Imperial TMV-1500 User manual
1
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
OPERATOR’S MANUAL
The manufacturer reserves the right to change specifications or make
improvements without notice and without incurring obligations to products
previously sold. Information contained herein is from data available at time of
printing.
VACUUM TANKER
OPERATOR’S MANUAL
Imperial
Imperial
Tank Model
Tank Serial Number
Date of Purchase
OPERATING INSTRUCTION MANUAL FOR TRUCK MOUNTED VACUUM TANKERS
MANUFACTURED BY IMPERIAL INDUSTRIES, INC.,WAUSAU, WI.
WARNING: Study this manual before operating or maintaining your
vacuum tanker and any of its components. You must understand and follow
the instructions in this manual, otherwise you and/or others can be seriously
injured. DO NOT operate this equipment if you have not read and understood
all of the safety and operating instructions. Also,DO NOT allow any other person
to operate this equipment if they have not read and understood all of the safety
and operating instructions.
2
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
TO THE PURCHASER
Congratulations on your purchase of an IMPERIAL
product. Your truck mounted vacuum tanker will
give you years of dependable service if the proper
operating and maintenance instructions are
observed. We recommend that you read this manual
carefully to become thoroughly familiar with your
tanker equipment prior to operation.
Thismanualcontainssectionsonsafety,specifications,
operation,maintenance,and trouble shooting. Each
section in this manual is clearly identified to help you
easily find the information you need.
The safety alert symbol will identify important
safety messages.When you see this symbol,carefully
read the message that follows.
The information in this manual covers IMPERIAL
Truck Mounted VacuumTankers and IMPERIALTruck
Mounted Portable Sanitation Service Tanks. It is
important to record your tank model number, tank
serial number, and date of purchase in the spaces
provided on page 1.This information will be useful
to your dealer when ordering parts for repair.
TO THE PURCHASER
Imperial
Imperial
3
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
CONTENTS
Contents
SAFETY PRECAUTIONS .................................................................................................................................... 4
General Safety Precautions ............................................................................................................................................................... 5
Safety Precautions for Handling Effluent...................................................................................................................................... 5
Safety Precautions for Entering Tanks............................................................................................................................................ 5
Safety Precautions for Operating Equipment............................................................................................................................. 6
SPECIFICATIONS................................................................................................................................................. 7
OPERATION.......................................................................................................................................................... 8
Operation Safety.................................................................................................................................................................................... 8
Vacuum Relief Valve.............................................................................................................................................................................. 8
Pressure Relief Valve............................................................................................................................................................................. 8
Vacuum/Pressure Gauge ..................................................................................................................................................................10
Moisture Trap (Secondary Shutoff)...............................................................................................................................................10
Final Filter...............................................................................................................................................................................................10
Oil Catch Muffler..................................................................................................................................................................................11
PTO Drive................................................................................................................................................................................................11
Fill Indicator...........................................................................................................................................................................................11
Load and Dump Valves......................................................................................................................................................................12
Vacuum Pump ......................................................................................................................................................................................12
Safety Suggestions for Vacuum Pumps.......................................................................................................................................12
Vacuum Pump Pre-Startup Procedure.........................................................................................................................................13
Vacuum/Pressure Control Handle .................................................................................................................................................14
Vacuum Pump Operation.................................................................................................................................................................14
Loading the Tank .................................................................................................................................................................................14
Mechanics of pneumatic-transport (transfer by means of vacuum) ...............................................................................15
Unloading ..............................................................................................................................................................................................16
Hydraulic Components .....................................................................................................................................................................16
Hoist Vacuum Tankers........................................................................................................................................................................16
Wash-Down Systems..........................................................................................................................................................................17
Cold Weather Operation...................................................................................................................................................................18
MAINTENANCE.................................................................................................................................................19
Moisture Trap / Secondary Shutoff ...............................................................................................................................................19
Final Filter...............................................................................................................................................................................................20
Primary Shutoff ....................................................................................................................................................................................20
PTO ...........................................................................................................................................................................................................22
PTO Driveline ........................................................................................................................................................................................22
Right Angle Gear Box.........................................................................................................................................................................22
Captured Mounting Bracket Springs............................................................................................................................................23
Standoff Wear-plate............................................................................................................................................................................23
Lighting Devices..................................................................................................................................................................................24
Backup Alarm........................................................................................................................................................................................25
Hydraulic Components .....................................................................................................................................................................26
Hoist Vacuum Tankers........................................................................................................................................................................26
Vacuum Pump ......................................................................................................................................................................................26
Basic Vacuum Pump Maintenance................................................................................................................................................26
Periodic Vacuum Pump Maintenance..........................................................................................................................................27
Cleaning the Exterior of the Vacuum Pump .........................................................................................................................27
Cleaning the Inside of the Vacuum Pump.............................................................................................................................27
Checking Rotor Vane Wear..........................................................................................................................................................28
Replacing Rotor Vanes..................................................................................................................................................................29
TROUBLESHOOTING VACUUM/PRESSURE PUMPS ..............................................................................30
4
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Throughout this manual, and on machine decals,
you will find precautionary statements followed by
specific instructions.In the interest of safety,take the
time to learn these precautions.
Precautionary statements dealing with personal
safety are preceded by the signal words DANGER,
WARNING, and CAUTION. These precautions are
intended for your personal safety and for the safety
of those working with you.
DANGER: Indicates a hazard or unsafe practice
that, if not avoided, will result in death or serious
injury.
WARNING: Indicates a hazard or unsafe practice
that, if not avoided, could result in death or serious
injury.
CAUTION: Indicates a hazard or unsafe practice
that, if not avoided, could result in minor injury.
