Aquatech B Series Operators Manual
Aquatech B Series Operators Manual
Aquatech B Series Operators Manual
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
B-5 SERIES
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
B-6 SERIES
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
B-15 SERIES
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
B-52 SERIES
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
KD-UNITS
OPERATION
SERVICE
& PARTS
M A N U A L
A Produst 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: sales@hi-vac.com
Aquatech Direct: Tel: 740.374.9171 • Toll Free USA: 800.800.1016 • Fax: 740.374.5447 • Web: www.aquatechinc.com • E-mail: sales@hi-vac.com
B SERIES
TABLE OF CONTENTS
PRE-DELIVERY INSPECTION FORM . ....................................................................................................... I.
CUSTOMER TRAINING FORM.................................................................................................................. III.
INTRODUCTION.........................................................................................................................................VI.
WARNINGS................................................................................................................................................VII.
SECTION 1 OPERATIONS
I. PRINCIPLES OF OPERATION
Positive Displacement Exhauster and Water Pump Units
Controls and Gauges
Dashboard Controls
Low Water Warning and Cold Weather Conditions
Hydraulics
Power Deck Systems Engagement-Sequence of Operation
Pendant Control
Side Operator’s Station
Air Purge Pump Prime
Cold Weather Blowout
Rear Operator’s Station
Rear Reel Controls
Reel Speed Controls
Foot Pedal Controls
Handgun and Handgun Quick Connect
SECTION 2 SERVICE
I. CUSTOMER SERVICE AND PARTS ORDERS
Ordering and processing of parts orders
Contacting the service department
Sales terms
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 Parts & Accessories Catalog located on the CD supplied with the unit or visit HI-VAC.COM.
I. SPARE PARTS
Spare Parts List
II. CONTROLS
Pendant Control Assembly
Rear Control Panel
Side ControlPanel
Foot Control Assembly
III. POWER TRAIN
Power Take Off (Split Shaft)
IV. WATER SYSTEM
Reel Swivel
Water Manifold
Standard Water Supply Lines
1” Relief Valve
1/2” Relief Valve
Strainer
Water Schematic
Manufacturer’s Manuals
VIII. BODY
Reel Assembly
Air Portal Assembly
Boom Hose
Filler Pipe Assembly
Sight Eye Assembly
Boom Turret Assenbly
Boom Assembly
Worm Gear Drive Bearing Assembly
Hinged Tank Support Prop
Polytank Installation Instructions
Installation of Water Fill Line
Polyethylene Water Tanks
Polytank Repair
X. OPTIONAL EQUIPMENT
As Shown
Note: The descriptions and instructions in ths manual cover the standard design of the equipment and any
included options where 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.
Unit Model:
Upon arrival at destination, the following procedures must be carried out.(Please initial on line below)
Prior to delivery to customer
5 Inspect exhaust system for clearance problems in and around entire _____________
exhaust system
7 Inspect for loose wires, hoses, cables, and correct as needed _____________
9 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) _____________
11 Inspect hydraulic motor chain and bolts on hose reel. (torque if necessary) _____________
12 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 _____________
13 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 _____________
14 Hydraulic system
• Operate entire hydraulic system-all functions
• Check all hoses, connections, and cylinders for leaks _____________
15 Install suction line strainer if removed for shipping. Fill tank and run pump.
Assure all air is purged and the water pressure develops smoothly _____________
Check for leaks. If unit is delivered during cold weather, refer to cold weather preperation.
THIS INSPECTION WAS PERFORMED BY:
Unit Model:
Operator and service personnel must be thoroughly instucted of the following: (Please initial on lines below)
Power Take off (PTO)
Hydraulic system
Pneumatic system
Water system
• With tank access door man way open - explain final filter _____________
• Nozzles _____________
Options
• Accumulator _____________
comments:_________________________________________________________________________
Thank you for purchasing your Aquatech unit, the most advanced American-made sewer
cleaning machine. Our quality of design and manufacture will assure you the greatest return
on your equipment investment.
Please consult this owner’s manual as the first step to resolving questions you may have
about the operation or service of your machine. If you are not able to find the answers, then
consult with your selling dealer. Finally, we at the factory will be happy to provide operating
information that this manual or your dealer are unable to provide.
Our warranty spells out all your rights and expectations with regard to this equipment.
Please consult it for a full definition of what is covered.
Thank you again for selecting the equipment preferred by industry professionals throughout
the world.
Your new Aquatech unit incorporates the very latest in pipe cleaning technology. 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. As a result, the machine will clean and operate in a far superior manner than
previously available.
The vacuum system provided is superior to any other available. It is capable of both wet and
dry operation, as well as operation under water.
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.
We are a company that is committed to continually striving to build an even better product.
Many ideas for improvements in previous models have come from users in the field. We
encourage you to make suggestions either through your distributor, Aquatech Regional
Sales Manager, or through our service department.
The central core of the hose is constructed of a material called “polyolefin”. This seamless layer of the hose
provides approximately 30% of the total hose strength.
Middle Layer
Bonded to the inner core is a band of high tensile polyester braid. This braid provides approximately 45% of the
total hose strength.
The outer jacket of the hose, bonded to the polyester braid, is an abrasion resistant polyetherurethane material.
It is designed to become very slippery when wet and provide as frictionless a surface as possible when travelling
through the pipeline. This outer jacket provides the final 25% of the total hose strength.
The maximum burst rating of a hose is approximately 2.5 times its rated working pressure. That is, a hose rated
for 2000 psi has a maximum burst rating of about 5000 psi.
If the outer jacket is torn or abraded to the point where the braided band is exposed, there has been a 25% loss
of the maximum burst rating, or 1250 psi. Although this is a serious loss from the maximum strength of the hose,
there is enough “cushion” in the design to compensate.
However, if both the outer jacket and the inner braid have become badly damaged, then 65% of the hose strength
has been lost, or about 3250 psi. Under ideal conditions, this leaves only 1750 psi as the burst rating of the hose
now.
If you must install new hose fittings, use only those specified by the
manufacturer for the hose supplied. Fittings have a color-coded band to
identify the hose they may be used with. Never use an incorrect fitting,
or a hydraulic hose fitting “off the shelf”.
Caution: We do not recommend splicing or repair of ruptured hose. We recommend replacement only. If hose
is spliced or repaired, we recommend you contact the hose manufacturer for proper instructions and correct
compatible splicing tools and mendors.
This machine is a combination vacuum and high pressure water jetting unit for cleaning sewer
drains or catch basins. It also performs other cleaning operations.
The vacuum generator is a rotary lobe, positive displacement exhauster. During operation of the
vacuum system, material is picked up at the end of the suction line and pneumatically conveyed
through the intake tubes, the boom hose, and through the boom intake valve, to the debris tank.
