HARBEN CENTURY PUMP SERVICE MANUAL This manual

HARBEN CENTURY PUMP SERVICE MANUAL This manual
Part No. 061357
HARBEN
CENTURY PUMP
SERVICE MANUAL
This manual contains
IMPORTANT Safety Information
Flowplant Group Ltd
Issue 6 November 2016
FLOWPLANT
CENTURY PUMP SERVICE MANUAL
AMENDMENTS
Change
Number
5
Page(s) Amended
Re-formatted
Date
05/16
Signature
TWC
5.2
Warranty section amended
10/16
GHM
6
Re-formatted / Health & Safety
section amended
28/11
AC
AMENDMENTS
FLOWPLANT
HARBEN
CENTURY TYPE PUMP
SERVICE MANUAL
Contents
Section
Page
FOREWORD
2
HEALTH AND SAFETY AT WORK
3
SECTION 1
PUMP TECHNICAL DATA
11
SECTION 2
PUMP INSTALLATION
22
SECTION 3
GENERAL OPERATING INFORMATION
29
SECTION 4
PUMP MAINTENANCE AND OVERHAUL PROCEDURES
44
SECTION 5
WARRANTY
72
A detailed contents list precedes each section
1
FLOWPLANT
Flowplant Century Pump Manual
FOREWORD
This manual is primarily concerned with the Harben Century Type Pump. In addition,
general safety and operating information for the equipment into which the pump is
installed is also included.
The conversion of pressurised water into a high velocity jet and its use as a cleaning
and cutting tool is now familiar to, and used by, many people in a wide range of
industries.
High pressure water can achieve remarkable results without the use of heat or
chemicals and cost savings over conventional maintenance methods can in many
cases show that a water jetting unit will pay for itself in hours rather than years.
Many companies have problems for which high pressure water offers a rapid
solution, yet hesitate to consider this method because of the generally accepted high
cost of such equipment. Backed by many years of design and manufacturing
experience, Harben pumps are setting new standards of performance and reliability.
The capital and operating costs are such that these offer and attractive return on
investment that really makes sense.
Flowplant Group Ltd have a policy of continual research and improvement and we
reserve the right to make such modifications and design changes as are considered
necessary in the light of experience, however, this copy of the manual will not be
amended.
No part of this manual may be reproduced or copied in any manner without written
permission from Flowplant Group Ltd.
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FLOWPLANT
Flowplant Century Pump Manual
HEALTH AND SAFETY AT WORK
There are two main categories of risk. These are:
a) Injury from impact of water
b) Injury from environment.
All persons involved in water jetting should be made aware of the risks.
INJURY FROM IMPACT OF WATER
In the event that a person is injured by the impact of a water jet, the injury caused
may appear insignificant and give little indication of the extent of the injury beneath
the skin and the damage to deeper tissues. Large quantities of water may have
punctured the skin, flesh and organs through a very small hole that may not even
bleed.
Immediate hospital attention is required and medical staff must be informed of the
cause of the injury. To ensure that this is not overlooked, all operators engaged on
jetting should carry an immediately accessible waterproof card which outlines the
possible nature of the injury and bears the following text which has been endorsed
by the Employment Medical Advisory Service (EMAS) of the Health and Safety
Executive:
THIS MAN HAS BEEN INVOLVED WITH HIGH PRESSURE WATER JETTING
AT PRESSURE UP TO 36750 LB/IN2 (250 MPA, 2500 BAR, 2548 KG/CM2)
WITH A JET VELOCITY OF 1536 MILES (2458 KM) PER HOUR.
Please take this into account when making your diagnosis. Unusual infections with
micro-aerophilic organisms occurring at lower temperatures have been reported.
These may have gram negative pathogens such as are found in sewage. Bacterial
swabs and blood cultures may therefore be helpful.
A letter containing this and other relevant information should be sent to the doctor of
each operator.
Where surgical examination is not immediately possible in remote situations, first aid
measures should be confined to dressing the wound and observing the patient
closely until a medical examination has been arranged.
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FLOWPLANT
Flowplant Century Pump Manual
If any person, object or article is accidentally struck by the jet, this fact must be
reported to the operator's representative.
INJURY FROM ENVIRONMENT
Work should only be carried out if it is safe to do so. A thorough examination of the
site should be carried out before work is started. Refer to the Warnings and
Cautions.
Special care should be taken where there is a danger of infection. There are many
situations where infection can take place. As a guide to avoiding infection, the
following points should be considered:
a) Full protective clothing must be worn.
b) Always clean scratches or cuts immediately. Disinfect and cover with a strip of
gauze and impermeable plaster. SEEK MEDICAL HELP.
c) Avoid rubbing eyes, nose or mouth with hands during working.
d) All contaminated clothing, vehicles and equipment should be thoroughly
cleaned.
e) Operators should wash thoroughly after work and before eating, drinking or
smoking.
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FLOWPLANT
Flowplant Century Pump Manual
SAFETY CODE OF PRACTICE
Full details of the Safety Code of Practice, when working with equipment containing
a Harben pump, are given in Section 3 of this manual. The basic rules of this code
are as follows:
1.
ALWAYS WEAR THE CORRECT PROTECTIVE CLOTHING.
2.
ALWAYS ENSURE ALL EQUIPMENT IS IN A FIRST CLASS CONDITION.
3.
NEVER WORK FROM A LADDER.
4.
NEVER USE THE GUN WITH THE TRIGGER LOCKED ON.
5.
NEVER POINT THE GUN AT ANYONE, EVEN IF SWITCHED OFF.
Only a responsible person who has received instruction in the operation of high
pressure water jetting equipment should be allowed to operate the equipment.
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FLOWPLANT
Flowplant Century Pump Manual
POTENTIAL HAZARDS AND MISUSE OF HIGH PRESSURE EQUIPMENT

Failure to follow the instructions where
this icon is shown can result in serious
injury or even death
Never use a jetter that isn’t regularly serviced according to the manufacturer’s
recommendations.

When a jetter is used to clean drains & sewers that are contaminated with a
hazardous substance it is possible these may be entrained in the resulting
aerosol and inhaled by operators. Consider using respiratory protection.

Do not spray flammable liquids – there is a risk of
explosion.

Ensure the correct fuel is used on all occasions or there
is a risk of explosion.

Never start the jetter when frozen. Operating a jetter whilst frozen could cause
high speed ice bullets to be ejected from the jetter hose on machine start up.

Never start jetting a drain, sewer or pipe unless the jet nozzle is safely inside
the drain and pointing in the direction that you intend it to travel.

When drain jetting a drain, sewer or pipe with an inside diameter that is not
small enough to prevent the hose from turning back on itself, a drain jet
extension (a piece of straight rigid tube equivalent to the pipe diameter)
should be fitted between the end of the hose and the nozzle.

Always use a safety leader hose at the beginning of the main jetting hose to
alert operators when the jet nozzle is nearing the manhole entrance.

Always consider the use of a tiger tail hose feed guide to protect the jetting
hose from abrasion and prevent premature failure.

Be aware that high pressure hoses can generate static electricity which may
need to be controlled when working in hazardous areas.

Never direct a high pressure water jet at electric power
lines or electrical equipment as serious injury or death
from electrocution could occur.

When jetting drains or sewers if there is a danger to the general public from
hoses laying across public walkways they must be covered in such a way as
to protect against injury from hose failure and tripping hazards.
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FLOWPLANT
Flowplant Century Pump Manual
POTENTIAL HAZARDS AND MISUSE OF HIGH PRESSURE EQUIPMENT
Failure to follow the instructions where this
icon is shown can result in serious injury
or even death

Before starting work, check and ensure the drain jets have no blocked holes
or nozzles as this may cause the pumping system to over pressurise which
could result in burst disc failure or bursting the jetting hose.

Never attempt to unblock a fully choked drain or pipe before considering the
consequence of releasing the blockage and having a plan to deal with it. E.g.
flooding, material ejection, drain nozzle ejection.

Never attempt to clean drains or pipes in one pass because this could lead to
debris build up behind the jet nozzle causing a pressure build up in the
drainage system. Be aware that a pressure build up in the drain or pipe could
cause the jet nozzle to be ejected at speed back towards the operator.

Never enter the manhole to either place the jet nozzle into or extract it from
the drain entrance unless the required confined space regulations have been
met.

Never work in a manhole with a radio remote control transmitter that is not
classified for use in such areas.

Never use the hydraulic hose reel facility as a winch to retract a jetting hose
that has become stuck in the drain or pipe. Damage to the hose could be
caused that will make subsequent hose failure more likely.

Never allow jetting hoses to become kinked and always remove from service
any jetting hose with an outer cover that has worn through to the reinforcing
braid.

Never use the high pressure jetting hose for any purpose other than sewer,
drain or pipe cleaning, e.g. winching vehicles or other plant.

Never use jetting nozzles and/or accessories that have not been calibrated for
the jetting machine pump performance as this could cause rapid over
pressurisation catching operators unaware.

Never attempt to clean a drain or pipe with a nozzle that has more forward
force than rear force. It could be ejected back toward the operator
causing injury.

Never attempt to clean a drain or pipe with a chain flail type jet that has
unequal chain lengths as this could lead to severe vibration and high pressure
hose failure.
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FLOWPLANT
Flowplant Century Pump Manual
POTENTIAL HAZARDS AND MISUSE OF HIGH PRESSURE EQUIPMENT
Failure to follow the instructions where this
icon is shown can result in serious injury
or even death

When using a venturi jet pump to remove fluid from a flooded manhole never
place your fingers into the pump inlet as they could be trapped by the
vacuum and cause injury.

When using a venturi jet pump to remove fluid from a flooded manhole always
secure the free end of the pump hose securely and ensure adequate drainage
is in place to deal with high volumes of pumped water.

Never use a dry shut type foot control valve on a jetter that does not have a
pressure unloader valve as this could result in burst disc failure or bursting the
jetting hose.

When using a dry shut type system be aware that high pressure can be
retained in the jetting hose even after the machine has been shut down.
Always discharge pressure in a safe manner after machine shut down.

When working with a gun always consider using a safety shroud to provide
the operator with greater protection in the event of a hose burst.

Never point the gun at anyone as injury from high pressure water will occur if
the jet stream comes into contact with body parts.

Never work on a slippery surface because the reaction force of the jetting gun
could cause you to become unstable and lose your footing.

Never work from a ladder as the reaction force of the jetting gun could cause
the ladder to fall backwards from the working area causing possible injury.

Never work from scaffolding unless it is designed, erected and managed by
competent persons and it is adequately secured to prevent it being pushed
over by jetting gun reaction forces.

When using the jetting gun to clean hard surfaces be aware that splash back
could contain hard debris travelling at speed.

When using the jetting gun to clean contaminated surfaces be aware that
splash back could contain dangerous contaminants.

Never use the jetting gun to clean a surface that could be damage or
penetrated by the water pressure unless that is the desired effect.
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FLOWPLANT
Flowplant Century Pump Manual
POTENTIAL HAZARDS AND MISUSE OF HIGH PRESSURE EQUIPMENT
Failure to follow the instructions where this
icon is shown can result in serious injury
or even death

Always ensure that an adequate area is cordoned off around the working
zone so that flying debris and contamination cannot injure passers-by.

Be aware that the use of water jetting guns fitted with oscillating or rotating
heads tend to produce higher hand arm vibration levels than simple fixed
head jets.

When using a jetting gun or nozzle to clean at floor level wear suitable
protective foot wear.

Never use a high pressure jetting gun to clean down PPE
whilst you or others are still wearing it as serious injury and
death could result.

Never use a high pressure jetting gun to wash or cool down
livestock as serious injury and death could result.

Drainage systems may carry bacteria and micro-organisms which can cause
severe illness or death. Avoid exposing eyes, nose, mouth, ears, hands, cuts
or abrasions to waste water or faecal matter during drain cleaning operations.
After working around drainage systems help protect yourself by always
washing hands.
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FLOWPLANT
Flowplant Century Pump Manual
PERSONAL PROTECTIVE EQUIPMENT (PPE)
All persons using high pressure water jetting equipment should use all necessary
PPE suitable for the task being carried out. This includes, but is not limited to:

