HydraMaster CTS 450 User manual

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

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............................................................. 1-13
Water Softener........................................................................1-13
Waste Water DisposalAdvisory..............................................1-14
MACHINE SPECIFICATIONS......................................................................Section 2
Machine Layout (Gas) ....................................................................... 2-3
Machine Layout (Diesel)....................................................................2-4
Component Descriptions ................................................................... 2-5

HydraMaster Corporation
CTS 450 Owner’s Manual
CTS 450Hot Carbonating Truckmount System
OPERATING INSTRUCTIONS .................................................................... Section 3
Start Up (Gas and Diesel Versions)...................................................3-1
Carpet or Upholstery..........................................................................3-2
Flood Extraction.................................................................................3-2
Solution Fill Procedure.......................................................................3-3
Shut Down.........................................................................................3-3
Safety Shutdown................................................................................3-4
General Operating Information..........................................................3-4
MACHINE MAINTENANCE.........................................................................Section 4
Engine................................................................................................4-1
Air Filter .............................................................................................4-1
Engine Oil and Filter Change.............................................................4-2
Engine Coolant..................................................................................4-3
Spark Plug Replacement (Gas Engine Only) .................................... 4-3
Fuel Filter (Gas Only) ........................................................................ 4-4
Fuel Separator (Diesel Engine) ......................................................... 4-4
Blower................................................................................................4-5
Blower Oil Change.............................................................................4-5
Recovery Tank...................................................................................4-6
Solution System.................................................................................4-8
 OriceManifold..................................................................................4-8
General Maintenance ........................................................................ 4-9
Freeze Guard Information..................................................................4-9
Maintenance Logs

CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
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

HydraMaster Corporation
CTS 450 Owner’s Manual
CTS 450Hot Carbonating Truckmount System
Fig. 1-1 Plywood Installation..............................................................1-8
Fig. 1-2 Astroturf and Roof Vent Installation...................................... 1-8
Fig. 1-3 Recommended Placement ..................................................1-9
Fig. 1-4 Installation Using Tie-down Cleats........................................ 1-10
Fig. 1-5 Hard Water Map....................................................................1-15
Figures2-1through2-6arephotosrelatingtomachinespecications
Figures 3-1 through 3-4 are photos relating to operating instructions
Figures 4-1 through 4-15 are photos relating to machine maintenance
Machine Assemblies and Parts Lists ................................................. 5-1
Fig. 5-1 Machine Assembly - Front View ........................................... 5-1
Fig. 5-2 Machine Assembly - Rear View............................................ 5-2
Fig. 5-3 Machine Assembly - Side View.............................................5-3
Fig. 5-4 Frame Assembly................................................................... 5-5
Fig. 5-5 Dash Assembly - Front View.................................................5-7
Fig. 5-6 Dash Assembly - Rear View ................................................. 5-8
Fig. 5-7 Brow Assembly - Front View................................................. 5-10
Fig. 5-8 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
List of Figures and Tables

CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
Fig. 5-13 Air Cleaner Assembly............................................................ 5-20
Fig. 5-14 Air Compessor Assembly ....................................................... 5-21
Fig. 5-15 Compressor Check Valve Assembly ......................................5-25
Fig. 5-16 Blower Assembly - CTS 450 Gas.......................................... 5-26
Fig. 5-17 Dump & Vacuum Bracket Assembly - Front.......................... 5-28
Fig. 5-18 Dump & Vacuum Bracket Assembly - Rear .......................... 5-29
Fig. 5-19 Coolant Heat Exchanger Assembly ...................................... 5-31
Fig. 5-20 Blower Exhaust Heat Exchanger Assembly..........................5-33
Fig. 5-21 15 Gallon Chemical Jugs Assembly ..................................... 5-35
Fig. 5-22 15 Gallon Chemical TankAssembly...................................... 5-37
Fig. 5-23 100 Gallon Universal Recovery TankAssembly ................... 5-38
Fig. 5-24 100 Gallon Universal Recovery Tank CoverAssembly......... 5-41
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. 5-29 Dash Assembly - Front View (CTS 450 Diesel).................... 5-48
Fig. 5-30 Dash Assembly - Rear View (CTS 450 Diesel)..................... 5-49
Fig. 5-31 Brow Assembly (CTS 450 Diesel).........................................5-52
Fig. 5-32 Frame Assembly (CTS 450 Diesel)....................................... 5-54
Fig. 5-33 Engine Assembly - Right View (CTS 450 Diesel) ................. 5-56
Fig. 5-34 Engine Assembly - Left View (CTS 450 Diesel).................... 5-57
Fig. 5-35 Air Cleaner Assembly (CTS 450 Diesel)............................... 5-61
Fig. 5-36 Blower Assembly (CTS 450 Diesel)...................................... 5-62

