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HydraMaster Boxxer 427 Manual

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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

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Summary of Contents for HydraMaster Boxxer 427

  • Page 1 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...
  • Page 2 Boxxer 427 HydraMaster Corporation...

  • Page 3: Table Of Contents

    Boxxer 427 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 ..............
  • Page 4 Boxxer 427 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 ........
  • Page 5 Boxxer 427 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 ..............
  • Page 6 Boxxer 427 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 ..........
  • Page 7 Boxxer 427 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.
  • Page 8 Boxxer 427 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.

  • Page 9: Quick Reference

    Boxxer 427 Quick Reference HydraMaster Corporation...
  • Page 10 Boxxer 427 Fuel Pump Assembly B4627 Rev— HydraMaster Corporation...

  • Page 11: General Information

    • 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? HydraMaster Corporation...

  • Page 12: Telephone Numbers

    Page 1-2 Boxxer 427 WARNING The manufacturer uses this symbol throughout the manual to warn of possible injury or death. CAUTION This symbol is used to warn of possible equipment damage. Hours Telephone Numbers Monday - Friday (425) 775-7276 Parts...

  • Page 13: Precautions

    Boxxer 427 Page 1-3 Precautions lthough 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.
  • Page 14 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. CAUTION 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.
  • Page 15 Boxxer 427 Page 1-5 WARNING 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).

  • Page 16: Ph Chart

    WARNING 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. CAUTION 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.

  • Page 17: System Operation

    System Operation he 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.

  • Page 18: Machine Specifications

    Page 1-8 Boxxer 427 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:...
  • Page 19 Boxxer 427 Page 1-9 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:...

  • Page 20: Spare Parts Recommendation

    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 ....(425) 775-7276 HydraMaster Parts Dept. Toll Free Fax..1-800-426-4225 Spare Parts List (078-340)
  • Page 21 Boxxer 427 Page 1-11 Spare Parts List (078-340) PART NO DESCRIPTION 056-001 Fuse, 10 amp 056-008 Fuse, 15 amp 056-010 Fuse, 25 amp 074-007 Gauge, Hi PSI (0-1500) 074-032 Meter, Chemical Flow Kit, Seal & Spring Hi PSI Kit, Comet Seal...

  • Page 22: Responsibilities

    Page 1-12 Boxxer 427 Responsibilities he Purchaser’s responsibilities are: Prior to arrival of unit, install s” exterior plywood flooring in the vehicle and cover it with artificial turf or apply a spray-on coating such as Rhino-lining to the van floor.
  • Page 23 Boxxer 427 Page 1-13 CORRECT INSTALLATION INCLUDES: • Vehicle of proper load carrying capacity (recommendation: ½ ton). • Installation of a safe fuel tap system and through-floor fittings as approved by Hydramaster • Placing the unit and recovery tank in your vehicle and securing them with bolts or tie down cleats.

  • Page 24: Vehicle Preparation

    Boxxer 427 Vehicle Preparation hen selecting a truck, remember the preferable vehicle for a Boxxer 427 installation is a cargo van with a heavy-duty suspension package and a half ton capacity. If a fresh water tank is added, a three quarter ton or larger capacity van, with a 2,400 pound payload capacity, is required.
  • Page 25 Boxxer 427 Page 1-15 PLACEMENT OF UNIT IN VEHICLE There are two recommended unit placements: SIDE DOOR: Most installations are side door. This provides rear access for accessories and hoses as well as unobstructed access to the component/working side of the machine, thus making it a bit easier to perform maintenance and/or repair without removing the unit from the truck.
  • Page 26 Page 1-16 Boxxer 427 Machine Tie Down Cleats Secure the machine to the floor of the van with the four tie down cleats provided. This safety measure will ensure that the machine will not slide inside the van. See the following illustration for the correct installation.
  • Page 27 WARNING Transportation in a vehicle of any vented fuel container that presently holds or has ever held a flammable liquid is strictly forbidden by HydraMaster Corpora- tion and by federal and state regulation. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 28: High Altitude Operation Preparation

    In turn, this can cause the water box to boil and the high pressure pump to cavitate. The heat control system settings will have to be adjusted to compensate for the elevation. These settings will vary according to elevation. Contact HydraMaster to obtain the recommended settings. HydraMaster Corporation...

  • Page 29: Local Water Precautions

    HydraMaster has included five hard water test strips with your machine. These can be used to test the water in your immediate and surrounding areas as they can vary greatly.

  • Page 30: Wastewater Disposal Advisory

    Page 1-20 Boxxer 427 HARD WATER AREA MAP The following map defines areas in the United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water cooled en- gines. For other countries, hard water area maps can be obtained from geological societies.
  • Page 31 The hidden benefit of this process is that the technician does not have to stop his cleaning to empty the recovery tank. HydraMaster makes an A.P.O. System available which can be ordered with new equipment or installed later.
  • Page 32 Page 1-22 Boxxer 427 This page intentionally left blank HydraMaster Corporation...
  • Page 33 Boxxer 427 Page 1-23 Figure 1-5 Hard Water Map HydraMaster Corporation...

