HydraMaster Boxxer 318 User manual

Boxxer 318
Owner’s Manual
HydraMaster North America, Inc.
11015 47th Avenue West, Mukilteo, Washington 98275
MAN-44101 Rev. 0, February 26, 2010
(182-076-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 HydraMaster North America, Inc.
All rights reserved. © 2010 HydraMaster NorthAmerica, Inc.

i: Boxxer 318 Owner’s Manual
Table of Contents
GENERAL INFORMATION...........................................................................SECTION 1
Contact Information................................................................................. 1-2
Warnings, Cautions and Notices.............................................................1-3
Machine Specications ...........................................................................1-10
Spare Parts List ......................................................................................1-11
High Altitude Operation .......................................................................... 1-12
Local Water Precautions.........................................................................1-12
CLEANING AND CHEMICALS..................................................................... SECTION 2
Precautions............................................................................................. 2-1
Preparing the Carpet for Extraction.........................................................2-2
Rinse and Recover..................................................................................2-2
Overwetting.............................................................................................2-3
Streaking.................................................................................................2-3
Cleaning Tool Tips...................................................................................2-4
SYSTEM OPERATION.................................................................................SECTION 3
Start-up Procedure.................................................................................. 3-1
Shut Down Procedure.............................................................................3-4
MACHINE MAINTENANCE..........................................................................SECTION 4
Operational Maintenance........................................................................4-2
Overall Machine Maintenance.................................................................4-3
High Pressure Pump Maintenance .........................................................4-4
Vacuum System Maintenance.................................................................4-8
Descaling Procedure (Required)............................................................. 4-9
Freeze Guarding..................................................................................... 4-10
Tensioning the Pump Drive Belt..............................................................4-12
WATER AND CHEMICAL SYSTEM ............................................................ SECTION 5
Water and Chemical Flow Operation......................................................5-1
ELECTRICAL SYSTEM................................................................................SECTION 6
TROUBLESHOOTING ................................................................................. SECTION 7
Heating System.......................................................................................7-2
Chemical System.................................................................................... 7-3
Engine.....................................................................................................7-4
High Pressure System ............................................................................7-7
Vacuum System......................................................................................7-9

Boxxer 318 Owner’s Manual: ii
8 - MACHINE ASSEMBLIES AND PARTS LIST...........................................SECTION 8
Machine Assembly Parts List.................................................................. 8-4
Frame Assembly Parts List .....................................................................8-8
Engine Assembly Parts List.....................................................................8-10
Blower Assembly Parts List.....................................................................8-11
Pump Assembly Parts List ......................................................................8-12
Chemical Pump Assembly Parts List ......................................................8-13
Heat Exchanger Assembly Parts List......................................................8-14
Silencer Assembly Parts List...................................................................8-15
Water Box Assembly Parts List...............................................................8-17
Dash Assembly Parts List .......................................................................8-20
Hi-PSI Manifold Assembly Parts List.......................................................8-22
By-Pass ValveAssembly Parts List.........................................................8-23
Idler Pulley Assembly Parts List..............................................................8-24
Exhaust Assembly Parts List...................................................................8-25
Electrical Panel Assembly Parts List.......................................................8-26
50 Gallon Universal Recovery TankAssembly Parts List........................8-28
70 Gallon Universal Recovery TankAssembly Parts List........................8-30
Cover, Single Vac. - 70 Gallon URTAssembly Parts List........................ 8-31
Vacuum Relief Valve Assembly Parts List............................................... 8-32
Dura-Flow APO 90° Assembly Parts List ................................................8-33
APO Connection Kit Assembly Parts List................................................8-34
Boxxer 318 on 85 RMT w/ 50 URTAssembly Parts List......................... 8-37
50 Gallon URT for 85 RMTAssembly Parts List.....................................8-39
Boxxer 318 on 85 RMT w/ 70 URTAssembly Parts List......................... 8-42
70 Gallon URT for 85 RMTAssembly Parts List.....................................8-44
85 Gallon Rotomolded TankAssembly Parts List ................................... 8-47
Dump and Vacuum Assembly Parts List................................................. 8-48
Chemical Jug Tray Assembly Parts List.................................................. 8-49
Machine Hose Routings..........................................................................8-50
HOW TO ORDER PARTS............................................................................SECTION 9
Warranty Parts Orders............................................................................9-1
Parts Orders............................................................................................9-1
Emergencies........................................................................................... 9-1

