HYDRAMASTER CDS 4.8, CDS 4.6 User Guide
Clutch Drive System
4.8 / 4.6 Owner’s Manual
HydraMaster North America, Inc. - 11015 47th Avenue West,
Mukilteo, Washington 98275
Copyright 2009 HydraMaster North America, Inc.
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
All rights reserved.
Revised July 10, 2009
HydraMaster North America, Inc.
Table of Contents
GENERAL INFORMATION ........................................................................... SECTION 1
Contact Information ........................................................................... 1-2
Warnings, Cautions and Notices ....................................................... 1-3
Machine Specications ...................................................................... 1-6
Responsibilities .................................................................................. 1-8
Purchaser’s Responsibility ................................................................ 1-8
Sales Representative’s Responsibility ............................................... 1-8
Local Water Precautions .................................................................... 1-9
Hard Water Advisory .......................................................................... 1-9
Hard Water Area Map ........................................................................ 1-10
Water Softener ................................................................................... 1-11
Waste Water Disposal Advisory ......................................................... 1-12
CHEMICALS AND CLEANING .................................................................... SECTION 2
Cleaning 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 System Maintenance ......................................................... 5-2
Chemical System Troubleshooting .................................................... 5-3
1.0. System will not prime ........................................................... 5-3
2.0. Chemical ow is unstable or low .......................................... 5-3
3.0. Chemical jug lls with water ................................................. 5-4
i - CDS 4.8 / 4.6 Owner’s Manual
WATER PUMP MAINTENANCE .................................................................. SECTION 6
Daily Maintenance ............................................................................. 6-1
Periodic Maintenance ........................................................................ 6-2
Water Pump Troubleshooting ............................................................ 6-3
1.0.Will not come up to normal cleaning pressure ...................... 6-3
2.0. No pressure reading on PSI gauge ...................................... 6-3
3.0. PSI gauge reads normal; low pressure from tool/wand ....... 6-4
4.0. Pressure pulsation ............................................................... 6-4
5.0.Water box empty or lls slowly .............................................. 6-4
6.0. Water box overows ............................................................. 6-5
ASSEMBLIES AND PARTS LISTS ............................................................... SECTION 7
CDS Machine Assembly Parts List .................................................... 7-3
CDS Recovery Tank Assembly Parts List .......................................... 7-6
CDS Recovery Tank Cover Assembly Parts List ............................... 7-7
CDS Instrument Panel Assembly Parts List....................................... 7-10
CDS Hi-PSI Manifold Assembly Parts List ......................................... 7-11
CDS By-Pass Valve Assembly Parts List ........................................... 7-12
CDS 4.8 Pump and Blower Assembly Parts List ............................... 7-15
CDS 4.6 Pump and Blower Assembly Parts List ............................... 7-18
CDS Pump Assembly Parts List ........................................................ 7-20
CDS DuraFlow Automatic 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-Gallon Rotomolded Fresh Water Tank Assembly Parts List ......... 7-42
85-Gallon Rotomolded Fresh Water Tank
with Reel Assembly Parts List ................................................. 7-43
125-Gallon HydraCradle Tank Assembly Parts List * ......................... 7-47
CDS Pass Through Assembly Parts List ........................................... 7-48
CDS Standard Heat Exchanger Assembly Parts List ........................ 7-49
CDS Heat Exchanger Assembly Parts List ........................................ 7-50
CDS Salsa 2005 - 2009 Assembly Parts List..................................... 7-51
Ford Hush Kit Mufer Assembly Parts List - 4.8 ............................... 7-52
Chevy Hush Kit Mufer Assembly Parts List - 4.8 ............................ 7-53
Silencer Assembly Parts List - 4.6 ..................................................... 7-54
CDS Belts Parts List .......................................................................... 7-55
Cleaning Wand Valve Assembly Parts List ........................................ 7-56
CDS 4.8 / 4.6 Owner’s Manual - ii
Cleaning Wand Solution Valve Assembly Parts List .......................... 7-57
Cleaning Wand Valve Stem Assembly Parts List ............................... 7-58
Hydra Hoe Wand Assembly Parts List ............................................... 7-60
GM Cowling Assembly, 2003 – 2009 Parts List (P/N 601-020-008) .. 7-61
2009 Ford Cowling Assembly Parts List (P/N 601-020-001) ............. 7-61
CDS Parts Kit List (P/N 000-078-069) ............................................... 7-61
2009 GM Throttle Kit Parts List (P/N 000-078-430) ........................... 7-62
2009 Ford Throttle Kit Parts List (P/N 000-078-405) ......................... 7-62
VACUUM BLOWER SYSTEM ...................................................................... SECTION 8
Vacuum Tank Inlet Filter .................................................................... 8-2
Vacuum Blower Lubrication ............................................................... 8-2
