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HydraMaster ChemDry CTS 400 Flex Owner's Manual And Maintenance Logs

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CTS 400 Flex Owner's Guide and
Maintenance Logs
Manufactured Exclusively for
HydraMaster
11015 47
Avenue West
th
Mukilteo, Washington 98275
MAN-46690 Rev. A, Jan 20, 2016
(P/N 000-182-406D)
No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or
electronic retrieval systems) without the express written permission of Harris Research Inc. Specifications and information in this
document are subject to change without prior notice. All rights reserved. © 2016 Harris Research Inc.

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Summary of Contents for HydraMaster ChemDry CTS 400 Flex

  • Page 1 CTS 400 Flex Owner’s Guide and Maintenance Logs Manufactured Exclusively for HydraMaster 11015 47 Avenue West Mukilteo, Washington 98275 MAN-46690 Rev. A, Jan 20, 2016 (P/N 000-182-406D) No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or electronic retrieval systems) without the express written permission of Harris Research Inc.
  • Page 3 Thank you again for choosing HydraMaster. We will continue, as we have for the last 4 decades to do everything possible to ensure that you remain a proud and satisfied HydraMaster owner.
  • Page 5 Introduction This Owner’s Guide provides you with important Contact Information, Warnings and Precautions, Operating Instructions and Maintenance Logs. Read the entire Owner’s Guide before using this product. Failure to heed Warnings can result in serious injury or death; failure to heed Cautions can result in equipment failure.

  • Page 6: Contact Information

    CONTACT INFORMATION If you have any questions regarding the operation, maintenance or repair of this machine, please contact your local distributor. When calling your distributor, be sure to reference the serial number and date of purchase. FOR YOUR REFERENCE: Serial No.______________________________________________ Date of Purchase:___________________ Purchased From (Distributor):_________________________________________ CTS 400 Flex Owner’s Guide: 2...

  • Page 7: Warnings, Cautions And Notices

    WARNINGS, CAUTIONS AND NOTICES The manufacturer uses this WARNING symbol throughout the guide to warn of possible injury or death. This CAUTION symbol is used to warn of possible equipment damage. This NOTICE symbol indicates that federal or state regulatory laws may apply, and also emphasizes supplemental information.
  • Page 8 Transporting a vented fuel container that presently contains, or has ever contained in the past, a flammable liquid is strictly forbidden by HydraMaster and by federal and state regulations. Doing so will increase the risk of fire and explosion. Serious injury or death may result.
  • Page 9 Never smoke in or around the truckmount. Doing so will increase the risk of fire and explosion. Serious injury or death may result. Be cautious when drilling holes through the van floor. Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit.
  • Page 10 Never operate the truckmount with a water hardness reading measuring 3.0 grains per gallon or higher. Using reading than 3.0 grains per gallon will cause scale to build up inside the truckmount water system. Scale build up causes serious component damage. Test all water prior to use and use water softening equipment if necessary.
  • Page 11 RESPONSIBILITIES The Purchaser’s Responsibilities Prior to purchasing a van, ensure that the payload is suitable for all of the equipment that will be installed and transported. This includes and is not limited to: the truckmount, recovery tanks, fresh water tanks and on-board water, hose reels, hoses, cleaning tools, chemicals, drying equipment, etc.

  • Page 12: Installation Responsibilities

    • Ensure proper connection of the fuel lines. • Ensure proper connection and installation of the battery. Verify that the battery is in accordance with HydraMaster’s recommendation. • Check the pump, vacuum blower and engine oil levels prior to starting the truckmount.
  • Page 13 MACHINE SPECIFICATIONS - CONSOLE Frame Dimensions 24.0" W x 31” H x 36" D Weight 570 lbs Engine- Briggs and Oil Type Synthetic 5W-30 Stratton Vanguard 18HP Capacity Approx. 1 1/2 quarts (48 oz.) when changing oil and filter Engine rpm 3,150 rpm Fuel Consumption 1.0 gph...
  • Page 14 Standard Equipment High Pressure Hose 1/4" High Temperature Lined/ Vinyl Cover - 100 ft. Vacuum Hose 2" Vacuum Hose- 100 ft. 1-1/2" Wand Whip Line- 10 ft. Recovery Tank 65 gallon MaxAir Universal Tank Battery Box Van Decal Van Installation Kit Owner’s Manual (on CD) Owner’s Guide (paper copy) Optional Equipment...
  • Page 15 MACHINE SPECIFICATIONS - FLEX ASSEMBLIES 50 Gallon Tank Dimensions 12” W x 33” H x 60” L with Frame Weight 113 lbs 35/15 Gallon Dimensions 12” W x 33” H x 53” L Tanks with Frame Weight 108 lbs Construction Frames Steel Tanks...