iii: Boxxer 318 Owner’s Manual
WARRANTY INFORMATION.......................................................................SECTION 10
Blower ....................................................................................................10-1
High Pressure Water Pump ................................................................... 10-1
Vacuum Tank ..........................................................................................10-2
Chemical System ...................................................................................10-2
Control Panel .........................................................................................10-2
Vacuum and Solution Hoses ..................................................................10-2
Cleaning Wand .......................................................................................10-2
Water Heating System ...........................................................................10-2
Hard Water Deposits ..............................................................................10-2
Warranty Procedure................................................................................10-3
ACCESSORIES AND CHEMICAL SOLUTIONS.......................................... SECTION 11

Boxxer 318 Owner’s Manual: iv
List of Figures
Figure 1-1. Hard Water Map of Mainland United States.....................................1-13
Figure 3-1. Location of Throttle, Choke, Optional Pump-In
Switch and Water Box........................................................................3-1
Figure 3-2. Front View of Boxxer 318 Console.....................................................3-2
Figure 4-1. Servicing the Valves ...........................................................................4-5
Figure 4-2. Recirculation Fitting............................................................................4-9
Figure 5-1. Annotated Water, Chemical and Solution
Flow Diagram - View 1 of 2................................................................5-2
Figure 5-2. Annotated Water, Chemical and Solution
Flow Diagram - View 1 of 2................................................................5-3
Figure 5-3. Annotated Chemical Flow Diagram ...................................................5-4
Figure 5-4. Exhaust Flow Diagram.......................................................................5-5
Figure 6-1. Electrical Schematic ...........................................................................6-2
Figure 6-2. Wiring Diagram - View 1 of 3..............................................................6-3
Figure 6-3. Wiring Diagram - View 2 of 3..............................................................6-4
Figure 6-4. Wiring Diagram - View 3 of 3..............................................................6-5
Figure 8-1. Machine Assembly - Front Left View ..................................................8-2
Figure 8-2. Machine Assembly - Front Right View................................................8-3
Figure 8-3. Frame Assembly - Front Left View......................................................8-5
Figure 8-4. Frame Assembly - Front Right View...................................................8-6
Figure 8-5. Frame Assembly - Rear View.............................................................8-7
Figure 8-6. Engine Assembly................................................................................8-9
Figure 8-7. Blower Assembly ..............................................................................8-11
Figure 8-8. Pump Assembly................................................................................8-12
Figure 8-9. Chemical Pump Assembly................................................................8-13

v: Boxxer 318 Owner’s Manual
Figure 8-10. Heat Exchanger Assembly..............................................................8-14
Figure 8-11. Silencer Assembly...........................................................................8-15
Figure 8-12. Water BoxAssembly.......................................................................8-16
Figure 8-13. Dash Assembly - Front ...................................................................8-18
Figure 8-14. Dash Assembly - Back....................................................................8-19
Figure 8-15. Hi-PSI Manifold Assembly ..............................................................8-21
Figure 8-16. By-Pass Valve Assembly................................................................8-23
Figure 8-17. Idler Pulley Assembly......................................................................8-24
Figure 8-18. Exhaust Assembly ..........................................................................8-25
Figure 8-19. Electrical Panel Assembly...............................................................8-26
Figure 8-20. 50 Gallon Universal Recovery Tank Assembly...............................8-27
Figure 8-21. 70 Gallon Universal Recovery Tank Assembly...............................8-29
Figure 8-22. Cover, Single Vac. - 70 Gallon URTAssembly...............................8-31
Figure 8-23. Vacuum Relief Valve Assembly ......................................................8-32
Figure 8-24. Dura-Flow APO 90° Assembly........................................................8-33
Figure 8-25. APO Connection Kit Assembly........................................................8-34
Figure 8-26. Boxxer 318 on 85 RMT w/ 50 URTAssembly - Right View............8-35
Figure 8-27. Boxxer 318 on 85 RMT w/ 50 URTAssembly - Left View...............8-36
Figure 8-28. 50 Gallon URT for 85 RMTAssembly.............................................8-38
Figure 8-29. Boxxer 318 on 85 RMT w/ 70 URTAssembly - Right View............8-40
Figure 8-30. Boxxer 318 on 85 RMT w/ 70 URTAssembly - Left View...............8-41
Figure 8-31. 70 Gallon URT for 85 RMTAssembly.............................................8-43
Figure 8-32. 85 Gallon Rotomolded Tank Assembly - Front View.......................8-45
Figure 8-33. 85 Gallon Rotomolded Tank Assembly - Back View.......................8-46
Figure 8-34. Dump and Vacuum Bracket Assembly............................................8-48
Figure 8-35. Chemical Jug Tray Assembly..........................................................8-49

