UltraVac T-475 Series Operations Manual - hi
Contents
1. yy WER A L umm 4 A St Am wa xm nan US m r Alin SA W m Gama ns mii AE wy AE CU ZU s WE UU A D ultra Vac A DIVISION OF Hi Vac CORPORATION Ultra Vac SERIAL NUMBER UV XXXX OPERATION SERVICE amp PARTS MAN UAL 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 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 A DIVISION OF Hi Vac CORPORATION TABLE OF CONTENTS WARRANTY INFORMATION FOR YOUR NEW ULTRA VAC UNIT MESSAGE TO NEW OWNER SECTION 1 SAFETY PRECAUTIONS GENERAL PRECAUTIONS AND WARNINGS PLEASE READ SAFETY FIRST SECTION 2 OPERATIONS PRESTART PROCEDURES START UP PROCEDURES MANUAL SHUTDOWN PROCEDURES AUTOMATIC SHUTDOWNS MACHINE AUTOMATIC SHUTDOWNS ENGINE DUMPING PROCEDURES SECTION 3 MACHINE SPECIFICATIONS w g lt POWERTRAIN HYDRAULIC SYSTEM VACUUM SYSTEM PNEUMATIC SYSTEM ELECTRICAL SYSTEM SPARE PARTS LIST T475 LOGIC P amp I DIAGRAM SECTION 4 MAINTENANCE POWER TAKE OFF FILTER BAG REMOVAL amp INSTALLATION HEPA FILTER TENSIONING V BELT DRIVES ADJUSTING THE LEVEL PROBE LUBRI2. COMPLIANCE WITH THE PRINTED INSTRUCTIONS AND TO SERVICE THE Ultra Vac UNIT ACCORDING TO THE METHODS AND SCHEDULES CONTAINED IN THE Ultra Vac UNIT S MANUAL EVIDENCE OF PURCHASER S SCHEDULED MAINTENANCE MUST BE REPORTED IN WRITING TO Hi Vac CORPORATION ON THE FORMS SUPPLIED TO PURCHASER IN THE Ultra Vac MAINTENANCE MANUAL SHOULD PURCHASER BELIEVE A DEFECT HAS BEEN DISCOVERED THE PURCHASER SHALL RETURN THE ALLEGED DEFECTIVE PART TO Hi Vac CORPORATION FOR EXAMINATION F O B THE Hi Vac PLANT MARIETTA OHIO IN THE EVENT PURCHASER DOES NOT SERVICE AND MAINTAIN THE Ultra Vac UNIT ACCORDING TO THE Ultra Vac MAINTENANCE MANUAL THE WARRANTY IS TO BE CONSIDERED NULL AND VOID AND Hi Vac CORPORATION S OBLIGATION HEREUNDER SHALL BE DEEMED FULFILLED THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF Hi Vac CORPORATION LIMITS OF LIABILITY Hi Vac CORPORATION SHALL NOT BE LIABLE FOR AND PURCHASER ASSUMES RESPONSIBILITY FOR ALL PERSONAL INJURY AND PROPERTY DAMAGE RESULTING FROM THE HANDLING POSSESSION OR USE OF YOUR Ultra Vac INDUSTRIAL VACUUM LOADER BY THE PURCHASER THE LIABILITY OF Hi Vac CORPORATION ARISING OUT OF THE SUPPLYING OF YOUR Ultra Vac INDUSTRIAL VACUUM LOADER OR ITS USE WHETHER ON WARRANTIES OR CLAIM OF NEGLIGENCE OR OTHERWISE SHALL NOT IN ANY CASE EXCEED THE COST OF
3. and the BLOWER LOW OIL indicator will light on the control panel This condition is to be reset after the problem is corrected by pressing the Fault Reset button HIGH BLOWER TEMPERATURE There is a high temperature sensing thermal switch and gauge located near the control panel The thermal switch sensor is located in the discharge pipe of the vacuum pump When the discharge air temperature reaches 350 F the unit will shut down and the BLOWER HIGH TEMP indicator will light on the control panel This condition is to be reset after the problem is corrected by pressing the Fault Reset button Blower Hi Temp Blower Low Oil Hopper Full Low Air Pressure ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 OPERATIONS ultraYac OPERATIONS AUTOMATIC SHUTDOWNS ENGINE The following conditions will shut off the engine fuel solenoid causing the engine to shutdown 1 Engine Oil Pressure When the oil pressure in the engine drops below a desired set point the engine will automatically shutdown This is designed in the switch and should not be tampered with Changing the set points may cause damage to engine Check engine immediately after the shutdown and correct problem 2 Engine Temperature When the engine coolant temperature rises above a desired set point the engine will automatically shutdown Check engine immediately after the shutdown and correct problem ULTRA VAC OPERATIONS PARTS amp
4. condition alarm Note This unit has been supplied with the new Drexelbrook The Point Series Level Probe During initial start up and after a loss of power the operator must wait approx 20 seconds to allow the probe to finish its calibration cycle The blower will not start and the Hopper Full light will remain on until the cycle is complete and the blower Fault Reset button is pushed Allow Engine to idle until air pressure is built up before engaging Vacuum Pump WARNING The Vacuum System will not begin operation until air pressure is at least 60 psi At engine idle speed Push and hold the Blower Engage button for 5 seconds to fully engage the PTO This will allow the Vacuum Pump to start Be sure to engage and disengage the blower at idle speed only WARNING Never engage Blower above 1 000 RPM s After Vacuum Pump is engaged press up on the throttle control until you are at operating speed 2200 RPM s Once the unit is at operating speed you may begin loading material Periodically check gauges to ensure the unit is running properly The Ultra Vac unit and engine have built in shutdowns If a shutdown occurs immediately stop work and remedy the situation ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 OPERATIONS ultra Vac OPERATIONS MANUAL SHUTDOWN PROCEDURES Before stopping unit allow the Ultra Vac to run for a moment to let the lines clean out 1 Press down on the throttle c
