Ultravac (105S Series) Operations Manual

105S SERIES
A DIVISION OF Hi-Vac® CORPORATION
OPERATION
SERVICE
& PARTS
M A N U A L
UV - XXXX
Hi-Vac Corporation
117 Industry Road
Marietta, Ohio 45750
Corporate: Tel: 740.374.2306 - Toll Free: 800.752.2400 - Fax: 740.374.5447
Web: www.hi-vac.com - E-mail: sales@hi-vac.com
Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

1
TABLE OF CONTENTS
INSPECTION OF YOUR NEW Ultra-Vac® UNIT
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 : MACHINE SPECIFICATIONS

ELECTRICAL COMPONENTS
HYDRAULIC COMPONENTS
PNEUMATIC COMPONENTS
MECHANICAL DRIVE SYSTEM
FILTER/RECEIVER COMPONENTS
RECOMMENDED SPARE PARTS LIST
HYDRAULIC SCHEMATIC
SECTION 3 : OPERATIONS
BASIC Ultra-Vac SYSTEM OPERATION
®
PRINCIPILES OF OPERATION
AUTOMATIC SHUTDOWNS (BLOWER)
PERFORMANCE SPECIFICATIONS
SECTION 4 : MAINTENANCE
RECOMMENDED LUBRICANTS
LUBRICATION MAINTENANCE RECORD
TENSIONING V-BELT DRIVES
FILTER BAG REMOVAL AND INSTALLATION
CLUTCH INSPECTION & ADJUSTMENT PROCEDURES
TOWING OPTION
BILL OF MATERIALS
SECTION 5 : PREVENTIVE MAINTENANCE

PREVENTIVE INSPECTION PROCEDURES
DAILY CHECK RECORD
WEEKLY CHECK RECORD
MONTHLY CHECK RECORD

2
SECTION 6 : TROUBLESHOOTING
TROUBLESHOOTING GUIDE FOR Ultra-Vac® MODEL 105 SELF-PROPELLED VACUUM UNITS
SECTION 7 : OPTIONS
OPTIONAL EQUIPMENT FOR Ultra-Vac® UNITS
SECTION 8 : ELECTRICAL
CONTROL PANEL SCHEMATIC
SECTION 9 : ACCESSORIES
ACCESSORIES
SECTION 9 : MANUFACTURERS MANUALS

NOTE: ITEMS LOCATED IN SEPERATE MANUAL(S)
JOHN DEERE ENGINE MANUAL HONEYWELL LIMIT SWITCH

NACD PTO BENDIX AIR COMPRESSOR
ROOTS BLOWER MANUAL
MONITOR LEVEL PROBE
KUNKLE RELIEF VALVE
HELAC ACTUATOR
PARKER HYDROSTATIC STEERING
PARKER HYDRAULIC FOOT CONTROL
GRESEN VALVE
EATON HYDRAULIC PUMP
HALDEX HYDRAULIC PUMP
GOYEN TIMER BOARD
DONALDSON HYDRAULIC TANK GAUGE
SPAN VACUUM GAUGE
DWYER PRESSURE GAUGE
STEMCO MOISTURE EJECTOR
BARKSDALE PRESSURE SWITCH
ASCO DIAPHRAGM VALVE
ALLENAIR SOLENOID VALVE
PARKER AIR FILTER

3
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. Check 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
Storage of your Hi-Vac® unit
Allow machine to be crated if at all possible while storing for short or long term durations.
1. For short-term storage. (30 days or less)
A. Rotate shafts every two to three weeks to avoid flat spotting of the ball bearings.
2. For storage over 30 days
A. To prevent damage due to corrosion, oxidation, etc., Refer to the maintenance manuals for each
component.
B. Make sure that the inlets to the piping manifold system are covered with the dust plugs to prevent
foreign objects from entering the system.
C. Add packages of desiccant to all electrical enclosures on sides of Hi-Vac®.
D. Turn off the compressed air supply to the Hi-Vac® and relieve any pressure in the compressed air
lines on the unit.

4
WARRANTY
Hi-Vac® CORPORATION WARRANTS TO THE ORIGINAL PURCHASER OF THE Hi-Vac® UNIT

QUOTED HEREIN THAT THE Hi-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 ORIG-
INAL PURCHASER AND WHICH Hi-Vac® CORPORATION’S EXAMINATION SHALL DISCLOSE TO ITS
SATISFACTION TO BE DEFECTIVE. THIS WARRANTY REQUIRES PURCHASER TO OPERATE
THE Hi-Vac® UNIT IN STRICT COMPLIANCE WITH THE PRINTED INSTRUCTIONS AND TO SER-
VICE THE Hi-Vac® UNIT ACCORDING TO THE METHODS AND SCHEDULES CONTAINED IN THE
Hi-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 Hi-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 Hi-Vac® UNIT ACCORDING TO THE Hi-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 Hi-Vac® INDUSTRIAL VACUUM CLEANER BY THE
PURCHASER. THE LIABILITY OF Hi-Vac® CORPORATION ARISING OUT OF THE SUPPLYING OF
YOUR Hi-Vac® INDUSTRIAL VACUUM CLEANER, OR ITS USE WHETHER ON WARRANTIES OR
CLAIM OF NEGLIGENCE OR OTHERWISE, SHALL NOT IN ANY CASE EXCEED THE COST OF
CORRECTING DEFECTS IN YOUR Hi-Vac® INDUSTRIAL VACUUM CLEANER AS HEREIN PRO-
VIDED. Hi-Vac® 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® 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 WITH THE ABOVE
CONDITIONS WILL BE CREDITED ON THE BASIS OF THE PRICES PAID AT TIME OF SHIPMENT.

5
MESSAGE TO NEW OWNER
Congratulations on your purchase of a new Ultra-Vac® INDUSTRIAL VACUUM
SYSTEM. Hi-Vac® Corporation is a leader in conveying and material pickup.
The use of a Ultra-Vac® system will not only save you money in the short term,
it will also put you on the cutting edge of today’s technology in vacuum systems.
With HiVac’s vast array of configurations, it is possible to meet every consumers
needs in material pickup for both wet and dry applications.
To get the most out of your new Ultra-Vac® INDUSTRIAL VACUUM SYSTEM,
please read and review the contents of this manual and become familiar with
the procedures within.
Thank you for your purchase and we look forward to serving you again in
the future.

6
SAFETY
PRECAUTIONS
CAUTION
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.
WARNINGS
Before attempting to operate the machine, read carefully and understand all instructions contained in
the manual.
* This unit to be operated by properly trained personnel only!
* Severe injury may occur if inlet contacts clothing, hair, or body!
* Stay clear of vacuum nozzle when blower is engaged!
* Hearing protection must be worn by operator and by those working near vacuum
loader!
* Moving parts can injure! Keep away from moving parts!
* Technical procedures should be strictly followed!
NOTICE
All specifications and part numbers subject to change without notice.

