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STS M-1500LG Operator's Manual

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Surface to Surface Inc.
®
Operators Manual
** M-1500LG **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Engine
Robin Engine Serial No. ______________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Links relating to this Manual
www.stsmixers.com
www.robinamerica.com
www.grpumps.com
Dealer
STS-146 Rev. 09/29/22
www.stsmixers.com

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  • Page 1 Surface to Surface Inc. ® Operators Manual ** M-1500LG ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Engine Robin Engine Serial No. ______________ Gorman-Rupp Pump GR-84B2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com www.robinamerica.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS PAGE STS Inc Warranty………………………………………………………….. Safety Statements………………………………………………...………… Safety Markings……………………………………………………………. Main Working Components (Photo)……………………………………… Introduction to the M-1500……………….………………………………. M-1500L Foot Print (top view)……………………………………………… M-1500L General Data Sheet………………………………………………. Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Polyethylene Plastic Reservoir Tanks …………………..……………...
  • Page 3 TABLE OF CONTENTS PAGE SECTION IV (Operating the M-1500 Unit.) Site set-up and pre-check…………………………………………….. Starting the engine and pump………………………..……………… Typical mixing operation……………………….……………………. 3 ways to mix product …………………….…..…….……….………. 35-36 Typical transfer / off-loading operation……………………………… Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….……...
  • Page 4 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair Information) GR Centrifugal Pump Owner’s Manual……………………..………… 51-62 Engine Manufacture Customer Help (web-site)………………………. Gruvloc® Pipe Couplings……………………….………………..…… 64-66 SECTION VIII (Parts Manual) M-1500L PARTS MANUAL…………………….……………….……. 68-73...

  • 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

    M-1500LG 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 M-1500LG 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 key switch to while the unit is in operation.
  • Page 8 M-1500LG 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 M-1500LG 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 LIFTING LUGS OR THE LIFTING POINT(S) BEFORE LIFTING OR MOVING THE UNIT, identified and labelled on the skid all fluid should be removed from the tank.

  • Page 10: Safety Markings

    M-1500LG 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: Introduction To The M-1500

    M-1500LG Operators Manual Congratulations on your acquisition of the world renowned M-1500 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: M-1500L General Data Sheet

    Model M-1500(GR) Surface to Surface Inc. Features and Benefits M-1500LG Mixer The M-1500L was designed and manufactured as a dual tank system that allows the HDD contractor two methods of mixing their bentonite mud requirements. This system allows the operator to mix 750...

  • Page 15: Identifying Your Machine & Components

    M-1500LG Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 16: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 17: Polyethylene Plastic Reservoir Tanks

    M-1500LG Description, Care and Maintenance Polyethylene Plastic Reservoir Tanks (750 us. gal) Maintenance of the tanks is required, but is simple. The tanks should be cleaned on a regular basis by opening any drain caps on the tank tees (see Fig.1 for an example) and or open the customer installed bottom tank drain (see Fig.2) and rinse the tank with clear water.
  • Page 18 M-1500LG Description, Care and Maintenance Polyethylene Plastic Reservoir Tanks (750 us. gal) INSTALLATION OF TANK DRAIN (CUSTOMER INSTALLED) • Find a suitable location on the tank floor for the drain to be installed, taking into consideration the placement of the unit on a trailer. LOOK under the deck for obstructions (cross-members, wiring, and axles, ect.) Allow room for a shut off valve.

  • Page 19: Gasoline Powered Centrifugal Pump

    M-1500LG Description, Care and Maintenance Gasoline 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 20 M-1500LG Description, Care and Maintenance Gasoline 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 M-1500LG Description, Care and Maintenance Gasoline 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 M-1500LG Description, Care and Maintenance Gasoline 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: Filter Shear System

    M-1500LG Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M-1500 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 M-1500LG Description, Care and Maintenance Filter / Shear System continued On top of the filter / shear housing (Fig.7) are three outlets that have 2” NPT ball valves connected to them. The outlets are labeled for their functions. An outlet will be labeled and connected to the internal jet gun (explained further on in this manual) mounted inside of the 1 reservoir tank.

  • Page 25: Venturi Mixing Tee

    M-1500LG 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 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

    M-1500LG Description, Care and Maintenance Wash Wand The M-1500 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

    M-1500LG 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 Jet Gun

    M-1500LG Description, Care and Maintenance Internal Tank Jet Gun(s) The Internal Jet Gun(s) (Fig.11a) are located inside the polyethylene plastic reservoir tanks, and their main function is to keep the slurry product in the tank moving. This function assures the elimination of dead spots in the tank and a consistent mixture of fluid.

  • 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

    M-1500LG Set-up and Installation of M-1500 in detail Permanent mounting of the unit The M-1500 is built on 2 sub frames 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 units 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 M-1500 Unit

    SECTION #IV Operating the M-1500 Unit...

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

    M-1500LG Operating the M-1500 Unit Site Setup & Pre-Check SITE SETUP • CHECK for overhead hazards if unloading the units to the ground. • UNLOAD the units by using the sub frame fork pockets (marked) with appropriate equipment. • and position the unit on solid level surface to avoid settling or upset.

  • Page 33: Starting The Engine And Pump

    M-1500LG Operating the M-1500 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 Gasoline Engine • Make sure the fuel shut off valve located under the fuel tank is open.

