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HydraMaster Boxxer 318 Owner's Manual

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Boxxer 318
Owner's Manual
HydraMaster North America, Inc.
11015 47
th
Avenue West, Mukilteo, Washington 98275
MAN-44101 Rev. 0, February 26, 2010
(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
or electronic retrieval systems) without the express written permission of HydraMaster North America, Inc.
All rights reserved. © 2010 HydraMaster North America, Inc.

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Summary of Contents for HydraMaster Boxxer 318

  • 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 North America, Inc. All rights reserved. © 2010 HydraMaster North America, Inc.

  • Page 2: Table Of Contents

    Water and Chemical Flow Operation ............5-1 eleCTRICAl SySTeM ................SeCTION 6 TROuBleSHOOTING ................. SeCTION 7 Heating System ..................7-2 Chemical System ..................7-3 engine ..................... 7-4 High Pressure System ................7-7 Vacuum System ..................7-9 i: Boxxer 318 Owner’s Manual...
  • Page 3 Dura-Flow APO 90° Assembly Parts list ..........8-33 APO Connection Kit Assembly Parts list ..........8-34 Boxxer 318 on 85 RMT w/ 50 uRT Assembly Parts list ......8-37 50 Gallon uRT for 85 RMT Assembly Parts list ........8-39 Boxxer 318 on 85 RMT w/ 70 uRT Assembly Parts list ......
  • Page 4 Control Panel ..................10-2 Vacuum and Solution Hoses ..............10-2 Cleaning Wand ..................10-2 Water Heating System ................10-2 Hard Water Deposits ................10-2 Warranty Procedure ................10-3 ACCeSSORIeS AND CHeMICAl SOluTIONS .......... SeCTION 11 iii: Boxxer 318 Owner’s Manual...
  • Page 5 Figure 1-1. Hard Water Map of Mainland united States ........1-13 Figure 3-1. location of Throttle, Choke, Optional Pump-In Switch and Water Box ................3-1 Figure 3-2. Front View of Boxxer 318 Console .............3-2 Figure 4-1. Servicing the Valves ................4-5 Figure 4-2. Recirculation Fitting ................4-9 Figure 5-1.
  • Page 6 Figure 8-24. Dura-Flow APO 90° Assembly ............8-33 Figure 8-25. APO Connection Kit Assembly............8-34 Figure 8-26. Boxxer 318 on 85 RMT w/ 50 uRT Assembly - Right View ....8-35 Figure 8-27. Boxxer 318 on 85 RMT w/ 50 uRT Assembly - left View ....8-36 Figure 8-28.
  • Page 7 1- General Information The Boxxer™ 318 is a carefully engineered truckmount designed by HydraMaster Corporation. The system utilizes an internal combustion engine to provide the power necessary to turn both a blower (also referred to as a vacuum pump) and a high pressure water pump.

  • Page 8: General Information

    To find a local distributor, please visit our website at http://www.hydramaster.com/owners/ locate/index.asp. If your question cannot be resolved by your distributor or by the information within this manual, you may contact HydraMaster Customer Service direct using the following phone numbers or e-mail addresses. Hours telephone numbers...

  • Page 9: 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 10 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 11 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 12 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 13 rESPOnSIBIlItIES the 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, drying equipment, etc.
  • Page 14 • 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 15 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. •...

  • Page 16: Machine Specifications

    MaCHInE SPECIfICatIOnS Overall Dimensions 24.0" W x 36" D x 31" H Weight 570 lbs. engine- Briggs and Oil Type Synthetic 5W-30 Stratton Vanguard 18 HP Capacity Approx. 1 1/2 quarts (48 oz.) when changing oil and filter engine rpm 3,150 rpm @ 14"...

  • Page 17: Spare Parts List

    Orifice, 0.061 dia. 000-180-004 Orifice, 0.033 dia. 000-074-007 Gauge, High psi (0-1,500) 000-049-023 Screen, Garden Hose 000-078-273 Kit, By-Pass Valve Repair w/Tapered Handle Miscellaneous 000-087-006 HydraMaster-Recommended Spray 1 ea Lubricant (part number is for a quantity of 1 can) 1-11: General Information...

  • Page 18: High Altitude Operation

    Contact the local Briggs and Stratton dealer or HydraMaster to obtain the proper jet size. your local Briggs and Stratton dealer can be located at http://vanguardengines.via.

  • Page 19: Figure 1-1. Hard Water Map Of Mainland United States

    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 318 in areas exceeding 3.0 grains per gallon.
  • Page 20 Another solution to the disposal problem is to equip your Boxxer 318 with an Automatic Pump-Out System (APO). These systems are designed to remove waste water from the extractor’s recovery system and actively pump the water through hoses to a suitable disposal drain.

