AUTOPRIME
Q RANGE PUMP UNIT
OPERATORS INSTRUCTIONS
AUTOPRIME
Q RANGE
OF DIESEL DRIVEN
MOBILE PUMPS
SPP Pumps Ltd.
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford, Glos
ENGLAND
Telephone:
+44 (0)1594 832701
Fax:
+44 (0)1594 836300
Document No: W72-008E
Revision No: .................. 9
Revision Note No: Windchill
Date Issued . Aug 2012
Produced at SPP Pumps,
Coleford, England
DECLARATION OF
FOR:
CONFORMITY
AUTOPRIME RANGE OF
DIESEL DRIVEN MOBILE
PUMP UNITS
TYPE:
QI100, QI150, QC/QP 150M,
QC/QP 200 and QHH80
Serial Number AS SHOWN ON THE PUMP NAMEPLATE
Responsible Person SPP PUMPS LTD.
Manufacturer SPP PUMPS LTD.
Registered Address Crucible Close
Mushet Industrial Park
Coleford, Glos
ENGLAND
GL16 8PS
It is hereby certified that this equipment complies with the essential health and safety requirements of
the Machinery Directive, and conforms to the standards listed below:
Directives:
'Council Directive 89/392/EEC - 'Machinery Directive'
'Council Directive 91/368/EEC, 93/44/EEC & 93/68/EEC - ‘Amendments’'
Harmonised Standards:
EN 292 Part 1 Safety of Machinery - Basic Concepts and
Part 2 General Principles for Design
pr EN 809: Pumps & Pump Units for Liquids - Safety Requirements
EN50081 Part2 EMC Generic Emission Standard - Industrial Environment
pr EN50082 EMC Generic Immunity Standard - Industrial Environment
Signed:
Name: Richard Martyn
Position: Engineering Manager - Authorised to sign on behalf of SPP Pumps Limited
Date: 1st October 2004
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 18
Operators Instructions for
AUTOPRIME Q Range Pump Unit
Manual No/Rev
W72-008E / 9
CONTENTS
1. INTRODUCTION ............................................................... 4
2. SAFETY PRECAUTIONS ................................................. 5
2.1 Safety Symbols ..................................................................................... 5
2.2 Pump Safety Precautions ..................................................................... 5
3. HANDLING & TRANSPORT ............................................. 5
3.1 Lifting .................................................................................................... 5
3.2 Road Trailer Version ............................................................................. 5
3.3 Site Trailer Version ............................................................................... 5
3.4 Skid Mounted and Pod Units ................................................................ 5
3.5 Trailer or Wagon Carriage .................................................................... 5
4. SERIAL NUMBER ............................................................ 6
5. OPERATING INSTRUCTIONS ......................................... 6
5.1 Before Starting ...................................................................................... 6
5.2 Starting .................................................................................................. 7
5.3 After Starting ......................................................................................... 7
5.4 Stopping ................................................................................................ 7
5.5 Problem Solving by Operator ................................................................ 7
6. PUMP MAINTENANCE CHART ....................................... 8
7. MAINTENANCE & SERVICE INSTRUCTIONS ............. 10
7.1 Preparation for Maintenance............................................................... 10
7.2 Pump Bearings ................................................................................... 10
7.3 Mechanical Seals ................................................................................ 10
7.4 Fuel Filler Gauge ................................................................................ 10
7.5 Coalescer Maintenance ...................................................................... 10
7.6 Coalescer Filter Element Replacement .............................................. 10
7.7 Coalescer Filter Mesh ......................................................................... 11
7.8 Non-Return Valve ............................................................................... 11
7.9 Vacuum Pump Belt Tension ............................................................... 11
7.10 Vacuum Pump Belt Replacement ....................................................... 11
7.11 Priming Tank Air Filter Maintenance ................................................... 12
7.12 Priming Tank Knitmesh Replacement ................................................ 12
7.13 Level Sensing Probes & Priming Control Box..................................... 13
7.14 Pump Impeller and Front Wear Plate ................................................. 13
8. PUMP FAULT FINDING.................................................. 13
8.1 Checking the operation of the priming system .................................... 13
8.2 Check the vacuum pump drive belts................................................... 13
8.3 Check the vacuum pump clutch ......................................................... 13
8.4 Check the solenoid valve .................................................................... 14
8.5 Priming filter blockage. ....................................................................... 14
8.6 Priming tank knitmesh filter blocked ................................................... 14
8.7 Volute non return valve not sealing ..................................................... 14
8.8 Air leak in priming system ................................................................... 14
8.9 Vacuum pump ..................................................................................... 14
8.10 Fault Finding Guide ............................................................................. 14
9. TECHNICAL DATA ......................................................... 16
9.2 General Arrangement ......................................................................... 17
10. SPARES & SERVICE ..................................................... 18
11. ENGINE OPERATORS HANDBOOK ............................. 18
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 18
Manual No/Rev
DRIVE END
SHAFT BEARING
VACUUM
PRIMING TANK
PUMP END
SHAFT BEARINGS
VOLUTE
STRAPPING
RING HITCH
HAND BRAKE
HOSE
CONNECTIONS
MECHANICAL
W72-008E / 9
AUTOPRIME Q Range Pump Unit
1. INTRODUCTION
The purpose of this handbook is to lay down
operating guidelines and routine maintenance
instructions for the AUTOPRIME Q Range of
diesel engine driven pumps, featuring the
electric priming system (SMARTprime).
