HOTWASH - Flowplant · this drawing is confidential and is supplied on the express condition that...

HHHOOOTTTWWWAAASSSHHHOperation & maintenance manual

003-270 H3004DLDW1003

TWIN REEL TRAILER

Section 1 IntroductionSection 2 Scope of SupplySection 3 Technical DataSection 4 Health & SafetySection 5 OperationSection 6 Circuit DiagramsSection 7 Diesel EngineSection 8 Hot water BoilerSection 9 PumpSection 10 Unloader Valve/Safety Valve/Safety GunSection 11 Parts lists/sparesSection 12 Running GearSection 13 Service DocumentsSection 14 Warranty and Certification

Flowplant ManufacturingGemini House, Brunel Road, Churchfields Industrial Estate,

Salisbury, Wilts, SP2 7PU, UK

Telephone: +44 (0)1722 325424 / Fax. +44 (0)1722 411329E-mail: [email protected]

Internet: http://www.flowplant.com

FLOWPLANT

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FLOWPLANT

AMENDMENTS

Operation & maintenance manual for:

UNIT: 003-270 UNIT H3004DLDW1003FOCS TWIN REEL HOTWASH

ISSUE DATE: 01/14

AMENDMENTS

Change Number Page(s) Amended Date Signature

New Addition 06/2015 TWC

FLOWPLANT

AMENDMENTS


FLOWPLANT

INTRODUCTION

SECTION 1 - Introduction

FLOWPLANT

INTRODUCTION


FLOWPLANT

INTRODUCTION

Read this manual before you operate or carry out any maintenance on the Hotwash unit.Important safety information is highlighted as WARNING and CAUTION instructions. Youmust obey these instructions. The use of warnings and cautions is defined below:

NOTICE

Carefully read the notices of this manual because they give importantinformation concerning safe installation, use and maintenance; familiariseyourself with the workings of the machine in order to rapidly switch it offand eliminate pressure.

This manual is an integral and essential part of the product, it will be consigned to the userin order to ensure the training/information for personnel.

The manufacturer does not assume responsibility for damage caused to persons, thingsor to the machine, in case of improper use.Carefully preserve this manual for any further consultation.

Make sure of the model of your cleaner by reading the details on the identification tag onthe machine. Upon delivery, inspect the machine for all accessories and for damage,which may occur during transport.

Follow the recommended operating procedures at all times, do not misuse the equipmentas this could result in injury or mechanical breakdown.

WARNING

Warnings are given where failure to observe the

instruction could result in injury or death to persons.

CAUTIONCautions are given where a failure to observe the instruction could

result in damage to the pump or to associated equipment.

FLOWPLANT

INTRODUCTION

1 INTRODUCTION

1.1 Scope of this manual

This manual provides operation and maintenance instructions for the HotwashTrailer.

Maintenance instructions included in this manual include:

(1) Routine maintenance to be carried out at specific times.

1.2 Composition of this ManualThis manual comprises the following further sections:

Section 2 Scope of Supply

This section defines the scope of supply of the equipment supplied.

Section 3 Technical Data

This section contains a performance specification for the pump / Engine / andHotwater Boiler.

Section 4 Health & Safety

This section details health and safety considerations when using highpressure pumping equipment.

Section 5 Operation

This section describes the recommended operating procedures for the unit.

Section 6 Circuit Diagrams

Details of the boiler / engine wiring and the hydraulic circuit.

Section 7 Industrial Diesel Engine LDW1003 FOCS

This section provides details on the Lombardini LDW1003 FOCS engine.

Section 8 Hotwater Boiler

This section provides details on the Tecnomec 12v vertical boiler.

Section 9 Pump Hawk HC506

This section provides details on the HC506 pump.

Section 10 Unloader Valve / Safety Valve / Safety Gun

Details of the Speck dry shut gun, unloader and safety valves.

Section 11 Spares Ordering & Recommended Kits / Parts list

How to identify and order recommended spares.

Section 12 Running Gear

FLOWPLANT

SCOPE OF SUPPLY

SECTION 2 - Scope of Supply

FLOWPLANT

SCOPE OF SUPPLY


FLOWPLANT

SCOPE OF SUPPLY

2 SCOPE OF SUPPLY

Unit: H3004D Build Code: 003-270

The General Arrangement Drawing No. 003-270/3 facing this page defines the scope ofsupply of the equipment in compliance with the above order.

The Hotwash trailer unit comprises of a Hawk plunger pump (See Section 9), directlycoupled to a Lombardini LDW1003 FOCS industrial diesel engine.

Water is supplied from a centrally mounted water tank passing through a filter into theNMT1820 high-pressure pump. The water is then pumped to a 12v Vertical oil fired boiler.The heated water is delivered to a two manual hose-reels, each equipped with 100ft of 3/8”hotwater hose.The system pressure and flow is regulated by an UL180 Unloader valve.

Pump: Hawk NMT1820R (18 lpm @ 200bar)

Engine: Lombardini LDW1003 FOCS

Filtration: Strainer Inline 1/2"NPT 80 Mesh

Boiler: 12V Vertical oil fired / thermal power 81,000 k/cal-h (dt 64°C)

WaterSupply:

Water is fed into the water tank; the water level is controlled by a 1/2” Ball-floatvalve.

Controls: The unit is controlled at the control panel located on the side of the unit.For operation instructions See Section 5.

PressureControl:

Pressure and flow are regulated by a Unloader valve Type UL180.

Safety relief: In the unlikely event of over pressurisation the system is protected with asafety Valve-Type-S250.

Unit 003270 shown.

FLOWPLANT

SCOPE OF SUPPLY


FLOWPLANT

TECHNICAL DATA

SECTION 3 - Technical Data

FLOWPLANT

TECHNICAL DATA


FLOWPLANT

TECHNICAL DATA

3. Technical data

3.1 HOTWASH Specification__________________________________________________________________

MODEL H3004D HOTWASHUNIT

Unit weight (Dry) (kg) 865 (665)

Dimensions LxWxH (Cm) 314.5x146x125.5

ENGINE

Make LOMBARDINI

Model LDW1003

R.P.M. 1725

Power (kW) 10.5

PUMP

Pump Type Hawk NMT1820R

No. of Cyl 3

Power Rating (kW) 8.1

Working pressure (Bar) 200

Flow (L/min) 18

TANK

Fuel tank capacity (Lt) 60

Water tank Capacity (Lt) 140

BOILER

Type (Stainless steel) 21 Lt.

Dimensions LxWxH (Cm) 53X30X78

Volt (*) (Volt-Hertz) 12V DC

Max. outlet water temperature (°C) 150

Gas-oil consumption (Boiler) (Lt./H) 9.1

FLOWPLANT

TECHNICAL DATA

3.2. Technical description

The LEUCO HAWK NMT1820 pump model is a 3 cylinder, positive displacementplunger pump, which is crank driven with reciprocating plungers.

Power from Lombardini engine is transmitted via a flexible Bowex drive coupling keyedto the input shaft.

The pump crankcase includes an oil site glass to indicate the level of lubricating oil.

Delivery pressure is manually set using a panel mounted UL180 Unloader valve.

Should the maximum working pressure (200 bar) be exceeded the S250 Safety reliefvalve will blow at 220 bar and the pump output will be dumped back to the tank.

The water is heated to 75°C (operating temperature - 150°C maximum) provided by anoil fired burner see below.The burner is a Tecnomec Type ‘A’ Vertical Boiler operating on a 12v electrical systemc/w stainless steel housing,

After heating, the water is then delivered to a manually driven hosereel mounted on thefront of the chassis.

Standard equipment includes:

Safety gun / Detergent injector / 30m x 3/8" high pressure hose / Tip nozzle.

Optional equipment:

Hot water mini Hoverclean floor cleaner / extra long handled hand lance.

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FLOWPLANT

TECHNICAL DATA


FLOWPLANT

HEALTH & SAFETY

SECTION 4 - Health & Safety

FLOWPLANT

HEALTH & SAFETY


FLOWPLANT

HEALTH & SAFETY

4 HEALTH & SAFETY

4.1 Introduction

This section should be read in conjunction with the WARNING and ATTENTION!notices contained throughout this manual or any safety notices on any items of theequipment supplied.

The use of WARNINGS and CAUTIONS is defined below:

All procedures and recommendations in this manual must be strictly adhered to byoperators of the unit, or by any person passing within close proximity.

All Company Safety Regulations applicable must be adhered to at all times.

The following notes, and safety notices throughout this manual, are intended toguide the operator in the safe use and maintenance of the equipment. Whilst everyeffort has been made for completeness, these notes and notices must besupplemented by the knowledge, training and experience of persons carrying outtheir tasks.

WARNING

Warnings are given where failure to observe theinstruction could result in injury or death to persons.

ATTENTION!Cautions are given where a failure to observe the instruction could

result in damage to the pump or to associated equipment.

FLOWPLANT

HEALTH & SAFETY

4.2 Safety notes

1. Operating procedures throughout this manual must be adhered to. In the caseof conflicting or ambiguous instructions, reference must be made to a SiteManagement or Safety Officer.

2. Any person operating, working with, or passing near, the unit must wear thenecessary protective clothing and equipment.

3. The Site Management should make available to operators or persons workingwith the unit, or part thereof, the appropriate technical documentation andshould ensure such persons read and understand the documentation prior tocommencing their duties.

4. Special tools should be used where recommended in this manual.

5. Prior to any maintenance or repair work being carried out, the unit, or partthereof, must be shut down and equipment isolated.

6. Any maintenance requirements in this manual should be adhered to asminimum maintenance requirements. Maintenance records should be up todate at all times.

7. Guards which are located within the unit must be fitted and secured inaccordance with the drawings and must not be loosened or removed whilst theunit, or part thereof, is operational. Should it be necessary to remove any guardfor access prior to start up of the unit, it must be re-fitted and secured beforestart up.

8. Oils, lubricants, greases and fluids used within the unit must be in accordancewith the recommendations given in this manual.

9. Coupling and uncoupling of the unit, or part thereof, must be carried out by fullycompetent personnel.

FLOWPLANT

HEALTH & SAFETY

4.3 Water jetting equipment

Operators, and the employers of operators, of water jetting equipment should befully conversant with the

'CODE OF PRACTICE

FOR THE USE OF HIGH PRESSURE WATER JETTINGEQUIPMENT',

Copies of the Code of Practice are available from Flowplant Group Ltd.

The following Water Jetting Safety Instructions are based on the Code of Practice.

WATER JETTING SAFETY INSTRUCTIONS

TRAINING

All persons using high pressure jetting equipment should be fully conversant withrelevant operating instructions, safety notes and Codes of Practice. If in doubt,contact Flowplant Group Ltd for advice on operator training.

SUPERVISION

All high-pressure water jetting operations should be under the control of a fullytrained supervisor, who will be aware of the potential hazards to operators andpassers-by.

JETTING AREA

Warning notices, "DANGER - HIGH PRESSURE JETTING" should be displayed atall possible access points to the jetting area. Notices are available from FlowplantGroup Ltd.

WARNINGHigh pressure water jetting can be extremely

dangerous if it is not properly controlled by fullytrained personnel.

FLOWPLANT

HEALTH & SAFETY

4.4 PERSONAL PROTECTION EQUIPMENT (PPE)

All persons using high pressure water jetting equipment should use all necessaryPPE suitable for the task being carried out.

PPE for consideration:-

• Body protection

• Eye / Face protection

• Foot protection

• Hand protection

• Vibration protection

• Head protection

• Hearing protection

• Respiratory protection

• Water jet penetration

• High visibility clothing

• Use of harness when working at height

A full range of Personal Protective Equipment (PPE) is available from FlowplantGroup Ltd

BASIC ENGINE NOISE LEVELS

Refer to engine noise level chart in section 10. Hearing protection should be used duringoperation of the equipment

FLOWPLANT

HEALTH & SAFETY

4.5 HIGH PRESSURE WATER HOSES – BS EN 1829-2

Connecting water hoses must be regularly checked to ensure that they are free fromexternal damage. Hoses with exposed or broken wires and damaged couplings or fittingsmay shear without warning and must be replaced immediately.