  • Page 34: Machine Assemblies And Parts Lists

    Boxxer 427 Page 1-25 Machine Assemblies and Parts Lists Figure 1-6 Machine Assembly - Front View - Left Side D-5570 Rev B HydraMaster Corporation...
  • Page 35 Page 1-26 Boxxer 427 Figure 1-7 Machine Assembly - Front View - Right Side D-5570 Rev B HydraMaster Corporation...
  • Page 36 Boxxer 427 Page 1-27 Figure 1-8 Machine Assembly - Rear View - Right Side D-5570 Rev B HydraMaster Corporation...
  • Page 37 Machine Assembly Parts List Item Part Number Description 610-001-033 Assembly, Frame - Boxxer 427 (Fig. 1-9 - 1-11) 610-050-033 Assembly, Top Cover - Boxxer 427 (Fig. 1-31) 000-041-424 Cover, Lower Left Side - Rear - Boxxer 427 000-041-426 Cover, Lower Left Side - Front - Boxxer 427 610-050-033 Assembly, Machine Left Side Cover (Fig.
  • Page 38 Boxxer 427 Page 1-29 Figure 1-9 Frame Assembly - Front View - Left Side D-5571 Rev D HydraMaster Corporation...
  • Page 39 Page 1-30 Boxxer 427 Figure 1-10 Frame Assembly - Front View - Right Side D-5571 Rev D HIDDEN ITEM 3 SUPRESSED IN THIS VIEW HydraMaster Corporation...
  • Page 40 Boxxer 427 Page 1-31 Figure 1-11 Frame Assembly - Rear View - Left Side D-5571 Rev D HydraMaster Corporation...
  • Page 41 610-003-033 Assembly, Engine - Boxxer 427 (Fig. 1-12 - 1-13) 610-002-033 Assembly, Blower - Boxxer 427 (Fig. 1-16) 610-020-033 Assembly, Dash Upper - Boxxer 427 (Fig. 1-21 - 1-22) 610-019-033 Assembly, Dash Lower - Boxxer 427 (Fig. 1-24 - 1-25) 610-006-033 Assembly, Coolant Heat Exchanger (Fig.
  • Page 42 Boxxer 427 Page 1-33 Figure 1-12 Engine Assembly - Rear View D-5572 Rev G HydraMaster Corporation...
  • Page 43 Engine Assembly Parts List Item Part Number Description 000-047-026 Engine, Briggs & Stratton 27HP 000-042-011 Housing, Air Cleaner - Daihatsu Engine 000-092-011 Mount, Engine 27 B&S - Boxxer 427 000-001-033 Adapter, Thermostat Housing 000-057-050 Gasket, Thermostat Housing Daihatsu Engine HydraMaster Corporation...
  • Page 44 000-094-081 Nut, 5/16"-18UNC Hex 2-Way Locking 000-033-117 Clamp, 1" Cushion Loop w/ 7/16" Mount Hole 000-052-063 Bushing, 14mm x 1/4" NPT Engine Oil Drain Adapter 000-068-746 Hose, Engine Oil Drain - Boxxer 427 000-174-019 Washer, 1/4" Lock 000-143-569 Screw, 6mm x 85mm Lg. Hex Head 000-154-144 Spacer, Air Cleaner - Boxxer 427 000-174-049 Washer, 5/16"...
  • Page 45 Page 1-36 Boxxer 427 Figure 1-14 Exhaust Assembly D-5580 Rev C HydraMaster Corporation...
  • Page 46 Description Fig. 1-15 Assembly, Diverter Valve Actuator - Boxxer 427 000-125-214 Tube, Diverter To Outlet Plenum - Boxxer 427 000-001-116 Adapter, 1.50" F Slip To Flare - Boxxer 427 000-094-027 Nut, #10-24UNC Hex 000-155-030 Spring, Leaf 000-138-010 Retainer, Leaf Spring 000-174-001 Washer, #10 Flat 000-143-132 Screw, #10-24UNC x 0.75"...
  • Page 47 Diverter Valve Actuator Assembly Parts List Item Part Number Description 000-169-169 Valve, Air Cylinder 000-015-926 Bracket, Air Cylinder Extension - Welded - Boxxer 427 000-094-092 Nut, 7/16"-20UNF Hex Jam 000-052-550 Elbow, 1/8" NPT x 3/16" Barb 000-015-750 Bracket, Air Cylinder Mount - Inner 000-015-748 Bracket, Air Cylinder Mount - Outer 000-143-573 Screw, 5/16-18 Shoulder, 3/8"...
  • Page 48 Boxxer 427 Page 1-39 Figure 1-16 Blower Assembly D-5573 Rev H Blower Assembly Parts List Item Part Number Description 000-111-167 Blower, MD 4007 C-Face Dual Shaft - Boxxer 427 Fig. 1-17 Assembly, Pump - Boxxer 427 HydraMaster Corporation...
  • Page 49 000-015-814 Bracket, Dominator Mounting - Boxxer 421 000-042-061 Housing, Bell - Boxxer 427 000-109-112 Pulley, 3.50" Pump Drive 000-001-115 Adapter, Blower Flange To 3" M Slip - Boxxer 427 000-174-057 Washer, 3/8" Lock 000-143-018 Screw, 3/8"-16UNC x 1.00" Lg. Grade 8 000-010-123 Belt, EPDM 40"...
  • Page 50 Boxxer 427 Page 1-41 Figure 1-17 Pump Assembly D-5574 Rev D HydraMaster Corporation...
  • Page 51 - - - Screw, 8mm x 1.0 x 12mm Lg. 000-154-145 Spacer, Comet Pump Clutch - Boxxer 427 000-052-753 Insert, #816 (1/2" NPT x 1" Barb) 000-114-019 Rail, HydraPump V / Chem Pump Mounting - Boxxer 427 1 HydraMaster Corporation...
  • Page 52 Boxxer 427 Page 1-43 Figure 1-18 Chemical Pump Assembly C-6555 Rev A OUTLET INLET Chemical Pump Assembly Parts List Item Part Number Description 000-106-110 Plug, Check Valve - Chemical Pump 000-064-015 Cover, Chemical Pump 000-111-030 Body, Chemical Pump 000-105-071 Mid Plate, Chemical Pump...
  • Page 53 Page 1-44 Boxxer 427 Figure 1-19 Pump Mounting Bracket Assembly D-5766 Rev F HydraMaster Corporation...
  • Page 54 Boxxer 427 Page 1-45 Pump Mounting Bracket Assembly Parts List Item Part Number Description 000-174-032 Washer, 3/8" Flat 000-094-014 Nut, 3/8"-16UNC Hex Zinc Plated 000-174-021 Washer, 3/8" Lock 000-015-893 Bracket, Pump Mounting - Welded 000-174-005 Washer, 3/8" Flat 000-143-139 Screw, 3/8"-16UNC x 4.00 Lg. Grd 8 000-169-070 Valve, Primary Vac.