SAFETY PRECAUTIONS 1
MACHINE
SPECIFICATIONS
CONTROL PANEL (Outside)

Part #U4102-0596
Tachometer Voltmeter Oil Pressure
Utility Air Pressure
Tattletale
Fuel
Temperature
Hopper Full Light
Emergency Stop
Low Utility Air Light
Key Switch
Pulse Filter Switch
Worklight Switch
Blower On Light Emergency Stop
Fault/Reset Button
Blower Disengage Button

Park/Run Switch
Blower Engage Button

MACHINE SPECIFICATIONS 1
CONTROL PANEL (Inside)

Part #U4102-0596
ITEM PART # DESCRIPTION QTY

1 U4109-0019-DI TIMER BOARD,8 OUTPUT,DIGITAL,12VDC 1
2 U4003-0105 SWITCH,PRESSURE,0-200 PSI, SINGLE SET 1

HYDRAULIC TANK & FILTER

1 U3907-0020 TANK,HYDRAULIC FOR 105 1
2 U3908-0014 GAUGE,FLUID LEVEL/TEMP LHA P/N SLT-1214 1
3 U3915-0004 FILLER NECK/BREATHER CAP ASSY. 1
4 U3914-0031 FILTER,SUCTION,HYD,10 MICRO,105 1

HYDRAULIC PUMPS

1 U3902-0053 PUMP,HYDRAULIC,PWRSTRG/TAILGATE,CW ROT. 1
2 U3902-0082 PUMP,HYD,1.7CUIN/REV,RH,1”KEYED SHAFT 1

ACCUMULATOR and ACCUMULATOR VALVE

1 U3904-0168 ACCUMULATOR,HYD,AD140A25T9A1,105 1
2 U4008-0013 GAUGE,AIR,0-300 P.S.I. 1
3 U3904-0148 VALVE,ACCUMULATOR,1PUL65-P-8T-10S,105 1

HYDRAULIC STEERING SYSTEM

PART # U3904-0037

FOOT PEDAL CONTROL

PART #U3904-0169

DUMP DOOR CONTROL

1 U3903-0018 CYLINDER,HYDR,1.5”BORE x 10” STROKE 2
2 U3904-0103 VALVE,HYD,4-WAY TAILGATE CONTROL 1
3 U6002-0065 VALVE,.25 NPT NEEDLE PNEUTROL #N20B 2

PARKING BRAKE RELEASE SYSTEM

1 U3904-0155 HAND PUMP,BRAKE RELEASE,105S 1
2 U3904-0154 VALVE,BRAKE ISOLATION,105S 1
3 U3904-0153 VALVE,BRAKE,SHORT CIRCUITING BALL,105S 1

PARKING BRAKE CONTROL

1 U4103-0426 SWITCH,LIMIT,STL RLLR LVR,LOW 5%PRETRVL 1
2 U3904-0165 VALVE,HYD,3-WAY,12VDC SOLENOID 1

PNEUMATIC COMPONENTS
AIR SUPPLY
4

1 N/A AIR COMPRESSOR,BENDIX,ENGINE MOUNTED 1
2 U1003-0022 TANK,AIR,SADDLE MOUNT,9.5”DIA 1
3 U4002-0029 FILTER,AIRLINE,.38FNPT,40MIC,MAN.DRN,POL 1
4 U4003-0123 MOISTURE EJECTOR,AUTOMATIC 1

DRIVE COMPONENTS
BLOWER DRIVE SYSTEM
11
2 3
9
7
10

1 05-0288 ENGINE,JD4045 TIER 3,80HP @ 2400RPM 1
2 N/A NACD PTO CLUTCH 1
3 06-0297 SHEAVE,5V7.5 X 3-SF 1
4 06-0228 BUSHING,SF X 2.25” X 1/2” KEY 1
5 06-0297 SHEAVE,5V7.5 X 3-SF 1
6 U3403-0120 BUSHING,IDLER,SF-BB1,WITH 1”-8NC STUD 1
7 06-0398 SHEAVE,5V9.75 X 3-SF 1
8 06-0033 BUSHING,SF X 1.5625 1
9 07-0107 BELT,3R5VX710 1
10 03-0405 BLOWER,ROOTS,711 U-RAI,VERT.GRS.HOR.FLOW 1
11 U0101-0264 CABLE,ENGINE SPEED CONTROL,VERNIER 1

FILTER/RECEIVER COMPONENTS
1
3 2
4 5
6 7

1 16-0295 VALVE,SOLENOID,MAC 12VDC 5
2 U4002-0027 VALVE DIAPHRAGM,2-WAY,5-125 PSI AIR 5
3 27-0005 LEVEL PROBE,MONITOR,12VDC,KA SRS 1
4 U4008-0001 GAUGE,VACUUM,0-30”HG,PANEL MOUNT 1
5 U4008-0002 GAUGE,DIFFERENTIAL PRESSURE,0-50” WC 1
6 U3701-0051 FILTER BAG,DRY,100 SERIES SNAP BAND,5”DIA 27
7 U3702-0023 CAGE,BAG,ALL 100 SERIES,FITS 5” DIA. 27
8 16-0267 VALVE,VACUUM RELIEF,3”,(15”HG) 1

ULTRAVAC MODEL 105S
RECOMMENDED SPARE PARTS LIST
QTY PART NO. DESCRIPTION
13 ft. 8000-0010 GASKET,TAILGATE,EXTRUDED SECTION

1 3802-0020 GASKET,PLENUM DOOR,100 SERIES
1 U4109-0019-DI TIMER BOARD,8 OUTPUT,DIGITAL,12VDC
1 U0101-0264 CABLE,ENGINE SPEED CONTROL,VERNIER
1 U4003-0042 SOLENOID ASSY, 12VDC
1 U4002-0027 VALVE DIAPHRAGM,2-WAY,5-125 PSI AIR
1 U4003-0048 VALVE,PNUEMATIC SOLENOID,1/8”NPT,12VDC
27 U3701-0051 FILTER BAG,DRY,100 SERIES SNAP BAND,5”DIA
27 U3702-0023 CAGE,BAG,ALL 100 SERIES,FITS 5” DIA. HOLE
1 U3914-0032 FILTER,HYDRAULIC,105 SUCTION
1 U4008-0013 GAUGE,AIR,0-300 P.S.I.
1 U4008-0001 GAUGE,VACUUM,0-30”HG,PANEL MOUNT
1 U4008-0002 GAUGE,DIFFERENTIAL PRESSURE,0-50” WC
1 U4103-0426 SWITCH,LIMIT,STL RLLR LVR,LOW 5%PRETRVL
1 U4003-0105 SWITCH,PRESSURE,0-200 PSI, SINGLE SET
* Prices, part numbers, and specifications subject to change without notice

OPERATIONS

OPERATIONS 1
BASIC ULTRAVAC SYSTEM OPERATION
This section of the manual will explain how and why an Industrial Vacuum Loader moves material. In order for a vacuum
loader to operate, two items must be present: air and a chamber in which a vacuum can be produced. The blower
(vacuum pump) moves a large volume of air out of the UltraVac storage hopper faster than it can be replaced, which
creates a negative pressure (vacuum) inside the hopper. Because the blower is constantly removing air from the hopper,
outside air will rush into the hopper at a similar rate in an attempt to fill the vacuum. This movement of air is what allows
the vacuum loader to move material. The velocity the air is moving determines the quantity, the speed, and the type of
material that can be moved. The volume of the hopper is much larger than the hose used to convey the material, which
causes the air velocity to drop. When the air velocity slows down, the heavier material falls out of the air stream and is
deposited in the storage hopper. The dust laden air then travels through the opening in the top of the front wall of the
hopper. The air stream moves down into the filter chamber and through the filters, depositing the dust on the outside of
the filter bags. The clean air enters the plenum chamber and exits the vacuum loader through the blower and exhaust
silencer. The UltraVac is designed to handle dusts and other materials having bulk weights of up to 200 lbs. per cubic foot.
However, remember that particle size and shape are also involved in conveying ability of the vacuum loader. Particle size
is limited to the hose size and the conveying velocity of the equipment.
AIR COMPRESSOR
An air cooled pressure lubricated compressor is driven from the engine. It supplies the air which is used for cleaning the
filter bags.
AIR RESERVOIR
This is the cylindrical tank directly behind the blower. It stores air for the Filtration System. A remote condensate drain
valve is located on the bottom of the tank. An in-line moisture trap is also on the tank. Both should be drained after every
shift. A pressure switch is installed in the system which will not actuate filter cleaning or the blower until the air pressure
reaches 60 PSI.
DUMP DOOR
The tailgate is opened and closed by the directional control valve. The tailgate must be completely sealed against air
leaks while loading and also to keep material from falling out while traveling. The gasket must be inspected regularly for
damage and wear.
DUST FILTRATION SYSTEM – THEORY OF OPERATION

