Operation Manual TD302
CE This machine is manufactured according to the regulations in the EC DIRECTIVE 2006/42/EC This manual should be read prior to starting the machine
Aquila Triventek Triventek A/S A/S • Industrivej 9 • 5580 Nørre Aaby • Denmark • Tel. 0045 70 22 12 92 •
[email protected] • ww w.aquila-triventek.com
Index Introduction
Page
Technical data Description TD302 Description Control panel Safety – Safety – General General Preparation Starting work Hot water operation Storage at sub-zero temperatures Storage in sub-zero temperatures - long term Maintenance Problem solving guide Oil burner manual Flame surveillance adjustment / Electrode adjustment Exploded view oil burner Exploded view oil burner top Exploded view hose reel high pressure Exploded view hose reel inlet Spare parts TD302 Spare parts operation compartment Spare parts engine compartment Spare parts electric box Unloader valve BKX-Valve High pressure pump Hawk HC930A Service intervals Electrical chart Nozzle/Pressure/Flow chart Pressure loss in high pressure hose Aquila Warranty Policy and Procedures
3 4 5 6 7 8 9 10 11 12 13-14 15 16 17-18 19-20 21-22 23-24 25-26 27-28 29-30 31-32 33 34-35 36-37 38-39 40 41 42 43
2
Technical Data Working pressure
30-300 bar
Water consumption
9-18 L/min.
Nozzle size
04
Engine
Kubota D722 3 cyl. diesel
High pressure pump
HAWK XLT HC930A
Engine/Pump rpm
3400/1300
Water temperature
99° C
Water tank
346 L.
Fuel tank
77 L.
Weight
520 kg.
Dimensions
L:275 x W: 160 x H:160 cm
3
Description TD302
4
Description Control panel
1.
2. 3.
1. Touch screen / PLC 2. System start up button 3. Emergency button 5
Safety - General This equipment should only be used by responsible adults who have read the instructions and received appropriate training. Follow national rules and regulations. Never direct the water-jet at people or electrical installati ons. Always work from a stable platform never from a ladder, for instance. Use only the hoses and nozzles recommended by Aquila Triventek A/S. Always remember to ensure the pistol grip is locked off during breaks. Do not dismantle the pistol grip before pressure has dropped and the oil burner has cooled down (See page 9. “Stop”) Do not use the machine in areas where there is a risk of fire and explosion. The technician room of the machine always has to be cl osed and locked during operation or shielded so that nobody can touch the moving or electric parts of the machine. Always use both hands to hold pistol and lance. ALWAYS use lances which are more than 50 cm in length. Emergency switch is located on the instrument panel. Do not hesitate to contact Aquila Triventek A/S, should you have any questions concerning defects or other aspects. IMPORTANT! The engine room is only to be opened at service. Never use it for storag e.
6
Preparation Open the fibre glass cover on the trailer at the back. Check and clean the water filter and connections. Ensure that the water tank has sufficient water (see water level pipe). It is very important that the water tank has sufficient water before starting the engine; otherwise the high pressure pump can be damaged. Ensure there is sufficient diesel. Never let the diesel level get under ¼ full. Clean the high pressure hose coupling. Connect pistol grip/spray lance or extension pipe to the high pressure hose reel. Check that the throttle grip is in the lowest position and that all switches are set at zero/0. The diesel engine automatically stops if, at any time during operation, the water level drops too low. A red light on the instrument panel will then indicate the reason for the shut-down. Please note: The oil level /charge control lamp is always on when the engine is not running.
7
Starting work Attach spray lance to high pressure hose. Press system button approximately 10 sec. Press password 1234. Press pre-heati ng and it turns on. Then press start until engine is started. Check that the machine is making pressure and sufficient wat er comes out. Let the engine run in approx. 5 min. until it reaches operation temperature. Open the pistol grip/spray lance. Adjust rpm by pressing rpm. up or down until the desired water output /pressure is achieved. If using nozzles with a smaller hole size than the original, only adjust until the max pressure is achieved, then let it fall about 5-10 bar. This ensures a minimal wear on the by-pass valve and it also brings the diesel consumption and pollution down. Close the pistol grip/spray lance and pull the high pressure hose t o the desired length. If you wish the fibre glass cover can now be close d and locked. THE MACHINE IS NOW READY FOR OPERATION.
