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QSCP150 PUMPSET
FOR
MIDCOAST WATER
CP150
150 mm X 150 mm
275 mm
PUMP NUMBER:
03QSCP15012121
JOB NUMBER:
W/O 12121
CP150
Single stage, volute type, 3 bladed fully open
Centrifugal pump
6" Table 'D'
6" Table 'D'
10mm
40mm
152mm Imp. Hub Dia. - 46mm
275mm STD.
245mm Imp. Outlet Width - 65.2mm STD.
Cutwater Clearance - 30mm STD
65mm
REAR: 0.36/0.69mm
FRONT: 0.36/0.69mm
1500rpm
255m3/hr
24.1HP at 1500rpm
2439rpm
MIN: 1300rpm
MAX: 2000rpm (Subject to available
HP)
42m (139ft)
435m3/hr (1600GPM)
MIN: -20oC
MAX: +80oC
o
MIN: -20 C
MAX: +120oC
Maximum Head:
Maximum Capacity:
Operating Temperature:
Operating Temperature
Casing:
Permissible Suction Press: MIN: Zero ABS MAX: 2.5 BAR (29.0 PSI)
Maximum Hydraulic Press: 6.2 BAR (90 PSI)
Bearing Sizes:
DRIVE END:
Taper Roller SKF 33111
PUMP END:
Taper Roller SKF 33111
Estimated Bearing Life:
MIN. SPEED/MAX. LOAD:
Indefinite
MAX. SPEED/MIN. LOAD:
26,000 Hours
Type of Bearing
Grease Lubrication Shell Alvania RA or equivalent
Lubrication:
Type of Shaft Steel:
Recessed Scavenger pumpout vanes to rear of
impeller external mounted mechanical seal, oil
lubricated silicon carbide interfaces
MA
EP
AC
DR
Hatz Coupling
If pump units are to remain unused for a long time all adjacent clearance
surfaces should be sprayed with a coating of 'Molyprotectoslip' to prevent rust
or seizure.
Items MA3, MA5 & MA41 should be fitted when assembling to the engine
4. Remove and discard the drain plug from the side of the engine base and fit the
oil return hose (AC32) from the compressor.
5. Ensure that all hoses from the compressor are fitted with no kinks or sharp
bends and are kept clear of the hot area of the engine and compressor.
6.
Fit the fuel lines and all other remaining chassis items.
Secure the guard (AC55) with screws (AC56). Ensure that the belt and pulleys
are free to rotate.
Insert ball (V10) then fit o-ring (V8) and cover (V7) with fasteners.
Push air muffler (EP16) into the exhaust hose (EP15). Fasten using clamp
(EP17).
DV150 TESTING
INSPECTION
1. Drain the water from the pump and the non-return valve (Ref items H27 &
V11).
2. Remove the non-return valve and inspect the ball and seat (Ref items V10 &
V9) for wear.
3. Drain the oil from the engine and the pump (Ref item MA29).
4. Dismantle the pump end completely (Ref items H31, H1, H3, H12, H4 and H5).
5. If the oil seal (MA31) has scored the collar (H20), it may be pushed in 2mm to
seal on an unscored area of the sleeve. Ensure that the oil seal is positioned
squarely and that it is less than 8mm from the machined face of the adaptor
(MA1).
6. Worn seal faces may be reclaimed by lapping faces to a surface finish of 3
sodium light bands. Note that the stationary seat was originally lapped both
sides and may be reversed in the wearplate (H12).
7. Check that the shaft rotates freely and has an end float less than 0.2mm.
8. Clean and inspect all components and renew where necessary. Do not use
abrasive materials or solutions to clean the ejector assembly. Renew all nitrile
seals.
9. Reassemble the complete pump end and non-return valve (Ref Fitting
Instructions).
10. Drain the fuel tank.
11. Detach fuel, oil and air hoses. Clean and ensure that they are not blocked.
Test the relief valves (MA26 at 3 to 5 psi, and AC78 at 90 to 100 psi).
