HH220i Smaster Manual

Customer :
Reference :
W/O
Sykes HH220i Installation, Operation & Maintenance Manual
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
7.
Dri-Prime Ejector Pack Assembly

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
Sykes Group Pty Ltd
Spare Parts & Service 24 hours: 1800 131950

Website: www.sykesgroup.com
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)
Sykes Group Pty Ltd

1 CUSTOMER SPECIFICATION
General Unit Information
Customer
Sykes Job Number
Sykes Serial Number
Plant Number
Pump Information
Pump Type
Pump Size
Impeller Diameter
HH220i
200mm x 150mm
432mm
Engine Information
Engine Make
Engine Serial Number
Tacho Serial Number
Electric Motor Information
Motor Make
Motor Serial Number
Chassis Information
Dry Weight
Wet Weight
Fuel Capacity
Trailer Information
VIN Number
Tyre Type
Axle Set Up
Pump Extras
Additional Information
Grease Lubricated Bearings
Oil Lubricated Bearings
Sykes Group Pty Ltd
Valvoline Multi Lube Lithium

grease EP Additives NLGI # 3
or Equivalent (high temperature
grease)
Valvoline Hydraulic oil 68 or
Equivalent Hydraulic oil

2 TECHNICAL DATA SHEET
!
MATERIALS OF CONSTRUCTION
Pump Casing:
SG Iron To AS1831 Grade 400/12
Suction Cover:
Tee Piece:
Bearing Bracket:
Pump Shaft:
Impeller:
Wear Plates:
Air Injector:
Mechanical Seal:
Non Return Valve
Compressor Pulley:
Drive Pulley:
Belt Section:
Compressor Details:

431 Stainless Steel
316 Stainless Steel
316 Stainless Steel
316 Stainless Steel
Silicon Carbide / Silicon Carbide
150mm Reflux Box NRV
40H150 Pitch Heavy
32H150 Pitch Heavy
390H150 Timing Belt
Bendix 2W 440 R Twin-in-line
cylinders 75mm x 50mm stroke, air
cooled 15cfm (410L/min) at 1000rpm
Lubrication from engine oil system.
Ejector Details:
Jet:
23-0415-2016S
Nozzle: 23-0414-2036S
Sykes Group Pty Ltd
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.:
Solids Handling Size:
Operating Speed:
Maximum Head:
Maximum Capacity:
Bearing Sizes:
HH220i
Centrifugal Single Stage, Volute
Type, 4 bladed fully open
200mm Table E
200mm Table E
16mm
75mm
200mm
432mm
380mm
75mm
MIN: 1400rpm MAX: 2200rpm
139m
1030 l/s
DRIVE END: 7317 BALL
PUMP END: NU318 ROLLER
Bearing Lubrication:
Grease or oil. Please refer to

customer specification page for
additional information

Sykes Group Pty Ltd

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 of
liquid delivered by the pump with variations in head. The intersection of this line at
2000rpm with the zero flow line shows the shut off head (41m) 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:
Static Discharge Head:
Friction Head:
Sykes Group Pty Ltd
Difference in elevation between liquid level of the

suction and the centre line of the pump.
Difference in elevation between liquid levels of the
centre line of the pump and the discharge.
Equivalent head necessary to overcome friction on the
interior surfaces of the pipework system including all
valves, bends and fittings.

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 this
duty.
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 NPSHR
curve (point D).
7)
8)
Dynamic Suction Lift Available (DSLA)
NPSHR = 1.1m (point E).
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 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 80.4kPa (8.2m). If the vacuum
gauge 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 will
provide minimal restriction to the flow.
The diameter of the suction pipe should be equal in diameter to the pump inlet
connection.
It is recommended to fit eccentric reducer in conjunction with pipe diameters
larger than the pump inlet to avoid the possibility of air pockets in the suction
pipework.
Sykes Group Pty Ltd

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 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.
3.3
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.
Sykes Group Pty Ltd

Figure A 100% Best Efficiency Flow
Figure B Reduced Flow
Figure C Radial Thrust
Sykes Group Pty Ltd

3.4
Cavitation
If the Net Positive Head Available of the pump is less than the Net Positive Head
Required, the pumpend liquid will vaporize in the region of the impeller eye i.e. where
the local pressure is less then the vapour pressure.
In this region, the fluid will consist of a liquid plus vapour cavities. This can, in the
extreme, result in the formation of a vapour 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 vapour during the initiation and the other from
vapour 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 vapour cavities.
(2) Significant reduction of performance due to vapour formation.
(3) The crackling noise (like gravel going through the pump) caused by vapour
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.
Sykes Group Pty Ltd

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
Pressure
Chemical
Radiant
Biochemical
Gravity
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 important
that these are documented, along with time frame and responsibilities.
How severely
could it hurt
someone or how
ill could it make
someone
How likely is it to happen?

