STS M2-H Operator's Manual

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STS M2-H Operator's Manual | Manualzz

Surface to Surface Inc.

®

Operators Manual

** M2-H **

USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)

Unit Serial No. _______________

Dealer

Hydraulic Motor

SNM2/11C106

Gorman-Rupp® Pump

STS-GR82E2 – Serial No. ________________

Control Valve

Serial No.__________________

Links relating to this Manual www.stsmixers.com www.grpumps.com

STS-102 Rev. 08/24/18 www.stsmixers.com

This page left blank intentionally

2

TABLE OF

CONTENTS

PAGE

STS Inc. Warranty ……………………………………………………….... 6

Safety Statements ………………………………………………..………… 7-10

Safety Markings …………………………………………………………… 11

Hydraulic Connections / Schematic…………………………...…………. 12

Main Working Components (Photo) ……………………………………… 13

Hose Connection (Hook-up) …………….…………………………………. 14

Introduction to the M2-H ……………….…………………………..……. 15

M2-H Foot Print (top view) ……………..…………………………………

M2-H General Data Sheet …………..…………………………………….

Identifying Your Machine & Components ……………………..….…….

16

17

18

SECTION II ( Description, Care and Maintenance)

Hydraulic powered centrifugal pump ………………………………….

20-23

Filter shear system ……...…………………………………………….

Venturi mixing tee …………...………………..………..…………….

Wash

Dry hopper & hopper valve ……………………………………..……

Internal tank jets …………………………………...…………………

24-25

26

27

28

29-30

Permanent mounting of unit …………………………...…………….. 32

Portable use of unit …………………….…………………….………. 32

3

TABLE OF

CONTENTS

SECTION IV (Operating the M2 Unit.)

PAGE

Site set-up and pre-check ……………………………………………..

34

Starting the hydraulic driven pump ………….……….…....….……… 35

Typical mixing operation ……………………….……………………. 36

Typical transfer / off-loading operation ……………………………… 37

Shutdown, cleanup & storage

Warm weather …………………………………….…………. 38

Cold/ freezing weather ………………………...……….…… 39

Prolonged periods of storage …….………………………..… 40

SECTION V (Trouble shooting)

Trouble Shooting the M2 ……..………..……….….…..……..……… 42-43

SECTION VI (Periodic Maintenance & Repair Information)

Maintenance Schedule …………………….….………………….…... 45

Centrifugal Trash Pump Seal Replacement ………………………..… 46

Bolt torque Specifications …………………………………….……... 47

Notes …………………………………………………….…………… 48

4

TABLE OF

SECTION VII (OEM Repair Information)

PAGE

GR Centrifugal Pump Owner’s Manual (condensed) ….……………… 50-61

Gruvloc® Pipe Couplings ……………………….……...………..…… 62-64

Sauer Danfoss Hydraulic motor …………..…….….….….….….……. 65-67

SECTION VIII

CONTENTS

(Parts Manual)

M2-H PARTS MANUAL ……………………….……………………. 69-71

5

Limited Warranty

United States and Canada

Surface to Surface Inc. or its subsidiary which last sold the product, warrants new products sold by it for use in the

United States and Canada to be, at the time of manufacture, free from defects in workmanship and materials. This warranty covers for a period of Twelve (12) Months of operation from the date of delivery for initial use, whichever comes first.

Exclusions and Additional Limitations

1. This warranty relates to the condition of the product at the time of manufacture and does not cover parts or service as a result of:

(a) Normal wear and tear or required maintenance including, without limitation, adjustments or replacement of components subject to wear and tear, such as belts, hoses, seals and/or packing, fuses, bulbs,

switches

(b) Abuse including, without limitation, neglect, improper operation, misapplication, overloading, accident or alterations not approved by Surface to Surface Inc.

(c) Lack of maintenance, including, without limitation, failure to inspect and maintain, improper repair, use of

“unapproved parts”, cracked engine heads and blocks unless caused by the failure of

an internally lubricated part or repair of engine valves, rings or guides.

2. The Company’s warranty does not apply to purchased components manufactured by others where separate warranty is made by the manufacture of such components and will be applied as interpreted by

the

3. All claims under his warranty shall be submitted in writing by the distributor to the Company, which will be the sole judge in determining the merits of the claim.

4. The company shall have the right to have all products or parts claimed to be defective returned to it and the cost of shipping such items shall be borne by the distributor.

……………………………………………………………………………………

Warranty Registration Card

In order to help us provide complete service for our product, please complete this card and return it.

If not returned, all requests for warranty will be denied.

Print Name: …………………………………………………………………….….

Model No. ………………………….. Serial No. …………………………………

Date of Purchase ………………………… Dealer ………………………………..

Return to: Surface to Surface Inc.

5150 Forest Rd. RR#3

Watford, Ontario, Canada

N0M 2S0

01/14/08

6

M2-H

SAFETY STATEMENTS

Your personal safety and the safe operation of this unit are the concern of Surface to Surface Inc., and by reading and understanding this manual and understanding the safety statements, you will decrease the risk of personal and equipment damage.

Safety statements are listed here and throughout this manual to draw your attention to potential hazards that may be encountered while operating this piece of equipment. While reading this manual, you will notice that certain safety statements will relate directly to the operation, or maintenance of that particular part of the unit and should be followed carefully. Decals on the unit also follow the same format as the warnings in this manual, and therefore should be kept in good repair to alert the operator and others of the potential hazard.

The engine / motor manual also contains hazard warnings which pertain to the engine / motor and should also be followed.

This safety alert symbol appears with most safety statements.

It means attention, become alert, your safety is involved!

Please read and abide by the message that follows the safety alert symbo l.

DANGER

Danger (the word "DANGER" is in white letters with a red rectangle behind it) indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

Danger is limited to the most extreme situations.

CAUTION

Caution (the word "CAUTION" is in black letters with a yellow rectangle behind it) indicates an potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

WARNING

Warning (the word "WARNING" is in black letters with an orange rectangle behind it) indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Caution "without the safety alert symbol" indicates an potentially hazardous situtation that can cause damage to the, machine, personal property and / or the environment or cause the machine to operate improperly.

7

M2-H

SAFETY STATEMENTS

The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference.

DANGER

IN AN EMERGENCY

rotate the flow control val ve lev er to the STOP position to halt the pump, and fluid fl ow.

WARNING

NEVER ATTEMPT TO REMOVE

OR CLEAN THE F ILTER SHEAR whil e the unit is in operation.

Ser ious personal inj ury will result.

DANGER

NEVER ATTEMPT REPAIRS

OR DISASSEMBLY

without shutting off the hydr aulic power source.

Ser ious personal inj ury will result.

CAUTION

DO NOT POSITION

ANY PART OF YOUR BODY

over the hopper, valve, or mixing tee whil e cleaning.

WARNING

NEVER USE BODY PARTS,

OR FOREIGN OBJECTS in an attempt to unplug or clean the hopper valve or mixing tee.

Ser ious personal inj ur y or damage will result.

WARNING

DO NOT REMOVE OR MODIFY

SAF ETY COVERS OR GUARDS.

Ser ious personal inj ury will result.

CAUTION

WHEN THE UNIT

IS IN OPERATION,

the fluid i n the piping may reach pressures up to 50 p.s.i.

8

M2-H

SAFETY STATEMENTS

continued

The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference.

CAUTION

TRAPPED FLUI D MAY BE PRESENT and will spill out when piping, hoses, pump or fi lter shear are remov ed.

CAUTION

WHEN TRANSFERRING FLUID to the drill rig, fluid pressure may reach or exceed 50 p.s.i.

CHECK the drill r ig manufacturers specifications regarding maximum i nlet pressures allowed for their pump.

CAUTION

NEVER LEAVE LIQUID IN THE

PUMP CASING, PIPING, OR HOSES duri ng freezing weather conditions, as damage will result.

Foll ow instruction for winteriz ing.

CAUTION

IMPROPER INSTALLATI ON OF THE

MECHANI CAL or GREASE SEAL will result in leakage and possible damage to the seal. All maintenance, operating and repair of this unit, must be done per the instructions in the operators manual for safety and r eliability.

CAUTION

AVOID ALLOWING FOREIGN MATERIAL into the Venturi Mixing Tee thru the

Hopper, by keeping the val ve closed when not in use.

CAUTION

CARE MUST BE TAKEN WHEN

INSTALLING THE COUPLER GASKETS.

If the gaskets are not pr operly lubricated and installed, a leak may devel op.

CAUTION

BEFORE STARTING THE HYDRAULIC MOTOR,

BE SURE THE PUMP IS PRIMED!

Check the pump by slowly & carefully opening the plug located on the top of the centrifugal pump discharge elbow.

A visual inspection can be made if the fluid escapes around the plug as it is loosened.

Remove the plug to v iew inside fluid level.

The centrifugal pump seal WILL be damaged if allowed to cavitate or run dry.

CAUTION

BEFORE STARTING OR RESTARTING the hydraulic motor and centrifugal pump, make sur e any v alves installed on the pump sucti on inlet line ar e open, and the fluid level in the tank is above the suction line.

9

M2-H

SAFETY STATEMENTS

continued

The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference.

CAUTION

The manufacturer should be consulted when considering alternative uses for this piece of equipment.

This unit was designed for the mixing and shearing of a dry additive, into a liquid stream.

Other uses may create unforeseen safety issues and personal injury r isk.

CAUTION

LIFTING LUGS OR THE LIFTING POINT(S) identified and labelled on the skid structure must be used in order to safely lift and transpor t the unit.

WARNING

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLIED MANUALS

AND

THIS MANUAL

REGARDING THESE

OPERATIONS.

10

M2-H

Safety Markings

Hazard and warning markings have been placed at appropriate points on the unit. International symbols have been used, in order to ensure universal understanding of the nature of the hazard. Please comply with all warnings and markings to ensure safe use of the equipment. These include but are not limited to: a) Lifting points c) High temperature areas e) Personal dangers b) Personal Protection recommendations d) Equipment dangers f) Fluid flow direction

SOME EXAMPLES FOUND ON THE EQUIPMENT

Personal Protection, Read and understand Operator’s manual and Maintenance manual

Lifting Point Hot Surface

Fluid Flow Direction

Lifting Point

CLEAN FILTER DAILY

Maintenance Instructions

11

M2-H

These guidelines must be followed or warrant will be voided. Any variation needs to be approved by Surface to Surface®.

SET-UP

Minimum Flow Rate: 10us gpm.

Maximum Flow Rate: 10.3us gpm.

