Hog Technologies HT500 User manual

Operations
Manual

2

3
WELCOME
We would like to extend to you our “Thank You”
for choosing a Hog Technologies Product!
Please take the time to read this operations manu-
al before attempting to operate your Waterblasting
system. This manual is an important aid in the
operation and maintenance of your new equip-
ment. The information is intended as a guide and
cannot cover every question you may have about
your equipment and every operating situation.
We encourage you to contact Hog Technologies
for any additional information you might need.
We provide rst class support to our customers
for all of the equipment we sell. Additionally, we
maintain a well stocked inventory of parts and
accessories in addition to technical sta with the
experience to satisfy all of your support ques-
tions. Please contact us for all of your support
issues and questions toll-free at [phone]
and on-line at www.hogtechnologies.com or www.
stripehogsupport.com.
Safety
High pressure, waterblasting equipment can cause
serious injury or even death if it is not operated or
maintained properly. Your manual has been writ-
ten to include a number of safety instructions to
assure the safe operation and maintenance of your
equipment. These instructions are in the form
of a General Safety Section as well as individual
DANGER, WARNING and CAUTION statements.
There are also CAUTION, WARNING AND DAN-
GER LABELS located on some components. You
should read these warnings carefully and make
sure you understand the nature of the hazard and
the precautions and recommended procedures
required to ensure your safety.
Major Component Operation Manuals
The suppliers of some of the major components
such as the engine and hydraulic pump, provide
their own owner’s manuals which have been in-
cluded with your equipment. You should read
the information in this manual and the manuals
of other suppliers completely and have a thor-
ough understanding of all component systems
and their proper operation before operating your
equipment.
REMEMBER - IT IS YOUR RESPONSIBILITY TO ENSURE THAT
YOUR EqUIPMENT IS SAFE FOR YOU AND YOUR cREw.
ALwAYS EXERcISE GOOD cOMMON SENSE wHEN INSTALLING
OR REPAIRING EqUIPMENT AND wHILE OPERATING
wATERBLASTING EqUIPMENT.
Warranty
The Hog Technologies Limited Warranty Statement
is included with this manual. It has been written
to be clearly stated and easily understood. If you
have any questions after reading the warranty,
please contact the Customer Service Department.
Hog Technologies, engine manufacturers, and the
suppliers of major components maintain their own
manufacturer’s warranty and service facilities.
Hog Technologies automatically validates your
warranty at the time of purchase and does not
require a warranty registration card. However,
the manufacturers of some major components
require a completed warranty registration card to
validate their warranty. It is important that you
properly complete any warranty registration cards
included with your equipment and mail them back
to the manufacturer to register your ownership.
This should be done within 15 days of the date of
purchase and before the unit is put into service.
Gasoline is Highly Flammable Warning on Engine

4
IMPORTANT:
The terms and conditions of the Hog Technologies
Limited Warranty are outlined in the warranty
statement included with this manual. The manu-
facturer will automatically honor the warranty to
the original purchaser for 15 days from the date
of purchase. However, during that 15 day period,
owners must comply with the steps outlined in
the warranty statement to validate their warranty.
All manufacturers are required by the US Govern-
ment to notify rst time owners in the event any
defect is discovered “which creates a substantial
risk of personal injury to the public.” It is essen-
tial that we have your warranty registration
card complete with your name and mailing
address in our les so that we can comply
with the law if it should become necessary.
Hog Technologies Customer Service will assist you
in lling in the serials numbers and other data re-
quired on your registration card if you experience
diculty. Your Warranty Registration Card will be
added to our permanent les.
Product Changes
Hog Technologies is committed to the continuous
improvement of our products. As a result, some
of the equipment described in this manual or
pictured in the catalog may change or no longer
be available.
WELCOME
All information, illustrations, and specica-
tions contained in this manual are based on
the latest product information available at
the time of publication. Hog Technologies
reserves the right to make changes at any-
time, without notice, in colors, materials,
equipment, specications, and models.
If you have questions about the equipment on your
Stripe Hog, please contact the Customer Service
Department.
Service
All warranty repairs must be authorized by Hog
Technologies Should a problem develop that is
related to faulty workmanship or materials, as
stated in the Limited Warranty, you should contact
our Customer Service Department to arrange for
assistance and prior approval for the necessary
repair. It is the owner’s responsibility to con-
tact Customer Service for prior authorization
for warranty service.