1-1: General Information
1- General Information
The Boxxer™ 318 is a carefully engineered truckmount designed by HydraMaster
Corporation.
Thesystemutilizesaninternalcombustion
engine to provide the power necessary to
turn both a blower (also referred to as a
vacuum pump) and a high pressure water
pump.
The heat of the engine and blower
exhausts is transferred to the high
pressure water in the nned tube heat
exchanger of the system.
Finally, the chemical is injected into the
pressurized water stream and the heated
solution is delivered to the cleaning tool.
The solution is recovered by the vacuum generated by the blower and is collected in the
recovery tank for proper disposal.
It is the purpose of this manual to help the technician properly understand, maintain and
service the truckmount. By following these guidelines carefully, you can expect years of
reliable operation.
This section contains the following helpful information:
Contact Information

Warnings, Cautions, and Notices

Responsibilities

Machine Specications

Spare Parts Lists
High Altitude Operation

Local Water Precautions

General Information: 1-2
CONTACT INFORMATION
If you have any questions regarding the operation, maintenance or repair of this machine,
please contact your local distributor.
To nd a local distributor, please visit our website at http://www.hydramaster.com/owners/
locate/index.asp.
If your question cannot be resolved by your distributor or by the information within this
manual, you may contact HydraMaster Customer Service direct using the following phone
numbers or e-mail addresses.
Hours Telephone Numbers E-mail Addresses
Monday-Friday [phone] Service Tech Support:
[e-mail]
7:00 a.m. to 5:00 p.m. [phone] Parts Parts Support:
[e-mail]
Pacic Standard Time [phone] Parts /
Service FAX
When calling your distributor, be sure to reference the serial number and the date of
purchase.
FOR YOUR REFERENCE:
Serial Number: _______________________________________________
Date of Purchase:_____________________________________________
Purchased From (Distributor): __________________________________

1-3: General Information
WARNINGS, CAUTIONS AND NOTICES
HydraMaster uses this WARNING symbol throughout the manual to warn of
possible injury or death.
This CAUTION symbol is used to warn of possible equipment damage.
This NOTICE symbol indicates that federal or state regulatory laws may apply,
and also emphasizes supplemental information.

General Information: 1-4
During the operation of the truckmount many components are in motion. Never touch any
part of the truckmount that is in motion. Serious injury may result.
During the operation of the truckmount many surfaces will become extremely hot. Never
touch hot surfaces. Serious injury may result.
The operation of this truckmount can produce noise levels exceeding 85 decibels
to a distance of 10 feet. The Occupational Safety and Health Administration (OSHA)
recommendsthe useof hearingprotective equipmentif apersonis exposedto anaverage
of 85 decibels over an eight hour period. Check with local and state agencies concerning
hearing conservation rules.
During the operation of the truckmount carbon monoxide and other toxic fumes are
produced. Position the vehicle so that any fumes produced will be directed away from
inhabited areas and any points of building entry (doors, windows, air conditioning units,
fans, etc.). Do not occupy the vehicle while the truckmount is in operation. Serious injury
may result.
Duringthe operationof thetruckmount chemicalsknown tothe StateofCalifornia tocause
cancer, birth defects and other reproductive harm are produced by the engine exhaust.
Never operate the truckmount with a portable gas container inside the vehicle. Doing so
will increase the risk of re and explosion. Serious injury or death my result.
Transporting a vented fuel container that presently contains, or has ever contained in
the past, a ammable liquid is strictly forbidden by HydraMaster and by federal and state
regulations. Doing so will increase the risk of re and explosion. Serious injury or death
may result.

