HH220i sMaster Manual

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Customer : Reference :

W/O

Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

TABLE OF CONTENTS 1.

CUSTOMER SPECIFICATION

2.

TECHNICAL DATA SHEET

3.

HOW TO READ A PERFORMANCE CURVE 3.1

Example Sykes’ CP150 Pump Curve

3.2

Generalisations

3.3

Radial Thrust

3.4

Cavitation

4.

RISK ASSESSMENT GUIDE

5.

RISK ASSESSMENT – HH220i

6.

PUMP OPERATING INSTRUCTIONS 6.1

Description of Pump Unit

6.2

Procedure Prior to Pump Start Up

6.3

Failure to Prime Pump 6.3.1

Air Leaks

6.4

Pump Dynamic Test

6.5

Ejector Test 6.5.1

7.

Dri-Prime Ejector Pack Assembly PUMP MAINTENANCE INSTRUCTIONS

7.1

General Pump Inspection Procedure

7.2

Pump Assembly Instructions 7.2.1

Pump Bearing Bracket

7.2.2

Centrifugal Pump

7.2.3

Ejector Package

7.2.4

Mechanical Seal

7.2.5

Non Return Valve Inspection Procedure

Sykes Group Pty Ltd

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Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

TABLE OF CONTENTS 1.

CUSTOMER SPECIFICATION

2.

TECHNICAL DATA SHEET

3.

HOW TO READ A PERFORMANCE CURVE 3.1

Example Sykes’ CP150 Pump Curve

3.2

Generalisations

3.3

Radial Thrust

3.4

Cavitation

4.

RISK ASSESSMENT GUIDE

5.

RISK ASSESSMENT – HH220i

6.

PUMP OPERATING INSTRUCTIONS 6.1

Description of Pump Unit

6.2

Procedure Prior to Pump Start Up

6.3

Failure to Prime Pump 6.3.1

Air Leaks

6.4

Pump Dynamic Test

6.5

Ejector Test 6.5.1

7.

Dri-Prime Ejector Pack Assembly PUMP MAINTENANCE INSTRUCTIONS

7.1

General Pump Inspection Procedure

7.2

Pump Assembly Instructions 7.2.1

Pump Bearing Bracket

7.2.2

Centrifugal Pump

7.2.3

Ejector Package

7.2.4

Mechanical Seal

7.2.5

Non Return Valve Inspection Procedure

Sykes Group Pty Ltd

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Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

7.3

Air Compressor 7.3.1

Description of Compressor

7.3.2

Fitting Instructions – Compressor Assembly

7.3.3

Compressor Belt Replacement

7.3.4

Compressor Kit

8.

PUMP DIAGNOSTICS 8.1

Trouble Shooting Guide

9.

PUMP UNIT SUB-ASSEMBLY

10.

PARTS LIST 10.1

Recommended HH220i Pump Spare Parts

10.2

Volute Parts List

10.3

Bearing Bracket and Shaft Parts List

10.4

Separation Tank and Ejector Package

10.5

Oil Reservoir

10.6

Compressor

11.

PUMP UNIT ACCESSORIES

12.

DIESEL ENGINE MANUAL (if applicable)

13.

ELECTRIC MOTOR MANUAL (if applicable)

Sykes Group Pty Ltd

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Sykes HH220i – Installation, Operation & Maintenance Manual

1

CUSTOMER SPECIFICATION

General Unit Information Customer Sykes Job Number Sykes Serial Number Plant Number Pump Information Pump Type Pump Size Impeller Diameter

HH220i 200mm x 150mm ∅432mm

Engine Information Engine Make Engine Serial Number Tacho Serial Number Electric Motor Information Motor Make Motor Serial Number Chassis Information Dry Weight Wet Weight Fuel Capacity Trailer Information VIN Number Tyre Type Axle Set Up Pump Extras Additional Information Grease Lubricated Bearings

Oil Lubricated Bearings

Sykes Group Pty Ltd

Valvoline Multi Lube Lithium grease EP Additives NLGI # 3 or Equivalent (high temperature grease) Valvoline Hydraulic oil 68 or Equivalent Hydraulic oil

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Sykes HH220i – Installation, Operation & Maintenance Manual

2

TECHNICAL DATA SHEET

     ! MATERIALS OF CONSTRUCTION

DESIGN DETAILS

Pump Casing:

SG Iron To AS1831 Grade 400/12

Suction Cover:

SG Iron To AS1831 Grade 400/12

Pump Designation: Pump Description:

Tee Piece: Bearing Bracket: Pump Shaft: Impeller: Wear Plates: Air Injector: Mechanical Seal: Non Return Valve Compressor Pulley: Drive Pulley: Belt Section: Compressor Details:

SG Iron To AS1831 Grade 400/12 SG Iron To AS1831 Grade 400/12 431 Stainless Steel 316 Stainless Steel 316 Stainless Steel 316 Stainless Steel Silicon Carbide / Silicon Carbide 150mm Reflux Box NRV 40H150 ½” Pitch Heavy 32H150 ½” Pitch Heavy 390H150 Timing Belt Bendix 2W 440 R Twin-in-line cylinders 75mm x 50mm stroke, air cooled 15cfm (410L/min) at 1000rpm Lubrication from engine oil system.

Ejector Details:

Jet: 23-0415-2016S Nozzle: 23-0414-2036S

Sykes Group Pty Ltd

Suction Flange: Delivery Flange: Nominal Casing Thickness: Nominal Shaft Diameter: Impeller Eye Diameter: Maximum Impeller O.D.: Minimum Impeller O.D.: Solids Handling Size: Operating Speed: Maximum Head: Maximum Capacity: Bearing Sizes:

HH220i Centrifugal Single Stage, Volute Type, 4 bladed fully open 200mm Table ‘E’ 200mm Table ‘E’ 16mm 75mm 200mm 432mm 380mm 75mm MIN: 1400rpm MAX: 2200rpm 139m 1030 l/s DRIVE END:  7317 BALL PUMP END:  NU318 ROLLER

Bearing Lubrication:

Grease or oil. Please refer to customer specification page for additional information

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Sykes HH220i – Installation, Operation & Maintenance Manual

Sykes Group Pty Ltd

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Sykes HH220i – Installation, Operation & Maintenance Manual

3 3.1

HOW TO READ A PERFORMANCE CURVE

Example Sykes’ CP150 Pump Curve

The lines sloping downwards from left to right represent the varying quantities of liquid delivered by the pump with variations in head. The intersection of this line at 2000rpm with the zero flow line shows the shut off head (41m) of pressure developed by the pump. Total Dynamic Head (m) = Static Suction lift (m) + Static Discharge Head (m) + Friction Head (m) Where: Static Suction Lift: Static Discharge Head: Friction Head:

Sykes Group Pty Ltd

Difference in elevation between liquid level of the suction and the centre line of the pump. Difference in elevation between liquid levels of the centre line of the pump and the discharge. Equivalent head necessary to overcome friction on the interior surfaces of the pipework system including all valves, bends and fittings.

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Sykes HH220i – Installation, Operation & Maintenance Manual

Duty Point: A pump operating at 95l/s at 29m (Total Dynamic Head). 1)

Draw a line upwards from Flow (x-axis) at 95l/s (point A).

2)

Draw a line across from Total Head (y-axis) at 29m (point C)

3)

Where the vertical line of 95l/s intersects the horizontal line of 29m (point B) determines the pump rpm speed and power required at this duty.

4)

∴ Pump

Speed Curve = 2000rpm.

5)

∴ Power

Requirement = 45kW to run the whole of the 2000rpm curve.

6)

To obtain NPSHR (Net Positive Suction Head Required), draw a line across from where the vertical line of the 95l/s intersects the NPSHR curve (point D).

