HydraMaster Boxxer 423s User manual

Boxxer 423s
Owner’s Manual
HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-45429 Rev. C, July 1, 2015
(P/N 000-182-728)
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. Specications and information in this document are
subject to change without prior notice. All rights reserved. © 2015 HydraMaster

i - Boxxer 423S Owner’s Manual
Table of Contents
GENERAL INFORMATION...........................................................................SECTION 1
Major System Components..................................................................... 1-3
Contact Information................................................................................. 1-4
Warnings, Cautions and Notices.............................................................1-5
Responsibilities.......................................................................................1-9
Machine Specications ...........................................................................1-12
High Altitude Operation...........................................................................1-14
Local Water Precautions.........................................................................1-14
INSTALLATION INFORMATION................................................................... SECTION 2
Operating the Boxxer 423s in Hot Weather ............................................2-2
Setting Up the Boxxer 423s ....................................................................2-5
Orientation of Fuel Pump........................................................................ 2-6
CLEANING AND CHEMICALS..................................................................... SECTION 3
Precautions............................................................................................. 3-1
Preparing the Carpet for Extraction.........................................................3-2
Rinse and Recover..................................................................................3-2
Overwetting.............................................................................................3-3
Streaking.................................................................................................3-3
Cleaning Tool Tips...................................................................................3-4
OPERATING INSTRUCTIONS.....................................................................SECTION 4
Start Up Procedure .................................................................................4-3
Shut Down Procedure............................................................................. 4-5
MACHINE MAINTENANCE..........................................................................SECTION 5
Operational Maintenance........................................................................ 5-2
Overall Machine Maintenance.................................................................5-4
Engine Maintenance ...............................................................................5-5
High Pressure Pump Maintenance .........................................................5-7
Vacuum System Maintenance ................................................................5-16
Descaling Procedure (Required)............................................................. 5-17
Freeze Guarding..................................................................................... 5-18
WATER AND CHEMICAL SYSTEM .............................................................SECTION 6
ELECTRICAL SYSTEM................................................................................SECTION 7
Electrical System Information..................................................................7-1

iii - Boxxer 423S Owner’s ManualBoxxer 423S Owner’s Manual - ii
SYSTEMS TROUBLESHOOTING............................................................... SECTION 8
Heating System....................................................................................... 8-2
Chemical System....................................................................................8-3
Engine..................................................................................................... 8-4
High Pressure System ............................................................................8-8
Vacuum System......................................................................................8-10
ASSEMBLIES AND PARTS LISTS...............................................................SECTION 9
Console Assembly Parts List...................................................................9-9
Console Assembly Parts List (continued)................................................9-10
Frame Assembly Parts List .....................................................................9-12
Blower Assembly Parts List..................................................................... 9-15
Pump Assembly Parts List ......................................................................9-17
Dash Assembly Parts List .......................................................................9-20
Differential Check Valve Assembly Parts List.......................................... 9-21
By-Pass Valve Assembly Parts List.........................................................9-23
Hi-PSI Manifold Assembly Parts List....................................................... 9-25
Electrical Panel Assembly Parts List....................................................... 9-27
Engine Assembly Parts List.....................................................................9-29
Blower Heat Exchanger Assembly Parts List.......................................... 9-31
Idler Pulley Assembly Parts List.............................................................. 9-32
Silencer Assembly Parts List................................................................... 9-33
Water Box Assembly Parts List...............................................................9-35
Exhaust Assembly Parts List................................................................... 9-36
Exhaust Manifold Assembly Parts List.................................................... 9-37
Exhaust Diverted Assembly Parts List ....................................................9-39
Diverter Valve Actuator Assembly Parts List...........................................9-40
Exhaust Diverter Valve Assembly Parts List ...........................................9-42
70 Gallon Universal Recovery Tank (URT) Assembly Parts List............. 9-44
70 Gallon Universal Recovery Tank (URT) Cover Assembly Parts List.. 9-46
100 Gallon Universal Recovery Tank (URT) Assembly Parts List........... 9-48
100 Gallon Universal Recovery Tank (URT) Cover Assembly Parts List 9-50
Vacuum Relief Valve Assembly Parts List...............................................9-51
Dura-Flow APO Assembly Parts List.......................................................9-53
APO Pump Assembly Parts List.............................................................. 9-54
Hose Routings.........................................................................................9-55
HOW TO ORDER PARTS............................................................................ SECTION 10
Warranty Parts Orders............................................................................ 10-1
Parts Orders............................................................................................10-1
Emergencies...........................................................................................10-1
WARRANTY INFORMATION.......................................................................SECTION 11
Blower ....................................................................................................11-1
High Pressure Water Pump ...................................................................11-1
Recovery Tank .......................................................................................11-1
Chemical System....................................................................................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

