HYDRAMASTER Boxxer 323HP User Guide
Boxxer 323HP
Owner’s Manual
HydraMaster North America, Inc.
11015 47th Avenue West, Mukilteo, Washington 98275
MAN-44134 Rev. 0, July 30, 2010
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 North America, Inc.
(182-501-D)
Table of Contents
GeNeRAl INfORMATION ...........................................................................SeCTION 1
System Concept
Contact Information
Warnings, Cautions and Notices
Responsibilities .......................................................................................1-9
Machine Specications
High Altitude Operation
local Water Precautions ......................................................................... 1-14
INSTAllATION INfORMATION ...................................................................SeCTION 2
Operating the Boxxer 323HP in Hot Weather .........................................2-2
Setting Up the Boxxer 323HP .................................................................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
Streaking
Cleaning Tool Tips ................................................................................... 3-4
................................................................................................. 3-3
...................................................................................... 1-3
................................................................................. 1-4
.............................................................1-5
........................................................................... 1-12
...........................................................................1-14
............................................................................................. 3-3
OPeRATING INSTRUCTIONS .....................................................................SeCTION 4
Setting the Temperature .......................................................................... 4-4
Start-up Procedure
Setting the Pressure for Cleaning operations ......................................... 4-5
Setting the Pressure for High Pressure Washing Operations ................. 4-6
Shut Down Procedure
MACHINe MAINTeNANCe ..........................................................................SeCTION 5
Operational Maintenance ........................................................................ 5-2
Overall Machine Maintenance.................................................................5-3
engine Maintenance ............................................................................... 5-4
High Pressure Pump Maintenance
Vacuum System Maintenance ................................................................ 5-15
Descaling Procedure (Required)
freeze Guarding .....................................................................................5-17
Tensioning the Pump Drive Belt
WATeR AND CHeMICAl SySTeM .............................................................SeCTION 6
.................................................................................. 4-4
............................................................................. 4-7
......................................................... 5-6
............................................................. 5-16
.............................................................. 5-19
i - Boxxer 323HP Owner’s Manual
eleCTRICAl SySTeM ................................................................................SeCTION 7
SySTeMS TROUBleSHOOTING ...............................................................SeCTION 8
Heating System
Chemical System
....................................................................................... 8-2
....................................................................................8-3
engine ..................................................................................................... 8-4
High Pressure System
............................................................................ 8-8
Vacuum System ...................................................................................... 8-10
ASSeMBlIeS AND PARTS lIST ................................................................. SeCTION 9
Machine Assembly Parts list .................................................................. 9-4
frame Assembly Parts list .....................................................................9-9
engine Assembly Parts list..................................................................... 9-12
Pump Assembly Parts list ......................................................................9-14
Dash Assembly Parts list .......................................................................9-17
electrical Panel Assembly Parts list ....................................................... 9-19
Blower Heat exchanger Assembly Parts list .......................................... 9-20
Blower Assembly Parts list .....................................................................9-21
Silencer Assembly Parts list ...................................................................9-22
Water Box Assembly Parts list ...............................................................9-24
exhaust Assembly Parts list ...................................................................9-25
Idler Pulley Assembly Parts list .............................................................. 9-26
Hi Pressure Manifold Assembly Parts list ..............................................9-27
By-Pass Valve Assembly Parts list .........................................................9-28
Dura-flow APO Assembly Parts list ....................................................... 9-30
70 gallon Universal Recovery Tank Assembly Parts list ........................9-32
Machine Hose Routings .......................................................................... 9-33
HOW TO ORDeR PARTS ............................................................................SeCTION 10
Warranty Parts Orders
............................................................................ 10-1
Parts Orders ............................................................................................ 10-1
emergencies ...........................................................................................10-1
Boxxer 323HP Owner’s Manual - ii
WARRANTy INfORMATION .......................................................................SeCTION 11