Ear protection

Eye protection: a helmet with chin guard and visor is recommended

Hand protection

Waterproof clothing

Safety boots with toe protection
Please note: A site specific Risk Assessment / Job Hazard Analysis must be
completed to analyse which PPE must be worn.
10
FLOWPLANT
Section 1
Pump Technical Data
11
FLOWPLANT
Section 1
Technical Data
Contents
Section
Page
1.1 Introduction
13
1.2 Pump Description
1.2.1 Function
1.2.2 Filtration
1.2.3 Fluid Flow
14
14
14
14
1.3 Identity
1.3.1 Manufacturer
1.3.2 Pump Operation / Identification
15
15
15
1.4 Design and Performance Data
1.4.1 Physical Data
1.4.2 Performance Characteristics
16
16
16
1.5 Equipment Details
17
1.6 Associated Publications
17
Illustration
Fig
Page
1.1 Pump General arrangement
18
1.2 Performance Data Litres
19
1.3 Performance Data Gallons
20
Tables
Table
Page
1.1 Pump Physical Data
16
1.2 Pump Performance Data
16
12
FLOWPLANT
Flowplant Century Pump Manual
1.1 INTRODUCTION
The Harben Century Type high pressure pump (Fig 1.1) is a radial piston diaphragm pump
which can be used for a number of industrial applications, including the following:
(a) High pressure cutting of board, plastic and other materials
(b) Water hydraulic systems
(c) Abrasive blasting and de-scaling
(d) Drain/sewer cleaning
(e) Tube de-scaling
(f) Desalination by reverse osmosis
(g) Pumping demineralised water
(h) Floor and surface cleaning
(i) Underwater cleaning
(j) Surface preparation
In addition to its reliability and long service intervals, the advantages of using this type of
pump include:
(a) Variable pressure and flow options without piston change
(b) Pumps can run dry without damage as there are no piston seals
(c) Filtration up to 150 microns
(d) No modification is required to pump sea water
(e) Pump has multi-cylinders therefore no pulsation
The pump is designed to be directly-coupled and flange-mounted, and can be supplied in
either bare-shaft form, or skid mounted, trolley mounted, trailer mounted or truck mounted
configurations. In addition, the pump can be mounted on an underwater ROV. Diesel
drive, electrical drive and hydraulic drive options are available .
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FLOWPLANT
Flowplant Century Pump Manual
1.2 PUMP DESCRIPTION
1.2.1 Functional
The following description of the Harben Century Type Pump applies equally to the 4 and 8
cylinder variants. Performance details of each type of pump are given later in this section.
The Century pump works on the radial piston design principle which uses one-way valves
in conjunction with tubular diaphragms, fitted with an internal support or mandrel. The
pumped fluid, which passes through this diaphragm, is enclosed by a cylindrical pressure
chamber or barrel, in the ends of which are fitted inlet and delivery valves.
The pump crankcase, which contains the only mechanical moving parts, is filled with
mineral hydraulic oil. This oil provides for the lubrication of all moving parts within the
crankcase, and as a means of pressure to compress the diaphragm.
As the pump shaft rotates, the piston advances and its ports pass the end of the cylinder,
sealing the chamber. Further advance of the piston causes the trapped oil to compress
the diaphragm around the mandrel, expelling the water in the diaphragm through the
delivery valve and into the delivery manifold.
When the piston retreats, the diaphragm reverts to its tubular form and draws water
through the inlet valve. Any oil slippage past the piston during the delivery stroke is made
up through the piston ports as they open to the crankcase oil.
All mechanical parts, with the exception of the inlet and delivery valves, run in the oilflooded crankcase and are therefore unaffected by contamination by the pump fluid, or by
running dry.
1.2.2 Filtration
Standard filtration for the pump is normally 50 microns. This filter is usually fitted to the
inlet of the supply tank or reservoir. This arrangement ensures that if the filter is neglected
to the point of blockage, the tank will empty and the pump will run dry, thus enabling the
dry-running qualities of the pump to be used as a filter maintenance indicator. Inlet
conditions required are flooded suction; pressure feeding is not necessary.
1.2.3 Fluid Flow
Arrangements are made on the pump for the incoming fluid to cool the crankcase oil.
The use of standard diaphragm/barrel assemblies provides a choice of flows, depending
upon the number of barrels fitted to a crankcase. The cylindrical form of these barrels is
well suited to containing high pressures. Three piston diameters are available to suit a
range of pressure up to 700 bar (10 000 psi).
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FLOWPLANT
Flowplant Century Pump Manual
1.3 IDENTITY
1.3.1 Manufacturer
The Harben Pumps are manufactured by:
Flowplant Group Ltd.,
Gemini House, Brunel Road,
Churchfields Industrial Estate, Salisbury,
Wiltshire, SP2 7PU, ENGLAND
Tel: +44 (0)1722 325 424
Fax: +44 (0)1722 411 329
www.flowplant.com
[email protected]
1.3.2 Pump Options/Identification
The Century Pump is available in either 4 or 8 cylinder options, with each having a choice
of piston/cylinder diameter options of 22.5 mm, 25.0 mm or 27.5 mm.
All barrels are given a letter code to indicate their position in the crankcase (refer to
Section 4, Fig 4.2). This letter code can be found stamped on the face adjacent the inner
cylinder. Letters A to H are used. Each barrel of a different code is given its own part
number.
A pump specification label is fitted on the pump crankcase, adjacent to the oil filler cap.
This label will give the pump type, ie number of cylinders and piston/cylinder diameter.
For example:
8
22.5
no. of cyl
piston dia.
The label also gives the pump serial number, the type of oil to be used (Shell Tellus or
equivalent), the maximum working pressure, the maximum working flow, and the pump's
year of manufacture.
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FLOWPLANT
Flowplant Century Pump Manual
1.4 DESIGN AND PERFORMANCE DATA
1.4.1 Physical Data
TABLE 1.1 PUMP PHYSICAL DATA
Pump diameter
Pump length
Inlet
Outlet
Shaft diameter
Shaft length
560 mm
451 mm
2 in BSP/50 mm dia. hose tail
1 /2 in BSP
45 mm
83 mm
Note: for full details of the pump physical data refer to Fig 1.1.
1.4.2 Performance Characteristics
For full details of the Century Series, Pump performance data, reference should be made
to the appropriate information given in Tables 1.2 and 1.3a/b.
TABLE 1.2
PUMP PERFORMANCE DATA - MAXIMUM WORKING PRESSURES
Pump/Cylinder
Diameter
22.5 mm
1000 rpm
(normal working speed)
10 000 psi
(700 bar)
8000 psi
(550 bar)
6000 psi
(415 bar)
25.0 mm
27.5mm
Notes:
i. As a rule, electrically-driven and diesel-driven pumps run at 1000 rpm, nominal.
ii. Quantity of cylinders does not, alter pump working pressure.
iii. Quantity of cylinders does alter flow rate.
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FLOWPLANT
Flowplant Century Pump Manual
1.5 EQUIPMENT DETAILS
Details relevant to the pump and associated equipment should be entered on the form
shown in Table 1.3, at the rear of this section, for future reference.
1.6
ASSOCIATED PUBLICATIONS
Associated with this manual are the following publications:
Operators guide
Code of practice
-
Part no. 061-225
Part no. 057-062
17
FLOWPLANT
13.939/13.982
OIL FILLER
WATER INLET
WATER DRAIN
OIL DRAIN
FLENDER PART 4 B200
COUPLING (CLAMPS COUNTER BALANCE)
6) OIL BLEED SCREW B.A.
7) WATER BLEED SCREWS B.A.
FITTED TO TOP BARRELS ONLY
8) HIGH PRESSURE OUTLET G1/2"
9) VIEW EXCLUDING COUPLING AND COUNTER BALANCE
10) 6 STUDS M10x1.5 28mm LG
ADAPTORS ARE AVAILABLE FOR A RANGE OF ELECTRIC
MOTORS AND DIESEL ENGINES: CONSULT MANUFACTURER
39.5/39.3
1)
2)
3)
4)
5)
PUMP DIMENSIONS ARE SYMMETRICAL ABOUT CENTRE LINE
DIMENSIONS ARE IDENTICAL FOR ALL PUMPS
NOTE: FOR CIRCUIT DIAGRAM SEE DRG D3
AFTER JULY 1982 2" BSP WATER INLET IS STANDARD
FOUR 1 1/4" BSP INLETS ON REQUEST
45.000
44.961
DRIVE SHAFT DIMENSIONS
KEYWAYS TO BS 4235
EXPANSION CHAMBER
(CRANKCASE OIL)
451
2
MAX. OIL LEVEL 4M FROM
CENTRE LINE OF PUMP
1
10
9
6
7
567.5
170 PCD
8
5
DIMENSIONS (IN mm) ARE IDENTICAL FOR ALL PUMP MODELS
i.e. 4 & 8 CYLINDERS
ROTATION VIEW ON DRIVE END OF SHAFT
560INLET SIDE OF PUMP)
(NOTE CAST ARROW ON
18
Fig 1.1 Harben Century Type High Pressure Pump
FLOWPLANT
MAX W.P. 700 BAR - 822.519 & 422.519
MAX W.P. 550 BAR - 825.019 & 425.019
MAX W.P. 420 BAR - 827.519 & 425.019
Century Pump Performance Graphs (1000 R.P.M)
NB. Max. speed of Century Pump 1200 rpm
800
12000
50hp
700
100hp
10000
600
90hp
60hp
120hp
8000
Pressure (PSI)
Pressure (BAR)
45hp
500
75hp
50hp
130hp
100hp
400
65hp
6000
110hp
70hp
300
55hp
80hp
55hp
190hp
4000
50hp
200
70hp
2000
100
0
20
40
422.519
422.519
422.519
0
60
80
100
Flow (Litres/min)
Fig 1.2 Performance Data Litres/min
19
825.019
822.519
120
140
827.519
160
0
180
FLOWPLANT
MAX W.P. 700 BAR - 822.519 & 422.519
MAX W.P. 550 BAR - 825.019 & 425.019
MAX W.P. 420 BAR - 827.519 & 425.019
Century Pump Performance Graphs (1000 R.P.M)
NB. Max. speed of Century Pump 1200 rpm
800
12000
50hp
700
100hp
10000
600
45hp
90hp
60hp
120hp
8000
500
Pressure (BAR)
75hp
50hp
130hp
100hp
400
65hp
6000
110hp
70hp
300
55hp
80hp
55hp
190hp
4000
50hp
200
70hp
2000
100
422.519
0
0
5
10
422.519
15
422.519
20
Flow (UK Gal/Min)
Fig. 1.3 Performance Data UK Gal/min
20
825.019
822.519
25
30
827.519
35
0
40
FLOWPLANT
Flowplant Century Pump Manual
Pump Type
Pump Serial No(s)
Engine Type
Engine Serial No
Gearbox Type
Gearbox Serial No
Motor Frame / kW
Motor Serial No
Max. Working Pressure of Pump
Max. Flow at Above Pressure
Single Gun HV Jet Size
Single Gun 15 Deg. Fan Jet
Twin Gun HV Jet Size
Twin 15 Deg. Fan Jet Size
Twin Gun Choke Size
Type of Safety Gun Supplied
High Efficiency Drain jets
3Rear HE drain jet
6Rear HE drain jet
3Rear 1Forward HE drain Jet
Bomb/Ram Jet
HV
Fan
Turbo/Dia 38mm Screama Jet
Dia 16mm Screama Jet
Jet Leader
Plough Jet
Jet Pump
Type
Jet Sizes
Rotoblast
Hovervac
This pump unit and all the accessories listed above have been tested at:
BAR
PSI
21
FLOWPLANT
Section 2
Pump Installation
22
FLOWPLANT
Section 2
Pump Installation
Contents
Section
Page
2.1 Introduction
24
2.2 Pump Mounting
2.2.1 General Details
2.2.2 Pump Fitting
2.2.3 Coupling Arrangements
25
25
25
26
2.3 Inlet Water
2.3.1 General
28
28
Illustration
Fig
Page
2.1 Pump Installation – Water Circuit Layout
24
2.2 Pump Installation – Prime Mover Arrangements
26
Tables
Table
Page
2.1 Century Gearboxes
27
2.2 Couplings for Century Gearboxes
27
2.3 Flywheel Couplings Perkins/Ford
27
2.4 Motor Half Couplings for Electric Motors
27
2.5 Bell Housings
27
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FLOWPLANT
Flowplant Century Pump Manual
2.1
INTRODUCTION
It may be the case that the pump has not been purchased as part of a trailer or skid.
The information given in this section is intended to enable customers to install the
pump package in a frame of their design. It will enable engineers to carry out
preliminary design work before submitting the design for Flowplant Group approval.
Refer to Section 1 for technical data and a description of the pump. Section 1, Fig 1.1
should be referred to for further technical details and installation data.
The illustration given in Fig 2.1 Century Series pump.
Fig 2.1 Pump Installation – Water Circuit Layout
24
FLOWPLANT
Flowplant Century Pump Manual
2.2
PUMP MOUNTING
2.2.1 General Details
The Century Series pumps are designed for direct drive and flange mounting. The normal
operating speed is 1000 rpm, nominal. Maximum operating speed is 1200 rpm. The pump
must rotate anticlockwise, looking at the front of the pump ('arrow' cast into crank- case).
The maximum inlet water pressure for the pump is 0.5 bar (5.0 metre head), whilst the
maximum oil pressure for the pump is 4.0 metre head to centre line of pump.
The pump can be inclined between horizontal and 45 degrees (delivery end uppermost).
If further inclination is required, between 45 degrees and vertical, Flowplant Group Ltd
should be contacted at the address given in Section 1.
The weight of a pump with oil in the crankcase, drive coupling fitted and bell housing,
depends on the number of cylinders fitted, as follows:
4 cyl - 160 kg
8 cyl - 205 kg
The engineer should ensure that all couplings are fitted with a 3 mm clearance. Where a
bell housing (pump mounting and coupling shaft and cover) cannot be fitted due to a
difference in spigot or bolt locations, an adaptor ring may be fitted. Refer to Para 9 for
further details of coupling arrangements.
It is recommended that a detailed layout be drawn and the following points considered:
(a) Selection of bell housing most suitable for adaptor ring. Additional machining to
the bell housing may be required.
