HydraMaster Diamond Products GTXR+, Owner'S Manual And Maintenance Logs

Page 1: ...formation in this document are subject to change without prior notice All rights reserved 2021 HydraMaster Diamond Products GTXR Owner s Guide and Maintenance Logs LTR REVISION DESCRIPTION CODE D B C D 2 3 4 8 7 6 5 4 3 2 DRAWN CHECKED APPVD SCALE 1 16 8 7 6 5 A S TOLERANCES X 1 XX 03 XXX 010 ANGULAR 2 BREAK ALL SHARP EDGES 0 005 015 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES APPLICATION NEXT...

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Page 3: ... Owner s Guide It is wise to keep the Owner s Guide in a visible location near the truckmount so that the log stays up to date Please note that records of maintenance must be kept and copies may be required to be furnished to HydraMaster before any warranty is honored The digital Owner s Manual contains information on everything from cleaning and chemicals to truckmount operation and maintenance I...

Page 4: ...ster direct using the following phone numbers HOURS TELEPHONE NUMBERS E MAIL ADDRESSES Monday Friday 7 00 a m to 5 00 p m Pacific Time Technical Support 800 426 1301 FAX 800 426 4225 Technical Support techsupport hydramaster com Customer Service Parts 800 426 1301 FAX 800 426 4225 Customer Service Parts parts hydramaster com When calling your distributor be sure to reference the serial number and ...

Page 5: ...Master uses this WARNING symbol throughout the guide to warn of possible injury or death This CAUTION symbol is used to warn of possible equipment damage This NOTICE symbol indicates that federal or state regulatory laws may apply and also emphasizes supplemental information ...

Page 6: ...rbon 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 c...

Page 7: ...r perform cleaning operations when the truckmount engine is running at the IDLE throttle position Failure to do so will increase the risk of serious component or engine damage Never operate the truckmount with the vehicle doors closed Doing so results in extremely high temperatures inside the vehicle and will lead to serious component or engine damage Never use concentrated acids or solvents inclu...

Page 8: ... mounted directly below the floor that can easily be damaged Before drilling holes in the floor of the vehicle inspect the underside of the vehicle for critical components Failure to do so may result in damage to the vehicle During the operation of this equipment surfaces will become hot Do not allow components such as hoses to touch hot surfaces Failure to heed this warning can result in equipmen...

Page 9: ...pplied to the floor such as Rhino Lining or Line X Prior to operating the truckmount read this manual in its entirety and familiarize yourself with the information contained here Special attention should be paid to all cautions and warnings The distributor is responsible for the correct installation of the truckmount The distributor is also responsible to train you in the correct and proper operat...

Page 10: ...and accessories in the vehicle and securing them with bolts and back up plates The distributor should verify that the owner is in agreement with the layout Ensure proper connection of the fuel lines Ensure proper connection and installation of the battery Verify that the battery is in accordance with HydraMaster s recommendation Check the pump vacuum blower and engine oil levels prior to starting ...

Page 11: ...tart and shut down the truckmount How to correctly clean with the truckmount Where and how often to check and change component oil levels Freezing damage and how to avoid it This includes explaining proper freeze guarding procedures How to do basic troubleshooting of the truckmount Hard water damage and how to avoid it This includes how to determine if hard water exists in your area and the instal...

Page 12: ...The heat of the engine and blower exhausts is transferred to the high pressure water in the finned tube heat exchanger of the system Finally the chemical is injected into the pressurized water stream and the heated solution is delivered to the cleaning tool The solution is recovered by the vacuum generated by the vacuum pump This solution is collected in the recovery tank for proper disposal ...

Page 13: ...Blower Gardner Denver 4005 Max Vac 14 Hg Oil Type AEON PD Synthetic Gear End Capacity Approx 5 8 oz Drive End Capacity Approx 4 7 oz Blower rpm 3 150 rpm Water Pump 3 5 gpm Plunger Pump Electric Clutch Control Oil Type 30W non detergent Capacity Approx 8 0 oz Pump Rate 3 5 gallons per minute Pump rpm 1 750 rpm Drive System Guardian Coupler Engine Exhaust Diverter Automated Diverter Control ADC Tem...

Page 14: ...m Gauge 0 30 Hg Solution Pressure Gauge 0 1 500 Psi Solution Pressure Adjustment Pre Wired Pump In Switch Pre Wired Pump Out Switch Fresh Water Inlet Water System Drain Valve Diagnostic Status Lights Engine Choke Engine Throttle Electrical Circuit Protection Fuse Protected Solution Temperature Control Selector Fresh Water Tank FWT 110 Gallon Rotomold Universal Recovery Tank URT 100 Gallon URT Wand...

Page 15: ...ory 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 machin...

Page 16: ...se fluid related components such as hoses fittings heaters pumps valves and water cooled engines For other countries hard water area maps can be obtained from geological societies Figure 1 Hard Water Map of Mainland United States The map shown in Figure 1 is provided for general reference only Water hardness in your geographical location should be confirmed by testing ...

