USER MANUAL

Submersible dredge pump

DOP3025
 Submersible dredge pump DOP3025

Manufacturer
Damen Dredging Equipment
Edisonstraat 32
P.O. Box 1021
3860 BA Nijkerk
The Netherlands

T. +31(0)33 - 2474040
F. +31(0)33 - 2474060
E. info@damendredging.com

Revision Nr. Revision date Description Responsible

0.2 2008-10 Initial issue LO

2008 DAMEN DREDGING EQUIPMENT

All rights reserved. No part of this book (nor attached / applicable drawings) may be
reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system, without prior
permission in writing from the copyright holder.

Damen Dredging Equipment is a member of the Damen Shipyards Group.

DOP3025 II
 Submersible dredge pump DOP3025

EC-DECLARATION OF CONFORMITY FOR MACHINERY

(Directive 98/37/EC, Annex II, sub A)

Damen Dredging Equipment

Edisonstraat 32, 3861 NE,
P.O. Box 1021, 3860 BA,
Nijkerk, The Netherlands

Herewith declares that:

Submersible dredge pump DOP 3025

is in compliance with the Machinery Directive 98/37/EC

The following harmonised standards have been applied:

EN 292-1, EN 292-2

Nijkerk, February 24th, 2008

D. Tenwolde
Director

DOP3025 III
 Preface

Preface
This manual has been written for the benefit of those personnel involved in the
operation, maintenance and repair of the pump. It contains information, which
is essential for the proper running and care of the unit. It also offers important
guidance in the prevention of accidents, which might cause injury to personnel
and / or damage to the unit.
This manual must be read and thoroughly understood before the pump is first
put into service. Its instructions and warnings must be followed closely.
Any suggestions for improvements to this manual are most welcome.

AFTER-SALES SERVICE
Please contact Damen Dredging Equipment (at the address given on this
manual's inside cover) for technical assistance, spare part enquiries and
warranty claims. Always mention machine type, part number and order number
when ordering spare parts.

SYMBOL DESIGNATION

 This is to warn of potential equipment damage and/or injury to

personnel.

 This is to warn of potential equipment damage.

 This is to draw attention to a point. It is not necessarily a

warning.

HOW TO INTERPRET INSTRUCTION SEQUENCES

Instructions numbered 1, 2, 3, etc. must be followed in numerical order. When a
numbered instruction is followed by further sub-instructions prefaced with a
hyphen (-), these must be followed in the order they are written before
proceeding to the next numbered instruction.
Sometimes instructions are prefaced with a bullet (). This is used solely to
differentiate one instruction from another and does not indicate any particular
order of execution.

APPENDICES

The appendices are listed on page IX and may be found in the documents on
CD-rom

DOP3025 IV
 Contents

Contents
Preface........................................................................................................ IV
Contents....................................................................................................... V
List of figures.............................................................................................. VII
List of tables .............................................................................................. VIII
List of appendices ....................................................................................... IX
Conditions of liability .................................................................................... X
Warranty...................................................................................................... XI
1 Introduction ..........................................................................................1
1.1 Applications ..................................................................................1
1.2 Advantages ..................................................................................1
2 Safety...................................................................................................3
3 Technical data .....................................................................................4
4 Description...........................................................................................6
4.1 Construction .................................................................................6
4.1.1 Pump unit ..........................................................................6
4.1.2 Cutter unit..........................................................................6
4.2 Working principle..........................................................................7
4.2.1 Pump unit ..........................................................................7
4.2.2 Cutter unit..........................................................................7
5 Installation............................................................................................8
5.1 Post-delivery inspection ...............................................................8
5.2 Transportation and storage ..........................................................9
5.2.1 Transportation ...................................................................9
5.2.2 Storage..............................................................................9
5.3 Connecting .................................................................................11
5.3.1 Connecting to hoisting/manoeuvring vehicle...................11
5.3.2 Hydraulic hoses...............................................................12
5.3.3 Water supply and discharge hoses .................................13
5.4 Hydraulic system ........................................................................15
5.4.1 General precautions ........................................................15
5.4.2 Hydraulic power supply ...................................................15
5.4.3 Hydraulic motor(s) ...........................................................16
5.5 Tests and adjustments ...............................................................18
6 Operation ...........................................................................................19
6.1 Operating the pump unit.............................................................19
6.1.1 Start-up ...........................................................................19
6.1.2 Shut-down .......................................................................19
6.2 Operating the cutter unit.............................................................21
6.2.1 Start-up ...........................................................................21
6.2.2 Shut-down .......................................................................21
6.3 Operating other appliances ........................................................21
7 Maintenance ......................................................................................22
7.1 General directions ......................................................................22
7.2 Periodical maintenance ..............................................................23
7.2.1 Dredge pump unit............................................................23
7.2.2 Cutter unit........................................................................24
7.2.3 Sand production mouth (including jet nozzles) ...............24
7.2.4 Geartbox .........................................................................24
7.2.5 Wear................................................................................24

DOP3025 V
 Contents

7.2.6 Shaft seal ........................................................................25

7.2.7 Bearing casing ................................................................26
8 Repair ................................................................................................29
8.1 Cutter unit...................................................................................29
8.1.1 Disassembly ....................................................................29
8.1.2 Re-assembly ...................................................................30
8.2 Pump unit ...................................................................................31
8.2.1 Disassembly ....................................................................31
8.2.2 Re-assembly ...................................................................37
8.3 Mechanical seal..........................................................................40
8.3.1 General directions ...........................................................40
8.3.2 Disassembly ....................................................................41
8.3.3 Re-assembly ...................................................................42
9 Troubleshooting .................................................................................44
10 Disposal .............................................................................................46
Index ...........................................................................................................47

DOP3025 VI
 List of figures

List of figures
Figure 1 Top view DOP3025 with sand production mouth...............12
Figure 2 Oil filling (motor on workbench) ...........................................17
Figure 3 Oil filling (motor fitted on DOP3025) ..................................17
Figure 4 Repositioning of wear-plates................................................25
Figure 5 Checking oil level in bearing casing on DOP3025.............26
Figure 6 Cutter unit ............................................................................29
Figure 7 Removing the suction-side cover and wear-plate ................31
Figure 8 Section of impeller nose.......................................................32
Figure 9 Dismounting locking assembly.............................................33
Figure 10 Removing the impeller .........................................................34
Figure 11 Removing the shaft-side wear-plate ....................................35
Figure 12 Removing the pump shell ....................................................36
Figure 13 Mounting the impeller...........................................................37
Figure 14 Detail of mechanical seal .....................................................40
Figure 15 Mechanical seal disassembly ..............................................42
Figure 16 Mechanical seal re-assembly...............................................43

DOP3025 VII
 List of tables

List of tables
Table 1 Technical data pump unit.......................................................4
Table 2 Technical data cutter unit.......................................................5
Table 3 Dimensions and weights ........................................................9
Table 4 Hose couplings ....................................................................13
Table 5 Hydraulic oil requirements ...................................................16
Table 6 Maintenance schedule .........................................................23
Table 7 Recommended oils ..............................................................27
Table 8 Troubleshooting mechanical system....................................44
Table 9 Troubleshooting hydraulic system .......................................45

