HARBEN CENTURY TYPE PUMP MK 4D SERVICE MANUAL
Contents
1. i i i i 1 ttt tt Page 1 7b MAX W P 700 BAR 822 519 amp 422 519 MAX W P 550 BAR 825 019 amp 425 019 MAX W P 420 BAR 827 519 amp 425 019 11000 RA Y dl N N N EEE ai ZEEE Ke NI AT gt EN NI N L lys N P J Century Pump Performance Graphs 1000 R P M At AL AA A p Ne N O _ ME d E a U _ s LL AL LLL pesar O LLL j j 22055214 Page 1 76 Page 1 7b Pump Type Pump Serial No s Engine 1 Engine Serial No GearboxType Gearbox Serial No aaa Motor Frame kW Motor Serial No Maximum Flow at Above Pressure Single Gun High Velocity Jet Size Single Gun 15 Degree Fan Jet Twin Gun High Velocity Jet Size Twin 15 Degree Fan Jet Size Twin Gun Choke Size Type of Safety Gun Supplied High Efficiency Drain Jets 3 Rear HE drain jet 6 Rear2. o eem 7 en s m s je s 2 PISTON CYLINDER amp SLIPPER ASSY 225 PISTON CYLINDER amp SLIPPER ASSY 250 PISTON CYLINDER amp SLIPPER ASSY 27 5 ofen i LEADERS IN CLEANING TECHNOLOGY Fig 4 6 Century Pump Parts List Page 4 25 26 y pL a N amp C 4 SO Fig 4 7 Selector Mk 2 Century Es 1 vess fose ozo _2 vess ose o aranna gem nee s os o s dES CIN m E fren avo ene pet em m s gt uns 5027 5 FETTE es ss L a L suena 1 J a essa fome fine Toscooe 1 jo Ls i Too mews Page 4 27 28 M 078 591 3 078 592 i lo ALTERNATIVE Tu ALTERNATIVE la SEE TABLE 1 SEE TABLE AO HOOD O 106 G Ng Or _ 3 E CATCH PLATE 5 g STAMPIENGMAVE DETAILS CAL OF TEST 078 593 3 CHOKE 96 CHOKE 7 lt x NSS Sie ESS PA 2222 LY 222 2 36077 AA E TSS 23 V N A mu 2 GEHT DON 2 ie RES Zr DL u S N gt SEAL GLYD RING 555046 0150 10 BS 013 PTFE ER _ 018 90 5 032 191 032 191 3 9
3. 100 Plug 39 may come out with the Screw or when the 2 Cylinder is removed Unscrew and remove the Cylinder 25 NOTE Although the previous operation is all that is necessary to change a Cylinder it is well worth removing the Spring 35 and the Diaphragm Protection Valve 33 and cleaning them thoroughly Always keep the Valve components in matched pairs at all times Page 4 16 3 Inspect the Seal 73 in Seat 34 and replace if necessary and fit 0 ring 74 into greased groove 4 Gently push Valve 33 into Seat 34 taking care not to damage Seal 73 and ensuring the Valve touches down onto the Seat Place complete assembly into the Barrel 5 Place Spring 35 into the Valve 6 Fit O ring 74 in the greased groove of the Cylinder and place on top of the Spring 35 7 Screw Cylinder 25 down Torque the Cylinder to that specified in Para 5 00 Insert Plug 39 and lock with Screw 100 Change Bearing 11 21 1 Using a press move the Eccentric out of the Bearing 11 Ensuring that the lip on the Eccentric is furthest away from the press ram 2 Fit new Bearing 11 Oil Seal 22 1 Remove old Oil Seal 81 2 Fit new Oil Seal 81 ensuring that the flat side of the Oil Seal is facing the outside of the pump and taking care not to damage the lip of the Seal Re Assemble Pumo 23 After carrying out any repair replacement procedures re assemble the pump as follows 1
4. Inlet nut 43 600 82 9 814 Shaft bolt 92 100 13 8 135 Cylinder 25 500 69 1 680 Banjo bolt 57 and 58 120 16 6 160 Delivery nut 49 and 51 250 34 5 340 Banjo nut 107 and 106 200 27 6 270 Refer to Para 8 and the drawings in this section to locate Item Number Service Kits 6 Service overhaul kits are available when carrying out repair or overhaul of the pump Details of kits for the Century type pumps accessories are as follows Description Part Number Kit Overhaul Valve and Diaphragm 4 cyl Mk 4 Century 024 032 Kit Overhaul Valve and Diaphragm 8 cyl Mk 4 Century 024 033 Kit Seal Mk 2 Century Selector 024 021 Kit Overhaul Mk 2 Century Selector 024 022 Kit Overhaul Mk 1Safety Relief Valve 024 023 Kit Overhaul Mk 2 Safety Relief Valve 024 044 Kit Seal Mk 9B Gun and FCV 024 035 Kit Overhaul Mk 9B Gun and FCV 024 036 Kit Seal Century Trigger Assembly 024 047 Kit Overhaul Century Trigger Assembly 024 048 Kit Overhaul High Speed Rotary Joint 024 030 Kit Seal High Speed Rotary Joint 024 031 Kit Overhaul Multi selector 024 042 PUMP OVERHAUL PROCEDURES Introduction 7 During the pump overhaul procedures reference should be made to the pump component and assembly drawings Figs 4 1 to 4 6 which include associated parts lists Also included are assembly drawings of the Mk 2 selector and safety relief valve Figs 4 7 and 4 8 8 Inthe following overhaul procedures the item number that follows the description of a part refers to t
5. Para 19 c Change Cylinder 25 Piston 26 and Slipper 27 Para 20 d Change Bearing 11 Para 21 e Change Oil Seal 81 Para 22 NOTE The following procedures must be carried out sequentially On completion of repairs replacement of pump components the pump should be re assembled using the procedure detailed in Para 23 Change Float Bearing 13 18 1 Remove Nuts 86 and Washers 103 to remove Bearing Retainer 9 2 Using a press remove the Float Bearing 13 The Bearing may be pressed out from either side 3 Fit a new Bearing 13 The Bearing may be pressed in from either side but the Circlip in the Bearing must face the inside of the Crankcase NOTE When fitting the Bearing 13 only press on to the outside race and not the inner race Dolly part no 201 011 is available for this purpose 4 Press in the Bearing so that 3 mm protrudes through the outside of the Crankcase 5 Refit Bearing Retainer 9 6 Press Bearing fully home so that it locates up against the stop in the Bearing Retainer 9 Change Bearing 12 19 1 Unscrew and remove the Shaft Bolt 92 and Washer 88 2 Slide Sleeve 7 off the Shaft 17 3 Remove Disc Springs 59 noting which way they were stacked and the quantity Page 4 15 4 5 6 7 8 9 10 11 12 13 14 15 16 Using circlip pliers remove Circlip 54 from the groove in Bearing 11 Lift off the Retaining Rin
6. The pump must rotate anticlockwise looking at the front of the pump arrow cast into crank case The maximum inlet water pressure for the pump is 0 5 bar 5 0 metre head whilst the maximum oil pressure for the pump is 4 0 metre head to centre line of pump The pump can be inclined between horizontal and 45 degrees delivery end uppermost If further inclination is required between 45 degrees and vertical Flowplant Group Ltd should be contacted at the address given in Section 1 The weight of a pump with oil in the crankcase drive coupling fitted and bell housing depends on the number of cylinders fitted as follows 4 cyl 160 kg 8 cyl 205 kg The engineer should ensure that all couplings are fitted with a 3 mm clearance Where a bell housing pump mounting and coupling shaft and cover cannot be fitted due to a difference in spigot or bolt locations an adaptor ring may be fitted Refer to Para 9 for further details of coupling arrangements It is recommended that a detailed layout be drawn and the following points considered a Selection of bell housing most suitable for adaptor ring Additional machining to the bell housing may be required b Sufficient coupling engagement on the shaft whilst maintaining the recommended clearance c Clearance between shafts careful design can eliminate the shortening of motor engine shaft Pump Fitting 8 When the pump is to be fitted in position the following points shoul
7. amp 8 S amp NOTES e POSSIBLE CHANGES IN THE QUANTITY USED AS TABLE SHOWS GENERAL QUANTITIES AND NOT ACTUAL AS EACH UNIT IS CALIBRATED INDIVIDUALLY IN HOUSE SPRINGS ARE MADE UP OF A COMBINATION OF BOTH 036 074 THK amp 036 075 THN AGAIN QUANTITIES MAY VARY Fig 4 8 Safety Valve Assembly Page 4 29 30 SECTION 5 WARRANTY SECTION 5 WARRANTY Page Warranty 5 3 Limited Warranty Policy 5 4 Non Warranty Items 5 4 Service and Spares 5 6 Page 5 1 2 WARRANTY FLOWPLANT WARRANTY The warrant period offered on all Flowplant manufactured equipment is 12 months from the date of despatch from the factory Exceptions to this 12 month warranty period include consumables such as jets valves hoses and components within abrasive systems Flowplant warranty department or your nearest distributor must be advised of a warranty claim within 10 days of the parts failure Flowplant or the distributor will endeavour to report its result to the customer within 10 days from the failure date When returning parts or components under warranty an advice note must always be included stating nature of failure date of purchase pump serial number and a contact name with telephone number Equipment which proves defective upon our inspection will be replaced free of charge ex works No allowance will be made for labour charges incurred in making exchanges replacements or repairs Before returning any
8. to Seat 41 and grease both Ensure Back Up Ring is fitted as shown 14 Push and turn Seat 41 anti clockwise into the Mandrel Assembly Fig 4 2 Inlet Valve Seat Back Up Ring and O Ring Fitting Page 4 12 15 Grease part no 054 041 the Seal 82 including the seal locating position in the Barrel 83 and push the complete assembly into the Barrel from the inlet end as far as it will go by hand 16 Grease both faces of the Collar 42 and fit it over the end of the Mandrel 116 and Seat 41 17 Grease the Inlet Nut 43 threads and screw it into the Barrel Torque the Inlet Nut to that specified in Para 5 18 Apply a thin even coat of grease over the end of the Barrel which protrudes into the Inlet Manifold 19 Check 0 rings 68 and 69 are not damaged and are in place 20 Locate the Inlet Manifold 16 on to Studs 101 and fit Nuts 105 and Washers 85 21 Fill the pump with oil see Table 4 2 for oil types and bleed each individual cylinder using Bleed Screws 93 22 Depending upon the type of pump carry out a reversal of the initial dismantling procedure detailed in Para 13 23 The pump may now require further oil bleeding in accordance with the procedure detailed in Section 3 Para 18 Separating Crankcase Halves 15 To inspect overhaul components within the Crankcase the two halves of the Crankcase have to be separated Although this operation can be achieved on the power unit it
