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STS M4-D Operator's Manual

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Surface to Surface Inc.
®
Operators Manual
** M4-D **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Engine
Yanmar Engine Serial No. ______________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Links relating to this Manual
www.stsmixers.com
www.grpumps.com
Dealer
STS-121 Rev. 02/08/23
www.stsmixers.co

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  • Page 1 Surface to Surface Inc. ® Operators Manual ** M4-D ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Engine Yanmar Engine Serial No. ______________ Gorman-Rupp Pump GR-84B2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com www.grpumps.com...

  • Page 2: Table Of Contents

    STS Inc Warranty………………………………………………………….. Safety Statements………………………………………………...………… Safety Markings……………………………………………………………. Main Working Components (Photo)……………………………………… M4 Hose Connections ……………….……………………………………. Introduction to the M4-D ……………….………….………….…………. M4-D Foot Print (top view)………………………………………………… M4-D General Data Sheet…………………………………………………. Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Diesel powered centrifugal pump.…….…………….………….….
  • Page 3 TABLE OF CONTENTS PAGE SECTION IV (Operating the M4 Unit.) Site set-up and pre-check…………………………………………….. Starting the engine and 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……………………..………… 49-60 Engine Manufacture Customer Help (web-site)………………………. Lofa Control Panel Manual ………………………………………….. 62-76 Gruvloc® Pipe Couplings……………………….………………..…… 77-79 SECTION VIII (Parts Manual) M4-D PARTS MANUAL…………………….……………….……. 81-84...

  • 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-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.
  • Page 7 M4-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 engine switch to while the unit is in operation.
  • Page 8 M4-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 9 M4-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 BEFORE STARTING THE ENGINE, BE SURE THE PUMP IS PRIMED! Check the pump by slowly & carefully opening the plug located on the top of the centrifugal pump beside the discharge elbow.

  • Page 10: Safety Markings

    M4-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:...

  • Page 12: M4 Hose Connections

    Surface to Surface Inc. (Hose Hook-ups) DRILL FLUID OUT [to Drill Rig] ** 2" NPT ** OUT FLOW [to Tank Gun(s)] ** 2" NPT ** PUMP INTAKE [in from Tank] ** 4" NPT ** This line should have a valve installed at the tank to facilitate shut down or reapirs.

  • Page 13: Introduction To The M4-D

    M4-D Operators Manual Congratulations on your acquisition of the world renowned M4-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 14: M4-D Foot Print (Top View)

    61.00" 62.50" M4-D(GR)Y Dry Weight: 1375 lbs Height: 49.00" ® Surface to Surface Inc. 11 / 17 / 11 DWR. NUM. DATE. M4-D (GR)Y REV.

  • Page 15: M4-D General Data Sheet

    Diesel engine driving a 4” centrifugal pump, it makes effective use of the proprietary 4 point mixing system. The M4-D can be used as a new installation or retrofitted into an existing system of tank(s). Since the unit is connected by hose 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 are easier to achieve.

  • Page 16: Identifying Your Machine & Components

    M4-D Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 17: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 18: Diesel Powered Centrifugal Pump

    M4-D Description, Care and Maintenance Diesel Powered Centrifugal Pump Care and maintenance of the engine and pump is 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 19 M4-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 20 M4-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 21 M4-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.

  • Page 22: 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 23 M4-D 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.

  • Page 24: Venturi Mixing Tee

    M4-D 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 25: Wash Wand

    M4-D 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 26: Dry Hopper With Table & Hopper Valve

    M4-D 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 27: 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 28 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 29: Set-Up And Installation Of Unit In Detail

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

  • Page 30: Permanent Mounting Of Unit

    M4-D 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 31: Operating The M4 Unit

    SECTION #IV Operating the M4 Unit...

  • Page 32: Site Set-Up And Pre-Check

    M-4-D 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 33: Starting The Engine And Pump

    M4-D Operating the M4 Unit Starting the Engine & Pump *** The Engine Operators Manual should be consulted for a more detailed engine start up and shut down procedures. Starting the Diesel Engine • Make sure the fuel shut off valve located under the fuel tank is open.

