HD150 Pump Maintenance Manual

SYKES GROUP PTY LTD
HD150 PUMPSET
FOR
Installation, Operation and Maintenance Manual.
Sykes Group Pty. Ltd.
SYKES GROUP PTY LTD

PUMP SPECIFICATION
PUMP TYPE:
PUMP SIZE:
ACTUAL IMPELLER DIAMETER:
HD150
150MM X 150MM
275MM
ENGINE / MOTOR TYPE:

PUMPSET NUMBER:
JOB NUMBER:
ENGINE / MOTOR NUMBER:
HOW TO READ A PERFORMANCE CURVE

The lines sloping downwards from left to right represent the varying quantities of liquid
delivered by the pump with variations in head. The intersection of this line at 1450rpm
with the zero flow line shows the shut off head (68m) of pressure developed by the
pump.
Total Dynamic Head (m) = Static Suction lift (m) + Static Discharge Head (m) +
Friction Head (m)
Where:
Static Suction Lift =
Difference in elevation between liquid level of
the suction and the center line of the pump.
Static Discharge Head =
Difference in elevation between liquid levels of

the center line of the pump and the discharge.
Friction Head
Equivalent head necessary to overcome friction

on the interior surfaces of the pipework system
including all valves, bends and fittings.
Example:
Required pump duty of 150l/s at 55m (Total Dynamic Head).
1)
Draw a line upwards from Flow (x-axis) at 150l/s (point A).
2)
Draw a line across from Total Head (y-axis) at 55m (point C)
3)
Where the vertical line of 150l/s intersects the horizontal line of 55m (point
B) determines the pump rpm speed and power required at this duty.
4)
Pump Speed Curve = 1450rpm.
5)
Power Requirement = 120kW to run the whole of the 1450rpm

curve.
6)
To obtain the suction lift, draw a line across where the vertical line of the
150l/s intersects the NPSHR (Net Positive Suction Head Required) curve
(point D).
7)
NPSHR = 6.3m (point E).
8)
Dynamic Suction Lift Available = Atmosphere (m) NPSHR (m)

= 9.8 6.3
= 3.5m
To determine the actual dynamic lift of pump, it is recommended to fit
a vacuum gauge on the suction side of the pump to obtain a vacuum

reading. The vacuum gauge, for this example, should read no more than
34.4kPa (3.5m). If the vacuum gauge reading is greater than 34.4kPa
then the pump will experience cavitation.
Note:
To ensure minimal losses to the total suction lift:
Keep suction pipes as short and straight as possible.
Eliminate all possibility of air pockets being trapped in suction
pipework.
When choosing foot valves, strainers, bends etc, select those which
will provide minimal restriction to the flow.
The diameter of the suction pipe should be equal in diameter to the
pump inlet connection. An eccentric reducer is recommended to be
fitted in conjunction with pipe diameters larger than the pump inlet to
avoid the possibility of air pockets in the suction pipework.
Generalisations
1)
Flow (l/s) decreases, as Total Head (m) increases.
2)
Flow (l/s) increases, Power used increases.
It is not recommended to operate the pump outside the recommended pump operating
range. To operate outside this area will lead to cavitation, vibration and non uniform
radial forces present in the pump. This drastically reduces the operating life of the
mechanical seal, bearings and efficiency of the pump. In addition, the pump alignment
will also be adversely effected due to excessive vibration. All this will result in an
increase of maintenance cost of the pump.
Radial Thrust
When a pump is operated at its best efficiency flow rate the velocities and hence the
pressures acting on the impeller are uniform around the volute. This is shown in Figure
A.
At flow rates other than best efficiency point, the pressure distribution is no longer
uniform. At reduced flow rates, the pressures increase spirally towards the cutwater
resulting in a radial reaction F as shown Figure B. This will lead to the following
operating problems:
Low efficiency of pump.
Noise vibration, reduced life of pump.
Increased radial loads on bearings due to unbalanced volute
pressures.
Temperature rise due to dissipated energy created by low efficiency.
A similar situation exists at flow rates beyond best efficiency flow rates, with an
approximate opposite (in direction) reaction. This also will lead to similar problems
associated with the reduced flow rates with an addition of poor suction performance
(high NPSHR). Figure C shows typical variation of radial thrust with flow rate.
100% Best Efficiency Flow

