hh220i smaster manual

8/19/2019 HH220i sMaster Manual

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Customer :

Reference : W/O


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Sykes HH220i – Installation, Operation & Maintenance Manual

Sykes Group Pty Ltd Spare Parts & Service 24 hours: 1800 131950Website: www.sykesgroup.com

TABLE OF CONTENTS

1. CUSTOMER SPECIFICATION

2. TECHNICAL DATA SHEET

3. HOW TO READ A PERFORMANCE CURVE

3.1 Example Sykes’ CP150 Pump Curve

3.2 Generalisations

3.3 Radial Thrust

3.4 Cavitation

4. RISK ASSESSMENT GUIDE

5. RISK ASSESSMENT – HH220i

6. PUMP OPERATING INSTRUCTIONS

6.1 Description of Pump Unit

6.2 Procedure Prior to Pump Start Up

6.3 Failure to Prime Pump

6.3.1 Air Leaks

6.4 Pump Dynamic Test

6.5 Ejector Test

6.5.1 Dri-Prime Ejector Pack Assembly

7. PUMP MAINTENANCE INSTRUCTIONS

7.1 General Pump Inspection Procedure

7.2 Pump Assembly Instructions

7.2.1 Pump Bearing Bracket

7.2.2 Centrifugal Pump

7.2.3 Ejector Package

7.2.4 Mechanical Seal

7.2.5 Non Return Valve Inspection Procedure


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7.3 Air Compressor

7.3.1 Description of Compressor

7.3.2 Fitting Instructions – Compressor Assembly

7.3.3 Compressor Belt Replacement

7.3.4 Compressor Kit

8. PUMP DIAGNOSTICS

8.1 Trouble Shooting Guide

9. PUMP UNIT SUB-ASSEMBLY

10. PARTS LIST

10.1 Recommended HH220i Pump Spare Parts

10.2 Volute Parts List

10.3 Bearing Bracket and Shaft Parts List

10.4 Separation Tank and Ejector Package

10.5 Oil Reservoir

10.6 Compressor

11. PUMP UNIT ACCESSORIES

12. DIESEL ENGINE MANUAL (if applicable)

13. ELECTRIC MOTOR MANUAL (if applicable)


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1 CUSTOMER SPECIFICATION

General Unit Information

CustomerSykes Job NumberSykes Serial NumberPlant Number

Pump Information Pump Type HH220iPump Size 200mm x 150mmImpeller Diameter ∅432mm

Engine Information

Engine MakeEngine Serial NumberTacho Serial Number

Electric Motor Information Motor MakeMotor Serial Number

Chassis Information Dry WeightWet WeightFuel Capacity

Trailer Information VIN NumberTyre TypeAxle Set Up

Pump Extras

Additional Information

Grease Lubricated Bearings Valvoline Multi Lube Lithiumgrease EP Additives NLGI # 3or Equivalent (high temperaturegrease)

Oil Lubricated Bearings Valvoline Hydraulic oil 68 orEquivalent Hydraulic oil


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2 TECHNICAL DATA SHEET

!

MATERIALS OF CONSTRUCTION DESIGN DETAILSPump Casing: SG Iron To AS1831 Grade 400/12 Pump Designation: HH220i

Suction Cover: SG Iron To AS1831 Grade 400/12Pump Description: Centrifugal Single Stage, Volute

Type, 4 bladed fully openTee Piece: SG Iron To AS1831 Grade 400/12 Suction Flange: 200mm Table ‘E’Bearing Bracket: SG Iron To AS1831 Grade 400/12 Delivery Flange: 200mm Table ‘E’

Pump Shaft: 431 Stainless Steel Nominal Casing Thickness: 16mmImpeller: 316 Stainless Steel Nominal Shaft Diameter: 75mmWear Plates: 316 Stainless Steel Impeller Eye Diameter: 200mmAir Injector: 316 Stainless Steel Maximum Impeller O.D.: 432mmMechanical Seal: Silicon Carbide / Silicon Carbide Minimum Impeller O.D.: 380mmNon Return Valve 150mm Reflux Box NRV Solids Handling Size: 75mmCompressor Pulley: 40H150 ½” Pitch Heavy Operating Speed: MIN: 1400rpm MAX: 2200rpmDrive Pulley: 32H150 ½” Pitch Heavy Maximum Head: 139mBelt Section: 390H150 Timing Belt Maximum Capacity: 1030 l/s

DRIVE END: 7317 BALLCompressor Details: Bendix 2W 440 R Twin-in-line

cylinders 75mm x 50mm stroke, aircooled 15cfm (410L/min) at 1000rpmLubrication from engine oil system.

Bearing Sizes:

PUMP END: NU318 ROLLER

Ejector Details:Jet: 23-0415-2016SNozzle: 23-0414-2036S

Bearing Lubrication: Grease or oil. Please refer tocustomer specification page foradditional information


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3 HOW TO READ A PERFORMANCE CURVE

3.1 Example Sykes’ CP150 Pump Curve

The lines sloping downwards from left to right represent the varying quantities ofliquid delivered by the pump with variations in head. The intersection of this line at2000rpm with the zero flow line shows the shut off head (41m) of pressure developedby 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 thesuction and the centre line of the pump.

Static Discharge Head: Difference in elevation between liquid levels of thecentre line of the pump and the discharge.

Friction Head: Equivalent head necessary to overcome friction on theinterior surfaces of the pipework system including all

valves, bends and fittings.


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Duty Point: A pump operating at 95l/s at 29m (Total Dynamic Head).

1) Draw a line upwards from Flow (x-axis) at 95l/s (point A).

2) Draw a line across from Total Head (y-axis) at 29m (point C)

3) Where the vertical line of 95l/s intersects the horizontal line of 29m(point B) determines the pump rpm speed and power required at thisduty.

4) ∴ Pump Speed Curve = 2000rpm.

5) ∴ Power Requirement = 45kW to run the whole of the 2000rpm curve.

6) To obtain NPSHR (Net Positive Suction Head Required), draw a line

across from where the vertical line of the 95l/s intersects the NPSHRcurve (point D).