Stopping Turn all Switches to zero/0 position. Press stop button an engine turns off. Relieve system pressure by releasing pistol grip.
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Hot water operation Only on machines for which Descalc-system has been bought as optional equipment! Ensure that there is sufficient Aqua-Decalc in the 5 L can under the instrument panel. Change the can if necessary. IMPORTANT! Only use original Aqua-Decalc otherwise there is no warranty on the machine.
Press system button approximately 10 sec. Press password 1234. Press pre-heating and it turns on. Then press start until engine is started. Let the engine run in approx. 5 min until it reaches operation temperat ure. Press oil burner and the page appears. Press s et temperature and give in the desired temperature. Press ON When the pistol grip is activated the burner will st art. If you wish for different temperature, press set temp and give in the desired temp. Adjust rpm by pressing rpm. up or down until the desired water output /pressure is achieved. If using nozzles with a smaller hole size than the original, only adjust until the max pressure is achieved, then let it fall about 5-10 bar. This ensures a minimal wear on the by-pass valve and it also brings the diesel consumption and pollution down. Close the pistol grip/spray lance and pull the high pressure hose t o the desired length. The oil burner will only operate when the trigger is squeezed. If you wish the fibre glass cover can now be close d and locked. THE MACHINE IS NOW READY FOR OPERATION.
Stopping Turn all switches to zero/0 position. After hot water operating the machine has to cool off. That means that the machine has to operate with cold water for min. 2 min. before drawing off water or dismounting the pistol grip. This it to prevent scaling and help preserve the hose pipes. Press stop button an engine turns off. Relieve system pressure by releasing pistol grip.
9
Storage at sub-zero temperatures The machine must be kept in a room without sub-zero temperatures. IMPORTANT! If not it can result in major damage. Driving to assignments where there is a risk of frost you must: IMPORTANT! Can only be used in mild frost conditions of about 0°C. Ensure there is sufficient diesel. Connect the high pressure hose to the inlet hose. The water tank has to be at least half full. Connect the high pressure hose to the inlet hose. Press system button approximately 10 sec. Press password 1234. Press pre-heating and it turns on. Then press start until engine is started. The water is now running pressure less in circulation + engine heat = Protection against mild frost. NOTE! There has to be used at connection, which can connect the high pressure hose with the inlet hose, so that you get complete circulation.
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Storage in sub-zero temperatures - Long term Empty the water tank by opening of the bottom tap (in front by the tow pole). Close after emptying. Fill 15 L concentrated de-icer in the water tank through the lid in the top of the water tank. The de icer has to be able to be mixed 1 part to 5 parts water and give protection down to -20 o C. Turn the ignition key to “ON”. Fill the water tank with water through the normal water filling (to ensure filtration). During filling the machine has to be turn on and off until "min. water level" does not light-up anymore. Mount pistol grip/spray lance. Start the engine with open pistol grip. When the coloured de-icer comes out of the nozzle, close the pistol grip. Stop the engine. Empty the water filter (by disconnecting) The machine is now protected in sub-zero temperatures. Check that the cool system of the diesel engine is sufficiently protected, max. 50% de-icer.
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Maintenance Daily check-up, 8 hours: Water filter should be flushed. Fast-acting couplings should be cleaned and greased.
12
Problem solving guide – please al so check separate PLC user manual Cause
Action required
Engine fails to start:
Emergency stop activated
Pull out the emergency stop.
Low water level in tank
Fill with water. Close the front fibre glass cover.
Engine coolent to hot
Let the machine cool off. Check the cooling water level and try again. If repeatedly overheating contact Aquila Triventek A/S or dealer.
Low engine oil pressure
Check oil level and refill if necessary.
Insufficient diesel
Fill diesel tank, see also air in diesel system.
Air in diesel system
The machine ventilates automatically. Let the ignition ON for 2 min. (diesel pump has to click 1 time/sec.) the machine is now ventilated. This has to be done if the machine has been emptied of diesel.
Alternator not charging
Control V belt on the alternator or contact Aquila Triventek A/S or dealer.
Water in tank to hot
Empty water tank and fill whit fresh water
Diesel pump is not working
Check electrical installations.
Diesel filter blocked
Change diesel filter.
Check fuses
Change defect fuses in instrument panel.
