2100 Fan

503082
2100 Fan Manual

Revision
Release history
0.
Initial release - 2-23-2007
1.
Restructured maintenance to share common pages with new blower manual. Misc updates to make consistant
with new blower manual. Updated warranty forms. Added MSDS for hydraulic oil. Removed Vickers pump pages in
Troubleshooting. (AC 3-30-2007)
2.
Updated biological safety warning. Updated rodder pump TS pages to match current production. (AC 5-3-2007)
3.
Added new central grease system to options. (AC 5-31-2007)
Vactor supplied International, Sterling/Freightliner chassis warranty

forms and Vactor warranty form is located in the General Section.
Fill out and send in before unit is put in service.
Warranty & Technical Service Team Directory

The Vactor/Guzzler Service Team provides assistance to all Vactor/Guzzler dealers and customers via remote
(telephone, e-mail, fax, etc.) and on-site (dealer/customer visits, field training, etc.) support operations.
Toll-Free Telephone (800) 627-3171

Fax (815) 673-1621 Website www.vactor.com
8:00 AM - 5:00 PM Monday-Friday (Central Time)
Technical Support 24 hours/Day, 7 Days/Week!
(877) 342-5374
Technical Support Specialists
These are your first point-of-contact members of the Service Team, for technical service related issues. These
experts facilitate the sewer cleaning and industrial product requests pertaining to unit performance, specification,
maintenance, repair/troubleshooting, parts identification, and features/options. Please direct your front-line
inquiries to these service professionals.
Tracy Krebsbach Service Manager Ext. 257

E-mail: tkrebsbach@vactor.com
Mike Hunter Ext. 259

E-mail: mhunter@vactor.com
Rod Watts Ext. 209

E-mail: rwatts@vactor.com
Josh Wiechman Ext. 363

E-mail: jwiechman@vactor.com
Thomas Wheeler Ext. 267

E-mail: twheeler@vactor.com
Direct Channel Quick Repair Technician
Warranty
Mike Rinaldo Warranty Administrator Ext. 241

E-mail: mrinaldo@vactor.com
EFFECTIVE DATE 2/23/2007
Pride in partnership ...

training from Vactor-Guzzler!
At Vactor-Guzzler, our partnership
with you includes our commitment to
insure that youre getting the maximum
performance from your Vactor, Guzzler,
Hydro-excavator, VaxJet, or GRV truck.
Thats why we offer a full range of
training giving you the know-how to
safely and efficiently operate, troubleshoot, repair, and maintain your equipment. Training to help you:
* operate safely and efficiently at
all times
* select the right tools for every
application and environment
* save time and money on troubleshooting and repairs
* protect your investment by using
proper maintenance techniques
Whether youre an operator, dealer,
mechanic, or contractor, Vactor-Guzzler
training will help you boost performance and your bottom line!
Make the most of your partnership
with Vactor-Guzzler. Call us today for
complete information on upcoming
training opportunities.

Training at Vactor-Guzzler takes
advantage of our multimedia classroom
and hands-on lab where youll enjoy working with our expert instructors. Small class
size and an informal atmosphere mean you
will have ample opportunity to ask
questions and get answers for your specific
needs.

In-the-field demonstrations provide
additional hands-on learning showcasing
the right tools and techniques for safe,
efficient operations. The key to getting the
maximum performance out of your VactorGuzzler equipment!

Learn about our entire range of
custom-crafted options and tools designed
to boost your systems performance in
every application. Weve refined our
products during thirty years of partnering
with our customers to develop the worlds
leading vacuum loader technologies!

Take a tour of our facility to see
how we build in quality at every step of the
design and production process. Meet with
our experts in engineering, manufacturing,
and customer service to get connected
with your entire Vactor-Guzzler support
team!
Training workshops held at our facility are typically two or three days in length,
depending on the topic and the audience. Sessions focus on the specific needs
of operators, mechanics, and dealers. On-site training at your location may also
be arranged. Call Mrs. Laura Reihl, Customer Service Coordinator, at
815 - 672 - 3171 extension 311 or visit our web site at www.vactor.com for
complete info. on training from Vactor-Guzzler!
A division of Federal Signal

Rev. date June 12, 2006
Contents
Vactor 2100 Series Operators Manual
Warranty & Technical Service Team Directory. ................................................ iv

Warranty Statement.......................................................................................... xiv
Warranty Claim Form........................................................................................ xvii
Forward............................................................................................................. xviii
Introduction....................................................................................................... xix
Service Hotline. ................................................................................................. xxi
Warranty Registration...................................................................................... xxii
International Chassis Warranty Form............................................................. xxiv
Sterling Warranty Registration Form. ........................................................... xxvi
Caterpillar Engine Warranty Registration Form. ........................................ xxviii
Operations ...............32
Overview..............................................................................................................32
Debris Body.........................................................................................................36
Debris Body - Float Ball & Screen....................................................................37
Debris Body Level Indicator...............................................................................38
Debris Body - Rear Door & Locks. ....................................................................39
Boom Operation...................................................................................................42
Boom - Pendant Control. ...................................................................................45
Vacuum Tube........................................................................................................46
Water Tanks........................................................................................................48
Water Tanks - Filling..........................................................................................49
Water Tanks - Draining.......................................................................................51
Symbols. ..............................................................................................................52
Water System - Rodder (Water) Pump...............................................................54
Water System - Rodder (Water) Pump - Water Flow........................................55
Water System - Rodder (Water) Pump - Options...............................................56
Water System - Draining.....................................................................................57
Water System - Draining - Rear Mounted Pump................................................58
Water System - Draining - Side Mounted Pump. ................................................59
Hose Reel............................................................................................................60
Hose Reel - Telescoping.....................................................................................61
Hose Reel - Rotating Option. .............................................................................62
Hose Reel - Reel Controls................................................................................63
Hose Reel - Water Valve....................................................................................64
Hose Reel - Manual Wind Guide.........................................................................65
Footage Counter. ...............................................................................................66
Hand Gun.............................................................................................................68
Handgun - Operation...........................................................................................72
Water System - Standard Rodder Nozzles........................................................74
EFFECTIVE DATE 5-31-2007
viii

Water System - Rodder Nozzle Theory.............................................................76
Water System - Rodder Nozzle Ratings. ...........................................................77
Water System - Decimal Chart...........................................................................83
Hydraulic Pump - Engaging (starting)................................................................84
Hydraulic Pump - Engaging (starting) - Manual Transmissions.........................85
Hydraulic Pump - Engaging (starting) - Auto Transmissions.............................86
Auxiliary Engine - Starting.................................................................................87
Fan.......................................................................................................................88
Hose Reel - Control Panel................................................................................89
Vacuum System - Inlet/Outlet Seals..................................................................92
Operating Procedures........................................................................................93
Operating Procedures - Sewer Systems. ..........................................................94
Operating Procedures - Visual Inspection.........................................................95
Operating Procedures - Hazards.......................................................................96
High Pressure Water..........................................................................................97
Starting Operation - Setting Up (Rodding)........................................................99
Starting Operation - Setting Up. .....................................................................100
Starting Operation - Rodding...........................................................................101
Jet-Rodding Operation......................................................................................102
Jet-Rodding Operation - Stop Rodding............................................................103
Vacuuming - Positioning The Truck. .................................................................104
Vacuuming - Set Up. ..........................................................................................105
Vacuuming - Operation......................................................................................106
Vacuuming Tips. .................................................................................................108
Simultaneous Rodding/Vacuuming.....................................................................109
Shutting Down. ................................................................................................. 110
Moving & Stowing Equipment............................................................................ 112
Dumping & Draining Debris Body...................................................................... 114
Dumping the Body.............................................................................................. 115
Dumping the Body - Controls........................................................................... 116
Debris Body Prop.............................................................................................. 118
Debris Body - Rear Door Prop. ....................................................................... 119
Options ...................122
Accumulator......................................................................................................122
Dual Accumulators. ..........................................................................................124
Aero Hose Reel.................................................................................................126
Auto Wind Guide................................................................................................130
Boom Worklights..............................................................................................134
Spotlight...........................................................................................................135
ix

Debris Body Washout. ......................................................................................136
Cyclone Separator............................................................................................138
5 x 5 Boom.........................................................................................................140
Decanting...........................................................................................................146
Extendable/Telescopic Boom............................................................................148
Flusher System.................................................................................................150
Folddown Pipe Rack..........................................................................................152
Grease Manifolds..............................................................................................154
Central Grease System....................................................................................156
Central Grease System - Installation..............................................................157
Central Grease System Components...............................................................158
Hand Gun Hose Reel.........................................................................................160
Hyrdo-Excavating Digging Gun.........................................................................162
Hydraulic Tool Package...................................................................................164
Inspection Port and Telescoping Ladder.........................................................166
Lateral Cleaning Kit. ........................................................................................168
Laval Separator.................................................................................................170
Load Limit Alarm................................................................................................172
Multi-Flow System............................................................................................176
Radio Remote Control Operation....................................................................178
Recirculating System........................................................................................182
Reclamation System. .........................................................................................184
Remote Drains...................................................................................................186
Safety Lights.....................................................................................................188
Tanks Joined......................................................................................................190
Trash Pump (internal).......................................................................................194
Vac On The Go (Fan units only)........................................................................196
Maintenance ...........202
New Unit Service Checklist..............................................................................202
Service Checklist..............................................................................................203
Lubrication.........................................................................................................205
Lubricants..........................................................................................................206
Lubrication - Grease Manifold..........................................................................208
Hydraulic Oil.....................................................................................................209
Hydraulic Oil Filter..........................................................................................210
Hydraulic System - Reservoir.......................................................................... 211
Boom Lubrication (telescopic or extendable)..................................................212
Fan Drive...........................................................................................................214
Fan Cleaning......................................................................................................215

Fan Replacement - 4 Cylinder units.................................................................217
Fan Replacement - 6 Cylinder units.................................................................219
Fluid Coupler Maintenance. .............................................................................222
Fluid Coupler Replacement..............................................................................223
Auxiliary Engine Transmission. .........................................................................229
Outlet Seal Adjustment....................................................................................230
Material Flow....................................................................................................231
Pre-job / Daily Checklist..................................................................................232
Make/Break Seal Adjustment............................................................................234
Rear Door Seal. ............................................................................................236
Butterfly Valve Adjustment.............................................................................240
Air System.........................................................................................................242
Hose Reel Assembly..........................................................................................244
Hose Reel Swivel Joint.....................................................................................245
Hose Reel - Center Shaft Bearing. .................................................................246
Telescopic/Rotating Hose Reel Bearing..........................................................247
Rodder Hose Replacement. ..............................................................................248
Shark Rodder Hose Replacement. ...................................................................249
Water System....................................................................................................252
Draining the Water System (Cold Weather)....................................................253
Y-Strainer..........................................................................................................258
Sewer Cleaning Hose Repair Instructions. .....................................................260
Rodder Hose Inspection & Mending Instructions............................................263
Swager Application Specifications. ..................................................................268
Piranha Hose.....................................................................................................269
Shark Hose........................................................................................................273
Reference - Bolt Torque..................................................................................294
Troubleshooting ....300
Fan - Cotta Gear Box. ......................................................................................300
Pump - Directional Valve Is Not Shifting.........................................................302
Water System - Rodder Pump...........................................................................303
Hydraulic System - Hoist..................................................................................310
Hydraulic System - Boom..................................................................................312
Power Distribution Board................................................................................315
Power Distribution Board - Basic....................................................................316
Power Distribution Board - Ground Switched................................................317
Power Distribution Board - Ignition Switched.................................................318
Power Distribution Board - Load Controlled.................................................319
John Deere Throttle. .......................................................................................320
xi

John
John
John
John
John
John
Deere Throttle
Deere Throttle
Deere Throttle
Deere Throttle
Deere Throttle
Deere Throttle
- Part Locations. ...........................................................321

- Schematic.....................................................................322
- Hose Reel Controls...................................................323
- Main Junction Box.......................................................326
- Verify Controls..........................................................327
- Throttle Programming................................................328
xii
Warranty Statement
WARRANTY STATEMENT
VACTOR MANUFACTURING COMPANY / GUZZLER MANUFACTURING COMPANY ( the Seller) warrants
that, on each new Vactor or Guzzler (hereafter known as Machine or Equipment or Unit), The Seller will
repair or replace, or cause to be repaired or replaced, any defect in material or workmanship which occurs within
one (1) year from the date of shipment by the original user-purchaser. This warranty extends only to the first
Purchaser of Equipment for use and only so long as the machine has been used and maintained in a normal
and reasonable manner as described in its operation and maintenance manual(s). This warranty shall not apply
to any Vehicle which has not been properly maintained or has been subjected to misuse, neglect, accident or
damage, or which has been modified, changed, or reworked in any way without the prior written approval of
Seller.
In addition to our standard warranty, Vactor Mfg., Inc. warrants the Glycol Recovery Vehicle (GRV) for an
additional six (6) months for a total of 18 months (1-1/2 years).
In addition to our standard warranty, Vactor Mfg., Inc. warrants the watertanks on 2100 series, HXX series and
Jetters for an additional 9 years against corrosion or rust through, making a total of 10 years warranty on water
tanks.
In addition to our standard warranty, Vactor Mfg., Inc. warrants the debris tanks on 2100 series and HXX series
for an additional 4 years against corrosion or rust through, making a total of 5 years warranty on debris tanks.
In addition to our standard warranty, Vactor Mfg., Inc. warrants the centrifugal compressor and housing on 2100
series and HXX series for an additional 4 years against corrosion or rust through, making a total of 5 years
warranty on the centrifugal compressor and housing.
This warranty may not be assigned by Purchaser. Repair or replacement by Seller shall not extend the warranty
period. Repairs or replacements are to be made only at Sellers authorized distributors location or at other
locations approved by the Seller in writing. Any repair or alteration that is not performed by an authorized
distributor will void this warranty.
The Seller will cause to repair or replace, as Seller may elect, any part or parts of such machine which Sellers
examination reveals to be defective in material or workmanship. Such repair or replacement will be at no cost to
Purchaser, but will be F.O.B. shipping point. It is expressly understood that Sellers liability is limited to furnishing
such parts within a reasonable period of time. Seller will not be liable for any damages losses or expenses
arising in connection with the use or inability to use said Equipment.
This warranty covers only malfunctions resulting from defects in material or workmanship of the Equipment,
and parts and components thereof manufactured by Seller. Major components of the Equipment are not of
Sellers manufacture including but not limited to power plants, air compressor systems, hydraulics, blowers,
truck chassis, transmissions, batteries or tires which are used by Seller as part of the equipment, but are not
warranted by Seller. Seller does, however assign to purchaser any warranty capable of assignment that is
extended by the manufacturer of such non-Seller.
Consumable items such as, but not limited to, light bulbs, electrical fuses, oil and air filters, filter bags and cages,
vacuum hose, vacuum elbows, vacuum line reducers and vacuum line gaskets are not warrantable under this
policy.
It is the Purchasers responsibility to use the Equipment for the purpose and in the manner described in the
Operational Manual supplied with the Unit, and to assume any liability for damage or injury resulting from
misuse, abuse, negligence, accident or improper maintenance, including the removal or alteration of safety
guards and devices installed on the equipment at the time of delivery to the original user-purchaser.
This Limited Warranty shall not apply to:
1.
Normal adjustments and maintenance services or damages that may result due to the improper
performance thereof.
2.
Normal wear parts such as but not limited to debris hose and tubes, filter bags and cages, oil and air
filters, etc.
xiv
VACTOR WARRANTY
3.
Repairs, modifications or alterations made without the written consent of the Seller in writing which, in the
Sellers sole judgment, have adversely affected the Machines performance, safety or reliability.
4.
Failures resulting from the machine being operated in a manner or for a purpose not recommended by the
Seller.
5.
Repairs or replacements made by the Purchaser without prior written consent by the Seller.
6.
Components or systems that have been subjected to misuse, negligence, accident, or improper
maintenance.
Used Equipment is sold AS IS. Seller makes NO WARRANTY concerning its merchantability, condition,
durability, age or model year, or fitness for any purpose whatsoever.
IT IS AGREED THAT THIS WARRANTY SETS FORTH PURCHASERS EXCLUSIVE RIGHT AND REMEDY
AGAINST SELLER WITH RESPECT TO THE EQUIPMENT. IT IS IN ADDITION TO THE INDIVIDUAL MODEL
WARRANTY SUPPLIED IN THE UNITS MANUAL. SELLER MAKES NO REPRESENTATION ABOUT THE
SUITABILITY OF THE EQUIPMENT FOR ANY PARTICULAR PURPOSE OR THE MERCHANTABILITY
THEREOF AND EXPRESSLY DISCLAIMS ALL LIABILITY FOR LOSSES OF USE, LOST PROFIT,
CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND OR NATURE, FROM WHATSOEVER CAUSE
OR THING ARISING, EVEN IF SELLER HAS BEEN ADVISED OF THE LIKELIHOOD OF SUCH DAMAGE
AND WHETHER OR NOT SUCH DAMAGES WERE OR WERE NOT FORESEEABLE, INCLUDING, BUT NOT
LIMITED TO, CLAIMS OF LIABILITY BASED UPON TORT, NEGLIGENCE, STRICT LIABILITY, OR BREACH
OF WARRANTY IN CONNECTION WITH THE MANUFACTURE, SALE, ALTERATION, USE, REPAIR OR
REPLACEMENT OF EQUIPMENT, OR ANY PART THEREOF.
The use of any part or parts in connection with the Equipment that have not been approved by Seller may
invalidate this warranty. Seller reserves the right to determine, in its sole discretion, if the use of non-approved
parts operates to invalidate the warranty.
Seller makes no representation that the machine has the capacity to perform any functions other than those
contained in sellers written literature, catalogs, or specifications accompanying delivery of the machine. Nothing
contained in this warranty shall make seller liable for loss, injury, or damage of any kind to any person or entity
resulting form any defect or failure in the machine.
No person or affiliated company representative is authorized to give any other warranties or to assume any
other liability on behalf of seller in connection with the sale, servicing, or repair of any machine manufactured by
seller. Seller reserves the right to make design changes or improvements in its products without imposing any
obligation upon itself to change, improve or replace previously manufactured products.
VACTOR / GUZZLER WARRANTY PROCESSING POLICY
The Warranty Processing Policy has been implemented by Guzzler Manufacturing Inc., (Guzzler) to expedite the
processing of warranty claims. This policy commits Guzzler to processing the warranty claim within sixty (60)
days of the issuance of the Return Goods Authorization (RGA) date.
The warranty processing policy, while imposing performance criteria upon Guzzler, requires the dealer/customer
to assure proper and timely submission of support materials to Guzzler to allow for completion within the
established period.
WARRANTY CLAIM PROCEDURE
When you have a claim for warranty, you must provide the following basic product information to the Warranty
Administrator to initiate any warranty claim processing.
Model Number
Serial Number
Chassis Vin Number
xv
VACTOR WARRANTY
This information must be included with any written documentation or be available when calling the Warranty
Administrator. Claims will not be processed without the above information.
The warranty administrator at Vactor may be reached in the following ways:
Telephone
815-672-3171
or by mail:
Vactor Manufacturing Inc.
815-673-3841
ATTN: Warranty Department
Fax
815-673-1621
1621 S. Illinois St.
Streator, Illinois 61364
Ask for Service or Warranty Administrator
Parts requested under warranty will be shipped with the understanding that the defective or filed parts are to
be returned to Vactor within thirty (30) days. When parts are requested, the Warranty Department will assign a
Return Good Authorization (RGA) number. This number will be put on a RGA form and either mailed or faxed to
the dealer/customer. This form MUST accompany any part being returned to the factory for warranty. The RGA
will have a date of initiation affixed to it. This date will be key in the performance of the dealer/customer and
Vactor under this policy.
Parts must be returned and received by Vactor within thirty (30) days of the initiation date affixed to the
Return Goods Authorization (RGA). Parts not returned within thirty (30) days will result in a rejection of
the claim and the replacement parts shipped will be due and payable.

The shipment must be freight pre-paid to:
Vactor Mfg. / Guzzler Mfg.
Streator, Illinois 61364
Return C.O.D. shipments will not be accepted. Return freight for approved claims will be reimbursed.
If Vactor determines that the parts do not need to be returned for warranty processing, the dealer/customer will
be notified in writing by Vactor.
Using the enclosed warranty claim form the dealer/customer is required to provide a brief description of the
failure or defect and enclose the form with the returned part(s) and RGA.
Upon receipt of the part(s) Vactor will inspect the parts to make a determination of warranty. Vactor will notify the
dealer/customer within sixty (60) days of the RGA initiation date of the warranty.
NOTE: Failure to return the requested parts within the set time frame will void the warranty claim.
Warranty labor will be paid at a Vactor established rate per hour. Warranty labor is paid on actual repair or
replacement time based on a flat rate schedule. Excluded from warranty reimbursement are: travel time,
mileage, towing or similar service, pre-delivery checks, routine adjustments, normal maintenance, inspections,
diagnostic time or testing.
WARRANTY REIMBURSEMENT WILL BE ISSUED AS A CREDIT TO THE DEALER/CUSTOMERS
ACCOUNT.
Please make copies of the claim form on the next page for submitting a claim.
xvi
Warranty Claim Form

VACTOR WARRANTY
xvii
VACTOR
orward
F
Vactor Manufacturing, Inc. is happy to welcome
you to our growing family of Vactor and Guzzler
customers. The current series of Vactors,
Guzzlers and accessory equipment are the latest
developments in the continuous research program
carried out by the Vactors engineering staff. This
program is formulated to bring you the latest and
most efficient pneumatic cleaning and jet-rodding
equipment available in the world today.
General Information Section
Terms: Standard terms are NET cash within 30 days

from date of invoice to customers with approved
credit.
Shipments: All shipments, unless otherwise quoted,
are F.O.B. ex--factory. Claims for shortages or
damages in transit shall be made by the Consignee
against the Carrier. If shipping instructions are
not given, we will decide how to ship. We are
not responsible for products after delivery to the
transportation company. We are not responsible for
delays resulting from causes beyond our control.
Good operation and a planned maintenance

program, as outlined in this manual, are of vital
importance in obtaining maximum performance and
long life. Instructions on the operation and preventive
maintenance of the current series Vactors and
Jet-Rodders, as well as applicable parts lists are
contained herein. The operator should familiarize
himself thoroughly with the contents of this manual
before operating the equipment or carrying out
maintenance procedures.
Returned Material: Goods will not be accepted for

return or credit unless pre-authorized by us. Credit
or allowance for authorized return of new parts will
be based on condition of part, price originally paid
and current parts prices. A restocking charge may be
made, if required. We will not allow credit for return
of used parts unless specifically authorized.
INFORMATION FOR ORDERING PARTS
The information, specifications, illustrations and

parts numbers in this publication are based on
the information in effect at the time of approval
for publication. We are constantly improving our
products and, therefore, reserve the right to make
changes at any time without notice.
Parts
When ordering parts or accessory equipment, refer
to the Vactor Manufacturing, Inc. name plate. The
name plate (one located on Vactor equipment, one
located in cab of truck) lists the model and serial
number of your Vactor. The model number and serial
number of your Vactor are also listed in the front of
the parts book. It is important that the model number
and serial number be included with ALL parts orders
to insure prompt service and necessary replacement
parts. Parts should be ordered from Vactor
Manufacturing, Inc. through your Vactor distributor.
If a question arises concerning your Vactor product

or this publication, please contact your Vactor
Manufacturing, Inc. distributor.
SALES POLICY
Prices: All merchandise will be billed at prices at the
time of shipment, unless otherwise stated.
Trucks
Refer truck parts orders to your local chassis
distributor following the instructions in the truck
manual.
xviii
VACTOR
I ntroduction
INTRODUCTION
PROPER USE OF THE PARTS MANUAL
This manual provides the general information that
will enable operation and maintenance personnel
to understand the unit and its accessories. Each
Vactor Parts Manual is customized for the individual
unit shown on the binder cover. Each Vactor unit
is unique unto itself. The individual specifications
and option package make this unit different from
any other unit. This manual shows those unique
differences and should only be used to order parts
for the serial numbered unit shown on the binder
cover. Use of this manual for any other unit may
cause incorrect parts to be ordered.
by Vactor such as engine components. It is also the

case for electrical and hydraulic components. When
an electrical or hydraulic component is referenced
(REF) it is normally shown in the electrical or
hydraulic schematics supplied for that unit. In some
cases the particular part number for a item shown in
the breakdown is left blank. These items are usually
electrical or hydraulic and are therefore shown in the
individual schematic for that unit.
EXAMPLE: The hydraulic cylinders do not have
part numbers listed. If you look at the hydraulic
schematic for the boom you will find all of the
individual cylinders listed.
Each manual has tabs A through L. An index of

these tabs is at the beginning of the manual. All of
the tabs may not be used on a particular unit. If a
section, or tab, is not used a sheet is installed in
that section explaining that the particular section
is not used. If the section is used, the particular
information shown on the index is illustrated in that
section.
This is done specifically because the same base

drawing can be used on many different units. Some
units may require a special spacer in the cylinder to
restrict its movement. Again, this would be reflected
in the part number shown in the schematic not in the
parts page.
If after going through the manual, you still cannot
find the particular part you are after, feel free to
contact the Vactor parts and service department.
Please have the model and serial number of the
unit that you are working on, available to give to the
parts and service representative at Vactor. He or
she must have the correct model and serial number
of the unit in order to look up and get the correct
information.
EXAMPLE: Section F is the BOOM section of the

manual If the particular unit does not have a boom
on it, this section is empty. If the unit does have a
boom on it, all of the information pertaining to that
particular boom is shown in that section.
Many times the information in a section will show
the word (REF) in place of a part number. This is
generally the case with items not normally supplied
xix
VACTOR
I ntroduction
This manual is for use only with units meeting Vactor/

Guzzler Mfg., standards. If your unit does not meet these
standards, contact your Vactor/Guzzler representive to
have your unit retrofit to meet these standards.
OWNERS MANUAL COVERING OPERATION,

SAFETY, UNIT IDENTIFICATION AND REGISTRATION
FOR VACTORS, GUZZLERS, VAXJETS AND JET
RODDERS.
Manufacturing, Inc.
Streator, IL 61364
Ph: 815-672-3171
Fax: 815-672-2779
Subsidiary of
Federal Signal
Corporation
IMPORTANT NOTICE
It is essential that everyone associated in any way with a Vactor Mfg. product thoroughly understand and
apply the contents of this manual. It is the responsibility of the owner to train his employees in the operation
and safety procedures while operating or repairing this equipment.
PLEASE KEEP VACTOR/GUZZLER MFG. INFORMED OF ANY CHANGE OF VEHICLE OWNERSHIP OR

ADDRESS.
THIS OPERATORS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF THE YOUR UNIT
AND SHOULD BE WITH THE VEHICLE AT ALL TIMES FOR READY REFERENCE.
xx
VACTOR
ervice Hotline
S
Vactor (EPG) Technical Service Hotline
24 Hour
Vactor now has in place a 24 hour a day service hotline. In the USA or Canada Call:
877-DIAL EPG or 877-342-5374. Outside the USA or Canada call 847-741-4330.
You will be asked for specific information pertaining to the type of unit you are calling about, Vactor, Elgin,
Guzzler, etc. You will be asked for the zip code you are calling from. Your call will then automatically be
transferred to the Vactor dealer closest to you. If it is after normal business hours and the closest dealer to you
does not have a 24-hour line, your call will be transferred to a factory service technician.
When the dealer or the technician answers, you will be asked for the model and serial number of the Vactor unit
you are working on. Please have that number available. It will definitely help to expedite our being able to help
you with any questions or problems you have. Our plan is to service our customers to the best of our ability 24
hours a day, seven days a week, no matter where you are in the world!
xxi
VACTOR
arranty Registration
W
Manufacturing, Inc.
Streator, IL 61364
Ph: 815-672-3171
Fax: 815-672-2779
Subsidiary of
Federal Signal
Corporation
WARRANTY REGISTRATION FORM

(Please fill out, copy, sign and send original signed copy to above address)
Model
Serial No.
Chassis Model No.
Chassis Serial No.
Date Warranty Mailed
Date Placed in Service
Distributor
Name
Address
City
GVW Rating
State
W/B
Zip
C/A
I have read, understand and will apply the contents of your Vactor/Guzzler Mfg. Warranty, Safety, Operation and
Maintenance Manual.
(WARRANTY VOID UNLESS SIGNED)
Owners Signature
xxii
International Chassis Warranty Form
Southland
International
Trucks, Inc.
INTERNATIONAL CHASSIS
WARRANTY UPDATE REPORT
This form registers both the chassis and engine.

Customer Name
Street Address
City, State, Zip Code
Maiiling Address
City, State, Zip Code
Business Contact Name
Phone Number
Fax Number
Chassis Model Number
Chassis Serial Number
Delivery Date
Mileage At Delivery
PLEASE RETURN TO:

Wayne Buckler
Southland International Trucks, Inc.
200 Oxmoor Boulevard
Homewood, AL 35209
Phone: 800-844-6226
Fax: 877-738-0146
Email: wbuckler@southlandtrucks.com
Sterling Warranty Registration Form

WAR275
FREIGHTLINER
Warranty Start
A DaimlerChrysler Company
*
*
LLC
Replaces Customer Warranty Acknowledgment - WAR392 and Delayed Warranty Start Form
Form must be completed and returned to Freightliner LLC.
Online registered
Vehicle is delayed start
NOT Online registered
Dealer
Contact Name
Annette Fisher
DLR / BB Code
Company Name
Dave Gill Trucks, Inc.
32 D F
Phone
309 / 698-7162
Email
Fax
309 / 698-9450
Address
City
3901 N. Main Street

State (Province)
East Peoria
Vehicle
61611
Vehicle Identification Number (VIN)
FTL
X STL
FCC
ALF
Date in
Service
Zip
Illinois
WST
Unimog
Distance at in service
Hours (if applicable)

MI
Customer
Name
Phone
Address
KM
HR
FAX
City
State / Providence
Zip
I certify that this vehicle will be used only for the following vocation (check one only: exclude for ALF, FCC, Unimog)
A85-001 Refuse
A85-002 Pick-up and Delivery
A85-005 Line Haul
A85-006 Rescue and Emergency
A85-016 Recreation
A85-007 Oil Field
A85-009 Farm
A85-015 Airport
A85-027 Heavy Machine Haul
A85-020 Fire
A85-011 Construction
A85-013 Mining
I understand that towing may not be
included in my coverage.
X A85-010 Utility/Repair Maintenance
A85-014 Wrecking
A85-012 Logging
I have reviewed the Customer Protection Plans.
I understand that all information,

reguarding this vehicle
I accept towing coverage for this

vehicle
I accept extended coverate tor this

vehicle.
(e.g., Recall and Field Service

Campaings, etc.) will be mailed
I reject towing coverage for this

vehicle
I reject extended coverate tor this

vehicle.
to the above (Customer)

name and address.
I acknowledge receipt of the applicable

Owner's Warranty Information book and
accept the terms and conditions set forth
therin including the Limited Warranty,
Warranty disclaimer, and Limitation
of Liability.
Customer signature
I certify that I have received the applicable

Maintenance Manual and aoperator's Manual.
I acknowledge that I have been instructed
on correct fifth wheel operation (if applicable).
I acknowledge that the Federal

Safety Standards and Emission
stickers are affixed to the driver's
doorframe.
Date
A Customer Signature and
Please return completed form to:
Correct Phone # Must be
Dave Gill Trucks, Inc.

Attn: Annette Fisher
3901 N. Main Street
East Peoria, IL 61611
included or Sterling will not

process this information.
Thank you.
Caterpillar Engine Warranty Registration Form
This is only required on Vactor supplied Sterling chassis.
Complete and return this form to:

Altorfer Power Systems
PO Box 2184
Cedar Rapids Iowa 52406-9811
Operations
Operations
Vactor 2100 Fan
verview
O
Operations
Passenger Side View
contained with its own water supply tanks, debris

tank, auxiliary engine, rodder pump, hose reel, high
pressure water hose, and hydraulic pump.
he Vactor 2100 uses high pressure water,

up to 2500 psi, to clear and clean sewer
lines and remove blockages. The unit is self-
Driver Side View
32
Vactor 2100 Fan
verview
O
NOTICE
Operations
! CAUTION
Due to available options, the control panel

illustrations reflected in this manual may not
appear the same on all units.
1.
Read the operating manual before

operating Vactor equipment.
2.
Prior to operation, perform daily maintenance on

the Vactor unit according to the Daily
Maintenance Check List in the Maintenance
Section of this manual.
Set the parking brake before operating the

Vactor.
3.
Turn on any safety lighting according to

procedures and local, state and federal law
requirements.
The operational systems on the Vactor are

dependent upon the options and capacities of the
vehicle as ordered. The vehicle is custom designed
to provide a combination of high-pressure water
and suction to perform in a designated area and

application. The water, hydraulic and vacuum
systems work together to provide a powerful
cleaning machine.
Basic Operation
debris body the higher the fan speed that is needed.

The shorter the distance, the lower the fan speed
needed. Material moving through a pipe or tube
creates a friction factor. The longer the tube or pipe,
the higher the friction factor called friction loss. Pipe
and tube diameter is a major factor when moving
material. Reducing the size of the tube or pipe
reduces friction loss but also reduces air movement.
Reducing a tube or pipe from eight inches to four
inches actually reduces the airflow by seventy-five
percent.
It is important to remember that the vacuum tube

uses air flow and not vacuum to pick up material.
Keep the suction end of the nozzle in the upright
position to receive air and material. Submerging the
nozzle in material stops airflow, prevents material
movement and creates a loading and unloading
effect on the fan. The catch basin nozzle is
designed to pull air into the pipe to move material.
The end is serrated with small holes; if the end is
submerged air is pulled in through the holes.
The weather and operating conditions cannot be
controlled, but the fan speed; water volume and
water pressure can be controlled. Fan speed
controls the volume of air and the speed of air
movement through the pipe and into the debris
body. If the soil or material breaks up easily the fan
can run at higher speeds and allow faster material
pick-up. Adjust the fan speed to move maximum
amount of material without carry over into the fan
housing.
CAUTION
Beware of carry over material from debris body
through the fan. Running the fan too fast with
light material can carry the material over into
the fan housing. This can cause an imbalance
condition in the fan and premature wear.
Fan speed is important when working in freezing

temperatures. High fan speeds cause wind chill
conditions because of the air velocity created.
The wind chill conditions cause ice build up in
the vacuum tube or boom which blocks material
movement.
CAUTION
If ice builds up in the boom, shut down the
vacuum system. Use hot water to heat the boom
tubes or move the vehicle inside to warm up.
Slowly retract the boom when the tubes have
warmed up. Do not retract the boom with ice
build up in the vacuum tube. Damage to the
boom and/or seal can occur. If hot water is
available, start the vacuum system and spray
hot water into the vacuum tube/nozzle. As the
ice breaks away it will be carried to the debris
body.
Proper fan speed will vary depending on the

material moved. Air velocity should be set so that
material does not hang in the pipe. Adjust speed to
the lowest setting to move the material efficiently.
Increase the speed as needed to pick-up large
rocks or heavy sludge. Watch the fan housing for
carry over material.
The further the distance from the work site to the
33
Vactor 2100 Fan
verview
O
Operations
2
3
4
1
5
Water System
The Vactor is a completely self-contained mobile

cleaning and vacuum collection unit It is designed
to serve two functions. First, it cleans by using high
pressure water and jet rodding action. Second, it
collects the waste and material that results from the
cleaning.
The water system begins near the rear of the unit

with the high pressure water pump. Water is brought
into the pump from the water tanks. The water is
filtered and pressurized by the water pump and
sent to the front of the unit. The water enters the
water hose which is stored on the hose reel. The
hose reel is used for jet rodding. Jet rodding is the
cleaning of sewer lines with high pressure water.
Additionally, the hose reel is the platform for many
of the controls used in the jet rodding function. With
a turn of a valve on the hose reel water is sent out
of the water nozzle on the end of the water hose.
Vacuum System
1
Waste material is vacuumed through the

vacuum hose and boom
Waste material first enters the Vactor through

the 8-inch inlet valve on top of the debris body.
Material drops out of the air stream and is

collected on the bottom of the debris body.
The major components of the water system as

illustrated in this section, are as follows:
The air stream leaves the debris body through

an outlet pipe
The air stream passes through the fan, and
Finally leaves the system through the fan

discharge pipe.
34
Water Pump
Water Hose and Hose Reel
Water Tank
Water Filter
Water Relief Valve (optional)
Hose reel Auto-wind
Hydraulic Pumps
Auxiliary Engine
Vactor 2100
ebris Body
D
Operations
Debris Tank
Rear door
Load-Level
Indicator
Decant Port
Water
Tank
Debris Body
The debris body normally serves as the receptacle
for material collected during rodding operations.
If so equipped, it may also serve as an additional
water tank. The debris body is a single-cylindrical
shell which can be raised or lowered hydraulically
to dump material collected during operations. It
has a configured size and capacity with a safe
and efficient design that shields the operator from
potential contamination. The tank is sealed at the
rear with a rear door. To prevent leakage, the rear
door has a gasket around the perimeter to seal the
debris body.
Rear
door
The standard debris tank is equipped with manual

locks for the rear door, a load-level indicator, a
decant port, a stainless steel float ball shut-off and
full dump controls. Hydraulic rear door locks are
optional.
Decant
Drain
Note: The rear door seal gasket and corresponding

surface of the debris body must be kept
clean to ensure safe and adequate operation.
Remember always to clean the rear door
before closing to prevent accidental damage
from foreign material sticking to the tank or
the gasket.
36
Vactor 2100
ebris Body - Float Ball & Screen

D
The air, moving debris into the body, is drawn

through vents located in the top front of the debris
body. After debris is deposited into the body, the air
continues through the vents and vacuum tube and is
exhausted.
Operations
Screens
Suction Tube
Float balls protect the vents. They consist of a

stainless steel ball suspended from the top of the
debris tank. The ball is an automatic shut off. If
the body fills with water the float balls block the air
vents to stop suction and prevent flooding the fan/
blower.
Float
balls in
screens
As the debris body is filled with liquids, the float

ball rises and will shut off the air flow to the fan/
blower when the debris body is full.
Level
Indicator
Float Ball
The floatballs are encased inside a debris screen.

The screen filters debris from the air before it exits
the body to the fan/blower.
Debris Tank
(Interior) - low
profile style
Filters should be cleaned with the handgun EVERY

TIME the debris body is dumped. It is important to
keep these clean; debris clogged in the screen will
result in a loss of airflow and productivity.
The float balls location will vary with options.

Optional pump off systems may cover the float ball
assembly as shown below.
Baffle
Suction
Tube
Screens
Screens
Suction
Tube
Screens
Screens
Debris Tank
(Interior) - with
optional pump off
Level
Indicator
Float Ball
Debris Tank
(Interior)
37
ebris Body Level Indicator

D
Vactor 2100
The load-level indicator is a float type gauge to

indicate the level of water and debris inside the
debris tank. When arrow is horizontal the debris
body is full and should be decanted or dumped. The
float starts raising when the debris body is about
half full. The indicator marks for the level gauge are
actually showing the level starting when the debris
body is about half full.
Operations
CAUTION
Over filling the debris body can cause carry over
and damage to the fan/blower.
Some units are equipped with an optional load limit

alarm system. See the Options Section for operating
instructions.
Debris Tank
(Interior)
Debris Body
Debris Body
Level Gauge
Floatball for
Load-level
Indicator
38
Vactor 2100
ebris Body - Rear Door & Locks

D
Rear Door
There are a variety of rear door options. Rear

doors may be dome or flat. On the flat doors, the
doors may be full size or half size and hinged in the
middle. The full doors are hinged at the top of the
debris body.
The rear door is hydraulically opened and closed
using the lever on the hydraulic manifold near the
control stand normally on the passenger side. The
rear door is opened with the aid of a sequence
valve. When opening, two door catches release the
door allowing the rear door to then hydraulically
open. Similarly, when closing, the door is
hydraulically lowered into position and the catches
pull the rear door tight against the debris tank. The
catches pull the rear door closed so that it may be
locked.
Flat Rear Door
CAUTION
The rear door must be unlocked before
attempting to open the rear door or serious
damage may be done to the unit.
Dome Rear Door

Hydraulic Control Manifold
39
Operations
Vactor 2100
ebris Body - Rear Door & Locks

D
Depending on the options ordered, the rear door is

locked either manually or hydraulically. Manual locks
are standard.
Hydraulic Door Locks
Operations
Hydraulic
Rear Door Lock
On units with hydraulic locks, the hydraulic rear door

lock lever is on the hydraulic manifold.
Manual Door Locks

The manual rear door locks use an over center
latch. To unlock, lift the handle which releases the
tension on the lock. Next, lift the handle and swing
it clear of the rear door catch. Before unlocking, turn
on the fan system and block of the end of the hose
at the boom. This will pull the rear door in slightly
and hold it until the all the locks can be released.
This prevents debris from falling on the operator.
Debris Tank
Rear Door
Manual Locks
Rear Door Unlocked
Rear Door Locked
Lock Catch
Over Center
Lock Lever
40
Rear Door
oom Operation
B
Vactor 2100
The boom connects the debris tank to the vacuum

tube and is also used to move and position the
vacuum tube. The boom is used to lift and position
the vacuum tube into the manhole. Hydraulic
cylinders lift and turn the boom which pivots on a
central cylinder.
Boom Operation
The joystick (optional) can be used when operating
from the front of the vehicle. The pendant is used in
front or in other locations around the vehicle.
42
Operations
Vactor 2100
oom Operation
B
Operations
The boom pivots on a pole mounted in front of the

debris tank. From this point, separate hydraulic
cylinders move the boom either up or down/left or
right.
Left/Right
Hydraulic
Cylinder
Up/Down
Hydraulic
Cylinder
WARNING
3" wide x 7" tall
.125 corner radius
Electrocution hazard
ENG. STANDARDS
Serious injury or death can

result from electrocution.
Check for overhead wires and
obstructions before raising or
moving boom. Do not leave
boom raised while vehicle is
unattended. Do not move
vehicle unless boom is in travel
mode. Do not allow boom to
contact the vehicle or any
obstruction.
Be aware of the vehicle's
surroundings before operating
any of the boom functions to
prevent death, injury or
equipment damage.
E0008 - GRAPHIC FILM - POLYCARBONATE

E0010 - DECAL LAYOUT SPECIFICATION
VACTOR Manufacturing Inc. STREATOR, IL.

NAME
DECAL,VACTOR BOOM
DR.
DATE
AC
1-11-2005
PART NO.
NONE
1800149
This document contains material and/or information which is the property of Vactor Manufacturing Inc., and supplied only on a
confidential basis. No transmittal or disclosure shall be made to any person, firm, or corporation without written approval of
Vactor Manufacturing Inc.. The controlled master copy of this document resides in electronic format. All printed copies of this
document are UNCONTROLLED.
DIMS. IN INCHES
LTR.
0
A
TOLERANCES UNLESS
NOTED +/- .032 per foot
Revision
Initial release
Updated arrow to ANSI electrical bolt
Refer to SAFETY
section in manual.
1800149 rev A
SCALE
43
By
Date
ECN No
AC
AC
1-11-2005
3-24-2005
5683
5820
Vactor 2100
oom
B
Operations
Boom Operation
The boom is controlled using either the pendant
or a joystick (optional) on the control panel. The
joystick can be used when operating from the front
of the vehicle. The pendant is used in front or other
locations around the vehicle.
Joystick
The joystick boom control is located on the front reel
control panel. Move the joystick, in the directions
shown on the control panel for raising, lowering and
moving left to right. A separate BOOM toggle switch
controls the EXTEND and RETRACT movements of
the boom.
Joystick
Pendant Control
Using the pendant control, push the UP button to
raise the boom. Push the DOWN button to lower
the boom. Push the LEFT or RIGHT buttons to
move the boom in either direction. The buttons are
momentary and will stop boom movement when the
button is released. If the boom does not stop when
the button is released, push the red STOP button
until the pendant control can be unplugged. The
POWER button turns the pendant control on and off.
Use this button in an emergency to stop pendant
control. A separate BOOM toggle switch also
controls the EXTEND and RETRACT movements
of the boom. The VACUUM RELIEF button controls
the vacuum relief valve. It is used normally to shut
off the vacuum and can be used in an emergency to
open the relief valve and relieve suction.
44
oom - Pendant Control

B
Vactor 2100
Operations
Pendant controls will vary from unit to unit

depending on the options ordered. The pendant
control is used to operate the boom from a location
other than the front of the vehicle. The boom is
entirely controlled by the remote Pendant or the
optional joystick on the control panel, if so equipped.
The Pendant is a remote portable yellow control box
used by the operator to direct the operation of the
boom. The pendant plugs into a receptacle below
the rodder hose on the front of the hose reel. The
top six push buttons on the pendant are used for
boom movement. The function of the buttons are:
1
Up - the boom will raise
Down - the boom will lower
Left - the boom will rotate left
Right - the boom will rotate right
Out - the boom will extend
In - the boom will retract
Remote
Pendant
The buttons are momentary switches and upon

releasing the button, the boom will cease moving.
The power on/off button controls power to the
pendant control. The vacuum relief on/off button
relieves the air flow at the boom inlet in an
emergency.
Vacuum
Relief
Button
Power
Button
The switch in the lower right-hand corner turns the

pendant control ON or OFF. Push this switch OFF in
any kind of a boom emergency situation.
Hose Reel
If there is a vacuum relief button on the pendant (as

shown in the picture) it opens or closes the vacuum
relief valve.
Pendant
Plug
45
Vactor 2100
acuum Tube
V
Position Vacuum Tube
Boom hose shown

in stowed position
on post style
storage.
The vacuum tube is maneuvered and controlled

using the pendant control. Plug the pendant control
into the pendant receptacle located underneath the
front reel. The vacuum must be off when attaching
vacuum tubes.
1.
Using the pendant control, release tension

on the vacuum tube by lowering boom
slightly.
2.
Remove the boom from its stored position

and swing boom from its stowed position into
position over basin.
3.
Stand the long catch basin nozzle in the catch

basin.
4.
Lower the boom until the vacuum tube and

catch basin nozzle are joined.
5.
Install the quick clamp to fasten the nozzle to

the vacuum tube.
Operations
Boom
Hose
Boom Hose
Storage Post
Standard style boom storage bracket.
Stored
Vacuum Tube
Ready for tube

attachment
Cut line
Quick Clamp
WARNING
Vacuum Hazard
Riesgo Por Altovaco
Cutting, crushing,
suffocation or body rupture
from the forces of vacuum
could result in serious injury
or death.
Trituracn, asfixia, amputacin

o desgarre corporal por las
fuerzas altovaco pudieran
resultar en lesiones serias o
mortales.
Stay clear of the suction

hose inlet end.
Mantngase lejos de la boquilla

de la manguera de succin.
Turn vacuum off before

attaching hose, pipe or
accessories.
Apague el compresor de
altovaco antes de conectar la
manguera, tubos o accesorios.
Keep suction hose inlet end

near ground level when
vacuum is operating.
Mantenga el extremo de la
manguera de succin cerca del
nivel del suelo cuando est
funcionando el compresor de
altovaco.
Refer to SAFETY
manual for details.
! ADVERTENCIA
46
Refirase a la seccin de
SEGURIDAD en el manual
para detalles.
1800174
6
.1
Vactor 2100
acuum Tube
V
Operations
If the vacuum hose needs to be extended, additional

vacuum tubes can be attached to the vacuum hose.
Vacuum tube extensions are stored on a tube rack
located on the side and/or rear of the unit.
When working with deeper basins, preassemble
pipes in horizontal position and slide into basin.
Vacuum
Tube Rack
Vacuum Tube
Extensions
Vacuum
Tube Rack
Vacuum Tube
Extension
Long Catch
Base Nozzle
47
Vactor 2100
ater Tanks
W
Operations
there may be a optional audible alarm that notifies

the operator of low water. The audible alarm can be
turned on or off from the front control panel.
The water tanks are used to hold water for use

during operations. There are two tanks located
on each side of the debris tank. The water tank
capacity is unique with each unit configuration.
Additionally, there is a sight gauge on each water

tank. A red float inside the clear tube gives the
operator the level of the water in the tank. This
gauge is used when the tanks are being filled with
water.
The water tank is equipped with a visual gauge

and possibly an optional electric low water light.
The electric sensor is located on the front near the
bottom of the water tank. When the water level
drops below the sensor, the low water light on the
operator control panel will illuminate. Additionally,
The water tanks should be filled prior to operating

the water pump.
Debris
Tank
Upper Water Tank

Water Level
Sight Gauge
Lower
Water
Tank
Water Tank Side View
48
ater Tanks - Filling

W
Vactor 2100
Operations
NOTICE
Due to weight restrictions, it may be better to
fill the water tanks near the work site. Know the
Gross Vehicle Weight Rating (G.V.W.R.). Know
the vehicle axle capacities. Do not exceed the
Gross Vehicle Weight (G.V.W.). It is possible to
overload the vehicle.
Filling the Water Tank

Park the truck centered with the hydrant on

the passengers side of the unit.
Check and clean y-strainers daily prior to

filling tanks. Make sure y-strainer gaskets are
in place.
Remove the cap on the hydrant and flush

the hydrant, or water supply, until water runs
clear.
Turn off fire hydrant and remove the water

fill hose from its compartment and attach it
securely to the hydrant, or water source.
If equipped, make sure the water filter screen

in the y-strainer is clean and in place. Be sure
both gaskets are on the filter housing cap.
Attach the other end of the water fill hose to

the water tank hose connection.
CAUTION
Prior to connecting the fill hose to the fire
hydrant always flush the fire hydrant or
contaminants may enter the vehicle water
system.
NOTICE
Always follow procedures established by the
water supplier.
Air Gap
CAUTION
When connecting the fill hose inspect the area
around the fire hydrant and place hose in a
position that will not impede traffic or cause
vehicles to strike the hose.
Auxiliary
Engine
Cover
Y-Strainer
(optional)
Water Fill Port
49
Vactor 2100
ater Tanks - Filling

W
Operations
Water Tank
Water Tank
Water Level Gauge
Water Level Gauge
Red Ball
Allow the tank to fill. The operator should

monitor the sight gauges located on the side
of the tank. A red ball inside a clear hose
floats upward as the water level rises. Turn
the water supply off when the gauge indicates
full and disconnect the hose from the water
source.
Remove any excess water by lifting the hose

at the water tank and walking toward the end
of the hose
Roll the fill hose securely and place in storage

compartment.
Replace any cap previously removed.
50
ater Tanks - Draining

W
Vactor 2100
Operations
All lower watertanks are equipped with water drains.

Additionally water drains for other system components
are also located under the water tanks. A variety of
plugs and valves are used. All drains should be opened
and flushed weekly. When not in use, typically overnight
the watertanks should be drained and empty.
Water tank drain
All drains must be left open to avoid freezing during

cold weather when unit is not being used.
Fan housing drain

(fan units only)
NOTICE
The fill mechanism installed on the Vactor
water system has an air gap as required by
OSHA to prevent siphoning water out of the
tank and back into the fire hydrant and water
supply. Do not modify or otherwise obstruct this
passageway. Any obstruction will cause water to
be spilled and sprayed onto the operator and/or
equipment or possibly contaminate the water
supply.
Air Gap
51
Vactor
ymbols
S
Shown are common industry
standard symbols used on the
various controls. Actual symbols
used will vary with options.
Refer to manual
Operations Section
STOP
Emergency
Stop
Refer to Service
manual
Valve
Open
Closed
On
Off
Lock
Unlock
Steady
Intermittent
Audible Alert
On / Off
Heater or
Cabinet heater
Slower / Faster
Increase
Decrease
Boom rotate
left or right
Water
Pressure
Adjustment Range
Max. to Min.
Oil
Hydraulic
Oil
Oil
Temperature
Water Level
Indicator
Boom retract
Boom extend
Hydraulic
Temperature
Oil Temperature
Boom down
Boom up
Timer
Worklights
Front - Side - Rear
52
Vibrator
Vactor 2100
ater System - Rodder (Water) Pump

W
The Vactor dual-action, single-piston jet rodder
water pump is designed exclusively for sewer
cleaning and provides jackhammer obstructionbreaking action and continuous-flow cleaning.
It is designed to be driven hydraulically and has
a one-to-one hydraulic-to-water ratio. For every
gallon of hydraulic oil pumped, one gallon of water
is pumped. There is a hydraulic cylinder on one
side of a sealed center block and a water cylinder
on the other side. The pump is loading constantly
and expelling hydraulic oil while also constantly
loading and expelling an equal amount of water. The
hydraulic pump is driven off the truck engine via a
power take-off (PTO) from the chassis engine. Front
control engagement/disengagement is standard.
A combination of water flow - GPM (gallons-perminute) and water pressure - creates thrust. Thrust
is used to propel the rodder nozzle through sewer
lines. The debris loosened by the nozzle movement
and water pressure is pushed to the rear of the
nozzle and picked up by the vacuum system.
Jackhammer Action
The pulsations of the pump piston create a
jackhammer effect that further helps to break up
debris caked on pipe walls and provides additional
cleaning power to burst through obstructions in
the line. It delivers maximum continuous flow and
up to 2500 PSI with minimal wear. At the nozzle,
this creates an additional forward thrust. If there is
an obstruction in the line, the pump cycle literally
causes the nozzle to jackhammer against the
obstruction until it is cleared. The jackhammer
action can be regulated by an optional accumulator.
54
Operations
Vactor 2100
ater System - Rodder (Water) Pump - Water Flow

W
1) Water passes through the heat exchanger (oil
cooler) from the watertank. The heat exchanger
allows the water to be used to cool the hydraulic
oil. Hydraulic oil circulates around a series of small
tubes which carries the water through the heat
exchanger in route to the rodder pump. 2) Water
then passes through a water supply line to a gate
valve which controls the supply of water to the
pump. 3) When opened the flow of water passes
through a Y-strainer which filters material from the
Operations
water so as to keep the pump from being damaged

by the material. A metal basket traps contaminants
as the water passes through. 4) The water enters
the right side of the pump in two locations and is
pressurized in the pump chamber. The left side of
the pump supplies the hydraulic pressure needed to
pressurize the water. 5) High pressure water leaves
the pump on the right side in two locations through
a hose that connects the pump with the hose reel.
Rear mounted pump from driver side
Water Pump
Rear mounted pump from

passenger side
4
Water end
Water Pump
Gate Valve
1
3
The heat exchanger is normally located on driver

side along the drive line. Note the water drain going
out to the driver side of the unit.
55
Vactor 2100
ater System - Rodder (Water) Pump - Options

W
Operations
Optional Water Relief Valve and Return Line

Water Pressure
Relief Valve
A water relief valve releases the excess water

pressure. This will send the excess pressurized
water back to the water tank through a separate
return line.
Rodder
Pump
Configurations of units vary greatly. Some units

have the water pump mounted on the passenger
side. All functions are the same, but vary in location
and orientation.
heat exchanger (oil cooler). The heat exchanger

allows the water to be used to cool the hydraulic
oil. Hydraulic oil circulates around a series of small
tubes which carries the water through the heat
exchanger in route to the rodder pump. 5) The water
enters the right side of the pump in two locations
and is pressurized in the pump chamber. The left
side of the pump supplies the hydraulic pressure
needed to pressurize the water. 6) High pressure
water leaves the pump on the right side in two
locations through a hose that connects the pump
with the hose reel.
1) Water from the water tank enters the pump

through a water supply line. 2) A gate valve controls
the supply of water to the pump. 3) When opened
the flow of water passes through a Y-strainer (if
equipped) which filters material from the water so
as to keep the pump from being damaged by the
material. A metal basket traps contaminants as the
water passes through. 4) Then passes through the
Water end
Water Pump
Heat Exchanger
Water Pump
Gate Valve
Y-strainer
56
ater System - Draining

W
Vactor 2100
Operations
Instructions for draining water system in freezing weather

1.
Open drains in all water tanks and allow tanks to

empty. Remove Y-strainers at fill and water
pump suction and other options if so equipped.
2. Remove quick disconnect from hand gun
outlet(s).
3. Open both high pressure ball valves on the hose
reel.
4. REMOVE rodder nozzle and SECURE hose end
to an adjacent hose loop so reel can rotate.
Point the hose end towards the ground as ice
and water may be ejected while running rodder
pump.
5. Start engine and engage water pump for two
minutes at slow speed to expel any water.
6. Turn OFF water pump.
7. Remove drain plugs from water pump or
optional drain valves and engage water pump
for one minute at slow speed to expel any water.
9. Rotate hose reel clockwise direction to expel
any water in hose.
10. Drain high pressure water gun.
11. Remove drain plugs for optional debris body

wash out system.
12. Open optional gate valve to water pump.
13. Locate heat exchanger in water pump suction
and open valves.
WARNING
High pressure water.