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, settling at the bottom of the tank. The spent air flows
through the ball check valve, and through a metal screen in the centrifugal scrubber
externally located at the front of the body. At this point the filtered air flow enters the exhauster
and is expelled through a silencer/muffler to the atmosphere.
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. When retrieving the nozzle under
water pressure, material that has built up in the sewer line is blasted loose and back flushed to the
manhole for removal with the vacuum system.
In the water system the water flows from the two water tanks, mounted outboard of the debris
tank, through a crossover manifold, through the water pump feed line, through the suction strainer
into the suction side of the pump. The pressurized water is then pumped forward to the water
control valve and routed, depending on the position of the valve, either to the hose reel for
cleaning, or by return lines to the water tank. The vacuum and water system can be used
simultaneously when cleaning sewers. This allows conveyance of flushed out materials and water
into the debris tank.
This machine is also designed for cleaning catch basins, wet wells, 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. 238080) for blasting loose packed debris and for wetting dry material. Grapple
tongs (part no. 234585) are used to remove long sticks and items that will not fit into the pickup
tube.
This machine may also be used for leaf pickups. Position the unit at the curb; rotate the boom
and extend it to reach all areas of the tree lawn and sidewalk. The boom is locked in place while
picking up leaves to provide maximum operator safety. To aid in the dumping process of compact
leaves, it is recommended that a couple hundred gallons of water be added to the bottom of the
debris tank prior to vacuuming. Unit must be equipped with the liquid ring option (part no. 380924).
It is important for the operator to fully familiarize him/herself with the location, appearance and
function of the various controls and gauges on any new Aquatech sewer cleaning machine. Please
read this section carefully, and refer to it whenever any section of the manual describes a control which
you cannot identify.
DASHBOARD CONTROLS
Several controls are mounted in the chassis cab itself. These controls allow the operator to engage
and disengage the water pump, exhauster, and hydraulic system. In addition, a low water warning light
and switch are among the standard controls in the chassis cab. The water pump and exhauster are
engaged and disengaged by electro-pneumatic solenoid valves. These solenoids are operated by
electric toggle switches in the cab or at the rear operator’s station. Because each manufacturer
will have a different cab layout, even among models of the same manufacturer, our description of
their location is general.
HYDRAULICS
The main split shaft PTO incorporates an additional output for the installation of the hydraulic
pump to supply power to all hydraulic functions. This pump is closed coupled to the PTO. Its drive
is automatically engaged whenever the PTO switch is activated in order to disengage the main
drive to the differential of the vehicle. When the witch is positioned for drive mode, the hydraulic
pump drive is disengaged.
1. Start engine.
Note: Because the main split-shaft PTO is actuated by means of electro-pneumatic solenoid
valves, there must be at least 90 psi in the air brake system. Check the air pressure
gauges on the dashboard to confirm this.
Note: This switch supplies power to the chassis relays (i.e. 4th gear lock-up, e-stop, and remote
throttles)..
Note: This switch supplies power to all the other switches and must be the first one turned on.
When turning unit off, this switch must be the last one turned off. A red light glows
inside the switch to indicate that the unit power is on.
7. Turn “PTO” switch to “On” position and wait for indicator light to illuminate.
Note: In order to keep the truck stationary while operating the water pump, exhauster or both,
the rear axle must be disengaged. This can be done by turning the “PTO” switch to “On”
position. This will cause the split shaft PTO to internally shift positions and disengage the
rear drive train of the vehicle.
Caution!! The pump systems should never be operated in a gear range greater than
indicated on either the dashboard label or the rear operator’s panel. Failure to heed
this caution may result in severe damage to the water pump or exhauster. Please
consult with the factory if the vehicle gear range is not specified.
9. You are now ready to engage the water pump and/or exhauster.
Note: To engage the water pump, turn the “Water Pump” switch to “On” position and wait for
indicator light to illuminate. The same procedure is used for the exhauster by turning the
“Exhauster” switch to “On” position and wait for indicator light to illuminate. Both power
systems can be run simultaneously if desired. To disengage either the water pump or
exhauster move the switch to the opposite position. The water pump and exhauster can be
engaged from the cab or rear operator’s control panel.
10. To disengage PTO, place transmission in “Neutral” position. Turn “PTO” switch to “Off”
position and wait for indicator light to turn off. Turn “Unit Power” switch to “Off” position and then
turn “PTO Enable” switch to “Off” postition. PTO should now successfully be disengaged.
PENDANT CONTROL
Customarily the pendant control is located and stored in a basket on the
passensger side of the vehicle. On most units the pendant control is a
yellow rectangular box with black push buttons. The pendant control is
wired into a unit control box on the passenger side of the vehicle. The
multi-wire cable is long enough to allow the operator to carry the pendant
to the work area. This connection allows the operator to disconnect the
pendant control from the unit control box and store the pendant control FLAPPER CLOSED LIGHT
in the cab or tool box when not in use. The pendant operates the boom.
It lowers and raises the boom, it telescopes the boom in and out, rotates FLAPPER CLOSE
the boom right and left, and energizes the boom valve. Each function
is controlled by a push button control. Pressing a button carries out a BOOM UP/DOWN
function, releasing a button stops a function. The actuation of the boom
is hydraulic, although the pendant performs electrical functions. Each BOOM IN/OUT
button makes an electrical solenoid operate a hydraulic valve. Therefore,
the main power switch and the hydraulic system/PTO must be turned BOOM LEFT/RIGHT
on when operating the boom. When transporting the unit, the pendant
should be stored in the basket, tool box or cab. Because the control is
rugged and can withstand some abuse, if dropped repeatedly, or run over
by the unit, the case will become cracked or crushed. This may cause
some or all of the functions of the pendant control to cease operation
and allow water to leak inside. Each operator should spend as much
time as necessary to become completely comfortable with each Func-
tion of the pendant control so that the operation of the boom becomes
almost natural.
Note: If you have constant problems with cavitation, it is likely that air is being sucked into the
pump somehow, or one or more valve springs have broken. If you experience repeated cavitation,
even though the pump has not been run out of water, you should request an inspection of the water
system to determine the cause.
Overflow Tube
Valve #1
Valve #1 Valve #2
Cold Weather
Main Water Recirculation
Supply Pump
Pump
Schrader
Schrader
Air Valve #2
Air Valve #1
Main Water
Supply
Tank Flush Valve
Pump
The control for the internal tank flush is near the side operator’s station. 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. Normally the valve is left in the
“Up” or “Hose Reel” position which directs the water flow to the hose reel control on the rear reel. When the
valve is placed in the “Down” or “Internal Flush” position, the water flow is diverted to the internal tank
nozzles in the debris tank, allowing high pressure flushing of the debris tank. When dumping the debris tank,
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.
Caution! Do not operate this system while the exhauster system is running, or at speeds in
excess of posted speed and gear range!
