KD-UNITSA Product of Hi-Vac Corporation OPERATION SERVICE & PARTS M A N U A L A Product of Hi-Vac Corporation • 117 Industry Road • Marietta, Ohio 45750 USA Corporate: Tel: 740.374.2306 • Toll Free USA: 800.752.2400 • Fax: 740.374.5447 • Web: www.hi-vac.com • E-mail:
[email protected] Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail:
[email protected] B SERIES tABLE TABLE A Product of Hi-Vac Corporation OF CONTENTS PRE-DELIVERY INSPECTION FORM . ....................................................................................................... I. CUSTOMER TRAINING FORM.................................................................................................................. III. UNIT IDENTIFICATION FORM...................................................................................................................VI. INTRODUCTION........................................................................................................................................VII. WARNINGS...............................................................................................................................................VIII. tABLE SECTION I. PRINCIPLES OF OPERATION B series positive displacement exhauster and water pump units Controls and gauges Dashboard controls Unit power/PTO enable Power deck systems engagement Engaging the water pump, pto and exhauster Low water warning and cold water conditions Hydraulics Pendant control Side operator’s station Air purge system (optional) Internal tank flushing (optional) Cold weather recirculation (optional) Rear operator’s station Rear reel controls Reel speed controls Foot pedal controls Handgun and Handgun quick connect II. HOW TO USE YOUR SEWER CLEANER Important safeguards Before going to work site Water jetting at the work site Vacuuming at the work site Leaving the work site Dumping the debris tank Cleaning the debris tank 1 OPERATIONS III. HELPFUL HINTS FOR USING YOUR AQUATECH CLEANER Where to start your cleaning program Water level indicators Cold weather storage IV. SPECIAL INSTRUCTIONS FOR HEAVILY LOADED LINES Opening stoppages Uneven joint in sewer line Culverts, drain tile, 18” and larger pipe Root and grease removal AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL tABLE SECTION I. CUSTOMER SERVICE AND PARTS ORDERS Ordering and processing of parts orders Contacting the service department Sales terms II. WARRANTY INFORMATION Limited product warranty/Warranty extensions Major components Special water tanks Polygraphite tanks SJR tanks Design modifications Warranty initiation Limitations and exclusions to warranty Claims procedures Replacement parts warranty III. TROUBLE SHOOTING GUIDE General maintenance schedule Trouble shooting common problems Water system Hydraulic system Vacuum system Electrical system Torque specifications Scheduled lubrication chart Filter replacement Standard Lubrication chart 2 SERVICE A Product of Hi-Vac Corporation SECTION 3 PARTS NOTE: Some of the parts information contained in this manual, has been provided by the original parts manufacturer and should only be used as a visual reference when ordering. For an accurate listing of part numbers and components on accessories, please refer to the Optional Equipment section of this manual. I. CONTROLS Pendant control Rear control panel Side control station Foot control II. POWER TRAIN Split shaft p.t.o. P.T.O. service/parts manual III. WATER SYSTEM Water system rear reel Water manifold assembly 1” relief valve 2000 psi PRV - 800 psi Suction line strainer assembly Water pump service manual AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL A Product of Hi-Vac Corporation IV. VACUUM SYSTEM P.D. Exhauster and ducting assembly (diagragm parts listing) Blower service manual V. HYDRAULIC SYSTEM Velocity check valve assembly Rear door hydraulics Rear reel actuation assemblies 4 spool reel control valve assembly Boom hydraulic motor assembly Boom control - 4 spool valve assembly Hydraulic filters Tank tipping valve Hydraulic service manuals Standard hydraulic schematic VI. PNEUMATIC SYSTEM Pneumatic SMC Valve Standard pneumatic belt drive schematic SMC service manuals VII. ELECTRICAL SYSTEM Electrical schematic VIII. BODY Reel Assembly Air portal assembly Hose assembly Filler assembly poly tank Sight eye assembly 8” turret assenbly 8" boom assembly Worm gear drive bearing Hinged tank support prop Poly tank installation instructions Installation of water fill line Polyethylene water tanks Poly tank repair IX. STANDARD EQUIPMENT Handgun Level Wind Assembly w/o Counter Hinged Rear Door Strainer X. OPTIONAL EQUIPMENT KD Units Level Wind w/ Counter Fluidizing Nozzle Unloader Valve Accessories (Refer to section) NOTE: The descriptions and instructions in ths manual cover the standard design of the equipment and any common deviations when possible. This manual does not cover all design details and variations nor does it provide for every possible contingency which may be encountered. When information cannot be found in this manual, contact your nearest AQUATECH Parts and Service Center. *When ordering parts always specify unit serial number. AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL PRE-DELIVERY INSPECTION FORM Customer: Unit Model: Unit Serial Number: AQUATECH DISTRIBUTOR: ® A Product of Hi-Vac Corporation Upon arrival at destination, the following procedures must be carried out.(Please initial on line below) Prior to delivery to customer 1 2 3 4 5 6 7 8 9 Engine, oil, water, fuel, air cleaner, fan belt Inspect rear axle seals for leaks Check all lights and reflectors Check tire pressure Inspect exhaust system for clearance problems in and around entire exhaust system Inspect universal joints; tighten bolts, if necessary Inspect for loose wires, hoses, cables, and correct as needed Check chassis specifications against customer specs; report any discrepancies to Hi-Vac® or truck dealer. Appearance: • Sweep out cab • Wash windows (inside and out) • Wash unit • Remove and clean all sight eyes (inside and out) • Inspect paint; (touch-up where necessary) Check fluid levels (see service manual): • Exhauster • High pressure water pump • Hydraulic tank • PTO split shaft Inspect hydraulic motor chain and bolts on hose reel. (torque if necessary) Electrical system: • Test hose reel operation payout and retrieve as well as hydraulic reel speed control • Test throttle control at both operator’s stations • Test boom pendant and operate each button • Test all lights supplied with unit Body: • Door hinges and locks. Check keys and latches for proper action. Adjust if necessary • Inspect all body mounting bolts (torque if necessary) • Inspect inside of tanks for packed components or foreign objects • Raise and lower tank, inspect closure seal _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ 10 _____________ _____________ 11 12 _____________ 13 _____________ I AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL PRE-DELIVERY INSPECTION FORM PAGE 2 14 Hydraulic system • Operate entire hydraulic system-all functions • Check all hoses, connections, and cylinders for leaks Install suction line strainer if removed for shipping. Fill tank and run pump. Assure all air is purged and the water pressure develops smoothly ® A Product of Hi-Vac Corporation _____________ _____________ 15 Check for leaks. If unit is delivered during cold weather, refer to cold weather preperation. THIS INSPECTION WAS PERFORMED BY: SIGNATURE:_____________________________________ DATE:_______________________ TITLE: ________ comments:__________________________________________________________________________ AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL II filter and service (if required) Operation of PTO air cylinder (if equiped) Boom internal flapper valve Street flusher.CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST Customer: Unit Model: Unit Serial Number: AQUATECH DISTRIBUTOR: ® A Product of Hi-Vac Corporation Operator and service personnel must be thoroughly instucted of the following: (Please initial on lines below) Power Take off (PTO) • • • • • Maximum operating speed How to engage and disengage Drive train service and lubrication Hydraulic pump location. on/off (optional) _____________ _____________ _____________ _____________ AQUATECH OPERATIONS. belt adjustment and alignment PTO oil level _____________ _____________ _____________ _____________ _____________ Hydraulic system • • • • • • • • Oil level inspection and time interval Location of filter and service Manual over-ride Location of flow control valves and explanation of adjustments Location of hydraulic pressure gauge Boom system operation Reel drive system and service Tipping and removal of reel (Front reels) _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ Pneumatic system • • • • Air reservoir. SERVICE AND PARTS MANUAL III . controls. lubrication Tank prop Hydraulic door locks Vibrator assembly (optional) _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ AQUATECH OPERATIONS. service Vacuum gauge Internal flushing system (optional) Exhauster drive system and controls Centrifugal scrubber and clean out screen Rear door operation and controls Rear door keeper Tank tipping operation. time interval Water “on/off” controls Pressure relief valve and operation Return line ball valve setting and service Handgun operation Winter recirculation Cold weather storage Water pressure operation Removal of ice from system Suction line strainer Gear box service oil levels ® A Product of Hi-Vac Corporation _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ Vacuum system and debris tank • • • • • • • • • • • • • • Debris tank inspection Door gasket cleaning Exhauster lubricating oil level Primary safety cut-off operation. time interval Packing lubrication. SERVICE AND PARTS MANUAL IV .CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST PAGE 2 Water system • • • • • • • • • • • • • • • Water tank inspection and repair Drain valve Water pump drive system and lubrication Oil level inspection. SERVICE AND PARTS MANUAL V . floating discharge (optional) With separator open .CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST PAGE 3 • • • • • • • Recycling system (optional) Door open.explain final filter Water draining system Cold weather operation Storage .explain cleaning and un-clogging With tank access door man way open .draining all water from systems ® A Product of Hi-Vac Corporation _____________ _____________ _____________ _____________ _____________ _____________ _____________ Accessories supplied with unit • • • • Options • • • Accumulator Proper nozzles to match volume/pressure Street flusher system _____________ _____________ _____________ Nozzles Hose guide Handgun assembly Review all available accessories _____________ _____________ _____________ _____________ THIS INSPECTION WAS PERFORMED BY: SIGNATURE:_____________________________________ DATE:_______________________ TITLE:________ comments:_________________________________________________________________________ AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL VI . REFER TO PANEL LOCATED ON DASH INSIDE TRUCK. RISK OF DANGER TO MACHINE AND INJURY TO OPERATOR MAY OCCUR. SHEET Customer: AQUATECH DISTRIBUTOR: Unit Model: Unit Serial Number: FOR MAXIMUM TESTED OPERATING SPEED.D. Chassis Information: Color: Make: Engine Information: Make: Transmission Information: Make: PTO Information(Split Shaft): Make: Exhaust Information: Make/Model: Volume= Maximum Vacuum= Maximum RPM@Pulley On Exhauster= Water Pump Information: Make/Model: Pump Volume= Pump Pressure= Maximum RPM@Pulley On Pump= Paint: Vin Number: Serial Number: Serial Number: Serial Number: Serial Number: Serial Number: AQUATECH OPERATIONS.® A Product of Hi-Vac Corporation UNIT I. NEVER EXCEED THE TEST SPEED OR GEAR. Our quality of design and manufacture will assure you the greatest return on your equipment investment. as well as operation under water. the most advanced American-made sewer cleaning machine. Thank you again for selecting the equipment preferred by industry professionals throughout the world. As a result. The vacuum system provided is superior to any other available. Please consult this owner’s manual as the first step to resolving questions you may have about the operation or service of your machine. the machine will clean and operate in a far superior manner than previously available. Your new Aquatech unit incorporates the very latest in pipe cleaning technology. We are a company that is committed to continually striving to build an even better product. Our warranty spells out all your rights and expectations with regard to this equipment. The cleaning action results from water traveling from the storage tank into the high efficiency water pump and being pumped to the hose reel and nozzle at high pressure and high volume. To achieve maximum results. the operators must become thoroughly familiar with the operation of the machine and completely understand correct nozzle selection and cleaning accessory use. If you are not able to find the answers. We encourage you to make suggestions either through your distributor. Many ideas for improvements in previous models have come from users in the field. Please consult it for a full definition of what is covered. It is capable of both wet and dry operation. SERVICE AND PARTS MANUAL VII . we at the factory will be happy to provide operating information that this manual or your dealer are unable to provide. or through our service department. Finally.INTRODUCTION MESSAGE TO NEW OWNER Thank you for purchasing your Aquatech unit. ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. Aquatech Regional Sales Manager. then consult with your selling dealer. The handgun is designed to shut off automatically when the actuator handle is released. Operators of Aquatech water jetting machines should be aware of the following safety warnings: • Using this machine for purposes other than cleaning sewer pipe is not recommended. Do not operate at pressure readings higher than these unless the manual specifically states that the system has been designed for higher pressures. At all times. operators of these systems must be aware of possible hazards. These systems operate under high pressure conditions with considerable water flow.WARNINGS AQUATECH WATER JETTING MACHINES Aquatech water jetting machines are designed to clean sewer pipe. and shifting the rear axle out of the drive line. • A handgun accessory is provided for the operator’s use when cleaning external areas of the sewer system. etc. SERVICE AND PARTS MANUAL VIII . the operator is responsible for the proper use of the machine. Therefore. but represents typical hazards and types of hazards. Whenever these components are raised. Never use a forward jet nozzle that will not turn off when released. • Fittings used on sewer hose must be of a type and installed in a manner that is approved by the hose manufacturer. Only use hose inside of sewer pipe. props must be used to protect workers who must work under them. • Always turn off unit power when moving the vehicle. Always use wheel chocks. • Never walk under raised components such as hydraulically actuated tanks. ® A Product of Hi-Vac Corporation YOUR LIFE COULD DEPEND ON IT!!! AQUATECH OPERATIONS. • Always wear required personal protective equipment.100 psi. • Never move the vehicle with the boom in a raised or otherwise unsecured position. • Never operate the machine in a stationary position without first setting the brakes. The handgun relief valve is set at 800 psi. This is not a complete list of all possible hazards. both sanitary and storm. never use as wash down hose. in an underground environment. • Water hose that is damaged into the braided lining must be repaired or replaced. • Never operate the water system with the relief valves removed. doors. The main relief valve is set at 2. or improperly adjusted. If it becomes badly abraded. use only those specified by the manufacturer for the hose supplied. or a hydraulic hose fitting “off the shelf”.5 times its rated working pressure. Proper swaging. This seamless layer of the hose provides approximately 30% of the total hose strength. That is. there is enough “cushion” in the design to compensate. The outer jacket of the hose. In order to guarantee this safety it is very important to keep a close watch on the condition of the hose whenever it is being used. Although this is a serious loss from the maximum strength of the hose. It is designed to become very slippery when wet and provide as frictionless a surface as possible when travelling through the pipeline. repair it or replace it. The central core of the hose is constructed of a material called “polyolefin”. AQUATECH OPERATIONS. However. or 1250 psi. This braid provides approximately 45% of the total hose strength. Fittings have a color-coded band to identify the hose they may be used with. All tooling. SERVICE AND PARTS MANUAL IX . the squeezing process which attaches a new fitting to the end of the hose. We recommend replacement only. bonded to the polyester braid. The maximum burst rating of a hose is approximately 2. If hose is spliced or repaired. This outer jacket provides the final 25% of the total hose strength. Under ideal conditions. including dies. Always inspect the hose every time you use it. your safety depends on safe hose. must be inspected regularly to assure the correct swage has been made. is very important. there has been a 25% loss of the maximum burst rating. or about 3250 psi. and greatest safety to the operator. we recommend you contact the hose manufacturer for proper instructions and correct compatible splicing tools and mendors. or a technician repairing the machine. this leaves only 1750 psi as the burst rating of the hose now. if both the outer jacket and the inner braid have become badly damaged. If you must install new hose fittings. Never use an incorrect fitting. a hose rated for 2000 psi has a maximum burst rating of about 5000 psi. Clearly. Caution: We do not recommend splicing or repair of ruptured hose.WARNINGS ® A Product of Hi-Vac Corporation HIGH PRESSURE SEWER CLEANING HOSE High pressure sewer hose is constructed from three separate layers of specially developed materials to ensure greatest strength to the hose. then 65% of the hose strength has been lost. Inner Layer Outer Jacket Middle Layer Bonded to the inner core is a band of high tensile polyester braid. as an operator using this hose. If the outer jacket is torn or abraded to the point where the braided band is exposed. is an abrasion resistant polyetherurethane material. and lift stations where the vacuum operation picks up the material in the manhole while the water pump supplies water to a lance (part no. 234585) are used to remove long sticks and items that will not fit into the pickup tube. 380924). The unit power switch should be turned off when transporting the unit. The spent air flows through the ball check valve. settling at the bottom of the tank. When retrieving the nozzle under water pressure. In the water system the water flows from the two water tanks. The water pump and exhauster are engaged and disengaged by electro-pneumatic solenoid valves. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 1 . The boom is locked in place while picking up leaves to provide maximum operator safety. our description of their location is general. depending on the position of the valve. and refer to it whenever any section of the manual describes a control which you cannot identify. positive displacement exhauster. and hydraulic system. the boom hose. either to the hose reel for cleaning. exhauster. or by return lines to the water tank. This machine is also designed for cleaning catch basins. a main power indicator light and switch. During operation of the vacuum system. The vacuum and water system can be used simultaneously when cleaning sewers. These controls allow the operator to engage and disengage the water pump. and a low water warning light and switch are among the standard controls in the chassis cab. through the suction strainer into the suction side of the pump. even among models of the same manufacturer. AQUATECH OPERATIONS. Please read this section carefully. CONTROLS AND GAUGES It is important for the operator to fully familiarize him/herself with the location. Unit must be equipped with the liquid ring option (part no. The vacuum generator is a rotary lobe. and through a metal screen in the centrifugal scrubber externally located at the front of the body. through the water pump feed line. wet wells. material is picked up at the end of the suction line and pneumatically conveyed through the intake tubes. UNIT POWER/PTO ENABLE The unit power switch supplies power to all the other switches. through a crossover manifold. Grapple tongs (part no. This allows conveyance of flushed out materials and water into the debris tank. Because each manufacturer will have a different cab layout. rear control functions will not function. The PTO Enable switch also needs to be turned on. mounted outboard of the debris tank. Position the unit at the curb. DASHBOARD CONTROLS Several controls are mounted in the chassis cab itself. appearance and function of the various controls and gauges on any new Aquatech sewer cleaning machine. This machine may also be used for leaf pickups. Push up to turn on the unit power switch and push down to turn it off. In addition. As the material enters the larger area of the debris tank the velocity of the air flow is reduced and the material drops out of the air stream. it is recommended that a couple hundred gallons of water be added to the bottom of the debris tank prior to vacuuming. 238080) for blasting loose packed debris and for wetting dry material. A red light glows inside the switch to indicate that the unit power is on. Without turning this switch on. It also performs other cleaning operations. The pressurized water is then pumped forward to the water control valve and routed. to the debris tank. To aid in the dumping process of compact leaves. A positive displacement triplex plunger water pump provides the water pressure and water flow to the cleaning nozzle which propels itself through the sewer line. At this point the filtered air flow enters the exhauster and is expelled through a silencer/muffler to the atmosphere. this switch must be the last one turned off. When turning unit off.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation POSITIVE DISPLACEMENT EXHAUSTER AND WATER PUMP UNITS This machine is a combination vacuum and high pressure water jetting unit for cleaning sewer drains or catch basins. material that has built up in the sewer line is blasted loose and back flushed to the manhole for removal with the vacuum system. These solenoids are operated by electric toggle switches in the cab or at the rear operator station. and through the boom intake valve. rotate the boom and extend it to reach all areas of the tree lawn and sidewalk. the hydraulic pump drive is disengaged. This will cause the split shaft PTO to internally shift positions and disengage the rear drive train of the vehicle. This connection allows the operator to disconnect the pendant control from the unit control box and store the pendant control in the cab or tool box when not in use. The transmission can then be placed in the required gear and the clutch released. LOW WATER WARNING AND COLD WEATHER CONDITIONS The low water control is the center switch on the dashboard. Pushing the switch up turns on the “winter” low water warning. When the center switch is positioned for drive mode. The pendant control is wired into a unit control box on the passenger side of the vehicle. Failure to heed this caution may result in severe damage to the water pump or exhauster. The multi-wire cable is long enough to allow the operator to carry the pendant to the work area. In order to keep the truck stationary while operating the water pump. The water pump and exhauster can be engaged from the cab or rear operator’s control panel. Check the air pressure gauges on the dashboard to confirm this. . This pump is closed coupled to the PTO. exhauster or both. HYDRAULICS The main split shaft PTO incorporates an additional output for the installation of the hydraulic pump to supply power to all hydraulic functions. On most units the pendant control is a yellow rectangular box with black push buttons.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation POWER DECK SYSTEMS ENGAGEMENT Before engaging any of the power systems on this vehicle. the clutch must be depressed as well. AQUATECH OPERATIONS. The main split-shaft PTO is actuated by means of electro-pneumatic solenoid valves. For vehicles with standard transmissions. A white light remains on during normal operations. Caution: The pump systems should never be operated in a gear range greater than indicated on either the dashboard label or unit identification sheet. move the switch marked water to the up or down position and verify that the indicator light is on. This can be done by moving the switch marked PTO to the ON position. the rear axle must be disengaged. The same procedure using the switch marked (vacuum) will allow you to engage the vacuum system. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 2 . Both power systems can be run simultaneously if desired.. AND EXHAUSTER To engage the water pump. ENGAGING THE WATER PUMP. a red light will glow in the switch in the event that the water level is depleted to a pre-determined level. This will disengage the rear axle and enable the hydraulic pump. you must first determine that there is at least 90 psi in the air brake system. Please consult with the factory if the vehicle gear range is not specified. On units equipped with the low water warning system. Its drive is automatically engaged whenever the center PTO switch is activated in order to disengage the main drive to the differential of the vehicle. THE PENDANT CONTROL Customarily the pendant control is located and stored in a basket on the passensger side of the vehicle. Pushing the switch down turns on the “summer” low water warning. To disengage either the water pump or exhauster move the switch to the opposite position. The hydraulic tank is also at the side operator’s station. Each function is controlled by a push button control. consult the illustration for switch operation. or run over by the unit. boom functions. This may cause some or all of the functions of the pendant control to cease operation and allow water to leak inside. and therefore hydraulic pressure. releasing a button stops a function. Oil temperature should not exceed 180 degrees. It lowers and raises the boom. A sight glass near the top of the tank indicates the correct oil level. Pressing a button carries out a function. that the pendant control is connected. There is also a unit control box with toggle switches. Consult the labeling to be sure you are operating the controls correctly. rotates the boom right and left. Each button makes an electrical solenoid operate a hydraulic valve. and energizes the boom valve. the pendant should be stored in the basket. flapper valve. the case will become cracked or crushed. When transporting the unit. It is at this operator’s station. although the pendant performs electrical functions. door lock/unlock. The oil level must be above 80 on the sight eye scale. as well. it telescopes the boom in and out. Operate engine at 1500 rpm during tank dumping and lock operating functions. The box contains a switch for: the throttle. Each operator should spend as much time as necessary to become completely comfortable with each Function of the pendant control so that the operation of the boom becomes almost natural. AQUATECH OPERATIONS. the main power switch and the hydraulic system/PTO must be turned on when operating the boom. It also contains a thermometer to measure hydraulic oil temperature. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 3 . Therefore. The actuation of the boom is hydraulic. tool box or cab. door open/close and an emergency stop button. SIDE OPERATOR’S STATION FLAPPER CLOSED LIGHT FLAPPER CLOSE BOOM UP BOOM DOWN BOOM OUT BOOM IN BOOM RIGHT BOOM LEFT There is also an operator’s station at the passenger side of the unit to allow the operator to control the tank dumping system. Because the control is rugged and can withstand some abuse. If the labels become unreadable or are inadvertently removed. Plastic labels at each control indicate the correct manipulation of the switch for the function it performs. The throttle control at this station allows the operator to control engine speed. if dropped repeatedly.PRINCIPLES OF OPERATION PENDANT CONTROL ® A Product of Hi-Vac Corporation The pendant operates the boom. AQUATECH OPERATIONS. Follow instructions for dumping the debris tank. Normally the valve is left in the “reel” position which directs the water flow to the hose reel control on the rear reel. Operate system until the tank is completely clean or the water supply is depleted. and severe pulsating of the sewer hose. Engage the water system from the cab. the valve diverts water flow to the internal tank nozzles in the debris tank. This is called “cavitation. Adjust the level of the rear door so that the jet spray from the internal nozzles is striking the middle of the door for maximum cleaning. Do not operate this system while the exhauster system is running. and the pulsating of the hose will be very mild. At this point it is safe to continue jetting. the water spray from the valve will become very intense. 4. Note: If you have constant problems with cavitation. As the pump develops greater pressure. it is desirable to use the internal tank flush system to thoroughly clean the interior of the tank without requiring the operator to manually wash it down. This procedure is usually only necessary when all water has been previously purged from the system. the suction line strainer has been removed for cleaning. When dumping the debris tank. Run the pump at an idle speed for several minutes until all air is expelled. which is normal for a triplex water pump. 6. By twisting the knurled knob in a counterclockwise direction. 