  • Page 55 Page 1-46 Boxxer 427 Figure 1-20 Water Box Assembly D-5575 Rev H HydraMaster Corporation...
  • Page 56 000-174-032 Washer, 3/8" Flat 000-174-057 Washer, 3/8" Lock 000-143-017 Screw, 3/8"-16UNC x 0.75" Lg. Hex Head Grd. 8 000-049-151 Assembly, Diffuser Filter - Boxxer 427 (Fig. 1-41) 000-050-754 Insert, #F816 (1/2" FPT x 1" Barb) 000-052-728 Bulkhead, 1/2" FPT x 3/8" FPT 27 000-157-0801 Assembly, Float Switch w/ Polyprop.
  • Page 57 Page 1-48 Boxxer 427 Figure 1-21 Dash Upper Assembly - Front View D-5576 Rev A HydraMaster Corporation...
  • Page 58 Boxxer 427 Page 1-49 Figure 1-22 Dash Upper Assembly - Rear View D-5576 Rev A HydraMaster Corporation...
  • Page 59 000-074-018 Meter, Rectangular w/o Bezel 000-025-002 Cable, Choke (3 Foot) 000-025-020 Cable, Throttle Kohler 000-084-011 Light, Red Led Indicator Mini 610-020-033 Assembly, Dash Guage Panel - Boxxer 427 (Fig. 1-23) 000-174-001 Washer, #10 Flat 000-174-014 Washer, #10 Lock 000-094-034 Nut, #10-24UNC Nylock 000-131-131 Trimlock, 3/8"...
  • Page 60 Boxxer 427 Page 1-51 Figure 1-23 Dash Guage Panel Assembly D-5585 Rev C HydraMaster Corporation...
  • Page 61 000-169-160 Valve, Chemical Metering 000-052-069 Nipple, 1/8" NPT Hex 000-169-0171 Valve, 3-Way Ball O-Ring Style 000-052-084 Elbow, 1/8" NPT Street 000-074-017 Guage, 0-30" Hg Vac. 2 1/2" Hydramaster Face 000-074-016 Gauge, Temperature 000-149-551 Thermostat, Potentiometer Dual Controller 000-094-070 Nut, 5mm Nylock...
  • Page 62 Boxxer 427 Page 1-53 Figure 1-24 Dash Lower Assembly - Front View D-5577 Rev E HydraMaster Corporation...
  • Page 63 Page 1-54 Boxxer 427 Figure 1-25 Dash Lower Assembly - Rear View D-5577 Rev E Dash Lower Assembly Parts List Item Part Number Description 000-100-143 Panel, Lower Dash - Boxxer 427 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port HydraMaster Corporation...
  • Page 64 Boxxer 427 Page 1-55 Dash Lower Assembly Parts List Item Part Number Description 000-052-096 Insert, #F23 (1/8" FPT x 3/16" Barb) 000-052-052 Quick Connect, 660 Male w/ Viton Standard 000-052-051 Quick Connect, 440 Female w/ Epdm O-Ring 000-052-071 Nipple, 1/4" NPT Hex 000-174-008 Washer, 5/8"...
  • Page 65 Page 1-56 Boxxer 427 Figure 1-26 By-Pass Valve Assembly C-5581 Rev C HydraMaster Corporation...
  • Page 66 Boxxer 427 Page 1-57 By-Pass Valve Assembly Parts List Item Part Number Description 000-052-128 Nipple, 3/8" NPT x 3/8" Male Propane 000-015-515 Bracket, By-Pass Valve Mounting 000-169-188 Valve, PSI Regulator 0-1500 PSI - Modified 000-106-008 Plug, 3/8" NPT Allen Head 000-052-023 Tee, 3/8"...
  • Page 67 Page 1-58 Boxxer 427 Figure 1-27 Hi-PSI Manifold Assembly C-5582 Rev A HydraMaster Corporation...
  • Page 68 Page 1-59 Hi-PSI Valve Assembly Parts List Item Part Number Description 000-090-057 Manifold, Hi-PSI - Boxxer 427 000-180-004 Orifice, Set Screw 0.033" 000-052-423 Bushing, Modified Set Screw Orifice 000-049-016 Filter, 1/4" NPT Replacement “Y” 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 000-106-111 Plug, 1/2"...
  • Page 69 Page 1-60 Boxxer 427 Figure 1-28 Electrical Control Panel Assembly C-5583 Rev D HydraMaster Corporation...
  • Page 70 Electrical Control Panel Assembly Parts List Item Part Number Description 000-100-137 Panel, Electrical Control - Boxxer 427 000-041-418 Cover, Electrical Control Panel - Boxxer 427 000-012-010 Block, Terminal 10 Post 000-157-022 Switch, Relay 000-084-010 Light, Green LED Indicator Mini 000-084-011 Light, Red LED Indicator Mini 000-084-012 Light, Yellow LED Indicator Mini 000-156-030 Stud, #10-32UNF x 2"...
  • Page 71 Page 1-62 Boxxer 427 Figure 1-29 Coolant Heat Exchanger Assembly D-5578 Rev A HydraMaster Corporation...
  • Page 72 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 000-174-019 Washer, 1/4" Lock 000-052-131 Elbow, 1" NPT x 1" Barb 000-125-194 Tube, Coolant Heat Exchager To Engine - Boxxer 427 000-068-250 Hose, 1" I.D. Green Stripe 000-068-250 Hose, 1" I.D. Green Stripe 000-068-250 Hose, 1"...
  • Page 73 Page 1-64 Boxxer 427 Figure 1-30 Blower Heat Exchanger Assembly D-5579 Rev B HydraMaster Corporation...
  • Page 74 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 000-140-021 Rivet, 1/4" Blind x 0.50" Lg. 000-052-086 Elbow, 3/8" NPT Street 000-013-059 Box, Inlet Plenum - Welded - Boxxer 427 000-013-060 Box, Outlet Plenum - Weldment - Boxxer 427 000-001-097 Adpater, Exhaust Turndown - Raw 000-143-002 Screw, 1/4"-20UNC x 1.00"...
  • Page 75 Item Part Number Description 000-041-416 Cover, Top Machine - Boxxer 427 000-041-422 Cover, Brow - Boxxer 427 000-100-153 Panel, Brow End - Weldment - Boxxer 427 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 000-174-001 Washer, #10 Flat 000-094-034 Nut, #10-24UNC Nylock 000-143-126 Screw, #10-24UNC x 0.50"...