9. 2 3 4 5 Place the Shaft 17 into the repair stand ensuring that O ring 72 is fitted and in good condition Assemble Delivery Crankcase 3 with Oil Seal 81 and Carrier 10 and with O ring 71 fitted so that the inner race of the Bearing 12 is supported Then from the outside slide the Sleeve 8 through the Bearing widest diameter on the outside Lubricate 0 ring 72 with pump oil to avoid damage Slide the Crankcase with Sleeve fitted over the Shaft Place Key 29 in the Shaft keyway Slide Bearing 11 with Eccentric 6 pressed in over the Shaft until it rests on Bearing 12 NOTE Lip on Eccentric 6 should face Bearing 12 Page 4 17 6 Fit Circlip 54 into the bottom Bearing groove then fit the Retaining Ring 28 over the Bearing to rest against it 7 Inspect O rings 71 ensuring they are in good condition Grease 0 rings 71 and Barrel bores of Crankcase NOTE During the following part of the procedure refer to Fig 4 3 for Barrel Code positioning 8 Starting with the Barrel marked A place this in the Crankcase with the Piston and Slipper Assembly in the Cylinder Locate the Slipper 27 into the Retaining Ring making sure that the Shear Pin 31 locates in the Barrel Fig 4 3 Barrel Code 9 Continue replacing the Barrels in an alphabetical and clockwise order 10 Place Retaining Ring 28 over Bearing and Slippers Fit Circlip 54 into Bearing groove 1
10. HE drain jet 3 Rear 1 forward HE drain jet Bomb Ram Jet HV Fan Plough Jet Jet Pump Type Jet Sizes Rotoblast Hovervac bar psi Page 1 8 PUMP DIMENSIONS ARE SYMMETRICAL ABDUT CENTRE LINE DIMENSIONS ARE IDENTICAL FOR ALL PUMPS ADAPTORS ARE AVAILABLE FOR A RANGE OF ELECTRIC 1 OIL FILLER MOTORS AND DIESEL ENGINES CONSULT MANUFACTURER 2 WATER INLET 3 WATER DRAIN NOTE FOR CIRCUIT DIAGRAM SEE DRG D3 4 DIL DRAIN AFTER JULY 1982 BSP WATER INLET IS STANDARD 5 FLENDER PART 4 B 200 FOUR 1 1 4 BSP INLETS ON REQUEST eerte ER COUPLING CLAMPS COUNTER BALANCE 6 DIL BLEED SCREW 7 WATER BLEED SCREWS FITTED TO TOP BARRELS ONLY 8 HIGH PRESSURE OUTLET 01 2 9 VIEW EXCLUDING COUPLING AND COUNTER BALANCE 10 6 STUDS M10x1 5 LG 28mm ROTATION VIEW ON DRIVE END DF SHAF NOTE CAST ARROW ON INLET SIDE OUP DIMENSIONS IN mm ARE IDENTICAL FOR ALL PUMP MODELS 560 ie 4 amp 8 CYLINDERS Fig 1 1 Harben Century Type High Pressure Pump Page 1 9 10 SECTION 2 PUMP INSTALLATION SECTION 2 PUMP INSTALLATION CONTENTS Introduction Pump Mounting General Details Pump Fitting Coupling Arrangements Inlet Water General ILLUSTRATIONS Fig 2 1 Pump Installation Water Circuit Layout 2 2 Pump Installation Prime Mover Gearbox Pump Coupling Arrangements TABLES Table 2 1 Century Gearboxes 2 2 Coupling for Century Gearboxes 2 3 Flywheel Couplings Perkins Ford
11. Replace if necessary 3 Wrong seat in float valve Replace if necessary assembly 4 Lowinlet pressure Increase pressure Pump Not Running Evenly also 1 Air in water Water bleed pump Para 19 refer to Pump faults 2 Airin crankcase oil Oil bleed pump Para 18 3 Worn Coupling Replace flexible elements and examine coupling 4 Faulty inlet or delivery Check valve condition valve 5 Diaphragm protection Re seat protection valve and valve check delivery valves for ware damage Burst Disc Failure or Safety 1 Incorrect burst disc Replace with correct disc Relief Valve Operating also refer to high system pressure 2 Incorrect valve setting Check certificate setting problem 3 Faulty valve Repair or replace as necessary 4 Faulty or fatigued burst Replace with new disc disc Page 3 12 TABLE 3 2 PUMP FAULT FINDING Problem Cause Action Mixing of Oil and Water in Crankcase Loss of pressure Pump not running evenly Worn or damaged delivery valves Damaged filter element allowing debris to jam delivery valve Check all delivery valves replace as necessary Check all diaphragms replace as necessary Replace oil Check filters replace as necessary Loss of crankcase oil through pressure hose Loss of pump pressure Pump not running evenly Inlet restriction may have been caused through a Blocked filters b Kinked inlet hose c Worn or damaged inlet
12. fittings Check wear damage correct rating and size Pump working pressure Check correct General Check pump for smooth running overheating leaks and security of components SIX MONTHLY 300 HOURS Inlet delivery valves Check for wear and damage Torque inlet nuts to 6001bft 82 9kgm 814Nm at 250 hours Diaphragms Check for wear and damage YEARLY 500 HOURS Crankcase oil Drain and renew Inlet delivery valves Check for wear and damage Pipes hoses and fittings Carry out detailed inspection TWO YEARLY 1000 HOURS Inlet delivery valves Replace Diaphragms Replace Page 4 3 TABLE 4 2 PUMP LUBRICATION CHART Manufacturer Type Oil Capacity litres ESSO Nuto H150 Number of Cylinders GULF LP 150 4 cyl 8 cyl MOBIL DTE Extra Heavy 13 0 11 0 ROC Kiron 150 TEXACO Rando HD 150 BP Energol HLP 150 AGIP OSO 105 SHELL Tellus 150 CENTURY OIL PWLM PETROFINA Hydran 51 CASTROL Hyspin AWS 150 Page 4 4 PUMP SERVICE INFORMATION General 3 The following paragraphs give details of recommended service tools torque settings and service kits to be used when carrying out pump overhaul procedures Recommended Service Tools 4 The following tools should be available when servicing the pump Description Part Number Repair stand Driftmandrel Separatormandrel Driftinlet valve guide Dolly mandrel into diaphragm Drif
13. now ready to use To Anti Freeze a Unit With an Anti Freeze Tank Fitted 22 1 Ensure the anti freeze tank is full of 3096 to 5096 anti freeze solution 2 Turn the 3 port valve to the anti freeze position and open valve on the anti freeze tank if fitted 3 Remove any jet or accessory from the end of the high pressure hose 4 Move the selector lever to the high pressure or on position 5 Holding the end of the hose start the engine 6 Allow engine to run on tick over until the anti freeze solution can be seen coming from the high pressure hose 7 Move the selector to the recycle dump position for 5 seconds this allows the dump hose to be anti freezed 8 If Jump Jet or Remote Control kits are fitted ensure they are anti freezed The unit is now anti freezed To Remove Anti Freeze From a Unit With an Anti Freeze Tank Fitted 23 1 Move the 3 port valve to the water position 2 Fill the water tanks 3 Place the outlet of the high pressure hose into the anti freeze tank 4 Place the selector lever in the high pressure position 5 Start the engine Allow it to run at tick over and pump anti freeze solution into the anti freeze tank Stop the engine when clear water is seen flowing out of the high pressure hose The unit is now ready to use Page 3 10 FAULT FINDING General 24 It is essential when fault finding on the pump that due regard is taken of the likely equipment faults Therefore Table 3 1 incl
14. of the Inlet Valve Assembly and Diaphragm as follows 1 Unscrew and remove Nuts 105 2 Pull the Inlet Manifold 16 off its Studs 101 3 Unscrew Inlet Nuts 43 using a 70 mm slogging spanner part no 202 266 taking care not to damage Studs 101 4 Insert a Drift part no 201 043 into the end of the Mandrel from delivery end Tap the end of the Drift to remove Collar 42 Inlet Seat 41 Spring 36 Valve 40 Mandrel Assembly 38 and Diaphragm 37 from the inlet end of the Barrel 5 Pull the Inlet Seat 41 from the Mandrel Assembly 38 Remove Valve 40 and Spring 36 Page 4 10 6 7 8 9 Using Extractor part no 201 082 remove Diaphragm 37 from Mandrel Assembly 38 Inspect the Diaphragm for splits or holes replace if necessary Inspect Spring 36 replace if necessary Inspect the seating faces of the Valve 40 and Seat 41 If either is badly pitted chipped or unevenly worn it must be replaced Inspect the bore of Bush 114 It should be noted that if the bore is worn it will prevent Valve 40 from shutting smoothly and squarely onto the Seat 41 and must be replaced if necessary The procedure for replacing the Bush is as follows i Remove the Pin 115 ii Screw an M12 tap into the Bush 114 until it bottoms Hold end of tap in a vice and gently tap the face of Mandrel 116 with a nylon mallet until the Bush is removed iv Carefully press a new Bush into the Man
15. on a chassis or a carrier which does not meet the Company s published requirements natural disasters or any by reason of force majeure In no circumstances shall the Company be liable for any special incidental consequential damage based upon breach of warranty breach of contract negligence strict liability in tort or any other legal theory This limited Warranty allocates the risks of product failure between the Company and the buyer and that allocation is recognised to both parties and reflected in the price of the goods Non Warranty Items The Warranty terms are a precise statement of Flowplant Group Ltd s intention to cover the replacement or repair cost on a standardised and agreed basis of any product failure resulting from defective material or sub standard workmanship during the manufacturing process Page 5 4 The following items are considered to be of a Maintenance nature and should not be subject of a claim Engine Manufacturers Warranty Applies Routine servicing of injector fuel injection equipment Heavy fuel consumption rectified by engine adjustment Adjustment of fan belts throttle and controls Tightening of all sump and cover bolt nuts water connections and exterior oilpipes and filter bolts Filters and the cleaning of filters Engine service components Adjustments Brakes Trailer Brake shoe adjustment bleeding and topping up of reservoir draining of air systems where not due to a defective
