Model 17/21 four stage
Contents
1. 5S 8 2 1 1072 088 NIN STSCOW LINS b Nod 0621 WNWIXY VGH 55444 3ON3A ANS NIA 135079 989 1 82 HIUN3I DIS VIIXI Ndatd 89 37IS 141 45 1 6 HION3T 39918 T 999041541 39 IVISJIVN HSNE 1NVd LIp2 SV MO14 G3XI SS IVISJIVN LAVAS 21443 NI 39NVH2 UWAD34 TWIxy 098119 WISSIVN TADS 13123449 38 TIM dh UTTTAdNWNI 38289 19I441VN 411144441 Z67778 D SINVA_30 UN 0 Tmi NWINI WISI D RI Wda Cle 0580587 33d 1515915 W WIXVW 1 52 12 0800 UN JASN SINIOd 549918 ON S 8 12 20 34 lddW VITVYLSNV SAATVA SANOd MHATISTIVE 91 22 89312 MIXV 015 Batescrew Pumps Operation and Service Manual 6 Jan 04 3 Description 3 1 Strainer 3 20 Wet End Assembly 3 3 Column Assembly 3 4 Discharge Head 3 5 Drive Extension 3 6 Drive Shaft 3 7 Motor Mount 3 8 Drive Motor 3 9 Discharge Pipe 3 1 Strainer The strainer serves to protect the impeller and stator from the entry of foreign bodies The design of the strainer is such as to have minimal effect on water flow whilst allowing the capture of possibly damaging material All pumps shall be fitted with a protective strainer On angle mounted pumps t2. 23 BATESCREW PUMPS AND VALVES SERVICE HISTORY PUMP 7634 DATE INSTALLED 12 Service Records Log DATE PES Rio lee GLAND COMMENT CLEANED CHECKED CLEANED CHECK GREASED GREASED 24 Batescrew Pumps Operation and Service Manual 6 Jan 04 13 WARRANTY The Company undertake that the goods manufactured by the Company shall be of first class materials and of sound workmanship and that the company will make good or replace any defective parts therein which under proper use may appear within six months of dispatch from the company s works and which have proven to be due solely to the use of defective materials or bad workmanship Provided always that such parts are promptly returned free to the company s works unless otherwise arranged and any defective parts to the Company s property The repaired or new parts will be returned to the site Any goods not of the Company s manufacture included in this tender are sold under such warranty only as the makers give us and we are able without legal expense to enforce but are not guaranteed by us in any way whatsoever The warranty does not cover malfunction resulting from misuse negligence alterations accident or lack of performance of normal maintenance service loss of time inconvenience loss of use of equipment
3. LOOSE FLANGE as per drawing GIBO PIPE O RING 527 o d 1000 long 20 mm diameter 527 i d O RING BOLTS M20 75 mm LOOSE FLANGE as per drawing INLINE N R V V N 3394 ADAPTOR 21 TB 21 TB inline Gal legs P RV 21 TB 700 T D 300 long NRV ADAPTOR BOLTS M20 75 mm PRESSURE RELIEF VALVE Bermad 150 mm 7 m setting RELIEF VALVE NRV BOLTS KNEE BRACES KNEE BRACE HEAD BOLTS NAMEPLATE M16 65 21 gal pair M24 50 P N 7634 J N 5628 970 RPM 28 15 Component Parts Drawings 74 72 AANT AOL 7 002 FN POL dO AVM ATA LAN dOL LINAN 2 40207 AIMO INITINOI LTVH Old ONY YOLON 7402 ALFAVS LIVAS Odd VAS Old 74 2 71740 LON NOISNGL dh O TOOLS NON PINTUVIT 22747 INGON DWIMVES d ONILVIE 45 4 INI Td NOI LIVH Old 29 TMVINI MIVId ONIMOOT AdVy HSNd Hae 51109 PONTI QNINNAY OL TIHA UIMVINI IT TIYUANI a 5 1708 YOLVLIS OL INTU ININNAY YOLVLIS WOLLOE SLTOG QNIY ININNOY INS OL YOLVLS LA TIUANI INS ALVId INIMIOT dO4 SITOH MOOT HHdV l YATTHAWI SONTYVHE ASN YUOLVIS 4ALVTd 207 YHdVI ALVId ONIMOOTI 517109 MIOT TAdVI YATTHAWI SONIYUVIE HSNE YUOIVIS YOLVIS GONG ALVId 207 Ydy SLTOH 18 OL INTY ee YI
4. NO OF STAGES 4 IMPELLER 17 21 8 1 2 TRIM Full STRAINER yes TYPE basket plate LOCKING PLATE yes B B H LUBRICATION grease TOP STATOR LUBE oil COLUMNS 21 gal8ft clamp 88 9 7 off Inter stator lube grease EXTENSION COLUMN 14 galclamp 88 9 4of 1 of 4 ft HEAD 21 36 degree oil MOUNTPLATE knee braces IMPELLER SHAFT 13 4 64 THREAD SIZE 13 4 nfrh LINESHAFT 1 3 4 1040 grade 96 long 11 off INTERMEDIATE TOP SHAFT 13 4 431 S S x Len RecReqx1170 TOP SHAFT _2 431 S S x Len Req 450 key 200 long top th200 80 MUFF COUPLINGS 13 4 nf rh x 14 CENTRE BEARING HOLDERS 21 clamp 88 9 NUMBER 70f21 440f 14 BOTTOM LUBE TUBE 3 gal 54 m fm 48 fm fm LUBRICATION TUBE 3nb 88 9 od 48 gal 22 off TOP LUBE TUBE 3 x 1235 LUBE TUBE JOINERS 3 x 1 3 4 x 23 TENSION NUT C4TN3 13 4 GLAND O ring 2plates THRUST BEARING No5 WATER COLLED OIL TANK amp FITTINGS 1 gallon set LTJ 3 13 4 23 off DISCHARGE PIPE FLANGE PUMP END FLANGE PIPE END LENGTH ANGLE MATERIAL PAINT GASKET amp BOLTS SET SPARE FLANGE amp PIPE O D HARDY SPICER DRIVESHAFT SERIES GWB687 40 COMPRESSED LENGHT30 EXTENDED LENGTH 32 ADAPTORS PTO DRIVE COUPLING BORE DIAM REG NO HOLES amp DIAM KEY WAY WIDTH DEPTH PTO DRIVEN COUPLING BORE DIAN2 3 4 REG NO HOLES amp DIAM KEY WAY WIDTH 1 2 DEPTH 1 4 PTO GUARD yes ELECTRIC MOTOR client to supply MAKE HP SPEED FRAME FOOT MOUNTED FLANGE MOUNTE
5. been removed X 15 Batescrew Pumps Operation and Service Manual 6 Jan 04 6 6 3 Removal Disassembly and Assembly Assemble Wet End Clean and inspect all parts replace anything that looks suspect check shafts and bushes for wear If in doubt contact Batescrew Technical Service Department Ph 0358742101 or FAX 0358742084 for correct advice Do not use non original or modified parts as quality and performance may suffer INSIST on only repairing with BATESCREW original pump parts BATESCREW stock most components for there pumps these can be supplied upon demand through your local irrigation agent or direct from BATESCREW SALES Do not return defective or worn parts into service as failure may cause severe damage to other pump components Assemble Wet End x X X X X X X X The correct position of the impeller on the shaft must have been established during disassembly if this was not done contact BATESCREW for help Install the top impeller taper on to the shaft at the location measured during disassembly large end away from the threaded end of the shaft Slide the impeller onto the taper and fit the taper locking plate Install and tighten the locking plate bolts evenly securing impeller the shaft checking that the dimension from end of the shaft to the taper has not changed Install the top running ring onto the top stator Slide the shaft and impeller into the stator running ring assembly Fit