5. Any trapped air acts as a spring cushion for the compressed water and causes the water to “bounce back” against the cushion of air. This can cause a loud knocking noise from the pump area. then slowly increase pump speed. the valve allows water flow to the rear reel. In the normal operating position. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 4 . even though the pump has not been run out of water.PRINCIPLES OF OPERATION AIR PURGE SYSTEM (OPTIONAL) ® A Product of Hi-Vac Corporation If your unit is equipped with the air purge and cold weather blowout system. or one or more valve springs have broken. When it is clear that all air has been expelled. The knocking sound should disappear. To increase the tank flushing capability increase the engine RPM. the valve will open and allow air trapped inside the pump to be expelled. perform the following steps: 1. allowing high pressure flushing of the debris tank. you will notice a brass tire valve on the pump. The control is the lever on the ball valve at the right side of the water pump plumbing on the pressure side of the pump. you should request an inspection of the water system to determine the cause. It is identified by a label: “TANK FLUSH”. close the knurled knob by turning in a clockwise direction and increase pump speed. 3. it is likely that air is being sucked into the pump somehow. severe damage can occur in the pump. or the pump has been run out of water. the control for the internal tank flush is also at the side operator’s station. The control valve for the Internal Flushing System is located in the high pressure line leaving the water pump. If you experience repeated cavitation. Open the rear door approximately half way. The small brass valve with the knurled cap on the pump head is provided to assist the purge of air trapped inside the discharge section of the water pump. outlined in this manual. Water will also be expelled at the same time. INTERNAL TANK FLUSHING (OPTIONAL) On units so equipped. 2. In tank flush mode.” If the air is not expelled. or at speeds in excess of posted speed and gear range! To operate this system. Failure to heed this caution may result in severe damage to the water pump or exhauster. Turn on unit power and water pump switch in the cab. raise idle rpm as needed. 5.PRINCIPLES OF OPERATION OPERATING THE COLD WEATHER RECIRCULATION SYSTEM (OPTIONAL) Follow the following procedure to operate the cold weather recirculation option (See illustration. providing more water for jetting operations. SUGGESTION: Always carry the handgun and nozzles in the heated cab of the truck when not in use to prevent freezing. 1) from the hose reel to the female swivel connector (Item No. 4) to the “on” position: straight up and down position.) ® A Product of Hi-Vac Corporation 1. 4). Unit can now be driven. disengage the rear axle through the PTO switch and engage the water pump normally. During warmer weather. 2. Remove retaining bolt (Item No. Please consult with the factory if the vehicle gear range is not specified. 5) on the restrictor valve handle and turn the ball valve handle (Item No. but do not disengage rear axle. 4. Caution: The pump systems should never be operated in a gear range greater than indicated on either the dashboard label or “unit identification sheet”. 3 ) located at the end of the plumbing beneath the water control valve (Item No. Turn ball valve handle (Item No. 2) to the “on” position. the switch should be in the SUMMER position. 1 3 2 4 6 5 AQUATECH OPERATIONS. In cold weather the switch should be in the WINTER position. the water pump will circulate water throughout the system and back to the tank. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 5 . 6. This allows more water to remain in the tank to accommodate recirculation. 3. Note: If water recirculation is desired with the truck stationary. As unit moves. Note: All units supplied with cold weather recirculation are equipped with two low water warning sensors controlled by the “SUMMER/WINTER” switch in the cab. Connect the 1" sewer hose (Item No. Turn the water control valve (Item No. 6) to the “on” position: straight in-line with valve. Pushing up the switch increases the engine speed. For operating the jetting and vacuum functions of the machine. The two buttons on the lower part of the panel control the articulation of the hose reel assembly. This is where most of the work is done. and a vacuum gauge to view the performance of the vacuum system and switches to turn water pump and blower on and off. depending on the function being performed. This allows the operator to be completely away from the flow of traffic if practical. all the controls and the operator’s station come with the reel as it articulates. a water pressure gauge to view the water pressure in the jetting system. It is possible to articulate this hose reel 180º around to the side of the machine so that the hose reel and operator’s station is all the way to the passenger side of the machine. The operator’s station is equipped with an electronic throttle switch to control the engine speed.When in the tank return position. while the truck can be parked along the curb-side. prolonged operation of the water pump without water will cause overheating and damage to the packings and other internal components of the water pump. Refer to the pump manufacturer’s section included in this manual for further information. When in the hose reel position. THE REAR REEL CONTROLS In addition to the controls at the rear operator’s station. several valves and controls are also mounted directly to the rear reel assembly at the back of the machine. Plastic labels indicate which position turns water on to the hose reel and which returns water to the water tanks. and the other will bring the hose reel assembly back to rest on the door stop pad. Caution: Always move the hose reel away from the door stop pad whenever the hose reel will be operated. the operator will use the rear operator’s station. Among the controls at the rear reel is the water valve handle to turn water on at the hose reel. AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 6 .PRINCIPLES OF OPERATION There are actually two operator’s stations. One button will cause the hose reel assembly to articulate out away from the tank door. a tachometer to view the engine’s speed. while pushing it down decreases the engine speed. the water flow is directed to the hose reel and through the water hose. Be sure the hose is fitted with a proper nozzle and in a working position before turning the valve to the hose reel position. Failure to do so may cause the door stop pad to be torn away from the reel ® A Product of Hi-Vac Corporation Caution: Although the water pump may be run for a short time without water. There may also be a water warning light on the rear station control panel. water flows through the control valve and returns to the water tanks. This is the normal position for the valve whenever the machine is not being used for jetting. When work is done at the side of the machine. THE REAR OPERATOR’S STATION There is also a toggle switch which controls the engine speed. It also allows direct access to manholes which are located on the tree lawn or sidewalk. located on the hose reel frame at the rear of the unit. (Refer to the Controls section of this manual for a parts listing) There is also a reel rotation control switch in the control panel that can be used in lieu of the foot pedals. The pedals are actually pneumatic bulbs which send air pressure to the control box also mounted near the reel. High water pressure may cause serious injury. The spray pattern can be very small and forceful. By slipping the hand gun hose quick connect coupler onto the coupler on the water manifold. or fanned out for a wider spray pattern. One pedal pays hose out. and moving it counter-clockwise will reduce the reel speed or effectively stop all hydraulic functions. THE FOOT PEDAL CONTROLS The foot pedal controls for front or rear reels are carried on a hook mounted near the reel. the other retrieves. a safe pressure at which to operate the handgun. Never point the handgun at yourself or other personnel while in use. This is set at the factory to 800 psi. THE HANDGUN AND HANDGUN “QUICK CONNECT” The handgun connect is located on the rear water manifold. and turning the handgun valve to on. The spray pattern from the handgun is controlled by moving the hand grip on the barrel end of the gun back and forth. This control box sends an electrical signal to the hydraulic valves which control the reel motor. AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 7 . either paying hose out. The pedals control the direction of rotation of the hose reel.PRINCIPLES OF OPERATION THE REEL SPEED CONTROLS ® A Product of Hi-Vac Corporation Allows the operator to control the speed at which the reel turns. or retrieving hose. Moving the control lever clockwise will increase the reel speed. The handgun will only operate when the reel water control is in the tank return position. There is a relief valve installed directly above the quick coupler fitting to control the amount of pressure to the handgun. the handgun (PN 131632) will operate. 3. Always use a hose guide in the manhole. use extreme caution when applying pressure to the hose. The middle switch on the three switch gang mounted to the dashboard or the control box will operate the main drive of the split shaft PTO. 4. toolbox. When entering a manhole. 9. Your Aquatech unit must never be run at speeds higher AQUATECH OPERATIONS. Water Jetting at the work-site 1. worn or leaking places. 5. 4. 2. 3. 6. Secure the sewer hose in the traveling position by locking it into the swivel fitting provided. Always use a leader hose at the end of the sewer cleaning hose. 8. On units with standard transmissions it is also advisable to depress the clutch pedal to the floor during this operation. Deflection is possible under these conditions and the nozzle could turn around. 5. Check to see that the boom is secure in the boom rest and latched and the boom pendant control is secure in its carrier. 11. Low water warning light in the cab indicates low water. Engage water pump. or cab. Place the water control valve on the hose reel to the “TANK RETURN” position. Disengage the rear axle by shifting the main drive of the split shaft PTO. Set the parking brake and block the wheels. 10. 7. 5. Select the correct gear range and proceed to the operator’s station to operate the unit. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 8 . Turn the PTO enable switch to the “ON” position. 4. proceed as recommended in the APWA handbook on safety. Perform required maintenance on truck chassis as specified in truck chassis manual. Open the water pump gate valve completely. When inserting a nozzle in a sewer section full of water or in very large diameter pipes. Before proceeding with the following instructions make certain that there is at least 90 psi of air pressure in the chassis air reservoir or damage to the PTO may result. Use only genuine Aquatech hose and repair parts. Use Cold Weather Recirculation in temperatures below 32 F. The sight tubes located on the rear of the water tanks shows the direct water level in all tanks. Never force nozzle or hose forward by pushing on it.PRINCIPLES OF OPERATION HOW TO USE YOUR SEWER CLEANER IMPORTANT SAFEGUARDS ® A Product of Hi-Vac Corporation 1. It must move under its own water power. 2. Follow all state and federal regulations. Check to assure that all tools are secured. Perform required maintenance as specified in the maintenance schedule. 3. b. a. o 6. Turn the unit power switch to the “ON” position. Fill the water tanks. Repair or replace if necessary. 6. Never enter a manhole that has stagnant water in it. Please refer to one or more of the following water level indicators. BEFORE GOING TO WORK SITE 1. 2. and that all cabinet doors are closed and latched. The transmission must be in neutral. Check for overhead lines that could come in contact with the boom. Always use a steel nozzle guide or nozzle extension longer than the pipe diameter. come up and out of the line and manhole to inflict injury to persons nearby. Position the unit at the manhole to be cleaned so that the sewer hose will feed off the reel directly into the manhole. Check hose and water network for weak. Refer to the “unit identification sheet” or “unit dashboard label” for the correct gear range in which to operate your sewer cleaning machine. turn on water pump and water control valve handle to the “Hose Reel” position and slowly increase the engine speed until reaching the desired pressure. 7. 13.” Running the engine at a higher rpm may be unsafe and result in personal injury and damage. and run water through the hose for at least one minute or until all ice is ejected. 11. d. Experience has shown that using the flexible hose guide with the rope end down works best. larger diameter pipes require higher pressure for more efficient cleaning. Disconnect the end of the sewer hose from the travel/safety coupling and route through the level wind. AQUATECH OPERATIONS. The “level wind” or hose guide is used to wind the hose on the reel evenly to ensure long hose life. The needle on the tachometer indicates the engine speed. The payout speed of the hose is controlled by the speed control knob. begin paying out the sewer hose by depressing the Pneumatic foot control pedal marked “PAY OUT”. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 9 . Caution must be exercised in using higher pressure in older pipes with mortar joints and pipes showing deterioration. then hand tighten selected nozzle on the end of the hose. Note: always use a leader hose at the end of the sewer cleaning hose. With the nozzle inserted in the sewer pipe. With the water pressure and engine speed set. 16.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation than specified on the unit dashboard label and on the “unit identification sheet. Insert hose through flexible hose guide. Operator experience. 12. the hose is plugged. move throttle control switch up momentarily to increase engine speed. the debris will enter the manhole. When retrieving the nozzle and winding the hose onto the reel. If you cannot locate this information. Install level wind assembly on its pivot pin directly under the reel. it is usually not necessary to use full operating pressure for preventative maintenance. Check local traffic regulations and for all overhead lines. 15. c. Position the hose reel over the manhole. Generally. or Hi-Vac Corporation directly at (740) 374 -2306. During the initial cleaning program. down to decrease. Engine speed should be about 1500 rpm to operate reel efficiently. At the rear operator’s station. Cold weather precautions: If the unit is subjected to freezing temperatures. Amount and type of debris to be removed. Age. condition and type of pipe. e. Select proper pump operating pressure based on the following: a. Leave the sewer hose in its traveling position. 