(A) VERY LIKELY
(B) LIKELY
(C) UNLIKELY
(D) VERY UNLIKELY
could happen
any time
could happen
sometime
could happen but

very rarely
could happen but

probably never will
(1) Kill or cause

permanent
disability or ill
health
(2) Long term

illness or
serious injury
(3) Medical
attention and
several
days off work
(4) First aid
needed
Sykes Group Pty Ltd

5 RISK ASSESSMENT HH220i
No.
Activity
Hazard & Type of Injury Risk
Likelihood
Consequence
Risk
Rating
Eliminate / Reduce / Control the risk by
Lifting of
Pumpset by
single point
lifting frame
Excessive lateral movement of unit - crushing
Setting up the
Pumpset
Slips, trips, strain, sprains and pinch points
Operation of
Pumpset
Excessive Noise hearing loss
Sykes Group Pty Ltd
Only qualified personnel to use lifting

equipment
Hoisting acceleration should not exceed
2
0.4m/sec
Ensure lifting equipment is in good
condition
Keep all personnel away from Pumpset
when it is suspended
Do not lift Pumpset by any other method
than the central lifting eye
Do not lift in extreme weather conditions
Stop & think
Correct PPE
Wear correct PPE
Stop and think
Inspect area to ensure safe working
conditions
Set up on level ground
Communicate with personnel
located/working in vicinity of Pumpset
Clean up any spillages causing trip
hazards
Do not operate Pumpset in known
unsafe conditions
Do not use Pumpset in any classification
of hazardous environment unless it has
been specifically designed to do so
Do not operate within a confined space
Wear hearing protection at all times
when working or operating around the
Pumpset
Stop & think

No.
Activity
Likelihood
Consequence
Risk
Rating
Operation of
Pumpset
Boom movement (Suction Hose Boom) pinch

points & crushing
Operation of
Pumpset
Running engine & Pump Unit moving parts,

hot pump parts, hot exhaust and manifolds on
engine possible burns, pinch points, cuts and
abrasions
Sykes Group Pty Ltd
Wear correct PPE

Stop & think
Do not operate Pumpset in known
unsafe conditions
Do not use Pumpset in any classification
of hazardous environment unless it has
been specifically designed to do so
Do not operate within a confined space
Keep all personnel away from Pumpset
when boom is tilted, raised or lowered
Do not move Pumpset whilst operating
the boom
Ensure boom lifting equipment is in good
condition
Do not operate Boom in known unsafe
conditions
Communicate with personnel
located/working in vicinity of Pumpset
Wear correct PPE
Stop & think
Educate employees of burn hazards on
engines
Keep access door on enclosures closed
and locked when not required to be open
Ensure that the engine is operated only
from the control panel or from the
operators position by one person only
Keep hands, arms, long hair, loose
clothing and jewelry away from pulleys,
belts and other moving parts
Do not remove any safety guards or
panel

No.
Activity
Operation of
Pumpset
Hydraulic, fuel, grease, oil, radiator coolant,

water pressure, movement of pump water
hose and battery electrolyte leaks
environmental pollution, poisoning, burns &
skin irritation
Likelihood
Consequence
Risk
Rating
Operation of
Pumpset
Possible electrocution electric shock and

burns
Sykes Group Pty Ltd
Stop & think

Wear correct PPE
Check all hoses for cracks and leaks
Check that all covers and caps are
secure on alternator, cooling
fan/radiator, engine & fuel tank
Ensure spillages are contained
MSDS available for all items used in
Pumpset
Educate employees of burn hazards
Wear correct PPE
Stop & think
Only Authorised Personnel to work on
electrical equipment
Check all conduits for splits, bare wires
or unsecured conduit fitting prior to
operation of Pumpset
Check all circuit breaker boards are
secure and sealed
Check all guards covering electrical
section are secured correctly
Do not attempt to connect or disconnect
load while standing in water or on wet or
soggy ground
Ensure all electrical power is isolated
from electrical equipment being serviced
Keep all electrical equipment clean and
dry
Keep terminals clean and tight
Test earth leakage equipment regularly
Ensure correct fire extinguisher is
available

No.
Activity
Likelihood
Consequence
Risk
Rating
Operation of
Pumpset
Possible fire and explosion burns, bodily

injuries and possible death
Maintenance Battery charging
Possible explosion burns and bodily injuries
Sykes Group Pty Ltd
Wear correct PPE

Stop & think
available
Do not refill the fuel tank while engine is
running
Never store oily rags in metal covered
containers
Do not smoke or allow sparks, flames or
other sources of ignition around fuel or
batteries
To avoid arcing keep grounded
conductive objects, such as tools, away
from exposed live electrical parts, such
as terminals
Do not operate the Pumpset system with
any known leaks in the fuel system
Open exhaust system drain plugs after
repeated failed start attempts
Wear correct PPE
Stop & think
Correctly isolate equipment
Do not smoke or allow sparks, flames or
other sources of ignition around batteries
To avoid arcing keep grounded
conductive objects, such as tools, away
from exposed live electrical parts, such
as terminals
When disconnecting battery disconnect
the negative battery terminal first
When reconnecting battery connect the
negative battery terminal last
Ensure adequate ventilation
Turn off power or disconnect the power
to the battery charger before making or
breaking connections with the battery