  • Page 76 D-5762 Rev - Machine Right Side Cover Assembly Parts List Item Part Number Description 000-041-419 Cover, Right Side Machine - Boxxer 427 000-105-313 Plate, Hydramaster Name- Roto Tank 000-174-001 Washer, #10 Flat 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head...
  • Page 77 D-5587 Rev - Machine Left Side Cover Assembly Parts List Item Part Number Description 000-041-417 Cover, Left Side Machine - Boxxer 427 000-105-313 Plate, Hydramaster Name- Roto Tank 000-174-001 Washer, #10 Flat 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head...
  • Page 78 Boxxer 427 Page 1-69 Figure 1-34 70 Gallon Universal Recovery Tank Assembly D-6860 Rev B HIDDEN HIDDEN HIDDEN HydraMaster Corporation...
  • Page 79 Page 1-70 Boxxer 427 70 Gallon Univesal Recovery Tank Assembly Parts List Item Part Number Description 000-159-128 Tank, 70 Gallon Universal Recovery - Weldment 610-003-015 Assembly, Cover - Dual Vac. (Fig. 1-35) 000-157-090 Float, Lever Switch 000-079-091 Kit, Dura-Flow APO - Production (Firg. 1-39)
  • Page 80 Boxxer 427 Page 1-71 70 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description 000-143-132 Screw, #10-24UNC x 0.75" Lg. Hex Head 000-106-049 Plug, 1" NPT Allen Head 000-174-060 Washer, 1/4" Flat Rubber Backed 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 000-094-113 Nut, 1/4"-20UNC Neoprene Wellnut...
  • Page 81 Page 1-72 Boxxer 427 Figure 1-35 70 Gallon Universal Recovery Tank Cover Assembly D-6890 Rev - 70 Gallon Universal Recovery Tank Cover Assembly Parts List Item Part Number Description 000-041-444 Cover, Dual Vac. 70 Gallon Universal Recovery Tank - 000-052-222 Elbow, 2" Barb x 2" FPT...
  • Page 82 Boxxer 427 Page 1-73 Figure 1-36 100 Gallon Universal Recovery Tank w/ APO Assembly D-6983 Rev A HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN 34 HIDDEN HIDDEN HIDDEN 30 HIDDEN 13 10 HydraMaster Corporation...
  • Page 83 Page 1-74 Boxxer 427 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description 000-159-129 Tank, 100 Gallon Universal Recovery - Weldment Fig -1-37 Assembly, Recovery Tank Cover - 100 Gallon 000-157-090 Float, Lever Switch 000-079-091 Kit, Dura-Flow APO - Production (Fig 1-39)
  • Page 84 Boxxer 427 Page 1-75 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 000-094-009 Nut, 1/4"-20UNC Hex Nylock 000-166-002 Tray, Soap Jug - Weldment 000-094-034 Nut, #10-24UNC Nylock 000-057-206 Gasket, Adapter - Universal Recovery Tank 000-052-085 Elbow, 1/4"...
  • Page 85 Page 1-76 Boxxer 427 Figure 1-37 100 Gallon Universal Recovery Tank Cover Assembly D-6919 Rev - 100 Gallon Universal Recovery Tank Cover Assembly Parts List Item Part Number Description 000-041-447 Cover, 100 Gallon Universal Recovery Tank - Weldment 1 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 000-057-015 Gasket, 1-1/2"...
  • Page 86 Boxxer 427 Page 1-77 Figure 1-38 Vacuum Relief Valve Assembly (Collector Box) C-7156 Rev - HydraMaster Corporation...
  • Page 87 Page 1-78 Boxxer 427 Vacuum Relief Valve Assembly (Collector Box) Parts List Item Part Number Description 000-015-182 Bracket, Vacuum Relief Valve 000-027-032 Cap, Vacuum Releif Valve 000-125-111 Pipe, Vacuum Relief Spring Guide 000-105-337 Plate, Vacuum Relief Valve Mounting 000-155-026 Spring, Vacuum Relief 000-143-198 Screw, 3/8"-16UNC x 4"...
  • Page 88 Boxxer 427 Page 1-79 Figure 1-39 Dura-Flow APO Pump Assembly D-5654 Rev E HydraMaster Corporation...
  • Page 89 Page 1-80 Boxxer 427 Dura-Flow APO Pump Assembly Parts List Item Part Number Description 000-111-169 Assembly, APO Pump - Jabsco 000-091-042 Motor, Bison 438 Series 000-015-891 Bracket, APO Clamp 000-015-890 Bracket, Tank Mounted APO Support 000-143-566 Screw, 1/4-28UNF x 0.75" Lg. Socket Head 000-143-074 Screw, 1/4"-20UNC x 0.50"...
  • Page 90 Boxxer 427 Page 1-81 Figure 1-40 Chemical Jug Tray Assembly C-4945 Rev C HydraMaster Corporation...
  • Page 91 Page 1-82 Boxxer 427 Chemical Jug Tray Assembly Parts List Item Part Number Description 000-166-021 Tray, Chemical Jug - Outer - Weldment 000-166-025 Tray, Chemical Jug - Inner 000-078-039 Vacuum Inlet Stopper 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 000-174-019 Washer, 1/4"...
  • Page 92 Item Part Number Description 000-052-074 Nipple, 3/8" NPT Hex 000-033-131 Clamp, Diffuser - Boxxer 427 000-125-222 Tube, Diffuser - Boxxer 427 000-027-115 Cap, 2" PVC Modified For Diffuser - Boxxer 427 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) HydraMaster Corporation...
  • Page 93 C-6549 Rev - Float Switch w/ Polypropylene Barrel Assembly Parts List Item Part Number Description - - - Stem, Float Switch 000-005-011 Float, Polypropylene Replacement- Boxxer 427 000-108-110 Shield, Poly Float Splash 000-139-010 Ring, Snap Ring (E-Clip) x 5/16" HydraMaster Corporation...
  • Page 94 Boxxer 427 Page 1-85 (To be Added) HydraMaster Corporation...
  • Page 95 Page 1-86 Boxxer 427 (To be Added) HydraMaster Corporation...

