hazard intensity level - Jon-Don
Contents
1. 4 1 LUDICAMIOTL ti 41 M ND EN 4 1 Solution Pump Replacemernt 42 Vacuum Motor Replacemern t 42 Pump Replacement Kits 43 Pressure Regulabor 43 Machine Troubleshoollng 44 TABLE OF CONTENTS GROUP PARTS LIST Base rss 5 1 Label and Strap Group 53 Pump GIOUD Aue 55 Recovery Tank Group 57 Solution Tank Group es 59 Vacuum Motor Group 5 11 Wiring Diagram 5 13 MID 5 14 222m mer 5 15 This manual contains following sections HOW TO USE THIS MANUAL SAFETY OPERATIONS MAINTENANCE 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 th2. GROUP GROUP PARTS LIST REF PARTNO QTY DESCRIPTION NUT 10 32 NYLOCK SS SCR 1 4 20 X 3 4 HHCS SS NP WASHER 1 4 ID X 5 8 OD SS WASHER 10 FLAT PLTD DRAW PULL LATCH STD 6 RIVET AL 3 16 X 1 2 CLOSED CASTER SWIVEL 4 SWIVEL 8 NUT 1 4 20 HEX NYLOCK SS 9 WASHER 5 X 1 25 FLAT GR8 PLT NUT 1 2 PUSH ON DOME CAP WHEEL 8 BLK CENTERED HUB AXLE ASSEMBLY COMANCHE SWITCH DPST LIGHTED ROCKER SCR 10 32 X 1 PPHMS 15 50 501858 1 PL EXTRACTOR 3 DWITCH SCR 10 32 X 1 2 PPHMS BLK NP BASE COMANCHE CLAMP 5 8 NYLON UL CSA RIVET ALUMINUM 3 16 X 3 4 HING SOL amp VAC TANK 4 X 8 FILTER INLINE 16A F55047 1 NUT M8 LABEL amp STRAP GROUP 5 3 LABEL GROUP PARTS LIST REF PARTNO QTY DESCRIPTION 500568 1 LABEL COMANCHE MAIN 500531 LABEL PROCHEM LOGO 6 X 1 75 320 05 VELCRO STRAP 500009 LABEL WARNING 5 4 PUMP GROUP TO SOLUTION TANK 5 5 PUMP GROUP PARTS LIST REF PARTNO QTY DESCRIPTION 20042 CLAMP 3 8 HOSE D SLOT 39233 HOSE 3 8 RUBBER X 17 ll 39403 HOSE 3 8 RUBBER X 5 sd al JW En 12 800398 HOSEBARB Y 3 8 ALL NYLON 39250 HOSE 3 8 RUBBER X 12 40043 HOSEBARB 3 8 X 3 8 90D 65220 FLOJET 100 PSI PUMP 220V 1000107206 31056 ELBOW 3 8 MPT X 1 4 FPT 87018 WASHER 10 X 9 16 OD 57090 NUT 10 32 HEX NYLOCK SS 56012 NIPPLE 1 4 FPT QD 390 09A WASHER 9 16 S S USS THICK 395
3. 5 10 VACUUM MOTOR GROUP 5 11 VACUUM MOTOR GROUP PARTS LIST REF PARTNO QTY DESCRIPTION 5 12 WIRING DIAGRAM 57104 3 CAPACITOR PUMP BACK OF SWITCH PLATE 1 gt 2 cn POWER CORD SCREW 70595 BLUE STRAIGHT VACUUM MOTOR 1 Lygtis SSSR SR Z p rl Z f Y SIDEWAYS Y VACUUM 7 MOTOR 2 lt 880380 7 5 13 NOTES NOTES 5 14 VEA 1 WARRANTY warrants your new machine to be free of defects in material and workmanship This warranty shall extend to the designated parts for the specific time period listed from the date of delivery to the user If PROCHEM receives notice of such defects during warranty period PROCHEM will either at it s option repair or replace products which prove to be defective Any local or distant transportation related service labor and diagnostic calls are not included Molded Components 5 year pro rated Vacuum s 1 year Pump 1 year Hinges 1 year Rocker Switches 1 year Heating Element 1 year Wheels and Casters 1 year Fittings hoses o rings and other maintenance items are not covered under warranty This warranty shall not apply to defects resulting from improper operation inadequate maintenance by the customer unauthorized modification misuse a unit that is improperly repaired or exposure to freezing temperature conditions To obtain war
4. an equipment grounding conductor and grounding plug The plug must be inserted into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician or service person if you are in doubt as to whether the outlet is properly grounded Do not modify the plug provided with the appliance if it will not fit the outlet have a proper outlet installed by a qualified electrician TECHNICAL SPECIFICATIONS Dimensions Length Lin 78 7cm 17 in 43 2cm Power Cabe ZW Power Cable 7 6M Dimensions Weight Emp 81 lbs 37kg Sin 787000000000 HEIGHT MACHINE OPERATIONS Solution Tank Solution Tank lid Vacuum Tank Vacuum Tank lid Vacuum Inlet Base Assembly Dump Valve Vacuum 2 Water Pump Vacuum 1 Solution Outlet Optional equipment 89226 Deluxe Professional Wand 39605 Hose Asm 1 5 Vac Sol 25ft 3 2 MACHINE OPERATIONS PRE RUN INSPECTION 1 Check all fittings and connectors for proper assembly 2 Check all hoses for leaks Repair or replace any damaged hoses 3 Check power cord s for any damage If damaged replace EQUIPMENT SET UP 1 Plug power cord from machine into properly grounded wall outlet 2 Turn vacuum motor switch on and off to make sure there is elect