Particular attention must be paid to end fittings and couplings for damage to threads andsealing faces. Should any fault be found they must be replaced.

All hoses shall be marked at a maximum spacing of 500mm with following informationclearly marked :-

1) Hose manufacturers identification

2) Maximum allowable working pressure (in bar)

3) Nominal bore (eg DN12)

4) Quarter and last two digits of assembly date (eg 4Q09)

In addition all hose assemblies shall be marked with the following :-

5) Manufacturers identification or part number.

6) Maximum allowable working pressure (in bar)

7) Quarter and last two digits of assembly date (eg 4Q09)

8) Standard BS EN 1829-2

The hoses intended use is water jetting, any other uses are strictly prohibited theyinclude:-

a) Using the hose for applications above the maximum working pressure.

b) Using the hose as a towing aid

c) Using the hose as a lifting or restraining device.

FLOWPLANT

HEALTH & SAFETY

4.6 FROSTY CONDITIONS

If frost has occurred there may be frozen water in the hose or pump which will cause adangerous blockage.

ATTENTION!

DO NOT START THE PUMP UNIT UNTIL IT HAS COMPLETELY THAWED OUT.

4.7 RISK ASSESSMENT

It is a mandatory requirement to carry out a risk assessment for each newapplication before commencing work. This must include calculating the reactionforce created by the jet, taking into account; pressure, flow, nozzle coefficient ofdischarge and pressure drop through the hoses fittings and gun.Should the calculation reveal a reaction force greater than 250N, for a hand heldapplication, additional support must be provided in the form of a gimbal or similardevice, otherwise the engine speed and hence water flow must be reduced.

BEFORE STARTING

Before starting the unit ensure that you, and anyone else who may bein control at any time, are fully aware of its controls and their function.

It is especially important that everyone knows how to stop the unit incase of an emergency.

Ensure that all the pre-operational checks have been completed, and that any necessaryactions have been taken.

SAFETY GUN

WARNINGIf the equipment is capable of creating a

Reaction force in excess of 250N, which isThe maximum recommended by the Code ofPractice for unsupported hand held jetting

Guns and lances.(Additional support may be required or the engine

Speed/pump flow reduced)

FLOWPLANT

HEALTH & SAFETY

a) Never point the Safety gun at anyone, even if switched off

b) When using the Deadman’shandle Safety Gun, the required jetshould be fitted correctly before

starting the unit. All other hose connections etc., must be checked beforeattempting to start the unit.

c) The water spray will also be very hot, avoid contact with people at all costs.

d) Do not allow children the opportunity to play with the equipment!

WARNINGHigh-pressure water can be extremelydangerous do not leave plantunattended!

WARNING: high-pressure jet ofwater Grip the lance with both

hands. Never direct the jet of watertoward people or animals.

FLOWPLANT

HEALTH & SAFETY

DURING OPERATIONS

If water appears from the hose, coupling or connector, often first sighted as a finemist, then the hose is damaged and could burst or a joint is loose or defective.STOP THE UNIT IMMEDIATELY!

No attempt should be made to adjust any hose, coupling or connector whilst thatpart of the system is under pressure.

HOTWATER BOILER

It is advised that contact with the surface of the boiler during and immediately afteroperation be avoided because of the heat generated, this will also apply to theoutlet fittings immediately after the boiler in the delivery line.

WARNING

Hot Surfaces can cause painful

Burns to the skin, please allow the

Unit time to cool down!

DURING MAINTENANCE

A unit undergoing maintenance should be isolated from other plant or suitablyidentified to ensure that it is not used inadvertently.

Maintenance must only be carried out by skilled personnel, who are conversant withthe nature and dangers of high-pressure water, of jetting safety regulations andcodes of practice.

TOOLS

The correct tools of the right size for the job must always be used to avoiddamaging the unit and possibly making it unsafe. Adjustable tools with serratedgripping jaws should not be used.

REPLACEMENT PARTS

Only replacement parts which have been obtained from or approved by FlowplantGroup Ltd are to be used when undertaking maintenance. Using any otherreplacement parts will normally invalidate the warranty and could be dangerous.

FLOWPLANT

HEALTH & SAFETY

PERFORMANCE

Never exceed the maximum rated pressure or engine speed.

Note: The maximum engine speed quoted refers to the “High Idle Speed” at no loadcondition i.e. at the lowest possible pressure.

4.8 RISK OF CARBON MONOXIDE POISONING (VANPACKS ONLY)

The hotwash vanpack uses a diesel burning boiler system and engine thatcould cause build-up of carbon monoxide gases in the vehicles storage & cab area.

The USER should have rear and side doors open when operating the machine, it isadvisable to also carry a carbon monoxide monitor in the rear and cab of the vehicle as anearly warning of any potential risks.

4.9 PRESSURE SAFETY DEVICES

Pressure relief valves should be checked for functionality and certified by themanufacturer or their authorised representative every 6 months. Pressure discs should bereplaced every 6 months to ensure continued safe operation and only manufacturer’soriginal replacements should be used

FLOWPLANT

HEALTH & SAFETY

4.10 LEGIONNAIRES’ DISEASE

Legionella Bacterium

The bacteria are common and are found naturally in water, usually in low numbers. Thebacteria do not seem to multiply below 20°C and will not survive above 60°C; watertemperatures between 20°C and 45°C being optimum for growth. The bacteria mayremain dormant in water temperatures between 6°C and 20°C, multiplying when watertemperatures reach a suitable level.

The bacteria also require food to multiply such as algae, amoebae and other bacteria. Thepresence of scale, sediment, sludge and other material within the system may beimportant in creating favourable conditions for the growth of bacteria as are biofilms (a thinlayer of micro-organisms which may form slime on the surfaces in contact with the water).

As the tanks of the unit are required to be emptied after the completion of jettingoperations, so that the daily checks required by the Operation & maintenance manual canbe carried out, each jetting operation will be commenced with fresh water.

In the event that the operations manual is ignored and the tanks not emptied, the risk ofbacterial growth within the system would increase but the ambient temperature of thewater in the tanks is likely to reach 20°C, and be maintained at that level, only inexceptional circumstances.

To prevent a build up of scale, sediment, sludge and other materials and reduce furtherany risk of Legionella bacteria growth, it is recommended that water storage tanks andassociated hose and pipe work be thoroughly cleaned and flushed through at least everysix months (preferably with hot water in excess of 70°C).

Flowplant Group Ltd

Gemini House, Brunel Road, Churchfields, Salisbury, Wilts, SP2 7PU, England.

Tel. +44 (0)1722 325424 Fax. +44 (0)1722 411329

FLOWPLANT

OPERATION

Section 5 - Operation

FLOWPLANT

OPERATION

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FLOWPLANT

OPERATION

FLOWPLANT

OPERATION

5. OPERATION

The Flowplant HOTWASH trailer is designed for industrial cleaning applications.

DESCRIPTION OF THE MACHINE

The Hotwash trailer unit is a fully certificated EEC approved towable hot waterjetting unit.

It can produce hot water up to a maximum temperature of 150 deg Celsius at apressure of 200 bar.Heat is produced by an efficient vertical oil fired burner directly fed from a fuel tank;it has a duct for exhaust smoke; 12VDC electric system; and a washing lance withgun (or other accessories).

5.1 Operating Conditions

Operators, and the employers of operators, of water jetting equipment should befully conversant with the ‘CODE OF PRACTICE FOR THE USE OF HIGHPRESSURE WATER JETTING EQUIPMENT’, hereafter referred to as ‘The Code ofPractice’.

Read Section 4 before operating the unit.

5.2 Daily Checks

All checks which should be carried out each day before operating the equipment aredetailed below.

They are: CLEANLINESS OF WATER FILTER

HC506 PUMP OIL LEVEL

DIESEL ENGINE OIL LEVEL

Remember, if the machine has previously been in operation then maintenancechecks may need to be carried out.

(Refer to Sections 8, 10, and 12 for service schedules)

WARNINGHigh pressure water jetting can be extremely

dangerous if it is not properly controlled by fullytrained personnel.

FLOWPLANT

OPERATION

5.3 Pre-start checks & procedures

Connections of equipment referred to are shown on drawing 003-244 in Section 2.

1. Ensure the trailer hand brake is applied and the rear prop stands are down.

2. Connect a mains water supply hose to the water tank inlet and fill the water tanks.Ensure a constant supply of water is available.

3. Connect the jetting guns or lances.

Note: The unit is equipped with 2 high-pressure manual hosereels.

4. Make sure there is plenty of fuel in the fuel tank.

5. Check all connections are secure and that there are no leaks.

WARNINGDo not use the pump if it has frozen

If the equipment has been inadvertently allowed tofreeze, it is essential that the whole system is firstthoroughly thawed out, then cautiously flushed withoutany nozzle or other restriction to the high-pressure hose.Ice which may have been retained in the system can beejected from the hose at high speed as the pump isstarted.These ‘bullets’ of ice can travel up to 20 to 30 metres,with possible lethal consequences.

Refer to Section 4 – Frost Precautions

FLOWPLANT

OPERATION

6. Ensure the pump inlet valve is open (as shown).

FLOWPLANT

OPERATION

5.4 Starting the engine/setting the operating pressure andtemperature.

The Hotwash trailer unit has not been supplied with a remote control facility whichwould enable the equipment to be operated by one person in accordance with the‘Single person Operation’ as detailed in the Code of practice.

Equipment referred to is shown on drawing: 003-268 in Section 2.

1. An operator should be positioned at the control panel. Additional operatorsshould be situated at the required jetting position holding a lance.

Note: The unit is equipped with a single manual high-pressure hosereel, theoperator must connect the gun to the hose.

Ensure the jetting gun triggers are not depressed!

2. Turn the keyswitch to the ON position. The green LED ‘’Power On’’ will beilluminated. (See Fig 2)

3. The engine can now be started by pressing the START button, the automaticstart up sequence will take approx 20 secs.(If the engine fails to start the appropriate fault light on the panel willilluminate).

4. With the engine running, the hotwater system can be switched ON & OFF.

WARNING

This equipment must be operated by two persons.When the unit is switched on they must always be in

sight of each other.

EMERGENCY SHUTDOWNAt any time during the starting procedure, or during normal jettingoperations, an emergency shutdown can be achieved by pressingstop/reset button.Or by pressing the emergency stop button located on the control panel.

FLOWPLANT

OPERATION

5. Depress the trigger on the gun to produce high pressure hot water, the temperaturecan be adjusted by means of a digital temperature controller if required,(see Fig 1 below) The controller is factory set to 85 deg/c.

To adjust the temperature• Press and hold the PRG & SET button for more than 5 sec, the display will

show the number ‘0’ (representing a password prompt).• Using the arrow keys scroll through until displaying the number ‘77’ confirm

by pressing SET.• Using the arrow keys scroll through until ST1 is selected, confirm by pressing

SET.• Set the required temperature by pressing the arrow keys up or down, press

SET to confirm the new value (the temperature is limited to a maximum of100 deg/c).

• Press and hold the PRG button for more than 5 sec to save the new values.

The recommended temperature for normal use is 80 to 88 deg/c (under full flowconditions the boiler will not exceed 88 deg/c).

• In specific applications where additional temperature is required reduce the waterflow to the gun; this can be achieved by fitting a smaller jet or using the pressureregulator to reduce the pressure.

• Do not allow the temperature to exceed 150 deg/c• The operator should be aware that the response time between the control system

and the boiler will differ, this means the temperature may also vary.• When the trigger is pulled, if the temperature is low number (1) LED will disappear

this indicates that the boiler is operating.

Temperature Controller (Fig 1)

6. To stop jetting, release the trigger on the gun, the Unloader will re-circulatethe flow back to tank.(Note. Pressure can be increased by turning the Unloader cap clockwise and

decreased by turning the cap anti-clockwise)

7. Depress the gun trigger to recommence jetting.

DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE OF 200 BAR (3000 PSI).

