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HydraMaster CTS 330 Manual

Hot carbonating truckmount system
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CTS 330 Hot Carbonating
Truckmount System
Manufactured Exclusively for
By
Mukilteo, Washington
Machine Serial Number _______________
HydraMaster
11015 47
Avenue West
th
Mukilteo, Washington 98275
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 HydraMaster.
Specifications and information in this document are subject to change without prior notice. All rights
reserved. © 2012 HydraMaster
MAN-45044 Rev. 0 March 23, 2012
(182-075-D)

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Summary of Contents for HydraMaster CTS 330

  • Page 1 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 HydraMaster. Specifications and information in this document are subject to change without prior notice. All rights reserved.

  • Page 3: Table Of Contents

    Local Water Precautions ..............1-13 Hard Water Advisory ............... 1-13 Hard Water Area Map ............. 1-13 Water Softener ................ 1-13 Waste Water Disposal Advisory ..........1-14 MACHINE SPECIFICATIONS ..............Section 2 Machine Layout ................. 2-3 Component Descriptions ..............2-4 CTS 330 Owner’s Manual...
  • Page 4 Blower ....................4-4 Blower Oil Change ................4-4 Recovery Tank ................... 4-5 Solution System ................. 4-6 Orifice Quick Connect Assembly ............4-6 Blower Heat Exchanger ..............4-7 General Information ................4-7 Freeze Guard Information..............4-7 Maintenance Logs CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 5 Vacuum System Troubleshooting ............7-3 Miscellaneous Troubleshooting ............7-4 ELECTRICAL SYSTEM ................Section 8 WATER AND CHEMICAL SYSTEM ............Section 9 ENGINE TROUBLE SHOOTING ..............Section 10 WARRANTY INFORMATION ............... Section 11 Limited Warranty Plan ............... 11-2 CTS 330 Owner’s Manual...
  • Page 6 HI-PSI Manifold Assembly ............ 5-13 Fig. 5-10 Purge Valve Assembly ............5-15 Fig. 5-11 Vacuum Solenoid Valves Assembly ........5-17 Fig. 5-12 Engine Assembly - Left View ..........5-19 Fig. 5-13 Engine Assembly - Right View ..........5-20 CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 7 Fig. 8-3 Wiring Diagram ................ 8-5 Fig. 9-1 Photo of Heat Exchanger ............9-1 Fig. 9-2 Solution Flow Diagram ............9-3 Reference Information Included with this manual are the following: Blower Owner’s Manual Engine Owner’s Manual Compressor Owner’s Manual CTS 330 Owner’s Manual...

  • Page 8: Quick Reference

    CTS 330 Hot Carbonating Truckmount System Quick Reference Fuel Pump Assembly B4627 CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 9: General Information

    • The heating system must maintain proper heat. • The vacuum tank must store dirty water until drained. As you can see, this machine is not just a simple turn-key operation where your only worry is “Does it start?” Page 1-1 : CTS 330 Owner’s Manual...

  • Page 10: Telephone Numbers

    (800) 426-1301 Harris Research, Inc. Tech Support (435) 755-0255 Hours HydraMaster Monday-Friday 6:00 am to 5:00 pm Pacific Standard Time Harris Research, Inc. Monday-Friday 8:00 am to 5:00 pm Mountain Standard Time Page 1-2 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 11: Precautions

    During the operation of this equipment, many surfaces on the machine will become very hot. When standing in the proximity of the van, care must be taken not to touch any hot surface such as the heater, engine, exhaust, and etc. Page 1-3 : CTS 330 Owner’s Manual...
  • Page 12 Transportation in a vehicle of any vented fuel container that presently has or has ever contained a flammable liquid is strictly forbidden by Harris Research Inc. and by federal and state regulations. Page 1-4 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 13 Foam passing through the blower could lead to equipment malfunction. Therefore, it is important to keep the vacuum tank foam free. WARNING 16. Vacuum Hose Do not leave the vacuum hose unattended during operation. This could cause bodily injury. Page 1-5 : CTS 330 Owner’s Manual...

  • Page 14: Responsibilities

     Checking the vacuum blower and engine oil levels prior to starting the unit.  Starting the unit to check engine and see that all systems function normally.  Checking all hoses, wands, etc. for correct operation. Page 1-6 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 15 5. How to troubleshoot the unit. 6. How to do basic repairs. 7. Safety precautions and their importance. 8. Freezing damage and how to avoid it. 9. Cleaning the orifices and how they function in the system. Page 1-7 : CTS 330 Owner’s Manual...

  • Page 16: Vehicle Preparation

    Hot Carbonating Truckmount System Vehicle Preparation hen selecting a truck, remember the preferable vehicle for a CTS 330 installation is a cargo van with a heavy-duty suspension package and a half ton capacity. If a fresh water tank is added, a three quarter ton or larger capacity van, with a 2,400 pound payload capacity, is required.
  • Page 17 (engine and component weight line up over drive shaft). Also, it is physically easier to load the unit into the rear door due to the height of the van bed. Figure 1-2 Recommended Placement Page 1-9 : CTS 330 Owner’s Manual...
  • Page 18 Never operate this machine with a portable gas can inside the truck. Doing so increases the risk of a fire or explosion. Mount a fire extinguisher just inside the rear or side door for emergencies. Page 1-10 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 19 WARNING Transportation in a vehicle of any vented fuel container that presently holds or has ever held a flammable liquid is strictly forbidden by HydraMaster Corporation and by federal and state regulation. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 20: High Altitude Operation Preparation

    This will make the engine run ‘rich’, and, in turn will result in the loss of power, excessive heat in the exhaust, and carbon buildup in the exhaust and heat ex- changer system. The jet sizes vary per engine and elevation. Consult HydraMaster to obtain proper jet size.

