HYDRAMASTER Boxxer 318 User Guide

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Boxxer 318

Owner’s Manual

HydraMaster North America, Inc.

11015 47th Avenue West, Mukilteo, Washington 98275

MAN-44101 Rev. 0, February 26, 2010

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.

(182-076-D)

Table of Contents

GeNeRAl INFORMATION ...........................................................................SeCTION 1

Contact Information ................................................................................. 1-2

Warnings, Cautions and Notices ............................................................. 1-3

Machine Specications ........................................................................... 1-10

Spare Parts list ......................................................................................1-11

High Altitude Operation ..........................................................................1-12

local Water Precautions .........................................................................1-12

CleANING AND CHeMICAlS .....................................................................SeCTION 2

Precautions .............................................................................................2-1

Preparing the Carpet for extraction.........................................................2-2

Rinse and Recover..................................................................................2-2

Overwetting .............................................................................................2-3

Streaking .................................................................................................2-3

Cleaning Tool Tips ...................................................................................2-4

SySTeM OPeRATION .................................................................................SeCTION 3

Start-up Procedure .................................................................................. 3-1

Shut Down Procedure .............................................................................3-4

MACHINe MAINTeNANCe ..........................................................................SeCTION 4

Operational Maintenance ........................................................................4-2

Overall Machine Maintenance.................................................................4-3

High Pressure Pump Maintenance ......................................................... 4-4

Vacuum System Maintenance ................................................................. 4-8

Descaling Procedure (Required) ............................................................. 4-9

Freeze Guarding .....................................................................................4-10

Tensioning the Pump Drive Belt ..............................................................4-12

WATeR AND CHeMICAl SySTeM ............................................................SeCTION 5

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

8 - MACHINe ASSeMBlIeS AND PARTS lIST...........................................SeCTION 8

Machine Assembly Parts list ..................................................................8-4

Frame Assembly Parts list .....................................................................8-8

engine Assembly Parts list..................................................................... 8-10

Blower Assembly Parts list .....................................................................8-11

Pump Assembly Parts list ......................................................................8-12

Chemical Pump Assembly Parts list ......................................................8-13

Heat exchanger Assembly Parts list ...................................................... 8-14

Silencer Assembly Parts list ...................................................................8-15

Water Box Assembly Parts list ...............................................................8-17

Dash Assembly Parts list .......................................................................8-20

Hi-PSI Manifold Assembly Parts list .......................................................8-22

By-Pass Valve Assembly Parts list .........................................................8-23

Idler Pulley Assembly Parts list .............................................................. 8-24

exhaust Assembly Parts list ...................................................................8-25

electrical Panel Assembly Parts list ....................................................... 8-26

50 Gallon universal Recovery Tank Assembly Parts list ........................8-28

70 Gallon universal Recovery Tank Assembly Parts list ........................8-30

Cover, Single Vac. - 70 Gallon uRT Assembly Parts list........................ 8-31

Vacuum Relief Valve Assembly Parts list ...............................................8-32

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 .........................8-42

70 Gallon uRT for 85 RMT Assembly Parts list .....................................8-44

85 Gallon Rotomolded Tank Assembly Parts list ................................... 8-47

Dump and Vacuum Assembly Parts list ................................................. 8-48

Chemical Jug Tray Assembly Parts list ..................................................8-49

Machine Hose Routings ..........................................................................8-50

HOW TO ORDeR PARTS ............................................................................SeCTION 9

Warranty Parts Orders ............................................................................9-1

Parts Orders ............................................................................................ 9-1

emergencies ...........................................................................................9-1

Boxxer 318 Owner’s Manual: ii

WARRANTy INFORMATION .......................................................................SeCTION 10

Blower

High Pressure Water Pump

....................................................................................................10-1

...................................................................10-1

Vacuum Tank .......................................................................................... 10-2

Chemical System ...................................................................................10-2

Control Panel ......................................................................................... 10-2

Vacuum and Solution Hoses Cleaning Wand

....................................................................................... 10-2

.................................................................. 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

list of Figures

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. Annotated Water, Chemical and Solution

Flow Diagram - View 1 of 2 ................................................................5-2

Figure 5-2. Annotated Water, Chemical and Solution

Flow Diagram - View 1 of 2 ................................................................5-3

Figure 5-3. Annotated Chemical Flow Diagram ...................................................5-4

Figure 5-4. exhaust Flow Diagram.......................................................................5-5

Figure 6-1. electrical Schematic ...........................................................................6-2

Figure 6-2. Wiring Diagram - View 1 of 3 ..............................................................6-3

Figure 6-3. Wiring Diagram - View 2 of 3 ..............................................................6-4

Figure 6-4. Wiring Diagram - View 3 of 3 ..............................................................6-5

Figure 8-1. Machine Assembly - Front left View ..................................................8-2

Figure 8-2. Machine Assembly - Front Right View ................................................8-3

Figure 8-3. Frame Assembly - Front left View ......................................................8-5

Figure 8-4. Frame Assembly - Front Right View ...................................................8-6

Figure 8-5. Frame Assembly - Rear View .............................................................8-7

Figure 8-6. engine Assembly ................................................................................8-9

Figure 8-7. Blower Assembly ..............................................................................8-11

Figure 8-8. Pump Assembly ................................................................................8-12

Figure 8-9. Chemical Pump Assembly ................................................................8-13

Boxxer 318 Owner’s Manual: iv

Figure 8-10. Heat exchanger Assembly..............................................................8-14

Figure 8-11. Silencer Assembly Figure 8-12. Water Box Assembly

...........................................................................8-15

.......................................................................8-16

Figure 8-13. Dash Assembly - Front ...................................................................8-18

Figure 8-14. Dash Assembly - Back ....................................................................8-19

Figure 8-15. Hi-PSI Manifold Assembly ..............................................................8-21

Figure 8-16. By-Pass Valve Assembly

................................................................8-23

Figure 8-17. Idler Pulley Assembly......................................................................8-24

Figure 8-18. exhaust Assembly ..........................................................................8-25

Figure 8-19. electrical Panel Assembly...............................................................8-26

Figure 8-20. 50 Gallon universal Recovery Tank Assembly ...............................8-27

Figure 8-21. 70 Gallon universal Recovery Tank Assembly ...............................8-29

Figure 8-22. Cover, Single Vac. - 70 Gallon uRT Assembly ...............................8-31

Figure 8-23. Vacuum Relief Valve Assembly ......................................................8-32

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. 50 Gallon uRT for 85 RMT Assembly .............................................8-38

Figure 8-29. Boxxer 318 on 85 RMT w/ 70 uRT Assembly - Right View ............8-40

Figure 8-30. Boxxer 318 on 85 RMT w/ 70 uRT Assembly - left View ...............8-41

Figure 8-31. 70 Gallon uRT for 85 RMT Assembly .............................................8-43

Figure 8-32. 85 Gallon Rotomolded Tank Assembly - Front View .......................8-45

Figure 8-33. 85 Gallon Rotomolded Tank Assembly - Back View .......................8-46

Figure 8-34. Dump and Vacuum Bracket Assembly ............................................8-48

Figure 8-35. Chemical Jug Tray Assembly..........................................................8-49

v: Boxxer 318 Owner’s Manual

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.

The heat of the engine and blower exhausts is transferred to the high

pressure water in the nned tube heat

exchanger of the system. Finally, the chemical is injected into the

pressurized water stream and the heated solution is delivered to the cleaning tool.

The solution is recovered by the vacuum generated by the blower and is collected in the recovery tank for proper disposal.

It is the purpose of this manual to help the technician properly understand, maintain and service the truckmount. By following these guidelines carefully, you can expect years of reliable operation.

This section contains the following helpful information:

Contact Information



Warnings, Cautions, and Notices



Responsibilities



Machine Specications



Spare Parts lists  High Altitude Operation



local Water Precautions 

1-1: General Information

COntaCt InfOrMatIOn

If you have any questions regarding the operation, maintenance or repair of this machine, please contact your local distributor.

To nd 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 E-mail addresses

Monday-Friday (425) 775-7275 Service

7:00 a.m. to 5:00 p.m. (425) 775-7276 Parts

Pacic Standard Time

(800) 426-4225 Parts /

Service FAX

techsupport@hydramaster.com

partssupport@hydramaster.com

Tech Support:

Parts Support:

When calling your distributor, be sure to reference the serial number and the date of purchase.

fOr YOUr rEfErEnCE:

Serial number: _______________________________________________ Date of Purchase:_____________________________________________ Purchased from (Distributor): __________________________________

General Information: 1-2

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.

1-3: General Information

During the operation of the truckmount many components are in motion. Never touch any part of the truckmount that is in motion. Serious injury may result.

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

The operation of this truckmount can produce noise levels exceeding 85 decibels to a distance of 10 feet. The Occupational Safety and Health Administration (OSHA) recommends the use of hearing protective equipment if a person is exposed to an average of 85 decibels over an eight hour period. Check with local and state agencies concerning hearing conservation rules.

During the operation of the truckmount carbon monoxide and other toxic fumes are produced. Position the vehicle so that any fumes produced will be directed away from inhabited areas and any points of building entry (doors, windows, air conditioning units, fans, etc.). Do not occupy the vehicle while the truckmount is in operation. Serious injury may result.

During the operation of the truckmount chemicals known to the State of California to cause cancer, birth defects and other reproductive harm are produced by the engine exhaust.

Never operate the truckmount with a portable gas container inside the vehicle. Doing so

will increase the risk of re and explosion. Serious injury or death my result.

Transporting a vented fuel container that presently contains, or has ever contained in

the past, a ammable liquid is strictly forbidden by HydraMaster and by federal and state regulations. Doing so will increase the risk of re and explosion. Serious injury or death

may result.

General Information: 1-4

Never smoke in or around the truckmount. Doing so will increase the risk of re and

explosion. Serious injury or death may result.

During the operation of the truckmount the exhaust system will become extremely hot.

Keep all ammable materials away from the truckmount exhaust system. Failure to do so will increase the risk of re and explosion. Serious property damage may result.

Never operate the truckmount when the vehicle is tilted more than 10 degrees in any direction. Doing so will result in improper lubrication of the internal components, and will increase the risk serious component or engine damage.

Never perform cleaning operations when the truckmount engine is running at the IDle throttle position. Failure to do so will increase the risk of serious component or engine damage.

Never operate the truckmount with the vehicle doors closed. Doing so results in extremely high temperatures inside the vehicle and will lead to serious component or engine damage.

Never use concentrated acids or solvents (including d-limonene) in the truckmount water system or chemical system. use of these products will cause serious component damage.

Never operate the truckmount with a water hardness reading measuring 3.0 grains per gallon or higher. using reading than 3.0 grains per gallon will cause scale to build up inside the truckmount water system. Scale build up causes serious component damage. Test all water prior to use and use water softening equipment if necessary.

1-5: General Information

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 oor that can easily be damaged. Before drilling holes in the oor of the vehicle, inspect the underside of the

vehicle for critical components. Failure to do so may result in damage to the vehicle.

General Information: 1-6

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. Payload capacity information is available through the auto dealer, the manufacturer’s web site, and is also located on the door pillar of the driver’s side door.

Purchase a heavy duty Group 24 battery for this truckmount. This is normally available from the installation dealer.

Prior to dropping your van off at the distributor for the truckmount to be installed, have a

spray-on bed liner applied to the oor such as Rhino Lining® or Line-X®.

Prior to operating the truckmount read this manual in its entirety and familiarize yourself with the information contained here. Special attention should 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 proper operation and maintenance of the truckmount.

Any modication of the truckmount may void the warranty.

the Distributor’s responsibility

acceptance of Shipment

Before accepting the truckmount, check the following:

The truckmount should be free from any damage during shipping. Do not sign the

•

delivery receipt until you have closely inspected the truckmount and noted any damage on the delivery receipt. Hidden damage may be present even if the box looks okay. It is recommended that the box be opened before signing for the shipment.

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

•

1-7: General Information

Installation responsibilities

ensure proper payload capacity. It is the distributor’s responsibility to verify that the • equipment package does not exceed the vehicle capacity.

Ensure installation of a safe fuel tap system and through-oor ttings as provided by

•

HydraMaster.

Proper placement of the truckmount, recovery tank, fresh water tank, and accessories

•

in the vehicle and securing them with bolts and back up plates. The distributor should verify that the owner is in agreement with the layout.

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.

Start and run the truckmount and check that all systems function properly.

•

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

ensure timely return of the document package.•

General Information: 1-8

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.•

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

Freezing damage and how to avoid it. This includes explaining proper freeze guarding • procedures.

How to do basic troubleshooting of the truckmount.

•

Hard water damage and how to avoid it. This includes how to determine if hard water • exists in your area and the installation and use of water softening systems.

The truckmount’s warranty and warranty procedures.

•

1-9: General Information

MaCHInE SPECIfICatIOnS

Overall Dimensions 24.0" W x 36" D x 31" H Weight 570 lbs. engine- Briggs and

Stratton Vanguard 18 HP

Vacuum Blower- Tuthill 3006 Competitor Plus Sl (Dual Splash lubrication)

Pump- HydraPump II Oil Type Synthetic 15W-50

Operating Pressure 0 - 1,000 psi Chemical System Heating System Finned Tube Heat exchanger Standard equipment High Pressure Hose 1/4" High Temperature lined/

Optional equipment Recovery Tank 70 gallon MaxAir universal

Oil Type Synthetic 5W-30

Capacity Approx. 1 1/2 quarts (48 oz.)

when changing oil and lter

engine rpm 3,150 rpm @ 14" Hg Oil Type Pneulube or other ISO 100

rating

Gear end Capacity Approx. 7.0 oz. Drive end Capacity Approx. 5.0 oz. Blower rpm 3,150 rpm @ 14" Hg

Capacity Approx. 8.0 oz. Pump Rate 3.5 gallons per minute Pump rpm 1,750 rpm

last Step Chemical Injection

Vinyl Cover - 100 ft.

Vacuum Hose 2" Vacuum Hose- 100 ft.

1-1/2" Wand Whip line- 10 ft.

Recovery Tank 50 gallon MaxAir universal

Tank

Cleaning Wand Stainless Steel S-bend

Replaceable Grip

Rebuildable Solution Valve Chemical Jug 5 gallon Battery Box Van Decal Van Installation Kit Operation Manual

Tank Fresh Water Tank 85 gallon Rotomolded Tank Automatic Pump Out (APO) Dura-Flow APO

General Information: 1-10

Spare partS LiSt

part No. Description Qty

Engine and Drive Train Components 000-106-016 Plug, Spark 2 000-049-049 Filter, Fuel 1 000-049-014 Filter, Oil 1 000-049-012 Filter, Air 1 000-010-125 Belt, 9440HD 1 000-152-011 Coupler Element 1

Electrical Components 000-056-010 Fuse, 25A 2 000-157-040 Switch, 20 Amp Rocker 2 000-157-022 Switch, Relay, 12V 2

Hydraulic Components 000-052-050 Quick Connect, 440 Male 2 000-052-051 Quick Connect, 440 Female 2 000-052-052 Quick Connect, 660 Male 1 000-052-053 Quick Connect, 660 Female 1 000-046-010 Diaphragm, Chemical Pump 1 000-169-186 Valve, 100 psi, Last Step Chemical 1 000-180-006 Orice, 0.061 dia. 1 000-180-004 Orice, 0.033 dia. 1 000-074-007 Gauge, High psi (0-1,500) 1 000-049-023 Screen, Garden Hose 1 000-078-273 Kit, By-Pass Valve Repair w/Tapered

Handle

Miscellaneous 000-087-006 HydraMaster-Recommended Spray

Lubricant (part number is for a quantity of 1 can)

1-11: General Information

1 ea

HIgH altItUDE OPEratIOn

elevation plays a key role in how the truckmount will operate. Operation at high altitude (above 5,000 ft.) may require a high-altitude carburetor jet. use of this jet at high altitude will improve power, reduce fuel consumption and help reduce excessive carbon build-up in the exhaust and heat exchanger systems.

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.

infonow.net/locator/.

lOCal WatEr PrECaUtIOnS

The quality of water varies greatly. Many areas have an excess of minerals in the water which results in what is commonly called “hard water.” These minerals tend to adhere to the insides of heater coils and other parts of the machines causing damage and a loss of

cleaning effectiveness. This inuences the reliability and efciency of equipment in direct

proportion to the level of hardness.

