HydraMaster Boxxer 421 Owner'S Manual Download Page 6

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Boxxer 421 Owner’s Manual

Boxxer 421

Machine Assemblies and Parts Lists .................................................

11-1

Fig. 11-7

Frame Assembly - Front View ........................................... 11-2

Fig. 11-8

Frame Assembly - Rear View - Left Side ........................... 11-3

Fig. 11-9

Frame Assembly - Rear View - Right Side ......................... 11-4

Fig. 11-10

70 Gallon Universal Recovery Tank Assembly .................... 11-7

Fig. 11-11

70 Gallon Universal Recovery Tank Cover Assembly .......... 11-10

Fig. 11-12

Dash Assembly ................................................................. 11-11

Fig. 11-13

Electrical Control Panel Assembly ..................................... 11-13

Fig. 11-14

Blower Heat Exchanger Assembly ..................................... 11-15

Fig. 11-15

Water Box Assembly ......................................................... 11-16

Fig. 11-16

Hydra Pump II Assembly .................................................... 11-18

Fig. 11-17

Chemical Pump Assembly ................................................. 11-20

Fig. 11-18

Fuel Pump Assembly ......................................................... 11-21

Fig. 11-19

Blower Assembly ............................................................... 11-22

Fig. 11-20

Vacuum Relief Valve (Collector Box) Assembly .................. 11-25

Fig. 11-21

Exhaust Assembly ............................................................. 11-26

Fig. 11-22

Diverter Valve Actuator Assembly ...................................... 11-28

Fig. 11-23

Hi PSI Manifold Assembly ................................................. 11-29

Fig. 11-24

Bypass Valve Assembly .................................................... 11-31

Fig. 11-25

Engine Assembly .............................................................. 11-33

Fig. 11-26

Briggs & Stratton Voltage Regulator Modification .............. 11-35

Fig. 11-27

Dura-Flow APO Pump Assembly ....................................... 11-36

Fig. 11-28

100 Gallon Universal Recovery Tank Assembly .................. 11-38

Fig. 11-29

100 Gallon Universal Recovery Tank Cover Assembly ........ 11-41

Summary of Contents for Boxxer 421

Page 1: ...his 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 Corporati...

Page 2: ...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 HighAltitude Operation...

Page 3: ...tion 4 Daily Weekly 4 1 Monthly Quarterly 500 Hours 4 2 De scaling 4 3 Machine Maintenance 4 4 Maintenance Log FREEZE GUARD Section 5 Vacuum Freeze Guard Procedure 5 1 Freeze Protection of Pump In Sys...

Page 4: ...Maintenance 9 2 Chemical Pump 9 3 Solution Flow Diagram 9 5 Chemical Flow Diagram 9 6 Exhaust Vacuum Coolant and APO Flow Diagram 9 7 Chemical Tank Troubleshooting 9 8 ENGINE TROUBLESHOOTING Section 1...

Page 5: ...2 Cleaning Stroke Procedure 2 3 Fig 4 1 Recirculation Fitting 4 3 Fig 5 1 Recirculation Fitting 5 1 Fig 6 1 Servicing the Valves 6 3 Fig 6 2 HydraPump IIAssembly 6 6 Fig 8 1 Wiring Schematic 8 2 Fig 8...

Page 6: ...15 Fig 11 15 Water BoxAssembly 11 16 Fig 11 16 Hydra Pump IIAssembly 11 18 Fig 11 17 Chemical Pump Assembly 11 20 Fig 11 18 Fuel Pump Assembly 11 21 Fig 11 19 BlowerAssembly 11 22 Fig 11 20 Vacuum Rel...

Page 7: ...1 42 Fig 11 31 85 Gallon Rotomolded Tank Assembly Front View 11 45 Fig 11 32 85 Gallon Rotomolded TankAssembly Rear View 11 46 Fig 11 33 85 RMT w Boxxer 421 Assembly Front View 11 49 Fig 11 34 85 RMT...

Page 8: ...Boxxer 421 Owner s Manual Boxxer 421 Recovery Tank Float Switch Top Float Shown B4624 Rev Fuel PumpAssembly B4627 Rev Quick Reference...

Page 9: ...or 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 T...

Page 10: ...he 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 Hours Telephone Numbers Monday Friday 4...

Page 11: ...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 becom...

Page 12: ...r repro ductive 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 PORTABLE PROPANE TANK Do not use a portabl...

Page 13: ...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 H...

Page 14: ...haust system The use of some chemicals through your mobile carpet cleaning plant can seri ously damage the internal plumbing high pressure pump chemical pump and heat exchangers These harmful chemical...

Page 15: ...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 dire...

Page 16: ...Ignition Electronic Keystart Vacuum Blower Dominator 4005 Tuthill M D Tri Lobe Pump HydraPump II 3 5 GPM Hot Seals 2500 PSI Chemical System Last Step Chemical Operating Pressure Up to 1 000 PSI Heatin...

Page 17: ...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 Va...

Page 18: ...tance 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 Par...

Page 19: ...106 016 Plug Vanguard Spark 2 106 045 Plug HD4 Coupling 1 OD x x LG EPDM 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 1 Full Port 1 1...

