HydraMaster Boxxer H2O User manual

11015 47thAvenue W, Mukilteo, WA 98275
Boxxer H2O
Machine Serial Number________________________
Copyright©2006
HYDRAMASTER©Corporation
Mukilteo,Washington
MAN-182-136
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 the
HYDRAMASTER©Corporation. All rightsreserved.

Boxxer H2O Owner’s Manual
Boxxer H2O
Table of Contents
TableofContents
List of Figures
QuickReference
GENERAL INFORMATION......................................................................... Section 1
TelephoneNumbers........................................................................... 1-2
Precautions....................................................................................... 1-3
Responsibilities..................................................................................1-5
Vehicle Preparation............................................................................1-7
HighAltitudeOperation Preparation ...................................................1-11
LocalWaterPrecautions ....................................................................1-12
MACHINE SPECIFICATIONS..................................................................... Section 2
Machine Layout .............................................................................. 2-2
OPERATING INSTRUCTIONS ................................................................... Section 3
MACHINE MAINTENANCE ........................................................................ Section 4
MaintenanceLog
MACHINE ASSEMBLIES AND PARTS LIST ............................................. Section 5
VACUUM SYSTEM..................................................................................... Section 6
VacuumSystemTroubleshooting....................................................... 6-3
MiscellaneousTroubleshooting.......................................................... 6-4
BlowerManual
ELECTRICAL SYSTEM ............................................................................. Section 7
Wiring Diagrams ............................................................................... 7-3
ElectricalTroubleshooting.................................................................. 7-5
ENGINE TROUBLESHOOTING................................................................. Section 8
HOW TO ORDER PARTS........................................................................... Section 9
WARRANTY INFORMATION...................................................................... Section 10
GoldenGuarantee®

HydraMaster Corporation
Boxxer H2O Owner’s Manual
Boxxer H2O
List of Figures
Fig. 1-1 Plywood Installation .................................................. 1-7
Fig. 1-2 Astroturf and Roof Vent Installation ............................ 1-7
Fig. 1-3 Recommended Placement ......................................... 1-8
Fig. 1-4 Installation Using Tie-down Cleats .............................. 1-9
Machine Assemblies and Parts Lists .......................................... 5-1
Fig. 5-1 Machine Assembly - Front View - Left Side ................. 5-1
Fig. 5-2 Machine Assembly - Front View - Right Side ................ 5-2
Fig. 5-3 Frame Assembly - Front View - Left Side .................... 5-3
Fig. 5-4 Frame Assembly - Front View - Right Side ................... 5-4
Fig. 5-5 Engine Assembly ...................................................... 5-6
Fig. 5-6 Blower Assembly ..................................................... 5-8
Fig. 5-7 Dash Assembly ........................................................ 5-10
Fig. 5-8 Exhaust Assembly .................................................... 5-12
Fig. 5-9 Machine Left Side Cover Assembly ............................ 5-14
Fig. 5-10 Machine Right Side Cover Assembly ........................... 5-15
Fig. 5-11 Recovery Tank Assembly .......................................... 5-16
Fig. 5-12 Recovery Tank Cover Assembly ................................. 5-18
Fig. 5-13 Vacuum Relief Valve Assembly ................................. 5-19
Fig. 5-14 Dura-Flow APO Pump Assembly ................................. 5-20
Fig. 7-1 Wiring Schematic ...................................................... 7-3
Fig. 7-2 Wiring Diagram . ....................................................... 7-4

Boxxer H2O Owner’s Manual
Boxxer H2O
Quick Reference
Fuel Pump Assembly
B4627 Rev—

Page 1-1: General Information
Boxxer H2O
TheHydraMaster Boxxer H20 is a purpose designed machineto accommodate the needs
of the Water Restoration Contractor who is extracting water and not cleaning carpet. The
basis of the machine is a 27 HP Liquid Cooled V Twin engine that is directly coupled via
the patented BUCS coupling system to aTuthill 4007 Dominator blower. This combination
produces over 400 CFM of air flow, more than enough to extract water with one or two
wands.
In addition to this high performance Power Pack, the Boxer H20 comes with a 100 gallon
recovery tank and the reliable Dura-Flo Automatic Pump Out is an option which allows
you to extract water without the need to shut down and empty the recovered water.
In addition to the obvious performance aspects of this machine, it was designed to deliver
maximumreliability andto beeasily serviced.All themajor componentshave been proven
in other HydraMaster Truckmounts and this new machine was put together with an eye
towards simple, quick maintenance. All service points are conveniently located so routine
maintenance takes only a few minutes to perform.
As with any machine, it is important to use the Boxxer H2O correctly. Operating the ma-
chine is simple; just start the engine with the vacuum hoses disconnected, let it warm up
for two or three minutes, advance the throttle to the maximum operating position, connect
the vacuum hoses and you are ready to extract water. We strongly suggest that the op-
erator of the machine be well acquainted with the IICRC guidelines for Flood Extraction
and with the various methods of carpet drying that are currently being used. It is also
recommended that the machine operator be familiar with the local municipality’s require-
ments for the proper disposal of waste water. Typically waste water is to be deposited in
the city sewer system and never in a gutter or storm drain where it would eventually find
it’s way into a stream, river, lake, ocean or public water supply system.
General Information

