SPP Pumps AC,AL User Manual

Page 1
AUTOPRIME PRODUCT
50_7514A
AC50 & AC75
100M & 150M
AC80 & AC100
OPERATORS HANDBOOK
AUTOPRIME
DIESEL DRIVEN
PUMPSETS
100M_31A
SPP Pumps Ltd. Crucible Close Mushet Industrial Park Coleford Gloucestershire ENGLAND GL16 8PS
Telephone:
01594 832 701
Fax:
01594 836 300
8010019A
A
0
3
_
M
0
0
1
Document No: . W72-002E
Revision No: .................. 12
Revision Note No: . R 39552
Date Issued . August 2012 Produced at SPP Pumps, Coleford, England
Page 2
We SPP Pumps Limited
Sound Level (dB)
Pump Model Measured Guaranteed LWA AC50 & AC75 105 108 AC80 & AC100 106 109 100M & 150M 103 106
Of Crucible Close Mushet Industrial Park Coleford Gloucestershire England GL16 8PS
Declare that:
Equipment: DIESEL DRIVEN CENTRIFUGAL PUMPS Model/Type: AC50 & AC75, AC80 & AC10, 100M & 150M Serial Number: As shown on the Pump Nameplate
in accordance with the following Directives:
Cross 2000/14/EC- Guaranteed sound power level. The conformity assessment procedure followed was in according with ANNEX V of the Directive.
DECLARATION OF
CONFORMITY
2004/108/EC The Electromagnetic Compatibility Directive and its amending directives
2006/42/EC The Machinery Directive and its amending directives
2000/14/EC The Noise Emissions Directive and its amending directives
have been designed and manufactured to the following specifications:
EN 809:1998+A1:2009 Pump and pump unit for liquids – common safety requirements EN 12162: 2001 Liquid pumps – Safety requirements – Proceedure for hydrostatic testing.
EN 292-2: 1991 Safety of Machinery- Basic concepts, general principles for design. EN 61000-6-4: 2001 Electromagnetic compatibility (EMC). Generic standards. Emission standard
for industrial environment.
EN 61000-6-1: 2001 Electromagnetic compatibility (EMC). Generic standards. Immunity for
residential, commercial and light-industrial environments.
EN 3744: 1995 Acoustics- Determination of sound power levels of noise sources using sound
pressure- Engineering method in an essentially free field over a reflecting plane
We hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications. The units comply with all essential requirements of the Directives
Signed:
Name: John Hollins
Position: Engineering Manager - Authorised to sign on behalf of SPP Pumps Limited
Mushet Industrial Park, Coleford, Gloucestershire, England, GL16 8PS
Date: 12 February 2010
W72-002E
A copy of this certificate has been submitted to the European Commission and UK Authority
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 16
Page 3
Operators Handbook for
Diesel Driven Pump Sets
Manual No/Rev
W72-002E / 11
CONTENTS
1. INTRODUCTION .................................................................................... 4
1.1 PUMP DESIGNATIONS ........................................................................................... 4
1.2 PUMP TYPES .......................................................................................................... 4
2. SAFETY PRECAUTIONS ...................................................................... 6
2.1 SAFETY SYMBOLS ................................................................................................. 6
2.2 PUMP SAFETY PRECAUTIONS ............................................................................. 6
3. TRANSPORT ......................................................................................... 6
3.1 ROAD TOWED ........................................................................................................ 6
3.2 TRAILER OR WAGON CARRIAGE ......................................................................... 6
3.3 MOVEMENT BY LIFTING ........................................................................................ 6
4. SERIAL NUMBER ................................................................................. 7
5. OPERATING INSTRUCTIONS .............................................................. 7
5.1 BEFORE STARTING ............................................................................................... 7
5.2 STARTING ............................................................................................................... 7
5.2.1 Canopy sets ................................................................................................... 7
5.2.2 Open sets ...................................................................................................... 8
5.3 AFTER STARTING .................................................................................................. 8
5.4 STOPPING ............................................................................................................... 8
