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Walinga Ultra-Vac 4510G Operator's Manual

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OPERATOR'S MANUAL
Ultra-Vac 4510G
English
00-154740-0 A
2025-03-31

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Summary of Contents for Walinga Ultra-Vac 4510G

  • Page 1 OPERATOR’S MANUAL Ultra-Vac 4510G English 00-154740-0 A 2025-03-31...
  • Page 2 TO OUR VALUED CUSTOMERS: The Walinga network of distribution centers and authorized dealers are dedicated to providing worldwide coverage of original parts and accessories for Walinga Pneumatic Conveying Systems. Our parts reflect Walinga’s continued commitment to provide our customers with the highest quality parts and service.

  • Page 3: Table Of Contents

    OPERATOR’S MANUAL Table of Contents Contact Information [00-154741-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Table of Contents [00-154741-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Literature Information [00-154741-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Identification of Machine [00-154741-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1...
  • Page 4 OPERATOR’S MANUAL Machine Safety Signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13 Safety Training Sign-Off Form - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33 Machine Life-Cycle Procedures [00-154745-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1...
  • Page 5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2 Limitations and Exclusions of the Walinga Warranty...
  • Page 6 Walinga Ultra-Vac. information on the controls and displays of the machine, specific operating instructions Some illustrations and diagrams may show including starting, operating all functions, safety shields, guards, or covers removed and stopping the machine, as well as for clarity.

  • Page 7: Identification Of Machine [00-154741-0]

    Identification of Machine ULTRA-VAC MODEL 4510G...

  • Page 8: Serial Numbers

    SERIAL NUMBERS Be prepared to provide the serial number of the unit, engine, blower and/or airlock to your Walinga dealer or representative when ordering parts or requesting service or other information. For easy reference, record the serial numbers as follows: Machine Serial Number Located on the right side of the frame.
  • Page 9 OPERATOR’S MANUAL Blower Serial Number Located on the top of the rear headplate of the blower. Airlock Serial Number Located on the outer rib of the endplate of the airlock. Identification of Machine 00-142201-0 A...

  • Page 10: Start-Up/Commissioning Form

    WALINGA Start-Up/Commissioning Form This form must be filled out by the sales representative and/or dealer, and signed by both the sales representative and/or dealer and the customer at the time of delivery. Delivery Date: MM/DD/YYYY Owner Operator Name Sales Representative / Dealer Name...
  • Page 11 (DHA) of their facility and the products and processes it contains. Based on this, Walinga understands that a DHA is required to be completed by the owner/operator prior to start-up/commissioning. In the event that a DHA is not available at start-up/commissioning, the owner/operator must provide written acknowledgement of their responsibility and intention to complete a DHA.
  • Page 12 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 00-154741-0 A Identification of Machine...

  • Page 13: Introduction [00-154742-0]

    Introduction ULTRA-VAC MODEL 4510G...

  • Page 14: Statement Of Importance

    INTENDED USE The Walinga Ultra-Vac has been designed for use in agricultural or similar operations in an outdoor environment for the moving of select granular commodities. Use of the machine in any other manner is considered as contrary to the intended use.

  • Page 15: Directional References

    A simplified representation of a pneumatic conveying system can be seen in Figure 2-2. At the heart of the Walinga system is a positive-displacement blower, sometimes referred to as an air pump. The blower unit creates a negative pressure (vacuum) in the primary air material separator (AMS), also known as the intake cyclone.
  • Page 16 Be advised that standard units are not supplied with blow-only kits. Walinga does not authorize the use of standard machines in blow-only operation without additional operational and safety hardware installed. If a standard unit is modified for blow-only operation, it is the responsibility of the owner and/or operator to ensure that all moving parts and inlets are adequately guarded.

  • Page 17: Machine Configuration [00-154743-0]

    Machine Configuration ULTRA-VAC MODEL 4510G...

  • Page 18: Model Variations

    STANDARD The standard 4510G Ultra-Vac model provides full functionality of a pneumatic conveying system featuring 4 in (10.16 cm) lines, a 510 Walinga Sound Reduction Technology blower, a 1314 airlock, Rhino Hyde lining, a self-contained hydraulic system, and a 37 horsepower gasoline engine.

  • Page 19: Safety [00-154744-0]

    Safety ULTRA-VAC MODEL 4510G...

  • Page 20: Safety Alert Symbol

    This safety alert symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on the Walinga Ultra-Vac and in the operator’s manual. When you see this symbol, be alert to the possibility of personal injury or death.

  • Page 21: General Safety

    OPERATOR’S MANUAL GENERAL SAFETY You are responsible for the safe operation and maintenance of your Ultra-Vac. You must ensure that you and anyone else who will operate, maintain, or work around your Ultra-Vac is familiar with the operating and maintenance procedures and safety information contained in this manual.

  • Page 22: Pre-Operation Safety

    PRE-OPERATION SAFETY ● Safety is a primary concern in the design and manufacturing of Walinga products. However, these efforts can be negated by a single careless act of an operator or bystander.
  • Page 23 OPERATOR’S MANUAL ● Properly train all new personnel and review instructions frequently with existing workers. Ensure only a properly trained and physically able individual will operate the machine. Any individual who has not read and understood all operating and safety procedures is not qualified to operate the machine.

  • Page 24: Installation Safety

    OPERATOR’S MANUAL INSTALLATION SAFETY ● Disconnect and remove all mechanical locks, anchor chains and any other transport devices that would hinder or prohibit the normal function of the Ultra-Vac upon start-up. Serious damage to the machine and/or personal injury to the operator or bystanders may result from attempting to operate the machine while mechanical locking devices are still attached and secured.

  • Page 25: Transportation Safety

    Provide tags at the work site and a sign-up sheet to record tag-out details. Do not perform any service or maintenance work unless the engine is OFF and the power is locked out. Safety lockout devices are available through your Walinga dealer parts department.

  • Page 26: Storage Safety

    OPERATOR’S MANUAL STORAGE SAFETY ● Store the Ultra-Vac on a firm, level surface in a dry area away from human activity. ● Secure the Ultra-Vac in place with wheel chocks if necessary. ● Support the hitch jack with an additional footing support if required, especially on softer surfaces.

  • Page 27: Hydraulic Safety

    OPERATOR’S MANUAL HYDRAULIC SAFETY ● The hydraulic system must only be operated in accordance with the system’s intended purpose. Do not modify or alter the hydraulic system in any manner. ● Ensure all components in the hydraulic system are kept in good condition and are clean. ●...

  • Page 28: Combustion Engine And Fuel Safety

    OPERATOR’S MANUAL COMBUSTION ENGINE AND FUEL SAFETY ● Use only the supplied or approved engine. ● Read and understand the operator’s manual of the engine. ● Always keep the equipment clear of accumulated dirt, dust, debris, and grease to prevent fire. ●...

  • Page 29: Safety Around Storage Structures

    OPERATOR’S MANUAL SAFETY AROUND STORAGE STRUCTURES Ultra-Vac operators and all other personnel in the vicinity or assisting with operation must strictly adhere to the procedures outlined below before entering a storage structure. For additional details regarding these procedures, reference Occupational Safety and Health Administration standards, or your local regulations.
  • Page 30 OPERATOR’S MANUAL ● Be aware of the extremely high suction at the intake nozzle of the Ultra-Vac. Keep clear of the nozzle intake area and never place the intake nozzle into material near your feet. ● Always check with the bin manufacturer before starting to unload a bin from the side. Side unloading may cause bin collapse.