Hard Water advisory

HydraMaster recognizes that any hard water deposits which might occur within the water system of our truckmounts is a serious problem. The precision technology of truckmount heat exchanger systems is intolerant of any foreign material. Hard water deposits will ultimately decrease the performance of the system and are expected to seriously lower the reliability of the machine.

To validate a machine’s warranty, HydraMaster requires that all machines operating in

designated “Hard Water Areas” (3.0 grains or more per gallon) be tted with a water

softening system, or a properly installed magnetic-type descaler must be used and maintained. Periodic descaling or acid-rinsing alone is not adequate in these areas. HydraMaster does not recommend any particular type or brand; however, the relative effectiveness of some types of magnetic descalers or softeners may require additional periodic use of descaling agents.

HydraMaster also recommends, in the strongest possible terms, that machines in all areas

be tted with a water softening system for improved operation and reliability.

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

General Information: 1-12

Hard Water area Map

The hard water map, shown in Figure 1-1, denes hard water areas in the continental

United States which compromise uid related components such as hoses, ttings, heaters,

pumps, valves and water-cooled engines. For other countries, hard water area maps can be obtained from geological societies.

Hard Water Map of Mainland United Statesfigure 1-1.

The map shown in Figure 1-1 is provided for general reference only. Water

hardness in your geographical location should be conrmed by testing.

Water Softener

Cleaning efciency 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.

Failure to use a water softener in these areas will invalidate the machine’s warranty. Referring to the hard water area map shown Figure 1-1, determine the quality of water in your area and take immediate action if the water hardness exceeds 3.0 grains per gallon.

The relatively low cost of a water softener service is more than made up for by an increased

life of machine parts, reduced chemical costs and continued cleaning efciency. The

water softener will also increase the effectiveness of the cleaning chemicals, therefore less chemical will be needed.

1-13: General Information

Contact a water softener distributor in your area for information on the rental of a simple water treatment unit to carry in your truck. Be sure to charge the water softener in accordance with the capability of the softener.

For example: If the softener will treat 900 gallons of water and the machine uses an average of 30 gallons/hour, for an average of 5 hours a day, this equals 150 gallons per day). In 6 days the machine would use 900 gallons of water. Therefore, the softener would need to be charged every 6 working days for maximum softening.

Waste Water Disposal advisory

There are laws in most communities prohibiting the dumping of recovered “gray” water from carpet cleaning in any place but a sanitary treatment system.

The cleaning rinse water, recovered into your unit’s vacuum tank, contains materials such as detergents, and must be safely processed before entering streams, rivers and reservoirs.

In most cases, an acceptable method of waste water disposal is to discharge into a

municipal sewage treatment system after rst ltering out solid material such as carpet ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV dump, etc. Permission should rst be obtained from any concerned party or agency.

One disposal method which usually complies with the law is to accumulate the waste water and haul it to an appropriate dump site. 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.

HydraMaster makes an APO System which can be ordered with new equipment or installed later.

When properly congured, the systems will continuously monitor the level of waste water and pump it out simultaneously with the cleaning operation. The hidden benet of this

process is that the technician does not have to stop his/her cleaning to empty the recovery tank.

IN ACCORDANCe WITH ePA, STATe AND lOCAl lAWS, DO NOT DISPOSe OF WASTe WATeR INTO GuTTeRS, STORM DRAINS, STReAMS, ReSeRVOIRS, eTC.

The penalties for non-compliance can be serious. Always check local laws and regulations to be sure you are in compliance.

General Information: 1-14

2 - Cleaning and Chemicals

your HydraMaster truckmount has been engineered using the latest and most sophisticated

technology available to produce the nest carpet cleaning results possible. Despite this,

it remains only a tool of the carpet cleaning trade and can produce only as a good a job as the person operating it.

HydraMaster strongly recommends attending an Institute of Inspection, Cleaning

and Restoration Certication (IICRC) approved school as soon as possible and to

always 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



Overwetting



Streaking



PrECaUtIOnS

The 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 buildup of scale and hard water deposits in your truckmount.

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

Increased demand for a neutralizing rinse results in the need for special care when using these acid based chemicals in your truckmount The negative side of these products is the corrosive effects the acid can have on metals, including

ttings, 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 products that have obviously caused failures.

2-1: Chemicals and Cleaning

PrEParIng tHE CarPEt fOr ExtraCtIOn

Pre-Vacuum the Carpet

Whether you instruct the customer to pre-vacuum or you offer it as part of your service, proper vacuuming will make your job easier with superior end results. The more time spent removing loose particulate soil, the easier it will be to remove the oily soil stuck to

the bers.

Pretreat the Carpet

This process of applying trafc 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 to

rinsing, you allow the product to dissolve and emulsify the oily, sticky binders holding the

soil to the ber. This will allow more soil to be removed in one or two cleaning passes and

help prevent over-wetting. Remember the solution coming out of your cleaning tool is only in contact with the carpet

ber for a few seconds. 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.

rInSE anD rECOVEr

Whether you are using a wand, RDM™ or an RX-20™, you should clean an area approximately 3 ft. x 3 ft. with the solution valve open then immediately go over that area with vacuum only to remove any excess moisture.

Olen ber is becoming more popular, particularly in commercial installations. The process mentioned above can leave excessive residual moisture because olen bers will not absorb any of the cleaning solution. You must only apply solution

during the backward 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 follow this procedure will cause solution to ow to the back of

the carpet along with some of the soil. This, along with any soil imbedded in the

backing, will be wicked to the surface of the bers as the carpet dries.

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

Chemicals and Cleaning: 2-2

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.

1. Clogged vacuum blower lter or vacuum tank lid not sealing properly.2. Vacuum tank drain valve left partially open.3. Obstructed, cut or kinked vacuum hoses.4. Obstructed vacuum hoses while cleaning a heavily foam-saturated carpet (it is 5. recommended to use a crystal type defoamer distributed evenly over the carpet).

StrEakIng

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

Possible reasons of streaking may include:

Clogged or improperly angled spray nozzles.

1. Spray nozzles that overlap, concentrating the solution.2. A partially clogged vacuum head.3. Inconsistent solution temperature.4.

2-3: Chemicals and Cleaning

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 owing]. This gives the

wand a second chance to pick up the solution on the carpet. If you do not run a dry pass, the carpet can take longer to dry, and, possibly, the pad under

the carpet can become saturated. Be aware of the carpet seams; try to use strokes that are parallel with the seam. Avoid

pulling the want across the seam. every stroke can peel the seam connection and pull

the carpet off the oor.

Also, tilt the wand handle down [head up] to move the tool forward, and away from you,

on the carpet. This means less pull on the carpet and less work for you.

Chemicals and Cleaning: 2-4

2-5: Chemicals and Cleaning

Chemicals and Cleaning: 2-6

rotary tool: rx-20

Rotary tools are easier to move on the carpet, but harder to control at rst. 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’ front pockets, with the tool resting at on the oor. Take your time in adjusting the tool’s height; make sure the head of the tool is at with the oor while you are holding the handle. Relax your posture; the more difcult it is to hold the tool’s head at on the oor surface, the more quickly you will tire.

While the tool is running, control the left and right movements of the tool by tilting the head to the front and back, and lifting the handles up and pushing the handles down. The tool can be driven to the forward and backward by tilting the head of the unit to the left and right. The head must be turning to use the self driving feature of the tool, and only requires

a slight bit of pressure to handles to get the head to move the tool across the oor.

As with the wand, drying times will be improved if you run a dry pass between wet passes.

Hold down the solution trigger and move the unit left or right across the oor 3 or 4 ft, then immediately back across the same pass, without the solution owing, to make the dry

pass. Make the next pass half-overlapping the previous pass.

Use the RX-20 in very heavily trafcked areas or if it has been a long time since the carpet

has been cleaned. Beware of the seam edges of carpets and transition edges between

oor surfaces. Use extreme caution when cleaning these areas.

Sometimes it is necessary to use an edge tool or wand to run the perimeter of the room

on in difcult-to-reach areas where the circular head of the rotary units will not reach.

2-7: Chemicals and Cleaning

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. The water will only just spray the top layer of the furniture and the vacuum will pull the dirty water back into the tool.

If you nd it necessary to do a dry pass, keep strokes short to limit the amount of water

that comes into contact with the fabric surface.

Chemicals and Cleaning: 2-8

Part #163-012

3 - System Operation

Start-UP PrOCEDUrE

Perform all daily and periodic maintenance as specied in Section 1. 4 of this Owner’s Manual. Connect a garden hose to supply water to the truckmount. If used, turn the “PuMP-IN” 2. switch to the “ON” position.

The water box must be full prior to starting the truckmount.

Connect the cleaning tool to the length of hose required to perform the cleaning 3. job. Turn the key to “ON”. Pull the choke and start the truckmount with the throttle cable

4. fully depressed (“IDle” position.) After the engine starts, push the choke in and allow the truckmount to run in “IDle” 5. for 2 - 3 minutes to warm up. Pull the throttle cable to full extension and twist the handle clockwise to lock.

6. Set the temperature to the desired level on the “TeMPeRATuRe” knob.7. If used, turn the “AuTO PuMP-OuT” switch to the “ON” position.8.

throttle

Choke

location of throttle, Choke, Optional Pump-In Switch and Water Boxfigure 3-1.

Optional

Pump-In Switch

Water Box

3-1: System Operation

Vacuum gauge

Pressure gauge

Blower lube

Port

Optional auto

Pump-Out Switch

temperature knob

Chemical Selection Valve

Chemical Metering Control knob

System Operation: 3-2

Pressure regulator

front View of Boxxer 318 Consolefigure 3-2.

Adjust the “PReSSuRe ReGulATOR” to the desired cleaning pressure level.9.

Suggested Settings:a.

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 10. from the system.

With the truckmount running at full throttle, block off the vacuum intake to the

recovery tank. The vacuum gauge should read 12”-14” Hg. This will assist in priming the chemical system.

Allow the chemical to ow through the chemical meter at full ow for 30

seconds. Turn the “CHeMICAl SeleCTION VAlVe” to “ON.” The restriction can now be c. removed from the vacuum inlet.

While spraying solution from the cleaning tool adjust the chemical ow by turning

the “CHeMICAl MeTeRING CONTROl KNOB”.

Begin cleaning.11.

Never perform cleaning operations when the truckmount engine is running at the IDle throttle position. Failure to do so will increase the risk of serious component or engine damage.

3-3: System Operation

SHUt DOWn PrOCEDUrE

Flush clean water through the chemical system for 10 seconds. Turn the “CHeMICAl 1. SeleCTION VAlVe” to “OFF.” Cool the truckmount down by turning the “TeMPeRATuRe CONTROl” dial to the 2. lowest position (counter-clockwise). Spray the cleaning wand into the vacuum hose

for 3 - 5 minutes. The chemical is now ushed from the truckmount, hoses and

cleaning tool. Remove the vacuum hose.

3. lubricate the blower to prevent it from rusting internally.4.

Allow the unit to run for a few minutes with the vacuum hose disconnected in a. order to remove moisture from the blower. Cap off the inlet(s) to the vacuum tank.

Spray a HydraMaster-recommended spray lubricant into the “BlOWeR luBe c. 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 d. down.

If freeze guarding is necessary perform the procedure at this time. See

5. page 4-10, the Freeze Guarding section in this Owner’s Manual. Return the engine throttle to the “IDle” position.6. Turn the key to “OFF.”7. Drain the water box using the valve.8. Drain the vacuum tank in an appropriate location.9.

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

Perform daily maintenance as specied in Section

10. 4 of this Owner’s Manual.

System Operation: 3-4

4 - Machine Maintenance

To avoid costly repairs and downtime, it is imperative to develop and practice good maintenance procedures. These procedures fall into daily, weekly, monthly and quarterly increments and are outlined in the following paragraphs. All maintenance must be

performed by qualied service personnel.

A maintenance log is provided in the Owner’s Guide.

may be required to be furnished to HydraMaster before a warranty claim is honored.

It is recommended that the log be afxed to the vehicle door near the truckmount for

convenience and to serve as a maintenance reminder. This section describes how to properly maintain the truckmount in the following areas:

Operational Maintenance



Overall Machine Maintenance



High Pressure Pump Maintenance



Vacuum System Maintenance



Descaling Procedure (Required)



Freeze Guarding



this log must be maintained and

4-1: Machine Maintenance

OPEratIOnal MaIntEnanCE

Daily 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 lters.• Inspect and clean the orices and lters.•

Inspect and clean the garden hose screen.• 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 lters for tears, holes, etc. Repair or replace as needed.

•

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 chang. Secure as needed.•

Flush the water and chemical systems with solution of equal parts white vinegar and • 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 high ambient •

temperatures.) Change oil lter every other oil change.

Monthly Maintenance

Check the engine air lter. 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 excessive carbon • buildup is visible. Check the coupler element (rubber insert) for cracks or wear. Replace as necessary.

• Change the blower oil after rst 100 hours of use.•

Machine Maintenance: 4-2

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. 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” duties should be performed.

after each job

Check the recovery tank and the recovery tank lters. Empty and clean as necessary.

Daily

Wipe the truckmount 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 as needed.• 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 chemical buildup.• Inspect the chemical feed line strainer and use solution of equal parts white vinegar • and water to remove any chemical buildup. Thoroughly clean the wand and inspect for clogged jets, debris in vacuum slot and

• leaking ttings at valve.

Thoroughly clean the vacuum and high pressure hoses including quick releases and

•

cuffs.

4-3: Machine 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 rear of the pump or between the “MIN” and “MAX” lines on the dipstick. 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. It may be necessary to replace the pump seals and check valves at 500 hours if the truckmount has been running in high ambient temperatures.

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

The pump should never be run dry. Running the pump dry will cause premature wear on the seals, packing and plungers. Running the pump dry for a prolonged period of time 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 truckmount. See page 4-10 of this section for freeze guarding information.

Service

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

Valve Maintenance (See Figure 4-1)

using a 22-mm wrench or socket, remove all six valve caps on the manifold of the 1. pump. examine each valve cap O-ring for cuts or distortions and replace if worn.2. using needle nose pliers, remove the suction and delivery check valves. The valve 3. assembly usually stays together when removing. If the valve comes apart, use the needle nose pliers or reverse pliers to remove the remaining parts. Inspect each suction and delivery check valve assembly for wear and pitting, and

4. replace 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 change of one pump.

figure 4-1. Servicing the Valves

4-5: Machine Maintenance

Replace old valves with new valves by placing the assembly in the valve chamber. 5.

Press down rmly on the top of the valve assembly. Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft-

6. lbs.

Removing and Replacing Pump Manifold

Remove the manifold of the pump by taking a 5mm Allen head wrench and removing

1. the eight head bolts.

With the pump rmly secured, take a medium sized at head screwdriver and apply

2. 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 pistons. Keep the manifold properly aligned with the pistons to prevent damage to the seals and pistons. When replacing the manifold, turn the crankshaft of pump until the top of the pistons

3. are closely aligned. lubricate the pistons and cylinders with grease and evenly press

the manifold toward crankcase until ush.

Seals and V-Packing Maintenance

Remove the manifold as described above. It is possible that the seal and brass

1. retainer ring assembly will stay on the piston or will remain in the manifold when removing it. Carefully remove the brass retainer ring/seal stack. Remove the low-pressure seal

2. using needle nose pliers. Discard the old seal.

Remove the outer O-ring by taking a small at head screwdriver and working it

3. under the O-ring. Simply roll off the old O-ring and discard. The old V-packing stack can be taken apart by hand and discarded.

Seals and V-Packing Reassembly

Generously lubricate parts with grease when reassembling. examine all brass 1. components for any damage or water residue build-up. Clean or replace as needed. Insert a new low pressure seal by working it in by hand.

2. Install the new outer O-ring by simply starting on one side and working it into the 3. groove.

Stack the new V-packing in the correct order and rmly press the assembly into the

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

5. pressing it into place. Re-install the manifold onto the pump as previously described.

