SPP Pumps S3T User Manual

HYDRAFLOW

HYDRAULIC SUBMERSIBLE PUMPS

OPERATORS INSTRUCTIONS

S3T Pump

Pump Weight 11 Kg Aluminium or 22 Kg Cast iron

SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS

Telephone:

++44(0)1594 832 701

Fax:

++44(0)1594 836 300

Document No: W79-007E
Revision No: 4

Revision Note No: Windchill

Date Issued. August 2012

Produced at SPP Pumps

Limited, Coleford, England

We

Of

SPP Pumps Limited

Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS

Declare that:

Equipment:
Model/Type:
Serial Number:

In accordance with the following Directive:

HYDRAULIC DRIVE SUBMERSIBLE PUMP
HYDRAFLOW S3T

As shown on the Pump Nameplate

DECLARATION OF CONFORMITY

2006/42/EC Machinery Directive

have been designed and manufactured to the following specifications:

EN 809:1998+A1:2009 Pumps and Pump Units for Liquids - Safety Requirements

EN 12100:2003 Parts 1 and 2 - Safety of Machinery

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 Directive.

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: 19 February 2010

W79-007E

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 2 of 12

Operators Instructions for

HYDRAFLOW S3T Hydraulic Submersible Pump

Manual No/Rev

W79-007E / 4

CONTENTS

1. INTRODUCTION 4

1.1 Power Unit 4

1.2 Hydraulic Hoses 5

1.3 Submersible Pumps 5

2. SAFETY PRECAUTIONS 5

2.1 Safety Symbols 5

2.2 Submersible Pump Safety Precautions 5

3. TRANSPORT & STORAGE 6

3.1 Transport 6

3.2 Storage 6

4. SERIAL NUMBER 6

5. OPERATING INSTRUCTIONS 6

5.1 Pump Installation 6

5.2 Operation 6

6. PUMP MAINTENANCE 6

6.1 Oil Specifications: 6

6.1.1 Hydraulic Oil: 6

6.1.2 Lubricating Oil: 7

6.2 Maintenance Chart 7

6.3 Pump Disassembly: 7

6.4 Pump Reassembly: 7

6.5 Pump Hose Connection: 7

7. TROUBLESHOOTING 8

7.1 Preliminary Check List 8

7.2 Troubleshooting Guide 9

8. PUMP SECTION DRAWING AND PARTS LIST 10

8.1 Pump Section Drawing 10

8.2 Parts List 11

9. SPARES & SERVICE 12

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 3 of 12

Manual No/Rev

Return Filter with

Fixed Displacement

Pilot Controlled

Pressure

Diesel

Suction

Strainer

Vent

Valve

(On/Off)

SCHEMATIC FOR HYDRAULIC

W79-007E / 4

HYDRAFLOW S3T Hydraulic Submersible Pump

1. INTRODUCTION

The purpose of this handbook is to lay down
operating guidelines and routine
maintenance for the HYDRAFLOW S3T
hydraulic drive submersible pump.

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

The S3T pump is designed to operate with
hydraulic input flows to 30 l/m (1.82m3/h)

and a maximum pressure of 172bar
(2500psi).

Operating this unit at pressures or flows in
excess of those listed above or connecting
this unit to a closed centre or reversing

Return Filter
Wear Indicator

Operators Instructions for

1.1 Power Unit

By-Pass Valve

circuit will cause damage to the unit and will
void the warranty!

The pump Is capable of a wide range of
applications as it is not subject to normal
suction lift limitations.

The power unit should be selected to meet
the power requirements of the pump for the
pump duty.

Hydraulic circuits must be open centre,
single direction and have an unrestricted
return flow from the hydraulic motor to the
oil reservoir. Please review the hydraulic
schematic.

Pressure

System Relief

Gauge

Valve

Hydraulic
Oli Cooler

Oil Reservoir

Valved Quick

Release Hose

Connectors

Compensated
Hydraulic Pump

Engine

Oil Reservoir

TYPICAL HYDRAULIC

SUBMERSIBLE PUMPS

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Hydraulic Motor

Page 4 of 12

Operators Instructions for

HYDRAFLOW S3T Hydraulic Submersible Pump

If you are not sure if the hydraulic power
source being used to drive this pump is
properly sized or connected, call Sterling
Fluid Systems Limited.

