STS MAC JR 1200E Operator's Manual
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STS MAC JR 1200E Operator's Manual

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Surface to Surface Inc.
Operators Manual
** MAC JR 1200E **
USE IN CONJUNCTION WITH M2-E922 MIXER MANUAL (ENCLOSED)
Unit Serial No. _______________
M2-E922 Mixer
Serial No. ______________
Links relating to this Manual
www.stsmixers.com
Dealer
STS-175 Rev. 03/12/19
www.stsmixers.com

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  • Page 1 ® Surface to Surface Inc. Operators Manual ** MAC JR 1200E ** USE IN CONJUNCTION WITH M2-E922 MIXER MANUAL (ENCLOSED) Unit Serial No. _______________ M2-E922 Mixer Serial No. ______________ Links relating to this Manual www.stsmixers.com Dealer STS-175 Rev. 03/12/19 www.stsmixers.com...

  • Page 2: Table Of Contents

    Safety Statements……………………………….…………….…...………… Safety Markings………………………………………….….………………. Main Working Components (Photo)…………………….………….……… Introduction to the MAC JR 1200E ……….……….…….…….…..………. MAC JR 1200E Foot Print (top view)……………………………………..… 13 MAC JR 1200E General Data Sheet ……………..……….…….……..……. 14-15 Identifying Your Machine & Components …………………………..……. SECTION II ( Description, Care and Maintenance) Base Skid with Tanks .……….………..…..…...…….….…..…….…...
  • Page 3 TABLE OF CONTENTS PAGE SECTION III (Set-up and Connection of unit in Detail) Site Set-up (work mode) ……………………………………..……….. Hose Connections ……………..………..….……….…..….….…….. Site Tear-down (transport mode) …………………….…..….…….….. SECTION IV (Operating the MAC JR 1200 Unit.) Site set-up and pre-check …………………………………………….. Mixing New Drilling Fluid …..………………………………..…… Transferring New Drill Fluid to Active Tank ………..……………….
  • Page 4 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair / Information) Leveling Jack Breakdown ………………………...…...…..…….……… Gruvloc® Pipe Couplings ………….…….….…..…….…….……..…… 52-54 SECTION VIII (Parts Manual) MAC JR 1200E PARTS MANUAL ………………….……………….…. 56-63...

  • Page 5: Sts Inc. Warranty

    Limited Warranty United States and Canada Surface to Surface Inc. or it’s subsidiary which last sold the product, warrants new products sold by it for use in the United States and Canada to be, at the time of manufacture, free from defects in workmanship and materials. This warranty covers for a period of Twelve (12) Months of operation from the date of delivery for initial use, whichever comes first.

  • Page 6: Safety Statements

    MAC JR 1200E SAFETY STATEMENTS Your personal safety and the safe operation of this unit are the concern of Surface to Surface Inc., and by reading and understanding this manual and understanding the safety statements, you will decrease the risk of personal and equipment damage.
  • Page 7 MAC JR 1200E SAFETY STATEMENTS The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. DANGER WARNING NEVER USE BODY PA RTS, NEVER TRANSPORT OR FOREIGN OBJECTS the unit without t he wheel locks...
  • Page 8 MAC JR 1200E SAFETY STATEMENTS continued The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. CAUTION CAUTION WHEN THE UNIT AVOID ALLOWING FOREIGN M AT ERIAL IS IN OPERATION, into the T anks.
  • Page 9 MAC JR 1200E SAFETY STATEMENTS continued The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. CAUTION T he manufacturer should be consulted when considering alternative uses for this piece of equipment.

  • Page 10: Safety Markings

    MAC JR 1200E Safety Markings Hazard and warning markings have been placed at appropriate points on the unit. International symbols have been used, in order to ensure universal understanding of the nature of the hazard. Please comply with all warnings and markings to ensure safe use of the equipment.

  • Page 12: Introduction To The Mac Jr 1200E

    The MAC Junior 1200 is built as one unit that includes 3 tanks, each with injector nozzles, a manifold assembly of hydro-cyclones, a STS M2 mixer and all the valves and piping to needed to create a smooth and effortless system.

  • Page 13: Mac Jr 1200E Foot Print (Top View)

    212" 25" MAC JR 1200E 96" (Transport mode) ** wheels down, tongue extended 86" (Work mode) ** wheels up, tongue retracted (transport mode) 73" (work mode) 36" (work mode) Surface to Surface Inc. 12" ® DWR. NUM. DATE. 01 / 17 / 13 MAC JR 1200E REV.

