HydraMaster CDS 4.8 User manual

HYDRAMASTER
Corporation
11015 47th Avenue W, Mukilteo, WA 98275
CDS 4.8
Overdrive
Machine Serial Number________________________
Copyright© 2
HYDRAMA TER© Corporation
Mukilteo, Washington
D-182- 5
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 HYDRAMA TER© Corporation. All rights
reserved.
Revised January 25, 2 1

Clutch Drive System
HydraMaster Corporation
CDS 4.8
Table of Contents
GENERAL INFORMATION .............................................................. ection 1
Telephone Numbers............................................................. 1-2
Precautions ........................................................................ 1-3
System Overview................................................................ 1-7
Machine Specifications ........................................................ 1-8
Spare Parts Recommendation ............................................... 1-11
Spare Parts List ......................................................... 1-11
Responsibilities ................................................................... 1-13
Local Water Precautions ....................................................... 1-15
Wastewater Disposal Advisory..................................... 1-17
Map ......................................................................... 1-19
CLEANING AND CHEMICAL ........................................................ ection 2
pH Chart ............................................................................ 2-4
OPERATING IN TRUCTION ......................................................... ection 3
Start Up............................................................................. 3-2
Shut Down......................................................................... 3-3
FREEZE GUARD ........................................................................... ection 4
Vacuum Freeze Guard Procedure ........................................... 4-1
Freeze Protection of Pump-In System ..................................... 4-3
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WATER AND CHEMICAL Y TEM ........................................................ ection 5
Water Flow Diagram ...........................................................................5-3
Proportioner Diagram ..........................................................................5-4
Chemical Tank Troubleshooting ............................................................5-5
HIGH PRE URE PUMP ...................................................................... ection 6
Pump Maintenance .............................................................................6-1
Service ............................................................................................6-3
Cat Pump Assembly Drawing and Parts List ............................................6-7
Pump Troubleshooting ...................................................................... 6-1
CD MACHINE A EMBLIE AND PART ............................................. ection 7
Machine Assembly Drawings and Parts Lists ...........................................7-1
CDS Belts ....................................................................................... 7-33
Cleaning Wand Assembly Drawings and Parts Lists ................................ 7-35
Bypass Valve Assembly Drawing and Parts List ..................................... 7-4
VACUUM Y TEM ............................................................................ ection 8
Lubrication Instructions .......................................................................8-4
Blower Troubleshooting.......................................................................8-5
Roots Blower Instruction Booklet
ELECTRICAL Y TEM ........................................................................ ection 9
Wiring Schematic ...............................................................................9-3
Wiring Diagrams ................................................................................9-5
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HydraMaster Corporation
CDS 4.8
ELECTRICAL Y TEM (cont.)
Electrical Troubleshooting ....................................................................9-6
MACHINE MAINTENANCE ............................................................... ection 10
Operational Maintenance ......................................................................10-2
Daily, Weekly .................................................................................1 -2
Monthly, Quarterly, Yearly................................................................1 -3
Appearance Maintenance ......................................................................10-4
Daily, Weekly .................................................................................1 -4
Long Term Maintenance Schedule ..........................................................1 -5
Drive Shaft Maintenance.......................................................................1 -6
Troubleshooting ..................................................................................1 -7
Maintenance Logs
HOW TO ORDER PART .................................................................. ection 11
WARRANTY INFORMATION ............................................................. ection 12
Golden Guarantee©
ACCE ORIE ............................................................................... ection 13
PRODUCT UPDATE ....................................................................... ection 14
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HydraMaster Corporation
CDS 4.8
List of Figures
Fig 1-1 Location of Water Softener ................................................. 1-16
Fig 1-2 Hard Water Map ................................................................ 1-19
Fig 2-1 pH Chart ........................................................................... 2-4
Fig 2-2 Cleaning Stroke Procedure ..................................................2-4
Fig 5-1 Water Flow Diagram........................................................... 5-3
Fig 5-2 Proportioner Diagram .......................................................... 5-4
Fig 6-1 Servicing the Valves ........................................................... 6-3
Fig 6-2 Servicing the Low Pressure and High Pressure Seals............... 6-5
Fig 6-3 Cat Pump .......................................................................... 6-8
Machine Assemblies and Parts:
Fig 7-1 CDS 4.8 Machine Assembly - Front View.............................. 7-1
Fig 7-2 CDS 4.8 Machine Assembly - Rear View............................... 7-2
Fig 7-3 CDS 4.8 Machine Assembly - Top and Front Views................ 7-3
Fig 7-4 Recovery Tank Assembly - Front View.................................. 7-5
Fig 7-5 Recovery Tank Assembly - Rear View................................... 7-6
Fig 7-6 Recovery Tank Lid Assembly ............................................... 7-1
Fig 7-7 Instrument Panel Assembly ................................................. 7-11
Fig 7-8 Dual Heat Exchanger Assembly............................................ 7-14
Fig 7-9 Pump and Blower Assembly ................................................ 7-16
Fig 7-1 Dash Box Assembly............................................................ 7-2
Fig 7-11 Dash Panel Assembly ......................................................... 7-22
Fig 7-12 Mix Tank Assembly ............................................................ 7-24
Fig 7-13 Mix Tank Cover Assembly................................................... 7-26
Fig 7-14 Horizontal Pump In Tank Assembly....................................... 7-27
Fig 7-15 Soap Jug Tray Assembly ....................................................7-29
Fig 7-16 Vacuum Relief Valve Assembly ............................................ 7-3
Fig 7-17 Salsa X Assembly .............................................................. 7-31
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Clutch Drive System
HydraMaster Corporation
CDS 4.8
Cleaning Wand Assembly and Parts:
Fig 7-18 Valve Assembly ................................................................. 7-35
Fig 7-19 Solution Valve Assembly..................................................... 7-36
Fig 7-2 Valve Stem Assembly ......................................................... 7-37
Fig 7-21 Hydra Hoe Wand Assembly ................................................. 7-38
Fig 7-22 Bypass Valve Assembly ...................................................... 7-4
Fig 9-1 Wiring Schematic ...............................................................9-2
Fig 9-2 Wiring Diagram, Sheet 1 .....................................................9-3
Fig 9-3 Wiring Diagram, Sheet 2 .....................................................9-4
Fig 1 -1 Drive Shaft Assembly ......................................................... 1 -6
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HydraMaster Corporation
Introduction
CDS 4.8
Section 1-1
6his manual contains operating instructions as well as information 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 functions
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 must provide a 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 provide a consistant water temperature.
 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?!
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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: am to 5: pm [phone] Service
PACIFIC STANDARD TIME (8 ) 426-4225 Parts / Service FAX
♦ WARNING ♦
♦ CAUTION ♦
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HydraMaster Corporation
Precautions
)though this unit has been factory adjusted, it may require additional adjustments to achieve optimum performance, for instance altitude may require carburetor
adjustment and ambient temperatures may require heat control adjustment. 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 921 2, 94 62
and 94 63 at the end of the manual.)
LEVEL OPERATION: During operation, van or trailer must be parked on level ground
not to exceed + or - 1 degrees. Failure to insure proper leveling may prevent proper
internal lubrication of engine, vacuum and/or high pressure components.
MOVING PART : Never touch any part of the machine that is in motion. Severe
bodily injury may result.
♦ CAUTION ♦
♦ CAUTION ♦
♦ WARNING ♦
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ACID RIN E AGENT : 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s ClearWater Rinse has been formulated to protect vital components.
HydraMaster will not warranty parts that have been damaged from using unprotected
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 AHard Water 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.
HOT URFACE : 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 ♦
♦ CAUTION ♦
♦ CAUTION ♦
♦ WARNING ♦
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HEARING PROTECTION: The Occupational Safety and Health Administration (OSHA)
recommends the use of hearing protection when a technician is exposed to an aver-
age of 85 decibels (this is an average of exposure over an 8 hour period). This
equipment can produce 85 decibels to a distance of 1 feet. Please check with your
local state agencies to see if OSHA standards apply to your application.
NO MOKING: 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 FUME : Do not occupy the vehicle when the cleaning equipment is operating.
Toxic fumes may accumulate inside a stationary vehicle.
ENGINE EXHAU T: The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects or other reproductive harm.
PORTABLE GA TANK: Never operate this machine with a portable gas can inside
the truck. Doing so increases the risk of a fire or explosion.
♦ WARNING ♦
♦ WARNING ♦
♦ WARNING ♦
♦ WARNING ♦
♦ WARNING ♦
♦ WARNING ♦
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PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or van. It
is dangerous and illegal in most states.
TRAN PORTATION OF FUEL CONTAINER : 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.
♦ WARNING ♦
♦ WARNING ♦
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HydraMaster Corporation
System Overview
6he HydraVan CDS machines are highly engineered cleaning plants designed by HydraMaster Corporation. The system utilizes the most current technology avail-
able in water heating and water recovery systems.
The water flow is as follows:
Water is fed into the machine under tap pressure. The water enters the machine and
is combined with cleaning solution as it enters the mix tank. The cleaning solution is
picked up from the mix tank by the high pressure pump and pumped under pressure
through the heating system and then out to the cleaning tool.
After the water is applied to the carpet, it is recovered by the vacuum system and
carried back to the recovery tank.
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.
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Machine Specifications
Frame: 13"W x 68"L x 38"H
Weight: 575 lbs.