5. CATION INTERVALS RECOMMENDED LUBRICANTS LUBRICATION MAINTENANCE RECORD FORM MAINTENANCE RECORD FORMS BILL OF MATERIALS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL A DIVISION OF Hi Vac CORPORATION SECTION 5 OPTIONS AS LISTED SECTION 6 ELECTRICAL ELECTRICAL SCHEMATIC SECTION 7 ACCESSORIES ACCESSORIES SECTION 7 MANUFACTURERS MANUALS JOHN DEERE ENGINE located in seperate manual TWIN DISC PTO located in seperate manual ROOTS BLOWER DREXELBROOK LEVEL PROBE LEESON MOTOR ASCO SOLENOID VALVE MAC SOLENOID VALVE ALLENAIR SOLENOID VALVE GRESEN VALVE KUNKLE RELIEF VALVE KEYSTONE VALVE GOYEN TIMER BOARD DWYER PRESSURE GAUGE MARSH PRESSURE GAUGE SPAN GAUGE WATTS AIR FILTER PARKER REGULATOR PARKER LUBRICATOR ZINGA FILTER HEAD amp FILTER BARKSDALE PRESSURE SWITCH UNITED ELECTRIC TEMP CONTROL STEMCO MOISTURE EJECTOR GLOBAL VIBRATOR CONDUCTIX GROUND REEL FLANDERS HEPA FILTER ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 ultraVac A DIVISION OF Hi Vac CORPORATION INSPECTION PROCEDURES All pieces received should be inspected for damage immediately upon receipt 1 Damage can be most easily detected by looking for scrapes on the paint 2 Inspect all sheet metal and structural steel for damage such as bends kinks or breaks 3 Check all wiring for abrasions cuts cracks etc If any are found repair or replace before connecting to power source 4 Chec
6. CE TWIN DISC POWER TAKE OFF MODEL SP111P301 Note For lubrication intervals recommended lubricants and clutch adjustment follow the recommendations of the PTO manufacturer This manual is located in the Manufacturer s Manuals section of this operations manual ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 MAINTENANCE A DIVISION OF Hi Vac CORPORATION FILTER BAG REMOVAL 1 With Ultra Vac unit shut off and parking brake on carefully climb on top of the collector body Open all plenum doors to gain access to filters and cages 2 Remove cages by carefully pulling up and out of the filler bag Be sure not to catch the bag on the cages The dry plenum will have 32 bags and cages and the wet side will have 8 bags and cages 3 On top of the filter bags there is a snapband sewn into the filter bag Simply fold snapbands in half and push bags through the tubesheet NOTE Do not pull filter bags up and out This will bring dirty material up into the clean side of the vacuum system which can cause serious damage to the blower By pushing them through the tubesheet you can keep all dirt in the baghouse 4 The bags can then be removed through the baghouse access doors or the tailgate ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 MAINTENANCE ultraVac MAINTENANCE FILTER BAG INSTALLATION 1 Be sure the baghouse tubesheets and plenum area is clean of debris 2 Slide clean bags fr
7. CORRECTING DEFECTS IN YOUR Ultra Vac INDUSTRIAL VACUUM LOADER AS HEREIN PROVIDED Hi Vac amp CORPORATION SHALL NOT IN ANY EVENT BE LIABLE FOR ANY LABOR EXPENDED BY THE PURCHASER ON ANY PART OR PARTS OR FOR ANY SPECIAL DIRECT OR INDIRECT OR CONSEQUENTIAL DAMAGES NO MATERIAL MAY BE RETURNED WITHOUT FIRST GETTING APPROVAL FROM Hi Vac amp CORPORATION ANY GOODS RETURNED WITH SUCH APPROVAL MUST BE SENT BACK WITH ALL TRANSPORTATION CHARGES PREPAID WITHIN 30 DAYS AFTER ISSUANCE OF APPROVAL GOODS RETURNED AND ACCEPTED IN ACCORDANCE E PRICES PAID AT TIME OF SHIPMENT ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 A DIVISION OF Hi Vac CORPORATION MESSAGE TO NEW OWNER Congratulations on your purchase of a new Ultra Vac Vacuum Loader This manual is supplied for your convenience to assist you in adequately maintaining servicing and operating your Ultra Vac Vacuum Loader Your Ultra Vac Vacuum Loader has been designed to give you many years of dependable trouble free service which can be attained only through conscientious care by your personnel Therefore cooperation practice and skill on the part of all personnel associated with your Ultra Vac is necessary to maintain maximum productivity The material in this manual has been carefully and thoughtfully prepared to provide a simple and understandable guide It should be carefully read and thoroughly understood by all personnel responsible for your Ultra Vac before engag
