HARBEN 903-1315 Operation & Maintenance Manual Download Page 8

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1.5. Composition of this Manual

This manual comprises the following further sections:

Section 2

Scope of Supply

This section defines the scope of supply of the equipment in compliance with the sales order.

Section 3

Technical Data

This section contains technical information about the unit.

Section 4

Operation

This section describes the recommended operating procedures 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

This section provides details of the pump and gearbox assembly.

Section 8

Engine

This section provides details about the engine.

Section 9

Circuit and Wiring Diagrams

This section includes the Hydraulic, Water and Electrical circuits including engine controller &

wiring loom.

Section 10

Parts List / Spares

How to identify and order spares

Section 11

Service Documents

Service logbook and checklist.

Section 12

Warranty & Certification

Section 13

Health & Safety Manual 903-1308

This manual details health and safety considerations in general and specific to water jetting

equipment.

Summary of Contents for 903-1315

Page 1: ...ck 903 1315 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 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 Section 13 Health Safety Manual 903 1308 Read the Health a...

Page 2: ...ance Manual for UNIT Eliminator Van Pack R 1 B11238 A ISSUE DATE 6 20 ISSUE No 3 AMENDMENTS Change Changes Date Signature 1 NEW ADDITION 5 20 GT 2 Added Anti Freeze System Pictures 6 20 GT 3 Updated manual to code 6 20 GT ...

Page 3: ...UIRED 14 3 2 TECHNICAL DESCRIPTION 15 3 2 1 PRIMARY COMPONENTS 15 3 2 2 ENGINE MONITORING 15 3 2 3 DELIVERY HOSE REEL 15 4 OPERATION 17 4 1 OPERATING CONDITIONS 17 4 2 DAILY CHECKS 17 4 3 PRE START CHECKS BLEED PROCEDURE 18 4 4 STARTING THE ENGINE SETTING THE OPERATING PRESSURE 19 4 5 PRE START CHECKS PROCEDURES 20 4 5 1 STARTING THE ENGINE 20 4 5 2 CHECKING THE OPERATING PRESSURE WITH A NOZZLE FI...

Page 4: ... WIRING DIAGRAMS 38 10 PARTS LISTS SPARES 42 10 1 INTRODUCTION 42 10 2 ORDERING SPARE PARTS 42 10 3 ACCESSORIES CONSUMABLES 43 10 3 1 ROUTINE MAINTENANCE 43 10 3 2 CONSUMABLES 43 10 3 3 ACCESSORIES 43 10 4 PARTS LIST 45 10 5 HYDRAULIC DIVERTOR VALVE ASSEMBLY 51 10 5 1 RECOMMENDED TOOLS 51 10 5 2 SERVICE KITS 51 10 6 TO DISMANTLE 52 10 7 TO ASSEMBLE 52 11 SERVICE DOCUMENTS 57 11 1 SERVICE CHECKLIST...

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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 elim...

Page 7: ...ghest standards so that they will work safely and reliably for many years It is important that you take time 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 ...

Page 8: ...he pump and unit Section 6 Fault Finding Fault diagnosis tables for the pump engine and ancillaries Section 7 Pump This section provides details of the pump and gearbox assembly Section 8 Engine This section provides details about the engine Section 9 Circuit and Wiring Diagrams This section includes the Hydraulic Water and Electrical circuits including engine controller wiring loom Section 10 Par...

Page 9: ...proximately 177 microns Pump is specified at 200microns The Speck high pressure plunger pump is driven by a Kubota D1105 E4B EU X1 18 5kW Stage 5 C TXT industrial diesel engine through a Speck NP25 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 back to tank The system is protected fr...

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

Page 11: ...11 NP25 Gearbox Detail 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: ...24 USG Recommended crankcase oil ISO VG 220 or SAE 90 Gear oil Valves Identical suction discharge NPSH Input 10 bar max Suction head 0 3 bar 3 1 2 Main Components Prime Mover Kubota D1105 E4B EU X1 18 5kW Stage 5 C TXT Drive Gearbox Speck NP25 Reduction box 2 176 1 3 1 3 Ancillaries Water Tank Capacity 88 gals 400 litres Supply Water Filter N05105 Hypro line strainer 177 micro mesh Pressure Gauge ...

Page 15: ...pump to run unevenly and cause excessive wear due to cavitation Water is diverted to the hose reel either using a 12VDC hydraulic diverter 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 cleaned daily if it bec...

Page 16: ... mounting theoretical discharge volume 3000rpm 3 gpm max speed 3200rpm max 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 17: ...ode of Practice is available upon request Please ensure that you read this Operation Maintenance Manual in conjunction with the Health Safety Manual before operation 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 leve...

Page 18: ...he 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 inside 6 Feed the end of the high pressure hose through the hose trace on the swinging arm in front of the hose reel Do not fit the nozzle or gun at this point H S Section 3 6 and 16 7 In order to avoid an interruption to the jetting operation please ensure that...