FLOWPLANT

OPERATION

8. The unit operator can press the red ‘HOT WATER OFF’ button if hotwater is no longer required. (Boiler shutdown).IMPORTANT! Always run high-pressure cold water through guns for at least30 seconds afterwards to cool the system down and prevent back-heating.The operator at the control panel must watch the additional operators with theguns/accessories, and be prepared to affect a rapid shut down if required.

5.5 Normal Shutdown

1. Turn the boiler off by pressing the red ‘HOT WATER OFF’ button at the controlpanel.

2. IMPORTANT! Run high-pressure cold water through the lance for at least 30seconds afterwards to cool the system down!

3. Release the triggers on the guns/lances to stop jetting.

4. Stop the engine by pressing the STOP/RESET button.

5. Turn the keyswitch to the OFF position.

6. Depress the triggers on the guns/lances to jet any remaining pressure out of thelines then remove the accessories and connections from the machine.

5.6 Notes on Jetting

If the jetting nozzles are too large or worn, the maximum pressure will not be achievable.

If the jetting nozzle is too small a percentage of the flow will be re-circulated and start topreheat the inlet water supply to the pump.

RAPID SHUTDOWNShould any unforeseen circumstances arise, including any signs of a leak, thejetting operation should be terminated immediately and the equipment shut downby pressing stop/reset button.Or by pressing the emergency stop button located on the control panel.

FLOWPLANT

OPERATION

Hotwash Controls (Fig 2)

FLOWPLANT

OPERATION

5.7 Frost Precautions

The Hotwash has a fully integrated antifreeze tank and is located on the rear panelof the trailer.

During periods when there is a risk of freezing the following steps should be taken:

To Antifreeze the machine:

1. Ensure there is enough water in the main tank to allow the pump to run, i.e.above the low level shut off switch.

2. Turn the pump inlet valve (located behind the nearside wheel under theframe,) to the OFF position as shown.

3. Ensuring the antifreeze tank is full, open the antifreeze valve located belowthe antifreeze tank as shown.

FLOWPLANT

OPERATION

4. Remove the gun or any nozzles from the ends of the hoses.

5. Start the engine and run at idle speed.

6. Hold the open ended hose away from the body pointing it to the ground andaway from any bi-standers.

7. Divert the antifreeze to the hoses. After a short period of time the antifreezemixture will start to come out of the hoses.IMPORTANT: Do not allow the antifreeze tank to run dry. This will causeserious damage to the pump.

8. Shut the engine off once the anti-freeze tank is close to empty.

9. Drain the tank of water. Once empty, close the tank drain valve.

10. Open the pump inlet valve to allow the antifreeze to fill the pump inlet line, asshown.

IMPORTANT: if the pump inlet valve is not opened the pump inlet line isat risk from freezing and will damage the pump when restarted.

11. Finally, close the antifreeze valve, remove the hoses from the tank and storesafely on the reels.

FLOWPLANT

OPERATION

To De-Anti Freeze the machine:

1. Fill the main tank with water.

2. Place the hoses either into the antifreeze tank (to re-use later) or to disard theantifreeze safely.

3. Ensuring that the antifreeze valve is closed, and the pump inlet valve isopen, start the engine and run the pump at idle, immediately diverting thewater to the hoses.

4. Pump out the remaining antifreeze solution from the high pressure hose backinto the container. Top up & check the strength of the anti freeze mixtureensuring it is at least a 50/50 mix.

5. Press ‘water off‘ button.

6. Turn engine off.

7. Revert back to normal operating conditions.

FLOWPLANT

OPERATION

___________________________________________________________________

SO YOU FORGOT TO TAKE PRECAUTIONS!IF THE PUMP IS FROZEN UP - IT SHOULD ON NO ACCOUNT BE STARTED

5.11 Additional Storage

ATTENTION!

When storing additional equipment take care not to overload thestorage areas around the vanpack. Take care especially around thebattery /electrical system, failure to do so may result in damage tothe vanpack and is a potential fire risk to the vehicle.

FLOWPLANT

CIRCUIT DIAGRAMS

Section 6 – Circuit Diagrams

FLOWPLANT

CIRCUIT DIAGRAMS


FLOWPLANT

CIRCUIT DIAGRAMS

6.1 Hydraulic Circuit

FLOWPLANT

CIRCUIT DIAGRAMS


FLOWPLANT

INDUSTRIAL DIESEL ENGINE

Section 7 – Diesel Engine

A copy of the Diesel Engine Manufacturers Operators HandbookIs supplied with this equipment.

The information contained within this section is only designedTo complement the handbook and is for general use only.

FLOWPLANT



FLOWPLANT


7.2 Recommended Service Parts for LDW 1003 FOCS

Pt No. Description 125 250 500 1000 2500

051-597 Sump Plug Washer 4670088 1 2 4 8 20

051-611 Air Filter Element 2175164 1 2 4 10

051-612 Oil Filter Element 2175107 1 2 4 10

051-600 Fuel Filter Element 2175042 1 2 4 10

051-613 Alternator Belt 2440316 1 2 5

051-614 Rocker Box Gasket 4400056 1 2 4

051-615 Fuel Rail O-rings 1200286 6 12 30

051-616 Injection Pump O-ring 1200213 3 6 15

051-617 Injection Pump Washer 4670082 3 6 15

051-618 Spark arrester 5989007 3 6 15

051-619 Cam Belt 2440338 1

051-620 Head Gasket 1.45mm (0 Notches) 4730742* 1

051-621 Head Gasket 1.55mm (1 Notch) 4730743* 1

051-622 Head Gasket 1.65mm (2 Notches) 4730744* 1

051-623 Gasket Set Less Head Gasket 8205073 1

* Only one of these is required depending on how many notches the one fitted to your enginehas.

The parts required to service an engine up to 3000 hours would be 1 X 2500 hour + 1 X 500hour kit.

This list is compiled using the standard service schedule for the engine, and does not includeany components that may fail during the life of the engine.

Engines operating in dusty conditions, continual high load or temperatures, etc. may requireadditional parts and service intervals.

If you require any further help with service or parts information, please contact the relevantdepartment. See below.

LOMBARDINI (UK) LTDUNIT 7, FERRY MILLS, OSNEY MEAD OXFORD. OX2 OESTEL: (01865) 793299 F.793301

FLOWPLANT


7.3 Spare Parts for LDW1003 FOCS

A LDW FOCS

FLOWPLANT


B LDW FOCS

C LDW FOCS

FLOWPLANT


D LDW FOCS

FLOWPLANT


E LDW FOCS

FLOWPLANT


F LDW FOCS

FLOWPLANT


G LDW FOCS

FLOWPLANT


H LDW FOCS

I LDW FOCS

FLOWPLANT


L LDW FOCS

FLOWPLANT


M LDW FOCS

FLOWPLANT


N LDW FOCS

LOMBARDINI (UK) LTDUNIT 7, FERRY MILLS, OSNEY MEAD, OXFORD, OX2 OESTEL: (01865) 793299 F.793301

FLOWPLANT

HOTWATER BOILER

Section 8 – Hot Water Boiler

FLOWPLANT

HOT WATER BOILER


FLOWPLANT

HOTWATER BOILER

TYPE ‘A’ 12 Volt

VERTICALBoiler

Spare parts List

Tecno.Mec - Casalgrande (RE) - ITALY

Via Canale, 114 - 42013 CASALGRANDE (RE) - ITALYTel. +39-0522-840805 Fax +39-0522-849962

Internet: http://www.tecnomec.com

FLOWPLANT

HOT WATER BOILER

8.1 Parts list

CALDAIA VERTICALE - VERTICAL BOILER Mod CV95 (220V 50 HZ)

Item Part No. Description Code Qty N/A1 071440 Complete combustion head CV/TC/06 12 071441 Star cover complete of: 940017 1

Inserto FTT/C di 4 101557 3Screw 4x14 100336 3Washer 4x12 AC.0006.BU 3

3 071442 Nut M6 AC.0024.BU 44 071443 Flat washer 6x12 102029 45 071444 Chimney ‘K’ Version 102001K 16 Coil 15lt 101489 1

071445 Coil 18-21lt 101490 17 071446 Duraboard gasket d.280 sp 20 101530 18 071447 Duraboard gasket d.295 th. 20 101531 110 071448 Stainless steel drum 21lt 102062X 1

Insert 6 101542 211 071449 Knob MOD.1100 112 071450 Air Sticker 100076 113 071451 Fan flange 970092 114 071452 Air regulator 101532 115 071453 Scroll 103111g 117 071454 Washer 5x15 AC.0015.BU 318 071455 Nut M5 101564 319 071456 Fan 101486AV 120 071457 Fan Flange 102490 121 071458 Grain screw 400065 123 071459 Bolt 8x20 100071 224 Burner motor 220v 50hz 400167 125 071460 Pump burner motor joint

coupling400167G 1

26 071461 Nipples ¼ 1/8 40093 227 Diesel pump POMPA213 128 071462 Copper washer 10x14x1 101211 229 071463 Drilled bolt 1/8 101219 230 Bundy hose boiler simbol 101506 131 071462 Copper washer 10x14x1 101211 234 071466 Blue pipette 12.00590 235 071467 High tension cable 700mm 400100 236 071468 Electrodes complete of 0775101 2

Screw 4x8 103005 237 071469 Seeger ring 24mm internal 104028 138 071470 Glass 104029 139 071471 Aluminium electrodesholder disc 104025 140 071472 Burner nozzle holder 400276 141 071473 Burner nozzle 1,35 60 210200 142 071474 Baffle disc 101496 1

Screw 4x14 100336 143 Transformer 220/50 400082 149 071475 Washer Aluminium 3/8” 101014 250 071476 Nut Self locking 3/8” 100034 2

Note: Items marked in black are not applicable to the 12 Volts boiler option.

FLOWPLANT

HOTWATER BOILER

Additional Parts Required For 12 Volts DC Option (Not Shown on dwg)

Item Part No. Description Code Qty N/AA 071-477 Box ABB 00856 1B 071-478 Lower Plate ABB00902 1C 071-479 Clamp PG9 2D 071-480 Clamp PG7 5E 071-481 Circuit Photo Cell FTC 12 RL GM 1F 071-482 Circuit ARC 12V ARC 209 12V 1

071-568 Circuit Board/12V ARC281 ARC 281 12VG 071-483 Photo Resistances GM 1

071-570 Photocell BRAMHA FC 8 BRAMHA FC 8 1H 071-484 Lead Connector BM9202 P+G 1I 071-485 H.T. Ignitor 12v GM 4 AMP 1

071-573 Ignition power supply Webster S3-33XB-BADC 1071-590 Ignitor 12v Constant duty Model: 5049 1

J 071-486 Burner Motor 12v 1K 071-487 Solenoid Valve 12v (Fuel) 1L 071-488 Screw Self thread 3.5x16 7M 071-489 Screw Self thread 3.5x9.5 3N 071-490 Screw Self thread 3.5x55 4O 071-491 Fuel Pump DELTA 1P Screw Self Piercing 3.5x9.5 4Q 071-493 Clamp+Mirror Photocell PG7 1R 071-499 Short Tube “BUNDY” 100167 1S 071-464 Longer Tube “BUNDY 2” 1015060 1T 071-569 Relay 12V/30A BOSCH 0 332 019 150 1

MAINTENANCEWARNING!If the boiler is out of order, immediately switch off the machine, andadvise the qualified personnel. Switch off the machine anddisconnect the water mains and do not effect any repair.Immediately contact qualified personnel. The repairs must be doneby the manufacturer or by an authorised after-sales centre, alwaysusing original spare parts.

The following operations must be done to avoid damage to mechanical parts and to keepyour boiler efficient.For all maintenance operations on the boiler, the high-pressure pump and on the machine ingeneral, it is necessary to contact qualified personnel or an authorised after-sales centre.

Before doing any maintenance on the Boiler:1. Switch off the machine (Turn the key-switch to the [0] position)2. Close the water tap and disconnect the supply.3. Drain Water tank4. Shut off diesel supply (Valve located underneath fuel tank)

Please ensure valve is opened again before starting unit.