5.4.1 Canopy sets ................................................................................................... 8
5.4.2 Open sets ...................................................................................................... 8
6. PUMP MAINTENANCE CHART ............................................................ 9
7. MAINTENANCE INSTRUCTIONS ....................................................... 10
7.1 COALESCER (100M, 150, 150M, 200) ................................................................ 10
7.2 OIL RESERVOIR (AC50, AC75, AC80 & AC100).................................................. 10
7.2.1 AC50 & AC75 .............................................................................................. 10
7.2.2 AC80 & AC100 .............................................. Error! Bookmark not defined.
7.3 COUPLING (open coupled sets) ............................................................................ 10
7.4 DRIVE BELT ADJUSTMENT ................................................................................. 10
7.5 PUMP VACUUM PRESSURE SEAL ..................................................................... 11
7.5.1 Close coupled AC50, AC75, AC80 and AC100 pumps ............................... 11
7.5.2 Open coupled pumps .................................................................................. 11
7.6 MECHANICAL SEALS ........................................................................................... 12
7.7 NON-RETURN VALVE .......................................................................................... 12
7.8 PUMP BEARINGS (Open coupled pump sets only) .............................................. 12
7.9 VACUUM PUMP .................................................................................................... 12
7.10 VACUUM PUMP AIR FILTER .............................................................................. 12
7.10.1 Standard air filter ....................................................................................... 12
7.10.2 High Capacity Air Filter .............................................................................. 13
7.11 VALVE GEAR ....................................................................................................... 13
7.12 SURGE CONTROL VALVE ................................................................................. 14
8. FAULT FINDING GUIDE ..................................................................... 15
9. TECHNICAL DATA .............................................................................. 16
10. SPARES & SERVICE ........................................................................ 16
11. COUPLING DETAILS (where applicable) ........................................ 16
12. ENGINE OPERATORS HANDBOOK ................................................ 16
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 16
Page 4
Manual No/Rev
Pump
W72-002 / 11
Operators Handbook for
Diesel Driven Pump Sets
1. INTRODUCTION
The purpose of this handbook is to lay down operating guidelines and simple routine maintenance for the AUTOPRIME range of diesel engine driven mobile pump sets fitted with vacuum pumps.
Instructions and statements contained within this handbook are given with our best intentions and are correct at the time of compilation. They are subject to alteration at any time.
1.1 PUMP DESIGNATIONS
These are derived from the nominal size of the pump discharge and suction pipes with prefix and suffix letters to signify:
A = Air Cooled C = Close Coupled M = High Capacity Pump Design
e.g. An AC100 pump set has an air cooled
engine, is close coupled and has 100mm (4”) bore suction and delivery connections, and -
1.2 PUMP TYPES
Pump Type Driver Starting Trailer
A 100M pump set is a 100m (4”) high
capacity pump. Note that these can be supplied in open or canopied form with either a four wheeled site trailer or two wheeled road trailer chassis.
Vacuum pumps are supplied to suit pumping requirements, there are four main sizes:-
10.2m3/hr (6ft3/min)
30.6m3/hr (18ft3/min)
42.6m3/hr (25ft3/min) 102m3/hr (60ft3/min).
This manual covers the range of units shown below. Note that some units can be fitted with either vacuum pressure seals or tandem mechanical seals. Ensure that the correct instructions and diagrams are being referred to for the particular unit under consideration. Other order specific components may also be fitted. If in doubt over any item consult the unit supplier.
Vacuum
Features
AC50 & AD1 Hand 2 wheel site -hand 6 cfm Close coupled