6. must only be done by suitably qualified personnel and correct safety protection must be fitted WARNING The direction of rotation of the motor is critical and the fitting of a motor of the wrong rotation will destroy the pump immediately Always check the motor direction by running the motor before fitting No warranty covers damage by reverse rotation THE MOTOR DIRECTION MUST BE ESTABLISHED BEFORE CONNECTING THE PTO SHAFT TO THE MOTOR DRIVE SHAFT 3 9 Discharge Pipe The outlet is fitted with a Batescrew standard flange adapters can be supplied to change this to any standard flange or seal joint required It should be noted that care should be taken in how the water is allowed to leave the pump outlet the water should never be allowed to drop directly upon the ground as wash away will cause soil erosion The use of a bubbler or other suitable outlet structure of the appropriate size will eliminate any erosion and allow unrestricted water release Batescrew Pumps Operation and Service Manual 6 Jan 04 4 Assembly and Installation 4 1 Pre Installation 4 2 Assembly 4 3 Fit Rail Supports 4 4 Fit Pump 4 5 Testing 41 Pre Installation Before any installation can be performed the site must be prepared The Pump will require A sound well constructed mounting pad at the top of the bank Confirmation of river depth bench mark and flood levels confirming the supply s ability to deliver rate required Electricity supply at the correct vo
7. the second stator to the top running ring and bolt into place Lock the impeller shaft so that the top impeller is up firm against the top stator Slide the impeller onto the shaft firm up against the second stator assembly Install the taper to the shaft and up into the impeller Fit the second impeller locking plate and bolts but do not tighten them yet Making sure that both the top and second impellers are firm against their stators thus locating them onto the shaft at the correct spacing tighten the locking plate bolts Install the second running ring and the third stator Check after each impeller is fitted that end float has not been diminished indicating correct impeller placement on the shaft Repeat the above until all impellers and running rings have been fitted Install the intake bell to the bottom running ring Check clearance of the shaft in the bushes and Lip seals replace if necessary For wear limits and clearances refer to TOLERANCES section of this manual Check impeller tip to running ring clearance max allowed is 3mm overall Check the list in this manual to be sure you have the correct lubricants and sealant ready 16 Batescrew Pumps Operation and Service Manual 6 Jan 04 6 Removal Disassembly and Assembly 6 4 Reassemble Pump Reverse procedure used to dissemble the pump then follow assembly section 4 Make sure all lubrication tubes are tight Test shafts on blocks to check for straig
8. 16mm55G BOLTS amp NUTS COL HEAD 2 S SDia x Len Req 16mm x 55mm GAL 300TTFM TOP LUBE TUBE 3 GAL Len to suit 134MCR12 MUFF COUPLING 13 4 RH M S 134MS96R LINESHAFT 8 FT 1040m s 1 3 4 1040 x 96 RH 21 25 2 DISCHARGE HEAD 36 DEG 21 36 DEG GAL 3 O RING 6 mm diameter 3 1 2 i d 4 O RING BOTTOM PLATE 5 O RING PLATE 12 mm Jig 0057 12 mm plate jig 0057 12mm65G NUTS amp BOLTS 0 RING PL 12mm x 65mm GAL 6 HEAD EXT COL ADAPTOR PLATE COLUMN 8FT x 14 14 17 8 12mm65G 8 reg male to 18 reg female 12mm 14 x96 COL CLAMP 3 BOLTS amp NUTS H AP COL 12mm x 65mm GAL 1 12mm45G_ BOLTS amp NUTS COL COL 12mm x 45mm GAL 4 27 Batescrew Pumps Operation and Service Manual 14 174 COLUMN 4 FT x 14 14 x48 COL GAL 6 Jan 04 3002 TENSION NUT 2 4 T Nx 3 Bate 3002N134R NUT 2PART 4 NuTx3 Bx1 3 4 LS134TN TENSION NUT LIPSEAL 13 T NUT STOOL BOLTS 1 3 4 x2 1 2 x3 8 SHCS M12 30 TENSION NUT STOOL as per drawing 10 TOP PLATE 762 profile drawing 11 PLATE STOOL BOLTS M16 70 mm 12 STOOL BEARING BOLTS M12 50 OT0001 OIL TANK amp FITTINGS STD 4 LITRE 38GLeMS GR LINE amp FITTINGS 5 5 3 8 S S x 6mtr LEN 30m 4 1LOGB GR LINE BRACKETS amp BOLTS FAB M S 1 LINE No5 BEARING ASSEMBLY 5
9. BH BEARING HOUSING No5 5 BC BEARING CARRIER No5 LS4BH TOP LIP SEAL 75 95 10 5 CAP 5 6315 BEARING CAP TOP BEARING No5 6315 5 7315 BOTT BEARING 7315 LS4BH BOTT LIP SEAL 75 95 10 8mm30ZP BOLTS 5mm x 30mm Z P 5 375CS CRUB SCREW 6mmGNS ST GREASE NIPPLE 0121004 10mm x 10mm 6mm 00 KEY 1 2 1 4 134TN12NF NUT amp CRUB SCREW B D 1 3 4 x12TP1x10mmC S 12mm45G BOLTS amp NUTS Bear Head COOLING 5 12mm x 45mm GAL 3 4 Braided PVCx20 13 m 2 34T12BS P COOLING PIPE ADAPTORS No 3 4 T x 1 2 BSP 223055 HOSE CLAMPS STAINLESS 1A 22 30 S S A5 m wv o 2 2 2 m o 2 no fa jajaja DIRECT DRIVE PARTS 17 75 MOTOR CLIENT TO SUPPLY SGA D355MC6 CMG 4 21 81 PTO ADAPTOR motor 95 25 mm 21 82 SHAFT GWB687 40 21 83 NUTS amp BOLTS Pto Agd Adp 1 2 unc 1 1 2 21 85 PTO ADAPTOR Bearing C l 2 750 1 2 1 4 21 86 NUTS amp BOLTS Pto Mtr Adp 21 89 PTO GAURD ANGLE BRACKET 1 2 unc 1 1 2 300 i d 5mm 1050 long as per drawing ANG BRACKET PLATE BOLTS COMPO BEND M20 150 long 21 TB 320 320 c c 21 TB 4 deg HEAD C BEND BOLTS M20 65 GASKET 21 Table B O RING 20 mm diameter 527 i d O RING BOLTS M20 75 mm
10. D notes grease lines on RHS correction bend double gibopipe inline non return valve 6 outlet for PRV V N 3394 Bermad 6 pressure relief valve setting 6 1Mts tension nut mount 14 diameter discharge pipe adaptor to 700 table D pto guard knee braces Slide Rail spacing 15 Modify screen and Bellmouth to suit slide rails support from bottom rring to slide rails to suit 21 column 26 Batescrew Pumps Operation and Service Manual BATESCREW PUMPS RECORD SHEET Cave amp Weier PUMP NO 7634 DATE 17 214sta 56 36d c ptcJOB NO 07 Aug 03 5628 6 Jan 04 NUMBER DESCRIPTION SIZE NO OF 17 1 S INLET SCREEN 17 S S MESH 477 long 12mm35G BOLTS amp NUTS IS BBH 12mm x 35mm GAL 17 8 5 A2 G L 17 A2 B B H G L 17 3 7 LS0 17 LB2 BUSH G L LIPSEAL G L s s spring LB2 1 3 4 2 1 4 3 1 3 4 x2 1 4 x3 8 17 3 9 BBH GREASE TUBE G L 15NB S S x 285 MM 38FGLSF FLEXIBLE G L with S S Fittings 3 8 R H amp S S FITT 16mm55G 17218A2 BOLTS amp NUTS BBH RR IMPELLER 17 21 8 1 2 16mm x 55mm GAL 17 A2 17 21 8 1 2 17 7 1 TAPER SLEEVE 1 3 4 17 7 3 LOCKING PLATE 17 LOCK PLATE 12mm50SS IMPELLER BOLTS 17 7 7 SLINGER PLATE 12mm x 50mm 304S S 17 SLING PLATE 17 6 2 RUNNING RING S S 17 S S RR FAB 16mm55G BOLTS amp NUTS RR ST 16m