1-5: General Information
Never smoke in or around the truckmount. Doing so will increase the risk of re and
explosion. Serious injury or death may result.
During the operation of the truckmount the exhaust system will become extremely hot.
Keep all ammable materials away from the truckmount exhaust system. Failure to do so
will increase the risk of re and explosion. Serious property damage may result.
Never operate the truckmount when the vehicle is tilted more than 10 degrees in any
direction. Doing so will result in improper lubrication of the internal components, and will
increase the risk serious component or engine damage.
Never perform cleaning operations when the truckmount engine is running at the IDLE
throttle position. Failure to do so will increase the risk of serious component or engine
damage.
Never operate the truckmount with the vehicle doors closed. Doing so results in extremely
high temperatures inside the vehicle and will lead to serious component or engine
damage.
Never use concentrated acids or solvents (including d-limonene) in the truckmount
water system or chemical system. Use of these products will cause serious component
damage.
Never operate the truckmount with a water hardness reading measuring 3.0 grains per
gallon or higher. Using reading than 3.0 grains per gallon will cause scale to build up
inside the truckmount water system. Scale build up causes serious component damage.
Test all water prior to use and use water softening equipment if necessary.

General Information: 1-6
Never allow water to freeze inside the truckmount. Serious component damage will occur.
Perform all freeze guarding procedures outlined in this digital Owner’s Manual.
Many vehicles have critical components mounted directly below the oor that can easily
be damaged. Before drilling holes in the oor of the vehicle, inspect the underside of the
vehicle for critical components. Failure to do so may result in damage to the vehicle.

1-7: General Information
RESPONSIBILITIES
The Purchaser’s Responsibilities
Prior to purchasing a van, ensure that the payload is suitable for all of the equipment
that will be installed and transported. This includes and is not limited to: the truckmount,
recovery tanks, fresh water tanks, on-board water, hose reels, hoses, cleaning tools,
chemicals, drying equipment, etc. Payload capacity information is available through the
auto dealer, the manufacturer’s web site, and is also located on the door pillar of the
driver’s side door.
Purchase a heavy duty Group 24 battery for this truckmount. This is normally available
from the installation dealer.
Prior to dropping your van off at the distributor for the truckmount to be installed, have a
spray-on bed liner applied to the oor such as Rhino Lining® or Line-X®.
Prior to operating the truckmount read this manual in its entirety and familiarize yourself
with the information contained here. Special attention should be paid to all cautions and
warnings.
The distributor is responsible for the correct installation of the truckmount. The distributor
is also responsible to train you in the correct and proper operation and maintenance of
the truckmount.
Any modication of the truckmount may void the warranty.
The Distributor’s Responsibility
Acceptance of Shipment
Before accepting the truckmount, check the following:
The truckmount should be free from any damage during shipping. Do not sign the
• deliveryreceiptuntil youhavecloselyinspectedthe truckmountandnotedanydamage
on the delivery receipt. Hidden damage may be present even if the box looks okay. It
is recommended that the box be opened before signing for the shipment.
Check the packing list and verify that all items are accounted for.
•

General Information: 1-8
Installation Responsibilities
Ensure proper payload capacity. It is the distributor’s responsibility to verify that the• equipment package does not exceed the vehicle capacity.
Ensure installation of a safe fuel tap system and through-oor ttings as provided by
• HydraMaster.
Proper placement of the truckmount, recovery tank, fresh water tank, and accessories
• in the vehicle and securing them with bolts and back up plates. The distributor should
verify that the owner is in agreement with the layout.
Ensure proper connection of the fuel lines.•
Ensure proper connection and installation of the battery. Verify that the battery is in• accordance with HydraMaster’s recommendation.
Check the pump, vacuum blower and engine oil levels prior to starting the
• truckmount.
Start and run the truckmount and check that all systems function properly.
•
Test all hoses, wands, etc. for correct operation.•
Ensure timely return of the document package.•

