Operator & Parts Manual
KaiVac® 2100 Series
2150 Serial Number 2150-2247 to Current

www.kaivac.com
© 2006-2013 Kaivac, Inc. All Rights Reserved
Revision Sheet
| Release No. | Date | Revision Description |
|---|---|---|
| 101513 | 10/15/13 | Operator & Parts Manual Released |
| 121713 | 12/17/13 | Modified the Rotomold Warranty to 5 years. |
Kaivac, Inc.
401 S. Third Street
Hamilton, OH 45011
OPERATOR & PARTS MANUAL
| Section | Title | Page # |
|---|---|---|
| 1.0 | GETTING STARTED | 1-1 |
| 1.1 | Limited Warranty Protection Plan | 1-1 |
| 1.2 | Warranty Registration Form | 1-2 |
| 1.3 | Safety Precautions | 1-3 |
| 2.0 | OPERATION | 2-1 |
| 2.1 | Preparing Your Kaivac For Use | 2-1 |
| 2.2 | Kaivac Tool Arrangement | 2-2 |
| 2.3 | Vac Tank & Hose Cleanout Instructions | 2-3 |
| 2.4 | Operating your Kaivac using S-I-M-P-L-E Process | 2-4 |
| 3.0 | MAINTENANCE | 3-1 |
| 3.1 | Machine Maintenance | 3-1 |
| 3.2 | Troubleshooting | 3-2 |
| 3.3 | Machine Diagrams | 3-5 |
| 3.4 | Parts List | 3-14 |
1.0 GETTING STARTED
1.1 Limited Warranty Protection Plan
The Kaivac has been engineered and tested to provide long lasting performance. This warranty covers defects in workmanship or materials under normal use and service from the date of purchase.
Kaivac, Inc. warrants the following components to be free from defects in materials and workmanship for these time periods:
1.) Extended Warranty for end users who use only Kaivac chemicals for the life of the machine.
- 5 years on rotationally molded parts
- 3 years on other parts (excluding wear items)
- 1 year on labor
2.) Standard Warranty (for approved non-Kaivac chemicals)
- 1 year parts and labor
3.) Chemicals that have not been approved by Kaivac (If uncertain, please contact Kaivac to verify your chemical before using).
- No warranty
All Kaivac replacement parts are guaranteed for 90 days from the date of installation. Normal wear items such as wheels, hoses, seals, gaskets, cords, casters, squeegees and GFCI are excluded from warranty coverage.
All warranty claims must be accompanied by a Return Authorization Number (RAN), which is available by calling the Kaivac, Inc. Customer Service Department. No returns will be accepted without a RAN.
This warranty does not apply to return freight costs, damage or defect caused by accident, negligence, misuse, fire or repair done by anyone other than a Kaivac authorized repair center. In no event shall Kaivac, Inc. be liable for incidental or consequential damages, or any damages to persons or property.
Please Note: Under no circumstances will the seller be liable for any loss, damage, expenses or consequential damages arising in connection with the use or inability to use seller’s product. Kaivac, Inc. reserves the right to make changes or improvements to its equipment without notice. Some states do not allow the exclusion or limitation of incidental or consequential damages. This warranty is in lieu of any other warranty expressed or implied, including any warranty of merchantability or fitness for a particular purpose.
1.2 WARRANTY REGISTRATION FORM
To be completed and mailed or faxed by the customer purchasing equipment. Return this warranty card within ten days of purchase.
Purchased By:
Name: ____________________________________________ Title: _____________________________
Company: ___________________________________________________________________________
Street Address: _______________________________________________________________________
City: ____________________________________ State: ___________ Zip Code: _________________