Vacuum Blower 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
Operational Maintenance................................................................... 10-1
Appearance Maintenance .................................................................. 10-4
Long-Term Maintenance Schedule .................................................... 10-5
Drive Shaft Maintenance ................................................................... 10-6
Troubleshooting ................................................................................. 10-7
Heating System ................................................................................. 10-7
Miscellaneous .................................................................................... 10-8
HOW TO ORDER PARTS ............................................................................ SECTION 11
Warranty Parts Orders ....................................................................... 11-1
Parts Orders ...................................................................................... 11-1
Emergencies ...................................................................................... 11-1
One Final Note................................................................................... 11-1
iii - CDS 4.8 / 4.6 Owner’s Manual
WARRANTY INFORMATION ....................................................................... SECTION 12
Blower ............................................................................................... 12-1
High Pressure Water Pump .............................................................. 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
List of Figures
Figure 1-1. Hard Water Map of Mainland United States ................................ 1-10
Figure 1-2. Conguration of Water Softener and CDS .................................. 1-11
Figure 2-1. pH Chart ........................................................................................ 2-1
Figure 2-2. Cleaning Stroke Procedure ...........................................................2-3
Figure 3-1. Location of Controller’s LED Lights
with Labels and RPM Trim Potentiometers ............................................3-4
Figure 3-2. Location of 3 Lights on Throttle Control Assembly ........................3-6
Figure 7-1. CDS Machine Assembly - Front View ...........................................7-1
Figure 7-2. CDS Machine Assembly - Rear View ............................................7-2
Figure 7-2. CDS Recovery Tank Assembly - Front View ................................. 7-4
Figure 7-3. CDS Recovery Tank Assembly - Rear View .................................. 7-5
Figure 7-4. CDS Recovery Tank Cover Assembly ...........................................7-7
Figure 7-5. CDS Instrument Panel Assembly - Front View .............................. 7-8
Figure 7-6. CDS Instrument Panel Assembly - Rear View ..............................7-9
Figure 7-7. CDS Hi-PSI Manifold Assembly .................................................. 7-11
Figure 7-8. CDS By-Pass Valve Assembly ....................................................7-12
Figure 7-9. CDS 4.8 Pump 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 - Overall View ..................................7-23
Figure 7-17. CDS Dash Box Assembly - Rear View ......................................7-24
Figure 7-18. CDS Dash Panel Assembly - Overall View ...............................7-26
Figure 7-19. CDS Dash Panel Assembly - Rear View ...................................7-27
Figure 7-20. CDS Water Box Assembly - Overview ......................................7-28
Figure 7-21. CDS Water Box Assembly - Parts View .................................... 7-29
Figure 7-22. CDS Diffuser Filter Assembly ....................................................7-31
Figure 7-23. CDS Vacuum Relief Valve Assembly ........................................7-32
Figure 7-24. CDS Front End 2003 - 2009 GM Assembly - Overview ............7-33
Figure 7-25. CDS Front End 2003 - 2009 GM Assembly - Parts View .......... 7-33
Figure 7-26. Horizontal Pump In Tank Assembly - Front ............................... 7-35
Figure 7-27. Horizontal Pump In Tank Assembly - Rear ................................ 7-36
Figure 7-28. Free Standing Tray Assembly ................................................... 7-38
v - CDS 4.8 / 4.6 Owner’s Manual
Figure 7-32. 85-Gallon Rotomolded Fresh Water Tank with Reel Assembly . 7-43
Figure 7-33. 125-Gallon HydraCradle™ Tank Assembly - Parts View 1 of 3 . 7-44
Figure 7-34. 125-Gallon HydraCradle Tank Assembly - Parts View 2 of 3 .... 7-45
Figure 7-35. 125-Gallon HydraCradle Tank Assembly - Parts View 3 of 3 .... 7-46
Figure 7-36. CDS Pass Though Assembly .................................................... 7-48
Figure 7-37. CDS Standard Heat Exchanger Assembly ................................ 7-49
Figure 7-38. CDS Heat Exchanger Assembly................................................ 7-50
Figure 7-39. CDS Salsa 2005- 2009 (Chevy) Assembly................................ 7-51
Figure 7-40. Ford Hush Kit Mufer Assembly - 4.8 ........................................7-52
Figure 7-41. Chevy Hush Kit Mufer 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 Assembly ......................................................7-59
Figure 9-1. CDS Electrical Schematic ............................................................. 9-2
Figure 9-2. CDS Wiring Diagram .....................................................................9-3
Figure 9-3. CDS Wiring Diagram .....................................................................9-4
Figure 10-1. Zerk Fittings and Spline Locations on Drive Shaft .................... 10-6
CDS 4.8 / 4.6 Owner’s Manual - vi
List of 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
1 - General Information
The Clutch Drive System (CDS) 4.8 and 4.6 Truckmounts are highly engineered carpet
cleaning machines developed, designed and manufactured by HydraMaster Corporation.