  • Page 31: Machine Safety Signs

    ● Informational safety signs are white or blue in color. ● Each safety sign is printed with its respective Walinga part number located in the bottom right corner. Reference this number on the safety sign, or identified in the following reproductions, to obtain replacement safety signs.
  • Page 32 OPERATOR’S MANUAL Figure 4-1: Front side of Ultra-Vac safety signs 4-14 00-154744-0 A SAFETY...
  • Page 33 OPERATOR’S MANUAL Figure 4-1 A Part Number: 53-18290-6 Location: positioned on the lower right surface of the boom saddle. Figure 4-1 B Part Number: 53-08013-6 Location: positioned on the lower right surface of the boom saddle. Figure 4-1 C Part Number: 53-80781-6 Location: positioned on the air slide of all intake...
  • Page 34 OPERATOR’S MANUAL Figure 4-1 D Part Number: 53-100397-6 Location: positioned on the front surface of the frame next to the battery enclosure. Figure 4-1 E Part Number: 53-18288-6 Location: positioned on the lower right corner of the front surface of the drive belt guard and the left angled surface of the drive belt guard.
  • Page 35 OPERATOR’S MANUAL Figure 4-1 G Part Number: 53-135151-6 Location: positioned on the lower right corner of the front face of the drive belt guard. Figure 4-1 H Part Number: 53-98505-6 Location: positioned on the lower right corner of the front face of the drive belt guard.
  • Page 36 OPERATOR’S MANUAL Figure 4-1 J Part Number: 53-106800-6 Location: positioned on the left angled surface of the drive belt guard. Figure 4-1 K Part Number: 53-16131-6 Location: positioned on the top surface of the electrical enclosure. Figure 4-1 L Part Number: 53-08560-6 Location: positioned on the left surface of the jack,...
  • Page 37 OPERATOR’S MANUAL Figure 4-1 N Part Number: 53-102592-6 Location: positioned on the left angled surface of the drive belt guard. Figure 4-1 O Part Number: 53-77753-6 Location: positioned on the front surface of the frame above the hydraulic pump and blower shaft coupling.
  • Page 38 OPERATOR’S MANUAL Figure 4-2: Left side of Ultra-Vac safety signs 4-20 00-154744-0 A SAFETY...
  • Page 39 OPERATOR’S MANUAL Figure 4-2 A Part Number: 53-77858-6 Location: positioned on the upper left side of the rear surface of the drive belt guard. Figure 4-2 B Part Number: 53-120857-6 Location: positioned on the left surface of the drive belt guard. Figure 4-2 C Part Number: 53-120493-6 Location:...
  • Page 40 OPERATOR’S MANUAL Figure 4-2 D Part Number: 53-05647-6 Location: positioned on the front left and rear right sides of the blower to indicate the front and rear oil level plugs. Figure 4-2 E Part Number: 53-05649-6 Location: positioned on the top surface of the blower inlet, below the...
  • Page 41 OPERATOR’S MANUAL Figure 4-2 G Part Number: 53-05646-6 Location: positioned on the top surface of the rear headplate of the blower. Figure 4-2 H Part Number: 53-08560-6 Location: positioned on the left surface of the boom swivel tube, centered between the two grease fittings.
  • Page 42 OPERATOR’S MANUAL Figure 4-3: Rear side of Ultra-Vac safety signs 4-24 00-154744-0 A SAFETY...
  • Page 43 OPERATOR’S MANUAL Figure 4-3 A Part Number: 53-15638-6 Location: positioned on the rear left surface of the primary AMS and the rear surface of the hydraulic controls mounting frame. Figure 4-3 B Part Number: 53-16131-6 Location: positioned on the top surface of the hydraulic controls mounting frame.
  • Page 44 OPERATOR’S MANUAL Figure 4-3 D Part Number: 53-04707-6 Location: positioned on the rear surface of the hydraulic reservoir. Figure 4-3 E Part Number: 53-98396-6 Location: positioned on the rear surface of the hydraulic reservoir. Figure 4-3 F Part Number: 53-18057-6 Location: positioned on the rear surface of the...
  • Page 45 OPERATOR’S MANUAL Figure 4-3 H Part Number: 53-137791-6 Location: positioned on the lower rear surface of the secondary AMS. Figure 4-3 I Part Number: 53-05650-6 Location: positioned on the top surface of the hydraulic controls mounting frame below the discharge pressure gauge.
  • Page 46 OPERATOR’S MANUAL Figure 4-3 K Part Number: 53-82114-6 Location: positioned on the upper rear left surface of the primary AMS. Figure 4-3 L Part Number: 53-08560-6 Location: positioned on the rear surface of the discharge cyclone section of the boom to indicate the grease fitting of the boom hinge.
  • Page 47 OPERATOR’S MANUAL Figure 4-4: Right side of Ultra-Vac safety signs SAFETY 00-154744-0 A 4-29...
  • Page 48 OPERATOR’S MANUAL Figure 4-4 A Part Number: 53-80921-6 Location: positioned on the upper right surface of the secondary AMS. Figure 4-4 B Part Number: 53-18289-6 Location: positioned on the right surface of the primary AMS above the access door. 4-30 00-154744-0 A SAFETY...
  • Page 49 OPERATOR’S MANUAL Figure 4-4 C Part Number: 53-94818-6 Location: positioned on the right surface of the frame. Figure 4-4 D Part Number: 53-120497-6 Location: positioned on the right surface of the frame above the airlock inlet. Figure 4-4 E Part Number: 53-18288-6 Location: positioned on the right surface of the...
  • Page 50 OPERATOR’S MANUAL Figure 4-5: Front of Ultra-Vac with belt guard removed safety signs Figure 4-5 A Part Number: 53-17704-6 Location: positioned on the front surface of the rear drive belt guard panel, only visible when the guard is removed. 4-32 00-154744-0 A SAFETY...

  • Page 51: Safety Training Sign-Off Form

    OPERATOR’S MANUAL SAFETY TRAINING SIGN-OFF FORM Walinga Inc. follows the general safety standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining the Ultra-Vac must read and clearly understand all safety, operating and maintenance information presented in this manual.
  • Page 52 OPERATOR’S MANUAL DATE EMPLOYEE’S NAME EMPLOYEE’S SIGNATURE EMPLOYER’S SIGNATURE 4-34 00-154744-0 A SAFETY...

  • Page 53: Machine Life-Cycle Procedures [00-154745-0]

    Machine Life-Cycle Procedures ULTRA-VAC MODEL 4510G...

  • Page 54: Reception, Assembly And Initial Set-Up

    ● Check to ensure all installed fasteners are tightened to the required torque. ● Register your Ultra-Vac by scanning the QR code affixed to the drive belt guard or visit: www.walinga.com/registration ● Register your engine as follows: ○ For Kohler engines: ■...

  • Page 55: Assembly

    OPERATOR’S MANUAL Assembly To allow for efficient shipping, the Ultra-Vac may arrive partially disassembled. Figure 5-1 identifies the disassembled components of the Ultra-Vac upon initial reception. A Main assembly B Hose carrier brackets C Lower boom elbow Figure 5-1: Disassembled components MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A...
  • Page 56 OPERATOR’S MANUAL To assemble the Ultra-Vac, proceed as follows: 1. Clear the area of bystanders, especially small children. 2. Position the machine on a solid, dry and flat surface that is clear of obstructions. Secure the machine by placing wheel chocks and ensuring the tongue jack is extended. Figure 5-2: Wheel chock and jack securement 3.
  • Page 57 OPERATOR’S MANUAL b. Fully insert the lower boom elbow into the DF coupler of the airlock outlet and tighten the tail bolts to secure it in place. Figure 5-4: Elbow coupler securement c. Position the quick coupler such that it is centered over the joint of the lower boom and the elbow.
  • Page 58 OPERATOR’S MANUAL 6. Install the hose carrier brackets as follows: a. Align the slots in the base of the hose carrier brackets with the holes and weld nuts on the Ultra-Vac frame. The hose carrier brackets are located as follows: ○...

  • Page 59: Initial Set-Up

    ● Ensure the dust hazard analysis as required by NFPA 652 has been completed and the incorporation of the Walinga equipment complies with all relevant standards and regulations. ● Ensure the area is clear of any bystanders and individuals not involved in the operation of the machine, especially small children.

