HYDRAMASTER CDS HYDRA VAN manual
Contents
1. e 0 787 Stroke co reca eser ud 0 472 Crankcase Capacity 10 oz Maximum Fluid Temperature 160 F Inlet Ports 1 1 2 Discharge Ports 2 3 8 NPT Pulley Mounting Either side Shaft Diameter 0 650 Weight Sse REED 12 1 Ibs Dimensions 10 77 x 9 06 x 5 147 13 13 L M 85 BAR 0 6 to 2 8 BAR 1200 RPM 20 mm 12mm 3L 719 12 3 8 Either side 16 5 mm 5 5 kg 273 5x230x130 5mm CAT PUMPS Model 29 OPERATING INSTRUCTION CAUTION CAT PUMPS are positive displacement pumps Therefore a properly designed pressure relief mechanism MUST be installed in the discharge piping Failure to install such relief mechanism could result in personal injury or damage to the pump or system Cat Pumps Corporation does not assume any liability responsibility for the operation of a customer s high pressure system Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 and 3930756 IMPORTANT DRIVE INFORMATION Pump speed and pump output in gallons per minute as tabulated 15 based upon a 1725 RPM drive motor Select motor pulley size and provide GPM of the approximate pump output desired Pump RPM and GPM ouiput are approximate values due to varia tions in pulleys belts and motors between manufact2. and replace vacuum tank seal NEN _ Defective or open vacuum tank dump valve Close valve Replace valve Fractured weld on vacuum tank Re weld as required or replace tank NEN Collapsed or kinked vacuum hose Reshape hose if possible and or eliminate kinks 0 Plugged vacuum hose _ i Remove obstruction by reversing the vacuum hose Restriction in cleaning tool Remove obstruction Worn end plates or lobes in vacuum blower Replace worn components NOTE Must be accomplished by DP 2 qualified technician Loose drive shaft between clutch and blower The set screws may come loose causing blower to stand still while engine may be turning properly NOTE Uniess the blower is seized making knocking noise your vacuum loss is not caused by a bad blower PROBLEM Blower is Seized Cause FREE Solution E NATL ET Rust Spray rust dissolving lubricant onto lobes to emulsify rust and _ _ _ 2 attempt to rotate vacuum lobes Foreign matter Disassemble and remove foreign matter and repair as required NOTE Disassembly must be accomplished by qualified technician NOTE The above mentioned rust foreign matter and seizing are often caused from foam traveling through the blower PROBLEM Noise in Vacuum Blower Cause Solution Loose Direct Drive Coupler Examine universal shaft for defects and reti
3. Cause Solution Damaged or worn chrome plating of the cylinders Replace cylinders Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Excessive pressure and or temperature of fluid being pumped Check pressures and fluid inlet temperature be sure they are within specified range Over pressure of pumps Reduce pressure Running Pump dry Do not run pump without water Front edge of piston sharp Replace with new piston Chrome plating of cylinders damaged causing excessive wear of cups May be caused by pumping acid solution Install new cups and cylinders Pump only fluid compatible with chrome PROBLEM Strong surging at the inlet and low pressure on the discharge side Cause Solution Foreign particles in the inlet or discharge valve or worn inlet and or discharge valves 16 Check for smooth lap surfaces on inlet and discharge valve seats Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone damaged cups and discharge valves cannot be lapped but must be replaced GENERAL INFORMATION FOR CAT PUMP REPAIR As you remove your discharge manifold there is a set of 3 check valves which usually fall out during dis assembly If the surfaces of these check valves are dirty or show signs of chemical build up it is probable that they would remain open causing pressure loss or pu
4. HYDRAMASTER CDS HYDRA VAN CLUTCH DRIVE SYSTEM OWNER S MANUAL HYDRAMASTER Corporation 20309 64th Ave W Lynnwood WA 98036 206 775 7272 Table of Contents Parts Ordes a ea eS E EEE R AERE E EOE RAS ROEE EE IN A PO 1 How to OrdeTeca eda ae E cites ERVA EEA AN NE apre dnm TO med ease sages 1 Warranty POliCY sass 2 Cleaning amp Chemical 2 Cleaning Stroke 2 Correct Cleaning Method 3 Water Flow 3 Water and Chemical Flow 414 1 1121 eene eene ettet nett 3 Water Softeliel su cce etia seda ies T SAT ea Ranga 4 Chemical Proportioning and Level Control Gi Tuer nb tione ng 4 Chemical Tank Troubleshootllg i uere tenore races SERES rA deir SES 4 5 Freeze t Ae DRE adsense EEEE EEEE 5 6 Bypass Valve Diagram and Parts List eene nennen nennt ennt 7 Jet Assembly Dig Gram 7 Wand Assembly nes 7 Valve Assembly Dia Urin ERE 7 S
5. cover of this owners manual HOURS MONDAY THROUGH FRIDAY 8 00am TO 6 00pm PACIFIC STANDARD TIME ROCK MT PST CENTRAL EASTERN TELEPHONE NUMBERS GENERAL OFFICES 206 775 7272 PARTS DEPT 206 775 7276 SERVICE WARRANT Y 206 775 7275 NEW EQUIPMENT SALES AND MARKETING 1 800 426 1301 FAX 206 771 7156 CLEANING AND CHEMICAL PRECAUTIONS INFORMATION Your 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 re mains only a tool of the carpet cleaning trade and it can produce only as good a job as the person operating 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 acrilan plush carpets Using high heat setting may result in fiber damage The use of some chemicals through your mobile carpet cleaning 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 NOT
6. WATER FLOW 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 above 2 Obstructed kinked or cut noses 3 Vacuum tank drain valve left partially open 4 Clogged vacuum blower filter or vacuum tank lid nor sealing properly 5 Cleaning a heavily foam saturated carpet without defoamer We recommend crystal type WATER AND CHEMICAL FLOW OPERATION This system has been designed to be the most simple and trouble free ever The incoming water flows directly to the mix tank Water will now flow through a proportioning valve which will simultaneously mix the chemical to achieve your desired solution The mix tank is equipped with 2 different float valves one of which responds to the water level of the tank and will maintain the proper volume of solu tion to be reserved for the cat pump The secondary float vaive is a safety valve that is designed to protect your system from sudden or unexpected loss of water supply If for example the water source at the house was turned off the water level of the mix 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 mete
7. 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 pur pose 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 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
8. rod Install the first o ring in the groove on the piston rod Next position back up ring against the shoulder in front of the first o ring Then install the second o ring Exercise caution as you slip the o ring over the thread end of the piston rod Examine sleeves for scoring or etching and replace Immerse sleeves in oil and carefully twist and push sleeve onto rod machined counter bore end first Next install seal retainers If wicks are used replace wicks thoroughly saturate with oil place in seal retainer and install retainer Place inlet manifold on pair of clearance blocks with crankcase side down and drive out old seals Invert inlet manifold with crankcase side up and install new seals Lubricate circumference of sea and install Prrrrrm A Lube seal with garder spring down using blue dct seal blue dot should be facing up when installed Slip lubricated seal inserters onto piston rod ends position inlet manifold onto pump and remove seal inserters NOTE Replace original quantity washers on studs before replacing inlet manifold NOTE Some models secure inlet manifold to crankcase Replace fasteners and torque per specification chart Reassemble piston assemblies and discharge manifold as described SERVICING CRANKCASE SECTION 1 While inlet manifold sleeves and seal retainers are removed examine crankcase seals for wear 2 Check oil level and for evidence of water in oil
