CHARGER II

MOBILE CLEANING UNIT

Operating Instructions (ENG)

MODELS: CHARGER II

Read instructions before operating the machine.

D

980176

01/05

MACHINE DATA LOG/OVERVIEW

MODEL _______________________________________

DATE OF PURCHASE __________________________

SERIAL NUMBER ______________________________

SALES REPRESENTATIVE # _____________________

YOUR DEALER

Name: ________________________________________________________________________________________

Address: ______________________________________________________________________________________

Phone Number:

_________________________________________________________________

Welcome…and congratulations on your 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 PRESCRIBED INSTALLATION PROCEDURES.

MAKE CERTAIN THAT THE WARRANTY FORM IS FILLED OUT BY THE DISTRIBUTOR FROM WHOM YOU

PURCHASED THIS UNIT AND RETURNED TO!

This operation and service manual is written specifically for the your Mobile Cleaning Unit which is manufactured for:

CLEANCO TRUCKMOUNTS

3750-19th STREET NE

CALGARY, AB, CANADA T2E 6V2

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

NOTE: Fill in information at top of this page and fax to Cleanco at 403-291-0546

980176 CHARGER II 01/05

1

TABLE OF CONTENTS

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

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

Receiving your unit............................................4

HOW TO USE THIS MANUAL

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

SAFETY

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

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

INSTALLATION & OPERATION

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

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

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

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

Chemicals & Water. ......................................3-3

Components ............

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

Water Pumping System ............................... 3-7

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

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

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

Water Supply connection............................. 3-11

Pre Run Inspection ..................................... 3-11

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

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

Starting Unit (Cleaning Mode)..................... 3-12

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

Waste Pump ................................................. 3-12

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

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

Shutdown & Daily Maintenance.................. 3-13

Freezing Protection...................................... 3-14

Removing Anti-freeze................................... 3-15

MAINTENANCE & SERVICE

Maintenance

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

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

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

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

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

Drive Belts, Pulleys And Hubs.................4-6

Float Valve, Water Pump Inlet Filter .......4-7

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

Bypass Manifold........................................4-7

Outlet Y-Strainer, Check Valve................4-7

Chemical Pump, Chemical &

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

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

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

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

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

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

General Service Adjustments

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

Vacuum Relief Valve ................................4-9

Vacuum Pump Drive Belts .......................4-9

Water Pump Drive Belt.............................4-9

Float Valve.................................................4-9

Bypass Manifold........................................4-9

Check Valve ..............................................4-9

Chemical Pump.........................................4-10

Packing Nut Adjustment

(Chemical Metering & Selector Valves ...4-10

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

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

2

980176 CHARGER II 01/05

PARTS LIST

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

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

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

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

Vacuum Pump.....................................5-9

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

Water Pump ...........

..................

.........5-11

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

Pressure Regulator &

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

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

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

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

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

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

Water Tank-Demand Pump-Optional5-31

Wiring Diagram ...................................5-33

Hose Diagram .....................................5-34

Wand Dual Jet .....................................5-35

Warranty ..............................................5-37

TABLE OF CONTENTS

980176 CHARGER II 01/05

3

RECEIVING YOUR UNIT

DEALER RESPONSIBILITY

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

ACCEPTANCE OF SHIPMENT

Every part of your 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. Operation and service manual with engine, water pump, and vacuum pump manuals.

3. Installation bolting kit.

4. Installation mounting plates.

5. Hose clamps for fuel & vacuum hoses.

6. Carpet wand.

7. Waste tank w/float switch.

8. Waste tank filter and strainer basket.

9. 100 ft. of 2” vacuum hose.

10. 1 vacuum hose connector.

11. 100 ft. of 1/4" high pressure hose with quick connects.

12. 50 ft. water supply hose with quick connect.

13. 5 gallon jug and holder.

Each unit will require a fuel system installation kit that is purchased separately from the unit and is specific for each manufacturer and model year of van.

4

980176 CHARGER II 01/05

HOW TO USE THIS MANUAL

This manual contains the following sections:

HOW TO USE THIS MANUAL

SAFETY

OPERATIONS

-

MAINTENANCE & SERVICE

PARTS LIST

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

Parts may be ordered from authorized dealers.

When placing an order for parts, the machine model and machine serial number are important. Refer to the MACHINE DATA box which is filled out during the installation of your machine. The MACHINE

DATA box is located on the inside of the front cover of this manual.

MODEL _____________________________________

DATE OF PURCHASE ________________________

SERIAL NUMBER ____________________________

SALES REPRESENTATIVE # ___________________

The model and serial number of your machine is on the lower front as shown.

The SAFETY section contains important information regarding hazard or unsafe practices of the machine. Levels of hazards is identified that could result in product or personal injury, or severe injury resulting in death.

The OPERATIONS section is to familiarize the operator with the operation and function of the machine.

The MAINTENANCE section contains preventive maintenance to keep the machine and its components in good working condition. They are listed in this general order:

Engine

Vacuum Pump

Drive Belts, Pulleys & Hubs

Chemical Pumps

Hoses

Exhaust Heat Exchanger

General Service Adjustments

Troubleshooting

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

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

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

DESCRIPTION – column is a brief description of the part.

SERIAL NO. FROM – column indicates the first machine the part number is applicable to. When the machine design has changed, this column will indicate serial number of applicable machine.

The main illustration shows the most current design of the machine. The column has an asterisk (*), call manufacturer for serial number.

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

NOTE: If a service or option kit is installed on your machine, be sure to keep the KIT

INSTRUCTIONS which came with the kit. It contains replacement parts numbers needed for ordering future parts.

NOTE: The 98# on the lower left corner of the front cover is the part number for this manual.

980176 CHARGER II 01/05

1-1

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. 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 any part of the exhaust system while this unit is running. Severe burns may result.

Before servicing this unit, allow it to "cool down." This will prevent burns from occurring.

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

Always wear hearing protection when unit is running. Always comply with your company’s Personal

Protection Equipment (PPE) plan. Always comply with local noise ordinance when operating units.

2-1

980176 CHARGER II 01/05

DO NOT leave the vehicle engine running while operating this unit.

Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.

Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. When disconnecting the battery, ALWAYS disconnect the negative (-) terminal FIRST.

DO NOT smoke around the unit. Gas fumes may accumulate and be ignited. The battery is also extremely flammable. This will prevent possible explosions.

DO NOT damage the vehicle in any manner during installation. When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle. Avoid any contact with moving parts, areas of high temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects.

There is no fuel solenoid shut off on this unit. Use only the provided abrasion resistant fuel hose for fuel lines.

When traversing the vehicle floor with fuel lines, always use a bulkhead adapter. This will prevent leakage and ensure that the hose is not punctured by vehicle vibration abrasion.

DO NOT exceed your vehicle's weight limit. The console with empty and accessories weighs approximately

710 lbs (800 lbs. if mounted on water tank). Make certain that the vehicle has the correct axle rating. This will prevent unsafe vehicle driving conditions.

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

We recommend using a metal partition between the seats and equipment.

DO NOT operate this unit without the water supply attached and turned on. The water pump and other vital components may be seriously damaged if this unit is permitted to operate dry without water. This unit is equipped with a low pressure shutdown device.

DO NOT bypass or operate this unit without the low pressure shut-down switch.

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

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

The winterizing loop hose assembly, Part #10-805380, is for winterizing use only. If used improperly, live steam may escape from this hose, causing it to whip around. Burns or injury may result.

Make certain that you receive complete training by the distributor from whom you purchased this unit.

This unit uses high pressure and temperature. Improper or irresponsible use may result in serious injury.

Do not modify this unit in any manner. Improper modification can cause severe personal injury or fatality.

CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects, or other reproductive harm.

980176 CHARGER II 01/05

2-2

HAZARD LEVEL INTENSITY

The following

WARNING LABELS are found on your cleaning unit. These labels point out

important

Warnings and Cautions which should be followed at all times. Failure to follow

warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage. Follow these instructions carefully!

DO NOT remove these labels.

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

Lower front panel decal

With warning labels

Part # 500836

Warning label

Part # 500769 (3)

2-3

Caution label

Part # 500770 (2)

980176 CHARGER II 01/05

ITEM

Engine speed

Water pump rpm

Vacuum pump rpm

Water flow rate

Water pump pressure

Vacuum relief valve

Waste tank capacity

Console weight

Console weight (with waste tank & accessories)

TECHNICAL SPECIFICATIONS

DIMENSION/CAPACITY

3200 rpm

1400 (idle speed)

1625 rpm

3200 rpm

3.5 GPM (maximum)

1000 PSI (maximum)

13” Hg

60 gallons

500 lbs. (590 lbs. If mounted on water tank)

710 lbs (If waste tank is empty)

(1225 lbs. If waste tank is full)

(1740 lbs. If auxiliary water tank & waste tank are full)

264 inch lbs 22 foot/lbs

264 inch lbs 22 foot/lbs

168 inch lbs 14 foot/lbs

TORQUE VALUES

Engine rear Vac pump pulley

Engine front stub shaft

Engine front water pump pulley on stub

JET SIZING:

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

Example:

Tri-jet wand uses three 95010 jets (95° spray angle w/ 010 orifice).