DOP3025 VIII
 List of appendices

List of appendices
1. Pump curve
2. Drawings and diagrams:
DOP3025-00.014:
Arrangement dredge pump
DOP3025-80.10.03:
Arrangement with Sand winning head
DOP3025-80.30.02:
Arrangement with Cutter unit
DOP3025-80.30.01:
Cutter unit (Poclai)n
DOP3025-84.10.02:
Hydraulic diagram pump drive (Parker)
DOP3025-84.31.03:
Hydraulic valve block pump drive
DOP3025-84.20.01:
Hydraulic diagram cutter drive (Poclain)
3. Information on other pump sizes
Folder
Pump curves
DOP 1515
DOP 1815
DOP 2320
DOP 3530-LD
4. Sub-supplier manuals (only on cd-rom)
Catalogue auxiliary valve PLC280 (Parker Hannifin)
Installation/Start-up manual Hydraulic motor F11 (Parker Hannifin)
Service manual Hydraulic motor F11 (Parker Hannifin)
Pilot operated relief valve VMP/B/L20-34 (Oleostar)
Instructions gearbox HVP-C2 (KA)
Installation guide Hydraulic motors (Poclain)
Repair manual MS-25/MS-125 for cutter drive (Poclain)
Hydraulic quick-connect couplings (Snap-Tite)
Technical information pressure transmitter PMC 41
(Endress+Hauser)
Oil product information GEM 1-68 (Klber)
Oil product data sheet DTE 16M (Mobil)
Oil product data sheet Mobilgear 629 (Mobil)
5. Certificate
Hoisting chain (Mennens)

DOP3025 IX
 Conditions of liability

Conditions of liability
Damen Dredging Equipment takes no responsibility if the installation is
used in a way other than that described in the user manual.
The manufacturer has the right to alter its equipment with no liability to
make the same changes to equipment that already has been delivered.
The manufacturer cannot be held liable if the client makes unauthorised
changes to the installation.
Use only original Damen Dredging Equipment parts for safe and efficient
functioning of the system. The correct tools must be used. Warranty
expires if non-genuine parts are used.
Local rules regarding accident prevention, safety, traffic and transport
must be followed.
Only properly trained personnel who are aware of the potential danger
are permitted to operate or maintenance this installation.
Damen Dredging Equipment has made this manual with the utmost care.
Nevertheless Damen Dredging Equipment cannot be held liable for
possible errors in this user manual.

 Failure to adhere to the instructions in this manual will be

considered negligence. Damen Dredging Equipment will not be
liable for any consequence resulting from negligence; the user
will bear full responsibility.

DOP3025 X
 Warranty

Warranty
The CONTRACTOR and/or seller warrants the satisfactory performance of
work contracted in respect of construction, material and treatment, which
implies that:
It shall deliver free of charge new parts for all those parts that during a
term of twelve (12) months after operation date become defective due to
inadequate construction and/or defective materials.
A maximum of eighteen (18) months after delivery date shall apply for the
period of time referred to in the first paragraph. Delivery date shall be
deemed to be the date stated on the "consignment note" and/or "bill of
lading".
Defects that have arisen due to normal wear, incompetent treatment or
operation, incompetent or incorrect maintenance, insufficient lubrication
and lubrication with defective material are not covered by the warranty.
Defects that have arisen after adaptations and/or repairs carried by and/
or on behalf of the CUSTOMER and/or the purchaser, or by third parties,
are not covered by the warranty.
No warranty is given for parts, machinery, instruments, equipment,
installations or assembly that have not been installed by the
CONTRACTOR and/or the seller, or for those parts, machinery,
instruments, equipment, installations or assembly that have been
installed but not delivered by it.
The warranty only applies if the CUSTOMER and/or purchaser have
complied with all its obligations financial or otherwise to the
CONTRACTOR and/or seller.
In no event does the warranty cover more than the delivery and
installation of new parts. In no event the CONTRACTOR and/or the seller
are liable for any other damage incurred by the CUSTOMER and/or the
purchaser.
Contrary to the aforementioned machinery, motors, instruments, the
warranty provisions laid down by the manufacturer shall cover equipment
or articles delivered with a manufacturer's warranty. If the manufacturer
does not provide warranty or provides a shorter warranty period then the
CONTRACTOR and/or the seller shall likewise provide no warranty or a
shorter warranty period.
Unless otherwise agreed, no warranty is given for machinery motors
instruments equipment or articles delivered that were not new at the time
of delivery.
A survey report, drawn up by an independent international claims
assessor or assessment agency, is required for warranty claims that
exceed a total amount of 3,500.00.
The CUSTOMER and/or purchaser shall submit in writing any warranty
claim to the CONTRACTOR and/or the seller within seven (7) days,
failing which the claim will lapse.

DOP3025 XI
 Warranty

Disassembly and/or installation costs of those parts that are covered by

the warranty shall only be borne by the CONTRACTOR and/or seller if its
own workforce can carry this out during the normal working hours within
the Netherlands borders. Additional costs such as crane assistance,
internal transport assistance from an external workforce etc. shall not be
borne by the CONTRACTOR and/or seller. If installation and/or
disassembly must be carried out outside the Netherlands borders, all
related costs shall be borne by the CUSTOMER.

DOP3025 XII
 Introduction

1 Introduction

This manual describes the standard configuration of the DOP 3025 pump, i.e.
hydraulic driven and equipped with a sand production mouth. Also contained in
this manual is the description of the cutter unit suitable for the DOP 3025, if
delivered.
For other possibilities and applications than the ones described in this manual,
refer to Appendix 3.
In cooperation with various dredging contractors Damen Dredging Equipment
developed the DOP pumps, a series of multi-functional submersible dredge
pumps. The knowledge gained over the years enables us to design
modifications for the DOP pump to meet your requirements, as well as
assisting and advising you on its operation.
The heart of this versatile dredge tool is a wear-resistant, compactly built
dredge pump with a maintenance-friendly seal. All wear parts can be easily
replaced and, depending on the job, supplied in different materials, varying in
hardness, toughness and price.

1.1 APPLICATIONS
Sand and gravel mining dredging.
Small-scale dredging operations, such as maintenance dredging in ports
and canals.
Dredging in restricted areas.
Unloading of hopper barges.
Suspended from an A-frame as a deep suction dredger, down to a depth
of 50 m.
Mounted on a cutter ladder.
Suitable as a mobile booster station.
Special applications such as environmental dredging.

1.2 ADVANTAGES
Proven design used by many contractors around the world.
Operation depth down to 50 m. For depths over 50 m, please consult
DDE.
Multi-functional, basic pump unit can be outfitted with various suction
mouths for specific purposes.
Executed with heavy duty mechanical seal which does not require gland
water or grease supply.
Discharge distances up to 1000 m with a single pump, depending on
conditions.
Spherical passage impeller up to 200 mm, depending on pump size.

DOP3025 1
 Introduction

Heavy-duty construction with protective casing to allow operation in

rough environments.
Available in different sizes to suit client requirements.
Very high production capacities.
Changeable wear parts made of highly wear-resistant material.
Available with hydraulic as well as electric drive.

DOP3025 2
 Safety

2 Safety
Most injuries that occur during operation and maintenance of equipment are
due to failure to observe basic safety rules and take adequate precautions.
Personnel must be trained to recognise and avoid potential hazards and to
perform their work using appropriate methods and tools.

The DOP pump must be operated only by personnel that is familiar with and
fully understands the information given in the user manual.

 Always read the user's manual entirely and follow the

instructions before starting-up the engine for the first time!

 Before installing using or maintaining any separate machine or

parts of the overall installation, first read the specific
instructions for these parts. These instructions can be found on
the CD-rom supplied with the user manual.

The DOP Submersible Dredge Pump may only be used to transfer

water suspended mixtures of mud, sand and gravel or similar solids.
Never hoist a pump into or out of the water whilst it is still running.

The DOP pump, its sub-assemblies and components must only be lifted
using certified hoisting equipment that is in good condition. Suitable
hoisting tools for maintenance can be provided by DDE.

The DOP pump must never be run without being connected to a

suitable discharge hose or pipe.

Beware of the torque reaction when the DOP pump or cutter starts.
Follow the instructions and precautions applicable to the pump's
hydraulic system.
The pump's protective shell is just that and must never be used as a
means of carrying aloft equipment or personnel.

The DOP pump's hydraulic system must be rendered inoperative before

any diagnostics or maintenance is performed on the unit.
Always use genuine DDE components for the replacement of proprietary
DOP pump parts. Most components installed on the unit have been
made according to DDE specifications.

