HYDRAMASTER CDS HYDRA VAN User Manual

.

-.— —

20309 64th Ave. W. I Lynnwod WA 98036 I [phone]

Corporation

,*..

.

I

Parts Orders
How to Order
Warranty Policy

Cleaning & Chemical Precautions ..;...........................................................................................2

Cleaning Stroke Procedure/Over. wettin'g ..................................................................................2

Correct Cleaning Method Diagram ..........................................................................................."3

Water Flow Diagram

Water and Chemical Flow Operation .........................................................................................3

Water Softeners

Chemical Proportioning and Level Control Diagram .................................................................4

Chemical Tank Troubleshooting

Freeze Protection

Bypass Valve Diagram and Parts List ........................................................................................7

Jet Assembly Diagram ...............................................................................................................7

Wand Assembly Diagram ..........................................................................................................7

Valve Assembly Diagram ..........................................................................................................7

Stem Assembly Diagram ...........................................................................................................7

.............................................................................................................................

...........................................................................................................................

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................................................................................................................

........................................................................................................................

.....................................................................................................................5.6

Table of Contents

1
1

2

3

4

...............................................................................................4.5

Vacuum System Information and Diagram ................................................................................~

Vacuum Tank Filter Bags .........................................................................................................~

Blower Lubricant and Filliing Procedure
Vacuum Blower Troubleshooting Guide

Vacuum Blower Warranty ........................................................................................................ll

Cat Pump, Operating Instructions, Drive Information, Dimensions, Specifications .....................l2-l3

Cat Pump, Exploded View, Parts List

Cat Pump Troubleshooting Guide ..............................................................................................l5.l6

Cat Pump, Repir Information, Service Kits

Cat Pump, Servicing the Pumping Section, Servicing the Valve Assemblies ...............................l8

Cat Pump, Servicing Sleeves and Seals, Servicing Crankcase Section
Cat Pump Warranty

Electric Diagram
Electrical System Troubleshooting

Maintenance Procedures
Maintenance Log

Warranty Information, Procedures

Golden Guarantee Limited Warranty Plan Text ..........................................................................24

..................................................................................................................2o

.......................................................................................................................2l

.............................................................................................2l

............................................................................................................22

.......................................................................................................................22

.............................................................................................23

...................................................................................8.9

...................................................................................lo

........................................................................................l4

..............................................................................l7

........................................19

To r?xpr?dfle your parts needs, please call your sales represen­tatwe. In most Instances, he either stocks or has access to parts
through a regional serwce center

In the event parts are unavailable locally, contact the factory and
ccwrdinate your needs. If this becomes necessary, always Indicate
the method of shipment you desire I e. U P S U P S Blue Label,
Air Freight, Alr Express, e[c,

REPLACEMENT PARTS

PART MO.

000-078-015

~00-078-019

. ..—-..

000-078-034

<00-076-005 Spray Jet 8006E

000-049-028

500-078-001

000-078-004

000-052-050

.- ~... .... —.—...——.

000-052-051

~00-052-052

.— .... ——. -——. .—. ._- —..

000-052-053

000-010-019

DESCRIPTION
Flow Meter Kit
Wand Valve Piu~cjer Kit
Pressure Bypass Valve Kit 1

Recovery Tank Flker Ba~
Cat 2!)0Short CU6 Kit Standard ‘“- I
Cat 290 Hot CUD KIt (Ootlonal)

440 Male C)ulck Connect
440 Female Quick Connect

-—.—. .—. ..—_.
660 Male Quick Connect ““

660 Female QUICK Connect-”
Belt, Pump Drive AX-26

QTY.

1
1

1

2

1

1
1
1
1

HOW TO ORDER

To obtain a proper diagnosis of your maliunctlon, and to order
warranty replacement paris. I! IS Impor(ant (hat you proceed In Ihe

,

following manner:

1

Call HydraMaster Warrarrly Serv{ce Dept. at [phone]

2,

Give the Warranty Service Representative lhe followlng
lnformat[on:

A, Name of your company and your address
B, Equipment Model (i.e CDS),
C. Date of purchase
D. Hours on the unit.
E. Sertal number of umt
F Name of person authorized to order parts.
G. Salesman unit purchased from
H. Descr~ptlon of rnalfunc!lon

1. Pressure readings on nigh pressure gauge with wand [urnea
on and off

3.

