HYDRAMASTER Corporation 11015 47th Avenue W, Mukilteo, WA 98275 Machine Serial Number________________________ Copyright© 2012 HYDRAMASTER© Corporation Mukilteo, Washington MAN-45068 Rev. 0 (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.
Boxxer 427 HydraMaster Corporation
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 ........................................................
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 .........................................................
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 .................
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 ...............................
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. 1-28 Electrical Control Panel Assembly .............................. 1-60 Fig.
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. 6-1 Servicing the Valves .................................................. 6-3 Fig.
Boxxer 427 Quick Reference HydraMaster Corporation
Boxxer 427 Fuel Pump Assembly B4627 Rev— HydraMaster Corporation
General Information Section 1-1 T his 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.
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.
Boxxer 427 Page 1-3 Precautions A 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. ! CAUTION THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor.
Page 1-4 Boxxer 427 ! CAUTION 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 equipment. 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 components.
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). 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. ! WARNING NO SMOKING: It is unsafe to smoke in or around the vehicle.
Page 1-6 Boxxer 427 ! 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 regulation. ! CAUTION The use of some chemicals through your mobile carpet cleaning plant can seriously damage the internal plumbing, high-pressure pump, chemical pump and heat exchangers.
Boxxer 427 Page 1-7 System Operation T he Boxxer heat exchanger system is a highly engineered cleaning plant designed by HydraMaster Corporation. The system utilizes a dynamic heating system comprised 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.
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.
Boxxer 427 Recovery Tank: Cleaning Wand: High Pressure Hose: Vacuum Hose: Standard Equipment: HydraMaster Corporation Page 1-9 70 Gallon Aluminum, Epoxy Finish Stainless Steel Replaceable Grip Rebuildable Solution Valve 4" High Temperature Lined/Vinyl Covered Hose Rated to 2250 PSI 2" Reinforced, 12" Reinforced.
Page 1-10 Boxxer 427 Spare Parts Recommendation D owntime 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 instances, he either stocks or has access to parts through a regional service center.
Boxxer 427 Page 1-11 Spare Parts List (078-340) PART NO DESCRIPTION 056-001 Fuse, 10 amp 2 056-008 056-010 074-007 074-032 TBD TBD 106-016 106-045 157-080 157-040 157-022 169-017 169-022 169-155 169-160 180-004 Fuse, 15 amp Fuse, 25 amp Gauge, Hi PSI (0-1500) Meter, Chemical Flow Kit, Seal & Spring Hi PSI Kit, Comet Seal Plug, Vanguard Spark 50 Series Element Switch, s/s Float Rocker Switch, Relay Valve, 3-way Chemical Valve, 1½” Full Port Check Valve, Last-Step Chemical Valve, 2-way Chemical Meteri
Page 1-12 Boxxer 427 Responsibilities T 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-liningTM to the van floor. ! CAUTION In Dodge vans the fuel tanks are located directly against the floor.Caution must be used when drilling any holes through the floor. (See Product Support Bulletin 94062 at the end of this manual.
Boxxer 427 Page 1-13 CORRECT INSTALLATION INCLUDES: • Vehicle of proper load carrying capacity (recommendation: 3/4 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. • Connecting gasoline lines. • Connecting the battery. • Checking the pump, vacuum blower and engine oil levels prior to staring the unit.
Page 1-14 Boxxer 427 Vehicle Preparation W 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. TRUCK PREPARATION The manufacturer recommends the installation of a spray-on bed liner in the vehicle prior to installation of machine.
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. REAR DOOR: Although this location partly limits working access, it does direct the noise away from the cleaning site.
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. 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. A sudden or crash stop will cause the machine to rocket forward. Protect yourself and the machine.
Boxxer 427 Page 1-17 ! WARNING Do not use a portable propane tank inside of the truck or van. It is dangerous and illegal in most states. ! 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 Corporation 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 1-18 Boxxer 427 High Altitude Operation Preparation T o have your machine run at it’s peak performance; you may have to make adjust ments depending on the elevation. Elevation plays a key role in how the machine will operate. The factory setting of the machine is set for elevations from 0—3,000 feet. Any time the machine is operated above 3,000 feet there are two areas on the machine the may need adjustment. The first area is the carburetor jet.
Boxxer 427 Page 1-19 Local Water Precautions T he quality of water varies greatly. Many areas have an excess of minerals in the water which results in what is commonly called “hard water.” These minerals tend to adhere to the insides of heater coils and other parts of the machines causing damage and a loss of cleaning effectiveness. This influences the reliability and efficiency of equipment in direct proportion to the level of hardness.
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 engines. For other countries, hard water area maps can be obtained from geological societies. WATER SOFTENER Cleaning efficiency and equipment life is increased, chemical use decreased, and the appearance of cleaned carpets enhanced when water softeners are incorporated in hard water areas.
Boxxer 427 Page 1-21 This cleaning rinse water, recovered into your unit’s vacuum tank, contains materials such as detergents. These must be processed before being safe for streams, rivers and reservoirs. IN ACCORDANCE WITH THE EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.
Page 1-22 Boxxer 427 This page intentionally left blank HydraMaster Corporation
Boxxer 427 Figure 1-5 Hard Water Map HydraMaster Corporation Page 1-23
Boxxer 427 Page 1-25 Machine Assemblies and Parts Lists Figure 1-6 Machine Assembly - Front View - Left Side D-5570 Rev B 2 5 3 8 7 8 HydraMaster Corporation 7 4 1
Page 1-26 Boxxer 427 Figure 1-7 Machine Assembly - Front View - Right Side D-5570 Rev B 6 HydraMaster Corporation
Boxxer 427 Figure 1-8 Machine Assembly - Rear View - Right Side D-5570 Rev B HydraMaster Corporation Page 1-27
Page 1-28 Boxxer 427 Machine Assembly Parts List Item Part Number Description Qty 1 610-001-033 Assembly, Frame - Boxxer 427 (Fig. 1-9 - 1-11) 1 2 610-050-033 Assembly, Top Cover - Boxxer 427 (Fig. 1-31) 1 3 000-041-424 Cover, Lower Left Side - Rear - Boxxer 427 1 4 000-041-426 Cover, Lower Left Side - Front - Boxxer 427 1 5 610-050-033 Assembly, Machine Left Side Cover (Fig. 1-33) 1 6 610-050-033 Assembly, Machine Right Side Cover (Fig.
