HYDRAMASTER MAXX 450D, MAXX 470D, MAXX 450 User Manual
HYDRAMASTER
11015 47th Avenue W, Mukilteo, WA 98275
MAXX
Corporation
450D/470D/
450 Diesel
Machine Serial Number________________________
Copyright© 2007
HYDRAMASTER© Corporation
Mukilteo, Washington
MAN-182-047
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 the HYDRAMASTER© Corporation. All rights reserved.
Revised September 12, 2007
MAXX 450D/470D/450 Diesel
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
Table of Contents
GENERAL INFORMATION......................................................................... Section 1
Telephone Numbers........................................................................... 1-2
Precautions ....................................................................................... 1-3
System Operation ............................................................................. 1-7
Machine Specifications ..................................................................... 1-8
Spare Parts Recommendation .......................................................... 1-11
Spare Parts List ...................................................................... 1-11
Responsibilities................................................................................. 1-13
Vehicle Preparation ........................................................................... 1-15
High Altitude Operation Preparation .................................................. 1-19
Local Water Precautions ................................................................... 1-21
Waste Water Disposal Advisory .............................................. 1-22
Map ........................................................................................ 1-24
Machine Assemblies and Parts Lists ................................................. 1-25
CLEANING AND CHEMICALS .................................................................. Section 2
pH Chart ............................................................................................ 2-3
OPERATING INSTRUCTIONS ................................................................... Section 3
Start Up ............................................................................................. 3-1
Shut Down ......................................................................................... 3-3
Freeze Guard .................................................................................... 3-5
Freeze Protection of Pump-In System ..................................... 3-8
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
MAXX 450 DIESEL ........................................................................................... Section 4
Diesel Fuel Flow Diagram .................................................................................. 4-2
Diesel Fuel Filter/Separator ............................................................................... 4-3
Diesel Wiring Schematic .................................................................................... 4-4
Diesel Wiring Diagrams .....................................................................................4-5
WATER AND CHEMICAL SYSTEM .................................................................... Section 5
Solution Flow Diagram ........................................................................................ 5-2
Chemical System Flow Diagram .......................................................................... 5-3
Exhaust, Vacuum, Coolant and APO Diagram ....................................................... 5-4
Chemical Tank Troubleshooting ............................................................................ 5-5
HIGH PRESSURE PUMP ................................................................................... Section 6
Pump Maintenance .............................................................................................. 6-1
Service ............................................................................................................... 6-3
Cat Pump Assembly Drawing and Parts List ......................................................... 6-7
Pump Troubleshooting ......................................................................................... 6-9
CLEANING WAND PARTS ................................................................................. Section 7
Cleaning Wand Assembly Drawings and Parts Lists .............................................. 7-1
VACUUM SYSTEM ............................................................................................. Section 8
Blower Troubleshooting ........................................................................................ 8-3
Roots Blower Instruction Booklet
ENGINE TROUBLESHOOTING .........................................................................Section 9
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
ELECTRICAL SYSTEM ....................................................................................Section 10
Wiring Schematic for 450D and 470D Models ..................................................... 10-2
Wiring Diagrams for 450D and 470D Models........................................... 10-3 —10-5
