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Parts › PartFinder › Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 › Operator manual
Form 3673to3855_01, Rev. 2005
Kaivac · Cleaning machine

Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual

3673to3855_01 Rev. 200544 pagesKaiZen Manual (Serial Numbers 3673-3855); KaiZen Manual (Serial Numbers 3856-4316); KaiZen Manual (Serial Numbers 4317-4455); KaiZen Manual (Serial Numbers 4456-4776) (KaiZen)
Free to read, no account neededEvery page has its own linkPart numbers link to the part
CERTIFICATE OF CONFORMITY

Certificate of Conformity

In short Kaivac, Inc. declares that the product named on this certificate was made and tested to the listed safety standards and carries the CE Mark. The certificate also lists the European and UK directives and regulations the product complies with.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‌​​​‌​⁠​​⁠​⁠⁠‍‌​‌‌​⁠⁠‌‌‌‌​‍⁠​​​⁠‌

We Kaivac, Inc.
401 S. Third Street
Hamilton, OH 45011 USA‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‌​​​‌​⁠​​⁠​⁠⁠‍‌​‌‌​⁠⁠‌‌‌‌​‍⁠​​​⁠‌

Declare and Certify that the following product

Machine
Type/Model
Serial Number
Date of Manufacture

Has been manufactured using the following standards and specifications;
And has been inspected and tested at our works in accordance with the relative specifications and drawings with which they comply in all respects;
And has been affixed with the CE Mark in Compliance with the following standards and specifications:

  • BS EN 292-1:1991 Safety of Machinery - Basic concepts, general principles for design. Part 1: Basic terminology, methodology.
  • BS EN 292-2:1991 Safety of Machinery - Basic concepts, general principles of design - Part 2: Technical principles and specifications.
  • BS EN 614-1:1995 Safety of Machinery - Ergonomic design principles - Part 1: Terminology and general principles.
  • BS EN 1050:1996 Safety of Machinery - Principles for risk assessment
  • BS EN 60204-1:1993 Safety of Machinery - Electrical equipment of machines - Part 1: Specification for general requirements.

and complies with the requirements of:

  • European Machinery directive 98/37/EC
  • UK Regulation 1992 no. 3073 - Supply of Machinery (Safety) Regulations 1992, and as amended.
  • European Low Voltage Directive 73/23/EC and as amended by 93/68/EC.
  • UK Regulation 1994 no.3260 - Electrical Equipment (Safety) Regulations 1994.
Place of Issue401 S. Third Street, Hamilton, OH 45011 USA
Date of Issue
Signature
Printed Name
PositionQuality Manager
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 1, used with permission. SES ref PF-6XU2-HN4H‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‌​​​‌​⁠​​⁠​⁠⁠‍‌​‌‌​⁠⁠‌‌‌‌​‍⁠​​​⁠‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 1 of 44
WINTERIZE

Winterize your Kaivac Equipment

In short Kaivac machinery that may be exposed to freezing temperatures should be winterized between uses. This is done by running windshield wiper fluid through the water tank and pump until the fluid runs out of the spray gun.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‍​​​‌​⁠​​‍⁠⁠‍‍​​‌‌​‍​‌⁠‌​​‌⁠‌⁠​‍‌

Your Kaivac machinery should be winterized between uses if it is to be exposed to freezing temperatures. To winterize your machine, pour 1/2 gallon of windshield wiper fluid into the empty water tank. Aim the spray gun into the water tank. Run the pump and spray the gun until the fluid begins running through.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‍​​​‌​⁠​​‍⁠⁠‍‍​​‌‌​‍​‌⁠‌​​‌⁠‌⁠​‍‌

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 2, used with permission. SES ref PF-2ML6-KPI7‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​‍​​​‌​⁠​​‍⁠⁠‍‍​​‌‌​‍​‌⁠‌​​‌⁠‌⁠​‍‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 2 of 44
COVER

Operator and Parts Manual

SERIAL# 3673 ON‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​⁠​​​‌​⁠​​​‍​‌⁠​⁠​​‍‍⁠​​​​‍​⁠​⁠​⁠‌

Line drawing of the KaiZen machine, a wheeled cleaning unit with tall tanks, carrying handles, a round access cover and two front wheels
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 3, used with permission. SES ref PF-2KK5-DXMH‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​​⁠​​​‌​⁠​​​‍​‌⁠​⁠​​‍‍⁠​​​​‍​⁠​⁠​⁠‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 3 of 44
WARRANTY

Warranty Registration Form

In short This form is filled out by the customer who purchases the equipment and mailed or faxed to Kaivac within ten days of purchase. Completing it earns a free Microfiber KaiTowel.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‌‌​​​‌​⁠​​‍⁠​‍‍‌​‌‌‍⁠‌⁠‍‍‍‌‌⁠‍‍‍‌‌

Free gift with completion of 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 ____

Phone Number ____ Fax ____

Date Purchased ____ Name of Distributor ____

☐ KaiVac® ☐ KaiZen™
Serial Number ____

Does your system include a KaiTutor™? ☐ Yes ☐ No

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 Machinery
  • ☐ Stairwell Cleaning
  • ☐ Locker and Shower Room
  • ☐ Hallway Cleaning
  • ☐ Classroom Cleaning
  • ☐ Other ____

Thank you very much for the information you have filled out for our records. As our way of saying thank you, we'd like to send you a free Microfiber KaiTowel.

Kaivac, Inc. · 401 South Third St. · Hamilton, Ohio 45011
Phone (513) 887-4600 · Fax (513) 887-4601 · Toll Free (800) 287-1136 · www.kaivac.com

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 5, used with permission. SES ref PF-TIOC-MNFX‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‌‌​​​‌​⁠​​‍⁠​‍‍‌​‌‌‍⁠‌⁠‍‍‍‌‌⁠‍‍‍‌‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 5 of 44
READ FIRST

READ FIRST

In short Read this manual before operating the machine. It stays at its best efficiency when run as described, maintained properly and regularly, and serviced with manufacturer parts only.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‌‍​​​‌​⁠​​​⁠​⁠‍‍​‍​⁠⁠⁠‌⁠⁠⁠⁠​‌‌‍‌‍‌

INSTALL DATE

Please fill out card for future records‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‌‍​​​‌​⁠​​​⁠​⁠‍‍​‍​⁠⁠⁠‌⁠⁠⁠⁠​‌‌‍‌‍‌

Install date-
Serial No.-

Read this manual prior to operation.

This machine will operate at its optimal efficiency if:

  • The machine is operated as described in this manual.
  • The machine is maintained properly and regularly- per maintenance instructions.
  • The machine is maintained with manufacturer parts only.

Carefully unpack and inspect your new KaiZen cleaning machine for shipping damage. Each unit is tested and thoroughly inspected before shipping. For instructions regarding shipping damage, contact Kaivac, Inc. immediately. All returns must have a Return Authorization Number (RAN), which is available by calling the Kaivac, Inc. Customer Service Department. Remember to protect your investment by registering your Warranty online at www.kaivac.com or mailing in the form on page iii.