5
WARNING
INcORREcT USE OF HIGH PRESSURE wATERBLASTING EqUIPMENT MAY cAUSE
SERIOUS INjURY OR EVEN DEATH.
DO NOT USE THIS EqUIPMENT wITHOUT PROPER SUPERVISION AND TRAINING.
ALL OPERATING AND MAINTENANcE PERSONNEL MUST BE THOROUGHLY TRAINED
IN SAFE OPERATION, INSTALLATION AND MAINTENANcE OF THIS EqUIPMENT, AND
PROVIDED wITH ADEqUATE SUPERVISION.
BEFORE ATTEMPTING TO cONNEcT, OPERATE, OR REPAIR THIS EqUIPMENT,
THOROUGHLY READ THESE INSTRUcTIONS AND ANY SAFETY wARNING OR
INSTRUcTION PAMPHLETS INcLUDED wITH YOUR SHIPMENT.
FOR ANY qUESTIONS cONcERNING SAFE OPERATIONS AND MAINTENANcE
PROcEDURES, cONTAcT YOUR HOG TEcHNOLOGIES REPRESENTATIVE PRIOR TO
USE.
[phone] OR [phone]
HOG TEcHNOLOGIES
www.HOGTEcHNOLOGIES.cOM

6
SAFETY WARNINGS AND INSTRUCTIONS
DANGER
WARNING
CAUTION
This manual has been written to include a number of safety instructions to assure the safe assembly,
operation and maintenance of your Hog Technologies Equipment. These instructions are in the form
of DANGER, WARNING, and CAUTION statements. The following denitions apply:
All instructions given in this book are as seen from the rear looking forward. Common industry ter-
minology is used throughout the manual.
IMPORTANT NOTE: Your Waterblasting equipment uses internal combustion engines and am-
mable fuel. Every precaution has been taken by Hog Technologies to reduce the risks associated with
possible injury and damage from re or explosion, but your own precaution and good maintenance
procedures are necessary to ensure the safe operation of your equipment.
HAZARDS OR UNSAFE PRAcTIcES wHIcH cOULD RESULT
IN MINOR PERSONAL INjURY OR PRODUcT AND PROPERTY
DAMAGE.
HAZARDS OR UNSAFE PRAcTIcES wHIcH cOULD RESULT
IN SEVERE PERSONAL INjURY OR DEATH.
MMEDIATE HAZARDS wHIcH wILL RESULT IN SEVERE
PERSONAL INjURY OR DEATH.

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TABLE OF CONTENTS
WELCOME ......................................................................................................................... 3
SAFETY WARNINGS AND INSTRUCTIONS............................................................................... 6
TABLE OF CONTENTS .......................................................................................................... 7
Section 1:
Safety Information
1.1 General Safety............................................................................................................. 9
1.2 Blasting and Personal Safety.........................................................................................10
1.3 Blasting Tool Nozzle Safety...........................................................................................12
1.4 Hose Safety ...............................................................................................................13
1.5 High Pressure Fitting Safety..........................................................................................13
Section 2:
HT500 Systems
2.1 Hydraulic Power System...............................................................................................15
2.2 Engine ......................................................................................................................16
2.3 Engine Fuel System.....................................................................................................17
2.4 12-Volt DC Electrical System.........................................................................................19
2.5 Hydraulic System........................................................................................................21
2.6 Hydraulic, UHP Hoses & Electrical Cables........................................................................28
Section 4:
Hog Technologies Tools
4.1 Hog Tools (Optional)....................................................................................................31
4.2 Hog Tool Waterblast Systems........................................................................................32
4.3 HT100 Hand Hog Blasting Guns.....................................................................................32
4.4 HT1000 Ground Hog and HT1100..................................................................................32
Section 5:
Waterblasting Operations
5.1 Equipment Setup ........................................................................................................33
5.2 Emergency Shutdown..................................................................................................34
5.3 HT500 Hog Pack Routine Start Up/Shutdown ..................................................................34
5.4 Hog Pack Operating Guidelines......................................................................................35
5.5 Operating in Freezing Conditions...................................................................................36
Section 6:
General Maintenance
6.1 Lubrication Points & Grease Fittings...............................................................................37
6.2 Engine ......................................................................................................................38
6.3 Fuel System ...............................................................................................................38
6.4 Electrical System ........................................................................................................40
6.5 High Pressure Blasting System .....................................................................................40
6.6 Hydraulic System Maintenance......................................................................................41
6.7 Lubrication Chart .......................................................................................................42

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TABLE OF CONTENTS
Section 7:
Components and Drawings
7.1 Hydraulic Manifold Flow Diagram...................................................................................43
Appendix A:
Troubleshooting Guide........................................................................................................45
Appendix B:
HT500 Specications..........................................................................................................47
Appendix C:
Hog Technologies Resources................................................................................................49
Stripe Hog Support Web Page .............................................................................................50