Figure A
Reduced Flow
Figure B
Radial Thrust
Figure C
Cavitation
If the Net Positive Head Available of the pump is less than the Net Positive Head
Required, the pumpend liquid will vaporise in the region of the impeller eye i.e. where
the local pressure is less then the vapor pressure. In this region the fluid will consist of
a liquid plus vapor cavities. This can, in the extreme, result in the formation of a vapor
lock and the prevention of the fluid entering the impeller.
This phenomenon is called cavitation. The cavitation cycle comprises therefore of two
phase changes; one from liquid to vapor during the initiation and the other from vapor
back to liquid during cavity collapse.
Cavitation may be caused by excessive suction lift, insufficient NPSHA or operation at
too high a speed. The resulting effects include:
1)
Pitting of material surfaces due to the continual hammering action of the

collapsing vapor cavities.
2)
Significant reduction of performance due to vapor formation.
3)
The crackling noise (like gravel going through the pump) caused by vapor cavity
collapse.
Severe cavitation usually results in excessive noise, vibration and damage to pump,
whereas mild cavitation may produce nothing more than a small reduction in pump
efficiency and moderate wear of pump components.
TECHNICAL DATA SHEET No. 1

DESIGN DETAILS:
Pump Designation:
Pump Description:
Suction Flange:
Delivery Flange:
Nominal Casing Thickness:
Nominal Shaft Diameter:
Impeller Eye Diameter:
Maximum Impeller O.D.:
Minimum Impeller O.D.:
Moment Inertia Impeller:
Solids Handling Size:
Wear Plate Clearances:
Design Speed: (PUMP)
Design Capacity:
Max HP at Design Speed:
Specific Speed:
Operating Speed: (PUMP)
Maximum Head:
Maximum Capacity:
Operating Temperature:
Operating Temperature
Casing:
Permissible Suction Press:
Maximum Hydraulic Test
Press:
Bearing Sizes:
Estimated Bearing Life:
Type of Bearing Lubrication:
Type of Shaft Seal:
HD150
Single stage, volute type, 3 bladed fully open impeller
submersible centrifugal pump (2 bladed sewage
version available)
DIA. 150mm Inlet with strainer
6 Table D
10mm
45mm
152mm Imp. Hub. Dia. 46mm
260mm STD
245mm Imp outlet width 65.2
Cutwater clearance 30mm STD
65mm
REAR: 0.36/0.69mm
FRONT: 0.36/0.69mm
1500 rpm
255m/hr
42.1 HP at 1500 rpm
2439
MIN: 1000rpm MAX: 1600rpm(Subject to available
HP and acceptable hydraulic pressure.)
24m
272m/hr
MIN: -20c
MAX : +60C
MIN: -20c
MAX : +100C
MIN: Zero ABS
4 BAR (60 PSI)
MAX : 2.5 BAR (36.2 PSI)
DRIVE END:
Ball bearing 6309Z
PUMP END:
Roller bearing NU309EC
MIN. SPEED/MAX. LOAD:
INDEFINITE
MAX. SPEED/MIN. LOAD:
26,000 hours
Oil lubrication from hydraulic system, oil seal is
removed from hydraulic motor to allow oil into
bearing housing and mechanical seal chamber.
Recessed scavage pumpout vanes to rear of impeller
external mounted mechanical seal, oil lubricated
silicon carbide interfaces
TECHNICAL DATA SHEET No. 2

MATERIALS OF CONSTRUCTION:
Pump Casing:
Suction Cover:
Bearing Bracket:
Pump Shaft:
Impeller:
Wearplates:
Mechanical Seal:
Strainer:
Chassis:
O- Rings:
SG iron as 1831 SG 400/12

Mild Steel
SG Iron as 1831 SG 400/12
431 Stainless Steel
316 Stainless Steel
316 Stainless Steel
Crane type 502-40mm
DIA. Silicon carbide interfaces
Galvanised Steel
Structural steel
Nitrile Rubber
POWER PACK DETAILS:

Hydraulic Pump:
Gear type cast iron construction
System Relief valve:
Solenoid Operated Unloader set to vent @ approx. 207 Bar
Aluminium block
Reservoir:
Mild steel Fabrication 200L capacity
Filters:
Suction Wire Gauze 150uM, Return Paper Element
25Um
Control:
Via Engine variable speed lever
Hose Size:
Normal Bore X 10m Length
Adaptor Coupling:
Hydraulic Pump: SAE B2 Bolt Flange c/w SAE B Spline
Shaft
Engine: SAE 5 Flywheel Housing with 8 Flywheel
SUBMERSIBLE PUMPEND
Hydraulic Motor:
Max. Drive Pressure:
Max. Pump Speed:
Impeller Diameter:
Solids Handling:
Weight:
Discharge:
Gear type cast iron construction

207 Bar (3000 psi)
1600 rpm
275mm
65mm
139kg
6 BSIO table D or bauer connection
Quick Release hose couplings fitted as standard.
NOTE:
1 BSP
BSP
BSP
motor delivery hose

motor return hose
Low pressure return hose
OVERALL DIMENSIONS AND WEIGHT

SKID BASE CHASSIS:
Overall Length:
Overall Width:
Overall Height:
Weight (dry):
Fuel capacity:
- 2400mm
- 1000mm
- 1300mm
- 1300kg
- 230L
MISCELLANEOUS DETAILS
Hydraulic Oil
- TELLUS 68 or equivalent
ENGINE RPM
PUMP RPM
MAX. HYD. HOSE LENGTH
1170
1300
1430
1460
35
30
25
20
1800
2000
2200
2250
EXCESSIVE HYDRAULIC PRESSURE WARNING (WHEN FITTED)

A flashing light mounted on top of the control box will activate when a pressure switch
registers 300 psi. This light when flashing is warning the operator that the oil pressure is
too high and excessive pressure is by-passing through the solenoid relief valve.
OPERATING AND MAINTENANCE INSTRUCTIONS

DESCRIPTION OF UNIT
The pump is a portable (skid base) Hydraulically driven submersible contractors pump.
The pump is capable of handling unscreened sewage, trade effluents, thick slurries and
solids up to 65mm. Power is provided by a Hatz 3L40C diesel comprises a hydraulic
motor driving a centrifugal pump. The impeller is of adjusting the variable speed lever
fitted to the engine. The complete pump unit is mounted on a skid base with integral
fuel tank and single point lifting frame. The pump body is SG iron construction fitted
with stainless steel wearplates secured by high tensile screws. The mechanical seal is
fitted externally to the pup. It is leak tight and suitable for sewage and sludges, using
silicon carbide faces. When pumping out vanes on the impeller ensure the seal is lightly
loaded and not contaminated by the main solid content.
Note: If your HD150 pumpset has been mounted on a trailer chassis it is
recommended that after approx. 5km of travel that all wheel nuts be inspected and retightened.
HYDRAULIC SYSTEM
The hydraulic system comprises a 200 litre oil reservoir, and a gear type pump and
motor. The pump is close coupled to the engine flywheel and the motor directly drives
the centrifugal pump. A timing device insures that the oil heats to operating temperature
before a load is applied and a pressure relief valve vents to reservoir in case of
blockage. The motor shaft lip seal is removed to allow oil into the bearing housing and
mechanical seal chamber. This oil is under return line pressure and returns to reservoir.
HD150 PUMP FEATURES
The centrifugal pump has independent bearings from the hydraulic motor, thus
pump loads do not effect the gear motor performance.
A two bladed sewage impeller is also available.
For ease of maintenance the hoses are fitted with quick connect couplings (10m
hoses STD).
A reservoir suction strainer and system filter ensures that the oil remains clean and
thus reduces wear to the motor and pump.
The submersible pump and motor assembly is fitted with a circular lifting frame
which also offers maximum protection during operation.
The engine control panel is weatherproof and mounted using anti-vibration fittings.
The panel houses the electric start, tachometer, system pressure gauge, and timing
device.
A flashing indicator light (when fitted) is mounted on top of the control panel. This
light is activated when the systems hydraulic pressure reaches 300psi. and the oil
begins to by-pass through the solenoid relief valve.
IMPORTANT
1. Before assembling a hydraulic motor to a pumpend, ensure that the motor shaft seal
has been removed and fill the bearing bracket with the hydraulic oil. (Refer to fig.
2.).
2. When starting a HD150 pumpset the hydraulic oil will by-pass back to the reservoir
for the first 5 minutes, allowing the system to warm up. When the timing device
reaches 5 minutes a solenoid relief valve will direct the oil to the pumpend. DO NOT
open the engine to top speed during this 5 minute warm up. Allow the oil to load the
pumpend at a slower engine speed. eg. 1600rpm, and then increase speed as
required.
3. An indicator light (when fitted) will flash if the hydraulic system pressure reaches an
excessive level and begins to by-pass. When this occurs shut down the pump and
search for a problem which may have caused this excessive pressure.
-
Blockage at impeller.
kinks in hydraulic hose.
quick connect couplings not fitted correctly.
engine speed too high.
hydraulic hose too long.
If after searching there appears to be no problem, re-start pump and gradually increase
the engine speed until the hydraulic pressure gauge registers approximately 3000psi,
this will be the pumps maximum performance setting for that particular duty.
Closely monitor the pump to ensure that the hydraulic pressure does not continue to
increase and begin by-passing again thus activating the excessive pressure indicator
light.

