HARBEN ˈPˈ TYPE PUMP SERVICE MANUAL
Contents
1. Engine Gearbox Gearbox Gear Input Engine Adaptor Adaptor Flender Output Coupling Drive Plate Ring Flexibles Coupling Flange Flywheel Ford FSD 016 020 012 160 016 032 016 054 N A N A 016 014 Perkins 3 152 016 020 012 160 016 032 016 001 016 038 012 146 016 014 Lister TX2 3 016 020 012 159 016 037 016 036 N A 012 183 016 034 Harz 3L40C 016 020 012 160 016 030 016 031 N A 012 194 016 014 Kubota V1505 016 020 012 159 016 096 016 095 N A 012 213 016 014 Lister LPWS3 016 020 012 159 016 032 016 107 N A 012 213 016 014 18 012 159 when 019 020 8 x 22 3516 option is selected Fig 2 3 Pump Installation Coupling Gearbox Arrangements for Diesel Drive COUPLING ELECTRIC MOTOR COUPLING P PUMP 023 093 BELL HOUSING MOTOR HALF COUPLINGS FOR ELECTRIC MOTORS Metric Frame Non hazardous Types Part Number Description 023 094 7 5 HP Motor coupling B140 Pt 1 023 034 10 HP Motor coupling B140 Pt 1 023 034 15 HP Motor coupling B140 Pt 1 023 036 20 HP Motor coupling B140 Pt 1 023 037 25 HP Motor coupling B140 Pt 1 023 037 40 HP Motor coupling B140 Pt 1 Fig 2 4 Pump Installation Coupling Arrangements for Electric Drive 19 INLET WATER General 10 11 NOTES 12 13 14 It is recommended that inlet water is filtered to between 50 and 150 microns Flowplant Group offer types of filter suitable for most applicat2. 40 Torque Settings 5 The torque settings for selected components are Drg Item No Ibft Nut nyloc M20 x 1 5 29 100 Valve nut delivery 44 100 Valve nut inlet 41 100 Adaptor 49 30 Adaptor 73 29 Set screw 20 20 Set screw 14 40 Holder for Burst Disc 64 25 Banjo bolt R3 118 kgm 13 8 13 8 13 8 4 1 4 0 2 8 5 5 3 5 16 3 135 135 135 41 39 27 54 34 160 Refer to Para 9 and the drawings in this section to locate Item Number Burst Discs 6 When carrying out any maintenance overhaul of the pump ensure the correct burst disc for its working pressure is fitted The available burst discs are as follows Colour Code Part Number Yellow 011 019 Blue 011 020 Red 011 021 Purple 011 022 Green 011 045 White 011 046 Black 011 047 Orange 011 107 Service Kits For Maximum Working Pressure 125 bar 1800 psi 140 bar 2000 psi 175 bar 2500 psi 210 bar 3000 psi 240 bar 3500 psi 275 bar 4000 psi 345 bar 5000 psi 415 bar 6000 psi 7 Service overhaul kits are available when carrying out repair or overhaul of the pump Details of kits for both the Standard P pump and the High Lift pump are as follows NOTE High Lift pumps are identified from Standard P pumps by the letter H being stamped after the serial number on the pump identification Plate a Standard P Pump Service Kit Kit overhaul valve and diaphragm 3 cyl P pump Kit overhaul valve and diaphragm 4 cyl P pump
3. NOTE Refer to Para 9 for drawing information 1 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 42 4 5 8 7 8 9 10 NOTE 11 12 NOTE 13 Disconnect the water inlet hose to the pump Disconnect the high pressure hose from the Delivery Manifold or Selector as fitted Drain water from the base of the Inlet Manifold 12 Replace when drained Disconnect the hose Snap Coupling from the top of the Crankcase to oil expansion bottle if fitted Remove either the Expansion Chamber 4 or the Adaptor from the top of the Crankcase and replace with a Lifting Eye Part No 061 077 Connect lifting tackle to the Lifting Eye Po not take the weight of the pump leave only slack cable Remove the bolts from the bell housing and pull off pump and bell housing If an adaptor ring is fitted it is usually best to leave it attached to the prime mover Before replacing the pump check the drive coupling stand off distance Replace the pump generally reversing the removal procedure Before operating the pump it may be necessary to bleed the pump of air If the pump fitted is new or has been overhauled carry out the running in procedure detailed from Para 15 Removal and Replacement of Diaphragms and Valves NOTES 1 In most cases the w
4. 280 bar 420 bar 4000 psi 5000 psi 4000 psi 5000 psi 280 bar 350 bar 280 bar 350 bar 4000 psi 4000 psi 4000 psi 4000 psi 280 bar 280 bar 280 bar 280 bar NOTES 1 EN1A and EN57 denote barrel materials EN1A is mild Steel with a Cadmium plating whilst EN57 is Stainless Steel self finish EN1A barrels have now been withdrawn and replaced with 57 2 Asarule electrically driven pumps run at 1000 rpm and diesel driven pumps run at 1250 rpm 3 Quantity of cylinders does not alter pump working pressure EQUIPMENT DETAILS 20 Details relevant to the pump and associated equipment should be entered on the form shown in Table 1 4 at the rear of this section for future reference ASSOCIATED PUBLICATIONS 21 Associated with this manual are the following publications Operators Guide Part No 061 225 Code of Practice Part No 057 062 Guide Do and Don t Booklet Part No 081 259 PRESSURE TABLE 1 2 PERFORMANCE DATA TYPE PUMP HORSEPOWER REQUIRED PERFORMANCE DATA FOR P TYPE PUMP AND HORSEPOWER REQUIRED 7000 ODO ODO aan a ee Pe HE ee 5000 o Himani ae FERNE Od 4 4000 OOOO O0 OE PH de 2122422 THEE Es 3000 12
5. Para CO NN 15 16 17 18 19 13 14 This page is intentionally left blank PUMP INSTALLATION INTRODUCTION 1 It may 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 PUMP MOUNTING General Details 2 The P and High Lift pumps are designed for direct drive and flange mounting The normal operating speeds are 960 rpm for the P pump and 1250 rpm for the High Lift pump Maximum operating speeds are 1000 rpm for the P pump and 1250 rpm for the High Lift pump The pumps can rotate either clockwise or anticlockwise as required 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 3 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 4 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 8 cyl 80 kg 6 cyl 68
