HYDRAMASTER BOXXER H2O User Manual

11015 47th Avenue W, Mukilteo, WA 98275

Boxxer H2O

Machine Serial Number________________________

Copyright© 2012

HYDRAMASTER© Corporation

Mukilteo, Washington

MAN-45052 Rev. 1

(182-136)

No part of this manual may be reproduced or used in any form or by any means (i.e. graphic,

electronic, photocopying or electronic retrieval systems) without the express written permission of the

HYDRAMASTER© Corporation. All rights reserved.

Revised May 25, 2012

Boxxer H2O

Boxxer H2O Owner’s Manual

HydraMaster Corporation

Boxxer H2O

Table of Contents

T able of Contents
List of Figures
Quick Reference

GENERAL INFORMATION......................................................................... Section 1

T elephone Numbers........................................................................... 1-2

Precautions....................................................................................... 1-3

Responsibilities..................................................................................1-5

Vehicle Prep aration............................................................................1-7

High Altitude Operation Preparation ...................................................1-11

Local Water Precautions ....................................................................1-12

MACHINE SPECIFICATIONS ..................................................................... Section 2

Machine Layout ................................................................................. 2-2

OPERATING INSTRUCTIONS ................................................................... Section 3

MACHINE MAINTENANCE ........................................................................ Section 4

Maintenance Log

MACHINE ASSEMBLIES AND PARTS LIST ............................................. Section 5

VACUUM SYSTEM ..................................................................................... Section 6

V acuum System Troubleshooting....................................................... 6-2

Miscellaneous Troubleshooting.......................................................... 6-3

Blower Manual

ELECTRICAL SYSTEM ............................................................................. Section 7

Wiring Diagrams ............................................................................... 7-3

Electrical Troubleshooting.................................................................. 7-5

ENGINE TROUBLESHOOTING................................................................. Section 8

HOW TO ORDER PARTS........................................................................... Section 9

WARRANTY INFORMA TION...................................................................... Section 10

Golden Guarantee®

Boxxer H2O Owner’s Manual

Boxxer H2O

List of Figures

Fig. 1-1 Roof Vents............................................................................ 1-7

Fig. 1-2 Recommended Placement ................................................... 1-8

Fig. 1-3 Installation Using T ie-down Cleats......................................... 1-9

Machine Assemblies and Part s List s ................................................. 5-1

Fig. 5-1 Machine Assembly - Front View - Left Side........................... 5-1

Fig. 5-2 Machine Assembly - Front View - Right Side......................... 5-2

Fig. 5-3 Frame Assembly - Front View - Left Side.............................. 5-3

Fig. 5-4 Frame Assembly - Front View - Right Side............................ 5-4

Fig. 5-5 Engine Assembly.................................................................. 5-6

Fig. 5-6 Blower Assembly .................................................................. 5-8

Fig. 5-7 Dash Assembly..................................................................... 5-10

Fig. 5-8 Exhaust Assembly ................................................................ 5-12

Fig. 5-9 Machine Left Side Cover Assembly ...................................... 5-14

Fig. 5-10 Machine Right Side Cover Assembly .................................... 5-15

Fig. 5-11 100 Gallon Universal Recovery T ank Assembly ..................... 5-16

Fig. 5-12 100 Gallon Universal Recovery T ank Cover Assembly ........... 5-19

Fig. 5-13 Vacuum Relief V alve Assembly ............................................. 5-20

Fig. 5-14 Dura-Flow APO Pump Assembly .......................................... 5-21

Fig. 7-1 Wiring Schematic .................................................................. 7-3

Fig. 7-2 Wiring Diagram . ................................................................... 7-4

Boxxer H2O Owner’s Manual

HydraMaster Corporation

Fuel Pump Assembly
B-4627 Rev -

Boxxer H2O

Quick Refer ence

Boxxer H2O Owner’s Manual

Boxxer H2O

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Boxxer H2O Owner’s Manual

HydraMaster Corporation

Boxxer H2O

General Information

The HydraMaster Boxxer H20 is a purpose designed machine to accommodate the needs
of the Water Restoration Contractor who is extracting water and not cleaning carpet. The
basis of the machine is a 27 HP Liquid Cooled V Twin engine that is directly coupled via
the patented BUCS coupling system to a T uthill 4007 Dominator blower. This combination
produces over 400 CFM of air flow, more than enough to extract water with one or two
wands.