The power unit should be located as near to
the pump location as possible. The
maximum length of hydraulic hose that may
be used without a significant reduction in
pump performance is 40m. However, by
increasing the hose diameter, performance
can be restored. Consult Sterling Fluid
Systems for more details.

The power unit is usually driven by a diesel
engine that may be mounted inside a noise­reducing canopy for use in noise sensitive
areas to comply with local noise regulations.

The fuel tank should be sized to give
extended running time. The running time
will depend upon the pumping load.

The power unit should be provided with
automatic shutdown to prevent damage in
the event of low levels of engine or
hydraulic oil and high engine or hydraulic oil
temperature.

The speed of the engine should be
adjustable to suit the load on the pump,
reducing the speed for reduced demand will
increase fuel efficiency and reduce wear.

To minimise the potential harmful effects on
the environment in the event of an oil leak
or spillage, Sterling Fluid Systems
recommend the use of Biodegradable
Hydraulic 46 Oil. However, the pump will
run satisfactorily on good quality hydraulic
oils of viscosity below 150SSU @ 38°C
(100°F) or equivalent specification.

Note: When using vegetable (Rape Seed) based

biodegradable oil it is important to check
the condition of the oil frequently as it tends
to breakdown more quickly than the more
expensive mineral or synthetic
biodegradable oils.

NOTE – DO NOT MIX OILS

To minimise wear and maintain pump
performance, the hydraulic oil must be
replaced regularly and the hydraulic circuit
must be fitted with a 10micron filter.

hoses are fitted incorrectly, damage or
danger may result.

The hoses are supplied with quick release
couplings that must be correctly fitted
before starting the pump. Due to these self­sealing couplings, the hoses will remain
filled with oil when not in use.

Damaged hoses should not be used, due to
the high pressure of the oil, a burst or leak
is hazardous, any damaged hose must be
replaced and returned to the supplier for
testing and repair before reuse.

1.3 Submersible Pumps

The S3T has a vortex impeller with 3”
discharge. This pump is from a wide range
of submersible pumps to suit a variety of
pump applications.

For borehole applications use slim-line
pumps, for compact high volume
requirements use axial flow pumps, for
open water pumping use a conventional
pump with a vertical side discharge port.

To pump sewage or similar liquids with
solids or sludge content use pumps with
vortex impeller and for maximum
performance with clean water use pumps
with a channel impeller.

All pumps are driven by simple and reliable,
compact hydraulic motors and are fitted with
mechanical seals.

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.

Manual No/Rev

W79-007E / 4

1.2 Hydraulic Hoses

The hydraulic hoses supplied for use with
this equipment are designed to prevent
incorrect connection, but if non-approved

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 5 of 12

2.2 Submersible Pump Safety Precautions

2.3.1

Ensure that the hydraulic power supply is
turned OFF and disconnect the hydraulic
hoses from the pump before working on the
pump.

Manual No/Rev

Max. Oil Flow

Max. Oil Press.

Kg

W79-007E / 4

HYDRAFLOW S3T Hydraulic Submersible Pump

Operators Instructions for

2.3.2

Check the type of liquid being pumped
before working on the pump. Residues
could be hazardous to your health. If in
doubt flush out with clean water before work
commences.

2.3.3

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. TRANSPORT & STORAGE

3.1 Transport

The pump is suitable for all normal forms of
transport. When lifting use the lifting point
provided. Ensure that the unit is strapped
down securely for vehicle transport.

3.2 Storage

The pump should be stored upright in a well
ventilated, dry location. For extended
storage refer to Sterling Fluid Systems for
guidance on additional protection.

4. SERIAL NUMBER

A serial number plate is attached to the
pump unit

This serial number must be quoted in any
enquiry for spares or service.

Serial No.