Machine Maintenance: 4-6

Plunger Maintenance

Remove the manifold as described above. Remove the packing retainers if they 1. remain on the pistons after removing the manifold. Remove the nut and washer on the end of the piston using a 13mm wrench or

2. socket. Slide the ceramic plunger and the remaining washer from the piston guide. Inspect

3. the ceramic piston, O-ring and washers for wear. Replace if necessary.

Plunger Re-assembly

Generously grease the piston guide. Replace the O-ring making sure it does not

1. twist or roll. Slide the lower washer and ceramic bushing onto the piston guide.

2. Place a small amount of lOCTITe 243™ on the piston guide threads. Replace the 3. old washer and thread the nut onto the piston guide. Torque to 4.5 ft-lbs.

Servicing the Crankcase

While the manifold and plungers are removed, rotate the crankshaft by hand. Closely

1. examine the crankcase oil seals for drying, cracking or leaking. Consult the local HydraMaster distributor if crankcase servicing is necessary.

4-7: Machine Maintenance

VaCUUM SYStEM MaIntEnanCE

The vacuum pump in this machine is commonly referred to as a “rotary positive displacement blower” or “blower” for short. The performance and life of the truckmount is greatly dependent on the care and proper maintenance it receives. Review the blower’s owner’s manual, which has been included, for a better understanding of this piece of machinery.

To protect the blower from overloading and damaging itself, a vacuum relief system is installed on the vacuum tank. When the vacuum tank inlet is completely sealed off, a maximum of 14” Hg will be attained.

Solid objects entering the blower will cause serious damage to the internal components of the blower. extreme caution should be used when the truckmount is being run for test purposes with the inlet to the blower open to the atmosphere.

Foam passing through the blower can lead to serious problems with the truckmount. It is important to keep the vacuum tank free of foam. The tank is protected from

overowing by a oat 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 truckmount.

lubricate the blower to prevent it from rusting internally by:

Allowing the unit to run for a few minutes with the vacuum hose disconnected in 1. order to remove moisture from the blower. Capping off the inlet(s) to the vacuum tank.

2. Spraying a HydraMaster-recommended spray lubricant into the “BlOWeR luBe 3. 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 4. down.

Periodically

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

Machine Maintenance: 4-8

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.

To descale the system, add an appropriate descaler chemical to the water box. Circulate it through the system. let it stand. Flush and repeat as necessary. Clean all screens and strainers, and check them frequently following descaling.

If using TM DeScaler™ through the ow meter, make sure to run clean water through the ow meter after this procedure.

To descale using the recirculation kit (P/N 000-078-058), start with an empty water box.

Fill a third of the water box with TM DeScaler. Follow the recommendations on the

TM DeScaler label for proportions. Verify that the oat is not lying horizontal, but oats below. Attach the recirculation tting provided in the kit to the garden hose quick connect

2. (see Figure 4-2) and this combination to the front of the truckmount.

Attach one section of the solution hose to the outgoing solution tting on the front

of the truckmount and the other end to the garden hose and recirculation tting

combination that is attached to the front of the truckmount. Additional hoses may be attached inline if descaling of hoses is needed. Start the truckmount and allow it to run for 3 - 5 minutes. Do not leave the TM

4. DeScaler solution in the system. Flush the system with clean water and turn the truckmount OFF.

figure 4-2. recirculation fitting

4-9: Machine Maintenance

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. Do not store in open or unlabeled containers. Keep out of reach of children and animals.

freeze guard Procedure

With the truckmount turned off and the incoming water line disconnected, open 1. the water box drain valve on the front of the truckmount. Allow the system to fully drain. Add 2 gallons of 50/50 antifreeze and water mix to the water box.

Attach a section of solution hose to the outgoing solution tting on the front of the 3.

machine. Attach the opposite end to the recirculation tting. (If more sections of

hose are to be freeze guarded attach those inline.) Start the truckmount and allow it to run for 2 to 3 minutes. This will distribute antifreeze

4. solution throughout the truckmount. Remove the chemical feed line from the chemical jug. Turn the selector valve to

5. “PRIMe.” This will vacuum the chemical remaining in the lines to the recovery tank.

If using the recirculation kit, skip ahead to Step 8.

Remove the quick connect tting from the garden hose. Attach the quick connect to

6. the machine. using a vacuum hose attached to the recovery tank, vacuum the water out of the quick connect. This will freeze guard the feed line to the water box. Remove the quick connect from the truckmount.

8. Spray the antifreeze and water mix out of the truckmount and into a container to reclaim the solution. Run the truckmount until it stops.

The truckmount is now freeze guarded. Remember to ush antifreeze from the

9. system prior to carpet cleaning. See the following procedure.

Machine Maintenance: 4-10

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.1. Attach the incoming water source to the front of the truckmount.2. Start the truckmount.3. Spray the solution through the hoses and wands into a sealable container until all 4. signs of antifreeze are gone.

Freeze Protection of the Pump-In System

Drain the fresh water tank.

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

3. the hose.

The next time the truckmount is used it may take a few minutes before the water

box begins to ll.

4-11: Machine Maintenance

tEnSIOnIng tHE PUMP DrIVE BElt

Remove the Boxxer 318 grill (P/N 000-100-170) to gain access to the idler pulley.1. loosen but 2. do not remove the ½”-13 x 2 ¼” long bolt (P/N 000-143-041) on the idler pulley. See Figure 8-17. Remove the right cover (P/N 000-041-452) of the machine to gain access to the

3. tensioning screw. Adjust the tension of the belt by turning the ¼”-20 x 4” long screw

4. (P/N 000-143-376). After the proper belt tension is achieved, tighten the ½” bolt on the idler pulley.5.

ensure there is no contact between idler assembly (including belt) and no other part of the truckmount. Contact between the parts could result in damage to the truckmount.

Replace the right cover and grill.

Machine Maintenance: 4-12

5 - Water and

Chemical 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 OPEratIOn

Fresh water is brought through the front of the truckmount into the water box. The level of

water in the box is maintained by the use of a oat valve. The water is then gravity fed to

the pump where it is pressurized. Next, the pressurized water enters the bypass valve. This valve allows manual adjustment

of the pressure level. When the valve at the wand is closed, nearly all of the water in the system is recirculated to the water box at this point. When solution is being used at the wand the necessary amount of high pressure water passes through the bypass valve and to the heat exchanger.

The pressurized water then travels to the exhaust heat exchanger. In the nned tube heat

exchanger, the temperature of the water is raised to the selected cleaning temperature. The heat necessary to do this is provided by both the engine and blower exhausts. The

heated water nally travels to the high pressure manifold.

The high pressure manifold houses both the temperature sensor for the heat control

system and a high temperature shutdown switch. There is an orice located in the manifold, referred to as a recirculation (or primary) orice which allows a small amount

of high pressure, high temperature water to pass back to the water box. This prevents excessive pressure building up in the heat exchanger when the wand valve is closed and no solution is exiting the truckmount.

The water that is being called for by the wand then exits the manifold and passes through a check valve. 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. After being pressurized, the chemical travels through the metering valve and is injected into the high pressure stream. This solution then exits the front of the truckmount and is delivered to the cleaning tool.

5-1: Water and Chemical System

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.

3. Water travels to the exhaust heat exchanger. In this nned tube heat exchanger the temperature of the water is raised to

cleaning temperature. the heated water travels to the high pressure manifold.

annotated Water, Chemical and Solution flow Diagram - View 1 of 2figure 5-1.

5-2: Water and Chemical System

7027 Rev. A

4. the high pressure manifold houses both the

temperature sensor for the heat control system and a

high temperature shutdown switch.

5. Water to the wand exits the manifold and passes through a check valve.

6. Water joins the chemical

where the solution is created.

annotated Water, Chemical and Solution flow Diagram - View 1 of 2figure 5-2.

5-3: Water and Chemical System

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 ow meter. After being pressurized,

the chemical travels through the metering valve and is injected into the high pressure stream. this solution

annotated Chemical flow Diagram figure 5-3.

then exits the front of the truckmount and is delivered to the cleaning tool.

Water and Chemical System: 5-4

7027 Rev. A

Exhaust flow Diagramfigure 5-4.

5-5: Water and Chemical 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 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.

6-1: electrical System

GND

TB1

-5

-3

TB1

HIGH TEMP

SOLENOID

V-4

GND

D-4

TB2

-3

TB2

-4

GND

CONTROLLER

SENSOR

SW-5

THERMOSTAT

TS-1

12V BATTERY

PS-1

GND

STATOR

VR-1

BATT

CARB

SOLENOID

V-1

SOL-1

VOLT. REG.

SOLENOID

STARTER

B&S ENGINE

MTR-1

YEL

ENGINE KILL LUG

PUMP-IN PUMP

FRESH WATER

PUMP IN SWITCH

SW-2

ONOFF

PMP-1

FRESH WATER PUMP-IN (OPTIONAL)

GND

87a

APO PUMP

RELAY

CR-5

GND

AUTOMATIC PUMP OUT

SWITCH

OFF

SW-3

AUTOMATIC PUMP OUT (OPTIONAL)

FS-3

AUTOMATIC PUMP OUT

FLOAT SWITCH

PMP-3

APO PUMP

TB1

-9

TB2-6TB3

-5

TB3

-1

TB3

-6

TB2

-3

N/O

TR7TR5TR6

TR3 TR4

TC-1

TR1 TR2

CONTROLLER

TEMPERATURE

TR8

ENGINE SHUTDOWN

RELAY

CR-1

87a

TB1

-4

GND

-4

TB1

GND

3 2

IGNITION SWITCH

SW-1

TB1

-1 FUSE

25A

F-1

FUSE

25A

F-2

PMP-2

FUEL PUMP

-2

TB1-3TB1

TB1

-6 GND

-2

TB1

HIGH TEMP SHUTDOWN

SW-4

WATER BOX

FLOAT SWITCH

TB1

-2

HOUR METER

HI-1

GND

-4

TB1

-2

TB1

-6 GND

-2

TB1

FS-1

FS-2

VACUUM TANK HIGH

WATER FLOAT

SWITCH

GND

L-2

GND

HIGH TEMP SOLENOID LIGHT

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

RENAMED SEVERAL COMPONENTS TO CREATE CONSISTANCY ACROSS DRAWINGS.

LRIP

4/2/2008

BRT

LOL

BRT

ELECTRICAL SCHEMATIC - BOXXER 318

10/15/2007

UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES

BREAK ALL SHARP EDGES 0.005-.015

TOLERANCES

.X= .1

.XX= .03

.XXX= .010

ANGULAR= 1°

11015 47th Avenue West,

Mukilteo, Washington 98275

PROPRIETARY INFORMATION

APPVD

CHECKED

DRAWN

125

MACHINE

FINISH

BRT CIR BRT

Electrical figure 6-1.

Schematic

7026 Rev. A

electrical System: 6-2

87a

TR7TR5TR6

TR3 TR4

TC-1

TR1 TR2

CONTROLLER

TEMPERATURE

TR8

13 (PUR/WHT)

27 (BLK)

28 (RED)

29 (BLU)

1 2 3 4 5 6

25 (BLK)

26 (WHT)

HIGH TEMP

SOLENOID LIGHT

(GRN) L-2

3 (YEL)

3(YEL) TO ENGINE STOP LUG (SHEET 1)

30 (WHT)

9 (WHT) TO ENGINE GROUND LUG - 14 GA (SHEET 1)

35 (WHT/BLK) TO PUMP IN PUMP PMP-1 (SHEET 1)

32 (WHT/GRN) TO FUEL PUMP PMP-2 (SHEET 1)

18 (BLK/WHT) TO HOUR METER- HI-1 (SHEET 3)

TO CONTROLLER SENSOR- SW-5 (SHEET 3) 26(WHT) 20 GA

TO CONTROLLER SENSOR- SW-5 (SHEET 3) 25(BLK) 20 GA

TO HARNESS P5-D (SHEET 1) 13(PUR/WHT)

TO THERMOSTAT

TS-1

(SHEET 3)

(RED) 20 GA

23(PNK) TO HIGH TEMP SHTDN SWITCH SW-4 (SHEET 3)

23 (PNK)

19 (BLK)

19(BLK) TO LOW WATER ENGINE STOP FS1- 20 GA (SHEET 1)

37 (RED) TO FUEL PUMP PMP-2 (SHEET 1)

20 (BLK) TO LOW WATER ENGINE STOP FS1 - 20 GA (SHEET 1)

20 (BLK)

31 (GRY) TO PUMP IN SWITCH SW2 -#2 (SHEET 3)

FUSE FU-1

FUSE FU-2

34 (BRN) 14 GA TO APO SWITCH SW3- #3 (SHEET 3) 7 (ORG) TO SOL 1-BATT (SHEET 1)

(ORG)

B-10

24 (PNK) TO HIGH TEMP SHTDN SWITCH SW-4 (SHEET 3)

B-11

B-13

B-12

(BLK)

(RED) 20 GA

(BLK) 20 GA

22 (WHT/RED)

30 (WHT)

22 (WHT/RED)

B-9

(ORG)

17 (WHT/ORG) TO HOUR METER- HI-1 (SHEET 3)

ENGINE SHUTDOWN

RELAY

CR-1

TERMINAL BLOCK- TB-1

21 (WHT/RED)

33 (RED)

1 (RED) 16 GA TO CARB SOLENOID V-1 (SHEET 1)

38 (BLK) 16 GA TO SW1-2 (SHEET 3)

6 (ORG) TO SOL 1-BATT (SHEET 1)

35 (ORG) 16 GA. TO IGNITION SW1-1 (SHEET 3)

B-14

B-15

25 A

PROPRIETARY INFORMATION

View 1 of 3

7025 Rev. e

Wiring Diagram - figure 6-2.

6-3: electrical System

TO TB1-6 (SHEET 2) 17(WHT/ORG)

TO TB1-1 (SHEET 2) 18(BLK/WHT)

TO TR-7 29(BLU)

TO TR-5 28(RED)

TO TR-6 27(BLK)

THERMOSTAT

TS-1

HOUR METER

HI-1

TO HARNESS P5-F (SHEET 1) 14(BRN) 14 GA

TO INLINE FUSE F-2 (SHEET 2) 34(BRN)14 GA

AUTOMATIC PUMP OUT

SWITCH

SW-3

FRESH WATER PUMP IN

SWITCH

SW-2

TO TB1-3 (SHEET 2) 31(GRY)

TO PUMP IN PUMP-PMP1 (SHEET 1) 50(GRY)

4 3

2 1

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 (SHEET 1) 10(YEL)

IGNITION SWITCH

SW-1

23(PNK) TO CR-1 #86 (SHEET 2)

HIGH TEMP SHUTDOWN

SW-4

25 (BLK) - TO CONTROLLER TR-4 20 GA (SHEET 2)

26 (WHT) - TO CONTROLLER TR-3 20 GA (SHEET 2)

CONTROLLER

SENSOR

SW-5

HI-PSI MANIFOLD ASSEMBLY

B-7

B-4

B-3

24(PNK) TO TB1-2 (SHEET 2)

TO CONTROLLER

(SHEET 2)

36(WHT)

B-8

PROPRIETARY INFORMATION

Wiring figure 6-3.

Diagram - View 2 of 3

7025 Rev. e

electrical System: 6-4

7025 Rev. e

HIGH TEMP SOLENOID

V-4

BIO

STATOR

VR-1

BATT

CARB

SOLENOID

V-1

SOL-1

MTR-1

VOLT. REG.

SOLENOID

STARTER

B&S ENGINE

YEL

12 (RED)16 GA

ENGINE KILL LUG

2 (BLK)

(WHT)

(BLK)

88(WHT/BLU)

86(WHT/RED)

74(WHT) 14 GA

73(BRN) 14 GA

70(WHT) 14 GA

73(BRN) 14 GA

TB-3

(BRN)

(WHT)

B-6

B-5

71(WHT)

69(WHT) 14 GA

APO PUMP

PMP-3

WEATHERPACK

CONNECTOR

(BLK)

(RED)

69(BLK) 14 GA

FEMALE- J-9

87a

75(BLK) 14 GA

CR-2

APO PUMP RELAY

71(WHT)

FS-2

FLOAT SWITCH

VACUUM TANK

FS-3

(BLK)

(WHT)

AUTOMATIC PUMP OUT

FLOAT SWITCH

(BLK)

(WHT)

72(PUR/WHT)

68(BRN) 14 GA.