Serious injury or death can result from sudden
release of high pressure water. Remove the
rodder hose nozzle and secure the hose end to
an adjacent hose loop so reel can rotate. Point
the hose end towards the ground as ice may
be ejected while running rodder pump.
Both pressure side water valves must be open
prior to operating rodder pump.
Refer to manual for details.
L-029A - 53695A rB
Decal is 8.000 wide by 5.000 tall
This decal is standard on all units and describes the

Corner radius is .125
general procedures for draining the system. More
detailed informationENG. STANDARDS
follows.
E0010 - Decal layout specifications
In addition to these specific

drain points, the
E0008 - Graphic film - polycarbonate
accumulator (optional) ball valve should be opened
to allow any water trapped in the
accumulatorManufacturing
to
VACTOR
Inc. STREATOR, IL.
drain. The handgunNAME
ports should be drained as well.
Open the handgun water ball valve and removeDECAL,DRAIN UNIT,L-029A
all
DR.
DATE
SCALE
PART NO.
the quick-connect handgun
connections.
AC
12-8-2005
53695A
NONE
TOLERANCES UNLESS
DIMS. IN INCHES NOTED +/- .032 per foot
LTR.
0
Initial release
By
-
Revised and updated

Line 9 was CCW / Reworded & revised
AC
AC
Revision
57
Date
-
ECN No.
-
12-8-2005
2-23-2006
6191
6277
Vactor 2100
ater System - Draining - Rear Mounted Pump

W
Operations
When the entire system is shut down for extended

periods or for maintenance follow this draining
procedure:
5.
Take filter cap off, remove the three-inch Ystrainer water filter and leave the filter out.
6.
Open the gate valve.
1.
Close the water supply gate valve.
7.
2.
Open the valves and remove any plugs for

the body washout and any other additional
options.
Allow water to drain from the supply line and

rodder pump.
3.
Open the heat exchanger drain valve
4.
Remove the two drain plugs on water end

cylinder or open optional rodder pump drain
valves in rear bumper. The rodder pump has
two drains.
Water end
3
4
Heat exchanger drain valve - normally

located on the driver side.
4
4
58
Vactor 2100
ater System - Draining - Side Mounted Pump

W
Operations
When the entire system is shut down for extended

periods or for maintenance follow this draining
procedure:
3.
Open the two ball valves on the bottom of the

rodder pump. Picture shows the drains in the
open position.
Procedure for draining the water system:
4.
Open the gate valve.
1.
Close the gate valve
5.
2.
Take filter cap off, remove the three-inch Ystrainer water filter and leave the filter out.
Allow water to drain from the supply line and

rodder pump.
Connecting Line Drain
Water Relief Valve Drain
1
2
Water end
4
5
Heat Exchanger Drain
Y-strainer Drain
Rodder Pump Drain
59
Vactor 2100
ose Reel
H
Front Side of Hose reel
Operations
Back Side of Hose reel
Hose Reel
Pay-in/Pay-out
Speed Control
Water
Pressure
Gauge
The rodder hose reel is located on the front of the unit

and holds the water hose that is fed into sewer lines.
The length of hose varies with the size and type. The
same basic hose reel configuration is used on both
fan and blower machines. The difference being the fan
engine or blower controls on the control box.
Pay-in/
Pay-out
Lever
Control
Panel
Hose Reel
(Front-side)
Footage
Counter
The hose reel has two sides to it which allows

for greater flexibility in operations. Operations
can be conducted from either side of the hose
reel depending on the position of the reel and the
manhole.
Pay-In/Pay-Out
Speed Control
Pay-in/Pay-out
Lever
Water
Pressure
Gauge
On the hose reel is the operator control panel

used in jetting along with all the controls to operate
the reel itself, including rotation and extension of
the hose reel. The hose reel can be rotated 270
degrees if equipped and extended if equipped with
the optional telescoping hose reel feature.
The major components on the front of the hose reel are:
Control Panels
Rodder Hose Valve
Pay-In/Pay-Out Lever
Speed Control Knob
Water Pressure Gauge
Footage Counter
Control
Panel
With the exception of the rodder hose valve and

footage counter, the same controls found on the
front may also be on the back depending on how
unit is configured.
There may be other features on the front of the

hose reel depending on the options ordered. Refer
to the Options Section for instruction on these
features.
Rodder
Ball Valve
60
ose Reel - Telescoping

H
Vactor 2100
The hose reel can be hydraulically extended

outward from the truck chassis using the HOSE
REEL switch. The extendable hose reel is useful
when lining up the hose with a manhole for rodding
operations. A toggle switch on the control panel
moves the reel in and out. The switch is momentary
and must be held in the OUT position to move the
reel out and held in the IN position to move the
reel in. When the switch is released it automatically
returns to the center position.
Hose Reel Extended and Rotated
The hose reel will extend up to about 15 inches.

Rotate the reel parallel to the bumper before
retracting.
Hose
Reel
Hose Reel
Extension
61
Operations
ose Reel - Rotating Option

H
Vactor 2100
Operations
The hose reel can rotate up to 270 degrees.

Placing the HOSE REEL LOCK-UNLOCK switch
in the unlocked position, allows the operator to
physically rotate the hose reel. This feature allows
the operator to position the rodder hose for optimum
performance. It turns on a bearing located on the
underside of the hose reel carriage. The hose reel
is locked in place with two air-activated cylinders.
The cylinders mesh with the gear to hold it in place.
When a switch is flipped, the cylinders retract and
the gear can turn freely.
To rotate the reel, unlock it by flipping the unlock
switch. There are two switches that can be used
to unlock the reel, but only one switch is needed.
The switches are located on either side of the hose
reel near the bottom. When either switch is flipped,
the two cylinders, one on each side of the gear, are
retracted.
Hose
Reel Rotation
Lock Switch
Once the reel is unlocked, it can be turned manually

in either direction toward the driver side or the
passenger side.
NOTICE
After it has been rotated into position, the reel can

be locked in place by flipping the reel lock switch.
The cylinders will mesh with the gear holding it in
place.
When locking the hose reel, make sure the hose

reel has completely stopped before placing the
switch in the locked position.
The hose reel must be extended before the reel
can be rotated the full 270 degrees.
Hose Reel Rotated Showing Front-side

Hose Reel Rotated Showing Back-side
CAUTION
CAUTION
Do not drive the vehicle with the hose reel in the

extended or unlocked position. Rotate the hose
reel parallel to the bumper before retracting.
Damage to the unit can occur if this warning is
ignored.
Allow the hose reel to completely stop before

locking the hose reel. The switch is intended
as a lock and not a stop. The hose lock will be
damaged if this warning is ignored.
62
ose Reel - Reel Controls

H
Vactor 2100
Reel Speed
Operations
Reel Control
48969
48969
Speed Control
Pay-in/Pay-out of Water Hose
The speed of the reel is controlled using the speed

control knob. Adjust the speed control knob for the
job at hand. The basic rule is the dirtier the pipe,
the slower the pay-out of the hose. Turn the knob
counter clockwise to increase the reel speed and
clockwise to decrease the speed of the reel.
The rodder hose reel is controlled using a

directional control valve mounted on the front of the
hose reel.
Nearly identical set of controls are located on the

ENG. STANDARDS
each side of the reel.
Units with telescopic hose reels have a speed
E0008 - Graphic film - Polycarbonate
control
on the back side of the hose reel. The rear
speed control needs to be open (counter-clockwise)
for normal operation and closed (clockwise) for
transport.
NAME
pump, which is normally live anytime the hydraulics

are running. Hose travel, forward and reverse, is
controlled by a directional control valve on the hose
reel.
When the hose is being unreeled, it is commonly

referred to as pay-out. Conversely when the hose
is being retracted or wound back onto the reel, it is
4.000" wide x 1.500" tall
commonly referred to as pay-in.
Turn the speed control knob completely
clockwise to
close before transporting.
Hose reel rotation is powered via a hydraulic

DECAL,REEL CONTROLS,HORIZONTAL
DR.
DATE
SCALE
PART NO.
Water Pressure
Front of
Gauge
AC Hose Reel 12-8-2005
NONE
Back of
Hose Reel
Pay-In/Pay-Out
Lever
Speed
TOLERANCES UNLESS
Control
DIMS. IN INCHES
48969
LTR.
0
Speed
Revision
By
AC
Initial release
Date
12-8-2005
Control
ECN No.
6191
Pay-In/Pay/Out
Lever
The truck engine must be running and hydraulic

pump engaged before the hose reel can be used.
The hose reel is extended using hydraulic cylinders
and requires hydraulic pressure to operate. The
hose reel lock is pneumatic and requires air
pressure to operate.
63
ose Reel - Water Valve

H
Vactor 2100
Operations
The rodder valve is used to supply high pressure

water to the hose reel. The valve is located on the
front of the hose reel.
The valve is a two-way ball valve with only two
positions Rodder On or Rodder Off.
Water
Pressure
Gauge
In the Rodder On Position, high pressure water

is being directed through the water hose and out
through the nozzle.
Rodder
Ball Valve
The rodder pump should not be turned on without

the ball valve turned on. Either the rodder pump ball
valve must be on or the hand gun water ball valve
must be on
Water Pressure Gauge
The pressure gauge measures the amount of water
pressure and is located next to the rodder valve.
There is an identical water pressure gauge on the
other side of the hose reel.
CAUTION
If the rodder pump is turned on with the water
ball valves closed, the rodder pump may stall
and cause serious damage to the rodder pump.
WARNING

result from sudden release of
high pressure water. The hose
end and water discharge
direction may become
uncontrolled.
One pressure side water valve
must be open prior to operating
rodder pump.
The rodder hose must be
properly in place before running
rodder pump.
1800151
64
3" wide by 5" tall - .125" corner radius
ENG. STANDARDS
E0008 - Graphic Film - Polycarbonate

Vactor 2100
ose Reel - Manual Wind Guide

H
Operations
A hose guide mounted on the hose reel is designed

to aid the operator in guiding the hose on and off
the reel. Move the handle from side to side as
the hose is unreeled or reeled in making sure the
hose is rewound in an orderly fashion. Proper unit
positioning will make hose rewinding easier.
Guide
Handle
Hose Guide
STEP 1
STEP 2
STEP 3
Unlock the assembly by lifting the

locking latch on the side of the roller
guide. Swing the top half of the
roller guide upward and allow it to
rest in the open position.
Place the hose in the bottom half of

the roller guide.
Lower the top half of the roller

guide. The hose should fit snug
between the two halves of the roller
guide. Lower the locking latch.
When not in use the secure the

handle with the chain provided.
65
ootage Counter
F
Vactor 2100
The footage counter is designed to keep track of

the length of hose inserted into a sewer line. The
counter is mounted on the hose heel.
Operations
Hose Reel
Footage
Counter
The counter displays the footage in a one-to-one

ratio. The footage counter can be reset to zero by
pulling the counter away from the reel and rotating
the knob.
The standard footage counter acts only as a marker.
It tracks the revolving hose reel, then translates
it into the approximate number of feet. It can not
provide precise hose measurement as the hose
length changes with each full rotation and the
footage counter shows the same count with each
full rotation.
Note: The footage counter is supplied as a
reference only. The numbers indicated by the
counter may not be the actual number of feet
(or meters) of hose fed into the sewer line. If
more accurate measurements are required
the optional Accucount can provide precise
measurements as it is programmable and
utilizes electronics and an encoder.
Counter
Display
66
Reset
Vactor 2100
and Gun
H
The hand gun controls are normally located on

the passenger side of the truck, other locations
are optional for convenience of operation. Several
optional high-pressure hand guns are available.
For additional information, see the Options Section.
Follow the instructions for the hand gun available
on the vehicle.
Operations
Hand Gun
Pressure
Valve
The maximum pressure of the handgun is set at

the factory for 600 psi. Adjustment of the handgun
pressure is controlled by the valve on the back of
the water tank.
Tool Box
Water
Tank
Water is supplied to the hand gun by a ball valve.

Turn the handle 90 degrees to the right to supply
water to the handgun. When the ball valve is
opened, high pressure water is supplied to the
available quick connections.
Hand Gun
Ball Valve
Hand Gun
Quick Disconnect
When not using the handgun, the ball valve should

be closed as shown in the picture to the right.
! CAUTION
The handgun system produces high-pressure
water. Make sure the handgun ball valve is in
the OFF position and pressure is relieved when
connecting or disconnecting the handgun quick
coupler.
Hand Gun
Pressure Valve
Water
Tank
Hand Gun Quick

Disconnect
Hand Gun Quick

Disconnect
Hand Gun Ball Valve

Hand Gun Ball Valve
Hand Gun Connection in Off Position
Hand Gun Connection in On Position
68
Vactor 2100
and Gun
H
The Vactor is equipped with a high pressure

handgun system. This consists of a handgun
assembly with a variable spray pattern, a water
hose and a quick-connect / disconnect system.
Operations
To Engage Water for Handgun Operation

Check the water tanks for adequate water supply.
With the pump disengaged, connect the highpressure handgun hose to the quick-coupler socket
behind the passenger side of the chassis cab,
making sure the coupler is fastened securely. Turn
the ball valve for the handgun ON, and close the
ball valve for the hose reel.
The standard handgun connection is mounted on

the side of the truck. Other locations are optional.
The handgun can be used for cleaning catch basins,
removing materials from basin walls, adding water
to the material for easier pick-up, flushing street
area around the work site and cleaning ledges and
ladders inside the basins. The standard handgun
and hose are normally stored in the vehicle tool
box. An optional hose reel is available to assist in
rewinding the handgun hose.
If increased water pressure is desired, increase

engine RPM by using the throttle control which is
located at the bottom of the hose reel control panel.
Turn the Rodder pump OFF if the hand gun water
system is not going to be utilized. Failure to do so
can cause premature wear of the hand gun relief
valve.
T-Handle Valve
When not using the handgun, the handgun ball

valve should be closed.
A valve on top of the water tank or in the vicinity of

the handgun quick-coupler is used to unload excess
pressure and adjust the handgun water pressure.
The standard handgun system has a maximum
operating pressure of 600 PSI.
! DANGER
Do not adjust the pressure in excess of 600 PSI,
serious injury or death may occur.
Handgun
Nozzle
Trigger
The handgun can be used to clean up work site and the rear door area after dumping.
69
Vactor 2100
and Gun
H
Operations
The following instructions are applicable to the

standard hand gun:
Main Water Valve

(Optional)
1.
Ensure the main water supply is available to

the water pump by placing the optional main
water valve in the open position .
2.
Ensure the HAND GUN ball valve is in the

OFF position.
3.
Ensure the RODDER PUMP toggle switch,

located on the front hose reel panel, is in the
OFF position.
4.
Place the RODDER ball valve, located on the

front hose reel, in the OFF position
5.
Remove the quick coupler socket from the

coupler plug.
6.
Connect the hand gun hose to the quick

coupler and ensure the coupler is securely
coupled.
Front of
Hose Reel
Rodder Valve
(Shown in ON
Position
Hand Gun
Ball Valve
Quick Coupler
Socket
70
Water Pressure
Gauge
Vactor 2100
and Gun
H
9.
7.
Place the HAND GUN ball valve in the ON

position.
8.
With the truck engine running and PTO

engaged, place the RODDER PUMP toggle
switch in the ON position.
Operations
Place the THROTTLE ON/OFF switch,

located on the front reel control panel, in the
ON position. The THROTTLE UP/DOWN
switch is used to increase or decrease the
engine speed. To increase engine RPM and
water pressure hold the THROTTLE UP/
DOWN switch in the UP position. To avoid
unnecessary wear to the relief valve do not
increase engine speed above that which is
needed to obtain a maximum of 600 PSI.
10. Depress the hand gun trigger to begin pressure

washing.
CAUTION
! WARNING
The hand gun operates under high pressure.
Never point the hand gun at another individual.
Severe injury can result from the high-pressure
water.
Do not increase speed of engine above that

which is necessary to obtain a maximum of
600-PSI water pressure while hand gun is being
used to prevent damage to the hose and hand
gun.
Always bleed pressure from hand gun before

disconnecting from high-pressure water
connection by pressing the hand gun trigger.
To prevent rodder pump damage, always open at

least one ball valve before engaging the pump.
71
andgun - Operation
H
Vactor 2100
The handgun has a variable spray pattern which is

controlled by pivoting the forward handle forward or
backward.
Operations
! WARNING
The hand gun operates under high pressure.
Never point the hand gun at another individual.
Severe injury can result from the high-pressure
water.
After Cleaning
After the cleaning is finished, reduce speed of the
truck engine. Turn off the high pressure water pump
by turning the switch to the OFF position. Idle the
truck engine a few minutes before shutting off.
Always bleed pressure from hand gun before

disconnecting from high-pressure water
connection by pressing the hand gun trigger.
CAUTION
To prevent rodder pump damage, always open at
least one ball valve before engaging the pump.
72
Vactor 2100
ater System - Standard Rodder Nozzles

W
When do my nozzles need servicing?
Operations
Standard Orifices
Signs of orifice wear:
Part No.
Size *
Orifices are as large or larger than the next

drill size.
47337
0.050
47338
0.055
System pressure cannot be achieved.
47339
0.060
Signs of nozzle wear:
47340
0.065
Wear rings (where applicable) are worn down.
45071
0.070
Orifice, retainer, or chamber area has been

breached.
45062
0.075
45044
0.080
There is noticeable leakage from area other

than the orifice.
44735
0.086
45043
0.090
All of these conditions require immediate

attention and/or replacement.
44736
0.095
45055
0.100
44738
0.103
45056
0.105
45042
0.110
44740
0.116
45057
0.122
45068
0.130
45079
0.135
44741
0.140
Also Available
48964A Stainless Steel
Retainer (each)
41848A Stainless Steel
Penetrator Plug
(used in all Vactor OEM nozzles)

* All sizes are in inches of diameter
Cut line
Nozzle labeling and Sizing

This chart is to be used for ordering a nozzle.
It will match your system specifications for the
nozzle style you request.
1st letter
Hose dia. (in)
A = 1-1/4
B = 1
C = 3/4
D = 1-1/2
Extensive testing allows Vactor nozzles to be

accurately sized to your system specifications.
Your hose size, desired flow, and pump
pressure are easily converted into the lettering
system described at right.
3rd letter
Pressure (psi)
A = 1850
B = 2000
C = 2500
D = 3000
Reorders and parts orders can be quickly

placed and processed when providing part
numbers and lettering.
Note: Nozzles are sized approximately 3-5
GPM below the specified flow rate to allow for
wear.
2nd letter
Flow (GPM)
A = 35
B = 40
C = 45
D = 50
E = 55
F = 60
G = 65
H = 70
I = 75
J = 80
K = 90
L = 100
M = 120
Made in USA
Part
No.
48980BJC
WARNING
High pressure
Operating tool outside of
sewer line may result in
serious injury or death.
Sewer maintenance tools
operate at high pressure.
Position tool two feet into
sewer line before operating.
Build pressure slowly to
ensure tool is positioned
correctly. Turn off pressure
source before removing tool
from sewer line.
48902
Example: If you want a Wedge nozzle on 1" hose at 80 GPM

and 2500 PSI the product chart above indicates part number
48980BJC would be the part to order.
74
5" wide x 3" tall
Vactor 2100
ater System - Standard Rodder Nozzles

W
15 - Provides 50% more forward thrust than 30
nozzles. This is better for high grades, long lines
and penetrating blockages. 15 nozzles also pull
material back through the line better.
3 General Purpose
Nozzle
58929 30- Larger
and heavier nozzle
for 8" and larger lines.
This nozzle has 30
replaceable jets which
gives it excellent
cleaning and forwardthrust capability.
Operations
30 - Provides thrust and radial impact force against

the wall of pipe to loosen debris. This nozzle does
a better job of cleaning the walls than the 15 due
to the jets of water hitting the wall more directly and
closer to the nozzle.
Penetrator Nozzle
Sand Nozzle
Sanitary Nozzle
6 Rearward jets, 1
forward jet
6 Rearward jets,
6 Rearward jets
2 forward jets
Comes in 15 and 30
Comes in 15 and 30
Comes in 15 and 30
60308 15 - Good
for cleaning and
unblocking plugged
lines with sand and dirt.
Forward jets are at

an outward angle not
to cross. Forward
jets wash down sand
buildups to allow nozzle
to cross and have rear
jets to clean or move
sand.
60306 15 - Standard
cleaning 4"-12" lines.
58927 30 - Good
for cleaning and
unblocking plugged
lines with grease and
other accumulations on
the walls of the pipe.
60307 15 - Good for

cleaning and unblocking
plugged lines with sand
and grease.
58926 30 - Same as
60307, but has more
sidewall impact.
Storm Nozzle
36058 #10 - Eight rearward fan-jets. Comes with
tungsten or non-tungsten carbide replaceable jets.
Good for storm and sanitary lines 10" and up. Fan
patter improves coverage on walls. Forms a water
cone to trap materials from passing. Good for
grease and detergent buildups, especially after use
of sand nozzle, which will cut grooves in the buildup.
This nozzle should be used with a larger skid to
prevent it from wearing out prematurely.
75
Good for loosening

debris in larger lines
and running long lines.
58756 30 - Standard
cleaning 4"-18" lines.
Good for cleaning
grease and other
debris.
Vactor 2100
ater System - Rodder Nozzle Theory

W
Operations
This calculated information is presented for reference only to help users better understand how a properly
functioning system works.
Thrust
Pressure drop
Thrust as it is utilized in a sewer cleaning operation

is a measure of the forward force produced by the
rearward discharge of water.
Friction generates heat, pressure drop is energy lost

to heat.
Theoretical maximum
assuming a single orifice
In any fluid system, friction, and therefore heat, is

generated because of the liquid flowing through the
hose. The faster a liquid travels, the more heat is
generated.
Thrust
(forward force)
30 gpm @ 2500 psi
78.0 lbf
30 gpm @ 3000 psi
85.4 lbf
35 gpm @ 2500 psi
93.6 lbf
60 gpm @ 2000 psi
139.5 lbf
60 gpm @ 2500 psi
156.0 lbf
80 gpm @ 2000 psi
186.0 lbf
80 gpm @ 2500 psi
208.0 lbf
100 gpm @ 2000 psi
232.5 lbf
140 gpm @ 2000 psi
325.6 lbf
30 gpm @ 2000 psi

60 gpm @ 2000 psi
69.8 lbf
139.5 lbf
Pressure drop is simply the difference in pressure

between any two point in a system. (This data
indicates the pressure at opposite end of a sewer
hose). This difference in pressure is a measure
of the working energy being transformed to heat
energy because of friction. This is energy that is no
longer available to do work. Pressure drop is system
inefficiency.
Pressure drop (PSI) per 100 ft of
1.0" ID sewer cleaning hose
Note 100% increase in thrust by doubling the

volume
60 gpm @ 1000 psi
60 gpm @ 2000 psi
98.7 lbf
139.5 lbf
Note 41% increase in thrust by doubling the

pressure
Flow (gpm)
PD (psi)
30
25
35
35
40
45
45
57
50
70
55
84
60
99
65
115
70
134
75
153
80
174
Pressure drop (PSI) per 100 ft of

3/4" ID sewer cleaning hose
76
Flow (gpm)
PD (psi)
20
41
30
100
40
166
50
233
60
318
Vactor 2100
ater System - Rodder Nozzle Ratings

W
Operations
77
Vactor 2100

W
Operations
78
Vactor 2100

W
Operations
79
Vactor 2100

W
Operations
80
Vactor 2100

W
Operations
81
Vactor 2100

W
Operations
82
ater System - Decimal Chart

W
Vactor 2100
Operations
Use the closest drill size that fits into the orifice to determine the orifice size.
INCH
DECIMAL
MM
INCH
DECIMAL
1/64
.0156
.396
#28
.1405
3.569
.257
6.528
1/32
.0312
.795
9/64
.1406
3.571
.261
6.629
#60
.040
1.016
#27
.144
3.658
17/64
.2656
6.746
#59
.041
1.041
#26
.147
3.734
.266
6.756
#58
.042
1.067
#25
.1495
3.797
.272
6.909
#57
.043
1.092
#24
.152
3.861
.277
7.036
#56
.043
1.092
#23
.154
3.912
.281
7.137
#55
.0465
1.181
5/32
.1563
3.970
9/32
.2813
7.145
3/64
.0468
1.191
#22
.157
3.988
.290
7.366
#55
.052
1.321
#21
.159
4.039
.295
7.493
#54
.055
1.397
#20
.161
4.089
19/64
.2969
7.541
#53
.0595
1.511
#19
.166
4.216
.302
7.671
1/16
.0625
1.588
#18
.1659
4.214
5/16
.3125
7.938
#52
.0635
1.613
11/64
.1718
4.366
.316
8.026
#51
.067
1.701
#17
.173
4.394
.323
8.204
#50
.070
1.778
#16
.177
4.496
21/64
.3281
8.334
#49
.073
1.854
#15
.180
4.572
.332
8.433
#48
.076
1.930
#14
.182
4.623
.339
8.611
5/64
.0781
1.984
#13
.185
4.699
11/32
.3438
8.733
#47
.0785
1.994
3/16
.1875
4.763
.348
8.839
#46
.081
2.06
#12
.189
4.801
.358
9.093
#45
.082
2.083
#11
.191
4.851
23/64
.3594
9.129
#44
.086
2.184
#10
.1935
4.915
.368
9.347
#43
.089
2.26
#9
.196
4.978
3/8
.375
9.525
#42
.0935
2.375
#8
.199
5.055
.377
9.576
3/32
.0937
2.383
#7
.201
5.105
.386
9.804
#41
.096
2.438
13/64
.2031
5.159
25/64
.3906
9.921
#40
.098
2.489
#6
.204
5.182
.397
10.084
#39
.0995
2.527
#5
.2055
5.22
.404
10.262
#38
.1015
2.578
#4
.209
5.309
13/32
.4063
10.320
#37
.104
2.642
#3
.213
5.41
.413
10.49
#36
.1065
2.705
7/32
.2188
5.558
27/64
.4219
10.716
7/64
.1094
2.779
#2
.221
5.613
7/16
.4375
11.113
#35
.110
2.794
#1
.228
5.791
29/64
.4531
11.509
#34
.111
2.819
.234
5.943
15/32
.4688
11.908
#33
.113
2.87
15/64
.2344
5.954
31/64
.4844
12.304
#32
.116
2.946
.238
6.045
1/2
.500
12.700
#31
.120
3.048
.242
6.147
1/8
.125
3.175
.246
6.248
#30
.1285
3.195
1/4
.250
6.35
There are four different types of drill

bits - fraction, number, letter and
metric. Use the one that is closest
to the orifice size needed.
#29
.136
3.454
.250
6.35
83
MM
INCH
DECIMAL
MM
Vactor 2100 Fan
ydraulic Pump - Engaging (starting)

H
The hydraulic pump is mounted to the rear of
the truck transmission and driven by a PTO. The
hydraulic pump provides hydraulic oil pressure for
operating the water pump, hose reel, boom and
any other hydraulic accessories. The PTO shifter is
located in the truck cab.
Operations
! DANGER
To prevent injury or death:
Do not go underneath the vehicle with the
engine running.
Do not work near a rotating drive shaft to
prevent getting entangled.
There are many combinations of PTO shifters

available with the Vactor. Always follow the
instructions posted in the cab for shifting the PTO
and engaging the hydraulic pump. Instructions are
normally located on the visor or dash. They vary
with the transmission style, chassis manufacturer
and options.
Do not attempt to engage or disengage the PTO

or other driven equipment from underneath the
vehicle with the engine running.
Do not attempt to engage or disengage the PTO
or other driven equipment from any position that
could result in getting entangled in the drive
shaft or moving machinery.
Do not attempt to work on an installed PTO with
the engine running.
The MODE
switch is
normally used
on automatic
transmissions.
84
Vactor 2100 Fan
ydraulic Pump - Engaging (starting) - Manual Transmissions

H
General procedure
CAUTION
To engage the PTO on a vehicle with a manual

transmission, proceed as follows:
1.
Apply parking brake.
2.
Place MASTER SWITCH in the ON position.

The Master Switch light should illuminate.
3.
Place the truck in neutral.
4.
Set engine to idle.
5.
Depress clutch fully.
6.
Move PTO shifter from the OUT position to

the IN position.
7.
Slowly release clutch.
To avoid transmission and/or PTO damage

When not in use, the PTO should be disengaged.
Always check for the red PTO warning light
before driving truck. This light indicates that the
PTO is engaged. Do not drive truck with the PTO
engaged unless using recirculation mode.
Do not attempt to engage PTO while the truck is
moving.
The red warning light next to the PTO shifter and

the OK TO PUMP light should illuminate, indicating
the PTO is engaged.
Notes: If equipped with cable type PTO shifter,
depress clutch and push PTO lever to full in
position and release.

Do not engage the PTO while moving or with

the clutch engaged.
Operations
85
Vactor 2100 Fan
ydraulic Pump - Engaging (starting) - Auto Transmissions

H
General procedure
CAUTION
There are several different types of PTO's available.

The standard one is shown here.
To avoid transmission and/or PTO damage

When not in use, the PTO should be disengaged.
Always check for the red PTO warning light
before driving truck. This light indicates that the
PTO is engaged. Do not drive truck with the PTO
engaged unless using recirculation mode.
The red warning light next to the shifter should

illuminate, indicating the PTO is engaged. If PTO
grinds, disengage PTO and repeat procedure.
Notes: On automatic transmissions, the gears turn
when the transmission is in neutral. Some
gear clashing will occur if the PTO is not
engaged properly.

Operations
Do not attempt to engage PTO while the truck is

moving.
Some units with automatic transmissions may

require a high range lock up or similar means
of locking the transmission. Check the vehicle
instructions supplied with each truck.
PTO Operation
Work Mode
1.
2.
3.
4.
5.
Apply Parking Brake

Set Engine to Idle
Select Neutral
Turn Master Switch ON
Select Mode ON
Road Mode
1. Switch Mode OFF
2. Turn Master Switch OFF
Ref. Note:
Auto transmissions

48895 rev A
3" wide by 5" tall - 1/8" corner radius

ENG. STANDARDS


NAME
DECAL,PTO OPERATION,AUTO TRANS

DR.
AC
DATE
SCALE
8-8-2005
PART NO.
48895
NONE
TOLERANCES UNLESS
LTR.
0
A
Revision
Initial release
Added master switch on/off
86
By
AC
AC
Date
8-8-2005
12-22-2005
ECN No.
6032
6204
uxiliary Engine - Starting

A
Vactor 2100 Fan
The auxiliary engine drives the fan, which develops

the airflow needed for suction pick-up. The auxiliary
engine ignition switch and throttle control are
located on the front reel control panel. Start the
auxiliary engine as follows:
1.
Perform daily maintenance as outlined on the

Daily Maintenance Check List located in the
Maintenance Section.
2.
Place the VACUUM RELIEF switch in the ON

position.
3.
Place the THROTTLE switch in the IDLE

position.
Operations
Auxiliary Engine Hood Latch

The auxiliary engine is protected by a cover that
slides out of the way to gain access to the engine.
It is held in place with a spring-loaded latch that is
pulled down which then releases the engine cover.
Engine Cover
Turn the IGNITION switch to the momentary START

position until the auxiliary engine starts, but not
longer than 15 seconds. Wait 30 seconds between
starting attempts. The switch will return to the ON
position automatically when released.
CAUTION
Engine Cover Latch
Do not hold the ignition switch in the start position for more than 15 seconds. Wait 30 seconds
between starting attempts to avoid damage to
the starter motor.
Engine Cover
Engine Cover Latch
Auxiliary Engine
Throttle Control
Auxiliary Engine
Ignition Switch
87
Vactor 2100 Fan
an
F
Operations
The Vactor vacuum system, consisting of a large

dynamically and statically balanced aluminum fan,
produces a smooth, safe and powerful airflow. This
unique system is capable of vacuuming debris from
great depths and significantly increases debris
volume and velocity. There is a single stage and
an optional two stage system available. The single
stage units are driven by a four cylinder engine and
the two stage by a six cylinder engine.
Single stage fan
Two stage fan
88
ose Reel - Control Panel

H
1
Vactor 2100 Fan

4
Operations
Control Panel on
Front of Hose Reel
15
Operator Control Panel (front)
14
13
12
Throttle Speed Switch
Pressure Light
Vacuum Relief Light
Vacuum Relief Switch
Hose Reel Extension Switch
Boom Extension Switch
Boom Joystick
Low Water Light Switch
Load Limit Switch
10 Auxiliary Engine Switch

10
11
11 Auxiliary Engine Speed Switch

12 Audible Alarm Switch
13 Boom Work Lights
14 Throttle Switch
15 Rodder Pump Switch
Switches
Note: Each of the switches are labeled on the
control panel for quick reference.
1.
extends and retracts the hose reel.
Throttle Speed Switch - This switch provides

the operator the ability to control the engine
speed from the master control panel. It is a
three-way momentary switch which increases
engine speed (rpm) when held in an upward
position which, in turn, increases the amount
of water pressure. When the throttle switch is
held in a downward position, the engine rpm
will decrease and so will the water pressure.
6.
Boom Extend/Retract Switch (optional)

controls the extension or retraction of the
boom.
7.
Boom Joystick (optional) controls the

movement of the boom, up/down or left/right.
8.
Low Water Light (optional) - This light

provides a warning when the water level in
the water tank has dropped below the sensor.
The sensor is near the bottom of the water
tank on the back.
2.
Pressure Warning Light - See number 15

below.
9.
3.
Vacuum Relief Light - This light will illuminate

when the vacuum relief switch has been
turned on.
Load Limit Switch (optional) - This switch will

provide an audible alarm when the debris
body has reached its capacity.
10.
Auxiliary Engine Switch. This Switch starts

the auxiliary engine.
11.
Auxiliary Engine Speed Switch - This controls

the speed of the auxiliary engine which in turn
controls the speed of the vacuum.
4.
Vacuum Relief Switch - This switch releases

the vacuum in the system. This switch is
used to activate the vacuum relief valves on
the unit.
5.
Hose Reel Extension Switch - This switch
89
ose Reel - Control Panel

H
Vactor 2100 Fan
12.
Audible Alarm (optional) - This switch gives

an audible alarm when the water in the tank is
low.
13.
Work Lights (optional)
14.
Throttle Switch - This switch provides the

operator the ability to control the engine
speed from the master control panel.
15.
Rodder Pump Switch - This switch turns the

water pump ON. A red light directly above
the switch will glow when the water pump
pressure is too high.
Operations
A second set of controls on the rear of the hose

reel allows the operator the flexibility to control the
operation from the backside of the hose reel. These
vary with configuration.
Operator Control Panel (back)
Throttle Speed Switch
Rodder Pump Switch
Hose Reel Extension Switch
Pressure Light
A description of these controls is the same as those

controls pertaining to the control panel on the front
of the hose reel.
Control Panel on Back of Hose Reel
90
ose Reel - Gauges

H
Vactor 2100 Fan
Operations
These gauges measure the auxiliary engine

performance.
1.
Engine Tachometer Gauge. This gauge

measures the engine speed.
2.
Oil Pressure Gauge. Measures the amount of

oil pressure in the auxiliary engine
3.
Volts Gauge. Measures DC voltage put out by

the auxiliary engine.
4.
Water Temperature Gauge. Measures the

temperature of the engine coolant in the
auxiliary engine.
2
3
91
Vactor 2100 Fan
acuum System - Inlet/Outlet Seals

V
The inlet and outlet seals permit the debris body to
easily be raised without having to disconnect hoses
to the boom and fan system.
Operations
Inlet Seal
When the fan is engaged for vacuuming, it is

important the debris tank and the fan inlet seals be
in good shape and not leaking. If they are torn, dirty
or not adjusted properly, loss of airflow at the end of
the debris hose will result. Both the inlet and outlet
seal can be adjusted in order to compensate for
wear.
Outlet Seal
The cone of the outlet seal must be adjusted so

that there is no air gap. One of two procedures can
be followed to eliminate any gap. See Maintenance
Section for the proper procedure to follow in making
the adjustments. If there is a gap, there will be
insufficient vacuum.
A similar procedure is followed for the inlet seal.
See the maintenance section for the procedures to
follow in making adjustments.
Outlet Seal
Inlet Seal
92
perating Procedures
O
Vactor 2100 Fan
The following pages cover cleaning catch basins

followed by a description of jet rodding operations
and simultaneous vacuum and jet rodding operation.
Be aware of traffic and pedestrians on the job site.
Use extreme caution while moving around the
vehicle to avoid contact with moving vehicles. When
moving the boom or vehicle make sure pedestrians
are clear of the area. Use orange safety cones to
mark the work area.
93
Operations
Vactor 2100 Fan
O
perating Procedures - Sewer Systems
Observe environmental
protection regulations
Operations
! WARNING
Biological hazards
Be mindful of the environment

and ecology.
Germs and other biological hazards are common

in sewers. Use goggles, face shield, gloves, long
sleeves and long pants to prevent injury and
contamination. Immediately treat all abrasions,
cuts and nicks for contamination. Get medical
attention for injuries associated with cleaning
sewers, drains and catch basins if biological
contamination is suspected. Serious illness may
result if this procedure is not followed.
Before draining any fluids, find

out the correct way to dispose of
them.
Observe the relevant environmental protection
regulations when disposing of oil, fuel, coolant,
brake fluid, filters, and batteries.
! WARNING
! WARNING
Sewer gas hazard.
Trip, fall and other hazards
Sewer lines often contain poisonous or

explosive gas such as methane. Do not enter
or bend over a sewer without proper ventilation
and personal protective equipment. If another
person needs help in a sewer, immediately call
for emergency assistance. Do not enter the
sewer to help unless you have been trained
to do so and have proper personal protective
equipment.
Open manholes and other access openings

create risks of trips and falls. Be aware of such
locations and do not step in or over them.
Ensure that manhole cover and other covers are
in place when job is completed. Failing to follow
these precautions may cause serious injury or
death.
Be aware of traffic and pedestrians on the
job site. Use extreme caution while moving
around the vehicle to avoid contact with moving
vehicles. When moving the boom or vehicle
make sure pedestrians are clear of the area. Use
orange safety cones to mark the work area.
Do not smoke in or around sewer lines, drains,

or catch basins.
Failure to follow these instructions may result in
death or serious injury.
! WARNING
Chemical waste hazard
Many chemicals are illegally dumped in storm
drains, catch basins and sewers. To prevent
contamination and injury wear chemical
resistant gloves, long sleeves, trousers and
safety glasses or face shields. Seek immediate
medical attention if exposure or contamination
is suspected.
94
Vactor 2100 Fan
perating Procedures - Visual Inspection

O
Before taking the Vactor to the job site, be sure to
follow the checklist for maintenance and lubrication
in the Maintenance Section of this manual.
Before starting any new job, meet with your

supervisor to discuss details such as hoses and
accessories needed to perform the job properly; any
special considerations related to the work site or
any anticipated hazards; and any safety precautions
an operator should take to ensure correct setup and
operations.
Visual Inspection
The operator should make a visual inspection of the
Vactor unit before use. A properly conducted pre-trip
inspection will prevent safety hazards and extend
the life of the Vactor unit.
1.
2.
Be especially aware of underground utilities.

All aspects of safety need to be considered, no
matter how routine using the equipment has
become.
To access the engine compartment, the hose

reel must be moved. Make a visual inspection
of the engine compartment for oil or water
leaks and loose or worn belts. Check and
adjust fluid levels as needed. When finished
under the hood, secure the hood.
When Arriving at Work Site

When arriving at the work site, turn on the hazard
and strobe lights. If equipped, the optional arrow
board should also be turned on. When parking
at the work site, position the truck between the
manhole and oncoming traffic, if possible. This
procedure uses the weight of the Vactor as a device
to protect the operator from any driver who doesnt
see or obey the safety cones set up around the
work area.
Begin at the hose reel and inspect the

condition of the rodder hose. Look for wear
on the exterior of the hose and damage such
as blisters, bubbles or knots. Check that
the fittings are neither too loose, have no
excessive play nor are too tight, cutting into
the rodder hose. Do not use, but immediately
repair or replace, that part of the rodder hose
that exhibits any of these characteristics.
3.
Check the control panel for damage or water

and oil leaks or both.
4.
Listen around the hose reel for air leaks.

Small leaks will get larger; repair immediately.
5.
Check the tires for pressure and wear.
6.
In the hydraulic fluid site gauges, the hydraulic

oil should be at the proper level..
7.
Look in the toolboxes to ensure all correct

accessories for the days assignments are
present. Keep tools well organized to save
time finding needed items. Greasy tools are
slippery, hard to control and unsafe. Keep
them clean.
8.
Carefully inspect the ground or floor under the

chassis for oil and water leaks. Listen for air
leaks.
9.
Visually inspect the rear door seal for leakage

or damage.
10.
Clean the windows and adjust the side

mirrors, as necessary for safe driving.
11.
Report all concerns found during inspection to

a mechanic or supervisor, or both, so needed
repairs can be evaluated and scheduled. If
necessary, personally point out the exact
location of each problem area.
Operations
All diesel engines should be allowed to warm up.

This provides an opportunity to perform other vital
checks over the entire truck.
The operator should wear a florescent-colored
vest while working at the work site. Because the
applications for which Vactor trucks are used
expose the operator to dirt and germs, gloves and
a long-sleeved shirt must be worn at all times while
the truck is in operation. Ear plugs guard against
hearing loss from engine noise. Protective eye wear
can save the operators sight from flying debris.
Some operating tools are quite heavy. Steel-toed
boots will provide not only protection, but also
support and comfort during a long day of standing.
After moving into position, set the transmission
into neutral and then set the parking brake. Before
leaving the cab, engage the hydraulic system by
following the engagement procedure posted in the
cab.
95
Vactor 2100 Fan
O
perating Procedures - Hazards
Operations
Cut line
WARNING
Do not operate jet-rodder with

damaged rodder hose or
rodder hose that is not
authorized by Vactor Mfg., Inc.
WARNING
Loose hose/nozzle
result from high pressure water
or impact from hose/nozzle.
Use rigid nozzle support/guard
of proper length.

result from rodder hose or
fittings failing.
Frequently inspect hoses and
fittings. Install fittings properly.
Vactor Mfg., Inc. accepts no
responsibility for this equipment
while operated with any other
hose than that hose furnished
by Vactor Mfg., Inc.
6.375" wid
.125 corne
Refer to SAFETY section in manual

for details.
1800152
Cut line
WARNING
! ADVERTENCIA
Vacuum Hazard
Riesgo Por Altovaco
Cutting, crushing,
or death.

mortales.

hose inlet end.


accessories.

altovaco.
para detalles.
Refer to SAFETY
manual for details.
6.375" wide x 6.25" tall

.125 corner radius
ENG. STANDARDS

VACTOR Manufactu
NAME
1800174
DECAL,VAC
DR.
AC
DATE
SCALE
11-20-2006
NO
This document contains material and/or information which is the p

confidential basis. No transmittal or disclosure shall be made to a
Vactor Manufacturing Inc.. The controlled master copy of this doc
TOLERANCES UNLESS
LTR.
0
96
Revision
Initial release
igh Pressure Water

H
Vactor 2100 Fan
When setting up for rodding operations use the

appropriate guide fin and hose guard (tiger tail) to
prevent the nozzle from turning in the pipe
wer pipe
and returning toward the operator. The
Se
length of the assembled nozzle and
guide fin must be greater
than the diameter of the
pipe to be cleaned.
Operations
Guide fin
Tip of nozzle
End of nozzle
Start of Hose
Hose guard
extended
(tiger tail)
Correct
Inspect the
minimum
rodder hose
length
often for
indications of damage
or wear. Check the
hose before each
use for movement in hose fittings, exposed hose
reinforcement, kinking or collapsing, blisters or
bubbles and fittings that are improperly installed or
cutting into the hose.
must match during splicing operations. Be aware of

the operating pressures associated with the vehicle
and the proper hose specifications for safe operation.
Waste Equipment Technology Association publishes
a variety of industry related recommended practice
guides. It is recommended that owners and operators
obtain Specification and repair/inspection procedures
for high-pressure hose used in connection with
sewer/catch basin cleaning equipment.
When splicing hoses read the

maintenance section of the
manual for instructions on hose
repair. All hose manufacturers
have instituted a color code
system for identification of the
hose, fittings and tools. When
repairing a rodder hose the inside
color of the hose, the color of the fitting
and the die colors must match. Fittings from one
manufacturer will not properly crimp onto hose from
another manufacturer. The outside color of rodder
hose indicates the pressure rating of the hose and
Waste Equipment Technology Association

4301 Connecticut Avenue, NW
Suite 300
Washington, DC 20008-2304
(Phone) (202) 244-4700
(Fax) (202) 966-4824
(E-mail) wastecinfo@WASTEC.org
(Web) http://www.wastec.org
! WARNING
! WARNING
High pressure water
Out of control hose can cause severe injury or

death.
High pressure water can cause serious injury

or death. The handgun operates under high
pressure. Never point the handgun at another
individual. Severe injury can result from the
high-pressure water.
The rodder hose creates tremendous pressure

and must not be fitted with a reducer or hand
held nozzle, or operated outside of the sewer
pipe. The back pressure created by such action
will cause loss of control and violent movement
of the hose and fittings, and the release of high
pressure water .
Special safety equipment is required when

operating the high-pressure handgun. Always
wear safety toe shoes or boots (waterproof
shoes or boots preferred), coveralls, face shield
and safety goggles and gloves (waterproof
gloves preferred).
Do not use improper fittings or use out of sewer

pipe. Refer to manual for details.
97
Vactor 2100 Fan
perating Procedures - Visual Inspection

O
Operations
Positioning the Truck
Setting up Water Hose
If possible, position the truck with the rodder hose

reel to one side and the end of the hose directly
over the manhole. If the rodder hose can be
inserted into the center of the manhole, retrieving
the hose is simplified.
When setting up for rodding operations, always

use a rigid hose guard (tiger tail) and guide fin
of proper length. The length of the guide fin and
nozzle should be greater than the diameter of the
sewer pipe. Hose support guards and guide fins
are used to protect the hose and to prevent nozzles
from reversing in the line and causing uncontrolled
acceleration and operator injuries. They help center
the nozzle in the pipe for better cleaning. They help
reduce nozzle body and leader hose wear. They
also prevent the nozzle from turning laterally if the
nozzle size is incorrect for the pipe diameter.
If the handgun valve is left open during rodding,
it will result in a loss of pressure in the rodder
hose.
Aligning the hose as it rewinds on the reel is a

simple matter when the hose comes straight up out
of the manhole. However, if there is a pulling force
on either side, aligning the hose as it returns can be
difficult.
The hose reel on the Vactor rotates 135 degrees
either way from center to aid in aligning the rodder
hose with the manhole. To rotate, unlock the hose
reel, rotate to the desired position and replace the
pin.
When the hose cannot be inserted directly into the
manhole, use additional hose guards (tiger tails) to
prevent damage to the hose.
98
Vactor 2100 Fan
tarting Operation - Setting Up (Rodding)

S
The jet rodding operation is used to clean and
remove blockage from sewer lines. The rodder hose
and nozzle is inserted into the sewer line and the
thrust from the nozzle propels the rodder hose and
nozzle through the sewer line.
Operations
Water
Hose
Reel
The nozzle breaks down material that may stick to

the sides of sewer lines and removes blockages.
Also, it adds water to the material for easier pickup
and moves the material to the vacuum nozzle. The
vacuum hose then removes the debris from the
basin.
Close the ball valve marked Handgun. Open the
ball valve marked Rodder. Using the reel control
lever, unwind enough rodder hose to install a hose
guard (tiger tail), leader hose and guide fin and
nozzle, approximately ten feet. Using the nozzle
selection guide located in the Description Section
of this manual, select the appropriate nozzle for the
application.
Tiger Tail
Catch Basin
1.
Push the rodder hose through the hose guard

(tiger tail) and attach a guide rope to the ring.
2.
Install the leader hose to the end of the rodder

hose. Tighten the leader hose hand-tight, plus
one-half turn.
3.
4.
5.
Install the appropriate guide fin on the end of

the rodder hose or the leader hose if used.
Tighten guide fin hand-tight, plus one-half
turn.
Screw the
appropriate nozzle
onto the end of the
guide fin. Tighten
the nozzle handtight, plus one-half
turn.
Tip of nozzle
Hose guard
Nozzle
Leader hose
Adapter
Using the reel

control lever and
attached rope, insert the nozzle into the sewer
pipe. Tie the rope in a position on the truck
bumper to prevent loss of the tiger tail.
Use additional tiger tails if necessary to

protect the rodder hose from sharp edges and
rough areas.
End of nozzle
Start of Hose
Rope
Notes: The tiger tail can be installed on the rodder

hose with the rope ring on the top or the
bottom, whichever is most convenient.

Hose guard
extended
(tiger tail)
Guide fin
99
Guide fin
A leader hose is used for easier pipe insertion

and to absorb the excessive wear and
damage to the first few feet of the rodder
hose. A standard leader hose is 30 inches
long. However, a leader hose of 10 to 20 feet
is optional. When retracting the rodder hose
from the sewer line, the operator knows the
nozzle is approaching the opening when the
leader hose is visible.
Vactor 2100 Fan
tarting Operation - Setting Up

S
Operations
! WARNING
The nozzle / guide fin combination must be in
the sewer pipe a minimum of two feet before
turning on the rodder pump. Failure to insert
the nozzle properly can cause the hose / nozzle
combination to come out of the pipe when the
rodder pump is turned on causing injury or
death.
In an emergency and/or if it is suspected the
nozzle has turned in the pipe and is returning
immediately turn the RODDER PUMP switch to
the OFF position.
WARNING

6.
Select the appropriate nozzle for the job and

install it onto the rodder hose.
7.
Place the rodder ball valve on the hose reel in

the ON position.
8.
With the hydraulic pump engaged, place the

rodder pump switch in the ON position.
9.
Using the truck throttle switches, place the

throttle on/off switch in the ON position and
hold the throttle up / down switch in the UP
position until the appropriate speed and
pressure is indicated on the pressure gauge
on the hose reel.
10.

rodder pump.
rodder pump.
Slowly unwind the hose reel; the available

water pressure will propel the nozzle into the
sewer line.
Notes: The rodder pump switch is constructed to

prevent accidental engagement. Pull on the
toggle switch lever and push up to activate.
In an emergency or to disengage the pump,
push the toggle lever down. The pump will
immediately stop.


uncontrolled.
The throttle speed controls both the water

pressure and vacuum pressure. For those
units equipped with the multi flow option, one
can be increased without increasing the other.
See options section for a discussion on the
operation of the multi flow option.