Control Valve
The control for the internal tank flush is near the side operator’s station. 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. Normally the valve is left in the
“Down” or “Off” position. When the valve is placed in the “Up” or “On” position, the water flow is sent to the
internal tank nozzles in the debris tank, allowing high pressure flushing of the debris tank. When dumping the
debris tank, 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.
Caution! Do not operate this system while the exhauster system is running, or at speeds in
excess of posted speed and gear range!
Hand Gun
Hose Reel
Tank Flush
The control for the internal floor flush is near the side operator’s station. 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. Normally the valve is left in the
“Up” or “Hose Reel” position which directs the water flow to the hose reel control on the rear reel. When the
valve is placed in the “Down” or “Internal Flush” position, the water flow is diverted to the internal floor nozzles
in the debris tank, allowing high pressure cleaning of the debris tank floor. When dumping the debris tank, it
is desirable to use the internal floor flush system to thoroughly clean the floor of the tank without requiring the
operator to manually wash it down.
Caution! Do not operate this system while the exhauster system is running, or at speeds in
excess of posted speed and gear range!
Control Valve
The control for the internal floor flush is near the side operator’s station. 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. Normally the valve is left in the
“Down” or “Off” position. When the valve is placed in the “Up” or “On” position, the water flow is sent to
the internal floor nozzles in the debris tank, allowing high pressure cleaning of the debris tank floor. When
dumping the debris tank, it is desirable to use the internal floor flush system to thoroughly clean the floor of the
tank without requiring the operator to manually wash it down.
Caution! Do not operate this system while the exhauster system is running, or at speeds in
excess of posted speed and gear range!
Hand Gun
Hose Reel
Tank Flush
A “Toggle Switch”, located on the side operator’s panel, is used to control an automatic 3-way valve for
selecting the direction of the water flow to the nozzles. Place the toggle switch in the “Up” position for “Tank
Flush” or in the “Down” position for “Floor Flush”. When dumping the debris tank, it is desirable to use the
internal tank and floor flush system to thoroughly clean the interior of the tank without requiring the operator to
manually wash it down.
Caution! Do not operate this system while the exhauster system is running, or at speeds in
excess of posted speed and gear range!
Toggle
Switch
Control Valve
Tank Flush Nozzles
Female
Swivel
Connector
Quick Connector
Hose Reel
Hand Gun
Female
Swivel
Connector
Quick Connectors
Hose Reel
Hand Gun
1. Connect the sewer hose (not shown) from the hose reel to the “Female Swivel Connector”
located at the end of the plumbing beneath the “Water Control Valve #1”.
2. Turn valve handle on the “Water Control Valve #1” to the “On” position as shown.
3. Turn “Water Control Valve #2” to the “Hose Reel” position.
Female
Swivel
Connector
4. Assure “Valve #3” and “Valve #4” (located on the water lines between the “Main Water
Supply Pump” and “Cold Weather Recircuulation Pump”) are “Open”.
5. Connect the Washdown and Hydro-X hoses into the “Quick Connectors” as shown below.
6. Assure “Hose Reel” and “Hand Gun” Valves are in the “Up” or “On” position and the
“Tank Flush” Valve is in the “Down” or “Off” position. This will direct the water from the
main water pump to the Jetting, Washdown, and Hydro-X hose Reels.
7. Assure truck is running prior to starting the cold weather recirculation pump. For information
on this pump, refer to page 10 of the “Principles of Operation” section of this manual.
8. Turn on the “Recirc Pump” Switch located in the cab to start the cold weather recirculation
pump.
9. The pump will now circulate water throughout the system and back to the tank.
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. In
cold weather the switch should be in the “Winter” position. This allows
more water to remain in the tank to accommodate recirculation. During warmer
weather, the switch should be in the “Summer” position, providing more water for
jetting operations.
Quick Connectors
Hose Reel Hand Gun Tank Flush
10. When cold weather recirculation is no longer required, turn off the “Aux Switch” in the cab
to stop the cold weather recirculation pump.
11. Assure “Valve #3” & “Valve #4” (located on the water piping) are open.
12. Open “Valve #2” (located on the cold weather recirculation pump).
13. Perform “Cold Weather Blowout”. Refer to page 6 of the “Principles of Operation”
section of this manual.
14. Close “Valve #2”, “Valve #3”, and “Valve #4” when all of the water has been expelled from
the system.
Caution!
Immediately after using the cold weather recircualtion option and every day during
cold weather, water must be drained from the recirculation pump as well as the piping
between the main water supply pump and the recirculation pump.
Valve #2 - On
Cold Weather Recirculation Pump
**If pump does not operate as described above contact your distributor.
MAINTENANCE (Pump):
Liquid to be pumped should be clean and free of debris. Liquid must flow freely. Make certain that liquid being
pumped is compatible with your pump and Viton seal. Do not pump flammable or hazardous material.
Do not run pump dry. Should pump chamber be emptied, follow instructions under “Start Up” to prime the
system. Precautions should be taken in cold weather to avoid freezing. Add anti-freeze to liquid or drain pump
completely when not in service. Do not operate a pump that contains frozen liquid. This will overload the
motor.
MAINTENANCE (Motor):
Motor draws 83 Amps. When using pump, make certain truck is running. Motor duty cycle is 50 minutes
maximum. Do not operate pump continuously for more than 50 minutes.
WARRANTY:
Mora USA warrantees this pump to be free from defects in material and workmanship. Period of warranty
shall be (1) year on pump and motor and (90) days on all other accessories from date product is received by
original buyer. Product must be inspected by Mora USA of.authorized service center. Approved warranties will
be repaired or replaced at the discretion of Mora USA.
Note: Assure the exhauster and water pump are in the “Off” position.
Unloader Air
On/Off Pressure
Valve Gauge Hose Reel Hand Gun Tank Flush
2. Disconnect the Hydro Excavation Hose from the “Quick Connector” and attach the Hydro
Excavation handgun (not shown).
Quick Connector
Unloader
On/Off Valve
Air
Pressure
Gauge
Water
Control
Valve
Water
Handgun 1/2” Needle Globe Valve
Valve
Note: Depending on the type of nozzle being used, it may be necessary to adjust the
Regulator to acheive your optimum operating pressure and flow. Turn the
Regulator handle clockwise to increase the pressure/flow and counterclockwise
to decrease the pressure/flow.
Unloader Air
On/Off Valve Pressure
Gauge
Regulator
The purpose of the Unloader Valve is to acheive an optimum pressure and flow of water to the
handgun zozzle.
The Unloader “On-Off” Valve provides control of the water system flow. The function of this
valve is to direct the water flow to the hose reel (in the “On” position), or back to the water tanks
(in the “Off” position).
