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HydraMaster CTS 450 Manual

Hot carbonating truckmount system
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CTS 450 Hot Carbonating
Truckmount System
™
Manufactured Exclusively for
By
Mukilteo, Washington
Machine Serial Number _______________
Copyright © 2012
HydraMaster Corporation
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 written permission by
HydraMaster© Corporation. All Rights Reserved.
Revised March 23, 2012

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Summary of Contents for HydraMaster CTS 450

  • Page 1 CTS 450 Hot Carbonating Truckmount System ™ Manufactured Exclusively for Mukilteo, Washington Machine Serial Number _______________ Copyright © 2012 HydraMaster Corporation 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 written permission by HydraMaster©...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents List of Figures Quick Reference GENERAL INFORMATION ................Section 1 Telephone Numbers................1-2 Precautions ..................1-3 Responsibilities .................. 1-6 Vehicle Preparation................1-8 High Altitude Operation Preparation ..........1-12 Local Water Precautions ..............1-13 Hard Water Advisory ............... 1-13 Hard Water Area Map .............
  • Page 4 Fuel Separator (Diesel Engine) ............4-4 Blower ....................4-5 Blower Oil Change ................4-5 Recovery Tank ................... 4-6 Solution System ................. 4-8 Orifice Manifold .................. 4-8 General Maintenance ................ 4-9 Freeze Guard Information..............4-9 Maintenance Logs HydraMaster Corporation CTS 450 Owner’s Manual...
  • Page 5 CTS 450 Hot Carbonating Truckmount System MACHINE ASSEMBLIES AND PARTS LIST ..........Section 5 WATER AND CHEMICAL SYSTEM ............Section 6 ELECTRICAL SYSTEM ................Section 7 WARRANTY INFORMATION ............... Section 8 Limited Warranty Plan ............... 8-2 CTS 450 Owner’s Manual...
  • Page 6 Brow Assembly - Rear View ..........5-11 Fig. 5-9 Compressor Regulator Assembly ......... 5-13 Fig. 5-10 Engine Assembly - Right View ..........5-15 Fig. 5-11 Engine Assembly - Left View ..........5-16 Fig. 5-12 Exhaust Assembly..............5-20 HydraMaster Corporation CTS 450 Owner’s Manual...
  • Page 7 Fig. 5-25 Vacuum Relief Valve Assembly ..........5-42 CTS 450 Diesel Fig. 5-26 Machine Assembly - Front View (CTS 450 Diesel) ....5-44 Fig. 5-27 Machine Assembly - Rear View (CTS 450 Diesel) ....5-45 Fig. 5-28 Machine Assembly - Side View (CTS 450 Diesel) ....5-46 Fig.
  • Page 8 Hot Carbonating Truckmount System Fig. 6-1 Solution Flow Diagram ............. 6-1 Fig. 7-1 Wiring Diagram CTS 450 Gas (Sheet 2) ........7-1 Fig. 7-2 Wiring Diagram CTS 450 Gas (Sheet 3) ........7-2 Fig. 7-3 Wiring Diagram CTS 450 Gas (Sheet 4) ........7-3 Fig.

  • Page 9: Quick Reference

    CTS 450 Hot Carbonating Truckmount System Quick Reference Fuel Pump Assembly B-4627 Rev- CTS 450 Owner’s Manual...

  • Page 10: 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 450 Owner’s Manual...

  • Page 11: 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 450 Owner’s Manual HydraMaster Corporation...

  • Page 12: 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 450 Owner’s Manual...
  • Page 13 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 450 Owner’s Manual HydraMaster Corporation...
  • Page 14 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 450 Owner’s Manual...

  • Page 15: 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 450 Owner’s Manual HydraMaster Corporation...
  • Page 16 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 450 Owner’s Manual...

  • Page 17: Vehicle Preparation

    CTS 450 Hot Carbonating Truckmount System Vehicle Preparation The preferable vehicle for the CTS 450 Truckmount installation is either a cargo van or a minivan with a heavy-duty suspension package. The van should have a minimum 1/2 ton capacity. Be cautious when drilling any holes through the van floor. Many vans have critical compo- nents mounted directly below the van floor that could be damaged by a misplaced drill bit.
  • Page 18 (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 1-3 Recommended Placement Page 1-9 : CTS 450 Owner’s Manual...
  • Page 19 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 450 Owner’s Manual HydraMaster Corporation...
  • Page 20 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 21: 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 22: 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 23: 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 24 CTS 450 Hot Carbonating Truckmount System Figure 1-5 Hard Water Map Page 1-15 : CTS 450 Owner’s Manual...

