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HARBEN 4018 DSK, Operation & Maintenance Manual

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HARBEN 4018 DSK Operation & Maintenance Manual Download Page 1

 

Harben Inc. 

P.O. Box 2250, Cumming, GA 30028 

Toll Free: (800)-327-5387    Tel: (770)-889-9535    Fax: (770)-887-9411 

email: [email protected]    web: www.harben.com 

 

 

 

 

Operation & Maintenance Manual

 

Original Instructions  

 

4018 DSK MULTI-SKID 

903-1313 

 

Section 1   

Introduction 

Section 2   

Scope 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 & Safety Manual 903-1308 

 

                                              

 

Read the Health and Safety Manual before 

operating any equipment. Failure to do so could 

cause serious injury or death. 

Summary of Contents for 4018 DSK

Page 1: ...ope 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 Safety Manual 903 1308 Read the Health and Safety Manual before operating any equip...

Page 2: ...4018 Multi Skid R 1 B11238 A ISSUE DATE 6 20 ISSUE No 4 AMENDMENTS Change Changes Date Signature 1 NEW ADDITION 3 20 JJ 2 Minor Changes Add Part number 5 20 GT 3 Added Bypass Valve section Minor Updates 6 20 GT 4 Updated manual to code 6 20 GT ...

Page 3: ... 1 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 4 4 RADIO CONTROL LAYOUT 1...

Page 4: ...RST DISCS 29 FAULT FINDING 30 6 1 FAULT FINDING ELECTRICAL 30 6 2 FAULT FINDING HYDRAULIC 31 6 3 PUMP FAULT FINDING 32 6 4 SELECTOR FAULT FINDING 34 PUMP 35 CIRCUIT DIAGRAMS 36 8 1 WATER CIRCUIT FOR DSK 4018 36 8 2 HYDRAULIC CIRCUIT FOR DSK 4018 36 ENGINE 37 PARTS LIST SPARES 38 10 1 INTRODUCTION 38 10 2 ORDERING SPARE PARTS 38 10 3 ROUTINE MAINTENANCE CONSUMABLE ITEMS 38 10 4 CONSUMABLE COMPONENT...

Page 5: ...3 WARRANTY 51 12 1 WARRANTY OF NEW PRODUCTS 51 12 2 WARRANTY OF MAJOR COMPONENTS 51 12 3 LIMITATIONS OF WARRANTY 53 ...

Page 6: ...ult 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 elimina...

Page 7: ...ke time to read the information provided in this operation and maintenance manual so that you understand how to make the most of the multi skid package in accordance with the instructions Harben multi skid 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 skid package describe...

Page 8: ...ion 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 multi skid package Section 9 Diesel Engine This section provides part details of the diesel engine Section 10 Parts list Spares Auxiliary Compo...

Page 9: ...s 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 21 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 ...

Page 10: ...8 Fig 2 1 DSK 4018 375 Manual Primary Components ...

Page 11: ...9 Fig 2 2 DSK 4018 375 Remote Primary Components ...

Page 12: ...10 Fig 2 3 DSK 4018 750 Manual 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: ...0 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 ________________________________________________________________________ 3 1 4 Services Required Mains water supply Positive head capable of delivering gr...

Page 15: ...he water 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 ho...

Page 16: ...ures 1 WARNING In cold weather check that machine is 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 vehicle is parked on a level surface and the hand brake is applied H S Sections 3 11 and 13 4 To fill water tank connect water supply to ...

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: ... will now go through a prestart glow plugs 3 Enter password 2010 to enter 4 You will now enter the run screen 5 Press the engine start button 6 The engine will now start and run in idle 7 The user can now increase and decrease the speed of the engine using the engine up and down speed 8 Increase the speed of the engine and when it is safe to turn the water on press the water on button 9 The engine...

Page 21: ...decreased using speed up and speed down button 14 Manual mode will not operate when radio mode is selected 4 7 Running the Multi Skid Package 1 CAUTION Fit the correctly sized nozzle to the high pressure hose Engine should not be running Potential injury can occur if a nozle is being put on the end of a hose H S Sections 3 and 6 2 Insert the nozzle approximately 6 feet into the drain before divert...

Page 22: ...p 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 allowing the de silting nozzle to continue moving into the duct cleaning as it goes To operate the jump jet open the jump jet valve on the control panel of the unit NOTICE D...

Page 23: ... hose this will allow you to achieve a performance of 4 000 PSI and up to 18 GPM 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 t...

Page 24: ...eration is finished wind in the hose before shutting down the engine Wind in the 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...

