WARNING: Study this manual before operating or maintaining your slide-in

vacuum tank and any of its components. You must understand and follow the
instructions in this manual; otherwise you and/or others can be seriously injured.
DO NOT operate this equipment if you have not read and understood all of the
safety and operating instructions. Also, DO NOT allow any other person to operate
this equipment if they have not read and understood all of the safety and
operating instructions.

SLIDE-IN VACUUM TANK

OPERATOR’S MANUAL
Date of Purchase: ______________________________________________
Tank Model: ___________________________________________________
Tank Serial Number: ____________________________________________
The manufacturer reserves the right to change specifications or make improvements
without notice and without incurring obligations to products previously sold. Information
contained herein is from data available at time of printing.
1
TO THE PURCHASER

Congratulations on your purchase of a Satellite product. Your slide-in vacuum tank

will give you years of dependable service if the proper operating and maintenance
instructions are observed. We recommend that you read this manual carefully to
become thoroughly familiar with your slide-in equipment prior to operation.

This manual contains sections on safety, setup, specifications, operation,

maintenance, and trouble shooting. Each section in this manual is clearly identified
to help you easily find the information you need.

TO THE PURCHASER
The safety alert symbol will identify important safety messages. When
you see this symbol, carefully read the message that follows.

The information in this manual covers all Slide-in Vacuum Tanks. It is important to
record your tank model number, tank serial number, and date of purchase in the
spaces provided on page 1. This information will be useful to your dealer when
ordering parts for repair.

Your vacuum tank warranty appears on the last page of this manual. Please read it
carefully, making sure you understand the warranty coverage as well as its
exceptions and limitations.

2
 machine safety are proceeded by
signal words NOTICE and
IMPORTANT. These precautions are
intended to help protect against damage
to your equipment and to inform operators
of helpful information.

` NOTICE: Indicates a possibly

dangerous situation that, if not
avoided, could result in damage to
equipment.

SAFETY PRECAUTIONS
„ IMPORTANT: Indicates helpful
information on operation of equipment.
SAFETY PRECAUTIONS
Throughout this manual, and on
machine decals, you will find
precautionary statements followed
by specific instructions. In the interest
of safety, take the time to learn these
precautions.

Precautionary statements dealing with

personal safety are preceded by the
signal words DANGER, WARNING,
and CAUTION. These precautions are
intended for your personal safety and
for the safety of those working with you.

DANGER: Indicates a hazard or

unsafe practice that, if not avoided,
will result in death or serious injury.

WARNING: Indicates a hazard

or unsafe practice that, if not avoided,
could result in death or serious injury.

CAUTION: Indicates a hazard

or unsafe practice that, if not avoided,
will result in death or serious injury.

Precautionary statements dealing with

3
GENERAL SAFETY PRECAUTIONS
WARNING: Sewage and
Follow these safety precautions, and wastewater contain bacteria, funguses,
parasites, and viruses that can cause
insist that those working with you follow
disease. While handling sewage or
them. waste water effluents, sewage workers
may be exposed to a variety of these
Most industrial equipment accidents can disease causing organisms including,
be avoided by observing safety but not limited to: E-coli, hepatitis A virus
precautions. (HAV ), salmonella typhi (which can cause
typhoid fever), shigella (which can cause
Remember: a careful operator is the best dysentery) and parasitic protozoa and
insurance against an accident. worms (such as Guardia lambia and
roundworm).
Safety Precautions for Handling
Effluent Proper work practices and personal
protective equipment (PPE) can help
protect you from becoming infected by
these agents. When handling sewage
and/or wastewater effluents, or after
contact with surfaces exposed to them,
observe the following recommendations
(as a minimum) regarding work practices
and PPE-s:

• DO NOT eat, drink, or smoke while you

are working with, or in the area of,
sewage effluent.

• Wash your hands thoroughly with clean

water and soap before eating, drinking,
or smoking and at the end of your work
DANGER: DO NOT stand near the day.
oil catch muffler or discharge valve when
loading or unloading the tank. Sewer The Portable Sanitation Association
gases vented out of the oil catch muffler International (PSAI) recommends
will settle downward. Sewer gases can rubbing your hands together for at least
also be expelled out of the discharge ten to 15 seconds after you have
valve when releasing tank pressure. worked up a good lather with the soap.
Inhaling sewer gases can cause severe The friction of rubbing your hands
injury or death. together loosens bacteria from your skin
and traps them in the lather to be rinsed
WARNING: DO NOT allow children down the sink.
or irresponsible people or unauthorized
persons near your work area or • Use personal protective equipment
equipment. Make certain everyone is such as coveralls or water-resistant suit,
clear of the truck and the immediate water-proof gloves and boots,
area before starting the engine, respirators, safety glasses,
engaging power, and operating the goggles, and face shields.
equipment. The inherent hazards of
septic pumping can cause serious injury • Properly store, clean, or dispose of
or death to untrained persons that enter contaminated personal protection
this area. equipment.

4
• Keep all cuts and wounds covered with sewage effluent needs to provide a clear
clean, dry bandages and protect them signal to sewage workers to wear PPEs
from exposure to sewage effluent. and wash hands thoroughly before
eating, drinking, or smoking.
• Change out of your work clothes and
boots before leaving work; DO NOT wear • In addition, even though public concern
them home. DO NOT keep your soiled remains high, the blood-borne viruses
work clothes with your other or your Hepatitis B and HIV (Aids) have not been
families’ clothes. Wash your work clothes linked in the U.S. to exposure to sewage -
separately in hot water. according to the hazard alert released by
the Center to Protect Workers’ Rights
• Both the CDC (Center for Disease
(which is the research and development
Control) and the Building and
institute of the Building and Construction
Construction Trades Dept. of the AFL-
Trades Dept., AFL, CIO) titled Biological
CIO recommend that sewage workers

SAFETY PRECAUTIONS
Hazards in Sewage and Wastewater
maintain up-to-date tetanus-diphtheria
Treatment Plants ©2000.
immunizations to counter the risk of soil-
contaminated injuries.
• Finally, as more data is collected on
• While studies in Scandinavia, England, biohazards, and as new biological threats
and the United States have not found a emerge, it is your responsibility as a
substantial increase in the prevalence of waste industry worker to remain
HAV among sewage workers (CDC educated about the hazards involved in
publication: MMWR, Vol. 48, No. RR-12), working with sewage and wastewater
stay abreast of any Hepatitis A outbreaks effluents. Several sources for obtaining
in your area, and contact your doctor up-to-date information are listed below:
about a vaccination should you have any
concerns about coming in contact with National Center for Infectious Diseases
this virus. (NCID) at (www.cdc.gov/ncidod) National
Institute for Occupational Safety and
• While the fecal coli form bacteria E-Coli Health (NIOSH) at (1-800-35-NIOSH or
has been regarded mainly as a food- www.cdec.gov/niosh)
borne illness, contact with farm animals
and contaminated water have arisen as OSHA (1-800-321-OSHA or
other sources of infection. In a number of www.osha.gov)
cases, water supplies were contaminated
due to runoff from structures such as
septic systems and agricultural manure WARNING: Always wear protective
lagoons that contain human and animal gloves, eye protection and, appropriate
fecal material respectively. clothing when working with sewage
effluent or septage. These materials may
For example, a CDC survey after the contain hazardous chemicals and
Midwest floods of 1993 found E. coli in bacteria, which can cause infection, injury,
11.1% of the samples collected from or even death due to contact.
more than 5500 domestic wells. In
identifying potential contamination Safety Precautions for Conned
sources within 100 feet of the wells, the Spaces
CDC found 47.1% of it coming from
septic systems, according to Homer
Emery, Ph.D., in Coli form bacteria,
biosolids and health risks, October 2000, WARNING: DO NOT reach into the
the Pumper. tank for cleaning without protective
clothing. Sewer gas can be absorbed
Knowing that E-Coli can be present in through the skin causing serious injury.
5
 WARNING: DO NOT attempt to enter WARNING: Keep all shields in place.
the tank of a portable slide-in unit. The Shields and covers are designed to
hatch provided on some tanks is intended protect the operator from entanglement in
to provide reach-in access for cleaning moving parts, which can lead to serious
only. DO NOT place your face or head injury or death. DO NOT remove shields
into the tank when reaching into it. These from the unit except when servicing; then
tanks are not designed to permit entry, replace immediately.
and any attempt to enter them could result
in serious injury or death.
WARNING: The truck's cornering
and braking abilities are reduced when
Safety Precautions for Operating the tank is loaded. Drive at a reasonable
Equipment speed with a loaded tank; reduce speed
on rough or hilly terrain, before making an
anticipated stop, and when cornering.