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 on site trailers, skid mounted, or
as a pod unit for customer’s to mount on
suitable foundations.
This Handbook covers the following pumps:
CONTROL
PANEL
RADIATOR
FILLER CAP
EXHAUST
SILENCER
Operators Instructions for
QI 100
driven by an Isuzu 3LB1 diesel engine
mounted in a bunded and sound reducing
canopy.
QI 150
driven by an Isuzu 3LD1 diesel engine
mounted in a bunded and sound reducing
canopy.
QC 150M (CAT) / QP 150M (Perkins
automatic priming mobile pump driven by a
CAT C2.2NA (QC) or a Perkins 404D-22
(QP) diesel engine mounted in a bunded and
sound reducing canopy.
QC 200 (CAT) / QP 200 (Perkins)
automatic priming mobile pump driven by a
CAT C2.2NA (QC) or a Perkins 404D-22
(QP) diesel engine mounted in a bunded and
sound reducing canopy.
QHH80 – 3” automatic priming, high head
mobile pump driven by an Isuzu 4LE2 diesel
engine mounted in a bunded and sound
reducing canopy.
VACUUM PUMP
DRIVE BELT
AND CLUTCH
COALESCER
(far side)
– 4” automatic priming mobile pump
– 6” automatic priming mobile pump
– 6”
– 8”
AIR FILTER
PUMP
LIGHTING BOARD
AND STRAPPING
CHANNEL
JACK STAND
ENGINE OIL FILLER
AND DIPSTICK
STRAPPING
& SECURITY LOOPS
UNIT
LIFTER
PRIMING
TANK
SUCTION
FLANGE
FUEL
FILLER
SOLENOID
VALVE
SEAL OIL
RESERVOIR
NON RETURN
FLAP VALVE
DELIVERY
FLANGE
FRONT PANEL
BALL OR
CHANNELS
Q Range Pump Components
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 4 of 18
Operators Instructions for
AUTOPRIME Q Range Pump Unit
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
2.2 Pump Safety Precautions
apply to all the following:-
This symbol gives warning of a hazard
to the pump itself, which in turn could
cause a risk to personal safety.
ATTENTION
2.2.1
This pump contains exposed moving
parts and hot surfaces DO NOT
OPERATE THE PUMP WITH THE
DOORS OPEN. Guards removed for
maintenance must be replaced before
starting the pump.
2.2.2
Never insert anything into the pump
casing whilst the pump is running and
the suction and delivery hoses are
disconnected.
2.2.3
Never use collapsible hoses on the
suction side of the pump and use all
pump flange holes to fit suction and
delivery hose connections.
2.2.4
Always lift pump sets vertically by the
lifting eye. Any side force will damage
the lifter. Never lift with suction or
delivery hoses attached. The increased
weight of these items may cause lifting
gear failure.
2.2.5
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.
2.2.6
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.
2.2.7
Always allow adequate ventilation for
diesel engines. Be aware of fire risks
from items such as exhaust pipes and
Manual No/Rev
W72-008E / 9
silencers. Never place flammable items
around the unit.
3. HANDLING & TRANSPORT
3.1 Lifting
The central lifting point is designed for
vertical lifting only and must not be used to
pull the unit sideways. Before lifting ensure
that the lifting point is not bent or damaged.
Do NOT use a lift truck with forks under the
fuel tank and do NOT lift with the hoses
attached.
3.2 Road Trailer Version
There is provision for a lighting board on
the rear of the unit. Remove the two pins
through the open ends of the U-section and
fit the lighting board against the rubber
buffers at the back. Replace the pins to
retain the lighting board in place.
3.3 Site Trailer Version
The site trailer is limited to off road use and
subject to a maximum speed of 10kph
(6mph).
3.4 Skid Mounted and Pod Units
All units have provision for lifting from a
central lifting point through the canopy.
The unit must be located on firm level
foundations. For details of any special
attachment points provided for pod units,
refer to the GA drawing supplied.
3.5 Trailer or Wagon Carriage
Transportation on a trailer or wagon will
require the unit to be strapped down. On
the trailer mounted units, front and rear
location points for straps are incorporated
into the unit: There are two shallow Uchannels on the ‘A’- frame at the front and
a turned up lip on the lighting board
channel at the rear of the unit.
