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HARBEN 4018 DPK, Operation & Maintenance Manual

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HARBEN 4018 DPK Operation & Maintenance Manual Download Page 2

 

1 

Operation & Maintenance Manual for: 

 

UNIT: 

 

 

DPK Truck units – Various - 9031297 

 

ISSUE DATE:  

6/20 

ISSUE No:

 

 

4 

 
 

 

AMENDMENTS 

Change 

Changes 

Date 

Signature 

1 

NEW ADDITION 

3/20 

JJ 

2 

REMOVE E-STOP IN MANUAL. MINOR EDITS 

5/20 

GT 

3 

Add Bypass Valve section. Minor Edits 

6/20 

GT 

4 

Updated manual to code 

6/20 

GT 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for 4018 DPK

Page 1: ...e of Supply Section 3 Technical Data Section 4 Operation Section 5 Routine Maintenance Section 6 Fault Finding Section 7 Harben P Type Pump Section 8 Circuit Diagrams Section 9 Engine Section 10 Parts List Spares Auxiliary Components Section 11 Service Documents Section 12 Warranty Certification Section 13 Health and Safety Section 903 1308 Read the Health and Safety Manual before operating any eq...

Page 2: ... Truck units Various 9031297 ISSUE DATE 6 20 ISSUE No 4 AMENDMENTS Change Changes Date Signature 1 NEW ADDITION 3 20 JJ 2 REMOVE E STOP IN MANUAL MINOR EDITS 5 20 GT 3 Add Bypass Valve section Minor Edits 6 20 GT 4 Updated manual to code 6 20 GT ...

Page 3: ... 2 MAIN COMPONENTS 12 3 1 3 ANCILLARIES 12 3 1 4 SERVICES REQUIRED 12 3 2 TECHNICAL DESCRIPTION 13 3 2 1 PRIMARY COMPONENTS 13 3 2 2 ENGINE MONITORING 13 OPERATION 14 4 1 OPERATING CONDITIONS 14 4 2 DAILY CHECKS 14 4 3 PRE START CHECKS PROCEDURES 14 4 4 CONTROL PANEL LAYOUT AND FUNCTION 15 4 4 1 CONTROL KEYS 15 4 4 2 TOGGLE SWITCH OPERATION 15 4 4 3 SCREEN LAYOUTS 16 4 5 RUNNING THE ENGINE MANUAL ...

Page 4: ...RICAL 30 6 2 FAULT FINDING HYDRAULIC 31 6 3 PUMP FAULT FINDING 32 6 4 SELECTOR FAULT FINDING 34 HARBEN PUMP 35 CIRCUIT DIAGRAMS 36 8 1 WATER CIRCUIT FOR DPK 4018 36 8 2 HYDRAULIC CIRCUIT FOR DPK 4018 36 8 3 ELECTRICAL DIAGRAMS 37 8 3 1 MANUAL WIRING DIAGRAM 37 8 3 2 RADIO WIRING DIAGRAM 38 ENGINE 39 PARTS LIST SPARES 40 10 1 INTRODUCTION 40 10 2 ORDERING SPARE PARTS 40 10 3 ROUTING MAINTENANCE CON...

Page 5: ...3 WARRANTY 44 12 1 WARRANTY OF NEW PRODUCTS 44 12 2 WARRANTY OF MAJOR COMPONENTS 44 12 3 LIMITATIONS OF WARRANTY 46 ...

Page 6: ... result in death or serious injury This will only be shown for the most extreme cases It is imperative that these symbols are paid attention to as to avoid any sort of injury Notices Carefully read the notices of this manual because they give important information concerning safe installation use and maintenance familiarise yourself with the workings of the machine to rapidly switch it off and eli...

Page 7: ...information provided here so that you understand how to make the most of the truck package and use it in accordance with the instructions Harben truck packages are powerful pieces of industrial equipment and should only be operated by competent users who understand that serious injury or death can occur through misuse The truck package described in this operation and maintenance manual are intende...

Page 8: ...kage Section 6 Fault Finding Fault diagnosis tables for the pump engine and ancillaries Section 7 Harben P Type Pump Details of the pump and gearbox assembly Section 8 Circuit diagrams Electrical Details This section includes the Hydraulic and water circuits of the truck package Section 9 Diesel Engine This section provides part details of the diesel engine Section 10 Parts list Spares Auxiliary C...

Page 9: ...rs the water to approximately 80 microns The P Type 8 22 radial piston high pressure diaphragm pump is driven by an industrial diesel engine through a 2 1 reduction gearbox The water is directed by a divert valve to a hydraulically driven hose reel with up to 500 feet of hose or at low pressure dumped back to tank The system is protected from over pressurization by a safety relief bursting disc Th...

Page 10: ...8 Figure 2 1 DPK 750 Manual Primary Components ...

Page 11: ...9 Figure 2 2 DPK 375 Manual Primary Components ...

Page 12: ...10 Figure 2 3 DPK 750 Remote Primary Components ...

