HydraMaster CDS 4.8 User manual

Clutch Drive System 4.8
Owner’s Manual
HydraMaster
11015 47th Avenue West
Mukilteo, Washington 98275
MAN-33149 Rev. E, January 2018
(P/N 000-182-038)
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 HydraMaster. Specications and information in this document are
subject to change without prior notice. All rights reserved. © 2018 HydraMaster

Table Of Contents
GENERAL INFORMATION ........................................................................ SECTION 1
Contact Information ........................................................................... 1-2
Warnings, Cautions and Notices ....................................................... 1-3
Machine Specications...................................................................... 1-6
Responsibilities.................................................................................. 1-8
Battery Relearn for Ford Van ............................................................. 1-9
Local Water Precautions.................................................................... 1-10
Waste Water Disposal Advisory......................................................... 1-13
CHEMICALS AND CLEANING ................................................................. SECTION 2
Cleaning Precautions......................................................................... 2-2
Cleaning Stroke Procedure................................................................ 2-2
Overwetting........................................................................................ 2-3
OPERATING INSTRUCTIONS.................................................................. SECTION 3
Before Operating the CDS................................................................. 3-1
CDS Start Up..................................................................................... 3-2
CDS Flood Restoration Work ............................................................ 3-3
CDS Shut Down................................................................................. 3-3
3 Speed Throttle Control Function..................................................... 3-5
FREEZE GUARD........................................................................................ SECTION 4
Draining the CDS............................................................................... 4-3
Freeze Protecting Pump In System................................................... 4-4
WATER AND CHEMICAL SYSTEM .......................................................... SECTION 5
Water and Chemical Flow Operation................................................. 5-1
Chemical System Maintenance ......................................................... 5-2
Chemical System Troubleshooting .................................................... 5-3
WATER PUMP MAINTENANCE................................................................ SECTION 6
Daily Maintenance ............................................................................. 6-1
Periodic Maintenance ........................................................................ 6-2
Water Pump Troubleshooting ............................................................ 6-3
i - CDS 4.8 Owner’s Manual

ASSEMBLIES AND PARTS LISTS............................................................ SECTION 7
Recovery Tank Assembly Parts List................................................... 7-6
Power Pack Assembly Parts List ....................................................... 7-9
Blower Assembly Parts List ............................................................... 7-11
Pump Assembly Parts List ................................................................. 7-14
Frame Assembly Parts List ................................................................ 7-16
CDS Front End Assembly Parts List - Chevy..................................... 7-18
CDS Front End Kit Assembly Parts List - Chevy (P/N 000-078-391) 7-19
CDS Front End Kit Assembly Parts List - Ford (P/N 000-078-392) ... 7-20
Dash Box Assembly Parts List........................................................... 7-22
Dash Panel Assembly Parts List........................................................ 7-24
Dual Heat Exchanger Assembly Parts List ........................................ 7-26
Instrument Panel Assembly Parts List ............................................... 7-29
By-Pass Valve Assembly Parts List ................................................... 7-30
Hi-Psi Manifold Assembly Parts List .................................................. 7-31
Di󰀨erential Valve Assembly Parts List ............................................... 7-32
Recovery Tank Cover Assembly Parts List ........................................ 7-33
Vacuum Relief Valve Assembly Parts List ......................................... 7-34
Water Box Assembly Parts List.......................................................... 7-37
Di󰀨user Filter Assembly Parts List ..................................................... 7-38
Float Valve Assembly Parts List......................................................... 7-39
Dura-Flow Automatic Pump Out ( APO) Assembly Parts List-
Production.......................................................................................... 7-41
Salsa Heat Exchanger Parts List (Chevy) ......................................... 7-43
Non Salsa Heat Exchanger Parts List ............................................... 7-44
Yaw Sensor Cooling Kit Parts List ..................................................... 7-45
Horizontal Pump In Tank Assembly Parts List ................................... 7-48
120 Gallon Pump-In Tank Fitting Assembly Parts List ....................... 7-49
85 Gallon Rotomold Fresh Water Tank Assembly Parts List ............. 7-52
Pass Through Assembly Parts List .................................................... 7-53
Chevy Cowling Assembly Parts List .................................................. 7-54
Ford Cowling Assembly Parts List ..................................................... 7-55
VACUUM BLOWER SYSTEM.................................................................... SECTION 8
Recovery Tank Inlet Filter .................................................................. 8-2
Vacuum Blower Lubrication ............................................................... 8-2
Vacuum Blower Troubleshooting ....................................................... 8-4
ELECTRICAL SYSTEM.............................................................................. SECTION 9
Troubleshooting ................................................................................. 9-2
CDS 4.8 Owner’s Manual - ii