A strap can be fitted directly across the A
frame located by the channels provided.
At the rear of the unit remove the two
lighting board retention pins from the
channel section. Place the strap along the
bottom edge of the channel and replace
the pins.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 18
Manual No/Rev
Typ
e
Net
t
SerialNo.
k
g
100-18/TR1/HS
T
475
9712345/1
A
W72-008E / 9
Under no circumstances should straps
be passed over the top of the canopy or
around the doors.
For security purposes, U shaped hoops are
welded to the chassis behind each wheel.
These may be used as additional points for
strapping down the unit for transport.
Operators Instructions for
AUTOPRIME Q Range Pump Unit
4. SERIAL NUMBER
The serial number plate is fitted, either to the
chassis and/or on the pump bearing housing,
or on later units inside the control panel door.
This serial number must be quoted in any
enquiry for spares or service.
Sterling Fluid Systems
Reading
RG31 7SP ENGLAND
Tel: 0118 932 3123 Fax: 0118 932 3302
5. OPERATING INSTRUCTIONS
5.1 Before Starting
Where instructions in this section are followed
by (LH) or (RH) this indicates either the left
hand or right hand side of the unit looking from
the pump (towbar) end.
5.1.1
Read this the safety and operating
instructions on the pump and in this
handbook carefully.
5.1.2
Position the pump set where it can
be levelled for before use and apply
hand brake to prevent movement.
5.1.3
Unclamp the jockey wheel and lower
it to level the pump set. Clamp in
position.
5.1.4
Unclamp the rear prop stand (RH),
lower into position and lock so that
the pump set is prevented from
movement in operation.
5.1.5
Suction and delivery connection
flanges are double drilled thus
allowing each quick release hose
connection to be rotated to most
orientations. Undo the retaining nuts
and rotate the quick release
connections to suit the application.
5.1.6
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.
5.1.7
Select and fit a suitable strainer for
the job in hand. Note that most ‘off
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 18
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 solids handling
capacity must be employed. Refer to
the Technical Data section for
details on specific pumps.
5.1.8
Check for sufficient fuel - tank gauge
(LH).
5.1.9
Check for sufficient engine
lubricating oil - dipstick (LH).
5.1.10
Check for sufficient engine coolant –
Ensure the engine is cold, remove
the radiator filler cap (LH) or the filler
cap in the top hose. The correct
level is when coolant is just visible at
the base of the filler neck. If an
expansion bottle is fitted check the
level is between the Max and Min
level marks on the bottle.
5.1.11
Check that oil is present in the pump
seal reservoir (RH over the non
return valve housing).
5.1.12
Ensure that the batteries are
charged and ready for use (RH).
5.1.13
Check the air filter monitor (LH
below engine air cleaner). If reading
is >12" remove filter and clean.
5.1.14
Check coalescer oil level - dipstick
(RH). Ensure dipstick is fully
tightened.
THEALE CROSS READING
STERLING FLUID SYSTEMS LTD.
KEYSWITCH
METER
OPTIONAL TACHOMETER
AND VARIABLE SPEED CONTROL
WARNING INDICATOR LAMPS
5.1.15
5.2 Starting
5.2.1.
ATTENTION
Operators Instructions for
AUTOPRIME Q Range Pump Unit
Ensure drain cocks in discharge line
and volute are closed (RH).
Ensure canopy doors are latched
closed. These act as guards for the
Manual No/Rev
rotating machinery inside.
5.2.2.
Lift the flap on the back of the pump
set to reveal the starting/monitoring
panel.
W72-008E / 9
TRIP
SWITCH
START/STOP
The panel comprises:
a) Four position keyswitch
(Off, 1, Heat, Start)
b) Trip switch / circuit breaker
c) Hours run counter (or a tachometer
with variable engine speed control)
d) Five warning indicator lamps
On / off indicator
Engine oil pressure
Engine water temperature
Coalescer oil level (Optionally,
this low oil level warning may be
provided with automatic engine
shutdown)
Battery Charge
5.2.3
Turn the ignition switch to the '1'
position. The ‘ON’ indicator will show
green and all three red warning
lights will flash, providing a check
that all circuits are healthy.
5.2.4
Turn the keyswitch to the ‘Heat’
position and hold for 5 seconds, turn
the keyswitch on to the 'Start'
position. Release the keyswitch once
the engine has fired is running.
5.2.5
If the engine fails to start, return the
keyswitch to the ‘O’ (OFF) position
and repeat the start sequence within
15 seconds.
5.3 After Starting
The pump will prime automatically once the
suction hose is submerged.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
ON OR
OFF
ENGINE OIL
PRESSURE
HOURS RUN
ENGINE WATER
TEMPERATURE
5.4 Stopping
5.5 Problem Solving by Operator
Page 7 of 18
COALESCER
OIL LEVEL
BERKSHIRE ENGLAND
Tel: +44 (0)118 932 3123
Fax: +44 (0)118 932 3302
5.4.1.
