Flowplant 003301 Operation & Maintenance Manual Download Page 1

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Operation & Maintenance Manual

Original Instructions

003301

– 320 SERIES DESILTER VANPACK

Section 1

Contents & Introduction

Scope of Supply

Technical Data

Operation

Routine Maintenance

Fault Finding

Pump

Engine

Wiring and Circuit Diagram

Section 10

Parts list / Spares / Auxiliary components

Section 11

Service Documents

Section 12

Warranty & Certification

061987

Summary of Contents for 003301

Page 1: ...ion Section 2 Scope of Supply Section 3 Technical Data Section 4 Operation Section 5 Routine Maintenance Section 6 Fault Finding Section 7 Pump Section 8 Engine Section 9 Wiring and Circuit Diagram Section 10 Parts list Spares Auxiliary components Section 11 Service Documents Section 12 Warranty Certification 061987 ...

Page 2: ...2 Operation Maintenance Manual for UNIT Unit 320 Series Desilter Radio Control R 1 B11238 A ISSUE DATE 10 2020 AMENDMENTS Change No Changes Date Signature 1 FIRST ISSUE 10 20 JHGS ...

Page 3: ...MP DATA 15 3 2 TECHNICAL DESCRIPTION 16 3 2 1 PRIMARY COMPONENTS 16 3 2 2 ENGINE MONITORING 16 3 2 3 DELIVERY HOSE REEL 16 3 3 INSTALLATION DETAILS 18 4 OPERATION 19 4 1 OPERATING CONDITIONS 19 4 2 DAILY CHECKS 19 4 3 PRE START CHECKS BLEED PROCEDURE 20 4 4 STARTING THE ENGINE SETTING THE OPERATING PRESSURE 20 4 5 PRE START CHECKS PROCEDURES 22 4 5 1 STARTING THE ENGINE 22 4 5 2 CHECKING THE OPERA...

Page 4: ...ILY MAINTENANCE 34 6 FAULT FINDING 35 6 1 EQUIPMENT FAULT FINDING 37 6 2 PUMP FAULT FINDING 39 6 3 SELECTOR FAULT FINDING 40 7 PUMP 41 8 ENGINE 42 9 CIRCUIT AND WIRING DIAGRAMS 43 10 PARTS LISTS SPARES 47 10 1 INTRODUCTION 47 10 2 ORDERING SPARE PARTS 47 10 3 ACCESSORIES CONSUMABLES 48 10 3 1 ROUTINE MAINTENANCE 48 10 3 2 CONSUMABLES 48 10 4 PARTS LIST 49 10 5 HYDRAULIC DIVERTER VALVE ASSEMBLY 55 ...

Page 5: ...5 11 SERVICE DOCUMENTS 62 11 1 SERVICE CHECKLIST 62 11 2 SERVICE LOGBOOK 63 12 WARRANTY 65 12 1 WARRANTY OF NEW PRODUCTS 65 12 2 WARRANTY OF SPARE PARTS 65 12 3 LIMITATIONS OF WARRANTY 66 ...

Page 6: ...machine in the case of improper use Carefully preserve this manual for any further consultation Identify the model of your machine by reading the details on the identification plate Upon delivery inspect the machine accessories for any damage which may occur during transport IMPORTANT Always follow the recommended operating procedures do not misuse the equipment as this could result in injury or m...

Page 7: ...ve engineers 1 4 The 320 Series Desilter Vanpack The 320 Series Desilter Vanpack is a highly versatile mobile high pressure water jetting unit which offers the benefits of proven power pack and pump performance with a comprehensive range of accessories Developed for a wide range of water jetting applications the Unit has been meticulously designed for safe and efficient use ...

Page 8: ... for the unit Section 5 Routine Maintenance This section details recommended routine maintenance requirements for the pump and unit Section 6 Fault Finding Fault diagnosis tables for the pump engine and ancillaries Section 7 Pump Details of the pump and gearbox assembly Section 8 Engine This section includes the Hydraulic Water and Electrical circuits including engine controller wiring loom Sectio...

