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HARBEN Eliminator VanPack Operation & Maintenance Manual

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Operation & Maintenance Manual
Original Instructions
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
Toll Free: (800)-327-5387
_________________________________________________________________________________________
Eliminator Van Pack
903-1315
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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Summary of Contents for HARBEN Eliminator VanPack

  • Page 1 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 Toll Free: (800)-327-5387 Tel: (770)-889-9535 Fax: (770)-887-9411 email: sales@harben.com...
  • Page 2 Operation & Maintenance Manual for: UNIT: Eliminator Van Pack (B11238/A) ISSUE DATE: 6/20 ISSUE No: AMENDMENTS Change Changes Date Signature NEW ADDITION 5/20 Added Anti-Freeze System Pictures 6/20 Updated manual to code 6/20...

  • Page 3: Table Of Contents

    1. Introduction 1.1. Contents 1. INTRODUCTION ......................3 1.1. C ........................3 ONTENTS 1.2. I ......................6 NTRODUCTION 1.3. S ....................7 COPE OF THIS ANUAL 1.4. T ................... 7 LIMINATOR ANPACK 1.5. C ..................8 OMPOSITION OF THIS ANUAL 2.
  • Page 4 4.9. H .................25 INDING AND NWINDING 4.10. F ....................26 ROST RECAUTIONS 5. ROUTINE MAINTENANCE ...................28 5.1. M ..................28 AINTENANCE ROCEDURES 5.2. G – S NP25 ............29 EARBOX UBRICATING HART PECK 5.3. G ..................30 ENERAL ORQUE ETTINGS 5.4. D ....................31 AILY AINTENANCE 6.

  • Page 6: Introduction

    1.2. Introduction Please ensure that you read this Operation & Maintenance Manual in conjunction with the Health & Safety Manual before operation. 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 Eliminator 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

    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.

  • Page 9: Scope Of Supply

    2. Scope of Supply 2.1. Scope of Supply Unit: ELIMINATOR VANPACK 2.2. Vanpack Assembly The General Arrangement drawing: 003-295, defines the components of the Eliminator Vanpack mounted Pump Assembly as follows: Water is fed from a “mains” supply through a manual low-pressure inlet hose reel into a plastic water storage tank.

  • Page 10: Detailed Drawings

    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 NP25 Gearbox Detail Hydraulic Diverter Valve 069-581...
  • Page 12 Hawk Safety Relief Valve 035-401...
  • Page 13 Speck Unloader Valve UL221 035-185...

  • Page 14: Technical Data

    3. Technical Data 3.1. Technical Data 3.1.1. Pump Data PUMP TYPE Speck NP25/54-200 [positive displacement] Number of cylinders Power rating (nominal) 22.5 hp Plunger diameter 25mm Crankshaft speed 1450rpm Maximum pressure Normal operating pressure 200 bar [2900psi] Flow rate Up to 54 L/min Crankcase lubrication Splash / Gravity Crankcase oil capacity...

  • Page 15: Technical Description

    3.2. Technical Description 3.2.1. Primary Components The primary components of the Eliminator Vanpack are as follows:  A prime mover in the form of a Kubota 3-cylinder water-cooled diesel engine which drives a Speck NP25 type high-pressure pump.  The pump can raise the water pressure up to 2900psi (200 bar).
  • Page 16 Note: 050-324 Hydraulic gear pump detail: - (Ratio 0.844/1.00, Output 4.35 cc/rev, direct 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: Operation

    4. Operation 4.1. Operating Conditions Operators of water jetting equipment should be fully conversant with the Water Jetting Association ‘Code of Practice 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.

  • Page 18: Pre-Start Checks & Bleed Procedure

    4.3. Pre-start Checks & Bleed Procedure 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.

  • Page 19: Starting The Engine & Setting The Operating Pressure

    4.4. Starting the Engine & Setting the Operating Pressure The Vanpack is supplied with a Radio Control System allowing One-man operation ‘OMO’ in accordance with the 'Single Person Operation’ as detailed in The Code of Practice. Starting procedures are provided for 'Local' operation where water to the high-pressure hose is controlled by the operator using the Control unit at the machine, and for 'remote' operation where water to the high-pressure hose is controlled by the hand-held radio control unit ‘RCU’.