5. be warranted to PROCHEM
6. 99 HOSE HP 23 0 1 4 MPT X 1 4 MPT 70614 SCR 10 32 X 1 1 8 PPHMS SS 39597 HOSE HP 15 0 1 4 MPT X 1 4 MPT 22014 COUPLER 1 4 F HEX 57104 NUT 10 32 W STAR WASHER PLTD por 14454 BRKT VALVE PY EE l 4 1 54182 MANIFOLD ASM PLATE CM MANIFOLD PLUG 1 4 BRASS PIPE SCR 10 32 X 1 PPHMS BLK STRAIN RELIEF 1 2 NPT TRUMPET CORD MOLD ENGLAND 220V 25 NUT 1 2 NPT CONDUIT WASHER 765 ID X 1 31 OD X 09T SS VALVE BPR 125 PSI BRKT VALVE SFTY 62964 66017 70547 73505 64 950582 57040 87173 84181 140587 DERI EMI 9 28 28 1 RECOVERY TANK GROUP RECOVERY TANK GROUP PARTS LIST REF PARTNO QTY DESCRIPTION 5 8 SOLUTION GROUP 5 9 SOLUTION TANK GROUP PARTS LIST REF PART NO a DESCRIPTION SERIAL DO NOTES SCR 6 X 1 2 PPHST LID SOLUTION TANK COMANCHE STRAINER 1 4 50 MESH ge ed NUT 516 18 NYLOCK SS AA WASHER SEAL 5 16 X 3 4 OD AA 6 35182 4 GASKET FRAME HOSEBARB 1 4 X 3 8 450 Tr 8 75379 TANK SOLUTION COMANCHE AA 9 56014 1 NIPPLE 1 4 CLOSE HING SOL amp 4 X 8 SCR 174 20 X 1 2 HHCS SS a WASHER 1 4 ID X 5 8 OD SS AA BRKT CORD WRAP NO HEATER AA SCR 14 20 X 1 2 PHTR BLK a A GASKET SOL VAC TANK CMNCH
7. AINTENANCE PUMP REPLACEMENT KITS 100 PSI FLOJET 65220 29219 PUMP HEAD VALVE ASM PUMP REPLACEMENT KITS 100 PSI SHURFLO 250 64B PRIOR TO SN 1000107206 250 67 Switch Asm Pump Head Replacement Bypass Valve Asm Diaphragm 65187 84161 29206 MAINTENANCE PRESSURE REGULATOR For best results with the pressure regulator we recommend that you clean and lubricate the piston and u cup with Superlube lubricant monthly or when pressure drop seems excessive 1 2 Turn unit off before lubricating Remove cap spring and spring retainer plate With fingertips remove piston and u cup Wipe piston and u cup clean of any film or scale Lubricate the piston and u cup with Superlube Reassemble regulator With pump ON re adjust pressure regulator for normal operation LUBRICATE U CUP WITH SUPERLUBE MONTHLY SPRING 555555505 xx ER IN PISTON SPRING GOLD 125 ps CAP TROUBLESHOOTING PROBLEM CAUSE SOLUTION Dead electrical circuit Check building circuit breaker or fuse box Loss of Power Faulty power cord Equipment not grounding Follow grounding instructions exactly Electrical shock Receptacle not grounded Contact an electrician to check building 5 wiring Internal wiring problem a trained service technician check machine s WIring Worn motor brushes Replace Vac motor speed varies Motor worn out Replace or doesn t run Faulty switch Replace Loo
8. ONSPICUOUS PLACE Also to avoid prolonged drying times do not spray too much solution in any one area A WARNING Before making any adjustments or performing any maintenance to your machine disconnect the power cord from the electrical source SHUT DOWN AND STORAGE 1 Turn Switch OFF Empty recovery tank completely and rinse several times to remove any dirt or debris that may be left behind Drain any unused cleaning solution from solution tank and rinse with clean water to remove any suds left behind by the cleaning chemicals NOTE Dispose of waste in a proper manner which would not violate any Local State or Federal law Run a small amount of clean water through pump if chemicals were used This will help insure the life of your pump Check the spray jet on the cleaning tool for full spray pattern and inspect vac head for any obstructions Remove as much moisture from system before storing in cold climates Excess water may freeze during storage and crack internal components causing damage to the unit MACHINE OPERATIONS MAINTENANCE DAILY MAINTENANCE Unplug power cord s before servicing or making any repairs Flush the entire system including floor tool hand tool etc with 1 to 3 gallons of clean hot water Vacuum out the solution tank Rinse tank with fresh water Periodically inspect the recovery tank and decontaminate if necessary using a Hospital Grade Virucide or a 1 10 bleach to water sol