TABLE OF CONTENTS

SectionPage
WARRANTY REGISTRATION FORMiii
READ FIRST/TABLE OF CONTENTSv
INTRODUCTIONvii
SAFETY PRECAUTIONS1-2
LIMITED WARRANTY PROTECTION PLAN3
MACHINE COMPONENTS/PREPARATION4
S·I·M·P·L·E PROCESS5-20
MACHINE MAINTENANCE21
TROUBLESHOOTING22-24
CHEMICAL INJECTION25
FLOW/ELECTRICAL DIAGRAMS26
PARTS LIST27-30
FIG.1 - WATER TANK ASSEMBLY31
FIG.2 - VAC TANK32
FIG.3 - COVER/PUMP MOTOR33
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 6, used with permission. SES ref PF-QFI5-DHOD‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‌‍​​​‌​⁠​​​⁠​⁠‍‍​‍​⁠⁠⁠‌⁠⁠⁠⁠​‌‌‍‌‍‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 6 of 44
INTRODUCTION

INTRODUCTION

INSPECTION

In short Unpack the new KaiZen and check it for shipping damage. If you find any, contact Kaivac, Inc. right away, and get a Return Authorization Number (RAN) from Customer Service before returning anything.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‍‌​​​‌​⁠​​⁠​‍‌⁠⁠​‍⁠‌​‍​⁠⁠‍‌‌⁠‍‍⁠⁠​

Carefully unpack and inspect your new KaiZen cleaning machine for shipping damage. Each unit is tested and thoroughly inspected before shipping. For instructions regarding any shipping damage, contact Kaivac, Inc. immediately. All returns must have a Return Authorization Number (RAN), which is available by calling the Kaivac, Inc. Customer Service Department.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‍‌​​​‌​⁠​​⁠​‍‌⁠⁠​‍⁠‌​‍​⁠⁠‍‌‌⁠‍‍⁠⁠​

WARNINGS

  • DO NOT operate with a frayed, worn or damaged electrical cord.
  • DO NOT use to pick up flammable or combustible materials.
  • DO NOT run the pump without water in the water tank or without filter.
  • DO NOT use hot water.
  • DO NOT remove the float shutoff.
  • ALWAYS test chemicals for compatibility on surfaces to be cleaned.
  • ALWAYS winterize your Kaivac equipment between uses if it will be exposed to freezing temperatures.

GROUNDING INSTRUCTIONS

In short The KaiZen must be grounded to reduce the risk of electric shock. Plug it only into a properly installed, grounded outlet, and do not cut the ground wire or modify the plug.

THE KAIZEN 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 KaiZen is equipped with a ground fault circuit interrupter (GFCI) to further reduce danger of electric shock. It must be maintained and tested regularly. An equipment grounding cord and plug is included with the unit. The plug must be inserted in an appropriate outlet that has been properly installed and grounded in accordance with all local codes and ordinances. Cutting off the ground wire or using a cord with an ungrounded plug will void the warranty on the unit, and Kaivac, Inc. will NOT accept responsibility for the unit.

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 KaiZen. If it will not fit the outlet, have a properly grounded outlet installed by a qualified electrician.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 9, used with permission. SES ref PF-43FC-GJP4‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‍‌​​​‌​⁠​​⁠​‍‌⁠⁠​‍⁠‌​‍​⁠⁠‍‌‌⁠‍‍⁠⁠​
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 9 of 44
SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

In short This section lists the basic safety rules for using the KaiZen: get trained, use it only as intended, keep the spray gun pointed away from people, use a GFCI, wear protective gear, and avoid actions that damage the pump or void the warranty.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‍⁠​​​‌​⁠​​⁠‍​​‌​⁠⁠​​​‌⁠‌‍‌⁠​‍⁠​​‍​

Equipment Warning

  • Read all instructions to ensure safe operation of the KaiZen.

Training

  • Proper training is required before using the KaiZen. Contact your authorized Kaivac distributor for training information.
  • Instruction placards are attached to each KaiZen and should not be removed. These placards show proper cleaning procedures and safety precautions.

Equipment Use

  • Use the equipment for the purposes specified by the manufacturer. Do not use the equipment for any other purpose.
  • See the S-I-M-P-L-E Operation section for proper use of the equipment.

Spray Gun

  • Never point the spray gun at people.

Prevention of Electrocution

  • Use the ground fault circuit interrupter (GFCI) with the KaiZen at all times.
  • Test the GFCI before each use.
  • Do not spray liquid from the KaiZen onto electrical outlets or on any electrical devices.

Personal Protection

  • Wear gloves, eye protection and ear protection when operating the KaiZen.

Machine Integrity

  • Do not run the pump dry. This will void the machine warranty.
  • Do not run hot water through the pump. This can cause pump cavitation and will void the warranty.
  • Always be sure the water tank and water line filters are clear of debris. Running the pump with clogged filters can cause pump damage.
  • Replace any damaged cords before use.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 11, used with permission. SES ref PF-KMGT-NFYX‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​‍⁠​​​‌​⁠​​⁠‍​​‌​⁠⁠​​​‌⁠‌‍‌⁠​‍⁠​​‍​
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 11 of 44
SAFETY

Winterize Your Kaivac Equipment

In short Kaivac machinery that will be exposed to freezing temperatures should be winterized between uses. Pour windshield wiper fluid into the empty water tank, aim the spray gun into the tank, and run the pump until the fluid runs through.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠​​​​‌​⁠​​‍‍‍‍⁠‍‌⁠‌‌​⁠‌​‌‌‍⁠‍​‌‍‌⁠

Your Kaivac machinery should be winterized between uses if it is to be exposed to freezing temperatures.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠​​​​‌​⁠​​‍‍‍‍⁠‍‌⁠‌‌​⁠‌​‌‌‍⁠‍​‌‍‌⁠

To winterize your machine:

  • Pour 1/2 gallon of windshield wiper fluid into the empty water tank.
  • Aim the spray gun into the water tank.
  • Run the pump and spray the gun until the fluid begins running through.

Chemical Use

  • Only use chemicals approved for use with the KaiZen. Use of non-Kaivac chemicals may cause machine damage and will reduce warranty periods.
  • Turn chemical line off when not in use.
  • Keep the appropriate chemical MSDS sheets on hand at all times.
  • Cleaning chemicals should not be put in the water tank (with the exception of KaiDri in small amounts). Chemicals in the water tank can harm operator and machine because:
    • Chemicals in the water tank must pass through the pump, which may cause premature pump failure.
    • Use of chemicals in the water tank voids the warranty.
    • Chemicals in the water tank will be aerosolized and may harm the operator.

Electrical

  • Connect to a properly grounded outlet only.
  • Do not pull the KaiZen by the cord or use the cord as a handle.
  • Do not close a door on the cord or pull the cord around sharp edges or corners.
  • Do not run over the cord.
  • Keep the cord away from heated surfaces.
  • Turn off the unit before unplugging.
  • Do not pull on the cord to unplug. Grasp the plug at the outlet and pull.

Prevention of Water Damage to Buildings

  • The KaiZen is to be used on water resistant building surfaces only. These include concrete, terrazzo, ceramic tile and quarry tile.
  • The KaiZen may be used for stripping on vinyl composite tile floors, but daily cleaning of resilient flooring using the KaiZen is not recommended.
  • Never overflow the water tank or the vacuum recovery tank.
  • Discontinue use if any leaks occur in the KaiZen.
CAUTION: Prior to cleaning, always inspect area to ensure that the surfaces to be cleaned are water-safe. In addition, check for poor construction, damaged walls and floors, missing or damaged tiles or grout, missing or insufficient caulk, and loose wall coverings. If problems are discovered, resolve them prior to cleaning in order to avoid any harm that may result from exposure to water or cleaning solution.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 12, used with permission. SES ref PF-SKXG-3TO4‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠​​​​‌​⁠​​‍‍‍‍⁠‍‌⁠‌‌​⁠‌​‌‌‍⁠‍​‌‍‌⁠
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 12 of 44
WARRANTY
SAVE THESE INSTRUCTIONS Violation of any of these instructions may void any and all warranties

Limited Warranty Protection Plan

In short This plan describes how long Kaivac covers the KaiZen for defects in workmanship or materials, depending on which chemicals are used. Parts must be returned to Kaivac with a Return Authorization Number (RAN) obtained from Customer Service.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠‌​​​‌​⁠​​​⁠⁠⁠​⁠⁠‍‌‌⁠‍⁠​‌‍‍‍‍⁠⁠‌‍⁠

The KaiZen 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. KaiChem 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 call Kaivac to check.
    • No warranty

* The parts in question must be returned to Kaivac for inspection by our warranty department. Return part(s) to: Kaivac, Inc.
230 Sycamore St. Hamilton, OH 45011
Attn: Allen, Warranty Dept.