67(PUR/WHT)

84(WHT) 14 GA.

66(ORG/BLK)

65(ORG)

TB2 A B

C D E F

70(WHT) 14 GA 72(PUR/WHT)

RECOVERY TANK ASSEMBLY

MALE- P-9

AUTOMATIC PUMP OUT (OPTIONAL)

5 (RED) - 6 GA

4 (ORG)

11 (BLK) 6 GA

8 (RED) 6 GA

12V BATTERY

PS-1

ENGINE

GROUND

LUG

8 (RED) 6 GA

(WHT) 14 GA

(WHT)

B-2

6 (ORG) - 14 GA 7 (ORG) - 14 GA

15 (WHT) 14 GA

9 (WHT) 14 GA

13 (PUR/WHT)

14 (BRN) 14 GA.

4 (ORG)

P-4

J-4

P-3

J-3

P-2

J-2

P-1

J-1

(BLK)

35(WHT/BLK)

50(GRY)

32(WHT/GRN)

(BLK)

37(RED)

(WHT/BLK)

FRESH WATER PUMP IN (OPTIONAL)

(BLK)

PMP-1

PMP-2

FUEL PUMP

PUMP IN PUMP

(BLK) (BLK)

WATER BOX

FLOAT SWITCH

FS-1

WATER BOX ASSEMBLY

TO TB1-6 (SHEET 2) 35(WHT/BLK)

TO SW2 - #3 (SHEET 3) 50(GRY)

TO TB1-3 (SHEET 2) 37(RED)

TO TB1-4 (SHEET 2) 32(WHT/GRN)

TO TB1-1 - 20 GA (SHEET 2) 20(BLK)

TO CR1-#86 - 20 GA (SHEET 2) 19(BLK)

B-1

1 (RED) 1 (RED)1 (RED)

1 (RED) TO TB1-2 (16 GA) (SHEET 2)

2 (BLK) TO SW1-3 (16 GA) (SHEET 3)

3 (YEL)

3 (YEL) TO CR1-#87 (SHEET 2)

7 (ORG) - 14 GA TO INLINE FUSE F-2 (SHEET 2)

6 (ORG) - 14 GA TO INLINE FUSE F-1 (SHEET 2)

9 (WHT) 14 GA TO TB1-5 (SHEET 2) 10 (YEL) TO SW1-4 (16 GA) (SHEET 3)

12 (RED) TO SW1-6 16 GA (SHEET 3)

13 (PUR/WHT) TO CONTROLLER TR-8 (SHEET 2)

14 (BRN) TO SW3- #2 - 14 GA (SHEET 3)

10 (YEL)

P-5

J-5

16 (BRN) TO SW1-5 16 GA (SHEET 3)

16 (BRN) 16 GA

(RED)

HARNESS

(WHT)

HARNESS

Wiring Diagram - View 3 of 3figure 6-4.

6-5: electrical System

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

HEatIng SYStEM

1.0 truckmount overheats and shuts down

1.1 The orice or lter screen

Remove and inspect. Clean as necessary.

are restricted.

1.2 The low pressure dump solenoid is restricted.

1.3 The dump solenoid is faulty.

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 the solenoid and test for functionality. If the

solenoid is operable, refer to a qualied service

technician to test the temperature controller and sensor.

2.0 Unable to achieve normal cleaning solution temperature

2.1 Temperature control knob

Inspect the knob. Adjust if necessary.

is turned down.

2.2 The dump solenoid is faulty.

Inspect the solenoid and test for functionality. If the

solenoid is operable, refer to a qualied service

technician to test the temperature controller and sensor.

2.3 Excessive solution ow at tool.

2.4 The heat exchanger has

The cleaning tool jet is too large or worn. Inspect the jet. Replace if necessary.

Descale the system.

hard water scale buildup.

2.5 The heat exchanger has blockage on the exhaust

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

side.

2.6 The heat selector valve is

Move the heat selector valve to the “HOT” position.

in the wrong position.

Troubleshooting: 7-2

CHEMICal SYStEM

1.0 System will not prime

1.1 The check valves in

chemical pump are faulty.

1.2 The chemical pump

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

Remove and inspect. Replace as necessary.

diaphragm is faulty.

1.3 The check valve in high

pressure pump is faulty

Remove the valve and inspect. Clean or replace as

necessary. (piston which chemical pump is attached to).

1.4 The lter on feed line in

Inspect and clean. chemical jug is clogged.

1.5 The feed line from

Inspect and repair. chemical jug is loose, pinched or damaged.

1.6 The chemical selector valve is faulty.

Inspect the valve for leaks between ports. Replace as necessary.

2.0 Chemical ow is unstable or low

2.1 Air is in the lines. Check that all ttings and connections are tight and

in good condition. Repair or replace as necessary.

2.2 The lter screen in the

Inspect and clean. chemical jug is partially obstructed.

2.3 The chemical selector valve is faulty.

2.4 The chemical metering valve is faulty.

2.5 The high pressure check valve is faulty.

Inspect the valve for leaks between ports. Replace as necessary.

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

3.0 Chemical is present in water box

3.1 The chemical pump

diaphragm is faulty.

3.2 The high pressure check

valve is faulty.

Remove and inspect the chemical pump diaphragm. Replace as necessary.

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

7-3: Troubleshooting

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. The amperage output from an automobile will damage the charging system of the truckmount.

1.3 The main fuse is blown. Check the main fuse.

If the fuse is blown, inspect the electrical system for worn or shorted wires. Repair or replace as necessary.

1.4 The vacuum blower has seized.

Attempt to turn the coupler by hand. If it will not turn refer to the Vacuum System Troubleshooting Section.

1.5 The ignition switch is faulty.

1.6 The starter solenoid is faulty.

Test to see if there is power both to and from the switch. Refer to the electrical Section.

Test to see if there is power to solenoid with ignition in “Start” position. Refer to electrical Section.

1.7 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.

1.8 None of the above. Refer to a qualied service technician for further

troubleshooting.

2.0 turns over but will not start. there is no spark. (To check for spark, refer to engine manual.)

2.1 The recovery tank is full. Drain the tank.

2.2 The recovery tank oat is

Inspect the oat. Repair or replace as necessary.

faulty.

2.3 The engine ignition system in faulty.

Troubleshooting: 7-4

Refer to a qualied service technician for further

troubleshooting.

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 carburetor.

Test 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.

3.2 The carburetor solenoid is faulty.

Test for power to the solenoid. Refer to electrical Section.

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

3.3 The engine is ooded. Pull the throttle cable completely and crank until the

engine starts.

3.4 The spark plugs are worn

Inspect and replace as necessary.

or dirty.

3.5 None of the above. Refer to a qualied service technician for further

troubleshooting.

4.0 Will not come up to normal operating rpm note: engine should be adjusted to run at 3,150 rpm under a vacuum load of 14” hg.

4.1 The throttle linkage is out of adjustment.

excessive load on the

4.2 engine.

excessive back pressure

4.3 on the engine exhaust.

Inspect for broken or loose linkage. Repair or replace as necessary.

Inspect and clean the recovery tank lters.

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

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

7-5: Troubleshooting

5.0 runs rough at high speed

5.1 The spark plug(s) are faulty.

5.2 The spark plug wire(s) are faulty.

5.3 Inadequate fuel supply to the carburetor.

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

Inspect the wires and connectors for damage or loose connections. Repair or replace as necessary.

Check if the fuel pump is mounted in a vertical position near the fuel source. Correct if necessary.

Check for blockage in the lter. Repair or replace as

necessary. If operating altitudes have changed, contact your

distributor to have the engine carburetor jets checked.

6.0 runs rich. (Black smoke)

6.1 The air lter is dirty. Inspect and replace as necessary.

6.2 The choke is partially

Inspect and adjust or repair as necessary.

closed. excessive fuel to the

6.3

Check to see if the proper fuel pump is installed.

carburetor.

If operating altitudes have changed, contact your distributor to have the engine carburetor jets checked.

7.0 Engine overheats

7.1 Poor ventilation in the van. Open all the van doors.

Install a roof vent in the van.

Remove any dividers or other objects impeding airow

around the truckmount.

low oil level. Check the level and ll as necessary.

7.2

7.3 The engine rpm is too high.

excessive back pressure

7.4 on the engine exhaust.

Troubleshooting: 7-6

Check the engine rpm. Adjust as necessary to run at 3,150 rpm under a vacuum load of 14” Hg.

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

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 the pump.

Test the pump output volume directly from the pump at normal running rpm. If the volume is below the

manufacturer’s specications, replace the seals and

inspect for defective valves.

1.3 The pump rpm is too low. Check for a loose pump belt. Adjust or replace as

necessary. Check the engine rpm and adjust as necessary to

3,150 rpm under a 14” Hg vacuum load.

1.4 The primary orice is missing or loose.

1.5 The primary and

secondary orices have

Remove and inspect. Tighten or replace as necessary.

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

been installed incorrectly.

1.6 The primary orice is worn.

Measure the orice size and replace as necessary.

Correct size is .033 in.

2.0 no pressure reading on gauge

2.1 The pump belt is broken. Inspect and replace if necessary.

2.2 The gauge is faulty. Replace the gauge.

3.0 the psi gauge reads normal; low pressure from wand

3.1 Restriction in the cleaning tool.

Inspect the tool jet(s) and clean or replace as necessary.

Inspect any lters in the cleaning tool and clean or

replace as necessary.

3.2 Faulty quick connect in the system.

3.3 Restriction in one of the solution hoses.

3.4 Hard water deposits

Inspect each quick connect and replace as necessary.

Remove the quick connects and inspect hoses. Clean or replace as necessary.

Descale the truckmount.

restricting the system.

7-7: Troubleshooting

4.0 Pressure pulsation

4.1 Air leak between the water box and pump.

4.2 The check valve(s) in the pump are faulty.

Check all the hoses and ttings for cuts, breaks,

cracks, etc. Repair as necessary. Remove each valve and inspect for correct

operation. See the Machine Maintenance Section.

5.0 Water box empty or lls slowly

5.1 Restriction in the water supply system.

5.2 The oat valve in the water box is faulty.

Inspect the supply system from the source through the incoming quick connect.

Disassemble and inspect the valve. Repair or replace as necessary.

6.0 The water box overows

6.1 The oat valve in the water box is faulty.

6.2 The oat has absorbed water and lost buoyancy.

6.3 The oat has come out of

Disassemble and inspect the valve. Repair or replace as necessary.

Detach the oat and check to see if it will oat to the

surface. Replace as necessary.

Adjust the oat as necessary.

adjustment.

Troubleshooting: 7-8

VaCUUM SYStEM

1.0 a weak vacuum at wand. the gauge reads normal.

1.1 Blockage in the hoses or wand tube

excessive length of

1.2 hose connected to the truckmount

2.0 a weak vacuum

2.1 Air leak somewhere in the vacuum system.

2.2 The vacuum blower is turning too slowly.

2.3 The vacuum gauge is defective.

Disconnect the hoses and check for an obstruction.

Do not attach excessive lengths of hose.

Check 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. Check the rpm of the engine. Adjust as necessary to

3,150 rpm under a 14” Hg vacuum load. Test the gauge and replace if necessary.

3.0 the vacuum gauge reads too high with no hoses attached

3.1 The lter in recovery tank

Remove and clean or replace as necessary.

is clogged.

3.2 The hose from recovery

Inspect and replace as necessary. tank to the vacuum blower is collapsed internally.

4.0 Excessive noise produced by the blower

4.1 The 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 qualied service technician.

4.2 The vacuum blower has

Refer to a qualied service technician.

internal damage.

7-9: Troubleshooting

5.0 the vacuum blower is locked and will not turn

5.1 Truckmount has been

inactive for a period of time and the blower was not properly lubricated

prior to nal shutdown.

Spray penetrating oil into the blower and let sit for at least 1 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.

Rust has possibly built up on the internal surfaces.

If unable to free up the blower in this manner, refer to

a qualied service technician.

5.2 There is internal damage

Refer to a qualied service technician.

to the blower.

6.0 Water in truckmount exhaust

6.1 The recovery tank has

Inspect the recovery tank. If full, drain the tank.

been lled with foam or overlled with water.

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.

6.2 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.

6.3 The heat exchanger is

Inspect and repair or replace as necessary.

leaking water.

Troubleshooting: 7-10

This section contains all the assemblies and parts lists associated with the Boxxer 318:

8 - Machine Assemblies and Parts list

Machine Assembly Parts lis  t Frame Assembly Parts lis  t engine Assembly Parts lis  t Blower Assembly Parts lis  t Pump Assembly Parts lis  t Chemical Pump Assembly Parts lis  t Heat exchanger Assembly Parts lis  t Silencer Assembly Parts lis  t Water Box Assembly Parts lis  t Dash Assembly Parts lis  t Hi-PSI Manifold Assembly Parts lis  t By-Pass Valve Assembly Parts lis  t Idler Pulley Assembly Parts lis  t

50 Gallon universal Recovery Tank Assembly Parts lis  t 70 Gallon universal Recovery Tank Assembly Parts lis  t Cover, Single Vac. - 70 Gallon uRT Assembly Parts lis  t Vacuum Relief Valve Assembly Parts lis  t Dura-Flow APO 90° Assembly Parts lis  t APO Connection Kit Assembly Parts lis  t Boxxer 318 on 85 RMT w/ 50 uRT Assembly Parts lis  t 50 Gallon uRT for 85 RMT Assembly Parts lis  t Boxxer 318 on 85 RMT w/ 70 uRT Assembly Parts lis  t 70 Gallon uRT for 85 RMT Assembly Parts lis  t 85 Gallon Rotomolded Tank Assembly Parts lis  t Dump and Vacuum Assembly Parts lis  t Chemical Jug Tray Assembly Parts lis  t

exhaust Assembly Parts lis  t electrical Panel Assembly Parts lis  t

Machine Hose Routing  s

8-1: Machine Assemblies and Parts lists

2 3 4 5 3 5 61 5 3

7010

Machine assembly - front left Viewfigure 8-1.

Machine Assemblies and Parts lists: 8-2

7345

rEVISIOnS

ltr rEVISIOn CODE DatE BY CHkD aPPVD

7010

Machine assembly - front right Viewfigure 8-2.

8-3: Machine Assemblies and Parts lists

Machine assembly Parts list

Item Part number Description Qty

1 - - - Assembly, Frame 1 2 000-041-451 Cover, Side - 19.900” x 14.316” 1 3 000-143-126 Screw, #10-24uNC x 0.50” lg. Hex Head 13 4 000-174-014 Washer, #10 lock 9

Item Part number Description Qty

5 000-174-001 Washer, #10 Flat 13 6 000-041-011 Cover, Top - Machine 1 7 000-041-452 Cover, Side - 17.250” x 14.316” 1

Machine Assemblies and Parts lists: 8-4

frame assembly - front left Viewfigure 8-3.

2623

18 2

26 13

WASHER, #10 S/S FLAT

25 2

SPACER, MACHINE RISING 4" x 35"

24 13

SCREW, #10-24UNC x 0.50" LG. HEX HEAD

23 4

SCREW, #10-24UNC x 0.50" LG. FLAT HEAD PHILLIPS

22 2

RIVET, AB4-3A ALUMINUM POP (1/8" x 1/4")

21 1

TRIMLOK, 3/8" x 1/8" RUBBER

20 1

PLATE, MACHINE SERIAL I.D.

19 1

HOSE, Ø 2.5" ID SILICONE X 14.5" LG.

18 1

FRAME WELDMENT- BOXXER 318

17 2

CLAMP, 2" CUSHION LOOP

16 2

CLAMP, 1" CUSHION LOOP

15 2

CLAMP, 1-1/4" s/s EDPM

14 1

CLAMP, 1-3/4" CUSHION LOOP VARIOUS

13 2

CLAMP, SIZE #44 HOSE

12 2

CAP, 2" X 3" FRAME END

11 1

BELT, #9430HD GATES AUTOMOTIVE

10 1

ASSEMBLY, IDLER PULLEY

9 1

ASSEMBLY, EXHAUST

8 1

ASSEMBLY, SILENCER

7011 Rev. B

8-5: Machine Assemblies and Parts lists

7011 Rev. B

2220

frame assembly - front right Viewfigure 8-4.

