HYDRAMASTER BOXXER 427 User Manual

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. Revised March 23, 2012
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 ........................................................ 1-8
Spare Parts Recommendation ............................................... 1-10
Spare Parts List ......................................................... 1-10
Responsibilities ................................................................... 1-12
Vehicle Preparation ............................................................. 1-14
High Altitude Operation Preparation ...................................... 1-18
Local Water Precautions ...................................................... 1-19
Wastewater Disposal Advisory .................................... 1-20
Hard Water Map ........................................................ 1-23
Machine Assemblies and Parts Lists ...................................... 1-25
Boxxer Hose Assemblies...................................................... 1-85
CLEANING AND CHEMICALS ........................................................ Section 2
pH Chart ............................................................................ 2-3
HydraMaster Corporation
Boxxer 427
OPERATING INSTRUCTIONS ......................................................... Section 3
Start Up ............................................................................ 3-1
Carpet or Hard Surface Cleaning ........................................... 3-1
Upholstery Cleaning ............................................................ 3-2
Flood Extraction.................................................................. 3-3
Shut Down ......................................................................... 3-4
Exhaust Diverter ................................................................. 3-5
FREEZE GUARD ........................................................................... Section 4
Freeze Protection of Pump-In System .................................... 4-3
WATER AND CHEMICAL SYSTEM .................................................. Section 5
Chemical System Maintenance ............................................. 5-2
Chemical Pump ................................................................... 5-3
Solution Flow Diagram......................................................... 5-5
Chemical Flow Diagram ....................................................... 5-6
Exhaust, Vacuum, Coolant and APO Flow Diagram.................. 5-7
Chemical Tank Troubleshooting ............................................ 5-8
HIGH PRESSURE PUMP ................................................................. Section 6
Pump Maintenance .............................................................. 6-1
Service .............................................................................. 6-2
HydraPump IV Drawing and Parts List ................................... 6-6
Pump Troubleshooting ......................................................... 6-8
CLEANING WAND PARTS ............................................................. Section 7
Cleaning Wand Assembly Drawing ........................................ 7-1
HydraMaster Corporation
Boxxer 427
VACUUM SYSTEM ....................................................................... Section 8
Blower Troubleshooting/Miscellaneous Troubleshooting ........... 8-3
MD Blower Instruction Booklet
ENGINE TROUBLESHOOTING ........................................................ Section 9
ELECTRICAL SYSTEM ................................................................... Section 10
Wiring Schematic ............................................................... 10-2
Wiring Diagrams ................................................................. 10-3,-4,-5
Electrical Troubleshooting .................................................... 10-6
MACHINE MAINTENANCE ............................................................ Section 11
Daily, Weekly ..................................................................... 11-1
Monthly, Quarterly, 500 Hours ............................................. 11-2
De-scaling .......................................................................... 11-3
Machine Maintenance ......................................................... 11-4
Maintenance Logs
HOW TO ORDER PARTS ............................................................... Section 12
WARRANTY INFORMATION .......................................................... Section 13
Golden Guarantee®
ACCESSORIES ............................................................................. Section 14
PRODUCT UPDATES .................................................................... Section 15
HydraMaster Corporation
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 .......................................... 1-25
Fig. 1-6 Machine Assembly - Front View - Left Side ................. 1-25
Fig. 1-7 Machine Assembly - Front View - Right Side ................ 1-26
Fig. 1-8 Machine Assembly - Rear View - Right Side ................. 1-27
Fig. 1-9 Frame Assembly - Front View - Left Side .................... 1-29
Fig. 1-10 Frame Assembly - Front View - Right Side ................... 1-30
Fig. 1-11 Frame Assembly - Rear View - Left Side ..................... 1-31
Fig. 1-12 Engine Assembly - Rear View .................................... 1-33
Fig. 1-13 Engine Assembly - Front View ................................... 1-34
Fig. 1-14 Exhaust Assembly .................................................... 1-36
Fig. 1-15 Diverter Valve Actuator Assembly ............................. 1-38
Fig. 1-16 Blower Assembly ..................................................... 1-39
Fig. 1-17 Pump Assembly ....................................................... 1-41
Fig. 1-18 Chemical Pump Assembly ......................................... 1-43
Fig. 1-19 Pump Mounting Bracket Assembly.............................. 1-44
Fig. 1-20 Water Box Assembly ................................................ 1-46
Fig. 1-21 Dash Upper Assembly - Front View ............................ 1-48
Fig. 1-22 Dash Upper Assembly - Rear View ............................. 1-49
5/30/01
HydraMaster Corporation
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. 1-29 Coolant Heat Exchanger Assembly ............................. 1-61