7) ∴ NPSHR = 1.1m (point E).

8) Dynamic Suction Lift Available (DSLA)

DSLA = Atmosphere (m) – Velocity Head (allow 1m) – NPSHR (m)

= 10.3m – 1m –1.1m

= 8.2m

To determine the actual dynamic lift of pump, it is recommended to fit a vacuumgauge on the suction side of the pump to obtain a vacuum reading. The vacuumgauge, for this example, should read no more than 80.4kPa (8.2m). If the vacuumgauge reading is greater than 80.4kPa 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 willprovide minimal restriction to the flow.

• The diameter of the suction pipe should be equal in diameter to the pump inletconnection.

• It is recommended to fit eccentric reducer in conjunction with pipe diameterslarger than the pump inlet to avoid the possibility of air pockets in the suctionpipework.


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3.2 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 pumpoperating range. To operate outside this area will lead to cavitation, vibration andnon-uniform radial forces present in the pump. This drastically reduces the operatinglife of the mechanical seal, bearings and efficiency of the pump. In addition, the pumpalignment will also be adversely effected due to excessive vibration. All this will resultin an increase of maintenance cost of the pump.

3.3 Radial Thrust

When a pump is operated at its best efficiency flow rate the velocities and hence thepressures acting on the impeller are uniform around the volute. This is shown inFigure – A.

At flow rates other than best efficiency point, the pressure distribution is no longeruniform. At reduced flow rates, the pressures increase spirally towards the cutwaterresulting 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 volutepressures.

• Temperature rise due to dissipated energy created by low efficiency.

A similar situation exists at flow rates beyond best efficiency flow rates, with anapproximate opposite (in direction) reaction.This also will lead to similar problems associated with the reduced flow rates with anaddition of poor suction performance (high NPSHR).

Figure – C shows typical variation of radial thrust with flow rate.


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Figure A – 100% Best Efficiency Flow Figure B – Reduced Flow

Figure C – Radial Thrust


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3.4 Cavitation

If the Net Positive Head Available of the pump is less than the Net Positive HeadRequired, the pumpend liquid will vaporize in the region of the impeller eye i.e. wherethe local pressure is less then the vapour pressure.In this region, the fluid will consist of a liquid plus vapour cavities. This can, in theextreme, result in the formation of a vapour lock and the prevention of the fluidentering the impeller.This phenomenon is called ‘cavitation’. The cavitation cycle comprises therefore oftwo phase changes; one from liquid to vapour during the initiation and the other fromvapour back to liquid during cavity collapse.

Cavitation may be caused by excessive suction lift, insufficient NPSHA or operationat too high a speed. The resulting effects include:

(1) Pitting of material surfaces due to the continual hammering action of thecollapsing vapour cavities.

(2) Significant reduction of performance due to vapour formation.

(3) The crackling noise (like gravel going through the pump) caused by vapourcavity 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.


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4 RISK ASSESSMENT GUIDE

The following RISK CLASSIFICATION table should be used to assess the degree of risk presented by

hazardous situations identified when carrying out the assessment.Consider:

Electrical Thermal Noise Mechanical Gravity

Pressure Chemical Radiant Biochemical

The numbers indicate how important it is to do something.

1 = Top priority – do something immediately

6 = Low priority – do something when possible

The table does not provide for control actions to be taken to minimise the risk and it is very importantthat these are documented, along with time frame and responsibilities.

How likely is it to happen?How severelycould it hurt

someone or howill could it make

someone

( A ) VERY LIKELY

could happenany time

(B) LIKELY

could happensometime

(C) UNLIKELY

could happen butvery rarely

(D) VERY UNLIKELY

could happen butprobably never will

(1) Kill or cause

permanentdisability or ill

health

1 1 2 3

(2 ) Long termillness or

serious injury 1 2 3 4

(3) Medicalattention and

severaldays off work

2 3 4 5

(4) First aidneeded 3 4 5 6


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Sykes Group Pty Ltd Spare Parts & Service 24 hours: 1800 13Website: www.sykesgrou

5 RISK ASSESSMENT – HH220i

No.

Activity Hazard & Type of Injury Risk Likelihood ConsequenceRisk

Rating

Elimi

1

Lifting ofPumpset bysingle pointlifting frame

Excessive lateral movement of unit - crushing B 1 1

•

•

•

•

•

•

• •

2Setting up thePumpset

Slips, trips, strain, sprains and pinch points B 3 3

•

•

•

•

•

•

•

•

•

3Operation ofPumpset

Excessive Noise – hearing loss B 2 2

•

•


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No.Activity Hazard & Type of Injury Risk Likelihood Consequence

RiskRating

Elimi

Operation ofPumpset

Boom movement (Suction Hose Boom) – pinchpoints & crushing

B 2 2

•

• •

•

•

•

•

•

•

•

Operation ofPumpset

Running engine & Pump Unit – moving parts,hot pump parts, hot exhaust and manifolds onengine – possible burns, pinch points, cuts andabrasions

B 3 3

•

•

•

•

•

•

•


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RiskRating

Elimi

Operation ofPumpset

Hydraulic, fuel, grease, oil, radiator coolant,water pressure, movement of pump waterhose and battery electrolyte leaks –environmental pollution, poisoning, burns &skin irritation

B 3 3

•

• •

•

•

•

•

Operation ofPumpset

Possible electrocution – electric shock andburns

B 1 1

•

• •

•

•

•

•

•

•

•

•

•


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RiskRating

Elimi

Operation ofPumpset

Possible fire and explosion – burns, bodilyinjuries and possible death

B 1 1

•

• •

•

•

•

•

•

•

4Maintenance -Battery charging

Possible explosion – burns and bodily injuries B 1 1

• • •

•

•

•

•

• •


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RiskRating

Elimi

Maintenance -Electrical

Possible electrocution – electric shock andburns

B 1 1

•

• •

•

•

•

•

•

• •

Maintenance –refilling fuel tank

Fuel leaks – environmental pollution,poisoning, burns & skin irritation

B 3 3

•

• •

•

•

•

•


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RiskRating

Elimi

Maintenance -mechanical

Engine, hydraulic pump and centrifugalpumpend maintenance – explosion, burns,pinch points, skin irritation

B 2 2

•

• •

•

•

•

• •

•

•

•

•


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6 PUMP OPERATING INSTRUCTIONS

6.1 Description of Pump Unit

The pump is basically a simple end suction pump which has a completely automaticpriming system built into the design. This enables the pump to self-prime from acompletely dry condition even with a long suction line. No liquid of any nature isrequired to prime the pump and therefore in temporary dry trench conditions the pumpwill 'snore' until such time as liquid is available.

