HYDRAMASTER CDS 4.8, CDS 4.6 User Manual

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Page 1

HYDRAMASTER

Corporation

1 1015 47th A venue W , Mukilteo, W A 98275

HYDRAMASTER© Corporation

Mukilteo, Washington

MAN-182-037-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 the HYDRAMASTER© Corporation. All rights reserved.

Revised September 06, 2007

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GENERAL INFORMATION ......................................................................... Section 1

Telephone Numbers........................................................................... 1-2

Precautions ....................................................................................... 1-3

System Operation ............................................................................. 1-7

Machine Specifications ..................................................................... 1-8

Spare Parts Recommendation .......................................................... 1-11

Spare Parts List ...................................................................... 1-11

Responsibilities................................................................................. 1-13

Local Water Precautions ................................................................... 1-15

Wastewater Disposal Advisory ............................................... 1-17

Map ........................................................................................ 1-19

CLEANING AND CHEMICALS .................................................................. Section 2

pH Chart ............................................................................................ 2-4

OPERATING INSTRUCTIONS ................................................................... Section 3

Start Up ............................................................................................. 3-2

Shut Down ......................................................................................... 3-3

FREEZE GUARD ........................................................................................ Section 4

Vacuum Freeze Guard Procedure ..................................................... 4-1

Freeze Protection of Pump-In System ................................................ 4-3

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WATER AND CHEMICAL SYSTEM .................................................................... Section 5

Water Flow Diagram............................................................................................ 5-3

Chemical System Troubleshooting ........................................................................ 5-5

HIGH PRESSURE PUMP ................................................................................... Section 6

Pump Maintenance .............................................................................................. 6-1

Service ............................................................................................................... 6-3

Cat Pump Assembly Drawing and Parts List ......................................................... 6-8

Pump Troubleshooting ....................................................................................... 6-11

CDS MACHINE ASSEMBLIES AND PARTS ......................................................Section 7

4.8 & 4.6 Assembly Drawings and Parts Lists ....................................................... 7-1

4.6 (Only) Assembly Drawings and Parts Lists .................................................... 7-37

Front End 2003+ GMC ...................................................................................... 7-52

CDS Belts ......................................................................................................... 7-66

Cleaning Wand Assembly Drawings and Parts Lists ............................................ 7-68

VACUUM SYSTEM ............................................................................................. Section 8

Lubrication Instructions ......................................................................................... 8-3

Blower Troubleshooting ........................................................................................ 8-5

Dominator Blower Instruction Booklet

ELECTRICAL SYSTEM ...................................................................................... Section 9

Wiring Schematic ................................................................................................ 9-2

Wiring Diagrams ................................................................................................. 9-5

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ELECTRICAL SYSTEM (cont.)

Electrical Troubleshooting .................................................................................... 9-9

MACHINE MAINTENANCE ............................................................................ Section 10

Operational Maintenance.................................................................................... 10-2

Daily, Weekly .................................................................................................... 10-2

Monthly ............................................................................................................. 10-3

Quarterly, Yearly ................................................................................................ 10-4

Descaling ......................................................................................................... 10-4

Overall Machine Maintenance ............................................................................ 10-5

Daily, Weekly .................................................................................................... 10-5

Long Term Maintenance Schedule ......................................................................... 10-7

Drive Shaft Maintenance ........................................................................................ 10-8

Troubleshooting ..................................................................................................... 10-9

Maintenance Logs

HOW TO ORDER PARTS............................................................................... Section 11

WARRANTY INFORMATION .......................................................................... Section 12

Golden Guarantee©

ACCESSORIES .............................................................................................. Section 13

PRODUCT UPDATES .................................................................................... Section 14

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List of Figur es

Fig 1-1 Location of Water Softener.............................................................. 1-16

Fig 1-2 Hard Water Map .............................................................................. 1-19

Fig 2-1 pH Chart .......................................................................................... 2-4

Fig 2-2 Cleaning S troke Procedure.............................................................. 2-4

Fig 5-1 Water Flow Diagram ....................................................................... 5-3

Fig 6-1 Servicing the Valves ........................................................................ 6-3

Fig 6-2 Servicing the Low Pressure and High Pressure Seals ...................6-5

Fig 6-3 Cat Pump ........................................................................................ 6-8

Machine Assemblies and Part s:

Fig 7-1 CDS 4.8 Machine Assembly - Front View .......................................7-1

Fig 7-2 CDS 4.8 Machine Assembly - Rear View........................................ 7-2

Fig 7-3 CDS 4.8 Recovery Tank Assembly - Rear View..............................7-4

Fig 7-4 CDS 4.8 Recovery Tank Assembly - Front View ............................. 7-5

Fig 7-5 CDS 4.6/4.8 Recovery Tank Cover Assembly................................. 7-8

Fig 7-6 CDS 4.6/4.8 Instrument Panel Assembly........................................ 7-9

Fig 7-7 CDS 4.6/4.8 Instrument Panel Assembly........................................ 7-10

Fig 7-8 CDS 4.6/4.8 Hi-PSI Manifold Assembly........................................... 7-13

Fig 7-9 CDS 4.6/4.8 By-Pass Valve Assembly ............................................ 7-15

Fig 7-10 CDS 4.6/4.8 Dual Heat Exchanger Assembly................................. 7-17

Fig 7-1 1 CDS 4.8 Pump and Blower Assembly.............................................7-19

Fig 7-12 CDS 4.6/4.8 Pump Assembly.......................................................... 7-23

Fig 7-13 CDS 4.6/4.8 Chemical Pump Assembly ......................................... 7-25

Fig 7-14 CDS 4.6/4.8 DuraFlow APO Pump Assembly.................................7-26

Fig 7-15 CDS 4.8 Dash Assembly ................................................................ 7-27

Fig 7-16 CDS 4.8 Dash Panel Assembly ...................................................... 7-29

Fig 7-17 CDS 4.8 Water Box Assembly ........................................................ 7-31

Fig 7-18 CDS 4.6/4.8 Diffuser Filter Assembly.............................................. 7-33

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Fig 7-18 CDS 4.6/4.8 Diffuser Filter Assembly.............................................. 7-33

Fig 7-19 CDS 4.8 Soap Jug Tray Assembly .................................................. 7-34

Fig 7-20 CDS 4.6/4.8 Vacuum Relief Valve Assembly .................................. 7-35

Fig 7-21 CDS 4.6/4.8 Salsa & Silencer Assembly ........................................ 7-36

Fig 7-22 CDS 4.6 Machine Assembly - Front View ....................................... 7-37

Fig 7-23 CDS 4.6 Machine Assembly - Back View ........................................ 7-38

Fig 7-24 CDS 4.6 Recovery Tank Assembly - Front View ............................. 7-40

Fig 7-25 CDS 4.6 Recovery Tank Assembly - Rear View .............................. 7-41

Fig 7-26 CDS 4.6 Pump & Blower Assembly ................................................ 7-44

Fig 7-27 CDS 4.6 Dash Box Assembly ......................................................... 7-48

Fig 7-28 CDS 4.6 Dash Panel Assembly ...................................................... 7-50

Fig 7-29 CDS 4.6/4.8 Front End 2003+ GMC Assembly ............................... 7-52

Fig 7-30 Horizontal Pump In Tank Assembly - Front ..................................... 7-54

Fig 7-31 Horizontal Pump In Tank Assembly - Rear ...................................... 7-55

Fig 7-32 Free Standing Tray Assembly .......................................................... 7-57

Fig 7-33 85 Gallon Rotomolded Fresh Water Tank Assembly - Front ........... 7-59

Fig 7-34 85 Gallon Rotomolded Fresh Water Tank Assembly - Rear ............ 7-60

Fig 7-35 85 Gallon Rotomolded Fresh Water Tank w/ Reel Assembly .......... 7-63

Fig 7-36 CDS Pass Through Assembly ........................................................ 7-64

Cleaning Wand Assembly and Parts:

Fig 7-37 Valve Assembly ............................................................................... 7-68

Fig 7-38 Solution Valve Assembly .................................................................. 7-69

Fig 7-39 Valve Stem Assembly ...................................................................... 7-70

Fig 7-40 Hydra Hoe Wand Assembly ............................................................. 7-71

Fig 9-1 Wiring Schematic, CDS 4.8 ............................................................ 9-2

Fig 9-2 Wiring Schematic, CDS 4.6 ............................................................ 9-3

Fig 9-3 Wiring Diagram, Sheet 2 CDS 4.8 .................................................. 9-5

Fig 9-4 Wiring Diagram, Sheet 3 CDS 4.8 .................................................. 9-6

Fig 9-5 Wiring Diagram, Sheet 2 CDS 4.6 .................................................. 9-7

Fig 9-6 Wiring Diagram, Sheet 3 CDS 4.6 .................................................. 9-8

Fig 10-1 Drive Shaft Assembly ...................................................................... 10-6

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Introduction

CDS 4.6/4.8

Section 1-1

his manual contains operating instructions as well as information required 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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♦ 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.