Page 9: ...r that filters the water to approximately 177 microns Pump is specified at 200microns The Harben P Type high pressure plunger pump is driven by a Kubota D1105 E4B EU X1 18 5kW Stage 5 C TXT industrial diesel engine through a Harben 2 0 1 Gearbox The water is directed by an electrically controlled Hydraulic diverter valve to a hydraulically driven hose reel c w 300 of hose or at low pressure dumped...

Page 10: ...10 2 3 Detailed Drawings Detailed drawings and parts lists for the above components are provided as follows The Pump Pump is detailed in Section 7 ...

Page 11: ...11 Hydraulic Diverter Valve 069 581 ...

Page 12: ...12 Hawk Safety Relief Valve 035 401 ...

Page 13: ...13 Speck Unloader Valve UL221 035 185 ...

Page 14: ...ocation Tracking Model 320 Series Van Pack Pressure Flow 200 Bar 45L pm Pump P Type Harben Engine Kubota 3 Cylinder Liquid Cooled Water Tank White Transparent 650L Breathable plastic tank Frame Lightweight Fibreglass canopy lightweight steel frame shot blasted and powder coated Hose Reel Variable speed Hydraulic driven reel with a 100m Capacity Dimensions TBC Weight Dry Weight from 475kg Build Opt...

Page 15: ... immersed Oil capacity litres 5 0 litres Weight kg 80 kg Recommended crankcase oil Shell Morlina 150 or Tellus 150 see section 6 Max inlet pressure 0 5 bar 5 0 metre head Max inlet temp 25 C Prime Mover Kubota D1105 E4B EU X1 18 5kW Stage 5 C TXT Drive Gearbox Harben 2 0 1 Water Tank Capacity 88 gals 400 litres Supply Water Filter N05105 Hypro line strainer 177 micro mesh Pressure Gauge Digitally ...

Page 16: ...ater will cause the pump to run unevenly and cause excessive wear due to cavitation 5 Water is diverted to the hose reel either using a 12VDC hydraulic diverter 6 A Hypro 177Micron mesh inline strainer is fitted to the suction line between the tank and the pump inlet Note This is a critical component which ensures that no contaminants are drawn into the pump inlet This filter must be inspected and...

Page 17: ... mounting theoretical discharge volume 3000rpm 11l pm max speed 3200rpm ma pressure 1707psi The speed and direction of the reel is controlled by a manual lever controlled spool valve c w safety relief and flow control this is situated just below and right of the high pressure hose reel ...

Page 18: ...18 3 3 Installation details Installation Drawing No 003 301 provides details of sizes weight and fixings for the 320 Series Desilter Vanpack together with inlet and outlet water connections ...

Page 19: ...manual the health and safety risks are highlighted with and you are required to read the relevant section in the Health Safety Manual 4 2 Daily Checks Carry out all daily checks Full maintenance checks are detailed in Section 5 Routine Maintenance They are Pump oil level Gearbox oil level Water filter cleanliness Engine oil level Engine coolant level Tank water level Cleanliness Diesel level Anti ...

Page 20: ...g One man operation OMO in accordance with the Single Person Operation as detailed in the Code of Practice Starting procedures are provided for Local operation where water to the high pressure hose is controlled by the operator using the Control unit at the machine and for remote operation where water to the high pressure hose is controlled by the hand held radio control unit RCU While the remote ...

Page 21: ...as low water as well as an audible warning It is preferable to have a full tank of water and provide the pump with a good positive head Emergency Shutdown Fig 4 1 Estop on control panel Twist to release NOTE Do Not allow unfiltered water into the pump At any time during the starting procedure or during normal jetting operations an emergency shutdown can be achieved by switching off the engine with...

Page 22: ... sight of the operator at the control panel Indirect Injection Diesel Engine Key Start Module Operating Procedure 1 Rocker Switch Bottom Right of Panel is the Master On Off 0 2 In position 1 On auxiliary circuits will be energized screen will be illuminated 3 Enter the 4 digit PIN using the up and down arrows to select numbers and the enter button to select ...

Page 23: ... now safely off 8 or in emergency situations press the stop button on the radio control panel or the emergency stop button on the main control panel 4 5 2 Checking the operating pressure with a nozzle fitted 1 Fit the correctly sized nozzle to the high pressure hose 2 Ensure the nozzle is secured in a safe position preferably within sight of the operator at the control panel 3 Press the water ON b...

