SYKES GROUP PTY LTD

CP100 PUMPSET
FOR

REF: W/O

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

SYKES PUMPS AUSTRALIA

PTY LTD
PUMP SPECIFICATION
PUMP TYPE:
PUMP SIZE:
ACTUAL IMPELLER DIAMETER:

CP100
100mm x 100mm
221MM

ENGINE / MOTOR TYPE:

PUMP NUMBER:
JOB NUMBER:
PLANT NUMBER:

N/A

ENGINE / MOTOR NUMBER:

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 1

DESIGN DETAILS:
Pump Designation:
Pump Description:

CP100
Single stage, volute type, 3 bladed fully open impeller
Centrifugal pump
Suction Flange:
4" Table 'D'
Delivery Flange:
4" Table 'D'
Nominal Casing Thickness:
10mm
Nominal Shaft Diameter:
40mm
Impeller Eye Diameter:
100mm
Maximum Impeller O.D.:
221mm STD
Minimum Impeller O.D.:
176mm.
Moment Inertia Impeller:
150kg/cm2
Solids Handling Size:
45mm
Wear Plate Clearances:
REAR: 0.36/0.69mm
FRONT: 0.36/0.69mm
Design Speed:
1700RPM
Design Capacity:
92m/hr
Design Efficiency:
63% Inc. NRV Fitted
Max HP at Design Speed:
18.5 HP at 1700 RPM
Specific Speed:
1640rpm
Operating Speed:
MIN: 1000rpm MAX: 2200rpm(Subject to available HP)
Maximum Head:
35.36m
Maximum Capacity:
164m/hr
Operating Temperature:
MIN: -20c
MAX : +100C
Operating Temperature Casing: MIN: -20c
MAX : +120C
Permissible Suction Press:
MIN: Zero ABS MAX : 2 BAR (29.0 PSI)
Maximum Hydraulic Test Press: 5.2BAR (75 PSI)
Bearing Sizes:
DRIVE END:
Taper Roller SKF 32009X
PUMP END:
Taper Roller SKF 32009X
Estimated Bearing Life:
MIN. SPEED/MAX. LOAD:
Indefinite
MAX. SPEED/MIN. LOAD:
80,000 Hours
Type of Bearing Lubrication:
Grease lubrication Shell Alvania RA or equivalent
Type of Shaft Seal:
Recessed Scavenger pumpout vanes to rear of impeller
external mounted mechanical seal, oil lubricated silicon
carbide interfaces

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Installation, Operation and Maintenance Manual.

TECHNICAL DATA SHEET No. 2

MATERIALS OF CONSTRUCTION:
Pump Casing:
Suction Cover:
Air Separation Tank:

SG IRON AS 1831 SG 400/12

SG IRON AS 1831 SG 400/12
SG IRON AS 1831 SG 400/12
(N.B. Suction cover & Separation Tank one casting)
Bearing Bracket:
SG IRON AS 1831 SG 400/12
Pump Shaft:
Stainless Steel 431
Impeller:
Stainless Steel 316
Wearplates:
Stainless Steel 316
Air Injector:
Stainless Steel 316
Seal Housing:
SG IRON AS 1831 SG 400/12
Mechanical Seal:
Crane type 502, Silicon Carbide/Silicon Carbide
Lip Seal:
Nitrile Rubber
N.R.V. Body:
SG IRON AS 1831 SG 400/12
N.R.V. Ball & Seat:
Polyurethane
Engine/Pump/Coupling: Fenner Type HRC (LISTER)/Flexible Bush & Finger Half Coupling
(HATZ)
Compressor Drive
Compressor Pulley: Tooth Belt " Pitch Heavy x 40 Teeth pitch DIA
Details:
6mm
Drive Pulley:
Tooth Belt " Pitch Heavy x 26 Teeth pitch
DIA97mm.
Number & Belt Section: 38mm Wide x 78 Teeth
Compressor Details:
Bendix 2W 440 R Twin-in-line Cylinders 75mm x 50mm Stroke, Air
cooled 15cfm (410L/min) at 1000rpm, Lubrication from engine oil
system.
Ejector Details:
JET: 23-0568-2016
VENTURI: 23-0569-2016

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Installation, Operation and Maintenance Manual.