MACHINE MAINTENANCE ....................................................................... SECTION 10
Operational Maintenance................................................................... 10-1
Appearance Maintenance.................................................................. 10-4
Long-Term Maintenance Schedule .................................................... 10-5
Drive Shaft Maintenance .................................................................. 10-6
Troubleshooting ................................................................................. 10-7
HOW TO ORDER PARTS .......................................................................... SECTION 11
Warranty Parts Orders....................................................................... 11-1
Parts Orders ...................................................................................... 11-1
Emergencies...................................................................................... 11-1
WARRANTY INFORMATION..................................................................... SECTION 12
Blower ............................................................................................... 12-1
High Pressure Water Pump .............................................................. 12-1
Vacuum Tank .................................................................................... 12-1
Chemical System............................................................................... 12-1
Control Panel .................................................................................... 12-1
Vacuum and Solution Hoses ............................................................. 12-2
Cleaning Wand and Tool.................................................................... 12-2
Water Heating System....................................................................... 12-2
Hard Water Deposits ......................................................................... 12-2
Warranty Procedure........................................................................... 12-2
For Your Reference:........................................................................... 12-2
iii - CDS 4.8 Owner’s Manual

List of Figures
Figure 1-1. Hard Water Map of Mainland United States........................................... 1-11
Figure 1-2. Conguration of Water Softener and CDS ............................................. 1-12
Figure 2-1. pH Chart................................................................................................... 2-1
Figure 2-2. Cleaning Stroke Procedure ...................................................................... 2-3
Figure 3-1. Location of Controller’s LED Lights with Labels and RPM Trim Potentiom-
eters............................................................................................................................. 3-5
Figure 3-2. Location of 3 Lights on Throttle Control Assembly................................... 3-7
Figure 5-1. CDS Flow Diagram .................................................................................. 5-5
Figure 7-1. Adhesive and Sealant Material Reference............................................... 7-2
Figure 7-2. Recovery Tank Assembly - View 1 of 3 .................................................... 7-3
Figure 7-3. Recovery Tank Assembly - View 2 of 3 .................................................... 7-4
Figure 7-4. Recovery Tank Assembly - View 3 of 3 .................................................... 7-5
Figure 7-5. Power Pack Assembly - View 1 of 2........................................................ 7-7
Figure 7-6. Power Pack Assembly - View 2 of 2........................................................ 7-8
Figure 7-7. Blower Assembly.................................................................................... 7-10
Figure 7-8. Pump Assembly - View 1 of 2 ................................................................ 7-12
Figure 7-9. Pump Assembly - View 2 of 2 ................................................................ 7-13
Figure 7-10. Frame Assembly .................................................................................. 7-15
Figure 7-11. CDS Front End Assembly - Chevy ....................................................... 7-17
Figure 7-12. Dash Box Assembly ............................................................................ 7-21
Figure 7-13. Dash Panel Assembly .......................................................................... 7-23
Figure 7-14. Dual Heat Exchanger Assembly........................................................... 7-25
Figure 7-15. CDS Heat Exchanger Core Assembly - Product Support .................... 7-26
Figure 7-16. Instrument Panel Assembly - View 1 of 2............................................. 7-27
Figure 7-17. Instrument Panel Assembly - View 2 of 2............................................. 7-28
Figure 7-18. By-Pass Valve Assembly...................................................................... 7-30
Figure 7-19. Hi-PSI Manifold Assembly.................................................................... 7-31
CDS 4.8 Owner’s Manual - iv