7)

∴ NPSHR

8)

Dynamic Suction Lift Available (DSLA)

= 1.1m (point E).

DSLA = Atmosphere (m) – Velocity Head (allow 1m) – NPSHR (m) = 10.3m – 1m –1.1m = 8.2m To determine the actual dynamic lift of pump, it is recommended to fit a vacuum gauge on the suction side of the pump to obtain a vacuum reading. The vacuum gauge, for this example, should read no more than 80.4kPa (8.2m). If the vacuum gauge reading is greater than 80.4kPa then the pump will experience cavitation. Note: To ensure minimal losses to the total suction lift:  • Keep suction pipes as short and straight as possible. • Eliminate all possibility of air pockets being trapped in suction pipework. • When choosing foot valves, strainers, bends etc, select those, which will provide minimal restriction to the flow. • The diameter of the suction pipe should be equal in diameter to the pump inlet connection. • It is recommended to fit eccentric reducer in conjunction with pipe diameters larger than the pump inlet to avoid the possibility of air pockets in the suction pipework.

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Sykes HH220i – Installation, Operation & Maintenance Manual

3.2

Generalisations (1) Flow (l/s) decreases, as Total Head (m) increases. (2) Flow (l/s) increases, Power used increases.

It is not recommended to operate the pump outside the recommended pump operating range. To operate outside this area will lead to cavitation, vibration and non-uniform radial forces present in the pump. This drastically reduces the operating life of the mechanical seal, bearings and efficiency of the pump. In addition, the pump alignment will also be adversely effected due to excessive vibration. All this will result in an increase of maintenance cost of the pump.

3.3

Radial Thrust

When a pump is operated at its best efficiency flow rate the velocities and hence the pressures acting on the impeller are uniform around the volute. This is shown in Figure – A. At flow rates other than best efficiency point, the pressure distribution is no longer uniform. At reduced flow rates, the pressures increase spirally towards the cutwater resulting in a radial reaction F as shown Figure – B . This will lead to the following operating problems: • Low efficiency of pump. • Noise vibration, reduced life of pump. • Increased radial loads on bearings due to unbalanced volute pressures. • Temperature rise due to dissipated energy created by low efficiency. A similar situation exists at flow rates beyond best efficiency flow rates, with an approximate opposite (in direction) reaction. This also will lead to similar problems associated with the reduced flow rates with an addition of poor suction performance (high NPSHR). Figure – C  shows typical variation of radial thrust with flow rate.

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Sykes HH220i – Installation, Operation & Maintenance Manual

Figure A – 100% Best Efficiency Flow

Figure B – Reduced Flow

Figure C – Radial Thrust

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Sykes HH220i – Installation, Operation & Maintenance Manual

3.4

Cavitation

If the Net Positive Head Available of the pump is less than the Net Positive Head Required, the pumpend liquid will vaporize in the region of the impeller eye i.e. where the local pressure is less then the vapour pressure. In this region, the fluid will consist of a liquid plus vapour cavities. This can, in the extreme, result in the formation of a vapour lock and the prevention of the fluid entering the impeller. This phenomenon is called ‘cavitation’. The cavitation cycle comprises therefore of two phase changes; one from liquid to vapour during the initiation and the other from vapour back to liquid during cavity collapse. Cavitation may be caused by excessive suction lift, insufficient NPSHA or operation at too high a speed. The resulting effects include: (1) Pitting of material surfaces due to the continual hammering action of the collapsing vapour cavities. (2) Significant reduction of performance due to vapour formation. (3) The crackling noise (like gravel going through the pump) caused by vapour cavity collapse.

Severe cavitation usually results in excessive noise, vibration and damage to pump, whereas mild cavitation may produce nothing more than a small reduction in pump efficiency and moderate wear of pump components.

Sykes Group Pty Ltd

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Sykes HH220i – Installation, Operation & Maintenance Manual

4

RISK ASSESSMENT GUIDE

The following RISK CLASSIFICATION table should be used to assess the degree of risk presented by hazardous situations identified when carrying out the assessment. Consider: Electrical

Thermal

Noise

Mechanical

Pressure

Chemical

Radiant

Biochemical

Gravity

The numbers indicate how important it is to do something. 1 = Top priority – do something immediately 6 = Low priority – do something when possible

The table does not provide for control actions to be taken to minimise the risk and it is very important that these are documented, along with time frame and responsibilities.

How severely could it hurt someone or how ill could it make someone

How likely is it to happen? (C) UNLIKELY

( A ) VERY LIKELY 

(B)  LIKELY

could happen any time 

could happen sometime

could happen but very rarely

could happen but probably never will

(1) Kill or cause permanent disability or ill health 

1

1

2

3

(2   ) Long term illness or serious injury 

1

2

3

4

2

3

4

5

3

4

5

6

(3) Medical attention and several days off work  (4) First aid

needed

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(D) VERY UNLIKELY

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Sykes HH220i – Installation, Operation & Maintenance Manual

5

No.

Activity

RISK ASSESSMENT – HH220i

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • •

1

Lifting of Pumpset by single point lifting frame

•

Excessive lateral movement of unit - crushing

B

1

1

• • • • • • • • • •

2

Setting up the Pumpset

Slips, trips, strain, sprains and pinch points

B

3

3

• • •

• •

3

Operation of Pumpset

Excessive Noise – hearing loss

B

2

2 •

Sykes Group Pty Ltd

Only qualified personnel to use lifting equipment Hoisting acceleration should not exceed 2 0.4m/sec Ensure lifting equipment is in good condition Keep all personnel away from Pumpset when it is suspended Do not lift Pumpset by any other method than the central lifting eye Do not lift in extreme weather conditions Stop & think Correct PPE Wear correct PPE Stop and think Inspect area to ensure safe working conditions Set up on level ground Communicate with personnel located/working in vicinity of Pumpset Clean up any spillages causing trip hazards Do not operate Pumpset in known unsafe conditions Do not use Pumpset in any classification of hazardous environment unless it has been specifically designed to do so Do not operate within a confined space Wear hearing protection at all times when working or operating around the Pumpset Stop & think

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Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • •

•

Operation of Pumpset

Boom movement (Suction Hose Boom) – pinch points & crushing

B

2

2

• • • • • • • • •

Operation of Pumpset

Running engine & Pump Unit – moving parts, hot pump parts, hot exhaust and manifolds on engine – possible burns, pinch points, cuts and abrasions

B

3

3

•

•

•

Sykes Group Pty Ltd

Wear correct PPE Stop & think Do not operate Pumpset in known unsafe conditions Do not use Pumpset in any classification of hazardous environment unless it has been specifically designed to do so Do not operate within a confined space Keep all personnel away from Pumpset when boom is tilted, raised or lowered Do not move Pumpset whilst operating the boom Ensure boom lifting equipment is in good condition Do not operate Boom in known unsafe conditions Communicate with personnel located/working in vicinity of Pumpset Wear correct PPE Stop & think Educate employees of burn hazards on engines Keep access door on enclosures closed and locked when not required to be open Ensure that the engine is operated only from the control panel or from the operator’s position by one person only Keep hands, arms, long hair, loose clothing and jewelry away from pulleys, belts and other moving parts Do not remove any safety guards or panel

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Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • •

•

Operation of Pumpset

Boom movement (Suction Hose Boom) – pinch points & crushing

B

2

2

• • • • • • • • •

Operation of Pumpset

Running engine & Pump Unit – moving parts, hot pump parts, hot exhaust and manifolds on engine – possible burns, pinch points, cuts and abrasions