  • Page 60: Break-In Inspections

    OPERATOR’S MANUAL ● Inspect the hydraulic system to ensure the hydraulic reservoir is filled to the required level with reference to Section 8: Specifications. Inspect all fittings and couplings to ensure they are free of dirt and debris and clean if necessary. Ensure there are no pinched, kinked or otherwise obstructed hydraulic lines.
  • Page 61 OPERATOR’S MANUAL After operating the Ultra-Vac for 5 hours: 1. Clear the area of all bystanders, especially small children. 2. Place all controls in neutral, stop the engine, disconnect all electrical sources, remove the ignition keys and wait for all moving parts to stop. 3.

  • Page 62: Transportation

    OPERATOR’S MANUAL TRANSPORTATION The Ultra-Vac has been designed for easy, safe and convenient transport between working locations. Refer to Section 4: Safety for specific transportation safety requirements. To prepare the Ultra-Vac for transport, proceed as follows: 1. Clear the area of bystanders, especially small children. 2.
  • Page 63 OPERATOR’S MANUAL c. Ensure the boom lift ball valve is in the open position. Figure 5-9: Boom lift ball valve open position d. Using the boom lift hydraulic control, lower the boom from the working position. Figure 5-10: Boom lowering MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A 5-11...
  • Page 64 OPERATOR’S MANUAL e. Remove the security pin in the latch handle and release the latch eye from the hook at the boom extension joint. Figure 5-11: Split boom joint Fold the extension to the transport position, aligning the boom latch plates, and secure the extension to the main boom using the attached lynch pin.
  • Page 65 OPERATOR’S MANUAL g. Secure the split boom security latch. Figure 5-13: Boom security latch h. Raise and disengage the boom rotation locking tab Figure 5-14: Disengaged rotation locking tab MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A 5-13...
  • Page 66 OPERATOR’S MANUAL Rotate the boom from the working position to the transport position so the boom is aligned with the boom saddle on the primary AMS by using the rotation arm. Use care to ensure no hydraulic or electrical lines become entangled or pinched. Figure 5-15: Boom rotation Lower and engage the boom rotation locking tab.
  • Page 67 OPERATOR’S MANUAL k. Secure the boom rotation arm in the holder with the attached strap. Figure 5-17: Boom rotation arm strap Ensure the saddle and boom are aligned and lower the boom until it is resting securely in the saddle. Figure 5-18: Boom transport position MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A...
  • Page 68 OPERATOR’S MANUAL 4. Secure the secondary AMS door in the transport position as follows: a. Ensure the secondary AMS and rubber p-extrusion seal are clear of any dirt and debris and firmly shut the door against the seal. Figure 5-19: Secondary AMS door b.
  • Page 69 OPERATOR’S MANUAL 5. Secure the plug in the primary AMS inlet as follows: a. Loosen the tail bolt of the primary AMS inlet and remove any intake hose or tubing attached. Figure 5-21: Intake line disconnection b. Ensure the inlet is clear of any dirt or debris. c.
  • Page 70 OPERATOR’S MANUAL 6. Secure all nozzles and adapters in the transport position as follows: a. Prepare the individual components for transportation by tightening all tail bolts and wingnuts of the couplers. For sweep nozzles, the pin of the handle brace may be removed and moved to the appropriate hole to angle the handle as necessary.
  • Page 71 OPERATOR’S MANUAL 7. Secure all intake lines in the transport position as follows: a. Lay all intake hoses and lines in the hose carrier brackets. Figure 5-25: Intake hose positioning b. Secure the lines with the provided straps. Figure 5-26: Hose carrier bracket straps MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A 5-19...
  • Page 72 OPERATOR’S MANUAL 8. Secure the jack in the transport position as follows: a. With the Ultra-Vac securely attached to the towing vehicle, completely raise the foot of the jack to achieve maximum ground clearance to prevent contact during transport. Figure 5-27: Raising the jack foot 9.
  • Page 73 OPERATOR’S MANUAL 10. Ensure the ignition key is removed from the engine. 11. Ensure your Ultra-Vac is in compliance with all local regulations regarding transporting agricultural equipment on public roads and highways. ● Use ANSI/ASAE S279.17 July 2013 as a minimum standard for lighting and marking of agricultural equipment on highways whether towing the Ultra-Vac during the day or night.

  • Page 74: Storage

    OPERATOR’S MANUAL 13. During transport, remain aware of potential overhead obstructions and maintain a safe distance for clearance. Be aware that electrocution can occur from overhead power lines without direct contact. 14. Do not allow any individuals to ride on the Ultra-Vac or tractor during transport. 15.
  • Page 75 OPERATOR’S MANUAL 4. Empty and clean out the secondary AMS with reference to Section 7: Maintenance and Adjustments. Figure 5-30: Secondary AMS preparation 5. Wash the entire machine thoroughly using a water hose or pressure washer to remove all dirt, dust, debris, and residue. The internal surfaces of the Ultra-Vac can be cleaned through flushing.
  • Page 76 OPERATOR’S MANUAL e. When conveying materials with oily characteristics or high moisture content, including milled feeds, the Ultra-Vac may need to be flushed on a more regular basis to remove residue build-up. Oily residues may require flushing and soaking with a suitable solvent to dissolve build-up. Any non-food-grade solvents must be cleaned from the machine using hot water and/or detergent flushing.
  • Page 77 OPERATOR’S MANUAL 10. Inspect the interior of the primary AMS to ensure it is empty. Figure 5-32: Primary AMS inspection 11. Apply never seize to the boom cylinder rod. Figure 5-33: Boom cylinder rod MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A 5-25...
  • Page 78 OPERATOR’S MANUAL 12. If the Ultra-Vac is to be stored for longer than two months, prepare the engine as follows: a. Add a fuel treatment to the fuel tank and run the engine for approximately three minutes to allow the stabilized fuel to disperse through the entire system. Figure 5-34: Fuel tank access b.
  • Page 79 OPERATOR’S MANUAL c. Remove the two spark plugs and pour approximately 1 oz (30 mL) of engine oil into the cylinders. Reinstall the spark plugs and crank the engine slowly to distribute the oil. Figure 5-36: Engine spark plug d. Remove the ignition keys. Figure 5-37: Engine ignition key MACHINE LIFE-CYCLE PROCEDURES 00-154745-0 A...
  • Page 80 OPERATOR’S MANUAL e. Disconnect the negative (—) engine battery cable. Figure 5-38: Engine starter and battery assembly 13. Disconnect the negative (—) unit battery cable. Figure 5-39: Unit negative battery cable 5-28 00-154745-0 A MACHINE LIFE-CYCLE PROCEDURES...
  • Page 81 OPERATOR’S MANUAL 14. Touch up all paint nicks and scratches to prevent rusting. 15. Store all hoses inside or under a shelter in a dry and secure area. 16. Move the Ultra-Vac to its storage position. The storage position should be chosen as a location that is dry, level and free of debris, and does not have frequent human activity in the vicinity.
  • Page 82 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 5-30 00-154745-0 A MACHINE LIFE-CYCLE PROCEDURES...

  • Page 83: Operation [00-154746-0]

    Operation ULTRA-VAC MODEL 4510G...

  • Page 84: Machine Features And Components

    OPERATOR’S MANUAL MACHINE FEATURES AND COMPONENTS A Boom B Discharge Cyclone C Primary AMS D Engine E Intake Line F Hose Carrier G Battery Enclosure H Fuel Tank I Electrical Enclosure J Intake Nozzle K Ball Coupler L Jack M Belt Drive N Hydraulic Pump Pressure Protection Valve P Blower...