WARNING: DO NOT allow anyone

to ride in the bed of the truck when the
slide-in unit is installed in it. Failure to
follow this precaution could result in
persons falling off the truck and possibly
getting run over, which could cause
serious injury or death.

WARNING: Before backing-up the

truck, inspect the area to be backed into,
and clear all hazards, pets, and people
from it.
DANGER: Stop the truck motor,
remove all persons from the truck cab, WARNING: When off-loading under
and chock the truck tires before servicing pressure, maintain control of the end of
any of the components on your slide-in the hose. Pressurized discharge can
unit. A truck that begins to roll is a cause a hose end to whip about and
crushing hazard that can lead to death. create the potential for spraying persons
in the area with effluent.
DANGER: Make sure the gas
engine on your slide-in unit is shut off
before servicing the vacuum pump. WARNING: Avoid contact with the
Contact with a rotating mechanism can vacuum pump during or immediately after
cause entanglement that can lead to operation Operating temperatures can
range from near200oF to over 300oF,
death.
depending on the make and model of
pump and on the working conditions.
Contact with a hot vacuum pump can
WARNING: Keep hands, feet, hair, cause severe burns.
and clothing away from moving parts.
Contact with a moving mechanism can
cause entanglement that can lead
dismemberment or death.
6
SPECIFICATIONS
General SPECIFICATIONS FOR YOUR
PORTABLE SLIDE-IN UNIT ARE LISTED
IN Table 2.1 below. All dimensions are
given in inches.

Table 2.1 Slide-in Specifications

SPECIFICATIONS
Model S-300 S-550
Gallon 200/waste 370/waste
Capacity 100/fresh 270/fresh
Overall
Length 71" 109"

Skid Width 48" 48"

Overall
Height 61" 61"
Empty
Weight 1,500 lbs. 1,800 lbs.
Loaded
Weight 3,367 lbs.* 4,601 lbs.*

Engine Honda GX240 - 9.0 h.p. Honda GX240 - 9.0 h.p.

Vacuum
Pump HXL3V HXL3V
Conde
Model 6

Water Pump WHALE 4300 - 4.9 g.p.m. Flojet 4300 - 4.9 g.p.m.
Inlet
Coupling 2" Cam Lock 2" Cam Lock
Outlet
Coupling 3" Cam Lock 3" Cam Lock

*Note: Loaded weights are based on a full

septic compartment and a 1/4 full fresh
water compartment (under normal
operating conditions, both compartments
will not be full at the same time).

7
**This diagram for 300 and 450 modules, 550 does not fit in pickup.

SETUP
operating on public roadways.
SET UP
The GVWR of your truck minus its base
Your portable slide-in unit comes
weight equals the total vehicle payload
assembled from the factory. The slide-in
that can be carried. The surest way to
unit is ready to put into use when you
verify the maximum payload a given
receive it, aside from some necessary
vehicle can carry is to begin by having
owner setup. This includes lifting the unit
your truck weighed at a certified scale.
into your truck bed, securing it to prevent
shifting, connecting the battery cable in
As a note of caution, the advertised
order to start the engine, and installing
payload weight for a particular truck may
the vacuum/pressure gauge.
not be the actual load that you can carry
with your truck.
Vehicle Weight Requirements
Advertised payloads often don’t take into
account the weight of options such as
Before setup, be sure that the truck you automatic transmissions that can add up
use to carry your slide-in unit has a to 100 pounds to your vehicle. In addition,
Gross Vehicle Weight Rating (GVWR) the advertised payloads may not take into
and a Gross Axle Weight Rating account the weight of passengers and
(GAWR) high enough to handle the gear (such as tools) being carried by the
combined weight of the slide-in unit and truck. Ignoring these factors could result
the liquid inside it. in your truck being found to be overload-
ed during a roadway weight inspection.
Exceeding the GVWR or GAWR of your
truck could damage it. More importantly,
A certified scale can provide an accurate
exceeding these ratings could impede
base weight of your vehicle, accounting
your ability to brake safely. In addition,
for all of the weight varying factors.
federal DOT regulations prohibit a vehicle
that exceeds its GVWR or GAWR from
8
Once the base weight of the vehicle is Lifting Unit into Truck
known, subtract this from the GVWR of
your truck to give the payload weight that Use hoist with at least a one (1) ton
can be carried. The payload capacity capacity rating to lift your slide-in unit
must be equal to or greater than the
into truck bed. To rig for lifting, fasten
weight of the slide-unit (and all liquid
the hoist chains to the built-in lift hooks
inside it) that you wish to carry. Loaded
and unloaded weights of the various on the slide-in unit (Figure 2.2).
Slide-in units can be found in the
specifications table on page 7.

To determine if the GAWR of your truck

can handle the load of a liquid filled slide-
in unit, first, obtain the weights of the
vehicle with just the front tires on the
scale and then with just the rear tires on
the scale. Note that for these weights to
be accurate, the approach and exit to the
scale must be level with the scale
surface. An inclined approach will shift
the weight toward the rear axle when the
front wheels are on the scale, skewing
the weight readings.
Securing Unit to Prevent Sliding
Next, take measurements to determine
where the slide-in unit will be positioned After lifting the slide-in unit into the truck
in the truck bed. With the position of the bed, fasten it securely to prevent sliding.
unit determined, measure the center of If allowed to slide, the unit can wear on
weight for the slide-in as per Figure 2.1. the bed floor and/or crash into, and
Use this measurement in the formula in break, the tailgate. Satellite Industries
Figure 2.1 to calculate the additional recommends that you use the optional
weight that will be added to each axle Mounting kit to fasten your slide-in unit
when carrying your slide-in unit (reference through the truck bed to the truck frame.
the loaded and unloaded weights of the
slide-in units in the specifications table on
The slide-in mounting kit requires that
page 7). The scaled weight plus the
holes be drilled into the frame of the
added weight provided by the slide-in unit
must remain with the GAWR. truck. Because the frame is the backbone
of the truck, proper frame integrity must
be maintained when attaching
WARNING: DO NOT exceed the components or equipment.
Gross Vehicle Weight Rating (GVWR) or
the Gross Axle Weight Rating (GAWR) for Observe the following precautions when
your vehicle when carrying your portable making any alterations to your truck
slide-in unit. Exceeding the GVWR or the frame:
GAWR of your vehicle can cause damage • Avoid applying heat to the frame with a
to the vehicle and can impede the braking torch or any other such equipment.
performance of the vehicle causing traffic • Avoid welding on the frame.
accidents and serious injury or death to • DO NOT use a torch to cut holes into
others. the frame.
• DO NOT cut notches in the frame rails.
• DO NOT drill holes in the frame rail

9
flanges; drill holes only in the web area of installation. Use 5/8”-11NC crown-lock
the frame lock nuts with these bolts. Fasten the
• New holes should be drilled as close as brackets to the outside of the truck frame
possible to the neutral axis of the web rails with the short leg of the bracket
(halfway between the flanges) or on the pointing outward (Figure 2.3).
same horizontal line as adjacent holes.
• Next, using the hole in the short leg of
If you have any questions or concerns the bracket as a guide, drill an 11/16” dia.
about drilling the frame for bracket clearance hole up through the truck bed.
attachment on your particular truck, Be careful when drilling up through the
consult your local truck dealership. In thin gage metal of the truck bed. If

