HydraMaster Boxxer 318HP User manual

HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-46477 Rev. A, February 13, 2015
(P/N 000-182-735)
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. Specications and information in this document are
subject to change without prior notice. All rights reserved. © 2015 HydraMaster
Boxxer 318HP
Owner’s Manual

i: Boxxer 318HP Owner’s Manual
Table of Contents
GENERAL INFORMATION...........................................................................SECTION 1
Contact Information ...........................................................................1-2
Warnings, Cautions and Notices .......................................................1-3
Responsibilities .................................................................................1-7
Machine Specications......................................................................1-10
High Altitude Operation .....................................................................1-12
Local Water Precautions....................................................................1-12
INSTALLATION INFORMATION................................................................... SECTION 2
Operating the Boxxer 318HP In Hot Weather....................................2-2
Setting Up the Boxxer 318HP............................................................ 2-5
CLEANING INFORMATION.........................................................................SECTION 3
Precautions........................................................................................ 3-1
Preparing the Carpet for Extraction...................................................3-2
Rinse and Recover............................................................................3-2
Overwetting........................................................................................3-3
Streaking............................................................................................3-3
Severe Cleaning Situations ...............................................................3-4
Cleaning Tool Tips .............................................................................3-6
OPERATING INSTRUCTIONS.....................................................................SECTION 4
Start-Up Procedure............................................................................ 4-4
Setting the Pressure for High Pressure Washing Operations............ 4-6
Shut-Down Procedure .......................................................................4-7
MACHINE MAINTENANCE..........................................................................SECTION 5
Operational Maintenance...................................................................5-2
Overall Machine Maintenance...........................................................5-3
High Pressure Pump Maintenance....................................................5-4
Vacuum System Maintenance...........................................................5-8
Descaling Procedure (Required) .......................................................5-9
Freeze Guarding................................................................................ 5-10
Tensioning the Pump Drive Belt.........................................................5-12
WATER AND CHEMICAL SYSTEM .............................................................SECTION 6
Water and Chemical Flow Operation.................................................6-1
ELECTRICAL SYSTEM................................................................................SECTION 7

Boxxer 318HP Owner’s Manual: ii
TROUBLESHOOTING .................................................................................SECTION 8
Heating System .................................................................................8-2
Chemical System...............................................................................8-3
Engine................................................................................................8-4
High Pressure System.......................................................................8-7
Vacuum System.................................................................................8-9
ASSEMBLIES AND PARTS LIST.................................................................SECTION 9
Console Assembly Parts List............................................................. 9-9
Frame Assembly Parts List................................................................9-12
Engine Assembly Parts List............................................................... 9-15
Blower Assembly Parts List ............................................................... 9-17
Pump Assembly Parts List.................................................................9-19
By-Pass Valve Assembly Parts List................................................... 9-20
Heat Exchanger Assembly Parts List.................................................9-22
Silencer Assembly Parts List ............................................................. 9-23
Water Box Assembly Parts List..........................................................9-25
Float Valve Assembly Parts List.........................................................9-26
Dash Assembly Parts List..................................................................9-29
Differential Check Valve Assembly Parts List....................................9-30
Orice Assembly Parts List ................................................................ 9-31
Idler Pulley Assembly Parts List.........................................................9-32
Exhaust Assembly Parts List ............................................................. 9-33
65 Gallon Universal Recovery Tank (URT) Assembly Parts List ....... 9-35
Dura-Flow Automatic Pump Out (APO) Assembly Parts List............. 9-37
Dura-Flow APO Pump Assembly Parts List....................................... 9-38
Hose Routings...................................................................................9-39

iii: Boxxer 318HP Owner’s Manual
HOW TO ORDER PARTS............................................................................ SECTION 10
Warranty Parts Orders.......................................................................10-1
Parts Orders ......................................................................................10-1
Emergencies......................................................................................10-1
WARRANTY INFORMATION.......................................................................SECTION 11
Blower ...............................................................................................11-1
High Pressure Water Pump ..............................................................11-1
Recovery Tank ..................................................................................11-1
Chemical System...............................................................................11-1
Control Panel ....................................................................................11-1
Cleaning Tool..................................................................................... 11-2
Water Heating System.......................................................................11-2
Hard Water Deposits .........................................................................11-2
Warranty Procedure...........................................................................11-2
HydraMaster Limited Warranty..........................................................11-3