♦ Notice ♦

If you have any questions regarding the operation, maintenance, or repair of this machine. Please contact your local distributor. 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 8:00 am to 5:00 pm (425) 775-7275 Service PACIFIC STANDARD TIME (800) 426-4225 Parts / Service FAX

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Precautions

♦ 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 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.

♦ 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.

HydraMaster’s 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.

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♦ 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 down-time. 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.

♦ 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 aver- age 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.

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♦ 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.

♦ 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.

♦ CAUTION ♦

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 at the end of this section), solvents (including d-Limonene), and some paint, oil and grease removers with a high concentration of solvents.

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System Operation

he HydraVan CDS machines are highly engineered cleaning plants designed by

HydraMaster Corporation. The system utilizes the most current technology avail-

able in water heating and water recovery systems.

The water flow is as follows:

Water is fed into the machine under tap pressure to the water box. The water is then picked up from the water box 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.

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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

Vacuum Blower: 4.6 - 45 Tuthill/M-D Tri-Lobe

4.8 - 47 Tuthill/M-D Tri-Lobe

Water Pump: CAT® 4.2 GPM Triple Plunger

4 gallons per minute

Chemical System: Mechanical, Meter Controlled

Heating System: Multiple Heat Exchanger (1000 PSI pressure)

Dual Shell and Tube Exchangers Optional Salsa Heat Package

Instruments:

Main Panel:

Electronic Tachometer, 0-3000 RPM* Water Temperature Gauge, 0-320° F Vacuum Gauge, 0-30 in 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, 0-1000 PSI

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Instruments (cont.) :

Side Panel:

Water Pressure Adjustment Blower Lubrication Port Water Temperature Adjustment Knob High Pressure Solution Outlets, QuickDisconnect 2 Fresh Water Inlet Fitting, Quick-Disconnect Water Box Drain Valve Chemical Controls

Recovery Tank: 100 gallon Aluminum

Cleaning Wand: Stainless Steel

Replacement Grip Rebuildable Solution Valve

High Pressure Hose:

1/4” High Temperature, Lined, Vinyl Covered Hose rated to 2200 PSI, 250° F

Standard Equipment:

150’ Solution Hose 150', 2" Vacuum Hose

5 gallon Chemical Jug Chemical Jug Holder Chemical Jug Fill Line

Power Transfer Package

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

10'. 1 ½” Vacuum Hose

50', Fresh Water Hose

10', 1 ½” Drain Line

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Standard Equipment (cont.) :

Van Finish Package

Van Decal Package

Monogrammed Jacket

Operation Manual

Custom Equipment Color

Oversize Air Handling Package

475 CFM High-Output Vacuum System (4.8)

Expanded Vacuum Recovery Tank Capacity

Hushkit Silenced System (4.8)

*The 4.8 CDS tachometer with the mag pick up located on

the power pack has been calibrated to represent the

engine speed of the vehicle.

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Spare Parts

own-time on the unit can be very expensive, because your truck-mounted 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

CDS Spare Parts List

PART NO DESCRIPTION QTY

049-023 Screen, Garden Hose 6 052-050 Quick Connect, 440 Male 2 052-051 Quick Connect, 440 Female 2 052-052 Quick Connect, 660 Male 1 052-053 Quick Connect, 660 Female 1 076-005 Spray Jet 8006E 1 078-019 Kit, Wand Valve Plunger 1

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CDS Spare Parts List (cont.)

PART NO DESCRIPTION QTY

078-102 Kit, Pressure By-pass Valve 1 078-270 Kit, Valve for 3CP Cat Pump 2 078-271 Kit, Seals for 3CP Cat Pump 1 157-022 Switch, Relay 1 157-040 Switch, 12 VDC Lighted 2 169-022 Valve, 1 ½” Full Port Ball 1

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Responsibilities

rior to the arrival of the unit, the van that it will be installed in should be delivered

to the installer.

Purchaser’s Responsibility:

It is the purchaser’s responsibility to Read the Owner’s Manual and to familiarize yourself with the information contained therein. Special attention should be paid to

all Cautions and Warnings.

Sales Representative’s 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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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 unit’s 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.

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Local Water Precautions

he 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 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 machine’s 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 de-scalers 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 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.

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♦ 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 3 grains per gallon. Failure to use a water softener in these areas will invalidate the machine’s 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

Figure 1-1 Location of Water Softener

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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.

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 unit’s 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 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 extractor’s recovery system and actively pump the water through hoses to a suitable disposal drain.

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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.

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Figure 1-2 Hard Water Map

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Cleaning and Chemicals

CDS 4.6/4.8

Section 2-1

our mobile carpet cleaning plant has been engineered using the latest 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.

♦ CAUTION ♦

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.

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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.

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.

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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.

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.

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Operating Instructions

CDS 4.6/4.8 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

customer’s hose, first connect the hose to the faucet and flush out any debris which may be in the hose. Afterwards connect the hose to the unit.

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.

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START UP

1. Make sure the van gear select lever is in the Park position and the emergency brake is set.

2. Start the van engine.

3. Turn key on CDS Dash. The RPM will automatically increase to the proper running speed. Engine RPM should be as noted in the Maintenance Section.

Note: The 4.8 CDS with the tachometer mag pick up located on the power pack has been calibrated to represent the engine speed of the vehicle.

4. Turn on the Pump clutch switch

5. Turn on the Pump in switch

6. Turn the heat control valve to “Max” only if you will be using water. Do not

activate the heat exchanger during flood extration work.

7. Turn the chemical selector valve to the “PRIME” position to purge any air from the system. Note: The prime hose is plumbed into the recovery tank. Leaving the valve in the “PRIME” position will cause excessive chemical usage.

a. When the chemical begins to flow through the flowmeter, with the flow indicator reading maximum flow and the PRIME line pulsing, turn the chemical selector valve to “ON”. Cap off vacuum if necessary.

b. While spraying the solution from the cleaning tool, adjust the chemical flow by turning the chemical adjustment knob to the desired level.

8. Turn the APO switch ‘ON’ if using the auto pump-out feature. NOTE: The pump will not engage until the water level rises inside the waste tank.

9. Now proceed with the cleaning operation.

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NOTE: The machine will automatically shut down when it reaches its full capacity due to the float switch located inside the waste tank. When this occurs,turn the switch off and empty the waste tank. Then turn the unit back on and continue to clean.

FLOOD DAMAGE WORK

When using equipment for flood damage, turn off the high pressure pump. This will reduce the engine power load and save on fuel consumption. Also, de-activate the heat exchangers to help prevent engine overheat problems.

SHUT DOWN

1. Flush clear water through the chemical system for 10 seconds. Note: 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.

2. Open the mix tank drain and actuate the wand valve to run fresh water through the water box, heat exchangers and cleaning tools. NOTE: Vinegar should be rinsed through the system weekly. De-scaler should be rinsed through the entire system monthly.

3. Lay vacuum hoses out in order for all moisture to be removed from the hoses. This prevents spillage of any dirty solution in your vehicle when storing the hoses.

4. Disconnect the hoses and put them away.

5. If you are using an outside water source, turn the water supply faucet off. Bleed 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

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6. Allow the unit to run for a few minutes with the vacuum hose disconnected in order to remove all moisture from the vacuum pump. Next plug the vacuum inlets. Spray lubricant into the lube port located on the front panel above the pressure gauge while the unit is running.

Spray for about 5 to 10 seconds. This will lubricate the vacuum pump and prevent it from rusting.

7. Remove the inlet plugs, then turn the machine off.

8. Before draining, it is recommended that the heat control knob be moved to the ‘OFF’ position. This will help to avoid potential engine overheat problems due to reduced coolant flow through the radiator.

9. Drain the waste tank. Do not dump waste in any area which might violate local, state or federal law. The pump-out system may be used to drain the waste tank into a sanitary drain system. When the waste tank is drained, lift waste tank lid and remove the filter screens. Clean out any accumulated debris. Rinse. Re-install.

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Freeze Guard

CDS 4.6/4.8

Section 4-1

ny freezing of this machine is not covered by warranty and during the colder

months of operation, careful protection should be of utmost concern.

The following precautions are recommended prior to and during cleaning:

1. Run the machine before leaving for the first job to insure nothing has frozen the night before, including hoses and wand.

