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.