01 x 3 = 030

Upholstery tool jet size:

Stair tool jet size:

80015

9502

980176 CHARGER II 01/05

3-1

OPERATION

INSTALLATION REQUIREMENTS

Prior to starting the installation, first read the

ENTIRE "Installation” section of this manual. Since the cleaning unit (with empty waste tank and accessories) weighs approximately 710 pounds (800 lbs. if mounted on water tank), consider the following recommendations before installing this unit.

1. The unit should

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

FUEL REQUIREMENTS

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

ENGINE OIL REQUIREMENTS

Use high quality detergent oil of at least API

(American Petroleum Institute) service class SF or

SG. Select the viscosity based on the air temperature at the time of operation as shown in the following table.

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

RECOMMENDED SAE VISCOSITY GRADE

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

2. If mounting in a trailer, make certain that the trailer is rated for the total weight of the

UNIT

AND TRAILER. Electric or hydraulic brakes should be provided, and a strict compliance with any State and Federal vehicle laws must be maintained.

3. The vehicle tires should have a load rating above the combined vehicle and unit weight.

4. We do not recommend using flooring materials that absorb water. This could result in rust and corrosion of the vehicle floor.

5. Padding under rubber floor mats should be removed before installing this unit.

6. We highly recommend using a galvanized drip tray under the console (Part #56-501845, or Part

#56-501930 for units mounted on a water tank.)

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

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.

3-2

980176 CHARGER II 01/05

CHEMICAL REQUIREMENTS

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

Esteam line of chemicals. For information on using the cleaning compounds, refer to the chemical manual.

WATER REQUIREMENTS

Hard water deposits will adversely affect the plumbing and heat exchange systems on this unit.

The map below will give you an idea of where areas of high water hardness may occur. However, any water supply obtained from a well is almost always hard water and a water softener will be needed to protect your equipment.

OPERATION

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

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

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

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

980176 CHARGER II 01/05

3-3

OPERATION

16

15

14

18

17

1

2

3

4

5

6

7

8

9

10

11

12

3-4

13

980176 CHARGER II 01/05

OPERATION

1. VACUUM GAUGE

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

2. WASTE PUMPOUT SWITCH

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

3. SOLUTION PRESSURE GAUGE

This gauge registers the amount of pressure in the system.

4. CHOKE

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

5. KEY SWITCH

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

6. THROTTLE

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

7. CIRCUIT BREAKERS

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

8. HOUR METER

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

9. OIL CUP

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

10. VACUUM INLET

The vacuum inlet serve as connecting point for vacuum hoses.

11. WATER INLET

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

12. WASTE PUMPOUT (OPTIONAL)

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

13. TEMPERATURE BYPASS VALVE

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

980176 CHARGER II 01/05

3-5

OPERATION

14. PRESSURE CONTROL REGULATOR

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

(This valve must be maintained in accordance with this manuals maintenance table.)

15. SOLUTION OUTLET

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

16. 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.

17. 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.

18. CHEMICAL METERING VALVE

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

3-6

980176 CHARGER II 01/05

NITROGEN ACCUMULATOR

VACUUM EXHAUST

RADIATOR-TYPE

HEAT EXCHANGER

BRIGGS & STRATTON

VANGUARD

ENGINE

OPERATION

PRESSURE REGULATOR

SOLUTION OUTLET

OUTLET Y-STRAINER

OUTLET CHECK VALVE

TEMPERATURE CONTROL VALVE

WATER INLET

VACUUM INLET

VACUUM

EXHAUST

WATER BOX

WATER PUMP

VERY HOT WATER FLOW

HOT WATER FLOW

WARM WATER FLOW

COLD WATER FLOW

BYPASS FLOW

ENGINE EXHAUST FLOW

VACUUM EXHAUST FLOW

VACUUM FLOW

980176 CHARGER II 01/05

145°

TEMPERATURE

RELIEF VALVE

WASTE TANK

3-7

OPERATION

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

WATER PUMPING AND HEAT

TRANSFER SYSTEM

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

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

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

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

= COLD WATER

= WARM WATER

= HOT WATER

= NO WATER

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

The next stage of plumbing and heat exchange takes place in the 2nd heater core located in the heater box. This is the hottest point of the gases coming from the vacuum pump and the engine.

These hot gases are forced through heater core #2 creating the second stage of heat transfer to the cleaning solution.

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

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

VACUUM EXHAUST

HEAT EXCHANGERS

WASTE TANK

THERMO

RELIEF

WATER PUMP B & S VANGARD ENGINE

TO PRESSURE

GUAGE

TEMPERATURE

CONTROL BYPASS

CHEMICAL

INJECTION

3-8

WATER

INLET

SOLUTION

OUTLET

PRESSURE REGULATOR

ACCUMULATOR

OUTLET CHECK VALVE

OUTLET Y STRAINER

980176 CHARGER II 01/05

CHEMICAL INJECTION SYSTEM

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

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

OPERATION

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

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

NITROGEN ACCUMULATOR

CHEMICAL PUMP

PRESSURE REGULATOR

SOLUTION OUTLET

OUTLET Y-STRAINER

OUTLET CHECK VALVE

TEMPERATURE CONTROL VALVE

WATER INLET

VACUUM INLET

CHEMICAL JUG

WATER PUMP

COLD WATER FLOW

BYPASS FLOW

VACUUM FLOW

CHEMICAL INJECTION

WATER BOX

FLOAT VALVE

145°

TEMPERATURE

RELIEF VALVE

WASTE TANK

980176 CHARGER II 01/05

3-9

OPERATION

VACUUM SYSTEM

The engine turning an air pump generates vacuum.

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

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

VACUUM EXHAUST

OUTLET

FROM PRESSURE

REGULATOR

TO WATER BOX

VACUUM EXHAUST

"RADIATOR TYPE"

COPPER

HEAT EXCHANGER

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

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

FROM PRESSURE

REGULATOR

TO

SOLUTION OUTLET

VACUUM EXHAUST

"RADIATOR TYPE"

STAINLESS STEEL

HEAT EXCHANGER

VACUUM

INLET

VACUUM

RELIEF

VALVE

LUBRICATION

CUP

VACUUM

GAUGE

3-10

STRAINER

VACUUM

SILENCER

LEVEL SENSOR

(ENGINE SHUT-OFF SWITCH)

VACUUM

BLOWER

FILTERS

WASTE TANK

980176 CHARGER II 01/05

PRE-RUN INSPECTION

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

Operate this unit and equipment only in a wellventilated area. Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or fatality.

DO NOT operate this unit where the exhaust may enter any building doorway, window, vent, or opening of any type.

CHECK FOR ADEQUATE FUEL

Check the fuel tank to be certain there is adequate fuel to complete the job. This unit uses approximately .95 to 1.25 gallons of fuel per hour, depending on the speed setting.

REMOVE TOOLS FROM VEHICLE

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

WATER SUPPLY CONNECTION

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

1. Connect the water supply hose to the water

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

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

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

OPERATION

HIGH PRESSURE HOSE

Before starting the unit, connect the

pressure hose

to the

outlet connection at the front of the unit.

Connect the cleaning tool to the pressure hose.

DANGER

WATER UNDER HIGH PRESSURE AT HIGH

TEMPERATURE CAN CAUSE BURNS,

SEVERE PERSONAL INJURY, OR COULD

BE FATAL. SHUT DOWN MACHINE,

ALLOW TO COOL DOWN, AND RELIEVE

SYSTEM OF ALL PRESSURE BEFORE

REMOVING VALVES, CAPS, PLUGS,

FITTINGS, FILTERS AND BOLTS.

ROTATING

MACHINERY.

WATER UNDER

PRESSURE AT HIGH

TEMPERATURE.

IMPROPER

MODIFICATION OF

EQUIPTMENT CAN

CAUSE SEVERE

PERSONAL INJURY

OR COULD BE

FATAL.

DANGER

DO NOT MODIFY

UNIT WITHOUT

WRITTEN

PERMISSION

FROM

MANUFACTURER

VACUUM HOSE

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

FILTERS

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

980176 CHARGER II 01/05

3-11

OPERATION

PRIMING THE CHEMICAL PUMP

1. Connect water hose to water inlet connection and turn on water supply.

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

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

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

5. Push in engine choke after engine has started.

6. Set throttle to idle speed.

7. Fill chemical container and inspect chemical filter.

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

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

WASTE PUMP (OPTIONAL)

1. If your unit is equipped with an automatic waste pump, connect one end of a garden hose to the pump-out connection on the console and the other end to an appropriate waste disposal.

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

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

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

waterways, or on ground areas. Always dispose of waste in accordance with Local, State, and

Federal laws.