  • Page 21: Cleaning And Chemicals

    HydraMaster’s ClearWater Rinse™ has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from using acid products that have obviously caused failures. 2-1: Chemicals and Cleaning...

  • Page 22: Preparing The Carpet For Extraction

    Relying on the rinse detergent to do the majority of the cleaning will result in overly long dry times and excess detergent residue left in the carpet. HydraMaster recommends the use of our pre-sprays: Fastbreak™ for residential carpet and Blitz™ for commercial carpet needs.

  • Page 23: Overwetting

    OVErWEttIng Overwetting is an annoyance to all concerned. extended drying times will leave the customer with a negative impression of both the cleaning company and the process used. There are several factors that will cause over-wetting: Too few vacuum strokes. Clogged vacuum blower filter or vacuum tank lid not sealing properly.

  • Page 24: 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 long with the solution trigger activated, go back up to the top of the stroke, and make a “dry “ pass [i.e. no solution flowing]. This gives the wand a second chance to pick up the solution on the carpet.
  • Page 25 2-5: Chemicals and Cleaning...
  • Page 26 Chemicals and Cleaning: 2-6...
  • Page 27 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 28 Upholstery tool: DriMaster use the upholstery tool on small rugs and furniture. When you clean rugs, be sure that the temperature and chemicals are safe for that particular type of rug. As with the larger tools, do not leave the surface of the upholstery too wet. Adjust the volume of water on the tool without it touching any surface: the water should just barely come out of the tool before the vacuum pulls it back in.

  • Page 29: System Operation

    3 - System Operation Start-UP PrOCEDUrE Perform all daily and periodic maintenance as specified in Section 4 of this Owner’s Manual. Connect a garden hose to supply water to the truckmount. If used, turn the “PuMP-IN” switch to the “ON” position. The water box must be full prior to starting the truckmount.
  • Page 30 Pressure gauge Vacuum gauge Optional auto temperature knob Blower lube Pump-Out Switch Port Chemical Selection Valve Chemical Metering Control knob Pressure regulator figure 3-2. front View of Boxxer 318 Console System Operation: 3-2...
  • Page 31 Adjust the “PReSSuRe ReGulATOR” to the desired cleaning pressure level. Suggested Settings: Carpet Cleaning: 300 - 400 psi Hard Surface Cleaning: 1,000 psi or as indicated on the tool Turn the “CHeMICAl SeleCTION VAlVe” to the “PRIMe” position to purge any air from the system.

  • Page 32: Shut Down Procedure

    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 33: Machine Maintenance

    A maintenance log is provided in the Owner’s Guide. this log must be maintained and may be required to be furnished to HydraMaster 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 34: Operational Maintenance

    Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed. • lubricate the blower with HydraMaster-recommended spray lubricant. Weekly Maintenance • Inspect the recovery tank filters for tears, holes, etc. Repair or replace as needed.

  • Page 35: Overall Machine Maintenance

    500 Hours • Change the blower oil. • Change the high pressure pump oil. • Check the engine valve clearance (intake and exhaust 0.004 - 0.006”) OVErall MaCHInE MaIntEnanCE Maintenance, troubleshooting and repair are much easier tasks to accomplish on a clean truckmount.

  • Page 36: High Pressure Pump Maintenance

    The next few pages explain how to disassemble and inspect all user serviceable parts of the pump. Do not disassemble the pump unless you are a skilled mechanic. For assistance, contact HydraMaster or your local HydraMaster distributor. Machine Maintenance: 4-4...

  • Page 37: Figure 4-1. Servicing The Valves

    Valve Maintenance (See Figure 4-1) using a 22-mm wrench or socket, remove all six valve caps on the manifold of the pump. examine each valve cap O-ring for cuts or distortions and replace if worn. using needle nose pliers, remove the suction and delivery check valves. The valve assembly usually stays together when removing.
  • Page 38 Replace old valves with new valves by placing the assembly in the valve chamber. Press down firmly on the top of the valve assembly. Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft- lbs. Removing and Replacing Pump Manifold Remove the manifold of the pump by taking a 5mm Allen head wrench and removing the eight head bolts.
  • Page 39 Torque to 4.5 ft-lbs. Servicing the Crankcase While the manifold and plungers are removed, rotate the crankshaft by hand. Closely examine the crankcase oil seals for drying, cracking or leaking. Consult the local HydraMaster distributor if crankcase servicing is necessary. 4-7: Machine Maintenance...

  • Page 40: Vacuum System Maintenance

    Capping off the inlet(s) to the vacuum tank. Spraying a HydraMaster-recommended spray lubricant into the “BlOWeR luBe PORT” for about 5 to 10 seconds while the unit is running. uncapping the inlet(s) and run the unit for another minute to allow the blower to cool down.

  • Page 41: 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 deposits. The frequency with which descaling procedures are required will vary. If the area has particularly hard water, you may have to descale often.

