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SYKES GROUP PTY LTD

HH125 PUMPSET
FOR

REF: W/O

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd


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Installation, Operation and Maintenance Manual.

SYKES GROUP PTY LTD


PUMP SPECIFICATION
PUMP TYPE:
PUMP SIZE:
ACTUAL IMPELLER DIAMETER:

HH125
150mm x 125mm
370mm

ENGINE / MOTOR TYPE:


PUMPSET NUMBER:
PUMPEND NUMBER:
JOB NUMBER:
PLANT NUMBER:
ENGINE / MOTOR NUMBER:
DRY WEIGHT:
FUEL CAPACITY:
WET WEIGHT:
Sykes Group Pty Ltd
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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd


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Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 1


DESIGN DETAILS:
Pump Designation:
Pump Description:
Suction Flange:
Delivery Flange:
Nominal Casing Thickness:
Nominal Shaft Diameter:
Impeller Eye Diameter:
Maximum Impeller O.D.:
Minimum Impeller O.D.:
Moment Inertia Impeller:
Solids Handling Size:
Wear Plate Clearances:
Design Speed:
Design Capacity:
Design Efficiency:
Max HP at Design Speed:
Specific Speed:
Operating Speed:
Outrigger Bearing to be fitted
above:
Maximum Head:
Maximum Capacity:
Operating Temperature:
Operating Temperature
Casing:
Permissible Suction Press:
Maximum Hydraulic Test
Press:
Bearing Sizes:
Estimated Bearing Life:
Type of Bearing Lubrication:
Type of Shaft Seal:

HH125(DV)
Single stage, volute type, 3 bladed fully open
Centrifugal pump
6" Table 'D'
5" Table 'D' complete with 5"-6" adaptor
18mm
50mm
90mm at tip, 76mm at eye
370mm (Outlet Width - 33.6mm)
250mm (Hub Dia. 80mm)
1022.8kg/cm
29mm
REAR: 0.50/0.70mm FRONT: 0.50/0.70mm
2200rpm
81m/hr
50%
110HP
460
MIN: 1600rpm
1800rpm
136m (447Ft)
180m/hr (660GPM)
MIN: -20c
MIN: -20c

MAX: 2400rpm

MAX : +100C
MAX : +177C

MIN: Zero ABS


MAX : 2BAR (29 PSI)
20.1 BAR (291 PSI)
DRIVE END:
SKF RMS16 Ball
PUMP END:
SKF CMR16
Roller
MIN. SPEED/MAX. LOAD:
15,000 hours
MAX. SPEED/MIN. LOAD:
11,280 hours
Grease lubrication Shell Alvania RA or
equivalent
Mechanical seal silicon carbide faces dry
running
lubrication from oil reservoir behind seat.
Pump out vanes on rear of impeller shroud.
Balance holes.

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Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 2


MATERIALS OF CONSTRUCTION:
Pump Casing:
Suction Cover:
Air Separation Tank:
Bearing Bracket:
Pump Shaft:
Impeller:
Wearplates:
Air Injector:
Seal Housing:
Mechanical Seal:
Lip Seal:
N.R.V. Body:
N.R.V. Rubber:
Compressor Drive Details:

Number & Belt Section:

S.G. IRON TO AS1831 GRADE SG 400/12


S.G. IRON TO AS1831 GRADE SG 400/12
S.G. IRON TO AS1831 GRADE SG 400/12
S.G. IRON TO AS1831 GRADE SG 400/12
431 Stainless Steel
316 Stainless Steel
316 Stainless Steel
316 Stainless Steel
St/Steel 316 Grade
Crane type 1A 2" CODE BJ1S1/D
Nitrile Rubber 2" ID x 3/8" Wide
S.G. IRON TO AS1831 GRADE SG 400/12
Nitrile or Polyurethane Rubber 55/60 Shore
COMPRESSOR PULLEY: Tooth Belt " Pitch Heavy x
40 Teeth (P/N. 26-0830-0243)
DRIVE PULLEY:
Tooth Belt " Pitch Heavy x
32 Teeth (P/N. 10-0000-0049)
1 x Timing Belt 38mm Wide 390H150 (P/N. 26-0840-9912)

Compressor Details:

Bendix 2W 440 R Twin-inline cylinders 75m x 50mm


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

Ejector Details:

Jet: 23-0415-2016S

Venturi: 23-0414-2036S

OPERATING & MAINTENANCE INSTRUCTIONS

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Installation, Operation and Maintenance Manual.