9. a Castle Rock Industries ca Priority Manufacturing Samurai PORTABLE EXTRACTOR Operating Instructions Read these instructions before using the machine Jon Don 800 556 6366 www jondon com MACHINE DATA LOG OVERVIEW MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE DEALER NAME OPERATIONS GUIDE NUMBER PUBLISHED YOUR DEALER Name Address Phone Number Machine Data Log Overview 2 Table of Contents 3 HOW TO USE THIS MANUAL How to use this Manual 1 1 SAFETY Important Safety Instructions 2 1 Hazard Intensity Level 2 2 Grounding Instructions 2 3 OPERATIONS Technical Specificalions 3 1 Machine Operallons 32 Pre Run Inspeclon 33 Equipment SetF up 33 Cleaning amp Emptying 33 Shut Down and Storage 3 4 MAINTENANCE Daily Maintenance 4 1 Periodic Malntenance 4 1 Monthly Maintenance 12201100 4 1 Semi annually
10. all be paid to other persons especially children When leaving unattended secure against unintentional movement The machine shall only be operated by instructed and authorized persons When leaving unattended switch off or lock the main power switch to prevent unauthorized use Do not handle the plug or machine with wet hands Do not unplug machine by pulling on cord To unplug grasp the plug not the cord Do not use with damaged cord or plug Follow all instructions in this manual concerning grounding the machine Do not pull or carry by cord use cord as a handle close a door on cord or pull cord around sharp edges corners Do not pull run machine over cord Keep cord away from heated surfaces Comnect to a properly grounded outlet See Grounding Instructions SAVE THESE INSTRUCTIONS 2 2 HAZARD INTENSITY LEVEL The following symbols are used throughout this guide as indicated in their descriptions HAZARD INTENSITY LEVEL There are three levels of hazard intensity identified by signal words WARNING and CAUTION and FOR SAFETY The level of hazard intensity is determined by the following definitions WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage FOR SAFETY To Identify actions which must be followed for safe operation of equipment Report machine damage or
11. am Note When replacing carbon brushes loosen wire terminal BEFORE removing screws on bracket Wire Terminal Note Place stop in groove If armature commutator is grooved extremely pitted or not concentric the motor will need to be replaced or sent to a qualified service center Wire Terminal Important These brushes wear quicker as the length shortens due to increased heat Spring inside brush housing will damage motor if brushes are allowed to wear away completely 3 8 9 5mm Periodically check the length of the carbon brushes Replace both carbon brushes when either 1 less than 3 8 9 5mm long MAINTENANCE Only qualified maintenance personnel are to perform the following repairs SOLUTION PUMP REPLACEMENT 1 Turn off all switches and unplug the machine 2 Unlatch the recovery tank from the base 3 Tip recovery solution tank to gain access to the base of machine 4 Remove solution hoses from fittings on pump Disconnect wires 5 Remove the screws that fasten the pump to the base 6 Reverse process to install new replacement pump VACUUM MOTOR REPLACEMENT Turn off all switches and unplug machine Unlatch the recovery tank from the base Tip recovery solution tank to expose vacuum s Locate the proper vacuum motor wires and disconnect Unfasten screws holding vacuum to plate Remove the vacuum motor Reverse process to install vacuum motor replacement M