If warranty replacement parts are ‘~eeded, please spec[fy
method of sh!pmenl desired NOTE: All replacement parls are
sent freight collect, va

A. U.P S
B. Air freight
C Alr mall
D. Air express
E. Auto Freight

4

Do not give malfunctioning parts to a HydraMas!er Sales or
Serwce Representatwe All parts must be returned directly
to Hydra Master, freight prepaid.
20309 64th Ave. W Lynnwood, WA 98036

1

...

.

HydraMaster WARRANTY POLICY

Effective April 1, 1988

HydraMaster warranty covers only defective materials and/or
workmanship for the periods listed, Labor, and/or diagnostic
reimbursement is specifically excluded.

Any questions you have regarding the warranty program should be
directed to the Warranty/Service Dept. Personnel at HydraMaster
Corporation.

We shall always endeavor to be fair in our evaluation of your
warranty claim, and shall provide you with a complete analysis of
our findings.

Written WARRANTY information is located inside the back
cover of this owners manual.

HOURS:

MONDAY THROUGH FRIDAY

8:OOam TO 6:OOpm

PACIFIC STANDARD TIME

,

PST ROCK MT.

CENTRAL

EASTERN

TELEPHONE NUMBERS

GENERAL OFFICES: [phone]
PARTS DEPT [phone]
SERVICEIWARRANTY [phone]
NEW EQUIPMENT SALES

AND MARKETING:

FAX:

AND

[phone]

CHEMICAL

1.800-426-1301

PRECAUTIONS INFORMATION

Your mobile carpet cleaning plant has been engineered using the

latest and most sophisticated technology available, to produce the
finest carpet clean[ng results possible. Desp!te this however, it re­mains only a tool of the carpet cleanlng trade, and it can produce
only as good a job as the person operattng It.

There are no short cuts to good carpet cleaning, it requires time,
cleaning knowledge and the use of good chemicals.

Manufacturer recommends the use of spotting agents, and traffic

lane cleaners prior to the actual cleaning of carpeting, as required.
CAUTION when cleaning cut-pile acrllan plush carpets: Using high

heat setting may result in ftber damage
The use of some chemicals through your mobile carpet cleanlng

plant can seriously damage the internal plumbing, high pressure
pump and heater. (Chemical such as concentrated acids and
some paint oil and grease removers w/high concentration of
solvents.)

Manufacturer recommends only the use of chemicals containing

rust and corrosion inhibitors and water softening agents to prevent
chemical build-up.

NOTE: At no time should a chemical solutlon with pH of less than 7
or higher than 10 be used In the unit.

CLEANING STROKE
PROCEDURE/OVER-WETTING

Purpose:

To ellminate excess moisture remaining In the carpet fiber and the
sawtooth appearance which results from diagonal movement of
the cleanlng tool on all types of carpet

Procedure:

Always move the cleaning iool In smooth forward and backward
strokes. Apply slight pressure to [he 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 mlntmize the “hopping” effect resulting on unsmooth
carpet. 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 to prevent saturation when cleanlng wand is stopped
twice at the same point al the rear of the cleaning stroke.

Failure to adopt this procedure can result In Increased chance of
“clean streaks”,
periods.

fiber shrinkage, brown out, and longer drying

pH CHART

1

234567891011 12

I I

1
+ ACID

I I I

I

— NEUTRAL

I I I I

‘ALKALINE~

I I

13 14

J

INCORRECT METHOD

—

CORRECT METHOD

Overlap Belween Strokes

~/l~/~b/+l,L,!’J>vlj /+: !; ‘; , ‘

,,/

‘1

T

,,

CLeaningTool’

II

Over-Wettinu

Over-wetting IS a;noylng to all concerned and sometimes leaves a
bad trnpresslon of the cleanlng process used

These are several areas that WIII cause over-wetting

1 Too few vacuum strokes or Improper saw Iooth vacuurv strokes

as shown above.