Working pressure too low:
Rpm too low
Adjust to max. rpm.
Nozzle to big
Check nozzle chart.
Pressure fluctuations
Please contact Aquila Triventek A/S or dealer.
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Cause
Action required
Oilburner:
Fails to start: Burner 1 overheated
Error on temperature sensor.
Burner 2 overheated
Error on temperature sensor.
Flame error burner 1
Turn of the oil burner and try again. If repeatedl y failing please contact Aquila Triventek A/S or dealer.
Flame error burner 2
Turn of the oil burner and try again. If repeatedl y failing please contact Aquila Triventek A/S or dealer.
Temperature too low
Check nozzle size/Thermostat adjustment.
Rpm too low
Adjust the power. Needs min. 1/4" power.
In the event of other problems, please contact Aquila Triventek A/S or local dealer
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Adjustment - Manual oil burner Mount manometer on oil pump (0-25bar). See photo 1. Mount lance with 1504 nozzle. Start engine; give full power so that the rpm will be about 1300.
Check that the air damper is placed with the two dots next to each other. See photo 2.
Let the burner burn constantly for 1 min. Then take a soot test (in the hole on the side of the chimney). See photo 3.
If the result is over 3 the oil pressure is lowered See photo 4 with 0,5 bar then take a new test. This is repeated until the soot number is fewer than 3; the oil burner must not get under 10 bar.
If the soot number is 0 or co2 is under 8%, the co2 is raised by increasing the oil pressure. This is made in steps of 0,5 bar, the oil pressure must not get over 12 bar, soot number 3 and CO 2 has to be 8-10%. By change of coil the air flow can be changed and it may be necessary to change the air damper adjustment (this is only done if it is impossible to get a satisfactor y result by changing the oil pressure). By too much soot there has to be given more air, by too little co2 there has to be given less air. No matter what this has to be kept: soot 0-3 best under 2 CO 2 8-10 % and oil pressure 1012 bar. High oil pressure and low air flow = effective oil burner. An optimal oil burner can give up to 90° C by maximum water flow. Control – Adjustment has to be done at any service. Very important by change of oil nozzle or coil.
15
Flame surveillance adjustment
Electrode adjustment
16
Oil burner
17
Spare part list Oilburner Pos Part No. 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32 33 34
Description
30081022 30057049 40605211 40600580 99178431 30196600 30056123 70003300 80100190 80100160 80100860 80100580 70120000 40280512
Chimney lid Air/oil mixer Safety valve Safety valve Sensor retainer Temp. body Microtherm Bonded seal ½” Nipple ½” Nipple ½”x3/8” Tee female ½” Nipple ½” female Flowswitch Kit repair flowswitch Disc 26mm Nut 24x1,5 30081021 Chimney 70185900 Motor for 12V oil pump 99176299 Bracket oil pump motor 70186200 Connector oil pump 70186100 Flexible shaft oil pump 30016000 Nipple 6L 1/8” 90° 70186000 -04 2001 Oil pump right 30057101 04 2001- Oil pump left 80202150 Hose connector ¼”x8 70031900 Fuel filter assy 70099500 Filter screen oilburner 80200840 Nipple brass ¼”x8 80200170 Nipple ¼” 80201330 Hose pipe ¼”x8mm 90° 3002212V Ignition coil 12V 30081039 Boiler cap 99176298 Air reducer 12V 70185800 Fan motor 12V 30081030 Mat 30081034 Heating coil
18
Oil burner top
19
Spare part list Oil burner top Pos Part No.