Blower ....................................................................................................11-1
High Pressure Water Pump ................................................................... 11-1
Vacuum Tank
Chemical System
.......................................................................................... 11-1
....................................................................................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
iii - Boxxer 323HP Owner’s Manual
list of figures
figure 1-1. Hard Water Map of Mainland United States .....................................1-15
figure 2-1. location of Roof Vents in Vehicle ......................................................2-1
figure 2-2. Recommended location of Boxxer 323HP 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 323HP Dash Assembly - View 1 of 2 ......................................4-1
figure 4-2. Boxxer 323HP Dash Assembly - View 2 of 2 ......................................4-2
figure 4-3. location of Chemical Pump Shutoff Valve ..........................................4-3
figure 4-4. Chemical Pump Shutoff Valve Is On
When Valve Handle Is In line with Chemical Pump ...........................4-5
figure 4-5. Chemical Pump Shutoff Valve Is Off
When Valve Handle Is Perpendicular to Pump ...................................4-6
figure 5-1. Remove Valve Cap and Valve Assembly ............................................5-7
figure 5-2. Inspect Manifold and Old Valves ........................................................5-7
Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve ..........5-8
figure 5-4. Apply Grease and Install Valves .........................................................5-8
figure 5-5. Replace Valve Capand Torque to 95 ft. lbs. (13 m kgs) ......................5-8
figure 5-6. Separate Manifold from Crankcase ....................................................5-9
figure 5-7. Seal Assemblies May Come Off with Manifold ...................................5-9
figure 5-8. examine Ceramic Plungers ................................................................5-9
figure 5-9. Remove Stainless Steel Plunger Bolt and Ceramic Plunger ............5-10
figure 5-10. Install O-ring, Apply Sealant and
Slide Plunger over Plunger Guide ..................................................5-10
figure 5-11. extract Retainers and Seals ...........................................................5-11
figure 5-12. Seal Kit and Insertion Tool for Seal Installation ..............................5-12
figure 5-13. Install Seal Assembly Using O-Ring Grease ..................................5-12
figure 5-14. Install Retainers into Cavities .........................................................5-13
figure 5-15. Press low Pressure Seal Assembly into Cavity .............................5-13
figure 5-16. Re-install Manifold and Torque fasteners ......................................5-14
figure 5-17. Torque Sequence in “X” Pattern .....................................................5-14
figure 5-18. Torque Bolts to 22 ft. lbs (3 m kgs) .................................................5-14
figure 5-19. Recirculation fitting ........................................................................5-16
Boxxer 323HP Owner’s Manual - iv
figure 6-1. Annotated Water, Chemical and
Solution flow Diagram - View 1 of 2 ..................................................6-3
figure 6-2. Annotated Water, Chemical and
Solution flow Diagram - View 2 of 2 ..................................................6-4
figure 6-3. Chemical flow Diagram - larger View ...............................................6-5
figure 6-4. exhaust flow Diagram........................................................................6-6
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. Machine Assembly - View of 1 of 2 .....................................................9-2
figure 9-2. Machine Assembly - View of 2 of 2 .....................................................9-3
figure 9-3. frame Assembly - View 1 of 4 ............................................................9-5
figure 9-4. frame Assembly - View 2 of 4 ............................................................9-6
figure 9-5. frame Assembly - View 3 of 4 ............................................................9-7
figure 9-6. frame Assembly - View 4 of 4 ............................................................9-8
figure 9-7. engine Assembly - View 1 of 2 .........................................................9-10
figure 9-8. engine Assembly - View 2 of 2 ......................................................... 9-11
figure 9-9. Pump Assembly - View 1 of 2 ...........................................................9-13
figure 9-10. Pump Assembly - View 2 of 2 .........................................................9-14
figure 9-11. Dash Assembly - View 1 of 2 ..........................................................9-15
figure 9-12. Dash Assembly - View 1 of 2 ..........................................................9-16
figure 9-13. electrical Panel Assembly...............................................................9-19
figure 9-14. Heat exchanger Assembly..............................................................9-20
figure 9-15. Blower Assembly ............................................................................9-21
figure 9-16. Silencer Assembly ..........................................................................9-22
figure 9-17. Water Box Assembly .......................................................................9-23
figure 9-18. exhaust Assembly ..........................................................................9-25
figure 9-19. Idler Pulley Assembly......................................................................9-26
figure 9-20. Hi Pressure Manifold Assembly ......................................................9-27
figure 9-21. By-Pass Valve Assembly ................................................................9-28
figure 9-22. Dura-flow APO Assembly ..............................................................9-29
figure 9-23. 70 gallon Universal Recovery Tank Assembly ................................9-31
v - Boxxer 323HP Owner’s Manual
Boxxer 323HP Owner’s Manual - vi
1- General Information
The compact but powerful Boxxer 323HP is a carefully engineered truckmount multisurface cleaning machine designed and manufactured by HydraMaster North America,
Inc.
