HYDRAMASTER Boxxer 421 User Guide
Boxxer 421
Owner’s Manual
HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-45049 Rev. 0, March 23, 2012
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 HydraMaster. Specications and information in this document are
subject to change without prior notice.
(182-
065
-D)
All rights reserved. © 2012 HydraMaster
Table of Contents
GENERAL INFORMATION ........................................................................... SECTION 1
System Concept ...................................................................................... 1-2
Contact Information ................................................................................. 1-3
Warnings, Cautions and Notices ............................................................. 1-4
Responsibilities ....................................................................................... 1-8
Machine Specications ........................................................................... 1-11
High Altitude Operation ........................................................................... 1-13
Local Water Precautions ......................................................................... 1-13
INSTALLATION INFORMATION ................................................................... SECTION 2
Orientation of Fuel Pump ........................................................................ 2-4
CLEANING INFORMATION ......................................................................... SECTION 3
Precautions ............................................................................................. 3-2
Preparing the Carpet for Extraction......................................................... 3-2
Rinse and Recover.................................................................................. 3-3
Overwetting ............................................................................................. 3-3
Streaking ................................................................................................. 3-3
Cleaning Tool Tips ................................................................................... 3-4
OPERATING INSTRUCTIONS ..................................................................... SECTION 4
Exhaust Diverter System......................................................................... 4-2
Start Up ................................................................................................... 4-5
Carpet or Hard Surface Cleaning ............................................................ 4-6
Upholstery Cleaning ................................................................................ 4-7
Flood Extraction ...................................................................................... 4-8
Shut Down............................................................................................... 4-9
MACHINE MAINTENANCE ......................................................................... SECTION 5
Operational Maintenance ........................................................................ 5-2
Overall Machine Maintenance................................................................. 5-3
High Pressure Pump ............................................................................... 5-5
Vacuum System ...................................................................................... 5-9
Freeze Guard .......................................................................................... 5-11
WATER AND CHEMICAL SYSTEM ............................................................. SECTION 6
Water and Chemical Flow Operation ...................................................... 6-1
Before Cleaning ...................................................................................... 6-1
Chemical System Maintenance............................................................... 6-2
Troubleshooting ...................................................................................... 6-3
i: Boxxer 421 Owner’s Manual
ELECTRICAL SYSTEM ................................................................................ SECTION 7
Troubleshooting ...................................................................................... 7-6
SYSTEMS TROUBLESHOOTING ............................................................... SECTION 8
High Pressure Pump ............................................................................... 8-6
Vacuum ................................................................................................... 8-9
ASSEMBLIES AND PARTS LISTS ............................................................... SECTION 9
Machine Assembly Parts List .................................................................. 9-7
Frame Assembly Parts List ..................................................................... 9-11
Engine Assembly Parts List..................................................................... 9-13
Dash Assembly Parts List ....................................................................... 9-16
Electrical Control Panel Assembly Parts List .......................................... 9-18
Blower Heat Exchanger Assembly Parts List .......................................... 9-19
Water Box Assembly Parts List ............................................................... 9-20
Pump Assembly Parts List ...................................................................... 9-21
Chemical Pump Assembly ...................................................................... 9-22