B

3

3

•

•

•

Sykes Group Pty Ltd

Wear correct PPE Stop & think Do not operate Pumpset in known unsafe conditions Do not use Pumpset in any classification of hazardous environment unless it has been specifically designed to do so Do not operate within a confined space Keep all personnel away from Pumpset when boom is tilted, raised or lowered Do not move Pumpset whilst operating the boom Ensure boom lifting equipment is in good condition Do not operate Boom in known unsafe conditions Communicate with personnel located/working in vicinity of Pumpset Wear correct PPE Stop & think Educate employees of burn hazards on engines Keep access door on enclosures closed and locked when not required to be open Ensure that the engine is operated only from the control panel or from the operator’s position by one person only Keep hands, arms, long hair, loose clothing and jewelry away from pulleys, belts and other moving parts Do not remove any safety guards or panel

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Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • •

Operation of Pumpset

Hydraulic, fuel, grease, oil, radiator coolant, water pressure, movement of pump water hose and battery electrolyte leaks – environmental pollution, poisoning, burns & skin irritation

• •

B

3

3 • • • • • • •

• •

Operation of Pumpset

Possible electrocution – electric shock and burns

B

1

1

•

• • • • •

Sykes Group Pty Ltd

Stop & think Wear correct PPE Check all hoses for cracks and leaks Check that all covers and caps are secure on alternator, cooling fan/radiator, engine & fuel tank Ensure spillages are contained MSDS available for all items used in Pumpset Educate employees of burn hazards Wear correct PPE Stop & think Only Authorised Personnel to work on electrical equipment Check all conduits for splits, bare wires or unsecured conduit fitting prior to operation of Pumpset Check all circuit breaker boards are secure and sealed Check all guards covering electrical section are secured correctly Do not attempt to connect or disconnect load while standing in water or on wet or soggy ground Ensure all electrical power is isolated from electrical equipment being serviced Keep all electrical equipment clean and dry Keep terminals clean and tight Test earth leakage equipment regularly Ensure correct fire extinguisher is available

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • •

Operation of Pumpset

Hydraulic, fuel, grease, oil, radiator coolant, water pressure, movement of pump water hose and battery electrolyte leaks – environmental pollution, poisoning, burns & skin irritation

• •

B

3

3 • • • • • • •

• •

Operation of Pumpset

Possible electrocution – electric shock and burns

B

1

1

•

• • • • •

Sykes Group Pty Ltd

Stop & think Wear correct PPE Check all hoses for cracks and leaks Check that all covers and caps are secure on alternator, cooling fan/radiator, engine & fuel tank Ensure spillages are contained MSDS available for all items used in Pumpset Educate employees of burn hazards Wear correct PPE Stop & think Only Authorised Personnel to work on electrical equipment Check all conduits for splits, bare wires or unsecured conduit fitting prior to operation of Pumpset Check all circuit breaker boards are secure and sealed Check all guards covering electrical section are secured correctly Do not attempt to connect or disconnect load while standing in water or on wet or soggy ground Ensure all electrical power is isolated from electrical equipment being serviced Keep all electrical equipment clean and dry Keep terminals clean and tight Test earth leakage equipment regularly Ensure correct fire extinguisher is available

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • •

Operation of Pumpset

Possible fire and explosion – burns, bodily injuries and possible death

•

B

1

1 •

• • • • • • •

4

Maintenance Battery charging

Possible explosion – burns and bodily injuries

B

1

1 • • • •

Sykes Group Pty Ltd

Wear correct PPE Stop & think Ensure correct fire extinguisher is available Do not refill the fuel tank while engine is running Never store oily rags in metal covered containers Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries To avoid arcing keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals Do not operate the Pumpset system with any known leaks in the fuel system Open exhaust system drain plugs after repeated failed start attempts Wear correct PPE Stop & think Correctly isolate equipment Do not smoke or allow sparks, flames or other sources of ignition around batteries To avoid arcing keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals When disconnecting battery disconnect the negative battery terminal first When reconnecting battery connect the negative battery terminal last Ensure adequate ventilation Turn off power or disconnect the power to the battery charger before making or breaking connections with the battery

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Sykes HH220i – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • •

Operation of Pumpset

Possible fire and explosion – burns, bodily injuries and possible death

•

B

1

1 •

• • • • • • •

4

Maintenance Battery charging

Possible explosion – burns and bodily injuries

B

1

1 • • • •

Sykes Group Pty Ltd

Wear correct PPE Stop & think Ensure correct fire extinguisher is available Do not refill the fuel tank while engine is running Never store oily rags in metal covered containers Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries To avoid arcing keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals Do not operate the Pumpset system with any known leaks in the fuel system Open exhaust system drain plugs after repeated failed start attempts Wear correct PPE Stop & think Correctly isolate equipment Do not smoke or allow sparks, flames or other sources of ignition around batteries To avoid arcing keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals When disconnecting battery disconnect the negative battery terminal first When reconnecting battery connect the negative battery terminal last Ensure adequate ventilation Turn off power or disconnect the power to the battery charger before making or breaking connections with the battery

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Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • •

Maintenance Electrical

Possible electrocution – electric shock and burns

B

1

1

• • • • • • • •

Maintenance – refilling fuel tank

Fuel leaks – environmental pollution, poisoning, burns & skin irritation

•

B

3

3 • • •

Sykes Group Pty Ltd

Wear correct PPE Stop & think Correctly isolate equipment Only Authorised Personnel to work on electrical equipment Do not attempt to connect or disconnect load while standing in water or on wet or soggy ground Ensure all electrical power is isolated from electrical equipment being serviced Keep all electrical equipment clean and dry Keep terminals clean and tight Test earth leakage equipment regularly Ensure correct fire extinguisher is available Stop & think Wear correct PPE Correctly isolate equipment Check all hoses and fittings for cracks and leaks Ensure spillages are contained MSDS available for fuel used in lighting tower Educate employees of burn hazards

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • •

Maintenance Electrical

Possible electrocution – electric shock and burns

B

1

1

• • • • • • • •

Maintenance – refilling fuel tank

Fuel leaks – environmental pollution, poisoning, burns & skin irritation

•

B

3

3 • • •

Sykes Group Pty Ltd

Wear correct PPE Stop & think Correctly isolate equipment Only Authorised Personnel to work on electrical equipment Do not attempt to connect or disconnect load while standing in water or on wet or soggy ground Ensure all electrical power is isolated from electrical equipment being serviced Keep all electrical equipment clean and dry Keep terminals clean and tight Test earth leakage equipment regularly Ensure correct fire extinguisher is available Stop & think Wear correct PPE Correctly isolate equipment Check all hoses and fittings for cracks and leaks Ensure spillages are contained MSDS available for fuel used in lighting tower Educate employees of burn hazards

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

No.

Activity

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • • • •

Maintenance mechanical

Engine, hydraulic pump and centrifugal pumpend maintenance – explosion, burns, pinch points, skin irritation

•

B

2

2 •

• • •

Sykes Group Pty Ltd

Stop & think Wear correct PPE Correctly isolate equipment MSDS available for items used in Pumpset Ensure spillages are contained Check all hoses and fittings for cracks and leaks Correctly de-energise hydraulic system Ensure guarding is in place and secure after maintenance is finished Do not remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relieve any excess pressure before removing the cap completely Educate employees on hazards of hot coolant and oil under pressure Educate employees of burn hazards Ensure correct fire extinguisher is available

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Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

Activity

No.

