Prochem EVEREST 650 User manual

Read these instructions before using the machine.
86352170-AU
12/29/16
Operating instructions (ENG)
MODELS:
EVEREST 650
HIGH PRESSURE
1.001-145.0
EVEREST 650
LOW PRESSURE
1.001-146.0
EVEREST 408
HIGH PRESSURE
1.001-151.0
EVEREST 408
LOW PRESSURE
1.001-152.0
Prior to Serial Number (Ref No. 1)
See Serial Number page or call
manufacturer.

186352170 EVEREST
Machine Data Label
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.

2
Machine Data Label . . . . . . . . . . . . . . . . . . . . . . . . . 1
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 100 Gallon Waste Tank . . . . . . . . . . . 12
Waste Tank To Console Connection. . . . . . . . . . . 13
Fuel Pump Assembly Installation. . . . . . . . . . . . . . 13
Van Bulkhead Installation . . . . . . . . . . . . . . . . . . . 14
Fuel Supply & Return Line Installation. . . . . . . . . . 15
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operations
Technical Specifications . . . . . . . . . . . . . . . . . . . . 17
Water Requirements . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Oil Requirements. . . . . . . . . . . . . . . . . . . . 19
Chemical Requirements. . . . . . . . . . . . . . . . . . . . . 19
Electronic Fuel Injection System . . . . . . . . . . . . . . 19
Emission Control Information. . . . . . . . . . . . . . . . . 20
Date Stamp Location . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel Pump And Filter. . . . . . . . . . . . . . . . . . . . . . . 20
Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Lower Control Panel . . . . . . . . . . . . . . . . . . . . . . . 25
Upper Control Panel . . . . . . . . . . . . . . . . . . . . . . . 26
Filter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Water Pumping And Heat Transfer System. . . . . . 29
Chemical Injection System. . . . . . . . . . . . . . . . . . . 32
Vacuum System. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pre-run Inspection / Setup . . . . . . . . . . . . . . . . . . . 34
Water Supply Connection . . . . . . . . . . . . . . . . . . . 34
High Pressure Solution Hose. . . . . . . . . . . . . . . . . 34
Vacuum Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Priming The Chemical Pump . . . . . . . . . . . . . . . . . 35
Waste Pumpout (Optional). . . . . . . . . . . . . . . . . . . 35
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Upholstery Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 36
Shutdown And Daily Maintenance. . . . . . . . . . . . . 36
High Pressure (3000 Psi) System Operation
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Pressure Shutdown & Return To Low Pressure
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
De-flooding Operations . . . . . . . . . . . . . . . . . . . . . 37
Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . 37
Winterizing Your Unit. . . . . . . . . . . . . . . . . . . . . . . 38
Removing Anti-freeze From The Unit . . . . . . . . . . 39
86352170 EVEREST
Table of Contents