16. procedure and ensure they are re assembled correctly 23 Fit Key 30 into the cleaned Shaft keyway 24 Clean the bore of Counter Balance 4 and Coupling 5 Check that both slide over the Shaft but do not assemble 25 Fit Bell Housing 84 using Nuts 86 with Washers 103 26 Grease the Shaft and the bores of the Counter Balance and Coupling 27 First push the Counter Balance on to the Shaft then push the Coupling on to the Shaft 28 Fit Drive Cap 56 into the end of the Coupling locating Pin 110 into the hole in the Shaft 29 Put a small amount of retaining compound on Cap Screw 102 and tighten it into the Shaft 30 Re fit pump as detailed in Para 9 Removal and Replacement of Pump Head Pump Running In Prior to running in the pump after overhaul or major component replacement the pump should be filled with oil to the correct level Refer to Lubrication Chart Table 4 2 for details of recommended oil types and pump oil capacities The pump should also be bled of air in accordance with the procedures given in Section 3 Paras 18 and 19 Page 4 19 NOTE Check the direction of pump rotation when first switched on 26 Run the pump at maximum pressure for the following periods whilst checking for leaks monitoring the flow and checking the results against pump performance data a Offload 30 minutes b 1 2 max pressure 60 minutes c Max pressure 60 minutes 27 The following points should be taken in
17. um rp x pm pt ee t Wan em c s wc soo tooo 3000 uc me comm lowplant Group Ltd 5 p cnet nice Sat ha chee eet tt ttt tet we wl oma zu sallsbury Witichire England P2 7PU Tel 01722 326424 Fax 01722 411328 x COPYRIGHT 2004 Fiouplant Group Lid Fig 4 5b Century Pump Barrel Assembly Spring Leaded Delivery AECDEFGHJK THS DRAWING CONFIDENTIAL AND EE SUPPLIED MATERIAL LIST LENPRSTUY W lo THE EXPRESS CONDITION THAT IT MOT xY COPED OR COMMUMICATED To OTHER PERSONS INFORMATION FOR ESTIMATION OF WEIGHT AND COST ONLY o KOT SCALE OR COMP ANES WITHOUT WHITTEN PERMISSION nere ura uc 9 s pee nmm s woe uw woe s s woe 1 es o meee 0 oea om 1 uemnaeremme e mom oem 1 1 1 1 earrcenrumonco mo moss o e qnem pem em qnem LLL eem qmm 1 1 poem e eem oom emm id emm pes mms T eem pee jme em poe eem pee jm _ fe oom pee dm id ee f eme je IC pee RR E INC mm IE s CI je E EL EC spem
18. 1 Screw retaining Screw 95 with Bonded Seal 64 through Crankcase into the Barrel leaving about one turn loose 12 Clean and check 0 ring 70 before placing it in greased groove of Delivery Crankcase 3 13 Slide the Sleeve 7 over the Shaft 17 and place the Disc Springs 59 over the Sleeve so that they rest on the Eccentric 6 14 Apply a small amount of retaining compound to the threads of the Shaft Bolt 92 and screw the Shaft Bolt with Washer 88 into the end of the Shaft 17 Torque the Shaft Bolt to that specified in Para 5 Page 4 18 24 25 15 Turn the pump to the vertical position Place Bolts 99 through the Delivery Crankcase and slide the Spacer Assemblies 112 over them 16 Grease O rings 71 and the Barrel bore of the Inlet Crankcase 2 17 Place the Inlet Crankcase 2 in its correct position over the Shaft and Barrels the oil filler should be at the top between Barrels A and H 18 Push the Inlet Crankcase 2 over the Barrels until the threads of Bolts 99 engage 19 Tighten Bolts 99 until the Crankcase halves are completely together Care should be taken to tighten diagonally and a little at a time 20 Fully tighten Screw 95 21 Fit Bearing Retainer 9 and 0 ring 71 using Nut 86 with Washers 103 22 Place the Bleed Rings 44 and Bleed Screws 93 over the Barrels NOTE f internal parts of the Barrels or Valves were removed refer to the appropriate
19. 2 4 Motor Half Couplings for Electric Motors 2 5 Bell Housings 10 Page 2 3 2 5 Page 2 1 2 PUMP INSTALLATION INTRODUCTION 1 Itmay be the case that the pump has not been purchased as part of a trailer or skid The information given in this section is intended to enable customers to install the pump package in a frame of their design It will enable engineers to carry out preliminary design work before submitting the design for Flowplant Group approval Refer to Section 1 for technical data and a description of the pump Section 1 Fig 1 1 should be referred to for further technical details and installation data 2 Theillustration given in Fig 2 1 Century Series pump TRAILER SKID MOUNTED RETURN TO TANK DUMP on foe DUWP DUMP 00 NOT RE CYCLE TRUCK MOUNTED RETURN TD TANK DUMP DUMP DO NOT RE CYCLE KEY HON PRESSURE SPRAY DIRECTION GF FLOW PRESSUR GAUGE 4 FILTER lt Cx SELECTOR VALVE 4 m 4 FLOAT VALVE ACCESSORY SAFETY RELIEF VALVE 08 WATER TANK PRESSURE DISC I FLOOBLE CONNECTION 3 4 PRESSURE CONTROL VALVE D T OPTIONAL ACCESSORY Fig 2 1 Pump Installation Water Circuit Layout Page 2 3 PUMP MOUNTING General Details 3 The Century Series pumps are designed for direct drive and flange mounting The normal operating speed is 1000 rpm nominal Maximum operating speed is 1200 rpm
20. Coupling M200 Iveco 7000 Series Page 2 5 TABLE 2 3 FLYWHEEL COUPLINGS PERKINS FORD PART NO DESCRIPTION 100 633 Coupling PT10 E180 CF Perkins T6354 4 1006TG 100 367 Coupling PT10 E180 CF Ford 2726T 023 593 Coupling PT10 E200 Iveco 7675Si TABLE 2 4 MOTOR HALF COUPLINGS FOR ELECTRIC MOTORS Metric Frame Non hazardous Types PART NO DESCRIPTION 100 487 37 kW 50 HP Motor Coupling B200 Pt 1 100 487 45 KW 60 HP Motor Coupling B200 Pt 1 023 304 55 KW 75 HP Motor Coupling B200 Pt 1 023 304 75 KW 100 HP Motor Coupling B200 Pt 1 023 304 95 kw 125 HP Motor Coupling B200 Pt 1 023 304 111 kw 150 HP Motor Coupling B200 Pt 1 TABLE 2 5 BELL HOUSINGS PART NO DESCRIPTION 100 084 Diesel Century Bell Housing 100 082 Bell Housing 37 kW 1111kW Electric 100 329 Adaptor Ring must be used on 75 111kW electric motors 012 186 Adaptor Ring must be used on diesel engines Page 2 6 INLET WATER General 10 11 12 13 14 It is recommended that inlet water is filtered to 50 microns Filtration to 150 microns is also possible Refer to Flowplant Group for advice Flowplant offer types of filter suitable for most applications Turbulent water will cause the pump to run unevenly and cause excessive wear due to cavitation For this reason water must first pass through a break water or header tank controlled by a ball valve or float devi
21. MATION CONTENTS Introduction Safety Code of Practice General Safety Gun Drain Sewer and Pipe Cleaning Hoses Underwater Recoil less Safety Gun Tube Cleaning Hoverclean Abrasive Injection Equipment Accidents Protective Equipment General Operating Instructions Introduction Starting Stopping To Oil Bleed the Pump To Water Bleed the Pump To Anti Freeze a Unit Without an Anti Freeze Tank To Remove Anti Freeze From a Unit Without an Anti Freeze Tank To Anti Freeze a Unit With an Anti Freeze Tank Fitted To Remove Anti Freeze From a Unit With an Anti Freeze Tank Fitted Fault finding General ILLUSTRATIONS Fig 3 1 Bleeding the Pump 3 2 Pump Fault Finding Diaphragm Failures and Indications of Other Problems TABLE Table 3 1 Equipment Fault Finding 3 2 Pump Fault Finding 15 16 17 18 19 20 21 22 24 Page 3 8 3 14 Page 3 11 3 13 Page 3 1 2 1 GENERAL OPERATING INFORMATION INTRODUCTION This section gives general information on safety protective clothing to be used by operators and general starting and stopping procedures when the pump is incorporated in a machine It should be remembered that the operating procedures given are to be used as a guide only and the equipment handbook operating procedures should be used where applicable SAFETY CODE OF PRACTICE BASIC RULES 1 ALWAYS WEAR THE CORRECT PROTECTIVE CLOTHING 2 ALWAYS ENSURE ALL EQUIPMENT IS IN A FIRST CLASS CONDI
22. Part No 061 357 HARBEN CENTURY TYPE PUMP MK 4D SERVICE MANUAL Issue 4 June 2014 Flowplant Group Ltd Gemini House Brunel Road Churchfields Industrial Estate Salisbury Wiltshire SP2 7PU United Kingdom t 44 0 1722 325424 f 44 0 1722 411329 e sales flowplant com HARBEN CENTURY TYPE PUMP SERVICE MANUAL CONTENTS FOREWORD HEALTH AND SAFETY AT WORK SAFETY CODE OF PRACTICE SECTION 1 PUMP TECHNICAL DATA SECTION 2 PUMP INSTALLATION SECTION 3 GENERAL OPERATING INFORMATION SECTION 4 PUMP MAINTENANCE AND OVERHAUL PROCEDURES SECTION 5 WARRANTY A detailed Contents list precedes each Section i ii FOREWORD This manual is primarily concerned with the Harben Century Type Pump In addition general safety and operating information for the equipment into which the pump is installed is also included The conversion of pressurised water into a high velocity jet and its use as a cleaning and cutting tool is now familiar to and used by many people in a wide range of industries High pressure water can achieve remarkable results without the use of heat or chemicals and cost savings over conventional maintenance methods can in many cases show that a water jetting unit will pay for itself in hours rather than years Many companies have problems for which high pressure water offers a rapid solution yet hesitate to consider this method because of the generally accepted high cost of such equipment B
23. TION 3 NEVER WORK FROM A LADDER 4 NEVER USE THE GUN WITH THE TRIGGER LOCKED ON 5 NEVER POINT THE GUN AT ANYONE EVEN IF SWITCHED OFF 2 This Code of Practice is intended to provide guidance on the safe operation of high pressure water jetting equipment 3 The term high pressure water jetting covers all water jetting including the use of additives and abrasives where there is an energy input to increase the pressure of water 4 This code applies to high pressure water jetting as defined above where there is a foreseeable risk of injury General 5 1 Onlya responsible person who has received instruction in the operation of high pressure water jetting equipment should be allowed to operate the equipment 2 Barriers should be erected around the cleaning bay or where the work is being done in situ round the section of plant concerned Access within 10 metres by persons other than the jetting team is strictly prohibited 3 Awarning notice UNAUTHORISED ENTRY High Pressure Water Jetting in Progress should be displayed on each side of the bay or on the plant where the work is to be done 4 Each member of the team should be provided with suitable waterproof clothing wellington boots with internal steel toe caps safety helmet with visor and ear defenders and gloves Refer to Para 14 for details of protective clothing available Page 3 3 SAFETY CODE OF PRACTICE Cont d General Cont d 5 Never attempt to chan
