HARBEN 4018 US Van Pack Operation & Maintenance Manual Download Page 1

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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

Unit 4018 US Van Pack

903-1314

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 US Van Pack

Page 1: ...cope 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 equi...

Page 2: ... 6 20 ISSUE No 6 AMENDMENTS Change Changes Date Signature 1 NEW ADDITION 09 19 JJ 2 UPDATE WARRANTY POLICY 10 19 JJ 3 Minor Changes Added part number 5 20 GT 4 Added multiple sections Minor changes 6 20 GT 5 Added Pictures to Anti Freeze Section 6 20 GT 6 Updated manual to code 6 20 GT ...

Page 3: ...A 11 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 LA...

Page 4: ...4 BURST 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 VANPACK 36 8 2 HYDRAULIC CIRCUIT FOR VANPACK 36 ENGINE 37 PARTS LIST SPARES 38 10 1 INTRODUCTION 38 10 2 ORDERING SPARE PARTS 38 10 3 ROUTING MAINTENANCE CONSUMABLE ITEMS 38 10 4 CONSUMABLE COMPONE...

Page 5: ...4 12 1 WARRANTY OF NEW PRODUCTS 45 12 2 WARRANTY OF MAJOR COMPONENTS 45 12 3 LIMITATIONS OF WARRANTY 47 ...

Page 6: ...l 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 familiarize yourself with the workings of the machine to rapidly switch it off and el...

Page 7: ... to read the information provided in this operation and maintenance manual so that you understand how to make the most of the vanpack in accordance with the instructions Harben vanpacks 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 vanpacks described in this operation and maintenan...

Page 8: ...mp and vanpack 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 vanpack Section 9 Diesel Engine This section provides part details of the diesel engine Section 10 Parts list Spares Auxilia...

Page 9: ...o 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 The engine an...

Page 10: ...9 Fig 2 1 4018 US Van Pack Remote ...

Page 11: ...10 Fig 2 2 4018 US Van Pack Manual ...

Page 12: ... 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 13: ...al capacity 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 greater than 16 USG ...

Page 14: ... settled and non turbulent discharging a smooth uninterrupted supply with a positive head of pressure to the inlet maximizing 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 con...

Page 15: ...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 to water supply The water will fill the tank via the inlet hose reel when the tank is full it will flow out the overflow NOTICE To comply with water authority bylaws never fill the tank by putting a hose directly i...

Page 16: ...nction 4 4 1 Control 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 Control panel fuse Power on keyswitch Enter button ...

Page 17: ...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 18: ...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 19: ...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 speed and pressure can now be i...

Page 20: ...d and decreased using speed up and speed down button 14 Manual mode will not operate when radio mode is selected 4 7 Running the Vanpack 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 diverting t...

Page 21: ...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 22: ... 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 23: ...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 24: ... following precautions to avoid frost damage 4 11 1 To Anti Freeze the Machine with an Anti Freeze 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 Anti Freeze Valve Tank Isolation Valve Drain V...

Page 25: ...e 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 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 M...

Page 26: ...EEZE SOLUTION INTO A CONTAINER NOTICE If the pump is frozen up it should on no account be started Operating the machine frozen will damage the pump and damages caused by misuse will not be covered under warranty NOTICE When the engine starts the pump will be pumping fluid and may be under pressure ...

Page 27: ...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 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 structura...

Page 28: ...mpleted daily with the vanpack 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 29: ...not attempt to repair or secure any hose while the high pressure pump is running H S Sections 3 and 6 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 150 AGIP OSO 105 SHELL Tellus Morlina 150 CENTURY OIL PWLM PETROFINA Hydra...

Page 30: ...ilable burst discs are as follows Color 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 31: ... 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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...35 Pump Refer to the P Type Service Manual Part No 061 352 included with your vanpack ...

Page 37: ...36 Circuit Diagrams For wiring diagrams relating to the engine refer to your engine handbook supplied with your vanpack 8 1 Water Circuit for VANPACK 8 2 Hydraulic Circuit for VANPACK ...

Page 38: ...37 Engine A copy of the Engine Manufacturer s Operators Handbook is supplied with this equipment ...

Page 39: ...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 40: ... SPOOL HYD FLOW CONTROL CV1185 SEE NOTES 1 020143 GEARBOX HARBEN 2 0 1 SAE5 FLANGE TIER 4 FINAL 1 021020 BELL HOUSING LISTER 1 023004 NUT NYLOC M6 4 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 032459 SPACER SHAFT HYDRAULIC H REEL MINI VANPACK 1 033010 SEAL DOWTY 1 2 7 033013 SEAL DOWTY 3 8 8 041...

Page 41: ...227 ADAPTOR 3 8 BSPM x 9 16JICM 2 900231 LOCK RING 1 1 4 1 900247 INSERT FOR HOSE 7 8 14JIC F SWVL x 1 2 OD 90DEG 2 900256 ADAPTOR 1 4 M X 1 2 M 1 900281 ADAPTOR 1 2 NPTM x 8JICM 2 900294 TEE 1 2 NPT FEMALE 2 900303 LOCK WASHER M12 PACK 100 TAX EXEMPT 2 900307 ADAPTOR 1 2 NPTM x 6JICM 1 900317 ADAPTOR 1 2 NPT MALE x 10 SAE MALE 1 900319 BUSHING 1 2 NPT FEMALE x 3 4 NPT MALE 1 900322 BALL VALVE 1 1...

Page 42: ...T HOSE 2 9031195 SAFETY LABEL SET RED WHITE SQUARE DIESEL UNITS 1 9031202 BATTERY CABLE E180 POSITIVE 24 IN 1 9031203 BATTERY CABLE E180 NEGATIVE 24 IN 1 9031204 FUEL TANK US VAN PACK 1 9031205 HYDRAULIC TANK US VAN PACK 1 9031207 100 GAL WATER TANK US VAN PACK 1 9031214 ML2000 R2 MURPHY FRONT METAL ENCLOSURE KIT 1 9031215 EXTENSION HARNESS MURPHY ML2000 KUBOTA D1803TI US VAN PACK REMOTE EPS9197X2...

Page 43: ...3738 E STOP TWIST TO RELEASE including NC ACTUATOR 78 3724 78 3732 1 903786 HOSE ASSY 451TC 3906 6 6 4 x 56 1 903787 HOSE ASSY 451TC 3906 6 6 4 x 60 1 903809 HOSE 2 CLEAR 1 903858 HOSE ASSY 451TC 0606 10 10 8 x 48 1 903915 HYDRAULIC MOTOR FOR ELILMINATOR 1 904052 JUMP JET TEE ASSEMBLY 1 904060 Frame US Vanpack 1 A180430 ROD STRAP RETAINER WATER TANK 4 A190821 STRAP ASSEMBLY RATCHET TYPE 25MM WIDE ...

Page 44: ...43 Service Documents 11 1 Service Checklist ...

Page 45: ...44 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: ...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 48: ...ury 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 goodwil...

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