SETUP
addition, most truck manufacturers possible, grind a sheet metal drilling point
publish a body builder’s guide that on the drill bit. Otherwise use a center-
contains specific recommendations for drill, and then step your way up to the final
frame alteration. Your dealership should hole size using several drill bits.
be able to help you obtain this guide.
• The next step involves welding the
Following all relevant precautions, use upper brackets to the slide-in rails. Take
the procedure below, while referring to the appropriate precautions before
Figure 2.3, to install the mounting kit: performing this welding. This includes
making sure the cap on the engine gas
• Determine an area of the frame to tank is affixed tightly, disconnecting the
which the lower mounting brackets can battery terminals, and attaching the
be bolted. The positioning of these ground cable of the welder as close as
brackets will have to take into account possible to the area being welded. Be
frame braces and other frame mounted on the alert for spilled gasoline or
components. Place the mounting points gasoline fumes. DO NOT weld if either
as far apart as possible (within the of these is present.
length of the slide-in rails) while locating
them in an area with enough space for From the top side of the truck bed,
drilling and bolting through the truck confirm the measurements for the hole
frame. locations and transfer these to the slide-
in unit rails. With the locations verified,
• Position the brackets against the frame clamp the upper brackets to the rails so
so that the top face of the bracket angle that the bottom of the short leg face
is about level with the top of the frame. is slightly above level with the bottom of
Make sure there is adequate clearance the rail. Make sure there is at least a
between the top of the bracket and the little clearance between the bracket and
underside of the truck bed to allow for the truck bed. Then, weld the upper
the normal flexing of the truck. After brackets to the slide-in rails.
determining the position of the brackets,
drill two 11/16” clearance holes in the • After the top brackets are welded to
long leg of each bracket. Then, using the the rails, lift the slide-in unit into the
brackets as a template, mark the hole truck bed using the procedure outlined
locations, and drill 11/16” dia. clearance in the previous section. To finish
holes through the truck frame. assembling the mounting kit, place 5/8”
bolts, purchased to the correct length for
• Bolt the lower brackets to the truck your installation, up through the frame
frame using 5/8”-11NC Grade 8 bolts. bracket, through the clearance hole in
These bolts are not included in the the truck bed, and up through the top
mounting kit and must be purchased in bracket.
the correct length for your specific
10
Fasten the two springs included with the welding if gas fumes are present.
kit over the two front-most bracket bolts Gasoline is highly explosive, and can
using 5/8” flat-washers and crown-lock result in serious injury or death if caused
lock nuts. Compress the springs to a to ignite.
measurement of 3-/8”. The rear brackets
do not use springs and therefore use a
shorter bolt length. Use 5/8” washers and WARNING: Before transporting your
crown- lock lock nuts on these bolts also, slide-in unit, make sure it is securely
and tighten securely. fastened into the truck bed in order to
keep it from sliding. If not fastened, the
With your slide-in unit bolted in using the
unit can crash into and break the tailgate,
mounting kit brackets, you can now safely
and possibly fall from the truck causing a
transport your unit without the danger of
traffic accident and/or severe injury or
having it slide around in the truck bed.
death to persons in the area.
When you need to use your truck for other
tasks, simply unbolt the slide-in unit and
lift it out of the truck. Electrical Setup

Your portable slide-in unit comes with a

WARNING: Before welding, make 12 volt battery for providing power to the
sure the cap on the engine gas tank is electric start gas engine and the motor for
affixed tightly, disconnect the battery the water pump. To make sure the
terminals, and attached the ground cable battery maintains its charge, it is
of the welder as close as possible to the disconnected during shipment (Figure
area being welded. DO NOT perform 2.4). Connect the battery before placing
11
your slide-in unit into service. In addition,
check the 15 amp system fuse to make
sure it has not been damaged during
shipment (Figure 2.5).

SETUP
Figure 2.5 System

Vacuum / Pressure Gauge Setup

The vacuum / pressure gauge on your

slide-in unit comes disassembled to
prevent damage during shipping. Simply
thread the gauge into the threaded hole
in the primary shut-off cover. Seal the
gauge threads by using Teflon tape,
Teflon thread sealant, or any other good
quality thread sealant.

Figure 3.1 Main Components of the Portable Slide-in Unit

Moisture Trap
Vacuum Tank

Oil Catch
Muffler
Vacuum Relief
Valve

Mediu Vacuum
m / Pressure
Pressur
Gauge
e
Hose

Waste Pressure
Hose Relief
Valve

Vacuum
Pump

Honda
Engine Medium
Discharge Valve
Pressure Wash

12
OPERATION
The main components of your Portable
Slide-in Unit are detailed in Figure
3.1.This illustration provides an
introduction to the components on
your slide-in that are referred to
throughout this manual.

Operation Safety

Operating vacuum tanks, and pumping

OPERATION
septic effluent, involves potential hazards.
Before operating your portable slide-in Vacuum Relief Valve
unit, you must understand and follow all
of the safety precautions in this manual. The vacuum relief valve serves to
safeguard against vacuum pump
Hazards frequently encountered in damage. It is located in the airline circuit
pumping include dangerous chemicals, just above the vacuum pump (Figure 3.1).
exposure to bacteria, explosive The vacuum relief valve is factory set to
atmospheres, falls, high-pressure water 18 Hg. This is the maximum continuous
jets, rotating drivelines, and poisonous vacuum rating (MCVR) of the vacuum
gasses. Because each pumping job is pump. This vacuum level also generates
unique, you may experience other the recommended maximum limit on
hazards as well. horsepower draw for the engine.

When dangerous situations arise, it is If you notice that the vacuum relief valve
your responsibility to make sure that no is not relieving vacuum when your tank
harm comes to persons, equipment, or reaches 18 Hg, you might need to reset
the surrounding environment. Make sure it. Use the following procedure to set the
that your job site is secured and safe for valve:
others both when you carry out the job
1. Loosen the locking nut located near
and when the job is complete.
the top of the vacuum relief valve.
Rotate the inner cylinder clockwise one
to two revolutions to reduce the setting
at which the valve opens. Retighten the
locking nut after making the adjustment.

2. Run the pump in the vacuum mode,

and check to see if the valve opens at
the MCVR as listed above.

3. Repeat steps one and two until you

attain the proper setting.

` NOTICE: DO NOT run your vacuum

pump above the pump manufacturer’s
maximum continuous vacuum rating.
Exceeding the maximum vacuum rating
could cause damage to the pump and/or
unit.

13
Pressure Relief Valve

A pressure relief valve is located in the

airline circuit next to the vacuum relief
valve (Figure 3.1). This valve serves to
prevent damage to the tank and motor. It
opens, to release air, when the pressure
in the tank reaches 6 psi. to 8 psi.

