Table of Contents
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Operation & Maintenance Manual
Original Instructions
4018 – DPK TRUCK MANUAL
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
903-1297
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 and Safety Section 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
Related Manuals for HARBEN 4018 DPK
Summary of Contents for HARBEN 4018 DPK
- Page 1 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 &...
- Page 2 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...
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Page 3: Table Of Contents
1. Introduction & Contents Contents 1.1. 1. INTRODUCTION & CONTENTS ..................1 1.1. C ........................1 ONTENTS 1.2. I ......................4 NTRODUCTION 1.3. S ....................5 COPE OF THIS ANUAL 1.4. T ....................5 RUCK ACKAGE 1.5. C ..................6 OMPOSITION OF THIS ANUAL SCOPE OF SUPPLY ......................7 2.1. - Page 4 YDRAULIC 6.3. P ....................32 AULT INDING 6.4. S ................... 34 ELECTOR AULT INDING HARBEN PUMP ......................35 CIRCUIT DIAGRAMS ....................36 8.1. W DPK 4018 ................... 36 ATER IRCUIT FOR 8.2. H DPK 4018 ................36 YDRAULIC IRCUIT FOR 8.3.
- Page 5 WARRANTY ....................... 44 12.1. W : ................44 ARRANTY OF RODUCTS 12.2. W ................. 44 ARRANTY OF AJOR OMPONENTS 12.3. L :..................46 IMITATIONS OF ARRANTY...
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Page 6: Ntroduction
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
Harben® truck packages 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. -
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 truck package. -
Page 9: Scope Of Supply
Scope of Supply 2.1. Scope of Supply Unit: 4018 DPK Truck Mounted Package 2.2. Pump Assembly Figure 2.1 defines the components of the DPK truck mounted package assembly as follows: The pump is driven by an industrial diesel engine. The engine drives the pump via a 2:1 reduction gearbox which reduces the pump rpm down to the correct shaft speed. -
Page 13: 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 14: Main Components
3.1.2. Main Components Engine ENGINE KUBOTA D1803TI TIER 4 FINAL Pump 020041AAB Harben P Type 8 22 Gearbox 020143 Harben P Type 2:1 Max Pressure 4000 PSI (for standard units) Max Flow 18 GPM (for standard units) _________________________________________________________________________ 3.1.3. Ancillaries Water tank 375 gal capacity each. -
Page 15: Technical Description
The primary components of the truck package are illustrated in Figures 2.1-2.3 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 16: Operation
Operation 4.1. Operating Conditions Operators of water jetting equipment should be fully conversant with the 'WJA 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. Please ensure that you read this Operation &... -
Page 17: 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 switch Light switch Control panel fuse... -
Page 18: 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 19 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 20: Running The Engine (Manual Mode)
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) Tank water level Ensure you have an adequate water supply and that the water tank is filled to the ball valve... -
Page 21: Running The Engine (Radio Mode)
9. Increase the speed of the engine and when it is safe to turn the water on, press the water on button 10. The engine speed and pressure can now be increased and decreased using speed up and speed down button. 11. -
Page 22: 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 23: 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 24: 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 25: 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 Sections 3 and 7) Take the following precautions to avoid frost damage: 4.11.1. -
Page 26: To De-Antifreeze The Machine
Put the jump jet valve into the “off” position. 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 10ft of hose. - Page 27 10. As the antifreeze mix reaches the top of the tank turn engine off. (Regularly check the strength of the antifreeze mixture ensuring it is at least a 50/50 mix) 11. Place the jump jet valve in the on position. 12.
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Page 28: Routine Maintenance
Check chassis mounting fixings (all should be between 60-65 ft lb. These will include the 3/8” fixing plates from truck chassis to Harben chassis and U Bolts if installed. 6 months / 150 Inspect tanks and fittings for leaks, thoroughly clean &... -
Page 29: Daily Maintenance
5.2. Daily Maintenance (H&S Section 11) The following must be completed daily with the truck 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... -
Page 30: 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 31: 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: Colour Code Part Number For Maximum Working Pressure Yellow 011019... -
Page 32: 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 33: 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 34: 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 35 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 36: 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 37: Harben Pump
Harben Pump Refer to the P Type Service Manual Part No. 061-352 included with your truck package. -
Page 38: Circuit Diagrams
Circuit Diagrams 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... -
Page 39: Electrical Diagrams
8.3. Electrical Diagrams 8.3.1. Manual Wiring Diagram... -
Page 40: Radio Wiring Diagram
8.3.2. Radio Wiring Diagram... -
Page 41: Engine
Engine A copy of the Engine Manufacturer’s Operators Handbook is supplied with this equipment... -
Page 42: 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 43: Parts List
10.5. Parts List For a detailed parts list of your unit please contact the Harben technical department. Truck types are listed below. 905073 - DPK 750 STATIONARY PIVOT REEL 108" CAB MANUAL 905074 - DPK 750 STATIONARY PIVOT REEL 108" CAB REMOTE 905084 - DPK 375 STATIONARY PIVOT REEL 84"... -
Page 44: Service Documents
Service Documents 11.1. Service Checklist... -
Page 45: Service Logbook
11.2. Service Logbook... - Page 46 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 • 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 48 12.3. Limitations of Warranty: The new product and spare parts warranty are 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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