In addition to this high performance Power Pack, the Boxxer H20 comes with a 100 gallon
recovery tank. The reliable Dura-Flo Automatic Pump Out is an option which allows you
to extract water without the need to shut down and empty the recovered water.

In addition to the obvious performance aspects of this machine, it was designed to deliver
maximum reliability and to be easily serviced. All the major component s have been proven
in other HydraMaster Truckmounts and this new machine was put together with an eye
towards simple, quick maintenance. All service point s are conveniently located so routine
maintenance takes only a few minutes to perform.

As with any machine, it is important to use the Boxxer H2O correctly. Operating the ma­chine is simple; just start the engine with the vacuum hoses disconnected, let it warm up
for two or three minutes, advance the throttle to the maximum operating position, connect
the vacuum hoses and you are ready to extract water. We strongly suggest that the op­erator of the machine be well acquainted with the IICRC guidelines for Flood Extraction
and with the various methods of carpet drying that are currently being used. It is also
recommended that the machine operator be familiar with the local municipality’s require­ments for the proper disposal of waste water. Typically waste water is to be deposited in
the city sewer system and never in a gutter or storm drain where it would eventually find
it’s way into a stream, river, lake, ocean or public water supply system.

Page 1-1: General Information

Boxxer H2O

The manufacturer uses this symbol throughout the manual to
warn of possible injury or death.

This symbol is used to warn of possible equipment damage.

This symbol is used to warn of regulatory or legal issues.

Monday - Friday [phone] Parts

8:00 am to 5:00 pm [phone] Service

PACIFIC STANDARD TIME [phone] Parts / Service FAX

Page 1-2: General Information

Hours Telephone Numbers

HydraMaster Corporation

Boxxer H2O

Precautions

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 SURF ACES: 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 blower, 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.

Page 1-3: General Information

Boxxer H2O

TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operating.
Toxic fumes may accumulate inside a stationary vehicle.

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 fire or explosion.

TRANSPORTA TION 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.

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.)

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 and vacuum blower.

The machine cannot be run in the IDLE position for carpet or floor extraction. This will void
the warranty.

EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or wood prod­ucts) to come in contact with the exhaust system.

Page 1-4: General Information

HydraMaster Corporation

Boxxer H2O

Responsibilities

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.)

T o purchase heavy duty 24- 60 amp hour battery and have the battery ‘slow’ charge if new .

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 opera-

tion 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
supervising the correct installation of the unit in your vehicle and thor­oughly training you in its operation, maintenance and precautions.

CORRECT INSTALLATION INCLUDES:

• Vehicle of proper load carrying capacity (recommendation: 3/4 ton).

• Installation of through-floor fittings for gasoline fuel lines.

Page 1-5: General Information

Boxxer H2O

• 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 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 recover 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.

• A thorough review of the unit warranty and warranty procedures.

.

Page 1-6: General Information

HydraMaster Corporation

Boxxer H2O

Vehicle Preparation

When selecting a truck, remember the preferable vehicle for a Boxxer H2O installation is a
cargo van with a heavy-duty suspension package and a 3/4 capacity. A 3/4 ton or larger
capacity van, with a 2,400 pound payload capacity, is required.

TRUCK PREP ARATION
The manufacturer recommends the installation of a spray-on bed liner in the vehicle prior
to installation of machine.

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
attractive 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 Vents

Page 1-7: General Information

Boxxer H2O

PLACEMENT OF UNIT IN VEHICLE
There are two recommended unit placements (shown in Figure 1-2):

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.

Figure 1-2 Recommended Placement

Page 1-8: General Information

HydraMaster Corporation

Boxxer H2O

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 stop or crash 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 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.

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.

Page 1-9: General Information

Boxxer H2O

Do not use a portable propane tank inside of the truck or van. Doing so may
increase risk of fire or explosion.

Transportation in a vehicle of any vented fuel cont ainer that presently holds
or has ever held a flammable liquid is strictly forbidden by HydraMaster Cor­poration and by federal and state regulation.

The engine exhaust from this product contains chemicals known to the St ate
of California to cause cancer, birth defects or other reproductive harm.