A 23 Hp Briggs and Stratton engine powers the Boxxer 323HP’s Tuthill 3006 vacuum
blower and the high pressure water pump, which is rated at 4 gpm (15 litres/minute).
The Boxxer 323HP’s innovative design features a stainless steel heat exchanger which
allows for heated, high pressure cleaning up to 2,500 psi (17,237 kPa).
Other features of the Boxxer 323HP include:
Dual oil bath and sight glasses for enhanced blower reliability•
0 - 2,500 psi (0 - 17,237 kPa) heated, without chemical•
0 - 1,200 psi (0 - 8,274 kPa) heated, with chemical•
A.D.C temperature control with instant heat up to 265° f (129.4° C)•
Optional Dura-flow Automatic Pump Out (APO)•
1-1: General Information
The Boxxer 323HP can be mounted onto a HydraMaster 85 gallon (322 litre) rotomolded
fresh water tank. The HydraMaster 70 gallon (265 litre) recovery tank, which comes in
the standard equipment package, or the 100 gallon (379 litre) recovery tank, offered as
an option, can be used with the 85 gallon fresh water tank installation.
This Owner’s Manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of the Boxxer 323HP. Component
troubleshooting guides have also been included for your convenience.
It is the purpose of this manual to help you properly understand, maintain and service
your Boxxer 323HP. follow the directions carefully and you will be rewarded with years
of protable, trouble-free operation.
It is imperative that no section of this manual be overlooked when preparing for operation
of the Boxxer 323HP. Please read the manual to familiarize yourself with the operation of
your Boxxer 323HP, paying special attention to all Warnings and Cautions.
This section of the manual contains the following information:
Contact Information
Warnings, Cautions and Notices
Machine Specications
Responsibilities
local Water Precautions
General Information: 1-2
SySteM COnCePt
This is how the Boxxer 323HP works:
Incoming water enters the water box and is pressurized by the high pressure water 1.
pump. The water is heated by the engine and blower exhaust in the cross ow heat
exchanger.
Cleaning solution is then injected into the pressurized water stream and the heated
2.
solution is delivered to the cleaning tool.
The solution is recovered by the vacuum generated by the vacuum pump and is
3.
collected in the recovery tank for proper disposal.
engine
Vacuum Blower
Silencer
Cross
Water Box
Flow Heat
exchanger
Water Pump
Photographs and illustrations included in this document can represent optional
equipment as well as standard equipment.
1-3: General Information
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.
Hours telephone numbers e-mail addresses
Monday-friday (425) 775-7275 Service
7:00 a.m. to 5:00 p.m. (425) 775-7276 Parts
Pacic Standard Time
(800) 426-4225 Parts /
Service fAX
techsupport@hydramaster.com
Tech Support:
Parts Support:
parts@hydramaster.com
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): __________________________________
General Information: 1-4
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.
1-5: General Information
Warnings and Cautions specic to the Boxxer 323HP 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. See page 1-10 of this Owner’s Manual for more information.
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.
General Information: 1-6
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.