Precautionary statements dealing with machine
safety are preceded by the signal words NOTICE and
IMPORTANT.These precautions are intended to help
protect against damage to your equipment and to
inform operators of helpful information.
►NOTICE:Indicatesapossiblydangeroussituationthat,
if not avoided,could result in damage to equipment.
★IMPORTANT: Indicates helpful information on
operation of equipment.
5
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
SAFETY PRECAUTIONS
General Safety Precautions
Follow these safety precautions,and insist that those
working with you follow them.
Most industrial equipment accidents can be avoided
by observing safety precautions.Remember:a careful
operator is the best insurance against an accident.
Safety Precautions for Handling Effluent
DANGER: DO NOT stand near the oil catch
muffler or discharge valve when loading or unloading
the tank. Sewer gases vented out of the oil catch
muffler will settle downward.Sewer gases can also be
expelled out of the discharge valve when releasing
tank pressure.Inhaling sewer gases can cause severe
injury or death.
WARNING:DONOTallowchildrenorirresponsible
people near your work area or equipment.Fatalities
have occurred when children have fallen or climbed
into unattended septic/holding tanks. Secure your
work area from entry of unauthorized persons in
the vicinity.
WARNING: Secure all access covers against
unauthorized entry after pumping a septic/holding
tank. Fatalities have occurred where children have
fallen into septic/holding tank openings that had not
been properly secured. Securely chain and padlock
above ground access openings. Bury underground
access openings by at least six inches of dirt.
WARNING: Always wear protective gloves, eye
protection and,appropriate clothing when working
with sewage effluent or septage. These materials
may contain hazardous chemicals, disposed of
through the drain, which can cause severe injury
or even death due to contact. These effluents also
contain bacteria,which can be a source of infection,
especially if exposed to open cuts or sores.
Safety Precautions for Entering Tanks
DANGER: DO NOT enter a transport, septic, or
holding tank without first cleaning and providing
adequate ventilation to the interior of the tank.
Sewer gas is deadly if inhaled;in addition,it depletes
the oxygen in a confined space, which can cause
asphyxiation.
DANGER: DO NOT enter a transport, septic, or
holding tank without using a respirator that supplies
grade D breathing air or a self-contained breathing
apparatus. In addition, DO NOT use this equipment
without training and familiarity with it. Entering a
tank exposed to sewage effluent without a correct
breathing apparatus, or with improper use of it, can
cause death.
DANGER: DO NOT enter a transport, septic, or
holding tank without protective clothing.Sewer gas
can be absorbed through the skin causing serious
injury or death.
WARNING:When entering a transport,septic,or
holding tank, always have someone standing by to
provide assistance,and always have a respirator that
supplies grade D breathing air or a self-contained
breathing apparatus on hand for them. In the event
of an attempted rescue,this equipment is necessary
to prevent death of the rescuer.
WARNING: Attach a safety-harness and rope to
any person that enters a transport,septic,or holding
tank.Have the safety-harness rope held by a person
standing by to provide assistance outside the tank.
An attempted rescue without the advantage of
a rope and harness can be life threatening to the
rescuer.
WARNING: Entry into a transport, septic, or
holding tank is confined space entry. Persons
entering these tanks for any purpose must be
trained in and follow OSHA confined space safety
procedures.
DANGER
DANGER
6
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
SAFETY PRECAUTIONS
Safety Precautions for Operating Equipment
DANGER: Stop the truck motor, remove all
persons from the truck cab,and chock the truck tires
before servicing any component under the truck;
this includes lubricating the vacuum pump or the
PTO driveline. Contact with a rotating mechanism
can cause entanglement that can lead to death. A
truck that begins to roll is a crushing hazard that
can lead to death.
WARNING: Keep hands, feet, hair, and clothing
away from moving parts. Contact with a moving
mechanism can cause entanglement that can lead
dismemberment or death.
WARNING:Escaping hydraulic oil under pressure
can have sufficient force to penetrate your skin,which
can cause serious injury. Before operating hydraulic
components, be sure all connections are tight and
hoses are not damaged. Relieve all pressure before
disconnecting hydraulic lines or repairing leaks.
CAUTION: When off-loading under pressure,
maintain control of the end of the hose. Pressurized
discharge can cause a hose end to whip about and
create the potential for spraying persons in the area
with effluent.
WARNING: Keep all shields in place.Shields and
covers are designed to protect the operator from
entanglement in moving parts, which can lead to
serious injury or death. DO NOT remove shields
from the unit except when servicing; then, replace
immediately.
WARNING: The truck’s cornering and braking
abilities are reduced when the tank is loaded. Drive
at a reasonable speed with a loaded tank; reduce
speed on rough or hilly terrain, before making an
anticipated stop, and when cornering.
WARNING:Make certain everyone is clear of the
tanker truck and the immediate area before starting
the engine, engaging power, and operating the
equipment.The inherent hazards of septic pumping
can cause serious injury or death to untrained
persons that enter this area.
WARNING: DO NOT allow anyone to ride on
the outside of the tanker truck when it is in motion.
Failure to follow this precaution could result in
persons falling off the truck and possibly getting run
over, which could cause serious injury or death.
WARNING:Before backing-up the truck,inspect
the area to be backed into,and clear all hazards,pets,
and people from it. Make sure that backup lights
and the back-up alarm are maintained and in good
working condition. Because of the truck mounted
tank, the driver will experience a large blind spot
behind the truck. Fatalities have occurred when
persons were run over by a tanker truck.
CAUTION: Avoid contact with the vacuum pump
during or immediately after operation. Operating
temperatures can range from near 200oF to over
300oF,depending on the make and model of pump
and on the working conditions. Contact with a hot
vacuum pump can cause severe burns.