Relief

Inlet Hose Size:

Outlet Hose Size:

3/4" minimum

3/4" minimum (

direct to reservoir

)

Caution:

As the hydraulic oil increases in temperature the hydraulic flow rate will rise above your set rate of 10 - 10.3 g.p.m. of hydraulic flow. The hydraulic flow valve should then be set back to the recommended flow rate of 10 – 10.3 g.p.m.

M2-H

RETURN LINES

PRESSURE LINES

1 2

3

IN

Flow Meter

4

5

6

IN FLOW

10.3 usgpm. MAX.

7

8

CUSTOMER SUPPLIED

OUT FLOW

TO OIL RESERVOIR

01-20-06

Specifications on hydraulic oil, operating temperature, and filtration can be found further on in this manual, on the Sauer Danfoss hydraulic motor data sheets.

Any problems or question may be answered by calling Surface to Surface ® at

(800) 567-0978 during normal business hours.

12

13

Surface to Surface Inc.

M2 Series

(Hose Hook-ups)

FLUID OUTLETS

[to Drill Rig & Tank Guns]

** 1 1/2" NPT **

PUMP INTAKE

[in from Tank]

** 2" NPT **

This line should have a valve installed at the tank to facilitate shut down or reapirs.

FLUID RETURN

[out to Tank]

** 2" NPT **

This line should discharge above the maximun fill line of the tank. The air space will stop the siphon action of the fluid.

"ALL HOSES SHOULD BE KEPT TO THE SHORTEST LENGHT POSSIBLE TO ACHIEVE MAXIMUN PREFORMANCE."

14

M2-H

Operators Manual

Congratulations on your acquisition of the world renowned M2 Mixing System. You have acquired the fastest and most efficient mixing system manufactured for mixing Bentonite drilling slurry (mud). As a manufacturer of HDD support equipment, we are well aware of the extreme conditions that HDD equipment is exposed to on a daily basis. Surface To Surface Inc. strives to overcome these conditions, with better design and manufacturing practices. Please feel free to call our toll free number

(1-800-567-0978) if you have any questions or concerns about your M2

Thank you, for choosing the M2 series mixer.

The M2 mixing unit was designed to mix dry or liquid drilling products with clean water, into a slurry. The slurry is continually circulated through the mixing cycle until it reaches the desired consistency. The operator can then transfer the final product to a second holding reservoir or directly to the drilling equipment .

The M2-H mixing unit consists of a hydraulic powered centrifugal pump, filter/shear unit, venturi mixing tee assembly, dry hopper, pressure wash wand, and a set of tank internal jets.

These components are all mounted together on a framed skid, built for portability or permanent installation. For ease of interpretation, looking at the mixing unit hopper straight on will be considered looking at the front of the unit. Hence the other long side, will be the rear and the ends will be right or left end.

RECORD OF OWNERSHIP:

Unit Serial No. __________________________________________

Motor Serial No.________________________________________

Pump Serial No:_________________________________________

Date Purchased/Leased:___________________________________

Dealer Purchased/Leased From:_____________________________

Special Custom Features:__________________________________

15

33"

IN

38"

M2-H (Hydraulic)

Dry Weight: 275 Lbs (125 Kg)

16

26 1/2"

Surface to Surface Inc.

®

DWR. NUM.

M2-H

DATE.

REV.

011 / 17 / 11

Universal 2” Mixer

Model M2-H

Surface to Surface Inc.

Features and Benefits M2-H Mixer

26 1/2"

Hydraulic

The M2-H universal mixer is designed around the time proven M series mixers of STS. Powered by the customer’s own power source. A 10gpm. hydraulic motor drives a centrifugal pump, making effective use of the proprietary 4 point mixing system. The M2-H can be used as a new installation or retro fitted into an existing tank. Since the unit is connected by hoses and not hard pipes, the placement of the mixer to the tank is less restricted and a configuration to suit the needs of the contractor and available space, are easier to achieve. The small size also makes it a portable, independent unit that is easier to transport from site to site.

33"

1 2

3

IN

4

5

38"

Specifications

Dimensions

Weight

Hopper Height & Size

Mixing System

Flow Valves

Skid Frame

Hydraulic gear motor

Hydraulic Valve

Hydraulic system

Pump

Pump Coupling

M2-H Mixer Benefits

33” W x 38” L x 26 1/2” H

275 Lbs

Small space saving footprint.

Light weight for easy transportation.

261/2” High Holds ½ of a bag Low hopper height reduces back strain.

2” Proprietary StS Mixing System Fast & efficient with high shearing ability.

Brass and Steel construction

Steel tube with lifting bale

Requires 10gpm. @ 1800psi

Withstand the abuse of daily operations

Built tough for the construction trade.

Use your own power source, no fumes in truck body

Variable speed controller

Open loop circuit

Allow mixing at various speeds.

Simple, field repairable, less maintenance

2” Cast iron centrifugal trash pump Gorman-Rupp 80 series

Hyd. Motor direct to Bearing Block No expensive couplers or inserts to replace.

Pipe Couplers

Pressure Wand

Bolt & Snap-groove type

Hopper maintenance wand

Fast cold weather draining of system.

Removal of build-up caused by additive.

Internal Tank Jets(supplied) Eductor Nozzles (5-1 fluid output) Fast and effective rolling and mixing action.

Mechanical Seal Self- Pressurizing Grease Seal Greaseable seal for more rugged working conditions

Replaceable Wear Plate Hardened plate ahead of Impeller Less wear on internal pump parts and is replaceable.

With a 40 second viscosity, the M2 produces 90 gpm @ 36psi through the nozzle and 52 gpm @ 36psi to the tank internal jets (5-1 mixing equals 260 gpm of mixing / rolling action in tank) and a discharge rate of 80 gpm @ 36psi

Check our website for the latest products and specifications www.stsmixers.com

Surface to Surface Inc.

5150 Forest Road, R.R.#3, Watford, Ontario, N0M 2S0

Tel: 1-800-567-0978

02/19/12

17

M2-H

Identifying Your Machine & Components

Location of Tags and PIN Plates

18

SECTION #II

Description, Care and Maintenance

19

IN AN EMERGENCY rotate the flow control val ve lev er to the STOP position to halt the pump, and fluid fl ow.

M2-H

Description, Care and Maintenance

Hydraulic Powered Centrifugal Pump

Care and maintenance of the hydraulic motor and pump are covered in this manual and/or the manufacturer operator’s manuals supplied and should be read and understood. We suggest the following daily checks be carried out prior to using the system. Check the fluid level in YOUR hydraulic reservoir is sufficient. Check the hydraulic filtering system is working properly. Check the pump seal grease cup is full

(see grease cup instructions Fig.5). Check that any water intake valve(s) are open and the reservoir tank has sufficient liquid to supply the centrifugal pump.

The pump is mounted directly to a bearing block and the hydraulic motor, so there is no “drive coupler” to check or maintain. The bearings in the bearing block are factory greased to provide constant lubrication. The pump is the primary component that will see the most wear due to the nature of the material it is handling therefore it will require regular checks, adjustments and maintenance.

There is a section of this manual dedicated to the pump itself and should be read and understood which will help should any problems or concerns arise in the field.

The pump should never be allowed to start or run dry, as this WILL damage the internal pump seal (grease seal) and render the unit inoperable until the seal is fixed.

To prime the pump or check to visually see if the pump is primed, slowly undo the priming plug (see fig. 3) on top of the pump and stop after about 3 turns. If the pump is primed, fluid & air will escape from around the plug threads. This indicates that the pump housing is full, and the plug can be tightened back up.

If no fluid is escaping from around the threads, completely remove the plug & carefully remove the plug.

Drill fluid or water can be poured into this opening to fill the pump cavity, and a visual of the fluid level inside the pump can be made. The level should be approximately to the top of the pump priming hole.

Another way to prime the pump is to have the tank FULL of fluid, and standing off to the side of the hopper, rotate the hopper valve SLOWLY to the open position. As the valve is opened, you will hear air escaping followed by fluid, into the hopper itself. Close the valve as the fluid enters the hopper. This means the fluid in the tank has filled the pump cavity of the pump and flowed from the outlet of the pump to the remaining piping on the unit.

DANGER

Fig.3

CAUTION

BEFORE STARTING THE HYDRAULIC MOTOR,

BE SURE THE PUMP IS PRIMED!

Check the pump by slowly & carefully opening the plug located on the top of the centrifugal pump discharge elbow.

A visual inspection can be made if the fluid escapes around the plug as it is loosened.

Remove the plug to v iew inside fluid level.

The centrifugal pump seal WILL be damaged if allowed to cavitate or run dry.

DANGER

NEVER ATTEMPT REPAIRS

OR DISASSEMBLY without shutting off the hydraulic power source (customer supplied)

Serious personal inj ury will result.

CAUTION

IMPROPER INSTALLATION OF THE

MECHANICAL or GREASE SEAL will result in leakage and possible damage to the seal. All maintenance, operating and repair of this unit, must be done per the instructions in the operators manual for safety and reliability.

20

Fig.4

M2-H

Description, Care and Maintenance

Hydraulic Powered Centrifugal Pump

CAUTION

TRAPPED FLUID MAY BE PRESENT and will spill out when piping, hoses, pump or filter shear are removed.

CAUTION

NEVER LEAVE LIQUID IN THE

PUMP CASING, PIPING, OR HOSES during freezing weather conditions, as damage will result.

Follow instruction for winterizing.

CAUTION

BEFORE STARTING OR RESTARTING the engine and centrifugal pump, make sure any valves installed on the pump suction inlet line are open, and the fluid level in the tank is above the suction line.

WARNING

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLIED MANUALS

AND

THIS MANUAL

REGARDING THESE

OPERATIONS.

21

M2-H

Description, Care and Maintenance

Hydraulic Powered Centrifugal Pump

Grease cup instructions (Fig.5)

Fill the grease cup through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal.

NOTE:

Some smoking and leakage may occur after installing a new seal assembly. This should stop after the pump has run a while and the lapped seal faces have seated in.

Fig.5

22

M2-H

Description, Care and Maintenance

Hydraulic Powered Centrifugal Pump

Grease cup instructions (Fig.5a)

GREASE

 

CUP

 

NEEDS

 

TO

 

BE

 

CLEANED

 

REGURALY

 

The grease cup may not perform its function properly (lubricating the seal) if it is not routinely cleaned of old hard grease build-up.

If the grease cup is always “topped up” instead of allowed to run to the full stroke of the plunger, the grease may dry out and build up inside of the cup and not allow the plunge to push to the full stroke. This in turn will stop the supply of grease to the seal causing premature seal failure.

As a precaution it is strongly recommended that every 30 days, the grease cup (or the top of the grease cup) be remove and the inside of the cup and the plunger be cleaned of all old grease.

Reassemble the plunger into the cup and check that the plunger sliders to the bottom of the now clean cup.

Fill with fresh grease.