Page 20: ...wner 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...

Page 21: ...on 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 d...

Page 22: ...s 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...

Page 23: ...n 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 tr...

Page 24: ...udden 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 machine be vented d...

Page 25: ...Transportation in a vehicle of any vented fuel container that presently holds or has ever held a flammable liquid is strictly forbidden by HydraMaster Corpora tion and by federal and state regulation...

Page 26: ...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 s...

Page 27: ...e 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 i...

Page 28: ...Page 8 23 Electrical System Boxxer 421 Figure 1 4 Hard Water Map...

Page 29: ...aint oil and grease re movers with a high concentration of solvents PRECAUTIONS There are no short cuts to good carpet cleaning It requires time cleaning knowledge and the use of good chemicals Theref...

Page 30: ...irm pressure on the forward stroke to ensure a posi tive lock for the vacuum and minimize the hopping effect resulting on carpet that is not smooth During the forward and reverse strokes movement to t...

Page 31: ...Page 2 3 Cleaning and Chemicals Boxxer 421...

Page 32: ...n operating pressure of 200 PSI must be maintained NOTE Under exceptionally long periods of No Flow conditions the Over Temp light may come on momentarily This indicates that the high temp solenoid is...

Page 33: ...from the vacuum inlet c Then while spraying solution from the cleaning tool adjust the chemical flow by turning the chemical adjustment knob as necessary 12 Commence cleaning Upholstery Cleaning 1 St...

Page 34: ...s to flow through the flowmeter with the flow indicator reading maximum flow and the PRIME line pulsing turn the chemical selector valve to ON and place the chemical PRIME line back into the chemical...

Page 35: ...ter box can overflow 3 Remove the vacuum hose 4 At this time the blower should be lubricated with an oil based lubricant See Lubrication in the Blower Operation and Maintenance Manual included in Sect...

Page 36: ...e temperature control system The Boxxer 421 can run in two different modes Cleaning Mode To run the machine in Cleaning mode a Turn the pump and diverter switch to the ON position b Adjust thermostat...

Page 37: ...s in proper adjustment If the poppet does not seat in one or both directions the valve is out of adjustment Perform the following steps to adjust the diverter actuator shaft 3 The end of the actuator...

Page 38: ...e required to be furnished to HydraMaster before the warranty is honored It is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a mainten...

Page 39: ...system with 50 50 white vinegar solution Change engine oil every 50 hrs MONTHLY Change oil filter every other oil change Check engine air cleaner filter Clean as necessary Remove pressure bypass valv...

Page 40: ...an water through the flow meter after this procedure To de scale using the recirculation kit part no 078 058 start with an empty mix tank Fill a third of the mix tank with T M DeScaler Follow the reco...

Page 41: ...the machine and spot potential problems before they occur The following maintenance is recommended by the manufacturer at the frequency indicated AFTER EACH JOB Check recovery tank s s filter and fil...

Page 42: ...reinstall If the bag is torn replace it Empty chemical from chemical container Wash out thoroughly to remove any chemical build up Inspect chemical feed line strainer and use 50 white vinegar water so...

Page 43: ...garden hose quick connect see Fig 4 1 and this combination to the front of the machine Attach one section of female female solution hose to the outgoing solution fitting on the front of the machine a...

Page 44: ...to a sealable container so that it may be used again To do this spray water through the hoses and wand until all signs of antifreeze are gone One manufacturer of antifreeze cautions WHEN DISPOSING OF...

Page 45: ...Remove the garden hose adapter from the pump in pump hose and position the hose so it is pointing outside the van 3 Turn on the pump in pump and run for 1 2 minutes till all the water is purged from t...

Page 46: ...filter BLOWER check oil level DRIVE SYSTEM tighten screws BELTS PULLEYS check for wear HIGH PRESSURE LINES check for chafing NUTS BOLTS check tightness Y FILTER check and clean ORIFICE inspect VAC REL...

Page 47: ...t operate the pump if the crankcase has been contaminated with water Do not leave contaminated oil in the pump housing or leave the housing empty Remove contaminated oil as soon as it is discovered an...

Page 48: ...O ring under the plug for cuts or distortion Replace it if it is worn Lubricate new O rings before installing 3 Grasp the valve retainer by the tab at the top with needle nose pliers then remove the O...

Page 49: ...Pressure Manifold 1 Using an M6 allen wrench remove all eight of the socket head bolts 2 Rotate the crankshaft by hand to start separation of the manifold head from the crankshaft 3 Insert two flat h...

Page 50: ...wear and replace if necessary 4 Reinstall the low pressure seal into the seal retainers with the garter spring down 5 Reinstall the high pressure seal a Lubricate the seal chamber in the manifold b C...

Page 51: ...Manifold 1 Slip the seal retainer over the ceramic plungers with the holes to the top and bottom and forward 2 Turn the shaft by hand to line up the plungers so that the end plungers are parallel 3 L...

Page 52: ...HydraMaster Corporation Page 6 6 High Pressure Pump Boxxer 421 Figure 6 2 HydraPump II C5043 Rev...

