Dv300 Std Mm

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SYKES PUMPS AUSTRALIAPTY LTD

CP300 PUMPSETFORDowdens

REF: W/O 08769

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Installation, Operation and Maintenance Manual.

Sykes Pumps Australia Pty. Ltd.

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PUMP SPECIFICATION

PUMP TYPE:

PUMP SIZE:

ACTUAL IMPELLER DIAMETER:

ENGINE / MOTOR TYPE:

MAXIMUM PUMP RPM:

PUMP NUMBER:

JOB NUMBER:

PLANT NUMBER:

ENGINE / MOTOR NUMBER:

A U S T R A L I A

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TECHNICAL DATA SHEET No. 1

DESIGN DETAILS:

Pump Designation: DV300Pump Description: Single stage, volute type, 4 bladed fully open

Centrifugal pumpSuction Flange: 300mm Table ‘E’ slotted flangeDelivery Flange: 250mm Table ‘E’ slotted flangeNominal Casing Thickness: 18mmNominal Shaft Diameter: 60mmImpeller Eye Diameter: 300mmMaximum Impeller O.D.: 430mm

Minimum Impeller O.D.: 390mmSolids Handling Size: 89mm

Wear Plate Clearances: REAR: 0.38/0.50mm FRONT: 0.38/0.50mmDesign Speed: 1000rpmDesign Capacity: 975m³/hrDesign Efficiency: 67%Max HP at Design Speed: 75kWSpecific Speed: 1667Operating Speed: MIN: 900rpm MAX: 1200rpmMaximum Head: 36mMaximum Capacity: 1100m³/hrOperating Temperature: MIN: -20°c MAX : +100°COperating TemperatureCasing:

MIN: -20°c MAX : +177°C

Permissible Suction Press: MIN: Zero ABS MAX : 2BAR (29 PSI)Maximum Hydraulic TestPress:

20.1 BAR (291 PSI)

Bearing Sizes: DRIVE END: SKF 6316 BallPUMP END: SKF NU316EC Roller

Estimated Bearing Life: MIN. SPEED/MAX. LOAD: 15,000 hoursMAX. SPEED/MIN. LOAD: 11,280 hours

Type of Bearing Lubrication: Grease lubrication Shell Alvania RA or equivalent.Type of Shaft Seal: Mechanical seal silicon carbide faces dry running

lubrication from oil reservoir behind seat. Pump outvanes on rear of impeller shroud. Balance holes.

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TECHNICAL DATA SHEET No. 2

MATERIALS OF CONSTRUCTION:

Pump Casing: SG IRON GRADE 400/12Suction Cover: SG IRON GRADE 400/12Air Separation Tank: SG IRON GRADE 400/12Bearing Bracket: SG IRON GRADE 400/12Pump Shaft: 431 Stainless SteelImpeller: 316 Stainless SteelWearplates: 316 Stainless SteelAir Injector: 316 Stainless SteelSeal Housing: SG IRON GRADE 400/12Mechanical Seal: Crane type 1A – 2 ½”

Lip Seal: Nitrile Rubber 2.36" ID x 3/8" WideN.R.V. Body: SG IRON GRADE 400/12N.R.V. Rubber: Nitrile or Polyurethane Rubber 55/60 ShoreEngine/Pump/Coupling:Compressor DriveDetails:

COMPRESSOR PULLEY: 2B Pulley – Link Belt,

φ140 (PCD)

DRIVE PULLEY: 2B Pulley – Link Belt, φ180 (PCD) to

suit TLB 2517 x φ60

Number & Belt Section: 2 x Link Belt ‘B’ Section (P/N: 340-4077) (1m each)Compressor Details: Bendix 2W 440 R Twin-in-line cylinders 75mmx50mm

stroke.Air cooled 15cfm (410L/min) at 1000rpm, Lubricationfromengine oil system.

Ejector Details: Jet: 23-0415-2016 Venturi: 23-0414-2036

ENGINE DETAILS: REFER TO ENGINE OPERATION, MAINTENANCE AND INSTALLATIONMANUAL.