Hazard & Type of Injury Risk

Likelihood

Consequence

Risk Rating

Eliminate / Reduce / Control the risk by • • • • • • •

Maintenance mechanical

Engine, hydraulic pump and centrifugal pumpend maintenance – explosion, burns, pinch points, skin irritation

•

B

2

2 •

• • •

Sykes Group Pty Ltd

Stop & think Wear correct PPE Correctly isolate equipment MSDS available for items used in Pumpset Ensure spillages are contained Check all hoses and fittings for cracks and leaks Correctly de-energise hydraulic system Ensure guarding is in place and secure after maintenance is finished Do not remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relieve any excess pressure before removing the cap completely Educate employees on hazards of hot coolant and oil under pressure Educate employees of burn hazards Ensure correct fire extinguisher is available

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

6 6.1

PUMP OPERATING INSTRUCTIONS

Description of Pump Unit

The pump is basically a simple end suction pump which has a completely automatic priming system built into the design. This enables the pump pump to self-prime from a completely dry condition condition even with a long suction line. No liquid of any nature is required to prime the pump and therefore in temporary dry trench conditions the pump will 'snore' until such time as liquid is available. It can handle unscreened sewage, trade effluents, thick slurries and solids up to a normal limitation of 75mm. The impeller is a 4 bladed, 316 Stainless Stainless Steel construction, design fully open. It is mounted on a shaft made from 431 stainless steel fitted in an SG iron bearing bracket; which also provides concentric location for the pump body. The pump body is SG iron construction fitted with Stainless Steel wear plates secured by high tensile steel screws. The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The arrangement incorporates glycol lubricated seal housing. Guards are fitted as standard to all moving parts.

Sykes HH220i – HH220i  – Installation, Operation & Maintenance Manual

6 6.1

PUMP OPERATING INSTRUCTIONS

Description of Pump Unit

The pump is basically a simple end suction pump which has a completely automatic priming system built into the design. This enables the pump pump to self-prime from a completely dry condition condition even with a long suction line. No liquid of any nature is required to prime the pump and therefore in temporary dry trench conditions the pump will 'snore' until such time as liquid is available. It can handle unscreened sewage, trade effluents, thick slurries and solids up to a normal limitation of 75mm. The impeller is a 4 bladed, 316 Stainless Stainless Steel construction, design fully open. It is mounted on a shaft made from 431 stainless steel fitted in an SG iron bearing bracket; which also provides concentric location for the pump body. The pump body is SG iron construction fitted with Stainless Steel wear plates secured by high tensile steel screws. The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The arrangement incorporates glycol lubricated seal housing. Guards are fitted as standard to all moving parts. Suction flange 200mm Table ‘E’. Delivery flange 200mm Table ‘E’. Note If your HH220i pumpset has been mounted on a trailer chassis, it is recommended that after approximately 5 km of travel that all wheel w heel nuts be inspected and re-tightened.

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Sykes HH220i – Installation, Operation & Maintenance Manual

6.2

Procedure Prior to Pump Start Up

The pump should be placed on a level area of ground. In order to put the pump to work the following procedure should be undertaken. 1. Ensure that the pump turns freely. 2. Ensure bearings are adequately lubricated. 3. Ensure oil level in bearing bracket is filled to centre line of pump shaft indicated by the sight gauge and oil level label. 4. The incline angle of pump should not to be greater than 10°. 5. Check pump runs without excessive noise, heat or vibration. 6. Position hoses to avoid unnecessary stress. Sharp bends should be eliminated and protective measures taken where hoses are exposed to abrasive surfaces. Collapsible type hoses MUST NOT be used on the suction side of the pump. 7. For diesel prime movers:Check engine fuel supply level and top up if necessary. (The fuel tank is built into the chassis). 8. Check engine oil level on dipstick and top up with recommended oil if necessary.

The pump will prime automatically once the suction hose intake is submerged.

Note For engine starting instructions or starting difficulties, refer to the manufacturer's handbook.

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6.3

Failure to Prime Pump

6.3.1 Air Leaks To test for air leaks, disconnect suction hose from pump and blank off suction entry. If the vacuum gauge registers a satisfactory reading, i.e. 9.14 metres, the leak will be in the suction hose. Re-couple hose to pump; remove intake and blank-off entry to hose. It should then be possible to locate leak. If the air leak is in the pump:a) Check that all drain plugs are screwed tightly in position b) Remove NRV Inspection cover and make sure that the valve is seating correctly.

6.4

Pump Dynamic Test

1. Before starting the engine, check that the shaft, pulleys and belt are free to rotate with the guards in position. 2. Start pump and run completely dry for a minimum period of 10 minutes (initial run up speed at 900rpm increasing during test to 1100rpm). During this period, generally check and observe for any unusual vibrations, overheating, fuel, oil or air leaks. 3. These faults must be rectified immediately to prevent a possible engine seizure. 4. After the dry running period, check that the pump unit will raise a minimum vacuum of 81kPa (8.3m).

Special Note Consult engine manufacturers handbook for oil, fuel, speed control and stop details.

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6.5

Ejector Test

6.5.1 Dri-Prime Ejector Pack Assembly 1. Check ejector and jet sizes:

Nozzle Jet

23-0414-2036S 23-0415-2016S

2. Clean the jet and nozzle with paraffin or similar cleaner. On no account should stiff wire be used as this will enlarge the bores. 3. Check the nozzle and jet bores for any sharp edges, burrs or rough surfaces. If damaged and no replacement is readily available, smooth and polish as well as possible to original form. 4. Alignment of jet and nozzle is important but this is preset by machining tolerances. 5. Assemble ejector unit and check performance on test unit. Operation Air Pressure: 40 psi approx. Minimum Pass Vacuum: 81kPa (8.3m). 6. A satisfactory arrangement for carrying out the performance test on the ejector unit is a plate fitted with a vacuum gauge as illustrated.

Figure 1 – Ejector Exploded Assembly Drawing 

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7 7.1

PUMP MAINTENANCE INSTRUCTIONS

General Pump Inspection Procedure 1. Drain the water from the pump and the non-return valve. 2. Remove the non-return valve and inspect the valve and seat for wear. 3. Drain the oil from the engine and the pump. 4. Dismantle the pump end completely. 5. If there is a mechanical seal problem, return to supplier for reconditioning. 6. Check that the shaft rotates freely with no end float. 7. Clean and inspect all components and renew where necessary. Do not use abrasive materials or solutions to clean the ejector assembly. Renew all nyltite seals. 8. Reassemble the complete pump end and non-return valve (refer to Fitting Instructions). 9. Drain the fuel tank. 10. Detach fuel, oil and air hoses. Clean and ensure that they are not blocked. Test the relief valve at 3 to 5 PSI. 11. Check pulley alignment and belt condition. Check the security of pulleys and flexible couplings. 12. Re-assemble the complete unit.

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7.2

Pump Assembly Instructions

7.2.1 Pump Bearing Bracket (for oil lubricated bearings) 1. Ensure all items are free from burrs and rust. 2. Visually check for porosity and blow holes in the castings and clean out any casting sand and swarf which may be present. 3. Ensure that all items are clean and that the seal faces are free from score or wear marks. 4. Check surface finish on shaft where oil seals run and polish if required. 5. Check shaft thread, retaining nut threads & lock washer tab slots. 6. Fit inner angular contact ball bearing to shaft (large inner race face to shaft shoulder). Retain with spacer tool and bearing lock nut. Allow to cool.  