No.
Activity
Likelihood
Consequence
Risk
Rating
Maintenance Electrical
Possible electrocution electric shock and

burns
Maintenance
refilling fuel tank
Fuel leaks environmental pollution,

poisoning, burns & skin irritation
Sykes Group Pty Ltd
Wear correct PPE

Stop & think
Only Authorised Personnel to work on
electrical equipment
Do not attempt to connect or disconnect
load while standing in water or on wet or
soggy ground
Ensure all electrical power is isolated
from electrical equipment being serviced
Keep all electrical equipment clean and
dry
Keep terminals clean and tight
Test earth leakage equipment regularly
available
Stop & think
Wear correct PPE
Check all hoses and fittings for cracks
and leaks
MSDS available for fuel used in lighting
tower

No.
Activity
Likelihood
Consequence
Risk
Rating
Maintenance mechanical
Engine, hydraulic pump and centrifugal

pumpend maintenance explosion, burns,
pinch points, skin irritation
Sykes Group Pty Ltd
Stop & think

Wear correct PPE
MSDS available for items used in
Pumpset
Check all hoses and fittings for cracks
and leaks
Correctly de-energise hydraulic system
Ensure guarding is in place and secure
after maintenance is finished
Do not remove the radiator filler cap until
the coolant has cooled. Then loosen the
cap slowly to relieve any excess
pressure before removing the cap
completely
Educate employees on hazards of hot
coolant and oil under pressure
available

6 PUMP OPERATING INSTRUCTIONS

6.1
Description of Pump Unit
The pump is basically a simple end suction pump which has a completely automatic
priming system built into the design. This enables the pump to self-prime from a
completely dry condition even with a long suction line. No liquid of any nature is
required to prime the pump and therefore in temporary dry trench conditions the pump
will '
snore'until such time as liquid is available.
It can handle unscreened sewage, trade effluents, thick slurries and solids up to a
normal limitation of 75mm.
The impeller is a 4 bladed, 316 Stainless Steel construction, design fully open. It is
mounted 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 secured
by 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.
Note
If your HH220i pumpset has been mounted on a trailer chassis, it is recommended that
after approximately 5 km of travel that all wheel nuts be inspected and re-tightened.
Sykes Group Pty Ltd

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 by
the 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 and
protective 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.
Note
For engine starting instructions or starting difficulties, refer to the manufacturer's
handbook.
Sykes Group Pty Ltd

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 in
the 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 seating
correctly.
6.4
Pump Dynamic Test
1. Before starting the engine, check that the shaft, pulleys and belt are free to rotate
with the guards in position.
2. Start pump and run completely dry for a minimum period of 10 minutes (initial run up
speed at 900rpm increasing during test to 1100rpm). During this period, generally
check 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 vacuum
of 81kPa (8.3m).
Special Note
Consult engine manufacturers handbook for oil, fuel, speed control and stop details.
Sykes Group Pty Ltd

6.5
Ejector Test
6.5.1 Dri-Prime Ejector Pack Assembly

1. Check ejector and jet sizes:
Nozzle
Jet
23-0414-2036S
23-0415-2016S
2. Clean the jet and nozzle with paraffin or similar cleaner. On no account should
stiff wire be used as this will enlarge the bores.
3. Check the nozzle and jet bores for any sharp edges, burrs or rough surfaces. If
damaged and no replacement is readily available, smooth and polish as well as
possible to original form.
4. Alignment of jet and nozzle is important but this is preset by machining
tolerances.
5. Assemble ejector unit and check performance on test unit. Operation Air
Pressure: 40 psi approx. Minimum Pass Vacuum: 81kPa (8.3m).
6. A satisfactory arrangement for carrying out the performance test on the ejector
unit is a plate fitted with a vacuum gauge as illustrated.
Figure 1 Ejector Exploded Assembly Drawing
Sykes Group Pty Ltd

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 use
abrasive materials or solutions to clean the ejector assembly. Renew all nyltite
seals.
8. Reassemble the complete pump end and non-return valve (refer to Fitting
Instructions).
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 and
flexible couplings.
12. Re-assemble the complete unit.
Sykes Group Pty Ltd

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 any
casting sand and swarf which may be present.
3. Ensure that all items are clean and that the seal faces are free from score or
wear 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 shaft
shoulder).
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 to
position 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.
Sykes Group Pty Ltd

17. Bolt rear outer bearing cover onto the bearing bracket using bolts, spring
washers, flat washers, sealing washers and O-rings. This will locate shaft in
bearing bracket. Ensure shaft turns freely.
18. Fit bearing bracket cover plate.
19. Fit mechanical seal as per instructions outlined in this manual.
Sykes Group Pty Ltd