14. If pressure starts to rise. The vehicle may face any direction. higher pressures are desired to remove larger amounts of debris. b. the engine at idle speed. The reel articulates from its rest position against the rear door o in a 180 arc by depressing the button on the control panel marked “OUT”. After the manhole has been cleaned once. The age and condition of the sewer cleaner hose must always be considered in operating at high working pressures. 9. Adjust speed to keep enough tension on the hose so it doesn’t become loose on the reel. DO NOT ALLOW THE DEBRIS TO CONTINUE INTO THE NEXT SECTION. it is recommended that the machine not be operated at maximum pressure. please call your selling dealer. Age of Sewer cleaning jet hose. Diameter of pipe. ice will probably form in the sewer hose and must be ejected for proper operation. Until the operator is fully experienced in the operation of the equipment. the warranty becomes null and void. 8. The reel is positioned at the manhole downstream from the stoppage or section to be cleaned. Upon such use. 10. Do not operate the unit for long periods of time when the debris tank is full. Failure to follow this procedure may result in serious deformation of the hose reel when the hose is pressurized during the next cleaning operation. and lowering the boom. Wind the remaining hose onto the reel. the debris tank becomes full. retracting. depress the foot control pedal marked “RETRIEVE” and begin retrieving the nozzle slowly. 2. raising. allow nozzle to discharge for a short period to wash out any debris buildup in the line end. If during the vacuuming process. The 3" relief valve will also “chatter and whistle. 3. The boom pendant includes controls for: Extending. the intake tube may be positioned just above the water level in the manhole or catch basin allowing a mixture of air. When vacuuming. 18. at sea level. as well as opening and closing the internal boom valve. a maximum of 1/4 tank of fresh water should be carried. Caution: Hose retrieving operations must be done while maintaining normal operating pressure in the water hose. with the desired water flow and pressure. Place a sufficient number of intake and/or extension tubes on the boom hose to reach the desired working depth. located at the rear of the hose reel. To clean the manhole area. the use of the optional fluidizer tube (Part # 240805) is recommended. When required. Please refer to the PENDANT CONTROL section in CONTROLS AND GAUGES for diagrams and explanations if you are not completely familiar with these operations. When the nozzle is 3 to 5 feet from the manhole. To ensure clean out of the last 3 to 5 feet of sewer line. follow the instruction for disengaging the exhauster PTO. VACUUMING AT WORK SITE 1. and by physically moving the tube around inside the catch basin to reach all areas where debris has collected. The vacuum tube can be positioned by use of the boom up/down control. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 10 . After the nozzle has reached the desired point. stop the reel and shut off the water supply to the nozzle. It is extremely important to always remove as much water as possible from the debris tank before driving the vehicle. the ball check valve will close which is indicated by loss of vacuum at the intake tube.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation 17. Caution: To avoid overloading of the truck chassis. not to exceed maximum RPM and gear as noted on the unit ID sheet and mounted in truck cab. the unit is capable of removing debris from below water level with the intake tube completely submerged. 6. To increase the exhauster speed. increase engine RPM to working speed. the debris tank and the water tanks must never be simultaneously loaded to full capacity. It is critical that the hose be rewound on the reel at its normal operating pressure. to flush the debris from the sewer line into the manhole. This is sufficient to wash down the debris tank. AQUATECH OPERATIONS. Begin vacuuming debris and water. 4. Be sure that the unit operator is completely familiar with the boom pendant controls. When traveling to the dump site with a fully loaded debris tank. This will help eliminate overloaded conditions. 5. water. connect the handgun quick disconnect and open the isolating 1/2" ball valve. Retrieve the hose at approximately 30% of full reel speed.” When the debris tank is full. 19. For lifting water more than 17 ft. and debris to enter. Hose reels deformed during machine operation are not covered under warranty. BE SURE THE AREA ABOVE THE VEHICLE. or when the underlying ground is soft or unstable. Proceed to dumpsite. AQUATECH OPERATIONS. Never lift the tank when the unit is parked on a grade. 3. NOTE: Do not run the exhauster in reverse to pressurize the tank. open the drain valve at the rear of the unit and allow the water to drain. Excess water may be removed from the debris tank by the following method. 1. Disengage the drive axles by placing the PTO switch in the “On” position. Before leaving the worksite for the dumpsite. ensure that the boom is in its travel position. level terrain on which to park the vehicle when setting up to dump. DUMPING THE DEBRIS TANK Caution: When dumping this vehicle. Procedure for opening the rear door and raising the tank: Note: Maximum operating speed for opening the rear door is shown on the “unit identification sheet. Engage the hydraulic system. Return hose reel to its travel position against the stop on the rear door. Do not attempt to raise the tank until the door has been opened to allow the debris to empty. This may damage the clutches in the PTO. c. IS FREE OF ELECTRICAL LINES OR ANY OTHER OBSTRUCTIONS ! 2.” a. With the exhauster pump disengaged. and block the wheels. and raise it to its highest point. Never drive this vehicle with the tank raised or the tank door opened.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation 7. 2. Unlatch boom and using the boom pendant control. extend the boom out a few inches. Position the truck at the dump site. set the parking brake. d. b. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 11 . Master power switch in the “On” position and PTO enable switch in the “On” position. always seek firm. Failure to follow these guidelines may result in a catastrophic accident in which the vehicle may tip over or the tank may shear from its mounting supports. LEAVING THE WORK SITE 1. Push and hold the toggle switch marked LOCKS upward to unlock the hydraulic door locks. Remove the suction line filter. After dumping is complete. Close the door by pushing the toggle switch marked DOOR. e. Engage the water pump. The 15 o nozzle is recommended for optimum cleaning of the tile in sections where accumulations are light or pipe diameters do not exceed 12 inches. (Optional) COLD WEATHER STORAGE The following procedure is required to prevent damage to the water pump and water system during cold weather conditions. will come on when there is approximately 3 minutes of operation time remaining. Do not exceed this pressure setting when operating. Turn the 3 way ball valve at rear reel water manifold to the “Hose Reel” position. increase the engine RPM with the throttle until the water pressure reaches 800 PSI on the pressure gauge. Leave the drain cap off until the machine is ready to be used. The sight level tube located on the water tanks which shows water level in both tanks. 3. The following method can be used to clean out the debris tank if unit is not equipped with optional Tank Flush System: Connect the handgun to the quick disconnect or optional 1/2" hose reel. 4. If accumulations are heavy. Open the drain in the water tank cross-over line. gasket and cover. to raise the debris tank as needed to allow the debris to completely dump out of the tank. Drain water from tanks by tipping the tank slightly. the 35o nozzle is recommended. There are two ways of determining the amount of water remaining: 1. CLEANING THE DEBRIS TANK ** The internal tank flush can be retrofitted to an existing machine. If your unit is not equipped with the 1/2" hose reel. Refer to the Service section of this manual for ordering instructions. Push and hold the hydraulic lever marked TANK. Low water warning light. If your unit has the optional 1/2" hose reel. Lock the door by pushing the toggle switch marked LOCKS and holding until the locks are completely closed. Raise the door with the toggle switch marked DOOR located on the side control panel. g. 1. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 12 . Push the switch up and hold until the door is completely open. WATER LEVEL INDICATORS It is important to pay attention to the amount of water remaining in the fresh water tanks when using the hose reel. behind the rear axle. turn the valve located at the reel to the ON position. under truck chassis. 2. allowing the water to flow to the handgun. Note: Make sure that the door is completely closed prior to closing the hydraulic locks. f. turn the water valve at the handgun quick disconnect to ON. lower the tank by pulling on the lever marked TANK until the tank is completely down on the sub frame. lower the tank. Once the water is removed. proceed to trunk lines and then to interceptors. HELPFUL HINTS FOR USING YOUR AQUATECH CLEANER WHERE TO START YOUR CLEANING PROGRAM Cleaning operations should begin at the outer reaches of the network. Deposits must be removed by the crew as cleaning proceeds. 2.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation d. AQUATECH OPERATIONS. the line is clean. from an external source. and then proceed with the above steps. stub lance. 6. ROOT AND GREASE REMOVAL The AQUATECH root cutter system. first propelling the cleaning nozzle 50 to 100 feet into the line and slowly withdrawing. move the unit to a heated garage immediately. the hose should be introduced into the manhole below the stoppage and worked upstream. let thaw out. to ease cleaning operations by preventing the nozzle from becoming caught on joints. open the ball valve to drain the water from the return line. 18" AND LARGER PIPE When cleaning such lines. etc. UNEVEN JOINT IN SEWER LINES It is recommended that nozzle guards. SERVICE AND PARTS MANUAL PRINCIPLES OF OPERATION 13 . Sting ray or Torpedo nozzle is recommended for this application since these will bore through large pipe and heavy accumulations best. The 35o and/or 15o nozzle. rocket nozzle or nozzle with a front orifice are recommended. SPECIAL INSTRUCTIONS FOR HEAVILY LOADED LINES In pipelines heavily loaded with sand or gravel. lance nozzle. Engage water pump in accordance with normal procedure and run pump approximately 15 seconds. Caution: If general circumstances lead to the interruption of the procedure and there is a presumption of ice formation in the system. the speed of withdrawal of the hose should be reduced. The single storm. may be used to cut out roots. Caution: The implementation of this procedure must be performed immediately after jetting operation or cold weather recirculation operation. it is advisable to insert the hose 4 to 5 feet into the line before delivering water to the cleaning nozzle. AQUATECH OPERATIONS. DRAIN TILE. (See Nozzle Selection guide in Accessory Catalog) Caution: All high velocity sewer cleaners will cause small amounts of water and sewer gas to enter buildings which do not have toilet vents or. Spin clean nozzles work most effectively on grease and detergent buildup. If the line is large and deposits are heavy. Apply 75 to 100 PSI of air pressure. Tie or wire the sewer cleaning hose end securely to reel and rotate clock-wise as if retrieving the hose from sewer. If equipped with cold weather recirculation option. OPENING STOPPAGES In the case of a line stoppage. employing either root saws. root cutter blades or brushes. Please refer to these instructions for proper operation and care of specialty nozzles. Special instructions accompany these nozzles. Do this until a solid stream of water no longer comes out of hose. When the withdrawal of the nozzle fails to bring additional deposits to the manhole. 7. have toilet vents that are clogged. 9. Special sand and penetrating nozzles are available for complete blockages. encrusted grease and detergent buildup. Open valve for handgun and push ball on male quick connect. 8. double storm. Leave this valve open until ready to use again. then 100 to 200 feet. Make certain the nozzle is removed. it is advisable to perform the cleaning operation in a progressive manner. ellipse nozzle or centralizer be used. Rotate until water no longer comes out. CULVERTS. to the air valve on the water pump to force the water from the water pump and hose reel.PRINCIPLES OF OPERATION ® A Product of Hi-Vac Corporation 5. Minimum billing of $100. 2. contact your nearest authorized Aquatech dealer or phone the Hi-Vac Customer Service Department. When placing orders . SERVICE AND PARTS MANUAL SERVICE 1 . contact the Hi-Vac Customer Service Department at: Phone: 740-374-2306 Fax: 740-374-5447 Every effort is made to ship all in-stock parts on the same day the order is received. 3. when the order is placed before noon. The part number(s) of the required items.O. This information is also located on the Identification Sheet. In addition to our Authorized Dealer network throughout the world. We must have your street address: we cannot ship to P. orders are shipped UPS. ocean freight. AQUATECH OPERATIONS. The information should be shown on the unit information sheet located at the front of this manual. Ohio. When information cannot be found in this manual. Type and serial numbers for the unit and chassis. second day air. first call your nearest Authorized Dealer. when you place your order: 1. If they are unable to assist you.SERVICE ® A Product of Hi-Vac Corporation CUSTOMER SERVICE AND PARTS ORDER Hi-Vac Corporation is committed to customer satisfaction. please have the following information available. To assure prompt delivery and processing of your parts orders. SHIPPING INSTRUCTIONS. SALES TERMS: The descriptions and instructions included in this manual cover the standard design of the equipment and any common deviations when possible. or truck freight if necessary due to weight restrictions. No material returns will be accepted unless accompanied by our Material Return Authorization form. whether your parts are to be shipped next day air. This manual does not cover all design details and variations nor does it provide for every possible contingency which may be encountered. When left unspecified. 