Page 24: ...n until engine tick over speed is reached then press the water off button and return the unit to the idle position Note If the pressure is significantly lower than expected turn the unit off and replace the worn nozzle in the gun with a new one Do not exceed the maximum operating pressure of 200Bar by fitting a smaller nozzle than is recommended as this will cause the Pressure relief valve or Safe...

Page 25: ...25 Fig 4 Operating with the Radio Remote ...

Page 26: ...utton this is indicated by the symbol of a hare See fig 5 8 To decrease engine speed press the red engine speed down button this is indicated by the symbol of a tortoise See fig 5 9 Press button 1 the water ON button to divert the water to the nozzle or gun See fig 5 10 Press button 1 again this will now divert the water back to tank See fig 5 11 To stop the engine reduce the Engine rpm press butt...

Page 27: ...nds until a beep is heard Once connected the screen should display as per Fig 5 Turning the remote control OFF Turn the handset off by pressing the red STOP button Fig 5 Handheld RADIO Control Unit RCU Button 1 Water on Water Off Button 2 Engine Start Stop Button 3 HI RPM up Button 4 LO RPM Down No lights RCU off Charging Details See handbook for charging instructions ...

Page 28: ...ng into the duct cleaning as it goes Critically the Jump Jet allows ducts to be de silted with pressures as low as 140 bar and only 40 l min meaning that even with fibre optic cable in situ there is negligible risk of causing any damage To operate the jump jet open the jump jet valve on the control panel of the unit 4 10 Hose reel winding and unwinding The high pressure hose is manually unwound an...

Page 29: ...riods when there is a risk of freezing the following precautions should be taken 1 Prepare 50 anti freeze solution 2 Remove nozzle or gun attachments from the delivery hose 3 Lower the water level in the tank 4 Fill the anti freeze Tank to maximum with the 50 solution 5 Move the T Port valve in the suction line to the upwards towards the antifreeze position and remove the lid from the Anti freeze ...

Page 30: ...ge the pump and damages caused by misuse will not be covered under warranty NOTE The hose should NEVER be tightly wound onto the hose reel drum when the hose is not pressurised as might occur when the hose has become trapped A tightly wound hose can easily crush the hose reel when it is next pressurised If you have reason to believe that the hose may have been tightly wound onto the reel when unpr...

Page 31: ...hly 50 hours First service contact Flowplant Service Six Monthly 100 hours Inspect tanks and fittings for leaks thoroughly clean flush through Tighten any loose joints Grease the hydraulic hose reel bearing blocks Check condition of 12volt start battery Grease battery terminals for protection Check alternator belt Yearly 300 hours Intermediate service of engine gearbox and pump required Contact Fl...

Page 32: ...aintenance please refer to the engine handbook supplied with the unit 5 2 Lubricating Oil Chart Manufacturer Type Oil Capacity litres ESSO Nuto H150 Number of Cylinders GULF LP 150 3 cyl 4 cyl 6 cyl 8 cyl MOBIL DTE Extra Heavy 6 5 6 0 5 75 5 0 ROC Kiron 150 TEXACO Rando HD 150 BP Energol HLP 150 AGIP OSO 105 SHELL Tellus Morlina 150 CENTURY OIL PWLM PETROFINA Hydran 51 CASTROL Hyspin AWS 150 ...

Page 33: ...44 143 200 20 447 559 670 279 391 The above Torque settings are for lightly oiled threads IMPORTANT DO NOT USE for DRY THREADS ALL THREADS MUST BE LIGHTLY OILED unless specified otherwise Where the nut material is softer than the bolt this must be considered and a lower torque figure calculated Contact Technical Dept The above Torque settings are to be used when no other specific torque is quoted ...

Page 34: ...move the mesh Flowplant part no N06021 Take precautions so as not to lose the sealing ring Flowplant part no N05108 Fig 6 1 Inlet Filter 2 Visually inspect all hoses for signs of chaffing or leaks Report any damage immediately to supervisor or manager With the machine running 3 Make further inspection for leaks If a leak is observed shut down immediately and report the leak to a supervisor or mana...

