HYDRAMASTER Boxxer 323HP User Guide

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Boxxer 323HP

Owner’s Manual

HydraMaster North America, Inc.

11015 47th Avenue West, Mukilteo, Washington 98275

MAN-44134 Rev. 0, July 30, 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.

(182-501-D)

Table of Contents

GeNeRAl INfORMATION ...........................................................................SeCTION 1

System Concept Contact Information Warnings, Cautions and Notices

Responsibilities .......................................................................................1-9

Machine Specications

High Altitude Operation

local Water Precautions ......................................................................... 1-14

INSTAllATION INfORMATION ...................................................................SeCTION 2

Operating the Boxxer 323HP in Hot Weather .........................................2-2

Setting Up the Boxxer 323HP .................................................................2-5

Orientation of fuel Pump ........................................................................2-6

CleANING INfORMATION .........................................................................SeCTION 3

Precautions .............................................................................................3-2

Preparing the Carpet for extraction.........................................................3-2

Rinse and Recover..................................................................................3-3

Overwetting Streaking

Cleaning Tool Tips ................................................................................... 3-4

................................................................................................. 3-3

...................................................................................... 1-3

................................................................................. 1-4

.............................................................1-5

........................................................................... 1-12

...........................................................................1-14

............................................................................................. 3-3

OPeRATING INSTRUCTIONS .....................................................................SeCTION 4

Setting the Temperature .......................................................................... 4-4

Start-up Procedure

Setting the Pressure for Cleaning operations ......................................... 4-5

Setting the Pressure for High Pressure Washing Operations ................. 4-6

Shut Down Procedure

MACHINe MAINTeNANCe ..........................................................................SeCTION 5

Operational Maintenance ........................................................................ 5-2

Overall Machine Maintenance.................................................................5-3

engine Maintenance ............................................................................... 5-4

High Pressure Pump Maintenance

Vacuum System Maintenance ................................................................ 5-15

Descaling Procedure (Required)

freeze Guarding .....................................................................................5-17

Tensioning the Pump Drive Belt

WATeR AND CHeMICAl SySTeM .............................................................SeCTION 6

.................................................................................. 4-4

............................................................................. 4-7

......................................................... 5-6

............................................................. 5-16

.............................................................. 5-19

i - Boxxer 323HP Owner’s Manual

eleCTRICAl SySTeM ................................................................................SeCTION 7

SySTeMS TROUBleSHOOTING ...............................................................SeCTION 8

Heating System Chemical System

....................................................................................... 8-2

....................................................................................8-3

engine ..................................................................................................... 8-4

High Pressure System

............................................................................ 8-8

Vacuum System ...................................................................................... 8-10

ASSeMBlIeS AND PARTS lIST ................................................................. SeCTION 9

Machine Assembly Parts list .................................................................. 9-4

frame Assembly Parts list .....................................................................9-9

engine Assembly Parts list..................................................................... 9-12

Pump Assembly Parts list ......................................................................9-14

Dash Assembly Parts list .......................................................................9-17

electrical Panel Assembly Parts list ....................................................... 9-19

Blower Heat exchanger Assembly Parts list .......................................... 9-20

Blower Assembly Parts list .....................................................................9-21

Silencer Assembly Parts list ...................................................................9-22

Water Box Assembly Parts list ...............................................................9-24

exhaust Assembly Parts list ...................................................................9-25

Idler Pulley Assembly Parts list .............................................................. 9-26

Hi Pressure Manifold Assembly Parts list ..............................................9-27

By-Pass Valve Assembly Parts list .........................................................9-28

Dura-flow APO Assembly Parts list ....................................................... 9-30

70 gallon Universal Recovery Tank Assembly Parts list ........................9-32

Machine Hose Routings .......................................................................... 9-33

HOW TO ORDeR PARTS ............................................................................SeCTION 10

Warranty Parts Orders

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

Parts Orders ............................................................................................ 10-1

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

Boxxer 323HP Owner’s Manual - ii

WARRANTy INfORMATION .......................................................................SeCTION 11

Blower ....................................................................................................11-1

High Pressure Water Pump ................................................................... 11-1

Vacuum Tank Chemical System

.......................................................................................... 11-1

....................................................................................11-1

Control Panel ......................................................................................... 11-1

Vacuum and Solution Hoses ..................................................................11-2

Cleaning Wand and Tool ......................................................................... 11-2

Water Heating System ............................................................................11-2

Hard Water Deposits ............................................................................... 11-2

Warranty Procedure

................................................................................11-2

ACCeSSORIeS AND CHeMICAl SOlUTIONS .......................................... SeCTION 12

iii - Boxxer 323HP Owner’s Manual

list of figures

figure 1-1. Hard Water Map of Mainland United States .....................................1-15

figure 2-1. location of Roof Vents in Vehicle ......................................................2-1

figure 2-2. Recommended location of Boxxer 323HP in Van ..............................2-3

figure 2-3. Install fuel Pump, Outlet Side Up.......................................................2-6

figure 2-4. fuel Pump Must Be in Vertical Position ..............................................2-6

figure 4-1. Boxxer 323HP Dash Assembly - View 1 of 2 ......................................4-1

figure 4-2. Boxxer 323HP Dash Assembly - View 2 of 2 ......................................4-2

figure 4-3. location of Chemical Pump Shutoff Valve ..........................................4-3

figure 4-4. Chemical Pump Shutoff Valve Is On

When Valve Handle Is In line with Chemical Pump ...........................4-5

figure 4-5. Chemical Pump Shutoff Valve Is Off

When Valve Handle Is Perpendicular to Pump ...................................4-6

figure 5-1. Remove Valve Cap and Valve Assembly ............................................5-7

figure 5-2. Inspect Manifold and Old Valves ........................................................5-7

Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve ..........5-8

figure 5-4. Apply Grease and Install Valves .........................................................5-8

figure 5-5. Replace Valve Capand Torque to 95 ft. lbs. (13 m kgs) ......................5-8

figure 5-6. Separate Manifold from Crankcase ....................................................5-9

figure 5-7. Seal Assemblies May Come Off with Manifold ...................................5-9

figure 5-8. examine Ceramic Plungers ................................................................5-9

figure 5-9. Remove Stainless Steel Plunger Bolt and Ceramic Plunger ............5-10

figure 5-10. Install O-ring, Apply Sealant and

Slide Plunger over Plunger Guide ..................................................5-10

figure 5-11. extract Retainers and Seals ...........................................................5-11

figure 5-12. Seal Kit and Insertion Tool for Seal Installation ..............................5-12

figure 5-13. Install Seal Assembly Using O-Ring Grease ..................................5-12

figure 5-14. Install Retainers into Cavities .........................................................5-13

figure 5-15. Press low Pressure Seal Assembly into Cavity .............................5-13

figure 5-16. Re-install Manifold and Torque fasteners ......................................5-14

figure 5-17. Torque Sequence in “X” Pattern .....................................................5-14

figure 5-18. Torque Bolts to 22 ft. lbs (3 m kgs) .................................................5-14

figure 5-19. Recirculation fitting ........................................................................5-16