All KaiZen 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.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 13, used with permission. SES ref PF-VXPS-UFEO‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠‌​​​‌​⁠​​​⁠⁠⁠​⁠⁠‍‌‌⁠‍⁠​‌‍‍‍‍⁠⁠‌‍⁠
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 13 of 44
MACHINE COMPONENTS AND PREPARATION

MACHINE COMPONENTS

In short This section names the 25 numbered parts and tools of the KaiZen machine. Use the drawing to match each number to its part.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠‍​​​‌​⁠​​⁠​‍⁠‍​‌​​⁠‌‌‍‍​‌‍‌‌‍​​‍​
Drawing of the KaiZen machine with its tools and accessories, with callout numbers 1 to 25 marking the squeegee head, chemical line, vac hose, vac tank, vac wand, gulper tool, hood, water tank, hoses, GFCI, blow nozzle, pressure gun, electric cord, lids, switches, chemical valve, wheel, metering tip pack, blow hose, window squeegee, placards and deck brush
No.Component
114 1/2" Squeegee Head
2Chemical Line
333' Vac Hose
4Vac Tank
5Vac Wand
6Gulper Tool
7Components Hood
8Water Tank
9Muffler and Hose
10GFCI
11Blow Nozzle
12Dump Hose
13Pressure Gun
14Electric Cord
15Pressure Hose
16Water Tank Lid
17Vac and Pump Switches
18Chemical Valve
19Vac Lid
208" Pneumatic Wheel
21Metering Tip Pack
22Blow Hose
23Window Squeegee
24Placards
25Deck Brush

MACHINE PREPARATION

In short Before a job, fill the water tank, prepare the cleaning solution, and check tools and supplies. Inspect all hoses and spray lines for damage, and test the GFCI before starting.
  1. Fill with clean cool water.
  2. 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.
  3. Check machine for all tools and supplies needed to complete task.
  4. Check all hoses and spray lines for damage prior to starting job. If damage is found, do not continue until proper repairs are completed.
  5. Test GFCI (Ground Fault Circuit Interrupter) to ensure it is working properly. You are now ready.
Five numbered illustrations of machine preparation: 1 filling the water tank, 2 chemical bottle with feed line and metering tip, 3 machine with tools and supplies, 4 hand checking a hose for damage, 5 hand pressing the Reset button on the GFCI plugged into an outlet
1 to 5
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 14, used with permission. SES ref PF-AFHS-SV4W‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠‍​​​‌​⁠​​⁠​‍⁠‍​‌​​⁠‌‌‍‍​‌‍‌‌‍​​‍​
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COVER

S*I*M*P*L*E™ No-Touch Cleaning Methods

KaiZen No-Touch Cleaning‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠⁠​​​‌​⁠​​‌⁠‍‍‍​⁠‌‌‌​‌‌‍‌⁠‌⁠⁠⁠‌⁠​​

Protected by U.S. Patent # 6,206,980; patents pending

  • Kitchens
  • Stairwells
  • Restrooms
  • Tank and Hose Cleaning
  • KaiTricks
  • Vacuuming Tricks
  • General Maintenance
  • Safety
  • Machine Components

Technical Support Info.

www.kaivac.com

Line drawing of the KaiZen machine on its cart, with a brush and squeegee tool on a pole standing upright and hoses coiled on the sides, inside a circle
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 15, used with permission. SES ref PF-JXPO-JKLH‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​​⁠⁠​​​‌​⁠​​‌⁠‍‍‍​⁠‌‌‌​‌‌‍‌⁠‌⁠⁠⁠‌⁠​​
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PRIMING PROCEDURE

Kaivac Priming Procedure

In short This procedure primes the pump on the KaiZen and KaiVac. Fill the water tank, turn on the vac and pump motors, and use the gun with the vacuum hose pressed against its nozzle to draw water into the pump. Priming is complete once the pump motor sound deepens and the vac has run 8 more seconds.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​​​​​‌​⁠​​⁠⁠⁠‍⁠⁠​⁠⁠‍​​⁠‍⁠​‍​⁠‍‌‌‍‍

KaiZen & KaiVac‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​​​​​‌​⁠​​⁠⁠⁠‍⁠⁠​⁠⁠‍​​⁠‍⁠​‍​⁠‍‌‌‍‍

A hand pressing the VAC rocker switch, with the PUMP rocker switch beside it; a dotted outline shows the hand's other position
1.
  1. Fill water tank with fresh water and turn on vac and pump motors.
  2. Press vacuum hose cuff against spray nozzle of gun tightly.
A hand holding the spray gun while the vacuum hose cuff is pressed against the gun's spray nozzle; arrows point to the valve, labeled VALVE IN OPEN POSITION, and to the hose cuff
2.
  1. Squeeze trigger on gun to allow vacuum suction to prime pump. When the pump has primed the pump motor sound will deepen.
  2. Release trigger and remove vac hose from nozzle. To prevent water from dripping out of vac hose, continue to run vac for a additional 8 seconds. Priming is now complete.
One hand squeezing the trigger of the gun, with an arrow pointing at the trigger, while the other hand holds the vacuum hose against the nozzle
3.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 16, used with permission. SES ref PF-SJBS-ZPA3‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​​​​​‌​⁠​​⁠⁠⁠‍⁠⁠​⁠⁠‍​​⁠‍⁠​‍​⁠‍‌‌‍‍
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SIMPLE No-Touch Cleaning Method

S.I.M.P.L.E. No-Touch Cleaning Method

Used in all procedures‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‌​​​‌​⁠​​​‍‌​​‌⁠​‍​​​‌‍​‍​‍​​⁠‌‍​

In short This page shows the six-step S.I.M.P.L.E. cleaning method in pictures: set up, inject chemicals, manually brush if needed, pressure wash and rinse, loop the spray line, then extract and dry. It is used in all procedures.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‌​​​‌​⁠​​​‍‌​​‌⁠​‍​​​‌‍​‍​‍​​⁠‌‍​

Set-up

Fill with clean cool water

Fill Water Tank (For KaiVac add 2 Caps of KaiDri for all others add 1 cap)

Select metering tip and insert into cap barb

Set-up step: a faucet icon, filling the machine with clean cool water, filling the water tank with KaiDri from a jug, and inserting a metering tip into the cap barb of a bottle

Inject Chemicals

*Chemicals

Fan Spray

Pinpoint

LOW Pressure Mode

Fan Spray

Inject Chemicals step: spray gun in LOW Pressure Mode with fan spray and pinpoint settings for chemicals, fan spraying a toilet, and a worker applying chemicals to a restroom floor

Manual Brush (OPTIONAL)

Manually brush heavily soiled areas

Manual Brush step: a worker brushing a floor with a long-handled brush, a worker scrubbing under a counter, and a worker brushing stairs

Pressure Wash & Rinse

*Water Only

Fan Spray

Pinpoint

HIGH Pressure Mode

PINPOINT Spray

Top to Bottom

Pressure Wash and Rinse step: spray gun in HIGH Pressure Mode with water only, pinpoint spray into a toilet, and a worker rinsing stairs from top to bottom

Loop Spray Line

Clockwise

HOOK

Adjust last loop (KaiVac only).