The Regulator controls the amount of air pressure directed to the Unloader Valve. Depending on
the type of nozzle being used, it may be necessary to adjust the Regulator to acheive your
optimum operating pressure and flow. Turn the Regulator handle clockwise to increase the
pressure/flow and counterclockwise to decrease the pressure/flow.
Unloader
“On-Off” Valve
Unloader Valve
Regulator
Discharge Valve
Pump
Hyd. Motor
Directional
Control
Valve
Suction Line
Hydraulic
Control
Lever
Shuttle
Valve
Intake Valve
Troubleshooting:
If pump fails to prime or stops pumping, check the following possible causes:
Discharge Valve
Pump
Hyd. Motor
Suction Line
Hydraulic
Control
Lever
Shuttle
Intake Valve Valve
Troubleshooting:
If pump fails to prime or stops pumping, check the following possible causes:
Operating Procedures:
2. Start Engine.
3. Engage Transmission:
A. MANUAL TRANSMISSION
I. Select Neutral
II. Engage Unit Power & PTO Enable
III. Depress Clutch, Engage PTO, and Select Reverse.
IV. Release Clutch Pedal
V. Engage Vacuum System
B. AUTOMATIC TRANSMISSION
I. Select Neutral
II. Engage Unit Power and PTO Enable
III. Engage PTO and Select Reverse
IV. Engage Vacuum System
4. Open both the Intake and the Discharge valves at the pump off pump.
5. Depress boom valve switch on pendant control and hold. In this mode, the Vacuum System creates positive
pressure inside the debris tank forcing water into the floating discharge tube and into the pump to help prime
the centrifugal pump.
7. Release Boom valve switch, Disengage vacuum system, and reverse transmission direction to drive (or
appropiate manual transmission gear).
8. Pull pump hydraulic control lever out to engage pump. (handle toward operator) Pump speed is controlled
by hydraulic oil flow, therefore engine speed is important to proper operation. Approximately 1,500 RPM's is
necessary for optimum pump operation.
9. After the operator has finished using the pump, the hydraulic control lever must be moved forward to the
fully closed position. Failure to fully close the valve may cause erratic, or no rear reel operation.
10. Fully close both the discharge and intake valves when pump off operation is complete. Failure to close both
valves will create a loss of vacuum pressure in vacuum mode.
WARNING: IN FREEZING TEMPERATURES, OPEN THE PETCOCK VALVE AT THE BOTTOM OF
THE PUMP-OFF PUMP TO ALLOW ALL WATER TO DRAIN FROM THE PUMP. FAILURE TO DO
SO WILL CAUSE ANY REMAINING WATER IN THE PUMP TO FREEZE, THEREFORE PUTTING
EXTREME PRESSURE ON THE PUMP AND ULTIMATELY CAUSING FRACTURE TO THE PUMP
HOUSING.
AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL
PRINCIPLES OF OPERATION 29
PRINCIPLES OF
OPERATION
WASTE WATER RECYCLING SYSTEM OPTION
1. With the engine running, clutch depressed, PTO Enable Switch in the “On” position,
Unit Power Switch in the “On” position, and PTO Switch in the “Engaged”
position, place the transmission in the correct gear.
2. Next, press the Green “Power On” Button located on the top center of the remote face
and a yellow light will illuminate. The yellow light will remain momentarily.
3. All wireless remote functions will now work by pressing the appropriate buttons. All
operators should become familiar with each function controlled by the wireless remote.
4. On the wireless remote, press the Red “Power Off” Button on the bottom of the remote
to turn off the remote.
POWER ON
POWER OFF
* For directions on how to enable all functions, refer to the manufacturer’s manual located in the . For di
“Controls” section of this manual.
1. Ensure the exhauster and water pump are in the “Off” position.
2. Begin at the side operator’s position.
3. The Water Control Valve must be in the “Down” or “Lateral Cleanout” position.
4. Disconnect hose from return line at the Quick Coupler and attach hand control and leader hose with
nozzle.
5. Unreel a sufficient amount of hose using the Hydraulic Control Valve to allow the hand control to be
operated from the side operator’s position.
5. Engage the blower and/or water pump and raise the RPM to desired speed.
6. Open Valve #1.
7. With the hand control in the open position, adjust the 1” needle globe valve (Valve #2) until the Water
Pressure Gauge reaches the desired water pressure.
Hydraulic
Control
Valve
Quick Coupler
The load limit alarm system is used to set off an alarm and illuminate a warning light when a
predetermined rear axle weight has been reached. This system consists of a microswitch mounted
above the rear axles trunion, an alarm that sounds when the switch has been tripped, a warning light
that illuminates, and a switch to turn off the alarm.
The microswitch is adjustable in height by means of the switch mounting screws. It can be moved
up to increase the allowable load or down to decrease the allowable load. The switch can also be
adjusted by resetting the flexible arm. This is accomplished by loosening the set screw and rotating the
flexible arm to the desired location and then retightening the set screw.
To properly set the alarm, load the vehicle such that the rear axle weight is at the maximum rear axle
weight desired. Loosen the mounting screws. Then raise or lower the microswitch until it activates the
TRUNION
MICROSWITCH
OFF SWITCH
If the boom is not properly seated, the “Boom Up” Light will illuminate and the “Boom Up”
Alarm will sound when the Parking Brake is released.
Limit Switch
Boom Cradle
If the boom is not properly stowed, the “Boom Up” Light located on the dashboard will
be illuminated and when the parking brake is released, the horn will sound.
Caution! Do not attempt to place the vehicle in gear. The unit will remain in “Work” mode,
even when changing the “PTO” and “Unit Power/Master” Switches from “Work” mode
to “Road” mode.
Safety Switch
Boom Cradle
Boom Up
Unit Power/Master (Road Mode) PTO (Road Mode) Light
Boom Up
Unit Power/Master (Road Mode) PTO (Road Mode) Light
Note: “Boom Up” Light in cab will begin to flash and remain flashing.
Note: Unit cannot be driven if “Boom Up” Light is on and “Boom Up Override”
is not engaged.
c. Press the “PTO” switch and change from “Work” mode to “Road”
mode.
d. Press the “Unit Power/Master” Switch and change from “Work”
mode to “Road” mode.
e. Release the parking brake.
Boom Up Override
The Vacuum Breaker System system utilizes the stored air on the truck chassis to control an air
actuated butterfly valve located on the strainer. The butterfly valve opens when the amount of
vacuum in the system needs to be reduced.
The vacuum breaker can be controlled from a switch on the Rear Opreator’s Panel, a switch on
the Side Operator’s Panel, and a rotary switch on the Remote Pendant.
Once the vacuum breaker is opened at one location, it must then be closed by the same switch.
Example: If the vacuum breaker is opened using the rotary switch on the Remote Pendant, it can
only be closed using the same switch on the Remote Pendant.
There is a light on the Rear Opreator’s Panel and on the Side Operator’s Panel to indicate the
vacuum breaker has been opened. There is no light indication on the Remote Pendant.
