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Surface to Surface Inc.
®
Operators Manual
** M4-H **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Hydraulic Motor
SNM2/19C106 – Serial No.__________________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Control Valve
Brand FC51 Serial No.__________________
Links relating to this Manual
www.stsmixers.com
www.grpumps.com
Dealer
STS-122 Rev. 02/08/23
www.stsmixers.com
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Table of Contents
Related Manuals for STS M4-H
Summary of Contents for STS M4-H
- Page 1 Surface to Surface Inc. ® Operators Manual ** M4-H ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Hydraulic Motor SNM2/19C106 – Serial No.__________________ Gorman-Rupp Pump GR-84B2 – Serial No. ________________ Control Valve Brand FC51 Serial No.__________________ Links relating to this Manual www.stsmixers.com...
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Page 2: Table Of Contents
Safety Statements………………………………………………...………… Safety Markings……………………………………………………………. Hydraulic Connections / Schematic………………………………………. Main Working Components (Photo)……………………………………… M4 Hose Connections ……………….……………………………………. Introduction to the M4-H ……………….………….………….…………. M4-H Foot Print (top view)………………………………………………… M4-H General Data Sheet…………………………………………………. Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Hydraulic powered centrifugal pump.…….…………….………….…. - Page 3 TABLE OF CONTENTS PAGE SECTION IV (Operating the M4 Unit.) Site set-up and pre-check…………………………………………….. Starting the hydraulic driven pump…………………..……………… Typical mixing operation……………………….……………………. Typical transfer / off-loading operation……………………………… Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….…… Prolonged periods of storage………………………………… **Optional self-loading feature……………………………...…………...
- Page 4 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair Information) GR Centrifugal Pump Owner’s Manual……………………..………… 50-61 Gruvloc® Pipe Couplings……………………….………………..…… 62-64 Sauer Danfoss Hydraulic motor …………..…….….….….….….……. 65-67 SECTION VIII (Parts Manual) M4-H PARTS MANUAL…………………….……………….……. 69-71...
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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
M4-H 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 M4-H SAFETY STATEMENTS The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. WARNING DANGER DO NOT REMOVE OR MODIFY IN AN EMERGENCY SA FETY COVERS OR GUA RDS.
- Page 8 M4-H 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 T RANSFERRING FLUID T RAPPED FLUID M AY BE PRESENT to the drill rig, fluid pressure may and will spill out when piping, hoses, reach or exceed 50 p.s.i.
- Page 9 M4-H 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 T he manufacturer should be consulted LIFT ING LUGS OR T H E LIFT ING POINT (S)
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Page 10: Safety Markings
M4-H 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:... -
Page 11: Hydraulic Connections / Schematic
M4-H These guidelines must be followed or warrant will be voided. Any variation needs to be approved by Surface to Surface®. SET-UP Minimum Flow Rate: 15.0 us gpm. Maximum Flow Rate: 16.5 us gpm. Relief Setting: 2250psi. Inlet Hose Size: 3/4"... -
Page 14: Introduction To The M4-H
M4-H Operators Manual Congratulations on your acquisition of the world renowned M4 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: M4-H Foot Print (Top View)
48.500 62.000 M4-H ( Hydraulic ) DRY WEIGHT 625 Lbs (284 Kg) ® Surface to Surface Inc. * Due to our continuing product improvement, specifications are subject to change without notice. * DWR. NUM. DATE. 09 / 19 / 12 M4-H REV. -
Page 16: M4-H General Data Sheet
A 17gpm. hydraulic motor drives a 4” centrifugal pump, making effective use of the proprietary 4 point mixing system. The M4-H can be used as a new installation or retrofitted into an existing system of tank(s). Since the unit is connected by hoses and not hard pipe, the placement of the mixer verses the tank(s) is less restricted and a configuration to suit the needs of the contractor is easier to achieve. -
Page 17: Identifying Your Machine & Components
M4-H Identifying Your Machine & Components Location of Tags and PIN Plates... -
Page 18: Description, Care And Maintenance
SECTION #II Description, Care and Maintenance... -
Page 19: Hydraulic Powered Centrifugal Pump
M4-H Description, Care and Maintenance Hydraulic Powered Centrifugal Pump Care and maintenance of the hydraulic motor 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. Check the fluid level in YOUR hydraulic reservoir is sufficient. - Page 20 M4-H Description, Care and Maintenance Hydraulic 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 M4-H Description, Care and Maintenance Hydraulic 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 M4-H Description, Care and Maintenance Hydraulic 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.
