Home

UltraVac HW-4915 Series Operations Manual - hi

1. ultraVac A DIVISION OF Hi Vac CORPORATION HVV 4915 SERIES VACUUM LOADER Serial Number UV X XXX OPERATION SERVICE amp PARTS M A N U AL 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 ullra A DIVISION OF CORPORATION TABLE OF CONTENTS INSPEGTION PROCEDURES ee aan Treten nen l WARRANTY LIMITS OF LIABILITY an nenn lI MESSAGE TO NEW OWNER tette es nina dadan ve d yan ra daka 111 WARNING S ee IV SECTION 1 OPERATIONS Prestart Procedures Start Up Procedures Operational Modes Shutdown Procedures Dumping Procedures Automatic Shutdowns Machine Automatic Shutdowns Engine SECTION 2 MACHINE SPECIFICATIONS Powertrain Body Hydraulic System Vacuum System Pneumatic System Electrical System Spare Parts List Bill of Materials SECTION 3 MAINTENANCE Filter Bag Removal Filter Bag Installation Recommended Lubricants Daily Checks before starting engine Daily Checks engine running clutch disengaged Daily Checks engine running clutch engaged Weekly Checks before starting engine Weekly Checks engine running clutch disengaged Monthly Checks before starting engine Maintenance Schedules amp Record Forms ULTRA VAC OPERAT
2. OPERATIONS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL A DIVISION OF Hi Vac CORPORATION OPERATIONS PRESTART PROCEDURES Before prestarting your Ultra Vac unit be sure you have read and understood all of the safety warnings and precautions located in the Machine Safety section 7 8 Truck must be located on level ground and set trailer brake Visually inspect the unit so that there are no obstructions which may cause harm to machine or operating personnel Check oil level in Vacuum Pump and Transfer Case Check oil and coolant levels in Engine Check Hydraulic oil level and add if necessary Check all Hydraulic hoses and fittings for leaks Repair if necessary Check that all doors are closed and locked Attach vacuum loading hose Remove dust cap from the end of hose You are now ready to start your Ultra Vac unit ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 OPERATIONS A DIVISION OF Hi Vac CORPORATION OPERATIONS START UP PROCEDURES Before starting up your Ultra Vac unit Be sure you have done all the pre start procedures located on the previous page 1 Start the chassis engine Be sure that the chassis parking brake has been applied Allow Engine to idle until air pressure is built up before engaging Vacuum Pump WARNING The Transfer case air system will not function properly until air pressure is at least 60 psi Depress the clutch pedal to disengage the transmi
3. MAINTENANCE RECOMMENDED LUBRICANTS 1 Positive Displacement Vacuum Pump Blowers Follow the recommendations of the blower manufacturers manual located in the Manufacturer s Manuals section 2 Hydraulic System a All hydraulic systems furnished for use on Ultra Vac units will be supplied with AW 46 oil b Tailgate locks and Pivot pins shall use a High Grade Lithium base No 2 Bearing grease 3 Engine Follow the recommendations of the motor manufacturers manual located in the Manufacturer s Manuals section 4 PTO Dexron III transmission fluid 5 Lubricator If applicable ISO VG32 or equivalent SCHEDULED LUBRICATION CHART CHANGE GEAR END OIL CHECK AFTER FIRST 6 34 PINTS BLOWER DAILY 200 HRS EACH IN DRIVE CHECK HIBON CHANGE END BLOWER 8702 DRIVE END OIL EVERY 1000 HRS amp MANUAL DAILY EVERY 6 MO HEREAFTER CHANGE MAIN HOUSING CHECK EVERY 12 25 QUARTS DEXRON III DAILY 300 HRS AW 46 HYDRAULIC OIL RESERVOIR CHECK ANNUALLY 35 GALLONS OIL SYSTEM DAILY REAR DOOR CYLINDER REAR DOOR PINS CHANGE LITHIUM 2 REAR DOOR HINGE PINS CHECK EVERY SHORT TANK TIPPING PINS MONTHLY 100 HRS FIBER CYLINDER PINS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 MAINTENANCE ullra A DIVISION OF CORPORATION MAINTENANCE LUBRICATION MAINTENANCE RECORD OWNER Ultra Vac SERIAL UV MODEL MAINTENANCE PERFORMED BY DATE RECORD Ultra Vac HOUR METER HOURS LUBRICATION OI
