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):_________________________________________

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) recommends the use of hearing protective equipment if a person is
exposed to an average 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.
During the operation of the truckmount chemicals known to the State of California
to cause 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.
Transportingaventedfuelcontainerthatpresentlycontains,orhasevercontained
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
extremelyhightemperatures insidethe vehicleandwill leadto seriouscomponent
or engine damage.
Neveruseconcentratedacidsorsolvents(includingd-limonene)inthetruckmount
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.
During the operation of this equipment, surfaces will become hot. Do not allow
components such as hoses to touch hot surfaces. Failure to heed this warning
can result in equipment damage which is not covered by warranty.

1-7: General Information
RESPONSIBILITIES
The Purchaser’s Responsibilities
Priortopurchasingavan,ensurethatthepayloadissuitableforalloftheequipmentthatwill
be installed and transported. This includes and is not limited to: the truckmount, recovery
tanks, fresh water tanks and any other 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
deliveryreceiptuntilyou havecloselyinspectedthe 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 any other
on-board water, 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
Frame Dimensions 24.0" W x 31” H x 36" D
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
Fuel Consumption 1.0 gph
Ignition Electric Key Start
Vacuum Blower- Tuthill
3006 Competitor Plus SL
(Dual Splash Lubrication)
Max. Vac. 12” Hg
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
Water Pump Oil Type 30W non-detergent
Capacity Approx. 8.0 oz.
Pump Rate 3.5 gallons per minute
Pump rpm 1,750 rpm
Operating Pressure 0 - 1,500 psi (Heated)
Chemical System Last Step Chemical Injection with
High Pressure Shutoff Valve
Heating System Finned Tube Heat Exchanger

1-11: General Information
Standard Equipment Recovery Tank 65 Gallon
Cleaning Tool RX-15 Rotary Hard Surface
Cleaning Tool
Hoses 2” x 50 ft Blue Vacuum Hose
1 1/2” x 10 ft Blue Whip Hose
1 1/2” Blue Dump Hose
1/4” x 100 ft Blue Solution
Hose
Chemical Jug 5 gallon
Battery Box
Van Decal
Van Installation Kit
Owner’s Manual (on CD)
Owner’s Guide (paper copy)
Available Equipment Dura-Flow Auxiliary Pump Out (APO)
Through Floor Exhaust Kit
RX-20 Rotary Extraction Tool
DriMaster 3 Upholstery Tool
70 Gallon Fresh Water Tank

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://www.briggsandstratton.com/us/en/support/dealerlocator.
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,that machinesinall areas
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.