STS M2-D2 Operator's Manual

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

Surface to Surface Inc.

Operators Manual

** M2-D2 **

USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)

Unit Serial No. _______________

Yanmar Engine

L100V – Serial No. ______________

Gorman-Rupp Pump

GR-82E2 – Serial No. ________________

Links relating to this Manual

www.stsmixers.com

www.yanmar.com

www.grpumps.com

Dealer

STS-101 Rev. 08/08/18

www.stsmixers.com

Table of Contents

Need help?

Do you have a question about the M2-D2 and is the answer not in the manual?

Questions and answers

Summary of Contents for STS M2-D2

Page 1 Surface to Surface Inc. ® Operators Manual ** M2-D2 ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Yanmar Engine L100V – Serial No. ______________ Gorman-Rupp Pump GR-82E2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com...
Page 2 This page left blank intentionally...
Page 3: Table Of Contents
TABLE OF CONTENTS PAGE STS Inc Warranty ………………………………………………………..Safety Statements ………………………………………………..………… 7-10 Safety Markings …………………………………………………………… Main Working Components (Photo) ……………………………………… Hose Connection (Hook-up) …………….…………………………………. Introduction to the M2-D ……………….…………………………..……. M2-D Foot Print (top view) ……………..………………………………… M2-D General Data Sheet …………..…………………………………….
Page 4 TABLE OF CONTENTS PAGE SECTION IV (Operating the M2 Unit.) Site set-up and pre-check …………………………………………….. Starting the engine and Pump ………………………..……………… Typical mixing operation (dry product) ……….….……….…………. Typical mixing operation (dry polymers) ……….….……….…………. Typical transfer / off-loading operation ……………………………… Shutdown, cleanup & storage Warm weather …………………………………….………….
Page 5 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair Information) GR Centrifugal Pump Owner’s Manual (condensed) ….……………… 50-61 Engine Manufacture Customer Help (web-site) …………...…………. Gruvloc® Pipe Couplings ……………………….……...………..…… 63-65 SECTION VIII (Parts Manual) M2-D PARTS MANUAL ……………………….……………………. 67-69...
Page 6: 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 7: Safety Statements
M2-D 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. Safety statements are listed here and throughout this manual to draw your attention to potential hazards that may be encountered while operating this piece of equipment.
Page 8 M2-D 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 ATTEMPT TO REMOVE IN AN EMERGENCY OR CLEAN THE FILTER SHEAR rotate the throttle control lever to while the unit is in operation.
Page 9 M2-D 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 TRANSFERRING FLUID TRAPPED FLUID MAY BE PRESENT to the drill rig, fluid pressure may and will spill out when piping, hoses, reach or exceed 50 p.s.i.
Page 10 M2-D 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 The manufacturer should be consulted LIFTING LUGS OR THE LIFTING POINT(S) when considering alternative uses identified and labelled on the skid for this piece of equipment.
Page 11: Safety Markings
M2-D 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. These include but are not limited to: a) Lifting points b) Flammable Liquids c) High temperature areas...
Page 13: Hose Connection (Hook-Up)
Surface to Surface Inc. M2 Series FLUID OUTLETS [to Drill Rig & Tank Guns] (Hose Hook-ups) ** 1 1/2" NPT ** PUMP INTAKE [in from Tank] ** 2" NPT ** This line should have a valve installed at the tank to facilitate shut down or reapirs. FLUID RETURN [out to Tank] ** 2"...
Page 14: Introduction To The M2-D
M2-D Operators Manual Congratulations on your acquisition of the world renowned M2-D Mixing System. You have acquired the fastest and most efficient mixing system manufactured for mixing Bentonite drilling slurry (mud). As a manufacturer of HDD support equipment, we are well aware of the extreme conditions that HDD equipment is exposed to on a daily basis.
Page 15: M2-D Foot Print (Top View)
26 1/2" 33" 39" M2-D (Diesel) Dry Weight: 350 Lbs (159 Kg) Surface to Surface Inc. ® 03 / 06 / 12 DWR. NUM. DATE. * Due to our continuing product improvement, specifications are subject to change without notice. * M2-D REV.
Page 16: M2-D General Data Sheet
M2-D Mixer The M2-D universal mixer is designed around the time proven M series mixers of STS. Powered by a 9 hp air-cooled diesel engine, driving a 2” centrifugal pump, making effective use of the proprietary 4 point mixing system. The M2-D can be used as a new installation or retro fitted into an existing tank.