Blower Assembly Parts List ..................................................................... 9-25
Vacuum Relief Valve (Collector Box) Assembly Parts List ...................... 9-26
Exhaust Assembly Parts List ................................................................... 9-28
Diverter Valve Actuator Assembly Parts List ........................................... 9-29
Hi PSI Manifold Assembly Parts List ....................................................... 9-31
By-Pass Valve Assembly Parts List ......................................................... 9-32
70 Gallon Universal Recovery Tank Assembly Parts List ........................ 9-35
70 Gallon Universal Recovery Tank Cover Assembly Parts List ............. 9-36
100 Gallon Universal Recovery Tank Assembly Parts List ...................... 9-38
100 Gallon Universal Recovery Tank Cover Assembly Parts List ........... 9-39
70 Gallon Universal Recovery Tank for
85 Rotomolded Tank Assembly Parts List ......................................... 9-41
85 Gallon Rotomolded Tank Assembly Parts List ................................... 9-44
85 Rotomolded Tank Assembly Parts List ............................................... 9-46
Chemical Jug Tray Assembly Parts List .................................................. 9-47
Hose Routings......................................................................................... 9-48
HOW TO ORDER PARTS ............................................................................ SECTION 10
Warranty Parts Orders ............................................................................ 10-1
Parts Orders ............................................................................................ 10-1
Emergencies ........................................................................................... 10-1
Boxxer 421 Owner’s Manual: ii
WARRANTY INFORMATION ....................................................................... SECTION 11
Blower ..................................................................................................... 11-1
High Pressure Water Pump .................................................................... 11-1
Vacuum Recovery Tank .......................................................................... 11-1
Chemical System .................................................................................... 11-1
Control Panel .......................................................................................... 11-2
Vacuum and Solution Hoses ................................................................... 11-2
Cleaning Wand ........................................................................................ 11-2
Water Heating System ............................................................................ 11-2
Hard Water Deposits ............................................................................... 11-2
Warranty Procedure ................................................................................ 11-2
ACCESSORIES AND CHEMICAL SOLUTIONS .......................................... SECTION 12
iii: Boxxer 421 Owner’s Manual
List of Figures
Figure 1-1. Boxxer 421 with Standard 70 Gallon Recovery Tank ................................. 1-1
Figure 1-2. Hard Water Map of Mainland United States ............................................. 1-14
Figure 2-1. Roof Vent Positions .................................................................................... 2-1
Figure 2-2. Recommended Placement ......................................................................... 2-2
Figure 2-3. Installation Using Tie Down Washers ......................................................... 2-3
Figure 2-4. Install Fuel Pump, Outlet Side Up .............................................................. 2-4
Figure 2-5. Fuel Pump Must Be in Vertical Position ..................................................... 2-4
Figure 4-1. Dash Assembly - View 1 of 2 ..................................................................... 4-1
Figure 4-2. Dash Assembly - View 2 of 2 .................................................................... 4-2
Figure 4-3. Location of Chemical Metering
Control and Chemical Pump Selector Valve ............................................. 4-6
Figure 4-4. Location of Blower Lube Port ..................................................................... 4-9
Figure 5-1. Service the Valves ...................................................................................... 5-6
Figure 5-2. Recirculation Fitting...................................................................................5-11
Figure 6-1. Flow Diagram - View 1 of 3 ........................................................................ 6-6
Figure 6-2. Flow Diagram - View 2 of 3 ........................................................................ 6-7
Figure 6-3. Flow Diagram - View 3 of 3 ........................................................................ 6-8
Figure 7-1. Electrical Schematic ................................................................................... 7-2
Figure 7-2. Wiring Diagram - View 1 of 3 ..................................................................... 7-3
Figure 7-3. WiringDiagram - View 2 of 3 ...................................................................... 7-4
Figure 7-4. Wiring Diagram - View 3 of 3 ..................................................................... 7-5
Figure 9-1. Machine Assembly - View 1 of 5 ............................................................... 9-2