AC75 Electric
AC80 TR1 Electric 2 wheel site - towed 18 cfm Close coupled
AC100 2 wheel road - towed
100M TR2 Electric 4 wheel site - towed 25 cfm
LPW3 Electric 4 wheel site - towed Noise reducing canopy
2 wheel road - towed
150 TS3 Hand 2 wheel site towed 60 cfm Bronze internals/coated
150M TS3 Hand 2 wheel site towed 60 cfm Bronze internals
TR3 Hand 4 wheel site towed
LPW4 Electric 4 wheel site towed Noise reducing canopy
2 wheel road - towed
200 CD4 Electric 4 wheel site - towed 25 cfm
200 60 cfm
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 4 of 16
Page 5
Operators Handbook for
EXHAUST
SILENCER
LUB OIL
DIPSTICK
(on underside
of filler cap)
VACUUM
LUB OIL
RESERVOIR
SILENCER
ENGINE
FILTER
UNIT
ENGINE
PRIMING
CONTROL
SUCTION
AIR
FILLERS
ENGINE
PRIMING
VALVE
COVER
CONTROL
UNIT
ENGINE
NON RETURN
BATTERY
REFLUX BOX
(NON RETURN
PUMP VACUUM
PRESSURE SEAL
AIR
COALESCER
Diesel Driven Pump Sets
DELIVERY FLANGE (on far side)
PRIMARY TANK
SUCTION FLANGE
BATTERY (electric start only)
50_75GAB
MINI BALL VALVE (in line)
Figure 0-1 AC50 Pump
EXHAUST
DELIVERY FLANGE
VACUUM PUMP
VACUUM PUMP SILENCER
VALVE COVER
ENGINE
VACUUM PUMP
KEYSWITCH & RUNNING HOUR RECORDER (electric start only)
(2” Bauers)
VACUUM PUMP OIL RESERVOIR
ENGINE OIL FILLER
BATTERY
FUEL
(both sides)
PUMP
ENGINE LUB OIL FILTER
FUEL TANK FILLER
STARTER MOTOR (if fitted)
and AC75 Pump
FUEL
FILTER
FILTER
LIFTER
UNIT LIFTER
VACUUM PUMP
(3" Bauers)
SURGE
VALVE
AIR CLEANER
FUEL
STOP LEVER
Site Trailer
VALVE COVER
TANK
Manual No/Rev
W72-002E / 11
FLANGE
8010023A
Figure 0-2 AC80 Pump
(3" Bauers)
and AC100 Pump
ENGINE OIL DIPSTICK
(4" Bauers)
Site Trailer
VACUUM PUMP
FUEL FILLER
SURGE
VALVE
TANK
SUCTION FLANGE
VALVE
100M_32A
EXHAUST SILENCER
PIVOTING TOWBAR
FUEL FILTER
LIFTER
ENGINE DIPSTICK
Figure 0-3 100M-25 Pump and 150M-60 Pump - Site Trailer - Open Set
ENGINE OIL
FILLER AND
DIPSTICK
EXHAUST
VACUUM PUMP
DELIVERY FLANGE
VALVE)
VALVE COVER
PRIMING TANK
SURGE CONTROL VALVE
FILTER
ENGINE COOLANT
SUCTION FLANGE
COALESCER VENT
100M_33A
VACUUM PUMP
FUEL FILLER
FUEL GAUGE
Figure 0-4 100M-25 Pump and 150M-60 Pump - Road Trailer. - Canopied Set
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 16
Page 6
Manual No/Rev W72-002 / 11
2. SAFETY PRECAUTIONS
2.1 SAFETY SYMBOLS
Safety instructions within this manual are marked with the following symbols:
This symbol refers to general mechanical aspects of safety.
This symbol refers to electrical safety.
ATTENTION
This symbol gives warning of a hazard to the pump itself, which in turn could cause a risk to personal safety.
Operators Handbook for
Diesel Driven Pump Sets
2.2.8
2.2.9
3. TRANSPORT
3.1 ROAD TOWED
Always allow adequate ventilation for diesel engines. Be aware of fire risks from items such as exhaust pipes and silencers. Never place flammable items around the unit.
Collapsible hoses must not be used on the suction side of the pump.
Lighting boards are provided for road going trailers.
2.2 PUMP SAFETY PRECAUTIONS
ATTENTION
apply to all the following:-
2.2.1
Never insert anything into the pump casing whilst the pump is running and the suction or delivery hoses are disconnected.
2.2.2
Moving parts are guarded to protect you. Guards removed for maintenance must be replaced before starting the pump.
2.2.3
If the supplied Bauer connections are not utilised, then use all flange bolts when fitting suction and delivery hoses.
2.2.4
Always lift pump sets vertically by the lifting eye. Do not lift with the forks of a fork truck under the fuel tanks. Never lift with suction or delivery hoses attached. The increased weight of these items may cause lifting gear failure.
2.2.5
Check the condition and security of the lifter frame or bracket at regular intervals.
2.2.6
Check the type of liquid being pumped before working on pump ends. Residues could be hazardous to your health. If in doubt flush out with clean water before work commences.
2.2.7
Personnel working on the pump unit must always wear clean, correctly fitting clothing and safety footwear. Clothing impregnated with oil or fuel can constitute a health hazard through prolonged contact with the skin and may also constitute a fire hazard.
3.2 TRAILER OR WAGON CARRIAGE
Transportation on a trailer or wagon will require the unit to be strapped or roped down. Always strap/rope the unit around the chassis - NEVER over the engine, pump or canopy (if fitted).
Ensure that the straps/ropes do not come into contact with any items (switches, drain taps, etc..) which may be vulnerable to damage during transit.