1-9: General Information
Training
The distributor should provide a thorough review of the operation manual with the
purchaser along with instruction and familiarization in:
How all the truckmount’s systems function.
•
All safety precautions and their importance.•
How to correctly start and shut down the truckmount.•
How to correctly clean with the truckmount.•
Where and how often to check and change component oil levels.•
Freezing damage and how to avoid it. This includes explaining proper freeze guarding• procedures.
How to do basic troubleshooting of the truckmount.
•
Hard water damage and how to avoid it. This includes how to determine if hard water• exists in your area and the installation and use of water softening systems.
The truckmount’s warranty and warranty procedures.
•

General Information: 1-10
MACHINE SPECIFICATIONS
Overall Dimensions 24.0" W x 36" D x 31" H
Weight 570 lbs.
Engine- Briggs and
Stratton Vanguard 18 HP Oil Type Synthetic 5W-30
Capacity Approx. 1 1/2 quarts (48 oz.)
when changing oil and lter
Engine rpm 3,150 rpm @ 14" Hg
Vacuum Blower- Tuthill
3006 Competitor Plus SL
(Dual Splash Lubrication)
Oil Type PneuLube or other ISO 100
rating
Gear End Capacity Approx. 7.0 oz.
Drive End Capacity Approx. 5.0 oz.
Blower rpm 3,150 rpm @ 14" Hg
Pump- HydraPump II Oil Type Synthetic 15W-50
Capacity Approx. 8.0 oz.
Pump Rate 3.5 gallons per minute
Pump rpm 1,750 rpm
Operating Pressure 0 - 1,000 psi
Chemical System Last Step Chemical Injection
Heating System Finned Tube Heat Exchanger
Standard Equipment High Pressure Hose 1/4" High Temperature Lined/
Vinyl Cover - 100 ft.
Vacuum Hose 2" Vacuum Hose- 100 ft.
1-1/2" Wand Whip Line- 10 ft.
Recovery Tank 50 gallon MaxAir Universal
Tank
Cleaning Wand Stainless Steel S-bend
Replaceable Grip
Rebuildable Solution Valve
Chemical Jug 5 gallon
Battery Box
Van Decal
Van Installation Kit
Operation Manual
Optional Equipment Recovery Tank 70 gallon MaxAir Universal
Tank
Fresh Water Tank 85 gallon Rotomolded Tank
Automatic Pump Out (APO) Dura-Flow APO

1-11: General Information
SPARE PARTS LIST
Part No. Description Qty
Engine and Drive Train Components
000-106-016 Plug, Spark 2
000-049-049 Filter, Fuel 1
000-049-014 Filter, Oil 1
000-049-012 Filter, Air 1
000-010-125 Belt, 9440HD 1
000-152-011 Coupler Element 1
Electrical Components
000-056-010 Fuse, 25A 2
000-157-040 Switch, 20 Amp Rocker 2
000-157-022 Switch, Relay, 12V 2
Hydraulic Components
000-052-050 Quick Connect, 440 Male 2
000-052-051 Quick Connect, 440 Female 2
000-052-052 Quick Connect, 660 Male 1
000-052-053 Quick Connect, 660 Female 1
000-046-010 Diaphragm, Chemical Pump 1
000-169-186 Valve, 100 psi, Last Step Chemical 1
000-180-006 Orice, 0.061 dia. 1
000-180-004 Orice, 0.033 dia. 1
000-074-007 Gauge, High psi (0-1,500) 1
000-049-023 Screen, Garden Hose 1
000-078-273 Kit, By-Pass Valve Repair w/Tapered
Handle 1
Miscellaneous
000-087-006 HydraMaster-Recommended Spray
Lubricant (part number is for a quantity of
1 can)
1 ea