Page 25: ...he Machine with an Antifreeze Tank 1 The valves to control the antifreeze procedure are located as shown 2 Shut the tank isolation valve 3 Open the tank drain valve 4 The handle for the 3 way ball valve should be in the vertical position 5 Put the jump jet valve into the off position 6 Open the antifreeze tank valve This tank must be full of an antifreeze mixture with strength of no less than a 50...

Page 26: ...SSURE 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 picture below 14 Stop the engine 15 Manually rewind the hose back on the reel and lock in position 4 11 2 To De Antifreeze the Machine 1 Shut the anti freeze valve 2 Shut the drain valve 3 Open the tank isolation va...

Page 27: ...ING 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: ... 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 12volt start battery Grease battery terminals for protection Check alternator belt Yearly 300 hours Intermediate service of engine gearbox and pump required Contact Harben Inc Closely inspect the structural integrity of the ...

Page 29: ...ed daily with the multi skid 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: ... S Sections 3 and 6 With the multi skid package 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 Energ...

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: ...convenience 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 ...

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 Pump Refer to the P Type Service Manual Part No 061 352 included with your multi skid package ...

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

Page 39: ...37 Engine A copy of the Engine Manufacturer s Operators Handbook is supplied with this equipment ...

Page 40: ...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 Routine Maintenance Consumable Items See Section 6 10 4 Consumable components See Section 6 ...

Page 41: ...ELECTOR VALVE P PUMP 1 021020 BELL HOUSING LISTER 1 023088 PART 1 NEUPEX B140 PERQUOTE 144 704 068 REV B Gearbox Coupling FEMALE 1 023093 PART 4 NEUPEX B140SAME AS 480 009 327 Gearbox Coupling MALE 2 023097 ADAPTOR 1 4 NPTM x 6 JICM 1 033010 SEAL DOWTY 1 2 4 033013 SEAL DOWTY 3 8 4 033015 SEAL DOWTY 1 1 041021 PLUG SQUARE HEAD 1 4 1 041044 PLUG SQUARE HEAD 1 2 2 042134 POLYPROPYLENE 1 1 4 FPTSTRAI...

Page 42: ...TOR 1 2 NPT MALE x 10 SAE MALE 1 900334 ELBOW PVC 2 FEMALE x FEMALE 1 900335 ELBOW PVC 2 MALE x FEMALE 2 900336 ADAPTOR PVC 2 MALE x 2 SLIP 3 900338 ADAPTOR 3 8 BSP 8 JIC M x M 4 900339 ADAPTOR ELBOW 8 JIC MALE x SWIVEL FEMALE 2 900340 ADAPTOR ELBOW BRASS 1 2 NPT MALE x 1 2 BARB 5 903001 9 DRAIN JET EXTENSION 1 903058 ADAPTOR 1 2 NPTM x 10 JICM 4 903076 ELBOW 2 M x 2 BARB NYLON 1 903092 REDUCER 2 ...

Page 43: ...NS FOR SIGHT TUBE 2 903124 I D PLATE FOR TRAILER 1 9031248 1 1 4 CLEAR PVC WATER TANK SIGHT SOCKET ADAPTOR 2 2 9031287 2 X 2 ANTIFREEZE RECIRCULATION LABEL 1 9031307 LABEL CAUTION NOZZLES MAY OVER PRESSURE REV ENGINE SLOWLY 1 903131 ADAPTOR 3 4 GH PIPE SWVL 1 903134 HOLE PLUG 1 903139 U BOLT 1 1 2 PIPE 2 903146 NIPPLE TN51212 3 4 NYLON 3 903149 CLAMP HOSE 28 1 903150 CLAMP HOSE 16 1 903151 CLAMP H...

Page 44: ...ASS 2 903689 HI TORQUE H D MOUNT 6 903690 COVER HDPE E180 REEL 1 903693 HOSE ASSY 471TC 0606 6 6 6 x 84 1 903705 NIPPLE 2 x 6 1 903706 CAP RUBBER 2 A F TANK 1 903709 SPACER SAE4 1 2 THICK 1 903770 HOSE ASSY 451TC 3906 10 10 8 x 47 2 903777 HOSE ASSY 451TC 0606 8 8 6 x 92 1 903778 HOSE ASSY 471TC 3906 10 10 8 x 101 1 903783 RUBBER SEAL PER FOOT 4 903784 ENCLOSED ADJUSTABLE DRAW LATCH 1 903802 HOSE ...

