SPP Pumps ACE80-100 Workshop Manual
AUTOPRIME ACE RANGE
CENTRIFUGAL PUMP
WORKSHOP MANUAL
AUTOPRIME
ACE RANGE
DIESEL DRIVEN
MOBILE PUMPS
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
This manual is a preliminary issue
for information only,
pending formal issue of
the complete manual.
Telephone:
+ 44 (0)1594 832 701
Fax:
+ 44 (0)1594 836 300
Page 1 of 21
Document No: W72-020E
Revision No: Preliminary 2
Revision Note No: Windchill
Date Issued. Aug 2012
Produced at SPP Pumps
Limited, Coleford, England
Manual No/Rev
Workshop Manual for
W72-020E / 1
ACE80/100 Diesel Driven Centrifugal Pumps
CONTENTS
1. INTRODUCTION...................................................... 3
2. SERIAL NUMBER ................................................... 3
3. SAFETY PRECAUTIONS ........................................ 4
6.1 Safety Symbols ................................................................ 4
6.2 Pump Safety Precautions ................................................. 4
4. HANDLING & TRANSPORT ................................... 4
6.1 Lifting ................................................................................ 4
6.2 Road Trailer Version ........................................................ 4
6.3 Trailer or Wagon Carriage ................................................ 4
5. FAULT FINDING GUIDE ......................................... 5
6. MAINTENANCE & REPAIR .................................... 6
6.1 A - Check & Service the Non Return Valve ...................... 6
6.2 B -Check & Service the Vacuum Air Filter ....................... 6
6.3 C - Check & Service the Priming Tank ............................. 6
6.4 D - Check Vacuum Pump Belt Tension ............................ 6
6.5 F – Full Pump Stripdown for Overhaul ............................. 7
7. PUMP ASSEMBLY PROCEDURE .......................... 8
6.1 Pump End Section Drawing ............................................. 8
6.2 Pump End Parts List: ........................................................ 9
6.3 Pump End Assembly (See section 7.1) ............................ 9
6.4 Priming Tank Parts List: ................................................. 10
6.5 Priming Tank Section Drawing ....................................... 10
6.6 Priming Tank Assembly .................................................. 12
6.7 Basic Pump Unit Construction........................................ 12
6.8 Option Builds .................................................................. 14
6.9 Final preparation ............................................................ 15
8. PUMP TEST PROCEDURE ....................................15
6.1
ENGINE, DRIVE, BATTERY & FITTINGS ..................... 16
6.2
BAUER FITTINGS .......................................................... 18
9.1
80-18 .............................................................................. 18
9.1
100-18 ............................................................................ 18
9.1
LABELS & TRANSFERS ................................................ 18
9.2
WIRING DIAGRAM ........................................................ 19
10. PARES & SERVICE ...............................................21
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 21
Workshop Manual for
ACE80/100 Diesel Driven Centrifugal Pumps
LIFTING
KEY
MOUNTING
STAND
DELIVERY
SUCTION
PRIMING
ENGINE
TANK
SPP Pumps Limited
Reading, RG31 7SP
Tel: ++44(0)118 932 3123
1. INTRODUCTION
The purpose of this handbook is to provide
repair and assembly instructions for the SPP
AUTOPRIME ACE Range of mobile diesel
engine driven 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.
These pumps are most commonly supplied
mounted on 2 wheel road trailers but can
also be supplied skid mounted, or as a pump
unit for customer’s to mount on a suitable
chassis or foundations.
ACE pumps are primed by a 25cfm vacuum
pump and are driven by a close coupled, aircooled diesel engine.
Manual No/Rev
W72-020E / 1
This Handbook covers the following pumps:
ACE80
driven by a Hatz 1D90 diesel engine
mounted on a fuel tank and road trailer or
skidThis unit is fitted with 3” Bauer hose
connections.
ACE100
pump driven by a Hatz 1D90 diesel engine
mounted on a fuel tank and road trailer or
skid. This unit is fitted with 4” Bauer hose
connections.
– An automatic priming mobile pump
– An automatic priming mobile
2. SERIAL NUMBER
The 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.
Where required, a trailer registration plate is
fitted to the front of the unit as required by
local regulations and the VIN number is
stamped fuel tank.
TANK
Type
Nett
Fax: 118 932 3302++44(0)
BAUER
ENGLAND
Serial No.
ACE Range Pump Components
BAUER
EYE
This manual is a preliminary issue
for information only,
pending formal issue of
the complete manual.