General Information: 1-12
HIGH ALTITUDE OPERATION
Elevation plays a key role in how the truckmount will operate. Operation at high altitude
(above 5,000 ft.) may require a high-altitude carburetor jet. Use of this jet at high altitude
will improve power, reduce fuel consumption and help reduce excessive carbon build-up
in the exhaust and heat exchanger systems.
Contact the local Briggs and Stratton dealer or HydraMaster to obtain the proper jet
size. Your local Briggs and Stratton dealer can be located at http://vanguardengines.via.
infonow.net/locator/.
LOCAL WATER PRECAUTIONS
The quality of water varies greatly. Many areas have an excess of minerals in the water
which results in what is commonly called “hard water.” These minerals tend to adhere to
the insides of heater coils and other parts of the machines causing damage and a loss of
cleaning effectiveness. This inuences the reliability and efciency of equipment in direct
proportion to the level of hardness.
Hard Water Advisory
HydraMaster recognizes that any hard water deposits which might occur within the water
system of our truckmounts is a serious problem. The precision technology of truckmount
heat exchanger systems is intolerant of any foreign material. Hard water deposits will
ultimately decrease the performance of the system and are expected to seriously lower
the reliability of the machine.
To validate a machine’s warranty, HydraMaster requires that all machines operating in
designated “Hard Water Areas” (3.0 grains or more per gallon) be tted with a water
softening system, or a properly installed magnetic-type descaler must be used and
maintained. Periodic descaling or acid-rinsing alone is not adequate in these areas.
HydraMaster does not recommend any particular type or brand; however, the relative
effectiveness of some types of magnetic descalers or softeners may require additional
periodic use of descaling agents.
HydraMasteralso recommends,inthe strongestpossible terms, thatmachines inallareas
be tted with a water softening system for improved operation and reliability.
Failure to take appropriate measures to prevent scale build up can result in
system failure and loss of warranty on affected parts.

1-13: General Information
Hard Water Area Map
The hard water map, shown in Figure 1-1, denes hard water areas in the continental
United States which compromise uid related components such as hoses, ttings, heaters,
pumps, valves and water-cooled engines. For other countries, hard water area maps can
be obtained from geological societies.
Hard Water Map of Mainland United StatesFigure 1-1.
The map shown in Figure 1-1 is provided for general reference only. Water
hardness in your geographical location should be conrmed by testing.
Water Softener
Cleaning efciency and equipment life is increased, chemical use decreased, and the
appearance of cleaned carpets enhanced when water softeners are incorporated in
hard water areas. HydraMaster strongly urges the use of water softener units with the
Boxxer 318 in areas exceeding 3.0 grains per gallon.
Failure to use a water softener in these areas will invalidate the machine’s warranty.
Referring to the hard water area map shown Figure 1-1, determine the quality of water
in your area and take immediate action if the water hardness exceeds 3.0 grains per
gallon.
Therelativelylowcostofawatersoftenerserviceismorethanmadeupforbyanincreased
life of machine parts, reduced chemical costs and continued cleaning efciency. The
water softener will also increase the effectiveness of the cleaning chemicals, therefore
less chemical will be needed.

General Information: 1-14
Contact a water softener distributor in your area for information on the rental of a simple
water treatment unit to carry in your truck. Be sure to charge the water softener in
accordance with the capability of the softener.
For example: If the softener will treat 900 gallons of water and the machine uses an
average of 30 gallons/hour, for an average of 5 hours a day, this equals 150 gallons per
day). In 6 days the machine would use 900 gallons of water. Therefore, the softener
would need to be charged every 6 working days for maximum softening.
Waste Water Disposal Advisory
There are laws in most communities prohibiting the dumping of recovered “gray” water
from carpet cleaning in any place but a sanitary treatment system.
The cleaning rinse water, recovered into your unit’s vacuum tank, contains materials
such as detergents, and must be safely processed before entering streams, rivers and
reservoirs.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after rst ltering out solid material such as carpet
ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV
dump, etc. Permission should rst 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 Boxxer 318 with an Automatic Pump-Out System (APO). 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.
HydraMaster makes an APO System which can be ordered with new equipment or
installed later.
When properly congured, the systems will continuously monitor the level of waste water
and pump it out simultaneously with the cleaning operation. The hidden benet of this
process is that the technician does not have to stop his/her cleaning to empty the recovery
tank.
INACCORDANCEWITHEPA,STATEANDLOCALLAWS,DONOTDISPOSEOF
WASTEWATERINTOGUTTERS,STORMDRAINS,STREAMS,RESERVOIRS,
ETC.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.