HydraMaster Corporation
Page 1-2: General Information
Boxxer H2O
The manufacturer uses this symbol throughout the manual to warn of possible
injury or death.
This symbol is used to warn of possible equipment damage.
Hours Telephone Numbers
Monday - Friday [phone] Parts
8:00 am to 5:00 pm [phone] Service
PACIFIC STANDARD TIME [phone] Parts / Service FAX

Page 1-3: General Information
Boxxer H2O
Precautions
Although this unit has been factory adjusted, it may require additional adjustments
to achieve optimum performance, for instance higher altitudes may require carburetor
adjustment. When required, consult an authorized representative.
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor.
Many vans have critical components mounted directly below the van floor that could be
damagedby a misplaced drill bit. (See ProductSupport Bulletins 92102, 94062 and 94063
at the end of the manual.)
ENGINE COOLING: Units employing internal combustion engines must not be enclosed
within a van with doors and windows closed. Excessive temperatures within the engine
will result in premature engine failure and a compromise of applicable warranty.
LEVEL OPERATION: During operation, van or trailer must be parked on level ground not
to exceed + or - 10 degrees. Failure to insure proper leveling may prevent proper internal
lubrication of engine and vacuum blower.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe bodily
injury may result.
The machine cannot be run in the IDLE position for carpet or floor extraction. This will void
the warranty.
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or wood prod-
ucts) to come in contact with the exhaust system.

HydraMaster Corporation
Page 1-4: General Information
Boxxer H2O
HOT SURFACES: During the operation of this equipment, many surfaces on the machine
will become very hot. When near the van for any reason care must be taken not to touch
any hot surface, such as blower, engine, exhaust, etc.
HEARING PROTECTION: The Occupational Safety and Health Administration (OSHA)
recommends the use of hearing protection when a technician is exposed to an average of
85 decibels (this is an average of exposure over an 8 hour period). This equipment can
produce 85 decibels to a distance of 10 feet. Please check with your local state agencies
to see if OSHA standards apply to your application.
NO SMOKING: It is unsafe to smoke in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so that the
fumes will be directed away from the job site. Do not park where exhaust fumes can enter
a building through open doors, windows, air conditioning units or kitchen fans.
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operating.
Toxic fumes may accumulate inside a stationary vehicle.
ENGINE EXHAUST: The engine exhaust from this product contains chemicals known to
the State of California to cause cancer, birth defects or other reproductive harm.
PORTABLE GAS TANK: Never operate this machine with a portable gas can inside the
truck. Doing so increases the risk of a fire or explosion.
TRANSPORTATION OF FUEL CONTAINERS: Transportation in a vehicle of any vented
fuel container that presently has or has ever contained a flammable liquid is strictly forbid-
den by HydraMaster Corporation and by federal and state regulation.

Page 1-5: General Information
Boxxer H2O
Responsibilities
The Purchaser’s responsibilities are:
Prior to arrival of unit, install 5/8” exterior plywood flooring in the vehicle and cover it with
artificial turf.
In Dodge vans the fuel tanks are located directly against the floor. Caution must be used
when drilling any holes through the floor. (See Product Support Bulletin 94062 at the end
of this manual.)
To purchase heavy duty 24- 60 amp hour battery and have the battery ‘slow’charge if new.
If the battery is not fully charged, damage can occur to the engine charging regulator.
Reading of owner’s manual: It is the purchaser’s responsibility to read the unit opera-
tion manual and to familiarize himself with the information contained therein.
Special attention should be paid to all Cautions and Warnings.
The Sales Representative’s responsibilities are:
ACCEPTANCE OF SHIPMENT:
1. If the unit shows any outward signs of damage, do not sign the delivery
receipt until you have closely inspected the unit and noted any damage
on the delivery receipt.
2. The salesman from whom you purchased your unit is responsible for
supervising the correct installation of the unit in your vehicle and thor-
oughly training you in its operation, maintenance and precautions.