Figure 9-2. Machine Assembly - View 2 of 5 ............................................................... 9-3
Figure 9-3. Machine Assembly - View 3 of 5 ................................................................ 9-4
Figure 9-4. Machine Assembly - View 4 of 5 ............................................................... 9-5
Figure 9-5. Machine Assembly - View 5 of 5 ............................................................... 9-6
Figure 9-6. Frame Assembly - View 1 of 3 .................................................................. 9-8
Figure 9-7. Frame Assembly - View 2 of 3 ................................................................... 9-9
Figure 9-8. Frame Assembly - View 3 of 3 ................................................................. 9-10
Figure 9-9. Engine Assembly...................................................................................... 9-12
Boxxer 421 Owner’s Manual: iv
Figure 9-10. Dash Assembly - View 1 of 2 ................................................................. 9-14
Figure 9-11. Dash Assembly View 2 of 2 .................................................................... 9-15
Figure 9-12. Electrical Control Panel Assembly ......................................................... 9-17
Figure 9-13. Blower Heat Exchanger Assembly ......................................................... 9-19
Figure 9-14. Water Box Assembly .............................................................................. 9-20
Figure 9-15. Pump Assembly ..................................................................................... 9-21
Figure 9-16. Chemical Pump Assembly ..................................................................... 9-22
Figure 9-17. Fuel Pump Assembly ............................................................................ 9-23
Figure 9-18. Blower Assembly .................................................................................... 9-24
Figure 9-19. Vacuum Relief Valve (Collector Box) Assembly ..................................... 9-26
Figure 9-20. Exhaust Assembly .................................................................................. 9-27
Figure 9-21. Diverter Valve Actuator Assembly .......................................................... 9-29
Figure 9-22. Hi PSI Manifold Assembly ...................................................................... 9-30
Figure 9-23. By-Pass Valve Assembly ........................................................................ 9-32
Figure 9-24. Briggs and Stratton Voltage Regulator Modication .............................. 9-33
Figure 9-25. 70 Gallon Universal Recovery Tank Assembly ....................................... 9-34
Figure 9-26. 70 Gallon Universal Recovery Tank Cover Assembly ............................ 9-36
Figure 9-27. 100 Gallon Universal Recovery Tank Assembly ..................................... 9-37
Figure 9-28. 100 Gallon Universal Recovery Tank Cover Assembly .......................... 9-39
Figure 9-29. 70 Gallon Universal Recovery Tank
for 85 Rotomolded Tank Assembly ........................................................ 9-40
Figure 9-30. 85 Gallon Rotomolded Tank Assembly - View 1 of 2 ............................. 9-42
Figure 9-31. 85 Gallon Rotomolded Tank Assembly - View 2 of 2 ............................. 9-43
Figure 9-32. 85 Rotomolded Tank Assembly with Boxxer 421 ................................... 9-45
Figure 9-33. Chemical Jug Tray Assembly ................................................................. 9-47
v: Boxxer 421 Owner’s Manual
Boxxer 421 Owner’s Manual: vi
- General Information1
The Boxxer 421 is a compact, yet powerful truckmount carpet cleaning system which
can also be used for hard-oor cleaning and pressure washing. This high performance
machine features a 21 Hp Briggs and Stratton engine and the dual oil bath Tuthill Dominator
4005 Tri-lobe Blower, which provides low noise, low vibration operation. The advanced
heat exchanger system utilizes two separate exhaust heat exchangers for capturing “free
heat”.
The Boxxer 421 comes standard with a 70 gallon recovery tank (shown in Figure 1-1), a
5 gallon chemical jug, 100 ft vacuum and solution hoses and a 10 ft whip hose.
Figure 1-1. Boxxer 421 with Standard 70 Gallon Recovery Tank
Options include:
a 100 gallon recovery tank•
an Automatic Pump Out (APO) system•
a Thru Floor Exhaust Kit•
an 85 gallon fresh water tank•
1-1: General Information
SYSTEM CONCEPT
The Boxxer 421 truckmount carpet cleaning system has many functions to perform
simultaneously.
The engine has to run at a consistent rpm. •
The vacuum has to pull air and dirty water back from cleaning site. •
The water pump provides stable pressure at proper water ow for cleaning. •
The chemical has to be injected into the water stream at the right concentration.•
The heating system must maintain proper heat. •
The recovery ta• nk must store dirty water until drained.
This is how the Boxxer 421 integrates all the functions:
Water is fed into the machine under tap pressure and it ows through the water conditioner
to the water box. (The water conditioner is offered as an option.) The solution is then
picked up by the high pressure pump and pressurized to the desired level. The water then
splits ow, as demanded by the technician.
The majority of the water ows to the by-pass valve assembly, then back to the water box.
The water ows from the water pump through the blower exhaust heat exchanger then
through the engine exhaust heat exchanger and out to the cleaning tool.