It can handle unscreened sewage, trade effluents, thick slurries and solids up to anormal limitation of 75mm.

The impeller is a 4 bladed, 316 Stainless Steel construction, design fully open. It ismounted on a shaft made from 431 stainless steel fitted in an SG iron bearing bracket;

which also provides concentric location for the pump body.

The pump body is SG iron construction fitted with Stainless Steel wear plates securedby high tensile steel screws.

The mechanical seal is leak tight using a silicon carbide face on a silicon carbide seat.The arrangement incorporates glycol lubricated seal housing.

Guards are fitted as standard to all moving parts.

Suction flange 200mm Table ‘E’.

Delivery flange 200mm Table ‘E’.

NoteIf your HH220i pumpset has been mounted on a trailer chassis, it is recommended thatafter approximately 5 km of travel that all wheel nuts be inspected and re-tightened.


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6.2 Procedure Prior to Pump Start Up

The pump should be placed on a level area of ground.

In order to put the pump to work the following procedure should be undertaken.

1. Ensure that the pump turns freely.

2. Ensure bearings are adequately lubricated.

3. Ensure oil level in bearing bracket is filled to centre line of pump shaft indicated bythe sight gauge and oil level label.

4. The incline angle of pump should not to be greater than 10°.

5. Check pump runs without excessive noise, heat or vibration.

6. Position hoses to avoid unnecessary stress. Sharp bends should be eliminated andprotective measures taken where hoses are exposed to abrasive surfaces.Collapsible type hoses MUST NOT be used on the suction side of the pump.

7. For diesel prime movers:-Check engine fuel supply level and top up if necessary.(The fuel tank is built into the chassis).

8. Check engine oil level on dipstick and top up with recommended oil if necessary.

The pump will prime automatically once the suction hose intake is submerged.

NoteFor engine starting instructions or starting difficulties, refer to the manufacturer'shandbook.


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6.3 Failure to Prime Pump

6.3.1 Air Leaks

To test for air leaks, disconnect suction hose from pump and blank off suction entry. If

the vacuum gauge registers a satisfactory reading, i.e. 9.14 metres, the leak will be inthe suction hose. Re-couple hose to pump; remove intake and blank-off entry to hose.It should then be possible to locate leak.If the air leak is in the pump:-

a) Check that all drain plugs are screwed tightly in position

b) Remove NRV Inspection cover and make sure that the valve is seatingcorrectly.

6.4 Pump Dynamic Test

1. Before starting the engine, check that the shaft, pulleys and belt are free to rotatewith the guards in position.

2. Start pump and run completely dry for a minimum period of 10 minutes (initial run upspeed at 900rpm increasing during test to 1100rpm). During this period, generallycheck and observe for any unusual vibrations, overheating, fuel, oil or air leaks.

3. These faults must be rectified immediately to prevent a possible engine seizure.

4. After the dry running period, check that the pump unit will raise a minimum vacuumof 81kPa (8.3m).

Special NoteConsult engine manufacturers handbook for oil, fuel, speed control and stop details.


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6.5 Ejector Test

6.5.1 Dri-Prime Ejector Pack Assembly

1. Check ejector and jet sizes: Nozzle 23-0414-2036SJet 23-0415-2016S

2. Clean the jet and nozzle with paraffin or similar cleaner. On no account shouldstiff wire be used as this will enlarge the bores.

3. Check the nozzle and jet bores for any sharp edges, burrs or rough surfaces. Ifdamaged and no replacement is readily available, smooth and polish as well aspossible to original form.

4. Alignment of jet and nozzle is important but this is preset by machiningtolerances.

5. Assemble ejector unit and check performance on test unit. Operation AirPressure: 40 psi approx. Minimum Pass Vacuum: 81kPa (8.3m).

6. A satisfactory arrangement for carrying out the performance test on the ejectorunit is a plate fitted with a vacuum gauge as illustrated.

Figure 1 – Ejector Exploded Assembly Drawing


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7 PUMP MAINTENANCE INSTRUCTIONS

7.1 General Pump Inspection Procedure

1. Drain the water from the pump and the non-return valve.

2. Remove the non-return valve and inspect the valve and seat for wear.

3. Drain the oil from the engine and the pump.

4. Dismantle the pump end completely.

5. If there is a mechanical seal problem, return to supplier for reconditioning.

6. Check that the shaft rotates freely with no end float.

7. Clean and inspect all components and renew where necessary. Do not useabrasive materials or solutions to clean the ejector assembly. Renew all nyltiteseals.

8. Reassemble the complete pump end and non-return valve (refer to FittingInstructions).

9. Drain the fuel tank.

10. Detach fuel, oil and air hoses. Clean and ensure that they are not blocked. Test

the relief valve at 3 to 5 PSI.

11. Check pulley alignment and belt condition. Check the security of pulleys andflexible couplings.

12. Re-assemble the complete unit.


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7.2 Pump Assembly Instructions

7.2.1 Pump Bearing Bracket (for oil lubricated bearings)

1. Ensure all items are free from burrs and rust.

2. Visually check for porosity and blow holes in the castings and clean out anycasting sand and swarf which may be present.

3. Ensure that all items are clean and that the seal faces are free from score orwear marks.

4. Check surface finish on shaft where oil seals run and polish if required.

5. Check shaft thread, retaining nut threads & lock washer tab slots.

6. Fit inner angular contact ball bearing to shaft (large inner race face to shaftshoulder).

Retain with spacer tool and bearing lock nut. Allow to cool.