Model

L/m

Bar

Weight

5. OPERATING INSTRUCTIONS

5.1 Pump Installation

5.1.1

BEFORE attempting to operate this pump,
read the safety and operating instructions
on the power unit and in its’ handbook and
this handbook carefully.

5.1.2

Check that the power unit has been
installed correctly by reference to the
operating instructions.

5.1.3

Check the hydraulic hoses visually for
damage that may have occurred since the

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

5.1.4

NOTE – Due to the pressure of the oil retained in

5.1.5

5.1.6

5.1.7

5.1.8

5.1.9

NOTE – Do not lower or raise the pump using the

5.2 Operation

6. PUMP MAINTENANCE

6.1 Oil Specifications:

6.1.1 Hydraulic Oil:

Page 6 of 12

pump was last run, any damage noted
should be reported and the hoses replaced
before the pump is run.

Ensure that the hydraulic couplings are
clean and free from grit or dust that may
prevent a leak-proof connection or
contaminate the oil. Connect the hydraulic
suction and delivery hoses making sure that
the hydraulic couplings are properly and
securely connected.

the hoses when disconnected, it is easier to
connect hoses to the RETURN circuit first.
This will allow the pressure to decay before
connecting to the pressure circuit. Always
connect the ‘Male’ hose end connection
first.

Lay out the hoses to the pump, ensuring
that each hose is fully uncoiled and is free
from kinks. The minimum bend radius of
the hose is 300mm.

If these hoses pass over roadways, ensure
that they are protected by suitable means to
prevent damage by crushing.

Connect the hydraulic hoses to the pump
unit, ensuring that the hydraulic couplings
are properly and securely connected.

Connect a suitable pump delivery hose to
the pump outlet connection and direct the
hose to the required discharge point.

Lower the pump unit into the liquid to be
pumped, ensuring that the pump remains
upright for best performance.

hydraulic hoses, a lifting point is provided on
the pump for attachment of a shackle and
lifting chain or rope.

Refer to the operating instructions for the
power unit for starting and stopping the
pump.

Sterling Fluid Systems recommend the use
of Bio-degradable Hydraulic 46 Oil.
However, the pump will run satisfactorily on
good quality hydraulic oils of viscosity below

Operators Instructions for

HYDRAFLOW S3T Hydraulic Submersible Pump

150SSU @ 38°C (100°F) or equivalent
specification.

Note: When using vegetable (Rape Seed) based

bio-degradable oil it is important to check
the condition of the oil frequently as it tends
to breakdown more quickly than the more
expensive mineral or synthetic bio­degradable oils.

NOTE – DO NOT MIX OILS

6.2 Maintenance Chart

Period Maintenance Items Required

Daily Check hydraulic hoses for damage and replace as required. Spare hydraulic hoses

Check Diesel fuel level, top-up as required. Diesel Fuel
Check Hydraulic oil level, top-up as required. Hydraulic Oil

Weekly Check the level and condition of the oil in the pump seal

chamber and top up if necessary.

500 hours Replace hydraulic oil filter element. (10 micron filter)

Change the oil in the pump seal chamber

1000 hours Drain hydraulic oil, clean the reservoir tank and replace with

new oil.

6.3 General

The only routine maintenance required
under normal use is to check oil in seal
cavity in top cover (#11). This oil is to be
20W hydraulic oil (approx. 1 oz.). Change
oil every 500 hours of operation. If no oil is
present or oil is emulsified, shaft seal may
need replacement.

Further maintenance may be required if:

(a) Pump discharge volume is inadequate.

(b) Oil leakage from pump is present.

6.4 Pump Disassembly:

6.4.1

Remove six 3/8" bolts (#12) From top
cover.

6.4.2

Remove top cover and motor assembly
from volute (#3).

6.4.3

Check condition of "O" ring (#10) and
replace if necessary.

6.4.4

Check for debris in the volute.

6.4.5

Check wear ring (#4). Replace if wear is
excessive.

