Vaccon 691-7001 User manual

Water System
Operation and
Maintenance
Manual
691-7001
Section 70Section 70
Section 70Section 70
Section 70
Auxiliary Engine Driven Water Pump

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Water System Operation
and Maintenance Manual
VAC-CON
Safety Instructions
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and correct tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could result in injury
or death.
DO NOT operate or perform any lubrication, maintenance or repair of this product until you have read and
understood the information provided to you by the manufacturer.
Safety precautions and warnings are provided in this manual and on the equipment. It is your responsibility to read
and understand these precautions for your own safety. If these warnings are not followed, bodily injury or death
could occur to you or other persons.
The hazards are identified by the safety alert symbol and followed by a signal word such as CAUTION,
WARNING OR DANGER as shown below.
The message that appears under the signal word explains the hazard and can be either written or pictorially
presented.
Vac-Con Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique that is not specifically recommended by Vac-Con Inc. is used, you must satisfy yourself that it is safe by
the operation, lubrication, maintenance or repair procedure that you choose.
The information, specifications and illustrations in this publication are based on the information that was available at
the time the publication was written. The specifications, torque values, pressures, measurements, adjustments,
illustrations, tools, part numbers and other items may change at any time. These changes can affect the service that
was given to the product. Always contact your Vac-Con Inc. dealer to obtain the most complete and current
information before starting any repair.

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Water System Operation
and Maintenance Manual
Handgun Operation
1. Position the water pump control valve and the hose reel control valve on the front of the hose
reel in the OFF position.
2. Start the auxiliary and run at idle speed.
3. Remove the quick disconnectplugfromthehandgunconnection.
4. Connect the female end of the handgun hose to the handgun, and connect the male end of the handgun hose
tothe handgun connection on the main frame.
5. Make sure the handgun trigger is in the OFF position.
6. To pressurize the handgun, turn ON the handgun system ball valve located on the front bumper curb side.
7. Turn the bottom pump control valve on the front of the hose reel to the ON position.
8. The pressure of the handgun system is set at 650 PSI at auxiliary engine idle speed.
NOTE: NEVER run the truck engine over idle speed while operating the handgun.
9. To depressurize the handgun system, turn OFF the bottom pump control valve first, then turn OFF the
handgunballvalve.
SAFETY NOTE: NEVER point the handgun at, or in the direction of another person while it is
pressurizedor personal injury could occur.

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Water System Operation
and Maintenance Manual
Debris Body Flushout Operation
1. Position the water pump control valve and the hose reel control valve on the front of the hose reel in the
OFF position.
2. Start the auxiliary engine and run at idle speed.
3. Open the debris body flushout ball valve which is located at the water pump.
4. Turn the bottom pump control valve on the front of the hose reel to the ON position. You now have water
to the flushout head inside the debris body.
5. Turn the water pump control throttle on the hose reel counter clockwise to increase the RPM’s of the
auxiliary engine, noting the corresponding water pressure increase.
NOTE: Maximum pressure for 30 GPM systems is 2000-2500 PSI, 60 GPM systems and above is 1800-
2000 PSI.
6. To depressurize the debris body flushout system, turn the auxiliary engine throttle control on the front hose
reel clockwise, reducing the auxiliary engine RPM’s to idle speed. The water pressure gauge will come
down to 700-1000 PSI.
7. Turn the bottom pump control valve on the front of the hose reel to the OFF position.
8. Turn the debris body flushout ball valve to the OFF position.
9. You are now ready to use any other water system on your truck. If you are finished with your cleanup
procedures, turn OFF the auxiliary engine.

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Water System Operation
and Maintenance Manual
Winter Recirculation Operation
1. Position the water pump control valve and the hose reel control valve on the front of the hose reel in the
OFF position.
2. Remove the pipe plug from the bulkhead swivel fitting located below the front bumper of the truck near the
level wind guide.
3. Connect the sewer hose to this swivel fitting, make sure it is tight.
4. Start the auxiliary engine at idle speed.
5. Turn ON the top hose reel control valve on the front of the hose reel.
6. Turn ON the bottom pump control valve on the front of the hose reel. You now have water traveling
through the hose reel and back to the water tanks.
7. Increase the auxiliary engine speed until it reaches 1500 RPM. This will provide ample water circulation
and allow the auxiliary engine to burn enough fuel so the engine will not drool.
NOTE: The auxiliary engine tachometer is located in the gauge panel on the auxiliary engine on the drivers
side of the truck.
8. To stop the recirculation system, first reduce the auxiliary engine RPM’s to idle speed.
9. Turn OFF the bottom pump control valve on the front of the hose reel.
10.Turn OFF the top hose reel control valve on the front of the hose reel.
11. Turn OFF the auxiliary engine.
12.Loosen the swivel fitting holding the sewer hose. There will be some system pressure, so you will
experience some water exposure.
13.After removing the sewer hose, replace and tighten the plug in the swivel fitting.
14.You are now able to utilize your water system.