GENERAL ARRANGEMENT
EXPLANATION OF PARTS LIST AND GUIDE TO THEIR USE

PUMP SUB-ASSEMBLIES

Volute & Front Cover/Separation Tank

MA

Engine Adaptor & Shaft - For Close Coupled Units

Valve Assembly - Heavy Duty Check Valve

EP

Ejector Pack - The Basic Part Of The Dri-Vac Air Priming

System

AC

Compressor Assembly - For Dri-Vac Ejectors

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Installation, Operation and Maintenance Manual.

OPERATING & MAINTENANCE INSTRUCTIONS

DESCRIPTION OF UNIT
The pump is basically a simple end suction pump which has a completely automatic
priming system built into the design. This enables the pump to self prime from a
completely dry condition even with a long suction line. No liquid of any nature is required
to prime the pump and therefore in temporary dry trench conditions the pump will 'snore'
until such time as liquid is available.
The Dri-Vac principal utilises a standard air compressor feeding a pneumatic ejector
mounted above the air/water separation tank. With this device, suction lifts up to 8.2m
(27ft) can be obtained.
It can handle unscreened sewage, trade effluents, thick slurries and solids up to a normal
limitation of 40mm.
The impeller is a three bladed, stainless steel construction, designed full open with shaft of
431 stainless steel. (A recessed impeller, for thick sewage, can be easily fitted).
The pump body is SG iron construction fitted with stainless steel wearplates secured by
high tensile steel screws.
The mechanical seal is fitted externally to the pump in its own self contained oil. It is leak
tight and suitable for sewage and sludges; using silicon carbide faces. Pump out vanes on
the impeller ensure the seal is lightly loaded and not contaminated by the main solid
content.
The pump unit is supported off a SAE 4 engine flange through a heavy duty cast iron
adaptor bracket.
The suction and delivery are 4" Table 'D' flanges.
Guards are fitted as standard to all moving parts.
Note: If your DV100 pumpset has been mounted on a trailer chassis it is recommended
that after approx. 5 km of travel that all wheel nuts be inspected and re-tightened.

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Installation, Operation and Maintenance Manual.

OPERATING & MAINTENANCE INSTRUCTIONS

Operation
Before attempting to start the unit familiarise yourself with the engine controls as
mentioned in the Manufacturers Handbook and also the starting procedure. It is advisable
to turn the unit over slowly by hand before starting, to ensure that all components are free
and easy to turn. Once started the compressor will automatically come in at the correct
speed to prime the pump unit. When the engine has started the pump requires no
adjustment as the engine speeds are set at WORKS.
REPAIRS
Seal Replacement
Drain water from pump and non-return valve. Drain oil from mechanical seal cavity.
Remove pump and non-return valve assembly complete, allowing direct access to the
mechanical seal assembly.
Remove mechanical seal and sleeve assembly, check oil seal (MA31) has not been
damaged or the adjacent sleeve scored. Renew where necessary ensuring that oil seal is
replaced squarely in its housing.
To renew the mechanical seal remove shaft sleeve (H20) complete with seal unit (H18). If
seal unit is in good condition it may only be necessary to remove carbide rotating face
from seal unit. Before fitting a complete new seal assembly ensure that all sharp edges
are removed and all working faces are clean and free from any foreign matter. To fit a
new seal smear the shaft sleeve and inside surfaces of seal bellows with a light oil or
swarfega. Do not use a heavy grease or silicon or P.T.F.E. base lubricant. Ensure the
seal unit is pressed square and evenly over the shaft sleeve and hard back against the
sleeve shoulder (H20). Fit o-ring (H21) to inside diameter of sleeve and ensure there are
no sharp edges where the o-ring passes over. Before fitting the seal rotating face into the
drive grooves use a small amount of grease on the rear face to secure face in position
whilst assembly is taking place. Fit rear wearplate carrying the seal static face using a
non-adhesive sealant on rear face of wearplate. Seal tension is automatically obtained
when the wearplate and impeller are re-fitted. Ensure rear impeller clearance is between
0.3mm and 0.6mm. Fill oil chamber with SAE20/20 grade of oil and check assembly
rotates freely. Rebuild pump casing assembly onto adaptor.
Compressor Belt Replacement
Remove pulley guard (AC55) setscrews (MA3) and pump support nuts (H48) and draw
pump assembly away from engine flywheel housing. Remove old belt and taperlock bush
from pump pulley (AC9). Ease replacement belt (AC11) over pulleys, realign pulleys and
refit taperlock bush. Check belt tension, refit pump unit onto engine. The compressor
tooth belt drive has fixed centres so no adjustment is necessary. The normal operating air
pressure is 2.75 -4.13 bar (40-60psi).

