hh125 smanual completed - master updated 30-3-06

8/19/2019 HH125 sManual Completed - Master Updated 30-3-06

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SYKES GROUP PTY LTD

HH125 PUMPSET

FOR

REF: W/O


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Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.


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SYKES GROUP PTY LTD

PUMP SPECIFICATION

PUMP TYPE: HH125

PUMP SIZE: 150mm x 125mm

ACTUAL IMPELLER DIAMETER: φ 370mm

ENGINE / MOTOR TYPE:

PUMPSET NUMBER:

PUMPEND NUMBER:

JOB NUMBER:

PLANT NUMBER:

ENGINE / MOTOR NUMBER:

DRY WEIGHT:

FUEL CAPACITY:

WET WEIGHT:


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TECHNICAL DATA SHEET No. 1

DESIGN DETAILS:

Pump Designation: HH125(DV)Pump Description: Single stage, volute type, 3 bladed fully open

Centrifugal pumpSuction Flange: 6" Table 'D'Delivery Flange: 5" Table 'D' complete with 5"-6" adaptorNominal Casing Thickness: 18mmNominal Shaft Diameter: 50mmImpeller Eye Diameter: 90mm at tip, 76mm at eyeMaximum Impeller O.D.: 370mm (Outlet Width - 33.6mm)Minimum Impeller O.D.: 250mm (Hub Dia. 80mm)

Moment Inertia Impeller: 1022.8kg/cm²Solids Handling Size: 29mmWear Plate Clearances: REAR: 0.50/0.70mm FRONT: 0.50/0.70mmDesign Speed: 2200rpmDesign Capacity: 81m³/hrDesign Efficiency: 50%Max HP at Design Speed: 110HPSpecific Speed: 460Operating Speed: MIN: 1600rpm MAX: 2400rpmOutrigger Bearing to be fitted

above:

1800rpm

Maximum Head: 136m (447Ft)Maximum Capacity: 180m³/hr (660GPM)Operating Temperature: MIN: -20°c MAX : +100°COperating TemperatureCasing:

MIN: -20°c MAX : +177°C

Permissible Suction Press: MIN: Zero ABS MAX : 2BAR (29 PSI)Maximum Hydraulic TestPress:

20.1 BAR (291 PSI)

Bearing Sizes: DRIVE END: SKF RMS16 BallPUMP END: SKF CMR16Roller

Estimated Bearing Life: MIN. SPEED/MAX. LOAD: 15,000 hoursMAX. SPEED/MIN. LOAD: 11,280 hours

Type of Bearing Lubrication: Grease lubrication Shell Alvania RA orequivalent

Type of Shaft Seal: Mechanical seal silicon carbide faces dryrunninglubrication from oil reservoir behind seat.Pump out vanes on rear of impeller shroud.Balance holes.


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TECHNICAL DATA SHEET No. 2

MATERIALS OF CONSTRUCTION:

Pump Casing: S.G. IRON TO AS1831 GRADE SG 400/12Suction Cover: S.G. IRON TO AS1831 GRADE SG 400/12Air Separation Tank: S.G. IRON TO AS1831 GRADE SG 400/12Bearing Bracket: S.G. IRON TO AS1831 GRADE SG 400/12Pump Shaft: 431 Stainless SteelImpeller: 316 Stainless Steel

Wearplates: 316 Stainless SteelAir Injector: 316 Stainless SteelSeal Housing: St/Steel 316 GradeMechanical Seal: Crane type 1A 2" CODE BJ1S1/DLip Seal: Nitrile Rubber 2" ID x 3/8" WideN.R.V. Body: S.G. IRON TO AS1831 GRADE SG 400/12N.R.V. Rubber: Nitrile or Polyurethane Rubber 55/60 ShoreCompressor Drive Details: COMPRESSOR PULLEY: Tooth Belt ½" Pitch Heavy x

40 Teeth (P/N. 26-0830-0243)DRIVE PULLEY: Tooth Belt ½" Pitch Heavy x

32 Teeth (P/N. 10-0000-0049)Number & Belt Section: 1 x Timing Belt 38mm Wide 390H150 (P/N. 26-0840-9912)

Compressor Details: Bendix 2W 440 R Twin-inline cylinders 75m x 50mmstroke. Air cooled 15cfm (410L/min) at 1000rpm,Lubrication from engine oil system.

Ejector Details: Jet: 23-0415-2016S Venturi: 23-0414-2036S

OPERATING & MAINTENANCE INSTRUCTIONS


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DESCRIPTION OF UNIT

The pump is basically a simple end suction pump which has a completelyautomatic priming system built into the design. This enables the pump to selfprime from a completely dry condition even with a long suction line. No liquid of

any nature is required to prime the pump and therefore in temporary dry trenchconditions the pump will 'snore' until such time as liquid is available.

