Xvac (X-15 Series) Operations Manual

A Product of Hi-Vac Corporation
X-15 SERIES
OPERATION
SERVICE
& PARTS
M A N U A L
A Product of Hi-Vac Corporation • 117 Industry Road • Marietta, Ohio 45750 USA
Corporate: Tel: 740.374.2306 • Toll Free USA: 800.752.2400 • Fax: 740.374.5447 • Web: www.hi-vac.com • E-mail: sales@hi-vac.com
X-15 SERIES10
TABLE OF CONTENTS
PRE-DELIVERY INSPECTION FORM . ....................................................................................................... I.
CUSTOMER TRAINING FORM/DELIVERY CHECKLIST.......................................................................... III.
MESSAGE TO NEW OWNER.....................................................................................................................VI.
WARNINGS................................................................................................................................................VII.
SECTION 1 OPERATIONS
I. PRINCIPLES OF OPERATION
Positive Displacement Exhauster and Water Pump Units
Controls and Gauges
Power Deck Systems Engagement
PTO Enable
Unit Power
PTO
Engaging the Exhauster
Low Water Warning and Cold Weather Conditions
Hydraulics
Side Operator’s Station
Air Purge Pump Prime and Cold Weather Blowout System
Antifreeze System
Cold Weather Recirculation System
Water Heater
Compartment Heater
Wireless Remote
Internal Tank and Floor Flush Option
II. HOW TO USE YOUR HYDROEXCAVATION UNIT

Important Safeguards
Before Going to the Work-Site
Hydro Excavating at the Work-Site
Vacuuming at the Work-Site
Leaving the Work-Site
Dumping the Debris Tank
Cleaning the Debris Tank
III. HELPFUL HINTS FOR USING YOUR X-VAC CLEANER

Water Level Indicators
Cold Weather Storage
X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

1
X-15 SERIES10
SECTION 2 SERVICE
1. CUSTOMER SERVICE AND PARTS ORDERS
2. SALES TERMS
3. STANDARD LIMITIED PRODUCT WARRANTY
4. WARRANTY EXTENSIONS
5. MAJOR COMPONENT WARRANTY
6. SPECIAL WATER TANK WARRANTY
7. MILD STEEL TANKS PRO-RATED WARRANTY (EXCEPT SJR TANKS)
8. STAINLESS STEEL TANKS PRO-RATED WARRANTY (EXCEPT SJR TANKS)
9. POLYGRAPHITE TANKS
10. SJR TANKS
11. DESIGN MODIFICATIONS
12. WARRANTY INITIATION
13. LIMITATIONS/EXCLUSIONS TO WARRANTY
14. CLAIMS PROCEDURE
15. REPLACEMENT PART WARRANTY
16. GENERAL MAINTENANCE SCHEDULE
17. TROUBLESHOOTING COMMON PROBLEMS
18. WATER PUMP COUPLING ASSEMBLY PROCEDURE
19. TORQUE SPECIFICATIONS
20. X-VAC STANDARD UNIT LUBRICATION POINTS
21. X-VAC STANDARD UNIT LUBRICATION POINTS INTERVALS
22. X-VAC STANDARD UNIT WATER PUMP, EXHAUSTER, PTO, AND HYDRAULIC SYSTEM LUBRICATION
INTERVALS
23. FILTER REPLACEMENT SCHEDULE
SECTION 3 PARTS
Note: Some of the parts information contained in this manual, has been provided by the original parts
manufacturer and should only be used as a visual reference when ordering. For an accurate listing of part numbers and
components on accessories, please refer to the Optional Equipment section of this manual.
I. SPARE PARTS LIST
II. CONTROLS
Side Operator’s Station
Wireless Remote Control
Vendor Manuals
III. POWER TRAIN

Blower Drive System
PTO Remote Fill
Vendor Manuals

2
X-15 SERIES10
SECTION 3 PARTS (Continued)

IV. WATER SYSTEM
Water Pump Drive System
Filler Pipe Assembly
Suction Valve and Strainer
Water Pump and Relief Valve
Hose Reel
Water Heater
Water System Schematic
Vendor Manuals
V. VACUUM SYSTEM
Blower and Silencers
Final Filter Assembly
Vacuum Breaker
Vendor Manuals
VI. HYDRAULIC SYSTEM

Hydraulic Tank & Heat Exchanger
Hydraulic Pumps
Water Pump Speed Control
Rear Door Cylinder
Cylinder & Wedge Assembly
Directional Control Valve Assembly
Boom Hydraulic Motor
Boom Control Valve Assembly
Hydraulic Filters
Low Pressure Hydraulic Schematic
High Pressure Hydraulic Schematic
Vendor Manuals
VII. PNEUMATIC SYSTEM

Pneumatic Valves and Separators
Pneumatic Schematic
Vendor Manuals
VIII. ELECTRICAL SYSTEM

Chassis wiring diagram
Electrical schematic
IX. BODY
Air Port Tube Assembly
Cyclones and Hoppers
Tube Rack
Worm Gear Dive Bearing
Boom Assembly
Hinged Tank Support Prop
Polytank Installation Instructions
Installation of Water Fill Line
Polyethylene WaterTanks
Polytank Repair

3
X-15 SERIES10
SECTION 3 PARTS (Continued)

X. OPTIONAL EQUIPMENT
As Shown
Accessories
NOTE: The descriptions and instructions in this manual cover the standard design of the equipment and any common
deviations when possible. This manual does not cover all design details and variations nor does it provide for every
possible contingency which may be encountered. When information cannot be found in this manual, contact your
nearest AQUATECH Parts and Service Center.
*When ordering parts always specify unit serial number.

4
Customer:

Unit Model: X-15
Unit Serial Number:
PRE-DELIVERY INSPECTION FORM (Page 1 of 2)
Upon arrival at destination, the following procedures must be carried out.(Please initial on line below)
Prior to delivery to customer
1 Engine, oil, water, fuel, air cleaner, fan belt ___________
2 Inspect rear axle seals for leaks ___________
3 Check all lights and reflectors ___________
4 Check tire pressure ___________
5 Inspect exhaust system for clearance problems in and around entire ___________
exhaust syste
6 Inspect universal joints; tighten bolts, if necessary ___________
7 Inspect for loose wires, hoses, cables, and correct as needed ___________
8 Check chassis specifications against customer specs; report any discrepancies

to Hi-Vac Corporation. ___________
9 Appearance:
• Sweep out cab
• Wash windows (inside and out)
• Wash unit
• Remove and clean all sight eyes (inside and out)
• Inspect paint; (touch-up where necessary) ___________
10 Check fluid levels (see service manual):
• Exhauster
• High pressure water pump
• Hydraulic tank
• PTO ___________
11 Electrical system:
• Test throttle control at operator’s station
• Test boom pendant and operate each button
• Test all lights supplied with unit
• Test wireless remote operation and operate each button ____________
13 Body:
• Door hinges and locks. Check keys and latches for proper action. Adjust if necessary
• Inspect all body mounting bolts (torque if necessary)
• Inspect inside of tanks for packed components or foreign objects
• Raise and lower tank, inspect closure seal ____________

I
PRE-DELIVERY INSPECTION FORM (Page 2 of 2)
14 Hydraulic system
• Operate entire hydraulic system-all functions
• Check all hoses, connections, and cylinders for leaks ____________
15 Install suction line strainer if removed for shipping. Fill tank and run pump.
Assure all air is purged and the water pressure develops smoothly ____________
Check for leaks. If unit is delivered during cold weather, refer to cold weather preperation.

THIS INSPECTION WAS PERFORMED BY:

SIGNATURE:________________________________ DATE:_ __________________ TITLE: ________
comments:__________________________________________________________________________

II
Customer:
Unit Model: X-15

Unit Serial Number:
CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST (Page 1 of 3)

Operator and service personnel must be thoroughly instucted of the following: (Please initial on lines below)
Power Take off (PTO)
• Maximum operating speed _____________
• How to engage and disengage _____________
• Drive train service and lubrication _____________
• Hydraulic pump location and alignment _____________
• PTO oil level _____________
Hydraulic system
• Oil level inspection and time interval _____________
• Location of filters and service _____________
• Manual over-ride operations _____________
• Location of flow control valves and explanation of adjustments _____________
• Location of hydraulic pressure gauge _____________
• Boom system operation _____________
Pneumatic system
• Air reservoir regulator, filter and service _____________
• Operation of PTO _____________

III
Water system
• Water tank inspection and repair _____________
• Drain valves _____________
• Water pump drive system _____________
• Oil level inspection, time interval _____________
• Packing lubrication, time interval _____________
• Water “on/off” controls _____________
• Pressure relief valve and operation _____________
• Return line ball valve setting and service _____________
• Handgun operation _____________
• Winter recirculation _____________
• Cold weather storage _____________
• Water pressure operation _____________
• Removal of ice from system _____________
• Suction line strainer _____________
• Water pump service oil level _____________
Vacuum system and debris tank
• Debris tank inspection _____________
• Door gasket cleaning _____________
• Exhauster lubrication oil level _____________
• Primary safety cut-off operation, service _____________
• Vacuum gauge _____________
• Vacuum breaker _____________
• Exhauster drive system and controls _____________
• Centrifugal scrubber and clean out screen _____________
• Rear door operation and controls _____________

• Tank tipping operation, controls, lubrication _____________
• Tank prop _____________
• Hydraulic door locks _____________

IV
• With separator open - explain cleaning and un-clogging _____________
• With final filter door open - explain final filter cleaning _____________
• Water draining system _____________
• Cold weather operation _____________
• Storage - draining all water from systems _____________
Accessories supplied with unit
• Handgun assembly _____________
Options
• Water heater _____________
• Equipment compartment heater _____________
• Antifreeze system _____________

THIS INSPECTION WAS PERFORMED BY:

SIGNATURE:________________________________ DATE:_ __________________ TITLE: ________
comments:__________________________________________________________________________