Page 35: ... The table below indicates potential problems and suggests an appropriate course of action Lamps Condition Solution Low oil pressure shutdown Check oil level top up if necessary Check and replace switch if faulty Check the oil pressure if the pressure is low Refer to the handbook for further advice Water coolant temperature shutdown Check Coolant level content top up if necessary Check and replace...

Page 36: ...e to crank the engine as this will damage the starter due to over cranking Charge warning indication Check the alternator V belt tension tighten the belt if it is slack and slipping Check the connecting terminals to the alternator Check the engine idle speed reset if necessary Refer to engine handbook for further advice ...

Page 37: ...single gun unit Clean the items and flush out the delivery line Replace the nozzle Replace the hose Adjust to correct speed Replace if necessary Replace with standard choke Low Water Level 1 Blocked or dirty pre filters 2 Faulty ball valve assembly 3 Wrong seat in ball valve assembly 4 Low inlet pressure Clean or replace elements Replace if necessary Replace the seat if necessary Increase pressure...

Page 38: ...rankcase oil through high pressure hose 2 Loss of pump pressure 3 Pump not running evenly 1 Inlet restriction may have been caused through a Blocked filters b Kinked inlet hose c Worn or damaged inlet valves d Excessive inlet hose length 2 Pump has been frozen 1 Clear restriction 2 Check inlet valves replace as necessary 3 Check diaphragms replace as necessary 4 Replenish oil 1 Mixing of Oil and W...

Page 39: ...blocked DISTINGUISHING FEATURE OF FAILURE ON DIAPHRAGM B 4 small impressions cause more damage on the inside than on the outside Reason Water filter blocked or inlet valves blocked DISTINGUISHING FEATURE OF FAILURE ON DIAPHRAGM C Shear through wall of diaphragm Reason Pump operated whilst frozen or wear and tear after several thousand hours A ...

Page 40: ...ing through the worn seat back to tank Replace the seats and the plug if also damaged If water leaks along spindle and past lever O ring and back up ring failure along shaft Replace O ring and back up ring 013 021 023 001 Water leaking along the gland nut thread Leaking selector seal Replace seal 012 095 ...

Page 41: ...41 7 Pump Flowplant offer a detailed manual with the Harben P Type Pump and this will be accompanied by this manual ...

Page 42: ...s manual Basic engine noise levels Engine RPM 1500 2000 3000 AT 1 METRE FULL LOAD db A 84 87 94 AT 7 METRE FULL LOAD db A 67 77 Replacement filters may be obtained from Flowplant Flowplant PART No ITEM 051 1057 ENGINE OIL FILTER 051 1058 ENGINE FUEL FILTER 051 1059 ENGINE AIR FILTER 054 020 ENGINE OIL 054 047 GEARBOX OIL 054 047 PUMP OIL ...

Page 43: ...43 9 Circuit and Wiring Diagrams ...

Page 44: ...09 0 5 1600 V 21W 031 1001 TeleRadio CanHi Rd Ferrule 023 3002 W Grey 051 4004 1 0 2450 W 21W 031 1001 4 20MA Rd Ferrule 023 3002 E Black 051 5002 1 5 1650 E 21W 031 1011 Com Ground 023 7024 E3 Black 051 4002 1 0 2650 Blk Ferrule 023 3004 Siren E4 Black 051 4002 1 0 1500 Red Female Spade 023 4003 Speed E5 Black 051 4002 1 0 1800 Blk Ferrule 023 3004 Tele E6 Black 051 4002 1 0 2000 Red Male Bullet ...

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Page 46: ...46 ...

Page 47: ...d use the information in this section To identify components for the pump or engine etc refer to the relevant parts in this manual 10 2 Ordering Spare Parts Order spare parts from Flowplant Group Ltd Gemini House Brunel Road Churchfields Industrial Estate Salisbury Wiltshire UK SP2 7PU Tel 44 0 1722 325424 Fax 44 0 1722 411329 sales flowplant com www flowplant com ...

Page 48: ...48 10 3 Accessories Consumables 10 3 1 Routine Maintenance For routine maintenance the following will be required 10 3 2 Consumables N0621 MESH FOR LINE STRAINER N015108 177 MICRON ...