  • Page 85: Controls And Displays

    OPERATOR’S MANUAL CONTROLS AND DISPLAYS Function: The speed of the airlock is controlled by the flow divider. The speed is set by moving the knob along the arc path. Range: The flow divider allows the speed to be set from no rotation at the 0 position to maximum rotation at the 10 position.
  • Page 86 OPERATOR’S MANUAL Function: The right lever of the hydraulic control bank controls the raising and lowering of the boom. Range: The lever is spring-loaded to return to the neutral center position. When the lever is pushed towards the front of the unit, the boom will lower.
  • Page 87 OPERATOR’S MANUAL Function: The ignition key switch provides a means to start, run and stop the engine. Range: The three position switch has a detent in the OFF and RUN positions and is spring-loaded to return to the RUN position from the START position.
  • Page 88 OPERATOR’S MANUAL Function: The vacuum relief valve allows air to enter the intake side of the system when the set vacuum pressure is exceeded to prevent the blower from overheating and excessive vacuum levels in situations where the intake has become restricted in some manner.
  • Page 89 OPERATOR’S MANUAL Function: vacuum pressure gauge measures the pressure on the intake side of the system. Range: The gauge is capable of measuring from -30 in Hg (-101.6 kPa) to 30 psi (206.8 kPa). Under normal conditions, the vacuum pressure should be between -10 in Hg (-33.8 kPa) and -15 in Hg (-50.8 kPa).

  • Page 90: Operation

    OPERATOR’S MANUAL OPERATION Pre-Operation For personal safety and to ensure the Ultra-Vac is in good mechanical condition, the following checks must be performed before operation of the Ultra-Vac: 1. Ensure the Ultra-Vac has been properly lubricated as per the described methods and schedule as outlined in Section 7: Maintenance and Adjustments.
  • Page 91 OPERATOR’S MANUAL b. Secure the Ultra-Vac independently by extending the jack, ensuring the frame of the Ultra-Vac is level, and restricting the wheels with the use of wheel chocks. Figure 6-17: Independent securement 7. Check the oil level in the blower reservoirs and adjust as necessary with reference to Section 7: Maintenance and Adjustments.

  • Page 92: Attaching And Unhooking

    OPERATOR’S MANUAL Attaching and Unhooking To connect the Ultra-Vac to a towing vehicle, proceed as follows: 1. Clear the area of bystanders, especially small children. 2. Clear the area of any foreign objects or debris, and ensure the area is level and dry. 3.
  • Page 93 OPERATOR’S MANUAL 7. Use the jack to raise or lower the Ultra-Vac hitch to provide sufficient clearance to position the hitch ball below the coupler. Figure 6-20: Hitch positioning 8. Position the towing vehicle such that the hitch ball is aligned with the coupler, as seen in Figure 6-20.
  • Page 94 OPERATOR’S MANUAL 10. Raise the jack completely to the transport position. Figure 6-22: Jack transport position 11. Ensure the frame of the Ultra-Vac is level. If the frame is not level, lower the jack, disconnect the coupler from the hitch ball and adjust the position of the coupler within the mounting bracket.
  • Page 95 OPERATOR’S MANUAL 12. Loop the breakaway switch connection around a fixed point on the towing vehicle and seat the plug into the switch. Ensure the connection is securely positioned within the body of the switch and around the point of the towing vehicle. Figure 6-24: Breakaway switch connection 13.
  • Page 96 OPERATOR’S MANUAL 14. Connect the 7-wire plug of the Ultra-Vac to the receptacle on the towing vehicle. Ensure the electrical connection is secure and the cable will not become entangled. Figure 6-26: Electrical connection 15. Remove the wheel chocks and ensure there are no loose components or debris on or around the Ultra-Vac.
  • Page 97 OPERATOR’S MANUAL 6. Disconnect the 7-wire cable from the towing vehicle. Ensure the plug and cable are positioned in a way such that they will not become entangled or pose a tripping hazard. 7. Disconnect the safety chains from the towing vehicle. Ensure the chains are positioned such that they will not become entangled or pose a tripping hazard.

  • Page 98: Machine Preparation

    OPERATOR’S MANUAL Machine Preparation To prepare the Ultra-Vac for operation, proceed as follows: 1. Clear the area of bystanders, especially small children. 2. Ensure the Ultra-Vac is properly attached to the towing vehicle as detailed in the previous section, Attaching and Unhooking, or has been secured in position independently with the use of wheel chocks and the jack.
  • Page 99 OPERATOR’S MANUAL 5. Remove the intake nozzle from the storage bracket on the Ultra-Vac and the steel flex tube from the hose carrier. Install the nozzle into the female coupling of the hose. Secure the nozzle in position by tightening the coupling tail bolts. Figure 6-31: Intake nozzle attachment 6.

  • Page 100: Starting The Machine

    OPERATOR’S MANUAL Starting the Machine To start the Ultra-Vac, proceed as follows: 1. Clear the area of bystanders, especially small children. 2. Ensure all steps of the previous sections, Pre-Operation and Machine Preparation, have been completed. 3. Ensure the suction nozzle is not in the product before start-up. Start-up under heavy suction may overload the drive belts and blower, causing significant damage.
  • Page 101 OPERATOR’S MANUAL b. Turn and hold the ignition key in the START position. Release the key as soon as the engine starts, allowing it to move to the RUN position. If the starter does not turn the engine over, move the key to the OFF position immediately. Figure 6-34: Engine ignition key START position c.
  • Page 102 OPERATOR’S MANUAL c. Use the boom lift control lever to lift the boom out of the saddle. Ensure the boom will have clearance above other components of the Ultra-Vac while rotating. Figure 6-36: Boom lift control raising d. Disengage the boom rotation locking tab. Figure 6-37: Disengaged boom rotation locking tab 6-20 00-154746-0 A...
  • Page 103 OPERATOR’S MANUAL e. Release the strap securing the manual boom rotation arm and use the arm to rotate the boom to the desired operational position. Ensure no hydraulic or electrical lines become entangled, pinched or disconnected during rotation. Figure 6-38: Manual boom rotation arm If necessary, the boom may be lowered slightly to improve ease of access.
  • Page 104 OPERATOR’S MANUAL h. Open the boom extension completely until the boom is straight. Secure the boom extension in place by clamping the security latch eye over the hook. Ensure there is a tight seal to prevent air leakage; adjust the latch if necessary.
  • Page 105 OPERATOR’S MANUAL k. Once at the desired height, move the boom lift ball valve to the closed position to prevent hydraulic bleed-back resulting in inadvertent lowering of a loaded boom. Figure 6-42: Boom lift ball valve CLOSED position If necessary, use the rotation arm to adjust the position of the boom. Once the desired operational position is achieved, engage the boom rotation locking tab.
  • Page 106 OPERATOR’S MANUAL 7. Set the preliminary airlock settings as follows: a. Pull on the airlock direction control lever to place it in the START detent position to start the airlock. Figure 6-44: Airlock direction control lever in operational position b. Check the arrow on the indicator wheel to ensure the airlock is turning in the correct direction.
  • Page 107 OPERATOR’S MANUAL c. Use the engine throttle control to increase the engine speed to approximately 3/4 throttle. d. Adjust the flow divider to set the airlock speed slightly slower than the recommended speed outlined in Table 6-1: Recommended airlock operational speeds found in the following section, Operation of the Machine.

  • Page 108: Operation Of The Machine

    OPERATOR’S MANUAL Operation of the Machine To operate the Ultra-Vac, proceed as follows: 1. Ensure all steps of the above section Starting the Machine have been completed. 2. Increase the engine speed to approximately 3/4 throttle. Figure 6-47: Engine 3/4 throttle position 3.
  • Page 109 OPERATOR’S MANUAL 6. Open the air slide on the intake nozzle approximately 2 in (5 cm) and insert the end of the nozzle into the product. The nozzle inlet should be submerged below the surface of the product, but with the air slide above the surface. Operate at these settings until the Ultra-Vac is warmed (approximately 10 minutes).
  • Page 110 OPERATOR’S MANUAL c. Set the airlock speed for maximum capacity as follows: Airlock speeds depend on the product and the distance being conveyed; the longer the suction distance, the slower the airlock should turn. For maximum capacity, the airlock pockets should be as full of the conveyed product as possible.
  • Page 111 OPERATOR’S MANUAL d. Adjust the opening of the air slide as necessary. For maximum capacity, the air slide should be opened as little as possible. If the Ultra-Vac begins to pulsate, open the air slide slightly until the pulsing stops to achieve the ideal balance of product and air flow.