OPERATION
Before attempting to start the unit, familiarise yourself with the engine starting
procedure and its controls as mentioned in the manufacturers'handbook.
STARTING
Check fuel & oil levels in the engine and ensure that the hydraulic oil reservoir is
fitted with the correct grade of oil - TELLUS 68 or equivalent.
Start the engine. The hydraulic oil will by-pass back to the reservoir for the first 5
minutes to allow the oil to warm up. The engine should only operate at 1600rpm
during this 5 minutes. Increase the speed as required once the pump is working.
The maximum speed is set at WORKS. Check the unit, if the oil pressure is in
excess of the recommended maximum and causing the vent at a system pressure
of 207 bar (300 psi) preventing excessive pressure causing major damage to the
hydraulic components.
STOP THE UNIT IMMEDIATELY if the flashing light activates and refer to the fault
finding chart.
HOW TO SET BY-PASS PRESSURE ON THE SOLENOID RELIEF VALVE (refer to
fig. 3.)
The hydraulic circuit is based around the relief valve. The relief valve is manually set as
follows:
1. Loosen the locknut on the relief valve and wind setting screw out.
2. Disconnect the hydraulic motor delivery hose (1" BSP quick connect hose end) at
chassis.
3. Start the unit and wait the 5 minute warm up period, then increase engine speed to
approximately 2000rpm.
4. Begin to wind in the relief valve setting screw. As the screw winds in the hydraulic
pressure reading will increase. When the pressure gauge reads 3000 psi, stop
winding the setting screw and lock it'
s position with the locking nut.
5. Reduce the engine speed and turn off the unit. Re-connect the 1" BSP quick
connect hose end. The relief valve is now set to vent back to the reservoir at 3000
psi.

HOW TO TEST THAT THE EXCESSIVE PRESSURE INDICATOR LIGHT IS
WORKING CORRECTLY (when fitted) refer to fig.3.
1. Loosen the lock nut on relief valve and wind setting screw out.
2. Disconnect hydraulic motor delivery hose (1" BSP quick connect hose end) at
chassis.
3. Start unit and wait the 5 minute warm up period, then increase engine speed to
approximately 2000rpm.
4. Begin to wind in the relief valve setting screw. As the screw winds in the hydraulic
pressure gauge reading will increase. When the pressure gauge reads
approximately 300 psi, the excessive pressure indicator light should begin to flash. If
the excessive indicator light does not flash at 3000 psi, then the unit is O.K., reduce
engine speed, turn off the unit and re-connect 1" BSP quick connect hose end.
5. If the excessive indicator light does not flash as 3000 psi, then refer to the fault
finding chart.
NOTE: a hydraulic pressure switch is linked to the hydraulic pressure gauge hose and
will switch power to the excessive pressure indicator light when at 3000 psi.
HOW TO SET HYDRAULIC PRESSURE SWITCH (when fitted) refer to fig.3.