6. 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 PRIOR TO USE DAILY AFTER 8 HOURS RUNNING Crankcase oil Pipes hoses and fittings Pump working pressure General Check for level fill if necessary refer to Section 3 Para 18 1 for procedure and Table 4 2 for oil types Check wear damage correct rating and size Check correct Check pump for smooth running overheating leaks and security of components Inlet delivery valves Diaphragms SIX MONTHLY 300 HOURS Check for wear and damage Check for wear and damage Crankcase oil Inlet delivery valves P Inlet delivery valves HL Pipes hoses and fittings YEARLY 500 HOURS Drain and renew Check for wear and damage Replace Carry out a detailed inspection Inlet delivery valves P Diaphragms 38 TWO YEARLY 1000 HOURS Replace Replace Table 4
7. Kit overhaul valve and diaphragm 6 cyl P pump Kit overhaul valve and diaphragm 8 cyl P pump Part No 023 236 Part No 023 237 Part No 023 238 Part No 023 239 41 Part No Description Quantity 3 cyl 4 cyl 6 cyl 8 cyl 011 060 Valve delivery 3 4 6 8 011 048 Valve inlet 3 4 6 8 012 032 Diaphragm 3 4 6 8 b High Lift Pump Service Kit Kit overhaul valve and diaphragm 3 cyl HL pump Part No 024 024 Kit overhaul valve and diaphragm 4 cyl HL pump Part No 024 025 Kit overhaul valve and diaphragm 6 cyl HL pump Part No 024 026 Kit overhaul valve and diaphragm 8 cyl HL pump Part No 024 027 Part No Description Quantity 3 cyl 4 cyl 6 cyl 8 cyl 011 060 Valve delivery 3 4 6 8 011 166 Valve inlet 3 4 6 8 012 032 Diaphragm 3 4 6 8 PUMP OVERHAUL PROCEDURES Introduction 8 During the pump overhaul procedures reference should be made to the pump assembly drawings including associated Parts List located at the rear of this section Also included are assembly drawings of the inlet manifold and inline and manifold selectors 9 Inthe following overhaul procedures the item number that follows the description of a part refers to the assembly drawings Figs 4 3 to 4 6 Where the letter M appears before the item number refer to the Inlet Manifold Assembly drawing Fig 4 7 Where the letter R appears before the item number refer to the Manifold Delivery Assembly drawings Figs 4 8 and 4 9 Removal and Replacement of Pump Head
8. bleed pump Para 19 Oil bleed pump Para 18 Replace flexible elements and examine coupling Check valve condition Check tightness of inlet and delivery nut Burst Disc Failure or Safety Relief Valve Operating also refer to high system pressure problem 1 Incorrect burst disc 2 Incorrect valve setting 3 Faulty Valve 4 Faulty or fatigued burst disc Replace with correct disc Check certificate setting Repair or replace as necessary Replace with new disc 34 Table 3 2 Pump Fault Finding Problem Cause Action Mixing of Oil and Worn or damaged delivery Check all delivery valves Water in valves replace as necessary Crankcase Loss of pressure Pump not running evenly Damaged filter element allowing debris to jam delivery valve Check all diaphragms replace as necessary Replace oil Check filters replace as necessary Loss of crankcase oil through high pressure hose Loss of pump pressure Pump not running evenly Inlet restriction may have been caused through a Blocked filters b Kinked inlet hose Worn or damaged inlet valves d Excessive inlet hose length Pump has been frozen Clear restriction Check inlet valves replace as necessary Check diaphragms replace as necessary Replenish oil Mixing of Oil and Water in Crankcase Diaphragm failure may have been through fatigue from exce
9. 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 possible 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 occupier s representative iv INJURY FROM ENVIRONMENT Work should only be carried out if it is safe to do so Athorough examination of t
10. i ee 2 224444411411111 EE ponpon 2000 et Hen 1 men OOOO ogi 1000 Litre min l UK Gal min I US Gal min FLOW PRESSURE TABLE 1 3 PERFORMANCE DATA HIGH LIFT TYPE PUMP HORSEPOWER REQUIRED PERFORMANCE DATA FOR HIGH LIFT PUMP AND HORSEPOWER REQUIRED GRAPH SHOWS P PUMP PERFORMANCE 1250 RPM DIESEL ENGINE GEARBOX SEE SEPERATE GRAPH FOR P PUMP PERFORMANCE 960 RPM ELECTRIC MOTOR Psi bar 5000 4000 3000 2000 1000 FLOW TABLE 1 4 EQUIPMENT SERIAL NUMBERS AND JET SIZES Pump Serial No s Engine Engine Serial No Gearbox Gearbox Serial No Motor Motor Serial No Maximum Working Pressure Of pump 0 Maximum Flow at Above Pressure ussseveseereversrraserssnennerevessevevssvanenvsnenseravessenesnevanessensvssrnseanenennene Single Gun High Velocity Jet Size Single Gun 15 Degree Jet Size Twin Gun High Velocitvlet de Twin 15 Degree FanJet 22 aaa TwinGunChokeSze Type of Safety Supplied 2 Standard Drain Jets 3 Rear drainjet a aeeaeseceeecseceesseceecssesecesaeseesaescessescaecoesaeseeesacse
11. is required the pump should be removed to the workshop The use of an assembly stand is recommended COUPLING CLEARANCE SITE OF PRESSURE GAUGE i lt REPLACEMENT fl OF PRESSURE end oOo DIAPHRAGM REPLACEMENT Fig 2 1 Pump Installation Pump Mounting 16 Pump Access 8 Reference should be made to Fig 2 2 for the pump access requirements In addition access is also required to the pressure disc Fig 2 1 A withdrawal distance of at least 25 mm should be allowed for removal of the inlet manifold OIL FILL SIGHT CHECK LEVEL OIL BLEED NUT TORQUE DELIVERY amp INLET SEE NOTE OIL DRAIN NOTE IT MAY BE NECESSARY FOR THE PUMP HEAD TO BE REMOVED TO CHANGE VALVES AND DIAPHRAGMS ACCESS IS NOT AVAILABLE ON ALL UNITS FOR THE FITTING OF A SOCKET AND TORQUE WRENCH TO THE INLET NUTS THUS IF A SOCKET CANNOT BE USED THEN THE HEAD MUST COME OFF ON SOME UNITS UNLESS THE BELL HOUSING IS REMOVED IT IS IMPOSSIBLE TO FIT A SOCKET Fig 2 2 Pump Installation Pump Access 17 Coupling Arrangements 9 For details of the engine gearbox coupling arrangements for diesel driven pumps refer to Fig 2 3 For details of the coupling arrangements for electrically driven pumps refer to Fig 2 4 BELL HOUSING 021 020 COUPLING P PUMP 023 093 COUPLING GEARBOX OUTPUT COUPLING GEARBOX INPUT COUPLING DIESEL ENGINE
