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STS M2-D922 Operator's Manual

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Surface to Surface Inc.
Operators Manual
** M2-D922 **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Yanmar Engine
L100V – Serial No. ______________
Gorman-Rupp® Pump
STS-GR82E2 – Serial No. ________________
Links relating to this Manual
www.stsmixers.com
www.yanmar.com
www.grpumps.com
Dealer
STS-106 Rev. 08/20/21
www.stsmixers.com

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  • Page 1 ** M2-D922 ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Yanmar Engine L100V – Serial No. ______________ Gorman-Rupp® Pump STS-GR82E2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com www.yanmar.com www.grpumps.com Dealer STS-106 Rev. 08/20/21...
  • Page 2 This page left blank intentionally...

  • Page 3: Table Of Contents

    Safety Statements………………………………………………...………… 7-10 Safety Markings……………………………………………………………. Main Working Components (Photo)……………………………………… M2-922 Hose Connections ……………….………………….……………. Introduction to the M2-D922 ……………….………..………..…………. M2-D922 Foot Print (top view)……………………………….…………… M2-D922 General Data Sheet…………………………………………………. 16 Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Diesel powered centrifugal pump.…….…………….………….….
  • Page 4 TABLE OF CONTENTS PAGE SECTION IV (Operating the M2-D922 Unit. Site set-up and pre-check…………………………………………….. Starting the engine driven pump…………….….…..…….……… Typical mixing operation……………………….……………………. 36-37 Typical transfer / off-loading operation……………………………… Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….…… Prolonged periods of storage…………………………………...
  • Page 5 GR Centrifugal Pump Owner’s Manual……………………..………… 52-63 Engine Manufacture Customer Help (web-site) …………...…………. Gruvloc® Pipe Couplings ………….…….….….………………..…… 65-67 SECTION VIII (Parts Manual - version 1) M2-D922 PARTS MANUAL…………………….…………….……. 69-71 SECTION IX (Parts Manual - version 2) MAC-JR-1200D Mixer PARTS MANUAL…………..….…..….…. 73-75...

  • Page 6: Sts Inc. Warranty

    Limited Warranty United States and Canada Surface to Surface Inc. or its 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-D922 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 8 M2-D922 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-D922 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-D922 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-D922 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 13: M2-922 Hose Connections

    FLUID OUTLET [to Active Tank] M2-D922 (Hose Hook-ups) FLUID OUTLET [to Mix Tank Gun "C"] ** 2" Female Cam-loc ** PUMP INTAKE [in from Mix Tank "A"] PUMP INTAKE [in from Pit] FLUID OUTLET ** 2" Female Cam-loc ** [to Cone Manifold "D"] ** 2"...

  • Page 14: Introduction To The M2-D922

    The M2-922 mixing unit consists of an diesel powered centrifugal pump, filter/shear unit, venturi mixing tee assembly, dry hopper with a table, a set of tank internal jets (customer installed) and a set of 3-way valves to allow quick connection / setup to the STS fluid cleaning and recovery unit.

  • Page 15: M2-D922 Foot Print (Top View)

    26 1/2" 33" 42 1/2" M2-D922 (Diesel) Dry Weight: 400 Lbs (182 Kg) ® Surface to Surface Inc. DW R. NUM. DA TE. 04 / 17 / 13 * Due to our continuing product improvement, specifications are subject to change without notice. * M2-D922 REV.

  • Page 16: M2-D922 General Data Sheet

    2” centrifugal pump, making effective use of the proprietary 4 point mixing system. The M2-D922 has a set of 3-way valves mounted to the suction & discharge ports of the pump that allow the operator to choose between two different inlet sources, and a different outlet.

  • Page 17: Identifying Your Machine & Components

    M2-D922 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-D922 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-D922 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-D922 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-D922 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.

  • Page 23: 3-Way Valves

    The M2-922 unit has 2 large 3-way valves (Fig. 6) mounted on the suction and discharge ports of the 2” pump. These valves are utilized when the M2-922 mixing unit is used in conjunction with a STS fluid cleaning and recovery unit.

  • Page 24: Filter Shear System

    M2-D922 Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.7a) system on the M2-922 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.7b) consisting of an outside housing and an internal filter / shear.
  • Page 25 M2-D922 Description, Care and Maintenance Filter / Shear System continued On the bottom of the filter / shear housing (Fig.8) 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 26: Venturi Mixing Tee

    M2-D922 Description, Care and Maintenance Venturi Mixing Tee The Venturi Mixing Tee (Fig. 9a.) is the very heart of this system and requires very little maintenance. However M2-922 parts may wear as a result of the application, in time and require replacement.