  • Page 42: 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 43 The reclaimed antifreeze solution may be used three times before being discarded. To freeze guard the hoses and wand perform Step 7 above with the items to be freeze guarded attached. Recovering Antifreeze for Re-use Attach all hoses and wands which have been freeze guarded to the truckmount. Attach the incoming water source to the front of the truckmount.

  • Page 44: Tensioning The Pump Drive Belt

    PUMP DrIVE BElt Remove the Boxxer 318 grill (P/N 000-100-170) to gain access to the idler pulley. loosen but do not remove the ½”-13 x 2 ¼” long bolt (P/N 000-143-041) on the idler pulley. See Figure 8-17.

  • Page 45: Water And Chemical System

    Finally, the water joins the chemical where the solution is created. 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 jug through the chemical meter.

  • Page 46: Figure 5-1. Annotated Water, Chemical And Solution

    figure 5-1. annotated Water, Chemical and Solution flow Diagram - View 1 of 2 7027 Rev. A 1. fresh water is brought through the front of the truckmount into the water box. 2. Pressurized water enters the by-pass valve. this valve allows manual adjustment of the pressure level.

  • Page 47: Figure 5-2. Annotated Water, Chemical And Solution

    figure 5-2. annotated Water, Chemical and Solution flow Diagram - View 1 of 2 7027 Rev. A 4. the high pressure manifold houses both the 6. Water joins the chemical temperature sensor for the heat control system and a where the solution is created. high temperature shutdown switch.

  • Page 48: Figure 5-3. Annotated Chemical Flow Diagram

    Chemical flow Diagram 7027 Rev. A 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 jug through the chemical flow meter. After being pressurized, the chemical travels through the metering valve and is injected into the high pressure stream.

  • Page 49: Figure 5-4. Exhaust Flow Diagram

    figure 5-4. Exhaust flow Diagram 7027 Rev. A 5-5: Water and Chemical System...

  • Page 50: Electrical System

    „ Wiring Diagram The Boxxer 318 electrical system operates on 12 V DC which is provided by the battery. Battery levels are maintained by a 20 Amp alternator that is built into the engine. When a new battery is installed, check that it is properly charged before installation or damage to the charging system may occur.
  • Page 51 BREAK ALL SHARP EDGES 0.005-.015 Mukilteo, Washington 98275 MACHINE TOLERANCES FINISH .X= .1 PUMP-IN PUMP .XX= .03 .XXX= .010 ANGULAR= 1° PMP-1 ELECTRICAL SCHEMATIC - BOXXER 318 DRAWN 10/15/2007 CHECKED 10/15/2007 APPVD 10/15/2007 electrical System: 6-2 SIZE PART NUMBER DRAWING NUMBER...
  • Page 52 figure 6-2. Wiring Diagram - 35 (ORG) 16 GA. TO IGNITION SW1-1 (SHEET 3) View 1 of 3 6 (ORG) TO SOL 1-BATT (SHEET 1) 7025 Rev. e 34 (BRN) 14 GA TO APO SWITCH SW3- #3 (SHEET 3) 7 (ORG) TO SOL 1-BATT (SHEET 1) FUSE 3(YEL) TO ENGINE STOP LUG 3 (YEL)
  • Page 53 THERMOSTAT IGNITION SWITCH TS-1 figure 6-3. Wiring TO TB1-6 (SHEET 2) 17(WHT/ORG) SW-1 Diagram - View 2 of 3 7025 Rev. e TO TB1-1 (SHEET 2) 18(BLK/WHT) HOUR METER HI-1 23(PNK) TO CR-1 #86 (SHEET 2) 24(PNK) TO TB1-2 (SHEET 2) 26 (WHT) - TO CONTROLLER TR-3 20 GA (SHEET 2) TO CONTROLLER (SHEET 2)
  • Page 54 figure 6-4. Wiring Diagram - View 3 of 3 7025 Rev. e B&S ENGINE MTR-1 1 (RED) 1 (RED) 1 (RED) 1 (RED) TO TB1-2 (16 GA) (SHEET 2) FRESH WATER PUMP IN (OPTIONAL) 2 (BLK) 2 (BLK) TO SW1-3 (16 GA) (SHEET 3) CARB 3 (YEL) TO CR1-#87 (SHEET 2) SOLENOID...

  • Page 55: Troubleshooting

    7 - Troubleshooting This section describes the standard troubleshooting procedures in the following areas: „ Heating System „ Chemical System „ engine „ High Pressure System „ Vacuum System 7-1: Troubleshooting...

  • Page 56: Heating System

    HEatIng SYStEM 1.0 truckmount overheats and shuts down 1.1 The orifice or filter screen Remove and inspect. Clean as necessary. are restricted. 1.2 The low pressure dump Inspect the solenoid and the hose that delivers solenoid is restricted. water to it. Clean or replace as necessary. 1.3 The dump solenoid is Check the main fuse.