Loop Spray Line step: a worker coiling the spray line clockwise around the machine, hanging it, and adjusting the last loop on the hook (KaiVac only)

Extract & Dry

Extract and Dry step: a worker using a floor tool to extract water near urinals, under a counter, and on stairs
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 17, used with permission. SES ref PF-OXTP-XZQW‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‌​​​‌​⁠​​​‍‌​​‌⁠​‍​​​‌‍​‍​‍​​⁠‌‍​
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NO-TOUCH RESTROOM CLEANING

No-Touch Restroom Cleaning

(Suggested chemical: KaiBlooey)‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‍​​​‌​⁠​​​‍​⁠‌​​‌⁠⁠⁠⁠​‍​⁠​‌‍‌‍⁠⁠⁠

In short This page is a 20-step picture guide to cleaning a restroom with the chemical injection spray gun. You turn the chemical valve on, apply cleaning solution to fixtures, rinse with high pressure, and finish by wet vacuuming the floor and drying surfaces.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‍​​​‌​⁠​​​‍​⁠‌​​‌⁠⁠⁠⁠​‍​⁠​‌‍‌‍⁠⁠⁠
Twenty numbered illustrations of the no-touch restroom cleaning method: turning the chemical valve on, setting the spray gun to low pressure chemical injection, applying chemical to fixtures in a circular pattern with timed injections, rinsing chemical from the line, switching to high pressure and rinsing top to bottom, cleaning toilet parts (Rim Shot, Slam Dunk, base), looping the hose onto wraps, squeegeeing mirrors, wet vacuuming the floor, and blow drying handles and seat tops
No-Touch Restroom Cleaning steps 1 to 20
  1. Turn chemical valve on. Check tank levels. Optional: Dust with KaiHose
  2. Adjust spray gun to chemical injection. Pull nozzle out and rotate for fan pattern. (Low pressure mode)
  3. (Pretest chemicals on all surfaces before using.) Inject chemicals on fixtures and soiled areas. Start at the nearest fixture traveling in circular pattern.
  4. 7 sec. Chemical injection. Apply cleaning solution to fixtures.
  5. 3 sec. Chemical injection. Apply cleaning solution to fixtures.
  6. 2 sec. chemical injection. 7 sec for high pressure rinse.
  7. Turn chemical valve off.
  8. Rinse chemical from line onto floor. Optional: Manually brush heavily
  9. Push nozzle in and rotate to a pinpoint pattern. Adjust spray gun for high pressure wash and rinse. (High pressure mode)
  10. Pressure wash fixtures in a top-to-bottom pattern. 15 sec for high pressure rinse.
  11. 6 sec. Pinpoint clean plumbing and seat top.
  12. 6 sec. Lift seat, clean hinges and seat bottom.
  13. Rim Shot: 4 sec. Place nozzle under rim and rotate.
  14. Slam Dunk: 4 sec. Spray into bowl.
  15. 10 sec. Spray bottom and base. Toilet Cleaning time 30 sec. (for high pressure rinse)
  16. Loop and dry hose onto wraps.
  17. Adjust last loop. (KaiVac model only)
  18. Squeegee mirrors and flat surfaces.
  19. Wet vac restroom floor from front to rear. Load paper, supplies and examine.
  20. *optional: Blow dry flush handles and toilet seat tops for immediate use.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 18, used with permission. SES ref PF-QQBR-VZYQ‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​‍​​​‌​⁠​​​‍​⁠‌​​‌⁠⁠⁠⁠​‍​⁠​‌‍‌‍⁠⁠⁠
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Hallway Cleaning

Hallway Cleaning

Method of Use

I. Apply Cleaning Solution

In short This method has two steps for cleaning a hallway. First you spray cleaning solution on the floor in a serpentine pattern, then you vacuum it off in passes that overlap the previous pass by 2 inches.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​⁠​​​‌​⁠​​⁠‍‌‌⁠‍‍‍⁠⁠​‌‍‌⁠‌​‍‍‌⁠⁠‍‌
  1. Unwrap the spray gun and pressure hose. Leave 2 loops wrapped on the No-Touch Cleaning machine.
  2. Using the spray gun, apply a wide spray pattern of cleaning solution to the floor in a serpentine manner. (1 gallon covers approximately 800 feet.)
  3. For daily cleaning of waxed floors, it is recommended that you use a neutral (pH7) cleaning solution, such as KaiO™ from Kaivac.

II. Vac Off

  1. Connect the KaiAuto™ head to the Vac Wand and hose.
  2. Start vacuuming to the right of, and away from, the No-Touch Cleaning machine, heading along the wall.
  3. Proceed along the wall until you reach the limit of the hose length.
  4. Turn to the left 180° heading back toward the machine with a 2" overlap of the previous pass.
  5. Swerve KaiAuto towards the wall just as you pass the No-Touch Cleaning Machine (now vacuuming the wall on the left side of the machine) and continue down the hall.
  6. At the end of the hose make a 180° right turn heading back towards the unit with a 2" overlap of the previous pass.
  7. Continue this method until you reach the far wall away from the cleaning machine.

(Please see the training video for more information.)‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​⁠​​​‌​⁠​​⁠‍‌‌⁠‍‍‍⁠⁠​‌‍‌⁠‌​‍‍‌⁠⁠‍‌

Step 1, Apply Solution, Spray ON: an operator with a spray gun, and a hallway diagram with a serpentine spray path along the hallway, starting from the machine in the alcove
Step 1 Apply Solution. Spray ON.
Step 2, Vac OFF: an operator with a vacuum wand, and a hallway diagram with overlapping vacuum passes running from START at the machine in the alcove down the hallway to FINISH
Step 2 Vac OFF.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 19, used with permission. SES ref PF-JWJQ-NMPP‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌​⁠​​​‌​⁠​​⁠‍‌‌⁠‍‍‍⁠⁠​‌‍‌⁠‌​‍‍‌⁠⁠‍‌
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OPERATION

Kitchen Cleaning

In short This page shows a five-step picture guide for cleaning a kitchen floor. You fill the tank, inject chemical on soiled surfaces, brush heavily soiled areas by hand, spray corners and base boards, then vacuum up the soiled liquid.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌​​​​‌​⁠​​⁠‍⁠‌‌⁠​‍‍‍‌‍‌‍‍‍‌⁠⁠​⁠​⁠⁠

(Suggested chemical: KaiPow)‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌​​​​‌​⁠​​⁠‍⁠‌‌⁠​‍‍‍‌‍‌‍‍‍‌⁠⁠​⁠​⁠⁠

Step 1: a hose with velcro wrapped in a tight spiral around a water faucet nozzle, with an arrow showing the wrapping direction
1

Wrap velcro in tight spiral fashion around water faucet nozzle and fill tank.

Step 2: a person wearing safety glasses injects chemical with a spray wand onto a highlighted soiled floor area beneath a kitchen table
2

Inject chemicals on soiled surfaces and floor.

Step 3: a person crouching beside a sink manually brushes the floor with a long-handled brush in a heavily soiled area
3

Manually brush floor in heavily soiled areas.

Step 4: a person crouching sprays pinpoint spray at a highlighted corner under kitchen equipment, with an arrow labeled Top To Bottom
4

Pinpoint spray works great removing soils in corners and around base boards.

Step 5: a person crouching vacuums soiled liquid from the floor under a sink with the wand laid flat, with the vacuumed spot highlighted
5

Vacuum soiled liquid from floor. Lay wand flat to maneuver under equipment and fixtures.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 20, used with permission. SES ref PF-MSPV-IQ4D‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌​​​​‌​⁠​​⁠‍⁠‌‌⁠​‍‍‍‌‍‌‍‍‍‌⁠⁠​⁠​⁠⁠
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KAIGROUTER

Connect spray line and vac hose to KaiGrouter

In short This page shows how to use the KaiGrouter once the spray line and vac hose are connected. First apply chemical with the fan spray, then switch to high pressure and work along the grout lines.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌‌​​​‌​⁠​​‍‌‌⁠​‍​⁠‌​​⁠⁠‌⁠‍‌‌​​‍​‌‌
  1. Turn valve to fan spray to apply chemical. Lift head off floor and move over floor spraying chemicals.
  2. Turn valve to high pressure setting, line up yellow guide line with grout lines, pull trigger and move along grout line.
Step 1: KaiGrouter head with spray line and vac hose lying on a tiled floor, the yellow circle marking the head with fan spray lines fanning out from the nozzles onto the floor, and a dashed double-headed arrow showing the hose and head being swept over the floor
1
Step 2: KaiGrouter head on a grout-lined tile floor with the yellow circle marking the guide line area, and two black arrows along the grout line showing the forward and back movement of the head
2
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 21, used with permission. SES ref PF-24TG-IX5J‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌‌​​​‌​⁠​​‍‌‌⁠​‍​⁠‌​​⁠⁠‌⁠‍‌‌​​‍​‌‌
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OPERATION