7.2.2 Centrifugal Pump

1. Slide Mechanical Seal onto shaft. Ensure the locking grub screws are screwed
back clear of shaft refer to mechanical seal section for complete installation
instructions.
2. Before fitting seal onto shaft ensure that all surfaces are clean and that all edges
over which the seal has to pass are rounded off. All working faces must be free
from any foreign matter.
3. Fit rear wear plate to volute using bolts, sealing washers and o-rings
respectively.
4. Fit volute onto Bearing Bracket using studs, nuts and washers. Apply antisieze
grease between mating surfaces.
5. Fit Spacer Ring onto shaft.
6. Before fitting the impeller apply anti-seize compound onto the threads. Screw
impeller onto shaft in a clockwise motion. The recommended grades of anti
seize is: - GA50 Molybond or equivalent (Molybdenum Disulphide).
7. Locate front wearplate onto front adaptor plate using bolt, sealing washer and
o-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 the
front wear plate. When this has been achieved measure the distance between
the front adaptor plate and the volute then add 0.040 (1.00mm / 1.10mm). This
will give you the amount of shims that have to be added to give you correct
clearance between the impeller and front wear plate.
9. Once this measurement has been achieved, remove front adaptor plate and add
appropriate shims. Then re-tighten front adaptor plate onto volute, than re-check
clearances by measuring the distance between the impeller and front wearplate
using feeler gauges. If the clearance is not 0.030 (0.70mm/0.85mm) then
repeat steps 9 & 10 until correct.
Sykes Group Pty Ltd

7.2.3 Ejector Package

1. Check that all items are clean and free from burrs. The jet and nozzle should
only be cleaned with paraffin or similar cleaner. Wire should not be used, as this
will enlarge the bores.
2. Do not use excessive jointing compound when fitting these items and ensure
that 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.
Sykes Group Pty Ltd

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
d) Pump Frame
b) Shaft Sleeve
e) Impeller
c) Stuffing Box Back Plate

f) Studs, Nuts & Bolts
2. Inspect and de-burr pump parts:

a. Replace shaft or repair shaft if worn in secondary sealing area under orings.
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 face
mis-alignment (square to shaft to within 0.13mm TIR and a good surface
to 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 pushing
on the collar & sleeve, making sure that the set screws are engaged in the
sleeve 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 suit
spear point grub screws. (Use Locktite 243)
6. Tighten remaining M6 x 6 Umbrako Grubscrews directly on top of the 6 grub
screws 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 the
sleeve and the seal.
Sykes Group Pty Ltd

9. Make all necessary pump connections and alignments. Hook up appropriate

tangential flush port depending on shaft rotation. (Connect flush in the direction
of 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 fluid
line 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. If
barrier fluid does not seem to be circulating, remove return line to bled
remaining air out of it. Reconnect and re-check flow.
Sykes Group Pty Ltd

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 with
fasteners.
Sykes Group Pty Ltd

7.3
Air Compressor
7.3.1 Description of Compressor
BENDIX AIR
COMPRESSOR
TYPE 2W 440 R.
Introduction: The very high air output of this twin cylinder

single stage air compressor makes it eminently suitable for
use on buses and special purpose heavy duty vehicles. It
has a balanced crankshaft and reed type air inlet and
delivery valves for greater efficiency and reliability at high
operating speeds.
It is available in either base or flange mounted versions
which are suitable for gear, belt, or shaft drive from the
vehicle engine.
The crankcase and cylinders form a single rigid weight
saving casting. The cylinder barrels are air cooled while
the cylinder head is cooled by water circulated from the
vehicle engine cooling system. The compressor may be
run in either direction of rotation at speeds of up to 2400
r.p.m. to deliver up to 9 bar pressure (130 p.s.i.) For
sustained operation at higher delivery pressures please
consult our Technical Services Department.
An unloader mechanism may be incorporated in the
cylinder head. In its absence, pressure regulation is by an
air delivery line mounted unloader valve, or by a D2
Governor used in conjunction with an AD2 Air Dryer. The
air inlet and delivery valves are contained in a valve plate
fitted between the cylinder barrels and the cylinder head.
The compressor lubricating oil is circulated under pressure
from the vehicle engine lubricating oil system.
Every effort has been made to ensure that the information in this
leaflet is correct but we reserve the right to amend or change this
information without notice.
Sykes Group Pty Ltd


Construction: Refer to Figs. 1 and 4. In Fig. 1 A is the
reed valve plate and B is the cast aluminium cylinder head
which is partially finned to assist cooling. C is the air
delivery connection and there are cooling water connections
at 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 the
cylinder head and valve plate, and two between the valve
plate and the finned cast iron cylinder/crankcase unit J.
The two aluminium pistons K each have two piston rings L
and an oil control ring M. The piston pins N are retained by
the circlips P. The front end of the forged steel crankshaft Q
runs in the ball bearing R. The front end cover S also carries
the crankshaft oil seal T.
The connecting rods U are made from a forged light alloy
which forms an excellent bearing surface. The rods run
directly 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 and
runs in a white metal bearing bush W. The rear end cover X
is threaded at Y for a lubricating oil connection from the
vehicle engine. Engine oil under pressure then flows
through drillings in the crankshaft to the main bearing at W
and to the big end bearings. The ball bearing R and the
other internal surfaces are lubricated by oil splash and mist.
The oil drains back to the vehicle engine through the open
bottom of the compressor crankcase.
General Specification:
Bore
Stroke
Swept Volume
Maximum Recommended Speed
Maximum Recommended Delivery
Pressure
Operating temperature Range
Maximum Continuous delivered
Air Temperature
(See '
Installation'
)
Weight
75mm
50mm
3
441.6 cm
2400 r.p.m.
9bar (130 p.s.i.)
-40C to + 80C
220C
19.5 kg
Also refer to the performance charts in Fig. 2.