Page 53: ...004 Plug 2 NPT Hex 1 6 052 086 Elbow 2 NPT Street 2 7 052 087 Elbow 2 NPT Street 1 8 143 141 Screw 4 20UNC x 2 Lg Whiz Lock 4 9 052 547 Nipple 2 NPT x w SAE 1 10 001 096 Adapter Chem Pump to Comet Pu...

Page 54: ...as necessary 1 6 Primary system control orifice has been exchanged with secondary hot water dump orifice Inspect and reverse as necessary 1 7 Primary orifice is worn Measure orifice size and replace...

Page 55: ...the water box If it is too high refer to Heating System section IV 4 2 There is an air leak between the water box outlet and the pump inlet Physically check all hoses and fittings for cuts breaks cra...

Page 56: ...e vacuum inlet on top of the machine is open To protect the vacuum blower from overloading and damaging itself there is a vacuum relief system installed on the vacuum tank When the vacuum tank inlet i...

Page 57: ...id VACUUM TANK FILTER BAGS HydraMaster filter bags are designed to trap lint sand and dirt that would normally collect at the bottom of your vacuum tank The use of these bags if emptied at the end of...

Page 58: ...ery tank drain valve is fully closed 2 2 Vacuum blower is turning too slowly Check engine RPM Adjust as necessary to 3000 RPM 2 3 The vacuum gauge is defective Test gauge and replace as necessary 3 0...

Page 59: ...water Remove recovery tank lid and inspect If full drain tank then inspect high level shutoff switch for proper operation Clean or replace switch as necessary 1 1 1 If foam is observed in recovery tan...

Page 60: ......

Page 61: ...Blower and drive mounting bolts must be secured Drive belts and coupling guards must be in place Noise level may require ear protection Blower heat can cause burns if touched TUTHILL VACUUM BLOWER SY...

Page 62: ...le subject to accidental starting Cover external moving parts with adequate guards Disconnect power before doing any work and avoid bypassing or rendering inoperative any safety or protective devices...

Page 63: ...e have tried to make these instructions as straightforward as possible We realize getting any new piece of equipment up and running in as little time as possible is imperative to production WARNING Se...

Page 64: ...l running speed and discharge temperature which must not be exceeded These limits are shown on the Specification Sheet Maximum Operating Limits on page 10 WARNING Keep hands feet foreign objects and l...

Page 65: ...eration of the blower without proper lubrication will cause the blower to fail and void its warranty WARNING NEVER ATTEMPT TO CHANGE OIL WHILE THE BLOWER IS IN OPERATION Failure to heed this warning c...

Page 66: ...tension and tighten if necessary START UP CHECKLIST We recommend that these startup procedures be followed in sequence and checked v off in the boxes provided in any of the following cases After maint...

Page 67: ...turer s recommended pressure Excessive blower tem perature Too much or too little oil in gear reservoir Too low operating speed Clogged filter or silencer Excessive pressure differential Elevated inle...

Page 68: ...r Operate the blower under a slight load allowing the blower to heat within safe limits The heat generated by the blower will quickly evaporate residual moisture 2 For carpet cleaning applications aft...

Page 69: ...EAR END TOTAL TIP DOWEL TIP PORT 3003 005 008 13 20 003 005 08 13 009 012 23 30 006 012 15 30 002 005 05 13 004 007 10 18 4005 22L3 5837 4005 22L3 7964 4007 22R3 7963 4007 22R3 5874 Min Drive Cl 012 3...

Page 70: ...by use of synthetic lubricants not recommended by Tuthill Vacuum and Blower Systems Due to its superior viscosity index Tuthill PneuLube provides the greatest ambient temperature flexibility Contact...

Page 71: ...2 8 Timing Gear 2 28 Spacer 2 9 Dowel Pin 4 29 Screw Socket Head 3 10 Drive Cover 1 30 Timing Shims 1 11 Roller Bearing 1 31 Timing Gear Key 2 12 Bearing 1 44 Dowel Pin 1 13 Bearing 2 45 Slinger 1 15...

Page 72: ...itial date of service on the original equipment Uncontested means the blower will be warranted for all causes of failure on the first blower failure An advanced replacement will be provided After the...

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Page 75: ...talled check that it is properly charged before installation or damage to the charging regulator may occur The orange wire going from the engine starter solenoid to terminal 5 on the ignition switch i...

Page 76: ...Page 8 2 Electrical System Boxxer 421 Figure 8 1 Wiring Schematic D 5149 Rev H...

Page 77: ...Page 8 3 Electrical System Boxxer 421 Figure 8 2 Wiring Schematic D 5148 Rev H Sheet 2...

Page 78: ...Page 8 4 Electrical System Boxxer 421 Figure 8 3 Wiring Schematic D 5148 Rev H Sheet 3...

Page 79: ...Page 8 5 Electrical System Boxxer 421 Figure 8 4 Wiring Schematic D 5148 Rev H Sheet 4...

Page 80: ...er 1 2 The stator winding is bad Check for AC voltage at the regulator rectifier The stator should be pro ducing an AC voltage of around 25 to 40 volts Check your Owner s manual for the exact voltage...

Page 81: ...ng the machine The low water float switch in the water box is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply If for ex ample the water source at...

