Prochem EVEREST 408 - User Manual

Questions and Answers

D
Donna FloresAug 20, 2025
Why is the vacuum weak on my Prochem EVEREST 408 Water System?
- A
  Alyssa Stokes DVMAug 20, 2025
  If the vacuum in your Prochem Water System is not up to par during cleaning, and the engine RPM is normal, start by checking the waste tank filter and pre-filter basket for clogs and clean or replace them. Inspect the vacuum gauge tubing for blockages. Also, check for damaged vacuum hoses causing leaks, and ensure the pre-filter and waste tank gaskets are properly sealed and positioned. Clear any blockages in the vacuum hose or plumbing. Tighten loose vacuum pump drive belts. Ensure the waste tank drain valve is closed and not damaged. Adjust the vacuum relief valve or replace its diaphragm if damaged. Clean plugged vacuum exhaust heat exchangers. If the issue persists, the vacuum pump may be worn out and require replacement.
J
Jennifer RodriguezAug 22, 2025
What to do if my Prochem Water System engine stops during cleaning?
- R
  Ryan Kemp Jr.Aug 22, 2025
  If the engine of your Prochem Water System stops while cleaning, first, check if the fuel tank is empty and add fuel if needed. Then, empty the waste tank if it's full. Inspect the main or engine circuit breaker on the control panel and reset it if tripped. If the engine coolant temperature is too high, determine the cause of overheating before restarting. Other potential causes include a defective fuel pump, float switch in the waste tank, or a high-temperature shutdown switch. Insufficient oil pressure or engine malfunction can also be the reason. For issues related to oil pressure or general engine malfunctions, refer to the ZZP416 Engine Operation and Maintenance Manual.
M
Matthew BooneAug 25, 2025
Why won't the engine on my Prochem EVEREST 408 Water System start?
- K
  Kelly MejiaAug 26, 2025
  If your Prochem Water System engine won't start and isn't turning over, first check if the main circuit breaker on the control panel has tripped and reset it. Ensure the battery terminals are clean and tight, and replace the battery if it's dead. Test the ignition switch for power; replace it if power isn't going through. Test the starter motor and replace if necessary. If the vacuum pump is seized, refer to the Gardner Denver Service & Repair Manual or contact a dealer.
E
Elizabeth ShafferAug 30, 2025
What causes my Prochem EVEREST 408 to crank but not start?
- J
  johnsonrobertAug 30, 2025
  If the starter turns over the engine of your Prochem Water System but it won't start, first, ensure the waste tank isn't full. If it is, empty it. If the waste tank is not the cause, the fuel pump may be defective and need replacement. Also, check if the unit is out of fuel and add fuel if necessary. If problems persist, refer to the ZZP416 Engine Operation and Main- tenance Manual for troubleshooting an engine malfunction.
R
Randy MartinSep 4, 2025
Why does the chemical flow meter on my Prochem Water System show flow when the valve is closed?
- J
  Joel GreenSep 4, 2025
  If the chemical flow meter on your Prochem Water System indicates flow even when the tool valve is closed, check for an external leak in the chemical piping and tighten the fittings, reapplying thread sealant if needed. Replace any damaged fittings. If this doesn't solve the problem, close the chemical valve on the control panel. If the flow meter still indicates flow, remove debris from or replace the outlet check valve. If flow continues, replace the chemical pump diaphragm and plastic disk. Also, inspect for an internal leak in the chemical valve causing continual flow through the prime tube, and tighten the valve packing nut. Replace the valve if necessary. Ensure the flow setup valve is closed.
S
steven70Sep 6, 2025
What to do if the solution pump on my Prochem EVEREST 408 Water System won't turn on?
- M
  mark45Sep 7, 2025
  If the solution pump on your Prochem Water System does not engage, first, make sure the solution pump switch is turned on. Next, check the solution pump circuit breaker on the control panel and press the reset button if it has been tripped. Examine the switch, electrical connections, and wiring for any defects, repairing connections as needed. If there is power going to the switch but not going out, replace the switch. If there is power in the switch but not at the clutch, replace the defective wire. If there is power at the clutch, replace the defective switch. Finally, check the solution pump belts and tighten or replace them if they are loose or broken.
I
imooreSep 9, 2025
How to fix a malfunctioning automatic waste pump on my Prochem EVEREST 408 Water System?
- T
  Thomas ArnoldSep 9, 2025
  If the automatic waste pump in your Prochem Water System is malfunctioning, start by replacing the float switch. If the float switch is not the problem, replace the diaphragm. Check the battery and charge or replace it if weak, and inspect the charging station. Also, check the pump-out circuit breaker on the control panel and reset it if tripped.
M
Marc SmithSep 12, 2025
What causes overheating in my Prochem EVEREST 408?
- D
  davislouisSep 12, 2025
  If your Prochem Water System is experiencing excessive heating, it could be due to a flow restriction caused by hard water scaling. Descale the unit and repair or replace any damaged plumbing components as necessary. Installing a water softener can help prevent future scaling. Also, ensure there is enough water flow by checking the jet size of the tool.
J
Jordan WeberSep 14, 2025
Why is my Prochem EVEREST 408 not heating properly?
- K
  Kimberly LynchSep 14, 2025
  If the heat output of your Prochem Water System is less than normal, first check the temperature relief valve on the water box to see if it's stuck open. Clean and test it, and replace if necessary. Next, test the temperature gauge and sensor, replacing any failed components. Also, check for a missing bypass orifice and replace it if needed. Finally, make sure the temperature control lever is properly set.
D
Daniel RamosNov 16, 2025
What to do if my Prochem Ultrasonic Jewelry Cleaner has loss of solution pump pressure?
- K
  Kenneth WilliamsNov 16, 2025
  If the solution pressure gauge reads below the normal operating pressure, it could be due to several reasons. First, check if the water supply is turned on or up, and inspect the water supply hose for kinks. Also, examine the float valve and adjust or replace it if necessary. Another cause may be that the solution pump inlet supply line is plugged or drawing air. In this case, examine the water inlet strainer inside the water box, remove accumulated debris, and replace it if required. Check for suction leaks and loose clamps or fittings, and tighten any loose fittings or clamps, replacing any ruptured hoses. Check the engine speed with a tachometer. Full throttle engine speed is 2200 RPM. Idle engine speed is 900 RPM. Other possible causes include dry or worn pressure regulator o-rings (lu...

