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Maintenance

Merlin

0711-SOM-00001, Issue: 03

19

© Tritech International Ltd.

• You will then have the gland housing in your hand. (see below)

• The rod will then pull out taking the gland and the piston out with it. You may need to take

off the hydralic cap on the body to allow the piston to be removed.

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Summary of Contents for Merlin

Page 1: ...Merlin 0711 SOM 00001 Issue 03 1 Tritech International Ltd Merlin Product Manual 0711 SOM 00001 Issue 03 ...

Page 2: ...ed by Tritech International Ltd on the understanding that it may not be copied used or disclosed to others except as authorised in writing by Tritech International Ltd Tritech International Ltd reserves the right to change modify and update designs and specifications as part of their ongoing product development programme All product names are trademarks of their respective companies ...

Page 3: ...oses 8 3 3 Hydraulics 9 3 4 Retro Flush Valve and Jet Bypass Valve 11 3 5 Seal Compensator 12 4 Principles of Operation 13 4 1 Suction Operation 13 4 2 Jetting Operation 13 5 Maintenance 14 5 1 Tools Required 14 5 2 Basic Procedures 14 5 3 Fitting Spacer to Retro Valve Actuator 15 6 Troubleshooting 21 A Motor Protector Assembly Procedure 22 B Merlin Assembly 24 C Merlin Actuator Spacer 32 ...

Page 4: ... revision numbers 3 A clear fault description 4 Details of any remedial action implemented Contamination If the product has been used in a contaminated or hazardous environment you must de contaminate the product and report any hazards prior to returning the unit for repair Under no circumstances should a product be returned that is contaminated with radioactive material The name of the organisati...

Page 5: ...opic Important When this is shown there is potential to cause harm to the device due to static discharge The components should not be handled without appropriate protection to prevent such a discharge occurring Caution This highlights areas where extra care is needed to ensure that certain delicate components are not damaged Warning DANGER OF INJURY TO SELF OR OTHERS Where this symbol is present t...

Page 6: ...cylinder operates a valve to reverse the flow at the nozzle to eject any object which may be causing an obstruction A second cylinder operates a bypass valve to provide a powerful direct jet to break up heavy and cohesive seabed mud and sand prior to excavation The pump may be configured to an intermediate position allowing combined use of suction and jettings Both the impeller and eductor have be...

Page 7: ...ttings Motor A B No 12 JIC male Motor case drain No 6 JIC male Actuator Connection No 4 JIC male Actuator Min pressure 120 Bar 1740 psi Max pressure 240 Bar 3480 psi Check Valve Norm Tritech Volvo Protector Assembly Alt Integrated Hydraulics FPR 1 22 0 5 cracking pressure 0 5 bar Output Typical output jetting Up to 600 litres min 8 Bar 160 USgpm 115 psi Typical output suction 2000 4000 litres min ...

Page 8: ... 10mm clearance through holes Not to scale dimensions in mm the pump should not be mounted using the motor or hose nozzles as attachment points Case bolts should not be used 3 2 Water Hoses Hose Types For correct hose sizes refer to Chapter 2 Specification The recommended hose type is heavy duty nylon spiral reinforced This hose type is usually semi transparent which assists visual inspection for ...

Page 9: ... area of approximately 80000mm Smaller nozzles may be used but material removal rates will be reduced Larger nozzles are of no benefit and will reduce performance A nozzle guard should be fitted that will pass a maximum of a 60mm diameter sphere or 50mm sided cube The pump can pass single objects of a larger size but if it takes in a stream of objects then blockages can occur Jet Nozzle The recomm...

Page 10: ...ll Industrial Hydraulics Ltd or equivalent products Hook up Figure 3 1 Hydraulic Hook up Orientation The pump is configured for correct rotation when the hydraulic supply is connected to the A port of the Volvo motor and the return line to the B port Figure 3 2 Motor viewed when fitted to Merlin with hydraulic fittings downwards ...

Page 11: ...ded that the installation be checked using a hydraulic flow meter equipped with a loading valve which can simulate the motor running under load In order to avoid pressure losses a minimum of inch bore pipes or hoses are used on the flow and return lines inch or larger is recommended Warning Under no circumstances should the flow be allowed to exceed the 25 litres per minute while testing in air Ex...

Page 12: ...s own miniature compensator On installation the compensator level should be checked The stem has an indicator groove showing when it is full If necessary gently apply grease via the grease nipple provided until the groove just shows or the grease is expelled from the overflow Caution Pump the grease very slowly to avoid building up excessive pressure in front of the motor face ...

Page 13: ...luid is then directed to the suction nozzle This feature can be used to clear a blocked suction nozzle or to complete a deburial operation by removing the sand and mud from around an object The optimum performance will be obtained with the nozzle pushed deep into the debris and agitated gently Where a great deal of debris is encountered it will be necessary to keep withdrawing the nozzle 4 2 Jetti...

Page 14: ...o work on the pump 22mm open ended spanner 13mm open ended spanner 18m ring spanner for actuator stripdown 10mm Allen key 8mm Allen key 6mm Allen key 5mm Allen key 2 5mm Allen key Dead blow hammer Loctite Studlock for reassembly For detailed assembly procedures refer to Appendix B Merlin Assembly 5 2 Basic Procedures Hydraulic Motor Shaft Seals The pumps are fitted with either an H red or V brown ...