FLOWPLANT

HOT WATER BOILER

8.2 Boiler Diagram

FLOWPLANT

HOTWATER BOILER

8.3 Combustion Head

FLOWPLANT

HOT WATER BOILER

8.4 Boiler viewed from above

FLOWPLANT

HOTWATER BOILER

8.5 Boiler Circuit – ARC 281 (05/02)

AR

C2

81

BO

SC

H12

V/3

0A

033

201

91

50

[14]

12

VD

C(

+)

20A

85 86

30

87

10A

B1

B6

OU

T2

(NC

)

BLO

CK

LIG

HT

OU

T1

(NO

)

B2

B3

B4

B5

OU

T3

(NO

)

B7

B8

[4]

0V

DC

(-

)

MB

EV

TR

CT

RL

CIR

CU

IT

EL

EC

TR

ICD

IAG

RA

MK

EY

MB

:B

urn

er

Mo

tor

(12

vdc,

12.4

A)

TR

:H

igh

Te

nsi

on

Tra

nsf

orm

er

12V

DC

EV

:E

lectr

ova

lve

(Fuelso

leno

idva

lve)

PC

:P

ho

to-e

lectr

icC

ell

AR

C:C

ircu

itB

oard

TH

:T

herm

ost

at.

PR

:P

ress

ure

sw

itch.

FL

:F

low

switc

h.

Note

:If

ele

ctr

icalp

rob

lem

socc

ur

with

the

boile

rci

rcuit

do

not

att

em

ptto

rect

ify,alw

ays

consu

lta

qua

lifie

dF

low

pantT

ech

nic

ian

for

advis

e.

[15

]12

VD

C(

+)

T1

(3)

PC

T6

(1+

)T5

T4

(3)

(2-)

(2+

)

(1-)

T2

T3

R7-1

R7

PR

-ve

+ve FL

TH

FLOWPLANT

HOT WATER BOILER


FLOWPLANT

HOTWATER BOILER

8.6 ADJUSTMENTS / SETTINGS

Fuel pump / Cleaning the Pump Filter.1. Ensure the boiler is off, take out the screws on the cover of the pump with a hexagon key.2. Take out he filter and clean it, then refit the filter.3. Close the pump cover with the same key.4. To set the pressure, unscrew the cap with a Hexagon key.5. Insert the pressure gauge to test pressure.6. Switch on the boiler.7. The pressure should be set to 10 bar, to make adjustments turn the regulating screw of the

pump with a screw driver, Clockwise to increase, and anti-clockwise to reduce.

Air Flow Regulation.

If there is insufficient airflow, the boiler will produce smoke with a risk of carbon dioxide.If the airflow is too great, the boiler will have difficulty in starting.Adjustments are carried out to the inlet (near the pump) and to the knob on the inlet of the boiler.The Knob is to be adjusted between the maximum and minimum.

Fuel pressureadjuster. SET FUEL PRESSURE TO

10 BAR

PV

12

mm

SUNTEC

SWIRL PLATE

NOZZLE

B. Swirl plate adjustment.

Make sure the electrodesare more than 3mm awayfrom the Jet or the Swirlplate.

3 mm

C. Electrode gap setting.

Remove 1/8" blank plugand fit gauge here.

A. Boiler fuel pump showing position to fit pressure gauge and adjuster screw.

FLOWPLANT

HOT WATER BOILER

8.7 Fitting Instructions for ARC281 Circuit

FLOWPLANT

HOTWATER BOILER

8.8 Technical features

Thermal power 81,000 k/cal-h

Fuel Type Diesel

Fuel Pressure 10 BAR

Voltage 12VDC

Blower Motor 110W

Protection IP54

Fuel Connections 1/4"

Max Coil pressure 200 BAR

Water Connection 3/8”

8.9 Trouble Shooting

Symptom Possible Causes

The pump does not run. The motor coupling is broken.

The pump is blocked.

The motor does not turn.

Thermal overload at motor. The motor and pump are blocked.

The motor is damaged.

The pump runs but the fuel does notcome out.

The Filter is dirty.

The nozzle is clogged up.

The Solenoid valve is blocked.

No connection to Solenoid valve.

Low fuel pressure. The filter is dirty.

Nozzle damaged.

Air in the fuel inlet.

Presence of water.

Damaged coupling Motor/pump.

Delayed Starting. Electrodes damaged.

Diesel Nozzle is dirty.

Air adjustment opened too much.

Air channels are dirty or clogged.

Pump pressure setting incorrect.

The boiler blocks. Defective Circuit.

Missed starting.

8.10 Recommended holding boiler Spares

Part No Description

071-570 Photocell

071-590 Ignitor

071-568 Circuit Board ARC 281

071-468 Electrodes (Complete)

071-446 Duraboard gasket d280

071-447 Duraboard gasket d295

071-569 Relay 12V/30A Bosch

071-473 Nozzle 1.75 60 210200 TECNOMEC

FLOWPLANT

HOT WATER BOILER


FLOWPLANT

HAWK PUMP

Section 9 – Hawk Pump

FLOWPLANT

HAWK PUMP


Dimensioni d'ingombro Overall dimensions

Lubrificazione: Olio SAE 10W-40Capacità: 0.65 LitriPeso pompa: 11.8 Kg

Lubrication: SAE 10W-40 OilCapacity: 0.65 LitresWeight: 11.8 Kg

PumpPompa

bar PSI 50 Hz

PressurePressione

VolumePortata

RPMgiri/min

PowerPotenza

NMT1220ES 200 3000 12.5

Caratteristiche Tecniche Technical CharacteristicsNMT ES2012

l/min GPM

60 Hz 50 Hz 60 Hz 50 Hz 60 Hz

HP kW

50 Hz 60 Hz 50 Hz 60 Hz

15.0 3.3 4.0 1450 1740 6.4 7.5 4.7 5.7

NMT1520ES 200 3000 15.0 18.0 4.0 4.7 1450 1740 7.7 9.2 5.7 6.8

NMT1820ES 200 3000 18.0 21.4 4.8 5.6 1450 1740 9.2 11.0 6.8 8.1

NMT2120ES 200 3000 21.0 25.0 5.5 6.6 1450 1740 10.7 12.8 7.9 9.4

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66 6666 66

33 3377 77

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111111114444

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99990000

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A termini di legge ci riserviamo la proprietà di questo disegno con il divieto di riprodurlo e/o divulgarlo a terzi senza il nostro consenso scritto.This page must not be dublicated nor distributed to any third person without our written approval. We will reserve all rights exclusively for our intellectual properties.

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1

2

3

4

6

8

9

1011

12

13

14

16

15

18

17

11

19

20

21

2213

14

23 16

24

25

26

27

28

29

26

30

31

25

32

33

34

35

3637

38

39

40

41

42

43

44

45

49 48

4647

5

7

12

16

23

NMT ES 2012

Part Number & Description Descrizione

Q.tà per ogni pompa

Q.ty for each Pump

NM

T12

20E

SN

MT

1520

ES

NM

T18

20E

SN

MT

2120

ES

2600.77 Plunger Seals 20mm

2600.77 Guarnizioni pistone Ø20

1

2600.54 Complete Seals Packing 20mm

2600.54 Pacco completo Guarnizioni pistone Ø20

3

2601.34 Plunger 20mm

2601.34 Pistone Ø20

3

2600.56 Complete Valve

2600.56 Valvola completa

6

2608.03 Plunger oil Seals

2608.03 Anelli tenuta olio Asta

1

2600.57 Complete Manifold

2600.57 Testata Completa

1

3100.28 Conn.rod-plun.rod assy

3100.28 Premontato biella-asta

3

Pos. Item

Codice Part

NumberDescription Descrizione


Q.ty for each Pump

NM

T12

20E

SN

MT

1520

ES

NM

T18

20E

SN

MT

2120

ES

1 0202.95 Crankcase Carter 1*2 0001.03 Plunger oil seal Anello radiale 3*3 0601.07 "O" Ring Ø1.78x31.47 "O" Ring Ø1.78x31.47 3*4 1201.44 Pressure ring 20mm Pressore Ø20 3*5 0002.52 "U" seal, dia.20mm Anello tenuta "U" Ø20 3*6 0300.66 Intermediate ring 20mm Diffusore Interm. Ø20 3*7 0002.60 "U" seal, dia.20mm Anello tenuta "U" Ø20 3*8 0603.07 Copper washer Guarnizione rame 1*9 1601.54 Inox plug G1/2 Tappo G1/2 inox 1

*10 1602.31 Manifold housing Testata 1*11 0601.19 "O" Ring Ø2.62x17.13 "O" Ring Ø2.62x17.13 6*12 3604.74 Valve assembly Valvola premontata 6*13 0601.65 "O" Ring Ø2.62x20.29 "O" Ring Ø2.62x20.29 6*14 1601.55 Valve plug Tappo valvola 615 1801.02 Manifold stud bolt Stainless Steel Vite TCEI M8x65 inox A2 70 816 1400.54 Washer Stainless Steel Rosetta Ø8.5 INOX 16*17 0603.06 Copper washer Guarnizione rame 1*18 1601.53 Inox plug G3/8 Tappo G3/8 inox 119 1503.01 Valve seat Sede valvola 620 1202.01 Valve plate Piattello valvola 621 0900.38 Valve spring Molla valvola 622 0604.05 Valve cage Gabbia valvola 6

� � �

33- 34- 35- 36 37- 38

11- 12- 13

3x ( 2 )

3- 4- 5- 6- 7- 8 9- 10- 11- 12

13- 14- 17- 1839- 40- 41- 42

43

SPARE PARTS KITS KIT RICAMBI

Posizioni Items

3x (3- 5- 7)

3- 4- 5- 6- 7

� � �

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PARTS LIST LISTA RICAMBI

Leuco Spa Rev 1.1 29/04/2014

NMT ES 2012

ItemPart

NumberDescription Descrizione


Q.ty for each Pump

NM

T12

20E

SN

MT

1520

ES

NM

T18

20E

SN

MT

2120

ES

23 1801.14Hex socket Screw M8x20 Stainless Steel

Vite TCEI M8x20 INOX A2 70 8

24 0500.61 Closed bearing housing Flangia chiusa 125 0601.63 "O" Ring Ø1.78x60.05 "O" Ring Ø1.78x60.05 226 0200.06 Roller bearing 33205 Cuscinetto a rulli 33205 2

0006.14 Single - ended shaft Albero semplice P.d.F. 1 �

0006.16 " " " " " " 1 �

0006.17 " " " " " " 1 �

0006.18 " " " " " " 1 �

28 0206.04 Crankshaft key Chiavetta 129 1600.15 Oil dip stick Tappo livello olio 130 0001.02 Crankshaft seal Anello radiale 131 0301.02 Shim Distanziale 332 0500.60 Bearing housing Flangia 3*33 0302.05 Plunger nut Stainless Steel Dado pistone INOX 3*34 1400.12 Copper spacer Ø 11.2/15x0.5 Rosetta rame Ø 11.2/15x0.5 3*35 1200.10 Plunger 20mm Pistone Ø20 3*36 1400.15 Copper spacer Ø 11.3/24x0.5 Rosetta rame Ø 11.3/24x0.5 3*37 0601.03 "O" Ring Ø1.78x7.66 "O" Ring Ø1.78x7.66 3*38 0009.04 Teflon ring Anello antiestrusione 3*39 0003.05 Plunger rod Stainless Steel Asta pistone INOX 3*40 0100.01 Connecting rod Biella 3*41 1502.06 Connecting rod pin Spinotto 3*42 1401.02 Spring washer Ø6 Rosetta elastica Ø6 6*43 1801.32 Connecting rod screw M6x30 Vite M6x30 644 0601.88 "O" Ring Ø 2.62x126.67 "O" Ring Ø 2.62x126.67 145 0203.59 Crankcase cover Coperchio posteriore 146 0601.14 "O" Ring Ø1.78x14 "O" Ring Ø1.78x14 147 1601.17 Brass plug G3/4 Tappo G3/8 ottone 148 0700.05 Sight glass, G3/4 Spia livello olio G3/4 149 1801.13 Cover screw Stainless Steel Vite M6x16 INOX A2 70 4

Part available Particol. disponibile

in kit only solo in kit

* Part available Particol. disponibile

in kit also anche in kit

�

PARTS LIST LISTA RICAMBI

� � � �

� � �

27

Leuco Spa Rev 1.1 29/04/2014

FLOWPLANT

UNLOADER / SAFETY VALVE / SAFETY GUN

Section 10 – Unloader Valve /

Safety Valve / Safety Gun

FLOWPLANT


FLOWPLANT


10.1 UL180 Unloader Valve

PerformanceModel Operating pressure Flow Rate Max. Code No.

