HydraMaster Boxxer 421 User manual

Copyright© 2007
HYDRAMASTER© Corporation
Mukilteo, Washington
MAN-182-065-D
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 rights re-
served.
Revised August 31, 2007
11015 47thAvenue W, Mukilteo, WA 98275

Boxxer 421 Owner’s Manual
Boxxer 421
Table of Contents
Table of Contents
List of Figures
Quick Reference
GENERAL INFORMATION ......................................................................... Section 1
Telephone Numbers ........................................................................... 1-2
Precautions ....................................................................................... 1-3
System Operation ............................................................................. 1-7
Machine Specifications ..................................................................... 1-8
Spare Parts Recommendation .......................................................... 1-10
Spare Parts List...................................................................... 1-10
Responsibilities................................................................................. 1-12
Vehicle Preparation ........................................................................... 1-14
High Altitude Operation Preparation .................................................. 1-18
Local Water Precautions ................................................................... 1-19
Wastewater Disposal Advisory ............................................... 1-20
Hard Water Map ..................................................................... 1-23
CLEANING AND CHEMICALS .................................................................. Section 2
pH Chart ............................................................................................ 2-3

HydraMaster Corporation
Boxxer 421 Owner’s Manual
Boxxer 421
OPERATING INSTRUCTIONS ................................................................... Section 3
Start Up ............................................................................................. 3-1
Carpet or Hard Surface Cleaning ...................................................... 3-1
Upholstery Cleaning .......................................................................... 3-2
Flood Extraction ................................................................................ 3-3
Shut Down ......................................................................................... 3-4
Exhaust Diverter ................................................................................ 3-5
MACHINE MAINTENANCE ........................................................................ Section 4
Daily, Weekly ..................................................................................... 4-1
Monthly, Quarterly, 500 Hours ............................................................. 4-2
De-scaling ......................................................................................... 4-3
Machine Maintenance ....................................................................... 4-4
Maintenance Log
FREEZE GUARD ........................................................................................ Section 5
Vacuum Freeze Guard Procedure ..................................................... 5-1
Freeze Protection of Pump-In System ................................................ 5-3
HIGH PRESSURE PUMP........................................................................... Section 6
Pump Maintenance ........................................................................... 6-1
Service.............................................................................................. 6-2
HydraPump II Drawing and Parts List ................................................. 6-6
Pump Troubleshooting ....................................................................... 6-8
VACUUM SYSTEM ..................................................................................... Section 7
Blower Troubleshooting/Miscellaneous Troubleshooting ..................... 7-3
MD Blower Instruction Booklet

Boxxer 421 Owner’s Manual
Boxxer 421
ELECTRICAL SYSTEM ............................................................................. Section 8
Terminal Assignments and Switch Positions ...................................... 8-1
Wiring Schematic .............................................................................. 8-2
Wiring Diagrams ............................................................................... 8-3,-4,-5
Electrical Troubleshooting .................................................................. 8-6
WATER AND CHEMICAL SYSTEM ........................................................... Section 9
Chemical System Maintenance ......................................................... 9-2
Chemical Pump................................................................................. 9-3
Solution Flow Diagram ...................................................................... 9-5
Chemical Flow Diagram .................................................................... 9-6
Exhaust, Vacuum, Coolant and APO Flow Diagram ........................... 9-7
Chemical Tank Troubleshooting ......................................................... 9-8
ENGINE TROUBLESHOOTING ................................................................. Section 10
MACHINE ASSEMBLIES AND PARTS LIST ............................................. Section 11
Hose Assemblies .............................................................................. 11-78
CLEANING WAND PARTS......................................................................... Section 12
Cleaning Wand Assembly Drawing .................................................... 12-1
HOW TO ORDER PARTS........................................................................... Section 13
WARRANTY INFORMATION ...................................................................... Section 14
Golden Guarantee®
ACCESSORIES .......................................................................................... Section 15