9
Section 1:
Safety Information
1.1 General Safety
Use Safety Training
Only trained personnel should be allowed to setup,
operate, or maintain this equipment. Water blast
operators should be made aware that the water
jet nozzles can cause serious bodily injury. Train-
ing supervisors should demonstrate the powerful
potential damage of the nozzles by showing new
trainees the eect of water jets cutting a piece
of 2 x 4 wood.
Check Water Supply
Use only clean water in any ultra high pressure
system. DO NOT accept water drawn from reten-
tion ponds, canals or other non-potable sources.
Work Area Safety
Remember, safety is rst! Only set up to work
in areas properly protected from trac and other
hazards. Always barricade the work area and post
signs warning personnel of the hazards associated
with high pressure waterblasting operations.
Outt all operators with proper safety apparel.
Steel toed, non-skid boots, hard hats with safety
shields or safety glasses, gloves, ear protection,
etc.
Most ultra high pressure waterblasting opera-
tions generate noise levels above 90 db. Hearing
protection is required in accordance with OSHA
standards.
Use Only Products Intended for High
Pressure Waterblasting Use
Know the pressure ratings of all equipment being
used and never exceed any operating pressure
higher than the rating of the weakest component.
This system is designed to work with pressures
up to but not exceeding 40,000 PSI (2,758 Bar).
Never Alter a Hog Technologies Product
Do not alter any product without written consent
from the manufacturer. Any alterations could
have serious consequences including bodily harm
or death.
Always Read Instructions
Read and follow all the manufacturer’s instructions
prior to using any Hog Technologies product. Con-
tact Hog Technologies should any questions arise.
Inspect Equipment
Inspect the condition of all components prior to
use. Do not use any item that is in questionable
condition. Use only components which are marked
with the recommended operating pressure. Never
exceed the operating pressure of the weakest
component in the system.
Check Connections
Check the condition of the connection threads prior
to connecting any ttings or hoses. Use an Anti-
seize compound on all ttings and hoses to pre-
vent “galling,” as galling will destroy the threads
and essentially the ttings and/or hose ends.
Tighten Connections
Properly tighten all high pressure connections.
Usually, snug plus a 15% tightening will properly
seal connections.
Purge System
Before attaching accessories to the high pressure
hoses, engage pump at low speed to purge the
system. Any dirt or debris in the system can clog
nozzle orice’s and cause system pressure to spike
excessively causing damage to components.
Test System
With the Waterblasting tools properly attached and
equipped with proper high cohesive nozzles, oper-
ate the pump at low pressure to check for nozzle
accuracy and leaks on spray bar, spray head, spray
bar or nozzles. Should any repairs or adjustments
be necessary, disengage the pump and shutdown
all engines to relieve all pressure before making
any required repairs or adjustments.
Set System Pressure
With system operating properly, set your pressure
according to methods described by pump manu-
facturers instructions. Refer to the pump oper-
ating manual for specications and instructions.
Use the Minimum Pressure Required
Do not exceed the operating pressure of the
system’s lowest pressure-rated component. All
equipment pressure rating and warning tags
should be left intact.
Be Prepared
If the equipment malfunctions or a malfunction is
suspected, immediately stop all blasting activity,