V
INTRODUCTION
MESSAGE TO NEW OWNER

Thank you for purchasing your X-VAC Hydro Excavator unit, the most advanced American-made
hydro excavation machine. Our quality of design and manufacture will assure you the greatest return
on your equipment investment.
Please consult this owner’s manual as the first step to resolving questions you may have about the
operation or service of your machine. If you are not able to find the answers, then consult with your
selling dealer. Finally, we at the factory will be happy to provide operating or service information that
this manual or your dealer are unable to provide.
Our warranty spells out all your rights and expectations with regard to this equipment. Please consult
it for a full definition of what is covered.
Thank you again for selecting the equipment preferred by industry professionals throughout the
world.
Your new X-VAC Hydro Excavator unit incorporates the very latest in hydro excavation technology.
The soil cutting action results from water traveling from the storage tank into the high efficiency water
pump and being pumped to the hose reel and nozzle at high pressure and low volume. As a result,
the machine will excavate and operate in a far superior manner than previously available.
The vacuum system provided is superior to any other available. It is capable of both wet and dry
operation, as well as operation under water.
To achieve maximum results, the operators must become thoroughly familiar with the operation of
the machine and completely understand correct nozzle selection and cleaning accessory use.
We are a company that is committed to continually striving to build an even better product. Many
ideas for improvements in previous models have come from users in the field.
OPERATIONS, SERVICE AND PARTS MANUAL

VI
WARNINGS
X-VAC HYDRO EXCAVATOR MACHINES

X-VAC Hydro Excavator machines are designed to remove material in an
underground environment. These systems operate under high pressure
conditions with low water flow. Therefore, operators of these systems must
be aware of possible hazards. This is not a complete list of all possible
hazards, but represents typical hazards and types of hazards. At all times,
the operator is responsible for the proper use of the machine.
Operators of X-VAC Hydro Excavator machines should be aware

of the following safety warnings:
• Using this machine for purposes other than hydro excavation is not
recommended.
• Water hose that is damaged into the braided lining must be repaired
or replaced.
• Fittings used on water hose must be of a type and installed in a
manner that is approved by the hose manufacturer.
• The handgun is designed to shut off automatically when the actuator
handle is released. Never use a forward jet nozzle that will not turn
off when released.
• Never operate the water system with the relief valves removed, or
improperly adjusted. The main relief valve is set at 2500 psi. Do not
operate at pressure readings higher than these unless the manual
specifically states that the system has been designed for higher
pressures.
• Never walk under raised components such as hydraulically actuated
tanks, doors, etc. Whenever these components are raised, props
must be used to protect workers who must work under them.
• Never operate the machine in a stationary position without first set-
ting the brakes, and shifting the rear axle out of the drive line. Always
use wheel chocks.
• Never move the vehicle with the boom in a raised or otherwise
unsecured position.
• Always turn off unit power when moving the vehicle.
• Always check for overhead obstructions before operating boom.
YOUR LIFE COULD DEPEND ON IT!!!
YOUR LIFE COULD DEPEND ON IT!!!
OPERATIONS, SERVICE AND PARTS MANUAL

VII
PRINCIPLES OF
OPERATION
POSITIVE DISPLACEMENT EXHAUSTER AND WATER PUMP UNITS

This machine is a combination vacuum and high pressure water unit for excavation of soil.
The vacuum pump is a rotary lobe, positive displacement exhauster. During operation of the vacuum
system, material is picked up at the end of the suction line and pneumatically conveyed through the intake
tubes, the boom hose, and to the debris tank. As the material enters the larger area of the debris tank the
velocity of the air flow is reduced and the material drops out of the air stream, settling at the bottom of the
tank. The spent air flows through the ball check valve, and through a metal screen in the centrifugal
scrubber externally located at the front of the body and though a final screen at the blower inlet. At this
point the filtered air flow enters the exhauster and is expelled through a silencer/muffler to the atmosphere.
A positive displacement triplex plunger water pump provides the water pressure and water flow to the hydro
excavation nozzle attached to the end of the handgun or lance.
In the water system, the water flows from the water tanks, mounted outboard of the debris tank, through a
crossover manifold, through the water pump feed line, into the suction side of the pump. The pressurized
water is then pumped forward to the water control valve and routed, depending on the position of the valve,
either to the hose reel for hydro excavation, or by return lines to the water tank. The vacuum and water
system can be used simultaneously when excavating soil. This allows conveyance of flushed out materials
and water into the debris tank.
CONTROLS AND GAUGES

It is important for the operator to fully familiarize him/herself with the location, appearance and function of the
various controls and gauges on any new X-VAC Hydro Excavator. Please read this section carefully, and refer
to it whenever any section of the manual describes a control which you cannot identify.
Several controls are mounted in the chassis cab itself. These controls allow the operator to engage and
disengage the water pump, exhauster, and hydraulic system. In addition, a main power indicator light and switch,
and a low water warning light and switch are among the standard controls in the chassis cab. The water pump
and exhauster are engaged and disengaged by electro-pneumatic solenoid valves. These solenoids are
operated by electric toggle switches in the cab. Because each manufacturer will have a different cab layout,
even among models of the same manufacturer, our description of their location is general. In addition there
is a switch that controls the “ON/OFF” function of the water heater and compartment heater.
POWER DECK SYSTEMS ENGAGEMENT

Before engaging any of the power systems on this vehicle, you must first determine that there is at least 120 psi
in the air brake system. Check the air pressure gauges on the dashboard to confirm this. The PTO is actuated by
means of electro-pneumatic solenoid valves. While engaging PTO systems using the switches described in the
following paragraphs, the vehicle transmission must be put into neutral and the parking brakes set. For vehicles
with standard transmissions, the clutch must be depressed as well.
Caution!
The transmission should never be operated in a gear range greater than indicated on either
the dashboard label or unit identification sheet.
Failure to heed this caution may result in severe damage to the water pump or exhauster.
Please consult with the factory if the vehicle gear range is not specified.

PRINCIPLES OF OPERATION 1
PRINCIPLES OF
OPERATION
PTO ENABLE
The PTO enable switch must be moved to the “Up” or “On” position. This switch enables the use of throttle
and e-stop functions.
UNIT POWER
The unit power switch supplies power to all the other switches and mounted equipment. When turning unit
off, this switch must be the last one turned off. Push up to turn on the unit power switch and push down to
turn it off. A red light glows inside the switch to indicate that the unit power is on. Without turning this switch
on, nothing will function. The unit power switch should be turned off when transporting the unit unless using
cold weather recirculation.
PTO
In order to keep the truck stationary while operating the water pump, exhauster or both, the rear axle must
be disengaged. This can be done by moving the switch marked PTO to the “Up” or “On” position. This
will cause the PTO to internally shift positions and disengage the rear drive train of the vehicle. This also
engages the hydraulic pumps for system operations of all hydraulic functions (water pump, boom, tailgate,
and tube rack).
ENGAGING THE EXHAUSTER

The same procedure using the switch marked (exhauster) will allow you to engage the vacuum system.
Both power systems can be run simultaneously if desired. When the procedure for engaging the desired
systems is complete, select the gear range referred to on the dashboard label, or the unit identification
section of this manual. Release the clutch.
LOW WATER WARNING AND COLD WEATHER CONDITIONS

The low water control is the center switch on the dashboard. On units equipped with the low water warning
system, a red light will glow in the switch in the event that the water level is depleted to a pre-determined
level. A white light remains on during normal operations. Pushing the switch up turns on the “winter” low
water warning. Pushing the switch down turns on the “summer” low water warning. The low water switch is
labeled “winter” and “summer”. During cold weather, 32o F (0o C) or below freezing, this switch should be
set to the “winter” position. This will cause the low water warning light to illuminatewith more water left in
the water tank. This allows more water to remain in the tank to help prevent possible freezing. During warm
weather, the switch can be set to the “summer” position, this allows more water to deplete from the tanks
before the low water warning light glows.
HYDRAULICS
The main tower PTO incorporates two additional outputs for the installation of the hydraulic pump to supply
power to all hydraulic functions and the drive system on the water pump. These pumps are close coupled to
the PTO. These drives are automatically engaged whenever the PTO switch is activated in order to
disengage the main drive to the differential of the vehicle. When the PTO switch is positioned in the “Off”
position for drive mode, the hydraulic pump drives are disengaged.

PRINCIPLES OF
OPERATION
SIDE OPERATOR’S STATION
There is an operator’s station at the passenger side of the unit to allow the operator to control
vaccuuming, pumping, tank flushing, and tank dumping operations. The control panel contains
switches for for the various operations and an emergency stop button. The engine throttle control
at this station allows the operator to control engine speed, and therefore hydraulic pressure.
Operate engine at 1500 rpm during tank dumping and lock operating functions. Plastic labels at
each switch indicate the correct manipulation of the switch for the function it performs. Consult the
labeling to be sure you are operating the controls correctly. If the labels become unreadable or are
inadvertently removed, consult the information in the electrical section for switch operation.

PRINCIPLES OF
OPERATION
AIR PURGE PUMP PRIME & COLD WEATHER BLOWOUT SYSTEM

(Page 1 of 2)
AIR PURGE PUMP PRIME

Air Purge Pump Prime Valve #1 (see next page) is provided to assist the purge of air trapped inside the
suction section of the water pump. There should be sufficient head pressure from the water in the water
tanks to expell any air trapped on the suction side of the pump. Close Air Purge Pump Prime Valve #1
(see next page) when a solid water stream runs from the overflow tube.
Air Purge Pump Prime Valve #2 (see next page) is provided to assist the purge of air trapped inside the
discharge section of the water pump. Any trapped air acts as a spring cushion for the compressed water
and causes the water to “bounce back” against the cushion of air. This can cause a loud knocking noise
from the pump area and severe pulsating of the sewer hose. This is called “cavitation”. If the air is not
expelled, severe damage can occur in the pump. Open the valve to allow air trapped inside the pump to be
expelled. Water will also be expelled at the same time. Run the pump at an idle speed for several minutes
until all air is expelled, then slowly increase pump speed. As the pump develops greater pressure, the water
discharged from the valve will become very intense. When it is clear that all air has been expelled, close the
Air Purge Pump Prime Valve #2 (see next page) and increase pump speed. The knocking sound should
disappear, and the pulsating of the hose will be very mild. This is normal for a triplex water pump. At this
point it is safe to operate the jetting, hydro or handgun operation. This procedure is usually only necessary
when all water has been previously purged from the system, the suction line strainer has been removed for
cleaning, or the pump has been run out of water.
Note: If you have constant problems with cavitation, it is likely that air is being sucked into the pump
somehow, or one or more valve springs have broken. If you experience repeated cavitation, even though the
pump has not been run out of water, you should request an inspection of the water system to determine the
cause.
COLD WEATHER BLOWOUT

Schrader Air Valve #1 (located near the Main Water Supply Pump) and Schrader Air Valve #2 (located
near the Hose Reel/Washdown Valve), are used to purge the system of any trapped water and return it to
the water tanks. By connecting the purge coiled hose assembly (not shown) to the Forced Air Disconnet
(see next page), and the Schrader Air Valves, air is then introduced at the valves and water is blown back to
tank. Assure the Cold Weather Blowout Valve #1 is open when using Schrader Air Valve #1 and closed
when completed.