  • Page 21: Local Water Precautions

    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 22: Waste Water Disposal Advisory

    HydraMaster makes an A.P.O. System available which can be or ered with new equipment or installed later. The penalties for noncompliance can be serious. Always check local laws and regulations to be sure you are in compliance.
  • Page 23 CTS 330 Hot Carbonating Truckmount System Figure 1-4 Hard Water Map Page 1-15 : CTS 330 Owner’s Manual...

  • Page 24: Machine Specifications

    Manual engine choke Blower lubrication port Recovery Tank: 50 gallon aluminum, epoxy finish High Pressure Hose: 3/16" high temperature, lined, vinyl covered Hose rated to 2200 psi, 250° F. Vacuum Hose: 2" reinforced Page 2-1 : CTS 330 Owner’s Manual...
  • Page 25 Vacuum recovery tank (1) fifteen gallon stainless steel solution tank with holder 100 ft, 2" vacuum hose 100 ft, 3/16" solution line 10 ft, 1½” recovery drain line Battery box Van installation kit Page 2-2 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 26: Machine Layout

    Ignition Switch – Main power control to the machine. Vacuum Gauge – Displays engine temp, solution temp (older versions), and vacuum. Heat Mode Light – Shows if the diverter is in heat mode. Exhaust Out – Engine and blower exhaust outlet. Page 2-3 : CTS 330 Owner’s Manual...

  • Page 27: Component Descriptions

    The vacuum pump is driven through the direct coupler by the engine (Figure 2-2). Figure 2-2 The air compressor is driven by a V-belt located between the blower and engine (Figure 2-3). Figure 2-3 Page 2-4 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 28: Operating Instructions

    This can be expedited by turning the solution valve to prime for 15 seconds, then returning the valve to cleaning mode. Page 3-1 : CTS 330 Owner’s Manual...

  • Page 29: Flood Extraction

    5. Replace the lids on the chemical tanks. 6. Reconnect hoses if necessary. 7. Position the Compressor Valve to CLEANING MODE. Figure 3-3 Notes: Solution tank recharge time will vary depending on the level of the solution. Page 3-2 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 30: Shut Down

    This will activate once the recovery tank has reached its full capacity. General Operating Information 1. In accordance with state and local EPA laws, do not dispose of wastewater into gutters, storm drains, streams, reservoirs, etc. Dispose wastewater into a treated sanitary system. Page 3-3 : CTS 330 Owner’s Manual...

  • Page 31: Machine Maintenance

    3. Carefully clean out cartridge and foam element. 4. Reinstall air filter cartridge. 5. Install cover and lock clamps. Figure 4-1 Note: Do not use pressurized air or solvents to clean cartridge and foam ring. Page 4-1 : CTS 330 Owner’s Manual...

  • Page 32: Engine Oil And Filter Change

    Engine oil capacity is approximately 1.75 quarts with filter. WARNING Failure to do this step will result in an insufficient amount of oil in the engine! 6. Check oil dipstick for proper level. 7. Re-install the oil fill cap. Page 4-2 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 33: Spark Plug Replacement

    3. Install the new filter. The filter has an arrow on it. The arrow should point towards the hose to the machine. HRI Part # 049-049 4. Tighten the hose clamps. Figure 4-5 Page 4-3 : CTS 330 Owner’s Manual...

  • Page 34: Blower

    Figure 4-7 4. Re-install the oil fill plug. 5. Attach grease gun to zerks and pump grease into the blower until grease flows out of the weep holes. Page 4-4 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 35: Recovery Tank

    This loss of vacuum will cause the blower to over heat. Figure 4-9 4. Remove the stainless steel floats and clean (Figure 4-10). Figure 4-10 Page 4-5 : CTS 330 Owner’s Manual...

  • Page 36: Solution System

     3/32 Allen wrench Orifice and Filter Maintenance Position Compressor Valve to PRESSURE RELIEF. 2. Remove the filter by disconnecting the stainless steel quick connect (Figure 4-12). WARNING Figure 4-12 NEVER disconnect under pressure! Page 4-6 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 37: Blower Heat Exchanger

    2. Turn the Solution Valve to the “Purge” position. 3. Turn the Air Valve to the “Cleaning Mode” position. 4. Run the machine for approximately 3 to 5 minutes. 5. Empty the recovery tank. Page 4-7 : CTS 330 Owner’s Manual...
  • Page 38 CTS 330 Hot Carbonating Truckmount System CTS 330 GENERAL MAINTENANCE LOG DAILY SERVICE OIL RECOMMENDATIONS ENGINE OIL check BLOWER 40 weight non-detergent MACHINE general inspection ENGINE 30 weight motor oil RECOVERY TANK FILTER BAG clean NOTE: Overhead valve engines can use multi-viscosity oil, but will RECOVERY TANK STAINLESS STEEL FILTER Clean experience increased oil consumption.

