SN 1230084-1 Raja L100-Mv150ic X c2.2t - PT Trakindo Utama
SN 1230084-1 Raja L100-Mv150ic X c2.2t - PT Trakindo Utama
SN 1230084-1 Raja L100-Mv150ic X c2.2t - PT Trakindo Utama
RAJA-L100
Customer:
Reference:
PT Trakindo Utama
1200030084-1
WORK O/NO.
PUMP SPECIFICATION
WO1200030084
REVIEWED BY
DATE REQUIRED 26/07/2012
COMPLETED BY COB
CUSTOMER
P.T.TRAKINDO UTAMA
DATE
10/05/2012
CUST O/NO
TU7208-01/02/03/04/05/06
SYKES REF
816694
MODEL NO
C2.2T
PUMP
QTY
CP150iC
MATERIAL
STD
ENGINE
CAT
DETAILS
DISCHARGE
PRIMING
COMPRESSOR
NRV
STANDARD EXTRAS
SINGLE POINT LIFT - GAL
QTY
TRAILER
QTY
SKID
RING/BALL
SITE/ROAD
FUEL SENDER
SINGLE/DUAL
BULLBAR - HD
ENGINE CANOPY - GAL
L/CRUISER
FUEL TANK
2 JACK STANDS
FUEL BUND
4 JACK STANDS
DBL SKIN
QTY
QTY
JOCKEY WHEEL
6
INTEGRAL
PONTOON
FULL CANOPY
BOLT ON
STD/HEAVY DUTY
DROP DISCHARGE
GALVANISED
BISALLOY SKID
QTY
DETAILS
80 L PLASTIC FUEL TANK
GALVANISED BASE CHASSIS
SUCTION HOSE
QTY
DISCHARGE HOSE
DETAILS
DETAILS
CAT YELLOW PUMPEND
CE MARKING
ADDITIONAL DETAILS/EXTRAS
QTY
TABLE OF CONTENTS
1.
INTRODUCTION
2.
CUSTOMER SPECIFICATION
3.
4.
4.2
Generalisations
4.3
Radial Thrust
4.4
Cavitation
5.
6.
7.
8.
Delivery Inspection
8.2
8.3
8.4
8.5
Pre-Start Checks
8.6
Starting Procedure
9.
10.
10.2
10.3
Air Leaks
10.4
10.5
Ejector Test
10.5.1
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11.
11.2
11.3
11.2.2
Centrifugal Pump
11.2.3
Ejector Package
11.2.4
Mechanical Seal
11.2.5
11.2.6
11.3
12.
Air Compressor
11.3.1
Preface
11.3.2
General Description
11.3.3
Performance Chart
11.3.4
Operation
11.3.5
Accessories
11.3.6
Piping
11.3.7
Installation Dimensions
11.3.8
Maintenance
11.3.9
11.3.10
12.1
13.
14.
PARTS LIST
14.1
14.2
14.3
14.4
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14.5
14.6
14.7
14.8
Chassis Accessories
15.
16.
17.
18.
19.
19.2
19.3
19.4
pH Compatibility Chart
19.5
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1 INTRODUCTION
Congratulations on the purchase of your new Sykes Pump.
With Sykes established quality control systems you can be assured your pump
was manufactured with a high level of control and has undergone extensive
testing on Sykes certified test facility.
Sykes are pleased to offer a 12 month warranty on your new pump. As with all
warranties, Sykes warranty is subject to regular maintenance as per the pump
manual. To ensure your warranty is maintained, make sure your pump is regularly
serviced. Sykes offer maintenance and repairs on our entire range and are able
to offer regular service agreements if required.
Sykes provide local service through a highly trained network of branches and are
able to meet your service and spare parts requirements around the clock. For
spare parts or service enquiries contact Sykes spare parts direct on 1800 131
950. Turnaround on parts is rapid with Sykes customer service ready to meet
your needs 24 hours a day with spare parts located at branches Australia wide
and around the globe.
Sykes also offer onsite application assistance and training to ensure your pump is
running at its optimum performance. Our Sykes trained staff will assess your
application and help to set up optimum operating settings which will help to
reduce unnecessary wear and tear on the pump whilst ensuring the pump is
operating at its most efficient duty point.
Should you have any after sales issues, please do not hesitate to contact your
local Sykes branch or contact Sykes After Sales Service on 02 4954 3333.
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2 CUSTOMER SPECIFICATION
General Unit Information
Customer
Sykes Job Number
Sykes Serial Number
Plant Number
Pump Information
Pump Type
Pump Size
Pumpend Serial No.
Impeller Diameter
Engine Information
Engine Make
Engine Serial Number
Tacho Serial Number
PT Trakindo Utama
WO1200030084
12CP150iC30084-1
MV150iC
150mm x 150mm
1230236-1
255mm
CAT C2.2T
C8Y00787
945 kgs
1015 kgs
80 ltrs
Trailer Information
VIN Number
Tyre Type
Axle Set Up
Pump Extras
Additional Information
Gearbox Serial Number
Control Panel Serial Number
K452211
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MV150iC Contractor
Diesel Drive
Compressor Prime Pump
MATERIALS OF CONSTRUCTION
DESIGN DETAILS
Pump Casing:
Pump Designation:
Suction Cover:
Pump Description:
Tee Piece:
Bearing Bracket:
Pump Shaft:
Impeller:
Wear Plates:
Air Injector:
Mechanical Seal:
Non Return Valve
Compressor Pulley:
Drive Pulley:
Belt Section:
Compressor Details:
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:
Ejector Details:
Jet:
23-0568-2016
Nozzle: 23-0571-2016
Bearing Lubrication:
MV150i Contractor
Centrifugal Single Stage,
Volute Type, 2 Bladed Fully
Open Impeller.