  • Page 112: Stopping The Machine

    OPERATOR’S MANUAL c. Only enter a storage structure when the grain level is less than 12 in (30 cm) above solid footing. d. Do not enter the storage structure if there is grain stuck on the walls. Avalanching grain can cause suffocation. e.
  • Page 113 OPERATOR’S MANUAL 4. Adjust the engine speed to 3/4 throttle. Stopping the engine at a lower speed may cause the engine to backfire, potentially causing damage to or failure of the internal components of the engine. Figure 6-54: Engine 3/4 throttle position 5.

  • Page 114: Clearing Blockages

    OPERATOR’S MANUAL 7. With reference to Section 7: Maintenance and Adjustments, review the maintenance schedule and perform any required maintenance on the Ultra-Vac. 8. Proceed to prepare the Ultra-Vac for storage or transportation with reference to Section 5: Machine Life-Cycle Procedures. In emergency situations, for example, if the safety of a person is threatened, it may be necessary to immediately shut-down the Ultra-Vac.
  • Page 115 OPERATOR’S MANUAL 4. If the blockage does not clear, alternate several times between the forward and reverse directions to loosen and dislodge the obstruction. 5. If the blockage does not clear, the blockage must be removed manually as follows: a. Refer to the above section, Stopping the Machine, to completely shut down the Ultra-Vac.
  • Page 116 OPERATOR’S MANUAL To clear a blockage from the intake or discharge line, proceed as follows: 1. With the Ultra-Vac still in operation and the airlock rotating, remove the intake nozzle from the material supply. 2. Slowly decrease and then slowly increase the engine speed. 3.

  • Page 117: Operating Tips And Hints

    Ultra-Vac. If you encounter a problem that is difficult to solve, even after having referenced the following tables, please contact your Walinga dealer or representative. Before you call, please have your Operator’s Manual and your Ultra-Vac’s serial number ready and available.
  • Page 118 OPERATOR’S MANUAL Table 6-2: Troubleshooting for mobile transfer unit ISSUE CAUSE SOLUTION Power source Check the engine RPM. Tighten all vacuum connections. Ensure all seals are in good condition. Tighten primary AMS to base. Check seal on secondary AMS bottom door. Close and secure.
  • Page 119 OPERATOR’S MANUAL ISSUE CAUSE SOLUTION Power source Check the engine RPM. Tighten all pressure connections. Ensure seals are in good condition. Air leaks Check the pressure relief valve. Clean or replace as required. Check the clearance between the lobes and the casing. Excessive clearance will Defective blower decrease the air flow.
  • Page 120 OPERATOR’S MANUAL ISSUE CAUSE SOLUTION Liners worn out Replace wear liners in the discharge cyclone or the primary AMS as required. Poor connections Tighten and seal all connections. Eliminate elbows. Keep lines as straight as possible and provide a large radius Lines wearing for any necessary bends.
  • Page 121 Adjust the operating conditions to set the pressure rise to below 10 psi (70 kPa). Engine overloading Pressure too high Add more air by opening the air slide. Blower impellers rubbing Consult your Walinga dealer or representative. OPERATION 00-154746-0 A 6-39...
  • Page 122 OPERATOR’S MANUAL Table 6-4: Troubleshooting for airlock ISSUE CAUSE SOLUTION A light grinding noise is normal for some time after adjustment of the airlock tip Tips hitting casing clearances. The noise will disappear after the tips seat fully on the casing. If the noise is excessive or does not decrease, re-adjust the tips where applicable.
  • Page 123 OPERATOR’S MANUAL Adjust the tips to decrease the clearance to the required specifications. Excessive clearance Excessive clearance causes operating problems including bridging and erratic Air loss through airlock between blade tips and flow. Prolonged operation with excessive clearances will cause uneven casing casing wear, resulting in lower performance even after tip adjustment.
  • Page 124 OPERATOR’S MANUAL Table 6-6: Troubleshooting for engine ✽ Possible Cause Improper Dirt in Fuel Broken Dirty Debris Incorrect Oil Engine Dirty Air Faulty Problem No Fuel Fuel Line Fusible Link Screen Level Overloaded Cleaner Spark Plug Will Not Start Hard Starting Stops Suddenly Lacks Power Operates Erratically...

  • Page 125: Maintenance And Adjustments [00-154747-0]

    Maintenance and Adjustments ULTRA-VAC MODEL 4510G...

  • Page 126: Maintenance Schedule

    OPERATOR’S MANUAL MAINTENANCE SCHEDULE HOUR READING AT TIME OF SERVICE: SERVICED BY: Every 8 HOURS or DAILY or 500 TONNES (18 750 BUSHELS) Check Drive Belt Tension and Alignment [7-4] Clean Secondary AMS [7-8] Inspect Muffler [7-11] Check Blower Reservoir Oil Level ✽...

