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HydraMaster Boxxer H2O Owner's Manual

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11015 47th Avenue W, Mukilteo, WA 98275
Boxxer H
O
2
Machine Serial Number________________________
Copyright© 2006
HYDRAMASTER© Corporation
Mukilteo, Washington
MAN-182-136
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.

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Summary of Contents for HydraMaster Boxxer H2O

  • Page 1 Mukilteo, Washington MAN-182-136 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.

  • Page 2: Table Of Contents

    Boxxer H Table of Contents Table of Contents List of Figures Quick Reference GENERAL INFORMATION ................. Section 1 Telephone Numbers ................1-2 Precautions ..................1-3 Responsibilities .................. 1-5 Vehicle Preparation ................1-7 High Altitude Operation Preparation ........... 1-11 Local Water Precautions ..............1-12 MACHINE SPECIFICATIONS..............
  • Page 3 Fig. 5-12 Recovery Tank Cover Assembly ......... 5-18 Fig. 5-13 Vacuum Relief Valve Assembly ......... 5-19 Fig. 5-14 Dura-Flow APO Pump Assembly ......... 5-20 Fig. 7-1 Wiring Schematic ............7-3 Fig. 7-2 Wiring Diagram ............7-4 Boxxer H O Owner’s Manual HydraMaster Corporation...

  • Page 4: Quick Reference

    Boxxer H Quick Reference Fuel Pump Assembly B4627 Rev— Boxxer H O Owner’s Manual...

  • Page 5: General Information

    As with any machine, it is important to use the Boxxer H2O correctly. Operating the ma- chine is simple; just start the engine with the vacuum hoses disconnected, let it warm up for two or three minutes, advance the throttle to the maximum operating position, connect the vacuum hoses and you are ready to extract water.

  • Page 6: Telephone Numbers

    This symbol is used to warn of possible equipment damage. Hours Telephone Numbers Monday - Friday (425) 775-7276 Parts 8:00 am to 5:00 pm (425) 775-7275 Service PACIFIC STANDARD TIME (800) 426-4225 Parts / Service FAX Page 1-2: General Information HydraMaster Corporation...

  • Page 7: Precautions

    Boxxer H Precautions Although this unit has been factory adjusted, it may require additional adjustments to achieve optimum performance, for instance higher altitudes may require carburetor 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.
  • Page 8 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 forbid- den by HydraMaster Corporation and by federal and state regulation. Page 1-4: General Information...

  • Page 9: Responsibilities

    Boxxer H Responsibilities The Purchaser’s responsibilities are: Prior to arrival of unit, install 5/8” exterior plywood flooring in the vehicle and cover it with artificial turf. In Dodge vans the fuel tanks are located directly against the floor. Caution must be used when drilling any holes through the floor.
  • Page 10 How the unit’s systems work. • How to troubleshoot the unit. • How to do basic repairs. • Safety precautions and their importance. • A thorough review of the unit warranty and warranty procedures. Page 1-6: General Information HydraMaster Corporation...

  • Page 11: Vehicle Preparation

    Boxxer H Vehicle Preparation When selecting a truck, remember the preferable vehicle for a Boxxer H O installation is a cargo van with a heavy-duty suspension package and a half ton capacity. A three quarter ton or larger capacity van, with a 2,400 pound payload capacity, is required. TRUCK PREPARATION The manufacturer recommends the installation of plywood flooring, covered with polypro- pylene-backed Astroturf (do not use rubber-backed), in the vehicle prior to installation of...
  • Page 12 (engine and component weight line up over drive shaft). Also, it is physically easier to load the unit into the rear door due to the height of the van bed. Figure 1-3 Recommended Placement Page 1-8: General Information HydraMaster Corporation...
  • Page 13 Boxxer H 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 follow- ing illustration for the correct installation. Figure 1-4 Installation Using Tie-down Cleats Ensure that the machine is well secured to the floor of the van with the hardware supplied.
  • Page 14 Transportation in a vehicle of any vented fuel container that presently holds or has ever held a flammable liquid is strictly forbidden by HydraMaster Cor- poration and by federal and state regulation. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 15: High Altitude Operation Preparation

    This will make the engine run ‘rich’, and, in turn will result in the loss of power, excessive heat in the exhaust, and carbon buildup in the exhaust system. The jet sizes vary per engine and elevation. Consult HydraMaster to obtain proper jet size. Page 1-11: General Information...

  • Page 16: Local Water Precautions

    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 equip- ment or installed later.

  • Page 17: Machine Specifications

    2" Reinforced, 1/2" Reinforced. Standard Equipment: Machine Power Console Full Instrumentation Vacuum Recovery Tank 100 ft, 2" Vacuum Hose 10 ft, 1-1/2" Wand Whip Line Battery Box Van Decal Package Van Installation Kit Operation Manual HydraMaster Jacket Page 2-1: Machine Specifications...

  • Page 18: Machine Layout

    Hour Meter - Displays total number of hours machine has been run during its lifetime. Exhaust Outlet - Engine and blower exhaust outlet. Lube Port - Allows blower to be lubricated. Vacuum Gauge - Displays engine temperature and vacuum. Page 2-2: Machine Specifications HydraMaster Corporation...

