Giant-Vac 65hp Series User manual

ASSEMBLYINSTRUCTIONS
SAFETYRULES
PARTSLIST
65hpseries
TruckLoader
Actual product may differ from product pictured above
Model No. Description
3800014 TL652951W
Manual No. 3100022
Revision: - 03/01/07
Not for
Reproduction

Manual No. 3100022
1 preliminaries
Congratulations!
You have just purchased one of the finest pieces of outdoor power equipment on the market today. If
properly cared for, your new truck loader will provide years of dependable service. Please read and follow
this instruction manual carefully in order to get the most out of your new equipment.
As you carefully uncrate your unit, you will find the following items:
1 Power Unit
1Discharge Stack &Elbow Assembly
1 12” x 6’ Metal Discharge Hose (standard units)
1 18” x 8’ Intake Hose (standard units)
1 Horizontal Hose Support Boom Member
1 Parts Accessory Kit including:
1 – 18” Intake Nozzle
4 – 18” Hose Clamps
1 – Hose Support Boom Horizontal Member
1 – 12” Squeeze Ring
1 – Package of assembly hardware
1 – Package containing operating manuals and warranty registration
Each product leaves our factory in excellent condition; occasionally, however, some damage may occur
during shipment. If any such damage is found upon initial inspection, immediately notify the transport
carrier who delivered your machine, as they are solely responsible for such damage, as well as any
subsequent adjustments necessary.
Before assembly, please take a moment and record your model number and serial number below for future
reference (both numbers are located on the silver tag adhered to the engine side of the impeller housing
assembly):
Model number_______________________________
Serial number________________________________
Also be sure to promptly fill out and return the warranty registration enclosed in your manual packet.
Your new loader requires very little assembly. Simply follow the instructions contained within this manual
to begin enjoying the benefits of your new unit.
CALIFORNIA PROPOSITION 65 WARNING
Gasoline and Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and
other reproductive harm.
As an owner of off-road gasoline or diesel engine equipment and/or as an employer, you also may have an obligation under the California
Occupational Safety and Health Act or under Proposition 65 to warn persons exposed to gas and diesel engine exhaust and/or other
Proposition 65 chemicals in and around your workplace. See California Health and Safety Code section 25249.5, Title 22 of the California
Code of Regulations at Section 1200 er seq., and Title 8 of the California Code of Regulations Section 5194.
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Manual No. 3100022
2 safetyrulesregardingoutdoorpowerequipment
PLEASE READ THE FOLLOWING BEFORE ASSEMBLING OR OPERATING UNIT
TRAINING
• Read, understand, and follow all instructions in the
manual and on the unit before starting. If the
operator(s) or mechanic(s) cannot read English it is
the owner’s responsibility to explain this material to
them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
• Only allow responsible adults, who are familiar
with the instructions, to operate the unit.
• Never let children or untrained people operate or
service the equipment. Local regulations may
restrict the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to themselves, other
people or property.
PREPARATION
• Evaluate the terrain to determine what
accessories and attachments are needed to
properly and safely perform the job. Use only
accessories and attachments approved by the
manufacturer.
• Wear appropriate clothing including safety shoes,
safety glasses and ear protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
• Inspect the area where the equipment is to be
used and remove rocks or any other such objects
which can damage the machine or the receiver box.
• Use extra care when handling gasoline and other
fuels. They are flammable and vapors are
explosive.
a) Use only an approved container.
b) Never remove fuel cap or add fuel with the
engine running. Allow engine to cool before
refueling. Do not smoke.
c) Never refuel or drain the machine indoors.
• Check that operator’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
OPERATION
• Never run an engine in an enclosed area.
• Operate only in the daylight or with good artificial
light, keeping away from holes and hidden hazards.
• Be sure all components are securely in place and
in good operating order before starting engine.
• Be sure of your footing while using equipment,
especially when backing up. Walk, don’t run.
• Do not operate the unit without discharge
connected to a debris receiver box.
• Slow down and use caution when making turns
and when changing directions on slopes.
• Never leave a running unit unattended. Always
stop engine, and remove keys before leaving unit.