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OPERATING & MAINTENANCE INSTRUCTIONS

DESCRIPTION OF UNIT

The pump is basically a simple end suction pump which has a completelyautomatic priming system built into the design. This enables the pump to selfprime from a completely dry condition even with a long suction line. No liquidof any nature is required to prime the pump and therefore in temporary drytrench conditions the pump will 'snore' until such time as liquid is available.

The DRI-VAC principal utilises a standard air compressor feeding apneumatic ejector mounted above the air/water separation tank. With thisdevice, suction lifts up to 8.2m (27 ft) can be obtained.

It can handle unscreened sewage, trade effluents, thick slurries and solids upto a normal limitation of 89mm.

The impeller is a four bladed, stainless steel construction, designed fully open.It is mounted on a shaft made from 431 stainless steel fitted in a SG ironbearing bracket; which also provides concentric location for the pump body.

The pump body is SG iron construction fitted with stainless steel wearplates.

The mechanical seal is leak tight and suitable for sewage and sludges using asilicon carbide face on a silicon carbide seat. The arrangement incorporates

an oil-filled seal housing.

Guards are fitted as standard to all moving parts.

For any engine details please refer to your engine manual or spare partsmanual.

Note: If your DV300 pumpset has been mounted on a trailer chassis it isrecommended that after approx. 5 km of travel that all wheel nuts beinspected and re-tightened.

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Operation

Before attempting to start the unit familiarise yourself with the engine controls

are mentioned in the Manufacturers Handbook and also the startingprocedure. It is advisable to turn the unit over slowly by hand before starting,to ensure that all components are free and easy to turn. Once started thecompressor will automatically come in at the correct speed to prime the pumpunit. When the engine has started the pump requires no adjustment as theengine speeds are set at WORKS.

Bearing Bracket And Pump

When replacing any castings, before use check for burrs, bruising, foreignbodies, porosity i.e. Bearing Bracket, Pump Body, Impeller, Shaft, SuctionCover, Seal Housing and Components.

Check the fit of the inner race for a reasonable transitional fit. When replacingthe inboard ball bearing it is fitted on the inner race only with Loctite "BearingFit" and cured with Loctite Grade T. Check the inner and outer race forexcessive wear and rough spots in rotation and if still present reject the ballrace. If alright repack approximately two thirds with new grease. ShellAlvania RA or No. 2 or near equivalent grade. Do not over-grease. Checkgrease cups for condition of grease and quantity. Check seal are notexcessively worn. Check water thrower is present and in reasonable

condition.

The bearings used are ball bearings: 4½" x 2" x 1.1/16"6316 S.K.F.

Roller bearings (adj to pump): 4½" x 2" x 1.1/16"NU316EC S.K.F.

Examine the shaft end over which the seal is fitted for burrs, bruises, etc.which are likely to damage the seal during fitting.

Preparation And Seal Fitting Of Mechanical Seal

Inspect seal seat face for blow holes, scores, or wear marks, etc. Ensure thatthere is a minimum lead-in radius of 1mm into the seal seat recess on sealextension housing.

When a seal is reconditioned, it should be ground to a surface finish of 10-20C.L.A. and lapped to within 3 sodium light bands. Seals with only a groundfinish are unsatisfactory, and will result in excessive wear of the faces.

Check that the lip seal in the rear of the seal housing is not excessively worn,

renew if required.

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Preparation And Seal Fitting Of Mechanical Seal - Cont'd

Extreme care should be taken when fitting the silicon carbide faced seal as

this material is very brittle and easily chipped.

If the seal cannot be inserted with fingers it should be pushed home with alength of soft tube or wood large enough in diameter to make contact aroundthe outer edge of the seat; clear of the sealing area.

Before fitting the rotating seal unit ensure that all surfaces are clean and thatall edges over which the bellows have to pass are rounded-off toapproximately 1mm radius. All working faces must be clean and free fromany foreign matter.

Smear pump shaft with light oil (not grease). Fit the taper tool over the shaft(Fig. 3) and mount seal face ring on the bellow unit. For assembly purposes itis permissible to put a smear of grease behind the ring, to hold it in placeduring assembly over the taper sleeve and into place on the shaft. A solublegrease is preferable e.g. Swarfega.

Before fitting the seal housing dampen the joint with water.