10
Safety Information
WARNING
WARNING
relieve the pressure and shutdown all engines in
the system before attempting any repair. Always
follow manufacturer’s repair instructions.
NOTICE:
Use Only Thoroughly Trained Personnel to
Perform Maintenance or Repairs.
Low Pressure Test
Following repairs, operate the system at low pres-
sure for a test. Bring equipment up to operating
pressure slowly.
Freezing Conditions
System hoses and spray head assemblies should
be drained of all water or lled with an anti-
freeze solution. Refer to pump manufacturer’s
procedures for maintaining equipment in freezing
climates. If you do decide to operate at freez-
ing temperatures or even temperatures below 60
degrees Fahrenheit, you will need to run the Hog
Pack hydraulic system at IDLE speed only until the
hydraulic oil temperature rises above 60 degrees
Fahrenheit.
Prior to starting operations, the operation of all
equipment components must be checked carefully
to ensure they are not frozen, have not been dam-
aged by frozen water and are operating properly.
Store Components Properly
Protect all components from damage when not in
use. Secure for travel.
1.2 Blasting and Personal Safety
Safety First – ALWAYS!
Whenever the pressure pump is engaged for set-
ting pressure or operations, always be sure work
area is clear of people, hands, feet, etc., before
engaging the high pressure switch on the Water-
blasting tool.
INjURIES FROM ULTRA HIGH PRESSURE wATERBLASTING
cAN BE VERY SERIOUS AND cAN RESULT IN A FATALITY.
ALwAYS MAKE SURE ALL PERSONNEL ARE A SAFE DISTANcE
FROM THE wORK AREA AND THE OPERATOR HAS A FIRM GRIP
ON THE TOOL BEFORE THE PRESSURE PUMP IS ENGAGED.
NEVER PUT HANDS, FEET OR ANY PART OF YOUR BODY IN OR
NEAR THE HIGH PRESSURE STREAM.
Equip All Personnel with Proper Safety Gear
Handheld waterblasting equipment can be ex-
tremely dangerous if proper precautions are not
observed. Operators handling the waterblasting
devices must be extremely carefully and wear pro-
tective gear designed for waterblasting. Remem-
ber that high pressure can instantly cause severe
injury or death if any part of the body is contacted
by the high pressure stream. Waterblasting tool
operators must be equipped with the following;
heavy duty, steel toed, non-skid knee high boots,
a heavy duty, protective rain suit, gloves, hard hat
with safety shield or goggles and ear protection.
Support team operators should be equipped with
a minimum of steel towed, non-skid safety boots,
heavy duty work clothes, gloves, hard hat, safety
glasses or goggles and ear protection.
MOST HIGH PRESSURE wATERBLASTING OPERATIONS
PRODUcE NOISE LEVELS THAT EXcEED 90 DB wHIcH cAN
cAUSE PERMANENT HEARING LOSS.
ALL OPERATORS AND SUPPORT PERSONNEL MUST wEAR EAR
PROTEcTION IN AccORDANcE wITH OSHA STANDARDS AND
PROVISION SHOULD BE MADE FOR REGULAR INSPEcTION
AND MAINTENANcE.
ALL PERSONNEL EXPOSED TO 90 DB OR GREATER NOISE
LEVELS SHOULD REcEIVE INSTRUcTION IN THE cORREcT
USE OF EAR PROTEcTION SO THAT THEIR NOISE EXPOSURE
LIES wITHIN THE LIMITS SPEcIFIED BY OSHA. NEVER ALLOw
ANYONE NEAR THE wORK AREA wITHOUT PROPER EAR
PROTEcTION.
REMEMBER: ULTRA HIGH PRESSURE BLASTING cAN cAUSE
DEBRIS TO BE PROjEcTED UNEXPEcTEDLY IN AND AROUND
THE wORK AREA THAT cAN cAUSE SEVERE INjURY. MAKE
SURE ALL PERSONNEL STAY wELL cLEAR OF THE BLASTING
AREA AND USE HARD HATS, EYE AND EAR PROTEcTION.
OSHA’s Permissible Noise Exposure
90 dB 8.0 hours
92 dB 6.0 hours
95 dB 4.0 hours
97 dB 3.0 hours
100 dB 2.0 hours
102 dB 1.5 hours
105 dB 1.0 hours
110 dB 30 minutes
115 dB 15 minutes

11
Safety Information
Use Safety Devices
Always use a safety shroud and a safety whip hose
with handheld control guns for operator protec-
tion against a burst occurring in the high pressure
hose connected the gun. Use of a hand grip and
shoulder stock on hand held guns will provide
greater operator comfort and control.
Check Blasting Head
Check the blasting Head for smooth and proper
operation before each shift. Do not use equipment
that has not been checked thoroughly.
Check Control Components
Check all switches, gun safety release levers and
control panel devices to ensure each is working
properly before beginning operations. Do not use
equipment if any device is malfunctioning.
Always Use Two Operators.
For safety purposes, at least two operators should
always be present during waterblasting opera-
tions with one tool and three operators present
when operating two tools. The primary operator
handling the waterblasting tool must have direct
control of the water pressure. The secondary
operator (assistant), should observe operations
from a safe distance (at least 12 feet (366 cm)
and be able to shutdown system pressure from
a secondary control to quickly relive pressure in
case of an emergency.
Brace Yourself and Be Prepared
Operators of handheld tools should always be
braced and maintain rm, solid footing at all times
before beginning any testing, pressure testing
the system or blasting. Be ready, the force from
the blasting head can exceed 50 lbs, moving the
operator backwards or o balance, causing loss of
control and/or the blast to cross the path of people
or equipment. Always make sure other members
of the crew are a safe distance from the operator
before blasting operations begin to ensure there
is no chance for them to come in contact with the
high pressure stream if the operator loses control.
If waterblasting in a man lift, on scaolding or
above ground level, always use a fall protection
device such as safety belts, harnesses, and fall
nets. Never operate handheld waterblasting
equipment while standing on slippery surfaces.
Start at Low Pressure
Always start blasting with the system at low pres-
sure, slowly increasing to operating pressure.
Engage and disengage Ultra High Pressure switch
at least two times at operating pressure to check
operation of tool high pressure switch before start-
ing blasting operations.
Check Your Hog Pack Dumping Pressure
When setting pressure ALWAYS ensure that the
system pressure drops to less than 100 PSI (7
Bar) immediately when the high pressure switch is
turned OFF. If this does not relieve system pres-
sure immediately to below 100 PSI when turned
o, do not use the equipment until repairs are
made to the dump valve (pressure relief valve).
Know Your Surroundings
Know your surroundings well – i.e. - hoses, people,
walls, moving vehicles, live lanes of trac, etc.
Never Blast When the Tool is Stopped
Always make sure High Pressure switch or trigger
is OFF BEFORE motion is stopped. Damage to
the surface will occur if blasting continues when
high pressure is supplied to a waterblasting tool
that is not moving.
Stop the Pump Before Passing the Tool
Never pass a waterblasting gun or any other
handheld waterblasting tool to another operator
without rst disengaging the high pressure pump
and water ow to the gun. Passing o handheld
waterblasting tools is extremely dangerous due
to the possibility of accidental trigger activation.

