vary in size and openings, individuals have their own preference as to where they want their units installed. We strongly recommend a side door installation for this and DO NOT recommend a rear door installation.
1.Enough space should be provided to assure adequate engine ventilation and room for service and maintenance.
2.The unit with waste tank and accessories must NOT exceed vehicle's axle weight limit. An empty 60 gallon waste tank and console weighs 1014 lbs.
3.DO NOT position the console closer than 12" from bottom of driver and passenger seats.
NOTE: For individuals who wish to make an engineering layout prior to positioning unit, refer to "Dimensional Data" illustrations for waste tank and console dimensions.
Installation
Bolting Down Unit And Waste Tank
NOTE: When positioning waste tank with respect to console, hook up the vacuum hose to waste tank. This will ensure that waste tank is positioned correctly. Proceed once unit and waste tank are positioned in vehicle in desired location.
Before drilling any mounting holes in vehicle floor, make certain that when drilling, you will not do any damage to fuel tank, fuel lines, or any vital component which might affect operation or safety of vehicle.
1.Using console and waste tank mounting holes as a template, drill six 13/32" diameter holes for mounting console and six more 13/32" diameter holes for mounting waste tank.
2.Using installation hardware kit:
a.Insert six 3/8-16 x 2" hex head cap screws with flat washers through mounting holes in console, and six 3/8-16 x 2" hex head cap screws with flat washers through mounting holes in waste tank.
b.Install mounting plates underneath vehicle floor.
c.Screw 3/8-16 hex head locknuts on mounting screws and tighten them until console and waste tank are firmly secured to vehicle floor.
Electrical Wiring
Ensure all electrical wiring and battery cables are free from contact with any metal edge. Engine vibration could cause metal edge to cut wiring and possibly result in a fire. Be aware of where battery cables are run.
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Installation |
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Layout with 60 Gallon Waste Tank |
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21" |
3781" |
BACK OF DRIVERS SEAT |
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IN REAR MOST POSITION. |
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2X 11" |
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2X 6 3 |
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16 |
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2X 123" |
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57" |
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711" |
2X 187" |
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16 |
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33" MIN. |
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6X Ø3" |
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671613" |
2X 1985" |
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2X 3641"
1611" 
293" |
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TOP VIEW |
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ENSURE THAT VAC INLETS ON CONSOLE |
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AND WASTE TANK ARE ALIGNED. |
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3915" CONSOLE |
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16 |
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393" WASTE TANK |
423" OVERALL HEIGHT |
8 |
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4 |
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FRONT VIEW |
1 |
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388" WASTE TANK |
12 |
86325860 PEAK GTX PROCHEM |
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Installation |
Layout with 100 Gallon Waste Tank |
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21" |
4981" |
BACK OF DRIVERS SEAT |
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IN REAR MOST POSITION. |
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2X 11" |
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2 |
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2X 6 3 |
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" |
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16 |
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2X 123" |
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6X Ø83" |
137" |
57" |
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8 |
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8 |
8 |
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711" |
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16 |
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33" MIN. |
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4 |
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2X 17" |
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6X Ø83" |
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8 |
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671613" |
2X 1985" |
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2X 3641"
1611" 
TOP VIEW |
2983" |
ENSURE THAT VAC INLETS ON CONSOLE
AND WASTE TANK ARE ALIGNED.
391516" CONSOLE
3938" WASTE TANK
4234" OVERALL HEIGHT
FRONT VIEW 
5081" WASTE TANK 
86325860 PEAK GTX PROCHEM |
13 |
Installation
Waste Tank To Console Connection
NOTE: Before connecting any hoses to the waste tanks, make certain the hose clamps are on each hose.
1.Connect the section of 2-7/8" I.D. internal vac hose between the 2-7/8" dia. vac outlet tube on the waste tank and the vacuum pump relief valve on the console. It may be necessary to cut this hose to fit. Tighten the hose clamps.
2.Connect the 2" I.D. waste removal hose to the 2" dia. tube at the bottom corner of the waste tank. Cut to desired length. Install brass ball valve on other end.
3.Connect 2-1/2" I.D. hose between waste tank vacuum inlet (upper right of waste tank) and vacuum inlet on lower side panel of console.
