Table of Contents
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Operation & Maintenance Manual
Original Instructions
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
Section 12
Section 13
Toll Free: (800)-327-5387
Unit 4018 US Van Pack
903-1314
Introduction
Scope of Supply
Technical Data
Operation
Routine Maintenance
Fault Finding
Harben P-Type Pump
Circuit Diagrams
Engine
Parts List / Spares / Auxiliary Components
Service Documents
Warranty & Certification
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.
Harben Inc.
P.O. Box 2250, Cumming, GA 30028
Tel: (770)-889-9535
email: sales@harben.com
Fax: (770)-887-9411
web: www.harben.com
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Table of Contents
Summary of Contents for HARBEN 4018 US Van Pack
- Page 1 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...
- Page 2 Operation & Maintenance Manual for: UNIT: Unit 4018 US Van Pack – R/1 (B11238/A) ISSUE DATE: 6/20 ISSUE No: AMENDMENTS Change Changes Date Signature NEW ADDITION 09/19 UPDATE WARRANTY POLICY 10/19 Minor Changes. Added part number 5/20 Added multiple sections. Minor changes...
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Page 3: Table Of Contents
Section 1 – Introduction & Contents Contents 1.1. SECTION 1 – INTRODUCTION & CONTENTS ..............2 1.1. C ........................2 ONTENTS 1.2. I ......................5 NTRODUCTION 1.3. S ....................6 COPE OF THIS ANUAL 1.4. T .......................6 ANPACK 1.5. C ..................7 OMPOSITION OF THIS ANUAL SCOPE OF SUPPLY ......................8 2.1. - Page 4 4.9. B ..................21 YPASS ALVE PERATION 4.10. H ............... 22 INDING AND NWINDING 4.11. F ....................23 ROST RECAUTIONS 4.11.1. T ........23 REEZE THE ACHINE WITH AN REEZE 4.11.2. T ................24 NTIFREEZE THE ACHINE ROUTINE MAINTENANCE ................... 26 5.1.
- Page 5 12.1. W : ................45 ARRANTY OF RODUCTS 12.2. W : ............... 45 ARRANTY OF AJOR OMPONENTS 12.3. L :..................47 IMITATIONS OF ARRANTY...
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Page 6: Ntroduction
1.2. Introduction Read this manual along with the Health and Safety Manual before you operate or carry out any maintenance on the high-pressure vanpack. Within this manual, the health and safety risks are highlighted with specific symbols. These will be referenced to sections within the Health and Safety Manual which you are required to read. -
Page 7: Scope Of This Manual
1.4. The Vanpack Harben® drain vanpacks have been designed to the highest 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. -
Page 8: Composition Of This Manual
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. -
Page 9: Scope Of Supply
Scope of Supply 2.1. Scope of Supply Unit: U.S. Vanpack 2.2. Pump Assembly Figures 2.1-2.2 defines the components of the vanpack assembly as follows: The pump is driven by an industrial diesel engine. The engine drives the pump via a 2.21:1 reduction gearbox which reduces the pump rpm down to the correct shaft speed. -
Page 12: Technical Data
Technical Data 3.1. Technical Data 3.1.1. Pump Data Pump Type Harben ‘P’ Type 8 22 (See Section 8) Pump diameter 16” approx. Pump length 15” approx. Inlet 1 ¼” dia. Outlet G1/2” (1/2” BSP) Shaft dia 30 mm Shaft length... -
Page 13: Main Components
3.1.2. Main Components Engine ENGINE KUBOTA D1803TI TIER 4 FINAL OPEN Pump 020041AAB Harben P Type 8 22 Gearbox 020143 Harben P Type 2:1 _________________________________________________________________________ 3.1.3. Ancillaries Water tank 100 gal capacity Supply filter 042134 Hypro line strainer / 170 micron mesh Monitoring &... -
Page 14: Technical Description
3.2.1. Primary Components The primary components of the vanpack are illustrated in Figures 2.1-2.2 which are as follows: A prime mover in the form of an industrial diesel engine which drives a Harben P Type high-pressure pump. The pump can produce high-pressure water up to 4000 psi. -
Page 15: Operation
Operation 4.1. Operating Conditions Operators of water jetting equipment should be fully conversant with the 'Industry Best Practices for The Use of High-Pressure Water Jetting Equipment’, hereafter referred to as 'The Code of Practice'. A copy of The Code of Practice is available upon request. Please ensure that you read this Operation &... -
Page 16: Control Panel Layout And Function
4.4. Control panel layout and function 4.4.1. Control keys Speed up Operating screen Menu password Radio on/off access screen Menu up key Menu down key Engine start Engine stop Water on Enter button Speed down Menu exit 4.4.2. Toggle switch operation Power on keyswitch Control panel fuse... -
Page 17: Screen Layouts