24. acked by many years of design and manufacturing experience Harben pumps are setting new standards of performance and reliability The capital and operating costs are such that these offer and attractive return on investment that really makes sense Flowplant Group Ltd have a policy of continual research and improvement and we reserve the right to make such modifications and design changes as are considered necessary in the light of experience however this copy of the manual will not be amended No part of this manual may be reproduced or copied in any manner without written permission from Flowplant Group Ltd iii HEALTH AND SAFETY AT WORK There are two main categories of risk These are a Injury from impact of water b Injury from environment All persons involved in water jetting should be made aware of the risks INJURY FROM IMPACT OF WATER In the event that a person is injured by the impact of a water jet the injury caused may appear insignificant and give little indication of the extent of the injury beneath the skin and the damage to deeper tissues Large quantities of water may have punctured the skin flesh and organs through a very small hole that may not even bleed Immediate hospital attention is required and medical staff must be informed of the cause of the injury To ensure that this is not overlooked all operators engaged on jetting should carry an immediately accessible waterproof card which outlines the possibl
25. ce Water leaving the tank should have lamina flow characteristics and be air free NOTES 1 If water is filtered before the tank then the tank must be sealed and vented to avoid contamination 2 Apressure flow check at the inlet to the pump is recommended The maximum inlet water pressure for the pump is 0 5 bar 5 0 metre head 3 Minimum recommended 0 05 bar 0 5 metre head 4 Minimum recommended inlet speed o 5 metres second 5 Recommended vortex in tank outlet pump inlet 6 Flowplant recommend return line to be on opposite side of tank to tank outlet pump inlet 7 Flowplant recommend that tank should be of sufficient size so that at full flow cannot be drained in under 4 minutes A pH value of 5 to 9 is recommended Although liquids outside this range may occasionally be pumped it is advisable to contact Flowplant Group at the address given in Section 1 for their advice Hose and pipe bores between the break water tank and pump should be a minimum of 50 mm 2 in and up to a length of 1 metre If a longer length of hose pipe is required refer to Flowplant Other points to be considered concerning inlet water are a Avoid long hose or pipe runs b Avoid hose or pipe runs that cause air pockets c Refer to circuit layout for mounting angle of pump d If water inlet temperature is over 30 C consult Flowplant Page 2 7 8 SECTION 3 GENERAL OPERATING INFORMATION SECTION 3 GENERAL OPERATING INFOR
26. cturer s recommendations REMEMBER The replacement or repair of tyres is not covered by the Company s warranty terms In the case of van and truck mounted equipment the warranty relating to the actual vehicle remains the responsibility of the vehicle manufacturer or supplier In order to comply with the provisions of the Health and Safety at Work Act 1974 in respect of articles manufactured supplied or installed for use at work we test all our products before they leave our factory and supply with them adequate instructions for their proper use Further copies of these instructions are available from us on request We shall not be liable for loss injury or damage of whatever nature caused by goods design technical information suggestions etc supplied by us where as the case maybe they have been structurally modified or misused or misapplied or have not been properly cared for and maintained and the purchaser hereby agrees to indemnify us against all such claims and demands or by whomsoever they are brought Service and Spares Flowplant provide service and spares cover in most parts of the world When ordering spares please quote a Your company name and address b Destination of parts if diffe c Description and part numbe d Quantity required e Price and method of payme f Delivery date g Order number h Confirmation of order When requesting service or repairs please state a b c d e f
27. d be noted a When the pump is first married up to the prime mover access is required to check coupling clearance When Flender B200 couplings are used sight gauge holes are drilled in the bell housing for this purpose b It depends on the particular installation whether the pump head is removed to a workshop for maintenance eg diaphragm or valve replacement or whether work is carried out in situ c Where a pump strip down is required the pump should be removed to the workshop The use of an assembly stand part no 100 279 is recommended Page 2 4 Coupling Arrangements 9 For details of the prime mover gearbox pump coupling arrangements for diesel driven and electrically driven pumps refer to Fig 2 2 and Tables 2 1 to 2 5 PUMP BELL HOUSIN FLYWHEEL PLING PUMP COUPLING E ARBOX UTPUT GEARBOX ADAPTOR RING GEARBOX INPUT DUPLING COUPLING 00 342 1100 366 Fig 2 2 Pump Installation Prime Mover Gearbox Pump Coupling Arrangements TABLE 2 1 CENTURY GEARBOXES PART NO DESCRIPTION 105 119 2 7 1 Gearbox Bare Shaft Century 105 120 2 25 1 Gearbox Bare Shaft Century 105 121 2 0 1 Gearbox Bare Shaft Century 105 125 1 86 1 Gearbox Bare Shaft Century TABLE 2 2 COUPLING FOR CENTURY GEARBOXES PART NO DESCRIPTION 100 342 Output Coupling B200 Pt 1 Flex Bore 57 mm Key 16 mm 100 366 Input Coupling B180 Pt 1 Flex Bore 45 mm Key 14 mm Perkins 1000 Series 023 594 Input
28. drel using a drift part no 201 044 v Usinga 1 9 mm diameter bit drill through 6 holes in Mandrel through wall of Bush see Fig 4 1 holes A vi Using a1 9 mm diameter bit drill through hole in Mandrel right through Bush see Fig 4 1 holes B vii Using a flat punch refit Pin 115 through Mandrel and Bush SEAL MANDREL BUSH PIN Me 118 114 1 INLET VALVE HOLE A Fig 4 1 Mandrel Assembly Page 4 11 10 To assemble Mandrel assembly 38 and Diaphragm 37 smear a light film of pump oil along the lobes of the Mandrel then push it into the Diaphragm ensuring there is no gap between Mandrel and Diaphragm at inlet end NOTE It may be easier to hold the Diaphragm with the Mandrel almost pushed home in one hand and hit the flat face of a nylon dolly part no 201 012 with a nylon mallet 11 Inspect Seal 82 Fig 4 1 If itis damaged replace as follows i Remove and discard old Seal ii Insert Dolly part no 201 061 into the end of the Mandrel iii Fit O ring part of Seal into the groove of the Mandrel iv Push the hard plastic part of Seal over the Dolly using Pusher part no 201 065 and locate it in the groove on top of the 0 ring part of the Seal v Using Shrinker part no 201 066 shrink the Seal enough to fit into the Barrel without damage 12 Place Valve 40 and Spring 36 into Bush 114 13 With reference to Fig 4 2 fit Back Up Ring 78 and O ring 76
29. e exception of the inlet and delivery valves run in the oil flooded crankcase and are therefore unaffected by contamination by the pump fluid or by running dry Filtration 9 Standard filtration for the pump is normally 50 microns This filter is usually fitted to the inlet of the supply tank or reservoir This arrangement ensures that if the filter is neglected to the point of blockage the tank will empty and the pump will run dry thus enabling the dry running qualities of the pump to be used as a filter maintenance indicator Inlet conditions required are flooded suction pressure feeding is not necessary Fluid Flow 10 Arrangements are made on the pump for the incoming fluid to cool the crankcase oil The use of standard diaphragm barrel assemblies provides a choice of flows depending upon the number of barrels fitted to a crankcase The cylindrical form of these barrels is well suited to containing high pressures Three piston diameters are available to suit a range of pressure up to 700 bar 10 000 psi IDENTITY Manufacturer 11 The Harben Pumps are manufactured by Flowplant Group Ltd Brunel Road Churchfields Salisbury Wiltshire SP2 7PU ENGLAND Tel 44 0 1722 325424 Fax 44 0 1722 411329 Pump Options Identification 12 The Century Pump is available in either 4 or 8 cylinder options with each having a choice of piston cylinder diameter options of 22 5 mm 25 0 mm or 27 5 mm 13 All barrels are given a letter c
30. e nature of the injury and bears the following text which has been endorsed by the Employment Medical Advisory Service EMAS of the Health and Safety Executive THIS MAN HAS BEEN INVOLVED WITH HIGH PRESSURE WATER JETTING AT PRESSURE UP TO 36750 LB IN 250 MPA 2500 BAR 2548 KG CM WITH A JET VELOCITY OF 1536 MILES 2458 KM PER HOUR Please take this into account when making your diagnosis Unusual infections with micro aerophilic organisms occurring at lower temperatures have been reported These may have gram negative pathogens such as are found in sewage Bacterial swabs and blood cultures may therefore be helpful A letter containing this and other relevant information should be sent to the doctor of each operator Where surgical examination is not immediately possible in remote situations first aid measures should be confined to dressing the wound and observing the patient closely until a medical examination has been arranged If any person object or article is accidentally struck by the jet this fact must be reported to the operator s representative iv INJURY FROM ENVIRONMENT Work should only be carried out if it is safe to do so A thorough examination of the site should be carried out before work is started Refer to the Warnings and Cautions Special care should be taken where there is a danger of infection There are many situations where infection can take place As a guide to avoiding infection the following poin