v - Boxxer 423S Owner’s ManualBoxxer 423S Owner’s Manual - iv
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 423s 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 423s Upper Dash Assembly...........................................................4-1
Figure 4-2. Boxxer 423s Lower Dash Assembly...........................................................4-2
Figure 4-3. Boxxer 423s Chemical System Control and Metering................................4-4
Figure 5-1. Remove Valve Cap and Valve Assembly...................................................5-8
Figure 5-2. Inspect Manifold and Old Valves................................................................5-8
Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve..................5-9
Figure 5-4. Apply Grease and Install Valves.................................................................5-9
Figure 5-5. Replace Valve Capand Torque to 95 ft lbs.................................................5-9
Figure 5-6. Separate Manifold from Crankcase......................................................... 5-10
Figure 5-7. Seal Assemblies May Come Off with Manifold........................................ 5-10
Figure 5-8. Examine Ceramic Plungers..................................................................... 5-10
Figure 5-9. Remove Stainless Steel Plunger Bolt and Ceramic Plunger ...................5-11
Figure 5-10. Install O-ring, Apply Sealant and Slide Plunger over Plunger Guide.....5-11
Figure 5-11. Extract Retainers and Seals.................................................................. 5-12
Figure 5-12. Seal Kit and Insertion Tool for Seal Installation..................................... 5-13
Figure 5-13. Install Seal Assembly Using O-Ring Grease......................................... 5-13
Figure 5-14. Install Retainers into Cavities................................................................ 5-14
Figure 5-15. Press Low Pressure Seal Assembly into Cavity.................................... 5-14
Figure 5-16. Re-install Manifold and Torque Fasteners............................................. 5-15
Figure 5-17. Torque Sequence in “X” Pattern............................................................ 5-15
Figure 5-18. Torque Bolts to 22 ft. lbs........................................................................ 5-15
Figure 5-19. Recirculation Fitting............................................................................... 5-17
Figure 6-1. Flow Diagram - View 1 of 3........................................................................6-3
Figure 6-2. Flow Diagram - View 2 of 3........................................................................6-4
Figure 6-3. Flow Diagram - View 3 of 3........................................................................6-5
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. Adhesive/Sealant Material Reference........................................................9-2
Figure 9-2. Console Assembly - View 1 of 6.................................................................9-3
Figure 9-3. Console Assembly - View 2 of 6.................................................................9-4
Figure 9-4. Console Assembly - View 3 of 6.................................................................9-5
Figure 9-5. Console Assembly - View 4 of 6.................................................................9-6
Figure 9-6. Console Assembly - View 5 of 6.................................................................9-7
Figure 9-7. Console Assembly - View 6 of 6.................................................................9-8
Figure 9-8. Frame Assembly - View 1 of 2 ................................................................9-11
Figure 9-9. Frame Assembly - View 2 of 2 ............................................................... 9-12
Figure 9-10. Blower Assembly - View 1 of 2.............................................................. 9-13
Figure 9-11. Blower Assembly - View 2 of 2.............................................................. 9-14
Figure 9-12. Pump Assembly .................................................................................... 9-16
Figure 9-13. Dash Assembly - View 1 of 2 ................................................................ 9-18
Figure 9-14. Dash Assembly - View 2 of 2 ................................................................ 9-19
Figure 9-15. Differential Check Valve Assembly........................................................ 9-21
Figure 9-16. By-Pass Valve Assembly....................................................................... 9-22
Figure 9-17. Hi-PSI Manifold Assembly..................................................................... 9-24
Figure 9-18. Electrical Panel Assembly - View 1 of 2................................................ 9-26
Figure 9-19. Electrical Panel Assembly - View 2 of 2................................................ 9-27
Figure 9-20. Engine Assembly - View 1 of 2............................................................. 9-28
Figure 9-21. Engine Assembly - View 2 of 2............................................................. 9-29
Figure 9-22. Blower Heat Exchanger Assembly....................................................... 9-30
Figure 9-23. Idler Pulley Assembly........................................................................... 9-32
Figure 9-24. Silencer Assembly................................................................................ 9-33
Figure 9-25. Water Box Assembly............................................................................ 9-34
Figure 9-26. Exhaust Assembly................................................................................ 9-36
Figure 9-27. Exhaust Manifold Assembly................................................................. 9-37
Figure 9-28. Exhaust Diverted Assembly ................................................................. 9-38
Figure 9-29. Diverter Valve Actuator Assembly........................................................ 9-40
Figure 9-30. Exhaust Diverter Valve Assembly ........................................................ 9-41
Figure 9-31. 70 Gallon Universal Recovery Tank (URT) Assembly.......................... 9-43
Figure 9-32. 70 Gallon Universal Recovery Tank (URT) Cover Assembly............... 9-45
Figure 9-33. 100 Gallon Universal Recovery Tank (URT) Assembly........................ 9-47
Figure 9-34. 100 Gallon Universal Recovery Tank (URT) Cover Assembly............. 9-49
Figure 9-35. Vacuum Relief Valve Assembly............................................................ 9-51
Figure 9-36. Dura-Flow APO Assembly.................................................................... 9-52
Figure 9-37. APO Pump Assembly........................................................................... 9-54