  • Page 96: Cleaning And Chemicals

    HydraMaster’s ClearWater Rinse has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from using unprotected acid products that have obviously caused failures. HydraMaster Corporation...
  • Page 97 Page 2-2 Boxxer 427 CLEANING STROKE PROCEDURE Purpose: To eliminate excess moisture remaining in the carpet fiber and the saw tooth appearance which results from diagonal movement of the cleaning tool on all types of carpet. Procedure: Always move the cleaning tool in smooth, forward and backward strokes. Apply slight pressure to the forward stroke while the solution is injected into the carpet.
  • Page 98 Boxxer 427 Page 2-3 HydraMaster Corporation...
  • Page 99 Page 2-4 Boxxer 427 This page intentionally left blank HydraMaster Corporation...

  • Page 100: Operating Instructions

    Boxxer 427 Page 3-1 Operating Instructions Boxxer 427 Section 3-1 START UP 1. Perform daily and periodic maintenance as specified in this Owner’s Manual. 2. Connect all required hoses, including a garden hose for water supply. 3. Connect the cleaning tool to the length of hose required to perform the cleaning.

  • Page 101: Upholstery Cleaning

    Page 3-2 Boxxer 427 Set cleaning pressure at desired level. Suggested Settings Carpet Cleaning: 300 – 400 psi; Hard Surface: 1000 psi or as indicated on the tool. Turn the chemical selector valve to the “PRIME” position to purge any air from the system.

  • Page 102: Flood Extraction

    Boxxer 427 Page 3-3 Set the temperature to desired level. If used, turn PUMP OUT switch to “ON” (switch light will be illuminated). Set cleaning pressure at desired level (300 –400 psi). Turn the chemical selector valve to the “PRIME” position to purge any air from the system.

  • Page 103: Shut Down

    Page 3-4 Boxxer 427 Shut Down 1. Flush clear water through the chemical system for 10 seconds. Turn off the chemical flowmeter. 2. Cool the machine by lowering the adjustable thermostat to the “LOW” position and the DIVERTER CONTROL switch to the “OFF” position while spraying the cleaning wand into the vacuum hose for three to five minutes.