  • Page 57: Chemical System

    CHEMICal SYStEM 1.0 System will not prime 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 The check valve in high Remove the valve and inspect.

  • Page 58: Engine

    EngInE 1.0 Will not turn over 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 59 3.0 turns over but will not start; there is spark. (To check for spark, refer to engine manual.) 3.1 Fuel is not reaching the Test for power to the fuel pump. Refer to electrical carburetor. Section. If power is present, inspect the fuel pump. Replace if necessary.
  • Page 60 5.0 runs rough at high speed 5.1 The spark plug(s) are Remove and inspect the plugs. Clean or replace as faulty. necessary. 5.2 The spark plug wire(s) are Inspect the wires and connectors for damage or faulty. loose connections. Repair or replace as necessary. 5.3 Inadequate fuel supply to Check if the fuel pump is mounted in a vertical the carburetor.

  • Page 61: High Pressure System

    HIgH PrESSUrE SYStEM 1.0 the pump will not come up to normal cleaning pressure 1.1 The pressure adjusting Inspect the valve. Repair or replace if necessary. valve is faulty. 1.2 Worn seals or valves in Test the pump output volume directly from the pump the pump.
  • Page 62 4.0 Pressure pulsation Check all the hoses and fittings for cuts, breaks, 4.1 Air leak between the water box and pump. cracks, etc. Repair as necessary. 4.2 The check valve(s) in the Remove each valve and inspect for correct pump are faulty. operation.

  • Page 63: Vacuum System

    VaCUUM SYStEM 1.0 a weak vacuum at wand. the gauge reads normal. 1.1 Blockage in the hoses or Disconnect the hoses and check for an obstruction. wand tube 1.2 excessive length of Do not attach excessive lengths of hose. hose connected to the truckmount 2.0 a weak vacuum 2.1 Air leak somewhere in the...
  • Page 64 5.0 the vacuum blower is locked and will not turn 5.1 Truckmount has been Spray penetrating oil into the blower and let sit for inactive for a period of at least 1 hour. Then very carefully use pipe wrench time and the blower was on the outer diameter of the pulley on the coupler not properly lubricated to attempt to free lobes of the blower.

  • Page 65: Machine Assemblies And Parts List

    8 - Machine Assemblies and Parts list This section contains all the assemblies and parts lists associated with the Boxxer 318: „ 50 Gallon universal Recovery Tank Assembly Parts lis „ Machine Assembly Parts lis „ 70 Gallon universal Recovery Tank Assembly Parts lis „...

  • Page 66: Figure 8-1. Machine Assembly - Front Left View

    figure 8-1. Machine assembly - front left View 7010 Machine Assemblies and Parts lists: 8-2...

  • Page 67: Figure 8-2. Machine Assembly - Front Right View

    rEVISIOnS rEVISIOn CODE DatE CHkD aPPVD figure 8-2. Machine assembly - front right View 7010 8-3: Machine Assemblies and Parts lists...

  • Page 68: Machine Assembly Parts List

    Machine assembly Parts list Item Part number Description Item Part number Description 000-174-001 Washer, #10 Flat - - - Assembly, Frame 000-041-011 Cover, Top - Machine 000-041-451 Cover, Side - 19.900” x 14.316” 000-041-452 Cover, Side - 17.250” x 14.316” 000-143-126 Screw, #10-24uNC x 0.50”...

  • Page 69: Figure 8-3. Frame Assembly - Front Left View

    figure 8-3. frame assembly - front left View 7011 Rev. B 8-5: Machine Assemblies and Parts lists...

  • Page 70: Figure 8-4. Frame Assembly - Front Right View

    figure 8-4. frame assembly - front right View 7011 Rev. B Machine Assemblies and Parts lists: 8-6...

  • Page 71: Figure 8-5. Frame Assembly - Rear View

    figure 8-5. frame assembly - rear View 7011 Rev. B 8-7: Machine Assemblies and Parts lists...

  • Page 72: Frame Assembly Parts List

    - - - Assembly, Blower 000-033-067 Clamp, 2” Cushion loop - - - Assembly, Water Box 000-055-188 Frame Weldment- Boxxer 318 - - - Assembly, Pump 000-068-122 Hose, Ø 2.5” I.D. Silicone X 14.5” lg. - - - Assembly, Dash 000-105-012 Plate, Machine Serial I.D.

  • Page 73: Figure 8-6. Engine Assembly

    ITEM 10 WAS 143-015; REN BOM. figure 8-6. Engine assembly 7013 Rev. A WASHER, 5/16" FLAT SCREW, 5/16"-18UNC x 1.75" LG. HEX PULLEY, AK47-H KEY, 1/4" x 1-1/2" LG. HOSE, 1/4" FUEL HOSE, DRAIN ENGINE, B&S 18HP COUPLER, 40 SERIES CLAMP, 1"...