Whether the wearplates or impeller have been replaced or not, the followingprocedures should be observed:-

* Ensure that the impeller will screw-up to the shaft shoulder and that thethread form has not been damaged.

* Using adjusting shim washers behind the impeller boss (if necessary)set the front and back clearance to within 0.38/0.50mm.

* Before finally fitting the impeller, grease shaft areas and pump casingbore where seal assembly passes through. This will also assist futureremoval of impeller and seal assembly. The recommended grades oflubricant for this are:- 'Copperslip' or 'Shell Alvania' grease plus

Molybdenum Disulphide or Rocal Anti-Seize compound J166.

* Non-adhesive sealant to be used on all plugs including filler and drainplug e.g. Boss White, Non-Adhesive Hermatite, Loctite HydraulicSealant.

If pump units are to remain in stock unused for long periods of time, alladjacent close clearance surfaces should be sprayed with an aerosol can ofMolyslip A.D.F. to prevent rust and seizure.

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Separation Tank And Ejector

Dri-Prime Ejector Pack Assembly:

Check ejector and jet sizes: Nozzle 23-0414-2036Jet 23-0415-2016

Clean the jet and nozzle with paraffin or similar cleaner. On no account shouldstiff wire be used as this will enlarge the bores.

Check the nozzle and jet bores for any sharp edges, burrs or rough surfaces.If damaged and no replacement is readily available, smooth and polish as wellas possible to original form.

Alignment of jet and nozzle is important but this is preset by machiningtolerances and the use of standard copper-asbestos washers.

Assemble ejector unit and check performance on test unit. Operation AirPressure: 40 psi approx. Minimum Pass Vacuum: 24" Mercury (27.24ft)

When the above figure is not obtained, the distance between the nozzle andejector may be slightly adjusted by an additional copper-asbestos washer withone or both to obtain the vacuum required.

A satisfactory arrangement for carrying out the performance test on theejector unit is a plate fitted with a vacuum gauge as illustrated.

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NON-RETURN VALVE

Ensure that all items are clean and free from burrs.

Visually check for porosity and blow holes in the castings and for scores orchaffing of the valve.

COMPRESSOR

The standard compressor pack assembly is a compressor driven directly fromthe engine.

As an option the compressor, complete with timing belts and pulleys, is alsoavailable as a direct drive off the pump shaft.

TEST PROCEDURE

VACUUM TEST

When the bearing bracket and complete pump end have been assembled andbefore the cavity behind the mechanical seal seat has been filled with oil, thepump should be subjected to a vacuum test to show up any air leaks.

Air leaks may occur from the mechanical seal, non-return valve, the ballN.R.V., in the ejector plate, pump joints, porous castings or from filling anddrain plugs.

The assembled pump end should seal against a minimum vacuum of 81kPa(8m). With closed valves, the vacuum should hold for a minimum of 5minutes.

Fill seal housing after test is completed with Shell engine oil or equivalent untilthe level reaches the threads of the filler hole.

Pressure test complete; pump unit to 1½ times maximum working pressurei.e. 2052kPa (300 psi).

DYNAMIC TEST

Rotate engine on starter for a minimum of six complete revolutions, listen forinjector 'creak' - indicating the injector pump is working.

Start pump and run completely dry for a minimum period of 10 minutes.During this period generally check and observe for any unusual vibrations,overheating, fuel, oil or air leaks.

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GENERAL MAINTENANCE

BEARINGS (GREASE CAPS)

CHECK FOR GREASE QUANTITY AND QUALITY AT EACH STARTUP OPERATION. USE SHELL ALVANIA RA OR NO. 2 OREQUIVALENT GREASE.

(REFER ITEM BB22 IN PARTS LISTING).

MECHANICAL SEAL

- CHECK OIL LEVEL AT EACH START UP OPERATION- FILL WITH A LIGHT ENGINE OIL TO WITHIN 25MM FROM

THE TOP OF THE RESERVOIR.

(REFER ITEM BB11 IN PARTS LISTING)

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PUMP PROBLEMS - Systems & Likely Causes

1. Pump does not prime Suction lift too great.Insufficient water at suction inlet.Suction inlet or strainer blocked.

Suction line not air tight.Suction hose collapsed.Non return valve ball not seatingMechanical seal drawing air into pumpEjector jet or nozzle blocked or badlyworn.Ejector non-return valve ball stuck.Separation tank cover blocked.Compressor pipe leaking air.Compressor no delivering sufficient airCompressor belt drive faulty.