HydraMaster Corporation
Page 1-6: General Information
Boxxer H2O
CORRECT INSTALLATION INCLUDES:
• Vehicle of proper load carrying capacity (recommendation: ½ ton).
• Installation of through-floor fittings for gasoline fuel lines.
• Placing the unit and recovery tank in your vehicle and securing them
with bolts or tie down cleats.
• Connecting gasoline lines.
• Connecting the battery.
• Checking the vacuum blower and engine oil levels prior to
staring the unit.
• Starting the unit to check the engine and see that all systems
function normally.
• Checking all hoses, wands, etc. for correct operation.
TRAINING:
• A thorough review of the operation manual with purchaser.
Instruction and familiarization in:
• How to correctly start up and shut down the unit.
• How to correctly recover with the unit.
• Where and how often to check and change component oil levels.
• How the unit’s systems work.
• How to troubleshoot the unit.
• How to do basic repairs.
• Safety precautions and their importance.
• A thorough review of the unit warranty and warranty procedures.
.

Page 1-7: General Information
Boxxer H2O
Vehicle Preparation
When selecting a truck, remember the preferable vehicle for a Boxxer H2O installation is
a cargo van with a heavy-duty suspension package and a half ton capacity. A three
quarter ton or larger capacity van, with a 2,400 pound payload capacity, is required.
TRUCK PREPARATION
The manufacturer recommends the installation of plywood flooring, covered with polypro-
pylene-backed Astroturf (do not use rubber-backed), in the vehicle prior to installation of
machine.
Be cautious when drilling any holes through the van floor. Many vans have
critical components mounted directly below the van floor that could be dam-
aged by a misplaced drill bit. (See Product Support Bulletins 92101, 94062,
and 94063 at the end of this manual.)
This provides ‘metal to wood’ mounting rather than ‘metal to metal’, provides insulation
and makes an attractive van interior. Astroturf should be color-keyed to the van interior.
See Figure 1-1 for correct placement of the plywood flooring.
Materials Needed:
1. Two sheets of 4 x 8 x s” exterior plywood
2. One 6' x 12' piece of commercial Astroturf
3. Sixteen 12” sheet metal screws
4. One quart marine adhesive (optional)
5. One staple hammer with 2” staples

HydraMaster Corporation
Page 1-8: General Information
Boxxer H2O
PLACEMENT OF UNIT IN VEHICLE
There are two recommended unit placements:
SIDE DOOR:
Most installations are 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 remov-
ing the unit from the truck.
REAR DOOR:
Although this location partly limits working access, it does direct the noise away from the
cleaning site. Some cleaners in the colder areas prefer this location because it puts the
weight over the rear wheels for better traction in ice and snow. Rear mounting requires the
unit to be slid to the right side as far as possible.
This 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). Also, it is physically easier to load the unit into the rear door due to the height
of the van bed.
Figure 1-3 Recommended Placement

Page 1-9: General Information
Boxxer H2O
Machine Tie Down Cleats
Secure the machine to the floor of the van with the four tie down cleats provided. This
safety measure will ensure that the machine will not slide inside the van. See the follow-
ing illustration for the correct installation.
Figure 1-4 Installation Using Tie-down Cleats
Ensure that the machine is well secured to the floor of the van with the hardware
supplied. Asudden stop or crash will cause the machine to rocket forward. Protect
yourself and the machine. SECURE IT!
It is recommended by the manufacturer that the exhaust from the front
of the machine be vented down under the truck to prevent carbon mon-
oxide from entering the job site. Always park the truck so the exhaust is
blowing away from the job site.
The manufacturer also recommends the installation of aluminum vents in
the truck roof to allow heat to escape.
Never operate this machine with a portable gas can inside the truck. Doing
so increases the risk of a fire or explosion.
Mount a fire extinguisher just inside the rear or side door for emergencies.

HydraMaster Corporation
Page 1-10: General Information
Boxxer H2O
Do not use a portable propane tank inside of the truck or van. It is danger-
ous and illegal in most states.
Transportation in a vehicle of any vented fuel container that presently holds
or has ever held a flammable liquid is strictly forbidden by HydraMaster Cor-
poration 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.

Page 1-11: General Information
Boxxer H2O
High Altitude Operation
Preparation
To have your machine run at it’s peak performance; you may have to make adjustments
depending on the elevation. Elevation plays a key role in how the machine will operate.
The factory setting of the machine is set for elevations from 0—3,000 feet. Any time the
machine is operated above 3,000 feet there are two areas on the machine the may need
adjustment.
The first area is the carburetor jet. The higher the elevation, the less air is provided to the
fuel mixture. This will make the engine run ‘rich’, and, in turn will result in the loss of
power, excessive heat in the exhaust, and carbon buildup in the exhaust system. The jet
sizes vary per engine and elevation. Consult HydraMaster to obtain proper jet size.