12. kg 4 cyl 58 kg 3 cyl 51 kg 5 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 6 It is recommended that a detailed layout be drawn and the following points considered a Selection of hell 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 Fig 2 1 15 7 When the pump is to be fitted in position the following points should be noted a When the pump is first married up to the prime mover access is required to check coupling clearance When Flender 8140 couplings are used sight gauge holes are drilled in the bell housing for this purpose b Where pumps are fitted with either a pressure gauge or selector not shown on Fig 2 1 sufficient access must be allowed for sight or operation If this is impracticable a remote pressure gauge and selector are recommended It depends on the particular installation whether the pump head is removed to a workshop for maintenance e g diaphragm or valve replacement or whether work is carried out in situ See also Fig 2 2 Note Where a pump strip down
13. 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 Backed 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 an attractive return on investment that really makes sense Flowplant Group Ltd have a policy of continual research and improvement and 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 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
14. or incorrect size of cutting nozzle Engine speed slow Leaks from hose pipes and connections Blocked inlet filter Inlet hose too long Loss of water through dump line of selector valve or gun when high pressure selected Loss of water through dump line of remote control kit if fitted Replace nozzle Adjust to correct speed Check connections for tightness Replace as necessary Clean or replace element Shorten hose length Check seats and seals Check seats and seals High System Pressure Blocked nozzle selector valve or gun Incorrect nozzle size Incorrect bore size Engine speed high Crushed delivery hose Two gun choke left in gun when operating as single gun unit Clean nozzle selector valve of gun and flush out delivery line Replace nozzle Replace nozzle Adjust to correct speed Replace if necessary Replace with standard choke 33 Table 3 1 Equipment Fault Finding Cont d Problem Cause Action Low Water Level 1 Blocked or dirty pre filters 2 Faulty ball valve assembly 3 Wrong seat in ball valve assembly Low inlet pressure Clean or replace elements Replace if necessary Replace if necessary Increase pressure Pump Not Running Evenly also refer to Pump faults 1 Airin water 2 Airin crankcase oil 3 Worn Coupling 4 Faulty inlet or delivery valve 5 Valve nut over tightened Water
15. 0 Barrel L 011 261 Barrel For example 011 252AB is C barrel EN57 ST ST with 22 mm cylinder IDENTITY Manufacturer 16 The Harben Pumps are manufactured by Flowplant Group Ltd Gemini House Brunel Road Churchfields Industrial Estate Salisbury Wiltshire SP2 7PU ENGLAND Tel 44 0 1722 325424 Fax 44 0 1722 411329 Pump Identification 17 A pump specification label is fitted on the pump crankcase adjacent to the oil filler cap This label will give the pump type no of cylinders piston cylinder diameter standard or high lift and barrel material For example 6 22 H 5 no of cyl piston cyl dia high lift ST ST The label also gives the pump serial number the type of oil to be used Shell Tellus or equivalent the maximum working pressure std 1000 rpm high lift 1250 rpm the maximum working flow and the pump s year of manufacture DESIGN AND PERFORMANCE DATA Physical Data 18 Pump diameter 405 mm Pump length 385 mm Inlet 28 6 mm dia Outlet 1 2 in SSP Shaft diameter 30 mm Shaft length 65 mm Performance characteristics 19 For full details of the P and High Lift Pump performance data reference should be made to the appropriate information given in Tables 1 1 1 2 and 1 3 TABLE 1 1 PUMP PERFORMANCE DATA MAXIMUM WORKING PRESSURES P 1000 High Lift 1250 Diameter EN1A 57 EN1A 57 4000 psi 6000 psi 4000 psi 6000 psi 280 bar 420 bar
16. 2 Pump Lubrication Chart Manufacturer Type Oil Capacity litres ESSO Nuto H150 Number of Cylinders GULF LP 150 3 Cyl 4 Cyl 6 Cyl 8 Cyl MOBIL DTE Extra Heavy 6 5 6 5 75 5 ROC Kiron TEXACO Rando HD 150 BP Energol HLP 150 AGIP OSO 105 SHELL Tellus 150 CENTURY OIL PWLM PETROFINA Hydran 51 CASTROL Hyspin AWS 150 39 PUMP SERVICE INFORMATION General 3 The following paragraphs give details of recommended service tools torque settings burst discs 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 042 177 Spanner open ended 9 16 whit x 5 8 whit 202 048 Spanner open ended 19 mm 202 036 Spanner open ended 1 3 8 whit 202 037 Spanner adjustable 12 202 302 Spanner combination 4 BA 202 150 Pipe grips 206 102 Hammer nylon 1 3 4 dia 206 001 Allen key 6 mm 206 103 Pliers circlip external 10 25 mm 205 001 Wrench T hex 4 mm 204 002 Screwdriver flat blade 10 206 101 Torque wrench 203 256 Socket reversible ratchet 1 2 square drive 203 242 Socket extension bar 250 mm 1 2 square drive 203 247 Socket 1 2 square drive 11116 203 129 Socket 1 2 square drive 17 mm 203 170 Drift mandrel 061 044 Dolly bearing 201 007 Set screws M8 x 50 mm 6 off 023 067 Bucket 15 litre 206 104