Page 82: ...ol adjust the chemical flow by turning the Chemical Adjustment Knob as necessary CHEMICAL SYSTEM MAINTENANCE The chemical lines may need to be flushed with vinegar periodically to prevent abnor mal ch...

Page 83: ...al Pump 1 4 000 105 071 Mid Plate Chemical Pump 1 5 000 046 010 Diaphragm Chemical Pump 1 6 000 097 055 O Ring Chemical Pump Midplate An Size 227 Viton 1 7 000 097 056 O Ring Check Valve Plug Chemical...

Page 84: ...Page 9 5 Water and Chemical Boxxer 421 Figure 9 2 Wiring Schematic D 5150 Rev Sheet 1 3...

Page 85: ...Page 9 6 Water and Chemical Boxxer 421 Figure 9 3 Wiring Schematic D 5150 Rev Sheet 2 3...

Page 86: ...Page 9 7 Water and Chemical Boxxer 421 Figure 9 4 Wiring Schematic D 5150 Rev Sheet 3 3...

Page 87: ...rn and shorted wires Repair or replace as necessary 1 4 2 If fuse is good inspect diverter relay and diverter switch If either is faulty replace 1 4 3 If switch and relay are good refer to qualified s...

Page 88: ...feed line in chemical jug is clogged Inspect and clean 1 5 Feed line from chemical jug is loose pinched or cut Inspect and repair 1 6 Three way prime valve is faulty Inspect valve for leaks between po...

Page 89: ...ace as necessary 3 0 Solution jug fills with water 3 1 Three way chemical valve is defective Check valve for leaks between ports Replace as necessary 3 2 Inlet check valve in chemical pump is faulty R...

Page 90: ...the starter solenoid If there is 12 volts at the battery connection and at the key switch connection with the key in the start position but there is not 12 volts on the starter connection of the solen...

Page 91: ...r to the Heating System section 1 0 2 5 The spark plugs are faulty Remove and inspect Replace as necessary 2 6 The engine ignition system is malfunctioning Refer to a qualified engine service technici...

Page 92: ...een 10 hg and 14 hg Too high or too low will cause severe damage to machine components 5 2 There is excessive load on the engine due to the blower to recovery tank hose becoming delaminated Remove and...

Page 93: ...y 7 3 Excessive fuel to carburetor Insure that fuel pump is proper PSI rating A fuel pump with a psi rating in excess of that of the pump supplied with the machine could overpower the inlet valve in t...

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Page 104: ...Page 11 1 Machine Assemblies and Parts List Boxxer 421 Machine Assemblies and Parts Lists...

Page 105: ...Page 11 2 Machine Assemblies and Parts List Boxxer 421 Figure 11 7 Frame Assembly Front View D 5057 Rev I HIDDEN HIDDEN HIDDEN BEHIND ITEM 5 12 41 11 15 11 37 38 55 14 54 28 30 11 30 11 35 30 43 36 23...

Page 106: ...Page 11 3 Machine Assemblies and Parts List Boxxer 421 Figure 11 8 Frame Assembly Rear View Left Side D 5057 Rev I 23 13 16 18 19 20 14 42 40 17 44 7...

Page 107: ...arts List Boxxer 421 Figure 11 9 Frame Assembly Rear View Right Side D 5057 Rev I 23 30 11 11 30 24 30 35 21 23 31 31 32 33 49 33 32 31 53 31 50 31 52 2 31 32 51 4 30 39 11 8 30 11 11 30 25 45 48 29 4...

Page 108: ...w 10 24UNC x 0 50 Lg Hex Head 13 12 000 143 542 Screw 1 4 28UNF x 0 50 Lg 2 13 000 174 007 Washer 1 2 Flat 2 14 000 174 008 Washer 5 8 Flat 3 15 000 174 030 Washer 5 8 I D x 7 8 O D x 0 010 Thk 1 16 0...

Page 109: ...ector Complete 1 43 000 033 050 Clamp 1 3 4 Cushion Loop 1 44 000 052 107 Insert 88 1 2 NPT x 1 2 Barb 1 45 000 143 094 1 Screw 3 8 16UNC x 0 75 Lg Socket Head 2 46 000 033 116 Clamp 1 1 2 Cushion Loo...

Page 110: ...421 Figure 11 10 70 Gallon Universal Recovery Tank Assembly D 6861 Rev B 5 24 25 19 17 18 9 9 1 30 4 3 21 23 20 12 11 8 31 32 33 6 13 10 34 29 25 16 15 27 26 7 3 HIDDEN HIDDEN 34 35 35 HIDDEN HIDDEN 2...

Page 111: ...rsal Recovery Tank 1 12 000 001 131 Adapter Tank To 2 5 Blower Hose Universal Recovery T 1 13 000 140 023 Rivet AB8 6AAluminum Pop 6 14 000 143 132 Screw 10 24UNC x 0 75 Lg Hex Head 2 15 000 143 051 S...

Page 112: ...er 3 8 Rubber Back 2 35 000 094 034 Nut 10 24UNC Nylock 2 36 000 106 049 Plug 1 NPTAllen Head 1 37 000 174 060 Washer 1 4 Flat Rubber Backed 4 38 000 143 002 Screw 1 4 20UNC x 1 00 Lg Hex Head 8 39 00...