  • Page 34: Typical Mixing Operation

    M4-D Operating the M4 Unit Typical Mixing Operation Mixing Operation • 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 35: Typical Transfer/Offloading Operation

    M4-D 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 36: Warm Weather

    M4-D Operating the M4 Unit Typical Warm Weather Shutdown & Storage Daily Shut Down • Push in the engine speed control tee handle (Fig. 13a) to the low speed position and allow the engine to run at low speed for 5 minutes.

  • Page 37: Cold/ Freezing Weather

    M4-D 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 38: Prolonged Periods Of Storage

    M4-D 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 39: Optional Self-Loading Feature

    M4-D 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 40: Trouble Shooting The M4

    SECTION #V Troubleshooting the M4 Unit...
  • Page 41 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 42 M4-D 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...

  • Page 43: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 44: Maintenance Schedule

    Basic M4-D (Diesel) Periodic Maintenance Schedule *** Consult the OEM engine manual for a more detailed maintenance schedule Engine Components Every Every Every Every Every Every Every 2000 50 hours 250 hours hours Maintenance Items hours (weekly) hours (monthly) hours...

  • Page 45: Centrifugal Trash Pump Seal Replacement

    M4-D 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 46: Bolt Torque Specifications

    M4-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.

  • Page 47: Notes

    M4-D NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 48 SECTION #VII OEM Repair Information...
  • Page 49 If there are any questions regarding the pump or follow the procedure. its application, which are not covered in this manual or in other literature accompanying this unit, please contact Surface to Surface or your STS distributor. Hazards or unsafe practices, which COULD Surface to Surface Inc 1-800-567-0978 result in minor personal injury or product or property damage.
  • Page 50 SAFETY This information applies to 80 Series basic pumps. The power source, which is used to drive Make certain that the unit and all piping or the pump, may differ from unit to unit. Refer to hose connections are tight, properly the manual accompanying the power source supported and secure before operation.
  • Page 51 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 52 OPERATION Add liquid to the pump casing when: 1. The pump is being put into service for the Review all SAFETY information in this manual. first time. Follow the instructions on all tags, labels and 2. The pump has not been used for a considerable decals attached to the pump.
  • Page 53 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 54 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 55 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 HD Machine Screw 060-GRX040317090 Keep cup full at all times.
  • Page 56 4. Check the temperature before PUMP AND SEAL DISASSEMBLY opening any covers, plates, or AND REASSEMBLY plugs. 5. Close any suction and discharge valves. Review all SAFETY information in Section A. 6. Vent the pump slowly and cautiously. Follow the instructions on all tags, label and 7.
  • Page 57 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 58 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 59 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 60 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 61 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 62 LOFA MC704 and MC704 G4 Operation and Troubleshooting Introduction This document provides general information on LOFA Industries MC704 control systems operation and troubleshooting. MC704 control systems are a very flexible platform for diesel engine control, monitoring, and protection, featuring LOFA’s powerful First Fault Diagnostics (FFD). After pinpointing the initial failure, FFD stores it in memory and alerts the end user via a single bright LED.
  • Page 63 Important Safety Information The warnings in this publication are not all inclusive. LOFA Industries cannot anticipate every potential hazard. Appropriate safety rules and precautions should be followed with any tool, work method or operating procedure. Improper procedures, tools and materials may cause damage or make the equipment unsafe to operate.
  • Page 64 Operation Turning the control system key to the run position starts a self-test which causes all LEDs to flash three times, activates the alarm output (if preheat is not used) for one second and enables the fuel run/stop solenoid output. After self-test, the LEDs indicate the state of the inputs they monitor. The normal indications are battery charge and oil pressure on most applications.
