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HydraMaster Boxxer 421 User Manual

HydraMaster Boxxer 421
179 pages
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Copyright© 2007
HYDRAMASTER© Corporation
Mukilteo, Washington
MAN-182-065-D
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 re-
served.
Revised August 31, 2007
11015 47th Avenue W, Mukilteo, WA 98275
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HydraMaster Boxxer 421 Specifications

General IconGeneral
BrandHydraMaster
ModelBoxxer 421
CategoryVacuum Cleaner
LanguageEnglish

Summary

General Information

Telephone Numbers

Contact details for support and parts.

Precautions

Safety warnings and operational guidelines.

System Operation

Explanation of how the cleaning system functions.

Machine Specifications

Technical details and features of the machine.

Spare Parts Recommendation

Recommended parts to keep on hand for maintenance.

Spare Parts List

List of part numbers, descriptions, and quantities.

Responsibilities

Defines roles of owner and manufacturer.

Vehicle Preparation

Guidelines for preparing the vehicle for installation.

High Altitude Operation Preparation

Adjustments needed for operating at high altitudes.

Local Water Precautions

Advice on dealing with water quality issues like hardness.

Wastewater Disposal Advisory

Guidance on proper disposal of waste water.

Hard Water Map

Visual guide showing water hardness levels by region.

Cleaning and Chemicals

pH Chart

Chart illustrating the pH scale for chemical compatibility.

Precautions

Warnings about using chemicals that can damage the system.

Cleaning Stroke Procedure

Proper technique for effective carpet cleaning strokes.

Over-Wetting

Causes and consequences of over-wetting during cleaning.

Operating Instructions

Start Up

Step-by-step procedure for starting the machine.

Carpet or Hard Surface Cleaning

Instructions for cleaning carpets and hard surfaces.

Upholstery Cleaning

Specific steps for cleaning upholstery.

Flood Extraction

Procedure for extracting water from flooded areas.

Shut Down

Steps for properly shutting down the equipment.

Exhaust Diverter System

Operation and adjustment of the exhaust diverter system.

Cleaning Mode

How to operate the system in cleaning mode.

Flood Damage Mode

How to operate the system in flood damage mode.

Adjustment After Installation

Procedure for adjusting the diverter valve after installation.

Machine Maintenance

Operational Maintenance

Routine maintenance tasks (daily, weekly, monthly, etc.).

Daily

Daily maintenance checks and procedures.

Weekly

Weekly maintenance checks and procedures.

Monthly

Monthly maintenance checks and procedures.

Quarterly

Quarterly maintenance checks and procedures.

500 Hours

Maintenance tasks required every 500 hours.

As Required: De-scaling

Procedure for removing scale deposits from the heating system.

Overall Machine Maintenance

Importance and procedures for overall machine upkeep.

After Each Job

Maintenance tasks to perform after each cleaning job.

Daily

Daily cleaning and inspection tasks.

Weekly

Weekly cleaning and inspection tasks.

Freeze Guard

Vacuum Freeze Guard Procedure

Steps to protect the vacuum system from freezing.

Recovering Antifreeze For Re-use

Procedure for recovering and reusing antifreeze.

Freeze Protection of the Pump-In System

Method for protecting the pump-in system from freezing.

High Pressure Pump

Pump Maintenance

Routine maintenance for the high-pressure pump.

Daily

Daily checks for the high-pressure pump oil level and condition.

Periodically

Recommended intervals for pump oil changes.

Service

Disassembly and inspection of pump components.

Servicing the Valves

Procedure for servicing the pump valves.

Removing the High Pressure Manifold

Steps to remove the high-pressure manifold.

Servicing the Plungers

Steps for servicing the pump plungers.

Reinstall the Ceramic Plungers

Procedure for reinstalling ceramic plungers.

Reinstall High Pressure Manifold

Steps to reinstall the high-pressure manifold.

Servicing the Crankcase

Inspection and service of the pump crankcase.

Pump Troubleshooting

Solutions for common pump issues.

Will not come up to normal cleaning pressure

Troubleshooting steps for low cleaning pressure.

No pressure reading on PSI gauge

Diagnosing issues with the PSI gauge reading.

PSI gauge reads normal; low pressure from wand

Troubleshooting low pressure at the wand.

Pressure pulsation

Identifying causes of pressure pulsation.

Water box empty or fills slowly

Troubleshooting slow filling or empty water box.

