HH220i sMaster Manual

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Reference

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Sykes HH220i

Sykes HH220i – Installation, Operation & Maintenance Manual – Installation, Operation & Maintenance Manual

Sykes Group Pty Ltd

Sykes Group Pty Ltd Spare Spare Parts Parts & & Service Service 24 24 hours: hours: 1800 1800 131950131950 Website: www.sykesgroup.com Website: www.sykesgroup.com

1 CUSTOMER SPECIFICATION

General Unit Information Customer

Sykes Job Number Sykes Serial Number Plant Number

Pump Information

Pump Type HH220i

Pump Size 200mm x 150mm

Impeller Diameter ∅_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 Valvoline Multi Lube Lithium

grease EP Additives NLGI # 3 or Equivalent (high temperature grease)

Oil Lubricated Bearings Valvoline Hydraulic oil 68 or

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2 TECHNICAL DATA SHEET

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MATERIALS OF CONSTRUCTION DESIGN DETAILS

Pump Casing: SG Iron To AS1831 Grade 400/12 Pump Designation: HH220i

Suction Cover: SG Iron To AS1831 Grade 400/12 Pump Description: Centrifugal Single Stage, Volute Type, 4 bladed fully open Tee Piece: SG Iron To AS1831 Grade 400/12 Suction Flange: 200mm Table ‘E’

Bearing Bracket: SG Iron To AS1831 Grade 400/12 Delivery Flange: 200mm Table ‘E’ Pump Shaft: 431 Stainless Steel Nominal Casing Thickness: 16mm

Impeller: 316 Stainless Steel Nominal Shaft Diameter: 75mm

Wear Plates: 316 Stainless Steel Impeller Eye Diameter: 200mm Air Injector: 316 Stainless Steel Maximum Impeller O.D.: 432mm Mechanical Seal: Silicon Carbide / Silicon Carbide Minimum Impeller O.D.: 380mm Non Return Valve 150mm Reflux Box NRV Solids Handling Size: 75mm

Compressor Pulley: 40H150 ½” Pitch Heavy Operating Speed: MIN: 1400rpm MAX: 2200rpm

Drive Pulley: 32H150 ½” Pitch Heavy Maximum Head: 139m

Belt Section: 390H150 Timing Belt Maximum Capacity: 1030 l/s

DRIVE END: 7317 BALL Compressor Details: Bendix 2W 440 R Twin-in-line

cylinders 75mm x 50mm stroke, air cooled 15cfm (410L/min) at 1000rpm Lubrication from engine oil system.

Bearing Sizes:

PUMP END: NU318 ROLLER Ejector Details: _Jet: _{23-0415-2016S}

Nozzle: 23-0414-2036S

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

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3 HOW TO READ A PERFORMANCE CURVE

3.1 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: Difference in elevation between liquid level of the suction and the centre line of the pump.

Static Discharge Head: Difference in elevation between liquid levels of the centre line of the pump and the discharge.

Friction Head: Equivalent head necessary to overcome friction on the

interior surfaces of the pipework system including all valves, bends and fittings.

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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 = 1.1m (point E).

8) Dynamic Suction Lift Available (DSLA)

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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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).

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Figure A – 100% Best Efficiency Flow Figure B – Reduced Flow

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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.

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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 Gravity Pressure Chemical Radiant Biochemical

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 likely is it to happen?

How severely could it hurt someone or how

ill could it make someone ( A ) VERY LIKELY could happen any time (B) LIKELY could happen sometime (C) UNLIKELY

could happen but very rarely

(D)VERY UNLIKELY

could happen but probably never will (1) Kill or cause permanent disability or ill health

1

2

3

(2 ) Long term illness or serious injury

1

2

3

4

(3)Medical attention and several days off work

2

3

4

5

(4)First aid

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Sykes Group Pty Ltd Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com

5 RISK ASSESSMENT – HH220i

No. Activity 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

• _{Only qualified personnel to use lifting}

equipment

• Hoisting acceleration should not exceed 0.4m/sec2

• _{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}

2 Setting up the

Pumpset Slips, trips, strain, sprains and pinch points B 3 3

• _{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}

3 Operation of

Pumpset Excessive Noise – hearing loss B 2 2

• Wear hearing protection at all times when working or operating around the Pumpset