WARNING
7
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
SPECIFICATIONS
SPECIFICATIONS
General specifications for your Imperial portable
sanitation service unit are listed in Table 2.1 below.
General specifications for your Imperial truck
mounted vacuum tanker are listed in Table 2.2 below.
All dimensions are given in inches.
Model Gallon Capacity Overall Length Tank Diameter Recommended GVW Cab to Axle Total Gross Weight
PTM-875 575/waste
300/fresh 130” 48” 19,500 84” 10,010
PTM-1100A 700/waste
400/fresh 132” 54” 19,500 84” 10,340
PTM-1500A 1100/waste
400/fresh 142” 60” 25,900 94” 14,100
PTM-2150A 1600/waste
550/fresh 159” 66” 25,900 108” 19,780
Table 2.1 Portable Sanitation Service Units
Table 2.2 Vacuum Tankers
Model Actual Gallon
Capacity Overall Length Tank Diameter Max Cab to Axle Total Gross Weight
TMV-1500 1,507 163” 54” 125” 15,824
TMV-2000 1,932 148” 66” 109” 20,286
TMV-2100 2,107 155” 66” 116” 22,124
TMV-2300 2,283 167” 66” 128” 23,972
TMV-2500 ALUM 2,500 179” 66” 140” 23,000
TMV-2500 2,458 179” 66” 140” 25,809
TMV-3000 2,942 179” 72” 128” 30,891
TMV-3200 3,150 191” 72” 140” 33,075
TMV-3400 3,359 203” 72” 152” 35,270
TMV-3600 ALUM 3,600 213” 72” 163” 33,120
TMV-3600 ALUM 3,600 194” 76” 142” 33,120
TMV-3600 3,567 215” 72” 164” 37,454
TMV-3800 3,755 192” 78” 141” 39,428
TMV-4000 ALUM 4,000 218” 76” 163” 36,800
TMV-4000 ALUM 4,000 197” 81” 142” 36,800
TMV-4000 4,000 204” 78” 153” 42,000
TMV-4300 4,254 216” 78” 165” 44,573
TMV-4500 4,490 228” 78” 177” 47,145
TMV-4800 4,735 240” 78” AS REQUIRED 49,145
TMV-5000 4,980 252” 78” AS REQUIRED 52,290
8
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
Vacuum Relief Valve
The vacuum relief valve serves to safeguard against
vacuum pump damage. It is located on your
secondary,pump,or in the airline circuit (Figure 3.1).
The vacuum relief valve is factory set to the pump
manufacturer’s maximum continuous vacuum rating
(MCVR).Table 3.1 lists the vacuum relief valve setting
for various brands of pumps.
If you notice that the vacuum relief valve is not
relieving vacuum when your tank reaches the MCVR
level for your specific pump,you might need to reset
it. Use the following procedure to set the valve:
1. Loosen the locking nut located near the top of
the vacuum relief valve. Rotate the inner cylinder
clockwise one to two revolutions to reduce the
setting at which the valve opens. Retighten the
locking nut after making the adjustment.
2. Run the pump in the vacuum mode, and check to
see if the valve opens at the MCVR as listed in table
3.1. or in your OEM pump manual.
3. Repeat steps one and two until you attain the
proper setting.
►NOTICE:Do Not run your vacuum pump above
the pump manufacturer’s maximum continuous
vacuum rating.Exceeding the maximum vacuum
rating could cause damage to the pump and/or
tank.
Pressure Relief Valve
A pressure relief valve is located on your secondary
or in the airline circuit (Figure 3.1).This valve serves
to prevent damage to the tank. It opens, to release
air,when the pressure in the tank reaches the factory
predetermined setting:
•The pressure relief valve on truck mounted vacuum
tankers is factory set at 10 psi.
•The pressure relief valve on portable sanitation
service units is factory set at 5-7 psi.
When the pressure relief valve opens to release
excess air, it creates a hissing sound that you should
be able to hear.Listen for this sound,and if the valve
does not open at the specified pressure as listed
above, reset it. Your vacuum tank is not a pressure
vessel, and exceeding a maximum pressure of 15
psi is dangerous.
DANGER
WARNING
OPERATION
IMPERIALTruck MountedVacuumTankers are custom
designed to meet individual customers’ needs.
However,some of the most common configurations
are illustrated in Figure 3.1. Use this illustration to
acquaint yourself with the main components on
your vacuum tanker.
Operation Safety
Operating vacuum tankers, and pumping septic
and/or holding tanks, involves potential hazards.
Before operating your vacuum tanker, you must
understand and follow all of the safety precautions
in this manual.
Hazards frequently encountered in pumping include
confined spaces, dangerous chemicals, exposure to
bacteria,explosive atmospheres,falls,high-pressure
water jets, pressurized hydraulic lines, rotating
drivelines, and poisonous gasses. Because each
pumping job is unique, you may experience other
hazards as well.
When dangerous situations arise, it is your
responsibility to make sure that no harm comes to
persons,equipment,or the surrounding environment.
Make sure that your job site is secured and safe for
others both when you carry out the job and when
the job is complete.
OPERATION
9
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
OPERATION
Basic Vacuum Tanker Components
Through the Tank Air-line
Access Hatch Vacuum Tank
Sight Eye Assembly
Work Light Assembly
Load/Dump Valves
Access/Clean-out Hatch
Vacuum Pump
Tool Box
Oil Catch Muffler
Mounting Springs
Formed Skid &
Rubber Sill
Pressure
Relief
Valve
Vacuum/
Pressure
Gauge
Vacuum
Relief
Valve
10
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
Figure 3.2 Vacuum / Pressure Gauge
★IMPORTANT: Any time that excess liquid
accumulates in the moisture trap,clean the inside
of your pump. Liquid contamination that enters
the pump can cause damage if you do not clean
the pump shortly thereafter.