4.Connect the 3/16" blue hose from the water box to the lower flare fitting (angled downward) on the waste tank.
5.Run the 5/8" water box overflow hose through the van floor. Prior to drilling through the van floor, ensure that no damage will occur in drilling area. Ensure that you are in compliance with all local environmental laws.
6.Connect the console engine shut-off cord to the waste tank level sensor cord.
7.Connect the 3/16" blue hose from the solution temp control valve to one of the 1/4" flare fittings (angled downward) on the waste tank.
8.Connect the 3/16" blue hose from the flow setup valve to one of the 1/4" flare fittings (angled downward) on the waste tank.
Fire Extinguisher
We recommend that a fire extinguisher, preferably rated for A, B, & C type fires, be installed inside the vehicle.
Fuel Pump Assembly Installation
Before drilling the fuel line holes in the vehicle floor, make certain that when drilling you will not do any damage to the fuel tank(s), fuel lines, brake lines, heat shields, or any other vital component which might affect the operation or safety of the vehicle.
Do not mount this assembly, any hoses or components near the catalytic converter, exhaust, or any areas of high temperature. Avoid any contact with moving parts, areas of high temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects.
1.Determine the position where the fuel pump assembly will be mounted. Check to ensure that the power cord length will support the mounting location. The pump should be mounted as low as possible and still be protected by the frame from road hazards. Mount the fuel pump with the discharge side of the pump higher than the suction side to eliminate the possibility of trapped air in the pump. Additional mounting holes are provided to allow for different mounting options.
2.Drill a 5/8" (.625) diameter hole in the vehicle floor for routing the fuel pump power cord to the truckmount console. Check to ensure that the cord length will support the location of the hole.
3.Route the power cord and install the hole grommet.
4.Do not connect the power cord to the truckmount console wiring harness until installation is complete.
14 |
86325860 PEAK GTX PROCHEM |
Installation
Van Bulkhead Installation
1.Select a location on the vehicle floor to drill the hole for the bulkhead adapter. This location should be situated in a position that eliminates the possibility of fuel line contact by either the operator(s) or accessories during the working hours or maintenance periods. Make certain that the supplied hoses will reach the location and work with the configuration you choose.
2.Drill a 5/8" (.625) diameter hole through the vehicle floor at the installation point chosen for the bulkhead.
3.Install the 1/8 NPT bulkhead adapter by inserting the adapter and tightening the nut on the opposite side of the van floor.
4.Attach the 1/8 NPT x 1/4 Hosebarb 90 degree elbow to the bulkhead inside the van to connect the fuel system to the console.
5.Attach the 1/4" fuel hose from the console to the 1/4” Hosebarb 90 degree elbow on the bulkhead.
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HOSEBARB ELBOW |
FUEL HOSE |
LOCTITE |
TO CONSOLE |
BULKHEAD ADAPTER |
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BULKHEAD GASKET |
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5/8" DIA HOLE |
VEHICLE FLOOR |
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FUEL HOSE FROM BYPASS FUEL FILTER
BULKHEAD GASKET
BULKHEAD NUT |
HOSEBARB ELBOW |
HOSE CLAMP
HOSE MOUNTING CLAMPS
USE AS NEEDED
86325860 PEAK GTX PROCHEM |
15 |
Installation
Fuel Supply & Return Line Installation
(Underneath Van)
1.Attach the 1/8 NPT x 5/16 Hosebarb 90 degree elbow to the bulkhead adapter underneath the van to be used for the fuel supply line.
2.Cut to length the 6' piece of 5/16" 50 PSI fuel hose used for the supply line from:
a.Bulkhead adapter to the outlet side of the bypass fuel filter.
b.Inlet side of the bypass fuel filter to the discharge side of the fuel pump.
c.Inlet side of the fuel pump to the outlet side of the inline fuel filter.
3.Cut to length the 6' piece of 1/4" fuel line to connect the bypass fuel filter with the fuel tank return using the appropriate fuel tap kit.
4.Check all hose clamps for tightness.