Page 113: ...Single Vac 70 Gallon Universal Recovery Tank Wel 1 2 000 052 222 Elbow 2 Barb x 2 FPT 1 3 000 057 202 Gasket End Recovery Tank 2 4 000 057 203 Gasket Middle Recovery Tank 2 5 000 057 204 Gasket Middle...

Page 114: ...rts List Boxxer 421 Figure 11 12 Dash Assembly D 5044 Rev G 12 23 2 23 20 17 16 22 17 17 3 19 21 18 23 26 24 24 24 14 21 21 30 29 23 23 29 30 27 27 16 31 22 35 33 27 27 36 28 28 31 37 6 9 11 10 4 13 7...

Page 115: ...0 1500 PSI 1 12 000 052 088 Elbow 1 4 FPT x FPT 1 13 000 157 040 Switch 20 AMP Rocker 4 14 000 169 160 Valve Chemical Metering 1 15 000 074 030 Meter Chemical Flow Raw 1 16 000 052 084 Elbow 1 8 NPT S...

Page 116: ...Washer 5 8 I D x 7 8 O D x 0 010 Thk 1 33 000 174 034 Washer 0 688 I D x 1 50 O D x 0 078 Thk 1 34 000 174 062 Washer 1 2 I D x 3 4 O D x 0 010 Thk 1 35 000 174 038 Washer 7 16 S A E Flat 1 36 000 068...

Page 117: ...10 000 084 011 Light Red LED Indicator Mini 1 11 000 033 066 Clamp 3 4 Spring 2 12 000 033 023 Clamp 3 4 Nylon Hose 1 13 000 174 001 Washer 10 Flat 8 14 000 143 126 Screw 10 24UNC x 0 50 Lg Hex Head...

Page 118: ...dment Blower Heat Exchanger 1 3 000 100 117 Panel End Weldment Blower Heat Exchanger 1 4 000 068 398 Hose 3 x 3 Lg Blue Silicon 1 5 000 068 398 Hose 3 x 6 Lg Blue Silicon 1 6 000 052 528 Nipple 3 8 M...

Page 119: ...HydraMaster Corporation Page 11 16 Machine Assemblies and Parts List Boxxer 421 Figure 11 15 Water Box Assembly C 5045 Rev A 13 15 10 14 2 1 6 3 11 5 8 9 8 12 7 4...

Page 120: ...314 Screw 8 x 1 2 Lg Pan Head 6 7 000 052 105 Insert 68 3 8 NPT x 1 2 Barb 1 8 000 174 063 Washer 1 5 O D x 1 073 I D x 0 075 Thk 2 9 000 057 052 Gasket 1 Garden Hose 1 10 000 005 007 Float Water Box...

Page 121: ...HydraMaster Corporation Page 11 18 Machine Assemblies and Parts List Boxxer 421 Figure 11 16 Hydra Pump II Assembly C 5043 Rev A 17 17 17 13 15 4 11 12 5 10 16 6 9 14 7 6 1 8 2 3...

Page 122: ...52 086 Elbow 3 8 NPT Street 2 7 000 052 087 Elbow 1 2 NPT Street 1 8 000 143 141 Screw 1 4 20UNC x 1 2 Lg Whiz Lock 4 9 000 052 547 Nipple 1 2 NPT x 3 4 SAE 1 10 000 001 096 Adapter Chemical Pump To C...

Page 123: ...000 111 030 Body Chemical Pump 1 4 000 105 071 Mid Plate Chemical Pump 1 5 000 046 010 Diaphragm Chemical Pump 1 6 000 097 055 O Ring Chemical Pump Midplate AN Size 227 Viton 1 7 000 097 056 O Ring Ch...

Page 124: ...Page 11 21 Machine Assemblies and Parts List Boxxer 421 Figure 11 18 Fuel Pump Assembly B 4627 Rev...

Page 125: ...e 11 19 Blower Assembly D 5041 Rev F INSTALL INSIDE WATER BOX 8 29 28 29 33 32 12 11 14 14 9 27 13 5 31 30 33 32 20 25 35 26 11 6 11 26 12 40 43 40 37 38 22 19 16 15 15 19 15 41 39 39 44 15 11 35 34 4...

Page 126: ...3 000 052 293 Insert 23 1 8 NPT x 3 16 Barb 2 14 000 094 096 Nut 3 4 16 Brass Water Box 4 15 000 052 106 Insert 1 8 NPT x 5 32 Barb x 90 5 16 000 169 070 Valve Primary Vac Solenoid 2 17 000 143 048 Sc...

Page 127: ...l Thread 4 37 000 109 040 Pulley AK41 H 1 38 000 020 019 Bushing H x 7 8 Bore 1 39 000 143 001 Screw 1 4 20UNC x 0 75 Lg Hex Head 2 40 000 052 083 Elbow 3 8 NPT Street x 45 3 41 000 068 219 Hose Spitf...