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Installation, Operation and Maintenance Manual.

OPERATING & MAINTENANCE INSTRUCTIONS

Engine Adaptor Assembly
Remove pump assembly from adaptor. Remove drive coupling and pump pulley (AC9)
from pump shaft. It may also be convenient for working to remove compressor (AC1).
Remove rear bearing cover (MA18) and press shaft (MA2) out of adaptor (MA1) dismantle
bearings (MA11). Inspect and clean all items and renew where necessary.
Reassemble adaptor and pump in the reverse order.

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - PUMP

1

Ensure all items are free from burrs and rust.

Visually check for porosity and blow holes in the castings and clean out all the
casting sand and swarf from the hollow in the separation tank cover (H31).

Ensure that all items are clean and that the seal faces are free from score or wear
marks.

Fit O-ring (H21) to the shaft collar (H20).

To fit the tight fitting synthetic rubber friction ring in the seal (H18) onto the sleeve
(H20) apply light oil or swarfega to the inside diameter of the friction ring and to the
outside diameter of the sleeve. Do not use a heavy grease, or silicon or PTFE
based lubricant. Ensure that the seal (H18) is hard against the shoulder on the
sleeve (H20) and that the spring can be compressed.

Fit the sleeve over the shaft MA2 and ensure that the lip seal MA31 is correctly
positioned over it. Locate the seal rotating face into seal.

Locate the O-ring (H15) and the seal seat (H18), into the rear wearplate (H12).
Place the seal seat into the wearplate (H12) and fit the circlip (H16). Ensure that
the seat is secure. Apply non-adhesive sealant (eg. boss white non adhesive
Hermatite or Locktite hydraulic sealant) to the back face of the wearplate (H12) and
secure it into the adaptor (MA1) with fasteners (H6 & H11).

Apply 'Copperslip' to the threads on the shaft (MA2). Fit shims (H24) having a total
thickness of 2mm and the impeller (H3) onto the shaft (MA2). Measure the gap
behind the impeller (H3), remove shims, then refit with shims, having a total
thickness of 2.5mm minus the gap measurement. Fit the impeller and check that
the gap behind it is between 0.3mm and 0.6mm and that the impeller rotates freely.

Locate the O-ring (H13) onto the wearplate (H12).

10

Fit studs (H10, H44 & H45) to the body (H1). The longer studs (H45) should be in
the lower holes.

11

Fit the front wearplate (H5) onto the front cover (H4) and secure with fasteners (H7
& H6).

12

Assemble the body (H1) onto the adaptor (MA1) carefully so as not to dislodge the
O-ring (H13). Check that the gap between the body and adaptor is about 3mm to
4mm all around the circumference, then secure with fasteners (H47 & H48).

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - PUMP (CONT'D)

13

Assemble front cover (H4) to pump body (H1). Secure tightly using fasteners (H47
& H48) until the front wearplate and the impeller just touch. Measure the gap
between the mating surfaces of the pump body (H1) and the front cover (H4).

14

Joints (H9) having a thickness of this gap measurement plus 0.5mm should be
fitted between the pump body (H1) and front cover (H4). After fitting joints (H9)
secure the pump body (H1) and the front cover (H4) with fasteners (H48 & H47).

15

Check that the gap between the front wear plate (H5) and the impeller (H3) is
between 0.3mm and 0.6mm and the impeller rotates freely.

16

Fit items H36, H37, H51, H52 and H53.

17

If pump units are to remain unused for a long time all adjacent clearance surfaces
should be sprayed with a coating of 'Molyprotectoslip' to prevent rust or seizure.

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - ADAPTOR

1

Ensure all items are free from burrs and rust.

Clean out all casting sand from the recess in the adaptor (MA1).

Check that all items are clean and free from foreign matter and that the bearings
(MA11) rotate freely.

Assemble the bearings (MA11) and press them onto the shaft (MA2) ensuring that
the tapers are correctly orientated.