Page 17: Identifying Your Machine & Components
M2-D Identifying Your Machine & Components Location of Tags and PIN Plates...
Page 18: Description, Care And Maintenance
SECTION #II Description, Care and Maintenance...
Page 19: Diesel Powered Centrifugal Pump
M2-D Description, Care and Maintenance Diesel Powered Centrifugal Pump Care and maintenance of the engine and pump are covered in this manual and/or the manufacturer operator’s manuals supplied and should be read and understood. We suggest the following daily checks be carried out prior to using the system.
Page 20 M2-D Description, Care and Maintenance Diesel Powered Centrifugal Pump Fig.4 CAUTION TRAPPED FLUID MAY BE PRESENT and will spill out when piping, hoses, pump or filter shear are removed. CAUTION NEVER LEAVE LIQUID IN THE PUMP CASING, PIPING, OR HOSES during freezing weather conditions, as damage will result.
Page 21 M2-D Description, Care and Maintenance Diesel Powered Centrifugal Pump Grease cup instructions (Fig.5) Fill the grease cup through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal.
Page 22 M2-D Description, Care and Maintenance Diesel Powered Centrifugal Pump Grease cup instructions (Fig.5a) GREASE CUP NEEDS TO BE CLEANED REGURALY The grease cup may not perform its function properly (lubricating the seal) if it is not routinely cleaned of old hard grease build-up. If the grease cup is always “topped up” instead of allowed to run to the full stroke of the plunger, the grease may dry out and build up inside of the cup and not allow the plunge to push to the full stroke.
Page 23: Filter Shear System
M2-D Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M2-D is an integral part of the mixing system and to operate efficiently requires daily cleaning of the stainless steel internal filter /shear. The filter / shear system is a two- piece unit (Fig.6b) consisting of an outside housing and an internal filter / shear.
Page 24 M2-D Description, Care and Maintenance Filter / Shear System continued On the bottom of the filter / shear housing (Fig.7) are two outlets that have 1 1/2” NPT ball valves connected to them. One of the outlets is to be connected to the internal tank jets inside of the reservoir tank (explained further on in this manual) and the other outlet is to be used as a discharge for the fluid after it is mixed.
Page 25: Venturi Mixing Tee
M2-D Description, Care and Maintenance Venturi Mixing Tee The Venturi Mixing Tee (Fig. 8a.) is the very heart of this system and requires very little maintenance. However M2 parts may wear as a result of the application, in time and require replacement. This wear will become evident, when the operator notices a reduction in the vacuum that helps pull in the dry product from the hopper.
Page 26: Wash Wand
M2-D Description, Care and Maintenance Wash Wand The M2 is equipped with a pressurized wash wand (Fig.9a) for clearing obstructions and accumulation in the jetting tee. It is recommended that the jetting tee be cleaned with the wash wand after the introduction of material into the hopper after each batch.
Page 27: Dry Hopper & Hopper Valve
M2-D Description, Care and Maintenance Dry Hopper and Hopper Valve The Dry Hopper (Fig.10) is used during the initial mixing of the dry product and fluid. The hopper requires very little daily maintenance. Keeping the inside surface of the hopper clean will help the dry product flow smoothly into the hopper valve and into the mixing tee.
Page 28: Internal Tank Jets
The internal tank jets are connected together in series, usually by a manifold design, (suggested by STS) were all jets receive the same amount of fluid and pressure. This manifold design is supplied with fluid from one of the outlets on the filter / shear housing (Fig.11b).
Page 29 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 30: Set-Up And Installation Of Unit In Detail
SECTION #III Set-up and Installation of Unit in Detail...
Page 31: Permanent Mounting Of Unit
M2-D Set-up and Installation of M2 in detail Permanent mounting of the unit The M2 is built on a sub frame with isolators (pucks) attached to the bottom. The unit can be fastened down to a permanent surface like a concrete pad, pull type trailer, flat deck of a truck or inside of a truck body.
