I. Purpose & Scope

To safely and effectively provide instruction on the inspection and proper use of Hydro Vacuum Excavators.

II. Definitions

Standard PPE – High Viz Garment, Hard Hat, Z-87.1 Safety Glasses, Gloves, Pants, Work Boots

III. Process

NOTE: Work instruction does not supplement the manual. For specific instructions for the exact model please refer to the owner’s manual. 

A. Potential Hazards

• Electric Shock Hazard
• Fire or Explosion Hazard
• High Noise Hazard
• Flying objects/debris
• Burn Hazard
• Moving parts hazard
• Crushing weight hazard
• Suffocation Hazard
• Pressure hazard
• Confined space hazard
• Hazardous atmosphere

B. PPE

• Standard PPE
• Hearing Protection
• Face Shield
• Respiratory protection – Recommended
• Tyvek suit – Recommended

C. Inspection

1. Inspect Trailer for the following:
   • Inspect trailer connection –  hooks are in place and the safety latches are in good working condition and snap back to their original position. 
   • Inspect trailer chains – not dragging on the ground. 
   • Pintle Hitch – safety pin in place, locked and not going to come out
   • Electrical Connections – Locked in place and will not come undone, and is firmly secure
   • Emergency Cable is secure and ready to activate trailer brakes. 
   • Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes.
   • Check hitch for wear and cracks. Lubricate if needed.
   • Check battery for 12V charge, no corrosion or leaks.
   • Check landing gear is secured in up position. 
   • Tool box is secured, and latches are tight. Ensure extra tools and hoses are available and stored before leaving the yard. 
2. Engine
   • Open the cabinet and verify oil levels from the dipstick. 
   • Check the air filter is clean and not clogged. 
   • Check  the belts for proper tension and no cracks or wear. 
   • Verify the overall engine bay for cleanliness, no excess fluid or build up to indicate leaks.
   • Check latches are in good shape and are secure. 
   • Check hydraulic fluid levels are good. 
   • Check hoses for bubbles, cracks, leaks, or tears.
3. Water Tank
   • Check for leaks or tears
   • Check for appropriate level 
4. Trailer Sides
   •  Hose and snorkel are secured.
   • Check for any ends breaks or cracks.
   • Check trailer deck for loose pieces that need to be removed or secured before transportation.
   • Remote is secured and cord will not get tangled or caught on any parts.
   • Ensure boom is secured in place and locked. 
5. Tires
   • Check tire pressure is correct. 
   • Tread depth is appropriate and more than 2/32nds. 
   • Check that tires do not have tears, bubbles or missing tread.
   • Ensure lug nuts are secured and tight and do not have rust or shininess. 
   • No cracks or welds. 
   • Check suspension are not missing or scissored and are properly secured. 
6. Hose
   • No tears, bubbles or exposed wires. 
   • Ensure hose real is secured to the trailer.
   • Ensure hose is secured to the attachment. 
7. Rear of Trailer
   •  Ensure beaker light is working and in good condition
   • Inspect lights for cleanliness and correct operation.
   • Inspect reflector tape, for cracks or tears and replace if needed.
   • Inspect sight glasses for cracks and has washer present. 
   • Ensure door is closed and secured. 
   • Ensure dump valve cap is in place and secured. 
   • License plate attached and light is working correct. 
8. Cyclone Filter
   • Open and verify there is no solid material in the filter, remove if found.  
   • Ensure lid is secured properly. 
9. Air Filter
   • Ensure filter is free of dirt and debris. If dirty, clean and replace. 
   • Low pressure water is used for cleaning and requires 24 hours to dry. 
10. General Inspection
    • Check all clearance lights work properly and have no loose wires. 
    • Check all DOT tape is in good repair.   
    • Check ramps (if equipped) and trailer bed for cracks.

D. Use

Start Unit

1. Open tank inlet valve.
   NOTE: Avoid idling engine with inlet valve closed.
2. If equipped with reverse flow, ensure vacuum is in “vacuum” mode before starting.
3. Insert key into ignition switch.
4. Turn key clockwise.
5. Run engine at low throttle for 5 minutes.