7. Fit inner race of roller bearing to shaft. Fit lock ring to shaft Loctite grub screws Wipe off excess loctite   

8. Fit roller bearing outer race to bearing housing. 9. Fit inner bearing covers. 10. After bearings are cooled on shaft, oil bearings, fit assembly into housing. 11. Position angular contact ball bearing slightly recessed into housing enough to position outer bearing spacer. 12. Remove temporary spacer tool from shaft. 13. Fit inner and outer bearing spacer. 14. Heat outer angular contact ball bearing. Fit bearing to shaft (large inner race face to bearing locknut) Fit locknut and lock washer Tighten until both bearings move together than bend over lock tab on lock washer Allow to cool   



15. Fit lip seals to bearings covers. 16. When bearing is cooled – oil and position shaft in bearing bracket. Sykes Group Pty Ltd

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17. Bolt rear outer bearing cover onto the bearing bracket using bolts, spring washers, flat washers, sealing washers and O-rings. This will locate shaft in bearing bracket. Ensure shaft turns freely. 18. Fit bearing bracket cover plate. 19. Fit mechanical seal as per instructions outlined in this manual.

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7.2.2 Centrifugal Pump  1. Slide Mechanical Seal onto shaft. Ensure the locking grub screws are screwed back clear of shaft – refer to mechanical seal section for complete installation instructions. 2. Before fitting seal onto shaft ensure that all surfaces are clean and that all edges over which the seal has to pass are rounded off. All working faces must be free from any foreign matter. 3. Fit rear wear plate to volute using bolts, sealing washers and o-rings respectively. 4. Fit volute onto Bearing Bracket using studs, nuts and washers. Apply antisieze grease between mating surfaces. 5. Fit Spacer Ring onto shaft. 6. Before fitting the impeller apply anti-seize compound onto the threads. Screw impeller onto shaft in a clockwise motion. The recommended grades of anti seize is: - GA50 Molybond or equivalent (Molybdenum Disulphide). 7. Locate front wearplate onto front adaptor plate using bolt, sealing washer and o-ring. 8. Fit studs into volute then locate front adaptor plate onto volute, then by tightening nuts move the front adaptor plate until the impeller starts to rub on the front wear plate. When this has been achieved measure the distance between the front adaptor plate and the volute then add 0.040” (1.00mm / 1.10mm). This will give you the amount of shims that have to be added to give you correct clearance between the impeller and front wear plate. 9. Once this measurement has been achieved, remove front adaptor plate and add appropriate shims. Then re-tighten front adaptor plate onto volute, than re-check clearances by measuring the distance between the impeller and front wearplate using feeler gauges. If the clearance is not 0.030” (0.70mm/0.85mm) then repeat steps 9 & 10 until correct.

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7.2.3 Ejector Package 1. Check that all items are clean and free from burrs. The jet and nozzle should only be cleaned with paraffin or similar cleaner. Wire should not be used, as this will enlarge the bores. 2. Do not use excessive jointing compound when fitting these items and ensure that it does not enter the bores. This may cause a blockage in the ejector. 3. Screw by hand the jet and the nozzle to the carrier plate. 4. Fit elbow to nozzle. 5. Place the ball in the carrier plate, and then secure ball seat. 6. Fit the carrier plate to the tee piece with gasket filters and fasteners. 7. Push exhaust hose onto the elbow. Fasten using clamp.

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7.2.4 Mechanical Seal Assembly Installation Instructions for a P3F Cartridge Seal

Prepare Pump for Mechanical Seal Installation 1. Clean pump parts: a) Shaft d) Pump Frame

b) Shaft Sleeve e) Impeller

c) Stuffing Box Back Plate f) Studs, Nuts & Bolts

2. Inspect and de-burr pump parts: a. Replace shaft or repair shaft if worn in secondary sealing area under orings. b. Remove all burrs that would cut secondary seals or cause misalignment. (Pay attention to old set-screw marks.) c. Check shaft run out (to be within 0.025mm (0.001”)) TIR per 25mm of shaft dia) end play (not to exceed 0.13mm (0.005”)) stuffing box face mis-alignment (square to shaft to within 0.13mm TIR and a good surface to seal, 1.60UMRA max) and condition of bearings. Replace if necessary. d. Drain & flush glycol reservoir.

Installation of the Mechanical Seal 1. Lubricate the shaft before sliding on seal. Slide the seal on the shaft by pushing on the collar & sleeve, making sure that the set screws are engaged in the sleeve without touching the shaft. 2. Make all necessary impeller or rotor adjustments as required. 3. Tighten the gland bolts evenly. 4. Tighten grub screws (3off s/s std grub screws, use Locktite 243) 5. Dimpling shaft: Drill into shaft through remaining grub screw holes (3off) to suit spear point grub screws. (Use Locktite 243) 6. Tighten remaining M6 x 6 Umbrako Grubscrews directly on top of the 6 grub screws in place. (Use Locktite 243) 7. Remove setting clips and cap head screws. 8. Turn shaft by hand, there should be no metal to metal contact between the sleeve and the seal.

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9. Make all necessary pump connections and alignments. Hook up appropriate tangential flush port depending on shaft rotation. (Connect flush in the direction of shaft rotation, eg; if the shaft is rotating clockwise, connect the flush (marked) clockwise). 10. Fill tank with Ethylene Glycol (mixture 30% Glycol, 70% Water), bled barrier fluid line free of air. 11. The seal is ready for pump start-up procedures.

Warning! Ensure once pump is operation that the barrier fluid is circulating. If barrier fluid does not seem to be circulating, remove return line to bled remaining air out of it. Reconnect and re-check flow.

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7.2.5 Non Return Valve Inspection Procedure 1. Ensure that all items are clean and free from burrs. 2. Visually check for porosity and blow holes in the castings and for scores or chaffing of the seat. 3. Ensure all bolts on inspection cover are secure. 4. Clean the delivery flange on the pump body and secure the valve to it with fasteners.

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7.3

Air Compressor

7.3.1 Description of Compressor

BENDIX AIR COMPRESSOR TYPE 2W 440 R.

Introduction: The very high air output of this twin cylinder single stage air compressor makes it eminently suitable for use on buses and special purpose heavy duty vehicles. It has a balanced crankshaft and reed type air inlet and delivery valves for greater efficiency and reliability at high operating speeds. It is available in either base or flange mounted versions which are suitable for gear, belt, or shaft drive from the vehicle engine. The crankcase and cylinders form a single rigid weight saving casting. The cylinder barrels are air cooled while the cylinder head is cooled by water circulated from the vehicle engine cooling system. The compressor may be run in either direction of rotation at speeds of up to 2400 r.p.m. to deliver up to 9 bar pressure (130 p.s.i.) For sustained operation at higher delivery pressures please consult our Technical Services Department. An unloader mechanism may be incorporated in the cylinder head. In its absence, pressure regulation is by an air delivery line mounted unloader valve, or by a D2 Governor used in conjunction with an AD2 Air Dryer. The air inlet and delivery valves are contained in a valve plate fitted between the cylinder barrels and the cylinder head. The compressor lubricating oil is circulated under pressure from the vehicle engine lubricating oil system.

Every effort has been made to ensure that the information in this leaflet is correct but we reserve the right to amend or change this information without notice.