Page 128: ...Spring Guide 1 4 000 105 337 Plate Vacuum Relief Valve Mounting 1 5 000 155 026 Spring Vacuum Relief 1 6 000 143 198 Screw 3 8 16UNC x 4 Lg Hex Head Full Thread 1 7 000 094 077 Nut 3 8 16UNC x 1 00 O...

Page 129: ...blies and Parts List Boxxer 421 Figure 11 21 Exhaust Assembly D 4884 Rev C 27 29 9 18 20 3 29 26 21 23 22 15 16 14 13 12 10 11 17 19 24 25 20 27 29 26 30 29 6 1 17 5 24 25 7 20 22 23 21 25 24 17 22 23...

Page 130: ...f Spring 1 13 000 174 001 Washer 10 Flat 2 14 000 143 132 Screw 10 24UNC x 0 75 Lg Hex Head 2 15 000 015 631 Bracket Air CylinderActuation 1 16 000 103 005 Pin Roll 0 125 x 0 500 Lg 1 17 000 057 146 G...

Page 131: ...mbly Parts List 2 3 4 1 4 6 8 5 1 7 1 000 169 169 Valve Air Cylinder 1 2 000 015 630 Bracket Air Cylinder Extension 1 3 000 094 092 Nut 7 16 20UNF Hex Jam 1 4 000 052 550 Elbow 1 8 NPT x 3 16 Barb 2 5...

Page 132: ...Page 11 29 Machine Assemblies and Parts List Boxxer 421 Figure 11 23 Hi PSI Manifold Assembly C 5123 Rev B 15 12 11 1 7 5 5 7 6 11 17 12 4 9 9 4 3 8 18 2 19 16 21 13 20 10 14 19...

Page 133: ...Wire x 1 00 Lg 2 8 000 106 008 Plug 3 8 NPTAllen Head 1 9 000 052 082 Elbow 1 4 NPT Street x 45 2 10 000 052 064 Bushing 1 2 NPT x 3 8 FPT 1 11 000 052 023 Tee 3 8 NPT Male Street 2 12 000 052 528 Ni...

Page 134: ...Page 11 31 Machine Assemblies and Parts List Boxxer 421 Figure 11 24 By Pass Valve Assembly D 5046 Rev C 14 12 9 10 4 3 8 5 2 7 6 11 17 16 15 2 13 1 18 19...

Page 135: ...015 515 Bracket By Pass Valve Mounting 1 7 000 052 142 Elbow 3 8 FPT x FPT 1 8 000 052 074 Nipple 3 8 NPT Hex 1 9 000 052 113 Cross 3 8 FPT 1 10 000 052 083 Elbow 3 8 NPT Street x 45 1 11 000 052 023...

Page 136: ...Page 11 33 Machine Assemblies and Parts List Boxxer 421 Figure 11 25 Engine Assembly D 5042 Rev A 8 3 7 7 6 8 7 7 5 4 10 11 1 12 2 HIDDEN HIDDEN 9 14 13 15...

Page 137: ...y 0 25 x 1 5 Lg 1 6 000 106 003 Plug 3 8 NPT Hex 1 7 000 143 185 Screw 8mm x 20mm Grade 8 8 Hex Head 4 8 000 057 082 Gasket Exhaust Manifold B S 21 HP 2 9 000 049 014 Filter 16HP Oil All B S 1 10 000...

Page 138: ...ts List Boxxer 421 Figure 11 26 Briggs and Stratton Voltage Regulator Modification B 3475 Rev 1 Briggs Stratton Voltage Regulator 1 2 000 178 026 Wire 16AWG Yellow 2 3 000 037 033 Butt Connector 22 Pi...

Page 139: ...raMaster Corporation Page 11 36 Machine Assemblies and Parts List Boxxer 421 Figure 11 27 Dura Flow APO Pump Assembly D 5654 Rev E 16 15 16 17 18 19 20 21 17 1 9 10 5 8 3 8 2 7 6 13 4 14 12 7 4 6 6 5...

Page 140: ...Flat 4 8 000 061 131 Knob Handle Rdm 2 9 000 052 723 Fitting 1 NPT Cam Lock Banjo 100F 1 10 000 052 724 Fitting 1 NPT Cam Lock Banjo 100B 1 11 000 157 022 Switch Relay 1 12 000 012 011 Block 6 Post 1...

Page 141: ...allon Universal Recovery Tank Assembly D 6918 Rev A 2 29 20 21 9 7 31 33 5 34 HIDDEN HIDDEN 19 16 HIDDEN HIDDEN 13 11 6 31 26 27 17 18 8 15 39 40 37 36 41 27 38 10 14 3 35 25 23 1 3 14 10 14 32 28 43...

Page 142: ...covery Tank 1 12 000 057 206 Gasket Adapter Universal Recovery Tank 2 13 000 140 023 Rivet AB8 6AAluminum Pop 6 14 000 143 126 Screw 10 24UNC x 0 50 Lg Hex Head 5 15 000 143 051 Screw 8 32UNC x 0 75 L...

Page 143: ...k 8 35 000 166 002 Tray Soap Jug Weldment 1 36 000 052 085 Elbow 1 4 NPT Street 1 37 000 052 090 Tee 1 4 NPT Branch M F F 1 38 000 169 082 Valve 12 Volt Solenoid 1200 PSI 1 39 000 052 071 Nipple 1 4 N...