  • Page 19: Operating Instructions

    Boxxer H Operating Instructions Start Up 1. Perform daily and periodic maintenance as specified in this Owner’s Manual. The machine cannot be run in the “IDLE” position for water recovery. This will void the warranty. Note: Never run machine on any speed other than full throttle. Running at any other speed will void the warranty.

  • Page 20: 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 21 2. Maintenance, troubleshooting, and repair is much easier to accomplish on a clean, well maintained unit. Regular cleaning of the machine offers you an opportunity to visually inspect all facets of the machine and spot potential problems before they occur. Page 4-2: Machine Maintenance HydraMaster Corporation...
  • Page 22 Boxxer H The following maintenance is recommended by the manufacturer at the frequency indi- cated. AFTER EACH JOB • Check recovery tank, s/s filter and filter basket as required. DAILY • Wipe machine down thoroughly with a damp cloth. • Flush recovery tank out thoroughly.

  • Page 23: Maintenance Log

    BOXXER H O MAINTENANCE LOG DAILY SERVICE OIL RECOMMENDATIONS BLOWER 40 weight non-detergent ENGINE OIL - check MACHINE - general inspection ENGINE 30 weight motor oil VACUUM TANK FILTER BAG - clean NOTE: Overhead valve engines can use multi-viscosity oil, but will BLOWER INLET - spray with lubricant experience increased oil consumption WEEKLY SERVICE...

  • Page 24: Machine Assemblies And Parts List

    Boxxer H Machine Assemblies and Parts Lists Figure 5-1 Machine Assembly - Front View - Left Side D-6800 Rev - Page 5-1: Machine Assemblies and Parts List...
  • Page 25 Machine Assembly Parts List Item Part Number Description 610-001-036 Assembly, Frame - Boxxer H2O (Fig. 5-3 & 5-5) 610-050-033 Assembly, Machine Left Side Cover (Fig. 5-9) 610-050-033 Assembly, Machine Right Side Cover (Fig. 5-10) Page 5-2: Machine Assemblies and Parts List...
  • Page 26 Boxxer H Figure 5-3 Frame Assembly - Front View - Left Side D-6801 Rev - Page 5-3: Machine Assemblies and Parts List...
  • Page 27 Boxxer H Figure 5-4 Frame Assembly - Front View - Right Side D-6801 Rev - HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN Page 5-4: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 28 Item Part Number Description 000-055-186 Frame, Weldment - Boxxer H2O 610-003-036 Assembly, Engine - Boxxer H2O (Fig. 5-5) 610-002-036 Assembly, Blower - Boxxer H2O (Fig. 5-6) 610-020-036 Assembly, Dash Boxxer H2O (Fig. 5-7) 601-003-036 Assembly, Exhaust - Boxxer H2O (Fig. 5-8) 000-092-017 Mount, Rubber Isolator - Boxxer H2O 000-105-012 Plate, Machine Serial I.D.
  • Page 29 Boxxer H Figure 5-5 Engine Assembly D-6802 Rev - Page 5-6: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 30 Boxxer H Engine Assembly Parts List Item Part Number Description 000-047-026 Engine, Briggs & Stratton 27HP 000-047-026 Air Cleaner - Daihatsu Engine 000-092-011 Mount, Engine 27 B&S - Boxxer 427 000-057-050 Gasket, Thermostat Housing Daihatsu Engine 000-047-026 Thermostat, Stock B&S 27HP 000-047-026 Thermostat Housing, B&S 27 HP Stock 000-174-007 Washer, 1/2"...
  • Page 31 Boxxer H Figure 5-6 Blower Assembly D-6803 Rev - Page 5-8: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 32 000-001-115 Adapter, Blower Flange To 3" M Slip - Boxxer 427 000-174-019 Washer, 1/4" Lock 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 000-013-069 Box, Blower Collector - Weldment - Boxxer H2O 000-093-104 Silencer, Weldment - Boxxer H2O 000-052-106 Insert, 1/8" NPT x 5/32" Barb x 90°...
  • Page 33 Boxxer H Figure 5-7 Dash Assembly D-6804 Rev - Page 5-10: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 34 000-025-002 Cable, Choke (3 Foot) 000-025-020 Cable, Throttle Kohler 000-157-040 Switch, 20 AMP Rocker 000-074-017 Guage, 0-30" Hg Vac. 2 1/2" Hydramaster Face 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port 000-084-011 Light, Red Led Indicator Mini 000-174-001 Washer, #10 Flat 000-174-014 Washer, #10 Lock 000-143-134 Screw, #10-24UNC x 1.00"...
  • Page 35 Boxxer H Figure 5-8 Exhaust Assembly D-6805 Rev - Page 5-12: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 36 Boxxer H Exhaust Assembly Parts List Item Part Number Description 000-125-223 Tube, Lower Exhaust - Boxxer H2O 000-093-103 Muffler, Weldment - Boxxer H2O 000-015-931 Bracket, Exhaust Support - Boxxer H2O 000-001-098 Adapter, Exhaust Turndown - Weldment 000-068-398 Hose, 3" I.D. x 3 Ply Silicone - Bulk 000-068-398 Hose, 3"...
  • Page 37 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 000-094-034 Nut, #10-24UNC Nylock...
  • Page 38 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 000-094-034 Nut, #10-24UNC Nylock...
  • Page 39 Boxxer H Figure 5-11 Recovery Tank Assembly D-6806 Rev - HIDDEN 11 HIDDEN 18 HIDDEN Page 5-16: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 40 Boxxer H Recovery Tank Assembly Parts List Item Part Number Description 000-159-066 Recovery Tank - Weldment - Maxx 450D/470D Fig. 5-12 Assembly, Recovery Tank Cover - 100 Gallon 000-049-057 Filter Basket, Recovery Tank Fig. 5-13 Assembly, Vacuum Relief Valve 000-049-013 Filter, Blower Inlet 3" NPT 000-012-002 Block, 6 Post Terminal 000-079-091 Kit, Dura-Flow APO - Production (Fig.
  • Page 41 000-086-008 Latch, Bungie - Strike 000-094-063 Nut, #6-32UNC Nylock 000-094-009 Nut, 1/4"-20UNC Hex Nylock 000-052-222 Elbow, 2" Barb x 2" FPT 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 000-094-034 Nut, #10-24UNC Nylock Page 5-18: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 42 Boxxer H Figure 5-13 Vacuum Relief Valve Assembly C-4237 Rev B USE BLUE LOCKTITE #242 Exhaust Assembly 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 000-105-067 Plate, Vacuum Relief Valve Mounting 000-155-026 Spring, Vacuum Relief 000-143-198 Screw, 3/8"-16UNC x 4"...
  • Page 43 Boxxer H Figure 5-14 Dura-Flow APO Assembly D-5654 Rev C Page 5-20: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 44 Boxxer H Dura-Flow APO 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 45 Boxxer H (To be Added) Page 5-22: Machine Assemblies and Parts List HydraMaster Corporation...
  • Page 46 Boxxer H (To be Added) Page 5-23: Machine Assemblies and Parts List...