Stairwell Cleaning

In short This page shows six illustrated steps for cleaning a stairwell: dust high areas, place a drain at the bottom of the steps, apply chemicals, wash and rinse, then remove soils with the floor squeegee tool.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌‍​​​‌​⁠​​‌​​‌‍⁠‍⁠‍‌⁠‌​⁠‌‌​‌​‍‍​‍⁠
  1. Insert KaiNozzle to blow-dust elevated areas.
    Hands inserting the KaiNozzle into the end of a hose or wand, with the connection highlighted in yellow
    1
  2. Position machine at bottom of stairs. Dust cobwebs from high and hard to reach areas using KaiBlower and squeegee wand.
    Worker in safety glasses standing by a staircase using the KaiBlower and squeegee wand to dust high areas, with the nozzle end highlighted in yellow
    2
  3. Position KaiDrain at bottom of steps to suction excess moisture.
    KaiDrain tool on a tiled floor with arrows showing liquid flowing toward it, connected to a hose, highlighted in yellow
    3

    KaiDrain is an instant drain for use when puddling occurs.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌‍​​​‌​⁠​​‌​​‌‍⁠‍⁠‍‌⁠‌​⁠‌‌​‌​‍‍​‍⁠

  4. Inject chemicals and apply to walls and stairs.
    Worker on stairs spraying chemicals onto walls and stairs, with the machine beside the stairs and a puddle area highlighted in yellow
    4
  5. Wash and rinse with high pressure spray to remove soils. In case of heavy soils, use KaiBrush on walls and stairs.
    Worker on stairs washing and rinsing with a high pressure spray wand, with the machine at the right and the wand tip highlighted in yellow
    5
  6. The floor squeegee tool sucks away soils and solution leaving stairwells sparkling clean. Soils are contained in the machine for later disposal.
    Worker on stairs using the floor squeegee tool on a hose, with the machine at the right and the tool highlighted in yellow
    6
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 22, used with permission. SES ref PF-6ORU-J4C2‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌‍​​​‌​⁠​​‌​​‌‍⁠‍⁠‍‌⁠‌​⁠‌‌​‌​‍‍​‍⁠
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KAIVAC TIPS

Kaivac Tips

In short This page gives illustrated tips for handling hoses and cords, filling the tank, cleaning wheel chairs, using the blow feature, and running the machine in dry vacuum mode. In dry vacuum mode you connect the spray line to the Wet/Dry Vacuum Converter, empty the vac tank, fill the water tank and turn on the pump and vac motor.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌⁠​​​‌​⁠​​​​⁠​‍‍⁠‌‌‍​​⁠⁠‌‍​⁠​‌‌⁠‌‍
Kaivac machine with hose and cord wrapped on it and one cord run out to a wall outlet

Remove only the needed hose or cord to reach area. Excess remains on the machine.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌⁠​​​‌​⁠​​​​⁠​‍‍⁠‌‌‍​​⁠⁠‌‍​⁠​‌‌⁠‌‍

Spray gun secured with the wrap and snap at the top left side of the machine, with hoses hanging below

Use the wrap and snap located on the top left side of your machine to secure the gun.

Person in safety glasses dumping the contents of a hose into a toilet

Dump into any toilet

Fill Hose

Fill hose with velcro wrapped in a tight spiral around a water faucet nozzle, arrow showing the wrap direction

Wrap velcro in tight spiral fashion around water faucet nozzle and fill tank.

Top of the machine with the fill hose wrapped and stowed on it

Wrap and stow the Fill Hose.

Wheel Chair

Person spraying cleaning solution on a wheel chair with the machine's spray gun

Spray proper cleaning solution on chair. Allow contact time. High pressure rinse to remove soils.

Hand using the KaiBlower hose to blow dry a wheel chair

Blow dry with KaiBlower.

Blow Feature

Blow hose coiled on the side of the machine, to be removed and attached to the outlet on the component hood

Remove blow hose from machine and attach one end to outlet on side of component hood.
(KaiZen Plus model shown)

Two views of the machine muffler, with the exhaust hose removed and the vac hose attached using the gray hose coupler

Remove exhaust hose from muffler and attach vac hose to muffler using the gray hose coupler.
(Standard KaiZen)

Hands inserting the KaiNozzle into the blow hose

Insert KaiNozzle to blow-dust elevated areas.

Person using the KaiBlower to dust and clean tall lockers

Use KaiBlower for dusting and cleaning lockers.

DRY VACUUM MODE OPERATION

STEP (1)

Machine with the spray gun being removed from the spray line and connected to the Wet/Dry Vacuum Converter on top
STEP (1)

Remove spray gun from spray line. Connect to Wet/Dry Vacuum Converter.

STEP (2)

Top of the machine with hand switching on the pump and vac motor switches
STEP (2)

Empty vac tank, fill water tank, turn on pump and vac motor.

Person cleaning a floor with a vacuum tool and hose attached to the machine in dry vacuum mode

With appropriate cleaning tool begin cleaning.

A full water tank should clean for approximately 60 minutes before vac fills. To continue, repeat steps 1 and 2.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 23, used with permission. SES ref PF-QY6P-V7KR‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‌⁠​​​‌​⁠​​​​⁠​‍‍⁠‌‌‍​​⁠⁠‌‍​⁠​‌‌⁠‌‍
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CLEANING PROCEDURES

Classroom Cleaning

Front Entrance Classroom

Floor plan of a front entrance classroom with desk near the top left, rows of student desks, windows on the left and hallway on the right. Blue arrows show the vacuum path from the START point at the entrance in the top right, weaving down and up each row, ending at STOP by the entrance.
Front Entrance Classroom
NOTE Park unit at entrance of classroom.

Cleaning Procedure

In short This page gives the daily and weekly cleaning routine for a classroom, with diagrams showing where to park the unit and the vacuuming path for front and rear entrance classrooms. Set up the machine for dry vacuuming, park it at the classroom entrance, and follow the path shown.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍​​​​‌​⁠​​​‌​‌‍‌‍​​‌⁠​⁠​⁠‌‌‌‍‌‍⁠​‌

I. Daily

  1. Set-up No-Touch Cleaning machine for dry vacuuming.
    • Attach Wet/Dry Converter and dry vacuum head.
    • Park unit at entrance (see illustration for location and vacuum flow pattern).
    • Plug unit into outlet.
  2. Close and lock all windows.
  3. Empty pencil sharpeners.
  4. Pick up large debris from floor (pencils, papers, etc.) and place in trash can.
  5. Empty trash can.
  6. Dry vacuum as shown in illustration. Clean aisle space directly in front of you, then clean under chair next to you. Repeat until row is finished.
  7. Spot clean floor with spray bottle and flat microfiber mop head.

II. Weekly

  1. Dry vacuum horizontal surfaces (teacher's desk, window sills, cabinets, etc.).
  2. Dry vacuum computer screens.
  3. Spot clean walls, desktops and windows.
  4. Clean inside trash can with spray gun and instant drain (gulper tool).
  5. Clean chalkboard and tray.