(b) Sufficient coupling engagement on the shaft whilst maintaining the recommended
clearance.
(c) Clearance between shafts; careful design can eliminate the shortening of
motor/engine shaft.
2.2.2 Pump Fitting
When the pump is to be fitted in position, the following points should be noted:
(a) When the pump is first married up to the prime mover, access is required to check
coupling clearance. When Flender B200 couplings are used, sight/gauge holes
are drilled in the bell housing for this purpose.
(b) It depends on the particular installation whether the pump head is removed to a
workshop for maintenance, e.g. diaphragm or valve replacement or whether work is
carried out in-situ.
(c) Where a pump 'strip-down' is required, the pump should be removed to the
workshop. The use of an assembly stand (part no 100-279) is recommended.
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FLOWPLANT
Flowplant Century Pump Manual
2.2.3 Coupling Arrangements
Arrangements are made on the pump for the incoming fluid to cool the crankcase oil.
The use of standard diaphragm/barrel assemblies provides a choice of flows, depending
upon the number of barrels fitted to a crankcase. The cylindrical form of these barrels is
well suited to containing high pressures. Three piston diameters are available to suit a
range of pressure up to 700 bar (10 000 psi).
For details of the prime mover/gearbox/pump coupling arrangements for diesel-driven and
electrically-driven pumps, refer to Fig 2.2 and Tables 2.1 to 2.5.
Fig 2.2 Pump Installation – Prime Movers/Gearbox/Pump Coupling Arrangements
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FLOWPLANT
Flowplant Century Pump Manual
TABLE 2.1 CENTURY GEARBOXES
PART NO
105-119
105-120
105-121
105-125
DESCRIPTION
2.7:1 Gearbox Bare Shaft Century
2.25:1 Gearbox Bare Shaft Century
2.0:1 Gearbox Bare Shaft Century
1.86:1 Gearbox Bare Shaft Century
TABLE 2.2 COUPLING FOR CENTURY GEARBOXES
PART NO
100-342
100-366
023-594
DESCRIPTION
Output Coupling B200 Pt 1, Flex Bore 57 mm, Key 16 mm
Input Coupling B180 Pt 1, Flex Bore 45 mm, Key 14 mm Perkins 1000 Series
Input Coupling M200 - Iveco 7000 Series
TABLE 2.3 FLYWHEEL COUPLINGS PERKINS/FORD
PART NO
100-633
100-367
023-593
DESCRIPTION
Coupling PT10 E180 CF - Perkins T6354.4/1006TG
Coupling PT10 E180 CF - Ford 2726T
Coupling PT10 E200 - Iveco 7675Si
TABLE 2.4 MOTOR HALF COUPLINGS FOR ELECTRIC MOTORS
(Metric Frame - Non-hazardous Types)
PART NO
100-487
100-487
023-304
023-304
023-304
023-304
DESCRIPTION
37 kW/50 HP Motor Coupling B200 Pt 1
45 KW/60 HP Motor Coupling B200 Pt 1
55 KW/75 HP Motor Coupling B200 Pt 1
75 KW/100 HP Motor Coupling B200 Pt 1
95 kW/125 HP Motor Coupling B200 Pt 1
111 kW/150 HP Motor Coupling B200 Pt 1
TABLE 2.5 BELL HOUSINGS
PART NO
100-084
100-082
100-329
012-186
DESCRIPTION
Diesel, Century Bell Housing
Bell Housing 37 kW - 111IkW, Electric
Adaptor Ring - must be used on 75 - 111kW electric motors
Adaptor Ring - must be used on diesel engines
27
FLOWPLANT
Flowplant Century Pump Manual
2.3 INLET WATER
2.3.1 General
It is recommended that inlet water is filtered to 50 microns. Filtration to 150 microns is
also possible. Refer to Flowplant Group for advice. Flowplant offer types of filter suitable
for most applications.
Turbulent water will cause the pump to run unevenly and cause excessive wear due to
cavitation. For this reason, water must first pass through a break water or header tank
controlled by a ball valve or float device. Water leaving the tank should have lamina flow
characteristics and be air free.
Notes:
1) If water is filtered before the tank, then the tank must be sealed and vented to avoid
contamination.
2) A pressure/flow check at the inlet to the pump is recommended. The maximum
inlet water pressure for the pump is 0.5 bar (5.0 metre head).
3) Minimum recommended 0.05 bar (0.5 metre head)
4) Minimum recommended inlet speed o.5 metres / second.
5) Recommended vortex in tank outlet / pump inlet
6) Flowplant recommend return line to be on opposite side of tank to tank outlet /
pump inlet.
7) Flowplant recommend that tank should be of sufficient size so that at full flow,
cannot be drained in under 4 minutes.
A pH value of 5 to 9 is recommended. Although liquids outside this range may
occasionally be pumped, it is advisable to contact Flowplant Group, at the address given
in Section 1, for their advice.
Hose and pipe bores between the break water tank and pump should be a minimum of 50
mm (2 in) and up to a length of 1 metre. If a longer length of hose/pipe is required, refer to
Flowplant.
Other points to be considered concerning inlet water are:
(a) Avoid long hose or pipe runs.
(b) Avoid hose or pipe runs that cause air pockets.
(c) Refer to circuit layout for mounting angle of pump.
(d) If water inlet temperature is over 30°C, consult Flowplant.
28
FLOWPLANT
Section 3
General Operating Information
29
FLOWPLANT
Section 3
General Operating Information
Contents
Section
Page
3.1 Introduction
31
3.2 Safety Code of Practice
3.2.1 General
3.2.2 Safety Gun
3.2.3 Drain/Sewer and Pipe Cleaning
3.2.4 Hoses
3.2.5 Underwater Recoil-less Safety Gun
3.2.6 Tube Cleaning
3.2.7 Hoverclean
3.2.8 Abrasive injection Equipment
3.2.9 Accidents
3.2.10 Protective equipment
31
32
32
33
33
33
34
34
34
34
35
3.3 General Operating Instructions
3.3.1 Introduction
3.3.2 Starting
3.3.3 Stopping
3.3.4 To Oil Bleed the Pump
3.3.5 To Water Bleed the Pump
3.3.6 To Antifreeze a Unit without an Antifreeze Tank
3.3.7 To Remove Antifreeze without an Antifreeze Tank
3.3.8 To Antifreeze a Unit With an Antifreeze Tank
3.3.9 To Remove Antifreeze With an Antifreeze Tank
36
36
36
36
37
38
39
39
39
40
3.4 Fault Finding
3.4.1 General
41
41
Illustration
Fig
3.1
3.2
Page
38
43
Bleeding the Pump
Pump Fault Finding
Tables
Table
2.1
Equipment Fault Finding
Page
41
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FLOWPLANT
Flowplant Century Pump Manual
3.1
INTRODUCTION
This section gives general information on safety, protective clothing to be used by operators,
and general starting and stopping procedures when the pump is incorporated in a machine. It
should be remembered that the operating procedures given are to be used as a guide only,
and the equipment handbook operating procedures should be used where applicable.
3.2
SAFETY CODE OF PRACTICE
BASIC RULES
1.
2.
3.
4.
ALWAYS WEAR THE CORRECT PROTECTIVE CLOTHING.
ALWAYS ENSURE ALL EQUIPMENT IS IN A FIRST CLASS CONDITION.
NEVER WORK FROM A LADDER.
NEVER USE THE GUN WITH THE TRIGGER LOCKED ON.
NEVER POINT THE GUN AT ANYONE, EVEN IF SWITCHED OFF.
This Code of Practice is intended to provide guidance on the safe operation of high pressure
water jetting equipment.
The term 'high pressure water jetting' covers all water jetting, including the use of additives
and abrasives, where there is an energy input to increase the pressure of water.
This code applies to high pressure water jetting as defined above where there is a
foreseeable risk of injury.
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FLOWPLANT
Flowplant Century Pump Manual
3.2.1 General
Only a responsible person who has received instruction in the operation of high pressure
water jetting equipment should be allowed to operate the equipment.
Barriers should be erected around the cleaning bay or where the work is being done 'insitu', round the section of plant concerned. Access within 10 metres by persons other
than the jetting team, is strictly prohibited.
A warning notice 'NO UNAUTHORISED ENTRY High Pressure Water Jetting in Progress'
should be displayed on each side of the bay, or on the plant, where the work is to be
done.
Each member of the team should be provided with suitable waterproof clothing,
wellington boots with internal steel toe caps, safety helmet with visor and ear defenders,
and gloves. Refer to Para 14 for details of protective clothing available.
Never attempt to change jets or accessories whilst the pump is operating, even if the flow
control selector valve is in the recycle (dump) position.
3.2.2 Safety Gun
Never point the safety gun at anyone, even if it is switched off.
When using the 'dead-mans handle' safety gun, the required jet should befitted to the
high pressure barrel (low pressure barrel is fitted with a diffuser) and tightened
correctly before starting the unit. All other hose connections, etc must be checked
before attempting to start the unit.
Water jetting guns should be properly maintained and care should be taken not to
damage the delicate components of the trigger mechanism.
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FLOWPLANT
Flowplant Century Pump Manual
3.2.3 Drain/Sewer
In addition to the protective clothing listed in Para 5(4), the other equipment should be used
when entering confined spaces, such as safety harness and rescue line, atmospheric
testing
equipment, escape breathing apparatus and hand lamps (intrinsically safe
where appropriate).
To prevent snaking or reverse travel of a flexible hose inside the tube being cleaned, a
section of steel pipe, slightly longer than the diameter of the tube to be cleaned, should be
connected between the flexible hose and the nozzle (drain jet extension).
During drain cleaning operations it is advisable to use a coloured leader hose to act as a
warning to the operator that the hose recovery is almost complete.
In addition to Where drain or pipe jetting operations are to be carried out remote from the
high pressure pump unit, i.e. where communication between the person controlling the pump
and the equipment operator is not possible, it is essential that a remote control kit or foot
control valve is used at the work point.
3.2.4 Hoses
Care should be taken to ensure that all hoses are maintained in good condition and are of
the correct specification for the pressure being used.
Never loop the hose into an excessively tight radius, particularly adjacent to couplings.
When fitting re-usable couplings, always ensure that the current type of couplings are being
used in relation to the hose specification.
3.2.5 Underwater Recoil-less Safety Gun
The Harben Underwater Recoil-less Safety Gun is designed for use under-water only.
Extreme care should be taken to avoid rear-facing balance jets when testing the equipment
above water.
If working in shallow water, where there is a possibility of the diver surfacing inadvertently
during water blasting, care should be taken to ensure that the recoil balance jet protection
tube is sufficiently long to prevent the diver directing it at himself.
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FLOWPLANT
Flowplant Century Pump Manual
3.2.6 Tube Cleaning
Where tube cleaning is to be done by means of a lance, the charge hand who operates the
remote control valve should first insert the lance into the tube, leaving the other end of the
lance supported by one man. Once the tube has been inserted, the other men required to
support the control lance should take up their places, and only then should the charge hand
operate the valve.
Note: When the person operating the remote control valve is unable to speak directly to the
man, or men, controlling the lance, a clearly understood system of signals and instructions
must be agreed upon.
A barrier should be placed at the far end of the tube being cleaned for protection against
flying debris.
A shield fitted to the lance to protect the operator from debris ejected by backward pointing
jets should be used for certain operations.
3.2.7 Hoverclean
The angle of the jet holders determine the rotational speed of the spray bar; this is set and
locked in position at the works, and on no account must this angle be altered.
3.2.8 Abrasive Injection Equipment
Because water/abrasive jetting can give rise to dangerous splash back, ensure all protective
clothing, detailed in 3.2.1, is used. Some abrasives are known to produce residues which
may be serious to health and should not be used for blasting, such as sand containing free
silica.
3.2.9 Accidents
In the event of a person being injured by the impact of a water jet, the injury
caused may appear insignificant and give little indication of the extent of the injury beneath
the skin and the damage to deeper tissues. Large quantities of water may have punctured
the skin, flesh and organs through a very small hole that may not even bleed/
Operators should carry a card which explains to medical staff the possible nature of the
injury, both relating to the high pressure water and any unusual infections that may be found
in sewage, such as leptospirosis, better known as Weil's Disease.
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FLOWPLANT
Flowplant Century Pump Manual
3.2.10 Protective Equipment
A range of top quality protective equipment is available from Flowplant Group Ltd, as follows:
PART NO.
DESCRIPTION
061037
061025
061026
061020
Waterproof Coverall Suit - size small
Waterproof Coverall Suit - size medium
Waterproof Coverall Suit - size large
Waterproof Coverall Suit - size extra large
065076
065061
065060
065057
065058
065066
065065
Metatarsal Safety Boots – size 6
Metatarsal Safety Boots – size 7
Metatarsal Safety Boots – size 8
Metatarsal Safety Boots – size 9
Metatarsal Safety Boots – size 10
Metatarsal Safety Boots – size 11
Metatarsal Safety Boots – size 12
065062
065013
Gauntlet Gloves
Complete Helmet Set
061054
‘No Unauthorized Entry – High Pressure
Jetting In Progress’ Safety Sign
061225
057062
061445
061259
Operators Safety Guide
Safety Code of Practice
Code of Practice (Sewer Drain Jetting)
Guide Do and Don’t Booklet
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FLOWPLANT
Flowplant Century Pump Manual
3.3 GENERAL OPERATING INSTRUCTIONS
3.3.1 Introduction
The following operating instructions are of a general nature with reference being made to the
appropriate manufacturer's handbook for the machine.
3.3.2 Starting
To start the unit, carry out the following instructions:
i.
Prior to starting the unit, carry out the following pre-checks:
a)
b)
c)
d)
Set the high pressure selector to the recycle (dump) position.
Ensure the unit is on level ground.
Check that the water supply is connected and the header tank is full.
Check that all guns and nozzles are connected. Ensure correct fitting and correct
size for the pressure required.
ii. Start the unit. Refer to the manufacturer's handbook for information concerning
engine/electric motor starting procedure.
Note: Before starting the unit and carrying out water and/or oil bleed operations
(refer to 3.3.4, 3.3.5 respectively), familiarise yourself with the units controls and
the stopping instructions (3.3.3).
iii. Move the selector to the High Pressure position.
iv. Increase engine rpm (if diesel) to achieve desired pressure.
3.3.3 Stopping
To shut down the unit, carry out the following instructions:
i.
Reduce engine revs to tick-over speed.
ii.
Move the high pressure selector to the recycle (dump) position.
iii.
Switch off the prime mover by following the instructions given in the manufacturers and
book for the engine/electric motor.
iv.
If there is the risk of freezing, follow the instructions given the frost precautions
(anti-freeze procedures, (3.3.6, 3.3.8).
v.
If the unit is to be stored for more than 7 days without running, an inhibitor should be
run through the system. Do not drain prior to storage; always leave full of fresh water
or inhibitor.
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FLOWPLANT
Flowplant Century Pump Manual
vi. Refer to the manufacturer's handbook for information concerning engine/ electric
motor protection/storage.
3.3.4 To Oil Bleed the Pump
As delivered from the factory, the pump would have already been oil bled (except pump
heads supplied separately). If necessary, oil bleed the pump as follows:
Note: Refer to the lubrication chart given in Section 4, Table 4.2 for details of pump oil types
and capacities.
i.
Fill the pump to the top of the crankcase with the correct oil (or ensure oil is in the
expansion bottle, if fitted).
ii.
Set the selector valve to the recycle (dump) position and start the engine/motor. Run
at 750 rpm tick-over to prime, or inch electric motor (on/off).
Note: If the unit is fitted with a shut-down protection device, hold in the override button
for 10 seconds (this allows the engine oil pressure to build up).
iii.
With reference to Fig 3.1, put a finger on top of an oil bleed screw on a lower barrel
and open the screw slowly using a suitable spanner. When air-free oil flows, tighten
the bleed screw firmly.
Note: Top up oil in the pump crankcase after each barrel has been bled.
iv.
Repeat the procedure detailed in iii. for each barrel, starting from the lower barrels
first.
v.
When the operator has taken up a working position, move the selector lever to the
High Pressure position and increase engine speed to reach working pressure.
vi.
If the delivery line vibrates or the pump does not run smoothly, stop the unit and carry
out a water bleed (3.3.5) and then repeat the oil bleed.
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FLOWPLANT
Flowplant Century Pump Manual
Fig 3.1 Bleeding the pump
3.3.5 To Water Bleed the Pump
CAUTION:
ON NO ACCOUNT OPEN THE WATER BLEED SCREWS WHEN THE PUMP IS
OPERATING UNDER PRESSURE.
Whenever the unit is started after being allowed to run dry, the following procedure must be
followed:
i.
Set the selector valve to the recycle (dump) position and start the engine/motor. Run
at 750 rpm tick-over to prime, or inch electric motor (on/off).
Note: If the unit is fitted with a shut-down protection device, hold in the override button
for 10 seconds (allows engine oil pressure to build up).
ii.
The pump is self-priming. If, however, any difficulty is experienced, stop engine,
loosen the upper bleed nipples and allow water to flow from each nipple (ensure that
the header tank remains full). Tighten nipples and repeat the procedure detailed in i.
To identify the bleed nipples, refer to Fig 3.1.
iii.
When the operator has taken up a working position, move the selector lever to the
High Pressure position and increase engine speed to reach working pressure.
Note: If the delivery line vibrates this indicates that air is still in the system. Stop the
unit and repeat the procedure detailed in i .
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FLOWPLANT
Flowplant Century Pump Manual
3.3.6 To Antifreeze a Unit Without an Antifreeze Tank
i.
Prepare 5 gallons (or larger quantity if required) of 30% to 50% anti-freeze solution.
ii.
Drain the water tanks.
iii.
Pour the anti-freeze solution into the break tanks.
iv.
Remove any jet or accessory from the end of the high pressure hose.
v.
Ensure the high pressure selector lever is in the dump (or off) position. Start the
engine and allow to run for 1 minute.
vi.
Holding the outlet end of the hose, move the selector to high pressure position and
allow the engine to run until the anti-freeze solution can be seen coming from the high
pressure hose.
vii.
Stop the engine. The unit is now anti-freezed.
3.3.7 To Remove Antifreeze from a Unit Without an Antifreeze Tank
Note: During this procedure, carry out the air bleed procedure detailed in Para 19, if
necessary.
i.
Drain any anti-freeze solution from break tanks into a container.
ii.
Fill break tanks with water.
iii.
Place the outlet of the high pressure hose into the container.
iv.
Place the selector lever in the high pressure position, and whilst holding the high
pressure hose, start the engine.
v.
Run the engine until all solution is returned to the container and clean water is seen
flowing from the hose. The unit is now ready to use.
3.3.8 To Antifreeze a Unit with an Antifreeze Tank Fitted
i.
Ensure the anti-freeze tank is full of 30% to 50% anti-freeze solution.
ii.
Turn the 3-port valve to the anti-freeze position and open valve on the anti-freeze tank
(if fitted).
iii.
Remove any jet or accessory from the end of the high pressure hose.
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FLOWPLANT
Flowplant Century Pump Manual
iv.
Move the selector lever to the high pressure (or on) position.
v.
Holding the end of the hose, start the engine.
vi.
Allow engine to run on tick-over until the anti-freeze solution can be seen coming from
the high pressure hose.
vii.
Move the selector to the recycle (dump) position for 5 seconds (this allows the dump
hose to be anti-freezed).
viii.
If Jump Jet or Remote Control kits are fitted, ensure they are anti-freezed.
The unit is now anti-freezed.
3.3.9 To Remove Antifreeze from a Unit with an Antifreeze Tank Fitted
i. Move the 3-port valve to the water position.
ii. Fill the water tanks.
iii. Place the outlet of the high pressure hose into the anti-freeze tank.
iv. Place the selector lever in the high pressure position.
v. Start the engine. Allow it to run at tick-over and pump anti-freeze solution into the anti
freeze tank. Stop the engine when clear water is seen flowing out of the high
pressure hose. The unit is now ready to use.
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FLOWPLANT
Flowplant Century Pump Manual
3.4 FAULT FINDING
3.4.1 General
It is essential when fault finding on the pump that due regard is taken of the likely
equipment faults. Therefore Table 3.1 includes likely equipment faults, whilst Table 3.2
gives likely pump faults. For details of engine faults refer to the appropriate
manufacturer's handbook. When investigating a pump diaphragm for possible failure,
refer to Fig 3.2.
TABLE 3.1 EQUIPMENT FAULT FINDING
Problem
Low System Pressure
High System Pressure
Cause
Action
1. Worn or incorrect size of
cutting nozzle.
Replace nozzle.
2.
Engine speed slow.
Adjust to correct speed.
3.
Leaks from hose,pipes
and connections.
Check connections for
tightness. Replace as
necessary.
4.
Blocked inlet filter.
Clean or replace element.
5.
Inlet hose too long.
Shorten hose length.
6. Loss of water through
dump line of selector
valve or gun when high
pressure selected.
Check seats and seals.
7.
Loss of water through
dump line of remote
control kit, if fitted.
1. Blocked nozzle, selector
valve or gun.
Check seats and seals.
2. Nozzle size too small.
Replace nozzle.
3. Hose bore size too small.
Replace hose.
4. Engine speed high.
Adjust to correct speed.
5. Crushed delivery hose.
Replace if necessary.
6. Two gun choke left in
gun when operating as
single gun unit.
Replace with STD choke.
41
Clean nozzle, selector valve
or gun and flush out delivery
line.
FLOWPLANT
Flowplant Century Pump Manual
Problem
Low Water Level
Pump Not Running Evenly
(also refer to Pump faults).
Burst Disc Failure or Safety
Relief Valve Operating (also
refer to high system
pressure problem).
Cause
Action
1. Blocked or dirty
pre-filters.
Clean or replace elements.
2. Faulty ball valve
assembly.
Replace if necessary.
3. Wrong seat in float valve
assembly.
Replace if necessary.
4. Low inlet pressure.
1. Air in water.
Increase pressure.
Water bleed pump (Para 19).
2. Air in crankcase oil.
Oil bleed pump (Para 18).
3. Worn Coupling.
Replace flexible elements
and examine coupling.
4. Faulty inlet or delivery
valve.
Check valve condition.
5. Diaphragm protection
valve.
Re-seat protection valve and
check delivery valves for
ware/damage
1. Incorrect burst disc.
Replace with correct disc.
2. Incorrect valve setting.
Check certificate/setting.
3. Faulty valve.
Repair or replace, as
necessary.
4. Faulty or fatigued burst
disc.
Replace with new disc.
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FLOWPLANT
Flowplant Century Pump Manual
Fig 3.2 Pump Fault Finding – Diaphragm Failure and Indication of Other Problems
43
FLOWPLANT
Section 4
Pump Maintenance and
Overhaul Procedures
44
FLOWPLANT
Section 4
Pump Maintenance & Overhaul Procedures
Contents
Section
Page
4.1
4.1.1
Routine Maintenance
Introduction
46
46
4.2
4.2.1
4.2.2
4.2.3
4.2.4
Pump Service Information
General
Recommended Service Tools
Torque Settings
Service Kits
48
48
48
49
49
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
Pump Overhaul Procedures
Introduction
Removal and Replacement of Pump Head
Removal and Inspection of Delivery Valves - 4 Cylinder Pumps
Removal and Inspection of Delivery Valves - 8 Cylinder Pumps
Removal and Inspection of Delivery Valves - 4 Cylinder Pumps
with Split Delivery Manifold
4.3.6 Removal and Inspection of Inlet Valve Assembly and Diaphragm
4.3.7 Separating Crankcase Halves
4.3.8 Renewing Crankcase Components
4.3.9 Re-Assemble Pump
4.3.10 Pump Running In
50
50
50
51
52
53
54
57
59
62
64
Illustrations
Fig
Page
4.1
Mandrel Assembly
4.2
Inlet Valve Seat – Back Up Ring and ‘O’ Ring Fitting
4.3
Barrel Code
4.4
Century Pump – Assembly
4.5
Century Pump – Parts List
4.6a/b Century Pump – Barrel Assemblies
4.7
Safety Valve Assembly
4.8
Selector Assembly
Tables
55
56
62
65
66
67/68
69
71
Table
Page
4.1
4.2
Pump Maintenance Schedule
Pump Lubrication Chart
46
47
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FLOWPLANT
Flowplant Century Pump Manual
4.1
ROUTINE MAINTENANCE
4.1.1 Introduction
The Maintenance Schedule (Table 4.1) gives details of pump maintenance only. For
details of equipment maintenance, refer to the appropriate handbook. Details of
pump oil capacities and recommended oil types are given in the Lubrication Chart
(Table 4.2). Refer to the manufacturer's handbook for diesel engine oil.
Whilst specific periods for routine (preventive) maintenance of the pump are given,
due regard should be taken of local regulations concerning the vehicle or machine.
Ensure the machine is operating within those regulations.
TABLE 4.1 PUMP MAINTENANCE SCHEDULE
CHECKLIST