Remove the outer race from the pump end bearings and press it 10mm into the
adaptor (MA1) from the pump end.

Insert the lip seals (MA17) into the bearing covers (MA13 & MA18) then smear
them with grease. Fit cover (MA13) and press it fully into the adaptor (MA1).
Secure with circlip (MA14).

Assemble the shaft (MA2) and bearings into the adaptor (MA1).

Fit the rear bearing cover (MA18) with fasteners (MA22 & MA23). To ensure
alignment, the screws (MA22) should each be rotated a quarter turn in sequence.
When the shaft becomes difficult to rotate, measure the gap between the face of
the cover and adaptor, with a feeler gauge. Remove the cover (MA18) and refit
with shims (MA20) having a total thickness slightly in excess of the gap
measurement. Secure the screws (MA22) and ensure that the shaft (MA2) rotates
freely and has an end float less than 0.2mm.

Check that the plug (MA28) has a 1.6 diameter hole and that the relief valve (MA26)
is set to 3-5psi before fitting to adaptor (MA1). Fit items MA25 & MA29 to the
adaptor.

10

Press the lip seal (MA31) squarely into the adaptor.

11

Fill the bearing housing with 0.2 litres of Shell Alvania RA grease.

12

Items C8, MA3, MA5 & MA41 should be fitted when assembling to the engine.

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - ENGINE

1

Ensure that the following are clean and free of burrs :

Spigot on the adaptor (MA1).
Shaft (MA2).
the engine spigot.
the flywheel.
the coupling.
flywheel housing adaptor. )
IF ENGINE IS HATZ
spacer ring.
)
IF ENGINE IS HATZ
Flywheel Coupling Adaptor )
IF ENGINE IS LISTER TX
Flywheel Housing Spacer Ring)
IF ENGINE IS LISTER TX

Check that the flexible bush and finger half coupling is correctly fastened to the
shaft and the bolt assembly to the flywheel. (HATZ).

Offer the pump end assembly onto the flywheel housing. Before securing with
fasteners (MA3 & MA5) check:
that there is between 1mm and 2mm clearance
FOR HATZ
between the flywheel and the coupling.
Ensure the pump shaft rotates freely with the engine.

Remove and discard the drain plug from the side of the engine base and fit the oil
return hose (AC32) from the compressor.

Ensure that all hoses from the compressor are fitted with no kinks or sharp bends
and are kept clear of the hot area of the engine and compressor.

Fit the fuel lines and all other remaining chassis items.

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - COMPRESSOR ASSEMBLY

1

Ensure all items are clean and that the hoses are free from foreign matter.

Do not use excessive jointing compound (eg. Stag, Neolite, Non-Adhesive

Hermatite etc) when fitting these items and ensure that it does not enter the bores.
This may cause a blockage in the oil or air lines.

Fit gasket (AC2) to the compressor (AC1) position on adaptor (MA1) and secure
with fasteners (AC4 & AC3).

Secure the compressor pulley (AC10) to the compressor (AC1) with the nut and
split pin. Remove the taperlock bush from the pump pulley (AC9) then pass the
pulley over the shaft (MA2). Ease the belt (AC11) over the pulleys, and fit the key
(MA41). Align the pulleys then refit the taperlock bush to the pump pulley (AC9)
and secure it to the shaft (MA2).

Remove and discard four cylinder head screws from the compressor and ensure
the compressed air port is located at the opposite end to fan.

Connect the compressed air hose (AC47) between the compressor (AC1) and the
jet sleeve (EP8).

Fit the oil pipe fittings (AC23, AC30 & AC32) to the compressor (AC1).

Connect air intake fittings (AC43 & AC20).

Secure the guard (AC55) with screws (AC56). Ensure that the belt and pulleys are
free to rotate.

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Installation, Operation and Maintenance Manual.

FITTING INSTRUCTIONS - EJECTOR PACKAGE

1

Check that all items are clean and free from burrs. The jet and nozzle should only
be cleaned with paraffin or similar cleaner. Wire should not be used as this will
enlarge the bores.

Do not use excessive jointing compound when fitting these items and ensure that it
does not enter the bores. This may cause a blockage in the ejector.

Fit the o-rings in their grooves (EP3) onto jet (EP1) and (EP4) onto nozzle (EP2) .