Dust laden air under vacuum enters the lower section of the filter chamber. The air travels through the filter bags, which
retains the dust particles, and flows into the upper plenum chamber, through the blower, and out of the silencer. During the
dust filtering operation, material collects on the outside of the filter bags, causing a reduction in porosity. In order to control
the pressure differential across the filters, a sequential timer periodically actuates the solenoid and diaphragm valves
which deliver a momentary surge of high pressure air. These surges are discharged through the blast pipes at high
velocity, which causes a reverse flow of air through the filter elements sufficient for cleaning. Since only a fraction of the
total filter area is cleaned at one instant, continuous vacuum flow through the collector at its rate capacities is assured.
During operation with new filter bags, there will be very little resistance across the collector until the bag becomes coated.
Filtering efficiency also increases as the bags become “coated” with dust. An important operating check is visual
inspection of the UltraVac discharge air. No dust should be visible from the blower exhaust. Should dust be visible, STOP
OPERATING IMMEDIATELY!!!

OPERATIONS 1
FEEDING MATERIALS AND CLEANING TOOLS

The manner in which materials are fed into a vacuum loading hose is important to provide the most efficient material
pickup. A NORMAL TENDENCY IS TO FEED THE HOSE TOO FAST BY JAMMING IT INTO THE DEBRIS. This will cut
the air velocity, causing material to drop out of the air stream and plug the hose. A uniform rate of feed and maintaining
the normal air velocity are most important in keeping material moving through the hose. If the hose should plug, wait until
material has cleared the hose, at which time pickup may again be resumed. Many types of cleaning tools are available for
vacuum loading machines. Their design and shape will depend on the job to be done. An accessory catalog is included in
the back of this manual. Contact your UltraVac Representative for any specially designed tools you might need.
FILTER BAGS
See bag installation instructions. It is important to handle the bags with care at all times. Blinded bags can sometimes be
rejuvenated without removal from the unit. Simply allow the cleaning cycle to operate without the blower running. This no-
load cleaning can be more effective than washing. (From 15 to 30 minutes are required for best cleaning)
FILTER SEQUENTIAL TIMER

To time the air blast which cleans dust off the filter bags, a solid state timing board is used, which is normally set between
12 and 18 second blast intervals.
If the filtration system stops operating, check the position of the ignition switch, or the in-line fuse and wiring.
The next step is to replace timer assembly. This is achieved by pulling the two multi-pin plugs and removing four screws.
HOSE
The ease in handling the hose will dictate where each size can best be utilized. Smooth bore rubber or PVC hose is
desirable, but for ease of handling, short lengths of lightweight hose may be used at the operator end of the run. Hose life
is in direct proportion to the type of material being handled and number of hours used. Heavy, abrasive materials mean
shorter hose life, whereas light materials which are less abrasive mean longer hose life.
HOPPER
The hopper is divided into two compartments—the front being the dust chamber which houses the filter bags and the rear
being the container where the material being loaded is deposited. The rear plate has a porthole arrangement where the
vacuum loading hose is attached. Inside the porthole is a deflector shield which directs the flow of material downward.
The hopper and dust chamber are separated by the double wall air duct and flap seal. The flap seal automatically opens
when the unit is shut down. If the tailgate is bent or gasket torn, material will leak out and air will leak into the body. This
lowers the loading efficiency of the machine. If the leak is bad enough, it will prevent loading completely. This applies also
to the loading port gasket, the hose adapter plate and the joints between filter chamber and hopper.
HYDRAULIC CYLINDERS
There are three cylinders used on self-propelled UltraVac units. One is for power steering which is located under the
driver’s seat. The other two are located on either side at the rear of the hopper. They open and close the dump door and
actuate the locking latches simultaneously. The door cylinders also have in-line restricting valves on the rear ports, which
controls oil flow. Towable units have only two cylinders for the dump door and are controlled by a hand pump.

OPERATIONS 2
HYDRAULIC DIRECTIONAL CONTROL VALVE

Its function is to open and close the dump door.
HYDRAULIC FILTER
It is a suction filter having a ball valve to shut off oil when changing filters—10 micron replaceable type.
CAUTION: Never run machine with valve closed.
HYDRAULIC FLUID RESERVOIR

The capacity of the hydraulic fluid reservoir is approximately 14 U.S. gallons. Most people’s contact with hydraulic system
will be limited to checking the fluid levels and adding or draining hydraulic fluid from the reservoir.
HYDRAULIC PUMP
This is a small gear pump driven directly from the rear of the Hydrostatic Transmission Pump. It supplies the hydraulic
pressure to actuate the tailgate cylinders and the power steering.
HYDROSTATIC DRIVE MOTORS

Drive rear wheels of the unit. The motors are powered by the variable speed hydrostatic transmission pump.
HYDROSTATIC TRANSMISSION PUMP

This is a variable speed pump which functions in either direction. It is controlled by a hydraulic foot pedal in the driver’s
compartment. The pump is belt driven off of the front of the engine.
INTAKE DEFLECTOR
The intake deflector is located just inside the rear loading port. The intake deflector should be inspected on a regular basis
because it is subjected to continuous wear. The deflector plate will require occasional replacement depending on the
amount and type of material being handled.
MAGNEHELIC DIFFERENTIAL PRESSURE GAUGE

This gauge indicates the differential pressure across the filter media. High differential pressure will warn you of possible
blinding of the filter media. It can also indicate the need for using the “filter only” mode of operation to rejuvenate the filter
media, or the need to replace the filter media.
PARKING BRAKE
The parking brake is engaged by a selector switch in the driver’s compartment. The brakes are engaged and the foot
pedal is disconnected when the parking brakes are on.
PLENUM HOUSING
The external housing surfaces should be treated as any other metal equipment; i.e., periodic painting to prevent corrosion.
The internal housing, particularly the top plenum (clean air chamber), should be thoroughly cleaned whenever tubes are
replaced. Good housekeeping in the clean air plenum is essential to avoid impregnating the filters from the clean side.
Should bags tear or other failures deposit considerable dust in the clean air plenum, it must be cleaned immediately!

