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HydraMaster MAXX 450D Manual

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HYDRAMASTER
Corporation
11015 47th Avenue W, Mukilteo, WA 98275
MAXX
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

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  • Page 1 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...
  • Page 2 MAXX 450D/470D/450 Diesel HydraMaster Corporation...

  • Page 3: Table Of Contents

    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 ..........
  • Page 4 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 ................
  • Page 5 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 ..................
  • Page 6 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 ..............
  • Page 7 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 ......
  • Page 8 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 ............
  • Page 9 MAXX 450D/470D/450 Diesel Quick Reference HydraMaster Corporation...
  • Page 10 MAXX 450D/470D/450 Diesel Quick Reference Recovery Tank Float Switch-Top Float Shown B4624 Rev— Fuel Pump Assembly B4627 Rev— HydraMaster Corporation...
  • Page 11 MAXX 450D/470D/450 Diesel Quick Reference Diesel Fuel Filter with Manual Priming Pump and Water Separator with Electric Motor. HydraMaster Corporation...
  • Page 12 MAXX 450D/470D/450 Diesel Quick Reference Diesel Fuel Flow Diagram HydraMaster Corporation...
  • Page 13 Introduction Maxx 450D/470D/450 Diesel Section 1-1 his manual contains installation and operation instructions as well as informa- 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.

  • Page 14: Telephone Numbers

    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...

  • Page 15: Precautions

    MAXX 450D/470D/Diesel Page 1-3 Precautions lthough this unit has been factory adjusted, it may require additional adjust- ments to achieve optimum performance, for instance altitude may require carburetor adjustment and ambient temperatures may require heat control adjust- ment. When required, consult an authorized representative.
  • Page 16 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 unpro- tected acid products that have obviously caused failures.
  • Page 17 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 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.
  • Page 18 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 ex- changers.

  • Page 19: System Operation

    System Operation he MAXX heat exchanger system is a highly engineered cleaning plant designed 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.

  • Page 20: Machine Specifications

    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.)
  • Page 21 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...
  • Page 22 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.

  • Page 23: Spare Parts Recommendation

    UPS, Blue Label, Air Freight, Air Express, etc. HydraMaster Parts Dept. Phone ....(425) 775-7276 HydraMaster Parts Dept. Toll Free Fax ..1-800-426-4225 Spare Parts List (078-330) PART NO...
  • Page 24 Page 1-12 MAXX 450D/470D/Diesel Spare Parts List (078-330 cont.) PART NO DESCRIPTION 049-023 Screen, Garden Hose 049-063 Filter, Air - Daiahtsu 049-068 Fuel Separator (450 Diesel Only) 052-050 Quick Connect, 440 Male 052-051 Quick Connect, 440 Female 052-052 Quick Connect, 660 Male...

  • Page 25: Responsibilities

    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.
  • Page 26 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 •...

  • Page 27: Vehicle Preparation

    MAXX 450D/470D/Diesel Page 1-15 Vehicle Preparation hen selecting a truck, remember the preferable vehicle for a Boxxer 421 installation is a cargo van with a heavy-duty suspension package and a half 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.
  • Page 28 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.
  • Page 29 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.
  • Page 30 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.

  • Page 31: High Altitude Operation Preparation

    The jet sizes vary per engine and eleva- tion. Consult HydraMaster to obtain proper jet size. Carburetor Jet- See chart below for specific jet size.
  • Page 32 Page 1-20 MAXX 450D/470D/Diesel Diverter Valve - Machines that are equipped with a diverter valve may need adjust- ment after the machine has been installed. Prior to running the machine, perform the following steps: Locate the actuator connected to the...

  • Page 33: Local Water Precautions

    HydraMaster has included five hard water test strips with your machine. These can be used to test the water in your immediate and surrounding areas as they can vary greatly.

  • Page 34: Waste Water Disposal Advisory

    Page 1-22 MAXX 450D/470D/Diesel HARD WATER AREA MAP The following map defines areas in the United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water cooled engines. For other countries, hard water area maps can be obtained from geological societies.
  • Page 35 The hidden benefit of this process is that the technician does not have to stop his cleaning to empty the recovery tank. HydraMaster makes an APO system available which can be ordered with new equip- ment or installed later.
  • Page 36 Page 1-24 MAXX 450D/470D/Diesel This page intentionally left blank HydraMaster Corporation...

  • Page 37: Machine Assemblies And Parts Lists

    MAXX 450D/470/Diesel Page 1-25 Machine Assemblies and Parts Lists This section will be revised as drawings become available HydraMaster Corporation...

  • Page 38: Fig

    Page 1-26 MAXX 450D/470/Diesel Figure 1-7 Maxx 450D/470D Frame Assembly - View 1 D-4355 Rev F HIDDEN DIESEL ONLY HIDDEN HIDDEN HIDDEN HydraMaster Corporation...
  • Page 39 MAXX 450D/470/Diesel Page 1-27 Figure 1-8 Maxx 450D/470D Frame Assembly - View 2 D-4355 Rev F HydraMaster Corporation...
  • Page 40 MAXX 450D/470/Diesel Frame Assembly Parts List Item Part Number Description 000-055-155 Frame, Final Stock - Maxx 450D/470D 000-055-138 Frame, Engine Cover - Maxx 450D/470D 000-015-600 Bracket, Heat Exchanger Mount 000-015-629 Bracket, After Burner Mounting Saddle 000-033-115 Clamp, After Burner Mount 000-143-096 Screw, 3/8"-16UNC x 1.00"...

  • Page 41: Fig

    000-174-003 Washer, 1/4" Flat 000-141-033 Rod, Heat Exchanger Strap - Retainer Fig. 1-24 Assembly, Diverter Valve Actuator - Maxx 450D/470D 000-143-004 Screw, 1/4"-20UNC x 1.50" Lg. Hex Head 000-174-021 Washer, 3/8" Lock 000-143-017 Screw, 3/8"-16UNC x 0.75" Lg. Hex Head Grd. 8 000-143-025 Screw, 3/8"-16UNC x 1.25"...

  • Page 42: Fig

    Page 1-30 MAXX 450D/470/Diesel Figure 1-9 100 Gallon Universal Recovery Tank Assembly D-6984 Rev - HIDDEN HIDDEN HIDDEN HIDDEN 34 HIDDEN HIDDEN HIDDEN HIDDEN HIDDEN 30 HIDDEN 13 10 HydraMaster Corporation...