3.3
MOVEMENT BY LIFTING
ATTENTION
If the unit is moved by lifting then the condition and security of the lifter must be checked before use.
The lift must always be vertical on the eye provided.
Never allow the unit to be subject to a ‘snatch’ loading.
Do not allow the unit to swing whilst being lifted.
Keep people away from the area underneath the lifted unit and the immediate surrounding area.
Failure to observe any of the above could result in personnel injury or death due to failure of the lifting gear.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 16
Page 7
Operators Handbook for
SPP Pumps Limited
Reading, RG31 7SP
Tel: ++44(0)118 932 3123
Diesel Driven Pump Sets
Manual No/Rev
W72-002E / 11
4. SERIAL NUMBER
A serial number plate is attached to the unit on the side of the priming tank. This serial number must be quoted in any enquiry for spares or service.
Type
ENGLAND
Fax: 118 932 3302++44(0)
5. OPERATING INSTRUCTIONS
5.1 BEFORE STARTING
5.1.1
Read this Handbook carefully.
5.1.2
Level the unit and jack or chock to prevent movement in use.
5.1.3
Check the engine fuel and lubricating oil levels. Top up as necessary.
5.1.4
If mechanical seals are fitted check
ATTENTION
5.1.8
the reservoir coolant or lubricant level.
5.1.5
Check the vacuum pump drive belt is correctly tensioned.
5.1.6
Hand start engines:- Check that the starting handle is serviceable.
Electric start engines:- Ensure that the
batteries are charged and ready for use.
5.1.7
Radiator cooled engines:- Check the coolant level and that the radiator is free from any debris. Note that these units are fitted with ‘puller’ fans and therefore it is the external face of the radiator which may become blocked.
Air cooled engines:- Check that air inlets
are unobstructed and that the cylinder vanes are free from debris.
AC50, AC75, AC80 & AC100:­Check oil levels in vacuum pump reservoirs.
Other units:- Draw off any water from the
vacuum pump coalescer oil sump via the tap in the side. Check the oil level which should be level with the underside of the cap.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
5.2 STARTING
Page 7 of 16
Nett
Serial No.
5.1.9
Check that the discharge non return valve is seating properly and that there is no debris in the ball chamber that may prevent correct operation.
5.1.10
Select and fit a suitable strainer for the job in hand. Note that most ‘off
ATTENTION
the shelf’ strainers are for general purpose use. As such they may not protect the pump against oversize solids. For applications where stones, etc., may be drawn in, then a strainer with holes slightly smaller than the pump handling capacity must be employed. Refer to the Technical Data section for details on specific pumps.
5.1.11
Connect suction and delivery hoses making sure that there are no sharp bends in the lines. Where the hoses pass over sharp edges or abrasive surfaces ensure that they are protected by suitable means to prevent chafing. Ensure that the suction hose end is fully submerged.
5.1.12
AC50 & AC75: Ensure that the mini ball valve connecting the suction line to the top cover of the pump is in the open position (screwdriver slot aligns with the axis of the body).
Other units: Check that the surge control
valve is fully screwed in. This is the large indented nut surrounding the surge control valve knob on the top of the priming tank.
5.2.1 Canopy sets
The starting panel on these units is under the
right hand door (looking from the tow bar end) and comprises:-
kg
Page 8
Manual No/Rev W72-002 / 11
a) three position keyswitch (Off, 1, &
b) protection override push button c) circuit breaker d) hours run counter e) four warning indicator lamps::­ Charge Oil pressure Water temperature Coalescer oil level
Turn the ignition switch to the '1' position.
All four warning lights will illuminate, providing a check that all circuits are healthy.
Press and hold the override push-button whilst turning the keyswitch to the 'Start' position. Release the keyswitch and push­button once the engine has fired and got away. Do not keep the override push­button depressed for more than 5 seconds after the engine is up to speed.
5.2.2 Open sets
Read the manufacturer’s instructions for the specific engine in conjunction with the following.
Hand start engines:-
1.
Push the decompressor lever(s) to the ‘Stop’ position.
2.
Ensure the stop/run lever is in the ‘Run’ position.
3.
Hand crank the engine as fast as possible and move the decompressor lever(s) to the run position while continuing to crank briskly until the engine starts.
4.
Remove the starting handle.
Electric start engines:-
1.
Push the decompressor lever(s) to the ‘Run’ position.
2.
Ensure the stop/run lever is in the ‘Run’ position.