17. ONS P and High Lift Barrels 11 12 13 14 15 P and High Lift type barrels now come in one material EN57 Spec 431 529 stainless steel for pressures up to 415 bar 6000 psi The barrels are always supplied as an assembly including baffle plate part no 012 001 seal 011 011 and inner cylinder The diameter of the cylinder varies for different pump performances Diameters available are 18 mm 20 mm and 22 mm All barrels are given a letter code 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 M are used Each letter is given a part number When ordering spare barrels each part number requires cylinder diameter and barrel material letter options The option code is shown as two letters The first indicates the barrel material A is for ENS7 and B is for EN1A The second indicates the cylinder diameter A is for 18 mm B is for 20 mm and C is for 22 mm The part numbers for barrels are as follows it should be noted that pistons are ordered separately Barrel Part No Letter Code 011 250 Barrel 011 251 Barrel B a 011 252 Barrel he Barrel material 011 253 Barrel D 57 011 254 Barrel E E i See alte B EN1A This option has been withdrawn 011 256 Barrel 5 Cylinder diameter 011 257 Barrel H A 18mm 011 258 Barrel 011 259 Barrel 011 26
18. Part No 061 352 HARBEN P PUMP SERVICE MANUAL 3 A Be N h TALA nm gt 9 es l N Issue 2 2 June 2012 Flowplant Group Flowplant Group Ltd Gemini House Brunel Road Churchfields Ind Est Salisbury Wiltshire SP2 7PU England t 44 0 1722 325424 f 44 0 1722 411329 Harben Inc P O Box 2250 Cumming GA 30028 USA t 1 770 889 9535 f 1 770 887 9411 HARBEN 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 This page is intentionally left blank ii FOREWORD This manual is primarily concerned with the Harben P Type Pump Details are also given of the similarly constructed High Lift Pump In addition general safety and operating information for the equipments using the pumps 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
19. SECTION 1 TECHINCAL DATA CONTENTS Introduction Pump Description Function Filtration Fluid Flow Pump Barrel Options P and High Lift Barrels Identity Manufacturer Pump Identification Design and Performance Data Physical Data Performance Characteristics Equipment Details Associated Publications ILLUSTRATION Fig 1 1 Harben P Type High Pressure Pump TABLES Table 1 1 Pump Performance Data Maximum Working Pressures 1 2 Performance Data P Type Pump and Horsepower Required 1 3 Performance Data High Lift Pump and Horsepower Required 1 4 Equipment Serial Numbers and Jet Sizes 10 11 16 17 18 19 20 21 10 This page is intentionally left blank TECHNICAL DATA INTRODUCTION 1 The Harben P Type high pressure pump Fig 1 1 is a radial piston diaphragm pump which be used for a number of industrial applications including the following 1 High pressure cutting of board plastic and other materials 2 Water hydraulic systems 3 Abrasive blasting and descaling 4 Drain sewer cleaning 5 Tube descaling 6 Desalination by reverse osmosis 7 Pumping demineralised water 8 Floor and surface cleaning 9 Underwater cleaning 2 In addition to its reliability and long service intervals the advantages of using this type of pump include 1 Variable pressure and flow options without piston change 2 Pumps can run dry without damage as there are no piston seals 3 Filtration of 50
20. 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 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 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 59 FLOWPLANT LIMITED WARRANTY POLICY Flowplant Group Ltd warrants its equipment to the original customer only to be in conformance with the
21. and address b Destination of parts if different from above c Description and part number d Quantity required e Price and method of payment f Delivery date g Order number h Confirmation of order 62 When requesting service or repairs please state a b d e f 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 63
22. assembly If the Delivery Valve 43 is removed for any reason or the delivery Valve Nut 44 is slackened the inlet Valve Nut 41 must be slackened off two turns and the delivery Valve Nut 44 tightened before the inlet Valve Nut 41 is retightened 1 2 3 4 5 6 7 8 9 Assemble Valves 43 and 45 46 Ensure components are clean and all 0 rings undamaged Ensure that the tapers in the Barrels are clean and dry Lubricate the external tapers of the Diaphragm with pump oil and insert the Diaphragm into the Barrel from the pump side Fit the Delivery Valve assembly 43 Confirm that it is a Delivery Valve and that it is fitted correctly Replace Valve Nut 44 and torque it to 135 Nm Lubricate Mandrel 52 with pump oil and push the Mandrel as far as possible into the Diaphragm 51 Fit Inlet Valve assembly 45 or 46 Confirm that it is an Inlet Valve and that it is fitted correctly Grease the outside of the Inlet Valve to ease assembly Replace Valve Nut 41 and fully tighten Where access is possible use a socket and torque wrench and torque the Valve Nut to 135 Nm The pump will now require oil bleeding in accordance with the procedure detailed in Section 3 Para 18 Pump Strip and Re Assembly NOTES 1 2 3 The work is best carried out in a Repair Stand Part No 042 177 Refer to Para 9 for drawing information When ordering replacement parts Bar