Boxxer 427 Figure 1-9 Frame Assembly - Front View - Left Side D-5571 Rev D HydraMaster Corporation Page 1-29
Page 1-30 Boxxer 427 Figure 1-10 Frame Assembly - Front View - Right Side D-5571 Rev D 2 16 8 15 HIDDEN 22 6 12 10 11 9 19 10 11 ITEM 3 SUPRESSED IN THIS VIEW HydraMaster Corporation
Boxxer 427 Page 1-31 Figure 1-11 Frame Assembly - Rear View - Left Side D-5571 Rev D 15 16 17 18 19 15 2 3 16 17 18 19 16 13 4 5 14 12 13 14 HydraMaster Corporation 12 21 20 1
Page 1-32 Boxxer 427 Frame Assembly Parts List Item Part Number Description Qty 1 000-055-168 Frame, Steel - Welded - Boxxer 427 1 2 610-003-033 Assembly, Engine - Boxxer 427 (Fig. 1-12 - 1-13) 1 3 610-002-033 Assembly, Blower - Boxxer 427 (Fig. 1-16) 1 4 610-020-033 Assembly, Dash Upper - Boxxer 427 (Fig. 1-21 - 1-22) 1 5 610-019-033 Assembly, Dash Lower - Boxxer 427 (Fig. 1-24 - 1-25) 1 6 610-006-033 Assembly, Coolant Heat Exchanger (Fig.
Boxxer 427 Page 1-33 Figure 1-12 Engine Assembly - Rear View D-5572 Rev G 29 2 22 19 18 7 21 28 5 6 4 23 5 34 21 20 21 33 32 31 25 24 26 27 14 13 11 9 8 9 13 10 HydraMaster Corporation 3 9 10 13 12
Page 1-34 Boxxer 427 Figure 1-13 Engine Assembly - Front View D-5572 Rev G 1 31 16 17 15 36 35 Engine Assembly Parts List Item Part Number Description Qty 1 000-047-026 Engine, Briggs & Stratton 27HP 1 2 000-042-011 Housing, Air Cleaner - Daihatsu Engine 1 3 000-092-011 Mount, Engine 27 B&S - Boxxer 427 1 4 000-001-033 Adapter, Thermostat Housing 1 5 000-057-050 Gasket, Thermostat Housing Daihatsu Engine 2 HydraMaster Corporation
Boxxer 427 Page 1-35 Engine Assembly Parts List Item Part Number Description Qty 6 000-047-026 Thermostat, Stock B&S 27HP 1 7 000-047-026 Thermostat Housing, B&S 27 HP Stock 1 8 000-174-105 Washer, 1-1/16" I.D. Self Aligning Spherical 2 Pc Set 2 9 000-174-007 Washer, 1/2" Flat 4 10 000-143-567 Screw, 1/2"-13UNC x 2.0" Lg. Hex Head Grd. 8 2 11 000-094-037 Nut, 1/2"-13UNC Hex 2-Way Locking - Z/P 2 12 000-143-568 Screw, 5/16"-18UNC x 2.50" Lg.
Page 1-36 Boxxer 427 Figure 1-14 Exhaust Assembly D-5580 Rev C 26 25 18 15 28 20 30 28 29 26 18 25 22 21 19 12 27 13 11 11 23 14 13 10 12 21 19 1 9 8 7 6 5 4 12 13 11 24 21 19 20 3 17 16 31 2 20 17 16 31 HydraMaster Corporation
Boxxer 427 Page 1-37 Exhaust Assembly Parts List Item Part Number 1 Fig. 1-15 Description Assembly, Diverter Valve Actuator - Boxxer 427 Qty 1 2 000-125-214 Tube, Diverter To Outlet Plenum - Boxxer 427 1 3 000-001-116 Adapter, 1.50" F Slip To Flare - Boxxer 427 1 4 000-094-027 Nut, #10-24UNC Hex 2 5 000-155-030 Spring, Leaf 1 6 000-138-010 Retainer, Leaf Spring 1 7 000-174-001 Washer, #10 Flat 2 8 000-143-132 Screw, #10-24UNC x 0.75" Lg.
Page 1-38 Boxxer 427 Figure 1-15 Diverter Valve Actuator Assembly C-5584 Rev B 6 5 4 9 8 10 1 3 2 7 Diverter Valve Actuator Assembly Parts List Item Part Number Description Qty 1 000-169-169 Valve, Air Cylinder 1 2 000-015-926 Bracket, Air Cylinder Extension - Welded - Boxxer 427 1 3 000-094-092 Nut, 7/16"-20UNF Hex Jam 1 4 000-052-550 Elbow, 1/8" NPT x 3/16" Barb 2 5 000-015-750 Bracket, Air Cylinder Mount - Inner 1 6 000-015-748 Bracket, Air Cylinder Mount - Outer 1 7 000-1
Boxxer 427 Page 1-39 Figure 1-16 Blower Assembly D-5573 Rev H 2 4 3 1 27 9 10 15 16 14 22 9 10 10 29 30 5 12 14 13 28 8 21 18 17 19 21 20 28 11 7 24 10 26 22 23 31 25 22 6 Blower Assembly Parts List Item Part Number 1 2 Description 000-111-167 Blower, MD 4007 C-Face Dual Shaft - Boxxer 427 Fig.