FIG #5a Shows clean grease cup & plunger and old, dried grease taken out of the cup, that was causing the plunger to “hang-up”.

23

 

M2-H

Description, Care and Maintenance

Filter / Shear System

The filter / shear (Fig.6a) system on the M2 is an integral part of the mixing system and to operate efficiently requires daily cleaning of the stainless steel internal filter /shear. The filter / shear system is a two-piece unit

(Fig.6b) consisting of an outside housing and an internal filter / shear. The filter / shear will trap any debris, such as parts of bags, stones, leaves grass etc. The proper procedure for cleaning the filter / shear is to close the suction valve from the reservoir tank to the pump, rotate the two “Outlet” valves to the closed position, remove the 3 inch Snap Loc coupler at the right end of the filter housing, remove the 2 inch Snap Loc coupler on the discharge pipe of the centrifugal pump. You will now be able to remove the internal filter / shear from the housing. After the internal filter / shear has been removed, you will see on the end of the filter

/ shear a pipe plug (Fig.6b). Remove the pipe plug and wash out the filter / shear with clear water. Reinstall the pipe plug into the filter / shear, reinstall the filter / shear in the housing. Do-not clamp the 3 inch coupler until the 2 inch coupler and gasket are properly lined up. After all pieces are correctly lined up, clamp the 3 inch coupler 1 st

and 2 inch coupler 2 nd

and reinstall the safety pins. Open all of the valves that were closed prior to removing the filter / shear.

Fig.6a

DANGER

NEVER ATTEMPT REPAIRS

OR DISASSEMBLY without shutting off the hydraulic power source (customer supplied)

Serious personal inj ury will result.

Fig.6b

WARNING

NEVER ATTEMPT TO REMOVE

OR CLEAN THE FILTER SHEAR while the unit is in operation.

Serious personal injury will result.

24

CAUTION

CARE MUST BE TAKEN WHEN

INSTALLING THE COUPLER GASKETS.

If the gaskets are not properly lubricated and installed, a leak may develop.

M2-H

Description, Care and Maintenance

Filter / Shear System continued

On the bottom of the filter / shear housing (Fig.7) are two outlets that have 1 1/2” NPT ball valves connected to them. One of the outlets is to be connected to the internal tank jets inside of the reservoir tank

(explained further on in this manual) and the other outlet is to be used as a discharge for the fluid after it is mixed. The discharge can be connected to another reservoir tank or directly to the drill rig. To control the flow of discharge, the ball valve can be used to regulate the flow. The speed of the engine can also be used to control the flow and pressure of the discharge. It is up to the customer to decide the piping arrangement and how they would use the discharge options. The discharge flow can have high pressure and high volume flows associated with it, and should be treated as such. If you are unsure of the installation and routing of this flow, contact Surface to Surface Inc. for more details.

Also on top of the housing is the outlet for the wash wand. The wash wand is explained in more detail further on in this manual.

Fig.7

CAUTION

WHEN TRANSFERRING FLUID to the drill rig, fluid pressure may reach or exceed 50 p.s.i.

CHECK the drill rig manufacturers specifications regarding maximum inlet pressures allowed for their pump.

CAUTION

TRAPPED FLUID MAY BE PRESENT and will spill out when piping, hoses, pump or filter shear are removed.

25

M2-H

Description, Care and Maintenance

Venturi Mixing Tee

The Venturi Mixing Tee (Fig. 8a.) is the very heart of this system and requires very little maintenance.

However M2 parts may wear as a result of the application, in time and require replacement. This wear will become evident, when the operator notices a reduction in the vacuum that helps pull in the dry product from the hopper. When mixing dry product, over time, you will see an accumulation of damp product inside of the mixing tee around the nozzle. If this accumulation is left unattended, over time it will build to the point of restricting the inlet of the mixing chamber. This situation is easily rendered, by using the wash wand to

“flush out the accumulation, and force it back into the fluid stream.

Fig.8a

CAUTION

AVOID ALLOWING FOREIGN MATERIAL into the Venturi Mixing Tee thru the

Hopper, by keeping the valve closed when not in use.

Nozzle

Fig.8b

Flush from this direction

Valve

Mixing Tee

Venturi

WARNING

NEVER USE BODY PARTS,

OR FOREIGN OBJECTS in an attempt to unplug or clean the hopper valve or mixing tee.

Serious personal injury or damage will result.

26

M2-H

Description, Care and Maintenance

Wash Wand

The M2 is equipped with a pressurized wash wand (Fig.9a) for clearing obstructions and accumulation in the jetting tee. It is recommended that the jetting tee be cleaned with the wash wand after the introduction of material into the hopper after each batch.

The wash wand uses the high-pressure fluid from the mixing system piping which can reach pressures of up to 50psi. CAUTION should always be used when handling the wash wand. A valve is located on the wash wand to regulate the flow of fluid.

The wash wand is not to be used as a poker or pry bar, but instead use the fluid from it to “wash” away accumulations. Be careful when putting the wash wand inside the mixing chamber that it does not block the fluid stream coming out of the nozzle, as it will spray back up the hopper and towards the operator.

The wash wand can also be used to get a fluid sample for testing purposes. An example of this (Fig.9b) is to check the viscosity of the fluid using a marsh funnel. Simply slow the engine speed down to reduce flow and pressure, and put the wash wand inside the hopper (with the hopper valve open) and open the small valve located on the wash wand. Rotate the valve handle to the on position, and let it flow for approx. 15 seconds, close the valve and place the wash wand in the screening area of the marsh funnel. Fill the marsh funnel to the proper volume, close the valve on the wand, and store back the small hose holder rack. Follow the instructions of the marsh funnel for the rest of the test.

The sample of fluid taken from the wash wand is the same as the fluid going out of the top discharge of the filter / shear housing to the drill rig or reservoir tank.

CAUTION

Fig.9a

DO NOT POSITION

ANY PART OF YOUR BODY over the hopper, valve, or mixing tee while cleaning.

CAUTION

WHEN THE UNIT

IS IN OPERATION, the fluid in the piping may reach pressures up to 50 p.s.i.

Fig.9b

WARNING

NEVER USE BODY PARTS,

OR FOREIGN OBJECTS in an attempt to unplug or clean the hopper valve or mixing tee.

Serious personal injury or damage will result.

27

M2-H

Description, Care and Maintenance

Dry Hopper and Hopper Valve

The Dry Hopper (Fig.10) is used during the initial mixing of the dry product and fluid. The hopper requires very little daily maintenance. Keeping the inside surface of the hopper clean will help the dry product flow smoothly into the hopper valve and into the mixing tee. The hopper is not ladders and should not be climbed on or sat upon as damage can result. The hopper can be removed with relative ease if needed for transporting size restraints. The securing knob at the rear side of the hopper should be checked regularly and kept tight to prevent movement.

The hopper valve must be kept free of dried Bentonite, ice or other buildups to reduce the chance of damage during opening and closing. The valve operates more smoothly if the surfaces are kept damp or wet.

All valves are to be opened and closed by hand. DO NOT FORCE THE VALVE OPEN OR CLOSED, visually check the valve if a problem occurs!

Fig.10

WARNING

NEVER USE BODY PARTS,

OR FOREIGN OBJECTS in an attempt to unplug or clean the hopper valve or mixing tee.

Serious personal injury or damage will result.

CAUTION

AVOID ALLOWING FOREIGN MATERIAL into the Venturi Mixing Tee thru the

Hopper, by keeping the valve closed when not in use.

28

CAUTION

DO NOT POSITION

ANY PART OF YOUR BODY over the hopper, valve, or mixing tee while cleaning.

M2-H

Description, Care and Maintenance

Internal Tank Jets

The Internal Tank Jets (Fig.11a) are supplies with the M2 unit, and are installed (by the customer) inside the reservoir tank, to keep the slurry product in the tank moving. This function assures the elimination of dead spots in the tank and a consistent mixture of fluid.

The internal tank jets are connected together in series, usually by a manifold design, (suggested by STS) were all jets receive the same amount of fluid and pressure. This manifold design is supplied with fluid from one of the outlets on the filter / shear housing (Fig.11b). The outlet has a ball valve to control the flow,

(Fig.11b) and should always be in the open position, unless you are cleaning the filter / shear (described earlier) or performing repairs on the system. If the valve is not closed, when preforming these tasks, a siphoning action can occur, pulling fluid from the tank and into the external piping. The internal tank jets requires little or no maintenance and will only require attention if they become clogged. Flushing the entire system daily with clear water should eliminate any problems with this piece of the system. The fluid passing through the internal tank jets is at a very high pressure and extreme caution should be used when viewing the inside of the tank.

The internal tank jets also acts as a relief valve to the system and relieves the pressure spikes caused when the flow to the drill rig or second reservoir tank is interrupted.

Fig.11a

Fig.11b

DANGER

NEVER ATTEMPT REPAIRS

OR DISASSEMBLY without shutting off the hydraulic power source (customer supplied)

Serious personal inj ury will result.

CAUTION

TO ENTER THE TANK is not recommended

Personal injury could result from the presents of hazardous fumes, remaining fluid or unit start-up.

CAUTION

NEVER OPERATE THE MIXING unit with the tank lid open.

CAUTION

WHEN THE UNIT

IS IN OPERATION, the fluid in the piping may reach pressures up to 50 p.s.i.

29

M2-H

Description, Care and Maintenance

Internal Tank Jets - Installation

How they work.

For every gallon of fluid passing through the jet nozzle from the manifold pipe, the jet nozzle will draw in another 4-5 gallon more from around the outside of the nozzle, creating a larger volume of fluid movement in the tank.

Connect the manifold to the outlet on the filter/shear of the STS Mixing Unit.

Each unit is shipped with 2-4 jet nozzles that have been properly sized for the unit.

Jet Nozzles

Manifold

ALL Jet Nozzles are mounted on one side of the tank to create a rolling effect in the tank.

2" steel or PVC/ABS pipe can also use for the manifold.

Cap or Seal Ends

Typical vertical installation in a round cone bottom tank

Pipes can be rolled to stop dead spots and couplers can be welded onto 2" pipe at different angle mount about 1/3 to 1/2 way up from the floor and aim toward the floor and oppisite wall to creat a rolling effect

For help with design and placement in your tank, call Surface to Surface Inc. and they will work with you to find the best solution

Typical horizontal installation in a tank

30

SECTION #III

Set-up and Installation of Unit in Detail

31

M2-H

Set-up and Installation of M2 in detail

Permanent mounting of the unit

The M2 is built on a sub frame with isolators (pucks) attached to the bottom. The unit can be fastened down to a permanent surface like a concrete pad, pull type trailer, flat deck of a truck or inside of a truck body. Securing the unit with adequate size and grade of fasteners is the sole responsibility of the customer and not of Surface to Surface Inc.