1800151

ENG. STANDARDS

E0010 - Decal
Tiger layout
Tale specifications

NAME
DECAL,HIGH PRESSURE WATER

DR.
AC
DATE
SCALE
1-11-2005
PART NO.
NONE
180
This document contains material and/or information which is the property of Vactor Manufacturing Inc., and supplied o
confidential basis. No transmittal or disclosure shall be made to any person, firm, or corporation without written appro
Vactor Manufacturing Inc.. The controlled master copy of this document resides in electronic format. All printed copies
DIMS. IN INCHES
TOLERANCES UNLESS
LTR.
0 Initial release
Rodder Hose
100
Revision
Nozzle
By
AC
Date
1-11-2005
EC
5
Vactor 2100 Fan
tarting Operation - Rodding

S
Operations
For safety reasons, the operator must know how to

quickly shut down the system. The operators life
and those around him may depend on it.
Allow the hose to feed itself through the line at a

moderate pace. DO NOT allow the hose to coil up in
the bottom of the manhole.
The operator must become thoroughly familiar with

the different features and controls on the hose reel
control panel. From truck to truck, the control panels
may not have the same controls or location based
on available options.
If the sewer is tightly plugged, it may be best to

feed the hose in 25-foot lengths and return. Repeat
this, in 25-foot increments, until the hose has gone
the complete distance. This prevents the line from
blocking up with material behind the nozzle. It also
helps allow debris to flow to the manhole. The
actual cleaning of the line takes place as the hose is
retrieved.
A water pressure gauge on the upper hose reel

monitors the water pressure. The red pressure light
comes on when the water pressure is exceeded.
Blinking on-and-off indicates that operation is
at a maximum pressure and safe to continue. A
steady red light indicates the chassis engine RPM
is too high. This can damage the hydraulic pump.
Immediately reduce the RPM until the pressure light
goes off.
Hose travel, both forward and reverse, is controlled

by the directional control valve next to the hose reel.
Push up on the handle to pay-out. Pull down on
the handle to return the hose to the reel. Adjust the
speed control knob for the job at hand. The basic
rule is the dirtier the pipe, the slower the retrieval of
the hose.
An optional low-water level light warns the operator

when the fresh water supply is low. When this light
illuminates, the operator should begin returning the
rodder hose to the reel. The rodder pump is not
effected by running it dry. However, the rodder hose
nozzle will plug if it is dragged through sewer pipe
debris without water pressure.
To achieve full system water pressure, increase the

RPMs. Watch the pressure gauge until it reaches
the rated maximum pressure. There is a relief valve
in the hydraulic circuit, set at the rated pressure, to
protect the hydraulic circuit from damage.
Another option for low-water warning is an audible

alarm. It will sound in case of low water level.
Hose guard
extended
(tiger tail)
Guide fin
Tip of nozzle
Nozzle Guide
1.
Prevents reversal of nozzle in line and

an unrestrained nozzle to accelerate
uncontrolled. Length of guide should be
greater than the diameter of sewer pipe
being cleaned.
2.
Helps center the nozzle in the pipe for

more complete cleaning.
3.
Helps reduce wear of nozzle body and

leader hose.
4.
Enables the nozzle to travel over

rough or broken sections of pipe and
minimizes the possibility of the nozzle
traveling up a lateral sewer line.
Cut line
WARNING

fittings failing.
ALWAYS USE A NOZZLE SUPPORT GUIDE

OR GUIDE FIN
End of nozzle
Start of Hose
101
WARNING
Loose hose/nozzle
of proper length.

for details.
1800152
J et-Rodding Operation
Vactor 2100 Fan
The travel speed of the nozzle into and out of

the sewer is controlled with the speed control
adjustment on the hose reel directional control. The
speed will also be affected by variables in engine
rpm and nozzle selection as these variables affect
hydraulic flow, water thrust and water pressure.
The units are equipped with a red warning light that
will illuminate when maximum system pressure is
exceeded. The unit should not be operated if this
light is on continuously. Should the light stay on all
the time, lower the engine rpm until the light goes
out. It is normal for this light to flicker on and off if
working at maximum water pressure. Note that the
flow rate of the nozzle will determine how high the
engine rpm will be to achieve maximum working
pressure. Typically as the flow rate of the nozzle
is reduced the required engine rpm to achieve
maximum working pressure will also be reduced.
Operations
CAUTION
Units with multi flow hydraulic systems will be

equipped with one or two adjustable relief valves
at the hose reel control station. These valves will
decrease the water flow and pressure without
changing the engine rpm. Note that utilizing these
valves to reduce flow and pressure will also
decrease the forward thrust created by the nozzle.
Do not continue to operate the unit if the

PRESSURE light illuminates. Damage to the unit
could occur.
In general sewer cleaning applications there

are a substantial number of variables that the
operator must review to have the unit perform to its
maximum capabilities. The size and type of the line,
the amount of material in the line and the grade of
the line are a few. These variables will determine
the proper nozzle selection. For example a line
that has been cleaned on a regular maintenance
schedule would require a lower flow nozzle and
lower pressures to clean. The operator in this
situation could clean longer lines with out utilization
of incremental cleaning. He would also utilize less
water and fuel while cleaning more lines.
better break through blockages. It also does a

better job of moving large amounts of material. The
additional flow is required to more efficiently move
the additional material down the line. Incremental
cleaning would be utilized. Incremental cleaning is
inserting the nozzle down the line in short intervals
and then returning it to the man hole with that
material. Trying to move too much material at one
time can create additional blockages in the line
or potentially getting the nozzle and hose stuck
in the line. The operator can determine how long
each increment should be based on the amount of
material he is removing from the line. Units can be
equipped with optional footage counters or hoses
can be marked to assist in incremental cleaning.
The same diameter line that had not been cleaned

in years would be heavily laden with material. In
this example the operator would chose a larger
flow nozzle with a lower degree of angle and
would employ incremental cleaning. The lower
degree nozzle creates more forward thrust to
Proper nozzle selection is the key to maximize the

performance and utilization of the sewer cleaning
equipment. Note that larger lines may utilize multiple
nozzles on different passes to maximize cleaning.
Operators with proper nozzle training will be more
productive.
102
Vactor 2100 Fan
J et-Rodding Operation - Stop Rodding

When the hose has reached the end of the run or
the line is clean, pull the hose back onto the reel by
pulling down on the directional control lever. This
should be done with the rodder pump on. If the line
is clean, a minimum of water pressure is needed.
When the nozzle gets close to the manhole, lower
the pressure completely by reducing the engine
RPM on the truck and turning off the rodder pump
switch. Remove nozzle from the pipe and wind
rodder hose onto the hose reel using the manual
wind guide.
Operations
WARNING

uncontrolled.
rodder pump.
rodder pump.
1800151

ENG. STANDARDS


NAME
DECAL,HIGH PRESSURE WATER

DR.
AC
DATE
SCALE
1-11-2005
PART NO.
NONE
1800151
DIMS. IN INCHES
TOLERANCES UNLESS
LTR.
0 Initial release
103
Revision
By
AC
Date
1-11-2005
ECN No.
5683
Vactor 2100 Fan
acuuming - Positioning The Truck

V
Operations
The ideal position of the truck for cleaning catch

basins, manholes and wet wells is with the vacuum
nozzle to one side of the front reel and the front
bumper approximately even with the opening. Once
the suction tube is released and nozzle attached,
the nozzle should be in a vertical position directly
over the basin or manhole opening as shown in the
photo to the left. With the truck in this position, the
boom can be used to move the suction tube and
nozzle up and down for most efficient cleaning.
Set the parking brake. Engage the hazard light
switch, causing the emergency lights to flash. If
possible, activate the rotating flasher and warning
lights. The truck engine should be running to power
the hydraulic pump and water pump.
! CAUTION
! CAUTION
Prior to leaving the truck and using the Vactor,

set the parking brake. For further safety the use
of wheel chocks is highly recommended.
Activate all warning lights (rotating, beacon,

strobe, arrow-boards, four-way flashers, etc.)
104
Vactor 2100 Fan
acuuming - Set Up
V
1.
Operations
Release tension on the vacuum tube by

lowering the boom slightly.
Vacuum Tube
2.
Remove the tube from the flange which

secures the tube while not in use, and swing
boom into position over the basin.
3.
Stand the long catch basin nozzle in the

manhole.
4.
Lower the boom until the vacuum tube and

catch basin nozzle are joined.
5.
Install the quick clamp

to fasten the nozzle to
the vacuum tube.
Quick
Clamp
WARNING
3" wide x 7" tall
.125 corner radius
ENG. STANDARDS



obstruction.

NAME
DECAL,VACTOR BOOM
DR.
DATE
AC
SCALE
1-11-2005
PART NO.
NONE
1800149
LTR.

equipment damage.
Catch
Basin
By
Nozzle Date
TOLERANCES UNLESS
DIMS. IN INCHES
Revision
Initial release
Updated arrow to ANSI electrical bolt
0
A
AC
AC
1-11-2005
3-24-2005
ECN No.
5683
5820
Refer to SAFETY
section in manual.
1800149 rev A
Cut line
WARNING
! ADVERTENCIA
Vacuum Hazard
Riesgo Por Altovaco
Cutting, crushing,
or death.

mortales.

hose inlet end.


accessories.

altovaco.
Refer to SAFETY
manual for details.
para detalles.
6.375" wide x 6.25" tall

.125 corner radius
ENG. STANDARDS


NAME
DECAL,VACUUM HAZARD
1800174
DR.
AC
105
DATE
SCALE
11-20-2006
PART NO.
1800174
NONE
TOLERANCES UNLESS
LTR.
Revision
By
Date
ECN No.
acuuming - Operation
V
Vactor 2100 Fan
For most operations, (including cleaning catch

basins, wet wells, sludge filter beds or digesters) the
best performance will be obtained from using the
nozzle in a vertical position.
Operations
Vacuum Tube
All vacuum trucks move material through air

conveyance. They rely on air movement to entrap
and carry away the debris. For proper operation
the end of the vacuum tube must be just above the
debris so that an air stream is maintained. Various
optional vacuum tubes are available to permit
vacuuming under water by providing, in effect a
snorkel to get air to the vacuum tube nozzle end.
Nozzle Holes
Use the boom to lower the nozzle into the material

to be removed. With most material, it helps to move
the nozzle up and down using the boom controls.
Lower the nozzle into the material and raise the
nozzle enough for the bottom of the nozzle to clear
the material, and then back down into the material.
Using this up and down motion will help loosen the
debris, especially compacted material.
When picking up water or slurries, allow the tip of
the nozzle to just clear the top of the water or slurry.
As material is removed, the nozzle can be tipped,
or the pipe and boom moved horizontally to reach
other material. Continually working the nozzle this
way enables the operator to observe the work area.
If the material to be picked up is not in a pile, use
a shovel, rake or hoe to work the material into the
nozzle. The handgun stream can be used to move
material toward the tip of the nozzle.
The catch basin nozzle has holes just above the
jagged or serrated edge at its base to allow air to
flow into the tube.
Cut line
During operation, observe the debris body level

gauge. When the indicator is horizontal the body is
full and must be drained and/or dumped.
Disconnect and Store Nozzle

Loosen the clamp holding the suction nozzle and
tube and return it to its storage compartment.
Return the suction nozzle and tube extensions
to their traveling locations. Attach the end of the
vacuum tube to the flange on the side of the
bumper. Lower the boom fully to its resting spot on
the cab guard.
WARNING
Vacuum Hazard
Riesgo Por Altovaco
Cutting, crushing,
or death.

mortales.

hose inlet end.


accessories.

altovaco.
Refer to SAFETY
manual for details.
106
! ADVERTENCIA
para detalles.
6.
.1
1800174
acuuming Operation
V
Vactor 2100 Fan
Operating Instructions
1.
2.
CAUTION
It is important to remember that the vacuum

tube uses air flow and not vacuum to pick up
material. Keep the suction end of the nozzle
in the right position to receive air and material
Beware of carry-over of material through the fan.

Running the fan too fast with light material can
carry the material into the fan. This can cause
an imbalance in the fan and premature wear.
Submerging the nozzle in material stops air

flow, prevents material movement and creates
a loading and unloading effect on the fan. The
catch basin nozzle is designed to pull air into
the pipe to move material. The end is serrated
with small holes; if the end is submerged, air
is pulled in through the holes.
3.
The weather and operating conditions cannot

be controlled, but the fan speed, water volume
and water pressure can be. The fan speed
controls the volume of air and the speed of
air movement through the pipe and into the
debris tank.
4.
If the soil or material breaks up easily, the

blower can run at higher speeds and allow
faster material pickup. The fan speed must
be adjusted to move maximum amounts of
material without carry-over into the fan.
5.
Fan speed is important when working in

freezing temperatures. High fan speeds
cause wind chill conditions because of the air
velocity. The wind chill conditions cause ice
build-up in the vacuum tube or boom, which
blocks material movement.
6.
Proper fan speed will vary depending on

the material moved. Air velocity should be
set so material does not hang in the pipe.
Adjust speed to the lowest setting to move
the material efficiently. Increase the speed
as needed to pick up large rocks or heavy
sludge. Watch the fan housing for carry-over
material. Any type of carry-over should be
avoided.
7.
The further the distance from the work site

to the debris body, the higher the fan speed
should be. The shorter the distance, the lower
the fan speed. Material moving through a pipe
or tube creates a friction factor. The longer
the tube or pipe, the higher the friction factor
- called friction loss. Pipe and tube diameter
is a major factor when moving material. The
standard Vactor unit comes with an eight-inch
diameter hose.
Operations
CAUTION
If ice builds up in the boom, shut down the
vacuum system. Use hot water to heat the boom
tubes or move the vehicle inside to warm up.
Slowly retract the boom when the tubes have
warmed up. Do not retract the boom with ice
build-up in the vacuum tube. Damage to the
boom or seal, or both, can occur. If hot water is
available, start the vacuum system and spray
it into the vacuum tube and nozzle. As the ice
breaks away, it will be carried into the debris
body.
107
acuuming Tips
V
Vactor 2100 Fan
1.
Always use a vacuum nozzle at the working

end of the tube.
2.
Never hold the open end of the hose with your

hand while vacuum system is on.
3.
Never guide debris to the nozzle end or open

end with your foot or hand.
4.
Do not remove obstructions from the nozzle

while the system is operating.
5.
For best performance, run the fan at a midrange or high range. Do not bury the nozzle in
the material. Air flow is required to convey the
material through the tube.
7.
Do not wear loose clothing or untied hair

when working on or near the unit or the open
end of the tube.
8.
Eliminate unnecessary bends or turns in the

tube.
9.
Always check the working condition of all

safety devices before starting the Vactor unit.
10.
Observe all safety instructions and markings

on the unit. Use ear plugs, safety glasses and
gloves.
11.
IN AN EMERGENCY
OR WHEN VACUUM
MUST BE STOPPED
Quickly:
Always open vacuum relief valves and reduce

RPM before attempting to dislodge any
obstruction in the vacuum tube.
6.
Be aware that the air system becomes hot

during vacuum operations.
Operations
Stop vacuuming.
Open vacuum relief valve.
Reduce fan engine RPM.
If required, shut down the engine.
Cut line
WARNING
! ADVERTENCIA
Vacuum Hazard
Riesgo Por Altovaco
Cutting, crushing,
or death.

mortales.

hose inlet end.


accessories.

altovaco.
Refer to SAFETY
manual for details.
para detalles.
6.3
.12
1800174
T
c
V
d
108
Vactor 2100 Fan
imultaneous Rodding/Vacuuming
S
Operations
The ability to remove material as rodding takes

place is a major advantage with this unit. By placing
the vacuum tube and suction nozzle into the
manhole while rodding, the sewer line is cleaned
and back washed debris is removed at the same
time.

Using the instructions for rodding, position the

rodding hose, guide fin and nozzle into the
sewer line.
Using the instructions for vacuum suction

operation, position the vacuum tube and
nozzle into the manhole.
By operating the suction tube and rodder at

the same time, the cleaning operation can
occur.
Catch
Basin
Nozzle
When ready to begin operations, the truck must

be running and the following procedures should be
followed.
1.
Inside the cab, turn on the master control

switch.
2.
Open the vacuum relief valve.
3.
Plug in the remote control pendant and

carry the pendant to the work area if desired.
4.
When the operator is ready, increase the RPM

to the desired range.
Rodder
Hose
Tiger Tail
When vacuuming, never attempt to guide or push

debris to the open end of the hose with your foot or
hand. Vacuum suction is powerful enough to suck a
limb into the hose. Do not reach into a vacuum hose
to free clogs. Always open the vacuum relief valve
and reduce the RPM before attempting to dislodge
any obstructions.
The rodder hose is positioned inside the tiger

tail and in the manhole. The operator has begun
simultaneous rodding and vacuuming by also
placing the catch basin (suction) nozzle into the
manhole.
If the air flow is not large enough to carry the

material, use the high range. Do not overload the
fan as that will pull debris into the fan. This will
result in a drop in efficiency. It will also make the
engine work harder than it has to, decreasing the
overall life of the unit.
The appropriate speed range is the lowest range
that will readily convey the material into the tube
and carry it to the debris tank. When vacuuming
material operated at least in the mid-range. This
will depend on the density of the material, and the
distance it has to travel to the tank.
109
hutting Down
S
Vactor 2100 Fan
When the clean out job is completed:

1.
CAUTION
Raise the boom above horizontal position and

allow the vacuum system to clear the tube of
debris.
2.
Place the VACUUM RELIEF switch in the ON

position.
3.
Allow engine to idle 3 - 4 minutes before shut

down.
4.
Reduce truck engine speed to idle.
5.
Turn off the rodder pump by placing the

RODDER PUMP switch in the OFF position.
Operations
Do not allow the auxiliary engine to idle for more

than 5 minutes. Extended idling will overheat the
fluid coupling and blow the fusible plug shutting
down the fan. This will require service for new
oil and a fusible plug.
110
hutting Down - Decant

S
Vactor 2100 Fan
Operations
Vacuuming can continue until the debris tank

capacity is reached. Then vacuum operations must
cease. Vacuum system must be off prior to draining
excess liquid from the debris body. Make sure the
auxiliary engine is shut off before decanting.
In liquid vacuuming, the level indicator or the
change of the sound of the fan (the float ball will
get sucked up) will indicate a full tank. As the tank
becomes full, the float in the debris tank rises
automatically with the load level to stop the flow of
air through the filtration system. Shut the system
down at this point and prepare for dumping or
draining.
Decant
Hose
Bracket
Decant or Draining Water from Debris Tank
Rear door
Draining the debris body before dumping will result

in fewer trips to the disposal site, less weight for
transportation and safer vehicle operation.
Decant
Drain
Do not raise the debris tank fully when decanting

water. Material in the debris tank can slide against
the rear door and thereby shutting off the decanting
process.
A water drain located in the rear door or right side of
the debris body allows draining excess water.
1.
Position the truck with the rear door over a

manhole at the worksite.
Attach and unroll the drain hose and place it

in the manhole.
3.
Open the decant (optional) valve.
4.
If the debris tank is less than half full, raise

the debris tank slightly to help drain.
5.
After excess water is drained, lower debris

tank, fold and replace hose.
NOTICE
Before draining water into a storm drain, sewer
or other location, ensure that local laws and
regulations do not prohibit offload.
NOTICE
Never overfill the debris tank. Do not exceed the
GVWR (gross vehicle weight rating.) The debris
tank can be completely filled as long as it does
not exceed its rated volumetric capacity.
111
Vactor 2100 Fan
oving & Stowing Equipment

M
Moving To a New Location
To move the truck to a new job site,
proceed as follows:
1.
Reduce truck engine speed to idle.
2.
Reel hose completely in.
3.
Place the reel SPEED CONTROL

knob in the full clockwise closed
position.
4.
Place the VACUUM RELIEF switch

in the ON position.
5.
Turn the auxiliary engine ignition

switch to the OFF position.
6.
Remove and stow the suction tube

nozzle and extension pipes.
7.
Secure vacuum tube.
8.
Stow suction nozzle and extension

pipes.
9.
Position boom in the stowed

position.
10.
Using instructions posted in cab,

disengage PTO.
11.
Move truck to new location.
Operations
Stowing Equipment
WARNING
It is important to check the area around

the vehicle and stow the equipment used
on a job site.
3" wide x 7" tall
.125 corner
radius
1.
Place
the VACUUM RELIEF switch
in the ON position.
STANDARDS
2. Let ENG.
idle
for 3 - 5 minutes before
shut down.

obstruction.
equipment damage.
Refer to SAFETY
section in manual.
3. Using the boom

controls,
lift the
VACTOR
Manufacturing
Inc. STREATOR
vacuum NAME
tube and remove the suction
DECAL,VACTOR BOOM
nozzle and
pipes.SCALE
Stow the
DR. extension
DATE
PART NO.
AC extension
1-11-2005
nozzle and
pipes with theNONE
This document contains material and/or information which is the property of Vactor Manufacturing Inc., a
confidential
basis. No transmittal or
disclosure
be made to anyof
person, firm, or corporation without
most used
attachment
on
theshallbottom
Vactor Manufacturing Inc.. The controlled master copy of this document resides in electronic format. All
the rack.document are UNCONTROLLED.
DIMS. IN INCHES
TOLERANCES UNLESS

4. Attach lower end
of vacuum tube to
LTR.
Revision
its flange on
the
front
bumper.
Secure
0 Initial release
with the quick
clamp.
A Updated arrow to ANSI electrical bolt
5. Reel rodder hose in completely and

remove nozzle, guide fin, tiger tail and
guide rope.
1800149 rev A
6. Place the reel SPEED CONTROL

knob in the full clockwise position.
112
7.
Place the HAND GUN ball valve in the OFF

position.
8.
Release water pressure from hand gun by

depressing trigger.
9.
Remove the hand gun from the quick coupler

and replace with quick coupler socket.
10.
Stow the hand gun and hose in the toolbox.
11.
Using the guide located in the cab, disengage

the PTO.
By
Date
AC
AC
1-11-20
3-24-20
Trim line
Vactor 2100
umping & Draining Debris Body

D
WARNING
WARNING
Operations
WARNING
ENG. STANDARDS
VACT
Crushing hazard.
Crushing hazard.
Electrocution hazard.
NAME
Serious injury or death can result

from falling debris body.

from falling rear door. Do not go
under the rear door when open.

from electrocution.
DR.
Do not go under a raised debris

body without the safety prop(s) in
place. Debris body must be empty
for service work.
Raise the box above the height of the
props. Tilt the prop(s) in place. Lower
debris body until it just rests on the
props.
Shut down and lock out the entire
system and chassis before servicing.
Use door prop or safety pin to

secure door before entering body,
working under or around the door.
Open the rear door to just clear the
prop and lower door until it just rests
on the prop. On units that use a
safety pin open the door until the pin
holes are aligned and insert pin.
Shut down and lock out the entire
system and chassis before servicing.
Unload any parts stored in debris
body before using machine.

obstructions before raising debris
body, opening rear door or raising
optional equipment. Do not leave
debris body, rear door or optional
equipment raised or partly raised
while vehicle is unattended. Do
not move vehicle with debris
body, rear door or optional
equipment raised.
surroundings before operating any of
the hydraulic functions to prevent
death, injury or equipment damage.
1800128 rev D
Dumping Body (Inside the Cab)

The truck engine must be started to dump the
debris tank containing the material collected. The
engine provides the power to the hydraulic system
which lifts the front of the tank and opens the rear
door
1.
Back the unit up to the dump site and park

on firm level ground. Pick a level area with
enough compaction to prevent the truck from
getting stuck.
2.
When in position, set the parking brake.
3.
Ensure there is adequate clearance overhead

for the debris tank to rise.
4.
Inspect the rear of the unit and the area that

the material will be dumped.
5.
Using the instructions located in the cab,

engage the PTO to activate the hydraulic
pump. See the section entitled Engaging the
PTO for proper instruction on engaging the
PTO or Work Mode.
114
AC
DATE
10-12-0
This document contains materia

confidential basis. No transmitta
Vactor Manufacturing Inc.. The
document are UNCONTROLLE
TOLE
DIMS. IN INCHES NOT
LTR.
0
A
B
C
D
Initial release
Reworded mid
Updated word
Updated arrow to
Added optional equip
Dumping
the
Body
Vactor 2100
Operations
The control station for dumping the material is

usually located on the passenger side of the unit.
Normally, there are two levers used for the dumping
operation. One lever is for unlocking the rear door
and the other is for raising the debris body. There
may be a third lever that controls the optional
hydraulic door opener.
Rear door
Manual Rear
Door Locks
Before either the rear door is opened or the debris

body raised, the rear door locks have to be opened.
Before unlocking manual locks, turn on the vacuum
system and block of the end of the hose at the
boom. This will pull the rear door in slightly and hold
it until the all the locks are released. This prevents
debris from falling on the operator.
Manual rear door locks - maintaining vacuum on

the debris body will prevent spillage of material on
the operator when the door is unlocked. Leave the
vacuum tube attached to the bumper mount to draw
vacuum in the debris body. Release vacuum before
raising debris body.
For those units with manual door locks, to release

the lock bolts, pull out on the handle. Twist the T
bolt to adjust lock tension if needed. If the unit is
equipped with optional hydraulic door locks, the
lever on the hydraulic control manifold is used to
unlock the rear door.
Rear Door
Locks Lever
Rear Door
Lever
115
Debris Body
Lever
Dumping
the
Body - Controls
Detent Position
Vactor 2100
Rear Door Detent/Body Neutral
The hydraulic control valve levers for the debris

body and rear door has four positions, UP,
NEUTRAL, DOWN and DOWN DETENT. The
control valve should be in the DOWN DETENT
position during transport or anytime the body hoist
or rear door is not in use.
Using the lever labeled Rear Door push the lever
to open the rear door. Using the lever labeled
Debris Body, push the lever in to raise the debris
body. The tank will begin to hydraulically raise
from the front and continue to raise until the hoist
lever is released. Fully raised, the tank will be in an
approximately 50 inclined position. The tank can
be stopped from raising further by releasing the
lever. The lever will return to its normal position. By
gravity, the tank will dump the material.
There are many different options that determine how
the dump controls are configured. Check the decal
in front of each lever to ensure proper operation.
116
Operations
Neutral Position
Dumping
the
Body - Clean Up
Vactor 2100
Operations
Using the hand gun, wash out the debris body,

paying particular attention to the door seal, lock
bolts, level indicator, float balls, screens, etc. and
the inside of the rear door.
Insert the rear door safety prop to secure the door
from accidentally falling during cleaning operations.
Visually inspect door seal. The door gasket and
mating surface on the debris body should be
completely cleaned so that it may form a complete
seal when it is closed.
Lowering Debris Body/Closing Door
The rear door must close with an air and watertight
seal. Make sure all debris is removed from the seal
before closing the door.
After the debris tank has been emptied and the seal
cleaned, remove the rear door prop and lower the
tank to its original operating position. Disengage the
hydraulics.
The tank should always be lowered first and then
the door closed. Never raise a loaded tank unless
the rear door is open and you intend to empty the
tank.
Rear
door
Gasket
Float balls
Rear
door
prop
Level indicator
117
ebris Body Prop

D
Vactor 2100
At any time the debris body is raised in order to

obtain easier access to the underside of the debris
body, all safety precautions must be followed. The
debris body should be stabilized and secured before
entering any space below it. The body prop is
normally located on the driver side towards the front
of the debris body. The unit should be parked on a
flat level surface.
1.
Raise the debris body so that the front of the

body is approximately 5 feet in the air.
Note: It must be sufficiently high enough in the air

to allow the safety prop to clear the body and
swing into position with the prop rest under the
body.
2.
Tilt the safety props towards the prop rest.
3.
After the top of the prop is in position, lower the

body until the prop is resting around the prop
rest. This will secure the body from falling.
Disengaging Safety Prop

1.
Raise the debris body to a sufficient height to

clear the safety prop socket by pulling prop
back to the stored position.
2.
The debris body can now be lowered.
118
Operations
ebris Body - Rear Door Prop

D
Vactor 2100
Operations
Any time access is required inside the debris body

all safety precautions must be followed for confined
space. The inside debris body must be fully cleaned
prior to entry.
Unlock the rear door.
2.
Fully raise the debris body.
3.
At this point the rear door will be hanging open

enough to put the prop in place.
4.
Remove the rear door prop locking pin and

lower the prop down.
Lower the debris body down.
6.
Verify the prop is properly seated in to the

socket as shown. If not raise the debris enough
for the prop to clear and lower again.
Espacio limitado
Entrada solo con
permiso.
6" wide by 4" tall - 1/8" corner radius

ENG. STANDARDS
E0008
- Graphic Film - Polycarbonate
Safety
E0010
- Decal layout specifications
Prop
Disengaging Safety Prop
Raise the debris body to a sufficient height for

the prop to clear the socket.
NAME
DR.
Raise the prop to the stored position and

secure with the locking pin.
3.
The debris body can now be lowered and the

rear door locked.
PELIGRO
1800148 rA
5.
2.
Cut line
Confined space
Enter by permit only.
1.
1.
DANGER
AC
DECAL,CONFINED SPACESafety
DATE
SCALE
12-29-04
PART NO.
Prop
Pin
NONE
1800148
DIMS. IN INCHES
LTR.
0
A
TOLERANCES UNLESS
Revision
Initial release
Corrected size to match artwork
By
Date
ECN No.
AC
AC
12-29-04
1-4-05
5666
5670
Debris Tank
STEP 1
STEP 2
STEP 3
Raise the debris body sufficiently to Align the end of the safety prop with Lower the debris body until the
allow safety prop to swing down and the slot in the rear door.
safety prop is engaged and the
clear the rear door.
rear door is securely resting on the
safety prop.
119
Options
Options
Vactor 2100
Accumulator
Options
The accumulator is a nitrogen charged bladder

that acts as a shock absorber for the jackhammer
action created by the rodder pump. The system
is engaged/ disengaged through a ball valve. The
amount of nitrogen charge depends on the pressure
capabilities of the individual unit. The accumulator
nitrogen precharge is normally set at 60% of the
water system rating.
Accumulator
Note: The accumulator only works at operating

pressures above the precharge pressure.
If the precharge pressure is 1400 PSI the
accumulator will have no effect on systems
operating below 1400 PSI.
Fan
If operating at a pressure below the pre-charge of

the accumulator, the jackhammer action of the pump
will still be noticeable. The system will act as though
the accumulator has not been turned on. Once the
pressure exceeds the pre-charge, the jackhammer
action will smooth out. The ACCUMULATOR control
valve usually located on the right side of the truck
is used to turn the accumulator ON and OFF. The
accumulator can be turned on or off at low pressure.
However, the operating pressure of the system must
be above the accumulator precharge to have any
effect on the rodder pump pressure.
Accumulator
Hose
If the accumulator is turned off while the system

is operating, pressure may be trapped in the
accumulator hose. A ball valve drain plug can be
removed to release trapped pressure. Always place
the ACCUMULATOR valve in the ON position and
vent through the rodder hose or handgun before
removing the drain plug.
Accumulator
Control Valve
(Off Position)
Accumulator
Control Valve
(On Position)
122
Vactor 2100
Accumulator
The water drain for the accumulator is normally

located on the back side of accumulator valve. Place
the accumulator valve on to relieve system pressure
before removing the drain plug.
Options
! WARNING
High Pressure Water Hazard
Always place the
ACCUMULATOR ball valve in the
ON position to relieve system
pressure before removing the accumulator ball
valve drain plug. Personal injury may occur if
this warning is ignored.
Drain for
Accumulator
123
Dual Accumulators
ccumulator
Vactor 2100
Accumulators are nitrogen charged bladders that

act as shock absorbers for the jackhammer action
created by the rodder pump. The amount of nitrogen
charge depends on the pressure capabilities of the
individual unit. The second accumulator is normally
configured for either jet rodding in combination
with the first or for use with the hand gun to reduce
vibrations. The accumulator nitrogen precharge
is normally set at 60% of the water system rating
when used for jet rodding. The second accumulator
is normally set to 60% of the first unless used for
the handgun. The handgun accumulator is set to
60% of the rated handgun pressure.
Options
! WARNING
High Pressure Water Hazard
Always place the ACCUMULATOR ball valve
in the ON position before removing the
accumulator ball valve drain plug. Personal
injury may occur if this warning is ignored.
If the accumulator is turned off while the system

is operating, pressure may be trapped in the
accumulator hose. A ball valve drain plug can be
removed to release trapped pressure. Always place
the ACCUMULATOR valve in the ON position and
vent through the rodder hose or handgun before
removing the drain plug.
Note: The accumulator only works at operating

pressures above the precharge pressure.
If the precharge pressure is 1200 PSI the
accumulator will have no effect on systems
operating below 1200 PSI.
One accumulator controls the jackhammer effect
on the rodder hose reel. The other accumulator
controls the jackhammer effect on the low-pressure
hand gun system.
The ACCUMULATOR control valves usually located
on the right side of the truck are used to turn the
accumulators ON and OFF. The accumulator can
be turned on or off at low pressure. However, the
operating pressure of the system must be above the
accumulator precharge to have any effect on the
rodder pump pressure.
Accumulators
Accumulator
Control Valve
124
ero Hose Reel

A
Vactor 2100
Options
The Aero Hose Reel is designed specifically for use

with Shark rodder hose. The reel is smaller diameter
requiring a tighter wrap for the hose.
The controls on the Aero Hose Reel are similar to
the larger reels but located in different locations.
Footage
Counter
Maintenance
Refer to the standard reel for greasing. Use the
same grease and frequency. There is a gearbox in
the hub that is permanently lubricated. For reference
it uses Castrol AP Gear Lubricant SAE 85W-140 or
equivalent.
Operator control panel

Water pressure
Located under the front

cover are the grease
zerks for the swivel joint
and reel shaft bearing.
Reel controls
Multi-flow
126
ir Purge System
A
Vactor 2100
Options
The air purge system uses compressed air to

remove water from the water lines, hoses and some
components.
Air from the chassis reservoir is used to pressurize
an auxiliary air tank. An air protection valve located
on the chassis reservoir protects the brake system.
If air pressure in the chassis reservoir drops to a
critical level, the protection valve closes to protect
the brake system air pressure. The brake system
has priority over any auxiliary components. As
added protection, a check valve in the purge system
allows air to flow into the water system but not
return to the reservoir.
Fill Reservoir
Valve
Purge
System
Valve
Note: The chassis air reservoir should be full when

activating the air purge system.
Reservoir
Pressure Gauge
The water system can be purged as follows:

1.
Remove nozzle from the rodder hose.
2.
Secure the end of the rodder hose to the hose

reel to prevent uncontrolled movement of the
hose when purging.
3.
Place the rodder pump ball valve in the ON

position.
4.
Make sure the PURGE SYSTEM ON ball

valve is in the OFF position.
5.
Place the FILL RESERVOIR ball valve in the

ON position.
6.
Fill the auxiliary tank to a maximum of 120

PSI.
7.
Place the FILL RESERVOIR ball valve in the

OFF position.
8.
Place the PURGE SYSTEM ON valve in the

ON position.
Auxiliary
Air Tank
When the rodder hose is purged of water, the

rodder pump ball valve can be placed in the OFF
position and other systems such as the hand gun
opened for purging. After the system is purged,
place the FILL RESERVOIR and PURGE SYSTEM
ON ball valves in the OFF position.
Notes: All drain plugs should be left open to keep
residual water from the tanks from migrating
to the rodder system during transport.

It may be necessary to refill the auxiliary tank

to completely purge the water system.
128
Vactor 2100
uto Wind Guide

A
The auto wind guide is used for winding the rodder

hose evenly and orderly onto the reel. It is a chaindriven roller guide assembly that travels the width
of the hose reel on a bar located near the bottom of
the reel. The guide includes a pinch roller on top of
the reel to help keep the rodder hose wraps tight.
The auto wind moves back and forth with the rodder
hose, keeping the hose aligned and straight. The
pinch roller, which is pneumatically operated, applies
moderate force to the top of the reel, keeping the
rodder hose aligned and tight.
Options
Pinch Roller
The pinch roller can be locked in place when

winding the rodder hose. A switch located at the
bottom left of the hose reel is used to lock the roller
in place.
Hose Reel
Air Cylinders
Hose Reel
Driver-side View
Auto Wind
Guide
Passenger-side
View
Pinch Roller
Lock Switch
Auto Wind
Guide
130
Vactor 2100
uto Wind Guide

A
Options
Adjustment
Handle
Auto Wind
Guide
If the roller guide assembly is not positioned on the

bar so as to properly guide the hose onto the reel,
it can be repositioned along the bar. The knurled
knob to the left of the guide assembly moves the
assembly along the bar when the knob is turned one
way or the other. Turn the knob until the assembly is
in line with the end of the hose on the reel.
Align the double roller on the wind guide with the

first wrap of the rodder hose. This can be done
hydraulically, by using adjustment handle on the
hose reel to rotate the reel or manually by using
the knob on the end of the wind guide. Pulling and
rotating the adjustment handle allows the guide to
be manually adjusted. Make sure the guide is going
the same direction.
Pull back on the handle about inch. Rotate the

handle either clockwise or counter clockwise to
adjust the double roller on the wind guide. Release
the handle once the wind guide is in the proper
position. The handle is spring-loaded and should
return to a locked position. Try rotating the handle to
be sure it is locked.
CAUTION
The handle must be in the locked position when
operating or damage to the wind guide can
occur.
STEP 1
STEP 2
STEP 3
Unlock the assembly by lifting the

locking latch on the side of the roller
guide. Swing the top half of the
roller guide upward and allow it to
rest in the open position.
Place the hose in the bottom half of

the roller guide.
Lower the top half of the roller

guide. The hose should fit snug
between the two halves of the roller
guide. Lower the locking latch.
131
uto Wind Guide

A
Vactor 2100
Options
In conjunction with the roller guide assembly, a

pinch roller is used. The pinch roller keeps pressure
against the hose on the reel to keep it from
unwinding. The pinch roller is on top of the reel on
the passenger side.
Pinch Roller
A switch on the hose reel activates the pinch roller.

The switch controls the flow of air to the cylinders.
By flipping the switch, air pressure is applied to the
two air cylinders, one on each side of the hose reel,
keeping pressure on the roller arm. This, in turn,
puts pressure on the rodder hose keeping it tight
while it is paying-in or paying-out. Maintenance
of the pinch roller assembly is minimal but very
important for proper operation.
Roller Clearance
The clearance between the roller and the inside wall

of the drum is very important. Excessive clearance
can allow the hose to pass by the roller causing
damage to the hose. The clearance needs to be
less than the width of the hose.
The clearance, should be approximately 5/8 of an
inch on reels with 1 inch hose and of an inch
on reels with inch hose. This clearance can be
adjusted by shimming the roller out using washers,
if the clearance is marginal. If there is excessive
clearance, the entire roller assembly may need to
be replaced. Contact the factory with the model
and serial number of the unit, and the amount of
clearance.
The bolt that holds the roller in position should
be torqued and Loc-tite applied to the threads. If
the bolt loosens or falls out, the roller can fall off
which could damage the hose. The bolt should be
tightened to 30 +/- 3 ft. lbs. torque.
Notes: The pinch roller should be used whenever
the hose reel auto-wind guide is being used.

The direction of the wind guide is controlled

by the rotation of the hose reel. Care must be
taken to ensure the hose reel and wind guide
are moving together. Operate the hose reel
enough to check hose reel and wind guide
travel.
132
oom Worklights
B
Vactor 2100
Options
The boom worklights are

mounted on the boom and can
be adjusted for best illumination.
A BOOM LIGHTS switch on
the control panel controls the
illumination of the lights.
The lights are mounted on
the 70 degree elbow and a
retractable cord reel is used
on extendable and telescopic
booms.
Optional
Work
Lights
Retractable Cord
Front hose reel controls
134
Vactor 2100
potlight
S
The spotlight connects to a receptacle on the right

side of the hose reel and can be used for manhole
work and work at night. The spotlight is stored in the
tool box.
Spotlight
135
Options
ebris Body Washout

D
Vactor 2100
Options
The debris body washout system is used to wash

out the debris body and aid in dumping. The
washout system has nozzles installed inside the
debris body, which can be activated by a debris
body washout valve. Operate only long enough to
fully clean out the debris body to avoid unnecessary
abrasive wear to the debris body.
The debris body can be washed out as follows:
1.
Fully open the rear door and raise the debris

body about one quarter up so it will drain.
2.
Make sure water is available in the water

tank.
3.
Place the HAND GUN ball valve and the

RODDER PUMP ball valve in the OFF
position.
4.
Place the BODY WASHOUT ball valve in the

ON position.
5.
Using the instructions posted in the cab,

engage the hydraulic pump.
6.
Place the RODDER PUMP switch in the ON

position.
7.
Adjust the chassis engine speed until

pressure is achieved the desired RPM.
Maintain the engine RPM until washout or
dumping is complete.
8.
When debris body washout is complete,

reduce the chassis engine RPM.
9.
Place the RODDER PUMP switch in the OFF

position.
10.
Place the BODY WASHOUT ball valve in the

OFF position and the RODDER PUMP or
HAND GUN ball valve in the ON position.
11.
Lower the debris after it has fully drained and

close the rear door.
Washout Spray
Nozzle
Body Washout
OFF
ON
Water Pump
All replacement nozzles need

to be the fan-style as originally
supplied.
NOTICE
Be sure the hose reel ball valve and the hand
gun ball valve are closed when using the debris
tank wash out system.
Valve
136
yclone Separator
C
Vactor 2100
Options
The cyclone separator uses air turbulence to

remove dirt and debris from the airflow and deposit
it in bottom of the separator.
Air leaving the float-ball vacuum shut-off in the
debris tank enters a cyclone housing located on
the driver side of the unit and directly in front of the
debris tank. It protects the fan by removing material
from the air stream before it reaches the fan.
The cyclone spins the air stream around the walls
of the housing until it reaches the bottom of the
cyclone house. The cyclone reduces particle matter
in the airstream leaving relatively clean air to return
to the top of the cyclone so that it may enter the
microstrainer on a blower machine or the fan.
Microstrainer
Cyclone
The vacuum filtration system requires some specific

cleaning for optimal operation. When a job is
completed, or the unit will be driven and parked
between work, or there will be more than a shift
of downtime between work, the cyclones need
to be cleaned. Some special conditions such as
high humidity combined with certain materials may
require more frequent cleaning.
Debris
Tank
Separator
PD machine shown
138
Vactor 2100
yclone Separator
C
Options
The cyclone separator should be inspected daily

for dirt, dust and debris. Inspect the separator more
often if working on jobs with excessive dust, dirt or
debris.
While standing to one side, open the separator door
and allow the debris to fall out. Inspect and remove
any remaining debris inside the separator.
Use the hand gun to thoroughly wash the cyclone
separator and door. Make sure the door seal is
clean and clear of any dust, dirt and debris.
For the cyclone separator to function the door
seal must be clean and seal properly. Check the
separator door seal by applying a thin layer of
grease to the seal and closing the door. When
the door is opened a complete imprint of the seal
should be left on the frame. If the imprint does
not reflect the entire seal the door is not sealing
properly. Inspect the door, seal and frame for wear
or damage and repair or replace as necessary.
WRONG
! WARNING
Biological hazards
Germs and other biological hazards are common
in sewers. Use gloves, long sleeves and long
pants to prevent injury and contamination.
Immediately treat all abrasions, cuts and nicks
for contamination. Get medical attention for
injuries associated with cleaning sewers, drains
and catch basins if biological contamination
is suspected. Serious illness may result if this
procedure is not followed.
CORRECT
Cyclone
Debris
Tank
Seal
Imprint
Separator
Door
Hand
Gun
Separator
139
Vactor 2100
5 Boom
140
Options
Vactor 2100
5 Boom - Safety
Options
! DANGER
WARNING
Always park and secure the boom before raising

the debris body.
Do not misuse the boom such as using it as a
3" wide x 7" tall

crane to lift heavy loads. Damage to the boom
.125 corner radius
and/or unit may result and may cause personal

injury or death.
obstruction.
equipment damage.
ENG. STANDARDS
Always be
(including the unit body) that may prevent

properVACTOR
movement Manufacturing
of the boom.
Inc. STREATOR, IL.
NAME
DECAL,VACTOR BOOM
DR.
AC
DATE
SCALE
1-11-2005
PART NO.
NONE
180014
This document contains material and/or information which is the property of Vactor Manufacturing Inc., and supplied only on
CAUTION
DIMS.Machine
IN INCHES
TOLERANCES UNLESS
can
be damaged
LTR.The boom operator

Revision
By viewDate
must maintain a clear
the release
boom during all movements to avoid
AC
1-11-2005
0 ofInitial
striking
the
parts
of
the
unit
and
surrounding
AC
3-24-2005
A Updated arrow to ANSI electrical bolt
structures.
Refer to SAFETY
section in manual.
1800149 rev A
aware of the boom position in

relation to over head wires, any obstruction
141
ECN N
5683
5820
5 Boom - Overview
Vactor 2100
The telescoping boom provides the operator with

greater ease and efficiency of operation. The
boom allows the unit to adapt to nearly all types of
cleaning circumstances that may arise.
Options
Fully retracted and stored
The 5 x 5 boom extends out five feet beyond the

normal boom extension and can then extend out
the vacuum hose an additional five feet. The boom
extension and hose extension are independently
controlled. It is operated hydraulically with the hose
reel control panel joystick, through a remote wired
pendant or optional wireless pendant. It can swing
horizontally about of 180 degrees, as well as move
vertically up or down.
Preparing the boom for operation.
The boom is entirely controlled by the remote
Pendant. The Pendant is a remote portable yellow
control box used by the operator to direct the
operation of the boom. It is connected at the front of
the unit with a cable. (See Pendant Section for the
proper hookup and operation of the pendant). The
top two buttons on the pendant are dedicated to the
automatic relief valve operation.
Boom extended
Boom
joystick
Extend
retract
buttons
Raise/
lower
hose
switch
Hose
extended
Pendant plug outlet

(twist off protective cover to access)
142
5 Boom Operation
Vactor 2100
Options
To move the boom out of its stored position, the boom

must be raised slightly to clear the boom cradle that it
rests upon. Once clear of the cradle, it can be raised,
lowered or rotated horizontally. Further it can be
extended or retracted as circumstances dictate.
Storing the Boom
The boom must be rotated to and lowered in to the
boom cradle for transport. It is swung into position
over the top of the body and allowed to seat in the
boom cradle. Lower the boom, until it firmly rests
in the cradle. The open end of the boom remains
hanging down next to the front bumper on the
passenger side. The hose end is placed over the
hose keeper.
Boom cradle
Hose keeper
CAUTION
Machine can be damaged
The boom operator must maintain a clear view
of the boom during all movements to avoid
striking the parts of the unit and surrounding
structures.
143
Vactor 2100
5 Boom Pendant
The pendant is the remote control device used for

activating the vacuum release valve and operating
the boom. The pendant is normally connected at
the lower front of the hose reel of the unit by a
cable. An optional wireless pendant may also be
used.
Options
! CAUTION
The pendant should be with the operator at
all times during the procedure so that in an
emergency, the vacuum can be released.
To attach the pendant cable rotate off the protective

cover. Push the plug onto the pins and tighten it by
turning the knurled collar clockwise until it locks in
place.
Eight buttons on the pendant are used for the boom.
The function of the buttons are:

Raise - retracts the vacuum hose
Lower - extends the vacuum hose
Up - raises the boom
Down - lowers the boom
Left - the boom will rotate clockwise
Right - the boom will rotate counterclockwise
Out - extends the boom
In - retracts the boom
Boom
joystick
Extend
retract
buttons
Raise/
lower
hose
switch
The buttons are momentary switches and upon

releasing the button, the boom will cease moving.
Additional buttons will vary with options.
Front hose reel controls
Pendant plug outlet

(twist off protective cover to access)
Optional
wireless
remote
control
Pendant plug
Pendant
144
5 Boom - Maintenance
Vactor 2100
Options
The flexible hosing connected to the boom should

be rotated end to end as well as turned on its axis
90 degrees. This should occur on a regular basis
and at least no longer than 150 hours of operation.
This will assure longer life of the hose so that
material being vacuumed will not unduly wear on
any one side of the vacuum hose.
Rotation is performed using the supplied spanner
wrench. Swing the boom out to the
passenger side and fully extend the hose.
Lower the boom as far as possible. A ladder
will be required to reach the hose end.
Refer to the regular Maintenance Section
for cleaning frequency and grease
specifications.
Grease zerk located at cylinder rod end in

between rails. Grease monthly.
145
Vactor 2100
Decanting
Options
Decanting should be done at job site for several

reasons.
Excessive weight can:

Lead to fines.
Make truck unsafe to drive.
Cause material to carry over into blower or

fan.
Cause unnecessary pressure on rear door

locking mechanisms.
Tailgate
Always check local government laws, regulations

and rules for decanting into sewers or catch basins.
Fewer trips to the disposal site will be needed if the
excess liquid is drained from the debris tank at the
job site. This also lightens the weight of the truck.
Decant
Port
The decant port allows liquid to be drained from the

debris tank. Besides placing the decant port on the
tailgate, it can also be positioned on the side of the
debris tank.
First position the unit over a manhole or near
the catch basin. If not equipped with an optional
valve turn on the vacuum system and operate in
mid-range. Unfold the nylon flat-hose and let it
hang down into the manhole opening. Turn off the
vacuum to allow the liquids to flow out. If equipped
with an optional valve open the valve and drain until
complete and close the valve.
Be sure to check for overhead obstructions. If none,
use the hydraulic controls to raise the debris tank as
high as needed to drain as much excess liquid as
possible. However, never raise the debris tank past
the first stage of the three-stage cylinder when the
tailgate is closed.
After the liquid has drained, lower the debris tank,
refold the hose and place it back into its bracket.
Note: The vacuum system must be shut down to
drain. Do not raise the debris tank fully when
decanting water. Material in the debris tank
can slide against the tailgate and thereby
shutting off the decanting process. This would
then make it difficult to lower the tank.
146
Extendable/Telescopic Boom
Vactor 2100
Options
Telescopic boom
Telescopic boom
The telescopic boom extends outward, pushing the

vacuum tube outward. This allows the operator to
position the vacuum tube over a manhole or into a
hard to reach job site.
Telescoping
tube
The telescopic boom can be maneuvered using the

BOOM switch located on the control panel or with
buttons located on the pendant control.
Extendable boom
The extendable boom extends outward, pushing
the vacuum tube outward, however as the boom
extends the end of the vacuum hose is pulled up.
Additional pipe must be added as the boom is
extended. This allows the operator to position the
vacuum tube over a manhole or into a hard to reach
job site. A guide located on the end of the boom
keeps the vacuum hose aligned and provides a
contoured surface for the tube to ride on.
hours of operation. This will assure longer life of

the hose so that material being vacuumed will not
unduly wear on any one side of the vacuum hose.
The extendable boom can be maneuvered using the

BOOM switch located on the control panel or with
buttons located on the pendant control.
Extendable boom
Maintenance
Fully extend and retract both boom styles and flush
with water daily. Wash down the telescoping tube
while fully extended on the telescopic boom.
The flexible hosing connected to the extendable
boom should be rotated end to end as well as
turned on its axis 90 degrees. This should occur
on a regular basis and at least no longer than 150
Pendent
Control Panel
Extendable boom
Boom Extend/
Retract Switch
Boom Extend/
Retract Buttons
148
lusher System
F
Vactor 2100
The components of the flusher system include

flusher nozzles (two or four), nozzle control valves,
water pump, hydraulic pump, water shut-off valve
and diverter valve. The control panel for the nozzles
is located in the cab.
The flusher pump is a separate water pump installed
on the right side of the truck. The flusher pump is
driven by an auxiliary hydraulic pump, which may
be driven by the engine or by a PTO. Engaging the
hydraulic pump varies according to the chassis and
type of drive.
Flusher Pump Operation
1.
Make sure the water tank is full.
2.
Open the water shut-off valve at the pump.
3.
Open the petcock on top of the flusher pump

to release trapped air. Close the petcock
when water comes out.
4.
Pull out on the diverter knob located on the

right side of the truck.
5.
Turn on the nozzles. Each nozzle is operated

separately.
6.
Start the truck engine and engage the flusher

hydraulic pump.
7.
Adjust the engine speed to the RPM for

desired flow and pressure.
Flusher Pump Shut-Down

1.
Disengage the flusher hydraulic pump.
2.
Turn off the nozzles.
3.
Push in the diverter valve on the right side of

the truck.
4.
Close water shut-off vale at the pump.
5.
In cold weather, open all petcocks and drain

excess water from the system.
150
Options
Folddown Pipe Rack
Vactor 2100
Fold-down pipe racks are used to store the

extension pipes. Each pipe rack can hold three
pipes ranging in size from three to ten feet long.
The pipe racks are normally mounted on the side
of the vehicle, but can also be mounted on the rear
door. The standard truck stores the extension pipes
and catch basin nozzle above the water tank. The
racks are designed to fold down for safe groundlevel retrieval of the pipes.
Remove locking pins before trying to lower the pipe
rack. Hold on to the pull bar handle when lowering
or raising the pipe rack. Reinstall locking pins after
pipe rack is raised.
Locking pin
installed
Locking pin
removed
152
Options
Folddown Pipe Rack
Vactor 2100
When stowing the pipes in the rack, placing the

most used pipe in the upper position will aide in
retrieving the pipes in the order needed. Secure the
pipes to the rack with a bungee cord.
153
Options
rease Manifolds
G
Vactor 2100
The grease manifolds are used to lubricate the

various lubrication points which can not be reached
from ground level. The grease zerks on the manifold
are attached to the lubrication points by heavy-duty
hoses.
The grease manifolds are lettered to correspond to
the lubrication points indicated on the maintenance
lubrication chart.
See individual manifold chart for each line location.
154
Options
Vactor
entral Grease System

C
Options
The central grease system option is

a progressive system consisting of
a feeder lines and a control system
(manifold block). The lubricant delivered
by the grease pump is fed to the lube
points by the individual progressive
feeder pistons at the preset metering
rate.
When grease is delivered under
pressure, the pistons in a feeder move to
their end position one after another. As a
result of the pistons motion, the lubricant
stored in front of the piston is displaced
and fed to the downstream outlet port
in a fractional amount. Once all the pistons have
moved to the left or right end position, all the
connected lube points have been supplied
with the specified amount of lubricant.
The plunger located under the last pair of
fittings is an indicator. As grease is pumped
into the manifold block the pistons inside
shuttle back and forth until each port has had
an equal amount of grease dispensed. When
the last piston moves the indicator pin will
move either in or out depending on its last
position. It may be necessary to fully repeat
the process to get enough grease to some
points. This can be confirmed by observing
that grease is just starting to ooze at all
points.
When the manifold block is not

easily accessible a remote grease
line will be located at ground access
level.
Two manifold blocks are normally installed, one to

feed the grease points on the debris body and the
other to feed grease points on the sub frame. They
are normally located towards the rear and middle
of the unit on the passenger side. Refer to the lube
drawing in the parts pages for additional details.
Manifold Block
(Fittings not shown)
The pistons can be seen in this

transparent version of the manifold
block. As each piston is moved it
pushed grease into the line. The
process keeps repeating as more
grease is pumped in.
156
Indicator Plunger
Vactor
entral Grease System - Installation

C
Options
When all the grease ports are not needed on a

manifold block a plug(s) needs to be removed.
At least half of the ports must be used. For
example four of the eight ports on an eight port
manifold must be used. Only even numbered
ports can be plugged starting with the highest
port number. They are on the side with the
indicator plunger. The plugs will to be removed
on replacement manifolds to match the existing
one.
To set up a manifold for fewer ports:
1.
Remove the fitting from the highest even

numbered port and discard the fitting.
2.
Using a hex wrench remove the plug from

inside the port and discard the plug.
3.
Install the port plug.