11. Install the PTO shaft to the thrust bearing end only using the high tensile bolts Make sure that PTO is not in connected to the drive motor until motor rotation has been established Follow the directional arrow on pump Install the oil tank and connect the oil lines to the tension nut with the fittings provided The line connectors are fitted each side of the tension nut one supplies oil the the lube tubes and one gives vapor return from the oil cavity it does not matter which fitting is on which hole unless one hole is higher than the other then the vapor line is to the highest hole Set the adjustable dripper that is installed at the oil discharge line from the bottom of the tank to 10 drips per second at least 1 2 hour before starting the pump The dripper must be supplying oil if the line fills then check for blocked lines or vapor lock it may be necessity for the pump to be turned over in order to start the dripper working Run the drive motor uncoupled from the PTO and make sure that the direction of rotation is correct Only when you are sure that the rotation is correct slide the PTO couplings into place fit the bolts and then install the PTO shaft safety cover top half NOTE It is the responsibility of the installer to check motor direction prior to installation Failure to do so may cause severe pump or motor damage thus voiding warranty Fit the discharge pipe and gaskets Install any concrete anchors making sure a
12. Losajng 49730 wrpaijsumop paryojsuzr dund SHY wo edid forjas ainssaid 9 s majo UMOP 00 YIN ULNJAL 006 edid 0916 quiol 0916 aabop p YDYSIRILP Landy PLOH 0 2099597425 JMI 2uijaiuso 2uojue absnyosig apis puny YI uo SIUL 250916 M 1 O s US wunjoo uorsuszza M FLO 2 JE Aquiasso Lapadu 2 2 96078 p 2 LAIM 9109 4 6 EOS 46 062746 4522 mu 96 66 OO 82 00 Td N 20 O SO If 20 day 040 80 607 on ay 6 TI 62964 fwmyom dog Hn SU W 6 Jan 04 lication Axial Flow Pum SINGLE STAGE CURVE DISPLAYED Introduction Potential Flow Rates 4 stage are up to 10 000 gpm 750 l s or Heads to 80 ft 24 mtrs This pump set is a PTO Coupled Electrically Driven Angle Mounted Irrigation Pump Depending on demand requirements The pump set was designed for pumping irrigation water from a river into a channel or Batescrew Pumps Operation and Service Manual pipe Batescrew 17 21 Four Stage Angle a 2 235 5341112 N SIYLIM gt
13. Operation amp Service Manual Pump 7634 17 21 Axial Flow Oil Lubricated Angle Application Four Stage PTO Coupled T T3 mi 3 orm teca Bay 03 5874 2101 Technical Services Department Fax 03 5874 2084 Batescrew Pumps amp Valves Australia BATESCREW PUMPS OPERATION amp SERVICE MANUAL 17 21 OIL LUBRICATED AXIAL FLOW INDEX 1 General Layout Drawing 3 Zi Introduction 4 3 Description 5 7 4 Assembly and Installation 8 12 3 Operation amp Maintenance 12 13 6 Removal Disassembly and Assembly 14 17 7 Alignments and Tolerances 18 8 Lubrication Chart and Service Schedule 19 9 Trouble Shooting 20 21 10 Tools Required 22 11 Pump Specifications 22 12 Service Records 23 24 13 Warranty 25 14 Data Sheets and Parts Lists 26 28 15 Component Parts Drawings 29 31 10 46270 ON IMT CHET AVIV 27 WT7FAS buronds sips PUS 03 nay ALIN EUG AGOLIVA 9299 LEIL N T 774 4 6076787 ILON FIVA SWOSTATA MI ojd 2 200 0 25 4017002 98 90 9 5 2 2 TTT F808FA4 89860 TA 0 24 8980 ZO SDIULYNOT sy 49194 0 2 7 7 7 2 STATVA UNV MISISILVA 9 ST VE 8 280 NE 08 Cl E REA amp H 70 d agn oqn Qu E QHO YDYSIUL JBE 87004 APLIS UAL JAUUDYI p ma
14. TIAANI ANZ 01 745 TIE 4LVId 29NIMOOT YOH 54708 MOOT HWdV L SONIYVHIE HSNE YOLVLS UIVId ONIMQO I YHdVd ULVId ONDIIOT YOH SLIOH MIOT 4 YTTIIANI HSH NTILLOYHL 51109 QNIY PONINNOI HL OL YUOLVIS TATIAANI ALP 501084 ONIY ONINNAY Hib OL YOLVIS dowd YOLVIS HIV SJ IOH dee dOldVdV NWATOD OL YOLSVIS WIL WHf1SSdud STVAS diT SLTOd HEAL AHH YI 44AT HIVIS LAVHS e ci 30 Poy MEN impeller 3 i I hi taper lock taper lock plate aper lockplate bolt 1 al running ring rd 3l
15. a machined slide that fits over the impeller shaft and is used to insert and release taper sleeves in impellers Accurate impeller positioning can be difficult without this tool and an impeller is easily damaged when removed by any other means Other Tools that may be required Stillson wrench 18 2 sets Medium size podger bar Feeler gauge set Set square 2 only 516 engineers hammers Hook wrench 32 76 mm Screw drivers Fine cut file Medium size brass hammer Imperial and metric Allen key sets Spirit level Vernier and measuring tapes String line Socket sets metric Imperial and metric ring spanners Emery cloth Cleaner and cloth Vee Blocks and dial gauge Lifting jib or crane Chain tongs Xx X X X X x X X Xo X X X X X X X X 11 Pump Specifications PUMP TYPE AXIAL PUMP SERIAL 7634 PUMP SIZE 17 21 MOUNT TYPE ANGLE DRIVE TYPE DIRECT DESIGNED FLOW 10100gpm COUPLED MOTOR TYPE Client MOTOR SERIAL Client DESIGNED HEAD 52ft TOTAL supplied supplied MOTOR HP 250 PRODUCTION DATE 08 2003 DESIGNED RPM 1470 RATING MOTOR DIR C W INSTALLATION 2003 DESIGNED HP 200 HP DATE 22 BATESCREW PUMPS AND VALVES SERVICE HISTORY PUMP 7634 DATE INSTALLED 12 Service Records Log DATE PES Rio lee GLAND COMMENT CLEANED CHECKED CLEANED CHECK GREASED GREASED