Boxxer 323HP Owner’s Manual - iv

figure 6-1. Annotated Water, Chemical and

Solution flow Diagram - View 1 of 2 ..................................................6-3

figure 6-2. Annotated Water, Chemical and

Solution flow Diagram - View 2 of 2 ..................................................6-4

figure 6-3. Chemical flow Diagram - larger View ...............................................6-5

figure 6-4. exhaust flow Diagram........................................................................6-6

figure 7-1. electrical Schematic ...........................................................................7-2

figure 7-2. Wiring Diagram - View 1 of 3 ..............................................................7-3

figure 7-3. Wiring Diagram - View 2 of 3 ..............................................................7-4

figure 7-4. Wiring Diagram - View 3 of 3 ..............................................................7-5

figure 9-1. Machine Assembly - View of 1 of 2 .....................................................9-2

figure 9-2. Machine Assembly - View of 2 of 2 .....................................................9-3

figure 9-3. frame Assembly - View 1 of 4 ............................................................9-5

figure 9-4. frame Assembly - View 2 of 4 ............................................................9-6

figure 9-5. frame Assembly - View 3 of 4 ............................................................9-7

figure 9-6. frame Assembly - View 4 of 4 ............................................................9-8

figure 9-7. engine Assembly - View 1 of 2 .........................................................9-10

figure 9-8. engine Assembly - View 2 of 2 ......................................................... 9-11

figure 9-9. Pump Assembly - View 1 of 2 ...........................................................9-13

figure 9-10. Pump Assembly - View 2 of 2 .........................................................9-14

figure 9-11. Dash Assembly - View 1 of 2 ..........................................................9-15

figure 9-12. Dash Assembly - View 1 of 2 ..........................................................9-16

figure 9-13. electrical Panel Assembly...............................................................9-19

figure 9-14. Heat exchanger Assembly..............................................................9-20

figure 9-15. Blower Assembly ............................................................................9-21

figure 9-16. Silencer Assembly ..........................................................................9-22

figure 9-17. Water Box Assembly .......................................................................9-23

figure 9-18. exhaust Assembly ..........................................................................9-25

figure 9-19. Idler Pulley Assembly......................................................................9-26

figure 9-20. Hi Pressure Manifold Assembly ......................................................9-27

figure 9-21. By-Pass Valve Assembly ................................................................9-28

figure 9-22. Dura-flow APO Assembly ..............................................................9-29

figure 9-23. 70 gallon Universal Recovery Tank Assembly ................................9-31

v - Boxxer 323HP Owner’s Manual

Boxxer 323HP Owner’s Manual - vi

1- General Information

The compact but powerful Boxxer 323HP is a carefully engineered truckmount multisurface cleaning machine designed and manufactured by HydraMaster North America, Inc.

A 23 Hp Briggs and Stratton engine powers the Boxxer 323HP’s Tuthill 3006 vacuum blower and the high pressure water pump, which is rated at 4 gpm (15 litres/minute).

The Boxxer 323HP’s innovative design features a stainless steel heat exchanger which allows for heated, high pressure cleaning up to 2,500 psi (17,237 kPa).

Other features of the Boxxer 323HP include:

Dual oil bath and sight glasses for enhanced blower reliability• 0 - 2,500 psi (0 - 17,237 kPa) heated, without chemical• 0 - 1,200 psi (0 - 8,274 kPa) heated, with chemical• A.D.C temperature control with instant heat up to 265° f (129.4° C)• Optional Dura-flow Automatic Pump Out (APO)•

1-1: General Information

The Boxxer 323HP can be mounted onto a HydraMaster 85 gallon (322 litre) rotomolded fresh water tank. The HydraMaster 70 gallon (265 litre) recovery tank, which comes in the standard equipment package, or the 100 gallon (379 litre) recovery tank, offered as an option, can be used with the 85 gallon fresh water tank installation.

This Owner’s Manual contains installation and operation instructions as well as information required for proper maintenance, adjustment and repair of the Boxxer 323HP. Component troubleshooting guides have also been included for your convenience.

It is the purpose of this manual to help you properly understand, maintain and service your Boxxer 323HP. follow the directions carefully and you will be rewarded with years

of protable, trouble-free operation.

It is imperative that no section of this manual be overlooked when preparing for operation of the Boxxer 323HP. Please read the manual to familiarize yourself with the operation of your Boxxer 323HP, paying special attention to all Warnings and Cautions.

This section of the manual contains the following information:

Contact Information



Warnings, Cautions and Notices



Machine Specications



Responsibilities



local Water Precautions 

General Information: 1-2

SySteM COnCePt

This is how the Boxxer 323HP works:

Incoming water enters the water box and is pressurized by the high pressure water 1.

pump. The water is heated by the engine and blower exhaust in the cross ow heat

exchanger. Cleaning solution is then injected into the pressurized water stream and the heated

2. solution is delivered to the cleaning tool. The solution is recovered by the vacuum generated by the vacuum pump and is

3. collected in the recovery tank for proper disposal.

engine

Vacuum Blower

Silencer

Cross

Water Box

Flow Heat

exchanger

Water Pump

Photographs and illustrations included in this document can represent optional equipment as well as standard equipment.

1-3: 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.

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

Tech Support:

Parts Support:

parts@hydramaster.com

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

FOr yOUr reFerenCe:

Serial no.____________________________________________________ Date of Purchase:_____________________________________________ Purchased From (Distributor): __________________________________

General Information: 1-4

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.

1-5: General Information

Warnings and Cautions specic to the Boxxer 323HP include the following:

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 ft (3.05 m). 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 8-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 may

result. See page 1-10 of this Owner’s Manual for more information. 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: 1-6

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.

Do not use a high pressure solution hose that is rated below the specications of

the Boxxer 323HP. Serious injury 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 of 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. Refer to Section 4 of this Owner’s Manual for more information.

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. Refer to page 2-2 of this Owner’s Manual for more information.

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.

1-7: General Information

Never operate the truckmount with a water hardness reading measuring 3.0 grains per gallon (3.79 litres) or higher. Using water with a reading of 3.0 grains per gallon or higher 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. for water hardness details, refer to pages 1-14 through 1-17, and for descaling procedures, refer to page 5-16 of this Owner’s Manual.

Never allow water to freeze inside the truckmount. Serious component damage will occur. Perform all freeze guarding procedures as outlined on page 5-17 of this 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: 1-8

reSPOnSIBIlItIeS

Purchaser’s responsibilities

Prior to purchasing a van or trailer, ensure that the payload is suitable for all of the • equipment that will be installed and transported. This includes and is not limited to: the truckmount, recovery tanks, fresh water tanks, on-board water, hose reels, hoses, cleaning tools, chemicals and drying equipment. 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 (500+ CC Amps) 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®.

Plywood and carpet are not recommended.

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 Warnings and Cautions. 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.

1-9: General Information

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

1. 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 you sign for the shipment. Check the packing list and verify that all items are accounted for.

Installation Responsibilities

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

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

•

HydraMaster. ensure proper placement of the truckmount, recovery tank, fresh water tank, and • accessories in the vehicle or trailer, and check that they are secured 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. Verify that the fuel pump is in accordance • with HydraMaster’s recommendation. 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 and other accessories for correct operation. Verify that the •

hoses meet or exceed HydraMaster’s specications.

ensure timely return of the document package.• ensure that all aftermarket fuel cells meet or exceed federal Motor Vehicle Safety •

Standards (FMVSS) and Department of Transportation (DOT) certications.

General Information: 1-10

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.

1. All safety precautions and their importance.2. How to correctly start and shut down the truckmount.3. How to correctly clean with the truckmount.4. Where and how often to check and change component oil levels.5. freezing damage and how to avoid it. This includes explaining proper freeze 6. guarding procedures. How to do basic troubleshooting of the truckmount.

7. Hard water damage and how to avoid it. This includes how to determine if hard 8. water exists in your area and the installation and use of water softening systems. The truckmount’s warranty and warranty procedures.

1-11: General Information

Machine SpecificationS

Frame Dimensions 24.0" W x 35" D x 31.5" H

(61 cm x 89 cm x 80 cm) Weight 500 lbs (227 kg) Engine - Briggs and

Oil Type 5W-30 Synthetic Stratton 23 Hp

Capacity Approx. 1 1/2 quarts, or

Engine rpm High - 3,000 rpm

Fuel Consumption @

12” Hg/1,200 psi Ignition Key Vacuum Blower - Tuthill

Max. Vac. 12” Hg (304.8 mm Hg) 3006 Competitor (Dual Splash Lubrication)

Oil Type PneuLube or other ISO 100

Gear End Capacity Approx. 7.0 oz (207 ml)

Drive End Capacity Approx. 5 oz (148 ml)

Blower rpm 3,200 rpm

48 oz (1.42 litres) when

changing oil and lter

(12” Hg / 2,500 psi) Idle - 1,500 rpm High - 1.0 gph

(3.79 litres/hr)

rating

Water Pump - General

Oil Type 15W-40 Pump

Capacity 14 oz (414 ml)

Pump Rate 4.0 gpm (15 litres/minute)

Pump rpm 1,700 rpm Operating Pressure 0 - 1,200 psi (Heated)

(0 - 8,274 kPa) with

Chemical

General Information: 1-12

0 - 2,500 psi (Heated) (0 - 17,237 kPa) without

Chemical

Chemical System Last Step Chemical

Injection with High

Pressure Shutoff Valve Heating System Stainless Steel Cross Flow Heat Exchanger Standard Equipment Recovery Hose 10 ft (3.05 m).