Page 1-40 Boxxer 427 Blower Assembly Parts List Item Part Number Description Qty 3 Fig. 1-20 Assembly, Water Box - Boxxer 427 1 4 Fig. 1-19 Assembly, Pump Mounting Bracket - Boxxer 427 1 5 000-015-814 Bracket, Dominator Mounting - Boxxer 421 1 6 000-042-061 Housing, Bell - Boxxer 427 1 7 000-109-112 Pulley, 3.50" Pump Drive 1 8 000-001-115 Adapter, Blower Flange To 3" M Slip - Boxxer 427 1 9 000-174-057 Washer, 3/8" Lock 5 10 000-143-018 Screw, 3/8"-16UNC x 1.00" Lg.
Boxxer 427 Page 1-41 Figure 1-17 Pump Assembly D-5574 Rev D 1 27 21 17 11 9 18 16 15 13 22 28 10 7 24 23 29 8 24 6 23 5 3 19 2 4 12 20 HydraMaster Corporation 25 26 14 23 24
Page 1-42 Boxxer 427 Pump Assembly Parts List Item Part Number Description Qty 1 000-111-041 Pump, Hydra Pump V - Boxxer 427 1 2 000-052-084 Elbow, 1/8" NPT Street 1 3 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 1 4 Fig.
Boxxer 427 Page 1-43 Figure 1-18 Chemical Pump Assembly C-6555 Rev A 2 9 7 1 8 10 5 6 OUTLET 11 3 4 9 INLET 1 7 10 8 Chemical Pump Assembly Parts List Item Part Number Description Qty 1 000-106-110 Plug, Check Valve - Chemical Pump 2 2 000-064-015 Cover, Chemical Pump 1 3 000-111-030 Body, Chemical Pump 1 4 000-105-071 Mid Plate, Chemical Pump 1 5 000-046-010 Diaphragm, Chemical Pump 1 6 000-097-055 O-Ring, Chemical Pump Midplate An Size -227 Viton 1 7 000-097-056 O
Page 1-44 Boxxer 427 Figure 1-19 Pump Mounting Bracket Assembly D-5766 Rev F 6 3 23 22 5 4 9 11 8 10 7 9 11 10 8 9 11 7 12 13 9 21 20 2 15 1 2 14 17 19 18 17 16 HydraMaster Corporation
Boxxer 427 Page 1-45 Pump Mounting Bracket Assembly Parts List Item Part Number Description Qty 1 000-174-032 Washer, 3/8" Flat 2 2 000-094-014 Nut, 3/8"-16UNC Hex Zinc Plated 2 3 000-174-021 Washer, 3/8" Lock 4 4 000-015-893 Bracket, Pump Mounting - Welded 1 5 000-174-005 Washer, 3/8" Flat 4 6 000-143-139 Screw, 3/8"-16UNC x 4.00 Lg. Grd 8 4 7 000-169-070 Valve, Primary Vac.
Page 1-46 Boxxer 427 Figure 1-20 Water Box Assembly D-5575 Rev H 3 2 7 10 8 12 13 14 27 16 15 24 4 19 21 16 22 26 23 19 21 10 22 5 23 9 11 20 1 5 6 9 10 17 25 10 17 5 18 HydraMaster Corporation
Boxxer 427 Page 1-47 Water Box Assembly Parts List Item Part Number Description Qty 1 000-159-107 Tank, Poly Water Box - Modified 1 2 000-041-005 Cover, 6" 1 3 000-143-314 Screw, #8 x 1/2" Lg.
Page 1-48 Boxxer 427 Figure 1-21 Dash Upper Assembly - Front View D-5576 Rev A 14 10 9 1 12 2 13 6 10 9 5 3 4 7 8 HydraMaster Corporation
Boxxer 427 Page 1-49 Figure 1-22 Dash Upper Assembly - Rear View D-5576 Rev A 15 8 HydraMaster Corporation 5 16 9 11
Page 1-50 Boxxer 427 Dash Upper Assembly Parts List Item Part Number Description Qty 1 000-100-141 Panel, Upper Dash - Boxxer 427 1 2 000-100-145 Panel, Grill - Boxxer 427 1 3 000-157-008 Switch, Ignition 1 4 000-074-018 Meter, Rectangular w/o Bezel 1 5 000-025-002 Cable, Choke (3 Foot) 1 6 000-025-020 Cable, Throttle Kohler 1 7 000-084-011 Light, Red Led Indicator Mini 4 8 610-020-033 Assembly, Dash Guage Panel - Boxxer 427 (Fig.
Boxxer 427 Page 1-51 Figure 1-23 Dash Guage Panel Assembly D-5585 Rev C 16 13 1 17 8 7 19 18 3 23 1 7 3 11 12 21 8 20 2 10 10 2 2 11 12 21 HydraMaster Corporation 6 5 4 20 9 22 13 10 14 15
Page 1-52 Boxxer 427 Dash Guage Panel Assembly Parts List Item Part Number Description Qty 1 000-100-150 Panel, Dash Gauge - Boxxer 427 1 2 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 3 3 000-169-160 Valve, Chemical Metering 1 4 000-052-069 Nipple, 1/8" NPT Hex 1 5 000-169-0171 Valve, 3-Way Ball O-Ring Style 1 6 000-052-084 Elbow, 1/8" NPT Street 1 7 000-074-017 Guage, 0-30" Hg Vac.