Page 144: ...versal Recovery Tank Weldment 1 2 000 078 039 Vacuum Inlet StopperAssembly Recovery Tank 1 3 000 057 015 Gasket 1 1 2 Bulkhead Fitting 2 4 000 052 219 Adapter 2 NPT x 2 F Slip 2 5 000 143 539 Screw 6...

Page 145: ...ist Boxxer 421 Figure 11 30 70 Gallon Universal Recovery Tank For 85 RMT Assembly D 7157 Rev 5 21 22 19 17 18 9 9 1 27 4 3 20 12 11 8 28 29 30 6 13 10 31 26 22 16 15 24 23 7 3 HIDDEN HIDDEN 31 32 32 H...

Page 146: ...Universal Recovery Tank 1 12 000 001 131 Adapter Tank To 2 5 Blower Hose Universal Recovery T 1 13 000 140 023 Rivet AB8 6AAluminum Pop 6 14 000 143 132 Screw 10 24UNC x 0 75 Lg Hex Head 2 15 000 143...

Page 147: ...rew 1 4 20UNC x 1 00 Lg Hex Head 8 36 000 094 113 Nut 1 4 20UNC Neoprene Wellnut 4 37 000 174 036 Washer 10 Flat Rubber Backed 2 38 000 174 001 Washer 10 Flat 2 39 000 052 662 Nipple 3 8 NPT x 1 4 M S...

Page 148: ...Page 11 45 Machine Assemblies and Parts List Boxxer 421 Figure 11 31 85 Gallon Rotomolded Tank Assembly Front View D 5566 Rev B 33 3 19 29 11 12 13 14 34 37 21 22 36 27 17 28 35 1 38 6 2...

Page 149: ...aster Corporation Page 11 46 Machine Assemblies and Parts List Boxxer 421 Figure 11 32 85 Gallon Rotomolded Tank Assembly Rear View D 5566 Rev B 17 5 26 24 25 10 9 15 34 8 4 7 30 39 16 32 6 23 18 31 2...

Page 150: ...6UNC x 4 Lg Hex Head Full Thread 6 12 000 174 005 Washer 3 8 Flat 6 13 600 011 003 Tie Down Cleat Washer 6 14 000 094 015 Nut 3 8 16UNC Hex 2 Way Locking 6 15 000 052 253 Elbow 1 8 NPT x 1 4 Barb 2 16...

Page 151: ...NPT x 1 2 NPT 1 32 000 052 052 Quick Connect 660 Male w Viton Standard 1 33 000 052 326 Nipple 3 4 NPT Close 1 34 000 055 169 Frame Rotomolded Fresh Water Tank Boxxer 1 35 000 052 726 Elbow 3 4 Street...

Page 152: ...blies and Parts List Boxxer 421 Figure 11 33 85 RMT w Boxxer 421 Assembly Front View D 7158 Rev 6 14 14 25 28 17 18 19 18 4 21 20 HIDDEN 13 16 10 11 22 10 HIDDEN 5 HIDDEN 9 HIDDEN 12 29 24 26 27 23 8...

Page 153: ...HydraMaster Corporation Page 11 50 Machine Assemblies and Parts List Boxxer 421 Figure 11 34 85 RMT w Boxxer 421 Assembly Rear View D 7158 Rev...

Page 154: ...p Garden Hose 1 12 000 052 281 Nipple 3 4 NPT x 3 4 Male Garden Hose 1 13 000 169 022 Valve 1 1 2 Full Port Ball 1 14 000 033 063 Clamp 1 1 2 T Bolt 2 15 000 068 135 Hose 1 5 I D Red Stripe 1 16 000 0...

Page 155: ...HydraMaster Corporation Page 11 52 Machine Assemblies and Parts List Boxxer 421 Figure 11 35 Chemical Jug Tray Assembly C 4945 Rev C 9 2 5 10 1 4 5 10 3 8 6 4 7 19 10 12 14 11 13 15 7 17 18 16...

Page 156: ...0 052 226 Insert 1 1 2 NPT x 1 1 2 Barb Grey 2 8 000 052 182 Nipple 1 1 2 NPT Close Galvanized 1 9 000 159 016 Jug 5 Gallon Plastic Chemical Standard 1 10 000 174 003 Washer 1 4 Flat 4 11 000 015 720...

Page 157: ...55 11 2 in 3 16 Plastic Vac Tee 052 155 3 16 Plastic Vac Tee 052 155 13 4 in 3 16 Plastic Vac Tee 052 155 Upr Primary Vac Solenoid Valve 24 in 169 070 3 16 Plastic Vac Tee 052 155 Upr Primary Vac Sole...

Page 158: ...nifold 090 010 Hi PSI Manifold OUT 301 2 in w JIC ends 090 008 068 644 3 8 Teflon After Burner 038 054 Hi PSI Manifold 090 010 491 2 in w JIC ends 068 645 3 16 Teflon Pressure Gauge 3 8 Female Cross 0...

