STS M-1500H User manual

Surface to Surface Inc. ®
Operators Manual
** M-1500H **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Hydraulic Motor
SNM2/19C106 – Serial No.__________________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Control Valve
Brand FC51 Serial No.__________________
Links relating to this Manual
www.stsmixers.com
www.grpumps.com
STS-143 Rev. 07/27/12 www.stsmixers.com
Dealer

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3
TABLE OF
CONTENTS
PAGE
STS Inc Warranty………………………………………………………….. 6
Safety Statements………………………………………………...………… 7-10
Safety Markings……………………………………………………………. 11
Hydraulic Connections / Schematic…………………………...…………. 12
Main Working Components (Photo)……………………………………… 13
Introduction to the M-1500H ………………..………..….………….……. 14
M-1500H Foot Print (top view)………………………….….……...……… 15
M-1500H General Data Sheet………………………………..…...………. 16
Identifying Your Machine & Components…….…….…….…….………. 17
SECTION II (Description, Care and Maintenance)
Polyethylene Plastic Reservoir Tank…………………….…………… 19-20
Hydraulic powered centrifugal pump.….….……..…….………….…. 21-24
Filter shear system……………………………………………………. 25-26
Venturi mixing tee……………………………..………..……………. 27
Wash wand……………………………………………………...……. 28
Dry hopper with table & hopper valve…………………………..…… 29
Internal tank jet gun ………….….………….…………...…………… 30
SECTION III (Set-up and installation of unit in Detail)
Permanent mounting of unit…………………………...…………….. 32
Portable use of unit…………………….…………………….………. 32

4
TABLE OF
CONTENTS
PAGE
SECTION IV (Operating the M-1500H Unit.)
Site set-up and pre-check…………………………………………….. 34
Starting the hydraulic driven pump…………….….…....…….……… 35
Typical mixing operation……………………….……………………. 36-38
Typical transfer / off-loading operation……………………………… 39
Shutdown, cleanup & storage
Warm weather…………………………………….…………. 40
Cold/ freezing weather………………………………….…… 41
Prolonged periods of storage………………………………… 42
**Optional self-loading feature……………………………...………… 43
SECTION V (Trouble shooting)
Trouble Shooting the M-1500H ……….…….….…….……....……… 45-46
SECTION VI (Periodic Maintenance & Repair Information)
Maintenance Schedule…………………….….………………….…... 48
Centrifugal Trash Pump Seal Replacement………………………..… 49
Bolt torque Specifications…………………………………….……... 50
Notes…………………………………………………….…………… 51

5
TABLE OF
CONTENTS
PAGE
SECTION VII (OEM Repair / Information)
GR Centrifugal Pump Owner’s Manual……………………..………… 53-64
Gruvloc® Pipe Couplings ………….…….….….………………..…… 65-67
Sauer Danfoss Hydraulic motor …………..…….….….….….….……. 68-70
SECTION VIII (Parts Manual)
M-1500H PARTS MANUAL …………….…..….…….….….….…. 72-77

6
Limited Warranty
United States and Canada
Surface to Surface Inc. or it’s subsidiary which last sold the product, warrants new products sold by it for use in the
United States and Canada to be, at the time of manufacture, free from defects in workmanship and materials. This
warranty covers for a period of Twelve (12) Months of operation from the date of delivery for initial use, whichever
comes first.
Exclusions and Additional Limitations
1. This warranty relates to the condition of the product at the time of manufacture and does not cover parts or
service as a result of:
(a) Normal wear and tear or required maintenance including, without limitation, adjustments or replacement of
components subject to wear and tear, such as belts, hoses, seals and/or packing, fuses, bulbs,
switches and ignition parts.
(b) Abuse including, without limitation, neglect, improper operation, misapplication, overloading, accident or
alterations not approved by Surface to Surface Inc.
(c) Lack of maintenance, including, without limitation, failure to inspect and maintain, improper repair, use of
“unapproved parts”, cracked engine heads and blocks unless caused by the failure of
an internally lubricated part or repair of engine valves, rings or guides.
2. The Company’s warranty does not apply to purchased components manufactured by others where separate
warranty is made by the manufacture of such components and will be applied as interpreted by
the supplier.
3. All claims under his warranty shall be submitted in writing by the distributor to the Company, which will be the
sole judge in determining the merits of the claim.
4. The company shall have the right to have all products or parts claimed to be defective returned to it and the
cost of shipping such items shall be borne by the distributor.
……………………………………………………………………………………
Warranty Registration Card
In order to help us provide complete service for our product, please complete this card and return it.
If not returned, all requests for warranty will be denied.
Print Name: …………………………………………………………………….….
Address: …………………………………………………………………………...
City: ……………………State/Province………………Zip/PC…………………...
Model No. ………………………….. Serial No. …………………………………
Date of Purchase ………………………… Dealer ………………………………..
Return to: Surface to Surface Inc.
5150 Forest Rd. RR#3
Watford, Ontario, Canada
N0M 2S0
01/14/08

