his manual contains operating instructions as well as information required
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for proper maintenance, adjustment and repair of this unit. Since the first
and most important part of repair work is the correct diagnosis of the problem,
component manual troubleshooting charts have been included for your convenience.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two
functions to perform, the truckmounted carpet cleaning plant has many functions to perform simultaneously.
The engine has to run at a consistent RPM.
The vacuum has to pull air and dirty water back from cleaning site.
The water pump must provide a stable pressure at proper water flow
for cleaning.
The chemical has to be injected into the water stream at the right
concentration.
The heating system must provide a consistant water temperature.
The vacuum tank must store dirty water until drained.
As you can see, it is not just a turn-key operation with one thing to worry
about, Does it start?!
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10/20/99
Page 1-2Clutch Drive System
♦ WARNING ♦
The manufacturer uses this symbol throughout the manual to warn of possible
injury or death.
♦ CAUTION ♦
This symbol is used to warn of possible equipment damage.
10/20/99
Business Hours and Telephone Numbers
Monday - Friday(425) 775-7276 Parts
8:00 am to 5:00 pm(425) 775-7275 Service
PACIFIC STANDARD TIME800) 426-4225 Parts / Service FAX
HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-3
Precautions
lthough this unit has been factory adjusted, it may require additional ad
adjustments to achieve optimum performance, for instance altitude may
A
require carburetor adjustment and ambient temperatures may require heat control adjustment. When required, consult an authorized representative.
♦ CAUTION ♦
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van
floor. Many vans have critical components mounted directly below the van
floor that could be damaged by a misplaced drill bit. (See Product Support
Bulletins 92102, 94062 and 94063 at the end of the manual.)
♦ CAUTION ♦
LEVEL OPERATION: During operation, van or trailer must be parked on level
ground not to exceed + or - 10 degrees. Failure to insure proper leveling may
prevent proper internal lubrication of engine, vacuum and/or high pressure components.
♦ WARNING ♦
MOVING PARTS: Never touch any part of the machine that is in motion.
Severe bodily injury may result.
HydraMaster Corporation
CDS 4.6
10/20/99
Page 1-4Clutch Drive System
♦ CAUTION ♦
ACID RINSE AGENTS: The increased demand for clear water rinsing results
in the need for special care when using these acid based chemicals in your
equipment. The negative side of these products is the corrosive effects the
acid can have on metals, including swivels, pumps, heat exchangers, etc.
HydraMasters ClearWater Rinse has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from
using unprotected acid products that have obviously caused failures.
♦ CAUTION ♦
HARD WATER PROTECTION: Failure to take appropriate measures to prevent
scale build up can result in system failure and loss of warranty on affected
parts. Test the water in your immediate and surrounding areas with hard water
test strips. Assume all water obtained from wells is hard. If you are operating
in a Hard Water Area (3.5 grains or more per gallon), use a water softening
system.
♦ CAUTION ♦
FREEZE PROTECTION: There is often little warning before a cold spell. Therefore, not protecting this equipment from freezing will result in costly downtime. Placing an electric heater in the truck or parking the truck indoors will
help to insure against freezing, but should not be the primary method of freeze
protection.
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HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-5
♦ WARNING ♦
HOT SURFACES: During the operation of this equipment, many surfaces on
the machine will become very hot. When near the van for any reason care
must be taken not to touch any hot surface, such as heater, engine, exhaust,
etc.
♦ WARNING ♦
HEARING PROTECTION: The Occupational Safety and Health Administration
(OSHA) recommends the use of hearing protection when a technician is exposed to an average of 85 decibels (this is an average of exposure over an 8
hour period). This equipment can produce 85 decibels to a distance of 10 feet.
Please check with your local state agencies to see if OSHA standards apply to
your application.
♦ WARNING ♦
NO SMOKING: It is unsafe to smoke in or around the vehicle.
♦ WARNING ♦
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so
that the fumes will be directed away from the job site. Do not park where
exhaust fumes can enter a building through open doors, windows, air conditioning units or kitchen fans.
♦ WARNING ♦
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is
operating. Toxic fumes may accumulate inside a stationary vehicle.
HydraMaster Corporation
CDS 4.6
10/20/99
Page 1-6Clutch Drive System
♦ WARNING ♦
ENGINE EXHAUST: The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects or other reproductive harm.
♦ WARNING ♦
PORTABLE GAS TANK: Never operate this machine with a portable gas can
inside the truck. Doing so increases the risk of a fire or explosion.
♦ WARNING ♦
PORTABLE PROPANE TANK: Do not use a portable tank inside of the truck or
van. It is dangerous and illegal in most states.
♦ WARNING ♦
TRANSPORTATION OF FUEL CONTAINERS: Transportation in a vehicle of any
vented fuel container that presently has or has ever contained a flammable
liquid is strictly forbidden by HydraMaster Corporation and by federal and state
regulation.
