Truckmount Troubleshooting

Identify and solve technical issues

Quickly diagnose and resolve issues with your Prochem or Sapphire truckmount. Select your model in the pull-down menu to access the relevant troubleshooting guide.

Rage Truckmount Troubleshooting Tips

ENGINE

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 exchanger is damaged from frozen water.

Inspect heat exchanger 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.

No vacuum hose connected.

Connect vacuum hose to vacuum inlet.

Temperature relief valve on water box is stuck open.

Clean temperature relief valve and test. Replace, if necessary.

Engine RPM is low.

Reset engine RPM.

Defective temperature gauge.

Test gauge and sensor. Replace failed component.

Temperature balance orifice missing

Replace orifice.

Automatic waste pump is malfunctioning or not operating normally

Defective waste pump float switch.

Replace float switch.

Broken diaphragm(s).

Replace diaphragm(s).

Weak battery.

Charge or replace battery if needed. Check charging station.

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

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

Inspect check valve for debris or damage.

Clean or replace if necessary.

Engine will not start
(The engine does not turn over)

Main circuit breaker on the control panel has been tripped.

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

Loose or corroded battery.

Clean, tighten, or replace the battery terminals.

Dead battery.

Recharge or replace battery.

Defective ignition switch.

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

Defective starter motor.

Test the starter motor. If necessary replace.

Vacuum pump seized.

Refer to Gardner Denver Service and Repair Manual.

Starter turns over engine, but will not start

Waste tank is full.

Empty the waste tank.

Defective fuel pump.

Replace the fuel pump.

Loose or broken wires leading to waste tank float switch.

Repair or replace any broken electrical connections.

Defective float switch in the waste tank.

Check switch for proper operation, replace as necessary.

Oil pressure switch (located on engine), fuel shut-off solenoid (located on engine).

Test these components. If any are defective, replace. Consult the Kohler Operation and Maintenance Manual.

Engine is malfunctioning

Refer to Kohler Engine Operation and Maintenance Manual.

Engine stops running
(While doing normal cleaning, the engine stops running)

Engine is out of gasoline

Add gasoline to the fuel tank.

Waste tank is full

Empty waste tank.

Main circuit breaker on the control panel has been tripped.

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

Defective fuel pump.

Replace fuel pump.

Defective float switch inside the waste tank.

Check switch for proper operation. Replace as necessary.

Oil pressure switch on engine has shut down, due to insufficient oil pressure.

Refer to the Kohler Engine Operation and Maintenance Manual. DO NOT restart the engine until the cause is determined and corrected.

No ignition in the engine or engine is malfunctioning.

Refer to the Kohler Engine Operation and Maintenance Manual.

Flow restriction caused by hard water scaling.

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

Not enough water flow.

Check jet size of tool.

BLOWER / VACUUM PUMP

Excessive Vacuum

Improper throttle adjustment.

Adjust throttle to set desired vacuum pressure.

Vacuum relief valve requires adjustment.

Readjust the vacuum relief valve.

Loss of vacuum. While cleaning, the vacuum is not up to specification. Engine RPM is normal.

Vacuum gauge is giving an improper reading.

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

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

Inspect hose(s), repair or replace.

Waste tank gaskets not sealing properly, not positioned properly

Inspect the gasket. Repair seal or replace Re-position lid(s).

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

Unplug vacuum hose or inlet plumbing.

Waste tank filter or strainer basket is plugged.

Clean or replace filter. Clean strainer basket.

Loose vacuum pump drive belts.

Tighten the drive belts

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

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

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

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 exchanger plugged.

Remove and clean.

Vacuum pump is worn out.

Replace the vacuum pump.

WATER PUMP

Loss of solution volume at cleaning tool orifice. Solution pressure gauge reads normal

Plugged orifice and/or screen in the cleaning tool.

Unplug or replace orifice and/or screen

Internal block between the pressure regulator manifold and the outlet manifold, or the solution screen is clogged

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

Outlet check valve is plugged

Examine the check valve, remove any debris

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

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

Cleaning tool valve is malfunctioning.

Repair or replace valve.

Hose inner lining is constricted.

Remove restriction or replace hose.

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

Check for air leaks. Replace faulty parts.

Loss of solution pump pressure. With the cleaning tool open, the solution pressure gauge reads below the normal operating pressure

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

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

Solution pump inlet supply line is plugged or drawing air.

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).

Improper engine speed

Using a tachometer, check the engine speed. Full throttle engine speed is 2900 RPM. Idle engine speed is 1500 RPM. Refer to the “engine speed” section for instructions on how to re-adjust.

Pressure regulator o-rings are dry.

Lubricate o-rings, using o-ring lubricant

Pressure regulator has worn o-rings

Check o-rings. If necessary, replace.

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

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

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 17.6 seconds).

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

Defective water pressure gauge.

Replace gauge

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

Replace Nozzle or change nozzle size.

Debris clogging water lines or water inlet disconnect.

Clean or replace as needed.

Belts loose or broken

Re-tension or replace as needed.

Loss of pump prime

Manually prime water pump.

Temperature Balance Orifice missing

Replace Orifice

CHEMICAL SYSTEM

Loss of chemical. With the cleaning tool valve open, no chemical

Chemical pump is improperly primed.

Refer to chemical pump priming instructions.

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

Unclog the strainer. If damaged, replace.

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

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

Chemical pump check valve(s) is clogged

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).

Chemical pump diaphragm is ruptured.

Disassemble the chemical pump and replace the damaged diaphragm.

Defective cylinder in the water pump.

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.

Solution pump does not engage

Solution pump circuit breaker has been tripped

Check the solution pump circuit breaker on the control panel. Press the circuit breaker reset button.

Defective electrical connection in the console wiring or defective switch.

Examine switch, electrical connections, and wiring. Repair any defective connections. If there is power going to the switch but not going out, replace the defective switch.

Solution pump has not been activated

Turn solution pump switch to on.

Loose or broken solution pump belts.

Tighten or replace belts.

Chemical flow meter indicates flow with the tool valve closed

External leak in chemical piping

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

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

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

Chemical pump diaphragm is ruptured

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

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

Tighten valve packing nut (see “General Service Adjustments” section in this manual). Replace valve, if necessary.