When fastening down the unit, care should be used when drilling holes to avoid such unseen items, as gussets, cross-members, wiring or other fixtures below the surface.

Adequate space or an opening will also have to be considered when mounting, for the removal of the filter / shear cartridge for regular cleaning and inspection.

Portable use of the unit

If the M2-H is to be used as a portable unit, there is a lifting bale (Fig.12) connected to the sub frame to support and balance the unit when lifting or moving. Properly approved and rated lifting apparatus should be used at all times and lifting done by qualified personal only.

The M2-H should only be placed on solid, level ground with a clear working area around it.

Fig.12

CAUTION

LIFTING LUGS OR THE LIFTING POINT(S) identified and labelled on the skid structure must be used in order to safely lift and transport the unit.

WARNING

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLIED MANUALS

AND

THIS MANUAL

REGARDING THESE

OPERATIONS.

32

SECTION #IV

Operating the M2 Unit

33

M2-H

Operating the M2 Unit

Site Setup & Pre-Check

SITE SETUP

CHECK for overhead hazards if unloading the unit to the ground.

UNLOAD the unit by using the sub frame lifting bale (marked) with appropriate equipment.

SET and position the unit on solid level surface to avoid settling or upset.

SET and position the unit to have a clear unobstructed working area of 10ft (3m) on all 4 sides.

CONNECT and secure all hoses onto the unit according to your layout.

SECURE the truck and/or the trailer that the unit is mounted on, from movement.

PROTECT any hoses connected between the M2, the tank, and drill rig, from possible damage or from being driven upon by a vehicle.

UNIT PRE-CHECK

READ the operators manual for proper starting and running procedures.

CHECK to assure the hydraulic oil reservoir has the proper fluid level for operating.

CHECK to assure the hydraulic filtering system is operating properly.

CHECK to assure the hydraulic variable speed controller is in the stop position.

CHECK to ensure the grease cup on the pump is full of grease and the winged/lugged nut on the top, is backed off to allow the shaft to retract into the grease cup.

CHECK to ensure any valves installed on the suction intake line between the tank and centrifugal pump are open.

CHECK to ensure there is sufficient fluid in the tank, to insure the centrifugal pump does not run dry.

CHECK to ensure the centrifugal pump is primed.

CHECK to ensure the ball valve on the discharge manifold connected to the “tank jets” is open.

CHECK to ensure the ball valve on the discharge manifold connected to the drill rig is closed.

CHECK to ensure the small ball valve connected to the Wash Wand is closed.

CHECK that the hopper valve is closed.

34

M2-H

Operating the M2 Unit

Starting the Hydraulic Motor & Pump

Starting the hydraulic driven pump

Make sure the hydraulic variable speed control lever (Fig.13) is in the stop position (all the way over to the left stop pin).

Start YOUR hydraulic power unit as per the manufactures instructions and let the hydraulic oil reach the recommended operating temperature.

Make sure the centrifugal trash pump is primed and all valves are open / closed as the previous instructions indicated.

Do a visual check for hydraulic fluid leaks.

 The hydraulic variable speed controller may now be SLOWLY rotated to the right, approximately 1/4 to start the trash pump, pumping fluid through the system. This will allow the hydraulic oil to fill the lines and come up to speed. At this point you should see fluid entering your reservoir tank via the fluid return hose.

Remember that the system is pumping fluid under pressure, even when the valve is at a low setting.

Gradually rotate the control lever (right) toward the high-speed position and set at the required speed

(GPM).

DO NOT EXCEED 10.3 GPM (Use flow meter to determine GPM)

Note: Whenever high-speed operation is not required, rotate the speed control lever (left) to approximately

1/2 speed, to extend hydraulic motor and pump life.

The Gorman-Rupp ® used on this unit is self-priming. Priming is not required as long as the pump is kept full of liquid.

Fig.13

CAUTION

BE FORE STAR TING THE H YDRA ULIC MOTOR,

BE SURE THE P UMP IS PRIME D!

Che ck the pump by sl owly & carefully ope ning the pl ug loc ated o n the top of the centrifugal pump dis charge elbow.

A v isual inspec tion c an be made if the fluid esc apes around the plug as it is l oosened.

Remov e the plug to v iew ins ide fluid lev el.

The centr ifugal pump seal WILL be damaged if allowed to cav i tate or run dry.

WARNING

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLI ED MANUALS

AND

THIS MANUAL

REGARDI NG THESE

OPERATIONS.

35

M2-H

Operating the M2-H Unit

Typical Mixing Operation

Mixing Operation

Operate the pump at high speed.

If not already open, open internal tank jet valve.

Open the hopper valve at the bottom of hopper where it joins the venturi-mixing tee.

Introduce the dry or liquid raw material into the hopper.

When mixing a new batch, introduce the 1 st

bag of dry product at a rate of 40 lbs. per minute. Once the first 40 lbs. of dry product are in the fluid stream, all dry products may be introduced as fast as the hopper will allow. This allows time for the 1 st

bag to be mixed well into the fluid and will now aid to suspend all remaining dry product that is added, into the fluid in the tank to achieve a better shear and stop any build-up in the tank.

Suction created by the venturi-mixing tee will draw the raw material into the jet stream for initial mixing.

Flush jetting tee with wash wand.

Close the butterfly valve on the hopper to keep debris out of the system.

Allow the mixing system to circulate the product until the desired consistency is attained.

A sample of the mixed fluid may be taken at from the wash wand as described earlier in this manual, on the wash wand description page.

Note: Whenever high-speed operation is not required, rotate the speed control lever (left) to approximately 1/2

speed, to extend hydraulic motor and pump life.

DANGER

IN AN EM ERGENCY rotate the flow control valve lever to the STOP position to halt the pump, and fluid flow.

WARNING

NEVER USE BODY PARTS,

OR FOREIGN OBJECTS in an attempt to unplug or clean the hopper valve or mixing tee.

Serious personal injury or damage will result.

CAUTION

DO NOT POSITION

ANY PART OF YOUR BODY over the hopper, valve, or mixing tee while cleaning.

CAUTION

AVOID ALLOWING FOREIGN MATERIAL into the Venturi Mixing Tee thru the

Hopper, by keeping the valve closed when not in use.

WARNING

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLI ED MANUALS

AND

THIS MANUAL

REGARDI NG THESE

OPERATIONS.

36

M2-H

Operating the M2 Unit

Typical Transfer/Offloading Operation

Transferring Operation

On the bottom of the filter / shear housing of the M2 you will see a second 1-1/2 in. ball valve

(1-1/2”NPT.) marked “Outlet”(the first “outlet” is connected to the internal tank jets)

A transfer hose with a minimum size of 1-1/2 in. can be attached to the ball valve to carry the finished product to a holding tank or directly to the drill rig.

Make the necessary connections at the holding tank or the drill rig.

Run the M2 pump at a favorable speed and slowly rotate the ball valve handle to the open position, to allow the fluid to flow to the holding tank or the drill rig.

The speed and pressure of the fluid flow is determined by the hydraulic motor speed.

If the unit is supplying the drilling rig directly, a valve that is controlled by the operator of the drill rig will be needed to stop the flow (normally mounted on the drill rig). The tank jet valve will need to be in the open position to act as a “relief” when the valve on the drill rig is closed.

If transferring to a reservoir tank, the “outlet” valve on the filter/shear housing is used to start / stop the flow of fluid.

When removing the mixed fluid from the tank (to the drill rig or reservoir), leave an amount of fluid in the bottom of the tank to keep the pump from sucking air (cavitation).

Close this “Outlet” valve, add water to the tank and begin mixing a new batch of mixed fluid.

DANGER

IN AN EMERGENCY rotate the flow control valve lever to the STOP position to halt the pump, and fluid flow.

CAUTION

WHEN TRANSFERRING FLUID to the drill rig, fluid pressure may reach or exceed 50 p.s.i.

CHECK the drill rig manufacturers specifications regarding maximum inlet pressures allowed for their pump.

CAUTION

WARNING

WHEN THE UNIT

IS IN OPERATION, the fluid in the piping may reach pressures up to 50 p.s.i.

REFER TO THE SAFETY

STATEMENTS IN THE

OEM SUPPLI ED MANUALS

AND

THIS MANUAL

REGARDI NG THESE

OPERATIONS.

37

M2-H

Operating the M2 Unit

Typical Warm Weather Shutdown & Storage

Daily Shut Down

Do not rotate hydraulic control valve suddenly while running at high speed.

Set the speed control lever at a low speed (1/8-1/4) position and allow the hydraulic motor to run at low speed for 2 to 5 minutes.

Make sure the butterfly valve under the hopper is closed.

Move the control lever to the most left position against the stop pin to stop the motor and pump.

STOP the hydraulic power source (customer supplied).

Close any valve(s) installed on suction line between pump and reservoir.

Remove the filter / shear as described in maintenance section.

Clean filter / shear as described in maintenance section.

Additional Week End Shut Down

Pump or drain remaining mixed fluid out of the tank and dispose of it according to local environmental approved practices.

Make sure both “Outlet” valves are open.

Disconnect the discharge hose that went to the drill rig or reservoir tank, at the drill rig or reservoir, and securely fasten it, back into the mixing tank to recirculate the fluid.

Fill and rinse the tank with clear water and then start the motor and pump. By pumping this water through the entire system, it will remove buildup and dilute any remaining mixed fluid in the system.

Open the valve on the wash wand and flush it back into the hopper. Open the hopper valve to drain, then close.

Move the control lever to the most left position against the stop pin to stop the motor and pump.

STOP the hydraulic power source (customer supplied).

Drain the remaining water out of the tank and dispose of it according to local environmental approved practices.

Remove centrifugal pump front drain plug. Replace the plug when the pump is empty.

Make sure both “Outlet” valves and wash wand valve are open.

Remove filter / shear and clean as described in the maintenance section of this manual.

DANGER

NEVER ATTEMPT REPAIRS

OR DISASSEMBLY without shutting off the hydraulic power source (customer supplied)

Serious personal inj ury will result.

CAUTION

CARE MUST BE TAKEN WHEN

INSTALLING THE COUPLER GASKETS.

If the gaskets are not properly lubricated and installed, a leak may develop.

WARNING

CAUTION

TRAPPED FLUID MAY BE PRESENT and will spill out when piping, hoses, pump or filter shear are removed.

REFER TO THE SA FETY

STATE MENTS IN THE

OEM SUPPLI ED MAN UALS

A ND

THIS MANUAL

REGA RDING THESE

OPE RATIONS.