• _{Stop & think}

Sykes Group Pty Ltd Spare Parts & Service 24 hours: 1800 131950 Website: www.sykesgroup.com No. Activity Hazard & Type of Injury Risk Likelihood Consequence

Risk

Operation of Pumpset

Boom movement (Suction Hose Boom) – pinch

points & crushing B 2 2

• Wear correct PPE

• Stop & think

• _{Do not operate Pumpset in known}

unsafe conditions

• _{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}

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

• _{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}

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Risk

Boom movement (Suction Hose Boom) – pinch

points & crushing B 2 2

• Do not operate Pumpset in known unsafe conditions

• _{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}

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

• _{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

Risk

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

• Stop & think

• _{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}

Possible electrocution – electric shock and

burns B 1 1

• _{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}

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Risk

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

• _{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

Possible electrocution – electric shock and

burns B 1 1

• _{Only Authorised Personnel to work on}

• _{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

Risk

Possible fire and explosion – burns, bodily

injuries and possible death B 1 1

• 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

4 Maintenance

-Battery charging Possible explosion – burns and bodily injuries B 1 1

• _{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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Risk

Possible fire and explosion – burns, bodily

injuries and possible death B 1 1

• Ensure correct fire extinguisher is available

• _{Do not refill the fuel tank while engine is}

running

• _{Never store oily rags in metal covered}

containers

other sources of ignition around fuel or batteries

• _{Do not operate the Pumpset system with}

any known leaks in the fuel system

• _{Open exhaust system drain plugs after}

repeated failed start attempts

4 Maintenance

-Battery charging Possible explosion – burns and bodily injuries B 1 1

• _{Correctly isolate equipment}

other sources of ignition around batteries

• _{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

Sykes HH220i

Sykes Group Pty Ltd

Sykes Group Pty Ltd Spare Spare Parts Parts & & Service Service 24 24 hours: hours: 1800 1800 131950131950 Website: www.sykesgroup.com Website: www.sykesgroup.com No.

No. Activity Activity Hazard Hazard & & Type Type of of Injury Injury RiskRisk Likelihood ConsequenceLikelihood Consequence

Risk Risk Rating

Rating Eliminate / Reduce / Control the risk byEliminate / Reduce / Control the risk by

Maintenance Maintenance -Electrical Electrical

Possible electrocution – electric shock and Possible electrocution – electric shock and burns

burns B B 1 1 11

•

• Wear Wear correct correct PPEPPE

•

• Stop Stop & & thinkthink

•

• _Correctly_{Correctly isolate}_{isolate equipment}_equipment •

• Only Only Authorised Authorised Personnel Personnel to to work work onon electrical equipment

•

• _Do_{Do not}_{not attempt}_{attempt to}_{to connect}_{connect or}_{or disconnect}_disconnect

load while standing in water or on wet or load while standing in water or on wet or soggy ground

soggy ground

•

• Ensure Ensure all all electrical electrical power power is is isolatedisolated from electrical equipment being serviced from electrical equipment being serviced

•

• _Keep_{Keep all}_{all electrical}_{electrical equipment}_{equipment clean}_{clean and}_and

dry dry

•

• _Keep_{Keep terminals}_{terminals clean}_{clean and}_{and tight}_tight •

• _Test_{Test earth}_{earth leakage}_{leakage equipment}_{equipment regularly}_regularly •

• Ensure Ensure correct correct fire fire extinguisher extinguisher isis available

available

Maintenance – Maintenance – refilling fuel tank refilling fuel tank

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

poisoning, burns & skin irritation B B 3 3 33

•

• _Stop_{Stop &}_{& think}_think •

• _Wear_{Wear correct}_{correct PPE}_PPE •

• Check Check all all hoses hoses and and fittings fittings for for crackscracks and leaks

and leaks

•

• _Ensure_{Ensure spillages}_{spillages are}_{are contained}_contained •

• _MSDS_{MSDS available}_{available for}_{for fuel}_{fuel used}_{used in}_{in lighting}_lighting

tower tower

•

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Sykes HH220i

Sykes Group Pty Ltd

Risk Risk Rating

Maintenance Maintenance -Electrical Electrical

Possible electrocution – electric shock and Possible electrocution – electric shock and burns

burns B B 1 1 11

•

• Correctly Correctly isolate isolate equipmentequipment

•

• _Only_{Only Authorised}_{Authorised Personnel}_{Personnel to}_{to work}_{work on}_on

electrical equipment electrical equipment

•

• Do Do not not attempt attempt to to connect connect or or disconnectdisconnect load while standing in water or on wet or load while standing in water or on wet or soggy ground

soggy ground

•

• _Ensure_{Ensure all}_{all electrical}_{electrical power}_{power is}_{is isolated}_isolated

from electrical equipment being serviced from electrical equipment being serviced