4. Eastern Time.FIRST: Contact your nearest Authorized Aquatech Dealer.00 applies to all orders. along with the quantity desired. A restocking charge of 20% applies to all Return Goods. etc. Box numbers. In the event you need parts or service. All specifications given have been calculated at sea level. Orders received after noon are shipped the next business day. we maintain a full stock of parts and accessories at our factory in Marietta. truck. All designs and specifications are subject to change without notice. f. This warranty will not cover failure caused by purchaser’s failure to perform normal maintenance by abuse. factory is allowed STAINLESS STEEL TANKS PRO-RATED WARRANTY (Except SJR tanks) First 5 years — No charge repair or replacement f. and no one shall have the authority to supersede or modify its provisions except in writing by the Company. or as provided in these terms. provided terms of inspection as outlined in Operator’s Manual are met. f.o. shall have whatever warranty and terms as are offered by the original manufacturer and shall not be covered by these provisions except where specifically stated.b.o.o.b.o.o. Use of replacement parts not supplied by the Company may void this warranty.b.O. This warranty shall be the only warranty in effect. WARRANTY EXTENSIONS The Company may wish to offer an extension to this warranty.o. factory is allowed 8th year — 40% of list price. factory 2nd year — 65% of list price. This extension will act to increase the period over which these terms may apply.b. but those which are not manufactured by the Company. The company guarantees for the lifetime of the tanks against failure from corrosion or rust through. warrants for a period of twelve (12) months from the date this product is accepted by the purchaser.b. MAJOR COMPONENT WARRANTY Components provided as part of this product. at its sole discretion. f. that all design and material of its own manufacture shall be free from defects. SERVICE AND PARTS MANUAL SERVICE 2 . SJR TANKS 10 year no charge repair or replacement against rust through or leaks. These warranties shall be provided upon request. factory is allowed POLYGRAPHITE TANKS 10 year warranty on all polygraphite water tanks. and agrees to cover repairs or replacements of defective tanks according to the following schedule: MILD STEEL TANKS PRO-RATED WARRANTY (Except SJR tanks) 1st year — No charge repair or replacement f.o.b.b. All parts supplied under the provisions of this warranty are F. f. but will not modify any of the terms except as may be expressly stated in writing by the Company.o.b. Ohio. f.b. Marietta. f. factory is allowed 5th year — 20% of list price. such defects to assure the product performs according to its published specifications at time of manufacture.B. factory is allowed 9th year — 20% of list price. SPECIAL WATER TANK WARRANTY The Company warrants its water tanks to be free from leaks.b. AQUATECH OPERATIONS. factory is allowed 3rd year — 50% of list price. f. The company agrees to repair or replace.o. at a price it may determine and publish.b. f. or by purchaser’s use of product for purposes not intended by design.o.SERVICE ® A Product of Hi-Vac Corporation STANDARD LIMITED PRODUCT WARRANTY Hi-Vac Corporation hereinafter called the Company.o. f. factory 6th year — 65% of list price. factory. factory is allowed 7th year — 50% of list price. Alterations or modifications to product without the express written permission of the Company may void this warranty. This warranty will not cover any part or service subject to normal wear or adjustment as described in the Operator’s Manual supplied with the product. factory is allowed 4th year — 40% of list price. The Company shall make good faith efforts on behalf of the purchaser to enforce any applicable warranty offered by its vendors. freight prepaid. subject to the conditions as stated herein. WARRANTY INITIATION The warranty shall begin at the date the product is accepted by the purchaser which shall be documented by the “Delivery Check List” included in the operating manual for the machine. precluded from the terms of this warranty except as already stated: Water pump Auxiliary engines Exhauster/vacuum pump Drive belts High pressure water hose Truck chassis Hydraulic pumps. representatives or employees. The original manufacturer’s decision shall be final and binding on both purchaser and the Company. the warranty shall begin in 30 days after shipment from the factory. or whatever warranty shall be offered and be enforceable upon the original manufacturer. Replacement parts purchased after the warranty period will carry a thirty (30) day warranty against defects in material or workmanship. AQUATECH OPERATIONS. The purchaser shall agree to these terms by virtue of acceptance of the machine or purchased part. for evaluation and determination of warranty by the original manufacturer. express or implied. All such defective parts must be returned to the factory. and signed by the purchaser. If this form is not returned to Hi-Vac. Any product which has been used as a demonstration unit will. whichever is longer. The Company must be notified by the delivering dealer in the same way as any newly manufactured machine. LIMITATIONS / EXCLUSIONS TO WARRANTY The company shall not be held liable. and shall in no way obligate the Company to perform such modifications to products manufactured before these changes were adopted. motors and valves Power Take-Off Electrical components Suction hoses and tubes Batteries Axles.O. REPLACEMENT PART WARRANTY Parts replaced during the warranty period will be warranted only during the term of the original warranty. as a result of any failure of the product to perform. or its agents. damages or expense charges incurred by purchaser. are the implied warranties of fitness for a particular purpose and merchantability. No part shall have been previously disassembled or tampered with in any way so as to void the manufacturer’s warranty.SERVICE ® A Product of Hi-Vac Corporation DESIGN MODIFICATIONS The Company reserves the right to make modifications to its design and specifications which shall in no way infer that previous designs and specifications are not fit for their originally intended purpose. The purchaser shall be responsible for payment of the replacement part until such time as the original manufacturer shall offer warranty replacement to the Company. by the factory in Marietta. No travel time allowances are made. there are no other warranties of any kind. properly filled out by the delivering dealer. Other than those expressly stated herein. Requests for return will be made at the discretion of the Company. Ohio. under the terms of this warranty. No extension of warranty is made by installation of the new part. tires CLAIMS PROCEDURE Warranty claims against the Company shall be made by the delivering dealer in accordance with the terms set forth in the “Warranty Request Claim” policy statement as set forth at the latest effective date. The following are specifically. All parts are supplied F. SERVICE AND PARTS MANUAL SERVICE 3 . and specifically excluded but not by way of limitation. Labor costs incurred to replace defective parts are specifically excluded from this warranty. at which time credit will be issued to the purchaser. have the full warranty as provided for in these terms. for any losses. The Company’s sole responsibility under these terms shall be the timely return of the defective part to the original manufacturer for warranty consideration. No freight allowances are made. and for such reasonable follow-up action as may be necessary to expedite the claim.B. though not exclusively. upon sale to the purchaser. 3. universal joints. 2. Inspect water pump jackshaft bearing set screws and tighten if necessary. (EVERY-6 MONTHS) 1. Inspect hose reel bearing set screws and bolts. Inspect water pump and exhauster drive belts for proper tension. Inspect PTO and drive shafts for loose and/or worn belts and bearings. 2. 4. 6. clean if necessary.SERVICE TROUBLESHOOTING GUIDE GENERAL MAINTENANCE SCHEDULE (DAILY) 1. (BI-WEEKLY) 1. Inspect the exhaust system for leaks or heating problems. SERVICE AND PARTS MANUAL NOTES: Multiple fittings usually indicate one on each side. and controls for operation and position. (WEEKLY) 1. 5. 3. 4. 5. in the water pump. 3. Inspect hose reel brackets. Inspect water pump suction line strainer. 7. 1. 2. Consult manual for specific interval. Inspect tension of hose reel drive chain. dirt or rust. Inspect nozzles for excessive wear or obstructed orifices. SERVICE 4 . Inspect water pump for excessive or abnormal wear. Inspect all high pressure hydraulic lines and connections for cuts and/or leaks. and pivot points for wear. linkages. and check pulleys for proper alignment. Remove and clean exhauster strainer and clean housing. **Indicates brush-on grease. 2. Inspect hydraulic system filter and clean or replace if necessary. and bearings. 5. applying Loctite to the set screws. Inspect drive train and PTO shafts. Grease weekly. Remove cap and drain exhauster silencer. Inspect the valves and springs. 4. bolts. Remove any foreign material. Vacuum tube o-rings should be greased once a week. 8. ® A Product of Hi-Vac Corporation 3. AQUATECH OPERATIONS. 4. Inspect all high pressure water lines and sewer cleaner hose for cuts and/or leaks. Inspect debris tank coating and re-coat as necessary. Inspect all valves. REMEDIES CONDITION: WATER PRESSURE TOO HIGH PROBABLE CAUSES Clogged nozzle. Pump starved for water. Wrong nozzle. SERVICE AND PARTS MANUAL REMEDIES SERVICE 5 . THIS IS THE SINGLE MOST COMMON PROBLEM WITH ALL HIGH PRESSURE SEWER CLEANERS. Open gate valve Consult chassis manual. Replace components as required. Note valves are set at the factory and adjustment by inexperienced people could result in damage to equipment or possible injury to personnel. Check for correct gear. Transmission slipping. Worn valves or valve components Replace orifice or nozzle. PROBABLE CAUSES Worn nozzle orifices. Leaks in the high pressure water system. Replace gauge. Inadequate engine speed. Locate and eliminate as required. Reduce speed AQUATECH OPERATIONS. replace suction hose if it leaks or is collapsed.SERVICE TROUBLESHOOTING COMMON PROBLEMS ® A Product of Hi-Vac Corporation The following is a list of possible problems which may be encountered during the life of this machine. Probable causes are listed in this section together with recommended solutions to these problems. Clean. check automatic transmission fluid level. WATER SYSTEM CONDITION: LOSS OF WATER PRESSURE. Replace valve Replace. contact your local authorized Aquatech dealer. Gauge is inaccurate. Replace with correct nozzle Shift to proper gear. Water control valve leakage bypassing or recirculating water back to the water tank. or replace seals. Relief valve leaks or otherwise malfunctions. Incorrect nozzle Incorrect gear Over speeding engine Clean jets. Gate valve in suction line partly closed. Open valve. If the resolution of these problems or any other problems are not readily apparent. Change to correct nozzle Consult engine manual. Clean suction line strainer. Clean suction line and hose of obstructions. Replace with correct nozzle. Sewer line is dry or too much fall in line. Specific performance cannot be guaranteed in sewer lines with pronounced grade. AQUATECH OPERATIONS. Worn valves or seals. Hose may be pinched on reel. inspect bearings. or replace valve seals. replace. Inspect and replace as required. SERVICE AND PARTS MANUAL REMEDIES Reel speed valve turned down too low. Inspect and replace as required. Check oil level and fill to proper level. A. Clean. Remove hose from reel. Remove gauge and test. Clean suction line strainer. PROBABLE CAUSES Pump starved for water. B. Open gate valve.) In sewer lines with steep grades. inspect for kinks. If pump has been operating with inadequate lubrication. Air in pump.SERVICE CONDITION: HAMMERING NOISE IN WATER PUMP. maintenance and cleaning must be performed in the downstream sewer line or with mechanical means. pump water through until it flows at a smooth steady stream. Disassemble and remove debris. PROBABLE CAUSES Clogged nozzle Incorrect nozzle Pressure gauge reading incorrect. Low oil level in water pump. SERVICE 6 . BUT SHOWS ADEQUATE PRESSURE. Understanding. If gauge reading is not correct. REMEDIES CONDITION: HOSE FAILS TO MOVE UP THE SEWER LINE OR FAILS TO REACH THE NEXT MANHOLE. collapsed sections. Remove nozzle from hose. usually 3% or more. Water control valve leaking therefore bypassing or recirculating water back to tank. Replace valve. Clean suction line and hose obstructions.) Introduce water into the upstream manhole and/or jump the hose by rapidly opening and closing the water control valve at maximum pressure. the propulsion of the nozzle and hose up the line will be affected. Clean. etc. Ensure the pump is properly primed. Speed valve up. Restriction in hose. In this situation. For best operation always pressurize hose when winding on reel. Bleed off air through the air purge valves. Broken valve spring. ® A Product of Hi-Vac Corporation Valve stuck open with debris. replace suction hose if it leaks or is collapsed. it is normally not necessary to clean lines with steep grades. Check to determine if they open at 15” Hg. Loose or broken chain on hydraulic motor. rebuild or replace. Tighten pressure relief set screw. If problem is not cured. PROBABLE CAUSES Reel speed valve turned down too low. Hydraulic relief valve relieving at too low a pressure. Repair or replace. CONDITION: LOSS OF VACUUM Drain or recycle water in debris tank. and valves on the recycling system. REMEDIES Blockage in the intake hose. Check engine tachometer. Fill to sight eye center dot. If this does not cure problem either rebuild or replace the valve. Remove the primary check valve cover and inspect the ball check. Lower the boom all the way to allow material to drop out through the hose. Inadequate engine speed. Leaking hoses or fittings. Disengage exhauster pump and evacuate the vacuum from the tank. Repair or replace as required.. REMEDIES VACUUM SYSTEM PROBABLE CAUSES Boom turret plugged. Disassemble and clean valve. Foot pedal or hose leaks. intake tube O-rings. Consult exhauster pump manual. Dump debris tank. Faulty vacuum reading. such as rear drain. Replace gauge. portal gasket. Exhauster pump malfunction. Relief should occur at 2000 PSI. Debris tank is full and check ball is closed. Inspect vacuum system for leaks. Hydraulic valve problem. Some areas to check first are: Rear door seal. Check to see that gate valves are closed. Tighten. Remove turret and clear blockage. AQUATECH OPERATIONS. Use toggle switch on control panel until pedals or hose can be replaced. Disassemble and clean. Check for correct gear. adjust throttle cable. Sticking vacuum relief valves. tank closure seal. SERVICE AND PARTS MANUAL SERVICE 7 . Vacuum system leak. Hydraulic pump or motor problem. Speed valve up. Hydraulic level too low in reservoir. consult engine manual. normally a high pitched sound is heard. Clean/lubricate/replace if necessary. Inspect intake tubes. Pressure discharge through boom hose. Loose exhauster pump drive belt.SERVICE HYDRAULIC SYSTEM ® A Product of Hi-Vac Corporation CONDITION: HOSE REEL WILL NOT RETRIEVE HOSE FROM SEWER. Switch terminal arcing within housing. 