16. are located in position horizontally by the bottom bearing and vertically by the top adjusting nut The pump impellers are balanced for vibrationless operation and should turn freely with no roughness if vibration or noise during running is encountered the pump may have been damaged the factory should be contacted and repairs made as soon as possible Any further damage caused by running a vibrating or damaged pump is not covered by warranty 3 3 Column Assembly The column acts as a pipe line for the flow of water it is also the support for the pump and shaft bearings Shaft bearings are positioned every 4 1 2m along the column within the lube tube and are lubricated from header tank at a rate of 10 drips per minute during and for at least 20 minutes before the pump is run It is imperative that the oil header tank is never allowed to run dry or be filled with dirty or non specified oil such action may cause serious damage to the pump The only oil recommended is SHELL TELLUS 32 or equivalent grade WARNING Such action will void warranty Standard column lengths are 4 ft 1 2m and 8ft 2 4m flanged mild steel fully hot dipped galvanized the line shaft is high tensile mild steel with a galvanized oil lubrication tube lube joiner tubes and mild steel muff couplings Shafts and lube tubes are screwed together in 4ft 1 2m lengths 3 4 Discharge Head Fitted to the top of the column is the Discharge Head unit which acts as the mo
17. art the motor and listen feel for any unusual noises or vibrations Adjust the flow with directional gate valves if fitted Check that seal leaks take up if not find the cause of leakage and adjust or repair Safely secure the pump site especially from children X Xx Xx X X X X X X X 22 During Operation Check the pump every couple of hours for unusual noises or vibrations Check the intake screen area for build up of foreign material at least twice a day Watch for seal leakage and adjust repair if needed Check oil lubrication rate adjust to 10 drops per minute if needed fill oil tank as needed with clean SHELL TELLUS 32 TEXACO 32 or equivalent oil On systems running continuously grease bearings once a week two pumps of SHELL ALV ANIA EP3 MOBIL TEXACO ALVANIA EP3 grease Check motor temperature regularly to assure motor is not overloading and overheating Check the tension nut for temperature and note motor amp draw Xx 12 Batescrew Pumps Operation and Service Manual 6 Jan 04 5 Operation 5 3 Shut Down Turn off motor and isolate all electrical circuits Shut all inlet and outlet gates One minute after pump has stopped turning close down lubrication oil flow If bearings have not been greased then grease nipples whilst they are warm Clean and secure site Note any defects and have them fixed whilst pump is idle Fill out pump user s register This operation direction
18. ce Manual 6 Jan 04 4 X X X Assembly and Installation Install the extension drive mount plates to the motor mount tower Fit the bearing mount stool and install the thrust bearing assembly Align the slot in the thrust bearing hollow shaft with the keyway in the top shaft and install the drive key make sure the drive key is firm but not binding as the shaft will need to slide so the correct top nut adjustment will be achieved Install the motor to the motor mount frame aligning it with the thrust bearing Install the bottom half coupling and slide it down the shaft clear of the top nut area Fit the top nut being sure the locking screws are backed out not fouling the thread Screw the top nut down against the thrust bearing boss pulling the line shaft up until the nut firms up and the pump can be felt to seize as the impeller touches the stator Back the top nut off 1 5 turns so that the impeller clears the stator If the top nut runs out of thread call BATESCREW for help If the line shaft does not drop as the top nut is backed off then the key way is most likely too tight or the line shaft is seizing at some point repair and retry When the top nut is correctly adjusted the pump should turn smoothly Tighten the top nut locking screw onto the keyway only Install the top PTO drive coupling to the drive shaft on the motor Install the PTO shaft safety cover bottom half to the mount frame
19. check even if you believe it has not been altered Just in case 17 Batescrew Pumps Operation and Service Manual 6 Jan 04 7 Alignment and Positioning Data Alignment and Positioning NOTES Column to flange alignment Align O D of each flange with 150mm ruler on the outside of the flange in 4 positions Lube tube to lube tube Must butt up tight and evenly spaced Shaft to shaft in joiners Must butt up tight and evenly spaced in joiner When assembling Rotate shaft after each component is attached to ensure correct alignment Shaft inside lube tube Must be in the centre at all times if not look for a bent shaft lubricant between shafts joiner non original or damaged shafts Straightness of shafts Shafts set on V blocks and checked for straightness 0 003 per 4ft 0 07mm per 1200mm Bush clearance on shaft 7 Tolerances PART NAME LIP SEAL TOP ROLLER BEARING BOTTOM ROLLER BEARING TENSION NUT LIP SEAL TENSION NUT BUSH LUBE TUBE JOINER BUSH LUBE TUBE ADAPTER BUSH STATOR BUSH STATOR LIP SEAL THROTTLING BUSH BELL MOUTH BUSH IMPELLER to R R RING 0 003 per 1 of diameter plus 0 004 TOLERANCE Ref skf Ref skf 1 5 mm 0 15 mm 0 15 mm 0 15 mm 0 15 mm 0 15 mm 0 15 mm 0 15 mm 3 00 mm 18 Batescrew Pumps Operation and Service Manual 6 Jan 04 8 Lubrication chart Recommended Oils and Greases PART LUBRICANT Oil lubrica
20. e Fit the next section of lube tube and line shaft Using a suitable lifting sling lift the discharge head so that it sits at the correct angle and slide it over the lube tube until it is positioned against the top column bolt it into place Align the knee braces with the rails and by moving the pump or braces align the rails pump slab correctly using the multiple choice holes built into the head and knee braces If alignment is not correct bolt holes in the knee braces may need to be reselected until correct ones are found remove the slings and fit any additional bracketing Fit the bottom gland plate to the extension mount stool in the head Fit the ring seal over the lube tube and slide it down into place against the head extension sealing flange smear the sealing flange with stag paste Fit the first drive extension outer sleeve over the lube tube and bolt into place Assemble the drive extension as you did with the column sections until all drive extensions lube tubes and line shafts are fitted do not forget to install lubricant into lube tube Fit the bearing mount to the top drive extension and bolt down Install the tension nut to the top of the lube tube using stag paste to seal the joint tighten firmly and bolt to the bearing mount Coat the tension nut lip seal with lubricant and carefully install it into the tension nut Install the last muff coupling and the top shaft 10 Batescrew Pumps Operation and Servi