OPERATIONS 3
PRESSURE RELIEF VALVE

It maintains the hydraulic pressure in all circuits at a predetermined setting, and is built into the hydraulic control valve.
SEAT SWITCH
Prevents the unit from moving if operator is not seated.
SOLENOID AND DIAPHRAGM VALVES

The sequential timer actuates the electric solenoid pilot valve. Every 3 to 20 seconds, the solenoid valve opens the
diaphragm valve for 100 milliseconds to allow a blast of high pressure air to escape. The air exits the diaphragm and
travels to a particular row of filter bags.
STEERING MECHANISM
The single front wheel is actuated by a steering wheel and power steering pump, hydraulic valves and cylinder. Power is
supplied by a small hydraulic pump driven by the engine.
ULTRAVAC DUST FILTRATION SYSTEM

The model 100 series vacuum loader employs 27 filter bags 30 inches long. The bags are made rigged by a wire
container with a built-in venture at the top. The filter bag assemblies protrude through the tube sheet and are snapped in
place.
VACUUM RELIEF VALVE

The relief valve prevents the vacuum inside the hopper from exceeding a predetermined level. The spring operated relief
valve opens, allowing outside air to enter the hopper. This valve is set at the factory and should be adjusted by trained
UltraVac service technicians. To gain access to the filter bags, the plenum cover must be unclamped and raised. The filter
bags can be changed by removing the cage and then the bag. To check the bags, merely look down through the venturis.
Leaking bags will have dust residue on the inside. Standard filters are designed to handle materials which produce and air
stream temperature of up to 275 degrees F. For higher temperature applications of up to 425 degrees F, Nomex or Teflon
filters must be used. The dust filter bag retains 99.9% of all dust particles 1 micron and larger.
WHEELS
All three wheels are of the same type. The tires are solid rubber, pressed-on type and are replaceable. The front wheel
bearings are greased through a fitting on the end of the axle shaft. The rear wheel bearings are inside the wheel drive
units and are lubricated by internal oil reservoirs.
Note: Tighten lug nuts after first 24 hours of use.
WHEEL HUB DRIVES

Transmit drive from hydrostatic motors to rear wheels. Wheel hubs also contain hydraulic brakes.

OPERATIONS 4
I. Check Fluid Levels:
A. DIESEL FUEL TANK – There is one (1) 30 gallon tank located in the middle of the right side of the
machine.
B. ENGINE OIL – Check the dipstick to assure engine is filled to proper level. See
vendor engine manual, located in the “Manufacturer’s Manuals” section, for location of dipstick
and grade of oil to be used.
C. HYDRAULIC OIL TANK – On top left front of body hopper. Level should be in the middle of the
sight glass on the tank. See “Recommended Lubricants” section for grade of oil to be used.
II. To Start Engine:

A. Assure parking brake is engaged by placing the “Park/Run” switch in the “Park” position.
B. The ignition switch is located on the control panel. Push the red Murphy “Tattletale” button and
turn the key to the “start” position. Once the engine starts, allow the key switch to return to the
“on” position and release the red Murphy “Tattletale” button.
Note: The throttle control is located to the right of the seat in the driver’s compartment. It is of
the vernier, screw type. When increasing and decreasing engine speed, we recommend
rotating the handle. For emergency, push down on the button located in the center of the
throttle handle.
Note: It is possible to control traveling speed of the UltraVac by increasing pedal movement
without adjusting the engine throttle. The maximum travel speed is approximately 5 mph.
III. To Drive Unit:

A. Disengage the parking brake by placing the “Park/Run” switch in the “Run” position.
B. Push the foot pedal forward to move the machine forward. For reverse, push the foot pedal
backwards.
Note: Operator must be seated for unit to move.
Note: It is possible to control traveling speed of the UltraVac by increasing pedal movement
without adjusting the engine throttle. The maximum travel speed is approximately 5 mph.
IV. To Operate Blower:

A. Assure tailgate and the plenum covers are closed.
B. Assure parking brake is engaged.
C. With the engine at idle speed, push and hold the “Blower Engage” button for about 5 seconds.
An air cylinder moves the clutch lever and engages the blower. DO NOT SLIP THE CLUTCH.
Note: If problems occur when engaging the blower, engine speed may need to be increased slightly.
Note: The clutch will not engage the blower until the air pressure reaches 60 PSI.
D. Increase engine speed to operating condition (2,800 RPM max.) for vacuuming.
V. To Disengage Blower:
A. Slow the engine to idle speed.
B. Push the “Blower Dis-Engage” button.
Note: After the engine has been running for an extended period at operating speed, it is best to
run at idling speed for a few minutes before switching off.

OPERATIONS 5
VI. To Empty Material From Hopper:

A. With the engine idling and the blower off, open the tailgate by pulling the handle on the hydraulic
“Hopper Dump” control valve (in front of and above the left hand rear wheel). The filter chamber
should empty automatically.
B. After the material has discharged, the vehicle should then be moved clear of the material so that
the operator may visually check both compartments to insure they have dumped clean.
C. Close the tailgate by pushing on the hydraulic “Hopper Dump” control valve handle.

Note: Hold the lever in the “closed” position until the tailgate is tightly closed.
VI. To Shutdown Unit:

A. Disengage blower by pressing the “Blower Dis-Engage” button.
C. Engage parking brake by placing the “Park/Run” switch in the “Park” position.
D. Turn the key switch to “Off” position.

OPERATIONS 6
AUTOMATIC SHUTDOWNS (BLOWER)
The following conditions will cause the clutch to disengage and the blower on the Ultra-Vac® Unit to shutdown
automatically.
1. HOPPER FULL
There is a level detector that extends into the hopper. When the hopper is full, the clutch will disengage,
the blower will shut down, and the “HOPPER FULL” indicator will light on the control panel. Check the
operation of the level probe and electrical connections.This condition is to be reset after the problem is
corrected by pressing the “FAULT/RESET” button before pressing the “BLOWER ENGAGE” button.
2. LOW UTILITY AIR PRESSURE

An air compressor supplies air to clean the filters and engage the clutch. If air pressure is not present
or if air pressure is too low, the clutch will disengage, the blower will shut down, and the “LOW UTILITY
AIR” indicator will light on the control panel. Check compressor, belts, valves, and air lines. This condition
is to be reset after the problem is corrected by pressing the “FAULT/RESET” button before pressing the
“BLOWER ENGAGE” button.
Note: Once the problem has been corrected, allow the unit to build up an adequate amount of air
pressure (80-100 psi) before engaging the blower.

OPERATIONS 7
PERFORMANCE SPECIFICATIONS
AIRFLOW……………………………………………...1430 CFM (max)

LOADING RATE……………………………………....250-500 LB./MINUTE
CONVEYING DISTANCE…………………………….300 FT. (max)
VACUUM RATING (Vacuum Gauge)………………..15 IN. HG.
NO LOAD VACUUM (Vacuum Gauge)………….......Between 1-6 IN. HG.
CAPACITY……………………………………………..1 cubic yard
VACUUM INTAKE………………………………….....Up to 6” hose
BLOWER TYPE………………………………............Positive Displacement Rotary Lobe
BLOWER RPM………………………………………..1800 RPM
AIR PRESS. REQ. TO START BLOWER…………..60 PSI (for clutch to engage blower)
DIFFERENTIAL PRESSURE GAUGE………………Between 1-7 IN. H2O
RELIEF VALVE………………………………………...Opens at 15 IN. HG. (at Sea Level)
AIR BLAST FOR FILTER CLEANING……………....Every 3-20 Seconds
105 MOBILITY SPEED……………………………….5 MPH (max)

OPERATIONS 8
MAINTENANCE

LUBRICATING INTERVALS
1 POSITIVE DISPLACEMENT VACUUM PUMPS (BLOWERS):