•

• _Keep_{Keep all}_{all electrical}_{electrical equipment}_{equipment clean}_{clean and}_and

dry dry

•

• _Keep_{Keep terminals}_{terminals clean}_{clean and}_{and tight}_tight •

• Test Test earth earth leakage leakage equipment equipment regularlyregularly

•

• _Ensure_{Ensure correct}_{correct fire}_{fire extinguisher}_{extinguisher is}_is

available available

Maintenance – Maintenance – refilling fuel tank refilling fuel tank

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

poisoning, burns & skin irritation B B 3 3 33

•

• _Check_{Check all}_{all hoses}_{hoses and}_{and fittings}_{fittings for}_{for cracks}_cracks

and leaks and leaks

•

• Ensure Ensure spillages spillages are are containedcontained

•

• _MSDS_{MSDS available}_{available for}_{for fuel}_{fuel used}_{used in}_{in lighting}_lighting

tower tower

•

• _Educate_{Educate employees}_{employees of}_{of burn}_{burn hazards}_hazards

Sykes HH220i

Sykes Group Pty Ltd

Risk Risk Rating

Maintenance Maintenance -mechanical mechanical

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

pinch points, skin irritation

B

B 2 2 22

•

• Stop Stop & & thinkthink

•

• Wear Wear correct correct PPEPPE

•

• MSDS MSDS available available for for items items used used inin Pumpset

Pumpset

•

• _Ensure_{Ensure spillages}_{spillages are}_{are contained}_contained •

and leaks and leaks

•

• _Correctly_{Correctly de-energise}_{de-energise hydraulic}_{hydraulic system}_system •

• _Ensure_{Ensure guarding}_{guarding is}_{is in}_{in place}_{place and}_{and secure}_secure

after maintenance is finished after maintenance is finished

•

• _Do_{Do not}_{not remove}_{remove the}_{the radiator}_{radiator filler}_{filler cap}_{cap until}_until

the coolant has cooled. Then loosen the the coolant has cooled. Then loosen the cap slowly to relieve any excess cap slowly to relieve any excess pressure before removing the cap pressure before removing the cap completely

completely

•

• _Educate_{Educate employees}_{employees on}_{on hazards}_{hazards of}_{of hot}_hot

coolant and oil under pressure coolant and oil under pressure

•

• _Educate_{Educate employees}_{employees of}_{of burn}_{burn hazards}_hazards •

available available

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Sykes HH220i

Sykes Group Pty Ltd

Risk Risk Rating

Maintenance Maintenance -mechanical mechanical

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

pinch points, skin irritation

B

B 2 2 22

•

• Correctly Correctly isolate isolate equipmentequipment

•

• _MSDS_{MSDS available}_{available for}_{for items}_{items used}_{used in}_in

Pumpset Pumpset

•

• Ensure Ensure spillages spillages are are containedcontained

•

and leaks and leaks

•

• _Correctly_{Correctly de-energise}_{de-energise hydraulic}_{hydraulic system}_system •

• _Ensure_{Ensure guarding}_{guarding is}_{is in}_{in place}_{place and}_{and secure}_secure

after maintenance is finished after maintenance is finished

•

• Do Do not not remove remove the the radiator radiator filler filler cap cap untiluntil the coolant has cooled. Then loosen the the coolant has cooled. Then loosen the cap slowly to relieve any excess cap slowly to relieve any excess pressure before removing the cap pressure before removing the cap completely

completely

•

• _Educate_{Educate employees}_{employees on}_{on hazards}_{hazards of}_{of hot}_hot

