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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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Summary of Contents for MAXX 450 Diesel

Page 1: ...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 r...

Page 2: ...MAXX 450D 470D 450 Diesel HydraMaster Corporation...

Page 3: ...mmendation 1 11 Spare Parts List 1 11 Responsibilities 1 13 Vehicle Preparation 1 15 HighAltitude Operation Preparation 1 19 Local Water Precautions 1 21 Waste Water Disposal Advisory 1 22 Map 1 24 Ma...

Page 4: ...Diagram 5 2 Chemical System Flow Diagram 5 3 Exhaust Vacuum Coolant andAPO Diagram 5 4 ChemicalTankTroubleshooting 5 5 HIGH PRESSURE PUMP Section 6 PumpMaintenance 6 1 Service 6 3 Cat PumpAssembly Dr...

Page 5: ...0 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 PA...

Page 6: ...rsal 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 P...

Page 7: ...su 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 Chem...

Page 8: ...r 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 Sea...

Page 9: ...MAXX 450D 470D 450 Diesel HydraMaster Corporation Quick Reference...

Page 10: ...MAXX 450D 470D 450 Diesel HydraMaster Corporation Recovery Tank Float Switch Top Float Shown B4624 Rev Fuel Pump Assembly B4627 Rev Quick Reference...

Page 11: ...MAXX 450D 470D 450 Diesel HydraMaster Corporation Diesel Fuel Filter with Manual Priming Pump and Water Separator with Electric Motor Quick Reference...

Page 12: ...MAXX 450D 470D 450 Diesel HydraMaster Corporation Diesel Fuel Flow Diagram Quick Reference...

Page 13: ...ractor lawn mower or cement mixer all having one or two func tions to perform the truckmounted carpet cleaning plant has many functions to perform simultaneously The engine has to run at a consistent...

Page 14: ...bol throughout the manual to warn of possible injury or death 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 7...

Page 15: ...damaged by a misplaced drill bit See Product Support Bulletins 92102 94062 and 94063 at the end of the manual ENGINE COOLING Units employing internal combustion engines must not be enclosed within a v...

Page 16: ...eas with hard water test strips Assume all water obtained from wells is hard If you are operating in a Hard Wa ter Area 3 5 grains or more per gallon use a water softening system FREEZE PROTECTION The...

Page 17: ...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 TOXIC FUMES Do not occupy the v...

Page 18: ...ained a flammable liquid is strictly forbidden by HydraMaster Corporation and by federal and state regulation The use of some chemicals through your mobile carpet cleaning plant can seriously damage t...

Page 19: ...tion 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 bel...

Page 20: ...acuum 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 Hea...

Page 21: ...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...

Page 22: ...ndard Equipment 50 ft Water Supply Line 150 ft Solution Line Dual Wand Vacuum Fittings Dual Wand Solution Fittings Battery Box with Holder Van Decal Package Van Installation Kit Operation Manual Hydra...

Page 23: ...ds If this becomes necessary always indicate the method of shipment you desire i e UPS Blue Label Air Freight Air Express etc HydraMaster Parts Dept Phone 425 775 7276 HydraMaster Parts Dept Toll Free...

Page 24: ...use 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 Li...

Page 25: ...ilities 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 recei...

Page 26: ...hall 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 Whe...

Page 27: ...tallation of a spray on bed liner in the ve hicle prior to installation of machine Be cautious when drilling any holes through the van floor Many vans have critical components mounted directly below t...

Page 28: ...location partly limits working access it does direct the noise away from the cleaning site Some cleaners in the colder areas prefer this location be cause it puts the weight over the rear wheels for b...

Page 29: ...h stop will cause the machine to rocket forward Pro tect yourself and the machine SECURE IT It is recommended by the manufacturer that the exhaust from the front of the machine be vented down under th...

Page 30: ...nsportation 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 The...

Page 31: ...r to obtain proper jet size Carburetor Jet See chart below for specific jet size Maxx 450D 700G Daihatsu Engine Maxx 470D 950G Daihatsu Engine Altitude P N BS D P N Jet Size Altitude P N BS D P N Jet...

Page 32: ...If the poppet does not seat in one or both directions the valve is out of adjustment Perform the following steps to adjust the diverter actuator shaft 3 The end of the actuator shaft is threaded into...

Page 33: ...ne s warranty HydraMaster requires that all machines operating in designated Hard Water Areas 3 5 grains or more per gallon be fitted with a water softening system or a properly installed magnetic typ...

Page 34: ...ers in conjunction with their machines prompts us to recommend the procedure to everyone in a hard water area The relatively low cost of a water softener service is more than made up for by an increas...

Page 35: ...rom 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 prob...

Page 36: ...Page 1 24 MAXX 450D 470D Diesel HydraMaster Corporation This page intentionally left blank...

Page 37: ...MAXX 450D 470 Diesel Page 1 25 HydraMaster Corporation Machine Assemblies and Parts Lists This section will be revised as drawings become available...

Page 38: ...orporation Figure 1 7 Maxx 450D 470D Frame Assembly View 1 D 4355 Rev F 20 16 13 19 18 23 32 18 17 20 8 32 33 35 30 42 41 8 3 47 47 10 27 26 28 26 25 27 24 28 31 48 30 45 6 HIDDEN HIDDEN HIDDEN HIDDEN...

