Prochem BLAZER PLUS User manual

980073

11/26/03

Operating Instructions (ENG)

MODELS: BLAZER PLUS

Read

instructions before operating the machine.

Mobile Cleaning Unit

MACHINE DATA LOG/OVERVIEW

BLAZER 980073 09/16/02

Welcome…and congratulations on your purchase of the BLAZER PLUS Mobile Cleaning Unit. This instruction

manual is a guide for operating and servicing your PROCHEM 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 PROCHEM dealer.

THIS UNIT MUST BE INSTALLED BY THE DEALER FROM WHOM YOU PURCHASED IT IN ACCORDANCE

WITH PRESCRIBED PROCHEM INSTALLATION PROCEDURES.

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

PURCHASED THIS UNIT AND RETURNED TO PROCHEM!

This operation and service manual is written specifically for the PROCHEM BLAZER PLUS Mobile Cleaning

Units which are manufactured by:

PROFESSIONAL CHEMICALS CORPORATION

325 SOUTH PRICE ROAD

CHANDLER, ARIZONA 85224

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

of Professional Chemicals Corporation.

YOUR DEALER

Name: __________________________________________________________________________________________________

Address: _______________________________________________________________________________________________

Phone Number: _________________________________________________________________________________________

MODEL _______________________________________

DATE OF PURCHASE __________________________

SERIAL NUMBER ______________________________

SALES REPRESENTATIVE # _____________________

DEALER NAME ________________________________

OPERATIONS GUIDE NUMBER ___________________

PUBLISHED __________________________________________

TABLE OF CONTENTS

BLAZER 980073 09/16/02

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

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

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

Receiving Your Unit.......................................3-2

Installation Requirements..............................3-3

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

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

Chemicals & Water........................................3-4

Water Pumping System.................................3-5

Heat Transfer System....................................3-6

Vacuum System.............................................3-9

Chemical System........................................3-10

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

Filling Auxiliary Water Tank........................3-11

High Pressure Hoses..................................3-11

Vacuum Hose.............................................3-13

Starting Unit (Cleaning Mode)....................3-13

Chemical Pump Priming.............................3-13

Waste Pump...............................................3-14

Cleaning......................................................3-14

Upholstery Cleaning....................................3-14

Stair Tool Cleaning......................................3-14

Shutdown & Daily Maintenance..................3-15

Freezing Protection.....................................3-16

Removing Anti-freeze..................................3-17

MAINTENANCE & SERVICE

Maintenance

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

Engine......................................................4-2

Vacuum Pump.........................................4-3

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

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

BypassManifold......................................4-4

Drive Belts, Pulleys And Hubs................4-5

Float Valve, Water Pump Inlet Filter.......4-5

Vacuum Inlet Filter...................................4-5

Outlet Y-Strainer, Check Valve...............4-6

Chemical Pump, Chemical &

Heat Bypass Valves ................................4-6

Nitrogen Accumulator..............................4-6

PressureRegulator..................................4-6

Vacuum Hoses ........................................4-6

Battery.....................................................4-7

Engine Exhaust Heat Exchanger............4-7

General Service Adjustments

Engine Speed..........................................4-8

Vacuum Relief Valve...............................4-8

Vacuum exhaust Heat Exchanger..........4-8

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

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

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

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

BypassManifold......................................4-10

CheckValve............................................4-10

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

Packing Nut Adjustment,

Chemical Metering & Selector Valves ....4-11

PressureRegulator..................................4-11

Waste Tank to Console Connection.......4-12

Fire Extinguisher......................................4-12

Battery Replacement...............................4-12

Auxiliary Water Tank Connection............4-13

Troubleshooting.......................................4-15

TABLE OF CONTENTS

BLAZER 980073 07/05/03

PARTS LIST

Front Panel.........................................5-1

Framework.........................................5-3

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

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

Water Pump.......................................5-11

Chemical Pump..................................5-15

BypassManifold.................................5-19

Bypass Solenoid................................5-21

Water Inlet..........................................5-23

Water Box ..........................................5-25

Vacuum Exhaust Heat Exchanger....5-27

Vacuum Heat Exchanger...................5-29

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

Automatic Pumpout............................5-33

Hose Accessories ..............................5-37

Wand-Tri-Jet......................................5-39

Wand-Dual-Jet...................................5-41

Stair Tool............................................5-43

Upholstery Tool..................................5-45

Shelf Assembly..................................5-47

Water Tank, Dual

With Demand Pump...........................5-49

Demand Pump...................................5-51

Hose Reel..........................................5-53

Water Box With

Auxiliary Water Tank..........................5-55

Waste Tank With

Auxiliary Water Tank..........................5-57

Wiring Diagram..................................5-59

Warranty ............................................5-60

HOW TO USE THIS MANUAL

BLAZER 980073 09/16/02

1-1

This manual contains the 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 this manual.