Page 19: ...ith the remote enabled all initial pressure checks must be made Either With a single operator and radio control unit RCU adjacent to the pump set and with the nozzle secure in a drain or pipe or the gun firmly held in the hand Or With two people one at the pump set and one in charge of the nozzle or gun Once the required operating pressure has been set remote operation can be safely conducted by o...

Page 20: ...ght 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 4 Momentarily press the Green button on the Controller this will automatically run through pre heat and prestart When cold Engine will start automatically and idle at a pre determ...

Page 21: ... the nozzle is secured in a safe position preferably within sight of the operator at the control panel 3 Press the water ON button at the control panel Select the required speed 4 Observe the pressure displayed on the control panel screen and note the pressure reading See Fig 3 Press the water off button and select idle Note If the pressure is significantly lower than expected turn the unit off an...

Page 22: ...tton to raise the engine speed 5 Pull the gun trigger and observe the pressure gauge mounted on the instrument panel note the pressure reading See Fig 3 Press the button 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 wi...

Page 23: ...utton this is indicated by the symbol of a hare See Fig 5 5 To decrease engine speed press the red engine speed down button this is indicated by the symbol of a tortoise See Fig 5 6 Press button 1 the water ON button to divert the water to the nozzle or gun See Fig 5 7 Press button 1 again this will now divert the water back to tank See Fig 5 8 To stop the engine reduce the Engine rpm press button...

Page 24: ...t Up No Lights RCU off Charging See handbook for charging instructions Turning the unit ON Pull out the red button at the base of the RCU Press both buttons 5 6 together and hold for at least 3 seconds 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 ...

Page 25: ...only drawing off the required length of hose to reach the work site and then to wind the hose back in using the hydraulic motor It should be remembered that the hose cannot be wound using the hydraulic motor unless the engine is running Therefore when a jetting operation 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...

Page 26: ... Start the engine and immediately press the water on button Water will exit the hose instantly the level on the antifreeze will begin to decrease rapidly When the water runs blue insert the end of the hose into the Antifreeze tank 7 Allow the antifreeze to circulate for a minimum of 30 seconds 8 Operate the jump jet kit for a few seconds to antifreeze the jump jet circuit 9 Quickly fully unwind th...

Page 27: ...hine DO NOT ATTEMPT TO JET ANY REMAINING ANTIFREEZE 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 ...

Page 28: ...an 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 Harben Closely inspect the structural integrity of the framework for signs of stress and cracking Specifically welded joints Che...

Page 29: ...side of the gearbox as the level indicator Manufacturer Type Oil Capacity litres Output shaft Above Input Input shaft Above Output ESSO Nuto H15 0 65 0 50 GULF MOBIL DTE 11 ROC TEXACO BP Energol SHF LT15 AGIP SHELL Tellus T15 CENTURY OIL Nevis No5 PETROFINA CASTROL Hyspin AWH 15 ...

Page 30: ...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 31: ...y with the unit switched OFF H S Section 11 1 Check condition of inlet water filter element Clean or replace Harben part no N05105 Unscrew the bowl to remove the mesh Harben part no N06021 Take precautions so as not to lose the sealing ring Harben part no N05108 ...

Page 32: ...igh pressure jetting from a damaged hose or hose connector can cause serious injury Do not attempt to repair or secure any hose while the high pressure pump is running H S Sections 3 and 6 With the machine running 4 Make further inspection for leaks If a leak is observed shut down immediately and report the leak to a supervisor or manager ...

Page 33: ...s 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 switch if faulty Check the water temp in the radiator if the temp is abnormally hot Refer to t...

Page 34: ...tion 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 35: ...e Worn pressure packings Replace spring Renew O rings Renew packings Excessive water leakage from pump Worn pressure packings Scored plungers Renew packings Replace plungers Water in crankcase Filler breather cap missing High humidity Replace cap Replace oil and reduce oil change interval Noisy operation Worn bearings Overhaul or replace pump Oil Leaks Worn pressure packings Worn oil seals Renew p...

Page 36: ...36 7 Pump Harben offer a detailed manual with the Speck NP25 54 200 Pump and this will be accompanied by this manual ...

Page 37: ...this manual Basic engine noise levels Engine RPM 1500 2000 3000 AT 1 METER FULL LOAD db A 84 87 94 AT 7 METER FULL LOAD db A 67 77 Replacement filters may be obtained from Harben Harben 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 38: ...38 9 Circuit and Wiring Diagrams ...

Page 39: ...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 42: ...vice kits you require you should 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 Harben Inc 2010 Ronald Reagan Blvd Cumming GA 30041 Tel 770 889 9535 Fax 770 887 9411 email sales harben com www harben com ...