12. Check pulley alignment and belt condition (Ref items AC9, AC10 & AC11).
Check the security of pulleys and flexible couplings.
13. Reassemble the complete unit.
TESTING
1. Fill the seal housing (Ref item MA28) with half a litre of SAE20/20 oil and the
bearing housing (Ref item MA25) with Shell Alvania RA grease.
2.
Fill engine with 5.3 litres of SAE 20/20 detergent oil for testing.
VACUUM TEST
1. The assembled pump should be subjected to a vacuum to show up any air
leaks. Disconnect the compressor hose, fit a compressor air line to the jet,
and hold a vacuum gauge assembly against the pump suction flange. The
pump end should seal against a minimum vacuum of 0.81 bar (24 inches
mercury). With closed valves the vacuum does not hold, air may be leaking at
the mechanical seal, non-return valves, pump joints or porous castings.
2. When the tests are successful, refit the compressor hose.
DYNAMIC TEST
1. Before starting the engine, check that the shaft, pulleys and belt are free to
rotate with the guards in position.
2. Rotate engine by hand for a minimum of six complete revolutions, listen for
injector 'creak' - indication the injector pump is working.
3. Start pump and run completely dry for a minimum period of 10 minutes (initial
run up speed at 1500rpm increasing during test to 1700rpm). During this
period generally check and observe for any unusual vibrations, overheating,
fuel, oil or air leaks.
4. These faults must be rectified immediately to prevent a possible engine
seizure.
5. After the dry running period check that the pump unit will raise a minimum
vacuum of 0.81 bar (24 inches mercury).
(Consult engine manufacturers handbook for oil, fuel, speed control and stop
details).
EJECTOR TEST
1. If the ejector was unsuccessful in the dynamic test, it may be tested, remove
the pump, as shown below.
2. Check the performance of the ejector.
Minimum allowable vacuum 0.81bar (24" Hg or 27.24 ft water) at an air
pressure of 2.75 - 4.14 bars (40-60 psi).
3.
When the test is successful, refit the ejector assembly to the pump.
STANDARD FITTINGS
WHEN PUMP IS POWERED BY HATZ ENGINE
1
1
10-0000-0010
10-0000-0006
HSP-100K
HSP-101E
AIR COMPRESSOR
COMPRESSOR KIT
PART NUMBER
267787
267805
295717
KW4785/1SP
KW5172/1SP
KW5172/2SP
KW5172/3SP
KX1223/13SP
SK2997/1
KX2542/1
KY2258/1SP
KY2331/1SP
SKR2790/00
SKR2790/10
SKR2790/20
DESCRIPTION
"C" RING (REAR)
OIL SEAL
BEARING (FRONT)
CON ROD COMPLETE
PISTON ASSEMBLY (STD)
PISTON ASSEMBLY (0.010"
o/s)
PISTON ASSEMBLY (0.020"
o/s)
END COVER ASSEMBLY
VALVE PLATE & HEAD
GASKET KIT
BASE MOUNT GASKET
CRANKSHAFT
VALVE PLATE ASSEMBLY
PISTON RING SET (STD)
PISTON RING SET (0.010" o/s)
PISTON RING SET (0.020" o/s)
PARTS LISTS
ILLUS.No.
H1
H2
H3
H4
H5
H6
H7
H9a
H9b
H9c
H10
H11
H12
H13
H15
H16
H18
H20
H21
H22
H24a
H24b
H24c
H28
H29
H30
H31
H33
H36
H37
H44
H45
H47
H48
H51
H52
H53
DESCRIPTION
Volute (Pump Body)
Impeller
Front Cover & Separation Tank
Wearplate (Front)
O-Ring Sealing Washer M12
O-Ring OR11x3 Viton
Stud M12 x 50
Joint (Body)
Joint (Body)
Joint (Body)
Stud (Body) M12 x 60
Stud M12 x 45
Wearplate (Rear)
O-ring (Wearplate)
O-ring (Seat)
Circlip (Seat)
Mechanical Seal
Shaft Collar
O-ring (Collar)
Tolerance Ring
Impeller Shim 0.25mm
Impeller Shim 0.5mm
Impeller Shim 1.0mm
Stud M8 x 45
Lockwasher M8
Nut M8
Separation Tank Cover
Filter (Separation Tank)
Setscrew M10 x 20
Lockwasher M10
Stud (Pump/Adaptor) M12 x 45
Stud (Pump/Adaptor) M12 x 55
Lockwasher M12
Nut M12
Stud (Flange) M16 x 60
Lockwasher M16
Nut M16
PART No.