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Sykes HH220i – Installation, Operation & Maintenance Manual Construction: Refer to Figs. 1 and 4. In Fig. 1 A is the reed valve plate and B is the cast aluminium cylinder head which is partially finned to assist cooling. C is the air delivery connection and there are cooling water connections at the two positions D. E is the air inlet connection. Each cylinder has an air delivery valve F and an air inlet valve G. Three gaskets are fitted at H, one between the cylinder head and valve plate, and two between the valve plate and the finned cast iron cylinder/crankcase unit J. The two aluminium pistons K each have two piston rings L and an oil control ring M. The piston pins N are retained by the circlips P. The front end of the forged steel crankshaft Q runs in the ball bearing R. The front end cover S also carries the crankshaft oil seal T. The connecting rods U are made from a forged light alloy which forms an excellent bearing surface. The rods run directly on the crankshaft journals and piston pins. This eliminates the need for separate bearing inserts. The rear end of the crankshaft carries a thrust washer V and runs in a white metal bearing bush W. The rear end cover X is threaded at Y for a lubricating oil connection from the vehicle engine. Engine oil under pressure then flows through drillings in the crankshaft to the main bearing at W and to the big end bearings. The ball bearing R and the other internal surfaces are lubricated by oil splash and mist. The oil drains back to the vehicle engine through the open bottom of the compressor crankcase. General Specification: Bore Stroke Swept Volume Maximum Recommended Speed Maximum Recommended Delivery Pressure Operating temperature Range Maximum Continuous delivered Air Temperature (See 'Installation') Weight

75mm 50mm 3 441.6 cm 2400 r.p.m. 9bar (130 p.s.i.) -40°C to + 80°C

220°C 19.5 kg

Also refer to the performance charts in Fig. 2. Installation: Standard ISO and DIN symbols for air compressors in pnuematic circuit diagrams are shown in Fig. 3. Because of the range of mounting and driving options the dimensions in Fig. 4 are typical only. Our Technical Services Department will supply detailed dimensions and information for each particular application. The Department should also be consulted if it is desired to mount the compressor at an appreciable angle. The compressor should be mounted where the maximum air flow will pass over it to help in ensuring that the delivered air temperature does not exceed 220°C. The cylinder/crankcase unit may be flange mounted instead of base mounted as in Fig. 4. Details are available on request.

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Sykes HH220i – Installation, Operation & Maintenance Manual

Maintenance: Before working on or around air brake systems and components always observe the following precautions: a) b)

c)

d)

e)

f) g)

Stop the engine before working under a vehicle. Always chock the vehicle wheels, because depleting the vehicle air system pressure may cause the vehicle to roll. Keep hands away from actuator push rods and slack adjusters. They may apply as the system pressure drops. Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes. Never remove a component or pipe plug unless you are certain all system pressure has been depleted. Never exceed recommended air pressure. Always wear safety glasses when working with air pressure. Never look into air jets or direct them at anyone.

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h)

i)  j)

Never attempt to dismantle a component until you have read and understand recommended procedures. Some units contain powerful springs and injury can result if not properly dismantled. Use only the correct tools and observe all precautions pertaining to the use of these tools.

At vehicle service intervals check the compressor for any leakages of water, oil, or air. If the compressor is slow to build up pressure the cylinder head and valve plate may be removed. The condition of the valve assemblies and the cylinder bores may then be checked and any excessive build up of carbon removed. Service Kits of replaceable items are available on request.

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Sykes HH220i – Installation, Operation & Maintenance Manual

7.3.2 Fitting Instructions – Compressor Assembly 1

Ensure all items are clean and that the hoses are free from foreign matter.

2

Do not use excessive jointing compound (eg. Stag, Neolite, Non-Adhesive Hermatite etc) when fitting these items and ensure that it does not enter the bores. This may cause a blockage in the oil or air lines.

3

Fit gasket to the compressor position on adaptor and secure with fasteners.

4

Secure the compressor pulley to the compressor with the nut and spring washer. Remove the taperlock bush from the pump pulley then pass the pulley over the shaft. Ease the belt over the pulleys, and fit the key. Align the pulleys then refit the taperlock bush to the pump pulley and secure it to the shaft.

5

Remove and discard four cylinder head screws from the compressor and ensure the compressed air port is located at the opposite end to fan.

6

Connect the compressed air hose between the compressor and the jet sleeve.

7

Fit the oil pipe fittings to the compressor.

8

Connect air intake fittings.

9

Secure the guard with screws. Ensure that the belt and pulleys are free to rotate.

7.3.3 Compressor Belt Replacement Timing Belt Procedure 1.

Remove pulley guard set screws and pump support nuts and draw pump assembly away from engine flywheel housing

2.

Remove old belt and taper lock bush from pump pulley.

3.

Ease replacement belt over pulleys, realign pulleys and refit taper lock bush.

4.

Check belt tension then refit pump unit onto engine.

5.

The compressor tooth belt drive has fixed centres so no adjustment is necessary. The normal operating air pressure is 3.44 - 5.17 bar (50-75psi).

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Sykes HH220i – Installation, Operation & Maintenance Manual

Link Belt Procedure 1

Remove pulley guard and old belt.

2

Place belt around pulleys without creating any tension.

3

Count the number of links and remove 7% (1 in 14).

4

Place belting around pump shaft and link up.

5

Fit around drive pulley and over compressor pulley rotating the drive shaft slowly.

6

The normal operating air pressure is 2.75 - 4.13 bar (40-60psi).

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Sykes HH220i – Installation, Operation & Maintenance Manual

7.3.4 Compressor Parts List

Ref.

A B C D E F G H

Description

Part Number

Bendix Air Compressor 2W 440 R KZ1087/14

49-0523-9915

Valve Plate Assembly c/w Reed Valve Kit & Air Inlet Valve Cylinder Head ¾” BSP Threaded Air Delivery Connection ½” Threaded Water Cooling Ports ¾” BSP Threaded Air Inlet Reed Valve Kit Air Inlet Valve 229502 Valve Plate & Head Gasket Kit

KY2331/1SP KZ1160/3

SK2955/1 SK2997/1

Comprising: Cyl.Head Gasket KX2466/2 Top Plate Gasket KX2799/2 Lower Plate Gasket KX2280/2

J K

L

Cylinder Body Piston Assembly (STD) (KW5172/1SP) Piston Assembly Piston Assembly Piston Ring Set (STD) Piston Ring Set (0.010” o/s) Piston Ring Set (0.020” o/s) Piston Ring Set (0.030” o/s)

KZ1094/1 1189082SP (KW5172/2SP) (KW5172/3SP) (SKR2790/00) (SKR2790/10) (SKR2790/20)

M N P

Oil Control Ring Set Connecting Rod Pin Rod Pin Snap Pin -

Q R S

Crankshaft Ball Bearing (NSK-6307-CE)  Front End Cover O-Ring, Inner Bearing Cover Crankshaft Oil Seal (CR13938)   Con Rod Complete (KW4785/1SP) Thrust Washer White Metal Bearing Bushing End Cover Assembly c/w Bushing “C” Ring - End Cover Lubricating Oil Inlet 1/8” BSP Base Mount Gasket 0.8mm Base Mount Gasket 0.4mm

T U V W X Y

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1189255SP 1189256SP SKR2962/00 SKR2962/10 SKR2962/20 SKR2962/30

Included in Piston Assy & Piston Ring Included in Piston Assembly Included in Piston Assembly

KY2258/1SP 1194120SP KX2491/1 1189619 267805 1194120SP KY2372/1 I811560066 KX1223/13SP 1189571 KX2542/1 KX2542/2

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Sykes HH220i – Installation, Operation & Maintenance Manual

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Sykes HH220i – Installation, Operation & Maintenance Manual

8 8.1

Pump Diagnostics

Trouble Shooting Guide

Pump System Problems   Pump

  Not

Does Not Prime

Enough Liquid

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Likely Cause

- Suction lift too great - Inlet of suction pipe insufficiently submerged - Suction inlet or strainer blocked - Excessive amount of air or gas in liquid - Viscosity and / or S.G. of liquid being pumped too high - Suction line not air tight - Suction hose collapsed - Non return valve ball not seating - Mechanical seal / Packing drawing air into pump - Pump’s priming system blocked or badly worn - Separation tank cover blocked - Pump’s priming hose leaking air - Pump’s priming system not delivering sufficient air - Pump’s priming system belt drive faulty - Incorrect engine speed - Discharge head too high - Suction lift too great - Suction inlet or strainer blocked - Suction line not air tight - Suction hose collapsed - Mechanical seal drawing air into pump - Obstruction in pump casing / impeller - Impeller excessively worn - Delivery hose punctured or blocked - Pump not primed - Air pockets in suction line - Inlet of suction pipe insufficiently submerged - Excessive amount of air or gas in liquid