  • Page 74: Engine Assembly Parts List

    Engine assembly Parts list Item Part number Description Item Part number Description 000-068-660 Hose, 1/4” Fuel 000-020-025 Bushing, H X 1” 000-077-010 Key, 1/4” X 1-1/2” lg. 000-033-046 Clamp, 1/2 Wide X 1/2 Tube 000-109-040 Pulley, Ak47-H 000-033-117 Clamp, 1” Cushion loop w/ 7/16 Mount Hole 000-143-375 Screw, 5/16”-18uNC X 1.75”...

  • Page 75: Blower Assembly Parts List

    figure 8-7. Blower assembly 7014 Blower assembly Parts list Item Part number Description 000-052-106 Insert, 1/8” NPT X 5/32” Barb X 90° 000-001-141 Adapter, 2.5” NPT X 2.5” O.D.Tube - elbow 000-111-134 Blower, 3006 Competitor 000-052-083 elbow, 3/8” NPT Street X 45° 000-068-219 Hose, Drain 000-001-140...

  • Page 76: Pump Assembly Parts List

    REVISIONS REVISION CODE DATE CHKD APPVD A ITEM 1 WAS P/N 111-142 LRIP 2/27/2008 L.O.L. B.R.T. B.R.T. (INCORRECTLY); ADDED ITEM17; B ITEM 17 WAS 174-049; RENUMBERED 12/14/2009 L.O.L. C.I.R. ECRB ECR # 1443 BOM. Pump assembly Parts list figure 8-8. Pump assembly 7016 Rev.

  • Page 77: Chemical Pump Assembly Parts List

    REVISIONS REVISION P CODE DATE DEL ITEMS 2 & 9; ADDED NOTES; - - - 08/15/2000 L.O.L. ADDED ITEM #10 (097-054) M.A. figure 8-9. Chemical Pump assembly 4416 Rev. B OUTLET Chemical Pump assembly Parts list INLET Item Part number Description 000-106-110 Plug, Check Valve - Chemical Pump...

  • Page 78: Heat Exchanger Assembly Parts List

    figure 8-10. Heat Exchanger assembly Heat Exchanger assembly Parts list 7012 Item Part number Description 000-038-072 Heat exchanger, 4 Row 000-013-073 Box, Outlet Plenum - Weldment 000-143-126 Screw, #10-24uNC x 0.50” lg Hex Head 000-174-001 Washer, #10 Flat 000-013-072 Box, Inlet Plenum - Weldment 000-140-021 Rivet, 1/4”...

  • Page 79: Silencer Assembly Parts List

    .XXX= .010 ANGulAR= 1° ASSeMBly, SIleNCeR DRAWN B.R.T. 01/10/2008 8-15: Machine Assemblies and Parts lists CHeCKeD l.O.l. 01/10/2008 APPVD B.R.T. 01/10/2008 - - - - - - PART NuMBeR DRAWING NuMBeR SIZe NOTeS: 7011 BOXXeR 318 1. ReFeReNCe BOM P/N 610-001-001.

  • Page 80: Figure 8-12. Water Box Assembly

    figure 8-12. Water Box assembly 7015 Rev. B ITEM NO. QTY. UNLESS OTHERWIS DIMENSIONS ARE I BREAK ALL SHARP EDG Machine Assemblies and Parts lists: 8-16 TOLERANCES .X= .1 .XX= .03 .XXX= .010 NOTES: ANGULAR= 1° REFERENCE BOM P/N 610-012-001. DRAWN B.R.T.

  • Page 81: Water Box Assembly Parts List

    Water Box assembly Parts list Item Part number Description Item Part number Description 000-159-001 Tank, Poly Water Box - Modified 000-052-105 Insert, #68 (3/8” NPT X 1/2” Barb) 000-052-156 Tee, 1/4” Plastic 000-052-086 elbow, 3/8” NPT Street 000-052-660 Bulkhead, 3/8” FPT X 3/8” FPT 000-143-017-1 Screw, 3/8”-16uNC X 3/4”...

  • Page 82: Figure 8-13. Dash Assembly - Front

    figure 8-13. Dash assembly - front 7018 Rev. C Machine Assemblies and Parts lists: 8-18...

  • Page 83: Figure 8-14. Dash Assembly - Back

    figure 8-14. Dash assembly - Back 7018 Rev. C LABEL LABEL LABEL LABEL ASSE To order a spare thermostat (P/N 000-149-560), specify ASSE P/N 000-149-561. WASH WASH WASH WASH WASH WASH WASH WASH WASH WASH WASH VALVE VALVE VALVE VALVE SWITC SWITC SPRIN...