Boxxer 427 Page 1-53 Figure 1-24 Dash Lower Assembly - Front View D-5577 Rev E 16 1 5 4 15 13 21 22 24 9 HydraMaster Corporation 11 9 2 17 18
Page 1-54 Boxxer 427 Figure 1-25 Dash Lower Assembly - Rear View D-5577 Rev E 16 12 19 10 8 6 26 8 6 27 7 29 14 18 30 20 31 32 3 30 15 28 22 23 21 25 Dash Lower Assembly Parts List Item Part Number Description Qty 1 000-100-143 Panel, Lower Dash - Boxxer 427 1 2 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port 1 HydraMaster Corporation
Boxxer 427 Page 1-55 Dash Lower Assembly Parts List Item Part Number Description Qty 3 000-052-096 Insert, #F23 (1/8" FPT x 3/16" Barb) 1 4 000-052-052 Quick Connect, 660 Male w/ Viton Standard 1 5 000-052-051 Quick Connect, 440 Female w/ Epdm O-Ring 2 6 000-052-071 Nipple, 1/4" NPT Hex 2 7 000-174-008 Washer, 5/8" Flat 4 8 000-174-007 Washer, 1/2" Flat 4 9 000-143-126 Screw, #10-24UNC x 0.50" Lg.
Page 1-56 Boxxer 427 Figure 1-26 By-Pass Valve Assembly C-5581 Rev C 12 11 9 10 13 5 3 5 13 4 1 6 14 9 2 7 8 HydraMaster Corporation
Boxxer 427 Page 1-57 By-Pass Valve Assembly Parts List Item Part Number Description Qty 1 000-052-128 Nipple, 3/8" NPT x 3/8" Male Propane 1 2 000-015-515 Bracket, By-Pass Valve Mounting 1 3 000-169-188 Valve, PSI Regulator 0-1500 PSI - Modified 1 4 000-106-008 Plug, 3/8" NPT Allen Head 1 5 000-052-023 Tee, 3/8" NPT Male Street 2 6 000-052-083 Elbow, 3/8" NPT Street x 45° 1 7 000-052-142 Elbow, 3/8" FPT x FPT 1 8 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) 1 9 000-052-086 El
Page 1-58 Boxxer 427 Figure 1-27 Hi-PSI Manifold Assembly C-5582 Rev A 14 10 11 3 12 13 9 5 2 6 8 6 4 7 1 HydraMaster Corporation
Boxxer 427 Page 1-59 Hi-PSI Valve Assembly Parts List Item Part Number Description Qty 1 000-090-057 Manifold, Hi-PSI - Boxxer 427 1 2 000-180-004 Orifice, Set Screw 0.033" 1 3 000-052-423 Bushing, Modified Set Screw Orifice 1 4 000-049-016 Filter, 1/4" NPT Replacement “Y” 1 5 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 1 6 000-106-111 Plug, 1/2" NPT Allen 2 7 000-155-020 Spring, 0.540 O.D. x 0.041 Wire x 1.00 Lg.
Page 1-60 Boxxer 427 Figure 1-28 Electrical Control Panel Assembly C-5583 Rev D 15 16 12 19 3 17 4 16 12 25 12 11 2 25 27 4 12 28 6 7 5 11 27 21 13 22 21 18 20 21 8 21 1 10 26 14 20 23 24 9 HydraMaster Corporation
Boxxer 427 Page 1-61 Electrical Control Panel Assembly Parts List Item Part Number Description Qty 1 000-100-137 Panel, Electrical Control - Boxxer 427 1 2 000-041-418 Cover, Electrical Control Panel - Boxxer 427 1 3 000-012-010 Block, Terminal 10 Post 1 4 000-157-022 Switch, Relay 2 5 000-084-010 Light, Green LED Indicator Mini 1 6 000-084-011 Light, Red LED Indicator Mini 1 7 000-084-012 Light, Yellow LED Indicator Mini 1 8 000-156-030 Stud, #10-32UNF x 2" Lg. Boxxer Elec.
Page 1-62 Boxxer 427 Figure 1-29 Coolant Heat Exchanger Assembly D-5578 Rev A 13 10 13 12 13 11 13 7 2 3 14 8 1 13 9 13 5 6 7 3 4 6 5 HydraMaster Corporation
Boxxer 427 Page 1-63 Coolant Heat Exchanger Assembly Parts List Item Part Number Description Qty 1 000-038-043 Heat Exchanger, Water To Water 1 2 000-052-086 Elbow, 3/8" NPT Street 1 3 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 2 4 000-052-083 Elbow, 3/8" NPT Street x 45° 1 5 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg.
Page 1-64 Boxxer 427 Figure 1-30 Blower Heat Exchanger Assembly D-5579 Rev B 5 11 12 3 1 11 6 10 9 3 8 11 8 9 13 11 7 10 2 4 2 4 4 HydraMaster Corporation
Boxxer 427 Page 1-65 Blower Heat Exchanger Assembly Parts List Item Part Number Description Qty 1 000-038-055 Core, Blower Heat Exchanger - Boxxer 427 1 2 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 2 3 000-140-021 Rivet, 1/4" Blind x 0.50" Lg. 4 000-052-086 Elbow, 3/8" NPT Street 3 5 000-013-059 Box, Inlet Plenum - Welded - Boxxer 427 1 6 000-013-060 Box, Outlet Plenum - Weldment - Boxxer 427 1 7 000-001-097 Adpater, Exhaust Turndown - Raw 1 8 000-143-002 Screw, 1/4"-20UNC x 1.
Page 1-66 Boxxer 427 Figure 1-31 Top Cover Assembly D-5586 Rev A 4 5 8 2 7 8 8 5 6 5 8 3 4 5 1 Top Cover Assembly Parts List Item Part Number Description Qty 1 000-041-416 Cover, Top Machine - Boxxer 427 1 2 000-041-422 Cover, Brow - Boxxer 427 1 3 000-100-153 Panel, Brow End - Weldment - Boxxer 427 1 4 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 8 5 000-174-001 Washer, #10 Flat 6 000-094-034 Nut, #10-24UNC Nylock 4 7 000-143-126 Screw, #10-24UNC x 0.50" Lg.