The hydraulic pressure switch should throw power to the excessive power indicator light
when the hydraulic pressure reaches 300 psi. The procedure to set the pressure switch
is as follows:
1. Loosen the lock nut on the solenoid relief valve and wind setting screw out.
2. Disconnect hydraulic motor delivery hose (1" BSP quick connect hose end) at
chassis.
3. Start the unit and wait the 5 minute warm up period, then increase engine speed to
approximately 2000 rpm.
4.
Begin to wind the relief valve setting screw, as the screw winds in the hydraulic
pressure gauge will increase. Continue to wind in the setting screw until the
hydraulic pressure gauge reads 3000 psi.
5.
Adjust the pressure switch until it activates the excessive pressure indicator light.
The pressure switch is now set to throw at 3000 psi.
PUMP PROBLEMS - Systems & Likely Causes

1.
Pumpend
does
not Too much head on pump.
discharge sufficient flow.
Pump end blocked or worn.
Discharge hose kinked or blocked.
Worn hydraulic motor or pump.
Pumpend running too slowly.
Quick connect hose ends not opening fully.
2. Pumpend Mechanical seal Shaft seal in hydraulic motor has not been
failure.
removed so no oil is reaching mechanical seal.
Excessive oil pressure in the hydraulic return
line due to a blockage or excessive length of
return hose.
3. Oil level in reservoir drops. Burst hydraulic hose.
Leaking hose end.
Mechanical seal in water pump failed.
4.
Hydraulic
system Pump speed too fast.
continually
by-passing Pumpend blocked.
(flashing light when fitted).
Kink/blockage in hydraulic hoses.
Quick connect hose ends not opening fully.
Solenoid relief valve set too low.
5. Hydraulic oil is milky.
Oil emulsified by water contaminated due to
mechanical seal or o-ring failure in pump end.
Also check oil reservoir is water tight.
6. Hydraulic oil aerated
Oil level in reservoir too low drawing air
through inlet filter.
Unit sited on extreme angle.
7. Hydraulic oil not directed to Solenoid valve not opening.
pumpend after 5 minute Timer unit faulty.
warm up.
Timer unit set on longer time.

MAINTENANCE
DAILY:
Check the level of the hydraulic oil in reservoir. The oil level is to be
maintained within 50mm of the top of the reservoir.
WEEKLY:
Visually check that the return line filter indicator. If the indicator has
reached the red sector the filter element must be changed.
Inspect the hydraulic pump and motor for oil leaks and check that all
mounting bolts are tight and secure.
Inspect all hydraulic hose ends and hoses for oil leaks.
3000HR SERVICE:
Drain off approximately 300ml of the hydraulic oil into a clean glass
container. Send the oil to an oil company for analysis. If O.K., continue to
use existing oil. If oil has broken down then drain or pump the oil with
fresh TELLUS 68 or equivalent (200L).
HD150 PUMPEND ASSEMBLY INSTRUCTIONS