Water Box Rotomolded 3 - 4 gallon

(11.4 -15 litres) capacity

Recovery Tank 70 gallon Universal Tank

(265 litre Universal Tank)

Cleaning Wand/Tool Stainless Steel S-bend

Replaceable Grip Rebuildable Solution Valve

100 ft (30.5 m)

Vacuum Hose

100 ft (30.5 m)

Solution Hose

Garden Hose Connector

Chemical Jug 5 gallon (19 litres)

Battery Box

Van Installation Kit

Owner’s Manual (on CD)

Owner’s Guide (printed) Optional Equipment 85 gallon (322 litre)

Rotomolded Tank

Automatic Pump-Out (APO)

2.5” (6.35 cm) Exhaust

Though Floor Kit

1-13: General Information

HIgH altItUDe OPeratIOn

elevation plays a key role in how the truckmount will operate. Operation at high altitude (above 5,000 ft [1,524 m]) 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. find your local Briggs and Stratton dealer 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 [3.79 litres]) 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: 1-14

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.

1-15: General Information

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 323HP 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.

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 (3,406 litres) of water and the machine uses an average of 30 gallons/hour (113.5 litres/hour), for an average of 5 hours a day, this equals 150 gallons per day (568 litres/day). In 6 days the machine would use 900 gallons (3,406 litres) of water. Therefore, the softener would need to be charged every 6 working days for maximum softening.

General Information: 1-16

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 323HP 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.

1-17: General Information

General Information: 1-18

2 - Installation Information

Although there are many different heavy duty vehicles and trailers used for carpet cleaning equipment, with a heavy-duty suspension package equivalent to a 3/4 ton capacity or a 3/4 ton HD van. If a fresh water tank is added, a one ton or larger capacity van is required.

Prior to installation of the Boxxer 323HP, HydraMaster recommends installing a sprayon bed liner in the vehicle. This provides ‘metal to cushion’ mounting rather than ‘metal to metal’ and makes for an attractive van interior.

HydraMaster also recommends installing roof vents in vehicles operated in hot weather locations. Roof vent positions are shown in distributor about selection and/or installation of powered roof vents.

the preferable vehicle for a Boxxer 323HP installation is a tandem axle trailer

figure 2-1. Consult your local RV

for best results, the fan should draw air into the vehicle which will supply cooler air to the air cleaner intake.

HydraMaster requires a powered roof vent above the air cleaner intake. failure to install a powered roof vent in such a manner may result in serious component or engine damage.

roof Vents in Vehicle

location of Figure 2-1.

2-1: Installation Information

OPeratIng tHe BOxxer 323HP In HOt WeatHer

HydraMaster recommends the following steps when operating the Boxxer 323HP during periods of hot weather (95º f [35º C] or higher). This will help ensure that your Boxxer 323HP continues to run at 100% capacity during even the hottest days.

A minimum of 9” (22.9 cm) of clearance is required on both sides of the Boxxer 323HP, 1. when installed. ensure that additional equipment or other materials are not stored at

the sides or on top of the machine. Unobstructed airow around the unit is critical for

cooling the engine and other components.

for side-door vans with “barn doors”, open the doors as wide as their construction 2. will allow. Be sure to open the doors beyond their standard “straight-out” position, if possible, by releasing the stops and putting the doors in their fully extended position.

Provide cross-ventilation. When possible, keeping the rear doors open while the

3. machine is running will substantially reduce the temperature inside the van or trailer

and will provide a path for cooling air ow. For rear-mount installations, open up the

other doors in the van.

Consider adding powered roof vents to the vehicle (if not already installed). These

vents can signicantly reduce interior temperatures and will result in much cooler

operation. A powered roof vent is required when the Boxxer 323HP is mounted on the optional 85 Gallon fresh Water Tank.

Installation Information: 2-2

Use caution when drilling any holes through the van oor. Many vans have critical components mounted directly below the vehicle oor that could be damaged by

a misplaced drill bit.

lOCatIng tHe BOxxer 323HP In VeHICle

There are two recommended entry points on the vehicle for the Boxxer 323HP installation: the side door or the rear doors.

Most installations are through the side door. This provides rear access for accessories and hoses as well as unobstructed access to the component/working side of the machine, thus making it a bit easier to perform maintenance and/or repair without removing the unit from the truck.

Rear mounting requires the unit to be slid to the right side as far as possible Although installing the Boxxer 323HP through the rear door partly limits working access, it does direct the noise away from the cleaning site.

In addition, rear mounting not only provides adequate working space on the component side of the unit but also improves weight distribution inside the van (engine and component weight line up over drive shaft). Some cleaners in colder geographical areas prefer this placement for better traction in ice and snow. Also, it is physically easier to load the unit into the rear door due to the height of the vehicle bed.

Figure 2-2. recommended location of Boxxer 323HP in Van

Secure Installation

No matter how the unit is installed, check to see if the Boxxer 323HP is properly secured

to the oor of the van with the hardware provided. This safety measure will ensure that the

machine will not slide inside the van. See figure 2-2 for the correct installation.

2-3: Installation Information

A sudden or crash stop will cause the machine to rocket forward if not properly secured. To prevent serious personal injury, ensure that the Boxxer 323HP is well

secured to the oor of the vehicle with the hardware supplied. Protect yourself

and the machine.

HydraMaster strongly recommends that the exhaust from the front of the machine be vented down under the truck to prevent carbon monoxide from entering the job site. always park the truck so the exhaust is blowing away from the job site.

Never operate this machine with a portable gas can inside the truck. Doing so

increases the risk of a re or explosion.

Mount a re extinguisher just inside the rear or side door for emergencies.

Do not use a portable propane tank inside of the truck or van. It is dangerous and illegal in most states.

Transporting any vented fuel container that presently holds or has ever held a

ammable liquid in a vehicle containing the Boxxer 323HP is strictly forbidden by

HydraMaster Corporation and by federal and state regulation.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Installation Information: 2-4

SettIng UP tHe BOxxer 323HP

Prior to operating the Boxxer 323HP, follow these steps:

Adjust the vacuum relief located on the recovery tank by capping all the vacuum 1. inlets. The machine should be set to 12” Hg maximum.

Setting the vacuum level higher than the recommended value can result in an increased risk of serious component damage.

The Boxxer 323HP is shipped from the factory with antifreeze added to the solution system. Recover this antifreeze and dispose of the recovered antifreeze as stated in the local laws and regulations.

KeeP ANTIfReeZe OUT Of ReACH Of CHIlDReN AND ANIMAlS. Drinking antifreeze can cause death.

If required, dispose of antifreeze at facilities licensed to accept household hazardous waste. If permitted, dispose of antifreeze in sanitary sewer systems. Do not pour antifreeze into storm sewers, septic systems, or onto the ground. Doing so causes health and environmental dangers.

ensure the antifreeze is completely drained from the solution system. If any antifreeze remains in the system, it could damage machine components and damage fabric.

2-5: Installation Information

OrIentatIOn OF FUel PUMP

For proper fuel pump operation and fuel ow, the

vehicle’s fuel pump must be installed in a lower position with respect to the fuel tank and in as vertical a position as possible (outlet side up - see figure 2-3 and figure 2-4).

Mount the fuel pump away from sources of heat .

Figure 2-3. Install Fuel Pump,

Outlet Side Up

Figure 2-4. Fuel Pump Must Be in Vertical Position

Installation Information: 2-6

Pump Can Push fuel

6.5 ft (2 m) Vertically

3 - Cleaning Information

The Boxxer 323HP 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 carpets or hard surfaces. This section describes the carpet cleaning procedure in the following areas:

Precautions



Preparing the Carpet for extraction  Rinse and Recover



Overwetting



Streaking



Cleaning Tool Tips



3-1: Cleaning Information

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 system 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.

reParIng 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.

Cleaning Information: 3-2

rInSe anD reCOVer

Whether you are using a wand or an RX-20™, you should clean an area approximately 3 ft. x 3 ft. (92 cm x 92 cm) with the solution valve open then immediately go over that area with vacuum only to remove any excess moisture.

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™ 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-Clean™. Acid - ClearWater Rinse™.

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.

Several factors that will cause overwetting include:

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.