4. 2 O 4 9 E STOP 1 U4008 0004 GAUGE AIR PRESSURE 0 200 PSI A120040 HOURMETER HOBBS 10 80VDC 3 HOLE ROUND ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 18 MACHINE SPECIFICATIONS ultraVac ELECTRICAL SYSTEM LEVEL PROBE MONITOR 12VDC KA SRS PART NO 27 0005 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 19 MACHINE SPECIFICATIONS ultral ac SPARE PARTS LIST 6 037010081 FILTERBAG 160z MICROFIBER 60 1216 68 7 U37020032 CAGE FILTER STL 60 LG 68 8 U3803 0032 GASKETBLOWER INLET HIBON 8702 HI SIL 03 0108 GASKET BLOWER TO MANIFOLD GASKET ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 20 MACHINE SPECIFICATIONS ultra ac A DIVISION OF Hi Vac CORPORATION MAINTENANCE ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL ultral ac MAINTENANCE FILTER BAG REMOVAL 1 With Ultra Vac unit shut off and parking brake on carefully climb on top of the collector body Open all baghouse doors to gain access to filters and cages Loosen the t bolt clamps and rotate the blast pipes up and out of the way 2 Remove cages by carefully pulling up and out of the filter bag Be sure not to catch the bag on the cages The baghouse will have 68 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
5. ONTHE FORMS SUPPLIED TO PURCHASERIN THE Ultra Vac MAINTENANCE MANUAL SHOULD PURCHASER BELIEVE ADEFECT HAS BEEN DISCOVERED THE PURCHASER SHALL RETURN THE ALLEGED DEFECTIVE PART TO Hi Vac CORPORATION FOR EXAMINATION F O B THE Hi Vac PLANT MARIETTA OHIO IN THE EVENT PURCHASER DOES NOT SERVICE AND MAINTAIN THE Ultra Vac UNITACCORDING TO THE Ultra Vac MAINTENANCE MANUAL THE WARRANTY IS TO BE CONSIDERED NULL AND VOID AND Hi Vac CORPORATION S OBLIGATION HEREUNDER SHALL BE DEEMED FULFILLED THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF Hi Vac amp CORPORATION LIMITS OF LIABILITY Hi Vac CORPORATION SHALL NOT BE LIABLE FOR AND PURCHASER ASSUMES RESPONSIBILITY FORALL PERSONAL INJURY AND PROPERTY DAMAGE RESULTING FROM THE HANDLING POSSESSION OR USE OF YOUR Ultra Vac INDUSTRIAL VACUUM LOADER BY THE PURCHASER THE LIABIL ITY OF Hi Vac CORPORATION ARISING OUT OF THE SUPPLYING OF YOUR Ultra Vac INDUS TRIAL VACUUM LOADER 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 Ultra Vac INDUSTRIAL VACUUM LOADER AS HEREIN PROVIDED 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 MATER
6. ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 8 MAINTENANCE ultra ac uiraa MAINTENANCE MONTHLY CHECKS before starting engine Perform the monthly maintenance checks listed below and record on record sheet 3 1 Vacuum Pump Lobe Wear Check the vacuum pump standpipe screen for visible dust by raising the collector body If dust is present remove the vacuum pump standpipe and remove the bolts around the standpipe located on top of blower Look for visible signs of wear on the tips of the vacuum pump lobes WARNING Be sure to put safety prop in place before removing the standpipe 2 Centrifugal Ring Open tailgate and inspect the wear plate of the centrifugal ring on ceiling of box inside your Ultra Vac Unit Repair or replace before it is worn through ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 9 MAINTENANCE ultraVac A DIVISION OF Hi Vac CORPORATION M AINTEN ANCE DAILY MAINTENANCE SCHEDULE BEFORE STARTING ENGINE ACTION PROCEDURE THE vacuum pume ano SSH TURES a E RECORD ON MAINTENANCE FORM 1 CENTER OF EACH TUBE 2 CHECK OIL IN THE ENGINE AND PULL THE ENGINE DIP STICK THE OIL RECORD ON MAINTENANCE FORM 1 SHOULD BE UP TO MARK ON STICK MERC ORE 7 0 INSPECT THE SIGHT GLASS THE SIDE OF THE HYDRAULIC TANK FORM 1 AFTER STARTING ENGINE BEFORE ENGAGING BLOWER NO ACTION PROCEDURE CHECK COMPRESSED AIR PRESSURE IMMEDIATELY AFTER STARTING THE AND RE
7. bring dirty material up into the clean side of the vacuum system which can cause serious damage to the blower By pushing them through the tubesheet you can keep all dirt in the baghouse 4 The bags can then be removed through the baghouse access doors located at the front and rear of the baghouse ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 1 MAINTENANCE ultra ac A DIVISION OF Hi Vac CORPORATION NOTE MAINTENANCE FILTER BAG INSTALLATION Be sure the baghouse tubesheets and plenum area is clean of debris Slide clean bags from top of unit down into the tubesheet holes When bag reaches the snapband fold the snapband in half and push down until the tubesheet fits into the groove in the snapband Unfold the snapband until it snaps back to round Snap band groove must fit tight in the tubesheet or bags will not seal properly causing serious damage to Vacuum Pump 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 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 Rotate the blast pipes back to their original location and tighten the T handled clamp Close the bag house doors and tighten the latches ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 MAINTENANCE