Boxxer 427 Page 1-67 Figure 1-32 Machine Right Side Cover Assembly D-5762 Rev 5 6 1 6 5 4 3 2 4 3 Machine Right Side Cover Assembly Parts List Item Part Number Description Qty 1 000-041-419 Cover, Right Side Machine - Boxxer 427 1 2 000-105-313 Plate, Hydramaster Name- Roto Tank 1 3 000-174-001 Washer, #10 Flat 2 4 000-143-166 Screw, #10-24UNC x 0.38" Lg.
Page 1-68 Boxxer 427 Figure 1-33 Machine Left Side Cover Assembly D-5587 Rev 5 6 1 6 5 4 3 2 4 3 Machine Left Side Cover Assembly Parts List Item Part Number Description Qty 1 000-041-417 Cover, Left Side Machine - Boxxer 427 1 2 000-105-313 Plate, Hydramaster Name- Roto Tank 1 3 000-174-001 Washer, #10 Flat 2 4 000-143-166 Screw, #10-24UNC x 0.38" Lg.
Boxxer 427 Page 1-69 Figure 1-34 70 Gallon Universal Recovery Tank Assembly D-6860 Rev B 43 42 40 8 6 2 9 5 29 HIDDEN 41 11 21 HIDDEN 40 22 10 29 39 14 16 13 HIDDEN 15 24 30 7 37 23 31 27 38 12 32 22 28 25 40 35 26 36 3 34 1 35 4 3 17 2 HydraMaster Corporation 33 18 19 20
Page 1-70 Boxxer 427 70 Gallon Univesal Recovery Tank Assembly Parts List Item Part Number Description Qty 1 000-159-128 Tank, 70 Gallon Universal Recovery - Weldment 1 2 610-003-015 Assembly, Cover - Dual Vac. (Fig. 1-35) 1 3 000-157-090 Float, Lever Switch 2 4 000-079-091 Kit, Dura-Flow APO - Production (Firg.
Boxxer 427 Page 1-71 70 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description Qty 32 000-143-132 Screw, #10-24UNC x 0.75" Lg. Hex Head 2 33 000-106-049 Plug, 1" NPT Allen Head 1 34 000-174-060 Washer, 1/4" Flat Rubber Backed 4 35 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 8 36 000-094-113 Nut, 1/4"-20UNC Neoprene Wellnut 4 37 000-174-036 Washer, #10 Flat Rubber Backed 2 38 000-174-001 Washer, #10 Flat 2 39 000-001-135 Adapter, Tank To Ø3.
Page 1-72 Boxxer 427 Figure 1-35 70 Gallon Universal Recovery Tank Cover Assembly D-6890 Rev 1 11 2 3 5 4 8 9 10 6 7 3 70 Gallon Universal Recovery Tank Cover Assembly Parts List Item Part Number Description Qty 1 000-041-444 Cover, Dual Vac.
Boxxer 427 Page 1-73 Figure 1-36 100 Gallon Universal Recovery Tank w/ APO Assembly D-6983 Rev A 12 11 2 6 28 29 19 25 20 26 9 15 HIDDEN 7 18 HIDDEN 29 30 13 HIDDEN 20 16 17 HIDDEN 32 8 14 37 HIDDEN 20 27 36 10 31 34 HIDDEN 30 HIDDEN 40 13 26 38 39 43 42 3 31 5 33 35 44 4 20 34 HIDDEN 31 30 HIDDEN 21 24 23 22 41 13 10 HydraMaster Corporation 3 1
Page 1-74 Boxxer 427 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number 1 2 Description Qty 000-159-129 Tank, 100 Gallon Universal Recovery - Weldment Fig -1-37 Assembly, Recovery Tank Cover - 100 Gallon 1 1 3 000-157-090 Float, Lever Switch 2 4 000-079-091 Kit, Dura-Flow APO - Production (Fig 1-39) 1 5 000-105-336 Plate, Vacuum Port Cover - 100 Gallon Universal Recov 1 6 000-049-152 Filter, Recovery Tank Basket 1 7 000-049-153 Filter, Flat - Recovery Tank 1 8 00
Boxxer 427 Page 1-75 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description Qty 31 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg.
Page 1-76 Boxxer 427 Figure 1-37 100 Gallon Universal Recovery Tank Cover Assembly D-6919 Rev - 8 2 1 5 6 7 9 3 4 10 11 9 100 Gallon Universal Recovery Tank Cover Assembly Parts List Item Part Number Description Qty 1 000-041-447 Cover, 100 Gallon Universal Recovery Tank - Weldment 1 2 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 1 3 000-057-015 Gasket, 1-1/2" Bulkhead Fitting 2 4 000-052-219 Adapter, 2" NPT x 2" F Slip 2 5 000-143-539 Screw, #6-32UNC x 0.50" Lg.
Boxxer 427 Page 1-77 Figure 1-38 Vacuum Relief Valve Assembly (Collector Box) C-7156 Rev - 7 5 HydraMaster Corporation 3 9 1 11 10 4 8 2 6
Page 1-78 Boxxer 427 Vacuum Relief Valve Assembly (Collector Box) Parts List Item Part Number Description Qty 1 000-015-182 Bracket, Vacuum Relief Valve 1 2 000-027-032 Cap, Vacuum Releif Valve 1 3 000-125-111 Pipe, Vacuum Relief Spring Guide 1 4 000-105-337 Plate, Vacuum Relief Valve Mounting 1 5 000-155-026 Spring, Vacuum Relief 1 6 000-143-198 Screw, 3/8"-16UNC x 4" Lg. Hex Head Full Thread 1 7 000-094-077 Nut, 3/8"-16UNC x 1.00" O.D.