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Water System Operation
and Maintenance Manual
Procedure to Purge Water System
Units Not Equipped With Air Purge
1. Drain all water from water tanks.
2. Remove nozzle from sewer hose.
3. Connect the end of rodder hose to the fitting provided on the hose guide.
4. Startauxiliaryengine.
5. Start truck engine.
6. Turn the top rodder hose control valve and the bottom pump control valve on the front of the hose reel to
the ON position.
7. Let run until all water is pumped from the hose.
8. Turn the bottom pump control valve and the top sewer hose control valve to theOFF position.
9. Disconnect the rodder hose from the fitting on the hose guide and attach the hose end to the hose on the
hose reel by means of a rope or tie strap.
10. Turn the top sewer hose control valve and the bottom pump control valve to the ON position.
11. Rotate the hose reel clockwise until no more water comes out of the hose.
12. Turn the bottom pump control valve, and the top sewer hose control valve to the OFF position.
13. Openall the handgun connections.
14. Turn the handgun ball valve and the bottom pump control valve to the ON position until all the water has
beendischarged.
15. Turn the bottom pump control valve and the handgun valve to the OFF position.
16. Leavethe handgun connection plugsout.
17. Turn the body flushout valve and the bottom pump control valve to the ON position until all of the water is
out of the body flushout system.

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Water System Operation
and Maintenance Manual
18. Turn the bottom pump control valve and the body flushout valve to the OFFposition.
19. OPEN all of the needle valves on the water pump chambers until all the water is pumped out.
NOTE: Leave the needle valves in the OPEN position.
20. Shut OFFauxiliaryengine.
21. Shut OFF truck chassis engine.
22. Remove the drain caps from the water system bulkhead fittings under the front bumper, curbside.
23. NOTE: Store unit with all the water system ball valves in the ON position.
CAUTION: Water freezes at 32 degrees F. If at all possible try to store unit in an area above this
temperature.

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Water System Operation
and Maintenance Manual
Procedure to Air Purge the Water System
Serial Numbers up to 0292655
1. Drain all water from water tanks.
2. Remove nozzle from sewer hose.
3. Startauxiliaryengine.
4. Start truck chassis engine.
5. Turn top sewer hose control valve and bottom pump control valve on the front hose reel to the ON
position.
6. Turn air purge valve on left side of the water pump to the OPEN position.
7. Allow air to push water from hose.
8. When hose is free of water, rotate hose reel clockwise until all water is drained out.
9. CLOSE air purge valve and turn OFF bottom water pump control valve and top sewer hose control
valve.
10. Remove handgunand plug from the handgunconnection.
11. TurnON handgun valve.
12. Turn ON bottom pump control valve.
13. OPEN air purge valve and wait for all water to be blown from handgun system.
14. Turn OFF bottom pump control valve.
15. Tune OFFhandgunvalve.
16. CLOSE air purge valve.
17. OPEN debris body flushout valve.
18. Turn ON bottom pump control valve.
19. OPEN air purge valve and wait for all water to be blown from water system hoses.
20. Turn OFF bottom pump control valve.
21. CLOSE debris body flushout valve.
22. CLOSE air purge valve.
23. OPEN drain valves at water pump.
24. OPEN air purge valve and wait for all water to be blown out of pump.
25. CLOSE air purge valve.
26. Shut OFF auxiliary engine.
27. Shut OFF truck chassis engine.
28. Remove drain caps from water system bulkhead fittings under bumper, curb side.
29. NOTE: Store unit with all the water system ball valves in the ON position.
CAUTION: Water freezes at 32 degrees F. If at all possible try to store unit in an area above this
temperature.
IF ABOVE PROCEDURE IS FOLLOWED, UNIT SHOULD BE FREE OF WATER.