  • Page 16: High Altitude Operation

    Hard Water Advisory HydraMaster recognizes that any hard water deposits which might occur within the water system of our truckmounts is a serious problem. The precision technology of truckmount heat exchanger systems is intolerant of any foreign material. Hard water deposits will ultimately decrease the performance of the system and are expected to seriously lower the reliability of the machine.
  • Page 17 Hard Water Area Map The hard water map, shown in Figure 1 defines hard water areas in the continental United States which compromise fluid related components such as hoses, fittings, heaters, pumps, valves and water-cooled engines. For other countries, hard water area maps can be obtained from geological societies.
  • Page 18 Cleaning efficiency and equipment life is increased, chemical use decreased, and the appearance of cleaned carpets enhanced when water softeners are incorporated in hard water areas. HydraMaster strongly urges the use of water softener units with the CTS 400 Flex in areas exceeding 3.0 grains per gallon.
  • Page 19 HydraMaster makes an APO System which can be ordered with new equipment or installed later. When properly configured, the systems will continuously monitor the level of waste water and pump it out simultaneously with the cleaning operation.
  • Page 20 CTS 400 Flex Owner’s Guide: 16...
  • Page 21 Operating Instructions BEFORE OPERATING THE CTS 400 FLEX Locate the van and equipment in a well-ventilated area. The CTS 400 Flex generates toxic fumes. Position the vehicle so that the fumes will be directed away from the job site. Do not park where exhaust fumes can enter a building through open doors, windows, air conditioning units or kitchen fans.
  • Page 22 START-UP PROCEDURE (ALL MODES) Perform all daily and periodic maintenance as specified in this Owner’s Guide. Ensure the Solution Control switch is in the “OFF” position. Connect all cleaning tools to the length of hose required to perform the cleaning job.
  • Page 23 CARPET/UPHOLSTERY PROCEDURE Ensure the Flex tank(s) is full. Connect all solution and vacuum hoses, and the APO hose (if equipped). Drain the water box by opening the water box drain valve on the dash. Select “CARPET/UPH.” on the Solution Control switch (see Figure 3). CARPET/UPH.

  • Page 24: Shutdown Procedure

    Cap off the inlet to the vacuum tank. Spray a HydraMaster-recommended spray lubricant into the blower lube port for about 5 to 7 seconds while the unit is running (see Figure 2). Allow the machine to run an additional 2 to 5 minutes under load to flush off lubricant.
  • Page 25 TILE/STONE CLEANING PROCEDURE Follow the start-up procedure. Connect a garden hose to the truckmount. If a pump in pump is used, turn the AUX switch to the “ON” position (see Figure 2). The water box must be full prior to starting the truckmount. Connect all solution and vacuum hoses, and the APO hose (if equipped).
  • Page 26 Set the temperature to the desired level on the “TILE/STONE TEMPERATURE” control knob. Adjust the “PRESSURE REGULATOR” located on the left hand side of the machine (see Figure 5), to the desired cleaning pressure level. Pressure Regulator Figure 5. Side View of CTS 400 Flex Console Optional: Press the Auto Pump Out (APO) switch to the “ON”...
  • Page 27 FLEX TANK OPERATION Make sure the 3-way ball valve levers are all in the downward or vertical position (see Figure 6). The levers on the Flex pumps control the direction of the chemical flow. When the levers are in the vertical position, the flow is turned “OFF”. LEVER 3-WAY BALL VALVES...
  • Page 28 There are 2 levers on the 35 Gallon/15 Gallon Tank Assembly, one for each tank (see Figure 6). There is 1 lever located on the 3-way ball valve on the 50 Gallon Tank Assembly (see Figure 7). Before operating the Flex System, turn the appropriate lever toward the direction of the flow (toward the hose connected to the pump strainer - see Figure 7 and Figure 8).
  • Page 29 Owner’s Guide. Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored. It is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder.

  • Page 30: Operational Maintenance

    • Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed. • Lubricate the blower lube port with HydraMaster-recommended spray lubricant. Weekly Maintenance • Inspect the recovery tank filters for tears, holes, etc. Repair or replace as needed.
  • Page 31 250 Hours • Check coupler element (rubber insert) for cracks or wear. Replace as necessary. 500 Hours • Change the blower oil. • Change the high pressure pump oil. • Check the engine valve clearance (intake and exhaust 0.004” - 0.006”) •...