  • Page 43: Gallon Universal Recovery Tank Assembly

    MAXX 450D/470/Diesel Page 1-31 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description 000-159-129 Tank, 100 Gallon Universal Recovery - Weldment Fig. 1-10 Assembly, Recovery Tank Cover - 100 Gallon 000-157-090 Float, Lever Switch 000-079-091 Kit, Dura-Flow APO - Production (Fig. 1-22)
  • Page 44 Page 1-32 MAXX 450D/470/Diesel 100 Gallon Universal Recovery Tank Assembly Parts List Item Part Number Description 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 000-094-009 Nut, 1/4"-20UNC Hex Nylock 000-166-002 Tray, Soap Jug - Weldment 000-094-034 Nut, #10-24UNC Nylock 000-057-206 Gasket, Adapter - Universal Recovery Tank 000-052-085 Elbow, 1/4"...

  • Page 45: Gallon Universal Recovery Tank Cover

    MAXX 450D/470/Diesel Page 1-33 Figure 1-10 100 Gallon Universal Recovery Tank Cover Assembly D-6919 Rev - 100 Gallon Universal Recovery Tank Cover Assembly Parts List Item Part Number Description 000-041-447 Cover, 100 Gallon Universal Recovery Tank - Weldment 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 000-057-015 Gasket, 1-1/2"...

  • Page 46: Vacuum Relief Valve Assembly

    Page 1-34 MAXX 450D/470/Diesel Figure 1-11 Vacuum Relief Valve Assembly C-6894 Rev - Vacuum Relief Valve Assembly Parts List Item Part Number Description 000-015-182 Bracket, Vacuum Relief Valve 000-027-032 Cap, Vacuum Releif Valve 000-125-111 Pipe, Vacuum Relief Spring Guide 000-105-332 Plate, Vacuum Relief Valve Mounting - Universal Recovery T 000-155-026 Spring, Vacuum Relief 000-143-198 Screw, 3/8"-16UNC x 4"...
  • Page 47 MAXX 450D/470/Diesel Page 1-35 Figure 1-12 Dash Assembly D-4359 Rev F HIDDEN BACK DETIAL HydraMaster Corporation...

  • Page 48: Fig

    Page 1-36 MAXX 450D/470/Diesel Dash Assembly Parts List Item Part Number Description 000-100-088 Panel, Main Dash - Maxx 450D/470D 000-100-096 Grill, Upper Dash Fig. 1-13 Assembly, Lower Dash Plumbing Connection Panel - Maxx 4 Fig. 1-14 Assembly, Upper Dash Instrument Panel - Maxx 000-100-102 Panel, Perforated Grill Fig.
  • Page 49 MAXX 450D/470/Diesel Page 1-37 Dash Assembly Parts List Item Part Number Description 000-033-057 Clamp, 1" Cushion Loop 000-052-089 Elbow, 1/8" NPT Female 000-143-328 Screw, #10-32UNF x 1/2" Lg. Phillips Head 000-174-014 Washer, #10 Lock 000-174-057 Washer, 3/8" Lock 000-174-032 Washer, 3/8" Flat 000-052-530 Nipple, 1/8"...
  • Page 50 000-100-094 Panel, Lower Dash Plumbing Connection 000-090-008 Manifold, Hi Pressure Fig. 1-29 Assembly, Hi-PSI Manifold - Maxx 450D/470D 000-052-052 Quick Connect, 660 Male w/ Viton Standard 000-052-050 Quick Connect, 440 Male w/ Viton Standard 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port 000-052-086 Elbow, 3/8"...
  • Page 51 MAXX 450D/470/Diesel Page 1-39 Figure 1-14 Upper Dash Instrument Panel Assembly C-4356 Rev A HydraMaster Corporation...
  • Page 52 Item Part Number Description 000-100-092 Panel, Upper Dash Instrument 000-074-016 Guage, Temperature 000-074-017 Guage, 0-30" Hg Vac. 2 1/2" HydraMaster Face 000-157-008 Switch, Ignition 000-157-040 Switch, 20 AMP Rocker 000-074-018 Meter, Rectangular w/o Bezel 000-084-011 Light, Red Led Indicator Mini...
  • Page 53 MAXX 450D/470/Diesel Page 1-41 Figure 1-15 Electrical Control Panel Assembly D-4548 Rev E HIDDEN HydraMaster Corporation...
  • Page 54 000-033-044 Clamp, 3/8" Tube 000-143-126 Screw, #10-24UNC x 0.50" Lg. Hex Head 000-072-010 Ignition Processor - 700G Daihatsu 000-072-009 Ignition Processor - 950G Daihatsu 000-029-016 Governor, Hall Affects Maxx 450D/470DD 000-029-030 Governor, Magnetic Pick Up - Maxx Diesel HydraMaster Corporation...

  • Page 55: Bypass Heat Exchanger

    MAXX 450D/470/Diesel Page 1-43 Figure 1-16 Bypass Heat Exchanger C-4587 Rev C Bypass Heat Exchanger Parts List Item Part Number Description 000-038-031 Core, 4" x 19" Tube & Shell Hx w/ 3" Ends 000-052-087 Elbow, 1/2" NPT Street 000-052-107 Insert, #88 (1/2" NPT x 1/2" Barb) 000-033-013 Clamp, Size #48 Hose 000-068-008 Hose, 3"...
  • Page 56 Page 1-44 MAXX 450D/470/Diesel Figure 1-17 Water-to-Water Heat Exchanger - Maxx 450/470 D-5995 Rev A HydraMaster Corporation...

  • Page 57: Water-To-Water Heat Exchanger

    MAXX 450D/470/Diesel Page 1-45 Water-to-Water Heat Exchanger Parts List Item Part Number Description 000-015-739 Bracket, Dual Hx Mounting - Right 000-015-735 Bracket, Dual Hx Mounting Channel 000-038-043 Heat Exchanger, Water To Water 000-033-020 Clamp, Size #16 Hose 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 000-052-083 Elbow, 3/8"...
  • Page 58 Page 1-46 MAXX 450D/470/Diesel Figure 1-18 Water Box Assembly D-4732 Rev H HydraMaster Corporation...

  • Page 59: Water Box Assembly

    MAXX 450D/470/Diesel Page 1-47 Water Box Assembly Parts List Item Part Number Description 000-159-105 Tank, Poly Water Box - Modified 000-015-640 Bracket, Water Box Mounting - Weldment 000-052-659 Bulkhead, 3/8" Mpt x Straight 000-097-042 O-Ring, Bulkhead Fitting w/ 3/8" NPT 000-174-027 Washer, 3/4"...

