HYDRAULIC PUMP

HY85 160
--------------------------------------------
Instructions handbook / Spare parts

Via Paesa – 46048 Roverbella (MN) – Tel. +39 03761685400 – Fax +39 03761685499
[email protected] – www.dragflow.it
 HYDRAULIC PUMP HY85 160
INSTRUCTIONS HANDBOOK
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CE DECLARATION OF CONFORMITY
THE MANUFACTURER
DRAGFLOW SRL
Via Paesa
46048 Roverbella (MN), Italy

This declaration of conformity is issued under the sole responsibility of the manufacturer Dragflow S.r.l.

DECLARES THAT THE MACHINE

Modello / Model : HY85 160
Submersible pump
Matr. N. / Serial N. : 6398
Anno / Year : 2019
DRAGFLOW

CONFORMS TO THE DIRECTIVE(S)

Directive 2006/42/EC of the European Parliament and the Council of 17 May 2006 on machinery and amending Directive
95/16/EC.

Riferimento norme armonizzate / Reference standards:

EN 12100:2010; EN ISO 4413:2010 (Hydraulic fluid power – general rules and safety requirements)

AND IT AUTHORIZED
DRAGFLOW SRL
Mr. Roberto Martinelli (Director)
Via Paesa
46048 Roverbella (MN), Italy

A COSTITUIRE IL FASCICOLO TECNICO PER SUO CONTO /

TO FORM A TECHNICAL FILE FOR IT

Roverbella (MN), Italy – 27/05/2019 Il fabbricante / The manufacturer

…………….……………………….

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INDEX

PRESENTATION..………………………………………………………………. pg. 3

WARRANTY REGULATIONS.…………………………………………………. pg. 4

1.0 DESCRIPTION…………………………………………………………………... pg. 5

2.0 TRANSPORT, ASSEMBLY AND DEMOLITION.……………………………. pg. 6

3.0 STARTING AND OPERATION…………..…..………………………………... pg. 9

4.0 MAINTENANCE AND CLEANING.…..………………………………………... pg. 10

5.0 NOISE…..…….…………………………………………………………………... pg. 13

HYDRAULIC CONNECTIONS……..…………………………………………... pg. 14

6.0 SAFETY…………………………………………………………………………... pg. 16

SPARE PARTS……..……………………………………………………………. pg. 17

WEAR SPARES……………...………………………………………….………. pg. 24

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PRESENTATION

This instructions manual has been conceived and structured for rapid and easy consultation, thanks to the
index ordered by subjects, and explanatory figures and tables.

GENERAL WARNINGS

This instructions manual must be studied by the owner of the machine, the technical personnel within the
factory, the operators, that is, all those that will be using the machine, the maintenance technician.
The manual is an integral part of the machine and contains information on its use, technical characteristics, as
well as instructions for handling, installation, assembling, regulation and maintenance.
It also contains a section for trouble-shooting, if necessary, and for the ordering of spares.
The DRAGFLOW S.r.l. technicians are always available, by telephone, fax or e-mail, to supply all the
explanations that may be needed.

This manual:
- must be considered as integral part of the machine until it is taken to the breakdown yard;
- must be kept in an easily accessible place and suitable for its preservation;
- must be consulted each time that there are problems or doubts on the operation of the machine;
- must be carefully followed for whatever regards the necessary maintenance operations set out in it.

In case it is lost, apply for a copy directly from DRAGFLOW S.r.l.

DRAGFLOW S.r.l. reserves the right to carry out all modifications to update the machine or instructions
manual according to the technological progress and the state of the art.
This constitutes no obligation to carry out modifications to the machines that have already been sold. If the
machine is ceded to a third party, it is recommended that of the instructions manual follow it.