2. Obstructed. kinked or cut hoses

3. Vacuum tank drain valve left partlaiiy open
4 Clogged vacuum blower filter or vacuum tank lid nor seallng

properly.

5 Cleanlng a heavily foam-saturated carpet without defoamer

(We recommend crystal type.)

L.+-$_..;&y=..=...

1

First

I

Cleanlng Cleanlng
Stroke Stroke

Second

‘WATER FLCIVV

A. Pressure Gauge
B. Hot Water Shut-Off Valve Controf K Heat Exchangers
C. Bypass Valve
D. High Pressure Solutlon Outlet
E. fncomina Water
F. Drain ­G, Radiator Water (Out)
H. Proportloner

1, Chemical MIX Tank

J Pump Inlake

L. Radia[or Water (In)
M Pump Output
N. Bypass Return

0. Chemical Flow Meter
P Chemical Jug

Q. High Pressure Pump

R Pump Inlel Filter

(no{ shown)

--_-..l

,

WATER AND

CHEMICAL FLOW

OPERATION

This system has been designed to be the most simple and trouble­free ever

The incoming water flows directly to the mlx tank. Water WIII now

flow through a proporhonlng valve which WIII simultaneously mlx
the chemical to achieve your desired solution. The mlx tank IS
equipped with 2 different float valves, one of which responds [o the
water level of the tank and WIII mainiain the proper volume of solu­tion to be reserved for the cat pump. The secondary float valve IS a

safety valve that IS designed to protect your system from sudden or
unexpected loss of water supply. ff, for example, the water source
at the house was turned off, the water level of the mlx tank
would drop. activating the secondary valve which automatically
disengages the electric pump clutch.

In conjunction with the incoming flow, the chemical ratio may be
obtained by an adjustment of the chemical flow meter during the fill
cycle of the mix tank. The chemical will flow from the chemical Jug
to the chemical flow meter, then to the proportioner where It IS
distributed into the mix tank at your de.wred proportion. This line

should be flushed with vinegar weekly to prevent abnormal
chemical build-up. This may be done by removing the clear plastlc
hose from the chemical jug and inserting it into a one quart con­tainer of vinegar. This should be done with the chemical flow meter
setting on 10 GPH with heater “off” Simply spray the wand for the
duration of the vinegar in the one quart container, then repeat the
process with clear water to void all lines of vinegar.

NOTE: With this unique chemical system, your chemical flow is
proportioned to the filling cycles of the mix tank, not the direct
spraying of the wand. Therefore, it is possible that as your wand IS
spraying, you may have no chemical flow. Also, the converse IS
true In that you may not be spraying your wand but, if the mlx tank

IS In a ftlhng cycle your chem{cal flow rmeter may read vour desired
flow

This chemical system WIII mlx a 1 1030 ratio when flow meter IS sei
at 5 GPH. Most chemical suppllers WIII recommend a 1 10 15 ratio
therefore you can either set the flow meter at 10 GPH, glwng you a

1 to 15 rat!o of chemical to cleaning water, or double the recoin.
mended strength of chemical in the 5 gallon jug ano set the flow
meter at 5 GPH, thereby attalnlng a 1 to 15 ral{o If IS lecom ­mended that you set the flow meter al 10 GPH for overall best

results. )

The water WIII now be siphoned frorr lhe bottoln ot lhe m!x tank to
the Cal Pump If the wand IS not spraying, the water WIII bypass
from the bottom of the brass pressure rellef valve to tne mix tank

3

.

WATER SOFTENER

Many areas of the country 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,

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 in the increased life of machine parts and cont[nued
cleaning efficiency. The water softener will also increase the effec­tiveness of the cleaning chemical being used, 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, Example: If the softener will treat 900 gallons of
water and the machines uses an average of 30 gallons per hour of
use on an average of 5 hours a day would be 150 gallons a day
would be treated, Five days would equal 750 gallons of water,
therefore, the softener would be changed every 6 working days for
maximum softening,

WATER SOFTENER HOOK-UP

CHEMICAL PROPORTIONING AND
LEVEL CONTROL

Valve Body Cap

/

/

f;?