DESCRIPTION OF UNIT
The pump is basically a simple end suction pump which has a completely
automatic priming system built into the design. This enables the pump to self
prime from a completely dry condition even with a long suction line. No liquid of
any nature is required to prime the pump and therefore in temporary dry trench
conditions the pump will 'snore' until such time as liquid is available.
The DRI-VAC principal utilises a standard air compressor feeding a pneumatic
ejector mounted above the air/water separation tank. With this device, suction
lifts up to 8.2m (27 ft) can be obtained.
It can handle unscreened sewage, trade effluents, thick slurries and solids up to a
normal limitation of 29mm.
The impeller is a three bladed, stainless steel construction, designed fully open. It
is mounted on a shaft made from 431 stainless steel fitted in a cast iron bearing
bracket; which also provides concentric location for the pump body.
The pump body cast iron construction fitted with stainless steel wearplates.
The mechanical seal is leak tight and suitable for sewage and sludges using a
silicon carbide face on a silicon carbide seat. The arrangement incorporates an
oil-filled seal housing.
The whole unit is mounted on a robust skid base chassis. It is fitted with towing
eyes, lifting frame. The fuel tank has a capacity of 580L.
Guards are fitted as standard to all moving parts.
For any engine details please refer to your engine manual or spare parts manual.
Note: If your HH125 pumpset has been mounted on a trailer chassis it is
recommended that after approx. 5 km of travel that all wheel nuts be inspected
and re-tightened.

OPERATING & MAINTENANCE INSTRUCTIONS


Operation
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Installation, Operation and Maintenance Manual.

Before attempting to start the unit familiarise yourself with the engine controls as
mentioned in the Manufacturers Handbook and also the starting procedure. 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 the compressor will
automatically come in at the correct speed to prime the pump unit. When the
engine has started the pump requires no adjustment as the engine speeds are set
at WORKS.
Bearing Bracket And Pump
When replacing any castings, before use check for burrs, bruising, foreign bodies,
porosity i.e. Bearing Bracket, Pump Body, Impeller, Shaft, Suction Cover, Seal
Housing and Components.
Check the fit of the inner race for a reasonable transitional fit. When replacing the
inboard ball bearing it is fitted on the inner race only with Loctite "Bearing Fit" and
cured with Loctite Grade T. Check the inner and outer race for excessive wear
and rough spots in rotation and if still present reject the ball race. If alright repack
approximately two thirds with new grease. Shell Alvania RA or No. 2 or near
equivalent grade. Do not over-grease. Check grease cups for condition of grease
and quantity. Check seal are not excessively worn. Check water thrower is
present and in reasonable condition.
The bearings used are ball bearings
Roller bearings (adj to pump)

4" x 2" x 1.1/16"


RMS16 S.K.F.
4" x 2" x 1.1/16"
C.R.M. 16 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 that
there is a minimum lead-in radius of 1mm into the seal seat recess on seal
extension housing.
When a seal is reconditioned, it should be ground to a surface finish of 10-20
C.L.A. and lapped to within 3 sodium light bands. Seals with only a ground finish
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.
Extreme care should be taken when fitting the silicon carbide faced seal as this
material is very brittle and easily chipped.

OPERATING & MAINTENANCE INSTRUCTIONS


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Installation, Operation and Maintenance Manual.

Preparation And Seal Fitting Of Mechanical Seal - Cont'd


If the seal cannot be inserted with fingers it should be pushed home with a length of
soft tube or wood large enough in diameter to make contact around the outer edge of
the seat; clear of the sealing area.
Before fitting the rotating seal unit ensure that all surfaces are clean and that all edges
over which the bellows have to pass are rounded-off to approximately 1mm radius. All
working faces must be clean and free from any foreign matter.
Smear pump shaft with light oil (not grease). Fit the taper tool over the shaft (Fig. 1)
and mount seal face ring on the bellow unit. For assembly purposes it is permissible
to put a smear of grease behind the ring, to hold it in place during assembly over the
taper sleeve and into place on the shaft. A soluble grease is preferable e.g. Swarfega.
Before fitting the seal housing dampen the joint with water.
Whether the wear plates or impeller have been replaced or not, the following
procedures should be observed:* Ensure that the impeller will screw-up to the shaft shoulder and that the thread
form has not been damaged.
* Using adjusting shim washers behind the impeller boss (if necessary) set the front
and back clearance to within 0.50/0.70mm.
* Before finally fitting the impeller, grease shaft areas and pump casing bore where
seal assembly passes through. This will also assist future removal of impeller and
seal assembly. The recommended grades of lubricant 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 drain plug e.g.
Boss White, Non-Adhesive Hermatite, Loctite Hydraulic Sealant.
If pump units are to remain in stock unused for long periods of time, all adjacent close
clearance surfaces should be sprayed with an aerosol can of Molyslip A.D.F. to
prevent rust and seizure.
Separation Tank And Ejector
Dri-Prime Ejector Pack Assembly:
Check ejector and jet sizes:

Nozzle
23-0414-2036S
Jet
23-0415-2016S
Clean the jet and nozzle with paraffin or similar cleaner. On no account should stiff
wire be used as this will enlarge the bores.