38

M2-H

Operating the M2 Unit

Typical Cold Weather Shutdown & Storage

Additional Winter and Freezing Weather Shut Down

Pump or drain remaining mixed fluid out of the tank and dispose of it according to local environmental approved practices.

Make sure both “Outlet” valves are open.

Fill and rinse the tank with clear water and then start the motor and pump. By pumping this water through the system, it will remove buildup and dilute any remaining mixed fluid in the system. Open the valve on the wash wand to flush it into the hopper, then close.

Move the control lever to the most left position against the stop pin to stop the motor and pump.

STOP the hydraulic power source (customer supplied).

Drain the remaining water out of the tank and dispose of it according to local environmental approved practices.

Disconnect all hoses and let them drain.

Remove centrifugal pump front drain plug. Leave the pump plug out.

Make sure both “Outlet” valves and wash wand valve are open.

Remove filter / shear and clean as described in the maintenance section of this manual. Leave filter / shear out of housing as this will allow remaining moisture to drain.

Open the hopper valve and pour in a suitable environmentally friendly anti-freeze until it runs out of the venturi open end (hose is disconnected).

Shut the hopper valve and pour a suitable environmentally friendly anti-freeze into the hopper until about 2” of fluid cover the valve. This will stop the valve from freezing around the edges.

CAUTION

NEVER LEAVE LIQUID IN THE

PUMP CASING, PIPING, OR HOSES during freezing weather conditions, as damage will result.

Follow instruction for winterizing.

CAUTION

CARE MUST BE TAKEN WHEN

INSTALLING THE COUPLER GASKETS.

If the gaskets are not properly lubricated and installed, a leak may develop.

WARNING

REFER TO THE SA FETY

STATE MENTS IN THE

OEM SUPPLI ED MAN UALS

A ND

THIS MANUAL

REGA RDING THESE

OPE RATIONS.

39

M2-H

Operating the M2 Unit

Prolonged Periods of Storage

Prolonged Periods of Storage

After a thorough cleaning of the internal and external components of the M2, the following steps should be applied to extend the life of your unit.

Prolonged periods of storage require extra care of the pump to protect from rusting internally. Separate the pump (as you would to replace the seal) to dry and spray with a protective oil film.

Prolonged periods of storage require other preparation. See engine OEM manuals.

WARNING

REFER TO THE SA FETY

STATE MENTS IN THE

OEM SUPPLI ED MAN UALS

A ND

THIS MANUAL

REGA RDING THESE

OPE RATIONS.

40

SECTION #V

Troubleshooting the M2 Unit

41

M2-H

Troubleshooting the M2 Unit

The M2 mixing unit is of a simple design with limited moving parts or consumable pieces.

The basic system works with a pump that draws fluid from a reservoir tank. The fluid then exits the pump and by building pressure, and velocity, forces the fluid through the filter / shear and into the mixing Tee. The fluid enters the mixing Tee through a nozzle and exists through a venturi. As the fluid enters the venturi, it creates a vacuum in the mixing tee to aid in introducing the dry product from the hopper into the mixing Tee and fluid stream. As the fluid passes through the venturi it carries the dry product with it and into the reservoir tank.

As the fluid travels through the filter / shear, a set amount of fluid is taken from that fluid stream and forced with pressure, to the internal tank jets inside the reservoir tank. Multiple tank jets distribute the fluid through out the tank to “stir up the tank.

The M2 can discharge fluid to the drill rig or another reservoir by allowing some fluid from the filter

/shear to be discharged and controlled by a valve.

A good rule to follow when troubleshooting is as follows

Everything before the pump is being sucked, “has vacuum".

Everything after the pump is being blown, “has pressure”.

The following, may aid in any problems that may arise.

No fluid flow / low fluid flow

Pump not primed. - Prime pump

Suction valve is closed - Open suction valve

Suction valve is broken and not opening inside properly. - Replace valve

Plugged suction inlet inside of the tank. - Clean build-up inside of the tank

Not enough fluid in the tank or cavitation - Add fluid to tank

Impeller wore and gap to big. - Shim the impeller or remove gaskets

Pump speed to slow. - Speed up pump (10.3 gpm.)

Blockage in pump. - Remove blockage

Fluid too thick to pump. - Thin fluid by adding more water.

Filter / shear is plugged. - Clean filter shear

Fluid backs up into hopper

No fluid flow / low fluid flow - See above solutions

Large build-up in mixing Tee - Clean mixing Tee

Blockage in small part of venturi. - Remove blockage in venturi

Pump speed is set to low - Increase speed of the pump (10.3 gpm.).

Dry product is slow or will not be drawn down through the hopper.

No fluid flow/ low fluid flow - See above solutions

Fluid is backing up into hopper - See above solutions

Dry product has lumps / lumps blocking hopper valve - New product or clean valve

Hopper valve closed - Open hopper valve

Buildup in throat of mixing Tee - Clean throat of mixing Tee

42

M2-H

Troubleshooting the M2 Unit

Tank does not stir / roll the fluid inside.

No fluid to the tank jets - Make sure “Outlet” valve is open.

Tank jet holes plugged. - Flush fresh water through system or clean tank jets.

Hose is disconnected from tank jet - Reconnect hose

No fluid flow/ low fluid flow - See above solutions

Discharge from the unit is slow or stopped.

“Outlet” discharge valve is closed - Make sure valve is open.

Discharge hose is blocked, kinked, or pinched off. - Repair problem(s) with hose.

A valve installed at the end of the discharge hose is closed or damaged. - Open or replace

valve.

No fluid flow/ low fluid flow - See above solutions

Wash wand has little or no flow or pressure.

Wash wand valve is closed or damaged - Open wash wand valve or replace.

Wash wand nozzle (hole in the end) is plugged - Shut off unit and clean out wash wand hole.

No fluid flow/ low fluid flow - See above solutions

Fluid does not seem to mix well or is slow to mix

Most of the above problems will cause poor mixing or slow mixing - See above solutions.

For problems that can not be solved by the above steps, call your local distributor or STSI (1-800-567-0978) and talk to a company representative who would be glad to assist you with your problem.

43

SECTION #VI

Periodic Maintenance & Repair Information

44

Consult Your Hydraulic Power Source OEM manual(s) for a more detailed maintenance schedule of your equipment.

STSI is not to be held liable for any discrepancy’s or errors in the schedule.

Basic M2-H (Hydraulic) Periodic Maintenance Schedule ***

Maintenance Items

Hydraulic Components on M2-H Unit

Every

8 hours

(daily)

Every 50 hours

(weekly)

Every

100 hours

Every 200 hours

(monthly)

Every

300 hours

Visual check of hoses and connections for oil leaks

Visual check of hoses for damage, wear, or kinks

Visual check of variable speed controller

Visual inspection of inline flow meter

Pump Components

Check General Condition Visual (Temperature, Unusual

Noise or Vibrations, Cracks, Leaks, Loose hardware.

Check & Fill grease cup for mechanical seal

Check pump mechanical seal for leakage (dripping)

Clean old grease build-up from inside of Grease Cup

Check front impeller clearance (wear plate)

Check rear impeller clearance (seal plate)

Inspect the check valve

Equipment Components

Wash out Jetting Tee

Remove & clean shear unit

General Condition Visual (Cracks, Leaks, Loose hardware

Clamps are tight and safety pins installed

Lube valve stems

Clean reservoir tank of build-up (internal)

Disassemble and visually inspect piping (internal)

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Every

400 hours

Every

2000 hours

(or yearly)

0

45

M2-H

Grease Seal Installation Instructions

Centrifugal Pump Application

When replacing the seal, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal.

Before installing the seal, inspect the bore of the seal liner for

PACKING RINGS SEAL PLATE excessive wear or grooves that might cause leakage or damage BRASS SEAL LINER

SPACER SLEEVE the new seal liner and arbor (or hydraulic) press to force the old liner out. After the liner is installed, drill a ¼” diameter hole

LARGE CHAMFER

STATIONARY

ELEMENTS through it to permit the flow of lubricant to the seal liner. Be careful to center the drill in the threaded lubrication hole so

ENGINE

CRANKSHAFT

ROTATING

ELEMENTS not to damage the threads. Debur the hole from the inside of the seal liner after drilling.

Clean the seal cavity and shaft with a cloth soaked in fresh

IMPELLER

SHIM

WASHERS cleaning solvent. Be sure to follow all safety precautions described on the solvent container.

Remove the new seal and inspect the precision finished faces to

STATIONARY

WASHER

SPRING

Figure 3. Grease Seal Assembly ensure that they are free of any foreign matter. To ease installation of the seal, lubricate the packing rings, spacer sleeve, and seal liner with water or a very small amount of oil and apply a drop of light lubrication oil on the precision finished faces. Refer to the illustration, and assemble the seal as follows.

STATIONARY

WASHER

Installation of the inboard rotating element is dictated by the configuration of the shaft shoulder. If there is a radius at the shaft shoulder, the larger chamfer on the I.D. of the inboard rotating element must be positioned toward the shaft shoulder. If there is an undercut at the shaft shoulder, the larger chamfer must be positioned away from the shaft shoulder. Determine the correct position for the rotating element and slide it onto the shaft.

Sub assemble the inboard stationary element, packing ring and spring washer, and press this subassembly into the lubricated seal liner. A push tube cut from a length of plastic will aid seal installation. The O.D. of the tube should be about the same size as the O.D. of the seal spring.

Install the spacer sleeve and spring.

Sub assemble the outboard stationary element, packing ring and spring washer. Press this subassembly into the lubricated seal liner. If the outboard rotating element has a chamfered side, install it with the chamfer facing the impeller end of the shaft.

If your pump requires a spacer washer, install the spacer washer with the chamfer on the I.D. positioned toward the seal.

Install the impeller adjusting shims and impeller (consult the operator’s manual for impeller clearance and installation instructions).

Before starting the pump, reinstall the automatic lubricating grease cup and piping (if removed for seal liner replacement).

Lubricate the seal as indicated below.

LUBRICATION

Fill the grease cup through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal.

POSITION

WHEN

EMPTY

POSITION

FOR

FILLING

POSITION

WHEN

IN USE

NOTE:

Some smoking and leakage may occur after installing a

GREASE

FITTING

CROSS

ARM new seal assembly. This should stop after the pump has run a while and the lapped seal faces have seated in.