Retighten all bolts after the DOP pump has been used for the first time.
Pay particular attention to the assembly bolts for the wear plates.

 Deep water is the DOP pump's normal working environment.

Therefore beware of the potential drowning hazards.

Safety helmet, boots and goggles must be worn when operating or

performing maintenance on the pump.
Observe national and local safety regulations relating to the pump's
operation and environment as well as instructions given in this manual.

DOP3025 3
 Technical data

3 Technical data
The technical information for individual parts of the dredge pump unit is listed in
the following table.

Technical data pump unit

General Manufacturer Damen Dredging

Equipment
Type DOP3025
Pump dimensions Diameter pump inlet 300 mm
Diameter pump outlet 250 mm
Discharge connection 300 mm
Spherical passage 155 mm
Number of impeller blades: 4
Direction of rotation: Clockwise
(seen from suction side looking towards pump)
Wear material Pump shell Ni-hard 4 cast iron
Impeller Bainitic nodular cast
iron
Wear plates Ni-hard 4 cast iron
Suction mouth Ni-hard 4 cast iron
These materials can be changed on client's request.
Shaft seal Type Mechanical seal
Pump performance Mixture capacity Refer to List of
appendices on page IX
Pump speed 700 rpm (approx.)
Maximum power at shaft 250 kW
Jet water Connection (diameter) 150 mm
Advised capacity (min.) 200 - 350 m3/hr
Pressure 5 bar
Pump unit drive Manufacturer Parker Hannifin
Type F11-250 QF-SH-F
Required oil flow 700 l/min
Required oil pressure P 225 bar

Table 1 Technical data pump unit

DOP3025 4
 Technical data

Technical data pump unit

Gearbox Manufacturer KA
Type HVP-C2 (ratio 2.03)
Table 1 Technical data pump unit

Technical data cutter unit

General Manufacturer Damen Dredging

Equipment
Type 5-1150-RU
Cutter speed 45 rpm (approx.)
Maximum power at shaft 38 kW
Cutter unit drive Manufacturer Poclain
Type MS25
Required oil flow 105 l/min (approx.)
Required oil pressure P 225 bar

Table 2 Technical data cutter unit

DOP3025 5
 Description

4 Description
4.1 CONSTRUCTION

4.1.1 Pump unit

The DOP submersible dredge pump is a sturdy dredging tool mounted within
a protective shell to protect the more delicate equipment and connections,
which allows operation in rough environments. The construction enables the
pump to be submerged at depths up to 500 meters. (Consult DDE for operating
at depth exceeding 50 meters.)

The DOP pump can be used suspended from a crane, A-frame or derrick. It
can also be mounted to an excavator stick, using a purpose-designed coupling.
The crane or excavator can be placed on shore or a suitable pontoon or vessel.

The basic DOP submersible dredge pump can be equipped with various
suction mouths for specific purposes but is standard delivered with a sand
production mouth. This mouth is used to take up loose soils e.g. free-running
sand. To help loosen the soil material jet water can be injected through nozzles
in the suction mouth. At the side of the DOP pumps protective shell a jet
water supply line is mounted, as well as the pumps discharge pipe.
The very high production capacity allows a discharge distance according to the
production graphs listed in appendix 1.
The changeable wear parts made of high resistant material and a large
spherical passage make the DOP submersible dredge pump a tool that can
be utilised at many production sites, even in areas with contaminated soil.
The pumps are available in different sizes to suit the clients requirements and
can be supplied with electrical or hydraulic motors. Refer to Appendix 3. The
pump is equipped with two hydraulic motors and a gearbox.

4.1.2 Cutter unit

The cutter unit on the DOP submersible dredge pump is used in locations with
packed sand or sandy clay. A fixed connection on the boom of a crane or cutter
ladder is necessary.
The cutter unit can be supplied with serrated or plain knives to churn up
compact soil.

DOP3025 6
 Description

4.2 WORKING PRINCIPLE

4.2.1 Pump unit

The submersible dredge pump is of the single-stage centrifugal type. A
mechanical seal prevents leakage at the exit of the pump shaft from the pump
shell. The pump is naturally primed by submerging the pump's casing. It will not
function above the water line, unless the pressure at suction side is positive,
e.g. priming with jet water.

The DOP pump can be used to transfer water-suspended mixtures of mud,

sand and gravel or similar solids.
The pump motors are to be driven by a hydraulic power supply.
Two hydraulic motors drive the pump, using a gearbox. When operated in
shallow water, gearbox-driven pumps must be cooled in a forced manner (max.
15 minutes).

4.2.2 Cutter unit

The cutter unit has its own hydraulic motor. The motors hydraulic hoses are led
up from the piping mounted to the cutter housing through the protective shell of
the DOP submersible dredge pump.
The cutter unit is to be driven by its own hydraulic power supply, separately
from that of the pump unit. For combined supply to pump and cutter please
consult DDE.

DOP3025 7
 Installation

5 Installation
5.1 POST-DELIVERY INSPECTION

1. Examine the exterior of the DOP pump unit for loose fasteners, oil leaks
and damaged or worn hydraulic pipes and hoses.
2. Inspect castings and weld areas for cracks and dents. DDE must be
contacted immediately if any such damage is discovered. The pump must
not then be operated until DDE have given their approval.
3. Check that there are no rags or packaging materials obstructing the
pumps inlet, discharge pipe or jet water pipe.
4. Check that the flange faces of the jet water pipe and discharge pipe are in
good condition.
5. Ensure that the quick release couplings are clean and undamaged and
that their threads are in good condition.
6. Most DOP pumps are delivered from the factory already filled with the
necessary lubricants. As a precaution the presence, condition and levels
of these fluids must be checked before attempting to operate the pump.
Filling and checking the fluid levels in the hydraulic motors is
described in section 5.4.3.
Filling and checking the fluid level in the bearing casing are
described in section 7.2.7.
7. The correction of most of the foregoing potential faults must be well within
the capabilities of a competent service mechanic. The customer is
encouraged to contact DDE at the first instance if he feels unsure of how
any such tasks must be undertaken.

DOP3025 8
 Installation

5.2 TRANSPORTATION AND STORAGE

5.2.1 Transportation
The DOP pump's high centre of gravity means that it cannot stand upright
unsupported. Similarly its cylindrical shape gives it a tendency to roll when laid
on its side.
The unit must be transported in a horizontal position with sufficient supports
and/or chocks to prevent it from moving.

 Avoid kinks and tight bends in the hose runs.

 NEVER lift or manoeuvre the DOP pump by pulling on its

hydraulic, discharge or water hoses.

For repair and transportation of the individual pump parts, the dimensions and
weights are listed below.

Dimensions and weights

UNIT Length Width Height/ Weight

diameter
[mm] [mm] [mm] [kg]
Dredge pump (including 4885 1840 1500 4100
sand production mouth)
Pump shell 404 1180 1065 705
Pump cover suction side 142 - 880 150
Suction mouth/ wear plate 170 - 714 90
Impeller 335 - 710 250
Wear plate shaft side 55 - 714 75
Suction pipe 800 1495 195
Sand production mouth 1265 840 625 240
Cutter unit (including 2195 - 1480 1200
cutter)
Cutter 730 - 1150 450
All dimensions and weights are approximations
Table 3 Dimensions and weights

5.2.2 Storage
5.2.2.1 Preparing for storage

When the DOP pump is to be stored out of service for more than two (2)
months the following precautions must be taken as a minimum:

DOP3025 9
 Installation

1. Clean any heavy accumulations of dirt or debris from the unit. Light
pressure washing with mild detergents is permissible. Solvent-based
cleaners must not be used.
2. Drain the bearing casing and refill with a suitable preservative oil.
3. Completely fill the hydraulic valve block with hydraulic oil and cover the
connectors.

 Make sure that no traces of water remain in the bearing or the

mechanical seal.