1
Repeat for each port that is not required.
157
Central Grease System Components

REV 0
Ref. 49237
10
2 3 4 15
16 17 18 19
11
12
13
6
14
Ref. 49237
REV 0
Parts List
Item
Part No.
Description
16697
GREASE ZERK
49237
6 POINT LUBE BLOCK, 5000 PSI RATED (not shown)
49238
49239
49240
PRE-LUBED HOSE, BULK, 5000 PSI RATED (not shown)
49241
STRAIGHT PUSHLOCK FITTING FOR BLOCK
49242
STRAIGHT PUSHLOCK FITTING FOR COMPONENT
49243
90 PUSHLOCK FITTING FOR COMPONENT
49244
GREASE TUBING, BULK,PRE-FILLED, 75
10
49245
BRACKETED CONNECTOR
11
49246
TUBE STUB
12
49247
SLEEVE
13
49248
UNION
14
49249
PLUG
15
49250
6 POINT LUBE BLOCK, W/FITTINGS INSTALLED
16
49251
8 POINT LUBE BLOCK, W/FITTINGS INSTALLED (not shown)
17
49252
10 POINT LUBE BLOCK, W/FITTINGS INSTALLED (not shown)
18
49265
12 POINT LUBE BLOCK, W/STRAIGHT FITTINGS INSTALLED

(not shown)
19
49237
12 POINT LUBE BLOCK (not shown)
20
49286
GREASE FILL LINE (not shown)
21
70338I
HYDRAULIC ADAPTER (not shown, used with 49286)
22
70331F
90 HYDRAULIC ADAPTER (not shown, used with 49286)
Tube fitting assembly

1.
Apply a thin film of oil to threads and inside of hose to be connected.
2.
Clamp sleeve in a vise and screw in hose until it stops. Note this is a left hand thread.
Turn counter clockwise to install.
3.
Screw in tube stub into sleeve with a wrench up to the stop (do not tighten).
and Gun Hose Reel

H
Vactor 2100
The hand gun hose reel is used for rewinding the

hand gun hose after use. The reel can automatically
rewind up to fifty feet of " hose, however some
are manually operated. The reels are located
in a variety of places on the units, typically the
front bumper or near the operator controls on the
passenger side.
Options
Hand gun
controls for
passenger side
mounted reel
neat the main
operator controls.
The hose reel will lock at any position by slowly

retracting the reel. When the job is complete rewind
the hose by pulling and releasing the hose.
The hose reel should be kept clean and repaired/
replaced. Consult the manufacturer's manual for
additional maintenance.
Do not allow the hose to fly back onto the reel on
spring return reels. Damage to the reel may occur.
Spring
return
reel
Reel ON/OFF valve
Reel ON/OFF valve
Manually operated reel
160
yrdo-Excavating Digging Gun

H
Vactor 2100
The high-pressure hydro-excavating digging gun

system uses up to full rodder pump pressure.
The digging gun can be used as an excavator for
removing soil, compacted debris and most hard to
remove materials. See the OPERATION section for
information on operating the vacuum system.
Options
Hose reel
A ball valve located on the side of the hose reel is

used to supply high-pressure water to the hand gun.
Gun
The digging gun can be used as follows:

1.
Place the RODDER switch in the OFF position.
2.
Place the rodder pump ball valve in the OFF

position.
3.
Place the reel ball valve in the ON position.
4.
Place the ACCUMULATOR ball valve in the ON

position.
5.
Back off the multi-flow to minimum.
6.
Place the RODDER switch in the ON position.
7.
Adjust the chassis engine speed to the desired

RPM.
8.
Adjust the gun pressure using the MULTIFLOW

control knob.
After the job is complete:

1.
Reduce the chassis engine RPM.
2.
Place the RODDER switch in the OFF position.
3.
Place the high pressure hand gun ball valve in

the OFF position.
4.
Depress the gun trigger lever to relieve

pressure from the reel.
Spring return reel
Reel ON/OFF valve
! WARNING
High pressure water
gloves preferred).
Digging gun controls are normally located at the

hose reel.
162
ydraulic Tool Package

H
Vactor 2100
The hydraulic tool package is used to provide

hydraulic pressure for the operation of hand tool
attachments (chainsaws, jackhammers and pumps).
A diverter valve allows the operator to divert
hydraulic pressure from main hydraulic pump for
use by the hand tool attachments. Quick couplers
are used to connect the hand tool to the vehicle
hydraulic system.
Options
Hydraulic Tool
Package Flow
Control
Make sure the quick couplers are firmly and

correctly attached to the vehicle. A leaking or poorly
attached quick coupler can allow hydraulic pressure
to escape.
Hydraulic
Tool Package
Connectors
Use the hydraulic tool package as follows:

1.
Connect the hand tool return and pressure

hoses to the quick couplers.
2.
Using the instructions posted in the cab,

3.
Pull the HYDRAULIC TOOL PACKAGE

control knob OUT to divert hydraulic pressure
to the hand tool.
4.
Move the adjustable flow control lever to set

the proper flow for the individual tool being
used.
5.
After the job is complete, push the control

knob IN to stop the flow of hydraulic pressure.
Hydraulic Tool
Package ON/OFF
164
I nspection Port
Vactor 2100
and
Telescoping Ladder
The inspection port, normally located on the topside

of the debris body, is used to inspect and monitor
the load. Many landfill operations regulate the
amount of liquid being dumped. The inspection port
allows the operator to monitor the fluid level and
decant liquid.
Make sure the vacuum is shut off before attempting
to remove the inspection port cover. Install the
inspection port cover before starting the vacuum
system. If the cover is not installed properly a
severe vacuum loss will occur when the vacuum
operation is started.
A ladder normally provides access to the inspection
port. After use, make sure the inspection port cover
is properly installed and the ladder is secured and
locked in position.
The telescoping ladder is normally used to access

inspection ports and for service. The locking storage
box is normally located behind the cab on either
side of the unit. To use follow the instructions on the
ladder.
166
Options
ateral Cleaning Kit

L
Vactor 2100
The lateral cleaning kit is used to clean smaller

diameter lateral and crossover (under 6 inch)
pipes. It allows the operator to use full rodder pump
pressure but at a reduced volume. The smaller size
reel uses up to 150 feet of half-inch hose rather
than the standard one-inch hose.
Options
Nozzle
Control valve
Follow all the safety procedures as when using the

standard rodding hose. Normally the lateral nozzle
and fittings will be long enough to prevent the
nozzle from reversing direction in the lateral pipe.
There are two ball valves that control the operation
of the Lateral Cleaning hose reel. The first one is
the RODDER ball valve on the front of the hose
reel. The RODDER ball valve must be in the closed
or OFF position for the lateral cleaning reel to have
proper pressure.
Hose reel
The other ball valve is the lateral cleaning reel ball

valve located next to the lateral hose reel.
Install the nozzle on the lateral cleaning hose and
insert the lateral cleaning hose and nozzle fully into
the pipe to be cleaned.
Place the lateral cleaning reel ball valve IN the ON
position. Turn the rodder pump (water pump) switch
ON and slowly increase the engine rpm to achieve
the desired pressure.
When the pipe is cleaned, reduce the water
pressure and rewind the hose using the hand crank
on the side of the reel. As the hose approaches the
pipe opening place the RODDER PUMP SWITCH in
the OFF position. Place the RODDER PUMP switch
in the OFF position.
168
ateral Cleaning Kit

L
Vactor 2100
When setting up for rodding operations use the

appropriate guide fin and hose guard (tiger tail) to
prevent the nozzle from turning in the pipe
wer pipe
and returning toward the operator. The
Se
length of the assembled nozzle and
guide fin must be greater
than the diameter of the
pipe to be cleaned.
Options
Guide fin
Tip of nozzle
End of nozzle
Start of Hose
Hose guard
extended
(tiger tail)
Correct
Inspect the
minimum
rodder hose
length
often for
indications of damage
or wear. Check the
hose before each
use for movement in hose fittings, exposed hose
reinforcement, kinking or collapsing, blisters or
bubbles and fittings that are improperly installed or
cutting into the hose.
must match during splicing operations. Be aware of

the operating pressures associated with the vehicle
and the proper hose specifications for safe operation.
Waste Equipment Technology Association publishes
a variety of industry related recommended practice
guides. It is recommended that owners and operators
obtain Specification and repair/inspection procedures
for high-pressure hose used in connection with
sewer/catch basin cleaning equipment.
When splicing hoses read the

maintenance section of the
manual for instructions on hose
repair. All hose manufacturers
have instituted a color code
system for identification of the
hose, fittings and tools. When
repairing a rodder hose the inside
color of the hose, the color of the fitting
and the die colors must match. Fittings from one
manufacturer will not properly crimp onto hose from
another manufacturer. The outside color of rodder
hose indicates the pressure rating of the hose and
Waste Equipment Technology Association

4301 Connecticut Avenue, NW
Suite 300
Washington, DC 20008-2304
(Phone) (202) 244-4700
(Fax) (202) 966-4824
(E-mail) wastecinfo@WASTEC.org
(Web) http://www.wastec.org
! WARNING
! WARNING
High pressure water
Out of control hose can cause severe injury or

death.

The rodder hose creates tremendous pressure

and must not be fitted with a reducer or hand
held nozzle, or operated outside of the sewer
pipe. The back pressure created by such action
will cause loss of control and violent movement
of the hose and fittings, and the release of high
pressure water .

gloves preferred).
Do not use improper fittings or use out of sewer

pipe. Refer to manual for details.
169
aval Separator
L
Vactor 2100
Options
Laval Separator removes solids from liquids. Upon

tangential entry, the liquid/solids are drawn through
internal tangential slots and accelerated into the
separation chamber, where solids heavier than
the carrying liquid are centrifugally separated and
allowed to accumulate in the units collection chamber
for eventual purging. The liquid (free of separable
solids) is then drawn to the vortex and up through the
separators outlet where it then flows into the water
tank.
Water Tank
Fill Port
170
Laval
Separator
oad Limit Alarm

L
Vactor 2100
Options
The load limit alarm is mounted on the debris

body float and signals the operator when the load
approaches the full limit.
The load limit alarm is activated using the LOAD
LIMIT ALARM switch located on the hose reel
control panel. Activate the alarm by placing the
LOAD LIMIT ALARM switch in the ON position.
When the load level approaches the full limit,
the sender located in the debris body activates a
horn, which signals the operator. An optional load
limit light, located on the control panel, may also
illuminate.
When the load level approaches the full limit,
the sender located in the debris body activates a
horn, which signals the operator. An optional load
limit light, located on the control panel, may also
illuminate.
Sender switch
172
ancover Storage
M
Vactor 2100
Options
Ramp and storage rack for standard manhole

covers. Secure ramp in travel position before
moving unit.
Travel position
Open for loading
174
Vactor 2100
ulti-Flow System
M
Options
The multi-flow system is designed to vary the flow

and pressure of the jet-rodder system. The flow
rate of nozzles used for jet-rodding operations
varies according to the orifice size. For optimum
performance the flow rate (GPM) and pressure
(PSI) supplied by the rodder pump should match the
requirements of the nozzle. The multi-flow system
allows the operator to vary the flow rate at the
control panel.
The multi-flow system uses an piston type hydraulic
pump with a swash plate drive system. The position
of the swash plate determines the length of the
piston stroke. A compensator valve attached to the
hydraulic pump controls the position of the swash
plate. The multi-flow knob on the control panel
controls the pressure available to the compensator
valve. Turn knob fully clockwise for full volume.
Multi-flow control
The various nozzles are rated up to 2500 PSI.

Using a lower pressure with the nozzle will reduce
the flow proportionately.
NOZZLE ORIFICE DIAMETER vs FLOW

500' X 1" Hose (Unless otherwise specified)/2000 PSI (Unless otherwise specified)
Orifice Size
Sanitary (6)
Penetrator
Sand
8 (Qty.)
0.080
35
40
45
0.086
40
45
50
0.090
45
50
55
0.095
50
55
60
0.100
55(60)
60
65
0.105
60
65
70
0.110
65
70
75
80
100
0.070
0.075
0.116
--
--
--
0.122
70
75
80
0.130
75
80
--
0.135
80
0.140
100*
176
60
Vactor 2100
adio Remote Control Operation

R
The radio remote control is an option. If equipped,

to operate the radio remote: disconnect the manual
remote control, (pendant control). Actual functions
and controls will vary with model and options.

Turn the Master switch on the control panel

ON.
Turn the Radio control switch on the control

panel to the on position.
Turn the Throttle switch on the control panel

to the up or ON position.
Turn the rodder pump switch on the hose reel

control panel to the OFF position.
Be sure the Recirculator switch is in the OFF

position.
Turn the Vacuum switch on the control panel

to the ON or up position.
The radio remote controls the boom operation,

up/down, left/right, extend and retract. It controls
the vacuum relief valve on/off. It can turn the water
pump on/off. It also can control the engine throttle
rpm. The maximum distance the radio control can
effectively operate from the truck depends a lot on
the operating environment. Buildings, terrain, other
pieces of large equipment between the operator
and the truck, will affect operating distance. The
optimum distance would be about 500 feet under
ideal conditions.
178
Options
ead Door Shield

R
Vactor 2100
Options
A read door shield can be mounted to the debris

tank to protect the rest of the truck and the operator
from splashing waste material during the dumping
process.
Read door Shield
180
ecirculating System
R
The recirculating system is designed to recirculate

water through the water system to prevent freezing
in temperatures to zero degrees. The recirculator
is designed to operate the high pressure rodder
pump within a closed loop with water returning to
the water tank after completing the circuit through
the jet rodder hose. The system is hydraulically
powered utilizing the hydraulic pump. It includes
all necessary items such as valves, hoses and a
hydraulic pump to make the system function. The
recirculating system is designed to be operated
while the truck is in motion or stopped.
e)
e)
de
rev 0
Options
Front
Bumper
Optional
Recirculating
Hose Connection
Refer to the operational decal on the driver side

visor in the cab for systems not shown here.
Steps for engaging the Recirculating System
1.
Attach the end of the water hose to the

recirculating hose connection at the bumper.
2.
Open the water valve on the water hose

reel.
3.
Turn the rodder pump on.
or Guzzler
Vactor 2100
Decal Replacement GuiDe
PTO or front crank driven
Recirculator Operation
Recirculator On (Road mode)
1. Apply parking brake

2. Turn Master Switch ON
3. Switch Mode ON (Automatic
transmissions only)
4. Fill water tanks
5. Connect rodder hose to
recirculator return line
6. Open rodder hose ball valve
7. Hydraulic Selector in Recirc.
Mode (if present)
8. Turn Rodder switch ON
9. Release parking brake to drive
Recirculator Off (Work mode)
1. Switch Mode OFF (Automatic

transmissions only)
2. Turn Master Switch OFF
3. Turn Rodder Switch OFF
4. Hyd. selector valve in normal
mode
47954NQ rB
Recirc - PTO or front

crank
Recirculator Operation
Recirculator
Control
Recirculator ON (Road mode)
1.
2.
3.
4.
Apply parking brake

Turn master switch ON
Fill water tanks
Connect rodder hose to
recirculator return line
5. Open rodder hose ball valve
6. Connect and seal boom hose to
bumper mount plate
7. Start auxiliary engine
8. Hyd. selector valve in recirculator
position
9. Turn rodder switch ON
10. Run auxiliary engine at midrange
11. Release parking brake to drive
Recirculator OFF (Work mode)
1.
2.
3.
4.
Turn rodder switch OFF

Hyd. selector valve in normal
mode
Shut down auxiliary engine
Turn master switch OFF
Fan engine driven

47954QF rA
Recirc - Aux engine

182
eclamation System
R
Vactor 2100
Options
The water reclamation system is used to filter debris

from water that has been vacuumed into the debris
body. The water is returned to the water system for
use in rodding operations. The system reduces the
need for clean water and refilling the water tanks.
Use of reclaimed water for jetting will reduce the life
expectancy of pump components.
Flow
control
Selector
knob
Reclamation can be accomplished at many debris/

water levels. The recommended level is when the
debris body level gauge just begins to move. The
operable range is from full level to well below the
indicator range. However, there must be water in the
debris tank for reclamation.
There must be clean water in the water tanks for
reclamation. The reclamation process uses small
amounts of clean water from the water tanks to filter
the debris/water. Clean water used for reclamation
is drawn from the water tanks at a slow rate of
approximately ten gallons-per-minute.
Reclamation can be accomplished without interrupting
a rodding operation if the gate valve from the debris
body to the rodder pump is open prior to closing the
gate valve from the water tank.
Basket speed and screen cleaning speed depends on
the type of material in the debris body. This setting will
vary from job to job.
Reclaiming Water
Start the reclamation process as follows:
1.
Pull the RECLAMATION selector valve to the

ON position. The filter basket should begin
rotating.
2.
Adjust the RECLAMATION flow control valve

to the desired position. The screen cleaning
process should begin.
3.
Close the gate valve from the water tank to the

rodder pump. The flow of water to the rodder
pump should stop.
4.
Open the gate valve from the debris body to the

rodder pump. Reclaimed water from the debris
body should begin to flow from the rodder pump
to the rodder hose.
When using reclaimed water for a rodding operation,

watch the water pressure gauge located on the
hose reel control panel. When the gauge indicates
an excessive drop in water pressure, reduce engine
speed and turn on the water tank to rodder pump gate
valve. Turn off the debris body to rodder pump gate
valve. Resume operation using clean water from the
water tanks.
184
eclamation System
R
Vactor 2100
Options
The rotary joint has two grease zerks for bearing

and seal lubrication. A small amount of medium
weight grease should be added for every 2 months.
Since this assembly is sealed, it will eventually
become filled, after which it will be impossible to
add grease. Care must be taken to not add grease
after it is filled because the pressure will cause the
front seals to pop out.
Two packing-type seals are used on the debris
side of the rotary joint. These packings should
be tightened after the first couple of weeks and
then checked monthly (160 hrs.). The packings
are checked and tightened by gland nuts A and B
outside the debris box.
To tighten the inner-shaft packing:

1.
Remove the chain guard.
2.
Loosen the set screw location behind the

sprocket.
3.
Place two wrenches on the bolt heads of the

small gland nut as shown.
4.
While preventing the shaft and sprocket from

turning, apply force to both wrenches so as to
turn the gland nut clockwise until tight.
To tighten the outer-shaft packing:

1.
Loosen the set screw on the outer housing

that is 90 degrees CCW from the hydraulic
motor mount.
2.
Place 2 wrenched on the bolt heads of the

large gland nut as shown.
3.
Apply force to both wrenches so as to turn the

gland nut clockwise, until tight.
4.
Re-tighten the set screw mentioned in Step 1.
5.
Replace the chain guard.
It is recommended that the filtration media, which is

wrapped around the filter basket, inside the debris
box, be visually inspected for damage such as rips
and tears.
185
emote Drains
R
Vactor 2100
The remote drain option allows the rodder pump to

be drained through the use of two ball valve handles
that protrude through the back bumper. By turning
both handles, water in the pump is allowed to drain.
Normally, on standard units, two drain plugs located
on the underside of the pump have to be removed
in order to let the water drain from the pump.
Options
Rear Bumper
Remote Drain
Valves
186
afety Lights
S
Vactor 2100
Options
Safety lights are needed at the work site. The

standard Vactor comes with hazard lights. Additional
lights can be mounted at various places around the
truck. They include a directional arrow light mounted
on the tailgate, and strobe lights.
Each light is controlled by individual switches either
in the truck cab or on the control panel at the hose
reel.
Boom
Boom Pivot
Strobe Light
Directional Arrow
Rear Door
188
Vactor 2100
anks Joined
T
Options
The tanks-joined option allows the operator to use

the debris tank as an extra water tank.
Air gap
The debris body is joined with the fresh water tanks

to increase fresh water storage. When the debris
tank is being used as a water tank, it cannot be
used to hold material that is vacuumed up. It can
be used to hold material once it has been emptied
of water. This means the water in the debris tank
should be used first; then the normal water tanks
should be used.
A gate valve or ball valve, located between the
debris body and the rodder pump, allows fresh
water from the debris body to flow to the rodder
pump. When the debris body is empty, the gate
valve should be closed and the water tanks gate
valve opened.
A fill port with an air gap is provided at the top of
the debris body door. Open the air gap gate valve
before filling the debris body with fresh water. When
the debris body gauge indicates a full debris body
shut off the water and close the air gap gate valve.
The water in the debris body is used first without
vacuum. After the debris body is empty the vacuum
system can be started and the debris body used for
debris and sewer or storm drain contents.
The vacuum system cannot be operated with the
debris body filled. Do not activate the vacuum
system until the debris body is emptied of fresh
water and the gate valves closed.
The air gap gate valve and the debris body gate
valve must be closed before activating the vacuum
system. A severe vacuum loss will occur if the
valves are left open.
Note: the debris body must be thoroughly cleaned
and drained before filling with fresh water.
Failure to properly clean the debris body
can contaminant the rodder pump and water
system.
Gate Valve or
Ball Valve
NOTICE
190
Vactor 2100
anks Joined
T
Options
Filling The Debris Tank With Water

1.
A separate fill hose and air gap are supplied

apart from the normal air gap and fill hose.
There is a separate shutoff valve for the upper
fill. Open this valve prior to connecting the fill
hose.
2.
Remove the drain plug and install filter screen

into the rear door.
3.
Ensure the filter screen is installed properly

and the debris body is clean prior to using the
tanks-joined option.
4.
Remove the two caps and install the tanksjoined hose between the two connectors.
Be sure to lock the over-center cam locks
to prevent the hose from leaking or coming
apart.
5.
Close and lock the rear door.
Air gap
Note: Make sure the debris body gate valve is

closed and the water tank gate valve is open
before starting the vacuum system during a
rodding operation. Vacuuming storm drain
or sewer contents with the debris body gate
valve open can introduce contaminants into
the water system.
NOTICE
191
ed to control what tank the water is being drained from. Be aware that
s higher than the normal water tanks.
VactorThis
2100means the debris body will
anks
T
Joined
Options
mal water
tanks
if both shut off valves are open at the same time.
Only
6.
Fill the debris tank and water tanks.
be open
at
a time.
7.
Note that separate shutoff valves are supplied
to control which tank is being used.
8.
Be aware that the debris tank is higher than the
tanks valve
first.
normal
water tanks. This means the debris tank
will more than fill the normal water tanks if both
shutoff valves are open at the same time. Only
one valve should be open at a time.
9.
Close the normal water tanks valve first.
10.
Open the tanks-joined valve. Turn the jet

rodder pump on and operate the water system
normally. When the debris body is empty, close
the tanks-joined valve, and use normal water
tanks.
oined valve. Turn the jet rodder pump

Open the normal tanks valve. Note the different
he water11. system
normally. When the
position of the valve handle. The valve is clearly
mpty, closelabeled.
the tanks joined valve.
12.
Remove the hose and reinstall the caps if the

debris body is going to be used to store waste
material. This will prevent any material from
accidentally entering the water system.
tanks valve. Note the different

alve handle. The valve is clearly
y is going to be used to store material,

and reinstall the caps. This will
rial from accidentally entering the
192
rash Pump (internal)

T
Vactor 2100
Options
The trash pump is designed to pump off excess

liquid while screening out solid waste. The pump
is hydraulically driven and located behind screens
inside the debris body. Because the trash pump
operates on an auxiliary hydraulic pump the vacuum
system, rodder system and trash pump may be
operated at the same time.
Some municipalities have ordinances against
pumping recovered liquid into local manholes;
including storm drains and sewers. Always check
local laws and regulations before pumping liquids
into manholes, sewers or storm drains. Excess
liquid is pumped from the debris body through a
three-inch pipe to a front or rear discharge port. A
hydrant type hose is used to move the liquid into a
manhole or dump site. A gate valve located at the
discharge point controls the discharge flow.
Inside Debris
Tank With
Side Pump
A hydraulic PUMP OFF valve located on the

curbside control panel of the vehicle controls the
trash pump operation. Operate trash pump decant
as follows:
1.
With the main hydraulic pump engaged;

connect the discharge hose to the discharge
outlet and place in the manhole.
2.
Open the decant gate valve.
3.
Place the PUMP OFF knob in the OUT-ON

position.
Side Pump
and decant
valve
The trash pump-off system should be activated

when the debris body is filled to just below the full
mark on the level gauge.
After use, place the PUMP OFF knob in the IN-OFF
position. Stow the hose and close the discharge
gate valve.
Front Decant
Gate Valve
Pump Off
Valve
194
Vac On The Go (Fan
Vactor 2100 Fan
units only)
Options
As standard fan machines have the ability to

vacuum on the go. It does not provide water or
boom functions. The optional vacuum on the go
provides boom functions and a water ring at the boom
inlet, operating at up to 10 gpm of water to aid in
vacuuming of dry materials. Vacuuming dry material
with out the water ring is not recommended as it
significantly increases wear in the fan system.
1.
Fill water tanks with water - open valves to

pump
2.
Install water ring on the end of the debris hose
3.
Connect the handgun hose to the water ring keep hose away from wheels during transport
4.
Boom control selector valve - select OUT/ON
5.
Water ring selector valve - select OUT/ON
6.
Close rodder hose ball valve - open handgun

ball valve
7.
Turn master switch in cab ON
8.
Start auxiliary engine and set on high range
9.
Turn rodder pump switch ON
Water ring selector
196
Boom selector
Maintenance
Maintenance
ew Unit Service Checklist
N
Vactor 2100 Fan
Maintenance
Perform these items in addition to all other service

and lubrication requirements.
New Unit First Time Service & Lubrication Checklist

1
ITEM
Service chassis (consult manufacturers manual)
Inspect all door seals
1st week
Inspect all vacuum hoses
1st week
Wash and clean entire truck
1st week
Inspect all safety equipment, guards, etc.
1st week
Drain air tanks
1st week
All grease zerks (unless otherwise noted)
1st week
Grease lift cylinder
1st week
Grease box hinges
1st week
10
Grease rear door hinges
1st week
11
Grease all clamp and lid screws
1st week
12
Change auxiliary engine oil
250 hours
13
Change auxiliary engine transmission oil
100 hours
14
Change hydraulic oil filter
100 hours
15
Change hydraulic oil and filter
500 hours
16
Driveline joints
1st week
17
Grease boom
1st week
18
Inspect / repair leaks
1st week
Performed By
Date
! DANGER
! CAUTION
Follow precautions needed for confined space

entry if work is required in the debris body.
Comply with all applicable federal, state, and
local regulations.
Use care when cleaning the unit. High pressure

washing can damage electrical and hydraulic
controls.
When
202
Service Checklist
Vactor 2100 Fan
The system should be serviced according to

the following schedule. Proper service of the
system includes proper lubrication. Consult the
lubrication checklist in conjunction with the service
checklist. The following time intervals are based
Maintenance
upon a normal eight hour working day. Frequency

of maintenance may have to be increased if the
system is placed into operation for longer periods of
time.
Service Checklist
8 Hrs.
or each
shift
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Check auxiliary engine oil level & coolant

Check hydraulic oil level
Check auxiliary engine water separator
Check battery (s)
Check all chassis fluid levels
Check auxiliary engine transmission oil level
Inspect rodder hose for wear, damage or proper fitting
Inspect hoses and gaskets for leaks and wear
Inspect all warning decals
Inspect proper functioning of vacuum relief valves
Inspect and clean debris body screens
Inspect make/break and boom tube seals
Inspect all door seals
Inspect and clean cyclone & dust box if equipped
Inspect hose reel drive chain tension
Drain air tank(s)
Check body/boom seals for leakage & condition
Inspect and clean the fan(s)
Drain and flush high pressure water pump
Inspect and rotate vacuum suction hose
Inspect high pressure wand and hand gun for damage
Check pressure limiting devices (hydraulic and water reliefs)
Check auxiliary engine fluid coupler
Wash and clean entire truck
Check Y-strainer screens
x
x
! CAUTION
100
Hrs. or
Monthly
500 Hrs.
or Every
6 Months
1000
Hrs. or
Every 12
Months
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
! DANGER
Use care when cleaning the unit. High pressure

washing can damage electrical and hydraulic
controls.
x
x
x
x
x
x
25
Hrs. or
Weekly

entry if work is required in the debris body.
Comply with all applicable federal, state, and
local regulations.
203
Vactor 2100 Fan
Service Checklist
Maintenance
All units are equipped with this general purpose

decal, normally located on the passenger side, to
assist operators.

Check blower or fan engine oil level
Check hydraulic oil level
Check transfer case oil level (if equipped)
Inspect all vacuum hoses
Drain, inspect and clean micro strainer (if equipped)
Inspect for proper functioning of vacuum relief valves
Inspect inlet head and inlet boot seals
Inspect the rodder hose for excessive wear, damage
or improper assembly of fittings
Inspect hoses and gaskets
Inspect and clean all door seals before closing doors
Drain air tanks and silencers (if equipped)
Inspect cyclones for excess material (if equipped)
Consult the OPERATOR'S manual for complete
details
Technical Service Hotline - 800-627-3171
General Operation
details on SAFETY and proper OPERATION of
this unit.
Cold weather operation - drain as required.
details.
Do not operate without manual, automatic and
safety vacuum reliefs installed and properly
operating.
10" wide x 10" tall

.25 corner radius
Daily Service Check List
WEEKLY (25HRS) GREASE POINTS
3
4
12
11
10
5
6
7
8
9
10
11
12
HOSE REEL PIVOT, HOSE GUIDE, EXTENSIONS & SHAFT

ALL DRIVELINE JOINTS
HOIST CYLINDER - UPPER & LOWER
DEBRIS BODY MOUNTING HINGE
REAR DOOR - ALL LOCKS AND PIVOT POINTS
REAR DOOR HINGES
VACUUM ENHANCER (OPTION)
LEVEL INDICATOR
TRASH PUMP OPTION (location will vary)
BOOM HINGES & SLEEVES
VACUUM RELIEF (FAN units only)
ALL SMALL DOOR HINGES
BLOWER UNITS
GREASEABLE BLOWERS ONLY - MONTHLY (100HRS)
3
FOR REPLACEMENT ORDER LABEL No. 1800165A rev A
204
ENG. STANDARDS
1
2
Vactor 2100 Fan
Lubrication
Maintenance
Lubrication Checklist
8 Hrs.
or each
shift
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
All grease zerks (unless otherwise noted)

Vacuum relief
All small door hinges
Driveline joints
Change auxiliary engine oil and filter
Change auxiliary engine transmission oil
Change hydraulic oil and filter
Grease boom swivel bearing
Grease boom sleeve
Grease boom lift cylinder
Grease boom hinge pin
Grease debris body hoist cylinder
Grease debris body hinge
Grease debris body rear door hinges
Grease debris body rear door locks & pivot points
Grease debris body fill indicator
Grease vacuum enhancer if equipped
Grease trash pump if equipped
Grease pinch roller if equipped
All clamp and lid screws
Hose reel swivel joints
Hose reel center shaft bearing
Hose reel bearing lubrication manifolds
Hose reel hose guide
Hose reel extensions and shaft
Change auxiliary engine fluid coupling oil
Grease - Unless otherwise noted grease all zerks

and required surfaces with Castrol Pyroplex
Red Grease #2 or equivalent. Special operating
conditions (excessive temperature or speed)
may require a different type of grease (consult
the factory). Do not over grease. When overflow
appears, stop adding grease and wipe off all excess
grease.
100
Hrs. or
Monthly
500 Hrs.
or Every
6 Months
First
First
250
x
x
1000
Hrs. or
Every 12
Months
x
x
x
x
250
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
every 4000 hours or 3 years
NOTICE
Keep grease fittings clean, accessible, and free
from damage. Grease fittings should be checked
every week. Examine and replace broken
fittings.
All clamp and lid screws should be lubed with an

anti-sieze compound.
Chassis service - refer to the chassis manual
25
Hrs. or
Weekly
205
Vactor 2100 Fan
L
ubricants
Maintenance
Anti-Wear Hydraulic Oils
1
2
3
4
5
6
7
8
9
10
GRADE
Gravity, API D 1298
Flash, COC, F D 92.
Viscosity cSt at 40 C D 445
Viscosity cSt at 100 C
Viscosity SUS at 100 F
Viscosity SUS at 210 F
Viscosity Index D 2270
Emulsion at 130 F D-1401
Turbine Oil Stability Test D 943 Hours
Rust Test, SSW D 665B
32
46
68
32.2
410
32
5.4
165
44.4
102
Pass
5000+
Pass
29.3
440
46
6.8
237
49
102
Pass
5000+
Pass
28.5
460
68
8.7
352
55.5
99
Pass
5000+
Pass
COTTA 1.4 (4 cylinder engine) & 1.6 (6 cylinder engine) Step-Up Transmissions
1
2
3
4
5
6
7
8
GRADE
PETROLEUM GEAR OILS
Castrol Isolube 68
Castrol Paradene R&O 68
Citgo Pacemaker T 68
Chevron Machine Oil Grade 68
Conoco Hydroclear Turbine Oil Plus 68
Mobil DTE Heavy Medium
Phillips Magnus Oil 68
Shell Turbo T 68
NOTES
Standard Fill
Fluid Couplings
1
2
John Deere 4 and 6 cylinder auxiliary engines

Houghto-Safe 1120 (Vactor P/N 47578D)
Fyrquel GR 46
NOTES
Standard Fill
Anti Freeze
John Deere 4 and 6 cylinder auxiliary engines
Castrol 50/50 Premix with SCA (Castrol P/N 80089)
1
Vactor P/N 47965 - 55 Gal

Vactor P/N 47965A - 5 Gal
* Standard fill
NOTES
Castrol Mix is Purplish in
color. Do NOT mix with
other brands or colors.
CAUTION
If proper levels are not maintained or improper
fluid used, damage may occur to the system.
206
Vactor 2100 PD
L
ubrication - Grease Manifold
An optional grease manifold provides grease to

inaccessible or difficult to reach points. Most units
will have three grease manifolds: 1) Hose Reel
Grease Manifold, 2) Boom Grease Manifold, and 3)
Rear Door Grease Manifold.
The hose reel grease manifold is standard and there
are two of them with one on each side near the
bottom and front of the hose reel.
Boom Grease Manifolds
Hose Reel Grease Manifolds
Hose Reel Grease Manifolds
Rear Door Grease Manifolds
208
Maintenance
H
ydraulic Oil
Vactor 2100 PD
Maintenance
anti-wear, anti-corrosion, anti-foaming and seal

conditioning characteristics. Consult the factory for
oil other than the recommended products.
The hydraulic system leaves the factory filled with

Castrol Hydraulic Plus Blue 46 (*) oil. This fluid is
recommended for all normal operation conditions
to 95 (F) ambient. The first change is for the filter
at 100 hours and oil every 500 hours or six months
after that. For continuous operation above 95 (F)
to 105 (F) ambient Castrol Hydraulic Plus Blue 68
is recommended. For continuous operation above
105 (F) ambient consult the factory. For operation
from -20 (F) to 70 (F) ambient use the Castrol
Hydraulic Plus Blue 32 oil. For continuous operation
below -20 (F) ambient consult the factory.
Filters should be changed whenever indicated by

the filter gauge. Contaminants allowed to remain
in the circuit not removed by the filters will cause
excessive wear and malfunctions.
The oil tank will normally feel hot to the touch.
Two sight glasss are installed to determine the oil
level are mounted on the side of the oil reservoir
tank Proper oil level should not be less than 1/2 as
viewed in the lower sight glass and not above 1/2
in the upper sight glass. Check the oil level every
eight hours. If the oil level is low, add proper grade
hydraulic oil.
Other hydraulic oils, if used, should be a quality

product carefully selected with assistance from a
creditable supplier. The oil should include thermal
stability, sheer stability, low-temperature fluidity,
Hydraulic Oil
Sight glasss
Filler cap
Hydraulic Oil
Reservoir
Reservoir
Cleanout
Port
CAUTION
If proper oil level is not
maintained or improper oil
used, damage may occur to
the hydraulic system.
209
H
ydraulic Oil Filter
Vactor 2100 PD
Maintenance
The filtering system used on the Vactor is

considered absolute filtering. Many filters only give
approximately thirty percent filtration of the particles
in the hydraulic oil. These filters are referred to as
nominal filters. Absolute filtering can give as much
as ninety eight percent filtration of the particles in
the hydraulic oil. Vactor uses and recommends only
the use of absolute filters.
Cyclone
Filters should be changed whenever indicated

by the filter gauge and any time the hydraulic oil
is changed. More frequent replacement could
be advisable, depending on operating conditions
or oil changes at more frequent intervals may
be necessary if oil condition becomes poor.
Contaminants allowed to remain in the circuit not
removed by the filters will cause excessive wear
and malfunctions.
Relief
Valve
Hydraulic
Oil Filter
The Indicator on the filter automatically resets after

maintenance and is color-coded as follows:

Green - Normal
Yellow - Warning
Yellow & Red - Service
The indicator signals the following conditions:

Clogged filter element
Fluid temperature below normal
Impending filter by-pass valve open condition
Indicator
Hydraulic oil filters should not be cleaned. They

should be replaced and the old filter properly
discarded in compliance with all federal, state and
local laws.
To change the filter, follow these steps.
1.
Shut down the system and relieve pressure

in the filter line.
2.
Unthread canister and remove. This may

require a strap wrench.
3.
Apply a thin film of oil to the new canister

seal.
4.
Install the new canister. Tighten only hand

tight.
5.
Start the hydraulic pumping system and

check for leaks. If oil seepage is noted,
apply additional hand torque to the canister
until seepage stops.
Hydraulic
Oil Filter
210
Vactor 2100 PD
H
ydraulic System - Reservoir
Maintenance
The hydraulic reservoir should be drained, flushed

and filled every 500 hours or six months whichever
comes first. The oil strainers should be removed
and cleaned each time the hydraulic oil is changed.
The hydraulic reservoir contains approximately 70
gallons of oil. When draining the reservoir a suitable
container must be used to hold the oil and prevent
spills. It may be necessary to drain the reservoir a
small amount at a time.
Filler cap
Hydraulic Oil
Reservoir
Change the hydraulic oil and clean the strainer as

follows:
1.
Place a suitable container below the hydraulic

reservoir and remove the drain plug from the
drain hose on the drivers side.
2.
Remove the reservoir cover bolt and cover
3.
Reach inside the reservoir and remove the oil

strainers by unscrewing them.
4.
Inspect the strainers for wear or damage.

Replace the strainers if worn or damaged.
5.
Using compressed air thoroughly clean the

strainers.
6.
Install the strainers in the hydraulic reservoir

and tighten hand tight plus one-half turn.
7.
Inspect the diffuser and replace if any damage

is present. Orient the diffuser towards the
front of the unit.
8.
Inspect the reservoir cover and seal for wear

or damage. If worn or damaged replace the
cover and seal.
9.
Install the cover on the reservoir and secure

with the cover bolt. Tighten to general torque
specifications.
10.
Fill the hydraulic reservoir using the specified

oil.
! WARNING
Never point the air nozzle
at a person. Compressed
air can penetrate the skin
and cause serious injury or
death.
Reservoir
Cleanout
Cover
Diffuser
(Note orientation)
Drain hose is normally located on

the driver side in front of the rear
wheels inside under the frame.
Strainer
When using compressed

air always use eye
protection and adjust air
pressure to 20 PSI or less.
211
B
oom Lubrication (telescopic
Vactor 2100 PD
or extendable)
Lubricate post swivel joints, cylinder ends and hinge

pins monthly. Weekly - Extend and retract boom
while using hand gun to wash inner and outer tube
and sealing area.
Maintenance
Cylinder
Ends
Hinge
Pin
Boom
Boom
Support
Swivel
Joints
Cylinder
Ends
Passenger Side
Hinge
Pin
Swivel
Joints
Driver Side
212
Cylinder
Ends
Vactor 2100 Fan
F
an Drive
Maintenance
The auxiliary engine drives a fluid coupler and

transmission, which in turn drives the fan assembly.
Most units are equipped with either a four or six
cylinder engine. All are accessed the same way.
The auxiliary engine, fluid coupler and transmission
are located behind the cab and underneath the
engine cover. Daily maintenance checks and
service, as shown in the Service Check List, can be
performed by releasing the cover latch and sliding
the cover outward. The cover slides along two rails
mounted under the cover.
Fluid
Coupler
Fan
Transmission
Auxiliary
Engine
Engine Cover
Open
Maintenance and repair procedures for the auxiliary

engine are contained in engine manuals supplied
with the vehicle.
Service for the fluid coupling is in the maintenance
section.
Engine Cover
Open
Engine Cover
Latch
Engine
Cover
Closed
Engine Cover
Open
Engine Cover
Latch
214
Vactor 2100 Fan
F
an Cleaning
Each fan needs to be inspected and cleaned at

least once a week even if the unit is equipped
with an optional fan washout system. There is one
washout plug on top of each fan housing. On units
with a single fan, the drain is located underneath the
lower left hand water tank. An additional drain for
dual fan systems is located in the front fan housing.
The procedure for cleaning the fan on a four or six
cylinder unit is the same:
1.
Dump the debris body.
2.
Remove the fan wash out plug or plugs.
3.
Remove the fan drain plug or plugs.
4.
Insert the hand gun nozzle into the washout

ports. Using the hand gun thoroughly clean
the fan and inside housing.
Maintenance
Fan
Washout Plugs
Fan
Exhaust
Fan
5.
After washing out the fan and housing, use

a flashlight to inspect the fan blades for wear
and tear.
6.
If necessary, replace the fan.
Front Fan Drain

Front Fan
Housing
Rear Fan Drain
! WARNING
Cut line
Do not run engine

with inspection
cover removed.
ADVERTENCIA
No poner el motor
en marcha con la
cubierta de
inspeccin retirada.
6.375" wide x 6.250" tall

.125 corner radius
SAFETY
INSTRUCTIONS
INSTRUCCIONES DE
SEGURIDAD
If fans cause excess

vibrations, shut engine off
and follow procedure as
described in the maintenance
section of the operator's
guide.
Si los ventiladores causan

vibraciones excesivas,
apagar el motor y seguir los
procedimientos descritos en
la seccin de mantenimiento
de la gua del operador.
CAUTION
ENG. STANDARDS

A build-up of material on the fan will cause an

out-of-balance
condition.
Operating
an out-ofVACTOR
Manufacturing
Inc. STREATOR,
IL.
NAME
balance
fan can cause
damage
to
the
fan,
fluid
DECAL,FAN WARNINGS
DR. or
DATE
SCALE
PART NO. remove
drive
auxiliary
engine.
If
necessary,
AC
1-11-2005
NONE
1800150
the intake elbow for proper cleaning.
1800150
215
DIMS. IN INCHES
TOLERANCES UNLESS
LTR.
0 Initial release
Revision
By
AC
Date
1-11-2005
ECN No.
5683
Vactor 2100 Fan
F
an Cleaning
5.
After washing out the fan and housing, use

a flashlight to inspect the fan blades for
wear and tear. If the fan tips show signs of
excessive wear inspect the unit for excessive
carry over during operation. There should
not be any regular visible debris in the fan
exhaust stream.
6.
If necessary, replace the fan.
Maintenance
Optional fan housing washout system

This system is part of the handgun system. To use:
1.
Open drain to each fan housing.
2.
Turn ON handgun valve.
3.
Turn ON fan housing valve.
4.
Turn ON the rodder pump.
5.
Continue running water until the housing

drains run clear.
6.
Turn OFF the rodder pump.
7.
Turn OFF fan housing valve.
8.
Turn OFF handgun valve.
9.
OPEN hose reel valves.
10.
Reinstall drain plugs to each fan housing.
Worn Fan
Good Fan
After
inspecting
fan(s) realign
nozzles to
face rearward
when
reinstalling
hole plugs.
Optional housing
washout controls
Verify that
nozzles are
not plugged.
216
Optional housing
washout lines
Vactor 2100 Fan
F
an Replacement - 4 Cylinder
Maintenance
units
A damaged or worn fan will cause vibration

and possible damage to the drive system. The
procedures for replacing the fan are different
depending on whether the unit is four cylinder or six
cylinder.
Four-Cylinder Unit
Replace the fan as follows:
1.
Air
Filter
Shut down the chassis and auxiliary engine.

Remove the ignition key and post notice of
maintenance on the steering wheel and front
control panel.
2.
Remove the elbow and hose assembly.
3.
Using an overhead support and lift, remove

the fan housing nuts.
4.
Remove the inlet cover.
5.
Remove the three bolts from the flange and

install in threaded holes
6.
Tighten the bolts evenly until the fan can be

moved back from the hub.
7.
Using a marker, match mark the hub and

shaft for positioning during installation.
Elbow and
Hose
Inlet
Cover
! WARNING
When performing maintenance on the vehicle,
always shut down the engine and remove the
ignition key. Post a notice on the steering wheel
and on the front control panel indicating that
maintenance is being performed on the vehicle.
Serious injury or death may occur if the vehicle
is started while performing maintenance on the
vehicle.
Installing Bolts
Hub Mounting
217
Vactor 2100 Fan
F
8.
units
Remove the hub from the drive shaft. If

necessary, tap a chisel into the split slot until
the hub slides off the shaft.
9.
Remove fan from housing.
10.
Clean the drive shaft by removing any rust or

rough spots.
11.
Place the new fan with new bushing in the

housing.
12.
Using the match mark, position the hub on the

drive shaft.
13.
Position the fan on the hub with the mounting

bolt holes aligned.
14.
Install the hub mounting bolts loosely.
15.
Install the inlet cover on the fan housing and

secure with mounting nuts. Torque nuts to
general torque specifications.
16.
Tighten the hub mounting bolts evenly and

alternately pulling the fan onto the hub with
a spacing of 1/16" - 1/8" between inlet cover
and curved portion of the inner fan. Tighten
the hub bolts to 36 - 40 ft. lbs. torque.
17.
Check fan to inlet cover clearance.
18.
Check for vibration and proper clearance by

operating fan at normal operating speed.
19.
Install the elbow and hose assembly. Torque

to general torque specifications.
Removing Hub
Installing Hub
SAE Bolt & Recommended Torque Chart for

Grade 5 Bolts
1/4 DIA
75-100 lb-in
5/16
157-210 lb-in
3/8
23-31 lb-ft
7/16
37-50
1/2
57-75
Maintenance
16
1/16" - 1/8"
Clearance
Single Fan System or Outer Fan on Dual Fan

System
218
Vactor 2100 Fan
F
Maintenance
units
Six Cylinder Unit

The outer fan housing must be removed to replace
the inner fan assembly.
For a six-cylinder unit, replace the fan as follows:
1.
Shut down the chassis and auxiliary engine.

Remove the ignition key and post notice of
maintenance on the steering wheel and front
control panel.
2.
Remove the elbow and hose assembly.
3.
Using an overhead support and lift, remove

the fan housing nuts.
4.
Remove the inlet cover.
5.
Remove the three bolts from the flange and

install in threaded holes.
6.
Tighten the bolts evenly until the fan can be

moved back from the hub.
Air
Filter
Elbow and
Hose
Inlet Cover
219
Housing
Nuts
Vactor 2100 Fan
F
units
7.
Using a marker, match mark the hub and

shaft for positioning during installation.
8.
Remove the hub from the drive shaft. If

necessary, tap a chisel into the split slot until
the hub slides off the shaft.
9.
Remove fan from housing.
10.
Clean the drive shaft by removing any rust or

rough spots.
11.
Using an overhead lift and support, remove

the outer fan housing.
12.
Remove the inner fan hub and fan using the

above steps.
13.
Place the new inner fan with new bushing in

the housing.
14.

drive shaft.
15.
Removing Hub
10

bolt holes aligned.
Hub
7
15
Installing Hub
Installing Hub Bolts
220
Maintenance
Vactor 2100 Fan
F
units
16.
17.
Install the outer fan housing and torque bolts

to general bolt specifications.
18.

alternately pulling the fan onto the hub with a
spacing of 3/16" - 1/4" between outer housing
19.
Check inner fan for vibration and proper

clearance by operating fan with inner fan
installed.
20.
Position the outer fan in the outer fan housing.
21.

drive shaft.
22.

bolt holes aligned.
23.
24.
Install the inlet cover on the fan housing and

secure with mounting nuts. Torque nuts to
general torque specifications.
25.

alternately pulling the fan onto the hub with
a spacing of 3/16" - 1/4" between inlet cover
26.
Check fan to inlet cover clearance.
27.
Check for vibration and proper clearance by

operating fan at normal operating speed.
28.
Install the elbow and hose assembly. Torque

to general torque specifications.
18
3/16" - 1/4"
Clearance
Inner Fan Spacing
25
3/16" - 1/4"
Clearance
Outer Fan Spacing
Note: The fan can be operated with only the inner

fan installed. Operate at normal operating
speed to check for vibration and proper
clearance. Adjust as necessary without having
to remove the outer fan.
Maintenance
221
F
luid Coupler Maintenance
Vactor 2100 Fan
The fluid coupler is mounted between the auxiliary

engine and fan. The fluid coupler performs similar
to a torque converter in an automatic transmission.
Periodic inspection and service are vital to proper
fan performance.
2 o'clock
10 o'clock
The fill/drain plug used on the fluid coupler is a

390 (F) fusible plug. The fill/drain plug must have
four marks in the plug to represent the 390. If the
temperature in the coupler exceeds 390 degrees,
the center of the plug will melt out and allow the
fluid in the coupler to drain. The hole may be
difficult to see, look for leaking oil. This protects the
coupler from excessive heat damage.
Fill Level
Fill Drain Plug
The oil in the fluid coupler must be changed every 3

years or 4000 hours. Change oil as follows:
1.
Remove the fill/drain plug.
3.
Rotate the fluid coupler until the fill/drain plug

is at the bottom and drain the oil into a drain
pan.
4.
Fluid Coupler
Rotate the fluid coupler until the fill/drain plug

is at the 10 o'clock or 2 o'clock position. The
fluid coupler fill/drain plug must be at either
the 10 o'clock or 2 o'clock position for proper
filling.
2.
Fluid Coupler Oil Type & Capacity

Use only Houghto-Safe or Fyrquel 220 in the fluid
coupler Vactor Part Number 47578D (2.5 Gallons)
Rock the fluid coupler gently during filling to

displace air. Fill to the line in the illustration or
just to the edge of the fill hole.
6.
Inspect the fill/drain plug for damage and coat

lightly with thread sealer.
7.
Install and tighten fill/drain plug.
Fluid Coupler
Capacity
Cummins 6 Cylinder Engine
9 Quarts
8 Quarts
5 Quarts
John Deere 6 Cylinder Engine

John Deer 4 Cylinder Engine
When all the oil is drained, rotate the fluid

couple until the fill/drain plug is at the 10
o'clock or 2 o'clock position.
5.
Maintenance
NOTICE
Due to high operating temperatures in the fluid
coupler, use only fluid coupler oils indicated in
the chart. These oils, supplied by a local distributor, are special fire retardant oils. Using other
oils may result in fill plug melt down and loss of
oil.
Note four marks on drain plug.

