HARBEN 4018 Operation & Maintenance Manual Download

Page: 2 / 49

Operation & Maintenance Manual for:

UNIT:

DPK Truck units – Various - 9031297

ISSUE DATE:

6/20

ISSUE No:

AMENDMENTS

Change

Changes

Date

Signature

NEW ADDITION

3/20

REMOVE E-STOP IN MANUAL. MINOR EDITS

5/20

Add Bypass Valve section. Minor Edits

6/20

Updated manual to code

6/20

All manuals and user guides at all-guides.com

Summary of Contents for 4018

Page 1: ...chnical 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 C...

Page 2: ...1297 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 m...

Page 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 S...

Page 4: ...NG 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 DIAGRA...

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 All manuals and user guides at all guides com...

Page 6: ...ous 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...

Page 7: ...e 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 o...

Page 8: ...ding 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 include...

Page 9: ...ately 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 hydrau...

Page 10: ...8 Figure 2 1 DPK 750 Manual Primary Components All manuals and user guides at all guides com...

Page 11: ...9 Figure 2 2 DPK 375 Manual Primary Components All manuals and user guides at all guides com...

Page 12: ...10 Figure 2 3 DPK 750 Remote Primary Components All manuals and user guides at all guides com...

Page 13: ...ength 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 lubricatio...

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...

Page 15: ...ulent 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 jetti...

Page 16: ...ting 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 vehic...

Page 17: ...ch 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...

Page 18: ...plash 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 All manuals...

Page 19: ...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 Al...

Page 20: ...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 saf...

Page 21: ...n 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 bu...

Page 22: ...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 Ju...

Page 23: ...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 th...

Page 24: ...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...

Page 25: ...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 isolati...

Page 26: ...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 DU...

Page 27: ...ve 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...

Page 28: ...hassis 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...

Page 29: ...k 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...

Page 30: ...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...

Page 31: ...s 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 b...

Page 32: ...rleaf 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 pres...

Page 33: ...e 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...

Page 34: ...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...

Page 35: ...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 thro...

Page 36: ...t 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 Wa...

Page 37: ...35 Harben Pump Refer to the P Type Service Manual Part No 061 352 included with your truck package All manuals and user guides at all guides com...

Page 38: ...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 All manuals and user guides...

Page 39: ...37 8 3 Electrical Diagrams 8 3 1 Manual Wiring Diagram All manuals and user guides at all guides com...

Page 40: ...38 8 3 2 Radio Wiring Diagram All manuals and user guides at all guides com...

Page 41: ...39 Engine A copy of the Engine Manufacturer s Operators Handbook is supplied with this equipment All manuals and user guides at all guides com...

Page 42: ...entify 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...

Page 43: ...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 9051...

Page 44: ...42 Service Documents 11 1 Service Checklist All manuals and user guides at all guides com...

Page 45: ...43 11 2 Service Logbook All manuals and user guides at all guides com...

Page 46: ...e 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 f...

Page 47: ...place 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...

Page 48: ...gligence 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 an...

Page 49: ...47 This page is left blank on purpose All manuals and user guides at all guides com...

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