11-0258-0115
QTY.
1
12-0282-3015
11-0259-0115
12-0283-0115
38-0785-4412
38-0787-4112V
1
1
1
8
38-1034-5413
38-1034-5423
38-1034-5443
12-0284-0115
38-1004-4112
38-0700-4112
41-0230-8712
38-0400-VS2S2/SS
28-0255-3215
38-1036-4112
41-0241-6112
36-0646-8913
36-0646-8923
36-0646-8933
21-0230-7915
23-0586-9923
4
A/R
A/R
2
6
4
1
1
1
1
1
1
1
1
A/R
A/R
A/R
4
4
4
1
1
1
1
4
2
12
12
8
8
8
VOLUTE
ITEM No.
MA1
MA2
MA3
MA5
MA11
MA13
MA14
MA17
MA18
MA20
MA20a
MA20b
MA20c
MA20d
MA22
MA23
MA25
MA26
MA28
MA29
MA31
MA41
DESCRIPTION
Engine Adaptor
Shaft (* see note below)
Setscrew M10 x 30
Lockwasher 10mm
Taper Roller Bearing
Bearing Cover (Front)
Circlip
Spiroseal
Bearing Cover (Rear)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Setscrew M8 x 25
Lockwasher 8mm
Grease Nipple
Relief Valve
Plug 3/8" BSP
Plug 3/8" BSP
Spiroseal
Key
PART No.
13-0174-0215
16-0400-8011
39-0069-9912
13-0172-0915
41-0232-8712
38-0809-4112
13-0173-0115
36-0650-9903
36-0650-9913
36-0650-9923
36-0650-9933
36-0650-9943
51-0003-8112
51-0010-2012
43-1048-4515
38-1033-4112
QTY.
1
1
9
9
2
1
1
2
1
A/R
A/R
A/R
A/R
A/R
3
3
1
1
1
1
1
1
NOTE:
WHEN ORDERING SHAFT (MA2)
STATE PUMP ENGINE TYPE SO
CORRECT SHAFT LENGTH CAN BE
SUPPLIED.
ILLUS. No.
EP1
EP2
EP3
EP4
EP5
EP8
EP12
EP13
EP15
EP17
DESCRIPTION
Ejector Jet
Ejector Nozzle
O-ring (Jet)
O-ring (Nozzle)
Ejector Collar
Jet Sleeve
Ball Seat
Ball
Toyo Hose
Hose Clamp
Vacuum Gauge
PART No.
23-0568-2016
23-0571-2016
38-1013-4112
38-1014-4112
23-0570-2011
23-0567-2011
23-0412-2011
39-0641-4113
001-0003
QTY
1
1
1
1
1
1
1
1
1
2
1
EJECTOR PACKAGE
ILLUS. No.