Screw by hand, the jet (EP1) and the nozzle (EP2) to the collar (EP5).

Release the location screw (H36) and insert the assembly into the separation tank
cover (H31), then re-tighten the screw (H36) so that it locates in the groove on the
nozzle (EP2).

Screw the jet sleeve (EP8) by hand into the separation tank cover (H31).
spanner should only be used for the final quarter turn.

Place the ball (EP13) in the separation tank cover (H31), then secure ball seat
(EP12).

Fit the separation tank cover (H31) to the pump body (H1) with gasket filters (H33)
and fasteners (H29 & H30).

Push the exhaust hose (EP15) onto the nozzle (EP2). Fasten using clamp (EP17).

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Installation, Operation and Maintenance Manual.

DV100 NON-RETURN VALVE

1

Ensure that all items are clean and free from burrs.

Visually check for porosity and blow holes in the castings and for scores or chaffing
of the valve ball and seat (V2 & V3).

Fit studs (V16,V7 andV13) into the body (V1).

Fit drain plug (V12) and locate the ball (V2) and valve seat V3 onto the body (V1).

Clean the delivery flange on the pump body (H1) and secure the valve to it with
fasteners (V15).

Fit joints (V5) and (V11) and cover (V6) with fasteners (V8 & V14).

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Installation, Operation and Maintenance Manual.

DV100 TESTING
INSPECTION
1

Drain the water from the pump and the non-return valve (Ref items H27 & V12).

Remove the non-return valve and inspect the ball and seat (Ref items V2 & V3) for
wear.

Drain the oil from the engine and the pump (Ref item MA29).

Dismantle the pump end completely (Ref items H31, H1, H3, H12, H4, H5 and
H20).

If the oil seal (MA31) has scored the seal sleeve (H20), it may be pushed in 2mm to
seal on an unscored area of the sleeve. Ensure that the oil seal is positioned
squarely and that it is less than 8mm from the machined face of the adaptor (MA1).

Worn seal faces may be reclaimed by lapping faces to a surface finish of 3 sodium
light bands. Note that the stationary seat was originally lapped both sides and may
be reversed in the wearplate (H12).

Check that the shaft rotates freely and has an end float less than 0.2mm.

Clean and inspect all components and renew where necessary. Do not use
abrasive materials or solutions to clean the ejector assembly. Renew all nyltite
seals.

Reassemble the complete pump end and non-return valve (Ref Fitting Instructions).

10

Drain the fuel tank.

11

Detach fuel, oil and air hoses. Clean and ensure that they are not blocked. Test
the relief valves (MA26 at 3 to 5 psi, and AC78 at 90 to 100 psi).

12

Check pulley alignment and belt condition (Ref items AC9, AC10 & AC11). Check
the security of pulleys and flexible couplings.

13

Reassemble the complete unit.

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Installation, Operation and Maintenance Manual.

TESTING
1

Fill the seal housing (Ref item MA28) with half a litre of SAE20/20 oil and the
bearing housing (Ref item MA25) with Shell Alvania RA grease.

Fill engine with 5.3 litres of SAE 20/20 detergent oil for testing.

VACUUM TEST
1

The assembled pump should be subjected to a vacuum to show up any air leaks.
Disconnect the compressor hose, fit a compressor air line to the jet, and hold a
vacuum gauge assembly against the pump suction flange. The pump end should
seal against a minimum vacuum of 0.81 bar (24 inches mercury). With closed
valves the vacuum should hold for a minimum of 5 minutes. If the vacuum does not
hold, air may be leaking at the mechanical seal, non-return valves, pump joints or
porous castings.

When the tests are successful, refit the compressor hose.

DYNAMIC TEST
1

Before starting the engine, check that the shaft, pulleys and belt are free to rotate
with the guards in position.

Rotate engine by hand for a minimum of six complete revolutions, listen for injector
'creak' - indication the injector pump is working.

Start pump and run completely dry for a minimum period of 10 minutes (initial run
up speed at 1500rpm increasing during test to 1700rpm). During this period
generally check and observe for any unusual vibrations, overheating, fuel, oil or air
leaks.
These faults must be rectified immediately to prevent a possible engine seizure.

After the dry running period check that the pump unit will raise a minimum vacuum
of 0.81 bar (24 inches mercury). If not, stop engine and refer to 'Ejector Test".