The DRI-VAC principal utilises a standard air compressor feeding a pneumaticejector mounted above the air/water separation tank. With this device, suctionlifts up to 8.2m (27 ft) can be obtained.

It can handle unscreened sewage, trade effluents, thick slurries and solids up to anormal limitation of 29mm.

The impeller is a three bladed, stainless steel construction, designed fully open. Itis mounted on a shaft made from 431 stainless steel fitted in a cast iron bearingbracket; which also provides concentric location for the pump body.

The pump body cast iron construction fitted with stainless steel wearplates.

The mechanical seal is leak tight and suitable for sewage and sludges using asilicon carbide face on a silicon carbide seat. The arrangement incorporates anoil-filled seal housing.

The whole unit is mounted on a robust skid base chassis. It is fitted with towingeyes, lifting frame. The fuel tank has a capacity of 580L.

Guards are fitted as standard to all moving parts.

For any engine details please refer to your engine manual or spare parts manual.

Note: If your HH125 pumpset has been mounted on a trailer chassis it isrecommended that after approx. 5 km of travel that all wheel nuts be inspectedand re-tightened.


Operation


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Before attempting to start the unit familiarise yourself with the engine controls asmentioned in the Manufacturers Handbook and also the starting procedure. It isadvisable to turn the unit over slowly by hand before starting, to ensure that allcomponents are free and easy to turn. Once started the compressor will

automatically come in at the correct speed to prime the pump unit. When theengine has started the pump requires no adjustment as the engine speeds are setat WORKS.

Bearing Bracket And Pump

When replacing any castings, before use check for burrs, bruising, foreign bodies,porosity i.e. Bearing Bracket, Pump Body, Impeller, Shaft, Suction Cover, SealHousing and Components.

Check the fit of the inner race for a reasonable transitional fit. When replacing theinboard ball bearing it is fitted on the inner race only with Loctite "Bearing Fit" andcured with Loctite Grade T. Check the inner and outer race for excessive wearand rough spots in rotation and if still present reject the ball race. If alright repackapproximately two thirds with new grease. Shell Alvania RA or No. 2 or nearequivalent grade. Do not over-grease. Check grease cups for condition of greaseand quantity. Check seal are not excessively worn. Check water thrower ispresent and in reasonable condition.

The bearings used are ball bearings 4½" x 2" x 1.1/16"RMS16 S.K.F.

Roller bearings (adj to pump) 4½" x 2" x 1.1/16"C.R.M. 16 S.K.F.

Examine the shaft end over which the seal is fitted for burrs, bruises, etc. whichare likely to damage the seal during fitting.

Preparation And Seal Fitting Of Mechanical Seal

Inspect seal seat face for blow holes, scores, or wear marks, etc. Ensure thatthere is a minimum lead-in radius of 1mm into the seal seat recess on sealextension housing.

When a seal is reconditioned, it should be ground to a surface finish of 10-20C.L.A. and lapped to within 3 sodium light bands. Seals with only a ground finishare unsatisfactory, and will result in excessive wear of the faces.

Check that the lip seal in the rear of the seal housing is not excessively worn,renew if required.

Extreme care should be taken when fitting the silicon carbide faced seal as thismaterial is very brittle and easily chipped.



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Preparation And Seal Fitting Of Mechanical Seal - Cont'd

If the seal cannot be inserted with fingers it should be pushed home with a length ofsoft tube or wood large enough in diameter to make contact around the outer edge ofthe seat; clear of the sealing area.

Before fitting the rotating seal unit ensure that all surfaces are clean and that all edgesover which the bellows have to pass are rounded-off to approximately 1mm radius. Allworking faces must be clean and free from any foreign matter.

Smear pump shaft with light oil (not grease). Fit the taper tool over the shaft (Fig. 1)and mount seal face ring on the bellow unit. For assembly purposes it is permissibleto put a smear of grease behind the ring, to hold it in place during assembly over thetaper sleeve and into place on the shaft. A soluble grease is preferable e.g. Swarfega.

Before fitting the seal housing dampen the joint with water.

Whether the wear plates or impeller have been replaced or not, the followingprocedures should be observed:-

* Ensure that the impeller will screw-up to the shaft shoulder and that the threadform has not been damaged.

* Using adjusting shim washers behind the impeller boss (if necessary) set the frontand back clearance to within 0.50/0.70mm.

* Before finally fitting the impeller, grease shaft areas and pump casing bore whereseal assembly passes through. This will also assist future removal of impeller andseal assembly. The recommended grades of lubricant for this are:- 'Copperslip' or'Shell Alvania' grease plus Molybdenum Disulphide or Rocal Anti-Seize compoundJ166.