OPERATING & MAINTENANCE INSTRUCTIONS


Separation Tank And Ejector - Cont'd

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Installation, Operation and Maintenance Manual.

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 well as possible
to original form.
Alignment of jet and nozzle is important but this is preset by machining tolerances and
the use of standard copper-asbestos washers.
Assemble ejector unit and check performance on test unit. Operation Air Pressure: 40
psi approx. Minimum Pass Vacuum: 24" Mercury (27.24ft)
When the above figure is not obtained, the distance between the nozzle and ejector may
be slightly adjusted by an additional copper washer with one or both to obtain the
vacuum required.
A satisfactory arrangement for carrying out the performance test on the ejector unit is a
plate fitted with a vacuum gauge as illustrated.

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

OPERATING & MAINTENANCE INSTRUCTIONS


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 or
chaffing of the valve.
COMPRESSOR
The standard compressor pack assembly comes complete with timing belts and
pulleys and is a direct drive off the pump shaft.
As an option a compressor, driven directly from the engine is also available.
TEST PROCEDURE
VACUUM TEST
When the bearing bracket and complete pump end have been assembled and
before the cavity behind the mechanical seal seat has been filled with oil, the
pump 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 ball N.R.V., in
the ejector plate, pump joints, porous castings or from filling and drain 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 5 minutes.
Fill seal housing after test is completed with Shell engine oil or equivalent until the
level reaches the threads of the filler hole.
Pressure test complete; pump unit to 1 times maximum working pressure i.e.
2052kPa (300 psi).
DYNAMIC TEST
Rotate engine on starter for a minimum of six complete revolutions, listen for
injector '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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Installation, Operation and Maintenance Manual.

OPERATING & MAINTENANCE INSTRUCTIONS


DYNAMIC TEST- Cont'd
After the dry running period check that the pump unit will raise a minimum vacuum
of 81kPa ie. 8m.
Couple hoses to the pump suction and delivery; test from a deep well pit at a
suction lift of approximately 7.5m. Record priming time.
This hydraulic test should be repeated several times until satisfied that all
components are functioning correctly. The duration of the hydraulic test should be
a minimum of 20 minutes.
At the end of the hydraulic test again check that the pump will raise a vacuum of
81kPa.
.

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

GENERAL MAINTENANCE
BEARINGS (GREASE CAPS)
CHECK FOR GREASE QUANTITY AND QUALITY AT EACH START UP
OPERATION. USE SHELL ALVANIA RA OR NO. 2 OR EQUIVALENT
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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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

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 seating
Mechanical seal drawing air into pump
Ejector jet or nozzle blocked or badly worn.
Ejector non-return valve ball stuck.
Separation tank cover blocked.
Compressor pipe leaking air.
Compressor no delivering sufficient air
Compressor 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 liquid Suction lift too great.
after a time.
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
Engine speed too high.
overheating
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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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

THIS PUMP IS DEFINED IN SUB-ASSEMBLIES

Volute

BB

Bearing Bracket

EP

Ejector Pack

ST

Separation Tank

DR

Flywheel Coupling

Non-Return Valve

Chassis

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

PARTS LISTS

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ILLUS.No.
H1
H2
H3
H4a
H4b
H4c
H5
H6
H8
H12
H13
H14
H15
H16
H17
H18
H19
H20
H21
H26
H28a
H28b
H29
H31
H50
H66
H68
H83

DESCRIPTION
Body
Impeller
Front Cover
Joint (Body)
Joint (Body)
Joint (Body)
Wearplate (Front)
Setscrew M12 x 36
Wearplate (Rear)
Seal Unit
Dowel Pin
Seal Extension Joint
Seal Housing
Bolt M6 x 55
Spring Washer M12
Stud M12 x 50
Nut M12
Spring Washer M12
Flat Washer M12
Plug
Impeller Shim
Impeller Shim
O Ring Sealing Washer SS
Viton O Ring
Setscrew M12x35 SS Sockethead
Oil Seal
Seal Spacer
O-ring (Seat)
Hose

PART No.
11-0195-0155
12-0244-3015
11-0196-0000
38-0300-5413
38-0300-5423
38-0300-5433
12-0243-0915
12-0251-0915
38-0814-BJ1S1/D
10-0000-0025
38-0333-5413
14-0303-2911

36-0557-8213
36-0557-8223
38-0785-4412
38-0787-4112V
38-0533-1913
24-0168-6111
38-1067-4112
346-5371

QTY.
1
1
1
A/R
A/R
A/R
1
8
1
1
1
1
1
4
4
12
12
12
2
A/R
A/R
4
4
1
1
1
1
12

VOLUTE

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Installation, Operation and Maintenance Manual.