PRINCIPLES OF
OPERATION
AIR PURGE PUMP PRIME & COLD WEATHER BLOWOUT SYSTEM

(Page 2 of 2)
Schrader
Air Valve #1
Air Purge Air Purge

Cold Weather Pump Prime Pump Prime
Blowout Valve #1 Valve #2 Valve #1
Schrader
Air Valve #2
Forced Air Disconnect

PRINCIPLES OF
OPERATION
ANTIFREEZE SYSTEM
Procedure:
1. Open the Valve on the bottom of the Antifreeze Storage Tank.
2. Turn Valve #1 to “Glycol” position (valve located just after the suction strainer).
3. Turn Valve #2 to “Glycol” position (valve located inside the enclosure on the right hand side above the
water pump).
4. Open Valve #3 (valve is inline with the Quick Coupler for the hose reel).
5. Engage the water pump to circulate fluid and continue running the pump until fluid is seen being . Engage the water
returned to the Antifreeze Storage Tank.
To return fluid back to the Antifreeze Storage Tank, close the Valve on bottom of the Antifreeze Storage
Tank and connect the purge coiled hose assembly (not shown) between the Forced Air Disconnect and
the Schrader Air Valve located on the water pump. Open the Cold Weather Blowout Valve and then open
the Air Supply Valve and purge and the system until all of the fluid is returned to the Antfreeze Storage
Tank.
Antifreeze Stroage Tank
Valve Valve #1
Valve #2
Cold Weather
Blowout
Air Valve
Quick Supply
Valve #3 Coupler Valve
Forced Air
Disconnect
Schrader
Air Valve

PRINCIPLES OF
OPERATION
COLD WEATHER RECIRCULATION SYSTEM
Quick
Valve #3
Side Operator’s Panel: Coupler
1. Connect the hydro excavation hose into the Quick

Coupler located to the left of the hose reel and open
Valve #3.
2. Place the Water Pump Speed Control to a center

position.
Cold Weather
Recirculation
Pump
Unit Water
Power Heater
Water Pump Speed Control
Truck Cab:
1. Turn on Unit Power Switch and Cold Weather Recirculation Pump Switch in the cab, but do not
disengage rear axle. If it is desired to use the boiler to heat water, the Water Heater Switch in the
cab should be placed in the “On” position.
2. Unit can now be driven. As unit moves, the water pump will circulate water throughout the system and
back to the tank.
Note: If water recirculation is desired with the truck stationary, disengage the rear axle through the PTO switch
and engage the water pump normally. Raise idle rpm as needed.
Caution! The pump systems should never be operated in a gear range greater than indicated on the
dashboard and truck labeling. Failure to heed this caution may result in severe damage to the water
pump or exhauster. Please consult with the factory if the vehicle gear range is not specified.
Suggestion: Always carry the handgun and nozzles in the heated cab of the truck when not in use to
prevent freezing.
Note: All units supplied with cold weather recirculation are equipped with two low water warning sensors
controlled by the “Winter/Summer” Switch in the cab. In cold weather the switch should be in the
“Winter” position. This allows more water to remain in the tank to accommodate recirculation. During
warmer weather, the switch should be in the “Summer” position, providing more water for hydro
excavation operations.

PRINCIPLES OF
OPERATION
WATER HEATER
The diesel fired boiler is used to heat the hydro excavating water during cold weather operations.
It is connected into the water system and the hydro excavating water always runs through the
boiler. To turn on the boiler, place the Water Heater Switch to the “On” position. The boiler can
also be used during cold weather recirculation operations. For operation of this unit, refer to the
manufacturer’s manual.
Water
Heater
Hotsy Boiler

PRINCIPLES OF
OPERATION
COMPARTMENT HEATER
The Compartment Heater is used to heat the equipment compartment during cold weather
operations when the unit is in use. It is connected to the chassis water system by valves mounted
on the passenger side of the chassis engine compartment.
These valves must be opened to allow the hot engine water to flow to the compartment heater.
They should be closed when the heater is no longer used.
The flow of water to the Compartment Heater is controlled by a Push/Pull Cable located at the
lower mount for the boiler. Pushed all the way in, the flow of hot water is closed off to the heater.
Pulled, the hot water is allowed to flow to the heater. The heater fan is controlled by a
Thermostat located on the wall and an Compartment Heater Switch located in the cab.
Compartment
Heater
Compartment Heater
Push/Pull Cable
Thermostat

PRINCIPLES OF
OPERATION
WIRELESS REMOTE
1. With the engine running, clutch depressed, PTO Enable Switch in the “On” position, Unit
Power Switch in the “On” position, and PTO Engage Switch in the “On” position, place
the transmission in the correct gear.
PTO Engage Switch

Unit Power Switch
PTO Enable Switch

PRINCIPLES OF
OPERATION
WIRELESS REMOTE CONTROL
2. Next, press the green “Power On” Button located on the top center of the remote face
and a yellow light will illuminate next to the “Power On” Button. The yellow light will
remain momentarily.
3. All wireless remote functions will now work by pressing the appropriate buttons. All
operators should become familiar with each function controlled by the wireless remote.
4. On the wireless remote, press the red “Power Off” Button on the bottom of the remote to
turn off the remote.
POWER “ON”
STOP
STOP *(DOOR UNLOCK)
*(DOOR LOCK)
BOOM RIGHT
BOOM LEFT
*(THROTTLE DOWN)
*(THROTTLE UP)
BOOM DOWN
BOOM UP *(TAILGATE CLOSED)
*(TAILGATE OPEN)
BOOM OUT
BOOM IN
VAC. BREAKER WATER PUMP
POWER “OFF”
TRANSMITTER
* . Items shown in parenthesis ( ) require the use of the shift button. For how to enable
this function, refer to the manufacturer’s manual located in the “Controls” section of
this manual.

PRINCIPLES OF
OPERATION
INTERNAL TANK and FLOOR FLUSH OPTION

The controls for the internal tank and floor flush are near the side operator’s station.
The control for the water flow is the lever on the ball valve located on the pressure side of the pump.
Normally the valve is left in the “Reel” position. When the valve is placed in the “Washdown” position,
the water flow is sent to the internal tank nozzles in the debris tank, allowing high pressure flushing
of the debris tank. When dumping the debris tank, it is desirable to use the internal tank and floor flush
system to thoroughly clean the interior of the tank without requiring the operator to manually wash it
down.
A “Toggle Switch”, located on the right side of the side operator’s panel, is used to control an
automatic 3-way valve for selecting the direction of the water flow to the nozzles. Place the toggle
switch in the “Up” position for “Tank Flush” or in the “Down” position for “Floor Flush”.
Caution! Do not operate this system while the exhauster system is running, or at
speeds in excess of posted speed and gear range!
To operate this system, perform the following steps:

1. Place the control valve in the “Washdown” position.
2. Select “Tank Flush” or “Floor Flush” using the toggle switch.
3. Engage the water system from the cab.
4. Open the rear door approximately half way. Follow instructions for dumping the debris tank,
outlined in this manual.
5. To increase the tank flushing capability increase the engine RPM.
6. Adjust the level of the rear door so that the jet spray from the internal nozzles is striking the
middle of the door for maximum cleaning (to be done when using the “Tank Flush”).
7. Operate system until the tank is completely clean or the water supply is depleted.
Floor Flush Nozzles
Toggle
Switch
Control Valve
Tank Flush Nozzles

PRINCIPLES OF
OPERATION
HOW TO USE YOUR hydro excavator unit
IMPORTANT SAFEGUARDS:
1. When entering any excavation, proceed as recommended in the APWA handbook on safety. Follow
all state and federal regulations.
2. Use only genuine Hi-Vac hose and repair parts.
o
3. Use Cold Weather Recirculation in temperatures below 32 F.
4. Check hose and water network for weak, worn or leaking places. Repair or replace if necessary.
5. Check for overhead lines that could come in contact with the boom.
Before proceeding with the following instructions make certain that there is at least 120 psi of air
pressure in the chassis air reservoir or damage to the PTO may result.
BEFORE GOING TO THE WORK-SITE:

1. Perform required maintenance as specified in the maintenance schedule.
2. Perform required maintenance on truck chassis as specified in truck chassis manual.
3. Check to see that the boom is secure in the boom rest and the boom pendant control secure
in a tool box or in the cab.
4. Check to assure that all tools are secured, and that all cabinet doors are closed and latched.
5. Fill the water tank. Please refer to one or more of the following water level indicators.
a. The sight tubes located on the rear of the water tanks shows the direct water level
in all tanks.
b. Low water warning light in the cab indicates low water.
6. Inspect and clean water suction line strainer and exhauster final filter.
Before proceeding to drive this vehicle, special attention must be given to assure that the boom is resting
properly in the travel position. Also, to avoid damage, be sure that the pendant control is properly
wound and placed in a tool box or truck cab.
HYDRO EXCAVATING at the work-site:

1. Position the unit as close to the work location as possible. Set the parking brake and block the wheels.
2. Open the water pump supply valve completely.
3. Disengage the rear axle by shifting the main drive of the tower PTO. The transmission must be in
neutral. On units with standard transmissions it is also advisable to depress the clutch pedal to the
floor during this operation.
4. Engage water pump. Refer to the dashboard and truck labeling for the correct gear range in which to
operate your Hydro Excavator machine. Select the correct gear range and proceed to the side
operator’s station to operate the unit. Your Hydro Excavator machine must never be run at speeds
higher than specified on the dashboard and truck labeling. Running the engine at a higher rpm may be
unsafe and result in personal injury and damage. Upon such use, the warranty becomes null and void.
If you cannot locate this information, please call your selling dealer, or the Hi-Vac Corporation direct at
(740) 374 -2306.
5. At the side operator’s station, move throttle control lever up momentarily to increase engine speed,
down to decrease. The needle on the tachometer indicates the engine speed.

Cold weather precautions: If the unit is subjected to freezing temperatures, ice will probably form in the
hydro excavation hose and must be ejected for proper operation. Leave the hose in its traveling position,
the engine at idle speed, and run water through the hose for at least one minute or until all ice is ejected. If
pressure starts to rise, the hose is plugged.