HydraMaster Corporation
Page 1-12: General Information
Boxxer H2O
Local Water Precautions
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 extracted water recovered into your unit’s vacuum tank must be processed before
being safe for streams, rivers and reservoirs.
INACCORDANCE WITH THE EPA, STATEAND LOCAL LAWS, DO NOT DISPOSE OF
WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.
In most cases, an acceptable method of waste water disposal is to discharge into a mu-
nicipal sewage treatment system after first filtering out solid material such as carpet fiber.
Access to the sanitary system can be obtained through a toilet, laundry drain, RV dump,
etc. Permission should first 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 yourself 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. Properly
designed, they will continuously monitor the level of waste water and pump it out simulta-
neously to the cleaning operation. The hidden benefit of this process is that the technician
does not have to stop his cleaning to empty the recovery tank.
HydraMaster makes an A.P.O. System available which can be ordered with new equip-
ment or installed later.
The penalties for noncompliance can be serious. Always check local laws and regulations
to be sure you are in compliance.

Page 2-1: Machine Specifications
Boxxer H2O
Machine Specifications
Frame: Welded Steel
Weight: 572 lbs.
Engine: Vanguard 27HP Briggs and Stratton
Pressurized Oil System
Spin-on Filter, Oil Cooler and Oil PSI Protection Switch
Ignition: Electronic, Keystart
Vacuum Blower: Dominator 4007, Tuthill/M-D Tri-Lobe,
Instruments: Hour Meter, Machine Runtime
Keyed Ignition, Start/Stop
Vacuum Gauge
APO Switch
Recovery Tank “Full” Light
Recovery Tank: 100 Gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel
Replaceable Grip
Vacuum Hose: 2" Reinforced, 1/2" Reinforced.
Standard Equipment: Machine Power Console
Full Instrumentation
Vacuum Recovery Tank
100 ft, 2" Vacuum Hose
10 ft, 1-1/2" Wand Whip Line
Battery Box
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket

HydraMaster Corporation
Page 2-2: Machine Specifications
Boxxer H2O
Machine Layout
Throttle Control - Controls the speed of the engine.
Choke - Pull style cable for cold starts.
Ignition Switch - Main power control to the machine.
APO Switch - Activates/Deactivates Automatic Pump Out.
Vacuum Tank ‘Full’ Light - Lights up when vacuum tank is full.
Hour Meter - Displays total number of hours machine has been run during its lifetime.
Exhaust Outlet - Engine and blower exhaust outlet.
Lube Port - Allows blower to be lubricated.
Vacuum Gauge - Displays engine temperature and vacuum.

Page 3-1: Operating Instructions
Boxxer H2O
Operating Instructions
Start Up
1. Perform daily and periodic maintenance as specified in this Owner’s Manual.
The machine cannot be run in the “IDLE” position for water recovery. This
will void the warranty.
Note: Never run machine on any speed other than full throttle. Running at any
other speed will void the warranty.
Flood Extraction
1. Start the engine with the THROTTLE cable to the “IDLE” position.
Allow the machine to run in idle for 2 - 3 minutes to warm up.
2. Connect required length of hoses.
3. Connect wand or tool.
4. Pull the THROTTLE cable to the “HIGH” position.
5. If used, turn PUMP OUT switch to “ON” .
6. Commence water extraction.
Shut Down
1. Remove the vacuum hose.
2. At this time, the blower should be lubricated with an oil-based lubricant. See
Lubrication in the Blower Operation and Maintenance Manual included in Sec-
tion 8 of this document.
3. Lower the engine RPMs to idle.
4. Turn the key off.
5. Drain the vacuum tank. The vacuum filter should be cleaned prior to mobiliza-
tion of the van.
Note: In accordance with the EPA, state and local laws, do not dispose of waste
water into gutters, storm drains, streams, reservoirs, etc.
6. Perform daily maintenance as prescribed in this manual.

Page 4-1: Machine Maintenance
Boxxer H2O
Machine Maintenance
To avoid costly repairs and downtime, it is imperative to develop and practice
goodmaintenanceproceduresfromthebeginning. These procedures fallintodaily, weekly,
monthly and quarterly increments, and are outlined below. All recommended mainte-
nance must be performed by competent service personnel.
Important: Record the date and machine hours on the maintenance log.
We have provided a maintenance log for your convenience at the end of this section.
Records of maintenance must be kept and copies may be required to be furnished to
HydraMaster before the warranty is honored. It is recommended that you affix a copy of
the log on the vehicle door near your unit for convenience and to serve as a maintenance
reminder.
OPERATIONAL MAINTENANCE
DAILY:
• Check engine oil level.
• Visually inspect machine for loose wires, oil leaks, etc.
• Lubricate blower with an oil based lubricant through blower inlet.
WEEKLY:
• Inspect vacuum tank s/s filter and filter basket for tears, holes, etc.
Clean, repair or replace as needed.
• One time change of oil and oil filter after first 20 hours of use.
• Check oil level in blower.
• Check drive system screws. Tighten as needed.
• Check all nuts and bolts. Tighten as needed.
• Inspect vacuum relief valve. Clean and lubricate as necessary.
• Clean vacuum tank thoroughly with high pressure washer.
• Check wiring for chafing.
• Change engine oil (every 50 hrs.).