HydraMaster Corporation
Boxxer 421 Owner’s Manual
Boxxer 421
List of Figures
Fig. 1-1 Roof Vent Installation .............................................................. 1-14
Fig. 1-2 Recommended Placement ..................................................... 1-15
Fig. 1-3 Installation Using Tie-down Cleats ........................................... 1-16
Fig. 1-4 Hard Water Map ..................................................................... 1-23
Fig. 2-1 pH Chart ................................................................................. 2-3
Fig. 2-2 Cleaning Stroke Procedure..................................................... 2-3
Fig. 4-1 Recirculation Fitting ........................................................... 4-3
Fig. 5-1 Recirculation Fitting ................................................................ 5-1
Fig. 6-1 Servicing the Valves .......................................................... 6-3
Fig. 6-2 HydraPump II Assembly ..................................................... 6-6
Fig. 8-1 Wiring Schematic ............................................................. 8-2
Fig. 8-2 Wiring Diagram Sht 1. ...................................................... 8-3
Fig. 8-3 Wiring Diagram Sht 2 ....................................................... 8-4
Fig. 8-4 Wiring Diagram Sht 3 ....................................................... 8-5
Fig. 9-1 Chemical Pump Assembly................................................. 9-3
Fig. 9-2 Solution Flow Diagram ..................................................... 9-5
Fig. 9-3 Chemical Flow Diagram .................................................... 9-6
Fig. 9-4 Exhaust, Vacuum, Coolant, and APO Flow Diagram .......... 9-7

Boxxer 421 Owner’s Manual
Boxxer 421
Machine Assemblies and Parts Lists ................................................. 11-1
Fig. 11-7 Frame Assembly - Front View ........................................... 11-2
Fig. 11-8 Frame Assembly - Rear View - Left Side ........................... 11-3
Fig. 11-9 Frame Assembly - Rear View - Right Side......................... 11-4
Fig. 11-10 70 Gallon Universal Recovery Tank Assembly .................... 11-7
Fig. 11-11 70 Gallon Universal Recovery Tank Cover Assembly .......... 11-10
Fig. 11-12 Dash Assembly ................................................................. 11-11
Fig. 11-13 Electrical Control Panel Assembly ..................................... 11-13
Fig. 11-14 Blower Heat Exchanger Assembly ..................................... 11-15
Fig. 11-15 Water Box Assembly ......................................................... 11-16
Fig. 11-16 Hydra Pump II Assembly .................................................... 11-18
Fig. 11-17 Chemical Pump Assembly ................................................. 11-20
Fig. 11-18 Fuel Pump Assembly ......................................................... 11-21
Fig. 11-19 Blower Assembly ............................................................... 11-22
Fig. 11-20 Vacuum Relief Valve (Collector Box) Assembly .................. 11-25
Fig. 11-21 Exhaust Assembly ............................................................. 11-26
Fig. 11-22 Diverter Valve Actuator Assembly ...................................... 11-28
Fig. 11-23 Hi PSI Manifold Assembly ................................................. 11-29
Fig. 11-24 Bypass Valve Assembly .................................................... 11-31
Fig. 11-25 Engine Assembly .............................................................. 11-33
Fig. 11-26 Briggs & Stratton Voltage Regulator Modification .............. 11-35
Fig. 11-27 Dura-Flow APO Pump Assembly ....................................... 11-36
Fig. 11-28 100 Gallon Universal Recovery Tank Assembly .................. 11-38
Fig. 11-29 100 Gallon Universal Recovery Tank Cover Assembly ........ 11-41

HydraMaster Corporation
Boxxer 421 Owner’s Manual
Boxxer 421
Fig. 11-30 70 Gallon Universal RecoveryTank For 85 RMT Assembly . 11-42
Fig. 11-31 85 Gallon Rotomolded Tank Assembly - Front View ........... 11-45
Fig. 11-32 85 Gallon Rotomolded Tank Assembly - Rear View ........... 11-46
Fig. 11-33 85 RMT w/ Boxxer 421 Assembly - Front View................... 11-49
Fig. 11-34 85 RMT w/ Boxxer 421 Assembly - Rear View ................... 11-50
Fig. 11-35 Chemical Jug Tray Assembly ............................................. 11-52
Fig. 12-1 Two-Jet Cleaning Wand Assembly ..................................... 12-1

Boxxer 421 Owner’s Manual
Boxxer 421
Recovery Tank Float Switch-Top Float Shown
B4624 Rev—
Fuel Pump Assembly
B4627 Rev—
Quick Reference

Page 1-1: General Infromation
Boxxer 421
General Information
This manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of this unit. Since the
first and most important part of repair work is the correct diagnosis of the problem,
component manual troubleshooting charts have been included for your convenience.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two functions
to perform, the truckmounted carpet cleaning plant has many functions to perform
simultaneously.
• The engine has to run at a consistent RPM.
• The vacuum has to pull air and dirty water back from cleaning site.
• The water pump provides stable pressure at proper water flow for cleaning.
• The chemical has to be injected into the water stream at the right
concentration.
• The heating system must maintain proper heat.
• The vacuum tank must store dirty water until drained.
As you can see, it is not just a turnkey operation where your only worry is “Does it
start?”