  • Page 84: Dash Assembly Parts List

    Washer, 3/8" Flat 000-074-007 Gauge, Pressure 0 -1,500 psi 000-174-038 Washer, 7/16" SAe Flat 000-074-017 Gauge, 30" Hg. Vacuum - HydraMaster 000-174-058 Washer, 21/32" I.D. X 27/32" O.D. Nylon 000-174-062 Washer,1/2" I.D. X 3/4" O.D. X 0.010" Thk 000-074-030 Meter, Chemical Flow Raw...

  • Page 85: Figure 8-15. Hi-Psi Manifold Assembly

    figure 8-15. Hi-PSI Manifold assembly REVISION 7019 Rev. A CHANGED EXPLODED ORIENT ITEMS 12 & 13 C NIPPLE, 3/8" M JIC x 3/8" NPT BUSHING, MODIFIED SET SCREW O 8-21: Machine Assemblies and Parts lists NIPPLE, 1/4" SAE x 1/4" NPT TEE, 3/8"...

  • Page 86: Hi-Psi Manifold Assembly Parts List

    Hi-PSI Manifold assembly Parts list Item Part number Description Item Part number Description 000-049-016 Filter, 1/4” NPT Replacement “y” 000-090-010 Manifold, Hi PSI 000-106-111 Plug, 1/2” NPT Allen Head 000-155-020 Spring, 0.540 O.D. x 0.041 Wire x 1.00 lg. 000-180-004 Orifice, Set Screw 0.033”...

  • Page 87: By-Pass Valve Assembly Parts List

    figure 8-16. By-Pass Valve assembly By-Pass Valve assembly Parts list 7078 Item Part number Description 000-169-188 Valve, PA Press Reg Mod 000-106-008 Plug, 3/8” NPT Allen Head 000-052-128 Nipple, 3/8” NPT x 3/8” M Propane 000-052-086 elbow, 3/8” NPT Street 000-052-105 Insert, #68 (3/8”...

  • Page 88: Idler Pulley Assembly Parts List

    figure 8-17. Idler Pulley assembly rEVISIOnS 7080 rEVISIOn CODE DatE CHkD Idler Pulley assembly Parts list Item Part number Description Item Part number Description 000-109-093 Pulley, 3” OD x 1.85” Bore 000-174-003 Washer, 1/4” Flat 000-154-049 Spacer, Pump Idler 000-143-376 Screw, 1/4”-20uNC x 4”...

  • Page 89: Exhaust Assembly Parts List

    rEVISIOnS rEVISIOn CODE DatE CHkD aPPVD figure 8-18. Exhaust assembly Exhaust assembly Parts list 7079 Item Part number Description 000-057-010 Gasket, exhaust Manifold - Vanguard 000-125-228 Tube, upper exhaust Weldment 000-143-124 Screw, 5/16”-18uNC x 1.75” lg. Hex Head 000-174-049 Washer, 5/16” Flat 000-094-081 Nut, 5/16”-18uNC Hex 2 Way locking 000-033-068...

  • Page 90: Electrical Panel Assembly Parts List

    figure 8-19. Electrical Panel assembly Electrical Panel assembly Parts list 7020 Rev. C Item Part number Description 000-100-171 Panel, electrical - 7" X 7.25" 000-074-125 Controller, Temp Single Analog Input - RTD 000-056-006 Fuse Holder, In-line - Weatherproof 000-157-022 Switch, Relay 000-084-010 light, Green led Indicator Mini 000-012-002...
  • Page 91 figure 8-20. 50 gallon Universal recovery tank assembly 7230 Rev. B HIDDeN HIDDeN HIDDeN HIDDeN HIDDeN 8-27: Machine Assemblies and Parts lists...

  • Page 92: Gallon Universal Recovery Tank Assembly Parts List

    50 gallon Universal recovery tank assembly Parts list Item Part number Description Item Part number Description 000-041-459 Cover, Recovery Tank - Weldment 000-052-662 Nipple, 3/8” NPT x 1/4” M SAe 000-169-082 Valve, 12 Volt Solenoid 1200 PSI 000-143-165 Screw, #6-32uNC x 3/8” lg. Button Head 000-086-008 latch, Bungee - Catch 000-052-073...
  • Page 93 figure 8-21. 70 gallon Universal recovery tank assembly 7067 Rev. C 8X HIDDEN 8X HIDDEN 2X HIDDEN 2X HIDDEN 23 2X 2X HIDDEN 2X HIDDEN DETAIL A NOTES: REFERENCE BOM P/N 610-003-015. PART OF LABEL SET P/N 000-081-039 8-29: Machine Assemblies and Parts lists ITEM'S 38 &...
  • Page 94 70 gallon Universal recovery tank assembly Parts list Item Part number Description Item Part number Description 000-174-003 Washer, 1/4" Flat 000-159-128 Tank, 70 Gallon uRT - Weldment - - - Assembly, Cover - Single Vacuum 000-174-019 Washer, 1/4" lock 000-052-071 Nipple, 1/4"...