Description
1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16
Nipple fitting 1/8“ 90° Nipple brass 1/8” Fitting brass 1/8” Magnetic valve 12V Nipple 1/8”x6mm Plug Nipple muff 1/8”x1/8” Nozzle holder Oil nozzle 1,75 60° H Oil nozzle 2,00 60° H Spark cap Sealing cap Sealing cap Electrode Electrode holder Gasket sensor holder Copper pipe 6mm
80201150 80200030 80201030 30013001 30020000 30006000 30065051 30057055 30002000 30002001 30057053 30057070 30057052 30057051 30057050 30081032 70062700
20
Hosereel for high pressure
21
Spare part list Hose reel high pressure Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Part No. 70155200 70155900 70155200 70056701 99176102 99176100 99178101 99176224 99176082 99176083 99176080 99176229 70057400 99176202 70020900
Description Hose reel plate Ø500x3 Inner tube for hose reel Ø186x214x2 Hose reel plate Ø500x3 Plastic handle Steel handle Hose reel bearing Hose reel bracket long Hose reel shaft Connector 14-S Connector 3/8” Connector ½” Connector ¾” Seegering 35mm Hose reel shaft ¾” Seal hose reel 3/4”
70110100 99176106 99178105
Lubrication nipple Swivel ¾” Hose reel bracket short
22
Hose reel inlet
23
Spare part list Hose reel inlet Pos
Part No.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
70155200 70155900 70155200 70110100 99176106 99178105 70155100 70057400 99176202 80201760 80201190 80201300 80201880 80201570 80201720 99176225 99176100 99178101 99176102 70056701
Hose reel plate ø500x3 Inner tube for hose reel ø186x214x2 Hose reel plate ø500x3 Lubrication nipple Swivel ¾” Hose reel bracket short O-ring water inlet Seegering 35 mm Hose reel shaft ¾” Hose nipple brass ¾” Nip fitting brass ¾“ 45° Fitting brass ¾” 90° Nip pipe ¾”x80 Nipple fitt. brass ¾” 90° Fitting brass ¾”x15 Hose reel shaft Hose reel bearing Hose reel bracket long Hose reel handle Handle plastic
x2
x2
x2 x2 x2
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TD302
25
Spare part list TD302 Pos Part No.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Handgrip w/lock Front light white Rubber mounting 7 pins plug Trailer coupling Trailer prop Jockey wheel Spare wheel Reflector Wheel arch plastic Block and holder Taillight left Lens taillight left Taillight right Lens taillight right Bumper bar
70121800 70082600 70184000 60062300 70184110 70192400 70172000 E1452000 60062110 70190700 70129100 70082110 70190800 70082120 70190900 70186810
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Operational compartment
17
18
15 14 2
13 3 4
12
11
5. 6
7
8
9
27
10
Spare part list Operation compartment Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Part No.
Description
70184200
85100170 A2500000 A2900000
Frontfolie Look at page 23+24 Water hose ¾” 25m. Water regulator Inlet strainer complete Screen Cat 1” Seal 1” water inlet Diesel tank Filter cap Screw nippel Look at page 21+22 HP-hose 3/8” 400 bar Spray gun Spray lance w/pressurea.
A3102000 A3117000
Flat jet nozzle ¼” 1504 Low pressure nozzle ¼”
85200200 40290112 21007106 21330740 21330730 70186900 99176310 A1842000
28
Engine compartment
29
Spare part list Engine compartment Pos. Part No.
Description
1 2 3 4 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Air cleaning filter D722 Battery 45Ah V-Belt XPA1232 (3pcs) Pump Hawk 930A Pump Hawk 950A Pump Hawk 980A Unloader 300bar Ball valve ¾” Level switch RW16PV Filter diesel D722 Fuel filter ¼” Filter screen oil burner Oil filter D722 Fuel pump 12V Thermostat D722 Gasket thermostat D722 Oil pressure contact Thermal sensor D722 Stop solenoid D722 Radiator cap D722 V-Belt XPZ912 Generator 65A-NAB900 Starter D722
50020722 70183800 461232A0 HC930000 HC950000 HC980000 40600412 70014300 60055200 50015722 70031900 70099500 50050722 70083900 50192011 50162612 50158411 50151818 50162513 70107910 46912Z00 60004600 50375611
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Electric Box
31
Spare part list Electric box Pos Part No. Qty.