31. ect the Ball 47 and Seat 45 If either is badly pitted chipped or unevenly worn it must be replaced 11 Inspect bore of Guide 48 Replace item if it is badly pitted chipped or unevenly worn 12 Fit the Seat 45 into the Delivery Nut 50 and 51 using a small hand press If a hand press is not available tap the Seat in with a nylon mallet making sure that it is tapped in squarely and no nylon from the mallet head goes into the Valve Assembly through the Seat hole 13 Grease the threads of the Delivery Nuts 50 and 51 before assembly 14 Re fit the Valve Assembly to the unit reversing the removal procedure given in Sub paras 7 to 1 in that order NOTE Where possible use a socket and torque wrench and torque the Delivery and Banjo Nuts to that specified in Para 5 Removal and Inspection of Inlet Valve Assembly and Diaphragm NOTES 1 It is recommended that oil is drained from the pump before commencing the following procedure 2 Refer to Para 8 for drawing information 13 The initial dismantling procedure depends upon the type of pump as follows 1 If 4 cylinder pump carry out the procedure detailed in Para 10 1 to 4 2 If8 cylinder pump carry out the procedure detailed in Para 11 1 to 3 3 If8 cylinder pump with split delivery manifold carry out the procedure detailed in Para 12 1 to 7 14 With the appropriate initial dismantling procedure Para 13 completed carry out removal and inspection
32. eed not be drained 2 Refer to Para 8 for drawing information 10 Carry out removal and inspection of Delivery Valves as follows 1 Unscrew and remove the four Nuts 107 not shown on drawings Page 4 7 2 3 4 5 6 7 8 9 Lift off Washers 91 not shown on drawings Delivery Tubes 19 not shown on drawings and Banjos 22 and 23 can now be pulled off Unscrew and remove Delivery Nut 51 containing the Valve Assembly Insert a flat blade screwdriver into the radial groove of Delivery Seat 45 and levering gently around ease Seat from Delivery Nut 51 Remove the Guide 48 and Ball 47 from Delivery Nut 51 Inspect the Ball 47 and Seat 45 If either is badly pitted chipped or unevenly worn it must be replaced Inspect bore of Guide 48 Replace item if it is badly pitted chipped or unevenly worn Fit the Seat 45 into the Delivery Nut 51 using a small hand press If a hand press is not available tap the Seat in with a nylon mallet making sure that it is tapped in squarely and no nylon from the mallet head goes into the Valve Assembly through the Seat hole 10 Grease the threads of the Delivery Nut 51 before assembly 11 Re fit the Valve Assembly to the unit reversing the removal procedure given in Sub paras 4 to 1 in that order NOTE Where possible use a socket and torque wrench and torque the Delivery and Banjo Nuts to that specified in Para 5 Remova
33. esel driven pumps run at 1000 rpm nominal 2 Quantity of cylinders does not alter pump working pressure 3 Quantity of cylinders does alter flow rate Page 1 5 EQUIPMENT DETAILS 17 Details relevant to the pump and associated equipment should be entered on the form shown in Table 1 3 at the rear of this section for future reference ASSOCIATED PUBLICATIONS 18 Associated with this manual are the following publications Operators guide Part no 061 225 Code of practice Part no 057 062 Page 1 6 MAX W P 700 BAR 822 519 amp 422 519 MAX W P 550 BAR 825 019 amp 425 019 MAX W P 420 BAR 827 519 amp 425 019 a i E E b a E AAT AURAT gA PAHU HT THET HAA s Page 1 7a H IM LT T NB Max speed of Century Pump 1200 rpm _ LL 1 100hp EEE Century Pump Performance Graphs 1000 R P M E N IX L K N E IN A O O O A RS a O NG SS O O SO O O A O SI O O 20448 yn HrVA 3 i i i i I I i i i i I P 8 1 19 p E
34. g h i j Your company name and address Location of machine unit if different from above Type and model of machine unit Pump serial number Problem s with machine unit Availability of machine unit for service or repairs Date of service and site contract Cost and method of payment Order number Confirmation of order Page 5 7 8
35. g 28 Noting the position of each Barrel before removal and dealing with one barrel at a time unscrew the previously loosened Capscrew 95 Lift the Barrel 83 out of the Delivery Crankcase gently tapping with a nylon mallet if required Take particular care that the Piston and Slipper Assembly 26 and 27 are not damaged as the Slipper is disengaged from the bottom of the Retaining Ring 28 Repeat the procedure detailed in sub paras 6 and 7 for the remaining Cylinders Lift off the Retaining Ring 28 and remove the Circlip 54 from the Bearing groove Pull vertically on the Bearing 11 and it and the Eccentric 6 will slide off the Shaft 17 Remove Key 29 from the Shaft keyway Lift the Delivery Crankcase vertically If the Drive End Sleeve stays in the Bearing 12 push it out from the inside Unscrew and remove four Nuts 86 and Washers 103 Remove Oil Seal Carrier 10 and O ring 71 Remove both Circlips and press the Bearing 12 out either way being careful of the Setscrews 97 and 98 Fit new Bearing 12 by fitting Circlip into Bearing groove and pressing from either side of the Crankcase until the Circlip rests against the Crankcase A Dolly part no 201 011 is available for this purpose NOTE When fitting the Bearing only press on the outer race and not the inner race Put the other Circlip 55 into the Bearing groove Change Cylinder Piston and Slipper 20 1 Unscrew and remove Screw
36. ge jets or accessories whilst the pump is operating even if the flow control selector valve is in the recycle dump position Safety Gun 6 1 Never point the safety gun at anyone even if it is switched off 2 When using the dead mans handle safety gun the required jet should befitted to the high pressure barrel low pressure barrel is fitted with a diffuser and tightened correctly before starting the unit All other hose connections etc must be checked before attempting to start the unit 3 Water jetting guns should be properly maintained and care should be taken not to damage the delicate components of the trigger mechanism Drain Sewer and Pipe Cleaning 7 4 2 3 4 Hoses 2 3 In addition to the protective clothing listed in Para 5 4 the other equipment should be used when entering confined spaces such as safety harness and rescue line atmospheric testing equipment escape breathing apparatus and hand lamps intrinsically safe where appropriate To prevent snaking or reverse travel of a flexible hose inside the tube being cleaned a section of steel pipe slightly longer than the diameter of the tube to be cleaned should be connected between the flexible hose and the nozzle drain jet extension During drain cleaning operations it is advisable to use a coloured leader hose to act as a warning to the operator that the hose recovery is almost complete Where drain or pipe jetting operati
37. goods to us for our inspection contact our depot for proper authorisation or the goods will not be accepted We shall repair or at our option replace free of charge any parts or components manufactured by us which fail due to faulty manufacture or material within 12 months of the date of despatch from our factory PROVIDED ALWAYS THAT a such parts or components have not been structurally modified or misused or misapplied and have been properly cared for and maintained and b they are returned to us carriage paid and all terms agreed by us for payment of such goods have been complied with and d any claim hereunder is made within 10 days of the date of discovery of the defect Our liability under this clause shall be in lieu and to the exclusion of any warranty or conditions implied or expressed by law as to quality or fitness for purpose of any goods supplied hereunder and save as provided in this clause we shall not be under any liability whether in contract tort or otherwise in respect of any defects in goods sold hereunder Page 5 3 FLOWPLANT LIMITED WARRANTY POLICY Flowplant Group Ltd warrants its equipment to the original customer only to be in conformance with the specification as agreed between the customer and the Company at the time of sale and to be free from defects in material and workmanship under normal and proper use for a period of twelve 12 calender months commencing from the date of acceptance of the
38. he lance supported by one man Once the tube has been inserted the other men required to support the control lance should take up their places and only then should the chargehand operate the valve NOTE When the person operating the remote control valve is unable to speak directly to the man or men controlling the lance a clearly understood system of signals and instructions must be agreed upon 2 A barrier should be placed at the far end of the tube being cleaned for protection against flying debris 3 A shield fitted to the lance to protect the operator from debris ejected by backward pointing jets should be used for certain operations Hoverclean 11 1 The angle of the jet holders determine the rotational speed of the spray bar this is set and locked in position at the works and on no account must this angle be altered Abrasive Injection Equipment 12 1 Because water abrasive jetting can give rise to dangerous splash back ensure all protective clothing detailed in Para 5 4 is used Some abrasives are known to produce residues which may be serious to health and should not be used for blasting such as sand containing free silica Accidents 13 1 In the event of a person being injured by the impact of a water jet the injury caused may appear insignificant and give little indication of the extent of the injury beneath the skin and the damage to deeper tissues Large quantities of water may have punc