Turn the keyswitch to the 'Off'
BATTERY
CHARGE
RG31 7SP
position. The unit will stop and the
key can be removed.
5.4.2.
Open the discharge cock to drain the
discharge line. Close after draining
is complete.
5.4.3.
Open the volute cock to drain the
volute. Close after draining is
complete.
5.4.4.
If the pump is not required
immediately, close and lock the
control panel and ensure that both
doors closed and locked.
In all the cases below, STOP the pump
before attempting to correct the problem. Do
NOT open the pump doors with the pump
running.
Engine running but not pumping:
5.5.1.
Check suction pipe for leaks, ensure
all hose fittings are air tight.
5.5.2.
Check for blockage of the strainer,
and clear any debris.
5.5.3.
Check for damage to the suction
hose both externally and internally,
replace damaged hose.
Manual No/Rev
W72-008E / 9
Operators Instructions for
AUTOPRIME Q Range Pump Unit
Pumping reduced with surging:
5.5.4.
Check that the impeller is clear of
debris and remove debris, if present.
5.5.5.
Check the non-return valve is clear.
Pump fails to prime after starting:
5.5.5.
Check suction hoses for leaks and
ensure all hose fittings are air tight.
5.5.6.
Check that volute drain cock is
closed.
5.5.7.
Check that the non-return valve is
Engine stops:
5.5.8.
Check engine fuel level, and refuel if
necessary.
5.5.9.
Check warning indicator lamps and
correct any faults indicated.
5.5.10.
Check the trip switch and reset.
Repeated resetting of the trip switch
indicates an electrical fault, call
service engineer.
free of debris and can seal when
closed.
6. PUMP MAINTENANCE CHART
Highlighted tasks in italics below are to be done by the pump operator, other tasks by the pump service
engineer. For engine maintenance periods refer to the engine operators handbook included within the
pump documentation pack.
PERIOD TASK
After first 500
hours of
operation
Daily Check and top up the coalescer oil. Check and top up the engine oil.
Weekly or
100 hours
Monthly or
500 hours
6 monthly or
3000 hours
9 monthly or
4500 hours
Annually or
6000 hours
Bi - annually
or 12000 hrs.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
IMPORTANT (Also required 500 hours after fitting a new vacuum pump)
Replace the four coalescer filter elements.
Replace the coalescer oil and oil filter.
Check and top up the diesel fuel. Check the fuel filter and drain off any
water.
Check and top up the mechanical seal oil reservoir level.
Check and top up the engine cooling water.
Check security of all fasteners & fittings. Check battery electrolyte level.
Check condition of battery connections. Check security of battery mountings.
Drain any water from coalescer. Check visually for leaks.
Check priming tank air filter, clean if dirty. Check fuel filler filter.
Check vacuum pump belt tension. Check for contamination of coalescer oil
Check the condition of the vacuum pump belts and renew if necessary.
Grease the drive end pump bearings with 15grms of grease.
Check and clean the level sensing probes. Check electrical connections.
Check condition of non-return valve & flap. Replace the four coalescer air filters.
Change mechanical seal coolant/lubricant. Change coalescer oil and oil filter.
Check the vacuum pump drive belts and renew if necessary.
Clear and clean or replace the small air filter on the solenoid valve.
Grease pump end pump bearing with 15 grams of grease.
Check condition of impeller and wear plate.
Check and replace the coalescer & priming tank knitmesh filters.
Repack pump bearings with grease.
Page 8 of 18
Operators Instructions for
AUTOPRIME Q Range Pump Unit
Manual No/Rev
W72-008E / 9
The maintenance schedule is given for guidance only. Site operating conditions may override the
suggested maintenance intervals. Adjustments to time scales will also have to be made if the pump is idle
for long periods.
IMPORTANT - Prior to movement or transport, check the following items:-
Wheel nut security. Tyre condition.
Towing hitch condition and security. Tyre pressures.
Brake adjustment (For road trailer where brakes are fitted)
Towing ‘A’ frame fasteners. Axle fasteners.
Lifter and stay fasteners. Engine to pump & chassis fasteners.
Note: Due to the initial stretch of new vacuum pump drive belts, it is necessary to check and re-tension
the drive belts after the first 50 hours running time on all new pumps and following the fitting
new drive belts. (See section 7.9)
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 9 of 18
Manual No/Rev
BRGHSGA
DRIVE END
PUMP END
N
E
W
C
O
A
S
3
REMOVE THE COALESCER LID
N
E
W
C
O
A
S
1
WATER DRAIN TAP
SCAVENGE
W72-008E / 9
Operators Instructions for
AUTOPRIME Q Range Pump Unit
7. MAINTENANCE & SERVICE INSTRUCTIONS
.
These instructions are for trained pump
service engineers.