When the cleaning solution reaches a preset high temperature, it is released from the
system and directed to the recovery tank. Then cool water enters the system to regulate
the temperature. The engine exhaust diverter bypasses the heat from the exhaust heat
exchanger and simultaneously releases water from the system and directs it to the
recovery tank.
As there is no guess work in the manufacture of these highly advanced cleaning machines,
there must be none in preparing it to get the job done in the eld. It is the purpose of this
manual to help you properly understand, maintain and service your cleaning plant.
The manual contains installation and operation instructions as well as information required
for proper maintenance, adjustment and repair of Boxxer 421. Component troubleshooting
charts have also been included for your convenience. Follow the directions carefully and
you will be rewarded with years of protable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this
equipment.
This section of the manual contains the following information:
Contact Information
Warnings, Cautions and Notices
Responsibilities
Machine Specications
High Altitude Operation
Local Water Precautions
General Information: 1-2
CONTACT INFORMATION
If you have any questions regarding the operation, maintenance or repair of this machine,
please contact your local distributor.
To nd a local distributor, please visit our website at
http://hydramaster.com/HowToBuy/DealerLocator.aspx
If your question cannot be resolved by your distributor or by the information within
the Owner’s Manual, you may contact HydraMaster direct using the following phone
numbers.
HOURS TELEPHONE NUMBERS E-MAIL ADDRESSES
Monday-Friday
Technical Support
(425) 775-7275
FAX : (800) 426-4225
techsupport@hydramaster.com
Technical Support
7:00 a.m. to 5:00 p.m.
Pacic Standard Time
Customer Service/Parts
(425) 775-7276
FAX: (425) 771-7156
Customer Service/Parts
parts@hydramaster.com
When calling your distributor, be sure to reference the serial number and date of
purchase.
FOR YOUR REFERENCE:
Serial No.____________________________________________________
Date of Purchase:_____________________________________________
Purchased From (Distributor): __________________________________
1-3: General Information
WARNINGS, CAUTIONS AND NOTICES
HydraMaster uses this WARNING symbol throughout the manual to warn of
possible injury or death.
This CAUTION symbol is used to warn of possible equipment damage.
This NOTICE symbol indicates that federal or state regulatory laws may apply,
and also emphasizes supplemental information.
General Information: 1-4
Warnings and Cautions specic to the Boxxer 421 include the following:
ENGINE COOLING: Units employing internal combustion engines must not be
enclosed within a van with doors and windows closed. Excessive temperatures
within the engine will result in premature engine failure and a compromise of
applicable warranty.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
HOT SURFACES: During the operation of this equipment, many surfaces on the
machine will become very hot. When near the van for any reason care must be
taken not to touch any hot surface, such as heater, engine, exhaust, etc.
HEARING PROTECTION: The Occupational Safety and Health Administration
(OSHA) recommends the use of hearing protection when a technician is exposed
to an average of 85 decibels (this is an average of exposure over an 8 hour
period). This equipment can produce 85 decibels to a distance of 10 feet. Please
check with your local state agencies to see if OSHA standards apply to your
application.
NO SMOKING: It is unsafe to smoke in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so
that the fumes will be directed away from the job site. Do not park where exhaust
fumes can enter a building through open doors, windows, air conditioning units
or kitchen fans.
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is
operating. Toxic fumes may accumulate inside a stationary vehicle.
1-5: General Information
ENGINE EXHAUST: The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects or other reproductive
harm.
PORTABLE GAS TANK: Never operate this machine with a portable gas can
inside the truck. Doing so increases the risk of a re or explosion.
TRANSPORTATION OF FUEL CONTAINERS: Transportation in a vehicle of any
vented fuel container that presently has or has ever contained a ammable liquid
is strictly forbidden by HydraMaster and by federal and state regulation.
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van
oor. Many vans have critical components mounted directly below the van oor
that could be damaged by a misplaced drill bit.