  • Page 95: Cover, Single Vac. - 70 Gallon Urt Assembly Parts List

    rEVISIOnS ReVISION CHKD CODe DATe APPVD ITeM 9 WAS QTy. 2; ITeMS 9-10 WeRe QTy. 4; lRIP C.I.R. W.B. 04/11/2007 l.O.l. figure 8-22. Cover, Single Vac. - 70 gallon Urt assembly 6891 Rev. A Cover, Single Vac. - 70 gallon Urt assembly Parts list Item Part number Description...

  • Page 96: Vacuum Relief Valve Assembly Parts List

    REVISIONS REVISION CODE DATE CHKD APPVD ADDED PART NUMBER; NEW NEXT ASSEMBLY LRIP 9/15/2009 AND USED ON. figure 8-23. Vacuum relief Valve assembly 6894 Rev. A NUT, 3/8"-16UNC HEX JAM S. STEEL 000-094-101 - - - NUT, 3/8"-16UNC x 1.00" O.D. KNURLED ASTM B16 000-094-077 4179...

  • Page 97: Dura-Flow Apo 90° Assembly Parts List

    figure 8-24. Dura-flow aPO 90° assembly 6313 Rev. A Dura-flow aPO 90° assembly Parts list Item Part number Description 000-091-042 Motor, Bison 438 Series 000-061-131 Knob, Handle 000-015-891 Bracket, APO Clamp 000-174-002 Washer, 1/4” Flat 000-143-074 Screw, 1/4”-20uNC x 0.50” lg. Hex Head Self-Tapping 4 000-094-027 Nut, #10-24uNC Hex 000-157-022...

  • Page 98: Apo Connection Kit Assembly Parts List

    rEVISIOnS rEVISIOn CODE DatE figure 8-25. aPO Connection kit assembly 7243 aPO Connection kit assembly Parts list Item Part number Description Item Part number Description HOSe, 3/4" I.D. PARKeR GST II - BulK RuBBeR INSeRT, #1212 (3/4" NPT x 3/4" BARB) NylON 000-094-009 Nut, 1/4”-20uNC Nylock...

  • Page 99: Figure 8-26. Boxxer 318 On 85 Rmt W/ 50 Urt Assembly - Right View

    8-26. Boxxer 318 on 85 rMt w/ 50 Urt assembly - right View 7087 8-35: Machine Assemblies and Parts lists...

  • Page 100: Figure 8-27. Boxxer 318 On 85 Rmt W/ 50 Urt Assembly - Left View

    CODE DatE CHkD aPPVD figure 8-27. Boxxer 318 on 85 rMt w/ 50 Urt assembly - left View 7087 ASSeMBly, APO CONNeCTION KIT VARIOuS - - - 7243 Machine Assemblies and Parts lists: 8-36 ASSeMBly, DuMP & VACuuM BRACKeT...

  • Page 101: Boxxer 318 On 85 Rmt W/ 50 Urt Assembly Parts List

    Boxxer 318 on 85 rMt w/ 50 Urt assembly Parts list Item Part number Description Item Part number Description 000-174-005 Washer, 3/8” Flat - - - Assembly, 85 Gallon Rotomolded Tank 000-174-021 Washer, 3/8” lock - - - Assembly, Machine 000-033-058 Clamp, Ø2.5”...
  • Page 102 figure 8-28. 50 gallon Urt for 85 rMt assembly 6526 HIDDeN HIDDeN HIDDeN HIDDeN HIDDeN HIDDeN Machine Assemblies and Parts lists: 8-38 NOTeS: ReFeReNCe BOM'S: 000-079-099 DuRA- 000-079-101 50 GAl 610-003-001 50 GAl 2. ITeM 26 IS PART OF P/N...

  • Page 103: Gallon Urt For 85 Rmt Assembly Parts List

    50 gallon Urt for 85 rMt assembly Parts list Item Part number Description Item Part number Description 000-094-063 Nut, #6-32uNC Nylock S/S - - - Assembly, Dura-Flow APO 90° 000-052-102 Insert, #46 (1/4” NPT x 3/8” Barb) 000-086-008 latch, Bungee - Catch 000-052-222 elbow, 2”...

  • Page 104: Figure 8-29. Boxxer 318 On 85 Rmt W/ 70 Urt Assembly - Right View

    8-29. Boxxer 318 on 85 rMt w/ 70 Urt assembly - right View 7247 Machine Assemblies and Parts lists: 8-40...