Proportlontng Valve Repair Kit
000078

Ball Nut
W ‘Set Screw

-’/

–C=U*::;

+7J

i

Outlet

Tube

L

Proportioning
Venturi

—Main Valve

Diaphragm

—

+------Adjustment

Screw

\,

-Chemical
“ck ‘p ‘ose<-”

Mounting
Bracket

8

f

Foot Valve and ‘;
Screen

—.

m

Underwater

Float

Assm.

~

Feed

Extension

,....- .

USl

L/

/

Float

Water Softener

CHEMICAL TANK TROUBLE SHOOTING

PROBLEM: No or Low Chemical Flow
Solution
Check that hoses in the tank are secured. Check that the

hose from the top of the flow meter to the side of the mix
tank IS secured with no kinks. Check the hose from the
bottom of the flow meter to the chemical jug for kinks or
cracks.

Check the foot valve and screen on the end of the hose

which goes into the mix tank. To check this screen for
proper function, remove it from the plastic hose. You
should be able to suck through the hose barb end, but you
should not be able to blow through the hose barb end. (If
you can not suck through it then rinse It out with vinegar. )
When screen IS removed the chemical fill hose should be
lifted into a vertical position so the ball In the foot valve
will seat by gravity. (This is only a temporary fix for low

water pressure areas. )
Check flow meter for float obstruction.
Check to insure that the adjusting screw on proportioning

venturi is backed out.
Is proportioning venturi closed? Soak in warm water or

vinegar solution,
Is incoming water pressure less than 20 PSI?
Cracked or defective chemical flow meter?
NOTE: If you are in a low water pressure area and find that

the volume of water entering the mix tank is not enough to
allow your venturi to siphon chemical, unscrew the spring
from the foot valve screen and remove the spring,

4

.

PRO EtLEM: Inability to Adjust Chemical with the Flow Meter
Solution
Debris lodged behind teflon seat In flow meter knob.

Teflon seat dismounting from flow meter knob.

PRQBLEM: Solution Reversing from Mix Tank to Chemical

Jug
Solution
Anti-siphon screen removed from chemical jug hos>,

Debrvs in anti-siphon screen,

PROBLEM: Mix Tank Overflows
solution
Float ball in mix tank hanging up (not moving freely)

Extension bracket plnchlng the float lever, restrlc!{ng full

act~on of the lever.

Plunger not seating properly on the valve. (Remove th6 2

screws which hold the extension assembly to [he valve
Do not lose or drop the screws. Remove the extension
assembly. Turn it upside down Inspect the plunger for
proper seattng. If there !s no debris obstructing the valve
or plunger, the plunger may be out of ad)ustmen[. To ad-

just, loosen the set screw on the ball nut and move the

ball toward the end of the rod 116’”. Retlghten set screw
Place extension assembly back Into posltlon Tighten the

two screws,

—.

..—

PROBLEM: Mix Tank Doesn’t Keep Up With Water Output
Solution
Check garden hose quick connect assembly screen

Check garden hose andor feed hose IP

kinks or blockage.
Float ball In mix tank hanging up (Not mo\lng treely, j
Extension bracket plnch[ng float lever, restricting full action of

lever

Valve plunger not opening fully To adjusl, remove the 2

screws which hold the extension assembly to the valve.

(Do not lose or drop the screws ) Remove lhe extension

assembly, turn It up side down To adjusl, loosen the set

screw on the ball nut Place vour Ihumb on the plunger

and press [t In 1 16” and sllde the oall nut w set screw

toward the plunger end 1 16’ Tghter Ihe set screw
Place ihe exten ;Iofl assembly back nto pos{tlon If the

tank starts to o\erflll, the ball nut m to close to Ihe valve

plunger and should be Imoved back away from the valve
plunger slightly.