 When freezing air temperatures are experienced or anticipated

ensure that the pump along with its discharge and water lines
are fully drained of water before the unit is stowed. The water
drain line at the base of the pumps bearing housing should
also be cracked open to drain whatever small quantity of water
may have collected there.

5.2.2.2 Servicing after storage

After a storage period the pump must be inspected. Follow the instructions
below.
1. Clean any heavy accumulations of dirt or debris from the unit if it was not
done at the time the pump was stored. Refer to step 1. of section 5.2.2.1.
2. Carry out the post-delivery inspection as described in section 5.1.
3. Drain the bearing casing and refill it with fresh oil.
4. Any routine service tasks that were due before the unit was put into
storage must also be performed.

DOP3025 10
 Installation

5.3 CONNECTING

5.3.1 Connecting to hoisting/manoeuvring vehicle

The DOP pump can be used suspended from a crane, 'A'-frame or
derrick. It can also be mounted to the stick of an excavator using a
purpose designed coupling. The crane or excavator can be placed on
shore or on a suitable pontoon or vessel.

 Make sure that whichever vehicle or machine is used to

suspend and manoeuvre the DOP pump has the proper
capacity to handle the pumps weight at the required reach.

 Make sure that whichever vehicle or machine is used to

suspend and manoeuvre the DOP pump is in good condition
and is in a stable attitude and location for handling the units
weight.

When attaching the unit to a single hoisting cable for suspension from a
crane etc., a certified three-leg chain sling with a safe working load in
excess of the unit's weight must be used. The chains must be shackled to
the lifting eyes located on the top of the unit.
When attaching the unit directly to an excavator stick, only a DDE
approved or supplied coupler may be used.

When a cutter unit is installed the DOP has to be supported rigidly, e.g.
with an excavator stick, using a coupler at the top of the unit, which can
be provided by DDE. If other appliances are used please consult DDE.

DOP3025 11
 Installation

5.3.2 Hydraulic hoses

Figure 1 Top view DOP3025 with sand production mouth

The unit's hydraulic power can be provided by connection to the hydraulic

system of certain crane and excavator models. It can alternatively be
driven by a stand-alone hydraulic power pack or the hydraulic system of
another vehicle. The requirements of the DOP pump's hydraulic system
are given in Table 1, chapter 3. For further requirements see section 5.4.

DOP3025 12
 Installation

The DOP pump is connected to its hydraulic power supply using flexible
hoses equipped with "Snap-Tite 75 series" quick-release couplings. Refer
to the Appendix 4. for details of these couplings.
Figure 1 is a plan view showing the position of the connectors, which are
already mounted on top of the unit. The hoses running from the power
pack must be terminated as follows:

Motor connection lines

Motor supply line (P):
Motor return line (T):
Motor case-drain line (L):
Table 4 Hose couplings
2" BSP nipple coupling half i.e. external
acme thread
2" BSP coupler coupling half i.e. internal
acme thread
1" BSP nipple coupling half i.e. external
acme thread

Once connected to the unit, the hoses are secured just above the
couplings using the strain relief clamp (refer to Figure 1, C).

 Ensure a slow start of the hydraulic motor so the system can

expel the air from the hydraulic supply lines through the
motors return line to the tank.

If provided, the cutter unit has its own hydraulic power supply of which the
hydraulic hoses are led up from the piping mounted to the cutter housing
through the pipe shell of the DOP pump. For combined supply to pump
and cutter please consult DDE.

 Ensure that all hose couplings are clean before making any
connections. Repair or discard any hoses with deep nicks and/
or abrasion damage.

 Avoid kinks and tight bends in the hose runs.

 NEVER lift or manoeuvre the DOP pump by pulling its

hydraulic, discharge or water hoses.

5.3.3 Water supply and discharge hoses

A flexible dredge hose of 300 mm internal diameter can be connected to
the unit's discharge flange (DL) (refer to Figure 1).
A flexible water supply hose of 150 mm internal diameter can be
connected to the unit's jet pipe flange (JL) (refer to Figure 1).

 Avoid kinks and tight bends in the hose runs.

DOP3025 13
 Installation

 Make sure that the bolts of the hose clamps of the jet water
hose have been tightened properly.

 Use hoses, which are appropriate for the max. pressure and
dredged material.

 Make sure all flange connections are tight, to ensure optimal

performance.

DOP3025 14
 Installation

5.4 HYDRAULIC SYSTEM

5.4.1 General precautions

 The following precautions must be observed at all times during

installation of the hydraulic system!

Always depressurise the DOP pump's hydraulic system before

connecting or disconnecting any hoses or other hydraulic components.
Always ensure that the case-drain hose is connected correctly. An absent
or incorrectly fitted case-drain hose can cause severe damage to the
dredge pump's hydraulic motors, bearing casing and mechanical seal.
All hydraulic hose couplings must be clean when they are connected.
Couplings on hoses that have been disconnected must be covered to
prevent them from collecting dirt and other debris.

 Leaks in the hydraulic system must be located with the utmost

care. NEVER use your hand to find or seal a leak. Liquid under
high pressure can easily penetrate clothing and skin and can
cause severe injuries. If this occurs seek immediate medical
attention.

All hydraulic hoses, pipes and connections must be checked daily for
leaks, cracks and signs of wear. Any such defects must be corrected
immediately having first depressurised the hydraulic system.
All quick-release hose couplings must be fully tightened to assure a good
flow of oil. The first stop when tightening the quick release coupling is the
spring-loaded valve. The coupling must be tightened beyond this point
until the second stop to ensure the complete opening of the valve.

 When the spring loaded valve in the quick release coupling has
been opened partly or not at all the leak-oil cannot flow back to
the hydraulic power system. This will result in damage to the
hydraulic motor.

Always ensure that the hydraulic pumps and motors are completely filled
with hydraulic oil before starting up the DOP unit.

 Check for compatibility between the oil supplied in the pump

motors and that in the power supply. Mixing conventional
mineral oils with environmentally friendly oils can for example
result in the formation of a scum, which will rapidly damage the
motors.

Working in a clean environment during installation of hydraulic equipment

is vital.

5.4.2 Hydraulic power supply

The hydraulic power can be supplied by the crane or excavator used to
manoeuvre the DOP pump or by an independent power supply on deck or on

DOP3025 15
 Installation

shore.

5.4.3 Hydraulic motor(s)

The hydraulic circuit diagram of the DOP pump drive is shown in drawing
DOP3025-84.10.02 that can be found in Appendix 2.
If provided, the cutter unit has its own hydraulic motor. The hydraulic circuit
diagram is shown in drawing DOP3025-84.20.01.
5.4.3.1 Hydraulic oil
The requirements for the unit's hydraulic oil are given in the table below.

Hydraulic oil requirements

Maximum system oil pressure 250 bar

Maximum system temperature 75C
Minimum system temperature -35C
Pour point -37C
Viscosity:
- at 40 C 71 cSt
- at 100 C 10.3 cSt
Viscosity index, min. 130
Water content 0.1%
Approved fluids:

Petroleum-based:
Automatic transmission Fluid type A HLP (DIN 51424)
API CD engine oil Type A

Environmentally friendly:
Vegetable fluid HTG
Synthetic Ester HE
Maximum hard particle contamination
ISO 4406 Class 18/13
NAS 1638 Class 9
Recommended filter mesh 10 mm
Table 5 Hydraulic oil requirements

5.4.3.2 Filling the hydraulic motor(s)

 It is essential that the DOP pump's motor is already filled with

hydraulic oil before the unit is started. The oil provides
essential lubrication to the motors' components during the first
moments of operation before the benefits of the DOP pump's
pressurised oil supply can be realised.

DOP3025 16
 Installation

The motor must always be filled when it is in a position where its output
shaft is horizontal. This ensures that it is filled with the maximum quantity
of oil.
When a motor is to be filled with oil on the workbench either of the two
drain-plug holes shown in Figure 2 may be used.