Page 32: Operating The M2 Unit
SECTION #IV Operating the M2 Unit...
Page 33: Site Set-Up And Pre-Check
M2-D Operating the M2 Unit Site Setup & Pre-Check SITE SETUP  CHECK for overhead hazards if unloading the unit to the ground.  UNLOAD the unit by using the sub frame lifting bale (marked) with appropriate equipment.  and position the unit on solid level surface to avoid settling or upset. ...
Page 34: Starting The Engine And Pump
M2-D Operating the M2 Unit Starting the Engine & Pump *** The Engine Operators Manual should be consulted for a more detailed engine start up procedure for both recoil and electric start engines The M2-D mixer IS NOT EQUIPED WITH A BATTERY. 12volt post terminals are installed on the unit and a remote battery and connection can be made.
Page 35: Typical Mixing Operation (Dry Product)
M2-D Operating the M2 Unit Typical Mixing Operation Dry Products Mixing Operation:  With the tank full of water.  Operate the engine at high speed.  If not already open, open internal tank jet valve.  Open the hopper valve at the bottom of hopper where it joins the venturi-mixing tee. ...
Page 36: Typical Mixing Operation (Dry Polymers)
M2-D Operating the M2 Unit Typical Mixing Operation Dry Polymers Mixing Operation:  With the tank full of water.  Operate the engine at high speed.  Open the hopper valve at the bottom of hopper where it joins the venturi mixing tee. ...
Page 37: Typical Transfer/Offloading Operation
M2-D Operating the M2 Unit Typical Transfer/Offloading Operation Transferring Operation  On the bottom of the filter / shear housing of the M2 you will see a second 1-1/2 in. ball valve (1-1/2”NPT.) marked “Outlet”(the first “outlet” is connected to the internal tank jets) ...
Page 38: Warm Weather
M2-D Operating the M2 Unit Typical Warm Weather Shutdown & Storage Daily Shut Down  Set the engine speed control lever (Fig. 13b) at the low speed position and allow the engine to run at low speed for 5 minutes. ...
Page 39: Cold/ Freezing Weather
M2-D Operating the M2 Unit Typical Cold Weather Shutdown & Storage Additional Winter and Freezing Weather Shut Down  Pump or drain remaining mixed fluid out of the tank and dispose of it according to local environmental approved practices.  Make sure both “Outlet” valves are open. ...
Page 40: Prolonged Periods Of Storage
M2-D Operating the M2 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M2, the following steps should be applied to extend the life of your unit.  Prolonged periods of storage require extra care of the pump to protect from rusting internally. Separate the pump (as you would to replace the seal) to dry and spray with a protective oil film.
Page 41: Trouble Shooting The M2-D
SECTION #V Troubleshooting the M2 Unit...
Page 42 M2-D Troubleshooting the M2 Unit The M2 mixing unit is of a simple design with limited moving parts or consumable pieces. The basic system works with a pump that draws fluid from a reservoir tank. The fluid then exits the pump and by building pressure, and velocity, forces the fluid through the filter / shear and into the mixing Tee.
Page 43 M2-D Troubleshooting the M2-D Unit  Tank does not stir / roll the fluid inside. No fluid to the tank jets - Make sure “Outlet” valve is open. Tank jet holes plugged. - Flush fresh water through system or clean tank jets. Hose is disconnected from tank jet - Reconnect hose No fluid flow/ low fluid flow - See above solutions ...
Page 44: Periodic Maintenance & Repair Information
SECTION #VI Periodic Maintenance & Repair Information...
Page 45: Maintenance Schedule
M2-D Periodic Maintenance Schedule Consult the OEM engine manual for a more detailed maintenance schedule Engine Components (as taken from engine manual) Every Every Every 2000 Every Every Every Every Maintenance Items hours hours hours (or hours (daily) hours hours hours (weekly) (monthly)
Page 46: Centrifugal Trash Pump Seal Replacement
M2-D Grease Seal Installation Instructions Centrifugal Pump Application When replacing the seal, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal. PACKING RINGS SEAL PLATE Before installing the seal, inspect the bore of the seal liner for...
Page 47: Bolt Torque Specifications
M2-D 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. ** "Dry"...
Page 48: Notes
M2-D NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