150mm Table D
150mm Slotted Table D or E
16mm
40mm
161mm
255mm
255mm
77mm
MIN: 1400rpm MAX: 2200rpm
44m
162l/s
Drive End:
33111Q Tapered Roller
Pump End:
33111Q Tapered Roller
Grease Lubrication Multi Lube
Lithium Grease EP Additives
NLGI #2 or Equivalent
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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:
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2)
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)
5)
6)
7)
8)
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4.2
Generalisations
(1) Flow (l/s) decreases, as Total Head (m) increases.
(2) Flow (l/s) increases, Power used increases.
4.3
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.
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4.4
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.
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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
CONSEQUENCES
PROBABILITY
A
11
12
16
13
17
20
10
14
18
21
23
15
19
22
24
25
Risk
1 to 3 - Red
Critical
4 to 10 - Yellow
High
11 to 15 - Blue
Medium
16 to 25 - Green
Low
A
B
C
D
E
Probability
Almost Certain
Likely
Occasional
Unlikely
Rare
5
4
Injury
Could cause injury
st
Could cause 1 Aid Injury
Environmental
No detrimental effect
Temporary or minor damage e.g. minor oil spill
Substantial temporary or minor permanent
damage e.g Minor water discharge
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Hazard
Initial Risk
P
C
Risk
C
Operation of Pumpset
Residual Risk
P
C
Risk
E
21
13
16
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Activity
Operation of Pumpset
Hazard
Boom movement (Suction
Hose Boom) pinch points &
crushing
Initial Risk
C
Operation of Pumpset
Operation of Pumpset
Residual Risk
D
12
12
17
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Activity
Operation of Pumpset
Hazard
Possible electrocution
electric shock and burns
Initial Risk
C
13
(Diesel Driven)
Operation of Pumpset
Possible electrocution
electric shock and burns
Residual Risk
21
17
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Activity
Maintenance Electrical
Battery charging
Hazard
Possible explosion burns
and bodily injuries
Initial Risk
B
Maintenance - Electrical
Possible electrocution
electric shock and burns
17
21
21
Residual Risk
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Activity
Maintenance - mechanical
Hazard
Engine, hydraulic pump and
centrifugal pumpend
maintenance explosion,
burns, pinch points, skin
irritation
Initial Risk
C
18
Residual Risk
21
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Customer Name:
Customer Representative:
Sykes Representative:
Pump Type:
Pump Serial Number:
Date of Commissioning:
Form: WP-04
Revision: 3
Date Issued: 28 September 2004
Commission Completed
Satisfactory:
YES
NO
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8.1
Delivery Inspection
Satisfactory
Yes
No
Defects
Action Taken
Comments
Date
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8.2
Defects
Action Taken
Comments
Date
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8.3
A
B
C
D
E
F
G
H
I
J
Defects
Action Taken
Comments
Date
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8.4
A
B
C
D
E
F
G
Defects
Action Taken
Suction Vacuum
Gauge
Comments
Pump Operating
Chart
Pressure Bleed
Valve
Date
Discharge
Pressure Gauge
Butterfly Control
Valve
Recommended Pump Set Up
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Defects
Action Taken
Comments
Date
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Defects
Action Taken
Comments
Date
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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.
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Special Note
Consult engine manufacturers handbook for oil, fuel, speed control and stop
details.
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
Pump end
Check for mechanical seal leaks
Change mechanical seal oil
Change mechanical seal
Check coupling alignment & condition
Change pump coupling rubber/s
Check/Adjust wet end clearances
Change pump wet parts, impeller / wear plates
Check bearing temperature
Check bearing end float
Replace pump shaft bearings
Check pump shaft seals
Change pump shaft seals
Check impeller for visual blockages
Replace volute
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Ancillaries
Check non return valve
Change non return valve seat/flap
Check vacuum gauge
Change vacuum gauge
Check pressure gauge
Change pressure gauge
Check gear box butterfly valve
Change gear box butterfly valve
Check all oil, water and air hose's condition
Check condition of hose coupling o-rings
Check for all mounting bolts, skid, chassis
Check shut down operations engine and pump
All guarding
For diesel servicing and panel operational checks.
250 hours 500 hours 750 hours 1,000 hours 6,000 hours
As Required
3 Months 6 months 9 months 12 months
3 years
= Daily Check
= Minor Service
= Major Service
= As Required
Notes:
1 Ancillaries are not included in major service schedule / pricing, please contact Sykes for assistance
2
Please refer to Service Schedule for detailed parts, service checks and labour information
Follow minor and major schedules outlined in Sykes Service Schedule. Use the service hours or
calendar time, whichever occurs first, in order to determine the maintenance intervals.