10/20/99
HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-7
System Overview
he HydraVan CDS machines are highly engineered cleaning plants designed
T
by HydraMaster Corporation. The system utilizes the most current
technology available in water heating and water recovery systems.
The water flow is as follows:
Water is fed into the machine under tap pressure. The water enters the
machine and is combined with cleaning solution as it enters the mix tank.
The cleaning solution is picked up from the mix tank by the high pressure
pump and pumped under pressure through the heating system and then
out to the cleaning tool.
After the water is applied to the carpet, it is recovered by the vacuum
system and carried back to the recovery tank.
As there is no guess work in the manufacture of these highly advanced cleaning plants, there must be none in preparing it to get the job done in the field. It
is the purpose of this manual to help you properly understand, maintain and
service your cleaning plant. Follow the directions carefully and you will be
rewarded with years of profitable, trouble-free operation.
It is imperative that no section be overlooked when preparing for operation of
this equipment.
HydraMaster Corporation
CDS 4.6
10/20/99
Page 1-8Clutch Drive System
Machine Specifications
Frame:13"W x 68"L x 38"H
Weight:575 lbs.
Construction:Tank:Marine Aluminum with Baked-on Epoxy Finish
Chassis:Painted Steel
Cowling:Fiberglass
Power Transfer:Electric Clutch-driven shaft, Key Activated
TM
Vacuum Blower:45 WhispAir
Water Pump:CAT® Triple Plunger 4 gallons per minute
Chemical System:Electro-mechanical, Meter Controlled
Component Power Pack
Equipment Cowling with Armrests
Vacuum Recovery Tank
Control Console
Dual Wand Hook-up
HydraMaster Heat Exchanger System
Freeze Guard System
Wheel Chock Set
Carpet Wand
150', 2" Vacuum Hose
10' 1½ Vacuum Hose
HydraMaster Corporation
CDS 4.6
150', HP Solution Line
50' Fresh Water Hose
10' 1½ Drain Line
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Page 1-10Clutch Drive System
Standard Equipment (cont.):
5 gallon Chemical Jug
Chemical Jug Holder
Chemical Jug Fill Line
Van Finish Package
Van-Sentry Package
Van Decal Package
Monogrammed Jacket
Operation Manual
Custom Equipment Color
Oversize Air Handling Package
Expanded Vacuum Recovery Tank Capacity
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HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-11
Spare Parts
own-time on the unit can be very expensive, because your truck-mounted
D
unit is capable of generating several hundred dollars per day. In order to
minimize such down-time, it is strongly recommended by the manufacturer
that you purchase and keep in your truck the parts listed below.
Parts Orders
To expedite your parts needs, please call your sales representative. In most
instances, he either stocks or has access to parts through a regional service
center. If further assistance is needed, contact the factory and coordinate your
needs. If this becomes necessary, always indicate the method of shipment you
desire, i.e. UPS, Blue Label, Air Freight, Air Express, etc.
HydraMaster Parts Dept. Phone ............. (425) 775-7276
HydraMaster Parts Dept. Toll Free Fax .... 1-800-426-4225
078-102Kit, Pressure By-pass Valve1
078-270Kit, Valve for 3CP Cat Pump2
078-271Kit, Seals for 3CP Cat Pump1
157-0012Switch, Tethered Float
157-022Switch, Relay1
157-040Switch, 12 VDC Lighted2
169-022Valve, 1½ Full Port Ball1
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HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-13
Responsibilities
rior to the arrival of the unit, the van that it will be installed in should be
P
delivered to the installer.
Purchasers Responsibility:
It is the purchasers responsibility to Read the Owners Manual and to familiar-
ize yourself with the information contained therein. Special attention should be
paid to all Cautions and Warnings.
Sales Representatives Responsibility:
Acceptance of Shipment
1. If the unit shows any outward signs of damage, do not sign the
delivery receipt until you have closely inspected the unit and noted any
damage on the delivery receipt.
2. The salesman from whom you purchased your unit is responsible for
supervising the correct installation of the unit in your vehicle and
thoroughly training you in its operation, maintenance and precautions.
Installation
Correctly installing the unit and recovery tank in your vehicle and
securing them with bolts and tie down washers.
Checking the pump, vacuum blower and engine oil levels prior to starting
the unit.
Starting the unit to check the drive system and see that all other
systems function normally.
Checking all hoses, wands, etc. for correct operation.
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CDS 4.6
10/20/99
Page 1-14Clutch Drive System
Training
A thorough review of the operation manual with the purchaser.