  • Page 127: Maintenance Safety

    OPERATOR’S MANUAL MAINTENANCE SAFETY Unsafe workshop and servicing practices increase the risk of injury around machinery. Review the following safety guidelines for important information regarding safety involved with maintenance operations. ● Read, understand and follow all operating, maintenance and safety information in the operator’s manual.
  • Page 128 OPERATOR’S MANUAL Drive Belt Tension and Alignment Rotational power is transmitted from the engine to the blower through the belt drive. To obtain efficient transmission of power and optimal belt life, the belts must be properly tensioned and the pulleys must be aligned. Belts that are too tight will stretch and wear quickly or overload the bearings on the input shaft of the blower.
  • Page 129 OPERATOR’S MANUAL 4. Use a belt tensioning tool to determine the belt deflection in a static condition. Reference Figure 7-2 and Table 7-1 for requirements. Table 7-1: Drive belt requirements Belt Tension Belt Deflection 6.30 lbs 0.40 in (2.86 kg) (10.16 mm) Figure 7-2: Drive belt deflection 5.
  • Page 130 OPERATOR’S MANUAL b. Turn the adjusting rods to achieve the correct belt tension. Turning the adjusting rods clockwise will INCREASE the belt tension. Turning the adjusting rods counter-clockwise will DECREASE the belt tension. Figure 7-4: Slide frame adjusting rods c. Ensure both adjusting rods are equally turned to maintain proper alignment of the engine shaft.
  • Page 131 OPERATOR’S MANUAL b. If the gap between the pulley and the straight edge exceeds 1/16 in (1.5 mm), the pulleys must be realigned. c. Review Figure 7-6 for the different types of alignment issues. Figure 7-6: Pulley and shaft misalignment d.
  • Page 132 OPERATOR’S MANUAL Cleaning of Secondary AMS The secondary AMS prevents dust, dirt, and contaminants from entering the blower. To maintain proper function, and to prevent significant damage to the blower, the secondary AMS must be regularly emptied and cleaned. The secondary AMS may need to be more frequently emptied if the Ultra-Vac is operated in dirty or dusty conditions.
  • Page 133 OPERATOR’S MANUAL 5. Remove the retainer and open the latch securing the secondary AMS door. Figure 7-8: Release of latch 6. Open the secondary AMS door and allow the accumulated dirt, dust, and debris to empty into the receptacle. Figure 7-9: Emptying secondary AMS MAINTENANCE AND ADJUSTMENTS 00-154747-0 A...
  • Page 134 OPERATOR’S MANUAL 7. Inspect the interior of the secondary AMS door. Ensure there is no contaminant build-up on the surfaces, paying careful attention to the surface where the seal meets the door. If necessary, scrape any contaminants off of the surfaces. Figure 7-10: Door –...
  • Page 135 OPERATOR’S MANUAL Inspection of Muffler The muffler serves to decrease the noise level of the Ultra-Vac. It has been designed to be self-cleaning, however, it is possible during operation, transport, or storage for dirt, dust, or debris to accumulate in the muffler. Due to the high temperatures the muffler can reach during operation, any foreign material can result in a fire hazard.
  • Page 136 OPERATOR’S MANUAL 6. If there are accumulated materials, clean the muffler as follows: a. Loosen the t-bolt clamps securing the muffler and airlock inlet elbow connecting hose. Figure 7-13: Removal of t-bolt clamps b. Remove the connecting hose. Figure 7-14: Removal of connecting hose 7-12 00-154747-0 A MAINTENANCE AND ADJUSTMENTS...
  • Page 137 OPERATOR’S MANUAL c. Use the wash-out port as an access point to flush the muffler with clean water. d. Allow the water and dirt, dust, and debris to drain from the muffler through the outlet pipe. Figure 7-15: Drainage of water and accumulated material e.
  • Page 138 OPERATOR’S MANUAL Once the muffler has been thoroughly cleaned, allow the assembly to dry. The blower can be run to assist the drying process. g. Replace the connecting hose and secure it in place by tightening the t-bolt clamps. Figure 7-17: Secured connecting hose 7.
  • Page 139 OPERATOR’S MANUAL Discharge Cyclone Wear Liner The Rhino Hyde lining of the discharge cyclone provides increased abrasion and wear resistance as well as noise reduction. Visually inspect the condition of the wear liner in the discharge cyclone. Check for any pitting, nicks, damage, wrinkling, bulging, or excessive wear and replace the liner as required.
  • Page 140 OPERATOR’S MANUAL 3. Remove the fasteners securing the drive belt guard and remove the guard. Figure 7-20: Drive belt guard fasteners 4. Rotate the blower by hand as necessary to gain access to the grease fitting. 5. Wipe the grease fitting with a clean cloth before greasing to avoid injecting dirt and grit. 6.
  • Page 141 OPERATOR’S MANUAL Lubrication of Airlock Motor Coupling To maintain smooth transmission of power from the airlock hydraulic motor to the airlock, the motor coupling must remain properly lubricated. To lubricate the motor coupling, proceed as follows: 1. Clear the area of bystanders, especially small children. 2.
  • Page 142 OPERATOR’S MANUAL 6. Lubricate the airlock motor coupling grease fitting. Figure 7-23: Airlock motor coupling lubrication location 7. If the fitting will not take grease, remove and clean thoroughly. Clean the lubricant passageway. Replace the fitting if necessary. 8. Install and secure the airlock motor guard and bolts. Ensure all guards are installed and secure before resuming operation.
  • Page 143 OPERATOR’S MANUAL Lubrication of Boom Swivel To ensure smooth rotation of the boom, the boom swivel must be properly lubricated. To lubricate the boom swivel, proceed as follows: 1. Clear the area of bystanders, especially small children. 2. Place all controls in neutral, stop the engine/power source, remove the ignition key, disconnect and ground the engine spark plug leads, disconnect the negative (—) engine battery cable, and wait for all moving parts to stop.
  • Page 144 OPERATOR’S MANUAL Lubrication of Rod End of Boom Lift Cylinder The boom lift cylinder functions to raise and lower the boom to position the discharge cyclone. For smooth and efficient operation, the cylinder must remain properly lubricated. To lubricate the rod end of the boom lift cylinder, proceed as follows: 1.
  • Page 145 OPERATOR’S MANUAL Lubrication of Boom Hinge To ensure smooth movement of the discharge cyclone end of the split boom from the transport to operational position, the boom hinge must remain properly lubricated. To lubricate the boom hinge, proceed as follows: 1.
  • Page 146 OPERATOR’S MANUAL Lubrication of Swivel Coupling For ease of use, some clean-up intake line couplings may be equipped with a swivel coupling. To ensure smooth movement of the swivel coupling, it must remain properly lubricated. To lubricate the swivel coupling, proceed as follows: 1.
  • Page 147 OPERATOR’S MANUAL 5. Lubricate the swivel coupling until grease pushes out of the seam between the coupling and the shank. Figure 7-28: Seam grease ejection 6. If the fitting will not take grease, remove and clean thoroughly. Clean the lubricant passageway.Replace the fitting if necessary.
  • Page 148 OPERATOR’S MANUAL Inspection of Vacuum and Pressure Relief Valves As the blower operates, it creates a vacuum on the intake side of the system to draw product in, and creates a pressurized flow on the discharge side to move the product from the airlock to the discharge cyclone.
  • Page 149 OPERATOR’S MANUAL Inspection of Airline Seals To maintain a sufficient vacuum and pressurized state on each side of the system, the air system must be well sealed. Each joint of the system has a seal, and these must remain in good condition for optimum performance.
  • Page 150 OPERATOR’S MANUAL 4. Check the condition of the primary AMS inlet seal as follows: a. Remove the plug from the primary AMS inlet. b. Visually inspect the seal, looking out for any nicks, tears, abraded areas, or any excessive wear. Figure 7-32: Primary AMS inlet seal c.
  • Page 151 OPERATOR’S MANUAL b. Visually inspect the interior foam seals, looking for any nicks, tears, abraded areas, or any excessive wear. Figure 7-34: Primary AMS access door seal c. Clean or replace any worn seals as required. d. Inspect the condition of the silicone seal between the exterior surface of the clear window and the window frame.
  • Page 152 OPERATOR’S MANUAL 6. Check the condition of the secondary AMS door seal as follows: a. Open and lower the secondary AMS door. b. Visually inspect the seal, looking for any nicks, tears, abraded areas, or any excessive wear. Figure 7-36: Secondary AMS door seal c.
  • Page 153 OPERATOR’S MANUAL b. Visually inspect the seal of the airlock outlet coupler, looking for any nicks, tears, abraded areas, or any excessive wear. Figure 7-38: Airlock outlet coupler seal c. Clean or replace any worn seals as required. d. Reinstall and secure the lower boom elbow. 8.

  • Page 154: Maintenance Materials

    An SAE multi-purpose lithium-based grease is also acceptable. Silicone Use a durable and flexible silicone, part number 92-14772-6. Blower Oil Use Walinga super duty blower oil, part number 98-13813-6. Refer to Table 7-2 for blower oil capacities. Table 7-2: Blower oil capacity Front (Drive)