4.4.3. Screen layouts Starting splash screen Software version Password screen Run screen entry – 2010 Minor programme updates - 1111 Password screen – Use enter, up and down buttons to enter password Manual Confirmation Screen... - Page 18 Main run screen (access by pressing menu exit key) Harben contact number Unit pressure Water on Engine speed indication Remote enable/control screen (Enter button will toggle between function) Run detail screen (access via the up and down keys)
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Page 19: Radio Control Layout
4.4.4. Radio control layout Radio control screen Engine start/stop Water on/off Speed/pressure up Speed/pressure down Button 5 – menu scroll Button 6 – menu scroll 4.5. Running the Engine (Manual Mode) With two people, one at the pump set and one in charge of the nozzle or gun. (H&S Sections 3, 4, 8, 9, 11, 15, and 16) If your machine is fitted with a radio remote control go to section 4.6. -
Page 20: Running The Engine (Radio Mode)
4.6. Running the Engine (Radio Mode) 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. Press the radio screen button. 6. -
Page 21: Harben ® Jump Jet
® Jump Jet The Harben Jump Jet system is a unique and exceptionally effective addition to the Harben 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. -
Page 22: Bypass Valve Operation
In normal operations, the valve will be shut by being turned clockwise until it seats. This will give the operator full pressure and flow. For example, on a Harben Jetter that is a 4018 model with ½” X 500’ of jetting hose, this will allow you to achieve a performance of 4,000 PSI and up to 18 GPM. -
Page 23: Hose Reel Winding And Unwinding
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 free using the Harben® Jump Jet™ kit or alternatively they should be pulled free by hand. -
Page 24: Frost Precautions
4.11. Frost Precautions During cold periods there is a risk of freezing overnight or when travelling on the road. Damage caused by freezing is expensive to repair and IS NOT COVERED UNDER WARRANTY. (H&S Section 7) Take the following precautions to avoid frost damage: Tank Isolation Drain Valve Anti-Freeze... -
Page 25: To De-Antifreeze The Machine
Open the antifreeze tank valve. This tank must be full of an antifreeze mixture with strength of no less than a 50/50 mix. Remove the gun or any jetting nozzle from end of the hose and unreel 10 feet of hose. Ensure the unit starts in dump (radio –... - Page 26 12. The machine can now be used in the normal manner. 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.
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Page 27: Routine Maintenance
Check engine fuel water trap for contamination (Ref section 9) 3 months / 50 hours First service contact Harben Inc. 6 months / 150 Inspect tanks and fittings for leaks, thoroughly clean & hours flush through (with hot water more than 158°F) ... -
Page 28: Daily Maintenance (H&S Section 11)
5.2. Daily Maintenance (H&S Section 11) The following must be completed 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... -
Page 29: Pump Lubricating Chart
2. Visually inspect all hoses for signs of chaffing or leaks. Report any damage immediately to supervisor or manager. Water at high-pressure jetting from a damaged hose or hose connector WARNING! can cause serious injury. Do not attempt to repair or secure any hose while the high- pressure pump is running. -
Page 30: Burst Discs
5.4. Burst Discs When carrying out any maintenance/overhaul of the pump, always ensure the correct burst disc for its working pressure is fitted. (H&S Section 5) The available burst discs are as follows: Color Code Part Number For Maximum Working Pressure Yellow 011019... -
Page 31: Fault Finding
Fault Finding Most of the problems experienced during jetting operations are likely to be caused by the pump or the associated hoses. These types of problems are covered in the pump fault finding chart, which is repeated at 6.3 overleaf for convenience. Also covered at 6.3 overleaf is a diagnosis of selector valve problems 6.1. -
Page 32: Fault Finding - Hydraulic
6.2. Fault Finding - Hydraulic Recommended Problem Possible Cause Action Low system Worn or incorrect size of Replace the old jetting pressure cutting nozzle Nozzle with a new one Engine speed slow Adjust to correct speed ... -
Page 33: Pump Fault Finding
6.3. Pump Fault Finding Recommended Problem Possible Cause Action Mixing of oil and Worn or damaged Check all delivery water in delivery valves. valves – replace as crankcase necessary Damaged filter element Loss of pressure allowing debris to jam Check all diaphragms delivery valve... - Page 34 Distinguishing features of failure on diaphragm 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...