The systems utilize the most current technology available in water heating and water
recovery systems.
As there is no guess work in the manufacture of these highly advanced cleaning systems,
there must be none in preparing the CDS to get the job done in the eld. 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 protable, 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.
It is imperative that no section be overlooked when preparing for operation of this equipment.
Please read this Owner’s Manual to familiarize yourself with the operation of the 4.8 and
4.6 Truckmount Systems, paying special attention to all Warnings and Cautions.
This section of the manual contains the following helpful information:
Contact Information
Warnings, Cautions and Notices
Machine Specications
Responsibilities
Local Water Precautions
1-1: General Information
Contact Information
If you have any questions regarding the operation, maintenance or repair of this machine,
please contact your local distributor.
To nd a local distributor, please 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
Pacic Standard Time (800) 426-4225 Parts / Service FAX
General Information: 1-2
Warnings, Cautions and Notices
HydraMaster uses 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.
1-3: General Information
Warnings and Cautions specic to the CDS 4.8 / 4.6 include:
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 the engine or the exhaust.
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.
NO SMOKING: It is unsafe to smoke in or around the vehicle. Do not allow any open
ames in or around the vehicle.
CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so that the
fumes will be directed away from the job site. Do not park where exhaust fumes can enter
a building through open doors, windows, air conditioning units or kitchen fans.
TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operating.
Toxic fumes may accumulate inside a stationary vehicle.
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.
MOVING PARTS: Never touch any part of the machine that is in motion. Severe bodily
injury may result.
General Information: 1-4
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 (see the pH chart in Figure 2-1),
solvents (including d-Limonene), and some paint, oil and grease removers with a high
concentration of solvents.
THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van oor.
Many vans have critical components mounted directly below the van oor that could be
damaged by a misplaced drill bit.
LEVEL OPERATION: During operation, the vehicle must be parked on level ground
not to exceed + or - 10 degrees. Failure to ensure proper leveling may prevent proper
internal lubrication of engine, vacuum and/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 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 at 3.0 grains or more
per gallon, use a water softening system.
FREEZE PROTECTION: Failure to take appropriate measures to prevent equipment
damage due to freezing can result in system failure and loss of warranty on affected
parts. Placing an electric heater in the vehicle or parking the vehicle indoors will help
ensure against freezing, but should not be the primary method of freeze protection.
1-5: General Information
Machine Specications
Frame: 23” W x 41.5” H x 61.0” L
Weight: 912 lbs.
Construction: Tank: Marine Aluminum with Baked-on Epoxy Finish
Chassis: Painted Steel
Cowling: Fiberglass
Power Transfer: Electric Clutch-driven shaft, Key Activated
Vacuum Blower: 4.6 - 45 Tuthill/M-D Tri-Lobe
4.8 - 47 Tuthill/M-D Tri-Lobe
Water Pump: Plunger pump, 4.0 gpm (at high speed), 2,500 psi, electric clutch
control
Chemical System: Mechanical, Meter Controlled
Heating 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 Gauge, Liquid Filled, 0-1,500 psi
Side Panel:
Water Pressure Adjustment
Blower Lubrication Port
Water Temperature Adjustment Knob
High Pressure Solution Outlets, Quick-Disconnect
Fresh Water Inlet Fitting, Quick-Disconnect
Water Box Drain Valve
Chemical Controls
General Information: 1-6
Recovery Tank: 100 gallon Aluminum
Cleaning Tool/
Wand: Stainless Steel
Replacement Grip
Rebuildable Solution Valve
High Pressure Hose:
1/4” High Temperature, Lined, Vinyl Covered
Hose rated to 2,200 psi, 250° F
Standard Equipment:
Power Transfer 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 ½” Vacuum Hose
50', Fresh Water Hose (Garden Hose)
10', 1 ½” Drain Line
5 gallon Chemical Jug
Chemical Jug Holder
Van Finish Package
Van Decal Package
Monogrammed Jacket
Owner’s Manual
Equipment Color Selection
Hushkit Silencer System (4.8)
1-7: General Information
Responsibilities
Prior to the arrival of the unit, the van that it will be installed in should be delivered to the
installer.
