11015 47th Avenue W, Mukilteo, WA 98275 - Interlink Supply Boxxer... · · Check the packing list and verify that all items are accounted for. Installation Responsibilities · Ensure

Copyright© 2007HYDRAMASTER® Corporation

Mukilteo, Washington

MAN-182-076-D

No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying orelectronic retrieval systems) without the express written permission of the HYDRAMASTER Corporation. All rights reserved.

Revised January 2008

11015 47th Avenue W, Mukilteo, WA 98275

ii - Boxxer 318 Owner’s Manual

GENERAL INFORMATION ........................................................................... Section 1Contact Information ........................................................................... 1-2Warnings, Cautions, and Notices ...................................................... 1-3Responsibilites ................................................................................. 1-7High Altitude Operation ...................................................................... 1-10Local Water Precautions ................................................................... 1-11

CLEANING AND CHEMICALS .................................................................... Section 2Precautions ....................................................................................... 2-2Preparing the Carpet for Extraction ................................................... 2-2Rinse and Recover ............................................................................ 2-3Over-Wetting ..................................................................................... 2-4Streaking ........................................................................................... 2-4

SYSTEM OPERATION ................................................................................. Section 3Machine Specifications ..................................................................... 3-2Spare Parts List ................................................................................ 3-3Operating Instructions ........................................................................ 3-4

MACHINE MAINTENANCE.......................................................................... Section 4Operational Maintenance .................................................................. 4-2Overall Machine Maintenance ............................................................ 4-3High Pressure Pump Maintenance .................................................... 4-4Vacuum System Maintenance............................................................ 4-8De-scaling Procedure (Required) ...................................................... 4-9Freeze Guarding ............................................................................... 4-10

WATER AND CHEMICAL SYSTEM ............................................................. Section 5Water and Chemical Flow Operation ................................................. 5-2Flow Diagrams .................................................................................. 5-3

ELECTRICAL SYSTEM ............................................................................... Section 6Electrical System Information ............................................................. 6-2Electrical Schematic .......................................................................... 6-3Wiring Diagram ................................................................................. 6-4

Table of Contents

iii - Boxxer 318 Owner’s Manual

TROUBLESHOOTING ................................................................................. Section 7Heating System ................................................................................. 7-2Chemical System .............................................................................. 7-3Engine .............................................................................................. 7-4High Pressure System ....................................................................... 7-6Vacuum System ................................................................................ 7-8

MACHINE ASSEMBLIES AND PARTS LIST ................................................ Section 8

HOW TO ORDER PARTS ............................................................................ Section 9Warranty Parts Orders ....................................................................... 9-2Parts Orders...................................................................................... 9-2Emergencies ..................................................................................... 9-2One Final Note .................................................................................. 9-3

WARRANTY INFORMATION ........................................................................ Section 10Blower ............................................................................................... 10-2High Pressure Pump ......................................................................... 10-2Vacuum Tank ..................................................................................... 10-2Chemical System .............................................................................. 10-2Control Panel .................................................................................... 10-2Vacuum and Solution Hoses .............................................................. 10-3Cleaning Wand .................................................................................. 10-3Water and Heating Systems .............................................................. 10-3Hard Water Deposits ......................................................................... 10-3Warranty Procedure........................................................................... 10-4

ACCESSORIES .......................................................................................... Section 11Genuine HydraMaster Accessories and Detergents ........................... 11-1

iv - Boxxer 318 Owner’s Manual

MACHINE MAINTENANCE.......................................................................... Section 4Fig. 4-1 Servicing the Valves ............................................................. 4-5Fig. 4-2 Recirculation Fitting .............................................................. 4-9

WATER AND CHEMICAL SYSTEM ............................................................. Section 5Fig. 5-1 Water Flow Diagram (Sheet 1) ............................................. 5-3Fig. 5-2 Water Flow Diagram (Sheet 2) ............................................. 5-4Fig. 5-3 Water Flow Diagram (Sheet 3) ............................................. 5-5

ELECTRICAL SYSTEM ............................................................................... Section 6Fig. 6-1 Electrical Schematic ............................................................. 6-3Fig. 6-2 Wiring Diagram (Sheet 1) ..................................................... 6-4Fig. 6-3 Wiring Diagram (Sheet 2) ..................................................... 6-5Fig. 6-4 Wiring Diagram (Sheet 3) ..................................................... 6-6

TROUBLESHOOTING ................................................................................. Section 8Fig. 8-1 Machine Assembly - Front Left View ..................................... 8-2Fig. 8-2 Machine Assembly - Front Right View ................................... 8-3Fig. 8-3 Frame Assembly - Front Left View ........................................ 8-5Fig. 8-4 Frame Assembly - Front Right View...................................... 8-6Fig. 8-5 Frame Assembly - Rear View ............................................... 8-7Fig. 8-6 Engine Assembly.................................................................. 8-9Fig. 8-7 Blower Assembly .................................................................. 8-11Fig. 8-8 Pump Assembly ................................................................... 8-13Fig. 8-8 Chemical Pump Assembly .................................................... 8-15Fig. 8-10 Heat Exchanger Assembly .................................................. 8-16Fig. 8-11 Silencer Assembly .............................................................. 8-18Fig. 8-12 Water Box Assembly .......................................................... 8-19Fig. 8-13 Dash Assembly - Front ....................................................... 8-21Fig. 8-14 Dash Assembly - Back ....................................................... 8-22Fig. 8-15 Hi-PSI Manifold Assembly .................................................. 8-25Fig. 8-16 Bypass Valve Assembly...................................................... 8-27Fig. 8-17 Idler Pulley Assembly .......................................................... 8-28Fig. 8-18 Exhaust Assembly .............................................................. 8-29Fig. 8-19 Electrical Panel Assembly .................................................. 8-31Fig. 8-20 50 Gallon Universal Recovery Tank Assembly ..................... 8-33Fig. 8-21 70 Gallon Universal Recovery Tank Assembly ..................... 8-36Fig. 8-22 Cover, 70 Gallon Universal Recovery Tank Assembly .......... 8-39Fig. 8-23 Vacuum Relief Valve Assembly ........................................... 8-40Fig. 8-24 Dura-Flow APO Assembly .................................................. 8-41

List of Figures

1-1: General Information

1- General InformationThis section contains the following helpful information:

Contact Information

Warnings, Cautions, and Notices

Responsibilities

High Altitude Operation

Local Water Precautions


HoursMonday - Friday

7:00 am to 5:00 pmPACIFIC STANDARD TIME

Telephone Numbers(425) 775-7276 Parts

(425) 775-7275 Service(800) 426-4225 Parts / Service FAX

Contact Information


Warnings, Cautions, and Notices

This symbol indicates a situation which, if not avoided, could result in death or seriousinjury.

This symbol indicates a hazardous situation which, if not avoided, could result in dam-age to the truck mount.

This symbol indicates that federal or state regulatory laws may apply.


During the operation of the truck mount many components are in motion. Never touchany part of the truck mount that is in motion. Serious injury may result.

During the operation of the truck mount many surfaces will become extremely hot.Never touch hot surfaces. Serious injury may result.

The operation of this truck mount can produce noise levels exceeding 85 decibels to adistance of 10 feet. The Occupational Safety and Health Administration (OSHA) recom-mends the use of hearing protective equipment if a person is exposed to an average of85 decibels over an eight hour period. Check with local and state agencies concerninghearing conservation rules.

During the operation of the truck mount carbon monoxide and other toxic fumes areproduced. Position the vehicle so that any fumes produced will be directed away frominhabited areas and any points of building entry (doors, windows, air conditioning units,fans, etc.). Do not occupy the vehicle while the truck mount is in operation. Seriousinjury may result.

During the operation of the truck mount chemicals known to the State of California tocause cancer, birth defects and other reproductive harm are produced by the engineexhaust.


Never operate the truck mount with a portable gas container inside the vehicle. Doingso will increase the risk of fire and explosion. Serious injury or death my result.

Transporting a vented fuel container that presently contains, or has ever contained inthe past, a flammable liquid is strictly forbidden by HydraMaster and by federal andstate regulations. Doing so will increase the risk of fire and explosion. Serious injury ordeath my result.

Never smoke in or around the truck mount. Doing so will increase the risk of fire andexplosion. Serious injury or death may result.

During the operation of the truck mount the exhaust system will become extremely hot.Keep all flammable materials away from the truck mount exhaust system. Failure to doso will increase the risk of fire and explosion. Serious property damage may result.

Never operate the truck mount when the vehicle is tilted more than 10 degrees in anydirection. Doing so will result in improper lubrication of the internal components, and willincrease the risk serious component or engine damage.

Never perform cleaning operations when the truck mount engine is running at the IDLEthrottle position. Failure to do so will increase the risk of serious component or enginedamage.


Never operate the truck mount with the vehicle doors closed. Doing so results in ex-tremely high temperatures inside the vehicle and will lead to serious component orengine damage.

Never use concentrated acids or solvents (including d-limonene) in the truck mountwater system or chemical system. Use of these products will cause serious componentdamage.

Never operate the truck mount with a water hardness reading measuring 3.0 grains pergallon or higher. Using reading than 3.0 grains per gallon will cause scale to build upinside the truck mount water system. Scale build up causes serious component dam-age. Test all water prior to use and use water softening equipment if necessary.

Never allow water to freeze inside the truck mount. Serious component damage willoccur. Perform all freeze guarding procedures outlined in this digital Owner’s Manual.

Many vehicles have critical components mounted directly below the floor that can easilybe damaged. Before drilling holes in the floor of the vehicle inspect the underside of thevehicle for critical components. Failure to do so may result in damage to the vehicle.


ResponsibilitiesTHE PURCHASER’S RESPONSIBILITIES

· Prior to purchasing a van, ensure that the payload is suitable for all of theequipment that will be installed and transported. This includes and is notlimited to: the truck mount, recovery tanks, fresh water tanks, on-boardwater, hose reels, hoses, cleaning tools, chemicals, drying equipment, etc.Payload capacity information is available through the auto dealer, themanufacturer’s web site, and is also located on the door pillar of thedriver’s side door.

· Purchase a heavy duty Group 24 battery for this truck mount. This isnormally available from the installation dealer.

· Prior to dropping your van off at the distributor for the truck mount to beinstalled, have a spray-on bed liner applied to the floor such as RhinoLining® or Line-X®.

· Prior to operating the truck mount read this manual in its entirety andfamiliarize yourself with the information contained here. Special attentionshould be paid to all cautions and warnings.

· The distributor is responsible for the correct installation of the truckmount.The distributor is also responsible to train you in the correct and properoperation and maintenance of the truck mount.

Any modification of the truck mount may void the warranty.


THE DISTRIBUTOR’S RESPONSIBILITY

Acceptance of Shipment

Before accepting the truck mount, check the following:

· The truck mount should be free from any damage during shipping. Do notsign the delivery receipt until you have closely inspected the truck mountand noted any damage on the delivery receipt. Hidden damage may bepresent even if the box looks okay. It is recommended that the box beopened before signing for the shipment.

· Check the packing list and verify that all items are accounted for.

Installation Responsibilities

· Ensure proper payload capacity. It is the distributor’s responsibility toverify that the equipment package does not exceed the vehicle capacity.

· Ensure installation of a safe fuel tap system and through-floor fittings asprovided by HydraMaster.

· Proper placement of the truck mount, recovery tank, fresh water tank, andaccessories in the vehicle and securing them with bolts and back upplates. The distributor should verify that the owner is in agreement withthe layout.

· Proper connection of the fuel lines.

· Proper connection and installation of the battery. Verify that the battery isin accordance with HydraMaster’s recommendation.

· Check the pump, vacuum blower and engine oil levels prior to starting thetruck mount.

· Start and run the truck mount and check that all systems function properly.

· Test all hoses, wands, etc. for correct operation.

· Timely return of the document package.


Training

The distributor should provide a thorough review of the operation manual with the pur-chaser along with instruction and familiarization in:

· How all the truck mount’s systems function.