If the pump is operated in ambient temperatures below -180C or above 380C and / or under severe conditions, perform maintenance at shorter
intervals. Severe services includes the following conditions; high temperatures, continuous high loads, vibration and dusty conditions.
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Grease Point
Grease Relief
Nipple
Notes:
1. Single point grease point to grease 2 off 33111 bearings
2. Single point grease relief nipple
3. Grease relief nipple set at 3 - 5 psi
4. Grease Specification: Multi Lube Lithium Grease EP Additives NLGI #2
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Operating Conditions:
Ambient Temperature
20 0C
Humidity / Dust
Moderate
Vibration
Moderate
Load
Moderate
1400 rpm
44 0C
5.2 grams
Speed
Bearing Temperature
1500 rpm
46 0C
5.2 grams
Speed
Bearing Temperature
1600 rpm
44 0C
5.6 grams
Speed
Bearing Temperature
1700 rpm
48 0C
7.0 grams
Speed
Bearing Temperature
1800 rpm
50 0C
8.4 grams
Speed
Bearing Temperature
1900 rpm
52 0C
9.4 grams
Speed
Bearing Temperature
2000 rpm
54 0C
9.6 grams
Speed
Bearing Temperature
2100 rpm
56 0C
10.0 grams
Speed
Bearing Temperature
2200 rpm
60 0C
10.4 grams
!WARNING!
Use this re-greasing schedule as a guide only.
Re-greasing quantities will change due to variances in Operating Conditions.
For re-greasing schedules to suit particular Operating Conditions please
contact Sykes for assistance.
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Operating Conditions:
Ambient Temperature
40 0C
Humidity / Dust
High
Vibration
High
Load
Heavy
1400 rpm
52 0C
10.4 grams
Speed
Bearing Temperature
1500 rpm
54 0C
16.0 grams
Speed
Bearing Temperature
1600 rpm
56 0C
16.8 grams
Speed
Bearing Temperature
1700 rpm
58 0C
21.2 grams
Speed
Bearing Temperature
1800 rpm
60 0C
25.4 grams
Speed
Bearing Temperature
1900 rpm
62 0C
25.8 grams
Speed
Bearing Temperature
2000 rpm
64 0C
26.0 grams
Speed
Bearing Temperature
2100 rpm
66 0C
26.6 grams
Speed
Bearing Temperature
2200 rpm
70 0C
28.0 grams
!WARNING!
Use this re-greasing schedule as a guide only.
Re-greasing quantities will change due to variances in Operating Conditions.
For re-greasing schedules to suit particular Operating Conditions please
contact Sykes for assistance.
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14. Joints having a thickness of this gap measurement plus 0.5mm should be
fitted between the pump body and front cover. After fitting joints secure the
pump body and the front cover with fasteners.
15. Check that the gap between the front wear plate and the impeller is between
0.3mm and 0.6mm and the impeller rotates freely.
16. Fit fasteners.
17. If pump units are to remain unused for a long time all adjacent clearance
surfaces should be sprayed with a coating of 'Molyprotectoslip' to prevent
rust or seizure.
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17. Fill oil chamber with SAE 20/20 grade of oil and check assembly rotates freely.
18. Rebuild pump casing assembly onto adaptor.
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Please note that the bolts must be tightened alternately (diagonal opposites)
in several steps until they have all reached the correct tightening torque.
Finally the tightening torque of all bolts must be checked all around.
2. Measure from engine bell housing to aluminium ring.
3. Install shaft key.
4. Slide driven hub onto shaft.
5. Fit vulcanised ring (rubber disc) with cap screws (supplied with coupling
(refer to Photo 4)) without washers.
6. Measure from pump engine adaptor flange to vulcanised ring so that
vulcanised ring locates centrally in aluminium ring (refer to Photo 5 & 6)
when assembled.
7. Tighten cap screws slightly.
8. Re-check measurement and adjust if necessary.
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Please note that the bolts must be tightened alternately (diagonal opposites)
in several steps until they have all reached the correct tightening torque.
Finally the tightening torque of all bolts must be checked all around.
10. Re-check measurement.
11. Assemble mating coupling part (pump / engine) ensure that teeth are
properly engaged (refer to Photo 9).
12. If any issues are encountered during Centamax SB coupling installation
contact Supervisor and fill in relevant Quality Action Report.
Photo 1
Photo 2
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Photo 4
Photo 3
Equal
Distance
Equal
Distance
Photo 5
Photo 6
Photo 7
Photo 8
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Photo 9
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This manual provides the owner with the necessary instructions to maintain its
compressor properly, so that the Customer gets the best service from it.
Hence, the owner is requested to go through the contents of the manual & become
well acquainted with the instructions herein.
In case any question arises related to the equipment or the manual the customer is
requested to contact the aftermarket division of SYKES GROUP PTY LTD.
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75 mm
Stroke
50 mm
Swept Volume
37.4 CFM
2400 RPM
-400C to +800C
2000C
Weight
20 Kg
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1150 rpm
Free Air Delivery
M ODEL : 2SC15
SIZE
: 50 & 50 x 75
20
19
18
17
15.35
16
14.38
15
13.41
14
12.61
13
12
11
10
0
10
1150 rpm
Motor BHP
M ODEL : 2SC15
SIZE
: 50 & 50 x 75
3.71
Motor (BHP)
3.31
2.95
2.61
0
0
10
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11.4.4 Operation
The following instructions should be used by the operator as a guide for the
general operation of the compressor. As the operator gains experience with the
compressor under actual conditions, a set routine should be established. After a
general overhauling or installation of new parts, the operator should be guided by
the instructions as though the compressor was new.