Purchaser’s Responsibility
If you are the purchaser, it is the your responsibility to read the Owner’s Manual and to
familiarize yourself with the information contained herein, paying special attention to all
Warnings and Cautions.
Sales Representative’s Responsibility
Acceptance of Shipment
If the unit shows any outward signs of damage, do not sign the delivery receipt until 1.
you have closely inspected the unit and noted any damage on the delivery receipt.
The sales representative from whom you purchased your unit is responsible for 2.
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, tools/wands and accessories for correct operation.•
Training
A thorough review of the Owner’s Manual with the purchaser.•
Instruction in and familiarization with: •
How to correctly start up and shut down the unit1.
How to correctly clean with the unit2.
Where and how often to check and change component oil levels3.
How the unit’s systems work, how to troubleshoot the unit4.
How to do basic repairs5.
Safety precautions and their importance 6.
How to avoid freezing damage7.
How to avoid hard water damage8.
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.•
General Information: 1-8
Local Water Precautions
The quality of water varies greatly. Many areas have an excess of minerals 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 inuences the reliability and efciency 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 machine’s warranty, HydraMaster requires that all machines operating in
designated “Hard Water Areas” (3.0 grains or more per gallon) be tted with a water
softening system, or a properly installed magnetic-type descaler must be used and
maintained. Periodic descaling 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 descaling agents.
HydraMaster also recommends, in the strongest possible terms, that machines in all areas
be tted with a water softening system for improved operation and reliability.
Failure to take appropriate measures to prevent scale build up can result in system failure
and loss of warranty on affected parts.
1-9: General Information
HARD WATER AREA MAP
The hard water map, shown in Figure 1-1, denes hard water areas in the lower 48 United
States which compromise uid related components such as hoses, ttings, 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 Mainland United States
The map shown in Figure 1-1 is provided for general reference only. Water hardness in
your geographical location should be conrmed by testing.
General Information: 1-10
WATER SOFTENER
Cleaning efciency and equipment life is increased, chemical use decreased, and the
appearance of cleaned carpets enhanced when water softeners are incorporated in
hard water areas. HydraMaster strongly urges the use of water softener units with the
CDS 4.8/4.6 machines in areas exceeding 3.0 grains per gallon (see Figure 1-2).
Failure to use a water softener in these areas will invalidate the machine’s warranty.
Referring to the hard water area map shown Figure 1-1, determine the quality of water in
your area and take immediate action if
the water hardness exceeds 3.0 grains
per gallon.
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 efciency. 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. 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 1-2. Conguration of Water
Softener and CDS
1-11: General Information
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.
The cleaning rinse water, recovered into your unit’s vacuum tank, contains materials
such as detergents, and must be safely processed before entering streams, rivers and
reservoirs.
In most cases, an acceptable method of waste water disposal is to discharge into a
municipal sewage treatment system after rst ltering out solid material such as carpet
ber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV
dump, etc. Permission should rst be obtained from any concerned party or agency.
One disposal method which usually complies 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 ordered with new equipment or
installed later.
When properly congured, the systems will continuously monitor the level of waste water
and pump it out simultaneously with the cleaning operation. The hidden benet of this
process is that the technician does not have to stop his/her cleaning to empty the recovery
tank.
IN ACCORDANCE WITH EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF
WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC.
The penalties for non-compliance can be serious. Always check local laws and regulations
to be sure you are in compliance.
General Information: 1-12
2 - Chemicals and Cleaning
Your mobile carpet cleaning plant has been engineered using the latest and most
sophisticated technology available to produce the nest carpet cleaning results possible.
Despite this, it remains only a tool of the carpet cleaning trade and can produce only as a
good a 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 some paint, oil and grease removers with a high concentration of solvents (see pH
chart in Figure 2-1.
Figure 2-1. pH Chart
2-1: Chemicals and Cleaning
CLEANING 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 trafc lane cleaners, as required, prior to the actual cleaning of carpeting.