· All safety precautions and their importance.

· How to correctly start and shut down the truck mount.

· How to correctly clean with the truck mount.

· Where and how often to check and change component oil levels.

· Freezing damage and how to avoid it. This includes explaining properfreeze guarding procedures.

· How to do basic troubleshooting of the truck mount.

· Hard water damage and how to avoid it. This includes how to determine ifhard water exists in your area and the installation and use of water soften-ing systems.

· The truck mount’s warranty and warranty procedures.


Elevation plays a key role in how the truck mount will operate. Operation at high alti-tude (above 5,000 ft.) may require a high-altitude carburetor jet. Use of this jet at highaltitude will improve power, reduce fuel consumption and help reduce excessive carbonbuild-up in the exhaust and heat exchanger systems.

Contact the local Briggs and Stratton dealer or HydraMaster to obtain the proper jetsize. Your local Briggs and Stratton dealer can be located atwww.briggsandstratton.com.

High Altitude Operation


Local Water PrecautionsMany areas of the country are regarded as hard water areas. Truck mounts operated inthese areas are subject to heavy mineral buildup in internal machine components,hoses and cleaning tools. These mineral deposits cause many problems includingreduced heat exchanger effectiveness, component failure and possible machine over-heating. Below is a map that identifies areas of hard water. To get more info, visitwww.systemsaver.com. You should always consider water from a well as hard water.

It is imperative that special precautions be taken with any truck mount operated in anarea in which the water hardness exceeds 3.0 grains per gallon (60mg/l). HydraMasterstrongly recommends the use of a water softener in these areas. The use of a watersoftener greatly reduces maintenance and related downtime. Periodic de-scaling andacid rinsing as described in this manual may not be adequate in hard water areas.

Failure to take appropriate measures to prevent scale build up can result in systemfailure and loss of warranty on affected parts.

2-1: Cleaning and Chemicals

2 - Cleaning and ChemicalsYour HydraMaster truck mount has been engineered using the latest and most sophisti-cated technology available to produce the finest carpet cleaning results possible. De-spite this, it remains only a tool of the carpet cleaning trade and can produce only as agood a job as the person operating it.

HydraMaster strongly recommends attending an Institute of Inspection, Cleaningand Restoration Certification (IICRC) approved school as soon as possible and toalways follow the IICRC guidelines when cleaning.

This section describes the carpet cleaning procedure in the following areas:

Precautions

Preparing the Carpet for Extraction

Rinse and Recover

Over-Wetting

Streaking


PrecautionsThe use of some chemicals (such as concentrated acids and/or solvents) in your truckmount can seriously damage the internal plumbing and high pressure pump.

HydraMaster strongly recommends purchasing a water softener to prevent the buildupof scale and hard water deposits in your truck mount.

HydraMaster recommends only the use of chemicals containing rust and corrosioninhibitors and water softening agents to prevent chemical buildup which may lead tocomponent failure and warranty invalidation.

Increased demand for a neutralizing rinse results in the need for special care whenusing these acid based chemicals in your truck mount The negative side of theseproducts is the corrosive effects the acid can have on metals, including fittings, pumps,heat exchangers, etc.

HydraMaster’s ClearWater Rinse™ has been formulated to protect vital components.HydraMaster will not warranty parts that have been damaged from using acid productsthat have obviously caused failures.

Preparing the Carpet for ExtractionPre-vacuum the carpet: Whether you instruct the customer to pre-vacuum or you offerit as part of your service, proper vacuuming will make your job easier with superior endresults. The more time spent removing loose particulate soil, the easier it will be toremove the oily soil stuck to the fibers.

Pretreat the carpet: This process of applying traffic lane type chemicals to the carpet(whether by sprayer or rotary scrubber) is essential prior to extraction with your truckmount.

By applying cleaning agents to the carpet and letting them dwell 10-20 minutes prior torinsing, you allow the product to dissolve and emulsify the oily, sticky binders holding thesoil to the fiber. This will allow more soil to be removed in one or two cleaning passesand help prevent over-wetting.


Remember the solution coming out of your cleaning tool is only in contact with thecarpet fiber for a few seconds. Relying on the rinse detergent to do the majority of thecleaning will result in overly long dry times and excess detergent residue left in thecarpet.

HydraMaster recommends the use of our pre-sprays: Fastbreak™ for residentialcarpet and Blitz™ for commercial carpet needs.

Rinse and RecoverWhether you are using a wand, RDM™, or an RX-20™, you should clean an areaapproximately 3 ft. x 3 ft. with the solution valve open then immediately go over thatarea with vacuum only to remove any excess moisture.

Olefin fiber is becoming more popular, particularly in commercial installations. Theprocess mentioned above can leave excessive residual moisture because olefin fiberswill not absorb any of the cleaning solution. You must only apply solution during thebackward stroke of the wand so it can be immediately captured by the vacuum head.RX-20™ and RDM™ users should follow each pass with a dry pass. Failure to followthis procedure will cause solution to flow to the back of the carpet along with some ofthe soil. This, along with any soil imbedded in the backing, will be wicked to the surfaceof the fibers as the carpet dries.

HydraMaster recommends the following rinse aids: Alkaline - Hydra-Dri Powder™ orHydra-CleanLiquid™. Acid - Clear Water Rinse™.


Over-WettingOver-wetting is an annoyance to all concerned. Extended drying times will leave thecustomer with a negative impression of both the cleaning company and the processused.

There are several factors that will cause over-wetting:1. Too few vacuum strokes.2. Clogged vacuum blower filter or vacuum tank lid not sealing properly.3. Vacuum tank drain valve left partially open.4. Obstructed, cut or kinked vacuum hoses.5. Obstructed vacuum hoses while cleaning a heavily foam-saturated carpet (it is

recommended to use a crystal type defoamer distributed evenly over the carpet).

StreakingStreaks in the carpet can appear in both clean or dirty areas and normally appear inheavily soiled, light colored carpets.

Possible reasons of streaking may include:1. Clogged or improperly angled spray nozzles.2. Spray nozzles that overlap, concentrating the solution.3. A partially clogged vacuum head.4. Inconsistent solution temperature.

3-1: System Operation

The Boxxer™ 318 is a carefully engineered truck mount designed by HydraMasterCorporation. The system utilizes an internal combustion engine to provide the powernecessary to turn both a vacuum pump and a high pressure water pump. The heat ofthe engine and blower exhausts is transferred to the high pressure water in the finnedtube heat exchanger of the system. Finally, the chemical is injected into thepressuriezed water stream and the heated solution is delivered to the cleaning tool.The solution is recovered by the vacuum generated by the vacuum pump. This solutionis collected in the recovery tank for proper disposal.

It is the purpose of this manual to help the technician properly understand, maintain andservice the truck mount. By following these guidelines carefully, years of reliable opera-tion can be expected.

This section describes the system in the following areas:

Machine Specifications

Spare Parts Lists

Operating Instructions

3 - System Operation


Machine SpecificationsOverall Dimensions 24.0" W x 35" D x 31.5" HWeight 480 lbs. (console only)

Oil Type Synthetic 5W-30Capacity Approx. 1 1/2 quarts (48 oz.) when changing

oil and filterEngine RPM 3150 rpm @ 14" HgOil Type PneuLube™ or other ISO 100 rating Gear End Capacity Approx. 7.0 oz.Drive End Capacity Approx. 5.0 oz.Blower RPM 3150 rpm @ 14" HgOil Type Synthetic 15W-50Capacity Approx. 8.0 oz.Pump Rate 3.5 gallons per minutePump RPM 1750 RPM

Operating Pressure 0-1000 psiChemical System Last Step Chemical InjectionHeating System Finned Tube Heat Exchanger

High Pressure Hose 1/4" High Temperature Lined/Vinyl Cover - 100 ft.2" Vacuum Hose- 100 ft.1-1/2" Wand Whip Hose- 10 ft.

Recovery Tank 50 gallon MaxAir™ Universal TankStainless Steel S-bendReplaceable GripRebuildable Solution Valve

Chemical Jug 5 gallonBattery BoxVan DecalVan Installation KitOwner's ManualRecovery Tank 70 gallon MaxAir™ Universal TankFresh Water Tank 85 gallon RotoMolded TankAutomatic Pump Out (APO) Dura-Flow™ APO

Engine- Briggs and Stratton Vanguard™ 18hp

Vacuum Blower- Tuthill® 3006 Competitor® Plus SL (Dual Splash Lubrication)Pump- HydraPump II

Optional Equipment

Standard Equipment

Vacuum Hose

Cleaning Wand


Spare Parts ListPart No. Description Qty

106-016 Plug, Spark 2049-049 Filter, Fuel 1049-014 Filter, Oil 1049-012 Filter, Air 1010-125 Belt, Gates 9440HD 1152-011 Coupler Element 1

056-010 Fuse, 25A 1056-008 Fuse, 15A 1157-040 Switch, 20 Amp Rocker 2157-022 Switch, Relay, 12V 2

052-050 Quick Connect, 440 Male 2052-051 Quick Connect, 440 Female 2052-052 Quick Connect, 660 Male 1052-053 Quick Connect, 660 Female 1046-010 Diaphragm, Chemical Pump 1169-186 Valve, 100 PSI, Last Step Chemical 1180-006 Orifice, 0.061" dia. 1180-004 Orifice, 0.033" dia. 1074-007 Gauge, High PSI (0-1500) 1049-023 Screen, Garden Hose 1078-005 Kit, Seal and Spring High PSI Regulator 1

Hydraulic Components

Engine & Drivetrain Components

Electrical Components


Operating Instructions

Start-up Procedure

1. Perform all daily and periodic maintenance as specified in this digital Owner’sManual.

2. Connect a garden hose to supply water to the truck mount. If used, turn the“PUMP-IN” switch to the “ON” position.

Water box must be full prior to starting the truck mount.

3. Connect the cleaning tool to the length of hose required to perform the cleaningjob.

4. Pull the choke and start the truck mount with the throttle cable fully depressed(“IDLE” position.)

5. After the engine starts push the choke in and allow the truck mount to run in“IDLE” for 2-3 minutes to warm up.

6. Pull the throttle cable to full extension and twist the handle clockwise to lock.7. Set the temperature to the desired level on the “TEMPERATURE” knob.8. If used, turn the “AUTO PUMP-OUT” switch to the “ON” position.9. Set the cleaning pressure to the desired level.

a. Suggested Settings:i. Carpet Cleaning: 300-400 psiii. Hard Surface Cleaning: 1000 psi or as indicated on the tool

10. Turn the “CHEMICAL SELECTION VALVE” to the “PRIME” position to purge anyair from the system.a. With the truck mount running at full throttle, block off the vacuum intake to

the recovery tank. The vacuum gauge should read 12"-14" Hg. This willassist in priming the chemical system.

b. Allow the chemical to flow through the chemical meter at full flow for 30seconds.

c. Turn the “CHEMICAL SELECTION VALVE” to “ON.” The restriction cannow be removed from the vacuum inlet.

d. While spraying solution from the cleaning tool adjust the chemical flow byturning the “CHEMICAL METERING CONTROL KNOB”.

11. Begin cleaning.


Never perform cleaning operations when the truck mount engine is running at the IDLEthrottle position. Failure to do so will increase the risk of serious component or enginedamage.

Shut Down Procedure

1. Flush clean water through the chemical system for 10 seconds. Turn the“CHEMICAL SELECTION VALVE” to “OFF.”

2. Cool the truck mount down by turning the “TEMPERATURE CONTROL” dial tothe lowest position (counter-clockwise). Spray the cleaning wand into thevacuum hose for 3-5 minutes. The chemical is now flushed from the truckmount, hoses and cleaning tool.

3. Remove the vacuum hose.4. Lubricate the blower. Cap off the inlet(s) to the vacuum tank. Inject a small

amount of light lubricating oil such as WD-40 Company’s 3-in-One® or WD-40®into the “BLOWER LUBE PORT”.