21. e discharge pipe and remove it Using a block and tackle plus a securing chain or similar devices secure the pump from sliding whilst allowing the pump to be slid upwards to gain access to all parts Remove the two bolts attaching the head to the knee braces Remove the column head securing bolts Slide the head assembly upwards until access is gained to the first lube tube joiner Unscrew the top lube tube from the joiner slide the lube tube up to expose the first muff coupling Unscrew the top line shaft out of the muff coupling If you are unable to unscrew a coupling strike opposite sides of the coupling at the same time with two 2kg hammers This loosens the coupling on the shaft stretching the thread and provided excessive damage is not done the coupling may be reused If in doubt replace the stretched coupling Unscrew the muff coupling from the lower line shaft Remove the head assembly Remove the lube tube joiner from the lower lube tube Lift the pump up the rails and support underneath the first column flange Unscrew the top shaft muff coupling Remove the lube tube clamp bolts and remove the half clamp Clean the stag jointing compound from the surface of the lube tubes and joiners and remove the lube tube line shaft Remove the column bolts at next column to be removed and remove the column exposing the next two lube tubes Unscrew the next lube tube at the joiner and remove it Remove the lube tube joiner and then remove th
22. e next lube tube exposing the line shaft muff coupling Remove the line shaft from the muff coupling and remove the muff coupling and lube tube joiner X Xx X X 14 Batescrew Pumps Operation and Service Manual 6 Jan 04 6 Removal Disassembly and Assembly 6 1 Disassembly Remove the lube tube clamp bolts and remove the half clamp Remove the next column and repeat the above procedure until all column sections and lube tubes have been removed Lift the wet end out of the rails and away to a stable and clean workspace Prepare the wet end for transport or rebuilding Clean and protect all column ends and registers Check exposed bearing clearances and if needed open every column joint and remove open every lube tube to check bearings and shafts This is advised as worn bearings will cause vibration and breakage problems later Itis strongly advised that the wet end be returned to the factory for repair or replacement any worn components be replaced with the original equipment only Xx X Check column sections for corrosion and machined flanges for distortion or damage Clean all reusable columns pay special attention to the mating faces and registers Inspect drive shafts for wear and corrosion If corrosion is severe replace only with genuine BATESCREW parts that are correctly end machined for true alignment Check all bolts and nuts removed from the pump and replace a
23. ection Motor bearing failure Repair motor check lubrication Foundation not sufficient under pumpset Remove and reinstall correctly 20 Batescrew Pumps Operation and Service Manual 6 Jan 04 9 Trouble Shooting Pump is producing insufficient or varying flow rates Cause Remedy Strainer blocked Remove pumpset and clear strainer Pump starving for water Provide more submergence for pump Submerged eddy currents Ensure more even flow to pumpset Drive coupling failure Replace coupling check alignment Motor seizing Repair motor check for rubbish at inlet Broken line shaft Remove and repair Muff Coupling disconnected Remove and replace repair check D O R Motor speed too slow one phase failure Replace motor or check supply fuses Static water level has dropped Repair deepen sump Impeller loose on shaft Remove and replace repair Discharge line closed or blocked Open valve or clear obstruction Column holed or blocked Remove and replace repair Impeller or stator damaged or worn Remove and replace repair Excessive head Check discharge head refer specifications Density or quality of pumped material poor Check supply cleanliness 21 Batescrew Pumps Operation and Service Manual 6 Jan 04 10 Tools Although no special tools are needed some operations are easier and safer with appropriate tools Impeller slide hammer This is
24. et is hard to turn 6 Jan 04 Cause Remedy Top shaft nut not properly adjusted Refer to Batescrew Lineshaft bearing not lubricated Check adequate oil flow from drip feeder Line shaft bent Remove and repair or replace Sand blocking impeller assembly Remove and clear sand Misalignment in pump Remove and refer to Overhaul section Water in oil tank Pump seal failure refer to Overhaul section condensation in tank Gland too tight Adjust Object inside pump jamming impeller Remove and repair or replace Discharge head not bolted square to column Adjust or clean and re align Misaligned thrust bearing gland or tension nut Adjust or clean and re align Pumpset vibrations Cause Remedy Drive coupling misaligned or damaged Realign or replace Drive motor or mounting bolt loose Tighten or replace Motor mount misaligned Realign mount or replace Motor out of balance Repair motor check for vermin in motor Impeller damaged or fouled Remove pump and repair replace or clear Damaged or worn line shaft bearings Remove pump and repair Strainer partially blocked Clean or repair Vortexing water flow entering pump Reduce speed to see if it stops Insufficient submergence Install in a deeper sump Pumpset worn out Remove refer to Overhaul s