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Water System Operation
and Maintenance Manual
Procedure to Air Purge the Water System
Serial Numbers 0292656 and up
1. Drain all water from water tanks.
2. Remove nozzle from sewer hose.
3. Startauxiliaryengine.
4. Start truck chassis engine.
5. Turn top sewer hose control valve and bottom pump control valve on the front hose reel to the ON
position.
6. Plug air line with female quick coupler into male quick coupler located below ballvalve.
7. Turn air purge valve on left side of the water pump to the OPEN position.
8. Allow air to push water from hose.
9. When hose is free of water, rotate hose reel clockwise until all water is drained out.
10. CLOSE air purge valve and turn OFF bottom water pump control valve and top sewer hose control
valve.
11. Remove handgunand plug from the handgunconnection.
12. TurnON handgun valve.
13. Turn ON bottom pump control valve.
14. OPEN air purge valve and wait for all water to be blown from handgun system.
15. Turn OFF bottom pump control valve.
16. TuneOFF handgunvalve.
17. CLOSE air purge valve.
18. OPEN debris body flushout valve.
19. Turn ON bottom pump control valve.
20. OPEN air purge valve and wait for all water to be blown from water system hoses.
21. Turn OFF bottom pump control valve.
22. CLOSE debris body flushout valve.
23. CLOSE air purge valve.
24. OPEN drain valves at water pump.
25. OPEN air purge valve and wait for all water to be blown out of pump.
26. CLOSE air purge valve.
27. Unplug air line from below air purge ball valve. (If this step is not done, damage to air brake system could
occur).
28. Shut OFFauxiliaryengine.
29. Shut OFF truck chassis engine.
30. Remove drain caps from water system bulkhead fittings under bumper, curb side.
31. NOTE: Store unit with all the water system ball valves in the ON position.
CAUTION: Water freezes at 32 degrees F. If at all possible try to store unit in an area above this
temperature.
IF ABOVE PROCEDURE IS FOLLOWED, UNIT SHOULD BE FREE OF WATER.

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Water System Operation
and Maintenance Manual
Water Filling Procedure
The water filling stations on VAC-CON units differ depending on the water capacity of the unit.
1. Position truck at water source to receive fresh water supply.
2. If filling from a hydrant, charge or purge the hydrant before hooking up your fill hose. Allow the hydrant to
rununtil clean wateris running through.Connect your fillhose.
NOTE: Using clear water will help extend water pump valves, valve seats, valve springs, and nozzle life.
3. Turn on the hydrant. As you fill the tanks you will see the water level rise in the sight tube. Fill tanks until
water begins to come out of the air vents in either the caps on the lower tanks or the caps on the upper
tanks, depending on which water system you have.
NOTE: Should you be required to fill from a source other than a hydrant, such as a creek, try to pump from the
top of the water level to avoid sucking gravel into the tank. If this is done on a regular basis it is recommended
that you install some sort of pre-strainer to ensure only clean water gets into your water system.
4. While you are still connected to your water source, this is a good time to prime your water pump. This is
accomplishedby following theseeasy steps:
A. Be sure all pet cocks and drain valves have been closed and remove quick disconnect plug from
handgunconnection.
B. Start the auxiliaryengine at idle.
C. Turn handgun valve ON. (frontbumper)
D. Turn water pump valve ON. (hose reel bottom valve)
E. Once you have a solid high pressure stream of water from the open handgun connection,
turn water pump valve OFF.
F. Turn handgun valve OFF.
G. Turn hose reel valve ON.
H. Turn water pump valve ON.
I. Once you have a good flow of water from your hose reel, turn water pump valve OFF.
J. Turn hose reel valve OFF.
K. Turn auxiliaryengine OFF.
L. Replace handgun quick disconnect plug.
Safety Notes
1. Be sure hose reel is connected to the hose swivel provided before turning hose reel on. This will prevent
anyone from being struck by the hose.
2. DO NOT operate or pressurize your sewer cleaning hose with a nozzle on it unless the nozzle has been
inserted into a pipe or a closed container.
3. NEVER put your hands in front of, or point a pressurized sewer cleaning hose at anyone. High pressure
water can cut a persons skin or cause injury to someone attempting to avoid the spray.