7
M-1500H
SAFETY STATEMENTS
Your personal safety and the safe operation of this unit are the concern of Surface to Surface Inc, and by
reading and understanding this manual and understanding the safety statements, you will decrease the risk of personal
and equipment damage.
Safety statements are listed here and throughout this manual to draw your attention to potential hazards that
may be encountered while operating this piece of equipment. While reading this manual, you will notice that certain
safety statements will relate directly to the operation, or maintenance of that particular part of the unit and should be
followed carefully. Decals on the unit also follow the same format as the warnings in this manual, and therefore should
be kept in good repair to alert the operator and others of the potential hazard.
The engine / motor manual may also contains hazard warnings which pertain to the engine / motor and should
also be followed.
This safety alert symbol appears with most safety statements.
It means attention, become alert, your safety is involved!
Please read and abide by the message that follows the safety alert symbol.
DANGER
WARNING CAUTION
CAUTION
Caution "without the safety alert symbol"
indicates an potentially hazardous
situtation that can cause damage to the,
machine, personal property and / or the
environment or cause the machine to
operate improperly.
Danger (the word "DANGER" is in white
letters with a red rectangle behind it)
indicates an imminently hazardous
situation, which, if not avoided, will
result in death or serious injury.
Danger is limited to the most extreme
situations.
Warning (the word "WARNING" is in black
letters with an orange rectangle behind it)
indicates an potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Caution (the word "CAUTION" is in black
letters with a yellow rectangle behind it)
indicates an potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.

8
M-1500H
SAFETY STATEMENTS
The following caution statements have been drawn from the instructions in this manual. They have
been assembled here for ready reference.
WARNING
NEVER USE BODY PARTS,
OR FOREIGN OBJECTS
in an attempt to unplug or cleanthe
hopper valveor mixingtee.
Serious personal inj uryor
damagewill result.
WARNING
Seriouspersonal injurywill result.
DO NOTREMOVE ORMODIFY
SAFETY COVERS OR GUARDS.
WARNING
whiletheunit isin operation.
Seriouspersonal injurywill result.
NEVER ATTEMPT TO REMOVE
OR CLEAN THE FILTERSHEAR
CAUTION
DO NOT POSITION
ANY PART OF YOUR BODY
over thehopper,valve,
or mixing teewhilecleaning.
CAUTION
NEVER OPERATE THE MIXING
unit with the tank lid open.
If viewing is necessary,open
onlythe small inspection
vent cap in the center of thelid.
CAUTION
WHEN THE UNIT
IS IN OPERATION,
thefluid in thepiping mayreach
pressures upto 50 p.s.i.
DANGER
IN ANEMERGENCY
rotatetheflowcontrolvalve
leverto theSTOPposition
to halt thepump, and fluid flow.
DANGER
NEVER ATTEMPT REPAIRS
OR DISASSEMBLY
without shutting offthehydraulic
power source(customer supplied)
Seriouspersonal injurywill result.