Page 39: ...7 HydraMaster Corporation Figure 1 8 Maxx 450D 470D Frame Assembly View 2 D 4355 Rev F 7 7 10 12 11 6 22 21 14 14 9 8 32 30 31 33 35 18 48 30 31 30 15 10 27 26 25 28 10 25 26 27 24 10 31 17 46 50 38 3...

Page 40: ...174 049 Washer 5 16 Flat 4 13 000 143 001 Screw 1 4 20UNC x 0 75 Lg Hex Head 2 14 000 094 010 Nut 1 4 20UNC Hex 4 15 000 108 115 Protector 5 8 Bumper 12 16 000 060 010 Grommet 1 5 16 I D 1 17 000 060...

Page 41: ...Diverter ValveActuator Maxx 450D 470D 1 38 000 143 004 Screw 1 4 20UNC x 1 50 Lg Hex Head 2 39 000 174 021 Washer 3 8 Lock 2 40 000 143 017 Screw 3 8 16UNC x 0 75 Lg Hex Head Grd 8 2 41 000 143 025 Sc...

Page 42: ...nk Assembly D 6984 Rev 2 28 19 20 9 7 31 5 32 HIDDEN 18 15 HIDDEN HIDDEN 12 11 6 29 25 26 16 17 8 14 10 13 3 33 24 23 22 1 3 13 10 13 30 27 HIDDEN HIDDEN HIDDEN 34 30 HIDDEN 30 34 HIDDEN HIDDEN 21 35...

Page 43: ...or Air Univeral Recovery Tank 1 12 000 140 023 Rivet AB8 6AAluminum Pop 6 13 000 143 126 Screw 10 24UNC x 0 50 Lg Hex Head 5 14 000 143 051 Screw 8 32UNC x 0 75 Lg Binder Head Phillips 2 15 000 094 05...

Page 44: ...PT Branch M F F 1 38 000 169 082 Valve 12 Volt Solenoid 1200 PSI 1 39 000 052 662 Nipple 3 8 NPT x 1 4 M SAE 1 40 000 052 073 Nipple 3 8 NPT x 1 4 NPT Hex 1 41 000 106 049 Plug 1 NPTAllen Head 1 42 00...

Page 45: ...ent 1 2 000 078 039 Vacuum Inlet StopperAssembly Recovery Tank 1 3 000 057 015 Gasket 1 1 2 Bulkhead Fitting 2 4 000 052 219 Adapter 2 NPT x 2 F Slip 2 5 000 143 539 Screw 6 32UNC x 0 50 Lg Button Hea...

Page 46: ...2 6 1 000 015 182 Bracket Vacuum Relief Valve 1 2 000 027 032 Cap Vacuum Releif Valve 1 3 000 125 111 Pipe Vacuum Relief Spring Guide 1 4 000 105 332 Plate Vacuum Relief Valve Mounting Universal Recov...

Page 47: ...n Figure 1 12 Dash Assembly D 4359 Rev F 4 22 24 19 2 22 21 24 23 22 3 9 20 26 22 27 10 6 22 27 10 BACK DETIAL 11 32 22 36 34 33 32 16 11 13 7 11 14 37 8 12 16 15 5 15 10 10 25 25 16 7 18 10 1 1 23 22...

Page 48: ...PT x 45 Street 1 13 000 052 531 Elbow 1 8 NPT x 1 4 SAE 1 14 000 052 084 Elbow 1 8 NPT Street 1 15 000 094 034 Nut 10 24UNC Nylock 7 16 000 052 099 Insert 26 1 8 NPT x 3 8 Barb 3 17 000 025 011 Cable...

Page 49: ...Assembly Parts List 7 13 2 14 12 9 5 16 17 17 19 4 11 8 3 23 1 15 24 21 20 10 6 16 22 19 18 31 000 033 057 Clamp 1 Cushion Loop 1 32 000 052 089 Elbow 1 8 NPT Female 2 33 000 143 328 Screw 10 32UNF x...

Page 50: ...052 074 Nipple 3 8 NPT Hex 1 9 000 174 007 Washer 1 2 Flat 4 10 000 174 032 Washer 3 8 Flat 2 11 000 174 008 Washer 5 8 Flat 1 12 000 052 071 Nipple 1 4 NPT Hex 2 13 000 052 528 Nipple 3 8 M JIC x 3 8...

Page 51: ...XX 450D 470 Diesel Page 1 39 HydraMaster Corporation Figure 1 14 Upper Dash Instrument Panel Assembly C 4356 RevA 13 5 17 16 18 19 7 7 8 7 1 7 7 7 1 6 2 9 12 4 3 10 5 5 5 1 11 15 15 18 19 14 20 15 15...

Page 52: ...r Mini 3 9 000 061 056 Knob TemperatureAdjustment 1 10 000 157 131 Switch 3 Way Speed Control 1 11 000 015 566 Bracket Upper Dash Instrument Hinge 2 12 000 074 007 Gauge 2 Dia 0 1500 PSI 1 13 000 149...

Page 53: ...esel Page 1 41 HydraMaster Corporation Figure 1 15 Electrical Control Panel Assembly D 4548 Rev E 22 23 12 19 18 12 12 11 3 11 15 9 6 2 14 14 HIDDEN 20 21 12 16 17 8 16 14 7 12 10 13 13 10 12 12 13 1...

Page 54: ...22 Switch Relay 3 11 000 143 062 Screw 10 24UNC x 0 75 Lg Pan Head Phillips 4 12 000 094 034 Nut 10 24UNC Nylock 10 13 000 143 166 Screw 10 24UNC x 0 38 Lg Hex Head 3 14 000 143 545 Screw 8 32UNC x 1...