Water box overflows

Diagnosing and fixing water box overflow issues.

Vacuum System

Vacuum Tank Filter Bags

Information and use of vacuum tank filter bags.

Vacuum System Troubleshooting

Diagnosing and resolving vacuum system issues.

Vacuum gauge will not come up to 12" hg

Troubleshooting low vacuum gauge readings.

Vacuum gauge reads too high with no hoses attached

Diagnosing high vacuum gauge readings without hoses.

Noisy vacuum blower

Identifying causes of a noisy vacuum blower.

Vacuum blower is locked and will not turn.

Troubleshooting a locked vacuum blower.

Miscellaneous Troubleshooting

Addressing other system issues and troubleshooting.

Water from exhaust

Diagnosing water appearing in the exhaust.

Electrical System

Terminal Assignments and Switch Positions

Details on electrical terminal connections and switch functions.

Wiring Schematic

Diagram illustrating the electrical system layout.

Wiring Diagrams

Detailed electrical circuit diagrams.

Electrical Troubleshooting

Steps to diagnose and resolve electrical issues.

Ignition Switch

Details on the ignition switch terminals, wiring, and positions.

Water and Chemical System

Chemical System Maintenance

Procedures for maintaining the chemical delivery system.

Chemical Pump

Information and parts for the chemical pump.

Solution Flow Diagram

Visual representation of the solution flow path.

Chemical Flow Diagram

Diagram showing the path of chemicals through the system.

Exhaust, Vacuum, Coolant and APO Flow Diagram

Diagram illustrating flow paths for exhaust, vacuum, etc.

Chemical Tank Troubleshooting

Solutions for problems related to the chemical tank.

Water and Chemical Flow Operation

How the chemical and water systems operate.

Heating System Troubleshooting

Diagnosing and resolving heating system issues.

Machine overheats and shuts down

Troubleshooting steps for overheating issues.

Unable to achieve normal cleaning solution temperature

Diagnosing problems with cleaning solution temperature.

Engine Troubleshooting

Will not turn over

Troubleshooting steps for an engine that won't crank.

Turns over but will not start. There is no spark

Diagnosing no-spark issues when the engine turns over.

Turns over but will not start. There is spark.

Troubleshooting no-start issues when spark is present.

Starts then dies immediately

Diagnosing engine shutdown after starting.

Will not come up to normal operating RPM

Troubleshooting issues with reaching normal engine RPM.

Runs rough at medium or high speed

Diagnosing rough engine operation at speed.

Engine overheats

Troubleshooting engine overheating issues.

Machine Assemblies and Parts Lists

Hose Assemblies

List and diagrams of various hose assemblies.

Frame Assembly - Front View

Illustrated parts breakdown of the front frame assembly.

Frame Assembly - Rear View - Left Side

Illustrated parts breakdown of the rear left frame assembly.

Frame Assembly - Rear View - Right Side

Illustrated parts breakdown of the rear right frame assembly.

Frame Assembly Parts List

Detailed list of parts for the frame assembly.

70 Gallon Universal Recovery Tank Assembly

Illustrated parts breakdown of the 70-gallon tank assembly.

70 Gallon Universal Recovery Tank Assembly Parts List

Detailed list of parts for the 70-gallon tank assembly.

70 Gallon Universal Recovery Tank Cover Assembly Parts List

Parts list for the 70-gallon tank cover assembly.

Dash Assembly

Illustrated parts breakdown of the dash assembly.

Dash Assembly Parts List

Detailed list of parts for the dash assembly.

Electrical Control Panel Assembly

Illustrated parts breakdown of the electrical panel.

Electrical Control Panel Assembly Parts List

Detailed list of parts for the electrical panel.

Blower Heat Exchanger Assembly

Illustrated parts breakdown of the blower heat exchanger.

Water Box Assembly

Illustrated parts breakdown of the water box assembly.

Water Box Assembly Parts List

Detailed list of parts for the water box assembly.

Hydra Pump II Assembly

Illustrated parts breakdown of the Hydra Pump II.

Hydra Pump II Assembly Parts List

Detailed list of parts for the Hydra Pump II.

Chemical Pump Assembly

Illustrated parts breakdown of the chemical pump assembly.

Fuel Pump Assembly

Illustrated parts breakdown of the fuel pump assembly.

Blower Assembly

Illustrated parts breakdown of the blower assembly.