8. A VAC OPERATIONS PARTS 8 SERVICE MANUAL 5 A DIVISION OF CORPORATION SAFETY PRECAUTIONS ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL A DIVISION OF CORPORATION CAUTION SOME DO S AND DON TS BEFORE GETTING STARTED WITH YOUR NEW Ultra Vac SYSTEM The safety of the operator is of great importance to us at Hi Vac amp Corporation The decals shields guards and other protective features that are designed into the machine are there for your protection Ahigh 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 PROCEED WITH CAUTION Before attempting to operate the machine read carefully and understand all instructions con tained in the manual IT IS VERY IMPORTANT THAT YOU UNDERSTAND THE FOLLOWING SAFETY WARNINGS IN FULL INJURY OR DEATH TO PERSONNEL AND OR DAMAGE TO MACHINE CAN RESULT Unit should ONLY be operated by thoroughly trained personnel Do not put your face or any portion of head in front of the nozzle Hearing protection MUST be worn by operator and those working near the vacuum loader not operate machinery without proper guards place Keep away from moving objects Do not put your hand in front of the intake nozzle while in operation Do not vacuum any flammable liquid Check that unit is properly stopped and parking brake applied so unit w
9. ANUAL 8 MACHINE SPECIFICATIONS ultraVac HYDRAULIC SYSTEM CYLINDER amp WEDGE ASSY UPPER LOWER DOOR PART NO A246523 P ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 9 MACHINE SPECIFICATIONS HYDRAULIC SYSTEM 35 GALLON HYDRAULIC TANK ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 10 MACHINE SPECIFICATIONS ultraVac HYDRAULIC SYSTEM HYDRAULIC VIBRATOR PART NO U3917 0007 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 11 MACHINE SPECIFICATIONS HYDRAULIC SYSTEM HYDRAULIC HOSE KIT PART U4901 0069 HOSE ASSY 3 4 R2 26 12FJICSX 12FJICS 3 14901 0069 03 HOSE ASSY 5 8 R2 93 10FJICSXHIOFJICSSR_ 1 HOSE ASSY 5 8 R2 138 10FJICSX 10FJICSS 4 5 14901 0069 05 HOSE ASSY 1 2 R2 123 8FJICSXHBFJICSLRO_ 3 6 04901 0069 06 HOSE ASSY 1 2 R2 123 8FJICSX 8FJICSSR9 7 _ U4901 0069 07_ HOSE ASSY 1 2 R2 51 8FJICSX BJICS 3 8 U4901 0069 08 HOSE ASSY 1 2 R2 23 8FJICSX 8FJICS 9 U4901 0069 09 HOSE ASSY 1 2 R2 135 8FJICSXHBFJICS 2 10 U4901 0069 10 HOSE ASSY 1 2 R2 122 8FJICSXHBFJICSLRO_ 1 HOSE ASSY 1 2 R2 117 8F JICSX 8FJICSSR9 Em 12 U4901 0069 12 HOSE ASSY 1 2 R2 111 8FJICSXHBFUICS 2 HOSE ASSY 1 2 R2 41 8F JICSX 8FJICS 3 14 _ U4901 0069 14_ HOSE ASSY 1 2 R2 39 8FJICSX BFJICS 2 HOSE ASSY 1 2 R2 63 8JICSX 8FJICS 16 U4901 0069 16 HOSEASSY 1 2 R2 70 48
10. CORD THE MAXIMUM ENGINE WATCH THE AIR PRESSURE PRESSURE ON MAINTENANCE FORM GAUGE AND NOTE THE MAXIMUM AIR PRESSURE LISTEN FOR THE AIR CANNON TO EXHAUS CHECK THE AIR CANNON FUNCTION AIR AND FOR THE AIR PRESSURE GAUGE AND RECORD ON MAINTENANCE TO DROP APPROXIMATELY 30 PSI THIS FORM 1 SHOULD HAPPEN APPROXIMATELY EVERY SECONDS LOOK AT ALL OF THE HOSES AND FITTINGS ON THE MACHINE AND ALSO LOOK ON THE GROUND UNDER THE MACHINE FOR DROPS OR POOLS OF OIL ALSO LISTEN FOR AIR LEAKING INSPECT COMPRESSED AIR AND HYDRAULIC HOSES AND THE FITTINGS FOR WEAR AND LEAKS RECORD ON MAINTENANCE FORM 1 AFTER STARTING ENGINE AFTER ENGAGING BLOWER AND WITH HOSE INLET UNCAPPED AT THE INLET ACTION PROCEDURE CHECK AND RECORD THE FILTER BAG SET THE ENGINE SPEED TO 1900 RPM AND DIFFERENTIAL PRESSURE ON LOOK AT THE FILTER BAG DIFFERENTIAL MAINTENANCE FORM 1 GAUGE ON THE CONTROL PANEL SET THE ENGINE SPEED TO 1900 RPM AND LOOK AT THE VACUUM GAUGE ON THE CONTROL PANEL SET THE ENGINE SPEED TO 1900 RPM AND INSPECT THE SILENCER DISCHARGE LOOK AT THE DISCHARGE OF THE CHECK AND RECORD THE NO LOAD VACUUM ON MAINTENANCE FORM 1 FOR VISIBLE DUST RECORD ON SILENCER IF THERE IS VISIBLE DUST MAINTENANCE FORM 1 STOP THE MACHINE AND FIX THE PROBLEM SET THE ENGINE SPEED TO 1900 RPM AND COMPLETELY COVER THE INLET TO THE MACHINE THE VACUUM GAUGE SHOULD INCREASE STEADILY AND THE VACUUM BREAKER OPEN AT 27 HG AND CLOSE AT APPROXIMATELY 25 HG CHECK THE VAC
11. FJICSXH8FJICS 1 HOSE ASSY 3 8 R2 11 5 8FJICSX 8FJICS 1 18 14901 0069 18 HOSE ASSY 3 8 R2 21 6FJICSX BFJICS 1 j ak Po oO N amp s J O J x ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 12 MACHINE SPECIFICATIONS VACUUM SYSTEM BLOWER amp SILENCERS ITEM PART DESCRIPTION 1 03 0108 BLOWER HIBON 8702 BH CCW HVV U4201 0333 SILENCER INTAKE HVV5015 HIBON 8702 3 U4201 0334 SILENCER EXHAUST HVV5015 HIBON 8702 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 13 MACHINE SPECIFICATIONS VACUUM SYSTEM 6 AIR OPERATED VACUUM RELIEF HVV4915 PART UV1 9171 ITEM PART DESCRIPTION QTY 16 0347 VALVE BUTTERFLY 12VDC ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 14 MACHINE SPECIFICATIONS PNEUMATIC SYSTEM ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 15 MACHINE SPECIFICATIONS ultraYac PNEUMATIC SYSTEM MANUAL DRAIN VALVE ITEM PART DESCRIPTION VALVE SOLENOID 12VDC REGULATOR QIX INT FIL U4003 0140 FILTER PURAGUARD AIR SYSTEM 04003 0141 VALVE PRESSURE PROTECTION 1 2 X 3 8 NPT U3904 0027 VALVE CHECK 1 2 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 16 MACHINE SPECIFICATIONS ultraVac PNEUMATIC SYSTEM ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 17 MACHINE SPECIFICATIONS ultraYac ELECTRICAL SYSTEM
