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
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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
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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—