  • Page 25: Machine Specifications

    Solution System: Dual High Pressure Tank compressed air fed Heating System: 1 Stainless Steel Coil Blower Exhaust Heat Exchanger 1 Stainless Steel Coil Coolant Heat Exchanger Drive System: Proprietary Engine to Blower Drive Bell Housing (Patent Pending) Page 2-1 : CTS 450 Owner’s Manual...
  • Page 26 1 2 ½ Gallon Stainless Steel Air Tank 150 ft, 2" Vacuum Hose 150 ft, 3/16" Solution Line 10 ft, 1½” Recovery Drain Line Battery Box Van Installation Kit Operation Manual Page 2-2 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 27: Machine Layout (Gas)

    Pump Out Switch – Electrical switch to activate Automatic Pump Out. Exhaust Out – Engine and Blower exhaust outlet. Auto-Pump Out Outlet – Hook up for the pump out garden hose. Compressor Swtich – Manual control for compressor. Page 2-3 : CTS 450 Owner’s Manual...

  • Page 28: Machine Layout (Diesel)

    Pump Out Switch – Electrical switch to activate Automatic Pump Out. Exhaust Out – Engine and Blower exhaust outlet. Auto-Pump Out Outlet – Hook up for the pump out garden hose. Compressor Switch - Manual control for compressor. Page 2-4 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 29: Component Descriptions

    Figure 2-3 The vacuum pump is driven through the drive bell housing by the engine. Figure 2-4 The air compressor is driven by a v-belt located at the front of the engine. Figure 2-5 Page 2-5 : CTS 450 Owner’s Manual...
  • Page 30 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 2-6 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 31 Dirty filters reduce pump performance by restricting air flow. Lubrication: The CTS 450 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 32: Operating Instructions

    - The engine throttle has three settings: IDLE, UPHOLSTERY, and CARPET. WARNING The machine cannot be run in the IDLE position for cleaning upholstery, carpet, or flood extraction. This will void the warranty. - The machine operates at a pressure of 100-120 psi. Page 3-1 : CTS 450 Owner’s Manual...

  • Page 33: Carpet Or Upholstery

    3. Set the cleaning mode switch to EXTRACTION MODE. 4. Connect vacuum hoses and tool. 5. If equipped, switch Auto Pump Out to ON. 6. Disconnect out-going quick connects on chemical tanks. Figure 3-2 Page 3-2 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 34: Solution Fill Procedure

    5. Disconnect all hoses. 6. Switch engine speed to IDLE mode. 7. Switch OFF ignition. 8. Drain and Flush recovery tank with clean water. 9. Remove and clean filter bag. (End of Day) Page 3-3 : CTS 450 Owner’s Manual...

  • Page 35: Safety Shutdown

    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. 2. Perform daily maintenance as prescribed in this manual. Page 3-4 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 36: Machine Maintenance

    2 Remove air filter cartridge. 3 Carefully clean out cartridge. 4 Reinstall air filter cartridge. 5 Install cover and lock clamps. Note: Do not use pressurized air or solvents to Figure 4-1 clean cartridge. Page 4-1 : CTS 450 Owner’s Manual...

  • Page 37: Engine Oil And Filter Change

    Engine oil capacity is 3.5 quarts. 6 Check oil dipstick for proper level. 7 Re-install the oil fill cap. Tools  11/16 inch wrench, Figure 4-4  Oil filter wrench Page 4-2 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 38: Engine Coolant

    3. Install the new plugs with a gap of 0.030”. Champion Part # RC12YC HRI Part # 000-106-016 4. Re-install the spark plug wires. Tools  5/8 inch spark plug socket,  0.030" feeler gauge Figure 4-7 Page 4-3 : CTS 450 Owner’s Manual...