9
M-1500H
SAFETY STATEMENTScontinued
The following caution statements have been drawn from the instructions in this manual. They have
been assembled here for ready reference.
CAUTION
TRAPPED FLUIDMAY BE PRESENT
and will spill outwhen piping, hoses,
pump or filter shear are remov ed.
CAUTION
AVOID ALLOWING FOREIGN MATERIAL
into the Ve nturi Mixing Tee thru the
Hopper, bykeeping the valve closed
whennot inuse.
CAUTION
NEVERLEAVE LIQUIDINTHE
PUMP CASING, PIPING, OR HOSES
duri ng free zing weather conditions,
as damage will result.
Followinstructionfor winterizing.
CAUTION
CAUTION
CARE MUSTBE TAKEN WHEN
INSTALLING THE COUP LER GASKETS.
If the gaskets are not properly lubricated
and installed, a leak may develop.
CAUTION
IMPROPER INSTALLATION OF THE
MECHANICAL or GREASE SEAL
will result inleakage andpossible
damage to the seal. All maintenance,
operating andrepair of this unit, must be
done per the instructions in the operators
manual for safetyand r eliability.
CAUTION
WHEN TRANSFERRING FLUID
to the drill rig, fluid pressure may
reach or exceed 50 p.s.i.
CHECK the drill r ig manufacturers
specifications regardingmaximuminlet
pressures allowedfor their pump.
BEFORE STARTING OR RESTARTING
the hydraulic motor and centrifugal pump,
make sure anyv alves installedon the
pump sucti on inlet line ar e open, and
the fluidlevel in the tank is above
the suction line.
CAUTION
BEFORE STARTING THE HYDRAULIC MOTOR,
BE SURE THE PUMP IS PRIMED!
Check the pump byslowly& carefully
opening the plug located on the top
of the centrifugal pump discharge elbow.
A v isual inspection can be made if the fluid
escapes aroundthe plugas it is loosened.
Remove the plugtov iewinside fluidlevel.
The centrifugal pump seal WILL be
damaged if allowed to cavitate or run dry.

10
M-1500H
SAFETY STATEMENTScontinued
The following caution statements have been drawn from the instructions in this manual. They have
been assembled here for ready reference.
CAUTION
CAUTION
Themanufacturer should beconsulted
whenconsidering alternativeuses
forthispieceof equipment.
Thisunit wasdesignedfor themixing
and shearingof adryadditive, into a
liquid stream.
Other uses maycreate unforeseen safety
issuesand personal injuryrisk.
CAUTION
BEFORELIFTINGORMOVINGTHEUNIT,
all fluid should beremoved fromthetank.
CAUTION
AVOID PLACING OBJECTS
on top or against thetankasdamage
mayresultfromtheweight.
CAUTION
LIFTINGLUGSORTHELIFTINGPOINT(S)
identified and labelled on theskid
structure must beused in order to
safelylift andtransport theunit.
TOENTERTHETANK isnot recommended
Personal injurycould result from
the presentsof hazardous fumes,
remaining fluid or unit start-up.
WARNING
REFER TOTHESAFETY
STATEMENTSIN THE
OEM SUPPLIED MANUALS
AND
THISMANUAL
REGARDINGTHESE
OPERATIONS.

11
M-1500H
Safety Markings
Hazard and warning markings have been placed at appropriate points on the unit. International symbols
have been used, in order to ensure universal understanding of the nature of the hazard. Please comply with
all warnings and markings to ensure safe use of the equipment. These include but are not limited to:
a) Lifting points b) Fluid flow direction
c) High temperature areas d) Personal Protection recommendations
e) Personal dangers f) Equipment dangers
g) Operating instructions
SOME EXAMPLES FOUND ON THE EQUIPMENT
Safet
y
Instructions
KEEP LID CLOSED
W
HILE MIXING
Liftin
g
Point
Personal Protection
,
Read and understand O
p
erator’s manual and Maintenance manual
Hot Surface
Fluid Flow Direction
Maintenance Instructions
Liftin
g
Point
CLEAN FILTER DAILY