25. he strainer should be fitted to the intake where it should be checked for damage and cleaned regularly Note In such applications it is important that no foreign bodies be allowed to lodge across the screen and inhibit flow or the pump run without a screen as objects taken in may cause vibrations and severe damage to the pump WARNING Damage to pumps from intake of foreign bodies is not covered by warranty The pump requires a solid base upon which it may be mounted preferably at 12 centres up the bank i e at each support rail join and a solid slab at the head and knee braces The supply must be adequate and clear of debris to avoid the impellers running dry at low water levels Typically a supply coverage of at least 1 5 times the intake diameter would be adequate however river conditions can effect this If in doubt as to the supply characteristics of your inlet ring Batescrew Technical Assistance for help Entrance velocities must be less than 2 5 ft sec 0 6 m sec Batescrew Pumps Operation and Service Manual 6 Jan 04 3 2 Wet End Assembly Consisting of four stages each having 17 diameter Stator Impeller and Running Ring also the wet end includes a 17 to 21 Column Adapter fitted to the bottom will be a Bell Mouth sized matched to the pump and including Bottom Bearing Pump rotation is provided via the stainless steel drive shaft that is connected to the impellers by taper lock locating clip and key The shaft and impellers
26. htness Make sure you assemble the lube tube joiner bearings equally onto each tube Muff couplings must be screwed equally onto each line shaft the machined shaft ends must be touching each other in the muff couplings so that correct alignment is maintained if this is not done vibrations and early pump failure will result Check each shaft for bends wear corrosion damage to machined ends or threads Only replace shafts with Original parts that are machined to fine tolerances the use of incorrectly finished shafts will destroy the pump and may cause irreparable damage Use the correct lubrication and sealants from the list in this manual as you assemble Fill every lube tube with 250 ml SHELL TELLUS 32 or equivalent oil as you assemble them Align all parts to the specifications given in the table in this manual Check after each stage for signs of tightness or roughness that would indicate incorrect alignment or faulty assembly Adjust the top nut to the original position if the pump is loading up adjust a further one turn if this does not give correct Impeller positioning you may have not aligned the impeller back onto the shaft in the correct position You may need to dismantle the pump to correct this For help ring Batescrew Technical Department Before reconnecting the drive always check the direction of rotation is correct as stated in original installation A drive turning in the wrong direction will destroy your pump Always
27. ll mounts are sitting flat 11 Batescrew Pumps Operation and Service Manual 6 Jan 04 4 Assembly and Installation 4 5 Testing Check by hand that the pump turns freely with no noise or roughness Check that all persons and animals are clear of the pump and that all safety devices are connected and in place especially all intake guards and covers Make sure all inlet and out let valves are open Run the pump for 15 seconds and check for smooth operation and lack of noise Check oil is running down the lubrication line check dripper is clear and running Check for excess temperature at tension nut Check all bolts and connections and restart the pump for 5 minutes If all is still well then turn pump over by hand and test for freeness and lack of noise Check the pump at regular intervals for leaks or noises Check and note motor amperage volts power factor and river level at time of test X X X X X Operation 1 Start Up Always check safety covers are fitted especially intake screens and electrical covers Check all personnel and animals are clear of intakes and outlets including channels Carry out service procedures as outlined in maintenance Fill lubrication oil tank and start oil lubrication at 10 drops per minute at least 15 minutes before the pump in needed Open the intake and outlet valves Ensure that water is present Turn on mains check for electrical problems live components bypassed fuses etc St
28. ltage and sufficient amps Lifting device or crane to lift pump onto the slide rails Site must be accessible with clear workspace 42 Assembly As a general rule these axial flow lift pumps are shipped from the factory in sections to facilitate easy assembly The column support pylons should have been positioned previously and they should be firm and stable prior to work commencing Please take careful note of all warnings and notations Refer to the parts break down and check that all parts are present and in good order Check that the pump length and diameter is correct and that a clear space of 5 to 0 75 times bell mouth width is achievable from the bell mouth to any objects or riverbank 4 3 Fit Support Rails Check that the support pylons have been fitted every 12 down the bank starting from the end of the concrete slab single pylon of substantial enough size and depth may be used and in this application the rail mount would be a cockie s perch type with support gussets each side of upright more traditional support is the single pylon each side system with a cross rail of 5 channel mounted between the two upright supports via adjusting slide bolts This setup gives ease of adjustment stable support and plenty of adjustment potential the pump support into place on the concrete slab in line with the position of the pylons using chemical anchors or Loxin bolts for this job Batescrew Pumps Operatio