NEVER dispose of waste in storm drains,

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

When this occurs, empty the waste tank before continuing.

CLEANING

Observe the following guidelines, while cleaning:

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

a. To check , hold the wand about one foot above the surface to be cleaned and open the wand valve. A full spray should be observed from the cleaning nozzles.

b. If the nozzles are not showing a full spray pattern, adjust nozzles for proper pattern, clean, or replace nozzles, if required.

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

3. When cleaning, keep the working opening

(mouth) flat on the surface being cleaned. Keep the wand moving when the valve is open.

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

3-12

980176 CHARGER II 01/05

UPHOLSTERY CLEANING

Upholstery tool, part #78513

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

2. Use one (1) “80015” spray tip in tool.

SHUTDOWN AND DAILY MAINTENANCE

1. Close chemical metering valve.

2. Allow the unit to run for 2 minutes with the vacuum hose disconnected to remove moisture.

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

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

4. Turn off ignition switch.

5. Disconnect all hoses and tools.

6. Drain waste tank and rinse with clean water.

OPERATION

FREEZING PROTECTION

If the unit is exposed to freezing weather the water in the unit may freeze, causing SERIOUS

DAMAGE to the unit. To avoid this, the following is recommended during the cold weather season.

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

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

If a heated building is not available, we recommend that you winterize the unit with anti-freeze. At present, it is only possible to winterize units, which do not have an auxiliary water tank. Units with auxiliary water tanks must be stored in a heated building when not in use.

OVERHEATING PROTECTION

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

980176 CHARGER II 01/05

3-13

OPERATION

WINTERIZING YOUR UNIT

1. Shut off the water supply. Disconnect the water

inlet hose from the front of your console.

2. Connect all high pressure hoses and tools that may have water in them.

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

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

5. Start the unit. Turn the solution pump switch

ON.

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

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

7. Turn the solution pump switch OFF. Attach the winterizing loop hose with attachment,

Part #10-805380, to the solution outlet connection and the water inlet connection. Turn the solution pump switch ON.

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

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

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

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

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

3-14

980176 CHARGER II 01/05

REMOVING ANTI-FREEZE FROM

THE UNIT

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

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

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

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

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

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

OPERATION

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

Turn the chemical valve to the ON

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

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

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

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

980176 CHARGER II 01/05

3-15

MAINTENANCE

SERVICE SCHEDULE

Engine

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

Vacuum Pump

Water Pump

Solution Inlet Tube Strainer

Vacuum Inlet Filter (In Waste Tank)

Vacuum Hoses

Automatic Waste Pump

Chemical Filter

Daily

Daily

Daily

Daily

Daily

Daily

Daily

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

Check oil level.** Fill to proper level

Check strainer for blockage, remove any debris

Clean filter, inspect, replace if damaged

Wash out with clean water

Inspect and remove any debris or sediment

Inspect daily

Vacuum Pump

Weekly* Check oil level. Fill to proper level

Water Box Float Valve

Weekly Check for proper seating and shut-off

Water Pump Inlet Filter

Weekly* Check for debris and clean

Battery

Weekly* Check for proper fluid level. Fill with distilled water only

Solution Outlet Y-Strainer

Weekly* Inspect and remove any debris or blockage

High Pressure Hoses

25 hrs Inspect for damage or impending damage

Pressure Regulator

Pressure Regulator

50 hrs

50 hrs

Lubricate o-rings

Lubricate plug behind spring

Engine

100 hrs Change engine oil***

Engine

100 hrs Change oil filter***

Engine

100 hrs Check fan belt tightness

Battery

100 hrs* Clean battery terminals

Automatic Waste Pumpout

100 hrs Clean inlet and outlet ports

Belts/pulleys

100 hrs Check belt wear and tension. Check pulley alignment.

Float Valve Seal

200 hrs.

Replace seal

Engine

200 hrs Service air cleaner elements*

Fuel Pump

200 hrs Check hose connections

Engine

200 hrs Check spark plugs for carbon deposits and proper gap

Chemical Valves

200 hrs Inspect and/or adjust packing nuts

Heat Bypass Valve

200 hrs Inspect and/or adjust packing nuts

4-1

980176 CHARGER II 01/05

MAINTENANCE

SERVICE SCHEDULE

Vacuum pump

250 hrs

Lubricate bearing on pulley end with grease

Vacuum Exhaust Heat Exchanger

500 hrs

Inspect cores and remove debris.

Water Pump

500 hrs

Change oil**

Pulley Set Screws & Hub Cap

Screws

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

Drive Pulley

500 hrs

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

Drive Pulley

500 hrs

Check pulley alignment

Drive Belts

500 hrs

Inspect and clean****

****

Drive Belts

500 hrs

Check belt tension****

Chemical Pump & Check Valves

500 hrs

Replace diaphragm and check valves.

Vacuum Lubrication Lines

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

Engine

500 hrs

Replace in-line fuel filter on engine.

Heater Core

500 hrs

Clean and inspect.

Engine

1000 hrs

Replace spark plugs.

Check Valve (Solution Outlet)

1000 hrs

Inspect, clean, and repair, if needed.

Waste Tank Shut-off Float Switch

Monthly

Check for debris hindering movement

Engine

Yearly

Flush radiator and change engine coolant.

Vacuum pump

Yearly

Drain, flush and replace oil*****

Nitrogen Accumulator

Yearly*

Replace Accumulator.

Waste Tank Filters/Strainers

Yearly

Engine

Yearly

Check for damage and blockage. Replace if needed.

Replace air cleaner element

Engine

3 years

Replace ignition wires.

* Or as often as required

** Change water pump crankcase oil after the first 50 hours

***Change engine crankcase oil and filter after the first 50 hours

****Perform drive belt, pulley and hub maintenance after the first 25 hours of operation, and then again at

100 hours

*****If using AEON PD synthetic lubricant, 4000 hours or every 2 years, whichever comes first

980176 CHARGER II 01/05

4-2

MAINTENANCE

KEY CHECKPOINTS

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

EXTERNAL FUEL PUMP MAINTENANCE

The power plant for the unit receives fuel from the main gas tank of your van/truck. An external fuel pump that provides this fuel is located on the underside of the van/truck. Loose fittings and hose connections will cause your unit to perform poorly.

Follow the recommended fuel pump maintenance in the Maintenance Schedule in this manual. Refer any additional questions to your dealer.

CHEMICAL SUPPLY SYSTEM

MAINTENANCE

The chemical supply system pulls chemicals from your chemical bottle utilizing a pump that works off the water pump pulsing. Any clogged filters or loose connections will result in a chemical supply system malfunction or a malfunction at the cleaning tool.

Maintenance of the solution outlet check valve and strainer are vital to effective cleaning operation and minimal unit downtime. Additionally, the hoses related to supplying water and chemical to the outlet manifold are under high pressures and experience thermal expansion and contraction. Periodic inspections of these hoses for tears, cracks, and failing connectors are necessary to avoid unwanted leaks. To keep your chemical system functioning properly, follow the chemical pump and solution outlet maintenance in the Maintenance Schedule in this manual. Refer any additional questions to your dealer.

HEAT EXCHANGER SYSTEM

MAINTENANCE

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

Additionally, the heat exchanger tubes are very sensitive to freezing conditions. As the water freezes during cold conditions, it expands in the heat exchanger tubes and causes damage. Often the tubes are cracked and require the replacement of the heat exchanger core. Refer to the Freeze

Protection instructions section in this manual. Refer any additional questions to your dealer.

VACUUM PUMP MAINTENANCE

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

The total function of the unit is based around the performance of the vacuum pump. Heat transfer used to raise the temperature of the solution is gained from the air drawn by the vacuum pump and solution is removed from the carpet with the vacuum suction of the vacuum pump. General maintenance actions for the vacuum pump as listed in this manual are vital to prolonged vacuum pump operations.

Daily lubrication of the pump is required to avoid seizure of the system. Also, waste tank filters and strainers must be maintained to prevent unwanted debris from entering the vacuum pump.

4-3

980176 CHARGER II 01/05

DO NOT service this unit while it is running. The high-speed mechanical parts as well as high temperature components may result in severe injury, severed limbs, or fatality.

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

ENGINE

(Refer to

Briggs & Stratton Vanguard Service And

Repair Instructions Manual for specific instructions)

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

Make certain that proper oil level is maintained.

NEVER overfill.

2. Change the break-in oil after the first 50 hours of operation. Thereafter, change oil every

100

hours of operation. USE ONLY BRIGGS &

STRATTON BRAND OIL FILTERS

(PN 42-902158) ANY OTHER TYPE OIL

FILTER WILL VOID YOUR ENGINE

WARRANTY. Torque drain plug to 10 ft lbs.

Oil Recommendation. See “ENGINE OIL

REQUIREMENTS” in Operations section.

NOTE: Using other than service class SG, SH,

SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage.