7. Fit inner race of roller bearing to shaft. Fit lock ring to shaft Loctite grub screws Wipe off excess loctite

8. Fit roller bearing outer race to bearing housing.

9. Fit inner bearing covers.

10. After bearings are cooled on shaft, oil bearings, fit assembly into housing.

11. Position angular contact ball bearing slightly recessed into housing enough toposition outer bearing spacer.

12. Remove temporary spacer tool from shaft.

13. Fit inner and outer bearing spacer.

14. Heat outer angular contact ball bearing. Fit bearing to shaft (large inner race face to bearing locknut) Fit locknut and lock washer Tighten until both bearings move together than bend over lock tab on lock

washer Allow to cool

15. Fit lip seals to bearings covers.

16. When bearing is cooled – oil and position shaft in bearing bracket.


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17. Bolt rear outer bearing cover onto the bearing bracket using bolts, springwashers, flat washers, sealing washers and O-rings. This will locate shaft inbearing bracket. Ensure shaft turns freely.

18. Fit bearing bracket cover plate.

19. Fit mechanical seal as per instructions outlined in this manual.


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7.2.2 Centrifugal Pump

1. Slide Mechanical Seal onto shaft. Ensure the locking grub screws are screwedback clear of shaft – refer to mechanical seal section for complete installationinstructions.

2. Before fitting seal onto shaft ensure that all surfaces are clean and that all edgesover which the seal has to pass are rounded off. All working faces must be freefrom any foreign matter.

3. Fit rear wear plate to volute using bolts, sealing washers and o-ringsrespectively.

4. Fit volute onto Bearing Bracket using studs, nuts and washers. Apply antisiezegrease between mating surfaces.

5. Fit Spacer Ring onto shaft.

6. Before fitting the impeller apply anti-seize compound onto the threads. Screwimpeller onto shaft in a clockwise motion. The recommended grades of antiseize is: - GA50 Molybond or equivalent (Molybdenum Disulphide).

7. Locate front wearplate onto front adaptor plate using bolt, sealing washer ando-ring.

8. Fit studs into volute then locate front adaptor plate onto volute, then by

tightening nuts move the front adaptor plate until the impeller starts to rub on thefront wear plate. When this has been achieved measure the distance betweenthe front adaptor plate and the volute then add 0.040” (1.00mm / 1.10mm). Thiswill give you the amount of shims that have to be added to give you correctclearance between the impeller and front wear plate.

9. Once this measurement has been achieved, remove front adaptor plate and addappropriate shims. Then re-tighten front adaptor plate onto volute, than re-checkclearances by measuring the distance between the impeller and front wearplateusing feeler gauges. If the clearance is not 0.030” (0.70mm/0.85mm) thenrepeat steps 9 & 10 until correct.


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7.2.3 Ejector Package

1. Check that all items are clean and free from burrs. The jet and nozzle shouldonly be cleaned with paraffin or similar cleaner. Wire should not be used, as thiswill enlarge the bores.

2. Do not use excessive jointing compound when fitting these items and ensurethat it does not enter the bores. This may cause a blockage in the ejector.

3. Screw by hand the jet and the nozzle to the carrier plate.

4. Fit elbow to nozzle.

5. Place the ball in the carrier plate, and then secure ball seat.

6. Fit the carrier plate to the tee piece with gasket filters and fasteners.

7. Push exhaust hose onto the elbow. Fasten using clamp.


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7.2.4 Mechanical Seal

Assembly

Installation Instructions for a P3F Cartridge Seal

Prepare Pump for Mechanical Seal Installation

1. Clean pump parts:a) Shaft b) Shaft Sleeve c) Stuffing Box Back Plated) Pump Frame e) Impeller f) Studs, Nuts & Bolts

2. Inspect and de-burr pump parts:a. Replace shaft or repair shaft if worn in secondary sealing area under o-

rings.b. Remove all burrs that would cut secondary seals or cause misalignment.

(Pay attention to old set-screw marks.)c. Check shaft run out (to be within 0.025mm (0.001”)) TIR per 25mm of

shaft dia) end play (not to exceed 0.13mm (0.005”)) stuffing box facemis-alignment (square to shaft to within 0.13mm TIR and a good surfaceto seal, 1.60UMRA max) and condition of bearings. Replace if necessary.

d. Drain & flush glycol reservoir.

Installation of the Mechanical Seal

1. Lubricate the shaft before sliding on seal. Slide the seal on the shaft by pushingon the collar & sleeve, making sure that the set screws are engaged in thesleeve without touching the shaft.

2. Make all necessary impeller or rotor adjustments as required.

3. Tighten the gland bolts evenly.

4. Tighten grub screws (3off s/s std grub screws, use Locktite 243)

5. Dimpling shaft: Drill into shaft through remaining grub screw holes (3off) to suitspear point grub screws. (Use Locktite 243)

6. Tighten remaining M6 x 6 Umbrako Grubscrews directly on top of the 6 grubscrews in place. (Use Locktite 243)

7. Remove setting clips and cap head screws.

8. Turn shaft by hand, there should be no metal to metal contact between thesleeve and the seal.


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9. Make all necessary pump connections and alignments. Hook up appropriatetangential flush port depending on shaft rotation. (Connect flush in the directionof shaft rotation, eg; if the shaft is rotating clockwise, connect the flush (marked)clockwise).

10. Fill tank with Ethylene Glycol (mixture 30% Glycol, 70% Water), bled barrier fluidline free of air.

11. The seal is ready for pump start-up procedures.

Warning! Ensure once pump is operation that the barrier fluid is circulating. Ifbarrier fluid does not seem to be circulating, remove return line to bledremaining air out of it. Reconnect and re-check flow.


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7.2.5 Non Return Valve Inspection Procedure

1. Ensure that all items are clean and free from burrs.

2. Visually check for porosity and blow holes in the castings and for scores or chaffing

of the seat.