3-3: Cleaning Information

CleanIng tOOl tIPS Wands

With a wand, keep cleaning strokes short, front to back, and run a “dry pass”. After pulling the wand for a strip of 3 or 4 ft (0.9 m or 1.2 m) long with the solution trigger

activated, go back up to the top of the stroke, and make a “dry “ 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.

Cleaning Information: 3-4

3-5: Cleaning Information

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.

Cleaning Information: 3-6

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.

3-7: Cleaning Information

Cleaning Information: 3-8

4 - Operating Instructions

This section describes how to operate the Boxxer 323HP, starting with a description of the dash assembly (see figure 4-1).

Ignition Switch

automatic

throttle Cable

(HIgH and

IDle)

Choke

Pump-Out Switch

Pump-In

Switch

Chemical Metering

Control knob

Chemical Pump

Valve

Figure 4-1. Boxxer 323HP Dash assembly - View 1 of 2

The dash assembly controls the:

System’s ignition switch and the engine throttle speed cable

• Automatic Pump-Out (APO) if included in the conguration• Pump-In system if included in the conguration•

Water pressure• Chemical metering• Water box drain•

4-1: Operating Instructions

The dash assembly includes the solution temperature control dial; the temperature, vacuum and pressure gauges; and the hour meter (see figure 4-2).

Pressure gauge

Vacuum gauge

Blower lube

Port

Solution

Port

temperature

gauge

temperature Control Dial

Pressure regulator

adjustment

(By-Pass) Valve

Figure 4-2.

Boxxer 323HP Dash assembly - View 2 of 2

The dash assembly also houses the blower lube port and the high pressure cleaning solution port where the wand/tool connects to the Boxxer 323HP.

Photographs and illustrations included in this document can represent optional equipment as well as standard equipment.

Operating Instructions: 4-2

To help achieve a high psi rating for high pressure washing, HydraMaster has added a chemical pump shutoff valve into the Boxxer 323HP’s pump system. The shutoff valve can be accessed from the side of the machine (see figure 4-3).

Chemical Pump Shutoff Valve

Figure 4-3.

location of Chemical Pump Shutoff Valve

Operating the Boxxer 323HP at pressure levels higher than 1,200 psi with the chemical pump shutoff valve turned on can result in serious component damage.

Before adjusting the pressure for high pressure washing operations, turn off the chemical pump shutoff valve by turning the handle, shown in figure 4-3, so that it is perpendicular with the pump. See pages 4-5 and 4-6 for details.

Note that there is a “CHeMICAl PUMP” valve located on the dash assembly (see figure 4-1). This is not to be confused with the chemical pump shutoff valve shown in

figure 4-3.

4-3: Operating Instructions

SettIng tHe teMPeratUre

Depending upon the type of cleaning jobs you need to do, there will be times where you will not need the maximum heat available. To adjust the temperature, the thermostat dial can be rotated counterclockwise to reduce the temperature and rotated clockwise to increase the temperature.

Start-UP PrOCeDUre

Perform all daily periodic maintenance as specied in this Owner’s Manual.1. Connect a garden hose to supply water to the truckmount. If the pump-in feature is 2. used on your system, push the “PUMP-IN” switch to the “ON” position. Connect the cleaning wand or tool to the length of hose required to perform the

3. cleaning job. Start the truckmount with:

The throttle cable in the “IDle” position.a. The pressure regulator adjustment (by-pass) valve loosened, turned all the b. way to the left.

Turn the ignition switch to “ON”. After you start the engine, allow the truckmount to

5. run in “IDle” for 2 - 3 minutes to warm up.

Never clean when the machine is in the “IDle” mode. failure to follow this caution may result in serious component or engine damage.

Pull the throttle cable all the way out and lock it into place.

6. Set the thermostat valve to the desired position.7. If the Automatic Pump-Out is included in your system’s conguration, press the 8. “AUTO PUMP-OUT” switch to the “ON” position.

Operating Instructions: 4-4

SettIng tHe PreSSUre FOr CleanIng OPeratIOnS

Adjust the “PReSSURe ReGUlATOR” to the desired level as follows:

Carpet Cleaning: 300 to 400 psi• Hard Surface Cleaning: up to 1,200 psi (or as indicated on tool)•

The chemical pump shutoff valve can be turned on for cleaning operations at 1,200 psi or lower.

The chemical pump shutoff valve is on when the handle of the integrated valve is in line with the pump (see figure 4-4).

Valve Handle

To protect the heat exchange system, the Boxxer 323HP is designed to open the pressure relief valve if the system registers more than 2,500 psi.

Turn the chemical pump shutoff valve

1. to the on position (see figure 4-4). Turn the “CHeMICAl PUMP” valve, 2. located on the dash assembly, to the “PRIMe” position to purge any air from the system (see figure 4-1 on page 4-1). With the truckmount running at

3. “HIGH”, block off the vacuum intake to the recovery tank. The vacuum gauge should read 12” Hg. This

Chemical Pump

Figure 4-4. Chemical Pump Shutoff

Valve Is On When Valve Handle Is In line

with Chemical Pump

will assist in priming the chemical system

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

4. Turn the “CHeMICAl PUMP” valve to “ON.” The restriction can now be removed 5. from the vacuum inlet.

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

6. the “CHeMICAl MeTeRING CONTROl” knob (see figure 4-1 on page 4-1). Begin cleaning.

4-5: Operating Instructions

SettIng tHe PreSSUre FOr HIgH PreSSUre WaSHIng OPeratIOnS

The chemical pump shutoff valve must be turned off during high pressure washing operations.

Valve Handle

The chemical pump shutoff valve is off when the handle of the integrated valve is perpendicular to the pump (see figure 4-5).

Turn the chemical pump shutoff

1. valve to the off position.

Adjust the “PReSSURe 2. ReGUlA T OR” up to 2,500 psi (or as indicated on the tool).

Chemical Pump

To protect the heat exchange system, the Boxxer 318 HP is designed to open the pressure relief valve if the system registers more than 2,500 psi.

Figure 4-5. Chemical Pump Shutoff

Valve Is Off When Valve Handle Is

Perpendicular to Pump

Operating at pressure levels higher than 1,200 psi with the chemical pump shutoff valve turned on can result in serious component damage. Turn off the chemical pump shutoff valve by turning the handle of the integrated valve so that it is perpendicular with the pump.

Setting the pressure level higher than the recommended value can result in an increased risk of serious component damage.

Operating Instructions: 4-6

SHUt DOWn PrOCeDUre

flush clean water through the chemical system for 10 seconds. Turn the “CHeMICAl 1. PUMP” valve” to “Off.” Cool the truckmount down by spraying the cleaning wand into the vacuum hose for 2.

3 - 5 minutes. The chemical should now be 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

down. If freeze guarding is necessary, perform the procedure at this time. See the freeze 5. Guarding section of this Owner’s Manual (page 5-17). Push the engine throttle cable to the “IDle” position.6. Turn the ignition switch to “Off.”7. Drain the water box using the valve.8. Drain the vacuum tank in an appropriate location.9.

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

Perform daily maintenance as specied in Section

10. 5 of this Owner’s Manual.

4-7: Operating Instructions

Operating Instructions: 4-8

5 - 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 below. All maintenance must be performed by qualied

service personnel.

A maintenance log, provided in the Owner’s Guide, must be correctly and completely lled

out. HydraMaster may request to inspect the logs 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 

5-1: 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.• Check the oil level in the blower. Add oil if needed.•

Inspect and clean orice and lters.• Inspect and clean the recovery tank 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 a HydraMaster-recommended 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 pump drive for wear and proper tension. Adjust 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 25 hours of operation.

•

Change the engine oil every 50 hours. (every 25 hours if operating in high ambient •

temperatures.) Change oil lter every 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 0.031 - 0.035” (0.8 - 0.9 mm). Replace if excessive • carbon buildup is visible or every 250 hours.

Change the blower oil after rst 100 hours of use (every 500 hours thereafter).

•

Machine Maintenance: 5-2

500 Hours

Change the blower oil.• Change the high pressure pump oil.• Check the engine valve clearance (intake and exhaust 0.012” [0.30 mm])•

Change primary fuel lter•

1,000 Hours

Change primary air lter

•

Check the fuel tank to ensure it is secure, and check that all components such as the •

ll cap and vent are working properly.