Cold Start

1. Open tank inlet valve.
   NOTE: Avoid idling engine with inlet valve closed.
2. If equipped with reverse flow, ensure vacuum is in “vacuum” mode before starting.
3. Insert key into ignition switch.
4. Turn key to on position. Cold start (glow plug) timer indicator will light.
5. Wait for cold start timer indicator to go off.
6. Turn key clockwise to start engine.
7. Run engine at low throttle for 5 minutes.

Position Vacuum Boom

1. Start engine.
2. Set hydraulic function switch to “Boom” position.
3. Remove vacuum hoses form storage. If using a vacuum boom on a truck, attach provided extension hose to help maneuver the tool.
4. Pull boom latch cable to release boom.
5. Use boom control to:
   • Raise boom until it clears saddle.
   • Extend/retract boom to desired length.
   • Raise/lower boom to desired height.
6. Rotate boom by manually swinging it left or right.

Remove Debris

1. Position vacuum hose in area to be excavated.
2. Start engine.
3. Open inlet valve if necessary to being excavation.
4. Use sight glasses to monitor debris level in tank. Vacuum will shut off when tank is full but always heed trailer and tank lifting capacities. Engine will remain running.

Pothole

1. Start engine.
2. Open water tank valve.
3. Move water pump switch to on.
4. Open inlet valve.
5. Position tool over area to be excavated and begin pothole.
6. Adjust water pressure as needed to match soil conditions and/or material of utility being exposed.
7. Ensure that water sprays from nozzle. If it does not nozzle may be clogged and pump will not function properly. Clean or replace nozzle as necessary.
8. When freshwater tank is empty, stop operation and turn water pump switch to off.

Drain Tank

1. Ensure that unit is hitched to vehicle.
2. Haul unit to approved dumping area.
3. Open drain/outlet valve and inlet valve.
4. Allow tank to drain in the horizontal position until tank is approximately half drained. Monitor sight glasses.
5. When tank is half drained, start engine and run at low idle.
6. Tilt tank up to help flush solids form tank.
7. Lower tank to the full horizontal position.
8. Close drain/outlet valve and inlet valve.
9. If further draining is necessary, open tank door.
10. Tilt tank up fully. Allow tank to drain completely.
11. Connect water pressure hose to water lance.
12. Turn water pump switch on. Adjust water pressure.
13. Use water lance to thoroughly rinse inside of tank and around door seal.
14. Return tank to the fully lowered horizontal position.
15. Close tank door.

Open/Close Tank Door

Open

1. If using optional reverse flow mode, turn off engine and ensure handle is down (in Vacuum mode).
2. If tank is tilted, lower tank fully before opening door.
3. Open tank inlet valve.
4. Set hydraulic function switch to door position.
5. Press UP on tethered control.

Close

1. Press DOWN on tethered control until the linkage on both sides of the tank is fully collapsed.
2. Close tank inlet valve.

Shut Down

1. Move machine to level ground.
2. Return all controls to neutral.
3. Run engine at low throttle with no load for at least five minutes to cool.
4. Shut of machine.
5. If leaving machine unattended, remove key.
6. For maintenance or long-term storage, disconnect battery using battery disconnect switch
   NOTE: Wait two minutes after shutting off machine before disconnecting battery.

E. Maintenance

FX Models

1. Spray water onto equipment to remove dirt and mud. Use water lance. Thoroughly rinse inside of tank and around door seal.
2. Exercise relief valve before each use. Pull valve handle, twist it a few times and release. Also ensure vents on valve are free of mud and other restrictions.
3. Clean water pump filter every 10 hours by following the below procedure.
   • Open filter housing.
   • Remove element and rinse housing thoroughly with water.
   • Inspect element for signs of collapse and for brittle or broken rubber seals on the ends of the element. Replace as needed.
   • Replace element and close filter housing.
4. Check torque of trailer hitch bolts. Torque varies by trailer model.
5. Check hydraulic brake actuator bolts. Tighten if loose.
6. Check hydraulic brake fluid level at master cylinder cap before each use. Fluid should be visible at top of master cylinder. Add DOT 3 or DOT 4 brake fluid and bleed brakes as needed.
7. Check battery connections for wear or corrosion. Keep connections clean and tight.
8. Check tire pressure and lug nut torque.
9. Check lights and reflectors for correct operation and cleanliness.
10. Check air filter whenever vacuum gauge goes over 16″ of mercury, change as needed following the below procedure.
    • Remove clamp.
    • Remove filter and discard.
    • Install new filter.
    • Replace clamp.
11. Empty cyclonic separator canister as needed. Open door and dump tank. Clean out cyclone through upper access door as needed.
12. Lube reverse flow 4-way valve at zerk with MPG as needed. Also open left access panel of power unit and lube zerk on other side of valve.
13. Change batteries in wireless control module as needed. Unit requires 3 AA batteries.
14. Clean Primary Shut-off valve as needed. Replace primary shut off valve as needed.