MAINTENANCE

3. Check the spark plugs every 200 hours. Clean if necessary. Replace the spark plugs every

1000 hours. NOTE: Never sandblast spark plugs. Spark plugs should be cleaned by scraping or wire brushing.

4. Replace the air cleaner element every year.

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

NOTE: If service or repair is required, contact an authorized Briggs & Stratton Service Center.

You will need to provide the serial number of the engine.

980176 CHARGER II 01/05

4-4

MAINTENANCE

VACUUM PUMP

Refer to the Vacuum Pump Operation and Service

Manual (P/N 67-945307) for specific instructions.

Lubrication: We recommend that you use AEON

PD Synthetic Blower Lubricant in the gear end of the vacuum pump for all operating temperatures. AEON

PD is formulated especially for positive displacement blower service to provide maximum blower protection at any temperature. One filling of AEON

PD will last a many times longer than a premium mineral oil.

NOTE: AEON PD (Part# 05-008039) is the oil in the vacuum pump. Topping off or adding petroleum oil to synthetic oil is NOT recommended.

1. Check the oil level daily to assure the proper level.

PROPER LEVEL cannot be overemphasized. Too little oil will ruin bearings and gears. Too much oil will cause overheating.

Use the illustration as a guide when adding oil.

2. To prevent rust from building up inside the vacuum pump (if moisture exists) we have provided a lubrication cup on the front of the unit.

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

3. Drain, flush and replace oil every 1500 hours or

yearly, whichever comes first. Change oil more frequently if inspection so indicates. With

AEON PD synthetic lubricant, perform the oil change maintenance

every 4500 hours or every 2 years, whichever comes first.

4. Vacuum pump lubrication is vital to performance of our pump. Failure to follow the maintenance schedule in the “Maintenance Schedule” can lead to permanent damage to your blower.

Refer to the Vacuum Pump Operation and

Service Manual (P/N 67-945307) for specific instructions.

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

4-5

980176 CHARGER II 01/05

WATER PUMP

Refer to the Water Pump Operation and Service

Manual for specific instructions (P/N 67-945621).

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

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

3. Change the crankcase oil with Cat Pump

Crankcase Oil, Part #05-008016, after the

first

50 hours of operation. Drain and refill the crankcase oil with Cat Pump Crankcase Oil

every 500 hours thereafter.

4. Other Cat approved oil equivalents are: Mobil

DTE 16, Amoco Rykow 68, and Shell Tellus

T68.

VACUUM INLET FILTER

(IN WASTE TANK)

1. The vacuum filter in the waste tank should be removed and cleaned daily. If this is done, the filter will last for a long period of time.

VACUUM RELIEF VALVE

While the unit is running at full RPM, block the air flow at the vacuum inlet connection and read the vacuum gauge. If adjustment is required, shut the unit down and adjust the vacuum relief valve locking nut tension. Start your unit and read the vacuum gauge. Repeat this process until the relief valve opens at 13" Hg.

MAINTENANCE

VACUUM PUMP DRIVE BELTS

To tighten the vacuum pump belts:

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

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

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

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

NOTE: When adjusting belt tension, make certain

that the engine shaft and vacuum pump shaft remain parallel, and the belt tension is equal throughout the belt width.

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

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

4. Check for pulley groove wear, clean belts and pulley grooves, check for worn belts, proper belt tension, and pulley alignment after the

first 25

hours and then again at 100 hours.

980176 CHARGER II 01/05

4-6

MAINTENANCE

WATER PUMP DRIVE BELT

To tighten the water pump belt:

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

2. Adjust the position of the belt tension adjusting bolt until the proper belt tension is achieved.

(1/2" deflection in the center of the belt, halfway between the pulleys).

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

4. Check belt and pulley every 100 hrs.

FLOAT VALVE (WATER BOX)

1. Check the float valve weekly for proper operation. If overfilling is a problem, check the plunger for a proper seal. Replace tip on plunger (PN 16-808164) if needed.

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

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

2. Disassemble the valve and check the piston and seat for damage, replace if needed. See the

“Illustrated Parts Listing” for a parts break-down.

WASTE TANK STRAINER BASKET

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

WASTE TANK FLOAT VALVE

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

Y-STRAINER (OUTLET)

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

2

and

4 weeks.

The Y-strainer should then be inspected

every

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

CHECK VALVE (OUTLET)

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

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

For the procedure, see the "General Service

Adjustments” section in this manual for details.

CHEMICAL PUMP

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

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

NOTE: Inspect chemical filter daily.

CHEMICAL AND HEAT BYPASS VALVES

Examine the packing nut on the chemical selector valve, heat bypass valve, and chemical metering valve every 200 hours. Keeping these valve packings properly adjusted will eliminate possible leakage from the valve stems and add to overall valve life.

For the procedure, see the "General Service

Adjustments” section in this manual for details.

4-7

980176 CHARGER II 01/05

NITROGEN ACCUMULATOR

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

PRESSURE REGULATOR

Lubricate the o-rings and bullet

every 50 hours.

Use o-ring lubricant Part #05-008035.

For the procedure, see the "General Service

Adjustments” section in this manual for details.

VACUUM HOSES

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

HIGH PRESSURE HOSES

Inspect your high pressure hoses for wear after the first 100 hours of use. Inspect every 25 hours

thereafter. If hoses show any signs of damage or impending rupture,

replace the hose.

MAINTENANCE

DO NOT attempt to repair high pressure hoses! Repairing high pressure hoses may result in severe burns and serious injury!

All high pressure hoses must be rated for 3000

PSI at 250°F. Thermoplastic hoses do not meet these specifications and should not be used.

Severe burns and injury may result if the hoses do not meet these requirements.

OPTIONAL WASTE PUMP-OUT

At the end of each work day, make certain that you remove any debris or sediment which may be inside the waste pump by pumping fresh water through the pump.

980176 CHARGER II 01/05

4-8

MAINTENANCE

SERVICE GENERAL ADJUSTMENTS

4. Clean the poppet and spring, inspect for wear or damage, and replace as needed.

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

DO

NOT over-tighten seat.

Tight wrap

On spring

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

ENGINE SPEED

This unit uses a factory installed Briggs & Stratton engine governor. The engine speed is adjusted using the “T” handle throttle control. Pushed in the engine is at idle speed (1400 rpm). With throttle control pulled out, engine operates at maximum rpm

(2850). By turning “T” handle clockwise , throttle can be locked at any engine speed between idle and maximum speed.

CHECK VALVE (SOLUTION OUTLET)

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

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

2. Remove the seat, using a 5/16" Allen wrench.

Use 5/16 Allen

Wrench to remove

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

6. Lubricate the o-rings with o-ring lubricant

Part #05-008035 and reinstall.

WATER BOX

1. Check inlet strainer for debris and blockage. A blocked strainer could damage the water pump if water flow is restricted.

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

CHEMICAL PUMP

The only repairs which the chemical pump may require is the replacement of the diaphragm or check valves. To replace the diaphragm, unscrew the cover from the body. When replacing the diaphragm, lubricate the outer edges of the diaphragm with o-ring lubricant Part #05-008035 and reassemble. To replace the check valves, unscrew the check valve caps. Replace the check valves and reassemble, using new o-rings.

DO NOT attempt to re-use o-rings once the check valves have been removed. See the “Illustrated

Parts Listing” for a parts break-down on the chemical pump.

DRIVE BELTS FOR WATER PUMP

AND VACUUM PUMP

Use only exact replacement for system drive belts.

Use only exact manufacturer and models for replacements.

4-9

980176 CHARGER II 01/05

MAINTENANCE

PACKING NUT ADJUSTMENT FOR

CHEMICAL METERING BYPASS AND

CHEMICAL SELECTOR VALVES

Examine the packing nut on the metering and selector valves for proper tension every 200 hours.

When turning the knob, there should be a small amount of resistance. If not, slightly tighten the packing nut. DO NOT over tighten. Keeping the valve packings properly adjusted will eliminate possible leakage from the valve stem and add to overall valve life.

Remove knob by loosening set screw to access packing nut.

CHEMICAL

SELECTOR

VALVE

PACKING NUT

(use 5/16" open end wrench to adjust)

CHEMICAL

METERING &

HEAT BYPASS

VALVE

PACKING NUT

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

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

PRESSURE REGULATOR

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

To adjust:

1. With your unit running, close the cleaning tool.

Check the pressure gauge. Open the tool valve.

We recommend setting the pressure regulator so that the pressure gauge reads 450 PSI with the tool valve open.

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

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

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

a) Shutdown the unit.

b) Relieve all pressure from the water system.

c) Remove the cap from the pressure regulator and

remove the stem with long nose pliers.

d) Clean and lubricate stem.

e) Reassemble pressure regulator.

980176 CHARGER II 01/05

4-10

MAINTENANCE

PROBLEM CAUSE SOLUTION

Loss of water pump pressure.

With the cleaning tool open, the water pressure gauge reads below the normal operating pressure.