  • Page 60: Cat 3Cp Pump Assembly

    Page 1-48 MAXX 450D/470/Diesel Figure 1-19 CAT 3CP Pump Assembly D-4354 Rev F PART OF PUMP(ITEM 1) CAT 3CP Pump Assembly Parts List Item Part Number Description 000-111-070 Pump, 4 Gpm CAT Hi Temp. Plunger 000-036-006 Clutch, Pump - CDS 4.8/ Maxx 000-015-682 Bracket, Pump Mount CAT 3CP 000-106-004 Plug, 1/2"...
  • Page 61 MAXX 450D/470/Diesel Page 1-49 CAT 3CP Pump Assembly Parts List Item Part Number Description 000-052-085 Elbow, 1/4" NPT Street 000-052-710 Elbow, 1/2" NPT x 45° Street - Modified 000-052-107 Insert, #88 (1/2" NPT x 1/2" Barb) 000-052-023 Tee, 3/8" NPT Male Street 000-169-050 Valve, High Pressure Safety (2200) 000-052-061 Bushing, 3/8"...
  • Page 62 Page 1-50 MAXX 450D/470/Diesel Figure 1-20 Air Pump Assembly C-5383 Rev A Air Pump Assembly Parts List Item Part Number Description 000-015-724 Bracket, Air Pump / Alternator Mounting 000-111-085 Pump, Air N/S 000-154-092 Spacer, Air Pump Pulley - 17mm Bore 000-109-083 Pulley, AK30 Mod.

  • Page 63: Fig

    MAXX 450D/470/Diesel Page 1-51 Figure 1-21 Chemical Pump Assembly C-6555 Rev A OUTLET INLET Chemical Pump Assembly Parts List Item Part Number Description 000-106-110 Plug, Check Valve - Chemical Pump 000-064-015 Cover, Chemical Pump 000-111-030 Body, Chemical Pump 000-105-071 Mid Plate, Chemical Pump...
  • Page 64 Page 1-52 MAXX 450D/470/Diesel Figure 1-22 Dura-Flow APO Assembly (Automatic Pump Out) D-5654 Rev E HydraMaster Corporation...
  • Page 65 MAXX 450D/470/Diesel Page 1-53 Dura-Flow APO Assembly Parts List Item Part Number Description 000-111-169 Assembly, APO Pump - Jabsco 000-091-042 Motor, Bison 438 Series 000-015-891 Bracket, APO Clamp 000-015-890 Bracket, Tank Mounted APO Support 000-143-566 Screw, 1/4-28UNF x 0.75" Lg. Socket Head 000-143-074 Screw, 1/4"-20UNC x 0.50"...

  • Page 66: Fuel Pump Assembly

    Page 1-54 MAXX 450D/470/Diesel Figure 1-23 Fuel Pump Assembly B-4627 Rev - HydraMaster Corporation...
  • Page 67 MAXX 450D/470/Diesel Page 1-55 Figure 1-24 Diverter Valve Actuator Assembly C-5386 Rev B HydraMaster Corporation...
  • Page 68 Page 1-56 MAXX 450D/470/Diesel Diverter Valve Actuator Assembly Parts List Item Part Number Description 000-015-772 Bracket, Diverter Air Cylinder Mounting 000-015-774 Bracket, Diverter Air Cylinder Foot - Top 000-015-774 Bracket, Diverter Air Cylinder Foot- Bottom 000-015-630 Bracket, Air Cylinder Extension 000-169-169 Valve, Air Cylinder 000-094-081 Nut, 5/16"-18UNC Hex 2-Way Locking...
  • Page 69 MAXX 450D/470/Diesel Page 1-57 Figure1-25 Blower MD 4005 Assembly D-5384 Rev C Blower MD 4005 Assembly Parts List Item Part Number Description 000-111-145 Blower, 4005 Dominator 000-093-082 Silencer, Bolt Down - Maxx 470D/Javelin 000-001-041 Adapter, Blower Inlet 000-015-633 Bracket, Blower Foot Front...
  • Page 70 000-001-101 Adapter, 2-1/2" NPT x 3" M Slip 000-015-781 Bracket, Idler Mounting - Maxx/Javelin 000-150-055 Bolt, Idler Pulley Shoulder - Maxx 450D/470D 000-143-552 Screw, 7/16"-14UNC x 7.875" Lg. Hex Head Grade 5 000-154-113 Spacer, 0.790 Id x 1.090 Lg. Idler Pulley - Maxx w/ Sheet Fra 000-109-074 Pulley, AK41 Bored 7/8"...
  • Page 71 MAXX 450D/470/Diesel Page 1-59 Figure1-26 Blower MD 4007 Assembly D-5385 Rev C Blower MD 4007 Assembly Parts List Item Part Number Description 000-111-147 Blower, MD 4007 000-093-082 Silencer, Bolt Down - Maxx 470D/Javelin 000-015-633 Bracket, Blower Foot Front 000-001-041 Adapter, Blower Inlet...
  • Page 72 000-001-101 Adapter, 2-1/2" NPT x 3" M Slip 000-015-781 Bracket, Idler Mounting - Maxx/Javelin 000-150-055 Bolt, Idler Pulley Shoulder - Maxx 450D/470D 000-143-552 Screw, 7/16"-14UNC x 7.875" Lg. Hex Head Grade 5 000-154-113 Spacer, 0.790 ID x 1.090 Lg. Idler Pulley - Maxx w/ Sheet Fra 000-109-074 Pulley, AK41 Bored 7/8"...
  • Page 73 MAXX 450D/470/Diesel Page 1-61 Figure 1-27 Exhaust Assembly - View 1 D-4541 Rev F HydraMaster Corporation...
  • Page 74 Page 1-62 MAXX 450D/470/Diesel Figure 1-28 Exhaust Assembly - View 2 D-4541 Rev F HydraMaster Corporation...
  • Page 75 000-094-081 Nut, 5/16"-18UNC Hex 2-Way Locking 000-143-132 Screw, #10-24UNC x 0.75" Lg. Hex Head 000-125-131 Tube, Exhaust To Cat. - Cat. Side 000-125-172 Tube, Air Pump - N/S - Maxx 450D/470D 000-015-725 Bracket, Exhaust Support - Maxx 450D/470D 000-015-756 Bracket, After Burner & Exhaust Cover...
  • Page 76 000-041-390 Cover, Exhaust Side - Maxx 450D/470D 000-052-507 Nipple, 3/8" NPT x 9/16"-18 37° JIC 000-141-033 Rod, Heat Exchanger Strap - Retainer 000-033-122 Clamp, Exhaust Support Mounting - Maxx 450D/470D 000-143-092 Screw, 5/16"-18UNC x 2.25" Lg. Hex Head 000-052-711 Bushing, 3/8" Inverted Flair 000-174-019 Washer, 1/4"...
  • Page 77 MAXX 450D/470/Diesel Page 1-65 HI-PSI Manifold Assembly Parts List Item Part Number Description 000-090-010 Manifold, Hi-PSI 000-180-006 Orifice, Set Screw 0.061" 000-180-004 Orifice, Set Screw 0.033" 000-052-423 Bushing, Modified Set Screw Orifice 000-149-039 Sender, Temperature 000-169-177 Valve, 3/8" FPT Check 65 PSI 000-049-016 Filter, 1/4"...
  • Page 78 Page 1-66 MAXX 450D/470/Diesel Figure 1-30 By-Pass Valve Assembly C-4900 Rev D HydraMaster Corporation...
  • Page 79 MAXX 450D/470/Diesel Page 1-67 By-Pass Valve Assembly Parts List Item Part Number Description 000-052-086 Elbow, 3/8" NPT Street 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 000-169-027 Valve, Thermal Relief 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 000-052-447 Tee, 3/8" Branch 000-052-128 Nipple, 3/8"...
  • Page 80 Page 1-68 MAXX 450D/470/Diesel Figure 1-31 Maxx 450D Daihatsu Engine Assembly - View 1 D-4351 Rev G HydraMaster Corporation...
  • Page 81 MAXX 450D/470/Diesel Page 1-69 Figure 1-32 Maxx 450D Daihatsu Engine Assembly - View 2 D-4351 Rev G HydraMaster Corporation...