9. 2 49 21985 Bac Up Ring Cylinder ui 3 20 27950 Seal Case 2 22 50 24459 Discharge Manifold ME 21 92519 Sems Comb Head Screw 25634 Discharge Manifoid S S 1 Me X 19 8 51 43442 Valve Spring Retainer 3 23 101798 Connecting Rod 3 52 43360 Valve Spring GNE MEE 3 24 101800 Piston Rod 3 53 43723 Valve 3 23 15945 SION Ein 54 43434 Discharge Valve Seat 3 26 20017 Seal Washer 3 56 81109 Hex Nut 8 gt 772 BE 01 N Seal s 57 101804 Hex Flange Nut 8 _ pow d 58 52327 S nne Slinger 758 25130 Shaft Protector 28771 O Ring Sleeve Viton 3 Electric Clutch Assembly 30 29003 Back Up Ring SI 3 59 152 005 Tapered Sleeve 1 poe aE agp Teflon 60 077 005 Key Electric Clutch 1 31 29614 Sleeve 29743 Unchromed 3 61 036 005 6 Electric Clutch 1 32 20854 58 washer 3 62 143 084 8 20 mm Socket Head Screw 1 51 SE Manifold 63 174 004 Flat Washer 5 16 US 1 25635 _ Inlet Manifold Stainless Steel 1 94 1742018 Lock Washer 58 08 l m DD CAT PUMP TROUBLE SHOOTING GUIDE PROBLEM Pulsation Cause Debris discharge valves of f pump Solution Clean or replace discharge valves PROB LEM Low Pressure Cause Worn nozzle Bel Pressure gauge inoperative or not registering accurately Relief valve Stuck partially plugged or improperly valve seat worn Inlet suction strainer clogged or improper size Worn piston assembly Abrasives in pumped fluid or
10. iae WEEKLY SERVICE DATEHRS DATE HRS DATE HRS DAIEHRS DATE HAS DATE HAS DATE HRS 25 BLOWER check levei 25 PUMP OIL check lop of sight gauge Sra 25 DRIVE SHAFT SYSTEM tighten set screws 25 BELTS amp PULLEYS check ughiness 25 PRESSURE LINES check lor chaling 25 NUTS 8 BOLTS check ughtness 25 BATTERY LEVELS check d 25 VACUUM TANK clean daily 25 WIRING check for chafing 25 CHEMICAL SYSTEM flush w vinegar MONTHLY SERVICE 100 ENGINE OIL change 100 BLOWER grease bearing 100 ENGINE AIR CLEANER clean 100 BY PASS VALVE grease cup 8 stem T op E A z QUARTERLY SERVICE 3 MONT 300 BLOWER OIL change 300 ENGINE compression 300 SPARK PLUGS change 500 DRIVE SHAFT Grease U Joints YEARLY TRUCK MAINTENANCE COMPLETE TUNE UP COOLING SYSTEM flush add new anti freeze 8 TRANSMISSION FLUID change 22 SERVICING SLEEVES AND SEALS DISASSEMBLY 3 Remove discharge manifold and piston assemblies as described Remove inlet manitotd containing seals Grasp sleeves and with pulling and twisting motion remove Ine sleeves from the piston rod NOTE Grasp sleeve with pliers only if replacing worn sleeves as this procedure will mar the sleeves Nexl remove seal retainer
11. may read your desired flow This chemical system will mix a 1 to 30 ratio when flow meter is set at 5 GPH Most chemical suppliers will recommend a 1 to 15 ratio therefore you can either set the flow meter at 10 giving you a 1 to 15 ratio of chemical to cleaning water or double the recom mended strength of chemical in the 5 gallon jug set the flow meter at 5 thereby attaining 1 to 15 ratio ilt is recom mended that you set the flow meter at 10 GPH for overall best results The water will now be siphoned from the bottom of the mix tank to the Cat Pump If the wand 16 not spraying the water will bypass from the bottom of the brass pressure relief valve to tne mix tank 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 continued cleaning efficiency The water softener will also increase the effec tiveness of the cleaning chemical being used therefore
12. otherwise express implied or statutory and HydraMaster shall have no liability for consequential incidental or other damages howsoever caused 5 25005 See Lele Aiea Ree 3 years VACUUM RECOVERY TANK CHEMICAL MIX 65 222222222 2 21 02122 0 000100400 0000004000900 05 00000 3 years ENGINE Through original Manufacturer Oa Direct Drive units sce original Manufacturer s warranty 2 years VACUUM BLOWER Through original Manufacturer See Cooper Industries nitrate tenente 2 years EXTERNAE MACHINE HOS ES eunte A aes eie pee De De p pedet ace boe A at Td e a teinte gant 1 year BELTS FITTINGS FILTER SCREENS GAUGES WATER HEATER OR HEAT EXCHANGER HIGH PRESSURE PUMP Toroogh original Manufsctorer ssccecscecssereceeescscseeeeseeesseaescacesecesseaeeseecenescacseeeeeevesanceneesntaeeseeusseteeesesssteserteetecseeereeeeeee components not specifically referenced in the above schedule are covered under this warranty for a period of one 1 year excepting those parts which are considered by HydraMaster to be expendable in normal use Freezing of any water or chemical related component will VOID all warranties on water or chemical related components internal or external of this equipment De
13. severe cavitation Inadequate water supply Fouled or dirty inlet or discharge valves _ Worn inlet or discharge valves _ Leaky discharge hose _ _ Tighten or repiac _ Solution ue Replace nozzle of proper size use correct belt Disassemble reseal and reassemble Check with new gauge replace worn or damaged gauge N 06090 Clean and adjust relief valve check for worn and dirty valve seats Kit available Clean Use adequate size Check more frequently Install proper filter Suction at inlet manifold must be limited to lifting less than 20 feet of water or 8 5 PSI vacuum Clean inlet and discharge valve assemblies Replace worn valves valve seats Replace discharge hose PROBLEM Pumps runs extremely rough pressure very low ause ET Restricted inlet or ring inlet imbing Inlet restrictions and or air leaks Damaged cup or stuck inlet or discharge valve Worn inlet m Solution Proper size inlet plumbing check for air tight seal Replace worn cup or cups clean out foreign materia worn valves replace Replace worn seals PROBLEM Cylinder O rings blown next to discharge manifold Pressures in excess of rated PSI Warped manifold Solution Check for plugged nozzle closed valves or improperly adjusted by pass valve manifold PROBLEM Leakage at the cylinder O rings at the discharge ma
14. 0 00 0 0000 0 00111 23 Golden Guarantee Limited Warranty Plan 1 1 1 4 4 4 2 4 1 00 24 To expedite your parts needs please call your sales represen tative In most instances he either stocks or has access to parts through a regional service center In the event parts are unavailable locally contact the factory and coordinate your needs If this becomes necessary always indicate the method of shipment you desire e UP S U P S Blue Label Air Freight Air Express etc REPLACEMENT PARTS PART NO DESCRIPTION QTY 000 078 015 Flow Meter Kit 7000 078 019 Wand Valve Plunger Kit Pressure Bypass Valve Kit 000 076 005 Spray Jet 8006E 000 049 028 Recovery Tank Filter Bag 000 078 001 Cat 290 Short Cup Kit Standard 000 078 004 290 Hot Cup Kit Optional _ ea ee ts Stains a aia I 4 000 049 023 Screen Garden Hose 2000 052 050 440 Male Quick Connect 2000 052 051 440 Female Quick Connect 2000 052 052 660 Male Quick Connect 2000 052 053 660 Female Quick Connect 000 010 019 Pump Drive AX 26 HOW TO ORDER To obtain a proper diagnosis of your maltunction and to order warranty replacement parts it is important that you proceed in the following manner 1 Call HydraMaster Warranty Service Dept at