Page 159: ...Page 12 1 Chemical Wand Parts Boxxer 421 Cleaning Wand Parts Figure 12 1 HydraHoe Two Jet Cleaning Wand Assembly...

Page 160: ...reet 1 5 052 072 Nipple Brass Close 1 6 052 050 Quick Connect 440 Male with Viton 1 7 169 074 Valve High PSI Brass 1 8 052 152 Compression Male HydraHoe Fitting 2 9 168 001 Tube HydraHoe Solution OD s...

Page 161: ...urs on the Unit D Unit Serial Number E Description of Malfunction 3 Once it has been determined which parts are needed to correct the problem with your machine make arrangements with your distributor...

Page 162: ...omer Service Department 425 775 7275 8 a m to 5 p m Monday through Friday PST We shall always endeavor to be fair in our evaluation of your warranty claim and shall provide you with a complete analysi...

Page 163: ...y as recommended in blower manual Failure to properly maintain blower safeguard systems such as waste tank filter screen vacuum safety relief valve and waste tank automatic shut off system Allowing fo...

Page 164: ...from engine and blower exhaust Damage to hoses from being run over by vehicles Kinking or cracking from failure to store or unroll hoses correctly Normal wear and tear from everyday use CLEANING WAND...

Page 165: ...ntaining current account status An invoice will be sent to the distributor for the amount of the parts sent The customer s faulty parts must be returned for evaluation prior to the expiration of the t...

Page 166: ......

Page 167: ...s have changed the shape of steam cleaning Our hoses and tanks are of the finest quality construction SafeClean Detergents have been specially prepared not only to give you exceptional cleaning but al...

Page 168: ...uckmount machines Accessories Hose reels Chemicals Please contact your local distributor for more product and pricing information For a distributor near you please visit www hydramaster com or call 1...

Page 169: ...xx Premium Heat Exchanger Systems Maxx 450 700 070 045 20 595 00 Maxx 450 Diesel 700 070 044 21 695 00 Maxx 470 700 070 047 21 695 00 CDS Overdrive Van Powered Systems Standard colors are HydraMaster...

Page 170: ...oe Carpet Cleaning Wand 495 00 000 163 104 2 S Bend 2 Jet Wand 525 00 100 011 106 1 S Bend 2 Jet Wand 299 00 000 163 008 Utility Cleaning Tool UT 40 379 95 000 163 010 DriMaster Upholstery Tool HydraM...

Page 171: ...m Interior Package Includes DFresh WaterTank DTwo Bin Back Door Shelf Assembly DCustom Three Tier Shelf DWand Storage Rack DStair Tool Holder DFurniture Tab Snap Block Holder and DRake Storage Clips H...

Page 172: ...0 1999 2003 Ford Diesel needs 2 369 95 000 078 425 2004 2007 Ford 299 95 000 078 042 2004 Sprinter Diesel 2004 2006 Dodge 222 95 000 078 407 2003 2007 Chev 2003 2007Astro w 1 neck 299 95 000 078 181 1...

Page 173: ...8 95 000 068 331 Gray 1 Diameter 25 Feet 53 95 000 068 036 Gray 1 Diameter 50 Feet 89 95 000 068 047 Orange 1 Diameter 50 Feet 89 95 000 068 316 Blue 1 Diameter 50 Feet 89 95 000 068 048 Orange 2 Diam...

Page 174: ...03 19 000 163 512 E2336 300S 300 34 38 36 1 316 49 000 163 513 E1244 200S 200 23 46 44 1 316 49 000 163 514 E1544 250S 250 26 46 44 1 327 57 000 163 515 E1844 300S 300 29 46 44 1 343 09 Live Hub Reels...

Page 175: ...2 143 17 Storage Reels for Solution or Garden Hoses Part No Model No Capacity Diameter Width Retail Price 000 163 560 605 18S Storage 300 x 1 4 18 5 118 42 000 163 561 605 18L 02 Live 1 4 300 x 1 4 18...

Page 176: ...1 33 Carpet Cleaning Detergent 800 200 B 4 x 1 gal 33 00 Rinse Out 950 140 B 4 x 1 gal 17 25 Neutralizing Fiber Rinse 950 140 E 55 gal 590 91 ClearWater Rinse 800 250 A 12 x 32 oz 8 83 Low Residue Fib...

Page 177: ...ackage Price Q C T 950 155 B 4 x 1 gal 18 75 Quarry and Ceramic Tile Cleaner Hydra Solv 950 165 B 4 x 1 gal 16 40 Hard Surface Degreaser Specialty Products Retail Unit Product Part Number Package Pric...

Page 178: ...Breeze Upholstery Products Retail Unit Product Part Number Package Price FabricMaster HEAVY DUTY 950 230 B 4 x 1 gal 17 80 Upholstery Pre Spray FabricMaster FINE FABRIC 950 220 B 4 x 1 gal 18 00 Upho...

Page 179: ...lb 8 37 Neutral Spotter 950 309 12 x 1 pt 6 26 SpotMaster GEL 950 250 A 12 x 1 qt 11 00 Paint Oil Ink Grease Spotter SpotMaster CSR 950 255 A 12 x 2 lbs 16 92 Coffee Stain Remover SpotMaster PRO 950...

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