NOTE: Item numbers used in the following instructions refer to the '
HD150 pumpend
general arrangement'drawing and parts list.
1. Clean and deburr bearing bracket (1), volute (8), impeller (7), cover plate (9), front
cover plate (6) and rear wear plate (5). Visually check all castings for porosity,
blowholes, cracks and bruising.
2. Visually inspect all areas over which o-rings will pass during assembly. Remove any
sharp edges and burrs. When fitting 0-rings ensure they have been well smeared
with rubber grease.
3. Shaft assembly - bearings (15, 16) may be heated for assembly of pressed on using
a suitable mandrel. Assemble the roller bearing (15) onto the pump shaft (2) making
sure that the bearing is hard against the shaft shoulder. Slide the inner and outer
pipe spacers (3.4). Assemble ball bearing (16) onto shaft and secure assembly with
circlip (21) onto shaft
4. Position shaft assembly into the bearing bracket (1) until the outer ring on the roller
bearing (15) registers against the bearing bracket shoulder. Secure assembly with
circlip (20) into bearing bracket.
NOTE: At this point we recommend that a rag type cover is used over the bearing
bracket end to protect the bearings.
5. Assemble volute (8), lifting frame (11) and bearing bracket (1) together using
fasteners (27, 31, 30). When using fasteners during assembly ensure that they are
treated with an anti-seize compound. Ensure that the lifting frame beam is running
parallel to the hydraulic motor (23) mounting holes.
6. Working through the volute (8), fit the mechanical seal body (22) onto the working
shaft, taking care that the mechanical seal face is not dropped and damaged.
7. Rear wear plate assembly - Position mechanical seal seat (22) into the rear wear
plate using o-ring (18) and circlip (24). Locate o-ring (12) onto rear wear plate.
8. Move rear wear plate assembly through volute and locate into it'
s position making
sure that o-ring (19) is properly seated in it'
s groove on the bearing bracket. Secure
the wear plate using fasteners (31, 28).
9. Apply anti-seize compound to the threads on the shaft (2) and fit shims (14) having
a total thickness of 2mm and the impeller (7) onto the shaft. Measure the gap
behind the impeller, remove impeller and shims and refit with shims having a total
thickness of 2.5mm minus the gap measurement. Check that the gap behind the
impeller is now between 0.3mm and 0.6mm and that the impeller rotates freely.
NOTE:
A shaft retention tool used when fitting the impeller is available through
Sykes Pumps Australia.
10.
Fit the front wear plate (6) onto the cover plate (9) and secure with fasteners (30,
31, 25).
11. Assemble the cover plate (9) to the volute (8) until the front wear plate (6) touches
the impeller. Measure the gap between the mating surfaces of the cover plate (9)
and the volute (9). Joint (13) having a total cover plate and volute. Check that the
gap between the front wear plate (6) and the impeller (8) is between 0.3mm and
0.6mm and that the impeller rotated freely.
12. Fit the strainer (10) to the cover plate (9) and secure these items to the volute (8)
using fasteners (30, 31, 26).
NOTE: The cover plate and strainer will only fit into the volute in one position, i.e.
The hole centres are not equally spaced.
13.
Fit the hydraulic motor (23) onto the bearing bracket (1) and secure with fasteners
(29, 31). Take care that the o-ring (17) is properly seated when fitting the hydraulic
motor (23).
PARTS LISTS
ILLUS.No.
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
Bearing Bracket
Shaft
Outer Pipe Space
Inner Pipe Space
Rear Wear Plate
Front Wear Plate
Impeller
Volute
Cover Plate
Strainer
Lifting Frame
O-Ring
13
Joints
14
Impeller Shims
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Roller Bearing NU309EC