Page 13: ... Shaft dia 30 mm Shaft length 65 mm Cylinder options 8 Power rating nominal 45 hp Plunger diameter 22 mm Shaft speed 1250 rpm Maximum pressure Up to 4000 psi 280 bar Max flow rate Up to 18 USG min 70 lpm Crankcase lubrication Fully immersed Oil capacity 1 3 USG Weight 176 lb Recommended crankcase oil Shell Morlina 150 or Tellus 150 see section 6 Max inlet temperature 77 F ...

Page 14: ...375 gal capacity each 750 gal capacity for 2 tank set Supply filter 042134 Hypro line strainer 170 micron mesh Monitoring control Standard engine controller and throttle Pressure control and safety 011046 Pressure disc white 4000 psi 011047 Pressure disc black 5000 psi Hot ambient temperature ________________________________________________________________________ 3 1 4 Services Required Mains wat...

Page 15: ... is settled and non turbulent discharging a smooth uninterrupted supply with a positive head of pressure to the inlet maximising the full potential of the pump The pressure valve directs high pressure water to the main jetting hose or diverts it back to the tank The control panel which includes the engine controller pressure gauge throttle high pressure selector jump jet valve hydraulic hose reel ...

Page 16: ...s not frozen before starting see Antifreeze section 4 11 Serious injury can occur from ice bullets H S Sections 3 and 7 2 Only operate the machine in a well ventilated area H S Sections 3 8 9 and 12 3 Ensure the towing vehicle and trailer hand brakes are applied H S Sections 3 11 and 13 4 To fill water tank connect water supply to the hydrant fitting on the street side of the truck NOTICE To compl...

Page 17: ...l Keys 4 4 2 Toggle Switch Operation Engine stop Water on Speed down Menu exit Menu password access Menu down key Radio on off screen Engine start Menu up key Operating screen Enter button Light switch Light fuse 12V charge point Control panel fuse Power on switch ...

Page 18: ...creen Layouts Starting splash screen Password screen Manual Confirmation Screen Software version Password screen Use enter up and down buttons to enter password Run screen entry 2010 Minor programme updates 1111 ...

Page 19: ...ine speed Harben contact number Water on indication Main run screen access by pressing menu exit key Remote enable control screen Enter button will toggle between function Run detail screen access via the up and down keys ...

Page 20: ...6 1 Switch on unit using toggle switch 2 The control system will now go through a pre start glow plugs 3 Enter password 2010 to enter 4 You will now enter the run screen 5 Ensure the open ended high pressure hose is in a safe position preferable within sight of the operator at the control panel H S Sections 3 and 6 6 Press the engine start button 7 The engine will now start and run in idle 8 The u...

Page 21: ...n in idle 11 The user can now increase and decrease the speed of the engine using the engine up and down speed on the handset 12 Increase the speed of the engine and when it is safe to turn the water on press the water on button on the handset 13 The engine speed and pressure can now be increased and decreased using speed up and speed down button 14 Manual mode will not operate when radio mode is ...

Page 22: ...rben high pressure pump which increases the effective duct cleaning distance up to and often beyond 500ft The Jump Jet operation will help the jet to travel further up the duct When required the operator can switch on the Jump Jet to create a cyclic vibration in the jetting hose The vibration travels along the entire length of the hose reducing friction between itself and the duct wall and allowin...

Page 23: ... Anytime there is a need to reduce the amount of water flow to the nozzle especially in applications that require the use of Mini Jet Kits that use 3 16 and even 1 8 mini hoses use of the bypass valve helps divert some of the water back to the tank which lessens the load on the engine and pump To use the valve 1 Turn the handle on the valve counterclockwise until it stops This opens the valve comp...

Page 24: ... hose before you intend to empty the tank CAUTION If the hose becomes stuck in the drain the hydraulic hose reel should NOT be used as a winch to try and free it and the towing vehicle should NEVER be driven away to drag the hose clear This will put severe strain on the reel framework which could lead to serious damage H S Section 3 6 and 13 Hoses that have become stuck can sometimes be pulsed fre...

Page 25: ... S Sections 3 and 7 Take the following precautions to avoid frost damage 4 11 1 To Anti Freeze the Machine with an Antifreeze Tank 1 The valves to control the antifreeze procedure are located as shown 2 Shut the tank isolation valve 3 The handle for the 3 way ball valve should be in the vertical position 4 Open the tank drain valve Anti freeze valve Drain valve Tank isolation valve 3 Way Ball Valv...

Page 26: ...eze tank If the hose is clean you may remove the strainer in the tank lid to make it easier 13 Restart the engine and allow the antifreeze to circulate Briefly about 2 seconds move the selector valve from HIGH PRESSURE to DUMP and back to HIGH PRESSURE use water on button for radio system Briefly about 4 seconds put the jump jet valve into the On position and then return to the Off position See pi...

Page 27: ...1 Place the jump jet valve in the on position 12 The machine can now be used in the normal manner DO NOT ATTEMPT TO JET ANY REMAINING ANTIFREEZE SOLUTION INTO A CONTAINER NOTICE If the pump is frozen up on no account should the unit be started until it has been thoroughly thawed NOTICE When the engine starts the pump will be pumping fluid and may be under pressure ...