• Never operate without guards securely in place.
Be sure all safety features are attached, adjusted
properly and functioning properly.
• Never operate with intake or discharge
components loose, removed or altered.
• Do not change the engine governor setting or over
speed the engine.
• Stop on level ground, shut off engine before
leaving the operator’s position for any reason
including emptying the receiver box or unclogging
the intake or discharge.
• Stop equipment and inspect impeller blades after
picking up unusually large or hard objects or
abnormal vibration occurs. Make necessary repairs
before resuming operations.
• Keep hands and feet away from the intake and
discharge.
• Never carry passengers and keep pets and
bystanders away.
• Do not operate the unit while under the influence
of alcohol or drugs.
• Slow down and use caution when making turns
and crossing roads and sidewalks.
• Use care when hooking or unhooking the machine
to a towing vehicle.
• Use care when approaching blind corners, shrubs,
trees or other objects that may obscure vision.
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Manual No. 3100022
2 safetyrulesregardingoutdoorpowerequipment(cont.)
SLOPE OPERATION
Slopes are a major factor related to loss-of-control
and tip-over accidents, which can result in severe
injury or death. All slopes require extra caution. If
you cannot back up the slope, or if you feel uneasy
on it, do not operate on it.
Do
• Remove obstacles such as rocks, tree limbs, etc.
• Watch for holes, ruts, or bumps. Uneven terrain
could overturn the unit. Tall grass can hide
obstacles.
• Use slow speed.
• Keep all movement on the slopes slow and
gradual. Do not make sudden changes in speed or
direction.
Do Not
• Do not start or stop on a slope. If tires lose
traction, stop the unit and proceed slowly straight
down the slope.
• Do not turn on slopes unless necessary, and then,
turn slowly and gradually downhill, if possible.
• Do not operate near drop-offs, ditches, or
embankments. The operator could lose footing or
balance or unit could suddenly turn over if a wheel
is over the edge of a cliff or ditch, or if an edge
caves in.
CHILDREN
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the unit and its activity. Never assume
that children will remain where you last saw them.
• Keep children out of the operating area and under
the watchful care of another responsible adult.
• Be alert and turn unit off if children enter the area.
• Before and during reverse operation, look behind
and down for small children.
• Never carry children. They may fall off and be
seriously injured or interfere with safe unit
operation.
• Never allow children to operate the unit.
• Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
EMISSIONS
• Engine exhaust from this product contains
chemicals known, in certain quantities, to cause
cancer, birth defects, or other reproductive harm.
• Look for the relevant Emissions Durability Period
and Air Index information on the engine emissions
label.
MAINTENANCE AND STORAGE
• Always observe safe refueling and fuel handling
practices when refueling the unit after
transportation or storage.
• Always follow the engine manual instructions for
storage preparations before storing the unit for both
short and long term periods.
• Always follow the engine manual instructions for
proper start-up procedures when returning the unit
to service.
• Never store the machine or fuel container inside
where there is an open flame, such as in a water
heater. Allow unit to cool before storing.
• Shut off fuel while storing or transporting. Do not
store fuel near flames or drain indoors.
• Keep all hardware, especially impeller bolt, tight
and keep all parts in good working condition.
Replace all worn or damaged decals.
• Never tamper with safety devices. Check their
proper operation regularly.
• Clean debris from units, drives, mufflers, and
engine to prevent fires. Clean up oil or fuel spillage.
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
• Never make adjustments or repairs with the
engine running unless specified otherwise.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use jack stands to support components when
required.
• Carefully release pressure from components with
stored energy. (e.g. springs)
• Check impeller on a regular basis for bent, worn
or cracked blades. Only replace impellers; never
straighten or weld them.
• Keep hands and feet away from moving parts.
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2 safetyrulesregardingoutdoorpowerequipment(cont.)
• Belts and belt guard components are subject to
wear, damage, and deterioration, which could
expose moving parts or allow objects to be thrown.
Frequently check components and replace with
manufacturer’s recommended parts, when
necessary.
• Check operation of brake, tail and license lights
frequently. replace as required.