UL180 10 – 200 bar* 5 – 30 l/min 00.0733

• Special version max. 280bar

Construction Characteristics• Ball Kick –Back Valve, Taper Kick-Back Valve or Plate Kick-Back Valve.• Interchangeable Stainless Steel Valve Seats.• Connections for Manometer, Pressure switch and Flow Switch.

OperationThe whole discharge must be guided through the valve. Should the actual operatingpressure exceed the adjusted operating pressure, the valve than acts as a pressureregulator. The valve switches to pressure-free bypass operation when the spray gun shutsoff and the spray pressure between the gun and valve remains idle.

The valve can be operated together with several spray guns. It is also possible to connectseveral pumps to one common discharge line.

FLOWPLANT


Speck UL180 Parts List

Item No. No. Off Code No. Description1 1 01.0402 Casing2 1 07.1549 Guide Plug ULH

2A 1 07.1885 Guide Plug ULHF3 1 06.0067 O Ring for 24 1 11.0378 Piston Rod ULH

4A 1 11.0423 Piston Rod ULHF5 1 07.1558 Lock Pin6 1 07.1875 Guide Ring7 2 06.0246 Support Ring for 88 1 06.1146 O Ring for 49 1 07.1551 Piston Body10 1 06.0499 O Ring for 911 1 06.0498 Support Ring for 1012 2 (1) 07.1553 Valve Body

12A 1 07.2415 Kick Back Valve Body (Kick Back Cone)12A 1 07.2771 Kick Back Valve Body (Kick Back Plate)13 2 (1) 07.0629 Ball

13A 1 07.2419 Kick Back Valve (Kick Back Cone)13A 1 07.2773 Kick Back Valve (Kick Back Plate)13B 1 06.0840 O Ring14 1 07.2571 Bypass Valve Spring15 3 (2) 06.0244 O Ring for 16 and 1816 1 07.1557 Plug G3/8"17 1 07.1554 Kick Back Valve Spring

17A 1 07.2413 Kick Back Valve Spring (Kick Back Cone)17 1 07.2781 Kick Back Valve Spring (Kick Back Plate)18 1 07.2772 Valve Plug G3/8"

18A 1 07.1556 Connecting Branch M21 x 1.5 Outer Thread18B 1 07.1910 Connecting Branch M22 x 1.5 Outer Thread18C 1 17.1869 Connecting Branch G3/8" Outer Thread18D 1 07.2162 Connecting Branch G1/2" Outer Thread18E 1 07.1907 Connecting Branch G3/8" Inner Thread18F 1 07.1908 Connecting Branch G1/2" Inner Thread18G 1 07.2005 Connecting Branch G1/4" Inner Thread19 2 07.3808 Plug20 2 06.0742 Copper Seal21 1 07.2414 Valve Plug G3/8" Outlet

21A 1 06.0986 O Ring for 2122 1 07.1889 Hexagon Nut23 1 07.1560 Centering Disc for 2424 1 07.1940 Pressure Spring25 1 07.1822 Hand Wheel26 1 05.0123 Axial Needle Bearing27 2 07.1880 Stop Nut28 1 07.1884 Nut29 1 07.1891 Retainer Disc ULF (H)30 1 07.1883 Disc ULF (H)

14.0024 Repair Kit Kick Back Ball14.0389 Repair Kit Kick Back Cone14.0448 Repair Kit Kick Back Plate

FLOWPLANT


FLOWPLANT


Maintenance Speck UL180 Unloader

Service and AdjustmentServicing and adjustment work are to be carried out by trade specialists only.

Renewal of Piston SealsScrew guide plug (2) out of casing, remove serrated pin (5) and take piston rod out of plug.Cut out worn seals.Put guide ring (6), O ring (8) and support ring (7) carefully over the threads onto the piston rod.Note order of installation.Clip the O ring (10) and support rings (11) onto the piston body. Check inner surfaces of casingand guide plug (dirt or damage wear seals out quickly).Grease all parts lightly with Silicone before reinstalling.

To Check ValvesScrew out plugs (16, 18A-G, 21) and examine balls (13), cones (13A) and valve plate (13A), aswell as valve bodies (12 /12A) for wear.Valve bodies can be screwed out with an inner-hexagon-key size 6. If the valve body (12) (kick-back ball version) is worn, the ball (13) must be impressed carefully against the sealing edges ofthe valve body. Glue in new valve bodies with Loctite 572. Allow to dry for 60 minutes beforeputting into operation.

Adjusting Pressure1. Valve should be tension-free i.e. loosen nut (22) and hand wheel (25) so that the piston rod canbe moved manually.2. Pressure spring (24) and nut (22) are to be tensioned by centring disc (23) with open gun, (incase of more guns, all have to be open) and while the pump is running. When the requiredoperating pressure has been reached, no more water should run out on the bypass side.The maximum operating pressure can be set on the hand-wheel-version by tightening and lockingthe stop nuts (27) to centring disc (23). Various operating pressures (up to max. operatingpressure) can be set by turning the hand wheel. If the nozzle hole is properly suited to the outputand pressure of the pump, no more water should flow through the bypass after the requiredoperating pressure has been reached. If the nozzle hole is too small to allow all the fluid to runthrough the hole after the required operating pressure has been reached, on no account is thevalve to be adjusted higher than the maximum operating pressure of the pump. In this case, thebypass is to be left partially open. Nevertheless, it is advisable to have suitable nozzles installed.

Fault FinderProblem Cause Solution

Unloader Valve SwitchesRepeatedly when gun is off.

Leaky Gun and/orpressure pipe.

Renew Gun, seal Pressure pipe.

Leaky O Rings (8, 10) Renew O Rings.Worn out kick backvalve body or O Ring.

Examine And Renew If Required.

Leaky Piston Rod.Defective O Ring/Support Ring

Renew Piston Rod Seals AndExamine Surfaces In Guide Case

Leaky Bypass at Nominal Pressure.

Nozzle To Small, TooMuch Water.

Install Larger Nozzle.

Worn Out BypassValve.

Examine Ball (13) and BypassValve Body (12) And Renew AsNecessary

Pressure Gauge Shows HighPressure Fluctuations WhenShutting Off Gun.

Valve Set Too HighAbove OperatingPressure.

Turn Back Hexagon Nut (22) orHand Wheel (25). Readjust LockingNuts.

Dirty Valve.Clean Valve (of Lime Deposits etc)Grease Parts Before reinstalling.

FLOWPLANT


10.2 Safety Valve Type - S250 VRP 200 (036116)

The safety valve is used on the Hotwash H3004D200 to protect the pump in case ofoverpressure. This is achieved by releasing the excess pressure in the system when allother devices fail. On the Hotwash the valve is used as an additional backup to theunloader valve.

Note: The valve could also be used to provide additional safety to an individual run ofpipework in a centralised cleaning system.

Safety valves are normally fitted into a “Tee”, so that they do not see the system flow.

• Safe and reliable intervention discharging all the flow.

• Prompt and effective damping action against dangerouspressure spikes.

The valve inlet is through the bottom section, the discharge issideway to the spring. The bypass line is returned to the tank.

FLOWPLANT make the necessary pressure adjustments tothe valve during the testing procedure, rendering the valve aSafety device, DO NOT ALTER THE SETTINGS!

Max Pressure Rated Flow Max Temp Connection Mass

250 bar 30 l/min 90°C 3/8” BSP 0.605 kg

Note: The S250 (VRP200) safety valve is pre-set to the required relief pressure for theHotwash unit. We advise that It should not be tampered with or adjusted, please contactFlowplant for a repair or replacement valve, or if you require further information pleasecontact below

Flowplant Group LtdGemini house, Brunel road, ChurchfieldsIndustrial Estate, Salisbury, Wilts. SP27PUTel: +44 (0)1722 325424 Fax: 411329

FLOWPLANT


10.3.1 Spray GunN05358 SPRAY GUN MV 920 SWIVEL INLET

Max Pressure Rated Flow Max Temp Inlet Outlet Mass280 bar 25 lpm 150°C 3/8” BSP F 1/4"BSP F 0.533 kg

10.3.2 LanceN05359 LANCE MV20/A 3’ (36” / 900mm) MOULDED PROTECTION

Max Pressure Max Flow Max Temp Inlet Outlet Mass250 bar 40 lpm 150°C 1/4” BSP M 1/4"NPT F 0.705 kg

FLOWPLANT

SPARES ORDERING & RECOMMENDED KITS

Section 11

Parts list / Spares Ordering /Recommended Kits

& Accessories

FLOWPLANT


11. SPARES ORDERING & RECOMMENDED SERVICE KITS

11.1 IntroductionThis section includes advice on obtaining spare parts.

To identify consumable items and service kits you require you should use theinformation in this section. To identify components for the pump or engine etc, refer tothe relevant parts in this manual.

11.2 Ordering spare parts

Order spare parts from:

Flowplant Group LtdGemini house, Brunel roadChurchfields Industrial Estate,Salisbury, Wiltshire, UK.SP2 7PU.Contact: Eric Moore (UK Spares)Tel : +44 (0)1722 325424Fax : +44 (0)1722 411329Email : [email protected]

Come visit our website:

When ordering, please state for each part required:

Assembly No. (See Front cover)Part number and description of part required.Drawing No. & parts list item number (If applicable)Quantity required.

FLOWPLANT


11.3 Routine Maintenance Consumable Items

For routine maintenance the following will be required:

Pump Crankcase lubricating oil SAE 20W-40W (Non foaming).

11.4 Consumable Components

Pt No. Description

043-314 Filter ½” NPT Inline Strainer 80 mesh

090-100 FUEL FILTER LARGE UNIVERSAL (E40460)

Note: Boiler & Engine fuel lines.

11.5 Accessories

Ancillary Equipment

Pt No. Description

055-458 Hose Assy 3/8” x 100’

Guns/Lance

Pt No. Description

N05-358 SPRAY GUN MV920 3/8" 280BAR 25 LPM

N05360 LANCE 5' CURVED

N05-359 GUN BARREL (LANCE) 3’

Jet Inserts

Pt No. Description

056-005 JET FAN 15 degree ¼” 1506 (1.6mm)

056-683 JET FAN 15 degree ¼” 15055 (1.5mm)

056-004 JET FAN 15 degree ¼” 1505 (1.4mm)

056-001 JET FAN 15 degree ¼” 1502 (0.91mm) > Note:2 gun operation.