Initial Start:
IMPORTANT
It is very important that the intake piping be clean and properly installed. It is
essential that this be done after installation or relocation of the compressor and
after a long shutdown or new parts installation
Preparation
When the installation of the compressor has been completed in accordance to the
instructions given, carry out the following procedure before starting the machine.
1. Clean up the base from vehicle, and remove oil, dirt and dust from the exterior
of the compressor.
2. Remove the air head and clean out with safety solvent every portion of the
interior and the crankcase oil sump to ensure a clean interior, free from dust
and dirt, which may have entered during shipping and installation. Never use
waste or a linty cloth to clean the interior of the machine.
The running and finished parts inside the crankcase are covered with a heavy antirust compound previous to shipment. It is not necessary to remove this coating
before starting the compressor, as it is soluble in the pump lubricating oil.
3. Fill the crankcase to the proper oil level on the oil sight glass with the
recommended grade of crankcase lubricating oil. Pour oil over all the bearings,
which can be easily reached through the frame or openings. On lubricated
units, fill the cylinder lubricator with the recommended grade of air cylinder
lubricating oil.
4. Prime the frame lubricating oil pump.
5. On lubricated units each cylinder force feed lubricator line must be
disconnected at the point where it is attached to the oil inlet side of the check
valve. The lubricator feeds must then be operated manually until all the air is
forced out of the lines and oil appears. The lines should now be reconnected
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and the lubricator given several additional turns to assure proper lubrication of
the cylinder as soon as the compressor is started. Once the compressor is
started, the oil lines will remain full of oil and require no further attention.
6. Drain the air intake pipe of any moisture, which may have accumulated. Be
sure that the air intake filter if properly installed and protected.
7. Before starting a new compressor be sure you are familiar with the starting and
stopping controls, and with the regulation and regulator controlling the load and
no-load operation.
8. Check the machines thoroughly to be sure there are no loose parts and that the
machine has not been tampered with since its erection.
9. The compressor lubricating oil is circulated under pressure from the vehicle
engine lubricating oil system.
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11.4.5 Accessories
Inlet Air Filter
The air that is drawn into a compressor should be free from dust, dirt and abrasive or
gritty particles that could damage cylinders, valves & moving parts. It is the purpose of
the inlet filter to remove all such particles from the ambient air, in order to safeguard
the performance of the compressor and prevent what might otherwise results in high
maintenance costs and needless compressor down time. Suction air filters also helps
in reducing the noise level of the compressors.
Cup Housing
Cup
Inner
Filter
Element
Washer
Nut
Safety Valve
Provided as a standard accessory on air head. Safety valve is set to open, when
the maximum permissible delivery pressure of the compressor is exceeded, thus
protecting compressor.
Ring
Top
Body
Plunger
Spring
Valve Seat
Lock Nut
Bottom Body
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11.4.6 Piping
Discharge piping is considered to be the piping between the compressor and the
system.
The discharge pipe should be of the full size as of the compressor outlet or larger
and it should run directly to the system.
The discharge should be as short and direct as possible with long radius elbows,
where bends are necessary.
All pipe fittings must be considered for the operating pressure. All pipe joints
should be tight and having no leaks in discharge system, leaks will reduce output
of the compressor. Leaks are easily located by squirting soap and water solution
around all joints and watching for bubbles.
Where a bare compressor is supplied, it is very important to observe the following
when installing the piping between the compressor and the system.
1. Never install a shut off valve (such as a gate or globe valve) between the
compressor and the system unless a safety valve is put in the piping
between the valve and the compressor.
If possible, run the piping down from the compressor discharge to permit
condensate to drain into the receiver. If this is not possible, install a drain leg. The
drain leg should project down from the compressor discharge and be at least 10
long (254 mm). Put a drain valve at the end of this pipe and drain at least weekly,
or as often as necessary.
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.
WARNING
DO NOT USE PLASTIC PIPE OR RUBBER HOSE AS DISCHARGE PIPE, AS
THEY CAN RESULT IN MECHANICAL FAILURE, PROPERTY DAMAGE & SEVERE
INJURY OR DEATH
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S YK ES
S YK ES
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11.4.8 Maintenance
Valve Maintenance
Air Head
Valve
Stopper
Discharge
Valve
Dowel
Valve Plate
Inlet Valve
Cylinder/
Crankcase
Maintenance
Before working on or around air brake systems and components always observe
the following precautions:
1)
2)
3)
4)
5)
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6)
7)
8)
9)
Always wear safety glasses when working with air pressure. Never look
into air jets or direct them at anyone.
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 Pump services 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.
SR.
NO.
DESCRIPTION
6
15
29
Con-Rod Bolts
Side Cover Bolt
Head Cover Bolt
Torque Setting
N.m
Ft.lbs
Min Max Min Max
8.1 9.5
6
7
16.3 19.0 12
14
28.5 32.6 21
24
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11.4.10
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.