(Consult engine manufacturers handbook for oil, fuel, speed control and stop details).

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Installation, Operation and Maintenance Manual.

EJECTOR TEST
1

If the ejector was unsuccessful in the dynamic test, it may be tested, remove from
the pump, as shown below.

Check the performance of the ejector.

Minimum allowable vacuum 0.81bar (24" Hg or 27.24 ft water) at an air pressure of
2.75 - 4.14 bars (40-60 psi).

When the test is successful, refit the ejector assembly to the pump.

EJECTOR TEST
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PUMP PROBLEMS - Systems & Likely Causes

1. Pump does not prime

2. Not enough liquid

3. Pump ceases to deliver

liquid after a time.

4. Pump takes excessive

power
5. Pump vibrating or
overheating
6. Pump leaking at seal
housing

Suction lift too great.

Insufficient water at suction inlet.
Suction inlet or strainer blocked.
Suction line not air tight.
Suction hose collapsed.
Non return valve ball not seating
Mechanical seal drawing air into pump
Ejector jet or venturi blocked or badly worn.
Ejector non-return valve ball stuck.
Separation tank cover blocked.
Compressor pipe leaking air.
Compressor not delivering sufficient air
Compressor belt drive faulty.
Incorrect engine speed.
Discharge head too high.
Suction lift too great.
Suction inlet or strainer blocked.
Suction line not air tight.
Suction hose collapsed.
Mechanical seal drawing air into pump.
Obstruction in pump casing/impeller.
Impeller excessively worn.
Delivery hose punctured or blocked.
Suction lift too great.
Insufficient water at suction inlet.
Suction inlet or strainer blocked.
Suction hose collapsed.
Excessive air leak in suction line.
Mechanical seal drawing air into pump.
Obstruction in pump casing/impeller.
Delivery hose punctured or blocked.
Engine speed too high.
Obstruction between impeller and casing.
Viscosity and SG of liquid being pumped too
high.
Engine speed too high.
Obstruction in pump casing/impeller.
Impeller damaged.
Cavitation due to excessive suction lift.
Mechanical seal damaged or worn.

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Installation, Operation and Maintenance Manual.

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Installation, Operation and Maintenance Manual.

STANDARD FITTINGS
WHEN PUMP IS POWERED BY HATZ ENGINE
1

10-0000-0010

10-0000-0006

Flywheel Housing Adaptor SAE 4 to

SAE 5
Spacer Ring (SAE 5)

WHEN PUMP IS POWERED BY LISTER TX ENGINE

1

HSP-100H

Flywheel Coupling Adaptor

HSP-101A

Flywheel Housing Spacer Ring

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Installation, Operation and Maintenance Manual.

AIR COMPRESSOR

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Installation, Operation and Maintenance Manual.

Ref.

A
B
C
D
E
F
G
H

J
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y

Description

Part Number

Bendix Air Compressor 2W 440 R KZ1087/14

49-0523-9915

Valve Plate Assembly c/w Reed Valve Kit & Air Inlet Valve
Cylinder Head
BSP Threaded Air Delivery Connection
Threaded Water Cooling Ports
BSP Threaded Air Inlet
Reed Valve Kit
Air Inlet Valve 229502
Valve Plate & Head Gasket Kit
Comprising: Cyl.Head Gasket KX2466/2
Top Plate Gasket KX2799/2
Lower Plate Gasket KX2280/2
Cylinder Body
Piston Assembly (STD)
(KW5172/1SP)
Piston Assembly
(KW5172/2SP)
Piston Assembly
(KW5172/3SP)
Piston Ring Set (STD)
(SKR2790/00)
Piston Ring Set (0.010 o/s)
(SKR2790/10)
Piston Ring Set (0.020 o/s)
(SKR2790/20)
Piston Ring Set (0.030 o/s)
Oil Control Ring
- Included in Piston Assy & Piston Ring Set
Connecting Rod Pin - Included in Piston Assembly
Rod Pin Snap Pin
- Included in Piston Assembly

KY2331/1SP
KZ1160/3

Crankshaft
Ball Bearing (NSK-6307-CE)
Front End Cover
O-Ring, Inner Bearing Cover
Crankshaft Oil Seal (CR13938)
Con Rod Complete
Thrust Washer
White Metal Bearing Bushing
End Cover Assembly c/w Bushing
C Ring - End Cover
Lubricating Oil Inlet 1/8 BSP
Base Mount Gasket 0.8mm
Base Mount Gasket 0.4mm