23. caused by adverse weather atmosphere conditions General all products e Fair wear and tear e Anywork carried out to improve the general finish of the machine above what is known to be the factory standard e Failure to maintain the equipment in accordance with the manufacturer 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
24. ceived 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 A warning 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 earmuffs and gloves Refer to Para 14 for details of protective clothing available 25 SAFETY CODE OF PRACTICE Cont d General Cont d 5 Never attempt to change 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 deadman s handle safety gun the required jet should be fitted 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 t
25. e lun Handa vi ot ot ot ht ei e ri ot el rd OG e He X Fig 4 8 Manifold Selector Assembly 54 8 DESCRIPTION spas Share ORORO feel Bonded 1 4 BSP gt m fn IKT See MN mr ME SL FRIST DS CY Ikea NE rh te SSS ANS 0o AD Q Fig 4 9 a Inline selector Assembly 55 FIN y Ae SIn Fig 4 9 b Inline Selector Assembly SECTION 5 WARRANTY Warranty Limited Warranty Policy Non Warranty Items Service and Spares SECTION 5 WARRANTY Page 5 3 5 4 5 4 5 6 57 58 This page is intentionally left blank 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
26. e solution 2 Drain the water tanks 3 Pour the 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 Stop the engine The unit is now anti freezed 31 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 Run the engine until all solution is returned to the container and clean water is seen flowing from the hose The unit is 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 30 to 50 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 h
27. e used with the pump A conversion kit is available for each barrel The number of conversion kits required equals the number of barrels in the pump supplied The conversion kit comprises the following items Part No Qty Casting Mandrel P Type High Temp Water Inlet 009 002 1 Valve inlet for High Temp Water Inlet 009 004 1 Valve Delivery High Temp Water Inlet 009 005 1 Barrel 0 Ring Viton BS135 60 P Type 009 008 2 Depending on the water hardness it may be necessary to install an industrial descaler in the water tank to prevent a build up of scale One point to consider when converting a pump and subsequently working out a maintenance program is that pump bearing life will be significantly reduced This will need to be considered in the maintenance program 21 22 This page is intentionally left blank SECTION 3 GENERAL OPERATING INFORMATION SECTION 3 GENERAL OPERATING INFORMATION 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 A
28. ff Ensure the unit is on level ground Check that the water supply is connected and the header tank is full Check that all guns and nozzles are connected Ensure correct fitting and correct size for the pressure required 2 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 Para s 18 and 19 respectively familiarise yourself with the units controls and the stopping instructions Para 17 3 Move the selector to the High Pressure position Stopping 17 To shut 1 2 3 4 5 down the unit carry out the following instructions 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 instructions given in the manufacturer s handbook for the engine electric motor If there is the risk of freezing follow the instructions given the frost precautions anti freeze procedures Para s 20 or 22 If the unit is to be stored for more than 7 days without running an inhibitor should be 29 run through the system Do not drain prior to storage always leave full of fresh water or inhibitor 6 Refer to the manufacturer s handbook for information concerning engine electric motor protection storage To Oil Bleed the Pump 18 As delivered from t
29. he delicate components of the trigger mechanism Drain Sewer and Pipe Cleaning 7 Hoses 26 1 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 2 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 3 During drain cleaning operations it is advisable to use a coloured leader hose to act as warning to the operator that the hose recovery is almost complete 4 Where drain or pipe jetting operations 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 1 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 2 Never loop the hose into an excessively tight radius particularly adjacent to couplings 3 When fitting re usable couplings always ensure that the correct type of couplings are being used in relat
30. he 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 the top of the oil cooler should just be visible or ensure oil is in the expansion bottle if fitted To identify the oil cooler refer to Item 11 on the drawings located Section 4 2 Set the 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 Ifthe 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 in the pump crankcase after each barrel has been bled 4 Repeat the procedure detailed in sub pars 3 for each barrel starting from the lower barrels first BLEED SCREW PISTON 121 Fig 3 1 Bleeding the Pump 30 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 If the delivery l
31. he 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 points 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 c 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 This page is intentionally left blank 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 1 ALWAYS WEAR THE CORRECT PROTECTIVE CLOTHING 2 ALWAYS ENSURE ALL EQUIPMENT IS IN A FIRST CLASS CONDITION 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 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 This page is intentionally left blank viii SECTION 1 TECHNICAL DATA
