HydraMaster Boxxer 427 Manual Download Page 1

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HYDRAMASTER

Corporation

11015 47th Avenue W, Mukilteo, WA 98275

Machine Serial Number________________________

HYDRAMASTER©

Corporation

Mukilteo, Washington

MAN-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

reserved.

Revised August 21, 2007

Summary of Contents for Boxxer 427

Page 1: ...2007 HYDRAMASTER Corporation Mukilteo Washington MAN 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 sy...

Page 2: ...Boxxer 427 HydraMaster Corporation...

Page 3: ...peration 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 Precau...

Page 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 Coolan...

Page 5: ...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 scalin...

Page 6: ...mbly 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 Asse...

Page 7: ...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...

Page 8: ...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 S...

Page 9: ...Boxxer 427 HydraMaster Corporation Quick Reference...

Page 10: ...Boxxer 427 HydraMaster Corporation Fuel Pump Assembly B4627 Rev...

Page 11: ...wn 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 va...

Page 12: ...hroughout the manual to warn of possible injury or death 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 72...

Page 13: ...and 94063 at the end of the manual ENGINE COOLING Units employing internal combustion engines must not be enclosed within a van with doors and windows closed Excessive temperatures within the engine...

Page 14: ...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 softe...

Page 15: ...es will be directed away from the job site Do not park where exhaust fumes can enter a building through open doors windows air condition ing units or kitchen fans TOXIC FUMES Do not occupy the vehicle...

Page 16: ...Corporation and by federal and state regula tion The use of some chemicals through your mobile carpet cleaning plant can seri ously damage the internal plumbing high pressure pump chemical pump and h...

Page 17: ...er 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 di...

Page 18: ...c 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 t...

Page 19: ...vered 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 Vacu...

Page 20: ...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...

Page 21: ...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 1 Full Port...

Page 22: ...attery 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 himsel...

Page 23: ...ll 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 st...

Page 24: ...ation 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 va...

Page 25: ...ion 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...

Page 26: ...p 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 truc...

Page 27: ...tion 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 The engine...

Page 28: ...el 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...

Page 29: ...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 ins...

Page 30: ...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 lif...

Page 31: ...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 yo...

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Page 33: ...Boxxer 427 Page 1 23 HydraMaster Corporation Figure 1 5 Hard Water Map...

Page 34: ...HydraMaster Corporation Boxxer 427 Page 1 25 Machine Assemblies and Parts Lists Figure 1 6 Machine Assembly Front View Left Side D 5570 Rev B 2 5 3 4 7 7 1 8 8...

Page 35: ...HydraMaster Corporation Page 1 26 Boxxer 427 Figure 1 7 Machine Assembly Front View Right Side D 5570 Rev B 6...

Page 36: ...HydraMaster Corporation Boxxer 427 Page 1 27 Figure 1 8 Machine Assembly Rear View Right Side D 5570 Rev B...

Page 37: ...610 050 033 Assembly Top Cover Boxxer 427 Fig 1 31 1 3 000 041 424 Cover Lower Left Side Rear Boxxer 427 1 4 000 041 426 Cover Lower Left Side Front Boxxer 427 1 5 610 050 033 Assembly Machine Left S...

Page 38: ...HydraMaster Corporation Boxxer 427 Page 1 29 Figure 1 9 Frame Assembly Front View Left Side D 5571 Rev D...

Page 39: ...HydraMaster Corporation Page 1 30 Boxxer 427 Figure 1 10 Frame Assembly Front View Right Side D 5571 Rev D 6 15 8 19 11 10 9 11 10 ITEM 3 SUPRESSED IN THIS VIEW HIDDEN 12 16 2 22...

Page 40: ...HydraMaster Corporation Boxxer 427 Page 1 31 Figure 1 11 Frame Assembly Rear View Left Side D 5571 Rev D 16 17 18 19 21 20 14 13 14 13 4 15 17 18 19 3 2 5 1 16 16 15 12 12...

Page 41: ...lower Heat Exchanger Fig 1 30 1 8 610 003 033 Assembly Exhaust Boxxer 427 Fig 1 14 1 9 000 093 092 Silencer Boxxer 427 Weldment 1 10 000 143 002 Screw 1 4 20UNC x 1 00 Lg Hex Head 4 11 000 174 019 Was...