Installation:
Standard ISO and DIN symbols for air
compressors in pnuematic circuit diagrams are shown in Fig.
3. Because of the range of mounting and driving options the
dimensions in Fig. 4 are typical only. Our Technical
Services Department will supply detailed dimensions and
information for each particular application. The Department
should also be consulted if it is desired to mount the
compressor at an appreciable angle. The compressor
should be mounted where the maximum air flow will pass
over it to help in ensuring that the delivered air temperature
does not exceed 220C.
The cylinder/crankcase unit may be flange mounted instead
of base mounted as in Fig. 4. Details are available on
request.
Sykes Group Pty Ltd

Maintenance: Before working on or around air

brake systems and components always observe the
following precautions:
a)
b)
c)
d)
e)
f)
g)
Stop the engine before working under a

vehicle.
Always chock the vehicle wheels,
because depleting the vehicle air system
pressure may cause the vehicle to roll.
Keep hands away from actuator push rods
and slack adjusters. They may apply as
the system pressure drops.
Never connect or disconnect a hose or
line containing air pressure. It may whip
as air escapes.
Never remove a component or pipe plug
unless you are certain all system pressure
has been depleted.
Never exceed recommended air pressure.
Always wear safety glasses when working
with air pressure. Never look into air jets
or direct them at anyone.
Sykes Group Pty Ltd
h)
i)
j)
Never attempt to dismantle a component

until you have read and understand
recommended procedures.
Some units contain powerful springs and
injury can result if not properly dismantled.
Use only the correct tools and observe all
precautions pertaining to the use of these
tools.
At vehicle service intervals check the compressor

for any leakages of water, oil, or air. If the
compressor is slow to build up pressure the
cylinder head and valve plate may be removed.
The condition of the valve assemblies and the
cylinder bores may then be checked and any
excessive build up of carbon removed. Service
Kits of replaceable items are available on request.

7.3.2 Fitting Instructions Compressor Assembly

1
Ensure all items are clean and that the hoses are free from foreign matter.
Do not use excessive jointing compound (eg. Stag, Neolite, Non-Adhesive

Hermatite etc) when fitting these items and ensure that it does not enter the
bores. This may cause a blockage in the oil or air lines.
Fit gasket to the compressor position on adaptor and secure with fasteners.
Secure the compressor pulley to the compressor with the nut and spring
washer. Remove the taperlock bush from the pump pulley then pass the
pulley over the shaft. Ease the belt over the pulleys, and fit the key. Align
the pulleys then refit the taperlock bush to the pump pulley and secure it to
the shaft.
Remove and discard four cylinder head screws from the compressor and
ensure the compressed air port is located at the opposite end to fan.
Connect the compressed air hose between the compressor and the jet
sleeve.
Fit the oil pipe fittings to the compressor.
Connect air intake fittings.
Secure the guard with screws. Ensure that the belt and pulleys are free to
rotate.
7.3.3 Compressor Belt Replacement

Timing Belt Procedure
1.
Remove pulley guard set screws and pump support nuts and draw pump
assembly 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 is

necessary. The normal operating air pressure is 3.44 - 5.17 bar (50-75psi).
Sykes Group Pty Ltd

Link Belt Procedure

1
Remove pulley guard and old belt.
Place belt around pulleys without creating any tension.
Count the number of links and remove 7% (1 in 14).
Place belting around pump shaft and link up.
Fit around drive pulley and over compressor pulley rotating the drive shaft
slowly.
The normal operating air pressure is 2.75 - 4.13 bar (40-60psi).
Sykes Group Pty Ltd

7.3.4 Compressor Parts List

Ref.
Description
Part Number
Bendix Air Compressor 2W 440 R KZ1087/14
49-0523-9915
A
B
C
D
E
F
G
H
Valve Plate Assembly c/w Reed Valve Kit & Air Inlet Valve
Cylinder Head
BSP Threaded Air Delivery Connection
Threaded Water Cooling Ports
BSP Threaded Air Inlet
Reed Valve Kit
Air Inlet Valve 229502
Valve Plate & Head Gasket Kit
KY2331/1SP
KZ1160/3
Cylinder Body
Piston Assembly (STD)
(KW5172/1SP)
Piston Assembly
Piston Assembly
Piston Ring Set (STD)
Piston Ring Set (0.010 o/s)
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Comprising: Cyl.Head Gasket KX2466/2

Top Plate Gasket KX2799/2
Lower Plate Gasket KX2280/2
Oil Control Ring

Set
Connecting Rod Pin Rod Pin Snap Pin
-
Sykes Group Pty Ltd
SK2997/1
KZ1094/1
1189082SP
(KW5172/2SP)
(KW5172/3SP)
(SKR2790/00)
(SKR2790/10)
(SKR2790/20)
Included in Piston Assy & Piston Ring
Included in Piston Assembly