  • Page 105: Figure 8-30. Boxxer 318 On 85 Rmt W/ 70 Urt Assembly - Left View

    REVISIONS REVISION CODE DATE CHKD APPVD figure 8-30. Boxxer 318 on 85 rMt w/ 70 Urt assembly - left View 7247 8-41: Machine Assemblies and Parts lists ASSEMBLY, DUMP & VACUUM BRACKET VARIOUS - - - 7088 HOSE, Ø1.5" RED STRIPE TYPE 55 - BULK...

  • Page 106: Boxxer 318 On 85 Rmt W/ 70 Urt Assembly Parts List

    Boxxer 318 on 85 rMt w/ 70 Urt assembly Parts list Item Part number Description Item Part number Description - - - Assembly, 70 Gallon uRT for 85 RMT - - - Assembly, 85 Gallon Rotomolded Tank 000-143-150 Screw, 3/8”-16uNC x 4” lg. Hex Head (Full Thread)
  • Page 107 figure 8-31. 70 gallon Urt for 85 rMt assembly 7246 HIDDEN HIDDEN HIDDEN HIDDEN 8-43: Machine Assemblies and Parts lists NOTES: REFERENCE BOM'S: 000-079-091 DURA-FLOW APO KIT. 000-079-102 70 GALLON URT MOUN 610-003-005 70 GALLON URT. 2. ITEM 24 IS PART OF P/N 000-081-039. 3.

  • Page 108: Gallon Urt For 85 Rmt Assembly Parts List

    70 gallon Urt for 85 rMt assembly Parts list Item Part number Description Item Part number Description - - - Assembly, Cover - Single Vacuum 000-094-063 Nut, #6-32uNC Nylock S/S 000-143-333 Screw, 1/4”-20uNC x 0.50” lg. Hex Head 000-174-029 Washer, 3/8” Rubber Backed 000-086-008 latch, Bungee - Strike 000-174-019...
  • Page 109 figure 8-32. 85 gallon rotomolded tank assembly - front View 5566 Rev. F 8-45: Machine Assemblies and Parts lists...
  • Page 110 figure 8-33. 85 gallon rotomolded tank assembly - Back View 5566 Rev. F Machine Assemblies and Parts lists: 8-46...

  • Page 111: Gallon Rotomolded Tank Assembly Parts List

    Valve, 3/4” FPT Ball Valve 000-052-142 elbow, 3/8” F X F Brass 000-052-087 elbow, 1/2” NPT Street 000-105-313 Plate, HydraMaster Name - Roto Tank 000-169-218 Valve, Float, Water Box 000-041-004 Cover, Poly Water Box Mod, W/Vent 000-052-086 elbow, 3/8” NPT Street...

  • Page 112: Dump And Vacuum Assembly Parts List

    figure 8-34. Dump and Vacuum Bracket assembly Dump and Vacuum assembly Parts list 7088 Item Part number Description 000-052-221 Insert, 2” NPT x 2” Barb (Grey) 000-143-017-1 Screw, 3/8”-16uNC x 3/4” lg. Hex Head 000-174-057 Washer, 3/8” lock 000-174-032 Washer, 3/8” Flat 000-052-226 Insert, 1-1/2”...

  • Page 113: Chemical Jug Tray Assembly Parts List

    figure 8-35. Chemical Jug tray assembly 4945 Rev. C Chemical Jug tray assembly Parts list Item Part number Description 000-166-021 Tray, Chemical Jug - Outer - Weldment 000-166-025 Tray, Chemical Jug - Inner 000-078-039 Vacuum Inlet Stopper 000-143-001 Screw, 1/4”-20uNC x 0.75” lg. Hex Head 000-174-019 Washer, 1/4”...

  • Page 114: Machine Hose Routings

    Machine Hose routings Manufactured Hoses (Crimped Ends) Hose routing Part no. Description from 000-068-587 3/8” X 17.5” lg. - Throb High Pressure Pump By-pass Valve 3/16” X 18.25” Lg. Teflon (JIC Ends) 000-068-518 High Pressure Pump Pressure Gauge 3/8” X 12” Lg. Teflon (JIC & MNPT Ends) 000-068-070 By-pass Valve Heat ex.

  • Page 115: 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. Labor and/or diagnostic reimbursement is specifically excluded.

  • Page 116: Warranty Information

    10 - Warranty Information This section lists causes of component failure that specifically void warranty coverage to avoid misunderstandings which might occur between truckmount owners and the manufacturer. Such causes as listed in this section shall constitute abuse or neglect. The following topics are covered in this section „...

  • Page 117: Vacuum Tank

    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 •...

  • Page 118: Warranty Procedure

    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 119: Accessories And Chemical Solutions

    11 - 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 carpet cleaning. In addition, our hoses, reels and tanks are of the finest quality construction.
  • Page 120 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 121 11 - 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 carpet cleaning. In addition, our hoses, reels and tanks are of the finest quality construction.

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