  • Page 39: Machine Assemblies And Parts Lists

    CTS 330 Hot Carbonating Truckmount System Machine Assemblies and Parts Lists Figure 5-1 Machine Assembly - Front Right View D-6150 Rev C Page 5-1 : CTS 330 Owner’s Manual...
  • Page 40 CTS 330 Hot Carbonating Truckmount System Figure 5-2 Machine Assembly - Front Left View D-6150 Rev C Page 5-2 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 41 CTS 330 Hot Carbonating Truckmount System Figure 5-3 Machine Assembly - Rear View D-6150 Rev C Page 5-3 : CTS 330 Owner’s Manual...
  • Page 42 000-052-226 Insert,1-1/2” NPT x 1-1/2” Barb (Grey) 000-169-022 Valve, 1-1/2” Full Port Ball 000-068-135 Hose, Ø1.50” I.D. Red Stripe Type 55 - Bulk 000-033-063 Clamp, 1-1/2” T-Bolt 000-081-215 Label, Caution Rotating Equipment 000-174-019 Washer, 1/4” Lock Page 5-4 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 43 CTS 330 Hot Carbonating Truckmount System Figure 5-4 Frame Assembly - Front Left View D-6151 Rev B Page 5-5 : CTS 330 Owner’s Manual...
  • Page 44 CTS 330 Hot Carbonating Truckmount System Figure 5-5 Frame Assembly - Front Right View D-6151 Rev b Page 5-6 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 45 CTS 330 Hot Carbonating Truckmount System Figure 5-6 Frame Assembly - Rear View D-6151 Rev B TO RECOVERY TANK TO CHEMICAL TANK TO RECOVERY TANK DASH REMOVED FOR CLARITY Page 5-7 : CTS 330 Owner’s Manual...
  • Page 46 000-068-030 Hose, 5/32” I.D. Vacuum - Bulk 000-068-030 Hose, 5/32” I.D Vacuum - Bulk 000-068-660 Hose, 1/4” Fuel - Trident - Bulk 000-068-015 Hose, 1/4” I.D. Rubber - Bulk 000-010-122 Belt, Compressor 000-033-003 Clamp, Size #4 Mini Page 5-8 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 47 CTS 330 Hot Carbonating Truckmount System Figure 5-7 Dash Assembly - Front View D-6152 Rev B Page 5-9 : CTS 330 Owner’s Manual...
  • Page 48 CTS 330 Hot Carbonating Truckmount System Figure 5-8 Dash Assembly - Rear View D-6152 Rev B Page 5-10 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 49 000-143-012 Screw, 5/16”-18UNC x 0.75” Lg. Hex Head 000-084-011 Light, Red LED Indicator Mini 000-033-023 Clamp, 3/4” Nylon Hose 000-052-066 Coupler, 1/4” FPT x 1/8” FPT 000-052-106 Insert, 1/8” NPT x 5/32” Barb x 90° 000-105-012 Plate, Machine Serial I.D. Page 5-11 : CTS 330 Owner’s Manual...
  • Page 50 000-140-001 Rivet, 1/8” x 1/4” Aluminum 000-081-243 Label, Dash 000-081-243 Label, Blower, Lube Port 000-081-243 Label, Engine Produces Toxic Gas 000-081-243 Label, Operating Instructions 000-081-215 Label, Solution Valve 000-033-057 Clamp, 1” Cushion Loop Page 5-12 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 51 CTS 330 Hot Carbonating Truckmount System Figure 5-9 HI-PSI Manifold Assembly C-6158 Rev A Page 5-13 : CTS 330 Owner’s Manual...
  • Page 52 000-169-095 Valve, 1/4” NPT Panel Mount - Full Port Ball 11 000-052-526 Nipple, 1/4” NPT x 1/4” JIC 000-052-745 Elbow, 1/4” NPT x 45° Street s/s 000-052-610 Coupler, 1/4” FPT Hex s/s 000-052-696 Insert, #44 (1/4” NPT x 1/4” Barb) s/s Page 5-14 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 53 CTS 330 Hot Carbonating Truckmount System Figure 5-10 Purge Valve Assembly C-6161 Rev A Page 5-15 : CTS 330 Owner’s Manual...
  • Page 54 000-157-148 Switch, Pressure 125 PSI 9 000-180-004 Orifice, Set Screw 0.033” 10 000-052-423 Bushing, Modified Set Screw Orifice 000-052-110 Insert, #F44 (1/4” FPT x 1/4” Barb) 000-068-131 Hose, 1/4” I.D. Hi Temp - Bulk 000-033-003 Clamp, Size #4 Mini Page 5-16 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 55 CTS 330 Hot Carbonating Truckmount System Figure 5-11 Vacuum Solenoid Valves Assembly C-6162 Rev - Page 5-17 : CTS 330 Owner’s Manual...
  • Page 56 000-169-156 Valve, Check - Diverter Control System 000-068-030 Hose, 5/32” I.D. Vacuum 000-068-030 Hose, 5/32” I.D. Vacuum 000-068-030 Hose, 5/32” I.D. Vacuum 000-068-030 Hose, 5/32” I.D. Vacuum 000-068-030 Hose, 5/32” I.D. Vacuum Page 5-18 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 57 CTS 330 Hot Carbonating Truckmount System Figure 5-12 Engine Assembly - Left View D-6153 Rev C Page 5-19 : CTS 330 Owner’s Manual...
  • Page 58 CTS 330 Hot Carbonating Truckmount System Figure 5-13 Engine Assembly - Right View D-6153 Rev C Page 5-20 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 59 000-033-057 Clamp, 1” Cushion Loop 000-143-001 Screw, 1/4”-20UNC x 0.75” Lg. Hex Head 000-174-019 Washer, 1/4” Lock 000-094-010 Nut, 1/4”-20UNC Hex - - - Filter, B&S Fuel (Comes w/ Engine) 000-057-010 Gasket, Exhaust Manifold - Vanguard Page 5-21 : CTS 330 Owner’s Manual...