Do not use a high pressure solution hose that is rated below the specications of
the Boxxer 323HP. Serious injury 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. Refer to Section 4 of this Owner’s Manual for
more information.
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. Refer to page 2-2 of this Owner’s Manual for
more information.
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.
1-7: General Information
Never operate the truckmount with a water hardness reading measuring 3.0 grains
per gallon (3.79 litres) or higher. Using water with a reading of 3.0 grains per
gallon or higher 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. for water hardness details, refer to
pages 1-14 through 1-17, and for descaling procedures, refer to page 5-16 of this
Owner’s Manual.
Never allow water to freeze inside the truckmount. Serious component damage
will occur. Perform all freeze guarding procedures as outlined on page 5-17 of
this 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.
General Information: 1-8
reSPOnSIBIlItIeS
Purchaser’s responsibilities
Prior to purchasing a van or trailer, 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 modication of the truckmount may void the warranty.
1-9: General Information
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
1.
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.
Check the packing list and verify that all items are accounted for.
2.
Installation Responsibilities
ensure proper payload capacity. It is the distributor’s responsibility to verify that the •
equipment package does not exceed the vehicle’s or trailer’s 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 or trailer, 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. Verify that the fuel pump is in accordance •
with HydraMaster’s recommendation.
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. Verify that the •
hoses meet or exceed HydraMaster’s specications.
ensure timely return of the document package.•
ensure that all aftermarket fuel cells meet or exceed federal Motor Vehicle Safety •
Standards (FMVSS) and Department of Transportation (DOT) certications.
General Information: 1-10
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.
1.
All safety precautions and their importance.2.
How to correctly start and shut down the truckmount.3.
How to correctly clean with the truckmount.4.
Where and how often to check and change component oil levels.5.
freezing damage and how to avoid it. This includes explaining proper freeze 6.
guarding procedures.
How to do basic troubleshooting of the truckmount.
7.
Hard water damage and how to avoid it. This includes how to determine if hard 8.
water exists in your area and the installation and use of water softening systems.
The truckmount’s warranty and warranty procedures.
9.
1-11: General Information
Machine SpecificationS
Frame Dimensions 24.0" W x 35" D x 31.5" H
(61 cm x 89 cm x 80 cm)
Weight 500 lbs (227 kg)
Engine - Briggs and
Oil Type 5W-30 Synthetic
Stratton 23 Hp
Capacity Approx. 1 1/2 quarts, or
Engine rpm High - 3,000 rpm
Fuel Consumption @
12” Hg/1,200 psi
Ignition Key
Vacuum Blower - Tuthill
Max. Vac. 12” Hg (304.8 mm Hg)
3006 Competitor (Dual
Splash Lubrication)
Oil Type PneuLube or other ISO 100
Gear End Capacity Approx. 7.0 oz (207 ml)
Drive End Capacity Approx. 5 oz (148 ml)
Blower rpm 3,200 rpm
48 oz (1.42 litres) when
changing oil and lter
(12” Hg / 2,500 psi)
Idle - 1,500 rpm
High - 1.0 gph
(3.79 litres/hr)
rating
Water Pump - General
Oil Type 15W-40
Pump
Capacity 14 oz (414 ml)
Pump Rate 4.0 gpm (15 litres/minute)
Pump rpm 1,700 rpm
Operating Pressure 0 - 1,200 psi (Heated)
(0 - 8,274 kPa) with
Chemical
General Information: 1-12
0 - 2,500 psi (Heated)
(0 - 17,237 kPa) without
Chemical
Chemical System Last Step Chemical
Injection with High
Pressure Shutoff Valve
Heating System Stainless Steel Cross Flow Heat Exchanger
Standard Equipment Recovery Hose 10 ft (3.05 m).