• Use only factory authorized replacement parts
when making repairs.
• Always comply with factory specifications on all
settings and adjustments.
• Only authorized service locations should be
utilized for major service and repair requirements.
• Never attempt to make major repairs on this unit
unless you have been properly trained. Improper
service procedures can result in hazardous
operation, equipment damage and voiding of
manufacturer’s warranty.
3 unitassembly&set-up
Note: Please refer to Parts List for correct part identification and placement. Parts list reference numbers
are called out by sheet number followed by reference number(s) on that sheet: (1:1) indicates Sheet 1,
reference number 1; (2:32,34-38) indicates Sheet 2, reference numbers 32 through 38 excluding 33; etc.
Important Safety Note: To prevent unit rollover during assembly and set up, lock
rear support leg in lowermost position possible. Failure to do this may result in
injury or death and/or damage to unit or property.
Manual No. 3100022
DISCHARGE ASSEMBLY
Safety Note: Assistance is required when installing discharge stack. If access to lifting
equipment is possible, it is highly recommended.
•Place stack & elbow assembly (3:1) atop
power unit, with discharge directed toward
towing hitch. Insert twelve 1/2-13 x 1-3/4”
hex bolts (3:2), each fitted with one flat
washer (3:3), through bolt flange holes,
securing with flat washers, lock washers and
nuts (3:3-5). Tighten securely.
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3 unitassembly&set-up(cont.)
•Slip one end of metal discharge hose (3:6)
onto barrel of discharge stack.
•Secure hose in place with squeeze ring (3:7),
tightening all bolts securely enough to dimple
hose against barrel of stack and thereby
prevent slippage of hose on stack assembly.
INTAKE ASSEMBLY
•Slip two hose clamps (2:9) onto one end of
intake hose (2:8), then slip end of hose onto
intake flange barrel (2:5), located in front of
impeller housing. Tighten clamps securely.
•Slip Hose support band (2:10) about halfway
up the length of the hose, with eye clip
facing up.
•Slip two hose clamps onto free end of intake
hose, followed by Intake Nozzle (2:11) with
handle pointed upwards and toward hose.
Tighten clamps securely.
HOSE SUPPORT BOOM ASSEMBLY
•Attach yoke end of Threaded spring guide
(5:5) to second thru hole of horizontal boom
member (5:2) with one 1/2-13 x 3” hex bolt
(5:3), securing with 1/2-13 lock nut (5:4).
Do not over tighten lock nut. Note: Be sure
spring guide and chain eye at end of boom
are both toward bottom of boom member.
•Attach horizontal boom member to vertical
boom member (5:1) with one 1/2-13 x 3”
hex bolt, securing with 1/2-13 lock nut. Do
not over tighten lock nut. Be sure spring
guide is toward base of vertical boom
member.
•Remove 3/4” hex nut and flat washer (5:6-7)
from bottom of threaded spring guide. Slip
thread down through hole in base of vertical
boom member, securing with same hardware
as previously removed.
Manual No. 3100022
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3 unitassembly&set-up(cont.)
HOSE SUPPORT BOOM ASSEMBLY (cont.)
•Lift assembly and install into boom pivot
brackets on discharge stack, first slipping top
portion of vertical boom member into top
bracket on stack, then dropping bottom
portion into bottom bracket.
1
2
•Catch S-hook on one end of boom support
chain (5:9) into chain eye at end of horizontal
boom member.
•Slip other end of chain through eye clip atop
hose support band, then adjust chain length
between hose and boom to about three feet
(3/4 of total length) by slipping S-hook on
end of chain through appropriate mid-link.
Manual No. 3100022
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3 unitassembly&set-up(cont.)
DEBRIS BOX CONSTRUCTION
WARNING: This unit is designed to be used in conjunction with a debris collection
box. NEVER run or operate your Truck Loader without a debris box.
Below are directions for constructing a simple, sturdy debris box for use in a standard pickup
bed:
•Cut four pieces of 3” angle iron to the inside length of the truck bed, four pieces to the inside width,
then four pieces that measure from the truck bed floor to approximately 8” higher than the top of the
unit discharge when the unit is connected to the truck. Either weld or securely bolt the box frame
together.