coolant and oil under pressure coolant and oil under pressure

•

• _Educate_{Educate employees}_{employees of}_{of burn}_{burn hazards}_hazards •

available available

Sykes HH220i

6 6 PUMP

PUMP OPERATING

OPERATING INSTRUCTIONS

INSTRUCTIONS

6.1

6.1 Description Description of of Pump Pump UnitUnit The pump is basically a

The pump is basically a simple end suction pump which has a simple end suction pump which has a completely automaticcompletely automatic priming system built into

priming system built into the design. the design. This enables the pThis enables the pump to self-prime from aump to self-prime from a completely dry conditio

completely dry condition even with a long n even with a long suction line. suction line. No liquid of any No liquid of any nature isnature is

required to prime the pump and therefore in temporary dry trench conditions the pump required to prime the pump and therefore in temporary dry trench conditions the pump will 'snore' until such time as liquid is

will 'snore' until such time as liquid is available.available.

It can handle unscreened sewage, trade effluents, thick slurries and solids up to a It can handle unscreened sewage, trade effluents, thick slurries and solids up to a normal limitation of 75mm.

normal limitation of 75mm. The impeller is a 4

The impeller is a 4 bladed, 316 Stainlesbladed, 316 Stainless Steel construction, s Steel construction, design fully open. design fully open. It isIt is mounted on a shaft made from 431 stainless steel fitted in an SG

mounted on a shaft made from 431 stainless steel fitted in an SG iron bearing bracket;iron bearing bracket; which also provides concentric location for

which also provides concentric location for the pump body.the pump body.

The pump body is SG iron construction fitted with Stainless Steel wear plates secured The pump body is SG iron construction fitted with Stainless Steel wear plates secured by high tensile steel

by high tensile steel screws.screws.

The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The arrangement incorporates glycol lubricated seal housing.

The arrangement incorporates glycol lubricated seal housing. Guards are fitted as standard to all moving parts.

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Sykes HH220i

Sykes Group Pty Ltd

6 6 PUMP

PUMP OPERATING

OPERATING INSTRUCTIONS

INSTRUCTIONS

6.1

6.1 Description Description of of Pump Pump UnitUnit The pump is basically a

The pump is basically a simple end suction pump which has a simple end suction pump which has a completely automaticcompletely automatic priming system built into

priming system built into the design. the design. This enables the pThis enables the pump to self-prime from aump to self-prime from a completely dry conditio

completely dry condition even with a long n even with a long suction line. suction line. No liquid of any No liquid of any nature isnature is

required to prime the pump and therefore in temporary dry trench conditions the pump required to prime the pump and therefore in temporary dry trench conditions the pump will 'snore' until such time as liquid is

will 'snore' until such time as liquid is available.available.

It can handle unscreened sewage, trade effluents, thick slurries and solids up to a It can handle unscreened sewage, trade effluents, thick slurries and solids up to a normal limitation of 75mm.

normal limitation of 75mm. The impeller is a 4

The impeller is a 4 bladed, 316 Stainlesbladed, 316 Stainless Steel construction, s Steel construction, design fully open. design fully open. It isIt is mounted on a shaft made from 431 stainless steel fitted in an SG

mounted on a shaft made from 431 stainless steel fitted in an SG iron bearing bracket;iron bearing bracket; which also provides concentric location for

which also provides concentric location for the pump body.the pump body.

The pump body is SG iron construction fitted with Stainless Steel wear plates secured The pump body is SG iron construction fitted with Stainless Steel wear plates secured by high tensile steel

by high tensile steel screws.screws.

The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat. The arrangement incorporates glycol lubricated seal housing.

The arrangement incorporates glycol lubricated seal housing. Guards are fitted as standard to all moving parts.

Guards are fitted as standard to all moving parts. Suction flange 200mm Table ‘E’.

Suction flange 200mm Table ‘E’. Delivery flange 200mm Table ‘E’. Delivery flange 200mm Table ‘E’. Note

Note

If your HH220i pumpset has been mounted on a trailer chassis, it is recommended that If your HH220i pumpset has been mounted on a trailer chassis, it is recommended that after approximately 5 km of travel that all w

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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

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6.5 Ejector Test

6.5.1 Dri-Prime Ejector Pack Assembly

1. Check ejector and jet sizes: Nozzle 23-0414-2036S

Jet 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.