  • Page 20: Pre-Start Checks & Procedures

    4.5. Pre-start Checks & Procedures 4.5.1. Starting the Engine Pre-start Checks Ensure the open-ended high-pressure hose is in a safe position, preferably within sight of the operator at the control panel. Indirect Injection Diesel Engine Key Start Module Operating Procedure 1.

  • Page 21: Checking The Operating Pressure With A Nozzle Fitted

    5. To divert water to the High-Pressure hoses, press the water on button on the control panel Speed / Pressure can be adjusted using RPM + and RPM - buttons. 6. Use the “Hare” button to raise the RPM and in-turn raise the water pressure 7.

  • Page 22: Checking The Operating Pressure With A Gun Fitted

    4.5.3. Checking the Operating Pressure with a Gun Fitted 1. Fit the gun (with the appropriately sized H.V. (pencil) or Fan Jet), to the high-pressure hose. WARNING! Ensure the gun is held firmly in the hand. If the operator loses control of the gun, it can hit someone and cause serious injury.

  • Page 23: Remote Operation Starting Procedure

    4.6. Remote Operation Starting Procedure 4.6.1. Starting the Engine 1. Switch on the Panel using the I/0 Rocker switch. (See Fig. 2) 2. Enter the PIN using the & Arrows and buttons on the controller. 3. Press the remote function on the controller (See Fig. 2) press to enable remote.
  • Page 24 Fig. 5 Handheld RADIO Control Unit (RCU) Remote  Button 1 - Water on / Water Off.  Button 2 - Engine Start Stop  Button 3 – HI (RPM Up)  Button 4 - LO (RPM Down)  Buttons 5&6 – Start Up ...

  • Page 25: Rapid Shutdown

    4.7. Rapid Shutdown Should any unforeseen circumstances arise, including any signs of a leak, the jetting operation should be terminated immediately, the equipment shut down, and the relevant managers informed. 4.8. Automatic Shutdown The engine will shut down automatically if the monitoring and control system detects a malfunction.

  • Page 26: Frost Precautions

    4.10. Frost Precautions During periods when there is a risk of freezing the following precautions should be taken: T-Port Valve Handle 1. Prepare 50% anti-freeze solution. 2. Remove nozzle or gun attachments from the delivery hose. 3. Lower the water level in the tank. 4.
  • Page 27 14. Replace the antifreeze tank lid. 15. Isolate the machine. 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. DO NOT ATTEMPT TO JET ANY REMAINING ANTIFREEZE SOLUTION INTO A CONTAINER...

  • Page 28: Routine Maintenance

    Check air filter cleanliness  Check engine fuel water trap for contamination  Three monthly / 50 hours First service contact Harben Service  Six Monthly / 100 hours Inspect tanks and fittings for leaks, thoroughly clean & flush through ...

  • Page 29: Gearbox Lubricating Chart - Speck Np25

    5.2. Gearbox Lubricating Chart – Speck NP25 Always us the sight glass in the side of the gearbox as the level indicator Oil Capacity (litres) Manufacturer Type Output shaft Input shaft Above Input Above Output ESSO Nuto H15 GULF MOBIL DTE 11 TEXACO Energol SHF LT15...

  • Page 30: General Torque Settings

    5.3. General Torque Settings TORQUE SETTING (Nm) Carbon Steel Stainless Steel Fastener Nominal Dia Grade (mm) Grade 8.8 Grade 10.9 Grade 12.9 Grade A2.5 A2.7 The above Torque settings are for lightly oiled threads. IMPORTANT! DO NOT USE for DRY THREADS.

  • Page 31: Daily Maintenance

    5.4. Daily Maintenance The following must be completed daily 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...
  • Page 32 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 33: Fault Finding

    6. Fault Finding Most of the problems experienced during jetting operations are likely to be caused by the Inlet water filter pump or the associated hoses. These types of problems are covered in the pump fault finding chart, which is repeated overleaf for convenience.
  • Page 34 Check the alternator ‘V’ belt tension, tighten the belt if it is slack and Charge warning slipping. indication Check the connecting terminals to the alternator. Check the engine idle speed, reset if necessary. Refer to engine handbook for further advice.

  • Page 35: Equipment Fault Finding

    6.1. Equipment Fault Finding Problem Possible Cause Recommended Action Worn or incorrectly sized nozzle. Replace nozzle. Blocked water filter. Clean filter element. Blocked suction hose. Remove obstruction. Damaged suction hose. Repair or replace. Low system Leaks in delivery hoses/couplings. Check all joints for tightness. pressure Replace any worn hoses.

  • Page 36: Pump

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

  • Page 37: Engine

    Basic engine noise levels Engine RPM 1500 2000 3000 AT 1 METER FULL LOAD db (A) AT 7 METER FULL LOAD db (A) Replacement filters may be obtained from Harben Harben PART No. ITEM 051-1057 ENGINE OIL FILTER 051-1058 ENGINE FUEL FILTER...

  • Page 38: Circuit And Wiring Diagrams

    9. Circuit and Wiring Diagrams...
  • Page 39 P00486 Kubota Wire No. Colour DIBs Dia (mm) Length (mm) Start Point Application End Point Colour Termination/Crimp Connector Termination/Crimp Connector White 051-5008 2900 A - 21W (031-1001) Temp Red Female Spade 023-4003 Brown 051-6003 2400 B - 21W (031-1011) Alternator Blue 8mm Ring 023-5012 Orange...

  • Page 42: Parts Lists / 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 43: Accessories & Consumables

    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 023-227 MINI JET KIT 20'COMPLETE MAX.
  • Page 44 ITEM HARBEN PART NO DESCRIPTION CODE 051-1057 Engine Oil Filter 051-1058 Engine Fuel Filter 051-1059 Engine Air Filter 051-1060 Engine Water Temp Switch 051-1061 Engine Oil Pressure Switch 051-1065 Alternator Fan Belt 054-020 Engine Oil 5.1 L 054-047 Gearbox Oil 0.35 L...

  • Page 45: Parts List

    051-1063 Engine Starter Motor 051-1064 Fuel Stop Solenoid 5 Amp Fuse Solenoid 20 Amp Fuse Murphy 10.4. Parts List Component Description 0118131 DRIP TRAY 320 UNIT 012061 PLUG BRASS FLANGED 1/2" BSP 013014 ADAPTOR 1/4" BSP M x 1/4" BSP M 415 BAR 013038 ADAPTOR 3/8"BSP x 1/4"BSP M/M 415BAR 013039...
  • Page 46 023041 O CLIP 3/4" 023047 HOSE CLIP DIA 30-40 JCS HI-GRIP S/S 0231060 1/2"BSP X 1 1/4BSP MALE/MALE PARALLEL 215 BAR 0231248 INSERT HOSE STRAIGHT 1" BSPM x 25mm DIA HOSETAIL 316 STAINLESS STEEL 0231414 INSERT HOSE 1/8" BSP 90 DEG FEMALE 023147 ADAPTOR 1"...
  • Page 47 041034 STUDDING M10 ZINC PLATED [PER 1.5 METER] 0422319 SUPPORT TANK FILL POINT VANPACKS (POWDER COAT) 0422956 BRACKET 3 WAY VALVE ASSY 115 SERIES MK2 (POWDER COAT) 0423179 CONTROL PANEL BOX 315 SERIES MK3 MURPHY 0423181 BRACKET UNLOADER VALVE 315 SERIES MK3 0423183 ENGINE FOOT KUBOTA D1105 0423185...
  • Page 48 061829 STATUTORY LABEL PLATE TRAILER 061851 LABEL 'BRITISH INDUSTY' 061864 LABEL WARNING DO NOT RUN PUMP DRY, SEE SECTION 5 OF MANUAL 061871 KEY RING HARBEN 061880 PEEL AWAY SAFETY STICKER 061886 USB MANUALS 061951 LABEL SET 320 SERIES 061970...
  • Page 49 0711240 TELERADIO RADIO CONTROL SYSTEM CANOPEN - TRANSMITTER AND RECIEVER 0711242 PRESSURE TRANSMITTER 0-300 BAR 4-20mA 0711340 12V CIGARETTE LIGHTER OUTLET PIXNOR UNIVERSAL WATERPROOF WITH CAP PANEL MOUNT 0711355 BATTERY 063 V SILVER 0711382 CONTROL PANEL MURPHY MPC-20 CUSTOM FRONT 0711383 WIRING LOOM CONTROL PANEL MPC-20 SINGLE 21 PIN CONNECTOR 0711387...
  • Page 50 N00862 SCREW GRUB M6 x 10 LG N00864 M10x10 GRUB SCREW N01280 ELBOW 1" BSP MXF MALLEABLE GALV N01282 ELBOW 1 1/4 BSP MXF MALLEABLE GALV N01456 3/8"BSPF SWIVEL X 3/8"BSPM 90DEG COMPACT ELBOW 415 BAR N01472 ELBOW 90DEG COMPACT 3/8 BSPF x 3/8 BSPF ZN N01492 ADAPTOR 1/2"...

  • Page 51: Hydraulic Divertor Valve Assembly

    10.5. Hydraulic Divertor Valve Assembly 10.5.1. Recommended Tools 054041 GREASE ESA 100 069186 LUBRICATING METAL PASTE 054003 OIL SHELL TELLUS 150 033275 DRIFT VALVE SPINDLE 10.5.2. Service Kits 024047 KIT SEAL CENTURY TRIGGER ASSY 013345 O RING BS019/90 015062 GLYD RING SEAL 015063 STEPSEAL 033279...

  • Page 52: T Odismantle

    10.6. To Dismantle 1. Unscrew the four M8 bolts (4) and remove cylinder (3) (DRG 026-111). 2. Unscrew the three M8 cap head screws (17) (DRG 035-255) and remove the adaptor (2) (DRG 026-111) from the water valve body (18) (DRG 035-255) 3.
  • Page 53 11. Apply metal paste to threads of cap (8) and screw into body (18) and torque to 41Nm (DRG 035-255) 12. Locate the adaptor cylinder (2) (DRG 026-111) onto the water valve body (18) DRG 035-255/3 and secure with the three M8 socket button headset screws (17) (DRG 035- 255) 13.
  • Page 54 Kit Hydraulic Divert Valve Installation - 026111 Component Description 035255 DIVERTER VALVE HYDRAULIC ACTUATION 6000PSI 078718 ADAPTOR CYLINDER TO BODY UNLOADER VALVE A030784 CYLINDER/COMPACT/63 DIA/10 STROKE/SINGLE ROD/PNEU 013500 BOLT SOCKET CAP HD M8-1.25 6G 60mm LG 8.8 Zn 013246 SCREW SET HEX HD M10-1.5 6G 20 LG HT 8.8 ZN 013094 WASHER S/COIL SQR.SECTION M10 SPRING STEEL ZN 069400...

  • Page 57: Service Documents

    11. Service Documents 11.1. Service Checklist...

  • Page 58: Service Logbook

    11.2. Service Logbook...

  • Page 59: Warranty

    12. Warranty 12.1. Warranty of New Products: Equipment manufactured and supplied by Harben is warranted to be free from defects in materials and workmanship for a period one year or 2000 operating hours, whichever occurs soonest, from the date of shipping from our factory.
  • Page 60 • Used for a purpose for which it is not designed • Applied to a use which has not been approved by Harben • Subject to misuse, negligence, lack of maintenance or accident • Repaired or altered in any way which, in our judgement, may adversely affect its performance and reliability •...

  • Page 61: Limitations Of Warranty

    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...

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903-1315

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