  • Page 47: Vacuum System

    Boxxer H Vacuum System The vacuum pump in this machine is commonly referred to as a ‘positive displacement lobe’ type blower. The performance and life of this unit is greatly dependent on the care and proper maintenance it receives. Because of the close tolerances between the lobes and housing of the vacuum blower, solid objects entering the inlet will damage the internal lobes, gears, bearings or drive system.
  • Page 48 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 49: Vacuum System Troubleshooting

    Boxxer H 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 ob- struction. 1.2. Excessive length of hoses connected to machine. Make sure machine is rated for the conditions under which it is being operated.

  • Page 50: Miscellaneous Troubleshooting

    1.2. Condensation. This will be more pronounced in cool weather and humid climates. Observe how long this condition persists after starting machine. If it is only until the machine warms up, it is normal. Page 6-4: Vacuum System HydraMaster Corporation...

  • Page 51: Electrical System

    Boxxer H Electrical System The 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 pos- sible. The entire electrical system operates on 12 volts DC which is provided by a battery. Bat- tery levels are sustained by a 16 amp alternator inside the engine.
  • Page 52 Boxxer H Figure 7-1 Wiring Schematic D-6838 Rev - Page 7-3: Electrical System HydraMaster Corporation...
  • Page 53 Boxxer H Figure 7-2 Wiring Diagram D-6837 Rev - Page 7-4: Electrical System HydraMaster Corporation...

  • Page 54: Electrical Troubleshooting

    Boxxer H 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.

  • Page 55: Engine Troubleshooting

    Boxxer H Engine Troubleshooting 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. Repair if necessary. WARNING: Do not attempt to jump-start this machine from a running vehicle.
  • Page 56 3000 RPM while it is under a vacuum load of between 10"hg and 14"hg. Too high or too low will cause severe damage to machine components. Page 8-2: Engine Troubleshooting HydraMaster Corporation 04/20/04...
  • Page 57 Boxxer H 4.2. There is excessive load on the engine due to the blower-to-recovery tank hose becoming delaminated. Remove and inspect the inside of the hose. Replace as necessary. 4.3. There is excessive back-pressure on the engine or blower exhaust. Check for clogged blower heat exchanger.
  • Page 58 8.2. Low engine oil level. Check oil level and replenish as necessary. 8.3. Engine RPM too high. Check RPM with an accurate tachometer. Adjust as necessary to 3000 RPM. 8.4. Restricted engine or blower exhaust. Disassemble exhaust components to locate restriction. Repair as necessary. Page 8-4: Engine Troubleshooting HydraMaster Corporation 04/20/04...

  • Page 59: How To Order Parts

    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. Page 9-1: How to Order Parts...
  • Page 60 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 peri- ods listed. Labor and/or diagnostic reimbursement is specifically excluded.

  • Page 61: Blower Manual

    Boxxer H Warranty Information To 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. BLOWER: • Failure to lubricate impellers daily with an oil based lubricant. •...
  • Page 62 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 informa- tion regarding your local distributor, call HydraMaster at (425) 775-7272 or email us at custsvc@hydramaster.com.

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