To Clean

1. 1. Open tank door.
   2. Spray Valve housing inside vacuum tank with high-pressure hose.
   3. Close tank door.

To Remove

1. 1. Loose three wingnuts and pull out valve housing.
   2. Remove ball.
   3. Clean ball and housing with high-pressure water.
   4. replace ball and housing.
   5. Tighten wingnuts.

HX Models

1. Check air intake system for dirt and debris every 10 hours. If clamp is loose, apply oil to threads and retighten. If hose is cracked or worn, replace.
2. Check battery every 10 hours and charge as needed.
   • Disconnect battery at battery disconnect switch, if equipped.
   • Ensure no ignition sources are near battery.
   • Loosen and remove battery cable clamps carefully, negative cable first.
   • Clean cable clamps and terminals to remove dull glaze.
   • Check for signs of internal corrosion in cables.
   • Connect battery cable clamps, positive cable first.
   • Tighten any loose connections.
   • Ensure that battery tie downs are secure.
   • Turn batter disconnect, if equipped, on.
3. Change batteries as needed on wireless remote control.
4. Check blower belt every 10 hours. Adjust as needed.
   • Check belt for excessive slack, damage or wear. Belt is properly tensioned when it moves about 1/4″ – 3/8″ when pushed at the long span.
     • To adjust, remove belt guard.
     • Loosen idler sheave bolt.
     • Loosen jam nut.
     • Rotate adjustment screw to properly tension belt.
     • Tighten jam nut.
     • Tighten idler sheave bolt.
     • Replace belt guard.
5. Check fan belt every 10 hours for excessive slack, damage or wear. Belt is properly tensioned when it moves about 1/4″ – 3/8″ when pushed at the long span.
   • To adjust, loosen alternator bolt.
   • Adjust to properly tension belt.
   • Tighten alternator bolt.
6. Check hydraulic pump belt every 10 hours for excessive slack, damage or wear. Belt is properly tensioned when it moves about 1/8″ – 1/4″ when pushed.
   • To adjust, loosen three bolts on pump mount.
   • Loosen jam nut.
   • Rotate adjustment screw to properly tension belt.
   • Tighten jam nut.
   • Tighten bolts to secure pump on mount.
7. Check water pump belt every 10 hours for excessive slack, damage or wear. Belt is properly tensioned when it moves about 1/8″ – 1/4″ when pushed.
   • To adjust, loosen three bolts on pump mount.
   • Loosen jam nut.
   • Rotate adjustment screw to properly tension belt.
   • Tighten jam nut.
   • Tighten bolts to secure pump on mount.
8. Lube blower as needed to help prevent rust and seizing during long-term storage.
   • Remove plug.
   • Start engine.
   • Spray light oil into port.
   • Run engine for 1-2 minutes.
   • Shut off machine.
   • Install plug.
9. Check coolant every 10 hours.
   • Check level at overflow bottle.
   • Add DEAC at fill as needed to keep level between LOW and FULL marks on overflow bottle.
10. Before start up and ever 10 hours, remove wing nut on the cyclonic separator canister to drain.
11. Check Debris Tank Deflector every 10 hours for buildup, wear, or damage. Clean or change as needed.
12. Check Debris Tank Door Seals/Fittings every 10 hours for wear, damage, or leaks. Change as needed.
13. Clean Debris Tank Primary Shutoff Valve as needed.
    • Loosen eight bolts to remove elbow weldment.
    • Remove ball.
    • Clean ball, housing, and seals with high-pressure water.
    • Inspect seals, change as needed.
    • Reassemble.
14. Check Dust ejector valve before startup and every 10 hours. Ensure valve is not inverted, damaged, plugged or cracked.
15. Whenever vacuum gauge goes over 15inHG, check blower relief air filter for dirt or debris.
16. Check Engine air filter restriction indicator every 10 hours.
17. Check Vacuum air filter every 10 hours and clean as needed.