32. ine 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 19 20 UNDER PRESSURE Whenever the unit is started after being allowed to run dry the following procedure must be followed 1 Set the 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 pars 1 To identify the bleed nipples refer to Item 72 on the drawings located Section 4 3 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 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 pars 1 To Anti Freeze a Unit without an Anti Freeze Tank 1 Prepare 5 gallons or larger quantity if required of 30 to 50 anti freez
33. ion to the hose specification SAFETY CODE OF PRACTICE Cont d NOTE The equipments detailed in Para s 9 10 11 and 12 are for specialist applications Underwater Recoil less Safety Gun 9 1 The Harben Underwater Recoil less Safety Gun is designed for use under water only Extreme care should be taken to avoid rear facing balance jets when testing the equipment above water 2 If working 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 charge hand who operates the remote control valve should first insert the lance into the tube leaving the other end of the 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 charge hand 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 jet
34. ions Turbulent water will cause the pump to run unevenly and cause excessive wear due to cavitations For this reason water must first pass through a break water or header tank controlled by a ball valve or float device Water leaving the tank should have lamina flow characteristics and be air free 1 If water is filtered before the tank then the tank must be sealed and vented to avoid contamination 2 A pressure 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 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 32 mm 1 in and up to a length of 1 metre If a longer length of hose pipe is required refer to the nearest authorised dealer Other points to be considered concerning inlet water are Avoid long hose or pipe runs Avoid hose or pipe runs that cause air pockets Refer to circuit layout for mounting angle of pump If water inlet temperature is over 25 consult the nearest authorised dealer unless 70 C Hot Water Conversion Kit is fitted see Para 15 Hot Water Conversion Kit 15 20 A Hot Water Harben P Pump Conversion Kit Part No 009 001 is available to enable hot water up to 70 C to b
35. l at a time remove the Circlip 40 from the Gudgeon Pin 39 Remove by pushing Gudgeon Pin down Remove Locknut 47 Disengage Piston 56 from the Con Rod 38 and remove Barrel Assembly Keep all components in individual Barrel Sets ie when re assembling use same Con Rod Gudgeon Pin and Cylinder When all Barrel Assemblies have been removed unscrew Nyloc Nut 29 Lift off the Washer 28 inner race of the Floating Bearing 32 Counter Balance 23 Retaining Ring 37 and Con Rods 38 Eccentric 35 and Bearing 36 Counter Balance 23 and Key 27 The Shaft 25 can now be pulled out through location Bearing 31 13 Remove Nyloc Nuts 17 and Washers 8 and lift off the Oil Seal Carrier 24 and Selector Support 58 14 Using a small hand press and Dolly Part No 201 007 remove Bearings 31 and 32 14 Carry out a re assembly of the pump generally reversing the procedure used in Para 13 noting the following points a When replacing the Shaft care should be taken to prevent the Shaft keyway from damaging the Oil Seal 10 b Barrels are letter coded and must be fitted in their correct position Fig 4 2 All bleed holes in the Barrels must be in the vertical position 3 CYLINDER AEJ 4 CYLINDER ADGK 6 CYLINDER ACEGJL 8 CYLINDER ABDFGHKM VIEW ON FRONT DELIVERY SIDE OF PUMP Fig 4 2 Pump Cylinder Code c Fit new Gudgeon Pin Circlips 40 whenever they have been removed from the G
36. nti Freeze Tank Fitted Fault finding General ILLUSTRATIONS Fig 3 1 Bleeding the Pump 3 2 Pump Fault Finding Diaphragm Failure TABLES Table 3 1 Equipment Fault Finding 3 2 Pump Fault Finding 15 16 17 18 19 20 21 22 23 24 23 24 This page is intentionally left blank GENERAL OPERATING INFORMATION INTRODUCTION 1 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 equipment 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 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 E 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 Only a responsible person who has re
37. num m OEI CI 5 6 7 3 6 6 lolcats mm OCC O O O OEI 000 DEI O 0 00 CC ODECICJIOD0O DC __________ __ __ a SE EE ___ __ __ __ 3 fo 6 fo ama oar men EE EE EEE EE SE DECI 00 O Co emos an on 1214 6 a un auon rene si sisi OLI __ 31414 0 a MEC CA O O O O LC OECD O CIC Fig 4 6 P Type and High Lift Pump Pump Parts List 11 Cem 02 10000 17T50000 OC IC I0000C1 _ TJ OIC O DO O 0 CITE E Soong opodgg nNooog il DOOD Ct M LU ovsun r B E 1 IR I 1 7 7 Bo OE iiime gres Bo i i 2222 i if Fig 4 7 P Type and High Lift Pump Inlet manifold Assembly 53 gris CECL a i u 9 Han v t GOE 4 GM OG Hs e rt e ds v t 4 OG ok ot EON OE 4 4 rt et et 6 amemenoseuansaana
38. of 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 450mm 065 023 Detector GAS BASEEFA Approved 065 022 Torch BASEEFA Approved 065 024 Breathing Apparatus 15 minute Escape Set 061 225 Operators Safety Guide 057 062 Safety Code Of Practice 061 259 Guide Do and Don t Booklet 28 GENERAL OPERATING INSTRUCTIONS Introduction 15 The following operating instructions are of a general nature with reference being made to the appropriate manufactures handbook for the machine The machine should be in the shut down position Starting 16 To start the unit carry out the following instructions 1 Prior to starting the unit carry out the following pre checks Set the high pressure selector to the recycle dump position Ensure engine motor is switched o