PRINCIPLES OF
OPERATION
VACUUMING AT WORK SITE:

1. Be sure that the unit operator is completely familiar with the wireless remote.
2. Place a sufficient number of intake and/or extension tubes on the boom hose to reach the
desired working depth.
3. Engage exhauster. To increase the exhauster speed, increase engine RPM to working
speed, not to exceed maximum RPM and gear as noted on the dashboard and truck
labeling.
4. Begin vacuuming debris and water. The vacuum tube can be positioned by use of the boom
up/down control, and by physically moving the tube around inside the hole to reach all areas
where debris has collected.
5. When vacuuming, the intake tube may be positioned just above the water level in the hole
allowing a mixture of air, water, and debris to enter. When required, the unit is capable of
removing debris from below water level with the intake tube completely submerged.
6. If during the vacuuming process, the debris tank becomes full, the ball check valve will close
which is indicated by loss of vacuum at the intake tube. The vacuum breaker will also
“whistle.” When the debris tank is full, follow the instructions for disengaging the exhauster
PTO.
Caution!
To avoid overloading of the truck chassis, the debris tank and the water tanks must never
be simultaneously loaded to full capacity. When traveling to the dump site with a fully loaded
debris tank, a maximum of 1/4 tank of fresh water should be carried. This is sufficient to wash
down the debris tank.
Do not operate the unit for long periods of time when the debris tank is full. It is extremely
important to always remove as much water as possible from the debris tank before driving the
vehicle. This will help eliminate overloaded conditions.
7. Excess water may be removed from the debris tank by opening the drain valve at the rear of
the unit and allow the water to drain. Ensure the exhauster is not engaged.

PRINCIPLES OF
OPERATION
LEAVING THE WORK SITE:

1. Before leaving the worksite for the dumpsite, assure the boom is in its travel position and
properly latched.
2. Proceed to dumpsite.
DUMPING THE DEBRIS TANK:

Caution!
When dumping this vehicle, always seek firm, level terrain on which to park the vehicle when
setting up to dump. Never lift the tank when the unit is parked on a grade, or when the
underlying ground is soft or unstable. Failure to follow these guidelines may result in a
catastrophic accident in which the vehicle may tip over or the tank may shear from its mounting
supports.
Do not attempt to raise the tank until the door has been opened to allow the debris to empty.
Never drive this vehicle with the tank raised or the tank door opened.
Be sure the area above the vehicle is free of electrical lines or any other obstructions.
1. Position the truck at the dump site, set the parking brake, and block the wheels.
2. Procedure for opening the rear door and raising the tank:
Note: Maximum operating speed for opening the rear door is 1500 RPM.
a. Disengage the rear axles.

b. Rotate the boom to the rear.
c. Your unit is equipped with hydraulic door locks, push and hold the toggle switch
marked LOCKS upward to unlock the hydraulic door locks.
d. Raise the door with the toggle switch marked DOOR located on the side control panel.
Push the switch up and hold until the door is completely open.
e. Push the switch up and hold to raise the debris tank as needed to
allow the debris to completely dump out of the tank.
f. After dumping is complete, pushi the switch and hold down until
the tank is completely down on the sub frame.
g. Close the door by pushing the toggle switch marked DOOR. If your unit is equipped
with hydraulic door locks, lock the door by pushing the toggle switch marked LOCKS
and holding until the locks are completely closed.
h. Next, open the gate valve located at the bottom of the hopper mounted below the
cyclone separator. Allow debris to drain. Close the gate valve.
i. Open and clean the exhauster final filter.
Note: Make sure that the door is completely closed prior to closing the hydraulic locks.
CLEANING THE DEBRIS TANK:

Refer to the “Internal Tank and Floor Flush Option” located on page 12 in the “Principiles of Operations”
section.

PRINCIPLES OF
OPERATION
HELPFUL HINTS FOR USING YOUR HYDROEXCAVATION UNIT
WATER LEVEL INDICATORS:

It is important to pay attention to the amount of water remaining in the fresh water tanks when using
the hose reel. There are two ways of determining the amount of water remaining:
1. The sight level tube located on the water tanks which shows water level in both tanks.
2. Low water warning light, will come on when there is approximately 3 minutes of operation time
remaining. (Optional)
COLD WEATHER STORAGE:

The following procedure is required to prevent damage to the water pump and water system during cold
weather conditions.
1. Open the drain in the water tank cross-over line, under truck chassis, behind the rear axle.
Leave the drain cap off until the machine is ready to be used.
2. Drain water from tanks by tipping the tank slightly. Once the water is removed, lower the
tank.
3. Remove the suction line filter, gasket and cover.
4. Turn the 3 way ball valve at rear reel water manifold to the “Hose Reel” position.
5. Engage water pump in accordance with normal procedure and run pump approximately 15
seconds.
6. Apply 75 to 100 PSI of air pressure, from an external source, to the air valve on the water pump
to force the water from the water pump and hose reel. Do this until a solid stream of water no
longer comes out of hose.
7. Tie or wire the sewer cleaning hose end securely to reel and rotate clock-wise as if
retrieving the hose from sewer. Make certain the nozzle is removed. Rotate until water no
longer comes out.
8. Open valve for handgun and push ball on male quick connect.
9. If equipped with cold weather recirculation option, open the ball valve to drain the water
from the return line. Leave this valve open until ready to use again.
Caution!
The implementation of this procedure must be performed immediately after hydro
excavating operation or cold weather recirculation operation.
Caution!
If general circumstances lead to the interruption of the procedure and there is a
presumption of ice formation in the system, move to the unit to a heated garage
immeadiately, let thaw out, and then proceed with the above steps.

SERVICE
CUSTOMER SERVICE AND PARTS ORDERS:

Hi-Vac Corporation is committed to customer satisfaction. In addition to our Authorized
Dealer network throughout the world, we maintain a full stock of parts and accessories at
our factory in Marietta, Ohio. In the event you need parts or service, first call your nearest
Authorized Dealer. Their name and number should be shown on the unit information sheet
located at the front of this manual.
To assure prompt delivery and processing of your parts orders, please have the following
information available, when you place your order:
1. Type and serial numbers for the unit and chassis. This information is also located on the
Identification Sheet.
2. The part number(s) of the required items, along with the quantity desired.
3. SHIPPING INSTRUCTIONS, whether your parts are to be shipped next day air, second
day air, truck, ocean freight, etc. When left unspecified, orders are shipped UPS, or truck
freight if necessary due to weight restrictions. We must have your street address: we
cannot ship to P.O. Box numbers.
4. When placing orders - FIRST: Contact your nearest Authorized Hi-Vac Dealer. If they are
unable to assist you, contact the Parts or Customer Service Departments at Hi-Vac:
Phone: 740-374-2306 Fax: 740-374-5447
Every effort is made to ship all in-stock parts on the same day the order is received, when
the order is placed before noon, Eastern Time. Orders received after noon are shipped the
next business day.
SALES TERMS:
The descriptions and instructions included in this manual cover the standard design of the
equipment and any common deviations when possible. This manual does not cover all
design details and variations nor does it provide for every possible contingency which may
be encountered.
When information cannot be found in this manual, contact your nearest Aquatech, Inc. Parts
and Service Center, or phone the Hi-Vac Service Department.
All specifications given have been calculated at sea level. All designs and specifications are
subject to change without notice.
No material returns will be accepted unless accompanied by our Material Return
Authorization form. A restocking charge of 20% applies to all Return Goods. Minimum
billing of $100.00 applies to all orders.
STANDARD LIMITED PRODUCT WARRANTY:
Hi-Vac hereinafter called the Company, warrants for a period of twelve (12) months from
the date this product is accepted by the purchaser, that all design and material of its own
manufacture shall be free from defects. The company agrees to repair or replace, at its sole
discretion, such defects to assure the product performs according to its published
specifications at time of manufacture.

SERVICE 1
SERVICE
This warranty will not cover any part or service subject to normal wear or adjustment as
described in the Operator’s Manual supplied with the product. This warranty will not cover
failure caused by purchaser’s failure to perform normal maintenance by abuse, or by
purchaser’s use of product for purposes not intended by design. Alterations or modifications
to product without the express written permission of the Company may void this warranty.
Use of replacement parts not supplied by the Company may void this warranty. All parts
supplied under the provisions of this warranty are F.O.B. Marietta, Ohio.
This warranty shall be the only warranty in effect, and no one shall have the authority to
supersede or modify its provisions except in writing by the Company, or as provided in these
terms.
WARRANTY EXTENSIONS
The Company may wish to offer an extension to this warranty, at a price it may determine
and publish. This extension will act to increase the period over which these terms may
apply, but will not modify any of the terms except as may be expressly stated in writing by
the Company.
MAJOR COMPONENT WARRANTY
Components provided as part of this product, but those which are not manufactured by the
Company, shall have whatever warranty and terms as are offered by the original
manufacturer and shall not be covered by these provisions except where specifically stated.
These warranties shall be provided upon request. The Company shall make good faith
efforts on behalf of the purchaser to enforce any applicable warranty offered by its vendors.
SPECIAL WATER TANK WARRANTY
The Company warrants its water tanks to be free from leaks, and agrees to cover repairs or
replacements of defective tanks according to the following schedule:
MILD STEEL TANKS PRO-RATED WARRANTY (Except SJR tanks)
1st year — No charge repair or replacement f.o.b. factory
2nd year — 65% of list price, f.o.b. factory is allowed
3rd year — 50% of list price, f.o.b. factory is allowed
4th year — 40% of list price, f.o.b. factory is allowed
STAINLESS STEEL TANKS PRO-RATED WARRANTY (Except SJR tanks)
First 5 years — No charge repair or replacement f.o.b. factory
POLYGRAPHITE TANKS
10 year warranty on all polygraphite water tanks. The company guarantees for the lifetime
of the tanks against failure from corrosion or rust through.
SJR TANKS
10 year no charge repair or replacement against rust through or leaks, f.o.b. factory, pro-
vided terms of inspection as outlined in Operator’s Manual are met.