TO USE/DAILY/AFTER 8 HOURS
RUNNING
Crankcase oil
Check for level, fill if necessary (refer to
Section 3, Para 18(1) for procedure and
Table 4. 2 for oil types).
Pipes, hoses and fittings
Check wear, damage, correct rating and
size.
Pump working pressure
Check correct.
General
Check pump for smooth running,
overheating, leaks, and security of
components.
Inlet/delivery valves
Check for wear and damage. Torque inlet
nuts to 6001bft/82.9kgm/814Nm at 250
hours
Diaphragms
Check for wear and damage.
Crankcase oil
Drain and renew.
Inlet/delivery valves
Check for wear and damage.
Pipes, hoses and fittings
Carry out detailed inspection
SIX MONTHLY/300 HOURS
YEARLY/500 HOURS
TWO YEARLY/1000 HOURS
Inlet/delivery valves
Replace
Diaphragms
Replace
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FLOWPLANT
Flowplant Century Pump Manual
TABLE 4.2 PUMP LUBRICATION CHART
Manufacturer
ESSO
GULF
MOBIL
ROC
TEXACO
BP
AGIP
SHELL
CENTURY OIL
PETROFINA
CASTROL
Type
Nuto H150
LP 150
DTE Extra Heavy
Kiron 150
Rando HD 150
Energol HLP 150
OSO 105
Tellus 150
PWLM
Hydran 51
Hyspin AWS 150
Oil Capacity (litres)
Number of Cylinders
4-cyl
8-cyl
13.0
11.0
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FLOWPLANT
Flowplant Century Pump Manual
4.2 PUMP SERVICE INFORMATION
4.2.1 General
The following paragraphs give details of recommended service tools, torque
settings, and service kits to be used when carrying out pump overhaul procedures.
4.2.2 Recommended Service Tools
The following tools should be available when servicing the pump:
Description
Repair stand
Driftmandrel,
Separatormandrel,
Driftinlet valve guide,
Dolly, mandrel into diaphragm
Driftvalve removal,
Puller coupling and C balance
Part No.
100-279
201-043
201-082
201-044
201-012
061-045
201-081
Part No.
206-010
202-304
202-302
202-301
202-150
202-264
202-266
201-003
201-004
201-061
201-065
201-066
201-083
Description
Hammerlump,2 kg
Spanner, adjustable, 6"
Spanner, adjustable, 12"
Spanner, adjustable, 15"
Spanner, combination, 4 BA
Spanner, slogging, 50 mm
Spanner, slogging, 70 mm
Spanner, open ended, 13 mm x 17
mm
Spanner, open ended, 9/16" whit. x
5/8" whit.
Spanner, plate, 61.3mm AF
Socket, 3/4" square drive, 70 mm
Socket, 3/4" square drive, 50 mm
Socket, 1/2" square drive, 17 mm
Socket, 1/2" square drive, 27 mm
Socket, 1/2" square drive, 1116"
Dolly, bearing crankcase
201-011
Dollyeccentric,
201-001
Dollyoil seal in,
Dollyoil seal out,
Dollyseal stretcher
Dollyseal pusher,
Dollyseal shrinker,
Press (small)
Wrench, hex 1/2" square drive, 8
x 100 mm
Plierslong nose, 5",
203-230
Socket, 1/2" square drive, 5/16"
203-204
205-021
Socket, converter, 1/2" F to 3/4" M
Socket, reversible ratchet, 1/2"
square drive
Socket, extension bar 250 mm, 1/2"
square drive
203-252
Torque wrench, Norbar No. 4
203-257
Screwdriver,flat blade,10"
206-201
Hammer, nylon. 1 3/4" dia.
206-001
48
202-010
202-048
201-151
203-283
203-282
203-170
203-180
203-129
203-242
203-247
FLOWPLANT
Flowplant Century Pump Manual
4.2.3 Torque Settings
The torque settings for selected components are:
Inlet nut
Shaft bolt
Cylinder
Banjo bolt
Delivery nut
Banjo nut
Drg Item No*
43
92
25
57 and 58
49 and 51
107 and 106
lbft
600
100
500
120
250
200
kgm
82.9
13.8
69.1
16.6
34.5
27.6
Nm
814
135
680
160
340
270
*Refer to 4.3.1 and the drawings in this section to locate Item Number.
4.2.4 Service Kits
Service/overhaul kits are available when carrying out repair or overhaul of the pump.
Details of kits for the Century type pumps/accessories are as follows:
Description
Kit Overhaul, Valve and Diaphragm, 4 cyl Mk 4 Century
Kit Overhaul, Valve and Diaphragm, 8 cyl Mk 4 Century
Kit Seal, Mk 2 Century Selector
Kit Overhaul, Mk 2 Century Selector
Kit Overhaul, Mk 1Safety Relief Valve
Kit Overhaul, Mk 2 Safety Relief Valve
Kit Seal, Mk 9B Gun and FCV
Kit Overhaul, Mk 9B Gun and FCV
Kit Seal, Century Trigger Assembly
Kit Overhaul, Century Trigger Assembly
Kit Overhaul, High Speed Rotary Joint
Kit Seal, High Speed Rotary Joint
Kit Overhaul, Multi-selector
49
Part No.
024-032
024-033
024-021
024-022
024-023
024-044
024-035
024-036
024-047
024-048
024-030
024-031
024-042
FLOWPLANT
Flowplant Century Pump Manual
4.3 PUMP OVERHALL PROCEDURES
4.3.1 Introduction
During the pump overhaul procedures, reference should be made to the pump
component and assembly drawings (Figs 4.1 to 4.6), which include associated parts
lists, Also included are assembly drawings of the Mk 2 selector and safety relief
valve (Figs 4.7 and 4.8).
In the following overhaul procedures, the item number that follows the description of
a part refers to the assembly drawings (Figs 4.1 and 4.3 to 4.6).
4.3.2 Removal and Replacement of Pump Head
Note: Refer to 4.3.1 for drawing information.
Carry out a removal and replacement of the Pump Head, as follows:
i.
Switch off and isolate the prime mover.
ii.
Switch off or disconnect the water mains supply to the tank.
iii.
Drain the water tank.
iv.
Disconnect the water inlet hose to the pump.
v.
Disconnect the small bleed hose at the top of the Inlet Manifold, if fitted.
vi.
Disconnect the high pressure hose from the Delivery Manifold.
vii.
Drain water from the Inlet Manifold.
viii.
Disconnect the hose snap coupling from the top of the Crankcase to Oil
Expansion Bottle.
ix.
Remove the hose from the top of the Crankcase, and replace with a Lifting
Eye (114).
x.
Connect lifting tackle to the Lifting Eye. Do not take the weight of the
pump, leave only slack cable.
xi.
Remove the bolts from the bell housing, and pull off pump and bell
housing.
Note: If an adaptor ring is fitted, it is usually best to leave it attached to the
prime mover.
xii.
Before replacing the pump, check the drive coupling stand-off distance.
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Flowplant Century Pump Manual
xiii.
Replace the pump, generally reversing the removal procedure.
Note: before operating the pump, it may be necessary to bleed the pump
of air.
xiv.
If the pump fitted is new or has been overhauled, carry out the running in
procedure detailed from 4.3.7.
4.3.3 Removal and Inspection of Delivery Valves – 4 Cylinder Pumps
Notes:
Oil need not be drained.
Refer to 4.3.1 for drawing information.
Carry out removal and inspection of Delivery Valves, as follows:
i.
Unscrew and remove the four Nuts (107 - not shown on drawings).Lift off
Washers (91 - not shown on drawings).
ii.
Delivery Tubes (19 - not shown on drawings) and Banjos (22 and 23) can now
be pulled off.
iii.
Unscrew and remove Delivery Nut (51) containing the Valve Assembly.
iv.
Insert a flat blade screwdriver into the radial groove of Delivery Seat (45) and
levering gently around, ease Seat from Delivery Nut (51)
v.
Remove the Guide (48) and Ball (47) from Delivery Nut (51).
vi.
Inspect the Ball
(47) and Seat (45). If either is badly pitted, chipped or
unevenly worn, it must be replaced.
vii.
Inspect bore of Guide (48). Replace item if it is badly pitted, chipped or
unevenly worn.
viii.
Fit the Seat (45) into the Delivery Nut (51) using a small hand press. If a hand
press is not available, tap the Seat in with a nylon mallet, making sure that it
is tapped in squarely and no nylon from the mallet head goes into the Valve
Assembly through the Seat hole.
ix.
Grease the threads of the Delivery Nut (51) before assembly.
x.
Re-fit the Valve Assembly to the unit reversing the removal procedure given in
Sub-paras (4) to (1), in that order.
Note: Where possible, use a socket and torque wrench and torque the
Delivery
and Banjo Nuts to that specified in 4.2.3.
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4.3.4 Removal and Inspection of Delivery Valves – 8 Cylinder Pumps
Notes:
Oil need not be drained.
Refer to 4.3.1 for drawing information.
Carry out removal and inspection of Delivery Valves, as follows:
i.
Unscrew and remove the Banjo Bolts (57 and 58) with Bonded Seal (65).
ii.
Pull off Delivery Tubes (18) and Banjos (20 and 21). Recover the Bonded
Seals (65) from between the Banjos and delivery Nuts.
NOTE Delivery Tubes are shown on Fig 1.1 (Section 1) linking each of the
Barrels, via the Banjos.
iii.
Unscrew and remove Delivery Nut (51) containing the Valve Assembly.
iv.
Place a nylon drift (part no 061-045) through the female threaded end of the
Delivery Nut until it touches the bottom of Guide (48), Tap the end of the Drift
gently until the Guide pushes the Seat (45) out from the recess in the Delivery
Nut
Note: If difficulty is experienced and the Valve Assembly is not completely
removed, use a flat blade screwdriver in the radial groove of the Delivery Seat
(45) and gently ease the Seat from the Delivery Nut. Guide (48) and Ball
(47) can now be removed.
v.
Inspect the Ball (47) and Seat (45). If either is badly pitted, chipped or
unevenly worn, it must be replaced.
vi.
Inspect bore of Guide (48). Replace item if it is badly pitted, chipped or
unevenly worn.
vii.
Fit the Seat (45) into the Delivery Nut (51) using a small hand press. If a hand
press is not available, tap the Seat in with a nylon mallet, making sure that it
is tapped in squarely and no nylon from the mallet head goes into the Valve
Assembly through the Seat hole.
viii.
Grease the threads of the Banjo Bolts (57 and 58) and Delivery Nut (49)
before re-assembly.
ix.
Re-fit the Valve Assembly to the unit reversing the removal procedure given in
Sub-paras iii to i in that order.
Note: Where possible, use a socket and torque wrench and torque the
Delivery and Banjo Nuts to that specified in 4.2.3.
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4.3.5 Removal and Inspection of Delivery Valves – 8 Cylinder Pumps with Split
Delivery Manifold
Notes:
Oil need not be drained.
Refer to 4.3.1 for drawing information.
Carry out removal and inspection of Delivery Valves, as follows:
i.
Unscrew and remove the four Nuts (106 - not shown on drawings).
ii.
Lift off Washers (90 - not shown on drawings)
iii.
Delivery Tubes (19 - not shown on drawings) and Banjos (22 and 23) can
now be pulled off.
iv.
Unscrew and remove the four Nuts (107 - not shown on drawings).
v.
Lift off Washers (91- not shown on drawings).
vi.
The second set of Delivery Tubes and Banjos can now be pulled off.
vii.
Unscrew and remove Delivery Nuts (50 and 51) containing the Valve
Assembly.
viii.
Insert a flat blade screwdriver into the radial groove of Delivery Seat (45)
and levering gently around, ease Seat from Delivery Nut (50 and 51)
ix.
Remove the Guide (48) and Ball (47) from Delivery Nut (50 and 51).
x.
Inspect the Ball (47) and Seat (45). If either is badly pitted, chipped or
unevenly worn, it must be replaced.
xi.
Inspect bore of Guide (48). Replace item if it is badly pitted, chipped or
unevenly worn.
xii.
Fit the Seat (45) into the Delivery Nut (50 and 51) using a small hand
press. If a hand press is not available, tap the Seat in with a nylon mallet,
making sure that it is tapped in squarely and no nylon from the mallet
head goes into the Valve Assembly through the Seat hole.
xiii.
xiv.
Grease the threads of the Delivery Nuts (50 and 51) before assembly.
Re-fit the Valve Assembly to the unit reversing the removal procedure
given in Sub-paras (7) to (1), in that order.
Note: Where possible, use a socket and torque wrench and torque the
Delivery and Banjo Nuts to that specified in 4.2.3.
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4.3.6 Removal and Inspection of Inlet Valve Assembly and Diaphragm
Notes: It is reccomended that oil is drained from the pump before commencing the
following procedure.
Refer to 4.3.1 for drawing information.
The initial dismantling procedure depends upon the type of pump, as follows:
i.
If 4-cylinder pump, carry out the procedure detailed in 4.3.3, i to iv.
ii.
If 8-cylinder pump, carry out the procedure detailed in 4.3.4, i to iii.
iii.
If 8-cylinder pump with split delivery manifold, carry out the procedure detailed in 4.3.5,
i to vii.
With the appropriate initial dismantling procedure completed, carry out removal and
inspection of the Inlet Valve Assembly and Diaphragm, as follows:
i.
Unscrew and remove Nuts (105).
ii.
Pull the Inlet Manifold (16) off its Studs (101).
iii.
Unscrew Inlet Nuts (43) using a 70 mm slogging spanner (part no 202-266), taking
care not to damage Studs (101).
iv.
Insert a Drift (part no 201-043) into the end of the Mandrel, from delivery end. Tap the
end of the Drift to remove Collar (42), Inlet Seat (41), Spring (36), Valve 40, Mandrel
Assembly (38) and Diaphragm (37) from the inlet end of the Barrel.
v.
Pull the Inlet Seat (41) from the Mandrel Assembly (38). Remove Valve (40) and
Spring (36).
Using Extractor (part no 201-082), remove Diaphragm (37) from Mandrel Assembly
(38). Inspect the Diaphragm for splits or holes, replace if necessary.
vi.
vii.
Inspect Spring (36), replace if necessary.
viii.