PROBLEM: Pump Pulsates When The Tank Is in a Fill Mode
Solution
Check that the hose which goes from- [he grav”plast!c venturi

to the bottom of the tank IS not drecled toward Ihe Cat
pump pick up port If It m a!rn II m ano[her drec[lon

!he mx tank for clog,

-----

FREEZE PROI”ECTION

Any freezing of this machine IS not covered by warranty and dur-

ing the colder months of operation, careful protection should be of

utmost concern
THE FOLLOWING PRECAUTIONS ARE RECOMMENDED:

Run machine before Ieawng for the Ilrst job to Insure nothing

1

has frozen the night before, Including hoses and wand
Insulate the garden hose from the cold ground by running t

2

through an extra 11z Inch vacuum hose

3

Leave truck doors closed until time cleaning begins, [hen operl
shghtly,

4

In colder climates, Insulating the truck walls and floor boards WIII
hetp protect the unit

Don’t procrastinate during the cleaning operation or [he hot

5

water solutlon Ihne WIII also freeze on the ground The solutlon
Ilne should be insulated (n extremely cold clrmates.

Whenever possible, the truck should be stored In a heated

6

garage at mght or over the weekend. If not possible, place a

1500 watt electric heater tnslde the truck, aimed directly
at the machine. Never use a propane heater - It causes ex­cessive moisture on the truck celllng and the poss~bllty of It

going out IS higher If the machine and truck are left outside with

a heater, you should first drain all possible water from the
machine cleaning tools and hoses. (They freeze also )

TO DRAIN THE MACHINE, FOLLOW THESE STEPS
A,B,Before shutting off the machine, remove the chemical Ilne from

the chemical jug and place in a mixture of 50/50 anti-freeze and
water. With the cleaning tool on, allow m!xture to fill chemical
system back to the chemical m{x tank.

Open the mix tank drain valve and allow the water to drain
thoroughly from the mlx tank.

C. Remember to close the drain valve prior lo next operation of

your CDS unit.
Check ENGINE Antifreeze regularly
BE SURE IT’S PROTECTED

Freezing will cause GRIEF,
mess with mother nature!

MONEY and DOWN-TIME. Don’t

5

FREEZE PROTECTION OF CLUTCH

DRIVE WITH PUMP-IN SYSTEM

1.

Start with machine In cleaning mode.
Drain chemical mix tank. (fig. 1)

2.
While chemtcal mlx tank IS draining: Insert chemical feed Irne

3.
into antifreeze prem!x lug and allow meter to fill with premix
anti freeze for 10 seconds. Close chemical flow meter when
protected, (fig. 2)

4

Shut machine down Connect short hose to high pressure
quick connector and dratn heat exchanger of cleaning water.
(fig. 3)

Remove pump-in system hose from water storage tank and in-

5

sert it into antifreeze premix jug. (fig. 4)

/.

6

Close chemical mlx tank drain valve and allow pump-in system
IO refill mix tank wllh antifreeze premix solutlon. (fig, 5)

Start unit wtth cleaning wand and hoses connected and spray

7.
into a bucket for 20 seconds to allow the antifreeze toprotect
the high pressure gauge and system Ihnes. After running the
wand spray for 20 seconds, shut wand off and let it run for

10 seconds 10 allow the bypass system to be protected. (fig. 6)

8.

Turn off cleantng system Master Power Switch. You /may want
to leave the pump-in hose out of the tank so it won’t freeze to
the residual water in the tank. The next day, refill the tank and
replace the hose, If layer of Ice, the hose w!II slt on top of it and
gain proper suction.

9,

Reconnect pump-in hose to water storage tank

fcomwed nexr page)

Fig, 1 Fig. 2

10. Place bucket under drain hose of chemical mix tank and open
drain valve again to reclaim antifreeze premix. When tank is

I

empty, reconnect short hose to high pressure quick connector
and drain heat exchanger into bucket, (fig. 7)

11, Shut off valves and pour all reclaimed antifreeze from bucket

back into the 5 gallon antifreeze premix lug so it can be used
again. (fig. 8)

12. Before cleaning the next day run unit for 3 minutes to void all
excess antifreeze from the system.

Fig. 3

Flg

4

tmnhwed nexl

page)

Fig. 5

Fig. 6

Fig. 7

Fig. 8

BYPASS VALVE

7

M9-lc31

Bypass Valve Parts List

R~F. NO. PART NO.

3.

000-105-101 Thrust Plate, Bypass

4.

