CP100i STD Pump Build & Service Manual Revision 1

CP100i
Basic Pump Build

&
Service Manual
Sykes Group Pty Ltd

Date Released: 30-Nov-07
Revision: 1
Sykes CP100i – Basic Pump Build & Service Manual
1 PUMP BUILD INFORMATION
Figure 1 – CP100i General Assembly Drawing
Page 2
Sykes Group Pty Ltd Spare Parts & Service 24 hours: 1800 131950
Website: www.sykesgroup.com
1.1 CP100i Build Specifications
Impeller Clearances
Front Rear
Min (mm) Max (mm) Min (mm) Max (mm)
0.45 0.65 0.50 0.65
Bearing End Float
Min (mm) Max (mm)

0.051 0.076
Initial Pump Bearing Set Up
Lubricant Grease Multi Lube Lithium Grease EP Additives NLGI #2
1. Fully pack the bearings starting from one side.
2. Swipe extra grease until the cavity is approximately one third full.
3. Do not under any circumstances completely fill the cavity as this may cause the
bearing to overheat.
Special Note:
Front Bearing Lip Seal to be reversed, so excess grease will release into bearing
frame cavity rather than to outside of bearing frame (engine adaptor side).
Page 3
Mechanical Seal
Quench Fluid Oil 15W40

Reservoir Capacity 0.85 Litres
BEFORE FITTING THE SEAL ENSURE SHAFT/SLEEVE IS CLEAN AND FREE FROM BURRS AND SHARP EDGES.
APPLY LIGHT OIL TO THE SHAFT/SLEEVE AND SEAL O-RING (ITEM 7). DO NOT USE HEAVY GREASE OR SILICON BASED LUBRICANT.
ENSURE SEAL GRUB SCREWS (ITEM 8) ARE NOT PROTRUDING BEYOND THE INSIDE DIAMETER OF THE SEAL RETAINER (ITEM 5).
CHECK SEAL FACE IS CLEAN AND FREE OF DEBRIS (ITEMS 2/3).
ENSURE THE SEAL UNIT IS PRESSED SQUARELY AND EVENLY OVER THE SHAFT. MAKE SURE IT IS HOME HARD BACK AGAINST THE COLLAR SHOULDER.
TIGHTEN GRUBS SCREWS (ITEM 8) EVENLY TO SECURE SEAL IN POSITION.
CHECK PUMP REAR WEARPLATE FOR BURRS AND SHARP EDGES. LUBRICATE SEAT O RING (ITEM 9) AND POSITION IN REAR WEAR PLATE O RING GROOVE.
CHECK SEAL SEAT (ITEM 1) IS CLEAN AND FREE OF DEBRIS. LOCATE IN REAR WEAR PLATE AND SECURE WITH CIRCLIP (ITEM 10).
LIGHTLY SMEAR STATIONARY SEAL FACE WITH CLEAN LIGHT OIL.
SEAL TENSION IS AUTOMATICALLY OBTAINED WHEN THE REAR WEAR PLATE IS FITTED.
FILL SEAL OIL CHAMBER WITH LIGHT OIL S.E.A. 20/20 AND CHECK ASSEMBLY ROTATES FREELY.
Page 4
Torque Ratings
Sykes Group uses the following bolts and studs in their pump builds and it is
recommended to use the following torque settings
HIGH TENSILE BOLT CLASS 8.8
Recommended Assembly Torques

Size
Nm ft.lbs
M8 22 16
M10 44 32
M12 77 57
M16 190 140
M20 370 270
M24 640 470
ENGINEERING STUD CLASS 4.6
Recommended Assembly Torques

Size
Nm ft.lbs
M8 8.5 6.3
M10 17 12
M12 30 22
M16 73 54
M20 143 106
M24 248 183
Page 5
2 SERVICE INFORMATION
2.1 General Information
Preventive maintenance is the easiest and least expensive type of maintenance.
Ensure that the safety information, warnings and the instruction are read and
understood before performing any maintenance procedures.
Follow the minor and major maintenance schedule outlined in Sykes Maintenance
Schedule. Use the service hours or calendar time, whichever occurs first, in order
to determine the maintenance intervals.
Sykes Group Pty Ltd uses the latest technology and highest quality components to
produce its pumps. Sykes Group recommends only using genuine Sykes parts.
Use the correct mechanical seal coolant, pump bearing lubricant as specified in
standard pump build & service manual.
Personnel at Sykes have been trained to provide expert service and parts support.
Some of the maintenance procedures requires special tools or must be completed
by qualified personnel.
If the pump is operated in ambient temperatures below -180C or above 380C and /
or under severe conditions, perform maintenance at shorter intervals.
Severe services includes the following conditions; high temperatures, continuous
high loads, vibration and dusty conditions.
Please contact Sykes Group for assistance.
Page 6
2.2 Service Matrix – CP100i

Daily 250 hours 500 hours 750 hours 1,000 hours 6,000 hours
As Required
3 Months 6 months 9 months 12 months 3 years
Pump end
1 Check for mechanical seal leaks
2 Change mechanical seal oil
3 Change mechanical seal
4 Check coupling alignment & condition
5 Change pump coupling rubber/s
6 Check/Adjust wet end clearances
7 Change pump wet parts, impeller / wear plates
8 Check bearing temperature
9 Check bearing end float
10 Replace pump shaft bearings
11 Check pump shaft seals
12 Change pump shaft seals
13 Check impeller for visual blockages
14 Replace volute
Priming System Compressor