LIGHTING BOARD
FUEL
kg
START
TOW
HITCH
JACK
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 21
Manual No/Rev
Workshop Manual for
W72-020E / 1
ACE80/100 Diesel Driven Centrifugal Pumps
3. SAFETY PRECAUTIONS
6.1 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
6.2 Pump Safety Precautions
apply to all the following:-
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
This symbol gives warning of a hazard
to the pump itself, which in turn could
cause a risk to personal safety.
ATTENTION
Hot surfaces and moving parts are guarded
to protect you. If these guards are removed
for maintenance, they must be replaced
before starting the pump.
Never insert anything into the pump casing
whilst the pump is running with the suction
and delivery hoses disconnected.
Collapsible hoses must not be used on the
suction side of the pump
Where the standard Bauer connections are
not used, use all pump flange holes to fit
suction and delivery hose connections.
Do not lift with fork of fork lift truck under the
fuel tank. Never lift with suction or delivery
hoses attached. The increased weight of
these items may cause lifting gear failure.
Always lift pump sets vertically by the lifting
eye. Check the condition of the lifter bracket
at regular intervals.
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.
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.
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.
2.2.10
When working near to the pump or in a
confined space with the pump running
personal ear protection is recommended.
4. HANDLING & TRANSPORT
6.1 Lifting
The central lifting eye is designed for lifting
only the pump unit as supplied by SPP
Pumps Limited. Due to the additional weight
of skid-mounted units, these may be fitted
with alternative lifting points and fork-lift
truck slots on the skid.
The central lifting eye is suitable only for
vertical lifting and must not be used to
pull the unit sideways.
4.1.1
Check the condition of the central lifting eye
or bracket before use.
4.1.2
Do NOT use a lift truck with forks under the
fuel tank and do NOT lift with the hoses
attached.
4.1.3
Never allow the unit to be subject to a
‘snatch’ loading.
4.1.4
Control the unit while lifting to prevent
swinging and keep personnel away from the
area below the unit and the immediate area.
6.2 Road Trailer Version
There is provision for alighting board to be
fitted to the rear of the unit. Place the
lighting board in the two brackets and insert
pins to retain the lighting board in place.
6.3 Trailer or Wagon Carriage
Transportation on a trailer or wagon will
require the unit to be roped or strapped
down. On the road trailer mounted units, set
the unit level with the front and rear prop
stands lowered and clamped. Place ropes
or straps over the chassis to hold the unit in
place. Do NOT place ropes or straps over
the engine or the pump unit and ensure that
ropes or straps do not come into contact
with controls, switches, taps or other
vulnerable parts.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 4 of 21
Worksh
op Manual for
ACE80/100 Diesel Driven Centrifugal Pumps
5. FAULT FINDING GUIDE
Pump Fails to Prime
Are
NO
all plugs
tight?
NO YES
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
W72-020E / 1
Check vertical
suction lift
Rectify &
re-test
Fit vacuum gauge
(28.5 0 30 ft H20)?
NO
Is belt drive
tension OK?
YES
Test the Vacuum
Pump directly
Reading
between
85 - 89 .5 kpa
NO
Rectify
B
Rectify
C
YES
YES
NO
Is
Reflux Valve
Ball seating
properly?
YES
Is Vacuum
Pump filter
blocked?
NO
Is Main
Valve float
gear free and
intact?
YES
Move
Pump
YES
NO
Rectify
C
Lift< or =
8.53m (28ft) for
ACE80/100
NO
Are hoses
leaking, collapsed
or blocked?
NO
Is intake
blocked?
NO
Is impeller
blocked?
YES
Rectify
YES
Rectify
YES
Rectify
F
Rectify
This manual is a preliminary issue
YES
D
for information only,
YES
Are all
joints sound &
leak free?
NO
Rectify
F
pending formal issue of
Excessive wear.
Remove Vacuum
Pump & either
overhaul or fit new or
exchange pump
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
the complete manual.
NO
Rectify
F
Is pump
casing free from
holes?
ACE80-100 Fault Finding Chart
Page 5 of 21
YES
Check impeller wear
plate clearances
and rectify F
Is the
pump or NRV
blocked or
damaged?