The Debris Probe is used to set off an alarm and illuminate a warning light when a predetermined level
has been reached in the Debris Tank. When this occurs, the operator can turn off the light and alarm
by using the toggle switch located in the Rear Operator’s Panel.
The operator shoud then follow the “Dumping The Debris Tank” instructions located within this
manual.
To engage the hydraulic back-up pump, turn the “Unit Power” switch to the “On” position in the cab. Go to
the side operator’s control panel and tun on the “Hydraulic Back Up” switch.
UNIT POWER
The control for the “Wet Ring Option” is near the side operator’s station. The control for
the water flow is the lever on the ball valve at the right side of the water pump plumbing on
the pressure side of the pump. Normally the valve is left in the “Down” or “Off” position.
When the valve is placed in the “Up” or “On” position, the water flow is sent to the spray
nozzles located inside the Boom Turret. This option is to be used when vacuuming dry
or very light material. The water from the spray nozzles add moisture to the material,
allowing it to fall down into the Debris Tank. Performing this action helps prevent the
material from continuing through the process and creating a potential hazzard to the
vacuum pump.
Spray Nozzles
(Inside Turret)
Wet Ring
Control Valve
IMPORTANT SAFEGUARDS
1. Never enter a manhole that has stagnant water in it.
2. When entering a manhole, proceed as recommended in the APWA handbook on safety. Follow all state
and federal regulations.
3. Use only genuine Aquatech hose and repair parts.
4. Always use a hose guide in the manhole.
5. Always use a leader hose at the end of the sewer cleaning hose.
o
6. Use Cold Weather Recirculation in temperatures below 32 F.
7. Check hose and water network for weak, worn or leaking places. Repair or replace if necessary.
8. When inserting a nozzle in a sewer section full of water or in very large diameter pipes, use extreme
caution when applying pressure to the hose. Deflection is possible under these conditions and the nozzle
could turn around, come up and out of the line and manhole to inflict injury to persons nearby.
9. Never force nozzle or hose forward by pushing on it. It must move under its own water power.
10. Always use a steel nozzle guide or nozzle extension longer than the pipe diameter.
11. Check for overhead lines that could come in contact with the boom.
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.
BEFORE GOING TO WORK-SITE
1. Perform required maintenance as specified in the maintenance schedule.
2. Perform required maintenance on truck chassis as specified in truck chassis manual.
3. Check to see that the boom is secure in the boom rest and latched and the boom pendant control is
secure in its carrier, toolbox, or cab.
4. Check to assure that all tools are secured, and that all cabinet doors are closed and latched.
5. Secure the sewer hose in the traveling position by locking it into the swivel fitting provided.
6. Fill the water tanks. Please refer to one or more of the following water level indicators.
a. The sight tubes located on the rear of the water tanks shows the direct water level in all tanks.
b. Low water warning light in the cab indicates low water.
8. The reel is positioned at the manhole downstream from the stoppage or section to be cleaned. The
vehicle may face any direction. Check local traffic regulations and for all overhead lines.
9. Position the hose reel over the manhole. The reel articulates from its rest position against the rear
o
door in a 180 arc by depressing the button on the control panel marked “OUT”. Engine speed should
be about 1500 rpm to operate reel efficiently.
10. Install level wind assembly on its pivot pin directly under the reel.
11. Disconnect the end of the sewer hose from the travel/safety coupling and route through the level wind.
Note: always use a leader hose at the end of the sewer cleaning hose.
12. Insert hose through flexible hose guide, then hand tighten selected nozzle on the end of the hose.
Experience has shown that using the flexible hose guide with the rope end down works best.
13. With the nozzle inserted in the sewer pipe, 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. Select
proper pump operating pressure based on the following:
a. Diameter of pipe.
Generally, larger diameter pipes require higher pressure for more efficient cleaning.
b. Age, condition and type of pipe.
Caution must be exercised in using higher pressure in older pipes with mortar joints and pipes
showing deterioration.
c. Amount and type of debris to be removed.
During the initial cleaning program, higher pressures are desired to remove larger amounts of
debris. After the manhole has been cleaned once, it is usually not necessary to use full operating
pressure for preventative maintenance.
d. Operator experience.
Until the operator is fully experienced in the operation of the equipment, it is recommended that
the machine not be operated at maximum pressure.
e. Age of Sewer cleaning jet hose.
The age and condition of the sewer cleaner hose must always be considered in operating at high
working pressures.
14. With the water pressure and engine speed set, begin paying out the sewer hose by depressing the
Pneumatic foot control pedal marked “PAY OUT”.
15. The payout speed of the hose is controlled by the speed control knob. Adjust speed to keep enough
tension on the hose so it doesn’t become loose on the reel.
16. The “level wind” or hose guide is used to wind the hose on the reel evenly to ensure long hose life.
When retrieving the nozzle and winding the hose onto the reel, the debris will enter the manhole.
DO NOT ALLOW THE DEBRIS TO CONTINUE INTO THE NEXT SECTION.
17. After the nozzle has reached the desired point, depress the foot control pedal marked “RETRIEVE” and
begin retrieving the nozzle slowly, with the desired water flow and pressure, to flush the debris from the
sewer line into the manhole. Retrieve the hose at approximately 30% of full reel speed.
18. When the nozzle is 3 to 5 feet from the manhole, stop the reel and shut off the water supply to the nozzle.
To ensure clean out of the last 3 to 5 feet of sewer line, allow nozzle to discharge for a short period to
wash out any debris buildup in the line end. Wind the remaining hose onto the reel.
19. To clean the manhole area, connect the handgun quick disconnect and open the isolating 1/2” ball valve,
located at the rear of the hose reel.
Caution! Hose retrieving operations must be done while maintaining normal operating pressure in the water hose.
It is critical that the hose be rewound on the reel at its normal operating pressure. Failure to follow this procedure
may result in serious deformation of the hose reel when the hose is pressurized during the next cleaning operation.
Hose reels deformed during machine operation are not covered under warranty.
AQUATECH OPERATIONS, SERVICE AND PARTS MANUAL
PRINCIPLES OF OPERATION 46
PRINCIPLES OF
OPERATION
VACUUMING AT WORK-SITE
1. Be sure that the unit operator is completely familiar with the boom pendant controls. The boom
pendant includes controls for:
Extending, retracting, raising, and lowering the boom, as well as opening and closing the internal boom
valve. Please refer to the PENDANT CONTROL section in CONTROLS AND GAUGES for diagrams
and explanations if you are not completely familiar with these operations.
2. Place a sufficient number of intake and/or extension tubes on the boom hose to reach the desired
working depth.
3. To increase the exhauster speed, increase engine RPM to working speed, not to exceed maximum
RPM and gear as noted on the unit ID sheet and mounted in truck cab.