Machine Assemblies and Parts lists: 8-6

7011 Rev. B

frame assembly - rear Viewfigure 8-5.

8-7: Machine Assemblies and Parts lists

frame assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 - - - Assembly, Heat exchanger 1 2 - - - Assembly, engine 1 3 - - - Assembly, Blower 1 4 - - - Assembly, Water Box 1 5 - - - Assembly, Pump 1 6 - - - Assembly, Dash 1 7 - - - Assembly, electrical Panel 1 8 - - - Assembly, Silencer 1 9 - - - Assembly, exhaust 1 10 - - - Assembly, Idler Pulley 1 11 000-010-124 Belt, #9430hd 1 12 000-027-110 Cap, 2” X 3” Frame end 2 13 000-033-012 Clamp, Size #44 Hose 2

14 000-033-050 Clamp, 1-3/4” Cushion loop 1 15 000-033-052 Clamp, 1-1/4” S/S eDPM 2 16 000-033-057 Clamp, 1” Cushion loop 2 17 000-033-067 Clamp, 2” Cushion loop 2 18 000-055-188 Frame Weldment- Boxxer 318 1 19 000-068-122 Hose, Ø 2.5” I.D. Silicone X 14.5” lg. 1 20 000-105-012 Plate, Machine Serial I.D. 1 21 000-131-131 Trimlok, 3/8” X 1/8” Rubber 1 22 000-140-001 Rivet, Ab4-3a Aluminum Pop (1/8” X 1/4”) 2 23 000-143-114 Screw, #10-24uNC X 0.50” lg. Flat Head Phillips 4 24 000-143-126 Screw, #10-24uNC X 0.50” lg. Hex Head 13 25 000-154-156 Spacer, Machine Rising 4” X 35” 2 26 000-174-001 Washer, #10 S/S Flat 13

Machine Assemblies and Parts lists: 8-8

3 2 7

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ITEM 10 WAS 143-015; RENUMBERED BOM.

ECR #1465

12/14/2009

L.O.L.

C.I.R.

ECRB

11 4

WASHER, 5/16" FLAT

S. STEEL

000-174-049

- - -

10 4

SCREW, 5/16"-18UNC x 1.75" LG. HEX HEAD GRD. 8 Z/P

STEEL

000-143-375

- - -

9 1

PULLEY, AK47-H

STEEL

000-109-040

- - -

8 2

KEY, 1/4" x 1-1/2" LG.

8630 STEEL 000-077-010

- - -

7 1

HOSE, 1/4" FUEL

RUBBER

000-068-660

- - -

6 1

HOSE, DRAIN

VARIOUS

000-068-219

- - -

5 1

ENGINE, B&S 18HP

VARIOUS

000-047-028

- - -

4 1

COUPLER, 40 SERIES

VARIOUS

000-039-054

- - -

3 1

CLAMP, 1" CUSHION LOOP w/ 7/16 MOUNT HOLE VARIOUS

000-033-117

- - -

7013 Rev. A

Engine assemblyfigure 8-6.

8-9: Machine Assemblies and Parts lists

Engine assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-020-025 Bushing, H X 1” 1 2 000-033-046 Clamp, 1/2 Wide X 1/2 Tube 1 3 000-033-117 Clamp, 1” Cushion loop w/ 7/16 Mount Hole 1 4 000-039-054 Coupler, 40 Series 1 5 000-047-028 engine, B&S 18hp 1 6 000-068-219 Hose, Drain 1

7 000-068-660 Hose, 1/4” Fuel 1 8 000-077-010 Key, 1/4” X 1-1/2” lg. 2 9 000-109-040 Pulley, Ak47-H 1 10 000-143-375 Screw, 5/16”-18uNC X 1.75” lg. Hex Head Grd. 8 Z/P 4 11 000-174-049 Washer, 5/16” Flat 4

Machine Assemblies and Parts lists: 8-10

8 7 6 5

3 2

APPVDCHKDByDATeCODeReVISIONlTR

rEVISIOnS

9 4 SCReW, 3/8-16uNC x 1" HeX HeAD - GRADe 8 STeel 000-143-018 - - - 8 4 WASHeR, 5/16" FlAT STeel 000-174-004 - - - 7 4 WASHeR, BlOWeR FeeT STeel 000-174-068 4763 6 1 ADAPTeR, 2.5" NPT TO 2.5" OD TuBe STeel 000-001-140 7050 5 2 HOSe, DRAIN VARIOuS 000-068-219 - - - 4 4 elBOW, 3/8" BRASS x 45° STReeT BRASS 000-052-083 - - -

7014

Blower assemblyfigure 8-7.

Blower assembly Parts list

Item Part number Description Qty

1 000-052-106 Insert, 1/8” NPT X 5/32” Barb X 90° 2 2 000-001-141 Adapter, 2.5” NPT X 2.5” O.D.Tube - elbow 1 3 000-111-134 Blower, 3006 Competitor 1 4 000-052-083 elbow, 3/8” NPT Street X 45° 4 5 000-068-219 Hose, Drain 2 6 000-001-140 Adapter, 2.5” NPT To 2.5” O.D.Tube 1 7 000-174-068 Washer, Blower Feet 4 8 000-174-004 Washer, 5/16” Flat 4 9 000-143-018 Screw, 3/8-16uNC X 1” Hex Head - Grade 8 4

8-11: Machine Assemblies and Parts lists

Pump assemblyfigure 8-8.

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ITEM 1 WAS P/N 111-142 (INCORRECTLY); ADDED ITEM17;

LRIP

2/27/2008

L.O.L.

B.R.T. B.R.T.

ITEM 17 WAS 174-049; RENUMBERED BOM.

ECR # 1443

12/14/2009

L.O.L.

C.I.R.

ECRB

17 4

WASHER, 5/16" FLAT

STEEL

000-174-004

- - -

16 4

SCREW, 5/16"-18UNC x 3/4" Lg.

S. STEEL

000-143-012

- - -

15 1

PUMP, HYDRAPUMP II

VARIOUS

000-111-042

- - -

14 1

ASSEMBLY - PUMP, CHEMICAL

VARIOUS

000-111-035

4416

13 1

PULLEY, AK74

STEEL

000-109-116

- - -

12 1

O-RING, ADAPTER - CHEMICAL PUMP

RUBBER

000-097-057

- - -

11 1

O-RING, Ø0.551 I.D. x Ø0.070 WALL

EPDM

000-097-002

- - -

10 1

HOSE, DRAIN

VARIOUS

000-068-219

- - -

Pump assembly Parts list

7016 Rev. B

Item Part number Description Qty

1 000-001-096 Adapter, Chem. Pump To Comet 1 2 000-020-013 Bushing, H X 24mm 1 3 000-052-083 elbow, 3/8” NPT Street X 45° 1 4 000-052-084 elbow, 1/8” NPT Street 1 5 000-052-086 elbow, 3/8” NPT Street 1 6 000-052-099 Insert, #26 (1/8” NPT X 3/8” Barb) 1 7 000-052-128 Nipple,3/8 MPT X 3/8SAe Flare 1 8 000-052-129 Insert #812, 1/2NPT X 3/4 Hose 1 9 000-052-531 elbow, 1/8” NPT X 1/4” SAe 2 10 000-068-219 Hose, Drain 1

12 000-097-057 O-Ring, Adapter - Chemical Pump 1

11 000-097-002 O-Ring, Ø0.551 I.D. X Ø0.070 Wall 1

13 000-109-116 Pulley, Ak74 1 14 000-111-035 Assembly - Pump, Chemical 1 15 000-111-042 Pump, Hydrapump Ii 1 16 000-143-012 Screw, 5/16”-18uNC X 3/4” lg. 4 17 000-174-004 Washer, 5/16” Flat 4

Machine Assemblies and Parts lists: 8-12

REVISIONS

LTR

REVISION

P CODE DATE BY

CHKD

APPVD

10 2 O-RING, CHEM. PUMP VALVE VITON-PARKER 2-1 RUBBER 000-097-054 - - -

9 6 SOC. HD. MACH. SCR., 5/16"-24UNF x 1.50" LG. S. STEEL 000-143-152 - - - 8 2 VALVE, CHECK, - LAST STEP CHEMICAL INJECTI VARIOIUS 000-169-155

OUTLET

INLET

DEL ITEMS 2 & 9; ADDED NOTES;

A - - -

L.O.L.

ADDED ITEM #10 (097-054)

08/15/2000

W.B. W.B.

M.A.

4416 Rev. B

Chemical Pump assemblyfigure 8-9.

Chemical Pump assembly Parts list

Item Part number Description Qty

1 000-106-110 Plug, Check Valve - Chemical Pump 2 2 000-064-015 Cover, Chemical Pump 1 3 000-111-030 Body, Chemical Pump 1 4 000-105-071 Mid Plate, Chemical Pump 1 5 000-046-010 Diaphragm, Chemical Pump 1 6 000-097-055 O-Ring, Chemical Pump Midplate AN Size -227 Viton 1 7 000-097-056 O-Ring, Check Valve Plug - Chemical Pump 2 8 000-169-155 Valve, Check - last Step Chemical Injection 2 9 000-143-152 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

8-13: Machine Assemblies and Parts lists

7012

rEVISIOnS

lTR ReVISION CODe DATe By CHKD APPVD

3 2

Heat Exchanger assemblyfigure 8-10.

Heat Exchanger assembly Parts list

Item Part number Description Qty

1 000-038-072 Heat exchanger, 4 Row 1 2 000-013-073 Box, Outlet Plenum - Weldment 1 3 000-143-126 Screw, #10-24uNC x 0.50” lg Hex Head 4 4 000-174-001 Washer, #10 Flat 4 5 000-013-072 Box, Inlet Plenum - Weldment 1

7 000-052-766 elbow, 3/8 MNPT x 3/8 JIC 2

6 000-140-021 Rivet, 1/4” Blind x 0.50” lg. 32

Machine Assemblies and Parts lists: 8-14

7075 Rev. A

125

FINISH

uNleSS OTHeRWISe NOTeD

BReAK All SHARP eDGeS 0.005-.015

PROPRIeTARy INFORMATION

11015 47th Avenue West,

DIMeNSIONS ARe IN INCHeS

Mukilteo, Washington 98275

TOleRANCeS

.X= .1

.XX= .03

MACHINe

2 3

ITeM 2 WAS 068-780; lRIP 2/12/2008 l.O.l. B.R.T. B.R.T.A

APPVDCHKDByDATeCODeReVISIONlTR

rEVISIOnS

ItEM nO. QtY. DESCrIPtIOn MatErIal Part nO. DWg. nO.

3 4 ClAMP, SIZe #44 HOSe S. STeel 000-033-012 - - - 2 2 HOSe, Ø 2.5" ID SIlICONe X 2.5" lG. SIlICONe 000-068-104 6318 1 1 SIleNCeR, Ø2.5" OD INleT/OuTleT STeel 000-093-108 7047

Silencer assemblyfigure 8-11.

Silencer assembly Parts list

Item Part number Description Qty

1 000-093-108 Silencer, Ø2.5” O.D. Inlet/Outlet 1

3 000-033-012 Clamp, Size #44 Hose 4

2 000-068-104 Hose, Ø 2.5” I.D. Silicone x 2.5” lg. 2

8-15: Machine Assemblies and Parts lists

18 18

22 6

SCREW, #8 x 1/2" LG. PAN HEAD

S. STEEL

21 1

COVER, 6"

PLASTIC

20 1

SWITCH, WITH PROTECTOR

VARIOUS

19 4

NUT, 1"-14UNS BRASS

UNS#36000

18 1

VALVE, FLOAT, WATER BOX

VARIOUS

17 3

WASHER, 3/8" FLAT

S. STEEL

16 1

CLAMP,SIZE 4 MINI HOSE

S. STEEL

15 1

HOSE,3/8"CLR W/BRAID

VARIOUS

14 1

BULKHEAD, 3/8" FPT x 3/8" FPT

BRASS

13 1

ELBOW, 3/8" NPT STREET

BRASS

12 1

INSERT, #26 (1/8" NPT x 3/8" BARB)

BRASS

11 1

VALVE, 165 F THERMAL

VARIOUS

10 1

TEE, 3/8" NPT MALE STREET

BRASS

9 1

TEE,3/8" MALE BRANCH

BRASS

8 2

INSERT, #68 (3/8" NPT x 1/2" BARB)

BRASS

7 1

NIPPLE, 3/8" NPT x 1/4" M SAE

BRASS

6 2

WASHER, 1.5" O.D. x 1.073" I.D. x 0.075" THK.

S.STEEL

5 1

INSERT, 3/4" BARB X STR

BRASS

4 2

O-RING, 1/2" BULK HEAD

BUNA-N

3 3

SCREW, 3/8"-16UNC x 3/4" LG. HEX HEAD

S. STEEL

2 1

TEE, 1/4" PLASTIC

PLASTIC

1 1

TANK, POLY WATER BOX - MODIFIED

POLYETHYLENE

ITEM NO.

QTY.

DESCRIPTION

MATERIAL

REVISIONS

LTR

REVISION

CODE

DATE

DEL ITEM 4 FLOAT, WATER BOX ASSY & ASSOC.

ITEMS. ADD ITEM 18. ITEM 19 WAS 000-094-097,

DWG. NO. - - -, QTY. 5. ITEM 6 WAS QTY. 3.

1463 4/22/2009

ITEM 1 WAS PART NO. SEE NOTES. DELETE NOTE

1463 4/29/2009

PROPRIETARY INFORMATION

11015 47th Avenue West,

Mukilteo, Washington 98275

BREAK ALL SHARP EDGES 0.005-.015

UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES

Water Box assemblyfigure 8-12.

7015 Rev. B

Machine Assemblies and Parts lists: 8-16

Water Box assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-159-001 Tank, Poly Water Box - Modied 1

2 000-052-156 Tee, 1/4” Plastic 1 3 000-143-017-1 Screw, 3/8”-16uNC X 3/4” lg. Hex Head 3 4 000-097-041 O-Ring, 1/2” Bulk Head 2 5 000-052-661 Insert, 3/4” Barb X Straight 1 6 000-174-063 Washer, 1.5” O.D. X 1.073” I.D. X 0.075” Thk. 2 7 000-052-662 Nipple, 3/8” NPT X 1/4” M SAe 1 8 000-052-099 Insert, #26 (1/8” NPT X 3/8” Barb) 1 9 000-052-447 Tee, 3/8” NPT Male Branch 1 10 000-052-023 Tee, 3/8” NPT Male Street 1 11 000-169-027 Valve, 165 F Thermal 1

12 000-052-105 Insert, #68 (3/8” NPT X 1/2” Barb) 2 13 000-052-086 elbow, 3/8” NPT Street 1 14 000-052-660 Bulkhead, 3/8” FPT X 3/8” FPT 1 15 000-068-326 Hose, 3/8”Clr w/Braid 1 16 000-033-003 Clamp, Size 4 Mini Hose 1 17 000-174-032 Washer, 3/8” Flat 3 18 000-169-218 Valve, Float, Water Box 1 19 000-094-097 Nut, 1”-14uNS Brass 4 20 000-157-0801 Switch, with Protector 1 21 000-041-005 Cover, 6” 1 22 000-143-314 Screw, #8 X 1/2” lg. Pan Head 6

8-17: Machine Assemblies and Parts lists

35 18

29 29

5116

LTR

REVISION

ADDED ITEM 19; ITEM 24 WAS QTY. 6;

ITEM 27 WAS 074-018; ITEM 47 WAS 169- 186; RENUMBERED BOM.