12. IAL MAY BE RETURNED WITHOUT FIRST GETTINGAPPROVAL 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 CRED ITED ON THE BASIS OF THE PRICES PAID AT TIME OF SHIPMENT ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 4 A DIVISION OF Hi Vac CORPORATION MESSAGE TO NEW OWNER Congratulations on your purchase of a new Ultra Vac Vacuum Loader This manual is supplied for your convenience to assist you in adequately maintaining servicing and operating your Ultra Vac Vacuum Loader Your Ultra Vac Vacuum Loader has been designed to give you many years of dependable trouble free service which can be attained only through conscientious care by your personnel Therefore cooperation practice and skill on the part of all personnel associated with your Ultra Vac is necessary to maintain maximum productivity The material in this manual has been carefully and thoughtfully prepared to provide a simple and understandable guide It should be carefully read and thoroughly understood by all personnel responsible for your Ultra Vac before engaging in both operation and the maintenance of the system The very best wishes from our entire organization are extended to you with the assurance that you will enjoy long and dependable service from this Ultra Vac ULTR
13. IONS PARTS amp SERVICE MANUAL 1 A DIVISION OF Hi Vac CORPORATION SECTION 4 SCHEMATICS Chassis Wiring Diagram Electrical Schematics Hydraulic Schematic Pneumatic Schematic SECTION 5 OPTIONS As Listed SECTION 6 ACCESSORIES Accessories SECTION 7 MANUFACTURERS MANUALS OMSI PTO Parts Manual Hibon Blower Manual Keystone Butterfly Valve Gresen Valve Winters Gauges Marsh Gauges Span Gauges Span Venting Cassapa Hydraulic Pump Parker Filter Global Hydraulic Vibrator Asco Valves Qix Filter Regulator Puraguard Filter Global Air Cannon SMC Pneumatic Valves Murphy Tachometer Hobbs Hourmeter Dwyer Instruments Nason Pressure Switch United Electric Vacuum Switch Monitor Level Probe Wilkerson Autodrain ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 A DIVISION OF Hi Vac CORPORATION INSPECTION PROCEDURES All pieces received should be inspected for damage immediately upon receipt 1 Damage can be most easily detected by looking for scrapes on the paint 2 Inspect all sheet metal and structural steel for damage such as bends kinks or breaks 3 Check all wiring for abrasions cuts cracks etc If any are found repair or replace before connecting to power source Check all conduit runs and fittings for defects Check vacuum pump for free rotation before starting under power for the first time after installation Compare the packing list attached to each piece of ea
14. L DRAINED amp PERFORMED CHANGED OIL ADDED CREASED VACUUM PUMP N A HYDRAULIC SYSTEM ENGINE N A VIBRATOR LUBRICATOR CLUTCH ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 MAINTENANCE ultraVac a MAINTENANCE DAILY CHECKS before starting engine Perform the daily maintenance checks listed below and record on record sheet 1 1 Vacuum Pump Oil Level Checking the vacuum pump oil level is critical and should be done frequently Some vacuum pumps have oil level sight gauges and others have oil level plugs Refer to the vacuum pump s maintenance manual located in the manufacturer s bulletins section to determine proper oil level requirements If oil is needed see Recommended Lubricants in the Maintenance section NOTE Unit must be on level surface to get an accurate oil level reading 2 Engine Oil amp Coolant Levels a Check engine oil when engine is cool to get a more accurate reading Record on Daily Maintenance Schedule Record b When engine is cool remove Radiator Cap and check Coolant level Record on Daily Maintenance Schedule Record CAUTION NEVER REMOVE RADIATOR CAP WHEN ENGINE IS WARM 3 Hydraulic Oil Check oil level on site glass on the side of the Hydraulic tank Record on Daily Maintenance Schedule Record 4 PTO Check the PTO fluid level in the sightglass located on the drivers side frame Fluid level should be at the cente