39. he assembly drawings Figs 4 1 and 4 3 to 4 6 Page 4 6 Removal and Replacement of Pump Head NOTE Refer to Para 8 for drawing information 9 Carry out a removal and replacement of the Pump Head as follows 1 Switch off and isolate the prime mover 2 Switch off or disconnect the water mains supply to the tank 3 Drain the water tank 4 Disconnect the water inlet hose to the pump 5 Disconnect the small bleed hose at the top of the Inlet Manifold if fitted 6 Disconnect the high pressure hose from the Delivery Manifold 7 Drain water from the Inlet Manifold 8 Disconnect the hose snap coupling from the top of the Crankcase to Oil Expansion Bottle 9 Remove the hose from the top of the Crankcase and replace with a Lifting Eye 114 10 Connect lifting tackle to the Lifting Eye Do not take the weight of the pump leave only slack cable 11 Remove the bolts from the bell housing and pull off pump and bell housing NOTE If an adaptor ring is fitted it is usually best to leave it attached to the prime mover 12 Before replacing the pump check the drive coupling stand off distance 13 Replace the pump generally reversing the removal procedure NOTE Before operating the pump it may be necessary to bleed the pump of air 14 If the pump fitted is new or has been overhauled carry out the running in procedure detailed from Para 15 Removal and Inspection of Delivery Valves 4 Cylinder Pumps NOTES 1 Oil n
40. in the pump crankcase after each barrel has been bled 4 Repeatthe procedure detailed in sub para 3 for each barrel starting from the lower barrels first Fig 3 1 Bleeding the pump Page 3 8 5 When the operator has taken up a working position move the selector lever to the High Pressure position and increase engine speed to reach working pressure 6 Ifthe delivery line vibrates or the pump does not run smoothly stop the unit and carry out a water bleed Para 19 and then repeat the oil bleed To Water Bleed the Pump CAUTION ON NO ACCOUNT OPEN THE WATER BLEED SCREWS WHEN THE PUMP IS OPERATING UNDER PRESSURE 19 Whenever the unit is started after being allowed to run dry the following procedure must be followed 1 Setthe selector valve to the recycle dump position and start the engine motor Run at 750 rpm tick over to prime or inch electric motor on off NOTE If the unit is fitted with a shut down protection device hold in the override button for 10 seconds allows engine oil pressure to build up 2 The pump is self priming If however any difficulty is experienced stop engine loosen the upper bleed nipples and allow water to flow from each nipple ensure that the header tank remains full Tighten nipples and repeat the procedure detailed in sub para 1 To identify the bleed nipples refer to Fig 3 1 3 When the operator has taken up a working position move the selector lever to the High Pressure positio
41. is recommended that the pump is removed from the unit and placed in a Century Pump Stand part no 100 279 16 Separate the Crankcase halves as follows NOTE Refer to Para 8 for drawing information 1 2 3 4 5 6 Remove the pump as detailed in Para 9 removal and replacement of pump head Unscrew the Capscrew 102 If necessary hold the Coupling 5 to stop the Shaft 17 rotating Lift the Cap 56 out of the recess in the end of the Coupling 5 Remove Coupling 5 and Counter Balance 4 from the Shaft 17 This operation is made easier using a Puller part no 201 081 Unscrew and remove Nuts 86 and Washers 103 Remove the Bell Housing 84 Page 4 13 7 Remove Key 30 from the Shaft 17 8 Place the pump in the repair stand 9 Drain the oil from the pump into a suitable container 10 Depending on the type of pump carry out one of the following operations a If unit contains a 4 cylinder pump carry out the procedure detailed in Para 10 1 to 3 b If unit contains an 8 cylinder pump carry out the procedure detailed in Para 11 1 to 3 c If unit contains an 8 cylinder pump with split delivery manifold carry out the procedure detailed in Para 12 1 to 6 11 Unscrew and remove Nuts 105 12 Pull Inlet Manifold 16 off of Studs 101 NOTE Depending on the nature of the repair or investigation either complete the appropriate operation for the pump detailed in Pa
42. l and Inspection of Delivery Valves 8 Cylinders Pumps NOTES 1 need not be drained 2 Refer to Para 8 for drawing information 11 Carry out removal and inspection of Delivery Valves as follows Page 4 8 1 2 3 4 Unscrew and remove the Banjo Bolts 57 and 58 with Bonded Seal 65 Pull off Delivery Tubes 18 and Banjos 20 and 21 Recover the Bonded Seals 65 from between the Banjos and delivery Nuts NOTE Delivery Tubes are shown on Fig 1 1 Section 1 linking each of the Barrels via the Banjos Unscrew and remove the Delivery Nut 49 containing the Valve Assembly Place a nylon drift part no 061 045 through the female threaded end of the Delivery Nut until it touches the bottom of Guide 48 Tap the end of the Drift gently until the Guide pushes the Seat 45 out from the recess in the Delivery Nut NOTE f difficulty is experienced and the Valve Assembly is not completely removed use a flat blade screwdriver in the radial groove of the Delivery Seat 45 and gently ease the Seat from the Delivery Nut Guide 48 and Ball 47 can now be removed 5 6 7 8 9 Inspect Ball 47 and Seat 45 If either is badly pitted chipped or unevenly worn it must be replaced Inspect the bore of Guide 48 Replace if it is pitted chipped or unevenly worn Fit the Seat 45 into the Delivery Nut 49 using a small hand press If a hand press is not available tap the Seat in with a
43. l drive and hydraulic drive options are available PUMP DESCRIPTION Functional NOTE The following description of the Harben Century Type Pump applies equally to the 4 and 8 cylinder variants of the pump Performance details of each type of pump are given later in this section 4 The Century pump works on the radial piston design principle which uses one way valves in conjunction with tubular diaphragms fitted with an internal support or mandrel The pumped fluid which passes through this diaphragm is enclosed by a cylindrical pressure chamber or barrel in the ends of which are fitted inlet and delivery valves 5 The pump crankcase which contains the only mechanical moving parts is filled with mineral hydraulic oil This oil provides for the lubrication of all moving parts within the crankcase and as a means of pressure to compress the diaphragm Page 1 3 6 Asthe pump shaft rotates the piston advances and its ports pass the end of the cylinder sealing the chamber Further advance of the piston causes the trapped oil to compress the diaphragm around the mandrel expelling the water in the diaphragm through the delivery valve and into the delivery manifold 7 Whenthe piston retreats the diaphragm reverts to its tubular form and draws water through the inlet valve Any oil slippage past the piston during the delivery stroke is made up through the piston ports as they open to the crankcase oil 8 All mechanical parts with th
44. le 1 1 Pump Physical data 1 2 Pump Performance Data Maximum Working Pressures 1 3a b Performance Data Century Type Pump and HP Required 1 3 Equipment Serial Numbers and Jet Sizes 10 11 12 15 16 17 18 1 5 1 7a b 1 8 Pages 1 1 2 Page 1 3 TECHNICAL DATA INTRODUCTION 1 Harben Century Type high pressure pump Fig 1 1 is a radial piston diaphragm pump which can be used for a number of industrial applications including the following a High pressure cutting of board plastic and other materials b Water hydraulic systems c Abrasive blasting and de scaling d Drain sewer cleaning e Tube de scaling f Desalination by reverse osmosis g Pumping demineralised water h Floor and surface cleaning i Underwater cleaning j Surface preparation 2 In addition to its reliability and long service intervals the advantages of using this type of pump include a Variable pressure and flow options without piston change b Pumps can run dry without damage as there are no piston seals c Filtration up to 150 microns d No modification is required to pump sea water e Pump has multi cylinders therefore no pulsation 3 The pump is designed to be directly coupled and flange mounted and can be supplied in either bare shaft form or skid mounted trolley mounted trailer mounted or truck mounted configurations In addition the pump can be mounted on an underwater ROV Diesel drive electrica
45. livery Manifold Removal and Inspection of Inlet Valve Assembly and Diaphragm Separating Crankcase Halves Renewing Crankcase Components Re Assemble Pump Pump Running In ILLUSTRATIONS Mandrel Assembly Inlet Valve Seat Back Up Ring and 0 Ring Fitting Barrel Code Century Pump Assembly Century Pump Barrel Assembly Century Pump Parts List Selector Mk 2 Century Safety Valve Assembly TABLES Pump Maintenance Schedule Pump Lubrication Chart Para oU Y 10 11 12 13 15 17 23 24 Page 4 11 4 12 4 18 4 21 4 23 a b 4 25 4 27 4 29 Page 4 1 2 PUMP MAINTENANCE AND OVERHAUL PROCEDURES ROUTINE MAINTENANCE Introduction 1 The Maintenance Schedule Table 4 1 gives details of pump maintenance only For details of equipment maintenance refer to the appropriate handbook Details of pump oil capacities and recommended oil types are given in the Lubrication Chart Table 4 2 Refer to the manufacturer s handbook for diesel engine oil 2 Whilst specific periods for routine preventive maintenance of the pump are given due regard should be taken of local regulations concerning the vehicle or machine Ensure the machine is operating within those regulations TABLE 4 1 PUMP MAINTENANCE SCHEDULE CHECKLIST TO USE DAILY AFTER 8 HOURS RUNNING Crankcase oil Check for level fill if necessary refer to Section 3 Para 18 1 for procedure and Table 4 2 for oil types Pipes hoses and