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

Water pump inlet supply line is plugged or drawing air.

Improper engine speed

Pressure regulator o-rings are dry.

Pressure regulator has worn o-rings

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

Turn the water supply on or up. Check for kinks in the water supply hose. Examine the float valve and adjust or replace.

Examine the water inlet filter inside the water box. Remove accumulated debris and replace if required. Check for suction leaks and loose clamps or fittings. Tighten any loose fittings or clamps. Replace any ruptured hose(s).

Using a tachometer, check the engine speed.

Full throttle engine speed is 3200 RPM. Idle engine speed is 1400 RPM. Refer to the

“engine speed” section for instructions on how to re-adjust.

Lubricate o-rings, using o-ring lubricant Part

#05-008035.

Check o-rings. If necessary, replace.

Clean or repair regulator. Adjust to working pressure. Lubricate o-rings, using o-ring lubricant Part #05-008035.

Low pump volume. (Measure the amount of water being returned to the water box from the pressure regulator.

It should fill a gallon container about every 17 seconds).

Defective water pressure gauge.

Examine the check valves, plunger cups, and cylinder head on the water pump. Repair, whenever required (refer to the water pump service manual).

Replace gauge

Orifice (spray nozzle) in the cleaning tool is worn, defective, or wrong size.

Debris clogging water lines or water inlet disconnect.

Replace Nozzle or change nozzle size.

Clean or replace as needed.

Loss of solution volume at cleaning tool orifice.

Water gauge reads normal.

Belts loose or broken

Loss of pump prime

Plugged orifice and/or screen in the cleaning tool.

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

Outlet check valve is plugged

Defective quick-connect on one or more of the high pressure hoses.

Cleaning tool valve is malfunctioning.

Hose inner lining is constricted.

Air leak in chemical supply line, priming valve or metering valve.

Re-tension or replace as needed.

Manually prime water pump.

Unplug or replace orifice and/or screen

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

Examine the check valve, remove any debris

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

Repair or replace valve.

Remove restriction or replace hose.

Check for air leaks. Replace faulty parts.

4-11

980176 CHARGER II 01/05

MAINTENANCE

PROBLEM CAUSE SOLUTION

Vacuum gauge is giving an improper reading.

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

Loss of vacuum

While cleaning, the vacuum is not up to specification. Engine

RPM is normal.

Vacuum hose(s) is damaged, causing a suction leak.

Waste tank gaskets not sealing properly, not positioned properly

Plugged vacuum hose or vacuum plumbing between vacuum inlet and strainer basket.

Waste tank filter or strainer basket is plugged.

Loose vacuum pump drive belts.

Inspect hose(s), repair or replace.

Inspect the gasket. Repair seal or replace

Re-position lid(s).

Unplug vacuum hose or inlet plumbing.

Clean or replace filter. Clean strainer basket.

Tighten the drive belts

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

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

Drain the waste tank. Close drain valve, if open. Remove the dump valve and, after inspecting, replace the defective components.

Re-adjust the vacuum relief valve. If the vacuum does not increase, remove and inspect the relief valve diaphragm. If damaged, replace

Vacuum exhaust heat exchangers are plugged with lint.

Vacuum pump is worn out.

Remove and clean.

Replace the vacuum pump.

Excessive Vacuum

Loss of chemical

With the cleaning tool valve open, no chemical

Improper throttle adjustment.

Vacuum obstruction

Adjust throttle to set desired vacuum perssure.

Inspect hoses for obstructions.

Vacuum relief valve requires adjustment.

Chemical pump is improperly primed.

The strainer at the inlet end of the chemical inlet line is clogged

Suction leak in the inlet line leading into the chemical pump.

Chemical pump check valve(s) is clogged

Chemical pump diaphragm is ruptured.

Defective cylinder in the water pump.

Readjust the vacuum relief valve.

Refer to chemical pump priming instructions.

Unclog the strainer. If damaged, replace.

Inspect inlet lines and flow meter for air leaksor damage and replace, if required.

Remove any debris from the chemical check valve(s). Replace chemical check valve(s) or seals, if necessary.

Chemical prime/on-off valve or chemical metering valve is defective. Replace valve(s).

Disassemble the chemical pump and replace the damaged diaphragm.

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

980176 CHARGER II 01/05

4-12

MAINTENANCE

PROBLEM CAUSE SOLUTION

Chemical flow meter indicates flow with the tool valve closed

Engine will not start

The engine does not turn over

External leak in chemical piping

Outlet check valve is full of debris or damaged, not allowing it to close properly

Chemical pump diaphragm is ruptured

Internal leak in chemical valve causing continual flow through prime tube returning to container.

Main circuit breaker on the control panel has been tripped.

Loose or corroded battery.

Dead battery.

Defective ignition switch.

Defective starter motor.

Vacuum pump seized.

Waste tank is full.

Tighten fittings. Re-apply thread sealant where required. If any fittings are damaged, replace.

Close the chemical valve on the instrument panel. If the flow meter does not indicate flow, remove debris or replace check valve, if necessary.

Close the chemical valve on the instrument panel. If the flow meter still indicates flow, replace the chemical pump diaphragm.

Tighten valve packing nut (see “General

Service Adjustments” section in this manual). Replace valve, if necessary.

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

Clean, tighten, or replace the battery terminals.

Recharge or replace battery.

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

Test the starter motor. If necessary replace.

Refer to Gardner Denver Service & Repair

Manual.

Empty the waste tank.

Starter turns over engine, but will not start

Defective fuel pump.

Loose or broken wires leading to waste tank float switch.

Defective float switch in the waste tank.

Internal engine problem.

Replace the fuel pump.

Repair or replace any broken electrical connections.

Check switch for proper operation, replace as necessary.

Consult the Briggs & Stratton Vanguard

Service And Repair Instruction Manual or contact your local Briggs & Stratton authorized repair center.

4-13

980176 CHARGER II 01/05

MAINTENANCE

PROBLEM CAUSE SOLUTION

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

Engine stops running

While doing normal cleaning, the engine stops running

Excessive heating

Waste tank is full

Main circuit breaker on the control panel has been tripped.

Defective fuel pump.

Defective float switch inside the waste tank.

No ignition in the engine or engine is malfunctioning.

Flow restriction caused by hard water scaling.

Not enough water flow.

Empty waste tank.

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

Replace fuel pump.

Check switch for proper operaton. Replace as necessary.

Refer to the Briggs & Stratton Engine

Operation and Maintenance Manual.

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

Install water softener.

Check jet size of tool.

Heat exchanger leaks

NOTE: The heat exchanger will produce water condensation discharge at times during normal operation.

DO NOT

confuse this with a leak.

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

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

Loss of temperature

The heat output of the unit is

LESS than normal.

Automatic waste pump is malfunctioning or not operating normally

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

Temperature relief valve on water box is stuck open.

Engine RPM is low.

Defective temperature gauge.

Defective waste pump float switch.

Broken diaphragm.

Weak battery.

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

Clean temperature relief valve and test.

Replace, if necessary.

Reset engine RPM.

Test gauge and sensor. Replace failed component.

Replace float switch.

Replace diaphragm.

Charge or replace battery if needed.

Check charging station.

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

980176 CHARGER II 01/05

4-14

FRAME

19

17

1

2

16

24

23

18

4

8

12

21

22

4

3

8

14

3

4

5

20

11

15

10

6

9

7

8

3

13

8

3

4

5-1

980176 CHARGER II 01/05

REF PART NO.

QTY DESCRIPTION

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

17

18

19

20

01-000259

790735

87162

70270

61458

03-000149

64-950383

02-000066

790487

790727

87151

56-501857

00-000078

790675

14 RECPT, SNAPIN 1/4 TURNFAST

1 BRKT, HOOD BLAZER XL

12 WASHER, 1/4 SPLIT LOCK PLTD

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

1 PNL, LWR FRNT

3 CLAMP, CABLE 1-1/4 ID 5/16 BLT

1 CABL, RETAIN VAC PLG 800

70481

02-000268 14 SPLITRING, RETAIN, 1/4 TURN

61395

70802

61462

500836

790605

790606

00-000272

58-700023

6

1

1

4

FLATWASHER, 1/4

DIPSTICK, CAT PUMP OIL 5CP

GUARD, PUMP BELT

WASHER, 1/4 SPLIT LOCK BLK

1 BRKT, FUEL LINE

1 SCR, 1/4-20 X 1” HXHD GRD8

1 ASSY, FRAME XL

4 SCR, 1/4-20 X 3/4 BHCS BLK

7 PAD, 1/4 TURN FAST, .188 THK

7 STUD, 1/4 TURN FAST

1 PNL, HOOD ASM BLZR X L

1 LABEL, LWR FRNT PNL

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

1 EL, 90DEG 1/8NPT X 1/4HB

7 STUD, 1/4 TURNFAST #85 OV

7 PAD, 1/4 TURN VIBR

SERIAL NO.

