HARBEN 4018 US Van Pack Manual

Harben Inc.
P.O. Box 2250, Cumming, GA 30028
Toll Free: (800)-327-5387 Tel: [phone] Fax: [phone]
email: sale[email protected]m web: www.harben.com
Operation & Maintenance Manual
Original Instructions
Unit 4018 US Van Pack
903-1314
Section 1 Introduction
Section 2 Scope of Supply
Section 3 Technical Data
Section 4 Operation
Section 5 Routine Maintenance
Section 6 Fault Finding
Section 7 Harben P-Type Pump
Section 8 Circuit Diagrams
Section 9 Engine
Section 10 Parts List / Spares / Auxiliary Components
Section 11 Service Documents
Section 12 Warranty & Certification
Section 13 Health & Safety Manual 903-1308
Read the Health and Safety Manual before
operating any equipment. Failure to do so could
cause serious injury or death.

1
Operation & Maintenance Manual for:
UNIT: Unit 4018 US Van Pack – R/1 (B11238/A)
ISSUE DATE: 6/20
ISSUE No: 6
AMENDMENTS
Change Changes Date Signature
1 NEW ADDITION 09/19 JJ
2 UPDATE WARRANTY POLICY 10/19 JJ
3 Minor Changes. Added part number 5/20 GT
4 Added multiple sections. Minor changes 6/20 GT
5 Added Pictures to Anti-Freeze Section 6/20 GT
6 Updated manual to code 6/20 GT

2
Section 1 – Introduction & Contents
1.1.
Contents
SECTION 1 – INTRODUCTION & CONTENTS ....................................................................2
1.1. C
ONTENTS ....................................................................................................................2
1.2. INTRODUCTION ..............................................................................................................5
1.3. SCOPE OF THIS MANUAL ................................................................................................6
1.4. THE VANPACK ...............................................................................................................6
1.5. COMPOSITION OF THIS MANUAL......................................................................................7
SCOPE OF SUPPLY ......................................................................................................8
2.1. SCOPE OF SUPPLY ........................................................................................................8
2.2. PUMP ASSEMBLY ..........................................................................................................8
2.3. DETAILED DRAWINGS ....................................................................................................8
TECHNICAL DATA ...................................................................................................... 11
3.1. TECHNICAL DATA ........................................................................................................ 11
3.1.1. PUMP DATA .............................................................................................................. 11
3.1.2. MAIN COMPONENTS .................................................................................................. 12
3.1.3. ANCILLARIES ............................................................................................................ 12
3.1.4. SERVICES REQUIRED ................................................................................................ 12
3.2. TECHNICAL DESCRIPTION ............................................................................................ 13
3.2.1. PRIMARY COMPONENTS ............................................................................................ 13
3.2.2. ENGINE MONITORING ................................................................................................ 13
OPERATION ................................................................................................................ 14
4.1. OPERATING CONDITIONS ............................................................................................. 14
4.2. DAILY CHECKS ............................................................................................................ 14
4.3. PRE-START CHECKS & PROCEDURES ........................................................................... 14
4.4. CONTROL PANEL LAYOUT AND FUNCTION ...................................................................... 15
4.4.1. CONTROL KEYS ........................................................................................................ 15
4.4.2. TOGGLE SWITCH OPERATION ..................................................................................... 15
4.4.3. SCREEN LAYOUTS ..................................................................................................... 16
4.4.4. RADIO CONTROL LAYOUT ........................................................................................... 18
4.5. RUNNING THE ENGINE (MANUAL MODE)........................................................................ 18
4.6. RUNNING THE ENGINE (RADIO MODE) ........................................................................... 19
4.7. RUNNING THE VANPACK .............................................................................................. 19
4.8. HARBEN
®
JUMP JET .................................................................................................... 20