MACHINE MAINTENANCE ............................................................................ Section 11
Daily .............................................................................................................. 11-1
Weekly, Monthly ................................................................................................ 11-2
Quarterly, De-scaling ........................................................................................ 11-3
Machine Maintenance ...................................................................................... 11-4
Maintenance Logs
HOW TO ORDER PARTS ............................................................................... Section 12
WARRANTY INFORMATION .......................................................................... Section 13
Golden Guarantee
ACCESSORIES .............................................................................................. Section 14
PRODUCT UPDATES .................................................................................... Section 15
HydraMaster Corporation
01/29/01
MAXX 450D/470D/450 Diesel
List of Figures
Fig 1-1 Roof Vent ......................................................................................... 1-16
Fig 1-2 Recommended Placement ............................................................. 1-16
Fig 1-3 Tie-down Cleats .............................................................................. 1-17
Fig 1-4 Actuator Location............................................................................. 1-20
Fig 1-5 Hard Water Map .............................................................................. 1-24
Machine Assemblies:
Fig 1-7 Frame Assembly-View 1 ................................................................. 1-26
Fig 1-8 Frame Assembly-View 2 ................................................................. 1-27
Fig 1-9 100 Gallon Universal Recovery Tank Assembly .............................. 1-30
Fig 1-10 100 Gallon Universal Recovery Tank Cover .................................... 1-33
Fig 1-11 Vacuum Relief Valve Assembly ....................................................... 1-34
Fig 1-12 Dash Assembly ............................................................................... 1-35
Fig 1-13 Lower Dash Plumbing Connection Panel Assembly ....................... 1-37
Fig 1-14 Upper Dash Instrument Panel Assembly ........................................ 1-39
Fig 1-15 Control Panel Assembly .................................................................. 1-41
Fig 1-16 Bypass Heat Exchanger.................................................................. 1-43
Fig 1-17 Water-to-Water Heat Exchanger ..................................................... 1-44
Fig 1-18 Water Box Assembly ....................................................................... 1-46
Fig 1-19 CAT 3CP Pump Assembly .............................................................. 1-48
Fig 1-20 Air Pump Assembly ......................................................................... 1-50
Fig 1-21 Chemical Pump Assembly .............................................................. 1-51
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
Fig 1-22 Dura-Flow APO Assembly (Automatic Pump Out) .......................... 1-52
Fig 1-23 Fuel Pump Assembly ...................................................................... 1-54
Fig 1-24 Diverter Valve Actuator Assembly .................................................... 1-55
Fig 1-25 Blower MD 4005 Assembly.............................................................. 1-57
Fig 1-26 Blower MD 4007 Assembly.............................................................. 1-59
Fig 1-27 Exhaust Assembly - View 1 ............................................................. 1-61
Fig 1-28 Exhaust Assembly - View 2 ............................................................. 1-62
Fig 1-29 Hi PSI Manifold Assembly ................................................................ 1-64
Fig 1-30 Bypass Valve Assembly .................................................................. 1-66
Fig 1-31 Maxx 450D Daihatsu Engine Assembly - View 1 ............................. 1-68
Fig 1-32 Maxx 450D Daihatsu Engine Assembly - View 2 ............................. 1.69
Fig 1-33 Maxx 470D Daihatsu Engine Assembly - View 1 ............................. 1-73
Fig 1-34 Maxx 470D Daihatsu Engine Assembly - View 2 ............................. 1-74
Fig 1-35 Engine Cover Support Assembly ..................................................... 1-78
Fig 1-36 Chemical Jug Tray Assembly .......................................................... 1-80
Fig 1-37 Dash Assembly - Maxx 450 Diesel .................................................. 1-82
Fig 1-38 Lower Dash Plumbing Panel Assembly - Maxx 450 Diesel ............. 1-85
Fig 1-39 By-Pass Valve Assembly - Maxx 450 Diesel ................................... 1-87
Fig 1-40 Daihatsu Engine Assembly - Maxx 450 Diesel - View 1 .................. 1-89
Fig 1-41 Daihatsu Engine Assembly - Maxx 450 Diesel - View 2 .................. 1-90
Fig 1-42 Water To Water HX Assembly - Maxx 450 Diesel ............................ 1-94
Fig 1-43 Electrical Control Panel Assembly - Maxx 450 Diesel ..................... 1-96