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Water System Operation
and Maintenance Manual
Tensioning Water System Drive Belts
Important Notes
1. It is very important that the drive belts are properly tightened.
2. Insufficiently tightened belts are a fire hazard and will cause excessive belt failure.
3. Excessively tightened belts will decrease bearing life and could cause shaft failure, and premature belt failure.
4. Correct belt tension MUST be maintained at all times during operation.
5. It is very important to watch the belts closely during the first 100 hours of operation as more frequent
adjustment may be required during this period when slight belt sealing and initial stretching will occur.
6. Belts or power bands MUST be replaced in complete “matched” sets.
7. Belts are within the correct tensioning range when a force of 20 to 30 pounds applied midway between the
sheaves is required to deflect each belt powerband, approximately 1/2".
8. DO NOT attempt to move or adjust the water pump or pump sheave. The engine takeups should be utilized
for belt tensioning.
9. DO NOT attempt to adjust belts unless the auxiliary engine control fuse has been removed from the control
panel.
Tightening Belts
1. Loosen the four engine mounting bolts.
2. Using an 1 1/8" wrench, adjust belt tension by turning both engine takeup rods an equal number of turns, one
or two turns at a time. Check tension and repeat if necessary.
3. Check sheave alignment with a straight edge or string, making sure the straight edge or string contacts the face
of both sheaves immediately above the shafts at the same time to make sure there is no angular misalignment
or offset between the sheaves.
4. Check for correct tension.
5. If misalignment exists, adjust one engine takeup rod at a time until sheaves are in alignment and belts are
correctly tensioned.
6. Tighten engine mounting bolts.
7. Recheck alignment and tension and make any further adjustments if necessary.
Belt Replacement
1. Remove belt guard.
2. Loosen the four engine mounting bolts.
3. Loosen the belts be moving the engine approximately 2" by means of the takeup rods using an 1-1/8"
wrench. Turn each takeup rod an equal number of turns.
4. Check the adjustment bolts on the pillow block mount to make sure they are tight against the pillow block.

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Water System Operation
and Maintenance Manual
Typical Swivel Joint Maintenance Parts
A. Grease Plug or Zerk Fittings
B. Balls
C. "O"Rings
D. ChevronPacking
E. BallPlugs
Service Parts for 1” and 1-1/4” Swivel Joints
Packingkitincludes: Chevron Packing and "O" Rings.
RepairKitincludes: Chevron Packing, Back-up Ring, Balls, and "O"Rings.
1-1/4"Swivel: Packing Kit - 663-0111
Repair Kit - 663-0108
1"Swivel: Packing Kit - 663-0107
Repair Kit - 663-0104
Lock Bar - 663-0124
Lock Bar Screw - 601-0322
Grease Zerk - 605-0003
1. SwivelNipple
2. HoldingNut
3. Body
8. Back-up Ring
9. Male Adapter Ring
10. Lock Bar

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Water System Operation
and Maintenance Manual
Servicing 1” and 1-1/4” Swivel Joints
1. Swivel joints are greased at the factory. Greasing is required on an occasional basis depending on usage.
2. Provision has been made for adjustment of the packing. After packing wears, remove the lock bar, turn nut
clockwise to next locking slot and reinstall lock bar. Process may be repeated until packing has worn too badly
to effect proper seal.
Repacking 1” and 1-1/4” Swivel Joints
1. Remove swivel fromtruck.
2. Remove lock bar #10.
3. Remove nut #2 and nipple assembly #1 from the body #3 by turning nut counter clockwise.
4. Remove back-up ring #8 from body.
5. Remove 2 packing rings #D.
6. Remove male adapter #9.
7. Clean packing chamber and reinstall male adapter #9, new packing #D, and back-up ring #8, grease all parts
thoroughly. Replace"O" ring if necessary.
8. Insert nut #2 and nipple assembly #1 in body #3 and reassemble. Rotate nipple occasionally as the nipple
passesthrough the packing.
9. Screw nut clockwise until compression on packing causes nipple to rotate with a mild amount of torque.
10. You do not need to handle the balls or disassemble the nut and nipple to repack the swivel joint.

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Water System Operation
and Maintenance Manual
Vac-Con Water Pump Service
VAC-CONpumps are precision machines which embody proven design concepts, exacting manufacturing proce-
dures,and full load testing.
Given proper installation and periodic maintenance, your VAC-CON pump will provide extended, low cost,
dependableservice inherentin its quality.
Since the reliability of any fine machine depends in part on the thoroughness of the operator, attention to all details of
proper periodic maintenance will pay large rewards in the form of dependable economic performance, with lowest
lifecycle cost.
Safety
The truck engine must be shut OFF with the key removed from the ignition and the water pump hydrostatic drive
system disengaged before attempting any service on the pumps or pump drive. Air surrounding the unit should be
freeof toxic, flammable, or explosive gases.
The tools needed should be planned for in advance (see valve removal instructions) and should be clean and of
adequate size. A torque wrench will be required to tighten connecting rod cap screws.
Storage
Change oil in crankcase prior to storage. Make certain pump is drained of all water (see air purge instructions) and
leave water pump drain valves in the OPEN position.
Lubrication and Maintenance
Refer to Water Pump Owners and Service Manual for repair procedures.
Referto lubrication diagram in Safety, Operation and Maintenance Manualfor proper lubricant.

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Water System Operation
and Maintenance Manual
Notes

Vac-Con Inc.
969 Hall Park Drive
Green Cove Springs, FL 32043
phone: [phone]
FAX: [phone]
www.vac-con.com
Vac-Con part number 691-7001
printed in USA
January 2002