4. Begin vacuuming debris and water. The vacuum tube can be positioned by use of the boom up/down
control, and by physically moving the tube around inside the catch basin to reach all areas where
debris has collected.
5. When vacuuming, the intake tube may be positioned just above the water level in the manhole or
catch basin allowing a mixture of air, water, and debris to enter. When required, the unit is capable of
removing debris from below water level with the intake tube completely submerged. For lifting water
more than 17 ft. at sea level, the use of the optional fluidizer tube (Part # 240805) is recommended.
6. If during the vacuuming process, the debris tank becomes full, the ball check valve will close which is
indicated by loss of vacuum at the intake tube. The 3" relief valve will also “chatter and whistle.” When
the debris tank is full, follow the instruction for disengaging the exhauster PTO.
Caution! To avoid overloading of the truck chassis, the debris tank and the water tanks must never be
simultaneously loaded to full capacity. When traveling to the dump site with a fully loaded debris tank, a maximum
of 1/4 tank of fresh water should be carried. This is sufficient to wash down the debris tank.
Do not operate the unit for long periods of time when the debris tank is full. It is extremely important to always
remove as much water as possible from the debris tank before driving the vehicle. This will help eliminate
overloaded conditions.
7. Excess water may be removed from the debris tank by the following method. With the exhauster
pump disengaged, open the drain valve at the rear of the unit and allow the water to drain.
Note: Do not run the exhauster in reverse to pressurize the tank. This may damage the clutches
in the PTO.
OPENING STOPPAGES
In the case of a line stoppage, the hose should be introduced into the manhole below the stoppage and worked
o o
upstream. The 35 and/or 15 nozzle, lance nozzle, stub lance, rocket nozzle or nozzle with a front orifice
are recommended.
SALES TERMS:
The descriptions and instructions included in this 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, Inc. Parts
and Service Center, or phone the Hi-Vac Service Department.
All specifications given have been calculated at sea level. All designs and specifications are
subject to change without notice.
No material returns will be accepted unless accompanied by our Material Return
Authorization form. A restocking charge of 20% applies to all Return Goods. Minimum
billing of $100.00 applies to all orders.
STANDARD LIMITED PRODUCT WARRANTY:
Hi-Vac hereinafter called the Company, warrants for a period of twelve (12) months from
the date this product is accepted by the purchaser, that all design and material of its own
manufacture shall be free from defects. The company agrees to repair or replace, at its sole
discretion, such defects to assure the product performs according to its published
specifications at time of manufacture.
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,
and shall in no way obligate the Company to perform such modifications to products manufactured
before these changes were adopted.
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, properly
filled out by the delivering dealer, and signed by the purchaser. If this form is not returned to Hi-Vac,
the warranty shall begin in 30 days after shipment from the factory.
Any product which has been used as a demonstration unit will, upon sale to the purchaser, have
the full warranty as provided for in these terms, subject to the conditions as stated herein. 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, under the terms of this warranty, for any losses, damages
or expense charges incurred by purchaser, or its agents, representatives or employees, as a result
of any failure of the product to perform. Other than those expressly stated herein, there are no other
warranties of any kind, express or implied, and specifically excluded but not by way of limitation, are
the implied warranties of fitness for a particular purpose and merchantability.
The following are specifically, though not exclusively, 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, motors and valves Power Take-Off
Electrical components Suction hoses and tubes
Batteries Axles, 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.
All parts are supplied F.O.B. by the factory in Marietta, Ohio. No freight allowances are made. No
travel time allowances are made. The purchaser shall agree to these terms by virtue of acceptance of
the machine or purchased part.
REPLACEMENT PART WARRANTY
Parts replaced during the warranty period will be warranted only during the term of the original
warranty. No extension of warranty is made by installation of the new part.
Replacement parts purchased after the warranty period will carry a thirty (30) day warranty
against defects in material or workmanship, or whatever warranty shall be offered and be enforceable
upon the original manufacturer, whichever is longer. Labor costs incurred to replace defective parts
are specifically excluded from this warranty.
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, at which time credit will
be issued to the purchaser. All such defective parts must be returned to the factory, freight
pre-paid, for evaluation and determination of warranty by the original manufacturer. Requests
for return will be made at the discretion of the Company. No part shall have been previously disas-
sembled or tampered with in any way so as to void the manufacturer’s warranty.
The Company’s sole responsibility under these terms shall be the timely return of the defective
part to the original manufacturer for warranty consideration, and for such reasonable follow-up action
as may be necessary to expedite the claim. The original manufacturer’s decision shall be final and
binding on both purchaser and the Company.
TROUBLESHOOTING GUIDE
(DAILY)
1. Inspect all high pressure water lines and hydro excavation hose for cuts and/or
leaks.
2. Inspect all oil lines and connections for cuts and/or leaks.
3. Inspect all valves, linkages, and controls for operation and position.
4. Inspect nozzles for excessive wear or obstructed orifices.
5. Inspect water pump suction line strainer, clean if necessary.
(WEEKLY)
1. Inspect tension of hose reel drive chain.
2. Inspect hose reel bearing set screws and bolts.
3. Inspect water pump and exhauster drive belts for proper tension, and check
pulleys for proper alignment.
4. Inspect water pump jackshaft bearing set screws and tighten if necessary,
applying Loctite to the set screws.
5. Inspect drive train and PTO shafts, universal joints, and bearings.
6. Remove and clean exhauster strainer and clean housing.
7. Inspect hydraulic system filter and clean or replace if necessary.
8. Remove cap and drain exhauster silencer.
(BI-WEEKLY)
1. Inspect water pump for excessive or abnormal wear. Remove any foreign
material, dirt or rust.
(EVERY 6 MONTHS)
1. Inspect the valves and springs, in the water pump.
2. Inspect hose reel brackets, bolts, and pivot points for wear.
3. Inspect debris tank coating and re-coat as necessary.
4. Inspect PTO and drive shafts for loose and/or worn belts and bearings.
5. Inspect the exhaust system for leaks or heating problems.
WATER SYSTEM
CONDITION: HOSE FAILS TO MOVE UP THE SEWER LINE OR FAILS TO REACH THE
NEXT MANHOLE, BUT SHOWS ADEQUATE PRESSURE.
PROBABLE CAUSES REMEDIES
Clogged nozzle. Clean.
Incorrect nozzle. Replace with correct nozzle.
Pressure gauge reading incorrect. Remove gauge and test. If gauge reading is not correct,
replace.
Restriction in hose. Remove hose from reel, inspect for kinks, collapsed
sections, etc. Hose may be pinched on reel. For best
operation always pressurize hose when winding on reel.
Water control valve leaking Clean, or replace valve seals.
therefore bypassing or recirculating
water back to tank.