General Accessories

Pt No. Description

TBA HOT WATER MINI HOVERCLEAN

023942 COUPLING Q/R LANCE 1/4"(F)

023943 COUPLING Q/R LANCE SNAP TO SUIT 1/4"(F)

056821 TURBO NOZZLE TN-220 NOZZLE 055 1.4MM

079045 PROTECTIVE HEAT SLEEVING 1M X 30MM ID

FLOWPLANT


11.6 Parts List / Hotwash Unit – 003270Component Description Qty

014195 SHOOT SPRING BOLT HEAVY DUTY FOR HOSEREELS 2

012061 PLUG BRASS FLANGED 1/2" BSP 2

012097 COUPLING QUICK-CONNECTING SELF-SEALING 3/8"BSPF 210BAR 2

013014 ADAPTOR 1/4" BSP M x 1/4" BSP M 415 BAR 1

013038 ADAPTOR 3/8"BSP x 1/4"BSP M/M 415BAR 3

013039 ADAPTOR 1/2" BSP M x 1/2" BSP M 415 BAR C-TXT 4

013203 ADAPTOR BHEAD 3/8" BSPM x 3/8" BSPM 415 BAR C/W LNUT 3

013224 ADAPTOR BHEAD 1/2" BSPM x1/2"BSPM 415BAR C/W LNUT 4

013594 SCREW SET CSK SOC HD M5 X 0.80-6G 16 LG HT 8.8 ZN 30

013604 WASHER 2 7/8"OD X 1 1/2"ID X 1/8 THICK ZN (MJS) 4

014146 HANDLE BLACK PLASTIC TYPE 1 750-317 RS 3

014150 REFLECTOR FRONT MARKER EEC APPROVED WHITE 78/03/00 2

014152 REFLECTOR REAR MARKER EEC APPROVED RED 78/01/00 2

014153 REFLECTOR SIDE MARKER(EEC APPROVED)SCREW ON TYPE 2

016271 COUPLING DENTEX B-28 BORED & KEYWAYED FOR 1" & 24mm SHAFTS 1

021087 ADAPTOR 1/4" PRESSURE GAUGE STAINLESS STEEL 700 BAR 1

023008 ADAPTOR 3/8"BSP M x 1/2"BSP F SWIVEL 415BAR 1

023025 INSERT FOR HOSE SWAGED 1/2"BSP FEM 1

023029 TEE 3/8"BSP F FIX 415 BAR 1

023041 O CLIP 3/4" 8

023142 INSERT HOSE 1/4" BSP 90 DEG FEMALE 8

023148 INSERT FOR HOSE SWAGED 1/2"BSP 90 DEG FEM 2

023265 ADAPTOR 1/4"BSP M x 1/4"BSP F SWIVEL 415 BAR 1

023481 ANGLE-SWIVEL JOINT 1/2BSPM X 1/2BSPF X 90DEG ZN 5000PSI WP 2

023482 INSERT FOR HOSE 1/2BSPM-BRASS 1

023485 UNLOADER.PANEL MOUNTING.(UL.180-00.0969) 1

023486 EXTENSION BARREL 1/4BSPF 50 LG HEX ZN 210 BAR 1

023546 COUPLING GEKA 1/2 BSPF / 1/2 HOSE INSERT BRASS CLAW TYPE 1

023653 1/4"BSPM-1/4"BSPF SWIVEL 90 COMP. ELBOW 250BAR 1

033005 ADAPTOR 3/8" BSP M x 3/8" BSP M 415 BAR 7

033006 ADAPTOR 1/2" BSP M x 3/8" BSP M 415 BAR ZN 1

033010 SEAL BONDED 1/2" BSP 400-825-4490-41 448 BAR SELF CENTRALISING 12

033011 ADAPTOR 1/2"BSP M x 1/4"BSP M 415BAR 4


036116 VALVE SAFETY -SPECK TYPE-S250 1

0421318 SPINDLE TWIN HOSEREEL HOTWASH 1

0421317 SUPPORT ARM TWIN HOSEREEL HOT WASH 1

0421004 HOLDER CHEMICAL CONTAINER LDW1003-HC530 HOTWASH 1

0421008 FRAME SUPPORT FWD LDW1003-HC530 HOTWASH 1

0421009 FRAME SUPPORT REAR LDW1003-HC530 HOTWASH 1

0421042 BRACKET SUPPORT RIVETED STRUT - HOTWASH 6

0421110 CANOPY HINGED REAR H3004D 1

FLOWPLANT


0421379 INSPECTION PLATE COVER/BELL HOUSINGS 1

0421389 BOX HOUSING FOR 071573 IGNITOR/12V BOILER 1

0421391 COVER FOR SPY HOLE/12V BOILER 1

0421411 BRACKET FOR RELAY PREHEAT LDW1003 FOCS - HOTWASH 1

0421412 BRACKET FOR RELAY STARTER LDW1003FOCS - HOTWASH 1

0421417 HEAT SHIELD ALLOY FOR FUEL TANK LDW1003FOCS H3004D 1

0421439 BASE PLATE FOR 12V BOILER HOTWASH 2

0421536 COVER FOR CHIMNEY 12V BOILER TECNOMEC HOTWASH 1

042985CANOPY HINGED FRONT STD HOTWASH (SMALL CANOPY WITH CHIMNEYHOLE) 1

042986 REAR PANEL STD HOTWASH 1

042987 FRONT PANEL STD HOTWASH 1

042988 PANEL N/S REAR STD HOTWASH (LARGE PLAIN PANEL) 1

042989 PANEL CONTROLS N/S FRONT STD HOTWASH 1

042990 PANEL O/S REAR GRILL / LDW 1003 FOCS STD HOTWASH 1

042991 PANEL O/S FRONT STD HOTWASH (SMALL PANEL) 1

043018 CAP HYD/FUEL TANK 2

043032 TOGGLE MEDIUM DUTY SPRING FASTNER ZINC PLATED 2

043071 TUBE SIGHT 1/2"O/D POLYCARBONATE 6FT LENGTH NB. 0.5

043075 VALVE 1/2"BSP SHUT OFF 250PSI TYPE 750 R751T 1

043133 LABEL UNIT SPECIFICATION 1

043162 CATCH PLATE ZINC PLATED 2

043314 LINE STRAINER 1/2"NPT 80 ON 20 SS MESH HYPRO 1

044451 FRAME CHASSIS H3004D HOTWASH TYPE APPROVED TRAILER 1

046046 BALL (FLOAT) VALVE 1/2 (MJS) TW11104/1 1

046046A POLY FLOAT 4" TO SUIT 046-046 1

050065 EXHAUST FLEXIBLE TUBING 1MTR ST.ST 40MM O/D 1

051235 HINGE 75 MM ZP FLUSH HINGE UNCRANKED FOR NO4 SCREW 5

052279 ENGINE LOMBARDINI LDW1003FOCS 10.5KW @ 1725RPM 22.4HP 1

055024 HOSE 1/2" P.V.C. CLEAR BRAIDED [PER METRE] HDPVC12 3.5

055088 HOSE 1/4" P.V.C. CLEAR BRAIDED (PER METRE) 4

055175 HOSE ASSY 3/8" 00.38M STR/ELB 3/8"BSPF EN 853 2SN 1

055325 HOSE FUEL 1/4" SAE100R6 (PER METRE) 4

055790 HOSE ASSY 3/8" PW2-06 0.382M ELB/ELB @ 180DEG 1

055791 HOSE ASSY 3/8" PW2-06 0.462M ELB/ELB @ 210 DEG 1

055792 HOSE ASSY 3/8" PW2-06 1.417M ELB/COMP ELB @ 180DEG 1

055793 HOSE ASSY 1/4" 0.32M STR/ELB EN 853 2SN 1

055794 HOSE 3/8" 1.692M ELB/ELB @ 90DEG EN 853 2SN 1

061088 SCREW SELF TAPPING 1/2" x 8 STEEL PAN HEAD 8

061424 LABEL TRIGGER WARNING HOTWASH 1

061425 LABEL "CLEAN WATER FILTER" HOTWASH [SEE NOTES] 1

061435 LABEL "CHEMICAL CONTROL" 1

061437 LABEL "CHECK OIL DAILY" 1

061438 LABEL "CLEAN DIESEL" 1

061439 LABEL "TANK DRAIN" 1

061440 LABEL "PRESSURE REGULATOR" 1

FLOWPLANT


061441 LABEL "WORKING PRESSURE" 1

061442 LABEL "2.5 BAR" 2

061458 LABEL COLD START PROCEDURE DTB/SUPER SIX 1

067855 PUMP ASSY HAWK NMT1820R 200 BAR 18 LPM (013039 & 033011) 1

071247 TAP CHEMICAL SPK99.048 SPECK 1

071248 SWITCH PRESSURE PDAH -4 -4G -C-H 1

071249 CAP FOR PRESSUR SWITCH DIN 43650A 1

071267 SWITCH FLOW R6FST53500(PSI) 1

071272 BATTERY HEAVY DUTY TYPE 085 1

071289 FILTER CHEMICAL FEED (SAME AS TW449201) 1

071409 BOILER TYPE 'A' VERTICAL 12V 300W 21L 200 BAR WP TECNOMEC 1

071412 FLOAT SWITCH R HORIZONTAL NYLON NO/NC 338-9722 Nitrile gasket 1

073072 STICKY BACK FOAM MJS 10

074081 BELL HOUSING CAST SAE5 - HC500I/HOTWASH 1

078102 WASHER SPACER H/REEL DTM 1

078299 HOLDER BLOCK 3/8"BSP F/F M14X1.0 THERMOSTAT 1

078417 EXTENDED HEX NUT M8 1

078436 SPACER PHOTO-CELL 12V BOILER TECNOMEC 1

079015 EXHAUST TAILPIPE 1.1/2" O.D. FLOWPLANT HOTWASH 1

081163 AXLE 'MEREDITH' T-BAR FIXED H.T. 1000KG 1141.231 NONE 1

085164 TANK WATER STD HOTWASH 1

085195 TANK FUEL/PLASTIC/HOTWASH 1

087060 AV MOUNT AL30/3 AVA 4

087110 GAUGE PRESSURE 63MM ST/ST - 400 BAR 1/4" BSP (SEE NOTES) 1

089079 MOUNT FOR ENGINE AVA-REF TW401900 4

090100 FUEL FILTER LARGE UNIVERSAL (E40460) 2

105323 HOSE REEL COATED RED 2

A024220 SCREW SELF TAPPING(PAN HEAD) NO.10 X 1IN LONG ZINC 4

A0300321 FASTENER EXHAUST CLAMP 1.5/8 2

A080129 HOSE 1/2" PVC (CLEAR) 1

A1404181 SCREW CAPSCREW M4 X 30MM LONG SOCKET HD STAINLESS 5

N01456 3/8"BSPF SWIVEL X 3/8"BSPM 90DEG COMPACT ELBOW 415 BAR 2

N01518 INSERT 1/2"BSP F 90 DEG COMPACT (PUSH IN) ZINC 415 BAR 4

043079 SUPPORT STAY 6529 - PROP ROD FOR DTX2 CANOPY 3

N05024 UNINS.CRIMP CONNECTOR H.DUTY 2

N05074 EARTH STRAP E89/18" 1

N05207 REFLECTIVE TRIANGLE 2

N05270 BATTERY CABLE RED 16MM SQ TYPE BK RS358-321 1

N05551 RED BALLS 3/8" DIA 1

N10001 BATTERY RETAINING BRACKET 1

023983 QUICK CLAW COUPLING 3/4" TAIL BRASS 1

071734 2 WAY OPEN SHORTING LINK BLACK 251-8569 RS HOTWASH 1

071764 FUSE BOX 4 WAY BLADE TYPE 1

090028 STRAINER "Y"-BRANCH 1/2" BSPT BRONZE 1

014203 LOCKABLE MINI HANDLE HOTWASH 1

061635 LABEL WARNING! MACHINE OPERATION 1

FLOWPLANT


061067 WASHER SEATING FOR 1/4"BSP GAUGE 1

023406 TEE 1/2"Mx1/2"Mx1/2"F SWIVEL ALL BSP 415BAR ZN 1

023025 INSERT FOR HOSE SWAGED 1/2"BSP FEM 1

043061 HOSE CLIP DIA 9.5-12 JCS HI-GRIP S/S 20

0422157 PAWL HOTSHOT 200 MINI LOCKING HANDLE 57mm LONG 1

0422152 COVER (DEEP) FOR INSTRUMENTS HOTSHOT 200 1

071776 HOTWASH CONTROL PANEL 12V LDW1003 FOCS 1

040227 STRAIGHT ADAPTOR 1/4" BSPT - 6mm PUSH IN 1

071786 RELAY 12V 120AMP RP/120-12 2

035182 VALVE 2 WAY 3/8"BSPP SHUT OFF 210 BAR 150 DEG C 2

050285 LOOM WIRING STANDARD HOTWASH CONTROL PANEL LDW1003 FOCS 1

023932 ELBOW 3/8"BSPT-3/8"BSP M/M FORGED 420BAR W.P 1

055795 HOSE ASSY 3/8" 1.60M STR/STR EN 853 2SN 1

071886 FLOAT SWITCH HORIZONTAL POLYPROPYLENE 1/2" NPT 397-0564 1

0422329 FLANGE ADAPTOR BOILER FLUE HOTWASH 1


033006 ADAPTOR 1/2" BSP M x 3/8" BSP M 415 BAR ZN 1

0231063 1/2"BSP MALE X 1/2" HOSE INSERT 1

033015 SEAL BONDED 1.0" BSP 400-830-4490-41 312 BAR SELF CENTRALISING 2

023360 ADAPTOR 1" BSP M x 1/2"BSP M 280 BAR WP 2

023165 O CLIP 5/8" 2

013332 WASHER PLAIN M8 FORM A S/S 8

0551421 HOSE ASSY DN10 3/8" PW2-06 0.23M CUT LGTH ELB/ELB 90 DEG 155 DEG C 1

0421975 EXTENSION BRACKET JOCKEY WHEEL H3004D TWIN H/REEL 1

071946 CABLE GLAND IP68 BLACK NYLON M20 4-9MM RS669-4660 2

0711033 LIGHT REVERSE LED 12/24VDC 81WM 1

0711029 LIGHT REAR COMBINATION INDICATOR/TAIL/STOP 151BAR 2

0711031 LIGHT REGISTRATION LED 12V BRITAX L868.00LDV 2

071992 CABLE TRAILER 2 CORE BROWN AND WHITE TTW1.0BRW 2 X 1MM SQ 2

071989 CABLE TRAILER 13 CORE GTW131 6

0711020 CABLE PLUG FLAMEPROOF M32 1

071988 PLUG 13 PIN TRAILER P13PN 1

061829 STATUTORY LABEL PLATE TRAILER 1

082143 NUMBER PLATE MOUNTING BRACKET 1

061844 LABEL BLACK AND YELLOW WARNING 150X40MM 2

0422620 BRACKET H3004D TRAILER TYPE APPROVED LIGHT COVER 4

0711021 13 PIN PLUG ADAPTOR, 13 PIN TRAILER 7 PIN CAR 0-695-69 1

061851 LABEL 'BRITISH INDUSTY' 1

081177 U-CLAMP 90MM SQ FOR CHASSIS 1141.231 PART NUMBER 104110 1

023028 TEE 3/8"BSP M 415BAR 1

FLOWPLANT


This page is intentionally blank

FLOWPLANT

RUNNING GEAR

Section 12 - Running Gear

FLOWPLANT

RUNNING GEAR


ISSUE No.1

Page 1 of 17

ISSUE No.1

Page 2 of 17

SERVICE SCHEDULE

BEFORE EACH JOURNEY

TASK SEE SECTION

Check the trailer visually for damageCheck connection to towing vehicle 1.4Check joint pins (adjustable height only) 4.0Check tyre pressures

AFTER THE FIRST 500 MILES OR 1 MONTH(In addition to the above)

TASK SEE SECTION

Re-torque wheel nuts/bolts 5.5Check/re-adjust braking system 3.2Check wheel hub for side play 5.1

AFTER EVERY 3000 MILES OR 3 MONTHS(In addition to the above)