Page 42: ...HydraMaster Corporation Boxxer 427 Page 1 33 Figure 1 12 Engine Assembly Rear View D 5572 Rev G 2 20 12 8 9 9 11 18 7 5 6 4 5 9 22 27 26 24 25 23 28 14 3 31 32 34 13 13 21 21 21 29 19 10 10 13 33...

Page 43: ...ly Parts List Item Part Number Description Qty 17 16 1 31 15 35 36 1 000 047 026 Engine Briggs Stratton 27HP 1 2 000 042 011 Housing Air Cleaner Daihatsu Engine 1 3 000 092 011 Mount Engine 27 B S Box...

Page 44: ...NPT Engine Oil Drain Adapter 1 17 000 068 746 Hose Engine Oil Drain Boxxer 427 1 18 000 174 019 Washer 1 4 Lock 2 19 000 143 569 Screw 6mm x 85mm Lg Hex Head 2 20 000 154 144 Spacer Air Cleaner Boxxe...

Page 45: ...rporation Page 1 36 Boxxer 427 Figure 1 14 Exhaust Assembly D 5580 Rev C 9 8 7 6 5 4 13 11 21 17 16 17 16 2 11 23 13 21 14 11 13 18 26 25 26 18 25 3 24 10 27 12 12 22 12 28 28 29 21 19 19 19 31 20 31...

Page 46: ...leville Diverter Valve 12 14 000 169 045 Valve Cast Exhaust Diverter 1 15 000 090 059 Manifold Boxxer 427 Engine Exhaust B S 27 Hp 1 16 000 057 177 Gasket Exhaust Donut 1 50 2 17 000 125 128 Tube 1 3...

Page 47: ...er 1 2 000 015 926 Bracket Air Cylinder Extension Welded Boxxer 427 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 5 000 015 750 Bracket Air Cylinder Mount Inner 1...

Page 48: ...73 Rev H Blower Assembly Parts List Item Part Number Description Qty 9 14 12 14 15 8 18 17 19 20 21 7 11 24 22 10 25 22 5 10 22 27 9 10 23 26 28 28 16 21 10 29 30 6 31 2 13 1 4 3 1 000 111 167 Blower...

Page 49: ...Screw 1 2 13UNC x 2 0 Lg Hex HD Grd 8 Bo 1 14 000 174 007 Washer 1 2 Flat 2 15 000 094 037 Nut 1 2 13UNC Hex 2 Way Locking Z P 1 16 000 015 897 Bracket Water Box Support 1 17 000 143 001 Screw 1 4 20...

Page 50: ...HydraMaster Corporation Boxxer 427 Page 1 41 Figure 1 17 Pump Assembly D 5574 Rev D 11 16 3 5 2 6 10 8 19 12 29 1 23 25 26 20 14 27 22 24 13 23 24 15 9 18 7 23 24 4 28 17 21...

Page 51: ...r 427 1 12 000 052 086 Elbow 3 8 NPT Street 1 13 000 052 128 Nipple 3 8 NPT x 3 8 Male Propane 1 14 000 052 517 Nipple 1 4 NPT Close 1 15 000 135 052 Regulator Hi PSI Snubber 1 16 000 052 527 Nipple 1...

Page 52: ...emical Pump 1 3 000 111 030 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 0...

Page 53: ...HydraMaster Corporation Page 1 44 Boxxer 427 Figure 1 19 Pump Mounting Bracket Assembly D 5766 Rev F 16 17 19 14 15 20 13 12 7 11 11 10 7 10 11 9 6 3 5 1 9 18 2 9 9 8 8 17 21 22 23 2 4...

Page 54: ...293 Insert 23 1 8 NPT x 3 16 Barb 3 11 000 143 047 Screw 6 32UNC x 7 8 Lg Pan Head Phillips 4 12 000 143 050 Screw 8 32UNC x 0 50 Lg Round Head Phillips 2 13 000 012 001 Block 4 Lead Electrical Termin...

Page 55: ...HydraMaster Corporation Page 1 46 Boxxer 427 Figure 1 20 Water Box Assembly D 5575 Rev H 2 10 19 10 22 23 20 22 23 12 9 5 10 16 14 8 10 11 13 21 21 26 17 17 3 7 27 24 4 19 9 6 5 18 5 25 1 16 15...