HydraMaster Corporation
Page 1-2: General Infromation
Boxxer 421
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.
This symbol is used to warn of regulatory or legal issues.
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 Infromation
Boxxer 421
Precautions
Although this unit has been factory adjusted, it may require additional adjustments to achieve optimum performance, for instance altitude may require carburetor
adjustment and ambient temperatures may require heat control adjustment. When
required, consult an authorized representative.
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.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
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 heater, 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.

HydraMaster Corporation
Page 1-4: General Infromation
Boxxer 421
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 condition-
ing 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 repro-
ductive 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.
PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or
van. It is dangerous and illegal in most states.
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 forbidden by HydraMaster Corporation and by federal and state regu-
lation.
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 damaged by a misplaced drill bit. (See Product Support Bulletins
92102, 94062 and 94063 at the end of the manual.)

Page 1-5: General Infromation
Boxxer 421
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, vacuum and/or high pressure com-
ponents.
The machine cannot be run in the IDLE position for cleaning upholstery, carpet or
floor extraction. This will void the warranty.
ACID RINSE AGENTS: The increased demand for “clear water” rinsing results in
the need for special care when using these acid based chemicals in your equip-
ment. The negative side of these products is the corrosive effects the acid can
have on metals, including swivels, pumps, heat exchangers, etc.
HydraMaster’s ClearWater Rinse has been formulated to protect vital compo-
nents. HydraMaster will not warranty parts that have been damaged from using
unprotected acid products that have obviously caused failures.
HARD WATER PROTECTION: Failure to take appropriate measures to prevent
scale build up can result in system failure and loss of warranty on affected parts.
Test the water in your immediate and surrounding areas with hard water test
strips. Assume all water obtained from wells is hard. If you are operating in a
“Hard Water Area” (3.5 grains or more per gallon), use a water softening system.
FREEZE PROTECTION: There is often little warning before a cold spell. There-
fore, not protecting this equipment from freezing will result in costly downtime.
Placing an electric heater in the truck or parking the truck indoors will help to
insure against freezing, but should not be the primary method of freeze protec-
tion.

HydraMaster Corporation
Page 1-6: General Infromation
Boxxer 421
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or
wood products) to come in contact with the exhaust system.
The use of some chemicals through your mobile carpet cleaning plant can seri-
ously damage the internal plumbing, high-pressure pump, chemical pump and
heat exchangers. These harmful chemicals include concentrated acid (see the
pH chart at the end of this section), solvents (including d-Limonene), and some
paint, oil and grease removers with a high concentration of solvents.

Page 1-7: General Infromation
Boxxer 421
System Operation
The Boxxer heat exchanger system is a highly engineered cleaning plant designed
by HydraMaster Corporation. The system utilizes a dynamic heating system com-
prised of two separate exhaust heat exchangers for capturing “free heat.”
The water flow is as follows:
Water is fed into the machine under tap pressure and it flows through the
water conditioner to the water box. The solution is then picked up by the high
pressure pump and pressurized to the desired level. The water then splits flow,
as demanded by the technician.
The majority of the water flows to the bypass valve assembly, then back to the
water box. The water demanded by the technician flows from the water pump
through the blower exhaust heat exchanger then through the engine exhaust
heat exchanger and out to the cleaning tool.
When the cleaning solution reaches a preset high temperature, it is released
from the system and directed to the recovery tank. Then cool water enters
the system to regulate the temperature. When equipped with an engine
exhaust diverter, the diverter bypasses the heat from the exhaust heat
exchanger and simultaneously releases water from the system and directs it to
the recovery tank.
As there is no guess work in the manufacture of these highly advanced cleaning
plants, there must be none in preparing it to get the job done in the field. It is the
purpose of this manual to help you properly understand, maintain and service your
cleaning plant. Follow the directions carefully and you will be rewarded with years of
profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this
equipment.