LEVEL OPERATION: During operation, van or trailer must be parked on level
ground not to exceed + or - 10 degrees. Failure to insure proper leveling may
prevent proper internal lubrication of engine, vacuum and/or high pressure
components.
The machine cannot be run in the IDLE position for cleaning upholstery, carpet or
ood extraction. This will void the warranty.
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.
General Information: 1-6
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.
HARD WATER PROTECTION: Failure to take appropriate measures to prevent
scale build up can result in system failure and loss of warranty on affected
parts. Test the water in your immediate and surrounding areas with hard water
test strips. Assume all water obtained from wells is hard. If you are operating
in a “Hard Water Area” (3.0 grains or more per gallon), use a water softening
system.
FREEZE PROTECTION: There is often little warning before a cold spell. Therefore,
not protecting this equipment from freezing will result in costly downtime. Placing
an electric heater in the truck or parking the truck indoors will help to insure
against freezing, but should not be the primary method of freeze protection.
EXHAUST SYSTEM: Do not allow ammable material (i.e. oil, fuel, plastic or
wood products) to come in contact with the exhaust system.
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. These harmful chemicals include concentrated acid (see
the pH chart at the end of this section), solvents (including d-Limonene), and
some paint, oil and grease removers with a high concentration of solvents.
1-7: General Information
RESPONSIBILITIES
Purchaser’s Responsibilities
Prior to purchasing a van, ensure that the payload is suitable for all of the equipment •
that will be installed and transported. This includes and is not limited to: the truckmount,
recovery tanks, fresh water tanks, on-board water, hose reels, hoses, cleaning tools,
chemicals and drying equipment. Payload capacity information is available through
the auto dealer, the manufacturer’s web site, and is also located on the door pillar of
the driver’s side door.
Purchase a 42 - 60 Amp hour battery and have the battery ‘slow’ charge if it is new. •
The battery is normally available from the installation dealer.
If the battery is not fully charged, damage can occur to the engine charging
regulator.
Prior to dropping your van off at the distributor for the truckmount to be installed, have •
a spray-on bed liner applied to the oor such as Rhino Lining® or Line-X®.
Plywood and carpet are not recommended.
Prior to operating the truckmount, read this manual in its entirety and familiarize •
yourself with the information contained here. Special attention should be paid to all
Warnings and Cautions.
The distributor is responsible for the correct installation of the truckmount. The •
distributor is also responsible to train you in the correct and proper operation and
maintenance of the truckmount.
Any modication of the truckmount may void the warranty.
General Information: 1-8
Distributor’s Responsibility
Acceptance of Shipment
Before accepting the truckmount, check the following
The truckmount should be free from any damage during shipping. Do not sign the 1.
delivery receipt until you have closely inspected the truckmount and noted any
damage on the delivery receipt. Hidden damage may be present even if the box looks
okay. It is recommended that the box be opened before you sign for the shipment.
Check the packing list and verify that all items are accounted for.2.
Installation Responsibilities
Ensure proper payload capacity. It is the distributor’s responsibility to verify that the •
equipment package does not exceed the vehicle capacity.
Ensure installation of a safe fuel tap system and through-oor ttings as provided by •
HydraMaster.
Ensure proper placement of the truckmount, recovery tank, fresh water tank, and •
accessories in the vehicle, and check that they are secured with bolts and back up
plates. The distributor should verify that the owner is in agreement with the layout.
Ensure proper connection of the fuel lines.•
Ensure proper connection and installation of the battery. Verify that the battery is in •
accordance with HydraMaster’s recommendation.
Check the pump, vacuum blower and engine oil levels prior to starting the •
truckmount.
Start and run the truckmount and check that all systems function properly.•
Test all hoses, wands and other accessories for correct operation.•
Ensure timely return of the document package.•
1-9: General Information
Training
The distributor should provide a thorough review of the operation manual with the
purchaser along with instruction and familiarization in
How all the truckmount’s systems function.•
All safety precautions and their importance.•
How to correctly start and shut down the truckmount.•
How to correctly clean with the truckmount.•
Where and how often to check and change component oil levels.•
Freezing damage and how to avoid it. This includes explaining proper freeze guarding •
procedures.