12. cuum motor without activating the float shutoff 1 Before proceeding make certain that the nozzle is 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 nozzle b Ifthe nozzle is not showing a full spray pattern adjust nozzle for proper pattern clean or replace nozzle 2 Normally chemical is applied on the push stroke while vacuuming is done on the pull stroke For heavily soiled carpets the hand tool may be used in the scrubbing manner applying chemical in both the push and pull stroke ALWAYS FINISH UP AN AREA WITH A VACUUM PULL STROKE 3 When cleaning keep the working opening wand mouth flat on the surface being cleaned Keep the wand moving when the valve is open The shutoff float inside the recovery tank will impede the vacuum flow when the tank is full When this occurs empty the recovery tank Do this by opening the dump valve located at the front of the machine NOTE Dispose of waste in proper manner which would not violate any Local State or Federal law Once the recovery tank has been emptied you may once again proceed with cleaning CAUTION gt Operating Vacuum shutoff has activated could draw water directly into the vac motor This will cause damage to the motor therefore voiding your warranty 44 CAUTION ALWAYS TEST CARPET FOR COLOR FASTNESS IN AN INC
13. faulty operation immediately Do not use the machine if it is not in proper operating condition Following is information that signals some potentially dangerous conditions to the operator or the equipment Read this information carefully Know when these conditions can exist Locate all safety devices on the machine Please take the necessary steps to train the machine operating personnel FOR SAFETY DO NOT OPERATE MACHINE Unless Trained and Authorized Unless Operation Guide is Read and understood In Flammable or Explosive areas In areas with possible falling objects WHEN SERVICING MACHINE Avoid moving parts Do not wear loose clothing jackets shirts or sleeves when working on the machine Use manufacturer approved replacement parts GROUNDING INSTRUCTIONS THIS PRODUCT IS FOR COMMERCIAL USE ONLY ELECTRICAL The amp hertz and voltage are listed on the data label found on each machine Using voltages above or below those indicated on the label will cause serious damage to the motors EXTENSION CORDS If an extension cord is used the wire size must be at least one size larger than the power cord on the machine and must be limited to 50 feet 15 5m in length GROUNDING INSTRUCTIONS This appliance must be grounded If it should malfunction or break down grounding provides a path of least resistance for electric current to reduce the risk of electric shock This appliance is equipped with a cord having
14. is manual MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE DEALER NAME OPERATIONS GUIDE NUMBER PUBLISHED The model and serial number of your machine 1 located inside the base directly above the pump HOW USE THIS MANUAL 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 1 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 The PARTS LIST section contains assembled parts illustrations and corresponding parts list The parts lists include a number of columns of information column refers to the reference number on the parts illustration PART NO column lists the part number for the part column lists the quantity of the part used in that area of the machine DESCRIPTION column is a brief description of the part SERIAL NO FROM column indicates the first machine the part number is applicable to When the machine design has changed this column will indicate serial number of applicable machine The main illustration shows the most current design of the machine The boxed illustrations show older design