3.
Turn the keyswitch to the ‘Start’ position whilst pressing the shutdown override push button (if fitted).
4.
Release the keyswitch and push-button once the engine has fired and got away. Do not keep the override push­button depressed for more than 5
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Start)
Operators Handbook for
Diesel Driven Pump Sets
5.3 AFTER STARTING
The pump will prime automatically once the suction hose is submerged. If the pump fails to prime refer to the fault finding guide.
5.4 STOPPING
5.4.1 Canopy sets
Turn the keyswitch to the 'Off' position. The unit will stop and the key can be removed.
Open the volute cock to drain the volute. Close after draining is complete.
5.4.2 Open sets
Read the manufacturer’s instructions for the specific engine in conjunction with the following:-
1.
ATTENTION
2.
ATTENTION
3.
1.
Page 8 of 16
seconds after the engine is up to speed.
Turn the engine stopping lever to the ‘Stop’ position and hold until the engine comes to rest. Never use the decompressor lever(s) for this purpose
Turn the keyswitch to the ‘Off’ position. Failure to turn the keyswitch off will leave the running hour recorder energised and counting which will result in a flat battery. Note that turning the keyswitch off does NOT stop the unit.
Open the volute cock to drain the volute. Close after draining is complete.
Page 9
Operators Handbook for
Diesel Driven Pump Sets
Manual No/Rev
W72-002E / 11
6. PUMP MAINTENANCE CHART
For engine maintenance periods refer to the engine operators handbook at the back of this publication.
PERIOD PUMP SET TASK
Daily All units Visually check for leaks
Check for vibration
Mechanical seal
units
100M,
150, 150M,
& 200
Check mechanical seal coolant/lubricant level and top up as required
Drain any water from coalescer, check oil level and top up as required
Hand test bearing housing for any sign of temperature rise
Weekly or 100 hrs
Monthly or 500 hrs
AC80 & AC100 Check oil level of vacuum pump reservoir
6 monthly or 1500 hrs
Vacuum pressure
Mechanical seal
All units Check all fastener security
Check the condition of the lifter bracket/frame and check the security of attachment to the unit
Check tension of vacuum pump drive belt
AC50 & AC75
100M,
150, 150M,
& 200
All units Check reflux ball is sealing on its seat
seal units
units
Check oil level of suction line reservoir Remove primary tank assembly and check pump internals
for wear Check valve gear - clean or renew filter element
Change coalescer sump oil Clean coalescer sump oil filter mesh Remove front cover and check pump internals for wear Check valve gear - clean or renew standard filter element.
Check high capacity filter element. Grease bearings
Check and if necessary renew vacuum pump drive belt Dismantle and clean valve gear, tank and connecting pipes
Dismantle and clean pump vacuum pressure seal Renew packing
Change mechanical seal coolant/lubricant
Annually or 6000 hrs
100M,
The above schedule is given for guidance but site operating conditions may override the suggested maintenance intervals.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
All units Check vacuum pump blade condition
Check bearing condition
150, 150M,
& 200
Renew coalescer filter mesh
Page 9 of 16
Page 10
Manual No/Rev
Force (kg)
producing
‘X’)
AC75
AC
100
belt
Canopied
Low noise
units
link belt
W72-002 / 11
Operators Handbook for
Diesel Driven Pump Sets
1.
7. MAINTENANCE INSTRUCTIONS
7.1 COALESCER (100M, 150, 150M, & 200)
Check the oil level in the coalescer tank and drain any water daily. The top of the oil should be level with the underside of the filler cap. Water is removed by means of the drain tap fitted to the side of the coalescer sump.
The filter mesh is accessed by removing the coalescer lid and must be cleaned regularly by washing in petrol or a similar spirit. When refitting ensure filter mesh is below exhaust port. The oil feed pipe should be cleaned in a similar manner and blown through with an air line.
7.4 DRIVE BELT ADJUSTMENT
Figure 0-2 Belt tensioning
Pump
sets
AC50 &
AC80 &
Others Timing
Belt type Deflec-
‘X’mm
V belt 5 1.5
V-belt 4 1.5
(toothed)
tion
deflection
4 1.5
Figure 0-1 Coalescer detail
7.2 OIL RESERVOIR (AC50, AC75, AC80 & AC100)
7.2.1 AC57 &AC75
Ensure that oil reservoir is always kept topped up.