How to do basic troubleshooting of the truckmount.•
Hard water damage and how to avoid it. This includes how to determine if hard water •
exists in your area and the installation and use of water softening systems.
The truckmount’s warranty and warranty procedures.•
General Information: 1-10
MACHINE SPECIFICATIONS
Frame 24”W x 32”H x 36”D
Steel with Baked-on Powder Coated
Finish
Weight 709 lbs.
Engine Vanguard 21 HP Briggs and Stratton
Pressurized Oil System Engine Oil:
5W-30 Synthetic
Spin-on Filter, Oil Cooler
Ignition Electric Keystart
Vacuum Blower Dominator 4005, Tuthill/M-D Tri-Lobe, Blower Oil:
Pneulube
Pump HydraPump II, 3.5 gpm Hot Seals,
2,500 psi
Pump Oil:
15W-50 Synthetic
Chemical System Last-Step Chemical
Operating Pressure Up to 1,000 psi
Heating System 1 Stainless Steel Engine Exhaust
Exchanger
1 Coil and Fin Blower Exhaust Heat
Exchanger
Instruments Water Pressure Gauge, Liquid Filled,
0 - 1,500 psi
Hour Meter, Machine Runtime
Keyed Ignition, Start/Stop
Chemical Flowmeter, Clear Acrylic,
0 - 10 gph
Vacuum Gauge
Temperature Gauge
Recovery Tank 70 Gallon Aluminum, Powder Coated
Finish
Cleaning Wand Stainless Steel ‘S’-bend
Replaceable Grip
Rebuildable Solution Valve
1-11: General Information
High Pressure
Solution Hose
100 ft , 1/4” High Temperature Lined/
Vinyl Covered
Hose Rated to 2,250 psi
Vacuum Hose 100 ft, 2” Reinforced Hose,
10 ft, 1 1-2” Reinforced Wand Whip Line
Standard Equipment Chemical Jug
Battery Box
Van Decal Package
Van Installation Kit
Owner’s Manual (on CD)
Owner’s Guide (paper)
HydraMaster Jacket
General Information: 1-12
HIGH ALTITUDE OPERATION
Elevation plays a key role in how the truckmount will operate. Operation at high altitude
(above 5,000 ft) may require a high-altitude carburetor jet. Use of this jet at high altitude
will improve power, reduce fuel consumption and help reduce excessive carbon build-up
in the exhaust and heat exchanger systems.
Contact the local Briggs and Stratton dealer or HydraMaster to obtain the proper jet
size. Find your local Briggs and Stratton dealer at
http://vanguardengines.via.infonow.net/locator.
LOCAL WATER PRECAUTIONS
The 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 inuences the reliability and efciency of equipment in direct
proportion to the level of hardness.
Hard Water Advisory
HydraMaster recognizes that any hard water deposits which might occur within the water
system of our truckmounts is a serious problem. The precision technology of truckmount
heat exchanger systems is intolerant of any foreign material. Hard water deposits will
ultimately decrease the performance of the system and are expected to seriously lower
the reliability of the machine.
To validate a machine’s warranty, HydraMaster requires that all machines operating in
designated “Hard Water Areas” (3.0 grains or more per gallon) be tted with a water
softening system, or a properly installed magnetic-type descaler must be used and
maintained. Periodic descaling or acid-rinsing alone is not adequate in these areas.
HydraMaster does not recommend any particular type or brand; however, the relative
effectiveness of some types of magnetic descalers or softeners may require additional
periodic use of descaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all areas
be tted with a water softening system for improved operation and reliability.
Failure to take appropriate measures to prevent scale build up can result in
system failure and loss of warranty on affected parts.
1-13: General Information
Hard Water Area Map
The hard water map, shown in Figure 1-2, denes hard water areas in the continental
United States which compromise uid related components such as hoses, ttings, heaters,
pumps, valves and water-cooled engines. For other countries, hard water area maps can
be obtained from geological societies.