15. 206 775 7275 2 Give the Warranty Service Representative the information following Name of your company and your address Equipment Model i e CDS Date of purchase Hours on the unit Serial number of unit Name of person authorized to order parts Salesman unit purchased from Description of malfunction Pressure readings on high pressure gauge with wand turned on and off crpmnmoouv 3 If warranty replacement parts are needed please specify method of shipment desired NOTE Ali replacement parts are sent freight collect via A U P S B Air freight C Air mail D Air express E Auto Freight 4 Do not give malfunctioning parts to a HydraMaster Sales or Service Representative All parts must be returned directly to HydraMaster freight prepaid 20309 64th Ave W Lynnwood WA 98036 HydraMaster WARRANTY POLICY Effective April 1 1988 HydraMaster warranty covers only defective materials and or workmanship for the periods listed Labor and or diagnostic 4 reimbursement is specifically excluded NOTES 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
16. 3 Rotate crankshaft 19 by hand to teel tor smooth bearing movement Examine crankshatt oil sea externally for drying cracking or leaking Consult factory or your local distributor if crankcase service 15 evidenced CAT PUMP WARRANTY This Cat Pump product is warranted by the manufacturer to be free from defects in workmanship and material for one year from date of manufacturer s shipment This warranty is limited io repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty shall be returned F O B Cat Pumps Corp Minneapolis Minnesota 55430 U S A for examination repair or replacement The express warranty set forth herein is in lieu of all other warranties express or implied including without limitation any warranties of merchantability or fitness for a particular purpose and all such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided hereunder and the manufacturer shall not be liable for any further loss damages or expenses including incidental or con sequential damages directly or indirectly arising from the sale or use of this product This warranty is subject to the following warranty conditions Important Conditions LUBRI
17. 5 Hamove and examina o rings and or back up nas on piston rod for wear and replace REASSEMBL Y 1 n Lubricate o rings and or back up rings and slip onto piston rod inatall the firat o ring in the groove on the piston rod Next posilion back up ring against the shoulder In front of the first o ring Then Install the second o ring Exercise caution you slip the o ring over the thread end of the piston rod Examine sleeves tor scoring or etching and replace Immersa sleeves in oil and carefully twist and push sleeve onto rod machined counter bore end first Next install seal retainers If wicks are used replace wicks thoroughly saturate wiih oil place In seal retainer and install retainer Place inlet manifold on pair of claarance blocka with crankcase side down and drive aut old seals Invert Inlet manifold with crankcase side up and Install naw seals Lubricate circumference of seal and install Prrrrrm A IMPORTANT Lube seal with garder spring down If using blue dol seal blue dot shouid be facing up when installed Slip lubricated seal Inserters onta piston rod ends posilion inlet manifold onto pump and remove seal inserters NOTE Replace original quantity washers on studs before replacing inlet manifoid NOTE Some models secure inlet manifold ta crankcase Repiace fasteners and torque per specification chart Reassemble piston assemblies and discharge manifo
18. CATION fill crankcase to the top of oil gauge window per specifications with Cat Pump oil or equilvalent SAE 40 weight hydraulic oil with antiwear and rust inhibitor additives Change initial fill after 50 hour run in period Change oil every three months or at 500 hour intervals thereafter Prrrrrm a lube seals need no lubrication Blue dot seals and wicks must receive three drops of Cat Pump oil per wick every 50 hours of operation LUBRICATION IS THE EASIEST MOST EFFICIENT AND LEAST EXPENSIVE OF PREVENTATIVE MAINTENANCE RPM and PRESSURE Pump operation must be within RPM and pressure specifications Pressure relief valve must be installed DO NOT PUMP ACIDS OR ABRASIVE FLUIDS with this unit Consult Cat Pumps for additional information on questionable fluids FREEZING CONDITIONS freezing conditions Pump must be protected from USE OF OTHER THAN CAT PUMP PARTS OR THEIR EQUIVALENT VOIDS THE WARRANTY 20 ELECTRIC DIAGRAM Vacuum Tank Switch Emergency Brake Switch Pump Clutch f Green Gray To Tach Sensor Blacx M HN 1 Magnet Drive Clutch pee NET E Magnet Le 1 J Vacuum Solenoid Valve Mix Tank Kill Switch 1 GER Pump in Pump a Master Brake Cylinder Brown To Master Brake Cylinder Red To Vac Tank Kill Switch i Fuse Gray To Horn
19. E At no time should a chemical solution with pH of less than 7 or higher than 10 be used in the unit pH CHART 1 2 3 4 5 6 7 8 9 13 14 NEUTRAL ALKALINE mm acn CLEANING STROKE PROCEDURE OVER WETTING Purpose To eliminate excess moisture remaining in the carpet fiber and the sawtooth appearance which results from diagonal movement of the cleaning tool on ali types of carpet Procedure Always move the cleaning tool in smooth forward and backward strokes Apply slight pressure to the forward stroke while the solu tion 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 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 cleaning wand is stopped twice at the same point at the rear of the cleaning stroke Failure to adopt this procedure can result in increased chance of clean streaks fiber shrinkage brown out and longer drying periods INCORRECT METHOD CORRECT METHOD Overlap Between Strokes Ww N A A 2 i 2v 4 72 he bes 58 7 Tool First Second Cleaning Cleaning Stroke Stroke
20. Examine and replace if worn Always lubricate o rings for ease of installation and to avoid damaging elastomers NOTE First install o ring in groove on seat towards seating surface then back up ring NOTE Models without outer groove on seat require the o ring to be placed on lip of retainer 6 Insert valve seats into manifold chambers 7 Position manifold back onto pump NOTE Lubricate o rings on cylinder and exercise caution when slipping manifold over cylinders to avoid damaging cylinder o rings 8 Replace fasteners and torque per specification chart NOTE Replace all original shims when used When new manifold is used reshim pump CAUTION When starting the pump check to see that there is no cylinder motion as this will cause premature failure of the cylinder o rings Center cylinder motion can be eliminated by switching with one of the end cylinders SERVICING SLEEVES AND SEALS DISASSEMBLY 1 Remove discharge manifold and piston assemblies as described 2 Remove inlet manifold containing seals Grasp sleeves and with a pulling and twisting motion remove the sleeves from the piston rod NOTE Grasp sleeve with pliers only if replacing worn sleeves as this procedure will mar the sleeves Next remove seal retainer 5 Remove and examine o rings and or back up rings on piston rod for wear and replace REASSEMBLY 1 Lubricate new o rings and or back up rings and slip onto piston
21. VS 50 500 938 015 CORF COS HE XCHANGER hy Bi fw MOUNT Sha BOG nobi HARNESS COS JING PRIMARY not shown 515 Sg GG HARNESS FORD SECONDARY shown Slc 100 051 010 VARNESS CHEY SECONDARY not shown e i 2 August dmm Corporation A 2394 20309 64th Avenue West Lynnwood WA 98038 HYDRAMASTER CORPORATION PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS RE USE OF WATER SOFTENERS For quite some time HYDRAMASTER has encouraged the use of water softeners in concert with its equipment With the introduction of the 3 5 AQUA CAT last year the issue of water softeners has once again come up Our increased use of exhaust gas heat ex changers requires us to reiterate our position con ceming watersofteners and the subsequent invalida tion of machine warranty claims due to hard water and or chemical deposits Included ineach HY DRAMASTER manual is a hard water area map The map graphically portrays the average hardness of water in each region of the United States This map does not excuse anyone living in a soft water area from Water Hardness Grains Per Gallon ava 7 DATE 17 FEB 92 5 9221 using water softeners if circumstances require it Under the heading of water softeners the manual states Many areas of the country have an excess of minerals in the water which result in what 15 commonly refered to