DRAGFLOW S.R.L. RETAINS ITSELF FREE FROM LIABILITY OF ANY KIND, AND ESPECIALLY FOR:
- improper use of the machine;
- use of the machine by personnel not trained to used it;
- power supply defects;
- maintenance defects;
- unauthorized and unforeseen modifications;
- use of spares that are not original or not specific for the model;
- non observance of the instructions;

The uses of the machine for different purposes are to be considered dangerous for the operator and for the
machine. Likewise, modalities of installation and utilizations different from that indicated in the present manual
could cause damage to persons and/or to the machine itself.

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WARRANTY REGULATIONS

DRAGFLOW S.r.l. guarantees the original user that the machine will be reasonably free from factory and
material defects.

This warranty lasts for 12 ( twelve ) months from the invoice date, and refers to the repairing of any defect that
will be recognized by DRAGFLOW S.r.l. as being subject to warranty.

The warranty does not apply to those parts that result defective because of incorrect use, handling or bad
observance of the use and maintenance instructions supplied by DRAGFLOW S.r.l.
The warranty is not applied for those listed parts subject to normal wearing:
- seals and gaskets, shaft sleeves, impeller, stirrer, wear-plates, casing, discharge adapter, excavator teeth
and electrical components;
The warranty on the electric motor is applied only if the standard electronic control console foreseen has been
installed.
If the Purchaser tries, either to repair any fault that is under guarantee, or obtain direct supply of the spare part
without previous written consent of DRAGFLOW S.r.l. the latter will not be responsible for the results of the
repair and will not be held to reimburse the expenses sustained by the Purchaser.

Any claim for warrantable failures shall be sent in writing to DRAGFLOW S.r.l. prior to the expiry of the
warranty period.
As soon as the spare is ready, the Client will make the defective part available to DRAGFLOW S.r.l.

The warranty is applied in one of the following ways and at the discretion of DRAGFLOW S.r.l. :
- replacement of defective part with a new one, made available in the offices of the Purchaser at the
lowest transport rate;
- repair of defective part, after this has been returned to DRAGFLOW S.r.l. with transport expenses
prepaid.

DRAGFLOW S.rl. declines all responsability for the expenses due to “down-time”, business costs and losses
deriving there from.
This warranty is the sole warranty provided by DRAGFLOW S.r.l.

There are no other warranties, explicit or implied, or of merchantability or fitness for a particular purpose.

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1.0 DESCRIPTION

STRUCTURAL DESCRIPTION OF THE MACHINE (Fig. 1)

The Dragflow hydraulic pumps are made of high quality materials and undergo severe controls before leaving
the factory.
They are essentially composed of a cover 1, on which the hydraulic motor 2 is fitted.
Inside the oil housing 3 is housed the group of seals 4 preventing the water from passing to the motor.
On the main shaft 10, inside the casing 5, there is a keyed impeller 6, made in high chrome content anti-wear
materials.
A wear plate 7, made with the same material, partially closes the impeller inlet.
Inside the strainer protection 8 houses a cutter 9 that rotates and stirs the mixture of solids in the water to be
pumped.

Fig. 1

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2.0 TRANSPORT, ASSEMBLY AND DEMOLITION

Dragflow pumps are generally transported encased inside a crate to avoid damage to the pump or parts of it.
The crate is arranged for unloading with a fork-lift truck, whose capacity must be able to sustain the weight of
the pump ( see data sheet enclosed in this instructions handbook ) as shown in Fig. 2.
The pump is placed inside the crate as seen in Fig. 3, it must be freed from the packing and lifted with ropes
hooked to the appropriate lifting plate A.

Fig. 2

Fig. 3

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INSTALLATION

1) Connect the delivery pipe.

- The delivery pipes must never form siphons (Fig. 5) pag. 6, to avoid problems due to the formation of
air pockets or deposits of solid material.
- Before connecting then pump to the hydraulic supply source, make sure that all the data on the rating
plate correspond ( max. pressure, etc. )

NO!

Fig. 4 Fig. 5

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Connect the oil supply pipes to the pump as indicated in Fig. 6.