Inspect the seating faces of the Valve (40) and Seat (41). If either is badly pitted,
chipped or unevenly worn, it must be replaced.
ix.
Inspect the bore of Bush (114).. It should be noted that if the bore is worn it will
prevent Valve (40) from shutting smoothly and squarely onto the Seat(41) and must
be replaced if necessary. The procedure for replacing the Bush is as follows:
a. Remove the Pin (115).
b. Screw an M12 tap into the Bush (114) until it bottoms.
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Flowplant Century Pump Manual
c. Hold end of tap in a vice and gently tap the face of Mandrel (116) with a nylon mallet,
until the Bush is removed.
d. Carefully press a new Bush into the Mandrel using a drift (part no 201-044).
e. Using a 1.9 mm diameter bit, drill through 6 holes in Mandrel through wall of Bush (see
Fig 4.1 - holes A).
f. Using a 1.9 mm diameter bit, drill through hole in Mandrel, right through Bush (see Fig
4.1 - holes B).
g. Using a flat punch, refit Pin (115) through Mandrel and Bush.
Fig 4.1 Mandrel Assembly
x.
To assemble Mandrel assembly (38) and Diaphragm (37), smear a light film of pump
oil along the lobes of the Mandrel then push it into the Diaphragm, ensuring there is
no gap between Mandrel and Diaphragm at inlet end.
Note: It may be easier to hold the Diaphragm with the Mandrel almost pushed home in
one hand, and hit the flat face of a nylon dolly (part no 201-012) with a nylon mallet.
xi.
Inspect Seal (82 - Fig 4.1). If it is damaged, replace as follows:
a. Remove and discard old Seal.
b. Insert Dolly (part no 201-061) into the end of the Mandrel.
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Flowplant Century Pump Manual
c. Fit '0' ring part of Seal into the groove of the Mandrel.
d. Push the hard plastic part of Seal over the Dolly, using Pusher (part no 201-065), and
locate it in the groove on top of the '0' ring part of the Seal.
e. Using Shrinker (part no 201-066), shrink the Seal enough to fit into the Barrel without
damage.
xii.
Place Valve (40) and Spring (36) into Bush (114).
xiii.
With reference to Fig 4.2, fit Back Up Ring (78) and '0' ring (76) to Seat (41), and
grease both. Ensure Back Up Ring is fitted as shown.
xiv.
Push and turn Seat (41) anti-clockwise into the Mandrel Assembly
Fig 4.2 Inlet Valve Seat – Back Up Ring and ‘O’ Ring Fitting
xv.
Grease (part no 054-041) the Seal (82), including the seal locating position in the
Barrel (83), and push the complete assembly into the Barrel from the inlet end, as far
as it will go by hand.
xvi.
Grease both faces of the Collar (42) and fit it over the end of the Mandrel (116) and
Seat (41).
xvii.
Grease the Inlet Nut (43) threads and screw it into the Barrel. Torque the Inlet Nut to
that specified in 4.2.3.
xviii.
Apply a thin even coat of grease over the end of the Barrel, which protrudes into the
Inlet Manifold.
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Flowplant Century Pump Manual
xix.
Check '0' rings (68 and 69) are not damaged and are in place.
xx.
Locate the Inlet Manifold (16) on to Studs (101) and fit Nuts (105) and Washers (85).
xxi.
Fill the pump with oil (see Table 4.2 for oil types), and bleed each individual cylinder
using Bleed Screws (93).
xxii.
Depending upon the type of pump, carry out a reversal of the initial dismantling
procedure detailed in 4.3.6.
xxiii.
The pump may now require further oil bleeding in accordance with the procedure
detailed in Section 3.3.4.
4.3.7 Separating Crankcase Halves
To inspect/overhaul components within the Crankcase, the two halves of the Crankcase
have to be separated. Although this operation can be achieved on the power unit, it is
recommended that the pump is removed from the unit and placed in a Century Pump Stand
(part no 100-279).
Separate the Crankcase halves as follows:
Note: Refer to 4.3.1 for drawing information.
i.
Remove the pump as detailed in 4.3.2 (removal and replacement of pump head).
ii.
Unscrew the Capscrew (102). If necessary hold the Coupling (5) to stop the Shaft (17)
rotating.
iii.
Lift the Cap (56) out of the recess in the end of the Coupling (5).
iv.
Remove Coupling (5) and Counter Balance (4) from the Shaft (17). This operation is
made easier using a Puller (part no 201-081).
v.
Unscrew and remove Nuts (86) and Washers (103).
vi.
Remove the Bell Housing (84).
vii.
Remove Key (30) from the Shaft (17).
viii.
Place the pump in the repair stand.
ix.
Drain the oil from the pump into a suitable container.
x.
Depending on the type of pump, carry out one of the following operations:
a. If unit contains a 4-cylinder pump, carry out the procedure detailed in 4.3.3. I to iii.
b. If unit contains an 8-cylinder pump, carry out the procedure detailed in 4.3.4 I to iii.
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Flowplant Century Pump Manual
c. If unit contains an 8-cylinder pump with split delivery manifold, carry out the procedure
detailed in 4.3.5 I to vi.
xi.
Unscrew and remove Nuts (105).
xii.
Pull Inlet Manifold (16) off of Studs (101).
Note: Depending on the nature of the repair or investigation, either complete the
appropriate operation for the pump detailed in 4.3.3, .4 or .5, or continue this procedure
from 4.3.7 xiii.
xiii.
Unscrew and remove the Bleed Screws (93) and pull the Bleed Ring (44) off the
Barrel.
xiv.
Unscrew Barrel retaining Capscrew (95) one complete turn only.
Notes:
(1) Only Capscrews adjacent to Barrels need be undone
(2) If a 4-cylinder pump, do not unscrew Capscrew (95).
xv.
Unscrew and remove eight Nuts (111, 121) and Washers (103) from Bolt (99).
xvi.
At the delivery side of the pump, unscrew Bolts (99) until end of Bolt is flush with the
Inlet Crankcase (2).
xvii.
Using a nylon mallet, tap the heads of Bolts (99), gently making the Inlet Crankcase
(2) separate from the Delivery Crankcase (3). Ensure the Crankcase halves separate
evenly. When the halves have almost separated, it may be necessary to unscrew
Bolts (99) a couple more turns and tap them again to completely disengage the
halves.
CAUTION
DO NOT UNSCREW BOLTS (99) MORE THAN IS NECESSARY. IF TOO FEW THREADS
ARE BEING USED IN THE INLET CRANKCASE, THREADS MAY BE STRIPPED WHEN
THE BOLTS ARE TAPPED.
xviii.
When halves are apart, unscrew and remove Bolts (99).
xix.
Lift Inlet Crankcase Remove Spacer Tube Assemblies (112).
xx.
Remove spacer tube assemblies (112).
xxi.
The pump is now prepared for Crankcase component repair or replacement.
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4.3.8 Renewing Crankcase Components
Once the crankcase has been opened (Para 16) the following major repairs/replacements
can be carried out:
a) Change Float Bearing (13) – 4.3.8.1
b) Change Bearing (12) – 4.3.8.2
c) Change Cylinder (25), Piston (26) and Slipper (27) – 4.3.8.3
d) Change Bearing (11) – 4.3.8.4
e) Change Oil Seal (81) – 4.3.8.5
Note:The following procedures must be carried out sequentially. On completion of
repairs/replacement of pump components, the pump should be re-assembled using the
procedure detailed in Para 23.
4.3.8.1
Change float bearing (13)
i.
Remove Nuts (86) and Washers (103) to remove Bearing Retainer (9).
ii.
Using a press, remove the Float Bearing (13). The Bearing may be pressed out from
either side.
iii.
Fit a new Bearing (13). The Bearing may be pressed in from either side, but the Circlip
in the Bearing must face the inside of the Crankcase.
Note: When fitting the Bearing (13), only press on to the outside race and not the
inner race. Dolly(part no 201-011) is available for this purpose.
iv.
Press in the Bearing so that 3 mm protrudes through the outside of the Crankcase.
v.
Refit Bearing Retainer (9).
vi.
Press Bearing fully home so that it locates up against the 'stop' in the Bearing Retainer
(9).
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Flowplant Century Pump Manual
4.3.8.2
Change Bearing (12)
i.
Unscrew and remove the Shaft Bolt (92) and Washer (88).
ii.
Slide Sleeve (7) off the Shaft (17).
iii.
Remove Disc Springs (59), noting which way they were stacked and the quantity.
iv.
Using circlip pliers, remove Circlip (54) from the groove in Bearing (11).
v.
Lift off the Retaining Ring (28).
vi.
Noting the position of each Barrel before removal, and dealing with one barrel at a
time, unscrew the previously loosened Capscrew (95).
vii.
Lift the Barrel (83) out of the Delivery Crankcase, gently tapping with a nylon mallet, if
required. Take particular care that the Piston and Slipper Assembly (26 and 27) are
not damaged as the Slipper is disengaged from the bottom of the Retaining Ring (28).
viii.
Repeat the procedure detailed in sub-paras (6) and (7) for the remaining Cylinders.
ix.
Lift off the Retaining Ring (28) and remove the Circlip (54) from the Bearing groove.
x.
Pull vertically on the Bearing (11) and it and the Eccentric (6) will slide off the Shaft
(17).
xi.
Remove Key (29) from the Shaft keyway.
xii.
Lift the Delivery Crankcase vertically. If the Drive End Sleeve stays in the Bearing (12),
push it out from the inside.
xiii.
Unscrew and remove four Nuts (86) and Washers (103). Remove Oil Seal Carrier (10)
and '0' ring (71).
xiv.
Remove both Circlips and press the Bearing (12) out either way, being careful of the
Setscrews ((97 and 98).
xv.
Fit new Bearing (12), by fitting Circlip into Bearing groove and pressing from either
side of the Crankcase until the Circlip rests against the Crankcase. A Dolly (part no
201-011) is available for this purpose.
Note: When fitting the Bearing, only press on the outer race and not the inner race.
xvi.
Put the other Circlip (55) into the Bearing groove.
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4.3.8.3
Change Cylinder (25), Piston (26) and Slipper (27)
i.
Unscrew and remove Screw (100). Plug (39) may come out with the Screw or when
the Cylinder is removed.
ii.
Unscrew and remove the Cylinder (25).
Note: Although the previous operation is all that is necessary to change a Cylinder, it is well
worth removing the Spring (35) and the Diaphragm Protection Valve (33) and cleaning them
thoroughly. Always keep the Valve components in matched pairs at all times.
iii.
Inspect the Seal (73) in Seat (34) and replace if necessary, and fit '0' ring (74) into
greased groove.
iv.
Gently push Valve (33) into Seat (34), taking care not to damage Seal (73) and
ensuring the Valve touches down onto the Seat. Place complete assembly into the
Barrel.
v.
Place Spring (35) into the Valve.
vi.
Fit '0' ring (74) in the greased groove of the Cylinder and place on top of the Spring
(35).
vii.
Screw Cylinder (25) down. Torque the Cylinder to that specified in Para 5.
viii.
Insert Plug (39) and lock with Screw (100).
4.3.8.4
Change Bearing (11)
i.
Using a press, move the Eccentric out of the Bearing (11), Ensuring that the lip on the
Eccentric is furthest away from the press ram.
ii.
Fit new Bearing (11).
4.3.8.5
Change Oil Seal
i.
Remove old Oil Seal (81).
ii.
Fit new Oil Seal (81), ensuring that the flat side of the Oil Seal is facing the outside of
the pump, and taking care not to damage the lip of the Seal.
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4.3.9 Re-Assemble Pump
After carrying out any repair/replacement procedures, re-assemble the pump as follows:
i.
Place the Shaft (17) into the repair stand, ensuring that '0' ring (72) is fitted, and in
good condition.
ii.
Assemble Delivery Crankcase (3) with Oil Seal (81) and Carrier (10), and with '0' ring
(71) fitted so that the inner race of the Bearing (12) is supported. Then, from the
outside, slide the Sleeve (8) through the Bearing (widest diameter on the outside).
iii.
Lubricate '0' ring (72) with pump oil to avoid damage. Slide the Crankcase, with Sleeve
fitted, over the Shaft.
iv.
Place Key (29) in the Shaft keyway.
v.
Slide Bearing (11), with Eccentric (6) pressed in, over the Shaft until it rests on Bearing
(12).
Note: Lip on Eccentric (6) should face Bearing (12).
vi.
Fit Circlip (54) into the bottom Bearing groove, then fit the Retaining Ring (28) over the
Bearing to rest against it.
vii.
Inspect '0' rings (71) ensuring they are in good condition. Grease '0' rings (71) and
Barrel bores of Crankcase.
Note: During the following part of the procedure, refer to Fig 4.3 for Barrel Code
positioning.
viii.
Starting with the Barrel marked 'A', place this in the Crankcase with the Piston and
Slipper Assembly in the Cylinder. Locate the Slipper (27) into the Retaining Ring,
making sure that the Shear Pin (31) locates in the Barrel.
Fig 4.3 Barrel Code
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ix.
Continue replacing the Barrels in an alphabetical and clockwise order.
x.
Place Retaining Ring (28) over Bearing and Slippers. Fit Circlip (54) into Bearing
groove.
xi.
Screw retaining Screw (95), with Bonded Seal (64), through Crankcase into the Barrel,