Water Box Rotomolded 3 - 4 gallon
(11.4 -15 litres) capacity
Recovery Tank 70 gallon Universal Tank
(265 litre Universal Tank)
Cleaning Wand/Tool Stainless Steel S-bend
Replaceable Grip
Rebuildable Solution Valve
100 ft (30.5 m)
Vacuum Hose
100 ft (30.5 m)
Solution Hose
Garden Hose Connector
Chemical Jug 5 gallon (19 litres)
Battery Box
Van Installation Kit
Owner’s Manual (on CD)
Owner’s Guide (printed)
Optional Equipment 85 gallon (322 litre)
Rotomolded Tank
Automatic Pump-Out (APO)
2.5” (6.35 cm) Exhaust
Though Floor Kit
1-13: General Information
HIgH altItUDe OPeratIOn
elevation plays a key role in how the truckmount will operate. Operation at high altitude
(above 5,000 ft [1,524 m]) 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.
find your local Briggs and Stratton dealer 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 inuences the reliability and efciency 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 [3.79 litres]) 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.
HydraMaster also recommends, in the strongest possible terms, that machines in all 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.
General Information: 1-14
Hard Water area Map
The hard water map, shown in figure 1-1, denes 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 conrmed by testing.
1-15: General Information
Water Softener
Cleaning efciency 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 323HP 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.
The relatively low cost of a water softener service is more than made up for by an increased
life of machine parts, reduced chemical costs and continued cleaning efciency. The
water softener will also increase the effectiveness of the cleaning chemicals, therefore
less chemical will be needed.
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 (3,406 litres) of water and the machine
uses an average of 30 gallons/hour (113.5 litres/hour), for an average of 5 hours a day,
this equals 150 gallons per day (568 litres/day). In 6 days the machine would use 900
gallons (3,406 litres) of water. Therefore, the softener would need to be charged every 6
working days for maximum softening.
General Information: 1-16
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 323HP 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 congured, the systems will continuously monitor the level of waste water
and pump it out simultaneously with the cleaning operation. The hidden benet of this
process is that the technician does not have to stop his/her cleaning to empty the recovery
tank.
IN ACCORDANCe WITH ePA, STATe AND lOCAl lAWS, DO NOT DISPOSe Of
WASTe WATeR INTO GUTTeRS, STORM DRAINS, STReAMS, ReSeRVOIRS,
eTC.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.
1-17: General Information
General Information: 1-18
2 - Installation Information
Although there are many different heavy duty vehicles and trailers used for carpet cleaning
equipment,
with a heavy-duty suspension package equivalent to a 3/4 ton capacity or a 3/4 ton HD
van. If a fresh water tank is added, a one ton or larger capacity van is required.
Prior to installation of the Boxxer 323HP, HydraMaster recommends installing a sprayon bed liner in the vehicle. This provides ‘metal to cushion’
mounting rather than ‘metal to metal’ and makes for an
attractive van interior.
HydraMaster also recommends installing roof vents in
vehicles operated in hot weather locations. Roof vent
positions are shown in
distributor about selection and/or installation of powered
roof vents.
the preferable vehicle for a Boxxer 323HP installation is a tandem axle trailer
figure 2-1. Consult your local RV
for best results, the fan should draw air into the vehicle
which will supply cooler air to the air cleaner intake.
HydraMaster requires a powered roof vent above the air cleaner intake. failure
to install a powered roof vent in such a manner may result in serious component
or engine damage.
roof Vents in Vehicle
location of Figure 2-1.
2-1: Installation Information
OPeratIng tHe BOxxer 323HP In HOt WeatHer
HydraMaster recommends the following steps when operating the Boxxer 323HP
during periods of hot weather (95º f [35º C] or higher). This will help ensure that your
Boxxer 323HP continues to run at 100% capacity during even the hottest days.
A minimum of 9” (22.9 cm) of clearance is required on both sides of the Boxxer 323HP, 1.
when installed. ensure that additional equipment or other materials are not stored at
the sides or on top of the machine. Unobstructed airow around the unit is critical for
cooling the engine and other components.
for side-door vans with “barn doors”, open the doors as wide as their construction 2.
will allow. Be sure to open the doors beyond their standard “straight-out” position,
if possible, by releasing the stops and putting the doors in their fully extended
position.