Page 56: ...Gasket 1 Garden Hose 1 12 000 005 007 Float Water Box 1 13 000 143 336 Screw 10 32UNF x 0 25 Lg Pan Head Phillips 1 14 000 052 099 Insert 26 1 8 NPT x 3 8 Barb 1 15 000 068 326 Hose 3 8 I D Clear w B...

Page 57: ...HydraMaster Corporation Page 1 48 Boxxer 427 Figure 1 21 Dash Upper Assembly Front View D 5576 Rev A 6 3 4 7 8 2 12 9 14 10 9 10 1 5 13...

Page 58: ...HydraMaster Corporation Boxxer 427 Page 1 49 Figure 1 22 Dash Upper Assembly Rear View D 5576 Rev A 11 9 8 15 16 5...

Page 59: ...2 Cable Choke 3 Foot 1 6 000 025 020 Cable Throttle Kohler 1 7 000 084 011 Light Red Led Indicator Mini 4 8 610 020 033 Assembly Dash Guage Panel Boxxer 427 Fig 1 23 1 9 000 174 001 Washer 10 Flat 18...

Page 60: ...HydraMaster Corporation Boxxer 427 Page 1 51 Figure 1 23 Dash Guage Panel Assembly D 5585 Rev C 16 17 18 1 13 8 7 19 3 2 2 6 5 4 14 1 22 23 21 15 10 10 13 20 3 20 11 12 21 11 12 2 8 7 10 9...

Page 61: ...Gauge Temperature 1 9 000 149 551 Thermostat Potentiometer Dual Controller 1 10 000 094 070 Nut 5mm Nylock 4 11 000 174 001 Washer 10 Flat 4 12 000 174 014 Washer 10 Lock 2 13 000 074 007 Gauge Pressu...

Page 62: ...HydraMaster Corporation Boxxer 427 Page 1 53 Figure 1 24 Dash Lower Assembly Front View D 5577 Rev E 4 18 13 15 9 2 9 22 24 1 17 11 21 5 16...

Page 63: ...sembly Rear View D 5577 Rev E Dash Lower Assembly Parts List Item Part Number Description Qty 8 19 10 12 6 8 6 7 18 14 22 23 25 30 31 32 3 26 27 28 29 21 30 16 20 15 1 000 100 143 Panel Lower Dash Box...

Page 64: ...000 052 105 Insert 68 3 8 NPT x 1 2 Barb 1 15 Fig 1 27 Assembly Hi PSI Manifold 1 16 Fig 1 26 Assembly By Pass Valve 1 17 000 169 064 Valve 3 8 NPT Full Port Ball 1 18 000 052 104 Insert 66 3 8 NPT x...

Page 65: ...HydraMaster Corporation Page 1 56 Boxxer 427 Figure 1 26 By Pass Valve Assembly C 5581 Rev C 5 1 6 8 2 4 9 12 13 13 10 11 5 7 14 9 3...

Page 66: ...Plug 3 8 NPT Allen Head 1 5 000 052 023 Tee 3 8 NPT Male Street 2 6 000 052 083 Elbow 3 8 NPT Street x 45 1 7 000 052 142 Elbow 3 8 FPT x FPT 1 8 000 052 104 Insert 66 3 8 NPT x 3 8 Barb 1 9 000 052...

Page 67: ...HydraMaster Corporation Page 1 58 Boxxer 427 Figure 1 27 Hi PSI Manifold Assembly C 5582 Rev A 11 5 8 6 4 7 1 2 3 10 14 12 9 13 6...

Page 68: ...T Replacement Y 1 5 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 1 6 000 106 111 Plug 1 2 NPT Allen 2 7 000 155 020 Spring 0 540 O D x 0 041 Wire x 1 00 Lg 1 8 000 052 023 Tee 3 8 NPT Male Street 1 9 000 05...

Page 69: ...ster Corporation Page 1 60 Boxxer 427 Figure 1 28 Electrical Control Panel Assembly C 5583 Rev D 2 11 12 16 12 16 12 15 12 6 5 11 13 8 1 17 18 21 21 21 22 20 21 20 9 19 10 23 26 27 27 25 4 3 25 4 28 7...