7.2.2 AC80 & AC100
Maintain the oil level between the maximum and minimum levels marked on the bottle.
7.3 COUPLING (open coupled sets)
Coupling details are provided at the back of this manual.
PowerTwist A section
1.6 1.5-2.0
To adjust belt tension, loosen the vacuum
pump holding nuts and slide the vacuum pump outward. When the correct belt tension is obtained re­tighten holding nuts. Ensure that the pump drive is in line after tightening.
Link belt drives can be further adjusted by
removing links.
DO NOT OVERTIGHTEN BELTS UNDER
ATTENTION
ANY CIRCUMSTANCES.
For AC50, AC75, AC80 & AC100 pumps
fitted with V belts and other pumps fitted with PowerTwist link belts, the belts can be replaced by slackening the vacuum pump holding down bolts. For other pumps it is necessary to disconnect the coupling to replace the belts.
7.5
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 10 of 16
Page 11
Operators Handbook for
Diesel Driven Pump Sets
PUMP VACUUM PRESSURE SEAL
The seal is product lubricated and therefore
requires only regular inspections of condition, signified by rate of leakage, and eventual replacement. To replace the packing:-
7.5.1 Close coupled AC50, AC75, AC80 & AC100 pumps
1.
Ensure the volute is drained and contains no harmful residues. A drain tap is located on the bottom of the volute.
2.
Disconnect the vacuum pump suction line from the top of the priming tank assembly. On AC80 and AC100 units disconnect the back priming line.
3.
Remove the complete priming tank and sump assembly from the volute. Note the number of gaskets fitted between the sump and volute. Examine their condition and either replace or retain for reuse
Manual No/Rev
W72-002E / 11
material is graphite impregnated braided P.T.F.E.
7.
Place the packing into the holder (see Figure 7-4), butting the two ends first then pressing the remainder of the packing into the holder (NB the length of the packing is greater than the circumference of the holder and some difficulty may therefore be experienced. The packing will protrude slightly from the face of the holder on completion.
Figure 0-3 Removing impeller (AC50 shown)
4.
Unscrew the impeller (LH thread for AC50 & AC75; RH thread for AC80 & AC100). See Figure 7-3. Note that this figure shows a AC50 unit. On an AC80 or AC100 unit the impeller would be tapped in the opposite direction of rotation. Record the number of shims fitted behind the impeller and retain for re use. Removal of the impeller exposes the vacuum pressure seal.
5.
Remove old packing from packing holder. Clean the holder. Examine the spring for signs of corrosion. Replace if necessary.
6.
Cut a length of packing (see Technical Data section for dimensions) ensuring the ends are square. The packing
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 11 of 16
Figure 0-4 Replacing vacuum pressure seal packing
1.
Refit the impeller ensuring that it secures the shims and spacer sleeve.
2.
Refit the complete priming tank assembly complete with gaskets.
7.5.2 Open coupled pumps
1.
Ensure the volute is drained and contains no harmful residues. A drain tap in the bottom of the volute is provided for this purpose.
2.
Remove guard from around pump shaft.
3.
Release screws holding the spring carrier to the rear cover plate and slide the spring carrier back along the pump shaft.
Note these are the protruding hexagon
headed screws NOT the countersunk recessed Alan screws which should not be touched. This will automatically withdraw the packing holder.
4.
Follow steps 5, 6 and 7 in section
7.5.1. above.
Page 12
Manual No/Rev W72-002 / 11
Operators Handbook for
Diesel Driven Pump Sets
5.
Slide the seal assembly back along the shaft to locate on backplate. Tighten securing nuts and screws evenly.
6.
Refit the shaft guard.
7.6
MECHANICAL SEALS
ATTENTION
1. Ensure that the coolant/lubricant level is maintained. It is imperative that the seals are never run dry. Immediate seal failure will result.
2. Any contamination of the fluid should be investigated immediately. Should a large loss of fluid be experienced then the pump must be stopped immediately.
3. Replacement of the seals is considered a workshop operation where higher standards of cleanliness can be maintained and the specialised tooling required is more readily available.
7.7 NON-RETURN VALVE
1. A ball type non return valve is fitted to the
pump discharge.
2. The ball should be regularly checked for
freedom of movement and absence of debris by inspection through the discharge.
3. On larger pumps the correct seating of the ball
can be checked through the delivery flange of the valve body. The valve body should be removed to check the seat for damage or wear.