•Line the inside front and sides with 3/4” exterior grade plywood.
•Cover the top of the frame with a heavy-duty mesh screening to allow for adequate ventilation.
•Cut a plywood door the width and height of the box frame. Install a heavy-duty hinge at the top of
the door and fasten it to the rear of the box frame. Install latches or other locking mechanisms
between the lower sides of the door and the box sides to keep the door from opening inadvertently.
•Mark the location on the door where the unit discharge meets the box, then cut a 16” diameter hole in
the door at that location. Install a rubber gasket around the hole to prevent debris blow-by – an old
13” or 14” inner tube works fine.
CONNECTING UNIT TO TOWING VEHICLE
•Install appropriate trailer plug onto end of unit wiring harness to match socket on towing vehicle.
Wiring scheme is as follows:
Red – Right signal
Yellow – Left signal
Brown – Taillights
Green – Ground
•Raise or lower support jack until unit sits level with ground. Back towing vehicle up to draw bar, then
visually check draw bar for proper height alignment with hitch receiver on vehicle. Raise or lower
draw bar if needed by relocating in any of the remaining sets of height adjustment holes.
•With assistance behind, back up slowly, aligning both draw bar with hitch receiver and discharge hose
with receiver box opening.
•Lock pintle ring in hitch receiver, connect safety chains to vehicle in a criss-cross fashion to cradle
draw bar in case of accidental disconnect, then connect wiring harness plug into trailer socket of
vehicle.
•Lift rear support leg and pin in uppermost position.
Note: To prevent possible rollover, lock rear support leg in lowermost position
possible when unit is parked or disconnected from towing vehicle.
Manual No. 3100022
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Your unit is now ready to be started and checked for proper operation. See your engine manual
for proper engine prep and operation.
4 unitoperation
GENERAL GUIDELINES TO OBSERVE DURING OPERATION
•Never allow a person to ride, sit or stand on the unit. Never allow a person to ride, sit or
stand on the towing vehicle other than in the driver’s cab of the towing vehicle.
•Make sure that the driver of the towing vehicle has the operator of the unit in full view at
all times. Also, when operating the unit, instruct the operator to stay to the side of the
machine, never in front or behind.
•Collecting debris into piles for the machine to intercept prior to startup will save time and
fuel as well as wear and tear on the unit.
•We recommend the following for the most efficient performance: if debris is very dry, run
the machine at approximately half throttle; this will help reduce the amount of small
particles of debris escaping through the ventilation screen. If debris is wet or partially
frozen, run the machine at full throttle.
•Lower intake hose boom assembly until nozzle floats 2-3 inches from the ground, then
adjust engine throttle so that when nozzle is pushed to the ground, suction can be broken
with moderate effort using three fingers of one hand. This will make operation relatively
easy and comfortable.
•Time and experience will be your best guide in finding the most efficient performance
from your unit.
UNCOUPLING UNIT FROM TOWING VEHICLE
•Disconnect taillight/brakelight plug from towing vehicle receiver.
•Unhook safety chains from rear of towing vehicle.
•Crank down wheel jack until unit weight is lifted from towing vehicle.
•Drop rear support leg to lowermost position and secure with clevis and bridge pin. Note:
Failure to follow this step can result in unit rollover and serious personal injury and unit
damage.
•Open pintle receiver latch on towing vehicle, determine if pintle ring on unit will clear
pintle receiver on vehicle (crank down wheel jack an additional turn or two if not), and
pull vehicle away.
Manual No. 3100022
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5 unitmaintenance
GENERAL MAINTENANCE
NOTE: Some maintenance services, such as engine repairs, electrical repairs, etc., should be
performed only by a qualified technician.
•Check overall condition of unit prior to each use, repairing or replacing worn, damaged or
missing components promptly. Check all fasteners regularly and tighten if necessary.
•Follow engine manufacturer’s recommendations for maintenance schedules. Use only
recommended parts, fluids and lubricants. Failure to follow manufacturer’s
recommendations may void manufacturer’s warranties.