Page 55: ...Bypass Heat Exchanger Parts List Item Part Number Description Qty 5 4 4 4 OUT IN 4 3 5 1 2 2 3 1 000 038 031 Core 4 x 19 Tube Shell Hx w 3 Ends 1 2 000 052 087 Elbow 1 2 NPT Street 2 3 000 052 107 Ins...

Page 56: ...MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 17 Water to Water Heat Exchanger Maxx 450 470 D 5995 RevA 15 14 2 1 15 16 8 7 9 6 5 7 8 16 24 20 4 22 8 7 4 19 4 21 13 12 10 11 9 4 23 4 17 4 18 1...

Page 57: ...Elbow 1 NPT x1 Barb Glass Filled Black Nylon 2 10 000 106 001 Plug 1 8 NPT 1 11 000 052 109 Insert F24 1 8 NPT x 1 4 Barb 1 12 000 068 015 Hose 1 4 Black Rubber 1 13 000 033 017 Clamp 1 4 I D Hose 2 1...

Page 58: ...1 46 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 18 Water Box Assembly D 4732 Rev H 12 13 16 26 21 12 18 20 19 23 24 27 25 29 28 2 3 4 6 7 8 9 17 12 13 14 16 10 11 11 1 13 2 28 29 27 15 31...

Page 59: ...3 000 094 097 Nut 1 14 Brass Water Box 4 14 000 052 023 Tee 3 8 NPT Male Street 1 15 000 052 662 Nipple 3 8 NPT x 1 4 M SAE 1 16 000 052 105 Insert 68 3 8 NPT x 1 2 Barb 2 17 000 157 031 Switch Side M...

Page 60: ...8 16 15 3 16 15 6 18 21 20 11 9 12 20 8 24 23 24 22 26 25 4 33 34 35 17 1 10 28 29 5 13 1 000 111 070 Pump 4 Gpm CAT Hi Temp Plunger 1 2 000 036 006 Clutch Pump CDS 4 8 Maxx 1 3 000 015 682 Bracket Pu...

Page 61: ...x Head 4 17 000 052 106 Insert 1 8 NPT x 5 32 Barb x 90 1 18 000 068 523 Hose 3 8 x 17 Lg Hi Temp Oil Drain 1 19 000 033 005 Clamp Size 5 Hose 1 20 000 068 587 Hose Throb 1 21 000 052 656 Plug SAE Fla...

Page 62: ...1 3 000 154 092 Spacer Air Pump Pulley 17mm Bore 1 4 000 109 083 Pulley AK30 Mod To 17mm Bore Maxx 1 5 000 174 004 Washer 5 16 Flat 4 6 000 143 029 Screw 3 8 16UNC x 1 25 Lg Torx Plus Button Head 1 7...

Page 63: ...er Chemical Pump 1 3 000 111 030 Body Chemical Pump 1 4 000 105 071 Mid Plate Chemical Pump 1 5 000 046 010 Diaphragm Chemical Pump 1 6 000 097 055 O Ring Chemical Pump Midplate An Size 227 Viton 1 7...

Page 64: ...Page 1 52 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 22 Dura Flow APO Assembly Automatic Pump Out D 5654 Rev E 16 15 16 17 18 19 20 21 17 1 9 10 5 8 3 8 2 7 6 13 4 14 12 7 4 6 6 5 22...

Page 65: ...lat 4 8 000 061 131 Knob Handle Rdm 2 9 000 052 723 Fitting 1 NPT Cam Lock Banjo 100F 1 10 000 052 724 Fitting 1 NPT Cam Lock Banjo 100B 1 11 000 157 022 Switch Relay 1 12 000 012 011 Block 6 Post 1 1...

Page 66: ...Page 1 54 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 23 Fuel Pump Assembly B 4627 Rev...

Page 67: ...MAXX 450D 470 Diesel Page 1 55 HydraMaster Corporation Figure 1 24 Diverter Valve Actuator Assembly C 5386 Rev B 4 13 8 5 2 9 12 10 9 14 1 3 9 11 14 9 10 6 7...

Page 68: ...ottom 1 4 000 015 630 Bracket Air Cylinder Extension 1 5 000 169 169 Valve Air Cylinder 1 6 000 094 081 Nut 5 16 18UNC Hex 2 Way Locking 1 7 000 143 573 Screw 5 16 18 Shoulder 3 8 Dia x 1 2 1 8 000 05...

Page 69: ...ower MD 4005 Assembly Parts List 10 8 1 31 30 12 27 21 13 20 15 16 19 11 17 16 19 18 19 30 30 4 26 24 25 23 29 22 24 23 32 22 29 30 5 6 33 2 7 31 34 3 14 34 34 34 9 28 1 000 111 145 Blower 4005 Domina...

Page 70: ...052 069 Nipple 1 8 NPT Hex 1 16 000 052 092 Tee 1 8 FPT 2 17 000 052 057 Nipple 1 8 NPT Close 1 18 000 052 084 Elbow 1 8 NPT Street 1 19 000 052 293 Insert 23 1 8 NPT x 3 16 Barb 3 20 000 033 117 Cla...

Page 71: ...y Blower MD 4007 Assembly Parts List 21 27 12 30 13 16 19 17 16 19 18 19 3 23 22 10 23 32 5 1 6 33 29 22 8 24 29 25 24 26 11 15 20 2 7 31 30 30 31 30 34 4 14 34 34 34 9 28 1 000 111 147 Blower MD 4007...