Figure 7-20. Di󰀨erential Valve Assembly.................................................................. 7-32
Figure 7-21. Recovery Tank Cover Assembly .......................................................... 7-33
Figure 7-22. Vacuum Relief Valve Assembly............................................................ 7-34
Figure 7-23. Water Box Assembly - View 1 of 2 ...................................................... 7-35
Figure 7-24. Water Box Assembly - View 2 of 2 ...................................................... 7-36
Figure 7-25. Di󰀨user Filter Assembly ....................................................................... 7-38
Figure 7-26. Float Valve Assembly ........................................................................... 7-39
Figure 7-27. Dura-Flow Automatic Pump Out (APO) - Production Assembly........... 7-40
Figure 7-28. Salsa Heat Exchanger Assembly (Chevy) ........................................... 7-42
Figure 7-29. Non Salsa Heat Exchanger Assembly ................................................. 7-44
Figure 7-30. Yaw Sensor Cooling Kit Assembly (Chevy).......................................... 7-45
Figure 7-31. Horizontal Pump In Tank Assembly - View 1 of 2................................. 7-46
Figure 7-32. Horizontal Pump In Tank Assembly - View 2 of 2................................ 7-47
Figure 7-33. 120 Gallon Pump-In Tank Fitting Assembly ........................................ 7-49
Figure 7-34. 85 Gallon Rotomold Fresh Water Tank Assembly - View 1 of 2........... 7-50
Figure 7-35. 85 Gallon Rotomold Fresh Water Tank Assembly - View 2 of 2........... 7-51
Figure 7-36. Pass Though Assembly........................................................................ 7-53
Figure 7-37. Chevy Cowling Assembly..................................................................... 7-54
Figure 7-38. Ford Cowling Assembly........................................................................ 7-55
Figure 9-1. Electrical Schematic................................................................................. 9-3
Figure 9-2. Wiring Diagram - View 1 of 2 .................................................................. 9-4
Figure 9-3. Wiring Diagram - View 2 of 2 ................................................................... 9-5
Figure 10-1. Zerk Fittings on Drive Shaft (Chevy and Ford)..................................... 10-6
List of Figures
Table 3-1. GM Throttle Controller LED Functions....................................................... 3-6
Table 3-2. Ford Throttle Controller Light Functions .................................................... 3-8
Table 7-3. Hose Routings ......................................................................................... 7-56
v - CDS 4.8 Owner’s Manual

CDS 4.8 Owner’s Manual - vi

1-1: General Information
The Clutch Drive System (CDS) 4.8 Truckmounts are highly engineered carpet cleaning
machines developed, designed and manufactured by HydraMaster Corporation. The
systems utilize the most current technology available in water heating and water recovery
systems.
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
protable, trouble-free operation.
This Owner’s Manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of the CDS 4.8. Component
troubleshooting guides have also been included for your convenience.
It is imperative that no section be overlooked when preparing for operation of this
equipment. Please read this Owner’s Manual to familiarize yourself with the operation of
the 4.8. Truckmount Systems, paying special attention to all Warnings and Cautions.
This section of the manual contains the following helpful information:
Contact Information
Warnings, Cautions And Notices
Machine Specications
Responsibilities
Battery Relearn for Ford Van
(Excerpt from Ford Econoline Owner’s Guide)
Local Water Precautions
Waste Water Disposal Advisory
1 - General Information

General Information: 1-2
CONTACT INFORMATION
If you have any questions regarding the operation, maintenance or repair of this machine,
please contact your local distributor.
To nd a local distributor, please visit our website at
https://hydramaster.com/dealer-locator/
If your question cannot be resolved by your distributor or by the information within this
manual, you may contact HydraMaster direct using the following phone numbers.
HOURS TELEPHONE NUMBERS E-MAIL ADDRESSES
Monday-Friday
7:00 a.m. to 5:00 p.m.
Pacic Time
Technical Support
[phone]
FAX : [phone]
Technical Support
[e-mail]
Customer Service/Parts
[phone]
FAX: [phone]
Customer Service/Parts
[e-mail]
When calling your distributor, be sure to reference the serial number and date of purchase.
FOR YOUR REFERENCE:
Serial No.
Date of Purchase:
Purchased From (Distributor):

1-3: General Information
WARNINGS, CAUTIONS AND NOTICES
HydraMaster uses this WARNING symbol throughout the manual to warn of
possible injury or death.
This CAUTION symbol is used to warn of possible equipment damage.
This NOTICE symbol indicates that federal or state regulatory laws may apply,
and also emphasizes supplemental information.

General Information: 1-4
Warnings and Cautions specic to the CDS 4.8 include:
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 the engine or the exhaust.
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. Do not allow any
open ames 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
operating. 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 reproductive
harm.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe
bodily injury may result.