6.4.6

Hold impeller (#7) securely and remove
socket head retaining screw (#5) and cone
washer(#6) from impeller end.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

6.1.2 Lubricating Oil:

6.4.7

6.4.8

6.4.9

6.4.10

6.4.11

6.4.12

6.4.13

6.4.14

6.5 Pump Reassembly:

6.5.1.

6.5.2.

Page 7 of 12

Manual No/Rev

W79-007E / 4

Look especially for a darkening in colour as
an indicator of reduced lubrication
performance or contamination and arrange
to drain the system, clean the tank and
replace with new oil.

Use clean Bio-degradable Hydraulic 46 Oil
or 20W Hydraulic Oil or Mobil 10W30
Synthetic Oil.

Hydraulic Oil
(approx 1 oz)
Oil Filter Element.
Hydraulic Oil (app. 1 oz)
Hydraulic Oil (100 l)
Cleaning Solvent

Using hex key wrench, or hex key socket
with impact wrench, unscrew impeller (#7)
(right hand threads).

Check impeller for wear and replace if
necessary.

Remove 2 bolts (#15) from handle (#16)
and remove.

Remove seal spring and washer.

Remove 2 motor mounting bolts (#21) from
top cover and carefully remove motor(#22).

Inspect "O" ring (#13) and replace if
necessary.

Check top cover for wear and replace if
wear is extreme.

Do not disassemble hydraulic motor (#22).
If hydraulic motor needs service, it should
be performed by a qualified Sterling Fluid
Systems Service Engineer or replaced.

Fasten motor to top cover making sure the
"O" ring (#13) is in place.

Install new shaft seal (#9) keeping the parts
extremely clean and using clean grease to
aid installation.

Manual No/Rev

W79-007E / 4

HYDRAFLOW S3T Hydraulic Submersible Pump

Operators Instructions for

6.5.3.

Screw impeller onto shaft and lightly tap on
vane to tighten.

6.5.4.

Install cone washer and socket head screw
and tighten while holding impeller firmly.

6.5.5.

Install drive assembly into volute making
sure "O" ring (#10) is in place.

6.5.6.

Install handle.

6.5.7.

Fill oil chamber in top cover (approx. 1 oz.).

6.5.8.

Test spin pump before using to check for
leaks.

6.6 Pump Hose Connection:

NOTE – When the pump hose connections have

been disconnected from the hydraulic motor
it is IMPORTANT to ensure that they are
refitted correctly. The inlet port on the

motor is normally fitted with the Female
quick release hose coupling.

7. TROUBLESHOOTING

7.1 Preliminary Check List

7.1.1.

Check the hydraulic power source to be
sure the oil flow volume and available
pressure is within the range of the
submersible pump. If the power source is
capable of supplying oil in excess of the
required flow, damage will result to the

hydraulic motor and/or pump components
due to over speeding.

7.1.2.

Be sure the submersible pump is connected
to a single direction open centre power
source. The submersible pump is not bi­directional and operating in reverse rotation
can cause seal failure in the hydraulic
motor. The system must be open centre
at all times (return flow from the
submersible pump motor must be allowed
to flow freely to the system oil reservoir).
Do not use hydraulic directional valves that
block the return flow when in the centre
position of the valve. This type of valve is
for hydraulic cylinder operation only and will
cause the submersible pump to stop
abruptly when moved to the centre position
of the valve. This will cause excessive
pressure on the return side of the motor
causing seal failure and possible shaft
damage.

7.1.3.

Be sure that the hydraulic hose connections
are clean and properly connected. When
using quick released hose couplers, you
muse be sure that they are completely
connected. A partly connected coupler will
result in seal damage to the hydraulic motor
and pump seal.

7.1.4.

