Hydrovac Maintenance Guide: Keep Your Truck Running and Earning

I've spent 25 years fixing hydrovac trucks, and I can tell you exactly which trucks break down and which ones don't. It's not luck. It's not the brand. It's maintenance — or the lack of it.

The trucks that show up on my emergency repair list are almost always the ones that skipped oil changes, ignored small leaks, and ran "just one more job" before getting that weird noise checked out. The trucks I rarely see for emergencies? They're the ones with operators who actually follow a maintenance schedule.

This guide covers everything I know about keeping hydrovac trucks running. Not the manufacturer's idealized schedule — the real-world stuff that actually prevents breakdowns.

The Philosophy: Pay Now or Pay More Later

Every maintenance task I'm about to describe costs money. I get it. But here's the math I've seen play out hundreds of times:

• Skipped blower oil change: Saved $50

• Resulting blower rebuild: Cost $8,000 + 3 days downtime

• Ignored small hydraulic leak: Saved a $20 hose

• Resulting pump damage from low fluid: Cost $4,000 + emergency service call

• Skipped pre-trip inspection: Saved 10 minutes

• Discovered brake problem on highway: Cost a whole lot more than 10 minutes

Every single "savings" from skipping maintenance eventually costs 10-50x more in repairs. I've never seen an exception.

Daily Maintenance: The 10-Minute Routine

Before every shift, someone needs to walk around that truck. It takes 10 minutes and catches 90% of problems before they strand you.

Pre-trip inspection checklist — I wrote a detailed guide on this, but here's the quick version:

Fluid Levels:

• Engine oil
• Coolant (when cold)
• Hydraulic fluid (sight glass)
• Water tank level
• DEF level (if equipped)

Visual Inspection:

• Walk around looking for leaks (oil, hydraulic, water, coolant)
• Check tire condition and pressure
• Look at hoses and belts
• Check boom and tank for damage
• Verify all lights work

Operational Checks:

• Brake test
• PTO engagement
• Boom rotation and extension (briefly)
• Water pump prime

Listen:

• Engine sound normal?
• Any unusual noises from blower, pumps, hydraulics?
• Air leaks?

This isn't bureaucratic nonsense — it's how you find the $50 problem before it becomes the $5,000 problem. I can't count how many emergency calls could have been prevented by a morning walk-around.

Weekly Maintenance Tasks

Once a week, dig a little deeper:

Blower System:

• Check blower oil level (top off if needed)
• Listen for bearing noise during operation
• Check blower belt tension and condition
• Inspect relief valve operation

Water System:

• Clean or check water strainer
• Inspect spray nozzles for wear
• Check hose reel operation
• Look for pump leaks

Hydraulic System:

• Check for new leaks (mark existing ones to track)
• Verify boom operation is smooth
• Test debris tank lift
• Check outrigger operation

Debris Tank:

• Inspect door seals (dollar bill test)
• Check door latch mechanism
• Look for tank corrosion
• Verify sight glasses are clear

Chassis:

• Grease all fittings (boom pivots, steering, suspension)
• Check for loose bolts
• Inspect air system (if equipped)

Monthly Maintenance

Monthly tasks take more time but prevent the big failures:

Engine Service:

• Oil and filter change (or per hour meter if you hit it first)
• Air filter inspection/replacement
• Fuel filter inspection (replace per schedule)
• Check all belt tensions
• Inspect coolant hoses

Blower Service:

• Change blower oil (every 200 hours or monthly, whichever comes first)
• Check shaft seals
• Inspect coupling to PTO
• Listen for internal noise changes

Hydraulic System:

• Check hydraulic filter (change per schedule)
• Inspect all hydraulic hoses for wear, chafing, cracks
• Clean hydraulic cooler fins
• Check hydraulic fluid condition

Safety Systems:

• Test all emergency stops
• Verify backup alarm works
• Check fire extinguisher
• Test all lighting

Seasonal Maintenance

Seasons matter, especially in the Northeast where I work:

Before Winter:

• Complete winterization checklist
• Switch to winter-weight hydraulic fluid if needed
• Test all heating systems (water tank, cab, engine block)
• Check battery condition and charging system
• Verify glow plug/intake heater operation
• Drain and treat fuel system if using summer fuel