1 Change compressor air filter
2 Check compressor air hose
3 Check/Clean priming tee filter
4 Change priming tee filter
5 Check priming tee ball/seat
6 Change priming tee ball
7 Check/clean priming tee jet/nozzle
8 Change priming tee jet/nozzle
9 Check compressor drive belt
10 Replace compressor drive belt
11 Check compressor performance
12 Change compressor air
Ancillaries
1 Check non return valve
2 Change non return valve seat/flap
3 Check vacuum gauge
4 Change vacuum gauge
5 Check pressure gauge
6 Change pressure gauge
7 Check gear box butterfly valve
8 Change gear box butterfly valve
9 Check all oil, water and air hose's condition
10 Check condition of hose coupling o-rings
11 Check for all mounting bolts, skid, chassis
12 Check shut down operations engine and pump
13 All guarding
14 For diesel servicing and panel operational checks. See relevant manuals.
= Daily Check
= Minor Service
= Major Service
= As Required
Notes:
1 Ancillaries are not included in major service schedule / pricing, please contact Sykes for assistance
2 Please refer to Service Schedule for detailed parts, service checks and labour information
3 Follow minor and major schedules outlined in Sykes Service Schedule. Use the service hours or
calendar time, whichever occurs first, in order to determine the maintenance intervals.
4 0 0
If the pump is operated in ambient temperatures below -18 C or above 38 C and / or under severe conditions, perform maintenance at shorter
intervals. Severe services includes the following conditions; high temperatures, continuous high loads, vibration and dusty conditions.
Page 7
Grease Lubrication Schedule – CP100i
Grease Point
Grease Relief
Nipple
Notes:
1. Single point grease point to grease 2 off 32009 bearings
2. Single point grease relief nipple
3. Grease relief nipple set at 3 - 5 psi
4. Grease Specification: Multi Lube Lithium Grease EP Additives NLGI #2
Page 8
Operating Conditions:
Ambient Temperature 20 0C
Humidity / Dust Moderate
Vibration Moderate
Load Moderate
Quantity of Grease required at

Bearings 32009 (2 off)
250 Hour Intervals
Speed 1400 rpm
1.0 grams
Bearing Temperature 44 0C
Speed 1500 rpm
1.0 grams
Speed 1600 rpm
2.0 grams
Speed 1700 rpm
2.0 grams
Speed 1800 rpm
2.0 grams
Speed 1900 rpm
2.1 grams
Speed 2000 rpm
2.1 grams
Speed 2100 rpm
2.1 grams
Speed 2200 rpm
2.2 grams
Speed 2300 rpm
2.2 grams
Speed 2400 rpm

2.2 grams
!WARNING!
Use this re-greasing schedule as a guide only.

Re-greasing quantities will change due to variances in Operating Conditions.
For re-greasing schedules to suit particular Operating Conditions please

contact Sykes for assistance.
Page 9
Operating Conditions:
Ambient Temperature 40 0C
Humidity / Dust High
Vibration High
Load Heavy
Quantity of Grease required at

Bearings 32009 (2 off)
250 Hour Intervals
Speed 1400 rpm
2.0 grams
Speed 1500 rpm
2.0 grams
Speed 1600 rpm
2.0 grams
Speed 1700 rpm
3.0 grams
Speed 1800 rpm
3.0 grams
Speed 1900 rpm
3.0 grams
Speed 2000 rpm
4.0 grams
Speed 2100 rpm
4.0 grams
Speed 2200 rpm
4.0 grams
Speed 2300 rpm
5.0 grams
Speed 2400 rpm
6.0 grams
!WARNING!
Use this re-greasing schedule as a guide only.

Re-greasing quantities will change due to variances in Operating Conditions.
For re-greasing schedules to suit particular Operating Conditions please

contact Sykes for assistance.
Page 10

CP100i STD Pump Build & Service Manual Revision 1

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CP100i

Basic Pump Build

Sykes Group Pty Ltd

1 PUMP BUILD INFORMATION

Figure 1 – CP100i General Assembly Drawing

1.1 CP100i Build Specifications

Bearing End Float

Min (mm) Max (mm)

Initial Pump Bearing Set Up

Lubricant Grease Multi Lube Lithium Grease EP Additives NLGI #2

1. Fully pack the bearings starting from one side.

Quench Fluid Oil 15W40

HIGH TENSILE BOLT CLASS 8.8

Recommended Assembly Torques

ENGINEERING STUD CLASS 4.6

Recommended Assembly Torques

2.1 General Information

Preventive maintenance is the easiest and least expensive type of maintenance.

Please contact Sykes Group for assistance.

2.2 Service Matrix – CP100i

Priming System Compressor

Grease Lubrication Schedule – CP100i

1. Single point grease point to grease 2 off 32009 bearings

2. Single point grease relief nipple

3. Grease relief nipple set at 3 - 5 psi

4. Grease Specification: Multi Lube Lithium Grease EP Additives NLGI #2

Quantity of Grease required at

Speed 2400 rpm

Use this re-greasing schedule as a guide only.

For re-greasing schedules to suit particular Operating Conditions please

Quantity of Grease required at

Use this re-greasing schedule as a guide only.

For re-greasing schedules to suit particular Operating Conditions please

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