Sewer line is dry or too much fall in A.) Introduce water into the upstream manhole and/or
line. jump the hose by rapidly opening and closing the water
control valve at maximum pressure.
VACUUM SYSTEM
(A) Continuity- Use OHM scale recorder or battery powered continuity test light.
(B) Current- The circuit must be opened to obtain current reading with the volt- meter; therefore, it is more
convenient to use a 12 VDC test light.
Moisture build-up in the chassis air Drain moisture from the system. Add
tanks. auto drain system.
Air solenoid valve not shifting. Check the electrical system and the
air system. Red light will illuminate on
actuated valve spool.
Defective seals in the main input shaft Contact an authorized service person.
control area.
Air solenoid valve not shifting. Check the electrical system and the
air system. Test the manual override
system on air valves.
Drive line shaft problem, sheared key Contact an authorized service person.
way, broken belt.
Water pump will not stay Air leak in the system. Replace leaking hoses, tubing, piping,
engaged. and fittings.
Air solenoid valve not shifting. Check the electrical system and the
air system. Test the manual override
system on air valves.
Drive line shaft problem, sheared key Contact an authorized service person.
way, broken belt.
Vacuum pump will not stay Air leak in the system. Replace leaking hoses, tubing, piping,
engaged. and fittings.
Air pressure coming out of PTO case. Seals leaking or defective in the
input shaft control housing, item #17.
Replace seal, Pos. #10, 11, 14.
PTO leaking oil, shaft seal areas. Case breather vent is plugged. Breather vent is set for 7# max. Check
ball could be corroded or jammed.
Note: You cannot blow 7#s by mouth.
Worn rubber vibration isolators. Check & replace if needed the four
rubber isolators.
Check input/output flange bolts. Check & tighten all mounting bolts.
Check water pump and vacuum pump Check & tighten all mounting bolts.
drive flange bolts.
Check water pump and vacuum pump Replace frayed, worn belts.
drive belts, drive sprockets, and
bearings.
Excessive vibration and drive line Check engine programming parameters. Radiator cooling fan should always be
chatter at low idle speed. in locked up mode when unit is in PTO
enable mode.
Bright
Alloy Cap Screws 1018 ft. lbs.
CAP SCREW DIAMETER YIELD STRENGTH PSI MIN. RECOMMENDED TORQUE
UNC UNF
¼ 58000 11 13
5/16 58000 21 23
3/8 58000 38 40
7/16 58000 55 60
½ 58000 85 95
9/16 55000 125 140
5/18 55000 175 210
¾ 55000 300 330
7/8 55000 450 490
1 50000 680 715
1-1/8 50000 885 990
1-1/4 40000 1255 1380
1-3/8 40000 1635 1875
1-1/2 40000 2180 2430
Heat Treated 1038 Hexagon Head Cap Screws, SAE Grade 5 ft. lbs.
YIELD TENSILE RECOMMENDED TORQUE
CAP SCREW DIAMETER STRENGTH PSI STRENGTH PSI
MIN. MIN.
UNC UNF
¼ 90000 120000 11 13
5/16 90000 120000 21 23
3/8 90000 120000 38 40
7/16 90000 120000 55 60
½ 90000 120000 85 95
9/16 90000 120000 125 140
5/8 90000 120000 175 210
¾ 90000 120000 300 330
7/8 81000 115000 450 490
1 77000 115000 680 715
1-1/8 77000 105000 885 990
1-1//4 77000 105000 1255 1380
1-3/8 77000 105000 1635 1875
1-1/2 77000 105000 2180 2430
2 4
6 7
9
REAR DOOR HINGE AND CYLINDER PINS
16
14 15
20
17
HYDRAULIC
HIGH DAILY CHANGE WHEN AMBER PANEL A383754-E
PRESSURE LIGHT ILLUMINATES
FILTER
WATER
SEPARATOR DAILY CLEAN AND REINSTALL, A373737-E
REPLACE IF DAMAGED OR
AFTER 2 YEARS
BOOM VALVE
LAST CHANCE DAILY CLEAN AND REINSTALL, A383767
FILTER REPLACE IF DAMAGED
WƌŽĚƵĐƚŽĨ,ŝͲsĂĐŽƌƉŽƌĂƟŽŶ
FLAPPER CLOSE
BOOM UP/DOWN
BOOM IN/OUT
BOOM LEFT/RIGHT
FLAPPER CLOSE
BOOM UP/DOWN
BOOM IN/OUT
BOOM LEFT/RIGHT
FLAPPER CLOSE
BOOM UP/DOWN
BOOM IN/OUT
BOOM LEFT/RIGHT
VACUUM BREAKER
OPEN/CLOSE
EMERGENCY STOP
FLAPPER CLOSE
BOOM UP/DOWN
BOOM IN/OUT
BOOM LEFT/RIGHT
PENDANT CONNECTION
PENDANT CONNECTION
3 4
6
7
WIRELESS REMOTE
PART # A387079
ITEM
Pos. PART
Part No. # DESCRIPTION
Description QTY
Qty ITEM
Pos. PART
Part No. # DESCRIPTION
Description QTY
Qty
1 1 A164435 Plug PLUG
A164435 1 1 24 22 TBA TBA
Washer EXTENSION 1 1
2 TBA Washer, copper 2 25 TBA Ring, elastic 1
2 TBA WASHER, COPPER 2 23 TBA O’RING 1
3 A164193 Ball 1 26 TBA Switch, pin 1
4 3 A164194A164436
Spring BALL 1 1
27
24
TBA
TBA
Spring
WASHER 1
1
5 4 TBAA164437 SPRING,DETENT
Nut, lock 1 1 25 TBA RING,ELASTIC
28 A164407 Washer, copper
1
1
6 5 A164439TBA Screw, NUT,
M12x20
LOCK 1 1 26 TBA
29 TBA Switch SWITCH,PIN 1 1
7 A164435 Stem 1
6 A164439 SCREW,M12x20 1 30 27 TBA Protection,
TBA wiring
SPRING 1 1
8 A164440 Fork, engagement 1
9 7 A164435
A164402 STEM
Nut, lock 1 1 28 A164407 WASHER D.18 1
10 8 A164441 Screw, FORK,SHIFTER
A164440 M8x37 1 1 29 TBA SWITCH 1
11 A164442 Ring 1
9 A164402 NUT, M8 1 30 TBA PROTECTION,WIRING 1
12 A164443 O’Ring 1
10
13 A164444 A164441
O’Ring SCREW 1 1
14 11 A164445 O’Ring RING
A164442 1 1
15 12 TBAA164443
Piston GASKET (O-RING) 1 1
16 A164447 O’Ring 1
13 A164444 GASKET (O-RING) 1
17 A163937 Washer, conical 1
18 14 TBAA164445
Screw, GASKET
M10x20 (O-RING) 1 1
19 15 TBA TBAHousing, cylinder
PISTON 1 1
20 A164450 Washer, conical 3
16 A164447 GASKET (O-RING) 1
21 TBA Screw, M8x40 3
22 17 TBAA163937 WASHER D.10
Extension 1 1
23 18 TBA TBA
O’Ring SCREW,M10X20 1 1
19 TBA HOUSING, CYLINDER 1
20 A164450 WASHER D.8 3
21 TBA SCREW,M8X40 3
SWIVEL,REEL,1-1/4”FNPT X 1-1/4”FNPT
PART # A130727-1
10 12
11 11
15
17 4
9 1
2
6
18
19
7
12
8 2
16
13
1
16 14
15
SUMP
SUMP
2 3
5 4
1” RELIEF VALVE
PART # A380516 (2500 PSI) / PART #A130963 (2000 PSI)
OUTLET OUTLET
INLET
UNLOADER-3/4”NPT,26GPM @ 4000PSI,GIANT
PART # 22973C
BY-PASS
OUTLET
INLET
VALVE,RELIEF,1/2”,800 PSI,SPS
PART #A130962
STRAINER,Y,2”,PVC,20 MESH
PART # A240029
4
1
7 8
4
1
7 8
4
1
7 8
2
3
VACUUM BREAKER
Part #A383746
4
3
MANUAL OVERRIDE 1
1 2
HYDRAULIC VIBRATOR