3. Wiring from valve to control box broken or disconnected. SERVICE AND PARTS MANUAL SERVICE 8 . PENDANT BOOM SWITCHES FUNCTION ERRATICALLY. Repair or replace. PTO WON’T RE-ENGAGE DRIVE AXLE. Check truck chassis battery and cell condition.Use OHM scale recorder or battery powered continuity test light. Water in pendant. REMEDIES Turn ignition/unit power switch “on”. 3. Faulty solenoid valve 1. clean. Unit power must be last switch turned off. Faulty solenoid valve. Switches turned off in wrong sequence. 2. Valve spool stuck or unsealed. Check for voltage at solenoid. Check for pinched or bare wire connections. Short circuit in solenoid(s) wiring connection. therefore. Dry out pendant control and seal leaks. PROBABLE CAUSES Ignition/unit power switch not “on”. Replace switch unit. 1. FLAPPER VALVE INTAKE CYLINDER ON BOOM INOPERATIVE. Pneumatic valve solenoid coil burned out. #2 AMP REPLACEMENT). switch terminals loose or disconnected. Repair and replace. Push button. 1. Replace 1. AQUATECH OPERATIONS. 2. Disassemble. 1. Push button switch contacts burned or disconnected. Frayed or broken harness wire. 1. 2. Secure terminal to post connections on switch. Test and replace if necessary. 2. 2.SERVICE ELECTRICAL SYSTEM ® A Product of Hi-Vac Corporation Important! Do not attempt to remedy any electrical problems without first examining the schematic wiring diagram and control wiring circuit drawing (see Electrical Section). it is more convenient to use a 12 VDC test light.meter.The circuit must be opened to obtain current reading with the volt. or replace. (B) Current. (A) Continuity. 3. CONDITION NO POWER BOOM VALVE NOT WORKING FUSE BLOWN (#1 TERMINAL BLOCK. 3. Check for voltage at solenoid. 3. PTO DOES NOT DISENGAGE DRIVE AXLE. Tighten or reconnect. Replace. 3. 2. Use proper instrumentation for current and continuity test results. Contact an authorized service person. check air compressor operation. Low air pressure. Defective seals in the main input shaft control area.SERVICE SERVICE PTO Troubleshooting Guide Caution moving parts OMSI PFT-PC4/3000 Hi-Vac P/N A164134 Problem PTO will not shift to pump mode. Drain moisture from the system. 100 to 120 is normal operating pressure. 100 to 120 is normal operating pressure. SERVICE AND PARTS MANUAL SERVICE 9 AQUATECH OPERATIONS. Air solenoid valve not shifting. hoses. hoses. Red light will illuminate on actuated valve spool. piping and fittings. Add auto drain system. Red light will illuminate on actuated valve spool. piping and fittings. even in neutral. Air solenoid valve not shifting. Replace leaking. AQUATECH OPERATIONS. Drain moisture from the system. Automatic transmissions hold a slight amount of torque on the system. PTO will not shift out of pump mode. Moisture build up in the chassis air tanks. Move unit forward or backward and attempt shifting again. Air leak in the system. check air compressor operation. Automatic transmissions hold a slight amount of torque on the system. Replace leaking. Contact an authorized service person. tubing. Defective seals in the main input shaft control area. Contact an authorized service person. Check for air leaks. Add auto drain system. Moisture build up in the chassis air tanks. Contact an authorized service person. Detent ball on shifting stem jammed or defective. Air leak in the system. even in neutral. ® A Product of Hi-Vac Corporation ® A Product of Hi-Vac Corporation Cause Low air pressure. Check the electrical system and the air system. Correction Check for air leaks. Move unit forward or backward and attempt shifting again. Detent ball on shifting stem jammed or defective. tubing. SERVICE AND PARTS MANUAL SERVICE 9 . Check the electrical system and the air system. Air solenoid valve not shifting. PTO wil not shift to pump mode. check air compressor ion. Contact an authorized service person. hoses. tubing. PTO wil not shift out of pump mode. Drive line shaft problem. Moisture build up in the chassis air tanks. Contact an authorized service person. Leaking. ure bui ld up in the chassis air tanks. pressure. Check the electrical system and the air system. AQUATECH OPERATIONS. hoses. worn clutch pack assembly. air pressure. Replace leaking. Contact an authorized service person. area. Contact authorized Check the electrical syst em and thean air syst em. tubing. Air leak in the system. shifting. Check the electrical system and the air system. Contact an authorizedCheck service person. worn clutch pack assembly. piping and fittings. Test the Replace leaking. Vacuum pump will not engage. Replace leaking. Add auto drain syst em. Drive line shaft problem. piping and fittings. Add auto drain system. Air solenoid Air leakvalve in the systnot em. piping and fittings. again. Detent ball on shifting stem jammed or defective. SERVICE AND PARTS MANUAL AQUATECH OPERATIONS. Red light service person. emergency stops located in the side and rear system control panels. defective. Contact an authorizedContact service person. hoses. Contact an authorized service person. Contact an authorized service person. Vacuum pump will not stay engaged. wil il uminate on actuated valve spool. PTO did not disengage from road mode. Air leak in the system. check air compressor operation. Worn orDefect defective theshaft clutch an authorized service person. manual system on air valves. 100 120 is normal Check for airoperat leaks. Air leak in the system. pressure. Automatic transmissions hold a slight amount of torque Move unit forward or backward and attempt shifting on the system. Check for air leaks. pipoverride ing and fit ings. even in neut ralthe .SERVICE SERVICE PTO Troubleshooting Guide Caution moving parts OMSI PFT-PC4/3000 Hi-Vac P/N A164134 Problem ® A Product of Hi-Vac Corporation ® A Product of Hi-Vac Corporation Problem Cause Cause Correction Correction Water pump will not engage. Automatic transmissions hold a slight amount of torque Move unit forward or backward and attempt shifting Defective seals in the main input shaft control area. again. 100 to 120 is normal operating Check for air leaks. Replace leaking. Contact an authorized service person. broken belt. defective. piping and fit ings. sheared key way. 100 to 120 is normal operating pressure. broken belt. tubing. Red light wil il uminate on actuated valve spool. leaking. Air leakMoi instthe system. Air solenoid valve not shifting. Air leak in the system. SERVICE AND PARTS MANUAL SERVICE 10 . tubing. piping and fittings. tubing. Check for air leaks. 100 tto o 120 is normal operating operating Low air Low pressure. ive seals inseals the maiin n input controlpack. even in neutral. Leaking. Replace leaking. Re-shift PTO. check air compressor operation. Emergency stops engaged or pushed in. Water pump will not stay engaged. Detent ball on shifting stem jammed or defective. Test the manual override system on air valves. Low air pressure. Check the electrical system and the air system. Drain moisture from thReplace e system. sheared key way. Air solenoid valve not shifting. pressure. tubing. hoses. Worn orondefective seals in Engine stalls when engaging PTO. Low air pressure. clutch pack. Drain moisture from the system. hoses. hoses. check air compressor operation. the system. & at tighten Automat ic transmiand ssionsvacuum hold a slightpump amount ofdrive torque flange Move uni t forward orCheck backward and tempt shiftall ing mounting bolts. hoses. maybe dumping fluid into case. Contact an authorizedwhen service person. Red light wil il uminate on actuBreather ated valve spool . Check front seal in hydraulic Replace leaking. all mounting bolts. Air leak in the system. hoses. 14. Defective seals in the main input shaft control area. item # 17.SERVICE SERVICE PTO Troubleshooting Guide Caution moving parts OMSI PFT-PC4/3000 Hi-Vac P/N A164134 ® A Product of Hi-Vac Corporation ® A Product of Hi-Vac Corporation Problem PTO leaking oil out of case breather. Check ball could be vent again. SERVICE AND PARTS MANUAL SERVICE 11 . Correction PTO wil not shift to pump mode. ent ball on shi fting stem jammed or defective. Check the electrical system and the air system. again. worn or defective seal. Air solenoid valve not shifting. Contact an authorized service person. PTO overheating. pressure. check air compressor operation. shaft seal areas. PTO is over filled with ATF fluid. Replace leaking. Contact an authorizedContact service person. Red light tighten wil il uminate on actuCheck ated valve & spool . Air solenoid valveflange not shiftinbolts. Contact an authorized service person. Worn rubber vibration isolators. Cracked. Replace seal. housing. Check for air leaks. piping and fit ings. Replace frayed. Check input/output on the system. Air pressure coming out of the PTO case. 11. 100 to 120 is normal operating pressure. worn belts. even in neutral. Add aut o drain system. Contact an authorized service person. r pressure. hydraulic pump. PTO fluid level too high. drive sprockets and bearings. is set for 7# max. Check & replace if needed the four rubber isolators. Fluid level to low. unit is in PTO enable mode. Check engine parameters. Check water pump and vacuum pump drive belts. Pos. Seals leaking or defective in the input shaft control pump. Excessive vibration. PTO leaking oil. backward and attempt shifting Check the electrical system and the air system. piping and fit ings. Worn or Det defective bearing. Defective seals in the main input shaft control area. an authorized service person. # 10. Correction Check for air leaks. Case breather vent is plugged corroded or jammed. Detent balprogramming l on shifting stem jammed or defective. Defective vacuum pump or water pump solenoids. even in neutral. Moisture build up in the chassis air tanks. Radiator cooling fan should always be locked up mode AQUATECH OPERATIONS. Check water pump bolts. 100 to 120 is normal operating Worn clutch Clutch packs dragging. Check fluid level using gauge stick Moisture build up in the chassis air tanks. Add auto drain system. Air leak in the system. on the system. Low aidiscs. Excessive vibration and drive line chatter at low idle speed. Drain moisture from the system. Check & tighten all mounting bolts. Drain moisture from tAuxiliary he system. Loose mounting bolts. PTO wil not shift out of pump mode. check air compressor operation. tubing. Contact an authorized service person. Check and add fluid to recommended level. Problem Cause Cause Low air pressure. "Note you cannot blow 7#s by Automatic transmissions hold a slight amount of torque Move unit forward ormouth". g. tubing. CAP SCREW DIAMETER ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1-1/8 1-1//4 1-3/8 1-1/2 YIELD STRENGTH PSI MIN. 150000 150000 150000 150000 150000 150000 150000 150000 150000 150000 150000 150000 150000 150000 RECOMMENDED TORQUE UNC 12 25 50 85 125 175 245 425 660 990 1470 2100 2750 3640 UNF 15 30 60 95 140 195 270 460 700 1050 1655 2310 3110 4100 AQUATECH OPERATIONS. SAE Grade 5 ft. 120000 120000 120000 120000 120000 120000 120000 120000 115000 115000 105000 105000 105000 105000 RECOMMENDED TORQUE UNC 11 21 38 55 85 125 175 300 450 680 885 1255 1635 2180 UNF 13 23 40 60 95 140 210 330 490 715 990 1380 1875 2430 Alloy Hexagon Head Cap Screws. CAP SCREW DIAMETER ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1-1/8 1-1//4 1-3/8 1-1/2 YIELD STRENGTH PSI MIN. lbs.SERVICE Torque Specifications Aquatech B-Series ® A Product of Hi-Vac Corporation Alloy Cap Screws 1018 ft. SAE Grade 8 ft. 130000 130000 130000 130000 130000 130000 130000 130000 130000 130000 130000 130000 130000 130000 TENSILE STRENGTH PSI MIN. Bright CAP SCREW DIAMETER ¼ 5/16 3/8 7/16 ½ 9/16 5/18 ¾ 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 YIELD STRENGTH PSI MIN. 90000 90000 90000 90000 90000 90000 90000 90000 81000 77000 77000 77000 77000 77000 TENSILE STRENGTH PSI MIN. SERVICE AND PARTS MANUAL SERVICE 12 . lbs. 58000 58000 58000 58000 58000 55000 55000 55000 55000 50000 50000 40000 40000 40000 RECOMMENDED TORQUE UNC UNF 11 21 38 55 85 125 175 300 450 680 885 1255 1635 2180 13 23 40 60 95 140 210 330 490 715 990 1380 1875 2430 Heat Treated 1038 Hexagon Head Cap Screws. lbs. EVERY 300 HOURS THEREAFTER CHANGE AFTER THE FIRST 100 HOURS.5 QUARTS ISO-220/FACTORY SUPPLIED ISO-220/FACTORY SUPPLIED 2 QUARTS **SYNTHETIC/OPTIONAL HYDRAULIC SYSTEM WATER PUMP AND EXHAUSTER DRIVE LEG BEARINGS OIL RESERVOIR CHECK DAILY ANNUALLY 35 GALLONS AW 46 HYDRAULIC MONTHLY 100 HRS.SERVICE SCHEDULED LUBRICATION CHART ITEM ITEM DETAIL PIVOT PINS SWIVEL BEARINGS (TWO FITTINGS UNDER GEAR) BOOM EXTENSION ARMS WORM BEARINGS BOOM GEARS TIPPING PINS TANK TIPPING AND REAR DOOR CYLINDER PINS REAR DOOR HINGE PINS REEL BEARINGS REEL REEL SWIVEL BEARING REEL CHAIN ® A Product of Hi-Vac Corporation INSPECT MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY SCHEDULE 100 HOURS 100 HOURS 100 HOURS 100 HOURS 100 HOURS 100 HOURS 100 HOURS 100 HOURS 100 HOURS WEEKLY 100 HOURS CHANGE AFTER FIRST 50 HOURS. EVERY 500 HOURS THEREAFTER CHANGE AFTER FIRST 50 HOURS. EVERY 300 HOURS THEREAFTER CHANGE EVERY 500 HRS CHANGE EVERY 500 HRS CHANGE EVERY 500 HRS QUANTITY 1-2 SHOTS 1-2 SHOTS 1-2 SHOTS 1-2 SHOTS COAT LIGHTLY 1-2 SHOTS 1-2 SHOTS 1-2 SHOTS 1-2 SHOTS 1-2 SHOTS COAT LIGHTLY LUBRICANT LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER LITHIUM #2 SHORT FIBER WATER PUMP (GENERAL MSS) CRANKSHAFT OIL CHECK DAILY 10. EVERY 500 HOURS THEREAFTER 4. 1-2 SHOTS LITHIUM #2 SHORT FIBER AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL SERVICE 13 .8 QUARTS ISO-220 PTO #164134 MAIN HOUSING CHECK WEEKLY 6 QUARTS DEXTRON III TRANSMISSION FLUID EXHAUSTER (ROOTS/624) GEAR END OIL DRIVE END OIL CHECK DAILY CHECK DAILEY 55 OUNCES 28 OUNCES ISO-220/FACTORY SUPPLIED ISO-220/FACTORY SUPPLIED **SYNTHETIC/OPTIONAL ISO-220/FACTORY SUPPLIED **SYNTHETIC/OPTIONAL EXHAUSTER (ROOTS 824/827) DRIVE END OIL CHECK DAILY 8 OUNCES EXHAUSTER (HIBON/TS56) GEAR END OIL DRIVE END OIL CHECK DAILY CHECK DAILY CHANGE AFTER FIRST 100 HOURS.5 QUARTS ISO-220 WATER PUMP (GENERAL MK) CRANKSHAFT OIL CHECK DAILY 14. HYD SUCTION FILTER CHECK DAILY CHANGE FILTER AFTER 50 HRS CHANGE ANNUALLY THEREAFTER CHANGE WHEN INDICATOR IS RED A110516 IN-TANK RETURN FILTER CHECK DAILY A110000-3 HIGH PRESSURE FILTER CHECK PERIODICALLY REPLACE EVERY SIX MONTHS OR SOONER A383754 LAST CHANCE FILTER CHECK QUARTERLY CLEAN WHEN CHECKING OTHER FILTERS A383767 AQUATECH OPERATIONS.SERVICE ® A Product of Hi-Vac Corporation FILTER REPLACEMENT ITEM DETAIL INSPECT SCHEDULE PART NO. SERVICE AND PARTS MANUAL SERVICE 14 . � � � � � � � � � � � � AQUATECH OPERATIONS. 4. Consult manual for specific interval. Grease weekly. 2. 