ILLUS.No.
BB1
BB2
BB2a
BB3
BB3a
BB4
BB5
BB6
BB6a
BB7
BB8
BB8
BB9
BB11
BB12
BB13
BB14
BB15
BB16
BB17
BB19
BB20
BB21
BB26
BB10
BB18
Not Shown

DESCRIPTION

PART No.
13-1118-0125
13-0063-0125
13-0063-0135
13-0010-0145
13-0010-0165
39-0009-9912
39-0057-9912

Bracket
Bearing Cover (Inner)
Bearing Cover (Inner Pump End)
Bearing Cover (Outer)
Bearing Cover (Outer Pump End)
Ball Bearing
Roller Bearing
Setscrew Outer Cover M10 x 25
Setscrew Outer Pump End M10 x90
Setscrew Inner Cover M10 x 65
Oil Seal
38-1069-9912
Oil Seal
38-1069-9912
Springwasher M10
Brearing Bracket
27-6000-8211
Oil Reservoir (Removable)
27-5000-8211
Setscrew M10 x 25
Shaft
16-0410-8611
Circlip 2"
345-4520
Stud M12 x 45
Nut M12
Springwasher M12
Springwasher M10
Flatwasher M10
1/8" BSP Grease Nipple
51-0003-8112
Bearing Housing
13-0179-0115
o
10-0000-0024
1/8" BSP x 90 Grease Nipple
Flatwasher
Extension Piece 1/8BSP M/F
10-0000-0025

QTY.
1
1
1
1
1
1
1
3
3
6
1
1
12
1
1
4
1
1
8
8
8
4
4
1
1
1
8
1

BEARING BRACKET
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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ILLUS. No.
DESCRIPTION
EP1
Ejector Jet
EP2
Ejector Nozzle

PART No.
QTY
23-0415-2016S
1
23-0414-2036S
1

EJECTOR PACKAGE
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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ILLUS. No.
ST1
ST2
ST5
ST6
ST8
ST9
ST10
ST11
ST12
ST13
ST14
ST16/17
ST21
Not Shown

DESCRIPTION
"T" Piece
Tank/Body Joint
Flat Washer M20
Ejector Carrier Plate
Stud M12 x 50
Nut M12
Flat Washer M12
Ball Seat
Ball
Plug 1" BSP
Filter
Elbow BSP FM to 3/4 Hosetail
Bolt M20 x 75
Vacuum Gauge

PART No.
348-4006
500-4051
23-0411-0115

23-0412-2011
39-0641-4113
P16
23-0413-2113
E12SBF
001-0003

QTY
1
2
16
1
4
8
8
1
1
1
1
1
8
1

SEPARATION TANK / EJECTOR


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Installation, Operation and Maintenance Manual.

ILLUS. No.
AC1
AC2
AC3
AC4
AC5
AC6
AC7
AC8
AC9
AC10
AC11
AC13
AC14
AC15

DESCRIPTION
Compressor (Bendix)
Gasket
Setscrew M10 x 25
Springwasher M10
Pulley - Pump ( bored to suit TLB) c/w
2517 x 1-7/8 Taper Lock Bush
Pulley (Compressor)
Belt 38 wide x 78 teeth (1/2 Heavy Pitch)
Fan Washer
Relief Valve
Air Cleaner
Adaptor (Air Cleaner)
Compressed Air Hose
Elbow BSP x BSP
Pulley/Belt Guard

PART No.
49-0523-9915
KX2542/1
10-0000-0039
10-0000-0035
26-0830-0243
26-0840-9912
36-0556--8111
10-0000-0004
54-0556-9912
A1212
42-0000-0009
E1208HMM

QTY
1
1
4
4
1
1
2
1
1
1
1
1
1
1

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ILLUS. No.
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16

DESCRIPTION
REFLUX BOX COMPLETE
Reflux Box Body
Stud M20 x 65
Nut M20
Stud M20 x 70
Flat Washer M20
Nut M20
Reflux Box Cover
O-Ring
Reflux Box Seat
Reflux Box Ball
Drain Cock
Joint
Nut M20
Flat Washer M20
Bolt M20 x 70

PART No.
356-2124HH
356-4061HH

356-4062
356-4153
356-4063
313-4169
920-9242
500-4051

QTY
1
1
8
8
4
4
4
1
1
1
1
1
1
8
8
8

REFLUX BOX ASSEMBLY 150MM HIGH HEAD


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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ILLUS.No.
C1
C2
C3
C4
C5
C6
C7

DESCRIPTION
Trailer Chassis
Battery Box
Filler Cap 2" BSP
Plug 2" BSP
Fuel Suction & Delivery Pipe
Fuel Hose Return & Delivery
Plug " BSP

PART No.
SPA-400

346-5372
340-6041

QTY.
1
1
1
3
2
2
1

CHASSIS

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ACCESSORIES

Description

Part No.

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

ENGINE

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