  • Page 82: Fig

    000-174-018 Washer, 5/16" Lock 000-143-083 Screw, 8mm x 30mm Lg. Grade 8 Hex Head Fig. 1-17 Assembly, Water To Water Heat Exchanger - Maxx 450D/47 000-015-729 Bracket, Left Front Foot - Daihatsu 000-015-731 Bracket, Right Front Foot - Daihatsu 000-015-737 Bracket, Radiator Mounting 000-015-741 Bracket, Rear Foot - Daihatsu 000-109-100 Pulley, 6"...
  • Page 83 MAXX 450D/470/Diesel Page 1-71 Maxx 450D Daihatsu Engine Assembly Parts List Item Part Number Description 000-143-146 Screw, 3/8-16UNC x 2-3/4" Lg. Hex Head 000-174-004 Washer, 5/16" Flat 000-094-100 Nut, 3/8"-16UNC Hex Nylock 000-094-043 Nut, 8mm Hex 000-052-097 Insert, #24 (1/8" NPT x 1/4" Barb) 000-033-017 Clamp, 1/4"...
  • Page 84 Page 1-72 MAXX 450D/470/Diesel Maxx 450D Daihatsu Engine Assembly Parts List Item Part Number Description 000-010-110 Belt, Xl7390 450D Air Pump 000-057-050 Gasket, Thermostat Housing Daihatsu Engine 000-015-782 Bracket, Choke Daihatsu (Manual) 000-033-124 Clamp, Daihatsu Choke (Manual) 000-143-551 Screw, Daihatsu Choke (Manual)
  • Page 85 MAXX 450D/470/Diesel Page 1-73 Figure 1-33 Maxx 470D Daihatsu Engine Assembly - View 1 D-4567 Rev H 50 48 HydraMaster Corporation...
  • Page 86 Page 1-74 MAXX 450D/470/Diesel Figure 1-34 Maxx 470D Daihatsu Engine Assembly - View 2 D-4567 Rev H HydraMaster Corporation...

  • Page 87: Fig 1-29 Hi Psi Manifold Assembly

    000-174-018 Washer, 5/16" Lock 000-143-083 Screw, 8mm x 30mm Lg. Grade 8 Hex Head Fig. 1-17 Assembly, Water To Water Heat Exchanger - Maxx 450D/47 000-015-729 Bracket, Left Front Foot - Daihatsu 000-015-731 Bracket, Right Front Foot - Daihatsu 000-015-737 Bracket, Radiator Mounting 000-015-741 Bracket, Rear Foot - Daihatsu 000-109-100 Pulley, 6"...
  • Page 88 Page 1-76 MAXX 450D/470/Diesel Maxx 470D Daihatsu Engine Assembly Parts List Item Part Number Description 000-143-146 Screw, 3/8-16UNC x 2-3/4" Lg. Hex Head 000-174-004 Washer, 5/16" Flat 000-094-100 Nut, 3/8"-16UNC Hex Nylock 000-094-043 Nut, 8mm Hex 000-052-097 Insert, #24 (1/8" NPT x 1/4" Barb) 000-033-017 Clamp, 1/4"...
  • Page 89 MAXX 450D/470/Diesel Page 1-77 Maxx 470D Daihatsu Engine Assembly Parts List Item Part Number Description 000-010-115 Belt, Xl7395 470D Air Pump 000-057-050 Gasket, Thermostat Housing Daihatsu Engine 000-015-782 Bracket, Choke Daihatsu (Manual) 000-033-124 Clamp, Daihatsu Choke (Manual) 000-143-551 Screw, Daihatsu Choke (Manual)
  • Page 90 Page 1-78 MAXX 450D/470/Diesel Figure 1-35 Engine Cover Support Assembly D-5637 Rev A HydraMaster Corporation...

  • Page 91: Engine Cover Support Assembly

    MAXX 450D/470/Diesel Page 1-79 Engine Cover Support Assembly Parts List Item Part Number Description 000-015-590 Bracket, Engine Cover Support 000-042-011 Air Cleaner - Daihatsu Engine 000-154-106 Spacer, 0.25" I.D. x 0.50" Lg. 000-033-007 Clamp, #28 Hose 000-174-003 Washer, 1/4" Flat 000-094-009 Nut, 1/4"-20UNC Hex Nylock...
  • Page 92 Page 1-80 MAXX 450D/470/Diesel Figure 1-36 Chemical Jug Tray Assembly C-4945 Rev C HydraMaster Corporation...

  • Page 93: Chemical Jug Tray Assembly

    MAXX 450D/470/Diesel Page 1-81 Chemical Jug Tray Assembly Parts List Item Part Number Description 000-166-021 Tray, Chemical Jug - Outer - Weldment 000-166-025 Tray, Chemical Jug - Inner 000-078-039 Vacuum Inlet Stopper 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 000-174-019 Washer, 1/4"...
  • Page 94 Page 1-82 MAXX 450D/470/Diesel Figure 1-37 Dash Assembly - Maxx 450 Diesel C-6057 Rev A HydraMaster Corporation...