Where instructions in this section are
followed by (LH) or (RH) this indicates either
the left hand or right hand side of the unit
looking from the pump (towbar) end
7.1 Preparation for Maintenance
Electric Shock & Accidental Starting
Hazard ISOLATE the equipment from any
mains supply connected before any
maintenance work is done.
For diesel engine driven pumps disconnect
the negative battery lead to prevent
inadvertent starting.
To avoid the possibility of maintenance
personnel inhaling dangerous fumes or
vapours. It is recommended that
maintenance work be carried out away from
the pump location by removal of the pump
unit to a suitable maintenance area.
No special tools are required for dismantling
and re-assembling, however, it is important
to ensure the suitable lifting equipment is
available and that the work is carried out in a
clean area.
7.2 Pump Bearings
The pump shaft runs on three bearings: a
roller bearing on the impeller end of the shaft
and a pair of angular contact bearings on the
drive end of the shaft. These bearings are
grease lubricated.
GREASE
NIPPLE
GREASE
NIPPLE
intervals are sufficient.
7.3 Mechanical Seals
The mechanical seals are cooled and
lubricated by oil. The oil reservoir is mounted
on top of the non-return valve cover. The
system oil capacity is approximately two
litres. The bottle should be filled to the MAX
mark when the unit is cold.
ATTENTION
7.4 Fuel Filler Gauge
Located in neck of fuel filler. Inspect for
debris. Remove and clean if necessary.
7.5 Coalescer Maintenance
COALESCER
Daily, check the oil level in the coalescer
LID
sump. If the level has risen, check for water
contamination, drain off any water present
and top-up the oil to the level between the
marks on the dipstick. Water is removed by
EXHAUST
means of the drain tap fitted to the side of
PORT
the coalescer sump.
(FAR SIDE)
7.6 Coalescer Filter Element Replacement
OIL FILLER
Coalescer filter elements must be replaced
& DIP STICK
after the first 500 hours or one month of
operation of a new vacuum pump, after
which they need to be replaced only when
the inside surface becomes heavily
discoloured i.e. black or dark brown. These
elements cannot be cleaned, new elements
must be fitted when required thus:
UNSCREW THE
ELEMENT CAPS
LIFT ELEMENTS
AND REPLACE
Only use oil of the correct grade
(see Technical Data section).
R
E
T
L
I
F
L
E
U
F
FILTER
MESH
OIL
PIPE
OIL
FEED
PIPE
OIL
FILTER
Grease is applied through two grease
nipples, one for the roller bearing and one for
the pair of angular contact bearings located
on the left side of the bearing bracket. Do
not over grease. Ten strokes (15 grams) of a
hand held grease gun at the specified
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
REPLACE THE
COALESCER
LID
Ensure that the seals at the top and bottom
of each filter element are fitted correctly.
Page 10 of 18
N
E
W
C
O
A
S
2
COMPRESS THE
FILTER & PUSH
PLACE. RETAIN
NRV 1
FLAP
FLAP TYPE
NON RETURN
BELTENS1
ATTENTION
Do not over tighten the retaining
knob as this will distort and crush
the filter element.
7.7 Coalescer Filter Mesh
Every year or more frequently if the pump
has been operating in a dusty atmosphere or
when the coalescer oil has become dirty, it is
recommended that the priming tank filter
mesh is replaced.
Operators Instructions for
AUTOPRIME Q Range Pump Unit
onto the seat and that nothing is trapped
between the hinge and the casting (both
above and below). Check that the disc is not
worn or torn and that the seat is not
excessively pitted. A more detailed
examination can be undertaken by removing
the cover on top of the valve. Replace the
cover gasket when refitting the valve cover.
DISCHARGE
FLANGE
FLAP
OPEN
FLAP
CLOSED
VALVE
Manual No/Rev
W72-008E / 9
ACCESS
COVER
UPWARDS INTO
WITH MESH AS
SHOWN
Drain the coalescer oil, disconnect the oil
feed pipes and remove the coalescer lid and
the coalescer element housing complete
with the filter elements. Remove the mesh
retaining the filter to give access for removal
of the knitmesh filter.
It is recommended that a new gasket is fitted
before re-fitting the coalescer element
housing.
The oil feed pipes should be cleaned in a
similar manner and blown through with an air
line.
7.8 Non-Return Valve
The non-return valve should be checked
regularly for freedom of movement, absence
of debris and good seating. The valve seat
should also be checked for damage or wear.
The flap type non-return valve is built in to
the pump casing and located under a cast
cover on top of the pump behind the
discharge flange. It consists of a hinged
rubber disc resting on a seat machined onto
the volute. The disc and seat can be
examined through the discharge flange once
the quick release hose connection is
removed. Check that the disc sits cleanly
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
7.9 Vacuum Pump Belt Tension
ATTENTION
7.10 Vacuum Pump Belt Replacement
Page 11 of 18
To adjust belt tension, loosen the pivot and
locking bolts and using a spanner on the
adjustment aid, slide the pulley outward.