3
4.9. B
YPASS VALVE OPERATION ......................................................................................... 21
4.10. HOSE REEL WINDING AND UNWINDING ....................................................................... 22
4.11. FROST PRECAUTIONS ................................................................................................ 23
4.11.1. TO ANTI-FREEZE THE MACHINE WITH AN ANTI-FREEZE TANK ....................................... 23
4.11.2. TO DE-ANTIFREEZE THE MACHINE ............................................................................. 24
ROUTINE MAINTENANCE ........................................................................................... 26
5.1. MAINTENANCE PROCEDURES ....................................................................................... 26
5.2. DAILY MAINTENANCE (H&S SECTION 11) ..................................................................... 27
5.3. PUMP LUBRICATING CHART ......................................................................................... 28
5.4. BURST DISCS .............................................................................................................. 29
FAULT FINDING .......................................................................................................... 30
6.1. FAULT FINDING - ELECTRICAL ...................................................................................... 30
6.2. FAULT FINDING - HYDRAULIC ....................................................................................... 31
6.3. PUMP FAULT FINDING .................................................................................................. 32
6.4. SELECTOR FAULT FINDING ........................................................................................... 34
PUMP ........................................................................................................................... 35
CIRCUIT DIAGRAMS ................................................................................................... 36
8.1. WATER CIRCUIT FOR VANPACK ................................................................................. 36
8.2. HYDRAULIC CIRCUIT FOR VANPACK ........................................................................... 36
ENGINE ........................................................................................................................ 37
PARTS LIST / SPARES ............................................................................................. 38
10.1. INTRODUCTION .......................................................................................................... 38
10.2. ORDERING SPARE PARTS .......................................................................................... 38
10.3. ROUTING MAINTENANCE / CONSUMABLE ITEMS ........................................................... 38
10.4. CONSUMABLE COMPONENTS ...................................................................................... 38
10.5. PARTS LIST ............................................................................................................... 39
10.5.1. REMOTE ................................................................................................................... 39
SERVICE DOCUMENTS ............................................................................................ 43
11.1. SERVICE CHECKLIST .................................................................................................. 43
11.2. SERVICE LOGBOOK ................................................................................................... 44
WARRANTY ............................................................................................................... 45

4
12.1. WARRANTY OF NEW PRODUCTS: ................................................................................ 45
12.2. WARRANTY OF MAJOR COMPONENTS: ....................................................................... 45
12.3. LIMITATIONS OF WARRANTY:...................................................................................... 47

5
1.2. Introduction
Read this manual along with the Health and Safety Manual before you operate or carry out
any maintenance on the high-pressure vanpack.
Within this manual, the health and safety risks are highlighted with specific symbols. These
will be referenced to sections within the Health and Safety Manual which you are required to
read. The sections to refer to in the manual will be labelled at the end of the highlighted
statement (Ex. H&S Section 2). There are three symbols that will be used to differentiate the
levels of severity. They are as follows:
o : This is the symbol for . This means that if an accident were to happen,
it would cause minor to moderate injury.
o : This is the symbol for . This means that if an accident were to happen,
it could result in a serious injury or possible death.
o : This is the symbol for . This means that if an accident were to happen,
it will result in death or serious injury. This will only be shown for the most extreme
cases.
It is imperative that these symbols are paid attention to as to avoid any sort of injury.
Notices
Carefully read the notices of this manual because they give important information concerning
safe installation, use and maintenance; familiarize yourself with the workings of the machine
to rapidly switch it off and eliminate pressure.
This manual is an integral and essential part of the product; it will be consigned to the user to
ensure the training/information for personnel.
The manufacturer does not assume responsibility for damage caused to persons, things 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.
CAUTION!Always follow the recommended operating procedures. Do not misuse the
equipment as this could result in injury or mechanical breakdown!

6
1.3. Scope of this Manual
This manual provides operation, maintenance, and safety instructions for the vanpack. Where
the vanpack 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.
Repairs to the pump crankcase are not considered maintenance operations as these should
be undertaken only by HARBEN INC, their approved agents, or at least competent automotive
engineers.
1.4. The Vanpack
Harben® drain vanpacks have been designed to the highest standards so that they will work
safely and reliably for many years. It is important that you take time to read the information
provided in this operation and maintenance manual so that you understand how to make the
most of the vanpack in accordance with the instructions. Harben® vanpacks are powerful
pieces of industrial equipment and should only be operated by competent users who
understand that serious injury or death can occur through misuse.
The vanpacks described in this operation and maintenance manual are intended to be used
for high-pressure water jetting in drain and pumping applications.
They will remove soft blockages, tree roots and hard scale, liquefying fats and restoring drain
flow by blasting high-pressure water through a drain nozzle connected to the end of a high-
pressure hose. Some models can be fitted with jump jets kits to increase the effective cleaning
distance.
Harben Vanpacks use diesel engines to power a high-pressure water pump up to 5,000 psi
and 18 GPM.
Additional accessories can be purchased from Harben®, such as: floor cleaners, jetting guns
and jet pumps which extend the range of work that can be carried out with the jetter. Safety
information relating to individual accessories is provided later in this section.