5.
Fit around drive pulley and over compressor pulley rotating the drive shaft
slowly.
The normal operating air pressure is 2.75 -
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12 PUMP DIAGNOSTICS
12.1 Trouble Shooting Guide
Pump System Problems
Likely Cause
Page 61
AllightSykes
Likely Cause
Pump Leaking at
AllightSykes
Pump Vibrating or
Overheating
Likely Cause
-
Page 63
AllightSykes
MA
Bearing Bracket
EP
Ejector Pack
AC
Compressor Assembly
AC
EP
BB
Page 64
AllightSykes
Page 65
AllightSykes
14 PARTS LIST
14.1 Recommended MV150i Pump Spare Parts
Description
Impeller
Front Wear Plate
Rear Wear Plate
O Ring (Seat)
Joint
Joint
Joint
Sealing Washer SS
O Ring (Sealing Washer SS)
Mechanical Seal
Impeller Shim
Impeller Shim
Impeller Shim
O Ring (Rear Wear Plate)
Circlip (Seat)
Belt (Compressor)
Gasket (Compressor)
Part Number
CP150I-316-C-255MM
CP150FWP-316
12-0284-0115
38-0700-4112
38-1034-5413
38-1034-5423
38-1034-5443
38-0785-4412
38-0787-4112V
38-0400-VS2S2/SS
36-0646-8913
36-0646-8923
36-0646-8933
38-1004-4112
41-0230-8712
26-0840-9912
KX2542/1
Quantity
1
1
1
1
2
2
2
8
8
1
3
3
3
1
1
1
1
Page 66
AllightSykes
Page 67
AllightSykes
Description
Volute (Pump Body)
Impeller
Front Cover & Separation Tank
Wearplate (Front)
O-Ring Sealing Washer M12
O-Ring OR11x3 Viton
Stud M12 x 50
Joint (Body)
Joint (Body)
Joint (Body)
Stud (Body) M12 x 60
Stud M12 x 45
Wearplate (Rear)
O-ring (Wearplate)
O-ring (Seat)
Circlip (Seat)
Mechanical Seal
Shaft Collar
O-ring (Collar)
Tolerance Ring
Impeller Shim 0.25mm
Impeller Shim 0.5mm
Impeller Shim 1.0mm
Skt Hd Capscrew
Flat Washer M8
N/A
Separation Tank Cover
Filter (Separation Tank)
Setscrew M10 x 20
Lockwasher M10
Stud (Pump/Adaptor) M12 x 45
Stud (Pump/Adaptor) M12 x 55
Lockwasher M12
Nut M12
Stud (Flange) M16 x 60
Lockwasher M16
Nut M16
Part Number
Quantity
CP150V-SGI
CP150I-316-C-255MM
11-0259-0115
CP150FWP-316
38-0785-4412
38-0787-4112V
1
1
1
1
8
8
4
A/R
A/R
2
6
4
1
1
1
1
1
1
1
1
A/R
A/R
A/R
4
4
38-1034-5413
38-1034-5423
38-1034-5443
12-0284-0115
38-1004-4112
38-0700-4112
41-0230-8712
38-0400-VS2S2/SS
28-0255-3215
38-1036-4112
41-0241-6112
36-0646-8913
36-0646-8923
36-0646-8933
21-0230-7915
23-0586-9923
1
1
1
1
4
2
12
12
8
8
8
Page 68
AllightSykes
AllightSykes
Description
Engine Adaptor
Shaft (* see note below)
Setscrew M10 x 30
Lockwasher 10mm
Taper Roller Bearing
Bearing Cover (Front)
Circlip
Spiroseal
Bearing Cover (Rear)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Setscrew M8 x 25
Lockwasher 8mm
Grease Nipple
Relief Valve
Plug 3/8" BSP
Plug 3/8" BSP
Spiroseal
Key
Part Number
Quantity
13-0174-0215
16-0400-8011-R4R
1
1
9
9
2
1
1
2
1
A/R
A/R
A/R
A/R
A/R
3
3
1
1
1
1
1
1
39-0069-9912
13-0172-0915
41-0232-8712
38-0809-4112
13-0173-0115
36-0650-9903
36-0650-9913
36-0650-9923
36-0650-9933
36-0650-9943
51-0003-8112
51-0010-2012
43-1048-4515
38-1033-4112
* Note:
When ordering Shaft state pump engine type so correct type of shaft length can be
supplied.
Page 70
AllightSykes
AllightSykes
Description
Ejector Jet
Ejector Nozzle
O-ring (Jet)
O-ring (Nozzle)
Ejector Collar
Jet Sleeve
Ball Seat
Ball
Toyo Hose
Hose Clamp
Vacuum Gauge
Part Number
Quantity
23-0568-2016
23-0571-2016
38-1013-4112
38-1014-4112
23-0570-2011
23-0567-2011
23-0412-2011
39-0641-4113
1
1
1
1
1
1
1
1
1
2
1
001-0003
Page 72
AllightSykes
Air Inlet
Water Outlet
29
SECTION - 3
Internal Detail of
2SC15 Compressor
28
KE
SY
Water Inlet
Air Delivery
27
23
25
22
20
19
24
21
10
26
(5)
4
Piston Ring
3
2
12
9
5
13
15
14
11
16
SY
KE
17
15
Lubricating
Oil Connection
1
18
White Metal Bearing Bush
Page 73
AllightSykes
SR. NO.