RELIEF

HOLE

Figure 4. Automatic Lubricating Grease Cup

46

M2-H

Bolt Torque Specifications

SAE SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

Lubricated *

Grade 5

Dry ** Lubricated *

Grade 8

Dry **

N.m ft-lbs N.m ft-lbs

9.5 7 12

N.m ft-lbs N.m ft-lbs

9 13.5

10 17 12.5

20 15 25 18 28 21 35 26

35

55

85

26

41

63

44

70

110

33 50

52 80

80 120

36

58

90

63

100

150

46

75

115

160 125

170

90

125

155

215

115 175

160 215

130

160

225

300

300

490

725

225

360

540

375

625

925

280 425

450 700

675 1050

310

500

750

550

875

1300

225

400

650

975

* "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

** "Dry" means plain or zinc plated without any lubrication.

Metric size

Thread size x pitch mm

N.m ft-lbs

M6 X 1.0 10.8 ± 1.0 8.0 ± 0.5

M8 x 1.25 25.5 ± 2.9

19.0 ± 2.0

M10 x 1.5 49.0 ± 4.9

36.0 ± 4.0

M12 x 1.75 88.3 ± 9.8

65.0 ± 7.0

M14 x 1.5 137.0 ± 9.8

101.0 ± 7.0

M16 x 1.5 226.0 ± 9.8

167.0 ± 7.0

Apply 60% torque to bolts that are not listed.

Apply 80% torque when tightened to aluminum alloy.

47

M2-H

NOTES:

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

48

SECTION #VII

OEM Repair Information

49

GR PUMP INTRODUCTION

Read this manual carefully to learn how to safely install and operate your pump. Failure to do so could result in personal injury or damage to the pump.

This Operation, and Maintenance section is designed to help you achieve the best performance and longest life from your pump.

This pump is an 80 Series, semi-open impeller, selfpriming centrifugal model with a suction check valve. The pump is designed for straight-in suction where the medium being pumped enters directly into the impeller eye. It is designed for handling most non-volatile, non-flammable liquids containing specified entrained solids. The basic material of construction for wetted parts is gray iron.

This manual cannot possibly provide detailed instructions and precautions for every aspect of each specific installation by the customer. Therefore, it is the responsibility of the owner/installer of the mixing unit to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.

If there are any questions regarding the pump or its application, which are not covered in this manual or in other literature accompanying this unit, please contact Surface to Surface or your STS distributor.

Surface to Surface Inc 1-800-567-0978

The following are used to alert maintenance personnel to procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel:

Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure required and the injury, which will result from failure to follow the procedure.

Hazards or unsafe practices, which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury, which could result from failure to follow the procedure.

Hazards or unsafe practices, which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possible damage, which could result from failure to follow the procedure.

NOTE

Instructions to aid in installation, operation, and maintenance, or which clarify a procedure.

50

SAFETY

This information applies to 80 Series basic pumps. The power source, which is used to drive the pump, may differ from unit to unit. Refer to the manual accompanying the power source before attempting to begin operation.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Lock out or disconnect the power source to ensure that the pump will

3. Allow the pump to completely cool

4. Check the temperature before opening any covers, plates, or

plugs.

5. Close any suction and discharge

valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

This pump is designed to handle most non-volatile, non-flammable liquids containing specified entrained solids.

Do not attempt to pump liquids for which the pump, driver and/or controls have not been approved, or which may damage the pump or endanger personnel as a result of pump failure.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Suction and discharge hoses and piping must be removed from the pump before lifting.

51

Make certain that the unit and all piping or hose connections are tight, properly supported and secure before operation.

Do not operate the pump without the shields and/or guards in place over the drive shaft, belts, and/or couplings, or other rotating parts. Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.

Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed discharge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.

SAFETY continued

Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to completely cool.

4. Check the temperature before opening any covers, plates, gauges, or plugs.

5. Vent the pump slowly and cautiously.

6. Refer to instructions in this manual before restarting the pump.

Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to completely cool before servicing.

52

Never run this pump backwards. Be certain that rotation is correct before fully engaging the pump.

Pumps and related equipment must be installed and operated according to all national, local and industry standards.

OPERATION

Review all SAFETY information in this manual.

Follow the instructions on all tags, labels and decals attached to the pump.

This pump is designed to handle most non-volatile, non-flammable liquids containing specified entrained solids.

Do not attempt to pump liquids for which the pump, driver and/or controls have not been approved, or which may damage the pump or endanger personnel as a result of pump failure.

PRIMING

Install the unit and hoses as described in this manual.

Make sure that the piping and hose connections are tight, and that the unit is securely mounted. Check that the pump is properly lubricated

(see LUBRICATION and REPAIR).

This pump is self-priming, but the pump should never be operated unless there is liquid in the pump casing.

Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. Extended operation of a dry pump will destroy the seal assembly.

53

Add liquid to the pump casing when:

1. The pump is being put into service for the

first time.

2. The pump has not been used for a considerable

length of time.

3. The liquid in the pump casing has evaporated.

Once the pump casing has been filled, the pump will prime and re-prime as necessary.

After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connecting piping and hoses are securely installed.

Otherwise, liquid in the pump forced out under pressure could cause injury to personnel.

To fill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fill cover or fill plug before operating the pump.

TROUBLESHOOTING

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Lock out or disconnect the power source to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

54

PREVENTIVE MAINTENANCE

Pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your 80 series pump.

Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so equipped) between regularly scheduled inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs.

The appearance of wearing parts should also be documented at each inspection for comparison as well.

Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.

For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspections should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

55

1

4

12/01/16

GR-82E2

2

3

5

6

8

9

7

10

2

Figure 1. Pump exploded view

56

9

10

11

12

13

7

8

5

6

3

4

REF #

1

2

14

15

16

17

18

19

DESCRIPTION

Grease Cup

3/8" Nut

3/8" L/W

Seal Plate Assembly

Brass Seal Liner

Casing Gasket Set

Grease Seal assembly

Shim Pack

Impeller

Wear Plate

Pump Casing

Stud

Pipe Plug

Hex Cap Screw

Fiber Washer

HD Machine Screw

L/W

Large Valve Weight

Check Valve Gasket

Small Valve Weight

Suction Flange

Filler Pipe Plug

GR-82E2 ASSEMBLY PARTS LIST

( P/N #060-GR82E2-KIT )

STS PART NUMBER

060-S36

060-GRD0615991

076-33622

060-GR427A10010

060-GR8314080

060-GR229G18000

060-GRGS1000

060-GR2X17090

060-GR6709100105.5

060-GR682215990

060-GR46472-309

060-GRC060615991

060-GRP1215079

060-GRB061415991

060-GRKF0618040

060-GRX040317090

060-GRJ0417090

060-GR19B10010

060-GR1361G19070

060-GR135415160

060-GR136113040

060-GR48271-063

QTY REQ.

1

11

11

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

19

11

14

15

18

2

12

13

16

17

GR-82E2

PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and decals attached to the pump.

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions, which are keyed to the sectional view (see Figure 1) and the accompanying parts list.

This manual will alert personnel to known procedures which require special attention, to those, which could damage equipment, and to those, which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established maintenance procedures are used, and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices.

Before attempting to service the pump, lock out or disconnect the power source to ensure that it will remain inoperative. Close all valves in the suction and discharge lines.

For power source disassembly and repair, consult the literature supplied with the power source, or contact your local power source representative.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Lock out or disconnect the power

source to ensure that the pump will

remain inoperative.

3. Allow the pump to completely cool

if overheated.

57

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close any suction and discharge

valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Suction and discharge hoses and piping must be removed from the pump before lifting.

For engine disassembly and repair, consult the literature supplied with the engine, or contact your local Honda representative.

Suction Check Valve Disassembly

Before attempting to service the pump, remove the pump casing drain plug (12) and drain the pump.

Clean and reinstall the drain plug.

For access to the check valve, remove the suction hose. Remove the nuts (2) and separate the suction flange (18) and check valve (16) from the pump casing (10).

Inspect the check valve parts for wear or damage.

If replacement is required, remove the hardware

(14, 15, 17) and separate the check valve gasket and weights.

Pump Casing and Wear Plate Removal

To service the wear plate (9), remove the nuts & lock washers (2) securing the pump casing to the seal plate (3) and engine. Separate the pump casing and remove the gasket set (5).

Inspect the wear plate for scoring or excessive wear.

To remove the wear plate, disengage the hardware (2, 13). Pull the wear plate out of the pump casing.

GR-82E2

PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY

Impeller Removal

Before removing the impeller, screw the cross arm on the automatic lubricating grease cup (1) clockwise until it rests against the cover (see Figure 4) to prevent the grease in the cup from escaping.

Remove the grease cup and piping (1).

Using a hardwood block of wood positioned against the impeller vain, strike the hardwood block with a hammer, in a counter clock-wise rotation (viewed from the impeller end).

Loosening the impeller is the same rotation as loosening a standard nut and bolt.

Inspect the impeller and replace it if cracked or badly worn. Slide the impeller adjusting shims (7) off the impeller shaft. Tie and tag the shims, or measure and record their thickness for ease of reassembly.

Seal Removal and Disassembly

Remove the outer rotating element, shaft sleeve, and remaining seal parts off the shaft as a unit.

Carefully remove the stationary and rotating seal elements, packing rings and washers, seal spring and spacer sleeve from the seal plate.

Inspect the seal plate and replace it if cracked or badly worn. To remove the seal plate (3) from the engine, remove the bolts and lock washers, or nuts and lock washers from the studs. Inspect the seal liner (4) for wear or grooves that could cause leakage or damage to the seal packing rings. The seal liner is a press fit into the seal plate and does not normally require replacement.

If the seal liner requires replacement, remove the seal plate assembly as described above, and position it on the bed of an arbor (or hydraulic) press.

Use a new sleeve to force the old one out. After the new liner is properly installed, a 1/4-inch (6,4 mm) diameter hole must be drilled through it to permit the flow of lubricant to the seal assembly. Be careful to center the drill in the threaded grease piping hole and not damage the threads. Debur the hole from the inside of the seal liner after drilling.

58

Seal Reassembly and Installation

(Figures 1 and 3)

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame.

Read and follow all precautions printed on solvent containers.

The seal is not normally reused because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emergency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non-oil based solvent and a clean, lint-free tissue.

Wipe lightly in a concentric pattern to avoid scratching the faces.

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leakage.

Clean and polish the shaft sleeve, or replace it if there are nicks or cuts on either end. If any components are worn, replace the complete seal.

Never mix old and new seal parts.

If a replacement seal is being used, remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter.

To ease installation of the seal, lubricate the seal liner (4) with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see Figure 3).

Slide the seal plate assembly over the impeller shaft and secure the seal plate to the engine using the bolts and lock washers or nuts and lock washers on studs.

Slide the inboard rotating element into the lubricated seal liner with the chamfered side toward the shaft shoulder.

GR-82E2

PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY

Seal Reassembly and Installation continued

(Figures 1 and 3)

Sub assemble the inboard stationary seat, packing ring and stationary washer. Press this unit into the lubricated seal liner until the seal faces contact.

A push tube cut from a length of plastic pipe or deep socket would aid in this installation. The I.D. of the tube or socket should be approximately the same size as the I.D. of the seal spring.