2. Insulate the garden hose from the cold ground by running it through an extra 1½ inch vacuum hose.

3. Leave truck doors closed until time cleaning begins, afterwards open slightly.

4. In colder climates, insulating the truck walls and floor boards will help protect the unit.

5. Do not procrastinate during the cleaning operation or the hot water solution line will also freeze on the ground. The solution line should be insulated in extremely cold climates.

6. Whenever possible, the truck should be stored in a heated garage at night or over the weekend. If not possible, place a 1500 watt electric heater inside the truck, aimed directly at the machine. Never use a propane heater. It causes excessive moisture on the truck ceiling and the possibility of it going out is higher. If the machine and truck are left outside with a heater, you should drain water from the machine cleaning tools and hoses. (They freeze also.)

To Drain the Machine, Follow These Steps:

A. Before shutting off the machine, remove the chemical line from the chemical

jug and place in a mixture of 50/50 antifreeze and water. Turn the chemical control valve to the “PRIME” position until coolant registers in the flow meter. With the cleaning tool on, allow mixture to fill the remainder of the chemical system.

B. Open the water box drain valve and allow the water to drain thoroughly from

the water box.

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To Drain the Machine, Follow These Steps (cont.):

C. (If equipped) Turn the heat exchanger valve to “SALSA SYSTEM”

D. Close the water box drain and fill the mix tank with 50/50 antifreeze and

water mixture. Run the unit for 1 minute to circulate the mixture through the machines low-pressure hoses. Spray through the wand or other tool into a suitable container until the mix tank shut-off switch activates (pump stops). This freeze guards the high-pressure circuit

E. Open the water box drain and drain out the residual fluid into a suitable

container. This antifreeze solution may be retained for reuse (attach freeze guard fitting to inlet quick connect and vacuum water out of the inlet line).

♦ CAUTION ♦

One manufacturer of antifreeze cautions:

“WHEN DISPOSING OF USED ANTIFREEZE COOLANT: Follow local laws and regulations. If required, dispose at facilities licensed to accept household hazardous waste. If permitted, dispose in sanitary sewer systems. Do not discard into storm sewers, septic systems, or onto the ground.”

♦ WARNING ♦

This warning appears on the label of one brand of antifreeze:

“HARMFUL OR FATAL IF SWALLOWED. Do not drink antifreeze coolant or solution. If swallowed, induce vomiting immediately. Call a physician. Contains Ethylene Glycol which caused birth defects in animal studies. Do not store in open or unlabeled containers.

“KEEP OUT OF REACH OF CHILDREN AND ANIMALS.”

BE SURE YOUR MACHINE IS PROTECTED! Freezing will cause GRIEF, LOST MONEY, and DOWN-TIME.

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FREEZE PROTECTION OF THE PUMP-IN SYSTEM

1. Drain the fresh water tank.

2. Remove 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 till all the water is purged from the hose.

NOTE: The next time the unit is used it may take a few minutes before the

water box begins to fill.

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Water and

Chemical System

CDS 4.6/4.8

Section 5-1

his high pressure chemical system has been designed to be simple and trouble free.

WATER AND CHEMICAL FLOW OPERATION

The chemical pump draws the chemical from the inlet filter which is in the chemical container. It flows through the flow meter indicating the GPH’s of chemical being used. The chemical then flows through the chemical pump to the chemical selector valve. The chemical valve can be used to prime the pump (evacuate air from the system), inject chemical into the system or turn the chemical flow off. In the “ON” position, chemical flows through the metering valve, and is injected into the heated water path just prior to its leaving the machine.

The low water float switch in the water box is a safety switch that is designed to protect your system from sudden or unexpected loss of water supply. If, for example, the water source at the house were turned off, the water level of the water box would drop, activating the low water float switch, which automatically disengages the system and prevents the water pump from running dry.

The desired chemical injection ratio may be obtained by an adjustment of the chemical metering valve during the spraying of water through the cleaning tool.

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CHEMICAL SYSTEM MAINTENANCE

The chemical lines may need to be flushed with vinegar periodically to prevent abnormal chemical build-up. This flushing may be done by removing the clear plastic hose from the Chemical Jug and inserting it into a one quart container of vinegar. This should be done with the Chemical Flowmeter setting 10 GPH. Simply spray water from the wand until the quart of vinegar is exhausted. Then repeat the process with one quart of clear water to void all lines of vinegar.

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Page 5-3 Clutch Drive System

Figure 5-1 Solution Flow Diagram

D-4002 Rev D

06/07/2005

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Page 5-4 Clutch Drive System

Chemical System

Troubleshooting

1.0. System will not prime

1.1. Check valves in chemical pump are faulty. Remove valves and inspect. Clean or replace as necessary.

1.2. Chemical pump diaphragm is faulty. Remove and inspect. Replace as necessary.

1.3. Check valve in high pressure pump (the one that the chemical pump attaches to) is faulty. Remove valve and inspect. Clean or replace as necessary.

1.4. Filter on feed line in chemical jug is clogged. Inspect and clean.

1.5. Feed line from chemical jug is loose, pinched or cut. Inspect and repair.

1.6. Three-way prime valve is faulty. Check valve for leaks between ports. Replace as necessary. Note: if the chemical system has been run dry, it is

frequently necessary to insert the prime hose from the chemical jug into the vacuum inlet for a “boost” to purge all of the air from the system. Machines produced after April, 2001 will have the prime hose connected directly to the vacuum system.

2.0. Chemical flow is unstable or low

2.1. Air in lines. Check that all fittings and connections are tight and in good condition. Repair or replace as necessary.

2.2. Filter screen in chemical jug is partially clogged. Inspect and clean.

2.3. Three-way chemical valve is faulty. Inspect valve for leaks between ports. Replace as necessary.

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2.4. Chemical metering valve is faulty or partially obstructed. Inspect valve and clean or replace as necessary.

2.5. High pressure check valve is faulty. Remove and inspect. Clean or replace as necessary.

3.0. Solution jug fills with water

3.1. Three-way chemical valve is defective. Inspect valve for leaks between ports. Replace as necessary.

3.2. Inlet check valve in chemical pump is faulty. Remove and inspect valve. Clean or replace as necessary.

4.0. Chemical in water box

4.1. Chemical pump diaphragm is faulty. Remove and inspect. Replace as necessary.

4.2. High-pressure check valve is faulty. Remove and inspect. Clean or replace as necessary.

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Pump Maintenance

CDS 4.6/4.8

Section 6-1

DAILY:

1. Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the back of the pump.

Use a 30 weight, non-detergent oil.

♦ CAUTION ♦

If the oil becomes discolored and contaminated, one of the oil seals may be damaged. Refer to the Service Section.

Do not operate the pump if the crankcase has been contaminated with water.

♦ CAUTION ♦

Do not leave contaminated oil in the pump housing or leave the housing empty. Remove contaminated oil as soon as it is discovered and replace it with clean oil.

PERIODICALLY:

1. Change the oil after the first 100 hours of operation, and every 400 operating hours thereafter. When changing, remove the drain plug on the oil drain hose so all oil and accumulated sediment will drain out.

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♦ CAUTION ♦

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

♦ CAUTION ♦

Protect the pump from freezing.

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Pump Service

he next few pages explain how to dissassemble and inspect all easily service

able parts of the pump.

♦ CAUTION ♦

Do not disassemble the hydraulic end unless you are a skilled mechanic. For assistance, contact HydraMaster (425-775-7275) or the distributor in your area.

1. Servicing the Valves (See illustrations above.)

A. Remove the hex valve plugs (top—discharge, bottom—inlet).

B. Unthread the valve plug and examine the o-ring under the plug for cuts or

distortion. Replace it if it is worn. Lubricate new o-rings before installing.

C. Grasp the valve retainer by the tab at the top with needle-nose pliers, then

remove the o-ring at the bottom of the valve chamber.

D. Inspect all valve parts for pitting, gouges, or wear. If wear is excessive,

replace valve assembly.

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1. Servicing the Valves (cont.)

E. Reinstall valve assemblies:

1. Using a clean towel, clean the valve chamber.

2. Install the o-ring into the high pressure manifold.

3. Install the valve assemblies into the high pressure manifold (the metal side of the valve faces the manifold).

4. Replace the O-ring on the hex valve plug.

5. Torque the plug to 72 foot pounds.

2. Removing the High Pressure Manifold

A. Using an M6 allen wrench, remove all eight of the socket head bolts.

B. Rotate the crankshaft by hand to start separation of the manifold head

from the crankshaft.

C. Insert two flat-head screwdrivers on opposite sides to further separate

the manifold from the crankshaft.