Final Filter
The final filter serves as a safety device to prevent
contaminates from entering the vacuum pump.
Depending upon the lint content of the material
being pumped,clean the final filter as often as every
day.
When cleaning the final filter, provide yourself with
gloves,eye protection,and protective clothing.Then,
use the following procedure:
1. Loosen the wing nuts and remove the cover.
2. Remove the nut on top of the filter and remove
the canister.
3. Clean the lint from the filter screen. If necessary,
swirl the filter in a pan of soapy water to loosen
the lint.
4. Reassemble in the reverse order.
WARNING: Wear protective gloves, eye
protection, and appropriate clothing when
cleaning the final filter.Being a component of the
vacuum system, the filter is subject to exposure
by sewage effluent or septage. These materials
may contain hazardous chemicals and bacteria,
which can cause infection, injury, or even death
due to contact.
WARNING:DoNotexceedamaximumpressure
of 15 psi with your vacuum tank.Exceeding 15 psi
pressure can cause the tank to rupture, which
could result in serious injury or death to persons
in the area.
Use the following procedure to set the pressure
relief valve:
1. Purge all air from the tank by slowly opening one
of the rear valves.Stand off to the side of the valve
to prevent possible injury from the direct flow of
releasing pressure.
2. After purging the tank of air, loosen the setscrew
located near the top of the pressure relief valve.
Rotate the inner cylinder clockwise one to two
revolutions to reduce the setting at which the
valve opens. Retighten the setscrew after making
the adjustment.
3. Run the vacuum pump in the pressure mode,and
check to see if the valve opens at the specified
setting as listed above.
4. Repeat steps one through three until you attain
the proper setting.
Vacuum/Pressure Gauge
A vacuum/pressure gauge is located on your tank or
in the airline circuit (Figure 3.1,page 9).As the gauge
needle moves counterclockwise of zero, the gauge
reads vacuum in inches of Mercury (in.Hg). As the
gauge needle moves clockwise of zero, the gauge
reads pressure in pounds per square inch (psi) (Figure
3.2).Use the gauge to determine when the tank has
reached operating vacuum or pressure.
Moisture Trap (Secondary Shutoff)
The moisture trap serves as a safety device to prevent
liquid from entering the vacuum pump. Check the
moisture trap daily for accumulation of liquid.
On tank mounted moisture traps,use the easy access
drain both to check for and to drain off any liquid.The
drain is located at the bottom of the moisture trap.
On frame mounted moisture traps, check for
accumulated liquid by viewing through the sight
eye.To drain liquid, remove the cover.
While the moisture trap helps prevent liquid from
entering the pump, excess accumulation may be
an indicator that some contamination has passed
into the pump.When excess liquid shows up in your
moisture trap, clean your vacuum pump using the
procedure on page 27 of this manual.
OPERATION
11
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
may not mesh properly.As slippage occurs between
the PTO clutch plates,the oil will rapidly heat up and
the viscous drag will quickly decrease.
★IMPORTANT: During cold weather operation,
power shift PTO-s may rotate in the disengaged
position when you first start your truck.To avoid
damage to equipment, make sure your vacuum
pump is not frozen before starting the truck,
and Do Not engage the PTO until the truck has
warmed up.
Fill Indicator
ImperialTruck MountedVacuumTankers are available
with three different kinds of fill indicators:sight tubes,
sight eyes, and float level indicators (Figure 3.3). All
fill indicators function automatically, as the tank is
loaded or unloaded.
A sight tube or float level indicator displays the liquid
level in the tank at all times.With sight eyes,the liquid
level in the tank is visible at the indicator positions.
★IMPORTANT: Clean the final filter regularly.
An excess buildup of lint in the final filter can
reduce airflow in the vacuum system, reducing
performance of the vacuum pump.Also,reduced
airflow through the vacuum pump can result
in overheating, leading to eventual pump
damage.
Oil Catch Muffler
The oil catch muffler collects oil expelled from the
vacuum pump and reduces pump noise.
Drain the oil catch muffler daily by opening the drain
at the base of the muffler chamber.You may need to
drain the pump more frequently when subjecting
it to heavy use. Properly dispose of the used oil; Do
Not reuse it.
Furthermore, anytime that you notice that water
has collected in the oil catch muffler, dry out the
vacuum pump interior using the procedure outlined
on page 15.
PTO Drive
Your Truck Mounted Vacuum Tanker is equipped
with a power take off (PTO) drive for powering your
vacuum pump. An OEM manual for the particular
drive on your vacuum system is included in the
literature packet that you received with your
IMPERIAL Vacuum Tanker. Review and follow the
operation procedures outlined in that manual.
Supplementary instructions are included below.
Engage the PTO drive in order to run the vacuum
pump. When you are finished loading or finished
pressure dumping your tank, disengage the PTO
drive to shut down the vacuum pump.
►NOTICE: Disengage the PTO to stop pump
operation upon completion of loading or
pressure dumping your tank.Failure to disengage
the PTO will keep the pump in operation and lead
to overheating and damage to equipment.
In extremely cold weather,the transmission oil in the
truck has high viscosity until it warms up. Viscous
drag can cause power shift PTO-s to momentarily
transmit high torque, which can cause output
rotation in the disengaged position. This rotation
could have sufficient force to damage a pump frozen
with ice.For this reason,make sure your pump is not
froze up before starting the truck in cold weather.
In addition, Do Not engage PTO driven equipment
until the vehicle has warmed up. If the PTO begins
to rotate in the disengaged position, the PTO gears
OPERATION
Figure 3.3 Fill Level Indicators
12
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
Vacuum Pump
The OEM Operation Manual for your vacuum pump
is included in the literature packet that you received
with your IMPERIAL Vacuum Tanker. Review and
follow the operation procedures outlined in that
manual.