DISMANTLING

Before doing anything on the pump, be sure to disconnect the hydraulic supply and the delivery pipes.

Warning: the machine that is considered completely useless must be removed from the department and
collected by the manufacturer or any other firm specialized in demolition. Remember that dismantling the
machine in your establishment will “produce” different materials ( metals, plastics, oil, etc. ) whose disposal
will be done in compliance with the legislative regulations in force in the state where the machine is found.

(DELIVERY) (RETURN)
PIPE 1” ¼ - 350 bar PIPE 1” ½ - 100 bar

(DRAINAGE)
PIPE ¾” return
free at the tank

Fig. 6

The drainage oil must be collected in non-pressurized tanks. “Free return” means
that there must be nothing that impedes the drainage ( narrowing, valves, filters, etc. )

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3.0 STARTING AND OPERATION

STARTING

The pump has been created to pump suspended matter, even with solid parts, as long as water is always
present. It can be used for civil and industrial purposes, as long as conditions described in this manual are
observed.
Check the direction of rotation: by passing very short impulses and check that the direction of rotation is that
indicated on the rating plate.
1) Immerse the pump in clear water.
2) If any priming problems should come up, stop and wait for about 30 seconds, leaving it immersed, until all
the air has been eliminated.
3) Check that: when pumping only water H2O, the operating pressure always stays at least 20 - 30% below
the set maximum pressure.
4) Slowly lower the pump until it comes into contact with the material.
5) Check the percentage of solid to avoid exceeding the maximum pressure threshold.
6) When clean water is not available, but only mud and other mixtures, check that the pump does not go over
the maximum pressure indicated on the rating plate (Fig. 7); however, if this does happen, create a further
load loss, by doing what is set out below:
- by adding pipes;
- by creating bottlenecks;
- raising the discharge height;
7) Before stopping the pump, it is always a good rule to pump water with very little solid in it, so that the pipes
are washed.

EMERGENCY SITUATIONS

The correct use of the machine excludes the

possibility of emergencies happening during
operation or during cleaning and maintenance,
unless the latter have not been done in compliance
with this instructions manual.
If there is any imminent mechanical danger, stop,
or have the pump stopped by disconnecting it from
the hydraulic supply. An accurate search for the
fault, or anomaly that caused the danger, must be
carried out soon afterwards, and once detected, MAX
see to resetting the operation of the machine and PRESSURE
of the protection set-up.
If necessary, have DRAGFLOW S.r.l. Service or
competent personnel from another firm carry out
any repairs or work.

Fig. 7

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4.0 MAINTENANCE AND CLEANING

Warning: maintenance and cleaning of the machine must be done after having stopped the machine.

1) Check the tightness of the fastening screws every 50 hours of pump operation.
2) Remove the 2 (two) plugs marked by the labels GREASE, Fig. 8, and restore the grease with 50 grams
of it for each greaser, using a hand grease gun. Seals zone must be greased every 8 hours.
3) Every 200 hours check the clearance between the impeller 47 and the lower wear plate 48 is as
follows (see Fig. 9). (Use the torque table for tightening).
- keep the pump in a vertical position;
- dismantle the side strainer 53 by removing the screws in position 21;
- check that the clearance is not more than 1,5 mm, if it is wider proceed as follows:
- slacken of the fastening screws 52;
- take the wear plate 48 at a distance of about 1,5 mm from the impeller 47, by turning the adjustment
screws 81 and locknuts 83;
- check that it rotates freely;
- fasten both the locknuts 83, the adjustment screws 81 and the fastening screws 52.
4) For customers that work with particularly abrasive materials having a very fine particle size, we advise
passing a jet of water under pressure, connecting it to the prepared threaded connector indicated with
H2O (Fig. 8). The pressure must be greater than that exerted by the pump to have continuous cleaning
of the area of the seals and so less wear.
It is compulsory to grease the area of the seals at the end of each shift or every 8 working
hours, use water resistant grease with LIQUILON.

