HydraMaster CTS 403 Flex Owner'S Manual Download

Page: 90 / 140

8-19: Assemblies and Parts Lists

Figure 8-16. Engine Assembly - Part 1 of 2

610-004-749 Rev. A

12X

000-049-053 FILTER, B&S VANGUARD FOAM AIR FILTER
000-049-012 FILTER, 16HP AIR-VANGUARD I/C

000-049-014 FILTER, OIL B&S

000-106-009

PLUG,1/8" NPT ALLEN HEAD

TORQUE TO

25 FT LBS

HIDDEN FROM VIEW

UNDER CARBURETOR.

000-049-258

FILTER, B&S FUEL

DETAIL A

SCALE

1 : 2

NOTES:

1. SEE ASY-45997 FOR ASSEMBLY INSTRUCTIONS.

2. SEE ENG-45975 OR ADHESIVE MATERIAL PRODUCTION LINE

REFERNCE CARD FOR SEALANT INFORMATION.
CUT ITEM 5 IN HALF.

ITEM NO. QTY.

DESCRIPTION

MATERIAL

PART NO.

WASHER, 5/16" FLAT, USS

STEEL

000-174-004

WASHER, 1/4" FLAT

STEEL

000-174-002

WASHER, #10 FLAT

S. STEEL

000-174-001

VALVE, CHECK - DIVERTER CONTROL

VARIOUS

000-169-156

3.33' TRIMLOK, 3/4" BULB x 3/16" OPENING (40" LG.)

VARIOUS

000-131-060

TEE, 3/16" PLASTIC VACUUM INSERT

ABS

000-052-155

SHAFT, B&S 23HP STUB

STEEL

000-150-169

SCREW, 5/16"-18UNC X 4.0" LG., HEX HEAD

S. STEEL

000-143-660

SCREW, 5/16"-18UNC X 3.5" LG. GRADE 8

STEEL

000-143-659

SCREW, #10-24UNC x 0.50" LG. HEX HEAD

S. STEEL

000-143-126

RIVET, AB4-3A ALUMINUM POP 1/8" x 1/4" LG. (GRIP RANGE 0.126"-

0.187")

ALUMINUM

000-140-001

PULLEY, AK47-H

STEEL

000-109-040

PLATE, ENGINE DUCT - COATED

ASTM A1008

CS TYPE B

000-105-562

NUT, 6MM HEX NYLOCK FLANGE S/S

STEEL

000-094-125

NUT, 5/16"-18UNC HEX

STEEL

000-094-012

NUT, 5/16"-18UNC HEX 2 WAY LOCKING

AISI 304

000-094-081

KEY, 1/4" x 1-1/2" LG. CLASS 2 FIT

AISI 8630

000-077-010

INSULATION, 1" HI-TEMP ALUM SLEEVE x 60" LG.

VARIOUS

000-131-139

INSERT, #23 (1/8" NPT x 3/16" BARB)

BRASS

000-052-293

HOUSING, RADIATOR DUCT - COATED

ASTM A1008

CS TYPE B

000-042-074

HOSE, DRAIN

VARIOUS

000-068-219

HOSE, 5/32" RUBBER VAC X 4.5" LG

RUBBER

000-068-1007

HOSE, 5/32" I.D. RUBBER/VACUUM X 1.5" LG.

RUBBER

000-068-1006

HOSE, 1/4" I.D. FUEL LOW PERM x 120" LG.

RUBBER

000-068-979

GASKET, ENGINE DUCT

NEOPRENE

000-057-226

GASKET, 1/2" X 1/4" X 18-1/8" LG.

VARIOUS

000-057-026

ENGINE, B&S 23HP

VARIOUS

000-047-037

COUPLER, GUARDIAN 7/8" X 1" BORE - 18/23 HP

VARIOUS

000-039-060

CLAMP, 1" CUSHION LOOP w/ 7/16 MOUNT HOLE

VARIOUS

000-033-117

BUSHING, H X 1"

STEEL

000-020-025

LTR

REVISION DESCRIPTION

CODE

DATE

CHKD

APPVD

A RELEASE DRAWING.

NEW

1/13/2020

L.O.L.

M.B.B.

ASSEMBLY, ENGINE - CTS 403 FLEX

REV

610-004-749

01/13/2020

USED ON

NEXT ASSY

APPLICATION

WEIGHT:

PART NUMBER

UNLESS OTHERWISE NOTED

DIMENSIONS ARE IN INCHES

BREAK ALL SHARP EDGES 0.005-.015

SIZE

11015 47th Avenue West,

Mukilteo, Washington 98275

PROPRIETARY INFORMATION

SHEET 1 OF 1

SCALE: 1:6

APPVD

CHECKED

DRAWN

125

MACHINE

FINISH

L.O.L.
M.B.B.

M.B.B.

PRJ000245

CTS 403 FLEX

- - -

610-050-749

- - -

TOLERANCES

.X= .1

.XX= .03

.XXX= .010

ANGULAR = 2°

CODE:

103.65

12X

000-049-053 FILTER, B&S VANGUARD FOAM AIR FILTER
000-049-012 FILTER, 16HP AIR-VANGUARD I/C

000-049-014 FILTER, OIL B&S

000-106-009

PLUG,1/8" NPT ALLEN HEAD

TORQUE TO

25 FT LBS

HIDDEN FROM VIEW

UNDER CARBURETOR.

000-049-258

FILTER, B&S FUEL

DETAIL A

SCALE

1 : 2

NOTES:

1. SEE ASY-45997 FOR ASSEMBLY INSTRUCTIONS.

2. SEE ENG-45975 OR ADHESIVE MATERIAL PRODUCTION LINE

REFERNCE CARD FOR SEALANT INFORMATION.
CUT ITEM 5 IN HALF.

ITEM NO. QTY.

DESCRIPTION

MATERIAL

PART NO.

WASHER, 5/16" FLAT, USS

STEEL

000-174-004

WASHER, 1/4" FLAT

STEEL

000-174-002

WASHER, #10 FLAT

S. STEEL

000-174-001

VALVE, CHECK - DIVERTER CONTROL

VARIOUS

000-169-156

3.33' TRIMLOK, 3/4" BULB x 3/16" OPENING (40" LG.)

VARIOUS

000-131-060

TEE, 3/16" PLASTIC VACUUM INSERT

ABS

000-052-155

SHAFT, B&S 23HP STUB

STEEL

000-150-169

SCREW, 5/16"-18UNC X 4.0" LG., HEX HEAD

S. STEEL

000-143-660

SCREW, 5/16"-18UNC X 3.5" LG. GRADE 8

STEEL

000-143-659

SCREW, #10-24UNC x 0.50" LG. HEX HEAD

S. STEEL

000-143-126

RIVET, AB4-3A ALUMINUM POP 1/8" x 1/4" LG. (GRIP RANGE 0.126"-

0.187")

ALUMINUM

000-140-001

PULLEY, AK47-H

STEEL

000-109-040

PLATE, ENGINE DUCT - COATED

ASTM A1008

CS TYPE B

000-105-562

NUT, 6MM HEX NYLOCK FLANGE S/S

STEEL

000-094-125

NUT, 5/16"-18UNC HEX

STEEL

000-094-012

NUT, 5/16"-18UNC HEX 2 WAY LOCKING

AISI 304

000-094-081

KEY, 1/4" x 1-1/2" LG. CLASS 2 FIT

AISI 8630

000-077-010

INSULATION, 1" HI-TEMP ALUM SLEEVE x 60" LG.

VARIOUS

000-131-139

INSERT, #23 (1/8" NPT x 3/16" BARB)

BRASS

000-052-293

HOUSING, RADIATOR DUCT - COATED

ASTM A1008

CS TYPE B

000-042-074

HOSE, DRAIN

VARIOUS

000-068-219

HOSE, 5/32" RUBBER VAC X 4.5" LG

RUBBER

000-068-1007

HOSE, 5/32" I.D. RUBBER/VACUUM X 1.5" LG.

RUBBER

000-068-1006

HOSE, 1/4" I.D. FUEL LOW PERM x 120" LG.

RUBBER

000-068-979

GASKET, ENGINE DUCT

NEOPRENE

000-057-226

GASKET, 1/2" X 1/4" X 18-1/8" LG.

VARIOUS

000-057-026

ENGINE, B&S 23HP

VARIOUS

000-047-037

COUPLER, GUARDIAN 7/8" X 1" BORE - 18/23 HP

VARIOUS

000-039-060

CLAMP, 1" CUSHION LOOP w/ 7/16 MOUNT HOLE

VARIOUS

000-033-117

BUSHING, H X 1"

STEEL

000-020-025

LTR

REVISION DESCRIPTION

CODE

DATE

CHKD APPVD

A RELEASE DRAWING.

NEW

1/13/2020

L.O.L.

M.B.B.

ASSEMBLY, ENGINE - CTS 403 FLEX

REV

610-004-749

01/13/2020

USED ON

NEXT ASSY

APPLICATION

WEIGHT:

PART NUMBER

UNLESS OTHERWISE NOTED

DIMENSIONS ARE IN INCHES

BREAK ALL SHARP EDGES 0.005-.015

SIZE

11015 47th Avenue West,

Mukilteo, Washington 98275

PROPRIETARY INFORMATION

SHEET 1 OF 1

SCALE: 1:6

APPVD

CHECKED

DRAWN

125

MACHINE

FINISH

L.O.L.
M.B.B.

M.B.B.

PRJ000245

CTS 403 FLEX

- - -

610-050-749

- - -

TOLERANCES

.X= .1

.XX= .03

.XXX= .010

ANGULAR = 2°

CODE:

103.65

DETAIL VIEW A

Summary of Contents for CTS 403 Flex

Page 1: ...ans i e graphic electronic photocopying or electronic retrieval systems without the express written permission of Harris Research Inc Specifications and information in this document are subject to cha...

Page 2: ......

Page 3: ...Operation 2 7 FREEZE GUARDING SECTION 3 Freeze Guarding the Carpet Upholstery System 3 2 Freeze Guarding the Tile System 3 3 MACHINE MAINTENANCE SECTION 4 Operational Maintenance 4 2 High Pressure Pu...

Page 4: ...rts List 8 35 Orifice Assembly Parts List 8 36 Pump Assembly Parts List 8 38 By Pass Valve Assembly Parts List 8 39 Silencer Assembly Parts List 8 40 Top Cover CTS 403 Flex Assembly Parts List 8 41 Wa...

Page 5: ...ders 9 1 Emergencies 9 1 WARRANTY INFORMATION SECTION 10 Blower 10 1 High Pressure Water Pump 10 1 Recovery Tank 10 1 Chemical System 10 1 Control Panel 10 1 Vacuum And Solution Hoses 10 2 Cleaning Wa...

Page 6: ...ASSY APPLICATION WEIGHT PART NUMBER UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES BREAK ALL SHARP EDGES 0 005 015 SIZE C 11015 47th Avenue West Mukilteo Washington 98275 PROPRIETARY INFORMATION SHEE...

Page 7: ...ntenance and troubleshooting of the CTS 403 Flex In addition assembly illustrations and parts ordering information are included for your convenience It is the purpose of this Manual to help you proper...

Page 8: ...is machine please contact your local distributor When calling your distributor be sure to reference the serial number and date of purchase FOR YOUR REFERENCE Serial No ________________________________...

Page 9: ...uses this WARNING symbol throughout the guide 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 r...

Page 10: ...oxide and other toxic fumes are produced Position the vehicle so that any fumes produced will be directed away from inhabited areas and any points of building entry doors windows air conditioning unit...

Page 11: ...ay result Never operate the truckmount when the vehicle is tilted more than 10 degrees in any direction Doing so will result in improper lubrication of the internal components and will increase the ri...

Page 12: ...unt Serious component damage will occur Perform all freeze guarding procedures outlined in the digital Owner s Manual Many vehicles have critical components mounted directly below the floor that can e...

Page 13: ...o the floor such as Rhino Lining or Line X Prior to operating the truckmount read this manual in its entirety and familiarize yourself with the information contained here Special attention should be p...

Page 14: ...s prior to starting the truckmount Start and run the truckmount and check that all systems function properly Test all hoses wands etc for correct operation Ensure timely return of the document package...

Page 15: ...umption 1 1 gph Ignition Electric Key Start Vacuum Blower Tuthill 3006 Competitor Plus SL Dual Splash Lubrication Max Vac 12 Hg Oil Type PneuLube or other ISO 100 rating Gear End Capacity Approx 7 0 o...

Page 16: ...acuum Hose 100 ft 1 1 2 Wand Whip Line 10 ft Recovery Tank 70 gallon MaxAir Universal Tank Through Floor Exhaust Kit Battery Box Van Decal Van Installation Kit Owner s Manual on CD Owner s Guide paper...

Page 17: ...CHINE SPECIFICATIONS FLEX ASSEMBLIES 50 Gallon Tank with Frame Dimensions 12 W x 33 H x 60 L Weight 113 lbs 35 15 Gallon Tanks with Frame Dimensions 12 W x 33 H x 53 L Weight 108 lbs Construction Fram...

Page 18: ...aMaster 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 intol...

Page 19: ...related 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 Figure 1 1 Hard Water Map of...

Page 20: ...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 efficiency The water softener will also increase the e...

Page 21: ...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 CTS 403 Flex with an Automatic Pump Out APO Thes...

Page 22: ...ditioning units or kitchen fans If this warning is not heeded personal injury and death can result 2 Check the fuel tank to be certain there is adequate fuel to complete the job 3 Connect the solution...

Page 23: ...ngine starts push the choke in 5 Adjust the throttle to full throttle 6 Select Carpet Upholstery Cleaning mode on the solution control switch Figure 2 1 CTS 403 Flex Dash Assembly APO Switch A B C D 3...

Page 24: ...Solution Control switch to OFF and empty the recovery tank Then turn the unit back on and continue to clean LTR REVISION DESCRIPTION CODE DATE BY CHKD AP A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 E F M...

Page 25: ...l throttle 6 Select TILE CLEANING on the Solution Control switch see Figure 2 3 Figure 2 3 Select TILE on Solution Control Switch LTR REVISION DESCRIPTION CODE DATE BY CHKD APPVD D C B A A B C D 1 2 3...

Page 26: ...n Failure to follow this caution will increase the risk of serious component or engine damage The machine will automatically shut down when it reaches its full capacity due to the float switch located...

Page 27: ...additional 2 to 5 minutes to flash off lubricant e Uncap the inlet set throttle at IDLE and run the unit for 1 minute to allow the blower to cool down 2 Remove the Vacuum Hose 3 If freeze guarding is...

Page 28: ...sition the flow is turned OFF 2 Open the Flex solution tank lid s and fill the solution tank s with appropriate ChemDry solution until the solution levels off below the tank vent hose hole Figure 2 5...

Page 29: ...d the hose connected to the pump strainer see Figure 2 6 and Figure 2 7 To drain the pumps turn the lever away from the flow To turn the flow off turn the levers downward or in the vertical position L...

Page 30: ...h an extra 1 vacuum hose 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 w...

Page 31: ...nd starting the next cleaning job drain the antifreeze completely from the Flex tanks and run water though the pumps until clear water drains from the machine WHEN DISPOSING OF USED ANTIFREEZE COOLANT...

Page 32: ...p ahead to step 6 5 Remove the quick connect from the truckmount 6 Spray the antifreeze and water mix out of the truckmount and into a container to reclaim the solution Run the truckmount until there...

Page 33: ...the garden hose adapter from the pump in pump hose and position the hose so it is pointing outside the van 3 Turn on the pump in pump and run for 1 2 minutes until all the water is purged from the ho...

Page 34: ...aintenance High Pressure Pump Maintenance Vacuum System Maintenance Descaling Procedure Required Tensioning the Pump Drive Belt Descaling Flex System as Required Pump Tuning Instructions Clean QC Filt...

Page 35: ...belt for wear and proper tension Tighten as needed Check all the hoses and wiring for wear and chafing Secure as needed Flush the water and chemical systems with solution of equal parts white vinegar...

Page 36: ...004 0 006 Change the fuel filter Check coupler rubber sleeve for cracks or wear Replace as necessary Coupler Sleeve Part Number 000 152 015 1000 Hours Change air filters Check carburetor Clean or rep...

Page 37: ...nated one of the oil seals may be damaged Do not operate the pump if the crankcase oil has become contaminated Do not rotate the drive shaft without oil in the crankcase reservoir The pump should neve...

Page 38: ...n and delivery check valves The valve assembly usually stays together when removing If the valve comes apart use the needle nose pliers or reverse pliers to remove the remaining parts 4 Inspect each s...

Page 39: ...king Maintenance 1 Remove the manifold as previously described It is possible that the seal and brass retainer ring assembly will stay on the piston or will remain in the manifold when removing it 2 C...

Page 40: ...e if necessary Plunger Re assembly 1 Generously grease the piston guide Replace the O ring making sure it does not twist or roll 2 Slide the lower washer and ceramic bushing onto the piston guide 3 Pl...

Page 41: ...Two brass knurled nuts are located on the side of the recovery tank see Figure 4 2 2 Increase the vacuum of the system by turning the nut clockwise tightening 3 Decrease the vacuum of the system by t...

Page 42: ...isconnected in order to remove moisture from the blower b Cap off the inlet to the vacuum tank c Spray a LPS TKX spray lubricant into the BLOWER LUBE PORT for about 2 to 3 seconds while the unit is ru...

Page 43: ...circulation kit P N 000 078 058 start with an empty water box 1 Fill a third of the water box with TM DeScaler Follow the recommendations on the TM DeScaler label for proportions Verify that the float...

Page 44: ...the hose The descaler will drain from the female QC fitting assembly hose quickly Have extra buckets ready to swap out because each bucket should fill quickly 4 Pour 5 gallons of descaler solution in...

Page 45: ...ve the right cover of the machine to gain access to the tensioning screw 4 Adjust the tension of the belt by turning the 4 long screw P N 000 143 376 5 After the proper belt tension is achieved tighte...

Page 46: ...ump head with a hex L key provided in the Flex Installation Kit see Figure 4 4 Clockwise increases the pressure Counterclockwise decreases the pressure Tools required include 1 16 hex L key one is pro...

Page 47: ...ition You do not need to start the unit since vacuum is not needed for this procedure 3 Select CARPET UPH on the Solution Control switch 4 With the pump still on disconnect the solution hose from the...

Page 48: ...ted less than 3 to 5 seconds turn the pump screw clockwise one complete turn 3 With the pump still on reconnect the solution hose onto the Flex unit see Figure 4 4 The pump should switch on 4 Repeat s...

Page 49: ...nch 3 Remove the assembly from the dash the orifice plate will remain in the assembly 4 Remove the filter and orifice see Figure 4 7 5 Clean with a wire brush Descale if necessary 6 Re install the ass...

Page 50: ...mately 4 Hg is required at a minimum Sudden changes in pressure during the use of the machine might also cause a flickering of the indicator light Though it is never a bad idea to check the condition...

Page 51: ...cleaned out with warm soapy water isopropyl alcohol or other method Protect the van and the rest of the machine from debris by replacing one side cover of the plenum access port and using low pressur...

Page 52: ...5 1 Solution Flow Paths 5 Solution Flow Paths This section shows the high and low pressure flow diagrams...

Page 53: ...TER FLOAT SWITCH INLET WATER VALVE M M BYPASS VALVE NATURAL SOLUTION PUMP BLOWER AND ENGINE EXHAUST OUT COPPER FINNED TUBE HEAT EXCHANGER NATURAL SOLUTION ORIFICE FILTER NATURAL SOLUTION OUT FROM FLEX...

Page 54: ...APO PUMP RECOVERY TANK DRAIN VACUUM BLOWER ENGINE EXHAUST BLOWER EXHAUST BLOWER VACUUM COMBINED EXHAUST APO DRAIN FLOW BLOWER EXHAUST STAINLESS STEEL HEAT EXCHANGER BLOWER EXHAUST COPPER HEAT EXCHANG...

Page 55: ...formation Electrical Schematic Wiring Diagram The CTS 403 Flex electrical system operates on 12 V DC which is provided by the battery Battery levels are maintained by a 20 Amp alternator that is built...

Page 56: ...PUMP OUT FLOAT SWITCH PMP 3 AUTOMATIC PUMP OUT 6 TB2 5 TB2 1 TB2 6 TB1 3 N O TEMPERATURE CONTROLLER TC 1 TR2 TR1 TR3 TR4 TR6 TR8 TR5 TR7 GND PMP 4 NATURAL SOLUTION PUMP GND TEMPERATURE SENSOR SW 6 HIG...

Page 57: ...OX FLOAT SWITCH FS 1 18 GRN WHT 24 PNK 31 GRN 2 P1 1 TO PUMP CLUTCH RELAY CR 3 30 44 RED BLK 38 BLU WHT 20 BLK WHT 24 PNK P 8 J 8 25 PNK TO HIGH TEMP SHUTDOWN SW 4 TO TB1 6 14 BRN 14 GA 3 2 PUMP CONTR...

Page 58: ...K BLK TB 2 1 2 3 4 5 6 30 BRN 14 GA 27 WHT 14 GA 30 BRN 14 GA 43 WHT RED 28 WHT BLU BLK WHT 02 BLK 12 RED 16 GA B S ENGINE STARTER STARTER SOLENOID VOLT REG MTR 1 SOL 1 BATT VR 1 ST PUMP CLUTCH RELAY...

Page 59: ...7 1 Troubleshooting 7 Troubleshooting This section describes the standard troubleshooting procedures in the following areas Heating System Engine Tile System Carpet UPH System Vacuum System...

Page 60: ...a qualified service technician to test the temperature controller and sensor 2 0 Unable to achieve normal cleaning solution temperature Possible Cause Solution 2 1 Tile temperature control knob is tur...

Page 61: ...m System Troubleshooting Section 1 5 The ignition switch is faulty Test to see if there is power both to and from the switch Refer to the Electrical Section 1 6 The starter solenoid is faulty Test to...

Page 62: ...looded Pull the throttle cable completely and crank until the engine starts 3 4 The spark plugs are worn or dirty Inspect and replace as necessary 3 5 None of the above Refer to a qualified service te...

Page 63: ...ition near the fuel source Correct if necessary Check for blockage in the filter Repair or replace as necessary If operating altitudes have changed contact your distributor to have the engine carburet...

Page 64: ...eck the level and fill as necessary Running the engine with a low oil level can cause severe damage to the engine If this situation occurs the engine should be inspected by a qualified service technic...

Page 65: ...ssary Check the engine rpm and adjust as necessary to 3 150 rpm under a 0 Hg vacuum load 1 4 The tile primary orifice is missing or loose Remove and inspect Tighten or replace as necessary 1 5 The til...

Page 66: ...connect and replace as necessary 3 3 Restriction in one of the solution hoses Remove the quick connects and inspect hoses Clean or replace as necessary 3 4 Hard water deposits restricting the system D...

Page 67: ...Disassemble and inspect the valve Repair or replace as necessary 6 0 The water box overflows Possible Cause Solution 6 1 The float valve in the water box is faulty Disassemble and inspect the valve Re...

Page 68: ...0 minutes Run pump until all vinegar is flushed out of tank then add water to tank and flush any additional debris or chemical solution out of system Clean orifice and screen and install 1 5 Air is tr...

Page 69: ...Check the rpm of the engine Adjust as necessary to 3 150 rpm under a 0 Hg vacuum load 2 3 The vacuum gauge is defective Test the gauge and replace if necessary 3 0 The vacuum gauge reads too high with...

Page 70: ...e blower in this manner refer to a qualified service technician 5 2 There is internal damage to the blower Refer to a qualified service technician 6 0 Water in truckmount exhaust Possible Cause Soluti...

Page 71: ...7 13 Troubleshooting...

Page 72: ...y listed here and then find the part number listed on that specific page In most cases you do not have to order the entire assembly to get a part If you have an electronic copy a pdf of this manual yo...

Page 73: ...sealants thread lockers adhesive primer anti seize and lubricant specifications that are used in the construction of HydraMaster equipment Refer to Figure 8 1 to identify those substances such as A1...

Page 74: ...000 078 614 C 1 1 1 1 1 1 B ITEM NO QTY 13 1 K 12 1 K 11 1 K 10 1 H 9 1 H 8 1 H 7 1 H 6 1 H 5 1 A 4 1 A 3 1 A 2 1 A 1 1 A M 1 BREAK ALL SHARP EDGE UNLESS OTHERWIS DIMENSIONS ARE IN TOLERANCES X 1 XX 0...

Page 75: ...000 163 751 ASSEMBLY TANK 35 15 GAL HRI FLEX KIT 1 3 610 003 749 ASSEMBLY 70 GALLON URT CTS 403 1 4 000 041 707 ASSEMBLY COVER PUMP HRI FLEX 1 5 601 021 752 ASSEMBLY PUMP PASSENGER HRI FLEX KIT 1 6 00...

Page 76: ...1 ITEM NO QTY 13 1 KIT T 12 1 KIT P 11 1 KIT IN 10 1 HOSE 9 1 HOSE 8 1 HOSE 7 1 HOSE 6 1 HARN 5 1 ASSE 4 1 ASSE 3 1 ASSE 2 1 ASSE 1 1 ASSE MACH FINI 125 BREAK ALL SHARP EDGES 0 0 UNLESS OTHERWISE NO...

Page 77: ...LON URT CTS 403 1 4 000 041 707 ASSEMBLY COVER PUMP HRI FLEX 1 5 601 021 752 ASSEMBLY PUMP PASSENGER HRI FLEX KIT 1 6 000 063 078 HARNESS WIRE CTS 403 FLEX 1 7 000 068 598 HOSE 1 1 2 DUMP BLUE 1 8 000...

Page 78: ...ies and Parts Lists Figure 8 6 Console Assembly View 1 of 6 610 050 749 Rev C 7 6 5 4 3 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 16 2 4X 38 4X 39 4X 37 5X 38 5X 39...

Page 79: ...Assemblies and Parts Lists 8 8 Figure 8 7 Console Assembly View 2 of 6 610 050 749 Rev C D 8 7 6 5 E F 1 5 6 9 24 14 22 27 31 30 32 32 27 21...

Page 80: ...8 9 Assemblies and Parts Lists Figure 8 8 Console Assembly View 3 of 6 610 050 749 Rev C D C 4 3 2 1 E F 1 7 1 11 4 26 14 33 29 13 24 14 14 25 3 27 10 28 17 19 22 23 27 23 20...

Page 81: ...Assemblies and Parts Lists 8 10 Figure 8 9 Console Assembly View 4 of 6 610 050 749 Rev C A B C 5 6 7 8 34 33 29 13 6 9 24 14 35 36 2X 7 21 20 19 30 31 28...

Page 82: ...11 Assemblies and Parts Lists Figure 8 10 Console Assembly View 5 of 6 610 050 749 Rev C 3 4 5 6 SCALE 1 4 A M B B M B B L O L DRAWN CHECKED APPVD 14 26 34 33 25 29 13 12 14 18 34 17 19 22 23 7 21 20...

Page 83: ...Assemblies and Parts Lists 8 12 Figure 8 11 Console Assembly View 6 of 6 610 050 749 Rev C 3 4 5 6 7 8 35 125 4 188 24 000 30 940 33 451 28 000...

Page 84: ...27 HOSE ASSEMBLY 3 16 TEFLON X 44 LG ORIFICE TO REC TANK 1 22 000 068 760 HOSE ASSEMBLY 3 16 TEFLON X 71 LG HX TO CHEMDRY SOL OUT 1 Item Part Number Description Qty 23 000 068 724 HOSE ASSEMBLY 5 16 T...

Page 85: ...30 FT LBS TORQUE TO 30 FT LBS REVISIONS LTR DESCRIPTION CODE DATE BY CHKD APPVD A RELEASED DRAWING ECR 2773 06 16 2017 P E C I R ECRB 13 4 WASHER BLOWER FEET COATED ASTM A36 000 174 068 12 8 WASHER 5...

Page 86: ...ower Feet Coated 4 Item Part Number Description Qty See Figure 8 1 for adhesive sealant information NOTES 1 SEE ENG 45975 OR ADHESIVE M PRODUCTION LINE REFERENCE C FOR SEALANT INFORMATION B 0 56 1 055...

Page 87: ...t of label set P N 000 081 555 Individual labels not available for purchase 17 9 8 33 36 30 8X 40 8X 32 34 28 5 27 4 3 25 37 31 4X 40 4X 11 38 16 45 000 081 556 LABEL DASH 000 081 410 LABEL THERMOSTAT...

Page 88: ...HEAD S STEEL 29 1 REGULATOR HI PSI SNUBBER BRASS 28 1 QUICK CONNECT 660 3 8 BRASS W EPDM O RING BRASS 27 1 QUICK CONNECT 440 FEMALE w EPDM O RING BRASS 26 1 QUICK CONNECT 1 4 FEMALE S S AISI 303 25 1...

Page 89: ...4 NPT 1 21 000 052 533 NIPPLE 3 8 JIC x 1 4 NPT 1 22 000 094 009 NUT 1 4 20UNC NYLOCK 4 23 000 180 031 ORIFICE PLATE 0 052 1 Item Part Number Description Qty Item Part Number Description Qty 24 000 1...

Page 90: ...97 FOR ASSEMBLY INSTRUCTIONS 2 SEE ENG 45975 OR ADHESIVE MATERIAL PRODUCTION LINE REFERNCE CARD FOR SEALANT INFORMATION CUT ITEM 5 IN HALF 3 3 A B C 4 5 6 7 8 TORQUE TO 25 FT LBS 22 30 4X 23 2 7 13 HI...

Page 91: ...16 OPENING 40 LG 25 2 TEE 3 16 PLASTIC VACUUM INSERT 24 1 SHAFT B S 23HP STUB 23 2 SCREW 5 16 18UNC X 4 0 LG HEX HEAD 22 2 SCREW 5 16 18UNC X 3 5 LG GRADE 8 21 4 SCREW 10 24UNC x 0 50 LG HEX HEAD 20...

Page 92: ...x 60 LG 1 14 000 077 010 KEY 1 4 x 1 1 2 LG CLASS 2 FIT 2 15 000 094 081 NUT 5 16 18UNC HEX 2 WAY LOCKING 4 16 000 094 012 NUT 5 16 18UNC HEX 1 17 000 094 125 NUT 6MM HEX NYLOCK FLANGE S S 4 18 000 10...

Page 93: ...Washingto TOLERANCES X 1 XX 03 XXX 010 ANGULAR 2 BREAK ALL SHARP EDGES 0 005 015 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES ASSEMBLY EXHAUST CTS 403 MACHINE FINISH 125 INSTALL AFTER EXHAUST ASSE...

Page 94: ...4 000 052 106 Insert 1 8 NPT X 5 32 Barb X 90 Degree 2 5 000 094 092 Nut 7 16 20UNF Hex Jam 1 6 000 094 117 Nut 5 16 18UNC Hex Spiralock 1 7 000 143 012 Screw 5 16 18UNC X 3 4 Lg 1 8 000 143 132 Screw...

Page 95: ...US 000 125 199 11 4 SCREW 5 16 18UNC x 5 8 LG GRD 5 HEX HEAD STEEL 000 143 572 10 2 SCREW 5 16 18UNC x 1 75 LG HEX HEAD S STEEL 000 143 124 9 4 SCREW 1 4 20 X 1 2 GD8 ZINC HHC STEEL 000 143 758 8 4 NU...

Page 96: ...X 2 WAY LOCKING 2 8 000 094 078 NUT 5 16 18UNC HEX FLANGE 4 9 000 143 758 SCREW 1 4 20 X 1 2 GD8 ZINC HHC 4 Item Part Number Description Qty 10 000 143 124 SCREW 5 16 18UNC x 1 75 LG HEX HEAD 2 11 000...

Page 97: ...ENG 45975 OR ADHESIVE MATERIAL PRODUCTION LINE REFERNCE CARD FOR SEALANT INFORMATION 2 DO NOT BEND TAB WASHERS UNTIL AFTER THE FASTENERS ON THE ASSEMBLY HAVE BEEN TORQUED LTR REVISION DESCRIPTION COD...

Page 98: ...4X e Spec 16 5 lbs ft or 200 lbs in s in NOTES 1 SEE ENG 45975 OR ADHESIVE MATERIAL PRODUCTION LINE REFERNCE CARD FOR SEALANT INFORMATION ITEM NO QTY DESCRIPTION MATERIAL PART NO 9 4 WASHER 5 16 TAB S...

Page 99: ...y View 1 of 2 610 001 749 Rev B See Figure 8 1 for adhesive sealant information 12 5 2 000 081 327 LABEL ANSI WARNING TEXT ONLY 1 000 081 558 CLEAN FILTERS ORIFICES 8 13 1 B ADDED 033 128 143 583 WAS...

Page 100: ...24 Frame Assembly View 2 of 2 610 001 749 Rev B 12 13 6 13 7 13 6 13 9 5 2 1 000 081 327 LABEL ANSI WARNING TEXT ONLY 1 13 3 10 13 15 4 10 13 14 000 081 461 LABEL TILE STONE REGULATOR 11 13 INSTALL P...

Page 101: ...027 110 CAP 2 X 3 FRAME END 2 6 000 033 057 CLAMP 1 CUSHION LOOP 2 7 000 033 050 CLAMP 1 3 4 CUSHION LOOP 2 8 000 033 046 CLAMP 1 2 WIDE X 1 2 TUBE 1 9 000 033 067 CLAMP 2 CUSHION LOOP 1 10 000 033 1...

Page 102: ...LL SHARP EDGES 0 005 015 SIZE C 11015 47th Avenue West Mukilteo Washington 98275 PROPRIETARY INFORMATION SHEET 1 OF 1 SCALE 1 1 APPVD CHECKED DRAWN 125 MACHINE FINISH B R T L O L B R T BOXXER 318 CTS...

Page 103: ...r Temp Single Analog Input RTD 1 3 000 052 293 Insert 23 1 8 NPT X 3 16 Barb 3 4 000 094 034 Nut 10 24UNC Hex Nylock 3 5 000 106 014 Plug Vent 1 6 000 143 700 Screw 6 32UNC X 1 25 Lg Socket Head 2 7 0...

Page 104: ...CH PRESSURE 1 125 PSI VA 6 1 SCREW 5 16 18UNC x 3 4 LG HEX HEAD S 5 2 SCREW 2 56UNC X 5 8 LG PAN PHILLIPS S S S 4 3 NUT 10 24UNC HEX NYLOCK S 3 2 FUSE 25 AMP VAR 2 2 FUSE HOLDER IN LINE WEATHERPROOF V...

Page 105: ...27 30 21 22 28 12 24 10 6 1 23 8 29 11 32 PART OF 000 149 025 25 4X 7 2X A3 A3 A3 A2 20 4 2X 5 2X 4 2X 5 2X 4 2X 5 2X 18 2 7 2X 31 17 13 19 9 3 25 8X 33 34 26 13 9 25 8X B B B B B B 2 ITEM NO Q 34 33...

Page 106: ...SENSOR 6 90 RTD 1 29 000 052 190 TEE 1 4 BRANCH SS 1 30 000 052 023 TEE 3 8 NPT MALE STREET 1 31 000 125 347 TUBE 2 5 OD x 3 5 LG AL 1 32 000 169 589 VALVE 3 8 HI PSI SS CHECK 1 33 000 174 001 WASHER...

Page 107: ...00 052 153 Housing Stabilizer Nozzle 2 4 000 052 530 Nipple 1 4 SAE X 1 8 NPT 1 5 000 052 586 Nipple 1 8 FPT X 1 4 SAE 2 6 000 052 582 Nipple Tee Jet Style Collar X 1 8 NPT 2 7 000 094 028 Nut Brass J...

Page 108: ...8 37 Assemblies and Parts Lists Figure 8 30 Pump Assembly 610 007 747 Rev B See Figure 8 1 for adhesive sealant information...

Page 109: ...w 1 8 NPT X 1 4 SAE 1 6 000 052 086 Elbow 3 8 NPT Street 1 7 000 068 219 Hose Drain 1 8 000 052 129 Insert 812 1 2NPT X 3 4 Hose 1 9 000 094 038 Nut 5 16 18UNC Hex Nylock 2 10 000 105 148 Plate Clutch...

Page 110: ...e Assembly Parts List 1 000 052 086 Elbow 3 8 NPT Street 1 2 000 052 105 Insert 68 3 8 NPT X 1 2 Barb 2 3 000 052 528 Nipple 3 8 M JIC X 3 8 NPT 1 4 000 052 074 Nipple 3 8 NPT Hex 1 5 000 106 008 Plug...

Page 111: ...4 Hose 2 5 Heat Flex NS X 1 5 Lg 1 3 000 068 985 Hose 2 5 Heat Flex NS X 12 Lg 1 4 000 108 036 Protector Silencer 1 5 000 143 583 Screw 10 24UNC X 0 50 Lg Hex Head Flange Z P 4 6 000 093 022 Silencer...

Page 112: ...COATED TITAN 325 1 2 000 081 559 LABEL DOME CTS FLEX 1 3 000 084 027 LAMP 12V LED 12MM PANEL MOUNT BLUE 2 4 000 094 034 NUT 10 24UNC HEX NYLOCK 10 5 000 094 058 NUT 10 32UNF HEX NYLOCK 4 6 000 100 388...

Page 113: ...E HOSE USE A 13 16 DRILL BIT TO ROUTE THE OVERFLOW HOSE TO THROUGH THE VAN S FLOOR 10 10 23 12 24 23 15 26 A3 A3 B 2 NOTES 1 SEE ENG 45975 OR ADHESIVE MATERIAL PRODUCTION LINE REFERNCE CARD FOR SEALAN...

Page 114: ...K HEAD 2 19 000 143 739 SCREW 8 15 X 3 4 LG PH SHEET METAL SS 6 20 000 143 017 1 SCREW 3 8 16UNC x 0 75 LG HEX HEAD 3 21 000 157 0801 SWITCH w PROTECTOR POLYPRO BARREL NC 1 22 000 159 190 TANK POLY WA...

Page 115: ...1 4 NPT BRONZE 25 1 PLUG 1 1 2 NPT BRONZE 24 1 PLUG 1 NPT BRONZE 23 1 PLATE BLOWER FLAT FILTER 22 8 NUT 1 4 20UNC NYLOCK 21 2 NUT 8 32UNC HEX NYLOCK 20 2 NUT 6 32UNC HEX NYLOCK 19 1 NUT 10 24UNC HEX N...

Page 116: ...TR REVISION DESCRIPTION B C D 8 7 6 5 4 3 A TOLERANCES X 1 XX 03 XXX 010 ANGULAR BREAK ALL SHARP UNLESS OTHE DIMENSIONS A C 750 010 749 10 750 010 758 10 Figure 8 36 70 Gallon Universal Recovery Tank...

Page 117: ...1 1 2 NPT BRONZE 1 26 000 106 046 PLUG 1 1 4 NPT BRONZE 1 27 000 108 179 PROTECTOR VACUUM RELIEF COATED 1 28 000 140 023 RIVET AB8 6A ALUMINUM POP 4 29 000 079 226 SACRIFICIAL ANODE MAGNISIUM 1 30 00...

Page 118: ...SIDE RECOVERY TANK 2 8 LATCH BUNGEE STRIKE PART OF 000 086 008 1 9 000 094 063 NUT 6 32UNC HEX NYLOCK 2 10 000 143 539 SCREW 6 32UNC x 0 50 LG BUTTON HEAD 2 B NOTES 1 ADHERE ITEMS 4 5 7 TO BOTTOM SIDE...

Page 119: ...AR 2 4 Vacuum Relieft Valve URT Assembly Parts List Item Part Number Description Qty 1 000 015 182 BRACKET VACUUM RELIEF VALVE FABRICATED 1 2 000 027 032 CAP SPUN VACCUM RELIEF VALVE 1 3 000 094 101 N...

Page 120: ...TERIAL PART NO 3 2 INSERT 1 1 2 NPT x 1 1 2 BARB GREY PVC 000 052 226 2 1 HOSE 1 5 I D RED STRIPE X 48 LG VARIOUS 000 068 882 1 2 CLAMP 2 T BOLT S STEEL 000 033 063 D C B A 1 2 3 3 2 1 DRAWN CHECKED A...

Page 121: ...S S NYLOK HALF 2 6 000 108 025 PROTECTOR MAGNESIUM ANODE UNMODIFIED 2 7 000 143 132 SCREW 10 24UNC x 0 75 LG HEX HEAD 2 8 000 143 171 SCREW 10 24UNC x 1 25 LG HEX HEAD 2 9 000 174 015 WASHER 10 EXTER...

Page 122: ...Protector Bulkhead 2 2 3 1 D ITEM NO QTY DESCRIPTION MATERIAL PART NO 4 2 PROTECTOR BULKHEAD AISI 304 2B 000 108 196 3 1 FRAME 12 X 53 TANK COATED STEEL 000 055 217 2 1 ASSEMBLY TANK 35 GAL 15 GAL VAR...

Page 123: ...Tank Flex Chemical Caddy Assembly Parts List 1 000 015 1265 Bracket Tank Stiffener 4 2 000 015 1264 Bracket Tank Tray Rib 3 3 000 094 071 Nut 1 4 20UNC Nylock Half 12 4 000 143 333 Screw 1 4 20UNC X...

Page 124: ...2 ELBOW 1 2 NPT X 1 2 H 4 2 COVER 6 ACCESS 3 11 CLAMP SIZE 6 MINI HO 2 5 CLAMP 1 CUSHION LOO 1 2 BULKHEAD A B C D 3 4 5 6 7 8 8 7 6 5 4 3 E F USED ON NEXT ASSY APPLICATION UNLESS OTHERWISE NOTED DIMEN...

Page 125: ...I D CLR X 54 LG BRAID DRAIN HOSE 1 Item Part Number Description Qty Item Part Number Description Qty 12 000 068 678 HOSE 1 2 I D CLRE X 78 LG BRAID VENT HOSE 2 13 000 089 003 MAGNET TREADMASTER 2 14 0...

Page 126: ...ssembly 000 163 751 Rev C 50 Gallon Tank Flex Kit Assembly Parts List 1 000 163 756 Assembly Chemical Caddy 50 Gallon 1 2 000 163 750 Assembly Tank 50 Gallon 1 3 000 055 215 Frame 12 X 60 Tank Coated...

Page 127: ...2 3X 50 Gallon Tank Flex Chemical Caddy Assembly Parts List 1 000 015 1265 Bracket Tank Stiffener 6 2 000 015 1264 Bracket Tank Tray Rib 3 3 000 094 071 Nut 1 4 20UNC Nylock Half 12 4 000 143 333 Scr...

Page 128: ...50 GALLON MODIFIED POLYETHYLENE 000 159 259 18 1 SCREW 10 24UNC x 0 50 LG HEX HEAD S STEEL 000 143 126 17 9 SCREW 8 15 X 3 4 LG PAN HEAD SS S STEEL 000 143 739 16 1 PLUG 3 8 NPT ALLEN HEAD S STEEL 000...

Page 129: ...041 707 Rev B Pump Cover Flex Assembly Parts List Item Part Number Description Qty 1 000 041 706 Cover Pump 1 2 000 089 003 Magnet 2 3 000 094 034 Nut 10 24UNC Nylock 2 4 000 143 107 Screw 10 24UNC X...

Page 130: ...0 033 003 1 1 ASSEMBLY PUMP HRI FLEX VARIOUS 601 021 800 ITEM NO QTY DESCRIPTION MATERIAL PART NO D C B E F UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES BREAK ALL SHARP EDGES 0 005 015 11015 47th A...

Page 131: ...or 2 Pole Water Tight Female 1 4 000 052 747 Elbow 3 8 S S Street 90 1 5 000 052 355 Elbow 3 8 NPT X 1 2 Hose GFBN 1 6 000 068 1032 Hose 1 2 I D PVC X 8 Lg Braided Pump to Strainer 1 7 000 052 749 Ins...

Page 132: ...601 021 752 601 021 800 PRESSURE SWITCH UPPER HOUSING VALVE HOUSING ASSEMBLY LOWER HOUSING ASSEMBLY Part No Description 000 078 938 Pressure Switch Kit 000 078 939 Upper Housing Kit Includes the Press...

Page 133: ...0 LG BLACK VACUUM HXER PLENUM BACK PRESSURE SENSOR 000 068 997 HOSE 1 4 I D RUBBER X 60 LG POP OFF VALVE THERMO VALVE TEE 000 068 969 HOSE 1 2 I D RUBBER x 69 LG FRESH WATER IN WB 000 068 968 HOSE 1 2...

Page 134: ...rrect the problem with your truckmount make arrangements with your distributor to either perform the repairs or ship the parts to you We shall always endeavor to be fair in our evaluation of your warr...

Page 135: ...How to Order Parts 9 2...

Page 136: ...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 prot...

Page 137: ...d tear from everyday use CLEANING WAND AND TOOL Failure to protect against freezing Obvious physical abuse of wand or tool WATER HEATING SYSTEM Over pressurization of the system recommended maximum wo...

Page 138: ...LUDING BUT NOT LIMITED TO INDIRECT SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE FURNISHING PERFORMANCE USE OF OR INABILITY TO USE THE MACHINE ANY EXTENSIONS OF OR MODIFICA...

Page 139: ...TO THE HYDRAMASTER STANDARD LIMITED WARRANTY Flex System items which are not included in HydraMaster Standard Limited Warranty Flex tank assemblies Flex diaphragm pumps Strainers These listed items ar...

Page 140: ......

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