  • Page 32: High Pressure Pump Maintenance

    HIGH PRESSURE PUMP MAINTENANCE Daily Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the rear of the pump or between the “MIN” and “MAX” lines on the dipstick.
  • Page 33 Valve Maintenance (See Figure 9) Using a 22-mm wrench or socket, remove all six valve caps on the manifold of the pump. Examine each valve cap O-ring for cuts or distortions and replace if worn. Using needle nose pliers, remove the suction and delivery check valves. The valve assembly usually stays together when removing.
  • Page 34 Replace old valves with new valves by placing the assembly in the valve chamber. Press down firmly on the top of the valve assembly. Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft- lbs. Removing and Replacing Pump Manifold Remove the manifold of the pump by taking a 5-mm Allen head wrench and removing the eight head bolts.
  • Page 35 Servicing the Crankcase While the manifold and plungers are removed, rotate the crankshaft by hand. Closely examine the crankcase oil seals for drying, cracking or leaking. Consult the local HydraMaster distributor if crankcase servicing is necessary. 31: CTS 400 Flex Owner’s Guide...

  • Page 36: Vacuum System Maintenance

    VACUUM SYSTEM MAINTENANCE The vacuum pump in this machine is commonly referred to as a “rotary positive displacement blower” or “blower” for short. The performance and life of the truckmount is greatly dependent on the care and proper maintenance it receives. Review the blower’s owner’s manual, which has been included, for a better understanding of this piece of machinery.
  • Page 37 Capping off the inlet(s) to the recovery tank. Spraying a HydraMaster-recommended spray lubricant into the “BLOWER LUBE PORT” for about 5 to 7 seconds while the unit is running. Uncapping the inlet(s) and run the unit for another minute to allow the blower to cool down.

  • Page 38: Descaling Procedure (Required)

    DESCALING PROCEDURE (REQUIRED) Scale deposits on the interior of the heating system can cause a noticeable loss in heating performance. Deposits of this kind result from hard water deposits. The frequency with which descaling procedures are required will vary. If the area has particularly hard water, you may have to descale often.

  • Page 39: Freeze Guarding

    FREEZE GUARDING To avoid permanent damage to the truckmount, it is imperative to follow the freeze guard procedure whenever the possibility of freezing temperatures exists. When disposing of antifreeze follow local laws and regulations. Do not discard into storm sewers, septic systems, or onto the ground. Antifreeze is harmful or fatal if swallowed.
  • Page 40 To freeze guard the hoses and wand perform step 6 with the items to be freeze guarded attached. Recovering Antifreeze for Re-Use Attach all hoses and wands which have been freeze guarded to the truckmount. Attach the incoming water source to the front of the truckmount. Start the truckmount.

  • Page 41: Tensioning The Pump Drive Belt

    TENSIONING THE PUMP DRIVE BELT Remove the CTS 400 Flex grill to gain access to the idler pulley. Loosen but do not remove the 2 ¼” long bolt (P/N 000-143-041) on the idler pulley. See Owner’s Manual. Remove the right cover of the machine to gain access to the tensioning screw. Adjust the tension of the belt by turning the 4”...
  • Page 42 DESCALING FLEX SYSTEM AS REQUIRED Connect a solution hose to the Carpet/Uph. Cleaning Solution Outlet. Route the other end of the solution hose to the Flex tank. Attach an open quick connect to the other end of the hose. The descaler will drain from the female QC fitting assembly/hose quickly. Have extra buckets ready to swap out because each bucket should fill quickly.
  • Page 43 PUMP TUNING INSTRUCTIONS Pump tuning for the CTS 400 Flex allows the pump pressure switch to turn off when there is no flow out of the tool. This reduces the pump operating temperatures and increases the pump durability. Pump tuning should be performed every 60 days. The pump pressure setting adjustment is performed by turning the hex screw, which is close to the center of the pump head, with a hex L-key, provided in the Flex Installation Kit - (see Figure 12).
  • Page 44 Start-up Pump Tuning Procedure Connect the tool’s solution hose to the quick disconnect. Turn the ignition switch to the “ON” position. You do not need to start the unit since vacuum is not needed for this procedure. Select “CARPET/UPH.” on the Solution Control switch. With the pump still on, disconnect the solution hose from the Flex unit.
  • Page 45 Adjustment If the pump continues to run for longer than 3 to 5 seconds, turn the screw counterclockwise until the pump switches off (see Figure 13). If the pump switches off as soon as the hose is disconnected (less than 3 to 5 seconds), turn the pump screw clockwise one complete turn.
  • Page 46 CLEAN QC FILTER AND ORIFICE Clean and inspect the in-line quick connect filter and orifice every 100 hours. Remove the quick connect assembly on the Carpet/Uph. Cleaning Solution Outlet (see Figure 14). Hold the hex closest to the panel using a 11/16” open end wrench and turn the hex assembly for the quick connect with a 13/16”...
  • Page 47 All material must be properly authorized by HydraMaster prior to being returned. When returning, please provide an explanation of the problem and include the serial number of the machine as well as the name of the selling organization. All defective material must be returned to HydraMaster within 60 days of authorization.
  • Page 48 FLEX SYSTEM WARRANTY - ADDENDUM TO THE HYDRAMASTER STANDARD LIMITED WARRANTY Flex System items which are not included in HydraMaster Standard Limited Warranty: • Flex tank assemblies • Flex diaphragm pumps • Strainers These listed items are covered for one (1) year only.