* Non-adhesive sealant to be used on all plugs including filler and drain plug e.g.Boss White, Non-Adhesive Hermatite, Loctite Hydraulic Sealant.

If pump units are to remain in stock unused for long periods of time, all adjacent closeclearance surfaces should be sprayed with an aerosol can of Molyslip A.D.F. to

prevent rust and seizure.Separation Tank And Ejector

Dri-Prime Ejector Pack Assembly:

Check ejector and jet sizes: Nozzle 23-0414-2036SJet 23-0415-2016S

Clean the jet and nozzle with paraffin or similar cleaner. On no account should stiffwire be used as this will enlarge the bores.


Separation Tank And Ejector - Cont'd


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Check the nozzle and jet bores for any sharp edges, burrs or rough surfaces. Ifdamaged and no replacement is readily available, smooth and polish as well as possibleto original form.

Alignment of jet and nozzle is important but this is preset by machining tolerances andthe use of standard copper-asbestos washers.

Assemble ejector unit and check performance on test unit. Operation Air Pressure: 40psi approx. Minimum Pass Vacuum: 24" Mercury (27.24ft)

When the above figure is not obtained, the distance between the nozzle and ejector maybe slightly adjusted by an additional copper washer with one or both to obtain thevacuum required.

A satisfactory arrangement for carrying out the performance test on the ejector unit is aplate fitted with a vacuum gauge as illustrated .


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NON-RETURN VALVE

Ensure that all items are clean and free from burrs.

Visually check for porosity and blow holes in the castings and for scores orchaffing of the valve.

COMPRESSOR

The standard compressor pack assembly comes complete with timing belts andpulleys and is a direct drive off the pump shaft.

As an option a compressor, driven directly from the engine is also available.

TEST PROCEDURE

VACUUM TEST

When the bearing bracket and complete pump end have been assembled andbefore the cavity behind the mechanical seal seat has been filled with oil, thepump should be subjected to a vacuum test to show up any air leaks.

Air leaks may occur from the mechanical seal, non-return valve, the ball N.R.V., inthe ejector plate, pump joints, porous castings or from filling and drain plugs.

The assembled pump end should seal against a minimum vacuum of 81kPa (8m).With closed valves, the vacuum should hold for a minimum of 5 minutes.

Fill seal housing after test is completed with Shell engine oil or equivalent until thelevel reaches the threads of the filler hole.

Pressure test complete; pump unit to 1½ times maximum working pressure i.e.2052kPa (300 psi).

DYNAMIC TEST

Rotate engine on starter for a minimum of six complete revolutions, listen forinjector 'creak' - indicating the injector pump is working.

Start pump and run completely dry for a minimum period of 10 minutes. During

this period generally check and observe for any unusual vibrations, overheating,fuel, oil or air leaks.


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DYNAMIC TEST- Cont'd

After the dry running period check that the pump unit will raise a minimum vacuumof 81kPa ie. 8m.

Couple hoses to the pump suction and delivery; test from a deep well pit at asuction lift of approximately 7.5m. Record priming time.

This hydraulic test should be repeated several times until satisfied that allcomponents are functioning correctly. The duration of the hydraulic test should bea minimum of 20 minutes.

At the end of the hydraulic test again check that the pump will raise a vacuum of81kPa.

.


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GENERAL MAINTENANCE

BEARINGS (GREASE CAPS)

CHECK FOR GREASE QUANTITY AND QUALITY AT EACH START UPOPERATION. USE SHELL ALVANIA RA OR NO. 2 OR EQUIVALENTGREASE .

(REFER ITEM BB22 IN PARTS LISTING).

MECHANICAL SEAL

- CHECK OIL LEVEL AT EACH START UP OPERATION- FILL WITH A LIGHT ENGINE OIL TO WITHIN 25MM FROM

THE TOP OF THE RESERVOIR .

(REFER ITEM BB11 IN PARTS LISTING).


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PUMP PROBLEMS - Systems & Likely Causes

1. Pump does not prime Suction lift too great.Insufficient water at suction inlet.Suction inlet or strainer blocked.Suction line not air tight.Suction hose collapsed.Non return valve ball not seatingMechanical seal drawing air into pumpEjector jet or nozzle blocked or badly worn.Ejector non-return valve ball stuck.Separation tank cover blocked.Compressor pipe leaking air.Compressor no delivering sufficient airCompressor belt drive faulty.

2. Not enough liquid 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.

3. Pump ceases to deliver liquidafter a time.

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 drawing air into pump.Obstruction in pump casing/impeller.Delivery hose punctured or blocked.