1-5: General Information
The use of some chemicals through your mobile carpet cleaning plant can
seriously damage the internal plumbing, high-pressure pump, chemical pump
and heat exchangers. These harmful chemicals include concentrated acid (see
the pH chart in Figure 2-1), solvents (including d-Limonene), and some paint, oil
and grease removers with a high concentration of solvents.
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van
oor. Many vans have critical components mounted directly below the van oor
that could be damaged by a misplaced drill bit.
LEVEL OPERATION: During operation, the vehicle must be parked on level ground
not to exceed + or - 10 degrees. Failure to ensure proper leveling may prevent
proper internal lubrication of engine, vacuum and/or high pressure components.
ACID RINSE AGENTS: Some acid rinse products can cause damage to internal
machine components. Failure to take appropriate measures to prevent acidic
corrosion can result in system failure and loss of warranty on a󰀨ected parts.
HARD WATER PROTECTION: Failure to take appropriate measures to prevent
scale build up can result in system failure and loss of warranty on a󰀨ected parts.
Test the water in your immediate and surrounding areas with hard water test
strips. Assume all water obtained from wells is hard. If you are operating in a hard
water area at 3.0 grains or more per gallon, use a water softening system.
FREEZE PROTECTION: Failure to take appropriate measures to prevent
equipment damage due to freezing can result in system failure and loss of
warranty on a󰀨ected parts. Placing an electric heater in the vehicle or parking the
vehicle indoors will help ensure against freezing, but should not be the primary
method of freeze protection.

General Information: 1-6
MACHINE SPECIFICATIONS
Frame 23” W x 41.5” H x 61.0” L
Weight 650 lbs (tank and console only)
Construction Tank Marine aluminum with baked-on epoxy nish
Chassis painted steel
Cowling, berglass
Power Transfer Electric clutch-driven shaft, key activated
Vacuum Blower 4007 Tuthill/M-D Tri-Lobe
Water Pump Plunger pump, 4.0 gpm (at high speed), 1,200 operating psi, electric
clutch control
Chemical
System
Last-step chemical injection, meter controlled
Heating System Engine heat recovery, multi-parallel heat exchanger system, optional
Salsa heat package
Instruments
Main Panel Electronic tachometer, 0-3,500 rpm
Water temperature gauge, 0-320 degrees F
Vacuum gauge, 0-30” hg
Hour meter, machine run-time
Keyed ignition, start/stop
Electronic circuit protection breaker, resettable
Machine status indicator lamps
Chemical owmeter, 0-10 gph
Solution pressure gauge, liquid lled, 0-1,500 psi
Side Panel Water pressure adjustment
Blower lubrication port
Solution temperature control selector
High pressure solution outlets, quick-disconnect
Fresh water inlet tting, quick-disconnect
Water box drain valve
Chemical controls

1-7: General Information
Recovery Tank 100 gallon aluminum
Cleaning Tool/
Wand
EVO Wand
Replacement grip
Rebuildable solution valve
High Pressure
Hose
1/4” high temperature, lined, vinyl covered
Hose rated to 2,200 psi, 250 degrees F
Standard
Equipment
Power transfer package
Component power pack
Equipment cowling
Vacuum recovery tank
Control console
Dual tool/wand hook-up
HydraMaster heat exchanger system
Freeze guard system
Wheel chock set
Carpet tool/wand
150 ft x 1/4” solution hose
150 ft, 2" vacuum hose
10 ft. 1 ½” whip hose
50 ft, fresh water hose (garden hose)
10 ft, 1 ½” drain line
5 gallon chemical jug
Chemical jug holder
Van nish package
Van decal package
Monogrammed jacket
Owner’s Manual (on cd)
Owner’s Guide (paper copy)

General Information: 1-8
RESPONSIBILITIES
Prior to the arrival of the unit, the van that it will be installed in should be delivered to the
installer.
Purchaser’s Responsibility
If you are the purchaser, it is the your responsibility to read the Owner’s Manual and to
familiarize yourself with the information contained herein, paying special attention to all
Warnings and Cautions.
Sales Representative’s Responsibility
Acceptance of Shipment
1. If the unit shows any outward signs of damage, do not sign the delivery receipt until
you have closely inspected the unit and noted any damage on the delivery receipt.
2. The sales representative from whom you purchased your unit is responsible for
supervising the correct installation of the unit in your vehicle and thoroughly training
you in its operation, maintenance and precautions.
Installation
• Correctly installing the unit and recovery tank in your vehicle and securing them with
bolts and tie down washers.
• Checking the pump, vacuum blower and engine oil levels prior to starting the unit.
• Starting the unit to check the drive system and see that all other systems function
normally.
• Checking all hoses, tools/wands and accessories for correct operation.
Training
• A thorough review of the Owner’s Manual with the purchaser.
• Instruction in and familiarization with:
1. How to correctly start up and shut down the unit
2. How to correctly clean with the unit
3. Where and how often to check and change component oil levels
4. How the unit’s systems work, how to troubleshoot the unit
5. How to do basic repairs
6. Safety precautions and their importance
7. How to avoid freezing damage
8. How to avoid hard water damage
• A thorough review of the unit warranty and warranty procedures.
• A thorough review of hard water precautions and warnings.
• How to determine hard water areas.
• Use of water softening systems.