Boxxer 427 Page 1-79 Figure 1-39 Dura-Flow APO Pump Assembly D-5654 Rev E 2 8 3 5 17 16 22 15 HydraMaster Corporation 1 5 16 9 17 6 7 7 6 18 10 13 6 19 8 20 4 14 21 12 4
Page 1-80 Boxxer 427 Dura-Flow APO Pump Assembly Parts List Item Part Number Description Qty 1 000-111-169 Assembly, APO Pump - Jabsco 1 2 000-091-042 Motor, Bison 438 Series 1 3 000-015-891 Bracket, APO Clamp 1 4 000-015-890 Bracket, Tank Mounted APO Support 1 5 000-143-566 Screw, 1/4-28UNF x 0.75" Lg. Socket Head 4 6 000-143-074 Screw, 1/4"-20UNC x 0.50" Lg.
Boxxer 427 Page 1-81 Figure 1-40 Chemical Jug Tray Assembly C-4945 Rev C 9 2 7 1 5 4 10 13 4 11 18 7 6 HydraMaster Corporation 8 3 19 10 12 14 17 10 16 5 15
Page 1-82 Boxxer 427 Chemical Jug Tray Assembly Parts List Item Part Number Description Qty 1 000-166-021 Tray, Chemical Jug - Outer - Weldment 1 2 000-166-025 Tray, Chemical Jug - Inner 1 3 000-078-039 Vacuum Inlet Stopper 1 4 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg.
Boxxer 427 Page 1-83 Figure 1-41 Diffueser Filter Assembly C-6554 Rev - 3 4 5 2 4 1 Diffuser Filter Assembly Parts List Item Part Number Description Qty 1 000-052-074 Nipple, 3/8" NPT Hex 1 2 000-033-131 Clamp, Diffuser - Boxxer 427 1 3 000-125-222 Tube, Diffuser - Boxxer 427 1 4 000-027-115 Cap, 2" PVC Modified For Diffuser - Boxxer 427 2 5 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) 1 HydraMaster Corporation
Page 1-84 Boxxer 427 Figure 1-42 Float Switch w/ Polypropylene Barrel Assembly C-6549 Rev 4 3 2 4 1 Float Switch w/ Polypropylene Barrel Assembly Parts List Item Part Number 1 --- Description Qty Stem, Float Switch 1 2 000-005-011 Float, Polypropylene Replacement- Boxxer 427 1 3 000-108-110 Shield, Poly Float Splash 1 4 000-139-010 Ring, Snap Ring (E-Clip) x 5/16" 2 HydraMaster Corporation
Boxxer 427 (To be Added) HydraMaster Corporation Page 1-85
Page 1-86 Boxxer 427 (To be Added) HydraMaster Corporation
Boxxer 427 Page 2-1 Cleaning and Chemicals Boxxer 427 Section 2-1 Y our mobile carpet cleaning plant has been engineered using the latest and most sophisticated technology available to produce the finest carpet cleaning results possible. Despite this, however, it remains only a tool of the carpet cleaning trade, and it can produce only as good a job as the person operating it. PRECAUTIONS There are no short cuts to good carpet cleaning.
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.
Boxxer 427 HydraMaster Corporation Page 2-3
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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. ! CAUTION Water box must be full prior to ignition. ! WARNING The machine cannot be run in the “IDLE” position for cleaning upholstery, carpet or floor extraction. This will void the warranty.
Page 3-2 10. 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. 11. Turn the chemical selector valve to the “PRIME” position to purge any air from the system. a. With the machine running at operating speed, block off the vacuum intake to the recovery tank. The vacuum gauge should read between 12"hg and 14"hg. This will assist in priming the chemical system. b.
Boxxer 427 Page 3-3 8. Set the temperature to desired level. 9. If used, turn PUMP OUT switch to “ON” (switch light will be illuminated). 10. Set cleaning pressure at desired level (300 –400 psi). 11. Turn the chemical selector valve to the “PRIME” position to purge any air from the system. a. With the machine running at operating speed, block off the vacuum intake to the recovery tank. The vacuum gauge should read between 12"hg and 14"hg. This will assist in priming the chemical system. b.
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. The chemical will be flushed from the unit, hoses and cleaning tool. NOTE: If the machine is not properly cooled, the water box can overflow. 3.
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. This will enable the machine to be used for flood extraction without the need for an inlet garden hose connected to the machine.
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. 2. The actuator shaft is connected to the diverter valve arm.
Freeze Guard Boxxer 427 Section 4-1 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. When using the recirculation kit (part no. 078058), fill a third of the mix tank with a 50/50 antifreeze mix. Verify that the upper float is not lying horizontal,but floats below.
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. NOTE: To freeze guard hoses and wand, perform the above step with all the hoses and wand attached. The machine is now freeze guarded. Remember to flush antifreeze from the system prior to carpet cleaning.
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. NOTE: The next time the unit is used it may take a few minutes before the mix tank begins to fill.
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Water and Chemical System Boxxer 427 Section 5-1 T 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. It flows through the flow meter indicating the GPH’s of chemical being used. The chemical then flows through the chemical pump to the chemical selector valve.
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. ! CAUTION Do not leave in the “PRIME” position forextended periods of time. Excessive chemicals will be used if it is not switched back ot “ON”or “OFF” c.
Boxxer 427 Page 5-3 Figure 5-1 Chemical Pump Assembly C-6555 Rev 3 5 4 6 2 9 1 7 10 8 OUTLET INLET 10 8 1 7 11 Chemical Pump Assembly Parts List Item Part Number Description Qty 1 000-106-110 Plug, Check Valve - Chemical Pump 2 2 000-064-015 Cover, Chemical Pump 1 3 000-111-030 Body, Chemical Pump 1 4 000-105-071 Mid Plate, Chemical Pump 1 5 000-046-010 Diaphragm, Chemical Pump 1 6 000-097-055 O-Ring, Chemical Pump Midplate AN Size -227 Viton 1 7 000-097-056 O-Ring, Check
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Boxxer 427 Figure 5.