  • Page 34: Typical Mixing Operation

    M-1500LG Operating the M-1500 Unit Typical Mixing Operations Guide lines for Mixing • Always operate the engine at high speed. • Open the hopper valve at the bottom of hopper where it joins the venturi mixing tee. • Introduce the dry or liquid raw material into the hopper.
  • Page 35 M-1500LG Operating the M-1500 Unit Typical Mixing Operations Scenario 1 • Open the 4” suction valve of the front tank, and #1 jet gun valve. All other valves are to be closed. • With both tanks full of fresh water operate engine at high speed.
  • Page 36 M-1500LG Operating the M-1500 Unit Typical Mixing Operations Scenario 3 Open the 4” suction valves of the front and rear tank, and #1 and #2 jet gun valves. All other valves are • to be closed. • With both tanks full of fresh water operate engine at high speed.

  • Page 37: Typical Transfer/Offloading Operation

    M-1500LG Operating the M-1500 Unit Typical Transfer/Offloading Operation Transferring Operation • On the top of the filter / shear housing of the M-1500 you will see a 2 in. ball valve (2”NPT.) marked “Drill Fluid”. • A transfer hose with a minimum size of 2 in. can be attached to the ball valve to carry the finished product to a holding tank or directly to the drill rig.

  • Page 38: Warm Weather

    M-1500LG Operating the M-1500 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 39: Cold/ Freezing Weather

    M-1500LG Operating the M-1500 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 “Tank Gun(s)” and “Drill Fluid” valves are open.

  • Page 40: Prolonged Periods Of Storage

    M-1500LG Operating the M-1500 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M-1500, 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: Optional Self-Loading Feature

    M-1500LG Operating the M-1500 Unit Optional Self-Loading Feature Self Loading (customer to install) If the self-loading feature of The M-1500 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 42: Trouble Shooting The M-1500

    SECTION #V Troubleshooting the M-1500 Unit...
  • Page 43 M-1500LG Troubleshooting the M-1500 Unit The M-1500 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 44 M-1500LG Troubleshooting the M-1500 Unit • Tank does not stir / roll the fluid inside. No fluid to the tank jet gun - Make sure “Tank Gun” valve is open. Tank jet gun holes plugged. - Flush fresh water through system or clean Tank jet gun...

  • Page 45: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 46: Maintenance Schedule

    Basic M-1500 Gasoline Periodic Maintenance Schedule *** Consult the OEM engine manual for a more detailed maintenance schedule Engine Components Every Every Every Every Every Every Every Maintenance Items 8 hours 50 hours 200 hours 2000 hours 100 hours 300 hours 400 hours (daily) (weekly)

  • Page 47: Centrifugal Trash Pump Seal Replacement

    M-1500LG 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 48: Bolt Torque Specifications

    M-1500LG 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

    M-1500LG NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 50 SECTION #VII OEM Repair Information...
  • Page 51 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 52 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 53 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 54 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 55 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 56 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 57 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 Kee p cup full at all tim es. HD Machine Screw 060-GRX040317090 Use #2 lithium base grea se.
  • Page 58 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 7.
  • Page 59 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 60 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 61 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 62 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 63 FOR ENGINE SERVICE GO TO: www.robinamerica.com On the left, go to Sales and Service Locator 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 67 SECTION #VIII (Parts Manual)
  • Page 68 BU-750L(GR) ASSEMBLY PARTS LIST ( P/N #BU-750L(GR) ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Skid Frame SR-L75001 Tank Strap SR-75089 750 gal. Tank 086-SR-75019 4" Tank Bung 086-4"TANK BUNG 90° PVC Suction Elbow SR-75075-A Tank Up-rite SR-75011 5/8" x 4" Gr. 8 Bolt 076-15319 5/8"...
  • Page 69 5/16" NC Nut 076-36304 5/16" L/W 076-33620 6" Hinge-Loc Coupler 020-390-20060-8 Filter Shear Housing SR-75026 1 1/2" NPT Pipe Plug 018-318-90252-5 3/8" x 1 1/2" Bolt 076-13109 3/8" L/W 076-33622 3/8" F/W 076-33008 3/8" Nut 076-36306 Filter Extension Pipe SR-L75073 Jetting Nozzel SR-75020-NE Jetting Tee...
  • Page 70 PU-G4 (GR) ASSEMBLY PARTS LIST ( P/N #PU-G4 ) REF # DESCRIPTION STS PART NUMBER QTY REQ. Engine / Pump Mount Base 060-GR84B2-10 3/8" x 2" Bolt 076-13111 3/8" F/W 076-33008 3/8" L/W 076-33622 3/8" Nut 076-36306 1/2" x 2" Bolt 076-13211 1/2"...
  • Page 71 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 tim es.
  • Page 72 Left Support Bracket SR-L15008-L 4" Flex Hose SR-L15009-B Pipe Support Shims SR-15009-A as required Pipe Support SR-15009 "KEEP LID CLOSED" Decal 070-STS-030-B 2" Rubber Hose SR-L15010-B Tank Bottom Drain 086-BF-220BD PAINT COLORS "Tank Gun" Decal 070-STS-027-B OR - Orange "#1" Decal...
  • Page 73 Jetting Tee SR-75021 Filter Shear Housing SR-75026 2" NPT Pipe Plug 018-318-90256-6 *** Removed from BU-750L Replace #SR-L75058-A with #SR-L15010-B and change valving on Filter Housing. to Suction TEE of other Tank REV.12/17/10...

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