Rear Entrance Classroom

Floor plan of a rear entrance classroom with desk at the top, rows of student desks, windows on the left and hallway on the right. Blue arrows show the vacuum path through the rows, starting from the unit parked at the bottom right corner entrance.
Rear Entrance Classroom
NOTE For oversized rear entrance classroom, park unit at front of classroom to start.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 24, used with permission. SES ref PF-J7S6-AFLX‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍​​​​‌​⁠​​​‌​‌‍‌‍​​‌⁠​⁠​⁠‌‌‌‍‌‍⁠​‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 24 of 44
SAFETY

Safety Tips

In short This page shows with pictures what to do and what not to do when using the machine. Use the proper way on steep inclines, check hoses, cords and the GFCI daily, and always wear gloves and safety eyewear.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‌​​​‌​⁠​​‌​​‌​‌‌​‍‍‌​​‍⁠⁠‌‍‌⁠‍​⁠‍
Crossed-out circle symbol beside a man pushing the machine with hoses and cord up a steep incline in the wrong way, leaning the machine back
Incorrect way. Could cause injury or damage to machine.

Incorrect way. Could cause injury or damage to machine.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‌​​​‌​⁠​​‌​​‌​‌‌​‍‍‌​​‍⁠⁠‌‍‌⁠‍​⁠‍

Yellow check mark beside a man using the proper way on a steep incline, with the machine turned and pulled behind him
Proper way for steep inclines.

Proper way for steep inclines.

Crossed-out circle symbol beside a hand holding a worn, damaged hose while another hand points at the damage
Never operate with worn hoses or cords. Inspect them daily.

Never operate with worn hoses or cords. Inspect them daily.

Yellow check mark beside a hand unplugging a cord from a wall outlet by grasping the plug
Remove by grasping plug. Never pull by cord.

Remove by grasping plug. Never pull by cord.

Bottle of chemical dripping a drop onto a surface for a compatibility test
Test chemicals on all surfaces for compatability.

Test chemicals on all surfaces for compatability.

Yellow check mark beside a hand pressing the RESET button on a GFCI plugged into a wall outlet
Inspect and test GFCI daily.

Inspect and test GFCI daily.

Crossed-out circle symbol beside a crouching man in a mask spraying a gun toward a wall power outlet
Never spray gun towards power outlets.

Never spray gun towards power outlets.

Crossed-out circle symbol beside a spray gun pointed at a person's hand
Never point at people.

Never point at people.

Yellow check mark beside two people wearing gloves and safety eyewear
Always wear gloves and safety eyewear.

Always wear gloves and safety eyewear.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 25, used with permission. SES ref PF-EMIM-LHVM‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‌​​​‌​⁠​​‌​​‌​‌‌​‍‍‌​​‍⁠⁠‌‍‌⁠‍​⁠‍
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 25 of 44
GENERAL MAINTENANCE

General Maintenance

In short This page lists routine checks for the machine: inspect the filters and muffler for dirt, keep tire pressure at 30 psi, wipe the unit clean, and lubricate the nozzle weekly. It also covers winterizing for sub freezing storage and transport, and caring for the floor squeegee and its tools.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‍​​​‌​⁠​​‍​​​‌⁠‍‌‌⁠⁠‌‍‍⁠​⁠⁠‍​‌‌⁠​

Inspect Filters for dirt.

Two views of filter inspection: on the KaiVac model a hand reaches to the filter cover near the hose and caster, and on the KaiZen model a hand touches the filter cover on the machine, each highlighted in yellow
(KaiVac model) (KaiZen Model)

(KaiVac model) (KaiZen Model)‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‍​​​‌​⁠​​‍​​​‌⁠‍‌‌⁠⁠‌‍‍⁠​⁠⁠‍​‌‌⁠​

If found, remove cover, clean filter screen and reinstall.

Inspect Muffler for soils.

Two views of muffler inspection: on the KaiVac model a hand reaches to the muffler near the hose and caster, and on the KaiZen model a hand works at the muffler beside a wheel, each highlighted in yellow
(KaiVac model) (KaiZen model)

(KaiVac model) (KaiZen model)

If found, remove stuffing, wash and reinstall.

Person's leg and boot beside the machine with a hand at the tire valve of the wheel, highlighted in yellow, for checking tire pressure

Keep tire pressure at 30 psi.

Person wiping the whole machine with a cloth, wheeled unit with hose coiled on its side

Wipe entire unit clean with an all purpose cleaner.

DO NOT PRESSURE WASH MACHINE
Person pouring windshield fluid from a gallon jug into the machine tank; jug labeled Windshield Fluid

Winterize system for outdoor storage or transport in sub freezing temperatures. Remove all water from tank, add 1/2 gallon windshield washer fluid. Run pump and spray until fluid is discharged from gun.

Nozzle tool with a spray can labeled Lube aimed at the nozzle joint, and a double arrow showing the nozzle moving forward and backward

(Weekly) Lubricate nozzle with penetration oil. Nozzle must move freely forward and backwards.

Unscrew locking collar to remove tools

Two views of the locking collar on the floor squeegee: a hand unscrewing the collar to remove the tool, and the squeegee rotating freely when the collar is snug

For Floor Squeegee, ensure brass ring is located in groove.

When collar is snug Floor Squeegee should rotate freely.

Floor Squeegee

A hand wiping the floor squeegee with a cloth, beside a drawing of the squeegee with callouts 1 squeegee head, 2 blades, 3 screw, 4 wheel, 5 wheel holder
Floor Squeegee
No.Part
1Squeegee Head
2Blades
3Screw
4Wheel
5Wheel Holder

Wipe Squeegee blades with cloth. Inspect tool for worn wheels and blades. Replace as needed.

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 26, used with permission. SES ref PF-J5EA-ZNOG‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍‍​​​‌​⁠​​‍​​​‌⁠‍‌‌⁠⁠‌‍‍⁠​⁠⁠‍​‌‌⁠​
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 26 of 44
Tank and Hose Cleaning

Tank and Hose Cleaning

In short This section explains how to flush and dry the vac hose and rinse the vac tank after use. Lower the hose end to the water surface, wrap the hose while the vac motor runs, then rinse the tank with clean water.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍⁠​​​‌​⁠​​‌​‍‌‍‍⁠​‌​‌‌​‍​⁠‌​‌⁠​‍‌‍
  1. Unwrap Vac Hose and lay it on floor.
  2. Lower end of Vac Hose to surface of water, gulping both air and water. This action flushes soils from line and quickly empties water tank.
  3. 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.
  4. With Dump Hose opened and positioned by floor drain, spray inside of vac tank with clean water moving hose in a circular pattern to ensure tank walls and float shutoff are rinsed.
Operator standing behind the machine holding the vac hose end down to the surface of the water in the tank, with a dashed outline of the tank, a highlighted hose end, an upward arrow, and the coiled hose on the floor; callouts 1 and 2 are marked
1 and 2
Operator wearing gloves wrapping the vac hose onto the machine, with a highlighted hand on the hose and arrows showing the wrapping direction; callout 3 is marked
3
Hand spraying clean water with a hose inside the open vac tank in a circular pattern, with the hose end highlighted and the control box with chemical, vac and pump switches beside the tank; callout 4 is marked
4
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 27, used with permission. SES ref PF-L63J-55ZD‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌‍⁠​​​‌​⁠​​‌​‍‌‍‍⁠​‌​‌‌​‍​⁠‌​‌⁠​‍‌‍
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 27 of 44
TOOL ARRANGEMENT