TASK SEE SECTION

Check/re-adjust braking system 3.2

AFTER EVERY 6000 MILES OR 6 MONTHS(ADJUSTABLE HEIGHT ONLY)

TASK SEE SECTION

Grease joints 4.2


TASK SEE SECTION

Lubricate the 50mm ball head (if fitted) 6.0Check/lubricate the jockey wheel and/or prop standApply grease to over-run coupling grease nipples 6.0Clean/inspect/re-grease joints 4.3


TASK SEE SECTION

Check/clean/re-grease wheel hub bearings 5.0

ISSUE No.1

Page 3 of 17

1.0 GENERAL INFORMATION

In order to maintain the function and safety of your trailer, only original parts of themanufacturers design must be used, and servicing undertaken by qualified personnel

1.1 TOWING LEVEL

Ideally the trailer should be towed level and not with the draw bar leaning up ordown excessively. Some countries allow ± 4° from the level (approximately±100mm) but in others it remains at the discretion of the user for safe operatingconditions.

1.2 CAPACITIES

For safety, warranty and legal reasons, do not exceed the maximum allowable fullyladen mass.

On a trailer�s drawbar assembly there may be 3 or more labels/stampings stating the maximum masses and other parameters. It is important to be aware that the label orstamping stating the lowest maximum gross mass overrules all others; generally thelabel affixed to the body of the trailer by the trailer or plant manufacturer states theactual maximum, as this will allow for wheel and tyre capacities.

1.3 TYRES & WHEELS

Within the EC, tyres must be marked with a Load Index (LI) and Speed Symbol,which designate the maximum carrying capacity per tyre at the maximum speed.

For trailer use, Car tyres may be given a bonus loading of 5% and Commercial Vantyres 10% due to the reduced speed limits that apply to trailers (in the UK 60mph).However, we would generally recommend working within the Load Index designationto allow for the possibility of operation over the normal speed limitations.

LOAD INDEXLI Kg LI Kg LI Kg LI Kg LI Kg LI Kg LI Kg

67 307 78 425 89 580 100 800 111 1090 122 1500 133 2060

68 315 79 437 90 600 101 825 112 1120 123 1550 134 2120

69 325 80 450 91 615 102 850 113 1150 124 1600 135 2180

70 335 81 462 92 630 103 875 114 1180 125 1650 136 2240

71 345 82 475 93 650 104 900 115 1215 126 1700 137 2300

72 355 83 487 94 670 105 925 116 1250 127 1750 138 2360

73 365 84 500 95 690 106 950 117 1285 128 1800 139 2430

74 375 85 515 96 710 107 975 118 1320 129 1850 140 2500

75 387 86 530 97 730 108 1000 119 1360 130 1900 141 2575

76 400 87 545 98 750 109 1030 120 1400 131 1950 142 2650

77 412 88 560 99 775 110 1060 121 1450 132 2000 143 2725

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SPEED SYMBOLSSpeed Symbol F G J K L M N P Q R

Max MPH 50 56 62 68 75 81 87 93 100 106

Max KMH 80 90 100 110 120 130 140 150 160 170

The maximum tyre pressure marked on the tyre is usually compatible with the loadindex and speed symbol. If in doubt, check with the manufacturer or with us.

1.4 CONNECTION TO TOWING VEHICLE

Firstly check the compatibility of your 50mm Ball Coupling or Towing Eye with theTowing Jaw/Ball connection on your vehicle.

Always fit the breakaway cable or safety chain in a loop, fastening back on itself, to asubstantial integral point on the towing vehicle. Ensure that the effective length is asshort a possible, but still allows articulation (e.g. for cornering) without applying thebrakes or tension through the chains.

WARNING: We do not recommendthe use of safety chains and abreakaway cable at the same time.

LEGAL NOTE: It is legal to usesafety chains up to a maximumgross trailer mass of 1500kg.

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2.0 ROUTINE CHECKS

2.1 VISUAL INSPECTION

Regular visual inspections will usually identify accidental damage if conductedsystematically.

2.2 TYRE DAMAGE

It is dangerous to neglect tyre damage, and should a blister, rupture or cut bedetected, exposing the casing, or the tyre suffers a violent impact (e.g. against akerb) such that there is a risk of internal damage, it is advisable to have the tyreexamined by a specialist as soon as possible.

2.3 WHEEL DAMAGE

Wheels damaged or distorted, or having wheel nut/bolt seatings cracked ordeformed must not be repaired or used in service.

WARNING: If the wheel is damaged, it is possible that the brake drum, stub axle orcomplete axle may have been damaged, so investigate further.

2.4 TOWING EYE, BALL HITCH & DRAWBAR ATTACHMENT

Gripping the towing eye or ball in both hands, pull back and forth, up and down,feeling for excessive moment. Replace any parts that are bent or deformed inanyway. Check the attachment of the Coupling Body to the Drawbar and of thedrawbar to the trailer/machine.

2.5 HAND BRAKE

Apply hand brake checking operation and effectiveness. If in doubt re-adjust brakingsystem (see section 3.2)

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3.0 BRAKING SYSTEM

3.1 WHEEL JACKING

On level ground, with the hand brake lever in the off position and overrun couplingdraw tube shaft fully extended forwards, secure one wheel with wheel chocks.Position your jacking device behind the opposite wheel, as near to a mainlongitudinal chassis member as possible, lift the wheel clear of the ground, then

secure with suitable axle stands.

3.2 BRAKING SYSTEM ADJUSTMENT

Where the transmission rod and brake cables are already connected, take thetension out of the system by winding back the nuts on the rod behind thecompensator.

It is now possible to begin the set up procedure:

3.3 WHEEL BRAKES

These can be adjusted by means of a 17mm, 19mm or 24mm AF Spanner(dependent on brake type) on the adjuster bolt head at the rear of the brake backplate.

Rotate each wheel only in the forwarddirection of travel, whilst tightening the boltuntil the wheel locks. Then, gradually backoff the adjuster nut until the wheel canrotate forwards with just a slightresistance/audible brushing of the brakedrum on the brake linings (This is bestjudged with the wheel and tyre fitted to thebrake drum)

If not already connected, connect theBowden (sheathed) cables to the brakes.

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3.4 COUPLING AND TRANSMISSION SYSTEM

Attach the opposite end of the outer cable to the anchor plate on the axle or drawbar, using the nut provided. Connect the inner cables to the compensator, lockingthe 2 plain nuts together in front of the compensator for each cable. If not alreadyconnected, attach the rear end of the brake rod to the compensator centre hole.

COUPLINGS WITH HANDBRAKE MOUNTED ON COUPLING BODY

Use the plain nuts behind the compensator to adjust, until the overrun output levercan be pulled rearwards by firm hand pressure (not loose) a maximum of 14mm(16mm for adjustable height models). For Knott couplings there should not be anymovement.

Maintain the compensator at 90º to the draw bar for even distribution of force intoeach cable. Ensure the cables are not �kinked� or damaged.

Meredith & Eyre Fixed Height Coupling up to2500kg GVM

Meredith & Eyre Adjustable Height Coupling upto 2000kg GVM

Meredith & Eyre Handbrake Applied Meredith & Eyre Handbrake after(Note Spring Store now compressed) automatic activation in the

reverse mode (Note Spring Storenow extended, Handbrake willfeel less tensioned)

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With the handbrake fully off, check that the spring store�s overall length is 185 to 190mm and is not applying a force to the U shaped guide on the side of the overrunlever. Adjusting is by the nut at the front of the assembly. This procedure shouldonly be necessary when replacement parts have been fitted.

COUPLINGS WITH HANDBRAKE MOUNTED ON DRAW BAR

The set up for the higher capacity Couplings is the similar to the above, with theexception of the setting of the handbrake spring store, which is more powerful dueto the higher transmission forces requirements for heavier trailers.

Use the plain nuts behind the compensator to adjust, until the overrun output levercan be pulled rearwards by firm hand pressure (not loose) a maximum of 18mm(8mm for adjustable height models).

Maintain the compensator at 90º to the draw bar for even distribution of force intoeach cable. Ensure the cables are not �kinked� or damaged.

Meredith & Eyre Fixed Height Coupling2500kg to 3500kg GVM

Meredith & Eyre Adjustable Height Coupling2200kg to 3500kg GVM

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With these models, the brake transmission linkage runs through the spring store,which must be set correctly to achieve automatic operational tensioning of thesystem.

Meredith & Eyre Fixed Height Coupling2500kg to 3500kg GVM

Meredith & Eyre Adjustable Height Coupling2200kg to 3500kg GVM

Leave the Handbrake and Spring Store connector loose while setting the overrunsystem as previously described. Finally, pull the spring store up to the hexagonaladaptor by sliding the spring and bracket forward. Tighten the 3 locking nuts on theconnector.

3.5 BRAKE PARTS

Brake shoes are recommended to be replaced when the lining thickness measureless than 2mm, as it is likely that they will be worn out before the next service.

Always replace both brake shoes together, regardless of the lining thickness on theother shoe. It is further advised that brake shoes should ideally be replaced as anaxle set to avoid uneven braking from side to side.

Right Hand Knott 203 x 40 AutoReverse Brake back plate assemblyshown.