Blower Assembly Parts List

Detailed list of parts for the blower assembly.

Blower Assembly Parts List (cont.)

Continuation of the blower assembly parts list.

Vacuum Relief Valve (Collector Box) Assembly

Illustrated parts breakdown of the vacuum relief valve assembly.

Exhaust Assembly

Illustrated parts breakdown of the exhaust assembly.

Exhaust Assembly Parts List

Detailed list of parts for the exhaust assembly.

Diverter Valve Actuator Assembly

Illustrated parts breakdown of the diverter valve actuator.

Hi PSI Manifold Assembly

Illustrated parts breakdown of the Hi PSI manifold assembly.

Hi PSI Manifold Assembly Parts List

Detailed list of parts for the Hi PSI manifold.

By-Pass Valve Assembly

Illustrated parts breakdown of the by-pass valve assembly.

By-Pass Valve Assembly Parts List

Detailed list of parts for the by-pass valve assembly.

Engine Assembly

Illustrated parts breakdown of the engine assembly.

Engine Assembly Parts List

Detailed list of parts for the engine assembly.

Briggs and Stratton Voltage Regulator Modification

Illustrated modification procedure for the voltage regulator.

Dura-Flow APO Pump Assembly

Illustrated parts breakdown of the Dura-Flow APO pump.

Dura-Flow APO Pump Assembly Parts List

Detailed list of parts for the Dura-Flow APO pump.

100 Gallon Universal Recovery Tank Assembly

Illustrated parts breakdown of the 100-gallon tank assembly.

100 Gallon Universal Recovery Tank Assembly Parts List

Detailed list of parts for the 100-gallon tank assembly.

100 Gallon Universal Recovery Tank Cover Assembly Parts List

Parts list for the 100-gallon tank cover assembly.

70 Gallon Universal Recovery Tank For 85 RMT Assembly

Illustrated parts breakdown for the 70-gallon tank for 85 RMT.

70 Gallon Universal Recovery Tank For 85 RMT Assembly Parts List

Detailed list of parts for the 70-gallon tank for 85 RMT.

85 Gallon Rotomolded Tank Assembly - Front View

Illustrated parts breakdown of the 85-gallon tank, front view.

85 Gallon Rotomolded Tank Assembly - Rear View

Illustrated parts breakdown of the 85-gallon tank, rear view.

85 Gallon Rotomolded Tank Assembly Parts List

Detailed list of parts for the 85-gallon tank assembly.

85 RMT w/ Boxxer 421 Assembly - Front View

Illustrated parts breakdown for 85 RMT with Boxxer 421, front view.

85 RMT w/ Boxxer 421 Assembly - Rear View

Illustrated parts breakdown for 85 RMT with Boxxer 421, rear view.

85 RTM w/ Boxxer 421 Assembly Parts List

Detailed list of parts for 85 RTM w/ Boxxer 421 assembly.

Chemical Jug Tray Assembly

Illustrated parts breakdown of the chemical jug tray assembly.

Chemical Jug Tray Assembly Parts List

Detailed list of parts for the chemical jug tray assembly.

Hose Assemblies

List of hose part numbers, descriptions, and lengths.

Hose Assemblies (cont.)

Continuation of the hose assemblies list.

Cleaning Wand Parts

HydraHoe Two-Jet Cleaning Wand Assembly

Illustrated parts breakdown of the cleaning wand.

Wand Assembly Parts List

Detailed list of parts for the cleaning wand assembly.

How to Order Parts

Warranty Parts Orders

Procedure for ordering parts under warranty.

Parts Orders

General procedure for ordering parts.

Emergencies

Procedure for obtaining parts during emergencies.

Warranty Information

Blower

Causes of warranty voidance related to the blower.

High Pressure Water Pump

Causes of warranty voidance for the pump.

Vacuum Tank

Causes of warranty voidance for the vacuum tank.

Chemical System

Causes of warranty voidance for the chemical system.

Control Panel

Causes of warranty voidance for the control panel.

Vacuum and Solution Hoses

Causes of warranty voidance for hoses.

Cleaning Wand

Causes of warranty voidance for the cleaning wand.

Water Heating System

Causes of warranty voidance for the water heating system.

Hard Water Deposits

Causes of warranty voidance related to hard water.

Warranty Procedure

Steps to follow for warranty claims and service.

Accessories

Genuine HydraMaster Accessories & Detergents

Information on genuine accessories and cleaning agents.

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