Summary

Safety Instructions

IMPORTANT SAFETY INSTRUCTIONS

Essential safety precautions to prevent injury, death, or equipment damage.

Hazard Intensity Levels

Explanation of hazard symbols (Warning, Caution, For Safety) and their meanings.

Safety Labels

Identification and location of warning and caution labels on the unit.

Installation Procedures

Vehicle Requirements

Specifications and considerations for the vehicle used to mount the unit.

Securing Unit and Waste Tank

Instructions for bolting the unit and waste tank securely to the vehicle floor.

Battery Connection

Instructions for correctly connecting the unit's battery cables.

Operating the Unit

Trouble Codes

List of Diagnostic Trouble Codes (DTCs), their causes, and MIL flash codes.

Water Pumping and Heat Transfer System

Explanation of how water is pumped and heated through the unit's systems.

Chemical Injection System

How chemicals are injected into the solution stream using pressure spikes and valves.

Vacuum System Operation

How the vacuum pump creates suction, compresses air, and transfers heat.

Pre-run Inspection and Setup

Essential checks and preparations before operating the unit.

Priming the Chemical Pump

Step-by-step guide for priming the chemical pump before operation.

Cleaning Procedures

Shutdown and Daily Maintenance

Procedure for shutting down the unit and performing daily maintenance tasks.

High Pressure System Operation (Optional)

Operating instructions for the optional 3000 PSI high-pressure system.

High Pressure Shutdown Procedure

Freezing Protection

Winterizing Your Unit

Detailed steps for winterizing the unit with antifreeze.

Removing Anti-freeze

Maintenance

Service Schedule

Comprehensive list of maintenance tasks and their recommended intervals.

Key Checkpoints

Important checks for optimal performance, operating life, and reduced downtime.

Engine Coolant System

Chemical Supply System Maintenance

Heat Exchanger System Maintenance

Maintenance of the heat exchanger system, including water softening and freezing protection.

Vacuum Pump Maintenance

Vital maintenance actions for prolonged vacuum pump operations and daily lubrication.

Engine Maintenance

Daily checks, oil changes, air cleaner, coolant, and fuel filter replacement.

Vacuum Pump Drive Belt Maintenance

Solution Pump Maintenance

Checking crankcase oil level, changing oil, and torque values for components.

Solution Pump Drive Belt Maintenance

Chemical Pump Maintenance

Rebuilding the chemical pump and inspecting the inlet tube strainer.

High Pressure Hose Inspection

Engine Coolant Replacement

Procedure for draining and replacing engine coolant every 2 years.

Chemical Pump Adjustments

Pressure Regulator Adjustments

Pressure Regulator Adjustment

How to adjust low and high-pressure regulators for desired operating pressure.

Troubleshooting Guide

Loss of Solution Pump Pressure

Diagnosing and resolving issues related to low solution pump pressure.

Loss of Solution Volume at Cleaning Tool Orifice

Troubleshooting low solution volume at the cleaning tool orifice when gauge reads normal.

Loss of Vacuum Issues

Diagnosing and resolving problems with insufficient vacuum during cleaning.

Loss of Chemical Issues

Troubleshooting reasons for no chemical flow from the cleaning tool.

Chemical Flow Meter Issues

Diagnosing issues where the chemical flow meter shows flow with the tool valve closed.

Solution Pump Not Engaging

Troubleshooting why the solution pump is not engaging or operating.

Engine Will Not Start

Diagnosing issues when the engine does not turn over.

Engine Cranks But Wont Start

Troubleshooting engine starting problems after it begins to crank.

Engine Stops During Cleaning

Diagnosing common reasons for the engine stopping during normal cleaning operations.

Excessive Heating Issues

Troubleshooting causes of excessive heating, such as water scaling or flow restrictions.

Heat Exchanger Leaks

Identifying and diagnosing leaks in the heat exchanger unit.

Loss of Temperature Issues

Troubleshooting reasons for low heat output from the unit.

Automatic Waste Pump Malfunctions

Diagnosing and resolving issues with the automatic waste pump's operation.

Parts Identification

Vacuum Blower (650;650 HP) Components

Low Pressure Solution Pump Components

High Pressure Solution Pump Components

Water Box (Low Pressure) Components

Low Pressure Regulator Components

Warranty Information

Limited Warranty

Details of the limited warranty for new machines, including coverage and exclusions.

Labor Cost Coverage

Component Warranty Details

Warranty Exclusions

Conditions and actions that void the product warranty.

Approved Parts and Warranty Validity

Prochem EVEREST 408 Specifications

General

Brand	Prochem
Model	EVEREST 408
Category	Water System
Language	English

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