39. ork can be carried out on the machine 2 Refer to Para 9 for drawing information 11 Carry out removal of Diaphragms and Valves as follows 1 2 On the Standard Delivery Manifold uncouple the Top Hose 70 and 71 from Adaptor 49 Uncouple the Inlet Manifold 12 by drawing back the Retaining Ring M2 opening the Spring Clip M4 and pulling the Inlet Manifold evenly off Valve Nuts 41 and Cooler 1 1 43 44 3 4 5 6 7 Unscrew the Valve Nut 41 two turns if the Delivery Valve 43 only is to be removed If Diaphragm 51 and Inlet Valve 45 or 46 are to be removed then unscrew the Valve Nut 41 completely Remove Valve Nut 44 completely If Diaphragms 51 are to be removed drain the oil from the pump Remove a Diaphragm 51 Mandrel 52 and Inlet Valve 45 or 46 refer to Fig 4 1 by placing a drift Part No 061 044 in the end of the Mandrel at the delivery end of the Barrel and tapping the drift gently with a mallet Remove the Delivery Valve 43 carefully using pipe grips Part No 206 102 INLET VALVE FOR PUMP PART No 011 048 ITEM 46 MAX PRESSURE 275 BAR MAX 1000 RPM SSN WA SN VALVE FOR HL PUMP PART 011 166 ITEM 45 MAX PRESSURE 415 BAR MAX 1300 RPM Fig 4 1 Inlet Valve Identification 12 Carry out re assembly of the Diaphragms and valves as follows NOTE On no account should Diaphragm 51 and Mandrel 52 be fitted as an
40. ose 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 Unit With an Anti freeze tank fitted 32 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 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 includes 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 Worn
41. p 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 A NY Ds aa iy Al Sum PEN ON u FG Ny N r Fig 4 3 P Type and High Lift Pump Pump Assembly 50 Fig 4 4 P Type and High Lift Pump Barrel Assembly 4 N 4 e gt SANN Fig 4 5 P Type and High Lift Pump Pump Cross Section 51 ca MEC 69 478 111 MA _ __ fons mes ener lun 0000 ome aur ammo J0000C E fen ann CIC O O _ OC O OO een Fern 00 O EC OCOC MODOC 100 DOC 52 COI 110 OCIO OO O II OEICADOO 5 CITI MOON O O O CI fossene OOO CI m OC ICE Jojafrufsjonap a ae 93 497 5 ala TIN __ lon an 131 6 Ja lm nn an Tue mem vr 40 om om ja 4 6 sasur KC Tanne 0000 CI La a me _______ 131414
42. rel 53 Baffle 54 Seal 55 and Cylinder 57 are supplied as an assembly Always quote the Pump Number see Identification Plate and Barrel Letter Code see Fig 4 2 when ordering 45 46 13 Carry out a strip of the pump as follows 1 2 3 4 5 6 7 NOTE 8 9 10 NOTE 11 12 Carry out the procedure for removal of Diaphragms and Valves as detailed in Para 11 Unscrew the Bleed Screws 21 from the Bleed Rings 48 and remove the Bleed Rings Remove the socket head Captive Screws 7 from the Cover Plate 10 with 0 Ring 9 from the delivery side of the pump then slacken Captive Screws 7 in Cover Plate 10 on the inlet side of the pump Slacken all Locknuts 47 half a turn only Unscrew all socket head Set Screws 69 that are holding down the End Plate and screw them into the adjacent tapped holes Tighten these Set Screws 69 down diametrically until the End Plate is lifted It may be necessary to put some freeing oil WD 40 around the Barrels before starting to withdraw the End Plate Progressively add packing between Set Screws 69 and the Crankcase until the End Plate is clear of the Barrels Alternatively Set Screw Part No 023 067 may be used dispensing with the need for packing If Barrels tend to come up with the lid as Set Screws are tightened and Locknuts 47 are slackened tap the Barrels down with a nylon mallet Working on one Barre
43. s 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 hazardous 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 punctured the skin flesh and organs through a very small hole that may not even bleed 27 SAFETYOIDE 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 Weirs Disease PROTECTIVE EQUIPMENT 14 Arange of top quality protective equipment is available from Flowplant Group Ltd as follows Part Number Description British Standard 061 037 Suit Waterproof Orange size small BS4170 061 025 Suit Waterpro
44. sesuesassasscesenseaees G Reardrain jet mea 3 Rear lforwardidrain je t iia de High Efficiency Drain Jets 3RearHEdrainjet sumisa dana G RearHE drainjet xiii dial 3 Rear 1 forward HE drain jet ___ Mini Jet Kit 207 Urna Turbo Dia 38mm Screma Jet Dia 16mm Screma Jet Jet Led SE JO NNN Jet Pump TYDE Jet 512 5 Hover union shave db a This pump unit and all the accessories listed above have been test at Incheded standard this selection con be eses In chort 0 LT ER oser one selection must be mode from soch column only apeciiying Fig 1 1 Harben P Type High Pressure Pump 11 12 This page is intentionally left blank SECTION 2 PUMP INSTALLATION SECTION 2 PUMP INSTALLATION CONTENTS Introduction Pump Mounting General Details Pump Fitting Pump Access Coupling Arrangements Inlet Water Fig 2 1 2 2 2 3 2 4 General Hot Water Conversion Kit ILLUSTRATIONS Pump Installation Pump Mounting Pump Installation Pump Access Pump Installation Coupling Gearbox Arrangements for Diesel Drive Pump Installation Coupling Arrangements for Electric Drive