Follow the recommendations of the blower manufacturer’s manual supplied with this manual.
2 HYDRAULIC SYSTEM:
Drain oil reservoir and replace with new oil every 1,000 hours of operation.
3 ENGINE:
Follow the recommendations of the engine manufacturer’s manual supplied with this manual.
4 CLUTCH:
Follow the recommendations of the clutch manufacturer’s manual supplied with this manual.
5 AIR COMPRESSOR:
Follow the recommendations of the air compressor manufacturer’s manual supplied with this manual.
NOTE: RECORD MAINTENANCE PERFORMED ON “LUBRICATION MAINTENANCE RECORD”.
RECOMMENDED LUBRICANTS
1 POSITIVE DISPLACEMENT VACUUM PUMPS (BLOWERS):

Reference blower manufacturer’s maintenance manual.
2 HYDRAULIC SYSTEM:
All hydraulic systems furnished for use on UltraVac units will be supplied with an S1 M 46 hydraulic oil.
3 ENGINE:
Reference engine manufacturer’s maintenance manual.
4 CLUTCH:
Reference clutch manufacturer’s maintenance manual.
5 AIR COMPERSSOR:
Reference air compressor manufacturer’s maintenance manual.

MAINTENANCE 1
LUBRICATION MAINTENANCE RECORD
OWNER
PLANT LOCATION BUILDING
Ultra-Vac® SERIAL # UV- MODEL
MAINTENANCE PERFORMED BY DATE:
RECORD Ultra-Vac® HOUR METER HOURS
LUBRICATION OIL DRAINED &

OIL ADDED GREASED
PERFORMED CHANGED
(1)
VACUUM PUMP
(2)
HYDRAULIC SYSTEM
(3)
ENGINE
(4)
CLUTCH
(5)
AIR COMPRESSOR

MAINTENANCE 2
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 the start or during the work cycle. The amount of peak load will vary
depending on the character of the driven machine of the drive system. To increase total tension, merely increase the
center distance. Before attempting to adjust the tension on 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.
GENERAL METHOD: The general method for tensioning v-belts should satisfy most drive requirements:
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 belts so that both 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 for 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 bowing 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 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 slack side.

MAINTENANCE 3
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 filter bag. Be sure not to catch the bag on the
cages. The dry plenum will have 27 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 tailgate.
FILTER BAG INSTALLATION

1 Be sure the baghouse, tubesheets and plenum area is clean of debris.
2 Slide clean bags from 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: Snap band groove must fit tight in the tubesheet, 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.

MAINTENANCE 4
MANUAL HYDRAULIC BRAKE RELEASE (TOWING OPERATIONS)
The manual hydraulic brake release option is used when there is no hydraulic pressure available from the
hydraulic system. It is intended for emergency towing operations only. The unit must be towed at no more than
1 MPH. This will prevent damage to the drive hubs.
Caution: Do not use this system with the engine running.
To release the brakes on the rear axles and allow the unit to be towed:
1. Assure Valve #2 is closed. This is accomplished by turning the valve clockwise until it seats.
2. Close Valve #3. The valve is closed when the handle is in the vertical position (as shown).
2. Pump the Hand Pump (Item #1) until a solid resistance is felt. This is accomplished by moving the
handle in a vertical up and down motion.
When the unit is to be returned to normal system configuration:
1. Open Valve #2 to relieve pressure and close when complete.
2. Open Valve #3. Asssure the handle is in the horizontal position.
Caution: Do not attempt to operate the drive system until the brake release system has been returned to
the normal system configuration.

MAINTENANCE 5
PREVENTIVE
MAINTENANCE

PREVENTIVE INSPECTION PROCEDURE
A. DAILY CHECKS: PERFORM THE DAILY MAINTENANCE CHECKS LISTED BELOW AND RECORD
MAINTENANCE PERFORMED ON “MAINTENANCE RECORD FORM 1”.
1. VACUUM PUMP OIL LEVEL (with machine NOT running): Checking the vacuum pump oil level is
critical and should be done consis tently. Some vacuum pumps have oil level sight gauges while others
have oil level plugs. Refer to the vacuum pump’s maintenance manual located in the “Manufacturer’s
Bulletins” section for proper oil level readings. Should oil be required, see “Recommended Lubricants” at
the end of this section.
NOTE: Vacuum units must be sitting level for proper readings.
2. FILTER BAG PRESSURE DIFFERENTIAL (with machine running): With the inlet to your machine open,
record the reading on the pressure differential gauge in inches H2O (water).
3. NO LOAD VACUUM (with machine running): With the inlet completely open (hose to powerhead inlet
disconnected), check the vacuum gauge reading. This “no load” reading is an important indicator of the
condition of the powerhead. The “no load” vacuum should be between 1 to 6 inches mercury (Hg). Record
the vacuum reading in “Hg”.
a. If no load vacuum reading is zero:
i. Inspect the vacuum gauge plumbing for hose rupture, loose fitting, or plugged line.
ii. Check that the inlet hose is properly connected on the hopper and that there are no
leaks.
b. If no load vacuum reading is higher:
i. Check for obstruction in the False Walls by opening the plenum.
ii. Check the pressure differential gauge. The reading should be between 1 and 7 inches of
water (H2O).
a. If higher than 10 inches of water, a visual inspection should be made by

opening the tailgate and inspect for excessive buildup of material on the filter bag
surfaces. Also check for bridging of material between bags.
4. DUST DISCHARGE (with machine running): Inspect the silencer discharge for visible dust in the air
stream.
a. Check the filter bags for rupture or leaks by opening the plenum.
NOTE: Shut the unit off immediately if dust is present. Any dust discharge should be corrected
immediately to protect the vacuum pump from wear.

PREVENTIVE MAINTENANCE 1
PREVENTIVE INSPECTION PROCEDURE
5. MECHANICAL VACUUM RELIEF VALVE (with machine running): Check the vacuum relief valve for
proper operation. With the machine running in a no-load condition, slowly block off the powerhead inlet
until 15 inches of mercury (at sea level) is indicated on the vacuum gauge. The relief valve should remai
closed. Continue to block off the powerhead inlet while watching the vacuum gauge. The relief valve
should open at 16 inches of mercury (at sea level) plus or minus ½ inch. Record where the valve opens
in inches of Hg.
NOTE: Do not check the relief valve with your hand! You will hear the in-rush of air when the valve
opens.

NOTE: Under no circumstances should the powerhead be used with a valve that opens higher than 16
inches of mercury.

6. COMPRESSED AIR REGULATOR FILTER BOWL (with machine running): Inspect the regulator
filter bowl sight glass and empty, if partially full. Refer to the regulator instructions found in the
component manual section.
B. WEEKLY CHECKS: PERFORM THE WEEKLY MAINTENANCE CHECK LISTED BELOW AND RECORD
1. BELT TENSION: Disconnect the battery cables on the engine units, remove the belt guard front
and check the tension per “tensioning v-belt drives” instructions contained in this section.

2. ELECTRIC CABLE: Visually inspect all electrical conduit, cables, and connections for signs of
abrasions for breaks.

3. LEVEL PROBE: Check the level probe for operatio n by touching the probe. The control panel power
must be on and the blower must be off. The “high level” light will pop “on” on the control panel.