Included in Piston Assembly
Crankshaft
Ball Bearing (NSK-6307-CE)
Front End Cover
O-Ring, Inner Bearing Cover
Crankshaft Oil Seal (CR13938)
Con Rod Complete
(KW4785/1SP)
Thrust Washer
White Metal Bearing Bushing
End Cover Assembly c/w Bushing
C Ring - End Cover
Lubricating Oil Inlet 1/8 BSP
Base Mount Gasket 0.8mm
Base Mount Gasket 0.4mm
SK2955/1
1189255SP
1189256SP
SKR2962/00
SKR2962/10
SKR2962/20
SKR2962/30
KY2258/1SP
1194120SP
KX2491/1
1189619
267805
1194120SP
KY2372/1
I811560066
KX1223/13SP
1189571
KX2542/1
KX2542/2

Sykes Group Pty Ltd

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
- Pumps priming system blocked or badly
worn
- Separation tank cover blocked
- Pumps priming hose leaking air
- Pumps priming system not delivering
sufficient air
- Pumps priming system belt drive faulty
Not Enough Liquid
Sykes Group Pty Ltd
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


Not Enough Pressure
Likely Cause
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 Deliver

Liquid After a Time
Pump Takes Excessive

Power
- 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 at
Mechanical Seal Housing
- Mechanical seal damaged or worn
Pump Bearings Have Short

Life
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
Sykes Group Pty Ltd

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 fitted
front-to-front instead of back-to-back
Dirt in bearings
Rusting of bearings from water in
housing


Pump Vibrating or
Overheating
Likely Cause
-
Sykes Group Pty Ltd
Engine speed too high

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 fitted
front-to-front instead of back-to-back
Dirt in bearings
Rusting of bearings from water in
housing

9 PUMP UNIT SUB-ASSEMBLY

H
Volute
BB
Bearing Bracket
ST
Separation Tank
EP
Ejector Pack
OR
Glycol Reservoir
AC
Compressor Assembly
AC
EP
OR
ST
BB
Figure 19 Typical HH220i Pumpend
Sykes Group Pty Ltd

Figure 20 HH220i General Assembly Drawing
Sykes Group Pty Ltd

10 PARTS LIST
10.1 Recommended HH220i Pump Spare Parts
Description
Impeller
Front Wear Plate
Stuffing Box Plate
Stuffing Box Plate Gasket
Shim - 0.25mm
Shim - 0.40mm
Shim - 0.80mm
Shim - 1.60mm
Mechanical Seal
Shaft Sleeve
Roller Bearing
Ball Bearing Angular Contact
Shaft
Sykes Group Pty Ltd
Part Number
12-0325-3015
12-0185-0115
12-0196-0115
98-430-807-162
38-0200-5413
38-0200-5423
38-0200-5433
38-0200-5443
001-1007JC
28-0210-3215
39-0094-9912
39-0091-9912
16-0200-8011-BU
Quantity
1
1
1
1
2
2
2
2
1
1
1
2
1

10.2 Volute Parts List
Figure 21 Volute Mechanical Seal Exploded Assembly Drawing
Sykes Group Pty Ltd

VOLUTE PARTS LIST

Illustration
number
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H13a
H13b
H16
H18a
H18b
H18c
H18d
H19
Not Shown
Description
Volute Body
Impeller
Front Wear Plate
Stuffing Box Plate
Adaptor Plate
Stud (M16 x 50)
Nut (M16)
Seal Washer (M16) & O Ring
Part Number
Quantity
11-0200-0115
12-0325-3015
12-0185-0115
12-0196-0115
10-0200-0000
1
1
1
1
1
4
4
4
38-0790-4412
38-0792-4412
Capscrew (M24 x 40)

Spring Washer (M24)
Flat Washer (M16) S/S
Spring Washer (M16)S/S
Gasket
Shim 0.25mm
Shim 0.4 mm
Shim 0.8 mm
Shim 1.6mm
Plug BSP
Epoxy Adhesive
98-430-807-162
38-0200-5413
38-0200-5423
38-0200-5433
38-0200-5433
P12
AC-068
12
12
2
2
1
A/R
A/R
A/R
A/R
2
1
MECHANICAL SEAL
Illustration
Description
number
H11
Shaft Sleeve (modified)
H12
Mechanical Seal
H14
Bolt (M16 x 20) S/S
Part Number
Quantity
28-0210-3215
001-1007JC
1
1
2
Part Number
Quantity
28-0200-3215
14-0300-0115
1
1
2
2
1
PACKED GLAND
Illustration
number
H11
H12
H14
H15
H17
Description
Shaft Sleeve
Gland followers (set of 2 halves)
Nut (M16) S/S
Stud (M16 x 65) S/S
Gland packing -
Sykes Group Pty Ltd
638-4003G