Instruction and familiarization in: how to correctly start up and shut
down the unit, how to correctly clean with the unit, where and how often
to check and change component oil levels, how the units systems work,
how to troubleshoot the unit, how to do basic repairs, safety precautions
and their importance, freezing damage and how to avoid it, hard water
damage and how to avoid it.
A thorough review of the unit warranty and warranty procedures.
A thorough review of hard water precautions and warnings.
How to determine hard water areas.
Use of water softening systems.
10/20/99
HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-15
Local Water Precautions
he quality of water varies greatly. Many areas have an excess of minerals
T
in the water which results in what is commonly called hard water. These
minerals tend to adhere to the insides of heater coils and other parts of the
machines causing damage and a loss of cleaning effectiveness. This influences
the reliability and efficiency of equipment in direct proportion to the level of
hardness.
HARD WATER ADVISORY
HydraMaster recognizes that any hard water deposits which might occur within
the water system of our truckmounts is a serious problem. The precision
technology of truckmount heat exchanger systems is intolerant of any foreign
material. Hard water deposits will ultimately decrease the performance of the
system and are expected to seriously lower the reliability of the machine.
To validate a machines warranty, HydraMaster requires that all machines operating in designated Hard Water Areas (3.5 grains or more per gallon) be fitted
with a water softening system or a properly installed magnetic-type de-scaler
must be used and maintained. Periodic de-scaling or acid-rinsing alone is not
adequate in these areas. HydraMaster does not recommend any particular type
or brand, however the relative effectiveness of some types of magnetic descalers or softeners may require additional periodic use of de-scaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines
in all areas be fitted with a water softening system for improved operation and
reliability.
HydraMaster Corporation
CDS 4.6
10/20/99
Page 1-16Clutch Drive System
HydraMaster has included five hard water test strips with your machine. These
can be used to test the water in your immediate and surrounding areas as they
can vary greatly. Assume all water obtained from wells is hard.
♦ CAUTION ♦
Failure to take appropriate measures to prevent scale build up can result in
system failure and loss of warranty on affected parts.
HARD WATER AREA MAP
The following map defines areas in the United States which compromise fluid
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.
WATER SOFTENER
Cleaning efficiency and equipment life is increased, chemical use decreased,
and the appearance of cleaned carpets enhanced when water softeners are
incorporated in hard water areas. The manufacturer strongly urges the use of
water softener units in areas exceeding 3½ grains per gallon. Failure to use a
water softener in these areas will invalidate the machines warranty. Using a
hard water area map as a reference, determine the quality of water in your area
and take action immediately, if necessary.
Reports from several of our machine users commending the results of the use
of water softeners in conjunction with their machines prompts us to recommend the procedure to everyone in a hard water area.
The relatively low cost of a water softener service is more than made up for by
an increased life of machine parts, reduced chemical costs and continued cleaning
efficiency. The water softener will also increase the effectiveness of the cleaning chemicals, therefore less chemical will be needed.
10/20/99
HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-17
Contact a water softener distributor in
your area for information on the rental
of a simple water treatment unit to carry
in your truck. Be sure to change the
water softener in accordance with the
capability of the softener. For example:
If the softener will treat 900 gallons of
water and the machine uses an average of 30 gallons per hour, for an average of 5 hours a day, this equals 150
gallons per day. In 6 days the machine would use 900 gallons of water.
Therefore, the softener would need to be changed every 6 working days for
maximum softening.
Figure 1-1 Location of Water
Softener
WASTE WATER DISPOSAL ADVISORY
There are laws in most communities prohibiting the dumping of recovered gray
water from carpet cleaning in any place but a sanitary treatment system.
This cleaning rinse water, recovered into your units vacuum tank, contains
materials such as detergents. These must be processed before being safe for
streams, rivers and reservoirs.
IN ACCORDANCE WITH THE EPA, STATE AND LOCAL LAWS, DO NOT
DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS,
RESERVOIRS, ETC.
In most cases, an acceptable method of waste water disposal is to discharge
into a municipal sewage treatment system after first filtering out solid material
such as carpet fiber. Access to the sanitary system can be obtained through a
toilet, laundry drain, RV dump, etc. Permission should first be obtained from
any concerned party or agency. One disposal method which usually complies
HydraMaster Corporation
CDS 4.6
10/20/99
Page 1-18Clutch Drive System
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 yourself with an
Automatic Pump-Out System. These systems are designed to remove waste
water from the extractors recovery system and actively pump the water through
hoses to a suitable disposal drain. Properly designed, they will continuously
monitor the level of waste water and pump it out simultaneously to the cleaning operation. The hidden benefit of this process is that the technician does not
have to stop his cleaning to empty the recovery tank. HydraMaster makes an
A.P.O. System available which can be ordered with new equipment or installed
later.
The penalties for non-compliance can be serious. Always check local laws and
regulations to be sure you are in compliance.