  • Page 27: Wash Wand

    M2-D922 Description, Care and Maintenance Wash Wand The M2-922 unit is equipped with a pressurized wash wand (Fig.10a) 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 28: Dry Hopper With Table & Hopper Valve

    M2-D922 Description, Care and Maintenance Dry Hopper with Table and Hopper Valve The Dry Hopper (Fig.11) 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 29: 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.12b).
  • Page 30 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 31: Set-Up And Installation Of Unit In Detail

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

  • Page 32: Permanent Mounting Of Unit

    M2-D922 Set-up and Installation of M2-922 in detail Permanent mounting of the unit The M2-922 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 33 SECTION #IV Operating the M2-922 Unit...

  • Page 34: Site Set-Up And Pre-Check

    M2-D922 Operating the M2-922 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 35: Starting The Engine Driven 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-D922 mixer IS NOT EQUIPED WITH A BATTERY. 12volt post terminals are installed on the unit and a remote battery and connection can be made. Use proper wiring size.

  • Page 36: Typical Mixing Operation

    M2-D922 Operating the M2-922 Unit Typical Mixing Operation Mixing Operation: Dry Products • 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 37 M2-D922 Operating the M2-922 Unit Typical Mixing Operation Mixing Operation: Dry Polymers • 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 38: Typical Transfer/Offloading Operation

    M2-D922 Operating the M2-922 Unit Typical Transfer/Offloading Operation Transferring Operation • On the bottom of the filter / shear housing of the M2-922 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 39: Warm Weather

    M2-D922 Operating the M2-922 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 40: Cold/ Freezing Weather

    M2-D922 Operating the M2-922 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 41: Prolonged Periods Of Storage

    M2-D922 Operating the M2-922 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M2-922, 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 42: Fluid Recovery Operation (Basic)

    /sump. • Shut off the M2-922 mixer, disconnect the STS fluid cleaning and recovery unit feed hose from the head assembly and secure it back into the pit/sump.

  • Page 43: Trouble Shooting The M2-922

    SECTION #V Troubleshooting the M2-922 Unit...
  • Page 44 M2-D922 Troubleshooting the M2-922 Unit The M2-922 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 45 M2-D922 Troubleshooting the M2-922 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...

  • Page 46: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 47: Maintenance Schedule

    M2-D922 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...

  • Page 48: Centrifugal Trash Pump Seal Replacement

    M2-D922 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 49: Bolt Torque Specifications

    M2-D922 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 50: Notes

    M2-D922 NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 51 SECTION #VII OEM Repair Information...
  • Page 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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 60 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 61 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 62 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 63 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 64 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 68 SECTION #VIII (M2-D922 Parts Manual) Use this Parts Manual if the mixer is used independently as a mixer only...
  • Page 69 BU-M2922 ASSEMBLY PARTS LIST ( P/N #BU-M2922 ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Crash Frame M2-601 2" NPT x Close Nipple 018-330-03700-3 2 1/2" x 2" Reducing Elbow 018-310-01042-0 2 1/2" NPT x Close Nipple 018-330-04000X 2 1/2" 3-way Ball Valve 022-0355N-T 2 1/2"...
  • Page 70 PU-M2-D922 ASSEMBLY PARTS LIST ( #PU-M2-D922) STS P/N QTY REQ. REF # DESCRIPTION Gorman-Rupp 2" Pump 060-GR8E2-KIT Yanmar Di esel Engine 033-L100V6D M8 Engine Stud 076-616-031 M8 F/W 076-40357 M8 L/W 076-40383 M8 Nut 076-40307 Spacer 076-607-H18-K Air Deflector M2-725 M8 x 1.25 x 14 bolt...
  • Page 71 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 72 SECTION #IX (MAC JR-1200D Mixer Parts Manual) Use this Parts Manual if the mixer is mounted on a MAC-JR-1200D Unit...
  • Page 73 BU-M2922 for MAC-JR ASSEMBLY PARTS LIST REF # DESCRIPTION STS PART NUMBER QTY REQ. Crash Frame M2-601-GHD 2" NPT x Close Nipple 018-330-03700-3 2 1/2" x 2" Reducing Elbow 018-310-01042-0 2 1/2" NPT x Close Nipple 018-330-04000X 2 1/2" 3-way Ball Valve 022-0355N-T 2 1/2"...
  • Page 74 PU-M2-D922 ASSEMBLY PARTS LIST ( #PU-M2-D922) STS P/N QTY REQ. REF # DESCRIPTION Gorman-Rupp 2" Pump 060-GR8E2-KIT Yanmar Di esel Engine 033-L100V6D M8 Engine Stud 076-616-031 M8 F/W 076-40357 M8 L/W 076-40383 M8 Nut 076-40307 Spacer 076-607-H18-K Air Deflector M2-725 M8 x 1.25 x 14 bolt...

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