Page 28: ...xing plates from truck chassis to Harben chassis and U Bolts if installed 6 months 150 hours Inspect tanks and fittings for leaks thoroughly clean flush through with hot water more than 158 F Tighten any loose joints Grease the hydraulic hose reel bearing blocks Check condition of 12 volt start battery Grease battery terminals for protection Check alternator belt Yearly 300 hours Intermediate serv...

Page 29: ...eted daily with the truck package switched OFF 1 Check condition of inlet water filter element Clean or replace Harben part no 042 134 Unscrew the bowl to remove the mesh Harben part no 903 245 Take precautions so as not to lose the sealing ring Harben part no 903 300 ...

Page 30: ...nning H S Sections 3 and 6 With the unit running 4 Make further inspection for leaks If a leak is observed shut down immediately and report the leak to a supervisor or manager 5 3 Pump Lubricating 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 ...

Page 31: ...ilable burst discs are as follows Colour Code Part Number For Maximum Working Pressure Yellow 011019 125 bar 1800 psi Blue 011020 140 bar 2000 psi Red 011021 175 bar 2500 psi Purple 011022 210 bar 3000 psi Green 011045 240 bar 3500 psi White 011046 275 bar 4000 psi Black 011047 345 bar 5000 psi Orange 011107 415 bar 6000 psi Burst disc holder showing White burst disc ...

Page 32: ... Also covered at 6 3 overleaf is a diagnosis of selector valve problems 6 1 Fault Finding Electrical As part of the control system there is a detailed log of all electrical alarms and shutdowns These will range from oil pressure to CanBus failure To access this menu use the following instructions 1 Enter 1111 into the low password screen a Main menu b Systems settings c Event history 2 The event h...

Page 33: ...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 Blocked or dirty pre filters Faulty ball valve assembly Wrong seat in ball valve assembly Low inlet pressure Clean or replace elements Replace if necessary Replace the seat if necessary Increase pressure Pump no...

Page 34: ...rs replace as necessary 1 Loss of crankcase oil through high pressure hose Loss of pump pressure Pump not running evenly Inlet restriction may have been caused through o Blocked filters o Kinked inlet hose o Worn or damaged inlet valves o Excessive inlet hose length Pump has been frozen Clear restriction Check inlet valves replace as necessary Check diaphragms replace as necessary Replenish oil Mi...

Page 35: ...phragm A B C Impression of the baffle on diaphragm Reason It has been inflated 4 small impressions cause more damage on the inside than on the outside Reason the diaphragm has pumped through mandrel delivery holes Shear through wall of diaphragm ...

Page 36: ...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 37: ...35 Harben Pump Refer to the P Type Service Manual Part No 061 352 included with your truck package ...

Page 38: ...36 Circuit Diagrams For wiring diagrams relating to the engine refer to your engine handbook supplied with your truck package 8 1 Water Circuit for DPK 4018 8 2 Hydraulic Circuit for DPK 4018 ...

Page 39: ...37 8 3 Electrical Diagrams 8 3 1 Manual Wiring Diagram ...

Page 40: ...38 8 3 2 Radio Wiring Diagram ...

Page 41: ...39 Engine A copy of the Engine Manufacturer s Operators Handbook is supplied with this equipment ...

Page 42: ...on 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 Harben Inc 2010 Ronald Reagan Blvd Cumming GA 30041 Tel 770 889 9535 Fax 770 887 9411 email sales harben com www harben com 10 3 Routing Maintenance Consumable Items See Section 5 10 4 Consumable Components See Section 5 ...

Page 43: ... listed below 905073 DPK 750 STATIONARY PIVOT REEL 108 CAB MANUAL 905074 DPK 750 STATIONARY PIVOT REEL 108 CAB REMOTE 905084 DPK 375 STATIONARY PIVOT REEL 84 CAB MANUAL 905100 DPK 750 STATIONARY PIVOT REEL 84 CAB REMOTE 905103 DPK 750 STATIONARY PIVOT REEL 84 CAB MANUAL 905104 DPK 375 STATIONARY PIVOT REEL 84 CAB REMOTE ...

Page 44: ...42 Service Documents 11 1 Service Checklist ...

Page 45: ...43 11 2 Service Logbook ...

Page 46: ...nd is not transferable We assume no responsibility for damage due to accident neglect abuse tampering or misuse or damage from repairs or alterations by others This warranty does not cover damage to the equipment resulting from the use of non genuine spare parts Warranty of Harben P Type Pump The warranty for the Harben P Type pump when fitted to a trailer truck or van pack unit manufactured by us...

Page 47: ...our machine 4 We will replace at the customers cost any part s returned for warranty inspection When our inspection has been completed we will advise if the parts s are covered by our warranty policy and if they are we will credit your account for the cost of the new part s minus taxes and shipping charges 5 Our warranty does not cover travel charges down time or consequential losses 6 No part s w...

Page 48: ...jury arising from the negligence of the company or its 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 goodwi...

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