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HydraMaster CDS 4.6 Owner'S Manual Download Page 38

6-1:   Water Pump Maintenance

6 - Water Pump Maintenance

The  CDS’  water  pump  features  a  dynamic  low-pressure  seal  retainer,  an  innovative 

intermediate ring, and superior low-pressure and high-pressure seals. With its ceramic 

plungers and nickel-plated forged brass manifold, this high-temperature pump is ideal for 

use in carpet cleaning.

you must perform daily and periodic maintenance 

on the pump to maintain maximum performance 

of seals and valves.

This section of the manual explains:

Daily Maintenance

 

„

Periodic Maintenance

 

„

Water Pump Troubleshooting

 

„

DAILY MAINTENANCE

Check the oil level and the condition of the 

1. 

oil. The oil level should be up to the center 

of the sight glass on the back of the pump.

use a SAe15W40 oil.

2. 

If the oil becomes discolored and contaminated, one of the oil seals may be damaged.  

Refer to the Pump owner’s Manual, included with the CDS 4.8 / 4.6 owner’s Manual, for 

more information.

Do not operate 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 replace it with clean oil.

 

Do not turn the drive shaft while the oil reservoir is empty.

Protect the pump from freezing.

Summary of Contents for CDS 4.6

Page 1: ...MAN 33149 Rev 0 182 038 D 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 North America Inc All rights reserved Revised July 10 2009 Clutch Drive System 4 8 4 6 Owner s Manual ...

Page 2: ...eaning 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 2 CDS Shut Down 3 3 3 Speed Throttle Control Function 3 4 Freeze Guard SECTION 4 Draining the CDS 4 2 Freeze Protecting Pump In System 4 3 Water and Chemical System SECTION 5 Water and Chemical Flow Operation 5 1 Chemical S...

Page 3: ...tic Pump Out APO Assembly Parts List 7 22 CDS Dash Box Assembly Parts List 7 25 CDS Dash Panel Assembly Parts List 7 27 CDS Water Box Assembly Parts List 7 30 Diffuser Filter Assembly Parts List 7 31 CDS Vacuum Relief Valve Assembly Parts List 7 32 CDS Front End 2003 2009 GM Assembly Parts List 7 34 Horizontal Pump In Tank Assembly Parts List 7 37 Free Standing Tray Assembly Parts List 7 38 85 Gal...

Page 4: ...wer Troubleshooting 8 3 1 0 Weak vacuum at tool wand 8 3 2 0 Vacuum gauge will not come up to 14 Hg 8 3 3 0 Vacuum gauge reads high with no hoses attached 8 3 4 0 Noisy Vacuum Blower 8 4 5 0 Vacuum Blower is locked and will not turn 8 4 Electrical System SECTION 9 Electrical Troubleshooting 9 5 1 0 CDS will not turn on 9 5 2 0 CDS shuts off while in use 9 5 Machine Maintenance SECTION 10 Operation...

Page 5: ...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 Accessories and Chemical Solutions SECTION 13 CDS 4 8 4 6 Owner s Manual iv ...

Page 6: ...and Blower Assembly Overview 7 13 Figure 7 10 CDS 4 8 Pump and Blower Assembly Parts View 7 14 Figure 7 11 CDS 4 6 Pump and Blower Assembly Overview 7 16 Figure 7 12 CDS 4 6 Pump and Blower Assembly Parts View 7 17 Figure 7 13 CDS Pump Assembly Overview 7 19 Figure 7 14 CDS Pump Assembly Parts View 7 20 Figure 7 15 CDS DuraFlow Automatic Pump Out APO Assembly 7 21 Figure 7 16 CDS Dash Box Assembly...

Page 7: ...anger Assembly 7 50 Figure 7 39 CDS Salsa 2005 2009 Chevy Assembly 7 51 Figure 7 40 Ford Hush Kit Muffler Assembly 4 8 7 52 Figure 7 41 Chevy Hush Kit Muffler Assembly 4 8 7 53 Figure 7 42 Silencer Assembly 4 6 7 54 Figure 7 43 Cleaning Wand Valve Assembly 7 56 Figure 7 44 Cleaning Wand Solution Valve Assembly 7 57 Figure 7 45 Cleaning Wand Valve Stem Assembly 7 58 Figure 7 46 Hydra Hoe Wand Assem...

Page 8: ...f Tables Table 3 1 GM Throttle Controller LED Functions 3 5 Table 3 2 Ford Throttle Controller Light Functions 3 7 Table 8 1 Lubricants for Oil Lubricated Gears and Bearings 8 3 vii CDS 4 8 4 6 Owner s Manual ...

Page 9: ...refully and you will be rewarded with years of profitable 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 and 4 6 Component troubleshooting guides have also been included for your convenience Itisimperativethatnosectionbeoverlookedwhenpreparingforoperationofthiseq...

Page 10: ... visit our website at http www hydramaster com owners locate index asp If your question cannot be resolved by your distributor or by the information within this manual you may contact HydraMaster Customer Service direct using the following phone numbers Hours Telephone Numbers Monday Friday 425 775 7276 Parts 7 00 a m to 5 00 p m 425 775 7275 Service Pacific Standard Time 800 426 4225 Parts Servic...

Page 11: ...ses 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 ...

Page 12: ... 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 flames 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 conditioni...

Page 13: ...d 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 affected parts HARD WATER PROTECTION Failure to take appropriate measures to prevent scale build up can result in system failure and loss of warranty on affected...

Page 14: ...System Multiple Heat Exchanger 1 200 psi pressure Dual Shell and Tube Exchangers Optional Salsa Heat Package Instruments Main Panel Electronic Tachometer 0 3 000 rpm Water Temperature Gauge 0 320 F Vacuum Gauge 0 30 Hg Hour Meter Machine Run Time Keyed Ignition Start Stop Electronic Circuit Protection Breaker Re settable Machine Status Indicator Lamps Chemical Flowmeter 0 10 gph Water Pressure Gau...