♦ CAUTION ♦

To avoid damage to either plunger or seal, keep the manifold properly aligned with the ceramic plungers when removing it.

D. Remove the seal retainer from the manifold and inspect for wear.

E. Examine the ceramic plunger for cracks or scoring (refer to

Plungers for replacement).

Servicing the

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3. Servicing the Low Pressure Seals and High Pressure Seals (See illustrations above.)

A. Remove the low pressure seal from the seal retainer using a 90 degree

pick tool.

B. Remove the high pressure seal from the manifold.

C. Inspect the low pressure seal and high pressure seal for wear and replace

if necessary.

D. Reinstall the low pressure seal:

1. Install the low pressure seal into the seal retainers with the garter spring down.

E. Reinstall the high pressure seal:

1. Lubricate the seal chamber in the manifold

2. Carefully square the high pressure seal into position by hand with the grooved side down (metal back facing out).

3. Examine the seal retainer’s o-ring and replace if worn. Lubricate the new o-ring before installing.

4. Next, press the seal retainers into the manifold until completely seated.

4. Servicing the Plungers (See illustrations above step 3.)

A. Using a hex tool, loosen the plunger retainer about three to four turns.

Push the plunger back to separate it from the retainer and finish unthreading the plunger retainer by hand.

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B. Unthread the plunger retainer with sealing washer.

C. Remove the ceramic plunger, keyhole washer and barrier slinger from

the plunger rod.

D. Reinstall the ceramic plungers:

1. Examine the sealing washer on the plunger retainer and replace it if it is cut or worn. Lubricate the new sealing washer for ease of installation and to avoid damage.

2. Apply Loctite 242™ to the threads of the plunger retainer and press it into the ceramic plunger. Thread hand tight, then torque the bolt to 4.4 foot pounds.

3. Install the seal retainer with holes to the top and bottom, and forward.

5. Reinstall High Pressure Manifold

A. Slip the seal retainer over the ceramic plungers with the holes to the

top and bottom and forward.

B. Turn the shaft by hand to line up the plungers so that the end plungers

are parallel.

C. Lightly lubricate the plungers and carefully slide the manifold head onto

the plungers while supporting it from the underside to avoid damaging the plungers.

D. Reinstall the socket head bolts and torque to 4.4 foot pounds.

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6. Servicing the Crankcase

A. While manifold, plungers, and seal retainers are removed, examine the

crankcase seals for wear.

B. Rotate the crankshaft oil seal externally for drying, cracking or leaking.

C. Consult your HydraMaster distributor if crankcase servicing is necessary

Figure 6-1: Cat Pump

Torque Chart

Torque

Pump Item Thread Inch Pounds Foot Pounds Nm

Plunger Retainer M6 55 4.4 6.2 Manifold Bolt M6 55 4.4 6.2 Valve Plugs M22 870 72.3 100.0 Bearing Case Screws M6 50 4.0 6.0 Crankcase Cover M6 50 4.0 6.0 Bubble Oil Gauge M28 45 3.6 5.0 Mounting Bolts M8 115 9.4 13.0

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Cat Pump Parts List

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ITEM PART NO. DESCRIPTION QTY

2 30057 Key (M6) 1 5 96031 Screw, Sems HHC, Bearing Cover (M8x16) 8

8 46910 Cover, Bearing 2 10 14028 O-Ring, Bearing Cover 1 11 43222 Seal, Oil, Crankshaft 2 15 14480 Bearing 2 20 46743 Rod, Connecting, Assembly 2 25 46928 Crankshaft, Dual End 3 32 46798 Cap, Oil Filler 1 33 14179 O-Ring, Oil Filler Cap 1 37 43987 Gauge, Oil, Bubble 1 38 44428 Gasket, Flat, Oil Gauge 1 40 92519 Screw, Sems HHC, Crankcase Cover (M6x16) 4 48 25625 Plug, Drain (3" x 11) 1 49 23170 O-Ring, Drain Plug 1 50 46940 Cover, Crankcase 1 51 14044 O-Ring, Crankcase Cover 1 53 46912 Crankcase 1 64 46746 Pin, Plunger Rod 3 65 46747 Rod, Plunger 3 70 147-013 Seal, Crankcase Oil for 3CP Cat Pump 3 75 43900 Slinger, Barrier 3 88 45697 Washer, Keyhole 3 90 46893 Plunger (M50) 3 98 46730 Seal, Washer 3 99 46729 Retainer, Plunger with Stud (M7) 3

100 46749 Retainer, Seal 3 106 43243 Seal, LPS with Spring 3 120 46896 Case, Seal 3

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Cat Pump Parts List

ITEM PART NO. DESCRIPTION QTY

121 13976 O-Ring, Seal case 3

127 44549 V Packing 6 128 44548 Adapter, Male 3 139 22179 Plug, Inlet ½” 1 163 17547 O-Ring 85, Valve Seat 6 164 46658 Seat 6 166 46429 Valve 6 167 43750 Spring 6 168 46583 Retainer, Spring 6 172 17549 O-Ring, Valve Plug 6 173 48365 Back up Ring, Valve Plug 6 174 45900 Plug, Valve 6 185 46895 Manifold, Head 1 193 87872 Bolt, HSH, Manifold Head (M8x70) 8 196 22187 Plug, Discharge d” 1 299 814843 Complete Head 1 300 078-271 Kit, Seal for 3CP Cat Pump 1 310 078-270 Kit, Valve for 3CP Cat Pump 1 350 30696 Valve Seal Removal Tool 1

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High Pressure System

Troubleshooting

1.0. Will not come up to normal cleaning pressure

1.1. Pressure adjusting valve is defective or dirty. Disassemble valve. Repair or replace as necessary.

1.2. Worn seals or valves in pump. Test pump output volume directly from pump at normal operating RPM. If volume is below manufacturers specifications, replace seals and inspect for defective valves.

1.3. Pump RPM is too low. Check engine RPM and adjust as necessary. Check for loose pump belt. Adjust tension as necessary.

1.4. High temperature dump solenoid is activated. Refer to Heating System section IV.

1.5. Primary system control orifice is missing or loose. Remove filter and inspect. Tighten or replace as necessary.

1.6. Primary system control orifice has been exchanged with secondary (hot water dump) orifice. Inspect and reverse as necessary.

1.7. Primary orifice is worn. Measure orifice size and replace as necessary.

2.0. No pressure reading on PSI gauge

2.1. Pump switch is not turned on. Turn on switch

2.2. No water in mix tank. Refer to section 5.0

2.3. Pump belt is broken. Replace belt.

2.4. Pump clutch is not activated. There is no water in water box. Check system back to source to locate cause of interruption to water flow.

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2.5. Pump clutch is not activated. There is water in the water box. Check for 12 volts at clutch. If 12 volts is present, replace clutch.

2.5.1. If 12 volts is not present, check fuse that supplies power to the low-water relay. If fuse is good and there is 12 volts at the relay, check low water switch in water box.

2.5.2. If low water switch has no continuity when float is up, replace the switch. If switch is good, replace the low water relay.

3.0. PSI gauge reads normal; low pressure from wand

3.1. There is a restriction in the cleaning tool. Inspect tool jet and clean or replace as necessary. Inspect any filters in the cleaning tool and clean or replace as necessary.

3.2. There is a defective quick connect in the system. Inspect each quick connect and replace as necessary.

3.3. There is a restriction in one of the solution hoses. Remove quick connects and inspect hoses. Clean or replace as necessary.

3.4. There are hard water deposits restricting the system between the afterburner

heat exchanger and the high-pressure solution connection at the front of the machine. Descale the machine. If this doesn’t solve the problem,

disassemble this portion of the system and locate restriction.

4.0. Pressure pulsation

4.1. Water in the water-box is too hot and is approaching boiling point. Check temperature of water in the water-box.

4.2. There is an air leak between the water box outlet and the pump inlet. Physically check all hoses and fittings for cuts, breaks, cracks or tightness. Repair as necessary.

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4.3. One of the intake or outlet valves in the high-pressure pump is defective or is

being held open by debris. Remove each valve and inspect for correct

operation.

5.0. Water box empty or fills slowly

5.1. There is a restriction in the water supply system. Inspect the supply system

from the source through the incoming quick connect for kinks, clogs or restricted filters. Clean or repair as necessary.

5.2. The float valve in the water box is defective. If there is adequate water flow

to the incoming valve in the water box, disassemble and inspect the valve. Repair or replace as necessary.

6.0. Water box overflows

6.1. There is either debris caught in the valve or the valve seal is bad. Disassemble

valve and repair or replace as necessary.

6.2. The float has absorbed water and has lost buoyancy. Detach float and check

to see if it will float to the surface. Replace as necessary.