  • Page 60 CTS 330 Hot Carbonating Truckmount System Figure 5-14 Exhaust Assembly D-6155 Rev B Page 5-22 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 61 000-106-120 Plug, M18 x 1.5 000-094-081 Nut, 5/16”-18UNC Hex 2-Way Locking 000-143-003 Screw, 1/4”20UNC x 1.25” Lg. Hex Head 000-174-003 Washer, 1/4” Flat 000-143-316 Screw, 5/16”-18UNC x 2.00” Lg. Hex Head 000-174-004 Washer, 5/16” Flat Page 5-23 : CTS 330 Owner’s Manual...
  • Page 62 CTS 330 Hot Carbonating Truckmount System Figure 5-15 Diverter Valve Actuator Assembly C-6154 Rev A Page 5-24 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 63 000-015-750 Bracket, Air Cylinder Mount - Inner 000-015-748 Bracket, Air Cylinder Mount - Outer 000-143-573 Screw, 5/16-18 Shoulder, 3/8” Dia x 1/2” 000-174-001 Washer, #10 Flat 000-174-014 Washer, #10 Lock 000-143-132 Screw, #10-24UNC x 0.75” Lg. Hex Head Page 5-25 : CTS 330 Owner’s Manual...
  • Page 64 CTS 330 Hot Carbonating Truckmount System Figure 5-16 Blower Assembly - Front View D-6156 Rev A Page 5-26 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 65 CTS 330 Hot Carbonating Truckmount System Figure 5-17 Blower Assembly - Rear View D-6156 Rev A Page 5-27 : CTS 330 Owner’s Manual...
  • Page 66 000-143-005 Screw, 1/4”-20UNC x 1.75” Lg. Hex Head 000-174-019 Washer, 1/4” Lock 000-174-003 Washer, 1/4” Flat 000-068-221 Hose, 3/8” x 24” Lg. Pump Drain 000-052-061 Bushing, 3/8” NPT x 1/4” FPT 000-052-085 Elbow, 1/4” NPT Street Page 5-28 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 67 CTS 330 Hot Carbonating Truckmount System Figure 5-18 Compressor Assembly D-6157 Rev D Page 5-29 : CTS 330 Owner’s Manual...
  • Page 68 000-143-324 Screw, 5/16”18UNC X 4” Lg Tap Hex Head Grd 5 000-154-149 Spacer, Belt Guard Stiffening - Coated 000-020-064 Spacer, Compressor Clutch 000-174-002 Washer, 1/4” Flat 000-174-004 Washer, 5/16” Flat 000-174-018 Washer, 5/16” Lock 000-174-170 Washer, Hardened, 5/16” Page 5-30 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 69 CTS 330 Hot Carbonating Truckmount System Figure 5-19 Blower Heat Exchanger Assembly D-6159 Rev A Page 5-31 : CTS 330 Owner’s Manual...
  • Page 70 000-068-728 Hose, 2” Silicone 000-174-001 Washer, #10 Flat 000-174-014 Washer, #10 Lock 000-143-126 Screw, #10-24UNC x 0.50” Lg. Hex Head 000-052-747 Elbow, 3/8” NPT Street 000-033-046 Clamp, 1/2 Wide x 1/2 Tube Page 5-32 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 71 CTS 330 Hot Carbonating Truckmount System Figure 5-20 15 Gallon Chemical Jug Assembly D-6163 Rev B TO COMPRESSOR TO HEAT EXCHANGER Page 5-33 : CTS 330 Owner’s Manual...
  • Page 72 000-180-021 Orifice, Set Screw #10-32UNF x Ø0.052” 000-049-137 Filter, In-Line - Quick Connect 000-052-696 Insert, #44 (1/4” NPT x 1/4” Barb) s/s 12 000-169-157 Valve, 1/4” NPT Check w/ Orifice 000-052-610 Coupler, 1/4” FPT Hex s/s 000-081-218 Label, Caution - Tank Page 5-34 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 73 CTS 330 Hot Carbonating Truckmount System Figure 5-21 15 Gallon Chemical Tank Assembly C-6109 Rev - Page 5-35 : CTS 330 Owner’s Manual...
  • Page 74 15 Gallon Chemical Tank Assembly Parts List Item Part Number Description 000-159-126 Tank, 15 Gallon Chemical 000-106-055 Plug, 1/4 s/s Chemical Container 000-097-006 O-Ring, #8 Buna 000-033-032 Clamp, CDS Throttle Cable 000-025-008 Cable, 150 Lb Test Page 5-36 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 75 CTS 330 Hot Carbonating Truckmount System Figure 5-22 Recovery Tank Assembly D-5530 Rev D Page 5-37 : CTS 330 Owner’s Manual...
  • Page 76 000-052-100 Insert, #44 (1/4” NPT x 1/4” Barb) 000-174-003 Washer, 1/4” Flat 000-174-019 Washer, 1/4” Lock 000-131-021 Trimlok, 5/8” x 1/8” 000-057-193 Gasket, Recovery Tank Outlet 000-001-129 Adapter, Recovery Tank Outlet 000-081-243 Label, Maintenance & Lubrication Schedule Page 5-38 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 77 CTS 330 Hot Carbonating Truckmount System Figure 5-23 Dura-Flow APO Assembly D-5654 Rev B Page 5-39 : CTS 330 Owner’s Manual...
  • Page 78 000-052-338 Insert, #1212 (3/4” NPT x 3/4” Barb) 000-169-009 Valve, 3/4” FPT Swing Check 000-052-281 Nipple, 3/4” NPT x 3/4” Male Garden Hose 000-057-055 Gasket, Garden Hose 000-027-014 Cap, Garden Hose Page 5-40 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 79 CTS 330 Hot Carbonating Truckmount System Figure 5-24 Vacuum Relief Valve Assembly C-4237 Rev B USE BLUE LOCKTITE #242 Page 5-41 : CTS 330 Owner’s Manual...
  • Page 80 000-125-111 Pipe, Vacuum Relief Spring Guide 000-105-067 Plate, Vacuum Relief Valve Mounting 000-155-026 Spring, Vacuum Relief 000-143-198 Screw, 3/8”-16UNC x 4” Lg. Hex Head Full Thread 000-094-077 Nut, 3/8”-16UNC x 1.00” O.D. Knurled 8 000-094-101 Nut, 3/8”-16UNC Hex Jam Page 5-42 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 81: Compressor System