HydraMaster also 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.
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.
HydraMaster will not warranty parts that have been damaged from using acid products
that have obviously caused failures.
Avoid using detergents and chemicals which create foam when those products are
agitated because foam passing 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 ber and eliminate the sawtooth
appearance which results from diagonal movement of the cleaning tool, follow these
steps.
Always move the cleaning tool in smooth, forward and backward stroke1.
Apply slight pressure to the forward stroke while the solution is injected into the 2.
carpet.
When extracting (drying), apply rm pressure on the forward stroke to ensure a 3.
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 4.
done at the extreme rear of the stroke.
Overlapping is also important to ensure even application of solution and prevent 5.
saturation when the cleaning tool is stopped twice at the same point at the rear of
the cleaning stroke Figure 2-2.
Chemicals and Cleaning: 2-2
Figure 2-2. Cleaning Stroke Procedure
Failure to adopt the previous procedure can result in increased chance of “clean streaks,”
ber shrinkage, brown-out and longer drying periods.
OVERWETTING
Overwetting is annoying to all 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 lter or vacuum tank lid not sealing properly.4.
Cleaning a heavily foam-saturated carpet without defoamer. 5.
2-3: Chemicals and Cleaning
3 - Operating Instructions
This section of the manual contains the following instructions:
Before Operating the CDS
CDS Start Up
CDS Flood Restoration Work
CDS Shut Down
3 Speed Throttle Control Function
BEFORE OPERATING THE CDS
Locate the unit and equipment in a well-ventilated area.1.
The CDS 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.
Check the fuel 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, rst connect the hose to the faucet and ush 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 concentrated chemical to nish 5.
the job. If not, mix and ll a 5 gallon chemical jug.
Connect all required hoses.6.
When connecting the pressure hose to the pressure outlet connections at the front of 7.
the unit, go to the farthest area to be cleaned and connect to the cleaning tool. This
ensures that you have the proper length of hose required to perform the cleaning.
3-1: Operating Instructions
CDS START UP
Make sure the vehicle’s gear select lever is in the Park position and the emergency 1.
brake is set
Start the vehicle’s engine.2.
Turn key on the CDS dash.3.
Select the cleaning speed appropriate for the cleaning job.4.
Turn on the PUMP CLUTCH switch. Adjust cleaning pressure to desired level.5.
Turn on the PUMP IN switch (if equipped).6.
Turn the heat control valve to “Max” only if you will be using water. Do not activate 7.
the heat exchanger during ood extraction work.
Turn the CHEMICAL SYSTEM valve to the “PRIME” position to purge any air from 8.
the system.
The prime hose is plumbed into the recovery tank. Leaving the valve in the “PRIME”
position will cause excessive chemical usage.
When the chemical begins to ow through the owmeter, with the ow indicator a.
reading maximum ow and the PRIME line pulsing, turn the CHEMICAL SYSTEM
valve to “ON”. Cap off vacuum if necessary.
While spraying the solution from the cleaning tool, adjust the chemical ow 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 pump will not engage until the water level rises inside the recovery tank.
Now proceed with the cleaning operation.10.
The machine will automatically shut down when it reaches its full capacity due to the oat
switch located inside the recovery tank. When this occurs, turn the switch off and empty
the recovery tank. Then, turn the unit back on and continue to clean.
CDS FLOOD RESTORATION WORK
When using equipment for ood damage, adjust the high pressure pump to zero. This will
reduce the engine power load and save on fuel consumption.
Operating Instructions: 3-2
CDS SHUT DOWN
Flush clear water through the chemical system for 10 seconds.1.
Open the water box drain and actuate the tool/wand valve to run fresh water through 2.
the water box, heat exchangers and cleaning tools.
If freeze guarding is necessary, perform the freeze guard procedure at this time. Draining
the water box to ½ full or less is recommended to reduce spillage inside the vehicle.
Rinse the system with vinegar on a weekly basis. Rinse the entire system with descaler
each month.
Lay vacuum hoses out in order for all moisture to be removed from the hoses. This 3.
prevents spillage of any dirty solution in your vehicle when storing the hoses.
Disconnect the hoses and put them away.4.
If you are using an outside water source, turn the water supply faucet off. Bleed 5.
pressure out of the supply hose by loosening the hose 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 located on the front panel above the pressure gauge.)
Remove the inlet plugs, then turn the 8. ignition “OFF” before draining the recovery
tank.