7.8 PUMP BEARINGS (Open coupled pump sets only)
1. The pump ends employ grease lubricated bearings which will give long service life provided they are:-
a)
Correctly lubricated at regular intervals
b)
Cleaned and, if removed, refitted with care
c)
Serviced with clean tools and in a clean area.
2. The early stages of bearing failure can be detected by noting either unusual vibration, bearing housing temperature rise or unduly noisy operation. If any of these signs be exhibited, the pump should be stopped and the cause investigated.
3. Greased bearings are pre-packed with lubricant during pump manufacture. Shrinkage and normal loss of grease necessitates re-
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 12 of 16
lubrication at regular intervals. These intervals will largely be determined by site conditions. The recommendations given in Table 1 are therefore for guidance only.
Radial Bearing
Non drive end
(NDE)
4 months
3000 hrs
Radial & Thrust
Bearing
Drive end (DE)
4 weeks
750 hrs
Table 1 Guidance Intervals for bearing re­greasing
4. The table is based on running speeds of 1450rpm with a bearing temperature not exceeding 70°C. Reduce the interval by half for every 15°C above 70°C.
5. Clean both the grease fittings and grease gun nozzle before use. For a hand grease gun apply 2 or 3 strokes to each nipple.
6. Overfilling can be as harmful to bearings as under-lubrication. Compaction of grease leads to it being churned by the rolling action of the bearings. This leads to overheating, breakdown of the lubricant and bearing failure.
7. Immediately after re-lubrication it is normal for the temperature of the bearing housing to rise in service. The temperature should soon drop to normal after a short period of running. If the temperature remains elevated or continues to rise, temporarily remove the grease nipples and allow any excess grease to escape.
7.9 VACUUM PUMP
Vacuum pump overhaul is beyond the scope of this manual. Should the vacuum pump be suspect then it is recommended that an exchange unit is fitted and the suspect unit returned for examination.
7.10 VACUUM PUMP AIR FILTER
7.10.1 Standard air filter
Standard air filters are located in the valve cover of the primary tank and should be checked regularly for cleanliness, distortion or damage (see
Page 13
Operators Handbook for
AIR FILTER
25PTFLTA
AIRFILTER
60PTFLT
A
60AFELE
A
X
Diesel Driven Pump Sets
Manual No/Rev
W72-002E / 11
Figure 7-5, Figure 7-6, Figure 7-7). Replace if distorted or damaged
1
2
Figure 0-8 High capacity air filter 25 & 60 cfm units
Undo the screws holding the retaining cover and remove (1) the cover to inspect the filter. The element pulls out (2). Note that the orientation of the unit should be as shown so that any debris from the filter falls away from the outlet connection when the unit is opened. It can then can easily be swept out with little chance of it entering the outlet. Replace the cover O ring when the filter is changed.
Figure 0-5 Air filter AC50 & AC75
Remove the four screws holding the filter cover and remove to expose the air filter element.
7.11 VALVE GEAR
Typical main valve assemblies are shown in Figure 7-9 and Figure 7-10 The areas arrowed should be checked regularly for wear or damage. Worn parts should be replaced. The main valve is located on the underside of the top cover.
Figure 0-6 Air filter 18 & 25cfm units
Undo the central nut holding the air filter cover and remove to expose the filter element.
Figure 0-7 Air filter 60cfm units
Undo the six nuts holding the top cover and remove the top cover complete to expose the air filter element.
7.10.2 High Capacity Air Filter
25cfm and 60cfm vacuum pumps have the option of a high capacity air filter which is located externally as shown in Figure 7-8 The high capacity filter is fitted in lieu of the standard element.
25PLTVLVA.PC
Figure 0-9 6cfm main valve assembly
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 13 of 16
Page 14
Manual No/Rev W72-002 / 11
Operators Handbook for
Diesel Driven Pump Sets
Figure 0-10 25 & 60cfm main valve assembly
7.12 SURGE CONTROL VALVE
Figure 0-11 Surge control valve
On 25 and 60cfm priming tanks a surge control valve is fitted. This should be checked regularly for signs of wear or damage. Components arrowed in Figure 7-11 are vulnerable to wear and should be replaced if worn excessively. The valve seat should be greased to prevent seizure.
---“---
60PTVLVA.PCX
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 14 of 16
Page 15
8. FAULT FINDING GUIDE
Pump Fails to Prime
Are
NO
all plugs
tight?