3
Maintenance
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . .40
Key Checkpoints. . . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine Coolant System (Radiator) . . . . . . . . . . . . .42
External Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . .42
Chemical Supply System . . . . . . . . . . . . . . . . . . . .42
Heat Exchanger System . . . . . . . . . . . . . . . . . . . . .42
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Vacuum Relief Valve. . . . . . . . . . . . . . . . . . . . . . . .44
Vacuum Pump Drive Belts . . . . . . . . . . . . . . . . . . .45
Solution Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Solution Pump Drive Belt . . . . . . . . . . . . . . . . . . . .46
Solution Pump Clutch . . . . . . . . . . . . . . . . . . . . . . .46
Float Valve (Water Box) . . . . . . . . . . . . . . . . . . . . .46
Pre-filter Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . .46
Waste Tank Vacuum Inlet Filter . . . . . . . . . . . . . . .46
Solution Screen (Outlet) . . . . . . . . . . . . . . . . . . . . .46
Temperature Balance Orifice . . . . . . . . . . . . . . . . .46
Check Valve (Outlet). . . . . . . . . . . . . . . . . . . . . . . .47
Chemical Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . .47
Vacuum Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
High Pressure Solution Hoses . . . . . . . . . . . . . . . .47
Optional Waste Pump-Out . . . . . . . . . . . . . . . . . . .47
Engine Coolant Replacement. . . . . . . . . . . . . . . . .47
General Service Adjustments. . . . . . . . . . . . . . . . .48
Check Valve (Solution Outlet). . . . . . . . . . . . . . . . .48
Chemical Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Packing Nut Adjustment For Chemical Valves . . . .49
Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . .49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Parts
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control Panel Mounting . . . . . . . . . . . . . . . . . . . . 64
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electronic Fuel Ignition . . . . . . . . . . . . . . . . . . . . . 70
Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Vacuum Blower 650/650HP . . . . . . . . . . . . . . . . . 74
Vacuum Blower 408/408HP . . . . . . . . . . . . . . . . . 76
Solution Pump - Low Pressure . . . . . . . . . . . . . . . 78
Solution Pump - High Pressure. . . . . . . . . . . . . . . 80
Solution Pump - Parts. . . . . . . . . . . . . . . . . . . . . . 82
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Helicoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Solution Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Side Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Water Box - Low Pressure . . . . . . . . . . . . . . . . . 100
Water Box - High Pressure . . . . . . . . . . . . . . . . . 102
Pressure Regulator - Low Pressure . . . . . . . . . . 104
Pressure Regulators - High Pressure . . . . . . . . . 106
Filter Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Waste Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Chemical Jug Floor Mount . . . . . . . . . . . . . . . . . 116
Hose Diagram - Low Pressure . . . . . . . . . . . . . . 118
Hose Diagram - High Pressure. . . . . . . . . . . . . . 119
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Options
Hose Accessories . . . . . . . . . . . . . . . . . . . . . . . . 124
Flexible Exhaust Diverter Kit- Optional . . . . . . . . 126
Automatic Pumpout - Dual Diaphragm - Optional 128
Wand - Titanium Six Jet - Optional . . . . . . . . . . . 130
Wand - Ergo Titanium Six Jet - Optional. . . . . . . 132
Wand - Quad Jet - Optional . . . . . . . . . . . . . . . . 134
Wand - Tri Jet -Optional . . . . . . . . . . . . . . . . . . . 136
Stair Tool - Optional . . . . . . . . . . . . . . . . . . . . . . 138
Upholstery Tool - Optional . . . . . . . . . . . . . . . . . 140
Shelf Assembly - Optional. . . . . . . . . . . . . . . . . . 142
Water Tank Dual with Demand Pump - Optional 144
Water Tank - Demand Pump - Optional . . . . . . . 146
Auxiliary Water Tank with Pump-Optional . . . . . 148
Hose Reel - Optional. . . . . . . . . . . . . . . . . . . . . . 150
Motorized Hose Reel - Tank - Optional. . . . . . . . 152
Motorized Hose Reel - Optional . . . . . . . . . . . . . 154
E Z - Charge Water Softener - Tank & Tray -
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
E Z - Charge Water Softener - Filter - Optional . 158
E Z - Charge Water Softener - Brine System -
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Suggested Spare Parts. . . . . . . . . . . . . . . . . . . . 162
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 163
86352170 EVEREST
Table of Contents

4
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
cleaning unit should arrive equipped with the
following items (unless otherwise specified) and
any optional accessories which were ordered.
NOTE: Do not modify unit without written permission
from manufacturer.
Equipment List:
1. Console.
2. Waste tank.
3. Fuel PumpAssembly, Power and Regulator
Cord.
4. Filter box.
5. 150 ft. of 2" vacuum hose.
6. 2 vacuum hose connectors.
7. 150 ft. of 1/4” solution pressure hose with quick
connects.
8. 50 ft. water supply hose with quick connect.
9. Installation bolting kit.
10. Installation mounting plates.
11. Operation and service manuals for engine, solution
pump, and vacuum pump.
12. Hose clamps for vacuum hoses.
86352170 EVEREST

5
How To Use This Manual
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.
The model and serial number of your machine is on the
side 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.
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 main-
tenance 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 & Hub
• 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.
• PARTNO. - column lists the part number for the
part.
• PRV NO. - Reference No.
• 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 illustra-
tion 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 part number for this manual is in the
lower left corner of the cover page.
Model:
Date of Purchase:
Serial Number:
Dealer:
Address:
Phone Number:
Sales Representative:
86352170 EVEREST

6
Safety
IMPORTANT SAFETY INSTRUCTIONS
When using this machine, basic precaution
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 whichis 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 all vehicle cargo area or trailer rear doors open in order to ensure adequate engine
ventilation.
DO NOT operate engine if gasoline is spilled.Avoid creating any ignition source 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 heat guards.The high speed moving parts, such as belts and pulleys,
should be avoided while this unit is running. Severe injury, damage, or fatality may result.
DO NOT service this unit while it is running. The high-speed mechanical parts as well as high temperature
components may result in severe injury or severed limbs.
Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.
Engine components can get extremely hot from operation. To prevent severe burns, DO NOT touch these areas
while the engine is running - or immediately after the engine is turned off.
DO NOT touch the exhaust 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.
DO NOT leave the vehicle engine running while operating this unit.
DangerousAcid, 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.
86352170 EVEREST
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!