Page 15: ... 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 Solution Hose 150 2 Vacuum Hose 10 1 Vacuum Hose 50 Fresh Water Hose Garden Hose 10 1 Drain Line 5 gallon Chemical Jug Chemical Jug Holder Van Finish Package Van Decal Package Monogrammed Jacket Owner ...

Page 16: ...ecautions 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 ...

Page 17: ...ecrease 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 fitted with a water softening system or a properly installed magnetic type descaler must be used and maintained Periodic descaling or acid rinsing al...

Page 18: ...elated components such as hoses fittings 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 confirmed by testing Figure 1 1 Hard Water Map of Mainland United States ...

Page 19: ...ater softener service is more than made up for by an increased life of machine parts reduced chemical costs and continued cleaning efficiency The water softener will also increase the effectiveness 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 B...

Page 20: ...omplies with the law is to accumulate the waste water and haul it to an appropriate dump site Another solution to the disposal problem is to equip your CDS with an Automatic Pump Out System APO These systems are designed to remove waste water from the extractor s recovery system and actively pump the water through hoses to a suitable disposal drain HydraMaster makes an APO System which can be orde...

Page 21: ... job as the person operating it This section of the manual contains the following information Cleaning Precautions Cleaning Stroke Procedure Overwetting 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 solvents including d Limonene and...

Page 22: ...ing through the blower could lead to serious mechanical failures To ensure proper cleaning use HydraMaster detergents and chemicals which are formulated with built in anti foaming agents When cleaning surfaces with excessive foaming residue use HydraMaster de foamer products as directed CLEANING STROKE PROCEDURE To eliminate excess moisture remaining in the carpet fiber and eliminate the sawtooth ...

Page 23: ... concerned and sometimes leaves the customer with a bad impression of the cleaning process used These are several conditions that will cause over wetting Too few vacuum strokes or improper saw tooth vacuum strokes as shown in 1 Figure 2 2 Obstructed cut or kinked hoses 2 Vacuum tank drain valve left partially open 3 Clogged vacuum blower filter or vacuum tank lid not sealing properly 4 Cleaning a ...

Page 24: ...el tank to be certain there is adequate fuel to complete the job 2 Position the wheel chocks on one of the front tires 3 If using a water supply hose which has not been used recently or if using a customer s 4 hose first connect the hose to the faucet and flush out any debris which may be in the hose Afterwards connect the hose to the unit Check the chemical jug to see if you have enough concentra...

Page 25: ...mical begins to flow through the flowmeter with the flow indicator a reading maximum flow and the PRIME line pulsing turn the CHEMICALSYSTEM valve to ON Cap off vacuum if necessary While spraying the solution from the cleaning tool adjust the chemical flow by b turning the CHEMICAL METERING CONTROL to the desired level Optional Turn the APO switch ON if using the Automatic Pump Out feature 9 The p...

Page 26: ... at the water supply Unhook the water supply hose and store it in the vehicle Allow the unit to run for a few minutes with the vacuum hose disconnected in order 6 to remove all moisture from the vacuum pump Plug the vacuum inlets Spray lubricant into the lube port for about 5 to 10 seconds 7 while the unit is running This will lubricate the vacuum pump and prevent it from rusting The lube port is ...

Page 27: ...on 7 The Throttle Controller must be initialized anytime the Data Link Cable DLC harness is disconnected from the Data Link Connector To initialize the system switch ignition key to OFF position plug in DLC harness switch the ignition on and then start the engine This allows the Throttle Controller to read the PCM engine computer On the Throttle Controller there are LED lights with corresponding l...

Page 28: ...stationary VSPEED Flashing Vehicle is moving RPM1 On Solid RPM1 mode selected engine at fast idle RPM1 Flashing RPM1 mode selected engine not at fast idle RPM2 On Solid RPM2 mode selected engine at fast idle RPM2 Flashing RPM2 mode selected engine not at fast idle RPM3 On Solid RPM3 mode selected engine at fast idle RPM3 Flashing RPM3 mode selected engine not at fast idle On GM gas engine vehicles...

Page 29: ...terminated by a safety condition violation For instance the SEIC will be terminated if the service brake is depressed at any time during its operation The 3 lights on the Throttle Control assembly indicate the following conditions refer to Figure 3 2 and Table 3 2 RED LIGHT the Throttle Control assembly is receiving power from the vehicle but 1 the SEIC process has not been initiated YELLOW LIGHT ...

Page 30: ... 1 Van ignition ON Red Green Yellow 2 CDS ignition ON 3 Recovery tank NOT full 4 SEIC IS active Chassis ready conditions HAVE been violated a 1 Van ignition ON Yellow 2 CDS ignition ON 3 Recovery tank IS full 4 SEIC IS active Chassis ready conditions HAVE NOT been a violated 1 Van ignition ON Yellow 2 CDS ignition OFF 3 Recovery tank NOT full 4 SEIC IS active Chassis ready conditions HAVE NOT been...

Page 31: ... from the cold ground by running it through an 2 extra 1 vacuum hose Leave vehicle doors closed until you begin cleaning afterwards open slightly 3 In colder climates insulating the vehicle walls and floor boards will help protect the unit Do not procrastinate during the cleaning operation or the hot water solution line will 4 also freeze on the ground The solution line should be insulated in extr...

Page 32: ...witch activates pump stops This freeze guards the high pressure circuit Open the water box drain and drain out the residual fluid into a suitable container 4 This antifreeze solution may be retained for reuse attach freeze guard fitting to inlet quick connect and vacuum water out of the inlet line One manufacturer of antifreeze cautions WHEN DISPOSING OF USED ANTIFREEZE COOLANT Follow local laws a...