3. Ensure all bolts on inspection cover are secure.

4. Clean the delivery flange on the pump body and secure the valve to it withfasteners.


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7.3 Air Compressor

7.3.1 Description of Compressor

BENDIX AIRCOMPRESSORTYPE 2W 440 R.

Introduction: The very high air output of this twin cylinder

single stage air compressor makes it eminently suitable foruse on buses and special purpose heavy duty vehicles. Ithas a balanced crankshaft and reed type air inlet anddelivery valves for greater efficiency and reliability at highoperating speeds.

It is available in either base or flange mounted versionswhich are suitable for gear, belt, or shaft drive from thevehicle engine.The crankcase and cylinders form a single rigid weightsaving casting. The cylinder barrels are air cooled whilethe cylinder head is cooled by water circulated from thevehicle engine cooling system. The compressor may be

run in either direction of rotation at speeds of up to 2400r.p.m. to deliver up to 9 bar pressure (130 p.s.i.) Forsustained operation at higher delivery pressures pleaseconsult our Technical Services Department.

An unloader mechanism may be incorporated in thecylinder head. In its absence, pressure regulation is by anair delivery line mounted unloader valve, or by a D2Governor used in conjunction with an AD2 Air Dryer. Theair inlet and delivery valves are contained in a valve platefitted between the cylinder barrels and the cylinder head.The compressor lubricating oil is circulated under pressurefrom the vehicle engine lubricating oil system.

Every effort has been made to ensure that the information in thisleaflet is correct but we reserve the right to amend or change thisinformation without notice.


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Construction: Refer to Figs. 1 and 4. In Fig. 1 A is thereed valve plate and B is the cast aluminium cylinder headwhich is partially finned to assist cooling. C is the airdelivery connection and there are cooling water connectionsat the two positions D. E is the air inlet connection.

Each cylinder has an air delivery valve F and an air inlet

valve G. Three gaskets are fitted at H, one between thecylinder head and valve plate, and two between the valveplate and the finned cast iron cylinder/crankcase unit J.

The two aluminium pistons K each have two piston rings Land an oil control ring M. The piston pins N are retained bythe circlips P. The front end of the forged steel crankshaft Qruns in the ball bearing R. The front end cover S also carriesthe crankshaft oil seal T.

The connecting rods U are made from a forged light alloywhich forms an excellent bearing surface. The rods rundirectly on the crankshaft journals and piston pins. This

eliminates the need for separate bearing inserts.

The rear end of the crankshaft carries a thrust washer V andruns in a white metal bearing bush W. The rear end cover Xis threaded at Y for a lubricating oil connection from thevehicle engine. Engine oil under pressure then flowsthrough drillings in the crankshaft to the main bearing at Wand to the big end bearings. The ball bearing R and theother internal surfaces are lubricated by oil splash and mist.The oil drains back to the vehicle engine through the openbottom of the compressor crankcase.

General Specification:

Bore 75mmStroke 50mmSwept Volume 441.6 cm

3

Maximum Recommended Speed 2400 r.p.m.Maximum Recommended DeliveryPressure 9bar (130 p.s.i.)Operating temperature Range -40°C to + 80°CMaximum Continuous deliveredAir Temperature(See 'Installation') 220°CWeight 19.5 kg

Also refer to the performance charts in Fig. 2.

Installation: Standard ISO and DIN symbols for aircompressors in pnuematic circuit diagrams are shown in Fig.3. Because of the range of mounting and driving options thedimensions in Fig. 4 are typical only. Our TechnicalServices Department will supply detailed dimensions andinformation for each particular application. The Departmentshould also be consulted if it is desired to mount thecompressor at an appreciable angle. The compressorshould be mounted where the maximum air flow will passover it to help in ensuring that the delivered air temperaturedoes not exceed 220°C.The cylinder/crankcase unit may be flange mounted instead

of base mounted as in Fig. 4. Details are available onrequest.


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Maintenance: Before working on or around airbrake systems and components always observe thefollowing precautions:

a) Stop the engine before working under avehicle.

b) Always chock the vehicle wheels,because depleting the vehicle air systempressure may cause the vehicle to roll.

c) Keep hands away from actuator push rodsand slack adjusters. They may apply asthe system pressure drops.

d) Never connect or disconnect a hose orline containing air pressure. It may whipas air escapes.

e) Never remove a component or pipe plugunless you are certain all system pressurehas been depleted.

f) Never exceed recommended air pressure.g) Always wear safety glasses when working

with air pressure. Never look into air jetsor direct them at anyone.

h) Never attempt to dismantle a componentuntil you have read and understandrecommended procedures.

i) Some units contain powerful springs andinjury can result if not properly dismantled.

j) Use only the correct tools and observe allprecautions pertaining to the use of thesetools.

At vehicle service intervals check the compressorfor any leakages of water, oil, or air. If thecompressor is slow to build up pressure thecylinder head and valve plate may be removed.The condition of the valve assemblies and thecylinder bores may then be checked and anyexcessive build up of carbon removed. ServiceKits of replaceable items are available on request.


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7.3.2 Fitting Instructions – Compressor Assembly

1 Ensure all items are clean and that the hoses are free from foreign matter.

2 Do not use excessive jointing compound (eg. Stag, Neolite, Non-AdhesiveHermatite etc) when fitting these items and ensure that it does not enter thebores. This may cause a blockage in the oil or air lines.

3 Fit gasket to the compressor position on adaptor and secure with fasteners.

4 Secure the compressor pulley to the compressor with the nut and springwasher. Remove the taperlock bush from the pump pulley then pass thepulley over the shaft. Ease the belt over the pulleys, and fit the key. Alignthe pulleys then refit the taperlock bush to the pump pulley and secure it to

the shaft.

5 Remove and discard four cylinder head screws from the compressor andensure the compressed air port is located at the opposite end to fan.