  • Page 104: Exhaust Diverter

    Boxxer 427 Page 3-5 Exhaust Diverter System The exhaust diverter system consists of two components; the diverter valve and the pump clutch. The diverter valve directs the flow of the exhaust through the coil heat exchanger or directly out of the machine via the diverter exhaust muffler. The pump clutch allows the pump to be turned on and off through a switch.
  • Page 105 Page 3-6 Boxxer 427 Adjustment After Installation: Machines that are equipped with a diverter valve may need adjustment after the machine has been installed. Prior to running the machine, perform the following steps: 1. Locate the actuator connected to the diverter valve arm which is located on the lower left hand side, behind the diverter valve.

  • Page 106: Freeze Guard

    Freeze Guard Boxxer 427 Section 4-1 VACUUM FREEZE GUARD PROCEDURE: To freeze guard your machine: 1. Start the machine. 2. Spray all of the water out of the system until the engine stops. 3. Add a half gallon of 50/50 antifreeze and water mix to the chemical mix tank and draw the antifreeze into the flow meter.
  • Page 107 Page 4-2 Boxxer 427 6. Spray the antifreeze and water mix out of the machine and into a container to reclaim the solution. Run the machine until it stops. NOTE: The reclaimed antifreeze solution may be used 3 times before being discarded.
  • Page 108 Boxxer 427 Page 4-3 FREEZE PROTECTION OF THE PUMP-IN SYSTEM 1. Drain the fresh water tank. 2. Remove the garden hose adapter from the pump-in pump hose and position the hose so it is pointing outside the van. 3. Turn on the pump-in pump and run for 1-2 minutes till all the water is purged from the hose.
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  • Page 110: Water And Chemical System

    Water and Chemical System Boxxer 427 Section 5-1 his high pressure chemical system has been designed to be simple and trouble free. WATER AND CHEMICAL FLOW OPERATION The chemical pump draws the chemical from the inlet filter which is in the chemical container.

  • Page 111: Chemical System Maintenance

    Page 5-2 Boxxer 427 b. When the chemical begins to flow through the flowmeter, with the flow indicator reading maximum flow for at least 10 seconds, turn the chemi cal selector to “ON”. The restriction can now be removed from the vacuum inlet.

  • Page 112: Chemical Pump

    Boxxer 427 Page 5-3 Figure 5-1 Chemical Pump Assembly C-6555 Rev - OUTLET INLET Chemical Pump Assembly Parts List Item Part Number Description 000-106-110 Plug, Check Valve - Chemical Pump 000-064-015 Cover, Chemical Pump 000-111-030 Body, Chemical Pump 000-105-071 Mid Plate, Chemical Pump...
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  • Page 114 Boxxer 427 Page 5-5 Figure 5.2, Solution Flow Diagram D5736 Rev A HydraMaster Corporation...
  • Page 115 Boxxer 427 Page 5-6 Figure 5.3, Chemical FLow Diagram D5736, Rev A HydraMaster Corporation...
  • Page 116 Boxxer 427 Page 5-7 Figure 5.4 Exhaust, Vacuum, Coolant & APO FLow Diagram D5736, Rev A HydraMaster Corporation...
  • Page 117 Boxxer 427 Page 5-7 Page 5-8 Heating System Troubleshooting 1.0. Machine overheats and shuts down 1.1. Primary orifice or filter screen is restricted. Remove and inspect. Clean as necessary. 1.2. Low pressure dump solenoid is restricted. Inspect solenoid and the hose that delivers water to it.
  • Page 118 Page 5-9 Page 5-8 Boxxer 427 2.5.1. Cleaning tool jet is too large or worn out. Inspect jet. Replace if necessary. 2.5.2. Cleaning solution pressure is too high. Adjust pressure to normal. Inspect pressure gauge for accurate reading. 2.6. Heat exchangers have hard water scale build up internally. Descale system.
  • Page 119 Page 5-10 Boxxer 427 Page 5-9 2.4. Chemical metering valve is faulty or partially obstructed. Inspect valve and clean or replace as necessary. 2.5. High pressure check valve is faulty. Remove and inspect. Clean or replace as necessary. 3.0. Solution jug fills with water 3.1.
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  • Page 121: High Pressure Pump