Figure 22 Volute Packed Gland Exploded Assembly Drawing

Sykes Group Pty Ltd

VOLUTE PARTS LIST

Illustration
number
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H13a
H13b
H16
H18a
H18b
H18c
H18d
H19
Not Shown
Description
Volute Body
Impeller
Front Wear Plate
Stuffing Box Plate
Adaptor Plate
Stud (M16 x 50)
Nut (M16)
Seal Washer (M16) & O Ring
Part Number
Quantity
11-0200-0115
12-0325-3015
12-0185-0115
12-0196-0115
10-0200-0000
1
1
1
1
1
4
4
4
38-0790-4412
38-0792-4412
Capscrew (M24 x 40)

Spring Washer (M24)
Flat Washer (M16) S/S
Spring Washer (M16)S/S
Gasket
Shim 0.25mm
Shim 0.4 mm
Shim 0.8 mm
Shim 1.6mm
Plug BSP
Epoxy Adhesive
98-430-807-162
38-0200-5413
38-0200-5423
38-0200-5433
38-0200-5443
P12
AC-068
12
12
2
2
1
A/R
A/R
A/R
A/R
2
1
MECHANICAL SEAL
Illustration
Description
number
H11
Shaft Sleeve (modified)
H12
Mechanical Seal
H14
Bolt (M16 x 20) S/S
Part Number
Quantity
28-0210-3215
001-1007JC
1
1
2
Part Number
Quantity
28-0200-3215
14-0300-0115
1
1
2
2
1
PACKED GLAND
Illustration
number
H11
H12
H14
H15
H17
Description
Shaft Sleeve
Gland followers (set of 2 halves)
Nut (M16) S/S
Stud (M16 x 65) S/S
Gland packing -
Sykes Group Pty Ltd
638-4003G

10.3 Bearing Bracket and Shaft Parts List
Figure 23 Bearing Bracket Exploded Assembly Drawing

Sykes Group Pty Ltd

BEARING BRACKET & SHAFT PARTS LIST

Illustration
Number
BB1
BB2
BB3
BB4
BB5
BB6
BB7
BB8A
BB8B
BB9
BB10
BB11
BB12
BB13
BB14
BB15
BB16
BB17
BB18
BB19
BB20
BB21
BB22A
BB22B
BB23
BB24
BB25
BB26
BB27
BB28A
BB28B
BB29
BB30
Description
Bearing Bracket
Bearing Cover Outer Rear
Bearing Cover Outer Front
Bearing Cover Inner
Roller Bearing 90 X 190
Angular Ball Bearing 85 X 180
Bolt (M12 x 160)
Flat Washer (M12)
Spring Washer (M12)
Bolt (M12 x 100)
Bolt (M12 x 40)
Bolt (M12 x 180)
Spiroseal 90 x 110
Clamp Ring
Socket Capscrew (M6 x 20)
Shaft
Lock Nut Bearing
Lockwasher Bearing
Bearing Spacers (Pair)
Spiroseal 75 x 95 x 10
Bearing Bracket Cover Joint 1.6mm
Stud (M20 x 70)
Flat Washer (M20)
Spring Washer (M20)
Nut (M20)
Plug 3/8 BSP
Plug 1/8 BSP
Bearing Bracket Cover Plate
Bolt (M12 x 40)
Flat Washer (M12)
Spring Washer (M12)
Sealing Washer (M12)
O-Ring 10.69 x 3.53 Viton
Part Number
Quantity
13-0164-0115
13-0169-0125-BU
13-0162-0115
13-0170-0115-OIL
39-0094-9912
39-0091-9912
1
1
1
1
1
2
3
9
9
3
3
3
1
1
1
1
1
1
1
1
1
8
8
8
8
1
1
1
4
4
4
4
4
38-1331-9912
28-0252-8811
16-0200-8011-BU
39-0096-9912
39-0097-9912
24-0093-8831
38-1328-9912
XH80BBJ-160
P06
P02
27-0200-8211-OIL
* 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 of
the inner races facing each other.
Sykes Group Pty Ltd

10.4 Separation Tank / Ejector Package Parts List
Figure 24 Separation Tank & Ejector Package

Exploded Assembly Drawing
Sykes Group Pty Ltd

EJECTOR PACKAGE PARTS LIST

Illustration
Number
EP1
EP2
Description
Ejector Nozzle
Ejector Jet
Part Number
Quantity
23-0414-2036S
23-0415-2016S
1
1
SEPARATION TANK PARTS LIST

Illustration
Number
ST1
ST2
ST3
ST4
ST5
ST6
ST7
ST8
ST9
ST10
ST11
ST12
ST13
ST14
Description
T Piece
Tank/Body Joint
Stud (M20 x 70)
Nut (M20)
Lockwasher (M20)
Carrier Plate
Carrier / Tank Stud (M12x 50)
Springwasher (M12)
Nut (M12)
Ball Seat
Ball
Carrier Plate Plug 1 B.S.P.
Fitter
BSP Elbow - Hosetail
Sykes Group Pty Ltd
Part Number
Quantity
348-4008
500-5003
1
2
8
8
8
1
4
4
4
1
1
1
1
1
23-0411-0115
23-0412-2011
39-0641-4113
P16
23-0413-2113
E12SBF