Slide the spacer sleeve onto the shaft until it seats against the inboard rotating element and install the seal spring.

Sub assemble the outboard stationary seat, packing ring and stationary washer. Press this unit into the lubricated seal liner. Install the outboard rotating element with the chamfered side toward the impeller.

Lubricate the seal assembly as indicated in

LUBRICATION after the impeller has been installed.

Impeller Installation

Inspect the impeller and replace it if cracked or badly worn.

The shaft and impeller threads must be completely clean before reinstalling the impeller.

Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or impossible without damage to the impeller or shaft.

Install the same thickness of impeller shims (7) as previously removed and screw the impeller onto the shaft until tight. Bump the impeller tight with a wood block or soft mallet.

The clearance between the back of the impeller and the seal plate should be between 0.010 and 0.020 inch

(0,25 to 0,51 mm).

Measure this clearance and add or remove shims from the impeller adjusting shim set until the correct clearance is achieved.

59

Pump Casing and Wear Plate Installation

If the wear plate assembly (9) was removed, install the new wear plate in the pump casing and secure it with the hardware (2 & 13).

Install a new set of casing gaskets (5) and slide the pump casing over the impeller and against the gaskets.

The clearance between the face of the impeller and the wear plate should be between .010 and .020 inch

(0,25 to 0,51 mm).

Remove gaskets from the gasket set until the correct clearance is achieved. Secure the pump casing to the seal plate with nuts & lock washers (2).

Suction Check Valve Installation

Inspect the check valve components and replace them as required. Sub assemble the check valve weights and gasket using the attaching hardware

(14, 15, 16, 17).

Install the check valve assembly on to the studs

(11). Large weight toward the pump casing.

Replace the suction flange onto the studs (11), and secure with the nuts (2).

Check the operation of the check valve to ensure proper seating and free movement.

Final Pump Reassembly

Be sure all hardware and drain plugs are tight, and that the pump is secure to the base and power source.

Install the suction and discharge lines / hoses and open all valves. Make certain that all piping connections are tight, and that the weight of the hose is independently supported and secure.

Before starting the pump, fill the pump casing with clean liquid.

Apply Pipe Sealant or equivalent compound to the fill plug (19). Reinstall and tighten the fill plug.

Refer back to OPERATION, before putting the pump back into service.

PACKING RINGS

IMPELLER

ENGINE

CRANKSHAFT

SEAL PLATE

BRASS SEAL LINER

SPACER SLEEVE

LARGE CHAMFER

STATIONARY

ELEMENTS

ROTATING

ELEMENTS

IMPELLER

SHIM

WASHERS

STATIONARY

WASHER

STATIONARY

WASHER SPRING

Figure 3. Grease Seal Assembly

LUBRICATION

Fill the grease cup (1) through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal (see Figure 4).

NOTE:

Some smoking and leakage may occur after installing a new seal assembly. This should stop after the pump has run a while and the lapped seal faces have seated in

Figure 4. Grease cup

60

Grease Seal Installation Instructions

Centrifugal Pump Application

When replacing the seal, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal.

Before installing the seal, inspect the bore of the seal liner for excessive wear or grooves that might cause leakage or damage

PACKING RINGS to the seal packing rings. If the seal liner must be replaced, use

IMPELLER the new seal liner and arbor (or hydraulic) press to force the

SEAL PLATE

BRASS SEAL LINER

SPACER SLEEVE old one out. After the liner is installed, drill a ¼” diameter hole through it to permit the flow of lubricant to the seal liner.

Be Careful to center the drill in the threaded lubrication hole

CRANKSHAFT so not to damage the threads. Debur the hole from the

ENGINE

LARGE CHAMFER

STATIONARY

ELEMENTS

ROTATING

ELEMENTS inside of the seal liner after drilling.

Clean the seal cavity and shaft with a cloth soaked in fresh

IMPELLER

SHIM

WASHERS cleaning solvent. Be sure to follow all safety precautions described on the solvent container.

Remove the new seal and inspect the precision finished faces to

STATIONARY

WASHER SPRING

Figure 3. Grease Seal Assembly

STATIONARY

WASHER ensure that they are free of any foreign matter. To ease installation of the seal, lubricate the packing rings, spacer sleeve, and seal liner with water or a very small amount of oil and apply a drop of light lubrication oil on the precision finished faces. Refer to the illustration, and assemble the seal as follows.

Installation of the inboard rotating element is dictated by the configuration of the shaft shoulder. If there is a radius at the shaft shoulder, the larger chamfer on the I.D. of the inboard rotating element must be positioned toward the shaft shoulder. If there is an undercut at the shaft shoulder, the larger chamfer must be positioned away from the shaft shoulder. Determine the correct position for the rotating element and slide it onto the shaft.

Sub assemble the inboard stationary element, packing ring and spring washer, and press this subassembly into the lubricated seal liner. A push tube cut from a length of plastic will aid seal installation. The O.D. of the tube should be about the same size as the O.D. of the seal spring.

Install the spacer sleeve and spring.

Sub assemble the outboard stationary element, packing ring and spring washer. Press this subassembly into the lubricated seal liner. If the outboard rotating element has a chamfered side, install it with the chamfer facing the impeller end of the shaft.

If your pump requires a spacer washer, install the spacer washer with the chamfer on the I.D. positioned toward the seal.

Install the impeller adjusting shims and impeller (consult the operator’s manual for impeller clearance and installation instructions).

Before starting the pump, reinstall the automatic lubricating grease cup and piping (if removed for seal liner replacement).

Lubricate the seal as indicated below.

LUBRICATION

Fill the grease cup through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal.

POSITION

WHEN

EMPTY

POSITION

FOR

FILLING

POSITION

WHEN

IN USE

CROSS

ARM

NOTE:

GREASE

FITTING

Some smoking and leakage may occur after installing a new seal assembly. This should stop after the pump has run a while and the lapped seal faces have seated in.

RELIEF

HOLE

61

Figure 4. Automatic Lubricating Grease Cup

62

63

64

Group 2 Gear Motors Technical Information

System Requirements

Hydraulic fluids

Ratings and data for gear motors are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion, and corrosion of internal components. They include:

 Hydraulic fluids following DIN 51524, part 2 (HLP) and part 3 (HVLP) specifications•

 API CD engine oils conforming to SAE J183•

 M2C33F or G automatic transmission fluids•

 Certain agricultural tractor fluids•

Use only clean fluid in the motor and hydraulic circuit.

Caution

Never mix hydraulic fluids.

Please see Sauer-Danfoss publication Hydraulic Fluids and Lubricants Technical Information,

520L0463 for more information. Refer to publication Experience with Biodegradable Hydraulic

Fluids Technical Information, 520L0465 for information relating to biodegradable fluids.

Temperature and viscosity

Temperature and viscosity requirements must be concurrently satisfied. Use petroleum / mineralbased fluids.

High temperature l imits apply at the inlet port to the motor. The motor should run at or below the maximum continuous temperature. The peak temperature is based on material properties. Don’t exceed it.

Cold oil, generally, doesn’t affect the durability of motor components. It may affect the ability of oil to flow and transmit power. For this reason, keep the temperature at 16 °C [60 °F] above the pour point of the hydraulic fluid.

Minimum (cold start) temperature relates to the physical properties of component materials.

Minimum viscosity occurs only during brief occasions of maximum ambient temperature and severe duty cycle operation. You will encounter maximum viscosity only at cold start. During this condition, limit speeds until the system warms up. Size heat exchangers to keep the fluid within these limits. Test regularly to verify that these temperatures and viscosity limits aren’t exceeded.

For maximum unit efficiency and bearing life, keep the fluid viscosity in the recommended viscosity range.

Fluid viscosity

Maximum (cold start)

Recommended range

Minimum mm

2

/s

[SUS]

1000 [4600]

12-60 [66-290]

10 [60]

Temperature

Minimum (cold start)

Maximum continuous

Peak (intermittent)

°C

[°F]

-20 [-4]

80 [176]

90 [194]

65

Group 2 Gear Motors Technical Information

System Requirements

Filtration

Filters

Use a filter that conforms to Class 22/18/13 of ISO 4406 (or better). It may be on the motor outlet

(discharge filtration) or inlet (pressure filtration).

Selecting a filter

When selecting a filter, please consider:

 Contaminant ingression rate • (determined by factors such as the number of actuators used in the system)

 Generation of contaminants in the system•

 Required fluid cleanliness•

 Desired maintenance interval•

 Filtration requirements of other system components•

Measure filter efficiency with a Beta ratio ( β x). For:

 Discharge filtration, with controlled reservoir ingression, use a • β 35-45 = 75 filter

 Pressure filtration, use a pressure filtration with an efficiency of • β 10 = 75.

β x ratio is a measure of filter efficiency defined by ISO 4572. It is the ratio of the number of particles greater than a given diameter (“x ” in microns) upstream of the filter to the number of these particles downstream of the filter. Fluid cleanliness level and β x ratio

Fluid cleanliness level (per ISO

4406)

β

β x ratio (discharge filtration) x ratio (pressure filtration)

Recommended inlet screen size

Class 22/18/13 or better

β 35-45 = 75 and β 10 = 2

β 10 = 75

100-125 µm [0.004-0.005 in]

The filtration requirements for each system are unique. Evaluate filtration system capacity by monitoring and testing prototypes.

66

Group 2 Gear Motors Technical Information

System Requirements

Reservoir

The reservoir provides clean fluid, dissipates heat, removes entrained air, and allows fluid volume changes associated with fluid expansion and during all system operating modes. A correctly sized reservoir accommodates maximum volume changes during all system operating modes. It promotes de-aeration of the fluid as it passes through, and accommodates a fluid dwell-time between 60 and

180 seconds, allowing entrained air to escape.

Minimum reservoir capacity depends on the volume required to cool and hold the oil from all retracted cylinders, allowing for expansion due to temperature changes. A fluid volume of 1 to 3 times the motor output flow (per minute) is satisfactory. The minimum reservoir capacity is 125% of the fluid volume.

Install the suction line above the bottom of the reservoir to take advantage of gravity separation and prevent large foreign particles from entering the line. Cover the line with a 100-125 micron screen.

The motor should be below the lowest expected fluid level.

Put the return-line below the lowest expected fluid level to allow discharge into the reservoir for maximum dwell and efficient deaeration. A baffle (or baffles) between the return and suction lines promotes deaeration and reduces fluid surges.

