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
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 1-2Boxxer 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.
HoursTelephone 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
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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 1-4Boxxer 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.
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CAUTION
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or
wood products) to come in contact with the exhaust system.
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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 1-6Boxxer 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.
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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 1-8Boxxer 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
Hour Meter, Machine Runtime
Keyed Ignition, Start/Stop
Chemical Flowmeter, Clear Acrylic, 0-10 GPH
Vacuum Gauge
Temperature Gauge
HydraMaster Corporation
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 1-10Boxxer 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
056-008Fuse, 15 amp2
056-010Fuse, 25 amp1
074-007Gauge, Hi PSI (0-1500)1
074-032Meter, Chemical Flow1
TBDKit, Seal & Spring Hi PSI1
TBDKit, Comet Seal1
106-016Plug, Vanguard Spark2
106-04550 Series Element8
157-080Switch, s/s Float1
157-040Rocker
157-022Switch, Relay2
169-017Valve, 3-way Chemical1
169-022Valve, 1½” Full Port1
169-155Check Valve, Last-Step Chemical2
169-160Valve, 2-way Chemical Metering1
180-004Orifice, Primary1
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 1-12Boxxer 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
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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 1-14Boxxer 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 1-16Boxxer 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 awayfrom 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 1-18Boxxer 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 1-20Boxxer 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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