2. Not enough liquid Incorrect engine speed.Discharge head too high.Suction lift too great.Suction inlet or strainer blocked.Suction line not air tight.Suction hose collapsed.Mechanical seal drawing air into pump.Obstruction in pump casing/impeller.Impeller excessively worn.Delivery hose punctured or blocked.

3. Pump ceases to deliver liquidafter a time. Suction lift too great.Insufficient water at suction inlet.Suction inlet or strainer blocked.Suction hose collapsed.Excessive air leak in suction line.Mechanical seal drawing air into pump.Obstruction in pump casing/impeller.Delivery hose punctured or blocked.

4. Pump takes excessive power Engine speed too high.Obstruction between impeller and casing.Viscosity and SG of liquid being pumped

too high.5. Pump vibrating or overheating Engine speed too high.

Obstruction in pump casing/impeller.Impeller damaged.Cavitation due to excessive suction lift.

6. Pump leaking at seal housing Mechanical seal damaged or worn.

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THIS PUMP IS DEFINED IN SUB-ASSEMBLIES

H Volute

BB Bearing Bracket

EP Ejector Pack

ST Separation Tank

OR Oil Reservoir

C Chassis

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PARTNUMBER

DESCRIPTION

267787 "C" Ring (Rear)

267805 Oil Seal

295717 Bearing (Front)

KW4785/1SP Cod Rod Complete

KW5172/1SP Piston Assembly (STD)

KW5172/2SP Piston Assembly (0.010" o/s)

KW5173/3SP Piston Assembly (0.020" o/s)

KX1223/13SP End Cover Assembly

SK2997/1 Valve Plate & Head Gasket Kit

KX2542/1 Base Mount Gasket

KY2258/1SP Crankshaft

KY2331/1SP Valve Plate Assembly

SKR2790/00 Piston Ring Set (STD)

SK2790/10 Piston Ring Set (0.010" o/s)

SK2790-20 Piston Ring Set (0.020" o/s)

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PARTS LISTS

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ILLUS.No. DESCRIPTION PART No. QTY.

BB1 Bearing Bracket 13-0160-0115 1

BB2 Bearing Cover Outer Rear 13-0156-0115 1

BB2a Bearing Cover Outer Front 13-0158-0115 1

BB3 Bearing Cover Inner 13-0157-0115 2

BB4 Ball Bearing SKF6316 39-0070-9912 1BB5 Roller Bearing SKF NU316EC 39-0071-9912 1

BB6 Set Screw (M12 x 60) 6

BB7 Hex. Head Bolt (M12 x 80) 6

BB7a Lock Washer (M12) 16

BB8 Spiro Seal 38-0543-1913 1

BB9 Spiro Seal 38-0543-1923 1

BB10 Grease Nipple (1/8" BSP) 51-0003-8112 1

BB11 Bearing Bracket Cover & Tank 27-6666-8211 1

BB12 Lock Washer (M6) 2

BB13 Shaft – DV300 16-0363-8831 1BB14 Bracket Body Stud (M20 x 70) 8

BB15 Bracket Body Nut (M20) 8

BB16 Bracket Body Lock Washer (M20) 8

BB17 Guard – DV300 27-1700-8211 1

BB18 Set Screw (M6 x 10) 2

BB19 Bearing Lock Nut SKF KM15 39-0072-9912 1

BB20 Lock Nut Washer SKF MB15 39-0073-9912 1

BB21 Bearing Clamp Ring 28-0254-8811 1

BB22 Socket Head Screw (M6 x 20) 1

BB27 Oil Reservoir Breather Plug 1BB29 Bolt (M12 x 40) 4

BB30 Extension Piece (1/8” BSP M/F) 10-0000-0025 1

BB31 Compressor Unit - Bendix 49-0523-9915 1

BB32 Compressor Pulley 2B - φ140 PCD 1

BB33 Pump Pulley 2B - φ180 PCD to suit

TLB 2517 x φ60

10-0000-0520 1

BB34 Link Belt ‘B’ Section (1m each) 340-4077 2

BEARING BRACKET

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ILLUS. No. DESCRIPTION PART No. QTY.

