Page 1
HYDRAFLOW
9
9
0
m
m
HYDRAULIC SUBMERSIBLE PUMPS
OPERATORS INSTRUCTIONS
S4VHL Pump
840 mm
500 mm
Pump Weight 79 Kg Aluminium or 140 Kg Cast iron
380 mm
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: W79-003E
Revision No: 4
Revision Note No: Windchill
Date Issued. August 2012
Produced at SPP Pumps
Limited, Coleford, England
Page 2
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 S4VHL
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
W79-003E
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 12
Page 3
Operators Instructions for
HYDRAFLOW S4VHL Hydraulic Submersible Pump
Manual No/Rev
W79-003E / 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 6
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 7
6.1 Oil Specifications: 7
6.1.1 Hydraulic Oil: 7
6.1.2 Lubricating Oil: 7
6.2 Maintenance Chart 7
6.3 Pump Disassembly: 7
6.4 Pump Assembly: 8
6.5 Pump Hose Connection: 8
7. TROUBLESHOOTING 9
7.1 Preliminary Check List 9
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
Page 4
Manual No/Rev
Return Filter with
Fixed Displacement
Pilot Controlled
Pressure
Diesel
Suction
Strainer
Vent
Valve
(On/Off)
SCHEMATIC FOR HYDRAULIC
W79-002E / 4
HYDRAFLOW S6TC Hydraulic Submersible Pump
1. INTRODUCTION
The purpose of this handbook is to lay down
operating guidelines and routine
maintenance for the HYDRAFLOW S4VHL
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 S4VHL pump is designed to operate
with hydraulic input flows to 95 l/m (5.7
m3/h) and a maximum pressure of 200bar
(2900psi).
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
Page 5
Operators Instructions for
HYDRAFLOW S4VHL 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.
1.2 Hydraulic Hoses
The hydraulic hoses supplied for use with
this equipment are designed to prevent
incorrect connection, but if non-approved
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 S4VHL has a vortex impeller with 4”
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
W79-003E / 4
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 12
Page 6
Manual No/Rev
Max. Oil Flow
Max. Oil Press.
Kg
W79-002E / 4
HYDRAFLOW S6TC Hydraulic Submersible Pump
Operators Instructions for
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.
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 on the top plate over the volute
casing.
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
pump was last run, any damage noted
should be reported and the hoses replaced
before the pump is run.
5.1.4
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.
NOTE – Due to the pressure of the oil retained in
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.
5.1.5
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.
5.1.6
If these hoses pass over roadways, ensure
that they are protected by suitable means to
prevent damage by crushing.
5.1.7
Connect the hydraulic hoses to the pump
unit, ensuring that the hydraulic couplings
are properly and securely connected.
5.1.8
Connect a suitable pump delivery hose to
the pump outlet connection and direct the
hose to the required discharge point.
5.1.9
Lower the pump unit into the liquid to be
pumped, ensuring that the pump remains
upright for best performance.
NOTE – Do not lower or raise the pump using the
hydraulic hoses, a lifting point is provided on
the pump for attachment of a shackle and
lifting chain or rope.
5.2 Operation
Refer to the operating instructions for the
power unit for starting and stopping the
pump.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 12
Page 7
Operators Instructions for
HYDRAFLOW S4VHL Hydraulic Submersible Pump
6. PUMP MAINTENANCE
6.1 Oil Specifications:
6.1.1 Hydraulic Oil:
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
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
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
250 hours Check the oil level in the pump bearing housing:
The level should be at the spill point of the fill plug (#18).
The pump holds about 1440ml do NOT overfill.
500 hours Replace the oil in the pump bearing housing Lubricating Oil (1440ml)
Replace hydraulic oil filter element. (10 micron filter) Oil Filter Element.
1000 hours Drain hydraulic oil, clean the reservoir tank and replace with
new oil.
6.3 Pump Disassembly:
6.4.1
Remove (6) bolts (#19) from lifting bracket (#3).
6.4.2
Remove the remaining (2) bolts holding the
bearing housing (#22) to the volute. Use
jacking bolts to separate if necessary. The
bolts holding the volute and bearing housing
together are the same thread as the jacking
bolts.