Description
1 1 1 1 1 2 3 4 5 6 7
PLC CPU Output card Input card Analogy input card End terminal PCB Spark Relay 70A 12V Relay Converter 12-24V Contact Contact Emergency stop Triple mounting Thermo element Screen Stop relay
60000014 60000022 60000023 60000017 60000018 70188400 60020500 60058700 60061002 60000800 60033100 60060500 60032600 80082300 60000019 50T00711
1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1
32
Unloader Valve Safety valve
This unloader/safety valve should not be repaired, but changed. Part no. 40600412
33
BKX Valve
34
Spare part list BKX Valve Pos 1 2 3 4 5 6* 7* 8* 9* 10 11* 12 13 14 15* 16* 17 18* 19* 20* 21* 22* 23 24 25 26 27 28 29 30 31 32* 33* 34* *
Part No. 40363111 40994311 40967111 40947511
40367111 40927711 40905011 40903811 40903815 40363112 40967511 40982112 40904011 40905111 40363113 40903814 40363117 40363120 40947312 40903812 40982111 40948511 40363118 40363114 40994411 40922511 40995111
40947313 40363116 40903813 70055600
Qty. 1 4 8 1 2 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 1 4 1 1
Description Valve casing bottom Bolt M12x70UNI 5931 Lock disc Ø12 Spring Ø26,2x28,5 Part of pos. 6 Valve with valve piece Back-up ring Back-up ring O-ring Part of pos. 6 O-ring Valve casing Gasket Ø21 Plug G1/2x16 O-ring Back-up ring Valve casing central O-ring Valve Valve stainless Spring O-ring Bolt G3/8x9,5 Disc Disc Valve casing top Bolt M12x120UNI 5931 Nut M16x1,5UNI 5588 Bolt M16x1,5x38
1 1 1
Spring By-pass valve O-ring Seal Kit BKX
* Spare parts for seal kit BKX
35
HAWK HC930A/950A/980A
36
Spare part list HAWK HC930A/950A/980A Pos
Part No.
Description
4,6,7,9 4,6,7,9 4,6,7,9 13,14,15 13,14,15 3,4,5,6,7,8,9 3,4,5,6,7,8,9 3,4,5,6,7,8,9 46,47,48,49,50,51 46,47,48,49,50,51 46,47,48,49,50,51 54 28 43 44 40 39
26290500 26290700 26291500 26001300 26001000 26290100 26290300 26291600 26000400 26020300 26291700 26010000 26060100 26020300 26060000 26060301 26070000
Seal kit HC930A Seal kit HC950A Seal kit HC980A Valve kit HC930A Valve kit HC950A/980A Seal kit compl. HC930A Seal kit compl. HC950A Seal kit compl. HC980A Plunger kit HC930A Plunger kit HC950A Plunger kit HC980A Crankshaft seal O-ring (frame) Crankcase cover Crankshaft gasket O-ring sight glass Sight glass
x6 x6 x3 x3 x3 x3 x3 x3
37
High Pressure Maintenance Schedule This High Pressure Cleaner is covered by EU Statutory and Safety at Work Regulations. Services have to be carried out every 200 working hours or annually. A service label with the due date of the next service should be placed on the instrument panel. A copy of the service report should be retained as proof of inspection. It can be extremely dangerous not to comply with the Statutory Regulations, and it is the owner’s responsibility to ensure that the services are carried out and certificates retained. 200 hours or annual schedule Engine
Check
Engine oil ** Oil filter Fuel filter for diesel engine and diesel pump Air filter Anti freeze minimum – 25°C Fan belt Battery Stop solenoid and fuel injection
Adjust/clean
Change
X X X 400 hours*
X X X X X
1000 hours*
High pressure/Water inlet system
High pressure oil pump *** V-Belts High pressure seals Valves Unloader Safety valve Swivel/hose reels Water filter Water tank stopcock Low water safety switch Check system seals for leaks High pressure hoses - change if over 2 years old or damaged Pressure test complete pressure system with +50% of maximum pressure
38
X 1400 hours* 600 hours* 1000 hours*
X X X X X X X X X X X X
400 hours*
Oil Burner
Fuel filter, oil burner and diesel tank Coil – descale Flow switch Microtherm Thermostat and sensor Oil burner nozzle Electrodes Flame surveillance CO Exhaust emission Smoke temperature De-scale fluid Thermostats Emergency stop/Warning lights
Check
Adjust/clean
Change
X X X X X X 400 hours*
X X X X X X X X
Trailer
Lights Tyres Air pressure in tyres Jockey wheel Break safety break away line Lid micro switch Chimney micro switch Front brake/dampening system
X X X X X X X X
*
The hours indicated are for guidelines only and do not form any part of warranty.
**
Engine oil: Shell T400 15W 40 or similar. Fill about 3 L. (check dip stick)
*** Pump oil: Shell T400 15W 40 or similar. Fill about 1.2 L. (only fill to the middle of the gauge oil bubble).
39
40
41
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