DESCRIPTION
PART NO.
CCN NO.
QTY
CYLINDER/CRANKCASE
IAR 0803
71005001
01
CRANK SHAFT
IAH 0804
71005002
01
IAF 0832
74005030
01
IAF 0830
74005028
01
CONNECTING ROD
IAH 0805
71005003
02
IAF 0806
74005004
04
PISTON (STD)
IAH 0807
71005005
02
PISTON PIN
IAF 0808
71005006
02
IAF 0809
74005007
04
10
IAF 0843
71005043
02 SET
11
BEARING
IAF 0814
74005012
01
12
O RING (FRONT)
IAF 0827
75005025
01
13
OIL SEAL
IAF 0816
75005014
01
14
BEARING COVER
IAH 0815
71005013
01
15
IAF 0817
74005015
06
16
O RING REAR
IAF 0842
75005042
01
17
BUSHING COVER
IAH 0839
71005039
01
18
THRUST WASHER
IAF 0819
74005017
01
19
SPACER PLATE
IAF 0820
71005018
01
20
DOWEL PIN
IAF 0826
74005024
04
21
IAF 0825
74005023
02
22
DISCHARGE VALVE
IAF 0821
72005019
02
23
VALVE STOPPER
IAF 0822
72005020
02
24
IAF 0823
74005021
04
25
NUT (M5)
IAF 0824
74005022
04
26
IAF 0834
75005032
01
27
IAH 0835
75005033
01
28
AIR HEAD
IAR 0833
71005031
01
29
IAF 0828
74005026
06
Page 74
AllightSykes
Page 75
AllightSykes
AC1
AC2
AC3
AC4
AC5
AC6
AC7
AC8
AC9
AC10
AC11
AC13
AC14
AC15
Description
Compressor (Bendix)
Gasket
Stud M10 x 40
Springwasher M10
Pump Pulley c/w TLB
Compressor Pulley
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
Part Number
Quantity
49-0523-9915
KX2542/1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
26-0851-9912
26-0724-0243
26-0840-9912
36-0556-8111
10-0000-0004
54-0556-9912
A1212
42-0000-0004
N1208H
27-2800-1000
Page 76
AllightSykes
AllightSykes
Description
Part Number
356-6000
356-4061
356-4064
356-4153
356-4063
313-4169
920-9242
500-4051
FB150TE
Quantity
1
8
8
4
4
4
1
1
1
1
1
1
1
8
8
8
Page 78
AllightSykes
DR1
DR2
DR3
DR4
Description
Complete Coupling Assembly
Flywheel Flange
Coupling Rubber Element
Hub (to suit 42mm shaft)
Bolt Set to suit Hub
Part Number
Quantity
CM-240-50-10-42
CM-0240-FL1-10
CM-0240-EL-50
CM-0240-H-SB1-42
CM-0240-BS
1
1
1
1
1
Page 79
AllightSykes
AllightSykes
Description
MV Chassis
Pump-End Support
MV - Lifting Frame
Control Box
MV - Sticky Back Rubber
GALVABOND SHEET 50 x 3
MV -Fuel Line Pickup
2" BSP Pipe Cap - Gal Mal c/w
Breather
Plug BSP GAL/MAL 1 1/2"
Plug BSPT Black 3/4"
80L Fuel Tank
MV - Rubber Insert for Fuel Tank
Magna Bulbs 6.5mmx1/4"
GALVABOND Sheet 320 x 3
Battery Box
Bolt (M12x55)
Nut (M12)
Washer (M12)
Bolt (M12x65)
Bolt (M20x55)
Washer (M20)
Nut (M20)
Part Number
Quantity
MV-1000
MV-1020
MV-1200
MV-2005
MV-2006
MV-2004
1
1
1
1
1
1
1
C50NB
P24
P12
MV-2001
MV-2003
MV-2007
MV-2002
340-8002
1
1
1
3
4
1
1
1
5
6
1
6
6
6
Page 81
AllightSykes
DESCRIPTION
HENRY PEWTER PLAQUE
GALV OPEN FRAME CHASSIS - MV150iC SUIT CAT2.2
PUMPEND SUPPORT C2.2T GALV
GALV LIFTING FRAME - MV150iC
Fuel Tank - PLastic - 80L
FUEL TANK PROTECTION SHEET
FUEL LINE PICKUP MV150iC
FUEL TANK STRAP
MAGNA BULBS
COMPRESSOR COOLANT KIT - MV-C2.2T
COMPRESSOR OIL DRAIN KIT - MV-C2.2T
FUEL KIT - MV-C2.2T
CANOPY - GALVANISED LIGHT WEIGHT MV150IC
PUMPSET
PUMPEND - MV150iC WATER COOLED 255mm IMP
NON RETURN VALVE - ASSEMBLY 150mm SGI TABLE-D
QTY
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
4 ea
1 ea
1 ea
1 ea
1 ea
1 ea
1 ea
2 ea
2 ea
1 ea
1 ea
4 ea
6 ea
2 ea
1 ea
1 ea
1 ea
1 ea
1 ea
2 ea
1 ea
1 ea
1 ea
1 ea
1 ea
AllightSykes
Page 83
AllightSykes
Description
1
Part/Drawing Number
CATC-2.2T
2
3
4
Page 84
AllightSykes
Description
Part Number
1
2
3
4
5
Page 85
AllightSykes
Page 86
AllightSykes
Date
Report No.