12
Safety Information
1.3 Blasting Tool Nozzle Safety
Check Flow Rating
Nozzles combined ow rating must be compatible
with the pump discharge and pressure rating. Re-
fer to your nozzle ow rating chart in this section.
Check Pressure Rating
Use only nozzles with a manufacturer’s pressure
rating of at least the pump’s operating pressure or
a burst rating of no less than 60,000 PSI (4,137
Bar.)
Check Orices
Prior to installation, make sure the nozzles have
no clogged orices. Also, check to ensure nozzles
are sharp and not excessively worn.
Check Connections
Be sure to never force a nozzle into the blasting
head. Clean threads to ensure nozzle is not cross-
threading. Use an ample amount of anti-seize
on threads only, never on the seat of the nozzle.
Inspect the seat area on nozzle to ensure a tight
seal. If it is damaged, do not use.
Connect Nozzle
Insert the nozzle into blasting head nger tight.
Using a 3/8” socket or box end wrench, tighten
the nozzle about 15% more. In some situations,
it may be necessary to tighten additionally. Be
certain the nozzle seat in the blasting head is in
good condition. If it is damaged, replace with a
new blasting head.
Clogged Nozzles
If a nozzle appears clogged, immediately disen-
gage pump. Remove any clogged nozzles and
replace with new nozzles. Any particles of the
smallest size will clog nozzles. Clogged nozzles
can create excessive pressure in pump.
Remove Nozzle from Service if:
A) Nozzle is split or damaged.
B) Nozzle is clogged.
C) Nozzle water spray is fanned out.
D) Nozzle’s ability to hold pressure is suspect.
E) Nozzle’s hex head is worn excessively from
blasting.
F) Nozzle threads are damaged.
Nozzle Flow Chart

13
Safety Information
1.4 Hose Safety
Ultra high pressure hoses are tough, but not in-
vincible. They require proper care and handling
to achieve the normal service life of 300 - 600
hours. If the hoses are abused, the service life
will be much shorter.
Stretched or abused hose can fail prematurely
and unexpectedly, which could cause injury to
personnel. Hoses that have been exposed to
excessive stretching or kinks should be removed
from service and discarded.
Check Pressure Rating
Only Use high pressure hoses with an operating
pressure rating of 36,000 - 40,000 PSI (2,482-
2,758 bar.)
Check Burst Rating
Do not use a high pressure hose that does not
have a listed burst rating or with a burst rating of
less than 60,000 (4,137 Bar) PSI the operating
pressure.
Take Proper Care of Your Hose
A) Protect the hose from contact with sharp
objects, abrasive surfaces and foot or wheel
trac.
B) Never subject ultra high pressure hose to a
tight radius, less than 30” (.7 m) or pull on
a coiled hose. Always make sure the hoses
is straight with no coils before pulling on the
hose to deploy it.
C) Never pull hard on an ultra high pressure hose
or expose the hose to heavy loads like drag-
ging equipment or deploying long lengths of
hose. This can stretch the hose and weaken
it. Never pull more than 25 feet of hose by a
coupler or tting. Always move long lengths
of hose by the hose itself to keep the strain
o the ttings.
D) When using a tractor or a hog tool, always op-
erate the equipment well within the maximum
distance to avoid straining or damaging hoses.
Check Pressure Rating
Only Use high pressure hoses with an operating
pressure rating of 36,000 - 40,000 PSI (2,482-
2,758 bar.)
Check Burst Rating
Do not use a high pressure hose that does not
have a listed burst rating of less than 60,000 PSI
(4,137 Bar.)
Retire Hose from Service if:
A) Cover is damaged and reinforcing wires are
exposed to rust and corrosion.
B) Cover is loose, has blisters or bulges.
C) Hose has been crushed or kinked.
D) End tting shows evidence of damage, slippage
or leakage.
E) Hose has been exposed to pressures of 2 times
the operating pressure.
F) Hose has been stressed or stretched.
Check Dump Valve Water Hoses
Any hose used for owing dumped water away
from the Hog Pack or back to the pump, clean
water tank or an auxiliary tank must have a
large enough diameter and PSI strength so that
potentially dangerous release pressure is allowed
full ow and release pressure is contained safely.
Keep hose in good condition.
1.5 High Pressure Fitting Safety
Fitting Ratings
Use high pressure ttings with a rating of 60,000
PSI (4,137 Bar.)
Check Fittings
Do not use ttings that have been cross threaded
or have damaged threads.
Fitting Connections
Use anti-seize compound on all hose and tting
connections to prevent galling. Do NOT use anti-
seize on the seating area of any connections.