15. ORD Ultra Vac HOUR METER _______ HOURS BEFORE STARTING ENGINE GAUGE CHECKED NEEDS REPAIRS ES ACTION READING poe REPAIR MADE CHECK U BOLTS HOLDING THE ULTRAVAC UNIT TO THE TRUCK CHASSIS CHECK ALL ELECTRICAL CONDUIT CABLES 2 AND CONNECTIONS FOR SIGNS OF BREAKS OR ABRASIONS AFTER STARTING ENGINE BEFORE ENGAGING BLOWER GAUGE CHECKED NEEDS REPAIRS ACON READING REPAIR MADE 4 CHECK THE COMPRESSED AIR SYSTEM FOR LEAKS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 15 MAINTENANCE MAINTENANCE MAINTENANCE RECORD FORM 3 MONTHLY OWNER Ultra Vac SERIAL UV n MODEL MAINTENANCE PERFORMED DATE RECORD Ultra Vac HOUR METER _________ HOURS BEFORE STARTING ENGINE GAUGE CHECKED NEEDS REPAIRS ASTON READING REPAIR MADE 1 CHECK VACUUM PUMP FOR LOBE WEAR 2 CHECK CENTRIFUGAL RING WEAR PLATE FOR WEAR ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 16 MAINTENANCE ultraVac A DIVISION OF Hi Vac CORPORATION SCHEMATICS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL ultraVac A DIVISION OF Hi Vac CORPORATION OPTIONS ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL NONE LISTED ultraVac A DIVISION OF Hi Vac CORPORATION ACCESSORIES ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL MANUFACTURER S MANUALS
16. R WEAR AND RECORD ON MAINTENANCE FORM 3 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 12 MAINTENANCE CHECK VACUUM PUMP BY LOOKING FOR DUST AROUND THE STANDPIPE SEAL IF DUST IS PRESENT REMOVE THE STANDPIPE AND INSPECT THE BLOWER LOBES VISUALLY INSPECT THE CENTRIFUGAL RING WEAR PLATE FOR SIGNS OF EXCESSIVE WEAR REPAIR OR REPLACE BEFORE WORN THROUGH ultravac MAINTENANCE MAINTENANCE RECORD FORM 1 DAILY OWNER Ultra Vac SERIAL UV ________________ MODEL MAINTENANCE PERFORMED BY DATE RECORD Ultra Vac HOUR METER HOURS BEFORE STARTING ENGINE ACTION GAUGE CHECKED NEEDS REPAIRS READING OK REPAIR MADE AFTER STARTING ENGINE BEFORE ENGAGING BLOWER GAUGE CHECKED NEEDS REPAIRS ACTION READING REPAIR MADE CHECK COMPRESSED AIR PRESSURE INSPECT COMPRESSED AIR AND 6 HYDRAULIC HOSES AND THE FITTINGS FOR WEAR AND LEAKS AFTER STARTING ENGINE AFTER ENGAGING BLOWER AND WITH HOSE INLET UNCAPPED AT THE INLET GAUGE CHECKED NEEDS REPAIRS ACTION READING REPAIR MADE CHECK AND RECORD THE FILTER BAG DIFFERENTIAL PRESSURE CHECK AND RECORD THE NO LOAD VACUUM INSPECT THE SILENCER DISCHARGE FOR VISIBLE DUST CHECK THE VACUUM BREAKER VALVE SETTING ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 13 MAINTENANCE ultraVac MAINTENANCE MAINTENANCE RECORD FORM 2 WEEKLY OWNER Ultra Vac SERIAL UvV ______________________ MODEL MAINTENANCE PERFORMED BY __ REC
17. UUM BREAKER VALVE SETTING AND RECORD ON MAINTENANCE FORM 1 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 10 MAINTENANCE A DIVISION OF CORPORATION MAINTENANCE WEEKLY MAINTENANCE SCHEDULE OR EVERY 40 HOURS OF OPERATION BEFORE STARTING ENGINE ACTION PROCEDURE CHECK U BOLTS HOLDING THE 4 VACUUM UNIT TO THE TRUCK CHASSIS AND RECORD ON MAINTNANCE FORM 2 CHECK OIL IN THE HYDRAULIC TANK AND RECORD ON MAINTENANCE FORM 1 USE A WRENCH AND TIGHTEN EACH OF THE NUTS ON THE U BOLTS HOLDING THE ULTARVAC TO THE TRUCK CHASSIS INSPECT THE SIGHT GLASS ON THE SIDE OF THE HYDRAULIC TANK AFTER STARTING ENGINE BEFORE ENGAGING BLOWER NO ACTION CHECK HIGH LEVEL PROBE AND RECORD ON MAINTENANCE FORM 2 CHECK THE COMPRESSED AIR SYSTEM FOR LEAKS AND RECORD ON MAINTENCE FORM 2 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 11 MAINTENANCE PROCEDURE OPEN THE REAR TAILGATE AND ENTER THE COLLECTOR BODY AND STOP THE LEVEL PROBE PADDLE THE HOPPER FULL LIGHT SHOULD TURN ON ALLOW THE AIR PRESSURE TO INCREASE TO ABOVE 100PSI TURN OFF THE ENGINE AND WATCH THE AIR PRESSURE GAUGE THE GAUGE SHOULD REMAIN AT THE SAME PRESSURE FOR MORE THAN 5 MINUTES A DIVISION OF CORPORATION MAINTENANCE MONTHLY MAINTENANCE SCHEDULE BEFORE STARTING ENGINE ACTION PROCEDURE 1 CHECK VACUUM PUMP FOR LOBE WEAR AND RECORD ON MAINTENANCE FORM 3 CHECK CENTRIFUGAL RING WEAR PLATE FO