Fig 2-1 pH Chart .......................................................................................... 2-3
Fig 2-2 Cleaning Stroke Procedure.............................................................. 2-3
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
Fig 3-1 Recirculation Fitting ......................................................................... 3-4
Fig 4-1 Diesel Flow Diagram ....................................................................... 4-2
Fig 4-2 Diesel Fuel Filter with Manual Priming Pump,
Water Separator with Electirc Motor................................................ 4-3
Fig 4-3 Diesel Wiring Schematic ................................................................. 4-4
Fig 4-4 Diesel Wiring Diagram Sheet 1 ....................................................... 4-5
Fig 4-5 Diesel Wiring Diagram Sheet 2 ....................................................... 4-6
Fig 4-6 Diesel Wiring Diagram Sheet 3 ....................................................... 4-7
Fig 5-1 Water Flow Diagram ....................................................................... 5-2
Fig 5-2 Chemical System Flow Diagram .................................................... 5-3
Fig 5-3 Exhaust, Vacuum, Coolant and APO Diagram ................................ 5-4
Fig 6-1 Servicing the Valves ............................................................... 6-2
Fig 6-2 Servicing the Low Pressure and High Pressure Seals............. 6-3
Fig 6-3 Cat Pump ............................................................................... 6-6
Fig 7-1 Valve Assembly ...................................................................... 7-1
Fig 7-2 Solution Valve Assembly ......................................................... 7-2
Fig 7-3 Valve Stem Assembly ............................................................. 7-3
Fig 7-4 HydraHoe Wand Assembly ..................................................... 7-4
Fig 10-1 Wiring Schematic for 450 and 470 Models ............................. 10-2
Fig 10-2 Wiring Diagram Sht 2 for 450 and 470 Models ....................... 10-3
Fig 10-3 Wiring Diagram Sht 3 for 450 and 470 Models ....................... 10-4
Fig 10-4 Wiring Diagram Sht 4 for 450 and 470 Models ....................... 10-5
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
Quick Reference
HydraMaster Corporation
Quick Reference
Recovery Tank Float Switch-Top Float Shown
B4624 Rev—
MAXX 450D/470D/450 Diesel
Fuel Pump Assembly
B4627 Rev—
HydraMaster Corporation
MAXX 450D/470D/450 Diesel
Diesel Fuel Filter with Manual Priming Pump
and Water Separator with Electric Motor.
Quick Reference
HydraMaster Corporation
Quick Reference
MAXX 450D/470D/450 Diesel
Diesel Fuel Flow Diagram
HydraMaster Corporation
Introduction
Maxx 450D/470D/450 Diesel
Section 1-1
his manual contains installation and operation instructions as well as informa-
T
tion required for proper maintenance, adjustment and repair of this unit. Since
the first and most important part of repair work is the correct diagnosis of the
problem, component manual troubleshooting charts have been included for your
convenience.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two functions to perform, the truckmounted carpet cleaning plant has many functions to
perform simultaneously.
• The engine has to run at a consistent RPM.
• The vacuum has to pull air and dirty water back from cleaning site.
• The water pump provides stable pressure at proper water flow for
cleaning.
• The chemical has to be injected into the water stream at the right
concentration.
• The heating system must maintain proper heat.
• The vacuum tank must store dirty water until drained.
As you can see, it is not just a turn-key operation with one thing to worry about,
Does it start?!
HydraMaster Corporation
Page 1-2 MAXX 450D/470D/Diesel
!
WARNING
The manufacturer uses this symbol throughout the manual to warn of possible
injury or death
!
CAUTION
This symbol is used to warn of possible equipment damage.
Hours Telephone Numbers
Monday - Friday (425) 775-7276 Parts
8:00 am to 5:00 pm (425) 775-7275 Service
PACIFIC STANDARD TIME (800) 426-4225 Parts/Service Fax
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-3
Precautions
lthough this unit has been factory adjusted, it may require additional adjust-
A
ments to achieve optimum performance, for instance altitude may require
carburetor adjustment and ambient temperatures may require heat control adjustment. When required, consult an authorized representative.
!
CAUTION
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor.
Many vans have critical components mounted directly below the van floor that
could be damaged by a misplaced drill bit. (See Product Support Bulletins 92102,
94062 and 94063 at the end of the manual.)
!
CAUTION
ENGINE COOLING: Units employing internal combustion engines must not be
enclosed within a van with doors and windows closed. Excessive temperatures within
the engine will result in premature engine failure and a compromise of
applicable warranty.
!
WARNING
LEVEL OPERATION: During operation, van or trailer must be parked on level ground
not to exceed + or - 10 degrees. Failure to insure proper leveling may prevent
proper internal lubrication of engine, vacuum and/or high pressure components.