6.3. The float has come out of adjustment. Readjust float as necessary.

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CDS 4.8 Machine

Assemblies & Parts

CDS 4.8

Section 7-1

Figure 7-1 CDS 4.8 Machine Assembly - Front View

D-7145 Rev -

TO ENGINE

FROM RADIATOR

TO RADIATOR

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Figure 7-2 CDS 4.8 Machine Assembly - Rear View

D-7145 Rev -

HIDDEN

13143

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Clutch Drive System Page 7-3

CDS 4.8 Machine Assembly Parts List

Item Part Number Description Qty

1 Fig. 7-3 & 7-4 Assembly, Recovery Tank - CDS 4.8 1

2 Fig. 7-11 Assembly, Pump & Blower - CDS 4.8 1

3 000-079-077 Assembly, Salsa 2005+ CDS (Fig. 7-21) 1

4 000-052-756 Hose, 3/8" x 36" Lg. Throb - CDS 1

5 000-068-030 Hose, 5/32" I.D. Vacuum - Bulk 1

6 000-068-030 Hose, 5/32" I.D. Vacuum - Bulk 1

7 000-068-459 Hose, 3/4" I.D. Green Stripe - Bulk 1

8 000-068-459 Hose, 3/4" I.D. Green Stripe - Bulk 1

9 000-068-085 Hose, 3/8" Hi Temp Black - Bulk 1

10 000-068-706 Hose, 3/16" x 70" Lg. Teflon w/ F JIC Ends 1

11 000-033-005 Clamp, Size #5 Hose 2

12 000-068-755 Hose, 3/8" x 31" Lg. Teflon w/ 3/8" JIC Ends 1

13 000-068-755 Hose, 3/8" x 31" Lg. Teflon w/ 3/8" JIC Ends 1

14 000-033-020 Clamp, Size #16 Hose 2

15 000-068-069 Hose, 3/4" I.D. Parker Gst II - Bulk 1

16 000-033-026 Clamp, Size #10 Hose 2

17 000-033-013 Clamp, Size #48 Hose 2

18 000-068-773 Hose, Ø3.0" x 15" Lg. Flexible Wire Reinforced 1

19 000-068-777 Hose, 1" x 45" Lg. Suction 1

20 000-033-132 Clamp, 1-1/2" T-Bolt 2

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Figure 7-3 CDS 4.8 Recovery Tank Assembly - Rear View

D-6977 Rev -

HIDDEN

42 43

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Figure 7-4 CDS 4.8 Recovery Tank Assembly - Front View

D-6977 Rev -

HIDDEN

27 28

HIDDEN

21 20

3 5

HIDDEN

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Page 7-6 Clutch Drive System

CDS 4.8 Recovery Tank Assembly Parts List

Item Part Number Description Qty

1 000-159-130 Tank, 100 Gallon CDS Universal Recovery - Weldment 1

2 Fig. 7-5 Assembly, Recovery Tank Cover - 100 Gallon CDS 1

3 000-105-336 Plate, Vacuum Port Cover - 100 Gallon Universal Recov 1

4 000-049-152 Filter, Recovery Tank Basket 1

5 000-013-070 Box, Vacuum Relief Valve - Universal Recovery Tank 1

6 Fig. 7-20 Assembly, Vacuum Relief Valve 1

7 000-049-153 Filter, Flat - Recovery Tank 1

8 000-015-932 Bracket, Flat Filter Securing - Universal Recovery Tank 1

9 000-049-154 Deflector, Air - Univeral Recovery Tank 1

10 000-057-206 Gasket, Adapter - Universal Recovery Tank 4

11 000-140-023 Rivet, AB8-6A Aluminum Pop 6

12 000-157-090 Float, Lever Switch 2

13 000-033-023 Clamp, 3/4" Nylon Hose 4

14 000-143-126 Screw, #10-24UNC x 0.50" Lg. Hex Head 6

15 000-094-059 Nut, #8-32UNF Nylock 1

16 000-086-008 Latch, Bungie 1

17 000-143-539 Screw, #6-32UNC x 0.50" Lg. Button Head Allen 2

18 000-094-063 Nut, #6-32UNC Nylock 2

19 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 12

20 000-174-019 Washer, 1/4" Lock 14

21 000-174-003 Washer, 1/4" Flat 22

22 000-106-019 Plug, 1-1/2" NPT 1

23 000-052-763 Nipple, 1-1/2" IPS Close s/s 1

24 000-169-022 Valve, 1-1/2" Full Port Ball 1

25 000-052-226 Insert,1-1/2" NPT x 1-1/2" Barb (Grey) 1

26 000-052-082 Elbow, 1/4" NPT Street x 45° 1

27 000-052-102 Insert, #46 (1/4" NPT x 3/8" Barb) 2

28 000-052-085 Elbow, 1/4" NPT Street 1

29 000-081-252 Label, Maintenance & Lubrication Schedule 1

30 000-143-333 Screw, 1/4"-20UNC x 0.50" Lg. Hex Head 2

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CDS 4.8 Recovery Tank Assembly Parts List