64 1

LABEL, DASH WARNING

63 1

LABEL, TEMERATURE

62 1

LABEL, RIGHT DASH

61 1

LABEL, LEFT DASH

60 1

ASSEMBLY, BYPASS VALVE

59 1

ASSEMBLY, HI PSI MANIFOLD

58 1

WASHER,1/2" ID x 3/4" OD x 0.010" THK

57 1

WASHER, 21/32" I.D. x 27/32" O.D. NYLON

56 1

WASHER, 7/16" SAE FLAT

55 2

WASHER, 3/8" FLAT

54 1

WASHER, 5/8" ID x 7/8" OD x 0.010" THK

53 1

WASHER, 7/16" LOCK

52 2

WASHER, #10 LOCK

51 4

WASHER, 5/8" FLAT

50 3

WASHER, 1/2" FLAT

49 4

WASHER, 1/4" FLAT

48 8

WASHER, #10 S/S FLAT

47 1

VALVE, CHECK 80 PSI - LAST STEP CHEMICAL BRASS

46 1

VALVE, CHEMICAL METERING

45 1

VALVE, 3/8" NPT FULL PORT BALL

44 1

VALVE, 3-WAY BALL O-RING STYLE

43 2

SWITCH, 20 AMP ROCKER

42 1

SWITCH, IGNITION - B & S

41 2

SPRING, 1/4" BELLEVILLE WASHER

40 1

THERMOSTAT, POTENTIOMETER

39 2

SCREW, 1/4"-28UNF x 0.50" LG. HEX HEAD

38 4

SCREW, #10-24UNC x 1.25" HEX HEAD

37 2

SCREW, #10-24UNC x 3/8" LG. HEX HEAD

36 2

SCREW, #10-24UNC x 0.50" LG. HEX HEAD

35 1

REGULATOR, HI PSI SNUBBER

34 1

TRIMLOK, 3/8" x 1/8" RUBBER

33 1

PANEL, GRILL

32 1

PANEL, DASH

31 1

NUT, 7/16"-24UNF - 2 WAY METERING VALVE

30 2

NUT, 7/16"-20UNF HEX JAM

29 4

NUT, 5MM NYLOCK

28 4

NUT, 1/4"-20UNC NYLOCK

27 1

METER, RECTANGULAR HOUR w/o BEZEL

26 1

METER, CHEMICAL FLOW RAW

25 1

GAUGE, 30" HG. VACUUM - HYDRAMASTER

24 1

GAUGE, PRESSURE 0 -1500 PSI

23 1

KNOB, TEMPERATURE ADJUSTMENT

22 1

ELBOW, 1/4" SAE x 1/4" NPT BRASS

21 1

ELBOW, 1/8" NPT x 1/4" SAE BRASS

20 1

NIPPLE, 1/4" SAE x 1/8" NPT

19 1

NIPPLE, 3/8" M JIC x 3/8" NPT

18 1

NIPPLE, 1/4" SAE x 1/4" NPT

17 1

CUP, GRAVITY FEED OIL BLOWER LUBE PORT

16 2

INSERT, #68 (3/8" NPT x 1/2" BARB)

15 1

INSERT, #66 (3/8" NPT x 3/8" BARB)

14 3

INSERT, #26 (1/8" NPT x 3/8" BARB)

13 1

INSERT, #F23 (1/8" FPT x 3/16" BARB)

12 1

TEE, 1/4" NPT BRANCH M-F-F

11 1

ELBOW, 1/4" FPT x FPT

10 1

ELBOW, 1/8" NPT STREET

9 1

NIPPLE, 3/8" NPT x 1/4" NPT HEX

8 1

NIPPLE, 1/8" NPT HEX

7 1

QUICK CONNECT, 660 3/8" BRASS W/ EPDM O-RING

6 1

QUICK CONNECT, 440 FEMALE w/ EPDM O-RING

Dash assembly - frontfigure 8-13.

7018 Rev. C

Machine Assemblies and Parts lists: 8-18

35 18

29 29

5116

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ADDED ITEM 19; ITEM 24 WAS QTY. 6;

LRIP

04/02/2008

L.O.L.

B.R.T. B.R.T.

ITEM 27 WAS 074-018; ITEM 47 WAS 169- 186; RENUMBERED BOM.

ECR #919

ECR #1504

12/14/2009

L.O.L.

C.I.R.

ECRB

64 1

LABEL, DASH WARNING

VINYL

SEE NOTES

7074

63 1

LABEL, TEMERATURE

VINYL

SEE NOTES

7072

62 1

LABEL, RIGHT DASH

VINYL

SEE NOTES

7071

61 1

LABEL, LEFT DASH

VINYL

SEE NOTES

7070

60 1

ASSEMBLY, BYPASS VALVE

VARIOUS

SEE NOTES

7078

59 1

ASSEMBLY, HI PSI MANIFOLD

VARIOUS

SEE NOTES

7019

58 1

WASHER,1/2" ID x 3/4" OD x 0.010" THK

S. STEEL

000-174-062

- - -

57 1

WASHER, 21/32" I.D. x 27/32" O.D. NYLON

NYLON

000-174-058

- - -

56 1

WASHER, 7/16" SAE FLAT

STEEL

000-174-038

- - -

55 2

WASHER, 3/8" FLAT

S. STEEL

000-174-032

- - -

54 1

WASHER, 5/8" ID x 7/8" OD x 0.010" THK

S. STEEL

000-174-030

- - -

53 1

WASHER, 7/16" LOCK

STEEL

000-174-022

- - -

52 2

WASHER, #10 LOCK

S.STEEL

000-174-014

- - -

51 4

WASHER, 5/8" FLAT

STEEL

000-174-008

- - -

50 3

WASHER, 1/2" FLAT

STEEL

000-174-007

- - -

49 4

WASHER, 1/4" FLAT

S. STEEL

000-174-003

- - -

48 8

WASHER, #10 S/S FLAT

S. STEEL

000-174-001

- - -

47 1

VALVE, CHECK 80 PSI - LAST STEP CHEMICAL BRASS

000-169-219

- - -

46 1

VALVE, CHEMICAL METERING

S. STEEL

000-169-160

- - -

45 1

VALVE, 3/8" NPT FULL PORT BALL

BRASS

000-169-064

- - -

44 1

VALVE, 3-WAY BALL O-RING STYLE

BRASS

000-169-0171

- - -

43 2

SWITCH, 20 AMP ROCKER

VARIOUS

000-157-040

- - -

42 1

SWITCH, IGNITION - B & S

VARIOUS

000-157-017

- - -

41 2

SPRING, 1/4" BELLEVILLE WASHER

301 S. STEEL

000-155-053

- - -

40 1

THERMOSTAT, POTENTIOMETER

VARIOUS

000-149-560

- - -

39 2

SCREW, 1/4"-28UNF x 0.50" LG. HEX HEAD

S. STEEL

000-143-542

- - -

38 4

SCREW, #10-24UNC x 1.25" HEX HEAD

S. STEEL

000-143-171

- - -

37 2

SCREW, #10-24UNC x 3/8" LG. HEX HEAD

S. STEEL

000-143-166

- - -

36 2

SCREW, #10-24UNC x 0.50" LG. HEX HEAD

S. STEEL

000-143-126

- - -

35 1

REGULATOR, HI PSI SNUBBER

BRASS

000-135-052

- - -

34 1

TRIMLOK, 3/8" x 1/8" RUBBER

RUBBER

000-131-131

- - -

33 1

PANEL, GRILL

ALUMINUM

000-100-170

7021

32 1

PANEL, DASH

STEEL

000-100-169

7017

31 1

NUT, 7/16"-24UNF - 2 WAY METERING VALVE

S. STEEL

000-094-098

- - -

30 2

NUT, 7/16"-20UNF HEX JAM

S. STEEL

000-094-092

- - -

29 4

NUT, 5MM NYLOCK

S. STEEL

000-094-070

- - -

28 4

NUT, 1/4"-20UNC NYLOCK

VARIOUS

000-094-009

- - -

27 1

METER, RECTANGULAR HOUR w/o BEZEL

PLASIC

000-074-170

- - -

26 1

METER, CHEMICAL FLOW RAW

VARIOUS

000-074-030

- - -

25 1

GAUGE, 30" HG. VACUUM - HYDRAMASTER

VARIOUS

000-074-017

- - -

24 1

GAUGE, PRESSURE 0 -1500 PSI

VARIOUS

000-074-007

- - -

23 1

KNOB, TEMPERATURE ADJUSTMENT

VARIOUS

000-061-056

- - -

22 1

ELBOW, 1/4" SAE x 1/4" NPT BRASS

000-052-532

- - -

21 1

ELBOW, 1/8" NPT x 1/4" SAE BRASS

000-052-531

- - -

20 1

NIPPLE, 1/4" SAE x 1/8" NPT

BRASS

000-052-530

- - -

19 1

NIPPLE, 3/8" M JIC x 3/8" NPT

BRASS

000-052-528

- - -

18 1

NIPPLE, 1/4" SAE x 1/4" NPT

BRASS

000-052-527

- - -

17 1

CUP, GRAVITY FEED OIL BLOWER LUBE PORT

S.STEEL

000-052-272

- - -

16 2

INSERT, #68 (3/8" NPT x 1/2" BARB)

BRASS

000-052-105

- - -

15 1

INSERT, #66 (3/8" NPT x 3/8" BARB)

BRASS

000-052-104

- - -

14 3

INSERT, #26 (1/8" NPT x 3/8" BARB)

BRASS

000-052-099

- - -

13 1

INSERT, #F23 (1/8" FPT x 3/16" BARB)

BRASS

000-052-096

- - -

12 1

TEE, 1/4" NPT BRANCH M-F-F

BRASS

000-052-090

- - -

11 1

ELBOW, 1/4" FPT x FPT

BRASS

000-052-088

- - -

10 1

ELBOW, 1/8" NPT STREET

BRASS

000-052-084

- - -

9 1

NIPPLE, 3/8" NPT x 1/4" NPT HEX

BRASS

000-052-073

- - -

8 1

NIPPLE, 1/8" NPT HEX

BRASS

000-052-069

- - -

figure 8-14. Dash assembly - Back

7018 Rev. C

To order a spare thermostat (P/N 000-149-560), specify P/N 000-149-561.

8-19: Machine Assemblies and Parts lists

Dash assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 - - - Chemical Metering Valve - Knob Only 1 2 - - - Knob, 3-Way Ball Valve (Part Of 000-169-0171) 1 3 000-001-148 Adapter, 2.5" exhaust Turndown 1 4 000-025-003 Cable, Choke With Detent 1 5 000-025-020 Cable, Throttle locking 1 6 000-052-051 Quick Connect, 440 Female w/ ePDM O-Ring 1 7 000-052-052 Quick Connect, 660 3/8" Brass w/ ePDM O-Ring 1 8 000-052-069 Nipple, 1/8" NPT Hex 1 9 000-052-073 Nipple, 3/8" NPT X 1/4" NPT Hex 1 10 000-052-084 elbow, 1/8" NPT Street 1 11 000-052-088 elbow, 1/4" FPT X FPT 1 12 000-052-090 Tee, 1/4" NPT Branch M-F-F 1 13 000-052-096 Insert, #F23 (1/8" FPT X 3/16" Barb) 1 14 000-052-099 Insert, #26 (1/8" NPT X 3/8" Barb) 3 15 000-052-104 Insert, #66 (3/8" NPT X 3/8" Barb) 1 16 000-052-105 Insert, #68 (3/8" NPT X 1/2" Barb) 2

33 000-100-170 Panel, Grill 1 34 000-131-131 Trimlok, 3/8" X 1/8" Rubber 1 35 000-135-052 Regulator, Hi PSI Snubber 1 36 000-143-126 Screw, #10-24uNC X 0.50" lg. Hex Head 2 37 000-143-166 Screw, #10-24uNC X 3/8" lg. Hex Head 2 38 000-143-171 Screw, #10-24uNC X 1.25" Hex Head 4 39 000-143-542 Screw, 1/4"-28uNF X 0.50" lg. Hex Head 2 40 000-149-560 Thermostat, Potentiometer (see note on page 8-19) 1 41 000-155-053 Spring, 1/4" Belleville Washer 2 42 000-157-017 Switch, Ignition - B & S 1 43 000-157-040 Switch, 20 Amp Rocker 2 44 000-169-0171 Valve, 3-Way Ball O-Ring Style 1 45 000-169-064 Valve, 3/8" NPT Full Port Ball 1 46 000-169-160 Valve, Chemical Metering 1 47 000-169-219 Valve, Check 80 psi - last Step Chemical 1

48 000-174-001 Washer, #10 S/S Flat 8 17 000-052-272 Cup, Gravity Feed Oil Blower lube Port 1 18 000-052-527 Nipple, 1/4" SAe X 1/4" NPT 1 19 000-052-528 Nipple, 3/8" M Jic X 3/8" NPT 1 20 000-052-530 Nipple, 1/4" SAe X 1/8" NPT 1 21 000-052-531 elbow, 1/8" NPT X 1/4" SAe 1 22 000-052-532 elbow, 1/4" SAe X 1/4" NPT 1 23 000-061-056 Knob, Temperature Adjustment 1 24 000-074-007 Gauge, Pressure 0 -1,500 psi 1 25 000-074-017 Gauge, 30" Hg. Vacuum - HydraMaster 1 26 000-074-030 Meter, Chemical Flow Raw 1 27 000-074-170 Meter, Rectangular Hour w/O Bezel 1 28 000-094-009 Nut, 1/4"-20uNC Nylock 4 29 000-094-070 Nut, 5mm Nylock 4 30 000-094-092 Nut, 7/16"-20uNF Hex Jam 2 31 000-094-098 Nut, 7/16"-24uNF - 2 Way Metering Valve 1 32 000-100-169 Panel, Dash 1

Machine Assemblies and Parts lists: 8-20

49 000-174-003 Washer, 1/4" Flat 4

50 000-174-007 Washer, 1/2" Flat 3

51 000-174-008 Washer, 5/8" Flat 4

52 000-174-014 Washer, #10 lock 2

53 000-174-022 Washer, 7/16" lock 1

54 000-174-030 Washer, 5/8" I.D. X 7/8" O.D.X 0.010" Thk 1

55 000-174-032 Washer, 3/8" Flat 2

56 000-174-038 Washer, 7/16" SAe Flat 1

57 000-174-058 Washer, 21/32" I.D. X 27/32" O.D. Nylon 1

58 000-174-062 Washer,1/2" I.D. X 3/4" O.D. X 0.010" Thk 1

59 - - - Assembly, Hi PSI Manifold 1

60 - - - Assembly, By-pass Valve 1

61 - - - label, left Dash 1

62 - - - label, Right Dash 1

63 - - - label, Temperature 1

64 - - - label, Dash Warning 1

7019 Rev. A

5 6

3 4

14 12

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

CHANGED EXPLODED VIEW TO

ORIENT ITEMS 12 & 13 CORRECTLY.

LRIP

1/17/2008

BRT

LOL

BRT

Hi-PSI Manifold assemblyfigure 8-15.

8-21: Machine Assemblies and Parts lists

Hi-PSI Manifold assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-049-016 Filter, 1/4” NPT Replacement “y” 2 2 000-155-020 Spring, 0.540 O.D. x 0.041 Wire x 1.00 lg. 2

3 000-180-004 Orice, Set Screw 0.033” 1

4 000-180-006 Orice, Set Screw 0.061” 1

5 000-149-540 Sensor, RTD Compression Fitting Style 1 6 000-052-587 Compression, 3/16” x 1/4” NPT Thermocouple 1 7 000-106-007 Plug, 1/4” NPT Allen Head 1

8 000-090-010 Manifold, Hi PSI 1

9 000-106-111 Plug, 1/2” NPT Allen Head 2

10 000-149-027 Sensor, 285°F Nason - 3/8” NPT 1

11 000-052-023 Tee, 3/8” NPT Male Street 1

12 000-052-527 Nipple, 1/4” SAe x 1/4” NPT 2

13 000-052-423 Bushing, Modied Set Screw Orice 2

14 000-052-528 Nipple, 3/8” M JIC x 3/8” NPT 1

Machine Assemblies and Parts lists: 8-22

7078

rEVISIOnS

lTR ReVISION CODe DATe By CHKD APPVD

7 1 BRACKeT, ByPASS VAlVe MOuNTING S. STeel 000-015-515 3899 6 1 elBOW, 3/8" F x F BRASS BRASS 000-052-142 - - - 5 1 INSeRT, #68 (3/8" NPT x 1/2" BARB) BRASS 000-052-105 - - - 4 1 elBOW, 3/8" NPT STReeT BRASS 000-052-086 - - - 3 1 NIPPle, 3/8" NPT x 3/8" M PROPANe BRASS 000-052-128 - - - 2 2 PluG, 3/8" NPT AlleN HeAD BRASS 000-106-008 - - -

By-Pass Valve assemblyfigure 8-16.