4. VACUUM LEAKS: Inspect all openings for possible damage to gaskets. With the machine running,
listen for audible leaks around doors, hose connections, flanges, etc..., and repair as required.
5. COMPRESSED AIR LINE LEAKS: Check for audible leaks in the compressed air lines to the
inlet vacuum breaker and/or the lift bags. Retighten fittings or repair as required. See engine
manual.
C. MONTHLY CHECKS: PERFORM THE MONTHLY MAINTENANCE CHECK LISTED BELOW AND RECORD
1. VACUUM PUMP LOBE WEAR: Remove the vacuum pump inlet pipe (the one on the side of the
blower between the blower and the hopper). Inspect lobes in accordance with manufacturer’s
specifications.
2. DEFLECTOR PLATE: Remove rear hose and visually inspect for excessive wear or holes on the
plate. If worn through, replace immediately!

MAINTENANCE RECORD
FORM 1 “DAILY”
OWNER
CHECKS NEEDS NO MAINTENANCE MAINTENANCE

PERFORMED MAINTENANCE NEEDED PERFORMED
(1)
VACUUM PUMP OIL
(2)
PRESSURE
DIFFERENTIAL OF
FILTER BAGS “H2O”
(3)
NO LOAD VACUUM
“Hg”
(4)
SILENCER DUST
DISCHARGE
(IS DUST PRESENT?)
(5)
MECHANICAL
VACUUM RELIEF
VALVE(S) AT “Hg”
(6)
COMPRESSED AIR
REGULATOR FILTER
BOWL CLEAN

MAINTENANCE RECORD
FORM 2 “WEEKLY”
OWNER

(1)
BELT TENSION
(2)
ELECTRIC CABLE
(3)
LEVEL PROBE
(4)
VACUUM LEAKS
(5)
COMPRESSED AIR
LINE LEAKS

MAINTENANCE RECORD
FORM 3 “MONTHLY”
OWNER

(1)
VACUUM PUMP LOBE
WEAR
(2)
DEFLECTOR PLATE

TROUBLESHOOTING

Troubleshooting Guide for UltraVac Model 105 Self-Propelled Vaccum Unit
The following guide will assist you in troubleshooting various problems with the Model 105. The manufacturers
bulletins contained in the manual will also assist you with servicing specific parts on the Model 105.
PROBLEMS:
1. FILTER BAGS, FILTER CLEANING SECTION 1.1
A. NOT CLEANING SECTIONS 1.1, 1.1.3

B. BLINDED SECTION 1.1.5
C. PREMATURE FAILURE SECTION 1.1.5
D. BROKEN FILTER BAG SECTION 10.2
E. TIMER BOARD SECTION 1.1.2
F. IMPROPER INSTALLATION SECTION 1.1.1
2. HYDRAULIC DRIVE NOT FUNCTIQNING SECTION 2.2.1,10.5
A. MAIN DRIVE PUMP SECTION 2.2.1
3. STEERING SECTION 2.1
A. AUXILIARY PUMP SECTION 2.1.1
4. ENGINE SECTION 4.1
A. NOT STARTING SECTION 4.1

B. OVER HEATING SECTION 4.2.1
5. BLOWER SECTION 5.1, 7.0
6. COMPRESSED AIR SECTION 1.1.4
7. TAILGATE SECTION 3.1, 10.6
8. IDGHVACUUM SECTION 6.1
9. LOW VACUUM SECTION 8.1,9.1,9.2
10. LEVEL SENSING SECTION 10.1.1

TROUBLESHOOTING 1
SECTION 1.1 - FILTER BAGS NOT CLEANING
1.1.1 IMPROPER INSTALLATION
Filter bags should be carefully installed into tube sheet. Snap band should be sealed all around the hole in the
tube sheet. Check the condition of the cage. Replace if it is collapsed.
1.1.2 TIMER BOARD:

The timer board is factory set and should not need any further adjustments. The following instructions should be
used to troubleshoot the timer board.
If the timer board is not functioning correctly, the filter bags will not be cleaned sufficiently. The timer board has a
green L.E.D. that will light when the timer board is powered on.
The timer board is enclosed in the timer box on the wall of the hopper. The timer board sends outputs to each of
the solenoids which in turn open the diaphragm valves pulsing compressed air into each bag. Each output has a
red L.E.D. light which flashes on when the output is active. The on-time of each output is about .2 second and off
time is 10 seconds.
The push to test button can be used to test the outputs on the timer board. When the button is depressed, the
timer will advance to the next output in sequence.
If the on-time is set below .2 seconds then the filter cleaning efficiency will be reduced. If the off-time is more than
10 seconds, filter cleaning efficiency will be reduced.
The timer board has a 2 (two) amp slo-blo fuse which should be checked first. If it is blown, then check for shorts
in wiring and solenoids. Replace the fuse after checking the wiring and the solenoids.
The timer board should be replaced if any of the following conditions occur:
• Burnt components or burnt areas on the board.
• Red L.E.D. for any used output does not light when it should.
• Fuse is OK, but green L.E.D. is not lit.
1.1.3 SOLENOIDS AND DIAPHRAGMS

The solenoids on the timer box open to allow the diaphragm valves to open. When the diaphragm valves open,
compressed air is released into the filter bags. These “pulses” of air are very short in duration. The compressed
air cleans the filter bags.
If the solenoid valve is stuck open or closed, the pulse cleaning cycle will be interrupted and will not sufficiently
clean the filter bags.
Dirt or dust in the compressed air can cause the diaphragm valves and the solenoid valves to stick.
If a solenoid valve is stuck open then you will have air flow through the valve all the time. Compressed air will
blow out the solenoid valve outlet and the diaphragm valve continuously.
Check to see if the valve is getting a constant voltage by examining the red L.E.D. light on the timer board. If the
timer board is functioning correctly, the solenoid valve should be replaced or rebuilt.
If the solenoid valve is working and air is still blowing out the diaphragm valve, the diaphragm valve may be faulty
or stuck open. Check the diaphragm valve. It may need cleaned, rebuilt, or replaced.
If a diaphragm valve does not open, no air will flow through the valve. This can be checked by checking the flow
at the outlet of the valve. Open the plenum door and check to see that you are getting air flow from all the blast
pipe outlets.

TROUBLESHOOTING 2
Check to make sure the solenoid is operating properly. This may be a faulty solenoid or an electrical problem
If the solenoid and the timer board are working correctly, check the diaphragm valve. Rebuild or replace the
diaphragm valve if needed.
Consult the manufacturer’s component section for detailed information about the diaphragm valves and the
solenoid valves.
1.1.4 LOW AIR PRESSURE

If the compressed air pressure is below 80 PSI, then the filter bags will not be cleaned sufficiently. Low air pressure can
be caused by the following:
PROBLEM SOLUTION

Diaphragm valves staying open....................................................Consult Section 1.1.3
Solenoid valves stuck open...........................................................Consult Section 1.1.3
Water trap full.................................................................................Empty water trap daily

Relief valve for compressed air system is stuck open...................The relief valve for the compressed air opens when
air pressure is above 120 P.S.I. If the relief valve is
not set correctly or is stuck open, then air pressure
is not maintained.
Drain cock open on air tank
Water trap outlet is open

Plugged air lines.............................................................................If ANY airlines are plugged or partially plugged, air
pressure will not be maintained and damage may
occur to the air compressor. If the water trap is not
drained daily, dirt and oil can build up throughout
the system. Check at the relief valve and at fittings.
Check at the check valve on the air tank.
Leaks in air lines.............................................................................Check all airlines for leaks.