14
THIS PAGE WAS LEFT BLANK
INTENTIONALLY

15
HT500 Systems
Section 2:
HT500 Hog Pack
2.1 Hydraulic Power System
Overview
The HT500 is a wheel mounted, portable hydraulic
system designed to provide hydraulic oil pressure
to the rotating blasting heads and 12-volt DC
power to the control switches on Hog Technologies
Tools. It also provides the hydraulic power that
activates the onboard ultra high pressure (UHP)
water control valves. A gasoline engine and fuel
system provides the power for the hydraulic pump
and the 12-volt DC electrical system. High pres-
sure water and vacuum, if required, are supplied
by separate units connected to the power pack
and/or the hog tool. The engine, fuel tank and all
hydraulic components, including the hydraulic oil
tank and high pressure control valves are mounted
on the unit making it completely portable.
The operation and maintenance requirements for
the engine is unique to the manufacturer. Each
engine manufacturer provides an owners informa-
tion manual with their product. It is important that
you read the manual carefully and become familiar
with the proper care and operation of the engine.
Warranty registration forms are included with the
information manuals. All requested information
on these forms should be lled out completely
and submitted to the dealer or manufacturer as
soon as possible.
The HT500 hydraulic power system is designed to
be used with the HT1000 Ground Hog walk behind
unit, the HT100 Hand Hog blasting guns, or the
HT1100 Hog Waller. With a weight of 600 lbs (272
kg) and compact size, it can be transported to the
job site in a pickup truck or small trailer.
Lifting the Hog Pack
The Hog Pack is designed to be lifted with a three
point harness and lifting equipment capable of lift-
ing at least 1000 lbs. Before lifting the unit, make
sure all hoses and electrical cables are removed.

16
HT500 Systems
There are three designated lifting points located
on the each side of the horizontal portions of
the rear handle, next to the unit chassis and the
forward handle. Only lift by attaching cables or
lifting straps to these points. Their locations are
marked in the photo on this page. The front and
rear handles can be also used to secure the unit
to the truck or trailer for transport.
2.2 Engine
The hydraulic and DC charging systems are pow-
ered by the onboard engine. Engine power is trans-
ferred to the hydraulic pump by a direct coupler
and the pump is always activated whenever the
engine is operating. Hydraulic and high pressure
components of the waterblasting system are manu-
ally controlled by trigger activated switches on the
blasting guns and Hog Waller or lever activated
switches on the Ground Hog unit that are connected
to the Hog Pack 12-volt DC electrical system.
The engine control panel, mounted on the front of
the unit, controls the starting, running and stopping
of the engine. A fuse in the panel protects the igni-
tion and starting circuits from an overload. Other
fuses near the battery protect the circuits for the
control switches and oil cooling fan. Most engines
are equipped with an hour gauge in the panel that
allows the operator to monitor engine run time. A
throttle lever and governor control engine speed.
Always check the oil levels and all systems before
starting the engine.
To start the engine:
Make sure that all hydraulic hoses, high pressure
water hoses and electrical harness are properly
connected and that all trigger switches and levers
on the waterblasting equipment are in the OFF
position.
Turn the STOP/ON/START Key switch to ON and,
for cold starting, pull out the choke lever. Set the
throttle lever to 1/3 throttle.
NOTICE:
The choke is not used when starting warm
engines.
The cooling fan for the hydraulic oil cooler
will automatically run when the ignition Key
switch is turned to the ON position.
HT500 Lifting Points