By-Pass Valve assembly Parts list

Item Part number Description Qty

1 000-169-188 Valve, PA Press Reg Mod 1 2 000-106-008 Plug, 3/8” NPT Allen Head 2 3 000-052-128 Nipple, 3/8” NPT x 3/8” M Propane 1 4 000-052-086 elbow, 3/8” NPT Street 1 5 000-052-105 Insert, #68 (3/8” NPT x 1/2” Barb) 1 6 000-052-142 elbow, 3/8” F x F Brass 1 7 000-015-515 Bracket, By-pass Valve Mounting 1

8-23: Machine Assemblies and Parts lists

figure 8-17. Idler Pulley assembly

8 7 6 5

3 2

rEVISIOnS

ltr rEVISIOn CODE DatE BY CHkD aPPVD

7080

Item Part number Description Qty Item Part number Description Qty

1 000-109-093 Pulley, 3” OD x 1.85” Bore 1 2 000-154-049 Spacer, Pump Idler 1 3 000-094-119 Nut, 1/2-13uNC Zinc Plated Square 1

Idler Pulley assembly Parts list

6 000-174-003 Washer, 1/4” Flat 1 7 000-143-376 Screw, 1/4”-20uNC x 4” lg. S/S - Full Thread 1

8 000-143-041 Screw, 1/2”-13uNC x 2-1/4” lg. Hex Head 1 4 000-015-942 Bracket, Idler Tension 1 5 000-094-009 Nut, 1/4”-20uNC Nylock 1

Machine Assemblies and Parts lists: 8-24

9 000-174-012 Washer, 1/2 SAe H/D 1

7079

3 2

PROPRIeTARy INFORMATION

DIMeNSIONS ARe IN INCHeS

uNleSS OTHeRWISe NOTeD

11015 47th Avenue West,

BReAK All SHARP eDGeS 0.005-.015

aPPVDCHkDBYDatECODErEVISIOnltr

rEVISIOnS

ItEM nO. QtY. DESCrIPtIOn MatErIal Part nO. DWg. nO.

16 1 GASKeT, HAlF DONuT VARIOuS 000-057-212 - - - 15 1 TuBe, 1.5" OD eXHAuST W/ PORT S. STeel 000-125-096 7045 14 1 PluG, M18 x 1.5 S. STeel 000-106-120 6237 13 1 TuBe,1-3/8" OD x 1/8" WAll x 7/8" lG. STeel 000-125-128 4634 12 1 GASKeT, eXHAuST DONuT 1.50" VARIOuS 000-057-177 - - - 11 4 SCReW, 1/4"-20uNC x 0.75" lG. HeX HeAD S. STeel 000-143-001 - - - 10 4 WASHeR, 1/4" FlAT S. STeel 000-174-003 - - -

9 1 TuBe, lOWeR eXHAuST WelDMeNT S. STeel 000-125-227 7065 8 1 GASKeT, Ø2.5" x 3.5" BCD ReMFleX 000-057-209 7069 7 1 ADAPTeR, eXHAuST FlANGe to 1.5" F SlIP S. STeel 000-001-116 5612 6 1 ClAMP, 1-1/2" eXHAuST S. STeel 000-033-068 - - - 5 6 NuT, 5/16"-18uNC HeX 2 WAy lOCKING STeel 000-094-081 - - - 4 10 WASHeR, 5/16" FlAT S. STeel 000-174-049 - - - 3 4 SCReW, 5/16"-18uNC x 1.75" lG. HeX HeAD S. STeel 000-143-124 - - - 2 1 TuBe, uPPeR eXHAuST WelDMeNT S. STeel 000-125-228 7060 1 2 GASKeT, eXHAuST MANIFOlD - VANGuARD VARIOuS 000-057-010 - - -

5 8

Exhaust assemblyfigure 8-18.

Exhaust assembly Parts list

Item Part number Description Qty

1 000-057-010 Gasket, exhaust Manifold - Vanguard 2 2 000-125-228 Tube, upper exhaust Weldment 1 3 000-143-124 Screw, 5/16”-18uNC x 1.75” lg. Hex Head 4 4 000-174-049 Washer, 5/16” Flat 10 5 000-094-081 Nut, 5/16”-18uNC Hex 2 Way locking 6 6 000-033-068 Clamp, 1-1/2” exhaust 1 7 000-001-116 Adapter, exhaust Flange To 1.5” F Slip 1 8 000-057-209 Gasket, Ø2.5” x 3.5” BCD 1 9 000-125-227 Tube, lower exhaust Weldment 1 10 000-174-003 Washer, 1/4” Flat 4 11 000-143-001 Screw, 1/4”-20uNC x 0.75” lg. Hex Head 4 12 000-057-177 Gasket, exhaust Donut 1.50” 1 13 000-125-128 Tube,1-3/8” O.D. x 1/8” Wall x 7/8” lg. 1 14 000-106-120 Plug, M18 x 1.5 1 15 000-125-096 Tube, 1.5” O.D. exhaust w/ Port 1 16 000-057-212 Gasket, Half Donut 1

8-25: Machine Assemblies and Parts lists

12 6 13 3

14 15

16 18

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ADDED ITEM 19; RENUMBERED BOM;

LRIP

2/12/2008

L.O.L.

B.R.T. B.R.T.

ITEM 17 WAS 060-002.

ECR #1427

10/22/2008

L.O.L.

C.I.R.

ECRB

19 2

FUSE, 25 AMP

VARIOUOS

000-056-010

- - -

18 4

CONNECTOR, "JUMPER" TERMINAL BLOCK

STEEL

000-037-011

- - -

17 1

GROMMET, 1.00" I.D. x 1.50" O.D.

RUBBER

000-060-014

- - -

16 1

CLAMP, 1/2" NYLON HOSE

NYLON

000-033-022

- - -

15 2

SCREW, 5/16"-18UNC x 3/4" Lg.

S. STEEL

000-143-012

- - -

14 2

WASHER, 5/16" FLAT

S. STEEL

000-174-049

- - -

13 2

NUT, #6-32UNC NYLOCK

304

000-094-063

- - -

12 1

TRIMLOK, 3/8" x 1/8"

VARIOUS

000-131-131

- - -

7020 Rev. C

Electrical Panel assemblyfigure 8-19.

Electrical Panel assembly Parts list

Item Part number Description Qty

1 000-100-171 Panel, electrical - 7" X 7.25" 1 2 000-074-125 Controller, Temp Single Analog Input - RTD 1 3 000-056-006 Fuse Holder, In-line - Weatherproof 2 4 000-157-022 Switch, Relay 1 5 000-084-010 light, Green led Indicator Mini 1 6 000-012-002 Block, 6 Post Terminal 1 7 000-041-460 Cover, electrical Panel 1

9 000-156-030 Stud, #10-32uNF X 2" lg. S/S 2 10 000-094-058 Nut, #10-32uNF - Nylock 2 11 000-094-108 Nut, #10-32uNF Wing 2

8 000-094-034 Nut, #10-24uNC Nylock 5

12 000-131-131 Trimlok, 3/8" X 1/8" 1 13 000-094-063 Nut, #6-32uNC Nylock 2 14 000-174-049 Washer, 5/16" Flat 2 15 000-143-012 Screw, 5/16"-18uNC X 3/4" lg. 2 16 000-033-022 Clamp, 1/2" Nylon Hose 1 17 000-060-014 Grommet, 1.00" I.D. X 1.50" O.D. 1 18 000-037-011 Connector, "Jumper" Terminal Block 4 19 000-056-010 Fuse, 25 Amp 2

Machine Assemblies and Parts lists: 8-26

rEVISIOnS

ltr rEVISIOn CODE DatE BY CHkD aPPVD

ITeM 25 WAS QTy. 4; Del ITeM 26 (143-539); RelOCATeD ITeMS 10,11,13 & 36; ADDeD NOTe 3.

lRIP 01/16/2008 l.O.l. B.R.T. B.R.T.

ITeM 20 WAS MISSING INFO. IN BOM; ADDeD NOTe 4; ReNuMBeReD BOM.

lRIP 2/19/2008 l.O.l. B.R.T. B.R.T.

ItEM nO. QtY. DESCrIPtIOn MatErIal Part nO. DWg. nO.

35 1 flOat, lEVEr SWItCH VarIOUS 000-157-090 - - - 34 2 SCrEW, #8-32UnC x 3/4" lg.BInDEr HEaD S. StEEl 000-143-051 - - - 33 1 BlOCk, 6 POSt tErMInal VarIOUS 000-012-002 - - - 32 1 ElBOW, 2" BarB x 2" fPt aBS 000-052-222 - - - 31 1 gaSkEt, 1-1/2" BUlkHEaD fIttIng VarIOUS 000-057-015 - - - 30 1 aDaPtEr, 2" nPt x 2" f SlIP aBS 000-052-219 - - - 29 1 BaSkEt, fIltEr - SMall VarIOUS 000-049-155 - - - 28 1 trIMlOk, 5/8" x 1/8" rUBBEr 000-131-021 - - -

27 1 laBEl, MaIntEnanCE & lUBE SCHEDUlE

3M 200 MP aDHESIVE

SEE nOtES 6561 26 1 nIPPlE, 1/4" nPt HEx BraSS 000-052-071 - - - 25 1 ElBOW, 1/4" fPt x fPt BraSS 000-052-088 - - - 24 1 tEE, 1/4" nPt BranCH M-f-f BraSS 000-052-090 - - - 23 1 ElBOW, 1/4" nPt StrEEt BraSS 000-052-085 - - - 22 1 InSErt, #46 (1/4" nPt x 3/8" BarB) BraSS 000-052-102 - - - 21 1 nIPPlE, 3/8" nPt x 1/4" nPt HEx BraSS 000-052-073 - - - 20 1 ValVE, 12 VOlt SOlEnOID 1200 PSI BraSS 000-169-082 - - - 19 1 nIPPlE, 3/8" nPt x 1/4" M SaE BraSS 000-052-662 - - - 18 1 nIPPlE, 1-1/2" IPS ClOSE s/s S. StEEl 000-052-763 - - - 17 1 ValVE, 1-1/2" fUll POrt Ball BraSS 000-169-022 - - - 16 1 InSErt,1-1/2" nPt x 1-1/2" BarB (grEY) PVC 000-052-226 - - - 15 1 tank, 50 gallOn UnIVErSal rECOVErY alUMInUM 000-159-132 7231 14 1 aDaPtEr, tank tO Ø2.5" x 90° BlOWEr HOSE StEEl 000-001-134 6887 13 8 nUt,1/4"-20UnC nYlOCk VarIOUS 000-094-009 - - - 12 1 aSSEMBlY, VaCUUM rElIEf ValVE - Urt VarIOUS SEE nOtES 6894 11 8 SCrEW, 1/4"-20UnC x 1.00" lg. HEx HEaD S. StEEl 000-143-002 - - - 10 16 WaSHEr, 1/4" flat S. StEEl 000-174-003 - - -

9 2 gaSkEt, aDPatEr - Urt rUBBEr 000-057-206 6897 8 2 latCH, BUngIE - StrIkE VarIOUS 000-086-008 - - - 7 1 trIMlOk, 5/8" x 1/8" rUBBEr 000-131-021 - - - 6 2 nUt, #8-32UnC nYlOCk S. StEEl 000-094-059 - - - 5 1 fIltEr, flat - UnIVErSal rECOVErY tank VarIOUS 000-049-153 6851 4 8 nUt, #6-32UnC nYlOCk s/s S. StEEl 000-094-063 - - - 3 2 latCH, BUngIE - CatCH StEEl 000-086-008 - - - 2 8 SCrEW, #6-32UnC x 3/8" lg. BUttOn HEaD StEEl 000-143-165 - - - 1 1 COVEr, rECOVErY tank - WElDMEnt alUMInUM 000-041-459 7241

NOTeS:

1. ReFeReNCe BOM P/N 610-003-001.

2. ITeM 12 IS PART OF P/N 610-003-001.

3. ITeM 27 IS PART OF lABel SeT P/N 000-081-039.

4. ITeMS 16-18 ARe PART OF P/N 000-078-052.

HIDDeN

- - -

BReAK All SHARP eDGeS 0.005-.015

FINISH

125

DRAWN

CHeCKeD

APPVD

MACHINe

Mukilteo, Washington 98275

PROPRIeTARy INFORMATION

B.R.T.

ANGulAR= 1°

11015 47th Avenue West,

.XXX= .010

DIMeNSIONS ARe IN INCHeS

l.O.l. B.R.T.

01/08/2008 01/08/2008 01/08/2008

ASSeMBly, 50 GAllON uRT

TOleRANCeS

.X= .1

.XX= .03

uNleSS OTHeRWISe NOTeD

- - -

7230 Rev. B

50 gallon Universal recovery tank assemblyfigure 8-20.

8-27: Machine Assemblies and Parts lists

50 gallon Universal recovery tank assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-041-459 Cover, Recovery Tank - Weldment 1 2 000-143-165 Screw, #6-32uNC x 3/8” lg. Button Head 8 3 000-086-008 latch, Bungee - Catch 2 4 000-094-063 Nut, #6-32uNC Nylock S/S 8 5 000-049-153 Filter, Flat - universal Recovery Tank 1 6 000-094-059 Nut, #8-32uNC Nylock 2 7 000-131-021 Trimlok, 5/8” x 1/8” 1 8 000-086-008 latch, Bungee - Strike 2 9 000-057-206 Gasket, Adapter - uRT 2 10 000-174-003 Washer, 1/4” Flat 16 11 000-143-002 Screw, 1/4”-20uNC x 1.00” lg. Hex Head 8 12 - - - Assembly, Vacuum Relief Valve - uRT 1 13 000-094-009 Nut, 1/4”-20uNC Nylock 8 14 000-001-134 Adapter, Tank To Ø2.5” x 90° Blower Hose 1 15 000-159-132 Tank, 50 Gallon universal Recovery 1 16 000-052-226 Insert, 1-1/2” NPT x 1-1/2” Barb (Grey) 1

19 000-052-662 Nipple, 3/8” NPT x 1/4” M SAe 1 20 000-169-082 Valve, 12 Volt Solenoid 1200 PSI 1 21 000-052-073 Nipple, 3/8” NPT x 1/4” NPT Hex 1 22 000-052-102 Insert, #46 (1/4” NPT x 3/8” Barb) 1 23 000-052-085 elbow, 1/4” NPT Street 1 24 000-052-090 Tee, 1/4” NPT Branch M-F-F 1 25 000-052-088 elbow, 1/4” FPT x FPT 1 26 000-052-071 Nipple, 1/4” NPT Hex 1 27 000-081-039 label, Maintenance and lube Schedule 1 28 000-131-021 Trimlok, 5/8” x 1/8” 1 29 000-049-155 Basket, Filter - Small 1 30 000-052-219 Adapter, 2” NPT x 2” F Slip 1 31 000-057-015 Gasket, 1-1/2” Bulkhead Fitting 1 32 000-052-222 elbow, 2” Barb x 2” FPT 1 33 000-012-002 Block, 6 Post Terminal 1

34 000-143-051 Screw, #8-32uNC x 3/4” lg. Binder Head 2 17 000-169-022 Valve, 1-1/2” Full Port Ball 1 18 000-052-763 Nipple, 1-1/2” IPS Close S/S 1

Machine Assemblies and Parts lists: 8-28

35 000-157-090 Float, lever Switch 1

2X HIDDEN

8X HIDDEN

DETAIL A

2X HIDDEN

NOTES:

REFERENCE BOM P/N 610-003-015.

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ITEM 32 WAS 143-539; RELOCATED ITEMS 10,16,18 & 40; ADDED NOTE 5;

LRIP

01/16/2008

L.O.L.

B.R.T. B.R.T.

ITEM 48 WAS MISSING INFO. IN BOM; ADDED ITEMS 31, 35 & NOTE 6; RENUMBERD BOM & UPDATED NUMBERS IN NOTES;

LRIP

2/26/2008

L.O.L.

B.R.T. B.R.T.

RENUMBERED BOM; DELETED P/N's 000- 143-001, 000-013-070 & 000-001-131; ADDED ITEMS 46 & 47; CHANGED QTY OF ITEM 17 WAS 3 NOW IS 2, ITEM 25 WAS 14 NOW IS 18, ITEM 26 WAS 14 NOW IS 2, ITEM 29 WAS 12 NOW IS 4, CHANGE P/N OF ITEM 20 WAS 143-165 NOW IS 143-539; UPDATED NOTES; REDRAWN IN SOLIDWORKS

ECR1572

12/8/2009

AJP

E.J. E.J.