HydraMaster Corporation
CTS 450 Owner’s Manual
CTS 450Hot 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. 7-4 Wiring Diagram CTS 450 Diesel (Sheet 1) ..............................7-4
Fig. 7-5 Wiring Diagram CTS 450 Diesel (Sheet 2) ..............................7-5
Fig. 7-6 Wiring Diagram CTS 450 Diesel (Sheet 3) ..............................7-6
Fig. 7-7 Electrical Schematic CTS 450.................................................. 7-7

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

Page 1-1 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
This manual contains installation and operation instructions as well as information
required for proper maintenance, adjustment and repair of this unit. Since the first and
most important part of repair work is the correct diagnosis of the problem, component
manual troubleshooting charts have been included for your convenience.
Unlike a garden tractor, lawn mower or cement mixer, all having one or two functions to
perform, the truckmounted carpet cleaning plant has many functions to perform simulta-
neously.
• The engine has to run at a consistent rpm.
• The vacuum has to pull air and dirty water back from cleaning site.
• The solution system provides stable pressure at proper water flow for cleaning.
• 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?”
General Information

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Page 1-2 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
The manufacturer uses this symbol throughout the manual to warn of possible injury
or death.
This symbol is used to warn of possible equipment damage.
Telephone Numbers
CTS Installer: _________________ ____________
HydraMaster/ChemDry Tech Support [phone]
HydraMaster Customer Service [phone]
Harris Research, Inc. Tech Support [phone]
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
CAUTION
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WARNING
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Page 1-3 : CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
CAUTION
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CAUTION
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CAUTION
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Precautions
1. Engine Cooling
Units employing internal combustion engines must not be enclosed within a van with
doors and windows closed. Excessive temperatures within the engine will result in pre-
mature engine failure and a compromise of applicable warranty.
2. Level Operation
During operation, van or trailer must be parked on level ground not to exceed + or – 10
degrees. Failure to ensure proper leveling may prevent proper internal lubrication of
engine, vacuum and/or high pressure components.
3. Moving Parts
Never touch any part of the machine that is in motion. Severe bodily injury may result.
4. Freeze Protection
There is often little warning before a cold spell. Failure to protect this equipment from
freezing will result in costly down time. Placing an electric heater in the truck or parking
thetruck indoors will helptoinsure against freezing, butshould not be theprimarymethod
of freeze protection.
5. Exhaust System
Do not allow flammable material (i.e. oil, fuel, plastic, or wood products) to come in con-
tact with the exhaust system.
6. Hot Surfaces
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.
WARNING
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WARNING
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WARNING
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HydraMaster Corporation
Page 1-4 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
7. Hearing Protection
TheOccupationalSafety andHealthAdministration (OSHA)recommendsthe useofhearing
protection when a technician is exposed to an average of 85 decibels. This is an average
of exposure over an 8 hour period. This equipment can produce 85 decibels to a distance
of 10 feet. Please check with your local state agencies to see if OSHAstandards apply to
your machine use.
8. Carbon Monoxide
This unit 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.
9. Toxic Fumes
Do not occupy the vehicle when the cleaning equipment is operating. Toxic fumes may
accumulate inside a stationary vehicle.
10. Engine Exhaust
The engine exhaust from this product contains chemicals known to the State of California
to cause cancer, birth defects, or other reproductive harm.
11. Carburetor Drain
Under no circumstances should the drain in the carburetor bowl be used when the ma-
chine is hot.
12. Portable Gas Tank
Never operate this machine with a portable gas can inside the truck. Doing so increases
the risk of a fire or explosion.
13. Transportation of Fuel Containers
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.
WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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Page 1-5 : CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
14. Vacuum System
When machine is being run for test purposes and the vacuum inlet on top of the machine
is open, caution should be used.
To protect the vacuum blower from over loading and damaging itself, there is a vacuum
relief system installed on the vacuum tank. When the vacuum tank inlet is completely
sealed off, a maximum of 12 inches Hg will be attained. At the end of each day, an oil
based lubricant should be sprayed into the blower lubrication port before shutting down
the machine. If this operation is not performed daily the vacuum blower will develop rust
deposits from moisture and will decrease the life of the vacuum blower.
15. Vacuum Tank
Foam passing through the blower could lead to equipment malfunction. Therefore, it is
important to keep the vacuum tank foam free.
16. Vacuum Hose
Do not leave the vacuum hose unattended during operation. This could cause bodily
injury.
WARNING
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WARNING
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CAUTION
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HydraMaster Corporation
Page 1-6 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
Responsiblities
The Purchaser’s responsibilities are:
Reading of Owner’s Manual: It is the purchaser’s responsibility to read the unit opera-
tion manual and to familiarize himself with the information contained therein. Special
attention should be paid to all Cautions and Warnings.
Prior to arrival of unit, install exterior plywood flooring in the vehicle and we suggest seal-
ing with a sealer.
Purchase a heavy duty group 24 - 60 amp hour battery and have the battery ‘slow’ charge
if new. If the battery is not fully charged, damage can occur to the engine charging regu-
lator.
The Equipment Installer responsibilities are:
ACCEPTANCE OF SHIPMENT:
1. If the unit shows any outward signs of damage, do not sign the delivery
receipt until you have closely inspected the unit and noted any damage
on the delivery receipt.
2. The equipment installer is responsible for the correct installation of the unit
in your vehicle and thoroughly training you in its operation, maintenance and
precautions.
Correct Installation Includes:
Installation of through-floor fittings for gasoline fuel lines.
Placing the unit and recovery tank in your vehicle and securing them with bolts or
tie down cleats.
Install and connect the fuel pump.
Connecting gasoline lines.
Connecting the battery.
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 1-7 : CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
Note: Under certain circumstances, machines may require modification for optimal per-
formance. Certain environmental conditions may require engine modification or control
function calibration.
Training Shall Include:
• A thorough review of the operation manual with purchaser.
• A thorough review of the unit warranty and warranty procedures.
• Instruction and familiarization in:
1. How to correctly start up and shut down the unit.
2. How to correctly clean with the unit.
3. Where and how often to check and change component oil levels.
4. How the unit’s systems work.
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.