!
CAUTION
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
HydraMaster Corporation
Page 1-4 MAXX 450D/470D/Diesel
!
CAUTION
ACID RINSE AGENTS: The increased demand for “clear water” rinsing results in
the need for special care when using these acid based chemicals in your equipment.
The negative side of these products is the corrosive effects the acid can have on
metals, including swivels, pumps, heat exchangers, etc.
HydraMaster will not warranty parts that have been damaged from using unprotected acid products that have obviously caused failures.
!
CAUTION
HARD WATER PROTECTION: Failure to take appropriate measures to prevent scale
build up can result in system failure and loss of warranty on affected parts. Test
the water in your immediate and surrounding areas with hard water test strips.
Assume all water obtained from wells is hard. If you are operating in a “Hard Water Area” (3.5 grains or more per gallon), use a water softening system.
!
CAUTION
FREEZE PROTECTION: There is often little warning before a cold spell. Therefore,
not protecting this equipment from freezing will result in costly down-time. Placing
an electric heater in the truck or parking the truck indoors will help to insure against
freezing, but should not be the primary method of freeze protection.
!
CAUTION
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or wood
products) to come in contact with the exhaust system.
!
WARNING
HOT SURFACES: During the operation of this equipment, many surfaces on the
machine will become very hot. When near the van for any reason care must be
taken not to touch any hot surface, such as heater, engine, exhaust, etc.
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-5
!
WARNING
HEARING PROTECTION: The Occupational Safety and Health Administration
(OSHA) recommends the use of hearing protection when a technician is exposed to
an
average of 85 decibels (this is an average of exposure over an 8 hour period). This
equipment can produce 85 decibels to a distance of 10 feet. Please check with
your local state agencies to see if OSHA standards apply to your application.
!
WARNING
NO SMOKING: It is unsafe to smoke in or around the vehicle.
!
WARNING
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so
that the fumes will be directed away from the job site. Do not park where exhaust
fumes can enter a building through open doors, windows, air conditioning units or
kitchen fans.
!
WARNING
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operat-
ing. Toxic fumes may accumulate inside a stationary vehicle.
!
WARNING
ENGINE EXHAUST: The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects or other reproductive harm.
!
WARNING
CARBURETOR DRAIN: Under no circumstances should the drain in the carburetor
bowl be utilized when the machine is hot.
!
WARNING
PORTABLE GAS TANK: Never operate this machine with a portable gas can inside
the truck. Doing so increases the risk of a fire or explosion.
HydraMaster Corporation
Page 1-6 MAXX 450D/470D/Diesel
!
WARNING
PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or van.
It is dangerous and illegal in most states.
!
WARNING
TRANSPORTATION OF FUEL CONTAINERS: Transportation in a vehicle of any
vented fuel container that presently has or has ever contained a flammable liquid is
strictly forbidden by HydraMaster Corporation and by federal and state regulation.
!
CAUTION
The use of some chemicals through your mobile carpet cleaning plant can seriously
damage the internal plumbing, high-pressure pump, chemical pump and heat exchangers. These harmful chemicals include concentrated acid (see the pH chart at
the end of this section), solvents (including d-Limonene), and some paint, oil and
grease removers with a high concentration of solvents.
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-7
System Operation
he MAXX heat exchanger system is a highly engineered cleaning plant designed
T
by HydraMaster Corporation. The system utilizes a dynamic heating system
comprised of three separate heat exchangers for capturing “free heat”.
The water flow is as follows:
Water is fed into the machine under tap pressure to the water box.
The water is then picked up by the high pressure pump and pressurized to the
desired level. The water then splits flow, as demanded by the technician.
The majority of the water flows to the bypass valve assembly, then back
through the blower exhaust heat exchanger, and back to the water box. The
water demanded by the technician flows from the water pump, through the
engine coolant heat exchangers, then through the engine exhaust heat
exchanger and out to the cleaning tool.