  • Page 95: Fig 1-30 Bypass Valve Assembly

    MAXX 450D/470/Diesel Page 1-83 Dash Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-100-088 Panel, Main Dash - Maxx 450D/470D 000-100-096 Grill, Upper Dash Fig. 1-37 Assembly, Lower Dash Plumbing Connection Panel - Maxx 4 Fig. 1-14...
  • Page 96 Page 1-84 MAXX 450D/470/Diesel Dash Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-033-057 Clamp, 1" Cushion Loop 000-052-089 Elbow, 1/8" NPT Female 000-143-328 Screw, #10-32UNF x 1/2" Lg. Phillips Head 000-174-014 Washer, #10 Lock HydraMaster Corporation...
  • Page 97 MAXX 450D/470/Diesel Page 1-85 Figure 1-38 Lower Dash Plumbing Connection Panel Assembly - Maxx 450 Diesel D-5997 Rev - HydraMaster Corporation...

  • Page 98: Fig 1-13 Lower Dash Plumbing Connection Panel Assembly

    000-100-094 Panel, Lower Dash Plumbing Connection 000-090-008 Manifold, Hi Pressure Fig. 1-29 Assembly, Hi-PSI Manifold - Maxx 450D/470D 000-052-052 Quick Connect, 660 Male w/ Viton Standard 000-052-050 Quick Connect, 440 Male w/ Viton Standard 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port 000-052-086 Elbow, 3/8"...
  • Page 99 MAXX 450D/470/Diesel Page 1-87 Figure 1-39 By-Pass Valve Assembly - Maxx 450 Diesel C-5996 Rev - HydraMaster Corporation...

  • Page 100: By-Pass Valve Assembly - Maxx 450 Diesel

    Page 1-88 MAXX 450D/470/Diesel By-Pass Valve Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-052-086 Elbow, 3/8" NPT Street 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 000-169-011 Valve, Hi Temp Control 180° 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 000-052-447 Tee, 3/8"...
  • Page 101 MAXX 450D/470/Diesel Page 1-89 Figure 1-40 Daihatsu Engine Assembly - Maxx 450 Diesel - View 1 D-6056 Rev A HydraMaster Corporation...
  • Page 102 Page 1-90 MAXX 450D/470/Diesel Figure 1-41 Daihatsu Engine Assembly - Maxx 450 Diesel - View 2 D-6056 Rev A HydraMaster Corporation...

  • Page 103: Fig

    000-020-055 Bushing, H 1-1/8, From Solid Steel 000-015-721 Bracket, Oil Funnel Support Fig. 1-20 Air Pump Assembly - N/S - Maxx 450D/470D 000-004-001 Alternator, Daihatsu 700G & 950G 000-154-114 Spacer, Alternator Mounting - Maxx 450D/470D 000-108-100 Guard, Oil Spill - Raw...
  • Page 104 Page 1-92 MAXX 450D/470/Diesel Daihatsu Engine Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-143-146 Screw, 3/8-16UNC x 2-3/4" Lg. Hex Head 000-174-004 Washer, 5/16" Flat 000-094-100 Nut, 3/8"-16UNC Hex Nylock 000-094-043 Nut, 8mm Hex 000-052-097 Insert, #24 (1/8" NPT x 1/4" Barb) 000-033-017 Clamp, 1/4"...
  • Page 105 MAXX 450D/470/Diesel Page 1-93 Daihatsu Engine Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-068-250 Hose, 1" Green Stripe 000-010-115 Belt, Xl7395 470D Air Pump 000-057-050 Gasket, Thermostat Housing Daihatsu Engine 000-015-645 Bracket, Radiator Support Maxx - Block Mount...
  • Page 106 Page 1-94 MAXX 450D/470/Diesel Figure 1-42 Water To Water HX Assembly - Maxx 450 Diesel D-4353 Rev F HydraMaster Corporation...

  • Page 107: Water To Water Hx Assembly - Maxx 450 Diesel

    MAXX 450D/470/Diesel Page 1-95 Water To Water HX Assembly - Maxx 450 Diesel Parts List Item Part Number Description 000-015-739 Bracket, Dual HX Mounting - Right 000-015-735 Bracket, Dual HX Mounting Channel 000-038-043 Heat Exchanger, Water To Water 000-033-020 Clamp, Size #16 Hose 000-052-086 Elbow, 3/8"...
  • Page 108 Page 1-96 MAXX 450D/470/Diesel Figure 1-43 Contol Panel - Maxx 450 Diesel D-6089 Rev - HydraMaster Corporation...

  • Page 109: Control Panel Assembly

    000-056-020 Fuse Panel 000-056-030 Diode Panel 000-018-040 Circuit Breaker, 50 AMP 000-157-022 Switch, Relay 000-029-016 Governor, Hall Affects Maxx 450D/470DD 000-143-062 Screw, #10-24UNC x 0.75" Lg. Pan Head Phillips 000-094-034 Nut, #10-24UNC Nylock 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 000-143-545 Screw, #8-32UNC x 1.00"...
  • Page 110 Page 1-98 MAXX 450D/470/Diesel Maxx 450D/470/Diesel Hose Assemblies Hose Hose From Part No. Descript. 068-015 ” Water to Water Heat Exchanger 12 in (169-081) 068-020 Maxx Hi Temp Valve (169-050) Recovery Tank 47 in 068-030 ” APO (111-012) Hard Water MagnaClean...

  • Page 111: Air Pump Assembly

    MAXX 450D/470/Diesel Page 1-99 Maxx 450D/470/Diesel Hose Assemblies Hose Hose From Part No. Descript. 068-085 Cat Pump Oil Drain Frame 17 in Modified Chemical Meter Chemical Last-Step Pump 33 in (078-032) (111-035) Air Filter Air Pump 22 in 068-086 Cat Pump Fill...
  • Page 112 Page 1-100 MAXX 450D/470/Diesel Maxx 450D/470/Diesel Hose Assemblies Hose Hose From Part No. Description 068-512 Water to Water Heat Exchanger Hi PSI Bypass Valve (169-081) (038-043) 068-513 Water to Water Heat Exchanger Water to Water Heat Exchanger (038-043) (038-043) 068-514...

  • Page 113: Maxx 450D/470D/450 Diesel

    Cleaning and Chemicals MAXX 450D/470D/450 Diesel Section 2-1 our mobile carpet cleaning plant has been engineered using the latest and most sophisticated technology available to produce the finest carpet cleaning results possible. Despite this, however, it remains only a tool of the carpet cleaning trade, and can produce only as good a job as the person operating it.