  • Page 39: Fuel Filter (Gas Only)

    3. Screw new filter on by hand until gasket contacts housing. Then tighten 1/3 turn more. 4. Install drain plug with new O-Ring. 5. Bleed air from fuel line. Start engine and check for leaks. Page 4-4 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 40: Blower

    Failure to do this step will result in an insufficient amount of oil in the blower will lead to damage or failure! 4. Re-install the oil fill plugs. Tools  11/16 wrench Figure 4-12 Page 4-5 : CTS 450 Owner’s Manual...

  • Page 41: Recovery Tank

    3. Rinse out the recovery tank thoroughly. Perform this operation daily. 4. Clean vacuum relief assembly as necessary. 5. Replace all parts before starting up machine. Page 4-6 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 42 CTS 450 Hot Carbonating Truckmount System This page intentionally left blank. Page 4-7 : CTS 450 Owner’s Manual...

  • Page 43: Solution System

    3. Clean the filter and orifice with fresh water or compressed air (Figures 4-14 and 4-15). Perform this operation daily. Tools Figure 4-13  3/32 Allen wrench Figure 4-15 Figure 4-14 Page 4-8 : CTS 450 Owner’s Manual HydraMaster Corporation...

  • Page 44: General Maintenance

    3. Turn the Air Valve to the “Cleaning Mode” position. 4. Position cleaning mode switch to CARPET MODE 5. Run the machine for approximately 3 to 5 minutes. 6. Empty the recovery tank. Page 4-9 : CTS 450 Owner’s Manual...
  • Page 45 CTS 450 Hot Carbonating Truckmount System ™ CTS 450 GENERAL MAINTENANCE LOG DAILY SERVICE OIL RECOMMENDATIONS ENGINE OIL check BLOWER 40 weight non-detergent MACHINE general inspection PUMP 30 weight non-detergent RECOVERY TANK FILTER BAG clean ENGINE 30 weight motor oil...
  • Page 46 CTS 450 Hot Carbonating Truckmount System CTS 450 Assemblies & Parts Figure 5-1 Machine Assembly - Front View D-5256 Rev D Page 5-1 : CTS 450 Owner’s Manual...
  • Page 47 CTS 450 Hot Carbonating Truckmount System Figure 5-2 Machine Assembly - Rear View D-5256 Rev E HydraMaster Corporation Page 5-2 : CTS 450 Owner’s Manual...
  • Page 48 CTS 450 Hot Carbonating Truckmount System Figure 5-3 Machine Assembly - Side View D-5256 Rev D Page 5-3 : CTS 450 Owner’s Manual...
  • Page 49 Item Part Number Description 610-001-029 Assembly, Frame - CTS 450 (Fig. 5-4) 610-020-029 Assembly, Dash - CTS 450 (Fig. 5-5 & 5-6) 610-003-029 Assembly, Engine - CTS 450 (Fig. 5-10 & 5-11) 610-002-029 Assembly, Blower - CTS 450 (Fig. 5-16) 610-019-029 Assembly, Dump &...
  • Page 50 CTS 450 Hot Carbonating Truckmount System Figure 5-4 Frame Assembly D-5258 Rev B Page 5-5 : CTS 450 Owner’s Manual...
  • Page 51 000-108-124 Protector, Muffler Heat Shield - CTS 450 000-055-159 Frame, Weldment - CTS 450 000-027-008 Cap, 3/8" FPT 000-027-034 Cap, Frame End - Modified - Maxx/CTS 450 000-052-488 Insert, #F66 (3/8" NPT x 3/8" Hose Barb) 000-033-050 Clamp, 1-3/4" Cushion Loop 000-033-053 Clamp, 1-1/2"...
  • Page 52 CTS 450 Hot Carbonating Truckmount System Figure 5-5 Dash Assembly - Front View D-5257 Rev E Page 5-7 : CTS 450 Owner’s Manual...