Page 72: ...052 069 Nipple 1 8 NPT Hex 1 16 000 052 092 Tee 1 8 FPT 2 17 000 052 057 Nipple 1 8 NPT Close 1 18 000 052 084 Elbow 1 8 NPT Street 1 19 000 052 293 Insert 23 1 8 NPT x 3 16 Barb 3 20 000 033 117 Cla...

Page 73: ...Figure 1 27 Exhaust Assembly View 1 D 4541 Rev F 20 19 4 13 7 11 17 13 11 7 13 19 13 25 13 7 28 11 13 1 15 10 8 33 33 9 15 5 27 10 17 13 13 25 25 25 40 13 25 34 13 18 21 26 24 22 23 10 25 13 25 13 25...

Page 74: ...Page 1 62 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 28 Exhaust Assembly View 2 D 4541 Rev F 39 31 39 38 39 32 30 38 38...

Page 75: ...NC x 5 8 Lg Hex Grd 5 12 13 000 174 049 Washer 5 16 Flat 20 14 000 143 124 Screw 5 16 18UNC x 1 75 Lg Hex Head 6 15 000 174 069 Washer 5 16 Inconel Belleville Diverter Valve 12 16 000 052 600 Elbow 1...

Page 76: ...2 507 Nipple 3 8 NPT x 9 16 18 37 JIC 2 34 000 141 033 Rod Heat Exchanger Strap Retainer 2 35 000 033 122 Clamp Exhaust Support Mounting Maxx 450D 470D 1 36 000 143 092 Screw 5 16 18UNC x 2 25 Lg Hex...

Page 77: ...77 Valve 3 8 FPT Check 65 PSI 1 7 000 049 016 Filter 1 4 NPT Replacement Y 2 8 000 052 074 Nipple 3 8 NPT Hex 1 9 000 052 086 Elbow 3 8 NPT Street 1 10 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 1 11 000...

Page 78: ...Page 1 66 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 30 By Pass Valve Assembly C 4900 Rev D 2 10 1 7 4 1 6 9 5 8 12 15 14 15 16 13 11 3...

Page 79: ...5 000 052 447 Tee 3 8 Branch 1 6 000 052 128 Nipple 3 8 NPT x 3 8 Male Propane 1 7 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 1 8 000 015 515 Bracket By Pass Valve Mounting 1 9 000 169 083 Valve Hi PSI B...

Page 80: ...Maxx 450D Daihatsu Engine Assembly View 1 D 4351 Rev G 60 48 59 21 58 62 53 49 52 62 3 6 13 25 56 48 51 48 54 55 50 48 15 6 14 14 6 10 16 18 33 19 31 28 6 6 14 27 57 44 48 6 34 14 23 21 23 22 22 21 48...

Page 81: ...ydraMaster Corporation Figure 1 32 Maxx 450D Daihatsu Engine Assembly View 2 D 4351 Rev G 15 15 23 21 23 21 22 45 45 17 12 6 14 22 42 14 6 15 43 30 36 35 26 39 38 37 23 21 22 11 61 1 6 2 22 20 19 15 4...

Page 82: ...Mounting 2 12 000 015 741 Bracket Rear Foot Daihatsu 2 13 000 109 100 Pulley 6 Dual V Belt Maxx 1 14 000 143 187 Screw 8mm x 25mm Lg Grade 10 9 Hex Head 17 15 000 174 049 Washer 5 16 Flat 16 16 000 0...

Page 83: ...Screw 1 4 20UNC x 0 75 Lg Hex Head 1 43 000 094 009 Nut 1 4 20UNC Hex Nylock 1 44 000 033 116 Clamp 1 1 2 Cushion Loop w 7 16 Mounting Hole 2 45 000 033 057 Clamp 1 Cushion Loop 2 46 000 174 001 Wash...

Page 84: ...mp 1 62 000 057 050 Gasket Thermostat Housing Daihatsu Engine 2 63 000 015 782 Bracket Choke Daihatsu Manual 1 64 000 033 124 Clamp Daihatsu Choke Manual 1 65 000 143 551 Screw Daihatsu Choke Manual 1...

Page 85: ...33 Maxx 470D Daihatsu Engine Assembly View 1 D 4567 Rev H 60 48 59 21 58 62 53 62 3 6 5 13 25 10 14 6 14 6 15 48 50 48 55 54 51 48 56 16 18 33 19 29 31 6 14 6 27 44 22 21 23 57 44 22 21 23 48 14 6 34...

Page 86: ...ydraMaster Corporation Figure 1 34 Maxx 470D Daihatsu Engine Assembly View 2 D 4567 Rev H 61 2 22 21 23 15 23 21 22 11 22 21 23 37 38 39 35 36 30 43 26 15 6 14 42 22 14 6 15 12 45 46 17 45 17 1 66 6 7...

Page 87: ...Mounting 2 12 000 015 741 Bracket Rear Foot Daihatsu 2 13 000 109 100 Pulley 6 Dual V Belt Maxx 1 14 000 143 187 Screw 8mm x 25mm Lg Grade 10 9 Hex Head 17 15 000 174 049 Washer 5 16 Flat 16 16 000 0...

Page 88: ...4 20UNC x 0 75 Lg Hex Head 1 43 000 094 009 Nut 1 4 20UNC Hex Nylock 1 44 000 033 116 Clamp 1 1 2 Cushion Loop w 7 16 Mounting Hole 2 45 000 033 057 Clamp 1 Cushion Loop 2 46 000 174 001 Washer 10 Fl...

