Flowplant 320 Series Manual

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Operation & Maintenance Manual
Original Instructions
003301 –320 SERIES DESILTER VANPACK
Section 1 Contents & Introduction
Section 2 Scope of Supply
Section 3 Technical Data
Section 4 Operation
Section 5 Routine Maintenance
Section 6 Fault Finding
Section 7 Pump
Section 8 Engine
Section 9 Wiring and Circuit Diagram
Section 10 Parts list / Spares / Auxiliary components
Section 11 Service Documents
Section 12 Warranty & Certification
061987

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Operation & Maintenance Manual for:
UNIT: Unit 320 Series Desilter Radio Control R/1 (B11238/A)
ISSUE DATE: 10/2020
AMENDMENTS
Change
No.
Changes
Date
Signature
1
FIRST ISSUE
10/20
JHGS

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1.Contents & Introduction
1.1.Contents
1. CONTENTS & INTRODUCTION....................................................................................3
1.1. CONTENTS....................................................................................................................3
1.2. INTRODUCTION..............................................................................................................6
1.3. SCOPE OF THIS MANUAL ...............................................................................................6
1.4. THE 320 SERIES DESILTER VANPACK ............................................................................7
1.5. COMPOSITION OF THIS MANUAL.....................................................................................8
2. SCOPE OF SUPPLY......................................................................................................9
2.1. SCOPE OF SUPPLY........................................................................................................9
2.2. VANPACK ASSEMBLY....................................................................................................9
2.3. DETAILED DRAWINGS..................................................................................................10
3. TECHNICAL DATA......................................................................................................15
3.1. TECHNICAL DATA ........................................................................................................15
3.1.1. PUMP DATA .............................................................................................................15
3.2. TECHNICAL DESCRIPTION............................................................................................ 16
3.2.1. PRIMARY COMPONENTS............................................................................................16
3.2.2. ENGINE MONITORING................................................................................................16
3.2.3. DELIVERY HOSE REEL ..............................................................................................16
3.3. INSTALLATION DETAILS................................................................................................18
4. OPERATION................................................................................................................ 19
4.1. OPERATING CONDITIONS.............................................................................................19
4.2. DAILY CHECKS ...........................................................................................................19
4.3. PRE-START CHECKS &BLEED PROCEDURE................................................................... 20
4.4. STARTING THE ENGINE &SETTING THE OPERATING PRESSURE.......................................20
4.5. PRE-START CHECKS &PROCEDURES ..........................................................................22
4.5.1. STARTING THE ENGINE..............................................................................................22
4.5.2. CHECKING THE OPERATING PRESSURE WITH A NOZZLE FITTED ....................................23
4.5.3. CHECKING THE OPERATING PRESSURE WITH A GUN FITTED .........................................24
4.6. “REMOTE”OPERATION STARTING PROCEDURE ............................................................ 26

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4.6.1. STARTING THE ENGINE .............................................................................................26
4.7. RAPID SHUTDOWN ......................................................................................................28
4.8. AUTOMATIC SHUTDOWN..............................................................................................28
4.9. HARBEN JUMP JET......................................................................................................28
4.10. HOSE REEL WINDING AND UNWINDING ........................................................................ 28
4.11. FROST PRECAUTIONS................................................................................................29
5. ROUTINE MAINTENANCE.......................................................................................... 31
5.1. MAINTENANCE PROCEDURES....................................................................................... 31
5.2. LUBRICATING OIL CHART ............................................................................................32
5.3. GENERAL TORQUE SETTINGS ......................................................................................33
5.4. DAILY MAINTENANCE ..................................................................................................34
6. FAULT FINDING..........................................................................................................35
6.1. EQUIPMENT FAULT FINDING.........................................................................................37
6.2. PUMP FAULT FINDING..................................................................................................39
6.3. SELECTOR FAULT FINDING ..........................................................................................40
7. PUMP...........................................................................................................................41
8. ENGINE .......................................................................................................................42
9. CIRCUIT AND WIRING DIAGRAMS............................................................................43
10. PARTS LISTS / SPARES........................................................................................... 47
10.1. INTRODUCTION..........................................................................................................47
10.2. ORDERING SPARE PARTS.......................................................................................... 47
10.3. ACCESSORIES &CONSUMABLES ...............................................................................48
10.3.1. ROUTINE MAINTENANCE .........................................................................................48
10.3.2. CONSUMABLES.......................................................................................................48
10.4. PARTS LIST ..............................................................................................................49
10.5. HYDRAULIC DIVERTER VALVE ASSEMBLY...................................................................55
10.5.1. RECOMMENDED TOOLS ..........................................................................................55
10.5.2. SERVICE KITS ........................................................................................................55
10.6. TO DISMANTLE.......................................................................................................... 56
10.7. TO ASSEMBLE ..........................................................................................................56