  • Page 53 CTS 450 Hot Carbonating Truckmount System Figure 5-6 Dash Assembly - Rear View D-5257 Rev E Page 5-8 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 54 000-105-012 Plate, Machine Serial I.D. 000-140-015 Rivet, 1/8" x 1/4" Lg. Pop 23 Fig. 5-7 & 5-8 Assembly, Brow - Dash - CTS 450 000-081-215 Label, Maintenance & Lubrication Schedule - CTS 450 000-081-215 Label, Engine Produces Toxic Gas - CTS 450...
  • Page 55 CTS 450 Hot Carbonating Truckmount System Figure 5-7 Brow Assembly - Front View D-5521 Rev D Page 5-10 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 56 CTS 450 Hot Carbonating Truckmount System Figure 5-8 Brow Assembly - Rear View D-5521 Rev D 14 25 14 13 Page 5-11 : CTS 450 Owner’s Manual...
  • Page 57 000-056-011 Fuse, 30 AMP Plug In 000-157-101 Switch, 15 AMP 115 Volt Toggle 000-108-144 Protector, Chrome Switch 000-081-215 Label, Dash - CTS 450 000-081-239 Label, Compressor Retro Kit - Dash - CTS 450 Page 5-12 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 58 CTS 450 Hot Carbonating Truckmount System Figure 5-9 Compressor Regulator Assembly C-6249 Rev B Page 5-13 : CTS 450 Owner’s Manual...
  • Page 59 000-052-085 Elbow, 1/4" NPT Street 000-052-100 Insert, #44 (1/4" NPT x 1/4" Barb) 000-174-001 Washer, #10 Flat 000-174-014 Washer, #10 Lock 000-143-126 Screw, #10-24UNC x 0.50" Lg. Hex Head 000-052-090 Tee, 1/4" NPT Branch M-F-F Page 5-14 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 60 CTS 450 Hot Carbonating Truckmount System Figure 5-10 Engine Assembly - Right View D-5259 Rev F Page 5-15 : CTS 450 Owner’s Manual...
  • Page 61 CTS 450 Hot Carbonating Truckmount System Figure 5-11 Engine Assembly - Left View D-5259 Rev F Page 5-16 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 62 000-047-016 Engine, Daihatsu 700G 000-109-078 Pulley, CAT Pump Drive 000-015-731 Bracket, Right Front Foot - Daihatsu 000-154-126 Spacer, Daihatsu Crank Shaft - CTS 450 000-015-872 Bracket, Radiator Mounting - CTS 450 000-015-831 Bracket, Radiator Channel 000-015-858 Bracket, Left Front Engine Mounting 610-003-029 Assembly, Exhaust - CTS 450 (Fig.
  • Page 63 000-068-250 Hose, 1" I.D. Green Stripe 000-174-069 Washer, 5/16" Inconel Belleville, Diverter Valve 000-094-043 Nut, 8mm Hex 610-007-029 Assembly, Air Compressor - CTS 450 (Fig. 5-14) 000-010-124 Belt, Compressor Clutch Drive - CTS 450 Page 5-18 : CTS 450 Owner’s Manual...
  • Page 64 Item Part Number Description 000-174-001 Washer, #10 Flat 000-094-034 Nut, #10-24UNC Nylock 610-003-029 Assembly, Air Cleaner - CTS 450 (Fig. 5-13) 000-174-018 Washer, 5/16" Lock 000-143-187 Screw, 8mm x 25mm Lg. Grade. 10.9 Hex Head 000-039-020 Coupler, C-Face Daihatsu - CTS 450...
  • Page 65 CTS 450 Hot Carbonating Truckmount System Figure 5-12 Exhaust Assembly C-5332 Rev C Page 5-20 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 66 000-105-181 Flange, Exhaust Donut 000-125-174 Tube, Exhaust Manifold Outlet - Weldment 000-093-091 Muffler, Diahatsu - Modified - CTS 450 000-001-112 Adapter, Final Exhaust - Weldment - CTS 450 000-057-070 Gasket, Manifold Daihatsu 700G & 950G 000-057-177 Gasket, Exhaust Donut 1.50"...