When the correct belt tension is obtained retighten the locking bolt and the pivot bolt.
PIVOT
BOLT
5kgs
6mm
LOCKING
BOLT
190mm
1/2" SQ
ADJUSTMENT
AID
Do not under-tension belts under
any circumstances.
Remove the vacuum pump drive guard if
fitted.
Slacken and remove the belt tension device
by removal of the pivot bolt and the locking
bolt.
From the main pump drive coupling, remove
the three screwed pins from the rubber
coupling to give a gap between the engine
Manual No/Rev
AIR FILTER
END CAP
AIRFILTER1
(FIVE EACH SIDE)
F
P
W72-008E / 9
drive plate and the rubber coupling.
Remove the old belts, if still present.
Check both sets of pulleys for any signs of
wear or contamination with oil or grease,
clean or replace if necessary.
Note: Gauges are available for checking the
pulley grooves.
ATTENTION
Fitting new belts to worn or
damaged pulleys will lead to
premature belt failure.
Carefully fit the new belts. These will be a
tight fit and care must be taken not to
damage them by using excessive force.
Replace the three screwed pins to connect
the rubber coupling to the engine drive plate.
Replace the belt tensioner and re-tension the
belts as in Section 7.9.
Replace the drive belt guard.
Run the pump for 30 minutes and recheck
the belt tension as in Section 7.9
For new belts, check the tension after the
first 50 hours of operation.
ATTENTION
Under tensioning of the belts will
lead to premature belt failure.
Over-tensioning of the belts may
lead to premature failure of belts, or
the vacuum pump clutch or
bearings.
Operators Instructions for
AUTOPRIME Q Range Pump Unit
RETAINING
KNOB
Ensure that the O-ring is in position in the
end cap and replace the end cap. Replace
the three knobs and tighten.
7.12 Priming Tank Knitmesh Replacement
The priming tank is mounted at the front of
the pump behind the moulded panel.
Drain the volute. Disconnect suction and
delivery hoses. Remove the suction quick
release connection if required for easier
access or handling purposes. Disconnect
the battery negative lead.
AIR
FILTER
AIR FILTER
BODY
7.11 Priming Tank Air Filter Maintenance
The priming air filter is mounted in the filter
housing on top of the priming tank. Access is
from left hand side of pump.
With the pump stopped, open the volute
drain valve to ensure that priming tank
pressure is dissipated. Unscrew the three
knobs holding the end cap and remove the
end cap. Ensure that the sealing O-ring is
not lost. Undo the knurled knob retaining the
filter and carefully withdraw the filter
element. Inspect for mechanical damage or
blockage. Ensure that the central stud
holding the filter has not been loosened or
bent.
Washing in water and drying before re-use
should clean stainless steel filters. If white
fibrous filter is fitted, this must be replaced.
Replace filter with care and do not over
tighten the retaining knob as this can
damage the filter.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 12 of 18
FRONT PANEL
SUPPORT BOLTS
L
E
N
.
A
Open the doors and remove the ten bolts
(five each side) holding the front panel
support to the canopy frame (six off) and
tank shroud (four off). Lift off the front panel
and its support
Loosen the clamps that hold the vacuum
pipe to the solenoid valve and the top of the
vacuum pump. Disconnect the vacuum pipe.
Operators Instructions for
AIRFILTER2
AIR FILTER &
SOLENOID VALVE
(Valve not shown)
AUTOPRIME Q Range Pump Unit
GASKET
KNITMESH
PRIMING
TANK
Remove the terminal box cover from the
solenoid valve and disconnect the wiring
inside. Note the positions of the terminations
for reconnection.
Separate the filter housing from the priming
tank by removing eight nuts and the rubber
gasket. The knitmesh can now be removed
from the priming tank.
Clean the knitmesh filter in water and dry it.
Inspect the filter and the rubber gasket and
replace any damaged items.
7.13 Level Sensing Probes & Priming Control
Box
The level sensing probes should be
withdrawn and cleaned periodically to keep
them in workable condition. W ipe any
deposit from the stainless steel tips.
The control box and cables to the level
sensing probes are sealed units for which no
customer maintenance is required. If these
items fail they may be replaced and/or
returned to SPP Pumps for examination.
Manual No/Rev
W72-008E / 9
retaining the inlet duct and remove the duct.
Remove the front wear plate by screwing two
M16 bolts into the jacking holes on the wear
plate.
Inspect the impeller and wear plate for
damage and corrosion.
Before re-assembly ensure all ‘O’ rings are
in good condition, clean and well greased.
Impeller to front wear plate clearance can be
altered by shimming. Measure the clearance
with a feeler gauge inserted through the
suction. When measuring the clearance
temporarily fit the nuts and clamp the front
wear plate to the volute to ensure that the
wear plate is fully home.