  • Page 114: Fig 2-2 Cleaning Stroke Procedure

    HydraMaster’s ClearWater Rinse has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from using unpro- tected acid products that have obviously caused failures. CLEANING STROKE PROCEDURE...
  • Page 115 MAXX 450D/470D/Diesel Page 2-3 OVERWETTING Overwetting is annoying to all concerned, and may leave a bad impression of the cleaning process used. THESE ARE SEVERAL AREAS THAT WILL CAUSE OVERWETTING 1. Too few vacuum strokes or improper saw-tooth vacuum strokes as shown in the following illustration.
  • Page 116 Page 2-4 MAXX 450D/470D/Diesel 3/18/05 HydraMaster Corporation...
  • Page 117 Page 3-1 MAXX 450D/470/Diesel Operating Instructions MAXX 450D/470/Diesel Section 3-1 START UP 1. Perform daily and periodic maintenance as specified in this Owner’s Manual. 2. Connect all required hoses, including a garden hose for water supply. 3. Connect the cleaning tool to the length of hose required to perform the cleaning.
  • Page 118 Page 3-2 MAXX 450D/470/Diesel If used, turn PUMP OUT switch to “ON” (switch light will be illuminated). Set cleaning pressure at desired level. Suggested Settings Carpet Cleaning: 300 - 400 psi; Hard Surface: 900 -1000 psi or as indicated on the tool.
  • Page 119 Page 3-3 MAXX 450D/470/Diesel The engine exhaust heat exchanger is bypassed, the heat will be obtained from the engine coolant and blower exhaust heat exchangers. Set the temperature to desired level. If used, turn PUMP OUT switch to “ON” (switch light will be illuminated).
  • Page 120 Page 3-4 MAXX 450D/470/Diesel Shut Down 1. Flush clear water through the chemical system for 10 seconds. Turn off the chemical flowmeter. 2. Cool the machine by lowering the adjustable thermostat to the “LOW” position and the DIVERTER CONTROL switch to the “OFF” position while spraying the cleaning wand into the vacuum hose for three to five minutes.

  • Page 121: Recirculation Fitting

    Page 3-5 MAXX 450D/470/Diesel Freeze Guard ANTIFREEZE PROCEDURE 1. Begin by attaching your garden hose, or pump-in hose, to the machine. Now, remove the chemical line from the chemical jug and place it in a 50/50 mixture of antifreeze and water. Turn ignition switch on. Spray water.
  • Page 122 Page 3-6 MAXX 450D/470/Diesel ANTIFREEZE PROCEDURE (cont.) 5. Remove the garden hose inlet fitting from the end of your garden hose and plug it into the front of the machine. Leave it plugged in until the next time the machine is used.
  • Page 123 Page 3-7 MAXX 450D/470/Diesel ANTIFREEZE PROCEDURE (cont.) WARNING This warning appears on the label of one brand of antifreeze: “HARMFUL OR FATAL IF SWALLOWED. Do not drink antifreeze coolant or solution. If swallowed, induce vomiting immediately. Call a physician. Contains Ethylene Glycol which caused birth defects in animal studies. Do not store in open or unlabeled containers.
  • Page 124 Page 3-8 MAXX 450D/470/Diesel This page intentionally left blank 02/21/06 HydraMaster Corporation...
  • Page 125 Maxx 450 Diesel MAXX 450D/470D/450 Diesel Section 4-1 3/8/01 HydraMaster Corporation...
  • Page 126 Page 4-2 MAXX 450D/470D/Diesel Figure 4-1 Diesel Fuel Flow Diagram 3/8/01 HydraMaster Corporation...

  • Page 127: Diesel Fuel Filter With Manual Priming Pump

    MAXX 450D/470D/Diesel Page 4-3 Figure 4-2 Diesel Fuel Filter with Manual Priming Pump, Water Separator with Electric Motor HydraMaster Corporation 3/8/01...
  • Page 129 MAXX 450D/470D/Diesel Page 4-5 Figure 4-4 Wiring Diagram-Diesel Only D-4912 Sht 2, Rev G HydraMaster Corporation 11/17/2006 5/22/00...
  • Page 130 MAXX 450D/470D/Diesel Page 4-6 Figure 4-5 Wiring Diagram-Diesel Only D-4912 Sht 3, Rev G HydraMaster Corporation 11/17/2006 5/22/00...
  • Page 131 MAXX 450D/470D/Diesel Page 4-7 Figure 4-6 Wiring Diagram-Diesel Only D-4912 Sht 4, Rev G HydraMaster Corporation 11/17/2006 5/22/00...
  • Page 132 Water and Chemical System MAXX 450D/470D/450 Diesel Section 5-1 his high pressure chemical system has been designed to be simple and trouble free. WATER AND CHEMICAL FLOW OPERATION The chemical pump draws the chemical from the inlet filter which is in the chemical container.
  • Page 133 Page 5-2 MAXX 450D/470D/Diesel This page intentionally left blank 10/24/02 HydraMaster Corporation...
  • Page 134 Page 5-2 MAXX 450D/470D/Diesel Figure 5-1 Solution Flow Diagram D4382 Sht 1 Rev 3/16/05 HydraMaster Corporation...

  • Page 135: Chemical System Flow Diagram

    Page 5-3 MAXX 450D/470D/Diesel Figure 5-2 Chemical System Flow Diagram D4382 Sht 2 Rev A 3/16/05 HydraMaster Corporation...

  • Page 136: Exhaust, Vacuum, Coolant And Apo Diagram

    Page 5-4 MAXX 450D/470D/Diesel Figure 5-3 Exhaust, Vacuum, Coolant and APO Diagram D4382 Sht 3 Rev 3/16/05 HydraMaster Corporation...
  • Page 137 MAXX 450D/470D/Diesel Page 5-5 Heating System Troubleshooting 1.0. Machine overheats and shuts down 1.1. Poor ventilation in vehicle. All cargo area doors must be open for proper ventilation. Roof vents are strongly recommended for machines that are operated in hot climates.
  • Page 138 Page 5-6 MAXX 450D/470D/Diesel 2.3. System will not switch into “Cleaning” mode. Inspect the two fuses that supply 12 volts to the temperature controller. If they have blown, carefully inspect wiring for damage before replacing fuse. 2.3.1. If the fuses are okay, refer to a qualified service technician to inspect the temperature controller and RTD sensor.
  • Page 139 MAXX 450D/470D/Diesel Page 5-7 2.0. Chemical flow is unstable or low 2.1. Air in lines. Check that all fittings and connections are tight and in good condition. Repair or replace as necessary. 2.2. Filter screen in chemical jug is partially clogged. Inspect and clean.
  • Page 140 Page 5-8 MAXX 450D/470D/Diesel This page intentionally left blank 10/24/02 HydraMaster Corporation...
  • Page 141 Pump Maintenance MAXX 450D/470D/450 Diesel Section 6-1 DAILY Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the back of the pump. Use a 30 weight, non-detergent oil.