  • Page 155: Adjustments

    OPERATOR’S MANUAL ADJUSTMENTS Changing Intake Nozzles The Ultra-Vac can be equipped with several different intake nozzles to best suit the required function. During normal operation, the standard straight nozzle should be used in combination with the steel flex hose intake line. However, for easier clean up, the straight nozzle can be exchanged for a clean-up nozzle in addition to a rubber intake hose for decreased weight and increased ease of movement.
  • Page 156 OPERATOR’S MANUAL 6. Insert the clean-up sweep nozzle into the rubber intake hose coupler and tighten the tail bolts to secure. Figure 7-42: Clean-up nozzle connection 7. Follow the standard operating procedures to convey the remaining grain using the clean-up nozzle. 7-32 00-154747-0 A MAINTENANCE AND ADJUSTMENTS...
  • Page 157 OPERATOR’S MANUAL Bin Loading In addition to using the discharge boom for unloading, the Ultra-Vac is also capable of loading directly into storage structures equipped with a discharge cyclone. To load a storage structure, proceed as follows: 1. Clear the area of bystanders, especially small children. 2.
  • Page 158 OPERATOR’S MANUAL 5. Attach the steel flex discharge hose to the airlock outlet coupler. NOTE: The steel flex hose is designed for material flow in one direction. A discharge hose must be used for bin loading. Do not connect an intake hose to the airlock outlet. Figure 7-45: Ultra-Vac bin loading connection 6.
  • Page 159 OPERATOR’S MANUAL 7. Ensure the tail bolts or other fastening methods of any adapters are tightened to secure the discharge hose in position. 8. Follow the standard operating procedures. Monitor the machine to ensure the airlock and blower do not become overloaded. 9.
  • Page 160 OPERATOR’S MANUAL Blow-Only Operation A standard Ultra-Vac unit operates as a ‘suck/blow’ unit, drawing air and grain into the primary AMS under vacuum and discharging the material under pressure. However, some units may be used in blow-only operation by having material drop directly into an intake hopper positioned above the airlock.
  • Page 161 OPERATOR’S MANUAL b. Secure an appropriately rated lifting mechanism to the lifting eye of the secondary AMS. Figure 7-49: Secondary AMS lifting eye c. Loosen the t-bolt clamps and remove the hose from the secondary AMS outlet pipe. Figure 7-50: Blower connecting hose removal MAINTENANCE AND ADJUSTMENTS 00-154747-0 A 7-37...
  • Page 162 OPERATOR’S MANUAL d. Loosen and remove the fasteners securing the primary AMS to the frame. Figure 7-51: Primary AMS frame fasteners e. Lift and remove the AMS assemblies. Figure 7-52: Removal of AMS assemblies 7-38 00-154747-0 A MAINTENANCE AND ADJUSTMENTS...
  • Page 163 OPERATOR’S MANUAL 2. Mount and secure an intake hopper to the frame above the airlock inlet. Figure 7-53: Airlock intake hopper 3. Fit a mesh or slotted guard over the product entry area of the airlock. The guard must be capable of supporting a minimum load of 270 lbs (123 kg) without permanent deformation with opening sizes in compliance with local or international guarding standards.
  • Page 164 OPERATOR’S MANUAL 4. Remove the blower intake assembly. 5. Attach an inlet screen or muffler to the blower inlet. This must be done to reduce blower noise and shield the rotating lobes of the blower. Figure 7-55: Inlet muffler assembly 6.
  • Page 165 OPERATOR’S MANUAL Installation of Boom Flex Hose In the event the boom flex hose is removed or must be replaced, it is important that it is properly installed to ensure the joints are sealed and it can smoothly move through all operational positions.
  • Page 166 OPERATOR’S MANUAL 4. Insert one end of the flex hose into the upper boom clamp and secure it in place by installing and tightening the hardware. FIgure 7-57: Upper flex hose positioning 5. Apply silicone to the inner surface of the bottom end of the flex hose. FIgure 7-58: Flex hose base silicone application 7-42 00-154747-0 A...
  • Page 167 OPERATOR’S MANUAL 6. Position and install the bottom of the flex hose onto the boom swivel tube. If necessary, the boom may be raised slowly to assist with correct positioning. FIgure 7-59: Flex hose base positioning 7. Assemble the lap joint clamp at the base of the flex hose. FIgure 7-60: Flex hose clamp hardware 8.
  • Page 168 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 7-44 00-154747-0 A MAINTENANCE AND ADJUSTMENTS...

  • Page 169: Specifications [00-154748-0]

    Specifications ULTRA-VAC MODEL 4510G...

  • Page 170: Technical Data

    OPERATOR’S MANUAL TECHNICAL DATA Standard Height (Transport Position) 89 in (2.26 m) 89.9 in (2.29 m) Standard Discharge Height 12.5 ft (3.81 m) 13.9 ft (4.23 m) Standard Length (Transport Position) 115 in (292 cm) 125 in (317 cm) Standard Width 96 in (244 cm) 96 in (244 cm)
  • Page 171 2.35 gpm (8.9 lpm) Pressure 1500 psi (10 300 kPa) Hydraulic Oil Capacity 24 L HYDREX XV Oil Type (98-17740-6) 510 Walinga Super Chrome, positive Model displacement blower FRONT (Drive) REAR (Idle) Blower Oil Capacity 0.84 L 1.25 L Walinga Super Duty Blower Oil...

  • Page 172: Bolt Torques

    OPERATOR’S MANUAL BOLT TORQUES The torque values for imperial and metric bolts and cap screws are given below in Table 8-1 and Table 8-2 respectively. Unless otherwise noted, tighten all bolts to the torques specified in the tables below. Check the tightness of bolts periodically. Replace any damaged or lost hardware with the same strength bolt.
  • Page 173 OPERATOR’S MANUAL Table 8-2: Metric torque specifications Bolt Torque Bolt Diameter 10.9 “A” [Nm] [lb-ft] [Nm] [lb-ft] Figure 8-2: Metric bolts 1050 1495 1103 2100 1550 2600 1917 3675 2710 SPECIFICATIONS 00-154748-0 A...

  • Page 174: Standards And Regulations

    OPERATOR’S MANUAL STANDARDS AND REGULATIONS Walinga follows the general safety standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA) with consideration of standards outlined by the National Fire Prevention Agency (NFPA), International Organization for Standardization (ISO), Occupational Health and Safety Standards (OH&S), and American National Standards Institute (ANSI).

  • Page 175: Warranty [00-142209-0]

    Warranty PNEUMATIC CONVEYING SYSTEMS...

  • Page 176: The Warranty

    (the “Walinga Warranty”). WARRANTY PERIOD The warranty period for the Walinga Warranty shall expire on the date that is the earlier of: two (2) years after the date of delivery to the original customer or upon the expiration of five hundred (500) hours of operation;...

  • Page 177: Required Warranty Claim Information

    WARRANTY CONDITIONS ● Equipment must be registered within thirty (30) days of being received by the buyer. It will be within the sole and unfettered discretion of Walinga as to whether it will honor its warranty on non-registered equipment. ● The buyer is responsible for promptly notifying Walinga of any defect to the equipment and making the equipment available to Walinga or its authorized facility for evaluation or repair.

  • Page 178: Warranty Claim Rejection

    OPERATOR’S MANUAL WARRANTY CLAIM REJECTION Without limitation, Walinga reserves the right to reject a warranty claim for any one or more of the following reasons: ● The warranty claim information provided is insufficient. ● The product evaluation does not substantiate the claim.

  • Page 179: Accessories And Attachments [00-154750-0]

    Accessories and Attachments ULTRA-VAC 10-1...

  • Page 180: Hoses And Lines

    A wide variety of accessories are available for your Ultra-Vac to improve your operational experience. Below are some of the available accessories and a general description of their function. Please contact your Walinga dealer or representative for accessories compatible with your specific Ultra-Vac, availability and ordering, or if you have any questions.
  • Page 181 BIN LOADING SYSTEMS Walinga offers all of the required components allow Ultra-Vac to discharge directly into a grain storage bin, with systems of...
  • Page 182 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 10-4 00-154750-0 A ACCESSORIES AND ATTACHMENTS...

  • Page 183: Parts List [00-154751-0]

    Parts List ULTRA-VAC MODEL 4510G 11-1...

  • Page 184: Model References

    OPERATOR’S MANUAL MODEL REFERENCES Table 11-1: Top-level model assemblies Features Reference Code Assembly Number Standard 11-144488-5 NOTE: Please be aware that the part numbers listed are for the unpainted version of the parts. Please specify if you require the parts/assemblies to be painted. 11-2 00-154751-0 A PARTS LIST...

  • Page 185: Structural Components

    OPERATOR’S MANUAL STRUCTURAL COMPONENTS Model Description Part Number HOSE CARRIER, 4510, CORNER 11-123434-5 STRAP, 15”, SNAPPI HOOKER 80-87238-6 CLEAN-UP LINE, 412, DM4X-DF4, VHD 36-84890-5 INTAKE LINE, 412, DF4-DM4, SS POLY 36-09696-5 HOSE CARRIER, 4510, FRONT 11-123435-5 STONE GUARD, 4510, CS, ALM 11-122347-4 COUPLER, BALL 2 5/16”, ADJ 11-17908-6...