Page 17: ...ly 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 efficiency 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 car...

Page 18: ... is to accumulate the waste water and haul it to an appropriate dump site Another solution to the disposal problem is to equip your GTXR with an automatic pump out system 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 automatic pump out system called the Automatic Wast...

Page 19: ...ed IDLE position see Figure 2 5 After the engine starts push the choke in and allow the truckmount to run in IDLE for 2 3 minutes to warm up 6 Pull the throttle cable to full extension and twist the handle clockwise to lock Figure 2 Location of Throttle Choke and Pump In Pump Clutch Switch LTR REVISION DESCRIPTION CODE DATE B B C D 2 3 4 8 7 6 5 4 3 2 DRAWN CHECKED APPVD SCALE 1 16 8 7 6 5 A P 11 ...

Page 20: ...5 4 3 8 7 6 5 A TOLERAN X XX XXX ANGULAR BREAK ALL S UNLESS O DIMENSIO APP NEXT AS 750 012 754 Figure 3 Front View of the GTXR Console Temperature Knob Optional Auto Pump Out Switch Chemical Selection Valve Chemical Metering Control Knob Vacuum Gauge Pressure Gauge Blower Lube Port ...

Page 21: ...et Cleaning 300 400 psi Hard Surface Cleaning 1 000 psi or as indicated on the tool LTR REVIS 4 8 7 6 5 4 8 7 6 5 Pressure Regulator Figure 4 Side View of the GTXR Console 11 Turn the CHEMICAL SELECTION VALVE to the PRIME position to purge any air from the system a With the truckmount running at full throttle block off the vacuum intake to the recovery tank The vacuum gauge should read 12 14 Hg Th...

Page 22: ...ve the vacuum hose 4 Lubricate the blower to prevent it from rusting internally a Allow the unit to run for a few minutes with the vacuum hose disconnected in order to remove moisture from the blower b Cap off the inlet s to the vacuum tank c Spray a HydraMaster recommended spray lubricant into the BLOWER LUBE PORT for about 5 to 7 seconds while the unit is running see Figure 3 d Allow machine to ...

Page 23: ...schedule and maintenance logs which must be correctly and completely filled out An Interval Hours Maintenance Chart is on page 43 and page 44 The manufacturer may request to inspect the logs before a warranty claim is honored Record the date and machine hours on the maintenance log provided for your convenience in the Owner s Guide Records of maintenance must be kept and copies may be required to ...

Page 24: ...l if needed Check the pump drive belt for wear and proper tension Tighten as needed Check all the hoses and wiring for wear and chafing Secure as needed Flush the water and chemical systems with solution of equal parts white 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 ...

Page 25: ...xhaust 0 004 0 006 Change the fuel filter Replace as necessary Check coupler rubber sleeve for cracks or wear Replace as necessary Coupler Sleeve Part Number 000 152 015 Replace the sacrificial anodes in the tank 1000 Hours Change air filters Check plug wires Replace as necessary Check carburetor Clean or replace as necessary Clean the heat exchanger core Replace as necessary Check coupler rubber ...

Page 26: ...minated 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 w...

Page 27: ...e suction and delivery check valves The valve assembly usually stays together when removing If the valve comes apart use the needle nose pliers or reverse pliers to remove the remaining parts 4 Inspect each suction and delivery check valve assembly for wear and pitting and replace if necessary The valve assembly consists of the plastic cage spring valve seat poppet and O ring One valve kit is need...

Page 28: ...and V Packing Maintenance 1 Remove the manifold as previously described It is possible that the seal and brass retainer ring assembly will stay on the piston or will remain in the manifold when removing it 2 Carefully remove the brass retainer ring seal stack Remove the low pressure seal using needle nose pliers Discard the old seal 3 Remove the outer O ring by taking a small flat head screwdriver...

Page 29: ...r Replace if necessary Plunger Re assembly 1 Generously grease the piston guide Replace the O ring making sure it does not twist or roll 2 Slide the lower washer and ceramic bushing onto the piston guide 3 Place a small amount of LOCTITE 243 on the piston guide threads Replace the old washer and thread the nut onto the piston guide Torque to 4 5 ft lbs Servicing the Crankcase 1 While the manifold ...

Page 30: ...blower open to the atmosphere Foampassingthroughtheblowercanleadtoseriousproblemswiththetruckmount It is important to keep the recovery tank free of foam The tank is protected from overflowing by a float kill switch however this switch is not activated by foam Daily At the end of each day the internal components of the blower need to be lubricated This helps to prevent rust deposits and prolongs t...

Page 31: ...using the recirculation kit P N 000 078 058 start with an empty water box 1 Fill a third of the water box with TM DeScaler Follow the recommendations on the TM DeScaler label for proportions Verify that the float is not lying horizontal but floats below 2 Attach the recirculation fitting provided in the kit to the garden hose quick connect see Figure 6 and this combination to the front of the truc...