When the cleaning solution reaches a preset high temperature, it activates the
exhaust diverter valve control, which prevents the exhaust gases from entering
the exhaust heat exchanger. Once the solution temperature falls below the set
point, the exhaust diverter valve activates to allow the exhaust gases to flow back
through the exhaust heat exchanger. If the exhaust diverter valve becomes inoperable for any reason, the high pressure solenoid valve is activated to release the
heated water from the system and is directed to the recovery tank. Then cool
water enters the
system to regulate the temperature.
As there is no guess work in the manufacture of these highly advanced cleaning
plants, there must be none in preparing it to get the job done in the field. It is the
purpose of this manual to help you properly understand, maintain and service your
cleaning plant. Follow the directions carefully and you will be rewarded with years
of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this
equipment.
HydraMaster Corporation
Page 1-8 MAXX 450D/470D/Diesel
Machine Specifications
Frame: 24.5"W x 47.75"L x 37.375"H
Weight: 600 lbs.
Cowling: Aluminum with Epoxy finish
Engine: Daihatsu Liquid Cooled 3 Cylinder, Cast Iron Block, Diesel as required.
Displacement: (450D) 697cc, (470D) 950cc, (Diesel) 850cc
Ignition: Electronically Triggered Coils (1 per cyl.)
12 v Electric Starter Motor
12 v, 40 amp Alternator, Regulated
Electronic Governor
Pressurized Oil System with Filter
Pressurized Cooling System
Triple Row Radiator
Vacuum Blower: Proprietary Dual Shaft Roots
(450D, Diesel) 45 RAI J WhispAir™, (470D) 47 RAI J WhispAir™
Chemical System: High Pressure Injected, Meter Controlled
Heating System: 1 Stainless Steel Coil Exhaust Heat Exchanger
2 Water-to-Water Copper Shell and Tube Heat
Exchangers: 1 Air-to-Water Copper Shell and Tube Heat Exchangers
Instruments and Controls: Water Pressure Gauge, Liquid Filled, 0-1500 PSI
Water Temperature Gauge, 0-250°F
Vacuum Level Gauge, 0-30" Hg
Hour Meter, Machine Run Time
Chemical Flowmeter, Clear Acrylic, 0-10 GPH
Chemical Metering Valve
Chemical Selector Valve
Heat Bypass Lamp
Overheat Protection Lamp
Overheat Shutdown Lamp
Overheat Engine Lamp
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-9
Instruments and Controls (cont.):
Engine Charging Lamp
Engine Oil Pressure Lamp
Engine Diagnostic Lamp
Pump Out Operating Lamp
“Vacuum Tank Full” Lamp
“Water Supply Low” Lamp
Keyed Ignition
Circuit Breakers Panel
Accessory Switches
Electronic Three Speed Engine Throttle
Mix Tank Drain Valve
Recovery Tank Drain Valve
Panel Mounted Pressure Adjustment Valve
Electric Engine Choke
Diverter Valve Control Switch
Blower Lubrication Port
Recovery Tank: 100 gallon Aluminum, Epoxy Finish
Cleaning Wand: Stainless Steel
—Grip and Replaceable Vacuum Lips with
Stainless Steel Solution Valve.
High Pressure Hose: ¼” High Temperature, Lined, Vinyl Covered
Hose rated to 2200 PSI, 250° F.
Vacuum Hose: 2" Reinforced, 1½” Reinforced
Standard Equipment: Machine Power Console
Full Instrumentation
WhispAirTM Vacuum Blower
MAXX™ Water Heating Package
Vacuum Recovery Tank
Carpet Cleaning Wand
5 gallon Chemical Jug
Chemical Jug Holder
Chemical Jug Fill Line
150 ft, 2" Vacuum Hose
10 ft, 1½” Wand Whip-line
10 ft, 1½” Recovery Drain Line
HydraMaster Corporation
Page 1-10 MAXX 450D/470D/Diesel
Standard Equipment: 50 ft, Water Supply Line
150 ft, ¼” Solution Line
Dual-Wand Vacuum Fittings
Dual-Wand Solution Fittings
Battery Box with Holder
Van Decal Package
Van Installation Kit
Operation Manual
HydraMaster Jacket
Optional Equipment: Please refer to Section 14.