17
HT500 Systems
WARNING
Turn the engine Key switch to the START position
and hold it there until the engine starts. If the
engine fails to start within 5 seconds, release the
Key switch, and wait at least 10 seconds before
operating the starter again. Using the electric
starter for more than 5 seconds at a time will
overheat the starter motor and can damage it.
When the engine starts, release the Key switch,
allowing it to return to the ON position.
Warm the engine at low speed for 2 or 3 minutes.
Gradually push the choke knob to the open posi-
tion as the engine warms up.
Set the engine throttle to maximum RPM before
beginning waterblasting operations.
Once the engine RPM is set, full power is available
to the hydraulic system. Refer to the operation
section of this manual for more information on
using the HT500 in waterblasting operations.
To stop the engine:
Turn the waterblasting systems OFF.
Move the throttle to allow the engine to operate at
idle speed for at least 5 minutes to allow internal
temperatures and hydraulic oil to cool.
Turn the Key switch to OFF.
IMPORTANT:
The engine control panel is unique to the en-
gine installed on your unit and may operate
dierently than explained above.
An owner’s manual for the engine has been
supplied with this manual. Please refer to
it for specic information on the operation
and maintenance of the engine on your unit.
DO NOT INHALE EXHAUST FUMES! EXHAUST cONTAINS
cARBON MONOXIDE THAT IS cOLORLESS AND ODORLESS.
cARBON MONOXIDE IS A DANGEROUS GAS THAT IS
POTENTIALLY LETHAL. NEVER OPERATE THE HOG PAcK
INSIDE A BUILDING OR ENcLOSED AREAS.
2.3 Engine Fuel System
The HT500 is equipped with a fuel tank mounted
above the hydraulic tank, just aft of the engine,
that supplies fuel to the carburetor by gravity.
The fuel tank is equipped with a vented fuel cap
Honda Engine Control Panel
In-line Fuel Filter
Typical Gasoline Engine Warning Label
Located on the Engine
and a fuel withdrawal line with an in-line fuel l-
ter. The threaded fuel cap is opened by turning
it counter clockwise.

18
HT500 Systems
WARNING
WARNING
WARNING
WARNING
The fuel lter is located in the fuel supply line
below the engine. It is important to monitor the
condition of the fuel lter and change it as rec-
ommended by the engine manufacturer. Always
make sure the engine is cool and completely drain
the fuel tank or turn the fuel valve at the tank
OFF, if your unit is equipped with this valve, be-
fore changing the fuel lter. Make sure to follow
the engine manufacturers recommendations and
procedures for servicing the fuel system.
Improper fuel storage techniques, limited equip-
ment usage, etc. can cause the fuel to become
contaminated. Occasionally, it may become nec-
essary to drain accumulating water and/or con-
taminated fuel from the bottom of the fuel tank.
NOTICE:
Refer to the maintenance section of this
manual and the engine owner’s manual for
additional information on the fuel system
and the proper fuel to use with your engine.
AVOID SERIOUS INjURY OR DEATH FROM FIRE OR EXPLOSION
RESULTING FROM LEAKING FUEL, INSPEcT SYSTEM FOR
LEAKS BEFORE EAcH SHIFT. AFTER THE FUEL FILTER HAS
BEEN cHANGED, PRIME THE FUEL SYSTEM AND cHEcK ALL
FITTINGS FOR LEAKS BEFORE AND AFTER STARTING THE
ENGINE.
Fuel Tank Refueling
Never begin waterblasting operations with a low
fuel condition. The fuel tank should be full at the
beginning of each shift. You should also make
sure to check for fuel leaks. Leaking fuel is a re
hazard and will increase fuel consumption. This
can cause a re or increase fuel consumption
enough to cause the Hog Pack to run out of fuel
prematurely and unexpectedly.
LEAKING FUEL IS DANGEROUS AND cAN cAUSE A FIRE
AND/OR EXPLOSION. FUEL IS VERY FLAMMABLE AND THE
VAPORS cAN EXPLODE. ALwAYS ALLOw THE ENGINE TO
cOOL BEFORE FUELING AND BE cAREFUL wHEN FILLING
THE FUEL TANK. NO SMOKING. NEVER FILL THE TANK wHILE
THE ENGINE IS RUNNING. DO NOT FILL THE TANK NEAR OPEN
FLAMES OR wHILE THE ENGINE IS HOT.
Fuel is very ammable and vapors can explode.
Always allow the engine to cool before fueling and
be careful not to overll the fuel tank. Always use
extreme caution while refueling.
Static electricity is generated by owing fuel and
can create a spark that can cause a re or explo-
sion. It is critical that the ll nozzle be in constant
contact with the fuel ll opening while fueling to
reduce the possibility of a static spark.
Filling the Fuel Tank
• Make sure all switches are in the “OFF” posi-
tion and that the Hog Pack is outside in a well
ventilated area.
• Estimate how much fuel is needed and avoid
overlling the fuel tank.
• Remove the cap.
• Put the nozzle in the fuel opening and make
sure it stays in contact with the fuel ll opening.
STATIc ELEcTRIcITY GENERATED BY FLOwING FUEL cAN
cAUSE A FIRE OR EXPLOSION. TO PREVENT STATIc SPARKS
wHEN FILLING THE TANK, MAKE SURE THE NOZZLE IS ALwAYS
IN cONTAcT wITH THE FUEL FILL OPENING.
• Fill the tank slightly less than the capacity to
avoid spilling fuel out of the fuel ll and to allow
for expansion.
NOTICE:
When the fuel tank is full, fuel will come out
through the ll and could spill on the engine
and Hog Pack components. Monitor the tank
and fuel ll tting closely while fueling to
prevent fuel from spilling.
• Remove the nozzle.
• Make sure the fuel cap gasket is in place and
in good condition. Install the cap on the fuel
ll and tighten hand tight.
SPILLED FUEL cAN cAUSE A FIRE OR AN EXPLOSION. MAKE
SURE YOU DO NOT SPILL ANY FUEL. IF A SMALL AMOUNT OF
FUEL IS SPILLED, USE A cLOTH TO REMOVE THE FUEL AND
PROPERLY DISPOSE OF THE cONTAMINATED cLOTH.