Ball bearing 6309Z
O-Ring (Hydraulic Motor BS242)
O-Ring (Seat)
O-Ring (Adaptor BS266)
Circlip (Bearing DIN 472 100x3)
Circlip (Bearing DIN 471 45x1.75)
Mechanical Seal
Hydraulic Motor (M330-11/4 ")
Circlip (Seat)
Stud S/S (M12x40)
Stud S/S (M12x45)
Stud S/S (M12x55)
Capscrew S/S (m12x45)
Setscrew S/S (M12x30)
Nut S/S (M12)
Spring Washer S/S (M12)
Flanged 90o Ball Discharge Bauer (Not shown
in drawing)
PART No.
13 0010 0000
16 0010 0000
28 0020 0000
28 0010 0000
12 0284 0115
12 0283 0115
12 0282 3015
11 0258 0115
11 0000 0100
27 0000 0200
27 0000 0100
38 1004 4112
38 1034 5413
38 1034 5423
38 1034 5443
36 0646 8913
36 0646 8923
36 0646 8933
39 0000 0100
39 0000 0200
38 0000 0100
38 0700 4112
38 0000 0200
41 0000 0100
41 0000 0200
38 0622 BR1-1
40 0000 0010
41 0230 8712
27 0000 0600
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
A/R
A/R
1
1
1
1
1
1
1
1
1
1
4
6
6
4
2
16
22
1
PUMPEND
ILLUS.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
41
42
43
44
45
DESCRIPTION
Nipple 11/16" UNO x 3/4" BSP (D95/1712)
3/4" BSP Nipple (d4/1212)
Reducing Bush 3/4" BSP (D6/1612)
Quick Connect Coupling 1"BSP Female
Quick Connect Coupling 1"BSP Male
Elbow 90o 3/4" BSP x 3/4 BSP (D30/1212
Quick Connect Coupling 3/4"BSP Female
Quick Connect Coupling 3/4"BSP Male
Reducing Bush 11/4"BSP x3/4"BSP (D620/12)
1/2" BSP Nipple (D4/0808)
Quick Connect Coupling 1/2"BSP Female
Quick Connect Coupling 1/2"BSP Male
3/4" x 1" BSP Nipple (D185/1612)
Elbow 90o 3/4" Male/Male (DO5/1212)
Strainer
11/2" BSP Socket
11/2" BSP M/F Black Elbow
1 1/16" UNO x 1 1/16" JIC Nipple (D52/1717)
1 1/16" JIC x 1 1/16" UNO Adaptor (DB66/1717)
3/4" BSP Tee (d96/121212)
3/4" BSP Socket
1/2" BSP Socket
1/2" BSP x 1/2" BSP M/F Adaptor 90 oUnion (DB45/0808)
Solenoid Valve - Manifold Plate (Delivery Hose)
Filter - Tank (Return Hose)
Tank - Hydraulic Pump (Suction Hose)
Solenoid Valve - Filter (Warm-up Hose)
Hydraulic Motor - Manifold Plate (Motor Return Hose)
Manifold Plate - Hydraulic Motor (Motor Delivery Hose)
Manifold Plate - Filter (Return Hose)
Manifold Plate - Tank (Low Pressure Oil Return Hose)
Hydraulic Motor - Manifold Plate (Low Pressure Oil Return
Hose)
Hydraulic Pump
Filter
Solenoid Valve
Hydraulic Motor
Pressure Gauge
Hydraulic Pressure Hose Assembly - 1500
Minimise Fitting P/No. 21030147
1 1/4" x 1 1/2" Tube Weld Flange TW5/2024 c/w O-Ring
DR/220
1 1/4" Split Flange clamp (D90/20)
1 1/2" Black Nipple
Elbow 90 o x 1/2" Male/Female (D05/0808)
Pressure Switch (Optional)
PART No.
40 0000 0050
20 0000 0010
20 0000 0020
20 0000 0030
20 0000 0040
20 0000 0050
20 0000 0060
20 0000 0070
20 0000 0080
20 0000 0090
40 0000 0020
40 0000 0070
40 0000 0080
40 0000 0010
40 0000 0090
40 0000 0140
QTY
4
3
3
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HYDRAULIC LAYOUT
ILLUS. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
DESCRIPTION
Chassis
Lifting Frame
Retaining Pin
Sight/Temperature Gauge
Battery Box
Filler Cap
Cork Gasket
Filler Breather
Plug 2"BSP
Plug 3/4" BSP
Return Nipple
Fuel Hose Delivery
Fuel Hose Return
Fuel Suction Pipe
Bolt M12x50 (High Tensile)
Lockwasher M12
Lockwasher M6
Setscrew M6x12
Bolt M8x25
Lockwasher
PART No.
27 0000 0400
27 0000 0500
27 0000 0300
27 0000 0060
340-8002
40 0000 0040
346-5041
340-6041
340-5005
346-5372
QTY.
1
1
1
1
1
1
1
1
3
1
1
1
1
1
4
4
4
4
20
20
CHASSIS

HD150 Pump Maintenance Manual

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SYKES GROUP PTY LTD

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

SYKES GROUP PTY LTD

ENGINE / MOTOR TYPE:

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

HOW TO READ A PERFORMANCE CURVE

Difference in elevation between liquid levels of

Equivalent head necessary to overcome friction

Required pump duty of 150l/s at 55m (Total Dynamic Head).

Draw a line upwards from Flow (x-axis) at 150l/s (point A).

Draw a line across from Total Head (y-axis) at 55m (point C)

Pump Speed Curve = 1450rpm.

Power Requirement = 120kW to run the whole of the 1450rpm

NPSHR = 6.3m (point E).

Dynamic Suction Lift Available = Atmosphere (m) NPSHR (m)

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

a vacuum gauge on the suction side of the pump to obtain a vacuum

Flow (l/s) decreases, as Total Head (m) increases.

Flow (l/s) increases, Power used increases.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

100% Best Efficiency Flow

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Pitting of material surfaces due to the continual hammering action of the

Significant reduction of performance due to vapor formation.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 1

MAX : 2.5 BAR (36.2 PSI)

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 2

SG iron as 1831 SG 400/12

POWER PACK DETAILS:

Gear type cast iron construction

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Quick Release hose couplings fitted as standard.

motor delivery hose

OVERALL DIMENSIONS AND WEIGHT

MAX. HYD. HOSE LENGTH

EXCESSIVE HYDRAULIC PRESSURE WARNING (WHEN FITTED)

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty. Ltd.

Installation, Operation and Maintenance Manual.

OPERATING AND MAINTENANCE INSTRUCTIONS

Sykes Group Pty. Ltd.