Page 89: ...Thermostat Housing Daihatsu Engine 2 63 000 015 782 Bracket Choke Daihatsu Manual 1 64 000 033 124 Clamp Daihatsu Choke Manual 1 65 000 143 551 Screw Daihatsu Choke Manual 1 66 000 015 645 Bracket Ra...

Page 90: ...Page 1 78 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 35 Engine Cover Support Assembly D 5637 RevA 1 10 2 3 7 13 5 15 9 12 7 8 5 6 7 8 11 16 4 14 4 17...

Page 91: ...94 009 Nut 1 4 20UNC Hex Nylock 2 7 000 052 106 Insert 1 8 NPT x 5 32 Barb x 90 4 8 000 169 070 Valve Primary Vac Solenoid 2 9 000 106 014 Plug Gearbox Vent 2 10 000 108 115 Protector 5 8 Bumper 2 11...

Page 92: ...Page 1 80 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 36 Chemical Jug Tray Assembly C 4945 Rev C 9 2 5 10 1 4 5 10 3 8 6 4 7 19 10 12 14 11 13 15 7 17 18 16...

Page 93: ...0 052 226 Insert 1 1 2 NPT x 1 1 2 Barb Grey 2 8 000 052 182 Nipple 1 1 2 NPT Close Galvanized 1 9 000 159 016 Jug 5 Gallon Plastic Chemical Standard 1 10 000 174 003 Washer 1 4 Flat 4 11 000 015 720...

Page 94: ...ydraMaster Corporation Figure 1 37 Dash Assembly Maxx 450 Diesel C 6057 RevA 20 10 10 1 19 2 10 16 12 11 7 16 14 8 16 5 10 17 22 21 22 23 21 30 31 25 25 27 27 26 22 29 24 22 4 9 15 15 22 22 23 28 13 3...

Page 95: ...052 078 Elbow 1 8 NPT x 45 Street 1 13 000 052 531 Elbow 1 8 NPT x 1 4 SAE 2 14 000 052 084 Elbow 1 8 NPT Street 1 15 000 094 034 Nut 10 24UNC Nylock 7 16 000 052 099 Insert 26 1 8 NPT x 3 8 Barb 3 17...

Page 96: ...poration Dash Assembly Maxx 450 Diesel Parts List Item Part Number Description Qty 31 000 033 057 Clamp 1 Cushion Loop 1 32 000 052 089 Elbow 1 8 NPT Female 2 33 000 143 328 Screw 10 32UNF x 1 2 Lg Ph...

Page 97: ...50D 470 Diesel Page 1 85 HydraMaster Corporation Figure 1 38 Lower Dash Plumbing Connection Panel Assembly Maxx 450 Diesel D 5997 Rev 5 6 16 17 19 17 16 15 4 1 24 11 8 21 22 19 3 7 18 13 2 23 14 12 9...

Page 98: ...reet 1 8 000 052 074 Nipple 3 8 NPT Hex 1 9 000 174 007 Washer 1 2 Flat 4 10 000 174 032 Washer 3 8 Flat 2 11 000 174 008 Washer 5 8 Flat 1 12 000 052 071 Nipple 1 4 NPT Hex 2 13 000 052 528 Nipple 3...

Page 99: ...MAXX 450D 470 Diesel Page 1 87 HydraMaster Corporation 2 15 14 15 16 13 4 1 12 9 10 3 8 11 5 1 1 6 7 Figure 1 39 By Pass Valve Assembly Maxx 450 Diesel C 5996 Rev...

Page 100: ...1 4 M SAE 1 5 000 052 447 Tee 3 8 Branch 1 6 000 052 128 Nipple 3 8 NPT x 3 8 Male Propane 1 7 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 1 8 000 015 515 Bracket By Pass Valve Mounting 1 9 000 169 083 Val...

Page 101: ...ihatsu Engine Assembly Maxx 450 Diesel View 1 D 6056 RevA 61 48 60 21 59 63 53 49 52 63 3 6 13 25 57 48 51 48 55 56 54 50 48 48 15 6 14 14 6 10 16 18 33 19 31 28 6 6 14 27 58 44 48 6 34 14 23 21 23 22...

Page 102: ...Master Corporation Figure 1 41 Daihatsu Engine Assembly Maxx 450 Diesel View 2 D 6056 RevA 8 15 15 23 21 23 21 22 45 45 17 12 6 14 22 42 14 6 15 43 30 36 35 26 39 38 37 23 21 22 11 62 6 2 22 20 19 15...

Page 103: ...Mounting 2 12 000 015 741 Bracket Rear Foot Daihatsu 2 13 000 109 100 Pulley 6 Dual V Belt Maxx 1 14 000 143 187 Screw 8mm x 25mm Lg Grade 10 9 Hex Head 17 15 000 174 049 Washer 5 16 Flat 16 16 000 0...

Page 104: ...001 Screw 1 4 20UNC x 0 75 Lg Hex Head 1 43 000 094 009 Nut 1 4 20UNC Hex Nylock 1 44 000 033 116 Clamp 1 1 2 Cushion Loop w 7 16 Mounting Hole 2 45 000 033 057 Clamp 1 Cushion Loop 2 46 000 174 001 W...