Boxxer 423S Owner’s Manual - vi

1-1: General Information
1 - General Information
The Boxxer 423s is the latest multi surface cleaning/water recovery system from
HydraMaster, featuring a 23 HP air-cooled engine and the dual oil bath Tuthill Dominator
4005 Tri-lobe Blower.
Available options for the Boxxer 423s include a 70 gallon recovery tank, a 5 gallon
chemical jug, 100 ft vacuum and solution
hoses, and a 10 ft whip hose.
Another HydraMaster option available with
the Boxxer 423s is the 70 gallon rotomold
(RMT) fresh water tank which is designed to
mount directly under the Boxxer 423s.
Other options include:
• a 100 gallon recovery tank
• an Automatic Pump Out (APO) system
• a Thru Floor Exhaust Kit
• Dura-Flow auto pump-out (APO)
• Hydra Cradle Fresh Water Tank
and Hose Reels
• Evolution Truckmount Wand
• RX-20 Rotary Extraction Wand

1-3: General InformationGeneral Information: 1-2
This Owner’s Manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of the Boxxer 423s. 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 423s. 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 423s. Please read the manual to familiarize yourself with the operation of
your Boxxer 423s, paying special attention to all Warnings and Cautions.
This section of the manual contains the following information:
Major System Components
Contact Information
Warnings, Cautions and Notices
Responsibilities
Machine Specications
High Altitude Operation
Local Water Precautions
Photographs and illustrations included in this document can represent optional
equipment as well as standard equipment.
MAJOR SYSTEM COMPONENTS
Blower
Water Box
Heat Exchanger
Pump
Engine
Silencer
Heat Exchanger

1-5: General InformationGeneral Information: 1-4
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://hydramaster.com/HowToBuy/DealerLocator.aspx
If your question cannot be resolved by your distributor or by the information within this
manual, you may contact HydraMaster direct using the following phone numbers.
HOURS TELEPHONE NUMBERS E-MAIL ADDRESSES
Monday-Friday
7:00 a.m. to 5:00 p.m.
Pacic Time
Technical Support
[phone]
FAX : [phone]
Technical Support
[e-mail]
Customer Service/Parts
[phone]
FAX : [phone]
Customer Service/Parts
[e-mail]
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): ____________________________________
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.

1-7: General InformationGeneral Information: 1-6
Warnings and Cautions specic to the Boxxer 423s 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. 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.
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.
Never smoke in or around the truckmount. Doing so will increase the risk of re
and explosion. Serious injury or death may result.
During the operation of the truckmount the exhaust system will become extremely
hot. Keep all ammable materials away from the truckmount exhaust system.
Failure to do so will increase the risk of re and explosion. Serious property
damage may result.
Never operate the truckmount when the vehicle is tilted more than 10 degrees in
anydirection.Doingsowillresultinimproperlubricationoftheinternalcomponents,
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.
Never operate the truckmount with the vehicle doors closed. Doing so results in
extremely high temperatures inside the vehicle and will lead to serious component
or engine damage.
Never use concentrated acids or solvents (including d-limonene) in the truckmount
water system or chemical system. Use of these products will cause serious
component damage.
Never operate the truckmount with a water hardness reading measuring 3.0 grains
per gallon or higher. Using reading than 3.0 grains per gallon will cause scale
to build up inside the truckmount water system. Scale build up causes serious
component damage. Test all water prior to use and use water softening equipment
if necessary.