8. ERATIONS PARTS amp SERVICE MANUAL 12 MAINTENANCE ultraVac MAINTENANCE DAILY CHECKS engine running clutch engaged Perform the daily maintenance checks listed below and record on Record Sheet 1 9 Filter Bag Pressure Differential a With the inletto your machine open Check differential gauge Reading should be between 1 and 7 of water H O Record the reading on the pressure differential gauge in inches H O water 1 If higher than 10 inches of water a visual inspection should be made for excessive buildup of material on the filter bag surfaces or bridging of material between bags This can be done through the side access door Differential 10 No Load Vacuum a With the inlet completely open and no hoses connected check vacuum gauge reading This no load reading is an important indicator of the condition of the unit The no load vacuum should be about 1 inch of mercury Hg Record vacuum reading in Hg 1 If no load vacuum reading is zero 0 a Inspect vacuum gauge plumbing for hose rupture loose fittings or plugged lines b Check that the box is properly seated on the standpipe and that there are no leaks Vacuum 2 If no load vacuum reading is higher a Check for obstruction in the cyclones and pipings by opening the top lids on each cyclone 11 Dust Discharge a Inspect the silencer for visible dust in the air stream NOTE Shut the unit off immediately if dust i
9. ION OF Hi Vac CORPORATION OPERATIONS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL ultra Vac OPERATIONS PRESTART PROCEDURES Caution Before prestarting your Ultra vac unit be sure you have read and understood all of 10 the safety warnings and precautions located in the Safety Precaution section of this manual Stop unit and be sure to set parking brake Visually inspect the unit so that there are no obstuctions which may cause harm to machine or operating personnel Check oil level in Vacuum Pump and Engine Check coolant level in Engine Check Hydraulic oil level and add if necessary Check all Hydraulic hoses and fittings for leaks Repair if necessary Check belts for proper tension Refer to belt tensioning in this manual Check that all doors are closed and locked and wet baghouse ball valves are closed Attach vacuum loading hose You are now ready to start your Ultra Vac unit ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 OPERATIONS ultraVac OPERATIONS A DIVISION OF Hi Vac CORPORATION START UP PROCEDURES Before starting up your Ultra Vac unit Be sure you have done all the Prestart Procedures located on the previous page 1 2 At the control panel turn key to start engine With engine running select which vacuum plenum to use i e wet dry left dry right or dry left and right Press the Fault Reset button to clear Hopper Full
10. SERVICE MANUAL 5 OPERATIONS ultra Ac OPERATIONS DUMPING PROCEDURES Before dumping material out of the collector body be sure that there are no personnel or obstuctions near the Ultra Vac This could result in damage to machinery or injury to personnel Dumping Dry Compartments 1 At engine idle turn Hydraulic Pump switch to ON Only engage Hydraulic pump at Idle speed 2 Pull the Gresen valve marked Lock Unlock to unlock tailgate prior to raising Be sure that there are no personnel at the back of the Ultra Vac unit 3 Pull the Gresen valve marked Tailgate Open Close to open the tailgate Be sure that there are no personnel at the back of the Ultra Vac unit WARNING Never open the tailgate without first unlocking This will cause damage to the equipment 4 Pull the Gresen valve marked Raise Lower to fully raise the collector body WARNING Be sure that the Ultra Vac is on a Gresen Valve level surface before raising the collector body Possible tipping may occur 5 Push and hold the Vibrator button for approximately 3 5 seconds to loosen any stuck material Repeat as required to fully empty the collector body 6 After inspecting the Blower Inlet Screen Lower the collector body close the tailgate and then lock the tailgate locks WARNING Never work under body or tailgate in the raised position unless the appropriate props are in place Never move the Ultra V
11. STACKING 12VDC CYLINDER AIR 2 5 B X 3 STROKE ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 11 MACHINE SPECIFICATIONS ultraVac PNEUMATIC SYSTEM i 61000119 LUBRICATORAIRPARKER 00 218 SPORTS 4 U4007 0080 FILTER COALESOING 3 8 NPT 20CFM 1 s 150454 _ REGULATORAIR 125 PSIGS NPTWIGAUGE 1 6 U4003 0048 VALVE PNUEMATIC SOLENOID W8 NPT12V00 2 s 15 0453 vave soenoe CS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 12 MACHINE SPECIFICATIONS ultraVac PNEUMATIC SYSTEM ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 13 MACHINE SPECIFICATIONS ultravac ELECTRICAL SYSTEM CONTROL PANEL PART U4102 0621 Blower Hi Temp Blower Low Oil Dry Left Dry Right Wet Hopper Full Low Air Pressure ITEM PART DESCRIPTION GAUGE AIR PRESSURE 0 200 PSI GAUGE VACUUM 0 30 HG PANEL MOUNT GAUGE DIFFERENTIAL PRESSURE 0 50 WC GAUGE FUEL LEVEL STEWART WARNER ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 14 MACHINE SPECIFICATIONS ELECTRICAL SYSTEM CONTROL PANEL PART U4102 0621 Emergency Stop Control Power On Hydraulic Pump Off On Push amp Hold Blower Engage Blower Engage Blower Disengage Dry Wet Selector Switch Vibrator ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 15 MACHINE SPECIFICATIONS ultra ac ELECTRICAL SYSTEM CONTROL PANEL PART U4102 0621 Engine Display Eng