12
M-1500H
These guidelines must be followed or warrant will be voided. Any variation needs to
be approved by Surface to Surface®.
SET-UP
Minimum Flow Rate: 15.0 us gpm.
Maximum Flow Rate: 16.5 us gpm.
Relief Setting: 2250psi.
Inlet Hose Size: 3/4" minimum
Outlet Hose Size: 3/4" minimum (
direct to reservoir )
Caution:
As the hydraulic oil increases in temperature the hydraulic flow rate will rise above
your set rate of 15.0 – 16.5 g.p.m. of hydraulic flow. The hydraulic flow valve should then be
set back to the recommended flow rate of 15.0 – 16.5 g.p.m.
Specifications on hydraulic oil, operating temperature, and filtration can be found further
on in this manual, on the Sauer Danfoss hydraulic motor data sheets.
Any problems or question may be answered by calling Surface to Surface®at
[phone] during normal business hours.
CF
EF
IN
1
2
3
4
5
6
7
8
9
01-20-06
RETURN LINES
PRESSURE LINES
CUSTOMER SUPPLIED
IN FLOW OUT FLOW
TO TANK
M4-H
16.5 usgpm. MAX.

13

14
M-1500H
Operators Manual
Congratulations on your acquisition of the world renowned M-1500 Mixing System. You have acquired
the fastest and most efficient mixing system manufactured for mixing Bentonite drilling slurry (mud).
As a manufacturer of HDD support equipment, we are well aware of the extreme conditions that HDD
equipment is exposed to on a daily basis. Surface To Surface Inc. strives to overcome these conditions,
with better design and manufacturing practices. Please feel free to call our toll free number
(1-800-567-0978) if you have any questions or concerns about your M-1500.
Thank you, for choosing the M-1500 series mixer.
The M-1500H mixing unit was designed to mix dry or liquid drilling products with
clean water, into a slurry. The slurry is continually circulated through the mixing cycle until
it reaches the desired consistency. The operator can then transfer the final product to a
holding reservoir or directly to the drilling equipment.
The M-1500 mixing unit consists of two 750 u.s. gal. (2839 litre) polyethylene plastic tanks,
hydraulic powered centrifugal pump, with a hydraulic oil flushed bearing block, filter/shear
unit, venturi mixing tee assembly, dry hopper with a table, tank internal jet gun and a
discharge valve to pump the finished slurry to a holding tank or the drill rig. These
components are all mounted on a frame type skid, built for lifting or solid mounting. For ease
of interpretation, looking at the mixing unit hopper straight on will be considered looking at
the front of the unit. Hence the other long side, will be the rear and the ends will be right or
left end.
RECORD OF OWNERSHIP:
Unit Serial No. __________________________________________
Motor Serial No._________________________________________
Pump Serial No:_________________________________________
Tank #1 Serial No:_______________________________________
Tank #2 Serial No:_______________________________________
Date Purchased/Leased:___________________________________
Dealer Purchased/Leased From:_____________________________
Special Custom Features:__________________________________

15

16
Surface to Surface Inc.
Features and Benefits M-1500H Mixer
The M-1500H was designed and manufactured as a dual tank system that allows the HDD contractor two methods
of mixing their bentonite mud requirements. This system allows the operator to mix 750 gallons of full yield mud in
less then eight (8) minutes, while holding 750 gallons of water reserve in the second tank for the next mix, or mix
1500 gallons of full yield mud in less then sixteen (16) minutes, in one large batch. The operator controls the two
methods of mixing by changing the direction of flows through the piping connections using the manual operated full
flow valves. The vacuum port located in the mixing tee has the ability to draw water from the second tank when
being used as a reservoir and the drill fluid can than be sent to your drilling rig with-out the use of a second pump.
Powered by the customer’s own power source, a 16 1/2gpm hydraulic motor drives a 4 inch centrifugal pump
making effective use of the proprietary StS mixing system. This model has been a popular choice of HDD contactors
due to its small space saving footprint relative to its capacity.
Specifications M-1500H Mixer Benefits
Dimensions 92”W x 140”L x 75”H Space saving design for its capacity.
Approx. Weight 2470lbs Excellent weight distribution
Hopper Height 39 inches high Waist high hopper reduces back strain.
Mixing System 4” Proprietary StS Mixing System Fast, efficient mixing time.
Mixing Tank ( 2 ) 750 gallon Roto-Mold Polyethylene Minimal maintenance required.
Skid frame ( 2 ) 5” Steel Channel, Welded Built for the rigors of the construction trade.
Hydraulic Gear Motor Requires 15-16½ us.gpm. @ 2000psi Use your own power source, no fumes in truck body
Hydraulic Valve Variable speed control Allow bentonite mixing at various speeds
Hydraulic system Open loop circuit Simple, field repairable, less maintenance
Pump 4” Cast Iron Centrifugal Trash Pump Rugged & Repairable for extended service life.
Pump Drive Hyd. Motor direct to Bearing Block No expensive couplers or inserts to replace.
Pipe Couplers Bolt and Snap –Groove Type Provide fast cold weather draining of system.
Pressure Wand Hopper Maintenance Wand Removal of blockages caused by additives.
Tank Drain ( 2 ) Bottom Tank Drains Supplied Provides fast cold weather tank drainage.
Also available in Diesel (M-1500D) – Gasoline (M-1500G) – Electric (M-1500E) models.
B