  • Page 14: Mac Jr 1200E General Data Sheet

    The mixer located at the rear of the unit is designed around the time proven M series mixers of STS. The MAC Junior 1200E is powered by a 10HP Teco/Westinghouse electric motor, driving a 2” centrifugal pump, making effective use of the renowned 4 point mixing system.
  • Page 15 Hopper Height & Size 26 1/2” High Holds ½ of a bag Low hopper height reduces back strain. Mixing System 2” Renowned StS Mixing System Fast & efficient with high shearing ability. Flow Valves Brass and Steel construction Withstand the abuse of daily operations Skid Frame 1”...

  • Page 16: Identifying Your Machine & Components

    MAC JR 1200E Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 17: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 18: Base Skid With Tanks

    MAC JR 1200E Description, Care and Maintenance Base Skid with Tanks The base skid is built to support the 3 tanks and allow the unit to be transported from work site to work site with a unique set of wheels that can be raised or lowered (Fig.1a) and a retractable tongue (Fig.1b) for connecting to a transporting device.
  • Page 19 MAC JR 1200E Description, Care and Maintenance Base Skid with Tanks There are 3 tanks atop of the base skid. The front tank is 600us. gal, and is referred to as the “active” tank. The middle tank is 300us. gal and is referred to as the “dirty” tank. The back tank is also 300us. gal and is referred to as the “mixing”...
  • Page 20 MAC JR 1200E Description, Care and Maintenance Base Skid with Tanks The middle and back tanks have labeled inlet ports (Fig.3a, 3b), on both sides of the unit, to receive the appropriate (labeled) fluid and should be used to make a safe and solid connection for the filling hoses.

  • Page 21: Internal Tank Nozzles

    Connect the manifold to the outlet on the filter/shear of the STS Mixing Unit. Each unit is shipped with 2-4 jet nozzles that have been properly sized for the unit.

  • Page 22: External Piping

    MAC JR 1200E Description, Care and Maintenance External Piping Mounted on the exterior of the tanks is a series of piping and valves (Fig.5) that allow the operator to move fluid from mixer to tanks and or tank to tank. The suction manifold is located at the bottom of the tanks and each tank has a valve installed to control the fluid flow.

  • Page 23: Leveling Jacks

    MAC JR 1200E Description, Care and Maintenance Leveling Jacks Mounted on the back corners and on the front of the MAC JR 1200 are crank type leveling jacks (Fig.6). These jacks are used to raise and lower the unit for transporting, and when setting up on site, to level the unit on uneven ground.

  • Page 24: Cone Head Assembly

    MAC JR 1200E Description, Care and Maintenance 2 Cone Head Assembly The 2 cone head assembly (Fig.7) is mounted on the front of the MAC JR 1200, over top of the active tank. The head assembly consists of 4 key components that are explained in more detail in following pages. The cone manifold, equally distributes the incoming fluid to the hydro-cyclones.

  • Page 25: Cone Manifold

    MAC JR-1200 Description, Care and Maintenance Cone Manifold The cone manifold (Fig.8) allows the oncoming fluid to be evenly distributed to the 2 hydro-cyclones. The cone manifold has a removable inlet pipe to allow for cleaning or winterizing. The manifold has a pressure gauge mounted on top. This gauge measures the fluid pressure inside the manifold, to set and keep the hydro-cyclones at the proper operating pressure “see affixed label on unit”.

  • Page 26: Hydro-Cyclones

    MAC JR 1200E Description, Care and Maintenance Hydro-cyclones The Hydro-cyclones (cones) (Fig.9a) are the first step in cleaning process of the spent drilling fluid. The fluid enters the cones from the manifold and the flow and pressure create a spiraling effect (like a tornado) inside of the cone.

  • Page 27: Over-Flow Box

    MAC JR 1200E Description, Care and Maintenance Over-Flow Box The over-flow box (Fig.10a) is located on the back side. This box collects all the over flow from the 2 hydro-cyclones. The hydro-cyclone over flow hoses (canes) are held in place by positioning the hoses in the center of the box between the 2 spacers (Fig.10b).

  • Page 28: Under-Flow Box

    MAC JR 1200E Description, Care and Maintenance Under-Flow Box The under-flow box (Fig.11a) is mounted on the front, underneath the hydro-cyclones. The under-flow from the hydro-cyclones sprays down onto the bottom of the box and then flows out of a 3”...