leaving about one turn loose.
xii.
Clean and check '0' ring (70) before placing it in greased groove of Delivery Crankcase
(3).
xiii.
Slide the Sleeve (7) over the Shaft (17), and place the Disc Springs (59) over the
Sleeve so that they rest on the Eccentric (6).
xiv.
Apply a small amount of retaining compound to the threads of the Shaft Bolt (92) and
screw the Shaft Bolt, with Washer (88), into the end of the Shaft (17). Torque the
Shaft Bolt to that specified in 4.2.3.
xv.
Turn the pump to the vertical position. Place Bolts (99) through the Delivery
Crankcase, and slide the Spacer Assemblies (112) over them.
xvi.
Grease '0' rings (71) and the Barrel bore of the Inlet Crankcase (2).
xvii.
Place the Inlet Crankcase (2) in its correct position over the Shaft and Barrels (the oil
filler should be at the top between Barrels 'A' and 'H').
xviii.
Push the Inlet Crankcase (2) over the Barrels until the threads of Bolts (99) engage.
xix.
Tighten Bolts (99) until the Crankcase halves are completely together. Care should be
taken to tighten diagonally and a little at a time.
xx.
Fully tighten Screw (95).
xxi.
Fit Bearing Retainer (9) and '0' ring (71) using Nut (86) with Washers (103).
xxii.
Place the Bleed Rings (44) and Bleed Screws (93) over the Barrels.
Note: If internal parts of the Barrels or Valves were removed, refer to the appropriate
procedure and ensure they are re-assembled correctly.
xxiii.
Fit Key (30) into the cleaned Shaft keyway.
xxiv.
Clean the bore of Counter Balance (4) and Coupling (5). Check that both
the Shaft, but do not assemble.
xxv.
Fit Bell Housing (84) using Nuts (86) with Washers (103).
xxvi.
Grease the Shaft and the bores of the Counter Balance and Coupling.
63
slide over
FLOWPLANT
Flowplant Century Pump Manual
xxvii.
First push the Counter Balance on to the Shaft, then push the Coupling on to the
Shaft.
xxviii.
Fit Drive Cap (56) into the end of the Coupling, locating Pin (110) into the hole in the
Shaft.
xxix.
Put a small amount of retaining compound on Cap Screw (102) and tighten it into the
Shaft.
xxx.
Re-fit pump as detailed in Para 9 (Removal and Replacement of Pump Head.
4.3.10 Pump Running In
Prior to running in the pump after overhaul or major component replacement, the pump
should be filled with oil to the correct level. Refer to Lubrication Chart (Table 4.2) for details
of recommended oil types and pump oil capacities.
The pump should also be bled of air in accordance with the procedures given in Sections
3.3.4, 3.3.5.
Note: Check the direction of pump rotation when first switched on.
Run the pump at maximum pressure for the following periods, whilst checking for leaks,
monitoring the flow and checking the results against pump performance data:
a. Off load - 30 minutes
b. 1 /2 max. pressure - 60 minutes
c. Max. pressure - 60 minutes.
The following points should be taken into account when determining maximum pressure to
be used when running in the pump:
Piston Size
22.5 mm
25.0 mm
27.5 mm
Maximum Pressure
700 bar (10000 psi)
550 bar (8000 psi)
420 bar (6000 psi)
a. If the pump is being used on a system that has a lower working pressure than
the maximum for the pump, then running in of the pump should be at the lower
pressure.
b. Check the pump Identification Plate for the maximum working pressure of the
pump before commencing the running in test. Some models of pumps have
working pressures lower than stated, in which case running in should be carried
out at the lower pressure.
64
FLOWPLANT
65
Fig. 4.4 - Century pump Assembly
1
3
2
FLOWPLANT
4
5
6
7
8
MANUFACTURERS UNABLE TO COMPLY MAY
SUBMIT ALTERNATIVES WHEN QUOTING.
A
WT
Kg/M
ALL DRAWINGS NOT TO THE LATEST
ISSUE ARE TO BE DESTROYED.
FLOWPLANT GROUP LTD.
QTY.
QUANTITY
ITEM
B
C
D
PART NO
DRG NO
4 CYL
QUANTITY
8 CYL
DESCRIPTION
REMARKS
ITEM
PART NO
DRG NO
4 CYL
DESCRIPTION
REMARKS
ITEM
PART NO
DRG NO
4 CYL
8 CYL
1
1
DESCRIPTION
REMARKS
BELL HOUSING (REF)
1
100-703
100-703
1
0
CRANKCASE ASSEMBLY
38
100-678
100-678
4
8
MANDREL ASSY
84
100-
2
100-701
100-701
1
0
CRANKCASE INLET
39
100-140
100-140
4
8
PLUG
85
100-097
100-097
8
8
WASHER MANIFOLD
3
100-702
100-702
1
0
CRANKCASE DELIVERY
40
100-674
100-674
4
8
VALVE INLET
86
013-304
NONE
14
14
NUT NYLOC M10
1
100-347
100-334
0
1
CRANKCASE ASSEMBLY
41
100-676
100-676
4
8
SEAT INLET
87
013-109
NONE
8
8
NUT NYLOC M12
2
100-334
100-334
0
1
CRANKCASE INLET
42
100-498
100-498
4
8
COLLAR
88
013-116
NONE
1
1
WASHER PLAIN M16
3
100-335
100-334
0
1
CRANKCASE DELIVERY
43
100-499
100-499
4
8
NUT INLET
89
013-232
NONE
6
6
SCREW HAMMER DRIVE
4
100-517
100-517
1
1
COUNTER BALANCE
44
100-184
100-184
4
8
BLEED RING
90
013-308
NONE
0
0
WASHER M20
5
023-305
023-305
1
1
COUPLING
45
100-563
100-563
4
8
SEAT DELIVERY
91
100-381
100-381
4
0
WASHER
6
100-515
100-515
1
1
ECCENTRIC
47
013-037
013-037
4
8
VALVE DELIVERY
92
100-653
100-653
1
1
SCREW SHAFT OIL CIRC
7
100-257
100-257
1
1
SLEEVE NON- DRIVE END
48
100-484
100-484
4
8
GUIDE DELIVERY VALVE
93
100-345
100-345
6
10
BLEED SCREW
8
100-652
100-652
1
1
SLEEVE DRIVE END OIL CIRC
49
100-299
100-299
4
8
NUT DELIVERY
94
013-081
NONE
8
8
SCREW SET CSK M8x16
9
100-336
100-336
1
1
BEARING RETAINER
95
013-298
NONE
4
8
SCREW SET CAP HD M10x20
10
100-654
100-654
1
1
OIL SEAL CARRIER OIL CIRC
96
013-029
NONE
6
6
WASHER PLAIN M10 FORM A
11
100-520
NONE
1
1
BEARING
52
100-442
100-442
1
1
OIL EXPANSION PIPE ASSY
97
013-181
NONE
8
8
SCREW SET CSK M10x50
12
100-054
NONE
1
1
BEARING
53
100-376
100-376
8
0
CIRCLIP
98
013-219
NONE
6
6
SCREW SET M10x40
13
100-056
NONE
1
1
BEARING
54
100-521
NONE
2
2
CIRCLIP
99
013-303
NONE
8
8
BOLT M10x130
14
061-047
061-077
1
1
LIFTING EYE
55
013-185
NONE
2
2
CIRCLIP
100
013-067
NONE
4
8
SCREW SOCKET HD M8x10
15
043-110
043-110
1
1
LABEL PUMP IDENTIFICATION
56
100-234
100-234
1
1
DRIVE CAP
101
100-465
100-465
8
8
STUD MANIFOLD
16
100-456
100-456
1
1
MANIFOLD INLET
57
100-333
100-333
2
6
BANJO BOLT
102
013-218
NONE
1
1
SCREW SET CAP HD M10x25
B
C
17
100-655
100-655
1
1
SHAFT CENTURY OIL CIRC
58
100-176
100-333
2
2
BANJO BOLT
103
013-305
NONE
30
30
WASHER M10
18
100-315
100-315
0
8
TUBE DELIVERY
59
100-071
NONE
1
1
DISC SPRING
104
013-111
NONE
8
8
WASHER M12
19
100-380
100-315
0
0
TUBE DELIVERY
60
100-343
100-343
8
8
SPACER TUBE
105
100-076
100-076
8
8
NUT MANIFOLD
20
100-316
100-316
0
2
BANJO 3-PORT
61
100-341
100-341
16
16
SEAL
107
013-004
013-004
4
0
NUT NYLOC M20
21
100-317
100-317
0
6
BANJO 2-PORT
62
032-191
032-191
1
1
CON' 1/2"BSPx1/2"BSP
108
013-490
NONE
2
2
DRAIN PLUG
22
100-379
100-379
0
0
BANJO 3-PORT
63
043-177
043-177
1
1
ADAPTOR
109
013-026
NONE
2
2
WASHER SEAL 3/8"BSP
23
100-378
100-378
0
0
BANJO 2-PORT
64
033-049
NONE
8
8
SEAL BONDED 1/8" BSP
110
013-221
NONE
1
1
PIN
24
078-709
078-709
4
0
BANJO 3-PORT
65
015-097
NONE
8
16
SEAL BONDED 3/8"BSP
111
013-030
NONE
12
8
NUT NYLOC M10
25
100-570
100-570
4
8
66
015-098
NONE
1
1
SEAL BONDED 1/2"BSP
112
100-094
100-094
8
8
SPACER ASSY
100-571
100-570
4
8
67
015-010
NONE
1
1
SEAL BONDED 2"BSP
113
100-573
100-573
4
8
PISTON,CYLINDER & SLIPPER ASSY 22.5
100-572
100-570
4
8
68
013-202
NONE
1
1
'O'RING
100-574
100-573
4
8
PISTON,CYLINDER & SLIPPER ASSY 25.0
100-560
100-560
4
8
69
013-201
NONE
1
1
'O'RING
100-575
100-573
4
8
PISTON,CYLINDER & SLIPPER ASSY 27.5
100-561
100-561
4
8
70
013-206
NONE
1
1
'O'RING
114
100-675
100-675
4
8
STOP INLET VALVE
100-562
100-562
4
8
71
013-191
NONE
10
18
'O'RING
115
100-348
NONE
4
8
PIN
27
100-509
100-509
4
8
SLIPPER
72
013-001
NONE
1
1
'O'RING
116
100-672
100-672
4
8
MANDREL
28
100-516
100-516
2
2
RETAINING RING
73
015-020
NONE
4
8
SEAL
117
100-401
100-334
1
1
CRANKCASE ASSY
29
100-063
100-063
1
1
KEY 8x10x69
74
013-222
NONE
4
8
'O'RING
118
100-334
100-334
1
1
CRANKCASE ASSY
30
100-064
100-063
1
1
KEY 14x9x82
75
013-302
NONE
8
16
'O'RING
119
100-335
100-334
1
1
CRANKCASE DELIVERY
31
100-337
100-337
8
8
SHEAR PIN
76
013-256
NONE
8
16
'O'RING
120
100-417
100-334
1
1
CRANKCASE ASSY
32
100-375
100-375
8
0
PLUG
77
013-279
NONE
4
8
'O'RING
121
013-723
NONE
8
8
NUT NYLOC M10
33
100-449
100-449
4
8
VALVE DIAPHRAGM PROTECTION
78
013-257
NONE
4
8
BACK UP RING
122
083-189
NONE
4
0
NUT M24 FULL
34
100-569
100-569
4
8
SEAT DIAPHRAGM PROTECTION
79
013-328
NONE
8
16
BACK UP RING
123
A162400
NONE
4
0
NUT M24 LOCKNUT
35
037-008
037-008
4
8
SPRING DIAPHRAGM PROTECTION
81
100-058
NONE
1
1
OIL SEAL
124
078-694
NONE
4
0
TUBE DELIVERY 4 CYL
36
100-673
NONE
4
8
SPRING
82
015-043
NONE
4
8
SEAL
37
100-186
100-186
4
8
DIAPHRAGM
83
100-497
100-497
4
8
BARREL MK4
26
E
TOLERANCES TO BE AS SPECIFIED BELOW UNLESS OTHERWISE STATED
OVER
UP TO AND INCLUDING
0
30
30
100
100
300
300
1000
1000
2000
* DELETE
ONE
RANGE
66
Flowplant Group Ltd.
Watt Road, Churchfields, Salisbury, Wiltshire. SP2 7UD
England.
Tel: (01722) 325424 Fax: 01722 411329 Tix: 477183
ISSUE
HEAT TREATMENT
DRAWN
DATE
DATE
PROTECTION
CHECKED
DATE
DRAWN
USED ON
APPROVED
DATE
CHECKED
FINISH:
SCALE
CALC
WEIGHT
TEST
2000
LEADERS IN CLEANING TECHNOLOGY
F
QUANTITY
8 CYL
C
COPYRIGHT 1999
STATUS
SUPERSEDES/SUPERSEDED BY
EXPOSED
AREA
MAGNETIC
D
CAST IRON
OPTION
AS ITEM 1
BUT ANODISED
E
TITLE
F
DRG NO
PART NO
FLOWPLANT
1
2
3
INFORMATION FOR ESTIMATION OF WEIGHT AND COST ONLY
A
ITEM
PART NO.
MATERIAL
SPEC
SIZE
WT
Kg/M
LENGTH
mm
QTY.
57
THIS DRAWING IS CONFIDENTIAL AND IS SUPPLIED
ON THE EXPRESS CONDITION THAT IT IS NOT
COPIED OR COMMUNICATED TO OTHER PERSONS
OR COMPANIES WITHOUT WRITTEN PERMISSION
FROM FLOWPLANT GROUP LTD.
DO NOT SCALE
IF IN DOUBT ASK !
TOTAL WT
Kg
65
20
5
4
ABCDEFGHJK
LMNPRSTUVW
XYZ
MATERIAL LIST
21
22
65
23
49
47
48
77
6
MANUFACTURERS UNABLE TO COMPLY MAY
SUBMIT ALTERNATIVES WHEN QUOTING.
7
8
Third angle projection
PARTS LIST
ALL DRAWINGS NOT TO THE LATEST
ISSUE ARE TO BE DESTROYED.
45
A
ITEM
PART No.
DRG. No
QTY
DESCRIPTION
REMARKS
PARTS LIST
76
83
ITEM
21
22
23
20
36
37
40
41
42
43
45
47
48
49
57
65
76
77
78
82
83
114
115
116
B
PART NUMBER
QTY
100317
100316
100379
100378
100673
100186
100674
100676
100498
100499
100563
013037
100484
100299
100333
015097
013256
013279
013257
015043
100497
100675
100348
100672
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
DESCRIPTION
BANJO DELIVERY MANIFOLD 2 PORT
BANJO DELIVERY MANIFOLD 3 PORT
BANJO DELIVERY MANIFOLD 3 PORT
BANJO DELIVERY MANIFOLD 2 PORT
SPRING INLET
DIAPHRAGM
VALVE INLET
SEAT INLET
COLLAR
NUT INLET
SEAT DELIVERY
VALVE BALL DELIVERY
GUIDE DELIVERY VALVE
NUT DELIVERY TUFTRIDED
BOLT DELIVERY BANJO
DOWTY SEAL 3/8"
O - RING
O - RING
BACK UP RING
GLYDRING
BARREL Mk 4 CENTURY
STOP INLET VALVE
PIN SPIRAL TYPE 5/65" OD 5/8" LG
MANDREL
B
C
C
D
D
E
E
37
115
116
82
114
36
40
76
TOLERANCES TO BE AS SPECIFIED BELOW UNLESS OTHERWISE STATED
OVER
UP TO AND INCLUDING
* DELETE
ONE
RANGE
F
LEADERS IN CLEANING TECHNOLOGY
* FINE
MACHINING
* MEDIUM
MACHINING
FABRICATION
UNMACHINED
Flowplant Group Ltd.
Gemini House, Brunel Rd, Churchfields,
Salisbury, Wiltshire, England. SP2 7PU
Tel: (01722) 325424 Fax: 01722 411329
0
30
30
100
100
300
300
1000
1000
2000
2000
0.5
0.8
0.1
0.15
0.2
0.3
0.3
0.5
0.7
1.0
1.5
2.0
0.5
1.0
1.5
2.0
3.0
3.0
ALL DIMENSIONS IN MILLIMETRES
GEOMETRICAL TOLERANCES TO BS 308
ANGULAR DIMS TO BE WITHIN:BENDING 2
MACHINED 0.5 ,
THREADS: BSP, TO MED. FIT. B.S. 2779
ISOMETRIC TO 6g / 6H
SURFACE ROUGHNESS: 1.6 MICRONS Ra
CONCENTRICITY TO WITHIN 0.2 T.I.R.
M/C RADII 1.5
DRILLED HOLES +0.13/-0.00
HOLE CENTRES TO BE 0.2
REMOVE ALL BURRS & SHARP EDGES.
41
42
43
ISSUE
HEAT TREATMENT
DRAWN
DATE
DATE
PROTECTION
CHECKED
DATE
DRAWN
USED ON
APPROVED
DATE
CHECKED
FINISH:
SCALE
CALC
WEIGHT
TEST
STATUS
C
COPYRIGHT 2004
SUPERSEDES/SUPERSEDED BY
Flowplant Group Ltd.
67
Fig. 4.6a - Century Barrel Assembly
78
EXPOSED
AREA
TITLE
F
DRG NO
PART NO
FLOWPLANT
1
3
2
INFORMATION FOR ESTIMATION OF WEIGHT AND COST ONLY
A
ITEM
PART NO.
MATERIAL
SPEC
WT
Kg/M
SIZE
LENGTH
mm
QTY.
5
8
20
21
5
7
THIS DRAWING IS CONFIDENTIAL AND IS SUPPLIED
ON THE EXPRESS CONDITION THAT IT IS NOT
COPIED OR COMMUNICATED TO OTHER PERSONS
OR COMPANIES WITHOUT WRITTEN PERMISSION
FROM FLOWPLANT GROUP LTD.
DO NOT SCALE
IF IN DOUBT ASK !
TOTAL WT
Kg
5
4
ABCDEFGHJK
LMNPRSTUVW
XYZ
MATERIAL LIST
18
3
19
6
7
8
Third angle projection
MANUFACTURERS UNABLE TO COMPLY MAY
SUBMIT ALTERNATIVES WHEN QUOTING.
PARTS LIST
ALL DRAWINGS NOT TO THE LATEST
ISSUE ARE TO BE DESTROYED.
A
ITEM
PART No.
DRG. No
QTY
DESCRIPTION
REMARKS
PARTS LIST
1
10
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
B
PART NUMBER
QTY
013256
013257
013279
015043
015097
100186
100316
100333
100348
100497
100498
100499
100672
100673
100674
100675
100676
100738
100739
100740
100744
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
O - RING
BACK UP RING
O - RING
GLYDRING
DOWTY SEAL 3/8"
DIAPHRAGM
BANJO DELIVERY BLOCK 3 PORT
BOLT DELIVERY BANJO
PIN SPIRAL TYPE 5/65" OD 5/8" LG
BARREL Mk 4 CENTURY
COLLAR
NUT INLET
MANDREL
SPRING INLET
VALVE INLET
STOP INLET VALVE
SEAT INLET
SEAT HE DELIVERY VALVE