6.4.3
Check the volute wear ring (#27) for wear. If
worn excessively (deeply grooved), remove ring
by using a puller or by tapping ring upward from
inside the volute. Replace the ring if required.
6.4.4
Check condition of "O" rings (#24 and #28) and
replace if necessary.
6.4.5
Remove (4) bolts (#9) from hydraulic motor
(#5). Because of it's extremely long life, close
tolerances, high efficiency and the relatively low
cost of a new motor, it is more economical to
replace the hydraulic motor than to rebuild if
worn. Inspect "O" ring (#10).
6.4.6
Place a drain pan on flat surface and turn
bearing housing upside down to drain oil from
housing.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
6.1.2 Lubricating Oil:
Page 7 of 12
Manual No/Rev
W79-003E / 4
to breakdown more quickly than the more
expensive mineral or synthetic biodegradable oils.
NOTE – DO NOT MIX OILS
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.
Lubricating Oil
Hydraulic Oil (100 l)
Cleaning Solvent
6.4.7
Secure the shaft from turning by locking
it with shaft retaining tool (part #
HT0609001) or suitable alternative tool.
6.4.8
Remove impeller locking screw (#30)
and retaining washer (#29) and unscrew
impeller (#26) counter-clockwise.
6.4.9
Inspect impeller for wear and inspect
wear plate (#23) for excessive wear.
Replace if severely worn.
6.4.10
Remove shaft seal cartridge (#25) and
inspect for wear. Seal should be replaced
whenever disassembling for repair.
6.4.11
Remove snap ring (#11) and remove
shaft (#13) and bearings (#12 and #14)
as in assembly. Applying heat evenly
over the bearing housing will facilitate
easy removal of shaft and bearing
assembly.
6.4.12
Visually inspect shaft, bearings and
inside of bearing housing. Replace if any
of these show signs of wear.
6.4.13
If bearing replacement is necessary, use
adequate bearing puller or press to
Page 8
Manual No/Rev
Mechanical Seal Arrangement
Mechanical Seal Arrangement
W79-003E / 4
HYDRAFLOW S4VHL Hydraulic Submersible Pump
remove bearings from shaft. Do NOT use heat
to remove bearing from shaft.
6.4 Pump Assembly:
Assembly is performed in the reverse order
of disassembly with care taken to be sure
that:
6.4.1
After shaft and bearing assembly are installed
in housing, snap-ring (#11) is secured and shaft
rotates freely.
Bearing
Housing
Operators Instructions for
6.4.2
Shaft seal (#25) is kept extremely clean
at all times. Be careful not to scratch
sealing surfaces. Install ceramic seal
seat into rubber boot carefully to be sure
rubber is seated properly. Install seal
cartridge onto shaft carefully using oil to
lubricate the carbon face and the rubber
bellows. Install the impeller slowly to be
sure it contacts the seal evenly and
applies pressure properly to seat the seal
assembly. Be sure carbon face of
rotating cartridge contacts smooth side of
stationary ceramic seat.
Shaft
Spring
Retainer
Impeller
Rubber cap
Polished
Ceramic Face
Carbon Face
Rubber Bellows
Exploded
6.4.3
"O" ring are properly installed in grooves.
6.4.4
Impeller locking screw (#30) is secured
properly to XX NM torque (40 ft. lbs.)(58
joules).
6.4.5
Drive assembly rotates freely before
installing into volute. The hydraulic motor
and seal will cause some drag. Be sure
hose ports are open on the motor so as not
to get hydraulic binding.
6.4.6
Anti-seize lubricant should be used on all
fasteners when re-assembling pump.
6.4.7
Bearing housing is refilled with oil to the
bottom of the fill plug (#15) spill point.
6.4.8
Before submersing pump, test run on dry
land.
Check for proper rotation of impeller.
(Counter-clockwise looking into volute inlet)
Assembled
The pump will run backwards and pump
water though at noticeably lower volumes.