NO YES
Operators Handbook for
Diesel Driven Pump Sets
Disconnect suction hose
Blank off suction entry
Fit vacuum gauge
Reading between
85 - 89 .5 kpa
(28.5 0 30 ft H20)?
Manual No/Rev
Check vertical
suction lift
W72-002E / 11
Rectify
Fit Vacuum Gauge
(28.5 0 30 ft H20)?
NO
Is oil level
correct?
YES
YES
Type of
unit?
OTHERS
Test the Vacuum
Pump directly
Reading between
85 - 89 .5 kpa
NO
Rectify
AC
50/75
YES
Is vacuum
pressure seal
leaking?
Rectify
Is the
mini ball valve
open?
YES
Is reflux
ball seating
properly?
YES
NO
YES
NO
YES
NO
Rectify
Rectify
Is Vacuum Pump filter
blocked?
6.1m (20ft) for AC50/75
8.53m (28ft) for AC80/100
9.75m (32ft) for others?
leaking, collapsed
or blocked?
NO
Rectify
Lift< or =
NO
Are hoses
NO
Is intake
blocked?
NO
Is impeller
blocked?
YES
Move
Pump
YES
Rectify
YES
Rectify
YES
Rectify
YES
Rectify
Is belt drive
tension OK?
YES
Excessive wear.
Remove pump &
either overhaul or fit
new or exchange
Vacuum Pump
NO
Rectify
NO
Rectify
Is float
gear free and
intact?
Rectify
casing free from
NO
Is pump
holes?
RectifyNO
YES
Are all
joints sound &
leak free?
YES
YES
Check impeller wear
plate clearances
and rectify
Is the
pump or NRV
blocked or damaged?
NO
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 15 of 16
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Manual No/Rev W72-002 / 11
Operators Handbook for
Diesel Driven Pump Sets
9.TECHNICAL DATA
PUMP TYPE AC50 &
AC75
VACUUM PUMP (f3/m) 6 18 25 60 25 60
SOLIDS HANDLING CAPABILITY (mm dia)
LISTER ENGINE TYPE AD1 TR1 TR2 LPW3 TS3 TR3 LPW 4 CD4
FUEL TANK CAPACITY (litres)
APPROX. RUNNING TIME ON FULL TANK (hrs)
IMPELLER BACK PLATE CLEARANCE
IMPELLER FRONT PLATE CLEARANCE
MECHANICAL SEAL COOLANT/LUBRICANT
PACKING 9.5 mm
COUPLING AXIAL N/A 0.5 mm (0.020")
ALIGNMENT ANGULAR N/A 1 degree
BEARING LUBRICATION N/A Grease: Texaco Multifak All Purpose EP2
VACUUM above 300C Texaco Regular Motor oil 30 *
PUMP OIL below 300C Texaco Ursatex 10W-30 *
28 40 44 50 52 48
14 69 75 69 122 130 122
14 20 21 20 28 10
0.50
0.019 - 0.059"
0.50
0.019 - 0.059"
square x 205
mm long
3/8" square x
8.07" long
* or equivalents conforming to API CC 5F, CCMC G2.D1, MIL-L-2104B or MIL-L-46152B
AC80 &
AC100
- 1.5 mm
- 1.5 mm
100M 150
0.30
0.012 - 0.024"
0.40
0.015 - 0.024"
Mobil Velocite Oil No. 6
Texaco Rando HD10
12.7 mm square x 270 mm long ½" square x 10.6" long
or equivalent to DIN 51825: KP2\K-30
150M 200
- 0.60 mm
- 0.60 mm
10. SPARES & SERVICE
SPP Pumps operate a comprehensive Spares and Service support network throughout the world, and can be contacted as follows:
SPARES & SERVICE Telephone: **44 (0) 1189 323123
For spare parts, supply only For breakdowns, spare parts and on-site fitting, pump installation and commissioning, and service contracts.
ask for -
For breakdowns outside office hours.
Spares & Service Office 1420 Lakeview Arlington Business Park Reading, Berkshire Direct Fax line: RG7 4SA ENGLAND
Copies of this manual are available from the SPP Pumps Spares & Service Department by quoting reference number W72-002E and the relevant issue number.
. ask for -
Telephone :
Spares Dept.
Service Dept.
**44 (0) 1189 323123
**44 (0) 1189 303259
11. COUPLING DETAILS (where applicable)
12. ENGINE OPERATORS HANDBOOK
The specific engine Operators Handbook from the manufacturer follow.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 16 of 16
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