Page 105: ...s List Item Part Number Description Qty 61 000 068 250 Hose 1 Green Stripe 1 62 000 010 115 Belt Xl7395 470D Air Pump 1 63 000 057 050 Gasket Thermostat Housing Daihatsu Engine 2 64 000 015 645 Bracke...

Page 106: ...Page 1 94 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 42 Water To Water HX Assembly Maxx 450 Diesel D 4353 Rev F 6 7 5 6 11 6 5 3 1 10 9 2 10 9 4 8 4 15 15 14 16 12 12...

Page 107: ...2 5 000 052 086 Elbow 3 8 NPT Street 3 6 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 3 7 000 052 083 Elbow 3 8 NPT Street x 45 2 8 000 068 250 Hose 1 Green Stripe Bulk 1 9 000 143 001 Screw 1 4 20UNC x 0...

Page 108: ...1 96 MAXX 450D 470 Diesel HydraMaster Corporation Figure 1 43 Contol Panel Maxx 450 Diesel D 6089 Rev 10 5 12 16 2 18 13 13 15 11 11 11 8 16 18 21 20 18 16 9 19 15 15 14 14 6 6 6 6 14 14 14 14 1 7 17...

Page 109: ...000 056 020 Fuse Panel 1 9 000 056 030 Diode Panel 1 10 000 018 040 Circuit Breaker 50 AMP 1 11 000 157 022 Switch Relay 3 12 000 029 016 Governor HallAffects Maxx 450D 470DD 1 13 000 143 062 Screw 10...

Page 110: ...052 155 4 in 169 070 Lwr Primary Vac Solenoid Valve 3 16 Plastic Vac Tee 052 155 2 in 169 070 3 16 Plastic Vac Tee 052 155 3 16 Plastic Vac Tee 052 155 4 in 3 16 Plastic Vac Tee 052 155 Diverter Cont...

Page 111: ...y Water Box Tank 159 105 10 in 068 230 Fuel Line 8 ft 068 250 Water to Water Heat Exchanger Water to Water Heat Exchanger 2 in 038 043 038 043 1 Barb x 1 Barb x 1 Barb Tee 1 Barb x 1 Barb Elbow for 7...

Page 112: ...mical Valve Hi PSI Brass Manifold Out 169 0171 090 008 068 519 Poly Water Box Tank 159 105 Cat Pump 7 in 068 521 Steam Chemical Jug Outer Tray Automatic Pump Out 111 012 24 in Hose 166 022 068 522 Blo...

Page 113: ...overs with a high concentration of solvents PRECAUTIONS There are no short cuts to good carpet cleaning It requires time cleaning know ledge and the use of good chemicals Therefore the manufacturer re...

Page 114: ...f the cleaning tool on all types of carpet Procedure Always move the cleaning tool in smooth forward and backward strokes Apply slight pressure to the forward stroke while the solution is injected int...

Page 115: ...RAL AREAS THAT WILL CAUSE OVERWETTING 1 Too few vacuum strokes or improper saw tooth vacuum strokes as shown in the following illustration 2 Obstructed cut or kinked hoses 3 Vacuum tank drain valve le...

Page 116: ...Page 2 4 MAXX 450D 470D Diesel HydraMaster Corporation 3 18 05...

Page 117: ...ing pressure of 200 PSI must be maintained NOTE Under exceptionally long periods of No Flow conditions the Over Temp light may come on momentarily This indicates that the high temp solenoid is acti va...

Page 118: ...or reading maximum flow and the PRIME line pulsing turn the chemical selector valve to ON and place the chemical PRIME line back into the chemical container c Then while spraying solution from the cle...

Page 119: ...hine b When the chemical begins to flow through the flowmeter with the flow indicator reading maximum flow and the PRIME line pulsing turn the chemical selector valve to ON and place the chemical PRIM...

Page 120: ...r box can overflow 3 Remove the vacuum hose 4 At this time the blower should be lubricated with an oil based lubricant See Lubrication in the Blower Operation and Maintenance Manual included in Sectio...

Page 121: ...50 antifreeze and water mix into the water box Run the machine until you see the antifreeze mix flowing through the wand This should use approximately q of the solution When using the Recirculation Ki...

Page 122: ...tion may be needed in the water box With the machine running spray the wand into a container to recapture the antifreeze solution Continue to spray the wand until the pump clutch shuts off Recovering...

Page 123: ...caused birth defects in animal studies Do not store in open or unlabeled containers KEEP OUT OF REACH OF CHILDREN AND ANIMALS FREEZE PROTECTION OF THE PUMP IN SYSTEM 1 Drain the fresh water tank 2 Re...

Page 124: ...Page 3 8 MAXX 450D 470 Diesel HydraMaster Corporation 02 21 06 This page intentionally left blank...

Page 125: ...HydraMaster Corporation 3 8 01 Maxx 450 Diesel MAXX 450D 470D 450 Diesel Section 4 1...

Page 126: ...HydraMaster Corporation 3 8 01 Page 4 2 MAXX 450D 470D Diesel Figure 4 1 Diesel Fuel Flow Diagram...

Page 127: ...MAXX 450D 470D Diesel Page 4 3 HydraMaster Corporation 3 8 01 Figure 4 2 Diesel Fuel Filter with Manual Priming Pump Water Separator with Electric Motor...

Page 128: ...Page 4 4 MAXX 450D 470D Diesel HydraMaster Corporation Figure 4 3 Wiring Schematic Diesel Only D 4913 Rev C 05 30 2006...