  • Page 29: Valves On The M2-922 Mixer

    MAC JR 1200E Description, Care and Maintenance Valves on the M2-922 Mixer Mounted on the M2-922 mixer are 2 valves that have been reconfigured for use with the MAC JR 1200 and are not explained properly in the enclosed M2-922 Operators Manual.

  • Page 30: Set-Up And Connection Of Unit In Detail

    SECTION #III Set-up and Connection of Unit in Detail...

  • Page 31: Site Set-Up (Work Mode)

    MAC JR 1200E Set-up and Connection of Unit in detail Site Set-up (work mode) A few general guidelines to follow when setting up a work site  Set all equipment on flat level solid ground.  Allow clear access around the MAC JR 1200.

  • Page 32: Hose Connections

    MAC JR 1200E Set-up and Connection of Unit in detail Fig.11 DANGER NEVER ATTEMPT TO PUT MAC JR 1200 Shown in Work Mode THE UNIT INTO OPERATION All hoses to be kept as short as possible without lowering th e unit to the ground Unit is on the ground and leveled.

  • Page 33: Site Tear-Down (Transport Mode)

    MAC JR 1200E Set-up and Connection of Unit in detail Site Tear Down (Transport mode) When the MAC JR 1200 is needed to change locations, a towing device will be required. ALL FLUID MUST BE REMOVED FROM ALL TANKS. Drain and disconnect all hoses that were connected to the unit.

  • Page 34: Operating The Mac Jr 1200 Unit

    SECTION #IV Operating the MAC JR 1200 Unit...

  • Page 35: Site Set-Up And Pre-Check

    MAC JR 1200E Operating the MAC JR 1200 Unit Site Setup & Pre-Check SITE SETUP  POSITION the unit to have a clear unobstructed working area on all 4 sides.  POSITION the unit on solid level surface to avoid settling or upset.

  • Page 36: Mixing New Drilling Fluid

    MAC JR 1200E Operating the MAC JR 1200 Unit Mixing New Drill Fluid The M2-922 Operators Manual (included separately) must be read and understood before using this piece of equipment! Mixing Operation With the “Mix” tank full of fresh water- ...

  • Page 37: Transferring New Drill Fluid To Active Tank

    MAC JR 1200E Operating the MAC JR 1200 Unit Transferring New Drill Fluid to Active Tank Transferring New Drilling Fluid to Active Tank  Switch the M2-922 mixer motor OFF.  Rotate the 3-way valve “A” to position “Flow to valve B”.

  • Page 38: Agitating The Active Tank

    MAC JR 1200E Operating the MAC JR 1200 Unit Agitating the Active Tank Agitating the Fluid in the Active Tank  Switch the M2-922 mixer motor OFF.  Close the “Mix” tank suction valve.  Open the “Active” tank suction valve.

  • Page 39: Cleaning The Dirty Fluid For Re-Use

    MAC JR 1200E Operating the MAC JR 1200 Unit Cleaning the Dirty Fluid for Reuse Cleaning the “Dirty” Fluid for reuse The “Dirty” fluid tank is now full of dirty fluid from your sump (customer supplied pump) and it is now ready to be “Cleaned”...

  • Page 40: Warm Weather

    MAC JR 1200E Operating the MAC JR 1200 Unit Warm Weather Shutdown & Storage Daily Shut Down  Follow “Daily Shut Down Instructions” in the M2-922 operators manual to shut down the mixer.  If tanks are empty, load some fresh water (100gal) into the mix tank and pump fresh water though the piping from tank to tank then suck all water back into the mix tank for reuse.

  • Page 41: Cold/ Freezing Weather

    MAC JR 1200E Operating the MAC JR 1200 Unit Cold Weather Shutdown & Storage Additional Winter and Freezing Weather Shut Down Note: all fluid is to be dispose of according to local environmental approved practices.  Follow “Additional Winter and Freezing Weather Shut Down Instructions” in the M2-922 operators manual.

  • Page 42: Prolonged Periods Of Storage

    MAC JR 1200E Operating the MAC JR 1200 Unit Prolonged Periods of Storage Prolonged Periods of Storage  Follow “ Prolonged Periods of Storage Instructions” in the M2-922 operators manual. After a thorough cleaning of the internal and external components of the MAC JR 1200, the following steps should be applied to extend the life of your unit.