FROM

NOTES:

FRAME

980176 CHARGER II 01/05

5-2

SIDE PANEL

8

9

10

11

1

7

6

2

4

3

5

4

12

13

5-3

980176 CHARGER II 01/05

REF PART NO.

QTY DESCRIPTION

7

8

5

6

3

4

1

2

9

10

11

12

13

790702

12-800099

57047

02-000066

12-800269

11-800354

13-806008

00-000078

66-945236

19-800075

790599

87162

70270

1 BRKT, WATER & VAC INLET XL

1 ELL, 1/8P X 1/4 POLY BR

1 NUT, 1/4-20 HEX NYLOCK

2 FLATWASHER, 1/4

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

1 NIP, 1/2 X 3/8 HEX BR

1 DCS, 3/8F X 3/8FP

1 SCR, 1/4-20 X 1” HXHD GRD8

1

1

1

2

2

KIT, VAC INL PLG BRU2

CUP, OIL FILL 1/8P

LABEL, WTR & VAC INLET BRKT

WASHER, 1/4 SPLIT LOCK PLTD

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

SIDE PANEL

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-4

CONTROL PANEL-UPPER

27

26

24

23

22

29

28

21

20

19

2

1

5

6

3

4

7

8

7

9

10

11

12

13

14

15

16

17

30

25

18

5-5

980176 CHARGER II 01/05

70270

790742

33-900162

33-900161

32-900174

32-900087

36225

36227

500833

500834

18-808513

49-802518

49-802505

73811

15-808106

12-800065

56032

140675

15-808022

11-800014

12-800093

57049

70162

87165

12-800101

12-800035

61456CB

54092

02-000066

87162

REF PART NO.

QTY DESCRIPTION

25

26

27

28

29

30

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

1 VALVE, METER 1/8FP

2 CONN, 1/8P X 1/4T

1 NIPPLE, 1/8 CLOSE

1 BRKT, FLOW METER

1 VALVE, 3-WAY BALL 1/8FP

1 ELL, STREET 1/8 BR

3 FTTG, BRB 1/8P X 5/16H

4 NUT, 6-32 HEX NYLOCK SS

4 SCR, 10-32 X 3/8 PPHMS SS

4 WASHER, #10 SPLIT LOCK PLTD

1 ELL, 1/4FP X 1/4T BR

1 ELL, 1/4FP X 1/4T BR

1 PNL, FRNT, BLZR,PC

1 METER, 0-60VDC HOUR

4 FLATWASHER, 1/4

4 WASHER, 1/4 SPLIT LOCK PLTD

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

2 PAD, PANEL

1 BREAKER, CIRCUIT, 25A

1 BREAKER, CIRCUIT, 30A

1 KEYSWITCH

1 SWITCH, TOGGLE

1 GAUGE, 0-1500 PSI

1 GAUGE, VACUUM 30” HG

1 LABEL, CONTROL PNL BLZR XL

1 LABEL, CHEM PNL XL

1 FLOWMETER, 1/8FP

1 CABLE, CHOKE

1 CABLE, THROTTLE

2 STANDOFF, 3-32 X 1/2 HEX NYL

CONTROL PANEL-UPPER

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-6

ENGINE

26

17

17

25

23

24

18

16

5

19

22

21

20

27

28

15

14

17

13

1

2

3

4

5

7

8

9

6

11

12

9

10

5-7

980176 CHARGER II 01/05

42-902005

42-902006

40-902147

52-501935

87083

70258

42-902169

57113

02-000143

70320

10-805291

12-800062

42-902158

54-500412

44-802250

44-802212

00-000340

44-802202

35-901002

02-000066

87162

70270

790626

57031

790711

42-902174

31-900027

31-900028

REF PART NO.

QTY DESCRIPTION

21

22

23

24

17

18

19

20

25

26

27

28

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

1 B&S CARTRIDGE AIR CLNR 394-018

1 ELEMENT (OUTER), AIR CLEANER

1 ENG, B7S 18HP VTWIN OHV

1 PULL, ENG, PWRVAC

2 WASHER, 5/16 SPLIT LOCK PLTD

2 SCR, 5/16-18 X 1.5 HHCS GR5PLT

1 PLUG, SPARK

4 NUT, 5/16-18 HEX NYLOCK

8 WASHER, 5/16 FLAT PLTD

4 SCR, 5/16-18 X 2” HHCS GR5PLTD

1 HOSE, HP 3/8 X 10

1 PLUG, 1/2T

1 B&S OIL FILTER #492-932

1 KEY, 1/4 SQ X 1.88

2 BELT, AX38 GOODYEAR MATCH

1 PULLEY, 2TA54

9 SCR, MACH 5/16-18 X 1” GR8

1 HUB, P1 X 1

1 SOLENOID, STARTER

1 FLATWASHER, 1/4

1 WASHER, 1/4 SPLIT LOCK

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

1 GSKT, EXHST, KHLR 25HP

3 NUT, 5/16-18 HEX

1 MANIFOLD, ENGINE EXH B&S

1 GASKET, EXHAUST MNFLD

1 TERM, INS DSC 1/4F 14-16W

1 TERM, INS DSC 1/4M 14-16W

SERIAL NO.

FROM

NOTES:

ENGINE

980176 CHARGER II 01/05

5-8

VACUUM PUMP

5-9

18

19

20

11

17

16

21

3

1

2

15

5

6

4

7

10

11

9

8

SUPPLIED

WITH PUMP

14

13

980176 CHARGER II 01/05

12

REF PART NO.

QTY DESCRIPTION

13

14

15

16

9

10

11

12

17

18

19

20

21

7

8

5

6

3

4

1

2

41-905024

54-501593

03-000112

09-805478

54-500680

44-802212

44-802250

00-000340

44-802204

57119

87171

56-501816

02-000057

00-000323

61-951142

04-000091

52-501573

56-501615

43-807074

12-800059

57117

1 PUMP, 3LVLTHC

1 NIP, VAC EXH OUTLET

2 CLAMP, HOSE #48

1 HOSE, VAC 2.88 X 2.5 BLK

1 KEY, 3/16 SQ X 7/8

1 PULLEY, 2TA54

2 BELT, AX38 GOODYEAR MATCH

3 SCR, MACH 5/16-18 X 1” GR8

1 HUB, P1 X 3/4”

4 NUT, 3/8-16 HEX NYLOCK

6 WASHER, 3/8 FLAT

1 BRKT, VAC ADJ

1 FLATWASHER, 1/2 HEAVY

2 SCR, 1/2-13 X 3-1/2 HHCS FULL THD

1 VALVE, VACUUM RELIEF

1 SPRING, VAC REL VLV

1

1

1

2

2

ELL, VAC REL VLV

STEM, VAC REL VLV #4 VAC

DIAPHRAM, VAC REL VLV

CONN, 1/8P X 1/4 POLY BR

NUT, 5/16-24 HEX PLTD

VACUUM PUMP

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-10

WATER PUMP & CHEMICAL PUMP

26

TO WATER BOX

2

4

27

28

3

5

25

24

36

35

37

32

33

32

31

30

35

32

36

23

21

20

6

8

15

16

18

1

7

9

TO FRONT

ENGINE PULLEY

16

17

18

19

20

10

22

13

29

11

12

14

29

20

5-11

980176 CHARGER II 01/05

WATER PUMP & CHEMICAL PUMP

SERIAL NO.

FROM

NOTES:

57113

70266

87163

87171

790544

52-501925

00-000336

12-800040

41-809158

790605

52-809125

52-809123

70254

52-502053

42-809047

42-809264

43-810105

52-502075

42-809265

43-810079

52-502052

03-000249

03-000113

12-800278

11-800299

12-800225

41-809153

12-800031

11-800224

44-802312

44-802252

00-000340

54-500680

87098

12-800029

70601

02-000143

REF PART NO.

QTY DESCRIPTION

29

30

31

32

25

26

27

28

33

34

35

36

37

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

1 CLMP, CABL 1/4ID 3/8BLT

1 CLAMP, HOSE #12 SST

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

1 ELL, STREET 1/2 45 DEG

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

1 PMP, WTR CAT 3CP1140

1 ELL, 1/4P X 1/4T BR

1 PLUG, 3/8 SOCHD BR

1 BELT, AX32 GOODYEAR MATCH

1 PULL, 1TA40

3 SCR, MACH 5/16-18 X 1” GR8

1 KEY, 3/16 SW X 7/8

1 WASHER, M8 SPLIT LOCK

1 PLUG, 1/4T BR

2 SCR, 5/16-1/8 X 2.75 HHCS GR5

2 WASHER, 5/16 FLAT PLTD

2 NUT, 5/16-18 HEX NYLOCK

4 SCR, 3/8-16 X 1” HHCSGR5PLT

4 WASHER, 3/8 SPLIT LOCK

4 WASHER, 3/8 FLAT

1 ASSY, PMP ADJ BRKT

1 HUB, PUMP WATER

1 SCR, CAP 3/8-16 X 3 ALL THD

1 ELL, 1/8P X 1/4T BR

1 PUMP, CHEM TM (O-RING) SS

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

1 ADPT, CAT CHEM PUMP

1 RETAIN, VALVE SPRING

1 SCR, M8 X 18 SHCS PLTD

1 CVR, CHEM PMP

1 DIAPHRAGM, CHEM PUMP

1 DISK, CHEM PUMP

1 O-RING, 1-58 ID X 1-3/4 OD VITON

2 CAP, CK\HK VLV-HP CHEM PMP

2 CHECK VALVE, CHEM PUMP

2 O-RING, 7/8 ID X 1-1/16 OD

1 BDY, CHEM PMP

980176 CHARGER II 01/05

5-12

WATER PUMP

5-13

5

1

2

10

12

13

4

3

14

15

18

11

9

18

8

9

15

7

6

17

16

980176 CHARGER II 01/05

REF

13

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

18

PART NO.