6.5 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. Refer to the Figure for the
correct position of each hose connection.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 8 of 12
Page 9
HYDRAFLOW S4VHL 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
PRESSURE
‘FEMALE’
CONNECTION
CONNECTION
SIDE OF MOTOR
INLET
OUTLET
‘MALE’
HOSE
OVERHUNG
SIDE OF
MOTOR
INLET
OUTLET
RETURN
PORT
OVERHUNG
Hose Connections
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
Operators Instructions for
HOSE
PORT
Manual No/Rev
W79-003E / 4
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.
7.2 Troubleshooting Guide
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
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
PUMP NOT PUMPING
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
Page 9 of 12
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
Page 10
Manual No/Rev
1,3
2
3
3
3
4
3
5
1
S4VHLPUMP
W79-003E / 4
HYDRAFLOW S4VHL Hydraulic Submersible Pump
Operators Instructions for
8. PUMP SECTION DRAWING AND PARTS LIST
8.1 Pump Section Drawing
7
6
1
3
5
9,4
10
11
12
13
14
19,4
20,20a
25
36
30
29
26
27
28
15
23
24
22
3
37,38
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 10 of 12
Page 11
HYDRAFLOW S4VHL Hydraulic Submersible Pump
7. 19394/F
Quick Release Flat Face Hydraulic Connector: 1"NPT Female
8. ---------
(Not used on this model)
37. HT0000176
Lock Washer, 5/8", stainless (4 req.)
38. HT0000179
Hex Bolt, 5/8 x 1", stainless (4 req.)
8.2 Parts List
Always mention serial # when ordering parts
Item Part # Description
1. HT9300313
HT9300146
2. -------- (Not used on this model)
3. HT9300290 Lifting Bracket
4. HT0000153 Lock Washer, 1/2", stainless (2 req.)
5. HT9300412 Hydraulic motor
6. 19394/M Quick Release Flat Face Hydraulic Connector: 1"NPT Male
9. HT0000154 Hex Bolt, 1/2" x 1", stainless (4 req.)
10. HT0700156 O Ring
11. HT0100157 Snap-ring
12. HT9300158 Bearing, upper
13. HT9300159 Shaft
14. HT9300158 Bearing, lower
15. HT0200161 Hex Plug
16. --------- (Not used on this model)
17. --------- (Not used on this model)
18. --------- (Not used on this model)
19. HT0009119 Hex Bolt, 1/2" x 1-1/2", stainless (8 req.)
20. HT0000166 Hex Bolt, 1/2" x 3/4", stainless (3 req.)
20a. HT9300287 Vent Bolt , stainless
21. HT0600153 Lock Washer, 1/2", stainless (4 req.)
22. HT9300151
HT9300227
23. HT9300167 Wear plate
24. HT0700168 O Ring
25. HT9300169
HT9303169
26. HT9300160 Impeller
27. HT9300171 Wear ring
28. HT0700168 O Ring
29. HT9300173 Cone Washer
30. HT0000174 Socket head bolt, 1/2" x 1-1/4", stainless
31. HT0003508 Hex Head Bolt (1/2" x 2" SS) (4 req.)
32. HT0000153 Lock Washer, 1/2", stainless (4 req.)
33. HT9300310A
HT9300310
34. HT9300314 O Ring (for 0310 )
35. HT9300308A Volute (Aluminium)
HT9300308 Volute (Ductile Iron)
36. HT9300294 Strainer Base
Pigtail Hose Assembly 1" x 3/4”
Pigtail Hose Assembly 1"
Bearing housing (Aluminium)
Bearing housing (Ductile Iron)
Seal Assembly (Standard Carbon/Ceramic)
Seal Assembly (Optional Silicon Carbide)
Discharge Adaptor 4" NPT(F) aluminium
Discharge Adaptor 4" NPT(F) ductile Iron
Operators Instructions for
Manual No/Rev
W79-003E / 4
Part Not Illustrated
19428
Bauer 4"Male/4NPT Male
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 11 of 12
Page 12
Manual No/Rev
W79-003E / 4
HYDRAFLOW S4VHL 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: +44 (0)118 932 3123
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: +44 (0)118 932 3123
Copies of this manual are available from the SPP Pumps Spares & Service Department by quoting reference
number W79-003E 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
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