Tool Arrangement

Front right view of the KaiZen cart with labels: Deck Brush, Window Squeegee, KaiDrain, Gallon Jug, KaiBlower, Vac Wand, Pressure Hose, Dump Hose, Vac Hose, GFCI Ground Fault Circuit Interrupter, Electric Cord, Optional Blow Motor, and Wet/dry Converter
FRONT RIGHT VIEW
Rear right view of the cart showing the KaiAuto and the Blow Hose, with a gallon jug and hoses stored on the cart
REAR RIGHT VIEW
Bottom view of the cart with labels: Muffler Hose, Water Filter, Electric Line, Pressure Hose, Muffler, and Bottom Plate
BOTTOM VIEW
Overhead view of the cart with Front at the top, Back at the bottom, Left and Right sides marked. Labels: Vac Wand & Squeegee, Dump Hose, Vac Hose, Clear Hose Wet/Dry Converter, KaiBlower, Electrical Line, Pressure Hose, KaiDrain, Chemical On/Off Valve, Window Squeegee, Metering Tip Pack, Wrap & Snap Tool Holders, Gallon Jug, KaiAuto, KaiHose, Deck Brush, and Blow Hose
OVERHEAD VIEW
Side view of the KaiZen cart with labels: 14 1/2" Squeegee Head, Chemical Line, Vac Tank, Water Tank Lid, Wet/Dry Converter, Dump Hose, 33' Vac Hose, Electric Cord, Components, Vac Wand, GFCI, Water Fill Port and Fill hose, Muffler & Hose, 8" Pneumatic Wheel, and Water Tank
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 28, used with permission. SES ref PF-4OVN-GSUW‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠​​​​‌​⁠​​‌‌⁠​‌‍‌⁠‍‍⁠​⁠​⁠‌‌‌​​​‍‌‍
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 28 of 44
SIGNAGE

Restroom Closed for Cleaning

Black sign page with the Kaivac cleaning systems logo at the top and the words Restroom Closed for Cleaning in large yellow italic letters
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 29, used with permission. SES ref PF-XTJ4-BCGK‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠‌​​​‌​⁠​​‌‌‌⁠​‌‌⁠‌​​​⁠‍​‌‌‍‍⁠⁠‍⁠​
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 29 of 44
SAFETY SIGN

Caution Wet Floor

Caution‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠‍​​​‌​⁠​​‍‍⁠​​‍‌​‍‌‍‌​‍‍​‌‍⁠⁠‍‍‌⁠

Wet

Floor

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 30, used with permission. SES ref PF-QDAW-NREN‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠‍​​​‌​⁠​​‍‍⁠​​‍‌​‍‌‍‌​‍‍​‌‍⁠⁠‍‍‌⁠
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 30 of 44
MACHINE MAINTENANCE

MACHINE MAINTENANCE

In short This table lists what to check or clean on each part of the machine: the floor squeegee, spray gun, hose, filters, tanks, leaks, electrical system and DVD system. Make sure the machine is unplugged before lifting the electrical cover assembly.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠⁠​​​‌​⁠​​‍‍⁠​‌​​‍‍‌‌‌‍‌​‍⁠⁠‍‍‍‌‍⁠
CAUTION Always make sure machine is unplugged before lifting electrical cover assembly
ItemProcedure
Floor SqueegeeCheck condition of rubber squeegee blades and wheels on the floor tool. Rough floor surfaces will cause the blades and wheels to wear out more quickly. Replace as necessary.
Spray Gun
  • Check spray pattern. If spray pattern will not pinpoint, clean orifice by removing it with an Allen wrench and flushing. Replace if not pinpointing.
  • If nozzle becomes difficult to move from high to low pressure lubricate nozzle with lithium grease.
Pressure Hose
  • Wipe clean after each use.
  • Check for cuts or frays in the hose jacket, particularly at the end of the fittings. Replace hose if cuts are found.
Water Filter
  • Check filter screens for debris and clean as needed. Be careful not to crush the end of the filter screen when replacing.
  • Check the clear filter bowl cover to be sure it is tight.
  • Check for leaks around filter and filter connections.
Water Tank
  • Check condition of filter in water tank. Clean as needed.
  • Empty the water tank to prevent mildew and bacteria growth. Empty tank by dipping the vacuum hose onto the water tank and transferring the water to the vacuum tank.
Vacuum Tank
  • Empty and flush vacuum tank.
  • Clean and disinfect.
  • Check the float shutoff screen to be sure it is not plugged up. A plugged filter screen restricts airflow and results in reduced suction.
LeaksBe alert for leaks around hoses, fittings, spray wand, tanks or elsewhere. Discontinue use until leaks are repaired.
Electrical System
  • The ground fault circuit interrupter (GFCI) must be tested before each use.
  • Electric cords must be inspected for tears or cuts in the insulation.
DVD SystemMake sure DVD player is dry and free of any debris placed on top or inside of storage compartment.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 31, used with permission. SES ref PF-GC5B-DB4N‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‌⁠⁠​​​‌​⁠​​‍‍⁠​‌​​‍‍‌‌‌‍‌​‍⁠⁠‍‍‍‌‍⁠
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 31 of 44
TROUBLESHOOTING

TROUBLESHOOTING

CAUTION Always make sure machine is unplugged before lifting electrical cover assembly
In short This table lists problems by machine area (electrical, vacuum system, blow dry system and DVD system), with the possible causes and the remedy for each. Unplug the machine before lifting the electrical cover assembly.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​​​​​‌​⁠​​‍​‍‌‌‍​⁠⁠‌⁠‍‌‌⁠‌⁠​‌‍⁠‍​​
AREAPROBLEMPOSSIBLE CAUSEREMEDY
ElectricalNo power to pump or vac motor.
  1. Machine not plugged in.
  2. Switch not “on.”
  3. GFCI tripped.
  4. Building circuit overloaded.
  5. Switch wires loose.
  6. Terminal block connections loose.
  1. Plug machine in.
  2. Check switches for “on.”
  3. Test and reset GFCI.
  4. Check and reset circuit.
  5. Disconnect power and check for loose wire.
  6. Disconnect power and check for loose wire.
Electrical burning smell.
  1. Vac motor brushes worn.
  2. Vac motor hung up.
  3. Pump motor hung up.
  1. Replace vac motor brushes.
  2. Remove vac motor and repair.
  3. Release pressure on hose and jog pump switch, or replace.
Vacuum SystemNo/Weak vacuum.
  1. Vac tank full.
  2. Squeegee blades or wheels worn.
  3. Float shutoff screen dirty.
  4. Float ball stuck.
  5. Damaged hose.
  6. Dump hose plug missing.
  7. Access lid not tight.
  8. Vacuum hose plugged.
  9. Too much liquid in vac hose.
  10. Vac hose still wrapped.
  11. Muffler plugged.
  12. Leak in vac tank.
  1. Empty vac tank.
  2. Replace wheels or blades and check periodically.
  3. Wipe off float screen to clean.
  4. Tap float and release/clean.
  5. Cut and repair/replace.
  6. Contact dealer and replace.
  7. Tighten lid hand tight.
  8. Flush hose to remove debris.
  9. Allow air in when vacuuming.
  10. Unwrap vac hose fully.
  11. Remove padding and clean.
  12. If repairable, clean and dry affected area and seal with silicone.
Moisture from exhaust.
  1. Vac tank full.
  2. Float shutoff missing.
  3. Excessive foam in vac tank.
  1. Dump vac tank.
  2. Replace.
  3. Use defoamer.
Blow Dry SystemNo air flow.1. Hose disconnected.1. Reconnect hose.
Moisture from nozzle.1. Water in blow hose.1. Dry blow line.
Suction not blow action.1. Vacuum hose connected to vac tank.1. Reconnect to vac motor exhaust hose.
DVD SystemNo power.
  1. Power cord not connected
  2. Power switch not on.
  1. Plug cord into dvd player.
  2. Turn switch on DVD player on.
No picture1. Screen is blank.1. Close and re-open lid. Play.
No audio1. No sound from player1. Check volume control knob.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 32, used with permission. SES ref PF-KR7T-GKXR‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​​​​​‌​⁠​​‍​‍‌‌‍​⁠⁠‌⁠‍‌‌⁠‌⁠​‌‍⁠‍​​
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 32 of 44
TROUBLESHOOTING