Fig. 1-30 Blower Heat Exchanger Assembly .............................. 1-64
Fig. 1-31 Top Cover Assembly ................................................ 1-66
Fig. 1-32 Machine Right Side Cover Assembly ........................... 1-67
Fig. 1-33 Machine Left Side Cover Assembly ............................ 1-68
Fig. 1-34 70 Gallon Universal Recovery Tank Assembly ............. 1-69
Fig. 1-35 70 Gallon Universal Recovery Tank Cover Assembly .... 1-72
Fig. 1-36 100 Gallon Universal Recovery Tank Assembly............ 1-73
Fig. 1-37 100 Gallon Universal Recovery Tank Cover Assembly .. 1-76
Fig. 1-38 Vacuum Relief Valve Assembly (Collector Box) ............ 1-77
Fig. 1-39 Dura-Flow APO Pump Assembly ................................. 1-79
Fig. 1-40 Chemical Jug Tray Assembly ..................................... 1-81
Fig. 1-41 Diffuser Filter Assembly ............................................ 1-83
Fig. 1-42 Float Switch w/ Polypropylene Barrel Assembly ........... 1-84
Fig. 2-2 Cleaning Stroke Procedure ........................................ 2-3
Fig. 2-1 pH Chart ................................................................... 2-3
Fig. 2-2 Cleaning Stroke Procedure .......................................... 2-3
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5/30/01
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. 6-2 HydraPump II Assembly .............................................. 6-6
Fig. 7-1 Two-Jet Cleaning Wand Assembly ............................... 7-1
Fig. 10-1 Wiring Schematic ...................................................... 10-2
Fig. 10-2 Wiring Diagram Sht 1. ............................................... 10-3
Fig. 10-3 Wiring Diagram Sht 2 ................................................ 10-4
Fig. 10-4 Wiring Diagram Sht 3 ................................................ 10-5
Fig. 11-1 Recirculation Fitting ................................................... 11-3
HydraMaster Corporation
Boxxer 427

Quick Reference

HydraMaster Corporation
Fuel Pump Assembly B4627 Rev—
Boxxer 427
HydraMaster Corporation

General Information

Section 1-1
his manual contains installation and operation instructions as well as information
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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.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two functions to perform, the truckmounted carpet cleaning plant 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 flow for cleaning.
The chemical has to be injected into the water stream at the right concentration.
The heating system must maintain proper heat.
The vacuum tank must store dirty water until drained.
As you can see, it is not just a turnkey operation with one thing to worry about, Does
it start?
HydraMaster Corporation
Page 1-2 Boxxer 427
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WARNING
The manufacturer uses this symbol throughout the manual to warn of possible injury or death.
!
CAUTION
This symbol is used to warn of possible equipment damage.
Hours Telephone Numbers
Monday - Friday (425) 775-7276 Parts
8:00 am to 5:00 pm (425) 775-7275 Service
PACIFIC STANDARD TIME (800) 426-4225 Parts / Service FAX
HydraMaster Corporation
Boxxer 427 Page 1-3
Precautions
lthough this unit has been factory adjusted, it may require additional adjustments
A
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. Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit. (See Product Support Bulletins 92102, 94062 and 94063 at the end of the manual.)
!
CAUTION
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.
!
CAUTION
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.
!
WARNING
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
!
WARNING
The machine cannot be run in the IDLE position for cleaning upholstery, carpet or floor extraction. This will void the warranty.
HydraMaster Corporation
Page 1-4 Boxxer 427
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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 compo- nents. HydraMaster will not warranty parts that have been damaged from using unprotected acid products that have obviously caused failures.
!
CAUTION
HARD WATER PROTECTION: Failure to take appropriate measures to prevent
scale build up can result in system failure and loss of warranty on affected parts. 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” (3.5 grains or more per gallon), use a water softening sys­tem.
!
CAUTION
FREEZE PROTECTION: There is often little warning before a cold spell. There-
fore, 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.
!
CAUTION
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or
wood products) to come in contact with the exhaust system.
!
WARNING
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.
HydraMaster Corporation
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.
!
WARNING
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.
!
WARNING
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is
operating. Toxic fumes may accumulate inside a stationary vehicle.
!
WARNING
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.
!
WARNING
PORTABLE GAS TANK: Never operate this machine with a portable gas can
inside the truck. Doing so increases the risk of a fire or explosion.
!
WARNING
PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or
van. It is dangerous and illegal in most states.
HydraMaster Corporation
Page 1-6 Boxxer 427
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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. 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.
HydraMaster Corporation
Boxxer 427 Page 1-7
System Operation
he Boxxer heat exchanger system is a highly engineered cleaning plant designed
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by HydraMaster Corporation. The system utilizes a dynamic heating system com-
prised of two separate exhaust heat exchangers for capturing “free heat.”
The water flow is as follows:
Water is fed into the machine under tap pressure and it flows through the water conditioner to the water box. The solution is then picked up by the high pressure pump and pressurized to the desired level. The water then splits flow, as demanded by the technician.