10/20/99
HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 1-19
Figure 1-2 Hard Water Map
HydraMaster Corporation
CDS 4.6
10/15/99
Cleaning and Chemicals
CDS 4.6
Section 2-1
our mobile carpet cleaning plant has been engineered using the latest
Y
and most sophisticated technology available to produce the finest carpet
cleaning results possible. Despite this, however, it remains only a tool of the
carpet cleaning trade, and it can produce only as good a job as the person
operating it.
PRECAUTIONS
There are no short cuts to good carpet cleaning. It requires time, cleaning
knowledge and the use of good chemicals. Therefore, the manufacturer recommends the use of spotting agents and traffic lane cleaners, as required, prior
to the actual cleaning of carpeting.
The use of some chemicals through your mobile carpet cleaning plant can
seriously damage the internal plumbing, high pressure pump and heater.
These harmful chemicals include concentrated acid (see the pH chart at the
end of this section), solvents, and some paint, oil, and grease removers with
a high concentration of solvents.
The manufacturer recommends only the use of chemicals containing rust and
corrosion inhibitors and water softening agents to prevent chemical build-up
which may lead to component failure and warranty invalidation.
♦ CAUTION ♦
The increased demand for clear water rinsing results in the need for special
care when using these acid based chemicals in your equipment. The negative
side of these products is the corrosive effects the acid can have on metals,
including swivels, pumps, heat exchangers, etc.
HydraMaster Corporation
10/20/99
Page 2-2Clutch Drive System
HydraMasters ClearWater Rinse has been formulated to protect vital components. HydraMaster will not warranty parts that have been damaged from
using unprotected acid products that have obviously caused failures.
The use of detergents and chemicals which create foam when agitated should
be avoided. Foam passing through the blower could lead to serious problems.
HydraMaster and SafeClean chemicals are formulated with built in anti-foaming
agents. When cleaning surfaces with excessive foaming residue use HydraMaster Powder Defoam as directed.
CLEANING STROKE PROCEDURE
Purpose:
To eliminate excess moisture remaining in the carpet fiber and the sawtooth
appearance which results from diagonal movement of the cleaning tool on all
types of carpet.
Procedure:
Always move the cleaning tool in smooth, forward and backward strokes.
Apply slight pressure to the forward stroke while the solution is injected into
the carpet. When extracting (drying), apply firm pressure on the forward stroke
to ensure a positive lock for the vacuum and minimize the hopping effect
resulting on carpet that is not smooth. During the forward and reverse strokes,
movement to the right or left should only be accomplished at the extreme rear
of the stroke. Overlapping is also important to ensure even application of
solution and prevent saturation when cleaning wand is stopped twice at the
same point at the rear of the cleaning stroke. This is illustrated at the end of
this section.
Failure to adopt this procedure can result in increased chance of clean streaks,
fiber shrinkage, brown-out and longer drying periods.
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HydraMaster Corporation
CDS 4.6
Clutch Drive System Page 2-3
OVER-WETTING
Over-wetting is annoying to all concerned, and sometimes leaves a bad impression of the cleaning process used.
These are Several Areas That Will Cause Over-wetting:
1.Too few vacuum strokes or improper saw-tooth vacuum strokes as shown
in the following illustration.
2.Obstructed, cut or kinked hoses.
3.Vacuum tank drain valve left partially open.
4.Clogged vacuum blower filter or vacuum tank lid not sealing properly.
5.Cleaning a heavily foam-saturated carpet without defoamer.
(We recommend crystal type.)
HydraMaster Corporation
CDS 4.6
10/20/99
Page 2-4Clutch Drive System
10/20/99
HydraMaster Corporation
CDS 4.6
Operating Instructions
CDS 4.6
Section 3-1
BEFORE OPERATING THE UNIT
1.Operate the unit and equipment only in a well ventilated area.
♦ CAUTION ♦
Exhaust fumes contain carbon monoxide and may be hazardous to your health.
Do not operate this truck where the exhaust may enter any building doorway,
window, vent, or opening of any kind.
2.Check the fuel tank to be certain there is adequate fuel to complete
the job.
3.Position the wheel chocks on one of the front tires.
4.If using a water supply hose which has not been used recently or if
using a customers hose, first connect the hose to the faucet and flush
out any debris which may be in the hose. Afterwards connect the hose
the unit.
5.Check your chemical jug to see if you have enough concentrated
chemical to finish the job. If not, mix and fill a five gallon chemical jug.
6.Connect all required hoses.
7.When connecting the pressure hose to the pressure outlet connections
at the front of the unit, go to the farthest area to be cleaned and
connect to the cleaning tool. This insures that you have the proper
length of hose required to perform the cleaning.
HydraMaster Corporation
10/20/99
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