HydraMaster Boxxer 427 User manual

HYDRAMASTER
Corporation
11015 47th Avenue W, Mukilteo, WA 98275
Machine Serial Number________________________
Copyright© 2007
HYDRAMASTER© Corporation
Mukilteo, Washington
MAN-182-068
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
reserved.
Revised August 21, 2007

Boxxer 427
HydraMaster Corporation

Boxxer 427
HydraMaster Corporation
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
Machine Assemblies and Parts Lists ...................................... 1-25
Boxxer Hose Assemblies...................................................... 1-85
CLEANING AND CHEMICALS ........................................................ Section 2
pH Chart ............................................................................ 2-3

Boxxer 427
HydraMaster Corporation
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
FREEZE GUARD ........................................................................... Section 4
Vacuum Freeze Guard Procedure .......................................... 4-1
Freeze Protection of Pump-In System .................................... 4-3
WATER AND CHEMICAL SYSTEM .................................................. Section 5
Chemical System Maintenance ............................................. 5-2
Chemical Pump ................................................................... 5-3
Solution Flow Diagram......................................................... 5-5
Chemical Flow Diagram ....................................................... 5-6
Exhaust, Vacuum, Coolant and APO Flow Diagram.................. 5-7
Chemical Tank Troubleshooting ............................................ 5-8
HIGH PRESSURE PUMP ................................................................. Section 6
Pump Maintenance.............................................................. 6-1
Service .............................................................................. 6-2
HydraPump IV Drawing and Parts List ................................... 6-6
Pump Troubleshooting ......................................................... 6-8
CLEANING WAND PARTS ............................................................. Section 7
Cleaning Wand Assembly Drawing ........................................ 7-1

Boxxer 427
HydraMaster Corporation
VACUUM SYSTEM ....................................................................... Section 8
Blower Troubleshooting/Miscellaneous Troubleshooting ........... 8-3
MD Blower Instruction Booklet
ENGINE TROUBLESHOOTING ........................................................ Section 9
ELECTRICAL SYSTEM ................................................................... Section 10
Wiring Schematic ............................................................... 10-2
Wiring Diagrams ................................................................. 10-3,-4,-5
Electrical Troubleshooting .................................................... 10-6
MACHINE MAINTENANCE ............................................................ Section 11
Daily, Weekly ..................................................................... 11-1
Monthly, Quarterly, 500 Hours ............................................. 11-2
De-scaling.......................................................................... 11-3
Machine Maintenance ......................................................... 11-4
Maintenance Logs
HOW TO ORDER PARTS ............................................................... Section 12
WARRANTY INFORMATION .......................................................... Section 13
Golden Guarantee®
ACCESSORIES ............................................................................. Section 14
PRODUCT UPDATES .................................................................... Section 15

Boxxer 427
HydraMaster Corporation
List of Figures
Fig. 1-1 Plywood Installation .................................................. 1-14
Fig. 1-2 Astroturf and Roof Vent Installation ............................ 1-14
Fig. 1-3 Recommended Placement ......................................... 1-15
Fig. 1-4 Installation Using Tie-down Cleats .............................. 1-16
Fig. 1-5 Hard Water Map ...................................................... 1-23
Machine Assemblies and Parts Lists .......................................... 1-25
Fig. 1-6 Machine Assembly - Front View - Left Side ................. 1-25
Fig. 1-7 Machine Assembly - Front View - Right Side ................ 1-26
Fig. 1-8 Machine Assembly - Rear View - Right Side ................. 1-27
Fig. 1-9 Frame Assembly - Front View - Left Side .................... 1-29
Fig. 1-10 Frame Assembly - Front View - Right Side ................... 1-30
Fig. 1-11 Frame Assembly - Rear View - Left Side ..................... 1-31
Fig. 1-12 Engine Assembly - Rear View .................................... 1-33
Fig. 1-13 Engine Assembly - Front View ................................... 1-34
Fig. 1-14 Exhaust Assembly .................................................... 1-36
Fig. 1-15 Diverter Valve Actuator Assembly ............................. 1-38
Fig. 1-16 Blower Assembly ..................................................... 1-39
Fig. 1-17 Pump Assembly ....................................................... 1-41
Fig. 1-18 Chemical Pump Assembly ......................................... 1-43
Fig. 1-19 Pump Mounting Bracket Assembly.............................. 1-44
Fig. 1-20 Water Box Assembly ................................................ 1-46
Fig. 1-21 Dash Upper Assembly - Front View ............................ 1-48
Fig. 1-22 Dash Upper Assembly - Rear View ............................. 1-49
5/30/01

Boxxer 427
HydraMaster Corporation
Fig. 1-23 Dash Guage Panel Assembly ..................................... 1-51
Fig. 1-24 Lower Dash Assembly - Front View ............................ 1-53
Fig. 1-25 Lower Dash Assembly - Rear View............................. 1-54
Fig. 1-26 By-Pass Valve Assembly ........................................... 1-56
Fig. 1-27 HI-PSI Manifold Assembly .......................................... 1-58
Fig. 1-28 Electrical Control Panel Assembly .............................. 1-60
Fig. 1-29 Coolant Heat Exchanger Assembly ............................. 1-61
Fig. 1-30 Blower Heat Exchanger Assembly .............................. 1-64
Fig. 1-31 Top Cover Assembly ................................................ 1-66
Fig. 1-32 Machine Right Side Cover Assembly ........................... 1-67
Fig. 1-33 Machine Left Side Cover Assembly ............................ 1-68
Fig. 1-34 70 Gallon Universal Recovery Tank Assembly ............. 1-69
Fig. 1-35 70 Gallon Universal Recovery Tank Cover Assembly .... 1-72
Fig. 1-36 100 Gallon Universal Recovery Tank Assembly............ 1-73
Fig. 1-37 100 Gallon Universal Recovery Tank Cover Assembly .. 1-76
Fig. 1-38 Vacuum Relief Valve Assembly (Collector Box) ............ 1-77
Fig. 1-39 Dura-Flow APO Pump Assembly ................................. 1-79
Fig. 1-40 Chemical Jug Tray Assembly ..................................... 1-81
Fig. 1-41 Diffuser Filter Assembly............................................ 1-83
Fig. 1-42 Float Switch w/ Polypropylene Barrel Assembly ........... 1-84
Fig. 2-2 Cleaning Stroke Procedure ........................................ 2-3
Fig. 2-1 pH Chart ................................................................... 2-3
Fig. 2-2 Cleaning Stroke Procedure .......................................... 2-3
5/30/01