Imperial Industries furnishes the following
information to provide a better understanding of
yourvacuumequipment.Thisinformationis intended
to augment (not replace) the OEM instructions for
your specific pump.
★IMPORTANT:Follow the operation procedures
outlined in your OEM pump manual in order to
keepyour warranty valid and toreceivemaximum
service life from your pump.
Safety Suggestions forVacuum Pumps
DANGER: Stop the truck motor, remove all
persons from the truck cab, and chock the truck
tires before servicing any component under the
truck, including lubricating the vacuum pump
or the PTO driveline. Contact with a rotating
mechanismcancauseentanglement thatcanlead
to death. A truck that begins to roll is a crushing
hazard that can lead to death.
WARNING:Keep hands,feet,hair,and clothing
away from moving parts. Contact with a moving
mechanism can cause entanglement, which can
lead to dismemberment or death.
CAUTION: Avoid contact with the vacuum
pump during or immediately after operation.
Operating temperatures can range from near
200oF to over 300oF, depending on the make and
model of pump and on the working conditions.
Contact with a hot vacuum pump can cause
severe burns.
OPERATION
Load and Dump Valves
Imperial vacuum tankers are available with either
manual or automatic load and dump valves.
Automatic valves may be air, hydraulic, or electric
operated.
On manual valves, use the handle mounted to the
valve to open and close it.On air,hydraulic,or electric
valves use the switch in the truck cab or, on the rear
step bumper,to actuate the valve.Switches mounted
on the rear step bumper are usually located on the
driver’s side, inside surface, of the bumper.
To allow for easy coupling to a vacuum or discharge
hose, both the load and the dump valves are
equipped with camlock-fittings.After you uncouple
your hoses,use the camlock fitting covers to keep dirt
and debris from collecting in the valves.
Some air valves may have a pressure regulator
plumbed into the airline. The pressure regulator is
factory set to close the valve at 30 psi. If you need
to readjust the regulator, set the pressure so that
the valve just completely closes. If a pressure gauge
is available, set the valve to close at 30 psi. Turning
the adjustment knob clockwise increases pressure.
Turning the adjustment knob counterclockwise
decreases pressure.
★IMPORTANT: On air valves with a pressure
regulator,DoNot settheclosingpressureabove 30
psi.A higher pressure setting may cause the valve
gate to wedge shut, making it difficult to reopen.
13
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
OPERATION
Vacuum Pump Pre-Startup Procedure
Perform the following procedure each time before
you operate the vacuum pump:
•Make sure that the rotor shaft turns freely by
hand.This is especially important in cold weather
to make sure that the pump is not frozen up with
ice.
•Check the level in the oil reservoir. Most pumps
have a dipstick for checking oil. The oil in the
reservoir requires periodic refilling because the
pump consumes oil in the process of lubrication.
Use only OEM recommended types and brands of
oil for your pump.Table 3.2 lists the manufacturer
recommended lubricants for the most popular
vacuum pumps supplied by Imperial Industries.
If you have difficulty obtaining a manufacturer
recommended oil, contact Imperial Industries
about its availability.
•If your pump model has grease fitting for the
bearings, add grease. It is important not to over
grease pump bearings.Use only one or two pumps
on the grease gun when greasing.
►NOTICE:Check the oil level in the rear housing at
regularintervals.Allowingthepumptorunlowonoil
during operation will result in damage to the pump.
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14
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
Finally, before using the pump to load the tank,
actuate the vacuum/pressure handle to be sure that
the pump is operating in each mode.
►NOTICE: If proper oiling is not achieved within
a few minutes,shut down pump and see“Trouble
Shooting” section on page 31 or consult an
IMPERIAL sales representative.
Loading the Tank
Use the following procedure to load your vacuum
tank:
•Remove the camlock fitting covers on the desired
load inlet.
•Couple the filler hose to the inlet.
•Set the vacuum/pressure handle on the pump to
the“vacuum” mode.
•Start the truck engine and engage the PTO. Run
the engine up to the recommended rpm-s for
your pump.Refer to the label affixed to your truck
dashboard, to your OEM pump manual, or to the
pump housing to determine the recommended
rpm for your vacuum pump.
•Allow the vacuum to build to the desired level
(usually about 15” Hg), and then open the inlet/
outlet valve and load the tank.
•When the tank is full, close the fill valve and
disengage the PTO in order to shut down the
pump.
Pay close attention to the fill indicator on your tank
so that you can promptly shut down your vacuum
pump when the tank is full.
If for any reason you can’t visually tell when the
tank is full, listen for a change of sound in the
vacuum pump. When the tank is full, the primary
shutoff stops airflow,creating a noticeable change
in the sound of the vacuum pump.
Also, in the unlikely event that the primary or
secondary shutoff activates due to extreme
air velocity, promptly shut down your vacuum
pump. Again, a change of sound in the vacuum
pump is your indicator to stop operation.This will
deactivate the shutoff, at which point you can
resume operation.
•After disengaging the PTO,deactivate the throttle
control to reduce the engine rpm.
★IMPORTANT: Do Not over grease the pump
bearings. Over greasing can cause damage to
the seals.
Vacuum/Pressure Control Handle
On most vacuum/pressure pumps, locating the
control handle in the center of its travel will cause the
pump to operate in a neutral free flow mode.
To obtain either vacuum or pressure,move the handle
either clockwise or counterclockwise according
to the instructions in your OEM pump manual. In
addition, you can observe the vacuum/pressure
gauge to verify which mode you are operating in.
Vacuum Pump Operation
After performing the pump pre-startup procedure,
position the vacuum \ pressure control handle in the
neutral position and engage the PTO.