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Page 23: Filter Shear System
M4-D Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M4 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 M4-H Description, Care and Maintenance Filter / Shear System continued On the left side of the unit (near the back side) is a upright “discharge manifold” (see Fig.7). The two outlets are connected to the filter shear and controlled by independent ball valves. The connections are 2” NPT thread.
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Page 25: Venturi Mixing Tee
M4-H Description, Care and Maintenance Venturi Mixing Tee The Venturi Mixing Tee (Fig8a.) is the very heart of this system and requires very little maintenance. However M4 unit 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
M4-H Description, Care and Maintenance Wash Wand The M4 unit 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 With Table & Hopper Valve
M4-H Description, Care and Maintenance Dry Hopper with Table and Hopper Valve The Dry Hopper and Table (Fig.10) are used during the initial mixing of the dry product and fluid. The hopper and table require very little daily maintenance, however care should be used that this unit does not become overloaded. -
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 discharge manifold (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.
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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
M4-H Set-up and Installation of M4 in detail Permanent mounting of the unit The M4 unit is built on a sub frame that can be bolted down to a permanent surface like a concrete pad, pull type trailer, flat deck of a truck or inside of a truck body. Securing the unit with adequate size and grade of fasteners is the sole responsibility of the customer and not of Surface to Surface Inc. -
Page 32: Operating The M4 Unit
SECTION #IV Operating the M4 Unit... -
Page 33: Site Set-Up And Pre-Check
M-4-H Operating the M4 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 Hydraulic Driven Pump
M4-H Operating the M4-H Unit Starting the Hydraulic Motor & Pump Starting the hydraulic driven pump • Make sure the hydraulic variable speed control lever (Fig.13) is in the stop position (all the way over to the left stop pin). -
Page 35: Typical Mixing Operation
M4-H Operating the M4 Unit Typical Mixing Operation Mixing Operation • Operate the pump 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 Transfer/Offloading Operation
M4-H Operating the M4 Unit Typical Transfer/Offloading Operation Transferring Operation • On the discharge manifold of the M4 you will see a 2 outlet with a ball valve (2”NPT.) that is not used. • A transfer hose with a minimum size of 2 in. can be attached to this outlet ball valve to carry the finished product to a holding tank or directly to the drill rig. -
Page 37: Warm Weather
M4-H Operating the M4 Unit Typical Warm Weather Shutdown & Storage Daily Shut Down • Do not rotate hydraulic control valve suddenly while running at high speed. • Set the speed control lever at a low speed (1/8-1/4) position and allow the hydraulic motor to run at low speed for 2 to 5 minutes. -
Page 38: Cold/ Freezing Weather
M4-H Operating the M4 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 the valves on the discharge manifold are open. -
Page 39: Prolonged Periods Of Storage
M4-H Operating the M4 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M4, 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 40: Optional Self-Loading Feature
M4-H Operating the M4 Unit Optional Self-Loading Feature Self Loading (customer to install) If the self-loading feature of The M4 is required, you will find a 2 in. NPT (suction) port located on the venturi-mixing tee below the hopper valve (Fig.14a). All units are shipped with a plug installed in the port. -
Page 41: Trouble Shooting The M4
SECTION #V Troubleshooting the M4 Unit... - Page 42 Troubleshooting the M4 Unit The M4 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 M4-H Troubleshooting the M4 Unit • Tank does not stir / roll the fluid inside. No fluid to the tank jets - Make sure discharge manifold valve is open. Tank jet holes plugged. - Flush fresh water through system or clean Tank jets...