10.5 Glycol Reservoir Parts List
Figure 25 Glycol Reservoir Exploded Assembly Drawing
Sykes Group Pty Ltd

GLYCOL RESERVOIR PARTS LIST

Illustration
Number
OR1
OR2
OR3
OR4
OR5
OR6
OR7
OR8
OR9
OR10
OR11
Description
Part Number
Quantity
Glycol Reservoir Assembly

Lid
Sight & Temperature Gauge
Hydraulic Nipple BSP
Reservoir Gasket
Nut (M12)
Springwasher (M12)
Plug (with breather)
Glycol Reservoir Hose Length 1
Glycol Reservoir Hose Length 2
Hose Clamps to suit reservoir hose
Nut & Hose Tails to suit
reservoir hose
Bolt (M10 x 30)
Flat Washer (M10)
Spring Washer (M10)
27-5000-8211
1
1
1
Sykes Group Pty Ltd
40-0000-0060
N04H
38-0350-5443
P08
1-319-0006
1-319-0006
OTK1011
HT0404
1
1
1
1
650mm
550mm
4
4
4
4
4

10.6 Compressor Parts List
Figure 26 - Compressor Assembly Drawing
Sykes Group Pty Ltd

COMPRESSOR PARTS LIST

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

10.7 Non Return Valve Parts List
Figure 27 Non Return Valve Explode Assembly Drawing
NON RETURN VALVE PARTS LIST

Illustration
Number
V1
V2
Description
Flexi-Check Valve 200mm
Flexi-Check Valve Flap 200mm
Sykes Group Pty Ltd
Part Number
Quantity
10-0000-0480
10-0000-0485
1
1

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
14 Flywheel Stub Shaft (3 shaft)
2
3
RFC280 Flex Coupling c/w 3535TLB to

suit shaft 75mm & 3
Inbuilt 24 hour Fuel Tank (2350 litres)
Discharge Pressure Gauges
8 Non Return Valve
6
7
6 Crane Geared Operated Butterfly

Valve
Hydro Flow Valve (Fuel)
Night Lights 2 only
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
14
Traffolyte Pump Operating Sign

(Recommended Pump Operating
Pressures at Various Speeds)
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)
AC-057
For further information please refer to the manufacturer's Operation and

Maintenance Manuals.
Sykes Group Pty Ltd

12 DIESEL ENGINE MANUAL

Your HH220i pumpend is driven by a ?? Liquid Cooled Diesel Engine
and comes complete with the following.
Description
Part Number
Mines Wiring to MDG-15
Water Separator Filter
Emergency Stop
Murphy Control Panel Gauges
Clip Type Lagging on Exhaust Pipes

Sykes Group Pty Ltd

13 ELECTRIC MOTOR MANUAL

Your HH220i pumpend is driven by a ??kW / ?Pole / IP?? / ?Phase /
???V Electric Motor and comes complete with the following.
Description
Part Number

Sykes Group Pty Ltd


HH220i Smaster Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

HH220i Smaster Manual

Hochgeladen von

Copyright:

Verfügbare Formate

Customer :

Sykes HH220i Installation, Operation & Maintenance Manual

TECHNICAL DATA SHEET

HOW TO READ A PERFORMANCE CURVE

Example Sykes CP150 Pump Curve

RISK ASSESSMENT GUIDE

RISK ASSESSMENT HH220i

PUMP OPERATING INSTRUCTIONS

Description of Pump Unit

Procedure Prior to Pump Start Up

Failure to Prime Pump

Pump Dynamic Test

Dri-Prime Ejector Pack Assembly

General Pump Inspection Procedure

Pump Assembly Instructions

Pump Bearing Bracket

Non Return Valve Inspection Procedure

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

Fitting Instructions Compressor Assembly

Compressor Belt Replacement

Trouble Shooting Guide

PUMP UNIT SUB-ASSEMBLY

Recommended HH220i Pump Spare Parts

Volute Parts List

Bearing Bracket and Shaft Parts List

Separation Tank and Ejector Package

PUMP UNIT ACCESSORIES

DIESEL ENGINE MANUAL (if applicable)

ELECTRIC MOTOR MANUAL (if applicable)

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

Oil Lubricated Bearings

Sykes Group Pty Ltd

Valvoline Multi Lube Lithium

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

2 TECHNICAL DATA SHEET

SG Iron To AS1831 Grade 400/12

SG Iron To AS1831 Grade 400/12

SG Iron To AS1831 Grade 400/12

Sykes Group Pty Ltd

Grease or oil. Please refer to

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

Sykes Group Pty Ltd

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

3 HOW TO READ A PERFORMANCE CURVE

Example Sykes CP150 Pump Curve

Sykes Group Pty Ltd

Difference in elevation between liquid level of the

Spare Parts & Service 24 hours: 1800 131950

Sykes HH220i Installation, Operation & Maintenance Manual

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

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

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

Pump Speed Curve = 2000rpm.

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

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

Dynamic Suction Lift Available (DSLA)