SERVICE 2
SERVICE
DESIGN MODIFICATIONS
The Company reserves the right to make modifications to its design and specifications which shall in
no way infer that previous designs and specifications are not fit for their originally intended purpose,
and shall in no way obligate the Company to perform such modifications to products manufactured
before these changes were adopted.
WARRANTY INITIATION
The warranty shall begin at the date the product is accepted by the purchaser which shall be
documented by the “Delivery Check List” included in the operating manual for the machine, properly
filled out by the delivering dealer, and signed by the purchaser. If this form is not returned to Hi-Vac,
the warranty shall begin in 30 days after shipment from the factory.
Any product which has been used as a demonstration unit will, upon sale to the purchaser, have
the full warranty as provided for in these terms, subject to the conditions as stated herein. The
Company must be notified by the delivering dealer in the same way as any newly manufactured
machine.
LIMITATIONS / EXCLUSIONS TO WARRANTY
The company shall not be held liable, under the terms of this warranty, for any losses, damages
or expense charges incurred by purchaser, or its agents, representatives or employees, as a result
of any failure of the product to perform. Other than those expressly stated herein, there are no other
warranties of any kind, express or implied, and specifically excluded but not by way of limitation, are
the implied warranties of fitness for a particular purpose and merchantability.
The following are specifically, though not exclusively, precluded from the terms of this warranty
except as already stated:
Water pump Auxiliary engines
Exhauster/vacuum pump Drive belts
High pressure water hose Truck chassis
Hydraulic pumps, motors and valves Power Take-Off
Electrical components Suction hoses and tubes
Batteries Axles, tires
CLAIMS PROCEDURE
Warranty claims against the Company shall be made by the delivering dealer in accordance with
the terms set forth in the “Warranty Request Claim” policy statement as set forth at the latest effective
date.
All parts are supplied F.O.B. by the factory in Marietta, Ohio. No freight allowances are made. No
travel time allowances are made. The purchaser shall agree to these terms by virtue of acceptance of
the machine or purchased part.
REPLACEMENT PART WARRANTY
Parts replaced during the warranty period will be warranted only during the term of the original
warranty. No extension of warranty is made by installation of the new part.
Replacement parts purchased after the warranty period will carry a thirty (30) day warranty
against defects in material or workmanship, or whatever warranty shall be offered and be enforceable
upon the original manufacturer, whichever is longer. Labor costs incurred to replace defective parts
are specifically excluded from this warranty.
The purchaser shall be responsible for payment of the replacement part until such time as the
original manufacturer shall offer warranty replacement to the Company, at which time credit will
be issued to the purchaser. All such defective parts must be returned to the factory, freight
pre-paid, for evaluation and determination of warranty by the original manufacturer. Requests
for return will be made at the discretion of the Company. No part shall have been previously disas-
sembled or tampered with in any way so as to void the manufacturer’s warranty.
The Company’s sole responsibility under these terms shall be the timely return of the defective
part to the original manufacturer for warranty consideration, and for such reasonable follow-up action
as may be necessary to expedite the claim. The original manufacturer’s decision shall be final and
binding on both purchaser and the Company.

SERVICE 3
SERVICE
GENERAL MAINTENANCE SCHEDULE
(DAILY)
1. Inspect all high pressure water lines and hydro excavation hose for cuts and/or
leaks.
2. Inspect all oil lines and connections for cuts and/or leaks.
3. Inspect all valves, linkages, and controls for operation and position.
4. Inspect nozzles for excessive wear or obstructed orifices.
5. Inspect water pump suction line strainer, clean if necessary.
6. Remove and clean exhauster strainer and clean housing.
(WEEKLY)
1. Inspect water pump and exhauster for loose mounting bolts and proper
alignment.
2. Inspect drive train and PTO shafts, universal joints, and bearings.
3. Remove and clean exhauster strainer and clean housing.
4. Inspect hydraulic system filter and clean or replace if necessary.
(BI-WEEKLY)
1. Inspect water pump for excessive or abnormal wear. Remove any foreign
material, dirt or rust.
(EVERY 6 MONTHS)
1. Inspect the valves and springs in the water pump.
2. Inspect debris tank coating and re-coat as necessary.
3. Inspect PTO and drive shafts for loose and/or worn belts and bearings.
4. Inspect the exhaust system for leaks or heating problems.

SERVICE 4
SERVICE
TROUBLESHOOTING COMMON PROBLEMS

The following is a list of possible problems which may be encountered during the life of this machine.
Probable causes are listed in this section together with recommended solutions to these problems. If the
resolution of these problems or any other problems are not readily apparent, contact your local authorized
X-Vac dealer.
WATER SYSTEM
CONDITION: LOSS OF WATER PRESSURE. THIS IS THE SINGLE MOST COMMON

PROBLEM WITH ALL HIGH PRESSURE SEWER CLEANERS.
PROBABLE CAUSES REMEDIES
Worn nozzle orifices. Replace orifice or nozzle.
Wrong nozzle. Change to correct nozzle.
Inadequate engine speed. Adjust throttle cable and consult engine manual.
Check for correct gear.
Gate valve in suction line partly Open valve.
closed.
Leaks in the high pressure water Locate and eliminate as required.
system.
Water control valve leakage Clean, or replace seals.
bypassing or recirculating water
back to the water tank.
Relief valve leaks or otherwise Replace. Note: Valves are set at the factory and
malfunctions. adjustment by inexperienced people could result in
damage to equipment or possible injury to personnel.
Pump starved for water. Clean suction line and hose of obstructions, replace
suction hose if it leaks or is collapsed.
Clean suction line strainer. Open gate valve.
Transmission slipping. Adjust, consult chassis manual, check automatic trans-
mission fluid level.
Gauge is inaccurate. Replace gauge.
Worn valves or valve components. Replace components as required.
CONDITION: WATER PRESSURE TOO HIGH

Clogged nozzle. Clean jets.
Incorrect nozzle. Replace with correct nozzle.
Incorrect gear. Shift to proper gear.
Overspeeding engine. Reduce speed.

SERVICE 5
SERVICE
WATER SYSTEM (Continued) A Product of Hi-Vac Corporation
CONDITION: HAMMERING NOISE IN WATER PUMP.

Pump starved for water. Clean suction line and hose obstructions, replace suction
hose if it leaks or is collapsed. Clean suction line strainer.
Open gate valve.
Valve stuck open with debris. Disassemble and remove debris.
Worn valves or seals. Inspect and replace as required.
Low oil level in water pump. Check oil level and fill to proper level. If pump has been
operating with inadequate lubrication, inspect bearings.
Air in pump. Bleed off air through blowout valves. Remove nozzle
from hose, pump water through until it flows at a smooth
steady stream.
CONDITION: HOSE FAILS TO MOVE UP THE SEWER LINE OR FAILS TO REACH THE
NEXT MANHOLE, BUT SHOWS ADEQUATE PRESSURE.
Clogged nozzle. Clean.
Incorrect nozzle. Replace with correct nozzle.
Pressure gauge reading incorrect. Remove gauge and test. If gauge reading is not correct,
replace.
Restriction in hose. Remove hose from reel, inspect for kinks, collapsed
sections, etc. Hose may be pinched on reel. For best
operation always pressurize hose when winding on reel.
Water control valve leaking Clean, or replace valve seals.
therefore bypassing or recirculating
water back to tank.
Sewer line is dry or too much fall in A.) Introduce water into the upstream manhole and/or
line. jump the hose by rapidly opening and closing the water
control valve at maximum pressure.
B.) In sewer lines with steep grades, usually 3% or

more, the propulsion of the nozzle and hose up the line
will be affected. Specific performance cannot be
guaranteed in sewer lines with pronounced grade.
Understanding, it is normally not necessary to clean lines
with steep grades. In this situation, maintenance and
cleaning must be performed in the down stream sewer
line or with mechanical means.
Reel speed valve turned down too Speed up valve.

low.

SERVICE 6
SERVICE
HYDRAULIC SYSTEM
CONDITION: HOSE REEL WILL NOT RETRIEVE HOSE FROM SEWER.

Loose or broken chain on hydraulic Repair or replace.
motor.
Hydraulic level too low in reservoir. Fill to sight eye center dot.
Leaking hoses or fittings. Repair or replace as required.
Hydraulic relief valve relieving at too Tighten pressure relief set screw. Relief should occur at
low a pressure. 2000 PSI.
Hydraulic valve problem. Disassemble and clean valve. If this does not cure
problem either rebuild or replace the valve.
Hydraulic pump or motor problem. Disassemble and clean. If problem is not cured, rebuild
or replace.
VACUUM SYSTEM
CONDITION: LOSS OF VACUUM

Debris tank is full and check ball is Drain or recycle water in debris tank. Dump debris tank.
closed.
Boom turret plugged. Remove turret and clear blockage.
Vacuum system leak. Inspect vacuum system for leaks, normally a high pitched
sound is heard. Some areas to check first are: Rear door
seal, tank closure seal, intake tube O-rings, portal gasket.
Check to see that gate valves are closed, such as rear
drain, and valves on the recycling system.
Blockage in the intake hose. Disengage exhauster pump and evacuate the vacuum
from the tank. Inspect intake tubes. Remove the primary
check valve cover and inspect the ball check. Lower the
boom all the way to allow material to drop out through the
hose. Pressure discharge through boom hose.
Inadequate engine speed. Check engine tachometer, adjust throttle cable, consult
engine manual. Check for correct gear.
Loose exhauster pump drive belt. Tighten.
Faulty vacuum reading. Replace gauge.
Exhauster pump malfunction. Consult exhauster pump manual.
Sticking vacuum relief valves. Check to determine if they open at 15” Hg.,
Clean/lubricate/replace if necessary.

SERVICE 7
SERVICE
ELECTRICAL SYSTEM
IMPORTANT!
Do not attempt to remedy any electrical problems without first examining the schematic wiring diagram
and control wiring circuit drawing (see Electrical Section). Check truck chassis battery and cell condition.
Use proper instrumentation for current and continuity test results.
(A) Continuity- Use OHM scale recorder or battery powered continuity test light.
(B) Current- The circuit must be opened to obtain current reading with the volt- meter; therefore, it is more
convenient to use a 12 VDC test light.
CONDITION PROBABLE CAUSES REMEDIES

NO POWER Turn ignition/unit power
Ignition/unit power switch not
“on”. switch “on”.
BOOM VALVE NOT WORKING Check for voltage at
Faulty solenoid valve.
solenoid. Replace.
FUSE BLOWN 1. Frayed or broken harness 1. Repair or replace.
(#1 TERMINAL BLOCK, wire. 2. Check for pinched or
#2 AMP REPLACEMENT). 2. Short circuit in solenoid(s) bare wire connections.
wiring connection. 3. Secure terminal to
3. Switch terminal arcing within post connections on
housing. switch.
PTO WON’T RE-ENGAGE DRIVE Switches turned off in wrong Unit power must be last
AXLE. sequence. switch turned off.
PTO DOES NOT DISENGAGE Faulty solenoid valve Check for voltage at
DRIVE AXLE. solenoid. Replace
PENDANT BOOM SWITCHES 1. Push button, switch terminals 1. Tighten or reconnect.
FUNCTION ERRATICALLY. loose or disconnected. 2. Replace switch unit.
2. Push button switch contacts 3. Dry out pendant con-
burned or disconnected. trol and seal leaks.
3. Water in pendant
FLAPPER VALVE INTAKE 1. Pneumatic valve solenoid coil 1. Test and replace if
CYLINDER ON BOOM burned out. necessary.
INOPERATIVE. 2. Valve spool stuck or 2. Disassemble, clean, or
unsealed. replace.
3. Wiring from valve to control 3. Repair and replace.
box broken or disconnected.