18. ch shipment 7 Verify the number of pieces and description of each piece shown on the packing slip REPORT ANY DAMAGE NO MATTER HOW SLIGHT IMMEDIATELY TO Hi Vac Corporation 117 Industry Road Marietta OH 45750 Attention Service Department Phone 740 374 2306 Toll Free 800 752 2400 Fax 740 374 5447 ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 3 ultra ac A DIVISION OF Hi Vac CORPORATION WARRANTY Hi Vac CORPORATION WARRANTS TO THE ORIGINAL PURCHASER OF THE Ultra Vac UNIT QUOTED HEREIN THAT THE Ultra Vac UNIT SHALL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USE AND SERVICE Hi Vac CORPORATION DOES NOT WARRANT COMMERCIAL ITEMS MANUFACTURED BY OTHERS SUCH AS DIESEL ENGINES TRUCK CHASSIS TIRES OR MOTORS Hi Vac CORPORATION S OBLIGATION UNDER THIS WARRANTY SHALL BE LIMITED TO THE REPAIR OR EXCHANGE OF ANY PART OR PARTS WHICH MAY PROVE DEFECTIVE UNDER NORMAL USE AND SER VICE WITHIN THE SHORTER PERIOD OF ONE 1 YEAR FROM THE DATE OF DELIVERY TO THE ORIGINAL PURCHASER AND WHICH Hi Vac CORPORATION S EXAMINATION SHALL DISCLOSE TO ITS SATISFAC TION TO BE DEFECTIVE THIS WARRANTY REQUIRES PURCHASER TO OPERATE THE Ultra Vac UNIT IN STRICT COMPLIANCE WITH THE PRINTED INSTRUCTIONS AND TO SERVICE THE Ultra Vac UNIT ACCORDING TO THE METHODS AND SCHEDULES CONTAINED IN THE Ultra Vac UNIT S MANUAL EVIDENCE OF PURCHASER S SCHEDULED MAINTENANCE MUST BE REPORTED IN WRITING TO Hi Vac CORPORATION
19. gine Check filter bags for rupture or leaks by opening the top access doors and looking for any signs of dust on top of the filter bags or under the inside of the top access door Discharge ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 7 MAINTENANCE MAINTENANCE WEEKLY CHECKS before starting engine Perform the weekly maintenance checks listed below and record on record sheet 2 1 Subframe Mounts Check bolts holding the vacuum unit to the trailer chassis Record on Weekly Maintenance Schedule Record 2 Electric Cable Visually inspect all electrical conduit cables and connections for signs of abrasions or breaks WEEKLY CHECKS engine running clutch disengaged Perform the weekly maintenance checks listed below and record on record sheet 2 3 Level Probe Check level probe for operation by holding the paddle Control panel must be on with the blower OFF The Hopper Full light will turn on on control panel If adjustment is necessary refer to the level probe manual located in this operations manual Record on the Weekly Maintenance Schedule Record 4 Compressed Air Lines and Vacuum Leaks Inspect all compressed air lines fittings and connections for possible leaks Check the openings for possible damage to gaskets With the machine running listen for audible leaks around doors hose connections flanges etc and repair as required Record on Weekly Maintenance Schedule Record
20. ill not tip or roll Do not lubricate adjust or repair the Ultra Vac unit unless engine is shut down Do not operate the unit with the levelprobe ON OFF switch in the OFF position ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 1 A DIVISION OF Hi Vac CORPORATION NOTE AS WITH ANY TYPE OF HEAVY DUTY EQUIPMENT CAUTION MUST BE EXERCISED IN ITS PROPER USE NEVER raise body when parked on uneven ground NEVER raise the body if baghouse is overloaded NEVER raise body unless the tailgate is fully open NEVER operate tailgate while body is in elevated position NEVER move the Ultra Vac unless the body is in the fully down position Clear the area behind the Ultra Vac of all personnel before opening or closing the tailgate NEVER inspect or work under the raised body without the safety body prop in place NEVER inspect or work under the open tailgate without a tailgate prop in place Do not operate the Ultra Vac unit while wearing loose clothing watches or rings Periodically check for any loose bolts or set screws WARNING FAILURE TO COMPLY WITH ANY OF THE ABOVE SAFETY INSTRUCTIONS OR THOSE THAT FOLLOW WITHIN THIS MANUAL MAY RESULT IN DAMAGE TO EQUIPMENT AND OR SEVERE INJURY OR DEATH PLEASE REMEMBER SAFE OPERATION BEGINS WITH A SAFE OPERATOR WE ASK YOU TO BE THAT TYPE OF OPERATOR ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 ultraVac A DIVISION OF Hi Vac CORPORATION
21. l or obstructions near the Ultra Vac This could result in damage to machinery or injury to personnel If equipped with manual dump door locks on the baghouse and cyclone hopper dump doors release the locks to allow the dump doors to open during each dumping of the collector body CAUTION Do raise the body if the baghouse is overloaded WARNING Failure to do so can result in sever injury or death and or damage to the equipment Dumping The Body 1 Pull the handle valve marked Lock Unlock to unlock tailgate prior to raising Be sure that there are no personnel at the back of the Ultra Vac unit 2 Pull the handle valve marked Tailgate Open Close to open the tailgate Be sure that there are no personnel at the back of the Ultra Vac unit WARNING Never open the tailgate without first unlocking This will cause damage to the equipment 3 Pull the valve marked Raise Lower to fully raise the collector body WARNING Be sure that the Ultra Vac is on a level surface before raising the collector body Possible tipping may occur 4 Pull the valve marked Vibrator On Off to run the hydraulic vibrator to loosen materials in the collector body baghouse and cyclone hopper Ensure the baghouse and cyclone hopper are completely empty of material after each dumping cycle ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 4 OPERATIONS ultraV ac OPERATIONS DUMPING PROCEDURES continued 5 After i