5. If freeze guarding is necessary perform the procedure at this time. See FreezeGuarding section of this digital Owner’s Manual.

6. Return the engine throttle to the “IDLE” position.7. Turn the key to “OFF.”

8. Drain the water box using the valve.9. Drain the vacuum tank in an appropriate location.

In accordance with the EPA, state and local laws, do not dispose of water into gutters,storm drains, streams, reservoirs, etc.

10. Perform daily maintenance as specified in this digital Owner’s Manual.

4-1: Machine Maintenance

4 - Machine MaintenanceTo avoid costly repairs and downtime, it is imperative to develop and practice goodmaintenance procedures. These procedures fall into daily, weekly, monthly and quar-terly increments and are outlined below. All maintenance must be performed by quali-fied service personnel.

A maintenance log is provided in the Owner’s Guide. This log must be maintainedand may be required to be furnished to HydraMaster before a warranty claim ishonored. It is recommended that the log be affixed to the vehicle door near the truckmount for convenience and to serve as a maintenance reminder.

This section describes how to properly maintain the truck mount in the following areas:

Operational Maintenance

Overall Machine Maintenance

High Pressure Pump Maintenance

Vacuum System Maintenance

De-scaling Procedure (Required)

Freeze Guarding


Operational MaintenanceDaily Maintenance:

-Check the engine oil level. Add oil if needed.-Check the high pressure pump oil. Add oil if needed.-Inspect and clean the recovery tank filters.-Inspect and clean the orifices and filters.-Inspect and clean the garden hose screen.-Inspect the truck mount for water and oil leaks, loose electrical connections, etc.and repair as needed.

-Lubricate the blower with a light oil based lubricant.

Weekly Maintenance:-Inspect the recovery tank filters for tears, holes, etc. Repair or replace asneeded.

-Inspect the vacuum relief valve. Clean and lubricate as necessary.-Clean the recovery tank thoroughly with pressure washer.-Check the oil level in the blower. Add oil if needed.-Check the pump drive belt for wear and proper tension. Tighten as needed.-Check all the hoses and wiring for wear and chafing. Secure as needed.-Flush the water and chemical systems with solution of equal parts white vinegarand water.

-Check all the nuts and bolts. Tighten as needed.-One time change of the high pressure pump oil after 50 hours of operation.(Every 500 hours thereafter.)

-One time change of the engine oil after 8 hours of operation.-Change the engine oil every 50 hours. (Every 25 hours if operating in highambient temperatures.) Change oil filter every other oil change.

Monthly Maintenance:-Check the engine air filter. Clean or replace as necessary.-Check the water level in battery. Fill as needed.-Clean the battery terminals as needed.

Quarterly Maintenance:-Check the fuel lines. Repair or replace as needed.-Clean and gap the spark plugs to 0.030 in (0.76 mm). Replace if excessivecarbon buildup is visible.

-Check the coupler element (rubber insert) for cracks or wear. Replace as nec-essary.

-Change the blower oil after first 100 hours of use.


500 Hours:-Change the blower oil.-Change the high pressure pump oil.-Check the engine valve clearance (intake and exhaust 0.004-0.006 in (.10-.15mm))

Overall Machine MaintenanceMaintenance, troubleshooting and repair are much easier tasks to accomplish on aclean truck mount. Regular cleaning of the truck mount offers the user an opportunity tovisually inspect all facets of the truck mount and spot potential problems before theyoccur. In addition to the operational maintenance the following “housekeeping” dutiesshould be performed.

After each job:-Check the recovery tank and the recovery tank filters. Empty and clean asnecessary.

Daily:-Wipe the truck mount down thoroughly with a damp cloth.-Wipe down the vacuum and high pressure hoses as needed.-Inspect and clean the vacuum slot on the cleaning wand.-Check the wand head for sharp edges that could tear carpet. File down asneeded.

-Clean the wand to maintain original appearance.-Visually inspect the hoses for abrasions, cuts, etc. Repair or replace as needed.

Weekly:-Empty the chemical container. Wash out thoroughly to remove any chemicalbuildup.

-Inspect the chemical feed line strainer and use solution of equal parts whitevinegar and water to remove any chemical buildup.

-Thoroughly clean the wand and inspect for clogged jets, debris in vacuum slotand leaking fittings at valve.

-Thoroughly clean the vacuum and high pressure hoses including quick releasesand cuffs.


DAILY

Check the oil level and the condition of the oil. The oil level should be up to the centerof the sight glass on the rear of the pump or between the “MIN” and “MAX” lines on thedipstick. The dipstick may be found by removing the oil cap.

PERIODICALLY

Change the oil after the initial 50 hours of operation and every 500 hours after that. Itmay be necessary to replace the pump seals and check valves at 500 hours if the truckmount has been running in high ambient temperatures.

High Pressure Pump Maintenance

If the oil becomes discolored or contaminated one of the oil seals may be damaged. Donot operate the pump if the crankcase oil has become contaminated. Do not rotate thedrive shaft without oil in the crankcase reservoir.

The pump should never be run dry. Running the pump dry will cause premature wearon the seals, packing and plungers. Running the pump dry for a prolonged period oftime may cause damage that cannot be repaired and voids warranty.

Do not run the pump with frozen water in the manifold. If there is a risk of freezing,freeze guard the truck mount. See the Freeze Guarding section of this manual.


SERVICE

The next few pages explain how to disassemble and inspect all user serviceable partsof the pump.

Figure 4-1. Servicing the Valves

Do not disassemble the pump unless you are a skilled mechanic. For assistance,contact HydraMaster or your local HydraMaster distributor.


Valve Maintenance (See Figure 4-1)

1. Using a 22mm wrench or socket, remove all six valve caps on the manifold of thepump.

2. Examine each valve cap o-ring for cuts or distortions and replace if worn.3. Using needle nose pliers, remove the suction and delivery check valves. The

valve assembly usually stays together when removing. If the valve comes apart,use the needle nose pliers or reverse pliers to remove the remaining parts.

4. Inspect each suction and delivery check valve assembly for wear, pitting, etc. andreplace if necessary. The valve assembly consists of the plastic cage, spring,valve seat, poppet and o-ring. One valve kit is needed for complete valve changeof one pump.

5. Replace old valves with new valves by placing the assembly in the valve cham-ber. Press down firmly on the top of the valve assembly.

6. Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft-lbs.

Removing and Replacing Pump Manifold

1. Remove the manifold of the pump by taking a 5mm allen head wrench andremoving the eight head bolts.

2. With the pump firmly secured, take a medium sized flat head screwdriver andapply pressure to the manifold by prying between the crankcase and manifold.Work around from all sides of the manifold evenly until it comes off of the pis-tons. Keep the manifold properly aligned with the pistons to prevent damage tothe seals and pistons.

3. When replacing the manifold, turn the crankshaft of pump until the top of thepistons are closely aligned. Lubricate the pistons and cylinders with grease andevenly press the manifold toward crankcase until flush.

Seals and V-Packing Maintenance

1. Remove the manifold as described above. It is possible that the seal and brassretainer ring assembly will stay on the piston or will remain in the manifold whenremoving it.

2. Carefully remove the brass retainer ring/seal stack. Remove the low-pressureseal using needle nose pliers. Discard the old seal.

3. Remove the outer o-ring by taking a small flat head screwdriver and working itunder the o-ring. Simply roll off the old o-ring and discard.

4. The old V-packing stack can be taken apart by hand and discarded.


Seals and V-Packing Reassembly

1. Generously lubricate parts with grease when reassembling. Examine all brasscomponents for any damage or water residue build-up. Clean or replace asneeded.

2. Insert a new low pressure seal by working it in by hand.3. Install the new outer o-ring by simply starting on one side and working it into the

groove.4. Stack the new V-packing in the correct order and firmly press the assembly into

the manifold.5. Install a new low pressure oil seal by laying the seal into the opening and evenly

pressing it into place.6. Reinstall the manifold onto the pump as described above.

Plunger Maintenance

1. Remove the manifold as described above. Remove the packing retainers if theyremain on the pistons after removing the manifold.

2. Remove the nut and washer on the end of the piston using a 13mm wrench orsocket.

3. Slide the ceramic plunger and the remaining washer from the piston guide.Inspect the ceramic piston, o-ring and washers for wear. Replace if necessary.

Plunger Reassembly

1. Generously grease the piston guide. Replace the o-ring making sure it does nottwist or roll.

2. Slide the lower washer and ceramic bushing onto the piston guide.3. Place a small amount of LOCTITE 243™ on the piston guide threads. Replace

the old washer and thread the nut onto the piston guide. Torque to 4.5 ft-lbs.

Servicing the Crankcase

1. While the manifold and plungers are removed, rotate the crankshaft by hand.Closely examine the crankcase oil seals for drying, cracking or leaking.

2. Consult the local HydraMaster distributor if crankcase servicing is necessary.


Vacuum System MaintenanceThe vacuum pump in this machine is commonly referred to as a “rotary positive dis-placement blower” or “blower” for short. The performance and life of the truck mount isgreatly dependent on the care and proper maintenance it receives. The manual for theblower has been included. Review the manual for a better understanding of this pieceof machinery.

To protect the blower from overloading and damaging itself, there is a vacuum reliefsystem installed on the vacuum tank. When the vacuum tank inlet is completely sealedoff a maximum of 14" Hg will be attained.

Solid objects entering the blower will cause serious damage to the internal componentsof the blower. Extreme caution should be used when the truck mount is being run fortest purposes with the inlet to the blower open to the atmosphere.

Foam passing through the blower can lead to serious problems with the truck mount. Itis important to keep the vacuum tank free of foam. The tank is protected from overflow-ing by a float kill switch; however, this switch is not activated by foam.

DAILY

At the end of each day the internal components of the blower need to be lubricated.This helps to prevent rust deposits and prolongs the life of the truck mount.

With the truck mount running and the recovery tank inlet(s) capped off, inject a smallamount of light lubricating oil such as 3-in-One® or WD-40® into the “BLOWER LUBEPORT” located on the front of the machine.

PERIODICALLY

Change the oil in both ends of the blower after the initial 100 hours of use. The oil is tobe changed each 500 hours of use thereafter.


Scale deposits on the interior of the heating system can cause a noticeable loss inheating performance. Deposits of this kind result from hard water deposits. The fre-quency with which de-scaling procedures are required will vary. If the area has particu-larly hard water, you may have to de-scale often.

To de-scale the system, add an appropriate de-scaler chemical to the water box. Circu-late it through the system. Let it stand. Flush and repeat as necessary. Clean allscreens and strainers, and check them frequently following de-scaling.

NOTE: If using TM DeScaler™ through the flow meter, make sure to run clean waterthrough the flow meter after this procedure.

To de-scale using the recirculation kit (part no. 078-058), start with an empty water box.Fill a third of the water box with TM DeScaler™. Follow the recommendations on theTM DeScaler™ label for proportions. Verify that the float is not lying horizontal, butfloats below.

Attach the recirculation fitting provided in the kit to the garden hose quick connect (seeFigure 4-2) and this combination to the front of the truck mount.

Attach one section of the solution hose to the outgoing solution fitting on the front of thetruck mount and the other end to the garden hose and recirculation fitting combinationthat is attached to the front of the truck mount. Additional hoses may be attached inlineif de-scaling of hoses is needed.

Start the truck mount and allow it to run for three to five minutes. Do not leave the TMDeScaler™ solution in the system. Flush the system with clean water and turn the truckmount OFF.

De-scaling Procedure (Required)

Figure 4-2 Recirculation Fitting


To avoid permanent damage to the truck mount it is imperative to follow the FreezeGuard Procedure whenever the possibility of freezing temperatures exists.

Freeze Guarding

When disposing of antifreeze follow local laws and regulations. Do not discard intostorm sewers, septic systems, or onto the ground.

Antifreeze is harmful or fatal if swallowed. Do not store in open or unlabeled containers.Keep out of reach of children and animals.