7
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 vanpack.
Section 4 Operation
This section describes the recommended operating procedures for the vanpack.
Section 5 Routine Maintenance
This section details recommended routine maintenance requirements for the pump and
vanpack.
Section 6 Fault Finding
Fault diagnosis tables for the pump, engine and ancillaries.
Section 7 Harben P-Type Pump
Details of the pump and gearbox assembly.
Section 8 Circuit diagrams/Electrical Details
This section includes the Hydraulic and water circuits of the vanpack.
Section 9 Diesel Engine
This section provides part details of the diesel engine.
Section 10 Parts list / Spares / Auxiliary Components
How to identify and order spares / auxiliary components.
Section 11 Service Documents
Service logbook and checklist.
Section 12 Warranty & Certification
Section 13 Health & Safety Manual
This manual details health and safety considerations in general and specific to water jetting
equipment.

8
Scope of Supply
2.1. Scope of Supply
Unit: U.S. Vanpack
2.2. Pump Assembly
Figures 2.1-2.2 defines the components of the vanpack assembly as follows:
The pump is driven by an industrial diesel engine.
The engine drives the pump via a 2.21:1 reduction gearbox which reduces the pump rpm
down to the correct shaft speed.
Water is fed from a mains supply 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 80 microns.
The ‘P’ Type 8 22 radial piston high-pressure diaphragm pump is driven by an
industrial diesel engine through a 2.21:1 reduction gearbox.
The water is directed by a divert valve, to a hydraulically driven hose reel with up to 500 feet
of ½” hose, or at low pressure ‘dumped’ back to tank.
The system is protected from over pressurization by a safety relief bursting disc.
The engine and system pressure can be monitored at the control panel situated at
the rear of the vanpack.
2.3. Detailed Drawings
Detailed drawings and parts lists for the above components are provided as follows:
The pump is detailed in Section 7.
Details of other parts and assemblies are included at Section 10.

9
Fig. 2.1
–
4018 US Van Pack Remote

10
Fig. 2.2
–
4018 US Van Pack Man
ual

11
Technical Data
3.1. Technical Data
3.1.1. Pump Data
Pump Type Harben ‘P’ Type 8 22 (See Section 8)
Pump diameter 16” approx.
Pump length 15” approx.
Inlet 1 ¼” dia.
Outlet G1/2” (1/2” BSP)
Shaft dia 30 mm
Shaft length 65 mm
Cylinder options 8
Power rating (nominal) 45 hp
Plunger diameter 22 mm
Shaft speed 1250 rpm
Maximum pressure Up to 4000 psi (280 bar)
Max flow rate Up to 18 USG/min (70 lpm)
Crankcase lubrication Fully immersed
Oil capacity 1.3 USG
Weight 176 lb
Recommended crankcase oil Shell Morlina 150 or Tellus 150 (see
section 6)
Max inlet temperature 77°F

12
3.1.2. Main Components
Engine ENGINE KUBOTA D1803TI TIER 4 FINAL OPEN
Pump 020041AAB Harben P Type 8 22
Gearbox 020143 Harben P Type 2:1
_________________________________________________________________________
3.1.3. Ancillaries
Water tank 100 gal capacity
Supply filter 042134 Hypro line strainer / 170 micron mesh
Monitoring & control Standard engine controller and throttle
Pressure control and safety 011046 Pressure disc white 4000 psi
011047 Pressure disc black 5000 psi
________________________________________________________________________
3.1.4. Services Required
Mains water supply Positive head capable of delivering greater than 16
USG/min
Note: Water pH value of 5 to 9 is recommended.

13
3.2. Technical Description
3.2.1. Primary Components
The primary components of the vanpack are illustrated in Figures 2.1-2.2 which are as follows:
 A prime mover in the form of an industrial diesel engine which drives a Harben P Type
high-pressure pump.
 The pump can produce high-pressure water up to 4000 psi.
 Note: See above or section 7 for performance options.
 A hydraulic driven hose reel with up to 500 feet of single wire braid high-pressure hose
with either a nozzle or gun attachment to deliver the high-pressure water to the work
application.
 Plastic water tank, acting as a reservoir, also ensuring the water is settled and non-
turbulent, discharging a smooth uninterrupted supply, with a positive head of pressure
to the inlet, maximizing the full potential of the pump.
 The pressure valve directs high-pressure water to the main jetting hose or diverts it
back to the tank.
 The control panel which includes the engine controller, pressure gauge, throttle, high-
pressure selector, jump jet valve & hydraulic hose reel controls.
 A Hypro 80 micron mesh inline strainer is fitted to the suction line between the tanks
and the pump inlet.
NOTICE: 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 hours run are monitored on the engine control panel.