When the pump is running, check oil flow in the
drip oiler sight window to ensure that the proper
lubrication is reaching the pump (Figure 3.4). Refer
to your OEM pump manual to determine specific
oiling rate (drip rate) for your pump.
If your vacuum pump is equipped with a manual
adjust drip oiler, pay close attention to the drip
rate and regulate it as necessary. Manual drip
oilers require periodic checking and adjustment. In
addition, readjust the drip oiler when changing oil
weight in your pump. See your OEM pump manual
for specific instructions on adjusting the drip oiler.
If your vacuum pump has an auto-lube oiler, the
oiler pump is preset at the factory and requires little
periodic adjustment. These oilers are adjustable,
however, should they go out of tune due to normal
operating conditions. See your OEM pump manual
for specific instructions on adjusting auto-lube
oilers.
★IMPORTANT: When adjusting your vacuum
pump oiler,use small adjustment increments (no
more than one turn at a time).This helps protect
against running the pump dry due to turning
the adjustment knob too lean or in the wrong
direction.
In addition to checking the lubrication system as
described above, make sure the pump is running
smoothly by listening for a pump sound with
minimum vibration.
OPERATION
15
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
►NOTICE: Do Not operate the pump faster
than the recommended rpm. Operation above
the recommended rpm will cause the pump to
overheat, resulting in damage to the pump.
►NOTICE: Shut down your vacuum pump
promptly when the tank is full. In addition, any
time the primary or secondary shutoff activates,
stop pump operation. At the point when either
of the shutoffs activates,the pump is susceptible
to overheating if kept running.This can damage
your pump.
Mechanics of pneumatic-transport
(transfer by means of vacuum)
A vacuum,as pertaining to pumping of liquid waste,
is a space with some of the air removed from it.
Your vacuum pump extracts air from your vacuum
tank,lowering the pressure inside of it.Atmospheric
pressure pushing against the liquid does the actual
loading of your vacuum tank. The liquid flows toward
the area of lower pressure created in the tank.
Vacuum is measured in inches of Mercury (in.Hg.
or “Hg.). This type of measurement is based on a
barometric mercury column. Standard atmospheric
pressure at sea level causes the mercury in this
instrument to rise 30 inches up into a glass tube with
a vacuum.The dial type pressure/vacuum gauge on
your tank (Figure 3.2,page 11) gives the same in.Hg.
reading as a mercury column.
Usually,15”Hg of vacuum is sufficient to load the tank
without placing undue stress on your pump.Table 3.3
lists the approximate vacuum levels required to lift
water a given distance.However, these figures must
be adjusted to compensate for the weight of the
material and the length and diameter of suction hose
being used. Effluent or septage may often weigh
more than water. Also, pumping these products
through a hose induces friction.Both of these factors
result in reduced lifting efficiency.
OPERATION
Drip Oiler
Sight Window
Drip Oiler
Adjustment Knob
Figure 3.4 Vacuum Pump Drip Oiler and Vacuum/Pressure
Control Handle
Vacuum/Pressure
Control Handle
In addition, both attainable vacuum and pumping
height decrease at higher altitudes.This is because
atmospheric pressure decreases with height.
Therefore,there is less pressure at hand to load your
tank.Table 3.4 lists the percentage loss of attainable
vacuum for every 1000-foot rise in elevation over
sea level.
While it is necessary to create enough vacuum to
handle pumping height, product weight, and hose
friction, it is important not to overstress the pump.
Pay close attention to your pump if it is necessary
to operate at a high in./Hg vacuum level.Air-cooled
pumps are especially vulnerable to overheating
when being operated for extended periods at high
vacuum levels.Liquid cooled pumps can handle this
type of operation much more readily.
In addition, operation at high in./Hg levels can also
result in moisture condensation in the pump. As
vacuum increases, water begins to evaporate from
the surface of the liquid in the tank. Anytime that
vacuum pump operation exceeds 15”Hg, water
vapor can begin to show up in the air circulating in
the vacuum system.
While most of this moisture collects in the oil catch
muffler, some of it will also accumulate inside the
pump.In order to prevent problems connected with
water collecting in your vacuum pump, dry it out
anytime that you notice that water has collected in
the oil catch muffler.
Use the following procedure to dry the pump out:
•Unload the tank
•Open a load or dump valve (to keep from building
vacuum)
•Run thepump invacuummodefor two tofive minutes
Water that is allowed to remain in your vacuum
pump can diminish performance and cause serious
damage. When water is present inside the pump,
sludge forms.This can restrict the vanes from moving
freely inside the rotor slots, reducing the efficiency
of your pump.In addition,water inside your vacuum
pump can freeze during cold weather operation.
Attempting to operate your pump if it is frozen inside
with ice will damage it.
►NOTICE:Do Not run your vacuum pump above
the pump manufacturer’s maximum continuous
vacuum rating.Exceeding the maximum vacuum
rating could cause damage to the pump and/or
tank.
16
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
★IMPORTANT: After operating your pump at
high in./Hg vacuum levels,dry the pump interior
out using the procedure outlined above.Water in
your vacuum pump can cause sludge formation
and freeze up in cold weather.
Unloading
You have two options when unloading your tank,
gravity dumping or pressure dumping. Either
method will effectively empty the tank; however,
pressure dumping increases discharge flow rate.
Begin the unloading procedure by placing the
vacuum pump control handle into neutral to relieve
any vacuum in the system, then use one of the
following procedures.
For gravity dumping, use the following
procedure:
1. Set the control handle on the pump to the
“pressure”mode.
2. Open the dump valve.
For pressure dumping, use the following
procedure:
1. Set the control handle on the pump to the
“pressure”mode.