Refit the inlet duct, priming tank, front
shroud, front panel and Quick release
connection.
8. PUMP FAULT FINDING
Refer to the operator’s problem solving
routines in section 5.5 and ensure that these
faults are not present.
These checks to be done by trained service
engineers:
8.1 Checking the operation of the priming
system
Disconnect the suction hose. Place a flat
board over the suction fitting to check that
the priming system and vacuum pump is
working.
If a vacuum gauge is fitted to the suction the
vacuum pump should produce a vacuum of
9 metres water.
7.14 Pump Impeller and Front Wear Plate
The impeller can be inspected for wear and
corrosion after the suction quick release
connection has been removed. Check the
inlet duct for signs of damage or blockage.
The impeller to wear plate clearance should
be 0.3 - 0.5mm.
A more thorough examination can be
conducted after the inlet duct and front wear
plate have been removed. The front wear
plate is clamped between the inlet duct and
the volute of the pump.
Disconnect the battery negative lead to
prevent accidental starting of the pump.
Remove the priming tank. Remove the front
section of the tank shroud. Remove the nuts
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
8.2 Check the vacuum pump drive belts
The vacuum pump drive belts run between
the pump shaft and the electric clutch on the
vacuum pump. See the maintenance
instructions in section 7.5 for the belt
tensioning method.
8.3 Check the vacuum pump clutch
The vacuum pump clutch is electrically
operated. If the clutch is disengaged the
belts still turn but the centre of the clutch will
be stationary.
The clutch requires 12 volts to actuate it.
This voltage controlled by a timer and
supplied via a relay by wire No 22 of the
wiring loom. If the wiring is disturbed during
investigations ensure that it is replaced
correctly.
Page 13 of 18
Manual No/Rev
W72-008E / 9
The priming system electrical circuit is
protected by a circuit breaker mounted on
the control panel. If this trips out, push the
central button to reset. If the breaker will not
reset or is constantly tripped then there is an
electrical fault.
The electrical supply to the clutch is
controlled by the level sensing probes, via a
timer. If there is no electrical supply to the
clutch, check that the power light is
illuminated on the priming control box. If this
is on then disconnect the clutch and check if
there is 12 Volts across the wires. If there is
then the clutch has failed and should be
replaced.
If the 12 Volt supply is not provided to the
clutch, check the continuity of the cables and
rectify any bad connections.
If the control box does not provide the 12
Volt supply for the clutch the control box is
faulty and must be replaced.
8.4 Check the solenoid valve
The electrically operated solenoid valve is
connected to the top of the priming tank. The
valve is reliable but If a fault is suspected it is
most likely to be a problem with the wiring.
Wire No 28 of the loom supplies 12 Volts,
wire No 8 is an earth return.
8.5 Priming filter blockage.
The priming tank air filter is mounted in the
top of the priming tank. To remove and
check the filter condition, follow the
instruction given in the maintenance section
of this manual.
8.6 Priming tank knitmesh filter blocked
It is extremely unlikely that the priming tank
knitmesh filter will ever become sufficiently
blocked to prevent priming. Instructions for
dismantling the unit and removing and
cleaning the knitmesh filter are given in the
maintenance section of this manual.
8.7 Volute non return valve not sealing
The volute non-return valve needs to seal if
the priming system is to function. The nonreturn valve can be examined by removing
the discharge quick release coupling - see
the relevant section of the maintenance
instructions. Ensure that there is nothing
jammed under the valve especially at the
back around the valve hinge.
Operators Instructions for
AUTOPRIME Q Range Pump Unit
release fitting has been moved or the
priming tank has recently been dismantled. If
the vacuum pump is working but not
achieving full vacuum fit a quick release
connection cap and gauge to the suction
pipe. Run the unit to achieve a vacuum, as
indicated by the gauge, then turn the unit off.
Note how long the vacuum takes to decay.
A pump in full working order will achieve a
vacuum of 9 metres water and hold it for in
excess of five minutes.
8.9 Vacuum pump
If the vacuum pump is considered to be at
fault no attempt should be made to
dismantle it. Obtain a replacement unit.
To check the operation of the vacuum pump,
disconnect the pipe running between the
priming tank and the vacuum pump.
Warning:- The pipe is stiff and very difficult
to remove. Do not disconnect the pipe while
the unit is running. If any solid objects, grit or
mud are drawn up the pipe they will cause
serious damage to the internals of the
vacuum pump. Disconnection of this pipe
should only be considered as a last resort.
Conduct other investigations before resorting
to this course of action.
Once the pipe between the vacuum pump
and the coalescer has been disconnected
start up the unit and place a small clean
board over the inlet to the vacuum pump.
The board should be held in place by the
action of the vacuum pump. Turn the unit off
before refitting the pipe.
The oil in the coalescer is used to both
lubricate the vacuum pump and create an
effective seal. If the vacuum pump
performance is poor check the coalescer oil
level, after having drained any excess water.