  • Page 67 C-5526 Rev A Air Cleaner Assembly Parts List Item Part Number Description 000-015-844 Bracket, Air Cleaner Mounting - CTS 450 000-047-016 Air Cleaner - Daihatsu Engine 000-033-007 Clamp, #28 Hose 000-068-765 Hose, 1.75" x ‘S’ Bend - Modified 000-094-009 Nut, 1/4"-20UNC Hex Nylock 000-174-003 Washer, 1/4"...
  • Page 68 CTS 450 Hot Carbonating Truckmount System Figure 5-14 Air Compressor Assembly C-5525 Rev G Page 5-23 : CTS 450 Owner’s Manual...
  • Page 69 Screw, 5/16”18UNC X 1.25” Lg. Hex Head 000-143-580 Set Screw, 5mm X 0.8 X 6mm Lg. Cup Point 000-020-064 Spacer, Compressor Clutch 000-052-090 Tee, 1/4” NPT Branch M-F-F 000-174-018 Washer, 5/16” Lock 000-174-170 Washer, Hardened, 5/16” Page 5-24 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 70 Compressor Check Valve Assembly Parts List Item Part Number Description 000-157-148 Switch, Pressure 125 PSI 000-052-088 Elbow, 1/4" FPT x FPT 000-052-100 Insert, #44 (1/4" NPT x 1/4" Barb) 000-033-117 Clamp, 1" Cushion Loop w/ 7/16" Mount Hole Page 5-25 : CTS 450 Owner’s Manual...
  • Page 71 Figure 5-16 Blower Assembly D-5371 Rev E Blower Assembly Parts List Item Part Number Description 000-111-165 Blower, 4005 C-Face 000-015-827 Bracket, Blower Foot - CTS 450 000-093-084 Silencer, 3" Blower - CTS 450 Page 5-26 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 72 Hot Carbonating Truckmount System Blower Assembly Parts List Item Part Number Description 000-015-840 Plate, Saddle Mounting - After Burner - CTS 450 000-015-829 Bracket, Blower Foot Adjustment - CTS 450 000-015-830 Bracket, Dual After Burner Saddle - Weldment 000-094-080 Nut, 3/4"-10UNC Hex...
  • Page 73 CTS 450 Hot Carbonating Truckmount System Figure 5-17 Dump & Vacuum Bracket Assembly - Front D-5520 Rev D Page 5-28 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 74 CTS 450 Hot Carbonating Truckmount System Figure 5-18 Dump & Vacuum Bracket Assembly - Rear D-5520 Rev D Page 5-29 : CTS 450 Owner’s Manual...
  • Page 75 Dump & Vacuum Bracket Assembly Parts List Item Part Number Description 000-015-821 Bracket, Dump & Vacuum Hose - Weldment - CTS 450 000-090-018 Manifold, Hi PSI s/s 000-169-095 Valve, 1/4" NPT Panel Mount - Full Port Ball 000-052-526 Nipple, 1/4" NPT x 1/4" JIC 000-052-095 Nipple, 1/4"...
  • Page 76 CTS 450 Hot Carbonating Truckmount System Figure 5-19 Coolant Heat Exchanger Assembly D-5523 Rev A Page 5-31 : CTS 450 Owner’s Manual...
  • Page 77 Hot Carbonating Truckmount System Coolant Heat Exchanger Assembly Parts List Item Part Number Description 000-038-065 Core, Coolant Heat Exchanger - Weldment - CTS 450 000-108-131 Protector, HX Pad 6.63" O.D. 000-052-340 Elbow, 3/4" NPT Street 000-052-384 Elbow, 3/4" NPT x 45°...
  • Page 78 CTS 450 Hot Carbonating Truckmount System Figure 5-20 Blower Exhaust Heat Exchanger Assembly D-5522 Rev - Page 5-33 : CTS 450 Owner’s Manual...
  • Page 79 Hot Carbonating Truckmount System Blower Exhaust Heat Exchanger Assembly Parts List Item Part Number Description 000-038-070 Core, Blower Exhaust HX - Weldment - CTS 450 000-108-131 Protector, HX Pad 6.63" O.D. 000-033-013 Clamp, Size #48 Hose 000-068-398 Hose, 3" I.D. 3 Ply Silicone 000-052-600 Elbow, 1/2"...