Page 33: ...water garden hose adapter from the pump in pump hose and 2 position the hose so it is pointing outside the van Turn on the pump in pump and run for 1 2 minutes until all the water is purged from 3 the hose The next time the CDS is used it may take a few minutes before the water box begins to fill ...

Page 34: ...e chemical solution flows through the flowmeter indicating the flow of chemical being used in gallons hour The chemical then flows through the chemical pump to the chemical selector valve The CHEMICAL SYSTEM valve can be used to prime the pump evacuate air from the system inject chemical into the system or turn the chemical flow off When the CHEMICAL SYSTEM valve is in the ON position chemical flo...

Page 35: ...t abnormal chemical build up To flush the chemical system Set the CHEMICAL FLOWMETER to10 gph 1 Remove the clear plastic hose from the chemical jug and insert it into a 1 quart 2 container of vinegar Spray water from the tool wand until the vinegar is gone 3 Repeat the process with 1 quart of clear water to void all lines of vinegar 4 ...

Page 36: ...pair 1 6 Three way prime valve is faulty Check valve for leaks between ports Replace as necessary If the chemical system has been run dry it may be necessary to prime the chemical system to purge all of the air from the system 2 0 Chemical flow is unstable or low 2 1 Air in lines Check that all fittings and connections are tight and in good condition Repair or replace as necessary 2 2 Filter scree...

Page 37: ...between ports Replace as necessary 3 2 Inlet check valve in chemical pump is faulty Remove and inspect valve Clean or replace as necessary 4 0 Chemical in water box 4 1 Chemical pump diaphragm is faulty Remove and inspect Replace as necessary 4 2 High pressure check valve is faulty Remove and inspect Clean or replace as necessary ...

Page 38: ...ance Water Pump Troubleshooting DAILY MAINTENANCE Check the oil level and the condition of the 1 oil The oil level should be up to the center of the sight glass on the back of the pump Use a SAE15W40 oil 2 If the oil becomes discolored and contaminated one of the oil seals may be damaged Refer to the Pump Owner s Manual included with the CDS 4 8 4 6 Owner s Manual for more information Do not opera...

Page 39: ...purities that may be in the oil during the running in phase If these impurities are not removed but are allowed to remain in the oil they may cause premature wear to the moving parts and the oil seals If the pump works in conditions with high humidity and with sharp temperature changes condensation may appear inside the crankcase Condensation mixing with the oil can change the oil s properties whi...

Page 40: ...worn Measure orifice size and replace as necessary Applies to SALSA option only 2 0 No pressure reading on PSI gauge 2 1 Pump switch is not turned on Turn on switch 2 2 No water in water box Refer to section 5 of this manual 2 3 Pump belt is broken Replace belt 2 4 Pump clutch is not activated There is no water in water box Check system back to source to locate cause of interruption to water flow ...

Page 41: ...chine If this doesn t solve the problem disassemble this portion of the system and locate restriction 4 0 Pressure pulsation 4 1 Water in the water box is too hot and is approaching boiling point Check temperature of water in the water box 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 as n...

Page 42: ...Water box overflows 6 1 There is either debris caught in the valve or the valve seal is bad Replace 6 2 The float has absorbed water and has lost buoyancy Replace 6 3 The float has come out of adjustment Re adjust float as necessary ...

Page 43: ...7 1 Assemblies and Parts Lists 7 Assemblies and Parts Lists CDS Machine Assembly Front View Figure 7 1 7145 Rev C ...

Page 44: ...Assemblies and Parts Lists 7 2 CDS Machine Assembly Rear View Figure 7 2 7145 Rev C ...

Page 45: ...DS 1 4 000 068 030 Hose 5 32 ID Vacuum Bulk 10 ft 5 000 068 459 Hose 3 4 ID Green Stripe Bulk 18 ft 6 000 068 085 Hose 3 8 Hi Temp Black Bulk 73 7 000 068 706 Hose 3 16 X 70 Lg Teflon W F JIC Ends 1 8 000 033 005 Clamp Size 5 Hose 2 9 000 033 020 Clamp Size 16 Hose 2 10 000 033 013 Clamp 48 Hose 3 2 11 000 068 764 Hose Ø3 0 X 15 Lg Flexible Wire Reinforce 34 12 000 068 777 Hose 1 X 45 Lg Suction 1...

Page 46: ...Assemblies and Parts Lists 7 4 CDS Recovery Tank Assembly Front View Figure 7 2 6977 Rev B ...

Page 47: ...7 5 Assemblies and Parts Lists CDS Recovery Tank Assembly Rear View Figure 7 3 6977 Rev B ...

Page 48: ...er Chemical Inlet High Pressure 1 CDS Recovery Tank Assembly Parts List 1 000 159 130 Tank 100 Gallon Universal Recovery Weldment 1 2 Assembly Recovery Tank Cover 100 Gallon 1 3 000 001 135 Adapter Tank To Ø3 0 X 90 Blower Hose 1 4 000 049 152 Filter Recovery Tank Basket 1 5 See Notes Assembly Vacuum Relief Valve URT 1 6 000 049 153 Filter Flat Universal Recovery Tank 1 7 000 015 932 Bracket Flat ...

Page 49: ...ry 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 Head Allen 2 6 000 086 008 Latch Bungie Strike 1 7 000 094 063 Nut 6 32UNC Nylock 2 8 000 052 222 Elbow 2 Barb x 2 FPT 2 9 000 057 202 Gasket End Recovery Tank 2 10 000 057 203 Gasket Middle Recovery Tank 3 11 000 057 205 Gasket Side Recovery Tank 100 Gallon...

Page 50: ...Assemblies and Parts Lists 7 8 CDS Instrument Panel Assembly Front View Figure 7 5 6988 Rev C ...

Page 51: ...7 9 Assemblies and Parts Lists CDS Instrument Panel Assembly Rear View Figure 7 6 6988 Rev C ...

Page 52: ...her 1 5 OD X 1 073 ID X 0 075 Thk 1 27 000 174 012 Washer 1 2 SAE H D 2 28 000 140 015 Rivet 1 8 X 1 4 Lg Pop 2 29 000 169 201 Valve 3 4 Heater Panel Mount 1 30 000 052 756 Insert 3 4 NPT X 3 4 Elbow 2 31 000 169 017 Valve 3 Way Ball O Ring Style 1 Item Part Number Description Qty 32 000 169 160 Valve Chemical Metering 1 33 000 052 069 Nipple 1 8 NPT Hex 2 34 000 174 030 Washer 5 8 Id X 7 8 OD X 0...

Page 53: ... 000 052 074 Nipple 3 8 NPT Hex 2 7 000 169 186 Valve 3 8 FPT x 3 8 FPT 100 PSI Check 1 8 000 149 039 Sender Temperature 1 9 000 052 061 Bushing 3 8 NPT x 1 4 FPT 1 10 000 052 113 Cross 3 8 FPT 1 11 000 050 060 Bushing 3 8 NPT x 1 8 FPT 1 12 000 052 582 Nipple Tee Jet Style Collar x 1 8 NPT 1 13 000 094 028 Nut Brass Jet Assembly 1 14 000 052 153 Housing Stabilizer Nozzle 1 15 000 052 586 Nipple 1...

Page 54: ...52 764 Elbow 1 4 SAE x 3 8 MNPT x 90 1 5 000 052 023 Tee 3 8 NPT Male Street 3 6 000 052 528 Nipple 3 8 M JIC x 3 8 NPT 1 7 000 052 105 Insert 68 3 8 NPT x 1 2 Barb 1 8 000 169 027 Valve Thermal Relief 165 F 1 9 000 052 099 Insert 26 1 8 NPT x 3 8 Barb 1 10 000 106 008 Plug 3 8 NPT Allen Head 1 11 000 143 126 Screw 10 24UNC x 0 50 Lg Hex Head 2 12 000 052 128 Nipple 3 8 NPT x 3 8 Male Propane 1 13...

Page 55: ...7 13 Assemblies and Parts Lists CDS 4 8 Pump and Blower Assembly Overview Figure 7 9 3802 Rev N ...

Page 56: ...Assemblies and Parts Lists 7 14 CDS 4 8 Pump and Blower Figure 7 10 Assembly Parts View 3802 Rev N ...

Page 57: ... Screw 1 2 13UNC X 1 75 Lg Hex Head Grade 4 30 000 174 012 Washer 1 2 SAE H D 4 31 000 094 037 Nut 1 2 13 UNC 2 Way Locking 4 32 000 174 001 Washer 10 Flat 1 33 000 143 132 Screw 10 24UNC X 0 75 Lg Hex Head 1 34 000 077 010 Key 1 4 X 1 1 2 Lg 1 35 000 020 020 Bushing 7 8 Taper Lock 1 36 000 020 026 Bushing 1 1 8 Taper Lock 1 37 000 077 012 Key 3 16 X 2 5 Lg Class 2 Fit 1 38 000 109 057 Pulley 40 T...

Page 58: ...Assemblies and Parts Lists 7 16 CDS 4 6 Pump and Blower Assembly Overview Figure 7 11 4431 Rev O ...

Page 59: ...7 17 Assemblies and Parts Lists CDS 4 6 Pump and Blower Figure 7 12 Assembly Parts View 4431 Rev O ...

Page 60: ... 000 174 021 Washer 3 8 Lock 7 29 000 077 010 Key 1 4 X 1 1 2 Lg 1 30 000 020 020 Bushing 7 8 Taper Lock 1 31 000 020 026 Bushing 1 1 8 Taper Lock 1 32 000 077 012 Key 3 16 X 2 5 Lg Class 2 Fit 1 33 000 109 057 Pulley 40 Tooth Gt2 8mx 10s 21 Engine Blower 1 34 000 109 058 Pulley 56 Tooth Gt2 8mx 56s 21 Engine Blower 1 35 000 143 373 Screw 1 4 20UNC X 2 G Hex Head Grd 5 1 36 000 143 548 Screw 1 4 2...

Page 61: ...7 19 Assemblies and Parts Lists CDS Pump Assembly Overview Figure 7 13 7429 Rev A ...

Page 62: ... 753 Insert 816 1 2 NPT X 1 Barb 1 10 000 105 550 Plate Pump Clutch 4 0 Gpm 1 11 000 143 141 Screw 1 4 20UNC X 1 2 Lg Whiz Lock 4 12 000 094 071 Nut 1 4 20UNC Nylock 4 13 000 052 085 Elbow 1 4 NPT Street 1 14 000 052 062 Bushing 1 4 M X 1 4 F 1 15 000 036 008 Clutch 24mm Single Groove 1 16 000 052 531 Elbow 1 8 NPT X 1 4 SAE 1 17 000 068 149 Hose CDS Blower Oil Drain 1 18 000 097 057 O Ring Adapte...

Page 63: ...7 21 Assemblies and Parts Lists CDS DuraFlow Automatic Pump Out APO Assembly Figure 7 15 5984 Rev C ...

Page 64: ... 000 143 074 Screw 1 4 20UNC X 0 50 Lg Hex Head Self Tapping 4 10 000 052 131 Elbow 1 NPT X 1 Barb Glass Filled Black Nylon 1 11 000 169 009 Valve 3 4 FPT Swing Check 1 12 000 052 338 Insert 1212 3 4 NPT X 3 4 Barb 1 13 000 174 050 Washer 1 Flat 1 14 000 027 014 Cap Garden Hose 1 15 000 057 055 Gasket Garden Hose 1 16 000 174 063 Washer 1 5 OD X 1 073 ID X 0 075 Thk 1 17 000 052 281 Nipple 3 4 NPT...

Page 65: ...7 23 Assemblies and Parts Lists CDS Dash Box Assembly Overall View Figure 7 16 7428 Rev A ...

Page 66: ...Assemblies and Parts Lists 7 24 CDS Dash Box Assembly Figure 7 17 Rear View 7428 Rev A ...

Page 67: ... Trimlok 18 Id X 3 8 1 7 000 143 114 Screw 10 24UNC X 0 50 Lg Flat Head 12 8 000 143 126 Screw 10 24UNC X 0 50 Lg Hex Head 3 9 000 143 046 Screw 6 32 X 500 Lg Phillips 2 10 000 174 043 Washer 6 Lock 2 11 000 060 002 Grommet Large Wiring 2 12 000 143 166 Screw 10 24UNC X 3 8 Lg Hex Head 12 13 000 174 015 Washer 10 Outside Star 3 14 000 105 053 Plate Dash Name 1 15 000 056 006 Fuse Holder In Line We...

Page 68: ...Assemblies and Parts Lists 7 26 CDS Dash Panel Assembly Overall View Figure 7 18 7427 ...

Page 69: ... 016 Gauge Temperature 1 6 000 074 006 Gauge Vacuum 1 7 000 084 011 Light Red LED Indicator Mini 3 8 000 084 004 Lamp Replacement Gauge 3 9 000 084 009 Lamp Socket Dashboard 3 10 000 157 040 Switch 20 Amp Rocker 3 11 000 157 008 Switch Ignition 1 12 000 157 131 Switch 3 Way Speed Control 1 13 000 052 084 Elbow 1 8 NPT Street 1 14 000 052 096 Insert F23 1 8 FPT X 3 16 Barb 1 15 000 174 052 Washer 3...

Page 70: ...Assemblies and Parts Lists 7 28 CDS Water Box Assembly Overview Figure 7 20 6990 Rev C ...

Page 71: ...7 29 Assemblies and Parts Lists CDS Water Box Assembly Figure 7 21 Parts View 6990 Rev C ...

Page 72: ...Hose 2 13 000 052 023 Tee 3 8 NPT Male Street 1 14 000 052 105 Insert 68 3 8 NPT X 1 2 Barb 1 15 000 015 938 Bracket Water Box Mounting 4 Gallon 1 16 000 041 005 Cover 6 1 17 000 143 314 Screw 8 X 1 2 Lg Pan Head 6 18 000 052 660 Bulkhead 3 8 FPT X 3 8 FPT 1 19 000 052 086 Elbow 3 8 NPT Street 3 20 000 174 063 Washer 1 5 OD X 1 073 ID X 0 075 Thk 2 21 000 143 001 Screw 1 4 20UNC X 0 75 Lg Hex Head...

Page 73: ...6554 5 4 2 3 4 1 1 000 052 074 Nipple 3 8 NPT Hex 1 2 000 033 131 Clamp Diffuser 1 3 000 125 222 Tube Diffuser 1 4 000 027 115 Cap 2 PVC Modified For Diffuser 2 5 000 052 104 Insert 66 3 8 NPT x 3 8 Barb 1 Diffuser Filter Assembly Parts List Item Part Number Description Qty ...

Page 74: ...Relief Valve 1 2 000 027 032 Cap Vacuum Relief Valve 1 3 000 125 111 Pipe Vacuum Relief Spring Guide 1 4 000 105 332 Plate Vacuum Relief Valve Mounting URT 1 5 000 155 026 Spring Vacuum Relief 1 6 000 143 198 Screw 3 8 16UNC x 4 Lg Hex Head Full Thread 1 7 000 094 077 Nut 3 8 16UNC x 1 00 OD Knurled 2 8 000 094 101 Nut 3 8 16UNC Hex Jam 1 Item Part Number Description Qty ...

Page 75: ...Assemblies and Parts Lists 7 33 CDS Front End 2003 2009 Figure 7 24 GM Assembly Overview 5481 Rev B CDS Front End 2003 2009 GM Assembly Parts View Figure 7 25 5481 Rev B ...

Page 76: ...earing CDS Clutch 2 11 000 139 005 Ring Snap CDS Clutch Shaft 2 CDS Front End 2003 2009 GM Assembly Parts List 12 000 077 008 Key 5 32 x 3 4 Woodruff 1 13 000 077 009 Key 3 16 x 3 4 Woodruff 1 14 Alternator 2003 GM Part of Van 1 15 000 143 562 Screw 5 16 18UNC x 0 75 Lg Flat Head Allen 4 16 000 174 104 Washer Idler Casting 2003 2009 GM 1 17 000 143 079 Socket Hd Mach Scr 1 4 20UNC x 0 50 Lg 1 18 0...

Page 77: ...7 35 Assemblies and Parts Lists 25 24 25 6 7 21 18 32 17 32 15 30 26 24 29 27 30 28 28 29 27 22 23 19 20 16 16 Horizontal Pump In Tank Assembly Front Figure 7 26 3700 Rev C ...

Page 78: ...Assemblies and Parts Lists 7 36 Horizontal Pump In Tank Assembly Rear Figure 7 27 3700 Rev C 14 9 31 2 31 8 5 3 33 6 7 30 24 25 25 24 26 10 12 11 10 12 11 13 31 4 1 28 27 29 31 ...

Page 79: ... 000 174 021 Washer 3 8 Lock 16 31 000 033 029 Clamp Size 12 Hose 4 32 000 033 003 Clamp Size 4 Mini 2 33 000 068 165 Hose Assembly Pump In Overflow 1 1 000 159 005 Tank 120 Gallon Horizontal Pump In Weldment 1 2 000 111 170 Filter Supplied With Pump 1 3 000 111 170 Pump Fresh Water 1 4 000 052 087 Elbow 1 2 NPT Street 1 5 000 052 129 Insert 812 1 2 NPT x 3 4 Barb 1 6 000 041 005 Cover 6 2 7 000 1...

Page 80: ...ir Mover Removable Weldment 2 2 000 083 001 Leg Tray Support Weldment 2 3 000 166 013 Bin 4 Compartment Removable Weldment 1 4 000 083 006 Leg Free Standing Tray Support Weldment 2 5 000 143 019 Screw 3 8 16UNC x 1 25 Lg Hex Head Grd 5 Zinc 24 6 000 174 005 Washer 3 8 Flat 24 7 000 174 021 Washer 3 8 Lock 24 8 000 094 014 Nut 3 8 16UNC Hex Zinc Plated 24 Item Part Number Description Qty ...

Page 81: ...7 39 Assemblies and Parts Lists 85 Gallon Rotomolded Fresh Water Tank Assembly Overall View Figure 7 29 5566 Rev E ...

Page 82: ...Assemblies and Parts Lists 7 40 85 Gallon Rotomolded Fresh Water Tank Assembly Front View Figure 7 30 5566 Rev F ...

Page 83: ...7 41 Assemblies and Parts Lists 85 Gallon Rotomolded Fresh Water Figure 7 31 Tank Assembly Rear view 5566 Rev E ...

Page 84: ... 052 Quick Connect 660 3 8 Brass w EPDM O Ring 1 21 000 052 326 Nipple 3 4 NPT Close 1 22 000 052 726 Elbow 3 4 Street Grey 1 23 000 052 105 Insert 68 3 8 NPT X 1 2 Barb 1 24 000 052 408 Nipple 3 8 NPT X 4 Lg 1 25 000 052 142 Elbow 3 8 F X F Brass 1 26 000 105 313 Plate Hydramaster Name Roto Tank 1 27 000 041 004 Cover Poly Water Box Mod W Vent 1 28 000 159 016 Jug 5 Gallon Plastic Chemical Standa...

Page 85: ... 7 32 5817 3 1 2 4 85 Gallon Rotomolded Fresh Water Tank with Reel Assembly Parts List 1 000 159 118 Assembly Rotomolded Tank 1 2 000 163 543 Reel Triple Electric 300 E2336 518S 1 3 000 174 057 Washer 3 8 Lock 4 4 000 143 017 1 Screw 3 8 16UNC x 3 4 Lg Hex Head 4 Item Part Number Description Qty ...

Page 86: ...Assemblies and Parts Lists 7 44 125 Gallon HydraCradle Tank Figure 7 33 Assembly Parts View 1 of 3 7582 Rev A ...

Page 87: ...7 45 Assemblies and Parts Lists 125 Gallon HydraCradle Figure 7 34 Tank Assembly Parts View 2 of 3 7582 Rev A ...

Page 88: ...Assemblies and Parts Lists 7 46 125 Gallon HydraCradle Tank Assembly Parts View 3 of 3 Figure 7 35 7582 Rev A ...

Page 89: ... 000 033 116 Clamp 1 1 2 Cushion Loop w 7 16 Mounting Hole 4 23 000 033 029 Clamp Hose Size 12 3 24 000 033 004 Clamp Size 6 Mini Hose 4 25 000 068 018 Hose 1 2 Rubber 18 26 000 068 459 Hose 3 4 Rubber Green Stripe 5 5 27 000 094 009 Nut 1 4 20UNC Nylock 8 28 000 094 034 Nut 10 24UNC Nylock S S 4 29 000 143 001 Screw 1 4 20UNC X 0 75 Lg Hex Head 5 30 000 143 314 Screw 8 X 1 2 Lg Pan Head 6 Item Pa...

Page 90: ...3 CDS Pass Through Assembly Parts List 1 000 125 182 Tube Pass Through 1 2 000 041 200 Cover 4 Round ABS Mod Pass Through 1 3 000 143 537 Screw 10 x 1 5 Lg Pan Head Sheet Metal 6 4 000 033 032 Clamp CDS Throttle Cable 2 5 000 025 008 Cable 150 Lb Test S S 1 Item Part Number Description Qty ...

Page 91: ...52 064 2 3 INSeRT 1212 3 4 NPT x 3 4 BARB BlACK Nyl 000 052 338 1 2 HeAT eXCHANGeR WATeR To WATeR HI PSI 2 x CoPPeR 000 038 046 Item No Qty Description Material Part Number Dwg No 21 7 15 20 16 17 1 1 5 2 18 2 uNleSS oTHeRWISe NoTeD DIMeNSIoNS ARe IN INCHeS 11015 47th Avenue West Mukilteo Washington 98275 PRoPRIeTARy INfoRMATIoN BReAK All SHARP eDGeS 0 005 0 015 G eCR 1238 06 06 2007 l o l C I R W...

Page 92: ...eet 1 5 000 052 408 Nipple 3 8 NPT X 4 Lg 1 6 000 052 142 Elbow 3 8 F X F Brass 1 7 000 100 154 Panel Salsa Inlet Weldment CDS 4 8 1 8 000 140 021 Rivet 1 4 Blind X 0 50 Lg 32 9 000 100 155 Panel Salsa Outlet Weldment CDS 4 8 1 10 000 108 140 Protector Salsa Insulation CDS 4 8 1 11 000 068 755 Hose 3 8 X 31 Lg Teflon W 3 8 JIC Ends 1 12 000 068 801 Hose 3 8 X 37 Lg Teflon W 3 8 JIC Ends 1 13 000 0...

Page 93: ...Salsa 2005 2009 Chevy Assembly Figure 7 39 5954 Rev A CDS Salsa 2005 2009 Assembly Parts List Item Part Number Description Qty 1 000 093 030 Silencer 3 Inlet and Outlet 1 2 000 068 187 Hose 3 X 30 Lg Nitrile 1 3 Heat Exchanger Assembly 1 ...

Page 94: ...003 Silencer Hush Kit Muffler 1 2 000 052 322 Adapter 3 Modified Hush Silencer 1 3 000 068 617 Hose 3 Silicone X 7 2 4 000 052 334 Adapter Vacuum Blower Inlet Fitting 1 5 000 093 094 Silencer 3 Cowl CDS Ford 2005 2009 1 6 000 033 034 Clamp 3 Muffler 1 7 000 001 026 Adapter 1 Item Part Number Description Qty Item Part Number Description Qty ...

Page 95: ...sh Kit Muffler 1 2 000 052 322 Adapter 3 Modified Hush Silencer 1 3 000 068 617 Hose 3 Silicone X 7 1 4 000 093 030 Silencer 3 Inlet And Outlet 1 5 000 068 187 Hose 3 X 30 Lg Nitrile 1 6 000 052 334 Adapter Vacuum Blower Inlet Fitting 1 7 000 001 026 Adapter 1 8 000 033 034 Clamp 3 Muffler 1 Item Part Number Description Qty Item Part Number Description Qty ...

Page 96: ... 54 Silencer Assembly 4 6 Figure 7 42 7693 1 000 093 002 Silencer Assembly CDS 1 2 000 068 162 Hose CDS Silencer 2 3 000 001 004 Elbow 3 OD X O 065 Wall 4 5 R W 2 1 Silencer Assembly Parts List 4 6 Item Part Number Description Qty ...

Page 97: ...7 55 Assemblies and Parts Lists CDS Belts Parts List Part Number Description Qty 000 010 118 GM Products 2003 to 2009 Gates K061145 1 000 010 053 Ford Products 2000 to 2009 Gates K060637 1 ...

Page 98: ... 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 Item Part Number Description Qty Cleaning Wand Valve Assembly Parts List Item Part Number Description Qty 6 052 152 Compression Male Hydra Hoe Fitting 1 7 143 002 Screw 20 x 1 HHC S S 1 8 094 009 Nut 20S S Nylock 1 ...

Page 99: ...alve Assembly Figure 7 44 1234 Rev A 1 600 012 001 Valve Body Sub Assembly 1 2 600 012 002 Valve Stem Sub Assembly 1 3 155 003 Spring HM Solution Valve 1 4 027 001 Cap Brass 1 Cleaning Wand Solution Valve Assembly Parts List Item Part Number Description Qty ...

Page 100: ...7 129 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 Solution Valve Flow Meter Small 1 5 139 004 Ring Solution Valve Stem Snap 1 Cleaning Wand Valve Stem Assembly Parts List Item Part Number Description Qty ...

Page 101: ...7 59 Assemblies and Parts Lists Hydra Hoe Wand Assembly Figure 7 46 2660 ...

Page 102: ... 153 Housing Brass Stabilizer Wand Nozzle Fitting 1 10 186 001 Stabilizer Jet Assembly Group 1 11 076 005 Jet No 6S S Hydra Hoe 1 Item Part Number Description Qty Hydra Hoe Wand Assembly Parts List Item Part Number Description Qty 12 094 028 Nut Brass Jet Assembly Group 1 13 143 005 Screw 20 x 1 HHC 2 14 143 012 Screw 5 16 18 x HHC S S 2 15 094 035 Nut 5 16 18S S Nylock Half 2 16 094 009 Nut 3 20 ...

Page 103: ... 020 001 000 041 069 Cowling 2009 Ford 1 000 131 060 Trimlok Seal 3 4 B 15 Part Number Description Qty CDS Parts Kit List P N 000 078 069 Part Number Description Qty 000 169 053 Valve 3 4 Heater Panel 1 000 087 006 Pennz Guard 12 oz Sp 1 000 078 175 Kit Water Hardness Test 1 000 078 077 Kit Freeze Guard Vac 1 000 068 178 Hose Water box Drain 1 000 052 247 Connector HM Fresh Water Garden Hose 1 000...

Page 104: ...ty 000 037 003 Connector Butt 14 16 5 000 037 004 Closed End Conn Medi 1 000 037 012 Terminal Fully Insulated 3 000 037 015 Terminal 5 16 Ring 1 1 000 037 022 Terminal 10 Awg Full 1 000 037 050 Terminal Male Pin 4 4 000 037 023 Terminal 10 Awg 1 000 037 033 Connector 22 Pink B 10 000 037 052 Connector Male 4 P 1 000 037 071 Terminal Fully Insulated 14 000 037 072 Terminal Fully Insulated 5 000 056...

Page 105: ...ubmersion in oil with the gear teeth serving as oil slingers At the drive end the bearings are also lubricated by submersion in oil with oil slingers attached on the shafts The performance and life of the vacuum blower is greatly dependent on the care and proper maintenance it receives Because of the close tolerances between the 3 lobes and housing of the vacuum blower solid objects entering the i...

Page 106: ...loat kill switch The switch is not activated by foam only by liquid VACUUM TANK INLET FILTER HydraMaster inlet filter screens are designed to trap lint hair and large objects that would normally collect at the bottom of your vacuum tank Clean the screen at the end of each job to eliminate build up of debris in the tank VACUUM BLOWER LUBRICATION Read the vacuum blower Owner s Manual included with t...

Page 107: ...cessary 2 3 Vacuum blower is turning too slowly Check blower rpm at tachometer on the CDS dash Blower rpm should be 2 times the tachometer rpm See the throttle control kit instructions for further troubleshooting assistance 3 0 Vacuum gauge reads high with no hoses attached 3 1 Filter in recovery tank is clogged Remove and clean or replace as necessary 3 2 Hose from recovery tank to blower is coll...

Page 108: ...0 Vacuum Blower is locked and will not turn 5 1 The machine has been unused for a period of time and the blower was not properly lubricated when it was shut down causing rust to build up on internal surfaces Spray penetrating oil into blower and let sit for at least 1 hour Then very carefully use pipe wrench on outer diameter of pulley on blower shaft and attempt to free up blower Do not use wrenc...

Page 109: ...n 12 volts DC which is provided by the vehicle s battery To avoid equipment damage it is very important to tie up any loose wires or hoses near the drive shaft area Tie wraps are sufficient for wires and small hoses When securing large hoses or wiring harnesses in the area of the drive shaft tie down the components with a hose clamp with a clear vinyl hose inserted onto the clamp On some installat...

Page 110: ...Electrical System 9 2 Figure 9 1 CDS Electrical Schematic 7425 Rev B ...

Page 111: ...9 3 Electrical System Figure 9 2 CDS Wiring Diagram 7426 Sht 2 Rev C ...

Page 112: ...Electrical System 9 4 Figure 9 3 CDS Wiring Diagram 7426 Sht 3 Rev C ...

Page 113: ...nections or damaged wires Check all wires from the control panel forward to the front of the vehicle If no problem is found but the breaker still trips refer to qualified service technician 2 0 CDS shuts off while in use 5 1 Recovery tank is full Empty tank and restart machine 5 2 Recovery tank float switch is dirty or defective Inspect float to see if the triangle mark on the float is facing up I...

Page 114: ...tenance log We have provided a maintenance log for your convenience at the end of this section Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored It is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder OPERATIONAL MAINTENANCE This section co...

Page 115: ...or wear Check pump pulleys for wear Check internal machine high pressure water lines for wear or chafing Remove the stainless steel blower inlet filter inside the recovery tank and thoroughly clean removing all lint build up Inspect for damage and re install Remove the filter screen from the fresh water garden hose inlet fitting Thoroughly clean and reinstall Empty chemical from the chemical conta...

Page 116: ...h the truck s cooling system Add new anti freeze Change the truck s transmission fluid Perform Descaling As Required Scale deposits on the interior of the heating system can cause a noticeable loss in heating performance Deposits of this kind result from hard water deposits excessive chemical use or improper chemicals The frequency with which descaling procedures are required will vary If your are...

Page 117: ...he machine and spot potential problems before they occur The following maintenance is recommended by the manufacturer at the frequency indicated Daily Wipe machine down thoroughly with a damp cloth Flush recovery tank out thoroughly Clean wand to maintain original appearance Wipe down vacuum and high pressure hoses as needed Visually inspect hoses for cuts etc Weekly Wipe down entire unit as neede...

Page 118: ...nterval Machine hours months of service High pressure water pump rebuild 2 000 24 Vehicle engine thermostat 2 000 24 Vehicle engine accessory drive belt 2 000 24 CDS clutch 3 000 36 CDS drive shaft 3 000 36 CDS blower silencer and exhaust plumbing 4 000 48 CDS and vehicle heater hoses 4 000 48 CDS wire harness 4 000 48 CDS clutch housing drive bearings 4 000 48 ...

Page 119: ...uld also be lubricated with a bearing grease with an application temperature range of 4 F to 347 F 20 C to 175 C the drive shaft manufacturer recommends Mobil Delvac Xtreme Service grease as the lubricant HydraMaster flexible drive shaft assemblies have two universal joints one on either end of the drive shaft The above mentioned lubrication interval refers to both universal joints Drive Shaft Mai...

Page 120: ...ing solution flow is too great Measure flow at tool 3 2 1 The jet in the cleaning tool is too large or worn out Test the tool for water flow and replace or repair jet as necessary 3 2 2 Cleaning solution pressure is too high Adjust pressure to normal Inspect pressure gauge for accurate reading 3 3 The system thermal valve is stuck open Remove recovery tank lid and check for premature flow from the...

Page 121: ...ution pressure is too high Adjust pressure to normal Inspect pressure gauge for accurate reading 4 5 Hard water deposits are in the system Descale system as directed in this Owner s Manual see Perform Descaling As Required subsection MISCELLANEOUS 1 0 Vehicle radiator overflows into coolant overflow container while machine is in use 1 1 Internal leak in coolant heat exchanger Pressure test each he...

Page 122: ... 25 CHEMICAL SYSTEM flush with vinegar 25 ENGINE RPM check with CDS unit operating 25 FLOAT SWITCHES check for debris MONTHLY SERVICE N A ENGINE OIL change every 2 000 miles 100 ENGINE AIR CLEANER inspect 100 BATTERY TERMINALS clean as needed QUARTERLY SERVICE 3 MONTHS 400 BLOWER OIL change PUMP OIL change 400 VEHICLE FUEL LINES check for chaffing or wear 400 CDS WIRING HARNESS check for chafing o...

Page 123: ...hip the parts to you PARTS ORDERS Call your local distributor In most instances they either stock or have access to parts through a regional service center EMERGENCIES If for any reason your distributor is unable to supply you with the necessary parts they may call us and arrange for expedited shipping HydraMaster sells parts only through authorized distributors and service centers ONE FINAL NOTE ...

Page 124: ...c shut off system Allowing foam to pass through blower HIGH PRESSURE WATER PUMP Failure to maintain proper oil level as recommended in pump manual Failure to change oil in pump at recommended intervals Failure to protect pump against freezing Failure to maintain pump protection shut off system Failure to use water softener in hard water areas Use of improper chemicals VACUUM TANK Failure to proper...

Page 125: ... be necessary with machines operating in designated Hard Water Areas 3 5 grains or more per gallon WARRANTY PROCEDURE Warranty coverage is available to you through your local distributor Please refer to the Golden Guarantee Limited Warranty document shipped to you with the Owner s Guide If you have moved to a new area or have purchased a used machine and need information regarding your local distr...

Page 126: ...lity HydraMaster s chemical solutions will help maintain your machine s water pump and water heating systems at peak efficiency and also help ensure fewer breakdowns HydraMaster s full line of machine accessories and chemicals can enhance cleaning performance while reducing your labor costs and include Upholstery Tools Wands Vacuum Hoses Tanks Van Accessories Hose Reels Carpet Care Detergents Rins...

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