 The motor must be in horizontal position to assure complete

filling.

Figure 2 Oil filling (motor on workbench)

When the motor (HM) is already fitted to the DOP pump, the whole unit
must be laid on its side with the motor filling plug (OF) uppermost as
shown in Figure 3. Filling cannot be accomplished by standing the unit
upright and pouring oil into the valve block expecting it to flow down a
case-drain (CD) line and then through a motor drain port. This is because
of a non-return valve located in the valve block (VB).

Figure 3 Oil filling (motor fitted on DOP3025)

DOP3025 17
 Installation

5.5 TESTS AND ADJUSTMENTS

The DOP pump is thoroughly tested at the manufacturers test site. Any
required adjustments have been made at the factory.
Always check whether the hydraulic motor and piping are completely filled with
hydraulic oil.

DOP3025 18
 Operation

6 Operation
6.1 OPERATING THE PUMP UNIT

 The operator of the DOP pump must be familiar with all its
features and operating instructions before first putting the unit
to work.

6.1.1 Start-up
Before starting-up the DOP pump perform the daily checks and maintenance
procedures listed in section 7.2.1.
Before starting-up the cutter unit (if installed) read section 7.2.2.
1. Ensure that the end of the discharge hose is securely anchored at the
desired location for depositing the pumped material.
2. Raise the DOP pump from its stowage position and swing it out over the
water.
3. Turn on the water supply for the jet water line (if present).
4. Manoeuvre the unit above the area to be dredged and then lower it fully
into the water.

 Ensure that the pumping section of the DOP pump unit has
been fully submersed below the water surface as the pump is
not self-priming.

 As the DOP pump is hoisted and manoeuvred its water,

discharge and hydraulic hoses must be carefully guided to
prevent kinks or sharp bends.

5. Start the hydraulic power pack's diesel engine at a low throttle setting.
6. Engage the drive to the power pack at idol speed. Wait until the pump
discharges water and then increase engine speed gradually.
7. Carefully move the DOP pump into the desired dredging position at the
required depth whilst ensuring that it is drawing in sufficient transport
water to prevent the discharge line from becoming clogged.

 NEVER hoist a running DOP pump into or out of the water as

the sudden pressure changes produced could cause severe
pump damage.

6.1.2 Shut-down

 When a cutter unit has been installed first read the instructions
on shut down of the cutter unit. See section 6.2.2.

DOP3025 19
 Operation

1. Raise the DOP pump above the dredging area into clear water. Allow
the pump some time to draw in water and flush out its discharge line.
2. Gradually reduce the speed of the diesel engine, and then turn off the
hydraulic drive.

 Guide all trailing hoses to prevent kinking.

3. Hoist the DOP pump out of the water and return it to its usual stowage
location.

 When it is freezing or if frost is expected, ensure that the pump

and its water supply and discharge lines are fully drained
before the unit is stowed. The water drain line at the base of the
pump's bearing casing must also be opened to drain any
present water.

DOP3025 20
 Operation

6.2 OPERATING THE CUTTER UNIT

6.2.1 Start-up

1. Perform steps 1 to 6 of section 6.1.1.

2. After start-up of the dredge pump switch on the hydraulic power supply
serving the cutter unit at low revolutions of the engine.
3. Increase the number of revolutions gradually.
4. Perform step 7 of section 6.1.1.

 For safe inspection or removing of any obstructions from the

cutter head, refer to chapter 2.

6.2.2 Shut-down

1. Move the cutter head from the bottom so the discharge line can be
flushed with water. This can take several minutes.
2. Reduce the revolutions of the cutter and turn it off, then proceed with step
2 of section 6.1.2 to shut down the pump.

6.3 OPERATING OTHER APPLIANCES

If another suction mouth is installed, or the pump configuration is not standard,
please consult the specific manual or DDE.

DOP3025 21
 Maintenance

7 Maintenance
7.1 GENERAL DIRECTIONS

 Read this chapter carefully and ensure to fully understand it

before performing maintenance and/or repair on this product.

 NEVER work at the dredge pump while the engine is running.

Therefore ALWAYS disengage the pump's drive.

The DOP pump operator and maintenance personnel are strongly

advised to adopt a regular routine of inspection and preventive
maintenance on the unit. It is often found that a "don't repair it until it
breaks down" philosophy results in lower and less predictable availability
of the machine along with higher repair costs.
Separate manuals have been provided for several of the sub-assemblies
that make up the complete DOP pump unit. Maintenance of such
components must be performed in accordance with the instructions given
in those manuals.
Always ensure that hydraulic and water supplies are turned off before
performing any inspection, maintenance or repair to the unit or its
components. The unit must also be disconnected from its hydraulic
power supply by undoing its quick release couplings.
All fasteners and threaded components on the unit are required to be
done up tightly but only those of the locking assembly are required to be
tightened to a specific torque. Refer to 8.2.2.
The maintenance schedule in section 7.2 lists the minimum maintenance
requirements for the DOP pump. Local operating conditions may require
changes to the content and frequency of some maintenance tasks.

DOP3025 22
 Maintenance

7.2 PERIODICAL MAINTENANCE

7.2.1 Dredge pump unit

The unit must be visually inspected every day before starting operations. Look
in particular for:
Oil or water leakage
Loose fasteners and couplings
Damaged hydraulic hoses
Damaged hoisting equipment.

 These defects must be repaired immediately!

Check the oil level (refer to section 7.2.7) and drain any water present
from the bearing casing.

Maintenance schedule DOP3025

Refer to
Action Frequency
section

Check oil filling hydraulic At initial start-up. 5.4

motor(s).
Check oil level in bearing Daily. 7.2.7
casing.
Drain water from base of Weekly or as required by 7.2.6
bearing casing. operational conditions.
Chemical analysis of oil in After first 100 hours of 7.2.6
bearing casing. operation, then after every
600 hours.
Change oil in bearing casing. After every 1200 hours of 7.2.7
operation or once a year;
whichever period is shortest.
Check gearbox oil level. Weekly. -
Change gearbox oil. After first 200 hours of -
operation, then after every
2000 hours or at least once a
year.
Chemical analysis of oil in Follow recommendations of 5.4
hydraulic system. hydraulic power pack
supplier.
Change oil in hydraulic system. Follow recommendations of 5.4
hydraulic power pack
supplier.
Table 6 Maintenance schedule

DOP3025 23
 Maintenance

Maintenance schedule DOP3025

Refer to
Action Frequency
section

Inspect pump wear parts. Weekly. 7.2.6

Check for wear of the cutter. Weekly. 7.2.2
Inspect hydraulic pipes & hoses. Daily. 5.4
Inspect water supply and Daily. 7.2.3
discharge hoses.
Inspect nozzles. Weekly. 7.2.3
Inspect hoisting equipment Daily. -
(cables, chains, couplers). Follow recommandations of
supplier.
Check for oil & water leaks. Daily. 5.4.1
Check for loose fasteners. Daily. -
Table 6 Maintenance schedule

7.2.2 Cutter unit

The cutter unit must be inspected for wear regularly. If severe wear is found,
the knives, if mounted, or the cutter head must be replaced. The knives can be
burned off and replacements can be welded on. For the hydraulic motor follow
the instructions of the motors manufacturer. Refer to Appendix 4.

7.2.3 Sand production mouth (including jet nozzles)

The sand production mouth is provided as the standard suction mouth of the
DOP submersible dredge pump. This suction mouth is equipped with jet water
nozzles.
The non-moving parts, such as the sand production mouth, are not subject to
wear as much as the moving parts of the DOP unit. The jet nozzles however,
can be subject to wear, depending on the purity of the supplied jet water. The
jet line and nozzles have to be checked for wear regularly and replaced if
necessary.