Page 15: ...ports should be blanked off with metal caps and the unit washed out with fresh water Leave the actuator valves in their retracted position Visually inspect the leading edges of the power pump impeller for damage and erosion Up to four blades may have leading edge damage of 5mm width and 4mm depth before replacement becomes essential If the majority of leading edges are eroded more than 3 5mm back ...

Page 16: ...m number Description Quantity 1 Wiper Seal 1 2 Front Gland Insert Seal 1 3 Front Gland Insert Shaft Seal 1 4 Front Gland Seal 1 5 Rear Gland Seal 1 6 Shaft and Piston Assembly Does not include item 7 1 7 Stroke Spacer for Retro Valve movement reduction 1 8 Piston Seal 1 9 Piston Glide Ring 1 ...

Page 17: ...ator that is found on the Superzip Merlin and newer Anchozip 10 pumps The procedure to disasemble the unit is as follows Remove the spherical bearing from the rod end This can be done by extending the rod and holding it tight in a vice From there you can put a screwdriver through the rod end spherical bearing and turn anti clockwise Once loosened it can be run off by hand Note Soft or aluminium ja...

Page 18: ... the top of the body To do this hold the cylinder body in the vice Then find a ring spanner and fit over the JIC fitting on the gland housing as below leave the cap on to protect the threads and increase the purchase in this example the spanner is 18mm Then pushing the spanner down anti clockwise the whole gland housing will turn ...

Page 19: ...9 Tritech International Ltd You will then have the gland housing in your hand see below The rod will then pull out taking the gland and the piston out with it You may need to take off the hydralic cap on the body to allow the piston to be removed ...

Page 20: ...s the opposite of this procedure Loctite should be used where the spherical bearing is attached the the rod Note If you are fitting the spacer to the actuator it would be prudent to label the actuator as modified to prevent possible issues if the actuator is used for another function ...

Page 21: ...p and check that the face of the impeller is not obstructed by material like rope fibre or shreds of plastic Check that the hydraulic motor runs freely without excessive noise or vibration Check that the hydraulic flow meets specification Note During the operational life of the Merlin pump wear on the Retro Valve core can sometimes lead to the Retro Valve actuator to go into a geometric lock This ...

Page 22: ...Appendix A Motor Protector Assembly Procedure ...

Page 23: ...e 111 and place an O ring 20 x 2 9 into the groove on the Valve Block F11 19 3 Base 9 Apply a small amount of anti galling compound to the threads of the BSP Connectors 1 2 10 M ount the assembled components from instruction 8 onto the F11 19 Volvo Motor 13 and tighten down using an adjustable spanner 11 P lace the Cap Female No 12 JIC Carbon Steel 11 Cap Female No 6 JIC Carbon Steel 12 onto the B...

Page 24: ...Appendix B Merlin Assembly Figure B 1 Main Pump ...

Page 25: ...3 N A N A Merlin Diffuser Assembly 1 4 S10536 TI MSZ PC013 01 Merlin Exhaust Nozzle 1 5 S10539 TI MSZ PC016 01 Merlin Suction Inlet Nozzle 1 6 S10540 TI MSZ PC017 01 Merlin Jetting Nozzle 1 7 S10541 TI MSZ PC018 01 Merlin Actuator Swivel Nut 1 8 S10557 TI 10 50 RSE C 50mm Stroke Actuator 1 9 S10464 TI 89510 M10 25 Fastener C Sink Allen Head M10 x 25 23 10 S10474 TI 89510 M6 25 Fastener C Sink Alle...

Page 26: ...Figure B 2 Merlin Body Merlin Body Assembly Instruction ...

Page 27: ... the Jetting Valve To implement this place the M8 x 16 SKT CAP 9 in one of the three holes in the Housing Mounting Plate 1 Hole 1 gives Low jetting High Flow Hole 2 Gives Medium jetting and Medium flow and hole 3 gives High jetting Low flow Item New Part Number Old Part Number Description QTY 1 S10528 TI MSZ PC005 02 Merlin Housing Mounting Plate 1 2 S10529 TI MSZ PC006 03 Merlin Housing Body 1 3 ...

Page 28: ...Figure B 3 Merlin Motor Mount Assembly ...

Page 29: ...C002 01 Merlin Impeller Boss to JK120H 1 4 S10527 TI MSZ PC004 01 Merlin Shaft Seal Retainer 1 5 S10526 TI MSZ PC003 01 Merlin Impeller Blade 1 6 S10434 TI 3000 01 037 Compensator Case 1 7 S10435 TI 3000 01 038 Compensator Piston 1 8 S10543 TI R SS 45 65 6 Seal Metric Oil Type R S S Spring 1 9 S10462 TI 89450 1 8 NPT Grease Nipple 316 S S 1 10 S10517 TI C0360 026 1000 S Compensator Spring 1 11 S10...

Page 30: ...Figure B 4 Merlin Diffuser Assembly ...

Page 31: ... amount of medium strength Loctite 240 on countersunk face 4 Ensure the Reverse Flush Valve 2 is free to rotate in the body Item New Part Number Old Part Number Description QTY 1 S10532 TI MSZ PC009 01 Merlin Eductor 1 2 S10533 TI MSZ PC010 01 Merlin Reverse Flush Valve 1 3 S10534 TI MSZ PC011 01 Merlin Reverse Valve Actuator Arm 1 4 S10535 TI MSZ PC012 01 Merlin Diffuser Body Black 1 5 S10464 TI ...

Page 32: ...Appendix C Merlin Actuator Spacer See Section 5 3 Fitting Spacer to Retro Valve Actuator for more information Figure C 1 Actuator Spacer ...

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