12. TIONS PARTS amp SERVICE MANUAL ultra ac A DIVISION OF Hi Vac CORPORATION ACCESSORIES ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL t L A DIVISION OF Hi Vac CORPORATION MANUFACTURER S MANUALS
13. ac with the collector body in the raised position Inlet Screen ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 OPERATIONS ultraVac OPERATIONS Dumping Wet Compartments 1 DUMPING PROCEDURES cont With the collector body lowered open the ball valves under the front of the collector body on both sides and drain the wet bag houses NOTE Wet bag houses should be drained after each use The collector body must then be dumped as described in steps 1 6 on the previous page Ball Valve NOTE The collector body may also be emptied through the optional tailgate drain valve After material is unloaded collector body lowered tailgate shut and tailgate locked you may then turn hydraulic pump to OFF _ Optional Tailgate Drain Valve ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 7 OPERATIONS t L 1 A DIVISION OF Hi Vac CORPORATION MACHINE SPECIFICATIONS ultraVac BODY a ai B rile Lie All ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 MACHINE SPECIFICATIONS ultraVac BODY ASSEMBLY REAR BODY T475 95 3 4 WIDE BOX PART U1007 3376 ultra Vac ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 MACHINE SPECIFICATIONS ultra Vac POWERTRAIN ENGINE and PTO PART U3201 0104 Engine PTO SEE JOHN DEERE ENGINE amp TWIN DISC PTO MANUALS FOR DETAILS ULTRA VAC OPERATIONS PARTS
14. adVacuum Check Mechanical Vacuum Relief Valves ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 18 MAINTENANCE ultra ac MAINTENANCE WEEKLY MAINTENANCE RECORD FORM 2 OWNER PLANT LOCATION BUILDING Ultra Vac SERIAL HUV ___________ MODEL MAINTENANCE PERFORMED BY DATE RECORD Hi Vac HOUR METER______ HOURS Gauge Checked Needs Repairs Reading OK Repair Made Check Belt Tension Check Subframe U Bolts Check Level Probe Check Compressed Air and Vacuum Lines ucc NA E Check ElectricCables NA NA j j S j ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 19 MAINTENANCE ultra ac MAINTENANCE MONTHLY MAINTENANCE RECORD FORM 3 OWNER PLANT LOCATION III BUILDING Ultra Vac SERIAL 8 UV ___________ MODEL MAINTENANCE PERFORMED BY DATE RECORD Hi Vac HOUR METER______ HOURS Gauge Checked Needs Repairs Reading OK Repair 1 Check Vacuum Pump Lobe Wear NA Za OS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 20 MAINTENANCE ultraVac A DIVISION OF Hi Vac CORPORATION OPTIONS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL OPTION 170 SHUTDOWN LOW BLOWER OIL OPTION 220 HIGH BLOWER TEMPERATURE SHUTDOWN OPTION 240 GROUND CABLE OPTION 50 REEL OPTION 440 STARTER 1 4HP MOTOR ultraVac A DIVISION OF Hi Vac CORPORATION ELECTRICAL ULTRA VAC OPERA
15. amp SERVICE MANUAL 3 MACHINE SPECIFICATIONS ultra Vac POWERTRAIN 12 800 350 RES TOP POST PART U3312 0006 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 MACHINE SPECIFICATIONS ultraYac POWERTRAIN SHEAVES BUSHINGS and BELT ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 MACHINE SPECIFICATIONS ultra ac HYDRAULIC SYSTEM PART 4 DESCRIPTION U3902 0069 PUMP HYD CLUTCH 1 55 CU IN DISP 5 4GPM U3914 0017 FILTER HYDRAULIC CARTRIDGE U3914 0021 FILTER HEAD HYD SUCTION U3907 0025 TANK HYDRAULIC 10 GAL HORIZONTAL U3904 0102 VALVE HYD 4 WAY 3 SPOOL W PRESSURE REL ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 MACHINE SPECIFICATIONS ultraVac VACUUM SYSTEM 1 0055 FILTER BAG WET4CUYDBOX e e U37010053 FILTER BAG DRY 6 OD X4 LONG 22 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 7 MACHINE SPECIFICATIONS ultraVac VACUUM SYSTEM ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 8 MACHINE SPECIFICATIONS ultraVac VACUUM SYSTEM 16 0267 VALVE VACUUM RELIEF 3 15 HG 20 0150 HEPA FILTER 24X24X11 1 2 HI TEMP GASKET ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 9 MACHINE SPECIFICATIONS ultra ac PNEUMATIC SYSTEM Wet Side ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 10 MACHINE SPECIFICATIONS ultraVac PNEUMATIC SYSTEM ITEM PART DESCRIPTION VALVE SOLENOID 3 4 WAY
16. ecking the vacuum pump oil level is critical and should be done frequently Some vacuum pumps have oil level sight gauges and others have oil level plugs If oil is needed refer to the vacuum pump manual located in the Manufacturer s Manuals section of this operations manual Record on Daily Maintenance Schedule Record Oil Sites Note Unit must be on level surface to get an accurate oil level reading 2 Engine Oil amp Coolant Levels a Remove Engine side cover to access the dipstick and oil fill spout Check engine oil when engine is cool to get amore accurate reading If oil is needed refer to the engine manual Record on Daily Maintenance Schedule Record b When engine is cool remove Radiator Cap and check Coolant level If coolant is needed refer to the engine Oil Fill manual Record on Daily Maintenance Schedule Record Dipstick CAUTION NEVER REMOVE RADIATOR CAP WHEN ENGINE IS WARM 3 Lubricator Check oil level in Lubricator If oil is needed refer to the lubricator manual located in the Manufacturer s Manuals section of this operations manual and record on Daily Maintenance Schedule Record Lubricator ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 10 MAINTENANCE ultra Vac MAINTENANCE DAILY CHECKS before starting engine Perform the daily maintenance checks listed below and record on Record Sheet 1 Hydrualic Tank Air Regulator 4 Compressed Air Regulator Fil