Loose belt on air compressor (if equipped)....................................A loose or broken belt (if equipped) on the air
compressor will cause the air compressor to wo
less efficiently or not at all. Tension the belt if it is
loose or replace it if it is broken.
Unloader valve on compressor stuck open
Consult the manufacturer’s component information for specific details about the air compressor, unloader, diaphragms,
and solenoids.

TROUBLESHOOTING 3
1.1.5 FILTER BAGS BLINDED & PREMATURE FAILURE
A Differential gauge mounted on the back of the unit will show if the filter bags are in need of replacement. Also, if
any dust is seen coming from the outlet of the blower silencer, the unit should be stopped immediately. A filter bag
may be torn and need replaced. Serious damage could occur to the blower.
Blinded filter bags may occur for the following reasons:

1.1.5.1 - Not being cleaned enough. See Section 1.1
1.1.5.2 - Low air pressure. Consult Section 1.1.4
1.1.5.3 - BAG MATERIAL, WET MATERIAL PICKED UP
The bag materials are specified according to the temperature of the material and the temperature of the airstream
over the bags. If the bag you are using is not rated for high temperatures and high temperatures are present in
the bag house, the bag will not last as long as it should. Consult Hi-Vac for the correct bag to use.
Some materials and applications require bags made of different materials or bags with specific coatings. Consult
Hi-Vac for the correct bag to use.
Wet materials will cause the bags to get blinded very quickly. The material cakes on the filter bag. A bag change is
required.
SECTION 2 – STEERING, DIFFICULT TO TURN
2.1.1 AUXILIARY PUMP

The auxiliary pump for the power steering and the tailgate is mounted on the engine. There should be hydraulic
oil flowing through the lines going to and from this pump. If no oil is flowing, check the auxiliary pump.
2.1.2 LOW HYDRAULIC FLUID
2.1.3 LOW IDLE

The engine R.P.M. determines the amount of hydraulic oil that is pumped to the power steering. Driving at very
low engine R.P.M.’s will make the unit harder to steer. When driving the unit, be sure that the engine R.P.M. is
above 1,000 R.P.M.
2.1.4 LEAK IN HYDRAULIC LINES

Check for and repair any hydraulic leaks.
2.1.5 HYDRAULIC FILTER

A very dirty hydraulic filter will reduce the flow of oil and cause sluggish performance.
2.2.1 DRIVE – WILL NOT MOVE CHECK THE PARKING BRAKE

If the parking brake switch is in the “park” position, the unit will not move.
2.2.2 FOOT PEDAL

Movement both forward and backwards is controlled via a foot pedal on the floor where the driver sits. Check the
foot pedal to make sure that it rocks back and forth. The foot pedal is connected to the main drive pump
directional control. Consult the manufacturer’s data for information.
2.2.3 FLUID LEVEL

The fluid level in the hydraulic tank should be properly filled.
2.2.4 MAIN DRIVE PUMP

The main drive pump is driven off the front of the engine. Make sure that all belts are tight and in place (if
equipped). Consult the manufacturer’s data in the manual for information on the drive pump.

TROUBLESHOOTING 4
SECTION 3 – TAILGATE
3.1.1 AUXILIARY PUMP

The tailgate opening and closing is powered by an auxiliary pump mounted on the back of the main drive pump. If
this pump is bad, the tailgate will not open or close. Consult Section 2.1.1
3.1.2 VALVE
Check the operation of the valve for opening and closing the tailgate.
3.1.3 CYLINDERS
There are hydraulic cylinders that open and close the tailgate. If these cylinders are not functioning properly, your
tailgate will not move or seal.
SECTION 4 – ENGINE WON’T START or ENGINE SHUTS DOWN
4.1.1 CHECK FOR DEAD BATTERY

Charge or replace.
4.1.2 FUEL LEVEL

Check to see that there is fuel in the tank.
4.1.3 MURPHY SHUTDOWNS

The engine will not start unless the small red button next to the key is held in while the key is turned. If the
oil pressure is too low or if the engine water temperature is too high, the engine will not start.
4.1.4 AIR IN FUEL LINE (DIESEL)

Fill fuel tank with diesel fuel and bleed fuel line of air.
4.2.1 ENGINE OVERHEATS

Check the level of antifreeze in the radiator and check for leaks in the radiator hoses.
4.2.2 AIR FLOW TO RADIATOR

Make sure that there is sufficient airflow to the radiator. Remove any debris from the radiator fins and the louvers
or screen on the door of the unit.
4.2.3 USING HOSE THAT IS TOO SMALL FOR THE UNIT

Using 3” or smaller hose for extended periods of time will overwork the blower and the engine.

TROUBLESHOOTING 5
SECTION 5 – BLOWER OVERHEATS
5.1.1 OIL LEVEL

Check oil level in blower and make sure it is full.
5.1.2 DIRTY FILTER BAGS

Refer to Section 1.1 of this manual.
5.1.3 VACUUM RELIEF VALVE STUCK IN CLOSED POSITION

Inspect the relief valve and correct the malfunction. Replace if necessary.
5.1.4 OBSTRUCTION IN CONVEYING HOSE

Free any obstructions in the conveying hose.
5.1.5 WORN VACUUM PUMP LOBES

The greater the wear, the less vacuum achieved and the hotter the vacuum pump will run.
SECTION 6 – HI VACUUM
6.1.1 RELIEF VALVE INCORRECTLY SET OR NOT OPENING

Check the relief valve and determine if it is jammed closed. Repair or replace.
6.1.2 BLOCKAGE IN MATERIAL LINE

Material blocking the hose must be removed.
6.1.3 USING HOSE THAT IS TOO SMALL

Use hose that is no smaller than 3” in diameter.
SECTION 7.0 – BLOWER WON’T ENGAGE/DISENGAGE
The engine P.T.O. clutch engages the blower. The engagement arm is pushed over center by an air cylinder. If the
compressed air supply falls below 60 psi then the P.T.O. will not engage or it will disengage if it is already
engaged.
7.1.1 LOW AIR PRESSURE (See Section 1.1.4)
7.1.2 FAULTY CYLINDER

An air cylinder moves the P.T.O. arm to engage and disengage the arm. If the air cylinder is malfunctioning, the
blower will not engage/disengage. Check all airlines. Check the solenoids for proper operation. The solenoids
actuate the cylinder movement.
7.1.3 Check P.T.O. clutch.