Page 1-10: General Information

HydraMaster Corporation

Boxxer H2O

High Altitude Operation

Preparation

Although this unit has been factory adjusted, it may require additional adjustments
to achieve optimum performance, for instance higher altitudes may require carburetor
adjustment. When required, consult an authorized representative. 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 system. The jet
sizes vary per engine and elevation. Consult HydraMaster to obtain proper jet size.

Page 1-11: General Information

Boxxer H2O

Local Water Precautions

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 extracted water recovered into your unit’s vacuum tank must be processed before

being safe for streams, rivers and reservoirs.

IN ACCORDANCE WITH THE EPA, ST A TE AND LOCAL LA WS, DO NOT DISPOSE OF
WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.

In most cases, an acceptable method of waste water disposal is to discharge into a mu­nicipal sewage treatment system after first filtering out solid material such as carpet fiber.
Access to the sanitary system can be obtained through a toilet, laundry drain, RV dump,
etc. Permission should first 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 machine with an Automatic Pump-Out System. 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. Properly designed, they will continu­ously monitor the level of waste water and pump it out simultaneously to the cleaning
operation. The hidden benefit of this process is that the technician does not have to stop
his cleaning to empty the recovery tank.

HydraMaster produces an A.P.O. System available which can be ordered with new equip­ment or installed later.

The penalties for noncompliance can be serious. Always check local laws and regulations
to be sure you are in compliance.

Page 1-12: General Information

HydraMaster Corporation

Machine Specifications

Frame: Welded Steel
Weight: 572 lbs.
Engine: Vanguard 27HP Briggs and Stratton

Pressurized Oil System
Spin-on Filter and Oil Cooler

Ignition: Electronic, Keystart

Vacuum Blower: Dominator 4007, Tuthill/M-D Tri-Lobe,

Instruments: Hour Meter, Machine Runtime

Keyed Ignition, Start/Stop
Vacuum Gauge
APO Switch
Recovery Tank “Full” Light

Boxxer H2O

Recovery T ank: 100 Gallon Aluminum, Epoxy Finish

Cleaning Wand: Stainless Steel

Replaceable Grip

Vacuum Hose: 2" Reinforced, 1-1/2" Reinforced.

Standard Equipment: Machine Power Console

Full Instrumentation
Vacuum Recovery Tank
100 ft, 2" Vacuum Hose
10 ft, 1-1/2" Wand Whip Line
Battery Box
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket

Page 2-1: Machine Specifications

Boxxer H2O

Machine Layout

Throttle Control - Controls the speed of the engine.
Choke - Pull style cable for cold starts.
Ignition Switch - Main power control to the machine.
APO Switch - Activates/Deactivates Automatic Pump Out.
Vacuum Tank ‘Full’ Light - Lights up when vacuum tank is full.
Hour Meter - Displays total number of hours machine has been run during its lifetime.
Exhaust Outlet - Engine and blower exhaust outlet.
Lube Port - Allows blower to be lubricated.
Vacuum Gauge - Displays engine temperature and vacuum.

Page 2-2: Machine Specifications

HydraMaster Corporation

Perform daily and periodic maintenance as specified in this Owner’s Manual.

The machine cannot be run in the “IDLE” position for water recovery. This
will void the warranty.

Never run the machine on any speed other than full throttle during water
extraction. Extracting at any other speed will void the warranty.

Start Up

Boxxer H2O

Operating Instructions

Flood Extraction

1. Start the engine with the THROTTLE cable to the “IDLE” position.
Allow the machine to run in idle for 2 - 3 minutes to warm up.

2. Connect required length of hoses.

3. Connect wand or tool.

4. Pull the THROTTLE cable to the “HIGH” position.

5. If used, turn PUMP OUT switch to “ON” .

6. Commence water extraction.

Shut Down

1. Remove the vacuum hose.

2. At this time, the blower should be lubricated with an oil-based lubricant. See
the blower manufacturer’s manual or the maintenance section for lubrication
information.

3. Lower the engine RPMs to idle.

4. Turn the key off.

5. Drain the vacuum tank. The vacuum filter should be cleaned prior to mobiliza­tion of the van.

In accordance with the EPA, state and local laws, do not dispose of waste water
into gutters, storm drains, streams, reservoirs, etc.

6. Perform daily maintenance as prescribed in this manual.

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Boxxer H2O

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HydraMaster Corporation