17. he HEPA filter With a new HEPA filter in place start the Ultra Vac unit with no hose connected and note the differential reading for the HEPA filter Typically this will be between 1 H O and 5 H O Monitor the HEPA differential reading daily When the differential reading increases by 5 H O or more from the orginal new filter reading the filter should be replaced ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 MAINTENANCE MAINTENANCE A DIVISION OF Hi Vac CORPORATION TENSIONING V BELT DRIVES Without exception the most important factor in the successful operation of a V belt drive is proper belt tensioning To achieve the long trouble free service associated with V belt drives belt tension must be sufficient to overcome slipping under maximum peak load This could be either at start or during the work cycle The amount of peak load will vary depending upon the character of the driven machine or drive system To increase total tension merely increase the center distance Before attempting to tension any drive it is imperative that the sheaves be properly installed and aligned If a V belt slips it is too loose Add to the tension by increasing the center distance Never apply belt dressing as this will damage the belt and cause early failure A Step 1 Reduce the center distance so that the belts may be placed over the sheaves and in the grooves without forcing them over the sides of the grooves Arrange the belt
18. ine Throttle ESA key Switch 8 Beacon Off On ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 16 MACHINE SPECIFICATIONS ultravac ELECTRICAL SYSTEM CONTROL PANEL PART U4102 0621 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 17 MACHINE SPECIFICATIONS A DIVISION OF Hi Vac CORPORATION CABLE STATIC GROUNDING 50 ON REEL PART U8000 0177 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 18 MACHINE SPECIFICATIONS ultra ac SPARE PARTS LIST QTY 2 3807 002 GASKET 10 STANDPIPE FOR 9 CU YD BOX U 10 32 2 oron 0032 0019 0090 0092 0014 0023 U3701 0053 0024 0019 DI 0002 0004 0105 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 19 MACHINE SPECIFICATIONS ultra ac A DIVISION OF Hi Vac CORPORATION MAINTENANCE ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac Hi Vac ultra Vac MAINTENAN
19. ing in both operation and the maintenance of the system The very best wishes from our entire organization are extended to you with the assurance that you will enjoy long and dependable service from this Ultra Vac ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 A DIVISION OF Hi Vac CORPORATION SAFETY PRECAUTIONS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL ultra ac A DIVISION OF Hi Vac CORPORATION CAUTION SOME DO S AND DON TS BEFORE GETTING STARTED WITH YOUR NEW Ultra Vac SYSTEM The safety of the operator is of great importance to us at Hi Vac Corporation The decals shields guards and other protective features that are designed into the machine are there for your protection A high percentage of the accidents that occur are due to careless behavior or misuse of machinery We ask you to be a careful operator and to properly service your machine ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 A DIVISION OF Hi Vac CORPORATION PROCEED WITH CAUTION Before attempting to operate the machine read carefully and understand all instructions contained in the manual IT IS VERY IMPORTANT THAT YOU UNDERSTAND THE FOLLOWING SAFETY WARNINGS IN FULL INJURY OR DEATH TO PERSONNEL AND OR DAMAGE TO MACHINE CAN RESULT Unit should ONLY be operated by thoroughly trained personnel Do not put your face or any portion of head in front of the nozzle Hearing protection MUST be worn by ope