  • Page 80 CTS 450 Hot Carbonating Truckmount System Figure 5-21 15 Gallon Chemical Jugs Assembly D-6117 Rev C Page 5-35 : CTS 450 Owner’s Manual...
  • Page 81 15 Gallon Chemical Jugs Assembly Parts List Item Part Number Description 000-015-869 Bracket, 15 Gallon Tank 000-159-127 Tank, 15 Gallon Chemical - CTS 450 (Fig. 5-22) 000-108-141 Tie Down Strap 000-081-218 Label, Caution - Tank - CTS 450 Page 5-36 : CTS 450 Owner’s Manual...
  • Page 82 15 Gallon Chemical Tank Assembly Parts List Item Part Number Description 000-159-126 Tank, 15 Gallon Chemical - CTS 450 000-106-055 Plug, 1/4 Ss Chemical Container - CTS 450 000-097-006 O-Ring, #8 Buna - New Rx Skid 000-033-032 Clamp, CDS Throttle Cable 000-025-008 Cable, 150 Lb Test...
  • Page 83 CTS 450 Hot Carbonating Truckmount System Figure 5-23 100 Gallon Recovery Tank Assembly D-5859 Rev D HIDDEN HIDDEN HIDDEN HIDDEN Page 5-38 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 84 000-052-182 Nipple, 1-1/2" NPT Close Galvanized 000-169-022 Valve, 1-1/2" Full Port Ball 000-052-532 Elbow, 1/4" SAE x 1/4" JIC x 90° 000-052-100 Insert, #44 (1/4" NPT x 1/4" Barb) 000-052-082 Elbow, 1/4" NPT Street x 45° Page 5-39 : CTS 450 Owner’s Manual...
  • Page 85 000-001-121 Adapter, Recovery Tank Outlet - Maxx - 100 Gal. 000-106-019 Plug, 1-1/2" NPT 000-052-731 Bushing, 3" NPT x 2-1/2" FPT Pvc Sch 40 000-157-090 Float, Lever Switch 000-081-215 Label, Maintenance & Lubrication Schedule Page 5-40 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 86 000-086-008 Latch, Bungie - Strike 000-094-063 Nut, #6-32UNC Nylock 000-094-009 Nut, 1/4"-20UNC Hex Nylock 000-052-222 Elbow, 2" Barb x 2" FPT 000-078-039 Vacuum Inlet Stopper Assembly - Recovery Tank 000-094-034 Nut, #10-24UNC Nylock Page 5-41 : CTS 450 Owner’s Manual...
  • Page 87 000-105-067 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 000-094-101 Nut, 3/8"-16UNC Hex Jam Page 5-42 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 88 CTS 450 Hot Carbonating Truckmount System CTS 450 Diesel Assemblies & Parts Figure 5-26 Machine Assembly CTS 450 Diesel - Front View D-5865 Rev C Page 5-44 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 89 CTS 450 Hot Carbonating Truckmount System Figure 5-27 Machine Assembly CTS 450 Diesel - Rear View D-5865 Rev C Page 5-45 : CTS 450 Owner’s Manual...
  • Page 90 CTS 450 Hot Carbonating Truckmount System Figure 5-28 Machine Assembly CTS 450 Diesel - Side View D-5865 Rev C TO CHEM JUG OUT TO FUEL SOURCE TO "T" ON CHEMICAL JUGS TO RECOVERY TANK TO APO PORT ON TO CHEMICAL MANIFOLD RECOVERY TANK Page 5-46 : CTS 450 Owner’s Manual...
  • Page 91 Description 610-001-031 Assembly, Frame - CTS 450 Diesel (Fig. 6-32) 610-020-031 Assembly, Dash - CTS 450 Diesel (Fig. 6-29 & 6-30) 610-003-031 Assembly, Engine - CTS 450 Diesel (Fig. 6-33 & 6-34) 610-002-029 Assembly, Blower - CTS 450 Diesel (Fig. 6-36) 610-019-029 Assembly, Dump &...
  • Page 92 CTS 450 Hot Carbonating Truckmount System Figure 5-29 Dash Assembly CTS 450 Diesel - Front View D-5867 Rev C Page 5-48 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 93 CTS 450 Hot Carbonating Truckmount System Figure 5-30 Dash Assembly CTS 450 Diesel - Rear View D-5867 Rev C Page 5-49 : CTS 450 Owner’s Manual...