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.

5-3: Machine Maintenance

engIne MaIntenanCe

engine Oil level Check

The engine oil level should be checked daily. It is recommended that the oil be checked

just before the engine is started for the rst time for that day. The oil level should be

between the ‘Add’ and the ‘full’ marks on the dipstick.

Do not operate the engine with the oil level below the bottom of the ‘Add’ mark on the dipstick, or above the top of the ‘full’ mark.

adding engine Oil

It is normal to add some oil in the period of time between oil changes. The amount will vary with the severity of operation. When adding or replacing engine oil, be sure the oil

meets or exceeds the recommended specication.

Changing engine Oil and Filter

The engine oil and lter must be changed every 50 hours or every 3 months whichever occurs rst. The oil and lter should be changed every 25 hours if the engine is operating

in dusty or extremely dirty areas, or during cold weather.

engine Oil Quality

To achieve proper engine performance and durability, it is important that you use only engine lubricating oils of the correct quality in your engine. Proper quality oils also provide

maximum efciency for crankcase ventilation systems, which reduces pollution.

Use only engine oils displaying the American Petroleum Institute (API) “starburst”

certication mark ‘FOR GASOLINE ENGINES’ on the container.

engine Oil Recommendation

While multi-viscosity oils are generally recommended, SAE 5W-30 synthetic is specically

recommended year round for your Boxxer 323HP engine.

Machine Maintenance: 5-4

Oil Filter

Briggs and Stratton engines use a Briggs and Stratton lter. An equivalent or better oil lter must be used when servicing the engine.

To replace the lter, use a proper lter wrench to remove the lter.

Clean the lter mounting base and lightly coat the gasket surface of the new lter with engine oil. Hand tighten the lter until the gasket contacts the base, then tighten another

½ turn. fill the engine with the correct amount of oil, run the engine and check for oil leaks

at the drain plug and oil lter gasket.

Spark Plugs

Always use the recommended spark plugs for your engine. Hotter or colder plugs, or similar plugs that are not exact equivalents to the recommended plugs, can cause permanent engine damage, reduce the engines useful life, and cause many other problems such as hard starting, spark knock and run-on. Installing new spark plugs regularly is one of the best ways to keep your engine at peak performance.

Fuel Filter

The fuel lter is located between the fuel pump and the fuel tank underneath the vehicle.

5-5: 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 side or 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.

Refer to the Pump Servicing Section on the following page for more information.

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 the freeze Guarding section on page 5-17 of this manual.

Machine Maintenance: 5-6

Servicing Valves on the High Pressure Pump

Removing a Valve

Remove the valve cap (30 mm) and extract the valve assembly (see 1. figure 5-1).

Figure 5-1. remove Valve Cap and Valve assembly

Remove the valve assembly (retainer, spring, valve plate, valve seat) from the valve cavity. Remove the O-ring and support from the valve cavity.3. examine the O-ring and replace if there is any evidence of cuts, abrasion, or 4. distortion. Inspect the manifold for wear or damage (see 5. figure 5-2). Inspect the old valves for wear or damage. Only one valve kit (P/N 000-078-519) 6.

is necessary to repair all the valves in the pump. (The kit includes new supports, O-rings, valve seat, valve poppet, spring and retainer; all are pre-assembled.)

Figure 5-2. Inspect Manifold and Old Valves

5-7: Machine Maintenance

Replace the center inlet check valve with a modied check valve 7. (P/N 000-169-212 - figure 5-3).

Modied Check Valve

Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve

8. install valves (figure 5-4).

Apply O-ring grease to O-rings and Replace valve cap and torque to 95 ft. lbs.(13 m kgs) see

9. figure 5-5).

Figure 5-4. apply grease

and Install Valves

Machine Maintenance: 5-8

Figure 5-5. replace Valve Cap

and torque to 95 ft. lbs. (13 m kgs)

Remove the fasteners retaining the manifold 10. Separate manifold from crankcase (see 11. figure 5-6).

Figure 5-6. Separate Manifold from Crankcase

It may be necessary to rotate crankshaft or tap manifold with rawhide or plastic mallet to loosen.

When sliding manifold from crankcase, use caution not to damage ceramic plungers.

12. figure 5-7)

The seal assemblies may come off with the manifold (see

Figure 5-7.

Seal assemblies May Come Off with Manifold

examine the ceramic plungers. The surface should be 13. smooth and free from scoring, pitting or cracks (see figure 5-8); if not, replace.

loosen the stainless steel plunger bolt.14.

Figure 5-8. examine

Ceramic Plungers

5-9: Machine Maintenance

Remove the stainless steel plunger bolt and ceramic plunger from the plunger guide 15. (see figure 5-9). If the slinger washer is removed, be certain it is re-installed or replaced.

16. Separate plunger bolt from ceramic plunger (see 17. figure 5-9).

Figure 5-9. remove Stainless Steel Plunger Bolt and Ceramic Plunger

Install new Teon18. ® back-up ring and O-ring on the plunger bolt. Apply a lm of O-ring grease on the outside of the O-ring (see

Apply removable anaerobic thread sealant (loctite19. bolt, carefully pressing the plunger bolt into ceramic plunger (see Slide new ceramic plunger over the plunger guide (see

20. figure 5-10).

figure 5-10).

542) to the threads of the plunger

figure 5-10).

Figure 5-10. Install O-ring, apply Sealant and Slide Plunger over Plunger guide

Torque plunger to 14.5 ft. lbs (2 m kgs).21.

Machine Maintenance: 5-10

extracting Seals With manifold removed from crankcase:

Insert proper extractor collet through main seal retainer (see

1. figure 5-11). Tighten collet and extract retainers and seals.

The Teon seals of the HT series will be damaged during disassembly so new

ones with have to be installed.

Figure 5-11.

extract retainers and Seals

5-11: Machine Maintenance

Replacing the Seal Assemblies Only one seal kit (P/N 078-518) is necessary to repair all the seals in the pump (see figure 5-12). Use an insertion tool for seal installation

Figure 5-12. Seal kit and Insertion tool for Seal Installation

To install a seal assembly:

Apply a lm of O-ring grease on the O-ring on the outside of the new high pressure seal.

1. Insert the high pressure seal into the cavity with the “U” shape down.2. Press high pressure seal into place.3. Apply a lm of grease on the O-ring on the brass retainer (see 4. figure 5-13).

Figure 5-13. Install Seal assembly Using O-ring grease

Machine Maintenance: 5-12

To install the intermediate retainers and the low pressure seals:

Insert the brass intermediate retainer into the cavity.1. Press the new low pressure seal into the brass low pressure seal retainer and install 2. a new O-ring on the outside (see figure 5-14).

Figure 5-14. Install retainers into Cavities

Press the low pressure seal assembly into the cavity (see

3. figure 5-15).

Figure 5-15. Press low Pressure Seal assembly into Cavity

5-13: Machine Maintenance

Re-Installing Manifold

Position the outer plungers at the same position (see 1. figure 5-16).

Re-install manifold and torque the fasteners in an “X” pattern to 50% of specication

2. and then retorque to 100% specication (see figure 5-17 and figure 5-18).

Figure 5-16. re-install Manifold and torque Fasteners

Figure 5-17. torque Sequence

in “x” Pattern

Machine Maintenance: 5-14

Figure 5-18. torque Bolts to

22 ft. lbs (3 m kgs)

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. The manual for the blower has been included. Review the manual for a better understanding of this piece of machinery.

To protect the blower from overloading and damaging itself, there is a vacuum relief system installed on the vacuum tank. When the vacuum tank inlet is completely sealed off a maximum of 12” 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.

To lubricate the blower:

Allow the unit to run for a few minutes with the vacuum hose disconnected in order

1. to remove moisture from the blower. Cap off the inlet(s) to the vacuum tank.

2. Spray a HydraMaster-recommended spray lubricant into the “BlOWeR lUBe 3. 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

4. down.

Periodically

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

5-15: Machine Maintenance

DeSCalIng PrOCeDUre (reQUIreD)

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

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 (see

figure 5-19) 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 to 5 minutes. Do not leave the TM DeScaler™ solution in the system. flush the system with clean water and turn the truckmount “Off.”