8.10 Fault Finding Guide
Unit does not start
•
Fuel consumed.
•
Trip switches need resetting.
•
Warning lights on & shutdown circuit
activated.
•
Battery with low charge level.
•
Refer to engine supplier’s manual for
engine checks.
8.8 Air leak in priming system
It is extremely unlikely that there will be air
leaks at any of the priming system sealing
faces. Leaks may occur if the suction quick
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 14 of 18
Unit does not prime
•
Volute drain tap open.
•
Air leak in priming system.
•
Air leak in suction hoses or fittings
•
Blockage in suction hoses or strainer.
•
Non return valve not sealing.
•
Internal damage to pipe from solenoid
valve to vacuum pump.
•
Solenoid valve not operating.
•
Solenoid valve blocked.
•
Priming tank air filter blocked.
•
Priming tank knitmesh blocked.
•
Vacuum pump belts loose or broken.
•
Vacuum pump electric clutch not
engaged.
•
Vacuum pump failure.
•
Suction head too great.
Operators Instructions for
AUTOPRIME Q Range Pump Unit
Unit does not pump
•
Blockage in delivery hoses.
•
Blockage in impeller.
•
Excessive impeller clearances.
•
Broken Impeller.
•
Pump drive coupling disengaged.
•
Delivery head too great.
Manual No/Rev
W72-008E / 9
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 15 of 18
Manual No/Rev
FUEL TANK CAPACITY
COOLANT/LUBRICANT
Above
Below
Texaco Ursatex 10W
-30
or equivalent conforming to
W72-008E / 9
9. TECHNICAL DATA
9.1 QI Pump Data
Operators Instructions for
AUTOPRIME Q Range Pump Unit
PUMP TYPE
VACUUM PUMP 65 cfm 110 m3/h
SOLIDS PASSAGE
CAPABILITY
ENGINE
TYPE Isuzu 3CD1 Isuzu 3CD1
APPROX. RUNNING
TIME (at full load) 50 hours 42 hours 26 hours
IMPELLER FRONT
PLATE CLEARANCE
MECHANICAL SEAL
Capacity:- 2 litres
QI 100
40mm dia. x
65mm.
QI 150
55mm dia. x
80mm.
Mobil Velocite Oil No. 6 or
QC 150M
QP 150M
55mm dia. x
80mm.
C2.2NA
Perkins
404D-22
220 litres
0.3mm to 0.5mm
0.012” to 0.020”
Texaco Rando HD10
QC 200
QP 200
75mm dia. x
90mm. 18mm dia.
CAT
QHH80
Isuzu 4LE2
Grease: Texaco Multifak All Purpose EP2
BEARING LUBRICANT
VACUUM
PUMP OIL
Capacity 5
litres
COALESCER FILTER Bosch 0451-103-093 or Crossland CF367
BATTERY 12V (345A cold cranking current)
TRAILER TYPE: Two Wheel Road Trailer with Fixed or Variable Height Tow Hitch
Tyre Size 185R13C
TYRE PRESSURES 58 psi (4 bar)
APPROX WEIGHT
FIXED TOW HITCH 1093kg 1123kg 1122 kg
APPROX WEIGHT
VARIABLE TOW HITCH 1133 kg 1155 kg 1157 kg
APPROX WEIGHT.
30° C
30° C
953 kg 978 kg
or equivalent conforming to DIN 51825:KP2\K-30
Texaco Regular Motor Oil 30 or equivalent conforming to
API CC 5F, CCMC G2 D1, MIL-L-2104B or MIL-L-46152B
API CC 5F, CCMC G2 D1, MIL-L-2104B or MIL-L-46152B
977 kg POD ONLY
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 16 of 18
3100 APPROX OVERALL
9.2 General Arrangement
1947
Operators Instructions for
AUTOPRIME Q Range Pump Unit
150
1920
1601
DNQ-GA
Manual No/Rev
W72-008E / 9
O
1524
385
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 17 of 18
Manual No/Rev
W72-008E / 9
Operators Instructions for
AUTOPRIME Q Range Pump Unit
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 323 123
For spare parts, supply only. ask for - Spares Dept.
For breakdowns, spare parts and on-site fitting, pump installation,
commissioning, and service contracts. ask for - Service Dept.
For breakdowns, outside office hours. Telephone : +44 (0)1491 201 613
Spares & Service Office
SPP Pumps Limited General Fax line: +44 (0)1189 323 302
1420 Lakeview
Arlington Business Park
Reading, Berkshire Direct Fax line: +44 (0)1189 303 259
RG7 4SA
ENGLAND
Copies of this manual are available from the SPP Pumps Spares & Service Department by quoting reference
number W72-008E and the relevant revision number.
11. ENGINE OPERATORS HANDBOOK
The specific engine operator's handbook from the manufacturer is included within the pump
documentation pack.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 18 of 18
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