•Lubricate impeller shaft bearings every 50 hours of operation. Use a high quality bearing
grease, available from your local dealer (or auto parts store).
•Maintain tire pressure as indicated on tire sidewall. Replace worn or damaged tires
promptly.
•Keep engine free from a buildup of grass, leaves or excessive grease. An accumulation of
these combustible materials may result in a fire, or simply impede performance.
•Never change attachments or make any adjustments, repairs or replacements until the
unit is completely shut down and the battery is disconnected.
Manual No. 3100022
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5 unitmaintenance(cont.)
STORAGE
•Keep the unit in locked storage to prevent unauthorized individuals, especially children,
from playing and/or tampering with the unit.
•When storing the unit for prolonged periods, it is recommended to disconnect the battery.
•Store fuel in an approved, clearly marked container.
•NO NOT store gasoline powered equipment or fuel containers in any closed area where
heat-radiating appliances or open pilot lights are present, unless the fuel has been
completely drained from the power equipment and the fuel containers.
REPLACEMENT PARTS
Replacement parts are available from your local Giant-Vac dealer.
Manual No. 3100022
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17
thru engine base
7
15
16
14
GIANT-VAC, INC.
Model 6001/6001CHW
Sheet 1 of 5
Engine Group
R0603.1
13
8
18
21
22
20
19 5
3
6
4
10
11
12
9
2
1
Trailer Frame present
on CHW models only
Fenders present on
CHW models only
Manual No. 3100022
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Giant-Vac Model TL652951W Truck Loader
SHEET 1 - ENGINE GROUP
REF # PART # DESCRIPTION QTY
1 10187 Loader base – skid mount model 1
1 10188 Loader base and trailer frame – CHW model 1
2 39023 65 HP Wisconsin engine 1
3 31824 5/8-11 x 2-1/2 hex bolt (engine mount bolt) 4
4 31326 5/8 lock washer 4
5 31489 5/8 flat washer 4
6 31825 5/8-11 nut plate 4
7 40103 Fuel tank 1
--- 31828 Brass fuel tank fitting – 1/4” IPT to 1/4” Farrell 1
--- 31830 Fuel tank plug – 3/8” IPT 2
--- 31753 1/4” copper fuel line – 10-1/4” length- into tank 1
--- 31753 1/4” copper fuel line – 32” length – into engine 1
--- 31827 Brass fitting – 90 degree – 1/8” IPT to 1/4” Farrell 1
--- 31755 1/4” rubber fuel line – 4” length 2
--- 27343 Fuel filter 1
--- 34041 1/2” hose clamp 4
8 40114 Fuel cap 1
9 40123 Fuel tank strap 2
10 31043 1/2” flat washer 4
11 31078 1/2” lock washer 4
12 31022 1/2” hex nut 4
13 31128 Impeller key 1
14 21519 Impeller 1
15 31328 5/8-11 x 2-1/2” impeller bolt 1
16 31326 5/8” lock washer 1
17 40100 Battery box 1
18 31763 Battery cable, ground – 16S 2
--- 31839 Cover, battery terminal - black 1
--- 31838 Cover, battery terminal – red 1
19 31097 3/8 x 1-1/4” hex bolt (bolts battery box to base) 2
20 31008 3/8” lock washer 2
21 31034 3/8” flat washer 2
22 39021 Battery 1
Manual No. 3100022
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Manual No. 3100022
7
6
See Engine Group
1
9
5
2
11 4
3
910 8
GIANT-VAC, INC.