42-809238

42-809239

42-809249

42-809381

42-809394

42-809401

42-809402

42-809403

42-809404

42-809405

42-809406

42-809407

42-809408

42-809409

42-809410

42-902380

43-807063

66-950441

DESCRIPTION

CAP, OIL FILTER

O-RING, OIL FILL CAP

WASHER, KEYHOLE M18

SLINGER, BARRIER

O-RING, BEARING CVR

COVER, CRANKCASE

O-FING, CRANK CVR

MANIFOLD, HEAD

PLUG, VALVE

RETAINER, SEAL

BOLT, MNFLD HD M8 X 65

RETAINER, PNLGR W/STUD

HYPRO CVR#0711-2200A

SEAL, OIL CRANKCASE

KIT, SEAL

GAUGE, OIL LEVEL

GASKET, OIL GAUGE

KIT, VALVE

WATER PUMP

SERIAL NO.

FROM

NOTES:

ORDER 1 EACH

ORDER 1 EACH TO

REPLACE ALL VALVES

980176 CHARGER II 01/05

5-14

HEAT EXCHANGER

9

10

13

3

2

1

4

5

6

7

30

24

23

8

26

27

2

26

25

22

COPPER CORE

20

28

29

SST CORE

12

19

15

17

18

16

11

6

5

4

14

14

5-15

9801980176 CHARGER II 01/05

790714

02-000143

790721

70270

87162

02-000066

790707

43-807080

03-000086

790708

790578

790668

790671

12-800282

11-800276

12-800345

36238

11-800224

790038

790680

OPEN

790801

790423

790050

57031

87083

70540

12-800161

790388

87090

REF PART NO.

QTY DESCRIPTION

25

26

27

28

29

30

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

3

SPACER, ENG SUPPORT

9

WASHER, 5/16 FLAT PLTD

3

SCR, 5/16-18 X 4.0 HHMS PLATED

26

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

24

WASHER, 1/4 SPLIT LOCK PLTD

24

FLATWASHER, 1/4

1

MUFFLER, VAC W/EXH TUBE

1

GASKET, VAC HE INLET

1 CLAMP, MFLR 1-1/4

1 TUBE, SILENCER/EXH MNFLD

1

PLT, BLNK CVR, VAC HE

1

COVER, SST CORE VAC HE

1 HSG, VAC HE

2

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

3

ELL, 3/8 BR

2

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

6

GROMT, 1/2ID C 1-1/4OD 1/8G 5/16W

6

PLUG, 3/8 SOCHD BR

3 MANIFOLD, HEATER CORE

1 COVER, COP CORE VAC HE

-

1 ASSY, HEATER CORE COPPER

4 PAD, REAR VAC HTR CORE

3 GASKET, VAC HE CVR

3 NUT, 5/16-18 HEX

6 WASHER, 5/16 SPLIT LOCK PLTD

3 SCR, 5/16-18 X 1 HHCS GR8 PLTD

1 FTTG, BRB 3/8P X 1/2H BR

1 ASSEMBLY, HEATER CORE SS

2 WASHER, 1/4 ID X 3/4 OD PLTD

HEAT EXCHANGER

SERIAL NO.

FROM

NOTES:

INCLUDES 17 & 20

980176 CHARGER II 01/05

5-16

PRESSURE REGULATOR & TEMPERATURE BYPASS

12

20

19

10

9

11

12

8

7

6

13

5

2

1

3

4

3

15

16

18

9

5-17

980176 CHARGER II 01/05

PRESSURE REGULATOR & TEMPERATURE BYPASS

SERIAL NO.

FROM

NOTES: REF PART NO.

QTY DESCRIPTION

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

790106

790713

11-800128

15-808081

790722

11-800429

14-806549

15-808094

12-800040

12-800225

15-808131

12-800065

12-800347

12-800141

87151

70481

87012

22015

15-808106

12-800261

1

ACCUMULATOR , 250PSI CAT 6026

1

MANIFOLD, PRESSURE REG

2

NIP, HEX 1/4 SST

1

REG, PRE W/O INNER SPRING

1

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

1

NIP, HEX 3/8 SST

1

SCREEN, CHECK VALVE

1

VALVE, CHECK

2

ELL, /18P X 1/4T BR

1

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

1

MNFLD, CHK VLV

2

CONN, 1/8P X 1/4T

1

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

1

CONN, 1/2P X 1/2T

2

WASHER, 1/4 SPLIT LOCK BLK

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

1

WASHER, 7/16 STAR

1

COUPLER, 1/4 QD

1

VALVE, METER 1/8FP

1

ELL, 1/8P X 1/4T 45 DEG

INCLUDES 7, 8

980176 CHARGER II 01/05

5-18

WATER BOX

5-19

22

19

21

20

19

18

23

24

17

16

15

14

13

3

10

9

11

12

5

1

3

4

2

6

7

8

980176 CHARGER II 01/05

REF PART NO.

QTY DESCRIPTION

00-000335

87162

02-000066

50-501763

58-500781

19-807014

12-800065

15-808075

790696

54-501715

12-800278

11-800299

70270

11-800300

14-806540

11-800345

57006

03-000246

12-800269

11-800041

03-000111

11-800361

15-808110

11-800432

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

17

18

19

20

4

SCR, 1/4-20 X 8 HXHD

4

WASHER, 1/4 SPLIT LOCK PLTD

2

FLATWASHER, 1/4

1

HOLD DOWN WTR BOX

1

MOLDING, WATER BOX

1

BALL, FLOAT

1

CONN, 1/8P X 1/4T

1

VLV, TEMP REL 145 DEG

1

TRAY, WTR BX

1

FLOAT ROD

1

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

1

ELL, STREET 1/2 45 DEG

4

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

2

NIP, 1/2 X CL

2

STRAINER, SUC END 1/2FP

1 PLUG, 1/4 SOCHD BRASS

2

NUT, 1/4-20 HEX

2

CLAMP, HOSE #8 SST

2

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

1

ELL, STREET 1/2 BR

2

CLMP, HOSE #10 9/16 MIN

1

ELL, 1/2 BR

1

VALVE, FLOAT

1

CAP, WATER BOX

WATER BOX

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-20

WASTE TANK

14

13

12

13

4

2

1

5

3

12

7

8

8

9

10

6

11

5-21

980176 CHARGER II 01/05

REF PART NO.

QTY DESCRIPTION

9

10

11

12

13

14

7

8

5

6

3

4

1

2

790652CB

56-501793

790620

14-806518

790733CB

12-800031

00-000072

87171

62986

57119

61-950621

11-800402

46-802510

67006

1

1

1

1

1

2

9

18

6

9

1

3

2

8

LID, 60G WST TNK

STRAINER BOWL

GSKT, WASTE TANK

STRAINER, WST TANK 2-1/2”

TNK, WST 60G, XL

ELL, 1/4P X 1/4T BR

SCR, 3/8-16 X 2” HXHD

WASHER, 3/8 FLAT

PLATE, TRUCKMOUNT SHIPPING

NUT, 3/8-16 HEX NYLOCK

ASSY, LVL SENS SHTOF SW

PLUG, 1-1/4 HXHD PVC

LATCH, DRAW 2-7/8 SST

RIVET, 3/16 OD X 5/8 AL

WASTE TANK

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-22

HOSE ACCESSORIES

2

1

3

12

11

13

16

15

14

2

10

4

9

5

6

7

8

17

21

19

18

20

5-23

980176 CHARGER II 01/05

REF PART NO.