Page 49 SECTION #VII OEM Repair Information...
Page 50 Surface to Surface or your STS distributor. Surface to Surface Inc 1-800-567-0978 Hazards or unsafe practices, which COULD result in minor personal injury or product or property damage.
Page 51 SAFETY This information applies to 80 Series basic pumps. The power source, which is used to drive the pump, may differ from unit to unit. Refer to the manual accompanying the power source Make certain that the unit and all piping or before attempting to begin operation.
Page 52 SAFETY continued Never run this pump backwards. Be certain Overheated pumps can cause severe that rotation is correct before fully burns and injuries. If overheating of the engaging the pump. pump occurs: 1. Stop the pump immediately. 2. Ventilate the area. 3.
Page 53 OPERATION Add liquid to the pump casing when: Review all SAFETY information in this manual. 1. The pump is being put into service for the Follow the instructions on all tags, labels and first time. decals attached to the pump. 2.
Page 54 TROUBLESHOOTING Review all SAFETY information in Section A. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Lock out or disconnect the power source to ensure that the pump will remain inoperative. 3. Allow the pump to completely cool if overheated. 4.
Page 55 PREVENTIVE MAINTENANCE Pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your 80 series pump.
Page 56 GR-82E2 ASSEMBLY PARTS LIST ( P/N #060-GR82E2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Grease Cup 060-S36 3/8" Nut 060-GRD0615991 3/8" L/W 076-33622 Seal Plate Assembly 060-GR427A10010 Brass Seal Liner 060-GR8314080 Casing Gasket Set 060-GR229G18000 Grease Seal assembly...
Page 57 GR-82E2 PUMP AND SEAL DISASSEMBLY 4. Check the temperature before AND REASSEMBLY opening any covers, plates, or plugs. 5. Close any suction and discharge Review all SAFETY information in Section A. valves. Follow the instructions on all tags, label and 6.
Page 58 GR-82E2 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Seal Reassembly and Installation Impeller Removal (Figures 1 and 3) Before removing the impeller, screw the cross arm Clean the seal cavity and shaft with a cloth soaked on the automatic lubricating grease cup (1) clock- in fresh cleaning solvent.
Page 59 GR-82E2 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pump Casing and Wear Plate Installation Seal Reassembly and Installation continued If the wear plate assembly (9) was removed, (Figures 1 and 3) install the new wear plate in the pump casing and Sub assemble the inboard stationary seat, packing secure it with the hardware (2 &...
Page 60 PACKING RINGS SEAL PLATE BRASS SEAL LINER SPACER SLEEVE IMPELLER LARGE CHAMFER STATIONARY ELEMENTS ENGINE ROTATING CRANKSHAFT ELEMENTS IMPELLER SHIM WASHERS STATIONARY WASHER STATIONARY SPRING WASHER Figure 3. Grease Seal Assembly LUBRICATION Fill the grease cup (1) through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole.
Page 61 Grease Seal Installation Instructions Centrifugal Pump Application When replacing the seal, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal. Before installing the seal, inspect the bore of the seal liner for PACKING RINGS SEAL PLATE...
Page 62 FOR ENGINE SERVICE GO TO: http://www.yanmar.com/products/industrial-engines/ On the bottom, go to “Find a Dealer” and follow prompts to find a center near you Surface to Surface has a limited engine parts inventory. Parts not in stock will have to be ordered.
Page 66 SECTION #VIII (Parts Manual)
Page 67 BU-M2X2 ASSEMBLY PARTS LIST ( P/N #BU-M2X2 ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Crash Frame M2-601-GHD 2" NPT Street 90° Elbow 018-310-01720-7 Pump Discharge Pipe M2-603 2" Hinge-Loc Coupler 020-390-20048-3 2" Coupler EPDM Gasket 020-390-078640 2" Filter Shear M2-604 1 1/2"...
Page 68 PU-M2-D ASSEMBLY PARTS LIST ( #PU-M2-D) STS P/N QT Y REQ. REF # DESCRIPT ION Gorman-Rupp 2" Pump 060-GR 8E2-KIT Yanmar Diesel Engine 033-L100V6D M8 Engine Stud 076-616-031 M8 F/W 076-40357 GREASE Grease Cup M8 L/W 076-40383 Instruction M8 Nut...
Page 69 GR-82E2 ASSEMBLY PARTS LIST ( P/N #060-GR82E2-KIT ) STS PART NUMBER REF # DESCRIPTION QTY REQ. Pipe to Hose connector 019-WEA_1868x8x4 3/8" Nut 060-GRD0615991 3/8" L/W 076-33622 Seal Plate Assembly 060-GR427A10010 Brass Seal Liner 060-GR8314080 Casing Gasket Set 060-GR229G18000 Grease Seal assembly...