This indicates the correct temperature fusible plug
222
F
luid Coupler Replacement
Vactor 2100 Fan
Replacement of the fluid coupler on four- and sixcylinder units is similar. The instructions below are
for four-cylinder units with any differences for sixcylinder units being noted in parenthesis.
Maintenance
! CAUTION
Wear eye protection and rubber gloves when
using mineral spirits or solvents as a cleaning
agent. Serious injury can occur if this warning
is ignored. Solvents cause injury if exposed to
eyes or skin.
Tools and Materials

Bell Housing P/N 82756B
Hex Head Cap Screws (1/2 - 13 x 1/12) (8)
Fine Sandpaper
! CAUTION
Fine Tooth File
Wear eye protection when using air pressure for

cleaning parts and materials. Air pressure can
penetrate skin. Never point the air nozzle at personnel. Serious injury can result if this warning
is ignored.
Fluid Coupler Kit P/N 47780 (Six Cylinder P/N

47827)
Grease
M8 x 1.25 x 30mm GR12.9 Socket Head Cap Screw
(20) P/N 43759B
M10 x 1.5 x 3.5 Hex Head Cap Screws (12) P/N
43613B
M10 Lock Washer (12)
Fluid Coupler
Mineral Spirits
Pilot Bearing Installation Tool
Pilot Bearing P/N 47746
Saf-T-Lok T42 Thread Lock
Seal Installation Tool
Shop Towels
Front of 6-cylinder
engine assembly
Four Cylinder John Deere Engine P/N 47828 (Six

Cylinder P/N 47826)
Spray Lubricant (for rubber)
Standard Tools Set
Transmission P/N 47781 (Six Cylinder P/N 47853)
6-cylinder rear
4-cylinder rear
Fill
plug
6-cylinder front
223
4-cylinder front
F
1.
Vactor 2100 Fan
Using mineral spirits and shop towels clean

the flywheel of grease, oil and dirt. Dry using
compressed air.
2.
Using a fine tooth file or sandpaper, remove

any burrs and imperfections along the O-ring
sealing surface.
3.
Using a bearing installation tool and hammer,

install pilot bearing in flywheel.
Maintenance
Pilot Bearing
Installation Tool
Installation Tool
Cleaning Flywheel
2
Installation Tool
Installing Pilot Bearing
O-Ring Sealing
Surface
O-Ring Seal Surface
224
F
4.
Vactor 2100 Fan
The fluid coupler part number is 47780 (sixcylinder fluid coupler part number is 47827).
Use the manufacturer's instructions for any
preassembly needed.
5.
Using a seal installation tool and hammer,

install the seal in the fluid coupler.
6.
Using a fine tooth file or sandpaper, remove

any burrs or imperfections from the fluid
coupler O-ring seat.
Maintenance
Installing Seal
6
Seal
Seal
Seat O-Ring in corner
of flange
4
O-Ring Installation
Seal
225
O-Ring
F
Vactor 2100 Fan
7.
Install O-ring and lubricate with a thin layer of

grease.
8.
Lightly coat an M8 x 1.25 x 30mm GR12.9

socket head cap screw with Saf-T-Lok T42
thread lock.
9.
Carefully position the fluid coupler in place on

the flywheel and secure with the M8 socket
head cap screw. While positioning the fluid
coupler on the flywheel be careful not to
damage or distort the O-ring.
10.
Coat each socket head cap screw with Saf-TLok T42 and install in fluid coupler/flywheel.
Tighten socket head cap screws alternately
180 apart to 18 - 20 ft. lbs. torque.
11.
Remove protective tape from the transmission

input shaft and clean with mineral spirits. Dry
with compressed air.
Lubricating O-Ring Seat
Tread Lock
Fluid Coupler Installation
226
Maintenance
F
12.
Vactor 2100 Fan
The bell housing will only bolt to transmission

one way. Position bell housing with wide
spacing at the bottom.
13.
Align bell housing and transmission bolt holes

and seat bell housing using a rubber mallet, if
necessary.
14.
Lightly coat eight (1/2 -13 x 11/2) hex head

cap screw with Saf-T-Lok T42 thread lock and
install in bell housing/transmission.
15.
Tighten cap screws to 90 +/- 7 ft. lbs. torque.
13
12
Seating Bell Housing
14
Bell Housing Installation
Thread Lock Application
15
Mounting Bolts
227
Maintenance
F
Vactor 2100 Fan
16.
Lubricant the inside of the fluid coupler with

spray lubricant.
17.
Lightly coat an M8 X 1.5 X 35 hex head cap

screw with Saf-T-Lok thread lock.
18.
Using an overhead hoist and lift, mount the

transmission and bell housing through the
fluid coupler to the engine. Use a rubber
mallet to position the transmission, if
necessary. Secure with an M10 lock washer
and the coated M10 X 1.5 X 3.5 hex head cap
screw.
19.
Lightly coat each M10 button head cap screw

with Saf-T-Lok thread lock and install with an
M10 lock washer in the transmission/engine.
Tighten to 35 - 37 ft. lbs. torque.
20.
Fill the fluid coupler with oil using the

instructions entitled Fluid Coupler
Maintenance.
16
Lubrication
18
Installing Transmission
228
Maintenance
Vactor 2100 Fan
A
uxiliary Engine Transmission
Maintenance
The auxiliary engine transmission is located

between the fluid coupling and the fan housing.
Normal oil change interval is every 500 hours or 6
months in normal use. Refer to the lubricant page
for the recommended oil.
Fill until oil is at the fill level plug.
Fill
Plug/
Vent
Transmission
Fill
Level
Plug
Auxiliary engine and transmission oil drain plugs

(Normally located under fan assembly on driver side
between frame rails. Marked with a T and E.)
229
O
utlet Seal Adjustment
Vactor 2100 Fan
The outlet seal can be adjusted by two different

methods. The band clamp around the outlet cone
can be either loosened or tighten as dictated by the
circumstances. If it is loosened, the outlet pipe will
seat deeper into the cone.
Outlet Cone
The second method, is to adjust the four bolts near

the outlet cone. Each of the bolts are in a slot which
allows the outlet cone to be slid in either direction.
After the bolts are loosened, the seal between the
cone and outlet pipe can be made tighter by sliding
the cone closer to the outlet pipe.
Maintenance
230
Band Clamp
aterial Flow
M
Vactor 2100 Fan
All areas where material flows are subject to wear.

The rate of wear varies greatly with the material and
operating conditions. All models are equipped with
a replaceable deflector to receive the highest wear
and to reduce the materials wear on other parts of
the system.
! DANGER
entry. Comply with all applicable federal, state,
and local regulation.
The deflector, cyclones, hoses, tubes, elbows,

boom turret and all areas in contact with the moving
material should be inspected monthly and repaired
or replaced as required. Highly abrasive and/or
corrosive materials will require more frequent
inspections.
Maintenance
231
P
re-job / Daily Checklist
Vactor 2100 Fan
Engine OFF, Engine Cool

Check
Item
Date
Radiator Coolant
_ __________
Battery Water
_ __________
Hydrometer
_ __________
Drive Belts
_ __________
Fan
_ __________
Alternator
_ __________
Crankcase Oil
_ __________
Fuel Tank
_ __________
Transmission Fluid
_ __________
Brake Function
_ __________
Brake Fluid
_ __________
Instrument Gages
_ __________
Windshield Wipers
_ __________
Windshield Washers _ __________
Mirrors
_ __________
Tire Wear
_ __________
Tire Damage
_ __________
Tire Inflation
_ __________
Hoses
_ __________
Frame
_ __________
Engine OFF
Check
Item
Date
Hydraulic pump oil level _ __________
Aux engine oil level
_ __________
Vacuum relief valves _ __________
Aux engine transmission

oil level
_ __________
Access door secured _ __________
Hoses, tubing, loose items

secured
_ __________
Water pump case oil level___________
Maintenance
Engine ON
Check
Item
Date
Engine Sound & Exhaust _ __________
Foot Brakes
_ __________
Emergency Brake
_ __________
Power Steering
_ __________
Cab Lights
_ __________
Headlights
_ __________
Tail lights
_ __________
Turn Signals, Rear
_ __________
Turn Signals, Front
_ __________
Clearance Lamps, Front _ __________
Clearance Lamps, Rear _ __________
Marker Lamps, Front _ __________
Marker Lamps, Rear _ __________
Instrument Panel Lamps _ __________
Instrument Panel Gages _ __________
Horn
_ __________
Heating and Ventilating _ __________
Air Conditioning
_ __________
Mirrors
_ __________
Seating
_ __________
Test Drive
_ __________
Engine ON - parking brake set
Check
Item
Date
Open rear door
_ __________
Install rear door safety prop__________

Inspect vacuum float balls___________
Inspect, clean rear door seal_________
Store rear door safety prop__________
Close rear door
_ __________
Hydraulic pump ON
when PTO is engaged _ __________
Note: It is recommended that the CHECK LIST be copied and used prior to each job. Failure to monitor the items
included in the check list prior to each job will increase the risk of accidental injury to personnel and/or damage
to the equipment.
232
M
ake/Break Seal Adjustment
Vactor 2100
The seals going into and out of the debris body

must be tight so there can be proper vacuum
pressure. The inlet seal is between the vacuum
hose and the debris body, and the outlet seal is
between the debris body and the microstrainer.
Maintenance
Inlet Seal
Boom
Vacuum
Hose
Inlet Seal
The inlet seal is adjusted by four bolts under the
vacuum hose. Each of the bolts are in a slot which
allows the vacuum hose to be slid in either direction.
After the bolts are loosened, the seal can be made
tighter by sliding the vacuum hose assembly closer
to the debris tank.
Inlet Seal
Seal
Adjusting
Bolts (4)
234
R
ear Door Seal
Vactor
Regularly clean the door, especially the door seal,

and lubricate the hinges. The door seal should be
cleaned each time the debris body is dumped.
! DANGER
Do not work underneath the rear door without
installing the rear door safety prop. Serious
injury or death may occur if the door falls due to
a hydraulic hose failure or accidental closure by
an operator.
The rear door seal provides an airtight seal for the

debris tank. It is important to keep the seal clean
and in good condition. Inspect the seal after each
dump and replace if damaged or worn. The seal
can be replaced on the vehicle or the door may
be removed and placed on supports with the seal
channel facing up.
Seal Replaced with Door Removed

If removing the door for installation of the seal off
the vehicle, use an overhead crane support and
lift to remove the door. Place it on supports with
the seal channel facing up.
Changing the Door Seal

Materials needed:

Replacement seal
3M Industrial Adhesive P/N 4799 (2 tubes

1002)
Cyanoacrylate adhesive (super glue)
Duckbill vise grip pliers
Hacksaw
Mallet
Maintenance
Seal Replaced with Door on Unit

When installing the seal with the door on the
vehicle, do the following:
a.
Use the instructions posted in the cab to

b.
Raise the debris tank. Install the debris

tank and rear door safety prop.
c.
Shut down the engine and remove the

ignition key.
d.
Post a notice on the steering wheel that

maintenance is being performed.
Rear door
! CAUTION
Rear door
Seal
When performing maintenance on the vehicle,

shut down the engine and remove the ignition
key. Also, post a notice on the steering wheel
that maintenance is being performed. Serious
injury may occur if the vehicle is started during
maintenance procedures.
! DANGER
Use an overhead crane support and lift to
secure the door before disassembling the door
hinges. Use the crane to remove the door and
position it for seal replacement. Do not work
underneath the door without proper support or
safety props, serious injury or death may occur.
236
Vactor
R
ear Door Seal
Procedure When Replacing the Door Seal
1.
Completely remove the seal and clean the

seal channel of all glue and dirt.
2.
Apply a generous amount of adhesive to all

sides of the seal channel.
4.
Maintenance
Starting at the top of the door, place the flat
surface of the new seal into the seal channel.
Joint must be at
top of door
3.
5.
If installing the seal with the door on the

vehicle, do the following:
Squeeze the seal with the duckbill pliers

while feeding the seal into the channel.
Make sure the end of the seal is cut squarely

for a proper seal at the end of the procedure.
Duck Bill
Vice Grip Pliers
Hacksaw
Excess Seal
237
R
ear Door Seal
Vactor
6.
If installing the seal with the door removed do

the following:
Maintenance
7.
Use the hacksaw to cut off excess seal to

form a flush, airtight mating surface between
seal ends. Coat one end of seal with the
cyanoacrylate adhesive before installing.
8.
If installing the seal with the door off of the

vehicle, use an overhead crane support and
lift to install the door on the debris tank.
Using a mallet, pull on the seal while

pounding the seal into the channel.
End Joint
Coat one end of seal with the
cyanoacrylate adhesive before installing.
238
B
utterfly Valve Adjustment
Vactor
A variety of air and hydraulic actuated butterfly style

valves from a number of different manufacturers are
used. A butterfly valve, shown at right, rotates a disc
in the material flow to open and closed positions
(shown in closed position). The valves are normally
actuated by switches or automatically by the system
controls. During servicing or use an inadvertent
actuation could result in an injury from the moving
parts. The valves can still remain active when
not installed unless the air or hydraulic lines are
disconnected and all safety precautions followed.
Maintenance
Hazardous
area
Old style
Actuator
Disc
Do not allow tools, arm, hands etc. in the butterfly

areas as serious injury may occur. Shut down all
systems and de-energize or disconnect the air or
hydraulic system to the valve before servicing.
End style adjuster
Note valve disc is

slightly rotated open
Butterfly Valve
Improperly adjusted valves can cause actuator

damage or disc bolt fatigue and failure. Valve should
open and close smoothly.
Butterfly pneumatic actuators are designed to allow
adjustment without the removal of the actuator end
caps. Typically there is a jam nut located on each
end of the actuator in the center of the end cap.
Newer style butterfly valves have the adjuster bolt
on the side of the actuator. One adjuster controls
the closed position and the other the open position.
Note valve disc is slightly rotated open
With the valve in the CLOSED position:

1.
New style
Determine which adjuster screw is for the

closed position. It will be the one that moves
the disc.
2.
Adjust the screw all the way in (for side

adjusters - out for end cap adjusters). This
should give you about 5 deg. adjustment.
3.
The disc should start to unseat in this position

and still provide shut-off.
4.
Tighten the jam nut and check your system to

see if the valve is providing shut-off.
5.
If the valve is not providing shut-off loosen the

jam nut and readjust to where the disc just
seals.
6.
Observe the valve operating:
Side style
adjuster
WARNING
Cut line
CLOSED Valve angle seat should be

between 3 and 5 degrees.
Valve should open and close
smoothly.
Cutting and crushing
hazard
Moving parts can crush and cut.
Keep clear when valve or
mechanism is operating.
1800169
3"
ENG. STANDARDS
240

E0009 - Vinyl film
VACTOR Manufacturing Inc. S
Vactor
ir System
A
All units use compressed air to operate
various valves and cylinders. The air
is normally supplied by the chassis air
system. Depending on options, unit or
chassis configuration there will normally
be one or more air tanks, filters or
dryers located on the unit in varying
locations.
Maintenance
Typical Manual
Air Valve
Maintenance
If equipped all air tank filters should be
checked daily and cleaned if necessary.
If upon a visual inspection, the filter is
dirty or clogged, it should be replaced.
Typical Remote Cable

Operated Drain Valve
Note: the chassis air tank should be

drained daily and the unit air filter
checked and cleaned if necessary every 48
hours. Cold or very humid weather may require
more frequent draining of the chassis air tanks.
When air is compressed the water vapor in the
air is put into the vehicles air system. The liquid
accumulates and affects system performance by
washing away lubricants, accelerating corrosion and
blocking air system components by freezing. High
humidity, high air consumption and cold temperatures
increase the water vapor collected in the air system.
Two common methods are used to address this issue
are automatic drains and desiccant-type air dryers.
Manual drains may also be found.
Automatic Air Drain
In-line dryers and

filters are normally
used on units with
blowers and transfer
cases for the air
shift.
Note: Alcohol injection systems are sometimes used

by others. They are very specialized and should
not be used as the alcohol can damage seals
and plastic parts in an air system.
Freezing conditions can create situations where
the frozen water can slow down or stop the proper
operation of the various components in an air system.
This can include chassis brakes, air valves and air
cylinders that operate safety systems such as vacuum
reliefs. When operating under these conditions proper
operation of the air systems should be routinely
verified. The frequency will vary with the conditions.
When the conditions exist for air system water
problems Vactor Manufacturing and most chassis
manufacturers recommend draining all system air
reservoirs every 2-3 hours of operation.
Typical In-line Air

Dryer and Filter
Typical desiccant
style air dryer with
replaceable filter
element.
Desiccant-type air dryers require routine replacement

of the desiccant element. Refer to the chassis service
manual.
Consult the Vactor Manufacturing Service Group
for recommendations and systems suited to your
applications.
242
H
ose Reel Assembly
Vactor 2100
Maintenance
Maintenance of the hose reel assembly should be

limited to 1) lubrication and adjustment of the drive
chain and 2) adjustment of the hose reel swivel to
prevent leaks.
Drive Chain Lubrication
Lubricate the chain using a good quality spray foam
lubricant.
Drive Chain Adjustment
With the truck engine off, check the slack in the
hose reel drive chain. The chain should have no
slack. If there is slack, adjust the chain as follows:
1.
Loosen the four drive motor bracket bolts.
2.
Loosen adjusting bolt lock nut.
3.
Tighten adjusting bolt until there is no slack in

the chain.
4.
Retighten lock nut on the adjusting bolt

securely.
5.
Motor Bracket Bolts
Lock Nut
Retighten drive motor bracket bolts to general

torque specifications.
Notes: Over time it may become necessary to

remove a half link or a link from the drive chain.
Adjusting Bolt
244
Vactor 2100
Hose Reel Swivel Joint
Maintenance
There are two swivel joints on the water hose reel

and both have grease zerks. One swivel joint is
located near the front center of the hose reel. The
other is positioned below the hose reel near the
middle.
Swivel Joint Packing Adjustment
Notches
If swivel leaks, remove the locking tab and loosen

the packing gland adjustment two notches. Use a
hand grease gun and give two pumps of grease.
Tighten the packing gland adjustment two notches
and recheck for leaks. Continue until leaking stops.
When all adjustment has been taken up, remove
packing gland and replace packing. Fill with grease
after repacking.
Swivel
Joint
Locking
Tab
245
Vactor 2100
H
ose Reel - Center Shaft Bearing
Greasing of the bearings on the center shaft should

be performed on a weekly basis. There is a grease
zerk for the center shaft on each end one on the
front of the hose reel and the other on the backside
of the hose reel. Do not over grease as these are of
a sealed bearing type, and over greasing will push
the seals out and allow dirt to enter the bearing.
Two pumps of the grease gun is sufficient.
Maintenance
Grease
Zerk
Center Shaft
246
Vactor 2100
T
elescopic/Rotating Hose Reel Bearing
Maintenance
The bearing used on the telescopic/rotating hose

reel bears the weight of the hose reel, rodder hose
and attachments. The bearing must be lubricated
properly to prevent bearing wear and damage.
Grease once a week or every 25 operating hours,
whichever comes first.
Hose Reel
Assembly
The bearing is lubricated through the grease zerks

located underneath the hose reel. When greasing
the bearing, grease cannot flow throughout the
bearing without rotating the hose reel. While
applying grease to the grease zerks, rotate the
hose reel back and forth. Bearing failure is usually
caused by lack of lubrication.
Grease
Zerks
247
R
odder Hose Replacement
Vactor 2100
Vactor uses only high quality jet rodder hose,

but even the best hose can wear out or become
damaged beyond repair. What constitutes damaged
hose and how to properly repair Vactor jet rodder
hose is discussed elsewhere in this manual. If the
hose needs to be replaced, follow these procedures:
1.
Start the unit and engage the hydraulic pump

using the procedure listed in the cab for your
unit. This may vary from one unit to the next.
2.
Go to the front hose reel and rotate the hose

reel so that the damaged or old hose runs
off the reel. The old hose can be run out on
the floor or wound up on an old reel to be
disposed of at a later date.
3.
Go back in the cab and shut the hydraulics

OFF once all the hose is off the reel.
4.
Remove the rear cover from the hose reel.
5.
Disconnect hose at connection on the rear

side of the hose reel and discard the hose.
6.
Feed the new hose through the hose reel

opening and connect the hose to the water
connection as shown.
7.
Go back in the cab and re-engage the

hydraulics.
8.
Wind the new hose onto the hose reel

keeping the wraps tightly aligned.
9.
If the unit is not going right back into service,

tie-wrap the hose end to prevent if from
unraveling.
! WARNING
Failure to shut the hydraulics off at this time

may cause accidental movement of the hose
reel, which may cause personal injury.
248
Maintenance
Vactor 2100
S
hark Rodder Hose Replacement
Vactor uses only high quality Shark jet rodder hose,

but even the best hose can wear out or become
damaged beyond repair. What constitutes damaged
hose and how to properly repair Vactor jet rodder
hose is discussed elsewhere in this manual. If the
hose needs to be replaced, follow these procedures:
1.
Start the unit and engage the hydraulic pump

using the procedure listed in the cab for your
unit. This may vary from one unit to the next.
2.
Go to the front hose reel and rotate the hose

reel so that the damaged or old hose runs
off the reel. The old hose can be run out on
the floor or wound up on an old reel to be
disposed of at a later date.
3.
Go back in the cab and shut the hydraulics

OFF once all the hose is off the reel.
4.
Remove the hose keepers from the hose reel.
5.
Disconnect hose at connection on the rear

side of the hose reel and discard the hose.
! WARNING
Failure to shut the hydraulics off at this time
may cause accidental movement of the hose
reel, which may cause personal injury.
249
Maintenance
Vactor 2100
S
hark Rodder Hose Replacement
6.
Feed the new hose through the hose reel

opening and connect the hose to the water
connection as shown.
7.
Reinstall all of the hose keepers that were

previously removed.
8.
Re-engage the hydraulics in the cab.
9.
Wind the new hose onto the hose reel

keeping the wraps tightly aligned. It may
be necessary to fill the hose with water and
pressurized to 15psi maximum to reduce
the risk of twisting and deformation. Refer to
manufacturer's manual for additional details.
10. If the unit is not going right back into service,

tie wrap the hose end to prevent it from
unraveling.
10
250
Maintenance
W
ater System
Vactor 2100
The water system must be maintained in summer

and winter. Accumulations of dirt and debris in the
water tanks and pump can cause excessive wear
and premature failures. Water freezing in the rodder
pump, lines or other components can cause severe
damage to the water system with water in the tanks.
The tanks should normally be left empty when the
unit will not be used. The tanks can be filled in 1015 minutes.
Draining and Flushing the Water Tank(s)

Vactor manufactures a variety of products with
a variety of styles and sizes of water tanks.
Regardless of style or size, draining and flushing the
water tanks is important for several reasons:

If the water tank inlet filter is damaged or the

gaskets are missing from the filter cap, foreign
material can enter the water tank, spread
through the entire water system into the
rodder pump damaging the pump seals and
into the oil cooler plugging or damaging the oil
cooler.
Foreign material can enter the water tank

through the air vents and filler point air gaps,
which are open and vulnerable to weather
conditions such as dust storms, high winds,
rain and snow. Contaminants form sludge
that when carried through the system can
damage the water tanks or other components.
Filling the water tanks from an unfiltered

source such as a hose or city water tower
rather than using the hydrant fill system may
allow direct access to chemical contamination,
which can create damage causing sludge.
Maintenance
Some city water systems contain high

concentrations of chemicals such as chlorine,
copper, calcium and iron. Certain chemicals
in the right concentrations and combinations
can damage the water system. A chemical
analysis of some damaged Vactor water
tanks has shown pitting caused by localized
galvanic action due to copper plating onto the
aluminum surface. For this chemical reaction
(nucleation of the pit) to occur the copper
residue must be present in a concentration of
at least 5 - 6 PPM and the water stagnant in
the tank for a long period of time. Even the
slightest movement of the water across the
aluminum surface would prevent the formation
of a residue and the pit would not form.
It is not always possible to determine if contaminates

such as foreign material and chemicals have
entered the system, therefore, draining and flushing
the water tanks and rodder pump regularly as
recommended removes all doubt and extends the
life of the water system.
252
raining
D
Vactor 2100
the
Water System (Cold Weather)
Maintenance
Instructions for draining water system in freezing weather

1.
Open drains in all water tanks and allow tanks to

empty. Remove Y-strainers at fill and water
pump suction and other options if so equipped.
2. Remove quick disconnect from hand gun
outlet(s).
3. Open both high pressure ball valves on the hose
reel.
4. REMOVE rodder nozzle and SECURE hose end
to an adjacent hose loop so reel can rotate.
Point the hose end towards the ground as ice
and water may be ejected while running rodder
pump.
5. Start engine and engage water pump for two
minutes at slow speed to expel any water.
7. Remove drain plugs from water pump or
optional drain valves and engage water pump
for one minute at slow speed to expel any water.
9. Rotate hose reel clockwise direction to expel
any water in hose.
10. Drain high pressure water gun.
11. Remove drain plugs for optional debris body

wash out system.
12. Open optional gate valve to water pump.
13. Locate heat exchanger in water pump suction
and open valves.
WARNING

Serious injury or death can result from sudden
release of high pressure water. Remove the
rodder hose nozzle and secure the hose end to
an adjacent hose loop so reel can rotate. Point
the hose end towards the ground as ice may
be ejected while running rodder pump.
Both pressure side water valves must be open
prior to operating rodder pump.
L-029A - 53695A rB
Decal is 8.000 wide by 5.000 tall
This decal is standard on all units and describes the

Corner radius is .125
general procedures for draining the system. More
detailed informationENG. STANDARDS
follows.
In addition to these specific

drain points, the
E0008 - Graphic film - polycarbonate
accumulator (optional) ball valve should be opened
to allow any water trapped in the
accumulatorManufacturing
to
VACTOR
Inc. STREATOR, IL.
drain. The handgunNAME
ports should be drained as well.
Open the handgun water ball valve and removeDECAL,DRAIN UNIT,L-029A
all
DR.
DATE
SCALE
PART NO.
the quick-connect handgun
connections. Drain
the
AC
12-8-2005
NONE
body washout if equipped.
53695A
TOLERANCES UNLESS
LTR.
0
Initial release
By
-
Revised and updated

Line 9 was CCW / Reworded & revised
AC
AC
Revision
253
Date
-
ECN No.
-
12-8-2005
2-23-2006
6191
6277
D
raining
Vactor 2100
the
Maintenance
CAUTION
An accumulation of ice in the rodder pump can
severely damage the pump. If there is even the
slightest possibility that ice has formed in the
pump, move the vehicle to a warm area and
allow the water system to warm completely
before use.
The water system must be drained in cold weather
to prevent freezing and accumulations of ice in the
rodder pump. The following procedure will help
prevent ice forming in the system:
1.
2.
3.
Move the vehicle to a suitable drain location

and shut unit down.
Y-Strainer
Clamp &
Cap
Remove the clamp, cap, gasket and screen

from the y-strainer. Some units may have
multiple y-strainers.
Ball Valve
Open the water tank drains and heat

exchanger drain, located on the bottom of the
water tanks.
Note: when draining is completed leave all valves

open, Y-strainers out and drain plugs out
when the unit will sit overnight or longer. This
will allow any residual water to drain.
Optional Y-Strainer at
air-gap
The heat exchanger is normally located on driver

side along the drive line. Note the water drain going
out to the driver side of the unit.
254
D
raining
4.
Vactor 2100
the
Remove the hand gun quick couplers/quick

disconnects from hand gun hose reel (if
equipped) and hand gun outlet at rear of
truck.
5.
Start truck engine and leave engine at idle.
6.
Using the instructions posted in the truck cab,

7.
Close the RODDER ball valve located on the

front hose reel and open the HAND GUN ball
valve.
8.
Place RODDER PUMP switch in the ON

position. Run until all water is expelled from
the hand gun system. Drain the handgun
before storage by walking the water out of the
hose while holding the valve open.
9.
Place RODDER PUMP switch in the OFF

position.
10.
Stand clear of all outlets and place RODDER

ball valve in the ON position and the
RODDER PUMP switch ON. Run until all
water is expelled from the rodder hose.
11.

position.
12.
Remove the rodder pump drain plugs or open

the drain ball valves (if equipped) and drain all
the water from the pump.
13.
Stand clear of all outlets and place RODDER

ball valve in the ON position.
14.

position.
15.
Run until all water is expelled from the rodder

pump.
16.

position.
17.
Using plastic ties, secure end of rodder hose

to adjacent wrap of hose on hose reel. Rodder
hose must be wound tightly and orderly on the
hose reel.
Water Tank
Water Tank Drain
Quick
Coupler
Hand Gun
Ball Valve
Hose
Reel
Hose Tied to
Adjacent Wrap

Maintenance
255
D
raining
Vactor 2100
the
18.
Ensure truck engine is at idle.
19.
While standing clear of rodder hose end,

place RODDER PUMP switch in the ON
position.
20.
After all water is expelled from rodder hose

and only air is discharged, place RODDER
PUMP switch in the OFF position.
21.
To discharge residual water from rodder

hose, rotate hose reel in a clockwise direction
(facing hose reel from front of truck) and
continue until all water is expelled.
22.
Place the HAND GUN and RODDER ball

valves in the ON position.
23.
Remove drain plugs from bottom of rodder

pump waterside, or open the optional remote
drain levers if so equipped.
24.

position.
25.
Operate rodder pump until all water and

debris is clear from drain plugs or remote
drains.
26.

position.
27.
Using instructions posted in cab, disengage

hydraulic pump.
28.
Remove three-inch plug located near right

rear wheel.
29.
Remove debris body washout drain plug and

open ball valves, if equipped.
30.
Store strainer cap, gasket, clamp, rodder

pump plugs, three-inch plug and quick
disconnects in toolbox.
31.
Open accumulator ball valve and remove

drain plug.
Rodder Pump Bottom

Water End
Drain Plug
Drain Plug
Optional Remote
Drain Valves

The unit is now ready for storage. On START-UP,
close rodder pump remote drain ball valves, place
either HAND GUN or RODDER ball valve in the
ON position, replace hand gun quick couplers/quick
disconnects and install screen, cap and clamp on Ystrainer, close water tank drains before filling water
tanks.
Maintenance
256
Vactor
Y-S
trainer
Maintenance
The Y strainer water filter is an important part of the

maintenance program to protect the water pump
from damage. The Y strainer comes in two different
sizes. Y strainers are normally either 2" or 3" and
may be an option depending on where it is located.
Each filter is inspected the same way and needs to
be inspected at least once a week and more often if
poor quality water is being used.
3" Y-strainer on water pump - Assembled
3" Y-strainer on water pump - Disassembled
2" Y-strainer at water fill - Assembled
2" Y-strainer at water fill - Disassembled
258
Vactor
Y-S
trainer
Maintenance
Remove the cap and the retainer from the filter

housing. Then remove the filter. Inspect the filter for
any damage. Replace any damaged filter. Inspect
the inside of the filter for any dirt, stones, grime, etc.
Be sure to clean any filter screen before reinstalling
the filter. NEVER reinstall a dirty or damaged filter.
Always inspect the filter cap prior to installation.
There are two gaskets on the filter cap. Both
gaskets must be intact and in place before installing
the filter cap. The outer gasket seals the cap to the
housing. Water will leak out if this gasket is not in
place.
The second gasket seals the cover to the filter
screen. If this gasket is missing, debris can bypass
the filter screen and get into the water tank and
eventually into the water pump causing damage to
the pump. Both gaskets must be intact and in place.
Replace any damaged or missing gasket.
Filter
Gaskets
259
Vactor
ewer Cleaning Hose Repair Instructions

S
Maintenance
Cut line
WARNING

WARNING
Loose hose/nozzle
of proper length.

fittings failing.

for details.
1800152
NOTICE OF LIABILITY DISCLAIMER

Vactor Mfg., Inc. neither manufactures nor assumes liability
for the High Pressure Rodding Hose. Vactor Mfg., Inc
does not guarantee this hose beyond the manufacturer's
warranties, which are printed on the hose. All hose liability
claims will be referred to the hose manufacturer.
The customer assumes any risk when using this hose. All
hose must be used in accordance with standard accepted
practices and replaced or repaired when damaged or worn.
260
6.375" wid
.125 corne
Vactor

S
Excerpts from WASTEC 2003 Guidelines for Sewer
Cleaning Hose Repair
Discard the damaged section of hose.

Inspect both of the hose ends very carefully as
follows:
High-pressure water is used in sewer cleaning

operations. The cleaning nozzle is connected to the
pump on the vehicle with a length of sewer cleaning
hose. Occasionally this hose may be damaged in
service. When damage occurs, the hose may be
repaired (mended). Hose, fittings, and assembly
equipment from various manufacturers differ
greatly and must NEVER be interchanged.
Consequently, each manufacturer color codes the
hose outer cover for operating pressure, and hose
inner tube, inspection gauges, fittings, and assembly
tooling for easy identification. The repairer shall
identify that all these items match the hose to be
repaired.
CAUTION: Proper inspection of the hose is critical.
WARNING: Failure to properly inspect, repair, or

test the hose assembly before being returned
to service can cause a failure of the hose.
Because of the high pressure generated, a
hose failure can occur, which may result in
damage to property, personal injury, or death.
The following instructions must be followed
explicitly.
Inspection after damage has occurred
Unreel the hose and disconnect the hose from both
the storage reel and the nozzle. Very carefully inspect
the hose for any of the following:

Hose burst;
Cover damage exposing the fabric reinforcing

braid;
Any areas containing a blister or bubble in the

outer cover;
Kinking or severe collapse of the hose (These

areas shall be repaired.); and,
Fittings cutting into hose at the edge of

connections (These areas also shall be
repaired.)
Determine the color of the hose inner liner.

Verify that the color is the same as the
inspection gauges, fittings, and assembly
tooling. If all these items are not the same
color, the hose end(s) shall not be mended until
the correct color-coded fittings, and assembly
tooling are obtained;
Check for any signs of entrapped water in

the fabric reinforcement layer. If any water is
present within the reinforcing layer, the hose
ends shall not be mended;
Check for any indication of separation of the

hose inner liner from the fabric reinforcement
or the fabric reinforcement from the outer layer.
The entire circumference shall be inspected. If
any separation of layers exist, the hose ends
shall not be mended; and,
With the manufacturers color-coded inspection

gauge provided, measure the wall thickness
around the entire circumference in accordance
with the manufacturers instructions. If any
portion of the wall thickness shows excessive
wear (as defined in the manufacturers
instructions), the hose ends shall not be
mended.
If the hose end(s) fail to meet any of the conditions

contained in sections a - d (above) the hose end(s)
shall not be mended. On any failed end, cut off an
additional four (4) to five (5) feet of hose. The failed
section of hose is to be discarded and the inspection
noted in sections a - d (above), is to be repeated on
the new end(s). If the hose fails to pass this second
inspection, the entire hose length shall be discarded.
Proceed with the assembly only if both ends of the
hose have been inspected and successfully met the
criteria of the section above.
Determine the total number of areas requiring repair,

plus the number of mender fittings all ready in the
hose. No mender shall be located within 50 feet of
the hose end or another mender.
Locate each area to be mended in a clear work area
to complete the repair.
Cut out the damaged areas of hose a distance of at
least 12 inches on each side of the damaged area.
Use the cutting tool recommended by the hose
manufacturer. The hose must be cut cleanly and
squarely.
Maintenance
261
Vactor

S
Assembly instructions
Sewer cleaning hose manufacturers color code the
hose inner liner, inspection gauges, fittings, and
assembly tooling for easy identification.
WARNING: Failure to identify and match the color
coding of hose, inspection gauges, fittings, and
assembly tooling to the specific manufacturer
may result in hose burst or fitting separation,
and could result in damage to property, personal
injury, or death. Follow the assembly instruction
provided by the specific manufacturer. Do not
use repair methods or equipment from any
other manufacturer.
TESTING: After completing the assembly operation,
the entire length of hose shall be pressure
tested as follows:

Position the hose so that the one end is

higher than the other. Completely remove
any entrapped air from the assembly by
filling with water and bleeding off all air
from the higher of the two end fittings;
Install a valve on one end which will

permit the slow relief of pressure. The
valve is to be compatible with the field
test pressure, as specified by WASTEC
standards
Connect the other end to a test pump

capable of pumping water at the field
test pressure as specified in WASTEC
standards
is present. The hose is unsafe for operation.

Immediately terminate the test. Isolate the damaged
area(s) and repeat the instructions for repairing of the
hose.
RETURN TO SERVICE: After successful completion
of the pressure test procedure, reconnect the
hose to the storage reel and return the mended
hose to service.
IN-SERVICE INSPECTIONS: Hoses in service should
be frequently inspected and monitored during
use for the following conditions:

Coupling movement at the hose fitting;
Damaged cover exposing the fabric

reinforcement;
Cover blisters or bubbles;
Hose kinking or severe flattening; and,
Mender fittings cutting into hose at the edge of

connections.
Replace the hose if any of these conditions are

present.
WARNING: A failure of the hose or fittings may occur

during pressure testing. The high pressures
involved pose a hazard that could cause
property damage, injury, or death. Locate
the hose in an area away from persons and
property, and stand clear of the hose when
pressure is applied;

Pressurize the hose at the field test

pressure for five (5) minutes;
Slowly bleed off pressure;
CAUTION: Make sure pressure is completely bled off

before proceeding
Inspect the hose assembly carefully for any of the
following:

Any signs of water leakage;
Any movement of the hose in the mender fitting;

and,
Any blisters or bulges in the cover.
If any of these conditions exist, additional damage

Maintenance
262
Vactor
R
odder Hose Inspection & Mending Instructions
Due to high pressure water used in sewer cleaning
operations, the rodder hose may incur damage,
which must be repaired. The following inspection,
repair and test procedures must be followed exactly.
! DANGER
Failure to properly inspect, repair and test the
rodder hose assembly before each use may
result in hose failure. Due to high pressure
generated during use, hose failure may cause
serious personal injury or death and/or damage
to the vehicle.
Inspection
It is the operators responsibility to frequently inspect
hoses for the following conditions:

Loose hose fittings
Damaged outer hose coverings exposing

fabric reinforcements
Blisters of bubbles in the hose cover
Kinking or collapse of hose
Fittings cutting into the hose
! DANGER
Damaged hose that is not inspected or repaired
can result in hose burst or coupling blow-off
that could result in serious injury, death or
property damage.
Inspect the rodder hose for the following conditions:
Proper inspection of the hose is critical. If any

of the listed hose end conditions are present, do
not mend the hose ends.
Unreel the rodder hose and disconnect from the

hose reel and nozzle. Inspect for any of the above
conditions. Any damaged areas must be repaired or
replaced.
1.
Determine the number of repairs needed plus

the number of mending repair fittings already
in the hose. Repair fittings must not be
located within 50 feet of another repair or the
end of the hose.
2.
Use a sharp knife or bench mounted cutting

tool to remove at least 12 inches from each
side of the damaged area. The hose must be
cut square.
3.
Carefully inspect the remaining hose ends for

any of the conditions shown here.
4.
Do not repair any unsatisfactory hose end.

Cut off an additional four to five feet of hose
and inspect the ends. If the hose fails a
second inspection, discard the entire length.
5.
If both hose ends are satisfactory, proceed to

the MENDING AND REPAIR section.
Maintenance
Hose Burst
Blisters Or Bubbles
Cover Damage
Hose crimping information provided by:

Eaton, Aeroquip Corporation. Reference their
document no. JA67D
Kinking Or Collapse
263
Vactor
R
Maintenance
NOTICE
! DANGER
A ruptured hose can result in severe personal
injury or death and property damage. To reduce
or eliminate the danger of a rupture, use only
fittings, gauges, hoses and tools with matching
color codes. Use only fittings that have pressure
ratings equal to or higher than the hose
requirements.
Always use matching color coded hose and

tools when swaging rodder hose.
Complete all mending, testing and inspection

procedures thoroughly before proceeding,
failure to do so may lead to hose or coupling
rupture, which can result in serious personal
injury or death and possible property damage.
a.
The color of the inner liner, inspection

gauges, fittings and assembly tooling must
be the same. If any item color does not
match, do not repair the hose.
b.
If there is any water present in the

reinforcement layer, do not repair the hose
using that hose end.
c.
If there is any sign of separation of the

tube from the fabric reinforcement or the
reinforcement from the outer cover, do not
repair the hose using that hose end.
d.
Using the inspection gauge, measure the

entire circumference of the hose end. If
any portion of the hose has excessive
wear or incorrect wall thickness, do not
repair the hose using the hose end.
Each manufacturer of hose, liners, fittings,

gauges, tooling and assembly equipment
has its own coloring coding system, which is
not compatible or interchangeable with other
systems.
264
Vactor
R
Maintenance
Mending and Repair

The following instructions are for swaging male pipe
couplings or splicers to Vactor rodder hose using
Part Number 44159 Swage assembly tools and
dies.
1.
Lubricate the die cavities
2.
Male Pipe Application: Lubricate the inside of

both die halves.
Splicer application: Lubricate the inside of all

four dies halves.
Swage Kit
Lubricate Die Cavities
Lubricate Inside Dies
265
Vactor
R
3.
Male Pipe Application: Place one die half into

one holder and place the pusher into the other
die holder.
Splicer Application: Place one die half into

each die holder.
4.
Male Pipe Application: As a reference for hose

length to be inserted, use a grease pen or
pencil to mark a line (approx. 1-11/16" for 1"
hose or 1-9/16" for hose) from each end of
hose.
Splicer Application: Same as above.
5.
Male Pipe Application: Insert hose into coupler

to reference line. If steps have been followed
correctly, hose will be completely inside
coupler. With the male pipe end in the pusher,
insert entire assembly into swager.
Maintenance
Die Half Installation
Splicer Application: Insert hose end into

splicer reference line. If steps have been
followed correctly, hose will be completely
inside splicer. Place assembly into swager
through top slots.
Marking Hose
Inserting Hose
266
Vactor
R
6.
Male Pipe Application: Place remaining die

half into holder over hose end.
Splicer Application: Place both remaining die

halves into holders over hose.
7.
Male Pipe Application: To secure die and

pusher, insert and tighten both cross bolts.
Splicer Application: To secure dies, insert and

tighten both cross bolts.
8.
Male Pipe Application: Do not use yoke.

Tighten draw bolts alternately and uniformly.
Splicer Application: Insert yoke into center

groove of splicer. Keep fitting centered while
tightening draw bolts uniformly and alternately.
9.
Male Pipe Application: Swaging process is

complete when pusher comes into contact
with yoke plate.
Splicer Application: Swaging process is

complete when contacts yoke plate.
10.
Male Pipe Application: Remove cross bolts.

Loosen draw bolts. Pry die holders apart.
Splicer Application: Same as above.
Maintenance
Installing Die Over Hose
Tighten Cross Bolts
Yoke (mender
fitting only)
Swaging Fitting
Swage Complete
267
S
wager Application Specifications
Vactor
When the swaging assembly is complete, use the

following chart to check the coupling for proper
Length X and Diameter.
! DANGER
To avoid injury, death or damage from a rupture
during pressure test, place the hose in an area
clear of all personnel and equipment.
Testing
After completing the assembly, pressure test the entire
hose.
1.
Completely bleed off pressure on hose before

proceeding.
On one end, install a block and bleed valve

compatible with the pressure rating of the hose.
2.
Remove all air from the hose as follows:
Raise open end of hose and fill with water
Operate bleed valve until all air has

escaped and only water is being released
Ensure hose is completely full of water
3.
Connect open end of hose to a test pump

capable of supplying water pressure at the
maximum pressure rating of the hose.
4.
Apply maximum pressure to the hose for at

least five minutes
5.
Bleed off pressure on hose.
6.
Inspect hose carefully for any of the following

conditions:
Water leakage
Loose hose fittings
Blisters or bulges under cover
Maintenance
If any of the listed conditions are present, the

hose is not safe. Repair or replace the damaged
areas or replace the entire hose assembly.
When hose has successfully completed the pressure

test, it is safe to use. Connect and wind hose on hose
reel.
Length and Diameter
HOSE TYPE
MALE PIPE
MENDER
DIES*
PUSHER
LENGTH X- MIN.
DIAMETER+/- .015
"
45268A
45267A
45269
45270
1.109"
1.172"
1"
43605
46142
44172
44174
1.156"
1.445"
1 "
44107
44153
44173
44175
Rodder hose field test pressure

Field Test Pressure = (Rated Max. Operating Pressure) + (25% (.25) Rate Max. Operating Pressure)

Rated Max. Operating Pressure
Field Test Pressure
2000
2500
3000
5000
2500
3125
3750
6250
268
P
iranha Hose
Vactor
Maintenance
FIELD REPAIR PROCEDURE FOR PIRANHA

ARMOR-BEACON SEWER CLEANING
HOSE
269
270
3. NEVER APPLY PRESSURE

TO A DAMAGED HOSE
2. NEVER EXCEED THE

MAXIMUM WORKING
TEMPERATURE
1. NEVER EXCEED THE

MAXIMUM WORKING
PRESSURE
HOSE BASICS
DANGER
4. HIGH PRESSURE HOSES

ARE DESIGNED TO USE
SPECIFIC FITTINGS AND
TOOLING. NEVER USE A
DIFFERENT BRAND OF
FITTINGS OR TOOLING.
FAILURE TO DO SO CAN
CAUSE DEATH, PERSONAL
INJURY AND PROPERTY
DAMAGE.
(See reverse side for excerpts from the 2003 WASTEC guidelines)
5. A KINKED, CRUSHED,
OR BLISTERED HOSE
WILL EVENTUALLY FAIL DO NOT RISK INJURY.
IMMEDIATELY REPAIR OR
REMOVE HOSE FROM
SERVICE
THE AGE OF THE HOSE DOES NOT

MATTER! IT IS UNFORTUNATE, BUT EVEN
HOSE USED (1) TIME CAN BE DAMAGED
IN SEVERE APPLICATIONS. THESE
HOSES MUST BE IMMEDIATELY
REMOVED FROM SERVICE.
LIKE STRANDS IN A BRIDGE CABLE, EACH

REINFORCEMENT FIBER PLAYS AN
EXACT ROLE IN THE ULTIMATE BURST
STRENGTH OF THE HOSE. A MINOR
SLICE OR NICK IN THE REINFORCEMENT
CAN RESULT IN TOTAL HOSE FAILURE.
HOSE AFTER EXPOSING WHITE BRAID REINFORCEMENT LAYER CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
IF YOU SEE IT - STOP IT: FAILURE TO PROPERLY REPAIR OR REPLACE
WARNING!
P
iranha Hose
Vactor
Maintenance
P
iranha Hose
Vactor
Maintenance
FIELD REPAIR PROCEDURE FOR PIRANHA ARMOR-BEACON SEWER

CLEANING HOSE
STEP 1
CUT ENDS OF HOSE SQUARELY.
STEP 2
LOCATE FLAT BRAIDED WIRE
BETWEEN YELLOW INNERCORE
AND WHITE BRAID
STEP 3
MARK A WIDE BY .875 LONG
RECTANGULAR AREA DIRECTLY
OVER THE FLAT BRAIDED WIRE.
STEP 4
CAREFULLY CUT THE
RECTANGULAR AREA OF THE
OUTER JACKET.
STEP 5
CAREFULLY REMOVE THE OUTER
JACKET.
STEP 6
CAREFULLY CUT WHITE BRAID IN
THE HORIZONTAL DIRECTION ONLY.
TAKING EXTREME CAUTION NOT TO
CUT THE YELLOW INNERCORE OR
FLAT BRAID WIRE.
REV B 12/02/04
Page 2 of 3
271
P
iranha Hose
Vactor
Maintenance
FIELD REPAIR PROCEDURE FOR PIRANHA ARMOR-BEACON SEWER

CLEANING HOSE
STEP 7
REMOVE LOOSE FIBERS FROM CUT
AREA TO ALLOW ACCESS TO FLAT
BRAID WIRE.
STEP 8
CAREFULLY FOLD BACK FLAT BRAID
WIRE ONTO HOSE JACKET. THE
DISTANCE FROM THE END ON THE
HOSE TO THE END OF THE WIRE
SHOULD BE 1.375.
STEP 9
CAREFULLY SLIDE PROPER FITTING
ONTO HOSE TO THE PROPER
INSERTION DEPTH. DO NOT TWIST
FITTING DURING INSTALLATION.
STEP 10
USING APPROVED PIRANHA ARMOR
BELT SWAGE DIE AND PUSHER,
SWAGE THE FITTING.
STEP 11
WITH A MULTIMETER, CHECK
RESISTANCE BETWEEN HOSE END
FITTINGS. VALUE MUST BE LOWER
THAN .02 MULTIPLIED BY THE
LENGTH OF HOSE IN FEET. (ex .02
x 600ft = 12 Ohms)
REV B 12/02/04
Page 3 of 3
272
Vactor
S
hark Hose
273
Maintenance
Vactor
S
hark Hose
274
Maintenance
Vactor
S
hark Hose
275
Maintenance
Vactor
S
hark Hose
276
Maintenance
Vactor
S
hark Hose
277
Maintenance
Vactor
S
hark Hose
278
Maintenance
Vactor
S
hark Hose
279
Maintenance
Vactor
S
hark Hose
280
Maintenance
Vactor
S
hark Hose
281
Maintenance
Vactor
S
hark Hose
282
Maintenance
Vactor
S
hark Hose
283
Maintenance
Vactor
S
hark Hose
284
Maintenance
Vactor
S
hark Hose
285
Maintenance
Vactor
S
hark Hose
286
Maintenance
Vactor
S
hark Hose
287
Maintenance
Vactor
S
hark Hose
288
Maintenance
Vactor
S
hark Hose
289
Maintenance
Vactor
S
hark Hose
290
Maintenance
Vactor
S
hark Hose
291
Maintenance
Vactor
S
hark Hose
292
Maintenance
eference - Bolt Torque

R
Vactor
294
Maintenance
Troubleshooting
Troubleshooting
an - Cotta Gear Box
F
Vactor 2100 Fan
Troubleshooting
Excessive Heat
Excess oil actually leads to oil loss by causing
excessive heat, which hardens the seals and results
in oil leaks.
Normal operating temperature ranges from 140 (F)
to 225. If temperature exceeds 225, proceed as
follows:
1.
Check oil level and if it is high, low or dirty:
a.
Drain oil thru a filter.
b.
Check the filter for debris from failing

bearings or gears.
c.
If there is debris, rebuild or contact Vactor

Manufacturing.
2.
Check seals for leaks and replace if necessary

as follows:
a.
Lubricate seal lip with oil.
b.
Avoid cutting seal lip on shaft during

installation.
Cotta
Gear
Box
Debris In Oil
Debris in oil drained from gear box indicates gear
and/or bearing failure. Rebuild the gear box or contact
Vactor Manufacturing.
Discolored Paint At Bearing Housing
Paint discoloration at the bearing housing indicates
bearing failure.
Silvery Paste On Drain Plug
Normal use causes minute particles that are attracted
to and collect on the magnetic drain plug and form a
silvery paste.
Increased Noise Level
If the noise level suddenly increases check the
following:
1.
Check gear box mounting, drive lines and shift

control linkages for loose connections, which
vibrate and cause noise.
2.
Check condition of fan, which can transmit

vibration thru drive line to gear box if
unbalanced.
3.
Drain, filter and check oil for debris, which

indicates gear and/or bearing failure.
300
Vactor 2100
ump - Directional Valve Is Not Shifting

P
The full flow relief valve located on the boom pole
weldment, below the hydraulic reservoir, supplies
pressure needed to shift the main spool of the
directional valve. If the directional valve is not shifting,
check the pilot pressure. See Section entitled Pump
Pilot Pressure Too Low.
Troubleshooting
1.
Clean the intake screen. If the screen has a

build-up of rust or is damaged replace it. Open
the ball valve and check for water flow from the
water tanks.
2.
Remove the intake manifold and inspect the

intake valves. One of the valves may be stuck
or has a slipped spring. Replace the valve
assembly if worn or damaged.
Correct Pressure On Only One Stroke

The rodder pump system includes two check valves
located between the water intake manifold and the
pump. A piece of dirt or scale can cause a check valve
to stick open.
Exhaust check
valves
Intake check
valves
Rodder pump system
302
ater System - Rodder Pump

W
Vactor 2100
Troubleshooting
Pump fails during full stroke
Pump cycles but no water at nozzle.
Pressure drops off and pump fails to pump water

during the full stroke. This restriction prevents water
from being drawn into the pump on the fill cycle.
The pump is cycling; however, it is failing to deliver

water to the nozzle. The intake screen is clean and
everything else is functioning properly
If water pressure drops and the pump fails during full

stroke, remove the intake screen. Clean the screen or
replace if the screen is rusted, damaged or worn.
1.
Examine the exhaust check valves. This would

suggest a damaged or broken exhaust check
valve located under the exhaust manifold.
Pump works during one stroke, but not both
2.
Pump fails to deliver water on both cycles; however it

does deliver water on one stroke.
Examine intake check valves for damage or

sticking. Replace if damaged.
3.
Check for worn seals on the water piston or

even a broken piston.
1.
Remove the intake screen and clean if dirty or

replace if rusted.
Pump fails to cycle.
2.
If still not working properly, open valve to check

water flow from tank:
When the pump fails to cycle, you will need a 12-volt

power supply and multimeter to check the following:
a.
Remove the intake manifold which

supplies water to the pump.
1.
Make sure the hydraulic pump is engaged

properly.
b.
Examine both intake check valves for

broken springs or debris causing valves
to stick in open position. Clean, repair or
replace.
2.
Check the fuse in the fuse panel on the side of

the control panel.
3.
Check the rodder pump switch on the hose

reel control panel to be sure it is ON and
functioning.
4.
Check the rodder pump relay in the control

panel on the hose reel.
Intake screen
303

W
Vactor 2100
Control panel.
Troubleshooting
Note: Open the junction box panel cover to reach the

relay.
Note: This test is done with the rodder pump switch

in the OFF position. The hydraulic system must
be engaged.
5.
Check to see if there is moisture in the rodder

pump relay in the electrical control box.
a.
Remove the relay to check for moisture

in relay or relay base.
b.
Dispel any moisture in relay base.
c.
Replace relay if moisture is inside the

relay case.
6.
If there is no moisture in the rodder pump relay,

test the relay as follows:
a.
c.
Using the screwdriver, push the solenoid

plunger from the opposite direction.
Rodder pump should shift back and stop.
CAUTION
Do Not use a test light when troubleshooting.
Severe damage to the electrical system can be
caused by a test light.
Using a 12-volt power supply, apply

negative to A and positive to B.
Relay diagram
Rodder pump solenoid

Plunger
This diagram refers to the pins at the bottom of the

relay.

b.
Using a multimeter, check for continuity

between terminals 4 & 7 and 6 & 9.
c.
If either circuit shows open, replace the

relay.
d.
If continuity checks are all right, connect

negative to terminal 5 and positive to
terminal 8.
e.
Using a multimeter, check for continuity

between terminals 1 and 7 and 3 and 9.
f.
If continuity checks good, install relay and

engage rodder pump. If either continuity
test fails, replace relay.
g.
If all continuity checks are good, reinstall

the relay and retry to operate the rodder
pump.
7.
If the rodder pump still wont work, proceed as

follows:
a.
Raise debris body and install safety prop.
b.
Use a screwdriver or punch to depress

the rodder pump solenoid plunger in the
center of the solenoid valve. When the
plunger is pushed in, the rodder pump
should activate one stroke and stop.
Vickers valve
Relay
! WARNING
Never work in, under or near raised debris body
without correctly installed safety prop. Failure to
do so may result in serious injury or death.
304

W
Vactor 2100
Troubleshooting
Proximity sensor test

If the relay is all right, but the pump still does not
shift, test the proximity sensor. To test the sensor, you
will need a multimeter.
Note: Always check the fuse to the rodder system
and the rodder ON-OFF toggle switch for power
before you start.
Note: A helper will be needed for steps from
Numbers 8 through 11.
Proximity Sensor
1.
Unscrew electrical connector from the sensor.
2.
Remove the proximity sensor from the water

pump.
3.
Reconnect the electrical connector.
4.
Turn the chassis ignition key on (engine not

running.)
5.
Turn the rodder pump switch to the ON

position.
6.
As a helper passes a piece of metal under

the sensor, watch the dual latching relay in
the electrical control panel for back and forth
movement.
8.
If the relay is all right, but the pump still does

not work, check the rodder pump sensor:
a.
Disconnect the electrical connector from

the sensor at the end of the rodder pump
shown below. Remove the sensor from
the end of the rodder pump.
8.
b.
Reconnect the electrical connector to the

sensor. With the electrical power ON and
the hydraulic power OFF, pass the sensor
across a metal object.
If the latching relay does not trip back-andforth, remove relay from control panel.
9.
Observe LED (light emitting diode) on the

sensor. The light should come on as the
sensor passes the metal object and go
off when moving away.
Using a multimeter, check the wire on terminal

B of the relay base. This wire should be
powered when there is no metal under the
sensor.
10.
The power should shift to the wire on

terminal No. 8 of the relay base when metal is
put under the sensor and the LED is ON.
11.
If the above checks are all right, the proximity

sensor circuit is working properly.
c.
d.
If the light stays on or stays off during

step (c), replace sensor.
e.
Reinstall if the sensor is good.
CAUTION
Use extreme care when installing the sensor.
Improper installation can cause damage to the
sensor or the sensing rod or both. Be sure the
sensing rod piston is in front of the sensor.
Screw the sensor in until it bottoms against the
piston, then back it out three turns. Hold the
sensor in this position and tighten the jam nuts.
B
8
305

W
Vactor 2100
Proximity sensor circuit (electrical) test.
Pump wont shift when manually operating

solenoid valve.
To test the proximity sensor circuit, a person will need

a 12-volt test light, 12-volt power source, proximity
connector (part No. 45906) and a 20-gauge, 4-wire
cable (part No. 45907).
1.
The proximity connector has four terminals.