| Model (check one) | Model (check one) | Model (check one) | Model (check one) |
|---|---|---|---|
| ☐ KV1750 | ☐ KV1250 | ☐ KV2150 | ☐ KV1715AC |
| ☐ KV1715 | ☐ KV1215 | ☐ OMNIFLEX Pump Box | ☐ OMNIFLEX Wet/Dry Vac |
Serial Number: __________________
Type of Business
- ☐ School/University
- ☐ Hospital/Health Care
- ☐ Contract Cleaner
- ☐ Industrial
- ☐ Office
- ☐ Other: _____________
Intended Uses (check all that apply)
- ☐ Restroom Cleaning
- ☐ Floor Stripping
- ☐ Kitchen Cleaning
- ☐ Carpet Extraction
- ☐ Cleaning Around Machines
- ☐ Stairwell Cleaning
- ☐ Lockers & Showers
- ☐ Hallway Cleaning
- ☐ Classroom Cleaning
- ☐ Other: ____________
Thank you for registering for our warranty program.
Please return completed forms to:
Kaivac, Inc.
401 S. Third Street
Hamilton, OH 45011
Or Fax to: (513) 887-4601
1.3 SAFETY PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS—SAVE THESE INSTRUCTIONS
- Connect to a properly grounded outlet. Do not remove ground pin.
- Inspect cord before using – do not use if cord is damaged.
- Keep all connections dry and off the ground.
- Do not touch plug with wet hands.
- This product is provided with a ground fault circuit interrupter built into the power cord. If replacement of the plug or cord is needed, use only identical replacement parts.
- Test the ground fault circuit interrupter (GFCI) before each use.
- Do not close a door on the cord or pull the cord around sharp edges or corners.
- Keep the cord away from heated surfaces.
- Do not spray liquid from the Kaivac onto electrical outlets or on any electrical devices.
- Turn off the unit before unplugging.
- Do not pull on the cord to unplug. Grasp the plug at the outlet and pull.
Grounding Instructions:
THE KAIVAC MUST BE GROUNDED. If it should malfunction or stop working, grounding provides a path of least resistance for the electrical current and reduces the risk of electrical shock. The Kaivac is equipped with a ground fault circuit interrupter (GFCI) to further reduce danger and risk of electric shock. It must be maintained and tested regularly. An equipment grounding cord and plug is included with the unit. Cutting off the ground wire or using a cord with an ungrounded plug will void the warranty on the Kaivac.
Improper connection of the equipment grounding cord can result in the risk of electrical shock. Ask a qualified electrician or service person to check the outlet grounding if you are unsure. Do not modify the plug provided with the Kaivac. If it will not fit into the outlet, have a properly grounded outlet installed by a qualified electrician.
- Read all the instructions before using the product.
- To reduce the risk of injury, close supervision is necessary when a product is used near children.
- Know how to stop the product and bleed pressures quickly. Be thoroughly familiar with the controls.
- Stay alert – watch what you are doing.
- Do not operate the product when fatigued or under the influence of alcohol or drugs.
- Keep operating area clear of all persons.
- Do not overreach or stand on unstable support. Keep good footing and balance at all times.
- Do not use to pick up flammable or combustible materials.
- Follow the maintenance instructions specified in the manual.
Personal Protective Equipment (PPE): It is recommended to wear proper personal protective equipment as required by the chemical product label instructions used in conjunction with the Kaivac.
FOR INDOOR USE ONLY
2.1 PREPARING YOUR KAIVAC FOR USE
- Fill machine with clean, cool water.