The majority of the water flows to the bypass valve assembly, then back to the water box. The water demanded by the technician flows 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. When equipped with an engine exhaust diverter, the 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 plants, there must be none in preparing it to get the job done in the field. It is the purpose of this manual to help you properly understand, maintain and service your cleaning plant. Follow the directions carefully and you will be rewarded with years of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this equipment.
HydraMaster Corporation
Page 1-8 Boxxer 427
Machine Specifications
Frame: 26"W x 45"L x 41"H
Aluminum Cast with Baked-on Epoxy Finish
Weight: 807 lbs.
Engine: Vanguard 27HP Briggs and Stratton
Pressurized Oil System Spin-on Filter, Oil Cooler and Oil PSI Protection Switch
Ignition: Electronic, Keystart
Vacuum Blower: Dominator 4007, Tuthill/M-D Tri-Lobe,
Pump: Comet FW5530S, 55 GPM Hot Seals, 3000 PSI
Chemical System: Last-Step Chemical
Operating Pressure: Up to 1,200 PSI
Heating System: 1 Water to Water Copper Shell and Tube Heat Exchanger
1 Copper Cross Flow Heat Exchanger Blower/Engine Exhaust
Instruments: Water Pressure Gauge, Liquid Filled, 0-1500 PSI
Hour Meter, Machine Runtime Keyed Ignition, Start/Stop Chemical Flowmeter, Clear Acrylic, 0-10 GPH Vacuum Gauge Temperature Gauge
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Boxxer 427 Page 1-9
Recovery Tank: 70 Gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel
Replaceable Grip Rebuildable Solution Valve
High Pressure Hose: 4" High Temperature Lined/Vinyl Covered
Hose Rated to 2250 PSI
Vacuum Hose: 2" Reinforced, 12" Reinforced.
Standard Equipment: Machine Power Console
Full Instrumentation Tuthill/M-D Tri-Lobe Vacuum Blower BoxxerTM Water Heating Package Vacuum Recovery Tank Carpet Cleaning Wand Chemical Jug 150 ft, 2" Vacuum Hose 10 ft, 1-2" Wand Whip Line 150 ft, Super Flex Solution Line Battery Box Van Decal Package Van Installation Kit Operation Manual HydraMaster Jacket
HydraMaster Corporation
Page 1-10 Boxxer 427
Spare Parts Recommendation
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
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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 in-
stances, he either stocks or has access to parts through a regional service center. If further assistance is needed, contact the factory and coordinate your needs. If this becomes necessary, always indicate the method of shipment you desire, i.e. UPS, Blue Label, Air Freight, Air Express, etc.
HydraMaster Parts Dept. Phone .................. (425) 775-7276
HydraMaster Parts Dept. Toll Free Fax......... 1-800-426-4225
Spare Parts List (078-340)
PART NO DESCRIPTION QTY
010-054 Belt, A38 Pump 1 046-010 Diaphragm, Chemical Pump 1 049-002 Filter, Fuel 1 049-008 Filter, S/S Vacuum Pump, 22”1 049-014 Filter, Vanguard Oil 2 049-016 Filter, ¼” Replacement Y 1 049-023 Screen, Garden Hose 1
TBD Filter, Vanguard Air 1
049-118 Filter, 4” s/s 1 049-030 Filter Bag, 92+ Truck Mount 2 052-050 Quick Connect, 440 Male 3 052-051 Quick Connect, 440 Female 2 052-052 Quick Connect, 660 Male 1 052-053 Quick Connect, 660 Female 1
HydraMaster Corporation
Boxxer 427 Page 1-11
Spare Parts List (078-340)
PART NO DESCRIPTION QTY
056-001 Fuse, 10 amp 2
056-008 Fuse, 15 amp 2 056-010 Fuse, 25 amp 1 074-007 Gauge, Hi PSI (0-1500) 1 074-032 Meter, Chemical Flow 1
TBD Kit, Seal & Spring Hi PSI 1 TBD Kit, Comet Seal 1
106-016 Plug, Vanguard Spark 2 106-045 50 Series Element 8 157-080 Switch, s/s Float 1 157-040 Rocker 157-022 Switch, Relay 2 169-017 Valve, 3-way Chemical 1 169-022 Valve, 1½” Full Port 1 169-155 Check Valve, Last-Step Chemical 2 169-160 Valve, 2-way Chemical Metering 1 180-004 Orifice, Primary 1
NOTE:
Engine Oil: 30 weight motor oil with a minimum standard of SE, SF, SG. Blower OIl: 40 weight non detergent Pump Oil: 40 weight non-detergent
HydraMaster Corporation
Page 1-12 Boxxer 427
Responsibilities
he Purchaser’s responsibilities are:
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Prior to arrival of unit, install s” exterior plywood flooring in the vehicle and cover it with artificial turf or apply a spray-on coating such as Rhino-lining
!
