Flowplant DTK500 User manual
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Operation & Maintenance Manual
Original Instructions
UNIT DTK500 DESILTER TRAILER MANUAL AND
RADIO
(004-424, 004-425)
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 Harben P Type Pump
Section 8 Circuit Diagrams
Section 9 Diesel Engine
Section 10 Parts list / Spares / Auxiliary components
Section 11 Service Documents
Section 12 Warranty & Certification
Section 13 Health and Safety Manual 061956
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Operation & Maintenance Manual for:
UNIT: DTK 500 TRAILERR/
004-424 4012 MANUAL
004-425 4012 RADIOA)
ISSUE DATE: 05/21
AMENDMENTS
Change
No.
Changes
Date
Signature
1
INITIAL RELEASE
03/21
SAS
2
HAV INFORMATION ADDED TO SECTION 4
PLUS HOSE SFATETY INFROMATION
05/21
SAS
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Contents & Introduction
1.1.Contents
CONTENTS & INTRODUCTION....................................................................................3
1.1. CONTENTS....................................................................................................................3
1.2. INTRODUCTION..............................................................................................................6
1.3. SCOPE OF THIS MANUAL ...............................................................................................7
1.4. THE TRAILER ................................................................................................................7
1.5. COMPOSITION OF THIS MANUAL.....................................................................................8
SCOPE OF SUPPLY......................................................................................................9
2.1. SCOPE OF SUPPLY........................................................................................................9
2.2. PUMP ASSEMBLY..........................................................................................................9
2.3. DETAILED DRAWINGS..................................................................................................10
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
3.3. INSTALLATION DETAILS................................................................................................13
OPERATION................................................................................................................ 15
4.1. OPERATING CONDITIONS.............................................................................................15
4.2. DAILY CHECKS ...........................................................................................................15
4.3. PRE-START CHECKS &PROCEDURES ..........................................................................15
4.4. STARTING THE ENGINE AND SETTING THE OPERATING PRESSURE .................................16
4.4.1. OPERATING STARTING PROCEDURE ..........................................................................16
4.4.2. CHECKING THE OPERATING PRESSURE WITH A NOZZLE FITTED.................................. 17
4.4.3. DPF REGENERATION................................................................................................18
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4.5. REMOTE OPERATION (IF APPLICABLE)..........................................................................22
4.5.1. STARTING THE ENGINE .............................................................................................22
4.6. RAPID SHUTDOWN ......................................................................................................23
4.7. AUTOMATIC SHUTDOWN..............................................................................................23
4.8. HARBEN®JUMP JET.................................................................................................... 24
4.9. HOSE REEL WINDING AND UNWINDING ..........................................................................24
4.10. FROST PRECAUTIONS................................................................................................26
4.10.1. TO ANTI-FREEZE THE MACHINE WITH AN ANTIFREEZE TANK:..................................... 26
4.10.2. TO DE-ANTIFREEZE THE MACHINE:..........................................................................28
4.10.3. TO ANTIFREEZE WITHOUT AN ANTIFREEZE TANK:...................................................... 29
4.10.4. TO DE-ANTIFREEZE: ...............................................................................................29
ROUTINE MAINTENANCE.......................................................................................... 30
5.1. MAINTENANCE PROCEDURES....................................................................................... 30
5.2. DAILY MAINTENANCE ..................................................................................................31
5.3. P-PUMP LUBRICATING OIL........................................................................................... 32
5.4. SAFETY RELIEF VALVE................................................................................................33
........................................................................................................................................... 33
FAULT FINDING..........................................................................................................34
6.1. SHUTDOWN PROBLEMS...............................................................................................34
6.2. EQUIPMENT FAULT FINDING.........................................................................................35
6.3. P-PUMP FAULT FINDING..............................................................................................36
6.4. SELECTOR FAULT FINDING (SEE SECTION 8).................................................................38
PUMP...........................................................................................................................39
CIRCUIT DIAGRAMS...................................................................................................40
8.1. HYDRAULIC CIRCUIT....................................................................................................41
8.2. WATER CIRCUIT..........................................................................................................42
8.3. ELECTRICAL CIRCUIT................................................................................................... 43
DIESEL ENGINE..........................................................................................................45
PARTS LISTS / SPARES...........................................................................................46
10.1. INTRODUCTION..........................................................................................................46
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10.2. ORDERING SPARE PARTS..........................................................................................46
10.3. SERVICE AND REPAIR PART NUMBERS ........................................................................47
SERVICE DOCUMENTS............................................................................................49
11.1. SERVICE CHECKLIST .................................................................................................49
11.2. SERVICE LOGBOOK...................................................................................................51
WARRANTY AND CERTIFICATION..........................................................................52
12.1. WARRANTY OF NEW PRODUCTS:................................................................................52
12.2. WARRANTY OF SPARE PARTS: ...................................................................................52
12.3. LIMITATIONS OF WARRANTY:...................................................................................... 53
12.4. DECLARATION OF CONFORMITY ................................................................................. 55
12.5. CERTIFICATE OF CONFORMITY ................................................................................... 57
HEALTH AND SAFETY MANUAL –061956 ............................................................. 59
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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!
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1.3.Scope of this Manual
This manual provides operation and maintenance instructions for the trailer. 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.
Repairs to the pump crankcase are not considered maintenance operations as these should
be undertaken only byFLOWPLANT,their approved agents, orat least competent automotive
engineers.
1.4.The Trailer
The Trailer 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.
It is plated at 1600 kgs and it has a maximum operational weight of 1500 kgs when filled with
water to the maximum level allowed by the inlet float valve.
The options fitted to and the accessories supplied with this Trailer are detailed in Scope of
Supply in Section 2
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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 Harben P Type Pump
Details of the pump assembly.
Section 8 Circuit diagrams/Electrical Details
This section includes the Hydraulic, Water and Electrical circuits.
Section 9 Diesel Engine
This section provides part details of the Kubota diesel engines.
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
- Warranty policy
- Declaration of Conformity
- Certificate of Conformity.
Section 13 Health & Safety
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Scope of Supply
2.1.Scope of Supply
Unit:
DTK 500 Desilter Trailer
Machine Build Code:
004424 4012 MANUAL
004425 4012 RADIO
2.2. Pump Assembly
The General Arrangement drawing No. 004-416 defines the components of the Trailer
assembly as follows:
The pump is driven by an industrial diesel engine.
The engine drives the pump via a reduction gearbox which reduces the pump rpm down to
the correct shaft speed.
Water is fed through the inlet hose reel from a mains supply into a plastic water storage tank;
the tank supplies the pump with a positive headof pressure via a Hypro 80mesh inline strainer
that filters the water to approximately 177 microns.
(Do not fill the water tank directly, always use the inlet hose reel (in order to comply
with Local Water Authority Regulations).
The ‘P’ Type 8 22 radial piston high-pressure diaphragm pump is driven by a Kubota 1803
3cyl industrial diesel engine through a 2.0:1 reduction gearbox.
The pump’s selector can direct the water at high-pressure to a hydraulically driven hose reel
or at low pressure ‘dumped’ back to tank.
The systems are protected from over pressurisation by a safety relief valve.
The engine and system pressure can be monitored at the control panel situated at the rear of
the trailer.
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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.
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