SERVICE 8
SERVICE
WATER PUMP COUPLING ASSEMBLY PROCEDURE (Page 1 of 4)

190453/530063 Assembly Process:
STEP #1 - Make sure the water pump shaft key is in the upward position. Apply Loctite Moly Paste to water pump shaft.
STEP #2 - Assemble PN 5030063 aluminum flange to water pump and torque the qty 6 bolts to 29.5 ft./lbs. (40 Nm).
STEP #3 - Slide PN 510446 pump side brass spacer onto water pump shaft.

SERVICE 9
SERVICE
STEP #4 - Slide pump side coupler assembly (Coupler, Cover, Snap Ring, and Insert) onto water pump shaft.
STEP #5 - Align the coupler set screw with the flange slot. Apply Loctite 243 threadlocker on set screw threads. Torque
set screw to 24.2 ft./lbs (33 Nm).
Rotate coupler and water pump shaft to align the second set screw in the pump side coupler with the flange slot. Apply
Loctite 243 threadlocker on set screw threads. Torque set screw to 24.2 ft./lbs (33 Nm).

SERVICE 10
SERVICE
STEP #6 - Apply Loctite Moly Paste on hydraulic motor splined shaft slide the hydraulic motor coupler assembly (With
Brass Spacer) onto hydraulic motor splined shaft until brass shim touches the “Shim Stop which Rotates with
Splined Shaft” and then apply Loctite 243 threadlocker on set screw threads. Torque coupler set screw to
24.2 ft./lbs. (33 Nm).
STEP #7 - Align the hydraulic coupler with slots in the insert and push into place tight against the aluminum flange.

SERVICE 11
SERVICE
STEP #8 - Install the hydraulic motor mounting bolts and torque to 132 ft./lbs. (180 Nm).
STEP #9 - Install plastic plug in flange set screw access hole on hydraulic motor side.
Coupler should be snug between water pump and hydraulic motor with slight end to end movement.

SERVICE 12
SERVICE
WATER PUMP COUPLING DISASSEMBLY PROCEDURE (Page 1 of 3)

190453/530063 Disassembly Process:
STEP #1 - Remove the hydraulic motor mounting bolts, and remove the hydraulic motor and splined coupler.
STEP #2 - Loosen the set screw from hydraulic motor side coupler and remove coupler from hydraulic motor splined
shaft.
STEP #3 - Using pliers, remove the black plastic insert from the coupler.

SERVICE 13
SERVICE
STEP #4 - Align the coupler set screw with the flange slot and loosen set screw, rotate coupler and water pump shaft to
loosen the second set screw.
STEP #5 - Using a puller, remove the coupler from the water pump shaft.
STEP #6 - Remove PN 510446 pump side brass spacer from water pump shaft.

SERVICE 14
SERVICE
STEP #7 - Remove qty. 6 bolts from PN 530063 aluminum flange and remove flange from water pump.

SERVICE 15
SERVICE
Torque Specifications A Product of
Aquatech Hi-Vac Corporation
B-Series
Alloy
BrightCap
CapScrews 1018
Screws ft. lbs.
1018 ft. lbs.
CAP SCREW DIAMETER YIELD STRENGTH PSI MIN. RECOMMENDED TORQUE
UNC UNF
¼ 58000 11 13
5/16 58000 21 23
3/8 58000 38 40
7/16 58000 55 60
½ 58000 85 95
9/16 55000 125 140
5/18 55000 175 210
¾ 55000 300 330
7/8 55000 450 490
1 50000 680 715
1-1/8 50000 885 990
1-1/4 40000 1255 1380
1-3/8 40000 1635 1875
1-1/2 40000 2180 2430
Heat Treated 1038 Hexagon Head Cap Screws, SAE Grade 5 ft. lbs.
YIELD TENSILE RECOMMENDED TORQUE
CAP SCREW DIAMETER STRENGTH PSI STRENGTH PSI
MIN. MIN.
UNC UNF
¼ 90000 120000 11 13
5/16 90000 120000 21 23
3/8 90000 120000 38 40
7/16 90000 120000 55 60
½ 90000 120000 85 95
9/16 90000 120000 125 140
5/8 90000 120000 175 210
¾ 90000 120000 300 330
7/8 81000 115000 450 490
1 77000 115000 680 715
1-1/8 77000 105000 885 990
1-1//4 77000 105000 1255 1380
1-3/8 77000 105000 1635 1875
1-1/2 77000 105000 2180 2430
Alloy Hexagon Head Cap Screws, SAE Grade 8 ft. lbs.

YIELD TENSILE RECOMMENDED TORQUE
CAP SCREW DIAMETER STRENGTH PSI STRENGTH PSI
MIN. MIN.
UNC UNF
¼ 130000 150000 12 15
5/16 130000 150000 25 30
3/8 130000 150000 50 60
7/16 130000 150000 85 95
½ 130000 150000 125 140
9/16 130000 150000 175 195
5/8 130000 150000 245 270
¾ 130000 150000 425 460
7/8 130000 150000 660 700
1 130000 150000 990 1050
1-1/8 130000 150000 1470 1655
1-1//4 130000 150000 2100 2310
1-3/8 130000 150000 2750 3110
1-1/2 130000 150000 3640 4100

SERVICE 16
SERVICE
X-VAC STANDARD UNIT LUBRICATION POINTS
Note: For item descriptions and lubrication intervals, refer to the “X-Vac Standard Unit Lubrication
Points Intervals” located within the “Service” section of this manual.
2 4
BOOM EXTENSION ARMS
BOOM WORM GEAR BEARINGS, BOOM TURRET

GEAR, BOOM TURRET SWIVEL BEARINGS
6 7
BOOM EXTENSION ARM BEARINGS
REAR DOOR HINGE AND CYLINDER PINS
VACUUM TUBE O-RING
BOOM PIVOT PINS

SERVICE 17
SERVICE
X-VAC STANDARD UNIT LUBRICATION POINTS

Note: For item descriptions and lubrication intervals, refer to the “X-Vac Standard Unit Lubrication
Points Intervals” located within the “Service” section of this manual.
10
BOOM LIFT CYLINDER
11
12
TIPPING CYLINDER PINS

DEBRIS TANK PIVOT PINS
13
REAR DOOR LOCK WEDGE

SERVICE 18
SERVICE
X-VAC STANDARD UNIT LUBRICATION POINTS INTERVALS

Item # Item Description # Points Inspect Interval Qty. Lubricant
1 BOOM WORM GEAR 2 MONTHLY 100 1-2 LITHIUM #2
BEARINGS HOURS SHOTS SHORT FIBER
2 BOOM TURRET GEAR 1 MONTHLY WEEKLY COAT LITHIUM #2
LIGHTLY SHORT FIBER
3 BOOM TURRET SWIVEL 2 MONTHLY 100 1-2 LITHIUM #2
4 BOOM EXTENSION ARMS 2 MONTHLY WEEKLY COAT LITHIUM #2
LIGHTLY SHORT FIBER
5 BOOM EXTENSION ARM 2 MONTHLY 100 1-2 LITHIUM #2
6 REAR DOOR HINGE PINS 2 MONTHLY 100 1-2 LITHIUM #2
HOURS SHOTS SHORT FIBER
7 REAR DOOR CYLINDER 2 MONTHLY 100 1-2 LITHIUM #2
PINS HOURS SHOTS SHORT FIBER
8 BOOM PIVOT PINS 2 MONTHLY 100 1-2 LITHIUM #2
9 VACUUM TUBE O-RING 1 MONTHLY WEEKLY COAT LITHIUM #2
LIGHTLY SHORT FIBER
10 BOOM LIFT CYLINDER 2 MONTHLY 100 1-2 LITHIUM #2
11 TIPPING CYLINDER PINS 2 MONTHLY 100 1-2 LITHIUM #2
12 DEBRIS TANK PIVOT PINS 2 MONTHLY 100 1-2 LITHIUM #2
13 REAR DOOR LOCK 4 MONTHLY WEEKLY COAT LITHIUM #2
WEDGES LIGHTLY SHORT FIBER

SERVICE 19
SERVICE
X-VAC STANDARD UNIT WATER PUMP, EXHAUSTER, PTO, and

HYDRAULIC SYSTEM LUBRICATION INTERVALS
Item Description Inspect Interval Qty. Lubricant
WATER PUMP DAILY REFER TO 2.13 REFER TO
CRANKSHAFT OIL MANUFACTURER’S QUARTS MANUFACTURER’S
(GENERAL HF SERIES) MANUAL MANUAL
EXHAUSTER DAILY REFER TO 2.4 REFER TO
GEAR END OIL MANUFACTURER’S QUARTS MANUFACTURER’S
(HIBON SIAV 8702) MANUAL MANUAL
EXHAUSTER DAILY REFER TO 3.2 REFER TO
DRIVE END OIL MANUFACTURER’S QUARTS MANUFACTURER’S
(HIBON SIAV 8702) MANUAL MANUAL
*PTO WEEKLY CHANGE AFTER FIRST 100 12.25 DEXRON III
MAIN HOUSING HRS, EVERY 500 HRS QUARTS TRANSMISSION FLUID
#A381618 THEREAFTER
HYDRAULIC SYSTEM DAILY ANNUALLY 35 S1 M 46 HYDRAULIC
OIL RESERVOIR GALLONS
* . For units equipped with the optional PTO Remote Fill, the total fluid requirement is slightly more than
what is specified for the PTO itself.