Page 129: ...MAXX 450D 470D Diesel Page 4 5 5 22 00 HydraMaster Corporation Figure 4 4 Wiring Diagram Diesel Only D 4912 Sht 2 Rev G 11 17 2006...

Page 130: ...MAXX 450D 470D Diesel Page 4 6 5 22 00 HydraMaster Corporation Figure 4 5 Wiring Diagram Diesel Only D 4912 Sht 3 Rev G 11 17 2006...

Page 131: ...MAXX 450D 470D Diesel Page 4 7 5 22 00 HydraMaster Corporation Figure 4 6 Wiring Diagram Diesel Only D 4912 Sht 4 Rev G 11 17 2006...

Page 132: ...box is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply If for ex ample the water source at the house were turned off the water level of the wate...

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Page 134: ...Page 5 2 MAXX 450D 470D Diesel HydraMaster Corporation 3 16 05 Figure 5 1 Solution Flow Diagram D4382 Sht 1 Rev A...

Page 135: ...Page 5 3 MAXX 450D 470D Diesel HydraMaster Corporation 3 16 05 Figure 5 2 Chemical System Flow Diagram D4382 Sht 2 Rev A...

Page 136: ...Page 5 4 MAXX 450D 470D Diesel HydraMaster Corporation 3 16 05 Figure 5 3 Exhaust Vacuum Coolant and APO Diagram D4382 Sht 3 Rev A...

Page 137: ...ve manually make sure exhaust system is cool to determine if the movement of the valve is restricted Repair or adjust as necessary 1 5 Diverter valve and or high pressure dump solenoid are not functio...

Page 138: ...ow Check RPM with accurate tachometer and adjust as necessary 2 7 Heat exchangers have hard water scale build up internally Descale system Chemical System Troubleshooting 1 0 System will not prime 1 1...

Page 139: ...ng valve is faulty or partially obstructed Inspect valve and clean or replace as necessary 2 5 High pressure check valve is faulty Remove and inspect Clean or replace as necessary 3 0 Solution jug fil...

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Page 141: ...te the pump if the crankcase has been contaminated with water Do not leave contaminated oil in the pump housing or leave the housing empty Remove contaminated oil as soon as it is discovered and repla...

Page 142: ...under the plug for cuts or distortion Replace it if it is worn Lubricate new o rings before installing C Grasp the valve retainer by the tab at the top with needle nose pliers then remove the o ring...

Page 143: ...inspect for wear E Examine the ceramic plunger for cracks or scoring refer to Servicing the Plungers for replacement 3 Servicing the Low Pressure Seals and High Pressure Seals See illustrations above...

Page 144: ...new sealing washer for ease of installation and to avoid damage 2 Apply Loctite 242 to the threads of the plunger retainer and press it into the ceramic plunger Thread hand tight then torque the bolt...

Page 145: ...hart Torque Pump Item Thread Inch Pounds Foot Pounds Nm Plunger Retainer M6 55 4 4 6 2 Manifold Bolt M6 55 4 4 6 2 Valve Plugs M22 870 72 3 100 0 Bearing Case Screws M6 50 4 0 6 0 Crankcase Cover M6 5...

Page 146: ...Page 6 6 MAXX 450D 470D Diesel HydraMaster Corporation 10 24 02 Figure 6 1 Cat Pump...

Page 147: ...Gauge 1 40 92519 Screw Sems HHC Crankcase Cover M6x16 4 48 25625 Plug Drain x 11 1 49 23170 O Ring Drain Plug 1 50 46939 Cover Crankcase 1 51 14041 O Ring Crankcase Cover 1 53 46534 Crankcase 1 64 46...

Page 148: ...756 Plug Valve 6 185 46616 Manifold Head 1 193 87870 Bolt HSH Manifold Head M8x65 8 196 22187 Plug Discharge 3 8 1 250 108 055 Protector 3CP Cat Pump Shaft 1 260 114 003 Rail Angle 3CP Cat 1 265 30651...

Page 149: ...l orifice has been exchanged with secondary hot water dump orifice Inspect and reverse as necessary 1 7 Primary orifice is worn Measure orifice size and replace as necessary 2 0 No pressure reading on...

Page 150: ...oo high refer to Heating System section IV 4 2 There is an air leak between the water box outlet and the pump inlet Physically check all hoses and fittings for cuts breaks cracks or tightness Repair a...

Page 151: ...IPTION QTY 1 169 058 Valve s s HM Solution 1 2 167 013 Trigger Hydra Hoe Valve Brass 1 3 052 082 Elbow Brass 45 Street 1 4 052 095 Nipple s s Hex 1 5 052 050 Quick Connect 440 M with Viton 1 6 052 152...

Page 152: ...Master Corporation 1 18 00 Figure 1 2 Solution Valve Assembly B1234 ITEM PART NO DESCRIPTION QTY 1 600 012 001 Valve Body Sub Assembly 1 2 600 012 002 Valve Stem Sub Assembly 1 3 155 003 Spring HM Sol...

Page 153: ...3 Valve Stem Assembly B3743 ITEM PART NO DESCRIPTION QTY 1 107 129 Plunger HM Solution Valve 1 2 139 003 Ring Keeper HM Solution Valve 1 3 097 010 O Ring HM Valve Plunger Large 1 4 097 022 O Ring Solu...

Page 154: ...Page 7 4 MAXX 450D 470D Diesel HydraMaster Corporation 1 18 00 Figure 1 4 Hydra Hoe Wand Assembly C2660...

