HydraMaster MAXX 450D User manual

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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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
01/29/01

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
Quick Reference

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
Recovery Tank Float Switch-Top Float Shown
B4624 Rev—
Fuel Pump Assembly
B4627 Rev—
Quick Reference