Page 49: ... 013936 GRUB SCREW S STEEL M4x6 LG A2 2 013938 SCREW HEX HEAD M10x1 25 x 30MM LG ZN 22 013943 FEMALE BOBBIN MOUNT TYPE 2 B AV 3015MF20 60 4 014013 HOSE CLIP DIA 20 30 JCS HI GRIP S S 4 014158 CLAMP STAUFF 3 4 O D WITH BASE PLATE 1 014201 P CLIP 25mm ZINC PLATED 1 014277 HANDLE 8535 202 2 014284 HOOD LATCH RUBBER 339 9151 5 014288 HOSE CLIP DIA 8 10 JCS HI TORQUE RS727 5914 4 015173 SEAL BONDED 1 B...

Page 50: ... BLANKING 1 2 BSP ST ST 550 BAR 1 023406 TEE 1 2 Mx1 2 Mx1 2 F SWIVEL ALL BSP 415BAR ZN MUST HAVE HEX BODY 1 023569 PIN CANOPY RETAINER 1 023609 ADAPTOR 1 1 4 BSPM X 3 4 BSPM ZN 210 BAR 2 023653 1 4 BSPM 1 4 BSPF SWIVEL 90 COMP ELBOW 415BAR 1 023712 ADAPTOR M16 X 1 5 3 8 BSP M M MS ZN 1MB 16 6 1 023847 ADAPTOR 1 1 4 BSP M F SWIV 2B 20 210 BAR 1 023932 ELBOW 3 8 BSPT 3 8 BSP M M FORGED 420BAR W P 1...

Page 51: ...KUBOTA D1105 315 SERIES MK3 1 0423186 BATTERY CRADLE 315 SERIES MK3 2018 1 043061 HOSE CLIP DIA 9 5 12 JCS HI GRIP S S 10 043074 VALVE 1 BSP SHUT OFF 200PSI TYPE 750 R751T 1 043186 ADAPTOR 1 BSPT 30MM UPVC HOSETAIL 1 043196 ELBOW 90 DEG THREADED 1 1 4 BSPF UPVC 2 043203 PLUG BLANKING 1 BSPT GALVANISED IRON do not use now use 044029 1 043222 INSERT HOSE 1 1 4 BSPM X 32 MM DIA HOSETAIL UPVC 3 043235...

Page 52: ... com 2 0551802 1 BLUE HOSE Autosiliconehoses com 2 0551817 1 BLUE U BEND 180DEG HOSE 1 055431 RUBBER FUEL LINE DIA 6MM 2 6 055985 HOSE ASSY DN10 3 8 1 05M STR ELB EN 853 2SN 1 058298 PIPEWORK HOSE JOINER 1 x 1 x 3 8 STEEL PLATED 1 058301 320 COOLANT RADIUS 25MM DIA 100MM CLR 1 059115 FRONT PANEL GRP MOULDED 320 SERIES supersedes 058 287 1 061030 SPACER D T D T T FUEL TANK 3 061434 LABEL E STOP SEL...

Page 53: ...EXTENDED HEX NUT M8 1 079261 EXHAUST FLANGE STUB KUBOTA D1105 1 079279 EXHAUST OUTLET FLANGED 90 DEGREE KUBOTA D1105 1 085344 TANK HYDRAULIC PLASTIC 315 SERIES MK2 BEHIND H REEL MOUNT 1 085389 TANK FUEL PLASTIC 320 SERIES MK1 1 085396 EXPANSION TANK 320 COOLING SYSTEM 1 085406 320 SERIES ANTIFREEZE TANK 1 085419 650L WATER TANK 320 DESILTER UNIT 1 094103 Elbow 45 deg Male Female 1 BSPT x malleable...

Page 54: ...EVEL GAUGE 5116 7 1 N05270 BATTERY CABLE RED 16MM SQ TYPE BK RS516 8038 1 9 N05798 HYDRAULIC FILTER U C C MX1518 102 RETURN FILTER 1 N10001 BATTERY RETAINING BRACKET 1 N15142 HYD HOSEREEL POWDER COAT 1 N15190 ADJUSTING SPACER CONVEX POWDER COAT 2 N20836A BEARING HOUSING HYD HOSE REEL POWDER COAT 1 N20838 HOSE REEL SHAFT FLUID END 1 N20839 HOSE REEL SHAFT ZINC PLATED 1 N20843 TRACE ROLLER 5 ...