Hard Water Map of Mainland United StatesFigure 1-2.
The map shown in Figure 1-2 is provided for general reference only. Water
hardness in your geographical location should be conrmed by testing.
General Information: 1-14
Water Softener
Cleaning efciency and equipment life is increased, chemical use decreased, and the
appearance of cleaned carpets enhanced when water softeners are incorporated in
hard water areas. HydraMaster strongly urges the use of water softener units with the
Boxxer 421 in areas exceeding 3.0 grains per gallon.
Failure to use a water softener in these areas will invalidate the machine’s warranty.
Referring to the hard water area map shown Figure 1-2, determine the quality of water
in your area and take immediate action if the water hardness exceeds 3.0 grains per
gallon.
The relatively low cost of a water softener service is more than made up for by an increased
life of machine parts, reduced chemical costs and continued cleaning efciency. The
water softener will also increase the effectiveness of the cleaning chemicals, therefore
less chemical will be needed.
Contact a water softener distributor in your area for information on the rental of a simple
water treatment unit to carry in your truck. Be sure to charge the water softener in
accordance with the capability of the softener.
For example: If the softener will treat 900 gallons of water and the machine uses an
average of 30 gallons/hour, for an average of 5 hours a day, this equals 150 gallons per
day. In 6 days the machine would use 900 gallons of water. Therefore, the softener would
need to be charged every 6 working days for maximum softening.
1-15: General Information
Waste Water Disposal Advisory
There are laws in most communities prohibiting the dumping of recovered “gray” water
from carpet cleaning in any place but a sanitary treatment system.
The cleaning rinse water, recovered into your unit’s vacuum recovery tank, contains
materials such as detergents, and must be safely processed before entering streams,
rivers and reservoirs.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after rst ltering out solid material such as carpet
ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV
dump, etc. Permission should rst be obtained from any concerned party or agency.
One disposal method which usually complies with the law is to accumulate the waste
water and haul it to an appropriate dump site. Another solution to the disposal problem
is to equip your Boxxer 421 with an Automatic Pump-Out System (APO). These systems
are designed to remove waste water from the extractor’s recovery system and actively
pump the water through hoses to a suitable disposal drain.
HydraMaster makes an APO System which can be ordered with new equipment or
installed later.
When properly congured, the systems will continuously monitor the level of waste water
and pump it out simultaneously with the cleaning operation. The hidden benet of this
process is that the technician does not have to stop his/her cleaning to empty the recovery
tank.
IN ACCORDANCE WITH EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF
WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS,
ETC.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.
General Information: 1-16
2- Installation Information
When selecting a truck, remember the preferable vehicle for a Boxxer 421 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 lb. payload capacity,
is required.
Be cautious when drilling any holes through the van oor. Many vans have critical
components mounted directly below the van oor that could be damaged by a
misplaced drill bit.
Truck Preparation
The manufacturer recommends the installation of a spray-on bed liner in the vehicle prior
to installation of machine.
This provides ‘metal to cushion’ mounting rather
than ‘metal to metal’ and makes for an attractive
van interior.
It is highly recommended that you have roof
vents installed in vehicles operated in hot
weather locations. Roof vent positions are shown
in Figure 2-1.
Roof Vent PositionsFigure 2-1.
2-1: Installation Information
Placement Of Unit In Vehicle
There are two recommended unit placements (see Figure 2-2).
Recommended PlacementFigure 2-2.
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. Some cleaners in the colder areas prefer this location because it puts the
weight over the rear wheels for better traction in ice and snow. Rear mounting requires
the unit to be slid to the right side as far as possible.
This not only provides adequate working space on the component side of the unit but also
improves weight distribution inside the van (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.
Installation Information: 2-2
Machine Tie Down Washers
Secure the machine to the oor of the van
with the four tie down washers provided. This
safety measure will ensure that the machine
will not slide inside the van. See Figure 2-3
for the correct installation.