2. Engage the tractor PTO to start the pump,and run
up to the recommended RPM for your vacuum
pump model.
3. Open the dump valve to begin unloading when
the pressure reaches the desired level (up to the
maximum psi set on the pressure relief valve).
OPERATION
WARNING: Do Not exceed the maximum
pressure of 15 psi with your vacuum tank.
Exceeding 15 psi pressure could cause the tank
to rupture, resulting in serious injury or death to
persons in the area.
After unloading the tank, disengage the PTO and
close the dump valve. It is important to disengage
the PTO before closing the valve to avoid pressure
buildup in the system.
Hydraulic Components
Imperial Truck Mounted Vacuum Tankers are
available with a variety of hydraulic operated and
driven components. Some of these components
include hydraulic hoists, hydraulic hatches, and
hydraulic pump drives.
Use the toggle switch mounted inside the truck
cab to actuate the hydraulic components on your
vacuum tanker, except for hoist cylinders.
On trucks with air brakes, use the air feathering
control lever mounted on the floor of the truck cab
to operate the hoist cylinder. On trucks without air
brakes, a feathering control cannot be installed.
These trucks use a non-feathering lever control to
activate the hoist cylinder.
Hoist Vacuum Tankers
Use the control lever mounted in the truck cab to
raise the tank for dumping sludge or other solids
from your hoist tanker. Before dumping the solids
from the tank, drain all liquid from the tank.
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17
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
1. Remove the body prop from its mounting
bracket.
2. Slide the end of the body prop with the hole in it
over the pin that protrudes from the tank skid.
3. Position the body prop so that it hangs vertically.
4. Lower the tank until the body prop is just resting
against the truck frame.
As a secondary precautionary measure when
working under the raised tank, place a hardwood
block across both frame members just ahead of the
rear hinge.
WARNING: Properly place the provided body
prop securely in position when you or anyone
else is under a raised tank for any reason. This
stop is for use under an empty tank only. Never
allow persons under the raised tank if it has not
been emptied. Failure to properly use this safety
stop could result in serious injury or death due
to crushing.
Wash-Down Systems
If your truck is equipped with a wash-down system
(Figure 3.5), you will have received an OEM manual
for the pressure water pump (included in your
literature packet). Review and follow the operation
procedures outlined in that manual.Supplementary
instructions are included below.
WARNING: Drain all liquid from your load
before lifting the tank and dumping the solids
from it.Your HoistVacuumTanker is not designed
to handle the forces generated by large volumes
of moving liquid.Attempting to raise the tank for
dumping,with liquid in it,can cause your truck to
overturn. An overturned truck can cause death
or serious injury to the operator and persons in
the area.
Trucks that have an air compressor system (e.g. a
truck with air brakes) use an air feathering control
to activate the hoist cylinder.The feathering control
allows the operator to prevent the jerking movement
that occurs with sudden starting and stopping of the
hydraulic cylinder. It also allows the ability to vary
the speed of cylinder movement.When moving the
control lever increasingly more in the direction of
actuation, the speed of movement increases.
Usually,smaller trucks do not have an air compressor
system, and will therefore have a cable control
installed.On these trucks,use the lever control inside
the truck cab to actuate the hoist cylinder.
In addition, single hydraulic-component hoist
tankers, that have a feathering control, incorporate
a limit switch that pulls the control lever into neutral
before the cylinder reaches the end of its stroke.
However, hoist tankers with a multiple hydraulic-
component system and hoist tankers with cable
control Do Not have a built in limit switch. When
operating the hoist cylinder on these types of
systems,move the control lever to neutral before the
cylinder reaches the end of its stroke. If you do not
stop the cylinder movement before the end of the
stroke, excessive pressure can build in the cylinder
tube causing it to distort and/or rupture.
►NOTICE: If your hoist cylinder does not have
a stroke limiter installed,Do Not run the cylinder
to the end of its stroke. Over pressurizing of the
cylinder will result if it is run at full pressure
to the end of its stroke, causing damage to
equipment.
A safety brace (referred to as a body prop) is provided
with your hoist tanker. The stop braces the tank in
the erect position if the hydraulic cylinder should
creep downward due to inherent oil seepage past
the valves in the system.
Use the body prop anytime you need to work under
the raised tank.However,only put the body prop into
use on an unloaded tank.Never allow persons under
the raised tank if it has not been emptied.
The body prop mounts to the inside of the truck
frame.Make sure the body prop is in good condition,
and then use the following procedure to place it
into service:
OPERATION
Figure 3.5 Washdown Systems:large size,top;small size, bottom
18
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
To operate the pressure water pump for the small
size wash-down system, make sure there is water in
the water tank, and then turn the pump switch on.
This pump does not require priming.
To operate pressure water pump on the large size
wash-down system, use the following procedure:
1. Open the ball valve attached to the pipe nipple
that comes out of your truck’s water tank.
2. Check to make sure the pump is primed by
opening the camlock-fitting cap attached to the
pump housing.
•If water flows out from the camlock fitting, the
pump is primed and the cap can be replaced.
•If no water flows out of the camlock fitting, add
water until the pump housing is full.Replace the
cap after filling the pump.
3. Press the on/off switch positioned at the top of the
pump housing.
4. When the water tank is empty, promptly shut the
pump off. As water flows through the pump it
lubricates the pump seal. Running the pump dry
(without water flowing through it) will damage
the seal.
During cold weather (below 32o), drain the liquid
from your pressure water pump to prevent freezing
and damage to the pump housing. This applies to
both types of systems. In addition, drain all water
lines and filters to protect them from freeze-up.
►NOTICE: Do Not start the DC-10 water pump,
included with the large size system,until you are
sure it is primed with water. Starting or running
the pump dry will cause scoring of the mechanical
seal, resulting in damage to the pump.