HydraMaster Corporation
Page 1-8 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
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.
Becautious when drillingany holes throughthe van floor. Many vans have criticalcompo-
nents mounted directly below the van floor that could be damaged by a misplaced drill bit.
TRUCK PREPARATION
The manufacturer recommends a spray-on bed liner or the installation of plywood floor-
ing, in the vehicle prior to installation of machine.
Thisprovidesametal-to-cushionmountingratherthan metal-to-metal,insulation andmakes
an attractive van interior.
Materials Needed:
1. 2 sheets 4 x 8 x 5/8" exterior plywood
2. 1 Gallon Polyurethane Wood Sealer
3. 16 - 1½” sheet metal screws
(See Figures 1-1 and 1-2 for correct placement of plywood flooring)
Roof Vents
Harris Research strongly recommends installing roof vents in vehicles operated in hot
weather locations.
Vehicle Preparation

Page 1-9 : CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
PLACEMENT OF UNIT IN VEHICLE
There are two recommended unit placements, side door and rear door. These recom-
mended placements are described below and illustrated in Figure 1-3.
SIDE DOOR:
Most installations are side door. This provides rear access for accessories and hoses as
well as unobstructed access to the component/working side of the
machine, thus making it a bit easier to perform maintenance and/or repair without remov-
ing the unit from the truck.
REAR DOOR:
Although this location partly limits working access, it does direct the noise away from the
cleaning site. Some cleaners in the colder areas prefer this location because it puts the
weight over the rear wheels for better traction in ice and snow. Rear mounting requires
the unit to be slid to the right side as far as possible.
This not only provides adequate working space on the component side of the unit but also
improves weight distribution inside the van (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

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Page 1-10 : CTS 450 Owner’s Manual
CTS 450 Hot Carbonating Truckmount System
Machine Tie Down Cleats
Secure the machine to the floor of the van with the four tie down cleats provided (See
Figure 1-4). This safety measure will ensure that the machine will not slide inside the van.
See the following illustration for the correct installation.
Figure 1-4 Installation Using Tie-down Cleats
Ensure that the machine is well secured to the floor of the van with the hardware supplied.
A sudden or crash stop will cause the machine to rocket forward. Protect yourself and the
machine. SECURE IT!
It is recommended by the manufacturer that the exhaust from the front of the machine be
vented down under the truck to prevent carbon monoxide from entering the job site. Al-
ways park the truck so the exhaust is blowing away from the job site.
The manufacturer also recommends the installation of 12 volt powered vents in the truck
roof to allow heat to escape.
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.
WARNING
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WARNING
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WARNING
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Page 1-11 : CTS 450 Owner’s Manual
Hot Carbonating Truckmount System CTS 450
Do not use a portable propane tank inside of the truck or van. It is dangerous and illegal
in most states.
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.
The engine exhaust from this product contains chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
If the battery location is at your option, first make sure it is in an approved battery container
and that it is covered and secured to the floor of the vehicle. Make sure the battery is
isolated from hot machine components. This will cause the battery to last longer and also
prevent the possibility of fire or explosion.
WARNING
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WARNING
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WARNING
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WARNING
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