    Dirty filters reduce pump performance by restricting air flow. Lubrication: The CTS 330 compressor is a dry, oil-less compressor. The product uses sealed grease packed bearings and does not require additional lubrication CAUTION DO NOT LUBRICATE.

  • Page 82: Vacuum System

    Read the vacuum blower manual carefully for proper oil change and grease application. The maintenance log may differ slightly from the manual, but the truck-mounted carpet cleaning machine application is very demanding of the vacuum blower and therefore it should be main- tained more regularly. Page 7-1 : CTS 330 Owner’s Manual...
  • Page 83 VACUUM TANK FILTER BAGS HydraMaster filter bags are designed to trap 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.

  • Page 84: Vacuum System Troubleshooting

    Running vacuum blower low on oil can cause severe mechanical damage. If this situ- ation occurs, it should be inspected by a qualified service technician. 4.2. Vacuum blower has internal damage. Refer to qualified service technician. Page 7-3 : CTS 330 Owner’s Manual...

  • Page 85: Miscellaneous Troubleshooting

    Remove and test. Replace as necessary. 1.3.2. If water is expelled while switch is in divert mode, the blower exhaust heat exchanger is leaking. Remove and test. Replace as necessary. Page 7-4 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 86: Electrical System

    Hot Carbonating Truckmount System Electrical System The CTS 330 electrical system, in keeping with the entire machine concept, has been kept to a minimum so as to keep any necessary troubleshooting as easy as possible. The entire electrical system operates on 12 volts DC which is provided by a battery. Bat- tery levels are sustained by a 16 amp alternator inside the engine.
  • Page 87 32(WHT) CLUTCH 24(BLK) PRESSURE 13(WHT) SWITCH 64(WHT) IGNITION 14(YEL) SW-3 SWITCH 63(WHT) VACUUM GAUGE 15(ORG) SW-2 VI-1 16(BRN) 62(WHT) 17(RED) 61(WHT) 65(WHT) *ALL WIRES ARE 18 GAUGE UNLESS OTHERWISE STATED TO ENGINE/RECOVERY TANK Page 8-3 : CTS 330 Owner’s Manual...
  • Page 88 48(WHT)-14 GA. 47(BLK)-14 GA. TO BATTERY + 52(RED)-14 GA. 53(RED)-14 GA. APO PUMP APO PUMP 25 AMP 48(WHT)-14 GA. RELAY PMP-2 CR-3 FUSE APO TERMINAL APO SWITCH FU-2 BLOCK SW-5 TB-3 TO BATTERY GROUND Page 8-4 : CTS 330 Owner’s Manual...
  • Page 89 BRIGGS & STRATTON ENGINE MTR-1 IGNITION SWITCH STARTER SOLENOID SW-2 SOL-1 STARTER STATOR FUEL PUMP PMP-1 N.O. N.C. (#4 GA.) VOLT. REG. HOUR VR-1 METER HI-1 RELAY SCHEMATIC (SHOWN IN "OFF" POSITION) BATTERY PS-1 Page 8-5 : CTS 330 Owner’s Manual...