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Page 35: Selector Fault Finding
6.4. Selector Fault Finding Selector problem Cause Action Loss of pressure and flow is Water leaking through the Replace the seats and the down worn seat back to tank plug if also damaged If water leaks along spindle O-ring and back up ring Replace O-ring and back up and past lever failure along shaft... -
Page 36: Pump
Pump Refer to the P Type Service Manual Part No. 061-352 included with your vanpack. -
Page 37: Circuit Diagrams
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: Engine
Engine A copy of the Engine Manufacturer’s Operators Handbook is supplied with this equipment... -
Page 39: Parts List / Spares
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... -
Page 40: Parts List
O RING 02-135 016398 COUPLING KUBOTA TIER 4 FINAL 018005 VALVE SPOOL HYD FLOW CONTROL CV1185 (SEE NOTES) 020143 GEARBOX HARBEN 2.0:1 SAE5 FLANGE (TIER 4 FINAL) 021020 BELL HOUSING LISTER 023004 NUT NYLOC M6 023088 PART 1 NEUPEX B140 PERQUOTE 144.704.068/REV B / Gearbox Coupling (FEMALE) - Page 41 KIT HYDRAULIC DIVERT VALVE INSTALLATION - 078321 PIN RESTRICTING SWING ARM H/REEL VANPACK 078857 HOSE REEL SHAFT TO SUIT 048117& 048112 085399 ANTI FREEZE TANK HARBEN VANPACK MK2 104482 WATER TRAY HOSE REEL KUBOTA VANPACK 900144 10GTX-S 900145 ELBOW 1/2"Fx7/8"JICM 900151 REDUCER 1/2"Mx1/4"F...
- Page 42 9031045 LABEL 'SAFETY FIRST' 9031046 LABEL 'CAUTION - HOT SURFACE' 9031047 LABEL 'NEVER ALLOW ANTIFREEEZE' 9031048 LABEL 'WARNING - DO NOT OPERATE WITH CANOPY OPEN' 9031049 LABEL 'DANGER - WATER JETS CAN CAUSE FATAL INJURIES' 9031050 LABEL 'WARNING - JETTER HOSES' 9031051 LABEL 'WARNING - PPE' 9031052...
- Page 43 903190 R8NC08-HY0808MP-08BPF-10 10 LEADER HOSE 903197 BARBED FITTING 1/2" HOSE x 1/2 FEMALE PIPE 903208 FILTER HEAD & ELEMENT 903224 BULKHEAD 1 1/4" TxT 903225 1 1/4 SCH 80PVC NIPPLE 2 INCH 903238 VALVE BALL 1 1/4" 903239 2" TIGERTAIL WITH RING & ROPE 903313 HOSE ASSY JUMP JET TEE 903358...
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Page 44: Service Documents
Service Documents 11.1. Service Checklist... -
Page 45: Service Logbook
11.2. Service Logbook... -
Page 46: Warranty
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 and when used only in the sewer and drain cleaning industry is five years or 2000 hours, whichever occurs soonest, from the date of shipping from our factory. - Page 47 Applied to a use which has not been approved by Harben Inc; or Subject to misuse, negligence, lack of maintenance or accident; or Repaired or altered in any way so as, in the judgement of Harben Inc, to adversely affect its performance and reliability; or Normal wear and tear...
- Page 48 12.3. Limitations of Warranty: The new product and spare parts warranty is limited to defects in material or workmanship of the product. It does not cover loss of time, inconvenience, property damage or any consequential damages. Repair or replacement of the product is your exclusive remedy. Our liability under this clause shall be in lieu and to this exclusion of any warranty or conditions implied or expressed by law as to the quality or fitness for purpose of any goods supplied hereunder PROVIDED THAT nothing in this clause shall operate so as to exclude liability for...