(KW4785/1SP)

SK2955/1
SK2997/1

KZ1094/1
1189082SP
1189255SP
1189256SP
SKR2962/00
SKR2962/10
SKR2962/20
SKR2962/30

KY2258/1SP
1194120SP
KX2491/1
1189619
267805
1194120SP
KY2372/1
I811560066
KX1223/13SP
1189571
KX2542/1
KX2542/2

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PARTS LISTS

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Installation, Operation and Maintenance Manual.

ILLUS.No.
H1
H3
H4
H5
H6
H7
H9a
H9b
H9c
H10
H11
H12
H13
H15
H16
H18
H20
H21
H24a
H24b
H24c
H28
H29
H30
H31
H33
H36
H37
H44
H45
H47
H48
H51
H52
H53

DESCRIPTION
Volute (Pump Body)
Impeller
Front Cover & Separation Tank
Wearplate (Front)
O-ring Sealing Washer M8
O-ring (Viton)
Stud M8 x 60
Joint (Body)
Joint (Body)
Joint (Body)
Stud (Body) M12 x 50
Stud M8 x 50
Wearplate (Rear)
O-ring (Wearplate)
O-ring (Seat)
Circlip (Seat)
Mechanical Seal
Seal Sleeve
O-ring
Impeller Shim 0.25mm
Impeller Shim 0.5mm
Impeller Shim 1.0mm
Skt Hd Capscrew M8 x 30mm
Flat Washer M8
N/A
Separation Tank Cover
Filter (Separation Tank)
Setscrew M10 x 20
Lockwasher M10
Stud (Pump/Adaptor) M12 x 45
Stud (Pump/Adaptor) M12 x 50
Lockwasher M12
Nut M12
Stud (Flange) M16 x 60
Lockwasher M16
Nut M16

PART No.
11-0240-0115
12-0265-3015
11-0241-0115
12-0266-0115
38-0775-4412
38-0777-4112V

QTY.
1
1
1
1
5
5
3
38-1035-1000
A/R
38-1035-1010
A/R
38-1035-1020
2
4
2
12-0267-0115
1
38-1004-4112
1
38-0700-4112
1
41-0230-8712
1
38-0400-VS2S2/SS
1
24-0137-3215
1
38-1005-4112
1
36-0647-8013
A/R
36-0647-8923
A/R
36-0647-8933
A/R
4
4
21-0230-7915
23-0586-9923

1
1
1
1
4
2
10
10
4
4
4

VOLUTE

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

DESCRIPTION
MA1
MA2
MA3
MA5
MA11
MA13
MA14
MA17
MA18
MA20
MA20a
MA20b
MA20c
MA22
MA23
MA25
MA26
MA28
MA29
MA31
MA41
MA42

Engine Adaptor
Shaft (* see note below)
Setscrew M10 x 40
Lockwasher 10mm
Taper Roller Bearing
Bearing Cover (Front)
Circlip
Spiroseal
Bearing Cover (Rear)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Shim (Bearing Cover)
Setscrew M8 x 20
Lockwasher 8mm
Grease Nipple
Relief Valve
Plug 3/8" BSP
Plug 3/8" BSP
Spiroseal
Key
Adaptor (Recessed)

PART No.
13-0166-0215
16-0380-8821
39-0056-9912
13-0171-8121
41-0231-8712
38-1083-4112
13-0168-0125
36-0649-9903
36-0649-9913
36-0649-9923
36-0649-9933
51-0003-8112
51-0010-2012
43-1048-4515
38-1007-4112
17-0219-0115

NOTE:
WHEN ORDERING SHAFT (MA2)
STATE PUMP ENGINE TYPE SO
CORRECT SHAFT LENGTH CAN BE
SUPPLIED.

Sykes Group Pty Ltd.

QTY
.
1
1
9
9
2
1
1
2
1
A/R
A/R
A/R
A/R
3
3
1
1
1
1
1
1
1

Installation, Operation and Maintenance Manual.