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.)
To purchase heavy duty 24- 60 amp hour battery and have the battery ‘slow’ charge if new.
TM
to the van floor.
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CAUTION
If the battery is not fully charged, damage can occur to the engine charging regulator.
Reading of owner’s manual: It is the purchaser’s responsibility to read the unit operation manual and to familiarize himself with the information contained therein.
Special attention should be paid to all Cautions and Warnings.
The Sales Representative’s responsibilities are:
ACCEPTANCE OF SHIPMENT:
1. If the unit shows any outward signs of damage, do not sign the delivery receipt until you have closely inspected the unit and noted any damage on the delivery receipt.
2. The salesman from whom you purchased your unit is responsible for super vising the correct installation of the unit in your vehicle and thoroughly training you in its operation, maintenance and precautions.
HydraMaster Corporation
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.
Starting the unit to check the engine and see that all systems function normally.
Checking all hoses, wands, etc. for correct operation.
TRAINING:
A thorough review of the operation manual with purchaser.
Instruction and familiarization in:
How to correctly start up and shut down the unit.
How to correctly clean with the unit.
Where and how often to check and change component oil levels.
How the unit’s systems work.
How to troubleshoot the unit.
How to do basic repairs.
Safety precautions and their importance.
Freezing damage and how to avoid it.
Hard water damage and how to avoid it.
A thorough review of the unit warranty and warranty procedures.
A thorough review of hard water precautions and warnings.
How to determine hard water areas.
Use of water softening systems.
HydraMaster Corporation
Page 1-14 Boxxer 427
Vehicle Preparation
hen selecting a truck, remember the preferable vehicle for a Boxxer 427
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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.
installation is a cargo van with a heavy-duty suspension package and a half ton
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CAUTION
Be cautious when drilling any holes through the van floor. Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit. (See Product Support Bulletins 92101, 94062, and 94063 at the end of this manual.)
This provides ‘metal to cushion’ mounting rather than ‘metal to metal’ and makes for an atractive van interior. It is highly recommended to install roof vents in vehicles operated in hot weather locations. Roof vent positions are shown in Figure 1-1.
Figure 1-1 Roof Vent
HydraMaster Corporation
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. 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.
Figure 1-3 Recommended Placement
HydraMaster Corporation
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. SECURE IT!
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WARNING
It is recommended by the manufacturer that the exhaust from the front of the 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.
The manufacturer also recommends the installation of aluminum vents in the truck roof to allow heat to escape.
!
WARNING
Never operate this machine with a portable gas can inside the truck. Doing so increases the risk of a fire or explosion.
Mount a fire extinguisher just inside the rear or side door for emergencies.
HydraMaster Corporation
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.
HydraMaster Corporation
Page 1-18 Boxxer 427
High Altitude Operation
Preparation
o have your machine run at it’s peak performance; you may have to make adjust
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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. The higher the elevation, the less air is provided to the fuel mixture. This will make the engine run ‘rich’, and, in turn will result in the loss of power, excessive heat in the exhaust, and carbon buildup in the exhaust and heat exchanger system. The jet sizes vary per engine and elevation. Consult HydraMaster to obtain proper jet size.
The second area that may need adjustment is the heat control system. The heat control system is also optimized to 0-3,000 feet. At higher altitudes the boiling point of water is lowered. In turn, this can cause the water box to boil and the high pressure pump to cavitate. The heat control system settings will have to be adjusted to compensate for the elevation. These settings will vary according to elevation. Contact HydraMaster to obtain the recommended settings.
HydraMaster Corporation
Boxxer 427 Page 1-19
Local Water Precautions
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
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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.
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” (3.5 grains or more per gallon) be fitted with a water softening system or a properly installed magnetic-type de-scaler must be used and maintained. Periodic de-scaling 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 de-scalers or softeners may require addi­tional periodic use of de-scaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all areas be fitted with a water softening system for improved operation and reliability.
HydraMaster has included five hard water test strips with your machine. These can be used to test the water in your immediate and surrounding areas as they can vary greatly. Assume all water obtained from wells is hard.
!
CAUTION
Failure to take appropriate measures to prevent scale build up can result in system failure and loss of warranty on affected parts.
HydraMaster Corporation
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. The manufacturer strongly urges the use of water softener units in areas exceeding 32 grains per gallon. Failure to use a water softener in these areas will invalidate the machine’s warranty. Using a hard water area map as a reference, determine the quality of water in your area and take action immediately, if necessary.
Reports from several of our machine users commending the results of the use of water softeners in conjunction with their machines prompts us to recommend the procedure to everyone in a “hard water” area.
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 effi­ciency. 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 change 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 per 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 changed every 6 working days for maximum softening.
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.
HydraMaster Corporation
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