NOTE: Fuel tap kit installation instructions are found with appropriate fuel tap kit. Refer to Fuel Tap Kit Information Sheet (86349940)
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CHECK VALVE |
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1/4" RETURN HOSE |
RETURN TO VEHICLE |
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FUEL SUPPLY |
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ELECTRICAL FUEL
PUMP ASSEMBLY
FROM VEHICLE
FUEL SUPPLY
FUEL FLOW
FUEL FILTER
ELECTRICAL CORD |
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BUSHING |
5/16" SUPPLY HOSE |
BULKHEAD CONNECTOR
5/16" SUPPLY HOSE
5/16" SUPPLY HOSE
BYPASS FUEL FILTER
FRONT OF VAN
HOSE MOUNTING CLAMP
USE AS NEEDED
16 |
86325860 PEAK GTX PROCHEM |
Installation
Battery Connection
Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes, and clothing.
Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in 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.
1.Attach the red positive (+) battery cable from the console starter solenoid to the positive (+) terminal on the battery and tighten the holding nut.
2.Next, attach the black negative (-) battery cable from the console ground to the negative (-) terminal on the battery and tighten the holding nut.
86325860 PEAK GTX PROCHEM |
17 |
Installation
Initial Operational Settings
NOTE: Due to temperature and altitude changes, the optimal settings for each truckmount must be adjusted after installation. Failure to make these adjustments may lead to poor unit performance and premature component failure.
Vacuum Pump
The maximum vacuum pressure obtainable at full throttle should be 13"Hg. If the unit is drawing a stronger vacuum (at full sealed suction) than 13" Hg, adjust the vacuum relief spring to 13" Hg.
Engine
Set RPM Values as shown below. Refer to Engine Operation Manual for adjustment instructions.
Throttle |
Load |
RPM* |
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Idle |
None |
1200 rpm |
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Full |
13" Hg. Vacuum |
2750 rpm |
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500 psi pressure |
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Full |
None |
2850 rpm |
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*±50 rpm tolerance
18 |
86325860 PEAK GTX PROCHEM |
Operations
Technical Specifications
ITEM |
DIMENSION/CAPACITY |
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Engine speed |
2850 rpm (high speed) Water Pump ON |
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1200 rpm (idle speed) Water Pump OFF. |
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Solution pump rpm |
1750 rpm |
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Vacuum pump rpm |
3250 rpm |
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Water flow rate |
3.5 GPM (maximum) |
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Solution pump pressure (low pressure) |
1200 PSI (maximum) |
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Vacuum relief valve |
13" Hg |
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Waste tank capacity |
60 gallons / 100 gallons |
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Console weight |
794 lbs. |
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Console weight (with 60 gallon waste |
1014 lbs. |
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tank & waste tank accessories) |
(1449 lbs. If waste tank is full) |
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Console weight (with 100 gallon waste |
1024 lbs. |
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tank & waste tank accessories) |
(1649 lbs. If waste tank is full) |
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TORQUE VALUES |
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Engine hub |
300 inch lbs |
25 foot/lbs |
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Vacuum pump hub |
300 inch/lbs |
25 foot/lbs |
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Front engine pulley |
216 inch/lbs |
18 foot/lbs |
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Solution pump clutch shaft bolt |
300 inch/lbs |
25 foot/lbs |
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86325860 PEAK GTX PROCHEM |
19 |
Operations
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. These engines are NOT designed to use E-85 or Flex Fuels.
Engine Oil Requirements
Use high quality detergent 10W-30 oil of at least API (American Petroleum Institute) service class SG, SH, SJ or higher.
NOTE: Using a lower service class oil or extending oil change intervals longer than recommended can cause engine damage.
NOTE: Synthetic oils meeting the listed classifications may be used with oil changes performed at recommended intervals. However to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil.
Altitude Requirements
Engines perform differently with increases/decreases in altitude. Be sure to check engine speeds during initial installation. See engine speeds in Technical Specifications section.
NOTE: To ensure correct engine operation at altitudes above 1525 meters (5000 ft.), it may be necessary to have an authorized Kohler dealer install a special high altitude jet kit in the carburetor. If a high altitude kit has been installed, the engine must be reconverted to the original jet size, before it is operated at lower altitudes, or overheating and engine damage can result.
Chemical Requirements
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 chemical manual.
20 |
86325860 PEAK GTX PROCHEM |
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.
Operations
If you are operating this unit in an area where the unit will be using water in which the harness exceeds 3-1/2 grains, we highly recommend a suitable water softener be installed. If using a water softener, it must have a five (5) GPM (or greater) flow capacity without any hose constrictions.