Connect the wires as follows:
Terminal No. 1 red wire
Terminal No. 2 white wire
Terminal No. 3 green wire
Terminal No. 4 black wire
2.
Connect the test proximity connector to the

proximity sensor to be tested.
a.
Connect the red wire to the 12-volt power

source.
b.
Connect the green wire to a good ground.
3.
Pass a metal object under the proximity sensor.

Connect the test light to the white wire, then
to the black wire. Power should shift back and
forth between the white and black wires as the
metal object is removed and inserted under the
sensor. Do this a couple of times to be sure
of the operation. If this occurs, the sensor is
working properly.
Troubleshooting
If the pump does not shift when the rodder pump

solenoid is manually operated, check the spool
inside the main control valve:
1.
Shut down the hydraulics and electrical power.
2.
Remove the four Allen-head bolts holding the

end cap on the main control valve directly
below the solenoid valve checked above.
3.
Check to make sure spool moves freely inside

valve.
4.
If the spool does not move freely, remove and

polish with a fine emery cloth.
5.
Reinstall spool, end cap and Allen bolts.

Tighten Allen bolts to general torque
specification.
Note: the LED should be on when the black wire

has power and be off when the white wire has
power.
4.
If after all of the above checks are completed

and the rodder pump still wont operate, do the
following:
a.
Locate the main solenoid control valve.
b.
Turn the rodder pump switch OFF and

leave the hydraulics engaged.
c.
Using a small punch or screwdriver,

depress the center portion of the solenoid
valve.
5.
Rodder pump solenoid
Do one side. When the plunger is held

in, the rodder pump should activate one
stroke and stop.
Plunger
Do the same thing on the other side of

the solenoid valve. The pump should shift
back the other way and stop.
Pilot pressure
test port
If the pump can be shifted manually, as

described, check the wiring between the relay
and the solenoid valve and check the individual
solenoids. Replace wiring and defective
solenoid valve or both.
Vickers valve
306
End
cap

W
Vactor 2100
Directional valve is not shifting.
Main directional valve is shifting, but rodder

pump wont function.
The hydraulic pilot pressure to shift the directional

valve is controlled by the pressure-reducing
valve located between the solenoid valve and the
directional valve.
The problem is internally in the rodder pump, broken

shaft, bad seals, etc., when the main directional valve
is shifting but the rodder pump still will not function.
Remove the rodder pump and disassemble.
This pressure-reducing valve might require

readjustment.
1.
Engage the hydraulics and turn ON the rodder

pump switch.
2.
Loosen the jam nut on the adjusting shaft

sticking out of the pressure-reducing valve.
3.
Screw the shaft in (clockwise) until the pump

starts to operate.
4.
Then turn the adjusting screw one full turn and

tighten the jam nut.
5.
If adjusting the pressure-reducing valve does

not work, replace it.
Troubleshooting
Correct pressure on only one stroke.

The rodder pump pressure is correct on one stroke,
but there is no or very little pressure on the other
stroke. One of the two intake check valves is stuck
open.
307
1.
Clean the intake screen. If the screen has

a build- up of rust or is damaged, replace it.
Open the ball valve and check for water flow
from the water tanks.
2.
Remove the intake manifold and inspect the

intake valves. One of the valves may be stuck
or has a slipped spring. Replace the valve
assembly if worn or damaged.

W
Vactor 2100
Troubleshooting
! WARNING
Do not increase hand gun pressure above 600
PSI. Damage to the system or injury may occur.
Correct pressure except when using handgun.
If the rodder pump pressure is correct, but there is
no pressure when using the handgun, check the ball
valves as follows:
1.
Check for proper position. Make sure rodder

hose ball valve on the front hose reel is OFF.
2.
Make sure handgun ball valve is ON. Having

both ball valves open (ON) at the same time
will reduce the amount of water available to the
handgun, because water is being directed in
two different directions. The correct ball valve
configuration is shown below.
3.
Hand Gun Ball Valve
Rodder Pump
Ball Valve
If handgun pressure is too low, the pressure

relief valve may be out of adjustment. Loosen
the locking jam nut and turn the T handle
clockwise (in.) Adjust the pressure to 600 PSI.
Replace any valve that cannot adjust to 600
PSI.
Insufficient water volume and pressure at nozzle.

If everything else works, but there is insufficient water
volume and pressure at the nozzle when rodding,
make the following checks:
1.
Make sure handgun ball valve is turned OFF to

maintain nozzle pressure.
2.
The nozzle being used is worn out or is sized

incorrectly for this particular unit. Check nozzle
being used for excessive wear or try a different
(known to be good) nozzle. See nozzle orifice
chart for proper sizing and flows.
3.
The rodder hose may be twisted or damaged,

restricting or losing water. Unwind the hose,
straighten or repair as necessary.
4.
Check the position of the ball valves. Handgun

ball valve must be closed (OFF) in order to
maintain pressure at the rodder nozzle.
5.
Check for leakage through the handgun

ball valve. Disconnect the quick-disconnect
coupling for the handgun hose. Be sure the
ball valve is in the closed (OFF) position. There
should be no water leaking out of the coupler
connection. If there is any water leaking out of
the quick coupler connection or leaking through
the ball valve, repair or replace the ball valve.
Hand Gun
Relief Valve
308

W
Vactor 2100
Troubleshooting
Pump pilot pressure too low

The full-flow relief valve (See photo at right) on the
boom pole weldment, below the hydraulic reservoir,
supplies pressure needed to shift the main spool of
the directional valve. If the directional valve is not
shifting, check the pilot pressure as follows:
1.
Shut down chassis engine and remove keys.
2.
Remove the rubber dust cover from the quick-

disconnect port on the Vickers valve.
3.
Install a 600-PSI gauge.
4.
Set chassis engine at idle and engage

hydraulic pump using the instructions in the
cab.
5.
Check pressure, which should be at least 130

PSI.
DO8 valve
Set pilot
pressure
here
DO8 valve
Note: Minimum pressure needed to shift valve is 100

PSI. Some systems have pressure of more
than 130 PSI.
6.
Adjust pressure by loosening lock nut and

tightening the adjusting bolt.
7.
Disengage hydraulic pump and shut down

truck engine.
8.
Remove gauge and reinstall dust cover.
Engine stalls when pump is turned on.

Several things can cause the engine to stall out when
the rodder pump toggle switch is turned on.
1.
2.
All ball valves are closed (OFF) causing the

rodder pump to deadhead. Turn one ball
valve ON.
D10 valve
The sensor may be defective or the sensor

wiring is bad. The rodder pump is at the end
of the stroke and is not being shifted. (See
Pump Fails to Cycle for proper trouble
shooting of the sensor.)
3.
The relay may be defective or the wiring

between the relay and the solenoid valve is
bad. The rodder pump is at the end of the
stroke and is not being shifted. (See Pump
Fails to Cycle for proper trouble shooting of
the relay.)
4.
The solenoid valve may be defective. The

rodder pump is at the end of the stroke and is
not being shifted. (See Pump Fails to Cycle
for proper trouble shooting of the solenoid
valve.)
D10 valve
- pilot
pressure
is set
remotely.
The valve
is normally
right behind
the debris
body
controls.
309
Vactor 2100
ydraulic System - Hoist

H
Many hydraulic system problems are due to low or

wrong hydraulic oil. Before investing too much time
and effort into troubleshooting, always check the
hydraulic oil level and the hydraulic oil specifications.
See the Maintenance Section of this manual for
hydraulic oil service and specifications.
Hoist
The hoist includes the hydraulic pump, hoist control
valve and debris body / boom lift cylinders.
Noisy hydraulic pump.
Note: Insufficient oil supply in the reservoir will
starve the pump and cause it to deliver charges of
air instead of oil when hoist is in the extreme raised
position.
Manual Hydraulic Operation.

In the event of an electrical failure or other system
failure, a manually operated hydraulic pump is
provided to lower the boom and retract any available
options. The hydraulic solenoid valves on the side
of the boom have push-type releases to operate the
hydraulic system manually. (See photo below.)
The primary causes of pump noise are a lack of

hydraulic oil known as starving the pump, or
operating in extremely cold temperatures. Check the
hydraulic oil level daily before operating. In extremely
cold weather, allow the unit to warm up completely
and slowly operate the hydraulic controls until the
hydraulic oil has warmed. See the Maintenance
Section for information on hydraulic oil level and
specifications.
Note: To operate a particular hydraulic component,

such as the boom, press and hold the button on the
end of the solenoid and pump the pump handle.
1.
Boom
In/Out
Boom
Up/Down
Boom
Left/Right
Troubleshooting
Check hydraulic oil reservoir level and service

as needed.
Note: Raising the hoist at a higher speed than

necessary may also starve the pump, which
will reduce hoisting speed and result in damage
to the unit.
Hand Pump
2.
Hose Reel
In/Out
Keep the truck engine speed at a moderate

level when using the hydraulic controls.
Extreme temperatures effects pump efficiency.

1.
During hot weather, the oil may become thin

and cause the hoist to be slow in raising
because the pump efficiency is reduced by the
thin oil.
2.
During cold weather, the oil may become thick

and cause the hoist to be slow in raising. Thick
oil will also retard the descent. Pump efficiency
is reduced because the oil is unable to flow
readily enough to supply the pump. This is
another case of starving the pump.
3.
Be sure to have the right viscosity oil for your

operating conditions. (See suggested oils in the
Maintenance section.)
Solenoid
Stack Valve
Hydraulic valve solenoid bank
Solenoid
Release
Lift cylinder creeping down or drifting.

The terms creeping down and drifting refer to the
hydraulic cylinder dropping slowly during operation.
The primary cause of this is a loss of hydraulic
pressure, either internally or due to leaks in the
system.
1.
310
Visually check for oil leaks at the following

points:
ydraulic System - Hoist

H

Cylinder sleeve packing
Hoses and connections
Tubing and connections
Pipe fittings
Pump mounting base
Vactor 2100
! WARNING
Always disengage the hydraulic pump, using

the instructions posted in the cab and shut
down the truck engine, before loosening or
disconnecting any hydraulic components.
Serious injury can occur if this warning is
ignored.
Note: A small particle of dirt between the ball and

seat of check valves and control spools can
result in pressure loss and damage to internal
parts. See the Maintenance Section for
information on hydraulic system service.
2.
CAUTION
Examine for debris in the check valves by

operating the hoist several times to dislodge
and pass the debris to the filter.
A small particle of dirt between the ball and seat

of check valves and control spools can result
in pressure loss and damage to internal parts.
See the Maintenance Section for information on
hydraulic system service.
Drifting can also be caused by hydraulic oil bypassing

internally and causing a lack of pressure at the
cylinder. Wear and damage can cause bypassing
around cylinder packing, control valve seals / spools
and actuating solenoid. If drifting continues after
checking for leaks and debris in the system, check
the system for bypassing.
Insufficient oil supply in the reservoir will

"starve the pump" and cause it to deliver
charges of air instead of oil when hoist is in the
extreme raised position.
Raising the hoist at a higher speed than
necessary may also "starve the pump," which
will actually reduce hoisting speed and result in
damage to the unit.
Poor hoist performance.

Air in the lift cylinder can cause many problems
including:

Failure to lift
Jerky hoist operation
Lift cylinder wont raise to full extension
Lift cylinder drops several inches when lowered
Note: Bleeding air from the lift cylinder can result in

a discharge of hydraulic oil from the cylinder.
Make sure the vehicle is in an appropriate area
for cleanup. Make sure surrounding personnel
are aware of the procedure.
Check the hydraulic reservoir oil level daily before
use. If air enters the hydraulic system, add oil to the
reservoir if needed and operate the hoist several
times. If necessary, raise the lift cylinder slightly and
loosen the manual bleeder valve on top of the debris
body lift cylinder. This will allow air to escape. When
the air is displaced, close the bleeder and lower the
cylinder. Check the hydraulic reservoir level.
Troubleshooting
311
ydraulic System - Boom

H
Vactor 2100
Troubleshooting
Nothing happens when control button Is pushed.

Pendant
The boom is controlled using the pendant control. If
nothing happens when a control button is pushed,
check the following:
1.
Check the circuit breaker in the electrical

control box.
2.
Using a multimeter, check for 12-volt at the

solenoid lead when the button is pressed. If
power is available at the lead, check for a bad
solenoid winding or corroded core.
3.
If power is not available at the lead, disconnect

the pendant control from the receptacle. Using
a multimeter, check for 12-volt pendant input at
the receptacle. If 12-volt is not available, check
for 12-volt at circuit breaker.
4.
If 12-volt is available at the receptacle, check

the pendant control for continuity between
the power input socket and the button output
sockets. If continuity is not available, check the
pendant control.
Pendant
Note: Diesel-powered units have a flow control valve

between the hydraulic pump and solenoid stack
valve. This valve controls the flow of hydraulic oil
to the solenoid stack valve. The valve includes a
spring and spool that can stick, blocking the flow of
hydraulic oil to the stack valve. The spool is between
two plugs in the valve body.
Boom doesnt stop when button is released.
A spool in the solenoid stack can stick, allowing
hydraulic oil to bypass the continued operating of the
boom. Check the operation of each solenoid spool.
1.
Press the solenoid release button on the

bottom of each solenoid.
2.
A sticking spool or broken spring can prevent

the spool from centering. If the spool continues
to stick, follow this procedure:
a.
Disengage the hydraulic pump
b.
Shut down the truck engine and remove

the ignition keys.
c.
Disassemble the solenoid and spool

assembly; repair or replace as necessary.
Control box behind cab
! WARNING
Always disengage the hydraulic pump, using the
instructions in the cab and shut down the truck
engine before loosening or disconnecting any
hydraulic components.
Boom fails to raise when up button is pushed.

1.
2.
Check operation of pendant control buttons.

See troubleshooting fault Nothing Happens
When Control Button Is Pushed.
Always vent residual pressure from the

hydraulic system before disconnecting any
hydraulic components. Serious injury can occur.
Check for proper hydraulic oil level. See

the Maintenance Section for information on
312
ydraulic System - Boom

H
Vactor 2100
hydraulic oil service and specifications.

3.
Check the hydraulic pump as follows:
a.
Insert a pressure gauge in the line

between pump and solenoid valve.
b.
When solenoid is actuated, check the

operating pressure, which should be
1275 PSI.
c.
4.
Check the suction tube to see if it is loaded

with mud or debris, which is causing excessive
weight. Clean as needed.
Troubleshooting
! CAUTION
In an emergency, press the pendant power
button to turn OFF the pendant.
Debris Leaks From Seal Between Inner and Outer

Tubes
If hydraulic pressure is below 1000 PSI,

replace pump.
Debris will leak from the seal between inner and outer
boom tubes while vacuuming when excess debris has
accumulated between the tubes. Debris will leak from
the seal after shut down when the vacuum system
has been shut down with debris still in tube. To clean
tube, follow one or more of these steps as needed:
Boom only raises part way.
1.
Raise boom, and allow vacuum to clear tube of

all debris.
2.
If leak does not stop:
Boom wont lower.
a.
If the boom fails to lower from the raised position,

follow this procedure:
Extend and retract boom while washing

seal area with handgun.
b.
Repeat step 1.
1.
3.
If leak still does not stop:
a.
Clean area between inner and outer

boom.
b.
Repeat step 1.
4.
If leaks continue, disassemble the boom and

check for debris, damage and wear.
Check hydraulic oil level in the hydraulic reservoir.

See the Maintenance Section for hydraulic oil service
and specifications.
2.
Increase the engine speed to 1,500 RPM to

increase oil flow and pressure.
Depress solenoid release button to be sure
spool is in the down position.
If the solenoid is centered and goes in the down

position, check the control buttons using the fault
Nothing Happens When Control Button Is Pushed.
Debris Leak From Bottom Of Inner Tube
Hydraulic squeal.
If the hydraulic system squeals when the raise button
is pushed, check the following:
Excess debris can corrode holes in bottom of tube.

Check bottom of inner tube for holes. Replace if
necessary.
1.
Check the suction tube for overload of debris

build-up causing by-pass of relief valve.
Debris Hose And Tube Wear Out Quickly
2.
Check the hydraulic:
a.
b.
Highly abrasive debris will damage inside of hoses

and tubes. To reduce wear and tear from abrasive
debris, take these corrective measures:
Insert a pressure gauge in the line

between pump and solenoid valve.
1.
When solenoid is actuated, check the

operating pressure, which should be
1,275 PSI.
Add more water to debris by using a water ring

or handgun.
2.
Reduce engine RPM, which reduces airflow and

abrasion from debris.
If the hydraulic pressure is below 1,000

PSI, replace the pump.
3.
Work more often from the front of the truck

rather than working from the sides, which
creates an "elbow" and more wear.
4.
Rotate the boom hose(s) 90.
c.
3.
Check hydraulic oil level. See the Maintenance

Section for information on hydraulic oil service
and specifications.
313
ower Distribution Board

P
Vactor
Troubleshooting
The power distribution board is used in a variety of models to control system functions. Basically it is a series of
relays on a circuit board with indicator lights and fuses. This provides a compact reliable system that is easier to
troubleshoot.
314
Vactor
ower Distribution Board

P
Troubleshooting
PTO relays are

normally part
of the throttle
interlock
systems.
(Normal configuration for 2100 series applications)
Part No. Description
44594A
Qty.
44594
POWER DISTRIBUTION BOARD
44594A
MICRO RELAY - SPDT
45543
RELAY - SPDT - 12V - 50A
45543
(Actual number of relays and circuit breakers used will vary

with application)
Inspect traces on both sides

of the board for damage.
Rear side of Power Distribution Board
Overloaded
circuit trace
Break in
circuit trace
315
316
Always check that the shunts are in the correct position. The bus bar must
have power for anything to work. The ground input at terminal 1 must be a
good system ground.
Primary troubleshooting can be done with the relay board diagnostic LEDs
7 30/40 Automotive Style Relays, 2 fully accessible 15A relays Input and output
LEDs for diagnostics shunt or external control of secondary coil input.
9 Relay Board PN100455, Basic Layout
ower Distribution Board - Basic

P
Vactor
Troubleshooting
Vactor
Shunts placed in the GND Position to match inputs for operation
Ground Switched Relays
ower Distribution Board - Ground Switched

P
317
Troubleshooting
Shunts are placed in the POS position to match input for operation
Positive (ignition) Switched Relays
ower Distribution Board - Ignition Switched

P
Vactor
318
Troubleshooting
Vactor
ower Distribution Board - Load Controlled

P
319
Troubleshooting
J ohn Deere Throttle
Vactor 2100 Fan

Troubleshooting
This information applies to all fan systems that are

run by four or six cylinder John Deere Tier II and Tier
III diesel engines with electronic controls. The throttle
operation is the same for all engines. Idle, mid-range
and full speeds are controlled by a group of resistors
in series. The higher the resistance the high the
engine RPM. The engine speed is also overridden to
idle by the vacuum relief.
The rotary throttle switch consists of two independent
single pole - single throw switches operated by a cam
to provide three combinations of positions.
Unless there is physical damage to the wiring or a
failed connection most throttle problems are caused
by:
1.
Failure of the rotary switch
2.
Failure of one of the three resistors
3.
Failure of the vacuum relief relay
Components are located in a variety of locations.
320
Vactor 2100 Fan
J ohn Deere Throttle - Part Locations

Front of hose reel
Front of hose reel
Behind cab
Front of
hose reel
Tier II engines
Forward side of fan

engine
321
Troubleshooting
Front of hose reel
Vactor 2100 Fan
J ohn Deere Throttle - Schematic
Troubleshooting
322
Vactor 2100 Fan
J ohn Deere Throttle - Hose Reel Controls
323
Troubleshooting
Vactor 2100 Fan
Troubleshooting
750 OHMS
resistor
2.5K OHMS
resistor
Green
Red
Bare switch No jumpers

Position 1
Red 1 & 2 closed
Green 3 & 4 closed
Position 2
Red 1 & 2 open
Green 3 & 4 closed
Position 3

All open
Resistance color
code chart for
reference
324
3
4
Vactor 2100 Fan
Troubleshooting
Switch configuration
Green
Switch
Pin
Switch
Pin
Idle
UP
DOWN
Mid-range
UP
OPEN
UP
OPEN
DOWN
OPEN
UP
High
Pin
750 OHMS
resistor
Red
2.5K OHMS
resistor
X - switch closed
Green
Red
Power distribution
board - Switch 1
IDLE
Mid-range Full Throttle

390 ohm
To fan engine
(C1.21 & C7.41)
Red 1-2
Vac Relief
Relay
750 ohm
Green 3-4
2.5 Kohm
To fan engine
(C1.22 & C7.42)
Power distribution
board - Switch 1
IDLE

390 ohm
To fan engine
(C1.21 & C7.41)
Red 1-2
Vac Relief
Relay
750 ohm
Green 3-4
2.5 Kohm
To fan engine
(C1.22 & C7.42)
Power distribution
board - Switch 1
IDLE

390 ohm
To fan engine
(C1.21 & C7.41)
Red 1-2
Vac Relief
Relay
750 ohm
Green 3-4
To fan engine
(C1.22 & C7.42)
325
2.5 Kohm
Vactor 2100 Fan
J ohn Deere Throttle - Main Junction Box
Troubleshooting
44594A (2)
45543 (7)
Power distribution board

(Refer to Power Distribution Board section in the
Troubleshooting Section for additional details)
Part No. Description
Qty.
44594
POWER DISTRIBUTION BOARD
44594A
MICRO RELAY - SPDT
45543
RELAY - SPDT - 12V - 50A
Fuses
(Normal configuration for 2100 series applications)
Behind cab
Vacuum
relief
relay
390 OHMS resistor normally

located under this cover
326
Vactor 2100 Fan
J ohn Deere Throttle - Verify Controls
Troubleshooting
The throttle controls up to the engine can be verified

using a common multimeter set to read Ohms.
Tier II engines
With the unit off unplug the connector and locate pins
R and S on the harness end at the auxiliary engine.
The readings should be:
Throttle setting
Ohms
RPM
Note:
To set the throttle the
vacuum hose must be
plugged and the vacuum
relief closed.
Idle
350 - 430
800
Mid-range
1000 - 1250
2200
3250 - 4000
4cyl 2670
6cyl 2400
Full Throttle
If any reading is out of range replace any bad

resistors, verify all connections are good, and replace
bad switches as required. If all are in range this test
verifies that the control system is good up to the
engine. Consult your local John Deere service center
to service the engine controls.
Tier III engines - the harness from the hose reel

control is located in the same general area as on the
Tier II engines, but it is loose and not mounted on
a bracket. Follow the harness from the engine back
to the units main harness. During the Tier II to III
transition an adapter cable was used. The connector
may be either a male or female as shown.
327
Forward
side of fan
engine
Vactor 2100 Fan
J ohn Deere Throttle - Throttle Programming
328
Troubleshooting
ult-Flow System
M
Vactor
Troubleshooting
Overview
The Vactor Multi-Flow system utilizes both RexRoth and Parker piston pump. These variable piston
pump are flow and pressure compensated. Most
pumps are internally load sensed, this means the
control pressure is created internally in the pump.
Note that many older units are externally load
sensed. It is important to identify which system
you have to utilize the proper trouble shooting
techniques. Review the unit hydraulic schematics
prior to any troubleshooting.
In addition to the compenstators on each pump,
fan units will have two remote relief valves in the
load sense circuit. These valves give the operator
the ability to destroke the pump manually. Positive
displacement or blower units will have the same
two relief valves and an additional 2-position
directional valve in the load sense circuit. This 2position directional valve dumps the load sense line
destroking the hydraulic pump when the Rodder
Pump is not in use.
Positive Displacement Blower Unit

1.
Rex-Roth piston pump
2.
2-position directional valve mounted to

silencer mounts rear leg on drivers (left) side.
3.
Remote relief valves (2) located on hose reel.
The Rodder Pump hydraulic system also includes

a mechanical main relief valve. It is important to
note that this relief is redundant. For the system to
operate correctly the pump compensators have to
control the system.
The following information will aid you in trouble
shooting and setting the system.
Examples of a Rex-Roth Internally compensated
piston pump setup in both the fan and positive
displacement blower configurations. The Parker
pump configurations will look almost identical.
Fan Unit
330
1.
Rex-Roth piston pump
2.
Remote relief valves (2) located on hose reel.
ult-Flow System
M
Vactor
Troubleshooting
Problem
Unit will not reach its certified water pressure.
Water system has been troubleshot and found to be
working correctly.
Set-up
1.
Ensure you have sufficient water in water

tanks for testing.
2.
Install test nozzle in the water nozzle test can

that is rated for the GPM and PSI of your unit.
Isolating Multi-Flow Relief Valves

1.
Remove hose reel front cover.
2.
Disconnect and plug compensator hose from

relief valve at front of hose reel.
3.
Cap tee fitting on remote relief valve
15.
4.
Start unit and engage hydraulics as specified

in the start-up portion of your units manual.
Remove and replace front remote relief valve

and repeat steps 4-7 to verify.
16.
Remove and replace rear remote relief valve

and repeat steps 4-7 to verify.
5.
Engage Rodder Pump switch at hose reel
6.
Slowly raise engine RPM to required

operating RPM and record GPM and PSI.
7.
Lower RPM to idle, disengage hydraulics and

shut unit down.
8.
If operating PSI is reached continue with step

9.
a.
If operating PSI is not achieved

on a blower unit go to 2-Position
Directional Valve Isolation
b.
If operating PSI is not achieved on a

fan unit go to Isolation Of Hydraulic
Pump Compensators.
9.
You have isolated the problem to one of the

two remote relief valves at the hose reel.
10.
Reconnect compensator hose to tee-fitting at

remote relief valve.
11.
Disconnect drain hose from front relief valve

and attach a short hose that will reach a
bucket or any container able to capture oil.
Compensator Hose
12.. Ensure the remote relief valve is turned all the

way in.
13.
Repeat steps 4-7.
14.
Verify results:
a.
If oil discharges from hose into the

bucket proceed to step 15.
b.
If no oil discharges from hose proceed

to step 16.
331
Return Hose
ult-Flow System
M
Vactor
2-Position Directional Valve Isolation

1.
Disconnect 1/4 hydraulic hose at 2-position

directional valve coming from compensators
on the pump.
2.
Plug 1/4 hose from compensators and cap

fitting on 2-position directional valve.
3.

4.
5.
Slowly raise engine RPM to required

6.

shut unit down.
7.
If operating pressure is achieved you have

isolated the problem to the 2-position
directional valve.
8.
Before we remove and replace the 2-position

directional valve we want to troubleshoot the
electrical portion of the valve.
2-Position Directional Valve Electrical Check-out

1.
Unit ignition key turned on but motor not

started.
2.
Master Switch ON.
a.
DO NOT use test lights on Vactor

electrical circuits.
b.
Input voltage for this circuit is 12 volts.
c.
2-position directional valve wiring

is standard on Vactor positive
displacement blower units but always
refer to your units electrical schematics
for verification prior to troubleshooting.
3.
Verify voltage at Rodder Pump switch at hose

reel.
4.
Verify voltage at Input 7 on distribution board

in main junction box.
5.
Verify voltage at Relay 6 on distribution board

in main junction box.
6.
Verify voltage at 2-position directional valve.
332
Troubleshooting
ult-Flow System
M
Vactor
Troubleshooting
Isolation Of Hydraulic Pump Compensators

1.
At this point you have isolated the remote

relief valves at the hose reel and the 2position directional valve (on blower Units).
Now we start to isolate the compensators on
the pump.
2.
We need to isolate the compensators

from one another so that we are only
troubleshooting one compensator at a time.
a.
This method saves you time in the

troubleshooting process and
b.
It allows you to recapture your oil with

minimum waste.
3.
In isolating the pump the first step is to get

used to starting at the same pump each and
every time.
4.
We will start with the pump furthest away from

the mounts wether it be a transfer case or a
mount bracket attaching the pump to a drive
shaft, this pump will be called pump #1. The
pump connected to the transfer case or pump
mount will be #2.
a.
a.
Rex-Roth Pump that has had the compensators

isolated from one another.
the hydraulic fluid contained to the

system and you have no waste.
Install Venturi on to hydraulic tank fill

neck and turn up to a vacuum of 2 and
work your way up as needed to hold
hydraulic oil in tank.
Disconnect the 1/4 hydraulic hose
that jumpers between the #1 and #2
compensator at the #2 pump.
5.
At this point you have the two compensators

separated but since the hoses end with quick
disconnects the oil has no where to go which
will cause both pump to go to full stoke.
6.
Attach the 248 or equivalent long jumper

hose to the #2 compensator jumper hose.
This destrokes the #2 pump.
7.
At this point we are only stroking one

hydraulic pump we need to downsize the
nozzle installed in the test can to a 35 or 40
GPM nozzle.
b.
Attach jumper hose that has the #4 JIC

STR Union to hose attached to the #1
compensator.
8.
c.
Attach second jumper hose the #2

compensator.

9.
d.
Cap unused port on #2 compensator

tee-fitting.
10. Slowly raise engine RPM to required

e.
Plug 1/4 hose going to 2-position

directional valve or relief valves.
11.

shut unit down.
f.
Disconnect air source from venturi.

Here you have two choices. You may
disconnect the venturi from the oil tank
and run your long dump hose into the
hydraulic tank fill neck or you can install
a quick disconnect into the 1/4 coupling
just right of the hydraulic tank fill neck
and connect the long jump hose to the
quick disconnect. If the second method
is used leave the quick disconnect in
for future troubleshooting. Either one of
these two methods allow you to keep
12.
Results:
a.
If system pressure did not reach

documented PSI proceed to step 13.
b.
If system pressure reached its

documented PSI we have just
successfully verified the #1
compensator is working properly.
Proceed to step 15.
13.
Remove and replace compensator.
14.
Repeat steps 8-11 for verification.
333
ult-Flow System
M
Vactor
Troubleshooting
15.
Disconnect long jumper hose from #1

compensator and attach it to the #2
compensator jumper hose.
13.
16.
Repeat steps 8-11.
At this point your main relief has been set.
17.
Results:
14.
Insert quick disconnect into oil tank coupling.
a.
If system pressure did not reach

documented PSI proceed to step 18.
15.
Turn both compensators back out three full

turns to original setting.
b.
If system pressure reached its

documented PSI we have just
successfully verified the #2
compensator and at this point the
hydraulic pump needs to be removed to
a authorized center for evaluation.
16.
Attach both 27 hoses to #4 JIC fittings

coming out of the compensators on hydraulic
pump
17.
Attach 248 hose to compensator of choice.

(Note: Get into a habit of starting with the
same compensator each time you isolate
pumps.)
18.
Attach hose to quick disconnect on oil tank.

(Note: The pump that is now connected to the
oil tank will show no load and will destroke.)
Install test nozzle onto the test can.
18.
Remove and replace compensator.
19.
Repeat steps 8-11 for verification.
Compensators must be set lower then the

main relief valve.
Setting Vactor Relief And Compensator

Pressures
Turn off chassis motor.
1.
Install the flow meter to the rodder hose.
19.
2.
Install test can to the rodder hose
3.
Install test nozzle onto the test can. (Note:

Nozzle for a 80 GPM System should be a
75-80 GPM nozzle based on the pressure
requirements of your particular system.)
Note: Nozzle for a 80 GPM System should be a

35-40 GPM nozzle based on the pressure
requirements of your particular system.
20.
Repeat step 5.
21.
At hose reel engage Rodder Pump switch.
4.
Turn both pressure compensators in 3 full

turns.
22.
Slowly increase engine RPM.
5.
Start engine and engage electrical and

hydraulics systems per instruction in your
manual.
23.
Watch pressure gage at front of hose reel.
24.
Repeat steps 10-13
25.
Adjust compensator in and reverify pressure

per steps 20-24 until required pressure is
obtained for your system.
26.
Repeat steps with second compensator but

set the second compensator 50 PSI higher
then first.
6.
At hose reel engage Rodder Pump switch
7.
Slowly increase engine RPM. (Note: As

the engine RPM increases you will also be
increasing the water/oil pressure)
8.
Watch pressure gage at front of hose reel. As

engine RPM increases so does the pressure.
Main Relief
2000 PSI System 3000 PSI
9.
Adjust main relief to required setting.
10.
Turn off Rodder Pump switch.
11.
Disengage hydraulics.
12.
Turn off Master switch in cab.
Compensator Relief
Note that the second compensator setting is
always set 50-100 PSI higher then the first
compensator. This is so there is separation
between the compensators.
Note: For the system to operate correctly the

pump compensators have to control the
system. For this to take place the Pump
334
Vactor
Troubleshooting
Mult-Flow System
Pressure Compensator
Pressure
Compensator
Flow Compensator
Flow
Compensator
Parker
Pump
Rex-Roth
Pump
Flow Compensator
Flow Compensator
335
Vactor
ult-Flow System
M
Troubleshooting
D08 Directional Valve Remote Mount
D08 Directional Valve Direct Mount

RELIEF VALVES
D10 Directional Valve Direct Mount
D10 Directional Valve Remote Mount
336
Vactor
Mult-Flow System
Troubleshooting
Parts List
Item
Part No.
Description
61464
TEST CAN WELDMENT
47829
FLOW METER, WATER, 10-150GPM, 1.25NPT
89191
VACUUM TRANSDUCER PUMP ASSY (VENTURI)
45633
QUICK CONNECT
70318
QUICK CONNECT - 1/4 FEMALE
47365AC
HYD HOSE ASSY - 1/4 X 248
47365E
HYD HOSE ASSY - 1/4 X 27
70352A
ADAPT, HYD, 4JIC X 4JIC STR UNION
43134
ADAPT, HYD, 4NPTF X 4JICF SWV STR
10
70338H
ADAPT, HYD, 4JIC X 4NPT, STR
11
47771
ADAPT, HYD, 4JIC CAP NUT
12
71164B
ADAPT, HYD, 4JIC PLUG
Qty.
337
Vactor 2100 Series & Jetter
Recommended Spare Parts
for
One Year
P/N
HOSE REPAIR
QTY
66286B
HOSE SWAGE REPAIR KIT (MACHINE & DIES) - 3/4
66286
HOSE SWAGE REPAIR KIT (MACHINE & DIES) - 1
66286A
HOSE SWAGE REPAIR KIT (MACHINE & DIES) - 1 1/4
45267
SPLICER/MENDER SWAGE (BLUE BAND) - 3/4 - 2500 PSI
45267A
SPLICER/MENDER SWAGE (BLUE BAND) - 3/4 - 3000 PSI
46142
SPLICER/MENDER SWAGE (BLUE BAND) - 1 - 2500 & 3000 PSI
44153
SPLICER/MENDER SWAGE (BLUE BAND) - 1-1/4 - 2500 & 3000 PSI
45268
MALE END SWAGE (BLUE BAND) - 3/4 - 2500 PSI
45268A
MALE END SWAGE (BLUE BAND) - 3/4 - 3000 PSI
43605
MALE END SWAGE (BLUE BAND) - 1 - 2500 & 3000 PSI
44107
MALE END SWAGE (BLUE BAND) - 1-1/4 - 2500 & 3000 PSI
47748D
HOSE SWAGE REPAIR KIT (MACHINE & DIES) - SHARK
47748E
SPLICER/MENDER SWAGE - SHARK
47748F
MALE END SWAGE - SHARK
P/N
RODDER HOSE
QTY
46916A
3/4 X 400 PLASTIC RODDER HOSE - 3000 PSI (BLUE)
46916
46916F
46916E
43569
1 X 400 PLASTIC RODDER HOSE - 2500 PSI (ORANGE)
43570
43571
43569E
46113B
1 X 400 PLASTIC RODDER HOSE - 3000 PSI (BLUE)
46113
46113C
46113D
476504
1 X 400 RUBBER RODDER HOSE (SHARK) - 3000 PSI (Black)
476505
476506
44109
1-1/4 X 500 PLASTIC RODDER HOSE - 2500 PSI (ORANGE)
P/N
LEADER HOSE
QTY
20201
3/4 X 36 LEADER HOSE
31096
1 X 30 LEADER HOSE
47650B
1 X 60 (SHARK) LEADER HOSE
44314
1-1/4 X 36 LEADER HOSE
40067B
3/4 SWIVEL
40196
1 SWIVEL
52846
FLEXIBLE HOSE GUIDE ASSEMBLY - 36
47650M
1 x 120 SHARK LEADER HOSE
47651C
3/4 X 120 SHARK LEADER HOSE
338
ecommended Spare Parts

R
P/N
for
One Year
NOZZLES
QTY
Note: designate flow, pressure & size when ordering

58756
SANITARY NOZZLE - 30 DEGREE
58926
SAND NOZZLE - 30 DEGREE
58927
PENETRATOR NOZZLE - 30 DEGREE
60308
PENETRATOR NOZZLE - 15 DEGREE
36058B
#10 STORM SEWER NOZZLE (TC INSERTS)
44205
TUNGSTEN CARBIDE INSERTS FOR 36058B
31685
FINNED PIPE WELD - 1 X 12 WIDE
34955
FINNED PIPE WELD - 1 X 12 NARROW
40797
BODY WASH-OUT NOZZLE - 60gpm only
P/N
BOOM
QTY
44861J
7-BUTTON PENDENT CONTROL w/30 CABLE
44861L
7-BUTTON PENDENT CONTROL w/30 CABLE w/VACUUM RELIEF
191138
JOYSTICK
27771
STEEL ELBOW - 70 DEGREE
34763
6 X 36 - ALUMINUM PIPE
34763A
34766
6 X 78 - ALUMINUM Catch BASIN NOZZLE w/FLANGED END
34763B
25637C
25637
25268
8 X 78 - ALUMINUM Catch BASIN NOZZLE w/FLANGED END
25637A
77045
6 SNORKEL NOZZLE KIT
50507
8 SNORKEL NOZZLE KIT
58990A
6 ADJUSTABLE AIR ADAPTER
58990
8 ADJUSTABLE AIR ADAPTER
47392
6 X 64 RUBBER DEBRIS HOSE
53348
6 HOSE END
45730
6 T-BOLT BAND CLAMP
42593
6 KING CLAMP
46564
8 X 62 RUBBER DEBRIS HOSE
46564A
8X60 RUBBER DEBRIS HOSE,8X60,RED GUM LINER
58795
8 HOSE END
46634
8 T-BOLT BAND CLAMP
32087
6 QUICK CLAMP
43442
6 GASKET
16584
8 QUICK CLAMP
16585
8 GASKET
339

R
for
One Year
P/N
Y-STRAINER FILL
QTY
45803
2 STRAINER SCREEN
46137
2 CAGE GASKET
46138
2 CAP GASKET
41280
3 STRAINER SCREEN (IF REQUIRED)
41272
3 CAGE GASKET (IF REQUIRED)
41271
3 CAP GASKET (IF REQUIRED)
20720A
HYDRANT HOSE (NO ENDS) - 2-1/2 X 25
20695
CLAMP - 2-1/2
20199B
HYDRANT HOSE END - 2-1/2
P/N
VACTOR RODDER PUMP
QTY
29385
CHECK VALVE - 2
29384D
CHECK VALVE - 3
45834
PROXIMITY SENSOR
45906
PROXIMITY SENSOR CONNECTOR
29826A
DRAIN PLUG - 3/4-16NF #8 O-RING
P/N
MYERS PUMPS
QTY
1201322
DP65-20, SUCTION VALVE & SEAT COMPLETE
1201321
DP65-20, DISCHARGE VALVE & SEAT COMPLETE
1650362
DP65-20, SPRING, SUCTION
1201363
DP65-20, SPRING, DISCHARGE
1201328
O-RING, DP65-20
1201329
O-RING, DP65-20
1200852
DP80-20, VALVE, SUCTION/DISCHARGE
1200850
DP80-20, SEAT, DISCHARGE VALVE
1200851
DP80-20, SEAT, SUCTION VALVE
1201361
DP80-20, SPRING, DISCHARGE
1201363
DP80-20, SPRING, SUCTION
P/N
HANDGUN CIRCUIT
QTY
45109
WATER HANDGUN ASSEMBLY
31014AG
EXTENSION HOSE - 1/2 X 300
40029
RELIEF VALVE
20188A
FEMALE COUPLER - 1/2
20189
MALE COUPLER - 3/4
P/N
WATER TANKS
QTY
45113
FLOAT - 6
45731
EXPANSION PLUG - 2
P/N
AUXILIARY ENGINE
QTY
47773
SWITCH - START
47772
SWITCH - THROTTLE CONTROL
340

R
for
One Year
P/N
BLOWER UNIT
QTY
42645
VACUUM GAUGE
46846
VACUUM GAUGE, MODEL 2103
42633
RELIEF VALVE - 3 VACUUM
P/N
HOSE REEL
QTY
46846D
PRESSURE GAUGE - 5000 PSI
46829
3/4 SWIVEL JOINT, 90 DEGREE TM
40052
1 SWIVEL JOINT, 90 DEGREE TM
40052A
REPAIR KIT FOR 3/4 AND 1 SWIVEL JOINTs
45556A
REEL CONTROL VALVE SEAL KIT
40939
REEL CONTROL VALVE HANDLE
40941
REEL CONTROL VALVE PIN KIT FOR 40939
16399L
PILLOW BLOCK BEARING
61297D
STOP TOOTH BLOCK
45551
AIR CYLINDER - HOSE REEL LOCK
45553
AIR VALVE - HOSE REEL LOCK
P/N
ELECTRICAL (None Specific)
QTY
44595A
FUSE - 5 AMP (RED SPADE TYPE)
44595
FUSE - 10 AMP (YELLOW SPADE TYPE)
45368
FUSE - 3 AMP (TUBE TYPE)
45634
44591
41548
45720
RELAY - DUAL LATCHING (RODDER PUMP)
45721
RELAY BASE
40241
TOGGLE SWITCH
40241A
TOGGLE SWITCH
44622
TOGGLE SWITCH - 3 POSITION (HOSE REEL IN/OUT)
P/N
BALL VALVES
QTY
40575
1/2 BALL VALVE
40575D
1/2 BALL VALVE HANDLE
40575C
1/2 BALL VALVE SEAL KIT
46581
3/4 BALL VALVE
40576
1 BALL VALVE
40576D
3/4 & 1 BALL VALVE HANDLE
40576C
1 BALL VALVE SEAL KIT
P/N
MISC.
QTY
42431
HYDRAULIC FILTER ELEMENT - 10 MICRON
341
PARTS INDEX
A . . . WATER SECTION
B . . . HOSE REEL SECTION
C . . . HYDRAULIC/PNEUMATIC
SECTION
D . . . ELECTRICAL SECTION
E . . . P.T.O. SECTION
F . . . BOOM SECTION
G . . . DEBRIS BODY SECTION
H . . . REAR DOOR SECTION
I . . . . AUX. ENGINE / BLOWER
SECTION
J . . . . FAN & FAN DUCT / FINAL
FILTER & FINAL FILTER DUCT
SECTION
K . . . WATER TANK SECTION
L . . . . OPTIONS SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PowerTech PlusTM 6.8 L Engine

Model: 6068HF485
JD Electronic Control
ENGINE PERFORMANCE CURVE

Rating:
Gross Power
Application: Industrial - Continuous
Power Bulge - 0%
Torque Rise - 26%
185 hp @ 2400 rpm

138 kW @ 2400 rpm
[See Option Code Table]
540
(732)
460
(624)
509 lb-ft
690 N m)
Torque
380
(515)
300
(224)
Air Intake Restriction ...................12 in.H2O (3 kPa)

Exhaust Back Pressure ........... 30 in.H2O (7.5 kPa)
Gross power guaranteed within + or - 5% at SAE J1995
and ISO 3046 conditions:
77 F (25 C) air inlet temperature
29.31 in.Hg (99 kPa) barometer
104 F (40 C) fuel inlet temperature
0.853 fuel specific gravity @ 60 F (15.5 C)
Conversion factors:
Power: kW = hp x 0.746
Fuel: 1 gal = 7.1 lb, 1 L = 0.85 kg
Torque: Nm = lb-ft x 1.356
All values are from currently available data and are subject
to change without notice.
220
(164)
Notes:
140
(104)
185 hp
(138 kW)
Power
60
(45)
0.36
(219)
0.32
(194)
Fuel Consumption
800
1000
1200
1400
1600
1800
2000
2200
2400
Engine Speed -- rpm
Engine Performance Curves
6068 - Industrial
Fuel -- lb/hp-hr (g/kWh)
Brake Power -- hp (kW)
405 lb-ft
(550 N m)
Torque -- lb-ft (N m)
STANDARD CONDITIONS*
Tier-3 Emission Certifications:
Certified by:
CARB; EPA; EU
Ref: Engine Emission Label
* Revised Data
Curve: 6068HF485185I_2400 ......................... Sheet 1 of 2
February 2005
December 2005
General Data
Model ............................................................... 6068HF485
Number of Cylinders ......................................................... 6
Bore and Stroke--in. (mm).............. 4.19 (106) x 5.00 (127)
Displacement--in.3 (L) ...........................................415 (6.8)
Compression Ratio ................................................. 17.0 : 1
Valves per Cylinder--Intake/Exhaust ............................ 2 / 2
Firing Order....................................................... 1-5-3-6-2-4
Engine Type ................................................ In-line, 4-Cycle
Aspiration ......................................................Turbocharged
Charge Air Cooling System................................... Air-to-Air
Engine Crankcase Vent System ................................ Open
Physical Data
Length--in. (mm) ...............................................44.1 (1120)
Width--in. (mm) ...................................................24.1 (611)
Height--in. (mm) ................................................41.7 (1058)
Weight, with oil*--lb (kg) .....................................1495 (678)
(Includes flywheel housing, flywheel & electrics)
Center of Gravity Location
From Rear Face of Block(X-axis)--in.(mm). 15.5 (395)*
Right of Crankshaft (Y-axis)--in. (mm)....... -0.1 (-2.24)*
Above Crankshaft (Z-axis)--in. (mm) ..............7.4 (189)
Maximum Allowable Static Bending Moment at Rear Face
of Flywhl Hsg w/ 5-G Load--lb-ft (Nm) ........600 (814)
Rearward
Thrust Bearing Load Limit --lb (N) Forward
Intermittent............................899 (4000) .....450 (2000)
Continuous ...........................495 (2200) .....225 (1000)
Max. Front of Crank. Torsional Vibration--DDA............ 0.25
Max. Continuous Damper Temp--F (C) ...............180 (82)
Electrical System
12 Volt 24 Volt
Min. Battery Capacity (CCA)--amp................ 800 ......... 570
Max. Allow. Starting Circuit Resist.--Ohm 0.0012 ...... 0.002
Starter Rolling Current
At 32 F ( 0 C)--amp ................................ 920 ......... 600
At -22 F (-30 C)--amp........................... 1300 ......... 700
Min. Voltage at ECU during Cranking--volts...... 6 ........... 10
Maximum ECU Temperature--F (C) ..................221 (105)
Max. VTG Actuator Surface Temp.--F (C) .........356 (180)
Maximum Harness Temperature--F (C) ............248 (120)
Air System
Maximum Allowable Temp Rise--Ambient Air to
Engine Inlet--F (C) ..............................................15 (8)
Maximum Air Intake Restriction:
Dirty Air Cleaner--in. H2O (kPa)........................25 (6.25)
Clean Air Cleaner--in. H2O (kPa)......................15 (3.75)
Engine Air Flow--ft3/min (m3/min) .....................496 (14.04)
Air Cleaner Efficiency--% ............................................. 99.9
Engine Installation Criteria

Charge Air Cooling System
Air/Air Exchr. Heat Rej.Btu/min(kW) ................ 1895 (33)
Compressor Discharge Temp.(Rated)
@ 77 F (25C) Ambient Air--F (C)............ 349 (176.1)
Compressor Discharge Temp.(Max.)--F (C)
@ any Ambient--F (C) .............................. 349 (176.1)
Max. Pressure Drop, thru CAC--in.H2O (kPa) ........ 64 (16)
Min. Pressure Drop, thru CAC--in.H2O (kPa) ........... 32 (8)
Intake Manifold Pressure--psi (kPa) ..................26 (182.0*)
Max CAC Out Temp @ 77F (25C) Amb.--F (C) 126(52)
Min CAC Out Temp @ 77F (25C) Amb.--F (C). 109(43)
Max CAC Out Temp @ any Ambient--F (C) ........ 190(88)
Cooling System
Engine Heat Rejection--BTU/min (kW) ................ 4790 (84)
Coolant Flow--gal/min (L/min)................................ 91 (346)
Thermostat Start to Open--F (C)......................... 180 (82)
Thermostat Fully Open--F (C)............................. 203 (95)
Engine Coolant Capacity--qt (L) ........................... 13 (11.9)
Minimum Pressure Cap--psi (kPa)...................... 14.5 (100)
Maximum Top Tank Temp--F (C) ...................... 230 (110)
Minimum Coolant Fill Rate--gal/min (L/min) .............. 3 (11)
Minimum Air-to-Boil Temperature--F (C)............. 117 (47)
Minimum Pump Inlet Pressure--psi (kPa) ............... 4.4 (30)
Exhaust System
Exhaust Flow--ft3/min (m3/min).............................. 943 (27)
Exhaust Temperature--F (C)............................. 606 (319)
Max. Allowable Back Pressure--in. H2O (kPa) ........ 40 (10)
Minimum Exhaust Restriction----in. H2O (kPa) .......... 16 (4)
Max. Bend. Moment on Turbo Out.--lb-ft (Nm)........ 5.2 (7)
Max. Shear on Turbo Outlet--lb (kg) ........................ 24 (11)
Fuel System
ECU Description ........................................... L14 Controller
Fuel System Description.......................................... HPCR*
Fuel Injection Pump ......................................... Denso HP3
Governor Type.....................................................Electronic
Total Fuel Flow--lb/hr (kg/hr) .............................. 159 (72.0)
Fuel Consumption--lb/hr (kg/hr)............................... 67 (31)
Max. Fuel Inlet Temperature--F (C) .................... 176 (80)
Fuel Temp. Rise, Inlet to Return--F (C) ............. 70.0 (39)
Max. Fuel Inlet Restriction--in. H2O (kPa) ............... 80 (20)
Max. Fuel Inlet Pressure--in. H2O (kPa) ................ NA (NA)
Max. Fuel Return Pressure--in. H2O (kPa) .............. 80 (20)
6068 - Industrial
Lubrication System
Oil Pressure at Rated Speed--psi (kPa) ................ 60 (413)
Oil Pressure at Low Idle--psi (kPa) ........................ 15 (105)
Max. Oil Carryover in Blow-by--lb/hr (g/hr) ........ 0.002 (1.0)
Max. Airflow in Blow-by--gal/min (l/min)................... 22 (85)
Max. Crankcase Pressure--in. H2O (kPa)................. 2 (0.5)
Performance Data
Rated Power--hp (kW) ......................................... 185 (138)
Rated Speed--rpm ...................................................... 2400
Breakaway Speed--rpm .............................................. 2470
Fast Idle Speed--rpm .................................................. 2600
Peak Torque--lb-ft (Nm)...................................... 509 (690)
Peak Torque Speed--rpm ........................................... 1400
Low Idle Speed--rpm .................................................... 800
BMEP--psi (kPa) ................................................ 147 (1016)
Friction Power @ Rated Speed--hp (kW) ................ 36 (27)
Altitude Capability--ft (m) .............................10,000 (3000)*
Ratio--Air : Fuel ......................................................... 31 : 1
Smoke @ Rated Speed--Bosch No. ............................... <1
Noise--dB(A) @ 1 m .................................................... 94.1
Power Bulge--% ................................................................ 0
Power Bulge Speed--rpm .............................................. NA
Torque Rise--%............................................................... 26
Engine
Speed
rpm
2400
2200
2000
1800
1600
1400
1200
1000
800
Power
hp (kW)
185 (138)
185 (138)
179 (134)
167 (124)
151 (113)
136 (101)
116 (87)
97 (72)
78 (58)
Torque
lb-ft (Nm)
BSFC
lb/hp-hr
(g/kWh)
405 (550)
442 (599)
470 (638)
487 (660)
497 (673)
509 (690)
509 (690)
509 (690)
509 (690)
0.362 (220)
0.350 (213)
0.342 (208)
0.339 (207)
0.344 (210)
0.355 (216)
0.332 (202)
0.337 (206)
0.360 (219)
All values at rated speed and power with standard options unless otherwise noted.
* Revised Data
Curve: 6068HF485185I_2400 ......................... Sheet 2 of 2
February 2005
November 2005
PowerTech 4.5 L Engine