6 Connect the compressed air hose between the compressor and the jetsleeve.

7 Fit the oil pipe fittings to the compressor.

8 Connect air intake fittings.

9 Secure the guard with screws. Ensure that the belt and pulleys are free torotate.

7.3.3 Compressor Belt Replacement

Timing Belt Procedure

1. Remove pulley guard set screws and pump support nuts and draw pumpassembly away from engine flywheel housing

2. Remove old belt and taper lock bush from pump pulley.

3. Ease replacement belt over pulleys, realign pulleys and refit taper lock bush.

4. Check belt tension then refit pump unit onto engine.

5. The compressor tooth belt drive has fixed centres so no adjustment isnecessary. The normal operating air pressure is 3.44 - 5.17 bar (50-75psi).


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Link Belt Procedure

1 Remove pulley guard and old belt.

2 Place belt around pulleys without creating any tension.

3 Count the number of links and remove 7% (1 in 14).

4 Place belting around pump shaft and link up.

5 Fit around drive pulley and over compressor pulley rotating the drive shaftslowly.

6 The normal operating air pressure is 2.75 - 4.13 bar (40-60psi).


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7.3.4 Compressor Parts List

Ref. Description Part Number

Bendix Air Compressor 2W 440 R KZ1087/14 49-0523-9915

A Valve Plate Assembly c/w Reed Valve Kit & Air Inlet Valve KY2331/1SPB Cylinder Head KZ1160/3C ¾” BSP Threaded Air Delivery ConnectionD ½” Threaded Water Cooling PortsE ¾” BSP Threaded Air InletF Reed Valve Kit SK2955/1G Air Inlet Valve 229502H Valve Plate & Head Gasket Kit

Comprising: Cyl.Head Gasket KX2466/2Top Plate Gasket KX2799/2Lower Plate Gasket KX2280/2

SK2997/1

J Cylinder Body KZ1094/1Piston Assembly (STD)(KW5172/1SP)

1189082SP

Piston Assembly (KW5172/2SP) 1189255SPK

Piston Assembly (KW5172/3SP) 1189256SPPiston Ring Set (STD) (SKR2790/00) SKR2962/00Piston Ring Set (0.010” o/s) (SKR2790/10) SKR2962/10Piston Ring Set (0.020” o/s) (SKR2790/20) SKR2962/20

L

Piston Ring Set (0.030” o/s) SKR2962/30MNP

Oil Control Ring - Included in Piston Assy & Piston RingSetConnecting Rod Pin - Included in Piston AssemblyRod Pin Snap Pin - Included in Piston Assembly

Q Crankshaft KY2258/1SPR Ball Bearing (NSK-6307-CE) 1194120SPS Front End Cover KX2491/1

O-Ring, Inner Bearing Cover 1189619T Crankshaft Oil Seal (CR13938) 267805U Con Rod Complete

(KW4785/1SP)1194120SP

V Thrust Washer KY2372/1W White Metal Bearing Bushing I811560066X End Cover Assembly c/w Bushing KX1223/13SP

“C” Ring - End Cover 1189571Y Lubricating Oil Inlet 1/8” BSP

Base Mount Gasket 0.8mm KX2542/1Base Mount Gasket 0.4mm KX2542/2


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8 Pump Diagnostics

8.1 Trouble Shooting Guide

Pump System Problems Likely Cause

Pump Does Not Prime - Suction lift too great- Inlet of suction pipe insufficiently

submerged- Suction inlet or strainer blocked- Excessive amount of air or gas in liquid- Viscosity and / or S.G. of liquid being

pumped too high

- Suction line not air tight- Suction hose collapsed- Non return valve ball not seating- Mechanical seal / Packing drawing air

into pump- Pump’s priming system blocked or badly

worn- Separation tank cover blocked- Pump’s priming hose leaking air- Pump’s priming system not delivering

sufficient air

- Pump’s priming system belt drive faulty

Not Enough Liquid - Incorrect engine speed- Discharge head too high- Suction lift too great- Suction inlet or strainer blocked- Suction line not air tight- Suction hose collapsed- Mechanical seal drawing air into pump- Obstruction in pump casing / impeller-

Impeller excessively worn- Delivery hose punctured or blocked- Pump not primed- Air pockets in suction line- Inlet of suction pipe insufficiently

submerged- Excessive amount of air or gas in liquid


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Not Enough Pressure - Speed too low-

Excessive amount of air or gas in liquid- Incorrect direction of rotation- Viscosity and / or S.G. of liquid being

pumped too high- Impeller Damaged- Impeller out of balance

Pump Ceases to DeliverLiquid After a Time

- Suction lift too great- Insufficient water at suction inlet- Suction inlet or strainer blocked- Suction hose collapsed

- Excessive air leak in suction line- Mechanical seal / Packing drawing air

into pump- Obstruction in pump casing / impeller- Delivery hose punctured or blocked

Pump Takes ExcessivePower

- Engine speed too high- Obstruction between impeller and casing- Viscosity and / or SG of liquid being

pumped too high- Incorrect direction of rotation

- Misalignment- Shaft bent

Pump Leaking atMechanical Seal Housing

- Mechanical seal damaged or worn

Pump Bearings Have ShortLife

- Obstruction in pump casing / impeller- Impeller out of balance- Shaft bent- Shaft running of centre because of worn

bearings or misalignment

- Misalignment- Bearings worn- Excessive thrust caused by mechanical

failure inside pump- Lack of bearing lubrication- Incorrect assembly of stacked bearings,

i.e. angular contact ball bearings fittedfront-to-front instead of back-to-back

- Dirt in bearings- Rusting of bearings from water in

housing


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Pump Vibrating or

Overheating

- Engine speed too high-

Obstruction in pump casing / impeller- Impeller damaged- Cavitation due to excessive suction lift- Impeller out of balance- Shaft bent- Shaft running of centre because of worn

bearings or misalignment- Misalignment- Bearings worn- Pump not primed- Pump or suction pipe not completely

filled with water- Inlet of suction pipe insufficiently

submerged- Suction or discharge re-circulation in

volute- Excessive thrust caused by mechanical

failure inside pump- Lack of bearing lubrication- Incorrect assembly of stacked bearings,

i.e. angular contact ball bearings fittedfront-to-front instead of back-to-back

- Dirt in bearings- Rusting of bearings from water in

housing


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9 PUMP UNIT SUB-ASSEMBLY

H Volute

BB Bearing Bracket

ST Separation Tank

EP Ejector Pack

OR Glycol Reservoir

AC Compressor Assembly

Figure 19 – Typical HH220i Pumpend

AC EPOR

ST

H

BB


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Figure 20 – HH220i General Assembly Drawing