Using a water softener will reduce maintenance and decrease down time caused by hard water scaling. It will also allow cleaning chemicals to be more effective in lower concentrations
If you require a water softener, your dealer has a model to meet your needs. Please contact your nearest distributor for information, price, and abailability.
86325860 PEAK GTX PROCHEM |
21 |
Operations |
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Components |
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22 |
86325860 PEAK GTX PROCHEM |
Components
1.Solution Temp Control Valve
This valve allows 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.
2.Vacuum Gauge
This gauge indicates in inches of mercury how much vacuum the system is producing at any given time.
3.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.
4.Engine High Temperature Shutdown Indicator
This light when activated signals an over heat condition with the engine. When this occurs, troubleshooting is required.
5.Solution Pressure Gauge
This gauge registers the amount of pressure in the system.
6.Solution Temperature Gauge
This gauge measures the temperature of the cleaning solution as it exits the machine.
7.Auxiliary Water Tank Pump Switch
The auxiliary water tank pump switch is used to actuate an optional fresh water demand pump.
8.Waste Pumpout Switch
This switch actuates the optional waste pumpout.
Operations
9.Solution Pump Switch
This switch serves to energize the magnetic clutch to turn the solution pump on or off. Turn clockwise for activating the pump and counter clockwise for deactivating the pump.
10.Choke
The choke 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.
Do NOT run engine with choke pulled out.
11.Ignition Switch
The ignition switch controls the power for the machine. To turn the machine on, turn solution pump switch counterclockwise to override and hold. Turn key clockwise until engine starts and release. Wait 5 seconds then release override switch. To stop engine rotate key to OFF position.
12.Throttle
The throttle is used to set the speed of the engine (rpm). The engine speed (rpm) may be increased by releasing the collar lock, pushing in the red button on the end of the handle, and pulling the handle straight out. Engine speed may be changed in smaller increments by rotating the throttle handle clockwise or counter-clockwise. The collar lock can be tightened to prevent the throttle from slipping and changing the engine speed.
13.Circuit Breakers
These serve to protect the circuits from electrical spikes and over loads and protects wires from damage and fire.
14.Hour Meter
The hour meter records the number of hours the unit has run. This serves as a time recorder for servicing the machine.
86325860 PEAK GTX PROCHEM |
23 |
Operations
15.Vacuum Inlets
The vacuum inlets serve as connecting points for vacuum hoses.
16.Exhaust
Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality. DO NOT run this unit in an enclosed area. DO NOT operate this unit where the exhaust may enter any building doorway, window, vent, or opening of any type
17.Solution Outlets
The solution outlets are the connecting points for the high pressure solution hoses. These outlets are quick disconnects that allow hoses to be plugged into the unit.
18.Solution Screen
The solution screen is located on the front of the machine. The function of this screen is to trap foreign particles from exiting the machine and plugging the orifices of the cleaning tools. This screen is part of the machine maintenance cleaning.
19.Chemical Check Valve
The chemical check valve allows chemicals to enter the system and travel in a singular direction to the wand. The chemical check valve prevents chemicals from traveling up-stream into the solution system of the unit.
20.Water Inlet
This quick connect allows the water supply hose to be connected to the unit.
21.Lubrication Cup
The lubrication cup allows lubricant spray to reach the vacuum blower.
22.Solution Pressure Regulator
The pressure regulator sets the pressure of the solution system. This spring loaded valve can be adjusted up or down. The pressure is increased by turning the valve clockwise or reduced by turning the valve counter clockwise. (This valve must be maintained in accordance with this manuals maintenance table.)
23.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.
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.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.
26.Flow Setup 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.
24 |
86325860 PEAK GTX PROCHEM |
Vacuum System
The engine turning a vacuum 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.
Operations
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 exhaust gases from the engine. This mixture of hot air and gases are then forced through 2 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.
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VACUUM |
HEATER COIL #1 |
INLET |
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HEATER COIL #2 |
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VACUUM
GAUGE
LUBRICATION
CUP
SILENCER |
VACUUM |
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PUMP |
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VACUUM |
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RELIEF |
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VALVE |
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LEVEL SENSOR |
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WASTE |
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TANK |
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STRAINER |
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FILTER |
86325860 PEAK GTX PROCHEM |
25 |
Operations
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 the strainer, into the solution pump. The water is pumped to the pressure regulator manifold, which provides and maintains the desired pressure setting.