  • Page 186: Blower Components

    OPERATOR’S MANUAL BLOWER COMPONENTS Model Description Part Number BLOWER, 510, CHR, 3.25” 43-09877-5 INLET HOSE, 5” DIA, 6” LG 73-08092-6 VACUUM GAUGE INST, BLOWER 11-116243-5 MOUNT GASKET, 510 BLOWER 96-00535-6 SUPER DUTY BLOWER OIL 98-13813-6 OUTLET PRESSURE GAUGE INST 11-116244-5 WASH-OUT CAP, 48FP 58-132775-6 T-BOLT CLAMP, 4-1/2”...

  • Page 187: Airlock Components

    OPERATOR’S MANUAL AIRLOCK COMPONENTS Model Description Part Number AIRLOCK, 1314-4A, CHR, HXS 30-37902-5 AIRLOCK MOUNT GASKET, 1314 80-63946-6 TIP WIPER BLADE, 1314 30-20471-4 ROTOR TIP, HARDOX, 1314 30-65702-4 DIRECTION INDICATOR WHEEL 11-36973-4 INDICATOR BELT, 6MM x 25” 96-13967-6 AIRLOCK DRIVE GUARD 11-56059-4 11-123301-5 OUTLET PIPE, 14”...

  • Page 188: Drive Components

    OPERATOR’S MANUAL DRIVE COMPONENTS Model Description Part Number DRIVE INST, 4510G, 37HP 11-122283-5 TENSION ROD INST, 3/4-10 x 8” LG 11-114401-5 V-BELT, 5VX780 11-74673-6 TACHOMETER / HOUR METER 11-82616-6 GROMMET, 1/2”, RB237 94-14945-6 BELT GUARD ASSY, 4510G, 2023 11-144520-5 VIBRATION MOUNT, 3/16” x 2” 80-13160-6 11-6 00-154751-0 A...

  • Page 189: Engine Components

    OPERATOR’S MANUAL ENGINE COMPONENTS Model Description Part Number ENGINE, KOHLER, EKECH980-3000, 37HP 11-135904-6 ENGINE OIL, 20W50 98-16084-6 AIR FILTER, INNER SAFETY ELEMENT 25 083 04-S ✽ AIR FILTER, PRIMARY ELEMENT 25 083 01-S ✽ OIL FILTER 52 050 02-S ✽ IGNITION KEY, SET OF 2 48 340 01-S ✽...

  • Page 190: Primary And Secondary Ams Components

    OPERATOR’S MANUAL PRIMARY AND SECONDARY AMS COMPONENTS Model Description Part Number VACUUM RELIEF VALVE, 2”, 16 Hg 39-77609-6 DRAW LATCH, GALV, 1100 lbs 28-80927-6 SECONDARY AMS DOOR, LATCHED 11-104329-4 DOOR SEAL, P-EXTRUSION 11-36769-4 T-BOLT CLAMP, 13-7/8” 28-80466-6 DOOR HINGE AND BAR 11-20252-5 WINDOW SPONGE SEAL, #R421A/B 80-03510-6...

  • Page 191: Lower Boom Components

    OPERATOR’S MANUAL LOWER BOOM COMPONENTS Model Description Part Number BOOM FLEX HOSE SUPPORT, 4510 11-124588-4 FLEX HOSE, 4”, SS, POLY 36-17087-6 CLAMP, LAP JOINT, 4”, SS 28-14704-6 MANUAL BOOM ROTATION ARM 11-38222-5 ROT ARM HOLDER RUBBER 11-43640-4 STRAP, 9”, SNAPPI HOOKER 80-87237-6 ROT ARM REST, BOLT-ON, 4510 11-123283-4...

  • Page 192: Upper Boom Components

    OPERATOR’S MANUAL UPPER BOOM COMPONENTS Model Description Part Number BOOM SWIVEL, TOP ASSY, 4510 11-122293-5 LATCH FINGER GRIP, 1” DIA 11-14632-6 LATCH RETAINER PIN, 142-156 94-19544-6 BOOM LATCH, W/ EXTENSION 11-37464-5 FLAT SEAL RING, 5.370 x 4.125 x .250 96-13344-6 CYCLONE BOOM END ASSY, 4”...

  • Page 193: Axle Components

    OPERATOR’S MANUAL AXLE COMPONENTS Model Description Part Number FENDER ASSY, CS, 4510, ALM 11-134351-5 11-85954-6 STUB AXLE SUSP, 3500 lbs, ELEC BRAKE FENDER ASSY, DS, 4510, ALM 11-134350-5 TIRE/RIM, ST205/75R15 5 ON 4.5 11-81170-6 MUDFLAP, 4510 20-123402-4 MUDFLAP WASHER PLATE, 4510 11-123401-4 PARTS LIST 00-154751-0 A...

  • Page 194: Hydraulic Components

    OPERATOR’S MANUAL HYDRAULIC COMPONENTS Model Description Part Number CYLINDER, 2” x 8”, HYS20SPE08-929 11-17572-6 CYLINDER SEAL KIT 11-18476-6 54-124047-6 PUMP, PLP20.4D0-49S1-LOc/OC-N-EL-FS-AV BALL VALVE, 3/8”, SAE 6, 7000 PSI 59-19548-6 HYDRAULIC PRESSURE GAUGE INST 11-116245-5 CONTROL LEVER, AL01/M8X200 59-60336-6 FLOW CTRL VALVE, 0 - 8 GPM, FC51 59-81791-6 HYD FILTER HEAD, SAF06-25-0 61-74993-6...

  • Page 195: Electrical - Hardware Components

    OPERATOR’S MANUAL ELECTRICAL — HARDWARE COMPONENTS Model Description Part Number 82-18198-6 JUNCTION BOX, 8” x 8” x 4” 82-17455 JAM NUT, 50845 FITTING, 1/2”, HOLE CRIMP 82-17485-6 82-17487-6 FITTING, 11/16”, HOLE CRIMP 82-17789-6 PUSH-IN CHOKE SEAL, 920413 GROMMET, 2-1/2”, OPEN 82-14371-6 11-154636-6 BATTERY ENCLOSURE LID...

  • Page 196: Electrical - Active Components

    OPERATOR’S MANUAL ELECTRICAL — ACTIVE COMPONENTS Model Description Part Number 82-18844-6 PLUG, 7-WIRE MALE, FLAT SPADE 82-18026-6 CABLE, 7 WIRE, 4/12, 2/10, 1/8 BREAKAWAY SWITCH 11-18746-6 82-17424-6 CABLE, 2 WIRE, 2/14 82-123035-6 CABLE, BATTERY, 1/0 BATTERY TERMINAL, 3-WAY, 2-4/0 82-80438-6 82-154630-6 BATTERY, 540 CCA, 12V 82-19092-6...

  • Page 197: Miscellaneous Components

    OPERATOR’S MANUAL MISCELLANEOUS COMPONENTS Model Description Part Number SILICONE, CLEAR, 366 NU FLEX 92-14772-6 SEALANT, WHITE, 3M 540 URETHANE 92-13573-6 98-13491-6 ANTI-SEIZE, AEROSOL, TORQUE MASTER COUPLING GREASE, SILVER STREAK 98-17473-6 GREASE FITTING, 3/8-18, 0° 57-120729-6 GREASE FITTING, 1/4-28, 0° 57-00625-6 GREASE FITTING, 1/4-28, 45°...
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  • Page 199 PAGE INTENTIONALLY LEFT BLANK...
  • Page 200 CORPORATE HEAD OFFICE: 5656 Highway 6N RR#5 Guelph, Ontario, N1H 6J2 PHONE (519) 824-8520 (519) 824-5651 www.walinga.com FACTORY DISTRIBUTION AND SERVICE CENTERS: 938 Glengarry Crescent 1190 Electric Avenue Fergus, ON, Canada, N1M 2W7 Wayland, MI, USA, 49348 PHONE (519) 787-8227...

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