Page 43: ...e 031 040 GUN MARK 2 SAFETY 6000 PSI OPTIONAL Jet Inserts 056 026 JET HIGH VELOCITY 2 1MM 056 180 JET FAN 15 DEGREE 15125 1 4 NPT S S General Accessories 056 097 JET DRAIN 1 2 BSP 3 x 1 0MM 30 DEGREES 056 413 JET DRAIN 1 2 BSP 3Rx1FWD DIAMETER 1 0 at 30 DEG 056 584 JET DRAIN 1 2 BSPM 6R X 0 8MM 30DEG HARBEN 013 290 PRESSURE GAUGE 10 000 PSI 055 093 HOSE ASSY LEADER 1 2 BSPM 1 2 BSPF 3 05M SAE100R8...

Page 44: ... Receiver 1 RSP 20 071 1242 Pressure Transmitter Transducer 1 RSP 21 071 1392 Magnetic Pick up 1 RSP 22 071 1408 Rocker Switch On Off Switch 1 RSP 23 071 272 Heavy Duty Battery 1 RSP 24 071 367 E Stop Twist to Release 1 RSP 25 071 786 Relay 12v 120amp 1 RSP 26 071 886 Float Switch Horizontal 1 2 NPT 1 RSP 27 071 901 Electrical Piston 1 RSP 28 071 902 Electrical Control Unit 1 RSP 29 078 393 Cable ...

Page 45: ...OPRENE RUBBER 14mm O D 6 35mm I D 3mm THK 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 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 BSP 400 830 4490 41 780 BAR SELF CENTRALISI...

Page 46: ...IV 2B 20 210 BAR 1 023932 ELBOW 3 8 BSPT 3 8 BSP M M FORGED 420BAR W P 1 023978 INSERT FOR HOSE 1 1 4 BSP FEM 90 DEG SWIV MS A50051 20 20 1 031340 TEE 3 8 BSP MALE FEMALE RUN MALE BRANCH ZINC 1 032459 SPACER SHAFT HYDRAULIC H REEL MINI VANPACK 1 033005 ADAPTOR 3 8 BSP M x 3 8 BSP M 415 BAR 2 033006 ADAPTOR 1 2 BSP M x 3 8 BSP M 415 BAR ZN 5 033010 SEAL BONDED 1 2 BSP 400 825 4490 41 448 BAR SELF C...

Page 47: ...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 1 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 ADAPTOR FLANGED 1 1 4 BSPM X 1 1 4 BSPM UPVC 1 044543 FRAME 320 SERIES MK1 VANPACK 1 047004 STEM ...

Page 48: ...HOSE Autosiliconehoses com 1 0551802 1 BLUE HOSE Autosiliconehoses com 1 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 0...

Page 49: ...ICAL UNIT CONTROL TYPE S FCESY7V12 1 073069 HEAT SHRINKABLE SLEEVING 9 5MM BORE RS398 177 0 2 0781010 MODIFICATION TO FLUID HEAD NP25 SPECK FOR JUMP JET 54 200 1 0781075 CABLE END MODIFIED TO SUIT YANMAR 1 0781130 DRIVE SHAFT 1 1 8 KEYED FOR KUBOTA 1105D 315 SERIES MK3 1 078393 CABLE GRIP HOLDER TO CLEVIS THROTTLE 1 078417 EXTENDED HEX NUT M8 1 079260 EXHAUST OUTLET FLANGED U BEND KUBOTA D1105 1 0...

Page 50: ...OCK HOUSING 1 C W GREASE NIPPLE POWDER COAT 1 N01799 BEARING NEEDLE BUSH 1 N01965 1 4 BSPF S STEEL CHECK VALVE C25P 9K 1 N02230 ADAPTOR 1 2 BSPM X 1 8 BSPM ZN 1 N05085 HANDLE GRIP PLASTIC 1 N05105 LINE STRAINER 1 1 4 HYPRO 1 N05114 SIGHT GLASS 10 2 N05116 SIGHT LEVEL 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 N100...

Page 51: ...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 CENTER 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 52: ...de of inner seal is visible when fitted DRG 035 255 4 Fit center 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 step seals facing end collar gently push lightly oil spindle 12 right the way through internal bore of stack until spindle 12 stops up against face of gland 11 DRG 035 255 6 Fit...

Page 53: ... METRIC X 18 ANDERTON 1 015062 GLYD RING SEAL SHAMBAN S 50992 5907 010 2 015063 STEPSEAL SHAMBAN S 55015 0100 80 2 032472 CHOKE MKII SOLINOID VALVE 1 033263 SPRING MOUNT BODY ASSY CENTURY GUN 1 033264 SCRAPER BODY ASSY CENTURY GUN 1 033268 CAP BODY CENTURY GUN 1 033293 CENTER COLLAR BODY ASSY CENTURY GUN MODIFIED 1 033294 END COLLAR BODY ASSY CENTURY GUN MODIFIED 2 033295 GLAND BODY ASSY CENTURY G...

Page 54: ...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...

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Page 57: ...57 11 Service Documents 11 1 Service Checklist ...

Page 58: ...58 11 2 Service Logbook ...

Page 59: ...haser and 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 Speck Pump The warranty for the Speck pump when fitted to a trailer truck or van pack unit manufactured by us and when...

Page 60: ...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 will ...

Page 61: ...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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