The model and serial number of your machine is on

the lower front panel of the machine.

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, Water Pump, 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

boxed illustrations show older designs. If

column has an asterisk (*), call

manufacturer for serial number.

-NOTES – column for information not

noted by the other columns.

NOTE: If a service or option kit is installed on your

machine, be sure to keep the KIT INSTRUCTIONS

which came with the kit. It contains replacement

parts numbers needed for ordering future parts.

MODEL _____________________________________

DATE OF PURCHASE ________________________

SERIAL NUMBER ____________________________

SALES REPRESENTATIVE # ___________________

DEALER NAME ______________________________

OPERATIONS GUIDE NUMBER __________________

PUBLISHED ________________________________

CONDENSED OPERATING INSTRUCTIONS

BLAZER 980073 09/16/02 2-1

IMPORTANT SAFETY INSTRUCTIONS

When using this machine, basic precaution

must always be followed, including the following:

READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.

Read the operator's manual before installing or starting this unit. Failure to adhere to instructions

could result in severe personal injury or could be fatal.

Operate this unit and equipment only in a well-ventilated area. Exhaust fumes contain carbon

monoxide 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 the exhaust diverter valve or 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.

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!

BLAZER 980073 09/16/02

2-2

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.

DO NOT cut or splice any of the vehicle fuel lines during fuel line installation. This may result in fuel

leaks and potentially dangerous conditions. There is no fuel solenoid shut off on this unit. Use only the

provided 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 waste tank and accessories weighs

approximately 670 lbs. 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.

HAZARD INTENSITY LEVEL

BLAZER 980073 09/16/02 2-3

The following WARNINGLABELS are found on your BLAZER PLUS console. These labels

point out important Warnings andCautions which should be followed atalltimes. 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.

Order Part #48-941212 to get a complete set of decals (safety and instrumentation) for your

BLAZER PLUS cleaning unit. The following decals must be placed in a prominent spot on the

vehicle that your unit is to be installed in where access is given to operate the unit. See next

page for suggested locations for these decal.

Decal, Fuel Clean-Up Decal, Carbon Monoxide

Part #48-941317 Part #48-941316

HAZARD INTENSITY LEVEL

BLAZER 980073 09/16/02

2-4

The decals should be placed in a prominent spot on

the vehicle where access is given to operate the

unit. The illustrations above suggest the location

and placement of the decals.

When placing the decals, be sure the area is clean

of any dirt and possible wax build-up. Place the

decal by starting at on edge and smoothing the

decal over to the other edge. This will help eliminate

air bubbles and allow the decal to adhere better.

After a time the decals may become damaged or

worn. If they become unreadable, they should be

replaced.

OPERATION

BLAZER 980073 09/16/02 3-1

TECHNICAL SPECIFICATIONS

ITEM DIMENSION/CAPACITY

Engine speed 3200 rpm (high speed)

1400 rpm (idle speed)

Water pump rpm 1480 rpm

Vacuum pump rpm 3200 rpm

Water flow rate 3.5 GPM

Water pump pressure 1000 PSI (maximum)

Vacuum relief valve 13” Hg

Waste tank capacity 52 gallons (at shut off)

Console weight 486 lbs.

Console weight (with waste tank & accessories) 670 lbs (1103 lbs. If waste tank is full)

TORQUE VALUES

Engine hub 264 inch lbs 22 foot/lbs

Vacuum pump hub 192 inch/lbs 16 foot/lbs

JET SIZING:

Prochem recommends floor tool tip sizing not exceed a total of “.04”. Using larger jet sizes on your BLAZER

PLUS may reduce cleaning temperatures.

Example: Dual jet wand uses two 11002 jets. (110° spray angle w/ 02 orifice)

02 x 2 = 04

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

Table of contents

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