000-105-102 P[ston Plate, Bypass

—.

5

000-078-101 Kli. Seal for 8vt)ass

DESCRIPTION

Valve

Valve

———.

“Q

Q;

1,

.’

5

AsiJ

bl!fjJ-

/’SF’

QTY.

1

1

JET ASSEMBLY

Brass Cap.

k

..- ‘ ‘

@

WAND ASSEMBLY

See “Valve Assembly’.”.

Frame Tube,

“x ‘

Bodv

\

‘8006E

Stablllzer

>~~ ‘

“ad

Handle Sleeve

,3

“S. S Solu[lon

Hose

S S Handle

VALVE ASSEMBLY

-..,.,.,

STEM ASSEMBLY

Keeper Ring +

Plunger --

‘Wand Ltp

I

Q+- Retaner

q3

I

Quick’

Connect

v

I

@—-

I
I

O-R,ng

VACUUM SYSTEM INFORMATION

%3LfGap

8

The vacuum blower incorporated in this machine is a positive
displacement lobe type, manufactured by Cooper Industries. The

performance and life of this unit is greatly dependent on the care
and proper maintenance it receives.

Because of the close tolerances between the lobes and housing of
the vacuum blower, solid objects entering the inlet will damage the
internal lobes, gears and bearing or direct drive coupler.

To prevent this, a stainless steel filter screen has been placed at
the vacuum inlet inside the vacuum recovery tank. This stainless
steel screen is finger tight and should be removed weekly for
cleaning.

Caution should be used when machine is being run for test pur­pose and the vacuum inlet on top of machine is open,

To protect the vacuum blower from overloading and damaging
itself, there is a vacuum relief system installed on the vac tank.
When the vacuum tank inlet is completely sealed off, a maximum
of 12 HG will be attained. A blower lube port is located above the
vacuum gauge; at the end of each day, LPS 1 or WD-40 is sprayed
in before shutting down the machine. See blower lubrication
illustration. If you fail to lubricate the vacuum blower daily, rust
deposits and moisture will decrease the life of the vacuum blower,

Caution: Foam passing through the blower could lead to serious
problems, therefore, it is Important to keep the vacuum tank foam
free.

,.

VACUUM FLOW

Filter Bag

r-T-7%-----=

FlrFTlll

“-’-z”i#

Vacuum

Hose To
Cleamng
Wand

w

Recovery Tank

\

Blower

Vacuum Blower Silencer

Exhaust

VACUUM TANK FILTER BAGS

HydraMaster filter bags are designed to trap most of the lint, sand

and dirt that would normally collect at the bottom of your vacuum
tank, The use of these bags, if emptied at the end of each job, will
eliminate the build-up of much of the debris in the tank and avoid a

mess The drawstring top of these bags is designed to be tied to

the incoming dirty w~ter’inlet in the v~cuum tan~
To re-order bags use part number 049-029.

“ty Water

Tank

‘Filter Bag

BLOWER LUBRICANT

Spray lubricant into blower lube port for 3 to 5
seconds, then immediately shut off machine.

Use only LPS 1 or WD-40 moisture displacing
lubricants.

At the gear end the timing gear teeth are lubricated by being
partially submerged. The gear teeth serve as 011 sllngers for

gear end bearings. At the drive end the bearings are grease

lubricated,

FILLING PROCEDURE

Remove square head vented oil fill plug (A) on gear end.
Remove oil level plug (B) located in the head plate. Fill gear

case until oil drips out of the o(I level hole (B)

Use lubricants as listed

Add fresh oil as required to maintain proper level, The 011
should be drained, flushed and replaced every 1500 hours or
more frequently If Inspection so indicates. The oil drain plug IS
at (C),

NOTE: Older units may have the 011 fill level and drain holes
located in the cast Iron gear case instead of In the head plate

Bearings on drive end of blower require grease Iubr[catlon
every 100 hours of operation. Bearings which require grease
lubrication will have a grease fitting (D) at each bearing. When
regressing, the old grease will be forced out of the vents during

operation. To prevent damage to seals, these vents must be

kept open at all times.

I

Serwce every 500 ho. u of ope(af, on

-

I

9