Be sure that the pump is submerged
adequately. This is especially important for
vortex impeller pumps since the impeller is
recessed up into the top of the volute.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 8 of 12

HYDRAFLOW S3T Hydraulic Submersible Pump

Clear debris from

Inlet or Strainer

Replace Layflat

Be sure Pump is

submerged initially to

Replace Motor

Replace Worn Parts

Check Vent Screw

(on some models) to

be sure it is not plugged

Lower Pump into liquid

Lay Pump on it’s side with

the discharge in 12 o’clock

Remove Layflat discharge

7.2 Troubleshooting Guide

Operators Instructions for

PUMP NOT PUMPING

Manual No/Rev

W79-007E / 4

Hydraulic Pressure High

(above 70 BAR - 1000PSI)

Submersible Pump

NOT Spinning

Hydraulic Motor or

Pump Bearings Seized

Replace Hydraulic Motor

or Pump Bearings

Impeller

Jammed

Remove Top Cover

and free Impeller

Submersible Pump

Spins

Discharge Head Too

High for Pump

Discharge Hose

Kinked or Plugged

Clear Hose of obstruction

Discharge Hose with

Rigid Hose or Pipe

Hydraulic Pressure Low

(below 70 BAR - 1000PSI)

Check Hydraulic Power

Unit with Submersible

Pump disconnected to be

sure it is functioning

properly

Lack of Water in Pump

Pump Inlet Obstructed

Pump not Properly

Submerged

Oil Filler Plug on

Bearing Housing

Air Trapped in Volute

while operating

position to allow air

to escape

hose that may trap air

Hydraulic Motor Worn

Excessive Wear

on Impeller

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 9 of 12

Manual No/Rev

W79-007E / 4

HYDRAFLOW S3T Hydraulic Submersible Pump

Operators Instructions for

8. PUMP SECTION DRAWING AND PARTS LIST

8.1 Pump Section Drawing

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 10 of 12

HYDRAFLOW S3T Hydraulic Submersible Pump

HT1009295

Strainer/Water with Plugs (opt.)

6. HT1009308

Cone Washer

7. HT1009309

Impeller

HT0009315

Lockwasher (6 req.)

16. HT1009319

Handle

17. HT0209320

Hydraulic Coupling, Male H.T.M.A.

HT0009315

Lockwasher

22. HT1009324

Hydraulic Motor

8.2 Parts List

Always mention serial # when ordering parts

Item Part # Description

1.

2. HT1009302

HT0009300
HT0009301

Hex Head Bolt (4 req.)
Lockwasher (4 req.)
Strainer/Trash

Operators Instructions for

Manual No/Rev

W79-007E / 4

3. HT1009303
HT1009488

Volute (Aluminum)
Volute (Ductile Iron)

4. HT1009305 Wear Ring

5. HT0009307 Impeller Retaining Screw, Socket Head

8. ---------- N/A

9. HT1009311 Shaft Seal Assembly

10. HT1009312 "O" Ring, Top Cover

11. HT1009313 Top Cover

12. HT0009314

Hex Head Bolt (6 req.)

13. HT1009316 "O" Ring, Motor

14. HT0309317 Pipe Plug

15. HT0009318
HT0009315

Hex Head Bolt (2 req.)
Lockwasher (2 req.)

18. HT0209321 Hydraulic Coupling, Female H.T.M.A.

19. HT0309322 Nipple

20. HT0209323 Elbow

21. HT0009318

Hex Head Bolt (2 req.)

23. HT0209325 Elbow

24. HT0309326 Nipple

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 11 of 12

Manual No/Rev

W79-007E / 4

HYDRAFLOW S3T Hydraulic Submersible Pump

Operators Instructions for

9. SPARES & SERVICE

SPP Pumps operate a comprehensive Spares and Service support network throughout the world, and can be
contacted as follows:

SPARES & SERVICE Telephone: [phone]

For spare parts, supply only. ask for - Spares Dept.

For breakdowns, spare parts and on-site fitting, pump installation and
commissioning, and service contracts. ask for - Service Dept.

For breakdowns outside office hours. Telephone : + 44 (0)118 930 3259

Spares & Service Office
SPP Pumps Limited General Fax line: + 44 (0)118 930 3259
1420 Lakeview
Arlington Business Park
Reading, Berkshire, RG7 4SA Direct Fax line: [phone]

Copies of this manual are available from the SPP Pumps Spares & Service Department by quoting reference
number W79-007E and the relevant issue number.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time

Page 12 of 12