Page 70: ...p Dual Independent 1 11 000 094 034 Nut 10 24UNC Nylock 2 12 000 174 001 Washer 10 Flat 4 13 000 060 002 Grommet Large Wiring 1 14 000 056 030 Diode Panel 1 15 000 033 053 Clamp 1 1 2 Cushion Loop 1 1...

Page 71: ...HydraMaster Corporation Page 1 62 Boxxer 427 Figure 1 29 Coolant Heat Exchanger Assembly D 5578 Rev A 13 12 11 2 3 5 6 1 3 4 6 5 9 8 14 13 13 13 13 13 10 7 7...

Page 72: ...8 NPT Street x 45 1 5 000 143 001 Screw 1 4 20UNC x 0 75 Lg Hex Head 4 6 000 174 019 Washer 1 4 Lock 4 7 000 052 131 Elbow 1 NPT x 1 Barb 2 8 000 125 194 Tube Coolant Heat Exchager To Engine Boxxer 4...

Page 73: ...HydraMaster Corporation Page 1 64 Boxxer 427 Figure 1 30 Blower Heat Exchanger Assembly D 5579 Rev B 11 12 11 3 1 3 6 8 9 10 7 11 13 11 10 8 9 5 2 4 2 4 4...

Page 74: ...4 Blind x 0 50 Lg 32 4 000 052 086 Elbow 3 8 NPT Street 3 5 000 013 059 Box Inlet Plenum Welded Boxxer 427 1 6 000 013 060 Box Outlet Plenum Weldment Boxxer 427 1 7 000 001 097 Adpater Exhaust Turndow...

Page 75: ...5 4 5 1 7 8 8 8 8 1 000 041 416 Cover Top Machine Boxxer 427 1 2 000 041 422 Cover Brow Boxxer 427 1 3 000 100 153 Panel Brow End Weldment Boxxer 427 1 4 000 143 166 Screw 10 24UNC x 0 38 Lg Hex Head...

Page 76: ...t Side Machine Boxxer 427 1 2 000 105 313 Plate Hydramaster Name Roto Tank 1 3 000 174 001 Washer 10 Flat 2 4 000 143 166 Screw 10 24UNC x 0 38 Lg Hex Head 2 5 000 094 034 Nut 10 24UNC Nylock 2 6 000...

Page 77: ...ure 1 33 Machine Left Side Cover Assembly D 5587 Rev 1 000 041 417 Cover Left Side Machine Boxxer 427 1 2 000 105 313 Plate Hydramaster Name Roto Tank 1 3 000 174 001 Washer 10 Flat 2 4 000 143 166 Sc...

Page 78: ...age 1 69 Figure 1 34 70 Gallon Universal Recovery Tank Assembly D 6860 Rev B 39 40 35 6 8 40 42 43 5 2 29 22 21 9 29 11 10 37 31 38 32 28 14 15 1 17 3 3 4 35 34 36 33 18 19 20 26 25 22 27 12 23 7 24 4...

Page 79: ...051 Screw 8 32UNC x 0 75 Lg Binder Head Phillips 2 13 000 094 059 Nut 8 32UNF Nylock 2 14 000 086 008 Latch Bungie 1 15 000 143 539 Screw 6 32UNC x 0 50 Lg Button Head Allen 2 16 000 094 063 Nut 6 32U...

Page 80: ...Washer 1 4 Flat Rubber Backed 4 35 000 143 002 Screw 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...

Page 81: ...niversal Recovery Tank 1 2 000 052 222 Elbow 2 Barb x 2 FPT 2 3 000 057 202 Gasket End Recovery Tank 2 4 000 057 203 Gasket Middle Recovery Tank 2 5 000 057 204 Gasket Side Recovery Tank 70 Gallon 2 6...

Page 82: ...rsal Recovery Tank w APO Assembly D 6983 Rev A 2 28 19 20 9 7 29 31 5 32 HIDDEN 18 15 HIDDEN HIDDEN 12 11 6 29 25 26 16 17 8 14 10 13 3 33 24 23 22 1 3 13 10 13 30 27 HIDDEN HIDDEN HIDDEN 34 30 HIDDEN...

Page 83: ...l Recovery Tank 1 12 000 140 023 Rivet AB8 6A Aluminum Pop 6 13 000 143 126 Screw 10 24UNC x 0 50 Lg Hex Head 5 14 000 143 051 Screw 8 32UNC x 0 75 Lg Binder Head Phillips 2 15 000 094 059 Nut 8 32UNF...