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11. SERVICE DOCUMENTS............................................................................................62
11.1. SERVICE CHECKLIST .................................................................................................62
11.2. SERVICE LOGBOOK...................................................................................................63
12. WARRANTY ..............................................................................................................65
12.1. WARRANTY OF NEW PRODUCTS:................................................................................65
12.2. WARRANTY OF SPARE PARTS: ...................................................................................65
12.3. LIMITATIONS OF WARRANTY:...................................................................................... 66

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1.2.Introduction
Please ensure that you read this Operation & Maintenance Manual in conjunction with the
Health & Safety Manual before operation.
Within this manual the health and safety risks are highlighted with and you are required
to read the relevant section in the Health & Safety Manual.
Notices
Carefully read the notices of this manual because they give important information concerning
safe installation, use and maintenance; familiarise yourself with the workings of the machine
in order to rapidly switch it off and eliminate pressure.
This manual is an integral and essential part of the product; it must be consigned to the user
in order to ensure the training/information for personnel.
The manufacturer does not assume responsibility for damage caused to persons, property or
to the machine, in the case of improper use. Carefully preserve this manual for any further
consultation.
Identify the model of your machine by reading the details on the identification plate. Upon
delivery, inspect the machine / accessories for any damage, which may occur during transport.
IMPORTANT: Always follow the recommended operating procedures; do not misuse the
equipment as this could result in injury or mechanical breakdown!
1.3.Scope of this Manual
This manual provides operation and maintenance instructions for the unit. Where the unit has
been fitted with proprietary components, details of these are also included in this manual.
This manual is compiled to match the Scope of Supply detailed in Section 2. All specifications,
descriptions and parts lists refer only to the components in the version of the unit detailed in
this scope of supply.
Maintenance instructions included in this manual include:
•Routine maintenance to be carried out at specific times.
•Maintenance of the high-pressure pump.

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Repairs to the pump crankcase are not considered maintenance operations as these should
be undertaken only by FLOWPLANT,theirapproved agents, or at least competent automotive
engineers.
1.4.The 320 Series Desilter Vanpack
The 320 Series Desilter Vanpack is a highly versatile mobile high-pressure water jetting unit,
which offers the benefits of proven power pack and pump performance with a comprehensive
range of accessories.
Developed for a wide range of water jetting applications, the Unit has been meticulously
designed for safe and efficient use.

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1.5.Composition of this Manual
This manual comprises the following further sections:
Section 2 Scope of Supply
This section defines the scope of supply of the equipment in compliance with the sales order.
Section 3 Technical Data
This section contains technical information about the unit.
Section 4 Operation
This section describes the recommended operating procedures for the unit.
Section 5 Routine Maintenance
This section details recommended routine maintenance requirements for the pump and unit.
Section 6 Fault Finding
Fault diagnosis tables for the pump, engine and ancillaries.
Section 7 Pump
Details of the pump and gearbox assembly.
Section 8 Engine
This section includes the Hydraulic, Water and Electrical circuits including engine controller &
wiring loom.
Section 9 Ancillaries
Section 10 Parts list / Spares
How to identify and order spares
Section 11 Service Documents
Service logbook and checklist.
Section 12 Warranty & Certification

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2.Scope of Supply
2.1.Scope of Supply
Unit:
UNIT 320 SERIES DESILTER RADIO
Machine Build Code:
003301
2.2. Vanpack Assembly
The General Arrangement drawing: 003-301, defines the components of the 320 Series
Desilter Vanpack mounted Pump Assembly as follows:
Water is fed from a “mains” supply through a manual low-pressure inlet hose reel into a plastic
water storage tank. The tank supplies the pump with a positive head of pressure via an inline
Hypro strainer that filters the water to approximately 177 microns, (Pump is specified at
200microns)
The Harben P-Type high-pressure plunger pump is driven by a Kubota D1105-E4B-EU-X1
18.5kW Stage 5 C-TXT industrial diesel engine through a Harben 2.0:1 Gearbox.
The water is directed by an electrically controlled Hydraulic diverter valve, to a hydraulically
driven hose reel c/w 300’ of ½” hose, or at low pressure ‘dumped’ back to tank.
The system is protected from over pressurisation by means of a Relief Valve.
The system pressure can be adjusted by means of an Unloader Valve.
The engine and system pressure can be monitored at the control panel situated at the rear of
the van.