Boxxer 427 Figure 5.
Boxxer 427 Figure 5.
Boxxer 427 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. Clean or replace as necessary. 1.3. Diverter valve is stuck or out of adjustment. Operate diverter valve manually (make sure exhaust system is cool) to determine if the movement of the valve is restricted.
Page 5-8 5-9 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. Chemical System Troubleshooting 1.0. System will not prime 1.1. Check valves in chemical pump are faulty. Remove valves and inspect. Clean or replace as necessary. 1.2.
Boxxer 427 Page Page5-10 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. Three-way chemical valve is defective. Check valve for leaks between ports. Replace as necessary 3.2. Inlet check valve in chemical pump is faulty. Remove and inspect valve. Clean or replace as necessary. 4.0.
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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. Use a 30 weight, non-detergent oil. ! CAUTION If the oil becomes discolored and contaminated, one of the oil seals may be damaged. Refer to the Service Section. Do not operate the pump if the crankcase has been contaminated with water.
Page 6-2 Boxxer 427 Service T he next few pages explain how to disassemble and inspect all easily-serviceable parts of the pump. ! 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; top—discharge bottom—inlet 2. Unthread the valve plug and examine the O-ring under the plug for cuts or distortion. Replace it if it is worn.
Boxxer 427 Page 6-3 Figure 6-1 Servicing the Valves TBD TBD 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. 3. Insert two flat-head screwdrivers on opposite sides to further separate the manifold from the crankshaft.
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). Servicing the Low Pressure Seals and High Pressure Seals (See Figure 6-1) 1. Remove the low pressure seal from the seal retainer using a 90 degree pick tool. 2.
Boxxer 427 Page 6-5 Reinstall the Ceramic Plungers: 1. Examine the sealing washer on the plunger retainer and replace it if it is cut or worn. Lubricate the new sealing washer for ease of installation and to avoid damage. 2. Apply Loctite 242™ to the threads of the plunger retainer and press it into the ceramic plunger. Thread ‘hand’-tight, then torque the bolt to 4.4 foot pounds. 3. Install the seal retainer with holes to the top and bottom, and forward. Reinstall High Pressure Manifold 1.
Page 6-6 Boxxer 427 Figure 6-2 Pump Assembly D-5574 Rev D 1 27 21 17 11 9 18 16 15 13 22 28 10 7 24 23 29 8 24 6 23 5 3 19 2 4 25 26 14 23 24 12 20 HydraMaster Corporation
Boxxer 427 Page 6-7 Pump Assembly Parts List Item Part Number Description Qty 1 000-111-041 Pump, Hydra Pump V - Boxxer 427 1 2 000-052-084 Elbow, 1/8" NPT Street 1 3 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 1 4 Fig.
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. If volume is below manufacturers specifications, replace seals and inspect for defective valves. 1.3. Pump RPM is too low. Check engine RPM and adjust as necessary to 3000 RPM.
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. 3.2. There is a defective quick connect in the system. Inspect each quick connect and replace as necessary. 3.3. There is a restriction in one of the solution hoses. Remove quick connects and inspect hoses. Clean or replace as necessary. 3.4.
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Cleaning Wand Parts Boxxer 427 Section 7-1 Figure 7-1 Valve Assembly C3652 ITEM PART NO.
Page 7-2 Boxxer 427 Figure 1-2 Solution Valve Assembly B1234 ITEM 1 2 3 4 PART NO.
Boxxer 427 Page 7-3 Figure 1-3 Valve Stem Assembly B3743 ITEM PART NO.
Page 7-4 Boxxer 427 Figure 1-4 Hydra Hoe Wand Assembly C2660 HydraMaster Corporation
Boxxer 427 Page 7-5 Hydra Hoe Wand Assembly Parts List ITEM PART NO.
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Boxxer 427 Page 8-1 Vacuum System Boxxer 427 Section 8-1 T he 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 8-2 Boxxer 427 ! CAUTION The vacuum tank is protected from overflowing by a vacuum tank float kill switch. 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.
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. 2.0. Vacuum gauge will not come up to 12" hg 2.1. There is an air leak somewhere in the vacuum system. Check vacuum relief valve for proper adjustment.
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. Do not use wrench directly on blower shaft. If unable to free up blower in this manner, refer to qualified service technician. 5.2.
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. Repair if necessary. WARNING: Do not attempt to jump-start this machine from a running vehicle. The amperage output from an automobile will damage the charging system of the truckmount. 1.3.
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. If it is low, add oil to the proper level. If the engine still will not start, disconnect the oil pressure switch. If the engine starts with the oil pressure switch disconnected, replace the oil pressure switch. 2.3.
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. If the engine starts, replace the switch. 4.1.1. Note: It is important to use only Briggs oil filters.
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. Check for clogged filter or obstructed fuel line. Also check to make sure the fuel pump is mounted vertically and is close to the fuel source. Repair as necessary. 7.0.
Boxxer 427 Page 10-1 Electrical System Boxxer 427 Section 10-1 T 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. Battery levels are sustained by a 16 amp alternator inside the engine.
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Boxxer 427 Figure 10 -1 Wiring Schematic D-5738 Rev E HydraMaster Corporation Page 10-2
Boxxer 427 Figure 10-2 Page 10-3 Wiring Diagram D-5737 Sht 2, Rev H ELECTRICAL PANEL [TO REC TANK PLUG #B] 7(ORG/BLK) [TO WATER BOX LOWER FLOAT] 1(BLK/WHT) [TO LOW WATER BOX FLOAT] 2(PUR) [TO ENGINE PLUG (P-1) - 16 GUAGE] 3(YEL) [TO REC TANK PLUG #A] 4(ORG) [TO REC TANK PLUG #E] 98(BLK) [TO FUEL PUMP] 32(WHT/GRN) [TO TB-3 #2-GND] 8(WHT) [TO PUMP IN PUMP] 35(WHT/BLK) [TO REC. TANK PLUG #C - 14 GA.] 9(WHT) 41(WHT) [TO ENGINE GROUND-10 GA.