Page 84: ...C Nylock 2 35 000 057 206 Gasket Adapter Universal Recovery Tank 2 36 000 052 085 Elbow 1 4 NPT Street 1 37 000 052 090 Tee 1 4 NPT Branch M F F 1 38 000 169 120 Valve Chemical Hi Temp Solenoid 12 Vol...

Page 85: ...Recovery Tank Weldment 1 2 000 078 039 Vacuum Inlet Stopper Assembly 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 32UNC...

Page 86: ...HydraMaster Corporation Boxxer 427 Page 1 77 Figure 1 38 Vacuum Relief Valve Assembly Collector Box C 7156 Rev 7 5 3 1 8 2 6 4 9 11 10...

Page 87: ...Valve 1 3 000 125 111 Pipe Vacuum Relief 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 Threa...

Page 88: ...HydraMaster Corporation Boxxer 427 Page 1 79 Figure 1 39 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 22...

Page 89: ...t 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 13...

Page 90: ...HydraMaster Corporation Boxxer 427 Page 1 81 Figure 1 40 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 91: ...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 Brack...

Page 92: ...2 3 4 1 Diffuser Filter Assembly Parts List Item Part Number Description Qty 1 000 052 074 Nipple 3 8 NPT Hex 1 2 000 033 131 Clamp Diffuser Boxxer 427 1 3 000 125 222 Tube Diffuser Boxxer 427 1 4 000...

Page 93: ...Parts List Item Part Number Description Qty Figure 1 42 Float Switch w Polypropylene Barrel Assembly C 6549 Rev 1 Stem Float Switch 1 2 000 005 011 Float Polypropylene Replacement Boxxer 427 1 3 000...

Page 94: ...HydraMaster Corporation Boxxer 427 Page 1 85 To be Added...

Page 95: ...HydraMaster Corporation Page 1 86 Boxxer 427 To be Added...

Page 96: ...usly damage the internal plumbing high pressure pump and heater These harmful chemicals include concentrated acid see the pH chart at the end of this section solvents and some paint oil and grease rem...

Page 97: ...extreme rear of the stroke Overlapping is also important to ensure even application of solution and prevent saturation when clean ing wand is stopped twice at the same point at the rear of the cleanin...

Page 98: ...Boxxer 427 Page 2 3 HydraMaster Corporation...

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Page 100: ...extraction This will void the warranty NOTE In order to achieve consistent adjustable temperatures an operating pressure of 200 PSI must be maintained Note Never run machine on any speed other than f...

Page 101: ...e in the PRIME position forextended periods of time Excessive chemicals will be used if it is not switched back ot ON or OFF c Then while spraying solution from the cleaning tool adjust the chemical f...

Page 102: ...aximum flow for at least 10 seconds turn the chemi cal selector to ON The restriction can now be removed from the vacuum inlet Do not leave in the PRIME position forextended periods of time Excessive...

Page 103: ...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 Section 8 of th...

Page 104: ...ntrol 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 knob to desired...

Page 105: ...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 shaft is th...

Page 106: ...vided in the kit to the garden hose quick connect see Fig 4 1 and this combination to the front of the ma chine Attach one section of female female solution hose to the outgoing solution fitting on th...

Page 107: ...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 USED ANTIFREEZ...

Page 108: ...nk 2 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 f...

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Page 110: ...t prior to its leaving 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...

Page 111: ...ter with the flow indicator indicating maximum flow and the PRIME line pulsing turn the Chemical Selector Valve to ON 3 Place the Chemical PRIME Line back into the chemical container 4 While spraying...

Page 112: ...cal Pump 1 3 000 111 030 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...

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Page 114: ...Boxxer 427 Page 5 5 HydraMaster Corporation Figure 5 2 Solution Flow Diagram D5736 Rev A...

Page 115: ...Boxxer 427 Page 5 6 HydraMaster Corporation Figure 5 3 Chemical FLow Diagram D5736 Rev A...

Page 116: ...Boxxer 427 Page 5 7 HydraMaster Corporation Figure 5 4 Exhaust Vacuum Coolant APO FLow Diagram D5736 Rev A...

Page 117: ...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 service technician to test temperature con...

Page 118: ...ter on 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 bet...