Model: 4045HF275
ENGINE PERFORMANCE CURVE

Rating:
Gross Power
125 hp @ 2400 rpm
93 kW @ 2400 rpm
[See Option Code Tables]
Application: Industrial
Intermittent / Continuous
273 lb-ft
(370 N m)
Intermittent Torque
280
(380)
125 hp
(93 kW)
Intermittent Power
100
(74)
113 hp
(84 kW)
60
(45)
Gross power guaranteed within + or - 5% at SAE J1995

and ISO 3046 conditions:
77 F (25 C) air inlet temperature
29.31 in.Hg (99 kPa) barometer
104 F (40 C) fuel inlet temperature
0.853 fuel specific gravity @ 60 F (15.5 C)
Conversion factors:
Power: kW = hp x 0.746
Fuel: 1 gal = 7.1 lb, 1 L = 0.85 kg
Torque: Nm = lb-ft x 1.356
All values are from currently available data and are subject
to change without notice.
Notes:
Continuous Limit
20
(15)
0.40
(242)
Fuel Consumption
0.36
(219)
1000
1200
1400
1600
1800
2000
2200
2400
Engine Speed -- rpm
4045 - Industrial
Fuel -- lb/hp-hr (g/kWh)
Brake Power -- hp (kW)
320
(434)
Torque -- lb-ft (N m)
360
(488)
341 lb-ft
(463 N m)
Air Intake Restriction ...................12 in.H2O (3 kPa)

Exhaust Back Pressure ........... 30 in.H2O (7.5 kPa)
Tier-2 Emission Certifications:
Certified by:
CARB; EPA; EU
Ref: Engine Emission Label
* Revised Data
Curve: 4045HF275125I ................................... Sheet 1 of 3
November 2001
November 2001
Common Specifications:
Engine Specification Data

Air System
General Data
Model ............................................................... 4045HF275
Number of Cylinders ......................................................... 4
Bore and Stroke--in. (mm).............. 4.19 x 5.00 (106 x 127)
Displacement--in.3 (L) ...........................................275 (4.5)
Compression Ratio ................................................... 17.0:1
Valves per Cylinder--Intake/Exhaust .............................. 1/1
Firing Order............................................................. 1-3-4-2
Combustion System .................................... Direct Injection
Engine Type ................................................ In-line, 4-Cycle
Aspiration ......................................................Turbocharged
Charge Air Cooling System................................... Air-to-Air
Engine Crankcase Vent System ................................ Open
Maximum Crankcase Pressure--in. H2O (kPa) .........2 (0.5)
Physical Data
Length--in. (mm) .................................................34.1 (867)*
Width--in. (mm) ...................................................25.1 (637)*
Height--in. (mm) ..................................................38.5 (979)*
Weight, dry--lb (kg) ..............................................993 (451)
(Includes flywheel housing, flywheel & electrics)
Center of Gravity Location
From Rear Face of Block (X-axis)--in. (mm) ....9.8 (249)
Right of Crankshaft (Y-axis)--in. (mm) ..............2.17 (55)
Above Crankshaft (Z-axis)--in. (mm).................5.7 (145)
Max. Allow. Static Bending Moment at Rear
Face of Flywhl Hsg w/ 5-G Load--lb-ft (Nm)....600 (814)
Thrust Brng. Load Limit (Forward)--lb (N) [I].....900 (4003)
[C] ....500 (2224)
Maximum Allowable Temp Rise--Ambient Air to

Engine Inlet--F (C) .............................................. 15 (8)
Maximum Air Intake Restriction
Dirty Air Cleaner--in. H2O (kPa)........................ 25 (6.25)
Clean Air Cleaner--in. H2O (kPa)........................... 12 (3)
[I] ............... 343 (9.7)
Engine Air Flow--ft3/min (m3/min)
[C]............... 325 (9.2)
Intake Manifold Pressure--psi (kPa) [I] .................16 (111)
[C].................. 14 (99)
Recommended Intake Pipe Diameter--in. (mm) ..... 3 (76.2)
Compressor Discharge Temp--oF (oC) [I] .......... 277 (136)
[C].......... 264 (129)
Max. Press. Drop Through CAC--in.H2O (kPa) ....... 52 (13)
Max. Temp. Out of CAC
@ 77oF (25oC) Ambient Air--oF (oC) ................. 140 (60)
Cooling System
Engine Heat Rejection--BTU/min (kW) [I]........... 2731 (48)
[C].......... 2504 (44)
Air/Air Exch. Heat Rejection--BTU/min (kW)[I] ...... 683 (12)
[C] ..... 626 (11)
Coolant Flow--gal/min (L/min) .............................. 51 (192)
Thermostat Start to Open--F (C) ......................... 180 (82)
Thermostat Fully Open--F (C)............................. 201 (94)
Engine Coolant Capacity--qt (L) ............................... 9 (8.5)
Recommended Pressure Cap--psi (kPa)................. 10 (69)
Maximum Top Tank Temp--F (C) ..................... 221 (105)
Minimum Coolant Fill Rate--gal/min (L/min) .............. 3 (11)
Minimum Air-to-Boil Temperature--F (C)............. 117 (47)
Lubrication System
Oil Pressure at Rated Speed--psi (kPa) ................ 50 (345)
Oil Pressure at Low Idle-psi (kPa) ......................... 15 (105)
In Pan Oil Temperature--F (C) .......................... 240 (115)
Exhaust System
Exhaust Flow--ft3/min (m3/min) [I] ..................... 794 (22.5)
[C]..................... 742 (21.0)
Exhaust Temperature--F (C) [I] ...................... 855 (457)
[C]...................... 828 (442)
Max. Allowable Back Pressure--in. H2O (kPa) ....... 30 (7.5)
Recd. Exhaust Pipe Diameter--in. (mm) ........... 4.0 (101.6)
Electrical System
Recommended Battery Capacity (CCA)
12 Volt System--amp ................................................ 640
24 Volt System--amp ................................................ 570
Maximum Allowable Starting Circuit Resistance
12 Volt System--Ohm........................................... 0.0012
24 Volt System--Ohm............................................. 0.002
Starter Rolling Current--12 Volt System
At 32 F ( 0 C)--amp ................................................ 780
At -22 F (-30 C)--amp........................................... 1000
Starter Rolling Current--24 Volt System
At 32 F (0 C)--amp ................................................. 600
At -22 F (-30 C)--amp............................................. 700
Fuel System
Fuel Injection Pump ................................ Stanadyne DE10
Governor Regulation................................................ 7-10 %
Governor Type .....................................................Electronic
Fuel Consumption--lb/hr (kg/hr) [I]................. 47.0 (21.5)
[C]................ 43.0 (19.6)
Total Fuel Flow--lb/hr (kg/hr)
[I]............... 194.0 (88.0)
Maximum Fuel Transfer Pump Suction--ft (m) fuel ... 3 (0.9)
Fuel Filter Micron Size @ 98% Efficiency........................ 2*
* Revised Data
November 2001
4045 - Industrial
April 2002
Engine Specification Data
Electronic Engine Controls (JDEC) Options
Performance Data
Rated Power--hp (kW) [I]..................................... 125 (93)
[C] .................................... 113 (84)
Rated Speed--rpm ...................................................... 2400
Peak Torque--lb-ft (Nm) [I]............................... 341 (463)
[C] .............................. 307 (417)
Peak Torque Speed--rpm............................................ 1400
Low Idle Speed--rpm .................................................... 800
BMEP--psi (kPa) [I] ......................................... 149 (1028)
[C] .......................................... 134 (928)
Friction Power @ Rated Speed--hp (kW) ................ 30 (22)
Altitude Capability -- ft (m) ............................ 10,000 (3050)
Ratio--Air : Fuel
[I] ................................................ 30.7:1
[C] ............................................... 31.8:1
Smoke @ Rated Speed--Bosch No. [I]......................... < 2
[C]........................ < 2
Noise--dB(A) @ 1 m [I] ............................................. 94.4*
[C]............................................. 93.1*
Performance System Option Code Table

Option Codes
Injection Pump Performance Software
S t a n d a r d F e a t u r e
161F
7264
163K
7265
E x t e n d e d F e a t u r e
163G
7264
161G
7265
System
Voltage
E C U
12V
24V
E C U
12V
24V
ECU Feature Software Option Code (8300 Group) Table

Industrial Applications - Stanadyne DE10
Option
Code
Oil
Governing
Pressure
Sensor
8305
8308
8309
8316
8317
8318
No
Yes
Yes
No
Yes
Yes
8% Droop
8% Droop
8% Droop
8% Droop
8% Droop
8% Droop
8310
8311
8312
8313
8314
8315
8319
8320
8321
8322
8323
8324
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
8% Droop
8% Droop
8% Droop
Selectable
Selectable
Selectable
8% Droop
8% Droop
8% Droop
Selectable
Selectable
Selectable
Cruise
Control
Engine Protection
ECU Software
External Input
S t a n d a r d F e a t u r e E C U
No
Derate Only
None
No
Derate Only
None
No
Derate w/shutdown
None
No
Derate Only
None
No
Derate Only
None
No
Derate w/shutdown
None
E x t e n d e d F e a t u r e E C U
Yes
Derate Only
Shutdown Only
Yes
Derate Only
Shutdown Only
Yes
Derate w/shutdown
Shutdown Only
No
Derate Only
Derate & Shutdown
No
Derate Only
Derate & Shutdown
No
Derate w/shutdown
Derate & Shutdown
Yes
Derate Only
Shutdown Only
Yes
Derate Only
Shutdown Only
Yes
Derate w/shutdown
Shutdown Only
No
Derate Only
Derate & Shutdown
No
Derate Only
Derate & Shutdown
No
Derate w/shutdown
Derate & Shutdown
Available Throttle
Inputs
Analog
Digital
None
None
None
None
None
None
2-State
2-State
2-State
Ramp
Ramp
Ramp
Two
Two
Two
Two
Two
Two
Two
Two
Two
Two
Two
Two
2-State
2-State
2-State
Adj. 3-State
Adj. 3-State
Adj. 3-State
Ramp
Ramp
Ramp
Ramp
Ramp
Ramp
Engine
Speed
rpm
Contin.
Limit
hp(kW)
2400
2200
2000
1800
1600
1400
1200
1000
113 (84)
113 (84)
109 (81)
102 (76)
93 (69)
82 (61)
-----------
Intermit.
Power
hp(kW)
125 (93)
125 (93)
121 (90)
113 (84)
102 (76)
91 (68)
75 (56)
52 (39)
Intermit.
Torque
lb-ft(Nm)
BSFC
lb/hp-hr
(g/kWh)
273 (370)
298 (404)
316 (428)
328 (445)
336 (456)
341 (463)
327 (444)
273 (370)
0.380 (231)
0.367 (223)
0.352 (214)
0.348 (212)
0.347 (211)
0.352 (214)
0.343 (209)
0.358 (218)
* Revised Data
November 2001
4045 - Industrial
July 2003
Vactor No. 47827

AC 7-6-2004
INSTALLATION AND MAINTENANCE

BEFORE ASSEMBLING AND OPERATING THE FLUID COUPLING,
CAREFULLY READ ALL THE SAFETY AND OPERATING
INSTRUCTIONS REPORTED IN THIS MANUAL.
ALWAYS FOLLOW ALL THE INSTRUCTIONS AND ASSURE THAT ALL
THE OPERATORS STANDING BY THE MACHINERY ARE WEARING
ALL THE PROTECTIVE EQUIPMENT NECESSARY FOR THE JOB
TYPE AND APPLICATION BEING PERFORMED.
DO NOT USE THE MACHINERY IF YOU DO NOT UNDERSTAND
THESE INSTRUCTIONS, AND IMMEDIATELY REFER TO THE
MANUFACTURER OR THE CUSTOMER SERVICE DESK FOR
ASSISTANCE.
THE COUPLING MUST BE PROTECTED BY A CONVENIENT COVER
GUARD TO AVOID PERSONAL INJURY TO PEOPLE.
AXIAL AND RADIAL VENTILATION OPENINGS SHOULD BE
INCORPORATED IN THE GUARD FOR HEAT EXCHANGE.
IF THE COUPLING IS FITTED WITH FUSIBLE PLUGS, THE SAID
OPENINGS SHOULD NOT BE DIRECTED TOWARDS OPERATORS
OR ANY HOT OR ELECTRICAL INSTALLATION.
FLUID COUPLINGS
...KDM... - ...KCG (KCM)
FLUID COUPLINGS KDM - KCG SERIES

GENERAL FEATURES
Fluid couplings KDM and KCG series include two disc half
couplings (KDM) or two gear half couplings (KCG) as indicated in
Fig. 3 e 3a. This kind of assembly offers the following advantages:
a Possible replacement of the fluid coupling without moving
the electric motor and the driven machine (it is not
necessary to perform any further alignment).
b The weight of the fluid coupling can be shared between the
driver and driven shafts.
1.4 Measure distance B for KDM, B1 for CKDM or B2 for CCKDM.

By adding to them the dimension G, dimensions M, M1 or M2
(minimum distance between shaft ends) can be determined. For
fluid couplings equipped with brake disc (KDMBP) or brake drum
(KDMB), dimension MB is obtained with a similar procedure by
adding to B, B1 or B2 the value G1 and G/2 (Tab. A).
1.5 Position the electric motor and driven machine according to said
dimensions M, M1, M2 or MB, MB1, MB2.
Align the shafts by using a dial indicator (Fig. 2). The alignment
tolerances, radial X, angular Y-Z, (Fig. 1 and 2) are shown in
Tab. A
1.6 Set the flanges pos. 50 near the hubs pos. 51 (KDM) or pos. 51a
(KDMB or KDMBP), acting for each half coupling on the 3
screws a and a1 (Fig. 2a and 2b). Inserting the spacers C,
dimension H=(H1+H2)/2 is reduced to the value H0; increasing
therefore the distance B between the two flanges pos. 50 from
approximately 3 to 7mm. In this way the fitting of the fluid
coupling in the respective centering position W is made easier.
1.7 Make sure that the connecting flanges of the fluid coupling and
of the half disc coupling are perfectly degreased. Insert the fluid
coupling between the two half couplings and fix with screws (56)
and relevant washers (66).
IMPORTANT! Before locking, remove the 3+3 screws (pos.
a) and relevant spacers (pos. C Fig. 2a and 2b), then tighten
screws pos. 56 uniformly according to the locking torque
shown in Tab. H.
1.8 Verify alignment once again together with the max H1 and min
H2 between hub (51) and flange (50) according to the allowable
values shown in Tab. A.
Fig. 3
1. ASSEMBLY OF KDM-CKDM-CCKDM
1.1 The disc half coupling includes: one hub (51), one disc pack
(52), one connecting flange (50), 6 calibrated screws and
relevant nuts (53 and 54), and three washers (59). These parts
are supplied ready to be used (Fig. 1).
1.2 If the half couplings are supplied with rough bores, the bore and
the keyway may be machined without disassembling the half
coupling referring to the surface S of the hub (51) Fig. 2. The
interference between the shaft and the hub must not
exceed 0.0005mm per mm of boring.
1.3 Clean parts accurately. Fit half couplings onto the relevant
shafts, the end of which must correspond with the end of the
hub.
Fig. 1
FIG.1
Z
...KDM
Y
H1
66-56
Fig. 2
Fig.2
52
50
53
50
51
54
51
H1
56-66
X
G/2
G/2
G1
FIG. 1a
51a
59
M
MB
Fig. 2a
Fig.2a
Fig. 2b
Fig.2b
51a
H2
W
a1
...KDMB
...KDMBP
c
KDM
152 US - 0609
9
11
12
13
15
17-19
21-24
27
29
34
M -0.4
MB 0-0.4
Tab. A
a1
H2
Disc G G1
Y-Z
coupling
cKDMBa max
1055
1065
1075
1085
1110
1140
1160
Max. misalignment (mm)

X H1-H2 H1+H2 Ho
2
19
0.16
70.2
5.7
0.20 0.10
23
27
32
41
50.5
0.25 0.15
0.30
0.40
62.5
0.20
0.19
90.2
7.6
0.22 100.3 8.3
0.25 130.4 11.0
0.32 15.50.5 13.3
0.40
200.5
16.7
0.45
200.6
16.6
* MINIMUM DISTANCE BETWEEN SHAFTS
(*) M STANDARD
KDM CKDM CCKDM
M
M1
M2
180
235
189
256
219 279
251 319
367
274 354
434
320 420
510
364 482
581
393 511
610
448 579
678
(*) MB for disc brake

KDMB CKDMB CCKDMB
MB
MB1
MB2
206.5
240.5
275.5
303.5
358.5
411.5
440.5
505.5
273.5
300.5
343.5
383.5
458.5
529.5
558.5
636.5
391.5
463.5
548.5
628.5
657.5
735.5

2. ASSEMBLY OF KCG-CKCG-CCKCG
2.1 The gear half coupling includes one connecting flange (50a),
one hub (51b), calibrated screws (53a), one sealing ring OR
(86), and two plugs H (Fig. 2a).
2.2 If the half couplings are supplied with rough bores, the bore and
the keyway may be machined referring to the surface S.
2.3 Clean parts accurately, grease the OR and insert them into the
proper seat in the connecting flange (50a).
2.4 Place the collars on the shafts, avoid damaging the OR. Install
the hubs (51b) on relevant shafts (long part of the hub towards
the shaft end). The hub/shaft ends shall coincide.
2.5 Measure distance C (KCG), C1 (CKCG), C2 (CCKCG). By
adding to them the dimension G (Tab. A1), dimensions M or M1
or M2 are determined (minimum distance between shaft ends).
2.6 Position electric motor and driven machine according to M, M1
or M2 dimension.
Align the shafts by using a dial indicator (Fig. 2a). The

alignment tolerances angular Y-Z (Fig. 1a), and radial X (Fig.
2a), depend on the rotational speed (see Tab. A1).
2.8 Grease the teeth of the hubs and connecting flanges and slide
these (50a) on the hubs (51b).
2.9 Apply the sealing paste or the gasket on the connecting
surfaces of the connecting flanges.
2.10 Insert the fluid coupling between the two half couplings. Fix
with the calibrated screws (53a) and nuts pos. 54a (only for
sizes 713 - Fig. 13). Tighten uniformly according to the
locking torque shown in Tab. H.
2.11 Remove the two plugs H of the flange (50a) Fig. 3a, and fill
with grease in one hole until it leaks from the other one.
Both holes should be in the horizontal position. Carry out
the activity on both flanges. Re-assemble the plugs H.
Regarding grease quantity and quality see Tab. A1.
2.7
Fig. 3a
FIG.3a
S
Fig.
1a
Fig.1a
Z
G/2
G/2
50a 51b
Fig.
2a
Fig.2a
53a
53a
86
H
RECOMMENDED GREASE
NORMAL OPERATION
Tab. A1
KCG
7
8
9
11
12
13
15
17-19
21-24
27
29
34
Speed r.p.m.
M std
500-1000 1000-2000 KCG CKCG CCKCG
y-z
x y-z x
M
M1
M2
143
148
180
189 247
0.25
201 268
211 286.5
0.25 0.20 0.15
257 325
373
255 337
417
325 427
517
414 532
631
0.35
443 561
660
509 640
739
152 US - 0609
KCG
C
140
145
177
186
198
208
252
250
320
408
437
503
C std
CKCG CCKCG
C1
C2
1"-S
244
265
289.5
320
332
422
526
555
634
Gear Coupling
Type
Grease
kg
PA G2 .
1"1/2-S
368
412
512
625
654
733
2x0.03
2x0.08
2"1/2-E
2"1/2-S
2x0.3
3"1/2-E
2x0.65
4"-E
2x0.98
AGIP
CALTEX
CASTROL
CHEVRON
ESSO
FINA
KLUBER
MOBIL
SHELL
TEXACO
TOTAL
CALTEX
KLUBER
TEXACO
GR MV/EP1
Coupling Grease
Impervia MDX
Polyurea Grease EP0
Fibrax 370
Marson EPL1 - Lical EPL1
Kluberplex GE 11-680
Mobilux EP0
Alvania Grease EPR-0/EP1
Coupling Grease
Specis EPG
HEAVY DUTY
Coupling Grease
Grafloscon C SG 500 plus
Coupling Grease

3. FLUID COUPLING FILLING INSTRUCTIONS
..KDM ..KCG - EK series
CKDM - CCKDM - CKCM - CCKCM series
Transfluid fluid coupling are not supplied with oil.

It is necessary to perform the following procedure.
3.1 With the coupling mounted (Fig. 4) rotate it till the X cast into
the housing is at the 12 Oclock position. This will put the fill
plug pos. 13 at the correct angle for the maximum fill level.
3.2 Fill the coupling till oil drains from the filler hole. It is useful to
gentle rock the coupling back and forth to purge trapped air
and removing the pipe plug found on the cover. This will aid in
venting the coupling.
3.3 Reinstall the plug using a quality thread sealant. The plug
torque values can be found in Tab. C.
3.4 The fillings marked X-1-2-3-4 may be chosen by the operators
to meet the best performance in terms of start-up and steady
running operation.
With the maximum fill X a condition of minimum slip and
maximum performance is achieved: the starting torque /
nominal torque ratio gets higher (value generally comprised
between 1.8 and 2.0); decreasing the oil quantity inside the
coupling (fill 1-2-3-4), the opposite result is obtained.
3.5 High slip causes overheating of oil contained in the working
circuit, with a consequent decrease in overall performance.
3.6 For normal operating conditions, use only ISO HM 32 (or
equivalent SAE 10W) oil types listed in Tab. B. At low ambient
temperatures (near 0 C), it is recommended to use ISO FD
10 (or equivalent SAE 5W) oil. For temperatures below 10
C, ask Transfluid.
3.7 For vertical mounted applications, the coupling recommended
oil fills are reported in Tab. B1 or B2 or B3.
Fluid couplings with delayed fill chamber (CK/CCK series) have

been designed to reduce the starting torque/nominal torque ratio to
value of less than 1.6. By enlarging the delay chamber to the
CK/CCK series this ratio can be improved to 1.3.
3.8 The starting torque limitation can be achieved by reducing the
oil quantity into the working circuit (fill 2-3-4) without
increasing the slip value at rated speed. In standstill position,
the delayed fill chamber contains part of the oil fill that flows to
the working circuit during start-up.
3.9 The transfer of the oil from the delay chamber to the working
circuit occurs by centrifugal force, through calibrated nozzles
(Fig. 5). Starting from size 15CK-CCK, such nozzles can be
changed, with the fluid coupling already installed, simply by
replacing the whole valve (sizes 15, 17 and 19) or the
calibrated screw only (pos. b) screwed into the valve pos. 57
(greater sizes).
Such a technical solution allows a very simple and easy
operation, practicable in a short time and moreover, with the
fluid coupling already installed.
During the re-installation of the valve, tighten according to the
torques indicated in Tab. H; remember to install the soft copper
gasket (pos. 58) and make sure that no leakage occurs; if
necessary use sealing paste on threads.
3.10 For each starting torque / nominal torque ratio, Transfluid can
give the exact oil fill. The fluid coupling with a delayed fill
chamber are generally to use with fill 2 (Tab. B2), while the
couplings equipped to use a double delayed fill chamber with
fill 3 (Tab. B3).
As fluid couplings are supplied without oil, follow the
instructions reported at par. 3.1 - 3.2 - 3.3 - 3.6.
3.11 For ver tical mounted applications, the couplings
recommended oil fills are reported in Tab. B2 and B3. Due to
delayed fill chamber peculiarity, for vertical mounting the
chamber must be downward.
Tab. B - Fluid recommendation

Coupling operating temperature
Fig. 4
OIL QUANTITY (lt.)

3
0.425
0.730
1.190
1.550
2.100
3.250
4.050
6.000
9.100
11.20
15.0
22.60
33.50
44.00
66.20
FIG.6
4
0.390 Tab. B2
0.650
CK
1.080
11
1.400
1.850
12
2.900
13
3.600
15
5.400
17
8.200
19
10.00
21
13.50
24
20.50
27
31.50
29
41.50
34
62.50
Gal. = lt
OIL QUANTITY (lt.)

2
3.350
4.800
5.800
8.600
13.60
16.50
23.00
31.20
50.00
63.00
92.50
x 0.2642
3
3.050
4.200
5.200
7.700
12.80
15.20
21.30
28.60
46.50
59.00
88.50
4
2.750 Tab. B3
3.600
CK
4.700
15
6.400
17
11.70
19
14.00
21
19.30
24
26.00
27
43.00
29
54.00
34
83.50
Gal. = lt
X
2 1
13
AIR
2
0.455
0.800
1.295
1.690
2.350
3.575
4.450
6.600
10.00
12.30
16.40
24.60
36.00
47.00
70.60
MAX OIL FILLING
OIL QUANTITY (lt.)

3
4
9.30
8.00
16.36 14.86
18.76 16.86
27.30 24.30
35.43 31.63
59.35 55.15
70.60 65.20
96.70 86.40
x 0.2642
X
1
0.505 0.480
0.920 0.860
1.510 1.405
1.950 1.820
2.750 2.550
4.100 3.875
5.200 4.850
7.650 7.150
11.70 10.90
14.20 13.30
19.00 17.80
28.40 26.50
42.00 39.00
55.00 51.00
82.50 76.60
x 0.2642
K
6
7
8
9
11
12
13
15
17
19
21
24
27
29
34
Gal. = lt
1 X
Tab. B1
Below 160 F
SAE 5W
Non-Detergent
Above 160 F
SAE 10W
Non-Detergent
Fig. 5
57
58
Tab. C
SIZE
FUSIBLE PLUG
N 7018Torque (lb-ft) D. nom
6
7-8-9
11-12
13-15
17-19
21-24
27-29
34
Nm = lb-ft
AB
8.9
1/8"
BB
17
1/4"
CB
21.4
3/8"
DB
32
1/2"
x 1.3558
152 US - 0609

4. OPERATION AND MAINTENANCE
4.1 FLUID COUPLINGS
The standard operating procedures for the coupling shall be applied
controlling stability and temperature. In order not to damage
coupling seals, temperature must not exceed 195 F. For higher
values, all seals, except the rotating ones in Viton, must be made of
special material.
In Tab. E causes and relevant remedies are indicated for the most
common problems that can appear in case of irregular operation.
1) Approximately 20 days after installation, check the fluid level
(activity to be carried out with cold oil), and tightening of
screws of the driver and driven side of the machine.
The fluid coupling is supplied with fusible plug calibrated at 280 F
(if requested also calibration at 250 F and 390 F are available,
according to the application).
If the fusible plug melts frequently, check oil level as indicated in
Tab. B1 - B2 - B3.
2) In case of installation of the switching pin, or the electronic
device for speed measurement, check that distances as
indicated in Fig. 6 and 7 are in conformity with the values
foreseen during installation stage.
It is recommended to replace the working fluid every 4000 hours

of operation.
3)
4.2 DISC COUPLINGS (for KDM series)

No particular maintenance is necessary.
It is recommended to check alignment indicated at para. 1.7 and
screw locking torque after the first hours of operation.
Every 3000 hours, check that there is no evidence of fatigue or
failures on external discs, and check alignment as per para. 1.8.
4.3 GEAR COUPLINGS (for KCG series)
It is recommended to check alignment as indicated at para. 2.7
and locking torque of calibrated screws (53a) or nuts (54a) after
the first operating hours. Every 3000 hours, replace grease
proceeding as indicated in para. 2.10 and check that there is no
evidence of wear on teeth.
Tab. E
SYMPTOM
TOO HIGH
TEMPERATURE
FUSIBLE PLUG
INTERVENTION
PERFORMANCE
DECREASE
INSUFFICIENT OPERATING
SPEED AND/OR
EXCESSIVE SLIP
NOISE AND VIBRATION

WHISTLE
CAUSE
REMEDY
INSUFFICIENT OIL LEVEL

TOO MANY CONSECUTIVE START-UPS
HIGHER ABSORPTIONS THAN SPECIFIED ON TAG
HIGH AMBIENT TEMPERATURE
JAMMED OR OVERLOADED DRIVEN MACHINE
TOO NEAR HEAT SOURCE
TOO CLOSE PROTECTION COVER
OIL LEVEL
Check level and possibly top off

Wait for cooling before restarting, or reduce number of start-ups
Remove causes and/or review motor/coupling dimensioning
Improve coupling ventilation
Remove source or introduce a shield
Introduce convenient air passages to improve heat exchange
Check oil level and fill with the right type if necessary
Replace if necessary (tab. D of page 3)
Verify whether using recommended oil specifications
Use correct oil type (see par. 3.6 at page 3)
Check motor rotating speed (if electric, check connections)
If required time is too long, reduce it to 3 s max.
Check alignment (page 1 par. 1.5 and 1.8 (KDM) - page 2 par. 2.7 (KCG)
Disassemble, check, replace bearings (and relative seals)
Substitute worn elements
Avoid small air passages between cover and machine
OIL TYPE SPECIFICATION

AMBIENT TEMPERATURE LOWER THAN 0 C
FAULTY MOTOR
STAR/DELTA INSERTION TIME
JAMMED OR BRAKED DRIVEN MACHINE
ALIGNMENT
FAULTY BEARINGS
ELASTIC COUPLING ELEMENT WORN
PROTECTION COVER
Fig. 6
5. ACCESSORIES
The fluid coupling can be equipped, beyond the standard fusible
plug, with safety devices avoiding oil to escape, and that, in the
case of the electronic overload controller, can manage a few more
parameters too.
The fusible plug is present as an element of further safety, though
being set at a higher temperature value.
Tab. E1
Dim.
5.1 SWITCHING PIN (Fig. 6)

This device is made of a fusible plug equipped with a metallic
pin inserted in the fusible alloy material of the plug.
In case the intervention temperature is reached, the alloy
material melts making the pin free so that it escapes due to
the centrifugal force, intercepting the cam of the switch,
activating it and supplying the relevant output signal, that can
be used as alarm or motor trip.
In case of external impeller as a driver, indicated in Fig. 9 the
switching pin operates in every condition, while in case of
external impeller as a driven part, it can be activated correctly
only in case of increase of the slip due to overload or to
excessive absorption.
Install fir mly the switch to the base unit according to
dimensions X, Y and Z of table G1, taking into account that the
pin of the fusible plug, in case of intervention, escapes by 16.5
mm and it shall move the cam of the switch.
152 US - 0609
Z
Y
16.5
2.5
60
30
10
50 70
9
10
30
X1
X2
(..KCG)
(..KDM)
X1
X2
Y
KCM CKCM ...KDM
CCKCM
7
108
262
8
117
272
9 144.5
136 287.5
11 151.5 153.5 143 300.5
12
163.5
153 323
13
175.5
170 335
15
200
199 358
17
197
218 382
19
197
210 400.5
21 289 261 260 423
24 290 262 261 460
27
311
277 491
29
336
302 524
34
393
353 584
Indicative dimensions
15
16
16
12
9
8
4
9
8
4
4
DIM
X1
X2

5.4 RESTORING OF THE SWITCHING PIN (Fig. 8)
5.4.1 Screw off the teflon cover and remove the small pin A with the
residuals of melted material.
5.4.2 Drive the fusible ring B on the small pin, paying attention to
the choice for the correct value of the temperature for the
fusible alloy material.
5.4.3 Put the small pin with the fusible ring in the housing C.
5.4.4 Using the tool D similar to that indicated, rivet the fusible ring
at bottom.
5.4.5 Make sure that the pin is blocked.
5.4.6 Screw the teflon cover on the plug body.
N.B.: Such activities must be carried out with fluid
coupling at ambient temperature.
(5.1)It is possible to install this system on all fluid couplings from size
13K even in case it has been not included as initial supply.
For couplings 7K12K, switching pins must be installed by
TRANSFLUID.
The package includes: percussion fusible plug, gasket, conical
plug, glue, instruction for installation.
The electrical connection of the switch shall be realized
with voltage not greater than 230 V and current max. 6 A.
NOTE: Regarding dimensions and further details , refer to
the relevant supplied instructions (TF6438).
5.2 ELECTRONIC DEVICE (Fig. 7a 7b 7c)
The electronic device for the control of overload is made by a
proximity switch and an electronic speed controller (Fig. 7a). It
reads the coupling output speed. When the resistant torque
increases the coupling slip increases, as a consequence the
output speed decreases. If this output speed decreases below
the controller set point for a time period greater than the period
of non-intervention time set, the switching of the internal relay
occurs.
It is possible to install this electronic system on all fluid
couplings where it has not been included as initial supply.
For couplings size 7K13K, it is sufficient to replace the two
screws placed at 180 along the external rim (as indicated in
Fig. 7c). For couplings size 15K34K KDM series it is
necessary to prepare two fixing holders as indicated in Fig. 8
Tab. F, and insert them below two screws and relevant washers
(pos. 56-66) at 180 (Fig. 7a).
For coupling KCG series It is necessary to install two screws
M10x16 and relevant nuts (Fig. 7b) into the proper threaded
holes at 180 on part 27 or 63 (reverse mounting).
It is necessary that the proximity switch be in line with the two
fixing holders (KDM) or screws (KCG), at a distance not greater
than 5 mm, while the controller can be installed in the most
suitable place as chosen by the operator, within a max. wiring
length of 20 m increasing properly the cable of the proximity
switch. Before cabling the wiring connections always check
the voltage supply.
N.B. For further details regarding electronic functions and
connections, refer to the relevant supplied instructions.
DIM.
C D
Fig. 7a
RPM
Fig. 7d
M18x1.5
1490
15-20
1
2
AT
78.50
56-66
Fig. 7b
27
63
Fig. 7c (only for 713)
Fig. 8
Fig.8
Tab. F
5.3 INFRARED TEMPERATURE (Fig. 7d)

21 31
11 9
15-17-19
The electronic controller (Fig. 7d) is used for 21-24
the detection of the
25 36 infrared
18 15 11
temperature in operation. A device is equipped with
27-29
sensor that, properly placed close to the fluid coupling, allows
28 38
17 12
34
an extremely accurate temperature measurement without
contact.
Temperature is shown on a proper display that allows the setting
of 2 alarm values (logic alarm on the first, relay alarm on the
second). The sensor should be positioned close to the external
impeller or the cover of the fluid coupling, choosing, for instance,
the solution as shown in Fig. 7d.
The distance between the sensor and the fluid coupling should
be approx. 15 - 20 mm (the cooling ribs dont disturb the correct
operation of the sensor itself).
In order to avoid that the shining surface of the fluid coupling
can produce reflexes that can distort the correct reading of the
temperature, it is necessary to paint opaque black the surface of
the coupling directly exposed to the sensor (a 6-7 cm stripe is
sufficient). Sensor cable has a standard length of 90 cm. In
case, it can be extended only with twisted and shielded wire for
thermocouples type K.
N.B. For further details regarding electronic functions and
connections, refer to the relevant supplied instructions.
Dim.
15-17-19 21
21-24
31
11
36
18 15 11
27-29
34
28
38
17 12
Fig. 9
A C B
60
2.5
30
7
R.1
B
E
25
152 US - 0609
Fig. 7
25
3.25
1.5
C

6. RECOMMENDED SPARE PARTS (Tab. 10-11-12-13)
When ordering spare parts, always mention the type of coupling and
specification number marked on the external impeller in the positions
indicated in Fig. 10 or on the opposite side (cover) (27K, 29K, and 34K
have a name plate showing the serial number also).
6.1 Seal kit ...KDM/...KCM item 4.5 (5a) - 6 (15) - 20-32 (41)
item (5a) only for ...CKDM/...CKCM - item (15) excluded 9-1113-17-19-21-24 KCM
item (32) only for 17-19 ...CKCM - item (41) only for 27-29-34
...KDM/...KCM.
6.2 Fusible plug pos. 13a.
6.3 Disc pack kit pos. 52-53-54.
6.4 Gear half coupling kit pos. 50a-51b-53a-86.
Fig. 10
7.
REPLACEMENT OF SEALING RINGS, BEARINGS AND

DISC PACKS (Fig 11-12-13-14)
NB: To operate on the surfaces described as follows, always
use a mallet in teflon, and not a metal hammer.
7.1 Remove screws pos. 56 (KDM) or 53a (KCG)
7.2 Remove the fluid coupling proceeding as indicated at page 1
pos. 1.6 (KDM) and page 2 (KCG)
7.3 Remove the oil from the coupling removing plugs pos. 13 on
cover and delay chamber and pos. 13a
7.4 If the coupling is equipped with delay chamber, remove it after
removal of screws pos. 34. Together with it, the flange pos. 27
or 27a (not to be removed) and seal ring pos. 15 will remain
7.5 Remove nuts pos. 11, insert two screwdrivers into the gap
between bearing carrier pos. 14 or 14a and cover pos. 3 or 3a
and lever up to the extraction of the bearing carrier and seal
ring pos. 15
7.6 Remove screws pos. 8-10, and remove cover pos. 3 by the help
of the mallet in teflon
7.7 Remove the bearing pos. 16 with a puller and recover the
screen pos. 47
Remove the flange pos. 63. For couplings from 9..K up to 19..K,
remove the screw pos. 25, insert a small threaded bar into the
hole for extraction Q (dimensions in Tab. L), so that pushing
against the end of the flange, allows the removal of the flange
itself. For couplings from 21..K up to 34..K, remove screws pos.
64 and washer pos. 65.
7.8 Remove the elastic ring pos. 18 and remove the impeller pos. 1
7.9 Remove the screws pos. 9 and the screen pos. 17 (11K24K)
or the closing disc pos. 40 (27K34K). Hitting on surface B of
shaft pos. 24, take off the bearing carrier pos. 23 or the seal
carrier pos. 19 (only for 27K34K) with sealing ring pos. 20.
7.10 During re-installation, proceed in the reverse sequence,
replacing the bearings and all seals. Interpose sealing paste
between surfaces of disc pos. 17 and impeller pos. 2, screwing
the screw with a thread restrainer Loctite 243 type.
7.11 For the replacement of the disc pack pos. 52, remove the flange
pos. 50, removing the nut pos. 54 and the calibrated screw pos. 53.
NB: For the tightening of nuts, screws and plugs, refer to the
tightening torques indicated in the following tables:
Tab. D for plugs pos. 13-13a
Tab. H for other pos.
78
A
3-B
10
Specifica
Bom
03
328
Data (mese
anno)
Date
(month+ +
year)
Data
di produzione
Production
date
(settimana
anno)
(week ++ year)
Tab. G
GASKET (VITON)
2395
...KDM
...KCG
SIZE
K..
7
8
9
11
12
13
15
17
19
21
24
27
29
34
(1)
(2)
CK...-CCK...
D
EA
FA
HA
KA
LA
MA
NA
OA
PA
QA
RA
EB
FB
HB
KB
LB
MB
NB
OB
PB
QB
RB
..KDM ..KCG
DISC
GEAR
PACK HALF
(1) KIT
COUPLING
CK..-CCK... 250F 280F 390F
(2) KIT
K...
W
X
1828
FUSIBLE PLUG
N7018
C
D
BA
BB
BC
EB
FB
HB
KB
1055
FA
1828 F
KA
Q
N
1829
R
O
1828
L NB
H OB
PA
PB
QA
QB
RA
RB
1065
1075
CA
CB
1 S
CC
1" 1/2 S
2" 1/2 E
1085
2" 1/2 S
1110
DA
DB
DC
1140
3" 1/2 E
1160
4" E
the kit includes: disc pack, calibrated screws, nuts

the kit includes: hub, calibrated screws and o-ring
Tab. L
DIM.
7-8
9-11-12
13-15-17-19
21-24
27-29-34
Q
M12
M20
M27
M36
M45
Tab. H
..KDM
..KCG
7-8
Screw
pos. 9
dia lb.ft
Nut
pos. 10
dia lb.ft
Nut
pos.11
dia lb.ft
Screw
Screw
pos. 25
pos. 34
dia lb.ft dia lb.ft
M6
M6
M7
12
M10
37
18
M16
M20
151 M8
295
M10
7.5
9-11
12
M8
18
13
15
M10 37
17-19
62
21
24
M14 100
27
29
34
M16 151
Nm = lb.ft x 1.3558
152 US - 0609
M8
7.5
18
M8
M10
M10
37
M12
63 M14
85
106
151 M16
295
M14
M16
M20
37
100
151
LOCKING TORQUE
Nut
Screw
pos. 37
pos. 48
dia lb.ft dia lb.ft
Pag.6
M14
18
37
100
M8
18
M10
37
M14
100
M16
151
M16
128
Screw (Nut)
53a (54a)
dia
lb.ft
1/4
9
28 UNF
Nut
pos. 54
dia lb.ft
3/8
24 UNF
31
M8
25
M8
30
49
84 M10
133
62
1/2
20 UNF
M10
M11
M14
M18
280
3/4
10 UNC 339
Screw
pos. 56
dia lb.ft
105
M22
535
M14
168
M24
686 M16
255
Valve
pos. 57
dia lb.ft
M10
11
M12
15
Screw
pos. 64
dia lb.ft
M12
105
M16
255

Fig.1
Fig.
-: 24... KDM)
Fig.1111(9
(924...KDM)
3
13
10 39
13a 17
27
12
54
53
52
50
66
11
56
56 66
59
14
51
16
15
63
26
20
25
21
14a
24
38
37
36
27
only for
15-17-19-21-24
13
33
KDMB
7a
11
12
34 35
5a
3a
18
47
22
23
57 58
POS.
1
2
3-3a
4
5-5a
6
7-7a
8
9
10
11
12
13
13a
14-14a
15
16
17
18
20
21
22
23
24
25
NAME
Internal impeller
External impeller
Cover
O-ring
O-ring or Gasket
O-ring or Gasket
Screw
Screw
Screw
Nut
Nut
Washer
Taper plug
Fusible taper plug
Bearing carrier
Sealing ring
Ball bearing
Shield
Elastic ring
Sealing ring
Ball bearing
Elastic ring
Bearing carrier
Shaft
Tie rod (except 21 24)
POS.
26
27
33
34
35
36
37
38
39
47*
50
51-51a
52
53
54
56
57
58
59
63
64
65
66
152 US - 0609
NAME
Washer
Flange motor side
Delay chamber
Screw
Washer
Screw
Nut
Washer
Washer
Oil retainer
Connecting flange
Hub
Disc pack
Calibrated screw
Nut
Screw
Complete valve
Gasket
Washer
Flange for shaft
Screw
Washer
Washer
51a
KDMBP
only for 21 - 24
65 64
only for 1534
PAG.
AG.7
7
7
63

Fig.12Fig.
(27
34... KDM)
12-: (2734...KDM)
5
13
10 39
13a
27
12
54
53
52
50
66
11
56
59
14
51
16
40
50
56 66
41
63
15
19
20
24
14a
38
37
64
36
65
27
only for
15-17-19-21-24
21
13
33
7a
..KDMB
11
12
34 35
5a
3a
47
18
22
23
57 58
POS.
1
2
3-3a
4
5-5a
6
7-7a
8
9
10
11
12
13
13a
14-14a
15
16
18
19
20
21
22
23
24
27-27a
NAME
Internal impeller
External impeller
Cover
O-ring
Gasket or O-ring
Gasket or O-ring
Screw
Screw
Screw
Nut
Nut
Washer
Taper plug
Fusible taper plug
Bearing carrier
Sealing ring
Ball bearing
Elastic ring
Seal carrier
Sealing ring
Ball bearing
Elastic ring
Bearing carrier
Shaft
Flange
POS.
33
34
35
36
37
38
39
40
41
47*
48
49
50
51-51a
52
53
54
56
57
58
59
63
64
65
66
152 US - 0609
NAME
Delay chamber
Screw
Washer
Screw
Nut
Washer
Washer
Closing disc
O-ring
Oil retainer
Screw
Washer
Connecting flange
Hub
Disc pack
Calibrated screw
Nut
Screw
Complete valve
Gasket
Washer
Flange for shaft
Screw
Washer
Washer
only for 1534
51a
..KDMBP
only for 34
48 49 27a

Fig. 13
11-13
- 13--17
17 -- 19
19 -- 21
(9(9- -11
21- -24
24KCM)
- KCM)
Fig.13
only for 7 - 8
13
10 39
2 13a 17
only for
17 - 19 - K.. - CK.. - CCKCM
12a
7
2
22a 23
14b
6a 39a
16
54a 53a 50a 51b 86
86 51b 50a 53a 54a

26a
25a
24a
25
20
26
21
38
63
37
24
36
27
13
only for
15-17-19-21-24
(CK.. - CCKCM)
15
only for 15
only for 21 - 24
64
31
32
65
33
24
7a
63
11
57 58
only for 17 - 19
12 14a 34 35
5a
3a
47
18
22
23
..KCGB
- 12
- 13
- 15- -21
21 -- 24
24 CK...-CCKCM)
(11(11
- 12
- 13
- 15
- CK.. - CCKCM)
POS.
NAME
POS.
NAME
25-25a
Internal impeller
1
Tie rod
POS. 26-26a NAME
POS.
Washer
2 NAME
External impeller
25-25a
Tie rodFlange
1
Internal
impeller
27-27a
3-3a
Cover
26-26a 31
WasherSeal carrier
2
External
impeller
O-ring
4
27-27a 32
Flange O-ring
3-3a
Cover
5-5a
Gasket or O-ring
31
Seal carrier
4
O-ring
Gasket or O-ring
6-6a
33
Delay chamber
32
O-ring Screw
5-5a
Gasket
34
Screw
7-7a or O-ring
33
Delay chamber
6-6a
Gasket
8 or O-ring
Screw
35
Washer
34
Screw Screw
7-7a
Screw
9
36
Screw
35
WasherNut
10
37
8
Screw
Nut
36
Screw Washer
11
Nut
9
Screw
38
37
Nut Washer
39-39a
12-12a
Washer
10
Nut
38
WasherSeal
Taper plug
47
11
Nut 13
13a
Fusible taper plug 39-39a
WasherSleeve
50a
12-12a
Washer
14-14a-14b
Hub
47* 51b-51c
Oil retainer
13
Taper plug Bearing carrier
15 taper
Sealing
53a
50a
Sleeve Calibrated screw
13a
Fusible
plug ring
16 carrier
Ball bearing
51b-51c 54a
Hub Nut
14-14a-14b Bearing
Complete
57
17 ringShield
53a
Calibrated
screwvalve
15
Sealing
58
Gasket
54a
Nut
16
Ball18
bearingElastic ring
Flange
for shaft
63
Sealing ring
20
57
Complete
valve
17
Shield
64
21 ring Ball bearing
58
GasketScrew
18
Elastic
65
22-22aringElastic ring
63
FlangeWasher
for shaft
20
Sealing
86
64
Screw O-ring
21
Ball 23
bearingBearing carrier
24-24a
65
Washer
22-22a
Elastic
ring Shaft
23
24-24a
Bearing carrier
ShaftUSA-09
152
86
152 US - 0609
Fig.
13a
Fig.13a
51c
only
KCM
onlyfor
for77-- 88 -- 12
-12 -- 15
15 -- KCM
5
11 12
27
14
15
25
26
O-ring
only for 1534
..KCGBP

Fig. 14(27
(2734...KCG)
-: 34... KCG)
Fig.14
5
13
10 39
13a
27
12
11
7
86 51b 53a 50a
40
14
50a 53a 51b 86
41
16
63
15
19
20
24
14a
B
38
37
64
36
65
27
only for
15-17-19-21-24
21
13
33
7a
..KCGB
11
12
34 35
5a
3a
47
18
22
23
57 58
POS.
1
2
3-3a
4
5-5a
6
7-7a
8
9
10
11
12
13
13a
14-14a
15
16
18
19
20
21
22
23
24
NAME
Internal impeller
External impeller
Cover
O-ring
Gasket or O-ring
Gasket or O-ring
Screw
Screw
Screw
Nut
Nut
Washer
Taper plug
Fusible taper plug
Bearing carrier
Sealing ring
Ball bearing
Elastic ring
Seal carrier
Sealing ring
Ball bearing
Elastic ring
Bearing carrie
Shaft
POS.
27-27a
33
34
35
36
37
38
39
40
41
47*
48
49
50a
51b-51c
53a
54a
57
58
63
64
65
86
152 US - 0609
NAME
Flange
Delay chamber
Screw
Washer
Screw
Nut
Washer
Washer
Closing disc
O-ring
Oil retainer
Screw
Washer
Sleeve
Hub
Calibrated screw
Nut
Complete valve
Gasket
Flange for shaft
Screw
Washer
O-ring
only for 1534
10
51c
..KCGBP
only for 34
48 49 27a
For Electric Motors and Internal

Combustion Engines:
ENERGY EFFICIENT
REDUCE POWER CONSUMPTION
PROTECT EQUIPMENT AND PROVIDE SMOOTH
ACCELERATION
IMPORTANT NOTICE, WARRANTY: Seller warrants its product
sold herein against defects in material and workmanship for a
period of 12 months from the date of invoice; provided, that the
installation, operation and maintenance of said product conforms
with any and all manufacturers specifications and all applicable
government health and safety regulations. Sellers obligation under
this warranty shall be limited to replacing and or repairing, at its
facility or facility so designated, any part thereof which has been
demonstrated to be defective. Seller shall not be responsible for
any and all costs related to the disassembly, transportation and
shipment to Sellers repair facility and reinstallation of any defective
part or parts repaired according to the terms of this warranty. The
Sellers sole responsibility shall be to repair and replace defective
parts according to the terms of this limited warranty; Sellers shall
not be responsible for any and all consequential damages
including, but not limited to, personal injury, property damage and
loss of income and profits. The drawings, charts, diagrams and
information contained in this sales package are for the sole
purpose of identifying the product and shall not be deemed to
create an expressed warranty that the goods shall conform to such
description. No affirmation, promise or description shall be
deemed part of the basis of the bargain.
This warranty is expressly in lieu of all other
warranties expressed or implied including the
warranty of merchatability and fitness for a particular purpose
or use and all other obligations or liabilities on the Sellers
part.
Seller neither assumes, nor autohorizes any other
persons to assume for it, any other liability in connection with the
sale of this product.
LOCAL DISTRIBUTOR
KRAFT POWER CORP.

1000B Northbrook Parkway Suwanee GA 30024 Tel. 770/963-6288
Toll Free 800/394-0078 Fax: 770/963-9678 E-mail transfluid@kraftpower.com
0609 - 152 US
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PARTS INDEX
SECTION
SECTION
SECTION
PN: 48841
Accu-Count 2.0
Users Guide
The Accu-Count 2.0 is a very simple to use hose distance
measuring system. Use the Menu buttons below the on-screen
text to select your option.
The RESET button will clear the counter back to zero.
The STORE button will store a time and date stamped distance
into the Accu-Count memory. You can store up to 10 unique
distance measurements to recall at a later time.
The RECALL button will allow you to view your stored
distance measurements.
Accu-Count 2.0 Setup Information
Menu Keys
Enter Key
Navigation Keys
** Make Sure You Have Installed The Coin Cell Battery Prior To Setup
Counter Setup
>
Choose the Counter option by pressing the menu key directly below the on-screen text. Use your
navigation keys to move between each of the parameters that need to be set. Use the Enter key to select.
>
Unit of Measure Setup - Select this by using your Navigation keys and pressing the Enter key. Use the
Navigation to move between Standard Units and Metric Units and press the Enter key to select.
>
Setup Reel Parameters - Select this by using your Navigation keys and pressing the Enter key. Use the
Navigation to move between the options. If your Vactor reel type is not listed, select each of the Custom
options and manually enter the information.
>
Setup Hose Parameters - Select this by using your Navigation keys and pressing the Enter key. Use you
Navigation to move between the options to select the hose type and diameter. If your hose type is not
listed, select Custom Entry and manually enter your hoses outside diameter.
>
Setup Hose Length - Select this by using your Navigation keys and pressing the Enter key. Use the
Navigation keys and the Enter key to type in your overall hose length (including any leader hose). Once
you have typed it in, select RET to return to the main menu.
>
Setup Encoder Direction - Select this by using your Navigation keys and pressing the Enter key. Select
the direction the hose reel / encoder is turning.
>
Once all parameters have been entered, select the Exit Counter Setup using your Navigation and Enter
keys.
System Setup (Date & Time)
>
Make sure you set up the counter first before setting up the system. Choose the System option by pressing
the menu key directly below the on-screen text. Use your navigation keys to move between Set Time and
Set Date. Use the Enter key to select. Using the Navigation keys and the Enter key enter either the
date or time.
>
The time is a 24 hr clock. Enter the time as HH-MM-SS. Dont forget to enter the dashes
>
The date is entered as DD-MM-YYYY. Dont forget to enter the dashes
>
To finish, use your Navigation keys and the Enter key to select Exit System Setup.
Accu-Count 2.0
Installation Instructions
PN: 48841
Install coin cell battery firmly into the board

Connect the power wires
Pin 1 or 3 - Ground
Pin 2 (Cener Pin) - +12 VDC
Connect the encoder:
Pin 1 - Encoder Channel A (White Wire)
Pin 2 - Encoder Channel B (Blue Wire)
Pin 3 - Encoder Shield (Green Wire)
Pin 4 - Encoder Power Ground (Black Wire)
Pin 5 - Encoder Power Supply (Red Wire)
Driver Board
Encoder
!
!
Battery
Battery Tab Removal
Power
The backup battery on the Accu-Count 2.0 has a plastic tab to

protect the battery against discharging before the Accu-Count
2.0 is placed into service. Although the battery is located
inside the Accu-Count 2.0's protective casing, it is possible to
reach the plastic tab using pliers or tweezers from the opening
on the side of the Accu-Count 2.0.
Also install the battery
into the driver board
before you setup the
system.
Cut Out Dimensions
Battery # CR2032
4.86
5.67
3.3V 235 mA/H
Crimp Terminal Information
Application Tooling
Hand Crimper - PN 11-01-0185
Extraction Tool - PN 11-03-0022
Insertion Tool - 63812-0000
3.82
4.41
0.51
Molex Part Number: 08-50-0114

Product Name: Kk
Molex Series: 2759
Gender: Female
Wire Size: 22, 24, 26, 28, 30
Wire Insulation Diameter: 1.57mm (0.062) max
Remtron Electronic Remote Controls.