TROUBLESHOOTING 6
SECTION 8.1 – LOW VACUUM
8.1.1 VACUUM RELIEF VALVE STUCK IN OPEN POSITION OR OPENING TOO SOON
Inspect the relief valve for something lodged in the valve.
KEEP HANDS CLEAR WHILE AIR IS BEING PULLED THROUGH THE VALVE.
8.1.2 GASKETS
Inspect all gasketed doors and gates for loss of vacuum from gaskets not sealing.
8.1.3 BLOWER RPM

The blower RPM is too low.
SECTION 9.1 – NO VACUUM

9.1.1 BLOWER
Check to make sure the blower is engaged and that the belts are in place and tensioned correctly.
9.1.2 DIRTY OR BLINDED FILTER BAGS

See Section 1.1
9.1.3 See Sections 5.1, 8.1, 9.1, 9.2.
9.1.4 RELIEF VALVE STUCK OPEN

Inspect the relief valve for something lodged in the valve. KEEP HANDS CLEAR WHILE AIR IS BEING PULLED
THROUGH THE VALVE. Replace if not functioning properly.
SECTION 10.1 – SHUTDOWNS
10.1.1 LEVEL PROBE

There is a level detector that extends into the hopper. When the hopper is full, the clutch will disengage,
the blower will shut down, and the “HOPPER FULL” indicator will light on the control panel. Check the
operation of the level probe and electrical connections.This condition is to be reset after the problem is
corrected by pressing the “FAULT/RESET” button before pressing the “BLOWER ENGAGE” button.
10.1.2 LOW UTILITY AIR PRESSURE

An air compressor supplies air to clean the filters and engage the clutch. If air pressure is not present
or if air pressure is too low, the clutch will disengage, the blower will shut down, and the “LOW UTILITY
AIR” indicator will light on the control panel. Check compressor, belts, valves, and air lines. This condition
is to be reset after the problem is corrected by pressing the “FAULT/RESET” button before pressing the
“BLOWER ENGAGE” button.
Note: Once the problem has been corrected, allow the unit to build up an adequate amount of air
pressure (80-100 psi) before engaging the blower.
SECTION 10.2 – VISIBLE DISCHARGE FROM BLOWER SILENCER

10.2.1 BROKEN BAGS
Replace any broken bags IMMEDIATELY after you detect dust or material discharging from the silencer.
SECTION 10.3 - BELTS WEARING TOO SOON

10.3.1 MISALIGNED BELTS
Misaligned belts will cause the belts to wear out quickly. Check belt tension on the belts. If they are too loose they
will wear out quickly

TROUBLESHOOTING 7
SECTION 10.4 – BELTS SQUEAL UNDER VACUUM
The belts are too loose and the tension should be checked and tightened to the proper tension.
10.4.1 BLOWER OIL LEVEL LOW (IF EQUIPPED)

Some units are equipped to monitor and shut down if the blower oil level is low.
10.4.2 HIGH TEMPERATURE (IF EQUIPPED)

Some units are equipped to monitor and shut down if the temperature of the air leaving the blower is too high.
SECTION 10.5 – BRAKES WON’T ENGAGE/DISENGAGE
10.5.1 PARKING BRAKE SWITCH

Make sure the parking brake is in the proper position. Check to see if the switch and contact block on the switch
are working. Check the wiring to the switch.
10.5.2 BRAKE SOLENOID

The brake solenoid valve actuates the hydraulic valve to engage the parking brake. Check the brake solenoid
valve for malfunction. Replace if necessary.
SECTION 10.6 – TAIL GATE NOT SEALING
10.6.1 GASKET
Check the tail gate gasket to make sure it is in place and not broken or torn. Replace if it is broken or torn.
10.6.2 CHECK CYLINDERS

Two hydraulic cylinders are open and close and lock the tail gate. Check these cylinders to see if they are
functioning correctly.
10.6.3 FULLY CLOSE

Make sure when you are closing the tail gate that you hold the lever on the valve until the tail gate locks are
engaged.
10.6.4 MATERIAL WEDGES

Material can wedge between the tail gate and hopper. Always move forward away from the pile before closing the
tail gate.

TROUBLESHOOTING 8
OPTIONS

OPTIONAL EQUIPMENT FOR ULTRAVAC UNITS
AIR LINE DRYER

The air line dryer heats and dries the air from the compressor and air lines, which reduces moisture and inhibits the
formation of rust in the air tank and air line. It is often used in conjunction with an automatic air tank drain valve.
AUTOMATIC AIR TANK DRAIN VALVE

The automatic air tank drain valve removes moisture from the air line and tank, reducing condensation and the possibil-
ity of rust in the tank or air lines. The automatic air tank drain valve is activated every time the air pressure reaches the
compressors rated maximum.
BIN LEVEL CONTROL

A bin level control can be of several styles, but is usually a paddle or ball-type. Its purpose is to indicate that the bin is full
and needs to be emptied. Timely emptying of the hopper lessens the possibility of filter blinding as the material level says
below that of the filter media compartment or baghouse.
BIN VIBRATORS
Bin vibrators have proven very effective in dealing with applications which involve powders, etc., that tend to cake or coat
the walls. This coating or caking can gradually diminish the total capacity of the hopper or eventually plug up the dump
chute. The vibration induced by the bin vibrator successfully eliminates most coating or caking, assuring you of full hopper
capacity, and lessens the possibility of the bottom dump chute being plugged up. If the bin vibrators alone can’t solve the
problem, consult factory or UltraVac representative.
BLOWER PROTECTION PACKAGE

Protection of the blower or vacuum pump is the most important insurance you have that your UltraVac will provide long
and trouble-free service. The blower protection package consists of two items:
1. Low oil gauge(s) which automatically shuts the blower down in the event of low oil in the blower, and
2. A high temperature gauge which will automatically shut the blower down if the blower operating
temperature rises above 3500 F.
HIGH TEMPERATURE FILTER MEDIA

If your application requires moving material which will produce an air stream temperature over 2750 F, it is advisable to
use specially designed high temperature filter media. Several filtering media which meet high temperature specifications
are available. Consult with an UltraVac representative to determine the filter media best suited to your individual
application.
SOUND ATTENUATION PACKAGES

Sound attenuation devices (mufflers, sound enclosures, sound chimneys, etc. ,) can reduce the noise level the UltraVac
adds to your work place. This can mean a quieter and more productive work environment.

OPTIONS 1
ELECTRICAL

ACCESSORIES

MANUFACTURER’S
MANUALS

Ultravac (105S Series) Operations Manual

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105S SERIES

A DIVISION OF Hi-Vac® CORPORATION

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

SECTION 1 : SAFETY PRECAUTIONS

SECTION 2 : MACHINE SPECIFICATIONS

SECTION 5 : PREVENTIVE MAINTENANCE

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

SECTION 9 : MANUFACTURERS MANUALS

JOHN DEERE ENGINE MANUAL HONEYWELL LIMIT SWITCH

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

REPORT ANY DAMAGE, NO MATTER HOW SLIGHT, IMMEDIATELY TO:

Storage of your Hi-Vac® unit

1. For short-term storage. (30 days or less)

2. For storage over 30 days

C. Add packages of desiccant to all electrical enclosures on sides of Hi-Vac®.

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

Hi-Vac® CORPORATION WARRANTS TO THE ORIGINAL PURCHASER OF THE Hi-Vac® UNIT

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

* This unit to be operated by properly trained personnel only!

* Severe injury may occur if inlet contacts clothing, hair, or body!

* Stay clear of vacuum nozzle when blower is engaged!

* Moving parts can injure! Keep away from moving parts!

* Technical procedures should be strictly followed!

All specifications and part numbers subject to change without notice.

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

CONTROL PANEL (Outside)

Tachometer Voltmeter Oil Pressure

Utility Air Pressure

Hopper Full Light

Pulse Filter Switch

Blower On Light Emergency Stop

Blower Disengage Button

Blower Engage Button

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

CONTROL PANEL (Inside)

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

HYDRAULIC TANK & FILTER

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

ACCUMULATOR and ACCUMULATOR VALVE

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

HYDRAULIC STEERING SYSTEM

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

FOOT PEDAL CONTROL

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

DUMP DOOR CONTROL

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

PARKING BRAKE RELEASE SYSTEM

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

PARKING BRAKE CONTROL

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

ITEM PART # DESCRIPTION QTY

Hi-VAC® OPERATIONS, PARTS, & SERVICE MANUAL

ITEM PART # DESCRIPTION QTY