Freeze Guard Procedure

1. With the truck mount turned off and the incoming water line disconnected, openthe water box drain valve on the front of the truck mount. Allow the system tofully drain.

2. Add 2 gallons of 50/50 antifreeze and water mix to the water box.

Attach a section of solution hose to the outgoing solution fitting on the front of themachine. Attach the opposite end to the recirculation fitting. (If more sections ofhose are to be freeze guarded attach those inline.)

3. Start the truck mount and allow it to run for 2 to 3 minutes. This will distributeantifreeze solution throughout the truck mount.

4. Remove the chemical feed line from the chemical jug. Turn the selector valve to“Prime.” This will vacuum the chemical remaining in the lines to the recoverytank.

When using the recirculation kit skip ahead to Step 7.

5. Remove the quick connect fitting from the garden hose. Attach the quick connectto the machine. Using a vacuum hose attached to the recovery tank, vacuum thewater out of the quick connect. This will freeze guard the feed line to the waterbox.


6. Remove the quick connect from the truck mount.7. Spray the antifreeze and water mix out of the truck mount and into a container to

reclaim the solution. Run the truck mount until it stops.8. The truck mount is now freeze guarded. Remember to flush antifreeze from

the system prior to carpet cleaning. See procedure below.

NOTE: The reclaimed antifreeze solution may be used three times before being dis-carded.

NOTE: To freeze guard the hoses and wand perform Step 7 above with the items to befreeze guarded attached.

Recovering Antifreeze for Re-Use

1. Attach all hoses and wands which have been freeze guarded to the truck mount.2. Attach the incoming water source to the front of the truck mount.3. Start the truck mount.4. Spray the solution through the hoses and wands into a sealable container until all

signs of antifreeze are gone.

Freeze Protection of the Pump-In System

1. Drain the fresh water tank.2. Remove the garden hose adapter from the pump-in pump hose and position the

hose so it is pointing outside the van.3. Turn on the pump-in pump and run for 1-2 minutes until all the water is purged

from the hose.

NOTE: The next time the truck mount is used it may take a few minutes before thewater box begins to fill.

5-1: Water and Chemical System

5 - Water andChemical System

This section describes the water and chemical systems in the following areas:

Water and Chemical Flow Operation

Water and Chemical Flow Diagrams


Water and Chemical Flow OperationFresh water is brought through the front of the truck mount into the water box. The level ofwater in the box is maintained by the use of a float valve. The water is then gravity fed tothe pump where it is pressurized.

Next, the pressurized water enters the bypass valve. This valve allows manual adjustmentof the pressure level. When the valve at the wand is closed, nearly all of the water in thesystem is re-circulated to the water box at this point. When solution is being used at thewand the necessary amount of high pressure water passes through the bypass valve and tothe heat exchanger.

In the finned tube heat exchanger the temperature of the water is raised. The heat neces-sary to do this is provided by both the engine and blower exhausts. The heated water thentravels to the high pressure manifold.

The high pressure manifold houses both the temperature sensor for the heat control systemas well as a high temperature shutdown switch. There are also two orifices located in themanifold. The larger “secondary” orifice leads to the high temperature dump solenoid.This solenoid opens when the controller senses that the water has reached the set pointthen closes when the temperature drops back below the set point.

The smaller “primary” orifice allows a small amount of high pressure, high temperaturewater to pass back to the water box. This prevents excessive pressure building up in theheat exchanger when the wand valve is closed and no solution is exiting the truck mount.

The water that is being called for by the wand then exits the manifold and passes through acheck valve. Finally, the water joins the chemical where the solution is created.

The chemical is pressurized by the HydraMaster diaphragm chemical pump attached tothe head of the water pump. This pump pulls the chemical from the jug through the chemi-cal meter. After being pressurized the chemical travels through the metering valve and isinjected into the high pressure stream. This solution then exits the front of the truck mountand is delivered to the cleaning tool.


Figure 5-1 Flow DiagramD-7027 Rev. - (Sheet 1)





6-1: Electrical System

6 - Electrical System

This section describes how the electrical system functions in the following manner:

Electrical System Information

Electrical Schematic

Wiring Diagram


The Boxxer 318 electrical system operates on 12 Volts DC which is provided by the bat-tery. Battery levels are maintained by a 20 Amp alternator mounted on the engine.

NOTE: When a new battery is installed, check that it is properly charged before installa-tion or damage to the charging system may occur.

Ignition Switch

Terminal No. Wire Color Function1 Brown Ground2 White To terminal block (system power)3 Black To engine stop lug on engine4 Yellow To starter solenoid5 Orange To inline fuse #16 Red To voltage regulator/rectifier

Switch Position ContinuityOff 1 + 3 + 6Run 2 + 5 + 6Start 2 + 4 + 5

Electrical System Information


Figure 6-1 Electrical SchematicC-7026 Rev. -

TR

2

-5-3

-3-4

-9

-6-5

-1

-6-3

TR

7

-2

TR

6

TR

3

TR

5

TC

-1

TR

1

TE

MP

ER

AT

UR

EC

ON

TR

OLL

ER

TR

4

TR

8

-4

-4

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SW

-1

-1

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-6

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IGN

ITIO

N S

WIT

CH

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63

5

4 21

TB

1

GN

D

TB

1T

B1

WA

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V-4

GN

D

D-4

TB

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GN

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SO

LEN

OID

HIG

H T

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P

SW

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SO

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TS

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-+

12V

BA

TT

ER

YP

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GN

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ST

AT

OR

ST

VR

-1

BA

TT

TH

ER

MO

ST

AT

CO

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RO

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V-1

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VO

LT. R

EG

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SO

LEN

OID

ST

AR

TE

R

ST

AR

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SO

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MTR-1

MTR-1

YE

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GIN

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LUG

PU

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PU

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B&S ENGINE

B&S ENGINE

SW

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ON

OF

F

PM

P-1

FR

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H W

AT

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PU

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OP

TIO

N

GN

D

87a

PU

MP

-IN

SW

ITC

H

CA

RB

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ND

30

86

87

AP

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OF

F

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AP

O O

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FS

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FLO

AT

SW

ITC

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85

PM

P-3

AP

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TB

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TB

3

TB

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AP

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a

87

85

30

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TB

1

GN

D

TB

1

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HU

TD

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F-1

25A

FU

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F-2

PM

P-2

FU

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PU

MP

TB

1T

B1

TB

1

GN

D

TB

1

25A

SH

UT

DO

WN

SW

-4

HIG

H T

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P

FLO

AT

SW

ITC

H

WA

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R F

LOA

T

HO

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ME

TE

R

TB

1

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HI-

1

TB

1

TB

1

GN

D

TB

1

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FU

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VA

C T

AN

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GN

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Figure 6-2 Wiring DiagramC-7025 Rev. B (Sheet 1)

HI-T

EM

P S

OLE

NO

IDV

-4 BIO

IN

FS

-1E

NG

INE

ST

OP

(BLK

)

(BLK

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LOW

WA

TE

R

WA

TE

R B

OX

AS

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MB

LY

(WH

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(WH

T)

(WH

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(BLK

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88(W

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86(W

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D)

74(B

LK)

14 G

ABA

73(B

RN

) 14

GA

70(W

HT

) 14

GA

73(B

RN

) 14

GA

654321

TB

-3

(BR

N)

(WH

T)

B-6

B-5

HA

RN

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S

69(W

HT

) 14

GA

AP

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P

(RE

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PM

P-3

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TO

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(BLK

)

(RE

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69(W

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) 14

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J-9

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86

87

85

75(B

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14 G

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30

71(W

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(BLK

)

(WH

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71(W

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72(P

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67(P

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84(W

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66(O

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65(O

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8 (R

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8 (RED) 6 GA

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14 G

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B-2

15 (WHT) 14 GA

9 (WHT) 14 GA

13 (

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14 (

BR

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14 G

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P-3

J-3

P-2

J-2

P-1

J-1

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32(W

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PM

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PU

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P

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SH

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B-1

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13 (

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TR

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TR

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14 (

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16 (

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SH

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ST

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P-5

10 (

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ST

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B&S ENGINE

YE

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YE

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14 G

A7

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1 (R

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1 (R

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GR

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16 G

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17 (

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TR

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TR

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AT

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TR

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13 (

PU

R/W

HT

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BLK

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28 (

RE

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34

56

25 (

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26 (

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30 (

WH

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9 (W

HT

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NG

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GR

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14

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35 (

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PU

MP

IN P

UM

P P

MP

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SH

EE

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)

32 (

WH

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RN

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P P

MP

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18 (

BLK

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HO

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ME

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RO

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SH

EE

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(WH

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20 G

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RO

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SW

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HA

RN

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S P

5-D

(S

HE

ET

1)

13(P

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DIVERT MODE LIGHT

22 (WHT/RED)

(SH

EE

T 3

)

(RE

D)

20 G

A

23 (

PN

K)

19 (

BLK

)

37 (

RE

D)

TO

FU

EL

PU

MP

PM

P-2

(S

HE

ET

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20 (

BLK

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31 (

GR

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PU

MP

IN S

WIT

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HE

ET

3)

(ORG)

(BLK)

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(BLK) 20 GA

22 (

WH

T/R

ED

)

30 (

WH

T)

TO

AD

JUS

TA

BLE

TE

MP

ER

AT

UR

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ON

TR

OL

TS

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21 (

WH

T/R

ED

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B-1

4

B-10

B-1

1

B-1

3

B-1

2

B-9

B-1

5

15 A

3 (Y

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35 (

OR

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16 G

A. T

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(SH

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INE

ST

OP

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H S

W-4

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ET

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23(P

NK

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SH

TD

N

ST

OP

FS

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0 G

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EE

T 1

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20 (

BLK

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OW

WA

TE

R E

NG

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ST

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20 G

A (

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LK)

TO

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AT

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FU

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34 (

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14 G

A T

O A

PO

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ITC

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W3-

#3

(SH

EE

T 3

)

7 (O

RG

) T

O S

OL

1-B

AT

T (

SH

EE

T 1

)

24 (

PN

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TO

HIG

H T

EM

P S

HT

DN

SW

ITC

H S

W-4

(S

HE

ET

3)

3085

87 87a

86

CR

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TE

RM

INA

L B

LOC

K-

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-1

33 (

RE

D)

1 (

RE

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16 G

A T

O C

AR

B S

OLE

NO

ID V

-1 (

SH

EE

T 1

)

38 (

BLK

) 16

GA

TO

SW

1-2

(SH

EE

T 3

)

6 (O

RG

) T

O S

OL

1-B

AT

T (

SH

EE

T 1

)

FU

SE

25 A



TO

TB

1-6

(SH

EE

T 2

) 17

(WH

T/O

RG

)

TO

TB

1-1

(SH

EE

T 2

) 18

(BLK

/WH

T)

TO TR-7 29(BLU)

TO TR-5 28(RED)

TO TR-6 27(BLK)

+

AD

JUS

TA

BLE

TE

MP

ER

AT

UR

E C

ON

TR

OL

TS

-1

HO

UR

ME

TE

R

HI-

1

2 3

TO

HA

RN

ES

S P

5-F

(S

HE

ET

1)

14(B

RN

) 14

GA

TO

INLI

NE

FU

SE

F-2

(S

HE

ET

2)

34(B

RN

)14

GA

AU

TO

MA

TIC

PU

MP

OU

TS

WIT

CH

SW

-3

PU

MP

INS

WIT

CH

SW

-2

TO

TB

1-3

(SH

EE

T 2

) 31

(GR

Y)

TO

PU

MP

IN P

UM

P-P

MP

1 (S

HE

ET

1)

50(G

RY

)

TO INLINE FUSE 1-F1 (SHEET 2) 35(ORG)

TO VOLTAGE REGULATOR (SHEET 1) 12(RED)

TO GROUND AT REGULATOR (SHEET 1) 16(BRN)

TO TB1-2 (SHEET 2) 38(BLK)

TO ENGINE KILL LUG (SHEET 1) 2(BLK)

TO STARTER SOLENOID SOL-1 (SHEEET 1) 10(YEL)

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7-1: Troubleshootiing

7 - Troubleshooting

This section describes the standard troubleshooting procdures in the following areas:

Heating System

Chemical System

Engine

High Pressure System

Vacuum System


Heating SystemPossible Cause SolutionThe orifice(s) or filter screen(s) are restricted

Remove and inspect. Clean as necessary. Note: Ensure the orifices are not interchanged.

