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

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

MAXX 450D/470D/450 Diesel
HydraMaster Corporation
Diesel Fuel Flow Diagram
Quick Reference

HydraMaster Corporation
Introduction
Maxx 450D/470D/450 Diesel
Section 1-1
This 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.
Unlike a garden tractor, 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 RPM.
• The vacuum has to pull air and dirty water back from cleaning site.
• The water pump provides stable pressure at proper water flow for
cleaning.
• The chemical has to be injected into the water stream at the right
concentration.
• The heating system must maintain proper heat.
• The vacuum tank must store dirty water until drained.
As you can see, it is not just a turn-key operation with one thing to worry about,
Does it start?!

Page 1-2 MAXX 450D/470D/Diesel
HydraMaster Corporation
The manufacturer uses this symbol 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 [phone] Parts
8:00 am to 5:00 pm [phone] Service
PACIFIC STANDARD TIME [phone] Parts/Service Fax
WARNING
!
CAUTION
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MAXX 450D/470D/Diesel Page 1-3
HydraMaster Corporation
Precautions
Although 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.
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor.
Many vans have critical components mounted directly below the van floor that
could be damaged by a misplaced drill bit. (See Product Support Bulletins 92102,
94062 and 94063 at the end of the manual.)
ENGINE COOLING: Units employing internal combustion engines must not be
enclosed within a van with doors and windows closed. Excessive temperatures within
the engine will result in premature engine failure and a compromise of
applicable warranty.
LEVEL OPERATION: During operation, van or trailer must be parked on level ground
not to exceed + or - 10 degrees. Failure to insure proper leveling may prevent
proper internal lubrication of engine, vacuum and/or high pressure components.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.
CAUTION
!
CAUTION
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CAUTION
!
WARNING
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Page 1-4 MAXX 450D/470D/Diesel
HydraMaster Corporation
ACID RINSE AGENTS: The increased demand for “clear water” rinsing results in
the need for special care when using these acid based chemicals in your equipment.
The negative side of these products is the corrosive effects the acid can have on
metals, including swivels, pumps, heat exchangers, etc.
HydraMaster will not warranty parts that have been damaged from using unpro-
tected acid products that have obviously caused failures.
HARD WATER PROTECTION: Failure to take appropriate measures to prevent scale
build up can result in system failure and loss of warranty on affected parts. Test
the water in your immediate and surrounding areas with hard water test strips.
Assume all water obtained from wells is hard. If you are operating in a “Hard Wa-
ter Area” (3.5 grains or more per gallon), use a water softening system.
FREEZE PROTECTION: There is often little warning before a cold spell. Therefore,
not protecting this equipment from freezing will result in costly down-time. Placing
an electric heater in the truck or parking the truck indoors will help to insure against
freezing, but should not be the primary method of freeze protection.
EXHAUST SYSTEM: Do not allow flammable material (i.e. oil, fuel, plastic or wood
products) to come in contact with the exhaust system.
HOT SURFACES: During the operation of this equipment, many surfaces on the
machine will become very hot. When near the van for any reason care must be
taken not to touch any hot surface, such as heater, engine, exhaust, etc.
CAUTION
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CAUTION
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CAUTION
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CAUTION
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WARNING
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MAXX 450D/470D/Diesel Page 1-5
HydraMaster Corporation
HEARING PROTECTION: The Occupational Safety and Health Administration
(OSHA) recommends the use of hearing protection when a technician is exposed to
an
average of 85 decibels (this is an average of exposure over an 8 hour period). This
equipment can produce 85 decibels to a distance of 10 feet. Please check with
your local state agencies to see if OSHA standards apply to your application.
NO SMOKING: It is unsafe to smoke in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so
that the fumes will be directed away from the job site. Do not park where exhaust
fumes can enter a building through open doors, windows, air conditioning units or
kitchen fans.
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operat-
ing. Toxic fumes may accumulate inside a stationary vehicle.
ENGINE EXHAUST: The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects or other reproduc-
tive harm.
CARBURETOR DRAIN: Under no circumstances should the drain in the carburetor
bowl be utilized when the machine is hot.
PORTABLE GAS TANK: Never operate this machine with a portable gas can inside
the truck. Doing so increases the risk of a fire or explosion.
WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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Page 1-6 MAXX 450D/470D/Diesel
HydraMaster Corporation
PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or van.
It is dangerous and illegal in most states.
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.
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. These harmful chemicals include concentrated acid (see the pH chart at
the end of this section), solvents (including d-Limonene), and some paint, oil and
grease removers with a high concentration of solvents.
WARNING
!
WARNING
!
CAUTION
!

MAXX 450D/470D/Diesel Page 1-7
HydraMaster Corporation
The 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.
The water is then picked up by the high pressure pump and pressurized to the
desired level. The water then splits flow, as demanded by the technician.
The majority of the water flows to the bypass valve assembly, then back
through the blower exhaust heat exchanger, and back to the water box. The
water demanded by the technician flows from the water pump, through the
engine coolant heat exchangers, then through the engine exhaust heat
exchanger and out to the cleaning tool.
When the cleaning solution reaches a preset high temperature, it activates the
exhaust diverter valve control, which prevents the exhaust gases from entering
the exhaust heat exchanger. Once the solution temperature falls below the set
point, the exhaust diverter valve activates to allow the exhaust gases to flow back
through the exhaust heat exchanger. If the exhaust diverter valve becomes inop-
erable for any reason, the high pressure solenoid valve is activated to release the
heated water from the system and is directed to the recovery tank. Then cool
water enters the
system to regulate the temperature.
As there is no guess work in the manufacture of these highly advanced cleaning
plants, there must be none in preparing it to get the job done in the field. It is the
purpose of this manual to help you properly understand, maintain and service your
cleaning plant. Follow the directions carefully and you will be rewarded with years
of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of this
equipment.
System Operation

Page 1-8 MAXX 450D/470D/Diesel
HydraMaster Corporation
Frame: 24.5"W x 47.75"L x 37.375"H
Weight: 600 lbs.
Cowling: Aluminum with Epoxy finish
Engine: Daihatsu Liquid Cooled 3 Cylinder, Cast Iron Block, Diesel as required.
Displacement: (450D) 697cc, (470D) 950cc, (Diesel) 850cc
Ignition: Electronically Triggered Coils (1 per cyl.)
12 v Electric Starter Motor
12 v, 40 amp Alternator, Regulated
Electronic Governor
Pressurized Oil System with Filter
Pressurized Cooling System
Triple Row Radiator
Vacuum Blower: Proprietary Dual Shaft Roots
(450D, Diesel) 45 RAI J WhispAir™, (470D) 47 RAI J WhispAir™
Chemical System: High Pressure Injected, Meter Controlled
Heating System: 1 Stainless Steel Coil Exhaust Heat Exchanger
2 Water-to-Water Copper Shell and Tube Heat
Exchangers: 1 Air-to-Water Copper Shell and Tube Heat Exchangers
Instruments and Controls: Water Pressure Gauge, Liquid Filled, 0-1500 PSI
Water Temperature Gauge, 0-250°F
Vacuum Level Gauge, 0-30" Hg
Hour Meter, Machine Run Time
Chemical Flowmeter, Clear Acrylic, 0-10 GPH
Chemical Metering Valve
Chemical Selector Valve
Heat Bypass Lamp
Overheat Protection Lamp
Overheat Shutdown Lamp
Overheat Engine Lamp
Machine Specifications