46. machine by the customer 1 year warranty on Century pump Inthe event of a change of ownership within the warranty period any remaining warranty entitlement may only be transferred to the new owner of the machine with the Company s written agreement This warranty applies to new equipment only This warranty provides for the free of charge replacement and fitment by the Distributor Dealer Agent or the Company s own Service Engineer of components which having been inspected by the Company are deemed to be defective in material or workmanship or do not conform to specification Replacement parts supplied by the Company for the purpose of repair may be genuine new or factory reconditioned parts Where replacement parts have been fitted or supplied within the warranty period these will only be warranted until the original machine warranty expires Genuine Flowplant Manufactured replacement parts purchased from the Company for normal repair purposes are guaranteed for six 6 calendar months from the retail sale date All other manufacturers warranties apply This warranty does not cover damage caused by shipment misuse or abuse of the equipment including operation beyond recommended specification limits failure to maintain the equipment in accordance with the Company s recommendations fitment to the equipment of any spurious replacement parts any unauthorised changes to the equipment original specification mounting
47. n and increase engine speed to reach working pressure NOTE If the delivery line vibrates this indicates that air is still in the system Stop the unit and repeat the procedure detailed in sub para 1 To Anti Freeze a Unit Without an Anti Freeze Tank 20 1 Prepare 5 gallons or larger quantity if required of 3096 to 5096 anti freeze solution 2 Drain the water tanks 3 Pourthe anti freeze solution into the break tanks 4 Remove any jet or accessory from the end of the high pressure hose 5 Ensure the high pressure selector lever is in the dump or off position Start the engine and allow to run for 1 minute 6 Holding the outlet end of the hose move the selector to high pressure position and allow the engine to run until the anti freeze solution can be seen coming from the high pressure hose 7 Stopthe engine The unit is now anti freezed Page 3 9 To Remove Anti Freeze From a Unit Without an Anti Freeze Tank NOTE During this procedure carry out the air bleed procedure detailed in Para 19 if necessary 21 1 Drain any anti freeze solution from break tanks into a container 2 Fill break tanks with water 3 Place the outlet of the high pressure hose into the container 4 Place the selector lever in the high pressure position and whilst holding the high pressure hose start the engine 5 Runthe engine until all solution is returned to the container and clean water is seen flowing from the hose The unit is
48. nylon mallet making sure it is tapped in squarely and that no nylon from the mallet head goes into the Valve Assembly through the Seat hole Grease the threads of the Banjo Bolts 57 and 58 and Delivery Nut 49 before re assembly Re fit the Valve Assembly to the unit reversing the removal procedure given in Sub paras 3 to 1 in that order NOTE Where possible use a socket and torque wrench and torque the Delivery Nut and Banjo Bolts to that specified in Para 5 Removal and Inspection of Delivery Valves 8 Cylinder Pumps With Split Delivery Manifold NOTES 1 Oil need not be drained 2 Refer to Para 8 for drawing information 12 Carry out removal and inspection of Delivery Valves as follows 1 2 3 4 5 6 7 8 9 Unscrew and remove the four Nuts 106 not shown on drawings Lift off Washers 90 not shown on drawings Delivery Tubes 19 not shown on drawings and Banjos 22 and 23 can now be pulled off Unscrew and remove the four Nuts 107 not shown on drawings Lift off Washers 91 not shown on drawings The second set of Delivery Tubes and Banjos can now be pulled off Unscrew and remove Delivery Nuts 50 and 51 containing the Valve Assembly Insert a flat blade screwdriver into the radial groove of Delivery Seat 45 and levering gently around ease Seat from Delivery Nut 50 and 51 Remove the Guide 48 and Ball 47 from Delivery Nut 50 and 51 Page 4 9 10 Insp
49. ode to indicate their position in the crankcase refer to Section 4 Fig 4 2 This letter code can be found stamped on the face adjacent the inner cylinder Letters A to H are used Each barrel of a different code is given its own part number Page 1 4 14 A pump specification label is fitted on the pump crankcase adjacent to the oil filler cap This label will give the pump type ie number of cylinders and piston cylinder diameter For example 8 22 5 no of cyl piston cyl dia The label also gives the pump serial number the type of oil to be used Shell Tellus or equivalent the maximum working pressure the maximum working flow and the pump s year of manufacture DESIGN AND PERFORMANCE DATA Physical Data 15 TABLE 1 1 PUMP PHYSICAL DATA Pump diameter 560 mm Pump length 451 mm Inlet 2 in BSP 50 mm dia hose tail Outlet 1 2 in BSP Shaft diameter 45 mm Shaft length 83 mm NOTE For full details of the pump physical data refer to Fig 1 1 Performance Characteristics 16 For full details of the Century Series Pump performance data reference should be made to the appropriate information given in Tables 1 2 and 1 3a b TABLE 1 2 PUMP PERFORMANCE DATA MAXIMUM WORKING PRESSURES Pump Cylinder 1000 rpm Diameter normal working speed 22 5 mm 10 000 psi 700 bar 25 0mm 8000 psi 550 bar 27 5mm 6000 psi 415 bar NOTES 1 Asarule electrically driven and di
50. ons are to be carried out remote from the high pressure pump unit i e where communication between the person controlling the pump and the equipment operator is not possible it is essential that a remote control kit or foot control valve is used at the work point Care should be taken to ensure that all hoses are maintained in good condition and are of the correct specification for the pressure being used Never loop the hose into an excessively tight radius particularly adjacent to couplings When fitting re usable couplings always ensure that the current type of couplings are being used in relation to the hose specification Page 3 4 SAFETY CODE OF PRACTICE Cont d NOTE The equipments detailed in Paras 9 10 11 and 12 are for specialist applications Underwater Recoil less Safety Gun 9 1 Harben Underwater Recoil less Safety Gun is designed for use under water only Extreme care should be taken to avoid rear facing balance jetswhen testing the equipment above water 2 Ifworking in shallow water where there is a possibility of the diver surfacing inadvertently during water blasting care should be taken to ensure that the recoil balance jet protection tube is sufficiently long to prevent the diver directing it at himself Tube Cleaning 10 1 Where tube cleaning is to be done by means of a lance the chargehand who operates the remote control valve should first insert the lance into the tube leaving the other end of t
51. paratus 15 minute Escape Set 061 257 Operators Safety Guide 057 062 Safety Code Of Practice Page 3 6 GENERAL OPERATING INSTRUCTIONS Introduction 15 The following operating instructions are of a general nature with reference being made to the appropriate manufacturer s handbook for the machine Starting 16 To start the unit carry out the following instructions 1 2 3 4 Stopping Prior to starting the unit carry out the following pre checks i Setthe high pressure selector to the recycle dump position ii Ensure the unit is on level ground Check that the water supply is connected and the header tank is full iv Check that all guns and nozzles are connected Ensure correct fitting and correct size for the pressure required Start the unit Refer to the manufacturer s handbook for information concerning engine electric motor starting procedure NOTE Before starting the unit and carrying out water and or oil bleed operations refer to Paras 18 and 19 respectively familiarise yourself with the units controls and the stopping instructions Para 17 Move the selector to the High Pressure position Increase engine rpm if diesel to achieve desired pressure 17 To shut down the unit carry out the following instructions 1 2 3 4 5 6 Reduce engine revs to tick over speed Move the high pressure selector to the recycle dump position Switch off the prime mover by following the instr
52. part Brake squeal from brake linings Replacement of linings due to fair wear and tear Tightness of air lines pipes Filters and the cleaning of filters Brake fluid Electrical all products Manufacturers Warranty Applies Cleaning of terminals General maintenance of batteries dynamo alternator starter etc Adjustment to ignition system components General adjustment to electrical control current settings Brushes and other items due to fair wear and tear Contactor tips and springs Replacement of lamps lenses and bulbs Steering Running Gear Front wheel alignment track adjustment Steering adjustment Hub bearing and float adjustment Jockey wheels Hydraulics all products Tightening of hydraulic fittings and couplings Filters and the cleaning of filters Hydraulic fluid Chassis self propelled and trailer mounted units General rattles Paint chips Alignment and adjustment of panels etc Deterioration of paint and external fittings due to neglect exposure and fair wear and tear Accidental damage Page 5 5 Lubrication all products Complete or partial lubrication services Corrosion all product e Damage caused by adverse weather atmosphere conditions General all products e Fair wear and tear Any work carried out to improve the general finish of the machine above e what is known to be the factory standard e Failure to maintain the equipment in accordance with the manufa
53. ra 10 11 or 12 or continue this procedure from sub para 13 13 Unscrew and remove the Bleed Screws 93 and pull the Bleed Ring 44 off the Barrel 14 Unscrew Barrel retaining Capscrew 95 one complete turn only NOTES 1 Only Capscrews adjacent to Barrels need be undone 2 If a 4 cylinder pump do not unscrew Capscrew 95 15 Unscrew and remove eight Nuts 111 121 and Washers 103 from Bolt 99 16 At the delivery side of the pump unscrew Bolts 99 until end of Bolt is flush with the Inlet Crankcase 2 17 Using a nylon mallet tap the heads of Bolts 99 gently making the Inlet Crankcase 2 separate from the Delivery Crankcase 3 Ensure the Crankcase halves separate evenly When the halves have almost separated it may be necessary to unscrew Bolts 99 a couple more turns and tap them again to completely disengage the halves CAUTION DO NOT UNSCREW BOLTS 99 MORE THAN IS NECESSARY IF TOO FEW THREADS ARE BEING USED IN THE INLET CRANKCASE THREADS MAY BE STRIPPED WHEN THE BOLTS ARE TAPPED 18 When halves are apart unscrew and remove Bolts 99 19 Lift Inlet Crankcase Page 4 14 20 Remove Spacer Tube Assemblies 112 21 The pump is now prepared for Crankcase component repair or replacement Renewing Crankcase Components 17 Once the crankcase has been opened Para 16 the following major repairs replacements can be carried out a Change Float Bearing 13 Para 18 b Change Bearing 12