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10 PARTS LIST

10.1 Recommended HH220i Pump Spare Parts

Description Part Number QuantityImpeller 12-0325-3015 1Front Wear Plate 12-0185-0115 1Stuffing Box Plate 12-0196-0115 1Stuffing Box Plate Gasket 98-430-807-162 1Shim - 0.25mm 38-0200-5413 2Shim - 0.40mm 38-0200-5423 2Shim - 0.80mm 38-0200-5433 2Shim - 1.60mm 38-0200-5443 2Mechanical Seal 001-1007JC 1

Shaft Sleeve 28-0210-3215 1Roller Bearing 39-0094-9912 1Ball Bearing Angular Contact 39-0091-9912 2Shaft 16-0200-8011-BU 1


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10.2 Volute Parts List

Figure 21 –Volute Mechanical Seal Exploded Assembly Drawing


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VOLUTE PARTS LIST

Illustrationnumber

Description Part Number Quantity

H1 Volute Body 11-0200-0115 1H2 Impeller 12-0325-3015 1H3 Front Wear Plate 12-0185-0115 1H4 Stuffing Box Plate 12-0196-0115 1H5 Adaptor Plate 10-0200-0000 1H6 Stud (M16 x 50) 4H7 Nut (M16) 4H8 Seal Washer (M16) & ‘O’ Ring 38-0790-4412

38-0792-44124

H9 Capscrew (M24 x 40) 12H10 Spring Washer (M24) 12H13a Flat Washer (M16) S/S 2H13b Spring Washer (M16)S/S 2

H16 Gasket 98-430-807-162 1H18a Shim – 0.25mm 38-0200-5413 A/RH18b Shim – 0.4 mm 38-0200-5423 A/RH18c Shim – 0.8 mm 38-0200-5433 A/RH18d Shim – 1.6mm 38-0200-5433 A/RH19 Plug ¾” BSP P12 2

Not Shown Epoxy Adhesive AC-068 1

MECHANICAL SEAL

Illustrationnumber


H11 Shaft Sleeve (modified) 28-0210-3215 1H12 Mechanical Seal 001-1007JC 1H14 Bolt (M16 x 20) S/S 2

PACKED GLAND

Illustrationnumber


H11 Shaft Sleeve 28-0200-3215 1H12 Gland followers (set of 2 halves) 14-0300-0115 1H14 Nut (M16) S/S 2H15 Stud (M16 x 65) S/S 2H17 Gland packing - ½” 638-4003G 1


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Figure 22 –Volute Packed Gland Exploded Assembly Drawing


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VOLUTE PARTS LIST

Illustrationnumber


H1 Volute Body 11-0200-0115 1H2 Impeller 12-0325-3015 1H3 Front Wear Plate 12-0185-0115 1H4 Stuffing Box Plate 12-0196-0115 1H5 Adaptor Plate 10-0200-0000 1H6 Stud (M16 x 50) 4H7 Nut (M16) 4H8 Seal Washer (M16) & ‘O’ Ring 38-0790-4412

38-0792-44124

H9 Capscrew (M24 x 40) 12H10 Spring Washer (M24) 12H13a Flat Washer (M16) S/S 2H13b Spring Washer (M16)S/S 2

H16 Gasket 98-430-807-162 1H18a Shim – 0.25mm 38-0200-5413 A/RH18b Shim – 0.4 mm 38-0200-5423 A/RH18c Shim – 0.8 mm 38-0200-5433 A/RH18d Shim – 1.6mm 38-0200-5443 A/RH19 Plug ¾” BSP P12 2

Not Shown Epoxy Adhesive AC-068 1

MECHANICAL SEAL

Illustrationnumber


H11 Shaft Sleeve (modified) 28-0210-3215 1H12 Mechanical Seal 001-1007JC 1H14 Bolt (M16 x 20) S/S 2

PACKED GLAND

Illustrationnumber


H11 Shaft Sleeve 28-0200-3215 1H12 Gland followers (set of 2 halves) 14-0300-0115 1H14 Nut (M16) S/S 2H15 Stud (M16 x 65) S/S 2H17 Gland packing - ½” 638-4003G 1


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10.3 Bearing Bracket and Shaft Parts List

Figure 23 –Bearing Bracket Exploded Assembly Drawing


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BEARING BRACKET & SHAFT PARTS LIST

IllustrationNumber


BB1 Bearing Bracket 13-0164-0115 1BB2 Bearing Cover Outer Rear 13-0169-0125-BU 1

BB3 Bearing Cover Outer Front 13-0162-0115 1BB4 Bearing Cover Inner 13-0170-0115-OIL 1BB5 Roller Bearing 90 X 190 39-0094-9912 1

BB6 Angular Ball Bearing 85 X 180 39-0091-9912 2BB7 Bolt (M12 x 160) 3

BB8A Flat Washer (M12) 9BB8B Spring Washer (M12) 9

BB9 Bolt (M12 x 100) 3

BB10 Bolt (M12 x 40) 3BB11 Bolt (M12 x 180) 3BB12 Spiroseal 90 x 110 38-1331-9912 1

BB13 Clamp Ring 28-0252-8811 1BB14 Socket Capscrew (M6 x 20) 1

BB15 Shaft 16-0200-8011-BU 1

BB16 Lock Nut Bearing 39-0096-9912 1BB17 Lockwasher Bearing 39-0097-9912 1

BB18 Bearing Spacers (Pair) 24-0093-8831 1BB19 Spiroseal 75 x 95 x 10 38-1328-9912 1BB20 Bearing Bracket Cover Joint 1.6mm XH80BBJ-160 1

BB21 Stud (M20 x 70) 8

BB22A Flat Washer (M20) 8BB22B Spring Washer (M20) 8

BB23 Nut (M20) 8

BB24 Plug 3/8” BSP P06 1BB25 Plug 1/8” BSP P02 1BB26 Bearing Bracket Cover Plate 27-0200-8211-OIL 1

BB27 Bolt (M12 x 40) 4BB28A Flat Washer (M12) 4

BB28B Spring Washer (M12) 4

BB29 Sealing Washer (M12) 4BB30 O-Ring 10.69 x 3.53 Viton 4

* Notes: 1. When ordering Shaft state pump engine type so correct type of shaft length can be

supplied.2. Ensure that the angular ball bearings (BB6) are fitted back-to-back either side of

bearing spacers (BB18). The set up is obtained by fitting the smaller shoulders ofthe inner races facing each other.


