HydraMaster BoxxerXL User manual

Boxxer XL
Owner’s Manual
HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-44348 Rev. 1, September 27, 2013
(000-182-886)
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. © 2013 HydraMaster

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i - Boxxer XL Owner’s Manual
Table of Contents
GENERAL INFORMATION........................................................................... SECTION 1
System Concept...................................................................................... 1-3
Contact Information................................................................................. 1-4
Warnings, Cautions and Notices............................................................. 1-5
Responsibilities ....................................................................................... 1-9
Machine Specications ........................................................................... 1-12
Spare Parts List....................................................................................... 1-14
High Altitude Operation ........................................................................... 1-15
Local Water Precautions ......................................................................... 1-15
INSTALLATION INFORMATION................................................................... SECTION 2
Operating the Boxxer XL in Hot Weather................................................ 2-2
Setting up the Boxxer XL ........................................................................ 2-5
Orientation of Fuel Pump ........................................................................ 2-6
CLEANING INFORMATION ......................................................................... SECTION 3
Precautions ............................................................................................. 3-2
Preparing the Carpet for Extraction......................................................... 3-2
Rinse and Recover.................................................................................. 3-3
Overwetting............................................................................................. 3-3
Streaking................................................................................................. 3-3
Cleaning Tool Tips................................................................................... 3-4
OPERATING INSTRUCTIONS..................................................................... SECTION 4
Setting the Temperature.......................................................................... 4-3
Start Up Procedure ................................................................................. 4-4
Setting the Pressure for Cleaning operations ......................................... 4-5
Shut Down Procedure............................................................................. 4-6
MACHINE MAINTENANCE.......................................................................... SECTION 5
Operational Maintenance........................................................................ 5-2
Overall Machine Maintenance................................................................. 5-4
Engine Maintenance ............................................................................... 5-5
High Pressure Pump Maintenance ......................................................... 5-7
Vacuum System Maintenance ................................................................ 5-16
Descaling Procedure (Required)............................................................. 5-17
Freeze Guarding ..................................................................................... 5-18
WATER AND CHEMICAL SYSTEM ............................................................. SECTION 6

Boxxer XL Owner’s Manual - ii
ELECTRICAL SYSTEM................................................................................ SECTION 7
Electrical System Information.................................................................. 7-1
SYSTEMS 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 LISTS............................................................... SECTION 9
Console Assembly Parts List................................................................... 9-7
Console Assembly Parts List (continued)................................................ 9-8
Chemical Jug Tray Assembly Parts List.................................................. 9-10
Frame Assembly Parts List ..................................................................... 9-12
Side Cover Assembly Parts List.............................................................. 9-13
Blower Assembly Parts List..................................................................... 9-15
Engine Assembly Parts List..................................................................... 9-17
Blower Heat Exchanger Assembly Parts List.......................................... 9-19
Pump Assembly Parts List ...................................................................... 9-22
Exhaust Heat Shield Protector Assembly Parts List................................ 9-23
Electrical Panel Assembly Parts List....................................................... 9-25
Hi PSI Manifold Assembly Parts List....................................................... 9-27
Differential Check Valve Assembly Parts List.......................................... 9-28
By-Pass Valve Assembly Parts List......................................................... 9-29
Water Box Assembly Parts List ............................................................... 9-32
Exhaust Assembly Parts List................................................................... 9-33
Diverter Valve Actuator Assembly Parts List ........................................... 9-35
Diverter Valve Box Assembly Parts List .................................................. 9-37
Dash Assembly Parts List ....................................................................... 9-40
Silencer Assembly Parts List................................................................... 9-41
70 Gallon Universal Recovery Tank (URT) Assembly Parts List............. 9-43
70 Gallon Universal Recovery Tank (URT) Cover Assembly Parts List .. 9-44
100 Gallon Universal Recovery Tank (URT) Assembly Parts List........... 9-46
100 Gallon Universal Recovery Tank (URT) Cover Assembly Parts List 9-47
Vacuum Relief Valve Assembly Parts List............................................... 9-48
Hose Routings......................................................................................... 9-49
HOW TO ORDER PARTS ............................................................................ SECTION 10
Warranty Parts Orders ............................................................................ 10-1
Parts Orders............................................................................................ 10-1
Emergencies ........................................................................................... 10-1

iii - Boxxer XL Owner’s Manual
WARRANTY INFORMATION ....................................................................... SECTION 11
Blower .................................................................................................... 11-1
High Pressure Water Pump ................................................................... 11-1
Vacuum Tank .......................................................................................... 11-1
Chemical System .................................................................................... 11-1
Control Panel ......................................................................................... 11-1
Vacuum and Solution Hoses .................................................................. 11-2
Cleaning Wand and Tool ......................................................................... 11-2
Water Heating System ............................................................................ 11-2
Hard Water Deposits............................................................................... 11-2
Warranty Procedure ................................................................................ 11-2
ACCESSORIES AND CHEMICAL SOLUTIONS.......................................... SECTION 12