When the pressure relief valve opens to

release excess air, it creates a hissing
sound that you should be able to hear. Figure 3.2 Vacuum / Pressure Gauge
Listen for this sound, and if the valve
does not open at the above pressure,
reset it. Exceeding the recommended 6
psi. to 8 psi pressure can create Vacuum / Pressure Gauge
excessive horsepower draw on your
engine causing it to overheat. A vacuum/pressure gauge is located on
your tank (Figure 3.1). As the gauge
needle moves counterclockwise of zero,
CAUTION: DO NOT exceed a the gauge reads vacuum in inches of
maximum pressure of 6 psi to 8psi with Mercury (in.Hg). As the gauge needle
your vacuum tank. Exceeding the moves clockwise of zero, the gauge reads
pressure can create the engine to pressure in pounds per square inch (psi)
overheat, which could result in damage to (Figure 3.2). Use the gauge to determine
equipment. when the tank has reached operating
vacuum or pressure.
Use the following procedure to set the
pressure relief valve: Moisture Trap (Secondary Shutoff)

1. Purge all air from the tank by slowly The moisture trap (also referred to as the
opening the rear dump valve. Stand off secondary shutoff) serves as a safety
to the side of the valve to prevent device to prevent liquid from entering the
possible injury from the direct flow of vacuum pump. Check the moisture trap
releasing pressure. daily for accumulation of liquid. Use the
easy access drain valve to empty the
2. After purging the tank of air, loosen the trap. The drain is located at the bottom of
setscrew located near the top of the the moisture trap.
pressure relief valve. Rotate the inner
cylinder clockwise one to two revolutions While the moisture trap helps prevent
to reduce the setting at which the valve liquid from entering the pump, excess
opens. Retighten the setscrew after accumulation may be an indicator that
making the adjustment. some contamination has passed into the
pump. When excess liquid shows up in
3. Run the vacuum pump in the pressure your moisture trap, clean your vacuum
mode, and check to see if the valve pump using the procedure on page 25 of
opens at the specified setting as listed this manual.
above.
„ IMPORTANT: Anytime that excess
4. Repeat steps one through three until liquid accumulates in the moisture trap,
you attain the proper setting. clean the inside of your pump. Liquid
contamination that enters the pump can
14
cause damage if you do not clean the Use the handle mounted to each valve to
pump shortly thereafter. open and close it.

Oil Catch Muffler To allow for easy coupling and

uncoupling of the vacuum or discharge
The oil catch muffler collects oil expelled hose, both the load and the dump valves
from the vacuum pump and reduces are equipped with cam lock-fittings.
pump noise.
There is a cam lock fitting cover for the

OPERATION
Drain the oil catch muffler daily by dump valve. When the discharge hose is
opening the drain at the base of the uncoupled, place this cover over the dump
muffler chamber. You may need to drain valve opening to keep dirt and debris from
the muffler more frequently when collecting in it.
subjecting the pump to heavy use.
Properly dispose of the used oil. DO Because dumping arrangements vary
NOT reuse it. widely from one operation to another,
discharge hose is not included with your
Furthermore, anytime that you notice that slide-in unit. Based upon your specific
water has collected in the oil catch requirements, procure the correct length
muffler, dry out the vacuum pump interior
of 3” discharge hose and a 3” cam lock
using the procedure outlined on page 18.
attachment to couple to the discharge
outlet.
Fill Indicator

Your Portable Slide-in Unit comes with a

sight tube and a fill indicator (Figure 3.4).
The sight tube displays the liquid level in
the freshwater compartment and displays
the liquid level in the sewage
compartment.

Figure 3.4 Sight Tube Fill Figure 3.5 Cam lock Coupling & Load Valve
I di t (on load hose)

Load and Dump Valves

Your slide-in unit comes with manual load

and dump valves (Figures 3.5 and 3.6).
15
 Safety Suggestions for Vacuum
Pump

WARNING: Keep hands, feet, hair,

and clothing away from moving parts.
Contact with a moving mechanism can
cause entanglement, which can lead to
dismemberment or death.

CAUTION: Avoid contact with the

Figure 3.6 Dump Valve & Cam lock vacuum pump during or immediately after
C operation. Operating temperatures can
range from near 200°F to over 300°F,
Vacuum Pump depending on the working conditions.
Contact with a hot vacuum pump can
The OEM Operation Manual for your
cause severe burns.
Masport HXL3V or Conde Model 6 vacuum
pump is included in the literature packet Vacuum Pump Pre-Startup
that you received with your Slide-in Unit. Procedure
Review and follow the operation
procedures outlined in that manual. Perform the following procedure each time
before you operate the vacuum pump:
Satellite Industries furnishes the following
information to provide a better • Make sure that the rotor shaft turns
understanding of your vacuum equipment. freely. This is especially important in cold
This information is intended to augment weather to make sure that the pump is not
(not replace) the OEM instructions for frozen up with ice.
your pump.
To verify that the rotor shaft turns freely,
„ IMPORTANT: Follow the operation make sure that the ignition switch on the
procedures outlined in your OEM pump gas engine is in the off position, and then
manual in order to keep your warranty pull once on the starter rope.
valid and to receive maximum service life
from your pump. • Check the level in the oil reservoir. Use
the dipstick at the rear of the pump (on the

16
oil reservoir) to check the oil level. Add oil,
as needed, through the dipstick port. The
oil in the reservoir requires periodic refilling
Pressure Vacuum
because the pump consumes oil in the Output Shaft
process of lubrication.

Use only OEM recommended types and

brands of oil for your pump. Table 3.1 lists
the manufacturer recommended lubricants
for the Masport HXL3V and Conde Model
6 vacuum pump supplied with your slide-in
Figure 3.7 Handle Positions / Vacuum Pump
unit. If you have difficulty obtaining
manufacturer recommended oil, contact
Satellite about its availability. procedure, you are ready to operate your
vacuum pump. The Gasport or Conde
• Add grease at the grease fitting on the pump on your portable slide-in unit is
front endplate (just above the output shaft) driven by an 8 hp Honda gas engine.
this fitting provides grease to the bearings.
It is important not to over grease the pump Before starting the engine, position the
bearings. Use only one or two pumps on vacuum / pressure control handle on the
the grease gun when greasing. pump in the neutral position.

` NOTICE: Check the oil level in the rear Next, move the throttle lever on the gas
housing at regular intervals. Allowing the engine away from the SLOW position,
pump to run low on oil during operation will about 1/3 of the way toward the FAST
result in damage to the pump. position and start the gas engine to put
the pump into operation. Make sure the
„ IMPORTANT: DO NOT over grease pump is running smoothly by listening for
the pump bearings. Over greasing can a pump sound with minimum vibration.
cause damage to the seals.
If the engine is not running fast enough,
Vacuum / Pressure Control Handle the vanes in the vacuum pump rotor will
not have enough centrifugal force to keep
them expanded in the rotor slots. This will
On your Masport HXL3V and Conde
result in excessive vibration as the vanes
Model 6 vacuum pump, locating the
control handle in the center of its travel Drip Oiler
will cause the pump to operate in a Vacuum/Pressure
neutral free flow mode. Adjustment Knob Control
Handle
In addition, use the control handle to Drip Oiler
select either the vacuum or pressure Sight Window
modes. Figure 3.7 details the handle
position in relation to the pump
orientation for vacuum and pressure
functions. You can also observe the
vacuum/pressure gauge to verify which
mode you are operating in.
Figure 3.8 Vacuum Pump Drip Oiler &
Vacuum Pump Operation Vacuum/Pressure Control Handle