Ensure that the machine is well secured
to the oor of the van with the hardware
supplied. A sudden or crash stop will cause
the machine to rocket forward. Protect
yourself and the machine. SECURE IT!
It is recommended by the manufacturer
that the exhaust from the front of the
Tie Down Washers
Installation Using Figure 2-3.
machine be vented down under the truck
to prevent carbon monoxide from entering the job site. Always park the truck so
the exhaust is blowing away from the job site.
Never operate this machine with a portable gas can inside the truck. Doing so
increases the risk of a re or explosion.
Mount a re extinguisher just inside the rear or side door for emergencies.
Transportation in a vehicle of any vented fuel container that presently holds or
has ever held a ammable liquid is strictly forbidden by HydraMaster 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.
2-3: Installation Information
ORIENTATION OF FUEL PUMP
For proper fuel pump operation and fuel ow, the
vehicle’s fuel pump must be installed in a lower
position with respect to the fuel tank and in as
vertical a position as possible (outlet side up - see
Figure 2-4 and Figure 2-5).
Mount the fuel pump away from sources of heat.
Install Fuel Pump, Figure 2-4.
Outlet Side Up
Installation Information: 2-4
Pump Can Push Fuel
6.5 ft Vertically
Fuel Pump Must Be in Vertical PositionFigure 2-5.
3 - Cleaning Information
The Boxxer 421 has been engineered using the latest and most sophisticated technology
available to produce the nest carpet cleaning results possible. Despite this, it remains
only a tool of the carpet cleaning trade and can produce only as a good a job as the
person operating it.
HydraMaster strongly recommends attending an Institute of Inspection, Cleaning and
Restoration Certication (IICRC) approved school as soon as possible and to always
follow the IICRC guidelines when cleaning carpets or hard surfaces.
This section describes the carpet cleaning procedure in the following areas:
Precautions
Preparing the Carpet for Extraction
Rinse and Recover
Overwetting
Streaking
Cleaning Tool Tips
3-1: Cleaning Information
PRECAUTIONS
The use of some chemicals (such as concentrated acids and/or solvents) in your
truckmount can seriously damage the internal plumbing and high pressure pump.
HydraMaster strongly recommends purchasing a water softener system to prevent the
buildup of scale and hard water deposits in your truckmount.
HydraMaster recommends only the use of chemicals containing rust and corrosion
inhibitors and water softening agents to prevent chemical buildup which may lead to
component failure and warranty invalidation.
Increased demand for a neutralizing rinse results in the need for special care when using
these acid based chemicals in your truckmount The negative side of these products is the
corrosive effects the acid can have on metals, including ttings, pumps, heat exchangers,
etc.
HydraMaster’s ClearWater Rinse™ has been formulated to protect vital components.
HydraMaster will not warranty parts that have been damaged from using acid products
that have obviously caused failures.
PREPARING THE CARPET FOR EXTRACTION
Pre-vacuum the carpet
Whether you instruct the customer to pre-vacuum or you offer it as part of your service,
proper vacuuming will make your job easier with superior end results. The more time
spent removing loose particulate soil, the easier it will be to remove the oily soil stuck to
the bers.
Pretreat the carpet
This process of applying trafc lane type chemicals to the carpet (whether by sprayer or
rotary scrubber) is essential prior to extraction with your truckmount.
By applying cleaning agents to the carpet and letting them dwell 10-20 minutes prior to
rinsing, you allow the product to dissolve and emulsify the oily, sticky binders holding the
soil to the ber. This will allow more soil to be removed in one or two cleaning passes and
help prevent over-wetting.
Remember the solution coming out of your cleaning tool is only in contact with the carpet
ber for a few seconds. Relying on the rinse detergent to do the majority of the cleaning
will result in overly long dry times and excess detergent residue left in the carpet.
HydraMaster recommends the use of our pre-sprays: Fastbreak™ for residential carpet
and Blitz™ for commercial carpet needs.
Cleaning Information: 3-2
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