29. m x 55mm GAL 17 8 4 STATOR 2 GL 1784 7 BUSH G L 17 STATOR G L LB2 1 3 4 x2 1 4 x2 3 4 LS0 17 LIPSEAL G L s s spring 1 3 4 2 1 4 3 8 17 8 15 STATOR GREASE LINE G L 15NB S S x 235 MM 38385 NIPPLE 3 8 HEX NIPPLE S S 38FGLSF FLEXIBLE G L with S S Fittings 3 8 R H amp S S FITT 17 8 6 A2 STATOR O L 17 A2 O L 17 8 13 SEAL PLATE A2 17 5 17 8 14 GRUBSCREW 2 ONLY 10mm x 45mmcsk 17 8 THROTTLING BUSH LB2 1 3 4 x2 1 4 x1 1 2 LS0 17 LIP SEALS 0 L 1 3 4 2 1 4 3 8 17 8 6 9 STATOR BUSH O L A2 12mm40SH S HEAD C SCREW A2 1 3 4 x2 1 4 x4 RHscr 12mm x 40mm S H C S 17 8 6 14 L T ADAPTOR O L 17 L T A x 2 1 2 L T 17 8 6 15 L T A BUSH O L 1 3 4 x2 1 4 x6 LB2 17 8 16 STATOR P BREAK TUBE 13442134R IMPELLER SHAFT 4STAGE 15NB S S x 235 MM 1 3 4 SS x 64 x 1 3 4R 16mm55G BOLTS amp NUTS STA ADP 16mm x 55mmGAL 17 21A ADAPTOR 17 21 17 21 ADP 16mm55G BOLTS amp NUTS ADP COL 21 17 8 COLUMN 8FT x21 16mm x 55mm GAL 21 x96 CLAMP GAL 16mm55G NUTS amp BOLTS COL COL 16mm x 55mm GAL 300LT54MF BOT LUBE TUBE COL PUMP 3 GAL X 48 FM X FM 300LTA48FF 3 NB GAL L T x 48 F M x F M 3 GAL x 48 F M x F M 300J134LS LUBE TUBE JOINERS Stube x 1 3 4 1 INTER SHAFT W L 5 5 1 3 4 S SDia x Len Req 2 TOP SHAFT S S
30. mount of never seize to the thread of the line shaft protruding from the lube tube in the pump and screw a muff coupling half way onto the line shaft Lift the next 8 section of drive shaft and lube tube from the ground and position at the correct angle to allow you to screw the line shaft into the muff coupling Apply a small amount of never seize to the thread of the line shaft and screw the shaft into the muff coupling until it bottoms firmly onto the bottom line shaft Apply liberal amounts of stag paste to the thread of the lube tube joiner and screw the suspended tube on to the joiner until it firmly butts against the bottom lube tube Using an appropriate lifting sling pick up the next column section and slide it along the rails over the lube tube Lineshaft until it butts against the existing top column make sure the spider mount web inside the column does not entangle the lube tube as it is fitted this is best achieved by making sure the spider is positioned to the topmost point and the natural droop of the lube tube will allow the correct entry Rotate the new column 180 degrees and fit the column flange bolts and nuts Fit the lube tube clamp saddle and two bolts and nuts with lock nuts Lower the pump assembly until the correct workstation is once again achieved Repeat all the steps again until all column sections are installed WARNING Do not forget to install 250 ml of oil into every lube tube as pump seizure may result if not don
31. n and Service Manual 6 Jan 04 4 3 4 3 Xo X 4 4 Fit Support Rails If customer supplied or some other type of weld insitue rail support pylons are to be used bolt the support rails together supported with bracing then weld the cross rails onto the pylons making sure of alignment and the 36 deg angle then refer to the Pump Fitting section below For BATESCREW supplied standard pump supports Run two string lines down the bank to give alignment for pylon upright positioning The knee braces are bolted to the pump support Fit Support Rails Install the pump knee brace support base onto the slab aligned with the desired center of the pump and orientated to the desired line of the pump down the bank Position the first set of upright support rail posts onto the pylons and attach the cross braces between them check they are vertical and correctly aligned When you are sure the uprights are true drill the bolt holes and fit the anchors into the pylons Bolt the first cross beam support between the first set of support uprights Position the second set of support uprights amp bolt the next cross bearer between them Repeat the procedure until all the support bearers are in place Join the slide rails together as you slide them into position on to the cross bearers down the bank The last or top slide rail bolts to the pump knee brace support base that has fishplates to accept it Using a string line and angle indicator adjus
32. ny showing wear 6 2 Disassembly of Wet End Assembly IT IS RECOMMENDED THIS BE DONE BY BATESCREW Remove any lube tubes shafts and grease line fittings that may still be attached Remove the stator to column adapter bolts and remove the column adaptor Remove the top stator to running ring bolts and remove the top stator exposing the top impeller and impeller shaft ready to measure Attachment of the impeller to the shaft is by taper lock with bolt on retaining plate The position of the top impeller on the shaft must be noted Measure from the top threaded end of the shaft to the impeller face and also the taper lock face Remove the intake bell to bottom running ring bolts and slide the intake from wetend Unscrew stainless steel bolts attaching the taper lock plate to the impeller and remove the taper lock plate from the bottom impeller Whilst protecting its end and thread rest the top end of the impeller shaft on a solid surface Being careful not to damage the impeller give the impeller a swift blow from below This will shock the impeller from the taper allowing its removal Remove the taper from the shaft Remove the impeller from the wet end Remove running ring to stator bolts and remove the running ring from the wet end Remove the stator to second running ring bolts and slide the stator from the shaft exposing the next impeller and locking plate Repeat the procedure until all impellers and running rings have
33. or other consequential damages The warranty does not exclude any condition or warranty implied by the trade practices act 1974 or any state legislation but in all other respects the warranty is in lieu of other warranties expressed or implied and all other obligations or liabilities No promise representation or statement by any employee representative or agent of the Company or by any other person shall add to vary or modify this warranty or give use to any obligation on the part of the company Further no promise representation or statement by any employee representative or agent of the Company relating to the suitability of the equipment for any purpose shall bind the company or give rise to any obligation on the behalf of the Company 25 Batescrew Pumps Operation and Service Manual 14 Data Sheets And Parts Lists 6 Jan 04 PUMP RECORD SHEET DATE 07 08 2003 PUMP NO 7634 CLIENT Cave amp Weier PUMP SIZE 17 214sta o l 56 36d c pto e a c The Bauhinias JOB NO 5628 PHONE NO 0749842600 QUOTE NO DD5023 Gai FAX NO 0749842522 ORDERNO 22259 ACC NO ADDRESS 4 Daniel st Emerald DATE ORDE1 7 07 2003 DELIVERYADDRESS _ tobe arranged CARRIER amp DETAILS CONSIGNMENT NO CARRIER NO DATE OF DELIVERY 13 09 2008 SOLD BY DD AGENT ANGLE APPLICATION ROTATION CW ELECTRIC DIRECT COUPLED PTO 10100gpmat52 4ft 200 hp