  • Page 142: Fig 6-1 Servicing The Valves

    CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic. For assistance, contact HydraMaster (425-775-7275) or the distributor in your area. 1. Servicing the Valves (See illustrations above.) A. Remove the hex valve plugs (top-discharge, bottom-inlet).
  • Page 143 MAXX 450D/470D/Diesel Page 6-3 2. Removing the High Pressure Manifold A. Using an M6 allen wrench, remove all eight of the socket head bolts. B. Rotate the crankshaft by hand to start separation of the manifold head from the crankshaft.
  • Page 144 A. While manifold, plungers, and seal retainers are removed, examine the crankcase seals for wear. B. Rotate the crankshaft oil seal externally for drying, cracking or leaking. C. Consult your HydraMaster distributor if crankcase servicing is necessary. 10/24/02 HydraMaster Corporation...
  • Page 145 MAXX 450D/470D/Diesel Page 6-5 Torque Chart Torque Pump Item Thread Inch Pounds Foot Pounds Plunger Retainer Manifold Bolt Valve Plugs 72.3 100.0 Bearing Case Screws Crankcase Cover Bubble Oil Gauge Mounting Bolts 13.0 HydraMaster Corporation 10/24/02...
  • Page 146 Page 6-6 MAXX 450D/470D/Diesel Figure 6-1 Cat Pump 10/24/02 HydraMaster Corporation...

  • Page 147: Fig 6-3 Cat Pump

    MAXX 450D/470D/Diesel Page 6-7 Cat Pump Parts List ITEM PART NO. DESCRIPTION 30047 Key (M5) 92519 Screw, Sems HHC, Bearing Cover (M6x16) 46901 Cover, Bearing 14028 O-Ring, Bearing Cover 43222 Seal, Oil, Crankshaft 14480 Bearing 46829 Rod, Connecting, Assembly 46927...
  • Page 148 Page 6-8 MAXX 450D/470D/Diesel Cat Pump Parts List (cont.) ITEM PART NO. DESCRIPTION 43750 Spring 44565 Retainer, Spring 17615 O-Ring 75, Valve Plug 46756 Plug, Valve 46616 Manifold, Head 87870 Bolt, HSH, Manifold Head (M8x65) 22187 Plug, Discharge ” 108-055...
  • Page 149 MAXX 450D/470D/Diesel Page 6-9 High Pressure System Troubleshooting 1.0. Will not come up to normal cleaning pressure 1.1. Pressure adjusting valve is defective or dirty. Disassemble valve. Repair or replace as necessary. 1.2. Worn seals or valves in pump. Test pump output volume directly from pump at normal operating RPM.
  • Page 150 Page 6-10 MAXX 450D/470D/Diesel 3.0. PSI gauge reads normal; low pressure from wand 3.1. There is a restriction in the cleaning tool. Inspect tool jet and clean or replace as necessary. Inspect any filters in the cleaning tool and clean or replace as necessary.

  • Page 151: Valve Assembly

    Cleaning Wand Parts MAXX 450D/470D/450 Diesel Section 7-1 Figure 7-1 Valve Assembly C3652 ITEM PART NO. DESCRIPTION 169-058 Valve, s/s HM Solution 167-013 Trigger, Hydra Hoe Valve - Brass 052-082 Elbow, ¼” Brass 45 Street 052-095 Nipple, ¼” s/s Hex...

  • Page 152: Valve Stem Assembly

    Page 7-2 MAXX 450D/470D/Diesel Figure 1-2 Solution Valve Assembly B1234 ITEM PART NO. DESCRIPTION 600-012-001 Valve Body Sub Assembly 600-012-002 Valve Stem Sub Assembly 155-003 Spring, HM Solution Valve 027-001 Cap, Brass 1/18/00 HydraMaster Corporation...
  • Page 153 MAXX 450D/470D/Diesel Page 7-3 Figure 1-3 Valve Stem Assembly B3743 ITEM PART NO. DESCRIPTION 107-129 Plunger, HM Solution Valve 139-003 Ring Keeper, HM Solution Valve 097-010 O-Ring, HM Valve Plunger - Large 097-022 O-Ring, Solution Valve Flow Meter - Small...
  • Page 154 Page 7-4 MAXX 450D/470D/Diesel Figure 1-4 Hydra Hoe Wand Assembly C2660 1/18/00 HydraMaster Corporation...