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-11
Spare Parts
own-time on the unit can be very expensive, because your truckmounted unit
D
mize such down-time, it is strongly recommended by the manufacturer that you
purchase and keep in your truck the parts listed below.
Parts Orders
To expedite your parts needs, please call your sales representative. In most instances, he either stocks or has access to parts through a regional service center.
If further assistance is needed, contact the factory and coordinate your needs. If
this becomes necessary, always indicate the method of shipment you desire, i.e.
UPS, Blue Label, Air Freight, Air Express, etc.
is capable of generating several hundred dollars per day. In order to mini-
HydraMaster Parts Dept. Phone ................. (425) 775-7276
HydraMaster Parts Dept. Toll Free Fax ........ 1-800-426-4225
Spare Parts List (078-330)
PART NO DESCRIPTION QTY
010-056 Belt, 4L230 Air Pump Drive (450D Only) 1
010-057 Belt, A28 APO Drive 1
010-059 Belt, A24 Air Pump Drive (470D Only) 1
010-061 Belt, A44 Pump Drive 1
010-080 Belt, BX40 Eng. Drive 2
010-110 Belt, XL7390, Air Pump Gate (450D only) 1
010-115 Belt, XL7395, Air Pump Gate (470D only) 1
056-007 Fuse, 10 amp Circuit 2
056-008 Fuse, 15 amp Circuit 1
046-010 Diaphragm 1
049-002 Fuel Filter 1
049-013 Filter, 3” Stainless Steel Vacuum Pump 1
049-014 Filter, Oil - Daihatsu 1
049-016 Filter, 4“ ‘Y’ 1
049-118 Filter, ¼" Chemical Filter 1
HydraMaster Corporation
Page 1-12 MAXX 450D/470D/Diesel
Spare Parts List (078-330 cont.)
PART NO DESCRIPTION QTY
049-023 Screen, Garden Hose 1
049-063 Filter, Air - Daiahtsu 1
049-068 Fuel Separator (450 Diesel Only) 1
052-050 Quick Connect, 440 Male 3
052-051 Quick Connect, 440 Female 2
052-052 Quick Connect, 660 Male 1
052-053 Quick Connect, 660 Female 1
056-010 Fuse, 25 amp. 1
074-032 Meter, Chemical Flow 1
078-019 Kit, H/M Solution Valve 1
078-273 Kit, Bypass Valve Repair 1
157-040 Switch, 12V DC Lighted, ON/OFF 1
157-080 Switch, s/s Float 1
157-131 Switch, 12V DC, Lighted ON/OFF/ON 1
157-008 Switch, Ignition 1
157-022 Switch, Relay 2
169-022 Valve, 1½" Full Port 1
169-155 Valves, Check 2
169-160 2-way Valve 1
169-017 3-way Valve 1
180-004 Orifice, Primary 1
180-006 Orifice, Secondary 1
NOTE:
Engine Oil: 30 weight motor oil with a minimum standard of SE, SF, SG.
Blower OIl: 40 weight non detergent
Pump Oil: 40 weight non-detergent
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-13
Responsibilities
!
CAUTION
Purchase heavy duty 42 - 60 amp hour battery and have the battery ‘slow’ charge
if new. If the battery is not fully charged, damage can occur to the engine charging
regulator.
Reading of Owner’s Manual: It is the purchaser’s responsibility to read the unit
operation manual and to familiarize himself with the information contained therein.
Special attention should be paid to all Cautions and Warnings.
The Sales Representative’s responsibilities are:
ACCEPTANCE OF SHIPMENT:
1. If the unit shows any outward signs of damage, do not sign the delivery
receipt until you have closely inspected the unit and noted any damage
on the delivery receipt.
2. The salesman from whom you purchased your unit is responsible for
supervising the correct installation of the unit in your vehicle and
thoroughly training you in its operation, maintenance and precautions.
Correct Installation Includes:
• Installation of through-floor fittings for gasoline fuel lines
• Placing the unit and recovery tank in your vehicle and securing them
with bolts or tie down cleats
• Install and connect the fuel pump.