7.2.4 Geartbox
The pump is equipped with two hydraulic motors, which requires a gearbox.
Both the DOP3025 and DOP3530LD gearboxes are of the same type, only
their ratio differs. For maintenance, refer to appendix 4.

7.2.5 Wear
The wear of pump shell, impeller and wear plates depends on:
its discharge pressure,
the material being pumped,

DOP3025 24
 Maintenance

the amount of cavitation.

Check the internal wear parts weekly when the pump starts work on a new
project. The interval between checks can be evaluated and adjusted,
depending on the new operating conditions.
We advise to reposition or replace the wear plates when 3/4 of the material is
worn-off.
7.2.5.1 Wear plates
Wear plates tend to wear specifically near the discharge of the pump. When a
wear plate (Figure 7, item WP and Figure 11, item WP) is worn, it must be
repositioned by 120 degrees around the pumps shell as shown in Figure 4
(the dark segments represent areas of severe wear). This way a wear-plate
can be repositioned 2 times, before it must be replaced.

Figure 4 Repositioning of wear-plates

7.2.5.2 Welded repairs

Adding layers of wear-resistant material by welding can repair the worn
surfaces of steel and cast-steel wear-parts. However, Ni-hard 4 and Bainitic
Nodular castings cannot be repaired in this manner.

The DOP pump's impeller is carefully balanced at the factory. Do not repair
the impeller by welding. This can cause imbalance, resulting in major damage
to the mechanical seal, the bearings and the impeller shaft. The warranty does
not cover pump damage caused by welded repairs to the impeller.

7.2.6 Shaft seal

A mechanical seal in good condition will always allows a small amount of water
leaking.
The oil specified for use in the bearing casing was chosen because of its great
reluctance to mix with water. Any water entering the less dense oil sinks to the
bottom of the oil's container forming a separate homogenised layer. Even if the
oil and water are vigorously agitated to mix them together they still resolve
themselves into two separate layers once the agitation has stopped.
Thus any water leaking into the bearing casing tends to settle at its base when
the DOP pump is left at rest in an upright position. This water must be drawn
off daily using the oil drain line (DP2) located at the base of the bearing casing
(refer to Figure 5).
Over time some water will become truly mixed with the oil. Once the oil's water
content reaches 0.1 % by volume, the oil must be changed. Samples of the oil
DOP3025 25
 Maintenance

must be regularly analysed for this and other contamination. These samples
can be drawn using the oil-drain line.

7.2.7 Bearing casing

7.2.7.1 Filling & checking oil level
The oil level in the dredge pump's bearing casing (Figure 5, item FP) must be
checked daily. The procedure is as follows (refer to Figure 3 & Figure 5):

Figure 5 Checking oil level in bearing casing on DOP3025

DOP3025 26
 Maintenance

1. Secure the DOP pump in an upright position.

2. Clean the areas surrounding the air vent (AV) and oil filler plugs (FP).
3. Remove the air vent plug for correct measurement.
4. Remove the oil filler plug, which is provided with a dipstick.
5. Check the oil level.
6. Add extra oil of the correct grade as necessary. For lubrication
specifications refer to Table 7.

 If the oil level is found to be significantly different to the

recommended level a sample must be taken and analysed. A
leaking mechanical seal may be the cause and result in the oil
becoming contaminated with water and/or dirt.

 It must be noted that even a new mechanical seal will allow a

certain leakage of oil and/or water.

7. Clean the air vent (AV) and oil filler plugs (FP) before reinstalling them
with new Dowty seals.

Recommended oils

Approximate
Location Type
quantity

Bearing casing 8.0 litres Klber GEM1-68

*Hydraulic motor pump unit 3.0 litres (each) Mobil DTE 16M

*Gearbox 7.0 litres Mobilgear 629

*Hydraulic motor cutter unit 5 litres Mobil DTE 16M

*Refer to Table 5 for a more complete description of suitable hydraulic oils.

Equivalent oil types may be used.

Never mix different types of oil.
Table 7 Recommended oils

7.2.7.2 Changing oil

The oil in the bearing casing must be changed after every 1200 hours of
operation or at least once a year (refer to Table 6). Follow the instructions
below.
1. Secure the pump in an upright position.
2. Clean the areas surrounding the air vent (Figure 5, AV), oil filler (FP) and
oil drain plugs (DP2).
3. Remove the air vent plug.
4. Remove the oil drain plug (DP2) at the end of the drain line.

DOP3025 27
 Maintenance

5. Drain the used oil into a suitable receptacle. A sample of this oil must be
subjected to a chemical analysis. Refer to Table 6.
6. After all the oil has drained from the bearing casing the drain plug (DP2)
must be cleaned and replaced using a new Dowty seal.
7. Refill the bearing casing with fresh oil (refer to Table 7) as described
above. Refer to Figure 5 for minimum/maximum level.
8. Remount the air vent plug (AV) and fill plug (FP) using new Dowty seals.

DOP3025 28
 Repair

8 Repair
8.1 CUTTER UNIT

Figure 6 Cutter unit

8.1.1 Disassembly

1. Disconnect the hydraulic hoses leading from the power supply to the
hydraulic motor (Figure 6, HM) of the cutter unit (CU). The hoses are
fitted with couplings with non-return valves, so oil spill will be kept to a
minimum.
2. Support the weight of the cutter unit (CU). Refer to Table 3 for weight and
size.
3. Remove the bolts and nuts (HT1, HN2) that connect the cutter unit (CU)
with the protective shell of the DOP pump and the bolts (HB1, HN1) that
connect the flange (F) of the suction mouth (SM) to the DOP pump.
4. Place the cutter unit (CU) in a stable upright position on the ground or a
workbench.
5. Support the weight of the cutter (C). Refer to Table 3 for weight and size.

DOP3025 29
 Repair

6. Remove the bolts (HT2) to remove the cutter (C) from the drive of the
hydraulic motor (HM).
7. Only if the hydraulic motor has to be replaced, disconnect the hydraulic
lines to the hydraulic motor (HM).
8. Remove the bolts (HB2, HN3) to separate the hydraulic motor (HM) from
the cutter unit (CU).

8.1.2 Re-assembly
If the hydraulic motor (HM) has not been removed proceed from step 3.
1. Lift the hydraulic motor (HM) and make sure all couplings and flanges are
clean, then connect the hydraulic motor (HM) to the cutter unit (CU),
using the bolts (HB2, HN3).
2. Reconnect the hydraulic lines to the hydraulic motor (HM).
3. Lift the cutter (C) (Refer to Table 3 for weight and size) and mount it to the
drive of the hydraulic motor (HM), using the bolts (HT2).
4. Check the O-ring (OR) for damage and replace if necessary.
5. Support the weight of the cutter unit and mount the bolts (HB1, HN1) that
connect the suction mouth flange (F) to the DOP pump and bolts (HT1,
HN2) that connect the cutter unit to the protective shell of the DOP
pump.
6. Connect the hydraulic hoses from the power supply to the hydraulic
motor (HM).

DOP3025 30
 Repair

8.2 PUMP UNIT

8.2.1 Disassembly

1. Remove the suction-side cover and wear plate as follows:

Secure the pump in a horizontal position.
Remove the suction pipe or cutter unit (refer to section 8.1).
Remove the mounting bolts, nuts and washers (Figure 7 HB1, HN,
W).
Remove the suction-side cover (PC) and the suction mouth/wear
plate (WP) as an assembly.
Inspect the O-ring (OR) for damage and discard if necessary.
Remove the bolts and Dubo-rings (HB2, DR, W) to separate the
wear plate (WP) from the suction side cover (PC).

Figure 7 Removing the suction-side cover and wear-plate

DOP3025 31
 Repair

2. Remove the impeller nose as follows:

Remove the rubber plug (Figure 8, P) from the impeller nose (IN).
Unscrew the hexagonal socket screw and Dubo-ring (HS, DR). If
necessary the bolt can be drilled out.
Lift out the impeller nose and the O-ring (OR) carefully.