3.SERVICE ® A Product of Hi-Vac Corporation B-SERIES STANDARD UNIT LUBRICATION CHART NOTES: 1. Multiple fittings usually indicates one on each side. **Indicates brush-on grease. SERVICE AND PARTS MANUAL SERVICE 15 . Vacuum tube o-rings should be greased once a week. LUBRICATION POINTS ITEM � � � � � � � � � �� �� �� � ��� �� DESCRIPTION �� � �� �� �� � � � � � � � ��� ��� ��� ��� � � � � ���� � �� � ��� ��� � � �� � � ��� � � ��� � � �� � � � � � � � ��� � � � ��� �� ��� � � �� � �� � � � � � � � ��� � �� � �� � �� � � � � � � �� � � � �� ���� �� ���� � ���� ��� ��� � �� � � � ����� � ��� � � ��� � �� � �� � � ���� �� �� � �� � ��� ��� � � QTY. Light Bulb Lens. SERVICE AND PARTS MANUAL CONTROLS 1 .CONTROLS PENDANT CONTROL PART # A122170 (B-10/5/15/52) ® A Product of Hi-Vac Corporation 1 CABLE NOT SHOWN 8 2 5 6 7 3 3 4 4 FLAPPER CLOSED LIGHT FLAPPER CLOSE BOOM UP BOOM DOWN BOOM OUT BOOM IN 3 4 3 4 BOOM LEFT BOOM RIGHT ITEM PART # DESCRIPTION QTY ITEM 1 2 3 4 5 6 7 8 PART 121718 122303 122401 122402 122403 122404 120465 122405 DESCRIPTION Cable Legend Plate Push Button-Black Contact Switch. N/O Block Module. Red Light Bulb Pendant Box QTY. 1 1 7 7 1 1 1 1 AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL CONTROLS 2 . GREEN HOSE RETRACT/EXTEND SWITCH ARTICULATE IN-OUT WATER PUMP/EXHAUSTER SWITCH SWITCH PROTECTOR POTENTIOMETER QTY 1 1 1 1 1 2 1 2 2 4 1 AQUATECH OPERATIONS. 11 Throttle Toggle Switch used with all other engines.CONTROLS REAR CONTROL PANEL ® A Product of Hi-Vac Corporation 3 1 6 5 10 9 8 2 10 9 8 7 4 Potentiometer used with Cummins/Mercedes engine only. VACUUM/PRESSURE GAUGE. ITEM 1 2 3 4 5 6 7 8 9 10 11 PART # 131765 131786 383409 120861 380131 122003 120861 120610 120861 120145 249014 DESCRIPTION GAUGE. WATER PRESSURE TACHOMETER THROTTLE SWITCH EMERGENCY STOP SWITCH LIGHT INDICATOR. CONTROLS SIDE CONTROLS ® A Product of Hi-Vac Corporation 3 5 1 2 3 4 2 ITEM 1 2 3 4 5 PART NO. SERVICE AND PARTS MANUAL CONTROLS 3 . 120861 120145 380131 120861 249014 DESCRIPTION SWITCH MON .OFF-MON SWITCH BOOT EMERGENCY STOP FRONT/REAR THROTTLE CONTROL SWITCH THROTTLE POTENTIOMETER QTY 6 7 1 1 1 AQUATECH OPERATIONS. 1 1 6 6 2 4 AQUATECH OPERATIONS.CONTROLS ® A Product of Hi-Vac Corporation FOOT CONTROL SUB-ASSEMBLY PART #242110-1 1 2 3 4 5 ITEM 1 2 3 4 5 PART # 176076 242112 103548 107010 110336 DESCRIPTION COIL TWIN POLY TUBE FOOT PEDAL CAPSCREW HEX NUT PNEUMATIC FOOT PEDAL QTY. SERVICE AND PARTS MANUAL CONTROLS . POWERTRAIN ® A Product of Hi-Vac Corporation SPLIT SHAFT PTO Part #A380643 AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL POWERTRAIN 1 . SERVICE AND PARTS MANUAL WATER SYSTEM 1 .WATER SYSTEM ® A Product of Hi-Vac Corporation WATER SYSTEM REAR REEL 1 2 4 3 ITEM 1 2 3 4 PART # 130727-1 130962 130820 130920 DESCRIPTION SWIVEL HANDGUN RELIEF VALVE MALE QUICK DISCONNECT 3-WAY BALL VALVE QTY 1 1 1 1 AQUATECH OPERATIONS. WATER SYSTEM WATER MANIFOLD ASSEMBLY 241239-3 ® A Product of Hi-Vac Corporation 14 11 16 7 9 6 13 8 2 5 12 1 4 15 ITEM � � � � � � � � � �� �� �� �� �� �� 3 PART NO. ������ ������ ������ ������ ������ � � � � � � �� ������ ������ ������ ������ ������ ������ ������ ������ � � � � � � �� DESCRIPTION � � � �� � � �� ������� ���� � �� �� ���� � � � � �� � � �� � �� � �� � �� �� � � �� � � � � �� � �� ���� � ����� ���� �� �� � � �� � ���� ���� ���� � ���� �� �� � � �� � ���� � � � �� � �� ���� �� �� ��� ��� ���� � � � �� �� � � � ���� �� ��� ��� ���� � �� ���� �� �� ��� ��� ���� � �� � ����� � �� �� � � �� � ���� �� ���� � �� �� �� ���� ���� � QTY. SERVICE AND PARTS MANUAL � 2 . � � � � � � � � � � � � � � WATER SYSTEM AQUATECH OPERATIONS. WATER SYSTEM ® A Product of Hi-Vac Corporation 1” RELIEF VALVE 2000 PSI PART # 130963 ADJUSTMENT SCREW LOCK NUT OUTLET OUTLET INLET AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL WATER SYSTEM 3 . SERVICE AND PARTS MANUAL WATER SYSTEM 4 .WATER SYSTEM ® A Product of Hi-Vac Corporation PRESSUE RELIEF VALVE 800 PSI PART # 130962 ITEM � � � � � � � � � PART # ������ ������ ������ ������ ������ ������ ������ ������ ������ DESCRIPTION � � � � � � �� � � � � � � �� � � � � � �� �� ����� � ���� �� �� � � ���� � � � �� � � � �� � � �� � �� ��� � � � � � � � ��� �� �� �� � ��� ��� � �� ��� �� �� � � �� QTY. � � � � � � � � � AQUATECH OPERATIONS. WATER SYSTEM 1 ® A Product of Hi-Vac Corporation 2 3 6 4 5 ITEM 1 2 3 4 5 6 STRAINER HOUSING NOT SHOWN PART # 380820 380820-1 380820-3 380820-4 380820-5 240034 DESCRIPTION “Y” STYLE SUCTION STRAINER. 3” POLY SCREEN. SERVICE AND PARTS MANUAL WATER SYSTEM 5 . 1/16” PERF STRAINER CAP CAMLOCK CAP STRAINER HOUSING O-RING. CAP QTY 1 1 1 1 1 1 AQUATECH OPERATIONS. WATER SYSTEM ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL WATER SYSTEM 6 . � � � � � � � � � � �� �� �� � � � � � � AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL VACUUM SYSTEM 1 .VACUUM SYSTEM EXHAUSTER AND DUCTING ASSEMBLY ® A Product of Hi-Vac Corporation 16 2 17 18 7 11 12 6 3 5 5 10 4 15 8 9 14 1 11 12 13 ITEM � � � � � � � � � �� �� �� �� �� �� �� �� �� � � � �� � �� PAR T # ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ D ESC R IPTION ��� � � �� �� �� �� �� �� � ������� � ���� � �� �� ��� � � � ��� ������ � � �� � �� ��� ��� � � � � � � � ��� � � � � � �� �� � � � �� ����� � �� � � � ��� � � � � � � � � � � �� ��� ��� � �� �� �� �� � � �� �� �� � � �� �� ��� � � � �� � � ���� ���� � ������� � � � � �� � � � � � �� � � � � �� �� ����� � �� �� � � � �� � �� � QTY . SERVICE AND PARTS MANUAL 1 .HYDRAULIC SYSTEM VELOCITY CHECK VALVE ASSEMBLY PART #164571 ® A Product of Hi-Vac Corporation 4 2 5 1 1 3 ITEM � � � � � PART # ������ ������ ������ ������ ������ DESCRIPTION � �� �� ��� �� � � ��� ���� ���� �� � � � ���� �� � � � � ���� �� ���� �� � ���� ���� �� � � � � ���� � � � ���� ���� � �� � �� �� ��� �� �� ���� ���� � ���� �� � � ��� � ��� � ��� � � � �� � QTY. � � � � � HYDRAULIC SYSTEM AQUATECH OPERATIONS. HYDRAULIC SYSTEM REAR DOOR HYDRAULICS ® A Product of Hi-Vac Corporation 2 1 4 5 3 4 5 ITEM 1 2 3 4 5 PART # 110015-1-RJ 246182 110019 246183 107323 DESCRIPTION HYDRAULIC CYLINDER KNUCKLE. SERVICE AND PARTS MANUAL HYDRAULIC SYSTEM 2 . REAR DOOR CYLINDER INTEGRATED VALVE ASS'Y (CHECK/RELIEF) PIVOT PIN.QTY 1 1 1 2 2 AQUATECH OPERATIONS. REAR DOOR CYLINDER COTTER PINX 2"1/4" . 380839 135910 383241 135490 DESCRIPTION REEL MOTOR #10 MSAE X #10 MJIC STR. ADAPTER HYDRAULIC RACK & PINION ACTUATOR #8 MSAE X #8 MJIC 90 DEGREE ELBOW QTY 1 2 1 2 AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL HYDRAULIC SYSTEM 3 .HYDRAULIC SYSTEM REAR REEL ACTUATION ASSEMBLIES ® A Product of Hi-Vac Corporation 4 3 1 2 ITEM 1 2 3 4 PART NO. HYDRAULIC SYSTEM 4 SPOOL REEL CONTROL VALVE ASSEMBLY 110517-2 ® A Product of Hi-Vac Corporation 5 7 1 6 4 3 2 ITEM 1 2 3 4 5 6 7 PART NO. 135436 135250 135175 110517 -24 135340 135500 249366 DESCRIPTION #8 MSAE X #8 MJIC 45 DEGREE ADA PTER RUN#8 MJIC X #8 MJIC X #8 FJIC TEE (PUMP OFF OPTION ONLY) #8 MSAE X #8MJIC X #8MJIC RUN TEE 4 SPOOL VA LVE #8 MSAE X #8 MJIC 90 DEGREE ELBOW #8 MSAE X #8 MJIC STRAIGHT ADA PTER 5 GPM PC FLOW CONTROL VALVE QTY 2 1 3 1 2 1 2 AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL HYDRAULIC SYSTEM 4 . SERVICE AND PARTS MANUAL HYDRAULIC SYSTEM 5 .HYDRAULIC SYSTEM BOOM HYDRAULIC MOTOR ASSEMBLY ® A Product of Hi-Vac Corporation 1 3 2 ITEM � � � PART NO. � � � AQUATECH OPERATIONS. ������ ������ ������ DESCRIPTION �� ��� � ��� �� � � � � � ���� � � � ���� �� ��� ��� ���� � � �� �� �� � �� ��� � � � � ���� �� �� � � � � � �� QTY. 4 SPOOL 24 VOLT VALVE ASSEMBLY 110517-2 ® A Product of Hi-Vac Corporation 1 MANUAL OVERRIDE 2 TYP 6 PLACES 3 MANUAL OVERRIDE ITEM 1 2 3 PART # 110517-24 135500 135301 DESCRIPTION INTEGRATED VALVE ASSY 24 VOLT #8 MSAE X #8 MJIC STRAIGHT ADAPTER #6 MSAE X #4 MJIC 90 DEGREE ELBOW QTY 1 6 1 6 AQUATECH OPERATIONS.HYDRAULIC SYSTEM BOOM CONTROL . SERVICE AND PARTS MANUAL HYDRAULIC SYSTEM . HP HYD FILTER. SERVICE AND PARTS MANUAL 7 . PALL.HYDRAULIC SYSTEM ® A Product of Hi-Vac Corporation 1 2 *PALL FILTER IS LOCATED FRONT OF POWERDECK *LAST CHANCE FILTER LOCATED ON TOP OF BOOM CONTROL VALVE ASSEMBLY ITEM 1 2 PART # 383754 383767 DESCRIPTION FILTER. LAST CHANCE QTY 1 1 HYDRAULIC SYSTEM AQUATECH OPERATIONS. 1 DESCR IPTION VALVE.TANK TIPPING QTY 1 HYDRAULIC SYSTEM AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL 8 .HYDRAULIC SYSTEM ® A Product of Hi-Vac Corporation 1 *When ordering parts always specify unit serial number. ITEM 1 PART # 110083. SERVICE AND PARTS MANUAL 1 .PNEUMATIC SYSTEM 1 2 3 ® A Product of Hi-Vac Corporation 4 5 6 8 8 8 7 *GREEN LIGHT – POWER ON * RED LIGHT .ENGAGED ITEM 1 2 3 4 5 6 7 8 PART# A100021-24CO A383737 A383736 A383733 A383733 A383733 A383734 A135406 DESCRIPTION PNEUMATIC INSTAL. SMC VALVES SMC WATER SEPARATOR SMC OIL SEPARATOR FLAPPER WATER BLOWER PTO OUT QTY 1 1 1 1 1 1 1 6 PNEUMATIC SYSTEM AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL PNEUMATIC SYSTEM 2 .PNEUMATIC SYSTEM ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. OPEN RING ANGLE SPROCKET (BOTTOM) NIPPLE CAP SPROKET (TOP) CHAIN HYDRAULIC MOTOR QTY.REEL HOSE. SERVICE AND PARTS MANUAL 1 . 1 1 1 1 1 1 1 1 1 1 1 1 BODY AQUATECH OPERATIONS.BODY REEL ASSEMBLY 240255-2 ® A Product of Hi-Vac Corporation 5 2 1 7 3 9 4 8 6 10 12 11 7 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART # 240309-1 240310-1 242874 242875 242718 246304 240312 132460 246187 160220 160440-19 380839 DESCRIPTION REEL SIDE PLATE REAR REEL SIDE PLATE FRONT SPOOL CENTER SHAFT . SERVICE AND PARTS MANUAL BODY 2 .BODY AIR PORTAL ASSEMBLY 242814 ® A Product of Hi-Vac Corporation 3 1 2 4 ITEM 1 2 3 4 5 PART # 154090 190230 154080 222005 176290 DESCRIPTION PORTAL BAR GASKET 11-3/4” I. PORTAL COVER CHECK BALL STAINLESS STEEL BALL SEAT QTY 1 1 1 1 1 AQUATECH OPERATIONS.D. SERVICE AND PARTS MANUAL BODY 3 .D.BODY ® A Product of Hi-Vac Corporation HOSE ASSEMBLY 1 2 ITEM 1 2 PART # 176630 220698 DESCRIPTION HOSE. 8” I. X 80” 8” POWER LOCK CLAMP QTY 1 2 AQUATECH OPERATIONS. BODY FILLER ASSEMBLY. SERVICE AND PARTS MANUAL BODY 4 . POLY TANK 243768-1 ® A Product of Hi-Vac Corporation 3 4 4 2 1 6 5 7 8 9 ITEM � � � � � � � � � PART # � � � � � � �� � � � � � � � �� � � � � � � � �� � ������ ������ ������ ������ ������ ������ DESCRIPTION � � � � � � � � � � � � � �� � � � � � � � � � � � � � � � �� � � � �� � � � � � � � � � � �� � �� �� � �� �� � ���� � � ��� � � ��� �� � �� �� � ��� � ����� � � �� � � � � � � � �� �� �� ��� �� ���� �� �� � ���� �� �� ���� ���� �� � � � ���� �� QTY. � � � � � � � � � AQUATECH OPERATIONS. HEAT TEMPERED GLASS GASKET QTY 1 1 1 1 1 BODY AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL 5 .BODY ® A Product of Hi-Vac Corporation SIGHT EYE ASSEMBLY 1 2 5 3 4 ITEM 1 2 3 4 5 PART # 153013 153000 153014 152890 153012 DESCRIPTION HAND WHEEL FRAME SIGHTEYE PRESSURE PAD LENS. BODY ® A Product of Hi-Vac Corporation BOOM TURRET ASSEMBLY 9 10 1 11 12 2 13 14 3 4 5 6 17 7 8 15 16 AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL BODY 6 . SERVICE AND PARTS MANUAL 7 . � � � � � � � � � ������ � �� ������ � �� ������ �� �� �� �� �� �� �� ������ ������ ������ ������ ������ ������ �� �� �� �� �� � BODY AQUATECH OPERATIONS.BODY ® A Product of Hi-Vac Corporation BOOM TURRET ASSEMBLY BILL OF MATERIAL ITEM � � � � � � � � PART # ������ ������ ������ ������ ������ ������ ������ ������ DESCRIPTION � � � � �� � � � � �� � � ������ � � ���� � ������ ��� ��� � � � ���� �� � �� ��� ��� � �� � � � � � �� ��� ��� � �� � � � �� �� � �� � �� � � � � ���� �� � � � �� � ��� � � � � �� � ������ � �� �� � �� � ��� ��� � � � � � � �� ���� �� � � �� ���� ������� � ������ �� � � � � � � �� � � � � � � � � � �� ����� ��� � �� �� � � �� ���� ������ � ������ �� � � �� � � �� � � � � � � � � � �� ���� �� � � �� ���� ������ � ������ ��� � � � � � � � � � �� ���� �� � � �� ���� � �� � �� � QTY. SERVICE AND PARTS MANUAL BODY 8 .BODY ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. (LH) 8" BOOM LIFT CYLND.. (RH) ANCHOR A RM. SERVICE AND PARTS MANUAL BODY 9 . GR. ASSY GANTRY 8" BOOM EXTENTION TUBE ASSY.BODY ® 8” BOOM ASSEMBLY BILL OF MATERIAL PAGE 2 OF 3 A Product of Hi-Vac Corporation ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PART # 240932 249777 241116 241117 241285-RJ 238440 240950 110210-RJ 192011 245581 192010 238446 160199-1 102700 107170 238409 238444 160284 241115 190907 105172 107298 DESCRIPTION TURRET HOUSING WELDMENT PNEUMATIC CYLINDER ANCHOR A RM. A SSY. 8" BOOM HOSE PIN CYLINDER ROD BUSHING PIN ANCHOR PLATE PIVOT "O" RING 1/2-13 x 1" LG. A SSY. CYLINDER 8" VALVE SEAT BOOM TUBE LOCK COUPLING 8" BOOM HOSE FLANGE GASKET A DA PTER CYLINDER MOUNTING CLA MP (WITHOUT LATCH PLATE) 3/16" x 2" SPLIT RING 1"-14 JAM NUT ROLLER. 8 HEX HD.QTY 1 1 1 1 1 1 1 1 1 1 3 1 2 4 1 5 1 2 2 1 12 24 AQUATECH OPERATIONS. CA P SCREW 1/2" PLATED LOCK WASHER . BODY 8” BOOM ASSEMBLY BILL OF MATERIAL PAGE 3 OF 3 ® A Product of Hi-Vac Corporation ITEM �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� �� PART # ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ � � � � � � �� � � � � � � � �� � ������ � � � � � � �� � ������ ������ ������ ������ ������ DESCRIPTION ����� �� � � �� ���� ������� � �� � ��� ��� � � � � � � �� � � �� �� ��� ������� � � � ������� � ��� � �� � � �� � � � � � � � � � �� ���� ��� � � �� � � ��� �� � ����� �� � � �� ���� � �� � � ��� � �� � � �� �� ��� �� ���� � ������ � �� �� � �� � � ��� � � ��� ��� �� �� ���� � ���� � �� �� � ���� � ��� � � � �� ���� � ���� � �� �� � ���� � ��� � � � �� ���� ���� �� �� ��� � ��� ���� � ������ �� � � � � � � � � �� � ������ � ������ �� � � �� � � �� � � � � � � �� � � �� �� � � � �� ��� � ��� � � �� �� � � � �� ��� � ��� ���� � �� � ��� �� ���� �� � � � � ��� � � � ������� QTY. � � � � � � � � � � � � � � � � �� � � � � AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL BODY 10 . 241090 AQUATECH OPERATIONS.BODY ® A Product of Hi-Vac Corporation WORM GEAR DRIVE BEARING ASSEMBLY PART No. SERVICE AND PARTS MANUAL BODY 11 . BODY WORM GEAR DRIVE BEARING ASSEMBLY PART No. � � � ������ � � � � � � � �� �� �� �� �� �� �� �� �� �� ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ � � � � �� ������ ������ ������ ������ ������ � � � � � � � � � � � � ��� � � � AQUATECH OPERATIONS. BILL OF MATERIAL ® A Product of Hi-Vac Corporation ITEM � � PART # ������ ������ DESCRIPTION ����� �� � � �� ���� ������ � ������ �� � � �� � �� � � � � �� �������� � ������ �� � �� � ��� ��� � � � � � � �� ������ � ������ �� � �� � � �� � � � � � � � � � �� ���� �� � � �� ����� � �� � � � �� � �� ���� �� � � �� ����� � �� � � � �� � �� � ����� � ���� �� � � � ��� � �� ���� � ���� �� � ����� � �� �� � �� ��� ��� � �� � � � � � �� ��� ��� � �� � ���� �� � �� � � ��� �� ���� �� � ������ � ������ �� � �� �� ���� �� � �� �� �� �� ��� ��� � �� � � � �� �� �� �� � � ��� � ��� �� �� ��� ��� � � ���� � �� � �� �� ��� ��� � � � � �� ��� � �� �� �� ��� ��� � �� �� ��� � QTY. 241090. SERVICE AND PARTS MANUAL BODY 12 . SERVICE AND PARTS MANUAL BODY 13 .BODY ® A Product of Hi-Vac Corporation HINGED TANK SUPPORT PROP 1 4 3 2 ITEM 1 2 3 4 PART # 245057 238216 238196 238227 DESCRIPTION TANK PROP CUP WELDMENT BODY PROP WELDMENT BODY PROP ARM WELDMENT TUBE CONNECTOR TOOL QTY 1 1 1 1 AQUATECH OPERATIONS. Secure the lower end of the tank straps to the tank trays using the holes provided. Adjust the tension of the turnbuckles until fully secure. lubricate the rubber seal located at the rear tank connection port. Push the front tank into position inserting the 6" PVC connector. place one lock washer followed by one beveled washer on each of the tension bolts. Please refer to INSTALLATION OF WATER FILL LINE WELDMENT #246145 before continuing this assembly. 