Item Part Number Description Qty

31 000-001-132 Adapter, Tank To Ø3.0" Blower Hose - Universal Recov 1

32 000-174-029 Washer, 3/8" Rubber Back 2

33 Fig. 7-17 Assembly, Water Box 1

34 000-166-033 Assembly, Soap Jug Tray - CDS 4.8 (Fig. 7-19) 1

35 Fig. 7-10 Assembly, Dual Heat Exchanger 1

36 Fig. 7-15 Assembly, Dash - CDS 4.8 1

37 000-174-001 Washer, #10 Flat 6

38 000-067-031 Hinge, Dash Box 1

39 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 3

40 Fig. 7-6 & 7-7 Assembly, Instrument Panel 1

41 000-094-113 Nut, 1/4"-20UNC Neoprene Wellnut 4

42 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 8

43 000-174-060 Washer, 1/4" Flat Rubber Backed 4

44 000-052-758 Insert, 1" NPT x 1" Barb 1

45 000-094-009 Nut, 1/4"-20UNC Hex Nylock 4

46 000-174-036 Washer, #10 Flat Rubber Backed 2

47 000-094-034 Nut, #10-24UNC Nylock 2

48 000-174-015 Washer, #10 Outside Star 5

49 000-094-004 Nut, #10-24UNC Hex 5

50 000-143-064 Screw, #10-24UNC x 1.00" Lg. Flat Head Phillips 4

51 000-068-459 Hose, 3/4" I.D. Green Stripe 1

52 000-033-020 Clamp, Size #16 Hose 2

53 000-068-017 Hose, 3/8" Bulk 1

54 000-033-005 Clamp, Size #5 Hose 2

55 000-143-114 Screw, #10-24UNC x 0.50" Lg. Flat Head 2

56 601-013-001 Stabilizer, Instrument Panel To Recovery Tank 1

57 000-068-018 Hose, 1/2" I.D. Rubber - Bulk 1

58 000-068-203 Hose, 3/16" x 34" Lg. 1/4" FJIC x 1/4" FJIC 1

59 000-068-734 Hose, 1/2" x 42.5" Lg. w/ 3/8" NPT & 3/8" SAE F Ends 1

60 000-068-326 Hose, 3/8" I.D. Clear w/ Braid 1

HydraMaster Corporation

Page 75

Page 7-8 Clutch Drive System

Figure 7-5 CDS 4.8 Recovery Tank Cover Assembly

D-7151 Rev -

CDS 4.8 Recovery Tank Cover Assembly Parts List

Item Part Number Description Qty

1 000-041-447 Cover, 100 Gallon Universal Recovery Tank - Weldment 1

2 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 1

3 000-057-015 Gasket, 1-1/2" Bulkhead Fitting 2

4 000-052-219 Adapter, 2" NPT x 2" F Slip 2

5 000-143-539 Screw, #6-32UNC x 0.50" Lg. Button Head Allen 2

6 000-086-008 Latch, Bungie - Strike 1

7 000-094-063 Nut, #6-32UNC Nylock 2

8 000-052-222 Elbow, 2" Barb x 2" FPT 2

9 000-057-202 Gasket, End - Recovery Tank 2

10 000-057-203 Gasket, Middle - Recovery Tank 3

11 000-057-205 Gasket, Side - Recovery Tank - 100 Gallon 2

HydraMaster Corporation

Page 76

Clutch Drive System Page 7-9

Figure 7-6 CDS 4.6/4.8 Instrument Panel Assembly

D-6988 Rev A

HydraMaster Corporation

Page 77

Page 7-10 Clutch Drive System

Figure 7-7 CDS 4.6/4.8 Instrument Panel Assembly

D-6988 Rev A

HydraMaster Corporation

Page 78

Clutch Drive System Page 7-11

CDS 4.6/4.8 Instrument Panel Assembly Parts List

Item Part Number Description Qty

1 000-100-168 Panel, Instrument 1

2 Fig. 7-8 Assembly, Hi-PSI Manifold 1

3 Fig. 7-9 Assembly, By-Pass Valve 1

4 000-105-012 Plate, Machine Serial I.D. 1

5 000-074-030 Meter, Chemical Flow Raw 1

6 000-174-008 Washer, 5/8" Flat 4

7 000-169-064 Valve, 3/8" NPT Full Port Ball 1

8 000-052-051 Quick Connect, 440 Female w/ EPDM O-Ring 2

9 000-106-029 Plug, 1" Hole 1

10 000-052-052 Quick Connect, 660 Male w/ Viton Standard 1

11 000-052-281 Nipple, 3/4" NPT x 3/4" Male Garden Hose 1

12 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) 1

13 000-052-096 Insert, #F23 (1/8" FPT x 3/16" Barb) 1

14 000-060-002 Grommet, Large Wiring 1

15 000-057-055 Gasket, Garden Hose 1

16 000-074-003 Guage, Hi-PSI (0-1000) 1

17 000-052-272 Cup, Gravity Feed Oil Blower Lubrication Port 1

18 000-027-014 Cap, Garden Hose 1

19 000-174-050 Washer, 1" Flat 1

20 000-135-052 Regulator, Hi PSI Snubber 1

21 000-169-009 Valve, 3/4" FPT Swing Check 1

22 000-052-338 Insert, #1212 (3/4" NPT x 3/4" Barb) 1

23 000-052-088 Elbow, 1/4" FPT x FPT 1

24 000-174-005 Washer, 3/8" Flat 2

25 000-052-128 Nipple, 3/8" NPT x 3/8" Male Propane 2

26 000-174-063 Washer, 1.5" O.D. x 1.073" I.D. x 0.075" Thk. 1

27 000-174-012 Washer, 1/2" SAE H/D Flat 2

28 000-140-015 Rivet, 1/8" x 1/4" Lg. Pop 2

29 000-169-201 Valve, 3/4" Heater Panel Mount 1

30 000-052-756 Insert, 3/4" NPT x 3/4"Elbow 2

HydraMaster Corporation

Page 79

Page 7-12 Clutch Drive System

CDS 4.6/4.8 Instrument Panel Assembly Parts List

Item Part Number Description Qty

31 000-169-0171 Valve, 3-Way Ball O-Ring Style 1

32 000-169-160 Valve, Chemical Metering 1

33 000-052-069 Nipple, 1/8" NPT Hex 2

34 000-174-030 Washer, 5/8" I.D. x 7/8" O.D. x 0.010" Thk. 1

35 000-094-098 Nut, 7/16"-24UNF - 2 Way Metering Valve 1

36 000-052-531 Elbow, 1/8" NPT x 1/4" SAE 1

37 000-052-084 Elbow, 1/8" NPT Street 1

38 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 3

39 000-068-491 Hose, 3/16" x 10" Lg. Teflon 1/4" NPT x 1/4" JIC F 1

40 000-068-518 Hose, 3/16" x 18.25" Lg. Teflon w/ F JIC Ends 1

41 000-052-022 Tee, 3/8" Insert 1

42 000-052-089 Elbow, 1/8" NPT Female 1

43 000-174-001 Washer, #10 Flat 6

44 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 2

45 000-068-017 Hose, 3/8" Bulk 1

46 000-068-017 Hose, 3/8" Bulk 1

47 000-033-005 Clamp, Size #5 Hose 4

48 000-052-530 Nipple, 1/8" MNPT x 1/4" SAE 1

49 000-131-027 Trimlok, 1/8" x 3/8" Lg. 1

50 000-174-014 Washer, #10 Lock 2

51 000-174-007 Washer, 1/2" Flat 1

52 000-143-327 Screw, #10-32UNF x 0.50" Lg. Hex Head 2

53 000-081-252 Label, Instrument Panel - CDS 4.6 / 4.8 1

54 000-081-252 Label, Bottom - Instrument Panel - CDS 4.6/4.8 1

55 000-068-757 Hose, 1/2" x 20.5" Lg. Rubber w/ 3/8" NPT x 3/8" SAE Femal 1

HydraMaster Corporation

Page 80

Clutch Drive System Page 7-13

Figure 7-8 CDS 4.6/4.8 Hi-PSI Manifold Assembly

D-6091 Rev B

HydraMaster Corporation

1614

1217

Page 81

Page 7-14 Clutch Drive System

CDS 4.6/4.8 Hi-PSI Manifold Assembly Parts List

Item Part Number Description Qty

1 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 1

2 000-052-071 Nipple, 1/4" NPT Hex 2

3 000-090-008 Manifold, Hi Pressure 1

4 000-106-002 Plug, 1/4" NPT Hex 1

5 000-052-530 Nipple, 1/8" MNPT x 1/4" SAE 1

6 000-052-074 Nipple, 3/8" NPT Hex 2

7 000-169-186 Valve, 3/8" FPT x 3/8" FPT 100 PSI Check 1

8 000-149-039 Sender, Temperature 1

9 000-052-061 Bushing, 3/8" NPT x 1/4" FPT 1

10 000-052-113 Cross, 3/8" FPT 1

11 000-050-060 Bushing, 3/8" NPT x 1/8" FPT 1

12 000-052-582 Nipple, Tee Jet Style Collar x 1/8" NPT 1

13 000-094-028 Nut, Brass Jet Assembly 1

14 000-052-153 Housing, Stabalizer Nozzle 1

15 000-052-586 Nipple, 1/8" FPT x 1/4" SAE 1

16 000-049-052 Filter Cartridge, 1/4" 1

17 000-180-009 Orifice, 0.027" Plate 1

HydraMaster Corporation

Page 82

Clutch Drive System Page 7-15

Figure 7-9 CDS 4.6/4.8 By-Pass Valve Assembly

C-6989 Rev A

HydraMaster Corporation

Page 83