Note position of sliding shoe relativeto adjuster or expander. To functioncorrectly the brake must beassembled in this way.

Left Hand Brake is a mirror image

Sliding (Auto Reverse)Brake shoe

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KNOTT COUPLINGS

Please follow the adjustment instructions above, but do not allow for the rearwardmovement of the overrun output lever, which is only required on Meredith & EyreCouplings. All Knott couplings operate in the same manner, so the type of housing � Cast A Frame, Pressed Steel A Frame or Pressed Steel Square Tube - is irrelevant tothe brake servicing.

Knott Cast Body Coupling

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4.0 ADJUSTABLE HEIGHT DRAW BARS

4.1 HEIGHT ADJUSTMENT / TIGHTENING JOINTS

The principle of the joints is steel pegs engaging with mating dimples, which can beseen between the joint plates.

While securing the assemblies, the equipment should be �rocked� as the joint pins are tightened to allow positive location.

When initially hand tight, they should be further tightened until the next visible �R� pin hole lines up for insertion of the pin.

For reference only, the actual torque figures if checked would be approximately �

TYPE A900 135-175Nm TYPE A1600 175-220Nm

TYPE A2400 230-300Nm TYPE A3500 410-475Nm

4.2 GREASING ADJUSTABLE JOINTS

There is a grease nipple at each joint pin position

4.3 CLEANING, INSPECTION & ASSEMBLY

Dismantle the joint pins and joints. Check condition and if serviceable clean, smearwith grease and reassemble.

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5.0 WHEEL HUB ASSEMBLIES

5.1 INSPECTION

Ensure the brake shoes (if braked) are clear of the drum with no interference. Cleanhub to remove any road debris.

Rotate the hub slowly � there should be no roughness or restriction

Rotate the hub rapidly � there should be no rumble, rattle or high-pitched noises.

Rock the wheel while holding at the top and the bottom to detect essential bearingendplay. The maximum movement should be 2mm measured at the Wheel Rim.

If any clearance / free movement appears to emanate from the suspension, checkthe axle housing for damage.

5.2 WHEEL HUB ASSEMBLIES WITH TAPER ROLLERBEARINGS

In order to re-set, remove the grease cap, split pin and set the Slotted nut.

It is generally accepted that a finger tight slotted nut will result in a correct settingand running clearance for normal bearing life. Always replace the split pin with a newone when setting is complete and re-fit the grease cap.

WARNING: It is our experience thatthe majority of bearingfailures are the result ofover-tightening of theSlotted nut or failure toreplace contaminatedgrease (e.g.: Water ingress� especially salt water).

The wheel bearings are greased onassembly at the factory and should be re-greased at a minimum every 24000 milesor 2 years with axle grease �Elf Multi 2� or equivalent.

Use the service interval to inspect the bearings for wear/damage. Replace the seal ifnecessary, lubricating the lip and bore, not the outside diameter.

WARNING: It is as important not to over pack the hub with grease, as it is toallow bearings to run dry.

5.3 REMOVAL OF HUB / BRAKE DRUM ASSEMBLY

Remove wheel, grease cap, split pin, slotted nut and washer and pull drum off thestub axle. To avoid contamination, take care not to drop the outer bearing cone ontothe floor.

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5.4 WHEEL HUB ASSEMBLIES WITH UNIT BEARINGS

These hubs require no maintenance, however at intervals of 24000 miles or 12months, the wheel hubs should be checked for side play and the complete hubreplaced if necessary.

WARNING: When refitting the hub always fit a new nut and tighten to a torque of280Nm (206 lbf.ft.)

5.5 WHEEL NUT / STUD TORQUE SETTINGS

WHEEL NUT / STUD Nm Lbf.ft

MIN. MAX. MIN. MAX.

WHEEL NUT ½� UNF 70 110 50 80

WHEEL NUT 5/8� UNF 135 160 100 120

WHEEL NUT M18 x 1.5 245 300 180 220

WHEEL STUD M12 x 1.5 65 90 50 65

WHEEL STUD M14 x 1.5 120 150 90 110

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6.0 OVERRUN COUPLING ASSEMBLY

The Coupling is greased on assembly, but will require periodic maintenance toensure a smooth operation of the braking system.

Re-grease the shaft bearings via the grease nipples provided at 6000 mile or 6month intervals. Also ensure correct functioning of all pivots, levers, ratchets and thespring store assembly. Grease all points of movement.

Meredith & Eyre Couplingwith bellows and shaft nipplesfeatured.

Meredith & Eyre Coupling,with damper and overrunoutput lever featured.

The hydraulic damper is sealed and maintenance free but its operation should bechecked if braking problems occur. If the damper is to be removed, enclose it in astrong cloth and do not stand directly in line as the damper contains oil and gasunder high pressure. To remove, release the 2 bolts at either end. The damper willneed to be slightly pre-compressed to be fitted. This is normal, and ensures that thebraking system works efficiently and that the trailer is towed on the drawtube, noton the damper as this would lead to premature failure.

Meredith & Eyre Couplings do not require for the towing ball head or eye to beremoved or loosened when replacing a damper.

Knott Couplings have the damper attached to the rear bolt of the towing head. Thesedampers in these couplings require a larger amount of pre-compression when beingfitted, so remove the cast L shaped bracket which attaches the damper to the rear ofthe coupling body and reassembly this onto the new damper before assembly ontothe coupling body.

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7.0 STUB AXLE / BRAKE BACK PLATE

A number of Meredith & Eyre axles feature a removable stub axle, as shown. Thisdesign is unique to Meredith & Eyre and illustrates our desire to keep replacementcosts as low as possible.

The large slotted nut onthe back of the arm istorqued to 230 nm (170lbf.ft). Removing this nutwill allow the stub axle beremoved.

When refitting, if the splitpin cannot be fitted aftertorque setting the slottednut, tighten the nutfurther until the nextavailable hole isaccessible.

The removal of this assembly is only necessary when the stub axle or brake backplate is to be replaced, e.g. after an accident. Make a note of how the parts arefitted and the position of the cable holder.

All other brakedrum components are accessed from the front via the grease cap.

All other Axles have a welded stub axle and brake back plate assembly, which cannotbe replaced. In the event of damage to a stub axle it is likely that the whole axle willneed to be replaced.

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8.0 TROUBLE SHOOTING

SYMPTOM CAUSE RECTIFICATIONIncorrect adjustment atwheel

Adjust

Brake cable seized Free off or replaceBraking is one-sided

Brake lining contaminatedwith grease

Replace

Coupling damper is weakor ineffective

ReplaceBraking during milddeceleration

Brakes over-adjusted Adjust


Brake cable sticking Free off or replace

Brakes under-adjusted Adjust

Coupling damper is weakor ineffective

Replace

Trailer Brakes snatchwhen braking

Drawtube stickingCheck over full stroke,lubricate if necessary


Replace

Failure of bond betweenbrake lining and shoe

Replace

Distorted/crackedBrakedrum

Replace

Brake Judder

Drums have rusty patcheson braking surface

Clean up with abrasivepaper and wipe out

Brakes over-adjusted AdjustTrailer brakes lock up

when reversing Incompatibility betweenCoupling and Brakes

Consultmanufacturer(s)

Brakes under-adjusted Adjust


Replace

Brake cables seized Free off or replace

Trailer brakes inoperative

Brake linings worn out Replace


Pull off springsstretched/broken

ReplaceHot brakes

Brake cables seized Replace

Brakes under-adjusted AdjustHandbrake will not hold on

a slope Incorrect setting of SpringStore

Adjust

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9.0 TORQUE FIGURES

Nm Lbf.ftApplication Fastener Size

MIN. MAX. MIN. MAX.

70 / 80mm Drawbar to Axle 3/8� UNF 40 55 30 40

90 / 100mm Drawbar to Axle M12 90 90 65 65

Towing Eye Cross bolts M10 55 55 40 40

Towing Eye Cross bolts M12 75 75 55 55

50mm Ball Head Cross Bolts M12 75 75 55 55

M&E Coupling to 80mmDrawbar

½� UNF 50 60 35 45


½� UNF 55 70 40 50


5/8� UNF 60 80 45 60

Knott Coupling to Drawbar M12 60 75 45 55

General Torque settings for Grade 8.8 Fasteners used withSelf Locking Nuts

Nm Lbf.ftFastener Size

MIN. MAX. MIN. MAX.

M8 x 1.25 25 25 17 17

M10 x 1.5 50 50 35 35

M12 x 1.75 90 90 65 65

M14 x 2.0 130 130 97 97

M16 x 2.0 200 200 150 150

FLOWPLANT


FLOWPLANT

SERVICE DOCUMENTS

SECTION 13 – Service Documents

FLOWPLANT

SERVICE DOCUMENTS

This page has been left intentionally blank.

FLOWPLANT

SERVICE DOCUMENTS

13.1 Introduction

FLOWPLANT

SERVICE DOCUMENTS


………………………………………………………….

FLOW 0322 Iss 1Type of service - Itermediate, Yearly

Type of Service ………………...…...………

Please state if other

Service provider used ………………………………………………………….

Date ……………………….…...……………Official Flowplant Stamp and Signature

Engineer ………………..…………...………


Engineer ………………..…………...………





Engineer ………………..…………...………



Service provider used


Engineer ………………..…………...………




Date ……………………….…...……………


Official Flowplant Stamp and Signature



Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………

Flowplant Unit Log Book

Serial Number -

Unit Number -

Sht 1 of 2Date of Manufacture -

Type of service - Itermediate, Yearly FLOW 0322 Iss 1


Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………





Engineer ………………..…………...………




Flowplant Unit Log Book

Serial Number -

Unit Number -

Date of Manufacture - Sht 2 of 2

FLOWPLANT

WARRANTY AND CERTIFICATION

SECTION 14 – Warranty and Certification

FLOWPLANT

WARRANTY AND CERTIFICATION


®

Warranty

Warranty of new products: Equipment manufactured and supplied by Flowplant is warranted to be free from defects in materials and workmanship. The warranty includes both parts and labour necessary to correct any such defects. The warranty period for new products is twelve months from date of despatch from our factory. We shall repair or, at our option, replace free of charge any product, part(s) or component(s) manufactured by Flowplant which fail due to faulty manufacture or material within the warranty period.

Warranty of spare parts: The warranty for new spare parts is six months from date of despatch on materials and workmanship. The warranty for reconditioned spare parts is 90 days from date of despatch on materials and workmanship. Provided always that

1. They are returned to Flowplant for inspection (carriage paid), along with a copy of the original part(s) sale invoice (where necessary); and

2. All terms agreed by Flowplant for payment of such goods have been complied with; and

3. If a defect/failure is discovered before the expiration of the warranty, notification must be given to the Flowplant service department immediately

4. Any claim hereunder is made within 30 days of the date of discovery of the defect/failure.

Provision of this warranty shall not apply to any Flowplant product which has been:

1. Used for a purpose for which it is not designed for; or 2. Applied to a use which has not been approved by Flowplant; or 3. Subject to misuse, negligence, lack of maintenance or accident; or 4. Repaired or altered in any way so as, in the judgement of Flowplant, to

adversely affect its performance and reliability

®

Limitations of warranty: The new product and spare parts warranty is limited to defects in material or workmanship of the product. It does not cover loss of time, inconvenience, property damage or any consequential damages. Repair or replacement of the product is your exclusive remedy. Our liability under this clause shall be in lieu and to this exclusion of any warranty or conditions implied or expressed by law as to the quality or fitness for purpose of any goods supplied hereunder PROVIDED THAT nothing in this clause shall operate so as to exclude liability for death or personal injury arising from the negligence of the company or its employees. Our obligations as aforesaid shall constitute the full extent of our liability in respect of any loss or damage sustained by the purchaser whether caused by any breach of this contract or by our negligence or otherwise and we shall not be liable to make good or pay for loss of use of the goods, loss of revenue, loss of profit or goodwill or any direct or consequential losses howsoever caused and the purchaser undertakes to indemnify us against any such claims against us by third parties. On order to comply with the provision of the Health and Safety at work etc. 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 them with adequate instructions for their proper use. Further copies of these instructions are available from us upon request.

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