PART #A245901-4
FLAPPER
WATER PUMP
VACUUM PUMP
PTO
1 2 3
1 2
FLAPPER
1 2
FLAPPER
WATER PUMP
VACUUM PUMP
VACUUM PTO
BREAKER
4 3
12
10
11
2
3 1
5 7
4
8 9
6
HOSE,BOOM,8” ID X 20’LG,PLASTIC
PART # A176627
HOSE CLAMP
PART #A220698
(2) REQUIRED
2
3
1. Assemble the right side polytank sections as shown. Using 2. Lift the entire right polytank assembly into position with
a liquid dish soap, lubricate the rubber seal located at the rear tank the base of the tanks resting firmly in the tank trays. The reservoir
connection port. Push the front tank into position inserting the 6" located at the base of the rear tank should rest in the cut out sec-
PVC connector. tion provided. Align the holes located at the top of the polytanks
with the strap retainers mounted on the debris tank.
Repeat same procedure for left side.
Rubber seal
3. Please refer to INSTALLATION OF WATER FILL LINE 5. With the turnbuckles attached, place one lock washer
WELDMENT PART # A246145 before continuing this assembly. followed by one beveled washer on each of the tension bolts. Place
the tension bolts (w/washers) through the top hole of the tank strap
4. Locate the following items: Eight tank straps, Eight turn- and thread it back into the turnbuckle.
buckles, Eight lock washers, and Eight beveled washers. Remove
the tension bolt from the turnbuckles. Remove the fastener from the DO NOT TIGHTEN!
“U” shaped end and place the turnbuckle through the spaces in the
top portion of each polytank. Attach the “U” shaped end to the strap Repeat front and rear both sides.
retainers located at either side of the debris tank as shown.
Tension Bolt
Tighten securely.
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.
Cap Screw
FRONT VIEW
VIEW FRONT RIGHT POLYTANK
WITH FILL LINE ASSEMBLY
BODY
A246122 Standard Lid
A246123 Fill Line Lid
Bottom View
General Informafion
Repairs to polyethylene tanks can be performed easily with a miniInurn of training. Repair technicians must exercise
prudent caution against melting completely through the poly material, but extreme caution is generally not necessary.
What this means is that the technician must realize that dire consequences are possible but not likely if he/she is rea-
sonably carel.
Typical repairs will involve repair of two basic types of damage: blernishes to the surface, and cracks or holes through
the material. A different repair approach will be appropriate for each type of damage.
Blemish Repairs
Blemishes to the surface of the poly tank can usually be repaired by first cleaning the area to remove any grease, oil or
dirt. Then apply heat using an electric heat gun. Such guns, 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.
Aquatech does not recommend the use of a torch to repair poly tanks.
Using the heat gun, and varying the distance of the gun from the surface of the material, work the heat
in a circular motion around the blemished area until the surface begins to become shiny. At this point the technician
should become Vely careful as the poly material is beginning to liquefy and will begin to flow. By allowing just enough
flow to fill any surrounding blemishes, and using a smooth metal obj ect such as a spoon or spatula, the material can
be manipulated and be made smooth. In cases where the material may have been heavily gouged, and some material
has been lost, the use of a stick of polyethylene material melted into the affected area can help fill it, then the tool can
restore the smooth surface.
Using an electric soldering gun with a wide, flat tip suitable for working with plastics, dip the hot tip into granulated poly-
ethylene (provided by Aquatech) and work small amounts into the crack or hole. Repeat as many times as necessary to
build the affected area up to the surrounding surface. Repeat the procedure on the opposite side if possible.
Use a smooth metal tool such as a spoon or spatula to work the material to conform with the surrounding surface. A
heat gun may used as a final step to completely smooth the area, but is not required.
Areas repaired with either technique will have all the qualities and properties of strength and stability as the original
area. Repaired sections can be put into service immediately upon cooling.
Recommended Tools
Tools recommended are a heat gun, 1000-1300 watts. Several manufacturers offer such a gun in the price range of
US$60.00 to US$ 150.00. Some manufacturers include Master, Weller and Ideal. These heat guns are also excel-
lent tools for thin wall shrink tubing and special solder/shrink electrical terminals. A soldering gun capable of accepting
altemate tips is also recommended. Such soldering guns can be purchased at electronic supply houses such as Radio
Shack, or at common retail outlets such as Sears. Weller is a respected manufacturer of good soldering tools. Forming
tools which are metal and smooth can be made from common items such as kitchen utensils, or purchased from body
shop suppliers. Since many different applications are possible, experience is the best judge of which particular tool to
obtain.
1 10
5 6 7
2
8
4
9
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.
Discharge Valve
(A140050)
Pump
(A381609)
Hyd. Motor
(A381608)
Directional
Control
Valve
(A110422)
Suction Line
(A176460)
Hydraulic
Control
Lever
Shuttle
Valve
(A110319)
Intake Valve
(A140050)
Discharge Valve
(A140050)
Pump
(A381609)
Hyd. Motor
(A381608)
Suction Line
(A176450)
Directional
Control
Valve
(A110422)
Hydraulic
Control
Lever
Shuttle
Intake Valve Valve
(A140050) (A110319)
Hose
(A176450) Separator Body
(A221420)
Strainer
Valve (A380820)
(A140050)
Valve
(A150700)
ITEM #2
ITEM #3
ITEM #1
TANK INTERCONNECT,B-SERIES,W/POLY
PART #A238210
2 1
3 4
INTEL-A-COUNT
Part #A338664-5