- Prepare the cleaning solution you will be using by attaching the chemical feed line and cap to the top of your chemical bottle and selecting the proper metering tip. (See placard for metering tip information)

- Check machine for all tools and supplies needed to complete task. See “Tool Arrangement” in Section 2.2 of this manual.

- If using a cleaning product that has high foaming use a foam inhibitor to cut down on foam. Pour 2 capfuls of inhibitor in the vac hose with vac running to coat inside of hose.

- Check all hoses and spray lines for damage prior to use. If damage is found, do not continue until proper repairs are completed.

- Plug in machine and test GFCI (Ground Fault Circuit Interrupter) to ensure it is working properly. You are now ready.

2.2 KAIVAC TOOL ARRANGEMENT
Front Right View

Front Left View


Overhead View

Bottom View

2.3 VAC TANK & HOSE CLEANOUT INSTRUCTIONS

- Unwrap vac hose and lay it on floor.
- Suck water and air from water tank. Lower hose end to surface of water gulping both air and water. This action flushes soils from line and quickly empties water tank.
*Dry vac hose by connecting hose ends to vac motor, then discharge air into vac tank


- Vac hose can now be wrapped onto machine. Leave vac motor running while wrapping to avoid water dripping from end of hose. To completely dry hose leave vac motor running for about 3 minutes.
- With Dump Hose opened to floor drain, spray inside of vac tank with clean water moving hose in a circular pattern to insure tank walls and float shutoff are rinsed.

Tank and Hose Cleaning
2.4 S.I.M.P.L.E PROCESS
*Applicable to all units, KV1700 Series shown for illustration.
Set-up



Inject



Manual Brush
Manually brush heavily soiled areas



Pressure wash and rinse



Loop



Extract



3.1 MACHINE MAINTENANCE
| Item | Procedure |
|---|---|
| Floor Squeegee |
|
| Spray Gun |
|
| Pressure Hose |
|
| Water Tank |
|
| Vacuum Tank |
|
| Leaks |
|
| Electrical System |
|
| Vacuum Wand |
|
| HEPA Filter |
|
3.2 TROUBLESHOOTING
| Area | Problem | Possible Cause | Solution |
|---|---|---|---|
| Electrical | No Power to pump or vac motor | Machine not plugged in | Plug machine in |
| Switch not “on’ | Check switches for “on” | ||
| GFCI tripped | Test and reset GFCI | ||
| Building circuit overloaded | Check and reset circuit | ||
| Switch wires loose | Disconnect power and check for loose wire | ||
| Connections loose | Disconnect Power and check for loose wire under panel | ||
| Electrical burning smell | Vac motor brushes worn | Remove vac motor and repair | |
| Vac motor hung up | Release pressure on hose and jog vac switch, or replace | ||
| Pump motor hung up | Release pressure on hose and jog pump switch, or replace | ||
| Vacuum System | No / Weak vacuum | Vac tank full | Empty vac tank |
| Squeegee blades or wheels worn | Replace wheels or blades and check periodically | ||
| Float shutoff screen dirty | Spray off float screen to clean | ||
| Float ball stuck | Tap float and release/clean | ||
| Damaged hose | Cut and repair/replace | ||
| Dump hose plug missing | Contact dealer and replace | ||
| Access lid not tight | Tighten lid hand tight | ||
| Vacuum hose plugged | Flush hose to remove debris | ||
| Too much liquid in vac hose | Allow air in when vacuuming | ||
| Vac hose still wrapped | Unwrap vac hose fully | ||
| Exhaust plugged | Remove HEPA filter and clean | ||
| Leak in vac tank | If repairable, clean and dry affected area and seal with silicone | ||
| HEPA Filter clogged | Remove HEPA filter and clean | ||
| Moisture from exhaust | Vac tank full | Dump vac tank | |
| Float shutoff missing | Replace | ||
| Excessive foam in vac tank | Use defoamer | ||
| Blow Dry System | No air flow | Hose disconnected | Reconnect hose |
| Moisture from nozzle | Water in blow hose | Dry blow line | |
| Suction, not blow action | Vacuum hose connected to vac tank | Reconnect to vac motor exhaust hose |
| Area | Problem | Possible Cause | Solution |
|---|---|---|---|
| High Pressure System | No water from pump or low pressure | Out of Water | Fill water tank |