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Page 44: Periodic Maintenance & Repair Information
SECTION #VI Periodic Maintenance & Repair Information... -
Page 45: Maintenance Schedule
Basic M-4 Hydraulic Periodic Maintenance Schedule *** Consult Your Hydraulic Power Source OEM manual(s) for a more detailed maintenance schedule of your equipment. .*** STSI is not to be held liable for any discrepancies or errors in the schedule. Maintenance Items Every 8 hours Every 50 Every 100... -
Page 46: Centrifugal Trash Pump Seal Replacement
M4-H Grease Seal Installation Instructions Centrifugal Pump Application When replacing the sea, 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. -
Page 47: Bolt Torque Specifications
M4-H 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 48: Notes
M4-H 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-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Hex Nut 060-GRD105991 Pipe Flange 060-GR175610010 Flange Gasket 060-GR1676G18000 Check Valve Seat 060-GR733610010 CAU TION Keep cup full at all times. HD Machine Screw 060-GRX040317090 Use #2 lithium base grease.
- Page 57 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. 6. Vent the pump slowly and cautiously. Follow the instructions on all tags, label and decals attached to the pump.
- Page 58 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Seal Reassembly and Installation (Figures 1 and 3) Impeller Removal Before removing the impeller, screw the cross arm Clean the seal cavity and shaft with a cloth soaked on the automatic lubricating grease cup (22) clock- in fresh cleaning solvent.
- Page 59 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pump Casing and Wear Plate Installation Seal Reassembly and Installation continued If the wear plate assembly (13) was removed, (Figures 1 and 3) install the new wear plate in the pump casing and secure it with the hardware (12). Sub assemble the inboard stationary seat, packing Install a new set of casing gaskets (17) and slide ring and stationary washer.
- Page 60 LUBRICATION Fill the grease cup (11) 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 (see Figure 4).
- Page 61 Grease Seal Installation Instructions Centrifugal Pump Application When replacing the sea, 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 excessive wear or grooves that might cause leakage or damage to the seal packing rings.
- Page 65 Group 2 Gear Motors Technical Information System Requirements Hydraulic fluids Ratings and data for gear motors are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion, and corrosion of internal components. They include: •...
- Page 66 Group 2 Gear Motors Technical Information System Requirements Filtration Filters Use a filter that conforms to Class 22/18/13 of ISO 4406 (or better). It may be on the motor outlet (discharge filtration) or inlet (pressure filtration). Selecting a filter When selecting a filter, please consider: •...
- Page 67 Group 2 Gear Motors Technical Information System Requirements Reservoir The reservoir provides clean fluid, dissipates heat, removes entrained air, and allows fluid volume changes associated with fluid expansion and during all system operating modes. A correctly sized reservoir accommodates maximum volume changes during all system operating modes. It promotes de-aeration of the fluid as it passes through, and accommodates a fluid dwell-time between 60 and 180 seconds, allowing entrained air to escape.
- Page 68 SECTION #VIII (Parts Manual)
- Page 69 PU-M4H(GR) ASSEMBLY PARTS LIST P/N #PU-M4H(GR) STS PART NUMBER QTY REQ. REF # DESCRIPTION Motor / Pump Mounting Base 060-GR84B2-10 1/2" x 2" Bolt 076-13211 1/2" L/W 076-33626 1/2" F/W 076-33012 1/2" Nut 076-36310 Motor Shim S/S 034-QA SHIM PACK Gorman-Rupp 4"...
- Page 70 BU-M4 (V2) ASSEMBLY PARTS LIST ( P/N #BU-M4 (V2) ) STS PART NUMBER QTY REQ. REF # DESCRIPTION 4" NPT 90° Street Elbow 018-310-01780-1 Pump Discharge Pipe M4-011 4" Groove-Loc Coupler 020-390-00034-7 4" Grooved 90° Elbow 020-390-01430-6 4" Hinge-Loc Coupler...
- Page 71 GR-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) REF # DESCRIPTION STS PART NUMBER QTY REQ. Hex Nut 060-GRD105991 Pipe Flange 060-GR175610010 Flange Gasket 060-GR1676G18000 Check Valve Seat 060-GR733610010 CAU TION Keep cup full at all times. HD Machine Screw 060-GRX040317090 Use #2 lithium base grease.
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