15. r cord is broken or frayed repair or replace immediately Don t take chances with electrical fire or shock Clean outside of all tanks and check for damage MONTHLY MAINTENANCE 1 Check all bearings for noise and wear Check all gaskets for wear and leakage Check pump pressure observe spray pattern and check gauge if necessary 4 Check overall performance of machine SEMI ANNUALLY 1 Check vacuum motor brushes LUBRICATION For hose fitting lubrication use a light silicone lubricant which will not damage o rings STORAGE Thoroughly clean machine if it is to be stored Protect this machine from freezing while in storage Vacuum Motor Carbon Brushes Replacement Windsor WARNING The green ground wire must be attached for safe operation See wiring diagram Carbon Brushes If armature commutator is grooved extremely pitted or not concentric the motor will need to be replaced or sentto a qualified service center These brushes wear quicker as the length shortens due to increased heat Spring inside brush housing will damage motor if brushes are allowed to wear away completely Important E 3 9 5mm Periodically check the length of the carbon brushes Replace both carbon brushes when either is less than 3 8 9 5mm long Vacuum Motor Carbon Brushes Replacement Ametek End Cap Carbon T WARNING The green ground wire must be u attached for safe operation See wiring diagr
16. ranty service products must be returned to a service facility designated by PROCHEM Customer shall prepay shipping charges for products returned to for warranty service and shall pay for return of the products to customer makes no other warranty either expressed or implied with respect to this product disclaims the implied warranties of merchantability and fitness for a particular purpose Any implied warranty of merchantability of fitness is limited to specific duration of this limited warranty This warranty gives you specific legal rights and may also have other rights which may vary from state to state or province to province The remedies provided herein are the customer s sole and exclusive remedies In no event shall PROCHEM be liable for nay direct indirect special incidental or consequential damages whether based on contract tort or any other legal theory Your PROCHEM unit is designed to give you years of reliable service However if a problem should arise after the warranty period follow troubleshooting procedures in the operation and service manual If you are still unable to determine the cause and solution to the problem contact your nearest distributor factory representative or for details of the services available Components provided by PROCHEM but supplied by other manufacturers will only be warranted to the extent that they shall
17. rical power at machine 3 Connect vac hose to machine Slide the swivel cuff over the outlet on the tank 4 Connect the hose to your machine and wand Pull back the knurled collar on the quick disconnect coupler and push onto the connection on the chassis To avoid leaks check to be that a positive connection was made 5 Pour clean hot water into the solution tank To avoid possible tank distortion water temperature must not exceed 140 F 60C 6 Add a non foaming cleaning solution concentrate for use in hot water extractors at the proportions noted on the container See list below into solution tank 7 Turn pump and vacuum switch s to the on position 8 Start cleaning A WARNING To prevent possible disease hazard before attempting to clean bodily fluids spills you must kill any viruses germs or bacteria present in the bodily fluid SUITABLE INCOMPATIBLE CHEMICALS CHEMICALS Alkalis Aldehydes Clorox Il Bleach Aromatic Hydrocarbons Defoaming Agents Butyls Detergents Carbon Tetrachloride Hydroxides Clorox Oxygen Bleaches Chlorinated Bleaches Soaps Chlorinated Hydrocarbons Sta Puf Fabric D Limonene Softener Lysol Vinegar Methyls MEK Perchlorethylene perc Phenols Trichlorethylene Registered Trademark 3 3 CLEANING amp EMPTYING TANKS WARNING Always use defoamer if foaming occurs Foam will suspend large particles which may damage vacuum as well as allow liquid into the va