14
Operation
4.1. Operating Conditions
Operators of water jetting equipment should be fully conversant with the 'Industry Best
Practices 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.
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
 tank water level
4.3. Pre-start Checks & Procedures
1. WARNING! In cold weather check that machine is not frozen before starting (see
Antifreeze section 4.11). Serious injury can occur from ice bullets. (H&S Sections 3
and 7)
2. Only operate the machine in a well-ventilated area. (H&S Sections 3, 8, 9, and 12)
3. Ensure the vehicle is parked on a level surface, and the hand brake is applied. (H&S
Sections 3, 11, and 13)
4. 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. (NOTICE: To comply with water
authority bylaws never fill the tank by putting a hose directly inside)
5. Feed off the hose reel approximately 10 feet of high-pressure hose. Do not fit the
nozzle or gun at this point! (H&S Section 3, 6, and 16)
6. WARNING! Inspect hose before using. Damaged hose can lead to serious injury
if put under pressure. (H&S Section 3, 6, and 16)
7. 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.
NOTICE: Do not drop the handheld “radio control unit” (RCU) down a manhole
as this could cause it permanent damage. Please use the lanyard provided.

15
Speed up
4.4. Control panel layout and function
4.4.1. Control keys
4.4.2. Toggle switch operation
Engine stop
Water on Speed down Menu exit
Menu password
access
Menu down key
Radio on/off
screen
Engine start
Menu up key
Operating screen
Control panel fuse
Power on keyswitch
Enter button

16
4.4.3. Screen layouts
Starting splash screen
Password screen
Manual Confirmation Screen
Software version
Password screen – Use
enter, up and down
buttons to enter
password
Run screen entry – 2010
Minor programme
updates - 1111

17
Unit pressure
Engine speed
Harben contact number
Water on
indication
Main run screen (access by pressing menu exit key)
Remote enable/control screen (Enter button will toggle between function)
Run detail screen (access via the up and down keys)

18
Button 6 – menu scroll
Speed/pressure down
c
Engine start/stop
4.4.4. Radio control layout
4.5. Running the Engine (Manual Mode)
With two people, one at the pump set and one in charge of the nozzle or gun. (H&S Sections
3, 4, 8, 9, 11, 15, and 16)
If your machine is fitted with a radio remote control go to section 4.6.
1. Switch on unit using toggle switch.
2. The control system will now go through a pre-start (glow plugs).
3. Enter password ‘2010’ to enter.
4. You will now enter the run screen.
5. Press the engine start button.
6. The engine will now start and run in idle.
7. The user can now increase and decrease the speed of the engine using the engine up
and down speed.
8. Increase the speed of the engine and when it is safe to turn the water on, press the
water on button.
9. The engine speed and pressure can now be increased and decreased using speed up
and speed down button.
10. Radio mode will not operate when manual mode is selected.
Radio control screen
cc
Water on/off
cc
Speed/pressure up
Button 5 – menu scroll

19
4.6. Running the Engine (Radio Mode)
1. Switch on unit using toggle switch.
2. The control system will now go through a pre-start (glow plugs).
3. Enter password ‘2010’ to enter.
4. You will now enter the run screen.
5. Press the radio screen button.
6. Press the enter button to turn the radio function on.
7. Switch on the radio handset by releasing the E-stop button.
8. Hold down button 5 and 6 on the radio handset until the buzzer sounds and the top
green LED on the handset lights.
9. Press the engine start button.
10. The engine will now start and run in idle.
11. The user can now increase and decrease the speed of the engine using the engine up
and down speed on the handset.
12. Increase the speed of the engine and when it is safe to turn the water on, press the
water on button on the handset.
13. The engine speed and pressure can now be increased and decreased using speed up
and speed down button.
14. Manual mode will not operate when radio mode is selected.
4.7. Running the Vanpack
1. CAUTION! Fit the correctly sized nozzle to the high-pressure hose. Engine
should not be running. Potential injury can occur if a nozle is being put on the end of
a hose. (H&S Sections 3 and 6)
2. Insert the nozzle approximately 6 feet into the drain before diverting the water through
the main jetting hose. (H&S Section 3, 6, 14, and 16)
3. Once inserted, press the water on button Water will now be diverted to the main jetting
hose.
4. To increase engine speed, use the speed up and speed down buttons
5. Adjust the engine speed until the desired pressure is reached. (H&S Section 5)
6. Once you have completed your jetting work and are ready to retrieve the nozzle
decrease the engine speed to idle. The unit will be running at around 700 psi. it is
recommended that you rewind your hose while under some sort of pressure. A tightly
wound hose that is re-energized could crush the drum of the reel. (H&S Section 3 and
6)