Page 55: ...013345 O RING BS019 90 4 015062 GLYD RING SEAL 2 015063 STEPSEAL 2 033279 OVERHAUL KIT CENTURY TRIGGER ASSY 013345 O RING BS019 90 4 015062 GLYD RING SEAL 2 015063 STEPSEAL 2 033293 CENTRE COLLAR 1 033264 SCRAPER 1 033294 END COLLAR 2 033295 GLAND 2 033296 SPINDLE 1 033275 DRIFT VALVE SPINDLE 1 Before attempting to overhaul the diverter valve the machine must be switched off and all hoses and adap...

Page 56: ... Gently ease both step seals 4 into glands 11 making sure step of inner seal faces pressure DRG 035 255 3 Gently ease both Glyd rings 3 into end collars 10 making sure stepped side of inner seal is visible when fitted DRG 035 255 4 Fit centre collar 9 between the two end collars 10 This may be a slide or a light press fit into the collars DRG 035 255 5 Holding glands 11 against end collars 10 with...

Page 57: ... 8 Then pressure can be gently released and spring mount 6 will stop against circlip 2 DRG 035 255 11 Apply metal paste to threads of cap 8 and screw into body 18 and torque to 41Nm DRG 035 255 12 Locate the adaptor cylinder 2 DRG 026 111 onto the water valve body 18 DRG 035 255 3 and secure with the three M8 socket button headset screws 17 DRG 035 255 13 Replace screw set washer 5 6 DRG 026 111 1...

Page 58: ...ENTURY GUN 1 033264 SCRAPER BODY ASSY CENTURY GUN 1 033268 CAP BODY CENTURY GUN 1 033293 CENTRE COLLAR BODY ASSY CENTURY GUN MODIFIED 1 033294 END COLLAR BODY ASSY CENTURY GUN MODIFIED 2 033295 GLAND BODY ASSY CENTURY GUN MODIFIED 2 033296 SPINDLE CENTURY GUN MODIFIED 1 033306 HOLDER FOR CHOKE 1 013039 ADAPTOR 1 2 BSP M x 1 2 BSP M 415 BAR 2 013345 O RING BS019 90 4 033010 SEAL BONDED 1 2 BSP 400 ...

Page 59: ...59 ...

Page 60: ...ON M10 SPRING STEEL ZN 1 069400 SOLENOID VALVE 4 2 HYD 12VDC CETOP 3 C W PLUG 1 069458 SUB PLATE SIDE PORTED ISO 03 3 8 BSP ESU 1 069459 VALVE HYDRAULIC PRESSURE REDUCING RELIEVING 1 033013 SEAL BONDED 3 8 BSP 400 823 4490 41 492 BAR 4 033005 ADAPTOR 3 8 BSP M x 3 8 BSP M 415 BAR 2 013014 ADAPTOR 1 4 BSP M x 1 4 BSP M 415 BAR 1 013038 ADAPTOR 3 8 BSP x 1 4 BSP M M 415BAR 2 013211 ADAPTOR BHEAD 1 4...

Page 61: ...61 ...

Page 62: ...62 11 Service Documents 11 1 Service Checklist ...

Page 63: ...63 11 2 Service Logbook ...

Page 64: ...64 ...

Page 65: ...ys from date of despatch on materials and workmanship Provided always that They are returned to Flowplant for inspection carriage paid along with a copy of the original part s sale invoice where necessary and All terms agreed by Flowplant for payment of such goods have been complied with and If a defect failure is discovered before the expiration of the warranty notification must be given to the F...

Page 66: ... employees Our obligations as aforesaid shall constitute the full extent of our liability in respect of any loss or damage sustained by the purchaser whether caused by any breach of this contract or by our negligence or otherwise and we shall not be liable to make good or pay for loss of use of the goods loss of revenue loss of profit or goodwill or any direct or consequential losses howsoever cau...

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