22. n record sheet 1 8 Filter Bag Pressure Differential A With the inlet to your machine open Check differential gauge mm mes Reading should be between 1 and 7 of water H O Record v the reading on the pressure differential gauge in inches H O 2 water 1 If higher than 10 inches of water a visual inspection should be made for excessive buildup of material on the filter bag surfaces or bridging of material between bags This can be done through the side access door Differential 9 No Load Vacuum A With the inlet completely open and no hoses connected check vacuum gauge reading This no load reading is an important indicator of the condition of the unit The no load vacuum should be about 1 inch of mercury Hg Record vacuum reading in Hg 1 If no load vacuum reading is zero 0 a Inspect vacuum gauge plumbing for hose rupture loose fittings or plugged lines b Check that the box is properly seated on the standpipe and that there are no leaks Vacuum 2 If no load vacuum reading is higher a Check for obstruction in the cyclones and pipings by opening the top lids on each cyclone 10 Dust Discharge A Inspect the silencer for visible dust in the air stream NOTE Shut the unit off immediately if dust is present Any dust discharge should be corrected immediately to protect the vacuum pump B If dust is present disengage the vacuum pump and shut down the en
23. nspecting the Blower Inlet Screen lower the collector body close the tailgate and then lock the tailgate locks WARNING Never work under body or tailgate in the raised position unless the appropriate props are in place Never move the Ultra Vac with the collector body in the raised position Inlet Screen ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 OPERATIONS ultraV ac OPERATIONS AUTOMATIC SHUTDOWNS MACHINE There are two types of automatic shutdowns on the HVV 4915 Machine shutdowns which are shutdowns directly related to the Unit and Engine shutdowns You will have to correct the problem before restarting MACHINE SHUTDOWNS The following conditions will cause the engine to return to an idle condition or stop the engine 1 HOPPER FULL Caused by material filling up inside the collector body and activating the Level Probe This is indicated by a light on the control panel Simply dump material out of the collector body and move the mode switch to the Vac OFF Reset position The Hopper Full light should go out Return the mode switch to either the Automatic or Manual positions and you may then continue loading Always return the Level Probe ON OFF switch to the ON position before resuming vacuuming operations 2 EMERGENCY STOP BUTTON In the event of an emergency situation press the emergency stop button This button will remove power from the control panel and will stop the engine To re
24. r of the sightglass Add remove fluid as appropriate ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 MAINTENANCE MAINTENANCE DAILY CHECKS engine running clutch disengaged Perform the daily maintenance checks listed below and record on record sheet 1 5 Compressed Air Pressure Switch When the engine is started watch the Air Pressue Gauge mounted on the rear of the battery box and the Low Air Pressure light The light will stay lit until the gauge reaches 60 PSI Record the air pressure at which the Low Pressure light goes out on the Daily Maintenance Schedule Record 6 Air Cannon When the air cannon is turned on listen for the air cannon to fire inside the baghouse doors Watch the Air Pressure Gauge for a drop of about 30 PSI This should happen approximately every 15 to 30 seconds Watch the air pressure gauge pressure rise to approximately 100 psi and the air cannon should fire Record on the Daily Maintenance Schedule Record 7 Compressed Air amp Hydraulic Lines When the engine is started inspect all air and hydraulic lines fittings and connections for leaks Look on the ground under unit for drops or pools of oil and record on the Daily Maintenance Schedule Record ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 MAINTENANCE ultra ac uiraa MAINTENANCE DAILY CHECKS engine running clutch engaged Perform the daily maintenance checks listed below and record o