22. ace ball bearing Properly tension belt PROBLEM Water in crankcase Cause E Solution May be caused by humid condensing into water inside the Change oil at 3 month 500 hour intervals using Cat Pump crankcase Crankcase Oil other approved oil every month or 200 hours P N 06100 1 1 45 Replace seals sleeve and O rings Leakage of manifold inlet seals and or piston rod sleeve O ring PROBLEM Oil leaking from underside of crankcase Cause Worn crankcase piston rod seals PROBLEM Oil leaking at the rear portion of the crankcase Cause Damaged or improperly installed oil gauge or crankcase rear cover O ring and drain plug O ring Solution m Replace oil gauge or cover O ring and drain plug O ring PROBLEM Oil leakage from drain plug Cause Loose drain plug or worn drain plug O ring Solution 2 Tighten drain plug or replace PROBLEM Loud knocking noise in pump Cause Solution Pulley loose on crankshaft Check key and tighten set screw Broken or worn bearing Replace bearings PROBLEM Frequent or premature failure of the inlet manifold seals Cause Solution Scored rods or sleeves Replace rods and sleeves Over pressure to inlet manifold Reduce inlet pressure per instructions PROBLEM Short cup life
23. as hard water These minerals tend to adhere to the insides of heater coils and other parts of the machine causing damage as well as loss of cleaning effectiveness the relatively low cost of a water softener service is more than made up for in the increased life of machine parts and continued cleaning efficiency The manuals also have advice on de scaling procedures As Stated in the manual any deposits that form on the inside of the machine may cause dam age Any damages resulting from hard water or chemical deposits are considered abuse and or ne glect and will not be covered by the HYDRAMASTER WARRANTY Avoid costly repairs and downtime by using whatever wa ter softening method that ts readily available Also remem ber to follow up the de scaling recommendations that are shown in your manual for more Information please contact your local HYDRAMASTER representative HYDRAMASTER CORPORATION 20309 64th Avenue West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN ALL HYDRAMASTEH DISTRIBUTORS DATE 15 Oct 1992 TRANSMISSION OIL COOLERS 5 92101 ON ALL CDS UNITS P N 000 078 080 HYDRAMASTER is recommending the installation of transmission oil coolers on all CDS installations The transmission oil cooler will be included in all CDS finish kits from this date forward The transmission oil coolers will be installed on the engine side ofthe radiator directly in front of the fan clut
24. belt for wear tighten as needed Check pump pulleys tighten as needed MAINTENANCE LOG Check lines for wear chafing Check all nuts and bolts tighten as needed Clean vacuum tank thoroughly with high pressure washer Flush water and chemical system with 50 50 white vinegar solution Check engine RPM s adjust to 2600 RPM s at the pump IMPORTANT Record date and machine hours on maintenance chart Monthly Grease blower bearing fittings Remove pressure bypass valve stem grease cup and stem reinstall Check water level in battery Clean connections as needed IMPORTANT Record date and machine hours on maintenance chart Quarterly Change oil in blower see blower manual OVERALL CARE OF UNIT MAINTAINING THE ORIGINAL APPEARANCE OF YOUR UNIT 15 IMPORTANT FOR TWO REASONS 1 It represents a big dollar investment for your cleaning business and its appearance should reflect that fact A dirty machine is not professional 2 Maintenance troubleshooting and repair is much easier to ac complish on a clean well maintained unit Regular cleaning of the machine offers you an opportunity to visually inspect all facets of the machine and spot potential problems before they occur DAILY CLEANING amp INSPECTION Engine oil check Garden hose screen clean Machine general inspection Blower inlet Clean vac tank filter bag after every job spray with LPS 1 after last job M
25. ch in locating the transmission oil cooler directly in front of the fan clutch two functions are accomplished First the transmission oil is cooled and second the fan clutch will be thermally activated and increase the airflow to the engine compartment Transmission oil coolers are available from the HYDRAMASTER Parts Department as a separate item under part number 000 078 080 HYDRAMASTER CORPORATION 20909 64th Avenue West Lynnwood WA 880386 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTEH CDS INSTALLERS DATE 27 OCT 1992 RE 93 CHEV BRAKE LINES 5 92102 CHEVROLET CARGO VANS FOR 1993 HAVE A NEW ROUTING FOR THEIR BRAKE LINES THEY NOW TRAVEL DIRECTLY OVER TOP OF THE TRANSMISSION CAUTION IS REQUIRED WHEN DRILLING THE MOUNTING HOLE ON THE PASSEN GER SIDE OF THE BLOWER FRAME THE BRAKE LINES CAN BE LOWERED OUT OF THE WAY BY UNBOLTING TWO 2 MOUNTING BRACKETS THAT HOLD THE LINES IN POSITION THE BLOWER MOUNTING BOLT FOR THIS FOOT SHOULD GO IN FROM THE BOTTOM THEN RE ATTACH THE BRAKE LINES HYDRAMASTER CORPORATION 20308 64th Avenuc West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTEH DISTRIBUTORS DATE 13 JAN 1993 RE DRIVE SHAFT LUBRICATION PSB 930101 IMPORTANT During the unseasonably cold weather HYDRAMASTER would like to take the oppor tunity to remind all HYDRAMASTER CDS Equipment users to make sure to check and lubricate the fittings
26. e by the Purchaser without HydraMaster s prior written consent Machinery equipment and accessories furnished by HydraMaster but manufactured by others are warranted only to the extent of the original manufacturer s warranty to HydraMaster HydraMaster agrees at its option to repair at the point of shipment or to replace without charge any parts or parts of products of HydraMaster s manufacture which within the specified warranty period shall be proved to HydraMaster s satisfaction to have been defective when shipped provided the Purchaser promptly notifies HydraMaster in writing of such alleged defect HydraMaster will pay all freight and transporation charges via normal ground shipping means for replacement of parts covered under this warranty This warranty covers parts as specified and does not cover labor which may be necessary in completing repairs HydraMaster s liability to Purchaser whether in contract or in tort arising out of warranties representation instructions or defects from any cause shall be limited to repairing or replacing the defective part or parts To qualify for warranty coverage defective parts must be returned to HydraMaster within 30 days No liability whatsoever shall attach to HydraMaster until said products have been paid for Except as stated in this section and in the preceding section titled Warranty and except as to title there are no guarantees or warranties of merchantability fitness performance or
27. e from bucket back into the 5 gallon antifreeze premix jug 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 BYPASS VALVE 169 101 24 21 7 Bypass Valve Parts List REF NO PART NO DESCRIPTION QTY 3 000 105 101 Thrust Plate Bypass Aenea dip Valve 1 4 000 105 102 Piston Plate Bypass tL Valve T 5 000 078 101 Kit Seal for Bypass amp 59 Valve 1 7 000 148 004 Seat amp O Ring Bypass 8 000 097 005 O Ring Bypass Valve Fitting m VALVE ASSEMBLY Trigger Compression 4 Fitting Nylock Nut Spring 2 O Ring Connect JET ASSEMBLY Brass Cap 2 IA 7 Stabilizer ep d g006E WAND ASSEMBLY See Valve Assembly v 24742 Frame Tube ES x x Handle Sleeve li 1 S S Solution 2 Hose S S Handle 2 Guide S S Screw SA See Jet C Assembly T7 Nylock Handle Clip Nu 3 wand Lip STEM ASSEMBLY a Retainer O O Ring Keeper Ring VACUUM SYSTEM INFORMATION 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