All Specifications Subject to Change Without Notice



Bentonite Mud Mixer
Model M-1500H
Surface to Surface Inc.
5150 Forest Road, R.R.#3, Watford, Ontario, N0M 2S0
Tel: [phone]
Check our website for the latest products and specifications
www.stsmixers.com
01/28/11
Hydraulic

17
M-1500H
Identifying Your Machine & Components
Location of Tags and PIN Plates

18
SECTION #II
Description, Care and Maintenance

19
M-1500H
Description, Care and Maintenance
Polyethylene Plastic Reservoir Tanks (750 us. gal)
Maintenance of this tanks is required, but is simple. The tanks should be cleaned on a regular basis by
opening the drain cap on the tank tee, located at the bottom right end of the tank (see Fig.1) and or open the
customer installed bottom tank drain (see Fig.2) and rinse the tank with clear water. Residue such as leaves,
stones, etc can be removed using a wet /dry vacuum.
All tank ports are of a threaded type bung (see Fig.1) with rubber gaskets. If a leak is noticed between
the tank and gasket, the connection can be tightened up by tightening the large nut flange in the direction of
the arrows on the nut (counter clock wise).
CAUTION
NEVER OPERATE THE MIXING
unit with the tank lid open.
If viewing is necessary, open
only the small inspection
vent cap in the center of the lid.
CAUTION
BEFORE LIFTING OR MOVING THE UNIT,
all fluid should be removed from the tank.
CAUTION
TO ENTER THE TANK is not recommended
Personal injury could result from
the presents of hazardous fumes,
remaining fluid or unit start-up.
Fig.1
DANGER
NEVER ATTEMPT REPAIRS
OR DISASSEMBLY
without shuttingoffthehydraulic
powersource (customer supplied)
Serious personal injurywill result.

20
M-1500H
Description, Care and Maintenance
Polyethylene Plastic Reservoir Tanks (750 us. gal)
INSTALLATION OF (CUSTOMER INSTALLED) TANK DRAIN
Find a suitable location on the tank floor for the drain to be installed, taking into consideration the
placement of the unit on a trailer. LOOK under the deck for obstructions (cross-members, wiring, and axles,
ect.) Allow room for a shut off valve.
Drill holes into floor of tank using the top (inside) portion of the drain as the template.
Make sure the holes are free of burs and both surfaces are clean.
Install the drain bung as per FIG 1. Note the gaskets are on the inside and outside of the tank.
Tighten nuts as to slightly squeeze the rubber gaskets.
Cut a hole into the deck of the trailer or truck for the piping and valve to be installed.
Install 2” pipe nipple and valve into tank bung with a sealant on the threads. CAUTION: DO NOT OVER-
TIGHTEN!
The nipple and valve should not extend to far from the tank without a support, as this will cause excess
stress on the threads, drain bung and the tank floor.
Fill with water and check for leaks.
GASKETS
CUSTOMER SUPPLIED
PIPING AND VALVE
TOP
(INSIDE)
BOTTOM
(OUTSIDE)
FIG 1
TANK FLOOR
1 3/4" Ø
IN FLOOR
Fig.2