Before Summer:

• Switch back to summer-weight hydraulic fluid if changed
• Clean all cooler fins thoroughly
• Check A/C system
• Verify cooling system capacity
• Inspect fan clutch operation

Spring/Fall:

• Brake inspection
• Suspension inspection
• Complete fluid analysis (optional but recommended)
• Full safety inspection

Hour-Based Maintenance

Some maintenance goes by operating hours, not calendar time:

Every 200 Hours:

• Blower oil change
• Air filter check
• General inspection

Every 500 Hours:

• Hydraulic filter change
• Full blower inspection
• Pump inspection
• Drive belt replacement

Every 1000 Hours:

• Hydraulic fluid analysis or change
• Full brake inspection
• Suspension inspection
• Major component inspection

Every 2000+ Hours:

• Consider blower rebuild inspection
• Major engine service
• Transmission service

Your hour meter is important. Actually pay attention to it.

The Stuff That Gets Skipped

In 25 years, I've noticed certain maintenance items get skipped more than others. These are the ones that come back to bite:

Blower Oil: "It's just oil, how important can it be?" Very. Read why. A $50 oil change prevents a $10,000 rebuild.

Door Seals: Easy to ignore until you can't build vacuum. Check them weekly with the dollar bill test. Replace when worn — it's cheap insurance.

Hydraulic Filters: Out of sight, out of mind. Until the contaminated oil kills your pump. Change them on schedule.

Greasing: "I'll do it tomorrow." Tomorrow turns into next month. Dry pivots wear fast and expensively.

Small Leaks: "It's just a drip." That drip is telling you something's about to fail. Fix it while it's still a drip.

Operator Habits That Kill Trucks

This is uncomfortable to write, but I see it constantly: operator mistakes that destroy equipment.

Short version:

• Running blower at max without adequate warm-up
• Engaging PTO at high RPM
• Ignoring warning lights "until the job's done"
• Overloading the debris tank
• Not cycling relief valves in cold weather
• Running low on hydraulic fluid

Train your operators. It's cheaper than repairs.

Documentation That Matters

Keep records. I know it's annoying, but:

• Track fluid consumption (sudden increase = problem)
• Log operating hours
• Document any issues, even minor ones
• Keep all service receipts
• Note when parts were replaced

When you do need repairs, this history helps me diagnose faster. It also helps with warranty claims and resale value.

When to Call a Professional

Do your daily and weekly stuff. But some things need professional attention:

Call for help when:

• Anything involving internal blower work
• Hydraulic system overheating
• Electrical problems beyond simple fuses
• Engine warning lights you can't identify
• Boom problems you can't diagnose
• Any time you've tried something twice and it didn't work

I provide maintenance and inspection services throughout Pennsylvania, New Jersey, New York, and the DC/Maryland area. I also offer fleet maintenance programs for operators running multiple trucks.

For the cost of one emergency repair, you can usually cover a year of professional maintenance. Think about which option makes more sense.

Building a Maintenance Schedule

Here's how I'd set up a maintenance program:

Daily: Pre-trip checklist (10 min) Weekly: Fluid checks, quick inspection (30 min) Monthly: Detailed inspection, blower oil, greasing (2-4 hours) Quarterly: Deep inspection, all filters, safety check (half day) Annually: Professional inspection, fluid analysis, major service (full day)

Put it on a calendar. Assign responsibility. Actually do it.

The Bottom Line

Maintenance isn't exciting. It doesn't make money directly. But it's the difference between a truck that runs reliably and one that leaves you stranded on job sites explaining to customers why you can't finish their project.

I've been fixing hydrovac trucks for 25 years. The trucks I see once a year for preventive maintenance run for years without major problems. The trucks I see on emergency calls are the ones that skipped maintenance until something broke.

You get to choose which category your truck falls into.

For help building a maintenance program or getting your truck inspected, call me at 272-296-9637. I cover PA, NJ, NY, and the DC area with mobile service. And check out the detailed guides linked throughout this article for specifics on each maintenance area.