7
Safety
Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the
ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. When
disconnecting the battery, ALWAYS disconnect the negative (-) terminal FIRST.
DO NOT smoke around the unit. Gas fumes may accumulate and be ignited. The battery is also extremely
flammable. This will prevent possible explosions.
DO NOT damage the vehicle in any manner during installation. When routing fuel lines DO NOT place the hose in
any location where damage may occur to the hose or vehicle. Avoid any contact with moving parts, areas of high
temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects.
DO NOT cut or splice any of the vehicle fuel lines during fuel line installation. This may result in fuel leaks and
potentially dangerous conditions. There is no fuel solenoid shut off on this unit. Use only the provided fuel hose for
fuel lines. When traversing the vehicle floor with fuel lines, always use a bulkhead adapter. This will prevent leakage
and ensure that the hose is not punctured by vehicle vibration abrasion.
DO NOT exceed your vehicle's weight limit: The console with empty 100 gallon waste tank and accessories weighs
approximately 1300 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. Pressure
wash hoses must be rated at 4000 PSI.
The winterizing loop hose assembly, 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.
86352170 EVEREST

8
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 equip-
ment. 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.
86352170 EVEREST

9
SOLUTION PRESSURE
LOW PRESSURE
SOLUTION REGULATOR
HIGH PRESSURE
SOLUTION REGULATOR
HIGH PRESSURE
SOLUTION OUTLET
TEMPERATURE
BALANCE ORIFICE
WARM
WATER OUTLET
WATER INLET
OIL DRAIN
ENGINE
VACUUM
LUBRICATION
LOW
PRESSURE
SOLUTION
SCREEN
CHEMICAL
CHECK
VALVE
CARPET AND
UPHOLSTERY
SOLUTION
LOW
PRESSURE
SOLUTION
OUTLETS
WARM
HOT
SafetySafety 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.
86352170 EVEREST
Caution label
P/N 86186510
Caution Tag
P/N 86186500
Front lower panel decal
(Low Pressure)
P/N 86179470
Front lower panel decal
(High Pressure)
P/N 86179480
Warning label
P/N 86186520
Caution label
P/N 86012220
Caution Label
P/N 86352580
Installation on
vehicle fuel door.
UNLEADED FUEL ONLY.
E85 FUEL WILL DAMAGE
INSTALLED EQUIPMENT.
CAUTION
WARM
TEMPERATURE
BALANCE ORIFICE
WARM
WATER OUTLET
WATER INLET
OIL DRAIN
ENGINE
LOW PRESSURE
SOLUTION REGULATOR
VACUUM
LUBRICATION
LUBRICATE
WITH VACUUM
INLETS SEALED
LOW
PRESSURE
SOLUTION
SCREEN
CHEMICAL
CHECK
VALVE
CARPET AND
UPHOLSTERY
SOLUTION
LOW
PRESSURE
SOLUTION
OUTLETS
HOT