Page 119: ...y 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 Remove and inspe...

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Page 121: ...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 and...

Page 122: ...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 ring at the...

Page 123: ...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 he...

Page 124: ...lace 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 Carefully squa...

Page 125: ...re 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...

Page 126: ...Page 6 6 Boxxer 427 HydraMaster Corporation Figure 6 2 Pump Assembly D 5574 Rev D 11 16 3 5 2 6 10 8 19 12 29 1 23 25 26 20 14 27 22 24 13 23 24 15 9 18 7 23 24 4 28 17 21...

Page 127: ...427 1 12 000 052 086 Elbow 3 8 NPT Street 1 13 000 052 128 Nipple 3 8 NPT x 3 8 Male Propane 1 14 000 052 517 Nipple 1 4 NPT Close 1 15 000 135 052 Regulator Hi PSI Snubber 1 16 000 052 527 Nipple 1...

Page 128: ...ary 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 as necessa...

Page 129: ...in 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...

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Page 131: ...TY 1 169 058 Valve s s HM Solution 1 2 167 013 Trigger Hydra Hoe Valve Brass 1 3 052 082 Elbow Brass 45 Street 1 4 052 095 Nipple s s Hex 1 5 052 050 Quick Connect 440 M with Viton 1 6 052 152 Compres...

Page 132: ...aster Corporation Figure 1 2 Solution Valve Assembly B1234 ITEM PART NO DESCRIPTION QTY 1 600 012 001 Valve Body Sub Assembly 1 2 600 012 002 Valve Stem Sub Assembly 1 3 155 003 Spring HM Solution Val...

Page 133: ...tem Assembly B3743 ITEM PART NO DESCRIPTION QTY 1 107 129 Plunger HM Solution Valve 1 2 139 003 Ring Keeper HM Solution Valve 1 3 097 010 O Ring HM Valve Plunger Large 1 4 097 022 O Ring Solution Valv...

Page 134: ...Page 7 4 Boxxer 427 HydraMaster Corporation Figure 1 4 Hydra Hoe Wand Assembly C2660...

Page 135: ...061 006 Handle Pressure Guide 1 8 052 151 Compression 1 8 Female Hydra Hoe Fitting 1 9 052 153 Housing Brass Stabilizer Wand Nozzle Fitting 1 10 186 001 Stabilizer Jet Assembly Group 1 11 076 005 Jet...

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Page 137: ...nd the 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 in...

Page 138: ...ANK 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 each job wi...

Page 139: ...very 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 140: ...emove 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 tank use d...

Page 141: ...a problem with 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 connect...

Page 142: ...ting 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 technician for inspe...

Page 143: ...between 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 Remov...

Page 144: ...ive 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 the carbureto...

Page 145: ...pt to a minimum so as to keep any necessary troubleshooting as easy as possible The entire electrical system operates on 12 volts DC which is provided by a battery Battery levels are sustained by a 16...

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Page 147: ...Boxxer 427 Page 10 2 HydraMaster Corporation Figure 10 1 Wiring Schematic D 5738 Rev E...

Page 148: ...Boxxer 427 Page 10 3 HydraMaster Corporation Figure 10 2 Wiring Diagram D 5737 Sht 2 Rev E...

Page 149: ...Boxxer 427 Page 10 4 HydraMaster Corporation Figure 10 3 Wiring Diagram D 5737 Sht 3 Rev E...

Page 150: ...Boxxer 427 Page 10 5 HydraMaster Corporation Figure 10 4 Wiring Diagram D 5737 Sht 4 Rev E...

Page 151: ...r rectifier 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...

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Page 153: ...d copies may be 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 serv...

Page 154: ...0 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 valve piston plate...

Page 155: ...ake sure to run clean 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 DeSca...

Page 156: ...ine 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 filter bag a...

Page 157: ...nd 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...

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Page 159: ...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...

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Page 161: ...Purchase C Hours 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 you...

Page 162: ...ce 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 analysis of our f...

Page 163: ...d viscosity 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 A...

Page 164: ...e 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 Failure to...

Page 165: ...aining 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 thi...

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Page 167: ...0 Rotary Extractors 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 exception...

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Page 169: ...Boxxer 427 Page 15 1 HydraMaster Corporation Product Updates Boxxer 427 Section 15 1...

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