20. k all conduit runs and fittings for defects 5 Check motor and vacuum pump for free rotation before starting under power for the first time after installation 6 Compare the packing list attached to each piece of each shipment 7 Verify the number of pieces and description of each piece shown on the packing slip REPORT ANY DAMAGE NO MATTER HOW SLIGHT IMMEDIATELY TO Hi Vac Corporation 117 Industry Road Marietta OH 45750 Attention Service Department Phone 740 374 2306 Toll Free 800 752 2400 Fax 740 374 5447 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 ultraVac A DIVISION OF Hi Vac CORPORATION WARRANTY Hi Vac CORPORATION WARRANTS TO THE ORIGINAL PURCHASER OF THE Ultra Vac UNIT QUOTED HEREIN THAT THE Ultra Vac UNIT SHALL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USE AND SERVICE Hi Vac CORPORATION DOES NOT WARRANT COMMERCIAL ITEMS MANUFACTURED BY OTHERS SUCH AS DIESEL ENGINES TRUCK CHASSIS TIRES OR MOTORS Hi Vac CORPORATION S OBLIGATION UNDER THIS WARRANTY SHALL BE LIMITED TO THE REPAIR OR EXCHANGE OF ANY PART OR PARTS WHICH MAY PROVE DEFECTIVE UNDER NORMAL USE AND SERVICE WITHIN THE SHORTER PERIOD OF TWO 2 YEARS OR FOUR THOUSAND 4 000 WORK HOURS FROM THE DATE OF DELIVERY TO THE ORIGINAL PURCHASER AND WHICH Hi Vac CORPORATION S EXAMINATION SHALL DISCLOSE TO ITS SATISFACTION TO BE DEFECTIVE THIS WARRANTY REQUIRES PURCHASER TO OPERATE THE Ultra Vac UNIT IN STRICT
21. ngine Perform the weekly maintenance checks listed below and record on Record Sheet 2 1 Belt Tension Disconnect battery cables and remove belt guard and check tension per Tensioning V belt Drives in the maintenance section Record on Weekly Maintenance Schedule Record 2 Subframe U Bolts Check U Bolts holding the vacuum unit to the truck chassis and record on Weekly Maintenance Schedule Record 3 Electric Cable Visually inspect all electrical conduit cables and connections for signs of abrasions or breaks ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 15 MAINTENANCE ultraVac MAINTENANCE WEEKLY CHECKS or Every 40 Hours of Operation engine running clutch disengaged Perform the weekly maintenance checks listed below and record on Record Sheet 2 Drexelbrook Level Probe 4 Level Probe Check level probe for operation by touching the probe Control panel must be on with the blower OFF The Hopper Full light will turn ON on control panel If adjustment is necessary refer to the Adjusting the Sensitivity Of the Level Probe section located in this manual or to the Drexelbrook probe manual located in the Manufacturer s Manuals section of this operations manual Record on the Weekly Maintenance Schedule Record 5 Compressed Air lines and Vacuum Leaks Inspect all compressed air lines fittings and connections for possible leaks Check the openings for possible damage t
22. o gaskets With machine running listen for audible leaks around doors hose connections flanges etc and repair as required Record on Weekly Maintenance Schedule Record ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 16 MAINTENANCE ultraVac MAINTENANCE MONTHLY CHECKS before starting engine Perform the monthly maintenance checks listed below and record on Record Sheet 3 1 Vacuum Pump Lobe Wear Check the vacuum pump standpipe screen for visible dust by raising the collector body If dust is present remove the vacuum pump standpipe and remove the bolts around the standpipe located on top of blower Look for visible signs of wear on the tips of the vacuum pump lobes WARNING Be sure to put safety prop in place before removing the standpipe 2 Centrifugal Separator Deflector Box Open tailgate and inspect centrifugal separator ring on ceiling of box inside your Ultra Vac Unit Repair or replace before it is worn through ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 17 MAINTENANCE ultravac MAINTENANCE DAILY MAINTENANCE RECORD FORM 1 OWNER PLANT LOCATION BUILDING Ultra Vac SERIAL UV MODEL MAINTENANCE PERFORMED BY DATE RECORD Hi Vac amp HOUR METER HOURS D ee Pa Due Reading OK Repair Made 6 Check Compressed Air Pressure Switch 7 CheckAirPurge System _8 Check Compressed Air 8 Hydraulic Lines 9 Check Filter Bag Pressure Differential 10 CheckNoLo
23. om top of unit down into the tubesheet holes 3 When bag reaches the snapband fold the snapband in half and push down until the tubesheet fits into the groove in the snapband 4 Unfold the snapband until it snaps back to round NOTE Tubesheet must fit tight in the snap band groove or bags will not seal properly causing serious damage to Vacuum Pump 5 Inspect cages to be sure they are straight no broken wires and free of burrs and sharp edges that could tear the bags when installed 6 Slide the cages down from the top Be sure to slide straight down to keep from damaging the bags The cages should slide tight against the tubesheet completely covering the bag ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 MAINTENANCE A DIVISION OF Hi Vac CORPORATION HEPA FILTER Description The HEPA filter option is designed to eliminate virtually any particulate from being discharged from the Ultra Vac unit The HEPA filter is located on the suction side of the vacuum pump between the clean side of the filter system and the inlet side of the vacuum pump In this design all of the air is filtered before it enters the vacuum pump assuring the air being discharged is clean Typical filter efficiency for a HEPA filter is 99 7 of all material down to 0 3 micron in size Maintenance Each Ultra Vac unit that is equipped with a HEPA filter also includes a filter differential gauge to show the condition of t