  • Page 90: Water And Chemical System

    The compressor valve’s purpose is to manually relieve the system of compressed air. This is done in situations such as removing the lids on the solution tanks. Page 9-1 : CTS 330 Owner’s Manual...
  • Page 91 By turning this valve to prime, it will relieve the pressure and allow the solution hose to be connected. The valve can also be used for priming the solution. Page 9-2 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 92 CTS 330 Hot Carbonating Truckmount System Figure 9-2 Solution Flow Diagram D-6168 Rev - Page 9 -3 : CTS Owner’s Manual...
  • Page 93 CTS 330 Hot Carbonating Truckmount System Page 9 -5 : CTS Owner’s Manual...

  • Page 94: Engine Troubleshooting

    There is a mechanical problem with the engine. If the engine can be turned over by hand and the vacuum blower is not locked, refer the engine to a qualified service technician to determine the cause of the problem. Page 10-1 : CTS 330 Owner’s Manual...
  • Page 95 3.1.2. If 12 volts is not present at the pump, check the wiring to the pump, including the fuse. Repair or replace as necessary. Note: If the fuse has blown, carefully inspect the wiring for a shorted or damaged wire. Repair immediately. Page 10-2 : CTS 330 Owner’s Manual HydraMaster Corporation...
  • Page 96 5.3.1. If adjustment is okay, there is a possibility of burned valves, burned head gasket or worn cylinders. Refer to qualified engine service technician. 5.4. Poor spark on one or both cylinders. Refer to qualified engine service technician. Page 10-3 : CTS 330 Owner’s Manual...
  • Page 97 Engine rpm too high. Check RPM with an accurate tachometer. Adjust as neces- sary to 3400 rpm (no load). 7.4. Restricted engine or blower exhaust. Disassemble exhaust components to lo- cate restriction. Repair as necessary. Page 10-4 : CTS 330 Owner’s Manual HydraMaster Corporation...

  • Page 98: Warranty Information

    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. Water Heating System: Failure to protect against freezing. Page 11-1 : CTS 330 Owner’s Manual...