SERVICE 20
SERVICE
FILTER REPLACEMENT SCHEDULE

ITEM DETAIL INSPECT SCHEDULE PART No.
HYDRAULIC CHANGE AFTER FIRST 50 HRS;

SUCTION DAILY CHANGE ANNUALLY A110516
FILTER THEREAFTER
HYDRAULIC
HIGH CHANGE WHEN AMBER PANEL
PRESSURE DAILY LIGHT ILLUMINATES A383754-E
FILTER
HYDRAULIC
PRESSURE CHANGE WHEN AMBER PANEL
RETURN DAILY LIGHT ILLUMINATES A384096-E
FILTER
WATER
SEPARATOR DAILY CLEAN AND REINSTALL, REPLACE
IF DAMAGED OR AFTER 2 YEARS A373737-E
OIL CLEAN AND REINSTALL, REPLACE

SEPARATOR DAILY IF DAMAGED OR AFTER 2 YEARS A383736-E
BOOM VALVE
LAST CHANCE CLEAN AND REINSTALL, REPLACE
FILTER DAILY IF DAMAGED A383767
CHECK DAILY
BLOWER INLET OR EACH CLEAN AND REINSTALL, REPLACE IF A383165
FILTER TIME UNIT IS DAMAGED
CARTRIDGE DUMPED
DIESEL HEATER CHANGE AS NEEDED OR EVERY 6 N/A

FILTER MONTHS

SERVICE 21
SPARE PARTS
RECOMMENDED SPARE PARTS LIST
PART # DESCRIPTION
A110516 FILTER ELEMENT,HYDRAULIC (FOR A110515)
A383754-E FILTER ELEMENT,HYDRAULIC (FOR A383754)
A384096-E FILTER ELEMENT,HYDRAULIC (FOR A384096)
A120866 SWITCH,TOGGLE,SPST,OFF-ON,LIGHTED
A120867 SWITCH,TOGGLE,SPDT,ON-OFF-ON,LIGHTED
A121735 BOOT,TOGGLE SWITCH
13-0100 SWITCH,VACUUM,0-30” HG
A131765 GAUGE,VACUUM/PRESSURE,FLANGE MOUNT,STAB
A131786 GAUGE,PRESSURE,0-5K PSI, W/FLANGE,STAB
A191100-NH GASKET,REAR DOOR,18’-6”,W/O HOLE
A381701 DOOR SEAL
A381599-RD RUPTURE DISC ASSY,FOR BOILER
A381048-29 PLUNGER,FOR HES25 GENERAL PUMP
A381048-48 VALVE ASSEMBLY,SUCTION/DISCHARGE
A381048-51 VALVE GUIDE, HE SERIES
A381048-52 SPRING, HE SERIES
A381048-53 VALVE POPPET,HE SERIES
A381048-F1269 KIT,REPACKING,HE25 GENERAL PUMP
A381048-F1274 KIT,REBUILD,HE25 SERIES
A130571-42 ELBOW,90D,SUPER SWIV,1/2”,MxF,BP,REEL

PARTS 1
CONTROLS
SIDE OPERATOR’S STATION (OUTSIDE)
1
2
ITEM PART # DESCRIPTION QTY

1 A383409 TACHOMETER,MURPHY,12V,7-21PUL/REV 1
2 A131765 GAUGE,VACUUM/PRESSURE,FLANGE MOUNT,STAB 1
3 A120040A HOURMETER,12/24V,VDO,RECTANGULAR 1

CONTROLS 1
CONTROLS
SIDE OPERATOR’S STATION (INSIDE)

1 13-0100 SWITCH,VACUUM,0-30” HG 1
2 A100104 FAN CONTROL KIT 1

CONTROLS 2
CONTROLS
WIRELESS REMOTE CONTROL

PART #A387082-10
TRANSMITTER
RECEIVER

CONTROLS 3
POWERTRAIN
BLOWER DRIVE SYSTEM
2
1

1 A381618 PTO,TOWER,OMSI,PFT-PCV/3000,SPEC 1
2 U3308-0269 DRIVESHAFT,BLWR,HIBON 8702,HVV SERIES 1
3 U3308-0270 COMPANION FLANGE,BLOWER,HIBON 8702 1
4 A382758 BLOWER,HIBON 8702,BH-CCW 1

POWERTRAIN 1
POWERTRAIN
PTO REMOTE FILL

PART #A249437-2
Note:
. For units equipped with the optional PTO Remote Fill, the total fluid requirement is slightly more
than what is specified for the PTO itself. Refer to the “X-VAC STANDARD UNIT WATER PUMP,
EXHAUSTER, PTO, and HYDRAULIC SYSTEM LUBRICATION INTERVALS” section in this manual
for PTO capacity.

POWERTRAIN 2
WATER SYSTEM
WATER PUMP DRIVE SYSTEM
1 3
2

1 A381048 PUMP,WATER,GENERAL HF25A,RH SHAFT 1
2 A383725 FLANGE/COUPLER,F/HF SERIES GENERAL PUMP 1
3 A384018 MOTOR,HYD,FIXED,CPAD C SPL 1
4 A383726 COUPLING,SHAFT,HF TO SAE C SPLINE,14T 1

WATER SYSTEM 1
WATER SYSTEM
FILLER PIPE ASSEMBLY,PVC,B-SERIES

PART # A243768-1
3 4
4
2 1
5 7
8 9

1 A236394-04 PIPE, PVC, 2” x 4” LG. 1
2 A236394-12 PIPE, PVC, SCH40, 2” x 23” LG. 1
3 A236394-06 PIPE, PVC, 2” x 31” LG. 1
4 A176770 ELBOW, PVC, 90D, 2” SCH40, SLIP X SLIP 2
5 A141180 NIPPLE, 2” NPT X 8” LG., TBE 1
6 A176780 ADAPTER, SCH40, 2” SLIP X 2” FNPT, PVC 1
7 A140090 FLANGE ADAPTER, W/2” FNPT, FOR A140080 NUT 1
8 A190830 WASHER, FILL LINE SWIVEL 1
9 A140080 NUT, BRASS SWIVEL, W/GSK, F/2.5” HYD HSE 1

WATER SYSTEM 2
WATER SYSTEM
SUCTION VALVE AND STRAINER
1 2 3

1 U4631-0012 VALVE,BALL,2”,BRASS,NON-FULL PORT 600WOG 1
2 A384053 STRAINER,Y,2”FNPT,POLY,20 MESH SCREEN 1
3 A130920 VALVE,BALL,1”,3-WAY,W/OFFSET STL HANDLE 1

WATER SYSTEM 3
WATER SYSTEM
WATER PUMP & RELIEF VALVE

1 A381048 PUMP,WATER,GENERAL HF25A,RH SHAFT 1
2 A381536 VALVE,RELIEF,1”,BAIRD,3300 PSI SET PRESS 1

WATER SYSTEM 4
WATER SYSTEM
HOSE REEL
PART # A130571

WATER SYSTEM 5
WATER SYSTEM
HEATER MODULE,700,000 BTU,12VOLT,DIESEL

PART # A381599

WATER SYSTEM 6
VACUUM SYSTEM
BLOWER & SILENCERS

1 A382758 BLOWER,HIBON 8702,CCW ROT,BTM SFT 1
2 A381606M SILENCER,INLET,HIB8702,36”OD,MODIFICATION 1
3 A381985 SILENCER,EXHAUST,HIB8702/840,X-VAC 1

VACUUM SYSTEM 1
VACUUM SYSTEM
FINAL FILTER ASSEMBLY

PART #A382772-4
1 4
3 2
* ITEM 3 AND 4 NOT VISIBLE

1 A382771-4 HOUSING,FILTER,12”INLET @ 45 DEG,8702 1
2 A381700 DOOR, CARTRIDGE FILTER HOUSING 1
3 A381701 DOOR SEAL 1
4 A383165-M849 CARTRIDGE ELEMENT,BLOWER INLET,10 MICRON 1

VACUUM SYSTEM 2
VACUUM SYSTEM
VACUUM BREAKER
1 2

1 A384821-1 VACUUM BREAKER,12”,X-10 TANK MOUNTED 1
2 A384815 VALVE,BUTTERFLY,12”,PNEU,WAFER STYLE 1

VACUUM SYSTEM 3
HYDRAULIC
SYSTEM
HYDRAULIC TANK & HEAT EXCHANGER

1 U3907-0031 TANK,HYD,30 GAL,HVV 1
2 A383197 HEAT EXCHANGER,55,000 BTU/HR,12V 1

HYDRAULIC SYSTEM 1
HYDRAULIC
SYSTEM
HYDRAULIC PUMPS

1 A384015 PUMP,HYD,LOAD SENSE,CPAD,CSPL 1
2 A381664 PUMP,HYD,.87CU IN/REV,A PAD,11T SPLINE 1
3 A249456 PUMP,HYD,RH ROT,B PAD,B SPINE,CASSAPA 1

HYDRAULIC SYSTEM 2
HYDRAULIC
SYSTEM
WATER PUMP SPEED CONTROL

PART #A384021

HYDRAULIC SYSTEM 3
HYDRAULIC
SYSTEM
REAR DOOR CYLINDER
3 1 4

1 A110015-1-RJ CYLINDER, HYDRAULIC, TANK DOOR, 5” X 6.75’ 1
2 A110019 VALVE, CHECK/RELIEF, INTEGRATED ASSEMBLY 1
3 A246183 PIN, PIVOT, REAR DOOR CYLINDER 2
4 08-0020 PIN,SPRING,1/4” DIA X 3-1/2”LG,PLN STL 4

HYDRAULIC SYSTEM 4
HYDRAULIC
SYSTEM
CYLINDER & WEDGE ASSY,UPPER & LOWER DOOR

PART #A246523-P (QTY 4)

HYDRAULIC SYSTEM 5
HYDRAULIC
SYSTEM
VALVE,HYD,12V,3 SPOOL,MDO6,DOOR & RACK

PART #A384030

HYDRAULIC SYSTEM 6
HYDRAULIC
SYSTEM
HYDRAULIC BOOM MOTOR

PART #A110186

HYDRAULIC SYSTEM 7
HYDRAULIC
SYSTEM
VALVE ASSEMBLY,BOOM CONTROL,4-SPOOL,12 VOLT

PART # A246521

1 A383767 FILTER,LAST CHANCE,CARTRIDGE 1
2 A249270 INTEGRATED VALVE ASSY W/MANUAL OVERRIDE 1

HYDRAULIC SYSTEM 8
HYDRAULIC
SYSTEM
HYDRAULIC FILTERS

1 A384096 FILTER,RETURN,INLINE,#20MSAE PORTS 1
2 A383754 FILTER,HYD,HI PRESS,PALL UH209 SERIES 1
3 A110515 FILTER ASSY.,HYD.,1-1/4”NPT,25M ELEMENT 1