Boxxer XL Owner’s Manual - iv
List of Figures
Figure 1-1. Hard Water Map of Mainland United States ........................................... 1-16
Figure 2-1. Location of Roof Vents in Vehicle ............................................................ 2-1
Figure 2-2. Recommended Location of Boxxer XL 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 XL Upper Dash Assembly............................................................. 4-1
Figure 4-2. Boxxer XL Lower Dash Assembly............................................................. 4-2
Figure 4-3. Rotate Temperature Dial to Select Temperature ...................................... 4-3
Figure 4-4. Turn Throttle Cable Knob Counterclockwise to Increase ......................... 4-4
Figure 4-5. Adjust Pressure by Rotating Valve Left (Decrease) or Right (Increase) . 4-5
Figure 4-6. Location of Blower Lube Port.................................................................... 4-6
Figure 5-1. Remove Valve Cap and Valve Assembly.................................................. 5-8
Figure 5-2. Inspect Manifold and Old Valves .............................................................. 5-8
Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve ................ 5-9
Figure 5-4. Apply Grease and Install Valves ............................................................... 5-9
Figure 5-5. Replace Valve Cap and Torque to 95 ft. lbs.............................................. 5-9
Figure 5-6. Separate Manifold from Crankcase ........................................................ 5-10
Figure 5-7. Seal Assemblies May Come Off with Manifold ....................................... 5-10
Figure 5-8. Examine Ceramic Plungers .................................................................... 5-10
Figure 5-9. Remove Stainless Steel Plunger Bolt and Ceramic Plunger .................. 5-11
Figure 5-10. Install O-ring, Apply Sealant and Slide Plunger over Plunger Guide .... 5-11
Figure 5-11. Extract Retainers and Seals ................................................................. 5-12
Figure 5-12. Seal Kit and Insertion Tool for Seal Installation .................................... 5-13
Figure 5-13. Install Seal Assembly Using O-Ring Grease ........................................ 5-13
Figure 5-14. Install Retainers into Cavities ............................................................... 5-14
Figure 5-15. Press Low Pressure Seal Assembly into Cavity ................................... 5-14
Figure 5-16. Re-install Manifold and Torque Fasteners ............................................ 5-15
Figure 5-17. Torque Sequence in “X” Pattern ........................................................... 5-15
Figure 5-18. Torque Bolts to 22 ft. lbs ....................................................................... 5-15
Figure 5-19. Recirculation Fitting .............................................................................. 5-17
Figure 6-1. Flow Diagram - View 1 of 3....................................................................... 6-3
Figure 6-2. Flow Diagram - View 2 of 3....................................................................... 6-4
Figure 6-3. Flow Diagram - View 3 of 3....................................................................... 6-5