AC1
AC2
AC3
AC4
AC5
AC6
AC7
AC7A
AC8
AC9
AC10
AC11
AC12
AC13
AC14
AC15
AC16
AC17
AC18
AC19
AC20
AC23
AC30
AC32
AC43
AC47
AC48
AC55
AC56
AC78
DESCRIPTION
Compressor (Bendix)
Gasket
Stud M10 x 40
Lockwasher M10
Coupling Nut M10 x 35
Flat Washer M10
Vibrating Mount M10
Stud M10 x 90
Nut M10
Pulley (Pump) c/w Taper Lock Bush
Pulley (Compressor)
Belt 38 wide x 78 teeth (" Heavy
Pitch)
Lockwasher M22
Fan Adaptor
Setscrew M6 x 15
Lockwasher M6
Fan
Fan Washer
Lockwasher M12
Setscrew M12 x 20
Air Cleaner
Oil Delivery Hose
Nipple BSP " x 3/8"
Oil Drain Hose
"- M/F Adaptor
Compressed Air Hose (S/S Teflon ")
Nipple " BSP x " BSP
Pulley Guard
Bolt M10 x 10
Relief Valve
PART No.
49-0523-9915
KX2542/1
10-0000-0026
10-0000-0027
26-0851-9912
26-0724-0243
26-0840-9912
17-0206-0115
54-0237-9912
36-0556-8111
54-0556-9912
42-0000-0005
42-0000-0002
A1212
42-0000-0004
27-2805-9821
10-0000-0004
QTY
1
1
4
8
4
4
8
4
4
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
4
1
COMPRESSOR ASSEMBLY
Sykes Group Pty. Ltd.
ILLUS. No.
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16
DESCRIPTION
REFLUX BOX COMPLETE
Reflux Box
Stud M16 x 65
Nut M16
Stud M20 x 70
Flat Washer M20
Nut M20
Reflux Box Discharge (Optional)
O-Ring
Reflux Box Seat
Reflux Box Ball
Drain Cock
Joint
6" T.E Blank Flange
Nut M16
Washer M16
Bolt M20 X 70
PART No.
356-6000
356-4061
356-4064
356-4153
356-4063
313-4169
920-9242
500-4051
FB150TE
QTY
1
8
8
4
4
4
1
1
1
1
1
1
1
8
8
8
REFLUX VALVE
HATZ COUPLING
ILLUS.No.
DR1
DR2
DR3
DESCRIPTION
Flywheel Coupling
Bolt Assembly
Taper Lock Bush 2017 x 42mm
PART No.
340-6004
10-0000-0007
QTY.
1
6
1
HATZ COUPLING
ILLUS.No.
C1
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C20
C21
DESCRIPTION
Chassis (Skid Base)
Filler Cap 2" BSP
Plug 2" BSP
Mounting Bracket
Bolt M12 x 50 (High Tensile)
Lockwasher M12
Plug 3/4" BSP
Return Nipple
Fuel Hose Delivery
Battery Box
Setscrew M6 x 12
Lockwasher M6
Fuel Return Hose
Fuel Suction Pipe
PART No.
QTY.
10-0000-0019
1
1
3
1
4
4
1
346-5041
1
340-6041
1
340-8002
1
4
4
340-5005
1
346-5372
1
Accessories
-
Part No.
Description
267787
267805
KX2279/2
KY2280/2
KX2466/2
KX2542/1
O-Ring
Oil Seal
Valve Plate Gasket
Valve Plate Gasket
Cylinder Head Gasket
Base Gasket
Pump End
No. Off
3
3
3
1
1
1
1
1
3
3
3
1
1
1
1
1
1
1
Part No.
38-1034-5413
38-1034-5423
38-1034-5443
38-1004-4112
38-0700-4112
41-0230-8712
38-0400-VS2S2/SS
38-1036-4112
36-0646-8913
36-0646-8923
36-0646-8933
23-0586-9923
23-0568-2016
23-0571-2016
38-1013-4112
38-1014-4112
39-0641-4113
26-0840-9912
Description
Joint
Joint
Joint
O-ring
O-ring
C-Clip
Mechanical Seal
O-ring
Impeller Shim
Impeller Shim
Impeller Shim
Filter
Jet
Nozzle
O-ring
O-ring
Ball
Belt
TRAILER CHASSIS
Your CP150 x Cummins B3.3T Pumpset has been mounted on a custom built
robust Dual axle site trailer as per Sykes drawing No. SPA-566 and comes
complete with the following:
-