move in and out in the rotor slots, and

After performing the pre-startup
pound against the cylinder wall. In this
17
case, increase the engine speed to Loading the Tank
eliminate the vacuum pump vibration and
protect against vacuum pump damage. With the pump in operation, use the
following procedure to load the tank on
When the pump is running, check oil flow your slide-in unit:
in the drip oiler sight window to ensure • Set the vacuum/pressure handle on
that the proper lubrication is reaching the the pump to the “vacuum” mode.
pump (Figure 3.8). The minimum • Move the throttle control lever on the
recommended oiling rate is 30 drops per gas engine to about 3/4 of the way
minute. To increase oil flow, turn the toward the FAST position (Figure 3.9).
adjustment knob on the drip oiler This will provide the recommended 1250
counterclockwise. To decrease oil flow, to 1300 rpm at the vacuum pump.
turn the adjustment knob clockwise.
Moving the throttle lever all the way open
Pay close attention to the drip rate of the will result in about 1600 rpm-s at the
manual adjust drip oiler on your vacuum vacuum pump. Because this is over the
pump, and regulate it as necessary. 1300 rpm that the pump is rated for, the
Manual drip oilers require periodic engine throttle lever must be backed
checking and adjustment. In addition, down just a bit from the fill throttle
readjust the drip oiler when changing oil position.
weight in your pump.
Making sure the throttle on the gas engine
Finally, before using the pump to load the is set to provide the optimum speed for the
tank, actuate the vacuum/pressure pump requires the attentive observation of
handle to be sure that the pump is the operator. If the pump is running too
operating in each mode. slow the vanes will make a clanking sound
as they move in the rotor slots. If the pump
` NOTICE: DO NOT run your vacuum is running too fast it will overheat.
pump at too slow a speed when starting
it. If excessive vibration is evident, speed • Allow the vacuum to build to the desired
up the gas engine drive until the pump level (usually about 15” Hg), and then
runs smoothly. Allowing the rotor vanes open the valve on the suction wand and
to pound against the cylinder wall by load the tank.
running at too slow a speed will damage
the vacuum pump.
When running the
„ IMPORTANT: When adjusting your vacuum pump,
vacuum pump oiler, use small adjustment position the throttle
control lever on the
increments (no more than one turn at a
gas engine at
time). This helps protect against running about ¾ of the way
the pump dry due to turning the
adjustment knob too lean or in the wrong
direction.

` NOTICE: If proper oiling is not

achieved within a few minutes, shut down
pump and see “Trouble Shooting” section
on page 31 or consult your sales
Figure 3.9 Throttle Control Lever Operating
representative.

18
• When the tank is full, close the fill valve area of lower pressure created in the tank.
and turn off the engine in order to shut
down the pump Vacuum is measured in inches of Mercury
(in.Hg. or “Hg.). This type of measurement
Pay close attention to the fill indicator on is based on a barometric mercury column.
your tank so that you can promptly shut Standard atmospheric pressure at sea
down your vacuum pump when the tank level causes the mercury in this instrument
is full. to rise 30 inches up into a glass tube with a
vacuum. The dial type pressure/ vacuum

OPERATION
If for any reason you can’t visually tell when gauge on your tank (Figure 3.2, page 14)
the tank is full, listen for a change of sound gives the same in.Hg. reading as a
in the vacuum pump. When the tank is full, mercury column.
the primary shutoff stops airflow, creating a
noticeable change in the sound of the Usually, 15" Hg of vacuum is sufficient to
vacuum pump. load the tank without placing undue stress
on your pump. Table 3.3 lists the
Also, in the unlikely event that the primary approximate vacuum levels required to lift
or secondary shutoff activates due to water a given distance. However, these
extreme air velocity, promptly shut down figures must be adjusted to compensate
your vacuum pump. Again, a change of for the weight of the material and the
sound in the vacuum pump is your length and diameter of suction hose being
indicator to stop operation. This will used. Effluent or seepage may often weigh
deactivate the shutoff, at which point you more than water. Also, pumping these
can resume operation. products through a hose induces friction.
Both of these factors result in reduced
lifting efficiency.
` NOTICE: DO NOT operate the pump
faster than the recommended rpm. In addition, both attainable vacuum and
Operation above the recommended rpm pumping height decrease at higher
will cause the pump to overheat, altitudes. This is because atmospheric
resulting in damage to the pump. pressure decreases with height. Therefore,

` NOTICE: Shut down your vacuum pump Table 3.3 Vacuum Levels vs Lift Height
promptly when the tank is full. In addition, Vacuum in. Hg. Lift Height (for water)
any time the primary or secondary shutoff
activates, stop pump operation. At the point 10 11'4"
when either of the shut-offs activates, the 15 17'
pump is susceptible to over-heating if kept 20 22'8"
running. This can damage your pump. 21 23'8'
22 24'9"
Mechanics of Pneumatic-Transport 23 26'
(transfer by means of vacuum) 24 27"2"
25 28'4"
A vacuum, as pertaining to pumping of 26 29'5"
liquid waste, is a space with some of the 27 30'6"
air removed from it. Your vacuum pump 28 31'7"
extracts air from your vacuum tank, 29 32'8"
lowering the pressure inside of it. 30 34'
Atmospheric pressure pushing against the
liquid does the actual loading of your
vacuum tank. The liquid flows toward the

19
there is less pressure at hand to load your Use the following procedure to dry the
tank. Table 3.4 lists the percentage loss of pump out:
attainable vacuum for every 1000-foot rise • Unload the tank
in elevation over sea level.
• Open a load or dump valve (to keep from
While it is necessary to create enough building vacuum)
vacuum to handle pumping height, product
weight, and hose friction, it is important not • Run the pump in vacuum mode for two
to overstress the pump. Pay close attention to five minutes
to your pump if it is necessary to operate at
a high in./Hg vacuum level. Air- cooled Water that is allowed to remain in your
pumps are especially vulnerable to vacuum pump can diminish performance
overheating when being operated for and cause serious damage. When water is
extended periods at high vacuum levels. present inside the pump, sludge forms.
Liquid cooled pumps can handle this type This can restrict the vanes from moving
of operation much more readily. freely inside the rotor slots, reducing the
efficiency of your pump. In addition, water
In addition, operation at high in./Hg levels inside your vacuum pump can freeze
can also result in moisture condensation in during cold weather operation. Attempting
the pump. As vacuum increases, water to operate your pump if it is frozen inside
begins to evaporate from the surface of the with ice will damage it.
liquid in the tank. Anytime that vacuum
pump operation exceeds 15"Hg, water ` NOTICE DO NOT run your vacuum
vapor can begin to show up in the air pump above the pump manufacturer’s
circulating in the vacuum system. maximum continuous vacuum rating.
Exceeding the maximum vacuum rating
While most of this moisture collects in the could cause damage to the pump and/or
oil catch muffler, some of it will also tank.
accumulate inside the pump. In order to
prevent problems connected with water „ IMPORTANT: After operating your
collecting in your vacuum pump, dry it out pump at high in./Hg vacuum levels, dry the
anytime that you notice that water has pump interior out using the procedure
collected in the oil catch muffler. outlined above. Water in your vacuum
pump can cause sludge formation and
Table 3.4 Vacuum vs Elevation freeze up in cold weather.
Attainable Percentage of
Elevation Maximum loss per 1,000
Vacuum Level feet elevation Unloading
0 29.921 ----
1,000 28.85 3.6% You have two options when unloading the
2,000 27.82 7.0% tank on your slide-in unit, gravity dumping
3,000 26.82 10.4% or pressure dumping. Either method will
4,000 25.84 13.6% effectively empty the tank, however
5,000 24.89 16.8%
pressure dumping increases discharge
6,000 23.98 19.9%
flow rate.
7,000 23.06 22.9%
Begin the unloading procedure by placing
8,000 22.20 25.7%
the vacuum pump control handle into
9,000 21.38 28.5%
neutral to relieve any vacuum in the
system, then use one of the following
procedures.
For gravity dumping, use the following
20
procedure: inlet opening (Figure 3.10). DO NOT use a
tight fitting on the inlet because this will not
1. Set the control handle on the pump to allow the fill port to self solvent.
the “pressure” mode.
2. Open the dump valve. When using the pressure water pump, you
will need to run the gas engine in order to
For pressure dumping, use the following provide a charge to the battery. Be sure to
procedure: open the valve on the suction wand (load
valve), and place the vacuum pump in the
1. Place the pump into operation using vacuum mode. This will allow air to flow
the procedures in the vacuum pump freely through the vacuum pump

OPERATION
pre-startup and vacuum pump
preventing it from overheating.
operation sections on pages 16-18.
2. Set the vacuum/pressure control
With the load valve and vacuum pump set
handle on the pump to the “pressure”
mode. as instructed above, use the following
3. Move the throttle control lever on the procedure to operating your pressure
gas engine to about ¾ of the way water pump:
toward the FAST position (Figure 3.9,
page 18)
4. Open the pump valve to begin
unloading when the pressure reaches
the desired level (up to the maximum
psi set on the pressure relief valve).

CAUTION: DO NOT exceed a

maximum pressure of 6 psi to 8 psi with
your vacuum tank. Exceeding this
pressure can cause the engine to
overheat, which could result in damage to
equipment. Figure 3.11 Wash Down
System
After unloading the tank, stop the gas
engine, and close the dump valve. It is • Make sure there is water in the slide-in
important to stop the engine before fresh water compartment.
closing the valve to avoid pressure • Start the gas engine and run at about
buildup in the system. 3/4 throttle (as per the instructions on page
18).
• Turn the pump start switch on (Figure
Wash-Down System 3.11). The pump does not require priming.
• When the water tank is empty, promptly
You will have received an OEM manual shut the water pump off to prevent over-
for the pressure water pump (included in heating.
your literature packet). Review and follow • Shut the gas engine off to prevent over-
the operation procedures outlined in that heating the vacuum pump.
manual. Supplementary instructions are
included below. Running the gas engine while using the
water pump will help recharge the slide-in
Before operating the wash-down system unit’s 12 volt battery. However, the
on your slide-in unit, first fill the water generator on the gas engine does not have
compartment through the fresh water inlet the capacity to keep up with significant
using a hose of a smaller diameter than amperage draws from the water pump.

21
 and the toggle switch is in the on position.
Additionally, the gas engine will also
provide a charge to the battery when the As an added note to pump operation,
sewage compartment is being filled during cold weather (below 32°), drain the
(during which time the water pump is not liquid from your pressure water pump to
in use). This will further add to the battery prevent freezing and damage to the pump
charge, however, large demands on the housing. In addition, drain all water lines
water pump can still leave the battery and filters to protect them from freeze-up.
depleted.

When using the water pump frequently WARNING: DO NOT use a tight
throughout the day it is necessary to fitting on the fresh water compartment fill
recharge the battery using a battery port. This port is designed to be self venting
charger. Usually, this can be done at the and performs this function with the use of
end of the day so as to avoid interfering

MAINTENANCE
your fill line of a smaller diameter. Failure to
with normal operation. allow the vent to function can result in
damage to the tank and serious personal
As an alternative, frequent high amperage injury.
demand on the water pump can be met by
wiring the unit into the electrical system of ` NOTICE: DO NOT allow water to freeze
your truck. This is a relatively inside the pump. Do not attempt to start the
straightforward process requiring the pump if water has frozen inside it. Freezing
following materials: water can damage your pump. Take the
truck into a warm area and allow the pump
• Number 12 automotive wiring the thaw out.
• A 15 amp fuse assembly
• A toggle switch assembly
Cold Weather Operation
Install the new circuit for the water pump by
splicing into an unused auxiliary circuit Use the following guidelines when
under the dashboard. Most vehicles have operating your vacuum tank in
some unused auxiliary circuits available for temperatures below 32°F.
various vehicle options. Use a test meter to
verify which line in the circuit has an Extremely cold weather can result in
amperage draw and which is the ground formation of ice inside the vacuum pump,
wire. due to residual moisture. If the pump
freezes up due to ice, take the truck into a
Route the wiring from under the dashboard warm area and allow the pump to thaw.
to the back of the truck where the toggle DO NOT use a blowtorch or other similar
switch will be located. Mount the toggle device to attempt to thaw a frozen vacuum
switch in a convenient location such as on pump.
the weldment stand that supports the slide-
in engine and pump assembly. Frigid temperatures could also cause the
dump or load valves to freeze shut. Hot
Splice the fuse assembly into the wiring water poured over a frozen valve should
run so that it will be in an accessible loosen the ice. DO NOT use a blowtorch or
location. Then, wire the run to the newly similar device to thaw a frozen valve. This
installed toggle switch. Finally, detach the method could damage the valve.
water pump wiring from the existing switch
and attach it to the new switch. The water
pump will now start up when the truck
ignition key is in the accessory position
22
Table 4.1 Lubrication Intervals
Required Lubrication Lubrication Interval
Gas Engine - Every time before startup
Check engine oil level
Per pump manufacturers recommendations or at a
Vacuum Pump –
Grease front bearing at grease fitting minimum every 4 hours of operation / daily

Per pump manufacturers recommendations or at a

Vacuum Pump -
minimum every 4 hours of operation / daily
Re-fill oil level in the rear housing

Reduction Gearbox - Weekly

Check the oil level in the gearbox
Gas Engine - Weekly
Check transmission oil level
To correspond with oil weight requirements for given air
Vacuum Pump -
Change oil in the rear housing temperature

Lubrication Locations = Oil lubrication points

= Grease lubrication points
= Check oil

Figure 4.1 Slide-in Lubrication Locations

Note: See the maintenance subsections in this manual for specific lubricant types and
lubrications intervals.

23
MAINTENANCE pump (including effluent) is a major cause
of pump failure. See page 26 for vacuum
pump cleaning procedure.
Lubrication and Maintenance
Intervals In addition, clean and/or replace the ball
seat in the primary shutoff any time that
Safe and reliable service from your Slide- excess liquid accumulates in the moisture
in Unit depends upon a regular schedule of trap. Excessive liquid in the moisture trap
lubrication and maintenance. Figure 4.1 can often be traced to improper sealing of
details the lubrication locations on your the ball seat in the primary.
slide-in unit. Tables 4.1 and 4.2 list
intervals for lubrication and maintenance.
„ IMPORTANT: Any time that excess
In addition, the following sections detail the
liquid accumulates in the moisture trap,
required lubrication and maintenance for clean the inside of your pump. Liquid
individual components. contamination that enters the pump can
cause damage if you do not clean the
pump shortly thereafter.
WARNING: before performing any
lubrication and maintenance, review and Primary Shutoff
follow the “SAFETY PRECAUTIONS” on
pages 5-7 and all safety precautions Inspect the primary shutoff every 2 weeks
listed below. to check the rubber ball seat and the
tightness of all fasteners.
Moisture Trap / Secondary Shut Off
To inspect the ball seat, begin by first
Check the moisture trap daily for collected removing the cap screws that fasten the
liquid. Use the easy access drain valve to primary shutoff access lid to the portal
empty the trap. The drain is located at the flange on the tank (Figure 4.2). After the
bottom of the moisture trap. fasteners are removed, lift the entire
shutoff assembly (which is fastened to the
In addition to checking for liquid, inspect access lid) out of the tank be careful not to
the ball seat and the fasteners every 2 let the portal gasket fall on the ground or
weeks. into the tank.

Check all moisture trap fasteners and Next, remove the cap screw at the
tighten as necessary. Road vibration over bottom of the float cage and reach up
time can loosen fasteners. through the cage tube to remove the
seat.
Remove the moisture trap cover to
examine the ball seat for hardened rubber, Next, remove the cap screw at the
nicks in the rubber, and a buildup of debris. bottom of the float cage and reach up
Any of these conditions may prevent through the cage tube to remove the
proper sealing. Clean and/or replace the seat.
ball seat as necessary.
Examine the ball seat for hardened
Any time that excess liquid accumulates in rubber, nicks in the rubber, and a buildup
the moisture trap, clean the inside of your of debris. Any of these conditions may
pump. While the moisture trap helps prevent proper sealing. Clean or replace
prevent liquid from entering the pump, the seat as necessary
excess accumulation may be an indicator
that some contamination has passed into Reassemble the primary shutoff in the
the pump. Contaminates entering the reverse order. Be sure to tighten all
24
fasteners adequately. This is important • After you are satisfied that the tank
because fasteners may become loose has been completely coated, drain the
due to vibration. This is especially critical tank as slowly and completely as
when driving extensive miles with an possible.
empty tank.
• Allow the drained tank to set
Wear protective gloves, eye overnight, after which time the tank is
protection, and appropriate clothing when ready for use.
inspecting and cleaning the primary shut
off. Being a component of the vacuum
Vacuum Pump
system, the shut off is subjective to
exposure by sewage effluent or septage.

MAINTENANCE
These materials may contain hazardous The OEM Operation Manual for your
chemicals and bacteria, which can cause vacuum pump is included in the literature
infection, injury, or even death due to packet that you received with your Slide-
contact. in Unit. Review and follow the
maintenance procedures outlined in that
manual.
„ IMPORTANT: Check the primary
shutoff regularly for the condition of the
Satellite Industries furnishes the following
ball seat and fastener tightness. Improper
information to provide a better
maintenance of the primary shutoff may
understanding of your vacuum
allow liquid to flow into the vacuum
equipment. This information is intended
pump, which will result in damage to the
to augment (not replace) the OEM
unit.
instructions for your specific pump.
Fresh-water Compartment Coating
Procedure
„ IMPORTANT: Follow the
maintenance procedures outlined in your
OEM pump manual in order to keep your
On Slide-in Units with a serial number
warranty valid and to receive maximum
before C29973 you can apply a coating to
service life from your pump.
the tank interior to keep your fresh water
looking good by preventing rust formation
Basic Vacuum Pump Maintenance
inside the tank. A coating material for this
purpose, named Type A coating, can be
ordered from Satellite. Use the following Basic maintenance on your vacuum pump
procedure to apply the coating to your involves maintaining proper oil flow,
tank interior: keeping the pump filled with oil, and
greasing the bearings
• Fill the fresh water compartment with • Using the oiler sight window, check for
clear water to the lowest level of the proper oil flow every time you operate
sight tube. your pump (Figure 3.8, page 17). The
oiling rate (drip rate) for the Masport
• Add two quarts of Type A coating to HXL3V or Conde Model 6 pump is 30
the tank. Then, allow a few minutes for drops per minute.
it to settle.
Pay close attention to the drip rate of
the manual adjust drip oiler and
• Next, fill the tank completely with clear
regulate it as necessary. Manual drip
water and slosh around to coat all
oilers require periodic checking and
surfaces including the top of the
adjustment. See the “Vacuum Pump
interior.
Operation” section, page 16, for drip
oiler adjustment procedure.
25
Table 4.2 Maintenance Intervals
(in addition to lubrication)

Component Required Maintenance Maintenance Interval

Check for accumulation of

Moisture Trap
li id
Clean rubber ball seat; check
Primary Shutoff Every 2
fastener tightness
eeks
Clean rubber ball seat; check
Moisture Trap Every 2
fastener tightness
weeks
Check tension on spring
Mounting Brackets Every
Month mounts
Vacuum Pump Clean pump interior Every three months

Clean pump exterior (to avoid

Vacuum Pump
Regu
b ild f d)
Vacuum Pump Clean drip oiler sight glass Periodically

Per pump manufacturers recommendations

Vacuum Pump Check rotor vane wear
(replace vanes that exceed 1/4" wear limit)

Figure 4.2 Primary Shutoff for Slide-in Units Figure 4.3 Vacuum Pump Cleaning

Primary
shutoff
access lid

Rubber Ball
Float Cage Seal

To access
the rubber
ball seal,
remove the
cap screw,
and reach
up through
Portal the bottom
Gasket f th fl t

26
 „ IMPORTANT: When adjusting your greasing.
vacuum pump oiler, use small
adjustment increments (no more than ` NOTICE: Check the oil level in the rear
one turn at a time). This helps protect housing at regular intervals. Allowing the
against running the pump dry due to pump to run low on oil during operation will
turning the adjustment knob too lean or result in damage to the pump.
in the wrong direction.
` NOTICE: Follow the manufacturer’s
• Check and refill the vacuum pump oil
recommended lubrication for your specific
reservoir every 4 hours of operation or
vacuum pump. Because of differing oil
daily.
pump types and heat generation
characteristics among vacuum pumps,
It is essential to check the oil level
using the incorrect oil can lead to
regularly because the pump consumes
overheating and mechanical failure.
oil in the process of lubrication.
Average usage of oil is approximately
1-2 quarts per 40 hours, depending „ IMPORTANT: DO NOT over grease
upon the type of operation the pump is the pump bearings. Over greasing can
subjected to. cause damage to the seals.

Use only OEM recommended types Periodic Vacuum Pump

and brands of oil for your pump. Table Maintenance
3.1, page 17, lists the manufacturer
recommended lubricants for the Other maintenance for your vacuum pump
Masport HXL3V or Conde Model 6 includes cleaning the exterior of the pump,
vacuum pump supplied with your cleaning of the pump interior, checking
slide-in unit. If you have difficulty rotor vane wear, and replacing worn rotor
obtaining manufacturer recommended vanes.
oil, contact Satellite Industries about its
availability. Cleaning the Exterior of the Vacuum
Pump
In addition to maintaining the proper oil
level in the pump, it is also necessary to
Clean the mud and dirt off the exterior of
use the correct oil weight depending on
your vacuum pump on a regular basis.
the air temperature in which the pump
This is especially important for air-cooled
will be operating. See Table 3.1, page
pumps that need to be clean to allow heat
16, for recommendations on oil weights
to radiate from them.
and corresponding air temperature.

When changing to a different weight oil, Cleaning Inside of the Vacuum

the manual drip oiler must be checked Pump
for the proper drip rate and adjusted if
necessary. See the “Vacuum Pump Occasionally a small amount of liquid, dirt,
Operation” section, page 16, for drip oiler or other contaminate may enter the pump,
adjustment procedure. restricting the ability of the vanes to glide in
the rotor slots. To prevent vane-restricting
• Grease the pump bearings every 4 buildup in your vacuum pump, clean the
hours of operation or daily. inside of your pump with a flushing fluid at
least every three months.
It is important not to over grease the In addition, clean the inside of your pump
pump bearings. Use only one or two any time that water shows up in the oil
pumps on the grease gun when catch muffler or if excess moisture begins
27
to accumulate in the moisture trap. Pay before placing the pump in the vacuum
attention to periodic cleaning because it mode to expel the flushing fluid.
will increase the life of your pump.
CAUTION: DO NOT position the
control handle to the pressure mode,
DANGER: Stop the truck motor, which would expel the fuel through the
remove all persons from the truck cab, and pump inlet. Incorrectly expelling the
chock the truck tires before servicing the flushing fluid through an open inlet (without
vacuum pump. A truck that begins to roll is the vacuum relief valve replaced) could

MAINTENANCE
a crushing hazard that can lead to death. cause it to spew out at the operator.

8. Restart the gas engine, and run the

DANGER: Make sure the gas pump at operating speed for about ten
engine on your slide-in unit is shut off seconds, and then stop the engine.
before servicing the vacuum pump.
Contact with a rotating mechanism can 9. After completing the above cleaning
cause entanglement that can lead to sequence, make sure that the ignition
death. switch on the gas engine is in the off
position, and then rotate the driveline
Use the following procedure to clean your slowly by pulling on the gas engine
vacuum pump: starter rope. Listen for a clicking sound
as each rotor vane drops in its slot. If not
1. Turn the gas engine off, make sure the all of the vanes are sliding freely in the
ignition switch is turned to off, and make pump rotor slots, repeat the above
sure your pump is in the non-operating procedure until they do slide freely.
mode.
DANGER: Before rotating the
2. Remove the vacuum relief valve from driveline manually by pulling the gas
the air line. (Figure 4.3). engine starter rope, make sure the
ignition switch is turned to off.
3. Create a flushing fluid with a 50/50
Contact with a rotating mechanism
mixture of diesel fuel and vacuum pump
oil. Place the control handle on the pump can cause entanglement that can lead
in the vacuum mode, and then pour 1/2 to death.
pint of the flushing mixture directly into
the pump inlet. 10. After completing the pump cleaning,
pour 4 to 8 oz. of oil into the pump. This
4. Next, turn the control handle to the will require that you remove and
neutral position to close the changeover reassemble the vacuum relief valve one
valve. more time. At this point, use Teflon
tape, Teflon thread sealant, or any other
5. Replace the vacuum relief valve. good quality thread sealant for the final
reassembly of the valve.
6. Start the gas engine and run the pump
at operating speed for about one minute. Finally, run the pump in neutral for about
a minute, and then drain the oil catch
7. Next, stop the gas engine, and then use muffler of the used flushing fluid.
the control handle to switch the pump to Properly dispose of the used flushing
vacuum mode. fluid. Your pump is now ready to put
back into service.
„ IMPORTANT: Be sure to replace the
vacuum relief valve in the inlet air line ` NOTICE: Add oil directly into the pump
after cleaning and before putting back into
28
service. This is important because the
cleaning procedure will rid the pump of Check vane wear at the interval
both dirt and the necessary oil for recommended in your OEM pump manual.
lubrication. It is important to stay on top of vane wear
Table 4.4 High Vane Wear Operating Conditions because most pump manufacturers do not
The conditions below will reduce vane life and warrantee damage caused by vane
necessitate more frequent vane wear checking breakage.
Fine grit in intake air (e.g. sand, rust, or soil dust
particles) You may need to change your vanes more
often than the manufacturer’s
Many long intervals in operation* recommendation if your pump is subjected
to very heavy use. See table 4.4 for
Many intervals of high Hg. operation* (e.g. as when
required to lift product a great distance). examples of heavy use factors that can
shorten vane life.
Consistent use of pressure dumping
When vane wear exceeds ¼” (for most
Running the pump dry on oil pumps), the vanes must be replaced. New
vanes, when bottomed in the rotor slots,
Using the wrong oil in pump (use only manufacturer will be flush with the outside diameter of
recommended oil in your pump)
the rotor. As such, vane wear is
Any situation in which the pump overheats determined by measuring how deep the
edge of the worn vane sits below the
Lack of periodic pump flushing maintenance
outside of the rotor.

Lack of pump flushing maintenance after water has In addition, if the pump volume declines
entered the pump significantly (i.e. it takes longer and longer
Attempting to engage a pump that is frozen with to fill the tank), then the vanes probably
ice(before thawing the pump out) need to be changed.
*Note: Pumps rated for continuous or heavy duty
operation (such as liquid cooled pumps) can handle Checking the vanes the Conde vacuum
these conditions more readily. pump supplied with your slide-in unit
involves disassembling one of the end

Rotor Shaft
O-Ring
End Plate
Seal
Bearing
Seal
Gasket
Bearing Plate
Drive Shaft

Rotor Vanes

Figure 4.4 Slide-in Vacuum Pump – Front End

A bl
Checking Rotor Vane Wear
29
plates from the pump in order to gain pump including removing bearings and
access to the rotor. Because of the time covers that may be press- fit into place. It is
this entails, it is advantageous to have a important to gather together the correct
fresh set of vanes on hand before tools, including tools for pulling parts free
checking. Then the new vanes will be from press-fits, before beginning the job.
ready for installation if you need them.
„ IMPORTANT: Be careful not to
Replacing Rotor Vanes damage bearing fits, shaft threads, or
sealing surfaces by hammering, prying or
Refer to the following instructions and the gripping with pliers.

MAINTENANCE
pump assembly diagram in Figure 4.4
when changing the rotor vanes on your Assemble the following tools before
vacuum pump. replacing rotor vanes:
• Stiff blade putty knife
Replacing the rotor vanes requires that the • Wrench set
pump be removed from the slide-in unit. To • Pry bars (two blunt tip pry bars or two
remove the pump, first remove the heavy duty, flat end, screw drivers)
coupling guard and the inlet and outlet • Properly sized sleeves for installing
airline hoses. Then, unbolt the pump from bearings
the slide-in mounting stand. Remove the • Replacement gaskets, O-rings, and
pump along with the pump side of the seals, or a rebuild kit
coupling. The coupling should separate • Soft head mallet
freely. Place the pump on a solid work
bench to ready it for changing the vanes. Replacement Procedure

Use the following procedure to replace the

WARNING: Wear protective rotor vanes in your vacuum pump:
gloves, eye protection, and appropriate
clothing when working with sewage 1. Remove the coupling half attached to
effluent or septage. These materials may the drive shaft, and then unbolt the drive
contain hazardous chemicals and shaft from the rotor shaft.
bacteria, which can cause infection,
injury, or even death due to contact. 2. Remove the drive shaft from the end of
the rotor shaft. If needed, tap the drive
shaft with a soft mallet to help free it from
„ IMPORTANT: When replacing rotor
the tapered rotor
vanes be sure to have replacement
shaft.
gaskets, O-rings, and seals on hand in
case any of these items should need
3. Remove the bolts from the bearing
replacing and/or be damaged during
plate, and then remove the bearing plate
disassembly.
from the end plate. The bearing plate
should come off relatively easily, and the
„ IMPORTANT: It may be seal should stay with it.
advantageous to replace gaskets, O-rings,
seals, and bearings when replacing rotor
vanes. Your CALUMET dealer offers a ` NOTICE: Be careful to avoid damaging
rebuild kit that includes these items. the seal as it slides off of the rotor shaft.
In addition, be careful not to damage the
Proper Tools for the Job gasket between the bearing plate and
the end plate.
Replacing rotor vanes will require
disassembly of the front end of the vacuum 4. Unbolt the end plate, and then remove it

30
 from the pump housing. Use the reassemble the vacuum pump and
following procedure to remove the end coupling assembly back onto the slide-in
plate: unit. Be sure to replace the coupling
guard after assembly.
• Use a stiff bladed putty knife to pry the
cover away from the housing until there
is a small gap all around. WARNING: Keep all shields in
place. Shields and covers are designed
• Once there is a big enough gap behind
to protect the operator from
the end plate, use two blunt tipped pry
entanglement in moving parts, which
bars or two flat head screw drivers,
can lead to serious injury or death. DO
placed opposite each other, to pry the
NOT remove shields from the unit
cover (and bearing) free of the rotor
except when servicing; then, replace
shaft.
immediately.

` NOTICE: Be careful not to damage the

O-ring between the end plate and the „ IMPORTANT: Be sure to use the
pump housing. correct size sleeve (one that fits against
the inner race of the bearing) when
installing the bearing back onto the rotor
„ IMPORTANT: The rotor bearing will
shaft. Use a soft mallet against the sleeve
usually remain pressed into the end plate
to press fit the bearing onto the shaft.
upon removal. Be careful when pulling the
bearing free of the rotor shaft that the rotor
does not fall down inside the pump
housing. It may be necessary to provide a
means of support for the rotor, such as a
block of wood under the rotor shaft.

5. Remove the rotor vanes, one at a time,

by first rotating the rotor so as to position
a vane at the bottom of the housing. With
the vane placed downward, there will be
enogh clearance around the rotor to
grasp the vane and slide it out the end of
the rotor slot.

6. After removing each vane, simply slide a

new vane (that has been dipped in oil)
into the rotor slot.

„ IMPORTANT: Always replace vanes

in sets.

7. Before reassembling, inspect the rotor

bore, bearings, seals, and gaskets, and
replace as necessary. Seals should be
soft and pliable, gaskets should not be
torn, and bearings should turn freely.

8. Reassemble the vacuum pump in the

reverse order of disassembly. Finally,
31
Troubleshooting Vacuum/Pressure Pumps

Reference Table 5.1 below for possible causes of Vacuum/Pressure pump problems and the most likely solutions.

Table 5.1 Trouble Shooting Vacuum/Pressure Pumps

TROUBLE SHOOTING

32