Directions for warranty assessment or unit repair.
Vactor manufacturing provides Remtron Electronic controls as an
option on its product lines. All failed units must be returned directly to
Remtron for repairs or warranty evaluations. Call 1-800-328-5570
and request a return authorization number. Remtron will require
the serial number from the tag on the unit being returned. Remtron
units carry an assigned warranty and all warranty evaluations and
repairs will be provided by Remtron. At no time should complete
units be replaced without specific authorization of the Vactor Service
Manager or Regional Field Service Managers. Any authorization
should include a case number with the relevant information.
This process substantially improves the turn around time. The
process is also required due to the electronic design of the units.
Vactor is not equipped to repair these components.
The Remtron units have auto link programming in units built after
2004. Units prior to that require programming of the transmitter to
match the frequency of the receiver.
Remtron ,Inc
1916 W. Mission Road
Escondido, California 92029
Reference Service Bulletin 217 - 05 FEB 2007
Wireless Control Systems
COMMAND PRO
23 SERIES
USERS MANUAL
Manual No. 142133 Rev. A

This Manual Covers the Following Model Numbers
Hand Held
Transmitters
Lever Style
Transmitters
23T10
23T14
23T18
23T20
23T23
23T44
Receivers
23R05
23R15
23R23
23RCAN
WARNING!
AVERTISSEMENT!
Read all safety and warnings before

installing and operating this system.
Lire toutes les consignes de scurit

et tous les avertissements avant de
faire fonctionner ce systme.
http://www.remtron.com
1916 W. Mission Road, Escondido, CA 92029-1114 Ph: 800-328-5570 Fax: 760-737-7810
REMTRON, INC.
COMMAND PRO RECEIVERS
The COMMAND PRO Series receivers have been tested and found to comply with the limits
for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed
to provide reasonable protection against harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause harmful interference to radio communications. However, there is no guarantee that harmful interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning this equipment on and off, the user is encouraged to try and correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna connected to the device that is receiving
the interference.
Increase the separation between our equipment and the equipment that is receiving
the interference.
Consult our factory or one of our Service Representatives for additional help.
Responsible Party:
Remtron, Inc.
1916 W. Mission Rd.
Escondido, CA 92029
Ph:
800 328-5570
760 737-7800
142133-A
04/03
Table of Contents
LIST OF ILLUSTRATIONS ........................................................................................... ii
WARNING INSTRUCTIONS ........................................................................................ iii
CONSIGNES DE SCURIT ......................................................................................... iv
INTRODUCTION ............................................................................................................ 1
ID Codes ...................................................................................................................... 1
Programming ............................................................................................................... 1
Programming Accessories .......................................................................................... 1
AutoLink ...................................................................................................................... 2
Options ...................................................................................................................... 2
TRANSMITTERS ............................................................................................................. 3
Transmitter Description .............................................................................................. 3
Transmitter Safety and Operational Features ......................................................... 5
Transmitter Specifications .......................................................................................... 6
RECEIVERS ...................................................................................................................... 7
Receiver/Decoder ....................................................................................................... 11
AutoLink ...................................................................................................................... 11
Power Supply ............................................................................................................... 11
Receiver Diagnostics ................................................................................................... 11
Safety Features ............................................................................................................. 11
OPERATION ..................................................................................................................... 12
Receiver Operation ..................................................................................................... 12
Transmitter Operation ................................................................................................ 12
INSTALLATION INSTRUCTIONS ............................................................................. 13
Antenna Location ......................................................................................................... 13
Receiver Mounting ...................................................................................................... 14
Receiver Wiring ........................................................................................................... 14
Power/Control Wiring ............................................................................................... 14
Installation Testing ...................................................................................................... 15
MAINTENANCE AND TROUBLESHOOTING ........................................................ 16
Monthly Inspection Schedule .................................................................................... 16
Transmitter Troubleshooting ..................................................................................... 16
Transmitter Repairs ..................................................................................................... 17
Battery Replacement ................................................................................................... 17
Changing the Transmitter Identity Code ................................................................. 17
Changing the Transmitter Keypad ........................................................................... 18
23T44 Switch Replacement ......................................................................................... 18
Transmitter Spare Parts List ....................................................................................... 20
Receiver Testing .......................................................................................................... 21
Receiver Troubleshooting .......................................................................................... 21
Receiver Repairs .......................................................................................................... 22
Fuse Replacement ....................................................................................................... 22
Changing the Receiver Identity Code ...................................................................... 24
WARRANTY STATEMENT .......................................................................................... 25
How to get service ....................................................................................................... 26
142133-A
04/03
List of Illustrations
Figure
Figure
Figure
Figure
Figure
Figure
Figure
142133-A
04/03
1.
2.
3.
4
5.
6.
7.
23 Series Transmitters ............................................................................... 4

23 Series Receivers .................................................................................... 8, 9, 10
Transmitter/Receiver Communication .................................................. 13
Antenna Clearance ..................................................................................... 13
23 Series Transmitters with back removed ............................................ 19
23R15 Fuse Locations ................................................................................ 22
23R23 Fuse Locations ................................................................................ 23
ii
WARNING INSTRUCTIONS
WARNING!
READ ALL INSTRUCTIONS

Failure to follow the SAFETY RULES may result in serious personal injury.
INSTALLATION
GROUND THE RECEIVER CASE. In order to insure safety of the system, the
receiver case must be firmly connected to earth ground.
PROVIDE A SAFETY CUTOFF SWITCH. If maintenance is required, the radio

must be disconnected from power to prevent accidental activation.
USE PROPER WIRING. Loose or frayed wires can cause accidental activation of
machinery.
DO NOT INSTALL IN HOT AREAS. This apparatus can be damaged by heat in

excess of 160 F.
DO NOT INSTALL IN HIGH VIBRATION AREAS. The life of this apparatus may
be shortened through long exposure to intense shaking or vibration.
PERSONAL SAFETY
MAKE SURE MACHINERY IS CLEAR BEFORE OPERATING. Do not activate

the remote system unless it is safe to do so.
TURN OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY.

Always disconnect the remote system before doing any maintenance to prevent
accidental operation of the machine.
CARE
KEEP DRY. If water or other liquids get inside, immediately dry the unit.
KEEP ANTENNAS CLEAN. Keep antenna connections clean and free of

corrosion.
142133-A
04/03
iii
CONSIGNES DE SCURIT
AVERTISSEMENT!
Le non respect des CONSIGNES DE SCURIT peut causer des blessures
srieuses.
INSTALLATION
RACCORDER LE BOTIER LA MASSE. Pour que le systme fonctionne en

toute scurit, le botier du rcepteur doit tre solidement raccord la masse.
FOURNIR UN INTERRUPTEUR DE SCURIT. Lors de travaux dentretien du

dispositif, dconnecter le poste radio afin dviter une mise en marche
accidentelle..
UTILISER LES FILS APPROPRIS. Des fils dcouverts ou uss peuvent

provoquer un dmarrage accidentel de la machinerie.
NE PAS INSTALLER DANS DES ENDROITS CHAUDS. Des tempratures

suprieures 160 F (71C) peuvent endommager lappareil.
NE PAS INSTALLER DANS LES ENDROITS SOUMIS DE FORTES

VIBRATIONS. Lexposition prolonge de cet appareil des vibrations ou des
secousses intenses peut en rduire la dure de vie.
SCURIT
SASSURER QUE LA MACHINERIE EST DGAGE AVANT DE LA FAIRE

FONCTIONNER. Ne pas faire fonctionner le systme de tlguidage moins que
cela puisse tre fait en toute scurit.
METTRE LE RCEPTEUR HORS TENSION AVANT DEFFECTEUR DES

TRAVAUX SUR LA MACHINERIE. Afin de prvenir la mise en marche
accidentelle de la machinerie, toujours dbrancher le systme de tlguidage avant
de deffectuer des travaux dentretien.
ENTRETIEN
GARDER AU SEC. Scher immdiatement lappareil, sil est expos de leau

ou tout autre liquide.
GARDER LES ANTENNES PROPRES. Garder les raccordements dantenne

propres et exempts de corrosion.
142133-A
04/03
iv
INTRODUCTION
The Remtron Command Pro Wireless Control Systems are designed for control of
industrial and commercial equipment. These rugged controls are built to survive the
wear and tear of life in factories, mills and construction industries. The 23 Series is
designed especially for the mobile markets. These systems comply with requirements
for operation under Part 15 of the FCC Rules and Regulations. This means neither the
operator nor the company need apply or register for a license to operate this
equipment.
The basic system consists of a transmitter and a receiver. The transmitter sends
commands to the receiver by means of radio waves in the 900 MHz band. Receivers
operate from 12 VDC vehicle power. Operation from 24 VDC is also available.
ID Codes
Each transmitter and receiver can be programmed for any one of 81 operating
frequencies plus a 16 bit address code. A single ID Code is used to set and identify
both the frequency and address. There are millions of codes so that no two systems will
ever by assigned the same code unless specifically requested for a particular
application.
Each system is fully programmed and tested before shipment from the factory and
should require reprogramming only in the case of spare management. (see
maintenance)
Programming
One of the key features of the decoder is Remtrons exclusive Manufacture
Application Program (MAP). The MAP determines how the outputs are directed, what
type they are, how they operate, what safety criteria is required, and what processing
time should be used for each one. In short, the MAP allows Remtron to match the
control requirements of almost any system. Remtron programs the MAP at the factory.
Programming Accessories
A stand-alone programmer, the RAC16A, is available for most applications. It
provides a convenient method for changing the ID Code and making basic application
changes to transmitters and receivers.
For operations that maintain multiple systems with a variety of configurations, a
RAC17 is recommended. The RAC17 is a computer-based programming system that
consists of an RS-232 interface box and a computer program for PC compatible
computers. This system allows storage of configurations including the MAP and ID
code for each system.
142133-A
04/03
AutoLink
Some receivers are provided with the AutoLink system which allows the
receiver to copy the ID code from any of the 23 series transmitters by the push of a
button.
Options
Custom Labels. Custom labels are available from the Remtron factory to best suit your
application.
Custom Programming. Output relays can be programmed to meet special control
requirements.
First-Come First-Serve (FCFS): The First-Come First-Serve option allows use of
multiple transmitters with one receiver, one at a time. The receiver scans a preset list of
ID Codes. When a valid signal is received, the receiver stops scanning and responds
only to that transmitters signal. When the signal is no longer being received (i.e., the
transmitter has been turned off or is out of range), the receiver again scans until another
valid signal is received.
Multiple Receivers Controlled By Multiple Transmitters Option. One transmitter
can control up to a maximum of six receivers with a rotary selector switch.
Extended Range Antenna. An extended range 900 MHz antenna, Model RAC7 is
available for special applications that require increased range.
Intrinsically Safe. Intrinsically Safe UL-approved systems with NEMA 7 receiver
enclosures are available for ratings of up to Class 1, Division 1, Group D.
The following features are offered on the 21T18, 21T20 and 21T23:
Push-button Selector. A selector switch is provided that selects A, B, or both for
systems that have multiple similar systems that need controlling separately or together.
Two LEDs indicate the active system in dual mode operation.
On transmitters with a single button selector switch, momentarily pressing the
selector switch will cycle the selection between functions. If A LED is lit (A
function is active), pressing the selector switch causes A LED to go out and B
LED to light (B function now active). Pressing the switch again will cause A LED
to light in addition to B LED (Both functions active). Pressing the switch again
will cause both LEDs to go out (no function is active).
On 23T20/23T23 transmitters, an optional rotary selector switch can control/

select up to 6 different receivers or functions.
142133-A
04/03
TRANSMITTERS
Transmitter Description
This section describes the safety/operational features, troubleshooting and
repair of the 23T10, 23T14, 23T18, 23T20, 23T23 and 23T44 transmitters. Many of the
features are common in all transmitters; therefore, descriptions have been combined for
the purposes of this document. To assist in finding the specific information for your
transmitter, the model number has been bolded and italicized.
Remtron hand held transmitters are housed in a rugged case molded from a
modified polymer plastic that stands up to extremely rugged use. A key feature is
Remtrons patented switch assembly for control inputs. This long-life elastomeric
keypad is ergonomically designed to provide easy operation over long periods of time
with exceptional reliability. A leather holster is available for ease of carrying the
transmitter, plus it offers added protection.
The 23T44 transmitters are housed in a rugged, lightweight case designed to
stand up to extremely rugged use. The transmitters use sealed push-button and toggle
switches for discrete inputs and high quality rotary joysticks for motion control
functions. A shoulder strap is provided to allow easy carrying and use of the
transmitter.
All transmitter functions are controlled by a microprocessor with a special
memory for configuration information. This offers a great degree of capability and
versatility, while at the same time provides simplicity of operation and maintenance.
The antenna is internal to the handheld transmitter cases, protecting it from
damage. The antenna on the 23T44 is enclosed in a protective plastic housing attached
to the transmitter case, protecting it from damage. A self-test LED indicator provides a
quick visual check of transmitter and battery status.
The transmitters are designed to be very efficient. Two AA batteries provide
power for the transmitter. (Three batteries for the 23T20/23T23, up to nine for the
23T44.) An additional feature automatically shuts the transmitter off after a
programmable time interval of inactivity to further extend the battery life.
These transmitters are programmable by means of an independent programming
unit (RAC16A) or a PC-based programmer (RAC17A) and computer equipped with an
RS-232 serial port.
142133-A
04/03
23T10
23T14
23T18
23T20
23T44
Figure 1: 23 Series Transmitters
(Example Label Shown)
142133-A
04/03
23T23
Transmitter Safety and Operational Features

WARNING!
Do not operate the system until you are familiar with radio-controlled
operation. If you are not familiar with radio-controlled crane operation,
contact your supervisor before attempting to use the radio control system.
AVERTISSEMENT!
Ne pas fair fonctionner le systme avant de bien connatre le fonctionnement
dune grue par tlguidage. Contacter lesuperviseur avant de faire toute
tentative de mise en marche par tlguidage, si le fonctionnement nest pas
connu.
The following describes the safety and operational features and characteristics of
the transmitters. Refer to Figure 1.
Status LED. The status LED provides an indication of the transmitter operation. Refer
to the section on Troubleshooting for a detailed description of the status LED indications.
Command Switches. The command switches are labeled according to their function.
If opposing commands are attempted, i.e., two commands that conflict with each
other, in most cases no function will result. In the case of ON/OFF functions,
OFF will predominate.
If more than one speed command is sent for the same function, the lower speed
will predominate.
Maintained on or off functions require separate commands for on and off.
On. Turns on the transmitter and puts the system in the active mode. The transmitter
will remain active until the OFF/ESTOP is pressed or the transmitter turns itself off
(see Auto Off).
Off/EStop. While depressed, sends an Emergency Stop command to the receiver. The
transmitter does not need to be actively ON to send this command. When this button
is released, the transmitter will be turned off.
Auto Off. The transmitter will turn itself off if no commands have been sent for a
predetermined time. Normally this time is set to 15 minutes, however it may be
programmed from 0 to 60 minutes, or disabled using a RAC16 Programmer.
(1 to 60 = minutes, 0 = disabled)
142133-A
04/03
Transmitter Specifications
Operating frequency band ........... 902 - 928 MHz
Channel spacing ............................. 300 KHz
Modulation ..................................... Digital Frequency Modulation based on Manchester Code.
Contains 16-bit address plus 16 bit CRC check.
Power, input ................................... AA cell batteries (Alkaline recommended)
Output power ................................ Meets FCC Part 15 requirements for license-free operation
Antenna ........................................... Circuit board, internal or front mounted (23T44)
Indicators ........................................ Self test LED indicator
Ambient Operating Conditions ... -20 F to +160 F
Model
Weight(1)
Dimensions
23T10
23T14
23T18
23T20
23T23
23T44
9 oz.
9 oz.
9 oz.
1.25 lb.
1.25 lb.
4 lbs.
2.75" x 6.5" x 1.0"

2.75" x 8.0" x 1.0"
2.75" x 8.0" x 1.0"
3.5" x 11.5" x 1.0"
3.5" x 11.5" x 1.0"
5.0" x 10.0" x 6.5"
Notes:
Number of
Commands
10
14
18
20
23
24 + 8(2)
Batteries
2
2
2
3
3
3, 6 or 9
(1) Weight includes batteries

(2) 23T44 can transmit 24 discrete plus 8 analog commands
Certifications
Model
FCC ID#
Industry Canada
Certification #
23T10
23T14
23T18
23T20
23T23
23T44
EGT810TX
EGT814TX
EGT818TX
EGT820TX
EGT823TX
EGT844TX
249 710 2624

249 710 31887
249 710 32099
249 710 31891
249 710 31892
249 710 31889
142133-A
04/03
RECEIVERS
This section describes the 23R05, 23R15, 23R23 and 23RCAN receivers. Many of
the features are common in all receivers; therefore, descriptions have been combined
for the purposes of this document. To assist in finding the specific information for your
receiver, the designation has been bolded and italicized.
Receiver Description
Command Pro series receivers contain sophisticated programs coupled to
electrically tough interfaces. These powerful systems offer several advantages:
Safety Three levels of safety insure safe operation even in the event of circuit
failures.
Reliability Wide use of surface mount parts and few interconnections between
boards provide greater reliability and easier service.
Simplicity Easy diagnostics and simple troubleshooting procedures makes
servicing quick and easy.
Versatility Programmability plus many options allow this system work on
virtually any equipment without modifications to the basic control system.
The receivers consist of one or two circuit boards mounted inside a NEMA 4
Extruded aluminum enclosure. Figures 2 shows the general arrangement of the
receivers.
142133-A
04/03
TNC Antenna
Connector
3.50
3.50
POWER
Model 23RCAN
Made in the U.S.A.
1916 W. Mission Rd.

Escondido, CA 92029
(800) 328-5570
Wiring Diagram
K3
K4
K5
K2
K3
POWER
8.28
SIGNAL
SAFETY
BROWN
YELLOW
PINK
TAN
VIOLET
GREY
GREEN
WHITE
ORANGE
BLUE
K2
K1
Made in the U.S.A.
BLK
RED
GND
+12VDC
K1
Connections
A
B
C
D
E
F
G
H
J
K
L
M
K4
Model 23R05
1916 W. Mission Rd.
Escondido, CA 92029
(800) 328-5570
MODEL RCR815
Tested to Comply
With FCC Standards
FOR INDUSTRIAL, HOME
OR OFFICE USE
YEL
CAN HI
VIO
CAN LOW
W H T Pendant IN
GRN Pendant GND
BLU
Safety Relay
ORN Safety Relay
n/c
n/c
n/c
n/c
RED Power
BLK
Gnd
MODEL RCR823
Tested to Comply
With FCC Standards
OR OFFICE USE
.25" D
(Typ)
TNC Antenna
Connector
Interface
Connector
AutoLink
Push-Button
Wiring Harness
23R05 Receiver
23RCAN Receiver
Figure 2 (a): 23 Series Receivers
142133-A
04/03
TNC Antenna
Connector
3.50
Model 23R15-2
1916 W. Mission Rd.
Escondido, CA 92029
(800) 328-5570
POWER
SIGNAL
OUTPUT
Made in the U.S.A.
Wiring Diagram
BLK
10 Amp
GND
RED
+12 VDC
K1
BLU/BLK
K2
BLU/WHT
K3
BLUE
K4
WHT/BLK
K16
ORN
K5
ORN/BLK
K6
ORN/RED
K7
BLK/RED
K9
GRN/BLK
K10
RED/BLK
K11
GRN/WHT
K12
RED/WHT
FORK CL
K14
WHT/RED
TELE IN
K15
BLU/RED
TELE OUT
BOOM UP
BOOM DN
SWING LT
SWING RT
OPR
FORK LT
FORK RT
ENG. HIGH
KNUCL UP
KNUCL DN
FORK OP
12.0
(+12 VDC)
10 Amp
K8
GRN
K8
BLK/WHT
K8
WHT
OUT N/O
OUT N/C
ESTOP IN
MODEL RCR815
Tested to Comply
With FCC Standards
OR OFFICE USE
23R15 Receiver
.25" D
(Typ)
AutoLink
Push-Button
Wiring Harness
Figure 2 (b): 23 Series Receivers
142133-A
04/03
TNC Antenna
Connector
3.00
Model 23R23
1916 W. Mission Rd.
Escondido, CA 92029
(800) 328-5570
POWER
SIGNAL
OUTPUT
Made in the U.S.A.
Connections
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Function Pin
K1
17
K2
18
K3
19
K4
20
K5
21
K6
22
K7
23
K8
24
K9
25
K10
26
K11
27
K12
28
K13
29
K14
30
K15
31
K16
32
Function
COM 1-6
COM 7-12
COM 13-18
COM 19-24
+12
+12
GND
GND
K17
K18
K19
K20
K21
K22
K23
K24
9.00
MODEL RCR823
Tested to Comply
With FCC Standards
OR OFFICE USE
Wiring
Connector
.25" D
(Typ)
AutoLink
Push-Button
23R23 Receiver
Figure 2 (c): 23 Series Receivers
142133-A
04/03
10
Receiver/Decoder
The Receivers use an advanced synthesized FM Receiver designed to work in
the presence of potential interfering signals that might be encountered from pagers, cell
phones, two way radios, etc. The microprocessor- based decoder insures a great deal of
safety as well as versatility. Commands are received on one of 81 possible frequencies
and are checked against a 16-bit address code for proper identity and further tested
against a 16-bit CRC check code. This insures only valid information meant only for the
particular unit is decoded. The microprocessor contains a programmable memory that
retains the frequency, address, and particular operating parameters for the system.
The receiver uses robust 15 Amp relays to insure long, reliable life of the system.
AutoLink
Some receivers utilize AutoLink to synchronize the ID Code between the
transmitter and receiver. This allows a quick and easy method to replace a transmitter
with a spare. (See Using AutoLink in the maintenance section)
Power Supply
Standard operating power for the receiver is 12 VDC automotive power.
Optional 24 VDC inputs are available. The 23R23 and 23RCAN will operate from
9 to 30 VDC.
Receiver Diagnostics
The receiver assembly monitors and indicates its status on a continuous basis.
The diagnostics are presented in a simple, easy to understand format.
Safety Features
Controlling industrial and commercial equipment requires that the wireless
control system be reliable with built-in safety features. These receivers offer a
maintained link system. This means for the system to operate, the signal from the
transmitter must be continuously received by the receiver. Loss of the transmitter
signal will cause the safety system to remove all commands from the system and open
the safety relay contact. Each transmission goes through several checks to insure that
the information being received is error free. Millions of combinations of frequencies
and address codes means that no two systems will ever be produced with the same
frequency and address code.
The safety relay is controlled by the microprocessor and by a hardware circuit to
ensure operation even in the event of circuit failure. During normal operations, this
relay is closed (activated). If for any reason valid data is not being received, this relay
will open. It is also opened any time an operator sends an E-Stop command.
142133-A
04/03
11
OPERATION
When operating any remote control system insure that all safety measures are
followed. Before activating the system make sure personnel are clear of the equipment
and that it is safe for the equipment to operate.
Make sure the vehicle is properly secured and prepared for the equipment to
operate.
Receiver Operation
If the receiver is on a separate power switch, turn on the receiver power before
using the transmitter.
When finished with the job, make sure the power to the receiver is turned off.
Transmitter Operation
IMPORTANT!
The EMERGENCY STOP button for the system is the OFF/ESTOP button.
Press and hold this button to stop all functions.
IMPORTANT!
Le bouton darrt durgence (EMERGENCY STOP) pour ce systme est le
bouton OFF/ESTROP. Appuyer et amintenir le loutn pour arrter toutes kes
functions.
1. Press and release the ON button. Verify that the status LED starts flashing at a
low rate. (The ACTIVE light on the receiver should light).
2. Press the required switches to operate the desired motion. Note that more than
one motion can be controlled at any time.
3. To stop sending any command, release the switch.
4. To turn the transmitter off, press the OFF button. (Note that the transmitter will
turn itself off if no commands are sent for a predetermined time if auto off is
enabled.)
142133-A
04/03
12
INSTALLATION INSTRUCTIONS
Ensure all of the components that were ordered for your system are present and
in good condition. If not, contact Remtron.
Antenna Location
The antenna is one of the most important components of a radio receiving
system. Proper placement of the receiver antenna will ensure reliable operation under
the most severe conditions. A direct line-of-sight path between the transmitter
antenna and receiver antenna provides best performance. Refer to Figure 3.
Direct Line of Sight
Antenna
Not Direct Line of Sight
RF
Antenna
RF
Transmitter
Transmitter
RECOMMENDED
UNACCEPTABLE
Figure 3. Transmitter/Receiver Communication (example)

In most cases, the antenna may be mounted directly on the receiver enclosure. In
determining the mounting location, the following items should be considered:
The antenna should be mounted vertically.
For optimum performance the antenna itself should have a minimum of eight (8)
inches of clearance in all directions excluding the wall or plate to which the
receiver cabinet is mounted (Refer to Figure 4). If the receiver enclosure location
is not suitable to provide this clearance and the antenna should be mounted at a
remote location, the Remtron Remote Antenna Mounting Kit should be used.
Call Remtron customer service for information.
8 inches
Top View of
Receiver
Antenna
8 inches
Front View
of Receiver
8 inches
Mounting Surface
Figure 4. Antenna Clearance (example)
142133-A
04/03
13
Receiver Mounting
To ensure safe and reliable system operation, the following items must be
considered when selecting a location for mounting the receiver:
Install the receiver in an environment where the ambient temperature during
operation does not drop below -20 F (-7 C) or rise above +160 F (+70 C).
Mount the receiver cabinet securely using appropriate locking-type hardware.
Receiver Wiring
The 23R05 and 23R15 receivers are prewired with a wiring harness that is
permanently attached to the receiver. The 23RCAN and 23R23 are provided with
interface connectors on the receiver. Information on the connection of the wires is
contained on the face of the receiver or provided separately.
WARNING!
Before starting this installation, ensure that the power has been disconnected
and that all applicable safety precautions are followed.
MISE EN GARDE!
Avant de procder linstallation, sassurer que le bras lvateur ou la grue
est hors tension et que toutes les consignes de scurit ont t respectes.
Power/Control Wiring
The relay circuits are designed to operate at 10 amps continuous over all
environmental conditions, and they will withstand momentary surges greater than 10
amps. If the combined current in any relay bank will exceed 10 amps continuous or 15
amp surge, contact Remtron Engineering regarding proper installation to insure
reliable operation.
Use the following steps to install the wiring to the receiver.
1. Connect the positive power wire (+12VDC or +24VDC) to a power source on the
vehicle. Note that the RED wire supplies power to both fuses. The power source
must be capable of supplying the necessary current for the intended loads. It is
recommended that a separate switch be installed to control power to the
receiver.
2. Connect the ground wire to chassis. Make sure this is a reliable connection. Use
of a star ground lug is recommended.
142133-A
04/03
14
3. Connect the remainder of the wires to the control relays as required.

NOTE:
Review the steps above to ensure the accuracy of the wiring before applying
power to the installation.
Installation Testing
Before putting the system into service, the following testing procedure must be
performed:
1. Apply power to the receiver.
2. Verify that PWR indicator turns on.
3. Turn on the transmitter.
4. Verify that the SIGNAL indicator flashes.
5. Verify that the safety circuit is active. Press EStop on the transmitter and verify
the safety circuit has deactivated the system.
6. Again Turn on the transmitter. Check each of the command functions for proper
operation.
142133-A
04/03
15
MAINTENANCE AND TROUBLESHOOTING

Monthly Inspection Schedule
Inspect the transmitter for damage to keypad and case.
Inspect all electrical and antenna connections to ensure they are clean and tight.
Ensure all terminal strips are firmly in place.
Transmitter Troubleshooting
The transmitters have an LED status indicator to aid in troubleshooting. Due to
the rough treatment it may be subjected to, most problems are likely to occur in the
transmitter. The transmitter should be thoroughly diagnosed before proceeding to the
receiver.
WARNING!
When testing the transmitter, the receiver may become active resulting in
system operation. Always assume the system is working and will respond
when testing a transmitter.
AVERTISSEMENT !
Lors dessais de fonctionnement du transmetteur, le rcepteur peut tre activ
et provoquer la mise en marche du systme. Toujours considrer que le
systme fonctionne et quil rpondra aux essais du transmetteur.
STATUS LED Troubleshooting Chart:
LED Indication
Possible Cause
LED is off
Transmitter is off
LED flashes at low rate
Transmitter is operating in a normal mode.
LED flashes at high rate
Command Switch is pressed
LED flashes on-off at a slow rate Batteries getting low. Batteries should be
( second on and second off) changed at the next convenient opportunity.
LED remains on continuously
LED will not light when

ON/OFF button is pushed
142133-A
04/03
Either a switch was activated at the time the

transmitter was turned on or a general failure
occurred that requires factory service. Ensure
no other switches are pressed while attempting
to turn the transmitter on.
Replace batteries. If this does not correct the
problem, the transmitter must be repaired.
16
Transmitter Repairs
CAUTION!
The transmitter electronic components are exposed when the back of the case
is removed. Take caution to prevent dirt or other contaminants from entering
the case. Do not allow the circuit to be scraped or damaged in any way.
AVERTISSEMENT !
Lorsque lendos du botier est enlev, les composants lectroniques sont
dcouvert. Prendre soin dviter de laisser la salet ou tout autre contaminant
entrer dans le botier. viter drafler ou dendommager le circuit de quelque
faon que ce soit.
Battery Replacement
Refer to Figure 5 for your particular transmitter.
1. Remove the screws on the back of the transmitter and remove the back of the
case. On the 23T44 open the battery compartment on the bottom of the
transmitter.
2. Remove and replace the AA Alkaline batteries. Be sure to observe the correct
polarity. On the 23T44 note that each set of three batteries is in parallel. Three,
six, or nine batteries may be used to power the transmitter. When using six or
nine batteries, use the same type and age to achieve the longest battery life.
3. Reassemble the transmitter in reverse order making sure the battery wires do not
get pinched between the case halves. Tighten the screws snugly.
Changing the Transmitter ID Code

Refer to Figure 5.
1. Remove the screws on the back of the transmitter and remove the back of the
case. On the 23T44 open the battery compartment on the bottom of the
transmitter.
2. Attach the programming plug to the four-pin connector on the circuit board, or
using the adapter, to the mini DIN connector under the battery compartment
cover (23T44). Verify the ID CODE is displayed.
3. Enter the new ID Code and press the PRG key.
142133-A
04/03
17
(Refer to the RAC16 or RAC17 Users Manual for more detailed instructions)
Changing the Transmitter Keypad (Handheld)

Refer to Figure 5.
1. Remove the screws in the back of the transmitter and remove the back of the
case.
2. Remove the batteries from the holder.
3. Remove the two (four) screws holding the printed circuit board assembly and
remove the board from the case.
4. Remove the nuts from the studs holding the support plate to the case front.
5. Remove the backing plate and rubber keypad from the case front.
6. Install the new rubber keypad onto the backing plate, making sure the tabs are
pulled through each slot.
7. Install the keypad and backing plate into the case front.
8. Apply a small amount of Torque Seal to the threads on the studs and install the
nuts on the studs finger tight plus 180 degree turn. DO NOT use locktite as most
formulations will cause the plastic to become brittle.
23T44 Switch Replacement

1. Loosen the four screws from the bottom of the transmitter. Carefully remove the
bottom plate.
2. Remove the four screws securing the circuit board to the bracket inside the case.
3. Locate the wires from the switch to be replaced. Note the exact position of the
plug on the board.
4. Replace the switch. Plug the new switch into the circuit board.
5. Replace the circuit board using care to make sure all connectors are firmly
seated in the encoder board and no wires are pinched between the transmitter
cover and the bottom.
6. Reinstall the case bottom (or top).
142133-A
04/03
18
ID# 28008C
ID# 28008C
Printed
Circuit Board
Assembly
(Remove These
Screws to
Replace Keypad)
ID# 28008C
Printed
Circuit Board
Assembly
(Remove These
Screws to
Replace Keypad)
Printed
Circuit Board
Assembly
(Remove Four
Screws to Replace
Keypad)
Programming
Plug
Programming
Plug
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
123456789012345678901234567890
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
Programming
Plug
23T10
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
12345678901234567890123456789
23T14 and 23T18
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
12345678901234567890123456
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
1234567890123456789012345
23T20 and 23T23
Figure 5: 23 Series Transmitters with back removed
142133-A
04/03
19
Transmitter Spare Parts List

Handheld Transmitters
Item ...................................................................................... Part #
Spare Transmitter (complete) .......................................... 23T10, 23T14, 23T18, 23T20 or 23T23
Shoulder Strap .................................................................... 620008-02
Battery Clip, negative ....................................................... 530130
Battery Clip, positive ........................................................ 530131
Case screws, 6-32 5/8 Phillips, stainless steel .............. 500047
Replacement Transmitter Label ...................................... Refer to Original Tx Serial #
Assembly, Switch Activator w/keypad (23T18) ........... 920086
Model
Leather
Holster
Rubber
Keypad
23T10
23T14
23T18
23T20
23T23
620006-03
620007
620007
620009
620009
920030
920035
920092
920043
920091
Water-repellent Circuit
Clear Pouch
Board
620011
620011
620011
620012
620012
21T44 Transmitter
Item ...................................................................................... Part #
Spare Transmitter (complete) .......................................... 21T44
Shoulder Harness .............................................................. 620029
Shoulder Strap .................................................................... 620008
Toggle Switch, maintained (ON/OFF/ON) ................. 920056
Toggle Switch, momentary ((ON)/OFF/(ON)) ............ 920057
Toggle Switch (ON/OFF/ON) locking ......................... 920058
Push-button Switch, Red .................................................. 920059
Push-button Switch, Black ................................................ 920060
Push-button Switch, E-Stop .............................................. 920061
Rotary Switch, 2-position ................................................. 920062
Test LED .............................................................................. 920071
Lever, Stepless ................................................................... 920090
Transmitter Antenna ......................................................... 900174
Transmitter Circuit Board ................................................ 900165-04
142133-A
04/03
20
900134
900149
900170
900156
900161
Receiver Testing
Receiver LEDs. Remtron 23 Series receivers use three basic LEDs for diagnostics.
LED Indicators
Receiver Action
PWR lit.
Receiver operating voltage is present.
SIGNAL flashes.
Signal is being received that matches the

decoders address.
OUTPUT lit.
One or more command outputs are energized.
Receiver Troubleshooting
The following steps should be followed when troubleshooting the receiver.
1. Check the PWR indicator; If PWR is not lit:
Check that the power source to the receiver is active.
If applicable, check the fuse for the receiver power input.
2. Turn the transmitter on;
If the receiver SIGNAL indicator remains off, test the transmitter.
Verify the ID Code is the same for the transmitter and receiver.
Verify transmitter batteries are fresh.
3. Only some functions are operating:
Check output voltage of the respective relays and the electrical circuits.
If applicable, replace fuse on the receiver circuit board.
Check the condition of the transmitter switches.
4. You are experiencing intermittent operation:
Check all connections.
Check antenna connections.
5. Operating range is short:
Check antenna connections.
On new installations, verify the receiver antenna is placed properly. If
necessary, use an antenna mounting kit to relocate the antenna to a more
favorable location.
142133-A
04/03
21
Receiver Repairs
The receivers have been designed for the utmost reliability. Other than fuses to
protect the basic power circuits, there are no serviceable items in the receiver.
Fuse Replacement
23R05
The 23R05 uses self healing fuses. Should an output become overloaded, the
fuse will open and stay open as long as the load is present at that output. When the
load is removed, the fuse will reset itself in one minute or less.
23R15 (Refer to Figure 6)
To replace a fuse on the circuit board:
1. Ensure power is turned off to all receiver power inputs.
2. Remove the mounting bolts from the end of the receiver by the interface cable.
3. Remove the four screws on the end of the receiver by the interface cable.
4. Gently pull the end cap and receiver board out of the case about 1 inch to expose
the fuses on the bottom edge of the circuit board.
5. Replace the appropriate fuse with a BUSS GMCV 125V, 10A M/D or equivalent
fuse.
6. Reposition the end cap and insert and snugly tighten the four screws.
MODEL RCR815
Tested to Comply
With FCC Standards
OR OFFICE USE
Circuit Board
F2
Remove four (4) screws
Figure 6: 23R15 Fuse Locations.
142133-A
04/03
22
F1
23R23 (Refer to Figure 7)

To replace a fuse on the circuit board:
1. Ensure power is turned off to all receiver power inputs.
2. Remove the receiver from its mounting.
3. Remove the four screws on the end of the receiver by the wiring connector.
4. Turn the receiver up side down. Gently pull the end cap and receiver board out
of the case about 1 inch to expose the fuses on the bottom edge of the circuit
board.
5. Replace the appropriate fuse with a 10 Amp (Littlefuse P/N 297010 or
equivalent) fuse.
6. Reposition the end cap and insert and snugly tighten the four screws.
7. Re-Install the receiver.
Model 23R23
1916 W. Mission Rd.
Escondido, CA 92029
(800) 328-5570
POWER
SIGNAL
OUTPUT
Made in the U.S.A.
Connections
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Function
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
Pin
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Function
COM 1-6
COM 7-12
COM 13-18
COM 19-24
+12
+12
GND
GND
K17
K18
K19
K20
K21
K22
K23
K24
Bottom Circuit Board
MODEL RCR823
Tested to Comply
With FCC Standards
OR OFFICE USE
F3 F4
Remove four (4) screws

Figure 7: 23R23 Fuse Locations.
142133-A
04/03
23
F1 F2
Changing the Receiver Identity Code

Using AutoLink
If the receiver is equipped with AutoLink, there will be a push-button switch on
the outside of the case. To allow the receiver to copy the ID Code from the transmitter:
1. Press and hold the AutoLink push-button on the receiver.
The Signal LED will start flashing.
2. Press and hold EStop on the transmitter until the Signal LED stops flashing. This
may take several seconds.
The Signal LED is on continuous.
3. Release the EStop command then release the AutoLink push-button. If the
AutoLink push-button is released first, again press and release the AutoLink
push-button on the receiver.
The Signal LED is off.
The transmitter and receiver will now be ready to use.
142133-A
04/03
24
WARRANTY STATEMENT
for
Command Pro 23 Series Material Handling Products
Period of Warranty: Remtron warrants the 23 Series products against malfunction or

breakage for a period of one year from the date of receipt of warranty registration card
or from the date of the original invoice if the card is not received within six months of
shipment from the factory.
Warranty Coverage: 23 Series products transmitters, receivers and accessories, in
normal and customary use, are conditionally warranted against malfunction or
breakage. The warranty does not cover: (a) defects or damage resulting from use of the
product in other than its normal and customary manner; (b) defects or damage from
misuse, accident or neglect; (c) defects from improper testing, operation, maintenance,
installation, alteration, modification or adjustment; (d) damage from unauthorized
repair or alterations; and (f) damage from water or corrosive materials beyond the
specification of the case or enclosure
Warranty Service: Products returned for repair (warranty or non-warranty), must be
assigned an RMA (Return Material Authorization) number by an Remtron Customer
Service representative. To allow us to more effectively address the repair issues, the
customer should provide a detailed description of the specific problem. Call 800-3285570 for service or RMA assignment. To receive warranty service, deliver or send the
product(s) along with the assigned RMA number to our factory.
General Terms of Warranty:
Remtron will repair or replace the defective unit, solely at our option in the event of
defect or failure to perform as specified, provided the product is returned in
accordance with the terms of this warranty. Replacement parts are covered for the
balance of the original warranty.
All costs of shipping to Remtron shall be borne by the purchaser. The warranty covers
the cost of return one-way shipping and handling of the product. The return shipment
will be via the same method as the product was shipped.
This warranty does not cover the costs of outside repair service except as authorized by
Remtron. If it is determined that a third party is necessary for the service or repair of
the Remtron product, prior approval by Remtron is required.
This warranty sets forth the full extent of Remtrons responsibility regarding the
product(s). Repair, replacement or refund of the purchase price, at Remtrons option
are the exclusive remedies. This warranty is given in lieu of all other express
warranties. All other warranties, expressed or implied, including without limitation
implied warranties of merchantability or fitness for a particular purpose , are
specifically excluded. In no event shall Remtron be liable for damages in excess of the
purchase price of the product(s), for any loss of use, loss of time, inconvenience,
commercial loss, lost profits or savings or other incidental, special or consequential
damages arising out of the installation, use or inability to use the product(s), to the full
extent that such may be disclaimed by law.
142133-A
04/03
25
How to get service

Products returned for repair (warranty or non-warranty), must be assigned an RMA
(Return Material Authorization) number by a Remtron Technical Support
Representative. To allow us to more effectively address the repair issues, the customer
is to provide a detailed description of the specific problem. Call 800-328-5570 for
service or RMA assignment. To receive warranty service, deliver or send the product
along with the assigned RMA number to our factory.
REMTRON, INC.
1916 W. Mission Rd.
Escondido, CA 92029
142133-A
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26
142133-A
04/03
P/N: 142133
04/17/03
Rev. A
MATERIAL SAFETY DATA SHEET

Date Issued: 01/01/05
SECTION A - IDENTIFICATION & EMERGENCY INFORMATION
Manufacturer's Name: BP Lubricants USA Inc.
Emergency Telephone Number: 410-574-5000
800-777-1466
Address: 9300 Pulaski Highway

Baltimore, MD 21220
PRODUCT NAME: Castrol Blue Hydraulic Plus

32 (Light), 46 (10), 68 (20), 100 (30)
Chemical Family: Petroleum Oil (Hydraulic Oil)
Product Appearance & Odor: Blue Liquid
Mild, Bland Petroleum Odor
Part Number: 4014, 4024, 4034, 4044

CAS Number (For Finished Product):
COMPLEX MIXTURE
CAS Number Not Applicable
HAZARDOUS MATERIALS IDENTIFICATION SYSTEM (HMIS)

Health - 1 Flammability - 1 Reactivity - 0
Hazard Rating: Least-0 Slight-1 Moderate-2 High-3 Extreme-4
SECTION B - COMPONENTS & HAZARD INFORMATION

COMPONENTS
Lubricating Oil Base Stock
CAS NO. OF
COMPONENTS
APPROXIMATE
CONCENTRATION
64741-88-4
64742-54-7
Greater than 87%
Mixture
Less than 13%
Proprietary Additives
Exposure Limit for Total Product: 5mg/m3 oil mist for an 8-hour workday. Basis: OOHS Reg. 29 CFR 1910.1000
CERLA Hazardous Substances: None known. If this product is accidentally spilled, it is not subject to any special reporting under the requirements of the
Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA). We recommend you contact local authorities to determine if there
may be other local reporting requirements. US TSCA Inventory: All components of this material are on the US TSCA Inventory. Threshold Planning
Quantity (TPQ), EPA Regulation 40 CFR 355 Extremely Hazardous Substances (SARA Sections 301-304): None. Toxic Chemical Release Reporting,
EPA Regulation 40 CFR 372 (SARA Section 313): Not Applicable.
SECTION C - PHYSICAL DATA (THE FOLLOWING DATA ARE APPROXIMATE OR TYPICAL VALUES.)
Boiling Range: Not Determined
Specific Gravity (H2O=1): .8623/.8762
Pour Point: -32C (-26F.)/-15C (+15F.)
Viscosity: 100C cSt 5.5/11.7
Solubility in Water: Negligible, Below 0.1%
Percent Volatile by Volume: NEGLIGIBLE

Vapor Pressure: NEGLIGIBLE
Vapor Density: GREATER THAN AIR
Evaporation Rate: NEGLIGIBLE
SECTION D - FIRE PROTECTION INFORMATION

FLASH POINT & METHOD: Min. ASTM D-92 C.O.C. C, (F.)
AUTO IGNITION TEMPERATURE:
210 (411) / 225 (440)
Not Determined
NATIONAL FIRE
PROTECTION ASSOCIATION
(NFPA)-Hazard Identification
Health - 1
Flammability - 1
Reactivity - 0
Basis: Recommended by BP Lubricants USA Inc.
Hazard Rating (NFPA):
4-Extreme 3-High 2-Moderate
1-Slight 0-Insignificant
MSDS Form 1.0
UNUSUAL FIRE & EXPLOSION HAZARDS:

None
Flammability Limits (% by volume in air):

Lower: Not determined Upper: Not determined
Page 1 of 2
SECTION D - FIRE PROTECTION INFORMATION (Continued)

HANDLING PRECAUTIONS: Use product with caution around heat,
sparks, pilot lights, static electricity and open flame.
DECOMPOSITION PRODUCTS UNDER FIRE CONDITIONS:
Fumes, smoke, carbon monoxide, sulfur oxides, and other decomposition products, in the case of incomplete combustion.
EXTINGUISHING MEDIA & FIRE FIGHTING PROCEDURES:
Foam, water spray (fog), dry chemical, carbon dioxide and vaporizing
liquid type extinguishing agents may all be suitable for extinguishing
fires involving this type of product, depending on the size or potential
size of fire and circumstances related to the situation. Plant fire protection and response strategy through consultation with local fire protection
authorities or appropriate specialists.
The following procedures for this type of product are based on the recommendations in the National Fire Protection Associations' Fire Protection Guide on Hazardous Materials. Use water spray, dry chemical,
foam, or carbon dioxide to extinguish the fire.
Water or foam may cause frothing. Use water to keep fire-exposed containers cool. Water spray may be used to flush spills away from exposures.
Minimize breathing of gases, vapor, fumes or decomposition products. Use
supplied-air breathing equipment for enclosed or confined spaces or as otherwise needed.
EMPTY CONTAINER WARNING: "Empty" containers retain residue
(liquid and/or vapor) and can be dangerous. DO NOT PRESSURIZE, CUT,
WELD, BRAZE, SOLDER, DRILL, GRIND OR EXPOSE SUCH
CONTAINERS TO HEAT, FLAME, SPARKS OR OTHER SOURCES OF
IGNITION: THEY MAY EXPLODE AND CAUSE INJURY OR DEATH.
Do not attempt to clean since residue is difficult to remove. "Empty" drums
should be completely drained, properly bunged and promptly returned to a
drum reconditioner. All other containers should be disposed of in an environmentally safe manner and in accordance with governmental regulations.
SECTION E - PROTECTION & PRECAUTIONS

VENTILATION: Use local exhaust to capture vapor, mists or fumes, if
necessary. Provide ventilation sufficient to prevent exceeding recommended exposure limit or buildup of explosive concentrations of vapor
in air. No smoking, flame or other ignition sources.
RESPIRATORY PROTECTION: Use supplied-air respiratory protection in confined or enclosed spaces, if needed.
PROTECTIVE GLOVES: Use chemical-resistant gloves, if needed, to
avoid prolonged or repeated skin contact.
EYE PROTECTION: Use splash goggles or face shield when eye contact may occur.
OTHER PROTECTIVE EQUIPMENT: Use chemical-resistant apron
or other impervious clothing, if needed, to avoid contaminating regular
clothing, which could result in prolonged or repeated skin contact.
WORK PRACTICES / ENGINEERING CONTROLS: Keep containers

closed when not is use. Do not store near heat, sparks, flame or strong oxidants. In order to prevent fire or explosion hazards, use appropriate equipment.
PERSONAL HYGIENE: Minimize breathing vapor, mist or fumes. Avoid
prolonged or repeated contact with skin. Remove contaminated clothing:
launder or dry-clean before reuse. Remove contaminated shoes and thoroughly clean before reuse; discard if oil-soaked. Cleanse skin thoroughly after contact, before breaks and meals, and at end of work period. Product is
readily removed skin by waterless hand cleaners followed by washing thoroughly with soap and water.
VARIABILITY AMONG INDIVIDUALS: Health studies have shown
that many petroleum hydrocarbons and synthetic lubricants pose potential
human health risks, which may vary from person to person. As a precaution,
exposure to liquids, vapors, mists or fumes should be minimized.
SECTION F - SPILL OR LEAK PROCEDURE

ENVIRONMENTAL IMPACT: Report spills as required to the appropriate authorities. US Coast Guard Regulations require immediate reporting of spills that could reach any waterway including intermittent dry
creeks. Report spill to the Coast Guard toll free number 800-424-8802.
PROCEDURES IF MATERIAL IS RELEASED OR SPILLED: Recover free product. Add sand, earth, or other suitable absorbent material
to the spill area. Minimize breathing vapors. Minimize skin contact.
Keep product out of sewers and watercourses by dicing or impounding. Advise authorities if the product has entered or may enter sewers, watercourses,
or extensive land areas. ASSURE CONFORMITY WITH ALL
APPLICABLE REGULATIONS.
WASTE DISPOSAL: Dispose of in an environmentally safe manner and in
accordance with all government regulations to include Federal, State, and
local requirements.
SECTION G - REACTIVITY
STABILITY: Stable
HAZARDOUS DECOMPOSITION PRODUCTS: Thermal decomposition products are highly dependent on the combustion conditions. A comHAZARDOUS POLYMERIZATION: Will not occur.
plex mixture of airborne solid, liquid, particulates and gases will evolve
when this material undergoes combustion. Carbon monoxide and other uniCONDITIONS & MATERIALS TO AVOID: Avoid heat, open flames dentified organic compounds may be formed upon combustion.
and oxidizing materials.
SECTION H - EMERGENCY & FIRST AID PROCEDURES AND PRIMARY ROUTES OF ENTRY
EYE CONTACT: If splashed into the eyes, flush with clear water for
15 minutes or until irritation subsides. If irritations persist, call a physician. SKIN CONTACT: In case of skin contact, remove any contaminated clothing and wash skin thoroughly with soap and water.
INGESTION: If ingested, DO NOT induce vomiting; call a physician
immediately.
INHALATION: Vapor pressure is very low. Vapor inhalation under ambient temperature conditions is not normally a problem. If overcome by vapor
from hot product, immediately remove from exposure and call a physician.
Administer oxygen, if available. If over-exposed to oil mist, remove from
further exposure until excessive mist oil condition subsides.
SECTION I - EFFECTS OF OVEREXPOSURE

SKIN: Prolonged or repeated skin contact may cause skin irritation. EYE: May cause eye irritation. INGESTION: Relatively nontoxic.
SECTION J - TRANSPORTATION INFORMATION

DEPARTMENT OF TRANSPORTATION (DOT) - DOT Identification Number: Not Regulated.
THE PRECISE COMPOSITION OF THIS MIXTURE IS PROPRIETARY INFORMATION. A MORE COMPLETE DISCLOSURE WILL BE
PROVIDED TO A PHYSICIAN OR NURSE IN THE EVENT OF A MEDICAL EMERGENCY.
MSDS Form 1.0
Page 2 of 2

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503082

2100 Fan Manual

Initial release - 2-23-2007

Added new central grease system to options. (AC 5-31-2007)

Vactor supplied International, Sterling/Freightliner chassis warranty

Warranty & Technical Service Team Directory

Toll-Free Telephone (800) 627-3171

Mike Hunter Ext. 259

Rod Watts Ext. 209

Josh Wiechman Ext. 363

Thomas Wheeler Ext. 267

Direct Channel Quick Repair Technician

EFFECTIVE DATE 2/23/2007

Pride in partnership ...

A division of Federal Signal

Vactor 2100 Series Operators Manual

Warranty & Technical Service Team Directory. ................................................ iv

Vactor 2100 Series Operators Manual

Vactor 2100 Series Operators Manual

Vactor 2100 Series Operators Manual

Vactor 2100 Series Operators Manual

- Part Locations. ...........................................................321

EFFECTIVE DATE 5-31-2007

Chassis Vin Number

EFFECTIVE DATE 3/27/2007

Vactor Manufacturing Inc.

ATTN: Warranty Department

1621 S. Illinois St.

Streator, Illinois 61364

Ask for Service or Warranty Administrator

The shipment must be freight pre-paid to:

Vactor Mfg. / Guzzler Mfg.

1621 S. Illinois St.

Streator, Illinois 61364

EFFECTIVE DATE 3/27/2007

Warranty Claim Form

EFFECTIVE DATE 3/27/2007

General Information Section

Terms: Standard terms are NET cash within 30 days

Good operation and a planned maintenance

Returned Material: Goods will not be accepted for

The information, specifications, illustrations and

If a question arises concerning your Vactor product

EFFECTIVE DATE 3/27/2007

General Information Section

by Vactor such as engine components. It is also the

Each manual has tabs A through L. An index of

This is done specifically because the same base

EXAMPLE: Section F is the BOOM section of the

EFFECTIVE DATE 3/27/2007

General Information Section

This manual is for use only with units meeting Vactor/

OWNERS MANUAL COVERING OPERATION,

PLEASE KEEP VACTOR/GUZZLER MFG. INFORMED OF ANY CHANGE OF VEHICLE OWNERSHIP OR

EFFECTIVE DATE 3/27/2007

General Information Section

Vactor (EPG) Technical Service Hotline

EFFECTIVE DATE 3/27/2007

General Information Section

WARRANTY REGISTRATION FORM

EFFECTIVE DATE 3/27/2007

International Chassis Warranty Form

This form registers both the chassis and engine.