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7 PUMP MAINTENANCE INSTRUCTIONS

7.1 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.

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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.

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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.

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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 b) Shaft Sleeve c) Stuffing Box Back Plate

d) Pump Frame e) Impeller f) Studs, Nuts & Bolts

2. Inspect and de-burr pump parts:

a. Replace shaft or repair shaft if worn in secondary sealing area under o-rings.

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

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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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Website: www.sykesgroup.com 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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Website: www.sykesgroup.com 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 75mm

Stroke 50mm

Swept Volume 441.6 cm3 Maximum Recommended Speed 2400 r.p.m. Maximum Recommended Delivery

Pressure 9bar (130 p.s.i.) Operating temperature Range -40°C to + 80°C Maximum Continuous delivered

Air Temperature

(See 'Installation') 220°C Weight 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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Website: www.sykesgroup.com Maintenance: Before working on or around air

brake systems and components always observe the following precautions:

a) Stop the engine before working under a vehicle.

b) Always chock the vehicle wheels, because depleting the vehicle air system pressure may cause the vehicle to roll. c) Keep hands away from actuator push rods

and slack adjusters. They may apply as the system pressure drops.

d) Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes.

e) Never remove a component or pipe plug unless you are certain all system pressure has been depleted.

f) Never exceed recommended air pressure. g) Always wear safety glasses when working with air pressure. Never look into air jets or direct them at anyone.

h) Never attempt to dismantle a component until you have read and understand recommended procedures.

i) Some units contain powerful springs and injury can result if not properly dismantled. j) 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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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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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.

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7.3.4 Compressor Parts List

Ref. Description Part Number

Bendix Air Compressor 2W 440 R KZ1087/14 49-0523-9915

A Valve Plate Assembly c/w Reed Valve Kit & Air Inlet Valve KY2331/1SP

B Cylinder Head KZ1160/3

C ¾” BSP Threaded Air Delivery Connection

D ½” Threaded Water Cooling Ports

E ¾” BSP Threaded Air Inlet

F Reed Valve Kit SK2955/1

G Air Inlet Valve 229502

H Valve Plate & Head Gasket Kit

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

SK2997/1 J Cylinder Body KZ1094/1 Piston Assembly (STD) (KW5172/1SP) 1189082SP Piston Assembly (KW5172/2SP) 1189255SP K Piston Assembly (KW5172/3SP) 1189256SP

Piston Ring Set (STD) (SKR2790/00) SKR2962/00

Piston Ring Set (0.010” o/s) (SKR2790/10) SKR2962/10

Piston Ring Set (0.020” o/s) (SKR2790/20) SKR2962/20

L

Piston Ring Set (0.030” o/s) SKR2962/30

M N P

Oil Control Ring - Included in Piston Assy & Piston Ring Set

Connecting Rod Pin - Included in Piston Assembly

Rod Pin Snap Pin - Included in Piston Assembly

Q Crankshaft KY2258/1SP

R Ball Bearing (NSK-6307-CE) 1194120SP

S Front End Cover KX2491/1

O-Ring, Inner Bearing Cover 1189619

T Crankshaft Oil Seal (CR13938) 267805

U Con Rod Complete

(KW4785/1SP)

1194120SP

V Thrust Washer KY2372/1

W White Metal Bearing Bushing I811560066

X End Cover Assembly c/w Bushing KX1223/13SP

“C” Ring - End Cover 1189571

Y Lubricating Oil Inlet 1/8” BSP

Base Mount Gasket 0.8mm KX2542/1

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HH220i sMaster Manual

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Customer

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Reference

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

1 CUSTOMER SPECIFICATION

2 TECHNICAL DATA SHEET

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 

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3 HOW TO READ A PERFORMANCE CURVE

4 RISK ASSESSMENT GUIDE

1

1

2

3

1

2

3

4

2

3

4

5

6

6 PUMP

PUMP OPERATING

OPERATING INSTRUCTIONS

INSTRUCTIONS

6

6 PUMP

PUMP OPERATING

OPERATING INSTRUCTIONS

INSTRUCTIONS

7 PUMP MAINTENANCE INSTRUCTIONS

BENDIX AIR

COMPRESSOR

TYPE 2W 440 R.