TROUBLESHOOTING

In short This section is a table of problems by machine area, with the possible causes and the remedy for each. This page covers the high pressure system (no water or low pressure, bad spray pattern) and the chemical injection system (no chemical flow).‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​‌​​​‌​⁠​​‌‍‌⁠⁠⁠⁠‍‍‍⁠⁠‍‍‌​‍‍⁠​⁠‌‌‌
CAUTION Always make sure machine is unplugged before lifting electrical cover assembly
AREAPROBLEMPOSSIBLE CAUSEREMEDY
High Pressure SystemNo water from pump or low pressure.
  1. Out of water.
  2. Gun nozzle plugged.
  3. Air in pump (vapor lock).
  4. Gun orifice missing.
  5. Tank filter plugged.
  6. Pressure hose damaged.
  7. Quick disconnect leaking.
  8. Injector plugged.
  9. Pulse hose damaged.
  10. Regulator failed.
  11. Hose kinked.
  12. Seals in pump need replaced.
  1. Fill water tank.
  2. Remove orifice with Allen wrench and clean.
  3. Use power prime technique.
  4. Replace orifice.
  5. Clean tank and filter.
  6. Repair or replace.
  7. Tighten or replace.
  8. Remove safety cap from chemical and blow small amounts of compressed air into line.
  9. Repair or replace.
  10. Replace.
  11. Unkink and check for damage
  12. Remove and replace seals.
Bad fan pattern or pinpoint pattern on gun.
  1. Debris in nozzle.
  2. Orifice damaged.
  1. Remove orifice with Allen wrench and clean.
  2. Remove and replace.
Chemical Injection SystemNo chemical flow.
  1. Out of chemical.
  2. Safety cap not secure.
  3. Chemical valve "off."
  4. Safety cap plugged.
  5. Spray gun in wrong mode.
  6. Metering tip plugged.
  7. Injector plugged.
  8. Air entering system.
  9. Injector installed backwards.
  1. Refill chemical.
  2. Check safety cap / tighten.
  3. Check on / off valve.
  4. Replace cap.
  5. Make sure gun nozzle is pulled out away from gun chemical mode.
  6. Check metering tip for clog.
  7. Remove safety cap from chemical and blow small amounts of compressed air into line.
  8. Check for air entering system around chemical lines or injector.
  9. 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.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 33, used with permission. SES ref PF-YHHE-N54D‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​‌​​​‌​⁠​​‌‍‌⁠⁠⁠⁠‍‍‍⁠⁠‍‍‌​‍‍⁠​⁠‌‌‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 33 of 44
TROUBLESHOOTING

TROUBLESHOOTING

CAUTION Always make sure machine is unplugged before lifting electrical cover assembly
AREAPROBLEMPOSSIBLE CAUSEREMEDY
Chemical Injection System Con't.Not enough chemical flow.1. Metering tip plugged.
2. Wrong metering tip.
1. Remove and clean.
2. Check and replace per chart.
Chemical line blows off safety cap1. Debris in injector.1. Remove safety cap from chemical and blow small amounts of compressed air into line.
Water backflows into chemical bottle.1. Bad seat on injector check valve.
2. Bad safety cap.
1. Check injector o-ring or replace.
2. Replace safety cap.
Dump SystemDump hose will not empty tank.1. Dump hose plug not removed.
2. Clog in bottom of tank.
1. Remove plug.
2. Tip dump contents, remove debris.
Dump hose leaks.1. Hose cut.
2. Clamp loose.
3. Dump plug bushing missing.
4. Plug missing.
1. If leak is less than 4" from tank side, cut and reattach, or replace.
2. Tighten hose clamp.
3. Replace bushing.
4. Replace plug.
Wheels and CastersWheels won't roll, or they rub.1. Flat tires.
2. Debris wrapped around axle.
3. Bearings tight.
4. Wheels too loose on axle.
5. Bearings falling out.
1. Inflate tires to 30 psi.
2. Check for debris on axle.
3. Grease bearings.
4. Remove wheel, add washers to take up slack.
5. Refer to remedy 4.
Squeegee HeadFloor streaks.1. Worn blades or wheels.1. Replace wheels and / or blades.
Squeegee head doesn't easily rotate when installed on wand.1. Brass ring on wand not in groove.
2. Coupling nut too tight.
1. Loosen coupling nut and re-position head on groove.
2. Loosen 1/2 turn.
Head won't stay on wand.1. Coupling nut cracked.
2. Brass ring worn.
1. Replace.
2. Replace.
Premature blade wear.1. Squeegee wheels worn.1. Check wheels for wear / replace.
Sucks to the floor too tightly.1. Squeegee wheels worn.1. Check wheels for wear / replace.
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 34, used with permission. SES ref PF-P45K-DLR6‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​‍​​​‌​⁠​​‌⁠‌​‍⁠⁠​‌‍​⁠⁠​‌​‌⁠​⁠​‌‌‍
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 34 of 44
Chemical Injection Chart

Chemical Injection Chart

In short This page lists which metering tip to use for the ounces of chemical per gallon at 300/500 PSI. It also shows how to fit the selected tip into the cap barb of the KaiCap and thread the cap onto the bottle with plug.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​⁠​​​‌​⁠​​⁠​​‌‍​⁠‌​‍‍⁠⁠​⁠‍​‍⁠‌‍‌⁠‌

METERING TIP CHART

TIPPSIOZ Per Gallon
Black300/5001.25 / 2
Aqua300/5003.00 / 4
Orange300/5004.75 / 5
Tan300/5009.50 / 10
None300/50035 / 40
Gloved hand inserting a metering tip into the barb of the KaiCap, with a tube above and an arrow pointing to the cap; label reads Select metering tip and insert into cap barb
KaiCap: Select metering tip and insert into cap barb
Bottle with plug below the KaiCap with a tube attached; a downward arrow shows the cap being threaded onto the bottle and plug, with a dashed line showing the tube running down inside the bottle
Bottle with plug: Thread cap onto bottle and plug
Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 35, used with permission. SES ref PF-IXWM-5R5F‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍​⁠​​​‌​⁠​​⁠​​‌‍​⁠‌​‍‍⁠⁠​⁠‍​‍⁠‌‍‌⁠‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 35 of 44
FLOW DIAGRAM

FLOW DIAGRAM

In short This page shows how air and water move through the machine in the vacuum system and the liquid system. It also gives the electrical wiring diagram, with a color-code key for the wires.‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍‌​​​​‌​⁠​​⁠‌⁠⁠‌‌‍⁠⁠‌‍‌‍‌​‌‍‌⁠‍​​‌‌

VACUUM SYSTEM

Vacuum system flow diagram showing the vac hose entering the dirty water tank, the vac float/filter shutoff on top of the tank, then the pre-muffler, the muffler and the vac exhaust, with arrows showing airflow
VACUUM SYSTEM

LIQUID SYSTEM

Rear view of the machine showing the liquid system connections: water tank, solution tank, water line, return line and pulse hose
LIQUID SYSTEM
Side view of the machine showing the spray gun connected by the pressure line to the solution tank, with the pulse hose and pulse hose cont. labeled, and arrows showing liquid flow
LIQUID SYSTEM

ELECTRICAL DIAGRAM

Electrical wiring diagram with the vacuum motor, blow motor and pump, the vac and pump switches, terminal blocks, and the GFCI power cord, with wires labeled BK, W and G
ELECTRICAL DIAGRAM

BK = BLACK
W = WHITE
G = GREEN
GFCI = GROUND FAULT CIRCUIT INTERRUPTER
= TERMINAL BLOCK‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍‌​​​​‌​⁠​​⁠‌⁠⁠‌‌‍⁠⁠‌‍‌‍‌​‌‍‌⁠‍​​‌‌

Source: Kaivac KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 Operator Manual 3673to3855_01 Rev. 2005, page 36, used with permission. SES ref PF-DSG2-QTYM‌‌​⁠‌‌​​‌​⁠​​‍‌‍⁠‍‌‍​​​​​‍‌​​​​‌​⁠​​⁠‌⁠⁠‌‌‍⁠⁠‌‍‌‍‌​‌‍‌⁠‍​​‌‌
KaiZen S/N 3673-3855 / KaiZen S/N 3856-4316 / KaiZen S/N 4317-4455 / KaiZen S/N 4456-4776 3673to3855_01 (2005)Page 36 of 44

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