 Do not drop the impeller nose!

Figure 8 Section of impeller nose

3. Remove the locking assembly as follows:

Loosen the clamping screws in several steps following diametrical
opposite sequence.
Insert the screws into the dismantling thread of the front cone and
tighten them gradually in diagonal opposite sequence up to 50% of
the required torque (70Nm).
Repeat this action up to the required torque.
When the front cone is loosened the rear cone can be loosened the
same way inserting the screws in the middle ring.

DOP3025 32
 Repair

Figure 9 Dismounting locking assembly

 Do not drop loose parts!

DOP3025 33
 Repair

4. Remove the impeller as follows:

Support the weight of the impeller (Figure 10, I), using a suitable
hoisting tool, crane and shackle, which can be provided by DDE.
Refer to Table 3 for weights.
Carefully slide the impeller (I) off the impeller shaft (IS) and take it
out of the pump shell (PS).

Figure 10 Removing the impeller

Remove the polyurethane ring (Figure 8, PU). Inspect it for damage

and discard if necessary.

DOP3025 34
 Repair

5. Remove the shaft-side wear plate as follows:

 When the pump shell will also be removed, this can be done
first. However, there is no need to.

Support the weight of the wear plate (Figure 11, WP).

Remove the bolts (HB2, DR, W) that connect the shaft-side wear
plate (WP) to the shaft-side cover (PC).
Remove the shaft-side wear plate, using a suitable hoisting tool.

Figure 11 Removing the shaft-side wear-plate

DOP3025 35
 Repair

6. Remove the pump shell as follows:

Support the weight of the pump shell (Figure 12, PS), using a
suitable hoisting tool. Refer to Table 3 for weights.
Remove the mounting bolts, nuts and washers (HB1, HN, W) from
the pump shell.
Separate the pump shell (PS) from the pump cover (PC).
Inspect the O-ring (OR) and replace if necessary.

Figure 12 Removing the pump shell

DOP3025 36
 Repair

8.2.2 Re-assembly

1. Check the shaft-side wear plates for wear at the indicated location
(Figure 4). Mount the shaft-side wear plate and pump shell as follows:
Level the shaft-side wear plate (Figure 11, WP) with the shaft-side
cover (PC).
Insert and tighten the mounting bolts (HB2) and new Dubo-rings
(DR). Use a suitable anti-seize compount (e.g. Copaslip).

 Never re-use the Dubo-ring.

Check the condition of the O-ring (Figure 12, OR). Replace if

necessary.
Position the pump shell (PS) against the pump cover (PC).
Insert and tighten the connection bolts (HB1, HN, W), using anti-
seize compount (e.g. Copaslip).
2. Mount the impeller using a suitable hoisting tool as follows:
Inspect the polyurethane ring (Figure 13, PU) for damage and
replace if necessary.
Carefully place the PU-ring (PU) and impeller (I) onto the pump
shaft.
Screw the mounting tool (PT, RE and N, included in the book box)
onto the end of the pump shaft.

Figure 13 Mounting the impeller

Draw the impeller (I) tight against the rotating part of the
mechanical seal (MSR).
3. Install the locking assembly.

DOP3025 37
 Repair

 Neither use oil containing Molybdenum Disulphide or high-

pressure additives nor grease or any similar lubricants. Either
substance will reduce the friction coefficient.

Verify that all contact surfaces including the screw thread and
screw head bearing surfaces are clean and lightly oiled.

 In case of re-use of the locking assembly, make sure that the

positiion of the dismantling threads of the front cone and
middle ring are positioned as in new assemblies.

 While tightening the screws, the hub has no axial movement

with respect to the shaft.

Slide the locking assembly into the hub bore and insert the shaft.
Tighten gradually in diagonal opposite sequence all screws up to
50% of the tightening torque of 70 Nm.
Repeat this action up to a tightening torque of 70 Nm.
Starting from the last tightened screw check, in continuous
sequence, that all screws are tightened at the indicated tightening
torque.
Repeat this action maximum twice. The locking assembly is
installed.

 Do not use an impact wrench.

4. Mount the impeller nose as follows:

Remove the impeller mounting tool (Figure 13, PT, N, RE).
Apply anti-seize compound to the nose recess in the impeller hub.
Inspect the impeller nose (Figure 8, IN) for wear.

 The impeller nose, complete with O-ring, bolt and Dubo-ring is

available as a replacement kit.

Insert the impeller nose (Figure 8, IN), supplied with a new O-ring
(OR).
Screw in the retaining bolt (HS) with a new Dubo-ring (DR).
Insert the rubber blanking-plug (P).
Ensure free rotation of the impeller (I).
5. Mount the suction-sides wear plate and pumpcover as follows:
Inspect and clean the mating faces of the pump cover (Figure 7,
PC), suction mouth / wear plate (WP) and pump shell (PS). Apply
anti-seize compound.
Level the suction-side wear plate (WP) with the suction-side cover
(PC).
Insert and tighten the mounting bolts (HB2) with new Dubo-rings
(DR).

DOP3025 38
 Repair

Check the condition of the O-ring (OR) at the suction-side cover.

Replace if necessary.
Position the suction-side cover (PC), complete with wear plate
(WP) against the pump shell (PS), using a suitable hoisting tool.
Insert and tighten the mounting bolts, nuts and washers (HB1, HN,
W).
Ensure the free rotation of the impeller (I).

DOP3025 39
 Repair

8.3 MECHANICAL SEAL

8.3.1 General directions

The mechanical seal protects the bearing casing against the ingress of water,
sand, mud etc. The seal is fitted as a cartridge assembly comprising a
stationary section (Figure 14, MSS) and a rotating section (MSR).

Figure 14 Detail of mechanical seal

 Take careful notice of the directions below.

The mechanical seal must not be removed from the pump unless it has
suffered damage or its integrity is in question.

The mechanical seal must only be removed or replaced on the DOP

pump as a complete cartridge using the locking clamps provided to hold
the stationary and rotating sections together. DDE will not accept any
warranty claims for mechanical seals, which are submitted for repair
having been disassembled or transported without their locking clamps in
place.

When re-assembling a DOP pump never fit a used mechanical seal or

one in which the stationary and rotary sections have been allowed to
separate. Always fit a new mechanical seal or one, which has been
reconditioned by DDE.
The mechanical seal is a delicate assembly, which requires that its
removal from a pump be undertaken with great care. Never employ
hammers or other impact tools to aid removal.
The manufacturer can refurbish a mechanical seal assembly up to three

DOP3025 40
 Repair

times.
Assemblies returned to the manufacturer for refurbishment must be
packaged carefully to avoid damage in transit.

8.3.2 Disassembly

1. Drain the oil from the bearing casing (refer to section 7.2.7).
2. Remove the impeller (refer to section 8.2).
3. Thoroughly clean the room around the mechanical seal with clean
flushing water.

 Do NOT use high-pressure cleaning equipment!

4. Secure the holder and rotating sections of the seal together, using the
locks (Figure 15, AC; included in the book box).
5. Remove and discard the polyurethane ring (Figure 13, PU) if that is not
done while removing the impeller.
6. Remove the bolts (Figure 14, HS) that hold the mechanical seal in place.
7. Screw three M8 bolts with a minimum thread length of 60 mm (Figure 15,
B2, supplied with the seal) into the tapped holes located around the seal's
mounting flange. Then evenly screw in these bolts to push out the
mechanical seal.

DOP3025 41
 Repair

Figure 15 Mechanical seal disassembly

8.3.3 Re-assembly

 A new or DDE reconditioned mechanical seal is delivered as a

cartridge held together with three locking clamps. These
clamps must not be removed until the cartridge has been
installed on the pump. It is vital to perform this work using
clean components, tools, etc.