1-9: General InformationGeneral Information: 1-8
Never allow water to freeze inside the truckmount. Serious component damage
will occur. Perform all freeze guarding procedures outlined in this digital Owner’s
Manual.
Many vehicles have critical components mounted directly below the oor that can
easily be damaged. Before drilling holes in the oor of the vehicle inspect the
underside of the vehicle for critical components. Failure to do so may result in
damage to the vehicle.
Use of the vacuum recovery system when stripping or otherwise removing wax
from oors is specically excluded as an approved use of the truckmount. Failure
to follow this exclusion may lead to component failure and will invalidate your
warranty.
Use of the vacuum recovery system for “dry cleaning”, without corresponding
solution application (i.e. duct cleaning), is specically excluded as an approved
use of the truckmount. Failure to follow this exclusion may lead to component
failure and will invalidate your warranty.
If concentrated acids or solvents are used to pre-treat surfaces before power
washing, do not recover them through the vacuum system. Failure to follow this
exclusion may lead to component failure and will invalidate your warranty.
RESPONSIBILITIES
Purchaser’s Responsibilities
• Prior to purchasing a van, ensure that the payload is suitable for all of the equipment
thatwillbeinstalledandtransported.Thisincludesandisnotlimited to:thetruckmount,
recovery tanks, fresh water tanks and any other 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.

1-11: General InformationGeneral Information: 1-10
Distributor’s Responsibility
Acceptance of Shipment
Before accepting the truckmount, check the following:
1. The truckmount should be free from any damage during shipping. Do not sign the
delivery receipt until you have closely inspected the truckmount and noted any
damage on the delivery receipt. Hidden damage may be present even if the box looks
okay. It is recommended that the box be opened before you sign for the shipment.
2. 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 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, 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.
• 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.
• Ensure timely return of the document package.
Training
Thedistributorshouldprovideathoroughreviewoftheoperationmanualwiththepurchaser
along with instruction and familiarization in:
1. How all the truckmount’s systems function.
2. All safety precautions and their importance.
3. How to correctly start and shut down the truckmount.
4. How to correctly clean with the truckmount.
5. Where and how often to check and change component oil levels.
6. Freezing damageand how toavoidit. This includes explainingproperfreezeguarding
procedures.
7. How to do basic troubleshooting of the truckmount.
8. Hard water damage and how to avoid it. This includes how to determine if hard water
exists in your area and the installation and use of water softening systems.
9. The truckmount’s warranty and warranty procedures.

1-13: General InformationGeneral Information: 1-12
MACHINE SPECIFICATIONS
Frame Dimensions 24”W x 31”H x 36”D
Weight 563 lbs
Engine 23HP Briggs and Stratton air-
cooled
Pressurized Oil System Engine Oil:
5W-30 Synthetic
Capacity Approx. 1 1/2 quarts, or
48 oz (when changing
oil and lter)
Engine rpm 3,000 rpm
Fuel Consumption 1.1 gph
Ignition Electric Keystart
Vacuum Blower -
Tuthill 4005 Oil Type Blower Oil: Pneulube
Gear End Capacity Approx. 5.8 oz
Drive End Capacity Approx. 4.7 oz
Blower rpm 3,000 rpm
Water Pump -
General Pump 4.0 gpm Plunger Pump, Electric Clutch Control Pump Oil: GP Series 100
Drive System Direct-drive Hayes 40-series
Coupler
Engine Exhaust Diverter Automated Diverter Control
(ADC) Temperature Control
Operating Pressure 1,000 psi
Chemical System Stainless Steel Last-Step
Chemical Injection, Meter
Controlled
Heating System Finned Tube Heat Exchanger
Standard Equipment Runtime Hour Meter
Chemical Flow Meter (0-10
Gph)
Chemical Flow Control Valve
Vacuum Gauge (0-30" Hg)
Solution Pressure Gauge
(0 - 1,500 Psi)
Solution Pressure Adjustment
Pre-Wired Pump-In Switch
Pre-Wired APO Switch
Fresh Water Inlet
Water System Drain Valve
Diagnostic/Status Lights
Engine Choke
Engine Throttle
Electrical Circuit Protection
(Fuse Protected)
Solution Temperature Control
Selector
Available Equipment Fresh Water Tank (FWT) 70 Gallon Rotomold
Universal Recovery Tank (URT) 70 Gallon URT
100 Gallon URT
Automatic Pump Out (APO)
Hoses
Wand
Thru Floor Kit

1-15: General InformationGeneral Information: 1-14
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://www.vanguardengines.com/where-to-buy/dealer-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.
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.
Figure 1-1. Hard Water Map of Mainland United States
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.