Line sizing

Choose pipe sizes that accommodate minimum fluid velocity to reduce system noise, pressure drops, and overheating. This maximizes system life and performance. Design inlet piping that maintains continuous motor inlet pressure above 0.8 bar absolute during normal operation. The line velocity should not exceed the values in this table:

Maximum line velocity

Inlet 2.5 [8.2]

Outlet 5.0

Most systems use hydraulic oil containing 10% dissolved air by volume. Under high inlet vacuum conditions the oil releases bubbles. They collapse when subjected to pressure, resulting in cavitation, causing adjacent metal surfaces to erode. Over-aeration is the result of air leaks on the inlet side of the motor, and flow-line restrictions. These include inadequate pipe sizes, sharp bends, or elbow fittings, causing a reduction of flow line cross sectional area. This problem will not occur if inlet vacuum and rated speed requirements are maintained, and reservoir size and location are adequate.

67

SECTION #VIII

(Parts Manual)

68

4

20

30

43

M2

42

31

45

27

28

29

21

19

14

17

18

16

15

22

20

20

23

PAT

ENT

PE

N

40

S/N

123

456

41

24

20

25

1

10

26

14

13

12

20

11

2

10

32

33

34

9

46

OUT

-LET

Clea n Filt er

CAU

TIO

N

48

47

49

8

7

6

35

3

36

5

4

44

45

46

47

48

49

40

41

42

43

16

17

18

19

20

11

12

13

14

15

28

29

30

31

32

33

34

21

22

23

24

25

26

27

REF #

1

2

3

4

5

6

7

8

9

10

35

36

DESCRIPTION

Crash Frame

2" NPT Street 90° Elbow

Pump Discharge Pipe

2" Hinge-Loc Coupler

2" Coupler EPDM Gasket

2" Filter Shear

1 1/2" Pipe Plug

3" Hinge-Loc Coupler

3" Coupler EPDM Gasket

Filter Shear Housing

1/4" Pipe Plug

3/8" x 2" Bolt

3/8" L/W

3/8" F/W

3/8" Nut

1 1/2" Ball Valve

1/2" 90° Street Elbow

1/2" NPT x 5/8" Hose Barb

PEX Hose Clamp

5/8" Clear Cotton Braid Hose

Adaptor

3/8" NPT x Close Nipple

3/8" Ball Valve

Wash Wand

2" Groove-Loc Coupler

2" Coupler EPDM Gasket

End Pipe

Pipe Clamp

2" Jetting Nozzel

2" Mixing Tee

2" Grooved Venturi

2" NPT Grooved Adaptor

2" Grooved Butterfly Valve

Foam Strip

Hand Knob

2" Hopper

Lifting Bale

Isolator Spacer

Rubber Foot Mount Kit

5/16" x 2" Bolt

5/16" L/W

5/16" F/W

5/16" Nut

Operators Manual Holder

3/16" Rivet

"Operators Manual" Decal

Mixing Nozzel (Jet Guns)

BU-M2X2 ASSEMBLY PARTS LIST

( P/N #BU-M2X2 )

STS PART NUMBER QTY REQ.

M2-601-GHD

018-310-01720-7

1

1

M2-603

020-390-20048-3

1

2

020-390-078640

M2-604

018-318-90252-5

020-390-20006-1

1

1

1

020-390-078681

M2-616

018-318-90156-X

076-13111

076-33622

076-33008

076-36306

022-423-00012-4

018-310-01620-9

018-1661268222X

025-PEX-SS3/4

025-K3150-050

M2-618

018-330-00980-4

022-423-00002-5

M2-619

020-390-00026-3

1

5

6

2

1

1

2

1

1

31"

1

1

1

6

6

6

020-390-078640

M2-607

M2-602-D

M2-608

M2-609

M2-610

M2-611

023-7005-011049

084-1/8" WSTRIP

084-135-039

M2-612

M2-620

M2-662-B

060-GR48152-603

076-13061

076-33620

076-33006

076-36304

084-9000-07

076-41228

070-STS-036

086-T2MP-L **2MP**

1

1

1

4"

1

2

1

1

2

1

2

1

1

1

2

1

2

4

2

1

4

Patent Plate

Serial Number Plate

"Logo" Decal

"M2" Decal

071-STS-002

071-STS-001-BNK

070-STS-029

M2-632

1

1

1

1

"Blue Safty Circles" Decal

"Out-let" Decal

"Caution pressure" Decal

"Clean Filter" Decal

Directional tape

070-STS-038

M2-633-B

M2-633-A

070-STS-027-A

STS-PIPE MARKER

1

2

1

1

28"

B

B

O

B

B

O

O

B

O

O

B

B

O

B

O

B

O

B

O

B

O

O

O

O

PAINT

Orange = O

Black = B

Surface to Surface Inc.

®

DW R. NUM.

BU-M2X2

DATE.

REV.

03 / 05 / 10

07 / 20 / 12

69

Grease Cup

Instruction

36

MAX FLOW

38

GREASE

39 xxx lbs

37

13

16

14

11

25

17

18

10

12

8

9

27

35

28

H

41

15

7

34

24

26

19

6

21

33

5

3

30

23

1

F

22

2

20

A

30

9

B

2

A

29

5

C

31

32

D

E

33

34

PU-M2-H ASSEMBLY PARTS LIST

( P/N #PU-M2-H)

REF #

1

2

13

14

15

16

17

18

19

20

21

22

23

24

DESCRIPTION

Gorman-Rupp 2" Pump

3/8" x 1 3/4" Bolt

3/8" F/W

3/8" L/W

3/8" Nut

Spacers

STS PART NUMBER QTY REQ.

060-GR82E2E-KIT 1

076-13110

076-33008

076-33622

076-36306

060-GR31131-072

5

8

5

5

4 3

4

5

6

7

8

9

10

11

12

29

30

31

32

25

26

27

28

33

34

3/8" x 1 1/2" Bolt

3/8" F/W

3/8" L/W

Bearing Block Mount

Foot Spacer

3/8" x 1 1/2" Bolt

3/8" F/W

3/8" L/W

3/8" Nut

Bearing Block

Bearing Block / Motor Gasket

3/8" x 4 1/4" SHCS

3/8" F/W

3/8" L/W

Hydraulic Motor (SNM2/11)

Key ( c/w Hyd. Motor)

5/8" ORB x 5/8" JIC 90° Elbow

3/8" ORB x 3/8" JIC 90° Elbow

3/4" ORB x 5/8" JIC Male Adpt

3/8" Hyd. Hose

5/8" x 3/8" JIC Reducing Adaptor 029-0603-10-6

5/8" JIC Sleeve Nut

5/8" JIC x 5/8" ORB TEE

5/8" Hyd. Hose

3/4" JIC Swivel Nut Run TEE

3/4" ORB x 3/4" JIC Male Adpt

3/4" ORB x 3/4" JIC 90° Elbow

Hydraulic Flow Control

1/4" x 2 1/2" Bolt

1/4" L/W

1/4" Nut

5/8" Hyd. Hose

3/4" ORB x 3/4" JIC Swievel

3/4" ORB x 3/4" JIC 90° Elbow

Flow Meter

Hyd Flow Control Mount

Cap (shipping purpose only)

Grease Cup

Grease Cup Mount

Pipe to Hose connector

Nylon Hose

076-13109

076-33008

076-33622

HTSP3-20

M2-708

076-13109

076-33008

076-33622

076-36306

HTSP3-02

036-200-06

076-23320

076-33008

076-33622

039-B1212004300

~~~~

029-2503-10-10

029-2503-6-6

029-0503-12-10

M-750HD-H03

029-06B-10

029-053T-10-10

M2-705-B

029-063T-12-12-12

029-0503-12-12

029-2503-12-12

046-FCRS1-12SAE

076-13013

076-33618

076-36302

M2-705-A

029-0506-12-12

029-2503-12-12

035-H700-A-020

M2-704

029-06CP-12

060-S36

M2-625

019-WEA_1868x8x4

025-1928-07

2

16 1/2"

1

1

1

1

2

2

1

2

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

2

2

2

1

1

1

1

1

2

1

1

4

4

4

33

WA

RN

G

32

31

40

PAINT:

Black = B

REF #

A

B

C

D

E

F (10)

P/N# HTSP3-02

(#9) BEARNING BLOCK ASSEMBLY PARTS LIST

DESCRIPTION

Bearing

Machined Shaft

Bearning Block Housing

Shaft Seal

Face Seal

Gasket

PART NUMBER

036-6010-2RS

036-300-J3A

036-300

036-CR17271

036-MVR1-40

036-200-06

QTY REQ.

2

1

1

2

1

1

35

36

37

38

31

32

33

34

39

40

41

"PRIME" Decal

Pressure Warning Tag

"DISCHARGE" Decal

"Directional " Decal

"Max flow" 3/8 Decal

"Max flow" 3/4" Decal

"Dry Weight" Decal

"Grease Cup Instruction" Decal

"GREASE" Decal

"SUCTION" Decal

"H" Decal

060-GR6588AH

060-GR6588BG

060-GR6588BJ

STS-PIPEMARKER

070-M3-023-B

070-M3-023-A

M2-703

060-GR6588BD

070-STS-021-B

060-GR6588AG

070-STS-030-G

1

1

1

3"

2

1

1

1

1

1

1

B

B

B

B

B

B

Surface to Surface Inc.

®

DWR. NUM.

#PU-M2-H

DATE.

REV.

12 / 13/ 11

08 / 24 / 18

70

1

4

2

08/23/18

GR-82E2

3

5

6

8**

9

7

10

2

3

4

5

6

7

8**

9

10

11

12

13

15

16

17

18

19

REF #

1

2

14

DESCRIPTION

Grease Cup

3/8" Nut

3/8" L/W

Seal Plate Assembly

Brass Seal Liner

Casing Gasket Set

Grease Seal assembly

Shim Pack

Impeller ( 60 Hz.)

Impeller ( 50 Hz.)

Wear Plate

Pump Casing

Stud

Pipe Plug

Hex Cap Screw

Fiber Washer

HD Machine Screw

L/W

Large Valve Weight

Check Valve Gasket

Small Valve Weight

Suction Flange

Filler Pipe Plug

GR-82E2 ASSEMBLY PARTS LIST

( P/N #060-GR82E2-KIT )

STS PART NUMBER

060-S36

060-GRD0615991

076-33622

060-GR427A10010

060-GR8314080

060-GR229G18000

060-GRGS1000

060-GR2X17090

060-GR6709_100105.5

060-GR6709_10010

060-GR682215990

060-GR46472-309

060-GRC060615991

060-GRP1215079

060-GRB061415991

060-GRKF0618040

060-GRX040317090

060-GRJ0417090

060-GR19B10010

060-GR1361G19070

060-GR135415160

060-GR136113040

060-GR48271-063

Remote mounted grease cup included in power units

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

QTY REQ.

1

1

1

1

11

11

19

11

14

15

18

2

12

13

16

17

71

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