Model 6001/6001CHW
Sheet 2 of 5
Intake Group
R0603.1
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Giant-Vac Model TL652951W Truck Loader
REF # PART # DESCRIPTION QTY
SHEET 2 - INTAKE GROUP
1 10179 Housing, impeller – complete with liner kit below 1
--- 70832 Liner, 2-pc replaceable wear – with hardware 1
2 31084 Bolt, hex - 1/2-13 x 1-1/4" 18
3 31078 Washer, lock - 1/2" 18
4 31022 Nut, hex - 1/2-13 18
5 20160 Flange, intake, 18” straight (skid version) 1
5 34059 Flange, intake, 18” 90 degree (CHW version) 1
6 31078 Washer, lock - 1/2 16
7 31022 Nut, hex - 1/2-13 16
8 34023 Hose, intake - 18" x 8' 1
9 34025 Clamp, hose - 18" 4
10 40112 Band, hose support – 18” – with hardware * 1
--- * 31141 Bolt, hex – 5/16-18 x 3-1/2” (support band hardware) 1
--- * 31004 Nut, hex - 5/16-18 2
11 20158 Nozzle, intake - 18" 1
Manual No. 3100022
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Manual No. 3100022
See Engine Group
3
5
4
61
7
3
2
GIANT-VAC, INC.
Model 6001/6001CHW
Sheet 3 of 5
Discharge Group
R0603.1
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Giant-Vac Model TL652951W Truck Loader
REF # PART # DESCRIPTION QTY
SHEET 3 - DISCHARGE GROUP
1 24624 Stack and elbow assy 1
2 31086 Bolt, hex - 1/2-13 x 1-3/4" 12
3 31043 Washer, flat - 1/2 24
4 31078 Washer, lock - 1/2" 12
5 31022 Nut, hex - 1/2-13 12
6 34026 Hose, discharge - 12" x 6' metal 1
7 34049 Ring, squeeze - 12" 1
Manual No. 3100022
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Manual No. 3100022
GIANT-VAC, INC.
Model 6001/6001CHW
Sheet 4 of 5
Trailer Group
R0603.1
18 19
15
13
12
11
10
14
15a
17
16
15a
thru
25 22
20
5
4
30 29
24 21
23
7
9
83
7
62
26
28
See Engine Group
27
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Giant-Vac Model TL652951W Truck Loader
SHEET 4 - TRAILER GROUP (CHW version only)
REF # PART # DESCRIPTION QTY
1 ----- Loader base and trailer frame (see engine group) ---
2 38004 Draw bar 1
3 31084 Bolt, hex - 1/2-13 x 1-1/4” 4
4 31078 Washer, lock - 1/2 4
5 31406 Nut, reverse lock - 1/2-13 4
6 31821 Bolt, hex - 1/2-13 x 7” 1
7 31043 Washer, flat - 1/2 4
8 31641 Chain, safety towing 2
9 31406 Nut, lock - 1/2-13 1
10 33173 Jack, dual wheel support 1
11 31033 Bolt, hex - 3/8-16 x 1" 4
12 31008 Washer, lock - 3/8 4
13 31009 Nut, lock - 3/8-16 4
14 33297 Axle, Torflex 1
15 32154 Bolt, hex, black oxide, 1/2-13 x 1-1/4 gr 5 4
15a 32155 Washer, flat, 1/2” 8
16 31078 Washer, lock - 1/2" 4
17 32156 Nut, hex end lock – 1/2-13 4
18 33051 Tire and wheel assy 2
19 31148 Lug nut 10
20 40105 Leg, support 1
21 31125 Pin, clevis - 3/8 x 4-1/2" 1
22 31126 Pin, bridge 1
23 31639 Light, tail/stop assy 2
24 31831 Harness, wiring 1
--- 31644 Clip, wiring harness, slip-on – large 10
--- 32012 Clip, wiring harness, bolt-on – 3/8” nom 2
--- 31562 Screw, self-tapping - #12 x 3/4 (secures bolt-on clips to frame) 2
25 32090 Screw, self-tapping - #10 x 1/2 (taillight ground) 2
26 31752 Bracket, license 1
27 31751 Light, license 1
28 31444 Bolt, hex - 1/4-20 x 1 – bolts license light assy to frame 2
--- 31013 Washer, lock - 1/4" 2
--- 31030 Nut, hex - 1/4-20 2
29 31125 Pin, clevis - 3/8 x 4-1/2" 1
30 31126 Pin, bridge 1
Manual No. 3100022
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Manual No. 3100022
1
3
6
7
8
76
45
4
3
2
9
GIANT-VAC, INC.
Model 6001/6001CHW
Sheet 5 of 5
Hose Support Boom Group
R0603.1
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