Construction: Tank: Marine Aluminum with Baked-on Epoxy Finish
Chassis: Painted Steel
Cowling: Fiberglass
Power Transfer: Electric Clutch-driven shaft, Key Activated
Vacuum Blower: 47 WhispAirTM , Dual Shaft
Water Pump: CAT® Triple Plunger
4 gallons per minute
Chemical ystem: Electro-mechanical, Meter Controlled
Heating ystem: Multiple Heat Exchanger (6 PSI pressure)
Dual Shell and Tube Exchangers
Instruments:
Main Panel: Electronic Tachometer, -3 RPM
Water Temperature Gauge, -32 ° F
Vacuum Gauge, -3 in Hg
Hour Meter, Machine Run-Time
Keyed Ignition, Start/Stop
Electronic Circuit Protection Breaker, Re-settable
Machine Status Indicator Lamps
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HydraMaster Corporation
Instruments (cont.) :
Side Panel: Chemical Flowmeter, -1 GPH
Water Pressure Gauge, Liquid Filled, -1 PSI
Water Pressure Adjustment
Blower Lubrication Port
Water Temperature Adjustment Knob and
(Exchanger By-pass)
High Pressure Solution Outlets, Quick-
(Disconnect (2))
Fresh Water Inlet Fitting, Quick-Disconnect
Mix Tank Drain Valve
Recovery Tank: 12 gallon Aluminum
Cleaning Wand: Stainless Steel Wand.
Stainless Steel Solution Valve and Tube
Jet Splash Guards
Insulated Handle Sleeves
Height Adjustable Handles
tandard Equipment:
Power Transfer Package
Component Power Pack
Equipment Cowling with Armrests
Vacuum Recovery Tank
Control Console
Dual Wand Hook-up
HydraMaster Heat Exchanger System
Freeze Guard System
Wheel Chock Set
Carpet Wand
15 ', 2" Vacuum Hose
1 '. 1 ½ Vacuum Hose
15 ', HP Solution Line
5 ', Fresh Water Hose
1 ', 1 ½ Drain Line
5 gallon Chemical Jug
Chemical Jug Holder
Chemical Jug Fill Line
Van Finish Package
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tandard Equipment (cont.) :
Van-Sentry Package
Van Decal Package
Monogrammed Jacket
Operation Manual
Custom Equipment Color
Oversize Air Handling Package
475 CFM High-Output Vacuum System
Expanded Vacuum Recovery Tank Capacity
Hushkit Silenced System
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HydraMaster Corporation
Spare Parts
,own-time on the unit can be very expensive, because your truck-mounted unit is capable of generating several hundred dollars per day. In order to minimize such
down-time, it is strongly recommended by the manufacturer that you purchase and
keep in your truck the parts listed below.
Parts Orders
To expedite your parts needs, please call your sales representative. In most in-
stances, he either stocks or has access to parts through a regional service center. If
further assistance is needed, contact the factory and coordinate your needs. 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 [phone]
HydraMaster Parts Dept. Toll Free Fax [phone]
CD 4.8 pare Parts List
PART NO DESCRIPTION QTY
49- 23 Screen, Garden Hose 6
52- 5 Quick Connect, 44 Male 2
52- 51 Quick Connect, 44 Female 2
52- 52 Quick Connect, 66 Male 1
52- 53 Quick Connect, 66 Female 1
76- 5 Spray Jet 8 6E 1
78- 15 Kit, Flow Meter 1
78- 19 Kit, Wand Valve Plunger 1
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CD 4.8 pare Parts List (cont.)
PART NO DESCRIPTION QTY
78-1 2 Kit, Pressure By-pass Valve 1
78-27 Kit, Valve for 3CP Cat Pump 2
78-271 Kit, Seals for 3CP Cat Pump 1
157- 12 Switch, Tethered Float
157- 22 Switch, Relay 1
157- 4 Switch, 12 VDC Lighted 2
169- 22 Valve, 1 ½ Full Port Ball 1
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HydraMaster Corporation
Responsibilities
2rior to the arrival of the unit, the van that it will be installed in should be delivered to the installer.
Purchasers Responsibility:
It is the purchasers responsibility to Read the Owners Manual and to familiarize
yourself with the information contained therein. Special attention should be paid to
all Cautions and Warnings.
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 salesman from whom you purchased your unit is responsible for supervis-
ing 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, wands, etc. for correct operation.
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Training
 A thorough review of the operation manual with the purchaser.
 Instruction and familiarization in:
- how to correctly start up and shut down the unit,
- how to correctly clean with the unit,
- where and how often to check and change component oil levels,
- how the units systems work, how to troubleshoot the unit,
- how to do basic repairs, safety precautions and their importance,
- freezing damage and how to avoid it,
- hard water damage and how to avoid it.
 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.
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