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2.3.Detailed Drawings
Detailed drawings and parts lists for the above components are provided as follows:
The Pump Pump is detailed in Section 7.

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Hydraulic Diverter Valve 069-581

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Hawk Safety Relief Valve 035-401

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Speck Unloader Valve UL221 035-185

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320 Series Desilter Van Pack
•Compact Design to Suit Smaller Vans
•Complies with the Latest Emissions Standards (*Jan 2020)
•Lightweight Safety Enclosure
•Radio Remote Control Operated (With Integrated LCD Display)
•Reduced Noise Levels
•Automatic SRV (Safety Relief Valve)
•Optional Service / Location Tracking
Model
320 Series Van Pack
Pressure & Flow
200 Bar @ 45L/pm
Pump
P Type Harben
Engine
Kubota 3 Cylinder Liquid Cooled
Water Tank
White / Transparent 650L Breathable plastic tank
Frame
Lightweight Fibreglass canopy / lightweight steel frame, shot blasted and powder coated
Hose Reel
Variable speed Hydraulic driven reel with a 100m Capacity
Dimensions
TBC
Weight
Dry Weight from 475kg
Build Options
•Remote Service Monitoring & Location Tracking (UK Only)
•Lightweight Tough Skin Hose

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3.Technical Data
3.1.Technical data
3.1.1. Pump Data
Pump Type
P Type 6 22 (See Section 8)
Pump width
405 mm
Pump length
385 mm
Inlet
28.6 mm dia
Outlet
G1/2” (1/2” BSP)
Shaft dia
30 mm
Shaft length
65 mm
No. of cylinders
6
Piston diameters
22 mm
Maximum pressure
200 Bar
Nominal Flow rate
45 lpm
Crankcase lubrication
Fully immersed
Oil capacity (litres)
5.0 litres
Weight (kg)
80 kg
Recommended crankcase oil
Shell Morlina 150 or Tellus 150 (see
section 6)
Max inlet pressure
0.5 bar (5.0 metre head)
Max inlet temp.
25°C
Prime Mover Kubota D1105-E4B-EU-X1 18.5kW Stage 5 C-TXT
Drive Gearbox Harben (2.0:1)
Water Tank Capacity 88 gals. (400 litres)
Supply Water Filter N05105 Hypro line strainer / 177 micro mesh
Pressure Gauge Digitally Displayed
Safety Relief Hawk (Automatic SRV)
Mains Water Supply Positive head.
Note: Water pH value of 5 to 9 is recommended.

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3.2.Technical Description
3.2.1. Primary Components
The primary components of the 320 Series Desilter Vanpack are as follows:
1. A prime mover in the form of a Kubota 3-cylinder water-cooled diesel engine which
drives a Harben P type high-pressure pump.
2. The pump is capable of raising the water pressure up to 2900psi (200 bar).
3. A Hydraulically driven hose reel c/w 91.44m (300 ft) of 2 wire braid high-pressure hose
with either a nozzle or gun attachment to deliver the high-pressure water to the
selected working site.
4. A plastic water tank 085-271, acting as a reservoir, ensures the water is settled and
non-turbulent, discharging a smooth lamina flow of uninterrupted air free supply, a
positive head of pressure to the pump inlet and maximising the pumps full potential.
The tank can be filled via the inlet reel by connecting to a mains inlet water supply
Note: Turbulent water will cause the pump to run unevenly and cause excessive wear
due to cavitation.
5. Water is diverted to the hose reel either using a 12VDC hydraulic diverter.
6. A Hypro 177Micron mesh inline strainer is fitted to the suction line between the tank
and the pump inlet.
Note: This is a critical component which ensures that no contaminants are drawn into the
pump inlet. This filter must be inspected and cleaned daily, if it becomes blocked it will cause
the pump to cavitate.
3.2.2. Engine Monitoring
Engine oil pressure and engine coolant temperature, together with alternator charge rate are
continuously monitored. Activation of the engine pressure or temperature switches will cause
an engine shutdown and the respective ‘FAULT’ to be displayed on the control unit.
Alternator failure will be displayed on the control unit.
3.2.3. Delivery Hose Reel
The hose reel drum on which the delivery hose is wound is driven by a powerful OMR315
hydraulic motor directly coupled to the hose reel hub. Hydraulic power is obtained from a
hydraulic gear pump driven from the engine P.T.O. (See below)