Turn the heat control valve to the ‘OFF’ position. This will help avoid engine overheat 9.
problems due to reduced coolant ow through the radiator.
Drain the recovery tank.10.
Do not dump waste in any area which might violate local, state or federal law. If
you have the optional Automatic Pump-Out (APO) system, drain the recovery tank into a
sanitary drain system.
When the recovery tank is drained, lift the recovery tank lid and remove the lter 11.
basket.
Clean out an12. y accumulated debris.
Rinse and re-install.13.
3-3: Operating Instructions
3 speed Throttle Control function
▬ For GM Vans ▬
The GM Throttle Controller must meet certain “Chassis Ready” conditions to elevate the
engine rpm, which are as follows:
Parking Brake is set1.
Gear shift is in “Park”2.
Foot is off Service Brake (brake pedal)3.
Foot is off Accelerator Pedal4.
Vehicle is stationary (no speed)5.
Engine is started and idling6.
The A/C / Heater switch is in off position7.
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 labels to provide status
and problem detection information (refer to Figure 3-1 and Table 3-1).
LED LIGHTS WITH
LABELS
Location of Controller’s LED Lights Figure 3-1.
with Labels and RPM Trim Potentiometers
3 TRIM POTS
Operating Instructions: 3-4
GM Throttle Controller LED FunctionsTable 3-1.
LED STATUS INDICATION
BUSS On Solid Unit ON and functioning
(harness connected to data
link)
BUSS Flashing Unit ON, but a problem was
detected
GEAR On Solid Transmission in PARK
GEAR Flashing Transmission NOT in Park
PK BRK On Solid Parking Brake Set
PK BRK Flashing Parking Brake is NOT set
SR BRK On Solid Service Brake is set (not
being used)
SR BRK Flashing Service Brake is NOT set
VSPEED On Solid Vehicle is 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, the PCM engine computer will cause the engine speed to
momentarily drop back to normal idle speed every time the air conditioner pump cycles on
or off. Make sure the operator of the CDS understands that the AC / HEAT switch needs
to be in the OFF position before activating the CDS unit.
3-5: Operating Instructions
▬ For Ford Vans ▬
The Ford 3 Speed Throttle Controller must meet certain “Chassis Ready” conditions to
elevate the engine rpm, which are:
Parking Brake is set.1.
Gear shift is in “Park”.2.
Foot is off Service Brake (brake pedal).3.
Foot is off Accelerator Pedal.4.
Vehicle is stationary (no speed).5.
Brake light circuit is functional.6.
Engine coolant is above 140° F.7.
Transmission Oil Temperature is below 240° F.8.
Maximum Catalytic Temperature has not been met.9.
SEIC (Stationary Elevated Idle Control)* will be 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: all the “Chassis Ready” conditions have been met and the SEIC 2.
process has been initiated.
GREEN LIGHT: the Throttle Control assembly is receiving power from the CDS and 3.
the SEIC process is operational.
Location of 3 Lights on Throttle Control AssemblyFigure 3-2.
* SEIC is Ford’s onboard computer throttle control strategy.
Operating Instructions: 3-6
1.Van ignition ‘ON’
2.CDS ignition ‘OFF’
1.Van ignition ‘ON’
2.CDS ignition ‘ON’
3.Recovery tank NOT full
4.SEIC NOT active
“Chassis ready” conditions HAVE NOT been meta.
1.Van ignition ‘ON’
2.CDS ignition ‘ON’
3.Recovery tank NOT full
4.SEIC IS active
“Chassis ready” conditions HAVE NOT been a.
violated
1.Van ignition ‘ON’
2.CDS ignition ‘ON’
3.Recovery tank NOT full
4.SEIC IS active
“Chassis ready” conditions HAVE been violateda.
1.Van ignition ‘ON’
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’
2.CDS ignition ‘OFF’
3.Recovery tank NOT full *
4.SEIC IS active
“Chassis ready” conditions HAVE NOT been a.
violated
Ford Throttle Controller Light FunctionsTable 3-2.
WHEN… CONTROL LIGHT(S)
Red
Red
Green
Yellow
Green
Red
Green
Yellow
Yellow
Yellow
**
**
*Turn CDS ignition “OFF” before draining recovery tank.
**SEIC process will continue until a “chassis ready” condition has been violated. To clear
single yellow light conditions, van ignition needs to be turned “OFF”.
3-7: Operating Instructions
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