1-17: General InformationGeneral Information: 1-16
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 423s 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.
Therelatively low costofa watersoftener service ismorethanmadeupfor byan 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.
Forexample: Ifthesoftenerwilltreat900gallonsofwaterandthemachineusesanaverage
of 30 gallons/hour, for an average of 5 hours a day, this equals 150 gallons per day. In 6
days the machine would use 900 gallons of water. Therefore, the softener would need to
be charged every 6 working days for maximum softening.
Waste Water Disposal Advisory
There are laws in most communities prohibiting the dumping of recovered “gray” water
from carpet cleaning in any place but a sanitary treatment system.
The cleaning rinse water, recovered into your unit’s vacuum tank, contains materials
such as detergents, and must be safely processed before entering streams, rivers and
reservoirs.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after rst ltering out solid material such as carpet
ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV
dump, etc. Permission should rst be obtained from any concerned party or agency.
One disposal method which usually complies with the law is to accumulate the waste
water and haul it to an appropriate dump site. Another solution to the disposal problem is
to equip your Boxxer 423s 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.
HydraMastermakesanAPOSystemwhichcanbeorderedwithnewequipmentorinstalled
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.
INACCORDANCEWITHEPA,STATEANDLOCALLAWS,DONOTDISPOSEOF
WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS,
ETC.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.

General Information: 1-18

2-1: Installation Information
Figure 2-1. Location of
Roof Vents in Vehicle
2 - Installation Information
Althoughtherearemanydifferentheavy dutyvehiclesused forcarpetcleaning equipment,
the preferable vehicle for a Boxxer 423s installation is a cargo van with a heavy-duty
suspension package and a 3/4 HD ton capacity. If a fresh water tank is added, a one ton
or larger capacity van is required.
Prior to installation of the Boxxer 423s, HydraMaster recommends installing a spray-
on 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 Figure 2-1. Consult your local RV
distributor about selection and/or installation of powered
roof vents.
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.

2-3: Installation InformationInstallation 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 423S IN VEHICLE
There are two recommended entry points on the vehicle for the Boxxer 423s 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 423s 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
sideoftheunit butalso improvesweightdistributioninsidethevan (engineandcomponent
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.
Secure Installation
No matter how the unit is installed, check to see if the Boxxer 423s 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.
Figure 2-2. Recommended Location of Boxxer 423s in Van
OPERATING THE BOXXER 423S IN HOT WEATHER
HydraMaster recommends the following steps when operating the Boxxer 423s during
periods of hot weather (95º F or higher). This will help ensure that your Boxxer 423s
continues to run at 100% capacity during even the hottest days.
1. A minimum of 9” (22.9 cm) of clearance is required on both sides of the Boxxer
423s, when installed. Ensure that additional equipment or other materials are not
stored at the sides or on top of the Boxxer 423s. Unobstructed airow around the
unit is critical for cooling the engine and other components.
2. For side-door vans with “barn doors”, open the doors as wide as their construction
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.
3. Provide cross-ventilation. When possible, keeping the rear doors open while the
Boxxer 423s is running will substantially reduce the temperature inside the van and
will provide a path for cooling air ow. For rear-mount installations, open up the
other doors in the van.
4. 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.

2-5: Installation InformationInstallation Information: 2-4
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 423s 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 423s 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.
SETTING UP THE BOXXER 423S
Prior to operating the Boxxer 423s, follow these steps:
1. Adjust the vacuum relief located on the recovery tank by capping all the vacuum
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 423s 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.

Installation Information: 2-6
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
Pump Can Push Fuel
6.5 ft (2 m) Vertically

3-1: Cleaning Information
3 - Cleaning and Chemicals
YourHydraMastertruckmounthasbeenengineeredusingthelatestandmostsophisticated
technology available to produce the nest carpet cleaning results possible. Despite this,
it remains only a tool of the carpet cleaning trade and can produce only as a good a job
as the person operating it.
HydraMaster strongly recommends attending an Institute of Inspection, Cleaning
and Restoration Certication (IICRC) approved school as soon as possible and to
always follow the IICRC guidelines when cleaning.
This section describes the carpet cleaning procedure in the following areas:
Precautions
Preparing the Carpet for Extraction
Rinse and Recover
Overwetting
Streaking
Cleaning Tool Tips
PRECAUTIONS
The use of some chemicals (such as concentrated acids and/or solvents) in your
truckmount can seriously damage the internal plumbing and high pressure pump.
HydraMaster strongly recommends purchasing a water softener to prevent the buildup of
scale and hard water deposits in your truckmount.
HydraMaster recommends only the use of chemicals containing rust and corrosion
inhibitors and water softening agents to prevent chemical buildup which may lead to
component failure and warranty invalidation.
Increased demand for a neutralizing rinse results in the need for special care
when using these acid based chemicals in your truckmount The negative side
of these products is the corrosive effects the acid can have on metals, including
ttings, pumps, heat exchangers, etc.
HydraMaster’s ClearWater Rinse™ has been formulated to protect vital components.
HydraMaster will not warranty parts that have been damaged from using acid products
that have obviously caused failures.