13

14

15

16

9

10

11

12

17

18

19

20

21

7

8

5

6

3

4

1

2

12-800078

08-805147

10-805060

56015

22015

56012

10-805108

10-805077

08-805155

15-808012

43-810014

43-810019

11-800354

10-805157

13-806009

10-805295

22015

10-805077

08-805155

56012

10-805122

HOSE ACCESSORIES

QTY DESCRIPTION

1

1

1

1

2

2

2

1

2

1

1

1

1

1

1

1

1

1

1

1

2

FITTING, BRB 2H BS PVC

CUFF, 2”

HOSE, VAC 2”X50’ W/ CUFFS & HOSE

NIPPLE, 1/4 HEX

COUPLER, 1/4 QD

NIPPLE, 1/4 FPT QD

HOSE, HP 1/4 X 50FT W/QD & VLVE

HOSE, HP 1/4 X 50’

GUARD, HOSE VINYL

VALVE, BALL 1/4FP

O-RING, 7/32ID X 11/32OD

O-RING, 3/8 ID X 1/2 OD

NIP, 1/2 X 3/8 HEX BR

HOSE, WATER 1/2 X 50’

DISCONNECT 3/8M X 3/8FP

HOSE, WATER 1/2 X 50’

COUPLER, 1/4 QD

HOSE, HP 1/4 X 50’

GUARD, HOSE VINYL

NIPPLE, 1/4 FPT QD

HOSE, HP 1/4 X 50FT W/QD

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-24

BATTERY-FLOOR MOUNT

2

1

3

4

5

6

7

8

2

10

9

2

5-25

980176 CHARGER II 01/05

REF PART NO.

7

8

5

6

3

4

1

2

9

10

00-000167

87162

02-000066

31-900179

36-900056

47-700007

56-500188

56-502049

00-000132

57006

QTY DESCRIPTION

1

1

1

1

4

4

2

2

SCR, 1/4-20 X 6” HXHD

WASHER, 1/4 SPLIT LOCK

10 FLATWASHER, 1/4

1 COVER, BATTERY TERMINAL

BATTERY

SHIELD, BAT MT HT

COVER, BATTERY

TRAY, BAT FLOOR MT

SCR, 1/4-20 X 1-1/2 HXHD

NUT, 1/4-20 HEX

BATTERY-FLOOR MOUNT

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-26

AUTOMATIC PUMPOUT-OPTIONAL

17

16

11

10

6

7

10

4

3

5

1

5

5-27

8

7

13

2

5

9,12,15

5

4

3

14

6

980176 CHARGER II 01/05

AUTOMATIC PUMPOUT-OPTIONAL

REF

13

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

PART NO.

70105

00-000132

57006

87162

02-000066

03-000176

09-805591

10-805484

12-800052

12-800367

12-800444

43-807008

50-502055

52-000123

52-501993

61-951306

61-951319

QTY DESCRIPTION

1

1

1

1

1

1

1

1

1

1

1

4

4

4

4

4

2

SCR, M4 X 60 PH

SCR, 1/4-20 X 1/ 1/2 HXHD

NUT, 1/4-20 HEX

WASHER, 1/4 SPLIT LOCK PLTD

FLATWASHER, 1/4

CLAMP, HOSE #16

HOSE, WASTE PUMP 1” X 8’

HOSE, GARDEN 3/4 X 75’

CAP, HOSE 3/4 BR

FTTG, BRB 1PX1H BR

FTTG, 1-1/4P X 1” H BR

WASHER, HOSE 5/8 ID 1” OD

BRKT, CTR HOOD FR

NUT, 1-3/16-12 UN HXHD

CONN, HOSE WATER OUTL

PUMP, HD AUTO

ASSY, LVL SENS SHUT OFF SW

SERIAL NO.

FROM

NOTES:

980176 CHARGER II 01/05

5-28

AUTOMATIC PUMPOUT-OPTIONAL

1

26

5

8

36

15

23

24

3

27

19

11

22

32

10

13

6

14

28

7

20

34

33

21

29

30

9

31

18

16

37

22

11

17

25

5

2

13

4

38

21

10

12

21

35

8

35

21

5-29

980176 CHARGER II 01/05

REF PART NO.

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

33

34

35

36

37

38

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

43-807118

43-810091

43-810100

43-810101

43-807116

45-801927

49-876301

50-502025

50-502026

00-000311

11-800504

52-501828

52-501829

52-501914

52-501915

52-501921

00-000210

00-000311

00-000312

00-000399

00-000241

57245

87162

87165

04-000312

04-000334

04-000335

04-000342

52-501822

16-808241

40-902151

43-807117

52-501934

52-501950

52-501822

56-502428

52-501821

52-501820

AUTOMATIC PUMPOUT-OPTIONAL

SERIAL NO.

FROM

NOTES: QTY DESCRIPTION

1

1

1

1

1

1

1

2

1

1

2

4

1

1

1

1

2

1

1

1

1

1

1

1

2

1

2

1

1

2

1

8

8

8

8

1

4

4

SCR, 1/4-20 X 3/4 SOCHD

SCR, 1/4-20 X 1/2 SHCS SS

SCR, CAP 1/4 X 1 SOCHD

SCR, CAP 1/4 X 1 3/8 SOC

SCR, CAP 10-32 X 2 SOCHD SS

NUT, 1/4-20 HEX NYLOCK SS

WASHER, 1/4 SPLIT LOCK

WASHER, #10 SPLIT LOCK

RING, RETAIN EXT 1/2

BALL, NYL ID

RING, SNAP 1-7/8D

SPRING, PUMP-OUT BALL PRESS

INL, HOSE CONN WST TNK

DIAPH, WST TNK PMP-OUT

MOTOR, 1/8HP 12V

GSKT, CVR TOP PMPOUT

GSKT, CVR SD PMPOUT

SEAL, PUMPOUT SHFT

SEAL PUMPOUT CAM

O-RING, 800/1000 .072

GSKT, IN/OUTLT WST TNK-PM

BRG, SHFT PUMP-OUT

VENT, UPR SHFT BRNG HSG

PL, CVR TOP PUMP-OUT

PL, CVR SD PUMP-OUT

SCR, 1/4-20 X 1/2 SHCS SS

GA, FLOW SIGHT 3/8 NPT

BTM, PLNGR WST TNK PMP-OUT

SHT, 3/4” STROKE WST TNK

RD, CONNECT WST PMP-OUT

GUIDE, PLNGR WST PUMP-OUT

PIN, WRIST PUMP-OUT

TOP, PLNGR PUMP-OUT

BUSH, THREADED

INL, HOSE CONN WST TNK

BRKT, PMP-OUT SW/CCT BRKR

TOP, WST TNK PUMP-OUT

BASE, WST TANK PMP-OUT

980176 CHARGER II 01/05

5-30

WATER TANK-DEMAND PUMP-OPTIONAL

4

6

4

10

4

13

5

12

1

2

3

11

8

7

4

4

8

9

13

5-31

980176 CHARGER II 01/05

WATER TANK - DEMAND PUMP-OPTIONAL

SERIAL NO.

FROM

NOTES: REF PART NO.

QTY DESCRIPTION

7

8

5

6

3

4

1

2

9

10

11

12

13

70305

87083

02-000143

03-000113

09-805278

09-805357

09-805446

12-800345

13-806009

14-806553

41-905049

20381-022

11-800275

4

4

4

6

1

1

1

1

1

1

1

1

1

SCR, 5/16-18 X 3/4 HHCS GR5 PL TDL

WASHER, 5/16 SPLIT LOCK PLTD

WASHER, 5/16 FLAT

CLAMP, HOSE #12 SST

HOSE, WATER 3/4 X 3”

HOSE, WATER .75 X 5.5

HOSE, WATER 5/8 X 55

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

DISCONNECT, 3/8M X 3/8FP

FILTER, DEMAND PUMP

PUMP, WATER BOOSTER FLOJET 2

KIT, PORT

ELBOW, ST 3/8 BR

980176 CHARGER II 01/05

5-32

WIRING DIAGRAM

HOUR METER

#54092

+ -

ENGINE

USE :

70305

87090

87083

FUEL SOLENOID

M F

REGULATOR

RED

F

STARTER

M

57030

RED 12Ga

RED

4Ga

I S

SOLENOID

#35-901002

70270

87162

02-000066

COM

N.O.

N.C.

WHT

BLK

GRN

NEG POS

BATTERY

#36-900056

WHT

BLK

GRN

ORG/WHT

RED/WHT

ENGINE SHUTOFF

SWITCH

#61-950621

GRN BLK

WHT

REAR OF

CONNECTORS

RED/WHT

ORG/WHT

WASTE TANK

EXTERNAL FUEL

PUMP

F M

M F

F

M

FUEL PUMP CORD

#790579

M

F

MAIN CIRCUIT BRKR

#33-900161

30

AMP

IGNITION SWITCH

#32-900174

PUMPOUT/AUX

CIRCUIT BRKR

#33-900162

25

AMP

PUMPOUT

TOGGLE SWITCH

#32-900087

A B C

FEMALE CONNECTOR

FOR PUMPOUT

A B

5-33

980176 CHARGER II 01/05

HOSE DIAGRAM

6") (3 341 805 09-

) /2" 8-1 (6 271 805 10-

980176 CHARGER II 01/05

5-34

WAND-DUAL-JET

5-35

980176 CHARGER II 01/05