• Connecting gasoline lines
HydraMaster Corporation
Page 1-14 MAXX 450D/470D/Diesel
Correct Installation (cont.)
• Connecting the battery
• Checking the pump, vacuum blower and engine oil levels prior to
starting the unit
• Starting the unit to check engine and see that all systems function
normally
• Checking all hoses, wands, etc. for correct operation.
NOTE: Under certain circumstances, machines may require modification for
optimal performance. Cerain environmental conditions may require engine
modification or control function calibration.
Training Shall Include:
• A thorough review of the operation manual with purchaser;
• Instruction and familiarization in:
1. How to correctly start up and shut down the unit
2. How to correctly clean with the unit
3. Where and how often to check and change component oil levels
4. How the unit’s systems work
5. How to troubleshoot the unit
6. How to do basic repairs
7. Safety precautions and their importance
8. Freezing damage and how to avoid it
9. Hard water damage and how to avoid it
10. Cleaning the orifices and how they function in the system
• A thorough review of the unit warranty and warranty procedures.
• A thorough review of hard water precautions and warnings.
• How to determine hard water areas.
• Use of water softening systems.
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-15
Vehicle Preparation
hen selecting a truck, remember the preferable vehicle for a Boxxer 421
W
ton capacity. If a fresh water tank is added, a three quarter ton or larger capacity
van, with a 2,400 pound payload capacity, is required.
TRUCK PREPARATION
The manufacturer recommends the installation of a spray-on bed liner in the vehicle prior to installation of machine.
installation is a cargo van with a heavy-duty suspension package and a half
!
CAUTION
Be cautious when drilling any holes through the van floor. Many vans have
critical components mounted directly below the van floor that could be
damaged by a misplaced drill bit. (See Product Support Bulletins 92101,
94062, and 94063 at the end of this manual.)
This provides ‘metal to cushion’ mounting rather than ‘metal to metal’ and makes
for an attractive van interior. It is highly recommended to install roof vents in
vehicles operated in hot weather locations. Roof vent positions are shown in
Figure 1-1.
Figure 1-1 Roof Vent
HydraMaster Corporation
Page 1-16 MAXX 450D/470D/Diesel
PLACEMENT OF UNIT IN VEHICLE
There are two recommended unit placements:
SIDE DOOR:
Most installations are 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 DOOR:
Although this location partly limits working access, it does direct the noise away
from the cleaning site. Some cleaners in the colder areas prefer this location because it puts the weight over the rear wheels for better traction in ice and snow.
Rear mounting requires the unit to be slid to the right side as far as possible.
This 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). Also, it is physically easier to load the unit into the rear door
due to the height of the van bed.
Figure 1-2 Recommended Placement
HydraMaster Corporation
MAXX 450D/470D/Diesel Page 1-17
Machine Tie Down Cleats
Secure the machine to the floor of the van with the four tie down cleats provided.
This safety measure will ensure that the machine will not slide inside the van. See
the following illustration for the correct installation.
Figure 1-3 Installation Using Tie-down Cleats
Ensure that the machine is well secured to the floor of the van with the hardware
supplied. A sudden or crash stop will cause the machine to rocket forward. Protect yourself and the machine. SECURE IT!
!
WARNING
It is recommended by the manufacturer 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.
The manufacturer also recommends the installation of aluminum vents in the
truck roof to allow heat to escape.
!
WARNING
Never operate this machine with a portable gas can inside the truck. Doing
so increases the risk of a fire or explosion.
Mount a fire extinguisher just inside the rear or side door for emergencies.
HydraMaster Corporation
Page 1-18 MAXX 450D/470D/Diesel
!
WARNING
Do not use a portable propane tank inside of the truck or van. It is dangerous and illegal in most states.
!
WARNING
Transportation in a vehicle of any vented fuel container that presently holds
or has ever held a flammable liquid is strictly forbidden by HydraMaster
Corporation and by federal and state regulation.
!
WARNING
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
HydraMaster Corporation
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