1-9: General Information
BATTERY RELEARN FOR FORD VAN
(Excerpt from Ford Econoline Owner’s Guide)
Because your vehicle’s engine is electronically controlled by a computer, some control
conditions are maintained by power from the battery. When the battery is disconnected
or a new battery is installed, the engine must relearn its idle and fuel trim strategy for
optimum driveability and performance. Flexible fuel vehicles (FFV) must also relearn the
ethanol content of the fuel for optimum driveability and performance.
To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park), turn o󰀨 all accessories and start the engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Release the parking brake. With your foot on the brake pedal and with the A/C on,
put the vehicle in D (Drive) and allow the engine to idle for at least one minute.
7. Drive the vehicle to complete the relearning process.
• The vehicle may need to be driven 10 miles (16 km) or more to relearn the idle
and fuel trim strategy along with the ethanol content for exible fuel vehicles.
• If you do not allow the engine to relearn its idle trim, the idle quality of your vehicle
may be adversely a󰀨ected until the idle trim is eventually relearned.
• For exible fuel vehicles, if you are operating on E85, you may experience poor
starts or an inability to start the engine and driveability problems until the fuel trim
and ethanol content have been relearned.
If the battery has been disconnected or a new battery has been installed, the clock and
radio settings must be reset once the battery is reconnected.

General Information: 1-10
LOCAL WATER PRECAUTIONS
The quality of water varies greatly. Many areas have an excess of minerals in the water
which results in what is commonly called “hard water.” These minerals tend to adhere to
the insides of heater coils and other parts of the machines causing damage and a loss of
cleaning e󰀨ectiveness. This inuences the reliability and e󰀩ciency of equipment in direct
proportion to the level of hardness.
Hard Water Advisory
HydraMaster recognizes that any hard water deposits which might occur within the water
system of our truckmounts is a serious problem. The precision technology of truckmount
heat exchanger systems is intolerant of any foreign material. Hard water deposits will
ultimately decrease the performance of the system and are expected to seriously lower
the reliability of the machine.
To validate a machine’s warranty, HydraMaster requires that all machines operating in
designated “Hard Water Areas” (3.0 grains or more per gallon) be tted with a water
softening system, or a properly installed magnetic-type descaler must be used and
maintained. Periodic descaling or acid-rinsing alone is not adequate in these areas.
HydraMaster does not recommend any particular type or brand; however, the relative
e󰀨ectiveness of some types of magnetic descalers or softeners may require additional
periodic use of descaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all areas
be tted with a water softening system for improved operation and reliability.
Failure to take appropriate measures to prevent scale build up can result in
system failure and loss of warranty on a󰀨ected parts.

1-11: General Information
Hard Water Area Map
The hard water map, shown in Figure 1-1, denes hard water areas in the lower 48 United
States which compromise uid related components such as hoses, ttings, heaters,
pumps, valves and water-cooled engines. For other countries, hard water area maps can
be obtained from geological societies.
The map shown in Figure 1-1 is provided for general reference only. Water
hardness in your geographical location should be conrmed by testing.
Figure 1-1. Hard Water Map of Mainland United States

General Information: 1-12
Water Softener
Cleaning e󰀩ciency and equipment life is increased, chemical use decreased, and the
appearance of cleaned carpets enhanced when water softeners are incorporated in hard
water areas. HydraMaster strongly urges the use of water softener units with the CDS 4.8
machines in areas exceeding 3.0 grains per gallon (see Figure 1-2).
Failure to use a water softener in these areas will invalidate the machine’s warranty.
Referring to the hard water area map shown Figure 1-1, determine the quality of water in
your area and take immediate action if
the water hardness exceeds 3.0 grains
per gallon.
The relatively low cost of a water
softener service is more than made up
for by an increased life of machine parts,
reduced chemical costs and continued
cleaning e󰀩ciency. The water softener
will also increase the e󰀨ectiveness of
the cleaning chemicals, therefore less
chemical will be needed.
Contact a water softener distributor in
your area for information on the rental
of a simple water treatment unit to
carry in your truck. Be sure to change
the water softener in accordance with the capability of the softener.
For example: If the softener will treat 900 gallons of water and the machine uses an
average of 30 gallons per hour, for an average of 5 hours a day, this equals 150 gallons
per day. In 6 days the machine would use 900 gallons of water. Therefore, the softener
would need to be changed every 6 working days for maximum softening.
Figure 1-2. Conguration of Water
Softener and CDS