4. Pump takes excessive power Engine speed too high.

Obstruction between impeller and casing.Viscosity and SG of liquid being pumped toohigh.

5. Pump vibrating oroverheating

Engine speed too high.Obstruction in pump casing/impeller.Impeller damaged.Cavitation due to excessive suction lift.

6. Pump leaking at seal housing Mechanical seal damaged or worn.


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PARTS LISTS


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ILLUS.No. DESCRIPTION PART No. QTY.H1 Body 11-0195-0155 1H2 Impeller 12-0244-3015 1H3 Front Cover 11-0196-0000 1

H4a Joint (Body) 38-0300-5413 A/RH4b Joint (Body) 38-0300-5423 A/RH4c Joint (Body) 38-0300-5433 A/RH5 Wearplate (Front) 12-0243-0915 1H6 Setscrew M12 x 36 8H8 Wearplate (Rear) 12-0251-0915 1

H12 Seal Unit 38-0814-BJ1S1/D 1

H13 Dowel Pin 10-0000-0025 1H14 Seal Extension Joint 38-0333-5413 1H15 Seal Housing 14-0303-2911 1H16 Bolt M6 x 55 4H17 Spring Washer M12 4H18 Stud M12 x 50 12H19 Nut M12 12H20 Spring Washer M12 12H21 Flat Washer M12H26 Plug 2

H28a Impeller Shim 36-0557-8213 A/RH28b Impeller Shim 36-0557-8223 A/RH29 O Ring Sealing Washer SS

Viton O Ring38-0785-441238-0787-4112V

44

H31 Setscrew M12x35 SS Sockethead 1H50 Oil Seal 38-0533-1913 1H66 Seal Spacer 24-0168-6111 1H68 O-ring (Seat) 38-1067-4112 1H83 Hose 346-5371 12

VOLUTE


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ILLUS. No. DESCRIPTION PART No. QTYEP1 Ejector Jet 23-0415-2016S 1EP2 Ejector Nozzle 23-0414-2036S 1

EJECTOR PACKAGE


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ILLUS. No. DESCRIPTION PART No. QTYST1 "T" Piece 348-4006 1ST2 Tank/Body Joint 500-4051 2ST5 Flat Washer M20 16ST6 Ejector Carrier Plate 23-0411-0115 1ST8 Stud M12 x 50 4ST9 Nut M12 8

ST10 Flat Washer M12 8ST11 Ball Seat 23-0412-2011 1ST12 Ball 39-0641-4113 1ST13 Plug 1" BSP P16 1

ST14 Filter 23-0413-2113 1ST16/17 Elbow ¾”BSP FM to 3/4” Hosetail E12SBF 1

ST21 Bolt M20 x 75 8Not Shown Vacuum Gauge 001-0003 1

SEPARATION TANK / EJECTOR


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ILLUS. No. DESCRIPTION PART No. QTYAC1 Compressor (Bendix) 49-0523-9915 1

AC2 Gasket KX2542/1 1AC3 Setscrew M10 x 25 4AC4 Springwasher M10 4AC5 Pulley - Pump ( bored to suit TLB) c/w

2517 x 1-7/8” Taper Lock Bush10-0000-003910-0000-0035

1

AC6 Pulley (Compressor) 26-0830-0243 1AC7 Belt 38 wide x 78 teeth (1/2” Heavy Pitch) 26-0840-9912 2AC8 Fan Washer 36-0556--8111 1AC9 Relief Valve 10-0000-0004 1

AC10 Air Cleaner 54-0556-9912 1AC11 Adaptor (Air Cleaner) A1212 1AC13 Compressed Air Hose 42-0000-0009 1AC14 Elbow ¾ BSP x ½ BSP E1208HMM 1AC15 Pulley/Belt Guard 1


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ILLUS. No. DESCRIPTION PART No. QTYREFLUX BOX COMPLETE 356-2124HH 1

V1 Reflux Box Body 356-4061HH 1V2 Stud M20 x 65 8V3 Nut M20 8V4 Stud M20 x 70 4V5 Flat Washer M20 4V6 Nut M20 4V7 Reflux Box Cover 356-4062 1V8 O-Ring 356-4153 1V9 Reflux Box Seat 356-4063 1

V10 Reflux Box Ball 313-4169 1V11 Drain Cock 920-9242 1V12 Joint 500-4051 1V13V14 Nut M20 8V15 Flat Washer M20 8V16 Bolt M20 x 70 8

REFLUX BOX ASSEMBLY – 150MM HIGH HEAD


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ACCESSORIES

Description Part No.


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ENGINE

hh125 smanual completed - master updated 30-3-06

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