    • Remove bolts to open cover.
    • Remove wing nut to remove filter element.
    • Wipe inside of housing and wash cover.
    • Clean element with low pressure water, as needed.
    • Allow element to dry completely.
    • Reassemble.
18. Check water pump filter every 10 hours.
    • Open filter housing.
    • Remove element.
    • Wipe inside of housing.
    • Inspect element for damage or wear.
19. Check hydraulic fluid every 10 hours.
    • Check level at sight glass.
    • Use provided tool to open fill.
    • Add THF at fill as needed to keep level at halfway point on sight glass.
20. Check hydraulic hoses for leaks before startup and every 10 hours.
21. Check lance spray nozzle every 10 hour to ensure water sprays in a rotary pattern. Clean or change as needed.
22. Check blower oil every 10 hours.
    • Check level at sight glass.
    • Add SGL at fill as needed to keep level at halfway point on sight glass.
23. Check engine oil every 10 hours.
    • While oil is warm, check level at dipstick.
    • Add DEO at fill as needed to keep level at highest line on dipstick.
24. Check water pump oil every 10 hours.
    • Check level at fill.
    • Add NDO at fill as needed to keep level at halfway point on dipstick.
25. Drain fluids from Power Pack Base as needed.
26. If reverse flow 4-way valve becomes difficult or impossible to engage, lube zerks on each side of valve with two pumps of MPG at each zerk.
    • If reverse flow is difficult or impossible to engage after lube, adjust valve.
      • Loosen nut.
      • Adjust bolt until desired operation is achieved.
        NOTE: Tightening bolt loosens valve.
      • Hold bolt and tighten nut to prevent further adjustment.
27. Exercise reverse flow relief valve before startup.
    • Pull handle, rotate back and forth, and release.
    • Ensure vents on valve are free of mud and other restrictions.
28. Check strobe light every 10 hours. Strobe light should flash. Change as needed.
29. Check weight gauge set screws for tightness before startup. Adjust gauge any time gauge face is loose, new options are installed on machine, or base trailer load otherwise changes.
    • Empty water and debris tanks.
    • Weight trailer.
    • Note empty trailer weight.
    • Raise tank until back lip of make/break seal tube is visible inside gauge window.
      NOTE: Tank must be lowered into position for weight reading to be accurate. If tank is not lowered into position, tank tilt cylinders will not be bearing full weight of tank.
    • Loosen set screws on gauge face, and rotate gauge until arrow points at empty trailer weight. For example, if empty trailer weights 10,000 pounds, rotate gauge until arrow indicates “10”.
    • With gauge arrow properly oriented, tighten gauge set screws to fix gauge in place.
      NOTE: Apply blue Loctite 24221 to set screws.
    • Fully lower tank.
30. Check hitch bolt torque before startup.
31. Check all lights and reflectors for correct operation and cleanliness before startup.
32. Check tire pressure and lug nut torque before startup.
33. Lube Extension shaft boom with MPS every 50 hours. Extend boom shaft fully from housing to lube.
34. Lube pivot boom three zerks with MPG every 50 hours.

FX30 and FXT30

FX50 and FXT50

FX60 and FXT60

FX65

HX30

HX50

(Performed by Authorized Personnel Only)

Manufacturer: TBD
Model: TBD

Potential Energy Hazards	Method of Neutralizing Energy	Permits Required
Electric  Air	LOTO  Disconnect lines	Safe work
Pneumatic  Gravity	Block/bleed  Release pressure	Hot work
Mechanical  Gas	Set fire watch  Confined space permit	Line blanking
Hydraulic  Water		Confined space

Lockout (Shut-Down Procedure)

1. Turn off engine and place the stop switch in the STOP Position.

Civil tool request form

Equipment Repair/Damage Reporting Form