Figure 5-19. recirculation Fitting

Machine Maintenance: 5-16

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 (7.57 litres) 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 “PRIME.” This will vacuum the chemical remaining in the lines to the recovery

tank. Remove the quick connect from the truckmount.

6. Spray the antifreeze and water mix out of the truckmount and into a container to 7. reclaim the solution. Run the solution until it stops.

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

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

The reclaimed antifreeze solution may be used three times before being discarded.

5-17: Machine Maintenance

To freeze guard the hoses and wand, perform the preceding procedure with the items to be freeze guarded attached.

Always check the freezing level of your reclaimed antifreeze with a glycol tester before reusing. Failure to do so may result in serious component damage.

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.

Machine Maintenance: 5-18

tenSIOnIng tHe PUMP DrIVe Belt

Remove the Boxxer 323HP grill to gain access to the idler pulley.1. Remove the engine duct plate.2. loosen but 3. do not remove the ½”-13 x 2 ¼” long bolt on the idler pulley. Remove the right cover of the machine to gain access to the tensioning screw.

4. Adjust the tension of the belt by turning the ¼”-20 x 4” long screw. 5. After the proper belt tension is achieved, tighten the ½” bolt on the idler pulley.6.

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.

Re-install the engine duct plate.

7. Replace the right cover and grill.8.

5-19: Machine Maintenance

Machine Maintenance: 5-20

6 - Water and Chemical

System

This section describes the Boxxer 323HP’s water and chemical systems, and includes the exhaust subsystem.

Parts of the text are also included in the section’s annotated illustrations which are referenced in the following paragraphs (see

The process starts when fresh water is brought through the front of the truckmount

1. into the water box, as indicated in figure 6-1. 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 by-pass valve. This valve allows manual

2. adjustment of the pressure level. When the valve at the wand is closed, the water in the system is recirculated to the water box. When solution is being used at the wand, the necessary amount of high pressure water passes through the by-pass valve and to the heat exchanger (see

figure 6-1 – figure 6-4).

figure 6-1).

In the cross ow heat exchanger, the temperature is raised. The heat necessary to

3. do this is provided by both the engine and blower exhausts (see figure 6-4. The heated water then travels to the high pressure manifold (see

Water temperature is controlled via a temperature sensor inside the high pressure

4. manifold. When the system achieves the maximum operating temperature, the high pressure solenoid opens and ows water into the recovery tank. This will reduce the

internal temperature of the machine.

Water that is recirculated through the pressure regulator back to the water box

5. travels past a thermovalve. This thermovalve monitors the water box temperature. When the thermovalve senses the water in the water box has reached its set point, it opens the low pressure thermovalve on the side of the water box and closes once the temperature drops back below the set point (see

The water that is being called for by the wand then exits the manifold and passes

6. through a check valve (see figure 6-2).

figure 6-2).

6-1: Water and Chemical Systems

figure 6-1).

finally, the water joins the chemical where the solution is created (see 7. figure 6-2).

The chemical is pressurized by the HydraMaster diaphragm chemical pump attached

8. to the head of the water pump. This pump pulls the chemical from the chemical, or

soap, jug through the chemical ow meter (see

After being pressurized, the chemical travels through the metering valve and

figure 6-3).

is injected into the high pressure stream. This solution then exits the front of the truckmount and is delivered to the cleaning tool (see

figure 6-3).

Water and Chemical System: 6-2

annotated Figure 6-1. Water, Chemical and Solution Flow Diagram View 1 of 2

8069

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 cross ow heat exchanger. In this heat exchanger the

temperature of the water is raised to cleaning temperature. the heated water

travels to the high pressure manifold.

6-3: Water and Chemical System

Figure 6-2. annotated Water, Chemical and Solution Flow Diagram - View 2 of 2

8069

4. Water temperature is controlled via a

temperature sensor

inside the high

pressure manifold.

When the system

achieves the

maximum operating

temperature, the

solenoid opens and

ows water into the

recovery tank.

6. the water that is being called for by the wand then exits the manifold and passes through a

check valve.

5. Water that is recirculated through the

pressure regulator back to the water box

travels past a thermovalve. this thermovalve

monitors the water box temperature.

Water and Chemical System: 6-4

Figure 6-3.

8069

Chemical Flow Diagram - larger View

the chemical is pressurized by the HydraMaster diaphragm chemical pump attached to

the head of the water pump. this pump pulls the chemical from the chemical, or soap,

jug through the chemical ow 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

6-5: Water and Chemical System

8069

exhaust Flow DiagramFigure 6-4.

Water and Chemical System: 6-6

7 - electrical System

This section includes drawings for the following:

electrical Schematic (see  figure 7-1) Wiring Diagram (

 figure 7-2 - figure 7-4)

The Boxxer 323HP 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.

7-1: electrical System

GND

eleCTRICAl SCHeMATIC - TMT3000/BOXXeR 323

4/16/2010

.XXX= .010

Mukilteo, Washington 98275

PROPRIeTARy INfORMATION

APPVD

CHeCKeD

DRAWN

125

DIMeNSIONS ARe IN INCHeS

BReAK All SHARP eDGeS 0.005-.015

ANGUlAR= 1°

UNleSS OTHeRWISe NOTeD

fINISH

11015 47th Avenue West,

e.J. e.J.

6 5

8 7

C.I.R.

TOleRANCeS

.X= .1

.XX= .03

MACHINe

TR8

-4

SW-1

-1

-2 -3

-6

-2

-4

-2

-6

-2

-5

-3

-3 -4

-9

-6 -5

-1

-6-3

TeMPeRATURe

TR7TR5TR6

TR3 TR4

TC-1

TR1 TR2

CONTROlleR

IGNITION SWITCH

-3

TB3

TB3TB2

N/O

GND

Off

TB1

HOUR MeTeR

HI-1

GND

TB1

SHUTDOWN

eNGINe SHUTDOWN

f-1

AUTOMATIC PUMP OUT (OPTIONAl)

fS-3

AUTOMATIC PUMP OUT

RelAy

25A

HIGH TeMP

SWITCH

SW-4

WATeR BOX

WATeR flOAT

fUSe

TB1

TB3

25A

fS-1

fS-2

VACUUM TANK HIGH

GAUGe

PMP-1

GND

TB2

HIGH TeMP SOleNOID lIGHT

SOleNOID

TT-1

V-4

TI-1

SOleNOID

SeNSOR

TS-1

- +

12V BATTeRy

PS-1

GND

TeMPeRATURe

GND

TB1

TB2

SW-5

D-4

l-2

GND

CONTROlleR

V-1

SOl-1

THeRMOSTAT

STARTeR

MTR-1

yel

TB1

eNGINe KIll lUG

PUMP-IN PUMP

fReSH WATeR

CR-5

GND

VOlT. ReG.

GND

STATOR

VR-1

BATT

CARB

SW-2

ONOff

TB1

fReSH WATeR PUMP-IN (OPTIONAl)

GND

SOleNOID

AUTOMATIC PUMP OUT

STARTeR

87a

APO PUMP

CR-1

87a

TB1

yel

B&S ENGINE

PUMP IN SWITCH

GND

TB1

GND

TB1

fUSe

f-2

PMP-2

fUel PUMP

TB1 TB1

TB1

GND

TB1

RelAy

flOAT SWITCH

PMP-3

APO PUMP

TB1

TB2

SWITCH

HIGH TeMP

flOAT SWITCH

SW-3

TeMPeRATURe

SeNDeR

TB1

reVISIOnS

lTR ReVISION CODe DATe By CHKD APPVD

-4

Figure 7-1. electrical Schematic

8068

electrical System: 7-2

FLOAT SWITCH

(RED)

HARNESS

(WHT)

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

4 (ORG)

FS-3

8 (RED) 6 GA

12V BATTERY

PS-1

ENGINE

V-1

SOL-1

MTR-1

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

(BLK)

PUMP IN PUMP

(BLK) (BLK)

WATER BOX

HIGH TEMP SOLENOID

SOLENOID

CONNECTOR

(BLK)

(RED)

69(BLK) 14 GA

FEMALE- J-9

87a

75(BLK) 14 GA

CR-2

APO PUMP RELAY

71(WHT)

B-6

B-5

71(WHT)

69(WHT) 14 GA

APO PUMP

70(WHT) 14 GA

WEATHERPACK

STATOR

(WHT)

(BLK)

68(BRN) 14 GA.