Page 155: ...D s s 1 7 061 006 Handle Pressure Guide 1 8 052 151 Compression 1 8 Female Hydra Hoe Fitting 1 9 052 153 Housing Brass Stabilizer Wand Nozzle Fitting 1 10 186 001 Stabilizer Jet Assembly Group 1 11 07...

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Page 157: ...ne is open caution should be used To protect the vacuum blower from overloading and damaging itself there is a vacuum relief system installed on the vac tank When the vacuum tank inlet is completely s...

Page 158: ...float kill switch 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 The...

Page 159: ...or replace as necessary 3 2 Hose from vacuum blower to recovery tank is collapsed internally Inspect and replace as necessary 4 0 Noisy vacuum blower 4 1 Vacuum blower is low on oil Inspect oil level...

Page 160: ...d humid climates Observe how long this condition persists after starting machine If it is only until the machine warms up it is normal 1 3 A heat exchanger is leaking Change the diverter mode switch b...

Page 161: ...noid replace the solenoid 1 5 The ignition switch is defective Test to see if there is 12 volts to the switch If there is but there is not 12 volts coming from the switch replace the switch 1 6 The va...

Page 162: ...ecessary 2 6 Fuel is not reaching the carburetor inlet Check the fuel pump If it is working check to see in the pump is delivering 12 oz minute flow to the carburetor 2 6 1 If it is not inspect the fu...

Page 163: ...safety function 4 4 The speed control governor or the throttle actuator is faulty Refer to qualified service technician for diagnosis and repair 4 5 There is excessive back pressure on the engine or b...

Page 164: ...n the carburetor causing excessive fuel to be supplied to the carburetor 6 3 1 There is dirt in the carburetor causing the carburetor inlet valve to be held open Refer to qualified engine service tech...

Page 165: ...flow 8 2 Low engine coolant level Check coolant level If low check for source of leak and repair before replenishing coolant 8 3 Fan belt loose or broken Check belt Adjust or replace as necessary 8 4...

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Page 167: ...ignition processor has a built in troubleshooting control It is labeled Engine Diagnostic on the status panel Refer to the Daihatsu engine troubleshooting section for this feature The entire electric...

Page 168: ...Page 10 2 MAXX 450D 470D Diesel HydraMaster Corporation Figure 10 1 Wiring Schematic 450D and 470D D 4380 Rev F 05 19 2006...

Page 169: ...MAXX 450D 470D Diesel Page 10 3 HydraMaster Corporation Figure 10 2 Wiring Diagram 450D 470D D 4381 Sht 2 Rev K 11 17 2006...

Page 170: ...MAXX 450D 470D Diesel Page 10 4 HydraMaster Corporation Figure 10 3 Wiring Diagram 450D 470D D 4381 Sht 3 Rev K 11 17 2006...

Page 171: ...MAXX 450D 470D Diesel Page 10 5 HydraMaster Corporation Figure 10 4 Wiring Diagram 450D 470D D 4381 Sht 4 Rev K 11 17 2006...

Page 172: ...his General Maintenance Log for specific maintenance intervals Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored It is recomm...

Page 173: ...te as necessary 12 Clean vacuum tank thoroughly with high pressure washer 13 Check the wiring for any chafing 14 Flush water and chemical system with 50 50 white vinegar solution 15 Check float switch...

Page 174: ...water or you see evidence of deposits in the water system you may have to de scale monthly To de scale your system add an appropriate de scaler chemical to your water box Circulate it through the hea...

Page 175: ...ortant for two reasons 1 It represents a big dollar investment for your cleaning business and its appearance should reflect that fact A dirty machine is not professional 2 Maintenance troubleshooting...

Page 176: ...recovery tank and thoroughly clean removing all lint build up Inspect for damage and reinstall 5 Remove filter bag Thoroughly clean and reinstall If torn replace 6 Empty chemical from chemical contai...

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Page 178: ...BELTS PULLEYS check for wear 25 HIGH PRESSURE LINES check for chafing 25 NUTS BOLTS check tightness 25 Y FILTER check and clean 25 ORIFICE inspect 25 VACUUM RELIEF VALVE inspect clean lube 25 VACUUM T...

Page 179: ...f Purchase C Hours on the Unit D Unit Serial Number E Description of Malfunction 3 Once it has been determined which parts are needed to correct the problem with your machine make arrangements with yo...

Page 180: ...vice Department at 425 775 7275 8 a m to 5 p m Monday through Friday PST We shall always endeavor to be fair in our evaluation of your warranty claim and shall provide you with a complete analysis of...

Page 181: ...ct oil grade and viscosity as recommended in blower manual Failure to properly maintain blower safeguard systems such as waste tank filter screen vacuum safety relief valve and waste tank automatic sh...

Page 182: ...from engine and blower exhaust Damage to hoses from being run over by vehicles Kinking or cracking from failure to store or unroll hoses correctly Normal wear and tear from everyday use CLEANING WAND...

Page 183: ...ors maintaining current account status An invoice will be sent to the distributor for the amount of the parts sent The customer s faulty parts must be returned for evaluation prior to the expiration o...

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Page 185: ...ors have changed the shape of steam cleaning Our hoses and tanks are of the finest quality construction SafeClean and HydraMaster Detergents have been specially prepared not only to give you exception...

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Page 187: ...HydraMaster Corporation 1 18 00 Product Support Bulletins MAXX 450D 470D 450 Diesel Section 15 1...

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