EJECTOR PACKAGE
Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

ILLUS. No.
EP1
EP2
EP3
EP4
EP5
EP8
EP12
EP13
EP15
EP17

DESCRIPTION

Ejector Jet
Ejector Nozzle
O-ring (Jet)
O-ring (Nozzle)
Ejector Collar
Jet Sleeve
Ball Seat
Ball
Toyo Hose
Hose Clamp
Vacuum Gauge

PART No.
23-0572-2016
23-0571-2016
38-1013-4112
38-1014-4112
23-0570-2011
23-0567-2011
23-0412-2011
39-0641-4113
001-0003

QTY
1
1
1
1
1
1
1
1
1
1
1

EJECTOR PACKAGE

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

ILLUS. No.
AC1
AC2
AC3
AC4
AC5
AC6
AC7
AC7A
AC8
AC9
AC10
AC11
AC12
AC13
AC14
AC15
AC16
AC17
AC18
AC19
AC20
AC23
AC30
AC32
AC43
AC47
AC55
AC56
AC78

DESCRIPTION
Compressor (Bendix)
Gasket
Stud M10 x 40
Lockwasher M10
Coupling Nut M10 x 35
Flat Washer M10
Vibrating Mount M10
Stud M10 x 90
Nut M10
Pulley (Pump) c/w Taper Lock Bush
Pulley (Compressor)
Belt 38 wide x 78 teeth (" Heavy Pitch)
Lockwasher M22
Fan Adaptor
Setscrew M6 x 15
Lockwasher M6
Fan
Fan Washer
Lockwasher M12
Setscrew M12 x 20
Air Cleaner
Oil Delivery Hose
Nipple BSP " x 3/8"
Oil Drain Hose
"- M/F Adaptor
Compressed Air Hose (S/S Teflon ")
Pulley Guard
Bolt M10 x 10
Relief Valve

PART No.
49-0523-9915
KX2542/1
10-0000-0026
10-0000-0027
26-0850-9912
26-0830-0243
26-0840-9912
17-0206-0115
54-0237-9912
36-0556-8111
54-0556-9912
42-0000-0005
42-0000-0002
A1212
42-0000-0007
27-2805-9821
10-0000-0004

COMPRESSOR ASSEMBLY

Sykes Group Pty Ltd.

QTY
1
1
4
8
4
4
8
4
4
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
4
1

Installation, Operation and Maintenance Manual.

REFLUX VALVE

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

ILLUS. No.
V1
V2
V3
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16

DESCRIPTION
REFLUX BOX COMPLETE
Reflux Box
Ball
Seat
Joint
Cover
Stud M16 x 40
Nut M16
Setscrew 12mm x 40
Nut 12mm
Joint
Drain Cock
Stud M16 x 50
Nut M16
Nut M16
Stud M16 x 70

PART No.
346-3024
346-4313
312-4212
346-6000
500-4035
346-4016

500-4033
920-9242

QTY
1
1
1
1
1
4
4
2
2
1
1
4
4
4
4

REFLUX VALVE

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

ACCESSORIES
Your CP100 Pumpend comes complete with the following extras:- 4" Table 'E' Flanged Discharge Spool Pipe

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

CP100 RECOMMENDED SPARES

Compressor
No. Off

Part No.

Description

1
1
1

267787
267805
SK2997/1

KX2542/1

O-Ring
Oil Seal
Valve Plate and Head Gasket
Kit
Base Gasket

Pump End
No. Off
3
3
3
1
1
1
1
1
3
3
3
1
1
1
1
1
1
1
1
1
1

Part No.

Description

38-1035-1000
38-1035-1010
38-1035-1020
38-1004-4112
38-0700-4112
41-0230-8712
38-0400-VS2S2/SS
38-1036-4112
36-0647-8013
36-0647-8923
36-0647-8933
23-0586-9923
23-0568-2016
23-0569-2016
38-1013-4112
38-1014-4112
39-0641-4113
26-0840-9912
12-0265-3015
12-0266-0115
12-0267-0115

Joint
Joint
Joint
O-ring
O-ring
C-Clip
Mechanical Seal
O-ring
Impeller Shim
Impeller Shim
Impeller Shim
Filter
Jet
Nozzle
O-ring
O-ring
Ball
Belt
Impeller
Front Wear Plate
Rear Wear Plate

Sykes Group Pty Ltd.

Installation, Operation and Maintenance Manual.

Sykes Group Pty Ltd.