HydraMaster Corporation
Page 1-8: General Infromation
Boxxer 421
Machine Specifications
Frame: 24"W x 33"L x 30"H
Steel with Baked-on Epoxy Finish
Weight: 370 lbs.
Engine: Vanguard 21 HP Briggs and Stratton
Pressurized Oil System
Spin-on Filter, Oil Cooler and Oil PSI Protection Switch
Ignition: Electronic, Keystart
Vacuum Blower: Dominator 4005, Tuthill/M-D Tri-Lobe,
Pump: HydraPump II, 3.5 GPM Hot Seals, 2500 PSI
Chemical System: Last-Step Chemical
Operating Pressure: Up to 1,000 PSI
Heating System: 1 Stainless Steel Engine Exhaust Exchanger
1 Coil and Fin Blower Exhaust Heat Exchanger
Instruments: Water Pressure Gauge, Liquid Filled, 0-1500 PSI
Hour Meter, Machine Runtime
Keyed Ignition, Start/Stop
Chemical Flowmeter, Clear Acrylic, 0-10 GPH
Vacuum Gauge
Temperature Gauge

Page 1-9: General Infromation
Boxxer 421
Recovery Tank: 70 Gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel ‘S’-bend
Replaceable Grip
Rebuildable Solution Valve
High Pressure Hose: 4" High Temperature Lined/Vinyl Covered
Hose Rated to 2250 PSI
Vacuum Hose: 2" Reinforced, 12" Reinforced.
Standard Equipment: Machine Power Console
Full Instrumentation
Tuthill/M-D Tri-Lobe Vacuum Blower
BoxxerTM Water Heating Package
Vacuum Recovery Tank
Carpet Cleaning Wand
Chemical Jug
100 ft, 2" Vacuum Hose
10 ft, 1-2" Wand Whip Line
100 ft, Super Flex Solution Line
Battery Box
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket

HydraMaster Corporation
Page 1-10: General Infromation
Boxxer 421
Spare Parts Recommendation
Downtime in the unit can be very expensive, because your truckmounted unit is
capable of generating several hundred dollars per day. In order to minimize such
downtime, it is strongly recommended by the manufacturer that you purchase and
keep in your truck the parts listed below.
Parts Orders
To expedite your parts needs, please call your sales representative. In most in-
stances, he either stocks or has access to parts through a regional service center. If
further assistance is needed, contact the factory and coordinate your needs. If this
becomes necessary, always indicate the method of shipment you desire, i.e. UPS,
Blue Label, Air Freight, Air Express, etc.
HydraMaster Parts Dept. Phone .................. [phone]
HydraMaster Parts Dept. Toll Free Fax......... [phone]
Spare Parts List (078-340)
PART NO DESCRIPTION QTY
010-054 Belt, A38 Pump 1
046-010 Diaphragm, Chemical Pump 1
049-002 Filter, Fuel 1
049-008 Filter, S/S Vacuum Pump, 22”1
049-014 Filter, Vanguard Oil 2
049-016 Filter, ¼” Replacement Y 1
049-023 Screen, Garden Hose 1
049-012 Filter, Vanguard Air 1
049-118 Filter, 4” s/s 1
049-030 Filter Bag, 92+ Truck Mount 2
052-050 Quick Connect, 440 Male 3
052-051 Quick Connect, 440 Female 2
052-052 Quick Connect, 660 Male 1
052-053 Quick Connect, 660 Female 1

Page 1-11: General Infromation
Boxxer 421
Spare Parts List (078-340)
PART NO DESCRIPTION QTY
056-001 Fuse, 10 amp 2
056-008 Fuse, 15 amp 2
056-010 Fuse, 25 amp 1
074-007 Gauge, Hi PSI (0-1500) 1
074-032 Meter, Chemical Flow 1
078-101 Kit, Seal & Spring Hi PSI 1
078-140 Kit, Comet Seal 1
106-016 Plug, Vanguard Spark 2
106-045 Plug, HD4 Coupling - 1" OD x x” LG, EPDM 8
157-080 Switch, s/s Float 1
157-040 Rocker
157-022 Switch, Relay 2
169-017 Valve, 3-way Chemical 1
169-022 Valve, 1½” Full Port 1
169-155 Check Valve, Last-Step Chemical 2
169-160 Valve, 2-way Chemical Metering 1
180-004 Orifice, Primary 1
180-006 Orifice, Secondary 1
NOTE:
Engine Oil: 30 weight motor oil with a minimum standard of SE, SF, SG.
Blower OIl: 40 weight non detergent
Pump Oil: 40 weight non-detergent

HydraMaster Corporation
Page 1-12: General Infromation
Boxxer 421
Responsibilities
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 Bulle-
tin 94062 at the end of this manual.)
To purchase heavy duty 42 - 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
operation 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 super
vising the correct installation of the unit in your vehicle and thoroughly
training you in its operation, maintenance and precautions.