Fig. 8
“GREASE”
-greasing
every 150
hours-

“WASHER” “GREASE”
water -greasing
washing every 8 hours-
A = 1,5mm

adjusting
blocking screws
thickness
screws

Fig. 9

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5) Check the level and the deterioration of the oil every

8 hours of operation by removing the plug labelled
“OIL” (Fig. 10). For a total oil change or topping up, “WATER”
water
the following steps have to be taken: washing
a) It is good practice to empty the pump completely
of the remaining oil. The exhausted lubricant must
be disposed of in conformity with the laws in force
in the country where the machine is used, since its
dispersal in the ground will pollute the water beds.
This is not necessary if the oil is simply topped up.
b) Remove the plug marked ”OIL”.
c) Top up until completely full using a funnel on side
up to the indicated "OIL LEVEL" (Fig. 11), approx
5 Kg of oil having the characteristics as in the table
following.
Fig. 10

Density at Viscosity Flash point

Oil type ISO Cst 40°C E 50°C I.V. Pour point °C
15/4 °C Cst 100°C V.A. °C
EP320 320 0,900 330 25,8 24,0 95 240 - 17

d) Before closing the plug change the copper washer to prevent leaks and water seeping in.
If the oil is “milky” white color the seals must be replaced.

"OIL" oil filling

Top up with funnel

OIL LEVEL

Fig. 11

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REPLACING THE SEALS

- Completely empty the oil from the oil chamber.

- Remove the filter 53 (Fig. 12) by unscrewing the screws 21.
- Unscrew the cutter 54 by hitting it smartly in an anticlock-
wise direction as shown in Fig. 13; make sure the impeller
47 (Fig. 12) is blocked with an iron rod.
- Remove the connection 56 (Fig. 12a), then the nut 57 and
the spacer 58.
- Extract the flange on the suction side 50 (Fig. 12) after
having removed the screws 52. With the flange pos. 50
the lower wear plate 48 also will come down.
- Remove the casing 45 (Fig. 12) after having removed the
screws 42.
- Extract the impeller 47 using two levers “A” (Fig. 12).
If it sticks use an extractor, taking care not to damage the
threaded part of the motor shaft.
- Remove the key 59 (Fig. 12) and immediately after the
sleeve 20 (Fig. 14). To remove the upper wear plate 46
unscrew the screws 42a.
- Remove the seals housing 67 and 65 after having
removed the screws 78 with the ring 68.
- Change the seals 27 (n° 1) and 34 (n° 1) with their wear
sleeve 39 (n° 1) and the o-ring 40 (n° 1). Then change the
seals 66 (n° 1), 41 (n° 3) and 36 (n° 2), the two lower shaft
sleeve 31 and 20, the three o-rings “OR” 28, 23 and 26 as
shown in Fig. 14 taking care not to damage any spare.

Fig. 12a

Fig. 12
Fig. 13

54

N.B. First block

the impeller Fig. 14
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- To reassemble follow the instructions in the reverse order keeping the pump in vertical position.
Remember to adjust the lower wear plate 48 (Fig. 9 pag. 9) as indicated in paragraph 3), before closing
the pump definitely.
Top up with new oil, according to the instructions of paragraph 5) pag. 10.
Periodically, check the state of the hydraulic system ( pipes, pipe fittings, etc. ).
If parts of the hydraulic equipment are to be replaced, only use components with characteristics
that are equal, or at least similar, to those of the original components.

PUTTING THE MACHINE OUT OF SERVICE

If for any reason whatsoever the machine should be temporarily placed out of service, it is important to
disconnect the hydraulic supply source, clean the fittings of pump and hydraulic motor and cover them to
protect them from dust.
To put it back into service again follow the instructions for starting up.

5.0 NOISE

The machine was designed and manufactured while at the same time keeping in due consideration air noise
hazards. The construction techniques used allow to limit the noise level within tolerable limits in compliance
with the Machine Directive 2006/42/CE.