The high pressure dump solenoid is restricted

Inspect the solenoid and the hose that delivers water to it. Clean or replace as necessary.Check the main fuse. If the fuse is blown, inspect electrical system for worn or shorted wires. Repair or replace as necessary.Inspect dump the solenoid and test for functionality. If the solenoid is operable, refer to a qualified service technician to test the temperature controller and sensor.

Possible Cause SolutionTemperature control knob is turned down Inspect the knob. Adjust if necessary.The dumb solenoid is faulty Inspect the solenoid and test for functionality. If the solenoid

is operable, refer to a qualified service technician to test the temperature controller and sensor.

Excessive solution flow at tool The cleaning tool jet is too large or worn. Inspect the jet. Replace if necessary.

The heat exchanger has hard water scale buildup

Descale the system.

The heat exchanger has blockage on the exhaust side

Inspect the interior of heat exchanger. Remove the debris and clean as necessary.

The truck mount overheats and shuts down

The dump solenoid is faulty

Unable to achieve normal cleaning solution temperature


Chemical System

Possible Cause SolutionThe check valves in chemical pump are faulty Remove the valves and inspect. Clean or replace as necessary.

The chemical pump diaphragm is faulty Remove and inspect. Replace as necessary.The check valve in high pressure pump is faulty (piston which chemical pump is attached to)

Remove the valve and inspect. Clean or replace as necessary.

The filter on feed line in chemical jug is clogged

Inspect and clean.

The feed line from chemical jug is loose, pinched or damaged

Inspect and repair.

The chemical selector valve is faulty Inspect the valve for leaks between ports. Replace as necessary.

Possible Cause SolutionAir is in the lines Check that all fittings and connections are tight and in good

condition. Repair or replace as necessary.The filter screen in the chemical jug is partially obstructed

Inspect and clean.

The chemical selector valve is faulty Inspect the valve for leaks between ports. Replace as necessary.

The chemical metering valve is faulty Remove and inspect the valve. Clean or replace as necessary.The high pressure check valve is faulty Remove and inspect the valve. Clean or replace as necessary.

Possible Cause SolutionThe chemical pump diaphram is faulty Remove and inspect the chemical pump diaphram. Replace as

necessary.The high pressure check valve is faulty Remove and inspect the valve. Clean or replace as necessary.

System will not prime

Chemical flow is unstable or low

Chemical is present in water box


EnginePossible Cause SolutionA loose or corroded battery terminal Clean and tighten the battery terminal connections.The battery is dead Recharge or replace the battery. Test the charging system.

Repair if necessary. WARNING: Do not attempt to jump start the truck mount from a running vehicle. The amperage output from an automobile will damage the charging system of the truck mount.Check the main fuse.If the fuse is blown, inspect the electrical system for worn or shorted wires. Repair or replace as necessary.

The vacuum blower has seized Attempt to turn the coupler by hand. If it will not turn refer to the Vacuum System Troubleshooting Section.

The ignition switch is faulty Test to see if there is power both to and from the switch. Refer to the Electrical Section.

The starter solenoid is faulty Test to see if there is power to solenoid with ignition in "Start" position. Refer to Electrical Section.

The starter motor is faulty Test to see if there is power to the motor with the ignition in "Start" position. Refer to the Electrical Section.

None of the above Refer to a qualified service technician for further troubleshooting.

Possible Cause SolutionThe recovery tank is full Drain the tank.The recovery tank float is faulty Inspect the float. Repair or replace as necessary.The engine ignition system in faulty Refer to a qualified service technician for further

troubleshooting.

Possible Cause SolutionTest for power to the fuel pump. Refer to Electrical Section.

If power is present, inspect the fuel pump. Replace if necessary.

Inspect the fuel lines between the source and the carburetor. Repair or replace as necessary.Test for power to the solenoid. Refer to Electrical Section.

If power is present, inspect the solenoid. Replace if necessary.

The engine is flooded Pull the throttle cable completely and crank until the engine starts.

The spark plugs are worn or dirty Inspect and replace as necessary.None of the above Refer to a qualified service technician for further

troubleshooting.

The engine will not turn over

The main fuse is blown

The engine turns over but will not start. There is NO SPARK. Note: To check for spark refer to engine manual.

The engine turns over but will not start. There IS SPARK. Note: To check for spark refer to engine manual.

Fuel is not reaching the carburetor

The carburetor solenoid is faulty


Engine (cont.)

Possible Cause SolutionThe throttle linkage is out of adjustment Inspect for broken or loose linkage. Repair or replace as

necessary.Inspect and clean the recovery tank filters.Inspect the recovery tank to the blower hose. Repair or replace as necessary.

Excessive back pressure on the engine exhaust

Inspect for blockage in the heat exchanger. Clean or replace as necessary.

Possible Cause SolutionThe spark plug(s) are faulty Remove and inspect the plugs. Clean or replace as necessary.

The spark plug wire(s) are faulty Inspect the wires and connectors for damage or loose connections. Repair or replace as necessary.Check to see if the fuel pump is mounted in a vertical position near the fuel source. Correct if necessary.

Check for blockage in the filter. Repair or replace as necessary.

Possible Cause SolutionA dirty air filter Inspect and replace as necessary.The choke is partially closed Inspect and adjust or repair as necessary.Excessive fuel to the carburetor Check to see if the proper fuel pump is installed.

Possible Cause SolutionOpen all the van doors.Install a roof vent in the van.Remove any dividers or other objects impeding airflow around the truck mount.

Low oil level Check the level and fill as necessary.The engine RPM is too high Check the engine RPM. Adjust as necessary to run at 3150

RPM under a vacuum load of 14" Hg.Excessive back pressure on the engine exhaust

Inspect for blockage in the heat exchanger. Clean or replace as necessary.

Poor ventilation in the van

Excessive load on the engine

Inadequate fuel supply to the carburetor

The Engine will not come up to normal operating RPM Note: Engine should be adjusted to run at 3150 RPM under a vacuum load of 14" Hg.

Runs rough at high speed

Runs rich. (Black smoke)

Engine Overheats


High Pressure System

Possible Cause SolutionThe pressure adjusting valve is faulty Inspect the valve. Repair or replace if necessary.Worn seals or valves in the pump Test the pump output volume directly from the pump at normal

running RPM. If the volume is below the manufacturer's specifications, replace the seals and inspect for defective valves.Check for a loose pump belt. Adjust or replace as necessary.Check the engine RPM and adjust as necessary to 3150 RPM under a 14” Hg vacuum load.

The primary orifice is missing or loose Remove and inspect. Tighten or replace as necessary.The primary and secondary orifices have been installed incorrectly

Inspect and reverse if necessary. Refer to the Machine Assemblies & Parts List Section.

The primary orifice is worn Measure the orifice size and replace as necessary. Correct size is .033 in.

Possible Cause SolutionThe pump belt is broken Inspect and replace if necessary.The gauge is faulty Replace the gauge.

Possible Cause SolutionInspect the tool jet(s) and clean or replace as necessary.Inspect any filters in the cleaning tool and clean or replace as necessary.

Faulty quick connect in the system Inspect each quick connect and replace as necessary.Restriction in one of the solution hoses Remove the quick connects and inspect hoses. Clean or

replace as necessary.Hard water deposits restricting the system De-scale the truck mount.

Restriction in the cleaning tool

The pump will not come up to normal cleaning pressure

The pump RPM is too low

No pressure reading on gauge

The PSI gauge reads normal; low pressure from wand


High Pressure System (cont.)Possible Cause SolutionAir leak between the water box and pump Check all the hoses and fittings for cuts, breaks, cracks, etc.

Repair as necessary.The check valve(s) in the pump are faulty Remove each valve and inspect for correct operation. See the

Machine Maintenance Section.

Possible Cause SolutionRestriction in the water supply system Inspect the supply system from the source through the

incoming quick connect.The float valve in the water box is faulty Disassemble and inspect the valve. Repair or replace as

necessary.

Possible Cause SolutionThe float valve in the water box is faulty Disassemble and inspect the valve. Repair or replace as

necessary.The float has absorbed water and lost buoyancy

Detach the float and check to see if it will float to the surface. Replace as necessary.

The float has come out of adjustment Adjust the float as necessary.

The water box overflows

Water box empty or fills slowly

Pressure pulsation


Vacuum System

Possible Cause SolutionBlockage in the hoses or wand tube Disconnect the hoses and check for an obstruction.Excessive length of hose connected to the truck mount

Do not attach excessive lengths of hose.

Possible Cause SolutionCheck the vacuum relief valve for proper adjustment.Carefully check all the vacuum hoses for a cut or break.Check the recovery tank lid gasket.Make sure the recovery tank drain valve is fully closed.

The vacuum blower is turning too slowly Check the RPM of the engine. Adjust as necessary to 3150 RPM under a 14" Hg. vacuum load.

The vacuum gauge is defective Test the gauge and replace if necessary.

Possible Cause SolutionThe filter in recovery tank is clogged Remove and clean or replace as necessary.The hose from recovery tank to the vacuum blower is collapsed internally

Inspect and replace as necessary.

Possible Cause SolutionThe blower is low on oil Inspect the oil levels and replenish as necessary. Note:

Running the blower with low oil levels can cause severe damage. If this situation occurs the blower should be inspected by a qualified service technician.

The vacuum blower has internal damage Refer to a qualified service technician.

A weak vacuum at wand. The gauge reads normal.

Air leak somewhere in the vacuum system

A weak vacuum

Excessive noise produced by the blower

The vacuum gauge reads too high with no hoses attached


Vacuum System (cont.)Possible Cause Solution

Spray penetrating oil into the blower and let sit for at leas t one hour. Then very carefully use pipe wrench on the outer diameter of the pulley on the coupler to attempt to free lobes of the blower. Do not use a wrench directly on the blower shaft.

If unable to free up the blower in this manner refer to a qualified service technician.

There is internal damage to the blower Refer to a qualified service technician.

Possible Cause SolutionInspect the recovery tank. If full, drain the tank. Inspect the high level shutoff switch for proper operation. Clean or replace the switch as necessary.If foam is in recovery tank, use defoamer on the carpet being cleaned.

Condensation in system This will be more common in cool weather and humid climates. If this is the cause it should dissipate after a few minutes of running.

The heat exchanger is leaking water Inspect and repair or replace as necessary.

Truck mount has been inactive for a period of time and the blower was not properly lubricated prior to final shutdown. Rust has possibly built up on the internal surfaces.

The recovery tank has been filled with foam or over filled with water

Water in truck mount exhaust

The vacuum blower is locked and will not turn

8-1: Machine Assemblies and Parts List

8 - Machine Assembliesand Parts List

This section contains all the assemblies and parts lists associated with the truck mount.