67(PUR/WHT)

84(WHT) 14 GA.

66(ORG/BLK)

65(ORG)

TB2 A B

C D E

AUTOMATIC PUMP OUT

FS-2

FLOAT SWITCH

ASSEMBLY

V-4

VACUUM TANK

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

B-2

72(PUR/WHT)

16 (BRN) 16 GA

5 (RED) - 6 GA

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

FUEL PUMP

11 (BLK) 6 GA

VR-1

72(PUR/WHT)

BATT

RECOVERY TANK

(OPTIONAL)

LUG

8 (RED) 6 GA

(WHT) 14 GA

(WHT)

FLOAT SWITCH

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)

(WHT)

AUTOMATIC PUMP OUT

MALE- P-9

GROUND

FS-1

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

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

WATER BOX ASSEMBLY

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

HARNESS

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) )2 TEEHS( )AG 61( 2-1BT OT )DER( 1)DER( 1

10 (YEL) TO SW1-4 (16 GA) (SHEET 3)

PMP-3

3 (YEL)

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

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

9 (WHT) 14 GA TO TB1-5 (SHEET 2)

CARB

VOLT. REG.

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

14 (

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

10 (YEL)

P-5 J-5

PMP-1

PMP-2

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

REVISIONS

DVPPADKHCYBETADEDOCNOISIVERRTL

5678

Figure 7-2. Wiring Diagram View 1 of 3

8067

7-3: electrical System

Wiring Figure 7-3.

87a

25 A

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

TR8

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

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

29 (BLU)

13 (PUR/WHT)

25 (BLK)

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

25 A

B-15

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

26 (WHT)

TR7TR5TR6

TR3 TR4

TC-1

B-14

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

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

(BLK) 20 GA

(GRN) L-2

3 (YEL)

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

27 (B

LK)

(BLK)

19 (BLK)

19(BLK) TO LOW WATER ENGINE

FU-1

3(YEL) TO ENGINE STOP LUG

(ORG)

TR1 TR2

CONTROLLER

B-13

B-12

30 (WHT)

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

TEMPERATURE

B-10

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

B-11

28 (RED)

90 (WHT) TO TEMP GAUGE TI-1 #G (SHEET 3)

SWITCH SW-4 (SHEET 3)

23 (PNK)

33 (RED)

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

22 (WHT/RED)

30 (WHT)

22 (WHT/RED)

B-9

(ORG)

HIGH TEMP

(SHEET 3)

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

23(PNK) TO HIGH TEMP SHTDN

STOP FS1- 20 GA (SHEET 1)

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

21 (WHT/RE

20 (BLK)

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

FUSE

FU-2

(RED) 20 GA

TS-1

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

TO THERMOSTAT

(RED) 20 GA

CR-1

TERMINAL BLOCK- TB-1

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

FUSE

SOLENOID LIGHT

(SHEET 1)

ENGINE SHUTDOWN

RELAY

91 (RED) TO TEMP GAUGE TI-1 #I (SHEET 3)

REC TANK PLUG P5-D (SHEET 1) 13(PUR/WHT)

PROPRIETARY INFORMATION

5678

11015 47th Avenue West,

Diagram - View 2 of 3

8067

electrical System: 7-4

Figure 7-4. Wiring Diagram

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

GAUGE

TT-1

89(ORG)

90(WHT) TO TB1-4 (SHEET 2)

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

TI-1

89(ORG)

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

64(ORG)

SW-1

TS-1

90(WHT)

HOUR METER

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

B-3

IGNITION SWITCH

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

HI-1

91(RED)

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

AUTOMATIC PUMP OUT

SW-2

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

SENSOR

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

TO TR-7 29(BLU)

TO TR-5 28(RED)

TO TR-6 27(BLK)

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

SHUTDOWN

(SHEET 2)

B-4

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

TO VOLTAGE REGULATOR (SHEET 1) 12(RED)

THERMOSTAT

SW-3

SWITCH

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

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

HIGH TEMP

TO CONTROLLER

SWITCH

SW-5

B-8

36(WHT)

FRESH WATER PUMP IN

SW-4

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

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

CONTROLLER

HI-PSI MANIFOLD ASSEMBLY

B-7

TEMPERATURE

TEMP. SENDER

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

TO REC TANK PLUG P5-F (SHEET 1) 14(BRN) 14 GA

5678

PROPRIETARY INFORMATION

- View 3 of 3

8067

7-5: electrical System

electrical System: 7-6

8 - Systems Troubleshooting

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

Heating System



Chemical System



engine  High Pressure System



Vacuum System



8-1: Systems Troubleshooting

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 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.

Systems Troubleshooting: 8-2

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.

8-3: Systems 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.

Systems Troubleshooting: 8-4

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 is faulty.

Refer to a qualied service technician for further

troubleshooting.

2.4 The water box is empty Attach an inlet garden hose to ll the water box.

If too many attempts are made to start the

engine prior to lling the water box, it is possible to ood the engine (see step 3.3 in

the next section).

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.

8-5: Systems Troubleshooting

4.0 Will not come up to normal operating rpm. Note: engine should be adjusted to run at 3,200 rpm under no vacuum load.

4.1 The throttle linkage is out of adjustment.

excessive load on the

4.2

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

Inspect and clean the recovery tank lters.

engine.

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

excessive back pressure

4.3 on the engine exhaust.

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

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

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.

Systems Troubleshooting: 8-6

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

Running the engine with a low oil level can cause severe damage to the engine. If this situation occurs, the engine should be

inspected by a qualied service technician.

7.3 The engine rpm is too high.

excessive back pressure

7.4 on the engine exhaust.

Check the engine rpm. Adjust as necessary to run at 3,200 rpm under no vacuum load.

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

8-7: Systems Troubleshooting

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

3,200 rpm under no 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 0.021”.

2.0 no pressure reading on gauge

2.1 The pump belts are

Inspect and replace if necessary.

broken.

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.

faulty quick connect in the

3.2 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.

Systems Troubleshooting: 8-8

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.

8-9: Systems Troubleshooting

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

3,200 rpm under no 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.

Systems Troubleshooting: 8-10

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.

8-11: Systems Troubleshooting

Systems Troubleshooting: 8-12

This section contains all the assemblies and parts lists associated with the Boxxer 323HP:

9 - Assemblies and Parts list

Machine Assembly Parts lis  t frame Assembly Parts lis  t engine Assembly Parts lis  t Pump Assembly Parts lis  t Dash Assembly Parts lis  t electrical Panel Assembly Parts lis  t Blower Heat exchanger Assembly Parts lis  t Blower Assembly Parts lis  t Silencer Assembly Parts lis  t

Water Box Assembly Parts lis  t exhaust Assembly Parts lis  t Idler Pulley Assembly Parts lis  t Hi Pressure Manifold Assembly Parts lis  t By-Pass Valve Assembly Parts lis  t Dura-flow APO Assembly Parts lis  t 70 gallon Universal Recovery Tank Assembly Parts lis  t Machine Hose Routing  s

9-1: Assemblies and Parts lists

2 5 7

5 6 4

6 5

8106 Rev. A

Machine assembly - View of 1 of 2Figure 9-1.

Assemblies and Parts lists: 9-2

576

REVISIONS

LTR

REVISION

CODE

DATE

CHKD

APPVD

NOTE 1 WAS 610-001-323 FOR THE FRAME.

LRIP

6/22/2010

L.O.L.

C.I.R. C.I.R.

8106 Rev. A

Machine assembly - View of 2 of 2Figure 9-2.

9-3: 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 3 000-041-452 Cover, Side - 17.250” X 14.316” 1 4 000-041-011 Cover, Top - Machine 1

Item Part number Description Qty

5 000-143-126 Screw, #10-24UNC X 0.50” lg. Hex Head 13 6 000-174-001 Washer, #10 flat 13 7 000-174-014 Washer, #10 lock 9

Assemblies and Parts lists: 9-4

1020

REVISIONS

LTR

REVISION

CODE

DATE

NOTE 1 WAS 610-001-323 FOR THE FRAME.