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Note: 050-324 Hydraulic gear pump detail: -
(Ratio 0.844/1.00, Output 4.35 cc/rev, direct mounting, theoretical discharge volume @
3000rpm = 11l/pm, max speed 3200rpm, ma pressure 1707psi)
The speed and direction of the reel is controlled by a manual lever controlled spool valve c/w
safety relief and flow control, this is situated just below and right of the high pressure hose
reel.

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3.3.Installation details
Installation Drawing No. 003-301 provides details of sizes, weight and fixings for the 320
Series Desilter Vanpack together with inlet and outlet water connections.

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4.Operation
4.1.Operating Conditions
Operators of water jetting equipment should be fully conversant with the Water Jetting
Association ‘Code of Practice for the use of high-pressure water jetting equipment’, hereafter
referred to as 'The Code of Practice'. A copy of The Code of Practice is available upon request.
Please ensure that you read this Operation & Maintenance Manual in conjunction with the
Health & Safety Manual before operation.
Within this manual the health and safety risks are highlighted with and you are required
to read the relevant section in the Health & Safety Manual.
4.2.Daily Checks
Carry out all daily checks. Full maintenance checks are detailed in Section 5 - Routine
Maintenance.
They are:
•Pump oil level
•Gearbox oil level
•Water filter cleanliness
•Engine oil level
•Engine coolant level
•Tank water level & Cleanliness
•Diesel level
•Anti-freeze level
•Radio Remote fully charged
If the unit has previously been in operation for more than 100 hours, other routine
maintenance checks may need to be carried out. Refer to section 7 and 8.
SAFETY RELIEF VALVES MUST BE RECALIBRATED EVERY 6 MONTHS

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4.3.Pre-start checks & bleed procedure
•In cold weather check that machine is not frozen before starting (see Antifreeze
section). Only operate the machine in a well-ventilated area.
•Park next to suitable clean water supply on a level ground
•Ensure vehicle handbrake is applied
•To fill water tank, connect to water supply. The water will fill the tank via the inlet hose
reel when the tank is full it will flow out the overflow.
•Feed the end of the high-pressure hose through the hose trace on the swinging arm in
front of the hose reel. Do not fit the nozzle or gun at this point!
•In order to avoid an interruption to the jetting operation please ensure that the hand
held ‘radio control unit’ is fully charged, this is to ensure the radio signal is at full
strength and not compromised while the unit is being operated in ‘remote’ mode.
4.4. Starting the engine & setting the operating pressure
The Vanpack is supplied with a Radio Control System allowing One-man operation ‘OMO’ (in
accordance with the 'Single Person Operation as detailed in the Code of Practice.
Starting procedures are provided for 'Local' operation where water to the high-pressure hose
is controlled by the operator using the Control unit at the machine, and for 'remote' operation
where water to the high-pressure hose is controlled by the hand-held radio control unit ‘RCU’.
While the remote-control facility is provided for single person jetting operation, it should be
noted that initial pressure check must bemade at the pumpset. Hence, even with the 'remote'
enabled, all initial pressure checks must be made
Either:
With a single operator and ‘radio control unit’ (RCU) adjacent to the pump set and with
the nozzle secure in a drain or pipe or the gun firmly held in the hand.
Or:
With two people, one at the pump set and one in charge of the nozzle or gun.
Once the required operating pressure has been set, remote operation can be safely conducted
by one person using the handheld ‘radio control unit (RCU)
Do not drop the handheld “radio control unit” (RCU) down a manhole as this
could cause it permanent damage. Please use the lanyard provided