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Sykes HH220i – Installation, Operation & Maintenance Manual

Pump System Problems   Not

Enough Pressure

  Pump

Ceases to Deliver Liquid After a Time

  Pump

Takes Excessive

Power

  Pump

Leaking at Mechanical Seal Housing

  Pump

Bearings Have Short

Life

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Likely Cause

- Speed too low - Excessive amount of air or gas in liquid - Incorrect direction of rotation - Viscosity and / or S.G. of liquid being pumped too high - Impeller Damaged - Impeller out of balance - Suction lift too great - Insufficient water at suction inlet - Suction inlet or strainer blocked - Suction hose collapsed - Excessive air leak in suction line - Mechanical seal / Packing drawing air into pump - Obstruction in pump casing / impeller - Delivery hose punctured or blocked - Engine speed too high - Obstruction between impeller and casing - Viscosity and / or SG of liquid being pumped too high - Incorrect direction of rotation -  Misalignment - Shaft bent - Mechanical seal damaged or worn - Obstruction in pump casing / impeller - Impeller out of balance - Shaft bent - Shaft running of centre because of worn bearings or misalignment -  Misalignment - Bearings worn - Excessive thrust caused by mechanical failure inside pump - Lack of bearing lubrication - Incorrect assembly of stacked bearings, i.e. angular contact ball bearings fitted front-to-front instead of back-to-back - Dirt in bearings - Rusting of bearings from water in housing

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Sykes HH220i – Installation, Operation & Maintenance Manual

Pump System Problems   Pump

Vibrating or Overheating

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Likely Cause

- Engine speed too high - Obstruction in pump casing / impeller - Impeller damaged - Cavitation due to excessive suction lift - Impeller out of balance - Shaft bent - Shaft running of centre because of worn bearings or misalignment -  Misalignment - Bearings worn - Pump not primed - Pump or suction pipe not completely filled with water - Inlet of suction pipe insufficiently submerged - Suction or discharge re-circulation in volute - Excessive thrust caused by mechanical failure inside pump - Lack of bearing lubrication - Incorrect assembly of stacked bearings, i.e. angular contact ball bearings fitted front-to-front instead of back-to-back - Dirt in bearings - Rusting of bearings from water in housing

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Sykes HH220i – Installation, Operation & Maintenance Manual

9

PUMP UNIT SUB-ASSEMBLY

H 

Volute

BB

Bearing Bracket

ST

Separation Tank

EP

Ejector Pack

OR

Glycol Reservoir

AC

Compressor Assembly

AC

EP

OR

ST

H

BB

Figure 19 – Typical HH220i Pumpend

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Sykes HH220i – Installation, Operation & Maintenance Manual

Figure 20 – HH220i General Assembly Drawing 

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Sykes HH220i – Installation, Operation & Maintenance Manual

10 PARTS LIST 10.1 Recommended HH220i Pump Spare Parts Description Impeller Front Wear Plate Stuffing Box Plate Stuffing Box Plate Gasket Shim - 0.25mm Shim - 0.40mm Shim - 0.80mm Shim - 1.60mm Mechanical Seal Shaft Sleeve Roller Bearing Ball Bearing Angular Contact Shaft

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Part Number 12-0325-3015 12-0185-0115 12-0196-0115 98-430-807-162 38-0200-5413 38-0200-5423 38-0200-5433 38-0200-5443 001-1007JC 28-0210-3215 39-0094-9912 39-0091-9912 16-0200-8011-BU

Quantity 1 1 1 1 2 2 2 2 1 1 1 2 1

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Sykes HH220i – Installation, Operation & Maintenance Manual

10.2 Volute Parts List

Figure 21 –Volute Mechanical Seal Exploded Assembly Drawing 

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Sykes HH220i – Installation, Operation & Maintenance Manual

VOLUTE PARTS LIST Illustration number H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H13a H13b

H16 H18a H18b H18c H18d H19 Not Shown

Description Volute Body Impeller Front Wear Plate Stuffing Box Plate Adaptor Plate Stud (M16 x 50) Nut (M16) Seal Washer (M16) & ‘O’ Ring

Part Number

Quantity

11-0200-0115 12-0325-3015 12-0185-0115 12-0196-0115 10-0200-0000

1 1 1 1 1 4 4 4

38-0790-4412 38-0792-4412

Capscrew (M24 x 40) Spring Washer (M24) Flat Washer (M16) S/S Spring Washer (M16)S/S

12 12 2 2

Gasket Shim – 0.25mm Shim – 0.4 mm Shim – 0.8 mm Shim – 1.6mm Plug ¾” BSP Epoxy Adhesive

98-430-807-162 38-0200-5413 38-0200-5423 38-0200-5433 38-0200-5433 P12 AC-068

1 A/R A/R A/R A/R 2 1

MECHANICAL SEAL Illustration Description number H11 Shaft Sleeve (modified) H12 Mechanical Seal H14 Bolt (M16 x 20) S/S

Part Number

Quantity

28-0210-3215 001-1007JC

1 1 2

Part Number

Quantity

28-0200-3215 14-0300-0115

1 1 2 2 1

PACKED GLAND Illustration number H11 H12 H14 H15 H17

Description Shaft Sleeve Gland followers (set of 2 halves) Nut (M16) S/S Stud (M16 x 65) S/S Gland packing - ½”

Sykes Group Pty Ltd

638-4003G

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Sykes HH220i – Installation, Operation & Maintenance Manual

Figure 22 –Volute Packed Gland Exploded Assembly Drawing 

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

VOLUTE PARTS LIST Illustration number H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H13a H13b

H16 H18a H18b H18c H18d H19 Not Shown

Description Volute Body Impeller Front Wear Plate Stuffing Box Plate Adaptor Plate Stud (M16 x 50) Nut (M16) Seal Washer (M16) & ‘O’ Ring

Part Number

Quantity

11-0200-0115 12-0325-3015 12-0185-0115 12-0196-0115 10-0200-0000

1 1 1 1 1 4 4 4

38-0790-4412 38-0792-4412

Capscrew (M24 x 40) Spring Washer (M24) Flat Washer (M16) S/S Spring Washer (M16)S/S

12 12 2 2

Gasket Shim – 0.25mm Shim – 0.4 mm Shim – 0.8 mm Shim – 1.6mm Plug ¾” BSP Epoxy Adhesive

98-430-807-162 38-0200-5413 38-0200-5423 38-0200-5433 38-0200-5443 P12 AC-068

1 A/R A/R A/R A/R 2 1

MECHANICAL SEAL Illustration Description number H11 Shaft Sleeve (modified) H12 Mechanical Seal H14 Bolt (M16 x 20) S/S

Part Number

Quantity

28-0210-3215 001-1007JC

1 1 2

Part Number

Quantity

28-0200-3215 14-0300-0115

1 1 2 2 1

PACKED GLAND Illustration number H11 H12 H14 H15 H17

Description Shaft Sleeve Gland followers (set of 2 halves) Nut (M16) S/S Stud (M16 x 65) S/S Gland packing - ½”

Sykes Group Pty Ltd

638-4003G

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Sykes HH220i – Installation, Operation & Maintenance Manual

10.3 Bearing Bracket and Shaft Parts List

Figure 23 –Bearing Bracket Exploded Assembly Drawing  Sykes Group Pty Ltd

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Sykes HH220i – Installation, Operation & Maintenance Manual