  • Page 94 Item Part Number Description 000-100-140 Panel, Dash - Weldment - CTS 450D 610-018-029 Assembly, Compressor Regulator - CTS 450 (Fig. 6-9) 000-015-220 Panel, Side - CTS 450 Diesel - Weldment 000-067-034 Hinge, Compressor Cover - CTS 450 000-140-001 Rivet, 1/8" x 1/4" Aluminum...
  • Page 95 Screw, 8.0mm x 20.0mm Lg. (Comes w/ Engine) - - - Timer, Glow Plug - Daihatsu 850D (Comes w/ Engine) 000-081-215 Label, Maintenance & Lubrication Schedule - CTS 450 000-081-215 Label, Engine Produces Toxic Gas - CTS 450 000-081-215 Label, Solution Valve - CTS 450...
  • Page 96 CTS 450 Hot Carbonating Truckmount System Figure 5-31 Brow Assembly CTS 450 Diesel D-5868 Rev B Page 5-52 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 97 CTS 450 Hot Carbonating Truckmount System Brow Assembly Parts List Item Part Number Description 000-100-136 Panel, Dash Brow - Weldment - CTS 450 000-074-025 Gauge, 0-30"Hg Vac. 2 1/2" 000-074-024 Gauge, Temperature 000-157-008 Switch, Ignition 000-074-018 Meter, Rectangular w/o Bezel...
  • Page 98 Hot Carbonating Truckmount System Brow Assembly Parts List Item Part Number Description 000-081-239 Label, Compressor Retro Kit - Dash - CTS 450 000-157-101 Switch, 15 AMP 115 Volt Toggle Figure 5-32 Frame Assembly CTS 450 Diesel D-5878 Rev A Page 5-54 : CTS 450 Owner’s Manual...
  • Page 99 000-108-124 Protector, Muffler Heat Shield - CTS 450 000-055-159 Frame, Weldment - CTS 450 000-027-008 Cap, 3/8" FPT 000-027-034 Cap, Frame End - Modified - Maxx/CTS 450 000-052-488 Insert, #F66 (3/8" NPT x 3/8" Hose Barb) 000-033-050 Clamp, 1-3/4" Cushion Loop 000-033-057 Clamp, 1"...
  • Page 100 CTS 450 Hot Carbonating Truckmount System Figure 5-33 Engine Assembly CTS 450 Diesel - Right View D-5866 Rev C Page 5-56 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 101 CTS 450 Hot Carbonating Truckmount System Figure 5-34 Engine Assembly CTS 450 Diesel - Left View D-5866 Rev C Page 5-57 : CTS 450 Owner’s Manual...
  • Page 102 000-047-017 Engine, Daihatsu 850 Diesel 000-109-078 Pulley, CAT Pump Drive 000-015-731 Bracket, Right Front Foot - Daihatsu 000-154-126 Spacer, Daihatsu Crank Shaft - CTS 450 000-015-872 Bracket, Radiator Mounting - CTS 450 000-015-831 Bracket, Radiator Channel 000-015-858 Bracket, Left Front Engine Mounting 610-003-029 Assembly, Exhaust - CTS 450 (Fig.
  • Page 103 000-010-124 Belt, Air Compressor - CTS 450 000-174-001 Washer, #10 Flat 000-094-034 Nut, #10-24UNC Nylock 610-003-031 Assembly, Air Cleaner - CTS 450 Diesel (Fig. 6-35) 000-174-018 Washer, 5/16" Lock 000-143-187 Screw, 8mm x 25mm Lg. Grade. 10.9 Hex Head 000-039-055 Coupler, C-Face 10 Pin CTS 450 Diesel...
  • Page 104 CTS 450 Hot Carbonating Truckmount System Engine Assembly CTS 450 Diesel Parts List Item Part Number Description 000-149-052 Thermostat, Daihatsu Engine Coolant 000-091-023 Starter, Daihatsu 700G Engine 000-015-223 Bracket, Throttle Lever 000-033-003 Clamp, Size #4 Mini 000-094-009 Nut, 1/4"-20UNC Hex Nylock 610-003-029 Assembly, Compressor Check Valve (Fig.