Machine Assembly

Frame Assembly

Engine Assembly

Blower Assembly

Pump Assembly

Chemical Pump Assembly

Heat Exchanger Assembly

Silencer Assembly

Water Box Assembly

Dash Assembly

Hi-PSI Manifold Assembly

Bypass Assembly

Idler Pulley Assembly

Exhaust Assembly

Electrical Panel Assembly

50 Gallon Universal Recovery Tank Assembly

70 Gallon Universal Recovery Tank Assembly

Cover, 70 Gallon Universal Recovery Tank Assembly

Vacuum Relief Valve Assembly

Dura-Flow APO Assembly

Machine Hose Routings


Figure 8-1 Machine Assembly - Front Left ViewD-7010 Rev. -

53 4 5 32 5 61 3


Figure 8-2 Machine Assembly - Front Right ViewD-7010 Rev. -

34 75


Item Part Number Description Qty

Machine Assembly Parts List

1 Fig. 8-3 - 8-5 Assembly, Frame 12 000-041-451 Cover, Side - 19.900" x 14.316" 13 000-143-126 Screw, #10-24UNC x 0.50" Lg Hex Head 134 000-174-014 Washer, #10 Lock 95 000-174-001 Washer, #10 Flat 136 000-041-453 Cover, Top - Machine 17 000-041-452 Cover, Side - 17.250" x 14.316" 1


Figure 8-3 Frame Assembly - Front Left ViewD-7011 Rev. -

3

2

2345

6

32

6

3

2

11

8

7

3

9

2

10

8

1


Figure 8-4 Frame Assembly - Front Right ViewD-7011 Rev. -

1532 152317 16 14

12 13

21

23

20

22

1819


Figure 8-5 Frame Assembly - Rear ViewD-7011 Rev. -

16

6 3 25 24 2



Frame Assembly Parts List

1 Fig. 8-13&14 Assembly, Dash 12 000-143-126 Screw, #10-24UNC x 0.50" Lg Hex Head 133 000-174-001 Washer, #10 Flat 134 000-143-114 Screw,#10-24UNC x 1/2" Flat Head Phillips 45 000-154-156 Spacer, Machine Raising - 4" x 35" x 1/4" Thk. 26 000-033-050 Clamp, 1-3/4" Cushion Loop 37 Fig. 8-18 Assembly, Exhaust 18 000-033-057 Clamp, 1" Cushion Loop 29 Fig. 8-7 Assembly, Blower 1

10 000-055-188 Frame Weldment- Boxxer 318 111 Fig. 8-6 Assembly, Engine 112 Fig. 8-19 Assembly, Electrical Panel 113 Fig. 8-12 Assembly, Water Box 114 Fig. 8-10 Assembly, Heat Exchanger 115 000-033-052 Clamp, 1-1/4" s/s EPDM 216 000-033-012 Clamp, Size #44 Hose 217 000-068-780 Hose, 2.5" ID - Silicone 118 000-140-001 Rivet, AB4-3A Aluminum Pop (1/8" x 1/4") 219 000-105-012 Plate, Machine Serial I.D. 120 000-027-110 Cap, 2" x 3" Frame End 221 Fig. 8-8 Assembly, Pump 122 000-010-125 Belt, #9440HD Gates Automotive 123 Fig. 8-17 Assembly, Idler Pulley 124 Fig. 8-11 Assembly, Silencer 125 000-131-131 Trimlok, 3/8" x 1/8" Rubber 1


Figure 8-6 Engine AssemblyC-7013 Rev. -

7

4

6

1

2

3

9

2

10

11

8 5



Engine Assembly Parts List

1 000-047-028 Engine, B&S 18HP 12 000-077-010 Key, 1/4" x 1-1/2" Lg. 23 000-109-040 Pulley, AK47-H 14 000-020-025 Bushing, H x 1" 15 000-068-660 Hose, 1/4" Fuel 16 000-033-046 Clamp, 1/2 Wide x 1/2 Tube 17 000-033-117 Clamp, 1" Cushion Loop w/ 7/16 Mount Hole 18 000-068-219 Hose, Drain 19 000-174-049 Washer, 5/16" Flat 4

10 000-143-015 Screw, 5/16-18UNC x 1 1/2" Hex Head 411 000-039-054 Coupler, 40 Series 1


Figure 8-7 Blower AssemblyD-7014 Rev. -

?

?

?

?

??

?

?

?

?

?



Blower Assembly Parts List

1 000-052-106 Insert,1/8 NPT x 5/32 Barb - Elbow 22 000-001-141 Adapter, 2.5" NPT x 2.5" OD Tube - Elbow 13 000-111-134 Blower, 3006 Competitor Sl 14 000-052-083 Elbow, 3/8" Brass x 45° Street 45 000-068-219 Hose, Drain 26 000-001-140 Adapter, 2.5" NPT To 2.5" OD Tube 17 000-174-068 Washer, Blower Feet 48 000-174-004 Washer, 5/16" Flat 49 000-143-018 Screw, 3/8-16UNC x 1" Hex Head - Grade 8 4


Figure 8-8 Pump AssemblyB-7016 Rev. -

9

4

8

3

2

1

5

6

7

16

13

14

15

9

10

12

11



Pump Assembly Parts List

1 000-111-142 Pump, Hydrapump II 12 000-020-013 Bushing, H x 24mm 13 000-109-116 Pulley, AK74 14 000-143-012 Screw, 5/16"-18UNC x 3/4" 45 000-174-049 Washer, 5/16" Flat 46 000-052-086 Elbow, 3/8" NPT Street 17 000-097-057 O-Ring, Adapter - Chemical Pump 18 000-068-219 Hose, Drain 19 000-052-531 Elbow, 1/4" SAE x 1/8" NPT 2

10 000-052-084 Elbow, 1/8" NPT Street 111 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 112 000-111-035 Assembly - Pump, Chemical (Fig. 8-9) 113 000-001-096 Adapter, Comet Pump To Chemical Pump 114 000-052-129 Insert, #812 115 000-052-083 Elbow, 3/8" Brass x 45° Street 116 000-052-128 Nipple, 3/8" NPT x 3/8" M Propane 1


Figure 8-9 Chemical Pump AssemblyC-4416 Rev. B

9

9

8

10

7

1

8

2

3

5

4

10

1

6

7

INLET

OUTLET


Chemical Pump Assembly Parts List

1 000-106-110 Plug, Check Valve - Chemical Pump 22 000-064-015 Cover, Chemical Pump 13 000-111-030 Body, Chemical Pump 14 000-105-071 Mid Plate, Chemical Pump 15 000-046-010 Diaphragm, Chemical Pump 16 000-097-055 O-Ring, Chemical Pump Midplate AN Size -227 Viton 17 000-097-056 O-Ring, Check Valve Plug - Chemical Pump 28 000-169-155 Valve, Check - Last Step Chemical Injection 29 000-143-152 Screw, 5/16"-24UNF x 1.50" Lg. Socket Head 6

10 000-097-054 O-Ring, Chem. Pump Valve Viton-Parker 2-114 2


Figure 8-10 Heat Exchanger AssemblyC-7012 Rev. -

6

1

543

2

7

6



Heat Exchanger Assembly Parts List

1 000-038-072 Heat Exchanger, 4 Row 12 000-013-073 Box, Outlet Plenum - Weldment 13 000-143-126 Screw, #10-24UNC x 0.50" Lg. 44 000-174-001 Washer, #10 Flat 45 000-013-072 Box, Inlet Plenum - Weldment 16 000-140-021 Rivet, 1/4" Blind x 0.50" Lg. 327 000-052-766 Elbow, 3/8 NPT x 3/8 JIC 2



Silencer Assembly Parts List

1 000-093-108 Silencer, Ø2.5" O.D. Inlet/Outlet 12 000-068-780 Hose, Ø2-1/2" I.D. Silicone 23 000-033-012 Clamp, Size #44 Hose 4

Figure 8-11 Silencer AssemblyB-7075 Rev. -

2

3 12

3


Figure 8-12 Water Box AssemblyD-7015 Rev. -

12

6

6

21

2

22

4

18

1013

15

16

17

19

20

12

14

12 11

5

18

14

7

9

238

1

9

25

24

3

11

7

11



Water Box Assembly Parts List

1 000-143-314 Screw, #8 x 1/2" Lg. Pan Head 62 000-041-005 Cover, 6" 13 000-052-156 Tee, 1/4" Plastic 14 000-005-007 Float, Water Box 15 000-159-107 Tank, Poly Water Box - Modified 16 000-143-017-1 Screw, 3/8"-16UNC x 3/4" Lg. Hex Head 37 000-174-032 Washer, 3/8" Flat 38 000-157-0801 Switch, With Protector 19 000-097-041 O-Ring, 1/2" Bulk Head 2

10 000-052-661 Insert, 3/4" Barb x Straight 111 000-094-097 Nut, 1-14" Brass 512 000-174-063 Washer, 1.5" O.D. x 1.073" I.D. x 0.075" Thk. 313 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 114 000-052-105 Insert, #68 (3/8" NPT x 1/2" Barb) 215 000-052-447 Tee, 3/8" Male Branch 116 000-052-023 Tee, 3/8" NPT Male Street 117 000-169-027 Valve, 165° F Thermal 118 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 219 000-052-086 Elbow, 3/8" NPT Street 120 000-057-052 Gasket, 1" Garden Hose 121 000-169-167 Valve, Mechanical - Incoming Water 122 000-143-336 Screw, #10-32UNF x 0.25" Lg. Phillips Head 123 000-052-660 Bulkhead, 3/8" FPT x 3/8" FPT 124 000-068-326 Hose, 3/8" I.D. Clear w/ Braid 125 000-033-003 Clamp, Size #4 Mini Hose 1


Figure 8-13 Dash Assembly - FrontD-7018 Rev. -

3

4

7

8

9

13

11

25

12

15

35

19

23

24

26

27

28

30

33

32

31

35

34

5

6

2

22

21

20

10

1

18

16

17

29

14


Figure 8-14 Dash Assembly - BackD-7018 Rev. -

55

48

46

45

60

38

30

36 40 41 4239 39

33

5344

43

47

49

38

51 50

5051

62

61

59

56

54

54

54

57

58

52

35

3937



Dash Assembly Parts List

1 000-100-169 Panel, Dash 12 000-074-018 Meter, Hour Rectangular w/o Bezel 13 000-074-017 Gauge, 30" Hg. Vacuum - Hydramaster 14 000-074-007 Gauge, Pressure 0 -1500 PSI 15 000-131-131 Trimlok, 3/8" x 1/8" Rubber 16 000-100-170 Panel, Grill 17 000-157-017 Switch, Ignition - B & S 18 000-061-056 Knob, Temperature Adjustment 19 000-081-039 Label, Temperature 1

10 000-157-040 Switch, 20 AMP Rocker 211 000-174-062 Washer,1/2" ID x 3/4" OD x 0.010" Thk 112 000-094-098 Nut, 7/16-24UNF Jam 113 000-074-030 Meter, Chemical Flow Raw 114 - - - Chemical Metering Valve - Knob Only 115 000-174-030 Washer, 5/8" Id x 7/8" Od x 0.010" Thk 116 000-169-0171 Knob, 3-Way Ball Valve 117 000-081-039 Label, Right Dash 118 000-143-542 Screw, 1/4"-28UNF x 0.50" Lg. Hh 219 000-143-126 Screw, #10-24UNC x 0.50" Lg. 220 000-094-009 Nut,1/4"-20UNC Nylock 421 000-174-003 Washer, 1/4" Flat 422 000-001-148 Adapter, 2.5" Exhaust Turndown 123 000-169-064 Valve, 3/8" NPT Full Port Ball 124 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) 125 000-081-039 Label, Dash Warning 126 000-052-052 Quick Connect, 660 3/8" Brass w/ Epdm O-Ring 127 000-052-051 Quick Connect, 440 Female w/ Epdm O-Ring 128 000-052-272 Cup, Gravity Feed Oil Blower Lube Port 129 000-081-039 Label, Left Dash 130 000-025-003 Cable, Choke With Detent 131 000-025-020 Cable, Throttle Locking 1