28. en PROBLEM Mix Tank Overflows Solution Extension bracket pinching the float lever restricting full action of the lever Plunger not seating properly the valve Remove th 2 screws which hold the extension assembly to the valve Do not lose or drop the screws Remove the extension assembly Turn it upside down Inspect the plunger for proper seating If there is no debris obstructing the valve or plunger the plunger may be out of adjustment To ad just loosen the set screw on the ball nut and move the ball toward the end of the rod 1 16 Retighten set screw Place extension assembly back into position Tighten the Check garden hose quick connect assembly screen Check garden hose and or feed hose to tne mix tank for clog kinks or blockage Float ball in mix tank hanging up Not moving freely Extension bracket pinching float lever restricting full action of lever Valve plunger not opening fully To adjust remove the 2 screws which hold the extension assembly to the valve Do not lose or drop the screws Remove the extension assembly turn it up side down To adjust loosen the set screw on the nut Place your thumb on the plunger and press it in 1 16 and slide the nul w set screw toward the plunger end 1 16 Tighten the set screw Place the extension assembly back into position If the tank starts to overfill the ball nut is to close to the valve plunger and should be moved back away f
29. es replacement parts without charge for thirty 30 days to customers maintaining current account status An invoice dated thirty 30 days from date of replacement parts shipment will be sent to the customer for the amount of the parts sent The customer s faulty parts must be returned for evaluation prior to the expiration of the thirty 30 day period Upon warranty approval a credit will be issued the customer for the replacement parts invoice Warranty disap proval or failure to return the faulty parts within the thirty 30 day period allowed will result in the customer being charged for the replacement parts sent 24 uum GOLDEN GUARANTEE LIMITED WARRANTY PLAN HydraMaster warrants truckmount machines of its manufacture to be free from defects in material and workmanship if properly installed maintained and operated under normal conditions with competent supervision No person agent representative or dealer is authorized to give any warranties on behalf of HydraMaster nor to assume for HydraMaster any other liability in connection with any of HydraMaster s products This warranty shall extend to the original purchaser of said equipment for the periods listed by component below from date of installation If repairs or replacements are made by the Purchaser without HydraMaster s written consent Hydramaster s warranty shall cease to be in effect No allowance will be granted for any repairs or alterations mad
30. esigned to move cooling air in and around the engine compartment thus reducing the possibility of over heating during operation The blower motor is secured to the frame of the vehicle with the hoses routed into and around the engine compartment A starter blanket is also included to insulate the starter motor from excess heat For more details please contact the HYDRAMASTER Service Department at A C 206 775 7275
31. ft 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 Before shutting off the machine remove the chemicai line from the chemical jug and place in a mixture of 50 50 anti freeze and water With the cleaning tool on allow mixture to fil chemical System back to the chemical mix tank B Open the mix tank drain valve and allow the water to drain thoroughly from the mix tank FREEZE GUARDING SOLUTION SYSTEM T3 x To Vac Tank d Connect teere guard quick coupler ro une or the Loosen i NOTE Dypass valve vetore Quick connects 2 26 23 FREEZE GUARDING INCOMING LINE To Vac Tank Connect garder nese s inlet connecta ta incoming wate male quick connect nat Slide ine vacuum hase all fne way user the inier connector and run Ihe vacuum anni all the moisture iS removed C Remember to close the drain valve prior to next operation of your CDS unit Check ENGINE Antifreeze regularly BE SURE IT S PROTECTED Freezing will cause GRIEF MONEY and DOWN TIME Don t mess with mother nature 5 FREEZE PROTECTION OF CLUTCH 6 Close chemical mix tank drain valve and allow pump in system to refil mix tank with antifreeze ix solution fig DRIVE WITH PUMP IN SYSTEM EWI hi TT d 7 Start un
32. gear 21 MAINTENANCE PROCEDURES To avoid costly repairs and down time it is imperative to develop and practice good maintenance procedures from the beginning These procedures fall into daily weekly monthly and quarterly in crements and are outlined below We have provided maintenance log for your convenience on page 39 it is recom mended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder Daily Check engine oil level nspect garden hose screen clean as needed Visually inspect machine for loose wires oil leaks water leaks etc Inspect recovery tank s s filter and filter bag for tears holes etc clean repair or replace as needed Lubricate blower with LPS 1 or WD 40 through blower inlet Daily Wipe machine down thoroughly with a damp cloth flush recovery tank out thoroughly Empty filter bag and inspect for rips tears etc replace as needed remove thoroughly clean and reinstall stainless steel filter screen in recovery tank inspect and clean vacuum slot on cleaning wand check wand head for sharp edges that could tear carpet file down as needed clean wand to maintain original appearance wipe down vacuum and high pressure hoses as needed visually inspect for cuts etc Weekly Check engine air cleaner filter clean as necessary Check high pressure pump oil add as necessary Check pump drive
33. ghten lock bolts Replace universal shaft Worn Gears Remove and replace gears NOTE Replacement of gears must be accomplished by a qualified technician Timing of vacuum blower has been changed due to worn components Replacement of components must be accomplished by a qualified technican Lack of Lubrication NOTE Permanent damage may have Lubricate as specified See index resulted from lack of lubrication Worn bearings Remove and replace bearings as required Must be 00 accomplished by qualified technician Debris and or foreign material build up NOTE A stainless Disassemble vacuum blower and remove foreign material steel filter is provided at vacuum inlet located in vacuum NOTE Disassembly should be accomplished by qualified tank technician only Replacement of worn parts is recom mended if this procedure is necessary Loose or missing mounting bolts Tighten or reinstall mounting bolts erates cae ane 20112 12 02 22221222 sinn EELS NEL UU UU VACUUM BLOWER WARRANTY All Sutorbilt California Series blowers are covered by this warranty Warranty period is 24 months from date of shipment or 18 months from date of installation whichever occurs first Sutorbilt will replace or repair any unit covered by this warranty without regard for the cause of failure Customers claiming relief under this warranty shall iss
34. hemical 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 1 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 PROBLEM Inability to Adjust Chemical with the Flow Meter Salution Solution Debris ladged behind teflon seat in flow meter knob Teflon seat dismounting from flow meter knob PROBLEM Solution Reversing from Mix Tank to Chemical Jug Solution Anti siphon screen removed from chemical jug hose Debris in anti siphon scre