The pressure regulator manifold includes a pulse hose 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 solution pump. Water that is not called for in the cleaning process is channeled through a copper heater core in the front of the heat exchanger box. This bypass water circulates several times through the heater core pre-warming the water.
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 water 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 water.
The third stage of plumbing and heat exchange takes place in the 2nd heater core located in the heat exchanger box. This is the hottest point of the gases coming from the vacuum pump and the engine exhaust. These hot gases are forced through heater core #2 creating the third stage of heat transfer to the cleaning water.
Finally, the cleaning water passes to the solution outlet manifold where cleaning chemicals are injected from the chemical pulse pump. This manifold serves as a temperature sensing point and the temperature control valve allows cooler water to enter the system for temperature sensitive upholstery applications. A check valve is located in this outlet manifold prohibiting chemicals from backing up into the system. Two connecting points for the high-pressure hoses are located at the end of the manifold.
The cleaning solution then passes through high pressure solution 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.
Pump damage can occur if it is “thermal shocked.” This may happen if the pump has run without the water supply turned on, allowing the pump to become overheated, and then turning on the water supply which sends fresh cool water to the pump without having a sufficient cool down period. Thermal shock typically ruins the seals and cracks the ceramic plungers.
26 |
86325860 PEAK GTX PROCHEM |
Operations
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= COLD WATER |
WASTE TANK |
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= WARM WATER |
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= HOT WATER |
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= NO WATER |
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VACUUM EXHAUST |
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HEAT EXCHANGERS |
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THERMO |
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RELIEF |
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WATER BOX |
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HELI-COIL ENGINE |
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ENGINE |
COOLANT HEAT |
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EXCHANGER |
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SOLUTION PUMP |
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ENGINE |
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THERMOSTAT |
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RADIATOR |
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TO PRESSURE |
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GAUGE |
TEMPERATURE |
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PULSE HOSE |
CONTROL BYPASS |
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MANIFOLD |
CHEMICAL |
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INJECTION |
WATER |
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INLET |
PRESSURE REGULATOR
SOLUTION OUTLET
MANIFOLD
CHEMICAL |
SOLUTION |
OUTLETS |
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CHECK |
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VALVE |
SOLUTION |
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SCREEN |
86325860 PEAK GTX PROCHEM |
27 |
Operations
Chemical Injection System
The chemical injection system is unique in that it utilizes the pressure spikes generated by the highpressure solution pump to move chemical into the main solution 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 drawn from the container, and through the flow meter, which indicates rate of flow. The chemical then moves to the chemical pulse pump where it is pressurized.
The chemicals flow to the chemical selector valve, which can turn off the chemical flow or when set to "Prime" sends it into the waste tank to purge air from the system, or when "CHEM" the chemical can be directed to the metering valve. The metering valve controls the amount of chemical that enters the solution outlet manifold.
The manifold assembly's check valve will not allow the chemicals to travel upstream into the plumbing system of the unit. The chemicals are mixed there with hot pressurized water that makes a cleaning solution. The flow setup valve is set to "Setup" while adjusting the chemical mix. This causes incorrectly mixed solution to safely drain to the waste tank until the manifold has the correct solution mix. Setting to "CHEM" lets the solution flow to the outlets for cleaning.
CHEMICAL
CHECK
VALVE SOLUTION SOLUTION
SCREEN OUTLETS
PRESSURIZED
HOT WATER
SOLUTION |
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OUTLET |
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FLOW SETUP |
MANIFOLD |
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VALVE |
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WASTE |
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TANK |
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CHEMICAL |
CHECK |
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METERING |
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VALVE |
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VALVE |
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CHEMICAL |
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SELECTOR |
CHEMICAL |
VALVE |
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PUMP |
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CHECK |
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VALVE |
FLOWMETER |
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CHEMICAL |
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CONTAINER |
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CHEMICAL FLOW |
INLET |
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CHEMICAL PRIME |
STRAINER |
SOLUTION FLOW |
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28 |
86325860 PEAK GTX PROCHEM |
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