54. to account when determining maximum pressure to be used when running in the pump Piston Size Maximum Pressure 22 5 mm 700 bar 10000 psi 25 0 mm 550 bar 8000 psi 27 5 mm 420 bar 6000 psi a Ifthe pump is being used on a system that has a lower working pressure than the maximum for the pump then running in of the pump should be at the lower pressure b Check the pump Identification Plate for the maximum working pressure of the pump before commencing the running in test Some models of pumps have working pressures lower than stated in which case running in should be carried out at the lower pressure Page 4 20 A TTA i ft Y C7 tp Sr gir M M AN 4 0 FR x 2 4 D OY 6 1 Fig 4 4 Century Pump Assembly Nor T RCM v 55 6 E 3 Page 4 21 22 4 p ow sj ABCDEFGHJK 3 SUPPLIED MANUFACTURERS UNABLE TO COMPLY MAY Third angle projection m xvz DRED eamrwo waren sec sce u Noora 0 4 ora mo LEADERS IN CLEANING TECHNOLOGY Fig 4 5a Century Pump Barrel Assembly Standard Delivery ABCDEFGHJK MANUFACTURERS UNABLE TO COMPLY MAY MATERIA LEST INE E sa eee PARTS LIST INFORMATION FOR ESTIMATION OF WEIGHT AND COST ONLY 0 4 A ISSUE ARE TO BE DESTROYED
55. ts should be considered a Full protective clothing must be worn b Always clean scratches or cuts immediately Disinfect and cover with a strip of gauze and impermeable plaster SEEK MEDICAL HELP Avoid rubbing eyes nose or mouth with hands during working d All contaminated clothing vehicles and equipment should be thoroughly cleaned e Operators should wash thoroughly after work and before eating drinking or smoking v vi SAFETY CODE OF PRACTICE Full details of the Safety Code of Practice when working with equipment containing a Harben pump are given in Section 3 of this manual The basic rules of this code are as follows 5 ALWAYS WEAR THE CORRECT PROTECTIVE CLOTHING ALWAYS ENSURE ALL EQUIPMENT IS IN A FIRST CLASS CONDITION NEVER WORK FROM A LADDER NEVER USE THE GUN WITH THE TRIGGER LOCKED ON NEVER POINT THE GUN AT ANYONE EVEN IF SWITCHED OFF Only a responsible person who has received instruction in the operation of high pressure water jetting equipment should be allowed to operate the equipment vii viii SECTION 1 TECHNICAL DATA SECTION 1 TECHNICAL DATA CONTENTS Introduction Pump description Function Filtration Fluid Flow Identity Manufacturer Pump Options Identification Design and performance data Physical data Performance Characteristics Equipment Details Associated publications ILLUSTRATION Fig 1 1 Harben Century Type High Pressure Pump TABLES Tab
56. tured the skin flesh and organs through a very small hole that may not even bleed Page 3 5 SAFETY CODE OF PRACTICE Cont d Accidents Cont d 2 Operators should carry a card which explains to medical staff the possible nature of the injury both relating to the high pressure water and any unusual infections that may be found in sewage such as leptospirosis better known as Weil s Disease PROTECTIVE EQUIPMENT 14 Arange of top quality protective equipment is available from Flowplant Group Ltd as follows PART NO DESCRIPTION BRITISH STANDARD 061 037 Suit Waterproof Orange size small BS4170 061 025 Suit Waterproof Orange size medium BS4170 061 026 Suit Waterproof Orange size large BS4170 061 020 Suit Waterproof Orange size extra large BS4170 065 029 Boots Wellington size 7 BS1870 065 016 Boots Wellington size 8 BS1870 065 017 Boots Wellington size 9 BS1870 065 018 Boots Wellington size 10 BS1870 065 019 Boots Wellington size 11 BS1870 065 002 Boots Wellington size 12 BS1870 065 004 Gloves BS1651 065 027 Helmet BS5240 065 006 Visor BS2092 065 005 Visor and Chin Guard BS2092 065 029 Ear Defenders BS5108 065 013 Helmet White BS5240 Visor and Chin Guard BS2092 Ear Defenders BS5108 065 021 Harness Safety Rescue BS1397 065 025 Sign Warning WATER JETTING 057 059 Sign Safety Warning adhesive 065 028 Cone Traffic 450 mm 065 023 Detector Gas BASEEFA Approved 065 022 Torch BASEEFA Approved 065 024 Breathing Ap
57. tvalve removal Puller coupling and C balance Dolly bearing crankcase Dollyeccentric Dollyoil seal in Dollyoil seal out Dollyseal stretcher Dollyseal pusher Dollyseal shrinker Press small Wrench hex 1 2 square drive 8 mm x 100 mm Plierslong nose 5 Torque wrench Norbar No 4 Screwdriver flat blade 10 Hammer nylon 1 3 4 dia Hammerlump 2 kg Spanner adjustable 6 Spanner adjustable 12 Spanner adjustable 15 Spanner combination 4 BA Spanner slogging 50 mm Spanner slogging 70 mm Spanner open ended 13 mm x 17 mm Spanner open ended 9 16 whit x 5 8 whit Spanner plate 61 3mm AF Socket 3 4 square drive 70 mm Socket 3 4 square drive 50 mm Socket 1 2 square drive 17 mm Socket 1 2 square drive 27 mm Socket 1 2 square drive 1116 Socket 1 2 square drive 5 16 Socket converter 1 2 F to 3 4 M Socket reversible ratchet 1 2 square drive Socket extension bar 250 mm 1 2 square drive Bucket 15 litre 100 279 201 043 201 082 201 044 201 012 061 045 201 081 201 011 201 001 201 003 201 004 201 061 201 065 201 066 201 083 203 230 205 021 203 257 206 201 206 001 206 010 202 304 202 302 202 301 202 150 202 264 202 266 202 010 202 048 201 151 203 283 203 282 203 170 203 180 203 129 203 204 203 252 203 242 203 247 206 104 Page 4 5 Torque Settings 5 The torque settings for selected components are Drg Item No Ibft kgm Nm
58. uctions given in the manufacturers and book for the engine electric motor If there is the risk of freezing follow the instructions given the frost precautions anti freeze procedures Paras 20 or 22 If the unit is to be stored for more than 7 days without running an inhibitor should be run through the system Do not drain prior to storage always leave full of fresh water or inhibitor Refer to the manufacturer s handbook for information concerning engine electric motor protection storage Page 3 7 To Bleed the Pump 18 As delivered from the factory the pump would have already been oil bled except pump heads supplied separately If necessary oil bleed the pump as follows NOTE Refer to the lubrication chart given in Section 4 Table 4 2 for details of pump oil types and capacities 1 Fill the pump to the top of the crankcase with the correct oil or ensure oil is in the expansion bottle if fitted 2 Setthe selector valve to the recycle dump position and start the engine motor Run at 750 rpm tick over to prime or inch electric motor on off NOTE If the unit is fitted with a shut down protection device hold in the override button for 10 seconds this allows the engine oil pressure to build up 3 With reference to Fig 3 1 put a finger on top of an oil bleed screw on a lower barrel and open the screw slowly using a suitable spanner When air free oil flows tighten the bleed screw firmly NOTE Top up oil
59. udes likely equipment faults whilst Table 3 2 gives likely pump faults For details of engine faults refer to the appropriate manufacturer s handbook When investigating a pump diaphragm for possible failure refer to Fig 3 2 TABLE 3 1 EQUIPMENT FAULT FINDING Problem Cause Action Low System Pressure 1 Worn or incorrect size of Replace nozzle cutting nozzle 2 Engine speed slow Adjust to correct speed 3 Leaks from hose pipes and Check connections for connections tightness Replace as necessary 4 Blocked inlet filter Clean or replace element 5 Inlet hose too long Shorten hose length 6 Loss of water through Check seats and seals dump line of selector valve or gun when high pressure selected 7 Lossof water through Check seats and seals dump line of remote control kit if fitted High System Pressure 1 Blocked nozzle selector Clean nozzle selector valve or valve or gun gun and flush out delivery line 2 Nozzle size too small Replace nozzle 3 Hose bore size too small Replace hose 4 Engine speed high Adjust to correct speed 5 Crushed delivery hose Replace if necessary 6 Two gun choke left in gun Replace with STD choke when operating as single gun unit Cont d Page 3 11 TABLE 3 1 EQUIPMENT FAULT FINDING Cont d Problem Cause Action Low Water Level 1 Blocked or dirty pre filters Clean or replace elements 2 Faulty ball valve assembly
60. valve Excessive inlet hose length Pump has been frozen Clear restriction Check inlet valves replace if necessary Check diaphragms replace as necessary Replenish oil Mixing of Oil and Water in Crankcase Diaphragm failure may have been through fatigue from excessive running hours Check all diaphragms replace as necessary Page 3 13 Page 3 14 FAINT CIRCULAR LINE IMPRINT ONLY INDICATES DELIVERY VALVE PROBLEMS ASSOCIATED WITH THIS BARREL lt DIAPHRAGM PROTECTION VALVE LIFTING FOUR SMALL IMPRESSIONS SIMILAR TO ILLUSTRATION REASON DIAPHRAGM PUMPING THROUGH MANDREL DELIVERY HOLES CAUSED BY INLET RESTRICTION SHEAR THROUGH WALL OF DIAPHRAGM CAUSED BY FATIGUE FROM EXCESSIVE RUNNING HOURS Fig 3 2 Pump Fault Finding Diaphragm Failure and Indication of Other Problems SECTION 4 PUMP MAINTENANCE AND OVERHAUL PROCEDURES SECTION 4 PUMP MAINTENANCE AND OVERHAUL PROCEDURES CONTENTS Routine Maintenance Introduction Pump Service Information General Recommended Service Tools Torque Settings Service Kits Pump Overhaul Procedures Fig 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Table 4 1 4 2 Introduction Removal and Replacement of Pump Head Removal and Inspection of Delivery Valves 4 Cylinder Pumps Removal and Inspection of Delivery Valves 8 Cylinder Pumps Removal and Inspection of Delivery Valves 4 Cylinder Pumps with Split De
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