34. outlines the suggested way to manually start run and close down your pump set It by no means covers every application and every eventuality Auto operation is not covered in this manual and correct operation of auto start stop and run pump stations must be set by the controller manufacturer installer bearing in mind the needs for protecting these pumps from running dry or out of lubrication If problems occur in start up or running of your pump set call Batescrew Technical Department for help Whilst Batescrew design and build these pumps with performance and safety in mind it is solely the responsibility of the operator to always maintain amp operate the equipment in a safe and appropriate manner bearing in mind today s ever changing occupational and health requirements Special care must be taken in relation to appropriate safety covers on all moving parts 13 Batescrew Pumps Operation and Service Manual 6 Jan 04 6 Removal Disassembly and Assembly 6 1 Disassembly The disassembly of the pump may be for any number of reasons It is assumed here that disassembly is for impeller replacement Note the direction of rotation of the pump VERY IMPORTANT Disassemble the pump in the reverse procedure as for assembly as described earlier in this manual until the drive extension has been removed Unscrew the bolts securing the head to extension drive seal plate then remove the seal plate and ring seal Disconnect th
35. t the support cross beams to achieve the correct angle and straightness of the support rails Check all nuts and bolts for correct tension Do not fit the top knee braces to the pump support base If you fit knee braces it will be in the way when assembling pump Install the motor support frame and extension drive support rails using a string line and angle indicator to get the correct alignment Fit Pump The wet end would have been supplied complete including the pump to column adaptor and some column sections check that this is undamaged and clean Using appropriate lifting equipment lift the main pump assembly wet end and attached column sections from the ground to a position above and in line with the support rails make sure the pump is held so that it sits at the correct angle and rotation for fitting Lower the pump assembly until it sits correctly in the support rails and secure it using a strong lifting device allow the pump to slide down the rails until the next column section and lube tubes will fit onto the work position Apply liberal amounts of stag paste to the thread of one lube tube joiner and Screw the lube tube joiner half way into the top of the lube tube protruding out of the top column section fitted to the pump Batescrew Pumps Operation and Service Manual 6 Jan 04 4 X Assembly and Installation Pump 250ml of Tellus 32 or 42 oil into the top lube tube to pre lube the pump Apply a small a
36. tion tank Shell Tellus 32 or equivalent Grease nipples Shell Alvania EP3 or equivalent Special Fittings Service Schedule Every 30 days in std conditions and every 7 Clean motor cooling fins and air intakes 2 2 days in severe conditions Every day if running continuously or 15 Fill oil tank minutes before start on intermittent use Once a week continuous running once a Grease nipples 4 month on intermittent 2 pumps only in each Check drive shaft coupling Once a month Check attaching nuts and bolts Once a month Twice a day on continuous use or every start Check pump for vibrations noise etc up on intermittent use Check inlet screen Daily Check wiring and lines Every start up Position Lubricant Sealant On the shaft inside bush Smear of TEFLON grease On the shaft inside lip seal SILICON grease On bolts amp inside nuts COPPER based grease Between grease line fittings TEFLON tape or paste Between flange faces Mix 1 2 multigrade oil amp black TAR paint On shaft inside couplings COPPER based grease On lube tube joints STAG jointing compound or TEFLON paste On shaft inside thrust bearing COPPER based grease On tension nut face to head STAG jointing compound On oil line fittings TEFLON tape or paste 19 Batescrew Pumps Operation and Service Manual 9 Trouble Shooting Pumps
37. unting point for column support it also contains the top drive shaft drive extension mounts The discharge head unit also turns the water flow through 36 deg so that correct pipe alignment can be achieved Usually mounted to the discharge head is the oil reservoir that provides the lubrication for the bearings in the pump 3 5 Drive Extension The drive extension continues the lube tube and drive shaft from the discharge head to the thrust bearing mount at a point above flood level it s purpose is drive shaft support and lubrication supply 3 6 Drive Shaft The drive shaft attaches to the top of the thrust bearing and connects the top shaft to the motor shaft The drive shaft must be covered with a safety cover by law and removal and operation without the safety cover is forbidden Batescrew Pumps Operation and Service Manual 6 Jan 04 3 Description 3 7 Motor Mount Motor mounting is achieved by a motor mounting frame which attaches to the pump mount plate and allows the motor to be attached in line with the pump shaft and thrust bearing whilst allowing room for the drive shaft to be fitted and access for shaft end play adjustment to be performed 3 8 Drive Motor The motor is a solid shaft foot mounted type selected for the power requirements of the individual job The RPM and HP of the motor are matched to the requirements of the pump at the rate and head required and should only be replaced with a similar motor Wiring of the motor
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