19
HT500 Systems
2.4 12-Volt DC Electrical System
The HT500 is equipped with a 12-volt DC electri-
cal system, alternator and an onboard battery
that provides electrical current for starting and
operating the engine. It also provides 12-volt
current for the hydraulic oil cooler fan and the
trigger switches and solenoids that control the
high pressure water and hydraulic motors on the
Waterblasting tools. The alternator recharges the
battery whenever the engine is operating. The
wires are color coded to assist in troubleshooting
electrical problems.
The 12-volt system is a standard small industrial
engine system. One battery is standard equip-
ment and is located in a battery tray just behind
the engine. The battery is accessed by removing
the stainless steel access panel on the right side
of the unit as shown in the picture in this section.
12-volt power is distributed to the waterblasting
controls and oil cooling fan through individual
circuits that are protected by in-line fuses near
the battery. Other fuses, located in the engine
control panel, protect the engine control circuits
and starter. The waterblasting tools are controlled
by switches in the triggers and control levers on
the Waterblasting tools that are connected to the
Hog Pack by special wire harnesses.
The DC electrical system on your equipment is
designed for a wet cell, industrial engine starting
battery. Do not attempt to use gel cell, absorbed
wet mat or other non wet cell batteries. The en-
gine charging system is not designed to recharge
these batteries which could cause unusually short
battery life, engine starting problems and dam-
age to the charging system. Always consult Hog
Technologies or the engine manufacturer before
changing the type of batteries in your HT500.
Refer to the engine owner’s manual for more in-
formation on battery specications and the engine
electrical system on your HT500. Contact Hog
Technologies Customer Service if you need as-
sistance correcting a problem with the electrical
system.
12-Volt Battery and In-line Fuses
Stainless Steel Battery Access Panel
12-Volt Cooling Fan

20
HT500 Systems
Hog Tool Wire Harness Connections
There are four female wire harness connection
plugs in the panel on the rear of the Hog Pack.
The rst two plugs, from left to right, are used
to connect the wire harnesses from the Hog Tool
control switches to the Hog Pack control circuits.
Plug three is wired in reserve and is not used. The
forth plug is used by an optional wire harness that
connects the Hog Pack control circuits to the UHP
pressure control on a Hog Technologies Stripe Hog
truck or skid mounted unit. The plug locations are
identied in the picture in this section and perform
the following functions:
1. Harness plug 1 connects the Hog Tool to the
mode valve control circuit for Manifold Port
Group 1. The circuit is protected by an in-line
fuse near the battery. When this harness is
connected, the control trigger or lever on the
Hog Tool will open or close the electrically ac-
tivated valve for Manifold Port Group 1 which
turns the hydraulic oil ow and high pressure
water to the Hog Tool connected to Port Group
1 ON and OFF.
2. Harness plug 2 connects the Hog Tool to the
valve control circuit for Manifold Port Group 2.
The circuit is protected by an in-line fuse near
the battery. When this harness is connected,
the control trigger or lever on the Hog Tool will
open or close the electrically activated mode
valve for Manifold Port Group 2 which turns
the hydraulic oil ow and high pressure water
to the Hog Tool connected to Port Group 2 ON
and OFF.
3. Harness plug 3 is for Manifold Port Group 3.
It is wired in reserve because Manifold Port
Group 3 is not used on Power Pack.
4. Harness plug 4 connects the Power Pack to
the high pressure valve (Dump Valve) control
circuit on a Hog Technologies Stripe Hog truck
or skid unit UHP pump system. The circuit is
protected by a fuse or circuit breaker located
in the truck or skid mounted electrical system.
When this optional harness is connected, the
UHP pump Dump Valve on the truck or skid unit
will be controlled by the Hog Tools connected
to the Hog Pack. The circuit senses when
2
134
1. Harness Plug 1 (Port Group 1) 3. Harness Plug 3 (wired in reserve)
2. Harness Plug 2 (Port Group 2) 4. Harness Plug 4 (Master Port Group)