  • Page 65 Preheat Options Preheat Output Preheat is a 3A positive output for control of an external power relay with predetermined preheat and afterglow times. A relay should be selected with appropriate amperage capacity for the installed cold starting aid (glowplug, intake air heater, etc.). Applications using multiple cold starting aids may require multiple relays.
  • Page 66 sender/switch combinations, swapping the WK or W and G terminal can cause unintended shutdowns. The system can be configured for temperature failure to indicate only. Warning If the temperature switch is not in contact with coolant due to coolant loss the engine is not protected from overheating. For best possible protection, LOFA recommends using our solid-state coolant level shutdown switch.
  • Page 67 Harness Sealed Connectors The provided sealed weather proof plug includes a grey locking device which must be released to separate the connectors. Press the tab on the connector housing to release the connectors. Warning LOFA does not recommend using dielectric grease or sealant with sealed connectors. These chemicals may cause seal damage and allow water entry.
  • Page 68 Battery Circuit Requirements Battery Positive Connection The electronic control system operates on either a 12 VDC or 24 VDC electrical systems. The unswitched battery positive connection to the control system is made at the weather proof connector. The control system provides switched positive battery Protection for the unswitched battery positive circuit is dependent on specific equipment configuration.
  • Page 69 system is equivalent to quickly turning the key switch to off and back to run without starting the engine. Since the control system did not sense a start signal, the fuel run/stop solenoid deactivates after 30 seconds. Voltage drops can be caused by transients from external equipment, improper wire sizes, faulty wiring or nearby lightning strikes.
  • Page 70 Welding on Equipment with Electronic Controls Proper welding procedures are required to avoid damage to electronic controls, sensors, and associated components. The component should be removed for welding if possible. The following procedure must be followed if the component must be welded while installed on equipment with electronic controls.
  • Page 71 General Troubleshooting For additional information, refer to engine manufacturer troubleshooting guide. No response from starter motor Possible Cause Possible Remedy No battery voltage to starter Verify wiring and battery connection (power and ground) Battery discharged Charge or replace battery, verify alternator charging Tripped overcurrent protection Correct fault, replace or reset overcurrent protection No signal from control system...
  • Page 72 Fuel Run/Stop Solenoid Troubleshooting Engine does not stop immediately Possible Cause Possible Remedy Back feed from motor (i.e., Add relay or blocking diode cooling fan) Sticking solenoid linkage Repair or replace solenoid linkage Fuel valve without check valve Install or repair check valve Fuel run/stop solenoid does not engage Possible Cause Possible Remedy...
  • Page 73 Control System Troubleshooting Control system does not perform self test Possible Cause Possible Remedy Tripped overcurrent protection Correct fault, replace or reset overcurrent protection Faulty connection to battery Correct battery connections (see Battery Circuit Requirements above) Control system performs normal self test, engine cranks, runs and shuts down Possible Cause Possible Remedy Only Battery LED illuminated...
  • Page 74 " Power Box Option The Power Box is a solid state, high current control system for mechanically governed, industrial diesel engines. In addition to allowing extended harnesses, the Power Box provides 3-wire fuel run/stop solenoid control to protect the pull coil from overheating. Power Box technology typically controls the starter solenoid, fuel run/stop solenoid and cold starting aid.
  • Page 75 Typical Schematics The following pages show typical schematics. Details vary from installation to installation. See the specific schematics for installation for details. Need MC704GT Panel Drawing.
  • Page 80 SECTION #VIII (Parts Manual)
  • Page 81 BU-M4 (V2) ASSEMBLY PARTS LIST ( P/N #BU-M4 (V2) ) REF # DESCRIPTION STS PART NUMBER QTY REQ. 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 82 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 83 PU-M4D(GR) ASSEMBLY PARTS LIST (3TNV70) ( P/N #PU-M4D(GR)Y ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Gorman-Rupp 4" Pump 060-GR84B2-KIT Install bolt 1/2" x 2" Bolt 076-13211 before filter shear 1/2" L/W 076-33626 1/2" F/W 076-33012 1/2" Nut 076-36310...
  • Page 84 060-GR6588BG "PRIME" Decal 060-GR6588AH "DISCHARGE" Decal 060-GR6588BJ "SUCTION" Decal 060-GR6588AG "Flammable" Decal 070-16020-A "Diesel Fuel Only" Decal 070-STS-030-A "D" Decal 070-STS-030-F "WEIGHT" Decal M4-049-D "Grease Cup" Decal 060-GR6588BD PAINT COLORS O - Orange B - Black HHB - High Heat Black...

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