  • Page 43: Trouble Shooting The Mac Jr 1200

    SECTION #V Troubleshooting the MAC JR 1200 Unit...
  • Page 44 MAC JR 1200E Troubleshooting the MAC JR 1200 Unit The MAC JR 1200 is used in conjunction with the M2-922 mixer. The M2-922 mixer has its own operators manual with a trouble-shooting section and should be referred to when there is a problem with the M2-922 mixing abilities.
  • Page 45 MAC JR 1200E Troubleshooting the MAC JR 1200 Unit continued  High manifold pressure. Valve “C” open to far. - Readjust valve. Hydro-cyclone(s) plugged. - Shutdown system and unplug cone(s). Manifold to cone outlet plugged. – Remove blockage.  Hydro-cyclone discharge irregular or roping.

  • Page 46: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 47: Maintenance Schedule

    MAC JR 1200E Electric Periodic Maintenance Schedule Maintenance Items Before Every 8 hours Every 50 hours Every 200 hours Every 1000 Every 2000 (daily) (weekly) (monthly) hours hours (or yearly) MAC JR 1200 Components Visual check of base skid and structure for damage.

  • Page 48: Bolt Torque Specifications

    MAC JR 1200E Bolt Torque Specifications Grade 5 Grade 8 SAE SIZE Lubricated * Dry ** Lubricated * Dry ** ft-lbs ft-lbs ft-lbs ft-lbs 13.5 12.5 5/16 7/16 9/16 1050 1300 * "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

  • Page 49: Notes

    MAC JR 1200E NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 50 SECTION #VII OEM Repair Information...
  • Page 55 SECTION #VIII (Parts Manual)
  • Page 56 1.000 Surface to Surface Inc. ® DATE. 11 / 23 / 12 DWR. NUM. Total Weight without Mixer and NO options = 2500 lbs (March 11 2019) Basket replaces "Y" strainer MT3X1500-84 REV. 03 / 07 / 19...
  • Page 57 MAC JR 1200 ASSEMBLY PARTS LIST STS PART NUMBER QTY REQ. REF # DESCRIPTION 5/8" x 4 1/2" Bolt 076-13321 Tank MT-3X1500-03 5/8" Stover Loc Nut 076-37272 Return Pipe MT-3X1500-22 3/8" U-Bolt MT-3X1500-28-A 2" NPT Cored Pipe Plug 018-318090256-6 3/8" L/W...
  • Page 58 MAC JR 1200 2" PIPING ASSEMBLY PARTS LIST M2-922 STS PART NUMBER QTY REQ. RE F # DESCRIPTION Mixer 2" Male Cam-loc x Hose Barb 025-200-E-AL Hose Clamp 025-HS-32 2" Rubber Hose MT-3X1500-40-D 2" NPT x Hose Barb 018-1661268241 2" NPT 90° Street Elbow...
  • Page 59 MAC JR 1200 2" SUCTION PIPING ASSEMBLY PARTS LIST STS PART NUMBER QTY REQ. REF # DESCRIPTION 2" Male Cam-loc x Hose Barb 025-200-E-AL Hose Clamp 025-HS-32 2" Rubber Hose MT-3X1500-40-D Suction Manifold MT-3X1500-20 2" Groove Bolt Type Clamp 020-390-00026-3 2"...
  • Page 60 MAC JR 1200 CONE HEAD ASSEMBLY PARTS LIST ( P/N #MT-3X1500-87) (No Flock) STS PART NUMBER QTY REQ. REF # DESCRIPTION 3/16" Large back-up washer 076-1133202 Shield Spacer H360-2-014-C Over-Flo Box Rubber Shield H360-2-014-B Rivet 3/8" x 3/8 grip 076-41027 1/4"...
  • Page 61 BOTTOM (note position of hole on spindle when mounting backing plate to spindle.) MAC JR 1200 WHEEL ASSEMBLY with ELECTRIC BRAKES P/N #MT-3X1500-130-R #MT-3X1500-130-L STS PART NUMBER QTY REQ. REF # DESCRIPTION Wheel Spindle with Flange c/w #5 MT-3X1500-136 7/16"...
  • Page 62 MAC JR 1200 CONE HEAD LIFT ASSEMBLY PARTS LIST STS PART NUMBER QTY REQ. REF # DESCRIPTION Left Side Slider #MT-3X1500-95-L Right Side Slider #MT-3X1500-95-R Push Mount #MT-3X1500-95-A Slide Rail #MT-3X1500-91 3/8" x 1 1/4" FHSCS 076-24287 3/8" L/W 076-33622 3/8"...

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