18. s If column has an asterisk call manufacturer for serial number NOTES column for information not noted by the other columns NOTE If a service or option kit is installed on your machine be sure to keep the KIT INSTRUCTIONS which came with the kit lt contains replacement parts numbers needed for ordering future parts IMPORTANT SAFETY INSTRUCTIONS When using an electrical appliance basic precaution must always be followed including the following READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE WARNING To reduce the risk of fire electric shock or injury Use only indoors Do not use outdoors or expose to rain Use only as described in this manual Use only manufacturer s recommended components and attachments If the machine is not working properly has been dropped damaged left outdoors or dropped into water return itto an authorized service center Do not operate the machine with any openings blocked Keep openings free of debris that may reduce airflow This machine 1 not suitable for picking up hazardous dust Machine can cause a fire when operating near flammable vapors or materials Do not operate this machine near flammable fluids dust or vapors This machine is suitable for commercial use for example in hotels schools hospitals factories shops and offices for more than normal housekeeping purposes Maintenance and repairs must be done by qualified personnel During operation attention sh
19. se vacuum dome Center and seal dome over tank Crack in dome of poor joint Replace or repair using acrylic plastic cement onl Lint or dirt clogging With power off clean screen vacuum screen Loose on vacuum Tighten cuffs turning counterclockwise Loss of vacuum hose Vac motor seals leaking 2 chamber Wash out with hose Pick lint out with a wire qq Vac motor hose or dome Replace gasket Pump inlet screen plugged Clean inlet screen ri r en valve on cleaning wand to Pump air locked ess trigger to op 9 relieve air Pump runs solution Internal or external leaking cuts in seals problem still exists change BPR Unit not plugged in Connect unit to 3 prong grounded outlet ump will not run rg Loose wiring See dealer P Solution hose fitting iat Clean with steel wool Soak in acetic acid white hard to connect On unos vinegar Lubricate lightly with silicone base lubricant Carpet not getting Severe soil conditions Make several passes at right angles to each other clean Use a pre spray Carpet too wet ES solution wand Make several passes without Leaving carpet too wet Check for loss of vac pressure Too much chemical Check label for correct solution concentration Light carpet with no brown prevention Solution not flowing Carpet browning Go over carpet with browning prevent only properly Faulty floor tool valve Repair or replace Faulty pump switch 4 5 4 6
20. ution Wastewater should be disposed of properly Occasionally check filter screen at the bottom of the solution tank and rinse clean with hot water if necessary Inspect hoses for wear Frayed or cracked hoses should be replaced to avoid vacuum or solution pressure loss Inspect power cord for wear or damage This cable will lie on wet carpet To prevent electrical shock replace cords that are frayed or have cracked insulation immediately Clean all dirt and obstructions from drain valve and gaskets to prevent possible leakage and premature wear Run clean water through solution pump when work is complete Empty both tanks and rinse run vacuum s for at least one minute to dry motor s Store with access covers removed to allow tanks to dry PERIODIC MAINTENANCE 1 Twice a month flush a white vinegar solution one quart vinegar to two gallons water or anti browning solution mixed as directed through the extractor This will prevent build up of alkaline residue in the system If spray jet becomes clogged remove the spray tip wash it thoroughly and blow dry NOTE Do NOT USE PINS WIRE ETC TO CLEAN NOZZLE AS THIS COULD DESTROY THE SPRAY PATTERN Apply silicone lubricant to solution nipple Periodically inspect all hoses electrical cable and connections on your machine Frayed or cracked hoses should be repaired or replaced to eliminate vacuum or solution pressure loss If the cable insulation on the powe
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