  • Page 105 CTS 450 Hot Carbonating Truckmount System Figure 5-35 Air Cleaner Assembly CTS 450 Diesel C-5879 Rev - Air Cleaner CTS 450 Diesel Assembly Parts List Item Part Number Description 000-015-844 Bracket, Air Cleaner Mounting - CTS 450 000-047-016 Air Cleaner - Daihatsu Engine 000-033-007 Clamp, #28 Hose 000-068-733 Hose, Air Cleaner To Carb.
  • Page 106 CTS 450 Hot Carbonating Truckmount System Figure 5-36 Blower Assembly CTS 450 Diesel D-6578 Rev - Page 5-62 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 107 000-015-827 Bracket, Blower Foot - CTS 450 000-093-084 Silencer, 3" Blower - CTS 450 000-015-840 Plate, Saddle Mounting - After Burner - CTS 450 000-015-829 Bracket, Blower Foot Adjustment - CTS 450 000-015-830 Bracket, Dual After Burner Saddle - Weldment 000-094-080 Nut, 3/4"-10UNC Hex...
  • Page 108 Hot Carbonating Truckmount System Engine Assembly CTS 450 Diesel Parts List Item Part Number Description 000-042-008 Housing, Bell - CTS 450 000-039-055 Coupler, C-Face 10 Pin CTS 450 Diesel 000-131-027 Trimlok, Crossfire Brow Page 5-64 : CTS 450 Owner’s Manual HydraMaster Corporation...
  • Page 109 CTS 450 Hot Carbonating Truckmount System Figure 6-1 Solution Flow Diagram D-5860 Rev C Page 6 -1 : CTS 450 Owner’s Manual...
  • Page 110 CTS 450 Hot Carbonating Truckmount System Figure 6-1 Solution Flow Diagram D-5860 Rev C Page 6 -3 : CTS 450 Owner’s Manual...
  • Page 111 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Gas Engine D-5503 Sht 2, Rev P 1(RED) 12 GA. - TO ALTERNATOR "B" 2(BLU) - TO ALTERNATOR "IG" 3(BLK) 12 GA. - TO STARTER SOLENOID "B" 4(BLU/BLK) - TO STARTER SOLENOID "ST"...
  • Page 112 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Gas Engine D-5503 Sht 3, Rev P 1(RED) 12 GA. - TO IGN. SWITCH "BAT" PAGE 2 2(BLU) - TO TB-2 "1" 3(BLK) 12 GA. - TO MAIN FUSE PAGE 4 55(RED) 4 GA.
  • Page 113 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Gas Engine D-5503 Sht 4, Rev P RECOVERY TANK ASSEMBLY TB-3 VACUUM TANK 73(ORG) (BLK) N.O. HIGH WATER FS-1 74(ORG/WHT) (WHT) 75(BLK)-14 GA 83(BLK)-14 GA 76(WHT)-14 GA 85(WHT)-14 GA...
  • Page 114 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Diesel Engine D-5638 Sht 1, Rev J 1(RED) 12 GA. - TO ALTERNATOR "B" 2(BLU) - TO ALTERNATOR "IG" 3(BLK) 12 GA. - TO STARTER SOLENOID "B" 4(BLU/BLK) - TO STARTER SOLENOID "ST"...
  • Page 115 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Diesel Engine D-5638 Sht 2, Rev J 1(RED) 12 GA. - TO IGN. SWITCH "BAT" PAGE 2 2(BLU) - TO TB-2 "1" 3(BLK) 12 GA. - TO MAIN FUSE PAGE 4 55(RED) 4 GA.
  • Page 116 CTS 450 Hot Carbonating Truckmount System Wiring Diagram - CTS 450 Diesel Engine D-5638 Sht 3, Rev J RECOVERY TANK ASSEMBLY TB-3 VACUUM TANK (BLK) 79(ORG) N.O. HIGH WATER FS-1 (WHT) 80(ORG/WHT) 81(BLK)-14 GA. 83(BLK)-14 GA 82(WHT)-14 GA. 85(WHT)-14 GA...
  • Page 117 CTS 450 Hot Carbonating Truckmount System Electrical Schematic - CTS 450 D-5502 Rev H Page 7-7 : CTS 450 Owner’s Manual...
  • Page 118 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 8-1 : CTS 450 Owner’s Manual...
  • Page 119 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-...

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