  • Page 155: Hydrahoe Wand Assembly

    MAXX 450D/470D/Diesel Page 7-5 Hydra Hoe Wand Assembly Parts List ITEM PART NO. DESCRIPTION 173-001 Wand Kit, 12" s/s Truckmount 082-004 Lips, 12" s/s HM Wand (2 Pieces) 169-055 Valve Assembly, s/s Hydra Hoe with Trigger 081-015 Label, “HydraMaster” Wand 154-001 Spacer, ¼...
  • Page 156 Page 7-6 MAXX 450D/470D/Diesel This page intentionally left blank 1/18/00 HydraMaster Corporation...
  • Page 157 Vacuum System MAXX 450D/470D/450 Diesel Section 8-1 he vacuum blower in this machine is a positive displacement lobe type. The performance and life of this unit is greatly dependent on the care and proper maintenance it receives. Because of the close tolerances between the lobes and housing of the vacuum blower, solid objects entering the inlet will damage the internal lobes, gears,bearings or drive system.
  • Page 158 The switch is not activated by foam, only by liquid. Vacuum Tank Filters HydraMaster filters are designed to trap lint that would normally collect at the bottom of your vacuum tank. These filters should be emptied at the end of each job.
  • Page 159 MAXX 450D/470D/Diesel Page 8-3 Blower Troubleshooting 1.0. Weak vacuum at wand. Gauge reads normal (10" to 14") 1.1. Clogged vacuum hoses or wand tube. Disconnect hoses and check carefully for an obstruction. 1.2. Excessive length of hoses connected to machine. Make sure machine is rated for the conditions under which it is being operated.
  • Page 160 Page 8-4 MAXX 450D/470D/Diesel Miscellaneous Troubleshooting 1.0.Water from exhaust 1.1. The recovery tank has been filled with foam or overfilled with water. Remove recovery tank lid and inspect. If full, drain tank then inspect high-level shutoff switch for proper operation. Clean or replace switch as necessary.
  • Page 161 Engine Troubleshooting MAXX 450D/470D/450 Diesel Section 9-1 1.0. Will not turn over 1.1. The circuit breaker on the wiring panel has tripped. This switch resets automatically. Remove wires and test for continuity. If the breaker does reset, inspect the unit to determine the cause of the tripped breaker.
  • Page 162 Page 9-2 MAXX 450D/470D/Diesel 2.1. Recovery tank is full. Empty the tank. 2.2. Recovery tank float is defective. Disconnect float. If engine starts, replace the float. 2.3. The high temperature shut-down function of the temperature controller has shut the engine down. Observe the temperature gauge. If it appears above normal operating range (250°...
  • Page 163 MAXX 450D/470D/Diesel Page 9-3 3.0. Turns over but will not start. There is no spark 3.1. The 15 amp fuse is blown. Check the fuse. If it is blown, inspect the wiring for a wire shorted to ground. Repair as necessary.
  • Page 164 Page 9-4 MAXX 450D/470D/Diesel 5.5. Low compression on one or more cylinders. Check compression. If low, check valve adjustment. If incorrect, adjust to proper specs. This operation should be performed by an experienced service technician. If adjustment is okay, there is a possibility of burned valves, burned head gasket or worn cylinders.
  • Page 165 MAXX 450D/470D/Diesel Page 9-5 8.0. Engine overheats 8.1. Poor ventilation in vehicle. All cargo area doors must be open for proper ventilation. Roof vents are strongly recommended for machines that are operated in hot climates. Any item that might restrict air flow to the machine such as other equipment or a solid divider between cargo and passenger areas should be moved or modified to permit proper air flow.
  • Page 166 Page 9-6 MAXX 450D/470D/Diesel This page intentionally left blank HydraMaster Corporation...
  • Page 167 Electrical System MAXX 450D/470D/450 Diesel Section 10-1 he MAXX electrical system has been specifically designed with the technician in mind. Often the most difficult problem to trace is an electrical failure. The MAXX series of machines utilizes a wiring Diagnostic Status Center which allows the technician or mechanic to trace all the electrical circuits from the front of the machine.
  • Page 169 MAXX 450D/470D/Diesel Page 10-3 Figure 10-2 Wiring Diagram- 450D & 470D D-4381 Sht 2, Rev K HydraMaster Corporation 11/17/2006...
  • Page 170 MAXX 450D/470D/Diesel Page 10-4 Figure 10-3 Wiring Diagram- 450D & 470D D-4381 Sht 3, Rev K HydraMaster Corporation 11/17/2006...
  • Page 171 MAXX 450D/470D/Diesel Page 10-5 Figure 10-4 Wiring Diagram- 450D & 470D D-4381 Sht 4, Rev K HydraMaster Corporation 11/17/2006...
  • Page 172 Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored. It is recommended that you affix a copy of the Log on the vehicle door near your unit for convenience and to serve as a maintenance reminder.
  • Page 173 Page 11-2 MAXX 450D/470D/Diesel OPERATIONAL MAINTENANCE (cont.) WEEKLY One time change of oil and oil filter after first 20 hours of use. One time check of the belt tensioning after first 25 hours of use. Check the oil level in blower.
  • Page 174 MAXX 450D/470D/Diesel Page 11-3 OPERATIONAL MAINTENANCE (cont.) QUARTERLY Change paper element in air cleaner. Check fuel lines. Clean and gap spark plugs. Change coolant. Grease blower bearing fittings. Change oil in blower. Change oil in pump. SEMI-ANNUALY Inspect chemical pump diaphragm and check valves for wear.
  • Page 175 Page 11-4 MAXX 450D/470D/Diesel DE-SCALING ( cont.) Attach one section of female/female solution hose to the outgoing solution fitting on the front of the machine and the other end to the garden hose and recirculation fitting combination that is attached to the front of the machine (or as many sections as you want, if you wish to de-scale your hoses).
  • Page 176 MAXX 450D/470D/Diesel Page 11-5 OVERALL MACHINE MAINTENANCE (cont.) 6. Check wand head for sharp edges that could tear carpet. File down as needed. 7. Clean wand to maintain original appearance. 8. Wipe down vacuum and high pressure hoses as needed.
  • Page 177 Page 11-6 MAXX 450D/470D/Diesel This page intentionally left blank 1/18/00 HydraMaster Corporation...
  • Page 178 MAXX 450D/470D/DIESEL GENERAL MAINTENANCE LOG DAILY SERVICE OIL RECOMMENDATIONS ENGINE OIL check BLOWER 40 weight non-detergent GARDEN HOSE SCREEN clean PUMP 5 - 30 weight synthetic motor oil MACHINE general inspection ENGINE 30 weight motor oil RECOVERY TANK FILTER BAG clean NOTE: Overhead valve engines can use multi-viscosity oil, but will experience increased oil consumption.
  • Page 179 EMERGENCIES If, for any reason, your distributor is unable to supply you with the necessary parts, they may call us and arrange for expedited shipping. HydraMaster sells parts only through authorized distributors and service centers. 1/18/00 HydraMaster Corporation...
  • Page 180 We shall always endeavor to be fair in our evaluation of your warranty claim, and shall provide you with a complete analysis of our findings. HydraMaster warranty covers only defective materials and/or workmanship for the periods listed. Labor and/or diagnostic reimbursement is specifically excluded.
  • Page 181 MAXX 450D/470D/Diesel Page 13-1 Warranty Information MAXX 450D/470D/Diesel Section 13-1 o avoid misunderstandings which might occur between machine owners and manufacturer, we are listing causes of component failure that specifically voids warranty coverage. Such causes as listed below shall constitute abuse or neglect.
  • Page 182 Page 13-2 MAXX 450D/470D/Diesel CHEMICAL SYSTEM: • Use of improper chemical. • Failure to use water softener in hard water area. • Operating machine without proper chemical filter screen. • Failure to protect against freezing. CONTROL PANEL: • Failure to protect flowmeter and water pressure gauge against freezing.
  • Page 183 Warranty coverage is available to you through your local Distributor. If you have moved to a new area or have purchased a used machine and need infor- mation regarding your local distributor, call HydraMaster at (425) 775-7272 or email us at custsvc@hydramaster.com.
  • Page 184 Page 13-4 MAXX 450D/470D/Diesel This page intentionally left blank 6/22/01 HydraMaster Corporation...
  • Page 185 These products can enhance your cleaning and reduce your labor costs! HydraMaster Machine accessories are the most innovative collection available in the cleaning industry. Our patented RX-20 Rotary Extractors have changed the shape of steam cleaning.
  • Page 186 Page 14-2 MAXX 450D/470D/Diesel This page intentionally left blank 1/18/00 HydraMaster Corporation...
  • Page 187 Product Support Bulletins MAXX 450D/470D/450 Diesel Section 15-1 1/18/00 HydraMaster Corporation...

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