  • Page 99: Limited Warranty Plan

    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 de-...
  • Page 100 C85281 03/10 SEPARATE DRIVE AIR COMPRESSOR AND VACUUM PUMPS SGH ‘B’ MODELS RATED 1/4-1 HP INSTALLATION, OPERATION, PARTS LIST AND MAINTENANCE GENERAL Establish a periodic time for checking and clean- ing all filters to obtain maximum satisfactory Operation and maintenance instructions as well as parts information presented herein relate to the service.
  • Page 101 PISTON & ROD ASSEMBLIES Consist of assembled piston and rod bearing and eccentric. Motor H.P. Number Vacuum Piston & 50 PSI Compressor 100 PSI Compressor (Rated) of Cylin- Model Rod Assy. ders Model Piston & Model Piston & Rod Assy. Rod Assy.
  • Page 102 MODEL NUMBER: This identifi es the specifi c model of the blower. SERIAL NUMBER: Each blower has a unique serial number. This number is to be used with any service issues and with any contact with the manufacturer. YEAR: This states the year that the blower was manufactured. MAWP: This states the maximum allowable working pressure (MAWP) of the blower casing.
  • Page 103 INLET INLET INLET Figure 1 illustrates that the air moves not between the rotors but between the rotors and the side of the housing. Also, the machine is bi-directional, meaning that the direction of rotation of the blower can make either side the inlet or discharge.
  • Page 104 4.2 SPECIFICATIONS TABLE 1 — SPECIFICATIONS APPROXIMATE OIL CAPACITY¹ OUNCES / MILLILITERS PORT VERTICAL FLOW HORIZONTAL FLOW SIZE APPROXIMATE WEIGHT GEAR END² DRIVE END³ GEAR END² DRIVE END³ MODEL IN / LBS. / 2002 3.4 / 1.7 / 5275 41 / 2004 3.4 / 1.7 /...
  • Page 105 WARNING The maximum pressure differential is based on the difference between the inlet pressure and the outlet pressure. The maximum pressure differential shall not be exceeded. Exceeding the maximum pressure differential will cause serious damage to the equipment and could cause bodily injury. WARNING The maximum allowable working pressure (MAWP) is based on the absolute pressure of the blower housing and is NOT the maximum allowable...
  • Page 106 WARNING The standard MAWP is per Table 2. The MAWP shall not be exceeded unless specifi c factory testing of the pressure containing components of the blower has been performed. WARNING Table 2 states the maximum operating speed in RPM (rotations per minute) and maximum temperature.
  • Page 107 be checked in a free state with feeler stock or verifi ed on a previously installed blower with the aid of a dial indicator. Less than .002” (.05 mm) spring or gap should be found. Use only clean new pipe and make certain it is free of scale, cuttings, weld beads, dirt, or any other foreign material.
  • Page 108 Do not use blowers on explosive or hazardous gases. Each size blower has limits on pressure differential, running speed, and discharge temperature. These limits must not be exceeded. Consult Table 2 for details pertaining to the allowable performance criteria. If it is necessary to take air from a remote source, such as in a vacuum application, the piping should be at least the same diameter of the blower inlet.
  • Page 109 DANGER Assure that properly sized vacuum breaks/relief valves are used on the inlet side of the blower. Also assure that properly sized pressure relief valves are used on the outlet of the blower. The sizing shall be such to assure that the proper fl...
  • Page 110 WARNING Do not start the blower until you are sure oil has been put in the gear housing and front cover (grease if 21 series). Operation of the blower without proper lubrication will cause the blower to fail and void the warranty. NOTE Most Competitor blowers are shipped from the factory in a left hand drive, vertical fl...
  • Page 111 5.3.2 FREQUENTLY ASKED QUESTIONS REGARDING LUBRICATION What is the functional detriment if the “wrong oil” is used? The lubricant is selected based on bearing and gear speed, and operating temperature. Too light of a lubricant increases wear by not separating the sliding surfaces and it will not remove the heat adequately.
  • Page 112 5.3.4 GREASE LUBRICATED BEARINGS — 21 (PLUS) SERIES ONLY Service drive end bearing at regular intervals. SUGGESTED LUBRICATION INTERVALS (See the Suggested Lubrication Intervals for FOR GREASE LUBRICATED BEARINGS Grease Lubricated Bearings table, to the right.) OPERATING HOURS PER DAY Use NLGI #2 premium grade, petroleum base grease with high temperature resistance and good SPEED...
  • Page 113 HAZARDS ASSOCIATED WITH HAZARDOUS PROCESS FLUIDS DANGER It shall be the responsibility of the installer to ensure that piping is adequate, sealing between pipe joints is adequate for the process fl uids and proper process and pressure protection devices are in place. It is also the responsibility of the installer to assure that process gasses are not vented in a manner that would be hazardous.
  • Page 114 A tight or driving fi t will force the drive shaft out of its normal position and cause internal damage. A loose fi t will result in shaft damage or breaking. The motor sheave must also fi t correctly and be properly aligned with the blower sheave.
  • Page 115 5.5.4 V-BELT TROUBLESHOOTING PROBLEM POSSIBLE CAUSES SOLUTION Belts slip (sidewalls glazed) Not enough tension Replace belts; apply proper tension Shock load Apply proper tension Drive squeals Not enough arc of contact Increase center distance Heavy starting load Increase belt tension Broken cord caused by prying on sheave Replace set of belts and install correctly Overloaded drive...
  • Page 116 6. OPERATION 6.1 GENERAL DANGER The blower is not intended to be used with explosive products or in explosive environments. WARNING Do not operate without guards in place. WARNING Maximum operating speed: Table 2 states the maximum operating speed in RPM (rotations per minute), the maximum pressure differential, maximum vacuum and maximum temperature rise.
  • Page 117 6.2 START-UP CHECKLIST We recommend that these startup procedures be followed in sequence and checked off ( ) in the boxes provided in any of the following cases: • During initial installation • After maintenance work has been performed • After any shutdown period •...
  • Page 118 CAUTION Do not touch hot surfaces. The upper limit of the blower operation is 445° F (229° C) Do not touch the blower while it is in operation and assure blower is cool when not in operation. CAUTION Use of a thermowell insulates the thermocouple. Invalid and delayed readings will result.