10
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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Installation
Lifting Unit Onto Vehicle
Since the console weighs approximately 1150 lbs., 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
100 gallon waste tank and console weighs 1300
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.
Bolting Down Unit And Waste Tank
When positioning waste tank with respect to console,
hook up the vacuum hose from blower 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.
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Installation
Layout with 100 Gallon Waste Tank
2'-81
2"
3'-43
4"
3'-111
8"
4'-31
8"
4'-41
8"
1'-15
8"105
8"55
16"
5'-61
2"
3'-2 1
16"
4'-513
16"
11
2"1'-91
2"
65
8"
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Installation
Waste Tank To Console Connection
NOTE: Before connecting any hoses to the waste
tank, make certain the hose clamps are on each
hose.
1. Connect the section of 4.5" I.D. internal vac hose to
the 4.5” diameter vac outlet tube on the waste tank
and to the vacuum pump relief valve on the
console. It may be necessary to cut this hose to fit.
Tighten the hose clamps.
2. Connect the 2” I.D. waste removal hose to the 2”
diameter tube at the bottom of the waste tank.
Connect other end to 2” tube on the Pre-Filter Box.
Tighten the hose clamps.
3. Connect the 3/16 blue hose from the water box
temperature relief valve to the 1/4 fitting (pointed
downward) on the waste tank that does not have a
spray jet installed inside the tank.
4. Connect the console engine shut-off cord to the
waste tank level sensor cord.
5. Connect the 3/16 blue hose from the Flow Setup
Valve to the other 1/4 fitting (pointed downward) on
the waste tank that has a spray jet installed inside
the tank.
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 compo-
nents 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 mounting location of the fuel system
assembly. Mount bottom of box parallel to the
ground and side perpendicular. Ensure that the
power cord length will support the mounting
location. Mount the pump as low as possible while
still being protected by the frame from road
hazards. The pump end with the electrical connec-
tions is the discharge end. Additional mounting
holes are provided to allow for different mounting
options.
2. Cut a 6" piece of 5/16 fuel hose and connect from
the outlet side of the fuel filter to the inlet side of
the fuel pump. Use supplied hose clamps and
fasten securely.
NOTE: On the high-pressure pump supplied with the
EFI unit, add 2-3 drops of lubricating oil to the inlet
side of the fuel pump to protect the pump during initial
startup.
3. Prior to drilling, check to ensure that the cord
length will support the location of the hole. Drill a
5/8" hole in the vehicle floor for routing the fuel
pump power cord to the truckmount console and
install the hole grommet. Drill a 1-3/8" hole in the
vehicle floor for routing the electronic fuel pressure
regulator cord to the truckmount console.
4. Do not connect the power cords to the truckmount
console wiring harness until installation is
complete.
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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. Install (1) 1/8P x 5/16 push-on hosebarb fitting on to the bulkhead (inside van).
5. Attach the 5/16" fuel hose from the console to the hosebarb fitting on the bulkhead. DO NOT USE HOSE
CLAMPS AT THIS CONNECTION.
BULKHEAD ADAPTER
BULKHEAD NUT
HOSEBARB
HOSEBARB
HOSE MOUNTING CLAMPS
FUEL HOSE
VEHICLE FLOOR
5/8" DIA HOLE
LOCTITE
FUEL PRESSURE REGULATOR
FUEL HOSE FROM
BULKHEAD GASKET
BULKHEAD GASKET
TO CONSOLE
USE AS NEEDED
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Installation
Fuel Supply & Return Line Installation
(Underneath Van)
1. Spray the inside of the supplied 90 degree plastic barbed fitting with water displacing lubricant. Push plastic
fitting onto the return tube on filler neck adapter tube until fitting securely snaps into place.
2. Measure and cut a length of 5/16" fuel hose and connect to the plastic barbed fitting on the return tube of the
filler neck adapter tube. Connect other end of hose to 1/4 x 5/16 brass hose adapter and attach adapter to 1/4"
fuel hose from electronic fuel pressure regulator. Fasten securely using supplied hose clamps.
3. Install (1) 1/8P x 5/16 push-on hosebarb fitting on to the bulkhead adapter.
4. Measure and cut a length of 5/16" fuel hose and connect between the outlet side of the electronic fuel pressure
regulator and the 1/8P x 5/16 push-on hosebarb fitting at the bulkhead. DO NOT USE HOSE CLAMPS AT
THIS CONNECTION.
NOTE: Fuel tap kit installation instructions are found with appropriate fuel tap kit. Refer to Fuel Tap Kit
Information Sheet (86349940)
CONNECTOR
CHECK VALVE
5/16" SUPPLY HOSE
HOSE MOUNTING CLAMP
FRONT OF VAN
BULKHEAD
BUSHINGS
ELECTRICAL CORDS
PUMP ASSEMBLY
ELECTRICAL FUEL
USE AS NEEDED
5/16" SUPPLY HOSE
FUEL SUPPLY
RETURN TO VEHICLE
FROM VEHICLE
FUEL SUPPLY
FUEL FLOW
FUEL FILTER
1/4" RETURN HOSE
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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.
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.
Fire Extinguisher
We recommend that a fire extinguisher, preferably
rated for A, B, & C type fires, be installed inside the
vehicle.
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Operations
Technical Specifications
Item Dimension / Capacity
Engine speed 2200 rpm (high speed)
900 rpm (idle speed)
Solution pump rpm 1357 rpm
Vacuum pump rpm 3125 rpm
Water flow rate 5 GPM (maximum)
Solution pump pressure (low pressure) 1200 PSI (maximum)
Solution pump pressure (high pressure) (Optional) 3000 PSI (maximum)
Vacuum relief valve 13" Hg
Waste tank capacity 100 gallons
Console weight (Model 408 & HP 408) 1065 lbs
Console weight (Model 650 & HP 650) 1150 lbs
Console weight (with waste tank & waste tank accessories)
(Model 408 & HP 408) 1215 lbs
Console weight (with waste tank & waste tank accessories)
(Model 650 & HP 650) 1300 lbs
Torque Values
Engine pulley 360 inch lbs 30 foot/lbs
Vacuum pump hub 300 inch/lbs 25 foot/lbs
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Operations
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 equip-
ment.
NOTE: Equipment malfunction or component failure
caused by hard water scaling is NOT covered under
the warranty.
If you are operating this unit in an area where the unit
will be using water in which the hardness exceeds
3-1/2 grains, we highly recommend a suitable water
softener be installed. If using a water softener, it must
have a five (5) GPM (or greater) flow capacity without
any hose constrictions.
Using a water softener will reduce maintenance and
decrease down time caused by hard water scaling. It
will also allow cleaning chemicals to be more effective
in lower concentrations.
If you require a water softener, your dealer has a model
to meet your needs. Please contact your nearest
distributor for information, price, and availability.
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