  • Page 49: Maintenance Logs

    Weekly Maintenance MAINTENANCE LOGS 1 Date Hour Meter Reading Technician Initials Inspect the recovery tank filters for tears, holes,         etc. Repair or replace as needed. Inspect the vacuum relief valve. Clean and ...

  • Page 50: Quarterly Maintenance

    Quarterly Maintenance Check the fuel lines. Repair or replace as needed.  Gap the spark plugs to 0.030”. Replace if  excessive carbon buildup is visible. Change the fuel filter.  Change pump drive belt.  250 Hours Maintenance Check coupler element (rubber insert) for cracks ...
  • Page 51 Weekly Maintenance Date Hour Meter Reading Technician Initials Inspect the recovery tank filters for tears, holes,         etc. Repair or replace as needed. Inspect the vacuum relief valve. Clean and    ...
  • Page 52 Quarterly Maintenance Check the fuel lines. Repair or replace as needed.  Gap the spark plugs to 0.030”. Replace if  excessive carbon buildup is visible. Change the fuel filter.  Change pump drive belt.  250 Hours Maintenance Check coupler element (rubber insert) for cracks ...
  • Page 53 Weekly Maintenance Date Hour Meter Reading Technician Initials Inspect the recovery tank filters for tears, holes,         etc. Repair or replace as needed. Inspect the vacuum relief valve. Clean and    ...
  • Page 54 Quarterly Maintenance Check the fuel lines. Repair or replace as needed.  Gap the spark plugs to 0.030”. Replace if  excessive carbon buildup is visible. Change the fuel filter.  Change pump drive belt.  250 Hours Maintenance Check coupler element (rubber insert) for cracks ...
  • Page 55 Weekly Maintenance Date Hour Meter Reading Technician Initials Inspect the recovery tank filters for tears, holes,         etc. Repair or replace as needed. Inspect the vacuum relief valve. Clean and    ...
  • Page 56 MAINTENANCE LOGS N Quarterly Maintenance Check the fuel lines. Repair or replace as needed.  Gap the spark plugs to 0.030”. Replace if  excessive carbon buildup is visible. Change the fuel filter.  Change pump drive belt.  250 Hours Maintenance Check coupler element (rubber insert) for cracks ...
  • Page 57 Weekly Maintenance Date Hour Meter Reading Technician Initials Inspect the recovery tank filters for tears, holes,         etc. Repair or replace as needed. Inspect the vacuum relief valve. Clean and    ...
  • Page 58 Quarterly Maintenance Check the fuel lines. Repair or replace as needed.  Gap the spark plugs to 0.030”. Replace if  excessive carbon buildup is visible. Change the fuel filter.  Change pump drive belt.  250 Hours Maintenance Check coupler element (rubber insert) for cracks ...
  • Page 59 Inspect and clean the garden hose screen. Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed. Lubricate the blower lube port with HydraMaster-recommended spray lubricant. INTERVAL IN HOURS CTS 400 Engine oil and filter Change engine oil and filter after first 8 hours;...
  • Page 60 Inspect and clean the garden hose screen. Inspect the truckmount for water and oil leaks, loose electrical connections, etc. and repair as needed. Lubricate the blower lube port with HydraMaster-recommended spray lubricant. INTERVAL IN HOURS CTS 400 Change engine oil and filter after first 8 hours; afterwards, change the engine oil and filter every 50 hours.

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