Boxxer 318HP Owner’s Manual: iv
List of Figures
Figure 1-1. Hard Water Map of Mainland United States...........................................1-13
Figure 2-1. Location of Roof Vents in Vehicle ............................................................2-1
Figure 2-2. Recommended Location of Boxxer 318HP in Van...................................2-3
Figure 2-3. Install Fuel Pump, Outlet Side Up............................................................2-6
Figure 2-4. Fuel Pump Must Be in Vertical Position...................................................2-6
Figure 4-1. Boxxer 318HP DashAssembly - View 1 of 2...........................................4-1
Figure 4-2. Boxxer 318HP DashAssembly - View 2 of 2...........................................4-2
Figure 4-3. Location of Chemical Pump Shutoff Valve...............................................4-3
Figure 4-4. Location of Pressure Regulator Valve......................................................4-4
Figure 4-5. Chemical Pump Shutoff Valve Is OFF when Perpendicular to Pump ......4-6
Figure 5-1. Servicing the Valves.................................................................................5-5
Figure 5-2. Recirculation Fitting..................................................................................5-9
Figure 6-1. Flow Diagram - View 1 of 3......................................................................6-2
Figure 6-2. Flow Diagram - View 2 of 3......................................................................6-3
Figure 6-3. Flow Diagram - View 3 of 3......................................................................6-4
Figure 7-1. Electrical Schematic.................................................................................7-2
Figure 7-2. Wiring Diagram - View 1 of 2 ...................................................................7-3
Figure 7-3. Wiring Diagram - View 2 of 2 ...................................................................7-4
Figure 9-1. Adhesive/Sealant Material Reference......................................................9-2
Figure 9-2. Console Assembly - View 1 of 6...............................................................9-3
Figure 9-3. Console Assembly - View 2 of 6...............................................................9-4
Figure 9-4. Console Assembly - View 3 of 6...............................................................9-5
Figure 9-5. Console Assembly - View 4 of 6...............................................................9-6
Figure 9-6. Console Assembly - View 5 of 6...............................................................9-7
Figure 9-7. Console Assembly - View 6 of 6...............................................................9-8
Figure 9-8. Frame Assembly - View 1 of 2 ...............................................................9-10
Figure 9-9. Frame Assembly - View 2 of 2 ............................................................... 9-11

v: Boxxer 318HP Owner’s Manual
Figure 9-10. Engine Assembly - Part 1 of 2..............................................................9-13
Figure 9-11. Engine Assembly - Part 2 of 2..............................................................9-14
Figure 9-12. Blower Assembly - View 1 of 2.............................................................9-16
Figure 9-13. Blower Assembly - View 2 of 2.............................................................9-17
Figure 9-14. Pump Assembly - View 1 of 2 ..............................................................9-18
Figure 9-15. Pump Assembly - View 2 of 2 ..............................................................9-19
Figure 9-16. By-Pass Valve Assembly......................................................................9-20
Figure 9-17. Heat Exchanger Assembly...................................................................9-21
Figure 9-18. Silencer Assembly................................................................................9-23
Figure 9-19. Water Box Assembly............................................................................9-24
Figure 9-20. Float Valve Assembly...........................................................................9-26
Figure 9-21. Dash Assembly - View 1 of 2 ...............................................................9-27
Figure 9-22. Dash Assembly - View 2 of 2 ...............................................................9-28
Figure 9-23. Differential Check Valve Assembly ......................................................9-30
Figure 9-24. Orice Assembly ..................................................................................9-31
Figure 9-25. Idler Pulley Assembly...........................................................................9-32
Figure 9-26. Exhaust Assembly................................................................................9-33
Figure 9-27. 65 Gallon Universal Recovery Tank (URT) Assembly..........................9-34
Figure 9-28. Dura-Flow APO Assembly....................................................................9-36
Figure 9-29. Dura-Flow APO Pump Assembly .........................................................9-38

Boxxer 318HP Owner’s Manual: vi

1-1: General Information
1- General Information
The Boxxer 318HP is a carefully engineered truckmount designed and manufactured by
HydraMaster for hard surface cleaning as well as carpet and upholstery cleaning. The
Boxxer 318HP can also be used for high pressure washing applications.
The system utilizes an internal combustion 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 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
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.
If your question cannot be resolved by your distributor or by the information within this
manual, you may contact HydraMaster direct using the following phone numbers.
HOURS TELEPHONE NUMBERS E-MAIL ADDRESSES
Monday-Friday
7:00 a.m. to 5:00 p.m.
Pacic Time
Technical Support
[phone]
FAX : [phone]
Technical Support
[e-mail]
Customer Service/Parts
[phone]
FAX: [phone]
Customer Service/Parts
[e-mail]
Whencalling yourdistributor,be sureto referencethe serialnumber anddate ofpurchase.
FOR YOUR REFERENCE:
Serial No.______________________________________________
Date of Purchase:___________________
Purchased From (Distributor):_________________________________________