HYDRAULIC SYSTEM 9
PNEUMATIC
SYSTEM
PNEUMATIC VALVES & SEPARATORS
1 2
VACUUM BREAKER
WATER RECIRCULATION
VACUUM PUMP
PTO

1 A383737 SEPARATOR,WATER,SMC 1
2 A383736 SEPARATOR,OIL,SMC 1
3 A383733 VALVE SECTION,SINGLE,SPR RETURN,4WAY,AIR 2
4 A383781 VALVE ASSY,2SPOOL,4WAY,12V,DRYVAC 1

PNEUMATIC SYSTEM 1
BODY
AIR PORT TUBE ASSY,12”PORTAL,HANDWHEEL

PART #A387389
2 1
4 5 3
* ITEM 3, 4, AND 5 NOT VISIBLE

1 A154080 COVER,PORTAL,12” CAST 1
2 A154090 BAR,PORTAL 1
3 A190230 GASKET,PORTAL,12” 1
4 A222005 BALL,FLOAT,10” DIA.,STAINLESS 1
5 A243860 BASKET ASSY,CHECK BALL,STANDARD B-SERIES 1

BODY 1
BODY
CYCLONES & HOPPERS
CYCLONE
CYCLONE
FRONT,X-15
REAR,X-15
PART #A383654-2
PART #A383654-3
HOPPER
PART #A381592
VALVE,
SWING GATE,6”
PART #A246115

BODY 2
BODY
ASSY,TUBEHOLDER,8”,HYDLIFT,X-10
A338421-2-X-10
CONTROL
SWITCH

BODY 3
BODY
8” HD WORM GEAR DRIVE BEARING ASSEMBLY

PART # A384052

BODY 4
BODY
HINGED TANK SUPPORT PROP
2
3

1 A245057 TANK PROP CUP WELDMENT 1
2 A238216 BODY PROP WELDMENT 1
3 A238196 BODY PROP ARM WELDMENT 1
4 A238227 TUBE CONNECTOR TOOL 1

BODY 5
BODY
POLYTANK INSTALLATION INSTRUCTIONS
1. Assemble the right side polytank sections as shown. 2. Lift the entire right polytank assembly into position with
Using a liquid dish soap, lubricate the rubber seal located at the the base of the tanks resting firmly in the tank trays. The reservoir
rear tank connection port. Push the front tank into position insert- located at the base of the rear tank should rest in the cut out sec-
ing the 6" PVC connector. tion provided. Align the holes located at the top of the polytanks
with the strap retainers mounted on the debris tank.
Repeat same procedure for left side.
Rubber seal
Right Rear Polytank PVC Connector Right Front Polytank
3. Please refer to INSTALLATION OF WATER FILL LINE 5. With the turnbuckles attached, place one lock washer
WELDMENT PART # A243768-1M before continuing this assembly. followed by one beveled washer on each of the tension bolts. Place
the tension bolts (w/washers) through the top hole of the tank strap
4. Locate the following items: Eight tank straps, Eight turn- and thread it back into the turnbuckle.
buckles, Eight lock washers, and Eight beveled washers. Remove
the tension bolt from the turnbuckles. Remove the fastener from the DO NOT TIGHTEN!
“U” shaped end and place the turnbuckle through the spaces in the
top portion of each polytank. Attach the “U” shaped end to the strap Repeat front and rear both sides.
retainers located at either side of the debris tank as shown.
Lock Washer Beveled Washer
Tank Strap Retainer

Tension Bolt
Tension Bolt
Turnbuckle Tank Strap
6. Locate the remaining 8 7. Once the polytanks are in

bolts, washers, lock wash- place and secured, locate the return
ers, and nuts. line connections located at the top of
the rear tanks.
Secure the lower end of the
tank straps to the tank trays Tank Strap
using the holes provided.
Tighten securely.
Adjust the tension of the

turnbuckles until fully
secure.
Return Line Connection
Repeat front and rear
both sides.

BODY 6
BODY
INSTALLATION OF WATER FILL LINE WELDMENT

PART # A243768-1
When installing the Water Fill Line Support

Weldment it will be necessary to replace the
existing cap screw that fastens the right front
turnbuckle to the top strap retainer and the
support weldment with cap screw provided.
Cap Screw
TOP VIEW FILL LINE ASSEMBLY

Water Fill Line Support
Weldment #A246145
Top Strap Retainer
#A243514
Turnbuckle
5/8" x 6" #A223641
Polytank
Fill Line Assembly
#A243768-1
FRONT VIEW
VIEW FRONT RIGHT POLYTANK
WITH FILL LINE ASSEMBLY

BODY 7
Top View
BODY
Outside View Front View Rear View Inside View

POLYETHYLENE WATER TANK
Part # A382461-BLACK Front Left

A384057-BLACK Front Right
A382465-BLACK Left Rear
A384058-BLACK Right Rear
A246118-2-BLACK Middle
BODY
Bottom View

8
BODY
POLYTANK REPAIR
General Informafion
Repairs to polyethylene tanks can be performed easily with a miniInurn of training. Repair technicians must
exercise prudent caution against melting completely through the poly material, but extreme caution is
generally not necessary. What this means is that the technician must realize that dire consequences are
possible but not likely if he/she is reasonably carel.
Typical repairs will involve repair of two basic types of damage: blernishes to the surface, and cracks or
holes through the material. A different repair approach will be appropriate for each type of damage.
Blemish Repairs
Blemishes to the surface of the poly tank can usually be repaired by first cleaning the area to remove any
grease, oil or dirt. Then apply heat using an electric heat gun. Such guns, in the range of 1000 to 1300
watts allow the application of heat in controllable amounts to avoid quick burn through which is possible with
a flame such as from a propane torch. Aquatech does not recommend the use of a torch to repair poly
tanks.
Using the heat gun, and varying the distance of the gun from the surface of the material, work the heat
in a circular motion around the blemished area until the surface begins to become shiny. At this point the
technician should become Vely careful as the poly material is beginning to liquefy and will begin to flow. By
allowing just enough flow to fill any surrounding blemishes, and using a smooth metal obj ect such as a
spoon or spatula, the material can be manipulated and be made smooth. In cases where the material may
have been heavily gouged, and some material has been lost, the use of a stick of polyethylene material
melted into the affected area can help fill it, then the tool can restore the smooth surface.
Cracks and Holes
When a crack or hole has developed in the polyethylene material another approach is advisable.
Cleaning the affected area is very important. It may be necessary to scrape away some of the material if it
is badly contaminated with grease, oil or dirt. The repair is best done when it can be approached from both
sides, although there are cases where this will clearly be impossible.
Using an electric soldering gun with a wide, flat tip suitable for working with plastics, dip the hot tip into
granulated polyethylene (provided by Aquatech) and work small amounts into the crack or hole. Repeat as
many times as necessary to build the affected area up to the surrounding surface. Repeat the procedure on
the opposite side if possible.
Use a smooth metal tool such as a spoon or spatula to work the material to conform with the surrounding
surface. A heat gun may used as a final step to completely smooth the area, but is not required.
Areas repaired with either technique will have all the qualities and properties of strength and stability as the
original area. Repaired sections can be put into service immediately upon cooling.
Recommended Tools
Tools recommended are a heat gun, 1000-1300 watts. Several manufacturers offer such a gun in the price
range of US$60.00 to US$ 150.00. Some manufacturers include Master, Weller and Ideal. These heat
guns are also excellent tools for thin wall shrink tubing and special solder/shrink electrical terminals. A
soldering gun capable of accepting altemate tips is also recommended. Such soldering guns can be
puchased at electronic supply houses such as Radio Shack, or at common retail outlets such as Sears
Weller is a respected manufacturer of good soldering tools. Forming tools which are metal and smooth can
be made from common items such as kitchen utensils, or purchased from body shop suppliers. Since many
different applications are possible, experience is the best judge of which particular tool to obtain.

BODY 9
OPTIONAL
EQUIPMENT
COMPARTMENT HEATER
PART #A381247

OPTIONAL EQUIPMENT 1
ACCESSORIES

ACCESSORIES 1

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A Product of Hi-Vac Corporation

II. HOW TO USE YOUR HYDROEXCAVATION UNIT

III. HELPFUL HINTS FOR USING YOUR X-VAC CLEANER

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

I. SPARE PARTS LIST

III. POWER TRAIN

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

SECTION 3 PARTS (Continued)

VI. HYDRAULIC SYSTEM

VII. PNEUMATIC SYSTEM

VIII. ELECTRICAL SYSTEM

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

SECTION 3 PARTS (Continued)

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

A Product of Hi-Vac Corporation

PRE-DELIVERY INSPECTION FORM (Page 1 of 2)

1 Engine, oil, water, fuel, air cleaner, fan belt ___________

2 Inspect rear axle seals for leaks ___________

3 Check all lights and reflectors ___________

4 Check tire pressure ___________

6 Inspect universal joints; tighten bolts, if necessary ___________

8 Check chassis specifications against customer specs; report any discrepancies

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

PRE-DELIVERY INSPECTION FORM (Page 2 of 2)

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

Unit Model: X-15

CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST (Page 1 of 3)

• Maximum operating speed _____________

• How to engage and disengage _____________

• Drive train service and lubrication _____________

• Hydraulic pump location and alignment _____________

• PTO oil level _____________

• Oil level inspection and time interval _____________

• Location of filters and service _____________

• Manual over-ride operations _____________

• Location of flow control valves and explanation of adjustments _____________

• Location of hydraulic pressure gauge _____________

• Boom system operation _____________

• Air reservoir regulator, filter and service _____________

• Operation of PTO _____________

X-VAC OPERATIONS, SERVICE AND PARTS MANUAL

CUSTOMER TRAINING FORM/DELIVERLY CHECKLIST (Page 2 of 3)

• Water tank inspection and repair _____________

• Drain valves _____________

• Water pump drive system _____________

• Oil level inspection, time interval _____________

• Packing lubrication, time interval _____________

• Water “on/off” controls _____________

• Pressure relief valve and operation _____________

• Return line ball valve setting and service _____________

• Handgun operation _____________

• Winter recirculation _____________

• Cold weather storage _____________

• Water pressure operation _____________

• Removal of ice from system _____________

• Suction line strainer _____________

• Water pump service oil level _____________

Vacuum system and debris tank

• Debris tank inspection _____________

• Door gasket cleaning _____________

• Exhauster lubrication oil level _____________

• Primary safety cut-off operation, service _____________

• Vacuum gauge _____________