47 8

NUT, 1/4"-20UNC NYLOCK

S STEEL

000-094-009

- - -

46 1

ADAPTER, TANK TO Ø2.5" x 90° BLOWER HOSE

STEEL

000-001-134

6887

45 1

DEFLECTOR, AIR - UNIVERSAL RECOVERY TANK

ALUMINUM

000-049-154

6905

44 1

LABEL, MAINTENANCE & LUBE SCHEDULE

3M 200 MP ADHESIVE

SEE NOTES

6561

43 1

BRACKET, FLAT FILTER SECURING

ALUMINUM

000-015-932

6877

42 1

ELBOW, 1/4" NPT STREET x 45°

BRASS

000-052-082

- - -

41 1

ASSEMBLY, DURA-FLOW APO - PRODUCTION

VARIOUS

000-079-091

5654

40 2

CLAMP, 3/4" NYLON HOSE

NYLON

000-033-023

- - -

39 1

PLUG,1" NPT BLACK NYLON

BLACK NYLON

000-106-049

- - -

38 1

PLUG, 1-1/4" NPT

ABS

000-106-046

- - -

37 1

PLUG, 1-1/2" NPT

PLASTIC

000-106-019

- - -

36 1

FILTER, RECOVERY TANK BASKET

VARIOUS

000-049-152

6850

35 6

RIVET, AB8-6A ALUMINUM POP

ALUMINUM

000-140-023

- - -

34 2

NUT, #10-24UNC NYLOCK

S. STEEL

000-094-034

- - -

33 4

WASHER, #10 FLAT RUBBER BACKED

S. STEEL

000-174-036

- - -

32 2

WASHER, #10 S/S FLAT

S. STEEL

000-174-001

- - -

31 2

SCREW, #10-24UNC x 0.75" LG. HEX HEAD

S. STEEL

000-143-132

- - -

30 4

NUT, 1/4"-20UNC NEOPRENE WELLNUT

NEOPRENE

000-094-113

- - -

29 12

SCREW, 1/4"-20UNC x 1.00" LG. HEX HEAD

S. STEEL

000-143-002

- - -

28 4

WASHER, 1/4" RUBBER BACKED

S. STEEL

000-174-060

- - -

27 2

SCREW, 1/4"-20UNC x 0.50" LG. HEX HEAD

S. STEEL

000-143-333

- - -

26 2

WASHER, 1/4" LOCK

S. STEEL

000-174-019

- - -

25 18

WASHER, 1/4" FLAT

S. STEEL

000-174-003

- - -

24 2

WASHER, 3/8" RUBBER BACKED

S. STEEL

000-174-029

- - -

23 2

SCREW, #8-32UNC x 3/4" LG. BINDER HEAD

S. STEEL

000-143-051

- - -

22 2

NUT, #8-32UNC NYLOCK

S. STEEL

000-094-059

- - -

21 2

NUT, #6-32UNC NYLOCK

304

000-094-063

- - -

20 2

SCREW, #6-32UNC x 0.50" LG. BUTTON HEAD

S. STEEL

000-143-539

- - -

19 1

FILTER, FLAT - UNIVERSAL RECOVERY TANK VARIOUS

000-049-153

6851

18 1

ASSEMBLY, VACUUM RELIEF VALVE - URT

VARIOUS

601-050-001

6894

17 2

GASKET, ADAPTER - URT

RUBBER

000-057-206

6897

16 1

LATCH, BUNGEE - STRIKE

VARIOUS

000-086-008

- - -

15 1

NIPPLE, 1-1/2" IPS CLOSE s/s

S. STEEL

000-052-763

- - -

14 1

BLOCK, 6 POST TERMINAL

VARIOUS

000-012-002

- - -

13 1

INSERT, 1-1/2" NPT x 1-1/2" BARB (GREY)

PVC

000-052-226

- - -

12 1

VALVE, 1-1/2" FULL PORT BALL

BRASS

000-169-022

- - -

11 1

FLOAT, LEVER SWITCH

VARIOUS

000-157-091

- - -

10 1

NIPPLE, 3/8" NPT x 1/4" M SAE

BRASS

000-052-662

- - -

9 1

VALVE, 12 VOLT SOLENOID 1200 PSI

BRASS

000-169-082

- - -

8 1

ELBOW, 1/4" FPT x FPT

BRASS

000-052-088

- - -

7 2

INSERT, #46 (1/4" NPT x 3/8" BARB)

BRASS

000-052-102

- - -

6 1

ELBOW, 1/4" NPT STREET

BRASS

000-052-085

- - -

5 1

NIPPLE, 3/8" NPT x 1/4" NPT HEX

BRASS

000-052-073

- - -

4 1

TEE, 1/4" NPT BRANCH M-F-F

BRASS

000-052-090

- - -

3 1

NIPPLE, 1/4" NPT HEX BRASS

000-052-071

- - -

2 1

ASSEMBLY, COVER - SINGLE VACUUM

VARIOUS

SEE NOTES

6891

1 1

TANK, 70 GALLON URT - WELDMENT

ALUMINUM

000-159-128

6862

ITEM NO.

QTY.

DESCRIPTION

MATERIAL

PART NO. DWG. NO.

MACHINE

FINISH

PROPRIETARY INFORMATION

11015 47th Avenue West,

Mukilteo, Washington 98275

TOLERANCES

BREAK ALL SHARP EDGES 0.005-.015

UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES

7067 Rev. C

70 gallon Universal recovery tank assemblyfigure 8-21.

8-29: Machine Assemblies and Parts lists

70 gallon Universal recovery tank assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-159-128 Tank, 70 Gallon uRT - Weldment 1 2 - - - Assembly, Cover - Single Vacuum 1 3 000-052-071 Nipple, 1/4" NPT Hex 1 4 000-052-090 Tee, 1/4" NPT Branch M-F-F 1 5 000-052-073 Nipple, 3/8" NPT X 1/4" NPT Hex 1 6 000-052-085 elbow, 1/4" NPT Street 1 7 000-052-102 Insert, #46 (1/4" NPT X 3/8" Barb) 2 8 000-052-088 elbow, 1/4" FPT X FPT 1 9 000-169-082 Valve, 12 Volt Solenoid 1200 psi 1 10 000-052-662 Nipple, 3/8" NPT X 1/4" M SAe 1 11 000-157-091 Float, lever Switch 1 12 000-169-022 Valve, 1-1/2" Full Port Ball 1 13 000-052-226 Insert, 1-1/2" NPT X 1-1/2" Barb (Grey) 1 14 000-012-002 Block, 6 Post Terminal 1 15 000-052-763 Nipple, 1-1/2" Ips Close S/S 1 16 000-086-008 latch, Bungee - Strike 1

25 000-174-003 Washer, 1/4" Flat 18

26 000-174-019 Washer, 1/4" lock 2

27 000-143-333 Screw, 1/4"-20uNC X 0.50" lg. Hex Head 2

28 000-174-060 Washer, 1/4" Rubber Backed 4

29 000-143-002 Screw, 1/4"-20uNC X 1.00" lg. Hex Head 12

30 000-094-113 Nut, 1/4"-20uNC Neoprene Wellnut 4

31 000-143-132 Screw, #10-24uNC X 0.75" lg. Hex Head 2

32 000-174-001 Washer, #10 S/S Flat 2

33 000-174-036 Washer, #10 Flat Rubber Backed 4

34 000-094-034 Nut, #10-24uNC Nylock 2

35 000-140-023 Rivet, Ab8-6a Aluminum Pop 6

36 000-049-152 Filter, Recovery Tank Basket 1

37 000-106-019 Plug, 1-1/2" NPT 1

38 000-106-046 Plug, 1-1/4" NPT 1

39 000-106-049 Plug,1" NPT Black Nylon 1

40 000-033-023 Clamp, 3/4" Nylon Hose 2 17 000-057-206 Gasket, Adapter - uRT 2 18 601-050-001 Assembly, Vacuum Relief Valve - uRT 1 19 000-049-153 Filter, Flat - universal Recovery Tank 1 20 000-143-539 Screw, #6-32uNC X 0.50" lg. Button Head 2 21 000-094-063 Nut, #6-32uNC Nylock 2 22 000-094-059 Nut, #8-32uNC Nylock 2 23 000-143-051 Screw, #8-32uNC X 3/4" lg. Binder Head 2 24 000-174-029 Washer, 3/8" Rubber Backed 2

Machine Assemblies and Parts lists: 8-30

41 000-079-091 Assembly, Dura-Flow APO - Production 1

42 000-052-082 elbow, 1/4" NPT Street X 45° 1

43 000-015-932 Bracket, Flat Filter Securing 1

44 - - - label, Maintenance & lube Schedule 1

45 000-049-154 Deector, Air - Universal Recovery Tank 1

46 000-001-134 Adapter, Tank To Ø2.5" X 90° Blower Hose 1

47 000-094-009 Nut, 1/4"-20uNC Nylock 8

6891 Rev. A

rEVISIOnS

lTR

ReVISION

CODe DATe By

CHKD

APPVD

ITeM 9 WAS QTy. 2; ITeMS 9-10 WeRe QTy. 4;

lRIP

04/11/2007

l.O.l.

C.I.R.

W.B.

Cover, Single Vac. - 70 gallon Urt assemblyfigure 8-22.

Cover, Single Vac. - 70 gallon Urt assembly Parts list

Item Part number Description Qty

1 000-041-443 Cover, Single Vac. 70 Gallon uRT 1 2 000-052-222 elbow, 2” Barb x 2” FPT 1 3 000-057-202 Gasket, end - Recovery Tank 2 4 000-057-203 Gasket, Middle - Recovery Tank 2 5 000-057-204 Gasket, Middle - Recovery Tank 2 6 000-057-015 Gasket, 1-1/2” Bulkhead Fitting 1 7 000-052-219 Adapter, 2” NPT x 2” F Slip 1 8 000-086-008 latch, Bungee - Strike 1 9 000-143-539 Screw, #6-32uNC x 0.50” lg. Button Head Allen 2 10 000-094-063 Nut, #6-32uNC Nylock 2

8-31: Machine Assemblies and Parts lists

6894 Rev. A

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

ADDED PART NUMBER; NEW NEXT ASSEMBLY

AND USED ON.

LRIP

9/15/2009

EJ EJ

8 1

NUT, 3/8"-16UNC HEX JAM

S. STEEL

000-094-101

- - -

7 2

NUT, 3/8"-16UNC x 1.00" O.D. KNURLED

ASTM B16

000-094-077

4179

6 1

SCREW, 3/8"-16UNC x 4" LG. HEX HEAD - FULL THREAD

S. STEEL

000-143-198

- - -

Vacuum relief Valve assemblyfigure 8-23.

Vacuum relief Valve assembly Parts list

Item Part number Description Qty

1 000-015-182 Bracket, Vacuum Relief Valve 1 2 000-027-032 Cap, Spun Vacuum Relief Valve 1 3 000-125-111 Tube, Vacuum Relief Spring Guide 1 4 000-105-332 Plate, Vacuum Relief Valve Mounting - uRT 1

Machine Assemblies and Parts lists: 8-32

Item Part number Description Qty

5 000-155-026 Spring, Vacuum Relief Valve 1 6 000-143-198 Screw, 3/8”-16uNC X 4” lg. Hex Head - Full Thread 1 7 000-094-077 Nut, 3/8”-16uNC X 1.00” O.D. Knurled 2 8 000-094-101 Nut, 3/8”-16uNC Hex Jam 1

6313 Rev. A

7 9

158

1 2 3

ltr DatE

20 4 SCReW, 1/4"-28uNF x 0.75" lG. SOCKeT HeAD S. STeel 000-143-566 - - - 19 1 INSeRT, 1" NPT x 3/4" elBOW NylON 000-052-757 - - - 18 1 ASSeMBly, APO PuMP - JABSCO VARIOuS 000-111-169 6244

17 1 FITTING, 1" NPT CAM lOCK - BANJO 100F PlASTIC 000-052-723 - - - 16 1 FITTING, 1" NPT CAM lOCK - BANJO 100B PlASTIC 000-052-724 - - -

15 1 FITTING, APO BulKHeAD AluMINuM 000-052-725 5683 14 1 GASKeT, APO BulKHeAD NeOPReNe 000-057-192 5684

13 2 SCReW, #6-32uNC x 5/8" lG. SOCKeT HeAD STeel 000-143-532 - - - 12 1 BlOCK, 6 POST TeRMINAl PlASTIC 000-012-011 - - - 11 8 NuT, 1/4"-20uNC NeOPReNe WellNuT NeOPReNe 000-094-113 - - -

10 1 BRACKeT, TANK MOuNTeD ON APO SuPPORT AluMINuM 000-015-890 5675

9 8 WASHeR, 1/4" RuBBeR BACKeD S. STeel 000-174-060 - - -

Dura-flow aPO 90° assemblyfigure 8-24.

Dura-flow aPO 90° assembly Parts list

Item Part number Description Qty

1 000-091-042 Motor, Bison 438 Series 1 2 000-061-131 Knob, Handle 2 3 000-015-891 Bracket, APO Clamp 1 4 000-174-002 Washer, 1/4” Flat 4 5 000-143-074 Screw, 1/4”-20uNC x 0.50” lg. Hex Head Self-Tapping 4 6 000-094-027 Nut, #10-24uNC Hex 1 7 000-157-022 Switch, Relay 1 8 000-143-002 Screw, 1/4”-20uNC x 1.00” lg. Hex Head 8 9 000-174-060 Washer, 1/4” Rubber Backed 8 10 000-015-890 Bracket, Tank Mounted on APO Support 1 11 000-094-113 Nut, 1/4”-20uNC Neoprene Wellnut 8 12 000-012-011 Block, 6 Post Terminal 1 13 000-143-532 Screw, #6-32uNC x 5/8” lg. Socket Head 2 14 000-057-192 Gasket, APO Bulkhead 1 15 000-052-725 Fitting, APO Bulkhead 1 16 000-052-724 Fitting, 1” NPT Cam lock - Banjo 100B 1 17 000-052-723 Fitting, 1” NPT Cam lock - Banjo 100F 1 18 000-111-169 Assembly, APO Pump - Jabsco 1 19 000-052-757 Insert, 1” NPT x 3/4” elbow 1 20 000-143-566 Screw, 1/4”-28uNF x 0.75” lg. Socket Head 4

8-33: Machine Assemblies and Parts lists

7243

rEVISIOnS

ltr rEVISIOn CODE DatE BY CHkD aPPVD

8 7 6

aPO Connection kit assemblyfigure 8-25.

aPO Connection kit assembly Parts list

Item Part number Description Qty Item Part number Description Qty

1 000-027-014 Cap, Garden Hose 1 2 000-057-055 Gasket, Garden Hose 1 3 000-052-281 Nipple, 3/4” NPT X 3/4” Male Garden Hose 1 4 000-174-063 Washer, 1.5” O.D. X 1.073” I.D. X 0.075” Thk. 1 5 000-015-719 Bracket, APO Outlet Mounting - Weldment 1 6 000-174-003 Washer, 1/4” Flat 2

Machine Assemblies and Parts lists: 8-34

7 000-094-009 Nut, 1/4”-20uNC Nylock 2

8 000-174-050 Washer, 1” Flat 1

9 000-169-009 Valve, 3/4” FPT Swing Check 1

10 000-033-020 Clamp, Size #16 Hose 2

11 000-052-338 Insert, #1212 (3/4” NPT X 3/4” Barb) 1

12 000-068-069 Hose, 3/4” I.D. Parker Gst Ii - Bulk 1

7087

Boxxer 318 on 85 rMt w/ 50 Urt assembly - right Viewfigure 8-26.

8-35: Machine Assemblies and Parts lists

rEVISIOnS

ltr rEVISIOn CODE DatE BY CHkD aPPVD

7087

Boxxer 318 on 85 rMt w/ 50 Urt assembly - left Viewfigure 8-27.

Machine Assemblies and Parts lists: 8-36

HYDRAMASTER Boxxer 318 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual