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55: CTS 400 Flex Owner’s Guide

INTERVAL HOURS - 25 TO 575

Engine oil and filter

Blower oil

High pressure

pump oil

Low pressure pump

tuning

SERVICE

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575

Inspect recovery tank

filters for tears,

holes, etc. Repair or

replace as needed.

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Inspect the vacuum

relief valve. Clean

and lubricate as

necessary.

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Clean the recovery

tank thoroughly with

pressure washer.

C/I

Check the oil level in

the blower. Add oil if

needed.

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Check the pump

drive belt for wear

and proper tension.

Tighten as needed.

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Check all the hoses

and wiring for wear

and chafing. Secure

as needed.

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Flush the water and

chemical systems

with solution of equal

parts white vinegar

and water.

Check all the nuts

and bolts. Tighten as

needed.*

CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH CH

Change the engine

oil and filter every 50

hours. (Every 25

hours if operating in

high ambient

temperatures or

heavy use

conditions.)

SERVICE

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575

Check the engine air

filter. Clean or

replace as

necessary.

Check the water level

in battery. Fill as

needed.

Clean QC filter and

orifice with water

C/I

Clean the battery

terminals as needed.

C/I

Lubricate inlet float

plunger with

SuperLube O-ring

grease #92003 or

equivalent.

C/L

SERVICE

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575

Check the coupler

element (rubber

insert) for cracks or

wear. Replace as

necessary.

Check the fuel lines.

Repair or replace as

needed.

Gap the spark plugs

to 0.030”. Replace if

excessive carbon

buildup is visible.

C/I

Change the fuel filter.

Change pump drive

belt.

SERVICE

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575

Change the blower

oil.

Change the high

pressure pump oil.

Check the engine

valve clearance

(intake and exhaust

0.004” - 0.006”)

Change the fuel filter.

SERVICE

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575

Change air filters.

Check carburetor.

Clean or replace as

necessary.

Replace the coupler

element (rubber

insert) for cracks or

wear. Replace as

necessary

Clean the heat

exchanger core.

Adjust

Check

Clean and Inspect

Clean and Lubricate

Flush

Replace

MAN-46783 Rev. A

Perform Flex pump tuning procedure every 60 days

DAILY MAINTENANCE CTS 400

Check the engine oil level. Add oil if needed.

Check the high pressure pump oil. Add oil if needed.

Inspect and clean the recovery tank filters.

Inspect and clean the orifices and filters.

Inspect and clean the garden hose screen.

Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed.

Lubricate the blower lube port with HydraMaster-recommended spray lubricant.

INTERVAL IN HOURS CTS 400

Change engine oil and filter after first 8 hours; afterwards, change the engine oil and filter every 50 hours.

Change the blower oil after first 100 hours of use.

Change high pressure pump oil after first 50 hours of operation. (Every 500 hours thereafter.)

C/I

C/L

* Check engine and blower mounting bolts, coupler retaining bolts, exhaust fasteners, etc.

Inspect and rinse the recovery tank.

Содержание ChemDry CTS 400 Flex

Страница 1: ...orm or by any means i e graphic electronic photocopying or electronic retrieval systems without the express written permission of Harris Research Inc Specifications and information in this document ar...

Страница 2: ......

Страница 3: ...eted by you and the distributor and returned to HydraMaster to activate your warranty Your warranty starts on the date of installation Please ensure the form is filled out completely and returned to u...

Страница 4: ......

Страница 5: ...f information The Machine Maintenance and Logs section is located within this Owner s Guide It is wise to keep the Owner s Guide in a visible location near the CTS 400 Flex so that the log stays up to...

Страница 6: ...this 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 _____________________________...

Страница 7: ...rer 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 stat...

Страница 8: ...monoxide 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 u...

Страница 9: ...e may 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...

Страница 10: ...kmount 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 ca...

Страница 11: ...to 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...

Страница 12: ...vels 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 pack...

Страница 13: ...Consumption 1 0 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...

Страница 14: ...acuum Hose 2 Vacuum Hose 100 ft 1 1 2 Wand Whip Line 10 ft Recovery Tank 65 gallon MaxAir Universal Tank Battery Box Van Decal Van Installation Kit Owner s Manual on CD Owner s Guide paper copy Option...

Страница 15: ...MACHINE 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 Fr...

Страница 16: ...ydraMaster 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 in...

Страница 17: ...id 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 Hard Water Map of...

Страница 18: ...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...

Страница 19: ...mplies 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 400 Flex with an Automatic Pump Out System AP...

Страница 20: ...CTS 400 Flex Owner s Guide 16...

Страница 21: ...ng 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 hose to the quick connect Carpet Uph Cleanin...

Страница 22: ...unt with the throttle cable fully depressed IDLE position see Figure 2 5 After the engine starts push the choke in and allow the truckmount to run in IDLE for 2 to 3 minutes to warm up 6 Pull the thro...

Страница 23: ...Auto Pump Out APO switch to the ON position The PUMP OUT system will not engage until the water level rises inside the recovery tank 6 Now proceed with the cleaning operation The machine will automati...

Страница 24: ...is running see Figure 2 d Allow the machine to run an additional 2 to 5 minutes under load to flush off lubricant e Uncap the inlet and run the unit for another minute to allow the blower to cool down...

Страница 25: ...in pump is used turn the AUX switch to the ON position see Figure 2 The water box must be full prior to starting the truckmount 3 Connect all solution and vacuum hoses and the APO hose if equipped 4 S...

Страница 26: ...ide the recovery tank 8 Now proceed with cleaning operation Never perform cleaning operations when the truckmount engine is running at IDLE throttle position Failure to follow this caution will increa...

Страница 27: ...evers are in the vertical position the flow is turned OFF 2 Open the Flex chemical tank lid s and fill the chemical tank s with appropriate ChemDry chemical until the chemical levels off below the tan...

Страница 28: ...e lever toward the direction of the flow toward the hose connected to the pump strainer see Figure 7 and Figure 8 To drain the pumps turn the lever away from the flow To turn the flow off turn the lev...

Страница 29: ...This section also includes a maintenance schedule and maintenance logs which must be correctly and completely filled out see page 45 page 52 An Interval Hours Maintenance Chart is on page 55 and page...

Страница 30: ...ck 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 and water Check all the nuts and bolts Tighten as need...

Страница 31: ...he engine valve clearance intake and exhaust 0 004 0 006 Change the fuel filter Check coupler element rubber insert for cracks or wear Replace as necessary 1000 Hours Change air filters Check carburet...

Страница 32: ...d 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 never be...

Страница 33: ...tion 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 eac...

Страница 34: ...Packing 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...

Страница 35: ...lace 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...

Страница 36: ...eely Two brass knurled nuts are located on the side of the recovery tank see Figure 10 2 Increase the vacuum of the system by turning the nut clockwise tightening 3 Decrease the vacuum of the system b...

Страница 37: ...minutes with the vacuum hose disconnected in order to remove moisture from the blower 2 Capping off the inlet s to the recovery tank 3 Spraying a HydraMaster recommended spray lubricant into the BLOWE...

Страница 38: ...the recirculation 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...

Страница 39: ...eeze and water mix to the water box 3 Attach a section of solution hose to the outgoing solution fitting on the front of the machine Attach the opposite end to the recirculation fitting If more sectio...

Страница 40: ...the truckmount 4 Spray the solution through the hoses and wands into a sealable container until all signs of antifreeze are gone Freeze Protection of the Pump In System 1 Drain the fresh water tank 2...

Страница 41: ...e 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 tighten...

Страница 42: ...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...

Страница 43: ...hich is close to the center of the pump head with a hex L key provided in the Flex Installation Kit see Figure 12 Clockwise increases the pressure Counterclockwise decreases the pressure Tools require...

Страница 44: ...position 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...

Страница 45: ...hose is disconnected 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 12 The pump should swit...

Страница 46: ...wrench 3 Remove the assembly from the dash the orifice plate will remain in the assembly 4 Remove the filter and orifice see Figure 15 5 Clean with a wire brush Descale if necessary 6 Re install the a...

Страница 47: ...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...

Страница 48: ...RANTY ADDENDUM 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...

Страница 49: ...days Check the water level in battery Fill as needed Clean the battery terminals as needed ATTENTION Special Maintenance Change the engine oil every 50 hours Every 25 hours if operating in high ambie...

Страница 50: ...n the heat exchanger core Check the engine valve clearance intake and exhaust 0 004 0 006 Quarterly Maintenance 1000 Hours Maintenance Gap the spark plugs to 0 030 Replace if excessive carbon buildup...

Страница 51: ...ck the water level in battery Fill as needed Clean the battery terminals as needed ATTENTION Special Maintenance Change the engine oil every 50 hours Every 25 hours if operating in high ambient temper...

Страница 52: ...n the heat exchanger core Check the engine valve clearance intake and exhaust 0 004 0 006 Quarterly Maintenance 1000 Hours Maintenance Gap the spark plugs to 0 030 Replace if excessive carbon buildup...

Страница 53: ...ck the water level in battery Fill as needed Clean the battery terminals as needed ATTENTION Special Maintenance Change the engine oil every 50 hours Every 25 hours if operating in high ambient temper...

Страница 54: ...n the heat exchanger core Check the engine valve clearance intake and exhaust 0 004 0 006 Quarterly Maintenance 1000 Hours Maintenance Gap the spark plugs to 0 030 Replace if excessive carbon buildup...

Страница 55: ...ck the water level in battery Fill as needed Clean the battery terminals as needed ATTENTION Special Maintenance Change the engine oil every 50 hours Every 25 hours if operating in high ambient temper...

Страница 56: ...nance Clean the heat exchanger core Check the engine valve clearance intake and exhaust 0 004 0 006 Quarterly Maintenance 1000 Hours Maintenance Gap the spark plugs to 0 030 Replace if excessive carbo...

Страница 57: ...ck the water level in battery Fill as needed Clean the battery terminals as needed ATTENTION Special Maintenance Change the engine oil every 50 hours Every 25 hours if operating in high ambient temper...

Страница 58: ...n the heat exchanger core Check the engine valve clearance intake and exhaust 0 004 0 006 Quarterly Maintenance 1000 Hours Maintenance Gap the spark plugs to 0 030 Replace if excessive carbon buildup...

Страница 59: ...bricate inlet float plunger with SuperLube O ring grease 92003 or equivalent C L C L C L C L C L SERVICE 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 Check the...

Страница 60: ...bricate inlet float plunger with SuperLube O ring grease 92003 or equivalent C L C L C L C L C L C L C L SERVICE 600 625 650 675 700 725 750 775 800 825 850 875 900 925 950 975 1000 1025 1050 1075 110...

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