45. 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 machine by the customer 2 year warranty on P pump lt 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 lt 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 lt 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 lt This warranty does not cover damage caused by shipment misuse or abuse of the equipment including operation be
46. ssive running hours Check all diaphragms replace as necessary 35 y 4 small impressions similar to illustration Reason diaphragm pumping through mandrel delivery holes Shear through wail of diaphragm Fig 3 2 Pump Fault Finding Diaphragm Failure 36 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 Burst Discs Service Kits Pump Overhaul Procedures Fig 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 a 4 9 b Table 4 1 4 2 Introduction Removal and Replacement of Pump Head Removal and Replacement of Diaphragms and Valves Pump Strip and Re Assembly Pump Running In Inlet Valve Identification Pump Cylinder Code Type and High Lift Pump Pump Assembly Type and High Lift Pump Barrel Assembly Type and High Lift Pump Pump Cross Section Type and High Lift Pump Pump Parts List Type and High Lift Pump Inlet Manifold Assembly Manifold Selector Assembly Inline Selector Assembly Inline Selector Assembly TABLES Pump Maintenance Schedule Pump Lubrication Chart 8 10 11 13 15 ILLUSTRATIONS Page 44 47 49 50 51 52 53 54 55 56 37 ROUTINE MAINTENANCE Introduction PUMP MAINTENANCE AND OVERHAUL PROCEDURES
47. the diaphragm around the mandrel expelling the water in the diaphragm through the delivery valve and into the delivery manifold When the 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 All mechanical parts with the 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 between 50 and 150 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 420 bar 6000 psi PUMP BARREL OPTI
48. to 150 microns 4 No modification is required to pump sea water 5 Pump has multi cylinders therefore no pulsation 6 Positive displacement thus high efficiency 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 electrical drive and hydraulic drive options are available PUMIP DESCRIPTION Functional NOTE following description of the Harben P Type Pump applies equally to the High Lift variant of the pump Performance details of each type of pump are given later in this section 4 The P 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 The pump crankcase which contains the only 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 As the 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
49. udgeon Pins d Gudgeon Pins with one Circlip already fitted should be inserted from beneath the Con Rods e Nyloc Nut 29 must be torqued to 135 Nm f When fitting the End Plate ensure that the Locknuts 47 are slack Tap down the End Plate as evenly possible and then tighten the Locknuts 47 before tightening the Set Screws 69 47 g Apply grease to the hose tail of the Valve Nut 41 to ease fitting of the Tee Moulding M3 h Apply grease to the outside of the Tee Moulding M3 in the area of the Retaining Ring 37 to ease removal and assembly of the Retaining Ring over the Tee Moulding Pump Running In 48 15 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 and Section 3 Para 18 1 for pump oil level procedure 16 The pump should also be bled of air in accordance with the procedures given in Section 3 Para s 17 18 and 19 Run the pump at maximum pressure for 10 minutes checking for leaks and monitoring the flow Check the results against the pump performance data The following points should be taken into account when determining maximum pressure to be used when running in the pump a If the pump is being used on a system that has a lower working pressure than the maximum for the pump then running in of the pum
50. xterior oilpipes and filter bolts e Filters and the cleaning of filters e Engine service components e Adjustments Brakes Trailer e Brake shoe adjustment bleeding and topping up of reservoir draining of air systems where not due to a defective part Brake squeal from brake linings e Replacement of linings due to fair wear and tear Tightness of air lines pipes e Filters and the cleaning of filters e Brake fluid Electrical all products Manufacturers Warranty Applies e Cleaning of terminals e General maintenance of batteries dynamo alternator starter etc e Adjustment to ignition system components e General adjustment to electrical control current settings e Brushes and other items due to fair wear and tear e Contactor tips and springs e Replacement of lamps lenses and bulbs Steering Running Gear e Front wheel alignment track adjustment e Steering adjustment Hub bearing and float adjustment e Jockey wheels Hydraulics all products Tightening of hydraulic fittings and couplings e Filters and the cleaning of filters Hydraulic fluid Chassis self propelled and trailer mounted units e General rattles Paint chips Alignment and adjustment of panels etc Deterioration of paint and external fittings due to neglect exposure and fair e wear and tear Accidental damage 61 Lubrication all products e Complete or partial lubrication services Corrosion all product e Damage
51. yond 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 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 60 The following items are considered to be of a Maintenance nature and should not be subject of a claim Engine Manufacturers Warranty Applies e Routine servicing of injector fuel injection equipment e Heavy fuel consumption rectified by engine adjustment e Adjustment of fan belts throttle and controls e Tightening of all sump and cover bolt nuts water connections and e
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