35. it with cleaning wand and hoses connected and spray CRISE MID MACAE into a bucket for 20 seconds to allow the antifreeze toprotect 2 Drain chemical mix tank fig 1 the high pressure gauge and system lines After running the 1 wand spray for 20 seconds shut wand off and let it run for 3 While chemical mix tank is draining Insert chemicai feed line 10 seconds to allow the bypass system to be protected fig 6 into antifreeze premix jug and allow meter to fill with premix anti freeze for 10 seconds Close chemical flow meter when 8 Turn off cleaning system Master Power Switch You may want protected fig 2 to leave the pump in hose out of the tank so it won t freeze to the residual water the tank The next day refill the tank and 4 pl 2127 short hose 9 high pressure replace the hose If layer of ice the hose will sit on top of it and VA du or and drain heat exchanger of cleaning water gain proper suction 9 Reconnect pump in hose to water storage tank fcontinued next page 5 Remove pump in system hose from water storage tank and in sert it into antifreeze premix jug fig 4 continued next page 10 Place bucket under drain hose of chemical mix tank and open drain valve again to reclaim antifreeze premix When tank is 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 antifreez
36. ith Pump In System PUMP IN SYSTEM FLOW Incoming Water Connection PISTON MODEL 290 Exploded View PARTS LIST Model 290 ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 20285 7 O Ring Buna N 1 _ 35 30315 Prmrmrm A Lube Seal 000006 3 2 44274 Crankcase 1 n 230325 Prrrrrm A Lube Seal Viton 3 85680 Stud M8 x 82 2 5 38 27004 Inlet Valve 3 4 84377 OtRing Filler Cap 1 39 430543 Bac Cup Piston _ NOE AN 5 44374 _OQil Filler Cap LEAN 222 40 30544 Bac Cup Ring Teflon 3 8 43340 7 O Ring Crankcase Cover 4 41 __43172__ Cup Viton 3 9 43339 Crankcase Cover 29474 Bac Cup Assembly 003 10 4397 Bubble Oil Gauge 1 ___42 27983 Piston Spacer 2 th ae 11 23170 O Ring Drain Plug 22 1 28 27002 Piston Retainer yb sd _ 122 2505 Drain Plug 24 44 27008 Conical Washer SS 6 15 92520 Sems Comb Head Screw 45 27000 _Nut SS M6 8 NU A M6 x 20 6 46 141458 7 Cotterpin a Crankshaft a t 101802 43834 Unch 17 1487 Rearing a 2 22223172 O Ring Cylinder Buna N 6 1212248 24159 Oil Seal Buna N 2 11377 O Ring Cylinder Viton _6 19 26536 O Ring Seal Case
37. ld described SERVICING CRANKCASE SECTION While inlet manifold sleeves and seal retainers are removed examine crankcase seals for wear Check oll level and far evidence of water in oll 3 Rotaie crankshaft by hand to feel for smooth bearing movement Examine crankshaft oli seal externally for drying cracking ar leaking Consult factory or your local distributor if crankcase service is evidencad APPLY GREASE ZERK FITTINGS EVERY 500 OPERATING HOURS LOCATION OF FITTINGS NOTED HERE ENLARGED VIEW 23 WARRANTY INFORMATION To avoid misunderstandings which might occur between machine owners and manufacturer we are listing causes of component failure that specifically voids warranty coverage Such causes as listed below shall constitute abuse or neglect BLOWER Failure to lubricate impellers daily with LPS 1 or WD 40 lubricant Failure to lubricate bearings Failure to maintain proper oil levels in the blower Failure to use the correct oil grade and viscosity as recommended Failure to properly maintain blower safeguard systems such as waste tank filter screen vacuum safety relief valve in vacuum tank lid and waste tank automatic shut off system Allowing foam to pass through blower HIGH PRESSURE WATER PUMP Operation of pump at pressure over 1200 PSI Failure to maintain proper oil level as recom mended Failure to change oil in pump at recommended intervals Failure to protect
38. 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 capabili ly 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 Garden Hose incoming Water From Faucet Water Softener CHEMICAL TANK TROUBLE SHOOTING CHEMICAL PROPORTIONING AND LEVEL CONTROL PROBLEM No or Low Chemical Flow Solution Valve Body Cap Proportioning Valve Repair Kit 000 078 r1 Ball Nut Extension W Set Screw Bracket qe eme HOSTE Valve Plunger Adjustment S Float 2 crew Asem Chemical Pick Up Hose 2 3 Mounting 2 Outlet s EN i Tube f Foot Valve and Screen Underwater Feed Proportioning Venturi Main Valve Diaphragm 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 c
39. ll cylinders from inlet manifold 3 Remove cotterpin nut and washer from piston rod 4 Next remove retainer spacer and piston cup assembly 5 Remove inlet valve REASSEMBLY 1 Examine inlet valve surfaces for pitting scale or grooves Reverse valve and sand inlet side of valve using 240 grit paper for clean surface or replace if evidence of excessive wear Slip onto rod 2 Examine piston seating surfaces and sand clean on flat surface using 240 grit paper If extreme pitting or sharp edges replace piston 3 Examine cup for wear cracking tearing or separation from the piston If worn replace and lubricate before installing on piston NOTE CUP INSTALLATION Wipe cup inserter with oil Slip bac cup ring when used onto piston Push cup over inserter and square with all surfaces Faulty cup installation causes premature cup failure Lubricate piston assembly and slip onto rod 4 Next replace piston spacer and retainer on rod Replace washer thread on nut and torque per specification chart NOTE Always replace with new Stainless Steel Cotterpin and turn ends under Examine cylinder walls for scoring or etching which causes premature wear of cups and replace if worn Lubricate cylinder and replace o rings and or back up rings if worn or damaged Carefully slip cylinders over rod ends and push into inlet manifold in their original position front to back Position discharge manifold onto
40. lsation Upon inspecting the valves make sure that the teflon buttons in the valve spring retainers are still intact Also examine the discharge manifold Look for problems such as cracks chemical buildup or warpage due to freezing If this discharge manifold is warped it will cause the check valves to stick and will result in loss of pressure The Cat pump cups are often the source of pressure loss Upon in spection they may appear melted or torn but often they will look good Replace them anyway There is no sure method of visually inspecting the cups HydraMaster recommends changing cups whether they look good or not Anytime your pump is being dismantled HydraMaster recom mends replacement of all rings and seals This is merely a con venience to the customer to make sure that the Cat pump is in top operating condition The prrm a lube seals located within the intake manifold will allow air to enter the pump it they are worn Again it is difficult to visually pinpoint a defective prrrm a lube seal Replace them all Within the piston sleeve cylinders there are 6 0 rings that are about 4 the size of a penny If these o rings are bad water will be pumped back into the oil tf this has occurred the oil will raise in level and appear milky If you are unable to repair seals right away change oil frequently Repair the pump as soon as possible so as not damage bearing or connecting rods SERVICE KITS 078 001 C
