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