| Gun nozzle plugged | Remove orifice with Allen wrench and clean | ||
| Air in pump (vapor lock) | Use power prime technique | ||
| Gun orifice missing | Replace orifice | ||
| Water tank filter plugged | Clean tank and filter | ||
| In - line bowl filter plugged | Remove filter cover and clean | ||
| Bowl filter lid loose | Gently tighten bowl cover | ||
| Pressure hose damaged | Repair or replace | ||
| Quick disconnect leaking | Tighten or replace | ||
| Injector plugged | Remove safety cap from chemical and blow small amounts of compressed air into line | ||
| Pulse hose damaged | Repair or replace | ||
| Regulator failed | Replace | ||
| Hose kinked | Unkink and check for damage | ||
| Seals in pump need replaced | Remove and replace seals | ||
| Bad fan pattern or pinpoint pattern on gun | Debris in nozzle | Remove orifice with Allen wrench and clean | |
| Orifice damaged | Remove and replace | ||
| Chemical Injection System | No chemical flow | Out of chemical | Refill chemical |
| Safety cap not secure | Check safety cap / tighten | ||
| Chemical valve “off” | Check on / off valve | ||
| Safety cap plugged | Replace cap | ||
| Spray gun in wrong mode | Make sure gun nozzle is pulled out away from gun chemical mode | ||
| Metering tip plugged | Check metering tip for clog | ||
| Injector plugged | Remove safety cap from chemical and blow small amounts of compressed air into line | ||
| Air entering system | Check for air entering system around chemical lines or injector | ||
| Injector installed backwards | If fluttering or pulsing sound can be heard while spraying or when machine is running it is possible that your injector is in backwards. Remove and reinstall | ||
| Kink in Chemical line | Replace Chemical line |
| Area | Problem | Possible Cause | Solution |
|---|---|---|---|
| Chemical Injection System continued | Not enough chemical | Metering tip plugged | Remove and clean |
| Wrong metering tip | Check and replace per chart | ||
| Chemical line blows off safety cap | Debris in injector | Remove safety cap from chemical and blow small amounts of compressed air into line | |
| Water back flows into chemical bottle | Bad seat on injector check valve | Check injector o - ring or replace | |
| Bad safety cap | Replace safety cap | ||
| Dump System | Dump hose will not empty tank | Dump hose cap not removed | Remove cap |
| Clog in bottom of tank | Tip dump contents, remove debris | ||
| Dump hose leaks | Hose cut | If leak is less than 4” from tank side, cut and reattach, or replace | |
| Clamp loose | Tighten hose clamp | ||
| Dump cap missing | Replace cap | ||
| Wheels and Casters | Wheels won’t roll, or they rub | Flat tires | Inflate tires to 30 p. s. i. |
| Debris wrapped around axle | Check for debris on axle | ||
| Bearings tight | Grease bearings | ||
| Wheels too loose on axle | Remove wheel, add washers to take up slack | ||
| Bearings falling out | Replace bearing assembly | ||
| Squeegee Head | Floor streaks | Worn blades or wheels | Replace wheels and / or blades |
| Squeegee head doesn’t easily rotate when installed on wand | Brass ring on wand not in groove | Loosen coupling nut and re-position head on groove | |
| Coupling nut too tight | Loosen 1 / 2 turn | ||
| Head won’t stay on wand | Coupling nut cracked | Replace | |
| Brass ring worn | Replace | ||
| Premature blade wear | Squeegee wheels worn | Check wheels for wear / replace | |
| Sucks to the floor too tightly | Squeegee wheels worn | Check wheels for wear / replace |
3.3 PUMP & ELECTRICAL DIAGRAM


3.3 MACHINE DIAGRAMS

3.3 MACHINE DIAGRAMS

3.3 MACHINE DIAGRAMS

3.3 MACHINE DIAGRAMS
Complete pump and motor assembly - PA2172150 (120V) PA2150240V –2 (240V)

3.3 MACHINE DIAGRAMS

3.3 MACHINE DIAGRAMS

3.3 MACHINE DIAGRAMS
HEPA HOUSING ASSEMBLY (HEPAHA2)

| # | PART NO. | PART DESCRIPTION |
|---|---|---|
| 1 | HCOVER | HEPA COVER |
| 2 | FKEEP2 | HEPA FILTER KEEPER |
| 3 | HEPA | HEPA FILTER |
| 4 | HEPAH2 | HEPA FILTER HOUSING |
3.3 MACHINE DIAGRAMS

Kaivac and KaiVac are trademarks of Kaivac, Inc. Southeastern Equipment & Supply is an independent dealer.