41. nifold and black powdery substance in the area of the O rings Cause Loose cylinders Cylinder motion c caused by improper shimming of the discharge manifold Solution Remove spacer shims on manifold studs Do not remove toc many shims or the ears of the manifold wil be bowed when the manifold is retightened causing looseness in the center cylinder PROBLEM Water leakage from under the inlet manifold Solution Worn inlet manifold seals Leaking sleeve O ring Install seals piston rod sleeves are scored replace sleeves and sleeve O rings PROBLEM Oil leak between crankcase and pumping section Cause Solution Worn crankcase piston rod seals Replace crankcase piston rod seals Excess oil from wicks Reduce quantity of oil per oiling PHOBLEM Oil leaking in the area of Crankshaft Cause _ Solution Worn crankshaft seal or improperly installed oil seal retainer Remove oil seal retainer and replace damaged gasket and or packing seals UpDoeg nost 15 CAT PUMP TROUBLE SHOOTING GUIDE continued PROBLEM Oil leaking in the area of Crankshaft Cause Bad bearing Solution Replace bearing PROBLEM Excessive play the end of the crankshaft pulley Cause Solution Worn main ball bearing from excessive tension on drive belt Repl
42. 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 water inlet in the vacuum tank To re order bags use part number 049 029 VACUUM TANK FILTER BAGS Incoming Dirty Water Filter Bag VACUUM FLOW Filter Bag Recovery Tank 2 Vacuum Hose To Cleaning Wand Exhaust Vacuum Blower Silencer 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 LUBRICATION At the gear end the timing gear teeth are lubricated by being partially submerged The gear teeth serve as oil slingers 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 ail level hole B Use lubricants as listed Add fresh oil as required to maintain proper level The oil should be drained flushed and replaced every 1500 hours or mare frequently if inspection so indicates The oil drain plug is at C NOTE Older units may have the oil 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 lubrication every 100 hour
43. on the universal joints that are connected to the shafts that attach the blower to the CDS clutch unit Ideally lubrication should be scheduled every 500 hours with 2 Bearing Grease 22155 APPLY GREASE ZERK FITTINGS EVERY 500 OPERATING HOURS LOCATION OF FITTINGS NOTED HERE ENLARGED VIEW HYDRAMASTER CORPORATION 20309 64th Avenue West Lynnwood WA 98036 EFFECTIVE IMMEDIATELY PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS DATE 26 JAN 1993 RE GROUNDING OF CDS UNITS PSB 93013 As result of improved performance it has been decided to inhance the grounding circuit by the addition of the following 10 AWG wire to run from the engine block to the blower frame Then from the frame to the mix tank ground lug Then to the neg ative terminal of the temperature gauge located in the instrument panel The upgrade will require 12 of 10 AWG wire 178 014 GROUND WIRE TO GAUGE 178 014 GROUND WIRE TO MIX TANK 178 014 Route wire and attach GROUND WIRE per illustration 1 TO MIX TANK 094 007 NUT 174 017 WASHER BLOWER FRAME MOUNTING LEG 5 CORPORATION 20309 84th Avenue West Lynnwood WA 98036 PRODUCT SUPPORT BULLETIN TO ALL HYDRAMASTER DISTRIBUTORS DATE 4 APR 1993 RE New CDS Van Cooling Kits PSB 930401 000 078 083 HYDRAMASTER has engineered a CDS Cooling Kit specifically d
44. posits and build up in the water system chemical system or heater system due to hardness in the water used or chemicals which result in deposits will void all warranties on affected components REV 5 92 HYDRA ASTE 25 RING SNAP COS CLUTCH SHAF KEY 5 32 MOISES SHAFT 005 ELECTRIC 1 15 5 M CP CDS 4 0 4 5 LOW PROFILE 18 Pa e an omm BET ANT 26 22 Eg 3 4 23 un 33 00 008 1 n 205 VAC TO SILENCER 8 0 amp L P 2h 33a 200 068 005 PUMP TO SILENCER 8 5 not shown np 290 293 SILENCER ASSEMBLY COS EXHAUST e 16 22 35h 990 993 006 SH ASSEMBLY COS 8 5 not shown 15 LG ENG 5 900 252 152 HOSE COS SILENCER EXHAUST ADAPTER 08 36 900 001 004 ADAPTER SILENCER EXHAUST 1 SLOWER 37 900 164 002 TRAY CHEMICAL SOAP JUG PAINTED BLOWER 38 000 011 005 BOX 005 DASH PAINTED 8 0 8 5 805 38a 500 013 001 BOX LOW PROFILE DASH PAINTED FORDS 39 000 051 031 KNOB VAC IN MANIFOLD E
45. pump replace fasteners and torque per specification chart SERVICING THE VALVE ASSEMBLIES DISASSEMBLY 1 Remove the fasteners securing the discharge manifold to the crankcase of the pump 2 Support the discharge manifold and tap from the backside and a soft mallet to separate from the crankcase and gradually work free from cylinders 3 Valve assemblies will remain in the manifold Pump models with the o ring groove on the outside of the valve seat require the assistance of a reverse pliers to remove the valve seat The valve spring and retainer will then fall out when the manifold is inverted Pump models without the o ring groove on the outside of the valve seat permit the seat valve spring and retainer all to fall out when manifold is inverted REASSEMBLY 1 Replace retainers in manifold chambers 2 Next insert spring into center of retainer 3 Inspect the valves for wear ridges or pitting and replace if necessary NOTE Seating side of flat valves may be lapped on flat sur face using 240 grit paper Quiet valves due to their shape must be replaced Insert valve over spring with recessed dish side down 4 Next examine the seating surface of the flat valve seats and lap with 240 grit paper or replace if evidence of excessive wear Quiet valve seats should be replaced if worn Lap new quiet valve and seat to assure positive seal 18 5 Some pump models have o rings and back up rings on the valve seat
46. pump against freezing Failure to maintain pump protection shut off system Failure to use water softener in hard water areas Use of improper chemicals VAC TANK Failure to properly maintain filtering devices in tank Failure to clean tank as recommended by manufacturer Failure to maintain vacuum safety release in tank Use of improper chemicals CHEMICAL PROPORTIONER Use of improper chemical Failure to use water softener in hard water area Operating machine without proper chemical filter screen Failure to protect against freezing CONTROL PANEL Failure to protect flow meter and water pressure gauge against freezing VACUUM AND SOLUTION HOSES Failure to protect hoses against freezing Failure to protect hoses against burns from engine blower exhaust Damage to hoses from being run over by vehicles Kinking or cracking from failure to store or unroll hoses correctly Normal wear and tear from everyday use CLEANING WAND Failure to protect against freezing Obvious physical abuse of wand WARRANTY PROCEDURE Warranty coverage is available to you ONLY through HydraMaster Corporation 20309 64th Ave West Lynnwood Washington 98036 When warranty parts are needed write HydraMaster Warranty Dept at the above address or call the Warranty Service Dept at 206 775 7275 No collect calls will be ac cepted Hours of Warranty Service Dept are 8 00 am to 6 00 pm Pacific Time IMPORTANT HydraMaster s warranty policy provid
47. r 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 15 distributed into the mix tank at your desired proportion This line should be flushed with vinegar weekly to prevent abnormal chemical build up This may be done by removing the clear plastic hose from the chemical jug and inserting it into a one quart con tainer 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 mix tank Pressure Gauge Hot Water Shut Off Valve Control Bypass Valve High Pressure Solution Outlet A Pump Intake B C D E Incoming Water F G H Heat Exchangers Radiator Water In Pump Output Bypass Return Chemical Flow Meter Chemical Jug Drain Radiator Water Out Proportioner High Pressure Pump Chemical Mix Tank Pump Inlet Filter not shown ovozga r aS is in a filling cycle your chemical flow meter