►NOTICE: Do Not allow water to freeze inside
the pump. Do not attempt to start the pump if
water has frozen inside it. Freezing water can
damage your pump. Take the truck into a warm
area and allow the pump the thaw out.
Cold Weather Operation
Use the following guidelines when operating your
vacuum tank in temperatures below 32°F.
Extremely cold weather can result in formation of ice
inside the vacuum pump,due to residual moisture.If
the pump freezes up due to ice,take the truck into a
warm area and allow the pump to thaw.Do Not use a
blowtorch or other similar device to attempt to thaw
a frozen vacuum pump.
Before starting your truck engine, make sure that
your pump is not frozen up inside with ice. This is
important because extremely cold weather can
cause power shift PTO-s to momentarily transmit
high torque,which can cause PTO output rotation in
the disengaged position. This type of PTO rotation
could have sufficient force to damage a pump that
is frozen.
Inaddition,DoNotengagethePTO drivenequipment
until the vehicle has warmed up.If the PTO begins to
rotate in the disengaged position,the PTO gears may
not mesh when attempting to engage the PTO.
Extremely cold weather could also cause the dump
or load valves to freeze shut.Hot water poured over
a frozen valve should loosen the ice. DO NOT use a
blowtorch or similar device to thaw a frozen valve.
This method could damage the valve.
OPERATION
19
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
Remove the moisture trap cover to examine the ball
seat for hardened rubber, nicks in the rubber, and
a buildup of debris. Any of these conditions may
prevent proper sealing.Clean and/or replace the ball
seat as necessary.
Any time that excess liquid accumulates in the
moisture trap, clean the inside of your pump. While
the moisture trap helps prevent liquid from entering
the pump,excess accumulation may be an indicator
that some contamination has passed into the
pump.Contaminates entering the pump (including
effluent) is a major cause of pump failure. See page
27 for vacuum pump cleaning procedure.
In addition, clean and/or replace the ball seat in
the primary shutoff any time that excess liquid
accumulates in the moisture trap.Excessive liquid in
the moisture trap can often be traced to improper
sealing of the ball seat in the primary.
★IMPORTANT: Any time that excess liquid
accumulates in the moisture trap,clean the inside
of your pump. Liquid contamination that enters
the pump can cause damage if you do not clean
the pump shortly thereafter.
MAINTENANCE
Safe and reliable service from your IMPERIAL
Truck Mounted Vacuum Tanker depends upon a
regular schedule of lubrication and maintenance.
Tables 4.1 and 4.2 list intervals for lubrication and
maintenance. In addition, the following sections
detail the required lubrication and maintenance for
individual components.
WARNING:Before performing any lubrication
and maintenance,review and follow the“SAFETY
PRECAUTIONS” on pages 5-6 and all safety
precautions listed below.
Moisture Trap / Secondary Shutoff
Check the moisture trap daily for collected liquid
(Figure 4.2).
On tank mounted moisture traps,use the easy access
drain both to check for and to drain off any liquid.The
drain is located at the bottom of the moisture trap.
On frame mounted moisture traps, check for
collected liquid by viewing through the sight eye.
To drain liquid, remove the cover.
In addition to checking for liquid, inspect the ball
seat and the fasteners every 2 weeks.
Check all moisture trap fasteners and tighten
as necessary. Driving the truck with an empty
tank causes vibration that over time can loosen
fasteners.
MAINTENANCE
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20
IMPERIAL TRUCK MOUNTED VACUUM TANKER MANUAL
★IMPORTANT: Clean the final filter regularly.
An excess buildup of lint in the final filter can
reduce airflow in the vacuum system, reducing
performance of the vacuum pump.Also,reduced
airflow through the vacuum pump can result
in overheating, leading to eventual pump
damage.
Primary Shutoff
Inspect the primary shutoff every 2 weeks to
check the rubber ball seat and the tightness of all
fasteners.
Your vacuum tanker is equipped with one of two
styles of primary shutoff, depending on which type
of air-line system the tank has.
To inspect the ball seat on external air-line systems
(Figure 4.3), begin by removing the primary shutoff
access lid.
Next, remove the float cage to gain access the ball
seat. Examine the ball seat for hardened rubber,
nicks in the rubber, and a buildup of debris. Any of
these conditions may prevent proper sealing.Clean
or replace the ball seat as necessary. Reassemble in
the reverse order;furthermore,be sure to tighten all
fasteners adequately.
MAINTENANCE
PTO
PTO Driveline
Right Angle Gearbox
Woods Coupling
Vacuum / Pressure Pump
Figure 4.1 Vacuum Pump Driveline Lubrication Locations
Note: see the maintenance subsections in this manual for specific lubricant types and lubrication intervals.
Lubrication Locations
= lubrication points
Final Filter
Clean the final filter as often as every day,depending
upon the lint content of the material being pumped.
For example,lint is more of a problem when pumping
holding tanks than when pumping septic tanks,
where the paper fibers in the effluent decompose.
When cleaning the final filter, provide yourself with
gloves, eye protection, and protective clothing and
then use the following procedure:
1. Loosen the wing nuts and remove the cover.
2. Remove the nut on top of the filter and remove
the canister.
3. Clean the lint from the filter screen. If necessary,
swirl the filter in a pan of soapy water to loosen
the lint.
4. Reassemble in the reverse order.
WARNING: Wear protective gloves, eye
protection and appropriate clothing when
cleaning the final filter.Being a component of the
vacuum system, the filter is subject to exposure
by sewage effluent or septage. These materials
may contain hazardous chemicals and bacteria,
which can cause infection, injury, or even death
due to contact.
This manual suits for next models
15
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