Air noise detection was effected by placing the probe two meters from the machine, along the whole perimeter
and at a meter from the floor. The noise was measured under vacuum. This because the machine itself does
not require any specific operation position fixed by the operator since it is normally immersed in water and
therefore the values are non-influencing.
The observations were done with a model HD9020K1 DELTA OHM PRECISION INTEGRATOR NOISE
METER in conformity with the: IEC651 class 1 standard
IEC804 class 1
IEC225 filters 1/3 octave
The instrument was calibrated with a DELTA OHM HH9101 calibrator conforming to the IEC942-1986 class 1.

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HYDRAULIC
CONNECTIONS

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- The DRAGFLOW pumps are only supplied with piston hydraulic motors, suitable for circuits where the
continuous operating pressure may reach 300 bar. These pressures can only be reached in the worst
conditions.
Make sure that in the hydraulic power unit, the safety valve is set from 250 up to 300 bar according to
the Dragflow pump model.
The drainage pipe from the motor must be connected directly to the tank without filters or any other
restriction in between.

- Start the pump out of the liquid to be pumped and check the direction of rotation and the speed with a
revolution counter. The speed must be adapted to the working conditions ( between 1000 – 1200 rpm,
the length of the pipes, vertical height above the water, etc. ), since good operation and the best
duration of the pump are obtained by working in the flow rate/head range corresponding to the model
concerned ( see the pump curve enclosed in this instructions handbook ).

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6.0 SAFETY

Introduction

Dragflow s.r.l. has designed and built the machine keeping in mind the results of a preventive and accurate
analysis of the risks connected to the use of the machine.
The protections and devices applied, therefore, represent the profuse commitment by the Dragflow S.r.l.
technicians to achieve the aim of safety sanctioned by the specific directives issued by the EEC. The
protections and devices are illustrated below with drawings.
Other instructions and information on the safety of the machine are contained in the paragraphs which deal
with the use, maintenance and repair.

All the organs in movement are segregated inside the pump structure.
The only rotating mechanical part is the agitator 54 ( Fig. 16 ), that for functional reasons cannot be protected
in any way.
In fact its specific function is that of cleaning the strainer 53 and stirring the solid bodies present in order to set
them in suspension in the liquid to be pumped ( Fig. 16 ).
On the pump there is a warning plate ( Fig. 15 ) to remind us of this danger.

When about to operate the pump, keep clear of this rotating part in order to avoid
accidents.

The strainer 53 ( Fig. 16 ) is made according to the suction capacity of the pump, and does not allow the
passage of particles of over 60 mm diameter.
It is a good rule not to come close to the pump when it is immersed in water to avoid dangerous situations.

Do not open without having first

releasing the hydraulic pressure.

On the pump there is a warning plate to remind us of this

danger ( Fig. 15 ). The driving hydraulic motor is fed oil under
pressure, therefore keep to the safety rules in the table.

Fig. 16
Fig. 15
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SPARE PARTS
HY85 160

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sect. A

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SECTION “A”

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POS. Q. PART NUMBER DESCRIPTION