Page 7-16 Clutch Drive System

CDS 4.6/4.8 By-Pass Valve Assembly Parts List

Item Part Number Description Qty

1 000-169-188 Valve, PSI Regulator 0-1500PSI - Modified 1

2 000-015-515 Bracket, By-Pass Valve Mounting 1

3 000-027-008 Cap, 3/8" FPT 1

4 000-052-764 Elbow, 1/4" SAE x 3/8" MNPT x 90° 1

5 000-052-023 Tee, 3/8" NPT Male Street 3

6 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 1

7 000-052-105 Insert, #68 (3/8" NPT x 1/2" Barb) 1

8 000-169-027 Valve, Thermal Relief 165° F 1

9 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 1

10 000-106-008 Plug, 3/8" NPT Allen Head 1

11 000-143-126 Screw, #10-24UNC x 0.50" Lg. Hex Head 2

12 000-052-128 Nipple, 3/8" NPT x 3/8" Male Propane 1

13 000-174-001 Washer, #10 Flat 2

14 000-174-014 Washer, #10 Lock 2

HydraMaster Corporation

Page 84

Clutch Drive System Page 7-17

Figure 7-10 CDS 4.6/4.8 Dual Heat Exchanger Assembly

D-3803 Rev H

HydraMaster Corporation

Page 85

Page 7-18 Clutch Drive System

CDS 4.6/4.8 Dual Heat Exchanger Assembly Parts List

Item Part Number Description Qty

1 000-038-046 Heat Exchanger, Water To Water Hi-PSI 2"X36" 1" NPT End 2

2 000-052-338 Insert, #1212 (3/4" NPT x 3/4" Barb) 3

3 000-052-064 Bushing, 1/2" NPT x 3/8" FPT 4

4 000-052-086 Elbow, 3/8" NPT Street 4

5 000-052-756 Insert, 3/4" NPT x 3/4"Elbow 1

6 000-033-029 Clamp, Size 12 Hose 2

7 000-052-528 Nipple, 3/8" M JIC x 3/8" NPT 2

8 000-068-066 Hose, 3/4" I.D w/ 180° Bend For HX 1

9 000-068-070 Hose, 3/8" x 12" Lg. Teflon w/ JIC Ends 1

10 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 8

11 000-174-019 Washer, 1/4" Lock 8

12 000-174-003 Washer, 1/4" Flat 8

13 000-094-010 Nut, 1/4"-20UNC Hex 8

14 000-131-042 Insulation, 4-1/8" x 1/2" 1

15 000-015-172 Bracket, Dual Heat Exchanger Mounting - Left 1

16 000-015-171 Bracket, Dual Heat Exchanger Mounting - Right 1

17 000-052-733 Elbow, 3/4" NPT Street - Modified 1

18 000-169-205 Petcock, Coolant 1/4" NPT 1

19 000-068-196 Hose, 3/8" I.D. x 11" Lg w/ 3/8" MNPT & 3/8" JIC Ends 1

20 000-068-091 Hose, 3/8" I.D. Clear - Bulk 1

21 000-033-003 Clamp, Size #4 Mini 1

22 000-174-002 Washer, 1/4" Flat 2

23 000-143-013 Screw, 5/16"-18UNC x 1.00" Lg. Grade 8 2

24 000-094-038 Nut, 5/16"-18UNC Nylock 2

HydraMaster Corporation

Page 86

Clutch Drive System Page 7-19

Figure 7-11 CDS 4.8 Pump & Blower Assembly

D-3802 Rev L

HIDDEN

2526

252627

HIDDEN

HydraMaster Corporation

30 19

23 32

Page 87

Page 7-20 Clutch Drive System

CDS 4.8 Pump & Blower Assembly Parts List

Item Part Number Description Qty

1 000-055-028 Frame, Pump And Blower 1

2 000-079-097 Assembly, Duraflow APO Pump - CDS (Fig. 7-14) 1

3 000-001-041 Adapter, Blower Inlet 1

4 000-001-042 Adapter, Blower Outlet - CDS 4.8 1

5 000-077-001 Key, #3 & #4 Vacuum Pump Drive 2

6 Fig. 7-12 Assembly, Pump - CDS 4.8 1

7 000-111-147 Blower, MD 4007 1

8 000-154-147 Spacer, Power Pack - Rear - CDS 4.8 Ford 2005+ 1

9 000-154-146 Spacer, Power Pack - Front - CDS 4.8 Ford 2005+ 1

10 000-008-020 Bearing, Pillow Block - 1-3/16" Bore 2

11 000-139-021 Snap Ring, 1-3/16" Shaft 2

12 000-150-040 Shaft, Drive Sprocket - CDS 4.8 1

13 000-052-505 Zerk Fitting,1/8" MNPT Grease Fitting-Straight 2

14 000-109-022 Pulley, AK54 H Pump 1

15 000-020-019 Bushing, #H x 7/8" Bore 1

16 000-108-065 Protector, CAT Pump Belt Shield 1

17 000-015-801 Bracket, Blower Mounting - CDS 4.8 2

18 000-143-017 Screw, 3/8"-16UNC x 0.75" Lg. Hex Head Grd. 8 4

19 000-174-057 Washer, 3/8" Lock 3

20 000-143-018 Screw, 3/8"-16UNC x 1.00" Lg. Grade 8 4

21 000-174-004 Washer, 5/16" Flat 13

22 000-143-025 Screw, 3/8"-16UNC x 1.25" Lg. Hex Head Grd 8 4

23 000-094-100 Nut, 3/8"-16UNC Hex Nylock 5

24 000-143-012 Screw, 5/16"-18UNC x 0.75" Lg. Hex Head 4

25 000-174-002 Washer, 1/4" Flat 10

26 000-174-018 Washer, 5/16" Lock 9

27 000-143-013 Screw, 5/16"-18UNC x 1.00" Lg. Grade 8 5

28 000-174-017 Washer, 1/4" Lock 2

29 000-094-010 Nut, 1/4"-20UNC Hex 2

30 000-143-096 Screw, 3/8"-16UNC x 1.00" Lg. Hex Head 2

HydraMaster Corporation

Page 88

Clutch Drive System Page 7-21

CDS 4.8 Pump & Blower Assembly Parts List

Item Part Number Description Qty

31 000-143-260 Screw, 3/8"-16UNC x 8.00" Lg. Hex Head w/ 6" Threads 1

32 000-015-173 Bracket, CAT Pump Tensioner Plate 1

33 000-174-012 Washer, 1/2" SAE H/D Flat 4

34 000-143-240 Screw, 1/2"-13UNC x 1.75" Lg. Hex Head - Grade 5 4

35 000-094-037 Nut, 1/2"-13UNC Hex 2-Way Locking - Z/P 4

36 000-143-002 Screw, 1/4"-20UNC x 1.00" Lg. Hex Head 1

37 000-143-548 Screw, 1/4"-20UNC x 2.00" Lg. Hex Head 1

38 000-109-058 Pulley, 56 Tooth GT2 8MX-56S-21 Engine & Blower 1

39 000-020-020 Bushing, 7/8" Taper-Lock 1

40 000-020-026 Bushing, 1-1/8" Taper-Lock 1

41 000-109-009 Pulley, 2.75" x 0.88" Pump Drive 1

42 000-015-930 Bracket, Tach. Magnetic Extension N/S - CDS 4.6 1

43 000-149-010 Sensor, CDS Magnetic Tach. 1

44 000-174-003 Washer, 1/4" Flat 1

45 000-109-057 Pulley, 40 Tooth GT2 8MX-40S-21 Engine & Blower 1

46 000-010-052 Belt, Polychain GT 1

47 000-010-051 Belt, #9380 CAT Pump Drive 1

48 000-077-010 Key, 1/4" x 1-1/2" Lg. Class 2 Fit 1

49 000-052-293 Insert, #23 (1/8" NPT x 3/16" Barb) 3

50 000-052-057 Nipple, 1/8" NPT Close 1

51 000-052-084 Elbow, 1/8" NPT Street 1

52 000-052-079 Cross, 1/8" FPT 1

53 000-033-057 Clamp, 1" Cushion Loop 1

54 000-174-001 Washer, #10 Flat 1

55 000-143-132 Screw, #10-24UNC x 0.75" Lg. Hex Head 1

56 000-077-012 Key, 3/16" x 2.5" Lg. Class 2 Fit 1

57 000-068-030 Hose, 5/32" I.D. Vacuum - Bulk 1

58 000-052-061 Bushing, 3/8" NPT x 1/4" FPT 2

59 000-068-149 Hose, CDS Blower Oil Drain 1

60 000-068-149 Hose, CDS Blower Oil Drain 1

HydraMaster Corporation

Page 89

Page 7-22 Clutch Drive System

CDS 4.8 Pump & Blower Assembly Parts List

Item Part Number Description Qty

61 000-094-012 Nut, 5/16-18"UNC Hex 2

62 000-154-153 Spacer, Tach. Sensor - CDS 4.8 1

63 000-143-373 Screw, 1/4"-20UNC x 2" Lg. Hex Head Grd 5 1

64 000-052-083 Elbow, 3/8" NPT Street x 45° 1

65 000-174-021 Washer, 3/8" Lock 8

HydraMaster Corporation

Page 90

Clutch Drive System Page 7-23

Figure 7-12 CDS 4.6/4.8 Pump Assembly

C-5493 Rev A

1 14

16 3

HydraMaster Corporation

Page 91

Page 7-24 Clutch Drive System

CDS 4.6/4.8 Pump Assembly Parts List

Item Part Number Description Qty

1 000-111-070 Pump, 4 GPM CAT Hi Temp. Plunger 1

2 000-111-035 Assembly, Chemical Pump (Fig. 7-13) 1

3 000-106-004 Plug, 1/2" NPT Hex 1

4 000-108-055 Protector, CAT 3CP Shaft 1

5 000-052-084 Elbow, 1/8" NPT Street 1

6 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 1

7 000-052-128 Nipple, 3/8" NPT x 3/8" Male Propane 1