NO
YES
Rectify
A
Manual No/Rev
Wor
kshop Manual for
61 M4 SELF LOCK NUT
9 MAIN INLET VALVE
29 AIR OUTLET VALVE
64 M10 STARLOCK WASHER
24 KNOB (NOT SHOWN)
27 SPRING
W72-020E / 1
ACE80/100 Diesel Driven Centrifugal Pumps
6. MAINTENANCE & REPAIR
The extent of disassembly will depend upon the
faults identified for rectification from the fault
finding guide in section 5. The code letters relate
to the workshop rectification procedures outlined
below:
6.1 A - Check & Service the Non Return Valve
1. Refer to the pump end section drawing in
section 7.1
2. the Remove the Bauer hose connection from
the delivery flange.
3. Remove the four long bolts (83) and lift off
the non-return valve body (80).
4. Remove the non-return valve ball (81),
examine for surface damage and replace if
damaged sufficiently to prevent a good seal
with the valve seat (82).
5. Lift and examine the valve seat, refurbish if
possible or replace if damaged sufficiently to
prevent a good seal with the ball.
6.2 B -Check & Service the Vacuum Air Filter
1. Refer to the priming tank section drawing in
section 7.5
2. Remove the air filter cover (6) by unscrewing
the nut (50).
3. Lift out the filter assembly (17) and examine.
4. If the filter is damaged, replace, if blocked or
dirty, clean the filter with a suitable solvent,
dry and replace.
6.3 C - Check & Service the Priming Tank
1. Refer to the priming tank section drawing in
section 7.5
2. Remove the eight M10 nuts (51) that retain
the top cover of the priming tank and lift off
the cover complete with float valve. Set
aside on a clean surface for examination.
3. Check that the float (14) is intact and not
punctured, replace if damaged.
4. Check that the fulcrum arm moves freely
and is connected to the air outlet valve (29).
Look for signs of wear on the fulcrum and
valve pins (15 &16) and replace if worn.
5. Remove the four M6 capscrews (66) and
carefully withdraw the main valve assembly
from the top cover.
6. Disassemble the valve and examine all
valves, seats and pins for wear and replace
as necessary.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 21
56 NYLON WASHER
10 AIR INLET VALVE
57 M4 WASHER
13 SPRING
11 DIAPHRAGM
32 O RING
8 VALVE SEAT
7 VALVE ROD
36 GASKET
30 FULCRUM BRACKET
58 M6 WASHER
66 M6 CAPSCREW
31 FULCRUM ARM
15 FULCRUM PIN
62 M8 SELF LOCK NUT
59 M8 WASHER
16 VALVE SUPPORT PIN
63 M6 STARLOCK WASHER
Main Valve Assembly
7. Reassemble as per paragraphs XXX to XXX
8. Check the condition of reflux ball valve (19)
and the valve seat (18) replace if damaged
and confirm that the pipe (2) is securely
fitted to the valve seat.
9. Check the surge control valve for general
condition and cleanliness, confirm that the
valve and spring retainer are not worn,
replace if necessary.
20 VALVE SEAT
28 VALVE SPINDLE
65 KLIP RING
21 VALVE
67 M8 WASHER
23 DISTANCE PIECE
22 SPRING RETAINER
65 KLIP RING
Surge Control Valve
10. Refit the top cover as per paragraphs XXX
6.4 D - Check Vacuum Pump Belt Tension
1. Remove guard.
2. Slacken the locking nut and the retaining
bolt, rotate the tensioner to adjust the
tension of the belt. Tighten the locking nut
and the retaining bolt and check the tension
thus:
Worksh
op Manual for
ACE80/100 Diesel Driven Centrifugal Pumps
FORCE
LOCKING
NUT
DEFLECTION
BOLT
RETAINING
Belt Tensioning
3. V Belt tension is correct when the deflection
is 4mm with a force of 1.5kg applied at the
centre of the longest run.
Note: DO NOT OVERTIGHTEN BELTS UNDER
ANY CIRCUMSTANCES.
Manual No/Rev
W72-020E / 1
6.5 F – Full Pump Stripdown for Overhaul
1. Refer to the pump assembly instructions in
section 7.
2. Full pump disassembly for examination of
internal clearances or for worn or damaged
parts is done generally in the reverse order
to pump assembly.
3. The use of suitable lifting equipment is
necessary to prevent injury and care must
be taken to remove any pumped liquids or
solids that may be hazardous to health
before commencing pump stripdown.
4. No special tools are required but the
installation of new mechanical seals will be
aided by the use of special tool no 22743.
This manual is a preliminary issue
for information only,
pending formal issue of
the complete manual.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 7 of 21
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