Dash Assembly Parts List

32 000-174-022 Washer, 7/16" Lock 133 000-094-092 Nut, 7/16"-20UNF Hex Jam 234 000-143-171 Screw, #10-24UNC x 1-1/4" Hex Head 435 000-174-001 Washer, #10 Flat 836 000-149-560 Thermostat, Potentiometer 137 000-174-038 Washer, 7/16 SAE Flat 138 000-174-007 Washer, 1/2 Flat 339 000-094-070 Nut, 5mm Nylock 440 000-052-088 Elbow, 1/4" FPT x FPT 141 000-135-052 Regulator, Hi PSI Snubber 142 000-052-527 Nipple, 1/4" SAE x 1/4" NPT 143 000-174-032 Washer, 3/8" Flat 244 000-052-096 Insert, #F23 (1/8" FPT x 3/16" Barb) 145 000-052-090 Tee, 1/4" NPT Branch M-F-F 146 000-052-532 Elbow, 1/4" SAE x 1/4" NPT 147 000-052-073 Nipple, 3/8" NPT x 1/4" NPT Hex 148 000-169-186 Valve, 100 PSI - Last Step Chemical 149 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 150 000-174-008 Washer, 5/8" Flat 451 000-052-105 Insert, #68 (3/8" NPT x 1/2" Barb) 252 Fig. 8-16 Assembly, Bypass Valve 153 Fig. 8-15 Assembly, Hi PSI Manifold 154 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 355 000-052-084 Elbow, 1/8" NPT Street 156 000-052-530 Nipple, 1/4" SAE x 1/8" NPT 157 000-143-166 Screw, #10-24UNC x 3/8" Lg. Hex Head 258 000-174-014 Washer, #10 Lock 259 000-169-0171 Valve, 3-Way Ball O-Ring Style 160 000-052-069 Nipple, 1/8" NPT Hex 161 000-169-160 Chemical Metering Valve 162 000-052-531 Elbow, 1/4" SAE x 1/8" NPT 1


Figure 8-15 Hi-PSI Manifold AssemblyC-7019 Rev. A

10

9

2

14

11

8751 63 4

12

9

13



Hi-PSI Manifold Assembly Parts List

1 000-049-016 Filter, 1/4" NPT Replacement “Y” 22 000-155-020 Spring, 0.540 O.D. x 0.041 Wire x 1.00 Lg. 23 000-180-004 Orifice, Set Screw 0.033" 14 000-180-006 Orifice, Set Screw 0.061" 15 000-149-540 Sensor, RTD Compression Fitting Style 16 000-052-587 Compression, 3/16" x 1/4" NPT Thermocouple 17 000-106-007 Plug, 1/4" NPT Allen Head 18 000-090-010 Manifold, Hi PSI 19 000-106-111 Plug, 1/2" NPT Allen Head 2

10 000-149-027 Sensor, 285°F Nason- 3/8" NPT 111 000-052-023 Tee, 3/8" NPT Male Street 112 000-052-527 Nipple, 1/4" SAE x 1/4" NPT 213 000-052-423 Bushing, Modified Set Screw Orifice 214 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 1



Bypass Valve Assembly Parts List

1 000-169-188 Valve, PA Press Reg Mod. 12 000-106-008 Plug, 3/8" NPT Allen Head 23 000-052-128 Nipple, 3/8" NPT x 3/8" M Propane 14 000-052-086 Elbow, 3/8" NPT Street 15 000-052-105 Insert, #68 (3/8" NPT x 1/2" Barb) 16 000-052-142 Elbow, 3/8" F x F Brass 17 000-015-515 Bracket, Bypass Valve Mounting 1

Figure 8-16 Bypass Valve AssemblyB-7078 Rev. -

6

5

1

3

4

2

7


Figure 8-17 Idler Pulley AssemblyB-7080 Rev. -


Idler Pulley Assembly Parts List

8

3

7

6

2

1

9

4

5

1 000-109-093 Pulley, 3" O.D.x 1.85" Bore 12 000-154-049 Spacer, Pump Idler 13 000-094-119 Nut, 1/2-13UNC Zinc Plated Square 14 000-015-942 Bracket, Idler Tension 15 000-094-009 Nut, 1/4"-20UNC Nylock s/s 16 000-174-003 Washer, 1/4" Flat 17 000-143-376 Screw, 1/4"-20UNC x 4" Lg. s/s - Full Thread 18 000-143-041 Screw, 1/2"-13UNC x 2-1/4" Lg. Hex Head 19 000-174-012 Washer, 1/2 SAE H/D 1


Figure 8-18 Exhaust AssemblyC-7079 Rev. -

6

2

18

15

22

5

22

13

21

18

21

12

11

21

22

1419

16

20

8

21

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Exhaust Assembly Parts List

1 000-057-010 Gasket, Exhaust Manifold - Vanguard 22 000-125-228 Tube, Upper Exhaust Weldment 13 000-143-124 Screw, 5/16"-18UNC x 1.75" Lg. Hex Head 44 000-174-049 Washer, 5/16" Flat 105 000-094-081 Nut, 5/16"-18UNC Hex 2 Way Locking 66 000-033-068 Clamp, 1-1/2" Exhaust 17 000-001-116 Adapter, Exhaust Flange To 1.5" F Slip 18 000-057-209 Gasket, Ø2.5" x 3.5" BCD 19 000-125-227 Tube, Lower Exhaust Weldment 1

10 000-174-003 Washer, 1/4" Flat 411 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 412 000-057-177 Gasket, Exhaust Donut 1.50" 113 000-125-128 Tube, 1-3/8" OD x 1/8" Wall x 7/8" Lg. 114 000-106-120 Plug, M18 x 1.5 115 000-125-096 Tube, 1.5" OD Exhaust w/ Port 116 000-057-212 Gasket, Half Donut 1


Figure 8-19 Electrical Panel AssemblyC-7020 Rev. A

5

12

2 4 7 8

9

8

9

9

17

1 5

18 11

10

15

14

9

3

13

6

16



Electrical Panel Assembly Parts List

1 000-084-010 Light, Green LED Indicator Mini 12 000-100-171 Panel, Electrical - 7" x 7.25" 13 000-033-022 Clamp, 1/2" Nylon Hose 14 000-131-131 Trimlok, 3/8" x 1/8" 15 000-094-063 Nut, #6-32UNC Nylock s/s 26 000-037-011 Connector, “Jumper” Terminal Block 47 000-012-002 Block, 6 Post Terminal 18 000-056-006 Fuse Holder, In-Line - Weatherproof 29 000-094-034 Nut, #10-24UNC Nylock s/s 5

10 000-074-125 Controller, Temp Single Analog Input - RTD 111 000-143-012 Screw, 5/16"-18UNC x 3/4" Lg. 212 000-041-460 Cover, Electrical Panel 113 000-094-108 Nut, #10-32UNF Wing 214 000-060-002 Grommet, Large Wiring 115 000-094-058 Nut, #10-32UNF - Nylock 216 000-156-030 Stud, #10-32UNF x 2" Lg. s/s 217 000-157-022 Switch, Relay 118 000-174-049 Washer, 5/16" Flat 2


Figure 8-20 50 Gallon Universal Recovery Tank AssemblyD-7230 Rev. A

HIDDEN

35

6

21

4

5

2

29

3

12

7

32

8

9

1123

24

34

19

14

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18

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25

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10



50 Gallon Universal Recovery Tank Assembly Parts List

1 000-159-132 Tank, 50 Gallon Universal Recovery 12 000-041-459 Cover, Recovery Tank - Weldment 13 000-049-155 Basket, Filter - Small 14 000-057-015 Gasket, 1-1/2" Bulkhead Fitting 15 000-052-219 Adapter, 2" NPT x 2" F Slip 16 000-052-222 Elbow, 2" Barb x 2" FPT 17 000-052-071 Nipple, 1/4" NPT Hex 18 000-052-090 Tee, 1/4" NPT Branch M-F-F 19 000-052-073 Nipple, 3/8" NPT x 1/4" NPT Hex 1

10 000-052-085 Elbow, 1/4" NPT Street 111 000-052-102 Insert, #46 (1/4" NPT x 3/8" Barb) 112 000-052-088 Elbow, 1/4" FPT x FPT 113 000-169-082 Valve, 12 Volt Solenoid 1200 PSI 114 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 115 000-157-090 Float, Lever Switch 116 000-052-763 Nipple, 1-1/2" IPS Close s/s 117 000-169-022 Valve, 1-1/2" Full Port Ball 118 000-052-226 Insert,1-1/2" NPT x 1-1/2" Barb (Grey) 119 000-012-002 Block, 6 Post Terminal 120 000-086-008 Latch, Bungie - Strike 221 000-086-008 Latch, Bungie - Catch 222 000-057-206 Gasket, Adpater - URT 223 000-143-051 Screw, #8-32UNC x 3/4" Lg.Binder Head 224 000-094-059 Nut, #8-32UNC Nylock 225 000-143-165 Screw, #6-32UNC x 3/8" Lg. Button Head 827 000-001-134 Adapter, Tank To Ø2.5" x 90° Blower Hose 127 000-094-063 Nut, #6-32UNC Nylock s/s 828 Fig. 8-23 Assembly, Vacuum Relief Valve - URT 129 000-174-003 Washer, 1/4" Flat 1630 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 8




31 000-094-009 Nut,1/4"-20UNC Nylock 832 000-131-021 Trimlok, 5/8" x 1/8" 133 000-131-021 Trimlok, 5/8" x 1/8" 134 000-049-153 Filter, Flat - Universal Recovery Tank 135 000-081-039 Label, Maintenance & Lube Schedule 1


Figure 8-21 70 Gallon Universal Recovery Tank AssemblyD-7067 Rev. A

2

15

19

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35

44

43

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34434434141610 3822

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1 000-001-131 Adapter, Tank To Ø2.50" Blower Hose 12 Fig. 8-22 Assembly, Cover - Single Vacuum 13 Fig. 8-24 Assembly, Dura-Flow APO - Production 14 Fig. 8-23 Assembly, Vacuum Relief Valve - URT 15 000-012-002 Block, 6 Post Terminal 16 000-013-070 Box, Vacuum Relief Valve Box - URT 17 000-015-932 Bracket, Flat Filter Securing 18 000-033-023 Clamp, 3/4" Nylon Hose 29 000-052-088 Elbow, 1/4" FPT x FPT 1

10 000-052-085 Elbow, 1/4" NPT Street 111 000-052-082 Elbow, 1/4" NPT Street x 45° 112 000-049-153 Filter, Flat - Universal Recovery Tank 113 000-049-152 Filter, Recovery Tank Basket 114 000-157-090 Float, Lever Switch 215 000-057-206 Gasket, Adpater - URT 316 000-052-102 Insert, #46 (1/4" NPT x 3/8" Barb) 217 000-052-226 Insert,1-1/2" NPT x 1-1/2" Barb (Grey) 118 000-081-039 Label, Maintenance & Lube Schedule 119 000-086-008 Latch, Bungie - Strike 120 000-052-763 Nipple, 1-1/2" IPS Close s/s 121 000-052-071 Nipple, 1/4" NPT Hex 122 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 123 000-052-073 Nipple, 3/8" NPT x 1/4" NPT Hex 124 000-094-034 Nut, #10-24UNC Nylock s/s 225 000-094-063 Nut, #6-32UNC Nylock s/s 226 000-094-059 Nut, #8-32UNC Nylock s/s 227 000-094-113 Nut, 1/4"20UNC Neoprene Wellnut 428 000-106-049 Plug, 1" NPT Allen Head 129 000-106-019 Plug, 1-1/2" NPT 130 000-106-046 Plug, 1-1/4" NPT 1




31 000-143-132 Screw, #10-24UNC x 0.75" Lg. Hex Head 232 000-143-165 Screw, #6-32UNC x 3/8" Lg. Button Head 233 000-143-051 Screw, #8-32UNC x 3/4" Lg.Binder Head 234 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 1235 000-143-333 Screw, 1/4"-20UNC x 0.50" Lg. Hex Head 236 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 437 000-159-128 Tank, 70 Gallon Urt - Weldment 138 000-052-090 Tee, 1/4" NPT Branch M-F-F 139 000-169-022 Valve, 1-1/2" Full Port Ball 140 000-174-001 Washer, #10 Flat 241 000-174-036 Washer, #10 Flat Rubber Backed 442 000-174-029 Washer, 3/8" Rubber Backed 243 000-174-003 Washer, 1/4" Flat 1444 000-174-019 Washer, 1/4" Lock 1445 000-174-060 Washer, 1/4" Rubber Backed 446 000-169-082 Valve, 12 Volt Solenoid 1200 PSI 1


Figure 8-22 Cover, 70 Gallon Universal Recovery Tank AssemblyD-6891 Rev. A

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10

8

9

4

5

3

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6

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1 000-041-443 Cover, Single Vac. 70 Gallon Universal Recovery Tank - Wel 12 000-052-222 Elbow, 2" Barb x 2" FPT 13 000-057-202 Gasket, End - Recovery Tank 24 000-057-203 Gasket, Middle - Recovery Tank 25 000-057-204 Gasket, Middle - Recovery Tank - 70 Gallon 26 000-057-015 Gasket, 1-1/2" Bulkhead Fitting 17 000-052-219 Adapter, 2" NPT x 2" F Slip 18 000-086-008 Latch, Bungie - Strike 19 000-143-539 Screw, #6-32UNC x 0.50" Lg. Button Head Allen 2

10 000-094-063 Nut, #6-32UNC Nylock 2


Cover, 70 Gallon Universal Recovery Tank Assembly Parts List


Figure 8-23 Vacuum Relief Valve AssemblyC-6894 Rev. -

7 5 3 1 4 8 2 6

1 000-015-182 Bracket, Vacuum Relief Valve 12 000-027-032 Cap, Vacuum Releif Valve 13 000-125-111 Pipe, Vacuum Relief Spring Guide 14 000-105-332 Plate, Vacuum Relief Valve Mounting - Universal Recovery T 15 000-155-026 Spring, Vacuum Relief 16 000-143-198 Screw, 3/8"-16UNC x 4" Lg. Hex Head Full Thread 17 000-094-077 Nut, 3/8"-16UNC x 1.00" O.D. Knurled 28 000-094-101 Nut, 3/8"-16UNC Hex Jam 1


Vacuum Relief Valve Assembly Parts List


Figure 8-24 Dura-Flow APO AssemblyD-5654 Rev. E

16 15 16 17 18 19 20 2117 1 9 105

8

382 7 6 13 4

14 127 46 65

22



Dura-Flow APO Assembly Parts List

1 000-111-169 Assembly, APO Pump - Jabsco 12 000-091-042 Motor, Bison 438 Series 13 000-015-891 Bracket, APO Clamp 14 000-015-890 Bracket, Tank Mounted APO Support 15 000-143-566 Screw, 1/4-28UNF x 0.75" Lg. Socket Head 46 000-143-074 Screw, 1/4"-20UNC x 0.50" Lg. Hex Head Self-Tapping 47 000-174-002 Washer, 1/4" Flat 48 000-061-131 Knob, Handle - RDM 29 000-052-723 Fitting, 1" NPT Cam Lock - Banjo 100F 1

10 000-052-724 Fitting, 1" NPT Cam Lock - Banjo 100B 111 000-157-022 Switch, Relay 112 000-012-011 Block, 6 Post 113 000-094-027 Nut, #10-24UNC Hex 114 000-143-532 Screw, #6-32UNC x 5/8" Lg. Socket Head 215 000-068-069 Hose, 3/4" I.D. Weatherhead - Blue - Bulk. 116 000-033-026 Clamp, Size #10 Hose 217 000-052-338 Insert, #1212 (3/4" NPT x 3/4" Barb) 218 000-169-009 Valve, 3/4" FPT Swing Check 119 000-052-281 Nipple, 3/4" NPT x 3/4" Male Garden Hose 120 000-057-055 Gasket, Garden Hose 121 000-027-014 Cap, Garden Hose 122 000-052-425 Bushing, 1" NPT x 3/4" FPT 1


Part No. Description From To068-587 3/8" X 17.5" Lg. - Throb High Pressure Pump Bypass Valve068-518 3/16" X 18.25" Lg. Teflon (JIC Ends) High Pressure Pump Pressure Gauge068-070 3/8" X 12" Lg. Teflon (JIC & MNPT Ends) Bypass Valve Heat Ex. Inlet068-070 3/8" X 12" Lg. Teflon (JIC & MNPT Ends) Heat Ex. Outlet Manifold068-517 3/16" X 23" Lg. Teflon (JIC Ends) Chemical Pump Chem. Selector Valve068-517 3/16" X 23" Lg. Teflon (JIC Ends) Chem. Selector Valve Solution Out Elbow068-723 3/16" X 75" Lg. Teflon (JIC Ends) Secondary Orifice Dump Solenoid068-626 3/8" x 28.5" Lg. Teflon (JIC Ends) Manifold Solution Out Check Valve068-627 3/16" X 44" Lg. Teflon (JIC Ends) Primary Orifice Water Box

Part No. Description From To068-018 1/2" Rubber - 67" Lg. Inlet on Dash Water Box068-069 3/4" Parker GST II - 50" Lg. Water Box High Pressure Pump068-086 1/2" Hi-Temp Rubber - 7" Lg. Plastic Wye Drain Valve068-086 1/2" Hi-Temp Rubber - 6" Lg. Bypass Valve Plastic Wye068-086 1/2" Hi-Temp Rubber - 37" Lg. Plastic Wye Water Box068-085 3/8" Hi-Temp Rubber - 33" Lg. Chem. Selector Valve Brass Tee068-085 3/8" Hi-Temp Rubber - 8.5" Lg. Water Box Brass Tee068-085 3/8" Hi-Temp Rubber - 72" Lg. Brass Tee Insert on Recovery Tank068-326 3/8" Clear w/ Braid - 28.5" Lg. Chemical Meter Chemical Pump068-326 3/8" Clear w/ Braid - 60" Lg. Chemical Jug Chemical Meter068-030 5/32" Rubber Vacuum - 54" Lg. Vacuum Gauge Elbow on Blower068-030 5/32" Rubber Vacuum - 45" Lg. Blower Lube Port Elbow on Blower

Hose Routing

Hose RoutingManufactured Hoses (Crimped Ends)

Cut-to-Length Hoses (Clamps on Ends)

Machine Hose Routings

9-1: How to Order Parts

9 - How to Order Parts

This section describes how to obtain a proper diagnosis of any malfunctions, and how toorder warranty replacement parts or repairs as outlined in the following areas:

Warranty Parts Orders

Parts Orders

Emergencies

One Final Note


WARRANTY PARTS ORDERS1. Call the local distributor where you purchased your equipment and ask for

the Service Department.

2. Have the following information ready:A. Equipment ModelB. Date of PurchaseC. Hours on the UnitD. Unit Serial NumberE. Description of Malfunction

3. Once it has been determined which parts are needed to correct the problem withyour truck mount, make arrangements with your distributor to either perform therepairs or ship the parts to you.

PARTS ORDERSCall your local distributor. In most instances, they either stock or have access to partsthrough a regional service center.

EMERGENCIESIf, for any reason, your distributor is unable to supply you with the necessary parts, they maycall us and arrange for expedited shipping.

HydraMaster sells parts only through authorized distributors and service centers.


ONE FINAL NOTEAny questions you have regarding the warranty program should be directed to the:

HydraMaster Customer Service Department(425) 775-7275,7 a.m. to 5 p.m.

Monday through Friday (PST).

We shall always endeavor to be fair in our evaluation of your warranty claim, and shallprovide you with a complete analysis of our findings.

HydraMaster warranty covers only defective materials and/or workmanship for the periodslisted. Labor and/or diagnostic reimbursement is specifically excluded.

10-1: Warranty Info

10 - Warranty InformationThis section lists causes of component failure that specifically void warranty coverage toavoid misunderstandings which might occur between truck mount owners and manufac-turer. Such causes as listed in this section shall constitute abuse or neglect.

The following areas are covered in this section:

Blower

High Pressure Water Pump

Vacuum Tank

Chemical System

Control Panel

Vacuum and Solution Hoses

Cleaning Wand

Water Heating System

Hard Water Deposits

Warranty Procedure

10-2: Warranty Info

BLOWER:• Failure to lubricate the impellers daily with an oil based lubricant.• Failure to lubricate the bearings as recommended in the blower manual.• Failure to maintain the proper oil levels in the blower.• Failure to use the correct oil grade and viscosity as recommended in the

blower manual.• Failure to properly maintain blower safeguard systems such as waste tank

filter screen, vacuum safety relief valve and waste tank automatic shut-offsystem.

• Allowing foam to pass through the blower.

HIGH PRESSURE WATER PUMP:• Failure to maintain the proper oil level as recommended in the pump manual.• Failure to change the oil in the pump at recommended intervals.• Failure to protect the pump against freezing.• Failure to maintain the pump protection shut-off system.• Failure to use water softener in hard water areas.• Use of improper chemicals.

VACUUM TANK:• Failure to properly maintain the filtering devices in the tank.• Failure to clean the tank as recommended by manufacturer.• Failure to maintain the vacuum safety release in the tank.• Use of improper chemicals.

CHEMICAL SYSTEM:• Use of improper chemicals.• Failure to use water softener in hard water area.• Operating truck mount without a proper chemical filter screen.• Failure to protect against freezing.

CONTROL PANEL:• Failure to protect flowmeter and water pressure gauge against freezing.

10-3: Warranty Info

VACUUM AND SOLUTION HOSES:• Failure to protect the hoses against freezing.• Failure to protect the hoses against burns from the engine and blower ex-

haust.• Damage to the hoses from being run over by vehicles.• Kinking or cracking from failure to store or unroll the hoses correctly.• Normal wear and tear from everyday use.

CLEANING WAND:• Failure to protect against freezing.• Obvious physical abuse of the wand.

WATER HEATING SYSTEM:• Over-pressurization of the system (recommended maximum working pres-

sure-1,000 PSI).• Failure to protect against freezing.

HARD WATER DEPOSITS:• Failure to use or maintain a water softening system or a properly installed

magnetic-type de-scaler, whichever might be necessary, with truck mount’soperating in designated “Hard Water Areas” (3.0 grains or more per gallon).

10-4: Warranty Info

WARRANTY PROCEDUREWarranty coverage is available to you through your local distributor.

If you have moved to a new area or have purchased a used machine and need informationregarding your local distributor, call HydraMaster at (425) 775-7275 or email us [email protected].

When calling your distributor, be sure to have the machine’s information (model and serialnumber) ready for the service representative.

IMPORTANT: HydraMaster’s warranty policy provides replacement parts without chargefor thirty (30) days to distributors maintaining current account status. An invoice will be sentto the distributor for the amount of the parts sent. The customer’s faulty parts must bereturned for evaluation prior to the expiration of the thirty (30) day period. Upon warrantyapproval, a credit will be issued the distributor for the replacement parts invoice. Warrantydisapproval or failure to return the faulty parts within the thirty (30) day periodallowed will result in the customer being charged for the replacement parts sent.

11-1: Accessories

AccessoriesThis section of the Owner’s Manual is devoted to accessories and detergents which wehave found to be helpful and useful. These products can enhance your cleaning and reduceyour labor costs!

Genuine HydraMasterAccessories & DetergentsHydraMaster truck mount accessories are the most innovative collection available in thecleaning industry. Our patented RX-20™ Rotary Extractors have changed the shape ofsteam cleaning. Our hoses and tanks are of the finest quality construction.

HydraMaster chemicals have been specially prepared, not only to give you exceptionalcleaning, but also to optimize your truck mount’s operation and reliability. Most detergentsdon’t work well under the high heat, high pressure conditions of truck mount use.SafeClean will maintain your machines’s water pump and water heating systems at peakefficiency and help ensure fewer breakdowns.

For more information, or to orderGenuine HydraMaster Accessories and Detergents

Call your nearest authorized HydraMaster Distributor.

Documents

11015 47th Avenue W, Mukilteo, WA 98275 - Interlink Supply Boxxer... · · Check the packing list and verify that all items are accounted for. Installation Responsibilities · Ensure