6 4 A2502120 SCREW
7 4 A2527052 SEAL WASHER
8 2 A6502018 GREASE NIPPLE
9 16 A2501207 SCREW
10 24 A2527046 SEAL WASHER
11 1 A1001110 BALL BEARING
15 1 A1501125VITON O-RING
17 2 A1501126VITON O-RING
18 1 F21168 OIL CHAMBER
19 6 A2501248 SCREW
20 1 F0157663 WEARING SPACER
21 4 A2501133 SCREW
22 4 A6504095 PLUG
23 1 A1501096VITON O-RING
25 1 F23171 GREASE SPACER
26 1 A1501097VITON O-RING
27 1 A6503044VITON SEAL
28 1 A1501108VITON O-RING
29 4 A6503042 WASHER
31 1 F42936/CH8 LOWER SHAFT SLEEVE
34 1 A6503044VITON SEAL
35 1 A1003010 THRUST BEARING
36 2 A6503011 SEAL
37 1 A1001097 BALL BEARING
38 1 A1001098 BALL BEARING
39 1 A6503005 UPPER SHAFT SLEEVE
40 1 A1501098VITON O-RING
41 3 A1502114VITON SEAL
42 32 A2501219 SCREW
43 1 F20637 BEARINGS FLANGE
44 1 F20636 SPACER
45 1 F19789_S6 CASING
46 1 F19790 UPPER WEAR PLATE
47 1 F19795 IMPELLER
48 1 F19792 LOWER WEAR PLATE
50 1 F19791V01 SUCTION COVER
52 6 A2501219 SCREW
53 1 G157661 STRAINER STAND
54 1 F19802 AGITATOR
55 1 A2501236 AGITATOR SCREW
56 1 F0157658 AGITATOR CONNECTIVE
57 1 F0157659 AGITATOR NUT
58 1 F0157660 AGITATOR SPACER
59 1 F0157656 KEY
60 1 P0152401 DISCHARGE ADAPTER Ø200
61 8 A2510006 WASHER

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POS. Q. PART NUMBER DESCRIPTION

62 8 A2501105 SCREW
64 1 A1002085 ROLLER BEARING
65 1 F42937 SEALS HOUSING
66 1 A6503048PTFE SEAL
67 1 F0157657 LOWER SEALS FLANGE
68 6 A2527042 SEAL WASHER
78 6 A2501162 SCREW
81 10 A2501233 SCREW
83 10 A2527035 NUT
88 1 F24609 + 164465 LIFTING FRAME
89 1 F39298 MOTOR SUPPORT
90 1 G0157662 MAIN SHAFT
94 1 F39299VITON O-RING
95 1 A4517020/1 HYDRAULIC MOTOR
97 1 F24509 SPACER
98 1 A2019025 SPRING WASHER
99 1 F39296 SPACER

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SAFETY SPARE PARTS

DRAGFLOW S.r.l. produces dredging pumps, they’re equipment for abrasive and heavy job. These kinds of
applications naturally wear the consumable parts of the machine. The wearing of the consumable parts will get
the performances of the machine lower such as the pumped solid materials little by little will be less.
To avoid to stop the equipment and lost time, DRAGFLOW S.r.l. qualified as your expert witness suggests to
keep ready at site or placed in your workshop the following spare parts :

POS. Q. PART NUMBER DESCRIPTION

11 1 A1001110 BALL BEARING

15 1 A1501125VITON O-RING
17 2 A1501126VITON O-RING
20 1 F0157663 WEARING SPACER
23 1 A1501096VITON O-RING
26 1 A1501097VITON O-RING
27 1 A6503044VITON SEAL
28 1 A1501108VITON O-RING
31 1 F42936/CH8 LOWER SHAFT SLEEVE
34 1 A6503044VITON SEAL
35 1 A1003010 THRUST BEARING
36 2 A6503011 SEAL
37 1 A1001097 BALL BEARING
38 1 A1001098 BALL BEARING
39 1 A6503005 UPPER SHAFT SLEEVE
40 1 A1501098VITON O-RING
41 3 A1502114VITON SEAL
47 1 F19795 IMPELLER
48 1 F19792 LOWER WEAR PLATE
54 1 F19802 AGITATOR
55 1 A2501236 AGITATOR SCREW
56 1 F0157658 AGITATOR CONNECTIVE
57 1 F0157659 AGITATOR NUT
58 1 F0157660 AGITATOR SPACER
60 1 P0152401 DISCHARGE ADAPTER Ø200
64 1 A1002085 ROLLER BEARING
66 1 A6503048PTFE SEAL
67 1 F0157657 LOWER SEALS FLANGE
94 1 A39299VITON O-RING

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