Name
Date Purchased
Date of Failure
Pump Description
Serial Number
Description of Failure
Failed Parts.
Part No.
Description
Qty
Y/N
Amount A$
Name
Date
Comments
Type of Cost
Parts Used
Other
TOTAL
Page 87
AllightSykes
DISCHARGE HOSE
I.D.
TYPE
LENGTH
STATIC DISCHARGE HEAD (Hd)
PUMP
DISCHARGE GAUGE
READING
OPERATING RPM
SUCTION HOSE
I.D.
TYPE
LENGTH
SUCTION GAUGE
READING
SUCTION RESTRICTIONS
TYPE
QTY
DISCHARGE RESTRICTIONS
TYPE
QTY
STRAINER
Y/N?
LIQUID PUMPED
S.G.
Ph
TEMP
Eg.
ELBOW
BUTT/W
Page 88
AllightSykes
19
Min -40 oC
Max 176 oC
Buna N
Min -4.4 oC
Max 121 oC
Polyurethane
Min -4.4 oC
Max 93.3 oC
Teadit NA-1002
(Gasket Material)
Min -29 oC
Max 260 oC
Page 89
AllightSykes
The below table show the effect of altitude on the Pumps Suction Lift / NPSHR
curve capabilities;
Altitude
(m)
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
Reduction in
Suction Lift
(m)
0
0.30
0.60
0.89
1.16
1.44
1.71
1.97
2.22
2.47
2.71
2.95
3.18
3.40
3.62
Altitude
In basic terms, the higher the altitude the less atmospheric pressure resulting in a
reduction of pressure differential between atmosphere and vacuum created in
Sykes self priming system resulting in a reduction of available suction lift.
Page 90
AllightSykes
The below table show the effect of temperature on the Pumps Suction Lift /
NPSHR curve capabilities;
Temperature
(oC)
15
20
30
40
50
55
60
65
70
75
80
85
90
95
100
Reduction in
Suction Lift
(m)
0
0.06
0.22
0.52
0.98
1.32
1.73
2.23
2.85
3.60
4.51
5.59
6.88
8.39
10.18
Temperature
In basic terms, the higher the water temperature the greater the reduction in
suction lift due to changing water vapour pressure and density.
Page 91
AllightSykes
Page 92
AllightSykes
80
100
150
18
32
32
40*
67*
70
18
200
250
125
125
173*
195
300
350
400
218*
280
280
380
340*
444*
30*
57*
18
125
125
125
163*
185*
195
82*
125
150*
280*
28*
70
For high static suction lifts oversized suction pipe / hose may be required even
at lower flow rates
This information this should be read in conjuction with the pump curve for
reference to the pumps recommended operating flow rates
Page 93
AllightSykes
FLOW
(L/sec)
2
4
6
8
10
12
14
16
18
20
25
30
40
50
60
70
80
90
100
112
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
2"
50
1.02
2.04
3.06
4.07
5.09
6.11
7.13
8.15
9.17
10.19
12.73
15.28
20.37
25.46
30.56
35.65
40.74
45.84
50.93
57.04
61.12
66.21
71.30
76.39
81.49
86.58
91.67
96.77
101.86
106.95
112.05
117.14
122.23
127.32
132.42
137.51
142.60
147.70
152.79
157.88
162.97
168.07
173.16
178.25
183.35
188.44
193.53
198.63
203.72
208.81
213.90
219.00
224.09
229.18
3"
75
0.45
0.91
1.36
1.81
2.26
2.72
3.17
3.62
4.07
4.53
5.66
6.79
9.05
11.32
13.58
15.84
18.11
20.37
22.64
25.35
27.16
29.43
31.69
33.95
36.22
38.48
40.74
43.01
45.27
47.53
49.80
52.06
54.32
56.59
58.85
61.12
63.38
65.64
67.91
70.17
72.43
74.70
76.96
79.22
81.49
83.75
86.01
88.28
90.54
92.81
95.07
97.33
99.60
101.86
4"
100
0.25
0.51
0.76
1.02
1.27
1.53
1.78
2.04
2.29
2.55
3.18
3.82
5.09
6.37
7.64
8.91
10.19
11.46
12.73
14.26
15.28
16.55
17.83
19.10
20.37
21.65
22.92
24.19
25.46
26.74
28.01
29.28
30.56
31.83
33.10
34.38
35.65
36.92
38.20
39.47
40.74
42.02
43.29
44.56
45.84
47.11
48.38
49.66
50.93
52.20
53.48
54.75
56.02
57.30
5"
125
0.16
0.33
0.49
0.65
0.81
0.98
1.14
1.30
1.47
1.63
2.04
2.44
3.26
4.07