Provide cross-ventilation. When possible, keeping the rear doors open while the
3.
machine is running will substantially reduce the temperature inside the van or trailer
and will provide a path for cooling air ow. For rear-mount installations, open up the
other doors in the van.
Consider adding powered roof vents to the vehicle (if not already installed). These
4.
vents can signicantly reduce interior temperatures and will result in much cooler
operation. A powered roof vent is required when the Boxxer 323HP is mounted on
the optional 85 Gallon fresh Water Tank.
Installation Information: 2-2
Use caution when drilling any holes through the van oor. Many vans have critical
components mounted directly below the vehicle oor that could be damaged by
a misplaced drill bit.
lOCatIng tHe BOxxer 323HP In VeHICle
There are two recommended entry points on the vehicle for the Boxxer 323HP installation:
the side door or the rear doors.
Most installations are through the side door. This provides rear access for accessories
and hoses as well as unobstructed access to the component/working side of the machine,
thus making it a bit easier to perform maintenance and/or repair without removing the unit
from the truck.
Rear mounting requires the unit to be slid to the right side as far as possible Although
installing the Boxxer 323HP through the rear door partly limits working access, it does
direct the noise away from the cleaning site.
In addition, rear mounting not only provides adequate working space on the component
side of the unit but also improves weight distribution inside the van (engine and component
weight line up over drive shaft). Some cleaners in colder geographical areas prefer this
placement for better traction in ice and snow. Also, it is physically easier to load the unit
into the rear door due to the height of the vehicle bed.
Figure 2-2. recommended location of Boxxer 323HP in Van
Secure Installation
No matter how the unit is installed, check to see if the Boxxer 323HP is properly secured
to the oor of the van with the hardware provided. This safety measure will ensure that the
machine will not slide inside the van. See figure 2-2 for the correct installation.
2-3: Installation Information
A sudden or crash stop will cause the machine to rocket forward if not properly
secured. To prevent serious personal injury, ensure that the Boxxer 323HP is well
secured to the oor of the vehicle with the hardware supplied. Protect yourself
and the machine.
HydraMaster strongly recommends that the exhaust from the front of the machine
be vented down under the truck to prevent carbon monoxide from entering the
job site. always park the truck so the exhaust is blowing away from the job
site.
Never operate this machine with a portable gas can inside the truck. Doing so
increases the risk of a re or explosion.
Mount a re extinguisher just inside the rear or side door for emergencies.
Do not use a portable propane tank inside of the truck or van. It is dangerous and
illegal in most states.
Transporting any vented fuel container that presently holds or has ever held a
ammable liquid in a vehicle containing the Boxxer 323HP is strictly forbidden by
HydraMaster Corporation and by federal and state regulation.
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
Installation Information: 2-4
SettIng UP tHe BOxxer 323HP
Prior to operating the Boxxer 323HP, follow these steps:
Adjust the vacuum relief located on the recovery tank by capping all the vacuum 1.
inlets. The machine should be set to 12” Hg maximum.
Setting the vacuum level higher than the recommended value can result in an
increased risk of serious component damage.
The Boxxer 323HP is shipped from the factory with antifreeze added to the solution
system.
Recover this antifreeze and dispose of the recovered antifreeze as stated in the local laws
and regulations.
KeeP ANTIfReeZe OUT Of ReACH Of CHIlDReN AND ANIMAlS. Drinking
antifreeze can cause death.
If required, dispose of antifreeze at facilities licensed to accept household
hazardous waste. If permitted, dispose of antifreeze in sanitary sewer systems.
Do not pour antifreeze into storm sewers, septic systems, or onto the ground.
Doing so causes health and environmental dangers.
ensure the antifreeze is completely drained from the solution system. If any
antifreeze remains in the system, it could damage machine components and
damage fabric.
2-5: Installation Information
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