25. s manner could result in damage to equipment or severe injury or death AUTOMATIC The engine increases speed until it reaches a preset maximum operational blower speed A hopper full light will lower the engine speed back to an idle condition Atthis point the box must be emptied before the operations can continue MANUAL In this mode engine speed it controlled through the throttle emulator Likewise a hopper full light will return the engine to a idle condition until the hopper has been emptied OFF RESET This switch position will allow the throttle to be used for dumping the box SHUTDOWN PROCEDURES Before stopping unit allow the Ultra Vac to run for a moment to let the lines clean out 1 At the side control panel move the mode switch to the OFF RESET position At this point the engine should return to an idle condition WARNING Never disengage Blower above 1 000 RPM s 2 If time allows let Vacuum Pump run at low RPM to cool down 3 On the dash disengage the blower by depressing the clutch and moving the blower switch to the off position Move the PTO switch to the OFF or Disengaged position Release the clutch 4 Turn the ignition key switch to Off position ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 OPERATIONS ultral ac OPERATIONS DUMPING PROCEDURES Before dumping material out of the collector body be sure that the parking brake is on and the unit is on level ground Also ensure there are no personne
26. ssion Switch the Road Pump switch located on the dash to the Pump position Put the transmission in the gear indicated on the label located on the dash Release the clutch At this point the rear drive shaft should be disengaged and hydraulic system is on At engine idle speed Depress the clutch pedal and Switch the Blower On Off switch to the On position Release the clutch At this time the blower will be turning Be sure to only engage and disengage at idle speed only WARNING Never engage blower above 1 000 RPM s 6 After Vacuum Pump is engaged switch the Auto Manual switch to the desired mode and increase the engine speed until you are at desired speed WARNING Level Probe ON OFF switch must be ON at all times during vacuuming operations Once the unit is at operating speed you may begin loading material Periodically check gauges to ensure the unit is running properly The Ultra Vac has built in shut downs If a shut down occurs immediately stop work and remedy the situation ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 OPERATIONS A DIVISION OF Hi Vac CORPORATION OPERATIONS OPERATIONAL MODES This unit has two operational modes They can be selected at the side control panel WARNING If your unit is equipped with a Level Probe ON OFF switch the switch must be in the ON position during vacuuming operations Failure to operate the unit in thi
27. sume loading pull out on the Emergency Stop button and follow the start up procedure AUTOMATIC SHUTDOWNS ENGINE ENGINE SHUTDOWNS See the Chassis Manual for instructions on engine warnings and fault displays ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 OPERATIONS MACHINE SPECIFICATIONS ultra ac POWERTRAIN OMSI PTO PART NO A249437 ULTRA VAC OPERATIONS PARTS 8 SERVICE MANUAL 1 MACHINE SPECIFICATIONS ultraVac BODY 10 0219 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 2 MACHINE SPECIFICATIONS ultraVac BODY ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 3 MACHINE SPECIFICATIONS ultraVac BODY SIGHT EYE ASSEMBLY 2 REQUIRED ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 4 MACHINE SPECIFICATIONS ultravac HYDRAULIC SYSTEM HYDRAULIC PUMP PART NO U3902 0085 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 5 MACHINE SPECIFICATIONS ultraVac HYDRAULIC SYSTEM DOOR LOCKE TALGATE TANK WHAA TE PUSH PEH TO TD PLLL CLOSE LOWER Ta VERATE ALL PAL RAGE PART 73904 0188 3 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 6 MACHINE SPECIFICATIONS ultraYac HYDRAULIC SYSTEM LIFT CYLINDER ASSEMBLY PART NO U3903 0053 ULTRA VAC OPERATIONS PARTS amp SERVICE MANUAL 7 MACHINE SPECIFICATIONS HYDRAULIC SYSTEM REAR DOOR HYDRAULICS ULTRA VAC OPERATIONS PARTS amp SERVICE M

UltraVac HW-4915 Series Operations Manual - hi

Contents

Download Pdf Manuals

Related Search

Related Contents