RING HE DELIVERY VALVE
SPRING HE DELIVERY VALVE
NUT HE DELIVERY VALVE
B
C
C
D
D
E
E
6
4
13
9
14
16
15
1
TOLERANCES TO BE AS SPECIFIED BELOW UNLESS OTHERWISE STATED
OVER
UP TO AND INCLUDING
* DELETE
ONE
RANGE
LEADERS IN CLEANING TECHNOLOGY
F
Flowplant Group Ltd.
Gemini House, Brunel Rd, Churchfields,
Salisbury, Wiltshire, England. SP2 7PU
Tel: (01722) 325424 Fax: 01722 411329
* FINE
MACHINING
* MEDIUM
MACHINING
0
30
30
100
100
300
300
1000
1000
2000
2000
0.1
0.15
0.2
0.3
0.5
0.8
0.3
0.5
0.7
1.0
1.5
2.0
FABRICATION
3.0
3.0
1.0
1.5
0.5
2.0
UNMACHINED
SURFACE ROUGHNESS: 1.6 MICRONS Ra
ALL DIMENSIONS IN MILLIMETRES
GEOMETRICAL TOLERANCES TO BS 308 CONCENTRICITY TO WITHIN 0.2 T.I.R.
M/C RADII 1.5
ANGULAR DIMS TO BE WITHIN:BENDING 2
DRILLED HOLES +0.13/-0.00
MACHINED 0.5 ,
THREADS: BSP, TO MED. FIT. B.S. 2779
HOLE CENTRES TO BE 0.2
ISOMETRIC TO 6g / 6H
REMOVE ALL BURRS & SHARP EDGES.
2
17
11
12
ISSUE
HEAT TREATMENT
DRAWN
DATE
DATE
PROTECTION
CHECKED
DATE
DRAWN
USED ON
APPROVED
DATE
CHECKED
FINISH:
SCALE
CALC
WEIGHT
TEST
STATUS
C
COPYRIGHT 2004
SUPERSEDES/SUPERSEDED BY
Flowplant Group Ltd.
68
Fig. 4.6b - Century Barrel Assembly Spring Loaded Type
EXPOSED
AREA
TITLE
F
DRG NO
PART NO
FLOWPLANT
* FINE
MACHINING
* MEDIUM
MACHINING
LEADERS IN CLEANING TECHNOLOGY
FABRICATION
UNMACHINED
Flowplant Manufacturing Ltd.
Gemini House, Brunel Road, Churchfields, Salisbury, Wilts.
SP2 7PU England. Tel: +44 (0) 1722 325424 F. 411329
Fig. 4.7 - Safety Valve Assembly
69
FLOWPLANT
Parts list
035221 – Safety Valve 2 Assembly
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
19
20
Part No.
013069
013525
015013
015014
015033
015098
032191
078597
036064
036065
036066
036067
036074
036076
036077
078591
078592
078594
013354
Description
WASHER S/COIL SQR.SECTION M6 SPRING STEEL ZN
SCREW SET SOCKET CAP HD M 6-1.0 6G 35 LG HT 8.8 ZN
O RING BS013 PTFE
SEAL GLYD RING 15MM DIA SHAFT
O RING BS018/90
SEAL BONDED 1/2" BSP 400-825-4490-73 761 BAR
ADAPTOR 1/2" BSP M x 1/2" BSP M 1000 BAR ST/ST
PLUNGER SAFETY RELIEF VALVE 2
CATCH NUT SAFETY VALVE
CATCH PLATE SAFETY VALVE MK2
CAP SAFETY VALVE
DISCHARGE ASSEMBLY SAFETY VALVE
DISC SPRING 20x10.2x1.10 ZINC PLATED
SPRING COMPRESSION SIR SPRINGMASTERS 459817
LABEL SAFETY VALVE
BODY SAFETY RELIEF VALVE
NUT RELIEF VALVE
CHOKE RELIEF 6.0
SEAL SAFETY RELIEF VALVE
70
Qty
1
1
1
1
1
1
1
1
1
1
1
1
71
1
1
1
1
1
1
FLOWPLANT
1
3
2
INFORMATION FOR ESTIMATION OF WEIGHT AND COST ONLY
A
ITEM
PART NO.
MATERIAL
SPEC
WT
Kg/M
SIZE
LENGTH
mm
QTY.
DO NOT SCALE
IF IN DOUBT ASK !
TOTAL WT
Kg
5
4
ABCDEFGHJK
LMNPRSTUVW
XYZ
MATERIAL LIST
THIS DRAWING IS CONFIDENTIAL AND IS SUPPLIED
ON THE EXPRESS CONDITION THAT IT IS NOT
COPIED OR COMMUNICATED TO OTHER PERSONS
OR COMPANIES WITHOUT WRITTEN PERMISSION
FROM FLOWPLANT GROUP LTD.
6
7
8
Third angle projection
MANUFACTURERS UNABLE TO COMPLY MAY
SUBMIT ALTERNATIVES WHEN QUOTING.
PARTS LIST
ALL DRAWINGS NOT TO THE LATEST
ISSUE ARE TO BE DESTROYED.
A
ITEM
PART No.
DRG. No
QTY
DESCRIPTION
REMARKS
PARTS LIST
ITEM
7
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
B
PART NUMBER
QTY
014007
014008
014009
015021
015022
015023
023002
036020
036021
036022
036023
036024
036025
036026
036027
8
2
1
1
1
2
4
1
1
1
1
1
2
2
3
1
12
6
13
6
DESCRIPTION
PIN SPIRAL TYPE 8MM X 16MM LG STAINLESS STEEL.
PIN CLEVIS
CLIP CLEVIS MK2 CENTURY SELECTOR
O RING BS016 PTFE
STEP SEAL 19.0MM DIA SHAFT C/W BS111/90 O RING
O RING BS027/90
KNOB PLASTIC 1032 M8 (SELECTOR LEVER)
BODY MK2 CENTURY SELECTOR
SPINDLE MK2 CENTURY SELECTOR
NUT RETAINING MK2 CENTURY SELECTOR
LEVER MK2 CENTURY SELECTOR
GLAND MK2 CENTURY SELECTOR
SEAT MK2 CENTURY SELECTOR
COLLAR MK2 CENTURY SELECTOR
LINK MK2 CENTURY SELECTOR
13
6
C
14
12
B
6
C
SECTION A-A
A
1
3
1
2
D
D
82
196
HIGH PRESSURE INLET
1/2" BSP
E
E
A
60
5
LOW PRESSURE OUTLET
1/2" BSP
HIGH PRESSURE OUTLET
1/2" BSP
TOLERANCES TO BE AS SPECIFIED BELOW UNLESS OTHERWISE STATED
OVER
UP TO AND INCLUDING
* DELETE
ONE
RANGE
LEADERS IN CLEANING TECHNOLOGY
F
Flowplant Group Ltd.
Gemini House, Brunel Rd, Churchfields,
Salisbury, Wiltshire, England. SP2 7PU
Tel: (01722) 325424 Fax: 01722 411329
* FINE
MACHINING
* MEDIUM
MACHINING
0
30
30
100
100
300
300
1000
1000
2000
2000
0.1
0.15
0.2
0.3
0.5
0.8
0.3
0.5
0.7
1.0
1.5
2.0
FABRICATION
3.0
3.0
1.0
1.5
0.5
2.0
UNMACHINED
SURFACE ROUGHNESS: 1.6 MICRONS Ra
ALL DIMENSIONS IN MILLIMETRES
GEOMETRICAL TOLERANCES TO BS 308 CONCENTRICITY TO WITHIN 0.2 T.I.R.
M/C RADII 1.5
ANGULAR DIMS TO BE WITHIN:BENDING 2
DRILLED HOLES +0.13/-0.00
MACHINED 0.5 ,
THREADS: BSP, TO MED. FIT. B.S. 2779
HOLE CENTRES TO BE 0.2
ISOMETRIC TO 6g / 6H
REMOVE ALL BURRS & SHARP EDGES.
Fig. 4.8 - Selector Mk2 - Century
COPYRIGHT 2004
71
5
10
ISSUE
HEAT TREATMENT
DRAWN
DATE
PROTECTION
CHECKED
DATE
DRAWN
USED ON
APPROVED
DATE
CHECKED
FINISH:
SCALE
CALC
WEIGHT
TEST
SUPERSEDES/SUPERSEDED BY
Flowplant Group Ltd.
4
DATE
STATUS
C
9
EXPOSED
AREA
TITLE
F
DRG NO
PART NO
FLOWPLANT
Section 5
Warranty
72
FLOWPLANT
Section 5
Warranty
Contents
Section
Page
5.1 Flowplant Warranty
74
5.2 Limited Warranty Policy
5.2.1 Non Warranty Items
5.2.2 Service and Spares
75
75
78
73
FLOWPLANT
Flowplant Century Pump Manual
5.1
FLOWPLANT WARRANTY
Warranty of new products:
Equipment manufactured and supplied by Flowplant is warranted to be free
from defects in materials and workmanship.
The warranty includes both parts and labour necessary to correct any such
defects.
The warranty period for new products is 12 months from date of despatch
from our factory or 2000 operating hours, whichever occurs soonest.
We shall repair or, at our option, replace free of charge any product, part(s) or
component(s) manufactured by Flowplant which fail due to faulty manufacture
or material within the warranty period.
Warranty of spare parts:
The warranty for new spare parts is 6 months from date of despatch on
materials and workmanship or 250 operating hours, whichever occurs
soonest.
The warranty for reconditioned spare parts is 90 days from date of despatch
on materials and workmanship.
Provided always that
a)
They are returned to Flowplant for inspection (carriage paid), along with
a copy of the original part(s) sale invoice (where necessary); and
b)
All terms agreed by Flowplant for payment of such goods have been
complied with; and
c)
If a defect/failure is discovered before the expiration of the warranty,
notification must be given to the Flowplant service department
immediately
d)
Any claim hereunder is made within 30 days of the date of discovery of
the defect/failure.
Provision of this warranty shall not apply to any Flowplant product which has
been:
a)
Used for a purpose for which it is not designed for; or
b)
Applied to a use which has not been approved by Flowplant; or
c)
Subject to misuse, negligence, lack of maintenance or accident; or
d)
Repaired or altered in any way so as, in the judgment of Flowplant, to
adversely affect its performance and reliability
74
FLOWPLANT
Flowplant Century Pump Manual
5.2
LIMITATIONS OF THE WARRANTY
The new product and spare parts warranty is limited to defects in material or
workmanship of the product. It does not cover loss of time, inconvenience,
property damage or any consequential damages. Repair or replacement of
the product is your exclusive remedy.
Our liability under this clause shall be in lieu and to this exclusion of any
warranty or conditions implied or expressed by law as to the quality or fitness
for purpose of any goods supplied hereunder PROVIDED THAT nothing in
this clause shall operate so as to exclude liability for death or personal injury
arising from the negligence of the company or its employees.
Our obligations as aforesaid shall constitute the full extent of our liability in
respect of any loss or damage sustained by the purchaser whether caused by
any breach of this contract or by our negligence or otherwise and we shall not
be liable to make good or pay for loss of use of the goods, loss of revenue,
loss of profit or goodwill or any direct or consequential losses howsoever
caused and the purchaser undertakes to indemnify us against any such
claims against us by third parties.
On order to comply with the provision of the Health and Safety at work etc.,
Act 1974 in respect of articles manufactured, supplied or installed for use at
work we test all our products before they leave our factory and supply them
with adequate instructions for their proper use. Further copies of these
instructions are available from us upon request.
5.2.1 Non Warranty Items
The Warranty terms are a precise statement of Flowplant Group Ltd's intention to
cover the replacement or repair cost, on a standardised and agreed basis, of any
product failure resulting from defective material or sub-standard workmanship during
the manufacturing process.
The following items are considered to be of a Maintenance nature and should not be
subject of a claim.
Engine (Manufacturers Warranty Applies)
 Routine servicing of injector/fuel injection equipment.
 Heavy fuel consumption rectified by engine adjustment.
 Adjustment of fan belts/throttle and controls.
 Tightening of all sump and cover bolt/nuts water connections and exterior
oilpipes and filter bolts.
 Filters and the cleaning of filters.
 Engine service components.
 Adjustments.
75
FLOWPLANT
Flowplant Century Pump Manual
Brakes (Trailer)
 Brake shoe adjustment/bleeding and topping up of reservoir/draining of air
systems where not due to a defective part.
 Brake squeal from brake linings.
 Replacement of linings due to fair wear and tear.
 Tightness of air lines/pipes.
 Filters and the cleaning of filters.
 Brake fluid.
Electrical (all products) Manufacturers Warranty Applies
 Cleaning of terminals.
 General maintenance of batteries, dynamo/alternator, starter etc.
 Adjustment to ignition system components.
 General adjustment to electrical control current settings.
 Brushes and other items due to fair wear and tear.
 Contactor tips and springs.
 Replacement of lamps, lenses and bulbs.
Steering/Running Gear
 Front wheel alignment, track adjustment.
 Steering adjustment.
 Hub bearing and float adjustment.
 Jockey wheels.
Hydraulics ( all products)
 Tightening of hydraulic fittings and couplings.
 Filters and the cleaning of filters.
 Hydraulic fluid.
Chassis (self-propelled and trailer-mounted units)
 General rattles.
 Paint chips.
 Alignment and adjustment of panels etc.
 Deterioration of paint and external fittings due to neglect, exposure and fair
 wear and tear.
 Accidental damage.
Lubrication (all products)
 Complete or partial lubrication services.
Corrosion (all product)
 Damage caused by adverse weather/atmosphere conditions.
76
FLOWPLANT
Flowplant Century Pump Manual
General (all products)
 Fair wear and tear.
 Any work carried out to improve the general finish of the machine above
 what is known to be the factory standard.
 Failure to maintain the equipment in accordance with the manufacturers
reccomendations.
REMEMBER:
i. The replacement or repair of tyres is not covered by the Company’s warranty terms.
ii. In the case of van and truck mounted equipment the warranty relating to the actual
vehicle remains the responsibility of the vehicle manufacturer or supplier.
In order to comply with the provisions of the Health and Safety at Work Act 1974 in
respect of articles manufactured, supplied or installed for use at work, we test all our
products before they leave our factory and supply with them adequate instructions
for their proper use. Further copies of these instructions are available from us on
request.
We shall not be liable for loss, injury or damage of whatever nature caused by
goods, design, technical information, suggestions, etc supplied by us where as the
case maybe they have been structurally modified or misused or misapplied or have
not been properly cared for and maintained, and the purchaser hereby agrees to
indemnify us against all such claims and demands or by whomsoever they are
brought.
77
FLOWPLANT
Flowplant Century Pump Manual
5.2.2 Service and Spares
Flowplant provide service and spares cover in most parts of the world. When
ordering spares, please quote:a)
b)
c)
d)
e)
f)
g)
h)
Your company name and address.
Destination of parts, if different.
Description and part number.
Quantity required.
Price and method of payment.
Delivery date.
Order number.
Confirmation of order.
When requesting service or repairs, please state:a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Your company name and address.
Location of machine/unit if different from above.
Type and model of machine/unit.
Pump serial number.
Problem(s) with machine/unit.
Availability of machine/unit for service or repairs.
Date of service and site contract.
Cost and method of payment.
Order number.
Confirmation of order.
78
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