Boxxer 427
HydraMaster Corporation
Fig. 4-1 Recirculation Fitting ................................................... 4-1
Fig. 5-1 Chemical Pump Assembly ........................................... 5-3
Fig. 5-2 Solution Flow Diagram ............................................... 5-5
Fig. 5-3 Chemical Flow Diagram .............................................. 5-6
Fig. 5-4 Exhaust, Vacuum, Coolant, and APO Flow Diagram ........ 5-7
Fig. 6-1 Servicing the Valves .................................................. 6-3
Fig. 6-2 HydraPump II Assembly .............................................. 6-6
Fig. 7-1 Two-Jet Cleaning Wand Assembly ............................... 7-1
Fig. 10-1 Wiring Schematic...................................................... 10-2
Fig. 10-2 Wiring Diagram Sht 1. ............................................... 10-3
Fig. 10-3 Wiring Diagram Sht 2 ................................................ 10-4
Fig. 10-4 Wiring Diagram Sht 3 ................................................ 10-5
Fig. 11-1 Recirculation Fitting ................................................... 11-3

Boxxer 427
HydraMaster Corporation
Quick Reference

Boxxer 427
HydraMaster Corporation
Fuel Pump Assembly
B4627 Rev—

HydraMaster Corporation
General Information
Section 1-1
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 with one thing to worry about, Does
it start?

Page 1-2 Boxxer 427
HydraMaster Corporation
The manufacturer uses this symbol throughout the manual to warn of possible
injury or death.
This symbol is used to warn of possible equipment damage.
Hours Telephone Numbers
Monday - Friday [phone] Parts
8:00 am to 5:00 pm [phone] Service
PACIFIC STANDARD TIME [phone] Parts / Service FAX
CAUTION
!
WARNING
!

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HydraMaster Corporation
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.
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.)
ENGINE COOLING: Units employing internal combustion engines must not be
enclosed within a van with doors and windows closed. Excessive temperatures
within the engine will result in premature engine failure and a compromise of
applicable warranty.
LEVEL OPERATION: During operation, van or trailer must be parked on level
ground not to exceed + or - 10 degrees. Failure to insure proper leveling may
prevent proper internal lubrication of engine, vacuum and/or high pressure com-
ponents.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
The machine cannot be run in the IDLE position for cleaning upholstery, carpet or
floor extraction. This will void the warranty.
WARNING
!
CAUTION
!
CAUTION
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CAUTION
!
WARNING
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Page 1-4 Boxxer 427
HydraMaster Corporation
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 sys-
tem.
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.
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or
wood products) to come in contact with the exhaust system.
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.
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
WARNING
!

Boxxer 427 Page 1-5
HydraMaster Corporation
HEARING PROTECTION: The Occupational Safety and Health Administration
(OSHA) recommends the use of hearing protection when a technician is exposed
to an average of 85 decibels (this is an average of exposure over an 8 hour
period). This equipment can produce 85 decibels to a distance of 10 feet. Please
check with your local state agencies to see if OSHA standards apply to your
application.
NO SMOKING: It is unsafe to smoke in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so
that the fumes will be directed away from the job site. Do not park where
exhaust fumes can enter a building through open doors, windows, air 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 reproduc-
tive 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.
WARNING
!
WARNING
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WARNING
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WARNING
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WARNING
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WARNING
!
WARNING
!

Page 1-6 Boxxer 427
HydraMaster Corporation
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 regula-
tion.
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.
WARNING
!
CAUTION
!

Boxxer 427 Page 1-7
HydraMaster Corporation
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.

Page 1-8 Boxxer 427
HydraMaster Corporation
Machine Specifications
Frame: 26"W x 45"L x 41"H
Aluminum Cast with Baked-on Epoxy Finish
Weight: 807 lbs.
Engine: Vanguard 27HP Briggs and Stratton
Pressurized Oil System
Spin-on Filter, Oil Cooler and Oil PSI Protection Switch
Ignition: Electronic, Keystart
Vacuum Blower: Dominator 4007, Tuthill/M-D Tri-Lobe,
Pump: Comet FW5530S, 55 GPM Hot Seals, 3000 PSI
Chemical System: Last-Step Chemical
Operating Pressure: Up to 1,200 PSI
Heating System: 1 Water to Water Copper Shell and Tube Heat Exchanger
1 Copper Cross Flow Heat Exchanger Blower/Engine
Exhaust
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

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HydraMaster Corporation
Recovery Tank: 70 Gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel
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
150 ft, 2" Vacuum Hose
10 ft, 1-2" Wand Whip Line
150 ft, Super Flex Solution Line
Battery Box
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket

Page 1-10 Boxxer 427
HydraMaster Corporation
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
TBD 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