4.89
5.70
6.52
7.33
8.15
9.13
9.78
10.59
11.41
12.22
13.04
13.85
14.67
15.48
16.30
17.11
17.93
18.74
19.56
20.37
21.19
22.00
22.82
23.63
24.45
25.26
26.08
26.89
27.71
28.52
29.34
30.15
30.97
31.78
32.59
33.41
34.22
35.04
35.85
36.67
14"
350
0.02
0.04
0.06
0.08
0.10
0.12
0.15
0.17
0.19
0.21
0.26
0.31
0.42
0.52
0.62
0.73
0.83
0.94
1.04
1.16
1.25
1.35
1.46
1.56
1.66
1.77
1.87
1.97
2.08
2.18
2.29
2.39
2.49
2.60
2.70
2.81
2.91
3.01
3.12
3.22
3.33
3.43
3.53
3.64
3.74
3.85
3.95
4.05
4.16
4.26
4.37
4.47
4.57
4.68
16"
400
0.02
0.03
0.05
0.06
0.08
0.10
0.11
0.13
0.14
0.16
0.20
0.24
0.32
0.40
0.48
0.56
0.64
0.72
0.80
0.89
0.95
1.03
1.11
1.19
1.27
1.35
1.43
1.51
1.59
1.67
1.75
1.83
1.91
1.99
2.07
2.15
2.23
2.31
2.39
2.47
2.55
2.63
2.71
2.79
2.86
2.94
3.02
3.10
3.18
3.26
3.34
3.42
3.50
3.58
18"
450
0.01
0.03
0.04
0.05
0.06
0.08
0.09
0.10
0.11
0.13
0.16
0.19
0.25
0.31
0.38
0.44
0.50
0.57
0.63
0.70
0.75
0.82
0.88
0.94
1.01
1.07
1.13
1.19
1.26
1.32
1.38
1.45
1.51
1.57
1.63
1.70
1.76
1.82
1.89
1.95
2.01
2.07
2.14
2.20
2.26
2.33
2.39
2.45
2.52
2.58
2.64
2.70
2.77
2.83
20"
500
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.13
0.15
0.20
0.25
0.31
0.36
0.41
0.46
0.51
0.57
0.61
0.66
0.71
0.76
0.81
0.87
0.92
0.97
1.02
1.07
1.12
1.17
1.22
1.27
1.32
1.38
1.43
1.48
1.53
1.58
1.63
1.68
1.73
1.78
1.83
1.88
1.94
1.99
2.04
2.09
2.14
2.19
2.24
2.29
Page 94
AllightSykes
AllightSykes
pH Level
Metals
Alkaline
14
13
12
11
Stainless Steels
Caustic Basic
10
9
Cast Iron
Neutral
8
7
6
Aluminium
Acid
5
4
3
2
1
0
Cast Iron
Stainless Steels
Page 96
AllightSykes
The results are for a standard compressor prime pump build with a Bendix
Compressor.
PUMP TYPE
JET
23-0568-2016
NOZZLE
23-0571-2016
CP80
CP100
CP150
CP200
CP300
CP300i
HH80
HH100
HH125
HH150
HH160i
HH200
HH250
MH300
XH100
XH150
JET
23-0415-2016
NOZZLE
23-0414-2036
The following tables show the performance data for the complete compressor
pump range at nominated speed (normal pump speed) and at maximum pump
speed.
These results are for a standard compressor prime pump built (Bendix
Compressor).
Page 97
AllightSykes
PUMP TYPE
CP80
CP100
CP150
CP200
CP300
CP300i
HH80
HH100
HH125
HH150
HH160i
HH200
HH250
MH300
XH100
XH150
COMPRESSOR /
PUMP PULLEY
RATIO
- 1.60
- 1.60
- 1.29
- 1.29
+ 1.56
+ 1.56
- 1.29
- 1.25
- 1.25
- 1.125
-1.125
- 1.125
- 1.125
- 1.125
- 1.125
- 1.125
PUMP TYPE
CP80
CP100
CP150
CP200
CP300
CP300i
PUMP
SPEED
(rpm)
2000
2400
2000
2200
1800
2200
1800
2000
1000
1200
1000
1200
COMPRESSOR
SPEED
(rpm)
1250
1500
1250
1375
1395
1705
1395
1550
1560
1872
1560
1872
BACK
PRESSURE
(psi)
50
58
50
54
54
65
54
60
59
66
59
66
VACUUM
PRESSURE
(kPa)
83.5
81.0
83.5
82.0
82.0
80.0
82.0
81.0
82.5
82.0
82.5
82.0
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AllightSykes
PUMP TYPE
HH80
HH100
HH125
HH150
HH160i
HH200
HH250
MH300
XH100
XH150
PUMP
SPEED
(rpm)
2000
2400
2000
2400
2000
2400
1800
2000
1400
2000
1800
2200
1800
2000
1800
1800
1800
1800
1800
1800
COMPRESSOR
SPEED
(rpm)
1550
1860
1600
1920
1600
1920
1600
1778
1120
1778
1600
1956
1600
1778
1600
1600
1600
1600
1600
1600
BACK
PRESSURE
(psi)
60
70
60
63
60
63
60
66
60
66
60
63
60
66
60
60
60
60
60
60
VACUUM
PRESSURE
(kPa)
81
79
83
82
83
82
83
82
83
82
83
82
83
82
83
83
83
83
83
83
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AllightSykes