Page 32: ...x 3 Attach a section of solution hose to the outgoing solution fitting on the front of the machine Attach the opposite end to the recirculation fitting If more sections of hose are to be freeze guarded attach those inline 4 Start the truckmount and allow it to run for 2 to 3 minutes This will distribute antifreeze solution throughout the truckmount 5 Remove the chemical feed line from the chemical...

Page 33: ... source to the front of the truckmount 3 Start the truckmount 4 Spray the solution through the hoses and wands into a sealable container until all signs of antifreeze are gone Freeze Protection of the Pump In System 1 Drain the fresh water tank 2 Remove the garden hose adapter from the pump in pump hose and position the hose so it is pointing outside the van 3 Turn on the pump in pump and run for ...

Page 34: ...al 3 Remove the right cover of the machine to gain access to the tensioning screw 4 Adjust the tension of the belt by turning the 4 long screw P N 000 143 376 5 After the proper belt tension is achieved tighten the bolt on the idler pulley 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 tru...

Page 35: ...33 Diamond Products GTXR Owner s Guide ...

Page 36: ...d lubricate as necessary Check the pump drive belt for wear and proper tension Tighten as needed Clean the recovery tank thoroughly with pressure washer Check the oil level in the blower Add oil if needed One time change of the high pressure pump oil after 50 hours of operation Every 500 hours thereafter Check all the nuts and bolts Tighten as needed Change the blower oil after first 100 hours of ...

Page 37: ...tenance Change the blower oil 1000 Hours Maintenance Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sleeve Part Number 000 152 015 Change the high pressure pump oil Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sl...

Page 38: ...d lubricate as necessary Check the pump drive belt for wear and proper tension Tighten as needed Clean the recovery tank thoroughly with pressure washer Check the oil level in the blower Add oil if needed One time change of the high pressure pump oil after 50 hours of operation Every 500 hours thereafter Check all the nuts and bolts Tighten as needed Change the blower oil after first 100 hours of ...

Page 39: ...tenance Change the blower oil 1000 Hours Maintenance Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sleeve Part Number 000 152 015 Change the high pressure pump oil Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sl...

Page 40: ...d lubricate as necessary Check the pump drive belt for wear and proper tension Tighten as needed Clean the recovery tank thoroughly with pressure washer Check the oil level in the blower Add oil if needed One time change of the high pressure pump oil after 50 hours of operation Every 500 hours thereafter Check all the nuts and bolts Tighten as needed Change the blower oil after first 100 hours of ...

Page 41: ...tenance Change the blower oil 1000 Hours Maintenance Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sleeve Part Number 000 152 015 Change the high pressure pump oil Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sl...

Page 42: ...d lubricate as necessary Check the pump drive belt for wear and proper tension Tighten as needed Clean the recovery tank thoroughly with pressure washer Check the oil level in the blower Add oil if needed One time change of the high pressure pump oil after 50 hours of operation Every 500 hours thereafter Check all the nuts and bolts Tighten as needed Change the blower oil after first 100 hours of ...

Page 43: ...tenance Change the blower oil 1000 Hours Maintenance Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sleeve Part Number 000 152 015 Change the high pressure pump oil Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sl...

Page 44: ...d lubricate as necessary Check the pump drive belt for wear and proper tension Tighten as needed Clean the recovery tank thoroughly with pressure washer Check the oil level in the blower Add oil if needed One time change of the high pressure pump oil after 50 hours of operation Every 500 hours thereafter Check all the nuts and bolts Tighten as needed Change the blower oil after first 100 hours of ...

Page 45: ...tenance Change the blower oil 1000 Hours Maintenance Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sleeve Part Number 000 152 015 Change the high pressure pump oil Check coupler rubber sleeve for cracks or wear Replace as necessary Replace as necessary Coupler Sl...

Page 46: ...25 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600 Check the coupler element rubber insert for cracks or wear Replace as necessary CH CH Check the fuel lines Repair or replace as needed CH CH Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible C I C I Change the fuel filter R R Change pump drive belt R R SERVICE 50 75 100 125 150 175 200 225 250 275 30...

Page 47: ... 875 900 925 950 975 1000 1025 1050 1075 1100 1125 1150 1175 1200 Check the coupler element rubber insert for cracks or wear Replace as necessary CH CH Check the fuel lines Repair or replace as needed CH CH Clean and gap the spark plugs to 0 030 Replace if excessive carbon buildup is visible C I C I Change the fuel filter R R Change pump drive belt R R SERVICE 650 675 700 725 750 775 800 825 850 8...

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Page 49: ...VAILABLE TO THE BUYER HYDRAMASTER WILL NOT BE LIABLE FOR ANY OTHER OR ADDITIONAL DAMAGES INCLUDING BUT NOT LIMITED TO INDIRECT SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE FURNISHING PERFORMANCE USE OF OR INABILITY TO USE THE MACHINE ANY EXTENSIONS OF OR MODIFICATIONS MADE TO THIS WARRANTY BY A DEALER DISTRIBUTOR OF HYDRAMASTER ARE THE SOLE RESPONSIBILITY OF THE DEALER...