Page 45: ... Z1022 HOSE GUIDE ARM BOTTOM SLIDE PLATE 1 Z132 PIVOT REEL BRG PLATE LOWER 1 Z133 PIVOT REEL BRG PLATE MID 1 Z135 PIVOT REEL BRG PLATE UPPR 1 Z139 HOSE GUIDE ARM SLIDING PLATE 1 Z304 GUIDE PLATE 4 Z310 STOP PLATE FOR CARRIAGE ROLLERS 3 Z702 POST WORKSTATION AND STROBE LIGHT FOR TALL REELS 1 Z710 TANK FUEL ALUMINUM 17 GAL 1 Z808A 10 GAL ANTIFREEZE CRADLE SKID UNITS 1 Z894 TANK HYDRAULIC ALUMINUM 1 ...

Page 46: ...2 2 042134 POLYPROPYLENE 1 1 4 FPTSTRAINER 1 043057 DUMP DIFFUSER 3 043140 BLACK 2 SQUARE 11GA ABS INSERT CAPS 7 043177 MALE PIPE x HOSE BARB2 x 2 NYLON ONLY 2 043201 MALE PIPExHOSE BARB1 1 4 NYLON ONLY 1 048008 ROLLER HOSE GUIDE 4 048010 SPACER HOSE GUIDE 4 055024 HOSE 1 2 ID NYLOBRAID 20 055024 HOSE 1 2 ID NYLOBRAID 30 061027 LABEL HARBEN 1 061093 VINYL CUSTOM DECAL 1 061880 PEEL AWAY SAFETY STI...

Page 47: ...ICM 6 903076 ELBOW 2 M x 2 BARB NYLON 1 903092 REDUCER 2 x 1 1 4 POLY 1 9031015 BALL VALVE 1 2 NPT F F LOW PRESSURE 600 PSI 2 WAY 1 9031029 HOSE ASSY 451TC 3906 8 8 6 X 59 2 9031041 LABEL NOTICE JETTER PERFORMANCE 4000 PSI 1 9031042 LABEL WARNING UNBLOCKING PIPES 1 9031043 LABEL WARNING NEVER PLACE YOUR HANDS NEAR LEAKS 1 9031044 LABEL WARNING ALWAYS WINTERIZE 1 9031045 LABEL SAFETY FIRST 1 903104...

Page 48: ...PTOR 2 2 9031249 HOSE ASSY 451TC 3906 6 6 4 x 22 5 2 9031250 HOSE ASSY 451TC 3906 6 6 4 x 26 1 9031287 2 X 2 ANTIFREEZE RECIRCULATION LABEL 1 9031307 LABEL CAUTION NOZZLES MAY OVER PRESSURE REV ENGINE SLOWLY 1 9031316 HOSE ASSY 471TC 3906 6 6 6 x 35 1 9031317 HOSE ASSY 471TC 3906 6 6 6 x 176 1 9031318 HOSE ASSY 451TC 3906 6 6 4 x 86 1 903134 HOLE PLUG 1 903139 U BOLT 1 1 2 PIPE 2 903149 CLAMP HOSE...

Page 49: ...H D MOUNT 2 903690 COVER HDPE E180 REEL 1 903705 NIPPLE 2 x 6 1 903706 CAP RUBBER 2 A F TANK 1 903770 HOSE ASSY 451TC 3906 10 10 8 x 47 2 903777 HOSE ASSY 451TC 0606 8 8 6 x 92 1 903783 RUBBER SEAL PER FOOT 4 903784 ENCLOSED ADJUSTABLE DRAW LATCH 1 903786 HOSE ASSY 451TC 3906 6 6 4 x 56 1 903790 HOSE ASSY 471TC 3906 10 10 8 x 80 1 903802 HOSE 1 1 4 NYLOBRAID 4 903802 HOSE 1 1 4 NYLOBRAID 4 903802 ...

Page 50: ...TE UPPR 1 Z139 HOSE GUIDE ARM SLIDING PLATE 1 Z304 GUIDE PLATE 4 Z310 STOP PLATE FOR CARRIAGE ROLLERS 3 Z702 POST WORKSTATION AND STROBE LIGHT FOR TALL REELS 1 Z710 TANK FUEL ALUMINUM 17 GAL 1 Z808A 10 GAL ANTIFREEZE CRADLE SKID UNITS 1 Z894 TANK HYDRAULIC ALUMINUM 1 Z947 A EXHAUST THRU FLOOR ASSEMBLY 1 Z950 A OPEN PLENIUM ASSEMBLY 1 Z951 TIER 4 FUEL FILTER BRACKET STAND 1 Z954A BRACKET REMOTE TEE...

Page 51: ...49 Service Documents 11 1 Service Checklist ...

Page 52: ...50 11 2 Service Logbook ...

Page 53: ...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 54: ...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 will be considered for replacement under warranty if it is subject to any of the following reasons for exclusion Used for a purpose for which it is not designed Applied to a use which has not been approved by...

Page 55: ...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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