v - Boxxer XL Owner’s Manual
Figure 7-1. Electrical Schematic ................................................................................. 7-2
Figure 7-2. Wiring Diagram - View 1 of 3 .................................................................... 7-3
Figure 7-3. Wiring Diagram - View 2 of 3 .................................................................... 7-4
Figure 7-4. Wiring Diagram - View 3 of 3 .................................................................... 7-5
Figure 9-1. Console Assembly - View 1 of 5 ............................................................... 9-2
Figure 9-2. Console Assembly - View 2 of 5 ............................................................... 9-3
Figure 9-3. Console Assembly - View 3 of 5 ............................................................... 9-4
Figure 9-4. Console Assembly - View 4 of 5 ............................................................... 9-5
Figure 9-5. Console Assembly - View 5 of 5 ............................................................... 9-6
Figure 9-6. Chemical Jug Tray Assembly.................................................................... 9-9
Figure 9-7. Frame Assembly ..................................................................................... 9-11
Figure 9-8. Side Cover Assembly.............................................................................. 9-13
Figure 9-9. Blower Assembly .................................................................................... 9-14
Figure 9-10. Engine Assembly .................................................................................. 9-16
Figure 9-11. Blower Heat Exchanger Assembly........................................................ 9-18
Figure 9-12. Pump Assembly - View 1 of 2 ............................................................... 9-20
Figure 9-13. Pump Assembly - View 2 of 2 ............................................................... 9-21
Figure 9-14. Exhaust Heat Shield Protector Assembly ............................................. 9-23
Figure 9-15. Electrical Panel Assembly..................................................................... 9-24
Figure 9-16. Hi PSI Manifold Assembly..................................................................... 9-26
Figure 9-17. Differential Check Valve Assembly ....................................................... 9-28
Figure 9-18. By-Pass Valve Assembly ...................................................................... 9-29
Figure 9-19. Water Box Assembly - View 1 of 2........................................................ 9-30
Figure 9-20. Water Box Assembly - View 2 of 2........................................................ 9-31
Figure 9-21. Exhaust Assembly ................................................................................ 9-33
Figure 9-22. Diverter Valve Actuator Assembly......................................................... 9-34
Figure 9-23. Diverter Valve Box Assembly................................................................ 9-36
Figure 9-24. Dash Assembly - Part 1 of 2 ................................................................. 9-38
Figure 9-25. Dash Assembly - Part 2 of 2 ................................................................. 9-39
Figure 9-26. Silencer Assembly ................................................................................ 9-41
Figure 9-27. 70 Gallon Universal Recovery Tank (URT) Assembly........................... 9-42
Figure 9-28. 70 Gallon Universal Recovery Tank (URT) Cover Assembly................ 9-44
Figure 9-29. 100 Gallon Universal Recovery Tank (URT) Assembly......................... 9-45
Figure 9-30. 100 Gallon Universal Recovery Tank (URT) Cover Assembly.............. 9-47
Figure 9-31. Vacuum Relief Valve Assembly............................................................. 9-48

Boxxer XL Owner’s Manual - vi
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1-1: General Information
1- General Information
The Boxxer XL is a mid-sized truckmount machine designed and manufactured by
HydraMaster. It is intended for multitasking in residential and commercial carpet/upholstery
cleaning.
The 31 HP Briggs and Stratton engine powers the Boxxer XL’s Tuthill 4007 Tri-Lobe
vacuum blower and the high pressure water pump, which is rated at 4 gpm (15 litres/
minute). The patented heat exchanger
system allows for a non-recirculating or
“dump-less” subsystem which reduces
the need to rell the fresh water tank or
empty the recovery tank. *
Purposely designed for quieter
operation, the Boxxer XL is rated
at approximately 68 dB through the
exhaust. (In comparison, a hair dryer
or food processor is rated at about
80 - 90 dB.)
Convenientandtime-savingmaintenance
was also a consideration throughout
the Boxxer XL’s design process. As a
result, the following components were
specically positioned to facilitate easy
servicing and troubleshooting:
• Heat exchanger core - easy to
remove for periodic maintenance and
cleaning
• Pump - oil level sight glass, oil ll
hole, and belts easy to see and easily
accessed
• Electrical box - located at the front of the machine to allow convenient access for
troubleshooting, if necessary
• Water box - easy to remove
• Coupler - rubber element can be checked and changed in minutes
* U.S. Patent No. 8,032,976

General Information: 1-2
Other features of the Boxxer XL include:
• Dual wand capability
• Aluminum belt guard which also serves as a heat shield
• Dura-Flow Automatic Pump-Out (APO) available as an option
• Exhaust Thru Floor available as an option
You can also select either the HydraMaster 70 gallon (265 litre) recovery tank or a 100
gallon (379 litre) recovery tank.
This Owner’s Manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of the Boxxer XL. Component
troubleshooting guides have also been included for your convenience.
The intent of this manual is to help you properly understand, maintain and service your
Boxxer XL. Follow the directions carefully and you will be rewarded with years of protable,
trouble-free operation.
It is imperative that no section of this manual be overlooked when preparing for operation
of the Boxxer XL. Please read the manual to familiarize yourself with the operation of your
Boxxer XL, paying special attention to all Warnings and Cautions.
This section of the manual contains the following information:
System Concept
Contact Information
Warnings, Cautions and Notices
Responsibilities
Machine Specications
High Altitude Operation
Local Water Precautions
Photographs and illustrations included in this document can represent optional
equipment as well as standard equipment.