1. Clean the end of the pump shaft (Figure 16, IS), the seal mounting
corners in the shaft-side pump cover and the surrounding area.
2. Check mating surfaces for damage and correct as necessary. Apply anti-
seize compound.
3. Check the condition of the seal cartridge's outside and inside O-rings
(OR). Replace if necessary.
4. Insert the mechanical seal, as one complete unit, into the housing in the
pump cover.

DOP3025 42
 Repair

Figure 16 Mechanical seal re-assembly

5. Replace and tighten the mounting bolts (HS) equally in a diagonal

sequence.

 The bore of the seal cartridge can be coated with soapy water
to help it to slide onto the pump shaft.

 NEVER use oil or grease for this purpose, as they would

prevent the seal from gripping the shaft in service. This is to
avoid lack of friction between the inner ring and the shaft.

 NEVER use force to mount the inner ring.

6. Remove the seal cartridge's locking clamps (AC, B3).

7. Place a new polyurethane ring (PU) on the shaft.
8. Mount the impeller. Refer to section 8.2.2.

DOP3025 43
 Troubleshooting

9 Troubleshooting

Mechanical system

Refer
Problem Cause Remedy
to

Bearing casing runs 1. Pump runs at full power,
warm (above 70C). with bearing casing
above water line.
2. Worn bearing.
3. Oil level in bearing
casing too low or too
high.
Mechanical vibrations 1. Impeller off balance
in pump. because of obstacle or
damage.
2. Impeller off balance
because of wrong
assembly.
3. Cavitation of pump.
Oil bearing casing is 1. Mechanical seal
coloured dark and / or leakage.
contains particles.
2. Excessive leakage of
mechanical seal.
Lack of production. 1. Worn impeller or worn
wear plates.
Cracked pump shell. 1. Worn pump shell.
Table 8 Troubleshooting mechanical system
Place pump in deeper
water. From there
dredge to desired
location.
Bearing to be replaced,
contact DDE.
Top up or lower oil level 7.2.7
in bearing casing.
Remove obstacle from 8.2
impeller. In case of
damage, contact DDE.
Disassemble impeller 8.2
check for damage and
re-assemble according
to instructions in user
manual.
Do not put the pump too
deep into soil. Lift the
pump some what.
Disassemble bearing 8.3
casing and mechanical
seal. Flush bearings and
replace mechanical seal.
Mechanical seal to be
replaced. Contact DDE.
Disassemble impeller
and re-assemble with
new parts.
Disassemble pump and
re-assemble with new
parts.

DOP3025 44
 Troubleshooting

Hydraulic system

Refer
Problem Cause Remedy
to

Medium hydraulic 1. Pressure line filled with
pressure, but low flow sand.
in dredge pressure
line.
Medium hydraulic 1. Impeller obstructed.
pressure, but no flow
in dredge pressure
line.
High hydraulic 1. Blocked hydraulic quick
pressure, but no flow release couplings.
in dredge pressure
line.
2.
Low hydraulic 1. Suction mouth of pump
pressure, and low clogged.
flow in dredge
pressure line.
2. Impeller clogged.
Hydraulic motor runs 1. Pump runs at full power,
warm (above 70C). with bearing casing
above water line.
2. Insufficient cooling
capacity for hydraulic oil.
3. Hydraulic motor worn.
Table 9 Troubleshooting hydraulic system
Take off pressure line
and remove sand.
Remove obstruction 8.2.1
from impeller.
Check the quick release
couplings and tighten
them properly.
Clear the blocked return
line.
Clean suction mouth.
Clean impeller. 8.2.1
Place pump in deeper
water. From there
dredge to desired
location.
Check hydraulic oil
cooler on power pack.
Replace or revise
hydraulic motor.

DOP3025 45
 Disposal

10 Disposal
Damen Dredging Equipment aims at manufacturing environment-friendly
products. Inquire about the opportunities to return the complete pump to DDE
after use, so it can start a second life after an extensive overhaul. If this is
impossible or unprofitable, then the pump can be converted into scrap.
When a dredge pump or parts of it are dismantled, waste materials should be
separated as follows:
Tap the oil from the pump drain(s) and submit it as chemical waste to a
local chemical waste collector / depot.
Plastics should be submitted to a local chemical waste collector / depot.
Steel (alloys) should be submitted to a local collection depot.
DDE recommends to submit wear parts (cast steel and cast iron) to our
foundry (address details can be obtained from DDE), due to the higher
scrap value compared to structural steel.
All other metals (copper and aluminum alloys) should be submitted
separately to a local collection depot.

DOP3025 46
 Index

Index

A I
Advantages ............................................ 1 Installation
Appendices ...........................................IV Connecting .................................... 11
Applications ........................................... 1 Hydraulic system ............................ 15
B Post-delivery inspection .................... 8
Tests and adjustments .................... 18
Bearing casing
Transportation and storage ................ 9
Changing oil ................................... 27
Introduction ............................................ 1
Filling & checking oil level ................ 26
Periodical maintenance ................... 26 M
C Maintenance ........................................ 22
Changing oil Mechanical seal
Bearing casing ............................... 27 Disassembly .................................. 41
Connecting Periodical maintenance ................... 25
Connection to hoisting/manoeuvring Re-assembly .................................. 42
vehicle ............................... 11 Repair ........................................... 40
Hydraulic hoses .............................. 12 O
Water supply and discharge hoses ... 13 Operating other appliances ................... 21
Construction Operation
Cutter unit ........................................ 6 Cutter unit ...................................... 21
Pump unit ........................................ 6 Pump unit ...................................... 19
Cutter unit P
Construction ..................................... 6
Periodical maintenance ......................... 23
Operation ....................................... 21 Bearing casing ............................... 26
Periodical maintenance ................... 24 Cutter unit ...................................... 24
Re-assembly .................................. 30 Mechanical seal ............................. 25
Repair ............................................ 29 Sand production head ..................... 24
Shut-down ..................................... 21 Shaft seal ...................................... 25
Start-up .......................................... 21 Wear ............................................. 24
Technical data .................................. 4 Pump unit
Working principle .............................. 7 Construction ..................................... 6
D Disassembly .................................. 31
Description ............................................. 6 Operation ....................................... 19
Dimensions and weights .......................... 9 Re-assembly .................................. 37
Disassembly Repair ........................................... 31
Cutter unit ...................................... 29 Shut-down ..................................... 19
Mechanical seal .............................. 41 Start-up ......................................... 19
Pump unit ...................................... 31 Technical data .................................. 4
Disposal .............................................. 46 Working principle .............................. 7
F R
Filling & checking oil level Re-assembly
Bearing casing ............................... 26 Cutter unit ...................................... 30
Hydraulic motor(s) .......................... 16 Mechanical seal ............................. 42
Hydraulic oil ................................... 16 Pump unit ...................................... 37
G Repair
Cutter unit ...................................... 29
General directions ................................ 22
Mechanical seal ............................. 40
H Pump unit ...................................... 31
Hydraulic system S
Filling the hydraulic motor(s) ............ 16
Safety .................................................... 3
General precautions ........................ 15
Sand production head
Hydraulic motor(s) .......................... 16
Periodical maintenance ................... 24
Hydraulic oil ................................... 16
Shaft seal
Hydraulic power supply ................... 15
Periodical maintenance ................... 25

DOP3025 47
 Index

Shut-down
Cutter unit ...................................... 21
Pump unit ...................................... 19
Start-up
Cutter unit ...................................... 21
Pump unit ...................................... 19
Storage .................................................. 9
Preparing for storage ........................ 9
Servicing after storage .................... 10
T
Technical data ........................................ 4
Transportation ........................................ 9
Troubleshooting .................................... 44
W
Wear ................................................... 24
Wear-plates .................................... 25
Welded repairs ............................... 25
Weights and dimensions ......................... 9
Working principle
Cutter unit ........................................ 7
Pump unit ........................................ 7

DOP3025 48