Boxxer 427 Figure 10-3 Page 10-4 Wiring Diagram D-5737 Sht 3, Rev H VI-1 VACUUM GAUGE S G TI-1 BACK TS-1 ADJUSTABLE I SYSTEM CONTROL 57(WHT) 94(PNK/BLK) 24(BLK) 23(BLU) 25(RED) PI-1 DIVERT VALVE SW-1 SWITCH 2 3 2 3 D11 63(BLK) 22(RED/BLK) 50(GRY) 16 GA. DASH PANEL ACC BAT ST IGNITION SW-5 SWITCH IGN 60(RED) 10 GA. 14(BLU/WHT) 58(RED) 20(BLK) 10 GA. HydraMaster Corporation 61(WHT) [TO VOLTAGE REGULATOR VR-1 - 12 GA.
Boxxer 427 Figure 10-4 Page 10-5 Wiring Diagram D-5737 Sht 4, Rev H #2 71(GRN/WHT) 68(BRN/WHT) "DIVERT MODE" ACTUATOR ARM RETRACTED (YEL) (YEL) STARTER SOLENOID SOL-1 ENGINE PLUG P-1 ENGINE MACHINE SIDE SIDE (ORG) 34(BRN/WHT) (BLK) 4 64(GRN/BLK) PUMP IN TANK (OPTIONAL) P-6 J-6 P-7 J-7 (BLK) 35(WHT/BLK) (BLK) (BLK) 50(GRY) 16 GA. 60(RED) 10GA. B-2 30A IN-LINE FUSE 10(WHT) 10 GA. 8(WHT) 3 3(YEL) 16 GA. 17(GRY) FU-7 (ORG) (RED) D8 69(WHT) 68(BRN/WHT) 58(RED) 12 GA.
Page Page10-6 10-5 Boxxer 427 Electrical Troubleshooting No. Problem/Possible Cause Solution 1.0 The engine is not charging the battery. 1.1 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. If necessary, replace the regulator/rectifier. 1.2 The stator winding is bad. Check for AC voltage at the regulator/ rectifier.
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Boxxer 427 Page 11-1 Machine Maintenance Boxxer 427 Section 11-1 T o avoid costly repairs and down-time, it is imperative to develop and practice good maintenance procedures from the beginning. These procedures fall into daily, weekly, monthly and quarterly increments, and are outlined below. All recommended maintenance must be performed by competent service personnel. Important: Record the date and machine hours on the maintenance log.
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. • Check wiring for chafing. • Flush water and chemical system with 50/50 white vinegar solution. • Change engine oil (every 50 hrs.). MONTHLY: • Change oil filter (every other oil change).
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, excessive chemical use, improper chemicals, etc. The frequency with which de-scaling procedures are required will vary. If your area has particularly hard water or you see evidence of deposits in the water system, you may have to de-scale monthly.
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 appearance should reflect that fact. A dirty machine is not professional. 2. Maintenance, troubleshooting, and repair is much easier to accomplish on a clean, well maintained unit.
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). • Remove stainless steel filter in recovery tank and thoroughly clean, removing all lint build-up. Inspect for damage and reinstall. • Remove filter bag. Thoroughly clean and reinstall.
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BOXXER 427 MAINTENANCE LOG MAX HRS DAILY SERVICE OIL RECOMMENDATIONS 8 ENGINE OIL - check BLOWER 40 weight non-detergent 8 PUMP OIL - check PUMP 5 - 30 weight synthetic motor oil 8 GARDEN HOSE SCREEN - clean ENGINE 8 MACHINE - general inspection 8 VACUUM TANK FILTER BAG - clean 30 weight motor oil NOTE: Overhead valve engines can use multi-viscosity oil, but will experience increased oil consumption 8 BLOWER INLET - spray with lubricant WEEKLY SERVICE See Note OIL - change with filter
Boxxer 427 Page 12-1 How to Order Parts Boxxer 427 Section12-1 T o obtain a proper diagnosis of your malfunction, and to order warranty replace ment parts or repairs, it is important that you proceed in the following manner: WARRANTY PARTS ORDERS 1. Call the local distributor where you purchased your equipment and ask for the Service Department. 2. Have the following information ready: A. Equipment Model B. Date of Purchase C. Hours on the Unit D. Unit Serial Number E. Description of Malfunction 3.
Page 12-2 Boxxer 427 ONE FINAL NOTE Any questions you have regarding the warranty program should be directed to the: HydraMaster Customer Service Department (425) 775-7275, 8 a.m. to 5 p.m. Monday through Friday (PST). 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.
Boxxer 427 Page 13-1 Warranty Information Boxxer 427 Section 13-1 T 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. BLOWER: • Failure to lubricate impellers daily with an oil based lubricant. • Failure to lubricate bearings as recommended in blower manual. • Failure to maintain proper oil levels in the blower.
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. VACUUM AND SOLUTION HOSES: • Failure to protect hoses against freezing. • Failure to protect hoses against burns from engine and blower exhaust. • Damage to hoses from being run over by vehicles.
Boxxer 427 Page 13-3 WARRANTY PROCEDURE 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 information regarding your local distributor, call HydraMaster at (425) 775-7272 or email us at custsvc@hydramaster.com. When calling your distributor, be sure to have the machine’s information; model and serial number, ready for the service representative.
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Boxxer 427 Page 14-1 Accessories Boxxer 427 Section 14-1 Genuine HydraMaster Accessories & Detergents T his section of your Owners Manual is devoted to Accessories and Detergents which we have found to be helpful and useful. 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.
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Boxxer 427 Page 15-1 Product Updates Boxxer 427 Section 15-1 HydraMaster Corporation
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