EP1 Ejector Jet 23-0415-2016S 1

EP2 Ejector Nozzle 23-0414-2036S 1

EJECTOR PACKAGE

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ILLUS. No. DESCRIPTION PART No. QTY

ST6 Ejector Carrier Plate 23-0411-0115 1

ST7 Refer to ST14ST8 Carrier / Tank Stud (M12 x 50) 4

ST9 Carrier / Tank Nut (M12) 4

ST10 Carrier / Tank Lock Washer (M12) 4

ST11 Ball Seat 23-0412-2011 1

ST12 Ball 39-0641-4113 1

ST13 Carrier Plate Plug 1” BSP P16 1

ST14 Filter – includes gasket 23-0413-2113 1

ST19 1” M/M Hydraulic Elbow E16BMF 1

ST20 1” Socket S16 1

SEPARATION TANK / EJECTOR

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ILLUS. NO. DESCRIPTION PART NO. QUANTITY

OR1 Oil Reservoir Assembly 27-5000-8211 1

OR2 Lid 1OR3 Sight & Temperature Guage 40-0000-0060 1OR4 Hydraulic Nipple ¼” BSP N04H 2OR5 Oil Reservoir Gasket 38-0350-5443 1OR6 Nut (M12) 1OR7 Springwasher (M12) 1OR8 Plug ½” (with breather) P08 1

OIL RESERVOIR ASSEMBLY

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ILLUS. No. DESCRIPTION PART No. QTY

AC1 Compressor (Bendix) 49-0523-9915 1

AC2 Gasket KX2542/1 1

AC3 Stud M10 x 40 4

AC4 Springwasher M10 4

AC5 Compressor Pulley 2B - φ140 PCD 1AC6 Pump Pulley 2B - φ180 PCD to suit

TLB 2517 x φ60

10-0000-0520 1

AC7 Link Belt ‘B’ Section (1m each) 340-4077 2

AC8 Fan Washer 36-0556-8111 1

AC9 Relief Valve 10-0000-0004 1

AC10 Air Cleaner 54-0556-9912 1

AC11 Adaptor (Air Cleaner) A1212 1

AC13 Compressed Air Hose 42-0000-0015 1

AC14 Nipple 3/4 BSP x 1/2 BSP N1208H 1

AC15 Pulley/Belt Guard 1

COMPRESSOR ASSEMBLY

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ILLUS.No. DESCRIPTION PART No. QTY.

C1 Chassis 27-3000-0000 1

C2 Battery Box 340-8002 1

C3 Filler Cap 2" BSP 1

C4 Plug 2" BSP 3

C5 Fuel Suction & Delivery Pipe 346-5372 2C6 Fuel Hose Return & Delivery 340-6041 2

C7 Plug ¾" BSP 1

CHASSIS

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ACCESSORIES

Description Part No.

• Single Point Lifting Frame 27-2000-0060

• 150mm Non Return Valve 10-0000-0450

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CHASSIS

Your QS/CP300 x Cummins 6BTA pumpset has been mounted

on a customised robust skid base chassis and enclosed in a

SYKES QS Acoustic Canopy and comes complete with the

following extras:

• In built fuel tank

• Single Point Lifting frame

• Lifting eyes (canopy only)

• Lockable access doors

• Forklift pick up points

• Drain plugs - Fuel, engine,oil,washdown

• Suction adaptor spool

• Pinchweld rubber on all doors

• Battery holder

• Battery

• Seperate Engine/Pump base frame

• Vibration mounts for Engine/Pump base frame

• Acoustic Insulation

• Perforated sheets for insulation

• water silencer box

• Discharge bauer

• Suction bauer

• Fuel access from outside enclosure

• Lockable fuel access flap

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ENGINE

Your QS/CP300 pumpend is driven by a Cummins 6BTA water

cooled diesel engine developing 119kw @ 2200 rpm.

For further information please refer to the Manufacturer's

Operation and Maintenance Manuals.

Documents

Dv300 Std Mm