24. ontrol until you are at engine idle WARNING Never disengage Blower above 1 000 2 If time allows let Vacuum Pump run at low RPM to cool down 3 Press the Blower Disengage button to stop Vacuum Pump 4 Turn key to stop engine ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 OPERATIONS A DIVISION OF Hi Vac CORPORATION OPERATIONS AUTOMATIC SHUTDOWNS MACHINE The following conditions will cause the blower to be automatically disengaged 1 HOPPER FULL This is caused by material filling up inside the collector body and activating the Level Probe This is indicated by a light on the control panel Simply dump material out of the collector body and press the Fault Reset button You may then continue loading LOW AIR PRESSURE If the Unit air pressure drops below 60 PSI the blower will disengage and the Low Air Pressure light will turn on Check all air lines for leaks and correct if necessary When air pressure builds back up to above 60 PSI push the Fault Reset button and restart the blower LOW OIL LEVEL IN THE GEAR CASE S OF THE VACUUM PUMP There are low oil level float switches installed near the vacuum pump Daily checks of the oil level by visually inspecting the oil level sight glasses on the vacuum pump will prevent a low oil condition Do not use level switches to check oil level In the event a loss of oil occurs during operation the unit will shut down
25. rator and those working near the vacuum loader Do not operate machinery without proper guards in place Keep away from moving objects Do not put your hand in front of the intake nozzle while in operation Do not put your face or any portion of head in front of the nozzle Do not vacuum any flammable liquid Check that unit is properly stopped so unit will not tip or roll Do not lubricate adjust or repair the Ultra Vac unit unless engine is shut down NEVER raise body unless the tailgate is fully open NEVER operate tailgate while body is in elevated position NEVER move the Ultra Vac with the body in the raised position Clear the area behind the Ultra Vac of all personnel before opening or closing the tailgate NEVER inspect or work under the raised body without the safety body prop in place NEVER inspect or work under the open tailgate without a tailgate prop in place Do not operate the Ultra Vac unit while wearing loose clothing watches or rings Periodically check for any loose bolts or set screws NOTE AS WITH ANY TYPE OF HEAVY DUTY EQUIPMENT CAUTION MUST BE EXERCISED IN ITS PROPER USE WARNING FAILURE TO COMPLY WITH ANY OF THE ABOVE SAFETY NSTRUCTIONS OR THOSE THAT FOLLOW WITHIN THIS MANUAL MAY RESULT IN SEVERE INJURY OR DEATH PLEASE REMEMBER SAFE OPERATION BEGINS WITH A SAFE OPERATOR WE ASK YOU TO BE THAT TYPE OF OPERATOR ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 ultraVac A DIVIS
26. rer s Manuals section of this operations manual 2 Hydraulic System a All hydraulic systems furnished for use on Ultra Vac units will be supplied with S1 M 46 Hydraulic fluid b Tailgate locks and Pivot pins shall use a High Grade Lithium base No 2 Bearing grease 3 Diesel Engine Follow the recommendations of the Engine manufacturers manual 3 Electric Motor Follow the recommendations of the Motor manufacturers manual located in the Manufacturer s Manuals section of this operations manual 4 Lubricator Follow the recommendations of the Lubricator manufacturers manual located in the Manufacturer s Manuals section of this operations manual ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 8 MAINTENANCE ultra Vac MAINTENANCE LUBRICATION MAINTENANCE RECORD OWNER PLANT LOCATION XB gt B B j 9 m BUILDING Ultra Vac SERIAL UV ___________ MODEL MAINTENANCE PERFORMED BY DATE RECORD Hi Vac HOUR METER______ HOURS LUBRICATION OIL DRAINED amp PERFORMED CHANGED OIL ADDED GREASED VACUUM PUMP N A HYDRAULIC SYSTEM N A DIESEL ENGINE N A ELECTRIC MOTOR N A N A LUBRICATOR N A ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 9 MAINTENANCE ultra ac MAINTENANCE DAILY CHECKS before starting engine Perform the daily maintenance checks listed below and record on Record Sheet 1 1 Vacuum Pump Oil Level Ch
27. s so that the top and bottom spans have about the same sag Apply tension to the belts by increasing the center distance until the belts are snug Step 2 Operate the drive a few minutes to seat the belts in the sheave grooves Observe the operation of the drive under its highest load condition usually starting A slight bow of the slack side of the drive indicates proper tension If the slack side remains taut during the peak load the drive is too tight Excessive bowing or slippage indicates insufficient tension If the belts squeal as the motor comes on or at some subsequent peak load they are not tight enough to deliver the torque demanded by the drive machine The drive should be stopped and the belts tightened Step 3 Check the tension on a new drive frequently during the first day by observing the slack side span After a few days of operation the belts will seat themselves in the sheave grooves and it may become necessary to readjust so that the drive again shows a slight bow in the back side ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 MAINTENANCE ultraVac MAINTENANCE ADJUSTING THE SENSITIVITY OF THE LEVEL PROBE Every standard Ultra Vac comes with a Drexelbrook Level Probe This probe is used for wet or dry applications The sensitivity of the probe may need to be adjusted according to the material that is filling the hopper or if the probe is replaced The Drexelbrook Level Probe used on the Ultra Vac unit