7. and Eight beveled washers. 5. and nuts. Eight turnbuckles. Attach the “U” shaped end to the strap retainers located at either side of the debris tank as shown. Tighten securely. 4.BODY POLYTANK INSTALLATION INSTRUCTIONS ® A Product of Hi-Vac Corporation 1. locate the return line connections located at the top of the rear tanks. Repeat front and rear both sides. Locate the remaining 8 bolts. Eight lock washers. Locate the following items: Eight tank straps. lock washers. With the turnbuckles attached. Lift the entire right polytank assembly into position with the base of the tanks resting firmly in the tank trays. washers. Rubber seal Right Rear Polytank PVC Connector Right Front Polytank 3. Once the polytanks are in place and secured. Place the tension bolts (w/washers) through the top hole of the tank strap and thread it back into the turnbuckle. The reservoir located at the base of the rear tank should rest in the cut out section provided. Remove the tension bolt from the turnbuckles. Using a liquid dish soap. DO NOT TIGHTEN! Repeat front and rear both sides. SERVICE AND PARTS MANUAL BODY 14 . Tank Strap Return Line Connection AQUATECH OPERATIONS. Repeat same procedure for left side. Lock Washer Tank Strap Retainer Beveled Washer Tension Bolt Tension Bolt Turnbuckle Tank Strap 6. Align the holes located at the top of the polytanks with the strap retainers mounted on the debris tank. 2. Remove the fastener from the “U” shaped end and place the turnbuckle through the spaces in the top portion of each polytank. Assemble the right side polytank sections as shown. 3) Top Strap Retainer #243514 Water Tank Strap Ass'y #244142 (Qty. SERVICE AND PARTS MANUAL BODY 15 . Cap Screw TOP VIEW FILL LINE ASSEMBLY Water Fill Line Support Weldment #246145 Turnbuckle 5/8" x 6" #223641 Polytank Fill Line Assembly #243768-1 1" x 1.BODY INSTALLATION OF WATER FILL LINE WELDMENT #246145 ® A Product of Hi-Vac Corporation When installing the Water Fill Line Support Weldment it will be necessary to replace the existing cap screw that fastens the right front turnbuckle to the top strap retainer and the support weldment with cap screw provided.5" x 25" 113 #236105-159 (Qty. 8) VIEW FRONT RIGHT POLYTANK WITH FILL LINE ASSEMBLY FRONT VIEW AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL Part # A Product of Hi-Vac Corporation BODY 246108 246109 246116 246117 246118 246119 246120 246122 246123 Front Left B15 Front Right B15 Left Rear B15 Right Rear B15 Front Right/Left B10/52 Middle Tanks B15 Left Rear B10/52 Left B6 Right Rear B10/52 Right B6 Standard Lid Fill Line Lid ® Bottom View 16 .BODY Top View Outside View Front View Rear View Inside View POLYETHYLENE WATER TANK AQUATECH OPERATIONS. 00 to US$ 150. Some manufacturers include Master. Cleaning the affected area is very important. Weller and Ideal. and varying the distance of the gun from the surface of the material. Weller is a respected manufacturer of good soldering tools. experience is the best judge of which particular tool to obtain. or at common retail outlets such as Sears. Cracks and holes When a crack or hole has developed in the polyethylene material another approach is advisable. SERVICE AND PARTS MANUAL BODY 17 . Use a smooth metal tool such as a spoon or spatula to work the material to conform with the surrounding surface. Recommended tools Tools recommended are a heat gun. then the tool can restore the smooth surface. work the heat in a circular motion around the blemished area until the surface begins to become shiny. Repaired sections can be put into service immediately upon cooling. Repeat as many times as necessary to build the affected area up to the surrounding surface. Repair technicians must exercise prudent caution against melting completely through the poly material.00. 1000-1300 watts. dip the hot tip into granulated polyethylene (provided by Aquatech) and work small amounts into the crack or hole. It may be necessary to scrape away some of the material if it is badly contaminated with grease.BODY POLYTANK REPAIR General Informafion ® A Product of Hi-Vac Corporation Repairs to polyethylene tanks can be performed easily with a miniInurn of training. By allowing just enough flow to fill any surrounding blemishes. Aquatech does not recommend the use of a torch to repair poly tanks. oil or dirt. in the range of 1000 to 1300 watts allow the application of heat in controllable amounts to avoid quick burn through which is possible with a flame such as from a propane torch. Typical repairs will involve repair of two basic types of damage: blernishes to the surface. In cases where the material may have been heavily gouged. AQUATECH OPERATIONS. and using a smooth metal obj ect such as a spoon or spatula. A heat gun may used as a final step to completely smooth the area. A soldering gun capable of accepting altemate tips is also recommended. Using the heat gun. Such guns. flat tip suitable for working with plastics. At this point the technician should become Vely careful as the poly material is beginning to liquefy and will begin to flow. or purchased from body shop suppliers. What this means is that the technician must realize that dire consequences are possible but not likely if he/she is reasonably careful. Then apply heat using an electric heat gun. Several manufacturers offer such a gun in the price range of US$60. Repeat the procedure on the opposite side if possible. the use of a stick of polyethylene material melted into the affected area can help fill it. Such soldering guns can be purchased at electronic supply houses such as Radio Shack. and some material has been lost. and cracks or holes through the material. Since many different applications are possible. Using an electric soldering gun with a wide. Areas repaired with either technique will have all the qualities and properties of strength and stability as the original area. but extreme caution is generally not necessary. the material can be manipulated and be made smooth. Blemish repairs Blemishes to the surface of the poly tank can usually be repaired by first cleaning the area to remove any grease. but is not required. Forming tools which are metal and smooth can be made from common items such as kitchen utensils. A different repair approach will be appropriate for each type of damage. although there are cases where this will clearly be impossible. oil or dirt. The repair is best done when it can be approached from both sides. These heat guns are also excellent tools for thin wall shrink tubing and special solder/shrink electrical terminals. HOSE ������ ������ ������ ������ � �� � ���� �� � � �� � � � � � �� � � � �� � � � � � � � �� � �� � �� � � � �� � � � � ���� � � �� � � � � � � � �� � ������� � � � � 131629 A DJ USTING HA NDGUN A SSEMB LY W/50 FT. HOSE ������ ������ ������ ������ � �� � ���� �� � � �� � � � � � �� � � � �� � � � � � � � �� � �� � �� � � � �� � � � � ���� � � �� � � � � � � � �� � ������� � � � � 131626 A DJ USTING HA NDGUN A SSEMB LY W/35 FT. SERVICE AND PARTS MANUAL STANDARD EQUIPMENT 1 .STANDARD EQUIPMENT HANDGUN ® A Product of Hi-Vac Corporation 131625 A DJ USTING HA NDGUN A SSEMB LY W/25 FT. HOSE ������ ������ ������ ������ � �� � ���� �� � � �� � � � � � �� � � � �� � � � � � � � �� � �� � �� � � � �� � � � � ���� � � �� � � � � � � � �� � ������� � � � � AQUATECH OPERATIONS. HOSE ������ ������ ������ ������ � �� � ���� �� � � �� � � � � � �� � � � �� � � � � � � � �� � �� � �� � � � �� � � � � ���� � � �� � � � � � � � �� � ������� � � � � 131628 A DJ USTING HA NDGUN A SSEMB LY W/45 FT. STANDARD EQUIPMENT ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL STANDARD EQUIPMENT 2 STANDARD EQUIPMENT HINGED REAR DOOR STRAINER ® A Product of Hi-Vac Corporation 1 10 5 6 7 2 8 3 4 9 ITEM � � � � � � � � � �� PART NO. ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ DESCRIPTION ��� � � ��� �� ��� � � ������� � � � � � �� �� � �� � � � � � � � � � � �� �� � �� � � ���� � �� ��� �� ��� ���� � �� � � �� � � � � � ���� ��� � �� ���� � ���� ��� � �� �� �� ��� ��� � �� �� � � ��� � � ��� � QTY. � � � � � � � � � � AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL STANDARD EQUIPMENT 3 OPTIONAL EQUIPMENT ® A Product of Hi-Vac Corporation KD UNITS instructions for mounting rear bumper and splash guard Description: The bumper assembly and splash guard are two separate components. The bumper and splash guard are tacked on the ends for shipping. They will need readjusting for assembly. The bumper assembly has one horizontal bar with two vertical bars extending from the horizontal bar. The splash guard is a flat rectangular sheet of metal that is weld onto the top of the vertical bars. The two sections are mounted to the rear of the tank. When the tank is in tipping operation the bumper and splash guard will tip with the tank when properly mounted. This provides for a smooth run-off when the debris tank is being emptied. It is important to mount the bumper and splash guard in the proper location. This will prevent problems when dumping and tipping the debris tank. On the bottom rear of the debris tank is the tank hinge assembly. The hinges are on the left and right sides of the debris tank. At the bottom of the debris tank, just below the tank opening, is the “cover plate bumper mount.” The cover plate bumper mount is positioned between the left and right tank hinge assembly. Weld the bumper and splash guard to the cover plate bumper mount. Mounting the bumper: Locate the center of the cover plate bumper mount and the center of the bumper assembly. Align the two centers together. Leave approximately ¼" space from the bottom edge of the cover plate bumper mount when mounting the bumper assembly to the cover plate bumper mount. When welding the bumper to the cover plate bumper mount, it is helpful to have two additional persons to hold the bumper in position. Weld the bumper to the cover plate bumper mount. Mounting the splash guard: Once the bumper assembly is mounted to the tank, weld the splash guard to the bumper assembly. Place the guard on top of the bumper assembly vertical bars extending from the cover plate bumper mount. The guard should fit perfectly onto the bumper assembly. If the guard is a little long or short, adjust it to fit snugly to the bumper. When the guard is in place weld it to the bumper. Note: Do not weld the bumper and splash guard to the truck chassis. This will cause difficulty when dumping and tipping the unit. The bumper assembly was designed to tip with the debris tank. If you have any question regarding mounting procedures contact our service department at 1-800-800-1016. Tank Hinge Assembly Bumper Assembly Splash Guard Bumper Splash Guard Cover Plate Bumper Mount Cover Plate Bumper Mount AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL OPTIONAL EQUIPMENT 1 SERVICE AND PARTS MANUAL OPTIONAL EQUIPMENT 2 .OPTIONAL EQUIPMENT ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. The Water Flow Adjustment Valve (Item #2) provides control for the amount of flow directed to the hose reel or back to the tank.OPTIONAL EQUIPMENT ® A Product of Hi-Vac Corporation REMOTE FLOW-SELECT WATER REGULATOR SYSTEM All “B” series units with the optional “Remote Flow-Select Water Regulator System” have the controls incorporated at the rear reel operator’s station. The operation of the standard Three Way Water Control Valve remains the same as the standard unit. pull the water flow handle up (on position). To lower water pressure. push the water flow handle down (off position). the amount of water directed to the hose reel decreases. or back to the water tanks (in the “OFF” position). To raise water pressure. The Water Flow “ON-OFF” Valve (Item #1) provides control of the water system flow.350 PSI) AQUATECH OPERATIONS. By turning the adjustment knob of this valve clockwise. By turning the knob counterclockwise. then raise the air pressure to desired psi by turning the water flow adjustment. the amount of water directed to the hose reel increases. 1 2 3 ITEM 1 2 3 PART # 380653 249018 215555 DESCR IPTION AIR REGULATOR PNEUMATIC VALVE PNEUMATIC UNLOADER VALVE (GENERAL PUMP) (2. then reduce the air pressure to 0 psi by turning the water flow adjustment. SERVICE AND PARTS MANUAL OPTIONAL EQUIPMENT 3 . The function of this valve is to direct the water flow to the hose reel water manifold (in the “ON” position). SERVICE AND PARTS MANUAL OPTIONAL EQUIPMENT 4 .OPTIONAL EQUIPMENT ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL OPTIONAL EQUIPMENT 5 .OPTIONAL EQUIPMENT ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. 8" diameters are aluminum.ACCESSORIES ® A Product of Hi-Vac Corporation High quality Aquatech intake and extension tubes. Tube Diameter 4" 4" 4" 4" 4" 4" 4" 6" 6" 6" 6" 6" 6" 8" 3' 4' 6' 8' 10' 15' 20' 3' 6' 8' 10' 15' 20' 8' Length 4" and 6" diameters are galvanized steel. Includes “O” ring and quick coupler fittings. Intake Tubes Part No. 150100 150110 150120 150125 150130 150140 150150 150160 150180 150185 150190 150200 150210 238010 Intake Tube with 1¼2" Agitator Pipe and Spray Nozzle Part No. 150250 150260 150270 150275 150280 150290 150300 150310 150320 150330 150340 150350 150360 239379 Tube Diameter 4" 4" 4" 4" 4" 4" 4" 6" 6" 6" 6" 6" 6" 8" 3' 4' 6' 8' 10' 15' 20' 3' 4' 6' 10' 15' 20' 5' 4" and 6" diameters are galvanized steel. SERVICE AND PARTS MANUAL ACCESSORIES 1 . 8" diameters are aluminum. Length AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 2 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 3 . ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 4 . ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 5 . ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 6 . SERVICE AND PARTS MANUAL ACCESSORIES 7 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. Used for cleaning calcium deposits.5 WT. three front faces with 30 degrees orifices and a front tip penetrator. dirt.625" to 2" LENGTH 1. Front Jets GPM 135993 135992 135991 135990 135989 4 4 4 N/A N/A 65 40 20 6 5 PSI 2200 3000 4000 4000 4000 NPT 1" .5" .ACCESSORIES ® A Product of Hi-Vac Corporation Triad Penetrator Triangular shape allows for excellent penetration.25" . grease and soap build-up.75" .125" Diameter . . Also very effective for ice penetration.25 to 3. Replaceable Part No.04 to 2 lbs. Made of stainless steel. AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 8 . ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 9 . ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 10 . SERVICE AND PARTS MANUAL ACCESSORIES 11 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 12 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 13 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS. SERVICE AND PARTS MANUAL ACCESSORIES 14 .ACCESSORIES ® A Product of Hi-Vac Corporation AQUATECH OPERATIONS.