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10.4 Separation Tank / Ejector Package Parts List

Figure 24 – Separation Tank & Ejector Package

Exploded Assembly Drawing


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EJECTOR PACKAGE PARTS LIST

IllustrationNumber


EP1 Ejector Nozzle 23-0414-2036S 1EP2 Ejector Jet 23-0415-2016S 1

SEPARATION TANK PARTS LIST

IllustrationNumber


ST1 “T” Piece 348-4008 1ST2 Tank/Body Joint 500-5003 2ST3 Stud (M20 x 70) 8ST4 Nut (M20) 8ST5 Lockwasher (M20) 8ST6 Carrier Plate 23-0411-0115 1ST7 Carrier / Tank Stud (M12x 50) 4ST8 Springwasher (M12) 4ST9 Nut (M12) 4ST10 Ball Seat 23-0412-2011 1ST11 Ball 39-0641-4113 1ST12 Carrier Plate Plug 1” B.S.P. P16 1ST13 Fitter 23-0413-2113 1

ST14 ¾” BSP Elbow - Hosetail E12SBF 1


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10.5 Glycol Reservoir Parts List

Figure 25 – Glycol Reservoir Exploded Assembly Drawing


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GLYCOL RESERVOIR PARTS LIST

IllustrationNumber


OR1 Glycol Reservoir Assembly 27-5000-8211 1OR2 Lid 1OR3 Sight & Temperature Gauge 40-0000-0060 1OR4 Hydraulic Nipple ¼” BSP N04HOR5 Reservoir Gasket 38-0350-5443 1OR6 Nut (M12) 1OR7 Springwasher (M12) 1OR8 Plug ½” (with breather) P08 1

Glycol Reservoir Hose Length 1 1-319-0006 650mmGlycol Reservoir Hose Length 2 1-319-0006 550mmHose Clamps to suit reservoir hose OTK1011 4Nut & Hose Tails ¼” to suitreservoir hose

HT0404 4

OR9 Bolt (M10 x 30) 4OR10 Flat Washer (M10) 4OR11 Spring Washer (M10) 4


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10.6 Compressor Parts List

Figure 26 - Compressor Assembly Drawing


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COMPRESSOR PARTS LIST

IllustrationNumber


AC1 Compressor (Bendix) 49-0523-9915 1AC2 Gasket KX2542/1 1AC3 Stud M10 x 40 4AC4 Springwasher M10 4AC5 Pulley (Pump) bored to 75mm shaft 10-0000-0037 1AC6 Pulley (Compressor) 26-0830-0243 1AC7 Belt 38wide x 78 teeth (1/2” Heavy Pitch) 26-0840-9912 1AC8 Fan Washer 36-0556-8111 1AC9 Relief Valve 10-0000-0004 1AC10 Air Cleaner 54-0556-9912 1AC11 Adaptor (Air Cleaner) A1212 1AC13 Compressed Air Hose 42-0000-0015 1AC14 Nipple ¾” BSP x ½” BSP N1208H 1AC15 Pulley / Belt Guard 1


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10.7 Non Return Valve Parts List

NON RETURN VALVE PARTS LIST

IllustrationNumber


V1 Flexi-Check Valve 200mm 10-0000-0480 1V2 Flexi-Check Valve Flap 200mm 10-0000-0485 1

Figure 27 – Non Return Valve Explode Assembly Drawing


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11 PUMP UNIT ACCESSORIES

Your HH220i pumpset has been mounted on a robust custom built skid

chassis and comes complete with extras include.

Description Part Number

1 14” Flywheel Stub Shaft (3 ½” shaft)

2 RFC280 Flex Coupling c/w 3535TLB tosuit shaft 75mm & 3 ½”

3 Inbuilt 24 hour Fuel Tank (2350 litres)

4 Discharge Pressure Gauges

5 8” Non Return Valve

6 6” Crane Geared Operated ButterflyValve

7 Hydro Flow Valve (Fuel)

8 Night Lights – 2 only AC-057

9 Green Flashing Light (Pump Operating)

10 Loss of Low Shutdown

11 9 kg Fire Extinguisher – 2 only AC-034

12 9 kg Fire Extinguisher Bracket – 2 only AC-035

13 Traffolyte Pump Operating Sign(Recommended Pump OperatingPressures at Various Speeds)

14 Jump Start Receptacle

15 Lockable Battery Isolator AC-017 & AC-017-NEW

16 8” Suction Bauer 8-319-4830

17 Suction Bauer ‘O’ Ring 8-319-4850

18 8” Split Intake 8-181-4022

19 8” Wire Armoured Suction Hose x 6 m 9-319-6186

20 Wiggins Fast Fill Fittings (Oil & Water)

For further information please refer to the manufacturer's Operation andMaintenance Manuals.


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12 DIESEL ENGINE MANUAL

Your HH220i pumpend is driven by a ?? Liquid Cooled Diesel Engine

and comes complete with the following.


1 Mines Wiring to MDG-15

2 Water Separator Filter

3 Emergency Stop

4 Murphy Control Panel Gauges

5 Clip Type Lagging on Exhaust Pipes



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13 ELECTRIC MOTOR MANUAL

Your HH220i pumpend is driven by a ??kW / ?Pole / IP?? / ?Phase /

???V Electric Motor and comes complete with the following.



hh220i smaster manual

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