28. s has a level detection range from approximately 6 inches from the probe tip to a level that applies pressure on the probe tip The level probe sensitivity may need to be adjusted to get the desired level of your particular material in the hopper To adjust the sensitivity refer to the manufacturer s manual located in the Manufacturer s Manuals section of this operations manual ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 MAINTENANCE ultra ac MAINTENANCE LUBRICATION INTERVALS 1 Positive Displacement Vacuum Pump Blower Follow the recommendations of the Blower manufacturer s manual located in the Manufacturer s Manuals section of this operations manual 2 Hydraulic System Drain oil reservoir and replace with new oil every 1000 hours of operation Grease fittings on tailgate locks and pivot pins 3 Engine Follow the recommendations of the engine manufacturer s manual Note Record maintenance performed on Lubrication Maintenance Record Form 4 Vibrator Lubricator Check oil level and add if necessary Follow the recommendations of the Lubricator manufacturer s manual located in the Manufacturer s Manuals section of this operations manual ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 7 MAINTENANCE ultraVac MAINTENANCE RECOMMENDED LUBRICANTS 1 Positive Displacement Vacuum Pump Blowers Follow the recommendations of the Blower manufacturers manual located in the Manufactu
29. s present Any dust discharge should be corrected immediately to protect the vacuum pump b If dust is present disengage the vacuum pump and shut down the engine Check filter bags for rupture or leaks by opening the top access doors and looking for any signs of dust on top of the filter bags or under the inside of the top access door Discharge ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 13 MAINTENANCE ultravac MAINTENANCE DAILY CHECKS engine running clutch engaged Perform the daily maintenance checks listed below and record on Record Sheet 1 12 Mechanical Vacuum Relief Valves with machine running a Check vacuum relief valves for proper operation With the machine running in a no load condition slowly block off hose inlet until 14 of mercury at sea level is indicated on the vacuum gauge Relief valve should remain closed Continue to block off powerhead inlet while watching vacuum gauge Relief valve should open at 15 of mercury at sea level 1 2 inch Record where valve opens in inches of Hg WARNING Do not check relief valve with hand Note You will hear the in rush of air when the valve opens Note Under no circumstances should the Ultra Vac be used with a valve that opens higher than 15 of mercury ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 14 MAINTENANCE MAINTENANCE A DIVISION OF Hi Vac CORPORATION WEEKLY CHECKS or Every 40 Hours of Operation before starting e
30. ter Bowl Drain water from compressed air filter by unscrewing the valve below the filter bowl Record on Daily Maintenance Schedule Record 5 Hydraulic Oil Check oil level from site glass on the side of the Hydraulic tank If oil is needed add the required amount of S1 M 46 Hydraulic fluid Record on Daily Maintenance Schedule Record ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 11 MAINTENANCE ultravac MAINTENANCE DAILY CHECKS engine running clutch engaged Perform the daily maintenance checks listed below and record on Record Sheet 1 Air Pressure Gauge Low Air Pressure 6 Compressed Air Pressure Switch a When the engine is started watch the Air Pressure Gauge and the Low Air Pressure light The light will stay lit until the gauge reaches 60 PSI Record the air pressure at which the Low Air Pressure light goes out on the Daily Maintenance Schedule Record 7 Air System a When the engine is started listen for the solenoids inside the plenum doors to exhaust air Watch the Air Pressure Gauge for a drop of about 10 PSI This should happen every 15 seconds for 8 times Record on the Daily Maintenance Schedule Record 8 Compressed Air amp Hydraulic Lines a When the engine is started inspect all air and hydraulic lines fittings and connections for leaks Look on the ground under unit for drops or pools of oil and record on the Daily Maintenance Schedule Record ULTRA VAC OP
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