  • Page 119 3. For extended shutdown, oil may be injected into the inlet of the heated blower just prior to shutting the blower down. The oil will provide a protective coating on the internals. Insure that the water is completely shut off after shutdown. 4.
  • Page 120 7. MAINTENANCE 7.1 GENERAL Regular inspection of your blower and its installation, along with complete checks on operating conditions will pay dividends in added life and usefulness. Also, service the drive per manufacturer’s instructions and lubricate the coupling or check belt drive tension. By use of thermometers and gauges, make sure that blower operating temperature and pressure remain within allowed limits.
  • Page 121 NOTE Oil levels should be checked every 24 hours of operation. Proper oil drain schedules require oil be changed before the contaminant load becomes so great that the lubricating function of the oil is impaired or heavy disposition of suspended contaminants occurs. To check the condition of the oil, drain a sampling into a clean container and check for the presence of water or solids.
  • Page 122 7.4 FACTORY SERVICE & REPAIR With proper care, Tuthill Vacuum & Blower Systems blowers will give years of reliable service. The parts are machined to very close tolerances and require special tools by mechanics who are skilled at this work. Should major repairs become necessary, contact the factory for the authorized service location nearest you.
  • Page 123 8. DISASSEMBLY AND REASSEMBLY 8.1 DISASSEMBLY OF BLOWER With proper maintenance and lubrication, normal life expectancy for gears, bearings, and seals can be achieved. However, over a period of time these parts must repaired or replaced to maintain the effi ciency of your blower.
  • Page 124 9. Remove cover. 10. Loosen the set screws on the oil slingers [Items 45 & 46] and remove the oil slingers from the rotor shafts. (Refer to Figure 12) 11. Remove ten (10) cap screws [15] that secure drive end plate [3] to housing Figure 10 - Pulling Driven Gear [1].
  • Page 125 2-LOBE UNITS 8.2 REASSEMBLY OF BLOWER ALL MODELS After thorough cleaning of the seal and bearing bores of both end plates apply a thin coat of sealant on the outside DRIVE diameter of the new seals and press them into the end plate using a tool that will bear on the outer edge of the seal.
  • Page 126 4. Install bearing retainers [Items 22 & 25] to both bearings. 5. Check clearances between the end of the rotors and the face of the end plate. Refer to assembly clearances chart on page 32 for proper clearances for your model blower, and refer to the Adjusting Rotor Interlobe Clearance section on page 29 for procedures for checking and adjusting clearances.
  • Page 127 AA reading is .009” (.23 mm) and BB reading .003” (.08 mm) by removing .006” (.15 mm) shims. the readings will change one half the amount removed or .003” (.08 mm). AA should then read .006” (.15 mm) and BB should read .006” (.15 mm). The fi nal reading should be within .002” (.05 mm) of each other.
  • Page 128 9. TROUBLESHOOTING Although Tuthill Vacuum & Blower Systems blowers are well designed and manufactured, problems may occur due to normal wear and the need for readjustment. The chart below lists symptoms that may occur along with probable causes and remedies. SYMPTOM PROBABLE CAUSE REMEDIES...
  • Page 129 10. ASSEMBLY CLEARANCES Values are shown in inches and millimeters. LOBES TO END PLATES LOBE TO CASING MODEL DRIVE END GEAR END TOTAL INTERLOBE TIP-DOWEL TIP-PORT .004 - .007 .003 - .005 .008 - .011 .005 - .009 .002 - .004 .003 - .006 2002 .10 - .18...
  • Page 130 12. RECOMMENDED LUBRICANTS RECOMMENDED MINERAL BASED LUBRICANTS AMBIENT SHELL CITGO CHEVRON EXXONMOBIL TEMPERATURE 0° to 32° F TELLUS ® S2 M 68 A/W 68 RANDO HD 68 DTE HEAVY MEDIUM (-18° to 0° C) (ISO 68) (ISO 68) (ISO 68) (ISO 68) 32°...
  • Page 131 13. SPECIAL TOOL DRAWINGS BEARING PRESSING TOOL (FOR ALL SERIES) SEAL PRESSING TOOL (FOR 21 & 22 SERIES) 1.524 1.524 19.05 R .06 R .12 1.524 1.524 ±.001 ±.005 ±.005 ±.005 ±.005 ±.005 ±.005 ±.001 ±.005 ±.005 ±.005 ±.005 ±.005 MODEL MODEL ±...
  • Page 132 PARTS LIST FOR MODEL COMPETITOR 21 (PLUS) SERIES ITEM PART DESCRIPTION HOUSING MOUNTING FOOT MOUNTING FOOT DRIVE END PLATE GEAR END PLATE GEAR COVER DRIVE ROTOR DRIVEN ROTOR GEAR SET DOWEL PIN COVER GREASE BEARING BEARING BEARING SCREW, HEX HEAD SCREW, HEX HEAD SCREW, HEX HEAD PIPE PLUG...
  • Page 133 PARTS LIST FOR MODEL COMPETITOR 22 (SL) SERIES ITEM PART DESCRIPTION HOUSING MOUNTING FOOT MOUNTING FOOT DRIVE END PLATE GEAR END PLATE COVER BE DRIVE ROTOR DRIVEN ROTOR GEAR SET DOWEL PIN COVER DE BEARING BEARING BEARING BALL SCREW, HEX HEAD SCREW, HEX HEAD SCREW, HEX HEAD PIPE PLUG...
  • Page 134 PARTS LIST FOR MODEL COMPETITOR 23 (GT) SERIES ITEM PART DESCRIPTION HOUSING MOUNTING FOOT DRIVE END PLATE GEAR END PLATE COVER BE DRIVE ROTOR DRIVEN ROTOR GEAR SET DOWEL PIN COVER DE BEARING BEARING BEARING BALL SCREW, HEX HEAD SCREW, HEX HEAD SCREW, HEX HEAD PIPE PLUG MAGNETIC PLUG...
  • Page 137 NOTES:...
  • Page 138 DECLARATION OF INCORPORATION Herewith we declare that the items detailed below are in conformity with the provisions of the Machinery Directive 2006/42/EC. Information on the items detailed are compiled per the Machinery Directive 2006/42/EC, Annex VII, part A and are the responsibility of the person listed below. The items detailed below must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the relevant directive(s).
  • Page 139 WARRANTY – BLOWER PRODUCTS Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale, Tuthill Vacuum & Blower Systems (the Seller) warrants products and parts of its manufacture, when shipped, and its work (including installation and start-up) when performed, will be of good quality and will be free from defects in material and workmanship.
  • Page 140 OPERATING DATA FORM / PRODUCT REGISTRATION It is to the user’s advantage to have the requested data filled in below and available in the event a problem should develop in the blower or the system. This information is also helpful when ordering spare parts. Model No.
  • Page 141 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 2912 SPRINGFIELD MO POSTAGE WILL BE PAID BY ADDRESSEE ATTN. CUSTOMER SERVICE TUTHILL VACUUM & BLOWER SYSTEMS PO BOX 2877 SPRINGFIELD MO 65890-2150...

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