    Boxxer 427 Page 6-1 High Pressure Pump -Maintenance Boxxer 427 Section 6-1 DAILY Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the back of the pump.
  • Page 122 CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic. For assistance, contact HydraMaster (425-775-7275) or the distributor in your area. Servicing the Valves (See Figure 6-1) 1. Remove the hex valve plugs;...
  • Page 123 Boxxer 427 Page 6-3 Figure 6-1 Servicing the Valves Removing the High Pressure Manifold 1. Using an M6 allen wrench, remove all eight of the socket head bolts. 2. Rotate the crankshaft by hand to start separation of the manifold head from the crankshaft.
  • Page 124 Page 6-4 Boxxer 427 CAUTION To avoid damage to either plunger or seal, keep the manifold properly aligned with the ceramic plungers when removing it. 4. Remove the seal retainer from the manifold and inspect for wear. 5. Examine the ceramic plunger for cracks or scoring (refer to Servicing the Plungers for replacement).
  • Page 125 1. While manifold, plungers, and seal retainers are removed, examine the crank- case seals for wear. 2. Rotate the crankshaft oil seal externally for drying, cracking or leaking. 3. Consult your HydraMaster distributor if crankcase servicing is necessary. HydraMaster Corporation...
  • Page 126 Page 6-6 Boxxer 427 Figure 6-2 Pump Assembly D-5574 Rev D HydraMaster Corporation...
  • Page 127 - - - Screw, 8mm x 1.0 x 12mm Lg. 000-154-145 Spacer, Comet Pump Clutch - Boxxer 427 000-052-753 Insert, #816 (1/2" NPT x 1" Barb) 000-114-019 Rail, HydraPump V / Chem Pump Mounting - Boxxer 427 1 HydraMaster Corporation...
  • Page 128 Page 6-8 Boxxer 427 High Pressure System Troubleshooting 1.0. Will not come up to normal cleaning pressure 1.1. Pressure adjusting valve is defective or dirty. Disassemble valve. Repair or replace if necessary. 1.2. Worn seals or valves in pump. Test pump output volume directly from pump at normal running RPM.
  • Page 129 Boxxer 427 Page 6-9 3.0. PSI gauge reads normal; low pressure from wand 3.1. There is a restriction in the cleaning tool. Inspect tool jet and clean or replace as necessary. Inspect any filters in the cleaning tool and clean or replace as necessary.
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  • Page 131: Cleaning Wand Parts

    Cleaning Wand Parts Boxxer 427 Section 7-1 Figure 7-1 Valve Assembly C3652 ITEM PART NO. DESCRIPTION 169-058 Valve, s/s HM Solution 167-013 Trigger, Hydra Hoe Valve - Brass 052-082 Elbow, ¼” Brass 45 Street 052-095 Nipple, ¼” s/s Hex 052-050...
  • Page 132 Page 7-2 Boxxer 427 Figure 1-2 Solution Valve Assembly B1234 ITEM PART NO. DESCRIPTION 600-012-001 Valve Body Sub Assembly 600-012-002 Valve Stem Sub Assembly 155-003 Spring, HM Solution Valve 027-001 Cap, Brass HydraMaster Corporation...
  • Page 133 Boxxer 427 Page 7-3 Figure 1-3 Valve Stem Assembly B3743 ITEM PART NO. DESCRIPTION 107-129 Plunger, HM Solution Valve 139-003 Ring Keeper, HM Solution Valve 097-010 O-Ring, HM Valve Plunger - Large 097-022 O-Ring, Solution Valve Flow Meter - Small...
  • Page 134 Page 7-4 Boxxer 427 Figure 1-4 Hydra Hoe Wand Assembly C2660 HydraMaster Corporation...
  • Page 135 Boxxer 427 Page 7-5 Hydra Hoe Wand Assembly Parts List ITEM PART NO. DESCRIPTION 173-001 Wand Kit, 12" s/s Truckmount 082-004 Lips, 12" s/s HM Wand (2 Pieces) 169-055 Valve Assembly, s/s Hydra Hoe with Trigger 081-015 Label, “HydraMaster” Wand 154-001 Spacer, ¼...
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  • Page 137: Vacuum System

    Boxxer 427 Page 8-1 Vacuum System Boxxer 427 Section 8-1 he vacuum pump in this machine is commonly referred to as a ‘positive dis- placement lobe’ type blower. The performance and life of this unit is greatly dependent on the care and proper maintenance it receives.
  • Page 138 The switch is not activated by foam, only by liquid. VACUUM TANK FILTER BAGS HydraMaster filter bags are designed to trap lint, sand and dirt that would normally collect at the bottom of your vacuum tank. The use of these bags, if emptied at the end of each job, will eliminate the build-up of much of the debris in the tank.
  • Page 139 Boxxer 427 Page 8-3 Vacuum System Troubleshooting 1.0. Weak vacuum at wand. Gauge reads normal (10" to 12" with hoses & wand attached) 1.1. Clogged hoses or wand tube. Disconnect hoses and check carefully for an obstruction. 1.2. Excessive length of hoses connected to machine. Make sure machine is rated for the conditions under which it is being operated.
  • Page 140 Page 8-4 Boxxer 427 5.1. The machine has been unused for a period on time and the blower was not properly lubricated when it was shut down, causing rust to build up on internal surfaces. Spray penetrating oil into blower inlet and let sit for at least one hour. Then very carefully use pipe wrench on outer diameter of pulley on blower shaft and attempt to free up blower.

  • Page 141: Engine Troubleshooting

    Boxxer 427 Page 9-1 Engine Troubleshooting Boxxer 427 Section 9-1 1.0. Will not turn over 1.1. There is a loose or corroded battery terminal. Clean and tighten the battery terminal connections. 1.2. The battery is dead. Recharge or replace the battery. Test the charging system.
  • Page 142 Page 9-2 Boxxer 427 2.1. Recovery tank is full. Empty the tank. 2.2. Recovery tank float is defective. Disconnect float. If engine starts, replace the float. 2.3. The oil pressure switch is preventing the engine from starting. Check the engine oil level.
  • Page 143 Boxxer 427 Page 9-3 3.5. There is a mechanical problem with the engine. Have engine inspected by a qualified engine service technician. 4.0. Starts then dies immediately 4.1. The oil pressure switch is activated. Check engine oil for proper level. If oil level is okay, disconnect switch.
  • Page 144 Page 9-4 Boxxer 427 6.5. Inadequate fuel supply to the carburetor. Test the fuel volume at the carburetor by removing the fuel line from the carburetor inlet and placing the line in a metal container with a minimum of 16 oz capacity. Turn on the ignition switch to operate the fuel pump. The fuel flow volume should be 12 oz / minute.