8 000-001-082 Adapter, Chemical Pump To CAT 3CP 1

9 000-097-057 O-Ring, Adapter - Chemical Pump 1

10 000-114-003 Rail, Angle CAT 3CP 1

11 000-052-086 Elbow, 3/8" NPT Street 1

12 000-052-753 Insert, #816 (1/2" NPT x 1" Barb) 1

13 000-106-003 Plug, 3/8" NPT Hex 1

14 000-036-006 Clutch, Pump - CDS 4.8/ Maxx 1

15 000-174-018 Washer, 5/16" Lock 1

16 000-143-187 Screw, 8mm x 25mm Lg. Grade. 10.9 Hex Head 1

17 000-052-085 Elbow, 1/4" NPT Street 1

18 000-052-062 Bushing, 1/4" NPT x 1/4" FPT 1

19 000-052-531 Elbow, 1/8" NPT x 1/4" SAE 1

20 000-068-149 Hose, CDS Blower Oil Drain 1

HydraMaster Corporation

Page 92

Clutch Drive System Page 7-25

Figure 7-13 CDS 4.6/4.8 Chemical Pump Assembly

C-4416 Rev B

OUTLET

INLET

CDS 4.6/4.8 Chemical Pump Assembly Parts List

Item Part Number Description Qty

1 000-106-110 Plug, Check Valve - Chemical Pump 2

2 000-064-015 Cover, Chemical Pump 1

3 000-111-030 Body, Chemical Pump 1

4 000-105-071 Mid Plate, Chemical Pump 1

5 000-046-010 Diaphragm, Chemical Pump 1

6 000-097-055 O-Ring, Chemical Pump Midplate An Size -227 Viton 1

7 000-097-056 O-Ring, Check Valve Plug - Chemical Pump 2

8 000-169-155 Valve, Check - Last Step Chemical Injection 2

9 000-143-152 Screw, 5/16"-24UNF x 1.50" Lg. Socket Head 6

10 000-097-054 O-Ring, Chem. Pump Valve Viton-Parker 2-114 2

HydraMaster Corporation

Page 93

Page 7-26 Clutch Drive System

Figure 7-14 CDS 4.6/4.8 DuraFlow APO Pump Assembly

D-5984 Rev B

6 53

CDS 4.6/4.8 DuraFlow APO Pump Assembly Parts List

Item Part Number Description Qty

1 000-111-169 Assembly, APO Pump - Jabsco 1

2 000-091-042 Motor, Bison 438 Series 1

3 000-015-908 Bracket, CDS Duraflow Power Pack 1

4 000-143-074 Screw, 1/4-20 x 1/2" Self Tapping 4

5 000-174-002 Washer, 1/4" Flat 6

6 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 2

7 000-033-020 Clamp, Size #16 Hose 2

8 000-068-528 Hose, 1" I.D. Reinforced 1

9 000-052-757 Insert, 1" NPT x 3/4" Elbow 1

10 000-052-758 Insert, 1" NPT x 1" Barb 1

HydraMaster Corporation

Page 94

Clutch Drive System Page 7-27

Figure 7-15 CDS 4.8 Dash Assembly

D-3932 Rev E

HydraMaster Corporation

Page 95

Page 7-28 Clutch Drive System

CDS 4.8 Dash Assembly Parts List

Item Part Number Description Qty

1 Fig. 7-16 Dash Panel Assembly - CDS 4.8 1

2 000-015-183 Bracket, Grounding Bus 1

3 000-015-184 Bracket, Relay Mounting 1

4 000-013-025 Dash Box, Painted 1

5 000-086-104 Latch, Dash Securing 1

6 000-157-022 Switch, Relay 2

7 000-131-027 Trimlock, 1/8" Id x 3/8" 1

8 000-143-114 Screw, #10-24UNC x 0.50" Lg. Flat Head 12

9 000-143-126 Screw, #10-24UNC x 0.50" Lg. Hex Head 3

10 000-143-046 Screw, #6-32UNC x 0.50" Lg. Pan Head 2

11 000-174-043 Washer, #6 Lock 2

12 000-060-002 Grommet, Large Wiring 2

13 000-143-166 Screw, #10-24UNC x 0.38" Lg. Hex Head 14

14 000-175-015 Washer, #10 Outside Star 2

15 000-105-053 Plate, Dash Name - HM 1

16 000-015-175 Bracket, Dash Box Support 1

17 000-131-027 Trimlock, 1/8" I.D. x 3/8" 1

18 000-174-015 Washer, #10 Outside Star 1

HydraMaster Corporation

Page 96

Clutch Drive System Page 7-29

Figure 7-16 CDS 4.8 Dash Panel Assembly

C-3820 Rev G

10 4

HIDDEN

1 15

HydraMaster Corporation

Page 97

Page 7-30 Clutch Drive System

CDS 4.8 Dash Panel Assembly Parts List

Item Part Number Description Qty

1 000-018-004 Breaker, 25 AMP Circuit 1

2 000-100-070 Panel, Dash - CDS 4.8 1

3 000-074-034 Gauge, Tach. Mag Pick Up 3-3/8" Dial Chev 03+ 1

4 000-074-018 Meter, Rectangular w/o Bezel 1

5 000-074-016 Gauge, Temperature 1

6 000-074-006 Gauge, Vacuum 1

7 000-084-015 Lamp, 12V 2W Round Red Indicator 3

8 000-084-004 Lamp, Replacement Guage 3

9 000-084-009 Lamp, Socket - Dashboard 3

10 000-157-040 Switch, 20 AMP Rocker 3

11 000-157-008 Switch, Ignition 1

12 000-033-049 Clamp, Indicator Lamp 3

13 000-052-084 Elbow, 1/8" NPT Street 1

14 000-052-096 Insert, #F23 (1/8" FPT x 3/16" Barb) 1

15 000-174-052 Washer, 3/8" Flat 1

16 000-056-006 Fuse Holder, Inline Weather Proof 1

17 000-056-003 Fuse, 15 AMP Plug In 1

18 000-074-019 Guage, Tach. 99+ Ford & 97-02 Chev 1

19 000-081-099 Label, Lower Dash - CDS 4.8 1

20 000-081-099 Label, Upper Dash - CDS 4.8 1

HydraMaster Corporation

Page 98

Clutch Drive System Page 7-31

Figure 7-17 CDS 4.6/4.8 Water Box Assembly

D-6990 Rev A

HydraMaster Corporation

17 6

Page 99

Page 7-32 Clutch Drive System

CDS 4.6/4.8 Water Box Assembly Parts List

Item Part Number Description Qty

1 000-159-107 Tank, Poly Water Box - Modified 1

2 000-015-938 Bracket, Water Box Mounting (4 Gallon) 1

3 000-041-005 Cover, 6" 1

4 000-143-314 Screw, #8 x 1/2" Lg. Pan Head 6

5 000-052-660 Bulkhead, 3/8" FPT x 3/8" FPT 1

6 000-052-086 Elbow, 3/8" NPT Street 3

7 000-052-023 Tee, 3/8" NPT Male Street 1

8 000-052-155 Tee, 3/16" Plastic Vacuum Insert 1

9 000-169-167 Valve, Mechanical Incoming Water - Water Box 1

10 000-052-105 Insert, #68 (3/8" NPT x 1/2" Barb) 1

11 000-174-063 Washer, 1.5" O.D. x 1.073" I.D. x 0.075" Thk. 4

12 000-057-052 Gasket, 1" Garden Hose 1

13 000-143-336 Screw, #10-32UNF x 0.25" Lg. Pan Head Phillips 1

14 000-052-099 Insert, #26 (1/8" NPT x 3/8" Barb) 1

15 000-068-326 Hose, 3/8" I.D. Clear w/ Braid Solution 1

16 000-033-005 Clamp, Size #5 Hose 2

17 000-094-097 Nut,1-14" Brass Water Box 3

18 000-052-662 Nipple, 3/8" NPT x 1/4" M SAE 1

19 000-097-041 O-Ring, 1/2" Bulkhead 2

20 000-174-032 Washer, 3/8" Flat 4

21 000-174-057 Washer, 3/8" Lock 4

22 000-143-017 Screw, 3/8"-16UNC x 0.75" Lg. Hex Head Grd. 8 4

23 000-049-151 Assembly, Diffuser Filter (Fig. 7-18) 1

24 000-052-754 Insert, #F816 (1/2" FPT x 1" Barb) 1

25 000-052-728 Bulkhead, 1/2" FPT x 3/8" FPT 1

26 000-157-0801 Assembly, Float Switch w/ Polypropylene Barrel 1

27 000-005-007 Float, Water Box 1

28 000-143-001 Screw, 1/4"-20UNC x 0.75" Lg. Hex Head 4

29 000-174-017 Washer, 1/4" Lock 4

30 000-174-039 Washer, 1/4" Outside Star 4

31 000-094-010 Nut, 1/4"-20UNC Hex 4

32 000-081-252 Label, Water Box 1

HydraMaster Corporation

Page 100

Clutch Drive System Page 7-33

Figure 7-18 CDS 4.6/4.8 Diffuser Filter Assembly

C-6554 Rev -

Diffuser Filter Assembly Parts List

Item Part Number Description Qty

1 000-052-074 Nipple, 3/8" NPT Hex 1

2 000-033-131 Clamp, Diffuser - Boxxer 427 1

3 000-125-222 Tube, Diffuser - Boxxer 427 1

4 000-027-115 Cap, 2" PVC Modified For Diffuser - Boxxer 427 2

5 000-052-104 Insert, #66 (3/8" NPT x 3/8" Barb) 1

HydraMaster Corporation

HYDRAMASTER CDS 4.8, CDS 4.6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

List of Figur es

Introduction

Cleaning and Chemicals

Operating Instructions

Freeze Guard

Pump Maintenance