1-3: General Information
SYSTEM CONCEPT
This Boxxer XL’s airow travels from the vacuum blower, combines with the engine
exhaust, streams through the heat exchanger and then through the silencer.
Heat Exchanger
Vacuum
Blower
High Pressure
Water Pump
Silencer
Engine
Water
Box

General Information: 1-4
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://hydramaster.com/HowToBuy/DealerLocator.aspx
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]
When calling your distributor, be sure to reference the serial number and date of
purchase.
FOR YOUR REFERENCE:
Serial No.____________________________________________________
Date of Purchase:_____________________________________________
Purchased From (Distributor): __________________________________

1-5: 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: 1-6
Warnings and Cautions specic to the Boxxer XL include the following:
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 ft (3.05 m). 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 8-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 may
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.

1-7: 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 of 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 (3.79 litres) or higher. Using reading than 3.0 grains per gallon (3.79
litres) 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: 1-8
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.
Use of the vacuum recovery system when stripping or otherwise removing wax
from oors is specically excluded as an approved use of the truckmount. Failure
to follow this exclusion may lead to component failure and will invalidate your
warranty.
Use of the vacuum recovery system for “dry cleaning”, without corresponding
solution application (i.e. duct cleaning), is specically excluded as an approved
use of the truckmount. Failure to follow this exclusion may lead to component
failure and will invalidate your warranty.
If concentrated acids or solvents are used to pre-treat surfaces before power
washing, do not recover them through the vacuum system. Failure to follow this
exclusion may lead to component failure and will invalidate your warranty.

1-9: General Information
RESPONSIBILITIES
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 and drying equipment. 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 (500+ CC Amps) 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®.
Plywood and carpet are not recommended.
• 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
Warnings and Cautions.
• 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.

General Information: 1-10
Distributor’s Responsibility
Acceptance of Shipment
Before accepting the truckmount, check the following:
1. The truckmount should be free from any damage during shipping. Do not sign the
delivery receipt until you have closely inspected the truckmount and noted any
damage on the delivery receipt. Hidden damage may be present even if the box looks
okay. It is recommended that the box be opened before you sign for the shipment.
2. Check the packing list and verify that all items are accounted for.
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.
• Ensure proper placement of the truckmount, recovery tank, fresh water tank, and
accessories in the vehicle, and check that they are secured 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 and other accessories for correct operation.
• Ensure timely return of the document package.

1-11: General Information
Training
The distributor should provide a thorough review of the operation manual with the
purchaser along with instruction and familiarization in:
1. How all the truckmount’s systems function.
2. All safety precautions and their importance.
3. How to correctly start and shut down the truckmount.
4. How to correctly clean with the truckmount.
5. Where and how often to check and change component oil levels.
6. Freezing damage and how to avoid it. This includes explaining proper freeze
guarding procedures.
7. How to do basic troubleshooting of the truckmount.
8. 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.
9. The truckmount’s warranty and warranty procedures.

General Information: 1-12
MACHINE SPECIFICATIONS
Frame Dimensions 24” W x 39” H x 41” D
(61 cm x 99 cm x 104 cm)
Weight 800 lbs (363 kg)
Engine - 31 HP Briggs
and Stratton V-Twin Air-
cooled
Oil Type 5W-30 Synthetic
Capacity 2.4 quarts (2.3 litres) -
when changing oil and lter
Engine rpm 3,000 rpm
Fuel Consumption 1.6 gph (6.1 litres/hour)
Ignition Electric Key Start
Vacuum Blower - Tuthill
Dominator 4007 (Dual
Splash Lubrication)
Oil Type
Max. Vac. 12” Hg
PneuLube or other ISO 100
rating
Gear End Capacity Approx. 5.8 oz. (171.5 ml)
Drive End Capacity Approx. 4.7 oz. (139 ml)
Blower rpm 3,000 rpm
Water Pump - General
Pump
Oil Type 15W-40
Capacity 14 oz (414 ml)
Pump Rate 4.0 gpm (15 litres/minute)
Water Box Rotomolded 4 gallons
(15 litres) capacity
Operating Pressure 0 - 1,200 psi
(0 - 8,274 kPa)
Chemical System Last Step Chemical
Injection
Heating System Cross Flow Heat
Exchanger
Copper Tube and Fin Heat
Exchanger