  • Page 145: Electrical System

    Boxxer 427 Page 10-1 Electrical System Boxxer 427 Section 10-1 he Boxxer electrical system, in keeping with the entire machine concept, has been kept to a minimum so as to keep any necessary troubleshooting as easy as possible. The entire electrical system operates on 12 volts DC which is provided by a battery.
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  • Page 147 Boxxer 427 Page 10-2 Figure 10 -1 Wiring Schematic D-5738 Rev E HydraMaster Corporation...
  • Page 148 Boxxer 427 Page 10-3 Figure 10-2 Wiring Diagram D-5737 Sht 2, Rev E HydraMaster Corporation...
  • Page 149 Boxxer 427 Page 10-4 Figure 10-3 Wiring Diagram D-5737 Sht 3, Rev E HydraMaster Corporation...
  • Page 150 Boxxer 427 Page 10-5 Figure 10-4 Wiring Diagram D-5737 Sht 4, Rev E HydraMaster Corporation...

  • Page 151: Electrical Troubleshooting

    Page 10-6 Boxxer 427 Page 10-5 Electrical Troubleshooting Problem/ Solution Possible Cause The engine is not charging the battery. The regulator/rectifier is bad. Check the B+ voltage from the regulator/rectifier to ground. With the engine running at normal RPM the voltage should be 12.5 to 14.5 DC volts.
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  • Page 153: Machine Maintenance

    Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored. It is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder.
  • Page 154 Page 11-2 Boxxer 427 WEEKLY (cont.): • Check pump pulleys. • Check high pressure water lines for wear or chafing. • Check all nuts and bolts. Tighten as needed. • Inspect vacuum relief valve. Clean and lubricate as necessary. • Clean vacuum tank thoroughly with high pressure washer.
  • Page 155 Boxxer 427 Page 11-3 AS REQUIRED: DE-SCALING Scale deposits on the interior of the heating system can cause a noticeable loss in heating performance. Deposits of this kind result from hard water deposits, exces- sive chemical use, improper chemicals, etc. The frequency with which de-scaling procedures are required will vary.
  • Page 156 Page 11-4 Boxxer 427 OVERALL MACHINE MAINTENANCE Maintaining the original appearance of your unit is important for two reasons: 1. It represents a big dollar investment for your cleaning business and its appear- ance should reflect that fact. A dirty machine is not professional.
  • Page 157 Boxxer 427 Page 11-5 WEEKLY • Wipe down entire unit as needed. • Apply good coat of auto wax to all painted surfaces inside and out, and to control panel. • Thoroughly clean recovery tank using high pressure hot water (unit with optional high pressure cleaning gun may be used for this).
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  • Page 159 BOXXER 427 MAINTENANCE LOG DAILY SERVICE OIL RECOMMENDATIONS BLOWER 40 weight non-detergent ENGINE OIL - check PUMP 5 - 30 weight synthetic motor oil PUMP OIL - check ENGINE 30 weight motor oil GARDEN HOSE SCREEN - clean NOTE: Overhead valve engines can use multi-viscosity oil, but will...

  • Page 161: How To Order Parts

    EMERGENCIES If, for any reason, your distributor is unable to supply you with the necessary parts, they may call us and arrange for expedited shipping. HydraMaster sells parts only through authorized distributors and service centers. HydraMaster Corporation...
  • Page 162 We shall always endeavor to be fair in our evaluation of your warranty claim, and shall provide you with a complete analysis of our findings. HydraMaster warranty covers only defective materials and/or workmanship for the periods listed. Labor and/or diagnostic reimbursement is specifically excluded.

  • Page 163: Warranty Information

    Boxxer 427 Page 13-1 Warranty Information Boxxer 427 Section 13-1 o avoid misunderstandings which might occur between machine owners and manufacturer, we are listing causes of component failure that specifically voids warranty coverage. Such causes as listed below shall constitute abuse or neglect.
  • Page 164 Page 13-2 Boxxer 427 CHEMICAL SYSTEM: • Use of improper chemical. • Failure to use water softener in hard water area. • Operating machine without proper chemical filter screen. • Failure to protect against freezing. CONTROL PANEL: • Failure to protect flowmeter and water pressure gauge against freezing.
  • Page 165 Warranty coverage is available to you through your local Distributor. If you have moved to a new area or have purchased a used machine and need infor- mation regarding your local distributor, call HydraMaster at (425) 775-7272 or email us at custsvc@hydramaster.com.
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  • Page 167 These products can enhance your cleaning and reduce your labor costs! HydraMaster Machine accessories are the most innovative collection available in the cleaning industry. Our patented RX-20 Rotary Extractors have changed the shape of steam cleaning.
  • Page 168 Page 14-2 Boxxer 427 HydraMaster Corporation...

  • Page 169: Product Updates

    Boxxer 427 Page 15-1 Product Updates Boxxer 427 Section 15-1 HydraMaster Corporation...
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