BEARING BRACKET & SHAFT PARTS LIST Illustration Number BB1 BB2 BB3 BB4 BB5 BB6 BB7 BB8A BB8B BB9 BB10 BB11 BB12 BB13 BB14 BB15 BB16 BB17 BB18 BB19 BB20 BB21 BB22A BB22B BB23 BB24 BB25 BB26 BB27 BB28A BB28B BB29 BB30

Description Bearing Bracket Bearing Cover Outer Rear Bearing Cover Outer Front Bearing Cover Inner Roller Bearing 90 X 190 Angular Ball Bearing 85 X 180 Bolt (M12 x 160) Flat Washer (M12) Spring Washer (M12) Bolt (M12 x 100) Bolt (M12 x 40) Bolt (M12 x 180) Spiroseal 90 x 110 Clamp Ring Socket Capscrew (M6 x 20) Shaft Lock Nut Bearing Lockwasher Bearing Bearing Spacers (Pair) Spiroseal 75 x 95 x 10 Bearing Bracket Cover Joint 1.6mm Stud (M20 x 70) Flat Washer (M20) Spring Washer (M20) Nut (M20) Plug 3/8” BSP Plug 1/8” BSP Bearing Bracket Cover Plate Bolt (M12 x 40) Flat Washer (M12) Spring Washer (M12) Sealing Washer (M12) O-Ring 10.69 x 3.53 Viton

Part Number

Quantity

13-0164-0115 13-0169-0125-BU 13-0162-0115 13-0170-0115-OIL 39-0094-9912 39-0091-9912

1 1 1 1 1 2 3 9 9 3 3 3 1 1 1 1 1 1 1 1 1 8 8 8 8 1 1 1 4 4 4 4 4

38-1331-9912 28-0252-8811 16-0200-8011-BU 39-0096-9912 39-0097-9912 24-0093-8831 38-1328-9912 XH80BBJ-160

P06 P02 27-0200-8211-OIL

* Notes:  1. When ordering Shaft state pump engine type so correct type of shaft length can be supplied. 2. Ensure that the angular ball bearings (BB6) are fitted back-to-back either side of bearing spacers (BB18). The set up is obtained by fitting the smaller shoulders of the inner races facing each other.

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

10.4 Separation Tank / Ejector Package Parts List

Figure 24 – Separation Tank & Ejector Package Exploded Assembly Drawing 

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

EJECTOR PACKAGE PARTS LIST Illustration Number EP1 EP2

Description Ejector Nozzle Ejector Jet

Part Number

Quantity

23-0414-2036S 23-0415-2016S

1 1

SEPARATION TANK PARTS LIST Illustration Number ST1 ST2 ST3 ST4 ST5 ST6 ST7 ST8 ST9 ST10 ST11 ST12 ST13 ST14

Description “T” Piece Tank/Body Joint Stud (M20 x 70) Nut (M20) Lockwasher (M20) Carrier Plate Carrier / Tank Stud (M12x 50) Springwasher (M12) Nut (M12) Ball Seat Ball Carrier Plate Plug 1” B.S.P. Fitter ¾” BSP Elbow - Hosetail

Sykes Group Pty Ltd

Part Number

Quantity

348-4008 500-5003

1 2 8 8 8 1 4 4 4 1 1 1 1 1

23-0411-0115

23-0412-2011 39-0641-4113 P16 23-0413-2113 E12SBF

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

10.5 Glycol Reservoir Parts List

Figure 25 – Glycol Reservoir Exploded Assembly Drawing 

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

GLYCOL RESERVOIR PARTS LIST Illustration Number OR1 OR2 OR3 OR4 OR5 OR6 OR7 OR8

OR9 OR10 OR11

Description

Part Number

Quantity

Glycol Reservoir Assembly Lid Sight & Temperature Gauge Hydraulic Nipple ¼” BSP Reservoir Gasket Nut (M12) Springwasher (M12) Plug ½” (with breather) Glycol Reservoir Hose Length 1 Glycol Reservoir Hose Length 2 Hose Clamps to suit reservoir hose Nut & Hose Tails ¼” to suit reservoir hose Bolt (M10 x 30) Flat Washer (M10) Spring Washer (M10)

27-5000-8211

1 1 1

Sykes Group Pty Ltd

40-0000-0060 N04H 38-0350-5443

P08 1-319-0006 1-319-0006 OTK1011 HT0404

1 1 1 1 650mm 550mm 4 4 4 4 4

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

10.6 Compressor Parts List

Figure 26 - Compressor Assembly Drawing 

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

COMPRESSOR PARTS LIST Illustration Number AC1 AC2 AC3 AC4 AC5 AC6 AC7 AC8 AC9 AC10 AC11 AC13 AC14 AC15

Description Compressor (Bendix) Gasket Stud M10 x 40 Springwasher M10 Pulley (Pump) bored to 75mm shaft Pulley (Compressor) Belt 38wide x 78 teeth (1/2” Heavy Pitch) Fan Washer Relief Valve Air Cleaner Adaptor (Air Cleaner) Compressed Air Hose Nipple ¾” BSP x ½” BSP Pulley / Belt Guard

Sykes Group Pty Ltd

Part Number

Quantity

49-0523-9915 KX2542/1

1 1 4 4 1 1 1 1 1 1 1 1 1 1

10-0000-0037 26-0830-0243 26-0840-9912 36-0556-8111 10-0000-0004 54-0556-9912 A1212 42-0000-0015 N1208H

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

10.7 Non Return Valve Parts List

Figure 27 – Non Return Valve Explode Assembly Drawing 

NON RETURN VALVE PARTS LIST Illustration Number V1 V2

Description Flexi-Check Valve 200mm Flexi-Check Valve Flap 200mm

Sykes Group Pty Ltd

Part Number

Quantity

10-0000-0480 10-0000-0485

1 1

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Sykes HH220i – Installation, Operation & Maintenance Manual

11 PUMP UNIT ACCESSORIES Your HH220i pumpset has been mounted on a robust custom built skid chassis and comes complete with extras include.

Description

Part Number

1

14” Flywheel Stub Shaft (3 ½” shaft)

2 3

RFC280 Flex Coupling c/w 3535TLB to suit shaft 75mm & 3 ½” Inbuilt 24 hour Fuel Tank (2350 litres)

4

Discharge Pressure Gauges

5

8” Non Return Valve

6 7

6” Crane Geared Operated Butterfly Valve Hydro Flow Valve (Fuel)

8

Night Lights – 2 only

9

Green Flashing Light (Pump Operating)

10

Loss of Low Shutdown

11

9 kg Fire Extinguisher – 2 only

AC-034

12

9 kg Fire Extinguisher Bracket – 2 only

AC-035

13

14

Traffolyte Pump Operating Sign (Recommended Pump Operating Pressures at Various Speeds) Jump Start Receptacle

15

Lockable Battery Isolator

AC-017 & AC-017-NEW

16

8” Suction Bauer

8-319-4830

17

Suction Bauer ‘O’ Ring

8-319-4850

18

8” Split Intake

8-181-4022

19

8” Wire Armoured Suction Hose x 6 m

9-319-6186

20

Wiggins Fast Fill Fittings (Oil & Water)

AC-057

For further information please refer to the manufacturer's Operation and Maintenance Manuals.

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

Sykes HH220i – Installation, Operation & Maintenance Manual

12 DIESEL ENGINE MANUAL Your HH220i pumpend is driven by a ?? Liquid Cooled Diesel Engine and comes complete with the following.

Description

Part Number

1

Mines Wiring to MDG-15

2

Water Separator Filter

3

Emergency Stop

4

Murphy Control Panel Gauges

5

Clip Type Lagging on Exhaust Pipes

For further information please refer to the manufacturer's Operation and Maintenance Manuals.

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com