LRIP

6/22/2010

55 5

WASHER, #10 FLAT

S. STEEL

54 2

SPACER, MACHINE RISING 4" x 35"

BLACK UHMW

POLYETHYLENE

53 5

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

S. STEEL

52 4

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

S. STEEL

51 2

RIVET, AB4-3A ALUMINUM POP 1/8" x 1/4" LG. (GRIP RANGE 0.126"-0.187")

ALUMINUM

50 1

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

RUBBER

49 1

PLATE, MACHINE SERIAL I.D.

S. STEEL

48 1

HOSE, Ø 2.5" ID SILICONE x 16" LG.

SILICONE

47 1

HOSE ASSEMBLY, 3/16" x 24" LG. TEFLON

S. STEEL

46 1

HOSE ASSEMBLY, 3/8" x 14.5" LG. TEFLON

S. STEEL

45 1

HOSE ASSEMBLY, 3/8" x 14.5 LG. TEFLON

S. STEEL

44 1

HOSE ASSEMBLY, 3/8" x 19.5 LG. TEFLON

S. STEEL

43 1

HOSE ASSEMBLY, 3/16" x 75" LG. TEFLON

S. STEEL

42 1

HOSE, 1/4' I.D. TRIDENT FUEL - BULK

RUBBER

41 1

HOSE ASSEMBLY, 3/8" x 10" LG. TEFLON

S. STEEL

40 1

HOSE ASSEMBLY, 3/16" x 44" LG. TEFLON

S. STEEL

39 1

HOSE ASSEMBLY, 3/16" x 23" LG. TEFLON

S. STEEL

38 1

HOSE ASSEMBLY, 3/16" x 23" LG. TEFLON

S. STEEL

37 1

HOSE, 3/8" I.D. CLEAR BRAID - BULK

VARIOUS

36 1

HOSE, 3/8" I.D. CLEAR BRAID - BULK

VARIOUS

35 1

HOSE, 3/4" I.D. PARKER GST II - BULK

RUBBER

34 1

HOSE, 5/32" I.D. VACUUM - BULK

RUBBER

33 1

HOSE, 5/32" I.D. VACUUM - BULK

RUBBER

32 1

HOSE, 1/2" I.D. - BULK

RUBBER

31 1

HOSE, 1/2" I.D. - BULK

RUBBER

30 1

HOSE, 1/2" I.D. - BULK

RUBBER

29 1

HOSE,1/2"RUBBER-BULK

RUBBER

28 1

HOSE, 3/8" I.D. - BULK

RUBBER

27 1

HOSE, 3/8" I.D. - BULK

RUBBER

26 1

HOSE, 3/8" I.D. - BULK

RUBBER

25 1

FRAME, COMPLETE - PAINTED

STEEL

24 1

WYE, 1/2" PLASTIC BARB

GFBN

23 1

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

BRASS

22 1

TEE, 3/8" INSERT

GFBN

21 1

FILTER, CHEMICAL INLET HIGH PRESSURE

VARIOUS

20 2

CLAMP, 2" CUSHION LOOP

S. STEEL

19 1

CLAMP, 1" CUSHION LOOP

VARIOUS

18 2

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

VARIOUS

17 1

CLAMP, 1-3/4" CUSHION LOOP VARIOUS

16 2

CLAMP, SIZE #12 HOSE

STEEL

15 2

CLAMP, SIZE #44 HOSE

S. STEEL

14 8

CLAMP, SIZE #5 HOSE

S.STEEL

13 10

CLAMP, SIZE #4 MINI HOSE

S. STEEL

12 2

CAP, 2" X 3" FRAME END

PLASTIC

11 2

BELT, #9447 HD GREEN BACK

VARIOUS

10 1

ASSEMBLY, DASH

VARIOUS

9 1

ASSEMBLY, SILENCER

VARIOUS

8107 Rev. A

Frame assembly - View 1 of 4Figure 9-3.

9-5: Assemblies and Parts lists

8107 Rev. A

5553

14 30 14

14 31

45 41

Frame assembly - View 2 of 4Figure 9-4.

Assemblies and Parts lists: 9-6

8107 Rev. A

Frame assembly - View 3 of 4Figure 9-5.

9-7: Assemblies and Parts lists

Frame assembly - View 4 of 4Figure 9-6.

133716

8107 Rev. A

Assemblies and Parts lists: 9-8

Frame assembly Parts list

Item Part number Description Qty

1 - - - Assembly, Blower 1 2 - - - Assembly, Water Box 1 3 - - - Assembly, electrical Panel 1 4 - - - Assembly, engine 1 5 610-007-015 Assembly, Pump 1 6 - - - Assembly, Heat exchanger 1 7 - - - Assembly, exhaust 1 8 - - - Assembly, Idler Pulley 1 9 - - - Assembly, Silencer 1 10 - - - Assembly, Dash 1 11 000-010-132 Belt, #9447 Hd Green Back 2 12 000-027-110 Cap, 2” X 3” frame end 2 13 000-033-003 Clamp, Size #4 Mini Hose 10 14 000-033-005 Clamp, Size #5 Hose 8 15 000-033-012 Clamp, Size #44 Hose 2

Item Part number Description Qty

30 000-068-018 Hose, 1/2” I.D. - Bulk 1 31 000-068-018 Hose, 1/2” I.D. - Bulk 1 32 000-068-018 Hose, 1/2” I.D. - Bulk 1 33 000-068-030 Hose, 5/32” I.D. Vacuum - Bulk 1 34 000-068-030 Hose, 5/32” I.D. Vacuum - Bulk 1 35 000-068-069 Hose, 3/4” I.D. Parker Gst Ii - Bulk 1 36 000-068-326 Hose, 3/8” I.D. Clear Braid - Bulk 1 37 000-068-326 Hose, 3/8” I.D. Clear Braid - Bulk 1

38 000-068-517 Hose Assembly, 3/16” X 23” Lg. Teon 1

39 000-068-517 Hose Assembly, 3/16” X 23” Lg. Teon 1

40 000-068-627 Hose Assembly, 3/16” X 44” Lg. Teon 1

41 000-068-641 Hose Assembly, 3/8” X 10” Lg. Teon 1

42 000-068-660 Hose, 1/4’ I.D. Trident fuel - Bulk 1

43 000-068-723 Hose Assembly, 3/16” X 75” Lg. Teon 1

44 000-068-736 Hose Assembly, 3/8” X 19.5 Lg. Teon 1

16 000-033-029 Clamp, Size #12 Hose 2 17 000-033-050 Clamp, 1-3/4” Cushion loop 1 18 000-033-052 Clamp, 1-1/4” S/S eDPM 2 19 000-033-057 Clamp, 1” Cushion loop 1 20 000-033-067 Clamp, 2” Cushion loop 2 21 000-049-118 filter, Chemical Inlet High Pressure 1 22 000-052-022 Tee, 3/8” Insert 1 23 000-052-102 Insert, #46 (1/4” NPT X 3/8” Barb) 1 24 000-052-407 Wye, 1/2” Plastic Barb 1 25 000-055-195 frame, Complete - Painted 1 26 000-068-017 Hose, 3/8” I.D. - Bulk 1 27 000-068-017 Hose, 3/8” I.D. - Bulk 1 28 000-068-017 Hose, 3/8” I.D. - Bulk 1 29 000-068-018 Hose, 1/2” I.D. - Bulk 1

45 000-068-737 Hose Assembly, 3/8” X 14.5 Lg. Teon 1

46 000-068-737 Hose Assembly, 3/8” X 14.5” Lg. Teon 1

47 000-068-888 Hose Assembly, 3/16” X 24” Lg. Teon 1

48 000-068-890 Hose, Ø 2.5” Id Silicone X 16” lg. 1 49 000-105-012 Plate, Machine Serial I.D. 1 50 000-131-131 Trimlok, 3/8” X 1/8” Rubber - Bulk 1 51 000-140-001 Rivet, Ab4-3a Aluminum Pop 1/8”” X 1/4” lg. 2 52 000-143-114 Screw, #10-24UNC X 0.50” lg. flat Head Phillips 4 53 000-143-126 Screw, #10-24UNC X 0.50” lg. Hex Head 5 54 000-154-156 Spacer, Machine Rising 4” X 35” 2 55 000-174-001 Washer, #10 flat 5

9-9: Assemblies and Parts lists

HYDRAMASTER Boxxer 323HP User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual