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HydraMaster BoxxerXL Owner's Manual

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Boxxer XL
Owner's Manual
HydraMaster
11015 47
Avenue West
th
Mukilteo, Washington 98275
MAN-44348 Rev. 1, September 27, 2013
(000-182-886)
No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or electronic
retrieval systems) without the express written permission of HydraMaster. Specifications and information in this document are
subject to change without prior notice. All rights reserved. © 2013 HydraMaster

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  • Page 1 No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or electronic retrieval systems) without the express written permission of HydraMaster. Specifications and information in this document are subject to change without prior notice. All rights reserved. © 2013 HydraMaster...
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  • Page 3: Table Of Contents

    Table of Contents GeNeRAL INfORMATION ................SeCTION 1 System Concept ..................1-3 Contact Information ................. 1-4 Warnings, Cautions and Notices ............. 1-5 Responsibilities ..................1-9 Machine Specifications ................1-12 Spare Parts List..................1-14 High Altitude Operation ................1-15 Local Water Precautions ................. 1-15 INSTALLATION INfORMATION ..............
  • Page 4 eLeCTRICAL SySTeM ................SeCTION 7 electrical System Information..............7-1 SySTeMS TROuBLeSHOOTING ............... SeCTION 8 Heating System ..................8-2 Chemical System ..................8-3 engine ..................... 8-4 High Pressure System ................8-7 Vacuum System ..................8-9 ASSeMBLIeS AND PARTS LISTS ............... SeCTION 9 Console Assembly Parts List..............
  • Page 5 WARRANTy INfORMATION ............... SeCTION 11 Blower ....................11-1 High Pressure Water Pump ..............11-1 Vacuum Tank ..................11-1 Chemical System ..................11-1 Control Panel ..................11-1 Vacuum and Solution Hoses ..............11-2 Cleaning Wand and Tool ................. 11-2 Water Heating System ................11-2 Hard Water Deposits ................
  • Page 6 List of figures figure 1-1. Hard Water Map of Mainland united States ........... 1-16 figure 2-1. Location of Roof Vents in Vehicle ............2-1 figure 2-2. Recommended Location of Boxxer XL in Van .......... 2-3 figure 2-3. Install fuel Pump, Outlet Side up ............. 2-6 figure 2-4.
  • Page 7 figure 7-1. electrical Schematic ................. 7-2 figure 7-2. Wiring Diagram - View 1 of 3 ..............7-3 figure 7-3. Wiring Diagram - View 2 of 3 ..............7-4 figure 7-4. Wiring Diagram - View 3 of 3 ..............7-5 figure 9-1. Console Assembly - View 1 of 5 ............... 9-2 figure 9-2.
  • Page 8 This page intentionally left blank. Boxxer XL Owner’s Manual - vi...
  • Page 9 1- General Information The Boxxer XL is a mid-sized truckmount machine designed and manufactured by HydraMaster. It is intended for multitasking in residential and commercial carpet/upholstery cleaning. The 31 HP Briggs and Stratton engine powers the Boxxer XL’s Tuthill 4007 Tri-Lobe vacuum blower and the high pressure water pump, which is rated at 4 gpm (15 litres/ minute).

  • Page 10: General Information

    • Dura-flow Automatic Pump-Out (APO) available as an option • exhaust Thru floor available as an option you can also select either the HydraMaster 70 gallon (265 litre) recovery tank or a 100 gallon (379 litre) recovery tank. This Owner’s Manual contains installation and operation instructions as well as information required for proper maintenance, adjustment and repair of the Boxxer XL.

  • Page 11: System Concept

    SySteM COnCept This Boxxer XL’s airflow travels from the vacuum blower, combines with the engine exhaust, streams through the heat exchanger and then through the silencer. High pressure Water pump Vacuum Blower Heat exchanger Silencer Water engine 1-3: General Information...

  • Page 12: Contact Information

    To find a local distributor, please visit our website at http://hydramaster.com/HowToBuy/DealerLocator.aspx If your question cannot be resolved by your distributor or by the information within this manual, you may contact HydraMaster direct using the following phone numbers. HOUrS teLepHOne nUMBerS...

  • Page 13: Warnings, Cautions And Notices

    WarnIngS, CaUtIOnS anD nOtICeS HydraMaster uses this WARNING symbol throughout the manual to warn of possible injury or death. This CAuTION symbol is used to warn of possible equipment damage. This NOTICe symbol indicates that federal or state regulatory laws may apply, and also emphasizes supplemental information.
  • Page 14 Transporting a vented fuel container that presently contains, or has ever contained in the past, a flammable liquid is strictly forbidden by HydraMaster and by federal and state regulations. Doing so will increase the risk of fire and explosion. Serious injury or death may result.
  • Page 15 Never smoke in or around the truckmount. Doing so will increase the risk of fire and explosion. Serious injury or death may result. During the operation of the truckmount the exhaust system will become extremely hot. Keep all flammable materials away from the truckmount exhaust system. Failure to do so will increase the risk of fire and explosion.
  • Page 16 Never allow water to freeze inside the truckmount. Serious component damage will occur. Perform all freeze guarding procedures outlined in this digital Owner’s Manual. Many vehicles have critical components mounted directly below the floor that can easily be damaged. Before drilling holes in the floor of the vehicle inspect the underside of the vehicle for critical components.

  • Page 17: Responsibilities

    reSpOnSIBILItIeS purchaser’s responsibilities • Prior to purchasing a van, ensure that the payload is suitable for all of the equipment that will be installed and transported. This includes and is not limited to: the truckmount, recovery tanks, fresh water tanks, on-board water, hose reels, hoses, cleaning tools, chemicals and drying equipment.
  • Page 18 • ensure proper connection of the fuel lines. • ensure proper connection and installation of the battery. Verify that the battery is in accordance with HydraMaster’s recommendation. • Check the pump, vacuum blower and engine oil levels prior to starting the truckmount.
  • Page 19 Training The distributor should provide a thorough review of the operation manual with the purchaser along with instruction and familiarization in: How all the truckmount’s systems function. All safety precautions and their importance. How to correctly start and shut down the truckmount. How to correctly clean with the truckmount.

  • Page 20: Machine Specifications

    MaCHIne SpeCIfICatIOnS frame Dimensions 24” W x 39” H x 41” D (61 cm x 99 cm x 104 cm) Weight 800 lbs (363 kg) engine - 31 HP Briggs Oil Type 5W-30 Synthetic and Stratton V-Twin Air- cooled Capacity 2.4 quarts (2.3 litres) - when changing oil and filter engine rpm...
  • Page 21 Available equipment High Pressure Solution 1/4" High Temperature Hose Lined/Vinyl Cover - 100 ft. (0.635 cm High Temperature Lined/Vinyl Cover -30.5 m) Vacuum Hose 2" Vacuum Hose - 100 ft. (5.08 cm Vacuum Hose - 30.5 m) 1-1/2" Wand Whip Line - 10 ft.

  • Page 22: Spare Parts List

    Spare partS LISt These parts, which come with the original engine, are also available from HydraMaster: part no. Description 000-049-014 Oil filter 000-049-049 fuel filter 000-049-053 foam Air filter 000-049-064 Air filter 000-057-227 exhaust Gasket 000-106-016 Spark Plug General Information: 1-14...

  • Page 23: High Altitude Operation

    Contact the local Briggs and Stratton dealer or HydraMaster to obtain the proper jet size. find your local Briggs and Stratton dealer at http://www.vanguardengines.com/where-to-buy/dealer-locator/...

  • Page 24: Figure 1-1. Hard Water Map Of Mainland United States

    Hard Water area Map The hard water map, shown in figure 1-1, defines hard water areas in the continental United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water-cooled engines. for other countries, hard water area maps can be obtained from geological societies.
  • Page 25 Cleaning efficiency and equipment life is increased, chemical use decreased, and the appearance of cleaned carpets enhanced when water softeners are incorporated in hard water areas. HydraMaster strongly urges the use of water softener units with the Boxxer XL in areas exceeding 3.0 grains per gallon.
  • Page 26 HydraMaster makes an APO System which can be ordered with new equipment or installed later. When properly configured, the systems will continuously monitor the level of waste water and pump it out simultaneously with the cleaning operation.

  • Page 27: Installation Information

    3/4 HD ton capacity. If a fresh water tank is added, a one ton or larger capacity van is required. Prior to installation of the Boxxer XL, HydraMaster recommends installing a spray-on bed liner in the vehicle. This provides ‘metal to cushion’ mounting rather than ‘metal to metal’...

  • Page 28: Operating The Boxxer Xl In Hot Weather

    OperatIng tHe BOXXer XL In HOt WeatHer HydraMaster recommends the following steps when operating the Boxxer XL during periods of hot weather (95º f [35º C] or higher). This will help ensure that your Boxxer XL continues to run at 100% capacity during even the hottest days.

  • Page 29: Figure 2-2. Recommended Location Of Boxxer Xl In Van

    Use caution when drilling any holes through the van floor. Many vans have critical components mounted directly below the vehicle floor that could be damaged by a misplaced drill bit. LOCatIng tHe BOXXer XL In VeHICLe There are two recommended entry points on the vehicle for the Boxxer XL installation: the side door or the rear doors.
  • Page 30 Protect yourself and the machine. HydraMaster strongly recommends that the exhaust from the front of the machine be vented down under the truck to prevent carbon monoxide from entering the job site.

  • Page 31: Setting Up The Boxxer Xl

    SettIng Up tHe BOXXer XL Prior to operating the Boxxer XL, follow these steps: Adjust the vacuum relief located on the recovery tank by capping all the vacuum inlets. The machine should be set to 12” Hg maximum. Setting the vacuum level higher than the recommended value can result in an increased risk of serious component damage.

  • Page 32: Orientation Of Fuel Pump

    OrIentatIOn Of fUeL pUMp For proper fuel pump operation and fuel flow, the vehicle’s fuel pump must be installed in a lower position with respect to the fuel tank and in as vertical a position as possible (outlet side up - see figure 2-3 and figure 2-4).

  • Page 33: Cleaning Information

    „ Overwetting „ Streaking „ Cleaning Tool Tips Contact HydraMaster sales to obtain a copy of HydraMaster’s Cleaning Reference Guide for more detailed information about specific processes such as stone, tile, concrete and grout cleaning. Also ask about HydraMaster’s Chemical Catalog.

  • Page 34: Precautions

    The negative side of these products is the corrosive effects the acid can have on metals, including fittings, pumps, heat exchangers, etc. HydraMaster will not warranty parts that have been damaged from using acid products that have obviously caused failures. preparIng tHe Carpet fOr eXtraCtIOn...

  • Page 35: Rinse And Recover

    rInSe anD reCOVer Whether you are using a wand or an RX-20™, you should clean an area approximately 3 ft. x 3 ft. (92 cm x 92 cm) with the solution valve open then immediately go over that area with vacuum only to remove any excess moisture. Olefin fiber is becoming more popular, particularly in commercial installations.

  • Page 36: Cleaning Tool Tips

    CLeanIng tOOL tIpS Wands With a wand, keep cleaning strokes short, front to back, and run a “dry pass”. After pulling the wand for a strip of 3 or 4 ft (0.9 m or 1.2 m) long with the solution trigger activated, go back up to the top of the stroke, and make a “dry “...
  • Page 37 3-5: Cleaning Information...
  • Page 38 Cleaning Information: 3-6...
  • Page 39 rotary tool: rX-20 Rotary tools are easier to move on the carpet, but harder to control at first. With a rotary tool, remember to keep strokes short and side-to-side. Before turning on the RX-20, adjust the handle; it should rest right below or even with the bottom of your pants’...
  • Page 40 If you find it necessary to do a dry pass, keep strokes short to limit the amount of water that comes into contact with the fabric surface. Grip Part #000-061-144 Upholstery Tool Part #000-163-012 for more information about HydraMaster accessories, please visit this web page: http://hydramaster.com/Products/Accessories.aspx. Cleaning Information: 3-8...

  • Page 41: Operating Instructions

    4 - Operating Instructions This section describes how to operate the Boxxer XL, starting with a description of the dash assembly (see figure 4-1). temperature pressure temperature Vacuum gauge gauge gauge Control Dial Hour Meter Ignition Switch with key pump-In Switch Choke Blower Lube port...

  • Page 42: Figure 4-2. Boxxer Xl Lower Dash Assembly

    As shown in figure 4-1, the dash assembly also includes the solution temperature control dial; the temperature, vacuum and pressure gauges; and the hour meter. The lower dash assembly houses the electrical box and the exhaust outlet as shown in figure 4-2.

  • Page 43: Setting The Temperature

    SettIng tHe teMperatUre Depending upon the type of cleaning jobs you need to do, there will be times where you will not need the maximum heat and vacuum available. The temperature can be adjusted to allow you to optimize the Boxxer XL to the size of the job. To adjust the temperature, rotate the dial from the warm setting to hot setting, or anywhere between the two as needed for the cleaning job (see figure 4-3).

  • Page 44: Start Up Procedure

    Start Up prOCeDUre Perform all daily periodic maintenance as specified in this Owner’s Manual. Connect a garden hose to the water inlet connector to supply water to the truckmount (see figure 4-1). If the pump-in feature is used on your system, push the Pump-In switch to the “ON”...

  • Page 45: Setting The Pressure For Cleaning Operations

    SettIng tHe preSSUre fOr CLeanIng OperatIOnS Adjust the cleaning pressure to the desired level using the Pressure Regulator Adjustment Valve (see figure 4-5). Typical settings are from 300 to 400 psi for carpet cleaning. figure 4-5. adjust pressure by rotating Valve Left (Decrease) or right (Increase) 4-5: Operating Instructions...

  • Page 46: Shut Down Procedure

    (counterclockwise) in order to remove moisture from the blower. Cap off the inlet(s) to the recovery tank. Spray a HydraMaster-recommended spray lubricant into the Blower Lube Port for about 5 to 10 seconds while the unit is running (see figure 4-6).

  • Page 47: Machine Maintenance

    A maintenance log, provided in the Owner’s Guide, must be correctly and completely filled out. HydraMaster may request to inspect the logs before a warranty claim is honored. It is recommended that the log be affixed to the vehicle door near the truckmount for convenience and to serve as a maintenance reminder.

  • Page 48: Operational Maintenance

    • Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed. • Lubricate the blower with a HydraMaster-recommended lubricant. Weekly Maintenance • Inspect the recovery tank filters for tears, holes, etc. Repair or replace as needed.
  • Page 49 250 Hours • Check the engine valve clearance (intake and exhaust 0.004” - 0.006” [0.101 mm - 0.152 mm]). • Check coupler element for cracks or wear. Replace as necessary. 400 Hours • Change fuel filter. 500 Hours • Change the blower oil. •...

  • Page 50: Overall Machine Maintenance

    OVeraLL MaCHIne MaIntenanCe Maintenance, troubleshooting and repair are much easier tasks to accomplish on a clean truckmount. Regular cleaning of the truckmount offers the user an opportunity to visually inspect all facets of the truckmount and spot potential problems before they occur. In addition to the operational maintenance the following “housekeeping”...

  • Page 51: Engine Maintenance

    engIne MaIntenanCe engine Oil Level Check The engine oil level should be checked daily. It is recommended that the oil be checked just before the engine is started for the first time for that day. The oil level should be between the ‘Add’...
  • Page 52 Oil filter Briggs and Stratton engines use Briggs and Stratton oil filters. An equivalent or better oil filter must be used when servicing the engine. To replace the filter, use a proper filter wrench to remove the filter. Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil.

  • Page 53: High Pressure Pump Maintenance

    HIgH preSSUre pUMp MaIntenanCe Daily Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the side or rear of the pump or between the “MIN” and “MAX” lines on the dipstick.

  • Page 54: Figure 5-1. Remove Valve Cap And Valve Assembly

    Servicing Valves on the High pressure pump Removing a Valve Remove the valve cap (30 mm) and extract the valve assembly (see figure 5-1). figure 5-1. remove Valve Cap and Valve assembly Remove the valve assembly (retainer, spring, valve plate, valve seat) from the valve cavity.

  • Page 55: Figure 5-3. Replace Center Inlet Check Valve With Modified Check Valve

    Replace center inlet check valve with modified check valve figure 5-3). Modified Check Valve figure 5-3. Replace Center Inlet Check Valve With Modified Check Valve Apply O-ring grease to O-rings and install valves (figure 5-4). Replace valve cap and torque to 95 ft. lbs.see figure 5-5). figure 5-4.

  • Page 56: Figure 5-6. Separate Manifold From Crankcase

    10. Remove the fasteners retaining the manifold Separate manifold from crankcase (see figure 5-6). figure 5-6. Separate Manifold from Crankcase It may be necessary to rotate crankshaft or tap manifold with rawhide or plastic mallet to loosen. When sliding manifold from crankcase, use caution not to damage ceramic plungers.

  • Page 57: Figure 5-9. Remove Stainless Steel Plunger Bolt And Ceramic Plunger

    14. Loosen the stainless steel plunger bolt. 15. Remove the stainless steel plunger bolt and ceramic plunger from the plunger guide (see figure 5-9). 16. If the slinger washer is removed, be certain it is re-installed or replaced. figure 5-9. remove Stainless Steel plunger Bolt and Ceramic plunger 17.

  • Page 58: Figure 5-11. Extract Retainers And Seals

    extracting Seals With manifold removed from crankcase: Insert proper extractor collet through main seal retainer (see figure 5-11). Tighten collet and extract retainers and seals. The Teflon seals of the HT series will be damaged during disassembly so new ones with have to be installed. figure 5-11.

  • Page 59: Figure 5-12. Seal Kit And Insertion Tool For Seal Installation

    Replacing the Seal Assemblies Only one seal kit is necessary to repair all the seals in the pump (see figure 5-12). use an insertion tool for seal installation figure 5-12. Seal kit and Insertion tool for Seal Installation To install a seal assembly: 1.

  • Page 60: Figure 5-14. Install Retainers Into Cavities

    To install the intermediate retainers and the low pressure seals: Insert the brass intermediate retainer into the cavity. Press the new low pressure seal into the brass low pressure seal retainer and install a new O-ring on the outside (see figure 5-14). figure 5-14.

  • Page 61: Figure 5-16. Re-Install Manifold And Torque Fasteners

    Re-Installing Manifold Position the outer plungers at the same position (see figure 5-16). Re-install manifold and torque the fasteners in an “X” pattern to 50% of specification and then retorque to 100% specification (see figure 5-17 and figure 5-18). figure 5-16. re-install Manifold and torque fasteners figure 5-17.

  • Page 62: Vacuum System Maintenance

    Cap off the inlet(s) to the vacuum tank. Spray a HydraMaster-recommended spray lubricant into the Blower Lube Port for about 5 to 10 seconds while the unit is running. uncap the inlet(s) and run the unit for another minute to allow the blower to cool down.

  • Page 63: Descaling Procedure (Required)

    DeSCaLIng prOCeDUre (reQUIreD) Scale deposits on the interior of the heating system can cause a noticeable loss in heating performance. Deposits of this kind result from hard water. The frequency with which descaling procedures are required will vary. If the area has particularly hard water, you may have to descale often.

  • Page 64: Freeze Guarding

    freeze gUarDIng To avoid permanent damage to the truckmount, it is imperative to follow the freeze Guard Procedure whenever the possibility of freezing temperatures exists. When disposing of antifreeze, follow local laws and regulations. Do not discard into storm sewers, septic systems or onto the ground. Antifreeze is harmful or fatal if swallowed.
  • Page 65 Remove the chemical feed line from the chemical jug. Turn the Chemical Selector Valve to “PRIMe.” This will vacuum the chemical remaining in the lines to the recovery tank. Remove the recirculation fitting from the truckmount. Loosen the fitting at the back of the pressure gauge with a wrench after the antifreeze has been added to the machine to purge the coolant out of the fitting.
  • Page 66 This page intentionally left blank. Machine Maintenance: 5-20...

  • Page 67: Water And Chemical System

    6 - Water and Chemical System This section describes the Boxxer XL’s water and chemical systems, and includes the exhaust subsystem (see figure 6-1 - figure 6-3). The process starts when fresh water is brought through the front of the truckmount into the water box.
  • Page 68 The chemical is pressurized by the HydraMaster diaphragm chemical pump attached to the head of the water pump. This pump pulls the chemical from the chemical, or soap, jug through the chemical flow meter.

  • Page 69: Figure 6-1. Flow Diagram - View 1 Of 3

    TEMPERATURE TT-1 SENDER figure 6-1. flow Diagram - View 1 of 3 FROM CHEMICAL 000-179-043 PUMP OUTLET MANIFOLD HIGH TEMPERATURE SHUTDOWN SOLUTION OUT SW-7 CHECK VALVE WATER BOX SOLUTION OUT INLET WATER VALVE COLD WATER IN 0-1200 PSI - COLD 50°F - 100°F HIGH PRESSURE - HOT 200°F - 255°F...

  • Page 70: Figure 6-2. Flow Diagram - View 2 Of 3

    figure 6-2. flow Diagram - View 2 of 3 OUTLET MANIFOLD 000-179-043 CHEMICAL ADJUSTMENT VALVE CHEMICAL PUMP 3-WAY PRIMING VALVE FLOW CHECK METER VALVES RECOVERY TANK HIGH PRESSURE LOW PRESSURE FILTER SOAP JUG Water and Chemical System: 6-4...

  • Page 71: Figure 6-3. Flow Diagram - View 3 Of 3

    figure 6-3. flow Diagram - View 3 of 3 000-179-043 VACUUM GAUGE ENGINE EXHAUST BLOWER LUBE BLOWER EXHAUST FROM WAND BLOWER VACUUM RECOVERY TANK COMBINED EXHAUST VACUUM RELIEF VALVE FILTER FILTER APO/DRAIN FLOW COOLANT FLOW VAC TANK FS-2 HIGH WATER FS-3 APO FLOAT PMP-3...
  • Page 72 this page intentionally left blank. Water and Chemical System: 6-6...

  • Page 73: Electrical System

    7 - electrical System This section describes how the electrical system functions in the following manner: „ electrical System Information „ electrical Schematic „ Wiring Diagram eLeCtrICaL SySteM InfOrMatIOn The Boxxer XL electrical system operates on 12 - 14 V DC which is provided by the battery.

  • Page 74: Figure 7-1. Electrical Schematic

    figure 7-1. electrical Schematic GREEN N.C. 000-179-042 Rev. B WHITE BLACK VACUUM TANK HIGH WATER FLOAT RELAY SCHEMATIC (SHOWN IN "OFF" POSITION) HEAT BYPASS LIGHT TEMPERATURE GAUGE Tl-1 electrical System: 7-2...

  • Page 75: Figure 7-2. Wiring Diagram - View 1 Of 3

    figure 7-2. Wiring Diagram - View 1 of 3 000-179-041 Rev. C 7-3: electrical System...

  • Page 76: Figure 7-3. Wiring Diagram - View 2 Of 3

    figure 7-3. Wiring Diagram - View 2 of 3 000-179-041 Rev. C electrical System: 7-4...

  • Page 77: Figure 7-4. Wiring Diagram - View 3 Of 3

    figure 7-4. Wiring Diagram - View 3 of 3 000-179-041 Rev. C SIDE SIDE 7-5: electrical System...
  • Page 78 this page intentionally left blank electrical System: 7-6...

  • Page 79: Systems Troubleshooting

    8 - Systems Troubleshooting This section describes the standard troubleshooting procedures in the following areas: „ Heating System „ Chemical System „ engine „ High Pressure System „ Vacuum System 8-1: Systems Troubleshooting...

  • Page 80: Heating System

    HeatIng SySteM 1. the truckmount overheats and shuts down possible Cause Solution 1.1. faulty sensor Inspect the engine overheat switch and test for functionality. 2. Unable to achieve normal cleaning solution temperature possible Cause Solution 2.1. Temperature control Inspect the knob. Adjust if necessary. knob is turned down.

  • Page 81: Chemical System

    CHeMICaL SySteM 1. System will not prime possible Cause Solution 1.1. The check valves in Remove the valves and inspect. Clean or replace as chemical pump are faulty. necessary. 1.2. The chemical pump Remove and inspect. Replace as necessary. diaphragm is faulty. 1.3.

  • Page 82: Engine

    engIne 1. the engine will not turn over possible Cause Solution 1.1. A loose or corroded Clean and tighten the battery terminal connections. battery terminal. 1.2. The battery is dead. Recharge or replace the battery. Test the charging system. Repair if necessary. Do not attempt to jump start the truckmount from a running vehicle.
  • Page 83 2. the engine turns over but will not start. possible Cause Solution 2.1. The recovery tank is Drain the tank. full 2.2. The recovery tank Inspect the float. Repair or replace as necessary. float is faulty. 2.3. The engine ignition Refer to a qualified service technician for further system in faulty.
  • Page 84 4. runs rough at high speed possible Cause Solution 4.1. The spark plug(s) Remove and inspect the plugs. Clean or replace as are faulty. necessary. 4.2. The spark plug Inspect the wires and connectors for damage or loose wire(s) are faulty. connections.

  • Page 85: High Pressure System

    HIgH preSSUre SySteM 1. the pump will not come up to normal cleaning pressure possible Cause Solution 1.1. The pressure Inspect the valve. Repair or replace if necessary. adjusting valve is faulty. 1.2. Worn seals or valves Test the pump output volume directly from the pump in the pump.
  • Page 86 4. pressure pulsation possible Cause Solution 4.1. Chemical pump is Prime the chemical pump. not primed. 4.2. Air leak between the Check all the hoses and fittings for cuts, breaks, cracks, etc. water box and pump. Repair as necessary. 4.3. The check valve(s) Remove each valve and inspect for correct operation.

  • Page 87: Vacuum System

    VaCUUM SySteM 1. Weak vacuum at wand. the gauge reads normal. possible Cause Solution 1.1. Blockage in the Disconnect the hoses and check for an obstruction. hoses or wand tube 1.2. excessive length of Do not attach excessive lengths of hose. hose connected to the truckmount 2.
  • Page 88 5. the vacuum blower is locked and will not turn possible Cause Solution 5.1. Truckmount has Spray penetrating oil into the blower and let sit for at least been inactive for a one hour. Then very carefully use pipe wrench on the outer period of time and the diameter of the pulley on the coupler to attempt to free blower was not properly...

  • Page 89: Assemblies And Parts Lists

    9 - Assemblies and Parts Lists Boxxer XL assembly drawings and parts list included in this section are as follows: „ Console Assembly Parts List „ Water Box Assembly Parts List „ exhaust Assembly Parts List „ Chemical Jug Tray Assembly Parts List „...

  • Page 90: Figure 9-1. Console Assembly - View 1 Of 5

    SEE DETAIL A figure 9-1. Console assembly - View 1 of 5 610-050-727 Rev. A DETAIL A SCALE 1 : 3 9-2: Assemblies and Parts Lists...

  • Page 91: Figure 9-2. Console Assembly - View 2 Of 5

    figure 9-2. Console assembly - View 2 of 5 610-050-727 Rev. A 9-3: Assemblies and Parts Lists...

  • Page 92: Figure 9-3. Console Assembly - View 3 Of 5

    figure 9-3. Console assembly - View 3 of 5 610-050-727 Rev. A 9-4: Assemblies and Parts Lists...

  • Page 93: Figure 9-4. Console Assembly - View 4 Of 5

    figure 9-4. Console assembly - View 4 of 5 610-050-727 Rev. A 9-5: Assemblies and Parts Lists...

  • Page 94: Figure 9-5. Console Assembly - View 5 Of 5

    figure 9-5. Console assembly - View 5 of 5 610-050-727 Rev. A 9-6: Assemblies and Parts Lists...

  • Page 95: Console Assembly Parts List

    Console assembly parts List Item part number Description Item part number Description 610-002-727 Assembly, Blower 000-068-328 Hose Assembly, 5/16” Teflon X 68” Lg. 610-005-727 Assembly, Blower Heat exchanger (Hi PSI Pump to By-Pass Valve) 000-068-529 Hose, 1” I.D. Rubber X 36” Lg. 610-018-727 Assembly, Dash 610-011-727...

  • Page 96: Console Assembly Parts List (Continued)

    Console assembly parts List (continued) Item part number Description Item part number Description 000-068-344 Hose, 5/32” I.D. Vacuum X 41.5” Lg. 000-143-126 Screw, #10-24uNC X 0.50” Lg. Hex Head (Blower Inlet to Vacuum Gauge) 000-052-575 Tee, 1/4” Insert M-M-M GfBN 000-068-978 Hose, 5/32”...

  • Page 97: Figure 9-6. Chemical Jug Tray Assembly

    figure 9-6. Chemical Jug tray assembly 610-015-040 Rev. B 9-9: Assemblies and Parts Lists...

  • Page 98: Chemical Jug Tray Assembly Parts List

    Chemical Jug tray assembly parts List Item part number Description Item part number Description 000-033-063 Clamp, 2” T-Bolt 000-166-025 Tray, Chemical Jug - Inner - Coated 000-068-882 Hose, 1.5” I.D. Red Stripe X 48” Lg. 000-166-023 Tray, Outer Chemical Jug - Coated 000-078-039 Vacuum Inlet Stopper 000-068-141...

  • Page 99: Figure 9-7. Frame Assembly

    figure 9-7. frame assembly 610-001-727 Rev. B 9-11: Assemblies and Parts Lists...

  • Page 100: Frame Assembly Parts List

    frame assembly parts List Item part number Description Item part number Description 000-001-098 Adapter, exhaust Turndown 000-143-114 Screw, #10-24uNC X 0.50” Lg. flat Head Phillips 000-055-212 frame - Coated 000-143-583 Screw, #10-24uNC X 0.50” Lg. Hex Head flange Z/P 000-154-156 Spacer, Machine Rising 4”...

  • Page 101: Side Cover Assembly Parts List

    figure 9-8. Side Cover assembly 610-023-741 Rev. B Side Cover assembly parts List Item part number Description 000-041-469 Cover, Side - Machine - Coated 000-089-003 Magnet 000-094-034 Nut, #10-24uNC Nylok 000-131-131 Trimlok, 3/8 X 1/8 Rubber edge Trim 1 ft 9-13: Assemblies and Parts Lists...

  • Page 102: Figure 9-9. Blower Assembly

    figure 9-9. Blower assembly 610-002-727 Rev. B 9-14: Assemblies and Parts Lists...

  • Page 103: Blower Assembly Parts List

    Blower assembly parts List Item part number Description Item part number Description 000-001-856 Adapter, Blower Outlet - Coated 000-077-011 Key, 3/16” X 1 1/2” Long 000-111-147 Blower, 4007 Dominator 000-094-014 Nut, 3/8-16 Hex Z/P 000-109-107 Pulley, 2 Groove 000-015-1221 Bracket, Blower foot - Coated 000-020-019 Bushing, #H X 7/8”...

  • Page 104: Figure 9-10. Engine Assembly

    figure 9-10. engine assembly 610-004-727 Rev. A 9-16: Assemblies and Parts Lists...

  • Page 105: Engine Assembly Parts List

    Hose, 5/32” (4mm) I.D.Vacuum - Bulk 000-174-049 Washer, 5/16” flat 000-052-293 Insert, #23 (1/8” NPT X 3/16” Barb) These parts, which come with the original engine, are also available from HydraMaster: • 000-049-014 Oil filter • 000-049-049 fuel filter • 000-049-053 foam Air filter •...

  • Page 106: Figure 9-11. Blower Heat Exchanger Assembly

    figure 9-11. Blower Heat exchanger assembly 610-005-727 Rev. D 9-18: Assemblies and Parts Lists...

  • Page 107: Blower Heat Exchanger Assembly Parts List

    Blower Heat exchanger assembly parts List Item part number Description Item part number Description 000-001-598 Adapter, Tank To 3.0” Blower Hose - Welded 000-131-015 Gasket, Heat exchanger Core 000-120-014 Angle, 3/4” X 3/4” X 1/8” X 12” Lg. 000-068-910 Hose, 3.0” I.D. X 3 Ply Silicone X 2” Lg. 000-052-815 Manifold, RTD 1/8”...

  • Page 108: Figure 9-12. Pump Assembly - View 1 Of 2

    figure 9-12. pump assembly - View 1 of 2 610-007-727 Rev. B 9-20: Assemblies and Parts Lists...

  • Page 109: Figure 9-13. Pump Assembly - View 2 Of 2

    figure 9-13. pump assembly - View 2 of 2 610-007-727 Rev. B 9-21: Assemblies and Parts Lists...

  • Page 110: Pump Assembly Parts List

    pump assembly parts List Item part number Description Item part number Description 000-001-154 Adapter, GP to Chem Pump S/S 4.0 Gallon 000-097-057 O-Ring, Adapter - Chemical Pump 000-015-1243 Bracket, Idler Tension - Coated 000-105-550 Plate, Pump Clutch - GP 4.0 gpm 000-109-106 Pulley, Ø3”...

  • Page 111: Exhaust Heat Shield Protector Assembly Parts List

    figure 9-14. exhaust Heat Shield protector assembly 610-024-727 Rev. A exhaust Heat Shield protector assembly parts List Item part number Description 000-089-003 Magnet 000-094-034 Nut, #10-24uNC Nylok 000-108-177 Protector, Heat Shield exhaust 000-143-565 Screw, 1/4”20uNC X 0.375” Lg. Button Head Socket 000-131-021 Trimlok, 5/8”...

  • Page 112: Figure 9-15. Electrical Panel Assembly

    figure 9-15. electrical panel assembly 610-011-727 Rev. D 9-24: Assemblies and Parts Lists...

  • Page 113: Electrical Panel Assembly Parts List

    electrical panel assembly parts List Item part number Description Item part number Description 000-012-002 Block, 6 Post Terminal 000-094-058 Nut, #10-32uNfNylok 000-033-022 Clamp, 1/2” Nylon Hose 000-094-108 Nut, #10-32uNfWing 000-100-314 Panel, electrical - Coated 000-037-011 Connector, Jumper Terminal Block 000-074-125 Controller, Temp Single Analog Input - RTD 000-100-253 Panel, electrical Box Cover - Coated...

  • Page 114: Figure 9-16. Hi Psi Manifold Assembly

    figure 9-16. Hi pSI Manifold assembly 610-008-727 Rev. A 9-26: Assemblies and Parts Lists...

  • Page 115: Hi Psi Manifold Assembly Parts List

    Hi pSI Manifold assembly parts List Item part number Description Item part number Description 000-052-113 Cross, 3/8” fPT 000-106-009 Plug, 1/8” NPT Allen Head 000-052-086 elbow, 3/8” NPT Street 000-052-051 Quick Connect, 440 female w/ ePDM O-Ring 000-149-039 Sender, Temperature 000-090-008 Manifold, High Pressure 000-052-071...

  • Page 116: Differential Check Valve Assembly Parts List

    figure 9-17. Differential Check Valve assembly 000-169-236 Rev. A Differential Check Valve assembly parts List Item part number Description 000-005-012 Ball, 0.500 diameter S/S 000-107-258 Body, Differential Check Valve Apply O-ring grease or equivalent to items 5 and 4 prior to installation. 000-106-180 Cap, Differential Check Valve 000-097-056...

  • Page 117: By-Pass Valve Assembly Parts List

    figure 9-18. By-pass Valve assembly 610-009-727 Rev. A By-pass Valve assembly parts List Item part number Description 000-015-515 Bracket, By-Pass Valve Mount - Weldment 000-052-142 elbow, 3/8” f X f Brass 000-052-086 elbow, 3/8” NPT Street 000-052-083 elbow, 3/8” NPT Street X 45 Degree 000-052-105 Insert, #68 (3/8”...

  • Page 118: Figure 9-19. Water Box Assembly - View 1 Of 2

    figure 9-19. Water Box assembly - View 1 of 2 610-010-727 Rev. B 9-30: Assemblies and Parts Lists...

  • Page 119: Figure 9-20. Water Box Assembly - View 2 Of 2

    figure 9-20. Water Box assembly - View 2 of 2 610-010-727 Rev. B 9-31: Assemblies and Parts Lists...

  • Page 120: Water Box Assembly Parts List

    Water Box assembly parts List Item part number Description Item part number Description 000-169-235 Assembly, float Valve 000-094-034 Nut, #10-24uNC Nylock 000-015-1226 Bracket, Water Box Mounting - Coated 000-097-041 O-Ring, 1/2” Bulk Head 000-106-014 Plug, Vent 000-052-728 Bulkhead, 1/2” fPT 000-052-660 Bulkhead, 3/8”...

  • Page 121: Exhaust Assembly Parts List

    figure 9-21. exhaust assembly 610-013-727 exhaust assembly parts List Item part number Description 000-033-068 Clamp, 1-1/2” exhaust 000-105-181 flange, Ø1.50” exhaust Donut - Coated 000-057-199 Gasket, exhaust Donut 000-057-146 Gasket, four Hole exhaust 000-094-081 Nut, 5/16”-18uNC Hex 2 Way Locking 000-094-078 Nut, 5/16-18uNC Hex flange 000-143-124...

  • Page 122: Figure 9-22. Diverter Valve Actuator Assembly

    figure 9-22. Diverter Valve actuator assembly 610-014-727 9-34: Assemblies and Parts Lists...

  • Page 123: Diverter Valve Actuator Assembly Parts List

    Diverter Valve actuator assembly parts List Item part number Description Item part number Description 000-052-059 Bushing, 1/4” MPT X 1/8” fPT 000-143-141 Screw, 1/4”-20uNC X 1/2” Lg. Whiz Lock 000-057-224 Gasket, Actuator 000-143-022 Screw, 3/8-16uNC X 1.75” Hex Head - Grade 8 000-143-573 Screw, 5/16”-18uNC X 7/8”...

  • Page 124: Figure 9-23. Diverter Valve Box Assembly

    figure 9-23. Diverter Valve Box assembly 000-169-230 Rev. C 9-36: Assemblies and Parts Lists...

  • Page 125: Diverter Valve Box Assembly Parts List

    Diverter Valve Box assembly parts List Item part number Description Item part number Description 000-020-069 Bushing, flapper - Diverter - Machined 000-105-551 Plate, Sealing - Diverter - fabricated 000-020-073 Collar, Diverter Alignment 000-105-552 Plate flapper Diverter- Coated 000-108-151 Protector, exhaust Diverter - fabricated 000-042-065 Housing, Top and Side - Diverter - fabricated 000-042-066...

  • Page 126: Figure 9-24. Dash Assembly - Part 1 Of 2

    figure 9-24. Dash assembly - part 1 of 2 610-018-727 Rev. B 9-38: Assemblies and Parts Lists...

  • Page 127: Figure 9-25. Dash Assembly - Part 2 Of 2

    figure 9-25. Dash assembly - part 2 of 2 610-018-727 Rev. B 9-39: Assemblies and Parts Lists...

  • Page 128: Dash Assembly Parts List

    Dash assembly parts List Item part number Description Item part number Description 610-009-727 Assembly, By-Pass Valve 000-052-530 Nipple, 1/4” SAe X 1/8” NPT 610-008-727 Assembly, Hi PSI Manifold 000-052-069 Nipple, 1/8” NPT Hex 000-094-098 Nut, 7/16”-24uNf - 2 Way Metering Valve 000-025-003 Cable, Choke With Detent 000-025-029...

  • Page 129: Silencer Assembly Parts List

    figure 9-26. Silencer assembly 610-021-727 Rev. C Silencer assembly parts List Item part number Description 000-033-013 Clamp, #48 Hose (3”) 000-052-917 elbow, Silicone Coupler 000-068-946 Hose, 3” X 3” Lg. Blue Silicone 000-068-620 Hose,3” X 4 1/2” w/Clamps 000-094-016 Nut, 3/8-16 Hex Wiz Lock 000-143-017 Screw, 3/8”-16uNC X 0.75”...

  • Page 130: Figure 9-27. 70 Gallon Universal Recovery Tank (Urt) Assembly

    figure 9-27. 70 gallon Universal recovery tank (Urt) assembly 610-003-577 Rev. A Item 3 is optional; lower float switch item 12 is only used when APO is installed. Items 24 and 25 are not used when APO is installed. Label P/N 000-081-332 is part of label set P/N 000-081-397 and cannot be sold separately.

  • Page 131: 70 Gallon Universal Recovery Tank (Urt) Assembly Parts List

    70 gallon Universal recovery tank (Urt) assembly parts List Item part number Description Item part number Description 000-001-135 Adapter, Ø3.0 Tank to X 90 Degree Blower Hose 000-094-113 Nut, 1/4”-20uNC Neoprene Wellnut 610-029-010 Assembly, Cover, 70 Gal, Dual Vac, uRT 000-094-009 Nut, 1/4”-20uNC Nylok 000-106-019...

  • Page 132: 70 Gallon Universal Recovery Tank (Urt) Cover Assembly Parts List

    figure 9-28. 70 gallon Universal recovery tank (Urt) Cover assembly 610-029-010 Rev. A 70 gallon Universal recovery tank (Urt) Cover assembly parts List Item part number Description Item part number Description 000-052-219 Adapter, 2” NPT X 2” f Slip - - - Latch, Bungee - Strike (Part of 000-086-008) 000-052-222 elbow, 2”...

  • Page 133: Figure 9-29. 100 Gallon Universal Recovery Tank (Urt) Assembly

    figure 9-29. 100 gallon Universal recovery tank (Urt) assembly 610-003-727 Rev. A Item 2 is optional; lower float switch item 13 is only used when APO is installed. Items 24 and 25 are not used when APO is installed. Label P/N 000-081-332 is part of label set P/N 000-081-397 and cannot be sold separately.

  • Page 134: 100 Gallon Universal Recovery Tank (Urt) Assembly Parts List

    100 gallon Universal recovery tank (Urt) assembly parts List Item part number Description Item part number Description 000-001-135 Adapter, Ø3.0 Tank to X 90 Degree Blower Hose 000-094-059 Nut, #8-32uNC Nylok 000-079-091 Assembly, Dura-flow APO - Production 000-094-113 Nut, 1/4”-20uNC Neoprene Wellnut 000-094-009 Nut, 1/4”-20uNC Nylok 610-029-001...

  • Page 135: 100 Gallon Universal Recovery Tank (Urt) Cover Assembly Parts List

    figure 9-30. 100 gallon Universal recovery tank (Urt) Cover assembly 610-029-001 100 gallon Universal recovery tank (Urt) Cover assembly parts List Item part number Description Item part number Description 000-052-219 Adapter, 2” NPT X 2” f Slip 000-094-063 Nut, #6-32uNC Nylok 000-041-465 Cover 100 uRT - Coated 000-094-009...

  • Page 136: Vacuum Relief Valve Assembly Parts List

    figure 9-31. Vacuum relief Valve assembly 610-026-724 Rev. B Vacuum relief Valve assembly parts List Item part number Description 000-015-182 Bracket, Vacuum Relief Valve - fabricated 000-027-032 Cap, Spun Vacuum Relief Valve 000-094-101 Nut, 3/8”-16 uNC Hex Jam 000-094-077 Nut, 3/8”-16uNC X 1.00” O.D. Knurled 000-105-332 Plate, Vacuum Relief Valve Mounting - Coated 000-143-198...

  • Page 137: Hose Routings

    Hose routings part no. Description Hose routing 000-068-1006 Hose, 5/32” I.D. Vacuum X 1.5” Lg. Check Valve to Vacuum Tee 000-068-1006 Hose. 5/32” I.D. Vacuum X 1.5” Lg. Blower Inlet to Check Valve 000-068-1009 Hose, 5/32” I.D. Vacuum X 22” Lg. Vacuum Tee to Check Valve 000-068-313 Hose, 5/32”...
  • Page 138 This page intentionally left blank. 9-50: Assemblies and Parts Lists...

  • Page 139: 10 - How To Order Parts

    We shall always endeavor to be fair in our evaluation of your warranty claim and shall provide you with a complete analysis of our findings. HydraMaster warranty covers only defective materials and/or workmanship for the periods listed. Diagnostic reimbursement is specifically excluded.
  • Page 140 this page intentionally left blank. How to Order Parts: 10-2...

  • Page 141: Blower

    Such causes listed in this section shall constitute abuse or neglect. BLOWer • failure to lubricate impellers daily with a HydraMaster-recommended lubricant, to lubricate bearings, to maintain proper oil levels, or to use the correct oil grade and viscosity as recommended in blower manual.

  • Page 142: Vacuum And Solution Hoses

    Guide. If you have moved to a new area or have purchased a used machine and need information regarding your local distributor, call HydraMaster at (425) 775-7272 or email us at: custsvc@hydramaster.com. When calling your distributor, be sure to have the machine’s information; model and serial number, ready for the service representative.
  • Page 143 12 - Accessories and Chemical Solutions HydraMaster’s machine accessories are the most innovative collection available in the cleaning industry. for example, our RX-20 Rotary extractors have changed the shape of steam cleaning. In addition, our hoses, reels and tanks are of the finest quality construction.
  • Page 144 this page intentionally left blank Accessories and Chemical Solutions: 12-2...

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