48. rom the valve plunger slightly PROBLEM Pump Pulsates When The Tank 16 in a Fill Mode Solution 1 Check that the hose which goes from the gray plastic venturi to the bottom of the tank is not directed toward the Cat pump pick up port If it is aim it in another direction two screws FREEZE PROTECTION Any freezing of this machine is not covered by warranty and ing the colder months of operation careful protection should be of utmost concern THE FOLLOWING PRECAUTIONS ARE RECOMMENDED 1 Run 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 172 inch vacuum hose 3 Leave truck doors closed until time cleaning begins then open Slightly 4 In colder climates insulating the truck walls and floor boards will help protect the unit 5 Don t procrastinate during the cleaning operation or the hot water solution iine 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 ex cessive moisture on the truck ceiling and the possiblity of it going out is higher lf the machine and truck are le
49. s of operation Bearings which require grease lubrication will have a grease fitting D at each bearing When regreasing 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 LUBRICATION INSTRUCTIONS OIL LUBRICATED GEARS AND BEARINGS Add fresh oil as required to proper lavel Dran and refill every 1500 hours of operation under normal service more tre quently when required Use good quality oil BLOWER OIL OIL VISCOSITY DISCHARGE GRADE CENTISTOKES TEMPER e 40 C SAE 10W SAE 20 45 100 SAE 40 200 13sec SAE 50 250 applications with extreme variations in ambient temperature 20W 50W multiple viscosity ail is recommended FOR GREASE LUBRICATED BEARINGS Service every 500 hours of operation BLOWER DISCHARGE TYPE TEMPERATURE GREASE 40 to 275 No 2 40 10 120 Bearing Grease 1 EVERY 100 HOURS VACUUM BLOWER TROUBLE SHOOTING GUIDE PROBLEM Loss of Vacuum Cause _ Solution Collapsed vacuum hose between blower and vacuum tank Remove and replace hose NOTE A special reinforced hose 2 18 required for replacement NE RUE 1222 Clogged stainless steel filter 8 ____ Remove and clean or replace stainless steel filter 2 Defective vacuum tank seal
50. tem Assembly Dig eran oi ots 7 Vacuum System Information and 4 200 4 41 2 0000 4404 211 8 Vacuum Tank Filter 8 Blower Lubricant and Filliing Procedure oic sss 8 9 Vacuum Blower Troubleshooting eene eene nennt 10 breonEs WVLCUACREUEET E 11 Cat Pump Operating Instructions Drive Information Dimensions Specifications 12 13 Cat Pump Exploded View Parts 1 54 14 Cat Pump Troubleshooting Guide 15 16 Cat Pump Repair Information Service Kits eene 17 Cat Pump Servicing the Pumping Section Servicing the Valve Assemblies ss 18 Cat Pump Servicing Sleeves and Seals Servicing Crankcase Section sss 19 Cat Me lici 20 Electric etri oe ehe desta nda io ibo Rs 21 Electrica System Troubleshooting 1 esee ise esen 21 Maintenance Procedures 2 edilir 22 Maintenance ota ocu 22 Warranty Information 10 1
51. ue a Purchase Order to Sutorbilt for a replacement unit Customer must obtain a Return Goods Authorization number from the factory and return blower prepaid to an Authorized Factory Repair Center as directed On receipt of the blower a credit memo wil be issued to offset the P O issued per 4 above Replacement unit will be shipped to customer at Sutorbilt s expense to any destination in the US or Canada B SUTORBILT reserves the right to withdraw the Uncontested Warranty where evidence indicates application outside the manufacturer s stated performance area or where there is evidence of abuse CONTACT SUTORBILT FOR THE LOCATION OF THE FACTORY AUTHORIZED SERVICE CENTER NEAREST YOU SUTORBILTANDUSTRIAL MACHINERY 2966 E Victoria Street LY SUTORBILT Compton CA 90224 213 639 7600 COOPER INDUSTRIES Telex 244337SUT FAX 213 639 7632 TE UE E EE Vf YE YE TE FED ADEM 11 1 30 33 2 28 Tt 5 73 145 5 2 8 80 1 57 3 15 80 1 08 8 06238 21 NPT INLET hy LIE 3 23 77 82 1 34 34 T unl Lite 3 94 100 gt I 10 17 273 5 SPECIFICATIONS U S Measure Volume 3 5 G P M Discharge Pressure 1200 P S Max inlet Pressure 8 5 to 40 P S I AIPM Loos Seve 1200 RPM
52. up Kit 078 006 Valve Kit 3 Cup 3 Valve Spring Retainer 6 O Ring Cylinder 3 Valve Spring 3 Cotterpin 3 Valve 1 Instruction Sheet 3 Valve Seat 1 Cup Inserter 3 O Ring Cylinder 1 Instruction Sheet 078 003 Seal Kit 3 Prrrrrm A Lube Seal 30860 Piston Kit 3 Cotterpin 6 O Ring Cylinder 2 Abrasive Paper 3 Back Up Ring Cylinder 1 Instruction Sheet 3 Bac Cup Piston 3 Bac Cup Ring 30431 Sleeve and Seal Kit 3 Cup 3 Prrrrrm A Lube Seal 3 Piston Spacer 3 Barrier Slinger 3 Piston Retainer 3 Cotterpin 3 Conical Washer M6 3 Sleeve 3 Nut M6 6 O Ring Sleeve 3 Cotterpin 1 Instruction Sheet 3 Inlet Valves 1 Instruction Sheet Repairing of Cat pumps is not a difficult task However before disassembling make sure you have the proper parts required 3 Prrrm a lube seals 1 bottle Cat 1 short or hot cup kit 6 piston sleeve rings Read instructions thoroughly prior to disassembly and follow directions as stated Oil all seals thoroughly prior 10 installation Remember a newly scarred seal is no better than one you just took out Pecos sites ET a PUMPING SECTION CUTAWAY Bac Cup Piston Spacer Bac Cup Ring Piston Retainer Cup Washer N YN Colter Pin x 2 Nut Cylinder Piston Rod Sleeve 17 SERVICING THE PUMPING SECTION DISASSEMBLY 1 2 Remove the discharge manifold as described Grasp cylinders by hand and with an up and down motion pu
53. urers and a 5 pump output tolerance Horsepower figures shown are brake horsepower figures For gas engine requirements follow engine manufacturer s recommenda tions In general use a gas engine with approximately double to electric motor horsepower HORSEPOWER REQUIREMENTS PRESSURE PSI 1000 MOTOR PULLEY SIZE Using 1725 RPM Motor amp Std Pump Pulley Q D PSI 800 PSI 1200 BAR BAR 70 85 2 4 2 1 17 DETERMINING THE PUMP R P M Rated G P M Rated R P M Desired G P M Desired R P M DETERMINING THE REQUIRED __GPM x PSI 1460 Electric Brake H P Required DETERMINING Pump Pulley Q D MOTOR PULLEY SIZE Pump R P M Motor 8 Note Consult engine manufacturer when using gas or dese engine Motor Pulley 0 0 EY GAT PUMPS AG Loretonoaha 5 CH 6300 ZUG Switzerland Drone 14212523140 Telex B65 160 cpag ch e CAT PUMPS DEUTSCHLAND GmbH Rastoxme Strasse 9 520 Weesbaden B Wast Germany Prove 061256 OC 21 2 lax 41 86712 CAT PUMPS VK ILTD 27 Staton Estata Fleet Hampshire GU 3 60 Engtand Phone F eet 22017 Telex 858888 MAPS CORPORATION PO Box 885 MINNEAPOLIS MN 55440 Prone 612 780 5440 Telex 290276 eN V CAT PUMPS INTERNATIONAL SA Harmoniestraat 29 B 2000 Antwerp Belgium Phone 03 237 72 24 Teiex 33847 PR Standard Garden R Hose Screen W
54. y Red White Mix Tank Kill Switch l xx Battery Orange Temo Sensor fied 14 Fuse Link ELECTRICAL SYSTEM The entire electrical system operates on 12 volts DC which is pro vided by your truck s battery Battery levels are sustained by a alternator designed within the engine White System Ground NOTE When new battery is installed insure itis charged before installation or damage to the charging regulator may occur PROBLEM Low Battery Voltage Cause Defective battery Corroded battery terminals Low battery fluid Loose wiring within electrical system Electrical short wiring system Poor ground connection Solution Remove and replace Clean terminals and battery posts Add water to appropriate level Examine all terminal connections and verify that they are secure Examine electrical systems for bare wires Examine terminal and remove corrosion if necessary PROBLEM Inoperative Hour Meter Cause Time is not advancing correctly Solution Verify 12 volts DC is available at the hour meter with the ignition switch turned on This can be accomplished with a volt meter or a test lamp Remove and replace hour meter if 12 volts is available A nylon gear within the clock may have been jammed due to a sudden jolt of the machine or truck You may try simply tapping on the meter to try to free the nylon
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